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I have a 97 F250 HD w351 EFI 180,000 miles replaced the trans a few years ago with an exchange rebuilt unit. Truck seemed to have a problem with TCC or OD hunting so I wired up a toggle switch to allow manual control as a diagnostic aid. Truck actual had a weak plug wire so replaced and kept the TCC manual switch. Everything worked just fine for quite awile especially when pulling my 5000lbs trailer. TCC switch could add a little RPM (and temp would creep up a bit, then I would just cancel the OD (a little more RPM) lock up the convertor, temp kools, we crest the grade and we boogy on down the road. However just recently the OD cancel button quit working, just gone dead. Tranny still goes in to auto OD around 50-60 MPH just no longer have a manual control.
Just replace the button? or wires? or is this common? is there an easy, likely solution? or?
I did not add the resistor when I installed the TCC manual control but it always worked OK when I needed it so? (yes I came close to stalling it a few times until I remembered it was in maual)
So your manual switch is on the TCC and the OD button you're referring to is the factory one on the end of the shifter?
If so, one of the little wires in the column probably broke from moving the lever around over the years. If you take the column covers off, you can see the wires going into the shifter. Unplug the little connector that you'll see and get a multimeter. Test between the wires (there's only 3) til you find continuity when pressing the OD button. If you don't, then you have a broken wire or a bad OD button.
You can get the shifter from the junkyard as a complete unit. If you just need a OD button it just pries out of the end of the shifter. If you just need the wires, grab those from the yard too.