On a 1972 with a 455 Olds and a 2004R. When in Drive and at WOT, the trans shifts too early, around 4400RPM. When the carb is at WOT, the TV cable is fully extended so that really can't be adjusted.

How to get the 2004R to shift around 5,500 RPM when in Driver without having to shift manually via shifter?

 

The TV cable is just for load. I believe that trans still uses traditional gov weighted and changing the weights will change shift points to a higher RPM at WOT based on engine rpm..

 

Yup, WOT shifts are controlled by the governor. It's a real PITA to get to - remove the pan, then remove the governor cover. It's surprisingly difficult to find the governor cover gasket by itself without a complete rebuild kit.
Lighter weights == later shifts.
I would recommend picking up a governor off ebay so you're working on an extra set of weights. Slowly lop off a bit at a time and see how it goes.
Or, if you had the transmission built by someone, hopefully they're experienced with these things and can set it up properly. I got my 200-4r from Extreme Auto and they had the governor set waaaaaay too high - bounced off the rev limiter trying to merge onto the freeway a few times. Sent the governor back to them, they put on different weights, now it's excellent.

CK's tech book has a good (but short) section on tuning the governor and sample weights. Note that the governor spins in relation to the driveshaft, so the rear axle ratio also affects the weight choice.
http://www.ckperformance.com/View/GM...CHNICAL-MANUAL

 

A Grand National or Monte SS might be close to what you want. You need to grind the small weight a lot and I stake the spring with screws tapped and threaded in. Doing this raises my shifts from low 4000's to around 5000.

 

x2 on above. Put a drain plug in the pan the first time you drop it as it likely will not be the last. Tuning the governor is trial & error and even tuning the speedo gears can take a try or three. Pan needs to drop each time for either.

 

the turbo 400 and I believe the 350 as well were nice, you could change gov weights quickly, cover was on the outside.

 

I got the correct bracket to work on a Demon carb. Can the TV cable be pulled too tight? In other words, if at WOT, can the cable be so tight that it pulls the valve in the valve body too far or prevents WOT due to the TV cable limiting the travel of the carb linkage?

 

The TV cable certainly can be set up wrong. It's best to use two people - one person pushes down on the throttle pedal, the other person makes sure the carb goes all the way to WOT and the TV cable is tight-ish.
Don't monkey-arm it. There is flex in the cable housing and the bracketry inside the transmission. You just want the cable to pull to where it hits the end of the travel.

 

Plenty of places to get the gasket by itself.
http://www.transmissionpartsusa.com/...-000036137.htm
http://www.makcotransmissionparts.com/54306B.html
as well as others

As far as the trans shift points go, this is why the factory performance vb/governor combos are more expensive. That is not to say the shift points on the other combos cant be worked over to attain the goals, but you have to value your time. And the trans fluids baths are only so much fun.

As pointed out above the spring should be "pinned" or it can make an exit and no shift condition.