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Technical Service Information

FORD E4OD
NEW "SPECIAL" CASE ASSEMBLY
FROM FORD MOTOR CO.
CHANGE: Currently, the "only" new case available from Ford Motor Company, for replacement in any E4OD
equipped vehicles, is a modified 4R100 case. Ford has machined out the dam in the case that
seperates center and rear lube, near the rear of the case, as shown in Figure 1.
CAUTION: This case requires special main spacer plate, spacer plate gaskets, speed sensor plugs
and extension housing, that do not come with the new case from Ford Motor Company.
We have provided you with a list of additional parts that will be required to use this case, under
"Parts Affected", depending on the model year that you are repairing. The older the unit, the more
parts required.

REASON: Cost savings due to not having to maintain seperate dies for the case assemblies.

PARTS AFFECTED:
REQUIREMENTS FOR 1996 THRU 1998 MODELS ONLY:
(1) SPACER PLATE - Ford Motor Co. part number F81Z-7A008-EA or F8UZ-7A008-CA, as shown
in Figure 2.
(2) CASE TO SPACER PLATE GASKET - Ford Motor Co. part number F81Z-7C155-AA, with
"White" stripe for identification, as shown in Figure 3.
(3) SPACER PLATE TO V.B. GASKET - Ford Motor Co. part number F81Z-7D100-AB, with "Blue"
stripe for identification, as shown in Figure 3.
(4) COOLER BYPASS ASSEMBLY - Ford Motor Co. part number F81Z-7H322-AA for 1996 models
only, as shown in Figure 4. 1997 and 1998 models came with cooler bypass.
(5) SPEED SENSOR PLUG - Ford Motor Co. part number F81Z-7H183-AA, and 2 are required, as
shown in Figure 5.
(6) LUBE ORIFICE PLUG - Ford Motor Co. part number F81Z-7E380-AA, which should come with
the new case from Ford, as shown in Figure 6.
(7) EXTENSION HOUSING - A 4R100 style with boss in the extension housing to retain the lube plug
in the new design case, as shown in Figure 6.

Continued on next Page

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PARTS AFFECTED (Cont'd):
REQUIREMENTS FOR 1989 THRU 1995 MODELS ONLY:
(1) SPACER PLATE - Ford Motor Co. part number F81Z-7A008-EA or F8UZ-7A008-CA, as shown
in Figure 2.
(2) CASE TO SPACER PLATE GASKET - Ford Motor Co. part number F81Z-7C155-AA, with
"White" stripe for identification, as shown in Figure 3.
(3) SPACER PLATE TO V.B. GASKET - Ford Motor Co. part number F81Z-7D100-AB, with "Blue"
stripe for identification, as shown in Figure 3.
(4) COOLER BYPASS ASSEMBLY - Ford Motor Co. part number F81Z-7H322-AA, as shown in
Figure 4.
(5) SPEED SENSOR PLUG - Ford Motor Co. part number F81Z-7H183-AA, and 2 are required, as
shown in Figure 5.
(6) LUBE ORIFICE PLUG - Ford Motor Co. part number F81Z-7E380-AA, which should come with
the new case from Ford, as shown in Figure 6.
(7) EXTENSION HOUSING - A 4R100 style with boss in the extension housing to retain the lube plug
in the new design case, as shown in Figure 6.
(8) MAIN VALVE BODY - Requires 1996 hydraulics which is identified by RF-F6 cast into the valve
body, in location shown in Figure 7, and checkball locations are shown in Figure 8.
(9) LOWER VALVE BODY - Requires 1996 hydraulics which is identified by RF-F6 cast into the
lower valve body, in location shown in Figure 7.
(10) LOWER VALVE BODY SPACER PLATE - The 1996 hydraulics version which is identified by the
2 holes for bathtub checkball and 3 small holes, as shown in Figure 7.
(11) ACCUMULATOR VALVE BODY - Requires 1996 hydraulics which is identified by RF-F6 cast
into the accumulator valve body and slot cast shut, as shown in Figure 7.
(12) CASE CHECKBALL LOCATIONS - Requires the 1996 and later case checkball locations, which
is eight checkballs in locations shown in Figure 9.
INTERCHANGEABILITY:
Parts that have been mis-matched, depending on what you have done, can create;
Harsh Shifts No Overdrive Bind in Manual 1
Lack of Lube Bind in Reverse Slip in Reverse

SERVICE INFORMATION:
Main Valve Body Spacer Plate .................. ...................................................... F81Z-7A008-EA
Main Valve Body Spacer Plate (Optional) ....................................................... F8UZ-7A008-CA
Case To Spacer Plate Gasket (White Stripe) .................................................... F81Z-7C155-AA
Spacer Plate To Valve Body Gasket (Blue Stripe) ............................................ F81Z-7D100-AB
Cooler Bypass Assembly .................................................................................. F81Z-7H322-AA
Speed Sensor Plugs (2 Required) ...................................................................... F81Z-7H183-AA
Lube Orifice Plug (Comes with new case) ........................................................ F81Z-7E380-AA

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FORD 4R100 MODIFIED CASE FOR USE IN E4OD MODELS

ADDED OIL DAM

DAM REMOVED

FORD 4R100 CASE FORD MODIFIED

4R100 CASE FOR
E4OD REPLACE
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Figure 1
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"SPECIAL" MAIN SPACER PLATE REQUIRED

FOR MODIFIED 4R100 CASE

F81P-DA

F81P-EA

Use Part Number

For Identification
F81Z-7D008-EA

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Figure 2
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CASE AND VALVE BODY GASKETS REQUIRED

FOR MODIFIED 4R100 CASE

Blue I.D. Stripe

F81Z-7D100-AB

White I.D. Stripe

F81Z-7C155-AA

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Figure 3
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"4R100" COOLER BYPASS

VALVE ASSEMBLY

TO COOLER
SEALING WASHERS

FROM COOLER
SEALING WASHERS

COOLER LINE
FITTINGS
OEM PART NUMBER
F81Z-7H322-AA

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Figure 4

SPEED SENSOR PLUG

F81Z-7H183-AA
(2 REQUIRED)

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Figure 5
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TYPICAL E4OD 4X4 WITHOUT

4 WHEEL DRIVE LUBE PLUG

With Shoulder No Shoulder

FORD 4R100 ALL OTHER

6.8L AND 7.3L 2 WHEEL DRIVE E4OD WITHOUT
2 WHEEL DRIVE APPLICATIONS LUBE PLUG

Added Boss With Shoulder No Shoulder

Must use extension housing with shoulder or boss,

to retain the lube orifice plug in the new case

LUBE ORIFICE PLUG

FORD PART NUMBER
F81Z-7E380-AA

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Figure 6
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VALVE BODY CASTINGS REQUIRED

FOR MODIFIED 4R100 CASE
REQUIRED LOWER I.D.-ROUGH FORGING
VALVE BODY NUMBER OF "RF-F6" WHICH
INDICATES "96" MODEL

"Two" Holes Over

REQUIRED LOWER The Bathtub
VALVE BODY
SPACER PLATE

THREE "SMALL" HOLES

Identification
One "V" Notch
I.D.-ROUGH FORGING
NUMBER OF "RF-F6" WHICH
INDICATES "96" MODEL
REQUIRED MAIN
VALVE BODY

-
6TP B
RF-F092-A
7A

I.D.-ROUGH FORGING
NUMBER OF "RF-F6" WHICH
INDICATES "96" MODEL

REQUIRED
ACCUMULATOR
VALVE BODY

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Figure 7
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VALVE BODY CHECKBALL LOCATIONS REQUIRED

FOR MODIFIED 4R100 CASE
VALVE BODY CHECKBALL LOCATIONS
REQUIRES THREE 1/4" RUBBER BALLS,
AND TWO 5/16" RUBBER BALLS

ROUGH FORGING
NUMBER LOCATION

RFF6TP-
7A092-AB

5/16" DIAMETER
CHECKBALL

5/16" DIAMETER 1/4" DIAMETER

CHECKBALL CHECKBALLS

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Figure 8
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4R100 "MODIFIED" CASE CHECKBALL LOCATIONS

REQUIRES EIGHT (5/16") RUBBER BALLS

CB-7 CB-8 BS-3 BS-1 CB-6

CB-1

INTERMEDIATE
ACCUMULATOR
REGULATOR CB-14 SHIFT 1 CB-9 SHIFT 2 1/4" STEEL BALL
FILTER ASSEMBLY AIR BLEED AIR BLEED EPC RELIEF BALL

Filter Assembly ......... F1TZ-7H194-A

EPC Spring ............... E9TZ-7D017-A

SPRING GOES INTO SPRING GOES INTO

THE CASE FIRST THE CASE FIRST
(USED ALL MODELS)
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Figure 9
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