E40D Trouble

I'm posting this to stay ahead of he curve and prep my self for what might be coming.

I was working on the Bronco the other day (checking fluids nothing fancy) and I noticed a buzzing noise coming from the transmission. It isnt loud but just enough to be heard while the key is on but the engine is off. From what I gather it is the solenoid pack making the buzzing noise. Currently drive-ability isn't effected and a loss of torque is never felt... but I occasionally get a hard shift from 2nd to 3rd. (never worried about those intermittent hard shift up till this point) I wouldn't be worried about this at all except that, after a 20min drive the transmission pan is hotter the my oil pan. I'm talking about to the touch of the hand noticeably hotter. I can leave my hand on the oil pan for 3-5 sec but the transmission hurts after 1.5sec. I know, not a very technical measurement but y'all get the idea.

My question is should i really worry about it?

or

Option 1: get the solenoid pack replaced?

Option 2: Full transmission rebuild?

Just hoping that I'm over thinking the whole issue and I can just make an adjustment myself and move on.

Yo Skitter,

Has check engine light come om while driving?

Is the Transmission Control Indicator Light & Switch (Overdrive) blinking while driving?

See this 96 Bronco-F-Series Workshop Manual 

Section 07-01A: Transmission, Automatic, E4OD
1996 All F-Series and Bronco with E4OD Automatic Transmission Workshop Manual
DIAGNOSIS AND TESTING
 
http://www.diesel-dave.com/vehic/manual/stj/stj71a24.htm#extract_1037

Look at;

Other Concerns: Transmission Overheating

No extra lights coming on. If some were it would be easy to pin point the problem. Couldn't find any extra info in the link you had. Only if their was a error code would I need to check those circuits.

Yo,

I know it would be "easy" with those lights on, but I had to ask you.

Here is the info in themlinl I gave you;

Transmission Overheating

Possible Component Reference/Action

257 — ELECTRICAL ROUTINE

Powertrain Control System

Electrical inputs/outputs, vehicle wiring harnesses, powertrain control module, torque converter clutch solenoid

Run On-Board Diagnostics. Refer to Powertrain Control/Emissions Diagnosis Manual for diagnosis. Perform Service Manual Pinpoint Test C 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.

357 — HYDRAULIC/MECHANICAL ROUTINE

Excessive Vehicle or Towing Loads, Severe Vehicle Usage

Refer to the Vehicle Specification Manual for load and GVW/GCW information. Refer to Owner's Manual.

NOTE: If auxiliary cooler is desired, use ONLY Ford original factory equipment installed to factory specifications.

Fluid

Improper level

Condition

Adjust fluid to proper level. Inspect according to instructions under Fluid Condition Check.

Transmission Cooling System

Damaged, blocked, restricted, or improperly installed

Perform Transmission Fluid Cooler Flow Test.

Inspect for damage, restrictions. Service as required.

Vehicle Concerns Causing Engine Overheating

Refer to Engine Condition and Cause charts.

Torque Converter Clutch

Not engaging

See Routine No. 240/340.

Other Concerns: Noise/Vibration — Forward Or Reverse

Possible Component Reference/Action

254 — ELECTRICAL ROUTINE

No Electrical Concerns

354 — HYDRAULIC/MECHANICAL ROUTINE

For Noises/Vibrations that change with engine speed:

Torque converter components

Fluid level (low) pump cavitation

Pump assembly

Engine drive accessories

Transmission oil cooler lines grounding out

Flywheel

Fluid filler tube grounding out

Locate source of disturbance. Service as required.

For Noise/Vibrations that change with vehicle speed:

Engine mounts

Loose, damaged

Driveline concerns

U-joints

Rear axle assembly

Suspension

Modifications/misalignment

1st gear

One-way clutch, gear set

Friction elements

Torque converter assembly

2nd gear

Intermediate OWC

Friction elements

Torque converter assembly

3rd gear

One-way clutch

Torque converter assembly

Friction elements

4th gear

One-way clutch

Gear set

Friction elements

Torque converter assembly

Reverse

Gear set

Friction elements

Torque converter assembly

Shaft spline fit

Slip yoke, park gear

Locate source of disturbance. Service as required.

For specific shifts or torque converter concern, refer to appropriate routines:

No Shift 1-2, Routine 320

No Shift 2-3, Routine 321

No Shift 3-4, Routine 322

No Shift 4-3, Routine 323

No Shift 3-2, Routine 324

No Shift 2-1, Routine 325

No Converter Cycling, Routine 242/342

Other Noises/Vibrations:

Main controls

Valve resonance

Shift cable

Vibration, grounding

Transmission fluid cooler lines or fluid filler tube

I have been trying to solve the issue because all solenoids do work but something from the PCM was off but I couldn't put my finger on it. So here is what I have done to fix this issue. Not saying that this will work for everybody but this is what fixed MY E40D troubles.

To stop the solenoids from buzzing/clicking I had to replace the MAP sensor with a BWD unit from O'reilly. Not only did the new MAP get rid of the noise but it fixed my drivibility issue where the bronco would want to loose power for a tenth of a second every time the throttle open'd from the closed position. And my hunting idle just about went away too. Instead of a idle that fluctuated 200-400rpms. It now fluctuates only 100-200rpms.

But that didn't solve the heat issue. this is one of the crazyest things I have done to solve an issue like this an I wouldn't recommend this to others but I put in a Banks Power ( _LINK_ ) Transcommand. $318 box that honestly isn't isn't that much more impressive over a RadioShack resistor. But it did solve my heat issue.