2G When O/D is on it feels like it’s in neutral after end clutch rebuild

[James_dsm]

My 1st, 2nd, and 3rd gear run fine with O/D off. As soon as I click O/D the car shifts, hesitates, and theres no power to the throttle, literally feels like neutral. Yesterday I just rebuilt the end clutch (Seals, Steels, Frictions, etc.) with the IPT kit. What else could be the issue? Transmission Fluid is fresh and at the right amount.

 

[steve]

It sounds like the end clutch still has an issue. Double check your work.

 

[1990TSIAWDTALON]

You've cut a seal or have the wrong size small seal installed. As Steve said, double check your work. Use vasoline/atf mix on the seals for lube.

 

[James_dsm]

You've cut a seal or have the wrong size small seal installed. As Steve said, double check your work. Use vasoline/atf mix on the seals for lube.

Okay I’ll look at it asap and keep yall updated, if it’s not the issue is there any other possible solutions?

 

[1990TSIAWDTALON]

Not really. It is a common issue. I have rebuilt several. If you put the wrong size small seal in, it will blow fluid past the seal and never couple the clutch pack hydraulically. Lube up all seals and double check that outside ring seal. Feel it with your fingers all the way around for any nick's. Just remove it for inspection and feel it all the way around for nick's. It should feel smooth all the way around.

 

[James_dsm]

Not really. It is a common issue. I have rebuilt several. If you put the wrong size small seal in, it will blow fluid past the seal and never couple the clutch pack hydraulically. Lube up all seals and double check that outside ring seal. Feel it with your fingers all the way around for any nick's. Just remove it for inspection and feel it all the way around for nick's. It should feel smooth all the way around.

Okay will do thank you sir, ill be able to check it on Wednesday i got my hands full today and tomorrow.

 

[1990TSIAWDTALON]

LIFE is a busy thing. That's why I call this my "hobby"

 

[James_dsm]

LIFE is a busy thing. That's why I call this my "hobby"

So i ended up double checking all my work, ensured everything was done correctly and seals are nice and lubricated. Still no fix to the problem. Any more suggestions?

 

[1990TSIAWDTALON]

And you were positive that you put the correct small seal in? There are 2 sizes. Just asking as the OD pack gets fed thru the center of the main shaft thru a hollow passage in the end of the shaft. How about the solenoids, are the both working? They must be so I'm still sus on the end clutch pack. Wish I were closer, I keep a rebuilt one on my shelf all the time.....but I have a main shaft that is broken at that spot so that car is on hold currently. And I wouldn't know which seal you needed, they are close to the same size.

 

[James_dsm]

And you were positive that you put the correct small seal in? There are 2 sizes. Just asking as the OD pack gets fed thru the center of the main shaft thru a hollow passage in the end of the shaft. How about the solenoids, are the both working? They must be so I'm still sus on the end clutch pack. Wish I were closer, I keep a rebuilt one on my shelf all the time.....but I have a main shaft that is broken at that spot so that car is on hold currently. And I wouldn't know which seal you needed, they are close to the same size.

I kept all my old seals to measure them together with the ones I received from IPT and make sure they were the correct size. Im gonna take one more look at it before ordering a new rebuild kit and starting over again

 

[1990TSIAWDTALON]

I have found the hard part on the rebuild was compressing the spring to seat the pack. If it isn't seated, the pack can't clamp under any amount of pressure. Just another thing to look at. I know it's a biatch to do it. Maybe go drive again and give it a go before you tear into it, again.

As another question, have you ever burned up a clutch pack. It can clog valves in the valve body which I, myself, have had to deal with as a lot of my valves were sticky or stuck because it had clutch pack material in the bores.

I just want to bring that up in case it has happened or anyone else is reading this. You gotta clean a VB after smoking a clutch most of the time to get it thing to shift right because of debris in the Valve Body valves/bores/passages.

Been there and had to do all of that for the record.
Marty

Edit for the thread:
THIS is what the end of the main shaft in our automatic transmissions looks like at the end clutch side. This was just a mechanical failure but you can see the hollow hole that feeds the end clutch for pressure.

 

[James_dsm]

I have found the hard part on the rebuild was compressing the spring to seat the pack. If it isn't seated, the pack can't clamp under any amount of pressure. Just another thing to look at. I know it's a biatch to do it. Maybe go drive again and give it a go before you tear into it, again.

As another question, have you ever burned up a clutch pack. It can clog valves in the valve body which I, myself, have had to deal with as a lot of my valves were sticky or stuck because it had clutch pack material in the bores.

I just want to bring that up in case it has happened or anyone else is reading this. You gotta clean a VB after smoking a clutch most of the time to get it thing to shift right because of debris in the Valve Body valves/bores/passages.

Been there and had to do all of that for the record.
Marty

Edit for the thread:
THIS is what the end of the main shaft in our automatic transmissions looks like at the end clutch side. This was just a mechanical failure but you can see the hollow hole that feeds the end clutch for pressure.

Is it properly seated if that snap ring sits in its groove?

 

[1990TSIAWDTALON]

Yes.

 

[James_dsm]

Yes.

At least I know I did that correctly

 

[petrosian]

Did you determine what the issue was? I’m preparing to do the same end clutch rebuild on my ‘92.

 

[James_dsm]

Did you determine what the issue was? I’m preparing to do the same end clutch rebuild on my ‘92.

Unfortunately my car skipped teeth and has no compression so I haven’t even been able to fix that either

 

[petrosian]

Gotcha! Sorry to hear that. Bookmarked this thread for future updates though.

 

[1990TSIAWDTALON]

It's not hard to do you just have to be very clean and get the correct small seal that fits the end shaft. There are 2 different sizes in all the rebuild kits. If you put the wrong seal in, it won't pressurize the pack so just be aware of that.
Soak all clutches in ATF for a half hour at least before you do it. I keep a rebuilt end clutch ready to go on the shelf but my main shaft BROKE the end off so it needs a little more than a new end clutch.