INTRODUCTION Updated

October, 2003
FORD 4R100

The Ford 4R100 transmission is an updated version of the E4OD and was first introduced in the 1999 model
year, and is currently found in the F250, F350, F450 and F550 Super Duty trucks, E150, E250, E350, E450 vans
and the Expedition/Navigator/Excursion vehicles equipped with the 5.4L, 6.8L, and 7.3L engines. Some of the
4R100 units are equipped with a Power-Take-Off (PTO) window on the left hand side of the transmission case.
The revisions in the 4R100 have created many new engineering changes that have affected many of the internal
and external parts that will affect the servicing, repairing and overhaul of these units.

We wish to thank Ford Motor Company

for the information and illustrations
that have made this booklet possible.

No part of any ATSG publication may be reproduced, stored in any retrieval system or transmitted in any form or
by any means, including but not limited to electronic, mechanical, photocopying, recording or otherwise,
without written permission of Automatic Transmission Service Group. This includes all text illustrations,
tables and charts.

The information and part numbers contained in this booklet have

been carefully compiled from industry sources known for their
reliability, but ATSG does not guarantee its accuracy.

Copyright © ATSG 2003

DALE ENGLAND JIM DIAL

FIELD SERVICE CONSULTANT TECHNICAL CONSULTANT
WAYNE COLONNA ED KRUSE
TECHNICAL SUPERVISOR TECHNICAL CONSULTANT
PETER LUBAN GREGORY LIPNICK
TECHNICAL CONSULTANT TECHNICAL CONSULTANT
JON GLATSTEIN DAVID CHALKER
TECHNICAL CONSULTANT TECHNICAL CONSULTANT
JERRY GOTT STANTON ANDERSON
TECHNICAL CONSULTANT TECHNICAL CONSULTANT
GERALD CAMPBELL ROLAND ALVAREZ
TECHNICAL CONSULTANT TECHNICAL CONSULTANT
MIKE SOUZA
TECHNICAL CONSULTANT

AUTOMATIC TRANSMISSION SERVICE GROUP

9200 S. DADELAND BLVD. SUITE 720
MIAMI, FLORIDA 33156
(305) 670-4161 1
 FOR D 4 R 1 0 0
INDEX PREVIOUS MENU
GOTO PAGE
IDENTIFICATION TAG LOCATION AND INFORMATION ............................................................... 3
GENERAL DESCRIPTION AND OPERATION ..................................................................................... 4
COMPONENT AND SOLENOID APPLICATION CHART ................................................................... 5
"PTO" GENERAL REQUIREMENTS .................................................................................................... 6
ELECTRICAL COMPONENT DIAGNOSIS ........................................................................................... 8
FLUID REQUIREMENTS ....................................................................................................................... 12
SOLENOID PACK TESTING .................................................................................................................. 12
ABBREVIATION DESCRIPTION .......................................................................................................... 14
DIAGNOSTIC TROUBLE CODE CHART AND DESCRIPTION ........................................................ 15
LINE PRESSURE TEST .......................................................................................................................... 21
NON-PTO AND PTO HYDRAULIC DIFFERENCES ........................................................................... 22
PWM AND NON-PWM OIL PUMP DIFFERENCES ........................................................................... 34
CASE CHECKBALL LOCATIONS ......................................................................................................... 38
VALVE BODY CHECKBALL LOCATIONS ........................................................................................... 39
AIR PRESSURE CHECKS ...................................................................................................................... 40
TRANSMISSION DISASSEMBLY ......................................................................................................... 41
COMPONENT REBUILD SECTION
TRANSMISSION CASE ASSEMBLY ................................................................................................ 55
FRONT AND REAR PLANETARY CARRIERS ............................................................................... 64
FORWARD CLUTCH HOUSING ...................................................................................................... 66
DIRECT CLUTCH HOUSING ........................................................................................................... 69
FORWARD, DIRECT, SUN SHELL SUB-ASSEMBLY .................................................................... 76
CENTER SUPPORT ASSEMBLY ...................................................................................................... 80
INTERMEDIATE/OVERDRIVE CYLINDER ASSEMBLY ............................................................. 82
OVERDRIVE GEARSET ASSEMBLY ............................................................................................... 84
COAST CLUTCH HOUSING DIFFERENCES ................................................................................ 88
COAST CLUTCH HOUSING ASSEMBLY ........................................................................................ 90
OIL PUMP ASSEMBLY ...................................................................................................................... 94
VALVE BODY ASSEMBLY ............................................................................................................... 100
TRANSMISSION FINAL ASSEMBLY ................................................................................................. 102
MANUAL VALVE CHECK .................................................................................................................... 111
MANUAL SHIFT LEVER DIFFERENCES ........................................................................................ 112
TORQUE SPECIFICATIONS ............................................................................................................... 115
VALVE BODY BOLT CHART AND IDENTIFICATION .................................................................... 116
BOLT CHART AND IDENTIFICATION ............................................................................................. 117
SPECIAL SERVICE TOOLS ................................................................................................................. 118

AUTOMATIC TRANSMISSION SERVICE GROUP

9200 S. DADELAND BLVD. SUITE 720
MIAMI, FLORIDA 33156
(305) 670-4161
Copyright © ATSG 2003

2
 Technical Service Information
TRANSMISSION IDENTIFICATION
WITH POWER TAKE OFF OPTION
Note: PTO is available as an option on 8500 GVW or above, Super Duty
F-Series trucks with 6.8L gasoline and 7.3L Diesel engines.
Ford 4R100 transmissions on other models are not PTO capable.

Ford XW4P-AC
RJL-B
004361
17
BD-9C
006- BA
RF F81P-7
98

For
d

Year Month Day

BD- 9 C 17
Build 9=1999 A=Jan
XW4P-AC 1

5G
Date 0=2000 B=Feb
RJL-B 2 1=2001 C=Mar
2=2002 D=Apr
004361 3 3=2003 E=May
BD-9C17 4 F=Jun
G=Jul
H=Aug
J=Sep
4X4 K=Oct
6520 004361 L=Nov
M=Dec

1 Assembly Part Number, Prefix And Suffix

2 Transmission Model
3 Serial Number
4 Build Date (Year, Month, Day)

Copyright © 2003 ATSG

Figure 1

AUTOMATIC TRANSMISSION SERVICE GROUP 3

 Technical Service Information
TRANSMISSION Shift Quadrant Indicator
DESCRIPTION AND OPERATION Vehicles equipped with the 4R100 transmission have
General Description a Transmission Control Switch (TCS), also referred to
The Ford 4R100 automatic transmission is a four as "Overdrive Cancel Switch", and a Transmission
forward speed unit with electronic shift control. It is Control Indicator Lamp (TCIL), located on the end of
designed for longitudinal powertrains for rear wheel the manual gear shift lever, as shown in Figure 3. The
drive vehicles. TCS is a momentary contact switch. When this
The 4R100 transmission features a four element switch is pressed, a signal is sent to the PCM to allow
torque converter design that includes Torque automatic shifts from 1st to 4th gear or from 1st to 3rd
Converter Clutch (TCC) and a gear train that includes gear. After the TCS has been pressed the PCM turns
three planetary gearsets. on the TCIL lamp ("OFF"), to indicate that overdrive
Some models provide for Power Take Off (PTO) has been canceled, as shown in Figure 3.
operation in all transmission shift lever positions.
During PTO operation in OD, 4th gear is disabled. The shift quadrant has the following positions, as
The hydraulic control system of the 4R100 unit has shown in Figure 2: P, R, N, D , 2 and 1.
five electronically controlled solenoids for:
Shift feel, through line pressure control. D position (TCS OFF) provides 1-2-3-4 automatic
Shift scheduling, through shift valve position. upshifts and downshifts. Coast braking occurs in 4th
Engine braking during coast conditions. gear. (TCIL Not Illuminated)
TCC apply (On/Off or Modulating).
D position (TCS ON) provides 1-2-3 automatic
Major Internal Components upshifts and downshifts. Coast braking occurs in 3rd
"Seven Friction Apply Elements" gear. (TCIL Illuminated)
Intermediate Band
Coast Clutch, Multi-disc 2 position provides a pull-in shift to 3rd gear with
Overdrive Clutch, Multi-disc coast braking. After an automatic downshift, a 2nd
Intermediate Clutch, Multi-disc gear hold occurs with coast braking.
Direct Clutch, Multi-disc
Forward Clutch, Multi-disc 1 position provides a pull-in shift to 2nd gear with
Low/Reverse Clutch, Multi-disc coast braking. After an automatic downshift, a 1st
gear hold occurs with coast braking.
"Three One-Way Clutches"
Overdrive Roller Clutch
Intermediate Sprag
Low Roller Clutch
"Three Simple Planetary Gearsets"
Overdrive
Forward
Reverse

"Typical" Shift Quadrant Indicator

TCS
SWITCH

P R N D 2 1 OVERDRIVE OFF

Copyright © 2003 ATSG TCIL LAMP

Figure 2 Figure 3
4 AUTOMATIC TRANSMISSION SERVICE GROUP
 Technical Service Information
FORD MOTOR COMPANY
4R100 ("PTO" Version Illustrated)
Overdrive Intermediate
Clutch Clutch Low/Reverse
Clutch
Coast Direct Forward
Clutch Clutch Clutch

Low GEAR RATIOS

Roller Clutch Reverse - 2.18
Intermediate 1st Gear - 2.71
Overdrive Intermediate 2nd Gear - 1.54
Roller Clutch Band
Sprag 3rd Gear - 1.00
4th Gear - 0.71

COMPONENT AND SOLENOID APPLICATION CHART

Fwd Int Dir O.D. Cst Int L/R O.D. Int Low SOLENOIDS
GEAR
Clut Clut Clut Clut Clut Band Clut Roller Sprag Roller SS1 SS2 CCS TCC EPC
Park/Neut On Off Off Off Mod
Reverse ON ON ON Hold On Off Off Off Mod
OD-1st ON Hold Hold On Off *Off *On Mod
OD-2nd ON ON Hold Hold On On *Off *On Mod
OD-3rd ON ON ON Hold Off On *Off *On Mod
OD-4th ON ON ON ON Off Off Off *On Mod
OD-3rd** ON ON ON ON Hold Off On On *On Mod
M-2nd ON ON ON ON Hold Hold On On On *On Mod
M-1st ON ON ON Hold Hold On Off On Off Mod

OD-3rd** = TCS "On" with TCIL illuminated showing "Off"

*On = If the PCM determines that powertrain operating conditions exist for TCC apply, the TCC solenoid may
be On (Modulating with PWM TCC units) in any forward gear except Manual 1st.
*Off = Will be "On", if the TCS switch is pushed.
Mod = Modulating at all times by the PCM and line pressure will be regulated based on throttle position,
engine load and vehicle speed.
Copyright © 2003 ATSG
Figure 4

AUTOMATIC TRANSMISSION SERVICE GROUP 5

 Technical Service Information
PTO "GENERAL" REQUIREMENTS:
(1) Obviously the case must be PTO capable with
PTO
the cast-in window in the transmission where the
Window
PTO unit mounts to the transmission, as shown in
Figure 5.
(2) Designed for use during Mobile (Some Models)
or Stationary conditions.
(3) PTO is available as an option only on 8500 GVW
or above, Super Duty F-Series trucks with 6.8L Ford XW4P-AC
RJL-B
004361

Gasoline and 7.3L Diesel engines. Ford 4R100

17
BD-9C
A
P-7006-B
RFF81
98

transmissions on other models are not PTO

capable. Ford

(4) Battery voltage must be supplied to the

Powertrain Control Module (PCM) input pin 4
on gasoline models, or pin 66 on diesel models, Copyright © 2003 ATSG
when the PTO is engaged. The processor uses
this information to raise EPC pressure to Figure 5
approximately 55 PSI so that you do not burn the
coast clutch. This voltage must be provided by TRANSMISSION FUNCTIONS
the PTO installer. DURING PTO OPERATION:
(5) Shift Solenoid 2 and the Coast Clutch Solenoid (1) Shift Solenoid 2 and Coast Clutch Solenoids are
must be energized when the PTO is turned ON. turned on, the coast clutch activates and does not
allow 4th gear operation during PTO operation.

"GENERAL" CONDITIONS FOR OPERATION

(2) Electronic Pressure Control (EPC) pressure is
(1) The vehicle is not in the crank or start mode. raised to approximately 55 PSI. This is why the
(2) The transmission range selector must be in the P, coast clutch will be smoked in a short period of
R, O.D, 2 or 1 position. The PTO will not operate time if a battery voltage wire is not supplied to
when selector is in the neutral position. EEC input pin 4 (gasoline) or pin 66 (diesel)
(3) PTO operation is inhibited when in cranking when the PTO is engaged, as this rise in pressure
mode, neutral, or 4th gear. would not occur.
(4) Transmission only operates 1st through 3rd
gears. Computer strategy does not allow 4th (3) The Transmission Control Indicator Lamp
gear to engage, under any conditions. (TCIL) illuminates.
(5) Transmission Fluid Temperature Sensor (TFT) (4) When the PTO is turned ON, the transmission
reading must be up to operating temperature. operates only in 1st through 3rd gears.
Overdrive 4th gear is not allowed by the PCM
GASOLINE ENGINE PTO OPERATION: strategy.
(1) PTO installer must obtain a "High Idle Throttle (5) The transmission shift schedule is early and shift
Control" from an aftermarket source. feel is very firm.
(2) Auxiliary Powertrain Control Module seen on (6) PTO operation can cause transmission fluid
Page seven, does not work on the gasoline engine temperature to exceed the recommended
models. APCM module works only on the 7.3L maximum limit of 250 degrees F. Failure mode
diesel engine. logic within PCM strategy prevents transmission
damage by disabling the PTO above this
(3) For stationary PTO operation an engine idle
temperature limit.
speed of 1300 RPM is required.
(4) The Torque Converter Clutch (TCC) engages Specific Operation For Diesel, See Page 7.
once the engine reaches 1300 RPM.

6 AUTOMATIC TRANSMISSION SERVICE GROUP

 Technical Service Information

DIESEL ENGINE PTO OPERATION:

"AUXILIARY" POWERTRAIN CONTROL MODULE

7.3L DIESEL ENGINE (ONLY)

The Auxiliary Powertrain Control Module (APCM) commands the Electronic Engine Control
(EEC) module to increase the idle speed during PTO operation. The APCM controls engine
speed from 1300 to 2500 RPM.
The Auxiliary Powertrain Control Module is a seperate option, it does not come standard with a
PTO capable transmission, and is for 7.3L diesel applications only.
Intended for stationary use only, and in stationary operation the PTO requires an engine idle speed
of 1300 RPM. During stationary PTO operation on the 7.3L diesel, the EEC increases the idle to
1300 RPM automatically.
During stationary PTO operation, the Torque Converter Clutch (TCC) engages once the RPM
reaches 1200-1300 RPM.
The following conditions must be met before the idle speed is increased:
1. Parking brake must be engaged for all applications.
2. No hydraulic brake actuation.
3. Accelerator pedal must be in the idle position.
4. Vehicle speed must be zero MPH.
5. Brake lights must be functional.

Ford AUXILIARY POWERTRAIN CONTROL MODULE

CHARGE PROTECTION APPLICATION
Charge Protection is used for maintaining battery charge.
Exclusively for light trucks with the 7.3L Diesel Engine.
In Charge Protection mode, the battery voltage is monitored and the
Intended for Stationary Use Only.
engine idle speed is increased as necessary, so the battery charge is
Order Guide Option Code 961.
maintained as required.
Charge Protection can be activated from in-cab and can be
programmed to activate automatically on engine start-up. KITS INCLUDE
Aux. Powertrain Control Module.
Mounting Hardware and Bracket.
Wiring Harness.
RPM CONTROL Instruction Booklet.
RPM Control is used for Operators Card.
RPM
CONTROL
CHARGE
PROTECT
POWER
Ford
RPM Control mode can be
activated from in-cab and LCD screen displays the current
can be programmed to
2500
engine speed or battery voltage.
activate automatically on
engine start-up. Each Single Arrow key contains a
The programmable speed preset speed allowing for four
presets range from 1300 to programmable RPM settings.

The Double Arrow keys can also be

This is the recommended
used to manually raise or lower the
method of elevating idle
engine speed at a faster or slower
speed for PTO operations.
rate.

Copyright © 2003 ATSG

Figure 6

AUTOMATIC TRANSMISSION SERVICE GROUP 7

 Technical Service Information
DIAGNOSTIC CONCERNS WITH PTO
CENTRAL JUNCTION BOX
EQUIPPED VEHICLES:
(1) Always ensure that PTO is turned OFF, before
any diagnostic procedures begin.
(2) Never perform any transmission special tests
(i.e. pressure test, stall test etc.) when the PTO is
turned ON.
(3) If a transmission concern or symptom goes
away with the PTO turned OFF, it is most likely
not a transmission concern.
(4) On Board Diagnostics operate normally during
PTO operation with the exception of the engine
misfire monitor. The circuit checks made by the
PCM and Failure Mode Effect Management
FUSE 19
(FMEM) capability will continue. The PTO
must be turned OFF to access Diagnostic
Trouble Codes (DTC's) and perform OBD tests.

Caution: If the batteries are disconnected for any

reason, the PCM "must" have a 7 mile drive cycle at
speeds above 50 MPH, before it remembers that it is
capable of running a PTO Red/Yellow

ELECTRICAL COMPONENT DIAGNOSIS Transmission Control Switch (TCS)

Accelerator Pedal Position Sensor (Diesel Only) Clutch Pedal Position (CPP) (Std Trans Only)
The Accelerator Pedal (AP) position sensor is Idle Validation Switch (IVS) (Diesel Only)
mounted on the accelerator pedal inside the vehicle Overhead Trip Computer Module
and detects the position of the accelerator pedal and
Generic Electronic Module (GEM)
sends this information as a varying voltage signal to
the PCM. The PCM then uses the monitored voltage Instrument Cluster Terminal A12
level of the AP sensor for control of EPC pressure and Instrument Cluster Terminal B11
shift scheduling. Copyright © 2003 ATSG
The Idle Validation Switch is fed voltage through Figure 7
fuse number 19, as well as the Transmission Control
Switch, as shown in Figure 7.
If the Idle Validation Switch feed voltage is lost for
any reason, the engine will immediately return to
idle and stay there until feed voltage is restored.

4X4 Low Switch

The 4X4 Low Switch is used to the PCM that the
transfer case system is operating in LOW range. The
PCM receives the 4X4 Low Switch input signal and
modifies shift scheduling for the lower gear ratio
(See Figure 8).
If the 4X4 LOW indicator fuse is blown, the
transmission will shift according to the 4X4 LOW
shift schedule, regardless of transfer case lever PCM PIN 14
Lt. Blue/Black
position.
Figure 8
8 AUTOMATIC TRANSMISSION SERVICE GROUP