Hey guys,
Common thing installers do is cut off a couple threads worth on TC bolts and clean it up so it runs into the converter's threaded pads easy and doesn't come anywhere near the converter.
NEVER use any kind of impact on them and torque them using blue or green locktite. Blue is easier to break lose later. Like Jesse said, if the bolt hits the converter, stop stop stop. Take a dremel and cut a couple threads off, clean it up and try again.
If you are putting in new bolts really pay attention to length. A dimple in the TC surface can be detrimental to TC clutch function. The clutch will hit the 3 dimples and chatter across them as it attempts to bend the clutch. A different problem with TC that can cause clutch failure is cocentric runout. This is a manufacturing problem. Basically if the apply plate of the housing isn't machined perfectly flat (coned shape), clutch apply won't be even and it will burn up the clutch/chatter. More common in custom housings. There are more. Sonnax has a technical series that list all kinds of problems. Whether the problem be in manufacture or installation or problem elsewhere in the trans(valves/pump).
Make sure you filled that TC up with tranny fluid and let it soak about an hour BEFORE you ran your truck. There are some sites out there with some info on proper TC installation and you'll find some on here if you search.
Forgot something. Your stock TC bolts will NOT hit the 9/11. If they've been replaced, they very well can. If your boost valve fell out, you only had it engaged in the first groove. MUST BE IN THE SECOND GROVE OR NOT ENOUGH PRESSURE IN SYSTEM. This happens a lot.
Did you touch your TCC valve lineup in the pump?
Also make sure that you plugged your TCC clutch solenoid's wires are still plugged on to the pressure switches and that the connector on the top driver's side of the tranny is installed all the way and is not damaged.
Jesse is close to you and is THOROUGHLY familiar with the wiring and TCC solenoid layout. Take his help if he offers. He's knows more than some people would lead you to believe.
If you take the pan off, also push on the TCC valve. It should have some spring to it. If it does not move or sticks, take it out of the bore, clean it up with scotchbrite and carb cleaner and put it back in. You can see it in the pic over on the right. There is a "plate" with a hole in it over the snap ring. Make sure the valve in there can move.
I've talked with Jesse a little. Wish I lived down there closer to yous guys. The weather up here sucks ass. Cold, dry, snowy, windy.
Blake