I cant wait to follow this rebuild.
I had my A4LD, 160K miles, well maintained, (never touched still working when pulled), 93 Explorer trans rebuilt by a guy who had been building Ford autos for HD applications for a long long time.
All hard parts were replaced and every possible update was performed. I dont claim to know much about building a durable A4ld, but I figured I could chime in with my experience thus far.
Transmission was installed in my BII last year, truck was onverted to a automatic at the same time including trucks PCM and necessary wiring. I used the floor shifter from a 2wd 84 BII, Explorer kick down cable and BII floor pedal assembly and master cyl blockoff plate
The Explorer a4ld was fitted with a 84 ranger shift arm, to work with my bell crank and floor shifter.
I cut the Explorer metal lines about 3-4" after they leave the trans & radiator. I flared the 4 end fitting pieces. I got the HD highest temp trans cooler lines I could get, routed the lines through the frame and to the radiator. I mounted a Hayden motorhome trany cooler in series with the stock Ford 3 core aluminum Ex radiator, 11 blade fan and HD clutch. I also replaced the Ford transmission mount and the T case gasket.
The torque converter was tested for hub runout and it was a HD braised unit from a local performance builder.
I believe the front pump seal of choice was a brass unit.
The A4LD works great! I use it or DD, towing, and 4x4ing. 4 months after install it blew a front pump seal.
New seal was pushed in and the converter was replaced, excessive hub runout.
Has been working fine ever since.
I have also added the aluminum pan with drain port and sender port. Autometer phantom trans temp gage.
I use the motocraft A4LD filter and change the fluid regularly.
I do have some sheilding beteen the exhaust and shift solenoids, and the trans cooler lines and headers.
I also purchased the AutoFAB transmission mount (WOW what a difference).
The tempature stays between 135-150 degrees under regular driving, has seen 180 when towing.
I plan to get a better cooler and possibly a aux fan I can flip on.
The trans should hold up, I ma hoping for at least 100K. I see a C5 in my trucks future however (trail rig).
Since my rebuild I have heard stories of the A4ld being rebuilt with all the guts of the later model automatic, and it working very well, while still retaining the computers 1-2 shift, 3-4 shift and converter lock up.
I am looking forward to getting the Apten chip to elp with the shift points. OD is pretty useless on the street in town, with 33's and 4.10 gears a little room for improvement is to be expected. Also the BII floor shifter likes to jump from D to OD wheen wheeling...possibly the bell crank and solid shift linkage with the BII body flex is too much, the Autofab mount helped greatly.
The a4ld can be built to work well and last if cared for, at least thats what I keep tlling myself! hahaha so far so good.....