I'm replacing the dead AOD tranny on my 89 this weekend and need some tips on what to look out for. Installing another AOD, but this ones built much better than stock. Also putting in a 2500 stall.
Have a buddy to help, those dang things are heavy. Use a jack to lower and raise it, that way the 2 of you can balance it and wiggle it into place. When installing it try to line up the converter, to flexplate bolts before mating the trans to the block. And before tightening any bellhousing bolts, get the nuts on the converter to flexplate studs. Also if have an old drive sahft, take off the yoke and stick it in the trans to keep any fluid from coming out. Even if you drain the pan fluid will still be in the internals and find it's way to the tail shaft.
I removed my AOD last spring. It was a bitch. I could have finished it had I had the right tools. Ended up just taking it into a tranny shop where they finished it for me. (i was actually converting it to a tremec 5-speed). My biggest problem was getting the bolts off. Their a pain on the top of the the tranny right behind your Intake manifold. Also the starter was annoying. Make sure that you have a universal swivle elbow for your wrech for the starter. You'll also have to come in through the right front suspension to get the the starter. That was a pain. Who ever designed the starter definitley didnt think about servicing it. Hope that will help you.
If you have patience, you can get the starter off from under the car. Also, you can get to the top bell housing bolts by dropping the tranny a bit(crossmember and driveshaft already removed) and using long extensions. Air tools are also a big plus. Look out for the tranny cooler lines so you don't kink them, bone up as much as you can on TV cable adjustment so you don't burn up your tranny on the first test run, and make sure you have at LEAST half if not more of the tranny filled with fluid before starting it be patient and paranoid and fill it up as much as you can. If you run it dry you will be very sad, like Kerry/Edwards the day after elections.
Is it at all worthwhile to remove the H-pipe while dropping and replacing the tranny? Looks like it'd make the crossmember quicker, and give more clearance to the transmission, but I'm not convinced it's worth the time..
(though, to be honest, if it is...I'll probably just replace the stocker with a catless H while I'm in there)
k, the H is coming out then.. with luck I'll find a decent deal on an offroad pipe to replace it with
transcoolors.. Should I replace the stocker at this point, or is it possible to flush it out? If the answer is replace, any suggestions of a good one to drop right into the stock loc?