Hi All,

My 1994 F150 (4.9L six cylinder) had an E4OD trans that was swapped out years ago with another E4OD (year unknown). The truck is only used about once a week for short runs. About 6 months ago, the trans started acting "buggy", and wouldn't shift into 3rd gear. It was as if the trans was starting out in 3rd gear, but would drive normally once it struggled to get up to speed. To drive it safely, I had to start out in 2nd gear (it does shift from 1st to 2nd), and manually shift it into 3rd gear at about 35/40 mph. I could tolerate this since I don't use the truck much. Here's the weird part: a few weeks ago I went out to use the truck, and my turn signals and brake lights had stopped working, but the trans was now shifting normally into 3rd gear! I don't know what to think about this. Any ideas?

 

If you have a tilt wheel, raise it to the top and see if the lights start working.

 

That trans is computer controlled so the first step is to find out if it sees any problems, given the description the MLPS could be failing but any sensor issues on the engine or trans can affect trans operation and it's better to know than guess.

 

Thanks sandymane, I tried raising the tilt wheel, but no luck with the lights.

That's a pretty low mileage F250 you have. I had the same in a 1990 F250 w/460 engine. Too much gas to drive every day, ha, ha. I used to have a sandy mane too, but now it's all gray.

 

The best way to start is to read the codes. www.troublecodes.net/ford

 

have you checked for codes, with engine at operating temp, and checked trans fluid after driving, does you 3rd brake light work when brake pedal is applied

 

I agree with Mark above. Here is a video that you can view if you like. You can use a paperclip instead of the jumper he uses.

 

Here are the codes:

KOEO test:

625 - (O, M) Solenoid/circuit failure – Electronic Pressure Control (EPC) current is low – Transmissions

633 - (O) 4x4L switch should be in 4×2 or 4×4 high for the test


KOER test:

536 - Brake on/off (BOO) switch not activated during self test

538 - Operating error during self test. Air Conditioning switched on

================================================== ================================================== ==================

Re: 633 - This is a 4X2 truck, so I don't know which switch they are referring to.
536 - Brake was operated as instructed, also repeated tests to verify. This could be related to the problem of my brake lights not working, as originally stated.
Third brake light also not working.
538 - A/C was not switched on, A/C doesn't work.
625 - This looks like a solenoid pack problem, from my research. Do you think?

Thanks everyone,
Harry

 

[QUOTE=Harry-the-hat;19105608]Here are the codes:

KOEO test:

625 - (O, M) Solenoid/circuit failure – Electronic Pressure Control (EPC) current is low – Transmissions

633 - (O) 4x4L switch should be in 4×2 or 4×4 high for the test


KOER test:

536 - Brake on/off (BOO) switch not activated during self test

538 - Operating error during self test. Air Conditioning switched on

================================================== ================================================== ==================

Re: 633 - This is a 4X2 truck, so I don't know which switch they are referring to.
536 - Brake was operated as instructed, also repeated tests to verify. This could be related to the problem of my brake lights not working, as originally stated.
Third brake light also not working.
538 - A/C was not switched on, A/C doesn't work.
625 - This looks like a solenoid pack problem, from my research. Do you think?

It is sure starting to sound like a computer problem to me. Since the trans was swapped out and the E4OD is computer controlled the communication between the two is suspect. You may have a bad computer or one that is not correct for the new trans. I would pull it out and inspect the board for bad and/or leaking capacitors. Also your computer should have a sticker that shows what computer it is and the calibration code on your door jam sticker will confirm if it is correct.
Before you pull it out I would see what one of the much more experienced guys say. You have several folks answering you that know much better than me. Sandy

 

Thanks Sandy. The trans has been in the truck for years, and worked fine with the computer all that time. That's not to say the computer hasn't gone bad now. I'll wait and see if others have an opinion.

 

It could be the solenoid, it could be the PCM, or most likely, a wiring harness problem.

 

may not be this bad but a check would help
E40D: The Importance Of A Clean Trans Harness. - Ford Truck Enthusiasts Forums

 

Thanks Mark. Sounds like the wiring harness would be a good place to start looking around.

 

Interesting link, thanks!

 

Hi Mark,

Here's an update on what I've found so far:

I removed the ECM, found 3 badly corroded capacitors, and replaced them. I also replaced the brake on/off switch, as an inexpensive try at fixing the brake lights. Here are the new codes:

KOEO test:

625 - (O, M) Solenoid/circuit failure – Electronic Pressure Control (EPC) current is low – Transmissions
633 - (O) 4x4L switch should be in 4×2 or 4×4 high for the test

KOER test:

536 - Brake on/off (BOO) switch not activated during self test
Only the 538 code - (Operating error during self test. Air Conditioning switched on) has changed, and not reappeared.

The brake lights are still not working, and the left front turn signal operates continuously, and the turn signals can not even be engaged, it just slips out of position. I have to disconnect the battery to turn of the turn signal (new ts flasher tried, too) Very strange. Do you have any idea where I should start looking for a wiring harness problem?

Thanks,
Harry