I just self-built/upgraded an AOD - after lots of research (very good site is baumannengineering.com) got baumann shift kit and a couple other small goodies. Found best kit/value at Art Carr, their premium kit included high perf clutch packs, etc, along with ALL other items needed. They also have manuals (ATSG) that are pretty decent, which have a listing of special tools available. I was able to make all of my special tools such as seal protectors, bushing drivers, etc. Took some fiddling, but worked out.
DON'T skimp on bargain parts!!!
From above post, where does one get the Factory Rebuild manual? I've also found public libraries to have the big Chilton type manuals that are very detailed and which you can usually photocopy right at the library.
HIGHLY recommend a cooler, maybe a trans temp gauge to track temps, and a shift kit to firm up shifts at least a little. Consider synthetic fluid although expensive, or maybe only slightly more expensive semi-synthetic such as Aamco.
PS - AOD or better an AOD/E swap is a great swap for street/highway because gives OD. Bolts pretty much right up, uses same driveshaft, starter and flex plate you have. Have to modify rear mount a little, or they're commercially available. Info at Baumann site, or email me for address of several good articles on the swap if you're interested.
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