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Old 08-26-2003, 12:07 PM
jimburke jimburke is offline
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E4OD dead, AOD swap?

I'm looking for any advice I can get. My 19 year old brother has a 1995 F150 4x4 with a dead E4OD tranny. He is planning on getting another to replace but will take a few months to save the money. I have a 1990 F150 with an AOD 2wd tranny off a 5.0 that he can use until the other is rebuilt. Can this be used behind a 4.9l - 300 inline 6? and what problems will we have to deal with. Any help would be much appreciated.

Last edited by jimburke; 08-26-2003 at 12:11 PM.
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Old 08-27-2003, 12:58 PM
jimburke jimburke is offline
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E4OD dead, AOD swap?

Ok, well so far we have had to change the flexplate and shield as everything binded and wouldn't turn once we bolted it together. With the flexplate and shield off the 5.0L , everything bolted up great and turns freely. I am going to use the starter off the 5.0L as it appears the ring gear is now further back in the bell housing.

Is there by chance a cheater assembly available to connect the transmission wiring assembly up? or will I need to cut into the existing wiring harness and use the plugs off the 1990?

Any help on the wiring would be greatly appreciated.
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Old 08-27-2003, 08:59 PM
E150X E150X is offline
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E4OD dead, AOD swap?

Don't take this as gospel but the flexplate is balanced for a 5.0 not a 4.9. Unless they have the same balance weight you could get severe vibration!
Also a 90 aod uses a Throttle Valve cable attached to the throttle linkage and must be adjusted properly or severe transmission damage could occur.
The problem with the e4od could just be the torque converter but you didn't list it's symtoms.
See if you can locate a flexplate for a 4.9 aod.
And a repair manual
Good luck.

Last edited by E150X; 08-27-2003 at 09:06 PM.
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Old 08-27-2003, 11:15 PM
jimburke jimburke is offline
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E4OD dead, AOD swap?

Thanx E150x

You are right on the money with the weighting of the flexplate. As for the symptoms, here they are, reverse and first worked fine but after that it was total slippage. The tranny fluid is burnt and there are metal filings in the pan.

I havent started the truck yet but I'll have to see how bad the vibration is. The tv cable is connected to the throttle and working properly. Might need a lil adjusting and will check it out before testdriving. I'm just curious about the electrical now. What has to be hooked up and what doesn't. Also is there a different voltage for each set-up? If anyone has a schematic, I'd appreciate it. I've checked out the manuals, but they don't have much for the transmission wiring.
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Old 09-04-2003, 10:21 PM
jimburke jimburke is offline
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E4OD dead, AOD swap?

Ok well here goes. After finally getting everything connected we had to put the original 1995 starter back on and it meshes fine. It appears Ford started using a solenoid on the starter somewhere between 1990 and 1995 in conjunction with the one mounted on the inner fender. I was able to use the neutral safety switch off the E4OD transmission (set in neutral position for starting) and then tucked the whole harness under the hood to help prevent corossion. Caution as the truck will now start in ALL gears!!! We ground the weight from the flywheel which eliminated the vibration ( E150x prewarned me about) The trickiest part was hooking up the shift cable from the column to the transmission as the 1990 donor truck used a rod linkage. We bolted the cable bracket from the E4OD tranny to the tv bracket from the AOD tranny, a short length of straight bar and the E4OD shift linkage together. With a little Macguivering the shifter even reads properly inside the truck. We also were able to use the driveshaft from the 1990 2 wheel drive, along with the rear flange from the 4x4 rear drive shaft to connect to the rear end without any change in the driveshaft length. We did have to make a U-joint from 2 to get the 2 to work together. After everything was completed, we had to make a minor adjustment to the tv cable and everything now works great including OD. At least I now know that the E4OD can be replaced with an AOD tranny.

But after all the screwing around with a Ford, I am glad I own a Chevrolet!
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Old 09-04-2003, 10:21 PM
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49, aod, e40d, e4od, f150, flexplate, ford, length, problems, rod, swap, swapping, transmission, tv, weight, wiring

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