Re: Rebuild help on 1993 E150 5.8L/E40d trans
The E4OD had some upgrades in 1996 so you'll want to incorporate those. The main one I believe is an internal support of the rotating parts. It's a heavy trans but with good cooling, updates, and reprogramming, it will work well. You'll need a bit higher stall converter to handle a cam that will support your stated power goal.
I think you can make real good torque with AFR 185s and a mild cam. It will actually feel much better to drive than a stock-stroke 351w that actually does make an honest 400 hp. I do think 9.5:1 compression ratio is a better target as well. A mild higher stall converter is still going to help get that barn moving.
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