Hi folks. Reassembling my tranny now but having issues with the 3 thrust washers with the 3 tangs.
I felt I was careful disassembling and laying out the output shaft but for some reason when I try to get it all back together I cant get the circlip on the output shaft with the three washers installed where I thought they went.
I have looked at this drawing:

http://www.makcotransmissionparts.com/m ... f/A904.pdf

Which shows four of the washers and their 3 tangs labeled as part 238. One thing it doesn't show which confuses me is the lack of a ball bearing placed in the output shaft which locks the shaft to the rear pump impeller. So I have some confusion if this layout is correct.

Anyone run into a problem like this or can anyone offer any insights?

I can take pictures if anyone would like to see the washers and anything else.

Thanks for any help.

John[/url]

_________________
Psychics will soon lead dogs to your body!

1963 Dodge Dart 270 convertible

The diagram you posted is wrong- it's for "late" model 904's (80's & 90's). Most of the major assemblies are similar to your early "cable-shift" unit but not all. You really need a Factory Service Manual for your car to get accurate diagrams & procedures, torque specs, etc.

If you can't properly seat the geartrain on the output shaft then I'd first check the rear pump & governor to see if either is preventing the shaft from moving as far forward as possible.

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63 Valiant Wagon
225 - 4 bbl

Thanks Wagon. I do have a manual for my car and have been somewhat confused about all of the different iterations of the dang tranny, thrust washer here thrust washer there. Crazy!
I have been able to assemble the output shaft and get the circlip installed, however this is with leaving one of the washers out.
I noticed that the wear pattern on two of the 3 tanged washers was even across both and that the wear pattern matched the planetary gear assys. However one of them shows wear only on the outer half of the surface so I am looking to match its mate.
Leaving out this washer makes the output shaft look right but what I am finding is that there is a lot of end play of the output shaft ~.25" so something is wrong there.
I have placed videos out on my website at: www.myfigtree.com/trannyoutputshaft/endplay.avi
if you would like to see the wear pattern and the end play I am experiencing you will need to download it.

Thanks again for your help and Happy Memorial Day.

John

_________________
Psychics will soon lead dogs to your body!

1963 Dodge Dart 270 convertible

It's been more than a few years since I rebuilt the 904 in my '63 BUT, in general you're supposed to assemble the "geartrain" (both annulus supports, planetaries, sun shell, washers) to the output shaft while the shaft is NOT in the case. Then check & adj geartrain endplay (where the rear annulus sits against a shoulder on the output shaft.

The "odd" wear pattern on the one thrust washer is likely because of the surface it rides against (annulus support?)- it has a large diameter thrust face & only part of the washer covers it. That washer doesn't show excessive wear so don't worry- just reuse it & put it back where it belongs. AFAIK your 904 has aluminum planetary carriers- I don't recall if they used 4 thrust washers on those or if one of the carrier faces WAS the thrust surface.

Once done you fit the one-way sprag clutch, rear drum & band. After that you then install the output shaft into the case, fit the rear pump & governor. So your "excess" endplay is irrelevant- that movement is controlled by the ball bearing that mounts into the tailshaft housing. Take the governor & rear pump off the output shaft & remove it from the case. Put the washer back & recheck endplay per factory manual.

SO, you check end play in the geartrain on the output shaft, assemble everything else & check endplay of the entire trans once the front pump is installed. (what manual do you have- it don't sound like the FSM)

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63 Valiant Wagon
225 - 4 bbl

So to update. I took it all apart again and found that the odd pattern is from the assembly that fits into the sprag.
I removed the bearings and the springs and there was the three holes that the thrust washer went into. I was so scared of these bearings that as they fell out I didnt realize that the thrust washer was behind it all!
I put the washer in and reassembled and was able to get the output shaft assembled and am now waiting on some parts for the valve body.
So much for saying well Ill take it apart so I can get familiar with it before the parts get here!
Thanks for all the help. Now on to the next befuddlement!
Cheers.

_________________
Psychics will soon lead dogs to your body!

1963 Dodge Dart 270 convertible