just got this home, the PO bypassed the stock fuel filter, I need a fuel system schematic, photos, or whatever you have, I cant figure it out. It will not start at all, no pops or anything, not even with WD-40...
what transmissions options were there in 91? the PO said he had it rebuild, but the bolts were all wrong, and some of the bolt holes dont line up...
it has a E4OD in it now but I am thinking it is the wrong tranny

 

Is it by any chance that the top two bolts don't line up.

 

actually, the top two are bolted in, but the first bolt clockwise and counterclockwise are not even close, maybe 1/2 or more off!?....

 

Not sure but I would say that you have a big block gas tranny and it will not work.

 

Sounds like a 460 transmission.

Can't remember which is which, but here is a gasser/diesel bolt pattern comparison.

 

does it smoke out of the exhaust at all when your turning it over?.and when you say bypassed the stock filter did he replace it with an inline filter?if not the injection pump could have got crap in it and possibly ruined it.have you tried to bleed the air out of the lines?if not crack a few injectors like 1/4 to 1/2 turn,then turn the motor over until fuel comes out then tighten them up and try to start it again.is the motor spinning over fast enough?are the glowplugs working?.i can keep going if needed.there are a few more things you can do to get it to fire up.

 

Check this out from another forum. You maybe able to make a diesel and 460 trans work, with alittle drilling. I know this is on a ZF but the patterns the same.
Goto post #9 click picture
TRANSformation

 

i dont know if i would try it

 

It looks like someone already did.

 

there was a little inline filter, and I think the bypass was plugged, I bought the right filter but am unsure if I have all the connections right, I would like to see a schematic or something to be sure.
I have not yet tried to bleed (new to diesels), so is the procedure to crack all the injector lines, crank until see fuel, re-tighten, then good?
what is the schrader valve for?
yes, please go on with more tips to get started, I plan working on it this week end as much as I can.

 

that looks about what the error is in the bolt pattern, and I am noticing what looks like a rear main seal drip, I am thinking the misalignment ruined the RMS?
and I see there is what looks like an aftermarket switch to activate the OD?
does all this mean I need to find a C6? or is what I have a gasser E4OD?

 

I forgot to mention, there are holes rubbed into the tranny case from the flywheel rubbing! I will take pix tomorrow, this really sucks, I got it for a good price but I wasn't expecting all these problems

 

I have never run into this on one of these, but the tranny has to be lined up within a very few thousanths, and bolted up tight.
Yes it will get the main seal also the mains and sometimes break the crank.
On the big cummins we have to line the bellhousing adapter up with a dial indicator and get to within 4 thousands.

 

I found a diesel E4OD out of a 95 van with 7.3 powerstroke, is the 95 version the same as what was in my 91 van, will it work?

 

I have seen diesel ZF cases broken from the torque.
They usually break in the bell housing area.

So a diesel ZF housing breaks when it is mounted on the diesel motor like it was designed to fit.

Now what chances do you think drilling more holes out in your garage with no jig to get everything centered and mounting a transmission designed for another motor with a bolt pattern for another motor on a diesel and not having problems are?

My guess, 90% chance you will have problems.

As for the fuel system, without the stock filter/water seperator you have nothing to seperate water from the fuel.
You also do not have a schrader valve to bleed air from the filter, or check fuel pressure from the lift pump.

The 94 version would be closer to what is supposed to be there.
I wonder if your van originally had a C6, and someone swapped in the 460 tranny for the overdrive.
If that were the case, the tranny PCM may be wrong as well.

Also as far as a diagram of the fuel system to see where your filter goes, there is not a filter like that installed.

Fuel line basics.

If you have two tanks, there is a tank selector valve, drivers side inside the frame rail a couple feet behind the motor.
With a single tank, no valve.

From either the single tank or the valve, 3"8" fuel line runs up to the lift pump, lower right front corner of the engine.
From there it originally went up to the filter/water seperator/fuel heater/schrader valve.
Exit out of that and into the IP fuel inlet.

So you can either install your filter before or after the lift pump, but before the IP.

Better option, take the inline filter back.
Now get a filter/water seperator unit and plumb it into the fuel system between the lift pump and IP like it was originally.

Racor is available at NAPA and is a decent setup.
Another option may be a salvage yard, get and reinstall an OEM filter/seperator in the original location.