E40D prpoblems after rebuild
05-10-2010, 01:13 PM
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E40D prpoblems after rebuild I'm an oldtime rebuilder who "retired" in 1982, I'm trying to help my son rebuild a E40D tranny and we're having a few issues. The E40D is a little after my time, so I'm not up on all the issues/problems/terminolgy.
The tranny started slipping going forward and eventually would only move if you shifted into "low", no problem in reverse.
We pulled the tranny and discovered that the forward cluch pack and OD cluch pack were totally toasted, so bad that there wasn't any material left on the cluch plates. The rest of the cluches (except reverse) showed extreme overheating. The OD sprag was destroyed. I rebuilt all the cluch packs and we replaced the OD sprag and races with new, reassembled the tranny and put back in the 1990 F250 4WD it came out of. Filled it with tranny fluid and same problem, very little movement forward unless we shift into "low", reverse is fine.
Ok, I know I'm old, but gee whiz, I air tested all the packs and inspected all the metal for damage, there was none. If there was any question in my mind, it was which way does the OD sprag turn and which way does it lock, there was no way to be 100% sure as the old one was destroyed. I installed the new one to turn counterclockwise and lock clockwise. Other than that, I'm 100% sure of the build. But obviously something isn't right. Any ideas folks?
Old Timer ....
The tranny started slipping going forward and eventually would only move if you shifted into "low", no problem in reverse.
We pulled the tranny and discovered that the forward cluch pack and OD cluch pack were totally toasted, so bad that there wasn't any material left on the cluch plates. The rest of the cluches (except reverse) showed extreme overheating. The OD sprag was destroyed. I rebuilt all the cluch packs and we replaced the OD sprag and races with new, reassembled the tranny and put back in the 1990 F250 4WD it came out of. Filled it with tranny fluid and same problem, very little movement forward unless we shift into "low", reverse is fine.
Ok, I know I'm old, but gee whiz, I air tested all the packs and inspected all the metal for damage, there was none. If there was any question in my mind, it was which way does the OD sprag turn and which way does it lock, there was no way to be 100% sure as the old one was destroyed. I installed the new one to turn counterclockwise and lock clockwise. Other than that, I'm 100% sure of the build. But obviously something isn't right. Any ideas folks?
Old Timer ....
05-10-2010, 02:57 PM
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The overdrive sprag is in correct.Did you check the low reverse sprag? I am pretty sure that the sprag is locked unless your in manual low then you take off on the low reverse clutch pack.It is also a good idea to put a solenoid pack in if there was alot of trash in unit also the MLPS(manual lever position sensor) should also be updated also.
05-10-2010, 03:46 PM
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The low/reverse is ok, no damage. I don't want to just go around replacing parts, that can get expense real quick and there isn't a lot of extra money here. Can the solenoid pack cause this, and if so, how? Thanks for the help.
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05-10-2010, 04:32 PM
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I am surprised that the sprag is in good condition after alot of miles and if the unit was overheated the springs tend to get weak and the race goes bad alot.The solenoid pack will not cause your problem but are not forgiving when they get metal and overheated.IMO it is the L-R sprag.
05-10-2010, 08:35 PM
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72blownvert/FTI Converters;
Believe me the LR sprag looked as good as the day it was manurfactured, nice and clean and no damage - no sign of overheating, no marks of any kind. It locks clockwise and rotates counterclockwise, no sign of wear on the sprags themselves.
performabuilt; Limp mode sound plausible, I don't own a "scanner", where might I get one and how do I use it (after my time)? What codes do I look for?
Old Timer ...
Believe me the LR sprag looked as good as the day it was manurfactured, nice and clean and no damage - no sign of overheating, no marks of any kind. It locks clockwise and rotates counterclockwise, no sign of wear on the sprags themselves.
performabuilt; Limp mode sound plausible, I don't own a "scanner", where might I get one and how do I use it (after my time)? What codes do I look for?
Old Timer ...
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05-11-2010, 08:11 AM
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performabuilt,
A check of the wiring harness and connectors reveal the speed sensor connector is crushed and we are unable to connect it. Would this cause the tranny to go into "limp" mode?
Anyone know where I can purchase a new connector or harness??
Old Timer ...
A check of the wiring harness and connectors reveal the speed sensor connector is crushed and we are unable to connect it. Would this cause the tranny to go into "limp" mode?
Anyone know where I can purchase a new connector or harness??
Old Timer ...
05-11-2010, 01:49 PM
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I managed to locate a new one at a dealer nearby for $38. Not too bad. I've also located a scanner for about the same money. I'll keep you all posted as to the results. Thanks for all your help.
05-14-2010, 03:30 PM
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Ok, got me a nice scanner for $200 (yeah I know, expensive), it reports the codes in verbose mode and at my age, that's a nice option. Here are the results:
Shift Selenoid 1 Circuit Failure
Shift Selenoid 2 Circuit Failure
Controller Clutch control circuit failure
Coast clutch circuit failure
Electronic Pressure control Circuit Failure
Mass Air flow sensor fault (Voltage higher than normal)
I think it's safe to say that the Selenoid pack is toast, what I don't know for sure are these two codes:
Controller Clutch control circuit failure
Coast clutch circuit failure
Are they also part of the selenoid pack, or do I need to look elsewhere?
Old Timer ...
Shift Selenoid 1 Circuit Failure
Shift Selenoid 2 Circuit Failure
Controller Clutch control circuit failure
Coast clutch circuit failure
Electronic Pressure control Circuit Failure
Mass Air flow sensor fault (Voltage higher than normal)
I think it's safe to say that the Selenoid pack is toast, what I don't know for sure are these two codes:
Controller Clutch control circuit failure
Coast clutch circuit failure
Are they also part of the selenoid pack, or do I need to look elsewhere?
Old Timer ...
05-14-2010, 07:48 PM
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The codes are:
DTC91, DTC92, DTC93, DTC94 DTC99, DTC56
We're using the INNOVA 1203 scanner at this link:
http://www.canobd2.com/Products/Tool...bd33a474b11543
The user manual is there too.
Old Timer ...
DTC91, DTC92, DTC93, DTC94 DTC99, DTC56
We're using the INNOVA 1203 scanner at this link:
http://www.canobd2.com/Products/Tool...bd33a474b11543
The user manual is there too.
Old Timer ...
