I had the same issue over and over ,then i sprung for the billet output shaft and havent had an issue since.I also broke a few input shafts.these trucks put alot of stress on these trannies.psi sounds kinda low if you ask me.Ive had it all the way up to 160 b4 and yes 160s high.
mods:2004 sierra ext sb,20s ,big brake kit w,hawk pads,air bagged,2006 6.0 lq4 swap,vortec supercharged10psi, air to water intercooled w/ dual electric fans on it ,snow meth injection kit,60lbers, e-fans ,big radiator swap ,cam 218 /222 548/550 comp .hardened prs .1.85 comp roller rockers ,guideplates ,crane double springs,trans 4l65e built .pacesetter l/ts true duals w/x pipe and magnaflows,14 bolt rearend swap ,3.73s,aroemotive fuel pump system w/elec.fuel controller and bypass regulator a/n fittings, taylor 10.5s interceptor gauge,aem w/b a/f ,autometer boost/vac NELSON 93 OCTANE TUNED .