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The old IDI trannies are not as strong as the transmissions put behind the powerstrokes. You may run into problems with breakage if you use the transmission from your old truck.
If you wanted to put the old e4od into the newer 95 truck, you would have to remove it, tear it down, and replace the output shaft and the tail housing. You would then need to source a transfer case.
from what I have read the torque converter is the main weak link in the older A4EOD, I will replace that for sure. I dont intend to do any heavy towing anyway. But the 90 donor truck has the transfer case and all on it already so it would be a bolt in affair. If I decide to stay with the stick on my 95 would I need a different output shaft to allow the transfer case to bolt up ? Or is it just a matter of removing the tail-shaft housing and bolting the transfer case up to the 5 speed.
The tail shafts are actually different. In order to replace the tail shaft, you have to dissasemble the guts of the tranny.
As far as strength goes, the torque converters have been upgraded, the front pumps had some issues, and the newer e40d has more clutches in the clutch packs to hold the increased power from the Powerstroke.
If nothing else, you could run the older trucks tranny until it got smoked. Meanwhile you could get a core tranmission and build it.
People buy older e40d from junkyards and put them in 95+ trucks quite often. It just won't last as long as it should due to the higher output of the newer motor.
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