94 ranger keeps bustin flexplates

[offduty]

Guy's
I am new to the site and my name is Rich, I was hoping I might gain some insight about my Ranger. First of all I put 375.000 miles on the origonal motor and had the trans rebuilt after about 170.000 miles. I was told by some guy these things will go 400.000 miles if you take care of them so I thought I would put 800.000 on it. The truck is a 94 supercab xlt with a 4.0 V-6 and I love it.

After putting a remanufactured Jasper motor in it I thought I would go with their tranny too. I just keep bustin flexplates and Jasper keeps replaceing the tranny, flexplate and torque converter. I have just busted my third flexplate and Jasper is sending an new motor and trans out, they beleive the motor may have something to do with it. I dropped $8000.00 in to this truck in motor and trans and all work has been done by a great mechanic.

I am so frustrated with this situation it breaks down at the most inappropriate times, the last time a week ago was on the way to a 6 week training session my chief sent me to 10 hours away. I bought an 88 Bronco to tow my boat because I thought the boat was breaking flexplates on my Ranger. I am at about $3500.00 with the tow bills and the new truck and Jasper does not pay all labor for their 100.000 mile warranties.

I have done a little research and this seems to be a common problem, but why I put 375.000 miles on the origonal motor and rebuilt trans with no problems. Now I have not gotten better than 5000 miles on the best of these 3 trannys.

I kept this truck because of its longevity record and the advice of others and my mechanic. If this keeps up I will take a huge loss and have to just about write this truck off any advice would be greatly appreciated.

Rich

 

[OldRedB2_84]

eliminate all that and swap a 5 speed in, better gas milage, and more power.

 

[offduty]

I have been thinking about the 5 spd 5R55E trans and could use the extra mileage but will it solve my flexplate pproblems?

 

[kunar]

I have been thinking about the 5 spd 5R55E trans and could use the extra mileage but will it solve my flexplate pproblems?

5r55e is an auto. i think he was referring to the 5 speed m5od which is a manual. that means you get a clutch and a flywheel, not a flex plate.

 

[snake]

You'd have to figure out what is busting them before I could tell you if swapping a certain component will fix it. I'd study the crank carefully to see if it is putting the flex plate in a bind somehow. I don't really suspect the tranny (unless the converter is warped or something) because with an auto tranny, the converter doesn't bolt to the tranny, it rides on the input shaft and therefore, in my thinking, couldn't be in a bind.

Where are the plates breaking? Near the crank bolt holes or closer to the ring gear?

 

[cocoasranger]

The front tip of the transmission input shaft is supposed to be supported by the pilot bearing which is pressed into a bore in the rear of the crankshaft. If the pilot bearing is missing or damaged the flex plate can move around putting strain on the flex plate and hub.

 

[snake]

He's got an auto... no pilot bearing.

 

[offduty]

Yeah guys it is an auto. The flexplates crack in a connect the dots fashion between the holes that bolt it to the crank.

I can not believe I am going on my fourth tranny, flexplate and torque converter. This time I will be getting a motor also, they think it may be causing the damage so Jasper wants to replace it. They say I will have to pay for labor and they will reimburse me if they find their product is faulty.
Thanks
Rich

 

[rickcdewitt]

ouch,look around this site at all the 5 speed manual swaps.its pretty easy and you can do it with all factory parts.for what you've been through so far it might be the easiest way to solve your problem?

on a side note-i'm doing a flexplate on an auto explorer and it looks like it might have broke before also?haven't really got any answers on why it might be doing this.

 

[offduty]

I am not looking for a manual trans, I paddled the canoe for quite a few years and moved to an automatic.
Thanks Rich

 

[shadetree]

I would hope the mech is installing the torque converter all the way back in the trans. If not this will put a hell of a bind on the flex plate. (Doubtful)

Engine was previously used with a manual trans, and the pilot bearing was not removed when installing the automatic?????????????(Also doubtful)

Over-torquing of the flex plate bolts.

Warped/off center crank hub. Very unusual.

Crank thrust bearing shot........... shady

 

[camping_mailman01]

I have to admit that history has never been my strongest suit, but it seems that there was a small hub that fits into the pilot bearing hole. It had to be aligned before you could bring the engine back far enough align the guides and start the hogshead to engine bolts. If the pilot bushing is still in the crank, this converter hub could push the p/bushing in a short ways allowing the hub to only go in a short distance. This would damage the tranny front imput shaft seal, and trans. I am not sure by your first post, but did you actually put this engine in yourself? If you did, when you installed the nuts on the torque converter to tighten down the flex plate, was there any distance between the flex plate and the converter that you had to force back so that you could start the nuts? If you did have to force it, this might suggest that the bushing is in there and by forcing it you forced the flex plate to warp to bridge the gap this would then eventually break the plate.

I mentioned history, as it was two years ago March that I put in my engine in and that is history since I have seen that. I have been out of the mainstream of auto mechanics for a while since heart problems made me quit full time, but I do not recall any auto tranny that doesn't have the alignment hub, nor any that are installed with the p/b in the crank.

 

[Thumper113]

Are both of the alignment dowels in the engine block?

 

[camping_mailman01]

Yep they are, but they are actually steel tubes that will end up with a set of bolts through them.

 

[offduty]

The engine was installed in 96 and is a Jasper reman 4.0 V-6 supposed to be to OEM specs and balanced with 100.000 mi 3 yr warranty. The first trans was installed around 9-07 by my mechanic who has done these before and I have a lot of faith in he has never had a problem with a jasper product until mine and has worked sucessfully on this type truck doing the same thing.

I have a new motor and am waiting on a new trans from Jasper to be delivered to Hartnell trans in Redding, Ca who will do the install hopefully next week as the trans should be here monday.

Rich