4R100 Rebuild Manual for the DIY

TARM

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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.
 

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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

Part 1 of 3

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TARM

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4R100 Disassembly Pictorial

4R100 Disassembly

Part 2 of 3

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Disassembly: 80​
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4R100 Disassembly Pictorial

4R100 Disassembly

Part 3 of 3

Images: 81-120



Disassembly: 81​
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Exploded Parts view and list

Exploded Parts View and List​



Outer Casing View​

Images 1-5​




Outer Casing: 1​
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Outer Casing: 2​
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Outer Casing: 3​
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Outer Casing: 4​
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Outer Casing: 5​
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Valve Body Exploded View & Parts List​

Images: 1-7




Valve Body Exploded View: 1​
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Valve Body Exploded View: 2​
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Valve Body Exploded View: 7​
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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​

Images 1-3




Pump Exploded View: 1​
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Pump Exploded View: 2​
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Pump Exploded View: 3​
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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​

Images 1-3




Check Ball Location: 1​
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Check Ball Location: 2​
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Check Ball Location: 3​
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Sonnax Sure Cure Shift Kit SC-4R100

Images: 1-7​



Sonnax Kit: 1
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Sonnax Kit: 2
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Sonnax Kit: 3
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Sonnax Kit: 4
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Sonnax Kit: 5
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Sonnax Kit: 6
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Sonnax Kit: 7
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Clutch Clearance Set Up Specs​

Images: 1-9




Clutch Clearance Set Up: 1
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Clutch Clearance Set Up: 2
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Clutch Clearance Set Up: 3
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Clutch Clearance Set Up: 4
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Clutch Clearance Set Up: 5
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Clutch Clearance Set Up: 6
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Clutch Clearance Set Up: 7
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Clutch Clearance Set Up: 8
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Clutch Clearance Set Up: 9
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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.
 

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4R100 Reassembly/Rebuild Pictorial

4R100 Reassembly/Rebuild

Part 1 of 6

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TARM

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4R100 Reassembly/Rebuild Pictorial

4R100 Reassembly/Rebuild

Part 2 of 6

Images: 41-80​





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TARM

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4R100 Reassembly/Rebuild Pictorial

4R100 Reassembly/Rebuild

Part 3 of 6

Images: 81-120​




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4R100 Reassembly/Rebuild Pictorial

4R100 Reassembly/Rebuild

Part 4 of 6

Images: 121-160​




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4R100 Reassembly/Rebuild Pictorial

4R100 Reassembly/Rebuild

Part 5 of 6

Images: 161-200​




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TARM

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4R100 Reassembly/Rebuild Pictorial

4R100 Reassembly/Rebuild

Part 6 of 6

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TARM

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4R100 Homemade Tools

4R100 Homemade Tools

Images: 1-9​



To rebuild the 4r100 there are a few tools that make life much better. They are very simple tools to fab up your self.


To service the reverse clutch piston seals you will need 2- 3 inch or longer 5/16 24 all thread studs. I didn’t have in my supplies and couldn’t find any at my local hardware store so I simple took a couple all thread 5/16 18 bolts. Ran a 5/16 24 thread die over them and cut the heads off. Perfect 5/16 24 studs.



To make installing the direct/forward drum a breeze. You can make a simple tool to install them as an assembly.

You can purchase this already made from several suppliers. I made mine from a single stick of 1/8 X 1 ¼ mild steel purchased from the local ace hardware.

I cut one piece at 17 inches and the other at 8.5

The 17 inches piece has bends at about 5 inches on both ends.

The 8.5 inch piece has bends at about 2 inches on each end

Hole drilled in the center of both and the ends of the 17 inch cut out to match the notches in the direct drum.
Works great!


To install the intermediate/ overdrive snap ring you will need a clutch spring compressor. You can buy these from various suppliers. I made mine very simply from a piece of plate aluminum and some tube steel and all thread.

I used the pump itself for a pattern to mark out the brace section and drilled the two holes. Again, using the pump itself for a pattern is suggested to get your bolt hole and length dimensions.

I then ground the ends of the brace/support to match the contour of the transmissions case itself.

Then tapping out the brace for the all thread and welding on a handle.
The flat press plate aluminum disc is simple just to 6 7/8 inches. This can be larger also.

You could use steel for the press plate.


The 4R100 is actually a very easy transmission to rebuild as long as you have a few simple tools to help you. You can purchase them from many suppliers or as here make them easily from some common materials.







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TARM

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Well that was 10 hours of work to get those posted. I will likely be adding more tomorrow or I guess its now latter today.:shrug:
 

TARM

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Are those all from your personal experience, TARM? Did you use an ATSG?


From other places on the forums. A guy by the name of Twistedwrench had put them up over time. I dug them up saved them. Then eventually uploaded to photobucket and finally posted them up here.

All the info I am posting up is what I am finding thru research and net searches. Just want to get it all in one place nicely organized in a step by step format so anyone with a reasonably about of skill and IMO most importantly being willing to stay organized could take on the job and successfully rebuild the 4R100

I need to obtain a ASTG 4R100 Manual so we can work on getting written step by step directions to go along with the pictorial steps. Along with that add in all the other stuff.

List of all tools and sizes not just special tool so a person can have them all laid out ready to go.

Any greases lubricants etc...

Info on the various kits available what is in a full rebuild kit. What other single items you can and when you should upgrade them etc...

All that kind of stuff all in one place nicely organized. That is the goal here. Then to add in any tip or helpful hints and tricks to making the job and outcome easier/better.
 

TARM

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Can a mod change the title to say 4R100 / E4OD instead of just 4r100

Thanks.

It would actually be real helpful if the posts in this thread could be left editable and not locked after 30mins. It can take longer than that just to fix one of these posts.
 

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