My AX4S-** rebuild

[rudedog]

Well, there definitely were times I wish I'd farmed it out, but, I started it, I was gonna FINISH it!!!! The technical aspect of the shift kit and drum assemblies were probably around a 6. The tear-down, about a 3, as long as you pay attention to what comes out, and when, you should be able to put it back together. I kinda cheated, after I got it all torn down, I reassembled it just to see if it all fit. The re-assembly I would put at about 8 simply because I wanted to MAKE SURE everything was going in according to the Ford cd, the ATSG book and viddy, as well as the two different sets of instructions for the shift-kit and ****-dam kit. Very taxing on the brain. Overall, I'd give the project about an 8 rating.
I'm going to look at an '07 vulcan engine in the morning(22,000 miles), to replace my original 189,000 mile engine. I've also got a gen3 sub-frame thats going to hold it all together. All that, will find it's home under the hood of my '93GL.

 

[n8rsk8r]

sounds like a plan!

 

[rudedog]

For the record, maybe a future sticky. My price list and part numbers and source.

O'Reilly
5-Qts merconV-Valvoline-full synthetic, $21.60

Napa.
filter kit, 1-7586 $12.69

Texas national trans parts.
lip seal protector kit, T-2400 $64.00
accumulator spring, 29372-D $3.20
accumulator spring, 29372-E $3.20
oil pump shaft, 29769 $25.50

www.bulkpart.com/Mako Distributing.
A36650B Sprag, E4OD overdrive, 34 element, $52.25
86006EA Master kit, AXODE/AX4S 1992-98, $132.53
B86020 Band AXOD/AXODE/AX4S/AX4N OD, $30.76
B86026 Band AXOD/AXODE/AX4S Low/intermediate, $31.39
A86915 Band GUIDE, AXOD/AXODE/AX4S, $1.80
86420EAK Solenoid Master kit, AXODE, $153.35
S86165B Superior **** dam kit AXOD/AXODE, $50.61
A86964AA Piston, AXOD/AXODE/AX4S FWD clutch (STEEL) SHO only, $70.13
M465TJ Trans Jel Red assembly **** by SPX Filtran, $3.99
Q86673B TURBINE SHAFT, AXODE/AX4S/AX4N, $15.95
T86165E TransGo Shift Kits AXODE/AX4S 91-up, $46.99

Kinetic (E-Bay).
Clutch spring compressor, $30.00


I have not purchased a torque converter as of yet, when I do I will update this post. I will most likely get it from Bulkpart along with their gauge and in-line filter kit.


A couple of other additions, for the TOTAL project cost, LOL.
Bingle Auto Salvage
2007 vulcan engine (U)-complete, $800.00

pick a part
1999 Taurus GL (vulcan) lower sub-frame with steering knuckles and rack and pinion, $220.00


having the energy to do all this shit, priceless



HAHAHAHAHA

 

[Call_Me_crazy]

Well, it's been a few days and I still need to get a torque converter. I called bulkpart.com and the tech told me that they were out of stock, and didn't know when they would have any more. I also need to know if the 93 was on/off, or PW modulated for the TCC. I ordered the master solenoid kit when I made my purchase, I got 3 shift solenoids, the big EPC solenoid, and actually 2 TCC solenoids, one of which had a blue colored connector, the other having a white connector. When I disassembled the trans, the TCC solenoid I removed had a white connector, which is what I replaced it with. I'm wondering why I also recieved a (blue) colored solenoid. Is the color difference the difference between being on/off and PW modulated?? The original solenoid and the blue solenoid actually have the same FORD part number, but the white solenoid that I installed, the numbers were ground off. But they ALL physically appear to be the same .

The new white solenoid installed

the blue solenoid on top, and the original solenoid on bottom.

bottom view of the same two, orifices and other dimensions seem to be the same.

My biggest problem is that this trans didn't have a torque converter when I got it. So I don't know what the "stamp" codes were, or how many "dimples" the turbine hub had on it. I did install a new 25 spline turbine shaft during the rebuild so that part is covered.

copied from bulkpart.com:
25 spline & 2 dimples on Turbine hub = Check codes for On-Off or Modulating clutch!
25 spline & 3 dimples on Turbine hub = Single plate modulating clutch
25 spline & 4 dimples on Turbine hub = Multiple plate modulating clutch

So!!! How do I determine which of the three torque converters I would need to get?? Any info will begreatly appreciated. Thanks, Rudy.

 

[n8rsk8r]

Chris confirmed with me the white is the right one for sho. Isn't this going into a regular taurus? I will try to find some info while waiting for my coffee to get done.

 

[n8rsk8r]

I have found a chart on TQ'***** me up when you get back on.

-Nathan

 

[rudedog]

Yes Nathan, it will be going in a GL, along with a gen3 subframe and an '07 vulcan. I'm going to have quite the mutt.

 

[n8rsk8r]

WELL.. depending on what of signal the ECM puts out is what type of solenoids you need. man.. have you ran this past a trans shop? What years for each, ECM, 1993 trans I know, and the 07' Vulcan is just the block? Not that you haven't thought of the differences, but have you in the engine/sensors/ecm? Again not that you haven't thought of it, but I hope all are compatable.

I know with my truck I used a different year block 2yrs newer, but everything was the same sensor-wise, fuel wise I just reused the intake and injectors, but the hardparts and sensors were the same.

 

[rudedog]

Yeah, I took all that into account. Right now the '07 is a complete running assembly. I am hoping that the ignition components can be used-CPS/CKP and coil. The injectors and fuel rail will need swapped with my stuff as it is not returnless. Thats basically it. I'll most likely end up making my own y-pipe, or modifying the EGR tube to work with the stock 93 rear exhaust manifold in order to keep the composite upper intake and 60mm TB. I really like the way the SHO has a single coil pack, and I'm hoping that it won't be that difficult to modify the wiring to work, otherwise, I'll have to swap the distributor, and possibly the front cover to accomodate the 93 balancer and pulley. I don't quite have the old one out, when it is, I can sit back and stare at it to see what exactly will and will not go.



As for the TTC solenoid, I was going to pull the side pan off my GL trans, to compare, dimensions and such. I figure if the part #'s match, then I'm golden, if not, I'll have to find another way.

 

[Call_Me_crazy]

Here's another update. Yesterday I managed to remove the steering shaft.

While I was down there I found some burnt wires going to my brake switch. Gotta fix those, wouldn't want a fire after all this work.

I also got some of the accessories removed, alt, p.s. pump, and A/C compressor.

All the wiring, the fan, and the air box have been disconnected and removed.

You might want to stop here, cause it gets ugly!!!

_______________________________________________________________________________

I was watching The Dukes of Hazzard earlier, and got an idea, the start of my push bar.

Ok, since you decided to stick around, on to the main event.
This is what your car will look like sitting four feet in the air.

This is what I said after trying to get the rear section of exhaust from where it lodged itself, after half an hour with no success.

Depression has set in, because AGAIN it started raining!!!! I can't catch a break, every time I've tried to work on this car since May, EVERY time!!!!

Later guys, its whiskey time!!!!!!

 

[n8rsk8r]

you'll get it buddy! Keep hitting it up! I was wondering how I was going to drop my engine out also, gave me an idea, thanks

 

[rudedog]

here is an up-date for those that are interested.

Nov. 25, 2007
It's been raining now for two days straight. All day today, and most of yesterday. Friday though, we managed to have a post turkeyday gtg. Attendees were Zorin, 96SHO, FFVulcanPowah, Rigo, Call_Me_Crazy and me. We went to Pappas BBQ (good stuff). Then came back to my place where we did some vulcan prep. Tim and Mark removed the stuff from the new engine as I removed the stuff from the old one. We've come to the conclusion that I will not at this time be able to use the upper composite intake, the EDIS components, and the exhaust manifolds. So, we swapped out the distributor, and added my phenolic spacer along with Mark's 2000 upper manifold. It looks pretty good. I really would have liked to keep it with all the '07 equipment, but, all in good time. Pics.

Dist. installed

Full view

2000 intake, Anonda Motorsports spacer

Nov. 28, 2007
update.........
Progress was hampered by rain for a couple of days. Its gone for now so I got out there yesterday and started swapping the distributor gear from the cam synchro. The new dist gear I had put on in Nov. of 06 was scrap again, gotta figure that out. I think there was some lateral play in the 93's cam causing it, not sure yet, we'll find out hopefully on disassembly. While I was installing the new gear onto the distributor shaft, it cracked making it useless also, so I went and bought a NEW distributor. $78 bucks BRAND SPANKIN NEW!!!!! I had to also get a couple of replacment gear sets for the window motors on our Ranger, so for today thats what I've done so far. Tore the doors apart and pulled the motors then reassembled everything, about 45 minutes total. Anyway I'll get the distributor stabbed and timed today and get the 2 small intake holes drilled and tapped for the retaining bolts. I'll probably get the y-pipe off the old motor as well as the manifolds and engine mounts. Then I can start loading everything onto the gen3 subframe. Its coming along slowly but surely. Pics to come as always.

as of last night.
OMG!!!!! It didn't rain today, something must be terribly wrong!!!! HAHAHAHA just kidding. I took my son to see his diabetes Dr.s today so I didn't get started till after we got home and ate lunch. So about 3:00 I went out and got a bit dirty.

Started by getting the old engine off the subframe and getting the trans ready also to come off. Disconnected the torque converter and bell housing, motor mounts and engine brackets.

I pulled my UDP and water pump pulley off and swapped them to the new engine.

Swapped both exhaust manifolds because the rear one dumps out in a downward position, where as the 07 dumps out straight into the fenderwell. The front one for the 07 would have been really close to the fan and also closer to the oil filter, so I swapped it for the 93 also, that way I can still use my Y-pipe for now.

the 93 rear manifold mounted on the new engine.

the 07 manifold removed, see the difference?

the 93 front manifold mounted.

and the 07 manifold

some tags on the new engine I had not seen before, engine number, etc.
front of front valve cover

back side of rear valve cover

rear side of engine block

rear side of block just under head

and lastly a small pile of parts, some will get re-used, some will not, LOL.

More tomorrow. I hope to have the engine and trans bolted together and on the gen3 frame, we'll see.

 

[rudedog]

And here's what I did today.

I almost did it!!!!! I was just a bit lazy this morning and kinda waiting on my sister a little bit. I have a TV to drop at her place and called several times, no answer. Sooo, I decided to chill and see if she called back, because I didn't want to be all dirty and have to go somewhere. Any way, about 3:00 again I started trying to get stuff done.

First, the timing pointer on the 07 front cover and the 07 balancer w/exciter ring with my UDP mounted.

Next, we have the specially prepared rebuilt SHO trans a la Rudy(me). With a NEW converter.

And lastly, we have the 07 engine married to the rebuilt trans.

Enjoy!!!

 

[n8rsk8r]

awesome!

 

[rudedog]

It's running again!!!! Have'nt driven it but just around the block (literally) just to see if it actually moved, LOL. I wasn't even going to do that, but I got bitched at by a friend that had a good point. "Why go through all the trouble to do it, post pics, do a blow by blow, and then NOT even see if it works? Just sounds stupid to me." It seems to have excellent power, more-so than before. It could be the fact that the engine is new, and doesn't have 164,*** miles on it, or it could be that the trans is doing what it's supposed to do, now. It could also be, I guess, the differences in gearing. I dunno, but so far ...... I LIKE IT!!!! I gotta get it inspected today, and also replace the front hub-bearings, as I didn't do that before I installed everything.