My truck is a two wheel drive with a 460 engine that makes about 330 horsepower. From a friend of mine who builds transmissions I got the core parts that I needed: A 460 style E4OD case and a core transmission (6 cylinder) with all of the hard parts including an output shaft and tail housing that could drive my mechanical speedometer. My core was a 1991 which is OK and really only a 1989 case should probably be avoided but I needed pretty much all of the updates that Ford did to the later models.
I updated mine to the newer style front pump, roller center support, newer style band servo, steel OD and forward planetaries. I used a Transgo "Tugger" shift kit which comes with upgraded snap rings for the OD piston and the coast clutch. I bought a rebuilding kit with Borg Warner clutches from Transgo along with a bushing kit, new thrust washers, new band and a low stall billet cover torque converter. My core transmission only had two clutch plates in the OD and intermediate so I changed the pressure plates to allow for three clutch plates. In my core the forward clutch was cooked and it only had three clutch plates so I put in another one with four.
Things to look for: Make sure that your output shaft has the same number of teeth as a C6(6 teeth). My core didn't which meant that I had to fool around getting the right gear to make the speedometer read correctly. I had to change the speedometer cable to one that would plug into the speed sensor at the transmission. My original one was made where the cable went into the trans tailshaft. Without question replace the aluminum OD planetary with the later steel version! I didn't do this on my trans at first and mine broke on me while running down the highway out in the middle of Kansas! I found a different transmission cooler to replace my original one. It was exactly the same but just about 2.5X taller. I used Joe Gibbs Driven AT3 fully synthetic fluid 17 quarts worth!
I think what I'd probably do knowing what I know now would be to find a core from about a '96 which would already have most of the upgrades and then just change the output shaft and tail housing.
Any sufficiently advanced technology is indistinguishable from magic --Arthur C. Clarke
Last edited by DaveMcLain; 03-20-2019 at 08:51 AM.