Thanks for the post.
The direct Drum is covered in Thread #5 (link below).
I have decided to stop the rebuild until I can get and install the solid teflon O-rings on the output shaft where it enters the direct drum.... (Accomplished)this is apparently a source of trouble... the direct drum not holding due to lack of pressure - or more appropriately leaks. Today I found a source for solid seals and the tool to install them. So I have them on order.
Also, I have been fretting privately about the "governor" bore (end case bore) on the case. This is where the steel rings on the output shaft seal ride, and between those rings the direct piston gets its feed. A leak there could result in a less than fully positive lockup in that clutch - and that clutch is a weak link in many failures. I decided to go ahead buy the tool to sleeve the end bore in steel.
Well to jump ahead in time the tool arrived. It is a spitting image of the same tool I used in the rear case of the A4LD. Here is what i bought off of E-bay... $475 retail I paid a fraction of that:
This enlarges the rear case bore to accept this steel sleeve
Which is either driven or pressed into place using this tool (shown with the sleeve on it)
and the oil feed hole is renewed using this long drill bit up through the new bushing
another look at the "business" end of this boring tool
You can see the bolts that attach to the case.. I will post pix here of that process...
Here is what the bore looks like before the bushing is pressed in
You put the bushing on an installer... you can pound it in, but since I have a press I will press it in...using red locktitte.... more pics to come of that process..
Here is the sleeve pressed in.... I didn't photgraph the process...it was mainly put the bushing on the installer, align it, and press it in. Pretty easy all in all.
Now we need to drill 2 holes into it. Here are the "tubes" leading to where it needs to be drilled
I'll squirt some cutting oil into each
Then I will drill them....
Until I break through... (bad pic sorry)
Then blow the bore out.... cleanup time...
Looking down this bore - daylight!
I will do the same with the other one and when I am finished I now have 2 holes in the sleeve:
Notice the burrs? If not try this view...
I used a knife to deburr them, the used 320 grit paper and finally scotchbrite.... all ready !
Actually, as i did these photographs... I noticed the bright line at the top of the right hand hole (In the initial hi def photos)... it was looking like a burr I might have missed.... I went back and rechecked and sure enough a SLIGHT one was there. I redid it with a knife and paper and scotchbrite and now it is fine. (Tranny building is all about attention to detail).
So, the case is ready. GUTS time when they are ready to go in!
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Direct Drum comments:
Your advice about splines there is a good one. Those are pretty shallow splines. Since I am using new that is not a worry, but if you reuse, check carefully.
The 1-2 aluminum accumulator piston was replaced by a completely different one. I have pics of the new one in the accumulator section. I am still futzing about the 2-3... will post my findings there when I am more confident.
I thought in a year I had assembled more or less everything and my investigation was mostly complete, but as I start the assembly.... I find out where my knowledge is spotty or just plain non-existent.
The TCCOA website has been a great help, but in just 6 years, I am finding it a bit dated in some areas. But then, discovery, and investigation is part of the fun.
Like you, I also understand that in '98 the frictions became more or less as good as they get. That has been troubling for me in some of the upgrades, especially since like in the direct the new stuff is non grooved and the steels are thinner. I have not yet soaked the Kevlar OD yet either.... I am really on the fence with that.
I do notice that this Diary is not very interesting to most folks on here - compared to the A4LD and the valve body rebuild diaries. But I wanted to do this rebuild, and so the info will be there for those who want it. I can imagine in time a lot of non-explorer folks may find it useful.
Anyway again thanks for throwing in your experiences and thoughts, they are an excellent and much appreciated addition.... please feel free to chime in anytime you think I miss the mark in/during the rebuild, or if you have questions etc.