A4LD rebuild progress

[Chrisman889]

Needless to say this rebuild is moving very slowly. Today I did manage to rebuild all of the clutch packs and came across one problem. The first drum that comes out, which is the OD drum I believe, has the steel plates that go in between each friction wheel. On the bottom, as you are resembling the "pack" is one thicker steel plate and then the very top is thicker as well. I noticed the very last steel, the thick one, had a black burn mark on it and was ridged on both sides where it looked burned. The rebuild kit I got did not include those thick steels just the thinner ones that go in between each friction plate. See following pics. Turns out that 3 of the thinner steels is equal to the thickness of the one thick one. My question is can I just put 3 thinner steels in there to replace the burnt and possibly warped steel? Or should I try to order a new one at the proper thickness, I myself don't see a problem but there may be one. Notice these following pics, maybe you can see the burn mark.

 

[Chrisman889]

Also, do all those friction modules have to be lined up exactly, with all the tabs lined up?

 

[BrooklynBay]

Don't add too many friction plates. The pictures didn't show in the first post. The plates should line up, but if you didn't do it, you will have to turn the drum while trying to install it to seat correctly.

 

[Chrisman889]

I'm adding the same amount of friction plates. It's the steel plates, there is a thick steel plate on the bottom and on the top of the stack. Im just wanting to put 3 of the .065 width steels together(no friction plates in between) to replace the one thick steel which is probably around .195. It's the final steel that you put the snap ring in. Are the pics showing now?

 

[JK080]

That drum sounds like it might be assembled incorrectly from a previous rebuild, I have never seen a pressure plate on the bottom of one of these. I would like to see the pictures if you could get them to work. The overdrive drum should have 3 steels and frictions and then a thick pressure plate on top. With around .030 clearance.

 

[Chrisman889]

That's exactly what it has, I wasn't sure about the bottom plate since I could never get it out, no dental picks at this time. It just may be a thin one. I think I should be fine with the 3 steels put together since it gives just about the same clearance as the other drums all assembled. I'm having a hard time with the pics for some reason.

 

[BrooklynBay]

Click the go advanced icon under the quick reply box then click manage attachments to upload the photos directly to a post.

 

[Chrisman889]

I guess I don't have those privileges, to post attachments. I may just order a new pressure plate instead of chancing it.

 

[PopRichie77]

BrooklynBay---Correct me if I am wrong, but it sounds like he did not remove the piston and replace the seal??

 

[Chrisman889]

BrooklynBay---Correct me if I am wrong, but it sounds like he did not remove the piston and replace the seal??

Piston? In the OD drum? I was unable to remove the bottom pressure plate, is there a seal under there like as in the forward drum?

 

[PopRichie77]

I may not be understanding correctly but if your putting clutch friction and steel plates in, then there is a piston under them for clamping them together.
Picture of what you are doing would be great.

 

[Chrisman889]

This is the OD drum after I reassembled it.

This is the pressure plate that is burnt. It goes on top of the stack of steels and friction plates.

OD drum with no steels or frictions, the bottom pressure plate doesn't seem to want to come out.

A better pic of the pressure plate, there is an actual ridge burnt into it.

 

[Chrisman889]

As far as I can see there is only one more thing to come out of that drum, and that is the plate holding down the springs.
I'm also really curious about what could have caused that much heat for that pressure plate to change color and produce a bur like that. It almost reminded me of a brake rotor that had been ground down with bad pads.

 

[BrooklynBay]

Remove the inner snap ring.

 

[JK080]

It looks like the overdrive planet was hitting the inner edge of that pressure plate, thats what caused those heat marks.

Take a side and top pic of the overdrive planetary.

Once you get that snap ring that holds those springs down out of the drum there will be a piston at the bottom of the drum, you should remove the piston and clean it and replace the two lip seals on the piston. All three drums are like this.

 

[Chrisman889]

Yes I did that on the forward drum. Now I need to go buy a spring compressor or make one. I did get the superior shift kit with the red springs for the reverse drum so I will need one anyway.
However my original ? On this thread was whether or not I could replace that burnt pressure plate which is .200 thick with 3 of the clutch steels which are .065 each which comes out to be .195 thick. Or do I need to buy a new pressure plate? Thanks for the Photobucket tip BrooklynBay, and all the info you have given in the past. Same to Jk080.

 

[BrooklynBay]

Make sure that you install the inner & outer lip seals in the proper direction.

 

[Chrisman889]

You can definitely see the wear on the planetary.

 

[JK080]

Couple of things, make sure the bushing or bearing is good in the tip of the output shaft and check the tip of this shaft for wear.

Check the inner lugs in the drum where the flat washer rides in the lugs, make sure they are not too hammered. It hard to see in the pic.

This washer can be flipped over and use the unworn edge if its worn.

These are things I have seen that will allow the planet to contact the plate.

You should replace the plate if you can, but it just needs to be flat, you could see if you could flat sand it and see if you can clean it up.

The planet looks like it was hitting the old steels too.

 

[Chrisman889]

My output shaft doesn't look like that one above. Mine looks pretty good though. Do you think I need a new planetary? Should I sand mine down to make it smooth again, where it was rubbing the steels. I did get a rebuild kit so there are all new steels.

Are you talking about this brass race inside the drum?