A4LD help needed, search is making me batty...

[stilllookin]

Good Friday evening all. This is my first post asking for help. Ive been lurking for a year or so and thought I had things pretty well in hand until hitting this latest SNAFU.

I purchased this '92 EB Explorer 4/10 with a bad trans and "bad head gasket" for a project/driver since it was cheap enough. Complete engine rebuild, including reman heads to replace the cracked ones, and transmission overhaul with all the goodies mentioned (within reason) in these forums.

Trans was so messed up I ended up needing hard parts when one of the clutch packs fused together and to the drum (ouch), new Torque Converter, and a new VB since the other was so messed up it couldn't really be saved.

Install all of this into the truck and get started up. Engine runs like a top but nothing coming out of the trans (i.e movement). Top up the fluid more and more until I get a little movement but still not right. Check with mechanic who did trans (good friend and even better mechanic) and it turns out the TC pulled part way out during install and isn't engaging the pump fully.

Drop trans, re-install TC and trans, top fluid up and I have forward gears but still no reverse. Band adjustments are all spot on, servo isn't ****ed in the bore. Did the pump get screwed up to the point I don't have enough pressure? I don't know and have to pull again.

Drop trans and pull bellhousing to inspect the pump and discover that my '92 may not even have the correct pump. From my research and reading the pump should be attached with allen head bolts requiring a 8mm wrench to remove (at least all after '87 are from my reading) but what's there is 6mm.

What is the problem?

Can I replace it with the newer 8mm and my problems go away? is it that the new TC is not engaging the pump because it's for the new pump design and not the older one? (tossed the old TC LONG ago so I can't compare) Any one got a pump alignment tool I can borrow just in case that's all this is?.

I appreciate any help you all can provide.

I've been searching for months and not getting much of a return on those efforts. I just don't want to have to drop this pig AGAIN if I don't have to.

Sorry it's so long but what the hay, first one might as well be a doozie.

Rich

 

[Jack Flash]

you need to check the front pump gears. your description of what happened above sometimes breaks them. I don't see where the type of attaching bolts would make any difference. you may now have metal filings in the pan and/or converter...
.
make sure the converter is filled before installing, too.

 

[stilllookin]

Jack Flash- thanks for the reply. I've pulled the pump down but there aren't any "broken" teeth on the gears. There is a bit of metal in the pan but nothing like I would expect if I had truly broken pump gear teeth.

Is there a clearance spec on the pump gear teeth that I should be checking? I thoroughly inspected the pump rotor and stator and see no scoring or visible damage.

With the high mileage (possibly as much as 200k) would it be prudent to rebuild the pump? Trans was making a whining noise before I dropped it so I still suspect the pump.

Thanks again for the help. I'll inspect again for smaller signs of damage. My eyes aren't as good as they once were.

 

[BrooklynBay]

There are different sizes for the torque converter & imput shaft. Do you know if they gave you the same size torque converter as your old one? The "snout" might be different. This link is in # 9 in my list of useful threads: http://www.sonnax.com/system/pdfs/108/original/TASC-TIP-10-04.pdf?1289926275. # 113 in my list of useful threads states that the input shaft should be 9-7/8" long.

 

[stilllookin]

BrooklynBay- Thanks for the information. I do not have the old converter, it went to the scrap yard a long time ago so I can't compare the snouts.

I measured the input shaft and compared it with the specifications listed in the .pdf from tip #113 and there is a bit of a disconnect. The input shaft measures 10 inches (as opposed to the documented 9 7/8) but only protrudes from the housing by 7/8 inch and not the 1 inch indicated in the article. This is the original shaft from the transmission, it was not changed at rebuild time so I don't understand where the disconnect is.

The PO had indicated the transmission had been "replaced" shortly after they bought the vehicle. I have no idea if it was a JY swap or a shop rebuild. At this point I'm blown away.

Is there somewhere I can look to identify the transmission by casting number? I really don't want to have to put this beast in and pull it again.

Thanks again for the feedback. I'm doing my homework and trying to get this right finally. No sitting on my hands here.

 

[stilllookin]

Well I got it in and working properly finally. It appears as thought the torque on the VB was not right and the fluid was about a quart low, but the combination spelled a no go in reverse. While it was out I performed all the tests I could with air and it passed without issues.

I've got all forward gears and reverse now, as it should be.


Thanks again everyone.

 

[BrooklynBay]

Thanks for the update!