94 Dead A4LD

[BrianDye]

Id love to get a serious set of tools, and do something like that, hopefully it wouldnt be because something went wrong lol! But yeah everything I do so far is just minor stuff, and A/V lol

Soon ill be getting down to the inside of the engine

 

[zjrog]

Who says I got special tools? Look, you can do a lot with a simple tool kit. Certainly , a set of deepwell sockets is a must, but I just don't have a lot of super special stuff. But! I do have some good friends!!!!

Now, for a stupid question. And yes, I'm trying to "cheap out". What are the chances I could flush the torque converter? OR, should I just suck it up and buy a replacement?

 

[BrooklynBay]

Don't reuse the old torque converter.

 

[zjrog]

Just asking. I'll go ahead and order one. I also forgot to order bands. And, instead of flushing the stock cooler, I scored a F350 trans cooler to install instead.

 

[zjrog]

On a positive note... The ATP Master Overhaul kit from RockAuto.com showed up today!!! Includes, steel and friction plates for the clutches, seals, O-rings, gaskets and such. Hoping for the overdrive planetary to show up tomorrow or Friday, and bands and torque converter on Friday or Saturday. I probably need to make hard lines for the F350 truck trans cooler as well. Need to finish cleaning parts so I can start putting things back together!!!! Yippee!

 

[zjrog]

Still waiting on the rest of my parts, but I'm about finished with the reverse and forward clutch rebuilds... Wow. This just isn't as much fun as cutting and welding things...

 

[Masterd]

Haven't hit any snags yet?

 

[zjrog]

Yes, I have. Misplaced the book my buddy loaned me, but then I found it and realized why the forward and reverse clutches weren't fitting together. I have to wait on the rest of my parts to get much further in assembly, but have a little more cleaning to do.

I hate waiting on parts.

 

[zjrog]

Will this be an issue? New part doesn't have the "cage" to it...

 

[BrooklynBay]

That cage is odd. Do both planetaries have the same number of gears?

 

[zjrog]

Yes. And I got an email from my buddy, he says that the "cage" was used in the 5R55 for input speed sensor. I just repeat what I'm told. But makes sense to me, 8 slots, 8 pulses per rotation... But yes, it fits where the old one did.

Edit... Besides, the ATSG manual shows the OD planetary without the "cage", as does the Ford manual I borrowed. So I probably had the wrong part in the trans from its previous rebuild (before I bought it...).

 

[zjrog]

So I'm putting this trans back together and I have run into a couple minor issues and one show stopper. First, ALL of my printed references are for NON 4.0 applications. So I spent a lot of time looking for a retaining ring I didn't have to begin with, and realized my output ring gear is different than that pictured. One shows the speed sensor ring in the Euro A4LD(e) too... I have a Ford training manual for the A4LD, but it shows only thrust washers, not any of the needle bearings my trans has. And with that, I have relied on the A4LD diary here for every thing I had questions about. One issue was the oil dam on the output...

The photos in the diary weren't real clear showing which way it sits. The small end faces towards the front of the trans. Minor, I know, but I almost broke it trying to get it seated...

And of course, my picture isn't any better...

The showstopper... I have this needle bearing torrington/thrust washer that I don't know where it goes. I've torn it down and I'm just not sure where I screwed this up. I cannot move forward and my friend I usually ask is out of town...

Its the smaller one in the pic, other parts are for size references.

I had put in the forward and reverse clutch assembly, but it was heavy and unwieldy by hand. So, I evened it out by using the input shaft to get a much better grip...

makes it easier. But its back out until I figure where that bearing goes.

If it weren't for this issue, I'd be done and be putting the trans back in the truck this weekend. So, I hope now to have it back together so I can get it in the truck next weekend. I really was hoping to move forward with the Ranger project soon. I'm picking up a 4.10 gearset for the D30 I'm putting under it, as well as picking up a set of slightly used 33s to slip under it... Now if it weren't raining this weekend, I could be working on my tent trailer...

And another question. I didn't have any Mercon fluid available so I prelubed the friction plates with some Mopar 7176+4 I had on hand. But when I am ready to fill the new torque converter, should I use Mercon or Mercon V? I'm using the waffle style friction, not the spiral new style.

 

[zjrog]

I'm dumb, figured where it went.. Pics later...

 

[zjrog]

OK... I have three parts left. Main case, torque converter and bellhousing. Dummy me, I got rid of the O-rings for the bellhousing bolts... Just why the rebuild kit doesn't have them, don't understand. Live and learn!!! Should have the replacement Orings in the next day or two.

So, I managed to get a better shot or two of that oil dam that wasn't in any of my printed documentation.

On to the bearing...

Now I hope it isn't backwards...

And the F350 cooler I still need to clean...

I had a couple left over pieces from the kit. The 2WD tailhousing seal, and two seals that were identical to others I used. And another question.

Which of the above pan gaskets is preferred? The rubber one, or the fibrous one? The rubber one came with the filter, the fibrous one came with the rebuild kit.

I bought two gallons of Mercon compatible ATF. Might that be enough, or do I need more? I know I need to prefill the torque converter, but will do that just before getting the A4LD back in the EX...

 

[Hitchhikingmike]

bump

 

[BrooklynBay]

The rubber gasket is probably reusable, and doesn't need any paste while the fiber one might need paste. Get another gallon of fluid.

 

[zjrog]

Rubber gasket is new with the new filter. I'll use it. And set the other one aside. I'll get another gallon later in the week... Thanks!

Not sure I want to do this again, but not afraid of the automatic trans anymore...

 

[BrooklynBay]

Install a drain plug in the pan to make it easier the next time. Check # 75 in my list of useful threads for more information: http://explorerforum.com/forums/showthread.php?t=206353

 

[zjrog]

Had to put installation on hold. My wife spent 8 days in the hospital for double pneumonia and a septic infection. She is home now, will be on oxygen for awhile. But she is resting and more comfortable than in the hospital.

This weekend I'm working on my daughter's XJ to get it ready for her long drive for a summer job after school is out next week. I hope to get the trans back in the EX next weekend.

 

[zjrog]

After lots of distractions, and overtime at work, we got the trans in this evening. The trans is connected and tight, the exhaust Y pipe is in and the O2 sensors connected. Considering the mess life has been of late, I'm pretty happy to get this much done this evening.