FORD TRUCKS

E REVISED EDITION

4
0
D

AUTOMATIC TRANSMISSION SERVICE GROUP

 Reprinted
May 2021

INTRODUCTION

INTRODUCTION
FORD E4OD
The FORD E4OD automatic transmission is a four speed unit with total electronic shift control and is designed
for operation in longitudinal powertrains for rear wheel drive applications. The E4OD is currently found in "F"
Series Trucks and "E" Series Vans.
The E4OD transmission features a four element torque converter design that includes Torque Converter Clutch
(TCC) and a gear train that includes three planetary gearsets. The hydraulic control systems of the E4OD
transmission has five electronically controlled solenoids for: Shift feel (through line pressure control), Shift
scheduling (through shift valve position control), Engine braking during coast operation (through shift valve
control) and TCC apply (ON/OFF).
Note: There have been many engineering changes in this transmission since its introduction in 1989.
ATSG also has available an "Update Handbook" which includes the many changes and is required along
with this manual for a proper overhaul or repair.

We wish to thank Ford Motor Company

for the information and illustrations
that have made this booklet possible.

No part of any ATSG publication may be reproduced, stored in any retrieval system or transmitted in any form or
by any means, including but not limited to electronic, mechanical, photocopying, recording or otherwise,
without written permission of Automatic Transmission Service Group. This includes all text illustrations,
tables and charts.

The information and part numbers contained in this booklet have

been carefully compiled from industry sources known for their
reliability, but ATSG does not guarantee its accuracy.

Copyright © ATSG 2003

800-245-7722 wwww.atsg.com

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INDEX
DESCRIPTION ................................................................................................................... 4

DIAGNOSIS AND TESTING.............................................................................................. 9

TEARDOWN....................................................................................................................... 36

ASSEMBLY.......................................................................................................................... 50

VALVE BODY....................................................................................................................... 66

COMPONENT ASSEMBLY............................................................................................... 68

SPECIFICATIONS ............................................................................................................. 108

TECHNICAL BULLETINS ............................................................................................... 109

CAUTION: ATSG service manuals are intended for use by professional,

qualified technicians. Attempting repairs or service without the proper
training, tools and equipment could cause injury to you or others and damage
to the vehicle that may cause it not to operate properly.

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E4OD

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CASE PASSAGE IDENTIFICATION
DIRECT
CLUTCH

FORWARD
CLUTCH LOW/REVERSE
CLUTCH
COAST
CLUTCH

OVERDRIVE
CLUTCH

INTERMEDIATE
LUBE

INTERMEDIATE Copyright © 2013 ATSG

CLUTCH

COMPONENT AND SOLENOID APPLICATION CHART

Fwd Int Dir O.D. Cst Int L/R O.D. Int Low SOLENOIDS
GEAR
Clut Clut Clut Clut Clut Band Clut Roller Sprag Roller SS1 SS2 CCS TCC EPC
Park/Neut On Off Off Off Mod
Reverse ON ON ON Hold On Off Off Off Mod
OD-1st ON Hold Hold On Off *Off *On Mod
OD-2nd ON ON Hold Hold On On *Off *On Mod
OD-3rd ON ON ON Hold Off On *Off *On Mod
OD-4th ON ON ON ON Off Off Off *On Mod
OD-3rd** ON ON ON ON Hold Off On On *On Mod
M-2nd ON ON ON ON Hold Hold On On On *On Mod
M-1st ON ON ON Hold Hold On Off On Off Mod

OD-3rd** = TCS "On" with TCIL illuminated showing "Off"

*On = If the PCM determines that powertrain operating conditions exist for TCC apply, the TCC solenoid may
be On (Modulating with PWM TCC units) in any forward gear except Manual 1st.
*Off = Will be "On", if the TCS switch is pushed.
Mod = Modulating at all times by the PCM and line pressure will be regulated based on throttle position,
engine load and vehicle speed.

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TEARDOWN

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1989 Early Check Ball Location

1/4” Steel EPC

Limit Ball
E9TZ-7D017-A

CHECK LIST
14 Plastic 5/16” Check Balls
1 Steel 1/4” Steel EPC Limit Ball & Spring
VB Gaskets are solid Black - No ID Stripes

1989 Late Check Ball Location

1/4” Steel EPC

Limit Ball
E9TZ-7D017-A

CHECK LIST
11 Plastic 5/16” Check Balls
1 Steel 1/4” Steel EPC Limit Ball & Spring
VB Gaskets are solid Black - No ID Stripes

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1990-1995 CASE CHECKBALL LOCATIONS 1996-1998 CASE CHECKBALL LOCATIONS
REQUIRES NINE 5/16" RUBBER BALLS REQUIRES EIGHT 5/16" RUBBER BALLS

EPC EPC
Ball and Spring Ball and Spring

1989-1995 VALVE BODY CHECKBALL LOCATIONS 1996-1998 VALVE BODY CHECKBALL LOCATIONS
TWO 5/16" RUBBER BALLS - ALL MODELS REQUIRES THREE 1/4" RUBBER BALLS,
AND TWO 5/16" RUBBER BALLS

RF-F0TP- RF-F6TP-
7A092-BA 7A092-AB

5/16" Rubber 5/16" Rubber 1/4" Rubber 5/16" Rubber

Checkballs Checkball Checkballs Checkball
SPECIAL NOTE:
Some 1995 models were built with 1996 production valve body, spacer plate, and valve body gaskets. Be
very careful to identify the parts on any 1995 model properly.
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COMPONENT ASSEMBLY

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FORD E4OD
OVERDRIVE SECTION FAILURE

COMPLAINT: Overdrive planetary and overdrive sprag failure due to lack of lube.

CAUSE: The cause may be a plugged or restricted lube passage in pump cover. There is a ball and spring
under the orificed cup plug making this passage prone to clogging up.

CAUSE: Clean out the lube passage.

To check for restriction blow into hole in pump cover (See Figure 56). Air should exit from
holes in rear of stator shaft as shown in Figure 57.

BLOW INTO HOLE HERE

FILTER BORE

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AIR SHOULD EXIT FROM

CUP PLUG AND LUBE HOLE
(Use #4 Easy Out to remove cup plug)

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THREE LUBRICATION POINTS

OIL PUMP ASSEMBLY "FRONT" SIDE EXPLODED VIEW

3 4
8

1 6
2 5
7

d
or
F
7A105-AA
RF-F81P

OIL PUMP ASSEMBLY "REAR" SIDE EXPLODED VIEW

12
13

10 11
9
KXV
9.8
KXV
9.8
KXV
9.8
KXV
9.8

KXV
9.8

KXV
9.8
KXV
9.8

KXV
9.8
KXV
9.8
KXV
9.8

RF-F81P-7B324-AA
98
107
KXV
9.8

KXV
9.8

Ford

Ford PN E9TZ-7H132-B
Front Lube Sonnax Aluminum Valve
Orifice PN 36425-01K

1 OIL PUMP CONVERTER SEAL 8 STATOR SHAFT AND OIL PUMP COVER ASSEMBLY
2 OIL PUMP CONVERTER HUB BUSHING 9 COAST CLUTCH SEAL RINGS (2 REQUIRED)
3 OIL PUMP BODY 10 STATOR SHAFT TO OIL PUMP COVER RETAINING BOLTS (3
4 OIL PUMP BODY TO CASE "O" RING REQUIRED)
SEAL 11 STATOR SHAFT ASSEMBLY
5 OIL PUMP INNER GEAR 12 OIL PUMP COVER ASSEMBLY
6 OIL PUMP OUTER GEAR

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THREE LUBRICATION POINTS

Center Lube Rear Lube

Center Support Feed Bolts should

be tightened to 72” lbs. Use blue
LockTite on the bolt threads.
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FORD E4OD
NO FLOW TO COOLER,
AFTER REBUILD
CHANGE: After rebuild, your E40D transmission is returned with premature planetary failure due to a lack of
lubrication, or if you checked lube flow before delivery, you find zero lube flow, and zero flow
from the front “To Cooler” fitting.
REASON: The cause may be, m&match of stator shaft and pump cover creating a totally blocked “To
Cooler” passage in the pump cover.
PARTS AFFECTED:
Install the proper stator shaft into the proper pump cover. The differences are as follows:
(1) 89-94 MODELS - Have a relief (Notch) cut into the pump cover on the inside diameter,
where the stator shaft presses into the cover, creating a passage for converter apply oil to get
into the “To Cooler” passage in the pump cover. Refer to Figure 53.

(2) 95-96 MODELS - The relief (Notch) cut in the pump cover was eliminated from the cover,
and the relief (Notch) cut was added to the stator shaft (See Figure 54).

(3) If for any reason, it becomes necessary to install a different stator shaft into your pump
cover, you must ensure that you are installing compatible parts.

89-94 Model pump cover with notch, MUST be used with the stator shaft without notch. Refer
to Figure 53.

95-96 Model pump cover without notch, MUST be used with the stator shaft with notch. Refer
to Figure 54. If you install a 89-94 stator shaft without notch, into a 95-96 pump cover without

SERVICE INFORMATION:
Reverse Clutch Piston (New Design) ................................................................ F6TZ-7D402-
A
Reverse Piston Outer Lip Seal (Package of 3) .................................................. F6TZ-7D403-
A
Reverse Piston Inner Lip Seal (Package of 3) ................................................... F6TZ-7D404-

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1995 - 1996 PUMP STATOR (WITH NOTCH)

1995 - 1996 PUMP COVER (WITHOUT NOTCH)

RF-F5
and F8 Cover

NO NOTCH IN
PUMP COVER
NOTCH IN
STATOR SHAFT

5. TO COOLER PASSAGE

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1989 - 1994 PUMP STATOR (WITHOUT NOTCH)

1989 - 1995 PUMP COVER (WITH NOTCH)

RF-E9 Cover

NOTCH TO PUMP COVER

NO NOTCH
TO STATOR SHAFT

5. TO COOLER PASSAGE

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INCORRECT ASSEMBLY
1989 - 1994 PUMP STATOR (WITHOUT NOTCH) WITH
1995 - 1996 PUMP COVER (WITHOUT NOTCH)
WILL CAUSE TOTAL BLOCKAGE TO COOLER PASSAGE

NO NOTCH IN COVER
OR STATOR SHAFT

5. TO COOLER PASSAGE

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FORD E4OD
NEW DESIGN FRONT PUMP
FOR 1995 MODELS
CHANGE: Beginning at the Start Of Production for all 1995 model E40D transmissions, Ford Motor Co.
Introduced an increased displacement Front Pump Assembly, 1.70 cu in/rev, versus 1.50 cu

REASON: To provide additional flow for more robust converter clutch functions and additional lube flow,
both of which will greatly increase transmission durability.
PARTS AFFECTED:
(1) FRONT PUMP BODY - Gerotor bore has an increased diameter to accommodate the new
design level outer gerotor. Previous outer gerotor diameter was 3.950” and the new design
level outer gerotor diameter is 4.083”. Refer to Figures 41 and 42. Also, the two holes in the
suction cavity were increased from .3 12” to .400”, as shown in Figures 41 and 42. Another
way to identify the new pump body is with the “Rough Forging Number” F5TP-7A105-AA,
and is found on the front seal side of the pump body. All of the oil passages in the new design

(2) OUTER GEROTOR - The lobes on the Outer Gerotor changed from the previous 11 lobes to
10 lobes on the new design, to accommodate the changes on the inner gerotor. The diameter of the
Outer Gerotor also changed from 3.950” to 4.083”. Refer to Figures 41 and 42. The changes on
both the inner and outer gerotor increased the cavity between the gerotors for ’ increased pump
volume, as shown in Figure 43.
(3) INNER GEROTOR - The lobes on the Inner Gerotor changed from the previous 10 lobes to 9
lobes on the new design, to accommodate the changes on the outer gerotor. Refer to Figures 41
and 42. The changes on both the inner and outer gerotor increased the cavity between the
gerotors for increased pump volume, as shown in Figure 43.
(4) FRONT PUMP COVER - Received casting changes with added ribs in strategic places to
increase torque retention when the two halves are torqued properly. The Pump Body to Pump
Cover bolts should be torqued to 18-23 ft.lbs, with the alignment ring in place. The easiest way
to identify the new design level Pump Cover is with the “Rough Forging Number” F5TP-
7B324-AA, and is located on the back side of the Pump Cover. All of the oil passages in the new
design Pump Cover remained the same as previous years.
INTERCHANGEABILITY:
(1) The new design level Front Pump Assembly will retro-fit back to all previous models, when
used as an assembly, and is recommended for all rebuilds. The new design Front Pump
Assembly is available under OEM part number F5TZ-7A 103-A.

(2) The new design level and previous design level gerotors will not interchange in any way.
SERVICE INFORMATION:
Front Pump Assembly (New 1995 Design) . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5TZ-
7A103-A

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1989 1994 PUMP BODY AND GEARS

ROUGH FORGING # E9TP-7A105-AB
(PREVIOUS DESIGN)

10 LOBES ON INNER
GEROTOR

11 LOBES ON OUTER OUTSIDE DIAMETER

GEROTOR IS 3.950”

5/16 .312” HOLES

IN SUCTION PLATE
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1989 1994 PUMP BODY AND GEARS

ROUGH FORGING # F5TP-7A105-AB
(NEW DESIGN)

9 LOBES ON INNER
GEROTOR

10 LOBES ON OUTER OUTSIDE DIAMETER

GEROTOR IS 4.083”

.400” HOLES
IN SUCTION PLATE
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1989 1994 Pump Body And Gears 1989 1994 Pump Body And Gears
Rough Forging # E9TP-7A105-AB Rough Forging # F5TP-7A105-AB
(previous Design) (new Design)

10 Lobes On Inner 9 Lobes On Inner

11 Lobes On Outer 10 Lobes On Outer

Outside Diameter Outside Diameter

Is 3.950” Is 4.083”

1. Lay a flat edge across the gears while they are in the
pump and measure clearance for each gear. Should be
between 0.0005”-0.002”.

2. While the gears are still in the body, measure the

clearance between the outer gear and pump body. Should
be no more than 0.006”.

3. Place pump body and gears onto a converter and

measure lobe to lobe clearance. Should be between
0.004” to 0.006”.
DOT side faces up

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 FORD E40D

DESCRIPTION ............................................................................... 4
DIAGNOSIS AND TESTING.............................................................. 9
TEARDOWN.................................................................................. 36
ASSEMBLY.................................................................................... 50
VALVE BODY................................................................................ 66
COMPONENT ASSEMBLY.............................................................. 68
SPECIFICATIONS ....................................................................... 108
TECHNICAL BULLETINS ............................................................... 109

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