A4LD No Overdrive after Rebuild Kit, HELP!

[Mikee]

I have a 1993 Ford Explorer 4X4 with the A4LD transmission. I installed a rebuild kit recently and everything seems OK except the Overdrive section does not engage when shifted into overdrive. When I shift to OD the vehicle tries to move the vehicle on level ground only but it is not engaging fully enough to drive the vehicle. I adjusted the OD band to two turns CCW from 10 ft-Lb tight that did not seem to change anything. I have a feeling that the reversing clutch in the OD section may be installed backwards, but I thought I installed it in accordance with the ATSG Technical Service manual (27Y02) instructions. The bearing has a larger OD lip (retainer) on one side than the other. I currently have the clutch installed with this large lip of the retainer facing outside the overdrive center shaft gear it rests into. Is there any definite way to tell if I have installed the one-way clutch backward? Would the other gears1-3 and reverse still work normally if I had the OD one-way clutch in backwards? Do you have any other suggestions of things I can check before I un-install the transmission again? Thanks for helping this new member. Mikee

 

[Jack Flash]

did you replace the OD sprag or take it out for some reason ? the only thing that I can think of is the sprag was put in backwards. without having one to check against, I don't remember which way (direction) it is supposed to hold.

if my feeble mind will remember to look tomorrow, I have one out on my work bench. if nobody beats me to it, I'll post which way it holds/releases.

if I remember right, this was addressed in the A4LD rebuild by Glacier. it's a long read, but I think it's in there somewhere.

...........jjf

 

[Mikee]

Still need help with A4LD Overdrive problem

Jack,
Did you have a chance to check your work bench to see which way the overdrive clutch goes in? We will be removing the transmission today and try to put the clutch in the correct way.

The ATSG Technical Service manual that I used during the rebuild read; " a. The one-way clutch assembly MUST be installed into the centershaft in such a way that the flanges of the inner and outer cages are toward the overdrive planet assembly which is toward the front of the transmission." This was not how I remember the clutch being installed when I took it out of the overdrive center shaft but I installed it according to the above instructions.

Another note in the same ATSG manual read; "b. The overdrive clutch washer, that is positioned between the overdrive planet carrier and centershaft must be installed in such a way that the "recessed ID" faces toward (not against sprag clutch)." My washer could not be installed this way because the 6 built-in tabs on the washer prevented it from being installed with the recesses ID facing forward. So I installed the washer with the recessed ID facing toward the rear of the transmission (the way it was during removal). The snap ring on the overdrive ring gear could not be installed unless I installed the washer with the recessed ID facing the rear of the transmission.

Another interesting thing in the same manual that reads; " PROPER ASSEMBLY BUILD UP CHECK CENTER SHAFT TURNS CLOCKWISE WHEN HOLDING OVERDRIVE PLANET ASSEMBLY" This drawinge shows a picture of some hands holding the overdrive ring gear (marked turns clockwise) while the center planet assembly is being held from rotating. I am pretty sure we did this test but something went wrong somewhere.

Anyway, From your response to my question it sounds like I did not put the clutch and possibly the washer in properly. At this point, I am getting brain burnt trying to solve this simple problem.

The vehicle actually belongs to my grandson and I thought it would be a great experience for him to learn how to jointly rebuild the transmission with his aging (67) grandfather. One of those memory building things...

So today, he and I will take the transmission out again and wait for your (and others) response to resolve this problem. Thanks to everyone for the help. Mikee

 

[Jack Flash]

I'm like the rest of the world, I like to know how some of these repair questions are resolved. Mikee emailed me the final outcome on his OD problem. The sprag was in backwards !

I have done everything wrong that a human can while working on vehicles. I can only guess that I've been lucky and never put a sprag in backwards. The answer to Mikee's inquiry made me read and think for a while.

glad the outcome was positive !

....jjf
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