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  #25  
Old 09-01-2012, 09:55 AM
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Re: Transmission slipping

Sounds like you are doing pretty good with this Frank! The rest of us will have a nice write up to follow if we ever have to rebuild our transmissions.
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  #26  
Old 09-01-2012, 10:26 AM
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Re: Transmission slipping

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Originally Posted by 01grand View Post
Sounds like you are doing pretty good with this Frank! The rest of us will have a nice write up to follow if we ever have to rebuild our transmissions.
If anybody ever needs, i have the ATSG (5)45RFE overhaul manual which in very good detail describes the whole teardown and rebuilding process from all the internal parts of the tranny. The manual in fact only mentiones 45RFE, but the transmission itself is 100% the same as the 5-45RFE. Only difference between the two is the programming of the TCM.
The rebuild itself is not that difficult if you take the time, the only problem sofar are the clutch piston return springs. You have to compress them to be able to remove the snapring and need to make some special tool in combination with a press, but for the rest smooth sailing sofar and in fact a nice and interresting job to do.
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  #27  
Old 09-02-2012, 11:27 AM
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Re: Transmission slipping

A few more pics. The first one shows the 2C/4C retainer/bulkhead in pieces. Its in fact a housing with an outer piston (the 2C, # 1 in pic 2) and an inner piston (the 4C), which will actuate on the holding clutches 2C and 4C. These clutches will hold a part of the planetary gear train, so that a different output speed will result.
The next 2 pictures show the 2C clutch pack (frictions and steels) how they will be inside the tranny. The steels (#2 in pic 2) will stay still inside the tranny housing and the frictions are coupled to the planetary gear train. The 2nd picture shows how the buildup of the steels should have been, first a steel against the piston, friction, steel and last the thick pressure plate. This pressure plate rests against a rim inside the tranny (so the buildup into the tranny is the other way around as i just discribed, thick pressure plate first). The 3rd picture shows how it was buildup during the rebuild by the "specialist" last year, the thick pressure plate resting against the piston.............
Attached Images
File Type: jpg CIMG0488a.jpg (57.3 KB, 10 views)
File Type: jpg CIMG0511b.jpg (74.5 KB, 11 views)
File Type: jpg CIMG0512b.jpg (75.4 KB, 11 views)
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  #28  
Old 09-05-2012, 05:29 PM
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Re: Transmission slipping

Finished today the Lo/reverse clutch assy and started disassembling the input clutch assy. This last one is quite interresting, because it has 3 clutches ( underdrive, overdrive and reverse) in one compact housing. Need to get a bigger circlip tool tomorrow to get the last circlip out of the way and then its cleaning time. Will post some pics tomorrow from the Lo/reverse clutch assy. Sofar no big difficulties in disassembling and assembling, only have to improvise a bit to compress the piston return springs.
Picture 1 shows the finished LO/reverse clutch assy.
Picture 2 the input clutch assy disassembled and cleaned.
Picture 3 the completed input clutch assy.
Attached Images
File Type: jpg CIMG0548a.jpg (195.5 KB, 6 views)
File Type: jpg CIMG0574a.jpg (141.2 KB, 7 views)
File Type: jpg CIMG0624a.jpg (75.5 KB, 6 views)
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  #29  
Old 09-07-2012, 08:26 PM
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Re: Transmission slipping

Today completed the input clutches. Will post some pictures later. One of the snap rings for the overdrive clutch will be replaced by a new (hopefully better) snap ring out of the Transgo reprogramming kit.
Also started cleaning the last remaining parts, the planetary gear trains. That will only be cleaning, because no parts will have to be changed there.
Picture 1 is showing the 3 different clutch axles, who are placed into each other. The longest is for the Underdrive clutch, the middle one for the overdrive clutch and the shortest one for the reverse clutch.
Picture 2 is showing a set of friction plates in a fluid bath just before installation. The fluid will penetrate the friction material and prevents dry operation from the start.
Picture 3 is showing the underdrive (the lowest 4) and overdrive (the upper 4) friction discs. The reverse discs are not in place yet.
Attached Images
File Type: jpg CIMG0575a.jpg (114.9 KB, 7 views)
File Type: jpg CIMG0614a.jpg (180.1 KB, 6 views)
File Type: jpg CIMG0620a.jpg (157.1 KB, 7 views)
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  #30  
Old 09-07-2012, 09:09 PM
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Re: Transmission slipping

Yay! then goes the assembly! make sure you have the bearings faced the right direction, it will eat up your endplay if even ONE is not in right
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  #31  
Old 09-14-2012, 10:57 PM
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Re: Transmission slipping

The planetary gear train is ready as well and now iīm waiting for the 2nd clutch rotor disc which has to be grind down 0.7 mm and which will be placed behind the pressure plate to compensate for the aluminum which was taken away by the wrong buildup. That will be ready next week and then it must be welded to the pressure plate, so that it canīt drop down. Then again i can measure the 2nd clutch pack clearance and when that is ok, the final buildup can be started.
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  #32  
Old 09-17-2012, 09:55 AM
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Re: Transmission slipping



ok im done...
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  #33  
Old 09-23-2012, 07:44 AM
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Re: Transmission slipping

So the tranny internals are back in place again. Strange thing is that according the rebuild manual there are only 3 different types of bearings, but mine has 4. Maybe that my "specialist" from last year used this thicker bearing to get the right endplay at the output shaft. There are in fact 2 bearings ( #5 and #6), who have a plastic filler ring under them, which are selective. You can get different sizes, so that the endplay for the input shaft (bearing #5) and the output shaft (bearing #6) can be adjusted.
3 bearings are of completely different sizes, but from the 9 others one is thicker and a bit larger at the outer diameter then the other 8. Because i didnīt red anything about it in the manual, i didnīt observe it during the teardown and now had to find out where it should fit. So after several tryouts (read: assembling and disassembling again), i found the right place. Still not 100% satisfied with this, because when using a thicker bearing (its around 1mm thicker), all components behind it will move this same distance as well. But i checked for any interference or other problem which could arrise from this, but seems to be all ok.

Picture 1 shows the empty tranny casing, ready to start the buildup. I put it vertical during the buildup, so that the bearings stay nicely in place and wonīt fall down.
Picture 2 shows a reaction internal gear assy which connects (later) to the 4C clutch friction discs (item 2). A 2C clutch friction disc (item 1) it put on top of the stationary steel disc and connects internally to the reaction carrier/reverse sun gear assy. Item 3 shows the #6 bearing, with the selective plastic plate underneath it. This plate will set the output shaft endplay.
Picture 3 shows the final steps before closing up the tranny with the round access disc. The oilpump is fixed in place and the input shaft endplay checked.

Byebye tranny guts, it was nice to work on you, but i hope to not see you back for a looong time.
Found a place to do the torque convertor cleaning, only have to find some time to bring it there. Also still waiting for the solenoid block gasket, but i can install that after the tranny is put back in place.
Attached Images
File Type: jpg CIMG0628a.jpg (66.2 KB, 9 views)
File Type: jpg CIMG0666a.jpg (96.7 KB, 12 views)
File Type: jpg CIMG0022a.jpg (64.5 KB, 11 views)
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  #34  
Old 09-23-2012, 12:26 PM
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Re: Transmission slipping

Looking good Frank! Hopefully soon you will be posting pictures of the Jeep back on the road!
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Old 09-23-2012, 08:08 PM
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Re: Transmission slipping

x2!
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  #36  
Old 09-24-2012, 09:25 PM
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Re: Transmission slipping

Today wanted to bring the torque converter to a specialist to open it up and to clean it properly for me. Its near impossible to get all sludge out of it without opening. To my surprise they opened it up right away, so that they could see if any other part(s) had to be replaced. Unfortunately i didnīt had my camera with me.
They just mount the converter on a lathe and open it up in 2 halfs. Didnīt look that bad inside, since i tried cleaning it with kerosene, but the surprise was the torque converter clutch friction material, which was still the OEM one. Payed the guy last year to change that................................
Good thing was that this shop had a refurbished converter ready to be installed and i could return mine. So now only (lack of) time is stopping me to go and install the transmission back into the jeep.
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