1st time rebuilding a 2004r myself

[dank GN]

So I decided that I want going to mail my trans back and I will try my hand at a soft rebuild . Basically I got it apart and noticed it got crazy hot . A trust washer gave out and took out my pump . Sent the parts out for a custom Bearing setup should be back next week

View attachment 204938

 

[dank GN]

Last but not least the washer that caused this . I can't believe such a inexpensive part can cause such a headache

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[David Husek]

Last but not least the washer that caused this . I can't believe such a inexpensive part can cause such a headache

The washer did not cause this failure. The screws that hold the stator were left loose or left out and caused this problem. Did you find the bolts in the pan?

 

[Steve V]

who built the unit?

 

[dank GN]

I would rather not say . He is taking care of it though . And no I didn't find a torq screws anywhere :-( does that connect that shaft to the back of the pump ?

 

[dank GN]

That trans took some hard launches . if those bolts weren't in Dave wouldn't it fail right away ?

 

[David Husek]

And no I didn't find a torq screws anywhere :-( does that connect that shaft to the back of the pump ?

Yes it connects the stator to the pump

That trans took some hard launches . if those bolts weren't in Dave wouldn't it fail right away ?

Not right away. The stator support fits snug in the bore of the pump and it supports the stator in the converter from spinning. If the pin in the stator support and screws were not there, it would have failed immediately. In your picture, you can see the twisting of the stator support and pin that broke the pump. Failure had nothing to do with the washer, just the necessary screws not being installed.

Get your converter checked also.

 

[dank GN]

Converter got a clean bill of Health . My converter guy just said it got crazy hot .



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[dank GN]

Thanks for your professional eyes a few more pics

Can u see the scratches is this something I should be concerned about I'm pointing to it with the tip of the pliers

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[TexasT]

I was under the impression that you should replace the torx screws with bolts so that's what I did on mine.

If the clearance was left loose could the thrust washer get pounded and fail causing this? Or I guess if the fasteners weren't installed.
Great pix, and great tech from the professionals.

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[bison]

The washer did not cause this failure. The screws that hold the stator were left loose or left out and caused this problem. Did you find the bolts in the pan?

^^^this


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[bison]

I was under the impression that you should replace the torx screws with bolts so that's what I did on mine.

If the clearance was left loose could the thrust washer get pounded and fail causing this? Or I guess if the fasteners weren't installed.
Great pix, and great tech from the professionals.

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That would be very unlikely. The only time that washer is hurt (when the bolts are in place) is when it's setup too tight. Look at the helix of the gears. That explains it.


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[dank GN]

 

[TexasT]

That would be very unlikely. The only time that washer is hurt (when the bolts are in place) is when it's setup too tight. Look at the helix of the gears. That explains it.


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So, loose is good (or ok) on that end? I had a hard time finding a yellow washer though I did find the thinner ones.

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[bison]

So, loose is good (or ok) on that end? I had a hard time finding a yellow washer though I did find the thinner ones.

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I don't know what you mean by loose. Too loose is no good and too tight is no good. If you were a little tight 2 case to pump gaskets could be used.


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[TexasT]

I don't know what you mean by loose. Too loose is no good and too tight is no good. If you were a little tight 2 case to pump gaskets could be used.


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Good stuff . I measured it and wrote it down but I don't have it handy with me. I remember it being in the loose end of the spec in the atsg manual. I did put the yellow washer in to tighten it up from where it was with the original washer.
Thanks

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[bison]

Good stuff . I measured it and wrote it down but I don't have it handy with me. I remember it being in the loose end of the spec in the atsg manual. I did put the yellow washer in to tighten it up from where it was with the original washer.
Thanks

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Keep in mind the front end play does not include the end play between the snap ring on the end of the input and the od carrier. If you include that clearance you will be too tight.


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[TexasT]

I pulled the input up to the snap ring then measured clearance from there. I noted the measurement when I could feel the snap ring, the pulled the input to its max to get a second reading. The difference between the two readings becomes the clearance. Am I explaining that correctly?
I'm no trans builder, just a hobbyist on a tight budget. Thanks for your help.

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[David Husek]

View attachment 204977

The damage would be much worse if the bolts were installed and then came loose. That damage is from the stator support rubbing after the thrust washer broke and fell into the pan.

 

[bison]

I pulled the input up to the snap ring then measured clearance from there. I noted the measurement when I could feel the snap ring, the pulled the input to its max to get a second reading. The difference between the two readings becomes the clearance. Am I explaining that correctly?
I'm no trans builder, just a hobbyist on a tight budget. Thanks for your help.

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Yes. For more fine tuning you can sand a couple thousandths off the thrust washer if you have a flat surface to sand on.


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