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Chuzie's '77 Project - Printable Version +- Carolina Broncos (https://cb4x4.com) +-- Forum: 66-96 Ford Broncos (https://cb4x4.com/forum-7.html) +--- Forum: Bronco Tech (https://cb4x4.com/forum-40.html) +--- Thread: Chuzie's '77 Project (/thread-659.html) |
Chuzie's '77 Project - chuzie - 07-19-2008 Looks like I am going to be on hold for a couple of days. My cheap-ass torque wrench killed one of my 1-way clutch outer hub bolts when trying to torque 20ft-lbs. I will try ford and hit the yards. More to come... Chuzie's '77 Project - chuzie - 07-20-2008 I tried the cheap way out and went to harbor freight to get a bearing/bushing tool kit and it only covered a couple of the bushing I need to replace (mostly greater than 1.25" which is the max the Kit will allow) so I am just going to get on the horn tomorrow to either find an automotive machine shop or tranny shop to replace my bushings. I can't justify paying so much money for a proper set when I am only going to use it once (unless I start doing trannies for a living). I also have to find a seal protector for my pistons. I can't get them on there and if I use much more force I am afraid I will cut a seal so that is on my list too. I snapped a bolt in the back of the one way clutch outer hub because my cheap torque wrench is, well, cheap. So I am going to have to find a replacement for it and likely the entire set of 6 since I now have to assume the others are over torqued and just didn't snap. Any suggestion sources please speak up. Let's see what else do I need at this point to finish the build..... -New neutral safety switch -Helical for the pan bolt hole that is stripped -Bushing replacement -Seal protector -Torque wrench that is worth a damn Haven't taken many pics yet but I will before I go back up with the unit. Here is one of the few I have taken so far. FWIW- I have yet to find any mechanical defect inside the transmission that would suggest why I could not sift into 3rd gear. Looks like it must have been the vacuum line. Whoops!!! ![]() Chuzie's '77 Project - chuzie - 07-22-2008 Here is the scoop to date. Paid $45.00 to have all my bushing removed and pressed back into place and to replace the One-Way clutch outer hub mounting bolt that I snapped with my cheap torque wrench. I actually went ahead and bought a full set of six since I should assume that I over torqued the rest and just got lucky they did not snap. Anyway, I started the real build today by installing the two servos and the one way clutch outer hub. Here are some tips I got from the tranny guy today. Make sure you scotch pad the movement surfaces for the o-rings that go to the servos or they may heat up during the break in period. He also caught a mistake I made with the pistons. I installed the wrong o-rings. One piston is supposed to have the square cut ring and the other receives the round o-ring. Don't miss that step. Also, it is easy to get all the o-rings mixed up since a handful of them are similar in size. I would say the best thing to do is to match up and identify the proper new o-rings to the old ones as they come off during tear down to prevent any confusion later down the road. ![]() Here you can see everything is pretty much out of the case except the outer hub in the back and the shift lever on the right side. ![]() Reverse servo installed along with shift lever ![]() Intermediate servo installed. Don't forget to scotch brite the walls and lube the o-rings. ![]() Here are the six one way clutch outer hub bolts I was talking about. ![]() This is the rev-high piston installed in the drum. Careful with that spring!!! I did not really need seal protectors since I lube the seals with petro and was gentle on the install. Remember to make sure you use the CORRECT seals. Chuzie's '77 Project - blazinchuck - 07-22-2008 looking good Chuzie!! great progress Chuzie's '77 Project - johnpaulgolf - 07-22-2008 Nice...keep it up...good tech!!! Chuzie's '77 Project - chuzie - 07-23-2008 So for today I did some backtracking. Why? Well because I completely forgot to accomplish some of the upgrade mods that are typical on a C4 rebuild. Last night I assembled the High/Rev pack and forgot 2 important things. 1.) Install a 5th friction plate instead of the stock 4 and 2.) drill some holes in the drum for faster oil evacuation. ![]() Here is the stock 4 pack with the thick plate at the top and measures about .850 ![]() Here is a set of 5 plates with a steel at the top replacing the thick one and it measures .843. No since I planned poorly I do not have an extra pressure plate and 2 new steels for this mod so I used old ones for the measurement and went ahead and ordered the new ones from Transtar today and they should be here in 2 days. I probably would not have a issue using a couple of the old steels but the old pressure plates were obviously deteriorating and that is unsat for an overhaul. I think I can wait a couple more days for new parts. ![]() Here is the return cooler line in the rear of the case. The typical mod is to clean it out with 5/32 bit and then ream it out with a 3/16 for a larger passage. ![]() So once again I removed the one way outer hub to accomplosh the other 1/2 of that rear mod is to create a 1/16" oiling hole in the case to feed the #9 thrust washer which is notorious for getting spun. The oil is supplied from the same return line in the case that was reamed. I also completed the mod by drilling a 1/8" hole in the thrust washer so it lines up with the hole in the case. You can't tell in the pic but it is chamfered. ![]() This is the #9 thrust washer with the 1/8" hole drilled to match the 1/16" hole in the case in the pic above. ![]() This is the REV/High drum that I had all nice and assembled yesterday. Today I took it back apart because I forgot to drill my 4ea. 5/16" holes. Oh, joy! Now I get to clean it again. looks like I get to make another trip to buy some solvent. ![]() Also ordered my stock TC today and should be here tomorrow. $45.00 ain't too shabby!!! When I get done I will post all my references for the build as well as the mods because God knows I ain't doing this stuff on my own! More to come... Chuzie's '77 Project - bucketobolts - 07-23-2008 Great job! Couldn't have done it any better myself:bdent: Chuzie's '77 Project - chuzie - 07-23-2008 bucketobolts, what is your opinion on my using a steel to cap off the pack rather than machining down the pressure plate? I know your article referenced machining the pressure plate to make room for the 5th disc. If anyone is interested bucket wrote a pretty good c4 upgrade article here Chuzie's '77 Project - johnpaulgolf - 07-23-2008 Chuzie are you seriouly running a C4 ewwwww!!! Chuzie's '77 Project - bucketobolts - 07-23-2008 I have used the beveled inner pressure plate from the forward clutch pack before. They are only $3-4 from a parts house. If you just use a steel it will deflect under pressure and cause the pack to fail. Here is the pick of the mine that I turned down form my transmission. Looks very similar to the inner forward pressure plate. I can't remember the exact thickness of the outer edge. ![]() |