1996 E-Super Duty

D

dbshelton

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Nov 3, 2008
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I have a 1996 E-Super Duty bus I use for a car hauler that currently has a 460/E4OD in it (4.63 rear and 13,600 loaded weight). I have a good 1993 12v Cummins and also fresh 2005 5R110 trans from a 6.0 truck that I bought. I have heard stories of all of the problems using the PCS trans computer with the 5R110. Can anyone give me any guidance or tips? I really like way the 5R110 works in 6.0 Ford trucks, but maybe I should go with the E4OD or a 47RH or ???? Will most likely change the rear ratio to 4.10 when I do the engine swap.
 
Anyone ever try swapping a later model computer with corresponding wiring to control the 5R110?
 
I would go with a good 47RH with hobb switches to control lock-up and over drive. I used to haul heavy with my 93 D250 with a turned screw and it's A-518 trans and couldn't kill the trans. If I had the money I'd go that route in my F550 haul truck for the lock up converter to help with mileage.
 
I talked with a transmission tuner guy about using an 03-04 6.0 Ford PCM as a standalone with an SCT tuner to control only the 5R110 in my 96 bus. He says he can make it work very well. I think I'm gonna go with this setup this should be fun. Now time to start hunting parts.
 
Trying to decide if I should change to a 4.10 or if I could use a 3.73 rear gear. No towing, 32" tall tires, 14,000# loaded weight, lots of frontal area. Also wonder if the 460 radiator is up to cooling the Cummins
 
Trying to make some of the mods to the bus before I tear it apart. Mounted the dual battery boxes on the frame and will make the rear gear change. I decided to go ahead and change the rear gear to a 3.73. That is this weekend's project. Got my trans adapter and flexplate from DCS and bolted all of that together last weekend to make sure it all fit. Still have to decide on a torque converter. Still running it on the stand to keep me motivated!
 

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I did figure out the 460 radiator is too wide for the 2004 E450 6.0 Intercooler so I will get a replacement radiator for that. From all of my measuring, it looks like I'll have to move the transmission crossmember back about 3" or so from stock but everything looks like it will fit. Motor mounts look like they won't be hard to fabricate. Moving the batteries from the engine compartment will free up some space when I get that finished. Last year I installed a 4" exhaust and a Donaldson muffler since I knew this swap was coming some day.
 
I would use a Ford 4r100 Transmission, although the 5r110 is a good trans in the original application, its not a great transplant transmission. The 4r100 is the same size as the e40d and tunes very well using a PCS transmission controller, it will be a lot less hassle.
 
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Seriously considered the 4R100 but since I already had the 5R110 I thought I would give it a chance. I consider it a challenge to make it work (with help).

The 3.73 gear change worked out well.
 
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