I have a E40d in a 1997 f250 power-stroke. I overhauled the transmission in my garage. I bought truck from a guy who said the transmission overheated and puked all the tyranny fluid out of it. When i got it home it had some internal damage to the forward/reverse sun assembly and needle bearing assembly, along with fictions that were completely gone and steels that were heat checked. I replaced damaged components and assembled. At 60 mph around 2000 RPMs i get a buzzing noised coming from the front of the transmission. I pulled the pan and found a piece of metal that looks like a fin inside the torque converter stuck to the magnet. I changed the fluid and filter and put a new remand torque converter and am still getting the buzzing noise that sounds like its coming from the front of the transmission. It happens around 60 MPH and 2000 RPM. Then i hear a click and it just goes away for a little while. If i floor it going up a massive hill by my house on the freeway I can get up to 90 MPH with no noise. I,m not a transmission guy but i want to learn. I am a diesel engine mechanic in the marine industry

 

Welcome. Mark Kovalsky is our guru on E40D's. If he doesn't come alone soon try sending him a PM. Good Luck.

 

I don't know what's going on. A fin from the converter is much too large to fit through the fluid passages from the torque converter to the pan. It has to have come from something else.

 

Cool, I thought I was the only non tech that builds their own automatics! I only have done an AOD and Euro units (722.3s and ZF 4HP24s)

You sure the buzzing is not some harmonic resonance coming through the cab? Loose heatshield? Balancer dying? Dipstick tube?

The only time I have experienced a distinctive 'buzz' was on my AOD at idle in park. I think it has something to do with the Transgo in it and wear on main pressure valve.

 

I will never rebuild another 722 of any flavor... after doing a handful on several diesel W123s and a few gasser 126s, never again.


Harmonics were my first thought, but I'd assume he inspected everything with it apart.

How loud is the click? Or is it a pop?