2002 s80 trans slipping swap or rebuild?

[bronco]

this transmission is not meant to be reassembled in the horizontal position. the shell falls off to one side and won't slot in to the second clutch. Ideally the whole assembly would be slid in as one unit but the reverse band doesn't really want to go in after the fact.

I wonder if the servo piston up top came off the band could be put on the drum and slid in with everything else

[SuperHerman]

As stated early on - it is easier to drop the parts in relative to sliding them in.

Many, myself included, managed to slide them in.

I recall using a long straight flat bar to keep things (shell) aligned (parallel), but as more parts go in it can be removed. Do you have the main shaft installed? If I recall I left it in and removed the clip on the end so I could slide things in without catching. Once the first pieces go in place it gets easier. It helps to use lots of assembly lube to hold things together.

[bronco]

As stated early on - it is easier to drop the parts in relative to sliding them in.

Many, myself included, managed to slide them in.

I recall using a long straight flat bar to keep things (shell) aligned (parallel), but as more parts go in it can be removed. Do you have the main shaft installed? If I recall I left it in and removed the clip on the end so I could slide things in without catching. Once the first pieces go in place it gets easier. It helps to use lots of assembly lube to hold things together.

The sticking point is second clutch. There is a whole bunch of things going on there. It has to slide over the 3rd and input clutch assembly while engaging the shell and passing thru the band

The band is whats annoying me , it keeps catching on the clutch drum. I actually almost had it I wrapped clothesline around the shell to support it and left the end hanging out so I could pull it out after but while I was doing that it got caught in the band and tweaked it then the drum slid back out

[bronco]

Ok so its basically back in . I find some annoying areas on the various youtube videos where they gloss over parts that are not exactly obvious

Where I left off yesterday the final drive planet snap ringed back in the case and the sun shaft in where it is supposed to be. but I have just added the forward band in .

I've added the first drum it is better to do these one at a time Forward band , its drum , manual low band then its drum that way you can make sure the bands are not cockeyed

Note after the second band and drum is in the gear inside the drum and the end of the sunshaft inside are nearly flush and if you grab that gear and turn it counter clockwise the drum you are turning will turn by itself and make i kind of screeching or wailing sound but if you turn clockwise the one way clutch with lock and both drums will turn.

[bronco]

Now the next part is where the first planet goes in

In this pic the side facing up goes into the trans first and you can see there is a raised lip that is splined inside . that inner spline engages the outside of the sunshaft but slides into the I guess spindle or nose of the final drive planet holder, which is bushed inside . so you are puting it into a tight area you have to wiggle it around because the inner part of the planetary is also meshing with the ring gear.

When its in right the sunshaft is going to basically be flush with the face of that planetary as pictured here

You have to be careful here because if you are fumbling around and trying it pulling it out could drag the hollow sunshaft out with it !!


That is the start of what went wrong on my adventure if the sunshaft comes out an inch or so you can push it back in , but if it comes 2 inches or more out then the park gear will fall down in behind and its not going to go back in without dismantling that part also and you need pan access so depending on how you have everything supported it becomes a whole big thing.

After that the oil dam goes back on and some grease to hold it against that planet is a good idea ,

then the next planet goes in and this is a double or 2 step engagement so you might have to fiiddle around quite a bit

[bronco]

The next thing to go in is the shell then the assembly containing the 3rd clutch and input clutch plus the 2 sprags and the sungear.

The way I did it was to put the 3rd clutches in then the snap ring then drop the 2 sprags in and use them to line up the 3rd clutch frictions then assemble the input frictions around the sprag. I found it very aggravating to try to drop both sprags in later. So I paint a dot on the bearing because basically as you are working the small sprag into the frictions it can be hard to tell when its seated . if its not seated it will rock back and forth and if you spin it the bearing will not move but once its seated in you can spin the sprags and they will drag the bearing around , the paint makes it more obvious that its moving.

here it is with both sprags fully seated I like to line one keyway up with the paint dot.

Then I pack the input clutch around the upper sprag and as you can see properly seated they are essentially flush

Then the sungear

Now just as a goof and to illustrate how everything fits I took the following pic after I took the sprags out again because I decided I needed more grease around the sprag to keep it from pulling out while i am trying to put this in.
The 4th gear clutch shaft goes up through this whole mess and the splines that are known for stripping out actually engage this sungear. Here is sort of a cutaway pic of that with the sprags left out note that the sun is bottomed out on the shaft in this pic but when the sprags are in the ring holds it up where it is supposed to be.

[bronco]

So here is the shell on the planet

and the


first time , which didnt work where I thought I could just stick a screwdriver in there to support the shell

here is my second attempt with a wooden wedge to support the band and I was going to reach around that with a screwdriver to move the shell about which also didnt work.

try 3 which didnt work with clothesline but i was on the right track however all the pics after came out too blurry and it was together before i realized and no way was I taking it apart again for a photo op.

try 4 used a clothesline held in place by greasing the inside of the case and pushing the rope into the grease back and forth in such a way that I knew it would all pull out after . by using grease you can work the rope up the sides if need be Picture how an anchor rope is laid on the deck of a ship so it doesn't foul when you drop anchor like in this clip but stuck with grease .



Try 4 also used a bent screw driver and a wooden wedge

and I stopped after that pretty much

Edited to add
I did look at removing the upper piston but that one is not a bolt in you have to push it in preferably with a clamp with the transmission out of the vehicle it didn't seem like a good idea, also just now I think that I could have used my rope trick inside the hub of the input/3rd clutch assembly to keep it from drooping down, or possibly inserted the 4th gear shaft in to do the same thing

[bronco]

I will send you a pm.

Look here for TransGo shift kits: https://tripleedgeperformance.com/

When I looked at accumulators I found a broken spring. It not hurt to look at them.

I read this when you posted but was thinking of the ones in the pan . I am ready to put the transfer plate on and just now looked at the 3-4 accumulator and found a broken spring in it

Ordered from triple edge just now looks like I'm stalled waiting on something I should have noticed sooner.

Although I still haven't received the side cover gasket yet so I couldn't do much more .

I guess I'll go through the valve body and what all while I wait

Wondering whether the 3-4 accumulator issue could have contributed to the heavy wear in the 2nd clutch .

This transmission didn't present a single code when I scanned it either interestingly

[bronco]

This is on pause until I get the accumulator spring kit from triple edge

Stupidly I didn't pull that accumulator apart when I dismantled the transmission I could have ordered the springs 4 or 5 days earlier

[SuperHerman]

bronco - your great work and photos are much appreciated. Keep us updated.

I am enjoying this thread.