IDIBRONCO
IDIBRONCO
That and the tail housing of the transmission.
6.9 E350 C6 to E4OD or 4R100?
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Olds64
Full Access Member
Make sure you get a Fuel Injection Pump Lever (FIPL) from the side of the IP when you source the transmission. It works like the VRV and vacuum modulator on the C6 trucks
I had my VRV rebuilt by Nick P. on Ford Trucks Enthusiast forum. His name is genscripter there. I don't know if he's on OBs. Here's his website.
www.nickpisca.com
I think you can buy a FIPL new at the parts store. If you don't have one that is properly adjusted you'd have to use a fully-manual valve body. I'm not even sure if those are available for the E4OD. I considered it briefly for my C6 but had the VRV rebuilt instead.
I had my VRV rebuilt by Nick P. on Ford Trucks Enthusiast forum. His name is genscripter there. I don't know if he's on OBs. Here's his website.
IDI Online - DIY Repair for the 6.9 and 7.3 IDI Diesel Van (and other vehicles)
DIY Repair for the 6.9 and 7.3 IDI Diesel Van (and other vehicles)
www.nickpisca.com
I think you can buy a FIPL new at the parts store. If you don't have one that is properly adjusted you'd have to use a fully-manual valve body. I'm not even sure if those are available for the E4OD. I considered it briefly for my C6 but had the VRV rebuilt instead.
nelstomlinson
Full Access Member
I suspect that a "fully-manual valve body" for an e4od could be made by hooking switches to the valve body connector, but it might not be simple to figure out which switches to which wires.
u2slow
bilge rat
I had the E4OD in my '97. Not great even with the PSD.
I would have swapped to a ZF5 had I kept the van.
I would have swapped to a ZF5 had I kept the van.
nelstomlinson
Full Access Member
I have an e4of in my ambulance with USShift controller. It's not a manual, but so far it's OK.
aggiediesel01
Full Access Member
Find the ATSG e4od rebuild manual and read through it to find all the availiable updates that were done through out its life cycle to help you pick the best version for what you want. I'm pretty sure there is a copy of them on this site in one of the older posts, give it a search. The 4R100 has all the same internal hard parts however the pump and solenoid body were designed to be controlled with a PWM signal that was used in the '99 and later PCMs. So you can use the 4R100 if you swap the necessary components back to the E4OD design or maybe you can get a 4R100 contoller from USSHIFT. The 4R100 has the cumulation of all the E4OD updated already installed, however there are some clutch packs where an extra friction and steel can be added to make them even stronger. Check with Brian's Truck Shop to find out which clutches are best to add to. Also you should upgrade the trans cooler to the 6.0 diesel trans oil cooler, on the truck chassis it's practically a bolt in component and it's nearly as large as the a/c condenser so it's very effective.
Olds64
Full Access Member
Did you have to use a FIPL with that aftermarket controller?
nelstomlinson
Full Access Member
Yes, the USShift controller uses the stock FIPL. Part of the controller setup is to calibrate the controller by letting it read the FIPL first with your foot off the gas pedal, then with the gas pedal fully depressed. No trying to adjust the FIPL.
IDIBRONCO
IDIBRONCO
He has the same screen name here too.
Genscripter was last seen here in 2021 
Cool to hear he did rebuild work. His website was helpful for me in identifying vacuum manifold ports/components
Cool to hear he did rebuild work. His website was helpful for me in identifying vacuum manifold ports/components
aggiediesel01
Full Access Member
This just popped up on YouTube from R&D Performance. Not a lot of details but Justin evidently put a 4R100 in his truck. The video was posted yesterday but it says content is from 2017 so who knows how long he’s had it done now but seems to run pretty nicely. He mentions in the video he’s running the Quick Shift 4 controller.
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Olds64
Full Access Member
^^^THIS^^^
It's a worthwhile investment for $20 or $30. I bought it before I had my VRV and C6 rebuilt. Don't forget; he who dies with the most tools wins!
Fredrickson
Full Access Member
I went on a google deep dive a while ago, and found the pdf versions of the ATSG E40D rebuild manual..
as well as the 1993 Powertrain/Drivetrain Manual should anyone need a copy.
as well as the 1993 Powertrain/Drivetrain Manual should anyone need a copy.
aggiediesel01
Full Access Member
Here's the ATSG manual and a couple references that are also pretty good. Also if you choose to upgrade some parts in the valve body or pump, stick with one brand of upgrades. Like buy Sonnex kits or Transgo Kits, don't buy some of each. I was told by Sonnex years ago when I did mine that they designed their kits to work together and they may not work as intended if you mix Transgo upgrade stuff with Sonnex or vice-versa.
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david85
Full Access Member
1989-1991 should have a speedometer cable style tailshaft. I read that some later models might still had the same tail shaft internally but the outside casing is blanked off. Best to look for an older transmission to avoid issues here. Note that almost all of the updates for the 4R100 will fit the E4OD. The older transfer case can also be installed on a newer transmission, if 4wd is planned.
ASTG makes good manuals for overhauling and updates. There are two separate manuals: Overhaul book (blue) and the update book (green). I recommend buying and reading through both before attempting an overhaul. YouTube also has several channels that documented the E4OD rebuild quite well over the years.
I've gradually changed my mind on shift kits over the years after seeing how they work, and the effect it has on the transmission. Personally, I'd rather wear out a clutch pack than wear out or break hard parts. There are certainly some updates that the aftermarket offers that are worth installing. But a mild shift kit is usually the most anyone might need.
Sonnax makes some great fixes for the E4OD and I'd recommend most of them. The main updates I would focus on are the OEM ford fixes. Put those in, along with a big cooler, and most of the E4OD's problems go away. If you need to tow heavy you can install more clutch packs and get higher torque capacity, without having to run higher line pressure.
I say that as someone who never drove or owned a stock E4OD, with a stock control system. From what I've read, the electrical systems can cause issues as they age, and it's not always clear what went wrong because of how basic the OBD1 setups were. I still have the original Baumannator TCS for about 15 years now in my truck. There are some limitations to what it can and can't be programmed to do, but it still works.
I might upgrade to the newer US Shift setup, because it has more options for programming the torque converter logic. That was my only real complaint with the original Baumann TCS.
ASTG makes good manuals for overhauling and updates. There are two separate manuals: Overhaul book (blue) and the update book (green). I recommend buying and reading through both before attempting an overhaul. YouTube also has several channels that documented the E4OD rebuild quite well over the years.
I've gradually changed my mind on shift kits over the years after seeing how they work, and the effect it has on the transmission. Personally, I'd rather wear out a clutch pack than wear out or break hard parts. There are certainly some updates that the aftermarket offers that are worth installing. But a mild shift kit is usually the most anyone might need.
Sonnax makes some great fixes for the E4OD and I'd recommend most of them. The main updates I would focus on are the OEM ford fixes. Put those in, along with a big cooler, and most of the E4OD's problems go away. If you need to tow heavy you can install more clutch packs and get higher torque capacity, without having to run higher line pressure.
I say that as someone who never drove or owned a stock E4OD, with a stock control system. From what I've read, the electrical systems can cause issues as they age, and it's not always clear what went wrong because of how basic the OBD1 setups were. I still have the original Baumannator TCS for about 15 years now in my truck. There are some limitations to what it can and can't be programmed to do, but it still works.
I might upgrade to the newer US Shift setup, because it has more options for programming the torque converter logic. That was my only real complaint with the original Baumann TCS.
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