Local remodeling contractor contacted me about rebuilding the transmission on his regular cab F-150 with a 4.2L V6 and 310K on the odometer. It had no movement in forward, but worked fine in reverse. He had it towed to my shop and I got started on it the next day. I found the transmission had been serviced at some point and the filter had separated from the o-ring and was laying in the bottom of the pan. The forward clutches were worn to the point there was no cross hatch pattern left. The forward clutch piston lip seal was cut and the OD band was burned and cracking from heat.
Full rebuild was done with new clutches, OD bad, seals, gaskets and Motorcraft filter. One of the upgrades I did on this rebuild was to replace the factory EPC solenoid. The upgraded solenoid was originally used in 5.4L trucks and is capable of producing more line pressure under load.
The valve body was rebuilt, new Sonnax shift valves were installed and a very mild Jmod was performed for crisper shifts;
hole 1 .160"
hole 2 .078 - 5/64"
hole 3 .180"
hole 4 .093"
hole 5 .093" - this hole was not drilled from the factory
hole 6 .160"
hole 7 not drilled
hole 8 not drilled
hole 9 .125"
hole 11 already a large slot from the factory
Transmission was assembled with a new Motorcraft filter and I replace the factory transmission pan with a Dorman pan equipped with a drain plug.

 

Nice. Did you use the solid teflon seals or the scarf cut seals for the direct clutch?

 

I use the solid teflon seals on all my rebuilds, they last much longer and seal much better. Even bought the special tool to install them.