So I decided to overhaul my E4OD.... - PowerStrokeNation : Ford Powerstroke Diesel Forum
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post #1 of 118 (permalink) Old 01-23-2012, 05:25 AM Thread Starter
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So I decided to overhaul my E4OD....

I bought my winter project, a '95 F350CCDRW, in non-running condition. Once I got it running I discovered that while it would drive, there was a grinding sound coming from the bellhousing at idle. Bummer. I searched on here and came to the conclusion that my torque converter was failing. I elected to pull the trans and have a look inside. I figured driving it would just do more damage and I plan to make this my daily driver when it's done. The fluid looked a little dark and had a slightly burned smell to it. Looking at the outside, I noticed it had a Ford Reman tag on the side, the date code was late 1998. I dropped the pan and found a little clutch material in the pan, not too much. But there were several metal shavings that I presume came from the failing converter. In hindsight, I could have probably just cleaned the pan, flushed/replaced the coolers, and swapped in the new converter and ran it. But I didn't know for sure what shape the internals were in.

I'll point out here that anyone contemplating a rebuild on their transmission needs to obtain a factory service manual. I only needed to fabricate one tool so far to pull the snap ring on the int/od piston. I've only rebuilt two automatic transmissions in my life (a C4 and a C6) and this is by far the most complicated automotive part I've ever dug into. Luckily, it comes apart in sub assemblies so you can divide it up and deal with it a little bit at a time.

Factory Ford reman trannys incorporate all available updates at the time of their build. I noticed this trans already had the "good" front pump in it. It has an engineering number beginning with "F8". The truck has 135,000 showing on the odometer, so I know this trans has less mileage than that on it. The pump looks good inside, the only thing that I want to change is the bushing for the converter.




I did notice that the input shell has some damage, the lugs from the direct drum left their mark:



I ordered up the latest 4R100 hardened input shell YC3Z-7D064-AA, the notches look a little different but it retrofits the E4OD without modification:




A close examination of the clutch packs revealed little wear, they were in great shape. It doesn't appear to be overheated, I'm guessing the burned fluid is from the converter. So I ordered a new set of Ford clutches for every pack except the intermediate set. For that I'm going with the Raybestos Z-pak set. I have a customer that uses them in his builds and said they were the way to go. I posted a question one here a while ago to see if anyone else was using them but I got no responses, but he's a sharp tech and if he's had success with them I would expect the same.

While I was ordering parts I also picked up the Ford DSO E4OD trans pan, F81Z-7A194-BA. It is identical to a factory 4X4 pan (my truck's a 2WD so I need to get a 4X4 filter too), but it has a drain plug already installed and it uses the newer style elastomeric pan gasket:

Just as a note, if your pan looks like this:

it needs a cork pan gasket. The rings around the bolt holes limit compression on the cork gasket.
If your pan looks like this:

it's made for the elastomeric gasket. It doesn't use the compression stops.
I also picked up a 6 pinion forward planet carrier. It's probably overkill for my stock engine daily driver, but I got it reasonably so I'll use it. It looks a little beefier than the aluminum 4 pinion carrier:

I also got the updated forward hub that was required to be used with the newer 4 and 6 pinion planet carriers. It looked identical to the one I took out, it's entirely possible that my reman trans already had the updated part in it.

I still have a few more parts to order, more to come!
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post #2 of 118 (permalink) Old 01-23-2012, 05:38 AM Thread Starter
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Re: So I decided to overhaul my E4OD....

Oh, and if you need your laugh for the day:

I wanted to get this truck in my standard two car garage for the winter to work on it. The problem? The truck is 22' long and my garage is only 21' 7" plus it has an electrical disconnect on the back wall. It fit, though, once I pulled both bumpers, the grille, the hitch, and the tailgate!




Taking all that off got me down to 21' 5". Luckily, the electrical box fit in the opening where I removed the grille and the frame horns straddled the conduit on the back wall so I had room to spare!
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post #3 of 118 (permalink) Old 01-23-2012, 12:23 PM
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Re: So I decided to overhaul my E4OD....

I'll be watching to see how this goes. I have never been inside an automatic transmission. I hope one day to have a BTS but my bet, I'll be attempting to do the build myself.

'97 SCLB 4x4, 3.55, D60 w/ TrueTrac, 6637, Banks Techni-cooler, BTS Trans, Tru-Cool 4921 Trans Cooler, 1.0 exhaust housing, no ebv, 3" DP, Straight Exhaust, E-Fuel, TW tunes, International WP, 203*, Isspro Gauges
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post #4 of 118 (permalink) Old 01-24-2012, 12:57 AM
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Re: So I decided to overhaul my E4OD....

i'm with PsRumors on this...

1996 F-250,Ext.cab,LB,4x4
stock tires

180K,6 pos chip,Open air filter, 3'' down pipe,fpr mod,ccv mod
4.10s gears!
Boost, Pryo and transmission gauges
sonnax shift improver kit
bronco tank mod
hayden cooler for transmission

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post #5 of 118 (permalink) Old 01-24-2012, 03:11 PM
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Re: So I decided to overhaul my E4OD....

I'm tired of hearing about the whole "pull your tranny and send it to us with $5000 so it can be built" mentality.

Kudos to you for doing this and double kudos for posting it up.

I can sympathize on the garage. We have a 24x24 and I can't walk around my 08 CC LB when its parked inside. I have to open the door first. I have to park it with the front bumper touching the wall to close the garage door.

Subscribed.

New truck.
08 F350 King Ranch
Long box CC 4x4
6.4 5R110
Soon to get a Cummins 6.7 transplant.

Old truck.
Red '99 2WD F250 CC SWB
3rd gen 325/610 Cummins, ZF6
Custom air ride suspension
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post #6 of 118 (permalink) Old 01-24-2012, 03:47 PM Thread Starter
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Re: So I decided to overhaul my E4OD....

Quote:
Originally Posted by me2 View Post
I'm tired of hearing about the whole "pull your tranny and send it to us with $5000 so it can be built" mentality.
It does seem like the standard response is "Get a BTS!". I think that says a lot about their reputation. I'm not here to knock BTS or JW (or any other quality custom trans builder for that matter), they build a great product and have great customer service from what I've read on here. And if you have a built truck and want to beat on it, you're probably better off dropping the money with them. But for my truck, with a stock 7.3, I can't justify spending that kind of money on just the transmission. This Ford reman lasted about 100k and would probably still be going if the torque converter hadn't failed so I expect to get comparable service out of it with the updated converter.

That being said, as I find useful info that's not already in the shop manual, I'll post it here for future reference. Like this:

Every separator plate (the steel plate between the valve body and the trans case has an ID on it.

See it? This one is Diamond, Semi-circle, Diamond. Knowing that and using Ford TSB 98-16-8 you can match it to the engineering number on the valve body and the two valve body gaskets to make sure:
#1. That you have a separator plate that matches your valve body
and
#2. That you have the right gaskets to go with your separator plate.

I'm working on fabbing the tools to disassemble the clutch drums now. I'll post more later.
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post #7 of 118 (permalink) Old 01-26-2012, 05:13 AM
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Re: So I decided to overhaul my E4OD....

Good to see someone else building there own trans! I had a similar situation with my truck, drug it out of the weeds and got it running. previous owner said trans was recent ford reman. Drove it for a couple weeks and I started to hear some bad grinding and popping. I am too cheap to pay someone else 2000 in labor so I pulled it out, got some manuals and had at it.

Mine is a 95 as well and I found that the aluminum 4 pinion intermediate planet was on the verge of explosion. I was lucky that it was still moving. At that time I wasnt really planning on any mods so I got the 6 pinion steel setup, some new friction and a tugger kit and ran it that way for 30k.

In that time I started adding bigger injectors and bigger turbo and all that stuff so I got a new billet lid low stall converter, alto power packs, 6 pinion steel rear planet and a bushing kit. When I tore it down again I was surprised to find only a few burnt clutches in the intermediate pack and a bit of wear on the direct pack.

I also built my own tools, one of the best ones is the tool that holds the shell so you can drop the whole gear train in already assembled.
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post #8 of 118 (permalink) Old 01-26-2012, 08:39 PM
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Re: So I decided to overhaul my E4OD....

dave 186 do you have any pic of that tool?

1996 F-250,Ext.cab,LB,4x4
stock tires

180K,6 pos chip,Open air filter, 3'' down pipe,fpr mod,ccv mod
4.10s gears!
Boost, Pryo and transmission gauges
sonnax shift improver kit
bronco tank mod
hayden cooler for transmission

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post #9 of 118 (permalink) Old 01-26-2012, 08:50 PM
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Re: So I decided to overhaul my E4OD....



Pretty simple, just a couple pieces of flat bar.

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post #10 of 118 (permalink) Old 01-27-2012, 04:18 PM Thread Starter
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Re: So I decided to overhaul my E4OD....

Cool tool Dave186! I'll be making one of those before I start the assembly.

I had about an hour before work yesterday so I made the compressor for the drums. I used a piece of scrap 3/4" Birch I had leftover in the wood shop, a 4" PVC pipe coupler, a 12" long piece of 5/8" threaded rod, and some nuts and flat washers. Got about $6 in it.


And here it is with the forward drum in it. You only need to tighten the nut until the pressure is released from the retaining ring, then you can remove the ring with a small screwdriver.

Newest project: 1995 F350 CC/DRW 2WD E4OD. 3" DP, 4" Diamond Eye system. But I'm still fixin' the broken stuff......
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