ATSG, TransGo Tugger Kit, steel planetaries, updated sun shell, quality steels and frictions, new torringtons, re-bush, re-seal. I made a couple of tools, you'll need a decent dial gauge that can bolt to the alloy case for precise measurements. Also, to really do it right, expect to buy or have access to the snap rings (the ones that are about 10" in diameter, come in about 6 different thicknesses.)
Most of all, the encouragement and help from members here, it made my project happen! Still very thankful to Trackspeeder, FORDF250HDXLT, OLDBULLand others. Seriously, I owe Trackspeeder some beers, my trans build would have been a slap-together-special without his numerous inputs and advice. You will need a good, accurate digital caliper. You MUST TAKE A TON OF PHOTOS as you disassemble, lay parts out, and re-assemble.
Your first time in this trans will be sort of recognizable yet NOT exactly like other transmissions that you may have done. Expect to be PRECISE with this transmission, setting the end play specs, as you swap guts from one case to another, you will end up with different stack tolerances, know this and be prepared to adjust for it. Also you've got to be willing to stack sections up, then tear them down again, probably several times; if you did this for a living you could do it in one sitting, I've built 4L80E's, but they do not compare to a well built E4OD- do it right.
Be sure you have a very clean work space, I have a 1/4" steel welding table which I cleared/dedicated to just this rebuild (you can't afford to lose parts, believe me...)
Oh, along with building some tools, you must get an INCH-POUND torque wrench, it is worth the money. I could not believe the number of strip outs I had to deal with, 3 in the valve body, 3 in the front pump, and several in the fluid pan. Whoever the shop was that "built" my trans before had NO IDEA what they were doing, I am convinced of that, they even used CAR guts in a DIESEL trans!!!
Prepare mentally that you will have to do some heli-coils, if you get into a denial state, that will be the beginning of "The End" for your project. (Heli-coils are actually STRONGER than OEM, as there is much more purchase area by the larger, harder threads.)
Another thought, in addition to the ATSG, a factory manual would be great either online or in sections. You can find sections online, also the resource here, the awesome forum members turned out to be the BEST resources, I cannot emphasize that enough. To get that help it is important to get photos, photos, photos (I used my waterproof phone camera and good lighting, probably took 5 pics for every ONE I posted. Lots of editing and posting.)
Speaking of posting, here is my E4OD build thread, I ended up doing a "Stage 3" build (upgraded torque convertor, billet input, performance frictions and steels, steel planetaries, better seals, TransGo, and TONS of attention to the specs and tolerances.
What I ended up with is a transmission that I still cannot believe. I haven't even messed with my shift parameters, it feels so positive and strong and runs right in the perfect temp range. I've stepped on it pretty good and there's been no fuss so far!
Here's my build, which also includes the rebuild of my BW1356, with flanged output upgrades:
https://www.oilburners.net/threads/1998-e4od-on-the-outside-wait-a-minute.69057/
Have fun!
Best regards,
George