Rebuilding my AT60E transmission

[Freakzilla]

I was just looking at this web site today: http://www.bulkpart.com/Merchant2/me...Code=4T60Ekits

The rebuild option is quickly becoming very appealing to me.

This will be my first time so please be gentle.

A little guidance on these kits would be appreciated...

I see the Master kit includes: overhaul kit, friction clutch plates & standard steel plates *does NOT include Rubber/metal (reusable) side cover gasket!

1. I have the Alldatadiy manual. It looks like it's got detailed rebuild info, should I still get the tranny manual?

2. Since I've had the TCC error for months, should I get a new torque converter? I have to get the code off my old TC, appearantly.

3. Should I replace all the solenoids, sensors and the internal harnes?

4. What is a shift kit? Is that so I can shift manually? I only wanted to do that to try to get it home.

5. I should get the kit with bonded gaskets and not the fiber ones, right? Should I get the gasket for the side cover or is the one on my AT60E reusable?

6. What special tools will I need?

Any help you guys could offer would be very appreciated.

[jmf1964]

Just a suggestion, you could probably find a good used one at a salvage yard for less money than a rebuild kit and all the special tools you would need, and they would probably give you some kind of a warranty with it, albiet not much, but some.
John

[Caddyshack100]

While no special tools are required for this job, you might want to have somebody rebuild it for you. There are several members on here who have had theirs done real cheap, around 1200 dollars or so. The problem with going to the wreckers for a used one is that the chances of you finding one in good shape is pretty rare as these trannys do not hold up well. Dont ask me how I know, I have rebuilt six of these paperweights .The last thing you want to do is put a wrecker tranny in and have it fail within 30 days, yes there is a warranty but this is too much of a PITA to replace easily. If you do want to proceed with your own rebuild then that master kit is the way to go, I would get the manual, as Alldata may be missing something. Make sure you flush your lines and replace the TC, and have a couple of strong friends to lift this, its heavy.

[Freakzilla]

I got a quote for around $1300 for an installed, used tranny. Not sure how used, but that may be a worst case scenario.

I they also quoted changing the shift and tcc solenoids for a really good price, I think I'm goin to try that first.

I think I could do it but the rebuild scares me. I'd like to help someone with theirs first.

[Caddyshack100]

Before doing this work etc... What is wrong right now with your transmission? And how many miles/KM is on it? These do not last generally past the 150k 230 km mark, although there are people who have gotten it past that. If your tranny has passed the above mileage milestone then you are on the road to a rebuild. If it has already been rebuilt once then the above procedure should be good, just remember when you put fresh tranny fluid in it may cause it to start slipping later as the fresh fluid will start to work on the varnish that is built up. Good luck and PM me if you need any further info.

[Freakzilla]

Originally Posted by Caddyshack100

Before doing this work etc... What is wrong right now with your transmission?

I've had the P039 code - TCC engagement problem, for months. It makes a grinding noise when idling in drive. The noise goes away in park. I'm pretty sure the OD has been working, though.

A few days ago I stopped at a traffic light and it wouldn't drive. I pulled over, turned the engine off then started it again and it drove.

Upon first starting, it will go through the gears then it seems to just go into neutral. I can then put it into first and drive in that gear but it eventually slips back to neutral. I say is seems like it is in neutral but I don't know, maybe it's just slipping very badly. I seems like it's not down shifting.

And how many miles/KM is on it? These do not last generally past the 150k 230 km mark, although there are people who have gotten it past that. If your tranny has passed the above mileage milestone then you are on the road to a rebuild.

It has 190,000 miles on it and the transmission has been rebuilt once for my mother who owned it before me.

If it has already been rebuilt once then the above procedure should be good, just remember when you put fresh tranny fluid in it may cause it to start slipping later as the fresh fluid will start to work on the varnish that is built up. Good luck and PM me if you need any further info.

Mr. Transmission is coming to tow it in for a diagnostic now. I'll post when they tell me something.

Thanks for your help!

[Freakzilla]

They called me back and said that something is producing metal which is clogging the filter and overheating the valves.

Said he would have to take it apart to find out what's wrong for $698 and the cost of replacing whatever parts are bad.

Said it could go as much as $1800.

[Caddyshack100]

That Sucks, but now you have to ask yourself if the car is worth that much, I don't know what is on the list of bad items, but I don't think 1800 dollars is your final price either. Is this a Canadian Car, because you mention Mr. Transmission, I dont think they have them in the states. Tranny companies in Canada operate on the al a carte menu price, first they charge you a price for taking it apart, ala the price you quoted, then once its apart, oh it needs this and that, if you want to reassemble it then you have paid out the money and no tranny. In this case, you are better to either cut your loss and take it home and fix it or bite the bullet and pay the unknown final price, hey at least you will have a warranty. They will of course tell you the horror story of you trying to fix it yourself, I know that is how AAMco got me, I was quoted 3300 dollars for mine on a Lumina, I told them I will fix it myself, 1 year later I went back to the Barrie Ammco and thanked them for trying to rip me off and told them that is how I got into fixing my own transmissions. It is really not hard if you follow the instructions and keep everything clean. If you think about it, there are alot of people who would not think twice about rebuilding a chevy 350, a tranny is not as hard as that.

[quins90lac]

i think my trany is heading for a rebuild as well it still shifts fine but id been shifting hard some times it dont do it all the time just once in a while

[Freakzilla]

You're the only one who thinks I could do it, Caddyshack... besides myself. I've read those rebuild videos are pretty good. If the pinheads at Mr. Transmission or AAMCO can do it, I can probably do it better. A deluxe rebuild kit, manual and video WITH a new torque converter is still less expensive than having them just take it apart. And I would know how to rebuild transmission.

They tried to talk me out of a used transmission installed for $1300 saying you never know how long that will last. Hell, I don't know how long their half-assed rebuild would last either. Even if I bought a used one myself, it seems the hardest part is removal and installation. How long did it take your first time? Maybe I'll slap a used one in and take my time rebuilding mine.

I don't know, I don't really have the money for this anyway.

In the meantime my backup transportation (Ford Windstar) needs a torque converter! On that note, I just got it back from AAMCO. I had them reseal it after springing a leak at the pump gasket. Funny thing was, when I filled the leaky transmission up with fluid it ran fine but they tell me it needs a TC. Now I have to rev it up and let off the gas to get it to shift. I wouldn't be suprised if they sabotaged it, I haven't had a chance to look at it since (Monday) I've been so pissed.

[Caddyshack100]

It took me about a day to remove the first transmission, but then it takes them about that long as well, I did not do a Caddy as I did not have one then, it was a FWD Chevy Lumina with 3.1. I had to remove both the engine and Tranny together, set the engine aside, and went to work on the tranny. I bought a Huge Plastic Bin from Crappy Tire and put the tranny parts into that to clean and wash them. Golden rule, make everything pristine and clean, your tranny will have grunge and old filings and grit from the bands and plates. Once you clean them, coat them with Tranny oil, some of the steel pieces will rust. What I would suggest, is going to the wrecker and getting a Tranny from them that is the same final drive for about 100 dollars and take it apart, rebuild it and swap it into your car and rebuild that one and sell it. Like I said above, you do not need special tools although the FSM is full of them but you can easily get by with not having them. You will need the space to remove the drivetrain and you will a jack or crane that can hoist the engine up and over the front of the car as this comes out with the engine. Other than that some sweat, a couple of sixpacks after the job is done and you should be good to go with the satisfaction of thinking of returning to that tranny shop with the car you have rebuilt. Good luck on whatever you decide

[Caddyshack100]

Sorry, I should have made it more clear, the crane is needed to hoist the car clear of the drivetrain, this comes out from below, you can remove just the tranny but you would need a hoist for that.

[Freakzilla]

Originally Posted by Caddyshack100

What I would suggest, is going to the wrecker and getting a Tranny from them that is the same final drive for about 100 dollars and take it apart, rebuild it and swap it into your car and rebuild that one and sell it.

Is there a "light rebuild" I could do on a used tranny? I mean, if I'm going to do a compmlete rebuild I may as well do it on my own transmission and save the hassle dealing with a used one.

Here's what I have been thinking about...

My number one priority now is making one of my two cars drivable so I can get to work.

Plan A: This weekend I may try to put a new TC in my minivan, if that works out well I'll have time to spend on rebuilding the Caddy tranny.

Plan B: Get the Caddy towed 50 miles back too my garage. There are two Pull-A-Part salvage yards near me, I can get a tranny and converter for $55 from another '95 Deville (they have some). I could put that on as a temperary fix just to get me on the road. Then I could take my time rebuilding my old tranny and keep it and a new TC as a back-up to the band-aid used tranny.

What is the very minimum you would do to a used tranny as a temporary measure.

I was thinking I could just check/replace the solenoids and cross my fingers. Maybe get a new TC if the funds are there.

I very much appreciate your help, thanks.

[Caddyshack100]

I can see where you are going with this. I know the pressure of having something working for work and that is your first priority. However, due to the nature of this tranny, in order to make sure everything is ok with it, you will have to pull everything out to see if nothing is broken. One thing on these units that does go is the Reverse Reaction Drum, it cracks and then you are back to square one. If you look at your manual and see a breakdown of the tranny, there is a tubular shaped item with fins on each end and holes all around it, it is about the size of a big tomato can. You need to check that and the only way is to take it apart, so you see, you might as well rebuild it with the new clutches and seals. Lastly the amount of work you will need to do to put this in should point the way to only doing it once. Good luck with the Ford.

[Freakzilla]

I called AutoDoctoRX who refered me to an independant ASE mechanic. He said he'd swap a tranny for me for $175.

I've also found a used tranny (not salvage) in town with 80,000 miles on it for $350.