My mason dump is running very well now. The engine is powerful enough to move the truck right along at 27000# (truck and trailer). The tranny has just about had it though. The PO paid someone $1600 to replace the trans less then 500 miles before I bought it but, as far as I'm concerned, it was money down the drain. It never shifted properly and leaked from the dipstick tube from day one. I set the TP sensor, which helped, but the damage is done. The truck is ok on short hauls with a light load but a 20 mile road trip, even empty, is a hair raiser. By the end of it, the tranny won't shift into 1st gear unless I do it manually. Overdrive is gone by about ten miles and TC lock up is gone after two or three. It seems to be getting worse by every run. It has always banged hard through the gears. It shifts brutally hard.
I have an Allison in a box truck that I don't use. I think it's the same tranny that you'd find in an old school bus. I also have (no death threats please) an E-350 bus with a Cummins 5.9 and C-6. Really nice professional conversion. I was thinking about doing a Cummins and Allison swap since the truck is two wheel drive and shouldn't be driven faster then about 65mph anyway.
Anyone done anything like this?

I have a piece of equipment to move today. I'm dreading it! Wish me luck!

 

You don't want that Cummins in that Ford. Let me take it off your hands for you. We don't want people to talk bad about you..

 

Is your Allison an AT-545?
I have three of these, two complete set-ups for Cummins and one spare out of a Volvo truck. I'm going to eventually use them in a '95 and '86/'91 CrewCab Dodge projects.
All I can tell you about them is they are generally in larger buses and around 40K# mid-size heavy-duty trucks. They are a 4 speed with no O.D. which I prefer as I'll set-up my "highway/cruising gear" by using the correct gear ratio in the rearends with my chosen tire size.

A Cummins/Allison 545 combo would be a heavy-duty unit for your needs/use and it's a proven combo used in a multitude of larger/heavier vehicles.

 

I've got a 92 with the E40D. Every couple of months or so It messes up (o/d light off flashes and it snaps your neck on every shift) I disconnect the battery for a couple of minutes and it goes back to working correctly. I know its not the correct way to solve the problem, but it will do until I can locate a donor truck with a 5 spd.

 

It's a 545 4 speed. These trannies are dirt cheap around here because of the surplus of old school buses. They are usually auctioned off and parted out after a few years as per school bus fleet regs. There's a place about 30 miles from me that sells AT545's by the container load. They can be had for $250 a unit, usually in good condition. I was saving the Cummins engine for my Case track loader and was planning to sell the motor mounts, bell housing, air cleaner/ducting etc. I haven't decided yet.
I like the IDI engine in my truck now (ambulance package). I always remembered the IDI as a dog but this one has *****. With an Allison behind it, I'd take it anywhere. The E4OD is going to leave me on the side of the road soon.
If I can find a complete school bus drivetrain, that would probably be the best way to do it....unless I can find the SAE plate and flex plate/TC and starter.
I would have to find all that stuff to get my Cummins/Allison in the truck anyway. I think the IDI/Allison swap would be easier.
I would be willing to hack the dog house right out to get an Allison in there.
Any suggestions?
I need to replace the Road Ranger in my Mack and when I do, the F-450 is coming off the road.

 

welcome to the site.but please start a new thread.

instructions:
click here:
Pre-Power Stroke Diesel (7.3L IDI & 6.9L) - Ford Truck Enthusiasts Forums
navigate to the "new thread" button.
it is located up toward the top,on the left,just above "Announcement:....etc.etc.etc." (in black letters.)

but you don't need to spend the large amount of $ for this swap anytime soon.
you can fix this problem yourself,and cheaply.

warning!
do not continue driving the vehicle like this.you will burn up your trans,and we'll have another member claiming the E40D is poor trans.

 

BTW FORDF250HDXLT, how is the B & M shift kit on your E4OD? I was thinking of getting one, is it worth it?

 

this guys thread his getting hijacked.

least we are on topic about the E40D i guess.
it's great.rather than stock where the clutch discs engage slowly,causing them to ware more,and produce extra heat,the shift kit makes them engage(press together) much quicker.
stage one/heavy duty is perfect.a shift that feels FIRM (think; a quick release of the clutch with a manual) but not slamming hard.
you know it when it finds the next gear.especially with a load on/in tow.
really nice.not like stock,where "comfort" was priority.

worth the cost,and the hassle of installation.no question.

 

if your interested in keeping the E40D,and see what yo can do with it.it sounds to me,like this would be the thread to start with:
https://www.ford-trucks.com/forums/1...-adj-fipl.html

also remember to flush the trans every 15k miles (severe use) don't go the 30k norm for a heavy hauling f-superduty (f450) rig.

it doesn't sound good though.
hopefully more advanced E40D guys hop in here,but by the sounds of things,your not to concerned on keeping it anyway.
to bad you didn't actually know what was done for the $1600 (of course,it could have just been a story.sure doesn't sound like a rebuild to me.or it was just a high mile replacement or something.)

 

I'm not sure weather the E4OD is a bad tranny or not but I do know that, built for the kind of abuse I'm dishing out, they start at around 3 grand with triple clutch TC. Neither the E4OD or the C6 will hold up in my mason dump towing a 9 ton Eager Beaver. Not stock anyway. I have a C6 minus 2nd gear that the Cummins killed. I really need something stronger. (What I NEED is my Mack+20 ton Eager Beaver!)
The F450 is convenient though.
I found a Cummins/Allison bell housing and other small parts on Craig'sList for $150 but it looks like an L10 to 700 series. What's that? SAE 1?
I called the school bus JY today but no call back. I may just start looking for another whole bus!