[Ricky Rocket]

I teach Auto Tech at a 2 year college. A student of mine rebuilt a E4OD in a 92 F150 4x4 with 5.8 engine.

After overhaul we have no 2nd and no 4th. Trans shifts 1,3, and T.C. lock-up. We used the Ford trans control box and confirmed the no 2nd and 4th. This should prove that its not a computer or sensor problem. Also with the control box on it reverse binds up.

We have had the valve body off a couple of times and inspected, replaced the spacer plate and gaskets, and air checked clutches - all seem ok. Pulled trans thinking maybe a one-way clutch or something else faulty - see no problems. we (I) am now stumped and need some E4OD expert advice. I come from GM background and am not very experienced with this trans.

Any advice would be greatly appreciated!

Thanks,
Rick

[LATECH]

Could be a shift solenoid problem Have you driven and then scanned for codes? It should throw something your way.
Trans control box???? what the ??
Are you trying to manipulate shift with a scanner? external controller?
Where is the PCM in all of this?

[LATECH]

Could also be Intermediate/OD band is not applying. Stuck servo (piston) /missing servo(piston) seal

[Crosley]

Well, 2nd gear and O-Drive in the trans are both clutch packs not bands.

I suggest you inspect the clutch packs for proper clearance.

What was the original failure?

Why was the separator plate replaced? What was used as replacement?

The bind up in reverse indicates something is applied that should not be.

Was the accumilator v-body section replaced or rebuilt or not?

Was the solenoid body replaced or not?

[Ricky Rocket]

Not sure about original failure because of an engine issue that wouldn't let us drive it. The student wanted to overhaul the trans mostly for the experience.

The spacer plate was replaced because when we first started diagnosing the problem after the overhaul I had him take the valve body off and check for proper check ball location and valve body assembly. We found that one of the filters in the spacer plate was on the wrong side and dented it when valve body was tightened. I thought "there is our problem, and this is a good learning experience". We replaced spacer and gaskets with OEM parts. Same shifting problem.

We now have the trans back out and disassembled thinking we would find something burnt or possible incorrect assembly etc. but we find nothing wrong.

The valve body and solenoid body were only cleaned up and re-used.

Thanks again,
Rick