i am an allison builder and am building a ford aod for a buddy i took five steels and five frictions out of the direct clutch, using a transtar kit to rebuild it that came with all new steels and frictions 5 an 5 dont fit back in it only 4 and 4 do is this normal

 

You might want to check with Transtar. Sometimes they will include in a kit parts for a std duty and parts for a heavy duty, depending on which you happen to be working on.

 

Not certain on the Transtar, but if the stack is count reconfigured or thicknesses changes from OE, re-confirming total stack height and snap ring thickness adjusting may be needed for spec clearance..

 

AOD transmissions came from the factory with two different thicknesses of plates. Drums changed according to the plate thickness. Seems like the plates you got from Transtar are the wrong plates for your drum.

80-early 83 cast iron drums used 0.80" frictions.
Late 83-up cast iron drums used 0.62" frictions.
All stamped steel drums had larger diameter frictions.

 

AOD transmissions came from the factory with two different thicknesses of plates. Drums changed according to the plate thickness. Seems like the plates you got from Transtar are the wrong plates for your drum.

80-early 83 cast iron drums used 0.080" frictions.
Late 83-up cast iron drums used 0.062" frictions.
All stamped steel drums had larger diameter frictions.

This post is corrected from previous post. Tried editing last post, but edit function does not work.