Let me see if I can help..
I am a great believer in fully manual setups.
If you have another computer running older OS.. up to Mountain Lion is fine or even windows you can load the old 5.6 utility which can be a big help for this.
Anyway please put the TC back as the main router.
When you do the setup.. please make sure all the names are short, no spaces and pure alphanumeric.
And I want you to setup different names for the different bands. So for eg. Base Station name = TCgen5 and wireless names TC24ghz and TC5ghz.
Please set WPA2 personal password that is 8-20 characters pure alphanumeric.
Please set the 2.4ghz channel to 11. (you can use other ones.. but 11 is a good start.. in UK or Europe you can use 13 instead).
So your wireless will look something like this.


Never hide the network.. Radio Mode probably won't exist .. and country will be where you are.. not Australia.
Now on the AE 1354 reset to factory again.
Give it a nice simple name.. AEgen4 would be nice.
Setup the wireless.

This should then work when you update.
I recommend you start in the same room.. so you know the link will work with no bother about signal level.
If you get errors at this point tell us or give screenshot (even better) of what is going on.
Do not use the setup wizard.. although you may need to start that way.. just so you can get to the edit.

I do have a similar setup and I have to say 7.6.4 firmware is terrible.. YMMV but I always have issues.. although I am doing the repeater between TCgen4 and a AEGen4 (same as yours).

It might provide an alternative.. just grab a second hand Gen4 or Gen5 AE and use that for the bridge.. run both on 7.6.1 and it could well work fine.
A secondhand AE is much better and cheaper than newest Express. Better wireless and more useful routing. Gigabit ports.