getting parts and tools to rebuild my e40d in a 96 PSD 4x4, what tools are you guys buying to make rebuilding these easier, can you list where you got it and how much.

i'm interested in rebuilding my tranny on a new rig i'm hopefully gonna pick up tomorrow too

I have several Snap on trans rebuild kits. Two of them are no longer available. Rebuilding an e4od is a pretty straight forward job as far as the actual parts replacement goes. BUT the e4od has many design flaws and inherent weaknesses, this is where it gets interesting. They have inadequate pump volume, inadequate rear planetary lubrication, the planetary "cages" are made of aluminum, tail housing is aluminum on the 4wd version, center bearing support is a poor design, valve body shifting is too soft, t/converter is marginal at best. etc. etc. The top builders have many of these parts custom made, and can't be purchased. For gas engines some of these parts are OK but not for a diesel. If doing your own rebuild buy the Suncoast master rebuild kit, and tugger shift kit, along with either a Suncoast converter or a Precession Industries Stallion converter. This combination will get you going in the right direction. I do not know of anybody else selling a good quality rebuild kit. I do know of a few real good builders if you want to just have it done right the first time. They are not cheap but well worth the money.
http://www.converter.com/
http://www.suncoastconverters.com/

6 pinion steel planetaries can be found in the diesel 4r100's, and possible the diesel e40d's. Also, the 4r100 tailhousings are cast iron. Should be a bolt on.

Brians Truck Shop does a good tranny, I think they'll sell kits.

You can also buy a kit to do your own monster box.

Like was already said, it's pretty straight forward. A seal installer kit for your tranny is a worthwhile buy.

Yes the iron tail housing from a 4r100 is a bolt on upgrade. The stock steel 4r100 planetary cages are still not strong enough. In my BTS 4r100 Brian used chromemolly planetary cages and input, output shafts. BTS does not sell any of his parts, except for valve bodies. But you can buy a Stallion t/converter from Precession which is the company that makes them for BTS. MonsterBox has been having some very serious quality control issues lately, and they are flat out refusing to honor the warranty so thats why I did not mention them. I can say from my own experience that BTS is the best builder of e4od/4r100 transmissions in the USA. They are worth every penny. I simply could not have done a better job myself, thats why I bought one of his trannies. There are a few other good builders but I don't have first hand experience with their products.
http://www.brianstruckshop.com/index.html