The SunCoast Category 3 4R100 Transmission Rebuild Kit has everything listed in our Category 2 4R100 Transmission Rebuild Kit, with the addition of our Billet Forward Clutch Drum.

The 4R Platform

The 4R100 transmission replaced the E40D transmission for the 1999 year model and was mated to the 7.3L Power Stroke diesel through the 2003 model year Ford trucks. The 4R100 proved to be a fairly reliable transmission in stock performance levels, however, once power adders are introduced the transmission, becomes the weak link in the drivetrain.

This electronically controlled overdriven unit boasts a first gear ratio of 2.71:1 and a second of 1.54:1, which makes it great for towing and hauling with a .71, overdrive fuel economy is also improved.

The Clutch Kit

This new 4R100 rebuild kit includes Alto Red Eagle clutches along with Kolene steels.

Red Eagle Friction is the go-to material for most performance applications. The lining has a unique dual-saturation, which imparts high friction coefficients and high heat resistance. Red Eagle clutches are designed to limit the amount of "slip" by providing a shorter lock-up time, generating less heat.

The proprietary process starts with the friction paper saturated in a phenolic resin, cured, and then saturated a second time in a silicate. The silicate imparts high heat resistance.

Red Eagle clutches:

Are designed with a softer, more resilient base paper.
Assure less wear against opposing steel plates.
Reduce the incidence of steel plates burning and warping.
The Intermediate Sprag

The factory sprag in the 4R100 transmission unit is notorious for failing when exposed to high levels of fatigue. This could include vehicles exposed to heavy towing or hauling or just higher-than-normal torsional fatigue. These factory sprags are typically 24- or 34-element sprags. In all SunCoast builds, these are replaced with heavy-duty 45 element sprags. This is an increase of up to 53% over the factory, offering unmatched performance and ensuring that premature failure does not occur.

Transgo Valve Body Calibration Kit

The valve body is the central nervous system of your transmission. Everything that transpires within the unit begins here. In our SunCoast builds, we exclusively use the TransGo HD2 Tugger Kit. This valve body calibration kit is perfect for exhaust braking and doubles the low clutch holding pressure in manual first gear for reliable downhill braking. You also have the ability to adjust shift firmness to your desired preferences. With the improved converter feed capacity, you benefit from better cooling and lubrication.

Corrects/Prevents/Reduces:

Codes 628, P1740, P1744
Soft shifts
2nd and 3rd burn-up
Converter burn-up
Reverse delay
No reverse hot
Converter slide/shudder
Pump buzz
Also Includes:

Pressure regulator boost valve
1-2 shift valve spring
Line regulator valve
Innovative line-to-lube components
High temp direct clutch seal
Coast clutch HD snap ring
OD housing spiral lock snap ring
An updated direct clutch outer seal
Calibration plate for firmness adjustments
Quick-fill valve
L/R mod boost valve
New Solenoid Pack

The 4R100 is equipped with a solenoid pack that controls shifting from gear to gear. This solenoid pack is comprised of electromagnetic solenoids. The integrity of these solenoids is imperative, as the flow rate and spray pattern could affect shift quality and clutch life. When failure occurs within the unit, it is not uncommon that the same particles and sediments you find in the bottom of the pan are also in the solenoids. This contamination of the solenoids can and will affect the fluid delivery to critical circuits within the unit.

In this SunCoast 4R100 rebuild, kit we replace the solenoid pack with a new one to ensure consistent shifts and long clutch life.

New Bushing Kit

As with any standard rebuild, this 4R100 rebuild kit also includes a new bushing kit, which also includes a new front pump bushing.

Intermediate Band

This SunCoast Category 4R100 Rebuild Kit also includes a new carbon fiber band. This band is used in manual second gear and during downshift engine braking. The carbon fiber material in this band is made to withstand a much higher heat range versus the factory material.

The Input Shaft

The input shaft on the 4R platform has always been the first weak link to bear its head once additional horsepower is applied. In this Category kit the factory shaft is replaced with our 300 Maraging Billet Input Shaft.

The Forward Drum Upgrade

The Ford 4R100 forward drum has been a sore spot for many 4R100 owners for quite a few years. These issues date back to the earlier C-6 and E40D platforms with repeated spline failures and snap ring blowouts. In this SunCoast Category 4R100 Transmission Rebuild Kit, the factory forward drum is replaced with a new billet one. The 4R100 billet forward drum is manufactured from 4140 heat treated stress relieved billet steel. This new drum corrects and eliminates the common issues with spline failure and snap ring blowouts.

The Torque Converter

This Category 1 SunCoast Torque Converter fits all 4R100 transmissions and is engineered to handle all of your everyday duties. Whether you're towing a camper or hauling dirt to a job site, this torque converter is designed to improve vehicle response and give you years of solid, reliable performance. It comes with furnace-brazed fins and hardened turbine splines. The clutches in this converter are carbon-graphitic for precise and accurate lock-up.

If you're looking to increase the performance of the factory unit and looking for a cost-effective solution, this is the converter for you. This converter, while great for heavy-duty towing and hauling, is not intended for racing.

KIT INCLUDES THE FOLLOWING:

Alto High Performance Clutch Kit
Alto High Performance Steel Module
Overhaul Kit
New Filter
New Bushing Kit
Transgo Tugger Kit
New Solenoid Pack
New Heavy Duty 45 Element Sprag
New High Performance Intermediate Band
Billet 300 Maraging Input Shaft
Billet Forward Clutch Drum
SunCoast Category 1 Triple Disc Billet Torque Converter

Features:

• Billet Lockup Apply Piston
• CNC-Machined Billet Steel Cover
• Balloon Plate
• 4140 Turbine Splines
• 4140 Hardened Hub
• 3 Carbon-Graphitic Clutch Discs
• Furnaced-Brazed Fins
• Torrington Thrust Bearing Stator Design
• Pressurized Hot Soak Leak Testing
• Computer-Balanced to Within .01 Gram
• Precision-Assembled by Caring American Workers

Fitment:

• Ford E-250 Econoline Club Wagon 1998-2003
• Ford E-350 Club Wagon 1998-2003
• Ford E-350 Econoline Club Wagon 1998-2003
• Ford E-350 Econoline 1998-2003
• Ford E-350 Super Duty 1998-2003
• Ford E-450 Econoline Super Duty 1998-2003
• Ford E-450 Super Duty 1998-2003
• Ford F Super Duty 1998-2003
• Ford F-250 HD 1998-2003
• Ford F-250 Super Duty 1998-2003
• Ford F-250 1998-2003
• Ford F-350 Super Duty 1998-2003
• Ford F-350 1998-2003
• Ford F-450 Super Duty 1998-2003