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I was wondering what year the E4OD came into the scene in broncos. I'm asking because I want to get 4.56 gears for my future 35's and still have overdrive for the freeway.
'91's definitely wrong. My '90 has the E4OD and so do lots of other '90s. I say '90 was the first year. Every '89 Bronco I've ever seen has the C6 behind the 351 or maybe the AOD behind the 302. The AOD remained behind the 302 for a few more years until the E4OD was the only avail auto starting in '92 or '93. People rip on the E4OD but it's largely based off the C6 and is not a bad tranny. I'd take one over the AOD anyday. You can build up the AOD w/aftermarket stuff to make it pretty strong, but that ain't cheap.
90 was the first year for the E40D in a Bronco. It's good tranny if it is rebuilt with all of the upgrades but that gets really expensive really fast! Your looking at a minimum of $2000 to get all of the upgrades and the necessary shift kit(it shifts way too soft otherwise.) There is also the tall 2.71 first gear that sucks if you want to help your low range any. If you have an 89 you also have to consider that I have been told that the E40d will not run unless it is plugged into the computer which I doubt an 89 had for an E40d. That means a new computer, also have you looked into the lengths of the c6 versus the E40d they may very in length which could mean different size driveshafts or at least modifying yours. Also does the E40D output shaft work with your current BW1356 t-case (the C-6 may have have a different output shaft which equals a new t-case. To make a long story short I dont think that it would be worth the money or trouble just for an overdrive. If you're going to that much trouble why not a zfs542 with a 4.14 first and a .73(?) overdrive? I'm am looking at a np435 which is a four speed manual with a 6.69 granny low and a 1:1 4th. Good Luck with your decision.
I always heard that 1990 was(technically...) the first year for the E4OD in mass production-and the Bronco&F-series brochures also say it was new for '90,but Ford may have let some E4ODs be installed in 1989 model trucks&Broncos.I could've sworn I've seen E4ODs listed in certain parts source books for "late'89" applications.There could be a few "1989" E4ODs.If so,my guess would be in motorhome/stripped chassis vehicles.On the other hand.....some parts books have listings for "7.5L(460)Bronco",and "7.5L(460)F-150"......I w-i-s-h that were the case.
I have a 91 F150 2WD with a 302. It has the fickle E4OD. Only 69K original miles...family member. Shifted really rough and put in new solenoid pack. This thing has a shift kit alright. Still shifts like crap so I took it elsewhere to have it scanned. ECT code is now up. Going to put on a new harness connector to the solenoid pack and put in a new ECT sensor. If that does not work I will put in a jet PCM. I have heard they really help out with everything from mileage, power, torque and transmission performance.
Okay, here is what I have to say about the E4OD. Yes, they did start in 1989 according to wikepedia. Most often they go sour because people don't shift into neutral at lights or in traffic. They also tow in overdrive and flush the tranny. You have got to change that filter and fluid from the pan every two or three oil changes. Yes, they are problematic until 1995 and 1996. Many updates occured. Solenoids, etc. Well, here is my problem. I want that tranny out of there....would prefer a remanufactured one for a 95-96 with a warranty. Autozone has some wonderful options all with 3 year warranties. Can I do this...without screwing with the wiring harness.
all the upgrades took place in 93 to the e4od. up till then it was a major pos, ford just didnt have it right just yet.the e40d is stronger then the aod stock vs stock. you can spend money on either and have a very strong unit though.
with either od tranny i would consider running 4.88 gears and 35's. this will put you at 2000-2200rpms at 65-70mph which is right in the sweet spot of your engine. when you run a larger tire dont only think about the size but the weight of the tire as well.