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RE4R03A Gearbox Rebuild
Well the reason for the gearbox rebuild was due to loosing everything above 2nd gear.
Manuals / Part breakdowns that I used can be found here: http://www.nissanpatrol.com.au/forum...851#post143851
Cost to repair
Gearbox
Master Rebuild Kit - $643.00
RE4R03A Gasket, Seals & Ring Kit
Band
Oil Filter
Full Set Of Clutch Frictions
Pump Brush
Change Over J6 Torque Convertor - $395.00
Refundable Deposit on Torque Convertor - $250.00
Freight - $60.00
Total: $1348.00
Automatic Transmission Fluid
Syntrans SYN III G/H 10W 20LTR - $125.40
Total: $125.40
Consumables
Emery cloth GP 180 grit x 50mm ( 50mtr roll ) - $34.53
Lanotec Citra-Force 750ml spray bottle x 2 ( wanted 1LTR but nobody local had stock - $ 36.37
Wet-Dry Sheet 9 x 11, 120 grit x 6 - $6.02
Total: $76.93
Total Cost Of Rebuild to Date - $1550.33 including GST
Rebuild Kit and Convertor supplied by:
Wholesale Automatic Transmissions
1/58 Barry Street
Bayswater, VIC, 3153, Australia
03 9762 8108
Consumables supplied by:
Nepean Boltmaster - Penrith Branch
42 Borec Road
Penrith, NSW, 2750, Australia
02 4722 3034
Automatic Transmission Fluid supplied by:
Gulf Western Premium Quality Lubricating Oil ( Aust )
1 Coombes Drive
Penrith, NSW, 2747, Australia
Phone: 61 2 4732 3305
Sales: 1800 248 919
Rebuild Kit has arrived :)
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20ltr of ATF
Attachment 7823
Emery cloth, Wet-Dry sheets, Lanotec Citra-Force
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Tags:
Auto gearbox failure
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21 Attachment(s)
Day 1 - Why didn't I just pay a mechanic 2 do this!!!
The day didn't go as planned, we didn't get the gearbox out, but tomorrow is another day.....
Had a bit of trouble removing the hand brake drum / 4wd selector / Rear tail shaft, they just didn't want to come off....
The day begins 4b up on stands
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Draning the gearbox oil - mmmm smelt a bit burnt :(
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Text 2 follow..........
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Day 2 - Gearbox comes out - The strip down begins
Well today was a bit more eventful than day 1, Gearbox dropped out pretty easy, gave it a quick bath with the pressure washer before starting 2 strip it down. Found a lot of metal on the magnet in the pan :( Also found a broken wire in the valve body ( not 2 sure what the wire is 4 yet ).
Below - Gearbox coming out :)
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Below - Removing the torque convertor and draining it
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Below - A quick bath.......the cleanest its been in years
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Below - Transfer Case after a bath
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Below - The strip down begins
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Below - Metal Anyone???
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Below - The Valve Body getting removed.....found a broken wire :(
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Below - Valve Body removed
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Below - Main Case and the internals
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Below - Can't really see it in the pics but some of the friction plates are know longer friction plates they are metal to metal!
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Below - The mess
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Below - Having a Hydrualic Press, just makes it so much easier
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Day 4 - Waiting for parts
Today was pretty much an uneventful day, was waiting on an email back from Wholesale Automatic 2 see if he had some parts that we needed. We got a hold of him after lunch and he said he had the parts but he needed 2 pull them out of a gearbox that he has there.
Went shopping for a Tap, tapered grub screw, and puller.
Could not source the puller we wanted so are getting one made up from a metal fabricator down the road from my old mans.
Text 2 follow
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Day 5 - Valve Body Strip Down
Still waiting on parts, but at least now I know Wholesale Auto has them all, won't turn up till Monday......was kinda hoping that we would have the box out, rebuilt and back in this week while I was on holidays, not going 2 happen, will have 2 wait till next weekend now :(
Used the time to strip the valve body down today and clean it up, so many parts in such a relatively small valve body *L*
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Day 6 & 7
Day 6
Spent most of the day fart arsin around with the valve body, putting it back together, unfortunately we never measured the springs when we took them out and the spring dimensions we have do not match the manuals spec sheet *L* had a good guess, will soon find out it we were right or not *LMAO*
Below - The spec sheet........mmmmmmm dimension does not match my springs, oh well........... lets put this spring here anyway!
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Sorry guys didn't take any other pics 2day.......was 2 busy holding a scotch in my hand :)
Day 7
Just another day I say 2 myself why did I want 2 do this for......
Day started ok, then turned 2 crap :(
More text 2 follow, after the following bottle of bourbon :)
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http://www.nissanpatrol.com.au/forum...isc/pencil.png
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Day 8 and 9
Day 8 - Clutch assembly day
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Day 9 - Clutch assembly day........again
Relising we had put the wrong springs into one of the clutches the day before and not remembering which one we had put them in cased a strip down of rebuild again *L* oh the joys
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Saturday 8th October 2011 ( Day 11 )
Arrived at my parents bright and earlier, let the fun and games begin
Below: Valve body in, oil pan on.....time 2 install, fat chance..........pan is just sitting on there 2 keep any dust out, Still waiting on the valve body 2 be bolted in.
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Below: Getting ready 2 solder the broken wire back on the Fluid Temperature Sensor
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Below: Evidence the previous owned had the gearbox out for some reason
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Below: Oil pump bolted up :)
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Below: Valve Body going back in
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Below: Gearbox going back in
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Below: Why is my back wet!!! The only part of the driveway that got wet under cover, right where I put my car on the stands! Rain rain go away!!!
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http://www.youtube.com/watch?v=aZ4lz0tt9DA