95 AODE Rebuild Fails Air Checks
Hello all, so I'm rebuilding my 95' Mustang GT's AODE to 98+ 4R70W specs, printed off the articles from this site, got my Transmission Bench 7 part video, ATSG book and update book and the workbench AOD book by my side and I get started.
Did all new bushings and torringtons, Alto reds, carbon OD band and new OEM reverse band. New reverse drum and shell with mechanical diode. 4R70W planetary and sun and stub shaft. Everything was going awesome right up until air checking forward and reverse with the front pump.
40-45psi on compressor, lots of Transjel on everything, I have the Sonnax sure cure solid teflons on the forward drum part of the stator as per the directions, new steel rings for reverse, and new solid teflons on the input shaft. Fails air checks reverse and forward, seems to leak right past all the rings, steels and teflons. Pistons don't appear to leak, poured ATF in there and rolled around while air checking and pistons do apply just fine, no sign of leaking from apply piston seals, but it is just leaking straight up the stator support and the input shaft.
Now, the teflons on the stator were pain in butt, expected that. I finally got them seated and decided to let them sit for hours to compress and make final install easier. Nope, it only rolled them and ruined them and then I had to use my OEM steel rings for forward that were in my rebuild kit.
To make matters worse, I decided to check intermediate endplay both with H gauge method and by putting on front pump and making sure input shaft spins freely and checked endplay with pump on by pulling input shaft forward. I put 100 inch lbs on the front pump bolts and one of them ripped the threads right out of the case! It was while using a thinner thrust washer took, so I ripped quite a lot of threads out, so now I am fixing that now with heli coil while hoping someone has some guidance for me.
I am not sure if the 40-45psi is too much or too little to check with, all books and videos seem to say it is the correct psi. All books and videos say there can be a "slight" air leak while air checking as long as apply pistons function and no leaks from piston seals. This is subjective and I'm first timer, so perhaps someone can tell me just about how much air leak is considered slight and how much is too much. The videos I seen there is no leak whatsoever and the piston will rise and fall in perfect timing with squeezing the air gun, so you could probably hold the air pressure and the piston will stay up for as long as you hold it. Mine will leak air out of the input and stator support until all the air pressure in my compressor leaks out and the piston then falls.
I thank you in advance for any help! I'm so close to completion yet so far.
Don't hate on me please just because I don't have a Tbird or Cougar. I love them just as much as any other Fords! I got a good deal on the 95' GT but was in market for another XR-7 because I regret selling my 88'
I love this forum and have used it extensively for any mods done to AOD's and 4R70W family.
95 Mustang GT GT40X heads XE264HR Explorer Intake. AODE, PI 3500 stall. 4.10 Gears. Coil over front.
1988 LX 5.0 Sold
1988 Cougar XR-7 5.0 Sold