I have a 94 Bronco w/5.0 & E4OD. Can I swap the E4OD out with a C-6 trans? If so, what will be involved? I want to do away with the electrical portion of the transmission. What parts would be needed for the swap.

 

The computer will need to be swapped. The ECA for E4OD equipped trucks monitors vehicle speed to maintain engine AND transmission performance together. Swapping to an ECA from a late 80's truck with an AOD might do the trick unless the ECA is still looking for that last RPM drop when the transmission hits overdrive.

The other hurdle to overcome is the fact that the BW-1356 transfer case was never married to the C6 from the factory so you would either need to swap T-cases as well or find/have made an adaptor. Not sure what changes that could necessitate in driveline geometry due to changes in length of the tranny-to-t-case length. The E4OD is a long sucker and has no separate bell housing.

Others may have additional info and insight.

 

Greystreak is right on the computer part. I am getting ready to do the swap of the E40D for a C-6 in my 91 ford Bronco. Look for an 87 or later bronco/truck for the C-6. The C-6 and E40D in the Bronco shared the circular bolt pattern of the housing to transfer case input, I dont know about the trucks or other transmissions. The other major hurdle is drive shaft lengths. The C-6 is a little shorter than the E4OD so you will need a longer rear drive shaft and a shorter front drive shaft. The rear drive shaft is another sticky situation because the yoke output changed in the 1987 to 1991 in how it was bolted to the transfer case output.

It is not an easy swap but if you take the time and look at Fordfuelinjection.com you will find what computer you need to look for to set up your vehicle for the swap.

Edit: I also wanted to note that the 5.8L engines and the 5.0 engines were not consistant on the how the rear output. I know the 5.8L engines used a double cardan joint at the output and used the same U-joints. The U-joint provider made special notes about differences between the 5.8 and 5.0 at the same point. I also ran into the issue that the u-joint provider did not note a double cardan u joint after 87 but the 88 bronce parts truck had it. In case you are wondering what a double cardan u-joint is you can google it and find out.

 

Every Bronco had a double-cardon joint at the front of the rear driveshaft from 1996 all the way back to the first units in 1966. Its what allowed the wheelbase to remain so short without sacrificing rear suspension articulation. If you find a Bronco without it, its been removed and you WILL have rear driveline issues with it. About the same time the E4OD became the only available automatic (about 1990-91 some '89's had the E4OD but the AOD was the primary automatic), the rear D/S output went from being a typical U-joint yoke to a flat flange that accepted a similar setup at the front of the D/S. It can be noted the BOTH the front AND rear mountings were changed to this type which allows for the removal of the rear driveshaft without the need to disassemble any of the U-joints therein.

 

wait, i have a 1988 F150, with a C6, and it has the same transfer case as my bronco. the 1356. grey, i think your mistaken on that little bit of info

 

As I may have been a little to general with my statement. I meant to say that the parts book lists two different carden joints for the 5.0 and 5.8 engines.

The other part of the swap that I have discovered is that you will need a shorter shift rod and the Bracketary for that rod. You will also need a very comprehenesive wiring diagram of the E4OD Manual lever position switch wiring and the C-6 wiring or better yet the appropriate wiring harness. Also the c-6 that I put in is 7 inches shorter than the E40D, so you will need a different transmission cross member and bracing. Oddly, I happened to have visual inspection access to both an AOD equiped truck and a C-6 equiped vehicle and this brace can be had in the 80's fords with c-6 and the AOD equiped trucks. I am not positive on the AOD transmission as it was a used car lot that I was doing a comparision. I do highly recommend the wiring diagram and an some ability to make heads or tails of it.