Mopar Muscle Association UK

Hi Hope Blue, Cannonball or some one else can help out here.

Although my 904 is still operating well after my problem about 450 miles ago I am planning a little winter project to build up another 904.
Will be looking at going away from the Aussie starter so am already taking that into account with the trans swap.

So If anyone has a 904 that is fit for rebuild please let me know.

More importantly I am expecting to hear back about one next week.
Either way I am wondering what is available in the way of rebuild kits that include the obvious seals, gaskets, clutches, bands.
Are there any kits sold here in the club or in the UK or should I order in from the US?

Rough prices or other parts I should be looking to replace while on the case?

Thanks in advance
Steve

Steve, I have a small block 904 you can have cheap, rebuild parts are readily available in the UK, I'll drop you a PM later.

US starter will need a ring gear to match
aussie converter ring gear may or may not....

might be easier picking up US converter

and then possibly felx plate


Dave

My Plan is to eventually replace the trans (including torque converter) so expecting that I'll find more US style that Aussie style here the starter motor will have to follow suite.

I am expecting that anyone selling a trans will be selling with the torque converter... don't think I am expecting too much there.

As the Mopar ring gear is on the torque converter and not the flex plate I did not even consider that the flex plate may use a different bolt pattern between the US and Aussie style. Am hoping it's just a differnet number of teeth on the ring gear.

Maybe I should try to get matching flex plate to save any nasty surprises later on???

Think you are more likley to run into this issues at the cross over point VC to VE....

i.e in the same year they went from 7 1/4 diffs to borgwarner

they went from US alternators starters etc to Bosch and Lucas

If your car is all orginal.......should be ok

slants from Oz were odd indeed
some used different flex plates from others
some used V8 starters

ther could be similar peculiarities on the v8 front

Dave

I'm running an Aussie 318,US flexplate,US 'vertor and 904.

Thanks Steve, good to know.


Dave, I have an Aussie Bosch starter, so think it is all original.

Thanks to Blue for providing what is proving to be a good 904 for this rebuild and for some great ongoing advice too.


Also got a US starter from Trev (to match the US ring gear from Blue).
Tested the starter and it's looking good to use as it is.

Have built a few spring compressors and the like out of some unused steel from the test plant equipment room at work and am at the stage where I have replaced the seals and friction plates in the clutches and have them set aside for the reassembly.
If time allows this week I'll be striping and rebuilding the pump and valve body.

The original 904 still seems to be going strong and is driven about 20+ miles every working day. (plenty of oil leaks though, you can see where I have parked at work!) and I hope it will allow me to do the replacement in my own good time. Spring or Summer is my plan.

Steve

Did not even get to go into the shed during last week, got some time on Saturday though.

Pump, stripped and rebuilt.
Valve body, stripped and rebuilt. - One small question for those in the know however....

Not worried, just wondering what I have got.
The valve body is different to that in my service manual so I am guessing that it is newer due to the fact that the shift valve end plate is more than just a plate.
See the pics below.

what you have there is the ultra desire able part throttle kick down unit
it replaces just the end plate it basicaly makes it so if you partially squeeze the throttle in top below circa 50 mph it will change down to 2nd and become more responsive

Thanks for the explanation.

You is well brave takin da Brain apart!

You must have a degree in Psycology or Summit???

Keep up the grand tour of a 904 LOL!

Best wishes Bacca.

Almost done now, just a rear seal and the snap ring cover to replace.
This is a pic taken just before the band adjustment and the pan was put in place.

With the original 904 in the VG still going 2000 miles after the problems I had with it I think I wont get to find out if I have truly been successful in this rebuild until I get the chance to swap them over in a few months.

If anyone else is contemplating doing a reco on a TF for the first time, here are a few observations.

It ain't too scary if you take your time and keep organised.

A few MUST haves other than your basic tool kit:
* Good advice - Thanks to Blue in my case!
* Service Manual
* Time - You will go slow on your first adventure
* Torque wrenches, both foot pound & inch pound
* Air compressor - Not really a must, but I would not want to do without.
* Pump puller - make your own
* Pump assembling tool - make your own
* Packing tape - doubled over on itself so there is no sticky side, use to hold the detent ball in place with one hand while locating the manual selector lever during reassembly.
* Clutch spring compressor - make your own.
* 6" G clamp to compress the servo springs.
* Plenty of clean plastic storage boxes to wash/keep the sub assemblies and parts in. Plenty of NEW plastic bags to keep all your parts clean once you have them apart and reassembled.
You don't have to do the whole thing all at once.

I was surprised at how easy the parts were to to obtain, I used Sussex Autos.

Satisfying job isn't it?

Dave wrote:Satisfying job isn't it?

Sure is.
Am keen to see if it works though.