Experienced typical speedsensor problems, loss of speedometer, dropped out of gear, limped home without overdrive. Pulled speed sensor and found gear drive damaged, very difficult to turn. Installed new sensor and gear drive, everything was beautiful, speedo was back, smooth shifts for about 50 miles, then same symptoms. Now stuck in KS trying to figure out ehy NEW sensor went bad so quickly? Any HELP would really be appreciated. 😢😢😢😢 Update, removed new sensor and found drive gear damaged again, but still spins freely.

 

Is this the speedo-gear type? It's possible the original trashed gear left crud in the gear teeth of the tranny shaft gear, or worse, the gear on the tranny shaft is shot.

Not sure if the tranny shaft gear is plastic or not.

 

​​​​​​​Thanks for the response, yes it is speedo gear type, it is mounted in the tail shaft housing, if the shaft is shot, can it be replaced by removing the housing?

 

You wouldn't need to replace the shaft. The speedometer "drive gear" just slips onto the shaft. Getting to it, you need to remove the tail shaft housing.

BUT - I've never worked on an E4OD, so please wait for someone else to answer before you delve into that - or get a shop manual somehow.

 

Yeah, i was able to get a look in there and can see the inside gear is also bad, got a replacement at a local dealer, gave me some encouragement so i am going in lol. Will post my results. Thanks again.

 

Gave up, allen screws holding drive shaft were getting ready to strip, had to soak them in penetrating fluid.
Got the housing off and found a fried bearing. Need a puller to get inside collar of bearing off, then finally will be able to drive gear.

 

Wow, sorry to hear that, but we tried, eh?

Taking it to a tranny shop?

 

Nope just had to wait till the penetrating oil did its job. Now trying to get bearing out. Apparently this section does not get fluid from transmission, 4 oz has to be added in its own filler hole. If it leaks a little and runs dry, the heat will melt the drive and driven gears and eventually tear up bearing. Who knew, certainly not the previous owner of this rig, but i bet most owners dont know.

 

I guess this isn't a slip-yoke setup? It's the flange-type.

Again, never worked on an E4OD so in a way, I'm learning a lot from this thread

 

http://www.thedieselstop.com/faq/9497faq/maint/96fman/stj65015.htm

 

I bought all parts for my rebuild for $150, Ford wanted $200 for 1 bearing.
https://www.allstategear.com/mobile/Category.aspx?id=1986