I just finshed rebuilding my 1991 e4od, I havent been able to finish installing it yet, after floods, and a host of other obsticals my step father just went into the hospital.
there is alot of stuff in there, very large undertaking. If you get the ASTG manuals, update and rebuild, it is a lot easier, I could not have done it without them. be sure to read the manuals several times, then re-read them it makes it posssible. be very carefull to stack parts up as you take them out, alot of the parts and bearing look the same but are really different with no way of telling which
is which. clean every single part as your putting it back together, if you do it sooner it is easy to missplace parts. you may look into getting new snaprings, I bent mine taking out and had to get new ones, its also cheap insurance.
I didnt make any tools or buy any tools, but it would have been ALOT easier and quicker if I had.
the money issue, like you I am on a tight budget, this truck is a luxury not a required part of my fleet. I got the rebuild kit and all the update parts Bauman carried, for the rest I went to ebay. It still cost me about $1200 in parts alone, $900 in updates and I purchased a new solenoid block.
even after rebuilding it, I still dont know anything about how it works, just was able to follow instructions, like assembling a model car.
Good luck, Jeremy
I found this site, http://www.network54.com/Forum/260730/
they have a ton of info on a bunch of transmissions.
here is some info I found,
Direct Drum Rebuild:
Compress direct drum pistion return spring to remove / reinstall snap ring. (we used a 4" pvc coupling
cut in have).
Also use a pvc coupling of appropriate size and drill press or vice to compress spring to remove / reinstall snap
Install Overdrive Cylinder Return Spring:</P>
Make round metal cage out of 1/4" round bar and weld ends together with stand bars to smaller cage with 3/8" flat stock across with 1/2" hole for allthread. (Must be large enough to allow for snap ring expansion.
Use plate with 1/2" on bottom of Intermediate cylinder and 1/2" allthread to compress intermediate spring; reinstall snap ring and release compression.
To Install Reverse one-way sprag inner race:
Use 5/16" x 3" long bolts with heads cut off and slot ends with hacksaw.
To install Shell/Forward/Direct hubs/one-way sparg assembly
Lay trans on side and install unit in to reverse planetary. Then stand trans back up verticle. (We made a heavy
duty verticle stand).
To install Intermediate / Overdrive Cylinder in case.
Place Cyinder in place; put snap ring next to cylinder; snap ring opening will be at bottom of case to allow draining. Using the same cage that was constructed for removing Overdrive return spring, place a flat bar or pipe with hole in it across cage; then bolt a flat 3/8" plate (or you can use 2x4 board) across pump mate surface of case; then use a jack screw and nut to push against bolted 3/8" plate or 2x4 to compress Overdrive / Intermediate
cylinder in to case until it is even with bolt hole center and a little more at the worm channel bolt hole.
Now, install snap ring; rotate ring until gap is at bottom and slowly release jack screw. Look at bolt hole opening
to see if cylinder threaded hole is in center.
Install Center Shaft and Coast Clutch as an assembly.
Place coast clutch on bench without friction and steels and snap ring.
Install Center Shaft in coast clutch and make sure it is seated all the way.
Install frictions and steels and snap ring in coast clutch..
Again lay transmission on side and install Center Shaft / Coast Clutch as an assembly.
You must center Pump bolts and keep teflon seal openings to bottom side of case with gaps
closed using goo.
Use 8mm bolt threads that have been welded to 2-1/2" long 3/8" O.D. bolt shanks; or </P>
3/8" O.D. metal sleeves that will fit over 3" long 8mm bolts (grind sleeves to fit slip in to pump
Pump should go in to case very easy except for last 1/4" inch. Watch telfon seals enter coast clutch to
make sure gaps do not open..