Valve bodies between 6F35 Generation 1 and 2 are also different which indicates the two are not interchangeable. It is important for the rebuild technician to pay close attention to parts differences between Generation 1 and 2. Also be sure to upgrade the center bushing to a bearing, very common upgrade. When I pulled all the tool boxes off it was like driving a new truck. I have a 90 bronco 5. Mind you this was a work truck and lived its entire life hauling a bed full of tools and the weekly pull of a 16ft trailer full of equipment. This manual will show the disassembly and assembly of both the Generation 1 and 2 transmissions as well as component differences and transmission specifications.
The one in my '96 is a few turns short of 200k and still shifts pretty good. Solenoid operation and control are also different between 6F35 Generation 1 and 2. Valve bodies between 6F35 Generation 1 and 2 are also different which indicates the two are not interchangeable. Hydraulic controls are also different between the 6T40 and 6F35 meaning valve bodies and oil passages will not be the same. The most important thing you can do for your rebuild is read everything you can find and then read the atsg manual and the atsg update manual. If I rebuild it Im gonna make sure it is bulletproof. I'm building mine for hauling and am choosing the parts to get it done.
They changed the wiring pinout and also the harness diode protection from the valve body to the harness. They were so radically changed that even the casings won't necessarily work with the newer components. So installing then 95 and up solenoid pack will need some mods. Solenoid operation and control are also different between 6F35 Generation 1 and 2. Everything else was internal changes but I can't begin to tell you exactly what those were in detail. Hydraulic controls are also different between the 6T40 and 6F35 meaning valve bodies and oil passages will not be the same.
Any suggestions on a good rebuild kit. This manual will show the disassembly and assembly of both the Generation 1 and 2 transmissions as well as component differences and transmission specifications. I put one in my first rebuild and will be either overhauling it or replacing it with another one in this new rebuild. Covers transmission assembly, dis-assembly, diagnosis, and troubleshooting. The more you want from it the more it will cost. I didn't know anything about the updates the first rebuild at 150k. They aren't cheap but will make or break a rebuild.
The biggest improvement for your trans will be using an F5 95-97 pump. Covers transmission assembly, dis-assembly, diagnosis, troubleshooting, and electronic controls and operation Note: There have been many engineering changes in this transmission since its introduction. This would be late 89-early 90. In addition, the transmission cooling systems are different between Generation 1 and 2 and cooler configuration can also be different depending on model. Covers transmission assembly, dis-assembly, diagnosis, troubleshooting, and electronic controls and operation.
Don't do a stock rebuild and throw it in a swamper and expect it to be bullet proof. But that's just my opinion. The hydraulic control systems of the E40D transmission has five electronically controlled solenoids for: Shift feel through line pressure control. Note: There have been many engineering changes in this transmission since its introduction. One thing I would watch for is the solenoid pack change that took place in 95.
Prior to that it may have been in the transmission but I was under the impression the 8. Ford 4R100 Transmission found in 1999 and up trucks. So whatever you buy will be the upgraded parts that were put into the 94+ units. Put the pump upgrades in there, both the pump itself and the pump's valve. You should be able to get a very short warranty that will protect you from having a dud from the start. The old 300 is loosing oil pressure and the trans is showing its age. This go around the trans is getting just a few mods to fix some of the known issues and a tugger valve body reprogrammer.
Ford yanked all of them once they did the internals upgrade in 94. This manual is directed towards the professional transmission technician, all builder notes and cautions should be adhered to in order to avoid mistakes or personal injury. Since then its been pretty good. I made all of mine except one, which I bought. I had to buy a couple custom tools to compress the springs, but they didn't cost too much. That being said the truck was retired from service career change about 5 years ago. The tranny just took a crap on me.