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  #1  
Old 07-20-2012, 06:52 PM
TARM TARM is offline
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Default 4R100 Rebuild Manual for the DIY

This is going to be a thread where myself and a few guys have decided to create a step by step manual for doing a complete 4r100 transmission rebuild.

The idea is to make it as clear and with as much detail as possible covering all aspects of it from removal and install from/back into the truck, dis-assembly, cleaning, rebuilding, upgrades, tools etc.

WE would be happy for anyone to help out and share knowledge they have tips tricks that make the job easier. Anything that would be positively constructive. But if you are just coming in to say its better to buy a BTS JW etc or to be negative about the idea then please just keep on moving along to another thread. If it does get mucked up with any BS we will have one of the mods clean it up. The idea is to minimize as much of the confusion and difficulty in knowing the proper steps etc as possible. At the end of this we plan to take all the info and put it into a logical order to create a step by step online manual of sorts for doing a 4r100 trans build yourself if you so choose or need to do so.


If you reading this thread and want to post please be sure to check the last post as one of us may be posting up a number of steps that take more than one post to conclude and we want them to be in order. There will be a message at the beginning and ending of the thread asking people to please not post until the last post is complete and there is no message on it not to post.
__________________
01' Excursion (forged): ********'s tuning, GTX4294r-1.15t4, Nate's Stage 5 Firehoses 465cc/200%, Stealth's SP1, ARP Studs, 910's (shimmed), DI Pushrods (SAE 4130 CM), Full Custom Fuel System, aFe-Big Boost, DE 4" Exhaust, BTS Trans, 99'-04' V code front/08'F code rear spring swap, PMF 4"Hanger-Shackle kit/5"Rear Blocks, Custom Valved Blistien's, Rear Sway bar, Bushwhackers Cut-out Flares, Fuel Hostage 20"x12" Black Wheels, Interco M16 40"x14.50"x20" Tires
  #2  
Old 07-20-2012, 09:13 PM
TARM TARM is offline
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Default 4R100 Disassembly Pictorial

This contains a step by step picture guide for the complete disassembly of the 4r100 transmission. There will be very little text other than what is in the pictures. Will be adding in text procedures to accompany the pictures at a later date.

Pictures are courtesy of TwistWrench



4R100 Disassembly

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__________________
01' Excursion (forged): ********'s tuning, GTX4294r-1.15t4, Nate's Stage 5 Firehoses 465cc/200%, Stealth's SP1, ARP Studs, 910's (shimmed), DI Pushrods (SAE 4130 CM), Full Custom Fuel System, aFe-Big Boost, DE 4" Exhaust, BTS Trans, 99'-04' V code front/08'F code rear spring swap, PMF 4"Hanger-Shackle kit/5"Rear Blocks, Custom Valved Blistien's, Rear Sway bar, Bushwhackers Cut-out Flares, Fuel Hostage 20"x12" Black Wheels, Interco M16 40"x14.50"x20" Tires
  #3  
Old 07-20-2012, 09:14 PM
TARM TARM is offline
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Default 4R100 Disassembly Pictorial

4R100 Disassembly

Part 2 of 3

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__________________
01' Excursion (forged): ********'s tuning, GTX4294r-1.15t4, Nate's Stage 5 Firehoses 465cc/200%, Stealth's SP1, ARP Studs, 910's (shimmed), DI Pushrods (SAE 4130 CM), Full Custom Fuel System, aFe-Big Boost, DE 4" Exhaust, BTS Trans, 99'-04' V code front/08'F code rear spring swap, PMF 4"Hanger-Shackle kit/5"Rear Blocks, Custom Valved Blistien's, Rear Sway bar, Bushwhackers Cut-out Flares, Fuel Hostage 20"x12" Black Wheels, Interco M16 40"x14.50"x20" Tires
  #4  
Old 07-20-2012, 09:14 PM
TARM TARM is offline
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Default 4R100 Disassembly Pictorial

4R100 Disassembly

Part 3 of 3

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__________________
01' Excursion (forged): ********'s tuning, GTX4294r-1.15t4, Nate's Stage 5 Firehoses 465cc/200%, Stealth's SP1, ARP Studs, 910's (shimmed), DI Pushrods (SAE 4130 CM), Full Custom Fuel System, aFe-Big Boost, DE 4" Exhaust, BTS Trans, 99'-04' V code front/08'F code rear spring swap, PMF 4"Hanger-Shackle kit/5"Rear Blocks, Custom Valved Blistien's, Rear Sway bar, Bushwhackers Cut-out Flares, Fuel Hostage 20"x12" Black Wheels, Interco M16 40"x14.50"x20" Tires
  #5  
Old 07-20-2012, 11:07 PM
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dentexpowerstroke dentexpowerstroke is offline
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Default

Can you also add what tools you used in each picture? Would be much appreciated.
__________________
01 f250 ccsb 4x4 400/400, twin terminators, s480, bts and supporting mods --- sold

2006 ccsb f250 155s and powermax

2012 ccsb lariat ultimate
  #6  
Old 07-20-2012, 11:25 PM
TARM TARM is offline
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Default Exploded Parts view and list

Exploded Parts View and List




Outer Casing View


Images 1-5





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Outer Casing: 2




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Valve Body Exploded View & Parts List


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Valve Body Exploded View: 1




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FORD 4R100

MAIN, LOWER, AND ACCUMULATOR VALVE BODY LEGEND


Item Description Item Description

1 LOWER VALVE BODY CASTING
2 HEX HEAD BOLT, (2 REQUIRED)
3 RETAINING PLATE
4 MANUAL 1-2 TRANSITION VALVE SPRING
5 MANUAL 1-2 TRANSITION VALVE
6 SPRING CLIP BORE PLUG RETAINER
7 ENGAGEMENT VALVE BORE PLUG
8 ENGAGEMENT VALVE SPRING
9 ENGAGEMENT VALVE
10 MAIN VALVE BODY CASTING
11 CHECK-BALL 1/4", (2 REQUIRED)
12 CHECK-BALL 5/16", (2 REQUIRED)
13 MANUAL CONTROL VALVE
14 MANUAL VALVE "E" CLIP
15 SPRING CLIP BORE PLUG RETAINER
16 LOW REVERSE MODULATOR VALVE SLEEVE
17 LOW REVERSE MODULATOR VALVE PLUNGER
18 LOW MODULATOR VALVE SPRING
19 LOW MODULATOR VALVE
20 LOW REVERSE MODULATOR VALVE
21 SPRING CLIP BORE PLUG RETAINER
22 3-4 SHIFT VALVE BORE PLUG
23 3-4 SHIFT VALVE SPRING
24 3-4 SHIFT VALVE
25 2-3 SHIFT VALVE SPRING RETAINING PLATE
26 2-3 SHIFT VALVE SPRING
27 2-3 SHIFT VALVE
28 SOLENOID REGULATOR VALVE SPRING RETAINING PLATE
29 SOLENOID REGULATOR VALVE SPRING
30 SOLENOID REGULATOR VALVE
31 COAST CLUTCH SHIFT VALVE SPRING RETAINING PLATE
32 COAST CLUTCH SHIFT VALVE SPRING
33 COAST CLUTCH SHIFT VALVE
34 4-3-2 SHIFT TIMING CONTROL VALVE PLUNGER RETAINING PLATE
35 4-3-2 SHIFT TIMING CONTROL VALVE PLUNGER SPRING
36 4-3-2 SHIFT TIMING CONTROL VALVE PLUNGER
37 4-3-2 SHIFT TIMING VALVE RETAINING PLATE
38 4-3-2 SHIFT TIMING VALVE
39 4-3-2 SHIFT TIMING VALVE SPRING
40 SPRING CLIP BORE PLUG RETAINER
41 1-2 SHIFT VALVE BORE PLUG
42 DRIVE 2 VALVE
43 1-2 SHIFT VALVE
44 1-2 SHIFT VALVE SPRING
46 ACCUMULATOR VALVE BODY CASTING (MODEL SENSITIVE)
47 SPRING CLIP BORE PLUG RETAINER
48 DIRECT CLUTCH ACCUMULATOR REGULATOR PLUNGER BORE PLUG
49 DIRECT CLUTCH ACCUMULATOR REGULATOR PLUNGER SPRING
50 DIRECT CLUTCH ACCUMULATOR REGULATOR PLUNGER
51 DIRECT CLUTCH ACCUMULATOR REGULATOR VALVE RETAINER
52 DIRECT CLUTCH ACCUMULATOR REGULATOR VALVE SPRING
53 DIRECT CLUTCH ACCUMULATOR REGULATOR VALVE
54 SPRING CLIP BORE PLUG RETAINER
55 O.D. CLUTCH ACCUMULATOR REGULATOR PLUNGER BORE PLUG
56 O.D. CLUTCH ACCUMULATOR REGULATOR PLUNGER SPRING
57 O.D. CLUTCH ACCUMULATOR REGULATOR PLUNGER
58 O.D. CLUTCH ACCUMULATOR REGULATOR VALVE RETAINER
59 O.D. CLUTCH ACCUMULATOR REGULATOR VALVE SPRING
60 O.D. CLUTCH ACCUMULATOR REGULATOR VALVE
61 SPRING CLIP BORE PLUG RETAINER
62 INT. CLUTCH ACCUMULATOR REGULATOR PLUNGER BORE PLUG
63 INT. CLUTCH ACCUMULATOR REGULATOR PLUNGER SPRING
64 INT. CLUTCH ACCUMULATOR REGULATOR PLUNGER
65 INT. CLUTCH ACCUMULATOR REGULATOR VALVE RETAINER
66 INT. CLUTCH ACCUMULATOR REGULATOR VALVE SPRING
67 INT. CLUTCH ACCUMULATOR REGULATOR VALVE
68 SPRING CLIP BORE PLUG RETAINER
69 LINE PRESSURE MODULATOR SLEEVE
70 LINE PRESSURE MODULATOR PLUNGER
71 LINE PRESSURE MODULATOR SPRING AND RETAINER ASSEMBLY
72 LINE PRESSURE MODULATOR VALVE SPRING
73 LINE PRESSURE MODULATOR VALVE
AUTOMATIC TRANSMISSION















Pump Exploded View


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Pump Exploded View: 1




Pump Exploded View: 2




Pump Exploded View: 3




1 PRESSURE REGULATOR VALVE
2 PRESSURE REGULATOR VALVE SPRING RETAINER
3 PRESSURE REGULATOR VALVE OUTER SPRING
4 PRESSURE REGULATOR VALVE INNER SPRING
5 PRESSURE REGULATOR BOOST VALVE
6 PRESSURE REGULATOR BOOST VALVE SLEEVE
7 PRESSURE REGULATOR BOOST VALVE SLEEVE SNAP RING
8 CONVERTER CLUTCH REGULATOR VALVE
9 CONVERTER CLUTCH REGULATOR VALVE SPRING
10 CONVERTER CLUTCH REGULATOR VALVE BORE PLUG
11 BORE PLUG RETAINER
12 CONVERTER CLUTCH CONTROL VALVE ("ON-OFF" ONLY)
13 CONVERTER CLUTCH CONTROL SPRING ("ON-OFF" ONLY)
14 CONVERTER CLUTCH CONTROL VALVE BORE PLUG
15 CONVERTER CLUTCH CONTROL VALVE LINE-UP ("PWM" ONLY)













Check Ball Locations Valve Body Exploded View


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Sonnax Sure Cure Shift Kit SC-4R100


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Sonnax Kit: 3




Sonnax Kit: 4




Sonnax Kit: 5




Sonnax Kit: 6




Sonnax Kit: 7

















Clutch Clearance Set Up Specs


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Clutch Clearance Set Up: 1




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Clutch Clearance Set Up: 3




Clutch Clearance Set Up: 4




Clutch Clearance Set Up: 5




Clutch Clearance Set Up: 6




Clutch Clearance Set Up: 7




Clutch Clearance Set Up: 8




Clutch Clearance Set Up: 9



If you find things like this on piston surfaces, do NOT just pass it and let it go. it will cause early failure.

Polish it smooth and evenly or replace it if in question. they are not worth guessing over.
__________________
01' Excursion (forged): ********'s tuning, GTX4294r-1.15t4, Nate's Stage 5 Firehoses 465cc/200%, Stealth's SP1, ARP Studs, 910's (shimmed), DI Pushrods (SAE 4130 CM), Full Custom Fuel System, aFe-Big Boost, DE 4" Exhaust, BTS Trans, 99'-04' V code front/08'F code rear spring swap, PMF 4"Hanger-Shackle kit/5"Rear Blocks, Custom Valved Blistien's, Rear Sway bar, Bushwhackers Cut-out Flares, Fuel Hostage 20"x12" Black Wheels, Interco M16 40"x14.50"x20" Tires
  #7  
Old 07-21-2012, 03:08 AM
TARM TARM is offline
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Default 4R100 Reassembly/Rebuild Pictorial

4R100 Reassembly/Rebuild

Part 1 of 6

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__________________
01' Excursion (forged): ********'s tuning, GTX4294r-1.15t4, Nate's Stage 5 Firehoses 465cc/200%, Stealth's SP1, ARP Studs, 910's (shimmed), DI Pushrods (SAE 4130 CM), Full Custom Fuel System, aFe-Big Boost, DE 4" Exhaust, BTS Trans, 99'-04' V code front/08'F code rear spring swap, PMF 4"Hanger-Shackle kit/5"Rear Blocks, Custom Valved Blistien's, Rear Sway bar, Bushwhackers Cut-out Flares, Fuel Hostage 20"x12" Black Wheels, Interco M16 40"x14.50"x20" Tires
  #8  
Old 07-21-2012, 03:10 AM
TARM TARM is offline
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Default 4R100 Reassembly/Rebuild Pictorial

4R100 Reassembly/Rebuild

Part 2 of 6

Images: 41-80






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__________________
01' Excursion (forged): ********'s tuning, GTX4294r-1.15t4, Nate's Stage 5 Firehoses 465cc/200%, Stealth's SP1, ARP Studs, 910's (shimmed), DI Pushrods (SAE 4130 CM), Full Custom Fuel System, aFe-Big Boost, DE 4" Exhaust, BTS Trans, 99'-04' V code front/08'F code rear spring swap, PMF 4"Hanger-Shackle kit/5"Rear Blocks, Custom Valved Blistien's, Rear Sway bar, Bushwhackers Cut-out Flares, Fuel Hostage 20"x12" Black Wheels, Interco M16 40"x14.50"x20" Tires
  #9  
Old 07-21-2012, 03:12 AM
TARM TARM is offline
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Default 4R100 Reassembly/Rebuild Pictorial

4R100 Reassembly/Rebuild

Part 3 of 6

Images: 81-120





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__________________
01' Excursion (forged): ********'s tuning, GTX4294r-1.15t4, Nate's Stage 5 Firehoses 465cc/200%, Stealth's SP1, ARP Studs, 910's (shimmed), DI Pushrods (SAE 4130 CM), Full Custom Fuel System, aFe-Big Boost, DE 4" Exhaust, BTS Trans, 99'-04' V code front/08'F code rear spring swap, PMF 4"Hanger-Shackle kit/5"Rear Blocks, Custom Valved Blistien's, Rear Sway bar, Bushwhackers Cut-out Flares, Fuel Hostage 20"x12" Black Wheels, Interco M16 40"x14.50"x20" Tires
  #10  
Old 07-21-2012, 03:13 AM
TARM TARM is offline
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Default 4R100 Reassembly/Rebuild Pictorial

4R100 Reassembly/Rebuild

Part 4 of 6

Images: 121-160





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__________________
01' Excursion (forged): ********'s tuning, GTX4294r-1.15t4, Nate's Stage 5 Firehoses 465cc/200%, Stealth's SP1, ARP Studs, 910's (shimmed), DI Pushrods (SAE 4130 CM), Full Custom Fuel System, aFe-Big Boost, DE 4" Exhaust, BTS Trans, 99'-04' V code front/08'F code rear spring swap, PMF 4"Hanger-Shackle kit/5"Rear Blocks, Custom Valved Blistien's, Rear Sway bar, Bushwhackers Cut-out Flares, Fuel Hostage 20"x12" Black Wheels, Interco M16 40"x14.50"x20" Tires
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