I've posted this before in the trans section and got only a limited response. I'm hoping someone will see it and know the solution to my problem.

I have a '92 F250HD 4WD with a 7.5L and a Ford supplied reman E4OD that has been updated to '98 modifications. The truck came with a factory plate-type trans cooler. A flow check at the cooler output indicates a normal flow rate. I'm the original owner and I had the same following problem with the first trans that was replaced at 65K miles (the trans replacement was the result of a mis-diagnosis by Ford).

On long, slow speed climbs (2-5 mph) in the back-country, the trans will sometimes suddenly belch about a quart of fluid from the converter area (not the over-flow on top). This is not a slow leak but a rapid discharge. After it cools-down, it doesn't leak fluid. The remaining fluid does not look or smell burned. I have had trans shops look at the fluid after an event and they confirm that it is fine. The engine temp is usually within the normal range when this occurs. When towing on the open road, this does not occur, even though the temp gauge reads higher.

I've tried operating the truck in 4WD in "D", in 4WD and 4L in "D", and in both using 1st and 2nd. Nothing works. I have a complete service (full drain including the TC) done every 15K miles and the trans shop says there is no sign of a problem in the pan (debris, etc.) The dealership and the trans shop guys say they have no idea what is causing the fluid to blow out. In desperation, I replaced the fan clutch but have not had a chance to test for the problem. There does seem to be more air moving through the radiator area.

The problem does not happen all the time and it seems the ambient temp is irrelevent. Does anyone have any idea what is causing this problem? I'm also interested in knowing what the best trans/transfer case configuration is when operating under low speed off road conditions.

Thanks for your time.

 

add a tranny cooler.

ZF5 speed and a np205 doubled with a NP203.....that's how I would do it

-cutts-

 

didn't he say he already had a flow check performed on the cooler? Perhaps the cooler is clogged? Might not be a bad thing to swap out if you can't get an exact diagnosis.

 

more coolers you have the cooler your fluid will stay! it is recommended that you run an aftermarket cooler along with your stock one when wheelin.

-cutts-

 

Check out TCI for their tranny coolers.
http://www.tciauto.com/cooling.htm

 

The stacked plate design cooler like the B&M is supposed to disappate more heat than the conventional style like the TCI. I like fish mans idea the best, dump the E4OD and put in the 5 speed.

 

How big a job would this be to do?! I would love to mate a 5 speed to my 460 EFI and run a doubler. Auto tranny's have problems.

 

I, too, have had problems with high temps in the E4OD tranny. I have added a temp guage just for the tranny, so I could monitor the temp on a regular basis. Normal daily driving the temp is just shy of 160. But I've seen it climb to about 210 when driving off-road, even in 2-3 ft of snow at about 8,000 feet.

Another thought, which is something I'm considering, is to add a small electric fan to the tranny cooler. Hooked up with a switch somewhere on the dash to turn the fan on and off when needed.

Hey 95-F-350-4x4,
Love your little pic in your postings

 

with your setup it is almost a direct bolt up! there is a ZF 5 speed for the 351W, 460, and 7.3L PSD, and 7.3L IDI

-cutts-

 

Sweet! So all I need to look for is a donor truck then? Would the bell housing on the 351W work for the 460? I'm sure I would have to tons of changes to the computer and stuff. Also what about the clutch assembely? Sounds like PITA but it would be sweet.

 

Gracias!

 

1) yes a donor truck is ideal
2) no 351 is a small block.....a 460 is a big block
3) not as much changing as you think cause your truck has a computer....if you find a truck like yours (same year) with the Zf it is a direct swap.
4) not sure about the clutch

-cutts-

 

Thanks for the responses. A manual trans is out of the question for several reasons. I did find that the plate type cooler is an OEM Tru-Cool product. They say it's rated at 10K lbs. I'm upgrading it to a 24K lbs capacity model. I bought an Auto Meter 2460 model "Z" series gauge and will install it the weekend. I'm going to use the pressure test port to mount the sender. My concern is that the threads are SAE and not meteric!

 

I've used the pressure test port to mount a Auto Meter Transmission Temperature Sending Unit into a E4OD and the threads are the same in the Transmaission as on the Sender, so you should be OK there.

 

Hey cutts will a 2wd ZF tranny work or would it be better to find a 4wd one so it will have the adapter to run the transfer case? Or are the manual ones divorced?