I have a 1991 F-150 302 with an E4OD trans. I just rebuilt the trans and put in a new torque converter. I have reverse but no forward gears. Also have a new MLPS. Could a bad solenoid assembly cause the no forward gears issue? I rebuilt it because it dropped all forward gears going down the road. 130000 miles so inside of trans was a mess and a bad TC. Now still no forward gears. Acts just like it did before the rebuild. Any help is appreciated.

 

nope.she should have forward motion without electrical signals.
did you put a new pump in?

 

Didn't put in new pump but checked to see if it was pumping fluid through the lines at the radiator and it was pumping loads of fluid at very good pressure. Also checked fluid level while not running then again while idiling. Fluid went down on the dipstick when running compared to not.

 

I thought the solenoid assembly that bolts to the valve body controled shifts in the transmission or atleast if it shifted into gear. Am I incorrect on that?

 

The manual spool controls selection of fwd/neut/rev pressure application to the solenoid pack. Also, it controls manual 2nd and 1st.

The solenoids control upshifting/downshifting with the selector in the D position. You should at least have 1st gear, even if it will not upshift automatically.

If the manual spool valve is positioned in any forward range, the computer cannot prevent the transmission from being 'in gear'.

Check torque on the solenoid pack and I think these have a little extra plate on one end of the sol pack. Make sure your manual spool is positioned correctly and the MLPS is correctly aligned.

Since it did this before you took it apart, I would think you would have found a blown one-way sprague if it had one. did you replace all 'consumable' parts such as the steels, frictions, thrust washers and sealing rings?

Sorry, but that's the extent of my knowledge of the E4OD. I'm more old school since the newest transmissions that I know intimately are the AOD, TH700R4/TH200-4R and the infamous Ford ATX transaxle.

 

Replaced all consumable parts. Only thing found in the rebuild was clutches were gone.....nothing else appeared bad or damaged. Could a stuck or bad valve in the valve body cause this? I did clean it but didn't remove all the valves. Goes into reverse nice and firm feeling. The manual spool and MLPS will only line up one way so don't think it is an issue. I did try to adjust it but still the same issue.

 

Does the transmission have manual 1st gear? Did you inspect/change out the low roller clutch in the reverse drum?

If installed backwards, transmission will not have any forward motion unless you put it in manual low.

A dirty valve body might cause this (stress the word might) but it seems like you would have codes, too. My truck had second gear solenoid go out so it was throwing two codes. Yours might not set a code, since you can't drive it.

Anyone else?

 

Doesn't move in any forward gear....D or 2 or 1 even if put in manually. Did the same thing right before I rebuilt it. I was driving along and then no forward gears. Figured it needed rebuilding so I did. Now still the same issue but all new parts. Ans yes all parts I could change in the transmission short of the valve body were changed.

 

Ok ran a KOEO and KOER test. These are the codes I got....KOEO--637-TOT sensor circuit above max voltage, 621- Shift solenoid 1 circuit failure, 622- Shift solenoid 2 circuit failure, 624- EPC solenoid or driver circuit failure, 626- Coast clutch solenoid circuit failure(E4OD), 629- Converter clutch control circuit failure......KOER--- 538- Insufficient RPM change during KOER dynamic response test, 213- Spout circuit open, 632- Overdrive cancel switch not changing states(E4OD), 636- TOT sensor voltage out of self-test range. Now what the hell does all that mean....lol I think the transmission solenoid circuit board is bad or wiring is bad or entire solenoid assembly is bad.

 

Okay, looks like either you have a blown fuse, your Solenoid pack took a dump, the wiring to the transmission plug/the plug itself is fried, low one-way clutch is not doing a thing or your ECU just checked out. I think you said the Sol Pack is the only thing not replaced?

Unplug the Sol Pack connector and see if it will go into any forward gear. Unplugged transmission condition is D = OD, 2 = 2, 1 = 1, I think. If the problem persists, do you know anyone with a Sol Pack you can borrow? You will need an '89 to '94 Sol Pack, if memory doesn't fail me. '95 and up have a different plug, 12 pin instead of 9 pin.

Sometimes, there is a connector failure, especially if your connector is full of transmission fluid when you unplug it. Should be dry or dielectric grease only in the connector.

*Blathering below was typed before I noticed your last post. I'll leave it for reference*

You know, since we're dealing with what amounts to a Simpson dual planetary gearset, About the only reasons it would not move forward would be;

1) Input shaft isn't turning forward clutch drum.

2) Forward clutch has no pressure.
a) Sealing rings on on the support have failed.
b) Seals in the drum were put in backwards, allowing fluid to escape.
c) Pump housing is cracked.

*I'll rule out 2a, 2b since you said you replaced them and the problem existed before you worked on the transmission*

3)Sun gear to sun shell engagement is stripped.

*Not likely; this would have been noticed and truck would not back up*

4) Low/reverse clutch hub not held by one way clutch.

*You said it would go into reverse; that means the low/reverse clutch hub is being held by the low/reverse clutch. To go forward, it needs either the one-way roller clutch to hold the drum stationary or the low/reverse clutch to engage and hold the drum. See #5 below*

5) Manual spool valve not indexed into linkage properly.

*This happened all the time at Sequoia. Can't remember which transmission, but my students would put the spool in backwards or fail to index it properly.*

6) Solenoid pack not tightened correctly/dirty separator plate allowing fluid leakage.

7) Solenoid pack has an internal failure/fracture.

8) Misplaced check ball

9) Massive internal hemorrhaging of fluid in the forward clutch drum circuit.

10) Loss of pump suction

11) Pump fried or hub on TC damaged too severely to turn pump.

*I'll rule out #10 and #11 for now, too. Truck will back up*

Typically, when the engine is running, provided you have pressure, placing the manual spool in the D position puts pressure to the forward clutch directly.

I still think I'm still missing something, here but since it will go into reverse, I'll rule out low pump pressure for now.

You know, I used to teach this stuff in the '80's at Sequoia Institute, before it became part of Wyotech. An E4OD is mostly akin to the C6, only with an overdrive/coast section tacked on in front of the conventional 3 speed gearset. having never taught the E4OD, I'm fishing around, here. It didn't come into the curriculum until after I was working there.

Not having a full tech manual in front of me doesn't help, either so I can't comment on what the overdrive/coast section might have to do with the issues you have. An exploded diagram does me some good but not much. I would have used shop air to test each clutch before I buttoned it up and slammed it home.

At this point, I don' really have anything more to add. I'm stumped so I'll go sit down over there.

*points to corner of room*

 

First of all thanks for all the info and help guys. Now...Where would the blown fuse be? I did replace the solenoid wire connector so don't beleive thats the problem. No other problems so don't beleive the ECU is a problem .....hopefully. Going to try the unplug thing and see what happens.

 

IF the turn signal flasher is bottom left, it's the bottom left fuse in the dash fuse panel, left of the steering column.

HTH

 

Ok checked fuse...it's good then swapped the solenoid pack with new one. All those codes are gone. Truck will move in reverse and now will move a little in 1st gear if I rev the engine up to a high RPM....still nothing in D or 2. Now I get a KOEO code of 452....insufficient input from vehicle speed sensor(VSS) and KOER code of 632.....overdrive cancel switch not changing states. Would the VSS cause the transmission to not go in ti gear like this? Also my anti-lock brake light and brake light are on now.

 

Okay, KOEO 632 - did you press the OD switch during the KOEO test? If not, that's why you got 632. If yo did press the switch, you have an issue with that switch or circuit.

KOEO 452 - that's the VSS or its wiring. A search here will give you the troubleshooting info for the VSS. Not sure if a no-output from the VSS could stop the transmission from going into a forward gear.

(edit) RABS and brake light on - I think this would happen if your brake lights were out. I'm not sure, though. (/edit)

Something still seems odd. I may be wrong, but I think that transmission will still function to a fashion while unplugged. I don't like the fact that it will only move forward slightly while being revved. That tells me the forward clutch is trying to turn the gearset.

Reverse is the direct clutch and the low/reverse clutch combination.

Manual Low is the forward clutch and the low/reverse clutch.

Just those two statements say the direct and low/reverse clutches are good and we may have a problem with the forward clutch.

FWIW, if it were me, that transmission would be out again and I would be giving that pump and the forward clutch some very close scrutiny. I think I would try to energize that clutch with shop air and a rubber tipped air nozzle. A good manual tells which passage is the forward clutch passage in the pump. first energize it on the pump, then with the gearset back in place and pump torqued in place.

Like I've said before; without the transmission and a good shop manual in front of me, I'm not sure where to go next. Just the fact that it did this both before and after the rebuild tells me the problem has been overlooked somehow.

Okay, I'll go sit down again. Anyone else?

"Anyone got an aspirin?"

 

Did you air check it before you put the trans in?