New Project '98 A604/41TE

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#16
Thanks, grcauto. I see on page 75 of the ATSG 'The output gear tapered roller bearings must have a preload of .02 to .05 millimeter (.0008 to .002 inch). I have not done this before so this will be new,

MT
 

grcauto

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#17
The differential is a very necessary adjustment which is what you are looking at on page 75. Also make sure the the end play is correct using the correct thrust plate for the 2/4 clutch described on page 56 and 57. End play in the shafts is what wipes planets. Don't short the thrust plate or preload. Also that bushings are good so the shafts do not have excessive side to side movement. Most can be done by feel and common sense.
There are good videos on you tube from guys that do total overhauls. Might be good to view one or two if you have a couple hours.
 

grcauto

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#18
Need to be aware of one or two snap rings (tappered or beveled) as they only go in one way and I think there may be something else that is critical for which way it's installed. Take your time and read each step and you'll be good.
 

bp042665

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#19
if your building the core with its planet not a problem the wining noise probably worn pump gears when in park and nuteral the pressure has no load but in gear it does and the wine goes away
 
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#20
The comment about the bearing pre-load in ATSG is in regards to the output gear. It's just a small blurb on page 75. I would be doing nothing with the diff. So I guess I just put a feeler gauge in between the gear and the case? Re: input clearance, it's done on the input drum, not the 2/4. I assume a cheapo hand-held dial indicator would do the job? Never done this stuff...yes, the UD and L/R pressure plates both have a beveled upper snap ring that must be oriented correctly. Hard for me to see the bevel but it's there. Yeah, on that core, I had installed that tranny in another van but used a different pump and converter, and it still made the whining sound. If I could be sure it was either the stripped front planet or something in the valve body, then I would build that tranny up and avoid all this stuff with the rear planet.

MT
 

grcauto

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#21
If you are not doing anything with the diff just pry and check for any excess play on the ring and side gears. If they are pretty tight I would not worry about shims. As for the output gear bearing if you can't tell there's movement you are probably good. I'm not sure I remember ever trying to use a feeler on one while assembled. If they had any movement we tore them down and used dial indicators to rebuild with new shims. Been several years since I've done any transmissions and my memory isn't the best.
 
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#22
Well finally got this thing screwed together...no lift, not even cement floor. Just dirt, floor jacks, blocks of wood, and cursing. These 604s have an irregular contour and the pan sits at an odd angle...test drive was good, nothing blew up. Has all gears and reverse. No CEL. With wheels off ground adding fluid I went from no movement from drive wheels to apparently overfilled by like 2 qts...not sure what that is. Too exhausted and beat up to correct it till Monday. My body needs recovery. I ain't 25 anymore. I want to thank all who helped with great advice. I think going forward I will see what my buddy with a general repair shop here in town would charge for R & R of the tranny, and I do the bench work. I simply cannot do the R & R on my back anymore,

MT
 

Mealticket

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#23
Looks like this thing will fly. Hey, any of you pros, could you tell me how many labor hours it would be to R & R an A604 on PT Cruiser or Dodge Avenger? This wouldn't include bench work, just remove and replace. My mechanic says look it up online but I see only Mickey Mouse action there,

MT
 

grcauto

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#24
Looks like this thing will fly. Hey, any of you pros, could you tell me how many labor hours it would be to R & R an A604 on PT Cruiser or Dodge Avenger? This wouldn't include bench work, just remove and replace. My mechanic says look it up online but I see only Mickey Mouse action there,

MT
I'm not around any service or labor guides right now but your mechanic should have a labor guide. He should be able to tell you how many hours. Tough to do estimating without a guide. Something just crossed my mind.....it should have stopped for a second because it's gone now.....Maybe it'll stop back by later on.
 

Mealticket

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#25
I should clarify that this mechanic is a friend that I've known for 35 years, and has cut me many many breaks plus free advise over the years. I ran into him at a sporting event so it was casual. He did give me his hourly rate.

MT
 

Mealticket

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#27
Looks to me like any PT Cruiser 2000-2010, and any Avenger from like 2008-2014. Based on your estimates above and what I have been modeling based on my buddys' hourly rate, this prolly will not work. Just when I was learning to work on those A604s...might be time for a new hobbie. BTW, took my radiator to a local tranny shop to flush out the tranny cooler tank, and he thinks either lack of lube or failed thrust bearings smoke the planets. Guess you could ask 5 pros and get 5 opinions,

D.