Ford C4 Automatic Transmission Rebuild - 11-28-05

	Here's the transmission with the bellhousing, intermediate servo piston, servo cover, and input shaft removed. The splined shaft sticking out of the front of the transmission is the pump stator.
	Low/reverse servo piston, servo cover, and tailshaft extension removed.
	Governor has been removed from the tailshaft.
	Valve body has been removed from the case.
	Pump and clutch packs/drums have been removed from the case.
	Reverse ring gear, hub, and thrust washers.
	The input shell. The weak stock planetary gearset (3 pinions) rides in this shell. For high power applications, you should upgrade the planetary. I went to a 6 pinion gearset; comparison pictures below.
	The pump - this is what creates the hydraulic pressure that is the basis of operation of an automatic transmission.
	Output shaft and reverse planetary gearset still in back of case.
	Here's a good shot of the intermediate band still in the front part of the case.
	This is the reverse-high clutches, steels, pressure plate, and snap ring.
	Reverse-high drum, piston, return spring, and spring retainer.
	Since I don't have a press, I hd to use 2 C clamps to compress the reverse-high piston return spring. Once compressed, I was able to remove the snap ring, spring retainer, spring, and piston.
	Here's the spring and retainer, snap ring, piston, drum, and the clutch pack and steels on the bottom.
	Reverse-high piston and drum.
	Forward clutches, steels, snap ring, belleville spring, piston, and drum.
	The forward clutch pack, which was toast! The car that I got it from was probably in the junkyard because of this transmission. There is no friction material left at all on either side of any of the clutches. No wonder it smelled burnt when I pulled the pan off in the junkyard! Just to give you an idea of how much force there is on the clutch pack when the piston applies, the almost 1/4" thick pressure plate was slightly bent into a conical shape! All the clutches and steels were also bent into a conical shape.
	Low-reverse planetary, carrier, and drum.
	Low-reverse clutch drum.
	The output shaft.
	Parking gear - this is splined onto the output shaft. When you put the shifter in park, a pawl engages in a slot in the gear, and that is all that keeps your vehicle from moving. More pics below.
	Parking pawl and spring. Engages in above gear.
	One-way roller clutch that prevents the low-reverse clutch drum from rotating backwards.
	Manual lever and shaft.
	The inside of the transmission pump, which is a rotor style pump. Inside gear is the drive gear, and the ouside gear is the driven gear.
	The valve body (bottom [pan-side]).
	The valve body (top).
	Valves and springs from within the valve body.
	Valves and springs from within the valve body.
	Valves and springs from within the valve body.
	The completed valve body. I put it in a ziploc back to make sure it stayed clean before installation.
	The completed valve body.
	Thanks to my organization system, I knew exactly where each part went, and I had nothing left over at all when I had the whole transmission back together! That is a rare accomplishment for me, but on this project I took my time and was careful. I really don't want to have to do anything over again once I have this in the car. Organizing my bolts, nuts, springs, anchor struts, etc, this way helped greatly in the reassembly process.
	The governor which is bolted to and rotates with the output shaft. The valves in the governor changes the main line pressure with output shaft speed.
	The governor.
	Getting ready to install the intermediate servo piston, spring, and cover. The servos apply the bands in the transmission that either hold or release a drum. Whether or not the band is applied or holding determines what/how the planetary gearset is turning. This is how you get different "gears" in the automatic transmission.
	Parking gear, pawl, and spring installed in the case. This is showing the engaged position (car would be in park right now). I can't stand people who pull into a parking spot, stop, and throw the car into park and let the car rock back and forth. The whole weight of the car is rocking back and forth on this gear and pawl. Use the parking brake!
	Output shaft, low-reverse planetary and drum, and low-reverse band are installed in the case. Notice the band is wrapped around the drum. When the low-reverse servo piston applies (via hydraulic pressure on one side of the piston), the band is clamped down on the drum and the drum stops turning.
	Stock planetary gearset on the left, aftermarket Power Planet 6 pinion planetary gearset is on the right. Now you can see why the stock gearset on the left is a weak link in this transmission. All forward power is transmitting through this gearset.
	Stock planetary gearset on the left, aftermarket Power Planet 6 pinion planetary gearset is on the right. Now you can see why the stock gearset on the left is a weak link in this transmission. All forward power is transmitting through this gearset.
	In order of assembly, from left to right, planetary gearset and carrier, forward clutch drum, reverse high clutch drum, and the input shell.
	Above mentioned components assembled and installed in the case.
	Pump and bellhousing installed (they share the same bolts).
	Anchor and apply struts are installed on the intermediate band.
	Governor bolts to the flange on the output shaft.
	Tailshaft extension.