I have a 1990 F-150 4x4, 5.8L, E4OD

This might be a long post, but I want you to know everything I know.

I got this truck on a trade and I don't know it's history. Here is what I am sure about, 1) the original owner worked it like a truck should be worked, but took his boots off before getting in, and 2) the kid I got it from has had it in deep water at some point.

The first thing I did was replace the TFI to get fire. The engine fired right up and is excellent.

Here is the transmission problem as best I can explain





From a stop...


Reverse - works correctly, no hesitation or jerk.

OD - 3 to 4 second wait for it to engage. Give a little throttle, immediate jerk and some power briefly until 2 - 3 MPH, then starts to act like its disengaged. From here I can slowly build up speed and at about 15 MPH things start getting better, by 25 or 30 MPH everything is lined out and at highway speeds you would never know there is a problem.

2 - 3 to 4 second wait for it to engage. Barely any throttle response until the truck builds momentum, then throttle response is great and it accelerates like it should.

1 - works correctly, no hesitation or jerk.

Manual Shifting 1 - 2 - OD, everything works perfectly, would never know there is a problem.

OD Off/On Button - Works great, smoothly shifts in and out of overdrive at highway speeds.

OD and 2, the issue is almost the same, except there is no "initial jerk" or
"brief power" in 2. This makes me think there are two issues, 1) something wrong with second gear (or getting there) and 2) Automatic shift is too quick at 1 - 2.

What is the 1 - 2 shift point supposed to be in MPH (no tach) generally speaking? (has 3.55 gears)

Just to be clear, there is no slipping or hesitation in 2 either once I have a little speed.

The issue just doesn't seem like a true slip to me.

Checked the fluid, was full, but old. A little dark, maybe a SLIGHT burnt odor, but I've seen worse. Dropped the pan and drained the torque converter. Pan had some sludge in it and there was some fuzz on the magnet (tiny particles only). Cleaned the pan and magnet, installed new filter, replaced everything and refilled it with O'Reilly brand because I'm planning on another change soon anyway. Please don't criticize.

This had no effect on the problem so I pulled the codes (the old fashion way)...

KOEO
47 - 4WD switch closed.
87 - Fuel pump primary circuit failure. When the FP relay was activated by the EEC, voltage was not detected on the control circuit.

CM
41 - HEGO sensor circuit indicates system lean (right side).
87 - Voltage was not detected on Fuel Pump Monitor while the engine was running.
95 - Fuel pump secondary circuit failure. The EEC senses infinite resistance to ground from the fuel pump on the Fuel Pump Monitor circuit.

Previous owner has the fuel system wiring completely jacked up. It's a wonder the engine can run at all, but does, and good, so I'm focusing on the tranny first.

HEGO lean, might be caused by the cracked exhaust manifold, and I don't always get this code. But I'll have to fix this propblem before inspection.

4WD switch closed is the only one that I think could really be an issue. The problem is same, no matter if in 2H, 4H, or 4L (other than a lower gear of course). I've ran the transfer case through all positions and even unplugged the 4wd switch connector, still throws the code.

Anyway, next I replaced the MLPS with the new style, upgraded plug, but this didn't change anthing.

After that I squirted in 2oz of Dr. Tranny for the fun of it. I've never used it, and I don't believe in additives, but I'm changing the fluid soon anyway. Was hoping I would get lucky and maybe a gummed up valve would come loose, or either it would blow up and I could put a standard in it. At any rate, it didn't make any difference.

Then I replaced the VSS (transfer case) and ABS sensor (rear diff), and I cleaned the solenoid pack connector (right side of tranny). While I had them off I ran the codes again to see if I could invoke a tranny issue, this time I got:

KOEO
56 - TOT sensor output is greater than Self-Test maximum value of 4.8 volts.
47 - 4WD switch closed.
87 - Fuel pump primary circuit failure. When the FP relay was activated by the EEC, voltage was not detected on the control circuit.
91 - Shift solenoid 1 circuit failure (E4OD).
92 - Shift solenoid 2 circuit failure (E4OD).
94 - Converter clutch solenoid circuit failure (E4OD).
93 - Coast clutch solenoid circuit failure (E4OD).
99 - Electronic pressure control circuit failure (E4OD).

...So now I know the computer can get tranny codes when there are some. The VSS, ABS and clean solenoid connector didn't change anything.

I ran the codes one final time with everything connected and here are the results (same as at first plus KOER):

KOEO
47 - 4WD switch closed.
87 - Fuel pump primary circuit failure. When the FP relay was activated by the EEC, voltage was not detected on the control circuit.

CM
41 - HEGO sensor circuit indicates system lean (right side).
87 - Voltage was not detected on Fuel Pump Monitor while the engine was running.
95 - Fuel pump secondary circuit failure. The EEC senses infinite resistance to ground from the fuel pump on the Fuel Pump Monitor circuit.

KOER
41 - No HEGO switching detected always lean (right side).

The last sensor I have to put on is the TPS, and I'm going to get busy on that here pretty quick.

If I've left anything important out please let me know. If there is anything I need to check I'll be happy to.

Thanks for taking the time to read all of this, I really hope someone can help me out here.

-Roger

 

Just wanted to post an update.

Today I went through the fuses with a multimeter and the one that drives the indicator lights and some of the guages was bad. I replaced it, so now I got my check engine light, all guages except temp and 4x4/Low Range working again.

BUT, the transmission is acting MUCH better now.

I still have a 3 or 4 second delay to engage in OD or 2. But now 2 doesn't have any problems whatsoever once it's in there manually.

OD still has a slight slip feel to it in second, but nothing like before replacing the fuse, and the shift points seem to be correct.

This makes me think it's still the TPS because OD has issues in second gear, but manual 2 works perfectly.

I'm going to test the TPS before I put one on, but I'll probably replace it anyhow since I already have it. I'll post the outcome here to help future readers.

The best advice I can give right now is to check the fuses with a multimeter, even if they look good, before you start throwing parts at it. Especially if you have no Check Engine, 4x4, or Low Range lights, Volt, or Oil Pressure guages, in this case be sure to check the fuse for "Seatbelt Buzzer; Warning Indicators; Tachometer; Diesel Glow Plug Control; Diesel Indicators" (#18 on this truck)

But I have no regrets about changing the sensors, they all had the potential to screw up eventually given their age the previous owner. I guess I was a teenager once myself.

 

Another update...

Haven't got around to the TPS yet, first I had to gravel road with my friend and a cold one...just to test it.

He's owned more of these trucks than myself, and as soon as he opened the door he asked "Are you driving around in 4 wheel drive?" I said "No I don't think so". Then durring the trip I locked in the hubs and tried a few things, sure enough I have been in 4 high this whole time. I tried my dangedest to jimmy the transfer case shifter forward one more position, but it's solid. When I got home I pulled the linkage rod off and shoved the selector on the transfer case itself back 1 more position and my 4x4 dash light went out. So now I'm in 2H for sure.

I took it for a test drive, and the tranny problem still exists as it did in the last post.

So I pulled the codes again...

KOEO
87

CM
41
62 - Converter clutch error (E4OD).
87
95

KOER
41

(no 47 this time)

Now this is starting to make sense, my problem could definantly be caused by the converter. And since it doesn't happen in M1 or M2, just in OD, I doubt it's a bad converter, just a bad signal.

No lock-up signal maybe? This comes through the solenoid pack connector right?

I'm thrilled to finally get some sort of transmission feedback from the codes. Still wondering if the throttle position sensor is the culprit...

Going to do that right now! ...Cause I'm out of beer anyway.

-Roger

 

Okay, the new TPS is installed and working. The tranny problem is still as it has been, greatly improved but very noticable.

Today me and a buddy took it out and cut some firewood, which gave me a good excuse to really try out 4H and 4L. The transfer, and 4WD is great after I did some toying around with the shift lever by the way. Didn't have any problems while working it today and lugging around.

So we just got back a little bit ago and I ran the codes again, they're still the same as in the last post:

Has anyone had this code before (62)? Were you able to solve the problem yourself? Or does anyone have some troubleshooting, testing, or ideas on how to fix it.

I still think the converter isn't being engaged by the computer in OD because M2 works great. But honestly I have no clue.

I'll summarize the problem once again...

From a stop...

R - Engages and works fine.

OD - Engages slow (3 to 4 seconds). first gear works great, shifts into second then begins to act like it's slipping, once it makes it to third everything is AOK again. The 2 - 3 shift seems to happen at about 40 MPH, so the engine is over-reving a little at that point, has 3.55 gears. OD also works (on and off) with the button at highway speeds, the shift is almost instant and very smooth.

2 - Engages slow (3 to 4 seconds), then works fine.

1 - Engages and works fine.

Manual shifting 1 - 2 - OD works great.

...but it might be helpful to read the entire thread to know where i started and what I've done.

I REALLY hope a few people will jump on this thread with me and give me some ideas. I've kind of exhausted the obvious stuff.

Please help me if you think you can, I'll try just about anything at this point.

Thanks,
Roger

 

Overnight I disconnected the battery to clear my CM.

I also did a little fixing on the brake bedal light switch. Mine has had an issue where sometimes it doesn't open when the brake is released, so the tail lights stay on until you tap it.

I've seen some posts for the same trasmission (but later years) that say the torque converter will unlock if you tab the break pedal.

Can anyone confirm that this is the same on a 1990 F150?

Anyhow, this morning I hooked the batter back up and got the pedal switch working right (for now at least). I took it for a drive and things seem to be getting better.

I ran the codes again:

KOEO
87

CM
41
95

KOER
41

So 62 is gone now. I think now I just need to drive it more. Hell, It could even come down to the Dr. Tranny I squirted in it early on, but I'll never know for sure.

In the mean time I'm going to hook up a dash light and 3 way toggle for the TCC lockup circut like you see alot of people doing on the forums. My hopes are that I can tell more about what's going on with the ECM and TCC circuit, and have the option to run the torque converter with a manual lockup. I'll hardly, if ever, use it, but it might help in diagnosis.

Still open to ideas or other people's experiences with this behavior though!

Thanks,
Roger