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I'm a newbie here and done my research before posting. All the problems with the E4OD appear to be when it's hot. My '92 F150 4x4 has an intermittent harsh shifting problem between 1-2-3 and 4 but only when it's COLD....mostly for the first 20 minutes of driving then it smooths out. Sometimes I can go for weeks without having trouble but it's becoming more frequent now. Going into reverse has always been a bit of a 'clunk'.
I did have the Manual Lever Sensor replaced at 110k after it was downshifting harshly when HOT. It's now at 151k.
Try disconnecting the Manual Lever Position Sensor and cleaning it out with electrical contact cleaner, reconnect it tight. Do the same with the senor on the differential. Sure worked for me!
Pour in more fluid. Many E4ODs have incorrect dipstick markings. One extra quart should be enough to test the theory without accidentally overdoing it.
Try disconnecting the Manual Lever Position Sensor and cleaning it out with electrical contact cleaner, reconnect it tight. Do the same with the senor on the differential. Sure worked for me!
Good luck,
TD
Hey TD....YOU ROCK!
I did exactly as you said and the truck is shifting smoother than ever. Both of the connectors had all kinds of dirt/mud/gravel pasted over them....(don't ya hate it when all that crap falls into your eyes when you're working on something?) I lubed the linkage points while under there and all is cool.
Dgeesaman - the level is already a tiny bit over the full mark so I think that is okay...fluid is clean too.
Happy to be of help...that's what this board is all about!
Rob - If it's a E4OD transmission (I think it's available on both 4x4 and 4x2 trucks), it is located on the driver side of the box...a black switch with a linkage connected to it. Diff connector should be the same as well.