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Old 03-18-2009, 02:43 AM
jakeshoe jakeshoe is offline
The Trans Guy
 
Join Date: Aug 2007
Location: Texas
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Default Re: 200-4R Rebuild ... step by step!

Congrats,
You now have an almost bare case. Be sure to install a new case bushing, and remove the case to lowclutch housing cup plug seal. Clean the case thoroughly, check for cracks, flaws, and stripped bolt holes.


Step by step re-assembly of the 200-4R.

Once your sub-assemblies are built you can begin re-assembling the transmission.
Now is a good time to let the friction clutch plates and band begin to soak in ATF.

The first thing you want to do after the case is cleaned and rear bushing replaced is to be sure a yoke will slide into the output bushing. It is easy to burr the bushing on install and once you assemble the 200-4R, you cannot access the bushing to deburr or replace it without complete disassembly.
Install a new rear seal.

Then positon the case to rebuild it. The preferred method is to use a bench mounted trans holding fixture. However you can set the case on an elevated platform with a small hole that allows access to the rear area for the output shaft to protrude.

There is an output shaft positioning tool that will make assembly of the rear portion easier. It is shown here:



Last edited by jakeshoe; 03-19-2009 at 03:59 AM.
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