I've just about had it with the E4OD in my '93 F250! When I got the truck the transmission was shifting hard and the OD light blinking. The speedometer and odometer in the dash cluster wasn't working so I figured that's what was causing it. I replaced the VSS sensor in the rear end but that didn't solve the problem. Replaced the cluster and disconnected the batteries to reset the code. Transmission shifted smooth as silk until I got up to to about 60 mph then the speedo needle went all crazy and the OD light started blinking again. I took it to the Ford dealership and it cost 140 bucks for them to figure out that the VSS sensor wasn't in properly and the vent tube for the rear end was clogged but they said the tranny has an internal problem. They didn't tear into it to figure out what it was. When I left the dealership with it the tranny shifted smooth as silk again but when I got up to 60 mph OD light starts flashing again and it starts shifting hard again but the speedo is working fine now! What the crap??? I don't know what the internal problem could be, when the OD light isn't flashing it shifts fine, doesn't slip or anything else. The only problem I know of with it is that sometimes, especially when its been setting for a few days, it is slow to go into gear when I first start it up like it's low on fluid but it's not low. Somebody said maybe the valve body leaking off fluid but once it goes into gear it shifts fine until it throws the trouble code. The code it's throwing is the vehicle speed sensor code. I don't know what else it could be but I know I'm about done with it. I'm ready to jerk it out and put a 5 speed tranny in it. What all would I need to do that and how much of a pain in the *** is it?

 

The ZF-5 spd is not a very hard swap at all. It involves finding a ZF-5 spd out of a 7.3 which is pretty easy. I think a DI ZF-5 spd would work too. Btw, welcome to the world of Manual transmissions and IDI engines. Once you find that it should be a simple swap out the transmissions, I found this on a PDF i had:

Items needed:
A) ZF5 transmission (Must fit 7.3 L diesel)
B) LuK solid flywheel conversion kit or equivalent from NAPA
C) Clutch/Brake pedal assembly
D) Clutch master cylinder/lines/slave cylinder
E) Wiring harness (neutral safety - backup lights) (or jumper the wires from the
automatic)
F) Modify or purchase 14” longer drive shaft (ZF5 is 13" or 14" shorter than the E4od)
G) Floor tunnel insert for shifter (or modify current insert)
H) Shift lever and rubber boot
I) Rear Cover Plate (between engine and trans) Ford PN F1TZ7007E (I just left mine
out)
J) Rear Engine Cover Plate (bottom dust cover for clutch)
K) Rubber Plug for automatic shifter cable hole to keep water out
L) Tube of body Sealant for floor insert and clutch master cylinder mounting

You can get all that stuff for like 1500 bucks, its expensive because of the flywheel conversion kit.

Normally if you purchase a JY ZF-5, they throw in a brake, clutch pedal assembly and MAYBE a master cylinder hose and slave cylinder. But for 1500 bucks, you will get another 300k out of your IDI easily from that ZF with a new clutch kit and whatnot in it.

 

BTW, if you want the PDF here it is, he goes through what he did and tips and tricks and whatnot: http://www.elmoreusa.com/e4odzf5.pdf << I looked it up because my buddy jared was thinking about throwing a ZF-5 into his 91 7.3 E4OD.

 

i would start tracing the lines to the VSS.look for any nicks that may be shorting out.
you shouldn't continue to drive the truck with the OD light flashing/inop speedo.failure could result.
im loving my E40D.

 

find a parts truck it has everything and it makes life easy. I did the swap and i had never even dropped a tranny before. It took me the weekend but if you have good mechanical skills it could be done faster

 

It can be done in a few hours if you got all the parts you need.

 

Wow, that's great info! Thanks a bunch!!

 

Personally I would go with the manual swap as well. I did it (c6 to t18) and love the manual. The hardest part was bleeding the master cyclinder lol.

 

i love my ZF, 5 gears is the way to go, you can pull down some pretty good MPG's on a 5 speed

 

all for what could be just a bare wire?
don't you boy's believe in the KISS method anymore?
i had this happen once when my dump ram came down and pitched the wires to the VSS.
i drover her home REAL slow and easy (25 mph and my hand on the shifter ready to slide her in neutral if needed with my eyes more focused on the speedo than the road. ) patched up the wires,and back in action.

 

I am definitely gonna do the switch. I'm gonna get the parts as I can afford them and do the swap when I get everything together. My buddy just bought a new 4 post lift and put it up in his garage so he is gonna get recruited into helping me do it in his garage, he just don't know it yet! Lol

 

Im all about keeping it simple...thats why i got a manual in the first place..

 

the only thing smiple about the e40d is when it craps it craps BIG TIME the c6 t19 and zf5 are simple trannys but the e40d is in no way simple it computer control for gosh sakes

we see more my e40d has tanken a crap on me thered them any other type imho only when the winter rolls around twe see more threads about gp them e40ds

 

joe carries a very valid point, the E4OD is just not a very favored transmission, my buddy jared blew his torque converter going up hill in 4lo @ 2 mph...no weight or anything on the truck....now he has shifting problems as well...I just dont like the E4OD, you can get better mileage with a ZF-5 or a T-18/19....

 

make sure you get the right pedals for your truck, the dashes changed in 92 so did the pedal mount, this is also one of the harder parts, they are a pain to get in