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7.3L IDI Diesels (Not Power Strokes) Technical discussion of topics related to vehicles powered by the 7.3 Liter In-Direct Injection Navistar engines.

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Old 03-18-2006, 01:25 PM   #1 (permalink)
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E40D Trans Shifting Problem

I have a 91 F-250, with 7.3 Lt Diesel engine, E40D Automatic Transmission and 3.9 axle with 120,000+ miles. The truck has been running fine from the day I bought it used around the first of December 05. The only problems I have had have been an oil leak at the back of the engine around the starter, which just requires me to check the oil often. The transmission has been pretty much ok except an occasional hard shift or bump as it shifts from take-off yet most of the time it shifts through all the gears smoothly. Just yesterday afternoon while on my way back home on the freeway, I stopped for diesel fuel then upon taking off from the truck stop I realized that the transmission was not shifting as it should. It will shift through the first several gears but going down the highway, it seemed it was not shifting into overdrive because the engine was racing while traveling at 50 to 70 MPH. I tried pushing the overdrive button on the dash and it made no difference in the way the engine had to work. After I got off the freeway again to check the trans. fluid levels, the levels were ok. As I left from where I was parked, the transmission was ok and shifting through all the gears fine and the over drive was working. I could also push the over drive button and tell the difference in the way the engine was having to work. In fact, it seems as if the truck was running better than the day I bought it. Could the transmission need an overhaul or is the problem a computer or electrical connection problem? The occasional hard shift or bump upon takeoff does concerns me a little but what appears to be the not shifting into overdrive and then seeming to correct it's self after stopping and perhaps running even better than before worry’s me. Anyone have any ideas? Anyone have this problem and can tell me what they had to do to correct it and an estimate on how much it could cost me to correct both the hard take off and especially this not shifting into overdrive? Any help is deeply appreciated.
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Old 03-18-2006, 01:58 PM   #2 (permalink)
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Re: E40D Trans Shifting Problem

Make sure all your connectors on the wiring harness and connectors at sensors are clean. I used electrical cleaning spray from auto store. The throttle position sensor needs to be in adjustment. The range I believe is 1.1-3.8 volts if not in right range shifting problems will happen. I drained my torque converter and put new fluid in. I thought my tranny was spent but after doing all the r&r it is running fine. It was slipping like it was fried but a new throttle position sensor, the clean up of connectors and the fluid flush did it just fine. Make sure your ground wires are clean. I was told to run a ground wire to the computer shield also but haven't due to the cold weather. Good luck and I hope everything works out for you. Scott
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1988 Ford F-350 X L T Lariat 7.3 L DRW Totally rock solid. The van is gone. Trucks are in. 1989 E-350 7.3L E40D Superduty cargo van used for construction no thrills only spills 360,000 miles on her New IP,alternator,vp,mc,brakes,pb,gp not an issue,drums,exhaust,wp,tps, starter and just a lot of tender loving care.
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Old 03-18-2006, 02:19 PM   #3 (permalink)
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Re: E40D Trans Shifting Problem

I would recomend you have a scanner check for your tranny sensors. They can cause Lots of problems on this tranny. I know.
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Old 03-18-2006, 03:01 PM   #4 (permalink)
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Re: E40D Trans Shifting Problem

Is the sensor the black box that is mounted about the center and top left side of the trans? It appears to have a wire harness plugged into the top of it.
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Old 03-18-2006, 04:07 PM   #5 (permalink)
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Re: E40D Trans Shifting Problem

Sensor on the left center where the linkage attaches is the neutral switch (has a fancy name from Ford), the connection on the right side is for the shift solenoids, tailshaft sensor is the speed sensor/speedometer drive, (your speed sensor may be on the differential) driver's side of IP is the FIPL (TPS), front of IP by oil fill is the engine speed sensor. Also there is an absolute barometric sensor. They all feed into the transmission computer to control the shifting.
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Old 03-18-2006, 04:49 PM   #6 (permalink)
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Re: E40D Trans Shifting Problem

[ QUOTE ]
Is the sensor the black box that is mounted about the center and top left side of the trans? It appears to have a wire harness plugged into the top of it.

[/ QUOTE ]

That one is the MLPS (Manual Lever Position Sensor). Don't mess with that one. The only adjustable sensor is the FIPL located on drivers side of the IP.

FIPL Adjustment

If a scan tool is not available, connect an ohm meter to the top and center FIPL terminals and adjust to 1800 ohms +/- 50 ohms. You can check the adjustment of the FIPL by back-probing the center wire of the FIPL sensor connector with a digital volt meter. The voltage should read 1.0-1.1 volts at idle, 1.6-1.9 at 30 MPH, and 2.0-2.5 at 55 MPH.
If these readings can't be achieved, replace the FIPL sensor and re-start this procedure. It may be necessary to remove the epoxy from the bracket screws (T-27 torx screws) to adjust a new FIPL sensor.
DIESEL FIPL SENSOR

DATE 1992

REASON
Early Black FIPL has High Failure Rate

RECOMMENDATION
Always replace the black colored early FIPL with the late gray colored FIPL, or any colored FIPL with 60 thousand or more miles.

PART NUMBER
F2TZ-9B989-C
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<font color="red">Link to GP Controller Diagram</font> <font color="blue">Link to "Electric Fuel Pump Wiring Diagram"</font>
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Old 03-18-2006, 07:32 PM   #7 (permalink)
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Re: E40D Trans Shifting Problem

CHECK YOUR HEADLIGHT SWITCH AND PIGTAIL ASSEMBLY!

When mine burned up the first time, I was hauling horses from Florida to Georgia. Lost A/C. LOST OVERDRIVE. Lost other things, too.

Darned near caught the truck on fire, probably. Not sure why the trans and A/C would have gone out when the headlight switch pigtail burned up, but they did...

Check them now... make sure you're not near a cab fire.


Mike
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Old 03-18-2006, 10:29 PM   #8 (permalink)
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Re: E40D Trans Shifting Problem

Hey Okie, do you also sit on top of the motor while going down the road to get the 30 mph and 55 mph readings.

It is a lot easier to get the readings without the truck running.
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93 F250, regular cab, 4x4, 7.3 NA, ZF5, 3.55, 209k miles, came home 2/28/06, soon to be turbo.
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Old 03-18-2006, 10:37 PM   #9 (permalink)
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Re: E40D Trans Shifting Problem

[ QUOTE ]
Hey Okie, do you also sit on top of the motor while going down the road to get the 30 mph and 55 mph readings.

It is a lot easier to get the readings without the truck running.

[/ QUOTE ]

What do you think I am? A dumby? Of course I do, I use a remote control to steer the truck [img]/ubbthreads/images/graemlins/rolleyes.gif[/img]. But, you being soo much smarter than me could just splice in 2 wires to the FIPL and run them into the cab and clip the DVOM to them and read it. Stop readjust, etc. But now that I have the Baumannator TCS hooked to my laptop, I can adjust everything and watch the results. Nanner, nanner. [img]/ubbthreads/images/graemlins/biggrin.gif[/img]OkieG
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<font color="red">1987 F350, 4X4, Crew Cab, DRW, w/'91 7.3 TURBO-CHARGED BY ATS, no-Wastegate(Turbo rebuilt by me 7/2005)</font>, <font color="blue">E4OD Auto, Aux Trans Cooler w/12" fan, w/Baumann Programable Trans Computer-12/05</font>, Rebuilt Injection Pump-2/03, Electric Fuel Pump, Coolant Filter, "BajaGringo Block Drains, 5-Row Radiator Core-9/04, 2 New Plastic Fuel Tanks w/new Sending Units/Pickups, Fuel Filler Neck Mods, Air Ram Intake, Air-Lift SuperDuty AirBags with Smart Lift Auto Leveling-7/2005 <font color="blue">Link to Photo of "OkieGringo Idler Pulley"</font>
<font color="red">Link to GP Controller Diagram</font> <font color="blue">Link to "Electric Fuel Pump Wiring Diagram"</font>
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Old 03-19-2006, 08:43 AM   #10 (permalink)
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Re: E40D Trans Shifting Problem

See, that's why having a van is awesome!! You just take off the doghouse and reach up to the motor while you're driving down the highway!!

Amateurs!
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Old 04-01-2006, 06:58 PM   #11 (permalink)
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Re: E40D Trans Shifting Problem

I found what the problem was. When I bought the truck the RPM gauge did not work but I never cared until the other day I figured I would go by the Ford Dealership and pick up a new RPM sensor, screwed it into the port in the IP gear box. Low and behold, the RPM gauge started working and the transmission started shifting as it should. The Ford Parts guy told me that the E40D must have the RPM gauge and sensor working and working correctly for the trans to shift correctly. What a difference it made!
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Old 04-02-2006, 01:00 AM   #12 (permalink)
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Re: E40D Trans Shifting Problem

If you had told us about the tach in the first post, we would have told you to replace it also. [img]/ubbthreads/images/graemlins/shrug.gif[/img]OkieG
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<font color="red">1987 F350, 4X4, Crew Cab, DRW, w/'91 7.3 TURBO-CHARGED BY ATS, no-Wastegate(Turbo rebuilt by me 7/2005)</font>, <font color="blue">E4OD Auto, Aux Trans Cooler w/12" fan, w/Baumann Programable Trans Computer-12/05</font>, Rebuilt Injection Pump-2/03, Electric Fuel Pump, Coolant Filter, "BajaGringo Block Drains, 5-Row Radiator Core-9/04, 2 New Plastic Fuel Tanks w/new Sending Units/Pickups, Fuel Filler Neck Mods, Air Ram Intake, Air-Lift SuperDuty AirBags with Smart Lift Auto Leveling-7/2005 <font color="blue">Link to Photo of "OkieGringo Idler Pulley"</font>
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Old 04-02-2006, 11:25 AM   #13 (permalink)
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Re: E40D Trans Shifting Problem

[ QUOTE ]
If you had told us about the tach in the first post, we would have told you to replace it also. [img]/ubbthreads/images/graemlins/shrug.gif[/img]OkieG

[/ QUOTE ]

Who in the world would think that a tachometer and transmission are at all related? Only in Ford world.
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1966 Mustang 200 I6, auto, 4 wheel disk, power brake retrofit, Corvette master.

Former vehicles, 1994 E350 7.3L IDI, 1985 International 1654 rollback, 6.9L IDI, (2) 1994 Ford E350 7.3L IDI, 1985 Ford F350 DRW 6.9L IDI, 1985 Ford F350 wrecker 6.9L IDI.

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Old 04-02-2006, 01:09 PM   #14 (permalink)
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Re: E40D Trans Shifting Problem

[ QUOTE ]
Who in the world would think that a tachometer and transmission are at all related? Only in Ford world.


[/ QUOTE ] Ya, or just as weird, a burned out brake light.
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Old 04-02-2006, 02:28 PM   #15 (permalink)
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Re: E40D Trans Shifting Problem

Sorry, never though to, never thought a RPM would gauge would matter. Thank you for all the help you give. It is appreciated.
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