i have a 91 e150 van 5.slow and aod trans. trans is from a 89 e150. had 160000 miles. i changed all external oil seals, removed front pump, disassembled, cleaned, inspected, changed 4 sealing rings, outer pump to case seal, clutch piston lip seals, reassembled pump to spec`s cleaned everything i could get to without totaly removing internals. removed valve body, disassembled, cleaned, installed trans go shift correction package, followed instructions to a t. i have 37 psi tv pressure with a 5/16 guage
(close pin) in proper spot at 800rpm. have kick down at 50-55 all up shifts are sweet all downshifts are sweet if i have shift selecter in D (1-2-3) if i keep shifter in OD (1-2-3-4)
and from od speed (while in 4th) if i apply the brakes and stop the van fast it seems to stay in od a little to long and when it finally does go from 4th to 3rd there is a slight delay in 3rd engagement like 1 sec where it feels like 3rd takes a little to long to enguage. after that 1 sec pause the rest of the downshifts are fine. and so are all upshifts. if i stop the van like normal it does`nt seem to be as noticable but still does it. any ideas? does anyone know the size (thickness)of the tv pressure gauge tool for f and e trucks with tv cable (not rod) (from what i gather the tool is different then a mustang) so i can be sure i have the tv pressure correct. i have like 1 or 2 psi with gauge removed so i must be pretty close. i would rather have a little to much tv pressure and beable to bring it down then not enough and smoke the trans. everything inside looked sweet nothing in the pan when first removed but it had been off before (no plastic plug) there was 60000 put on that fluid that i know of . the guy i got 89 van from got it at 99000 and drove it till 160000 and he never changed the fluid there is a trailer package on the van with electric brakes so this aod has pulled a double axel camper trailer or boat.
i wonder if the od band is to tight or some seals deeper in the trans are shady no big deal i am in the process of building a monster c6 for this van just need the aod to get me buy till i`am done thanks for looking

 

I just did the same thing to the AOD in my bronco. Did you install the green or yellow spring in the 2-3 capacity valve (step 2A)? I installed the yellow spring but my 2-3 shift is really soft, I'm thinking of putting the green or red one in. My AOD does the late down shift thing too, but decreasing the TV pressure a little seamed to help. I would also like to know the dimensions of the gauge tool, I have been trying to find one for a while now. Also does your AOD have a 4th accumulator, mine just has an empty hole in the case.

 

i used the green spring and it is nice. you can feel it shift not to hard to bust the rear axel lol but better then stock. the acumulator hole in my trans was empty also. what i use to set tv pressure is a cloth pin (cloths line) it is real close to 5/16 and i adjust my tv to 37psi. i`am still waiting for some sizes for the actual tool. it seems like it is classified G14 information that i cant seem to find anyone with the tool to give me the thickness of it.
T86L-70332-A is what they call for but there is no info on who makes the tool. i`am thinking it is a ford rotunda tool that comes in the ford aod transmission tool kit but dont hold me to that. the cloths pin is really close to what it should be. i think everyone just takes a guess at what size it is but better to have to much pressure then not enough. do you have the endplay checking tool for the aod transmission. i need the sizes and i will have my friend make one at his machine shop. as for lip seal protectors i made my own and it worked pretty good. i used kodak glossy picture printer paper taped it together (completely tape the seame so the seals dont get paper cuts) use the glossy side of the paper and i lubed it up with vasaline so it would slide.
i also made my own clutch spring compressor works good. some 5/16 allthread and some plate steel. i also installed a drain plug in my trans pan.
the factory should have installed one in it to start with. i will be installing one in all of my trannies. tired of fluid everywhere. i have a stock pile of aod transmissions in my garage (7) and 2 c6`s. i just did this trans so i can drive while i get the rest of the parts i need to change over to a c6 after rebuild and modifications. full roller bearing c6. no thrust washers. with wide ratio kit, 6 gear front planet, 4 gear rear planet, lots of extra clutches, thick ones brand new pump, (nos) R servo, E apply leaver, i`am going to put a bearing in the tail housing instead of the bushing. 351w bronco 4x4 torque converter (better stall) all internals and hard parts are brand new nothing used or rebuilt just the case and valve body. i`am installing an engine oil filter relocator kit on my frame rail and running my trans lines through it so the garbage stays out. change the filter everytime i change the engine oil (buy 2 filters ph8a) trans should last forever behind a mild 302 after all is said and done i will have about $600 in the c6