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I'm really looking for an f250 5.4 with a manual something in the 99-04 range. BUT, if I were to settle for an auto what does it take in terms of money and know how to "bullet proof" these autos. How much good do these mods really do in terms or making the trans reliable?
First and foremost, the key is maintenance. The 4R100 is a reliable trans as long as it's maintained, i.e. change the fluid at regular intervals (30,000), perhaps add an inline filter, drop the pan and clean the magnet. There is some debate on how often you should change the filter in the trans because its basically a screen, but for $30 or so, why not?
That being said, when you're looking at trucks, check the fluid. Visually inspect it, maybe give it a sniff. Take my truck for example. I got my SD with 110,000 miles on it. When I drained the pan, the fluid looked like metallic chocolate syrup from hell and smelled like hot metal. Not what one wants to see when draining the trans. Food for thought.
As far as mods, I'm in the dark. Hopefully some of the other members whos knowledge in these areas is far greater than mine will throw in some advice.