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Good Afternoon I've been rebuilding a 1993 E40D with a monster transmission rebuild kit and I've gotten to the part where you have to compress the return spring for the Intermediate piston and I am unable to compress the spring enough to install the snap ring. I've tried using a homemade tool inspired by the youtube channel "Transmission Bench" and I've ordered a tool for this but both tools have warped and are unable to compress the piston enough to be flush with the groove for the snap ring. I've already disassembled everything and put it back together in the chance I accidentally added an extra plate or bushing but still the problem persists. Has anyone else run into this problem or have any advice?
Originally Posted by Northumbria;[url=tel:20731067
20731067[/url]]Good Afternoon I've been rebuilding a 1993 E40D with a monster transmission rebuild kit and I've gotten to the part where you have to compress the return spring for the Intermediate piston and I am unable to compress the spring enough to install the snap ring. I've tried using a homemade tool inspired by the youtube channel "Transmission Bench" and I've ordered a tool for this but both tools have warped and are unable to compress the piston enough to be flush with the groove for the snap ring. I've already disassembled everything and put it back together in the chance I accidentally added an extra plate or bushing but still the problem persists. Has anyone else run into this problem or have any advice?
hi, could you send some pics of what parts you need Help with, only so that I know we’re talking about the same thing
Do the bolt holes in the case for the center support line up?
Is the piston for the intermediate clutch contacting the clutch plates?
I use the tool with these, the tool is plastic and bends easily, I have to tap the housing down with the tool adding pressure to get it to go all the way down.
The Bolt holes for the center support line up with the case and I don't believe the piston is touching the plates.
Looking through the bolt hole in the case will show how far I can compress the piston until it gets very hard to turn the tool. Am I just not compressing the spring enough with the tool? I didn't want to resort to percussive maintenance on something of this sort. As I said the tool which is probably very cheap steel has started to warp from the tension.
Ok I remember that part now. Had to make my own tool too. Get it all stacked up and your tool on there, nice and compressed, then you gotta add inward pressure to the tool to get that last 1/64 of an inch to get the snap ring. It’s a little sketchy since we don’t have the real nice expensive tools
Good afternoon to those to whom it concerns, Due to work I have been unable to work on the transmission till now. I decided to try and install the snap ring with just the piston and no spring and even with the piston bottomed out and touching the steel plates the snap ring still won't fit into its groove. Does this mean I have too many plates? I have four steel plates and three friction plates. It is a 1993 E40D, Any recommendations would be greatly appreciated on what could be the cause of the height offset. As you can see in the picture it is just a slight offset that is keeping the snap ring out of the groove.
The intermediate clutch should have a thick plate and three thinner plates with three clutches. The think plate fits into the case first followed by clutch and steel plates ending with a steel on top.
I think some of the think plates have a step across one side of the plate along the outer edge, if you have this kind of plate the step side of the plate goes into the case facing down, maybe you have yours with the step up and its lifting the clutch pack up preventing the snap ring to be installed into the groove in the case.
This side goes into the case first, a clutch disk does NOT ride against this side
Alright I got it. The intermediate clutch pack has different metallic plates that mate to the clutches. Ensure you're replacing the 1 for 1 on thickness. I incorrectly put in ALL thick plates when really I needed two thin, one thick. Since there's so many variants of this trans the kit includes lots of variability.
Cheers!
Alright the way I wrote that could be confusing. In my the whole clutch pack there is a super thick plate like 3/8ths (guessing) that goes in first. Followed by clutch disk, thin steel plate, clutch disk, thin steel plate, clutch disk and a medium thickness disk @ .125" lastly.
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