Thread: Transmission Rebuild Has Begun

I have that and the green update manual. You can even partially see it in some of the pictures as I followed it nearly to the letter.

Im also glad to see you over here. Ive bugged you enough with questions on the other forum, so its good I can bug you here too, LOL.

Originally Posted by 3800seV2.0

You can find a bunch of good stuff on my site:

Directory listing of /Pictures/GP/rebuild/Docs/

But you should really just spend the $15 on an ATSG 4T65E service manual.

So he is here. Never met ya, but wanted to say your write ups have helped me quite a bit.

I got the case cleaned up today. I'll be probably sanding it down some to smooth out some of the rough spots so that I can get it powder coated. Get the servo covers and side cover and diff cover cleaned up and let the powder coater have at it.

















The bell housing area has some streaks of some kind in it that I could not get cleaned up despite full strength simple green max, a tooth brush, steel wool and a Mr. Clean Magic Eraser. Nevertheless, it doesnt or wont affect everything being powder coated.

If I dont forget, I'll get the pictures of the other smaller stuff when I get it cleaned up.

Looks good Scotty! You guys are lucky living south of the winter SALT band! Most cases areound here are pretty horid looking and have oxidation all over them. Make sure you remove the stator support also. I see a lot of cases with the miscolored look that you said and I can see it in the pics. Not sure what it is from but I have seen near brand new housings look like that also so it may just be from the final wash they get.... Caustic cleaners are NASTY on aluminum! It looks like you had some metal debris under the ring gear where it goes into the case, make sure you knock down any high spots as the ring gear should sit somewhat loose in the case.

I dont know if that is from metal debris Trannyman. I mean, Im not the expert here obviously, but looking at it, it did not look to be from debris but I can get some close up shots.

At first I thought they had used some type of glue or epoxy to hold the ring gear in there. The manual says to grab the thing and lift it straight out, but that wasnt happening with this one. So I had to take a block of wood and pound it out. It didnt take a lot of pounding, but it did require it to be done.

That all said, I will get in there and make sure its all smooth. But I would surely like to hear if you have any further input 'cause that part of the disassembly didnt go as expected.

Oh, and yeah, I am GLAD I live below the salt band, I have seen what that does to aluminum. This GTP originally hailed from Texas, so I doubt it has ever seen any road salt except what has been laid down here and Im anal about washing that stuff off as soon as I can.

How many miles: right at 117k

Were you able to remove the harness without breaking any of the plastic clips on the solenoid connectors? Yes everything came out with no problems. I even have a spare tranny with about 100k on it that I pulled the harness out of with no breakage

Chain stretch was within specs according to how the manual has you check it.

I have a 300M input shaft, I'll put in a hardened 4th clutch hub shaft, I'll be going to a single chain set up with stock gearing. The input shaft may ultimately overkill by leaps and bounds, and I probably dont need a hardened pump or output shaft. I think Trannyman would agree too. But I am contemplating getting them because I am anal about that kind of stuff and since I got it all tore down my thoughts are going along the line of why not build it to exceed anything I'll ever need. But we'll see how that goes I have yet to purchase the pump or output shaft.

looks good man :-) im thinking about doing a rebuild on my blown tranny myself but dont know if i got the balls to tear it down and replace the parts as well as inspect and put everything back together again. i started reading through the manual 3800SE posted but dunno what ALL the parts i need for a rebuild. i was planning on getting the master overhaul from trannyman dave along with a hardned 4th gear hub but what else would i need? also would i need special/specific tools?

You're going to need a seal puller, a couple different varieties to make sure you have all the bases covered. A torque wrench to say the least. I have a 3/8" drive and a 1/2" drive, but at least the 3/8" for sure.

Im going to have Trannyman do all the valve body work and updates. That area is more than I care to deal with, in addition the tools and such needed to do the work are way expensive for a one time deal.

At that point, I guess its just a matter of what all you want to do to the tranny. Im opting to go with a single chain set up while Im in there. You'll need the standard tools obvious, wrachets, sockets, etc. There are a couple other tools that would be needed as well.

The manuals mentioned in this thread are invaluable. But most of all, if you have ANY reservations about doing the work I would opt for letting Trannyman do the rebuild. Im a little more daring and a tad bit of a risk taker when it comes to things like this because I like to learn. But I also have another vehicle to drive and a spare tranny, so Ive tried to prepare for things as well.

Its fun work to me, relaxing and challenging. But I can see where it would be a little nerve racking too. If you have never done it before then the uncertainty of whether or not you have done each and everything the way it should be can be a little to deal with. Particularly since you wont find out until you got it installed back in the car and everything buttoned back up.

I wish there was a place around here I could take the tranny and have them hook it up and check functionality. Sorta like the machine Jaspers has to check their trannies after rebuilds. That would put to rest some of the concerns.

I have disassembled a Ford 4F27E transmission, but I never rebuilt it or put it back together either. But I became fascinated with auto trannies doing that and have waited a very long time for an opportunity to do what I am doing now. I can say I have enjoyed it to such a degree that if Trannyman would hire me and I could make the money I make now Id work for him in a heartbeat.

Scotty,

Any more progress on your tranny?

You really cleaned up that case really well. I'm getting ready to start the inspection of individual parts and pieces and you're right, a little nerve racking.

BTW, what updates and valve body work is trannyman doing for you? You mean checking the electronics and such, or what other updates are necessary? Just asking as I'm kinda in the middle of this and wanted to make sure I'm not missing something.

No, no other work has been done. Ive been saving to have the valvebody work done and to get my single chain. After that it will be close to putting it all back together. Trannyman is going to do all the Sonnax updates (tools are expensive for a one time job) and replace all the solenoids and such.

I would do it myself but Id rather have someone with the tools already and the experience to check all the little things that the manual probably doesnt tell you about. The way its going it probably wont be ready for Branson, but thats okay, as long as its all done the way it should be.

cool, glad the info helped out.