I just ordered another shaft and will send this one back. Reason being is I’m short other parts and can’t get much further with the build anyway. Seems I have a sun gear that the wide Sonnax bushing won’t fit. The bushing came in the kit from Dana. I have 2 oems on order. My 2-3 shift valve finally came in and that finished off the valve body. I'm on my 2nd TCC apply valve for the pump. The first one arrived in an open, empty envelope. So I filed a claim and got my money back on that one. But now UPS has mixed up another package that I had inbound and they are sending it back instead of the empty package I refused to take. That had my 2-4 servo pin in it. Getting to be a pain. I’m glad I ordered a kit from Dana. Just the few parts I needed to order have come from 5-6 different places. Anyway I did get the reverse input drum finished and the input drum also. I’ll get the pump finished tomorrow. Bumping up against memorial day weekend so I think I’m going to call it in a day or two and pick it back up on the other side.

 

Are you pressing the bushings in or knocking them in? The Sonnax bushing might be tight as first, but you can get it to fit.

 

Pressing it in. I tried to sand the OD of the bearing and the ID of the sun gear but it just wont go. I can see the bushing joint starting to open up. A couple oem bushings are cheap enough.

 

Finally got the correct late style reaction shaft. Also got the 2 oem sun gear bushings to replace that wide Sonnax bushing. They pressed in like butter.

I keep trying to get the output shaft endplay tightened up to .025 ish. I have .045 as measured in the picture with the assembly upside down on the bench. So I took it apart, added .020 in shims between the rear support and bearing like the picture shows, and reinstalled everything back into the case. When I check the endplay it still has .045. So I put another .020 in shims for a total of .040. Put it all back in the case and I still have .045 endplay. Honestly I can’t see how adding the shims where I did is going to tighten the endplay up. Where am I going wrong?

 

Why does everyone here have issues with establishing and setting thrust clearance/ end-play?


O well... try and post a video of how you are stacking the components, and then how the measurement is being taken.
It sounds like incorrect assembly/ missing components...
Make sure that all your thrust bearings are in place.

 

I always liked tearing down and fixing these when at the dealer. Haven't been through one in a while now. Still a lot to learn.

 

Here is the lineup. Lip of bearing toward planet and reaction shaft. Second pic shows black tab washer, sun gear WITH snap ring, lip of bearing toward rear support, and then on the other side of the rear support .040 shims, then the bearing, black side down.

I am measuring the endplay on the bench per the Sonnax instructions I posted earlier and get .045 with a feeler gauge. Get the same when I use a dial indicator. This “end play” is the gap between the snap ring and the planet? How does putting shims between the rear support and case tighten up the gap between the snap ring and planet? I am miss understanding something here.

 

I couldnt get a video tape, pictures not enough to help? 4 Torrington bearings and a plastic tab washer. what's my next move?

 

Have you taken a measurement with all components installed for the rear half of the Transmission (Output-Shaft Snap-Ring to Low-Reverse Piston)?
If not, then please do so.
I noticed that the Low-Roller Clutch and Inner-Race were not installed... make sure to install these parts when you assemble the Rear Half of the Transmission into the case to measure clearance.
Some people find it easier to have the Transmission inverted with the Output-Shaft pointing upward with a Dial-Indicator resting on the end of the Output-Shaft.
Pull up on the Output-Shaft (or push up from inside the Case) to obtain your measurement.

Good luck.

 

I installed all components in the case up to the snap ring and still get .045. I did manage to get the input shaft endplay to .015 with a 69 washer.

Attached is a short video of the output shaft endplay.

 

I apologize, for some reason End-Play is an issue for DIY builders...
and it aggravates me.

What are you using for Shims now?
Also, once the Rear-Section End-Play is finalized... the Front-Section will need to have about 0.005" more clearance than the Rear-Section.

 

Its all good my friend. I put it back together sans the shims this time to get a base line video

 

Okay, try and shim the Rear-Section in the case...
and lets see what happens.

 

I added 2 shims (.020 total, I have gone as far as .040 in shims with no affect on the endplay) between the bearing and rear support. Then I built the transmission to the pump except for the 3/4 clutch and 2/4 band. The output shaft endplay stays the same at .045 no matter what combination of shims I use