would it go into limp mode without the overdrive light flashing??

 

i think the '90's E40D pcm could yes.
but no matter really,you don't need to have the pcm tell you something is wrong.
everything your describing points to an incorrectly pinned MLPS is too blame.
if not,your out nothing as its free to check anyway.

 

Its not that hard to swap it over. If you can only find a 2wd ZF5 then you can installed a divorced transfer case.

I have some experience with this 2wd to 4x4 conversion. Donor truck makes is nice.





I still havent installed the ZF5 , I have been super busy , but it s coming, the E4OD is coming otu as soon as I get time.

 

thats a nice conversion there going from 2wd to 4x4

im gonna check my wiring tomorrow, that diagram is sweet, im gonna use that and check that 91 f250 too to double check myself

 

I'll disagree!!!

The transmission side of things is a piece of cake. Either get a 4x4 tranny (easy) or do the divorced transfer case where you have to fab up a crossmember, then do some driveshaft work.

However!! Putting a 4wd front axle in a 2wd truck is not easy or fun. The 2wd has a coil spring suspension. The 4x4 is a leaf spring suspension. NONE OF THESE PARTS ARE BOLT ON SWAPS! You can take most of the parts off the 4x4 truck if you have a donor, but you need to carefully measure and drill holes to put them on a 2wd truck. Not to mention, the front frame horns are different so you CAN"T bolt on the front shackle mount for the springs without some modification to the frame.

I did it because I found a 2wd truck for cheap and figured it would be a good project. I spent a lot of money and time converting and it was not worth it. I and most other people, would do better buying a 4x4 to start with.

Chris 72, if you did the swap and you're happy with it, good for you. I'm mostly happy with mine. If I could find the time to redo my front springs the right way (or at least swap on some better springs) I'd be a lot happier. But mine is my daily driver, and that really throws a wrench in things as I don't currently have a backup vehicle.

 

Well i double checked the connector today on the neutral safety switch, sure enough i had it pinned completley backwards, well i switched everything around and the truck fired up in park like its suppose to

now for the bad part, took it three miles down the road and the overdrive light starts flashing arrggggg the e4od is winning this battle

 

good job.
that's to be expected though.because all you did was correct the mistake you made when you had a flashing OD to start with.
now that,that is addressed,now you simply need to get a code scanner that will work for the trans and get the code that was originally causing the OD light flash (limp mode.)
example:
Actron/OBD I code scanner for Ford 1984-1995 (CP9015) | Code Reader | AutoZone.com
so basically your just back to square one.however! all was not lost,because the old MLPS swapped to the updated plug type was worth the effort.heck i just did it myself for preventive maintenance too.
so now at this point,rather than replacing sensors by guessing,you'll get the code first to point you in the right direction for proper diagnoses.

GO PATS!

 

Well a buddy of mine is gonna let me borrow his scanner, i really dont think i have a internal problem because just for gp i power braked the old girl and she fried the right rear tire the trans feels strong to me

one last thing when the engine is cold the tach jumps around, does the tach sensor affect the trans at all?

 

yeah,never even think about a hard parts issue with the E40D until the very end.
it's just that limp mode,or some other electrical issue can make an owner sure think it's a mechanical failure due to the symptoms.it's rarely the case at all compared to the electrical issues.
the tach sensor must be working correctly because the pcm must know the rpms of the engine at all times to determine which gear to place the trans in.

 

I would try the cheap scanner at the parts store and they will read the codes for you my father in-law has the big fancy snap-on scanner and no codes showed up I went to Orielly's and used thiers and got 8 and thanks Fordf250hdxlt for all the help on mine it is running and pulling great now

 

your welcome ihf.great to hear.