Yo J,
As advised;
DTCs 91/
621, 92/622, 93/626, 94, 629, 641 and 652 indicate solenoid did not change state when requested by the Powertrain Control Module (PCM).
DTC 566 or 629 indicates the CCO or SS3/4-4/3 did not change state when requested by the PCM.
Possible causes:
Damaged solenoid/assembly.
Open or shorted harness (internal/external).
Damaged PCM.
Note: Do not use a STAR Tester for this step. Use a VOM or DVOM.
Disconnect electrical connector on the speed control servo, if equipped.
VOM/DVOM on 20 volt scale.
Connect negative test lead to STO circuit at Data Link Connector (DLC) and meter positive test lead to B+.
Jumper STI circuit to SIG RTN at the DLC.
miesk5 Note, here is the DLC PIN DIAGRAM;
Perform Key On Engine Off Self-Test until Continuous Memory DTC have been displayed.
VOM/DVOM will indicate less than 1.0 volt when test is complete.
Depress and release throttle.
Does voltage increase?
Yes REMAIN in Output State DTM. GO to TC2.
No DEPRESS throttle to WOT and RELEASE. If STO voltage does not go high, PERFORM Pinpoint Test Step QC1. Leave equipment hooked up.
TC2 CHECK SOLENOID ELECTRICAL OPERATION
Key on, engine off.
Disconnect transmission connector.
Using a mirror, inspect both ends of the connector for damaged or pushed out pins, corrosion, loose wires, etc. Service as necessary.
Refer to the schematic and table of this Pinpoint Test.
Connect VOM/DVOM positive test lead to VPWR circuit and negative test lead to solenoid circuit of the transmission vehicle harness connector.
miesk5 Note, here is the 95 E4OD Solenoid Connector pin diagram;
VOM/DVOM on 20 volt scale.
While observing DVOM, depress and release throttle several times to cycle solenoid output ON and OFF.
Does the suspect solenoid output voltage change at least 0.5 volt?
Yes RECONNECT connector. REFER to the Transmission Group in the Service Manual.
No REMOVE jumper wire. GO to TC3.
TC3 CHECK CONTINUITY OF SOLENOID SIGNAL AND VPWR HARNESS CIRCUITS
Key off.
Solenoid transmission connector disconnected.
Disconnect Powertrain Control Module (PCM). Inspect for damaged or pushed out pins, corrosion, loose wires, etc. Service as necessary.
Install breakout box, leave PCM disconnected.
Refer to schematic and table in this Pinpoint Test.
Measure resistance between suspect PCM signal output pin at the breakout box and signal output pin at transmission vehicle harness connector.
Measure resistance between Test Pin 37/57 at the breakout box and VPWR pin at transmission vehicle harness connector.
Is each resistance less than 5.0 ohms?
Yes GO to TC4.
No SERVICE open circuit(s). REMOVE breakout box. RECONNECT all components. RERUN Quick Test
TC4 CHECK SOLENOID HARNESS FOR SHORTS TO POWER OR GROUND
Key off.
Breakout box installed, PCM disconnected.
Transmission connector disconnected.
Refer to schematic and table in this Pinpoint Test.
Measure resistance between PCM signal output pin and Test Pin 37/57 at the breakout box.
Measure resistance between PCM signal output pin and Test Pins 40/60 and 46 at the breakout box and chassis ground.
Is each resistance greater than 10,000 ohms?
Yes REFER to Service Manual, Transmission Diagnosis for internal harness and solenoids. IF OK, REPLACE PCM. REMOVE breakout box. RECONNECT all components. RERUN Quick Test.
NoSERVICE short circuits. REMOVE breakout box. RECONNECT all components. RERUN Quick Test.
I can't find QC1. Will look for it tomorrow.
⊙⊙⊙
DIAGNOSTIC TROUBLE CODES (DTCS)
553 AND 552: CHECK VOLTAGE OF VPWR CIRCUIT
AIRB/AIRD circuits shorted to power.
AIRB/AIRD circuits open or grounded.
AIRB/AIRD resistance out of range.
Damaged Powertrain Control Module (PCM).
DTCs 553 and 552 indicate that voltage output for Secondary Air Injection solenoid(s) did not change when activated.
miesk5 Note; this set of tests includes use of Ford's old Break-Out Box; so, as I mentioned in another thread here; In place of the break-out box, go to the EEC connector pin instead; substitute EEC connector pin Number for breakout box number. Using;
EEC IV Connector Pin Diagram
Source: by Ryan M at
EEC IV Connector Pin LEGEND Bronco & Ford Truck & Van: 4.9, 460, 5.0, 5.8;
Source: by Ryan M (Fireguy50) at
Ford Fuel Injection
Disconnect AIRB/AIRD solenoid connector.
Key on, engine off.
Measure voltage between VPWR circuit and battery ground of one solenoid, then repeat for the other solenoid.
Is each voltage greater than 10.5 volts?
Yes GO to KC10 .
No SERVICE open harness circuit. RECONNECT both solenoids. RERUN Quick Test.
KC10 MEASURE AIRB/AIRD SOLENOID RESISTANCE
Key off.
Disconnect both AIRB/AIRD solenoid connectors and measure both solenoid resistances.
Is each resistance between 50 and 100 ohms?
Yes go to KC11 .
No REPLACE AIRB/AIRD solenoid assembly. RECONNECT both solenoids. RERUN Quick Test.
KC11 CHECK CIRCUIT CONTINUITY
Key off.
Disconnect Powertrain Control Module (PCM). Inspect for damaged or pushed out pins, corrosion, loose wires, etc. Service as necessary.
Install breakout box, leave PCM disconnected.
Measure resistance between AIRB circuit at breakout box and AIRB circuit at vehicle harness connector.
Measure resistance between AIRD circuit at the breakout box and AIRD circuit at vehicle harness connector.
Is each resistance less than 5.0 ohms?
Yes Go to KC12 .
No SERVICE open harness circuit. REMOVE breakout box. RECONNECT PCM and both solenoids. RERUN Quick Test.
KC12 CHECK FOR SHORT TO GROUND
Key off.
Breakout box installed, PCM disconnected.
Disconnect both AIRB/AIRD solenoids.
Measure resistance between AIRB circuit at the breakout box and Test Pins 40, 46 and 60. Measure resistance between AIRD circuit at the breakout box and Test Pins 40, 46 and 60 at the breakout box.
Is each resistance greater than 10,000 ohms?
Yes GO to KC13 .
No SERVICE short to ground. REMOVE breakout box. RECONNECT PCM and AIRB/AIRD solenoids. RERUN Quick Test.
KC13 CHECK FOR SHORT TO POWER
Key off.
Breakout box installed, PCM disconnected.
Both AIRB/AIRD solenoids disconnected.
Measure resistance between AIRB circuit at the breakout box and Test Pins 37 and 57. Measure resistance between AIRD circuit at the breakout box and Test Pins 37 and 57 at the breakout box.
Is each resistance greater than 10,000 ohms?
Yes REPLACE PCM. REMOVE breakout box. RECONNECT both solenoids. RERUN Quick Test.
No SERVICE short to power. REMOVE breakout box. RECONNECT PCM and AIRB/AIRD solenoids. RERUN Quick Test. If DTC is present, REPLACE PCM.