JEGS 555-60937 Shift Kit Instruction Manual

Shift Kit
555-60937
1989-Up | Ford E40D & 4R100

Introduction

We would like to take this opportunity to thank you for purchasing this JEGS 1989-Up Ford E40D, 4R100 Shift Kit. We welcome any comments or feedback you might have. If you have any questions about this product or about the installation procedure, please feel free to contact us at 1.800.345.4545.

Features

• Smoother shifting
• Reduced TCC (Torque Converter Clutch) slip codes
• Increased cooling and lubrication

This kit is designed to address the following:

• Codes
• 628
• P1740
• P1744
• Soft shifts
• 2nd-3rd burn-up
• Converter burn-up
• Reverse delay
• No reverse when hot
• Converter Shutter
• Pump buzz

NOTE
PARTIAL INSTALLATION DOES NOT REQUIRE THE REMOVAL OF THE TRANSMISSION. INSTALLATION OF THE ENTIRE KIT, INCLUDING THE DIRECT CLUTCH SEAL, NEW CONVERTER REGULATOR, AND PRESSURE REGULATOR SPRINGS, REQUIRES THAT THE TRANSMISSION MUST BE REMOVED AND DISASSEMBLED.

Valve Body Identification

Installation (Valve Body)

1. ACCUMULATOR PISTONS. Install the new springs onto the 3rd and 4 th accumulator pistons.
2. REGULATOR LINE VALVE. Install the steel regulator line valve and 2nd accumulator springs.
3. LINE BOOST VALVE. Install the white line boost spring if your vehicle shifts hard on light throttle and slow speeds.

Installation (Ball Location)

1. Enlarge three “D” holes with the 0.081 in. drill bit.
   • No action is necessary if the holes are already bigger or not there.
   • Don’t drill any new holes.

2. EPC RELIEF. Reuse the original spring. Install with the new poppet valve.

3. Install tapered orifice bushing at “X”.

4. Ensure the gaskets don’t cover any holes in the plate.

CHECK ALL DETAILS

• The plate has 89 holes – Install a “T” plastic check ball
• This application will use all 11 check balls
• Plate has 90 hole – Don’t use “S & T” checkballs
• Plate has 2T hole – Don’t use “R, S, & T” checkballs
• All check balls are5/16 in.
• See the key at bottom of the page.

Installation (Front Pump)
REQUIRES TRANSMISSION REMOVAL

1. Install a direct clutch seal into the direct drum.
   • Before installing the seal, clean any debris out of the groove
   • Roll the seal inside out as you install it.
   • Install the seal with the stripe showing.

2. Check location “A” on the pump cover. If there is no hole here, leave it alone. If your cover has a hole, it needs to be plugged in.

3. LOCKUP FIRMNESS. This step is only for transmissions with an orifice cup plug at “B” on the pump cover
   • Normal: 0.076 in.
   • Firm: 0.086 in.
   • Firmest: 0.093 in.

4. Install a yellow spring with the converter regulator.

5. When reassembling the boost valve, replace the original spring seat, springs, and boost valve with the new kit components.

Additional Information

1. 2ND GEAR CLUTCH. Stacking the clutch plates incorrectly will result in no 2nd gear. The thick backing plate goes in the case first.
2. EPC SOLENOID. Don’t adjust.
3. SPRAG ROTATION. See the diagram below for assembly.
4. CASE CONNECTOR. Follow the shift solenoid sequence in the chart below.
5. SOLENOID PACK. If the casting has hole “B”, install the solenoid pack as it is. No drilling is required.
   • If there is no hole “B”, drill six size 1/8 in. holes “C”. Drill the seventh hole through the partition at “D”.

NOTE
Solenoid packs with a “B” hole ceased production in the late 1990s. These packs should be replaced to ensure long-term durability.

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