A number of SD40-2s have been rebuilt into other models. Some of the most unusual are the
metre gauge BB40-2s for use in Brazil. Conversely, several other models of EMD locomotive have sometimes been rebuilt to SD40-2 standards, including the
SD40,
SD45 and
SD45-2. Normally, this consists of electrical upgrades (-2) and replacing the 20-cylinder prime mover with a 16-cylinder version, often built for
GE Capital in Poland using EMD's manufacturing drawings and specifications. An outgrowth of this may be
GE Transportation's second-sourcing of EMD repair parts. The unusually troublesome
SD50 have also been rebuilt into the equivalent of SD40-2s, rather than scrapping them. The 645F block and crankshaft are inherently good designs (indeed, the lessons learned with the 645F became part of the
710G); lowering the rating from at 950 rpm to at 900 rpm solved the mechanical and electrical reliability issues.
SD40N Union Pacific has rebuilt 486 of their SD40-2's into SD40N's at their Jenk's shop. These units received a microprocessor control system to increase adhesion, control options, and extend the life of the locomotive.
SD40-3 The Dash 3 suffix is not part of any official lineup, and is a loose designation for rebuilt Dash 2 series EMDs among several different railroads. One example of an SD40-3 rebuild program is the one conducted by
CSX at its Huntington, WV Shops. It started in 2010 with 10 units upgraded and numbered 4000-4009; in 2011, 20 units went through the program and were numbered 4010-4029 and in 2012 another 20 units followed and were numbered 4030-4049. One of the most notable rebuilds was SD40-2
8888, (now rebuilt to 4389), which in 2001 was involved in a runaway incident caused by the failure of the engineer to notice the train gradually accelerating during yard switching. These locomotives feature new cabs, air conditioning systems, and other new technologies. Norfolk Southern also has an ongoing SD40-3 rebuild program as of 2023.
SD22ECO The
SD22ECO is an EMD SD40-2 or similar, repowered with an EMD 8-710-ECO engine. The resulting locomotive is rated at , and meets EPA Tier II emissions regulations.
SD30C-ECO The
SD30C-ECO is an EMD SD40-2 re-powered with an EMD 12-710 prime mover. The locomotive is rated at and meets EPA Tier 0 emissions regulations. A similar rebuild, the
SD40E3 was carried out by CSX in early 2017.
ET23DCM ET23DCM (SD23T4) locomotive in Worcester, Massachusetts The
ET23DCM is an EMD SD40-2 rebuilt by
Wabtec, and repowered with a
GE Evolution Series Inline 6 cylinder prime mover. This locomotive meets the EPA Tier 4 emission standards. CSX has ordered 15 locomotives, and Wabtec constructed one demonstrator locomotive. == Preservation ==