This thread is kinda beat to death - but I'm getting my truck back today after about a month. Ran by the trans shop yesterday to chat and get an update and they found some odd stuff on teardown. The friction disks were worn in "unusual" ways ... those where heavy slippage d/t whatever the initial cause of the issue was were worn in that way. But a lot of the other friction material was worn in odd patterns. Some showed signs of degradation at the corners of the material (if you've not seen these in modern applications it's like a small brake rotor ... or clutch disk ... and the friction material is on these alternating triangles (one up, one down) around the circumference. If I'd thought about it - I would have taken pics (my bad). And others had excessive wear on the inside circumference of the disk but not the outside ... like the pressure was too high on the inner loop vs. outer.
He's done work on these 10-speeds (10r80) in diff. applications - never seen it like this. I suppose the issues of a bad solenoid or other damage could have lead to a cascade effect where downstream issues were amplified. He actually didn't think this particular trans had been "abused" ... he wasn't sure what the overriding cause could have been - but based on the wear patterns he's just kind of stumped. Round about way of saying - he thinks in the next couple of years he's gonna be seeing a lot more 10r80s coming through for rebuilds. Take that w/ whatever grains of salt you might like.
BTW - the relearning of these is super-annoying. According to instructions he's got from Ford - there's a 10+ mile sequence of running through the gears at low RPM ... followed by slowing and cycling through Park, R, N, Drive ... repeated multiple times. That just gets it back to "new" ... the learn-in takes a lot of normal driving ... then there's a process for the paddle-shifters after that. He said you can just drive it - but that you want to spend the time getting it all formatted or you'll wind up w/ sub-optimal shifting-comfort-wise or not strong enough on the "performance" side.
Just a little food for thought on my experiences here ... either way, i'm just happy to be getting it back.