Hi guys,

I purchased an '94 F150 with the E4OD transmission. The transmission shifts hard (almost stalls the engine) through all gears, and leaks fluid from the pan gasket. Fluid is reddish brown in color. I don't want to get stranded somewhere if the trans goes out, so I'm going to rebuild it.

I've got the ATSG rebuild manual for this trans and found several helpful write-ups as well. I have good mechanical skills and I have plenty of time.

The truck will primarily be used for towing a 6X12 enclosed trailer. Not going on any road trips with it, just around town. The engine is 100% stock and I intend to leave it that way. If the transmission performs like it did when new, I'm satisfied.

First I need a rebuild kit. The truck is a 4X2, 4.9L engine. I'm not doing racing or off-road driving, so I don't need anything fancy. Here's what I'm considering:

This one: Ford E4OD E40D Transmission Deluxe Overhaul Rebuild Kit 1989 1995 F250 F350 | eBay

This one: Ford E4OD E40D Transmission Deluxe Rebuild Kit 89-95 Level 2 + Transgo Fix More

Or this one if it's worth the extra money: E4OD Ford Transmission Red Eagle Powerpack Rebuild Deluxe Kit 1989 95 Level 2 | eBay

Which of these would y'all recommend for my transmission?

I also need suggestions for what upgrades to get. I'll be putting in a separate trans cooler and probably a shift kit. Do I need anything else?

Thanks!

 

I went a little crazy when I did mine. But, I'm at 6-700 HP with plans for more. Here's a list of upgrades I did to mine.

ATS Billet Input shaft: http://www.atsdiesel.com/ats2/produc...p?p=3049103104

ATS Billet Intermediate Shaft: http://www.atsdiesel.com/ats2/produc...p?p=3049203104

TCS Billet Forward Drum: http://tcsproducts.com/products/prod...d-clutch-drum/

Center Support machined for snap ring: http://www.ebay.com/itm/271417456108?_trksid=p2057872.m2749.l2649&ssPageName=STRK%3AMEBIDX%3AIT
Steel 6 Pinion Rev Planet: http://www.ebay.com/itm/200935513914?_trksid=p2057872.m2749.l2649&ssPageName=STRK%3AMEBIDX%3AIT
45 Element Intermediate Sprag: http://www.ebay.com/itm/371094777308?_trksid=p2057872.m2749.l2649&ssPageName=STRK%3AMEBIDX%3AIT
Overdrive Spiral Snap Ring: http://www.ebay.com/itm/271647736899?_trksid=p2057872.m2749.l2649&ssPageName=STRK%3AMEBIDX%3AIT
Intermediate Band Apply Servo: http://www.ebay.com/itm/371094777660?_trksid=p2057872.m2749.l2649&ssPageName=STRK%3AMEBIDX%3AIT
PowerTow Shift Kit Fairbanks: http://www.ebay.com/itm/270833991321?_trksid=p2057872.m2749.l2649&ssPageName=STRK%3AMEBIDX%3AIT
Red Eagle Kolene Powerpack Rebuild Master Kit: http://www.ebay.com/itm/271513888111?_trksid=p2057872.m2749.l2649&ssPageName=STRK%3AMEBIDX%3AIT
Four Pinion Steel Overdrive Planet,6 pinion steel forward planet gear kit,Teflon Coated Pump Gears,Hardened Shell, all picked up here: http://www.transmissioncenter.net/e4od.htm


Here is a very good thread on rebuilding,a lot of good info: E4OD rebuild

 

I'm at 145 HP and I'm not planning on more. But I'll look through those upgrades and see which ones I want.

Thanks for the rebuild thread!

 

FYI, if you go to the later model 4 pinion od YOU MUST use a 95 up input shaft.

Catastrophic ENGINE damage will result.

Don't ask how I know.

 

Six Pinion front & rear planetary gears, short input shaft(comes as a kit with the O/D planetary, as I recall) 4 pinion OD planetary set, TransGo "Tugger" kit, and a high quality rebuild kit...

Also, get a hold of the Factory Service Manual on CD, and print out Chapter 7, covering Transmission teardown & rebuild...

Just did all that...
Scott

 

Scott,

Thanks for the info! Would you recommend any of the rebuild kits I posted earlier, or do I need something better?

 

TransGo "Tugger" kit: this is their "top of the line" overhaul kit for the valve body: It also reprograms for better shifting, stronger application, etc- makes a very solid tranny... FOLLOW their directions PRECISELY... I found the springs in the valve body to be not only distorted, but destroyed when I removed them... The kit has all the ones which need replacement- as well as upgrades for the valve body. I recommend the kit- even if you are not planning anything extreme, as it will give you a bulletproof setup...This is their website: TransGo E4OD/4R100: 4R100-HD2_
This is the seller I got it from: http://www.ebay.com/itm/Ford-4R100-Tugger-TransGo-Transmission-Reprogramming-Kit-4R100-HD2-Tugger-/192024860101?hash=item2cb592d5c5
You can find them on e-bay at a reasonable price, just search around...
Here is a list of the items I purchased on e-bay, with links to the sellers I bought from: I feel I got good deals:
Transmission Bushing Kit: (ALL bushings for the trans.) http://www.ebay.com/itm/171370865381?_trksid=p2057872.m2749.l2649&ssPageName=STRK%3AMEBIDX%3AIT
Sonnex Anti-Drainback Valve (Goes in pump) http://www.ebay.com/itm/351406521970?_trksid=p2057872.m2749.l2649&ssPageName=STRK%3AMEBIDX%3AIT
Rear Planetary Gear (6 pinion, Reuse the old ring/cup) http://www.ebay.com/itm/200935513914?_trksid=p2057872.m2749.l2649&ssPageName=STRK%3AMEBIDX%3AIT
Overdrive Planetary, with input shaft(4 pinion) http://www.ebay.com/itm/182245555803?_trksid=p2057872.m2749.l2649&ssPageName=STRK%3AMEBIDX%3AIT
Forward Planetary Gear (6 pinion, reuse old ring/cup gear) http://www.ebay.com/itm/121997636457?_trksid=p2057872.m2749.l2649&ssPageName=STRK%3AMEBIDX%3AIT
Center Support Upgrade Kit (I returned mine, as I found I already had the upgrade, apparently from a previous rebuild... But good looking stuff, good price!) http://www.ebay.com/itm/321994240819?_trksid=p2057872.m2749.l2649&ssPageName=STRK%3AMEBIDX%3AIT
Intermediate Band Servo (Mine looked fine, but was replaced anyway... Manual calls for a disk & retainer ring: they were eliminated by Ford , and not necessary, so don't worry about them) http://www.ebay.com/itm/201117676975?_trksid=p2057872.m2749.l2649&ssPageName=STRK%3AMEBIDX%3AIT
ALL the Torrington Bearings for the transmission (These are the flat roller bearings) http://www.ebay.com/itm/4R100-E4OD-Transmission-Torrington-Bearing-Kit-Ford-Lincoln-1989-1997-Koyo-Brand-/201345822092?hash=item2ee1256d8c
Pump Unit- (I replaced mine because I managed to damage it...) http://www.ebay.com/itm/E4OD-Ford-F5-Transmission-Pump-89-98-FREE-SHIPPING-/311780309993?vxp=mtr
Neutral Safety/Range Switch: http://www.ebay.com/itm/361764198998?_trksid=p2057872.m2749.l2649&ssPageName=STRK%3AMEBIDX%3AIT
I went with this Torque Convertor from APW: http://www.autopartswarehouse.com/sk.../ATCF59HS.html

And, from Rock Auto, the PA CARGO Deluxe Kit for E4OD: https://www.rockauto.com/en/moreinfo...121982&jsn=363

Other than a couple items I piked up along the way, this constitutes a list of the items I put together for my rebuild, at the best prices I could find at the time... I have had no problems with any of the parts, but have not driven her yet- I am hoping to finish the engine/trans rebuild reinstallation today! But- The parts were of apparently good quality: in my opinion (from my 30+ years of playing with cars) nothing is of dubious quality.

I HAVE NO FINANCIAL INTEREST IN, OR ASSOCIATIONS WITH, ANY OF THESE SELLERS IN ANY WAY BEYOND HAVING PURCHASED FROM THEM: I am only supplying a list of those items I, myself, purchased for my own rebuild, and the sources, prices paid, etc. Read through, make your own decisions and selections based on your needs...

Additionally, you may wish to wait until you have torn down the transmission before ordering the non-wear items: I found I already had the upgraded center support, for example, and did not need the one I'd purchased, and had to make a return for a refund (No problem at all with the company I used...). Best to tear down first, and then order- you'll know better what you will need.

Good luck with it!
Scott

 

Oh- and the manual calls for a few "special tools" The one for holding the forward/reverse clutch packs would be QUITE useful: but I didn't see the sense spending around $100 for a tool I would use once: I made one out of 1/8" x 1" wide flat stock... Worked rather well. Fun part is disengaging it when the packs are in place without pulling them back out- and thus knocking everything apart again... For compressing the Direct Drum Clutch Piston Spring, I used a second piston(I had purchased a good used set, because my spring had exploded...) and a set of four clamps to CAREFULLY move it into compressed position. BE CAREFUL IF YOU USE THIS METHOD! That spring set is under a LOT of pressure!... And as to the one for moving the Center Support into place, it is simply a bar which fits into the snap ring groove, with a bolt and pressure plate. I used a bar in place, and a round end pry bar to gently work it into position... Again- I have a LOT of experience with this sort of thing. It may be worth the money to you to buy the tools... You can always sell them again afterwards...

Scott

 

Thanks for the wealth of information Scott! I'm curious about why you replaced all the pinion gears, are they a weak point in these transmissions?

Here's the rebuild kit I'm considering:

Ford E4OD E40D Transmission Deluxe Rebuild Kit 89 95 Level 2 Transgo Fix More | eBay

Does it look like a good one for my situation?

Thanks!

 

I replaced the pinions for the simple reason they were upgraded items: My transmission came from the factory with 3-pinion planetary gears on all three sets: These were later upgraded to 4 pinion, and then later still, 6 pinion for the forward & reverse gear sets. It gives more strength to the drive unit. The center support upgrade to a ball bearing from a bushing is also a strengthener...If you are going to tear it down anyway, may as well go all the way and upgrade everything you can!

That kit looks pretty complete: The only thing I do not see is the reprogramming kit for the valve body: It shows the bushing kit, but you may have to purchase the "Tugger" kit separately- I HIGHLY recommend that one: As I mentioned- I found the springs in my accumulator had literally shredded themselves, and looked like chain-mail armor when I removed them! I would ask if it includes the "TransGo Tugger" kit- if not, askif they have a kit with it, or purchase one separately.

One other suggestion, and something I did not do due to money at the time: You may want to look into a rebuilt solenoid pack: they are a known weak spot, and easiest to replace when tearing down the tranny. They can be done with the transmission in place, but a lot easier with it out...

By the way- 15 quarts of Mercon V will run you about $90... The E4OD takes 15.7 qts according to the manual...

 

Looks like I'll be getting the following parts:

- Rebuild kit I posted earlier
- Transgo Tugger reprogramming kit
- Center Support Kit
- Anti-Drainback valve
- 16 quarts of transmission fluid

I think I read somewhere that if the torque converter fails, it will damage the transmission in the process. Is this true? If so, I will replace it as well. If I don't need a torque converter, I'll probably spend the money on a solenoid pack instead.

Thanks!

 

I was unsure of mine, but there is no way to really bench test one, so I figured that with the trouble involved in changing one, may as well do it all at once!

Scott

 

The transmission shifts hard, sometimes stalls the engine and shudders around 40 mph. Would any of these be caused by the torque converter?

 

The PCM Computer or bad wiring controls how hard it shifts.
The TC clutch does engage about 40MPH but that is also controlled by the PCM computer.
So I would say no to your question.

 

Thanks! And just to clarify, is the torque converter a sealed unit or is it immersed in transmission fluid?

The trans is low on fluid due to a pan gasket leak. Probably why it shifts hard. However, it has been driven for an indefinite number of miles with low fluid, so I figured it's time for a rebuild.