I have been killing my brain trying to figure out this issue any help will be greatly appreciated. I have no manual 1st or auto 1st. 05 expedition 2wd, bought banner rebuild kit and pro king low stall tc. I used correct stator rings, have checked solenoids and sensors and hard wiring connector. All ohm out and test fine. I also get power to solenoids and can feel click on. Have used spare known good tcc, epc, shift solenoids. Also swapped MLPS with known good spare. Double checked valve body and check ball locations, all seem good. still same problem. P0731 and O/D light flashing when supposed to shift into 2nd gear and realizes its already in 2nd. Intermediate clutch clearance was checked using my own gauge bar. Adjusted for the thickness of .700 for oem gauge bar. The o-ring for filter that came with kit seems sloppy but holds in place fine, don't like it so much but don't believe thats the issue. I have 70-80 psi on the Intermediate pressure with it in D and in manual 1st. Any ideas on what I need to check for this issue? If clearance was incorrect on intermediate reverse wouldn't work right? and would still have 0-5 psi on pressure test with in drive or 1st? Reverse works great.

Pressures @ idle (did not test drive or stall test pressures waiting on new kit with longer line)
P R N D 2 1
line 45 120 45 70 80 80
direct 0 0 0 0 0 0
forw. 0 0 0 70 70 70
epc 0 15 0 20 30 30
inter. 0 0 0 70 80 80

 

If the intermediate clutch was mechanically locked on it would bind in manual low and manual 2nd and still have reverse, showing no pressure on the gauge for the intermediate clutch.

The solenoid regulator valve can stick, when this happens the solenoids are fed more oil than they can exhaust and wrong gear starts can happen, showing oil pressure on the gauge for the intermediate clutch.

I would pull the valve body and check this valve, some shift kits come with a steel valve that seems to work well.

I have used both the Sonnax valve and the Superior shift kit without issues.

 

You have way low pressure in the forward gears. Did you inspect the boost or spool valve?

 

Thanks for the replies. I'm hoping it's just a valve body issue. I will pull it and inspect it all again. Will order a shift kit and install it too. I did use special brushes and cleaned all bores well and didn't notice any issues, all moved freely. Probably be this weekend when I have chance to pull valve body again. Will update, thanks again.

 

Update, ordered a reman valve body and trans is now working great. Thanks for the help!