'95 E4od in '93 F250 7.3idi - SHIFT ISSUES!!! Need help!
1) While driving my '93 F250 7.3idi with an E4od at about 45mph it suddenly started grinding loudly and slowing me down to, let's say, 2nd gear. I drove it home that way, as it would not go faster. Made some calls to mechanic friends and all of them said, "Yup, you need a new tranny or have yours rebuilt."
2)Truck sat for a few years, as I just did not have the money for this project.
3) Ended up buying a professionally rebuilt '95 E4od (with torque converter) from a good friend who insisted that it would work in my '93. Had my backyard mechanic neighbor install it. He is kind of a shady character, but he owed me money that he didn't have, so he did the work to pay off that debt. And I have seen him do some pretty darn amazing mechanical work in the past. It was my affordable option to get that tranny installed. My original tranny is currently in the truck bed, but no torque converter is with it. I'm curious as to why no torque converter is with it.
4) Since the truck sat for so long I ended up having to put a new Fuel Injection Pump in the truck, and now the engine runs great. But the truck would start off and not leave 2nd or 3rd gear. OD "off" light was also flashing. Bought myself a code reader and started doing LOTS of research and work.
5) Originally showed codes 23, 66, 67, 91, 93, 94 and 99. I replaced both wiring harness pigtails (black 8-pin and grey 9-pin) at the tranny. The grey one was in bad shape, and the black one was on it's way. Eliminated codes 66, 91, 93, 94 and 99. Also eliminated flashing OD light. Now I just have 23 and 67. (I know what those codes mean). Test drove truck, and now it shifts what seems to be 1st, 2nd, 3rd, but NOT 4th. All shifts are at very high RPM's (yellow range on tach), and it seems to want to go into 4th, but it neutrals out for a second, then picks up 3rd again.
6) Replaced FIPL or TPS with new grey one. Adjusted it to 1.175v at Idle, and I get 3.5v at WOT, and made sure it read no open lines as I gave it throttle slowly. (I think if I adjust a screw on the new Fuel Injection Pump I can give it more throttle and bring that voltage up closer to 4.5v.) Checked codes again, with WOT. I still get 23 and 67. The 23 may disappear once I make that adjustment.
7) I noticed that at some point during all of this my truck would not start in Park. Only in Neutral will it start. I made sure the 2 appropriate t30 torx bolts were tight under the steering wheel. Still no start in Park. I made sure my MLPS was adjusted correctly (lines matched up when in Neutral). That was correct. I pulled the shift cable at the tranny end, with shifter levers on column and on tranny in Park. Still only a Neutral start. Still codes 23 and 67.
8) Seeking to address the 67 code, I removed the MLPS, and tested to make sure it fell within the resistance specs in each position (P, R, N, D, 2, 1). In each position it tested perfectly.
9) I also have checked all of my fuses for continuity. They are good. My dome light and all brake lights work, too.
So this is where I am at now... good fuses, no brake lights out, good MLPS, new FIPL/TPS, shift lever steering column bolts are tight. Codes 23 and 67 still exist. Truck won't start in Park, only Neutral. Truck takes off in 1st, shifts to 2nd at high RPM, shifts to 3rd at high RPM, won't shift to 4th. In 3rd at real high RPM it may try to shift into 4th, but it Neutrals out for a second, then picks back up 3rd. Truck sound like it is pulling a fulling loaded trailer up a mountain, working very hard.
I'm at a total loss! I'm wondering if the problem has to do with the fact that it is a '95 tranny in a '93 truck. I did some reading on that, and some people mention that the solenoids are different, and have different connectors for the wiring harness, but the connectors are exactly the same as the ones on my original '93 tranny, and both the original and new wiring harness pigtails fit perfectly on the new '95 tranny. I think I gave you all of the information I have, so as to eliminate questions that don't need to be asked. Again, when I started out on this project I never once touched a diesel engine before. I have learned a ton, but obviously there is more learning to do. Anyone have any ideas as to what I need to do. I REALLY don't want to have to take this into the tranny shop! Thanks so much.



