Update

Removed transmission. Forward clutch pack was worn. Ended up replacing all the clutch packs and the bands. Everything else was fine.

Trans back in van and working

 

Time and money wise what did you have invested start to finish with this?

Sounds a lot cheaper than a used tranny with unknown life expectancy.

 

Two years ago my transmission (4R100) overheated (failed fan clutch + 100F day + stop & go driving = overheating trans) and puked fluid. Towed it home, drained what was left, refilled the transmission, replaced the fan clutch and all has been well. About to drain and refill it again, while adding a larger cooler & electric fans and external filter.

When this happened, I began investigating rebuilding the transmission myself (before the trans had cooled and I found out it was still ok), and I realized that there are several updates/mods that a good trans shop will do when rebuilding a 4R100, plus the specialized tools needed. It would have been more expensive, or close to it, after purchasing the tools, getting stuff machined, buying the parts, etc. to do it myself versus having a good shop do the work. Of course, I would have gone with high-end/performance replacement parts, whereas a shop wouldn't unless you asked for them. I've replaced pumps and valve bodies, but I have not opened up an automatic before.

I keep meaning to buy a junkyard 4R100 to rebuild at my leisure, but like most things with me, I just haven't gotten around to it.

-Remi
01 E-350 15-Passenger 20valve
99 ExpyEB 4x4 32valve

 

I figure by the time all is said an done I've got around $1100 invested in this.

This includes all new sensors, shift sensor,shift solenoids. New shift cable. All purchased during my orginal troubleshooting

This is how I lucked out:
Bought a junk yard tranny with 80K, got it home and the tailshaft was to short. They actually gave me a 2003 F-150 tranny not realizing it was wrong. Brought it back with mine to show it was not right. He sent me to the local trans shop. (which happens to be a very reputable shop). After some discussion I chose to have them open mine up since it would be cheaper to do that. A day later mine was ready to go... with a 1 year warrantee to boot, all for the price of a jy tranny.

Since the starter was out and in bad shape I replaced that as well. 9.5 qts of tranny oil later I ran it to NYC (3 hr drive) did 3 jobs and then drove back with no issues.