Almost 3 months ago I blew the input seal on the tranny. It was on its way out anyhow, and I originally planned on swapping a NV4500 in. The new house and lousy economy have slowed that plan to just an idea.

The other night I decided to just start taking it all apart. I'm no automatic expert by any means, I'm an electrician, but I have enough knowledge I think to handle it.

Yesterday I started taking it all apart. FYI, the biggest problem I had with the tranny in the end was high-ish temps often pegging above 200 in 70-90 degree weather around town, and as a result (sometimes when cold too) the TCC seemed like it would start locking up at a stop light, bogging the motor down after it shifted to first gear. TCC also slipped under 50% + throttle. It sounds stupid, but when it was "bogging down" or locking up or what not, it would not do a burnout if I counted on it, never had a problem with that before. Trans would also slip pretty bad downshifting into first or second gear, like going into neutral for a half second. Moderate towing once in a while, light plowing for 3 years. 170k on truck, 60k on rebuild by AAMCO. [duhhh]

That being said, here's what I found. (Keep in mind, obvious to the untrained eye. Please excuse lack of proper terminology!)
-Front band was worn to the rivet on the adjuster side, center of band. Scored the basket a wee bit, just enough to feel it with a naked finger. (Replace?)

-ALL clutches/steels seem worn, nothing looks burnt or too badly warped. Heavy clutch fiber residue on all parts in tranny.

-With the rear planetary in main case, the aluminum case holding the planet gears is concerning-teeth on AL seem worn, gears themselves seem chewed up. Outter ring gear seems ok, rear band and basket seem to be alot better than the front.

-The thrust bearing front input shaft rides in (pressed into back of front cover) is all chewed up along the rear edges, looks like it was not installed properly. Surface of shaft seems ok.

I just took off the O/D unit, haven't torn it down yet besides the clutches. Besides being dirty, they don't look too bad.

I am on a budget or at least a time period, but I want this done right. Are there any key parts I should be looking at that could cause this? Where can I get QUALITY replacement parts? Are there any upgrades available while I'm in here to get more than 60k out of the tranny? Obviously I am going to replace all clutch packs, seals, bands, etc.

Any words of advice are greatly appreciated, I think I'm a little lost with what to look for in some aspects. The manual should help, but I got impatient. Thanks again.

If the steels look like they've been hot i'd replace them.also i'd be very careful with the od, don't want that spring to come flying out of there with 800 lbs of force. If you think its questionable I'd replace it, if its worn replace it, might as well spend some dough now and than have to tear it all back down because you didn't replace it. Might be just as cheap to buy an after market trans.

KD band is history as you surmised. I'm guessing the basket is front drum outer surface where the band rides. You will be amazed at what very fine sanding will do to surface. Will probablly clean up nicely. Clutch wear is generally not big issue although you replace. When they are warped and the steels are warped you had a problem with that clutch. Clutch fiber is probablly the TC lockup clutch failed and went everywhere. The material contiminates the cooler circuit and calls for through cleaning blowing out of coooler and lines. Carefull there may be a one way check valve in cooler lines. You can easilly fail. Blow way fluid flows. From front line to coolers and back into tranny through rear line.
You lost me on thrust bearing. Description?
Rear plantary with Alum carrier. The planet teeth look wierd. It is a broaching proscess thet makes them look scalloped(???). If they are damaged you should be able to tell, easily. Thrust bearing in reap planet rides against a stainless steel washer. Will show some minor markings.
Get a service manual. Converter fail is my diagnois from description of parts and my iminagation. JMHO

Pictures would help tremendously also.

Well, the thrust bearing in question supports the input shaft, and it is pressed into the stationary outer shaft. I have not taken this assembly apart, which is part of this front plate bolted to the front case behind the torque converter. Viewing this bearing is from the back of this plate. TCC slippage was definetely a problem in the last 5,000 miles under full boost and 3/4 throttle or more. So far, none of the steels appear to be obviously warped, however they have not been mic'd. Pictures are coming hopefully to show my progress and/or details of the issue. Gears in the aluminum carrier match what you say, and a service manual is in the works anyhow. I am waiting on the decompression tool to finish OD unit. Thanks for all the help, and I will keep you posted!