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Old 10-01-2007, 05:27 PM   #1
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E40D Transmission Died on my Sportsmobile

This might be a helpful thread for the future on rebuilding a E40D
Transmission or anyone who has a E40D transmission on your
Sportsmobile:

My transmission seized and quit this weekend while heading up highway
330 up to Big Bear this weekend on my shorted vacation. Had about
70k miles on the van.
It basically overheated, slipped and slipped and died. The ATF fluid
was not pink, but brown (burnt); it was pinkish in color last month.

Almost made it to the side shoulder on the 330 when it quit but
didn't make it and my buddy in his van had to David Blain in
30seconds a chain with a hook to tow me 10 yards up the hill to a
safe spot; cars where starting to pile up waiting behind us going
uphill.

No forward in any speed. Reversed worked. A big "Oh Well.."

Making a long story short regarding 4 hour wait for a tow and the
question and answer game with AAA; for example: "Does it have running
water?" Say "NO!" and then the tow back to home.
It was quite scary seeing the 10k lbs sporto on the back of a flat
bed tow coming down the mountain on highway 330.

Next day we tried diagnosing ourselves; with Ford Manuals and
Google. No Codes from the PCM. Tried reseting the PCM
(disconnecting the battery for 2min). End of Day, we pulled the
transmission pan and discovered aluminum shavings that was floating
on top of the atf remaining in the pan. Pretty much decided then
that it was shot.. and found a local transmission shop that knew the
E40D transmission well.

Since I'm the second owner of my Sportsmobile, I suspected it to be
damaged by the first but found out that the E40D is known to have
issues.
Especially if you have extra torque, Power Diesel, V10, etc.. or more
weight.

After 4 hours of researching from Google, we realized that there were
quite a few problems with the E40D transmission and there were alot
of good upgrades for it if your rebuilding.

And yes, I'm having it rebuilt to be bullet proof now:
Shift Kit, Steel Planetaries, Solenoids, Valve Body, temperture gauge
with sending unit, etc..

Here is another link discussing the E40D transmission:
http://www.fourwheeler.com/projectbuild ... 150_transm
ission_rebuild/index.html

Alot of the upgrades come from a outfit called Transgo:
http://www.transgo.com/

I'll keep in touch with updates on the rebuild, it'll be done by
Friday.

Bummed at first but now excited about the upgrades for the rebuild.
"We can rebuild him. We have the technology. We can make him better
than he was. Better...stronger...faster."
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Old 10-10-2007, 05:25 PM   #2
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Update on my Transmission rebuild:

The Sporto is back in action.
Got it back on last Friday. It took half a day to remove the
transmission/transfer case (Borg Warner) with the Quigley Adapter, 2
days to get the parts and assemble, and 1/2 day to install and test.

New transmission is built to be bulletproof for a heavy van carry a
enduro dual purpose motorcycle on the back.

Ended up costing $4k (most of it upgraded parts - $3k for parts and
$1k for tear down and install) with most of the goodies recommended
for the E40D transmission.

Some of the upgrades include: TCI cooler(removed the lines going to
the radiator and making it stand-alone, Steel Planetary 6 pinion
(instead of aluminum), new valvebody springs, new accumulator body,
new Shift Kit, new Solenoid Pack, new clutches, new Torque convertor,
sprags and temp gauge.

Shifts and drives like a dream.. so far.

Now I need to re-schedule that enduro/sportsmobile vacation that was
cut short..

NRL
96 Sportsmobile E-350 Quigley 4x4 460v8 RB31 Custom

ps. Heard that alot of PSD's will go through the E40D Transmission
sooner (half it's life), since PSD have more torque/power..
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Warn12kWinch,FFloater,LSlip,Pwtrx Locker 4.10 305x70x16 ToyoMTs,Eagle Alloys,Stove,4CF Ppane Fridge, Air CompTank,Supersprings, Bilstein Shocks,Deavers,CastIron Diff Case, Bullet Proof ReBuilt Transmission, Tubulator DeRale Trans Pan Cover, SSExhaust, KyoceraSolar, Tripplite UPS, 8D AGM, TivoHD, 24in HDLED
95 FJ80 ARB/Kaymar/Emu
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Old 12-23-2020, 01:09 AM   #3
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Late. reply....

A bit of a late reply, but just had a transmission failure on our 2002 SMB E-350 Powerstroke diesel, and like you, trying to take this crisitunity to improve upon the original.

If you have any advice on best way to go I’d appreciate any direction you can give.

Thanks,

Walt
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Old 12-23-2020, 09:18 AM   #4
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Quote:
Originally Posted by waltsb2020 View Post
A bit of a late reply, but just had a transmission failure on our 2002 SMB E-350 Powerstroke diesel, and like you, trying to take this crisitunity to improve upon the original.

If you have any advice on best way to go I’d appreciate any direction you can give.

Thanks,

Walt

Do you know what transmission is in your van?
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Old 12-23-2020, 09:25 AM   #5
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A 2002 will have the 4R100.

IMO, the factory "HD" reman is best/easiest option. Some of the custom rebuilders can make something more robust, but it'll cost more, and can be a hassle later if something goes wrong on the rebuild.

Then after the rebuild, add a Tru-Cool max transmission cooler, and add a tune that'll keep the torque converter locked up more.
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Old 12-23-2020, 09:30 AM   #6
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Quote:
Originally Posted by waltsb2020 View Post
A bit of a late reply, but just had a transmission failure on our 2002 SMB E-350 Powerstroke diesel, and like you, trying to take this crisitunity to improve upon the original.

If you have any advice on best way to go I’d appreciate any direction you can give.

Thanks,

Walt

The two best in the business:


BTS Transmission
E4OD | 4R100 | 5R110 Ford Diesel Powerstroke Transmissions


- or -


John Wood Transmission
John Wood Automotive - *




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Old 12-23-2020, 11:15 AM   #7
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Quote:
Originally Posted by carringb View Post
A 2002 will have the 4R100.

IMO, the factory "HD" reman is best/easiest option. Some of the custom rebuilders can make something more robust, but it'll cost more, and can be a hassle later if something goes wrong on the rebuild.

Then after the rebuild, add a Tru-Cool max transmission cooler, and add a tune that'll keep the torque converter locked up more.

My ford HD 3 year warranty tranny had a towel in it and no new clutches when it failed after 3.5 years. I was so mad. My local guy (he passed away) built the equivalent of the BTS/JW and it was dramatically different/better. My point is you could be much better off spec'ing your own build from a trusted local shop. My experience anyway.
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Old 12-23-2020, 04:34 PM   #8
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A towel? Holy chit man.
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Old 12-23-2020, 10:24 PM   #9
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Hey guys, just saw the posts. Appreciate the input....will explore the BTS, John Wood options and talk to my local shop that's working on it.

Merry Christmas,

Walt
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