I need to rebuild a 904 TF. Is this really as difficult and daunting task as it looks? I'm looking at the 70 plus pictures in this one 'How to' book and I'm thinking,"How will I ever get all the pieces back together and in the correct sequence?"
For those who have done this successfully, what's the secret?

ahtoews@shaw.ca

I is not really that difficult. Follow the instructions in the book, and take it apart into subassemblies. Lay them on the bench in order, with the thrust washers in the correct place. Then dissasemble the subassemblies, and repair.
Charrlie_S

flturbo6@aol.com

Charlie's tip about working with "sub-assemblies" is a good suggestion. There are 3 main areas in a TF which can be delt with in sections, in order of dis-assembly, these sections are:
- Valvebody
- Front pump, clutches and bands. ("friction parts" and seals)
- Rear drive assembly. (gears, sprag & govenor)

Most used TFs can be "freshened-up" without going into the rear drive assembly. Simply remove the valve body and set that aside, remove the front pump and change the clutch packs and bands along with the servo seals that apply the force.

If you want to up-grade to the low first gear or get the 4 pinion planetary gears into the trans, you have to disassemble more (dig in deeper) to swap those parts.

I like to get the trans done in "one sitting" and then do the valvebody as a seperate effort. (usually installing a shift kit)

A key to success is having a clean, open, well lit working space and to lay everything out so you can keep track of the order. Automatic transmissions do not have much in the way of repetitive sub-assemblies so all those individual parts just go together one way. Pay attention, limit distractions and minimize "sitting around in pieces" time. Clean parts are a must.

If at all possible, find a spare trans. to "blow apart" for practice and possible HD replacement parts. (V-8 998-999 are great to use for this "dry run" review)

The tough jobs are replacing the seals in the clutch drums and changing the front pump bushing and then re-aligning the pump halfs. Read-up on these procedures and see if you can talk a trans shop into doing this "bench job" for you. (they have some great tools that really helps)
DD

To realign the pump halves, I do the pump bushing and seal first. Then put the pump halves together with the bolts loose. Put the pump into the empty trans case backwards, this aligns the halves,now tighten the bolts, and remove the pump.

flturbo6@aol.com

So guys in your experience, any special tools you rent or have accumulated over the years to do this job? Taking apart? putting back together? measuring?
Wrt replacement parts, seals, etc, is there a specific 'rebuild kit'you would recommended ?

ahtoews@shaw.ca

Al, some of the bushings can be changed using a cam bearing driver. The cluch pack with the coil springs can be a handfull, I've done it using C-clamps and it's a struggle. Charlie S, didn't you show me a tool you made to compress the springs or was that Chad's creation?
Cecil

ceh52@quik.com

I have a homemade tool for compressing the springs in the clutch packs, it works on all aluminum tourqe flytes, powerglides and, if I remember right the Ford C-4 trans also. I think Chad has one also. I use thin, about .005 thick feeler stock to work the clutch piston lip seals into place. To me, this is the most agravating part of the rebuild. For the bushings, I have some homemade drivers. Machined them up when I worked as a machinist.
Al, what year trans are you using? makes a difference in the kit.

flturbo6@aol.com

Although I don't know if they have auto trans tools, you can borrow specialized tools from Auto Zone, about 40 different tools, it's a great no cost service!