I've been reading forever. My eyes, back and wrists hurt. My transmission is going out. It's running on the hot side,190-195 just around town. Gets up to 200-210 climbing long grades empty. I have a Derale 180 degree thermostat and a 6.0 cooler. This trans used to run 180-185 all day/night loaded or unloaded. Fluid is not burnt, but it is full of metallic flake. Pan magnet has a gross amount buttery smooth ferrous metal. 207000 miles. Still runs and shifts OK. I was going to order a trans and swap it myself, but then I found the ASTG manual and set of videos by transmissionbench.com. I'm about a week into spending several hours a day getting schooled in the 4R100. At this point I've decided to rebuild it myself with the following parts:

Part Name - Brand - Part Number - Description

Torque Converter - Torco - F60BC LS - Low Stall Billet Triple Disk

Raybestos GPZ frictions - Raybestos - RGPZ-4100 - Performance friction clutches.

Raybestos Kolene Steels - Raybestos - STMFORD07K - This is a Kolene steel set. It was short 1 steel for the forward/direct clutch pack. Order an extra 36126A. It is also short 1 overdrive steel. Order an extra 36120K.

Overhaul Kit - PA Cargo - K36900F - This is the Transtec brand seal and gasket kit. It is supposedly a little better that the Seal Aftermarket Products version.

Kevlar Intermediate Band - PTB - PTB-36320E-K - Not sure why this is better, but kevlar sounds strong.

Solenoid Pack - PA Cargo - 36949B - This is a NEW solenoid pack.

Sonnax O/D locking snap ring - Sonnax - 36744-01 - (Not needed if using the Transgo Tugger Kit) Prevents the intermediate Overdrive Snap Ring from popping out.

Transfer case gasket - Ford - E7TZ-7086-A - Not included in the seal and gasket kit.

Transgo Tugger Kit - Transgo - 4R100-HD2 - A popular choice for this trans. Firms up the shifts and replaces a lot of parts that wear out.

Transgo Lock up Conversion Kit - Transgo - 4R100-LU - Converts the torque converter lock up from PWM to ON/OFF. Less torque converter slip = less heat and wear.

45 Roller Sprag Intermediate - PA Cargo - 36962HD - This is actually made by Borg Warner. Standard replacement on all rebuilds. Heard of the mechanical diode failure. This is the fix.

Intermediate Band Servo Piston Bonded - PA Cargo - 36907E - This is a standard replacement part on all rebuilds.

OD and Coast Clutch Bonded Pistons - ? - K36900-99 - Not sure the brand but this is a standard replacement for all rebuilds.

Filter Kit - Motorcraft - FT114 - A new pan filter.

Bushing Kit - Seal Aftermarket Products - K37980A - The sun shell bushings in this kit were too tight for my output shaft. I'd recommend getting different kit.

Billet 300m input shaft - TCS - TCS-499700 - This new input shaft is good for up to 2000 ft lbs of torque.

Cooler bypass Valve kit - Sonnax - SNX-36605-02K - Used to rebuild the cooler bypass. When this wears out, fluid can bypass the cooler and overheat the trans.

Magnafine Filter - Magnafine - 3/8 inch - Insurance in case I missed any metal sludge in the system. Good preventative maintenance. Get the metal body version. The plastic ones are known to split.

Speed Sensors - FORD - F81Z7M101AA - New input and output speed sensors. Both are the same part.

Torrington Koyo Thrust bearing kit - Sonnax - SBK-F5 - A set of 9 new thrust bearings

Thrust Washer Set - Seal Aftermarket Products - 46470E - All new thrust washers.

Machined Center Support with Sonnax Snap Rings - Custom - I bought this from shiftrite transmissions. It is machined to allow for an additional snap ring to prevent wear. The snap ring part number is Sonnax 36743-02.

EDIT To Add:

Front Lube/Drainback Valve Kit - Sonnax - 36425-01K - Prevents drainback of the front pump. This valve is metal. The stock one is plastic and known to melt if your trans gets hot.

Center Support Gasket - Sonnax - 36743G - This gasket is in the Transtec gasket kit, but the Sonnax one has a ruberized coating on three of the ports to help it seal better and prevent leakage.

Center Support Shim - Sonnax - 36743-01 - Of the three center support bolts accessible from the valve body area, one has a gap between the case and center support. This fills the gap and prevents deflection of the case.

One Piece Rear Case Bushing - Sonnax - 36008 D - The rear of the case has 2 bushings that are known to spin out and ruin the case. This one piece prevents that.

Bushing Driver - Sonnax - T36008A - Required to install the one piece case bushing. Don't try it without it.

Overdrive 12 Roller Cage - ? - 36961C - Most of the time this is reuable, but since my trans had so much metal in it, I decided to replace it. And the cage is plastic and 17 years old.

17 Roller Cage - ? - 36960C - Most of the time this is reuable, but since my trans had so much metal in it, I decided to replace it. And the cage is plastic and 17 years old.

6.0 Transmission Cooler - ? - FO4050104 - I tried to flush mine. Don't do it. Order a new one.

Front Pump - ? - 36500DA - My front pump has excessive wear. I ordered a low mileage used one since the Ford dealer wanted $650 for a new one and its on back-order with no expected ship date.

I've done a few transmission swaps but have never dug into an auto slush box before. I'm going to try and document this adventure as things move forward. I would love to hear any feedback on my parts choices. Thanks.

 

I've not done a 4R100, but used to build Mopar transmissions for street/strip use along time back. Checking clearances & fit, especially when using aftermarket parts, is crucial. Some fit out of the box, but some required extra machining/fettling. Hth

 

When you dig into it you will need a press or a harbor freight bead breaker with some welded fixtures on it to compress the retaining ring. I am sure there are other ways to do this but my grandfather wanted a bead breaker anyways for the 800 lawnmowers and atvs he seems to have in the yard (really only 3)... (SMH) Glad to see you have the spiral retaining ring in there from sonnax. Also the Harbor Freight engine stand works great on saving your back if you don't have the bench space and makes for easy handling and rotation. Look forward to progress updates on your build, It was daunting watching my grandfather do it but as long as you do it in a clean environment, and utilize the info available it should be a cake walk.

 

If you haven't already, watch the Transmission Bench E4OD/4R100 rebuild series on Youtube - . The guy is obviously trying to sell stuff off his website, but the rebuild is very detailed. I just rebuilt the E4OD in my Bronco following this. It wasn't my first auto rebuild (I've done a couple of 4L60Es), but this was by far the easiest because the guy is so detailed. When I rebuilt the 4L60s, I used a youtube video and the ATSG manual. This time, I didn't even bother buying the manual. The guy in this video series covers everything extremely well. The only advice I have is to be extremely organized. It really isn't that hard to rebuild an auto transmission, but there are a lot of parts. The only thing I really deviated from the videos is that I put all my small parts into labeled ziplock bags. In the videos, he just puts them into a couple of boxes. Putting them into ziplock bags helped me stay more organized, and I could see which parts/bolts were which.

Good luck!

 

Meuckster rebuild his years ago. Ill see if i cant find it. He gave some serious details on how-to, parts he'd use and tooling

 

There is some 4R100 rebuilding information in the 7.3L PSD Tech Folder. It may not be exactly what you are looking for, but might help too.

I will be watching this thread for content to add to the tech folder as well.

EDIT: Here is a link from the 7.3L PSD Tech Folder that may be of use... https://redirect.viglink.com/?format...chnical%20Data

 

Thanks for the comments. I've ordered a bench style clutch spring compressor on eBay for the 2 clutch packs that need it. I'm also going to make the tool in the transmission bench videos to remove the pump and to compress something else in the case (can't remember what it is called). The transmission bench videos are what gave me the confidence to tackle this myself.

 

While you have the center support apart. Add Sonnax 36743G Center Support Gasket. Note this might be included with the center support if its pre machined.

Drain back valve Sonnax 36425-01K

To make life easier, use Sonnax piece case bushing.

 

You should also add a bypass rebuild kit. I know Sonnax has one, there may be others.

 

Thanks for that. I overlooked the drainback valve because it comes in the Superior Kit from transmissionbench which I'm not getting. I think this is the only thing that is not covered by the transgo tugger kit. The machined center support comes with a gasket, but I don't think it has the silicone rings added to it like the Sonnax one. I'll add them both to my list.

Thanks. It's on there. I debated going with a bypass delete, but after reading the consequences, I think the rebuild kit is the best route.

Today, I made the tools from the transmissionbench videos, ordered all the parts, and picked up fluid from Wally World.


4r100 Rebuild Stand



4R100 Transmissionbench Tool



Pump Halves Alignment Tool

 

I just rebuilt my 4r100 the week of August 6th according to Jimmy Williams of transmissionbench.com. And Jimmy is right. You can do it. My truck has 334000 miles and developed a leak. At that mileage, it wasn't going to just pull the tranny and fix a leak. I installed the master kit with the Transgo reprogramming kit. The lesson your watching will come on a USB drive with the master kit. And Jimmy answers his phone direct when you call him or he calls you right back direct. Heck of a guy. If you set up a small plywood work bench, you can drill a 3/8 hole thru it and then use a piece of the allthread to compress the retaining springs in the clutch assemblies as needed. Get or have a good set of inside and outside snap ring pliers. The combo pliers will not cut it. save yourself SEVERAL hours of frustration. I bought a small plastic swimming pool to caught the fluid for the tranny during tear out. I really enjoyed rebuilding my transmission and would do it again. I don't know your skill level, but mine would be a bit below average. This transmission never shifted as firm as it does now. I still can't believe I did it. I wish I could come help you. Good luck. PM me if you want.

 

I'm glad to hear you were successful using the transmissionbench videos. That give me even more confidence. Thanks for the tip on the pliers and the swimming pool. I was going to use my snap ring pliers set from HF, but you just gave me an excuse to buy a new tool.

My vehicles only go to the mechanic for CA smog checks. I do everything else myself. That's why I was so torn on taking it in for a rebuild.

 

I can tell by the pictures you posted that you have a transmission jack. (the bag with the chain in it) Mine is a stock 4X4. I drove the front of my truck up onto 2X12s which is on level ground and chalked the rear tires. That way I could still jack the truck up on one side enough to get the tranny out while still on the jack. Try not to man handle that transmission. I bet it weighs 300 plus with the fluid in it and working and working out is not the same thing. And you think you have confidence now, wait till your finished. It's hard to find anybody to do things right. I'm starting the thinking process of rebuilding the engine one day. Best of Fun, (not luck because it works) Enjoy, Take your time, Do not get frustrated, Set your self up for success like your doing, and know that when your finished, that transmission will be better than the day it was made. Helpful video--- Diesel tech Ron 7.3 rear main seal replacement.

 

https://www.ford-trucks.com/forums/1...1-rebuild.html

https://www.ford-trucks.com/forums/1...arts-list.html

https://www.ford-trucks.com/forums/9...-your-day.html

https://s571.photobucket.com/user/mu...pgrades?page=1

 

I believe the video below is the one that @ajbrown208 was referring to.

Also, I have included this thread in the 7.3L PSD Tech Folder due to the fact that there are some great resources of information linked, sited and given in the form of advice. Also, @ebbnflow is on the right track for success and I think he will keep this thread populated with information and pictures that will be a valuable resource for FTE'rs in the future.