E4OD Shudder [Archive] - FSB Forums

: E4OD Shudder


csa900
01-08-2007, 07:01 PM
I'm contemplating the Transgo HD2 for my E4OD when I drop the pan to change filter and gasket. My 91 Bronco has 93,000 miles on it, unknown maintenance schedule by PO. However, the fluid is clean and shifts perfect (although soft for my taste) from 1 - 2 and 2-3. Ocassionally I get a real lazy 3 to od shift, particularly at mid throttle. Can anyone confirm the shift kit fixing this? It's kinda hard to diagnose since it only does it occasionally. Also, thhe Transgo kit refers to Torque Converter Shudder. At 45-50 mph, my truck almost feels like it has a miss. The truck seems confused as to what gear it should be in as (I assume) it is locking and unlocking the TC? Any experience with this problem?

Thanks in advance!

fairlane_68
01-08-2007, 08:57 PM
Try draining the fluid out of the pan and torque converter. E4OD's are notorious for shuddering, and Ford narrowed it down to the torque converter. It's the result of old fluid. Hence, the manufacturer's recommendation to have the tranny flushed every 30K miles.

csa900
01-08-2007, 09:05 PM
Thanks

Bronco4Life
01-08-2007, 10:16 PM
Hence, the manufacturer's recommendation to have the tranny flushed every 30K miles.

Whoa, got a link to the TSB for that?

csa900
01-12-2009, 10:08 PM
I apologize for digging up an old thread, but I ran across my own thread when searching. My shudder problem is corrected since I did a few fluid changes and added a trans cooler and external filter. I now have 112,000 miles on my truck. Fluid stays perfectly clean, transmission performs almost perfect except for the occasional lazy shift from 3rd to OD. Pulled codes and I get a 311, which is correct because previous owner pulled thermactor equip. Thanks in advance for any input.

davepthomas
01-12-2009, 10:34 PM
hmmm.....interesting. i just changed the tranny fluid & filter in my '96 (E4OD) and i get an occasional shudder when i give it gas and it seems like it wants to downshift, but can't make up it's mind. i'm wondering if i used a different tranny fluid from what was in it

DNBELOWBRONCO
01-12-2009, 10:51 PM
Should be regular Mercon but I guess Ford says you can use MercV (synthetic) now! I myself think I'll just stay with reg Mercon for now, haven't had any problems as of yet...:thumbup-Kevin-

mikelaubach
02-09-2009, 02:03 AM
Should be regular Mercon but I guess Ford says you can use MercV (synthetic) now! I myself think I'll just stay with reg Mercon for now, haven't had any problems as of yet...:thumbup-Kevin-


Where are you finding Mercon (original) a year and a half after it was discontinued? My area dried up long ago.

--MIKE--

Need4racin
02-09-2009, 02:06 AM
advanced auto, DEX/MERC, $11 a 4 Quart jug.

csa900
05-27-2011, 09:19 AM
Well, I finally got around to doing something about my transmission (see my original start to this post).
Due to the research I did on this site, I passed on doing the TransGo kit, and instead purchased a street mod valve body from Paul's Clutch Boxes (search "Punisher Valve Body" on FSB.com.)
This is the single best mod I have done to my truck. All of my tranny issues are resolved, and the shifts are phenomenal. And Paul is fantastic to deal with.
If you have an E4OD in your truck, I would highly recommend you talk to Paul about his valve body for it.
For the record, my lazy shift got worse over time due to an issue with the original valve body.

miesk5
05-28-2011, 10:47 AM
yo,
Good stuff csa!

And for posterity;
MERCONŽ is being replaced by MERCONŽ V as a Service Fluid TSB 06-14-04 for 80-96 Bronco & all Fords to Current
FORD: 1980-1997 Crown Victoria
1981-1997 Mustang, Thunderbird
1981-2003 Escort
1986-1993 Festiva
1986-1997 Taurus
1989-1997 Probe
1994-1997 Aspire
1995-2000 Contour
1980-1996 Bronco
1981-2003 F-150
1981-2004 E-Series, F-Super Duty
1983-1996 Ranger
1986-1996 Aerostar
1991-1997 Explorer
1993-2004 F-53 Motorhome Chassis
1995-1998 Windstar
1997-2004 Expedition
2000-2005 Excursion
2001-2007 Escape
1987-2000 F- & B-Series
2000-2007 F-650, F-750
LINCOLN: 1980-1997 Town Car
1981-1997 Continental
1993-1997 Mark VIII
1998-2004 Navigator
2002-2003 Blackwood
MERCURY: 1980-1997 Grand Marquis
1981-1997 Cougar
1986-1997 Sable
1987-1999 Tracer
1995-2000 Mystique
1999-2002 Cougar
1993-2002 Villager
1997 Mountaineer
2005-2007 Mariner
MERKUR: 1985-1989 XR4TI

This article supersedes TSB 01-15-07 to update the vehicle application chart.

ISSUE: MERCONŽ Automatic Transmission Fluid is being replaced by MERCONŽ V as a service fluid.

ACTION: Beginning immediately all automatic transmission / transaxle applications requiring MERCONŽ can now be serviced using MERCONŽ V or MERCONŽ Automatic Transmission Fluid or dual usage fluids labeled MERCONŽ / MERCONŽ V. After July 1, 2007, MERCONŽ Automatic Transmission Fluid will no longer be manufactured, therefore, availability of this fluid will only continue for however long it takes to deplete what remains in inventory.

SERVICE PROCEDURE
Service automatic transmissions requiring MERCONŽ with MERCONŽ V or MERCONŽ Automatic Transmission Fluid or dual usage fluids labeled MERCONŽ / MERCONŽ V. For proper fluid application on current and past model vehicles equipped with automatic transmissions / transaxles refer to the fluid usage chart.
CAUTION: AUTOMATIC TRANSMISSIONS / TRANSAXLES THAT REQUIRE MERCONŽ V SHOULD STILL ONLY USE MERCONŽ V OR DUAL USAGE FLUID LABELED MERCONŽ / MERCONŽ V.
CAUTION: MERCONŽ SP, MOTORCRAFT PREMIUM AUTOMATIC TRANSMISSION FLUID AND MOTORCRAFT M5 ATFS ARE UNIQUE FLUIDS AND MUST BE USED IN APPLICATIONS RECOMMENDING THAT PARTICULAR FLUID. USE OF ANY OTHER FLUID MAY CAUSE REDUCED FUNCTIONALITY OR TRANSMISSION DAMAGE.
CAUTION: THE FUNCTIONAL CHARACTERISTICS OF FLUIDS FOR CVT TRANSMISSIONS ARE VERY DIFFERENT THAN THOSE OF OTHER AUTOMATIC TRANSMISSION FLUIDS (ATFS). USE OF A FLUID OTHER THAN MOTORCRAFT CONTINUOUSLY VARIABLE CHAIN TYPE TRANSMISSION FLUID OR ONE LABELED AS MEETING MERCONŽ C WILL CAUSE FUNCTIONALITY CONCERNS AND
INTERNAL TRANSMISSION DAMAGE.
CAUTION: DO NOT USE AUTOMATIC TRANSMISSION FLUID SUPPLEMENTS, ADDITIVES, TREATMENTS OR CLEANING AGENTS.

PART NUMBER PART NAME
XT-2-QDX MERCONŽ (Quart)
XT-2-DDX MERCONŽ (55 Gal. Drum)
XT-5-QM MERCONŽ V (Quart)
XT-5-DM MERCONŽ V (55 Gal. Drum)

----

I have a post here on the level check frommy 96's owner's guide, for hot and cold level readings. Here it is from Workshop Manual for 96
Check Fluid Level and Condition

Fluid Level Check
MERCONŽ is being replaced by MERCONŽ V as a Service Fluid TSB 06-14-04 for 80-96 Bronco & all Fords to Current
ACTION: Beginning immediately all automatic transmission / transaxle applications requiring MERCONŽ can now be serviced using MERCONŽ V or MERCONŽ Automatic Transmission Fluid or dual usage fluids labeled MERCONŽ / MERCONŽ V. After July 1, 2007, MERCONŽ Automatic Transmission Fluid will no longer be manufactured, therefore, availability of this fluid will only continue for however long it takes to deplete what remains in inventory.

SERVICE PROCEDURE

Service automatic transmissions requiring MERCONŽ with MERCONŽ V or MERCONŽ Automatic Transmission Fluid or dual usage fluids labeled MERCONŽ / MERCONŽ V


CAUTION: Vehicles equipped with 4x4 applications must have the 4x4 gearshift selector lever in any position other than neutral.

NOTE: If the vehicle has been operating for an extended period at high speeds or in city traffic during hot weather, or pulling a trailer, the vehicle should be turned off for about 30 minutes to allow the fluid to cool before checking.



Under normal circumstances, you do not need to check the fluid level of the transmission, since the vehicle does not use up transmission fluid. However, if the transmission is not working properly, for instance, the transmission may slip or shift slowly, or if you notice some sign of fluid leakage, the fluid level should be checked.

It is preferable to check the transmission fluid level at normal operating temperature after approximately 32 km (20 miles) of driving. However, if necessary, you can check the fluid level without having to drive 32 km (20 miles) to obtain a normal operating temperature if outside temperature is above 10°C (50°F).

With the vehicle on a level surface, start the engine and move the transmission gearshift selector lever through all of the gear ranges allowing sufficient time for each position to engage. Securely engage the transmission gearshift selector lever in the park position, fully set the parking brake control (2780) and leave the engine running.

Wipe off the fluid level indicator cap, pull thefluid level indicator (7A020) out and wipe the indicator end clean. Put the fluid level indicator back into the fluid filler tube and make sure it is fully seated. Pull the fluid level indicator out and read the fluid level.

CAUTION: The vehicle should not be driven if the fluid level is below the bottom hole on the fluid level indicator and outside temperature is above 10°C (50°F).

When checking fluid at normal operating temperature, the fluid level should be within the crosshatched area or HOT marked area on the fluid level indicator. When the vehicle has not been driven, and outside temperature is above 10°C (50°F), the fluid level should be between the holes or COLD marked area on the fluid level indicator.

http://www.thedieselstop.com/faq/9497faq/maint/stj/images/dd0618a.gif
http://www.thedieselstop.com/faq/9497faq/maint/stj/images/d17102a.gif

High or Low Fluid Level

A fluid level that is too high may cause the fluid to become aerated due to the churning action of the rotating parts of the transmission. Aerated fluid will cause erratic control pressure, that may result in harsh/soft shifts or engagements, damage to the clutch materials, improper torque converter operation, and the aerated fluid may be forced from the vent (7034). If fluid level is high, excess fluid MUST be removed. Refer to Fluid Change — Drain/Refill under Verification of Condition in the Diagnosis and Testing portion of this section.

A fluid level that is too low will affect transmission operation, such as: slipping, slow engagements, damage to internal hardware. Low level may indicate fluid leaks that may cause transmission damage. If fluid level is low, refer to the following procedure.

Adding Fluid

Only Motorcraft MERCONŽ Multi-Purpose Automatic Transmission Fluid XT-2-QDX or MERCONŽ equivalent should be used in all Ford automatic transmissions. Before adding any fluid, be sure that the correct type will be used.

Add fluid in 0.24L (0.5 pint) increments through the fluid filler tube to bring the level to the correct area on the fluid level indicator. If an overfill occurs, excess fluid must be removed.

Fluid Change — Drain/Refill

Normal maintenance and lubrication requirements do not necessitate periodic automatic transmission fluid changes. If a major service, such as a clutch, band, bearing, etc., is required in the transmission, it will have to be removed for service. At this time, the converter, transmission cooler and cooler lines must be thoroughly flushed to remove any contamination.

CAUTION: Use only MERCONŽ service fluid as the use of any other fluids may result in a transmission malfunction or failure.

There is no scheduled automatic transmission fluid change requirement for E4OD transmissions, except for conditions listed below. Transmission fluid level should be checked when performing other maintenance service and adjusted to specified levels.

The automatic transmission fluid, filter and seal assembly should be changed every 33795 km (21,000 miles) under any of the following conditions:

Sustained high speed driving during hot weather at or above +32°C (+90°F)
Towing a trailer for distances over 1609 km (1,000 miles)
Accumulating 8047 km (5,000 miles) or more per month
Continuous running service.
When filling a dry transmission and converter start with a minimum of 6.2 liters (6.5 quarts). Refer to Specifications in this section for capacity. Check the fluid level.
Loosen, then remove the transmission fluid pan attaching bolts to drain fluid.

CAUTION: Cork gaskets and elastomeric gaskets are not interchangeable. If you remove a cork gasket, replace it with a cork gasket. If you remove an elastomeric gasket, clean, inspect and reuse unless gasket is damaged. Be careful not to cut or bend elastomeric gasket.

Remove transmission pan gasket. If transmission is equipped with a cork gasket, discard it. If transmission is equipped with the new elastomeric reusable gasket, clean, inspect and reuse unless damaged.



Perform required internal repair and cleaning.

Drain the torque converter by removing drain plug.

Thoroughly flush torque converter (7902), cooler lines and transmission in-tank radiator cooler and auxiliary cooler (if equipped).

After torque converter has been drained, install new torque converter drain plug and tighten to 24-27 Nm (18-20 lb-ft).

CAUTION: Mixing 4x4 and 4x2 transmission fluid filters and transmission pan assembly components could cause transmission damage.

Select the appropriate style filter assembly and transmission pan for either 4x2 or 4x4 models.

http://www.thedieselstop.com/faq/9497faq/maint/stj/images/d16541a.gif

CAUTION: Cork gaskets and elastomeric gaskets are not interchangeable. If you remove a cork gasket, replace it with a cork gasket. If you remove an elastomeric gasket, clean, inspect and reuse unless gasket is damaged. Be careful not to cut or bend elastomeric gasket.

NOTE: A unique transmission pan and pan retaining bolts are required to use the new elastomeric gasket for past model service. The cork style gasket will be retained for past model service where a new transmission pan is not required. If the transmission pan is damaged and requires replacement, a kit will be available. This kit will contain a transmission pan, elastomeric gasket and 20 pan bolts having an increased thread length to accommodate current and past model usage.

http://www.thedieselstop.com/faq/9497faq/maint/stj/images/dd0611a.gif

If transmission is equipped with a cork gasket, discard it and install a new gasket. If transmission is equipped with the new elastomeric reusable gasket, clean, inspect and reuse unless damaged.


Start engine. Move the transmission range selector lever through all gear ranges, checking for engagements.

Check and adjust the transmission fluid level in 0.24 liter (0.5 pint) increments to the proper level (crosshatched area of the fluid level indicator at normal operating temperatures).

Fluid Condition Check

Make the normal fluid level check. Refer to Fluid Level Check under Verification of Condition in the Diagnosis and Testing portion of this section.

Observe color and odor of the fluid. It should be red, not brown or black. Odor may indicate overheating condition, clutch disc or band failure.

Use an absorbent white facial tissue and wipe the fluid level indicator. Examine the stain for evidence of solid particles and for engine coolant signs (gum or varnish on fluid level indicator).

If particles are present in the fluid or there is evidence of engine coolant or water, the transmission pan must be removed for further inspection.
If fluid contamination or transmission failure is confirmed by further evidence of coolant or excessive particles in the transmission pan, the transmission must be disassembled and completely cleaned and serviced. This includes cleaning and flushing the torque converter and transmission cooling system. Repair or replace radiator.
During disassembly and assembly, all overhaul checks and adjustments of clearances and end play must be made.
After the transmission has been serviced, all diagnostic tests and adjustments listed in the Diagnosis by Symptom Charts under Diagnosis by Symptom in the Diagnosis and Testing portion of this section must be completed to make sure that the problem has been corrected.

Road Testing Vehicle

The following Shift Point Road Test and Torque Converter Operation Test provide diagnostic information on transmission shift controls and torque converter operation.

Shift Point Road Test

This test verifies that the shift control system is operating properly.

Bring engine and transmission up to normal operating temperature.

Operate the vehicle with the gearshift selector lever in (D) range.

Apply minimum throttle and observe the speeds at which the upshift occurs and the torque converter engages. (Refer to Automatic Transmission Special Specification Bulletin FPS-12180-96 for actual speed.)
E4OD APPLICATIONS SHIFT SPEEDS — APPROXIMATE* MPH
http://www.thedieselstop.com/faq/9497faq/maint/stj/stj71a13.htm#extract_1003

*(1) Nominal shift speed at sea level is shown. Actual shift speed will depend on tire brand, size and axle ratio. Refer to Automatic Transmission Special Specification Bulletin FPS-12180-96 for actual speeds.

D is the same as (D) with the transmission control switch actuated (light on).



With the vehicle in OVERDRIVE (fourth gear), depress the transmission control switch. The transmission should downshift to third gear. Remove foot from accelerator pedal; engine braking should occur.

Press accelerator pedal to floor (wide-open throttle). Transmission should shift from 3rd to 2nd gear, or 3rd to 1st depending on vehicle speed. Torque converter clutch should disengage and then reapply.

With vehicle (D) range above 80 km/h (50 mph) and less than half throttle, move the transmission gearshift selector lever from (D) range to manual 2 range and remove foot from accelerator pedal. The transmission should immediately downshift into second gear. With the vehicle remaining in manual 2 range, move transmission gearshift selector lever into manual 1 range, and release accelerator pedal. Transmission should downshift into 1st gear at speeds BELOW 48-56 km/h (30-35 mph).

If transmission fails to upshift/downshift or torque converter clutch does not apply and release, refer to Diagnosis by Symptom Index under Diagnosis by Symptom in the Diagnosis and Testing portion of this section for concern diagnosis.

Torque Converter Operation Test

This test verifies the torque converter clutch control system and the torque converter are operating properly.

Perform Quick Test as stated in the Powertrain Control/Emissions Diagnosis Manual OBDI or OBDII. Check for a code 628, 629, 652, P0741, P0743, P1742, P1744, P1743. Refer to Pinpoint Tests in the Diagnosis and Testing portion of this section for diagnosis.

Connect a tachometer to the engine.

Bring engine to normal operating temperature by driving the vehicle at highway speeds for approximately 15 minutes in (D) range.

After normal operating temperatures are reached, maintain a constant vehicle speed of about 80 km/h (50 mph), and tap the brake pedal (2455) with the left foot.

Engine rpm should increase when the brake pedal is tapped, and decrease about five seconds after the brake pedal is released. If this does not occur, refer to Torque Converter Operation Concerns in the Diagnosis by Symptom Index under Diagnosis by Symptom in the Diagnosis and Testing portion of this section.

If the vehicle stalls in (D) at idle with the vehicle at a stop, move the gearshift selector lever to the manual 1 position. If the vehicle stalls, the cause may be the converter control valve in the pump. Service as required. If the vehicle doesn't stall in manual 1, refer to the Electrical Diagnosis in the Powertrain Control/Emissions Diagnosis Manual OBDI or OBDII for powertrain control module (PCM) (12A650) and Vehicle Harness Diagnosis.


As Ford mentions in my earlier reply...Thoroughly flush torque converter (7902), cooler lines and transmission in-tank radiator cooler and auxiliary cooler (if equipped).
altho you're not replacing major tranny components, it's a good thAng to do.

Cooler Fitting Locations/Flow Direction Front ŧ" Pipe Cooler feed/out Rear ŧ" Pipe Return/in
Source: by TCI Automotive tciauto.com

and consider the Filter, In-Line, Emerging Enterprises, MagnefineŽ or Power Steering XC3Z-7B155-AA Installation Instructions; Ford XC3Z-7B155-AA; this filter is cited in E4OD/4R100 Filter, In-Line Kit TSB 00-23-10 for 89-96
Source: by Emerging Enterprises, MagnefineŽ

http://www.emergingent.com/magnefine/installation_page.htm


Filter, In-Line TSB 00-23-10 for 89-96 Bronco & F Series, etc.
Source: by Ford via by thedieselstop.com pdf (http://www.thedieselstop.com/faq/9497faq/tsb/tsb/files/002310.pdf)

Anafiel
06-01-2011, 06:18 PM
Ok, I'm going to jump in on this thread instead of starting a new one, as the title is completely correct for my issue.

I get a shudder kinda sound/feeling between OD and 3rd. Its not reproducible on demand. Usually is when I'm going up a hill, apply light throttle and downshift from OD to 3rd. I get a slight shudder as third catches.

All other times shifting is fine. Maybe just a little soft compared to the C6 in my '85, but still pretty solid. Fluid is dirty and discolored.

I followed the drive-ability tests Miesk5 provided above to the best of my ability. Upshifts occur at the proper speed/rpm. Manual downshifts brake the engine properly, and are solid. The only deviation I get from the test performed is when I do the TC test. At a steady 45mph, and touching the brake, the RPMs increase just about 100 RPM, and IMMEDIATELY drop back down. The test procedure indicates that the RPM should drop back down after 5 seconds, but my test (performed at least 10 times) had the RPMs dropping back down right away.

Ford indicates that dirty or old fluid can cause/aggravate this symptom. I have no idea how many miles this tranny or fluid have on it as the PO had owned this truck for just a short while. The Odometer clocks 264K. Like I said, fluid is dirty and discolored.

Should I just change the fluids first and see what happens? Does my TC test indicate a failing TC?

To be honest, I'm terrified to change the fluid because of all the horror stories of failed transmissions after a fluid change.

miesk5
06-02-2011, 06:27 AM
yo,
You should edit your Q out here and begin a new thread so we don't get you mixed-up. Because I almost has someone here buy a part that wasn't correct for his year; I got his year confused w/original poster (not that there is an issue with years here for this problem, but...)
Some will say changing the fluid may loosen accumulated varnish deposits that could cause sticking of da valves in
the valve body, etc.
But, others will say it may not be too late to flush it and TC out as well as tranny cooler/and lines, install the in-line filter as Ford advises

Filter, In-Line TSB 00-23-10 for 89-96 Bronco & F Series, etc.
TSB 00-23-10 Transmission Fluid In-Line Filter Kit
Publication Date: NOVEMBER 6, 2000

FORD: 1980-1997 THUNDERBIRD
1980-2001 CROWN VICTORIA
1984-2001 MUSTANG
1985-1990 BRONCO II
1985-2001 RANGER
1987-1997 AEROSTAR
1989-1996 BRONCO
1989-1997 F SUPER DUTY, F-250 HD
1989-2001 ECONOLINE, F-150, F-250 LD, F-350, F-450
1991-2002 EXPLORER
1997-2001 EXPEDITION
1999-2001 F-250 HD, SUPER DUTY F SERIES
2000-2001 EXCURSION
LINCOLN: 1982-2001 TOWN CAR
2000-2001 LS
1998-2001 NAVIGATOR
MERCURY: 1980-2001 GRAND MARQUIS
1987-1997 COUGAR
1997-2002 MOUNTAINEER

ISSUE: Contamination from prior transmission concerns or excess wear may be trapped in the transmission fluid cooling system. This debris must be removed by properly cleaning the transmission cooling system. After cleaning, some contamination may still remain. The remaining contamination may be reintroduced into the fluid cooling system of a repaired/replaced transmission causing premature or repeat failures.

ACTION: After every overhaul or transmission exchange, clean, flush and backflush the transmission fluid cooling system which includes: fluid cooler, auxiliary cooler, cooler lines, and Cooler Bypass Valve (CBV), if equipped. Perform the cooler flow test to ensure proper transmission fluid flow volume on the transmission return line through the cooling system. Once proper fluid flow volume is verified install the Transmission Fluid In-Line Filter Kit (XC3Z-7B155-AA) in the fluid cooler return line (transmission fluid flow coming out of the fluid cooler going into the transmission). Refer to the following Service Procedure for details.

SERVICE PROCEDURE
NOTE: THIS IN-LINE TRANSMISSION FLUID FILTER KIT CAN BE INSTALLED ON ALL TRANSMISSIONS WITH 8mm (5/16") AND 9.5mm (3/8") TRANSMISSION FLUID COOLER LINES.
NOTE: THIS IN-LINE TRANSMISSION FLUID FILTER KIT WILL ALSO BE SUPPLIED WITH ALL E4OD/4R100 AND OTHER FORD QUALITY REMANUFACTURED (FQR) TRANSMISSIONS. AFTER ANY OVERHAUL OR TRANSMISSION EXCHANGE PRIOR TO CONNECTING THE TRANSMISSION FLUID COOLING SYSTEM TO THE TRANSMISSION, FOLLOW THE STEPS BELOW.
1. Clean, flush and backflush transmission fluid cooling system.
NOTE: VEHICLES EQUIPPED WITH STAND-ALONE OIL-TO-AIR (OTA) FLUID COOLERS CANNOT BE PROPERLY FLUSHED. ADDITIONALLY, 1998-2001 CROWN VICTORIA/GRAND MARQUIS AND TOWN CAR HAVE OIL-TO-AIR (OTA) FLUID COOLERS EQUIPPED WITH A TERMINAL BY-PASS VALVE. FOR ALL VEHICLES EQUIPPED WITH STAND-ALONE OTA COOLERS, THE OTA COOLER
MUST BE REPLACED ON EVERY OVERHAUL OR TRANSMISSION EXCHANGE. REFER TO THE APPROPRIATE SERVICE/WORKSHOP MANUAL FOR PROCEDURE
2. Once the fluid cooling system has been cleaned, flushed and backflushed, connect the cooler lines and perform the transmission fluid flow test to ensure proper fluid flow. Refer to the appropriate Service/Workshop Manual for procedure. If proper fluid flow volume is not obtained, refer to appropriate Service/Workshop Manual for repair procedure. The transmission fluid coolers, auxiliary cooler, OTA, cooler lines, CBV (if equipped), transmission fluid pump or internal filter may be restricted or damaged and require replacement.
CAUTION: FAILURE TO FOLLOW THE KIT INSTRUCTIONS MAY CAUSE INTERNAL TRANSMISSION ASSEMBLY DAMAGE AND REPEAT REPAIRS.
3. Only after proper transmission fluid flow volume is present, install the Transmission Fluid In-Line Filter Kit (XC3Z-7B155-AA). Follow the instructions provided with the kit.
4. Once the filter is installed: with the transmission fluid return line disconnected from the transmission, verify fluid flow through the filter. Once the fluid flow in-and-out of the filter is verified, connect the transmission fluid return line to the transmission. Check and adjust proper transmission fluid level to normal operating range at normal operating temperature and check for leaks, kinks and chafe points (refer to the "Do's and Don'ts" chart in the kit instructions).
NOTE: THE FILTER INCLUDED IN THIS KIT WILL ALSO BE AVAILABLE AS A SEPARATE PART (XC3Z-7B155-BA). IT IS RECOMMENDED THAT THIS IN-LINE FILTER BE CHANGED EVERY 48,000 KILOMETERS (30,000 MILES).

PART NUMBER PART NAME
XC3Z-7B155-AA Transmission Fluid In-Line Filter Kit (Complete)
XC3Z-7B155-BA In-Line Filter Only (Separate)

OPERATION DESCRIPTION TIME
002310AB Perform Flow Test And Install In-Line Fluid Filter 0.7 Hr.

002310A Additional Time To Retest Fluid Flow Before Installing
In-Line Filter. (To Be Used Only After Additional Repairs Are Performed) 0.3 Hr.


Filter Clip Alternative; "... have seen many threads and received many pm's as of late speaking of the stay-put filter clip used to keep the filters from falling out of the pump in the e4od. there is an alternative to using this clip. it is more expensive but also has more benefits than just using this clip. you can get a trans pan from a 03 super-duty truck. this pan has little humps in the bottom to but up against the bottom of the filter and this keeps the filter from falling down. this pan also has a drain plug and extra capacity for 1.5 more qts of fluid. this pan also allows you to use the much better elastomer gasket. it is reusable and virtually leak-proof. much better than the cork design. it does require the use of a 4x4 filter..."
Source: by thePUNISHER (Paul) at http://fullsizebronco.com/forum/showthread.php?t=155429

Filter Clip pics in a 96 5.0
Source: by Tony K (Boat Dude, Big Blue) at http://www.supermotors.net/registry/7833/23964


Filter, In-Line, Emerging Enterprises, MagnefineŽ or Power Steering XC3Z-7B155-AA Installation Instructions; Ford XC3Z-7B155-AA; this filter is cited in E4OD/4R100 Filter, In-Line Kit TSB 00-23-10 for 89-96
Source: by Emerging Enterprises, MagnefineŽ http://www.emergingent.com/magnefine/installation_page.htm


Filter, Internal, Grommet Warning; "...When ever you go to change your trans filter, Always make sure to pull out the little round rubber do hicky thingamabob. Lets call it a gromit or a seal? Theres this part of the trans filter that is inserted into the trans (a round tube that goes up into this hole ); Now the tube has a gasket of sorts that wraps around the tube ( kinda like a wide O-ring )It form a seal between the tube and the hole it goes in. Well what ended up killing my trans was that fact that the last guy that changed the trans filter didnt notice that this o-ring thing (gromit Or what ever) did'nt come out with the filter it stayed in the hole! He left it in there; & installed the new filter witch had its preinstalled gromit already; So what he did, is he (unknowingly) stacked two gromits on top of each other, Witch did not let the filters tube fit as it should. It was starving itself for fluid!! It was sucking air as well as tranny fluid! (in other words not working right) ..."
Source: by BlancoBronco (Cam C , Project BLANCO) at http://fullsizebronco.com/forum/showthread.php?t=20560


Fluid & Filter and Ford Pan w/Drain Plug Change and Filter Clip in a 94
Source: by sewiv (Sandy) at http://fullsizebronco.com/forum/showthread.php?t=130945


Fluid Change Interval (scroll); "...For 1995, Ford Motor Company has reduced the mileage interval of automatic transmission fluid changes to 30,000 miles. This applies to all transmissions except the E40D transmission used in Ford trucks. The E40D change interval is 15,000 miles. Ford engineers stated that the intervals were reduced due to fluid degradation especially in humid climates. As you all know, the above-mentioned service intervals are for "normal driving" conditions, severe duty conditions (fleet, city driving, short trips, dusty conditions, hilly areas, towing, snowplowing) require more frequent service. Always change the transmission filter when you change the fluid..." MIESK5 NOTE; fluids should be changed every 21,000 MILES using Ford's Severe Duty Schedule if Towing a trailer or carrying a heavy load. Operating in severe dust conditions. Extensive idling, such as police, taxi or door-to-door delivery service. Snowplowing, Off-Road operation. Short trips of less than 10 miles (16 km) when outside temperatures remain below 0°F (-18°C)
Source: by Bruce R at http://atp-inc.com/Portals/0/tech/95-26.html


Torque Converter Cleaning, Diagnosis Procedure & Replacement Guidelines TSB 96-26-12 for 85-96
ISSUE Torque converter replacement guidelines and torque converter/transmission (or transaxle) cooling system cleaning procedures are now available to reduce repeat repairs.
ACTION Refer to the following guideline to properly diagnose and service torque converters and to properly clean the torque converter and transmission cooling system using forward flushing/backflushing. For diagnosis, service and cleaning, refer to to the appropriate model/year Service Manual, Sections 07-01, 07-02, 03-03, 307-01, 307-02, or 303-03.


Diagnostic Procedure

Prior to torque converter replacement, all diagnostic procedures must be followed. This is to prevent the unnecessary replacement of good torque converters. Only after a complete diagnostic evaluation can the decision be made to replace the torque converter.

The normal diagnostic procedure is as follows:

Premliminary inspection.
Know and understand the customers concern.
Verify the concern:
--Perform the Torque Converter Clutch Operation Test

Perform diagnostic procedures:
Run On-Board Diagnostics
--Repair all non-transmission-related Diagnostic Trouble Codes (DTCs) first.

--Repair all transmission DTCs.

--Rerun On-Board Diagnostic to verify repair.

Perform Line Pressure Test
Perform Stall Speed Test
Diagnosis by Symptom Routines - Use the index to locate the appropriate routine that best describes the symptom(s). The routine will list all possible components that may cause or contribute to the symptom. Check each component listed, diagnose and service as required, before servicing the torque converter.
Service Procedure - Replacement

The torque converter must be replaced if one or more of the following statements are true:

A torque converter malfunction has been determined based on completed diagnostic procedures
A converter stud(s), impeller hub or bushing is damaged
If there is discoloration of the torque converter (due to overheating)
The torque converter is found to be out of specification when performing the following checks (as applicable):
Torque Converter One-way Clutch Check
End Play Check
Stator-to-Turbine Interference Check
Converter Leakage Check
Stator-to-Impeller Interference Check
If there is evidence of transmission assembly or fluid contamination due to the following failure modes:
Torque Converter Replacement Policy Failure Modes
Major metallic failure
Multiple clutches or clutch plate failures
Sufficient component wear which results in metallic contamination

Service Procedure - Torque Converter And Transmission Cooling System Cleaning

When the torque converter is replaced, the following actions must take place:

All cooler lines must be thoroughly cleaned by Back and Forward Flushing using Service Manual procedure.
All coolers (in-tank and auxiliary) must be thoroughly cleaned by Back and Forward Flushing using Service Manual procedure.
All Cooler By-Pass Valves (CBV), if equipped, must be removed and thoroughly cleaned using Service Manual procedures. Replace rubber coated sealing washers prior to reinstalling CBV. Replace CBV if damaged or plugged.
Perform Transmission Cooler Flow Test - If the Transmission Cooling System fails the Flow Test, the coolers, CBVs or lines must be replaced. If the coolers are to be replaced, use only factory approved service parts.
If the torque converter is not being replaced, the following actions must take place:

The torque converter must be thoroughly cleaned:
Torque converters with drain plugs can be cleaned using the Rotunda Torque Converter Cleaner. Follow the instructions included with the equipment.
Torque converters without drain plugs can be cleaned by hand. Partially fill the converter using clean transmission fluid (as recommended for the particular transmission). Hand agitate the converter and then thoroughly drain the fluid. Refill with new fluid, specified for the transmission, and reinstall.
All cooler lines must be thoroughly cleaned by Back and Forward Flushing using Service Manual procedure.
All coolers (in-tank and auxiliary) must be thoroughly cleaned by Back and Forward Flushing using Service Manual procedure.
All Cooler By-Pass Valves (CBV), if equipped, must be removed and thoroughly cleaned using Service Manual procedures. Replace rubber coated sealing washers prior to reinstalling CBV. Replace CBV if damaged or plugged.
Perform Transmission Cooler Flow Test - If the Transmission Cooling System fails the Flow Test, the coolers, CBVs or lines must be replaced. If the coolers are to be replaced, use only factory approved service parts.
REQUIRED TOOLS
Tool Number Description
014-00028 Rotunda Converter/Oil Cooler Cleaner
014-00752 Rotunda Oil Cooler Flusher Kit
T77L-7902-R Converter Clutch Holding Tool
T76L-7902-C Converter Clutch Torquing Tool
TOOL-4210-C Dial Indicator With Bracketry
T80L-7902-A End Play Checking Tool
014-R1075 Torque Converter Leak Check Tool And Gasket
007-00500 New Generation Star (NGS) Tester
007-00085D Rotunda Transmission Tester Kit - includes all cables and overlays required for transmission/transaxle diagnosis. Refer to the Service Manual for the correct cable/overlay combination to use. Individual cables/overlays and the tester may be ordered separately from Rotunda.


Read more in my post here http://fullsizebronco.com/forum/showthread.php?t=189566

Anafiel
06-02-2011, 08:44 AM
Thanks! I started a new thread over here:

http://www.fullsizebronco.com/forum/showthread.php?t=194696

AussieF100
06-02-2011, 04:20 PM
My E4OD works fine in every gear, except it has a harsh change. Is this normal? Anyone?

MitchellPSP
02-01-2013, 11:03 PM
My E4OD has a similar problem with shuddering...but Im unsure whether to comdemn the TC yet. My EEC pulled up an old code of 628 however, I have no current codes (even after the codes have been wiped clean, the 628 comes back as an old code). From a stop, when I accelerate with mid-throttle, the engine seems like its bogging down for a little while, then magically the power is back. Its a 300i6 BTW. The tranny had a full change (TC and pan flush) so the fluid is new, the MLPS is new, and at highway speeds its fine. All shifts are fine. The truck responds to throttle (as in, not slipping) but it shudders in OD or when the RPM's are low at a cruising speed. I know the 300's arent speed demons but the power should be fairly constant...I am leaning toward the TC clutch not fully disengaging...has this happened to anyone else? familiar?

MitchellPSP
02-01-2013, 11:05 PM
Also, the radiator is brand new...so I dont believe there would be contamination in the cooling system.

garymunson
02-02-2013, 09:47 AM
Are you sure the correct fluid was used? Fords MUST use Mercon fluid. Almost every case of shudder/slip is caused by bad fluid. My symptoms were exactly like yours. In my case I bought my Bronco from an ederly guy who drove very gently, wearing out the fluid without it appearing bad. Mercon contains a friction modifier that can wear out without the fluid looking/smelling bad. Do a change like in this link. http://www.ford-trucks.com/article/idx/0/057/article/Changing_ATF_Fluid_in_a_E4OD_and_4R100_transmissio n.html Don't waste money on a filter change. The one you take out will not be dirty. Our Broncos have a short piece of hose on the cooler line at the radiator for the purpose of changing fluid. Ford does not recommend ever changing the filter. It is designed with enough capacity to last the life of the tranny. Search the links for E4OD for more on this. Adding a friction modifier like Lucas Tranny Fix or Mr Tranny is also a good idea but not without a full fluid change as described. Let us know how it works..

MitchellPSP
02-02-2013, 02:35 PM
I used the exact same as listed on the dipstick...mercon. I have heard some people argue that mercon 5 is ok and others say no way...I stuck with the oem recommend. It seems like it has always hesitated... from 2nd it seems worse. I even seem to get a stumble/shudder fresh off of a upshift...lately it seems worse

csa900
02-02-2013, 05:19 PM
Try some Dr. tranny Instant Shudder fix (got mine at oreilly's). I've added that after ever fluid change, and added an external trans filter per this site. 130k HARD miles and it shifts perfect.

blackbronco92
02-02-2013, 05:52 PM
http://www.fullsizebronco.com/forum/showthread.php?t=217448

Refer to that thread

MitchellPSP
03-20-2013, 10:53 PM
The shudder fix took away a lot of the shudder but she still hesitates like its having a hard time keeping a grip. Im getting tired of it and thinking of swapping to a M5OD-2. I read a thread where a guy was able to do it fairly easily but his swap didnt have an airbag...he had to swap out the steering column and I wanted to know if there is any special consideration for an airbag.

MitchellPSP
03-20-2013, 10:54 PM
And for anyone who wants to chime in anything about the ZF...forget it, I dont need to pull bobcats on goosneck trailers.

garymunson
03-25-2013, 12:23 AM
If you are talking about a funny 'bump' feeling when starting out, have you greased your driveshaft slip joint? That's another frequent issue... Most of our trucks have slip joint boots that are rotting from age and letting the grease dry out/get washed away. Hard to find the right boot. A shock boot the right size works pretty good.

southbfd
05-16-2013, 01:44 AM
Need help I have 1993 ford bronco it is showing a 629 error code. I know what it is. Can someone please explain it to me. and is it serious

mikelaubach
05-16-2013, 10:31 AM
code 629; converter clutch solenoid circuit fault or lock up solenoid circuit fault


Any wiring issues? Broken connectors, cut/ripped wires? According to http://www.fullsizebronco.com/forum/showthread.php?t=122096, it could be a solenoid pack issue as well. But start with the easy/cheap/free stuff first:

"The connector on the passenger's side of the transmission is the shift solenoid connector.

Pull these connectors and inspect them and the wiring very thoroughly. Get some electric contact cleaner and spray down the connectors on the harness and the transmission thoroughly. After you have done this, be sure to let them dry. Reconnect them and see if your condition approves. Pull codes again and see what you are left with."

And more data and testing for the pack can be found here: http://www.fullsizebronco.com/forum/showthread.php?t=47918&highlight

Hope that gets you started.