TASC Force Tips
- Author: Frank Biolsi
Small things are often the cause of problems that can create grief in our everyday operations. Those seemingly inconsequential items can and on occasion do bring production to a halt. What seemed like nothing of great importance now becomes the stopper.
Many of you who call us for technical support and advice ask for items that fit this description. While we are always open to new ideas for new products that solve root-cause problems, there are times when these parts are already readily available and reasonably priced. It’s just that few rebuilders know about them. So, here are a few brief tips for you on some of the parts you asked for and where you can find them.
In the past the plastic four-tab washer between the two planets in the 4L80-E/400 has not been available separately. The plastic four-tab washer has always been serviced with the metal four-tab washer that is also used between the output shaft and the selective spacer. In 2002 GM changed the output carrier by eliminating two of the washer locating holes and changing the four-tab plastic washer into a two-tab plastic washer. This new two-tab plastic washer back-services all years of 4L80-E & 400, regardless of whether the carrier has two or four locating holes. The good news is the new plastic washer is available as GM part number 24214809.
Problems can occur in your E4OD if you are updating the overdrive planet only and try to use the late-style No. 3 washer with a sprag-style overdrive one-way clutch. The late-style washer has a larger inner diameter and will not properly support the OD-sprag inner race, allowing the inner race to move out of position and contact the OD planet.
In OE production there are two versions of the No. 3 thrust washer, depending on which overdrive planet and one-way clutch the unit came with. The early OD planets have two cut-outs to accept the No. 3 thrust washer. The later planets eliminated the cut-outs, and the No. 3 thrust washer is located by a lip and notch on the outer diameter.
Ford has a hybrid service No. 3 washer that allows the late planet to be used with the early OD sprag. The hybrid washer has the outer-diameter lip like the later washer and the smaller inner diameter like the earlier washer.
Thanks to Maura Stafford, Gregg Nader, Ed Lee and Jeff Brown for their help with these tips.
Frank Biolsi is the manager of technical-support services at Sonnax and a member of the TASC Force™ (Technical Automotive Specialties Committee), a group of recognized industry technical specialists, transmission rebuilders and Sonnax Industries Inc. technicians. ©2006 Sonnax