A904 renew w/pics, tools

Cleaning all the parts is a time consuming job. Lately I just disassemble everything and put it in boxes and haul it 5 miles to the machine shop and have them hot tank everything. They only charge $20 and in only takes them about 1/2 hr. to do it so I wait rather than stand for 2+ hrs. at my parts cleaner cleaning parts. My low back doesn't like that prolonged standing anymore.

A fool proof way to align the pump halves is to use 2 or 3 large hose clamps connected together to make one really big one that'll slip over the o.d. of the pump. You then snug the big hose clamp assy. down and it perfectly aligns the pump and then tighten the pump bolts. And leave the big outer o-ring off the pump when you first put it together to check the end play. Unless you get really lucky you'll have to pull the pump out again to swap to a different thickness selective thrust washer and leaving the o-ring off makes it super easy to get the pump back out. Once you have the end play set then install the o-ring.

btw; did you air pressure test components after the main assy. was completed, right? It's a great idea to do so you'll know there's no issue at all with the main assy. It always sucks when you do all that work and install it only to have it not work right because a lip seal rolled when you were assembling a clutch pack piston or a reaction shaft sealing ring broke when you installed the pump. And lets say you do modifications, such as installing the Trans-go kit and something doesn't work right you know the problem has to be in the valve body cause the parts in the main power assy. worked when pressure tested. If you'd like a chart to show you where to inject air to test each sub assy. I can post it.