Mike, Rick Miller (
IndyCars) has done transmissions, and should be a good resource for you. Are you there, Rick?
I had never touched the inside of an automatic trans until I rebuilt a GM 200-4R overdrive trans. My approach
was to buy the ATSG industry manual and a DVD that showed the basic tear down, inspection and rebuild process.
I also bought a manual for building a high performance 200-4R trans that I followed religiously.
I took several hundred photos as I disassembled the trans, trying to capture it from several angles. You just never
know what's going to help at a later date. As you tear it apart, I would put the pieces in a bag and label it. It's much
easier to do this as you disassemble, rather than later when everything is in pieces and your looking back at that pile
of parts. So you will need to buy a box of Ziploc bags in Snack, Quart and Gallon sizes. Use a diagram like below
and put numbers on everything, I even used a Sharpie to write directly on the part sometimes.
For the valve body you might get away without pulling it apart. But you will need to inspect the valves for free
movement using a small screwdriver or scribe to push on the valve and see if it snaps back. If they are all moving
freely, then you could consider leaving the valve body intact. If not, then it will be required to tear into it. As you
can see below, I used some plastic VHS tape slip covers to keep all the pieces of a valve lineup in the exact same
order them came out during disassembly. Ziploc bags are not going to work for the valve body.
For tools I got by with improvising for the most part. It did get frustrating at times trying to get snap ring out while
compressing some springs at the same time, but I made it work. If you have to, take it to a transmission shop and
let them disassemble/assemble something for you.
Oh, get yourself some Assemblee Goo, it works much better than Vaseline to hold pieces in place while you are working.
One other thing to make note of is the direction that the Lip Seals are pointing. Again pics when you disassemble
the sub-assemblies.
After everything was done, I had a small leak when the trans was maybe a bit overfull. Turned out to be a o-ring
on the servo cover, which is accessible externally. The o-ring slid down on to the piston, so I move it back into position
on the cover and all was good. Took me about 20 minutes to fix. After that it performed perfectly.
Below is my build thread for the 200-4R.
TBucket 200-4R Transmission Project | Grumpys Performance Garage
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