I have a 94 F150, 2wd, 302, and was originally an AODE. I swapped in an M5OD/M5R2, and ever since then, Ive had a problem with the truck cutting out at part throttle. WOT is perfect and pulls good for what it is. Its only at a certain point in the throttle. There dont appear to be any vacuum leaks, and nothing else was changed during the trans swap. I replaced the TPS, the speed sensor on the trans is working properly, and the only codes are for the lack of the automatic trans. I had a problem with the AODE converter clutch and I came across a deal for the complete M5OD setup for $150. I dont tow with the truck, or haul heavy loads. I just putt around town with it, so I dont want to hear how "weak" the Mazda 5-speed is. Back to the swap and the issue im having. I left all of the automatic wiring, including the MLPS which was left in the neutral position. It starts bucking/cutting out in 2nd, 3rd, 4th, and 5th at the same spot in the throttle it seems. There is no CEL illuminated either. Im completely stumped. Ive read many posts about people swapping in M5OD/ZF transmissions in place of AODE/E4OD units and pretty much followed everything to a t. Does anyone have any ideas as to what I can check?

 

Did you have to change your PCM when you did the swap?

 

No. I retained the stock PCM. I've done a dozen stick swaps into Fox body Mustangs, and never had to swap the PCM. I figured the truck would be the same way. It's weird though, it's only at a certain point in the throttle. That's what made me think it was the TPS even though it scaled fine. It was the original factory Ford part, so I figured it's best to change it anyway. I'm stumped. I've read a half dozen posts that said the stock auto PCM was retained. Driving easy is perfectly fine, and wide open is fine. It's just that 40-50% throttle point is when it happens

 

Have you checked your distributor? Might be a faulty PIP.

 

No I haven't yet. Maybe I'll give it a look. I just don't understand. It didn't have this problem before the swap. All I had to dead with was the AODE lockup chatter in 3rd gear. I was trying to avoid throwing parts at it thinking something magically failed at the exact time I swapped the trans

 

I hear ya. These trucks can be finicky, at times. Good luck chasing down the problem.

 

I should also add, the problem only seems to occur when the truck is warm. The truck also has a new ECT, Motorcraft O2 sensor, and IAT. All tuneup parts (cap, rotor, plugs, wires) are new as well. Fuel pressure is also spot on

 

If it does it when warmed up to operating temp, I would also suggest taking a look at your TFI module. Is yours mounted on the distributor (known for heat sink issues) or mounted on the drivers side?

 

It's mounted by the drivers side hood hinge on a heat sink. Would it only do it at 40-50% throttle though?

 

It shouldn't be a problem since you have the remote mounted one. Usually, when they go bad they get too hot and engine stalls. Once they cool down, engine will re-start no problem. But that does not sound like your symptoms. I would check out your timing to see if it's set correctly, just to rule that out. Is your spout connector plugged in?

 

Yep, spout is plugged in. It has never died out. Just cuts out like I said above. The spout is plugged in, and the timing has not been touched. Like I said, nothing was changed/touched except for the transmission. Nothing

 

Just trying to rule some things out, hope you understand. You said that you installed new TPS. Was it Motorcraft? The reason I ask is that I had an F150 with TPS issues, was throwing codes. And I installed cheap after market/ Chinese TPS. They would work for awhile but codes would come back with idle fluctuations. Finally, spent more for the Motorcraft TPS and problems resolved.

 

Yep, I always use all factory parts. I never use oriental stuff. Still trying to figure it out

 

Well, let us know what it was. This one has me stumped.

 

Once I figure it out....