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Rebuild

From 1994 Ford Bronco, documented by pfun41.

67 photos
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1994 Ford Bronco - This is the rebuild kit I bought from Napa. I got one that included both friction and steels for the clutches. 1994 Ford Bronco - The rebuild kit does not come with any of the bands, they have to be purchased separately. This is the overdrive band I bought. 1994 Ford Bronco - That black stuff is burnt clutch material. It can cause all sorts of problems so the first step is to clean it off. 1994 Ford Bronco - I washed it out with brake cleaner then took a lunch break while it dried. 1994 Ford Bronco - Im beginning with the direct drive (3rd gear) clutches as they are one of the first pieces that gets installed in the tranmission. These cl… 1994 Ford Bronco - New clutches going in. You can see a friction disk here.The disks are installed in an alternating order; steel>friction>steel ect. The clut… 1994 Ford Bronco - The top steel is thicker than the others and is the only one that will be reused. 1994 Ford Bronco - Snap ring in. clutches installed. 1994 Ford Bronco - The output shaft has 4 steel and 2 nylon seals which must be replaced. 1994 Ford Bronco - The nylon seals are removed and the steel ones have been unclipped. To unclip them push down at one end and at the opposite side of the sha… 1994 Ford Bronco - All the seals are removed. To remove the metal seals pull the ends apart and slide them carefully off the shaft. In this pic the one farthe… 1994 Ford Bronco - New metal seals installed. They should be installed in the opposite order they were removed (leftmost first, rightmost last). To reclip the… 1994 Ford Bronco - Nylon seals installed. They are a little tricky, be careful as they are delicate and should not be stretched any more than necessary. 1994 Ford Bronco - The direct drive clutches and output shaft are assembled as one unit before installation. The direct drive drum is placed face down in the… 1994 Ford Bronco - The output shaft is carefully placed into the direct clutch drum and drive shell and a snap ring holds the output shaft to the drive shell. 1994 Ford Bronco - Make shure the case is clean before reassembly. This bearing must be installed right side up and prelubed with ATF. 1994 Ford Bronco - The assembly is carefully placed into the tranmission case. Do not drop it in.It must be seated all the way. 1994 Ford Bronco - This hub and bearing, washer are installed next. First the washer (far right) then the bearing (middle) and the hub (left). They must be in… 1994 Ford Bronco - The outer spines spines on the hub mate with the spines on the friction disks. Make shure it is seated all the way. 1994 Ford Bronco - The planetary gearset does not need to be disassembled unless the bushings are bad. Aside from the sun gear (center) and bushings this is a… 1994 Ford Bronco - Unfortunately I do not have a picture but the reverse band goes in next. Since the reverse band was in good shape and not burnt I reused it… 1994 Ford Bronco - Sun gear removed. Don't lose the bearing. 1994 Ford Bronco - Planetary gearset assembly installed. The sun gear is also installed in this pic. With the sun gear removed the assembly can be held in the… 1994 Ford Bronco - In this picture the anit-clunk spring can be seen in the upper right between the case and planetary gearset. It is installed with the tabs… 1994 Ford Bronco - The case snap ring is installed after the planetary gearset and anti-clunk spring. Note: If the snap ring will not fit into the groove make… 1994 Ford Bronco - Forward clutch hub. 1994 Ford Bronco - There is a sun gear on the bottom of this assembly which can be installed into the transmission before the rest to make things a little eas… 1994 Ford Bronco - The forward clutch hub is set into place. There are a few gears and splines that need to line up before it seats fully. 1994 Ford Bronco - Internal view of a transmission part, likely a torque converter or clutch assembly. 1994 Ford Bronco - The forward clutches are the second set that will be replaced. 1994 Ford Bronco - Forward clutch disks removed. Note that some are burnt more than others. Also not the extra steel on the far right. That will be covered mo… 1994 Ford Bronco - There are two steels that will be reused from the forward clutches. The one on the left is thicker and installed last. The one on the right… 1994 Ford Bronco - Here is another view of the special steel disk. you can see the wave shape I mentioned here. 1994 Ford Bronco - The special steel is installed first followed by a normal steel. the rest of the clutch set alternates like the rest. 1994 Ford Bronco - Clutches installed. The thicker steel is installed last and visible here. Remember the clutches need to be installed wet. 1994 Ford Bronco - The forward clutch assembly can now be set into place. make shure It's seated all the way. 1994 Ford Bronco - Reverse drum and intermediate clutch assembly. 1994 Ford Bronco - Reverse clutches. These aren't too bad except for a little discoloration on disks to the left. 1994 Ford Bronco - The bottom and top steels are thicker and are reused. 1994 Ford Bronco - Reverse clutches assembled. 1994 Ford Bronco - Reverse clutch drum installed into the transmission case. 1994 Ford Bronco - Intermediate clutches. These aren't too bad. 1994 Ford Bronco - Old and new overdrive bands. Note the burnt band. The new one is coated with ATF just like the friction disks. 1994 Ford Bronco - Overdrive band installed. 1994 Ford Bronco - Close-up view of a transmission torque converter housing, showing internal mechanical components. 1994 Ford Bronco - Intermediate clutches installed. The bottom steel is thicker and has a ridge on it. The ridge faces down when installed. The new pump gaske… 1994 Ford Bronco - 2 of the pump bolts are used to seat the pump,then the guide bolt is removed. 1994 Ford Bronco - Here are the complete accumulator and servo assemblies. from left to right: 2-3 accumulator reverse servo overdrive servo 1994 Ford Bronco - 2-3 accumulator piston installed. 1994 Ford Bronco - Close-up view of a transmission valve body, showing its complex internal passageways. 1994 Ford Bronco - The pin on the reverse servo must engage the reverse band. If it doesn't a screwdriver can be placed in the hole and used to move the band… 1994 Ford Bronco - Close-up of a disassembled automotive component, a spring and seal mechanism. 1994 Ford Bronco - New seals on the overdrive servo. 1994 Ford Bronco - I reused the oring on the piston as my kit did not have one that fit. 1994 Ford Bronco - Overdrive servo installed. 1994 Ford Bronco - Close-up of an automatic transmission valve body, showing its complex internal structure. 1994 Ford Bronco - This is a transmission valve body, a complex component with many passages and ports. 1994 Ford Bronco - A disassembled transmission valve body lies on a plastic sheet with tools and other components. 1994 Ford Bronco - Close-up of a complex valve body, likely from a transmission, with a ratchet tool nearby. 1994 Ford Bronco - Close-up of an automatic transmission valve body, showing its complex internal passages. 1994 Ford Bronco - A disassembled transmission valve body is laid out on a white tarp with tools and a diagram. 1994 Ford Bronco - Close-up of a transmission valve body, showing internal components and fluid passages. 1994 Ford Bronco - Close-up view of a transmission valve body, revealing its complex internal workings. 1994 Ford Bronco - Close-up of an automatic transmission valve body, showing its intricate internal structure. 1994 Ford Bronco - The transmission pan is off, revealing the filter and the intricate workings inside the automatic transmission. 1994 Ford Bronco - Transmission and torque converter disassembled, with various automotive parts visible in the background. 1994 Ford Bronco - An automatic transmission and torque converter assembly is shown on a red stand, likely for repair or rebuild.