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  #1  
Old August 4th, 2008, 09:04
Mesh's Avatar
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AW4 Teardown & Rebuild (Lots of Pics)

The kit Iím using is the ATP RM30 which contains friction, steels, gaskets, seals. I also had an ATSG manual to help me along the way; I wouldnít attempt a rebuild without it. This is an ongoing project last time I pulled the engine and rebuilt the transfer case (Link) now itís time for the transmission. Tools used for teardown; snap ring pliers, one pick, two regular screw drivers and a couple sockets. My projects have no budget and the reason for the rebuild is? Donít care.

The AW4 needs servicing like every other transmission in the world itís not a big deal like some may believe. There are a lot of parts, to keep it organized I put each clutch pack in a Ziploc bag and labeled it. When I put it back together I will take one out at a time clean it replace the parts and reassemble back in the case this way Iím only working with a handful of parts at a time. Iíll spend the next couple days cleaning parts and replacing clutch packs and try and keep you guys updated.






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  #2  
Old August 4th, 2008, 09:50
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Re: AW4 Teardown & Rebuild (Lots of Pics)

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Old August 4th, 2008, 09:59
philip_g philip_g is offline
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Re: AW4 Teardown & Rebuild (Lots of Pics)

Wow, there's pretty much no way I'd get that thing back together.
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Old August 4th, 2008, 10:20
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Re: AW4 Teardown & Rebuild (Lots of Pics)

I didn't even think a brand new tranny would be that clean, much less one needing a rebuild.
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Old August 4th, 2008, 10:22
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Re: AW4 Teardown & Rebuild (Lots of Pics)

X2 on subscribed!



Be careful you don't get any dirt in that clean transmission, LOL!
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Old August 4th, 2008, 10:33
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Re: AW4 Teardown & Rebuild (Lots of Pics)

nice...i'm following this one, as I intend to do the same
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Old August 4th, 2008, 10:33
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Re: AW4 Teardown & Rebuild (Lots of Pics)

So what happens from here?
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Old August 4th, 2008, 11:24
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Re: AW4 Teardown & Rebuild (Lots of Pics)

Bad ass dude! Definitely bookmarking this thread!
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Old August 4th, 2008, 12:31
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Re: AW4 Teardown & Rebuild (Lots of Pics)

Subscribed!!!

I have rebuilt a couple TH350's anda TH400, but the AW4 would be a new one for me.....
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Old August 4th, 2008, 12:39
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Re: AW4 Teardown & Rebuild (Lots of Pics)

uh...subscribed!
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  #11  
Old August 4th, 2008, 13:23
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Re: AW4 Teardown & Rebuild (Lots of Pics)

Just realized from reading your engine thread that it has 230K on it....was the tranny that clean when you took it apart?
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  #12  
Old August 4th, 2008, 21:51
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Re: AW4 Teardown & Rebuild (Lots of Pics)

Quote:
Originally Posted by Stallacrew
So what happens from here?
Next clean case with solvent and blow off with compressed air to remove all particles. Then start with the last clutch pack compress remove snap ring remove old friction and steels again clean. then soak new friction plates in transmission fluid and reassemble pack. There is more to it I'll try and take some pictures.

Quote:
Originally Posted by UNCC_99XJ
Just realized from reading your engine thread that it has 230K on it....was the tranny that clean when you took it apart?
The external case was caked with oil and dirt I started cleaning it with a putty knife. The inside was covered with a black film pictures make it look 10x better. Also the external case needs to be clean before its opened if dirt gets inside and even if you do another cleaning it can cause problems.
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  #13  
Old August 5th, 2008, 00:42
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Re: AW4 Teardown & Rebuild (Lots of Pics)

in
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  #14  
Old August 5th, 2008, 08:51
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Re: AW4 Teardown & Rebuild (Lots of Pics)

So here is the transmission oil pump puller. My R&D team has been working on this tool for months. I didnít make this tool so he said the deal is if you figure it out you can use it.



Hopefully I don't have to work late all this week so I can get started.
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  #15  
Old August 10th, 2008, 23:50
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Re: AW4 Teardown & Rebuild (Lots of Pics)

Sorry about the delay. Finally finished a little more what I have left is one clutch pack, oil pump, valve body, and the overdrive support which the new o-rings are incorrect. I'm stuck until I get the right o-rings.

A couple things I ran into are the first-reverse brake pack did not fall within spec and had to add an extra steel to fix it. Two more packs were the same but I was able to swap some thicker steels to compensate.

Some more pics.









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