I desperately need to overhaul the E4OD in my '93 Bronco HD w/351W. It is at 120K miles, has a bone-jarring TCC chatter and also has a high-speed rumble @ 65 - 75 mph that is drive-shaft-speed related - - likely worn case bushing for output shaft (?). I've had the rear drive shaft rebuilt and balanced, and can find no evidence of pinion problems in the diff.

Incidentally, I also have the 351W/E4OD combo in my '95 ClubWagon, I absolutely hate the way it shifts too, but I don't see a need to o/h it.

Ideally, when I am done I would like it to shift like the C6 w/shift kit did in my old F-150 and I need a torque converter for towing & mild hill climbing. I have a multitude of questions…

-Is there any updated info beyond that which is available @ http://www.technicalevolution.com/e40d.htm or the famous zip file from Dieselzen?

-Is there a single o/h kit that I can purchase? Or do I need to buy myriad parts from different sources? If I buy a solenoid pack from ATI, will that be enough or do I also need a shift kit? Whose shift kit is best? I have heard that TransGo is best, but I've seen some postings complaining that they are not enough. Can anyone offer me some guidance?

-I am very frustrated with the T/C selection. To me, the Hughes 46LXTM looks to be the best, but is it worth the money or are they all the same? The local shop says that a new converter from Motorcraft is the best thing available... Is this true? What recommendations can you make for my application? I just need low-end torque for hill climbing and towing. But I would be happier if it also had quick throttle response and 0 - 60. BTW, I also plan to o/h the engine at the same time with new cam (Crane 444232), lightly ported GT40P heads, headers and duals.

Any header and/or muffler tips are also appreciated. I would like it to rumble a bit, but not be unruly on the highway or off-throttle…

Thanks!

 

If by TCC, you mean Torque Converter Clutches (or Torque Converter in general) I have found that adding some Friction Modifier, the same stuff you put in your limited slip rear-end, will greatly reduce or even eliminate that problem chatter. The E4OD is so big, just add the whole bottle (what is it, six or eight ounces, if that? I don't remember) Very, very common on Ford trannies. Tranny shops will charge you a fortune and sometimes this will cure the whole thing. What can it hurt, if it don't work you're only out the few bucks for the friction modifier. My buddy had the same problem couple years ago, I told him to add it, and it worked great. And he tows a forty foot Scarab with his F250!!

 

By TCC I mean Torque Converter Clutch.

I changed the fluid, drained the converter and added a full bottle of LubeGard (Red) (no, that wasn't the only thing I added after draining the tranny - I also added 16! quarts of Motorcraft's best) in February. It only chattered occasionaly until May when it got warmer. Now it is back to it's bone-jarring, teeth-rattling, butt-numbing, fist-clenching TCC chattering ways.

Had LubeGard fixed my TCC woes, I still would have the high-speed rumble that I believe is output-shaft bushing related that would still require a teardown...