ANYONE EVER REBUILD AN AOD

macx · 01-13-2001, 03:00 AM

baumannengineering.com says pre-88 AOD's have inferior rear geartrain lube and are very suspect - likely worn out. I did my 89 & upgraded some stuff. Researched, got Carr's premium kit because it already had Alto Red clutches in it plus all the bearings/bushings etc. Mine had the cast drum, I upgraded to stamped steel ($100) so I could put the 8 direct clutches in instead of the max 6 for the cast drum. My motor is not real hot, that was kind of overkill. I would highly recommend Carr's zero leak 2-3 accumulator and A od servo and hd (not kevlar) od band. If you get the $500 wide ratio Ford gearset kit, then you can also use the wider od band. The hardest part without the special tools is putting in the lip seals into the clutch drums - I cut strips of alum cans but was a real pain. Also the rear case bushing has to go in from inside - I had to fabricate a bushing driver and used it on my slide hammer handle to get the length to get into the case. Helps to put the bushings in the freezer awhile to shrink them a little. Also takes a big set of bushing drivers - lots of different sizes. The ATSG manual (not very good) said .010" per clutch in direct clutch pack, Carr said total of only about .030 but I think that was for race only. Local rebuilder said looser is OK for better fluid flow. After doing it, I'd say stick to the .010 per disc. Instead of the expensive bar to measure total end play, assemble the trans and sit up on tailshaft end. Pull up on hollow input shaft - that's your total end play. I used Baumann shift kit - you need a kit that eliminates "cutback" - that's lowering the internal line pressure for 2-3 and 3-4 shifts for smoothness, but allows toomuch slip. Saying all this, I wish I'd of taken Baumann's advice and gotten an AOD/E - the AOD's weak points are all engineered out and a good quality stock rebuild /E with a kit is better than a beefed AOD. I've seen some specialty shops drill out the lube holes in the clutch pack drums for better lube flow, too. read the baumann site - lots of good info. good luck!

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01-13-2001, 03:00 AM	#6
macx Registered Member Join Date: Oct 1999 Location: Gordonville MO USA Posts: 448	baumannengineering.com says pre-88 AOD's have inferior rear geartrain lube and are very suspect - likely worn out. I did my 89 & upgraded some stuff. Researched, got Carr's premium kit because it already had Alto Red clutches in it plus all the bearings/bushings etc. Mine had the cast drum, I upgraded to stamped steel ($100) so I could put the 8 direct clutches in instead of the max 6 for the cast drum. My motor is not real hot, that was kind of overkill. I would highly recommend Carr's zero leak 2-3 accumulator and A od servo and hd (not kevlar) od band. If you get the $500 wide ratio Ford gearset kit, then you can also use the wider od band. The hardest part without the special tools is putting in the lip seals into the clutch drums - I cut strips of alum cans but was a real pain. Also the rear case bushing has to go in from inside - I had to fabricate a bushing driver and used it on my slide hammer handle to get the length to get into the case. Helps to put the bushings in the freezer awhile to shrink them a little. Also takes a big set of bushing drivers - lots of different sizes. The ATSG manual (not very good) said .010" per clutch in direct clutch pack, Carr said total of only about .030 but I think that was for race only. Local rebuilder said looser is OK for better fluid flow. After doing it, I'd say stick to the .010 per disc. Instead of the expensive bar to measure total end play, assemble the trans and sit up on tailshaft end. Pull up on hollow input shaft - that's your total end play. I used Baumann shift kit - you need a kit that eliminates "cutback" - that's lowering the internal line pressure for 2-3 and 3-4 shifts for smoothness, but allows toomuch slip. Saying all this, I wish I'd of taken Baumann's advice and gotten an AOD/E - the AOD's weak points are all engineered out and a good quality stock rebuild /E with a kit is better than a beefed AOD. I've seen some specialty shops drill out the lube holes in the clutch pack drums for better lube flow, too. read the baumann site - lots of good info. good luck!