Yo Brian,
OK, Great on the testing!
Also, is the OD off/on LED blinking at end of shift lever?
Ford describes it as E4OD Transmission Control Indicator Lamp (TCIL)& Transmission Control Switch (TCS)
The light stays OFF when the Transmission Control Switch (TCS) attain the overdrive gear position.
The light stays ON when the Transmission Control Switch (TCS) is toggled—indicating the vehicle is prevented from shifting into the overdrive gear position
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If the CEL is burned out, connect CEL © to a 12V test light, and the light's other terminal to a 12V source on the same vehicle.
by Steve
Note that Steve has twisted the PIN identification around, so just use his diagram above for the burnt out bulb test, and when you see Joe's Diagram you will see the correct identification.
=
I have to read more on heat-related E4OD issues; a WAG is E4OD Filter and fluid; quality, last changed? etc. then the self-test for codes will help with sensor issues (wiring harnesses, throttle position sensor, vehicle speed sensor, shift solenoid 1, shift solenoid 2
And a WAG to show how a DTC can be used to do pin-point tests on a sensor; DTC 637 - TOT sensor circuit above maximum voltage possible causes: Damaged TOT sensor. Open harness circuit(s). Damaged processor. or the transmission was overheated. 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. Code 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.
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This is by Ford:
Shift Concerns: Some or All Shifts Missing
Possible Component
Reference/Action
210 — ELECTRICAL ROUTINE
Powertrain Control System •Perform Shift Point Road Test.
•Electrical inputs/outputs, vehicle wiring harness, powertrain control module, throttle position sensor, Transmission Range (TR) sensor, vehicle speed sensor, shift solenoid 1, shift solenoid 2
•Run On-Board Diagnostics. This the Self-Test for Codes by BroncoJoe; or with a Code Scanner, costs about $30.00 at parts stores or AMAZON etc.
Clear code, road test, rerun On-Board Diagnostics.
310 — HYDRAULIC/MECHANICAL ROUTINE
Fluid
•Improper level 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.
•Condition
•Adjust fluid to proper 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.
2.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.
3.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.
Shift Linkage (Internal/External) or Cable
•Damaged, misadjusted, disconnected
•Inspect and service as required. Verify linkage adjustment as outlined. After servicing linkage, verify that the transmission range (TR) sensor is properly adjusted. Refer to In-Vehicle Service in this section.
Filter Assembly and Seal
•Plugged, damaged
•Inspect filter assembly and seal for damage. Service as required.
•Filter seal damaged
Main Controls (VALVE BODY)
•Valves stuck, damaged, misassembled
•Inspect for damage. Service as required.
For diagnosis related to a specific shift, see Reference/Action •To diagnose specific No Shift, refer to the appropriate shift routine.
No Shift 1-2, Routine 220/320
No Shift 2-3, Routine 221/321
No Shift 3-4, Routine 222/322
No Shift 4-3, Routine 223/323
No Shift 3-2, Routine 224/324
No Shift 2-1, Routine 225/325
Shift Concerns: No 2-3 Shift (Automatic)
Possible Component
Reference/Action
221 — ELECTRICAL ROUTINE
Powertrain Control System
•Electrical inputs/outputs, vehicle wiring harness, powertrain control module, throttle position sensor, vehicle speed sensor, shift solenoid 1, shift solenoid 2; SEE MORE BELOW all this stuff.
•Run On-Board Diagnostics. Refer to Powertrain Control/Emissions Diagnosis Manual for diagnosis. Perform Service Manual Pinpoint Test A using Rotunda Transmission Tester 007-00085 and Cable and Overlay 007-00107 or equivalents as outlined in this section. Service as required. Clear codes, road test and rerun On-Board Diagnostics.
This the Self-Test for Codes by BroncoJoe; or with a Code Scanner, costs about $30.00 at parts stores or AMAZON etc.
321 — HYDRAULIC/MECHANICAL ROUTINE
Main Controls (VALVE BODY)
•Bolts not tightened to specification
•Retighten bolts to specification.
•Gaskets damaged
•Inspect for damage and replace.
•SS1 malfunction
•Refer to Electrical Routine No. 221.
•Direct clutch accumulator regulator valve, 2-3 shift valve, springs — stuck, missing, damaged, misassembled
•Inspect for damage. Service as required.
•Air bleed for SS2 circuit damaged or missing
•Inspect for damage. Replace case.
•Improper components used in rebuild
•Verify that proper components are used.
Center Support Assembly
•Feedbolts missing, not tightened to specification
•Inspect, install new feedbolts and tighten to specification.
•Seal rings damaged
•Inspect for damage. Service as required.
•Assembly damaged
•Inspect for damage. Service as required.
•Outside diameter or case bore damaged or leaking
•Inspect for damage. Service as required.
Direct Clutch Assembly
•Assembly
•Air check clutch assembly as outlined in this section.
•Stator support seals damaged
•Inspect for damage. Service as required.
•Seals, piston, cylinder damaged
•Inspect for damage. Service as required.
•Friction elements missing or damaged
•Inspect for damage. Service as required.
•Ball check missing, damaged
•Inspect for damage. Service as required.
---
Shift Concerns: No 3-4 Shift (Automatic)
Possible Component
Reference/Action
222 — ELECTRICAL ROUTINE
Powertrain Control System
•Electrical inputs/outputs, vehicle wiring harnesses, powertrain control module, throttle position sensor, vehicle speed sensor, shift solenoid 1, shift solenoid 2
•Run On-Board Diagnostics. Refer to Powertrain Control/Emissions Diagnosis Manual for diagnosis. Perform Service Manual Pinpoint Test A using Rotunda Transmission Tester 007-00085 and Cable and Overlay 007-00107 or equivalents as outlined in this section. Service as required. Clear codes, road test and rerun On-Board Diagnostics.
322 — HYDRAULIC/MECHANICAL ROUTINE
Main Controls
•Bolts not tightened to specification
•Retighten bolts to specification.
•Gaskets damaged or misaligned
•Inspect for damage and replace.
•Shift solenoid 1, shift solenoid 2 malfunction
•Refer to Electrical Routine No. 222.
•Overdrive accumulator regulator valve and spring, 3-4 shift valve and spring — damaged, stuck, misassembled, missing
•Inspect for damage. Service as required.
•Improper components used in rebuild
•Verify that proper components were used in the rebuild.
Overdrive Clutch Assembly
•Assembly
•Air check clutch assembly as outlined in this section.
•Clutch plates burnt, missing
•Inspect for damage. Service as required.
•Cylinder damaged
•Inspect for damage. Service as required.
•Feed bolts loose, missing, leaking, seals damaged
•Install new feedbolts and tighten to specifications.
•Cylinder check ball missing
•Inspect for damage. Service as required.
Overdrive One-Way Clutch Assembly
•Damaged
•Inspect for damage. Service as required.
Overdrive Planet Assembly
•Damaged
•Inspect for damage. Service as required
==========
a long shot since it ran ok for the testing;
NO 2-3 UPSHIFT - E40D
TSB 94-7-16
http://www.revbase.com/BBBMotor/TSb/DownloadPdf?id=43693
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E4OD Controls & Solenoids
Powertrain Control Module (PCM) 12A650:
On vehicles equipped with gasoline engines, the operation of the E4OD automatic transmission is controlled by the powertrain control module. Many input sensors provide information to the powertrain control module, which then controls the actuators that affect transmission operation.
On vehicles equipped with diesel engines, the operation of the E4OD automatic transmission is also controlled by the powertrain control module. However, some of the input sensors are different.
Air Conditioning (A/C) Clutch 2884:
Description: The air conditioning clutch is an electromagnetic clutch that is energized when the clutch cycling A/C pressure cut-off switch closes. The A/C pressure cut-off switch is located on the suction accumulator-drier. The closing of the A/C pressure cut-off switch completes the circuit to the clutch and draws it into engagement with the compressor driveshaft. Used as an input to determine electronic pressure control when the air conditioning clutch is engaged to compensate for the additional load on the engine.
Symptoms: Failed on — electronic pressure control slightly low with A/C off. Failed off — electronic pressure control slightly high with A/C on.
Diagnostic Trouble Code 539.
Brake On/Off (BOO) Switch 13480:
Description: The brake on/off switch tells the powertrain control module when the brakes are applied. The switch is closed when the brakes are applied and open when they are released. The PCM uses this signal to disengage torque converter clutch when brake is applied.
Symptoms: Failed on or not connected — Torque converter clutch will not engage at less than 1/3 throttle. Failed off — Torque converter clutch will not disengage when brake is applied.
Diagnostic Trouble Code 536.
Distributor Ignition (DI) System:
Description: On gasoline engines, the profile ignition pickup sensor sends a signal to the powertrain control module indicating the engine rpm and the crankshaft position.
Symptoms: Engine will stall or miss.
Diagnostic Trouble Code 211.
4x4 Low (4x4L) Switch:
Description: The low range switch is located on the transfer case cover. It provides an indication of when the 4x4 transfer case gear system is in the LOW range. Modifies shift schedule for 4x4L transfer case gear ratio.
Symptoms: Failed on — Early shift schedule in 4x2 and 4x4H. Failed off — Shifts delayed in 4x4L. If the 4x4 low indicator light fuse is blown, the transmission will shift according to 4x4 low shift schedule regardless of transfer case position.
Diagnostic Trouble Codes 633, 691.
Manifold Absolute Pressure (MAP) Sensor — Gasoline Engines:
Description: On gasoline engines, the manifold absolute pressure (MAP) sensor senses atmospheric pressure to produce an electrical signal. The frequency of this signal varies with intake manifold pressure. The powertrain control module monitors this signal to determine altitude. The PCM then adjusts the E4OD shift schedule and EPC pressure for altitude.
On diesel engines, the MAP sensor measures boost pressure. The PCM monitors this signal and adjusts EPC pressure.
Symptoms: Firm shift feel, late shifts at altitude.
Diagnostic Trouble Codes: 126-129.
Programmable Speedometer/Odometer Module (PSOM):
Description: The programmable speedometer/odometer module receives input from the rear brake anti-lock sensor, which is mounted on the rear axle differential housing. The PSOM processes this input signal information and relays it to the powertrain control module and the speed control module. This signal tells the powertrain control module the vehicle speed in miles per hour (mph). Used as an input in determining shift scheduling and electronic pressure control.
Symptoms: Harsh engagements, firm shift feel, abnormal shift schedule, unexpected downshifts may occur at closed throttle, abnormal torque converter clutch operation or engages only at wide-open throttle (WOT). May flash transmission control indicator lamp.
Diagnostic Trouble Code 452.
Transmission Control Switch (TCS) and Transmission Control Indicator Lamp (TCIL):
Description: The transmission control switch (TCS) is a momentary contact switch. When the switch is pressed, a signal is sent to the powertrain control module. The powertrain control module then energizes the transmission control indicator lamp and the coast clutch solenoid, applying the coast clutch to provide engine braking and cancels fourth gear operation. The TCIL indicates overdrive cancel mode activated (lamp on), electronic pressure control circuit shorted or monitored sensor failure (lamp flashing).
Sensor: Transmission Control Switch.
Symptoms: No overdrive cancel when switch is cycled.
Diagnostic Trouble Codes: 632, P1780, tested during Key On Engine Off (KOEO) On-Board Diagnostic only.
Actuator: Transmission Control Indicator Lamp.
Symptoms: Failed on — overdrive cancel mode always indicated, no flashing for electronic pressure control circuit shorted. Failed off — overdrive cancel mode never indicated, no flashing for electronic pressure control circuit shorted, also may be due to a bad fuse. Erratic operation (flashing) may be due to a wiring concern.
Diagnostic Trouble Code 631
Throttle Position (TP) Sensor 9B989:
Description: 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
Vehicle Speed Sensor (VSS) 9E731:
Description: The vehicle speed sensor is a variable reluctance sensor that sends an AC/frequency signal to the powertrain control module. The vehicle speed sensor signal is used by the powertrain control module to calculate vehicle speed in mph. Used as an input in determining shift scheduling and electronic pressure control.
Symptoms: Harsh engagements, firm shift feel, abnormal shift schedule; unexpected downshifts may occur at closed throttle, abnormal torque converter clutch operation or torque converter clutch engages only at wide-open throttle. May flash transmission control indicator lamp.
Diagnostic Trouble Code 452.
****** 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.
Transmission Range (TR) Sensor 7A247:
Description: 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.
Symptoms: Harsh engagements, firm shift feel.
Diagnostic Trouble Codes: 634, 654, 667, 668.
Transmission Solenoid Body:
Description: The powertrain control module controls the E4OD transmission operation through four on/off solenoids and one Variable Force Solenoid. These solenoids and transmission fluid temperature sensor are housed in the transmission solenoid body assembly. All are part of the transmission solenoid body and are not serviced individually. Additionally, in 1995, the protection diodes that were on the solenoid body have been moved to the PCM. Refer to the following information for the functions of these solenoids.
The four on/off solenoids operate in the following manner:
When the solenoid is off, the fluid pressure feed is blocked by a check ball. The check ball is held in place by the solenoid piston.
When the solenoid is turned on by the PCM, the piston is pulled up, releasing the check ball and allowing fluid pressure to be applied to the check valves and/or other components controlled by the solenoid.
Electronic Pressure Control (EPC) Solenoid:
Description: The Electronic Pressure Control solenoid is a variable force solenoid. The variable-force type solenoid is an electro-hydraulic actuator combining a solenoid and a regulating valve. It supplies electronic pressure control which regulates transmission line pressure and line modulator pressure. This is done by producing resisting forces to the main regulator and the line modulator circuits. These two pressures control clutch application pressures.
Symptoms: Failed on — minimum electronic pressure control pressure (minimum transmission torque capacity). Limit engine torque (partial fuel shut-off, heavy misfire). Flashing transmission control indicator lamp.
Failed off — maximum electronic pressure control pressure, harsh engagements and shifts. May flash transmission control indicator lamp.
Diagnostic Trouble Codes: 624,* 625,*
CAUTION: The electronic pressure control pressure output from the variable force solenoid is NOT adjustable. Any modification to the electronic pressure control solenoid will affect the transmission warranty. (*Output circuit check, generated only by electrical condition.)
Torque Converter Clutch (TCC) Solenoid:
Torque converter clutch solenoid provides torque converter clutch control by shifting the converter clutch control valve to apply or release the torque converter clutch.
Symptoms: Failed on — engine stalls in drive at idle low speeds with brake applied or manual 2. Failed off — converter clutch never engages. May flash transmission control indicator lamp.
Diagnostic Trouble Codes: 629,* P0741,** P0743,** P1743, P1742, P1744. (*Output circuit check, generated only by electrical condition. **May also be generated by other non-electronic related transmission hardware condition.)
Coast Clutch Solenoid (CCS) 7M107:
The Coast Clutch Solenoid provides coast clutch control by shifting the coast clutch shift valve. The solenoid is activated by pressing the transmission control switch or by selecting the 1 or 2 range with the transmission gearshift selector lever. In manual 1 and 2, the coast clutch is controlled by the solenoid and also hydraulically as a fail-safe to ensure engine braking. In reverse, the coast clutch is controlled hydraulically and the solenoid is not on. NOTE: On certain applications, the coast clutch is controlled by the PCM in the overdrive position (TCS OFF) in gears 1, 2, and 3.
Symptoms: Failed on — Third gear engine braking with (D) range selected. Failed off — No third gear engine braking in overdrive cancel.
Diagnostic Trouble Codes: 626,* 628,** 643,* 652,* P0741,** P0743,* P1754.*
(*Output circuit check, generated only by electrical conditions. **May also be generated by other non-electronic related transmission hardware condition.)
Shift Solenoids 1 and 2:
Shift solenoids 1 and 2 provide gear selection of first through fourth gears by controlling the pressure to the three shift valves.
Shift Solenoid 1:
Symptoms: Improper gear selection depending on failure mode and manual lever position; refer to the Shift Solenoid Operation Chart. May flash transmission control indicator lamp.
Diagnostic Trouble Codes: 617,** 618,** 619,** 621,* P0750,* P0751, P0781,** P0782,** P0783.** (*Output circuit check, generated only by electrical conditions. **May also be generated by other non-electronic related transmission hardware condition.)
Shift Solenoid 2:
Symptoms: Improper gear selection depending on failure mode and manual lever position; refer to the Shift Solenoid Operation Chart. May flash transmission control indicator lamp.
Diagnostic Trouble Codes: 617,** 618,** 619,** 622,* P0755,* P0781,** P0782,** P0783,** P0756. (*Output circuit check, generated only by electrical conditions. **May also be generated by other non-electronic related transmission hardware condition.)
for a 96; sim to your year
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