Rescue
I did what Grant suggested to me. Brilliant, photos here:



I used stuff called SilentCoat , which is cheap and really good and tough. Also used it as a bonnet liner. As it is so thin, it did not inhibit the arirflow to put it on the box as well as the tunnel roof.
https://www.silentcoat.co.uk/

 

Yes that yellow crap was annoying. I think i ate some of it as it was pretty brittle. I had ripped most of it out so I could get my 3 ft of extensions up in there anyways and was gonna ask later on what type of material to use so thanks for the input already.

 

Took some.more stuff off today and found this


broken low band 1 - 2 accumulater spring.

The spring shown here




So guess ill grab one lol.

also how do I get this off? (The part that connects to the drive shaft) the nut wasnt on very tight. Maybe a 1/4 past hand tight. That normal? Should it pull off or should I take out the internals first? It moves maybe 1/8 but I dont want to beat on it if it doesn't come off that way lol.




Besides that all thats left is to remove the pump and the internals. I wonder what mysterious stuff i will find.

 

A gear puller is what you need to get that off.

 

So....

When I went to remove the manual shaft from the case the nut broke right off with no effort. It was pretty rusty and if you go way back the original lever was rusted and broke when i got it.



This is where I am now.

I need to go get a 3/8 12 point. Wierd my set doesn't have one or its missing. Oh well. So not completely disassembled.

And also included a pictures of the first clutch pack clutches. The steels don't look to band but the others are warn.

So gonna call the transmission shop and see if they can get me 3 things

Torrington bearing set, reverse servo spring, and the manual shaft. I know i can order online but will check local.places first.

Also I have to go away for a week in 2 weeks for work so thats gonna really slow my progress down.

 

Really impressed, great thread - cheers for keeping the updates coming.
I look forward to your progress, you do not muck around.
With all your research on this box how are you feeling about taking this on?

 

I appreciate this tip. I have added it to my list too.

 

Actually pretty good. Because its a well know and used transmission the information out there is plenty.

Also I couldn't find a 12 point 3/8 anywhere... so used a 10mm 12 point 🤔 it worked. All order a 3/8 Just gonna have something to eat and then get back at it.

Also local transmission shop had all 3 items. Quoted me worst case couple hundred...ugh. but I know the spring is 15 usd, sshaft is about 40 to 50 usd. And the torrington bearing set is another 50 usd. So if its around 150 for all 3 ill be happy. Should be all in tomorrow. Better than waiting weeks to order from USA.

so.once I get it all torn apart I can start cleaning everything.

 

Now to clean everything

 

these are the 2 bushings that come with the kit. I think they are left one is torque converter bushing and the right one is the tail houseing bushing. Just because the front and rear seals both come with the kit.

I know for sure the right one is as its the only one that matches. The smaller one im kinda iffy about. It has like a puzzle piece connector on it.

 

Well got some cleaning done and got a bunch of seals replaced so far. Had to stop as im waiting for that stuff tomorrow but im already ready to reassemble the first 3 packs. So tomorrow after work ill do that then start working on replacing the clutches.

Hard to take.pics when my hands are covered in fluid all the time lol. The bushings all look good and everything so far seems to be in fairly good shape. The book I have shows a lot of the older model th400, where mine is an 88 so has been updated with some better internals already. Its going fairly smoothly.

I'll see if I can get some better pics tomorrow. I'm also making notes in the book if anyone down the road has questions

 

Worked yesterday and by the time I get home its too damn hot. Today is suppose to be the peak with Temps reaching 35C and humidex making it feel like 40 to 45C. Im still waiting for all the parts I ordered anyways.

Took 2 pics. 1 of my work setup and also the assembly lube I am using. Its great lube and when it get hot.it turns into trans fluid. Supper tacky to hold things in place

 

So I used my home made compressor (steering wheel puller, threaded 1/2 rod and some nuts/washers) and got the direct clutch apart.




Well look at this. What a disaster in there.



Seal was ripped. Clutches where badly burned out. i think this was one of my bug problems. Almost like it was all flued together.

Anyways I'm busy tomorrow with work and bbq afterwards. Next update will be Saturday.

 

Got off work early and picked up my parts so had an hour to put some things back together.

Got the bottom half back together and a new clutch pack put in.



Scrap part pile is growing.



Rest of the fractions soaking plus the last band.



Whats left to do

 

Still pluging away. I haveing trouble getting the lip seal to seat properly so I'm just taking a break.

But when i took the intermediate drum a part i was surprised and happy that I found it has the roller sprag. Which is better for high performance applications and is desired. Apparently they only came in the early 400s big blocks 3/4 tonne trucks but maybe because of the power of the jag at the time jaguar decided to put it in. Who knows. So if you have one in good condiiton sitting on the bench they are worth a few hundred USD as they are desired for the high HP.

 

Not much progress today as im waiting for the lock ring plier tool I ordered. Suppose to be here today. I did get that lip seal to seat. Just took patience.

I did figure out what clutch plates go where for which drum. I'll take pics later.

Also discovered that usually it is recommended to have a wave steel plate installed first when building the pack to help with a more gentle engagement. So what jaguar did was instead of a waved plate they used a special plate first then the standered plate on top of that then the usually friction steel etc. They must have did this to make the shift more refined. I was puzzled for a bit as to why I had removed to extra steels (one from each drum) but then figured it out.

Also installed the more heavy duty springs that came with my shift kit in the intermediate/ direct drum. This gives a better engagement for up to 7500 rpms. Not thatbill be going over 6500 lol.




So from the book I have and from the videos I watch during this rebuild, at least my 1988, the th400 from the jaguar side of things they must have got GM to install better/high performance stuff.

 

funny 5 minutes after I posted the tool showed up.

So go the direct drum back together in in the case.

Got most of the forward drum a part but the big lip seal was ripped and I can't seem to get the main inner part out. I sprayed it and will let it sit overnight.

 

Got the forward drum all back together in in the case.



Don't freak out if you are reading a generic book about rebuilding a th400 and don't have this part..steel apply plate..there were minor changes throughout the years.



So now onto the pump



Keep track of which bolts as they are different lengths...all 1/2 socket



This was a little sticky so took it apart and cleaned it. Smooth now after reinstall. Also do not install an aftermarket kit spring in here unless you are gonna make over 450hp. Lol



so now I need to replace the bushing but I dont have a bushing kit so I'm gonna check work. After that its just replace the seals and putting the halves back together then reinstall in case.

 

Pumps in. I was able to take some dies from work to get the bushing and seal in.

Time to put it on the bench and work on the back side.

Also i forgot to mention when I pulled out the governor during teardown it looked like the inner valve is stuck. I havent cleaned it up yet but hopefully I good cleaning will get it functioning again

 

So got almost everything back together today. Just need to do the tail stock and oil pan.

The governor was stuck so I took it apart and cleaned it is polished it. Works like a charm now.

Thin is it will be ready to go back in basically tomorrow but I want to put in a 2500 stall. But they are about 500 to 700 and I have a 2 week vacation coming up. So I might not get it put in til Sept. lol.





The valve behind the vacuum modulator was sticking as well so polished that up. Smooth as butter now.

Also I did a test after the pump was installed with compressed air and it passed! I think lol. True test will be when I turn the key haha.

video I used for the governor


I just wrapped the shaft and placed it in the vive to punch out the pin. Reused everything as gear was fine.