Few questions about my Bronco

1994 Full Size Bronco

302

e4od 

Auto locking hubs

1) I want to change out the auto hubs for manual. Whats the best brand to get

2) e4od tranny is slipping in high gear, now its starting to slip in lower gears as well. I want to be sure it inside thats going bad or something outside thats a simple and inexpensive fix. Rundown on tranny:

Cold it shifts fine, no problems up or down

Sometimes engine will cut off when put into park and can not be re started until I turn key off, then it will start.

When tranny slips its like going down road at highway speed, then its like it went into neutral for a few seconds then back into gear.

Maybe something like:

Needs external ccooler

Wires dirty 

Maybe radiator is cloged and fluid is not flowing fast enough

Bad torque converter

I am going to replace the torque converter with a new one if I have the tranny rebuilt. 

3) How hard would it be to install a C6 instead of the e4od? Wiring issues? vacuum?

4)Transfer case. Was thinking about installing a manual one instead of the push button one. How hard would that be?

Thanks for input.

yo BILL,

WELCOME!

I'll post a few replies to your Qs for now and enter them in case I lose internet.  Will bbl or Wed.

Hubs:

Warn or Mile marker are good; I have Warn standard on my 96 & they have worked well for 18 yrs, the lock-unlock decals fell off. But operates well; have to maintain them as with any rotating parts.

Warn® vs. Mile Marker Product Review (for a GM, but applicable)
Source: by Shawn S  http://chevy.off-road.com/chevy/article/articleDetail.jsp?id=200787

"...Manual Hub OPERATING INSTRUCTIONS: ONLY use fingers to turn dials. DO NOT USE PLIERS. Set the hublock dials to “FREE” and transfer case to 2-high for all driving that does not require four wheel drive. To engage four wheel drive set the hublock dials to “LOCK” and set the transfer case to 4-high or 4-low. Return the transfer case to 2-high before disengaging hublocks. Do not drive on hard surface roads in 4-wheel rive because it can cause drive train damage. Do not move the vehicle if the hubs are anywhere between “FREE” and “LOCK” or it will damage the hublocks. Driving with only one hublock engaged can cause drive train damage. Driving with the hublocks in ”FREE’’ and transfer case in 4-low can cause drive train damage. To ensure lubrication of the front axle, engage hublocks for a minimum of one mile monthly..."
Source: by Warn®

5 ***** Automatic Hubs  to Warn® & Bearing Replacement w/ Bearing Locknut Torque Settings in a 90; and, Wheel Bearing Locknut Torque Settings for 80-96 MANUAL HUBS, NOT Factory Auto Hubs; Ford Pickups and Bronco; "...Using a lockout spanner (ford # T59T-1197-B or equivalent ) and a torque wrench, tighten the inner bearing adjusting nut to 50 foot pounds while rotating the wheel back and forth and seating the bearing. Back off the adjusting nut approximately 45 degrees. Assemble the lock washer by turning the inner lockout to align the pin with the nearest hole in the lock washer. To lock it, install the outer lock nut and tighten it to 150 foot pounds. Grab the top of the tire with one hand and the bottom of the tire with the other. Move the tire in and out on the spindle. End play should be less than .006 – inch.).." Thanks to 90beater (Topher, Chris)!!!!
Source: by 90beater (Topher, Chris) at http://bronco.tophersworld.com/writeup_hubs.htm

Operational Test; "...To CHECK FOR PROPER ENGAGEMENT, dial both hubs to LOCK and raise the front left corner of the vehicle off the ground. Spin the lifted tire. The drive line will turn if the Hub is engaging properly. TO CHECK FOR PROPER DISENGAGEMENT, dial the lifted wheel hub into FREE and spin the lifted wheel. If the drive line does not turn AND you hear NO ratcheting sounds, the hub is disengaging properly. Repeat step 5- 6 with the right wheel & hub. NOTE: The hubs are not required to seat against the wheel housing when installed, they may move in and out quite easily. This “float” is normal and will not affect performance..."
Source: by Warn®  http://warn.iwebcat.com/imgVD/WAR/61420C0-pn20990.pdf

Tire Diameter/Circumference & Air Pressure Differences; "...You will recall that at the beginning of this section, we mentioned that we had made sure that all four tires on our truck were the same size, were worn the same amount, were inflated to the specified pressure and were subjected to reasonable loading. Avoiding driveline windup was the reason for this. Figure 18A shows that tires of even slightly different size roll different distances every revolution. Figure 18B shows that the same effect is true for tires that are the same size but inflated or loaded differently. Operating a 4 x 4 in 4WD with tires of different size or inflation will produce driveline windup, even when driving straight ahead! If the vehicle is being driven in 4WD on dry, hard pavement, the driver will notice drag and may experience the hop, skip, bounce effect as the front or rear wheels release the windup..." in Four Wheel Drive (4X4) General Information, Operation & Troubleshooting TSB 92-1-8 for Bronco, F Series & Ranger (COMPLETE); Includes Electric Shift On The Fly (ESOF) Troubleshooting & Hub Operation; see page 4-6 & Figures
Source: by Ford

NEW URL for Four Wheel Drive (4X4) General Information, Operation & Troubleshooting TSB 92-1-8 for 92 & Prior Year Bronco, F Series & Ranger; Includes Electric Shift On The Fly (ESOF) Troubleshooting after 92 by Ford via

http://www.revbase.com/BBBMOTOR/TSb/DownloadPdf?id=35193

==============

1356 Electric Shift to Manual Shift Swap in a 95
Source: by Shadofax (TheJuice, The Juice, Mark Z)

====

94 Bronco-Econoline-F-Series Workshop Manual by Ford

https://www.motorcraftservice.com/pubs/content/~WSRM/~MUS~LEN/21/SRMLEFT.HTM

Section 07-01A:
Transmission, Automatic, E4OD

https://www.motorcraftservice.com/pubs/content/~WSRM/~MUS~LEN/24/SRMS71AL.HTM

E4OD Diagnosis by Symptom Routines

https://www.motorcraftservice.com/pubs/content/~WSRM/~MUS~LEN/21/SRM71A09.HTM

 SEE: SHIFT CONCERNS: FEEL — SOFT/SLIPPING

213 — ELECTRICAL ROUTINE Powertrain Control System

• Perform Shift Point Tests.

• Electrical inputs/outputs, vehicle wiring harnesses, powertrain control module

• Run On-Board Diagnostics. Refer to PC/ED Manual for diagnosis. Perform Service Manual Pinpoint  MIESK5 Note, See  Self Test for Diagnostic Trouble Codes (DTC)s by BroncoJoe19 below

(Throttle position sensor, engine RPM sensor, electronic pressure control, transmission oil temperature sensor)  
READ MORE

================

Try a Self Test for Diagnostic Trouble Codes (DTC)s by my pal, BroncoJoe19

http://broncozone.com/topic/14269-code-reader/?&pid=74587&mode=threaded

The engine temperature must be greater than 50° F for the Key On Engine Off (KOEO) Self-Test and greater than 180° F for the Key On Engine Running (KOER) Self-Test.
Run it around to heat the engine up and shift thru all gears incl Reverse. Then turn off all accessories/lights, etc.

Make sure A/C is off and transmission is in Park (automatic) or in Neutral for a Manual & release clutch.

Do Key On Engine Off (KOEO) portion first.

And Post em here according to:
KOEO
&
KOER          

YO

Do the self-test; as a WAG;

Nagging Neutral Nonsense & Pinpoint Test, Manual Manual Lever Position (MLPS) also called Transmission Range (TR) Sensor. Some of the problems the MLPS can cause are wrong gear starts, TCC hunting, no 4th gear, engine stalling, high or erratic line pressure & a sudden neutral condition; The negative lead of the multimeter should be placed at the MLPS signal-return ground terminal at the MLPS...This sensor is responsible for more malfunctions than any other sensor in the sys- tem, and the kicker is that it seldom stores a code 67 or 634..."
Source: by Pete L site is gone; I can retrieve first page but we have other resources for testing (Except for the 94 Ford manual posted here; it uses a special MLPS tester!)

Manual Lever Position/Transmission Range (MLP/TR) Sensor - E4OD Controls Overview, Sensors, DTC (s) & Diagram; "... The powertrain control module sends voltage to the Transmission Range (TR) sensor. The TR sensor incorporates a series of step-down resistors which act as a voltage divider. The powertrain control module monitors this voltage which corresponds to the position of the gearshift selector lever (P, R, N, (D), 2 or 1). The powertrain control module uses this information to determine the desired gear and electronic pressure control pressure. The TR sensor is located on the outside of the transmission at the gearshift selector lever. Harsh engagements, firm shift feel. DTC 634, 654, 667, 668, P0705, P0707, P0708, P1705



by Steve at http://www.supermotors.net/registry/media/704885

Manual Lever Position Sensor (MLPS) Pinpoint Test, Bronco
Source: by bas zelf at http://www.f150online.com/forums/pre-1997-models/299004-e4od-tranny-slipping-d.html#post2801460

Use bas's Test with this Manual Lever Position Sensor (MLPS) Connector Pin-Out Diagrams
Source: by Steve



Manual Lever Position Sensor (MLPS) Connector Re-Pining; "...comes with a matching vehicle harness connector. The problem is that you have to remove the pins and their wires from the old vehicle harness connector. What ever you do don't pull all the pins out at the same time because you will never figure out were they go. Easiest thing to do is remove one pin at a time and re-install it into the new connector..."
Source: by miesk5 at Ford Bronco Zone Forums

Transmission Fluid Temperature (TFT) Sensor:
Description: The transmission fluid temperature sensor is located on the solenoid body assembly in the transmission sump. It is a temperature-sensitive device called a thermistor. The resistance value of the transmission fluid temperature sensor will vary with temperature change. The powertrain control module monitors voltage across the transmission fluid temperature sensor to determine the temperature of the transmission fluid. The powertrain control module uses this signal to determine whether a cold start shift schedule is necessary. The cold start shift schedule lowers shift speeds to allow for the reduced performance of cold engine operation. The powertrain control module also uses the transmission fluid temperature sensor input to adjust electronic pressure control pressure for temperature effects and inhibit torque converter clutch operation during the warm-up period.
Symptoms: Torque converter clutch and stabilized shift schedule happens too soon after a cold start. Codes P1783 or 657 indicate transmission fluid temperature exceeds 132°C (270° F), results in increased EPC pressure and torque converter clutch engagement. May flash transmission control indicator lamp.
Diagnostic Trouble Codes: 636, 637, 638, 657, P0712, P0713, P1711, P1783. 

The throttle position sensor is a potentiometer that is mounted on the throttle body on gas applications and on the fuel injection pump lever on diesel applications. The throttle position sensor detects the position of the throttle plate or lever and sends this information as a voltage signal to the powertrain control module.
If a malfunction occurs in the throttle position sensor circuit, the powertrain control module will recognize that the throttle position sensor signal is out of specification. The powertrain control module will then operate the E4OD transmission at a higher line pressure to prevent transmission damage. This high line pressure causes harsh upshift and engagements. Used as an input to determine shift scheduling and electronic pressure control.
Symptoms: Harsh engagements, firm shift feel, abnormal shift schedule, abnormal or no torque converter clutch operation. May flash transmission control indicator lamp.
Diagnostic Trouble Codes: 121, 122, 123, 124, 125, 167, P0121, P0122, P0123, P1120, P1121, P1124, P1125.