:smoking:Zerone, whats your beef with the BTR box? I know they wont handle big power, but I find mine better to drive than the rubbish 6 speed auto Holden use. I know you can program the 6 speed, but do we need 6 gears with the modern power?
Hahaha....
The transmission guy that worked on my (and most of my friends) BTR boxes told me that there are ever only three types of BTR/ION transmission owners,
1) Ones that regularly replace their BTR Transmissions,
2) Ones that rebuild their boxes so as they no longer have to replace their BTR boxes, and
3) Ones that have converted to a manual box.
The problem is not that they cant handle big power, the problem is that most of the time they cant handle stock power outputs !
Their biggest problem is temperature. If they overheat, they fry the internal wiring, which causes solenoids to stop doing their thing, and bands to wear out very very quickly.
I had my original BTR box for 11 years, which means like yourself, I fell in to the second category. (I had a heavy duty external oil cooler fitted, an adjustable S5 solenoid (mechanical shift kit), bearings and a couple other things adjusted and upgraded.
The BTR89 was behind the 8 ball when it was introduced an the 91 EA Series III, (It wasn't released with the 88 EAs as BTR and Ford were having serious calibration issues with shift feel and quality).
The EEC-V helped with the shift feel purely through processing power (Not through any mechanical refinement),
The AUs brought about "some" of the overheating issues through the use of a much larger integrated trans oil cooler on the radiator, as well thicker walls separating the coolant from the oil to stop induced heat from the motor. (Though an external trans cooler was recommended for V8s and any Falc that was to tow a load, or was taxi / police spec).
As for BAs, the BA was/is a f@#$ing brilliant car, even despite the BTR transmission fitted...
The ZF transmission was the best thing Ford did to the BFII (Look at the difference in resale values between 4 Speed and 6 Speed BF/BFII)
I even worked for a Taxi rank in Sydney around 2003 for a few months.
They had a stock pile of old Borg Warner 3 speeds (Think XF/EA) that they were fitting to EF/EL/AU taxis, because they didnt have to replace the boxes.
At one stage because of the demand for used Borg Warner 3 speeds, they were harder and more expensive to source than reconditioned BTR93/BTR95 4 speeds.
Some more Ford History,
around the time that the BA was released, BTR demoed their 6 speed auto box to both Ford and Holden.
Ford fitted a couple to some test mules, and decided that the box was too rough, couldnt handle the Boss and XR6Ts torque, and needed too much calibration to make the thing smooth. (They were already heading down the path of testing ZF transmissions for the BFII).
Holden apparently hooked the thing up to an electric motor, gave it a few turns, then put the thing in the corner of a warehouse somewhere.