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My 2004 Explorer

Discussion in 'Modified 2002 - 2005 Explorers' started by 4pointslow, February 27, 2016.

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    1. 4pointslow

      4pointslow Explorer Torture Tester Elite Explorer

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      I just got a notice that my Elite status expired?
      I am supposed to be good until 11/2018,
      What is going on?
       
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    3. 4pointslow

      4pointslow Explorer Torture Tester Elite Explorer

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      I have been driving my 2004 for weeks after making my new EGR tube.
      The EGR monitor still has not run, the evap monitor has not run also.
      There is some information about IAT temps being over 140 causing the EGR monitor to not run, so I switched my IAT reading to be the one from the maf and not the one in my lower intake manifold.
      Drove it to work and back today, still did not run.
      So now I am wondering why.
      I did turn everything back on in the tune, maybe a glitch in the Advantage3 tuning software.
      I am thinking of creating a fresh new tune and adding all my changes, but with never having the EGR turned off.
       
    4. 4pointslow

      4pointslow Explorer Torture Tester Elite Explorer

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      Last edited: September 23, 2017
    5. 4pointslow

      4pointslow Explorer Torture Tester Elite Explorer

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      After some transmission work I was inspired to look to see why my EGR monitor was not running.
      The old factory scan tool called the WDS told me to come to a complete stop and accelerate at 50 to 75% throttle up to 45 MPH to get the EGR monitor to run.
      It still would not run.
      My IAT readings were a little high so I plugged in an IAT sensor with long pigtail and stuck it in front of the grill to grab some fresh air.
      IAT readings were lower but the EGR monitor still wont run.

      I decided to drive with the WDS hooked up and monitor the EGR stuff.
      I found out that the EGR is never being commanded on, the EVR duty cycle sits at 0 all the time.
      There must be something in my tune that is preventing it from running, it may be the baro or map readings.
      With a boosted vehicle they tell you to lock the baro reading at one setting and leave it there so the PCM doesn't miscalculate baro from having boost in the intake.
      I plan to look into it further and try to figure it out. I only have until February of next year to get it straightened out.
       
    6. 4pointslow

      4pointslow Explorer Torture Tester Elite Explorer

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      I forgot to mention that I used output state command on the EVR at Idle and the EGR valve opened and the engine ran rough.
      The DPFE sensor on the ESM (egr system module) assembly showed an increasing voltage indicating an increase in EGR flow.
      So the EVR and EGR valve function and so does the feedback sensor. Got to be something in my tune.
       
    7. 4pointslow

      4pointslow Explorer Torture Tester Elite Explorer

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      Transmission worked for a day after replacing the solenoid pack. Now it is acting up again.
      Back to the drawing board.
       
    8. 4pointslow

      4pointslow Explorer Torture Tester Elite Explorer

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      Tried a valve body, problem still there.
       
    9. Joe in NY

      Joe in NY Active Member

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      The actual slipping is caused by the worn out servo bores and the painfully slow shift speeds of ford transmissions. I put a shift kit in my VB and that definitely helped with shifting. However, this is a band-aid/prevention solution. It will help as it speeds the shifts up but the bores already have some wear in my trans.. :/
       
    10. CDW6212R

      CDW6212R Hauls the mail. Elite Explorer

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      Yes, that could be it. I've read on the Sonnax site of their many special parts, and the tools to install them. You/we hope that you don't ever have case wear issues, or VB bore issues, because those special tools are very expensive, for each unique part they sell.
       
    11. CDW6212R

      CDW6212R Hauls the mail. Elite Explorer

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      Was their any evidence of gasket wear at all, in the center areas? Sonnax suggests that movement of the case itself(the deep fluid channels in the case(side to side)), vibrates and damages the gaskets. They describe installing set screws down into those channels in 2-3 places, to keep them from moving. I'm aiming to do that with my 5R55E very soon.
       
    12. Dono

      Dono V8 Limited turbo and retired SC 4.0 OHV Elite Explorer

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    13. 4pointslow

      4pointslow Explorer Torture Tester Elite Explorer

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      The servo bores were already sleeved with bushings, I was just afraid that one might have broken or something.
      I did not do them, they had previously been done.
      You can even buy a case on eBay that has already had the bores sleeved, for about $150.00-$200.00
       
    14. 4pointslow

      4pointslow Explorer Torture Tester Elite Explorer

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      Transmission problem solved.
      It was the intermediate servo piston.
      The brand new one from Ford that I installed, it lasted 1 year and 4 months.
      Where they sit they are not far from the cat and there is a heat shield there as well.
      I am sure there is a little more heat coming from my cats since I have a supercharger on the engine.

      I had a used one laying around, it was from this transmission, I put it aside soaking in fluid when I rebuilt it.
      I have not had time to clean my garage since then and I am glad as I might have thrown it out.
      I ordered a new one (another OEM) off eBay to keep in stock. lol.

      Here is the bad one.
      IMG_1138.JPG IMG_1147.JPG
       
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    15. 4pointslow

      4pointslow Explorer Torture Tester Elite Explorer

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      I am having a celebratory beer now.
      I am also going to let a cat out of a bag.
      Check my thread on My 98 supercharged Ex.
       
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    16. 4pointslow

      4pointslow Explorer Torture Tester Elite Explorer

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      So time has been running out for me to figure out why my EGR and Evap monitors have not been running on this 2004 Explorer.
      In the past I noticed my EGR was never being commanded on and I have experimented with tune settings with no luck.
      I have to have it inspected by the end of February and time is running out.

      Tonight I finally figured it out.
      There are to things in the tune called Baro Pressure Max, and Baro Pressure Min.
      The tuning software says to set them both to 27 if you are boosted or have a highly modified engine, so the PCM doesn't learn a false Baro reading.

      On older cars(2003aprox) that didn't have a baro sensor the PCM used the MAF(at wot) to calculate baro.
      In one of the older engine performance diagnostics classes I used to teach, it was stated that you could diagnose a dirty(contaminated) MAF sensor by looking at the baro reading and comparing It to a chart in the PC/ED manual under the pinpoint testing for the MAF sensor. If the battery was disconnected you would have to road test the vehicle at WOT for it to relearn or it would sit on a preset value that looked extremely low.

      On vehicles with the ESM(egr system module) type EGR system, the DPFE sensor on it is used for a baro reading at key on engine off. In the newer engine performance class I teach it mentions that you can not use the baro reading to diagnose a dirty maf anymore since they are using the EGR sensor instead.

      Anyway, I set the Baro min and max back to stock and the EGR is now being commanded on and the monitor runs and passes.
      The stock settings are 18 for min and 31.87 for max.
      I will play with them some more if time permits but for now I am going to drive it around to get all the monitors ready and get a new inspection sticker on as soon as possible.

      baro.jpg
       
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    17. 2000StreetRod

      2000StreetRod Staff Member Moderator Elite Explorer

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      Excellent technical detective work! I'm glad you've resolved the issue.
       
    18. 4pointslow

      4pointslow Explorer Torture Tester Elite Explorer

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      Thanks!
      So the notes in Advantage3 we can not take for face value all the time.
      When the vehicles calculated Baro, the notes were correct that said to set values to 27 or whatever.
      When vehicles have changing characteristics the notes may not apply anymore.

      I just got all my monitors to run except Evap which always seems to run last anyway.
      New problem, my scanner picked up a P0606 which is a ram or rom failure in the PCM.
      This code sets from rewriting the tune in the PCM and will not turn the check engine light on.
      It may however show up when getting inspected and draw attention to the vehicle.

      I just turned off the PCM's ability to set that code and had previously turned off another one (P0605 I think).
      So now the PCM can not set codes for Ram and Rom failures.

      Time to drive it some more to get the monitors ready again.....
       
    19. Dono

      Dono V8 Limited turbo and retired SC 4.0 OHV Elite Explorer

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      Lol. you sure get deep in the programming.

      How do you get that p100 off? it just doesn't seem easy to use the correct driving styles to get all the pcm tests to run.
       
    20. 4pointslow

      4pointslow Explorer Torture Tester Elite Explorer

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      Some vehicles are harder than others to make that P1000 go away.
      Mine is still there and will be until the evap monitor runs but where I am at it doesn't matter.
      I am allowed 1 not ready monitor on my 2004, and my 1998's are allowed 2 not readys.
      There are PDF files from Ford that talk about the drive cycle and the conditions that are necessary to run the monitors.
      EGR likes stop and go traffic, the Cat monitors like steady state driving but need it to happen at three different throttle percentages.
      The list goes on...
      If you find and download the PDF files, it is a good read.
      The one for my 2004 is titled 2004 MY OBD System Operation Summary for Gasoline Engines.
       
    21. 4pointslow

      4pointslow Explorer Torture Tester Elite Explorer

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      I got my sticker.
      I can sleep at night now, for 2 years.
      I wonder why the Baro reading in my cheap Wal-Mart scan tool was showing 15.1?
      Truck seems to have a low idle after starting, definitely effects of the baro reading being different from when it was locked at a higher number.
      I will play around with it when I have more time.
       
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    22. 4pointslow

      4pointslow Explorer Torture Tester Elite Explorer

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      I just reloaded the tune with min and max Baro altered and Baro on the cheap scan tool read 14.2
      While experimenting I had set them to Max - 30.50 and Min - 29
      (I previously had them at 27,29, and even 30 for both and EGR never worked)
      So the 14.2 and the 15.1 I am getting leads me to believe the reading is to be added to 14.7 to equal real Baro/Atmospheric pressure?
      That would have given me 28.9 and 29.8 while today according to my iphone the pressure is 30.

      It has been warm for two days, last night was around 60F.
      So I was able to work on the truck and get it inspected and now it is getting cold again.
      Tuesday is even calling for snow again.
      For now I am going to get back to working on my house since it is cold out, the trucks will get all my attention when it warms up.
       

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