Typical E40D trans slips in and out of overdrive - Page 2 - Diesel Forum

rotaryboots · 10-02-2008, 07:40 AM

yeah I didn't know about remanufactured FIP's either But its says reman clear as day on the side of it. I'm pretty sure reman doesn't mean its been rebuilt I think, so in theory I've got a pretty much brand new FIP that I won't have to worry about for a very long time.

So the speedo will move when I hook it up to a drill and the key is off? I thought the the vss and another sensor all had to be in working order for it to move, hence all the speedo problem posts I've seen when searching. I'll give it a shot though. When I did a code check I got a code that had to do with the VSS (before I hooked it back up correctly) and then another I can't rememeber off the top of my head, and then the typical FIPL code cause i didn't open the throttle when I checked.

I noticed that when I'm driving around the OD light flashes but when I get out on the highway and get up to speed like in 3rd or OD and its slips (which feels like someone just puts it into neutral) the OD light stops flashing until it goes back into gear then it starts flashing again.

When I first unplugged it I noticed the inside of the connector was wet and I can't remember if there was a o ring still on it or not. But, I'll find out that later today. When I'm at the junk yard today I'll see if the trans clip is something I can get off a truck there. And If I have to I'll just order up a new connector for next week.

I'm thinking the slipping is mostly connector related because it is frequent but random. Sometimes it will stay in OD without slipping for a few miles other times it won't hardly stay in for 1/4 mile.

So whats the sensor next to where the speedo cable plugs into the trans? Anything to worry about?
Oh, its getting cold here in Montana too

rotaryboots · 10-04-2008, 03:05 AM

Well I have some good news and bad news.

Good news is I've tracked down some problems... bad news is I now have to fix them

First thing I found wrong is actually the FIPL I think. I can get it right at 1.1 volts at idle but at WOT it only gives me 3.58 max. Thats not very close to the 4 volts it should be at I hear so I'm gunna order a new FIPL really soon.

Next thing I tracked down and took a very long time to figure out was the speedo problem. I could spin the speedo cable manually and the speedo would jump and move like it should but when I'd hook it back up to the trans nothing would happen. Finnaly after a long while of searching I took out what I think is the speed sensor (not the one in the diff) this is the part that the speedo cable plugs into and also has a wire connector going to it and a gear on the end. Well the part's gear was fine but when I put my finger in the hole and felt the other gear... its pretty much smooth so the speed sensor's gear wasn't even attaching or moving. Whats bad enough is now I have to take the entire driveline input piece out and replace it with another one with a good gear on it.

After these things are fixed it should work

M.L.S.C. · 10-04-2008, 04:05 AM

If the E4OD tailshaft VSS is like any other mechanical VSS I've seen then you ain't got no issue with the other gear, as tis actially machined in the output shaft, and therefore steel - so you got a steel gear driving a plastic one, if there's wear guess which one would lose the battle.

rotaryboots · 10-04-2008, 09:16 PM

thats true. the gear in the tail shaft is metal and the speed sensor is plastic but the plastic gear is fine and the tail gear is smooth which is very weird. Is it that hard to take the tail shaft out, just the allen bolts and it slides out right? two options i have is to take the metal gear out and re groove it or go to a junk yard and get another gear. either way i think the tail shaft need to come out.

M.L.S.C. · 10-05-2008, 12:09 PM

I think you may have to drop the trans for that sorta surgery...

rotaryboots · 10-05-2008, 05:56 PM

so taking out the allen bolts look like they hold the tail shaft in won't do anything? I don't really have to take the metal gear out I think, if I can get to it I can check out its condition and maybe re grove it a little just so the speed sensor will mesh with it enough. Is there a trans diagram that includes the tail shaft so I can get a better idea of the work needing to be done?

rotaryboots · 10-05-2008, 10:03 PM

Well never mind about the diagram. I took the tail shaft case out (which is actually part of the 4x4 transfer case). The inside is very simple and believe it or not the speedo gear on the main shaft IS plastic and it slides right off. So, tomorrow I'm going to get a new one at the parts store because this gear is beyond bad. As I thought the middle wear the speed sensor meshes is pretty much smooth.

Well I've figured out the trans problem is probably speed related cause the OD light will start to flash in every gear but it depends on how fast you're going cause at 3k rpm in 1st it starts to flash at about 2K rpm in 2nd it will flash and in drive it starts to flash once it changes gears. I'm guessing getting the speed sensor some input will probably fix a problem and then a new FIPL will make it perfect.

M.L.S.C. · 10-05-2008, 11:06 PM

So plastic main gear on the tailshaft? Interesting, but as long as you can find a new gear tis all good. By the way, how's your tachometer? If the sensor for that is on its way out it will cause issue with the trans PCM.

rotaryboots · 10-06-2008, 01:22 AM

ya thought about that too but the tach works perfect and looks pretty newish as in it's metal is still pretty shinny.

Mark Kovalsky · 10-06-2008, 08:20 AM

Quote:

Originally Posted by M.L.S.C.

So plastic main gear on the tailshaft?

Yes, E4ODs had a plastic gear on the output shaft to drive the speedo gear. It's not uncommon in the trans world. The gear cut into the output shaft is less common.

rotaryboots · 10-08-2008, 01:55 AM

Ok great news guys, I went to the ford dealership for the gear I was needing and the funny thing is A. I went to a dealership for a part B. They had it in stock and C. It cost me 5 bucks so I was happy.

The Gear I got for it was the the stock yellow drive gear which I though wasn't available anymore and I mated it with a yellow gear for the VSS. Anyway I tore into the case again and got it all put in and sure enough my speedo finally works and the best part is so does my trans. Its now flawless. I'm gunna get the GPS out tomorrow and check the speedo acuracy cause the old VSS gear that was on the truck is actually a tan color once I cleaned it up and the one I got for it was a yellow. The teeth difference is the old gear is 19tooth and the gear I bought is a 18tooth, so I'm guessing it could be off by maybe 5mph or so but I'll find out in the morning.

The main thing is that its all working as it should with no flashing lights or nothing