o/d off not working

[skipc10]

This one may need a real tranny guru!

Got a '96 4.0L, 4WD auto (4E55 trans) and it works great, except the o/d shutoff doesn't want to work. Changed fluid and it was fine, as was the pan, etc. Changed fluid regularly, now has 115k on it. Shifts fine, etc, except for the past 50k miles it doesn't seem to want to obey the o/d off button. If I play with the cooler hoses, or if it's very cold out, it will more likely work, but as it gets warmer it doesn't want to turn off again, or turn on. A shutdown and restart always resets it to o/d-on as it should.

Tried overfilling and underfilling the fluid, but at most it might get it to work for one time out then it's non-responsive again. It has a cooler I put on when new. It will almost always work once if I open the line to do something to it. I've tried openning it just for that reason and it will work once, but that's a little tough to do every startup

My books have MOST of the wiring info EXCEPT for this button, and whether it goes to the computer or directly to the trans. It doesn't 'feel' like an elctrical switch problem, it's more running and temp related.

Can anyone give me guidance on figuring this out, like what affects that part of the tranny operation, likely causes, how it's wired up, sensitivities to things like fluid level (like it wants extra fluid as it gets old or something), etc in this type tranny? Other than this it's great, no codes either. I want to tow with it now and I'd like to keep it from going back and forth into O/D when I do, so now I need it....

Please cc my email if you can with replies.

Thanks in advance.

 

[cjbarker02]

I had the same problem when I bought my 97 4.0 and when i was getting the ball joints done i asked them to check out the o/d because I would click the button but no dash light would come on. The ford dealership said the switch on the steering colomn was broken. They fixed it for around 50 bucks, which was picked by my aftermarket warranty. I think the part was cheaper than 50 though as they charged for labor. I would look into replacing the switch. i bet it isn't difficult and inexpensive and will probably solve your prob. hope this helps

 

[skipc10]

Thanks!

Did you happen to see the wire colors or how they got to it? It's bundled deep inside the column.

 

[cjbarker02]

nope, I didn't see the wires. sorry.

I like the new switch though. It works ...and on a smaller note, its brand new which makes me want to change the one ne the other side of the csteering colomn so they both look clean. It adds a nicer touch anyhow.

 

[yosh18981898]

I get a kick out of all you guys with auto trans problems. If you had the standard manual trans you wouldn't have the problems- plus it would be much better for off-road driving

 

[skipc10]

I thought about it, but not after looking at the tow capacities with a manual trans. Autos tow much more with everything else the same.

I also wouldn't want to start from stop with 5000 lbs behind me while uphill with one!!!

 

[skipc10]

THAT'S IT

Well, I took the column cover off and it's obvious which 2 wires they are. Stuck some pins in them and tested voltage - the switch is intermittent. However, wiggling the wires around made things a little better, so based on what I see, they bend back and forth slightly when you use the gear lever, and the wire is stiff, so it's probably a break near the bending point and not the switch.

The lever is easy to replace, but tracing the wires back into the abyss would take a good amount of time. Plus, a new switch and harness will likely break again after using it since it's the wires flexing and not the switch I think.

I decided I will put a black pushbutton (radio shack) on the column just above and ahead of the key switch. That way I know it's there, it matches, and it doesn't move around. Will wire in some very flexible twisted pair to mate up with where I've cut it off.

The on/off seems 100% reliable just touching the cut wires together.

Thanks again!!!!!

 

[dan leon]

I get a kick out of all you guys with manual trans shifter and clutch maintenance, and getting stuck in stop and go traffic. Just kidding, my 96 Explorer has an auto and my 99 Z28 has a manual 6spd - both are a blast!!!

Dan

 

[Alec]

Offtopic:

BTW, autos seem to be better offroad in most situations

But now that I have a manual car I love it! However, my trail rigs will most likely always be autos.

 

[skipc10]

FINAL REPORT

OK, in case anyone was interested, the little pushbutton works great! It cost $2.39 to fix.

Radio Shack has a nice, all black, low profile, small pushbutton (I have one now too). I drilled a hole just above the keyswitch and mounted it, then used an old PC CDaudio cable (2 very flexible conductors and shield) to solder to the switch and provide a disconnect where I cut the old one off. The shielding and all is overkill and not used - just its 2 conductors. I liked it because it's so flexible and small and one cable/unit.

It looks like it belongs there IF you look hard enough to find it, yet it's very conveniently placed (I think better so than on the shifter button).

Thanks again!

 

[yosh18981898]

what do you mean autos are better for off road? I think its downright anoying trying to get the truck to climb over a large large rock or up a steep embankment with the auto trans because EVERY auto trans will slip. you have sit there revving on the engine until the stupid torque converter finally engauges. With a manual trans there is no slip- you just have to let the clutch out and you are fully engauged- NO SLIPPING!! The only reason autos tow more than manuals is becuase the manual doesn't come stock with a heavy duty clutch (another great idea from ford- don't get me wrong, I love fords!) I have a heavy duty towing/drag racing clutch in mine and I garruntee you I could outtow you on road and off road. This makes sense because the manual doesn't wasted the engine's power through slipping. If you don't believe me take a stock X with a manual and a Stock X with an auto and put them on a dyno- the x with the manual WILL have more horsepower AND more torque at the rear wheels.

 

[dan leon]

Having driven both types of transmissions in trucks, I believe that a/t's are better for the type of on/off road driving that I do.