Abstract: A kit for modifying an OE vehicle transmission includes a replacement forward piston housing, forward clutch hub and a forward clutch and a replacement direct piston housing, direct clutch hub and a direct clutch. A drum extends between and operably connects the replacement forward piston housing and direct piston housing. The kit includes a replacement sprag shaft. The forward clutch hub and forward clutch and the direct clutch hub and direct clutch are positioned between the forward piston housing and the direct piston housing. At least a portion of the forward clutch and at least a portion of the direct clutch are operably mounted to the drum. The forward piston housing and direct piston housing do not counter rotate relative to one another. A power flow module for an OE vehicle automatic transmission is disclosed.

Abstract: A kit for modifying an OE vehicle transmission includes a replacement forward piston housing, forward clutch hub and a forward clutch and a replacement direct piston housing, direct clutch hub and a direct clutch. A drum extends between and operably connects the replacement forward piston housing and direct piston housing. The kit includes a replacement sprag shaft. The forward clutch hub and forward clutch and the direct clutch hub and direct clutch are positioned between the forward piston housing and the direct piston housing. At least a portion of the forward clutch and at least a portion of the direct clutch are operably mounted to the drum. The forward piston housing and direct piston housing do not counter rotate relative to one another. A power flow module for an OE vehicle automatic transmission is disclosed.

Abstract: A kit for modifying an OE vehicle transmission includes a replacement forward piston housing, forward clutch hub and a forward clutch and a replacement direct piston housing, direct clutch hub and a direct clutch. A drum extends between and operably connects the replacement forward piston housing and direct piston housing. The kit includes a replacement sprag shaft. The forward clutch hub and forward clutch and the direct clutch hub and direct clutch are positioned between the forward piston housing and the direct piston housing. At least a portion of the forward clutch and at least a portion of the direct clutch are operably mounted to the drum. The forward piston housing and direct piston housing do not counter rotate relative to one another. A power flow module for an OE vehicle automatic transmission is disclosed.

Abstract: Methods of modifying a OE prior art transmission, including Ford's AOD, AODE and 4R70W transmissions, to strengthen the transmission by replacing components known to fail. In one example, the intermediate shaft and direct clutch cylinder of an OE transmission are replaced to eliminate the splined connection joining the two components, to simultaneously eliminate the weak splined connection while also making space within the transmission available for an increased diameter shaft. Aspects of the present disclosure also include kits for increasing the strength of a transmission and methods of assembling a transmission.

Abstract: Systems and methods for stabilizing the ring gear in a Powerglide transmission are disclosed. Systems may include a radial stabilization member mountable to the planet carrier and individual bearing members mountable to an inner surface of the ring gear in opposition to the radial stabilization member. Axial stabilization may also be provided by an axial stabilization member configured and dimensioned to be positioned between the ring gear mid-step and reverse clutch pack apply plate. Methods include mounting the radial stabilization member on the planet carrier using attachment means and securing the bearing members to the inner surface of the ring gear in a spaced relationship.

Abstract: Systems and methods for stabilizing the ring gear in a Powerglide transmission are disclosed. Systems may include a radial stabilization member mountable to the planet carrier and individual bearing members mountable to an inner surface of the ring gear in opposition to the radial stabilization member. Axial stabilization may also be provided by an axial stabilization member configured and dimensioned to be positioned between the ring gear mid-step and reverse clutch pack apply plate. Methods include mounting the radial stabilization member on the planet carrier using attachment means and securing the bearing members to the inner surface of the ring gear in a spaced relationship.

Abstract: A replacement torque converter cover designed to withstand mechanical stresses generated in the torque converter lock-up clutch of ALLISON transmissions when such transmissions are utilized with diesel engines and other high-torque truck engines. The original equipment cover includes through-drilled holes for receiving unitary threaded stud pins, which function to attach the cover to the engine crankshaft externally and to drive the lock-up clutch piston internally during operation. The present replacement cover provides a lock-up clutch piston interface wherein such through-drilled holes and unitary threaded stud pins are eliminated, which substantially reduces stress concentration and mechanical fatigue in the replacement cover.

Abstract: A replacement torque converter cover designed to withstand mechanical stresses generated in the torque converter lock-up clutch of ALLISON transmissions when such transmissions are utilized with diesel engines and other high-torque truck engines. The original equipment cover includes through-drilled holes for receiving unitary threaded stud pins, which function to attach the cover to the engine crankshaft externally and to drive the lock-up clutch piston internally during operation. The present replacement cover provides a lock-up clutch piston interface wherein such through-drilled holes and unitary threaded stud pins are eliminated, which substantially reduces stress concentration and mechanical fatigue in the replacement cover.

Abstract: An intermediate shaft assembly for an automotive transmission wherein hydraulic fluid intake ports in the rotating shaft assembly are designed to increase hydraulic fluid flow and improve lubrication to mating components served by the shaft lubrication circuit is disclosed. The hydraulic fluid intake ports are laterally offset from the center plane of the shaft assembly to increase the angle of entry to fluid entering the intake ports and configured to produce a scooping effect within the fluid surrounding the intake ports upon shaft rotation, which substantially increases hydraulic flow into the shaft and counteracts the inhibitory effect of centrifugal force on fluid flow within the ATF intake ports. In addition, the present intermediate shaft assembly includes a flexible transitional diameter to impart axial flexion to the shaft during peak torque events and also provides semicircular spline relief grooves, which reduce areas of stress concentration and potential breakage of the shaft.

Abstract: A pump drive shaft for an automatic transaxle wherein the cross-sectional profile of the internal flow tube has been modified to a non-cylindrical configuration to increase the flow of transmission fluid through the pump drive shaft from the torque converter. A selected surface of the non-cylindrical tube is positioned at a predetermined angular orientation within the pump drive shaft to provide increased radial clearance between the flow tube and the fluid inlets/outlets to increase the flow of transmission fluid from the torque converter. In various embodiments the flow tube is elliptical, rectangular, bi-lobular in cross-section or a variation thereof, which produces an axially extending fluid passage between the flow tube and the fluid inlets/outlets having an increased cross-sectional and flow capacity from the torque converter. The present disclosure also sets forth a method of installing the present internal flow tube within the pump drive shaft.

Abstract: A high performance intermediate servo assembly wherein the servo piston has been modified to provide at least a 17% increase in surface apply area and a corresponding increase in hydraulic pressure delivered to the 2nd gear clutch band which it actuates. The present servo piston is reconfigured to an overall length equivalent to the assembled stack-up dimensions of the original equipment servo piston, accumulator, accumulator spring, and spring retainer components and integrates the critical working surfaces thereof to retain proper function. Such original equipment components have been eliminated to simplify the intermediate servo assembly operation since shift feel is not a concern in this application. O-ring seals on the original equipment servo piston are replaced by high performance seals such as quad-lobed seals to ensure hydraulic integrity under the increased fluid pressure generated. A method of replacing the original equipment components with the present servo assembly is disclosed.

Abstract: A planetary gear carrier assembly having an upgraded thrust bearing with an increased surface contact area and corresponding dynamic load rating capable of withstanding the axial thrust forces generated by engagement of the planetary gears in a General Motors 4L60, 4L60E or other similar transmission. The present carrier assembly includes an upgraded radial roller bearing having an increased number of roller elements of a greater axial length than the original equipment manufacture. The upgraded thrust bearing is accommodated by machining semicircular cutouts of a predetermined dimension and axial length coextensive with the inner surface of a central opening in the carrier housing, which is the only access for installation of the thrust bearing. The larger diameter bearing is installed within the carrier housing by passing it through the central opening in alignment with the semicircular cutouts after assembly of the carrier housing is complete.

Abstract: A high performance intermediate servo assembly wherein the servo piston has been modified to provide at least a 17% increase in surface apply area and a corresponding increase in hydraulic pressure delivered to the 2nd gear clutch band which it actuates is disclosed. The present servo piston is reconfigured to an overall length equivalent to the assembled stack-up dimensions of the original equipment servo piston, accumulator, accumulator spring, and spring retainer components and integrates the critical working surfaces thereof to retain proper function. Such original equipment components have been eliminated to simplify the intermediate servo assembly operation since shift feel is not a concern in this application. Further, the standard O-ring seals on the original equipment servo piston are replaced by high performance seals such as quad-lobed seals to ensure the hydraulic integrity of the present intermediate servo assembly under the increased fluid pressure generated.

Abstract: An intermediate shaft assembly for an automotive transmission wherein hydraulic fluid intake ports in the rotating shaft assembly are designed to provide increased hydraulic fluid flow and improved lubrication to mating components served by the shaft lubrication circuit is disclosed. The hydraulic fluid intake ports are laterally offset from the center plane of the shaft assembly to increase the angle of entry to fluid entering the intake ports and configured to produce a scooping effect within the fluid surrounding the intake ports upon shaft rotation, which substantially increases hydraulic flow into the shaft and counteracts the inhibitory effect of centrifugal force on fluid flow within the ATF intake ports. In addition, the dimensions of fluid plug orifices and of lubrication outlets on the present shaft assembly have been calibrated to regulate the increased ATF flow and to deliver effective lubrication to the aforementioned mating components.

Abstract: An apparatus and method for repairing hydraulic fluid leakage from the low/reverse gear fluid circuit of an automatic transmission case is disclosed. The present repair kit comprises a deformable grommet seal used in combination with a steel shim to replace the original equipment gasket, which is the source of the fluid leakage. Installation of the steel shim compresses the grommet seal in the fluid passage thereby creating a leakproof seal and maintaining the integrity of the low/reverse piston fluid circuit. In addition, the steel shim functions as a spacer in replacement of the original equipment manufacture gasket, which is discarded, and also provides a non-compressible backing surface to prevent distortion of the piston retainer when it is assembled and fastened against the shim.

Abstract: A high performance intermediate servo assembly wherein the servo piston has been modified to provide at least a 17% increase in surface apply area and a corresponding increase in hydraulic pressure delivered to the 2nd gear clutch band which it actuates is disclosed. The present servo piston is reconfigured to an overall length equivalent to the assembled stack-up dimensions of the original equipment servo piston, accumulator, accumulator spring, and spring retainer components and integrates the critical working surfaces thereof to retain proper function. Such original equipment components have been eliminated to simplify the intermediate servo assembly operation since shift feel is not a concern in this application. Further, the standard O-ring seals on the original equipment servo piston are replaced by high performance seals such as quad-lobed seals to ensure the hydraulic integrity of the present intermediate servo assembly under the increased fluid pressure generated.