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This is really strange. So far no help, nobody has ever heard of this happening. The crank in my f100 302 auto is being shoved forward untill the flywheel contacts the flexplate, the thrust bearing has worn out before and the guy I got it from is a old ford mech. He says it was the trans fluid pressure and he has 2 mustangs that have the identical setup tranny and motor. he says he regulated the pressure for awhile but now it is real noisy in rev and it seems only when it gets warmed up. I read a tech sheet on the web that says the crossover exhast pipe is superheating the trans fluid and causeing the tourque converter to bulge. That seems a little off since there is a quarter of an inch before it contacks anything. The article also said that the exhast being there super heats the oil on the bearing and it loses its viscosity. BJ said both the mustangs have the same exhast systems and no problem. He has had them since new in 65. The truck is a 77 with only 65000 on it.
Help!!! I do not want to rebuilt it and have the same hassle again!
Unless your exhaust is RED HOT glowing, i cant see even that causing a problem. Never heard of such a thing, but then again, who knows. If your thurst bearings are bad, is it possible that the torque converter was never seated properly? Maybe the conveter was forced into the pilot shaft hole in the crank? Something is binding somewheres. If you un bolt the converter bolts form the ring gear, you should be able to turn the converter by hand a bit. If you cant, then there is something seriously wrong in there.
If the t/c was seated properly it's possible that something else was messed up in the front pump or something else in that area. Or the t/c has ballooned from some other problem. This is the first time I've ever heard of this outside of a nitrous'ed car with a stock converter.