December 2023

The automotive industry has witnessed significant advancements over the years, with automatic transmissions playing a pivotal role in enhancing the driving experience. One notable innovation in this domain was the introduction of the Ford AOD (Automatic Overdrive) transmission in the early 1960s. While groundbreaking, the AOD transmission had its fair share of initial flaws and limitations.

In this blog, we will delve into the features of the Ford AOD transmission, its evolution, and how Gearstar has transformed it into a high-performance powerhouse.

AOD Transmission: Pioneering Overdrive Technology

The Ford AOD transmission was a trailblazing invention, one of the first four-drive automatic transmissions to incorporate an overdrive unit. This innovation aimed to improve fuel efficiency and reduce wear and tear on the transmission components. Introduced in the early 1960s, it marked a significant step in simplifying drivability and enhancing the overall driving experience.

However, like most pioneering designs, the AOD had its early challenges. Some issues included parts requiring replacement, snapped input shafts, and burnt-out clutch packs. These initial setbacks prompted Ford to refine and improve the AOD transmission over time.

AOD Transmission Production and Successors

The production of the Ford AOD transmission spanned over a decade, from its inception in the 1960s until 1993. In 1994, it was succeeded by the electronic AODE transmission. Despite its replacement, the AOD’s legacy continues to influence modern-day transmissions, often incorporating overdrive technology for enhanced efficiency.

Heavy-Duty, High-Performance Components of Ford AOD Transmissions

The Ford AOD transmission initially entered the market as the premier domestic automatic overdrive transmission, offering four speeds. This design allowed the engine to operate at lower RPMs, boosting fuel efficiency and minimizing component wear. However, the early years of the AOD were marked by challenges, including the overdrive Band susceptibility to failure, making it clunky for some enthusiasts.

Over time, aftermarket modifications and input from racing enthusiasts spurred improvements in the AOD transmission. These enhancements included strengthening the overdrive unit, redesigning key components such as the reverse drum and overdrive band to increase friction and holding power, and eventually developing successors like the 4R7XX and AODE transmissions.

Gearstar’s Custom Performance AOD Transmissions

Despite its initial shortcomings, the AOD transmission can be a robust and reliable choice for those seeking efficiency and performance. Gearstar takes the AOD to new heights by retrofitting it with aftermarket components to meet the needs of performance enthusiasts.

Our line of performance AOD transmissions, built by master technicians passionate about power, offers a range of options tailored to high-performance driving. Each transmission has a high-capacity 4-plate intermediate clutch, updated 3rd accumulator piston, extra capacity servo, and more. Rigorous testing ensures that every Gearstar transmission is operating perfectly before leaving our facility.

Specifications of AOD – Level 2 Transmission

Transmission specifications can make all the difference in how your vehicle performs on the road or track. In this section, we will take an in-depth look at the specifications of the AOD – Level 2 Transmission offered by Gearstar and explore why it is a standout choice for enthusiasts.

• Compatibility with Small Block Engines

The AOD – Level 2 Transmission is engineered to be compatible with small block engines. This compatibility is a crucial factor for those looking to enhance the performance of their vehicles with smaller yet powerful, engine configurations. Small block engines are known for their agility and power-to-weight ratio, making them popular among performance enthusiasts. The AOD – Level 2 Transmission is tailored to work seamlessly with these engines, ensuring optimal power delivery and performance.

• Impressive Horsepower Rating

One of the standout features of the AOD – Level 2 Transmission is its impressive horsepower rating. With a horsepower capacity 400, this transmission is designed to handle the demands of high-performance applications. Whether you have a modified small block engine or other power-enhancing modifications, the AOD – Level 2 Transmission is up to the task. It provides the necessary strength and durability to transmit power efficiently, enhancing acceleration and overall performance.

• Torque Handling Capability

Torque is the force that propels your vehicle forward, and having a transmission that can handle high torque levels is essential for performance-oriented driving. The AOD – Level 2 Transmission excels, with a torque handling capability of up to 375 ft-lbs. This means it can effectively transfer the engine’s torque to the wheels, allowing for improved traction and acceleration.

• High-Performance Converter

The converter plays a critical role in an automatic transmission, facilitating power transfer from the engine to the transmission. In the case of the AOD – Level 2 Transmission, it comes equipped with an HD (High-Performance) converter. This high-performance converter is designed to efficiently transmit power, reduce power loss, and enhance overall drivability.

• Stall Speed Range

Stall speed refers to the engine speed at which the torque converter locks up and transfers power to the transmission. The AOD – Level 2 Transmission offers a stall speed range of 1600-2200 RPM (Revolutions Per Minute). This range is carefully selected to complement the transmission, engine, and vehicle performance characteristics.

Key Components Of The AOD- Level 2 Transmission

Behind every high-performance transmission lies a meticulous selection of key components that are engineered to work in harmony, ensuring optimal power delivery and durability. Before getting a Ford AOD transmission, you should focus on diverse options before you explore multiple options:

In this section, we will focus on the essential key components of the AOD – Level 2 Transmission offered by Gearstar, highlighting their significance and contribution to its exceptional performance.

• Master Overhaul Kit with New Steel Plates

The foundation of any reliable transmission is a master overhaul kit with new steel plates. This kit includes essential components such as gaskets, seals, and friction plates designed to replace worn-out or damaged parts. Including new steel plates enhances the transmission’s durability, ensuring it can withstand the demands of high-performance driving. This overhaul kit forms the backbone of the AOD – Level 2 Transmission’s longevity and reliability.

• Transgo Reprogramming Shift Kit

Precise shifting is a hallmark of a well-tuned transmission. The Transgo Reprogramming Shift Kit is a critical component that fine-tunes the transmission’s shift points and characteristics. It optimizes shift timing and firmness, resulting in smoother gear transitions and improved overall drivability. Whether accelerating aggressively or cruising constantly, this shift kit ensures that the transmission responds precisely to your driving demands.

• Raybestos Frictions

Friction plays a crucial role in a transmission’s ability to transfer power efficiently. The Raybestos frictions used in the AOD – Level 2 Transmission are designed for high-performance applications. These frictions offer exceptional heat resistance and durability, making them well-suited for the increased demands on the transmission during spirited driving. With Raybestos frictions, you can trust that your transmission will maintain consistent performance even under intense conditions.

• Filter, New Bearing Kit, and New Bushing Kit

Proper filtration and bearing support are essential for the longevity of a transmission. Including a high-quality filter ensures that contaminants are removed from the transmission fluid, preventing damage to critical components. Additionally, new bearing and bushing kits provide essential support and reduce friction within the transmission, enhancing its overall efficiency and lifespan. These components work in tandem to maintain the transmission’s integrity and performance.

• High Capacity 4 Plate Intermediate Clutch and High Capacity Direct Clutch

Clutches are central to the transmission’s ability to engage and disengage gears effectively. The AOD – Level 2 Transmission has a high-capacity 4-plate intermediate clutch and a high-capacity direct clutch. These components are engineered to handle high-performance applications’ increased power and torque levels. They deliver robust engagement and precise control, transferring power seamlessly.

• Updated 3rd Accumulator Piston and Extra Capacity Servo

The 3rd accumulator piston and servo are pivotal in controlling the transmission’s shifting behavior. An updated 3rd accumulator piston ensures smoother transitions between gears, reducing harsh shifts and enhancing overall drivability. The extra capacity servo enhances the transmission’s ability to apply pressure, improving clutch engagement and ensuring that shifts are crisp and reliable.

• Heavy Duty Remanufactured Pump and Aluminum Pan

Efficient fluid circulation maintains the Ford AOD transmission’s temperature and performance. The heavy-duty remanufactured pump included in the AOD – Level 2 Transmission ensures consistent fluid flow, preventing overheating and ensuring all components receive the necessary lubrication. Additionally, the aluminum pan provides added durability and easy access to fluid changes, contributing to the transmission’s overall longevity.

• Transmission Mount and Custom 360-degree Adjustable Shift Linkage Arm

The transmission mount and shift linkage arm are critical for ensuring the transmission’s stability and precise shifting. The transmission mount securely holds the transmission in place, reducing vibrations and ensuring proper alignment with the drivetrain. The custom 360-degree adjustable shift linkage arm allows for precise adjustments, enabling fine-tuning of shift points and linkage geometry to match the specific requirements of your vehicle and driving style.

Gearstar: Your Partner in High-Performance Transmissions

In conclusion, the Ford AOD transmission, despite its initial flaws, remains a versatile and valuable component in the automotive world. Gearstar’s commitment to excellence has transformed this transmission into a high-performance workhorse, offering enthusiasts a reliable and customized solution for their power-hungry needs.

Footnotes

Whether you’re seeking improved efficiency or unleashing the full potential of your vehicle, Gearstar’s custom AOD transmissions are engineered to exceed your expectations.

When it comes to maximizing the performance of your vehicle, the Ford transmission plays a crucial role. Whether you’re towing heavy loads, conquering off-road terrains, or simply looking to boost your vehicle’s power, the Ford E4OD / 4R100 Performance Transmissions Level 3 from Gearstar is the ultimate solution.

In this comprehensive guide, we will focus on the specifications and features of this high-performance transmission, designed to handle extreme duty towing and off-road adventures.

Power and Torque Of The Transmission

One of the standout features of the Ford Transmissions is its remarkable power capability. With a rating of 600 horsepower, this transmission is built to handle the most demanding situations with ease. Whether you’re upgrading your Ford vehicle for increased power or seeking to enhance your towing capacity, this transmission is up to the task.

Torque: Up to 550 ft-lbs

In the world of high-performance transmissions, torque is king. The Ford E4OD / 4R100 Performance Transmissions Level 3 can handle torque levels of up to 550 ft-lbs. You can count on it to deliver the necessary torque to tackle steep inclines, pull heavy trailers, or power through challenging off-road terrain.

Converter: HD Furnace Brazed Billet Cover Multi-Clutch Lock-up

The converter is a critical component of any transmission, and the Gearstar Level 3 transmission doesn’t disappoint. It features a Heavy-Duty Furnace Brazed Billet Cover Multi-Clutch Lock-up converter. This converter design ensures efficient power transfer and lock-up engagement, enhancing performance and fuel efficiency.

Stall Speed: 1300-2200 RPM

The stall speed of a torque converter is a crucial factor in a transmission’s performance. The Ford E4OD / 4R100 Performance Transmissions Level 3 has a stall speed ranging from 1300 to 2200 RPM. This wide range allows versatility, enabling optimal performance across various driving conditions.

Upgraded Components for Extreme Durability

To handle the increased power and torque levels, Gearstar equips the Level 3 transmission with a host of upgraded components:

• Master Overhaul Kit with Alto Hardened Steels

The Ford transmission includes a master overhaul kit with alto-hardened steels, ensuring the utmost durability and longevity.

• Raybestos High Energy High Heat Frictions

Raybestos high-energy, high-heat frictions are incorporated into the Level 3 transmission, offering superior heat resistance and improved performance under heavy loads.

• Transgo Heavy Duty Reprogramming Shift Kit with Gear Command

Gearstar integrates a Transgo heavy-duty reprogramming shift kit with Gear Command, enhancing shift control and optimizing gear engagement for maximum performance.

• Filter and Cooler Bypass Tube Assembly

The transmission includes a new cooler bypass tube assembly and a filter, ensuring efficient fluid circulation and cooling during extreme use.

Enhanced Clutch Packs

The Gearstar Level 3 transmission sets itself apart by incorporating high-capacity clutch packs, representing a critical component within the transmission’s architecture.

These clutch packs testify to Gearstar’s commitment to durability and performance excellence. Comprising a combination of specialized friction materials, steel components, and precise engineering, these high-capacity clutch packs are meticulously designed to withstand the increased power and torque levels that the Level 3 transmission is engineered to deliver.

These clutch packs play a pivotal role in transmitting power from the engine to the transmission, ensuring smooth and efficient gear engagements, as well as reliable torque transfer. Whether you’re towing heavy loads, navigating challenging off-road terrain, or simply seeking to harness greater power for your vehicle, these high-capacity clutch packs are engineered to provide consistent and dependable performance, even in the most demanding conditions.

In essence, they form an integral part of the Level 3 transmission’s ability to handle extreme-duty applications with unwavering precision and reliability, making it a top choice for those who demand the utmost performance from their Ford vehicle.

The Gearstar Level 3 transmission boasts high-capacity clutch packs, including:

• High Capacity 5 Plate Forward Clutch Pack

• Direct 6 Plate Clutch Pack

• Intermediate 4 Plate Clutch Pack

• Overdrive 3 Plate Clutch Pack

These clutch packs are designed to handle the increased power and torque, providing reliable and consistent performance.

• Steel Overdrive Planetary Gear Set

A steel overdrive planetary gear set enhances the transmission’s durability and power handling capabilities.

• Hardened Drive Shell and Updated Spiral Snap Ring Kit

Including a hardened drive shell and an updated spiral snap ring kit further reinforces the transmission’s strength and longevity.

• New Kickdown Band and Hardened Input Shaft

The Gearstar’s Ford transmission has a new kick-down band and a hardened input shaft for improved control and durability.

• 45 Element Intermediate Sprag and New Overdrive Sprag Assembly

The intermediate sprag with 45 elements and the new overdrive sprag assembly ensure reliable power transmission and engagement.

• High-Volume Pump Assembly with New Gears

A high-volume pump assembly with new gears enhances fluid circulation and cooling, which is critical for performance and longevity.

• Steel 6 Pinion Front Planetary and Roller Bearing Center Support

These components are designed to withstand the increased stress and power levels, ensuring consistent performance.

• New Bushing Set and Thrust Washer Set

The Gearstar Level 3 transmission includes a new bushing set and thrust washer set, providing a solid foundation for the transmission’s components.

• Complete Torrington Bearing Kit

Including a complete Torrington bearing kit further enhances the transmission’s durability and reliability.

• Updated Late Model Solenoid Pack

The Ford transmission features an updated late-model solenoid pack, improving shift control and responsiveness.

Standalone Controller Requirement*

It’s important to note that this transmission requires a standalone controller in non-OEM applications. This controller ensures precise control and optimization of the transmission’s performance characteristics.

In non-OEM (Original Equipment Manufacturer) applications, it is imperative to acknowledge that the Ford E4OD / 4R100 Performance Transmissions Level 3 necessitates the integration of a standalone controller. This controller is the linchpin in facilitating precise management and optimization of the transmission’s performance attributes.

By orchestrating the various functions and parameters of the transmission, the standalone controller ensures that every gear change, torque transfer, and shift point is meticulously calibrated to harmonize with the specific demands of the vehicle and driving conditions.

In essence, it empowers drivers to tailor the transmission’s behavior to their exact preferences and requirements, guaranteeing a seamless and optimized driving experience.

Quality Assurance Through Rigorous Testing

Gearstar takes pride in its commitment to quality and performance. Each transmission is custom-built by one of their five master technicians from start to finish. Before leaving the facility, every transmission and converter package undergoes extensive testing on a dynamometer, equivalent to 100 miles of real-world driving. This rigorous testing ensures the transmission and converter are in perfect operating condition, delivering top-notch performance and reliability.

Gearstar’s unwavering dedication to quality and performance is exemplified through a meticulous and highly personalized approach to the construction and testing of their transmissions. Each transmission is meticulously custom-built, with the entire process overseen by one of their five master technicians.

These experts bring experience and knowledge to ensure that every component is assembled to the highest standards, from the initial stages to the final touches.

Gearstar’s Testing Regimen

However, Gearstar’s commitment to excellence doesn’t end with assembly. Before any transmission and converter package leaves its facility, it undergoes an extensive and rigorous testing regimen on a dynamometer. This testing process is designed to simulate 100 miles of real-world driving.

The Simulation

During this simulation, the Ford transmission and converter are subjected to various operating conditions and loads, ensuring they perform flawlessly and reliably under the most demanding circumstances. This exhaustive testing not only identifies and rectifies any potential issues but also fine-tunes the transmission’s performance characteristics to achieve optimal functionality.

Ultimately, Gearstar’s dedication to quality assurance guarantees that every customer receives a transmission and converter package in perfect operating condition, delivering top-tier performance and unwavering reliability.

It reflects their commitment to providing customers with a product that meets and exceeds expectations, setting a high standard in high-performance transmissions.

Concluding Comments

In high-performance transmissions, the Ford Transmissions from Gearstar stands out as a top-tier option. With a power rating of 600 horsepower, the ability to handle up to 550 ft-lbs of torque, and a host of upgraded components designed for extreme durability, this transmission is the ultimate choice for those seeking to push their Ford vehicle to the limits.

Whether you’re towing heavy loads, embarking on off-road adventures, or craving more power, the Gearstar Level 3 transmission is the answer.

Trust in Gearstar’s commitment to quality and performance, backed by rigorous testing, to deliver the utmost reliability and power for your Ford vehicle.

Undoubtedly, the GM 4L80E Performance Transmission Level 4 is a name to be reckoned with. With a staggering horsepower capacity 800 and the ability to handle up to 700 ft-lbs of torque, this transmission is engineered to offer the best results. To know more about the transmission, you need to explore a series of options before you look at other options.

In this blog post, we will focus on the components that make up this formidable transmission, exploring the technical intricacies that set it apart in the automotive industry.

Custom-Built Converter: The Heart of the Beast

At the core of the GM 4L80E Level 4 transmission is a custom-built and custom-stalled 10.5” Lock-Up Billet Racing converter. This converter is meticulously crafted to match the performance requirements of the Level 4 transmission. Its stall speed ranges from 2800 to 3600 RPM, ensuring the engine’s power is efficiently transmitted to the drivetrain. The billet construction enhances durability and heat dissipation, making it an ideal choice for high-performance applications.

Master Overhaul Kit with Alto Hardened Steels

Inside the Level 4 transmission, precision and strength go hand in hand. The master overhaul kit includes alto-hardened steels, which are designed to withstand the punishing forces generated by high-powered engines. These steels ensure that the transmission’s components can endure the rigors of intense driving conditions, providing longevity and reliability.

Raybestos Stage I Frictions

Friction is the key to transmitting power within the transmission, and the Raybestos Stage I frictions excel in this regard. These high-performance friction plates are engineered to deliver consistent and reliable power transfer, even under extreme conditions. They are a crucial element in maximizing the Level 4 transmission’s performance capabilities.

Transgo Reprogramming Kit

The purpose of the kit is to optimize shift points, improve shift quality, and enhance overall performance. Also, the GM 4L80E Level 4 transmission incorporates a Transgo reprogramming kit. This kit fine-tunes the transmission’s hydraulic control system, ensuring that gear changes are seamless and responsive. It’s a vital component that transforms the Level 4 transmission into a precision instrument.

Filter, Bearings, Bushings, and Thrust Washers

In addition to the components mentioned above, the transmission consists of components suitable for performance transmissions.

The inclusion of several essential components further ensures the transmission’s longevity and reliability:

• Filter

The filter prevents contaminants from entering the transmission, preserving the integrity of its internal components.

• Torrington Bearing Kit

New Torrington bearings are installed to minimize friction and support smooth gear engagement.

• Bushing Kit

New bushings reduce wear and maintain proper alignment of internal components.

• Thrust Washer Kit

Thrust washers play a critical role in controlling axial movement within the transmission, preventing excessive wear, and maintaining precise tolerances.

New Internal Wiring Harness

Modern transmissions rely heavily on electronic controls, and the GM 4L80E Level 4 is no exception. A new internal wiring harness is incorporated to ensure reliable communication between the transmission and the vehicle’s control system. This harness is engineered to handle the demands of high-performance applications, promoting seamless integration.

Solenoids and Sensors for Enhanced Control

Precise control is paramount in high-performance transmissions. The GM 4L80E Level 4 includes several new solenoids and sensors to achieve this:

• Manifold Pressure Switch

This switch monitors the intake manifold pressure and assists in determining the optimal shift points, enhancing overall performance.

• EPC Solenoid

The Electronic Pressure Control (EPC) solenoid regulates transmission line pressure, ensuring that shifts are crisp and efficient.

• PWM Solenoid

The Pulse Width Modulation (PWM) solenoid plays a crucial role in controlling torque converter lock-up, contributing to improved fuel efficiency and performance.

• Input & Output Speed Sensors

These sensors provide essential data to the transmission control module, facilitating precise gear selection and shift timing.

• 1-2 Shift Solenoid and 3-4 Shift Solenoid

These solenoids govern the engagement of gears, ensuring smooth transitions between gears.

Enhanced Clutch Assemblies

The purpose of enhanced clutch assemblies is to handle the increased power and torque of the Level 4 transmission; several clutch assemblies have been upgraded:

• Expanded Capacity Forward Clutch Drum

This component allows for greater clutch engagement, accommodating the increased power output.

• Extra Capacity Second Gear Clutch Assembly

The second gear is reinforced to handle elevated performance levels, providing durability and reliability.

• Expanded Capacity Third Clutch Drum

The third clutch drum is also expanded to ensure it can handle the power while maintaining performance.

Upgraded Shafts and Pistons

Power transmission through the transmission’s internals is made possible by the following upgrades:

• Heat-Treated Input Shaft

This heat-treated input shaft is designed to withstand immense torque levels, preventing deformation and ensuring longevity.

• 300M Main Shaft

The 300M main shaft is renowned for its strength and durability, making it a critical component in the Level 4 transmission.

• 300M Forward Clutch Hub

The forward clutch hub is also constructed from 300M steel, enhancing its capacity to handle power.

• Updated Molded Steel Direct Clutch Piston

The direct clutch piston is reinforced with molded steel, providing greater durability and longevity.

• Updated Reverse Band

The reverse band is upgraded to handle the demands of high-performance driving, ensuring reliable reverse gear engagement.

Additional Performance Enhancements

The GM 4L80E Level 4 transmission is not just a mere assembly of parts; it’s a meticulously crafted engineering marvel. Within its robust framework, several strategically selected additional components have been integrated to push its performance capabilities to the absolute limit.

Supplementary Components

These supplementary components serve as the transmission’s backbone, enhancing its ability to handle the immense power and torque levels demanded by high-performance applications. They are the unsung heroes working harmoniously with the core components, ensuring the transmission’s exceptional performance and reliability.

Among these critical enhancements include a new Low Roller Assembly, a Wide Kickdown Band with a New Apply Piston, a Heavy Duty Intermediate Sprag, an Updated Boost Valve, Updated TCC Regulator Valve, and Line to Lube Pressure Regulator Valve.

Collectively, these additional components elevate the GM 4L80E Level 4 transmission to the pinnacle of high-performance transmission technology, delivering a driving experience that combines power, precision, and reliability for enthusiasts who demand nothing but the best.

The GM 4L80E Level 4 transmission is equipped with several additional components to maximize its performance capabilities:

• New Low Roller Assembly

The low roller assembly contributes to smooth and efficient gear engagement, especially in lower gears.

• Wide Kickdown Band w/New Apply Piston

The wide kickdown band ensures that downshifts are responsive and effective, allowing the transmission to adapt to various driving conditions.

• Heavy Duty Intermediate Sprag

The intermediate sprag is reinforced to prevent slipping and provide consistent performance.

• Updated Boost Valve

The boost valve enhances line pressure control, ensuring that shifts are firm and precise.

• Updated TCC Regulator Valve

The Torque Converter Clutch (TCC) regulator valve is updated to improve lock-up control and fuel efficiency.

Blue Printed Pump & Valve Body

The pump and valve body are meticulously blueprinted to exacting standards. This process ensures that hydraulic fluid is delivered precisely to the transmission’s components, guaranteeing optimal performance and durability.

Transmission Mount and OEM Steel Pan

To ensure secure installation and support, a transmission mount is included in the Level 4 package. Additionally, a new OEM steel pan is provided, enhancing the transmission’s structural integrity and overall performance.

Concluding Comments

The GM 4L80E Performance Transmission Level 4 by Gearstar represents the pinnacle of performance and durability in the automotive industry. With its ability to handle 800 horsepower and up to 700 ft-lbs of torque, it is the perfect choice for enthusiasts seeking to unlock the full potential of their vehicles.

Footnotes

The meticulous selection of components, from the custom-built converter to the upgraded clutch assemblies and solenoids, ensures that this transmission can withstand the demands of high performance driving while delivering smooth and precise shifts.

Whether you are on the track or the street, the GM 4L80E Level 4 transmission is ready to take your driving experience to a new level of performance and excitement.