Yo,
OK,
Here is the 96 Bronco-F-Series Workshop Manual (PARTIAL) by FORD via
http://www.diesel-dave.com/vehic/manual/stj/stjleft.htm
E4OD
Section 07-01A: Transmission, Automatic, E4OD
1996 All F-Series and Bronco with E4OD Automatic Transmission Workshop Manual
DIAGNOSIS AND TESTING
Diagnosis by Symptom
http://www.diesel-dave.com/vehic/manual/stj/stj71a24.htm#extract_1037
Without a code, this is what a Ford mechanic would inspect and test;
For Poor Vehicle Performance:
Possible Component Reference/Action
253 — ELECTRICAL ROUTINE
Powertrain Control System
Perform torque converter operation test.
Electrical inputs/outputs, vehicle wiring harnesses, powertrain control module, other engine related items:
torque converter clutch solenoid,
throttle position sensor,
transmission range (TR) sensor, miesk5 note, this could be faulty and will NOT SET A CODE under certain circumstances,
transmission fluid temperature sensor.
Run On-Board Diagnostics. miesk5 note, this is the code test.
Refer to Powertrain Control/Emissions Diagnosis Manual for diagnosis. Perform Service Manual Pinpoint Tests B, C and D using Rotunda Transmission Tester 007-00085, Cable and Overlay 007-00107 and the Transmission Range (TR) Sensor Cable "B" (MLPS Manual Lever Position Sensor Tester Cable) 007-00086 or equivalent as outlined in this section. Service as required. Clear codes, road test and rerun On-Board Diagnostics.
353 — HYDRAULIC/MECHANICAL ROUTINE
Shift Linkage (Internal/External) or Cable
Damaged, misadjusted
Inspect for damage. 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.
Shift Scheduling
Perform Shift Point Road Test procedure as outlined in this section.
Improper
Go to the appropriate diagnostic routines for shift concerns
No. 210-211.
Engagements
Improper gear selection
Go to the appropriate diagnostic routines for shift concerns
No. 215/315.
Converter Clutch Always Applied
Go to routine No. 341.
Converter One-Way Clutch
Damaged
Go to Torque Converter Checks in this section.
..
See
No Shift 3-2, Routine 224/324
&
No Shift 2-1, Routine 225/325
...
Look through the Symptoms for more.
From your information do you agree it may be heat related? It seems to be Hall Effect, also called the Profile Ignition Pick-up (PIP) Signal, & TFI Module failures due to heat.
Was the TFI Module replaced?
A major cause of failure is heat, especially typical on Ford, is intermittent failure. The vehicle runs okay for a while, then stops. When it cools, it runs okay for a while longer. Then it stops again. And so on. This is a fairly certain indication of a heat failure fault. But a code is usually set.
If the engine is stumbling or hesitating, check spark plugs wires. Plugs that indicate a lean fuel condition may be due to a vacuum leak in the intake manifold or unmetered air getting past the airflow sensor. See
http://www.aa1car.com/library/spark_plug_fouling.htm
*** or an EGR valve that is stuck open. ***