92 XLT A4LD upgrades

[Glacier991]

I have a 92 XLT with about 200K on it, and am planning to rebuild the powertrain, engine back. I'll get into 4.0 engine upgrades, but for now am curious if anyone can help point me in a good direction for trannie upgrades. For example, I understand certain EOD parts can be swappped into the A4LD to strengthen it. I also kno that in 93-1/2 thrust washers were replaced by torrington bearings (whatever those are). I'll be working on it this summer so there is no rush, but when I do a trannie rebuild, I usually find a host of upgrades to make em more bulletproof. Altho... 200K ain't bad. Thanks for any help...

Chris

 

[jon42]

Im rebuilding mine right now(kinda).Ive scoured the net looking for stock parts and havent come accross much in the way of stout peices in the trans parts suppliers.Altho there are racing shops that are out there that have "built"this trans up for competition applications.300h.p was a limit,i read on this trans as the shafts bend after applying more.Yea i heard about the use of "torrington"bearings.Havent figured out yet in what placements they could be applied other than the O/D planet and the forward or or reverse planet assemblies.Probably unless you plan to squeeze the max horsies from your squirel cage, a stock build will suffice.Id be intersted to hear about using EOD parts in this trans.The common melting point of the A4LD used to be the O/D planet in the 85 to 89 trans. Either "makco" or "acerecon"offers a modified heavy duty planet for 90 to 95 a4ld,s.and 4r44e,s.$50 shekels. Chris...keep posting and let me(and everyone looking) what you find.........jon

 

[Glacier991]

Jon.... thanks for the reply. I see a lot of other posts out there as well... but few have any specifics. I was thinking hen i finally get all my homework done I might do a "complete with pics" rebuild for this site to repay the help along the way (like yours). I hear what you are saying on the Torringtons.... I was curious how the internal case dynamics could handle this addition... but then Ford has a way of making changes and not saying much... (like asking you to make your own measuring tool out of a used center support until they made a guage bar in 93 - which almost no one knows about). As I see it adding clutch plates to each pack, improving the valve body for a heavier piston, and MAYBE improved bands (e.g. high perf) and one way clutch and the convertor are about the limits of off the shelf upgrades (with some blueprinting added in). I am going to look into how Ford incorporated torringtons into the 93-1/2 and 94 though. Any other ideas people have are welcomed... this should be a fun project. I'm not looking to make a 300HP monster, just a trannie that does what I want it to for another 200K. As bad a press as the A4LD has gotten, the old C3 was a prety good workhorse. And, as usual, by the time Ford gets it all fixed, someone has to move on to something "newer" to begin the process all over again. Maybe I'll finance this project by renting the tools to others who are frustrated with the trannie shop's rebuilds. <g>

Chris

 

[Glacier991]

Jon... and all... futher post here


My research has suggested the following areas for upgrades to my 92 A4LD (and yes folks remember LD means light duty)

In no particular order:

1. Case center support. It was upgraded in 93 for bearings and not washers. (Maybe this is where the torringtons went). There is an upgrade kit from Aceomatic, and a parallel kit for what is in front and behind. A done deal for me.

2. OD Planetary. Definitely plan to beef this up. Most manufacturers made ths mistake and a lot of trannies later added gears or otherwise beefed up the planetaries. Aceomatic offers one, as does Matco.

3. Valve body. This will be flattened on a flat block, and have a Heavy Duty boost valve from Sonnax added. (Sonnax 39946-02K).

4. I will replace my pump with one from Ford. (Hey it has 200 K on it)

5. There is a TSB on the 1 way clutch, I want to see if there is something here to improve.

6. I am wondering about the governor bore. I have the sleeving kit and apparatus but is says it is for 2WD. Should I resleeve the 4WD ? Can I ?

7. I am looking into beefier bands, mainly for other than low/ reverse.

8. I will make sure I have the latest direct clutch drum, and will add the upgraded set offered by Alto, adding a plate (www.altousa.com) bring it to 7.

9. Will look into external filter, but I question the necessity. I have a stock towing cooler (which is why to me I have 200K on this trannie. I ALWAYS buy the towing package) but again, that will "depend".

10. The comnvertor will get replaced, I am still looking for a beefier built one... there is a place here in Sacramento, called PDQ that specializes in convertor rebuilds that may have one. Ideas accepted gratefully.

11. Curious about my options for the front pump bushing. Sounds like a potential trouble spot.

12. There is a low sprag update kit. Hmmm... bears checking out.

13. The sun gears were upgraded in 93-94. Checking that out, also reverse applicability.

14. Sounds like a new flywheel spacer may be a good idea as a matter of course.

15. I generally think replacing the flexplates is a good idea while you are there.

That is my laundry list for now. I welcome comments, suggestions, additions and anything else.

Oh before I go... on the subject of tools. You KNOW this is a C-3 based trannie when 90% of the tools are 74 Rotunda tools. I have a full tool set for the A4LD (74 and others, including the "new" 93 tools), and hopefully can share what I find "essential" and what I find "nice to have".

Thanks... Chris

 

[jon42]

Hmm.In 93,since they went to bearings on the center support,did they modify the support as well?Would a guy need to purchase a 93 support or would it be possible to just use the older support with the upgraded bearings?A part number chase on this i suppose would tell. My 91 utilizes 3 planets on the overdrive.Am not sure that the modified heavy duty unit im ordering has more than this.I believe that the modified version of the rear planets went fron 3 gears to 6.Or that may be just the difference between the LD and HD trans(4x4).I read somewhere they went from an aluminum carrier in this position to steel in the later years.Chris...inspect the O/D drum where the front pump seals ride.Mine has 125 K on it and i found grooves from seal wear. severe. I found the clutch upgrade as well,(going from 6 frictions to 7).I see that the older a4ld,s had 2 frictions in the O/D drum and 3 in the newer.The more the merrier in the other clutches ...id say.You can go kevlar lined frictions for over kill too.The govorner is a small chunk of metal...does that mean inexpensive as well?If so (and you got the peso,s).a new one would ease your conscience as this device is responsible for shifting irregularities among many an A4LD owner. Another area of wear that is critical to determining weather to use your original case is the back of the trans where the govorner body seals ride in the case.The seals are steel in this application and the case is aluminum. Converters.....grow on trees but healthy ones from specialty shops...spendy. when my front seal puked it wiped the front bushing.Went to a trany shop to get one as ford doesnt seem to have a part number for this .The mechanic just threw a grey colored metal one at me(i forget the name of the metal...same as crank bearing material)But i found there are about 3-4 different types.either spliced or one peice in either bronze? or the other grey metal.(your a mechanic ..you know what i mean).Ive never worked on a C3 but when i rebuilt my A4LD(the 1st time) I used about 2 sockets ,a allen wrench and a screw driver....oh and had to buy snap ring pliers for 1 snap ring....that was it.I centered the front pump by wraping a peice of tape around the converter snout to center the pump onto the bellhousing.when i disassembled it 150 miles later ,there was no rubbing as if off centerd.So it seem to work.Just have to account for the oil clearance here i believe.(but i would have used the centering tool ...if i had it) .........jon

 

[SteveVB]

Originally posted by Glacier991
Jon... and all... futher post here


My research has suggested the following areas for upgrades to my 92 A4LD (and yes folks remember LD means light duty)

.

2. OD Planetary. Definitely plan to beef this up. Most manufacturers made ths mistake and a lot of trannies later added gears or otherwise beefed up the planetaries. Aceomatic offers one, as does Matco.

The upgraded OD planets usually have the race welded, the ATSG update book describes a billet piece but I have had no luck in locating. I have reference to a stronger OD planet in a web write up, but no details



3. Valve body. This will be flattened on a flat block, and have a Heavy Duty boost valve from Sonnax added. (Sonnax 39946-02K).

Both Trans Go and Suoperior have shift improvement kits for the A$LD. They appear the same - except that the superior includes 20 clutch springs and some kits include a steel Boost pressure valve and spring- I dont htink it is the sonnax one. Sonnax syas theirs is annodized alum. Sonnax has the Boost Pressure Valve and sleeve also available in oversized. They have a few part numbers for the valve I havent sorted them all out yet. The info I have gathered seems to say replace the sleeve and valve during the rebuild.



4. I will replace my pump with one from Ford. (Hey it has 200 K on it)

5. There is a TSB on the 1 way clutch, I want to see if there is something here to improve.

6. I am wondering about the governor bore. I have the sleeving kit and apparatus but is says it is for 2WD. Should I resleeve the 4WD ? Can I ?

]I had the same question, the sleeve is steel replacing the stock aluminum bore is that correct? Sonnax seems to make parts for the problem areas so I can't see why this wouldnt be a good upgrade.



7. I am looking into beefier bands, mainly for other than low/ reverse.

8. I will make sure I have the latest direct clutch drum, and will add the upgraded set offered by Alto, adding a plate (www.altousa.com) bring it to 7.

Also a possibility to use later model waffle or spiral type plates for greater holding power - I have been told that the clutch plates from the 4r55 or 5r55 drums will work. I dont know whether this is better than the Alto Power Pack or not.



9. Will look into external filter, but I question the necessity. I have a stock towing cooler (which is why to me I have 200K on this trannie. I ALWAYS buy the towing package) but again, that will "depend".

10. The comnvertor will get replaced, I am still looking for a beefier built one... there is a place here in Sacramento, called PDQ that specializes in convertor rebuilds that may have one. Ideas accepted gratefully.

www.protorque.com not cheap but recommended by the english guy who runs 500-600 hp thru his A4LD



11. Curious about my options for the front pump bushing. Sounds like a potential trouble spot.

As you know it is machined in place - an exchange bell housing is the way to go IMO here, and with the number of front pump seal leaks reported after a rebuild, the pump (your #4), bushings and crank bushing (your #14) should all be replaced in a rebuild


12. There is a low sprag update kit. Hmmm... bears checking out.

13. The sun gears were upgraded in 93-94. Checking that out, also reverse applicability.

14. Sounds like a new flywheel spacer may be a good idea as a matter of course.

mandatory in my view


15. I generally think replacing the flexplates is a good idea while you are there.

That is my laundry list for now. I welcome comments, suggestions, additions and anything else.

Oh before I go... on the subject of tools. You KNOW this is a C-3 based trannie when 90% of the tools are 74 Rotunda tools. I have a full tool set for the A4LD (74 and others, including the "new" 93 tools), and hopefully can share what I find "essential" and what I find "nice to have".

Thanks... Chris [/QUOTE

 

[Glacier991]

Steve...


Very helpful reply. Hang in there and let's try and find the "ultimate" possible rebuild. I'm still on training wheels here and you sound like you have been there. I guess my only hesitation is making folks who wanna rock carwl thin we are gonna fix all the problems of using a light duty trannie on a HD application.

I just want to do a quality job that equals to exceeds OEM specs when I bought it. Your help is appreciated.

Chris

 

[Glacier991]

Latest additions...

First the waffle or spiral plates in this app are not recommended I am told, too grabby.

It is suggested you replace the 3-4 shift solenoid with a new design, Ford E8T2-7M107A

There is an updated OD spring retainer. Ford E5T2-7A527-A. Better safeguard against losing a retaining spring clip.

ALso saw a recommendation to replace the low/reverse servo "o" ring with an older model C-6 seal, a double lipped lip seal as I uneratand it. I wanna see what Transtec offers here first though.

The torringtons come is various sizes for spacing purposes on the center support.... has be wondering about other possible applications... pretty thin little devils.

Anyway, that's the latest. I'm about ready to assemble a pricing list and supplier list.

Chris

 

[jon42]

Just found an upgrade at "acerecon" for the thrust washer to bearing upgrade on the center support...no price given tho