Hi folks. Newbie here. Trying to find my way around, haha. Been reading what I can find on swapping over my E40D with a stick. 460 gas, long utility bed, 2 WD Dually. Had it overhaulled about a year and half ago, blew the front seal again last week. Fortunately helpers got it shut down fast, over to the side, I went out and pulled it back. I've just about had all the enjoyment I need from the automatic. Never did perform like I thought it should, couldn't even spin a tire in the sand, much less pull the truck up a decent hill to get to certain locations. I'm in the windmill business, and take the old gal maybe even places where it's not supposed to be, but dissapointment runs high with the tranny here.
Starting to find parts for a swap, pedal assembly, hydraulics, etc., but no trans yet. Drive shaft, if I can't find one, can have one redone by a local driveshaft shop. Still searching. Don't know if I will take 5 or 6 speed, whatever I can to shed some headaches, unless I'm in for more than I have already. 2 grand at a moments notice and undependable reliability on this thing is taking years off my life, and I can't afford that. lol
To get going, at the moment, will take it out, re-install the from seal, get as large as an oil cooler as I can fit in the front, and hope for the best to get 'er back on the road, if no damage from the heat has occurred. I know heat is a critical enemy, and that's when the seal went the other day. 100+ temps outside.

The brake on the end of the tranny now is optional for me. If I can't get another on a manual tranny I can drag my foot, or bail out. ha. Main thing is to get this thing more reliable, and substitute un-ending cost and trouble for more reliable service.
Thanks for reading my ramblings. Any help will be much appreciated. Thanks!

 

Guessing you drive the interstate a lot, so a zf5 is about your only logical choice. The 6 speeds will not bolt up. You may be able to find a super duty transmission with the brake already on it, but I THINK a 4wd transmission will work. Just bolt your brake up where the transfer case would normally. If you do not get many responses here, you may try over on the 87-96 section. A lot of knowledgeable guys over there that will know that transmission like the back of their hand. Please run an e-brake on that truck, especially with a straight shift.

 

Thanks Ron. Mostly kidding about the Ebrake, but I hope to find one that mine will fit on. I had heard a 4wd one where the transfer case was will take the set up off mine.

Okay on the 5 speed, was unaware the 6 won't bolt up. A friend says to just slip in a C-6 they were bullet proof. Maybe.... maybe not. Also considering using older type 4 speed. they were cast and last till the cows come home. That would involve a 460 housing one to fit the 4 speed, and who knows what flywheel off an older model ford.

Got the trans out today, yep the seal was out. no surprise just dissapointment. Any, will try to put a new one in, and get it going to get some work done with it untill I get stuff collected for the changeover. Thanks again.

 

E4od are actually good transmissions. It was fords HD trans of the era. And came behind lightnings and diesels. Ive always had good luck out of them, one with over 250k. Make sure the shaft doesn't have a wear ring on it eating seals.

Does your truck have mass air and obd2? I ask, because I don't know how well the auto computer will play with a swap. That's probably a question you can get answered over in the other section. I know the older trucks without mass air, you could just take the sensor off the side of the transmission and keep it plugged into the harness to keep everything happy. Will probably work with yours as well, just something to beware of.

 

Ron, I know they are. Just happens they're not good for me. Yeah, the computer was brought up on the other posting in the other section. I never thought about that, but we will see. I will remember to watch for that. In the meantime, new seal today, re-install, and see what happens. If it goes, then I will have more time to gather parts for the swap.
Thanks!