Re: 200-4R Rebuild ... step by step!
 

How do you dual feed the direct clutchs?

Re: 200-4R Rebuild ... step by step!
 

You leave off the center sealing ring in the direct drum (actually on the drum), and the 2nd sealing ring on the center support, and then block the bolt that goes in the reverse passage by welding the hole up.

But you MUST use the billet forward drum, or the first time it WOTs from 2nd to 3rd, it will snap the shaft.

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.
http://i32.photobucket.com/albums/d8...e/100_3637.jpg

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:
http://i32.photobucket.com/albums/d8...e/100_3983.jpg
http://i32.photobucket.com/albums/d8...e/100_3984.jpg
http://i32.photobucket.com/albums/d8...e/100_3985.jpg

Re: 200-4R Rebuild ... step by step!
 

i would be very greatful to see the rest of the article:hail:

Re: 200-4R Rebuild ... step by step!
 

It allows adjustment to properly position the output shaft so that it cannot move while you are trying to assemble.

Before you assemble the parts into the rear of the trans, you need to check rear endplay on the bench. Completely assemble all parts as shown below. Once it is assembled you can check the rear endplay using a feeler gauge, adjust endplay by changing the selective washer, and then assemble into the case.

Begin assembly by positioning the output shaft vertically. An old yoke can be put in a vise or welded to a bench to make this easier.
http://i32.photobucket.com/albums/d8...e/100_3988.jpg


The install the output ring gear if not pressed onto the shaft as most are.http://i32.photobucket.com/albums/d8...e/100_3989.jpg


Next install the rear torrington bearing. This is easy to forget.
http://i32.photobucket.com/albums/d8...e/100_3990.jpg




Next install the 4 tang thrust washer on the back of the rear planetary carrier. Retain with petroleum jelly or trans assembly lube.

http://i32.photobucket.com/albums/d8...e/100_3991.jpg

Re: 200-4R Rebuild ... step by step!
 

Install a torrington bearing in the front side of the rear carrier. There is usually a plastic thrust washer here. Do not use it, replace it with the torrington bearing as GM did on the later model 200-4Rs.
http://i32.photobucket.com/albums/d8...e/100_3992.jpg


Install the low roller clutch (sprag) and then the inner race by turning. The race should have the splined side up.


http://i32.photobucket.com/albums/d8...e/100_3994.jpg

Install the carrier into the rear ring gear:

http://i32.photobucket.com/albums/d8...e/100_3995.jpg

Now you can install the low support onto the rear carrier.
http://i32.photobucket.com/albums/d8...e/100_3996.jpg

Re: 200-4R Rebuild ... step by step!
 

Next install the thrust washer on the rear of the sun shell, and install the sun shell and gear into the low support and over the output shaft. Spin until it seats
http://i32.photobucket.com/albums/d8...e/100_3997.jpg
http://i32.photobucket.com/albums/d8...e/100_3998.jpg

Now install the front sun gear with the grooved side down against the sun shell snap ring.

http://i32.photobucket.com/albums/d8...e/100_3999.jpg

Then install the torrington bearing.

http://i32.photobucket.com/albums/d8...e/100_4000.jpg

Re: 200-4R Rebuild ... step by step!
 

http://i32.photobucket.com/albums/d8...e/100_4001.jpg
You are ready for the front planetary carrier now. Spin it on until it seats.

http://i32.photobucket.com/albums/d8...e/100_4002.jpg

Install the torrington bearing on top of the carrier.

http://i32.photobucket.com/albums/d8...e/100_4003.jpg

Now install the input ring gear, thrust washer, selective washer, and snap ring.


http://i32.photobucket.com/albums/d8...e/100_4006.jpg

Re: 200-4R Rebuild ... step by step!
 

http://i32.photobucket.com/albums/d8...e/100_4005.jpg
Check endplay with a feeler gauge between the snap ring and selective washer. .005-.010" is ideal here. Take the time to get it right.

You are now ready to disassemble the rear section and install it in the case.

Disassemble it to the rear planetary. Set the output shaft, rear ring gear, and rear carrier assembly in the case. Position the output shaft using the tool or other means so that the ring gear lugs line up with the parking pawl.

http://i32.photobucket.com/albums/d8...e/100_4007.jpg

http://i32.photobucket.com/albums/d8...e/100_4008.jpg

Re: 200-4R Rebuild ... step by step!
 

Now begin to install the low/reverse clutch pack, begin with a steel plate. Then a friction, and alternate until you end with a steel plate. There should be 6 frictions and 7 flat steels. Once you install the last steel, install the cushion plate.

http://i32.photobucket.com/albums/d8...e/100_4009.jpg
http://i32.photobucket.com/albums/d8...e/100_4010.jpg
http://i32.photobucket.com/albums/d8...e/100_4011.jpg

Now install the case to support snap ring. It is a very thin flimsy ring.

http://i32.photobucket.com/albums/d8...e/100_4012.jpg