Hello

I was talking to a guy with an 01 E350 van and he was telling me how he is constantly going through neutral safety switches. It can be anywhere from 1 month to sometimes 4 and then he has a no starter crank problem. He has lights and all, just no crank. He buys a new neutral safety switch, installs it and away he goes again for a while.

Has anyone heard about a problem like this ?

 

I haven't heard of that many going bad. Where is he getting his parts from? Maybe try a different supplier, check for damaged pins or chaffed wiring to the switch?

The more common problem seems to be some loose screws in the gear selector lever that makes the truck think it's in R. Has he tried wiggling the gear selector, holding the lever higher up in the park position, or attempted starting in neutral when he has this problem?

 

I agree with Chris. There has to be a reason. All electrical switches have a cycle rating on them. Some of them are 10,000 or so cycles.(on/off) There has to be something else contributingto the failure of the switch.

 

neural saftey switches are normally the last switch to go bad
in vehicles and equipment I have owned since 1962 I have yet to replace one and can count on one hand the total I have replaced on vehicles and equipment I have repaired
the normal is an adjustment or wiring problem

 

Well I'll check a few things and see what I can come up with. I'll post anything I find

 

How do I set the neutral switch in the proper position? The truck will start in all positions of the selector on the switch.

 

There is no Neutral Safety Switch (per se as we're used to with older vehicles) On 97-04 (7.3's with the 4R100 were produced for overseas purchases through 04)

What your likely referring to is the Transmission Range Selector. Which, has one connector and five pins.

This serves several functions. It has a 5VDC Reference Voltage which is switched by ground to signal the PCM.

The others monitor Vehicle Speed and the ESOF 4x4 System (the latter are GEM monitored).

Besides allowing a Start based on transmission shift position, it also ensures the speed of the vehicle (transmission output shaft speed / speed sensor) voltage is low enough to allow the 4x4 to be engaged safely.

The only adjustment is the Indicator Position on the attachment which is connected to it and displays the proper position on the Dash. However, miss aligned dash indicators are usually the bushings in the linkage needing replacing (99.9%).

It will only install one way as their are detents on the backside of the unit which marry with their opposing parts on the transmissions linkage itself.

Fuse #19 controls the monitoring of the PCM, GEM, 4x4, and the Transmission Range Selector.

What may be occurring is there is a short in one of the circuits which provide the data to the switch. Such as the Speed Sensor, 4x4 Selector Position, Signal Grounding (Short to Ground), a Bad Ground, or defective field sensor.

Or, it could be as simple as a corroded pin on a connection.

If it's receiving more than xx VDC it will not permit a shift into 4wd or allow the PCM to signal the Starting Circuit.

Possibly, when he replaces the unit, moving the harness is eliminating a short which over time occurs again. If it has visible damage, there may be a dead short drawing higher than designed amperage or there may be accessories added to the circuit affecting its lifespan.

I would suggest the wiring be scrutinized and connectors cleaned.

I'll see if I can obtain a wiring diagram for your vehicle and post it.

The other data received and sent to the PCM is the Shift Solenoid Position. Only about 25Ω or about +/- 1.0 VDC Signaling Circuit.

There is an Ω Circuit Chart somewhere for troubleshooting but, for the life of me I can't find it here at home.

 

Yea, It's seems were are in agreement the switch is fine, when he changes it, he is touching or making contact till it acts up again, I got a picture its nopt great but at least it will give you an idea. your looking for the dk blue/orange wire in and out to the tan/red wire out.