1996 Ford Explorer 4L V6 (4R55E) Blinking OD

[harrisd]

1996 Ford Explorer 4L V6 (4R55E) Blinking OD

Original owner 250K miles, vehicle in good shape.

Transmission drive train history
4R55E Transmission
@165K
Shift Solenoid 2 malfunction(Broken Band)
Transmission rebuilt
@197K
Transfer Case rebuilt, don't remember original issue.
@200K
Transmission would intermittently disengage at above 50-60 mph no error.
Torgue converter failing, Shop said it didn't get replaced the rebuild and should have. Performed second rebuild do to debris in transmission, no charge.
@208K
Engine starter grinding when starting, starter was not the cause.
Flex plate failing due to fracture forming around crank shaft flange.
Replaced flexplate.
@250K PRESENT PROBLEM
Blinking OD: DTC code0174 TTC(Torque Converter Clutch solenoid) malfunction.
Drive symptom after code sets.
Experience hard downshifting when stopping, no shifting problem when accelerating to speed.

Trouble shooting done so far.
1)Took the car back to the shop, they replaced the TCC solenoid no charge, but the problem still exists. Shop said to take to Ford to check electrical wiring to PCM. Shop said any further work they would have to charge for, so took car home.
2)I have the original 96 Ford electrical system manual, so I verified the wiring and computer as good.
3)Did experience once while on a trouble shooting drive the speedometer got flaky between 70-75mph, only did it once. I went ahead and replaced the VSS sensor, since this can cause a blinking OD. Didn't resolve the blinking OD issue.
4)For trouble shooting would reset the code after car was cooled down. Would perform test drive, car would up-shift and downshift fine, but after about 3-5 miles with about 3-4 stops above about 45mph the code would
evntually set. Then the hard downshifts would start occurring.

At this point I've read quite a bit on this problem from this and another forum. I'm leaning toward replacing the valve body with a re-manufactured unit.

Does anyone have any suggestions.

 

[Sams01XplrSprt]

welcome

 

[BrooklynBay]

Welcome to this forum! Was the internal wiring harness on the transmission checked? The code you have listed is for a different problem. Check this link which is # 51 in my list of useful threads: http://www.explorerforum.com/forums/showthread.php?t=177975

 

[harrisd]

Your correct, I missed typed the error code in my post, the error I got was P0741, good catch. I checked the continuity in the harness from the PCM to the transmission.
There is an additional interconnect between the engine and firewall you can't reach so I checked the complete path from the PCM to the transmission, it checked out good.

 

[BrooklynBay]

That code usually means that the valve body is worn. P0741 Torque Converter Clutch Circuit Performance or Stuck Off.

 

[harrisd]

That code usually means that the valve body is worn. P0741 Torque Converter Clutch Circuit Performance or Stuck Off.

Last weekend I finally got around to replacing the valve body I purchased a replacement from Central Valve Body on the Web they gave about a $40.00 discount for mentioning I heard about them on the explorerforum plus if you return your core within about two weeks theirs no core charge. They provide the return shipping label, just repack the core in the same box. Their rebuilt valve bodies use Sonnex replacement parts and up-dates.
The price was $229.00 for the unit, their are other possibilities such as
Ford TSB Article No. 97-22-4 for the the P0741 code, since the transmission has been torn down a couple of times I was leaning toward the valve body. There are also specific Sonnex Updates which pertain to correcting a P0741 error.
I did encounter an additional problem, the internal solenoid wire harnesses wire insulation was so brittle that it immediately fractured and chipped off when attempting to clear the wiring to remove the valve body. I checked the web and Ford and found replacements were available either way. I decided on Ford since I figured the addition of shipping costs would be about the same. The harness cost was close to $100.00. Though there is a Ford TSB Article No.96-7-26, which pertains to 4R66E's built before 11/30/95, which my vehicle didn't pertain too.
I also purchased a Ford Motor Company Techtran Manual from Makco for $24.00 to better insure no mistakes during dis assembly and reassembly. This all may sound pricey, but in the previous reworks that has been done have been around $1700.00+. I'm planning on donating the car to a relative who needs a car.
To replace the valve body you are suppose to insert two alignment pins body before valve installation. These pins cost about $45.00 each, I was able to fabricate the larger diameter pin based on information I found on the Web and access to a lathe and matching 6mm thread die. However the smaller pin I had to wing it, but diameter is close to the valve bodies 6mm diameter bolts.
Anyway I haven't been able to burn any big miles yet, but the error hasn't yet reappeared. Till I get about 500 miles on it will I feel the problem is solved, even though it typically only took 5 miles to see the error.
Thanks for your response, I'll let you know in a few hundred miles if my money was spent wisely.
FYI:Also there is a TSB Article No.06-14-4 pertaining to Fords discontinuation of regular Mercon and the change to the use of Mercon V fluid.