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Rather than rebuild my E4od, would it be more cost effective to replace it with a rebuilt C6? Are the bolt patterns from a 7.5 gas to a 7.3 diesel different? Thanks.
I'm not sure about the bolt pattern, but I know the torque converter for the diesel has a slower stall speed and you'll have to your drive shaft shortened, also the c-6 has a mechanical kick down linkage, the e-40 does it electronically. Although if you could get a c-6 from an older pre e-40 diesel you can get everything you need. Just a comment, I have an 84' 6.9L c-6 that gets 12 MPG, and I have a 92' 7.3L e-40 that gets 16 MPG.
I have a 90 E4OD. It was rebuilt in Dec. It runs great now. I had the heaviest valve body put it when they did it. There is a light, medium and heavy. It slams right into gear, no slipping. My truck loaded weighs about 9k and I am towing a trailer that is about 6k. Make sure you have a big cooler in it. I am using synthetic fluid. There are also companies that make heavy duty torque converters. Banks has one but it is costly.