E40D Automatic Transmission
We have had several inquiries regarding the "E40D" automatic transmission since its recent introduction to the industry. The purpose of this bulletin is to provide body builders the technical information necessary when modifying E40D transmission related components on 1989 Econoline and F-Series vehicles.
1. The E40D transmission is a fully automatic, electronically controlled unit, and requires battery positive power hot at all times to the electronic control assembly.
Follow these guidelines along with your electrical and vacuum troubleshooting manuals when installing electrical load disconnect switches:
1989 Econoline Vehicles (All Engines) - Fuse link "L" must remain hot at all times. Fuse link "L" is the blue fusible wire attached to the starter relay battery terminal with an eyelet connector. This fuse link feeds a black/orange 12 ga. wire that supplies power to the electronic control assembly.
1989 Econoline Vehicles (Gas Engines) - This eyelet connector will include an additional blue fusible link that feeds a yellow 14 ga. wire which powers and protects the fuel pump relay circuit.
1989 F-Series Vehicles (7.3L Diesel Engine) Fuse link "W" must remain hot at all times. Fuse link "W" is a blue fusible wire attached to the starter relay battery terminal with an eyelet connector. This fuse link feeds a yellow 14 ga. wire that supplies power to the electronic control assembly. Note: fuse link "W" also powers the stop and hazard lamps which are protected by fuse # 1 in the fuse panel.
1989 F-Series Vehicles (Gas Engines) - A 10 ga. yellow wire attached to the starter relay battery terminal feeds three blue fusible links (see page 17 of your electrical manual). Locate the splice that connects the three blue fusible links 13 inches from the eyelet. Fuse link "F" feeds trailer tow, fuse link "N" feeds the electronic control assembly and fuse link "W" feeds the fuel pump relay. Fuse link "N" feeds a 14 ga. yellow wire which is the fusible link that must remain hot at all times. The blue wire is the actual fuse link and must remain in this circuit and its length must remain at 150 mm +/- 13 mm.
2. The neutral start/backup lamp switch has been revised to a multi-function "Manual Lever Position Sensor". This means the transmission wiring harness and connectors have changed which increases the number of circuits. When installing aftermarket throttle kickers follow the direction shown in the following illustrations when splicing to the neutral start circuit.
Figure 1:
Figure 1 - All 1989 Fl5O-F350/F-Super Duty
Figure 2:
Figure 2 - 1989 Econoline equipped with gas engines
Figure 3:
Figure 3 - 1989 Econoline equipped with 7.3L Diesel engine
3. The electronic control system has very strict grounding requirements. Incorrect or missing grounds can greatly affect engine and transmission operation. It is most important that all OEM ground circuits remain unchanged. Ground the second unit body to the chassis frame in at least two locations, and add an additional frame to engine ground cable to increase the ground path to the battery.
4. Sensors of the electronic system such as vehicle speed sensor, rpm sensor, fuel pump injector level sensor, etc., must not be shared by any other circuit because of the adverse effect on the electronic automatic transmission operation.
Figure 4:
5. If a tachometer signal is required on an F-Series 7.3L Diesel not equipped with a factory installed tachometer, the signal can be picked up from pin number 36 of the electronic control module 60-pin connector (see Figure 4). Do not splice into this circuit if vehicle is equipped with a factory installed tachometer.
This connector can be found on the lower left hand corner of the dash panel in the engine compartment. Disconnect all battery ground connections and remove the module connector using a 10 mm socket. There will be a dark green/yellow 18 ga. wire in pin 36 of the module. Use the diagram provided in Figure 4 to locate this circuit. Splice in to this wire and solder the connection to pick up the tach signal. Reinstall the module connector.
6. With the introduction of the E40D you will notice that an additional hose has been "T'eed" into the heater hose system. This hose was added to circulate hot water quicker to the transmission cooler and improve cold weather performance of the E40D transmission. For the 7.3L Diesel, we recommend that an auxiliary heater return line be installed directly to the water pump by removing the existing pipe plug and installing an appropriate nipple (a long nipple cannot be used because of excessive vibration input to the aluminum water pump housing).
7. Before adding fluid, be sure that the correct type will be used. Using any fluid other than Motorcraft Mercon Multi-Purpose Automatic Transmission Fluid (Ford Part No. E4AZ-19582-B) and Ford Specification ESP-M2C166-H or equivalent, could result in transmission malfunction and/or failure.
8. Ford recommends that all batteries be disconnected before welding to body and chassis components. Disconnecting the batteries will result in a memory loss on electronic engine and/or transmission controlled vehicles. The vehicle will require several miles of driving in various driving modes to restore its memory and regain optimum operating conditions.