My '95 Club Chateau (E-150) van made a weird screaming noise on the road last week. It lasted for about a second or two. For about a day after that happened, I noticed that it was "hard shifting" in lower gears. (This has a 4-speed transmission; I think it's a D040 or something like that. And the engine is a 5.0 8 cyl, if that matters in this discussion.)

I took it to my Ford dealer to see what the problem was. They read the codes and said that it came back "628 - Excessive Torque Converter Clutch (TCC) Slippage" and that I needed a new transmission. Estimated at about $3,000. They reset the codes, which they said told the van that everything was OK and to stop hard shifting, and it's like normal now. But they said it's going to return, and I'll need to really do something about the tranny then.

I went to a transmission shop and found out I can get a rebuilt tranny for about $1,800, which is a lot better. But is it possible this was a fluke and that the computer hiccuped, and everything will be OK and I DON'T need a new transmission?

Anyone with an experience like this would be helpful to hear from. Or a pro that knows these computers well enough to know how reliable a report like that is.

Thanks in advance,

Allan

 

First, you went to the "stealer" for repair work...bad idea.

Well how many miles are on your van? That TCC slip could be two things: Internal lockup clutch in Torque Converter is bad OR TCC Lockup solenoid is going bad.

I am sure you could test the solenoid fairly easily with an ATSG manual and an Ohm meter. If it checks out m'kay then you'd prolly need a rebuilt converter.

 

Thanks for your reply, Hit Man. I'm sorry I forgot to say how many miles our van has. It's only got 100,000. That seemed low to me to have to already replace the transmission. But the second shop I went to that specializes in transmissions said they usually need to be replaced about every 100K. Is that bogus? I'm sure a transmission shop would say that!

I'm not mechanically inclined and can't do that ohm meter test myself. Is it something I could ask a smaller shop to do for me? And do you have any idea what either of the two suspected causes you stated might cost me to repair?

Thanks,

Allan

 

I hate to dissapoint you but the dealer and transmission shop are right. You could try and have the trans shop just replace the converter for about $300, but the rest of the trans will probably be toast soon anyway. $1800 is what I paid for an E4OD overhaul with upgrades, shift kit and external cooler. Mine died at 112,0000 miles, about average.

Here is what is happening. The torque converter clutch is supposed to lock the converter together at cruise. It is controlled by the computer. Yours is worn out and the noise was probably the TCC finally dying. The hard shifting is due to the computer increasing oil pressure to the max in order to compensate for the slippage. When the codes were reset, the oil pressure is returned to normal. The problem will return, but if you don't have money for the repairs right now, you can disconnect the battery for a couple of minutes in to reset the computer. Your engine may run rough for a few miles after that type of reset.

Jim

 

I guess I don't understand enough to know what the repercussions are if I keep resetting the computer. Is it just hiding a real problem that should really be attended to now?

I think we want to keep this vehicle and don't mind spending the $1800 (well, I mind, but you know what I mean--at least we don't have car payments on this van)... but I don't want to do it if this is just the beginning of major expenses. And if it's safe to keep resetting the computer until I *really* have to replace the transmission, maybe I'll do that to buy me another 10K or something and forestall the big expense. But is that a bad idea?

What else can I expect to come up with this van, or once the tranny is replaced, as long as I'm doing regular maintenance (and we are religious with that)--my wife even still does the mfr's suggested maint checks, some of which I am doubtful of the necessity--can we expect nothing unusual until the whole engine needs rehauling in a couple hundred thousand miles?

Appreciate further input!

Allan

 

The transmission is really the only weak point. The '95 version of the 5.0 engine and the 8.8 rear axle are both excellent if properly cared for. My rear axle did go out, but that was because it had been submerged in water and the fluid not changed. You cannot expect, however, that a gasoline engine will last 300,000 miles without internal work. It may, but the averages are against it.

Jim

 

Would it be normal for the engine to last maybe 200K though?

I've found out a little more from the transmission shop I think I'll use, and he's convinced me that rebuilding my own transmission with all the after-market updates he can put in will give me a better transmission than Ford gave me when I bought the vehicle.

So I'll probably bite the bullet and do it now. (He says that if I do it now, it may cost me less than if I wait for the hard-shifting to begin again and the computer code to come back.)

I was just hoping to find out here if I can expect relatively trouble-free and minimal expense from this vehicle once the transmission is fixed. It sounds like that may be the case. Of course, things can always go wrong. But I'm hoping this van will do us well to keep it...

Thanks again!

Allan

 

When you rebuild that E4OD, it needs some upgrades:

45 element intermediate sprag
Extra Clutches in the direct drum
Big Trans Cooler
TransGo shift kit

You could also do 6 pinion planetaries but since you are not in this for High Performance useage, the stockers should be fine

Main reason that trans died is due to the super slow shift times, that builds heat, and heat = death for an automatic. That TransGo will speed up the shifts and keep them nice.