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You Have to Build a Stout Transmission if Jesse James Will be at the Throttle

For the past several months Super Duty Headquarters in Gilbert, Arizona, has been working one very special project—a full-custom, double-throw-down pre-runner for non-other than Jesse James. Yes, that Jesse James.

Author

Picture of Paul Morton

Paul Morton

Words & Photography

They started with a stock, two wheel drive, Crew-Cab Chevy truck, and since that time they have put literally hundreds of hours into custom fabrication work that will make it suitable for one of the most infamous people to ever customize a V-twin.

Along with an incredible amount of custom fabrication work, SDHQ has also bolted on a Magna Charger, and installed massive 35-inch BFGoodrich Bajas, leaving the stock transmission between a rock and hard place. With upwards of 140 additional horsepower, the increased torque subjected on the transmission (in an effort to turn larger, heavier wheels and tires), it just didn’t seem like a good idea to leave the transmission in its stock state just, especially with Jesse James behind the controls. To address this concern, the truck was sent off to Doug’s Performance Transmission, which is right around the corner from SDHQ, in Mesa, Arizona.

Once at Doug’s the transmission was extracted from the truck, and quick work was made of tearing it down and getting right into the re-build. To accomplish this, a few stronger parts were used to better handle the abuse that we knew going in that Jesse will impart on this truck (come on, you’ve seen his shows). Other than trading out stock parts for the more durable aftermarket pieces, for the most part the transmission was left stock—not even the stall speed was altered. Doug Jr. did leave out the cushion spring for the 3/4 clutches, and adjusted the force motor to make for a more aggressive shift. The bottom line is Doug’s used their downright impressive performance experience to upgrade the parts with a surgeon’s precision, as they so aptly identified those parts that were most likely to fail under the circumstances they will be put in.

A family owned and operated business, Doug’s is much more than a Mom and Pop shop. They have been repairing, servicing and re-building stock transmissions, as well as building high-performance racing transmissions for 30-plus years. It all started with Doug Sr., but this job quickly turned into a passion and a career. Twenty-two years later, Doug Jr. joined in on the effort, and the team was formed. They’ve been building a solid business, as well as a lot of solid transmissions, ever since. You can find them at the same place they have been for the past 8 years, and with the quality of work they do, it’s safe to say they aren’t going anywhere soon. They do it all, from stock import cars to race-ready, off-road trucks, like Jesse’s.   

This is what a separates the men from the boys, here Darren removes the transmission pan to drain its fluids. He does it without spilling a drop. Then he removed the transmission crossmember and the front section of the exhaust. After that he was able to unbolt the transmission from the engine and remove it from the truck.

After that the transmission was taken into the clean room and setup on a rotating transmission stand. Neatly laid out on the workbench was a series of beefed-up performance parts that were going to be installed in this new transmission. They include a hefty Alto band, Raybestos Blues, a Superior billet servo, Alto Reds and a hardened reverse reaction shell. With everything in order, Doug Jr. started by removing the bell housing from the front of the transmission and the servo from the side of the transmission. After that he removed lock-up solenoid from the pump that is located just in front of the valve body, under the transmission. At that point he was able to unbolt and then remove the pump, which just lifted out from the center of the transmission.

With the pump out of the way, Doug removed the two drums. The large one in the front is the reverse drum, the smaller one to the left with the input shaft sticking out of it is the input drum-it controls low, forward and gears 3 and 4. To the far left is the servo and the pump that concealed it all (it’s sitting in the back). The thinner band that Doug is holding was removed from around the reverse drum and will be replaced by the larger, stronger-clamping heftier Alto band. The band will clamp around the drum to apply second and fourth gear.

After a snap ring was removed the front planetary (planet), along with the ring gear and hub, were pulled out as a unit. This exposed the reverse reaction shell which was replaced by a hardened heavy-duty unit, which is much stronger than stock, although it looks exactly the same.

At the back of the transmission Doug removed the tail housing so that he could knock out the low/reverse sprag. At the workbench, the rear planet and hub receive a liberal coat of trans lube, which is the only prep they need for re-installation—after that, they are rotated into place inside the transmission case.

Before he installed them, Doug showed us the difference between the stock reverse clutches and the Alto Reds that will replace them. Made out of a more substantial material, the Alto Reds will handle more heat, which is a major factor in transmission failure. Once stacked, the Alto Reds with the steels (in alternating order—steel, clutch, steel, clutch, etc.), Doug was able to install the first reverse steel in the transmission over the top of the reverse piston (which was not removed because this was a new transmission) and around the rear planetary that was just installed. He pointed out the index mark that is on all the steels, which won’t allow you to install them backwards. This first steel is followed by the series of clutches and steels that were previously shuffled together. The final step is to install the anti-clunk spring, which is pretty self-explanatory.

At that point Doug re-installed the low/reverse sprag and secured it with a snap ring.

After that, a new hardened steel shell was dropped into place, the front planetary hub and ring gear were re-installed, followed by the front planet. Then the output shaft was slid in place from the rear of the transmission through everything that had just been installed. It was secured with yet another snap ring.

Next Doug removed the stock intermediate clutches from the reverse drum—more Alto Reds to come…

After that he tore down the input drum, which meant removing more stock steels and clutches. He showed us the cushion spring for the clutches that will not be reused, as this was to be an aggressive-shifting performance transmission.

To re-build the input drum, Doug started by alternating more clutches and steels, but this time he used Raybestos Blues, as they feel these are the best choice for this application. To install them back into the input drum, Doug started with the first steel, which only fit in one direction, and then followed it with a series of alternating clutches and steels. This is the first of three sets of steels and clutches that will go in this one drum. After the low gear/clutches are stacked in place, the input sprag is twisted into place. The second set of clutch/steels that cover forward, were then stacked in place followed by a snap ring to secure it all. Last but not least are the 3/4 gear/clutches, followed by one last snap ring-for this section anyway. On the flip side, Doug installed the bearing at the back of the input drum.

Back to the reverse drum, Doug installed yet another set of Alto Reds and factory steels.

Here the stacked reverse drum and input drum were dropped into the case as a single unit. To align the clutch/discs onto the front planetary ring gear and allow the drums to slide all the way into place, Doug used a pair of pliers to twist the input shaft back and forth until everything was lined up properly.

Remember that hefty new Alto band we showed you earlier? Here Doug lines up the band with the dowel, and slides it into place around the reverse drum.

A new Superior Billet Servo was then pieced together before being installed. Doug had to align various aluminum pieces and then install a serious of Teflon rings and rubber O-rings as per the instructions. Once assembled Doug just installed it into the case.

Nearing the finish line, Doug installed the pump gasket, dropped in the pump and tightened it down in a crosshatch pattern.

At the bottom of the transmission, behind the valve body, Doug removed the 1/2 accumulator for access to the force motor. He turned it clockwise 1/2-turn to increase main line pressure. This will make for a more aggressive shift. Once the adjustment was made Doug simply bolted the accumulator back into place.

Just forward of the valve body Doug re-installed the lock-up solenoid that was removed at the beginning of the build. After that, he installed a new pick up filter, before installing the pan. Finally the tail housing was re-installed at the back of the transmission, and up front the bell housing was bolted back into place. All that was left to do at this point was re-install the transmission, fill it with Dextron 3 ATF, and take the truck out for drive.

Just before the transmission went in, however, the torque converter was attended to. Next door at Mesa Drive Shaft, Travis opened up the torque converter to make sure everything was in order. Other than polishing the hub with some Emery cloth, he didn’t do anything but inspect the converter’s internal parts. According to him, these new GM converters don’t need any modification like the older ones might have. Travis could have increased the stall speed, but that was not a necessary upgrade for this build.

ARTICLE SOURCES

Picture of Doug’s Performance Transmission

Doug’s Performance Transmission

310 E. Southern Ave.
Mesa, AZ 85210

(480) 964-3832

Picture of AZ Driveshaft

AZ Driveshaft

formerly Mesa Driveshaft Service, Inc.
310 E. Southern Ave.
Mesa, AZ 85210

(480) 898-1957

Picture of Super Duty Headquarters (SDHQ)

Super Duty Headquarters (SDHQ)

525 E. Baseline Rd Suite 108
Gilbert, AZ 85233

(877) 969-2929

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