4r100 rebuild
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Junior User
Joined: Mar 2008
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4r100 rebuild
My dad just bought a 2000 f350 single wheel 4x4 with a 7.3 litre. He doesn't have much money so he and I had been looking for a really clean truck with some mechanical issue. The one we found has no foward except manual low. I have rebuilt several of these transmissions in stock form because I work at a ford dealer but would like to build this one to last. As i said at the start he doesn't have all that much money or he would just buy an already built one. I want to incorperate all the tricks i know with as much knowledge as i can find i read an article from diesel power about the john woods build up and found some good info. I have read that a good shift inprover is vital. I am trying to decide about the tugger or the sonnax. I also want some suggestions about the clutchs I was reading about the single sided frictions and them having 30% more holding power but how do they hold up. Any suggestions would be of a great help. sorry for the long winded post just want to get all my ducks in a row before i get started.
More Turbo
Joined: Feb 2004
Posts: 643
Likes: 3
From: North Branford
Sonnax and Trans Go offer really good kits to fix the issues associated with the 4R100. Sonnax you play with springs and shims. Trans Go you play with drill bits and springs. 
If you use the Tran Go kit, replace the spiral lock snap ring with the Sonnax equivalent. Much better part.
If you use aftermarket frictions, follow the manufacturer specs. Ford spec can be to sloppy.
Another part to attack is the low reverse clutch pack. Its to sloppy. You can thicker steels, or add a friction and steel. Adding material to the stack will require machine work to the pressure plate. 020 to 040 for clearance works well.
Here is a couple of parts sources.
www.racerxautomotive.com
www.tranmissionpartsusa.com
If you use the Tran Go kit, replace the spiral lock snap ring with the Sonnax equivalent. Much better part.If you use aftermarket frictions, follow the manufacturer specs. Ford spec can be to sloppy.
Another part to attack is the low reverse clutch pack. Its to sloppy. You can thicker steels, or add a friction and steel. Adding material to the stack will require machine work to the pressure plate. 020 to 040 for clearance works well.
Here is a couple of parts sources.
www.racerxautomotive.com
www.tranmissionpartsusa.com
Lead Driver
Joined: Jun 2003
Posts: 8,298
Likes: 25
From: Damon (South East Texas)
I used Alto Red Eagle friction discs, with hardened splines for longevity, in my 4R100. I was told you can use a snap ring from the 5R110 on the L/R clutch pack. It is thicker and will remove the excessive clearance from the stock clutch pack thickness. I wasn't able to acquire one for mine, but mine worked out fine anyway. Here is a link to some of the mods that I did when I rebuilt mine earlier this year. 4R100 Rebuild and Upgrades pictures by mueckster - Photobucket I used the TransGo E4OD-HD2-D reprogramming kit, along with few other mods that weren't included in the kit. The 4R100-HD2 Tugger kit includes some of the mods that aren't included in the H2-D, but I took them a few steps further in the upgrades. If you have any questions, feel free to PM me.
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Joined: Feb 2009
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Everyone pretty much buys a BTS or a John Wood sorry man. We can't all be like Roland and mastermind our own trans builds 
He is definatley one of the best sources for you as well as Kovalsky.
He is definatley one of the best sources for you as well as Kovalsky.
Senior User
Joined: Jan 2009
Posts: 353
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From: elk plain, wa
i would go with the tugger shift kit we install them at the dealer for customers on rebuilds and every one has been really happy with it and also i would look for a kit that uses more frictions then the stock tranny uses and a good site to get after market clutches is CT POWERTRAIN PRODUCTS Home Page this is were we get our parts for the rebuild and on the 2000 you will need to upgrade the intermediate one way and hub to the newer 4r100 one way also if you have the money i would upgrade the convertor to a after market one cause the factorys come apart which you probably already know about
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Senior User
Joined: Jan 2009
Posts: 353
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From: elk plain, wa
[quote=1973dieselhighboy;9521128]i would go with the tugger shift kit we install them at the dealer for customers on rebuilds and every one has been really happy with it and also i would look for a kit that uses more frictions then the stock tranny uses and a good site to get after market clutches is CT POWERTRAIN PRODUCTS Home Page this is were we get our parts for the rebuild and on the 2000 you will need to upgrade the intermediate one way and hub to the newer 4r100 one way also if you have the money i would upgrade the convertor to a after market one cause the factorys come apart which you probably already know about and also planetarys if you have the money and are wanting to build the engine up
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Lead Driver
Joined: Jun 2003
Posts: 8,298
Likes: 25
From: Damon (South East Texas)
Here is also another good kit 4R100 Rebuild Kit Super Heavy Duty 1998 & Up 4 Wheel Drive Regular And Super Duty (Gas & Diesel) :: 4R100 ---- E4OD4R100.COM :: Ford Rebuild Kits :: Pro-Built Automatics that is pretty complete; includes steels, bushings, and quite a few more parts. It also has the Tugger kit with TC lock-up valve. I didn't use this kit, but it contains quality parts for a good solid rebuild. I chose to buy some of my parts and upgrades individually to strengthen the areas I was most concerned with.
Hotshot
Joined: Jan 2002
Posts: 17,988
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From: La La Land
..... a good site to get after market clutches is CT POWERTRAIN PRODUCTS Home Page this is were we get our parts for the rebuild
How's their customer service, otherwise...?
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More Turbo
Joined: Feb 2004
Posts: 643
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From: North Branford
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