Inspection of a 904 torqueflite

Did you put both of the thrust plates on the sunshell that you replaced. There is a thrust plate and a thrust washer on both sides of the sunshell. Did you put both those in when you assembled the sun gear to the sunshell. With that amount of end play it sounds like you have missed one somewhere.
The thrust plates are large shiny silver discs that get assembled when you put the sun gear into the sunshell before you put the snap rings on that hold the sun gear into the sunshell. Take a picture for us of both sides of your sunshell as assembled.

I’ve ruled out the output shaft support, the output shaft itself, and the planets. The thrust washers are all .50 and new. I remember they are the same as the old ones.

Some pictures are small because it won’t let me resize them using Flickr.
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This is the rear ring gear as pressed up against the seat of the shaft.

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Front view of rear ring gear

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Here is the rear planet with the thrust washer that seats up against the rear ring gear

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Here is the rear planet set with the front thrust washer. When I take the sun shell off. This is usually stuck to it. A butter knife comes in handy to remove it.

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Back side of sun shell. These large plat plates on the front side and the back are from the old shell.....as is the gear. His gear sits a bit more loose in the shell than the old one did. Even though everything was directly transferred over.

It came with its own sun gear in the mail. I didn’t use that one but that one was somewhat loose on there as well. I think some of the 904 shells I had were like this. However....there are also no wear patterns of any kind.

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2.74 front gear with the shim under it

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Thrust washer on the front planet. Back side

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Thrust washer on the front side of the front planet.

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Large thrust washer.
This specs put new at .120......it’s new. The old one did as well except where it was dug into and worn.

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Here is the gap. This runs about .097

The snap ring that was in there was .042
Given the 904 I just finished up. I’d have to take it back apart to look at the difference I think this is wrong. I really hate taking that pump out. I guess I’m going to have to get a slide hammer made for that.

I don’t see where I messed this up. It all seems perfect except for that snap ring.