e4od Electronic Controls Testing

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1992 Ford Pickup 7.3L Eng F350

E4OD ELECTRONIC CONTROLS APPLICATION APPL ICATION E4OD APPLICATIONS Models E150/250 Bronco & "F" Series

Engine 4.9L PFI 4.9-5.0L PFI

"E" Series

5.8L PFI

Bronco & "F" Series

5.8L PFI

E250/350, F250/350 & "F" Super Duty

7.3L Diesel

E250/350, F250/350 & "F" Super Duty

7.5L PFI

DESCRIPTION DESCRIPTION & OPERATION OPERATION Tip: E4OD STARTS OUT IN HIGH GEAR FIXED WITH A PIECE OF WIRE..WITH PICTURES The center of the EEC-IV system is the Electronic Control Assembly (ECA). The ECA receives information from various sensors and switches. Based on information received, the ECA generates output signals to control engine and transmission operation. The EEC-IV system controls 3 major areas of engine operation: air/fuel mixture, ignition, and emission control. In addition. the system controls A/C compressor clutch operation, idle speed, and transmission solenoids. The system has self-diagnostic capabilities. The engine control system consists of the ECA, sensors, switches, switches, and solenoids. In order for the ECA to perform properly, properly, it must be kept constantly informed of engine operating conditions. It is the task of the engine sensors to supply the ECA, via electrical signals, with specific information required to determine engine operating conditions. The ECA will then send out electrical signals to control air/fuel ratio, emission controls, idle speed, ignition t iming, and transmission solenoids. Perform all possible test steps under TROUBLE SHOOTING in the AUTO TRANS OVERHAUL - FORD E40D article. If referred here by trouble shooting charts or testing procedure, proceed with self-diagnostics. Some circuit tests in this article may also be used by the experienced technician to help bench test and diagnose solenoids. Transmission fault codes are only output in the KOEO Self-Test.

NOTE: In addition to transmission fault codes, engine related fault codes may be output during QUICK TEST procedure. These fault codes pertain to engine performance and must be repaired first, as engine performance will greatly affect transmission operation. For information and testing procedures of engine related fault codes and components, see appropriate TESTS W/CODES - EEC-IV article in the ENGINE PERFORMANCE PERFORMANCE section.

SELF-DIAGNOSTIC SYSTEM DIAGNOSTIC FORMATS QUICK TEST and CIRCUIT TESTS are diagnostic formats used to test and service EEC-IV system. QUICK



TEST allows technician to identify problems and retrieve service codes. CIRCUIT TESTS check circuits, sensors and actuators. Before starting any circuit test, follow all steps under QUICK TEST to find correct circuit test. If vehicle passes QUICK TEST and no driveability symptoms or intermittent faults exist, EEC-IV system is okay. okay. SERVICE CODES During QUICK TEST , 3 types of service codes are r etrieved: KOEO, KOER and Continuous Memory codes. See QUICK TEST for self-test procedures. Codes may be cleared from ECA memory after they have been recorded or repaired. See CLEARING CODES . KOEO & KOER Codes (Hard Faults) These codes indicate faults are present at time of testing. A hard fault may cause CHECK ENGINE or MALFUNCTION MALFUNCTION INDICATOR INDICATOR LIGHT (MIL) to glow and remain on until fault is repaired. If KOEO or KOER codes are retrieved during KOEO SELF-TEST or KOER SELF-TEST, use SERVICE CODE REFERENCE & DEFINITION CHARTS to find correct testing and repair procedures. Continuous Memory Codes (Soft Faults) These codes indicate a fault that may or may not be present at time of testing. These codes are used to diagnose intermittent problems. Continuous Memory Codes are retrieved during KOEO SELF-TEST. Some codes may turn on MIL or CHECK ENGINE light. Corresponding soft trouble code will be retained in ECA memory. memory. If fault does not reoccur within 40 warm-up cycles (80 cycles on some models), ECA will automatically clear code. Technician may clear service codes from memory. See CLEARING CODES . Intermittent faults may be caused by a sensor, connector or wiring-related problem.

CAUTION: Continuous Memory Codes should be recorded when retrieved during KOEO SELF-TEST. These codes may be used to identify intermittent problems that exist after all KOEO and KOER codes have been repaired and a Code 11 or 111 (pass code) has been obtained. Failure to follow this procedure may result in unnecessary unnecessary testing. Some Continuous Memory Codes faults may not be valid after KOEO and KOER codes are repaired. RETRIEVING CODES Service codes are retrieved from EEC-IV system through self-test connector. Various methods and test equipment may be used to access these codes: Analog Volt-Ohmmeter Volt-Ohmmeter (VOM) Scan tester In-Dash Malfunction Indicator Light (MIL) or CHECK ENGINE light. SELF-TEST CONNECTOR LOCATIONS Application Bronco & "F" Series "E" Series READING CODES

Location Left Front Inner Fender Panel Right Front Inner Fender Panel



TEST allows technician to identify problems and retrieve service codes. CIRCUIT TESTS check circuits, sensors and actuators. Before starting any circuit test, follow all steps under QUICK TEST to find correct circuit test. If vehicle passes QUICK TEST and no driveability symptoms or intermittent faults exist, EEC-IV system is okay. okay. SERVICE CODES During QUICK TEST , 3 types of service codes are r etrieved: KOEO, KOER and Continuous Memory codes. See QUICK TEST for self-test procedures. Codes may be cleared from ECA memory after they have been recorded or repaired. See CLEARING CODES . KOEO & KOER Codes (Hard Faults) These codes indicate faults are present at time of testing. A hard fault may cause CHECK ENGINE or MALFUNCTION MALFUNCTION INDICATOR INDICATOR LIGHT (MIL) to glow and remain on until fault is repaired. If KOEO or KOER codes are retrieved during KOEO SELF-TEST or KOER SELF-TEST, use SERVICE CODE REFERENCE & DEFINITION CHARTS to find correct testing and repair procedures. Continuous Memory Codes (Soft Faults) These codes indicate a fault that may or may not be present at time of testing. These codes are used to diagnose intermittent problems. Continuous Memory Codes are retrieved during KOEO SELF-TEST. Some codes may turn on MIL or CHECK ENGINE light. Corresponding soft trouble code will be retained in ECA memory. memory. If fault does not reoccur within 40 warm-up cycles (80 cycles on some models), ECA will automatically clear code. Technician may clear service codes from memory. See CLEARING CODES . Intermittent faults may be caused by a sensor, connector or wiring-related problem.

CAUTION: Continuous Memory Codes should be recorded when retrieved during KOEO SELF-TEST. These codes may be used to identify intermittent problems that exist after all KOEO and KOER codes have been repaired and a Code 11 or 111 (pass code) has been obtained. Failure to follow this procedure may result in unnecessary unnecessary testing. Some Continuous Memory Codes faults may not be valid after KOEO and KOER codes are repaired. RETRIEVING CODES Service codes are retrieved from EEC-IV system through self-test connector. Various methods and test equipment may be used to access these codes: Analog Volt-Ohmmeter Volt-Ohmmeter (VOM) Scan tester In-Dash Malfunction Indicator Light (MIL) or CHECK ENGINE light. SELF-TEST CONNECTOR LOCATIONS Application Bronco & "F" Series "E" Series READING CODES

Location Left Front Inner Fender Panel Right Front Inner Fender Panel



KOEO & KOER SELF-TEST SELF-TEST Codes Question: 1992 f-150 4x4 All service codes codes are 2 or 3-digit numbers. numbers. Some vehicles vehicles may output a 2 or or 3 digit code for the same same fault. See SERVICE CODE REFERENCE & DEFINITION CHARTS . ECA outputs codes one digit at a time. These codes indicate current faults in system and should be serviced in order of appearance. Codes are shown as voltage pulses (needle sweeps) on an analog Volt/Ohmmeter (VOM). See Fig 1. If using VOM, pay careful attention to length of pauses in order to read codes correctly. A 1/2-second pause occurs between number of sweeps in a digit, and a 2-second pause occurs between digits in a code. A 4-second pause occurs between each code. KOEO codes are separated from Continuous Memory codes by a 6-second delay, a single 1/2-second sweep (Separator) and another 6-second delay. Record codes in order received. Scan tester, if used, will count pulses and display them as a digital code. STAR Series Tester will add a zero (0) to single-digit Separator Code (10) and Dynamic Response Code (10). Dynamic Response Code is displayed in KOER SELF-TEST. See Fig 1. If using CHECK ENGINE light, service codes are displayed as flashes. Separator Separator Puls e Single 1/2-second separator pulse is issued 6-9 seconds after last KOEO code. Continuous Memory Codes (soft faults) are then displayed 6-9 seconds after 1/2-second separator pulse. Some digital test equipment may display separator code as "10" instead of "1". Pass Codes A Code 11 11 or 11 111 indicates no service service codes were were recorded in that portion portion of test; system passes passes that portion of test. If Code 11 or 111 is not retrieved in KOEO SELF-TEST, codes retrieved during KOER SELF-TEST may not be valid. Code 11 or 111 (pass code) must be obtained in KOEO SELF-TEST. A Code 11-1-11or 111-1-111 output during KOEO SELF-TEST indicates no KOEO code or Continuous Memory Code was recorded. Separator code may appear as "10" instead of "1" on some test equipment. Continuous Memory Memory Codes Codes These codes result from information stored by ECA during continuous self-test monitoring. Codes are displayed after separator pulse code in KOEO SELF-TEST. Use these codes for diagnosis only when KOEO SELF-TEST and KOER SELF-TEST result in Code 11 or 111 (pass code) and all steps under QUICK TEST are successfully completed. (A few codes are exceptions which may be checked after KOEO codes have been repaired). These codes indicate faults recorded within last 40 engine starts (80 engine starts on some models). Fault may or may not be currently present. See SERVICE CODE REFERENCE & DEFINITION CHARTS . Fast Codes At start of KOEO SELF-TEST SELF-TEST and after Wide Wide Open Throttle (WOT) (WOT) request in KOER SELF-TEST SELF-TEST,, ECA outputs short bursts of information, known as FAST CODES, which were used by manufacturer during assembly. With most equipment, these code bursts are not visible; an entire code sequence lasts less than 1/2 second. If this fluctuation is visible on test equipment, ignore it.



Fig 1: Reading Service Codes (2-Digit Codes Shown; 3-Digit Codes Similar)

Courtesy of FORD MOTOR CO.

CLEARING CODES To clear codes from ECA memory, start KOEO SELF-TEST . When service codes appear on test equipment or CHECK ENGINE light, disconnect jumper wire from Self-Test Input (STI) connector. If using STAR Series Tester, unlatch center button. This procedure erases Continuous Memory Codes from ECA memory. If problem has not been corrected or fault is still present, hard code will immediately be reset in ECA memory. memory.

CAUTION: DO NOT disconnect disconnect vehicle battery to clear codes. This will erase stored operating information from Keep-Alive Memory (KAM). To clear KAM, disconnect negative negative battery terminal for at l east 5 minutes.

WARNING: When battery is disconnected, disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. See COMPUTER RELEARN PROCEDURES in the APPLICATIONS & IDENTIFICATION section before disconnecting battery.

QUICK TEST



DESCRIPTION Following procedures are functional tests of EEC-IV system. The following 5 basic test steps must be carefully followed in sequence, otherwise misdiagnosis or replacement of non-faulty components may result: Visual Check Equipment Hookup KOEO (Key On, Engine Off) SELF-TEST Computed Timing Check KOER (Key On, Engine Running) SELF-TEST Diagnostic Diagnostic Ai ds Question: 1/2 shift After each service service or repair procedure procedure has been completed, completed, repeat QUICK QUICK TEST to ensure all all EEC-IV systems work properly and service codes are no longer present. VISUAL CHECK & EQUIPMENT HOOKUP Complete a basic inspection of engine compartment and all components before proceeding proceeding to self-diagnostic tests. Ensure vacuum hoses and EEC-IV wiring harnesses are properly connected. Apply parking brake, brake, and place shift shift lever in "P" position. position. Block drive wheels. wheels. Turn off off all electrical loads. loads. Connect appropriate test equipment to vehicle as follows: An alog alo g Volt-Oh Vol t-Oh mm eter (VOM) 1. Turn ignition switch to OFF position. Set VOM at 0-15V DC range. Connect positive lead of VOM to positive battery terminal. 2. Connect negative VOM lead to Self-Test Output (STO) terminal of self-test connector. See Fig 2. Connect timing light, and go to KOEO SELF-TEST . Activate KOEO SELF-TEST by connecting jumper wire from Self-Test Self-Test Input (STI) pigtail to signal signal return terminal of self-test self-test connector with ignition on. Scan Tester Follow manufacturer's instructions instructions to hook h ook up equipment and record service codes. STAR Series Tester Turn ignition switch to OFF position. Connect color-coded adapter cable leads to diagnostic tester. tester. Connect 2 service connectors of adapter cable to vehicle self-test connector and STI pigtail connector. connector. Connect timing light. Go to KOEO SELF-TEST.



Fig 2: Connecting Self-Test Diagnostic Equipment


KOEO SELF-TEST Ensure engine is at normal operating temperature. If engine does not start (or stalls after starting), continue KOEO SELF-TEST. DO NOT depress throttle on gasoline engines. Turn ignition off. Wait 10 seconds. Ensure test equipment is properly attached. Turn ignition on (engine off). Record all KOEO and Continuous Memory Codes. If a Code 11 or 111 (pass code) is not retrieved in KOEO portion of test, service KOEO codes at this time. Service any engine codes recorded before servicing transmission codes (Codes 86, 89, 566 and 629). If ECA will not output codes, see appropriate TESTS W/CODES article in the ENGINE PERFORMANCE section.



If service codes are retrieved, observe the following procedures: If CHECK ENGINE or SERVICE ENGINE SOON light is on, service codes in order retrieved. On vehicles equipped with DIS and EDIS ignition systems, see SYSTEM/COMPONENT TESTS article or SYSTEM/COMPONENT TESTS - DIESEL article in the ENGINE PERFORMANCE section if Continuous Memory Code 45, 46, 48, 215, 216, 217, 232 or 238 is retrieved during KOEO SELF-TEST. Repair ignition system as necessary. If vehicle has a no-start condition, go to appropriate no-start CIRCUIT TESTS in appropriate TESTS W/CODES article in the ENGINE PERFORMANCE section. If vehicle displays a Code 11 or 111 (pass code) and does not have any of symptoms described in previous steps, go to COMPUTED TIMING CHECK. COMPUTED TIMING CHECK Turn ignition off, and wait 10 seconds. Using jumper wire or test equipment, activate KOER SELF-TEST. If engine starts and stalls (or stalls during self-test), go to CIRCUIT TEST S (System Test) in TEST W/CODES EEC-IV article in the ENGINE PERFORMANCE section. Start engine, and check for following: If Code 98 or 998 is displayed, EEC-IV system is operating in Failure Mode Effects Management (FMEM). Vehicle cannot be diagnosed in KOER SELF-TEST; rerun KOEO SELF-TEST . Check computed timing after last service code has been displayed. Timing will remain fixed for 2 minutes after last code has been retrieved unless self-test is deactivated. Computed timing, at crankshaft, should equal base timing (see vehicle emission decal) plus 20 degrees BTDC. This timing may vary 3 degrees (+/-). If computed timing is within specification, perform KOER SELF-TEST . If timing is not within specification, go to step 2) of CIRCUIT TEST PA (TFI), PB (DIS) or PC (EDIS). See appropriate TESTS W/CODES article in the ENGINE PERFORMANCE section. KOER SELF-TEST Diagnostic Ai ds DO NOT enter this test sequence until a Code 11 or 111 (pass code) has been retrieved in KOEO SELF-TEST. If system has not passed KOEO SELF-TEST, codes recorded in KOER SELF-TEST may not be valid. Deactivate self-test by removing and reconnecting jumper wire or by procedure specified by test equipment in use. Start engine, and run it for 2 minutes at 2000 RPM to warm Heated Exhaust Gas Oxygen (HEGO) sensor. Turn engine off, and wait 10 seconds. Activate KOER SELF-TEST using a jumper wire or appropriate procedure for test equipment used. Start engine. Record all service codes displayed. Check following items: If engine starts and stalls (or stalls during self-test), go to CIRCUIT TEST S. See TESTS W/CODES - EEC-IV article in the ENGINE PERFORMANCE section. See menu below. If Code 98 or 998 is displayed, EEC-IV system is operating in Failure Management Effects Mode (FMEM) and vehicle has not passed KOEO SELF-TEST. Vehicle cannot be diagnosed while in FMEM mode. See Code 98 or 998 in SERVICE CODE REFERENCE CHARTS of TESTS W/CODES - EEC-IV article in the ENGINE PERFORMANCE section. See menu below. If vehicle is equipped with a Brake On-Off (BOO) switch, brake pedal must be depressed and released after ID code portion of test. On vehicles with Power Steering Pressure Switch (PSPS), turn steering wheel at least 1/2 turn and release within 1-2 seconds after ID code portion of test. If Dynamic Response Code appears, perform a brief Wide Open Throttle (WOT). DO NOT perform



WOT unless requested. If a Code 11 or 111 (pass code) is retrieved during KOER SELF-TEST, service Continuous Memory Codes retrieved in KOEO SELF-TEST. See TESTS W/CODES - EEC-IV article in the ENGINE PERFORMANCE section. If a Code 11 or 111 (pass code) is retrieved during Continuous Memory Code portion of KOEO SELF-TEST (Code 11-1-11 or Code 111-1-111) and no driveability problem exists, EEC-IV testing is complete. If driveability problems are still present, go to TROUBLE SHOOTING in the AUTO TRANS OVERHAUL - FORD E40D article. If KOER codes are present, see SERVICE CODE REFERENCE & DEFINITION CHARTS . If system will not output codes, go to CIRCUIT TEST QA. See appropriate TESTS W/CODES article in the ENGINE PERFORMANCE section. CONTINUOUS MONITOR MODE (WIGGLE TEST) Continuous Monitor Mode allows technician to attempt to recreate an intermittent fault while monitoring system. This mode, also called wiggle test, may be used in both KOEO SELF-TEST and KOER SELF-TEST. Circuit tests specify use of this procedure to identify intermittent faults in specific circuits or components. KOEO Wiggl e Test Proc edure Connect test equipment. See Fig 2. Turn ignition on, and activate self-test using jumper lead or diagnostic tester. Wait 10 seconds, and then deactivate and reactivate self-test. Wiggle test mode is now activated. Tap, move and wiggle suspect sensor and/or harness area. If a fault is detected, a service code may be stored in memory and indicated at diagnostic tester or scan tester. Retrieve code, and perform appropriate test. See SERVICE CODE REFERENCE & DEFINITION CHARTS . KOER Wiggl e Test Proc edure Connect test equipment. See Fig 2. Turn ignition off, and wait 10 seconds. Start engine. Activate self-test using jumper lead or diagnostic tester. Wait 10 seconds, and then deactivate and reactivate self-test. DO NOT turn engine off. KOER wiggle test mode is now activated. Tap, move and wiggle suspect sensor and/or harness area. If a fault is detected, a service code may be stored in memory and indicated at diagnostic tester or scan tester. Retrieve code, and perform appropriate test. See SERVICE CODE REFERENCE & DEFINITION CHARTS .

ADDITIONAL SYSTEM FUNCTIONS Additional diagnostic system features are available to help diagnose driveability problems and service EEC-IV systems. FUNCTIONS CHECK ENGINE Light & Malfun cti on Indic ator Li ght (MIL) CHECK ENGINE light and MIL are intended to alert driver of certain malfunctions in EEC-IV system. Light may also be used to retrieve service codes stored in ECA. When hooked up for KOEO SELF-TEST or KOER SELF-TEST, light will display all codes which turn on light during vehicle operation, not just Continuous Memory Codes. If light comes on during vehicle operation, vehicle should be inspected as soon as possible. Immediately turning off engine is not necessary; vehicle can be driven with light on. If light comes on and then goes off during vehicle operation, code causing light to glow will be stored in ECA memory as a Continuous Memory Code. Light should come on when ignition is turned on and go out when engine is started. If hard fault codes are not



present, ECA turns out light when it receives a Profile Ignition Pick-Up (PIP) signal. If light does not come on, see SYMPTOMS in TESTS W/O CODES - GASOLINE article in the ENGINE PERFORMANCE section. Output State Check Output State Check is used as an aid in servicing output actuators and solenoids associated with EEC-IV system. It allows technicians to energize and de-energize most system output actuators on command. This mode is entered from KOEO SELF-TEST after all codes have been retrieved. Leave KOEO SELF-TEST activated, and depress throttle to initiate test sequence. Each time throttle is depressed and released, output actuators will change state (from on to off or off to on). Failure Management Effects Mode (FMEM), Code 98 Or 998 FMEM mode allows system operation when sensors fail or transmit signals that are out of normal operating range. During FMEM mode, ECA substitutes a mid-range signal for defective sensor while continuing to monitor sensor. If faulty sensor's signals return to normal operating range, ECA will use those signals. A Code 98 or 998 will be displayed when FMEM mode is in effect. Hardware Li mit ed Operatio nal Strategy (HLOS) If a number of system or sensor failures are present and ECA is not receiving enough information to operate, ECA will switch to HLOS mode. ECA will output fixed values to allow operation of vehicle. Driveability concerns will be present. ECA will not output service codes in this mode. Cylind er Balance Test This test helps identify a weak or non-contributing cylinder in engines with sequential PFI fuel systems. ECA shuts off fuel supply to each injector and measures RPM drop. It computes variation between cylinders and identifies weak ones. This test mode is entered from KOER SELF-TEST after all codes have been displayed. Within 2 minutes after codes have been displayed, lightly depress throttle (a 2-3 degree throttle angle is required, not a wide open throttle). After a brief stabilizing period, ECA will activate test procedure. Test will be repeated if throttle is depressed within 2 minutes of final code output. During second and third test sequences, percentage of allowable variation between cylinders is reduced. Service codes displayed during this test identify weak or non-contributing cylinder. See CYLINDER BALANCE TEST SERVICE CODES table. If Code 90 is displayed during this test, system has passed test. If Code 77 is displayed, repeat cylinder balance test. If throttle is moved during this test, Code 77 will appear, indicating test is not completed. Total test time is about 3 minutes. CYLINDER BALANCE TEST SERVICE CODES Service Code

Application

90

Pass

10

Cylinder No. 1

20

Cylinder No. 2

30

Cylinder No. 3

40

Cylinder No. 4

50

Cylinder No. 5

60

Cylinder No. 6

70

Cylinder No. 7

80

Cylinder No. 8

77

Retest



SUMMARY If no service codes (or pass code 11-1-11 or 111-1-111) is present but driveability problem still exists, return to TROUBLE SHOOTING in AUTO TRANS OVERHAUL - FORD E40D article.

SERVICE CODE REFERENCE & DEFINITION CHARTS CODE REFERENCE & DEFINITION CHART (1991) Fault Code (1)

Code Definition

Circuit Test & Step

KOEO Codes 91/621

Shift Solenoid No. 1 (SS1) Circuit Failure

TC18

92/622


TC18

99/624

Electronic Pressure Control (EPC) Circuit Failure

TC20

98/625

Electronic Pressure Control (EPC) Driver Circuit Open In ECA

TC20

93/626

Converter Clutch Solenoid (CCS) Circuit Failure

TC18

94/627

Converter Clutch Control (CCC) Solenoid Circuit Failure

TC18

89/629


TC18

97/631

Overdrive Cancel Indicator Light (OCIL) Circuit Failure

TC10

47/633

4X4 Switch Closed

TC10

26/636

Transmission Oil Temp (TOT) Sensor Out Of Self-Test Range

TC30

56/637

Transmission Oil Temp (TOT) Circuit Open

TC40

66/638

Transmission Oil Temp (TOT) Circuit Grounded

TC50

65/654

Manual Lever Position (MLP) Sensor Not In Park Position

TC1

Continuous Memory Codes 29/452

Insufficient Input From Vehicle Speed Sensor (VSS)

DP1

49/617

1-2 Shift Error

TC90

59/618

2-3 Shift Error

TC90

69/619

3-4 Shift Error

TC90

99/624


TC90

62/628

Converter Clutch Error

TC90

67/634

Manual Lever Position (MLP) Sensor Voltage Out Of Range

TC90

56/637


TC90

66/638


TC90

65/632

Overdrive Cancel Switch (OCS) Not Changing State

TC10

26/636

Transmission Oil Temp (TOT) Sensor Voltage Out Of Self-Test Range

TC30

KOER Codes


(1)


Fault codes are listed with 2-digit code/3-digit code.

CODE REFERENCE & DEFINITION CHART (1992) Fault Code (1)

Code Definition

Circuit Test & Step

KOEO Codes 49/617

1-2 Shift Error

TG90

59/618

2-3 Shift Error

TG90

69/619

3-4 Shift Error

TG90

91/621


TC1

92/622


TC1

99/624


TC10

98/625

Electronic Pressure Control (EPC) Driver Circuit Open In ECA

TC10

94/627


TC1

93/629


TC1

97/631

Overdrive Cancel Indicator Light (OCIL) Circuit Failure

TB1

47/633

4X4 Switch Closed

TB1

26/636

Transmission Oil Temp (TOT) Sensor Voltage Out Of Self-Test Range

TE1

56/637


TE10

66/638


TE20

00/654

Manual Lever Position (MLP) Sensor Not In Park Position

TD1

Continuous Memory Codes 29/452

Insufficient Input From Vehicle Speed Sensor (VSS)

DS1

99/624


TG90

62/628

Converter Clutch Error

TG90

67/634

Manual Lever Position (MLP) Sensor Voltage Out Of Self-Test Range

56/637


TG91

66/638


TG91

TD1

KOER Codes 65/632

Overdrive Cancel Switch (OCS) Not Changing State

TB1

26/636

Transmission Oil Temp (TOT) Sensor Voltage Out Of Self-Test

TE1

(1)

Fault codes are listed with 2-digit code/3-digit code.

CIRCUIT TESTS (1991)



CIRCUIT TEST - VEHICLE SPEED SENSOR (VSS) Diagnostic Ai ds Perform this test when directed by QUICK TEST . This CIRCUIT TEST is intended to diagnose: Vehicle Speed Sensor (VSS). VSS wiring harness circuits. ECA. Fig 3: Vehicle Speed Sensor Circuit


VSS WIRE COLOR IDENTIFICATION Application

Wire Color Pin 3 (+)

"E" Series

Dark Green/White

All Others

Gray/Black

Wire Color Pin 6 (-) Orange/Yellow Pink/Orange

Preliminary Instructio ns Record and clear continuous memory codes. Warm engine to normal operating temperature. In Low gear, accelerate hard to 25 MPH and coast down to a stop. Shut off engine. Perform KOEO SELF-TEST . Go to 1. 1. Continuous Memory Code 29/452 Code 29/452 indicates there is insufficient input to ECA from VSS. Possible causes for this code are: 1. Faulty VSS. 2. Open or shorted circuit. 3. Faulty ECA. Perform appropriate drive cycle procedure. If Code 29/452 is still present, go to step 2). If code is not present or complaint cannot be verified, fault cannot be duplicated at this time. Clear codes, and see TROUBLE SHOOTING in the AUTO TRANS OVERHAUL - FORD E40D article.



2. Check VSS Circuit Continuity Turn ignition off and wait 10 seconds. Remove ECA 60-pin connector and inspect for damaged pins, corrosion, or loose wires. Repair as necessary. Install breakout box. With ECA and VSS disconnected, set DVOM on 200-ohm scale. Measure resistance between test pin No. 3 at breakout box and VSS DIF (+) circuit at VSS vehicle harness connector. See Fig 4. Also measure resistance between test pin No. 6 at breakout box and VSS DIF (-) circuit vehicle harness connector. If both readings are 5 ohms or less, go to next step. If readings are 5 ohms or more, service open circuit in VSS wiring harness. After repairs, reconnect all components and repeat step 1). Fig 4: Checking VSS Circuits


3. Check VSS Circuits For Shorts To Power Or Ground Turn ignition off. With ECA and VSS disconnected, install breakout box. Set DVOM on 200-k/ohm scale. Measure resistance between test pin No. 3 and test pins No. 37, 40 and 6. If all readings are greater than 500 ohms, remove breakout box, reconnect components and go to step 4). If any reading is less than 500 ohms, repair short(s) in VSS wiring harness and reconnect components. After repairs, repeat step 1). 4. Checking VSS Resistance Turn ignition off and wait 10 seconds. Disconnect VSS. Set DVOM on 2-k/ohm scale. Measure resistance across vehicle speed sensor. If reading is 190-250 ohms, replace ECA. Remove breakout box, reconnect components and repeat step 1). If reading is NOT 190-250 ohms, replace vehicle speed sensor and repeat appropriate drive cycle procedure. CIRCUIT TEST TC - E4OD AUTOMATIC TRANSMISSION Diagnostic Ai ds Perform this test only when directed by QUICK TEST. To prevent replacing good components, be aware following non-EEC areas may be at fault: Engine base condition (cam timing, valves rings, etc.). Brakes. Transmission fluid, friction elements and cooling. This test is not intended to diagnose transmission. This test is intended to diagnose: Wiring harness circuits CCC, CCS, 4WD LOW, EPC, OCIL, OCS, SS1, SS2, SIG RTN, TOT, MLP, EPC PWR and VPWR. Faulty ECA.


Fig 5: E4OD & MLP Circuit





Fig 6: 4WD Low & Overdrive Cancel Harness Schematic


1) Code 634, 654 & 67: Check Resistance Through MLP Sensor Code 67/634 indicates that total resistance in the MLP sensor is out of Self-Test range when the selector lever is in "P" (correct range is 3770-4607 ohms). Code 654 indicates that selector lever was not in Park position during self test. Possible causes for this fault are: faulty MLP sensor, open or shorted harness, faulty ECA. Turn key off and wait 10 seconds. Disconnect ECA 60-pin connector and i nspect for corroded or damaged pins. Service or repair as necessary. Install breakout box, leaving ECA disconnected. With KOEO, measure resistance between test pins No. 30 and 46 at the breakout box while moving the selector from "P" to "L" and back to "P". Record specifications and compare to specification table. See MLP RESISTANCE SPECIFICATIONS table. If resistance is within specification, go to step 3). If resistance is not as specified, go to next step.



MLP RESISTANCE SPECIFICATIONS Gear Position

Min. Ohms

Max. Ohms

"P"

3770

4607

"R"

1304

1593

"N"

660

807

"D"

361

442

"2"

190

232

"1"

78

95

2) Checking Continuity Of MLP Harness Ensure key is off and MLP sensor is disconnected from harness. Use a mirror to inspect ends of transmission harness connector at MLP sensor for damage or corrosion. Repair as necessary. Install breakout box, leaving ECA disconnected. Measure resistance between test pin No. 30 at the breakout box and corresponding pin at the MLP sensor vehicle harness connector. Measure resistance between test pin No. 46 at the breakout box and corresponding pin at the MLP sensor vehicle harness connector. If both resistances are less than 5 ohms, go to next step. If resistances are not as specified, repair open circuit. Remove breakout box, reconnect components and rerun QUICK TEST . 3) Check MLP Harness For Short To Power Or Ground Turn key off. Ensure MLP sensor harness is disconnected. Install breakout box leaving ECA disconnected. Set DVOM on 200-k/ohm scale. Measure resistance between test pin No. 30 and test pins No. 37 and 57 at the breakout box. Measure resistance between test pin No. 30 and test pins No. 40, 46 and 60 at the breakout box. Measure resistance between test pin No. 30 at the breakout box and chassis ground. If all resistances are 10 k/ohms or more, go to next step. If resistances are less than 10 k/ohms, repair short circuits. Remove breakout box, reconnect components and rerun QUICK TEST . 4) Checking ECA Output Voltage Ensure key is off. Disconnect MLP sensor from harness. Install breakout box and connect ECA. With KOEO, set DVOM on 20-volt scale. Measure voltage between test pins No. 30 and 46 at the breakout box. If voltage is 4.75-5.25 volts, service or adjust MLP sensor. If voltage is not as specified, replace ECA, reconnect components and rerun QUICK TEST .

NOTE: A break in step numbering sequence occurs at this point. Procedure skips from step 4) to step 10). No test procedures have been omitted. 10) Code 47/633, 65/632, 97/631: Verify Self-Test Mode Code 47/633 indicates 4WD LOW selector lever is not in 2WD or 4WD High position during KOEO Self-Test. This condition may be accompanied by an early shift in the 4WD High range. Code 65/632 indicates that Overdrive Cancel Switch (OCS) is not cycled between the engine I.D. code and "Goose Test" in the KOER Self-Test. Code 97/631 indicates an Overdrive Cancel Indicator Light (OCIL) fault during KOEO Self-Test. Possible causes for this fault are: faulty 4WD LOW switch, faulty OCS switch, burned out bulb, open harness, shorted harness or faulty ECA. Rerun QUICK TEST . If none of the above codes are present and fault cannot be duplicated at this time, testing is complete. If Code 97/631 is present, go to step 12). If any other codes are present, go to next step. 11) Cycle 4WD LOW Or Overdr ive Cancel Switch Circui t Turn key off and wait 10 seconds. Disconnect ECA 60-pin connector, and inspect for corroded or damaged pins. Service or repair as necessary. Install break-out box, l eaving ECA disconnected. With KOEO, set DVOM on 20-volt scale. 4WD LOW CIRCUIT - Measure voltage between test pin No. 12 and test pins No. 40 and 60 at the breakout box while cycling the Overdrive Cancel Switch (OCS). Move transfer case lever between



4WD and 2WD positions several times. OVERDRIVE CANCEL SWITCH (OCS) CIRCUIT - Measure voltage between test pin No. 41 and test pins No. 40 and 60 at the breakout box while cycling the Overdrive Cancel Switch. Toggle the switch on the dash several ti mes. If voltage cycles, remove breakout box. Replace ECA and rerun QUICK TEST. If voltage does not cycle, go to step 14) for driveability faults or next step for other faults. 12) Checking Circuits For Shorts To Ground Ensure key is off, breakout box is installed and ECA is disconnected. Set DVOM on 200-k/ohm scale. 4WD LOW CIRCUIT - Disconnect 4WD LOW switch. Measure resistance between test pin No. 12 and test pins No. 40 and 60 at the breakout box. OVERDRIVE CANCEL SWITCH (OCS) CIRCUIT - Disconnect Overdrive Cancel Switch. Measure resistance between test pin No. 41 and test pins No. 40 and 60 at the breakout box. If resistance(s) is 10 k/ohms or more, go to step 15) for Code 47/633 or 65/632. Go to next step f or Code 97/631. If resistance is less than 10 k/ohms for Code 47 or 633, repair short circuit and rerun KOEO Self-Test; for Code 65/632, repair short circuit and rerun KOER Self-Test. If Code 65 or 632 is still present, go to step 14). For Code 97/631, repair short circuit and rerun KOEO SELF-TEST . 13) Checking Key Power Through OCIL Circuit With KOEO, ensure breakout box is installed and ECA is disconnected. Set DVOM on 20-volt scale. Measure voltage between test pin No. 32 and test pins No. 40 and 60 at the breakout box. If voltage is 10.5 volts or more, remove the breakout box, replace ECA and rerun QUICK TEST . If voltage is less than 10.5 volts, go to next step. 14) Checking Continuity Of LED Harness (4WD Low Or Overdrive Cancel) With key off, disconnect ECA 60-pin connector and inspect for corroded or damaged pins. Service or repair as necessary. Install breakout box, leaving ECA disconnected. Set DVOM for diode check. Disconnect 4WD LOW switch. 4WD LOW CIRCUIT - Measure voltage between Key Power Circuit at the fuse No. 18 (+ probe) and test pin No. 12 (- probe) at the breakout box. OCS-OCIL CIRCUIT - Measure voltage between Key Power Circuit at the fuse No. 5 (+ probe) and test pin No. 32 (- probe) at the breakout box. If voltage is greater than 2 volts, go t o next step. If voltage is 2 volts or less, check for a faulty indicator bulb (4WD LOW LED or OCIL) or defective fuse in fuse panel. If fuse is okay, repair open circuit. Remove break-out box and reconnect ECA. Rerun QUICK TEST . 15) Checking Continuity Of The 4WD LOW Or Overdrive Cancel Switch Harness With key off, breakout box installed and ECA disconnected, disconnect appropriate switch. 4WD LOW CIRCUIT - Measure resistance between test pin No. 12 at the breakout box and 4WD LOW circuit at the 4WD LOW switch vehicle harness. OCS-OCIL CIRCUIT - Measure resistance between KEY PWR at fuse panel (ohmmeter positive lead) and power side of OCS harness connector (ohmmeter negative probe). Measure resistance between test pin No. 41 at breakout box and signal side of OCS harness connector. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open circuit(s) as necessary. Remove breakout box, reconnect components and rerun QUICK TEST . 16) Checking Circuit(s) For Shorts To Power With key off, ensure breakout box is installed and ECA is disconnected. Set DVOM on 200-k/ohm scale. 4WD LOW CIRCUIT - Disconnect 4WD LOW switch. Measure resistance between test pin No. 12 and test pins No. 37 and 57 at the breakout box.



OCS-OCIL CIRCUIT - Disconnect OCS switch. Measure resistance between test pin No. 41 and test pins No. 37 and 57 at the breakout box. Measure resistance between test pin No. 32 and test pins No. 37 and 57 at the breakout box. If resistance(s) are 10 k/ohms or more, remove breakout box, replace appropriate switch and rerun QUICK TEST . If resistance(s) are less than 10 k/ohms, repair short circuit(s). Remove breakout box, reconnect ECA and rerun QUICK TEST.

NOTE: A break in step numbering sequence occurs at this point. Procedure skips from step 16) to step 18). No test procedures have been omitted. 18) Service Code 91/621, 92/622, 93/626, 94/627, 998 & 99/624 Circuit Identification These service codes indicate that the appropriate on/off solenoid is out of Self-Test range. This may cause harsh, early or late shifting. Reading should be 9-14.5 volts when ON and less than 1.0 volt when OFF. Code 98 indicates Electronic Pressure Control (EPC) solenoid may have a faulty driver in the ECA. Code 99/624 indicates a faulty EPC circuit which may cause harsh shifting and clutch wear. Code 89/629 should be tested the same as 94/627. Possible causes for these codes are: solenoid resistance is out of limits, harness circuit is open or grounded, or faulty ECA. Fig 7: Solenoid & Circuit Identification Chart

If any of the listed codes are present, go to step 20) for 7.3L Diesel vehicles or ENTER OUTPUT STATE CHECK for all others. If codes are not present, go to KOEO SELF-TEST procedures.



ENTER OUTPUT STATE CHECK - Turn key off and wait 10 seconds. Set DVOM on 20-volt scale. A VOM or DVOM MUST be used for this test.

CAUTION: DO NOT perform Output State Check on 7.3L Diesel-E4OD vehicles, or damage to transmission may occur. This check is for 4.9L/5.0L/5.8L/7.5L E4OD vehicles only. Connect DVOM negative (-) test lead to STO circuit at Self-Test connector and positive (+) test lead to battery positive. Jumper STI circuit to SIG RTN at the Self-Test connector. Perform KOEO SELF-TEST until all Continuous Codes have been displayed. DVOM will indicate less than 1.0 volt when test is complete. Depress and release throttle. If voltage increases, remain in Output State Check and go to next step. If voltage does not increase, depress throttle to WOT and release. If STO voltage does not increase, go to CIRCUIT TEST QC in appropriate TESTS W/CODES article in the ENGINE PERFORMANCE section. Leave test equipment hooked up. 19) Check Suspect E4OD Solenoid Electrical Operation With KOEO, disconnect transmission solenoid bulkhead connector. Use a mirror to inspect both ends of connector for damage or corrosion. Service or repair as necessary. Connect DVOM positive test lead to VPWR circuit and negative test lead to ECA signal test pin at bulkhead connector (see step 18). Set DVOM on 20-volt scale. While observing DVOM, depress and release throttle several times to cycle output on and off. If suspected solenoid output circuit voltage change is 1.0 volt or more, service or repair solenoid. If voltage change is less than 1.0 volt, remove jumper and go to next step. 20) Checking Voltage Of VPWR TO E4OD Transmission Solenoids Turn key off and wait 10 seconds. Leave transmission bulkhead connector disconnected. Use a mirror to inspect both ends of connector for damage or corrosion. Service or repair as necessary. With KOEO, measure voltage between VPWR circuits test pins No. 37 and 57, (EPC power pin 35 on Diesel) at E4OD transmission harness connector and ground. Ensure voltage is greater than 10.5 volts. If voltage is within specification, go to next step. If resistance is not as specified, go to step 22). 21) Checking E4OD Transmission Solenoid Resistance Turn key off and wait 10 seconds. Disconnect ECA 60-pin connector and inspect for corroded or damaged pins. Service or repair as necessary. Install break-out box, leaving ECA disconnected. Connect transmission bulkhead connector. Set DVOM on 200-ohm scale. Measure resistance between test pins No. 37 and 57 (pin No. 35 on diesel) and ECA signal test pin at the breakout box (see step 18). If resistance is within specification, replace ECA, remove breakout box and rerun QUICK TEST . See Fig 8. If resistance is not as specified, go to next step.



Fig 8: Solenoid Resistance Chart

22) Checking Continuity Of E4OD Solenoid Harness Turn key off and wait 10 seconds. Install breakout box, leaving ECA disconnected. Disconnect transmission bulkhead connector. Measure resistance between the ECA signal test pin at the breakout box and transmission bulkhead connector (see step 18). Measure resistance between test pins No. 37 and 57 (test pin No. 35 on 7.3L Diesel) at the breakout box and EPC PWR and VPWR pins at the E4OD transmission bulkhead connector. See Fig 9. If all resistances are less than 5 ohms, go to next step. If resistance is 5 ohms or more, remove breakout box, repair open circuit and reconnect ECA and solenoids. Rerun QUICK TEST . 23) Checking E4OD Solenoid Harness For Short To Ground Turn key off and wait 10 seconds. Install breakout box, leaving ECA disconnected. Ensure transmission bulkhead connector is disconnected. Set DVOM on 200-k/ohm scale. Measure resistance between ECA signal test pin and test pins No. 40, 46 and 60 at the breakout box. See Fig 7. Measure resistance between the ECA signal test pin at the breakout box and chassis ground. If all resistances are 10 k/ohms or more, go to next step. If resistances are less than 10 k/ohms, repair short circuit(s), remove breakout box, and reconnect ECA and solenoid(s). Rerun QUICK TEST . 24) Checking E4OD Solenoid Harness For Short To Power Turn key off and wait 10 seconds. Install breakout box, leaving ECA disconnected. Ensure transmission bulkhead connector is disconnected. Set DVOM on 200-k/ohm scale. Measure resistance between ECA signal test pin and test pins No. 37 and 57 at breakout box. See Fig 7. If all resistances are 10 k/ohms or more, repair or replace solenoids as necessary. If resistances are less than 10 k/ohms, repair short circuit(s), remove breakout box, and reconnect ECA and solenoid(s). Rerun QUICK TEST . 25) Check Solenoid Driver Signal With key off, install breakout box and leave ECA connected. Disconnect transmission bulkhead connector. Connect a test light between test pin No. 37 or 57 and the ECA signal test pin at the breakout box. See Fig 7. With KOEO, wait 10 seconds. Initiate KOEO Self-Test. If test light flashes momentarily and then stays off, repair transmission solenoids as



necessary; driver signal is okay. If test light does not flash, replace ECA, reconnect solenoid(s) and rerun QUICK TEST . If test light is always on, solenoid driver is shorted to ground in ECA. Replace ECA, reconnect solenoid(s) and rerun QUICK TEST.

NOTE: A break in step numbering sequence occurs at this point. Procedure skips from step 25) to step 30). No test procedures have been omitted. 30) Code 26/636: Check Transmission Oil Operating Temperature Code 26/636 indicates Transmission Oil Temperature (TOT) sensor is out of Self-Test range. Correct voltage is 0.21-3.50. Possible causes for this fault are: TOT resistance is out of range or ECA is faulty. Drive vehicle normally in city traffic for 20-30 minutes to bring tr ansmission oil temperature to at least 50° F (10°C). In extremely cold weather, a longer warm-up drive may be necessary. Rerun QUICK TEST . If code 26/636 is still present, go to next step. If code 26/636 is no longer present, service or repair other codes as necessary. 31) Checking For VREF At Throttle Position Sensor (TPS) Refer to wiring circuit diagrams in VREF checks. Turn key off and wait 10 seconds. Disconnect ECA 60-pin connector and inspect for corroded or damaged pins. Service or repair as necessary. Install breakout box and connect ECA to breakout box. Disconnect TPS (FIPL on 7.3L Diesel) and set DVOM on 20-volt scale. With KOEO, measure voltage between VREF and SIG RTN at the TPS (or FIPL) vehicle harness connector. If voltage is 4.0-6.0 volts, reconnect TPS (or FIPL) and go to next step. If voltage is not as specified, go to CIRCUIT TEST C in appropriate TESTS W/CODES article in the ENGINE PERFORMANCE section. 32) Checking Resistance Of TOT Sensor Ensure transmission temperature is 50° F (10°C). If transmission has cooled down, repeat test drive. Turn key off and wait 10 seconds. Ensure breakout box is installed and ECA is disconnected. Ensure bulkhead connector is connected at transmission. Set DVOM on 200-k/ohm scale. With KOEO, ensure transmission oil pan is "warm to touch" on side away from exhaust manifold. Measure resistance between test pin No. 42 (test pin No. 7 on 7.3L Diesel) and test pin No. 46 at the breakout box. If resistance is within specification, go to next step. See Fig 9. If resistance is not as specified, repair or replace TOT sensor.



Fig 9: TOT Resistance Chart

33) Checking TOT Sensor Resistance In Relation To Oil 1Temperature Change TOT sensor may be within specification range (.8-100 k/ohms) and not correspond to temperature. Ensure transmission fluid is at operating temperature. Measure TOT resistance again and compare to resistance recorded in step 32). If resistance increased or decreased due to temperature change, replace ECA. If resistance did not change, replace breakout box, reconnect ECA, and replace temperature sensor.

NOTE: A break in step numbering sequence occurs at this point. Procedure skips from step 33) to step 40). No test procedures have been omitted. 40) Code 56/637: Attempt To Generate Code 66/638 Code 56/637 indicates TOT signal is greater than Self-Test maximum value of 4.80 volts. Possible causes for this fault are: faulty TOT sensor, open harness circuit, faulty ECA. Turn key off and wait 10 seconds. Disconnect transmission bulkhead connector from TOT sensor. Inspect for corroded or damaged pins. Service or repair as necessary. Insert a jumper wire at the bulkhead connector between TOT SIGNAL and SIG RTN. Run KOEO SELF-TEST . If Code 66/638 is present, remove jumper wire and service or replace TOT sensor. If Code 66/638 is not present, remove jumper wire and go to next step. 41) Check Continuity Of TOT SIGNAL & SIG RTN Circuit Turn key off and wait 10 seconds. Ensure bulkhead connector is disconnected at transmission. Disconnect ECA 60-pin connector and inspect for corroded or damaged pins. Service or repair as necessary. Install break-out box, leaving ECA disconnected. Measure resistance between TOT SIGNAL at the bulkhead connector and test pin No. 42 (test pin No. 7 on 7.3L Diesel) at the breakout box. Measure the resistance between SIG RTN at the bulkhead connector and test pin 46 at the breakout box. If both resistances are less than 5 ohms, replace ECA, remove breakout box, reconnect ECA and bulkhead connector. Rerun QUICK TEST . If resistances are 5 ohms or more, repair open circuits, r emove breakout box and reconnect ECA.



Rerun QUICK TEST.

NOTE: A break in step numbering sequence occurs at this point. Procedure skips from step 41) to step 50). No test procedures have been omitted. 50) Code 66/638: Attempt To Generate Code 56/637 Code 66/638 indicates that TOT signal is less than 0.15 volt (Self-Test minimum value). Possible causes for this fault are: faulty TOT sensor, grounded harness or faulty ECA. Turn key off and wait 10 seconds, then disconnect transmission connector from bulkhead connector. Inspect for corroded or damaged pins. Service or repair as necessary. Run KOEO Self-Test. If Code 56/637 is present, service or replace TOT sensor. If Code 56/637 is not present, go to next step. 51) Checking VREF At TPS Refer to wiring circuit diagrams in VREF checks. Turn key off and wait 10 seconds. Disconnect ECA 60-pin connector and inspect for corroded or damaged pins. Service or repair as necessary. Install breakout box and connect ECA to breakout box. Disconnect TPS (FIPL on 7.3L Diesel) and set DVOM on 20-volt scale. With KOEO, measure voltage between VREF and SIG RTN at the TPS (or FIPL) vehicle harness connector. If voltage is 4.0-6.0 volts, reconnect TPS (or FIPL) and go to next step. If voltage is not as specified, go to CIRCUIT TEST C in appropriate TESTS W/CODES article in the ENGINE PERFORMANCE section. 52) Checking TOT Signal For Short To Ground Turn key off and wait 10 seconds. Ensure bulkhead is disconnected at transmission. With breakout box installed and ECA disconnected, set DVOM on 200-k/ohm scale. Measure resistance between test pin No. 42 (test pin No. 7 on 7.3L Diesel) and test pins No. 40, 46 and 60 at the breakout box. If all resistances are 10 k/ohms or more, replace ECA and remove breakout box. Reconnect components and rerun QUICK TEST . If resistances are less than 10 k/ohms, repair short circuit, remove breakout box and reconnect components. Rerun QUICK TEST.

NOTE: A break in step numbering sequence occurs at this point. Procedure skips from step 52) to step 90). No test procedures have been omitted. 90) Checking MLP, TOT Sensor & E4OD Solenoid Drive Cycle Bring engine to operating temperature. Verify transmission fluid level and that all components are connected. Run KOEO Self-Test and record Continuous Memory Codes. If Codes 49/617, 59/618 or 69/619 are present, go to step 96). If Codes are not present, record and clear Continuous Memory Codes. Select "D" range and enable "OD". Drive vehicle in city traffic using moderate acceleration. Hold throttle opening steady while transmission is shifting through all four gears and hold throttle steady for an additional 15 seconds. Apply brakes while coming to a stop and remained stopped for 20 seconds. Repeat previous drive step. Rerun KOEO Self-Test and record Continuous Memory Codes. If a Code 111 or 11 is present, go to next step. If Code 29 or 452 is present, go to CIRCUIT TEST DP, step 1). For Codes 56/637, 62/628, 66/638, 67/634, 99/624, go to step 92). 91) Attempt To Generate Continuous Memory Code 56/637, 62/628, 66/638, 67/634 or 99/624 Before performing any procedures in this step, complete the drive cycle test. Drive vehicle approximately 15 minutes over a rough road to simulate road shock. Observe MIL LED while driving for indication of a fault. If MIL flashes ON and OFF, go to next step. If light does not flash, fault may not be duplicated at this time. Testing is complete. 92) Check Circuit Using KOEO Continuous Monitor Mode Enter KOEO Continuous Monitor Mode. Observe VOM or STAR LED for indication of a fault while performing the following. MLP SENSOR (CODE 67/634) - Lightly tap on MLP sensor to simulate road shock. Wiggle



connector at MLP sensor. Go to next step. TRANSMISSION SOLENOIDS (CODES 62/628 OR 99/624) AND TOT SENSOR (CODES 56/637 OR 66/638) - Wiggle transmission bulkhead connector. If a fault is indicated, isolate fault and service or repair as necessary. Clear Continuous Memory Codes and rerun QUICK TEST . If a fault is not indicated, go to step 95). 93) Checking EEC-IV Harness Ensure vehicle is still in KOEO Continuous Monitor Mode. Observe VOM for an indication of a fault while performing the following: using illustration in step 94), grasp harness close to sensor or transmission connector and perform "Wiggle" test while working from transmission to dash panel and ECA. If a fault is indicated, isolate fault and service as necessary. Clear Continuous Memory Codes and rerun QUICK TEST . If no fault is indicated, go to step 95). 94) Circuit Diagram For Continuous Monitor Mode Refer to E4OD Vehicle Harness Circuit Diagram. See Fig 10.



Fig 10: E4OD Vehicle Harness Circuit

95) Checking ECA & Harness Connectors Turn key off and wait 10 seconds. Disconnect ECA 60-pin connector. Disconnect ECA 60-pin connector and inspect for corroded or damaged pins. Service or repair as necessary. If connectors and terminals are okay, fault may not be duplicated at this time. Clear Continuous Memory Codes. If connectors or terminals are faulty, service or repair as necessary. Clear codes and rerun QUICK TEST . 96) Isolating Faults For Continuous Memory Codes 49/617, 59/618 Or 69/619 Codes 49/617, 59/618 or 69/619 indicate that the transmission went through 4 consecutive incorrect shifts in an upward or downward shift sequence. When changing a gear, the SS1 or SS2 solenoid remained ON or OFF an extended amount of time. Possible causes for these faults are: intermittent harness continuity or stuck shift solenoid. Rerun KOEO SELF-TEST . If any other codes appear during the KOEO Self-Test in addition to Codes 49/617, 59/618, 69/619, service other codes first. If other codes do not appear, go



to next step. 97) Checking Circuits Using KOEO Continuous Monitor Mode Enter KOEO Continuous Monitor Mode. Observe VOM or STAR LED for indication of a fault while performing the following: wiggle, shake or bend a small section of system harness while working from dash panel and ECA to transmission bulkhead connector. If a fault is indicated, disconnect connectors and inspect connectors and harness for damage. Clear codes and rerun QUICK TEST . If a fault is not indicated, service or replace SS1 and SS2 solenoids as necessary.

CIRCUIT TESTS (1992) CIRCUIT TEST DS PROGRAMMAB LE SPEEDOMETER/ODOMETER MODULE (PSOM) Diagnostic Ai ds Perform this test when directed by QUICK TEST. This CIRCUIT TEST is intended to diagnose: PSOM output to ECA. PSOM (+) and PSOM (-) wiring harness circuits. Faulty ECA. To prevent replacement of good components, be aware following non-EEC related areas and components may be cause of problem: Cruise control system. Rear anti-lock brake system. Instrumentation system. Fig 11: Programmable Speedometer/Odometer Module (PSOM) Circuit




Fig 12: Identifying Programmable Speedometer/Odometer Module (PSOM) Connector Terminals


1) Continuous Memory Code 29/452 Code 29/452 indicates ECA detected incorrect output from VSS sometime during vehicle operation. Possible causes for this code are: PSOM output to ECA. PSOM (+) and PSOM (-) wiring harness circuits. Faulty ECA. Turn ignition off. Remove ECA 60-pin connector. Inspect terminals, and r epair if damaged. Install EEC-IV Breakout Box (T83L-50-EEC-IV), leaving ECA disconnected. Measure resistance between test pins No. 3and 6 at breakout box. If resistance is 21-55 k/ohms, go to step 4). If resistance is not 21-55 k/ohms, go to step 2). 2) Check PSOM Circuit Continuity Ensure ignition is off. Disconnect PSOM wiring harness connector. Measure resistance between test pin No. 3 at breakout box and PSOM + circuit at PSOM wiring harness connector. If resistance is less than 5 ohms, repair open circuit and repeat QUICK TEST . If resistance is more than 5 ohms, go to next step. 3) Check PSOM Circuit For Open Ensure ignition is off. Measure resistance between test pin No. 3 and test pins No. 6, 37 and 40 at breakout box. If resistance is 10 k/ohms or less, repair open circuit and repeat QUICK TEST . If resistance is more than 10 k/ohms, go to step 4). 4) ECA Test Turn ignition off. Connect ECA to breakout box. Connect wiring harness connector to PSOM. Set DVOM on 20-volt AC scale. Start engine, and warm it to normal operating temperature. Measure voltage between test pins No. 3 and 6 while gradually increasing vehicle speed to 50 MPH. If maximum voltage is less than 4.5 volts, fault is in instrument cluster. If maximum voltage received is more than 4.5 volts, replace ECA. CIRCUIT TEST TB 4X4 LOW & OVERDRIVE CANCEL SWITCH (OCS) Diagnostic Ai ds Perform this test only when directed by QUICK TEST . To prevent replacing good components, be aware following non-EEC areas may be at fault: Engine base condition (cam timing, valves rings, etc.). Brakes. Transmission fluid, friction elements and cooling.



Transfer case linkage or internal condition. This test is only intended to diagnose: Harness circuits 4x4 LOW/ OCIL and OCS. Faulty ECA. Fig 13: 4x4 Low & Overdrive Cancel Circuits (Touch Drive Option)




Fig 14: 4x4 Low & Overdrive Cancel Circuits (Without Touch Drive Option)


1) Code 47/633, 65/632 Or 97/631 Code 47/633 indicates 4x4 Low selector lever is not in 4x2 or 4x4 HIGH position during KOEO Self-Test. Code 65/632 indicates Overdrive Cancel Switch (OCS) is not cycled between engine ID code and WOT check during KOER Self-Test. Code 97/631 indicates OCS circuit fault during KOEO Self-Test. Possible causes for these faults are: Faulty 4x4 Low switch or 4x4 selector lever position. Faulty OCS switch or switch not cycled. OCS bulb burned out. OCS circuit open or grounded. Faulty ECA. Perform QUICK TEST . If no codes are present, fault is intermittent and cannot be duplicated at this time. See TROUBLE SHOOTING in the AUTO TRANS OVERHAUL - FORD E40D article. If Code 47/633 or 65/632 is present, go to step 2). If Code 97/631 is present, go to step 3). 2) Cycle 4x4 Or Overdrive Cancel Switch Turn ignition off. Disconnect 60-pin ECA connector. Inspect terminals, and repair if damaged. Install EEC-IV Breakout Box (T83L-50-EEC-IV), leaving ECA disconnected. Turn ignition on. To check 4x4 LOW circuit, measure voltage between test pin No. 12 and test pins No. 40 and 60 at breakout box. To check OCS circuit, measure voltage between test pin No. 41 and test pins No. 40 and 60 at breakout box while cycling overdrive cancel switch. If voltage cycles, replace ECA and repeat QUICK TEST . If voltage does not cycle, go to step 3). 3) Check Circuits For Short To Ground Turn ignition off. Leave ECA disconnected from breakout box. Disconnect OCS. To check 4x4 LOW circuit, measure resistance between test pin No. 12 and test pins No. 40 and 60 at breakout box. To check OCS circuit, measure resistance between test pin No.



41 and pins No. 40 and 60 at breakout box. If resistance is more than 10 k/ohms, go to step 4) (Code 97/631) or step 6) (Code 47/633 or 65/632). If resistance is 10 k/ohms or less, repair short circuit. Repeat QUICK TEST . If code is still present, go to step 5). 4) Check Power Through OCIL Circuit Turn ignition off. Leave ECA disconnected from breakout box. Measure voltage between test pin No. 32 and test pins No. 40 and 60 at breakout box. If voltage is more than 10.5 volts, replace ECA and repeat QUICK TEST . If voltage is 10.5 volts or less, go to next step. 5) Check Outpu t Driv er Volt age Signal Turn ignition off. Leave ECA disconnected from breakout box. Disconnect OCS. To check 4x4 LOW circuit, connect DVOM positive lead on KEY POWER terminal of fuse panel and negative lead on test pin No. 12 at breakout box. See Fig 15. To check OCS circuit, connect DVOM positive lead on KEY POWER terminal of fuse panel and negative lead on test pin No. 32 at breakout box. If either voltage reading is less than 2 volts, check bulb and fuse. If bulb and fuse are okay, repair open circuit and repeat QUICK TEST . If both voltage readings are 2 volts or more, go to next step.



Fig 15: Identifying KEY POWER Terminal in Fuse Panel


6) Check Circuit Continuity Turn ignition off. Leave ECA disconnected from breakout box. Disconnect OCS. To check 4x4 LOW circuit, connect DVOM positive lead on KEY POWER terminal of fuse panel and negative lead on test pin No. 12 at breakout box. To check OCS circuit, connect DVOM positive lead on KEY POWER terminal of fuse panel and negative lead on power side of OCS wiring harness connector. Connect DVOM positive lead on test pin No. 41 at breakout box and negative lead on power side of OCS wiring harness connector. If either resistance reading is 5 ohms or more, repair open circuit and repeat QUICK TEST . If both resistance readings are less than 5 ohms, go to next step. 7) Check Circuits For Short To Power Turn ignition off. Leave ECA disconnected from breakout box. Disconnect OCS. To check 4x4 LOW circuit, measure resistance between test pin No. 12 and test



pins No. 37 and 57 at breakout box. To check OCS circuit, measure resistance between test pin No. 32 and test pins No. 37 and 57 at breakout box. Measure resistance between test pin No. 41 and test pins No. 37 and 57 at breakout box. If resistances are more than 10 k/ohms, replace switch and repeat QUICK TEST . If any resistance is 10 k/ohms or less, repair short circuit and repeat QUICK TEST. CIRCUIT TEST TC - TRANSMISSION SOLENOIDS Question: CODE 624 ELETRONIC PRESSURE CONTROLL Diagnostic Ai ds Perform this test only when directed by QUICK TEST . To prevent replacing good components, be aware following non-EEC areas may be at fault: Engine base condition (cam timing, valves rings, etc.). Brakes. Transmission fluid, friction elements and cooling. This test is not intended to diagnose transmission. This test is intended to diagnose: Wiring harness circuits M/CCC, CCO, CCS, EPC, SS3/4, SS1, SS2, SS3, SIG RTN, EPC PWR and VPWR. Faulty ECA. CIRCUIT TEST TC ACRONYMS Acronym

Definition

CCO

Converter Clutch Overdrive

CCS

Coast Clutch Control

CCC

Converter Clutch Control

EPC

Electronic Pressure Control

SS

Shift Solenoid



Fig 16: E4OD Solenoid Circuits (Bronco, "E" Series & "F" Series)


E4OD SERVICE CODE IDENTIFICATION Application

ECA Pin No.

KOEO Code

CCC

53

94/627

CCS

55

93/629

EPC

38

99/624, 998

SS1

52

91/621

SS2

19

92/622

TEST PINS NO. 35, 37 & 57 (EPC PWR) WIRE COLOR IDENTIFICATION Application

Wire Color

Bronco, "E" & "F" Series

Red Or Red/White

1) Output State Check Code 91/621, 92/622, 93/629, 94/627, 629, 641 or 652 indicates shift solenoid did not respond to ECA command. Possible causes for these faults are: Faulty Manual Lever Position (MLP) sensor. Circuit open or grounded. Faulty ECA. To enter Output State Check, use only VOM or DVOM. DO NOT use scan tester. Turn ignition off. Disconnect cruise control servo wiring harness connector. Connect DVOM negative lead to STO terminal at self-test connector. Connect positive lead to positive battery t erminal. Install a jumper wire between SIG RTN terminal at self-test connector and STI terminal. Perform KOEO SELF-TEST until



continuous memory test is complete. DVOM will read less than 1.0 volt when test is complete to indicate ECA has entered Output State Check. Depress and release throttle. If voltage increases, remain in Output State Check and go to step 2). If voltage does not increase, depress throttle to WOT and release. If STO voltage goes high, go to step 2). If STO voltage does not go high, leave test equipment connected. Check and repair throttle linkage as necessary or disconnect cruise control (if equipped). Go to next step. 2) Check Solenoid Electrical Condition Turn ignition off. Disconnect transmission wiring harness connector. Inspect terminals, and repair if damaged. Connect VOM or DVOM positive test lead to solenoid VPWR connector. Connect negative test lead to appropriate solenoid terminal at transmission wiring harness connector. Cycle solenoid output on and off by depressing and releasing throttle 3-5 times. If voltage output changes 0.5 volt or more, fault is in transmission. If voltage output does not change 0.5 volt or more, go to next step. 3) Check Continuity Between Solenoid & VPWR Circuits Turn ignition off. Leave transmission wiring harness disconnected. Disconnect 60-pin ECA connector. Inspect terminals, and repair if damaged. Install EEC-IV Breakout Box (T83L-50-EEC-IV), leaving ECA disconnected. Measure resistance between ECA output signal terminal at ECA wiring harness connector and output signal terminal at transmission wiring harness connector. Measure resistance between breakout box test pins No. 37 and 57 and VPWR terminal at transmission wiring harness connector. If either resistance is less than 5 ohms, repair open circuit and repeat QUICK TEST . If both resistances are 5 ohms or more, go to next step. 4) Check Solenoid Circuit For Short To Power Or Ground Turn ignition off. Leave ECA disconnected from breakout box. Leave transmission wiring harness disconnected. Measure resistance between ECA output signal test pin and test pins No. 37 and 57 at breakout box. Measure resistance between ECA output signal test pin and pins No. 40, 46 and 60 at breakout box. Measure resistance between ECA output signal test pin and chassis ground. If either resistance is less than 10 k/ohms, repair short circuit and repeat QUICK TEST . If all resistances are 10 k/ohms or more, replace ECA and repeat QUICK TEST.

NOTE: A break in step numbering sequence occurs at this point. Procedure skips from step 4) to step 10). No test procedures have been omitted. 10) Check VPWR To Solenoid Code 86/566 or 89/629 indicates shift solenoid did not respond to ECA command. Code 99/624 indicates failure of EPC circuit. Code 98/625 indicates EPC driver failure. Possible causes for these faults are: Faulty solenoid. Circuit open or grounded. Faulty ECA. Turn ignition off. Disconnect transmission wiring harness connector. Turn ignition on. Measure resistance between VPWR and EPC PWR terminal at transmission wiring harness connector and chassis ground. If voltage is less than 10.5 volts, repair open circuit and repeat QUICK TEST . If voltage is 10.5 volts or more, go to step 11). 11) Check Solenoid Resistance Turn ignition off. Leave transmission wiring harness connector disconnected. Measure resistance between VPWR and EPC PWR terminal and suspect component terminal at transmission wiring harness connector. If resistance is not 3-7 ohms, fault is in transmission. If resistance is 3-7 ohms, go to step 12). 12) Check Solenoid Signal & VPWR Circuit Continuity Turn ignition off. Disconnect 60-pin ECA connector. Inspect terminals, and repair if damaged. Install EEC-IV Breakout Box (T83L-50-EEC-IV),



leaving ECA disconnected. Measure resistance between breakout box test pins No. 37 and 57 (No. 35 for 7.3L Diesel) and VPWR/EPC PWR terminal at transmission wiring harness connector. Measure resistance between test pin No. 32 at breakout box and EPC solenoid terminal at transmission wiring harness connector. If resistance is 5 ohms or more, repair open circuit and repeat QUICK TEST . If resistance is more than 5 ohms, go to next step. 13) Check Circuit For Short To Power Or Ground Turn ignition off. Leave ECA disconnected from breakout box. Leave transmission wiring harness connector disconnected. Measure resistance between test pin No. 38 and test pins No. 37 and 57 (No. 35 for 7.3L diesel) at breakout box. Measure resistance between test pin No. 38 and test pins No. 40, 46 and 60 at breakout box. If either resistance is less than 10 k/ohms, repair short circuit and repeat QUICK TEST . If all resistances are 10 k/ohms or more, replace ECA and repeat QUICK TEST.

NOTE: A break in step numbering sequence occurs at this point. Procedure skips from step 13) to step 20). No test procedures have been omitted. 20) Check Solenoid Resistance KOEO Code 621 (SS1), 622 (SS2), 641 (SS3) or 643 (CCC) indicates failure in shift solenoid circuit. Possible causes for these faults are: Faulty shift solenoid. Circuit open or grounded. Faulty ECA. Turn ignition off. Disconnect transmission wiring harness connector. Measure resistance between suspect shift solenoid at transmission wiring harness connector and chassis ground. If resistance is 13-17 ohms, go to next step. If resistance is not 13-17 ohms, go to step 22). 21) Check Shift Solenoid For Short To Power Turn ignition off. Disconnect transmission wiring harness connector. Disconnect 60-pin ECA connector. Inspect terminals, and repair if damaged. Turn ignition on. Measure voltage between suspect shift solenoid at transmission wiring harness connector and chassis ground. If voltage is more than 0.5 volt, repair short to power and repeat QUICK TEST . If voltage is 0.5 volt or less, go to next step. 22) Check Shift Solenoid For Short To Ground Turn ignition off. Leave transmission wiring harness connector disconnected. Measure resistance between suspect shift solenoid at transmission wiring harness connector and chassis ground. Measure resistance between suspect shift solenoid and other circuits at transmission wiring harness connector. If either resistance is less than 10 k/ohms, repair short circuit and repeat QUICK TEST . If all resistances are 10 k/ohms or more, go to next step. 23) Check Shift Solenoid Circuit Continuity Turn ignition off. Leave transmission wiring harness connector disconnected. Install EEC-IV Breakout Box (T83L-50-EEC-IV), leaving ECA disconnected. Measure resistance between suspect shift solenoid at breakout box and suspect shift solenoid terminal at transmission wiring harness connector. If resistance is 5 ohms or more, repair open circuit and repeat QUICK TEST . If resistance is less than 5 ohms, go to next step. 24) Check Shift Solenoid For Short To Power In Transmission Turn ignition off. Leave ECA disconnected from breakout box. Reconnect transmission wiring harness connector. Measure voltage between test pin No. 60 and suspect shift solenoid terminal at breakout box. If voltage is 0.5 volt or more, replace or repair solenoid short to power. If voltage is less than 0.5 volt, replace ECA and repeat QUICK TEST .

NOTE: A break in step numbering sequence



occurs at this point. Procedure skips from step 24) to step 30). No test procedures have been omitted. 30) Continuous Memory Codes 621, 622, 641 & 643 Continuous Memory Code 621 (SS1), 622 (SS2), 641 (SS3) or 643 (CCC) indicates a failure was detected in shift solenoid circuit during last 80 warm-up cycles. Possible causes for these faults are: Faulty shift solenoid. Circuit open or grounded. Turn ignition off. Check shift solenoid circuit between ECA and transmission. Repair or replace as necessary. If circuits are okay, go to next step. 31) Check For Intermittent Short Or Open Turn ignition off. Disconnect 60-pin ECA connector. Inspect terminals, and repair if damaged. Install EEC-IV Breakout Box (T83L-50-EEC-IV), leaving ECA disconnected. Turn ignition on. Connect test light between test pin No. 37 and suspect shift solenoid terminal at breakout box. See IDENTIFYING SHIFT SOLENOID TEST CIRCUITS table. Test light should be at partial brightness. Observe test light while wiggling and bending shift solenoid circuit between transmission and ECA. An open or short to power will be indicated by light going off. A short to ground will be indicated by light getting bright. Repeat procedure for all solenoids. If fault is indicated, isolate and repair as necessary. If no fault is indicated, go to next step. IDENTIFYING SHIFT SOLENOID TEST CIRCUITS Shift Solenoid

Test Pin No.

SS1

11

SS2

51

SS3

52

CCC

55

32) Check For Intermittent Short To Ground Turn ignition off. Leave ECA disconnected from breakout box. Disconnect transmission wiring harness connector. Turn ignition on. Connect test light between test pin No. 37 and suspect shift solenoid terminal at breakout box. Test light should be off. Observe test light while wiggling and bending shift solenoid circuit between transmission and ECA. A short to ground will be indicated by light turning on. Repeat procedure for all solenoids. If fault is indicated, isolate and repair as necessary. If no fault is indicated, problem is intermittent and cannot be duplicated at this time. CIRCUIT TEST TD - MANUAL LEVER POSITION (MLP) SENSOR Diagnostic Ai ds Perform this test only when directed by QUICK TEST . To prevent replacing good components, be aware following non-EEC areas may be at fault: Engine base condition (cam timing, valves rings, etc.). Electrical (alternator, battery, add-on devices, etc.). Transmission shift linkage. This test is not intended to diagnose transmission. This test is intended to diagnose: Wiring harness circuits MLP, TSR, TSL, TSD, TSOD and SIG RTN. ECA.



Fig 17: Manual Lever Position (MLP) Sensor Circuit


TEST PIN NO. 30 (MLP) WIRE COLOR IDENTIFICATION Application

Wire Color

Bronco, "E" Series & "F" Series

Light Blue/White

TEST PIN NO. 46 (SIG RTN) WIRE COLOR IDENTIFICATION Application

Wire Color

Bronco, "E" Series & "F" Series

Black/White

1) KOEO Codes 67/634, 522 & 654 KOEO Codes 67/634 522 and 654 indicate MLP sensor is out of self-test range (3770-4607 ohms) when gear selector is in Park position. Possible causes for these faults are: Linkage not adjusted correctly. Faulty Manual Lever Position (MLP) sensor. Circuit open or grounded. Faulty ECA. Turn ignition off. Apply parking brake. Place transmission gear selector in Neutral position. Place Manual Lever Position (MLP) sensor gauge in sensor slot. If gauge does not fit, loosen MLP mounting bolts and adjust sensor as necessary. If gauge fits, go to next step. 2) Check MLP Sensor Circuit Continuity Turn ignition off. Disconnect MLP sensor wiring harness connector. Disconnect 60-pin ECA connector. Inspect terminals, and repair if damaged. Install EEC-IV Breakout Box (T83L-50-EEC-IV), leaving ECA disconnected. Measure resistance between MLP terminal at MLP sensor wiring harness connector and test pin No. 30 at breakout box. Measure resistance between SIG RTN terminal at MLP sensor wiring harness connector and test pin No. 46 at breakout box. If either resistance is more than 5 ohms, repair open circuit and repeat QUICK TEST . If both resistances are 5 ohms or less, go to next step. 3) Check MLP Sensor For Short To Power & Ground Turn ignition off. Leave ECA and MLP sensor disconnected. Measure resistance between test pin No. 30 and test pins No. 40, 46 and 60 at breakout box. Measure resistance between test pin No. 30 and chassis ground. If resistance is less



than 10 k/ohms, repair short circuit and repeat QUICK TEST . If resistance is 10 k/ohms or more, go to next step. 4) Check MLP Sensor Resistance Turn ignition off. Connect MLP sensor. Leave ECA disconnected from breakout box. Measure resistance between test pins No. 30 and 46 at breakout box while cycling gear selector. See MLP SENSOR RESISTANCE table. If resistance is within specification, replace ECA and repeat QUICK TEST . If resistance is not within specification, replace MLP sensor and repeat QUICK TEST. MLP RESISTANCE SPECIFICATIONS Gear Position

Min. Ohms

Max. Ohms

"P"

3770

4607

"R"

1304

1593

"N"

660

807

"D"

361

442

"2"

190

232

"1"

78

95

NOTE: A break in step numbering sequence occurs at this point. Procedure skips from step 4) to step 7). No test procedures have been omitted. 7) Incorrect Shift/No Shift Turn ignition off. Check transmission fluid. Add or replace as necessary. Test drive vehicle to determine transmission shift patterns. If transmission always remains in 3rd gear when vehicle is operated with shift lever in Drive or Overdrive position, go to step 10). If transmission does not remain in 3rd gear, go to next step. 8) Visual Inspection Visually check select switch and solenoid wiring harness between ECA and transmission. Repair or replace wiring harness as necessary. If wiring harness is okay, go to next step. 9) Diagnose Transmission Shift Patterns If transmission upshifts and downshifts correctly, EEC-IV system is okay. Fault is in transmission. If transmission does not shift correctly, check harness and connectors for intermittent opens and shorts. 10) Code 634 Code 634 indicates ECA has received incorrect voltage signals from gear select sensors. Clear continuous memory codes. Start engine. Shift gear selector to each position, leaving selector in each gear for 10 seconds. Turn ignition off. Shift gear selector to PARK position. Perform KOEO Self-Test. If Code 634 is not present, fault is intermittent. Go to next step. If Code 634 is present, go to next step.

NOTE: A break in step numbering sequence occurs at this point. Procedure skips from step 10) to step 20). No test procedures have been omitted. 20) Recheck For Code 634 Clear continuous memory codes. Turn ignition on. Shake, wiggle and bend select switch wiring harness circuit between ECA and transmission. Verify Shift gear selector through entire range and then place in PARK position. Perform KOEO SELF-TEST . If Code 634 is present, isolate fault and repair as necessary. If Code 634 is not present, go to next step.



21) Inspect Circuit Turn ignition off. Inspect t ransmission switches and harness connectors for corrosion and damaged pins. Inspect wiring harness for incorrect routing. If any faults are found, repair or replace as necessary. If no faults are found, problem is intermittent and cannot be found at this time. CIRCUIT TEST TE - TRANSMISSION OIL TEMPERATURE (TOT) SENSOR Diagnostic Ai ds Perform this test only when directed by QUICK TEST . To prevent replacing good components, be aware following non-EEC areas may be at fault: Transmission fluid level. Transmission fluid temperature. Ambient temperature. This test is intended to diagnose: TOT sensor. Wiring harness circuits TOT and SIG RTN. Faulty ECA. Fig 18: Transmission Oil Temperature (TOT) Sensor Circuit


TOT SENSOR SPECIFICATIONS Temperature °F (°C)

(1)

Volts

(1)

Ohms

32 (0)

3.88

96,255

41 (5)

3.71

75,201

50 (10)

3.53

59,175

59 (15)

3.32

46,883

68 (20)

3.10

37,387

77 (25)

2.86

30,000

86 (30)

2.62

24,215



95 (35)

2.38

19,657

104 (40)

2.15

16,043

113 (45)

1.92

13,161

122 (50)

1.71

10,050

131 (55)

1.51

8990

140 (60)

1.33

7487

149 (65)

1.17

6265

158 (70)

1.03

5260

167 (75)

0.90

4450

176 (80)

0.78

3775

185 (85)

0.69

3215

194 (90)

0.60

2750

200 (95)

0.52

2361

(1)

Value may vary by 15 percent. 1) KOEO Code 26/636 KOEO Code 26/636 indicate TOT sensor is out of self-test range. Possible causes for these faults are: Transmission fluid incorrect temperature. Incorrect sensor resistance. Faulty ECA. Ensure transmission fluid temperature is more than 50°F (10°C). Repeat QUICK TEST . If Code 26/636 is present, go to next step. If Code 26/636 is not present, test is complete. 2) Check VREF At Throttle Position Sensor (TPS) Turn ignition off. Disconnect TPS sensor wiring harness connector. Disconnect 60-pin ECA connector. Inspect terminals, and repair if damaged. Install EEC-IV Breakout Box (T83L-50-EEC-IV). Connect ECA to breakout box. Turn ignition on. Measure voltage between VREF and SIG RTN terminals at TPS wiring harness connector. If voltage is 4-6 volts, go to step 3). If voltage is not 4-6 volts, there is a fault in the 5-volt reference circuit. See wiring diagram or go to CIRCUIT TEST C in appropriate TESTS W/CODES article in the ENGINE PERFORMANCE section. 3) Check TOT Sensor Resistance Turn ignition off. Disconnect ECA from breakout box. Allow transmission to cool. Turn ignition on. Measure and record voltage between test pin No. 46 and TOT test pin at breakout box. Start engine, and warm transmission to normal operating temperature. Disconnect ECA from breakout box. Measure voltage between test pin No. 46 and TOT test pin at breakout box. If voltage is within specification, replace ECA and repeat QUICK TEST . If voltage is not within specification, fault is in transmission.

NOTE: A break in step numbering sequence occurs at this point. Procedure skips from step 3) to step 10). No test procedures have been omitted. 10) KOEO Code 56 Or 637 KOEO Code 56 and 637 indicate TOT sensor output exceeds self-test



maximum voltage. Possible causes for these faults are: Transmission fluid temperature incorrect. Open wiring harness circuit. Faulty ECA. Turn ignition off. Disconnect TOT wiring harness connector. Inspect terminals, and repair if damaged. Connect jumper wire between TOT and SIG RTN terminals. Perform KOER SELF-TEST . If Code 66/638 is present, fault is in transmission. If Code 66/638 is not present, go to next step. 11) Check TOT & SIG RTN Circuit Continuity Turn ignition off. Leave TOT sensor disconnected. Disconnect 60-pin ECA connector. Inspect terminals, and repair if damaged. Install EEC-IV Breakout Box (T83L-50-EEC-IV), leaving ECA disconnected. Measure resistance between TOT circuit at TOT wiring harness connector and TOT test pin at breakout box. Measure resistance between SIG RTN circuit at TOT wiring harness connector and TOT test pin at breakout box. If either resistance is more than 5 ohms, repair open circuit and repeat QUICK TEST . If each resistance is 5 ohms or less, go to step 12). 12) Check TOT Sensor For Short To VPWR Turn ignition off. Leave ECA and TOT sensor disconnected. Measure resistance between TOT test pin and test pins No. 37 and 57 at breakout box. If resistance is more than 10 k/ohms, replace ECA and repeat QUICK TEST . If resistance is 10 k/ohms or less, repair short circuit and repeat QUICK TEST.

NOTE: A break in step numbering sequence occurs at this point. Procedure skips from step 12) to step 20). No test procedures have been omitted. 20) KOEO Code 66 Or 638 KOEO Code 66 and 638 indicate TOT sensor output is lower than self-test minimum voltage. Possible causes for these faults are: Damaged TOT sensor. Shorted wiring harness circuit. Faulty ECA. Turn ignition off. Disconnect transmission wiring harness connector. Inspect terminals, and repair if damaged. Perform KOEO Self-Test. If Code 56 or 637 is present, fault is in transmission. If Code 66/638 is not present, go to step 21). 21) Check VREF At Throttle Position Sensor (TPS) Turn ignition off. Disconnect TPS sensor wiring harness connector. Disconnect 60-pin ECA connector. Inspect terminals, and repair if damaged. Install EEC-IV Breakout Box (T83L-50-EEC-IV). Connect ECA to breakout box. Turn ignition on. Measure voltage between VREF and SIG RTN terminals at TPS wiring harness connector. See Fig 19. If voltage is 4-6 volts, go to step 22). If voltage is not 4-6 volts, there is a fault in the 5-volt reference circuit. See wiring diagram or go to CIRCUIT TEST C in appropriate TESTS W/CODES article in the ENGINE PERFORMANCE section.



Fig 19: Identifying Throttle Position Sensor (TPS) Connector Terminals


22) Check TOT Sensor Resistance Turn ignition off. Disconnect ECA from breakout box. Measure resistance between TOT test pin at breakout box and test pins No. 40, 46 and 60. If resistance is more than 10 k/ohms, replace ECA and repeat QUICK TEST . If resistance is 10 k/ohms or less, repair short circuit and repeat QUICK TEST.

NOTE: A break in step numbering sequence occurs at this point. Procedure skips from step 22) to step 25). No test procedures have been omitted. 25) Check Transmission Wiring Harness Turn ignition off. Check transmission internal and external wiring and connectors for damage and corrosion. Repair or replace if necessary. If wiring is okay, replace TOT sensor and repeat QUICK TEST .

NOTE: A break in step numbering sequence



occurs at this point. Procedure skips from step 25) to step 90). No test procedures have been omitted. 90) Continuous Memory Code 637/638 Continuous Memory Code 637/638 indicates TOT sensor output is lower than during previous 80 warm-up cycles; a fault has been detected in TOT circuit. Possible causes for these faults are: Intermittent fault in TOT sensor. Intermittent short or open in wiring harness. Turn ignition off. Disconnect 60-pin ECA connector. Inspect terminals, and repair if damaged. Install EEC-IV Breakout Box (T83L-50-EEC-IV). Connect ECA to breakout box. Connect DVOM between test pins No. 2 and 46 at breakout box. Turn ignition on. Shake and bend TOT and SIG RTN wires between transmission and ECA. Voltage should remain stable or change gradually. If voltage drops or surges abruptly, fault in circuit is indicated. If fault is indicated, isolate and repair as necessary. If no faults are found, problem cannot be located at this time. CIRCUIT TEST TG - ELECTRONIC TRANSMISSION CONTINUOUS MEMORY SERVICE CODES Diagnostic Ai ds Perform this test only when directed by QUICK TEST . This test is intended to diagnose: Wiring harness circuits CLS, SS1, SS3, EPC, TOT, MLP and VPWR. ECA. Fig 20: E4OD Electronic Transmission Circuit


TEST PINS NO. 35, 37 & 57 (EPC PWR) WIRE COLOR IDENTIFICATION Application

Wire Color



"E" Series (Except Diesel) All Others

Red White/Red

NOTE: Procedure begins with step 90). No test procedures have been omitted. 90) Vehicle Preparation Ensure all components are connected. Ensure transmission fluid is correct level. Warm engine to normal operating temperature. Perform KOEO SELF-TEST . If Code 49/617, 56/637, 59/618, 66/638, 69/619, 62/628, 645, 646, 647, 648 or 656 is present, go to step 93). If none of these codes are present, go to next step. 91) Drive Cycle Test (E4OD) With transmission gear selector in DRIVE position, press Overdrive Cancel Switch (LED should light). Moderately accelerate vehicle to 40 MPH for at least 15 seconds (30 seconds above 4000' elevation). Transmission should be in 3rd gear. While holding speed steady, press Overdrive Cancel Switch (LED should go off) and accelerate from 40 MPH to 50 MPH. Transmission should shift from 3rd gear to 4th gear. Hold speed steady for 15 seconds. While holding speed steady, lightly apply and release brakes to turn brakelights on. Maintain 50 MPH for about 5 seconds. Stop and park vehicle for a minimum of 20 seconds with transmission gear selector in DRIVE position. Repeat procedure 5 times. After completing drive cycle test, perform KOEO SELF-TEST . If Code 99/624, 67/634 or 651 is present, go to step 92). If none of these codes are present but Code 29/452 is present, go to CIRCUIT TEST DS . If Code 11/111 is present, fault cannot be duplicated at this time. 92) Code 99/624, 67/634 Or 651 Code 99/624 and 651 indicate Electronic Pressure Control (EPC) failure. Code 67/634 indicates that Manual Lever Position (MLP) sensor is out of calibration. Possible causes for these faults are: Faulty EPC solenoid. Faulty MLP sensor. Circuit open or grounded. Damaged ECA connector pins. Turn ignition off. Disconnect 60-pin ECA connector. Inspect terminals, and repair if damaged. Install EEC-IV Breakout Box (T83L-50-EEC-IV). Connect ECA to breakout box. To test EPC solenoid, connect DVOM to EPC test pin and EPC VPWR test pin at breakout box. To test MLP sensor, connect DVOM to MLP test pin and test pin No. 46 at breakout box. For EPC solenoid and MLP sensor, turn ignition on. Voltage for EPC should be less than 10 volts. Voltage for MLP should be less than 5 volts. Shake and bend EPC/MLP wiring harness. Lightly tap on components to simulate road shock. Voltage should remain stable. If voltage changes or exceeds specification, fault in circuit is indicated. If fault is indicated, isolate and repair as necessary. Clear continuous memory codes, and repeat QUICK TEST . If no faults are found, problem cannot be located at this time. 93) Check Circuit Harness & Connectors Shake and bend EEC--IV wiring harness. Lightly tap on components to simulate road shock. Perform KOEO Continuous Monitor Mode. See CIRCUIT TEST KOEO CONTINUOUS MEMORY CODES table. If fault is indicated, isolate and repair as necessary. Clear continuous memory codes, and repeat QUICK TEST . If no faults are found, problem cannot be located at this time. CIRCUIT TEST KOEO CONTINUOUS MEMORY CODES Code

Fault



49/617

1 - 2 Shift Incorrect

56/637

Excessive TOT Circuit Voltage

59/618


66/638

Inadequate TOT Circuit Voltage

69/628


619


645

Inadequate 1st Gear Command Response

646

Inadequate 2nd Gear Command Response

647

Inadequate 3rd Gear Command Response

648

Inadequate 4th Gear Command Response

656

Continuous Slippage Detected

WIRING DIAGRAMS



Fig 21: E4OD Wiring Diagram (1989 Bronco & "F" Series - Diesel)



Fig 22: E4OD Wiring Diagram (1989 Bronco & "F" Series - Gasoline)



Fig 23: E4OD Wiring Diagram (1990 Bronco & "F" Series - Diesel)



Fig 24: E4OD Wiring Diagram (1990 Bronco & "F" Series - Gasoline)



Fig 25: E4OD Wiring Diagram (1989-90 "E" Series - Diesel)



Fig 26: E4OD Wiring Diagram (1989-90 "E" Series - Gasoline)



Fig 27: E4OD Wiring Diagram (1991-92 Bronco & "F" Series - Diesel)



Fig 28: E4OD Wiring Diagram (1991-92 Bronco & "F" Series - Gasoline)


Fig 29: E4OD Wiring Diagram (1991 "E" Series - Diesel)




Fig 30: E4OD Wiring Diagram (1991 "E" Series - Gasoline)


Fig 31: E4OD Wiring Diagram (1992 "E" Series - Diesel)


e4od Electronic Controls Testing

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