4R70W rebuild

[88grandmarq]

I had the privilege of working on a local Georgia Crown Vic recently, A very clean 2002 black LX sport with 82K on the odometer. The owner of the car says he found the transmission dipstick not seated in the filler tube (raised about 2") about 4-5 months ago and after that the transmission started shuttering, then eventually stopped going in any forward gear. Fortunately, he stopped driving the car and trailered it to me. The transmission came out of the car with out incident, other than 3 of the 4 exhaust flange bolts breaking.

http://i1033.photobucket.com/albums/a414/88grandmarq/2002_CVsport_black/IMG-20130602-00096_zps8likwcyz.jpg

http://i1033.photobucket.com/albums/a414/88grandmarq/2002_CVsport_black/IMG-20130602-00091_zpsx0nee179.jpg

http://i1033.photobucket.com/albums/a414/88grandmarq/2002_CVsport_black/IMG-20130602-00092_zpspeghxntf.jpg

http://i1033.photobucket.com/albums/a414/88grandmarq/2002_CVsport_black/IMG-20130602-00090_zps7arm8nzn.jpg

Once I got the transmission apart, I found the intermediate and direct clutches were de-laminating, the forward clutches were burned and the OD band was burned and starting to pit.

The friction material peeled off the clutch discs like wet paper, I have never seen anything like it.

Intermediate clutch
http://i1033.photobucket.com/albums/a414/88grandmarq/2002_CVsport_black/IMG-20130602-00097_zpsfbotfcpl.jpg

http://i1033.photobucket.com/albums/a414/88grandmarq/2002_CVsport_black/IMG-20130602-00098_zpsteofzo2k.jpg

http://i1033.photobucket.com/albums/a414/88grandmarq/2002_CVsport_black/IMG-20130602-00099_zpsbxy7cb0a.jpg

Clutch De-lamination - AKA wet paper
http://i1033.photobucket.com/albums/a414/88grandmarq/2002_CVsport_black/IMG-20130602-00100_zpsit9xo0cu.jpg

Direct clutches
http://i1033.photobucket.com/albums/a414/88grandmarq/2002_CVsport_black/IMG-20130602-00101_zpsi0br5ynk.jpg

http://i1033.photobucket.com/albums/a414/88grandmarq/2002_CVsport_black/IMG-20130602-00102_zpski1i8lwk.jpg

[88grandmarq]

OD Band
http://i1033.photobucket.com/albums/a414/88grandmarq/2002_CVsport_black/DSCF0010_zps4s3jxprm.jpg

There was some evidence of water in the fluid and the case, most of the water I found was in the pan and the extension housing.

http://i1033.photobucket.com/albums/a414/88grandmarq/2002_CVsport_black/IMG-20130602-00087_zpsq5gbi2fh.jpg

http://i1033.photobucket.com/albums/a414/88grandmarq/2002_CVsport_black/IMG-20130602-00089_zpsu1mvyzah.jpg

http://i1033.photobucket.com/albums/a414/88grandmarq/2002_CVsport_black/IMG-20130608-00112_zps2xkrxtcy.jpg

http://i1033.photobucket.com/albums/a414/88grandmarq/2002_CVsport_black/IMG-20130608-00113_zpsp7w2ttlg.jpg

I also found evidence the output speed sensor had contacted the ring gear on the output shaft, damaging the sensor.

http://i1033.photobucket.com/albums/a414/88grandmarq/2002_CVsport_black/DSCF0013_zpstyr83hqn.jpg

http://i1033.photobucket.com/albums/a414/88grandmarq/2002_CVsport_black/IMG-20130608-00106_zpsvuku79jq.jpg

http://i1033.photobucket.com/albums/a414/88grandmarq/2002_CVsport_black/IMG-20130608-00116_zpslotythi8.jpg

The direct clutch piston showed some signs wear on the inner face where the seal rides, there was also some machine markings that did not polish out, I replaced the piston with a good used piston.

http://i1033.photobucket.com/albums/a414/88grandmarq/2002_CVsport_black/DSCF0020_zpsio1xwpoz.jpg

http://i1033.photobucket.com/albums/a414/88grandmarq/2002_CVsport_black/DSCF0021_zps4af7bd7z.jpg

[88grandmarq]

The valve body was completely disassembled and cleaned. The separator plate also showed signs of water intrusion (mild rust build up). I cleaned and drilled the separator plate according to Jerry's specifications (Jmod) and installed updated Sonnax shift valves.
The stock pressure regulator valve showed moderate wear.

http://i1033.photobucket.com/albums/a414/88grandmarq/2002_CVsport_black/DSCF0012_zpsvx8oqsev.jpg

http://i1033.photobucket.com/albums/a414/88grandmarq/2002_CVsport_black/DSCF0011_zpsjeg9zepx.jpg

http://i1033.photobucket.com/albums/a414/88grandmarq/2002_CVsport_black/DSCF0018_zpsfdo8vzqa.jpg

Going back together, the transmission got new rubber seals and gaskets, new high energy direct and intermediate clutches, new forward clutches, new reverse clutches and new OD band. I removed the wave plate in the forward clutch and increased it to 6 clutches. This will improve the torque capacity of the transmission. I also installed a spiral snap ring on the mechanical diode intermediate one way clutch. The intermediate one way clutch and the reverse drum see very high RPM in 3rd gear and the OEM snap ring is notorious for getting flung off at this high RPM. The new spiral ring has an outer retainer that you crimp or stake when its assembled, so the spiral ring isn't going anywhere, even at high RPM.

http://i1033.photobucket.com/albums/a414/88grandmarq/2002_CVsport_black/IMG-20130608-00119_zpsjjjpsmxu.jpg

The transmission installed with out any serious problems. I filled it with 14 qts of Mercon V and went for a test drive. All 4 gears engaged properly but I immediately noticed there was no lock up. 10 miles later the CEL light came on and OD Light started flashing, a quick scan of the codes revealed codes p0741, p1740 and p1744, which confirmed the TCC solenoid wasn't working. I let the car cool for an hour, dropped the pan and swapped the TCC solenoid with a spare, refilled with fluid and test drove again, confirming Lock up was working.

[Odinson]

Awesome writeup! Thanks.

If I ever suspect water got into the trans (like and open dipstick or dislocated tube) I will immediately drop the trans fluid. I did not know the gears could delaminate like that!

Amazing 3rd post. More! More!

[jwibbity]

I'm definitely bringing my trans to you if it ever breaks when i move down to Georgia

[RF Overlord]

Holy moley, that transmission was gorked.

VERY nice write up...and I wish you lived in New England... :(

[bill64]

nice write up. We used to get (in the 80's) gm hydromatic 125 auto transmissions with de laminating frictions but that was a manufacturing defect... I bet water in the trans had a lot to do with that! also, water don't lube to well, how did the bushings look?

[RacerX]

Found this little suprise when I took mine apart this past Saturday to find out why my 1-2 shift was delayed, but, manual 1-2 worked fine. Intermediate clutch snap ring came off and destroyed the thrust washer, burned intermediate clutches/plates and sprag. Allready had the parts including locking spiral snap ring. Eric asked last October why my 1-2 shift at the track seemed a little delayed. Good catch Eric!

http://www.mercurymarauder.net/gallery/data/695/medium/IMG_1107a.jpg (http://javascript<b></b>:;)

[88grandmarq]

nice write up. We used to get (in the 80's) gm hydromatic 125 auto transmissions with de laminating frictions but that was a manufacturing defect... I bet water in the trans had a lot to do with that! also, water don't lube to well, how did the bushings look?

there wasn't a lot of water in the transmission, just enough to contaminate the already old, worn, brown fluid. He also got lucky because he stopped driving the car.

I took the transmission completely apart and inspected everything, from the front pump to the rear extension housing bushing and found NO evidence of lack of lubrication.

:banana:

[88grandmarq]

Found this little suprise when I took mine apart this past Saturday to find out why my 1-2 shift was delayed, but, manual 1-2 worked fine. Intermediate clutch snap ring came off and destroyed the thrust washer, burned intermediate clutches/plates and sprag. Allready had the parts including locking spiral snap ring. Eric asked last October why my 1-2 shift at the track seemed a little delayed. Good catch Eric!

http://www.mercurymarauder.net/gallery/data/695/medium/IMG_1107a.jpg (http://javascript<b></b>:;)

Ouch... spiral snap ring is your friend. this is the cheapest place I have found them;
http://www.transmissionpartsusa.com/AOD_AODE_Spiral_Snap_Ring_1980 _ON_p/270-00027782d.htm

I highly recommend you install the updated OD band with the High energy material. 7L3Z-7F196-A

there is also an updated mechanical diode one way clutch. It has more teeth and more holding power. 7L3Z-7A089-D

:beer:

[RacerX]

Hehe! I was lucky. I anticipated replacing the snap ring, not realizing what I would find, and other internals that I had from a wide ratio FB 4STB run once! :)

http://www.mercurymarauder.net/gallery/data/579/medium/IMG_0867a.jpg (javascript:;)

Check out the broken output shaft at bottom left!!! 1400ftlbs of torque!

http://www.mercurymarauder.net/gallery/data/579/medium/IMG_0876a.jpg (javascript:;)

New spiral snap ring.

http://www.mercurymarauder.net/gallery/data/695/medium/new_locking_snap_ring.jpg (javascript:;)

[wickedmerc]

Holy moley, that transmission was gorked.

VERY nice write up...and I wish you lived in New England... :(

+1 I fear the day my trans starts to go...it can't last forever! :(

Welcome to the site BTW. Awesomely comprehensive write-up. Very cool! :cool:

[babbage]

What a shame to see a loli-pop in the pan = never dropped before. Nice job on the rebuild.

[88grandmarq]

What a shame to see a loli-pop in the pan = never dropped before. Nice job on the rebuild.

yeah, the original fluid was nasty. adding water didn't help.

[88grandmarq]

changed my picture hosting and lost a few of the pictures. but most of them are there now.

[Gerry24]

Great write up 88Marc, I always enjoy you taking apart these trannys. Too bad you're not in Florida.

[fordmike65]

Just wanted to thank you for your help through this thread and PM's. Rebuilt the trans in my '03 Marauder just a lil over a year ago. Was still performing pretty well, but with about 80k I figured it wouldn't hurt. A few pics from the rebuild.

http://uploads.tapatalk-cdn.com/20160125/b2098b827f41ab32e885be5039be41 25.jpg

http://uploads.tapatalk-cdn.com/20160125/4d2be1a5594686803123e9facbd4a0 b8.jpg

http://uploads.tapatalk-cdn.com/20160125/29e57f61d993c1b689114dd1e07957 ec.jpg

http://uploads.tapatalk-cdn.com/20160125/c34e26ab3a187a3724fa21c8bfc767 30.jpg

http://uploads.tapatalk-cdn.com/20160125/4c5af504390b9e6ba4807354cdfe15 c5.jpg