The shifter shaft for the A4LD (and several other) Ford automatic transmissions has a two-part seal - metal and rubber - to prevent leaking of ATF from the transmission case where the shifter shaft assembly goes from inside to outside of the tranny to connect to the gear shift cable assembly.
The photo below shows the bore of the A4LD transmission case (driver’s side) where the shifter shaft seal is located.
To replace this seal, which is almost always necessary after removing the shifter shaft assembly, as the sharp edges of the groove in the shift shaft usually cut off the sealing lips of the shift shaft seal, a seal driver is needed for installing the seal. Having learned the hard way, a hammer and plate won’t do the job. The seal driver is not cheap (prices as high as $83.00) and being a tightwad, went the home-made route.
With a hacksaw, cut a 1-7/8” long piece from 1-1/4” diameter steel bar stock and a 1/2” long piece from 3/4” steel bar stock found in junk box.
Faced the ends of the 3/4” diameter piece on the milling machine to get square ends and a smooth surfaces on the ends.
Drilled a 1/4” diameter hole through the center of the 3/4” piece, and used a 1/4” diameter bolt and nuts to hold this assembly in a drill press chuck. With the drill press running, used a file to reduce the diameter from about 0.750” to 0.742”, for clearance with the bore shown in the photo above. Used a fine emery cloth section to polish to the final diameter.
Faced the ends of the 1-1/4” diameter piece in the milling machine to get square ends and smooth surfaces.
With a propane torch, using 95 % antimony 5 % tin acid core solder, soldered the two pieces together so the about 1/4” of the 3/4” diameter piece sticks out from the 1-1/4” diameter piece.
The best way to get the solder to “wet” the surfaces of the steel parts is to clean the surface down to bare shiny metal and then scrub the surfaces to be soldered with lacquer thinner to remove any traces of oil or grease. REMEMBER THAT LACQUER THINNER IS EXTREMELYH FLAMMABLE AND CAN IGNITE EXPLOSIVELY. Please read the label on the container for safety practices.
Sorry, no photos taken during making of this tool.
The finished driver is shown below………..
The following photo shows the seal driver at work..
For the application of this seal driver, click to the following link…….
http://www.explorerforum.com/forums/showthread.php?t=227701
....