maintenance suggestions for used A4LD while out of X?

[saxon]

maintenance suggestions for used A4LD while out of X? (Servo & Governor upgrades)

I'm pulling a known good A4LD from a 1993 EB 4WD and installing it into a 1991 EB 4WD.

I remember reading that there are a pair of servos that can only be replaced when the transmission is out and that the governor can only be replaced when the transfer case is off.

I'm planning on replacing the low/reverse servo seals (the updated kind: http://www.transmissionpartsusa.com/A4LD_4R44E_5R55E_reverse_servo_d_ring_kit_p/230-00023256k.htm), and the following 'new' (3 week old, zero miles) parts pulled from my broken A4LD: the OD and TCC solenoids, the transmission modulator valve, and the Sonnax manual sleeve indexer (http://www.transmissionpartsusa.com/A4LD_Manual_valve_index_sleeve_p/400-005694701.htm.

Should I have a go at the other two servos and the governor while the transmission is out?

Seems like a convenient time to do so but I also don't want to throw $ at a non-problem.

 

[BrooklynBay]

You could upgrade the governor with the Sonnax part: Governor weight 56615-35 35 mm ($4.46). those servos are a good idea to replace. The largest size to date are the ZC (plain cover that looks a little different than the regular one). Here are some part numbers: 23963A 4R44E, 5R55E servo piston (ZC-2.314") 1997-on ($9.52). Servo Overdrive Piston (5R55E) 2.330" Diameter. 3011 1997-98 2473015. Servo Cover - Intermediate/Overdrive (largest ID of all covers) 3021 1995-UP 2276021. Servo and Cover Assembly - Largest Apply Area (firms shift) 1985-94 2273001.

 

[saxon]

follow-up questions on OD & Int. Servo selection

I found the ZC 2.314" 5R55E servo piston to be used in the OD location: http://www.transmissionpartsusa.com/4R44E_4R55E_servo_piston_ZC_1997_on_p/230-00023953a.htm

I also found the largest Servo Cover sold by these guys (also 2.314"): http://www.transmissionpartsusa.com/4R44E_5R55E_Servo_piston_cover_2_314_p/230-00023970g.htm

Nice description of the Sonnax servos: http://www.transhardparts.com/parts/parts/56528M.htm

Glacier991 recommends re-using the stock size 2.100" AB cover and buying a new stock size servo piston for the intermediate servo. http://www.explorerforum.com/forums/showpost.php?p=1410781&postcount=52. Is that a correct understanding of the exterior servo upgrade?

but, I am alas, still confused. I don't have the update manuals handy so what I'm confused about may be in those; anyway,

If I am using the 2.314" cover for the OD servo, don't I then have to use the 2.314" servo?

If I can find the largest size 2.330" servo, I would then need to find a 2.330" cover, wouldn't I?

If I've completely misunderstood, feel free to throw correction my way.

Why would I want the 2.330" servo anyway? Firmer shifts? I'm towing a trailer with 2 motorcycles - I don't want the shifts to be too firm and yank the bike too hard (although they feel like mush now; I had difficulty in feeling any of the shifts when I drove the '93 home).

The Sonnax governor part you mentioned isn't listed by Transmissionparts.usa but they will probably upload the part no. when I call them tomorrow. http://www.transhardparts.com/parts/parts/56615-35.htm

Finally, Glacier991 mentions an upgrade spring for the Governor (the whimpy of the two springs in photo no. 1): http://www.explorerforum.com/forums/showpost.php?p=970081&postcount=20. However, I cannot find mention of where he found that spring. I will ask transmissionparts.usa when I call them tomorrow.

Anyone? Brooklyn? Glacier? Brain?

I'm not going to install my extensively rebuilt valve body (from the "always forward" 1991) just yet; I want to feel what a "before and after" is like. This fall when the racing season is over, I will change the trans. fluid and swap in the fancy VB then.

Finally, transmissionparts.usa also does not list the gasket between the back of the transmission and the transfer case and NONE of the local auto shops can even order the gasket. Anyone know where I can find that by itself or is that a Ford only item? Once again, I will ask the guys at transmissionparts.usa if they carry that on the shelf and can add it to the on-line database.

 

[BrooklynBay]

I could answer a few question, but not all of them. Axiom, and TransmissionPartsUSA show different specs for the ZC piston, and cover. Glacier pointed out in the end of the diary part 4 what the actual specs are. You are better off getting the matching piston/cover set. Look at post # 2 in this thread for the part #s. The shifts will be a little firmer with the larger piston, because you will have a little more fluid adding apply pressure. It won't make you feel like you are driving a Mustang, but you will feel a firmer shift. The Sonnax governor is a complete part, so you don't have to look for any other springs to buy. I don't know what the part # of the gasket is, but if you contact any place that sells transmission parts, you should be able to locate one. WWW.Drivetrain.Com has break out views of transfer cases. Maybe they might show some parts #s of individual parts. You could do a search on WWW.PartsVoice.Com too.

 

[saxon]

I need to buy two new O-rings for the servo covers, correct?

Do I use the same O-ring w/o regard to what size servo and servo cover I'm using? That doesn't make sense, seems like there should be different O-rings for the different size servos (but as I just mentioned in another post I'm saying this w/o ever having seen an A4LD off the car so maybe this is obvious once you've seen the servos).

This is the O-ring that I think I need two of (ouch, ended in a preposition): http://www.transmissionpartsusa.com/Ford_A4LD_4R44E_servo_cover_o_ring_p/230-00023264a.htm

 

[Glacier991]

The exterior size of the servo covers is the same whether the teeny CB ot the biggest ZC... the innards are hollowed out more for the ZC. So yes they are the same EXTERIOR size. Good idea to replace the O rings.

The return spring for the governor was in the Transgo VB kit.

The larger servo cover will equate to more holding power on the band. I am using ZC in the front (OD) on my A4LD rebuilds and the AB in the intermediate position.

The servo piston and the cap are matched pairs. A ZC cap needs the right sized servo to go in it.

 

[BrooklynBay]

That is the correct O ring in the above link. Before buying individual parts, find out if parts like O rings come on the new covers before you buy them. They are usually found in the soft parts rebuild kits along with other O rings, seals, gaskets, etc.

 

[saxon]

thanks guys.

any ideas on where to get the gasket between the transfer case and the back of the A4LD?

Do I need to buy a basic gasket kit to get that?

 

[BrooklynBay]

I know that they sell the 4X2 extension housing gasket by itself, or in a kit. You would have to check for a 4X4 gasket on one of the parts websites. It might come in a kit, but you would have to specify that you are getting it for a 4X4, not a 4X2.

 

[Glacier991]

I do not think there is any difference between the gasket on the 2 WD or 4 WD models.

 

[saxon]

Wouldn't the back end of an A4LD be the back end of an A4LD? The 4WD would have a transfer case behind it and the 5-speed would have an output shaft and housing, wouldn't they? Bummer that the factory Ford A4LD manual isn't here yet; that should be an interesting read.

I just spent the last 30 minutes making a final shopping list for the new servos, covers, and various external upgrades,... and my browser crashed. Now I'm tired and grumpy. Will post the list tomorrow morning.

 

[BrooklynBay]

I think that Glacier is correct about it being the same gasket. Saxon, you made a point about the back of an A4LD's case being the same dimensions going to the extension housing. The back of the 4x4 housing is bolted to the transfer case. I was thinking about that area if they had a gasket. Here is the information for the extension housing gasket that is between the A4LD, and the extension housing: Extension housing gasket 1985-up 56272 D4ZZ-7086-B 23127 ($0.38).

 

[saxon]

final 'external rebuild' parts list

My final shopping list: (note that I'm using 3-week old TCC and OD solenoids from my broken A4LD so I didn't list the part numbers for those parts here. Also the parts co. in Florida said that there are several different gaskets between the A4LD and the transfer case and that I should either do a relief drawing or bring the t. case with me and go to a local supply shop for the gasket). Wonder if Ford could get the correct one from the VIN?

Anyway, here is the parts list for my 'external rebuild' while the A4LD is out of the car:

Hard parts:

Reverse Servo D-Rings: http://www.transmissionpartsusa.com/A4LD_4R44E_5R55E_reverse_servo_d_ring_kit_p/230-00023256k.htm

Manual valve sleeve indexer: http://www.transmissionpartsusa.com/A4LD_Manual_valve_index_sleeve_p/400-005694701.htm

5R55E OD servo piston (ZC – 2.314”): http://www.transmissionpartsusa.com/4R44E_4R55E_servo_piston_ZC_1997_on_p/230-00023953a.htm

5R55E OD servo cover (ZC – 2.314”):
http://www.transmissionpartsusa.com/4R44E_5R55E_Servo_piston_cover_2_314_p/230-00023970g.htm

Intermediate servo piston (new, stock 2.100” size; re-use the old cover):
http://www.transmissionpartsusa.com/C3_A4LD_4R44E_Servo_piston_AA_or_AB_1974_on_p/230-00023952a.htm

Sonnax flywheel spacer:
http://www.transmissionpartsusa.com/ProductDetails.asp?ProductCode=400-056000CS6&CartID=2

35mm governor Sonnax upgrade weight:
http://www.transmissionpartsusa.com/ProductDetails.asp?ProductCode=400-005661535&CartID=2

Soft Parts:

Servo cover O-Rings (2):
http://www.transmissionpartsusa.com/Ford_A4LD_4R44E_servo_cover_o_ring_p/230-00023264a.htm

trans. Fluid fill tube O-Ring:
http://www.transmissionpartsusa.com/Filler_Tube_O_Ring_p/250-000025266.htm

Reverse/low servo gasket:
http://www.transmissionpartsusa.com/FORD_C3_A4LD_reverse_servo_cover_gasket_p/230-000023128.htm

And some fluid:

LubeGard Black ATF supplement:
http://www.transmissionpartsusa.com/LUBEGARD_Black_ATF_fluid_supplement_p/301-000061910.htm

 

[BrooklynBay]

Most of the time the low/reverse servo gasket is reusable. That picture shows only a governor weight. I thought that they sold the entire governor as a whole. I know that Ford sells a 38 MM weight too, but I don't know if that will interchange with the stock governor housing assembly.

 

[BrooklynBay]

If you are going to drop the valve body to replace the 2 solenoids, then I would suggest that buy a new TCC filter that snaps into the separator plate. Here is the information: TCC filter that snaps onto the separator plate for 1988-up 56712 E8TZ-7N113-B 23330A ($1.95).

 

[BrooklynBay]

Check this link for more information: http://www.explorerforum.com/forums/showpost.php?p=1451701&postcount=5

 

[BrooklynBay]

If you drop the valve body, you will need 2 new gaskets. Here is the information on them: 56287 E8RY-7C155-A 1985-1995 Upper valve body gasket. 56287X 56320AA is .015" thick ($2.28). 56280 E8RY-7D100-A 1985-1995 lower valve body gasket. 56280X 56321AB is .015" thick ($2.28). TransmissionPartsUSA only has the regular ones, and doesn't have these think ones. Axiom has them. They are a little cheaper on WWW.Wittrans.Com. Find out if TransmissionPartsUSA started to sell them, since you are ordering from them anyway.

 

[saxon]

Aaacckkkk! I thought I could swap out the solenoids w/o pulling off the valve body. You would think I could remember that after all the time I spent doing the VB rebuild on my broken A4LD a few weeks ago.

I'm still interested in doing a 'before and after' comparison between the stock VB and my rebuilt and upgraded one; if I have to pull the VB off to swap the solenoids, I will wait for a bit to swap them and will do the VB swap at the same time.

There are no races scheduled for the last weekend of July (one of 3 weekends off between now and mid. Oct.); I could swap the VB and solenoids then if I can't do the solenoids now. I have already have one or two extras of the regular thickness VB and separator plate gaskets.