Section 07-01A: Transmission, Automatic, E4OD
1996 All F-Series and Bronco with E4OD Automatic Transmission Workshop Manual
DIAGNOSIS AND TESTING

Rotunda Transmission Tester

Use Rotunda Transmission Tester 007-00085 or equivalent to diagnose electronically controlled transmissions (7003). The following instructions outline the setup and use of this tester in the pinpoint tests for the E4OD.

 

Illustrations



E4OD Overlay for Use with E4OD Transmission




 

Overlays and Adapters

Overlay and Cable Correctly Installed LEDs: Only LEDs with the (O) symbol will light when the overlay and cable correctly match.

 

Tester Jacks

  1. VPWR Pin Jacks (red): Vehicle Power (VPWR) test points for solenoid circuits.

  1. Solenoid (TCC, EPC) Signal Line Pin Jacks (black): Signal line test points for solenoid circuits.

  1. BAT + (red) and BAT - (black) Pin Jacks: Battery reference points when measuring circuits for shorts.

  1. TFT Pin Jacks: Test points for transmission fluid temperature sensor.

 

LEDs and Controls

  1. Status LEDs: LED off when not activated by tester (solenoid not activated, open circuit or signal line short to ground). LED will turn green when activated by tester and current draw is correct. LED will turn red when activated by tester and current draw is excessive (short to battery positive voltage [B+]). All LEDs light orange during On-Board Diagnostic.

  1. Solenoid Activate Buttons: Energize respective solenoids during click testing and activate selected circuits during DRIVE mode testing.

  1. Bench/Drive Switch: Selects operating mode, either BENCH or DRIVE.

Instructions

NOTE: The Rotunda Transmission Tester 007-00085 or equivalent must be used to perform the Pinpoint Tests.

The Rotunda Transmission Tester 007-00085 and cable and overlay 007-00107 or equivalents allows a technician to operate the electrical portion of the transmission independently of the vehicle electronics, which allows the technician to determine transmission concerns. The transmission tester usage is divided into six steps:

Preliminary Inspections

Before any diagnostic testing is done on vehicle some preliminary checks must be performed, as outlined below. Be sure to write down findings, especially any DTCs found, for future reference.

  1. Check transmission fluid level and condition.
  2. Check for add-on items (phones, computers, CB radio, etc.).
  3. Visually inspect wiring harness and connectors.
  4. Check for vehicle modifications.
  5. Check shift linkage for proper adjustment.
  6. Verify customer concern:
  7. Vehicle must be at normal operating temperature.
  8. Perform vehicle On-Board Diagnostics.
  9. Record all DTCs.
  10. Service all nontransmission codes.

Installation Procedures

Installing the transmission tester at the transmission connector allows separation of the vehicle electronics from transmission electronics. Disconnecting normal vehicle electronics will set additional codes and cause firm shifts. (Disconnecting the transmission connector defaults transmission to maximum line pressure).

NOTE: During tester usage, additional DTCs may be set. Therefore, it is important that all codes are erased after service has been made. To verify elimination of all codes rerun On-Board Diagnostics.

NOTE: The following manuals should be available to assist in diagnosis of electronically controlled transmissions:

  1.  CAUTION: Do not attempt to pry off connectors with a screwdriver. This will damage the connector and could result in transmission concerns. If vehicle is equipped with transmission heat shields (7A434), remove them. Always replace transmission heat shields after service.

     CAUTION: Route all cables away from heat sources.

    Disconnect vehicle wiring harness at transmission connector.

  1. Turn tester solenoid select switch to the OHMS CHECK position.

  1. Install appropriate overlay onto tester. Connect appropriate interface cable to transmission tester and then to the appropriate transmission connectors.

  1.  CAUTION: Route gauge line away from heat sources.

    Install a line pressure gauge into line pressure tap on transmission.

  1. Plug transmission tester power supply into cigar lighter (15A044) receptacle. At this time, all LEDs should illuminate for a short period and then turn off. This is the tester internal circuit check.

  1. Position Bench/Drive switch to BENCH mode.

Static Testing Engine Off

Static testing procedures allow for shop testing of the transmission in the vehicle or on the bench. Completion of these tests prove out transmission electronics.

Resistance/Continuity Tests

 CAUTION: For resistance checks, be sure the tester solenoid select switch is set to the OHMS CHECK position or damage to the ohmmeter may result.

Resistance/Continuity Tests EPC Solenoid

If out of specification, refer to Pinpoint Test E under Pinpoint Tests in the Diagnosis and Testing portion of this section.

Resistance/Continuity Tests Shift Solenoid 1, Shift Solenoid 2, Torque Converter Clutch Solenoid, Coast Clutch Solenoid

Refer to following charts for values.

If out of specification, refer to Pinpoint Test A (Shift Solenoid 1, Shift Solenoid 2); Pinpoint Test C (Torque Converter Solenoid), Pinpoint Test G (Coast Clutch Solenoid) under Pinpoint Tests in the Diagnosis and Testing portion of this section.

E4OD SOLENOID RESISTANCE SPECIFICATIONS
SolenoidResistance (Ohms)
Shift Solenoid 120-30
Shift Solenoid 220-30
Torque Converter Solenoid20-30
Coast Clutch Solenoid20-30
Electronic Pressure Control Solenoid4.0-6.5

Resistance/Continuity Tests Transmission Fluid Temperature (TFT) Sensor

If out of specification, refer to Pinpoint Test B under Pinpoint Tests in the Diagnosis and Testing portion of this section.

TFT SENSOR RESISTANCE SPECIFICATIONS
TemperatureResistance
°C°F(Ohms)
(-)40-(-)20(-)40-(-)4967k-248k
(-)19-(-)1(-)3-31248k-100k
0-2032-68100k-37k
21-4069-10437k-16k
41-70105-15816k-5k
71-90159-1945k-2.7k
91-110195-2302.7k-1.5k
111-130231-2661.5k-0.8k
131-150267-3020.8k-0.54k

Solenoid Voltage Test

 
  1. Set tester Bench/Drive switch to BENCH mode.

  1. Set voltmeter to 20-volt DC range.

  1. Connect voltmeter positive lead to the appropriate solenoid vehicle power (VPWR). Connect voltmeter negative lead to the appropriate solenoid.

  1. NOTE: LED will turn green when solenoid activates and turn OFF when deactivated. LED will turn red if an activated solenoid/harness is shorted to B+. LED will remain OFF if an activated solenoid/harness is shorted to ground or if there is no continuity.

    Using a Digital Volt-Ohmmeter (DVOM), check for voltage across each solenoid by activating the solenoid switches. Depress the appropriate switch. The LED should illuminate, the voltage should change and an audible click may be heard. If LED does not illuminate, a short to ground condition exists.

  1. Observe and record values.

 

Dynamic Testing Engine On

 

Dynamic testing allows the transmission to be proven out electronically and hydraulically.

Preliminary Setup

  1. Set Bench/Drive switch to DRIVE mode.

  1. Set rotate gear select switch to GEAR SELECT "1" position.

  1. Place vehicle in PARK.

  1. Start engine.

EPC Solenoid Functional Test

 
  1. Observe line pressure. Record value. Line pressure should go to maximum. If not, refer to the Diagnosis by Symptom Index under Diagnosis by Symptom in the Diagnosis and Testing portion of this section for diagnostic tips. Also, refer to Pinpoint Test E under Pinpoint Tests in the Diagnosis and Testing portion of this section for electronic pressure control solenoid diagnosis.

  1.  CAUTION: Do not attempt to hold the electronic pressure control switch depressed (minimum line pressure) and stall the transmission (holding the vehicle with the brake while depressing the throttle with the transmission in gear), transmission damage will result.

    Depress electronic pressure control switch. Line pressure should drop to a minimum value. Record value. If not, refer to the Diagnosis by Symptom Index or Pinpoint Test E for the electronic pressure control solenoid.

Transmission Engagements

  1. Verify that MODE switch is in DRIVE mode.

  1. Turn GEAR SELECT dial to 1.

  1. Start engine.

  1. Shift vehicle from PARK to REVERSE.

  1. Depress EPC switch. Line pressure should drop to idle pressure. While holding EPC switch down, shift vehicle from PARK to REVERSE.

  1. Shift vehicle from PARK to DRIVE.

  1. Shift vehicle from DRIVE to PARK.

  1. Depress EPC switch. Pressure should drop to idle pressure.

  1. Depress EPC switch. Line pressure should drop to idle pressure. While holding EPC switch down, shift vehicle from PARK to DRIVE.

  1. Release EPC Switch.

Upshifts/Downshifts

  1. NOTE: Upshifts and downshifts will be firm during this procedure. Pressure gauges may be removed. These tests should be performed on the road. If performed on the hoist, feel at all shifts when they are engaged may not be possible.

    LEDs will turn green when solenoids are activated and turn OFF when deactivated. Refer to the appropriate overlay for the proper status shift sequence of the shift solenoids during upshifts and downshifts.

    Move transmission range selector lever into OVERDRIVE and accelerate to 24 km/h (15 mph), select 2nd gear by rotating gear selector to second.

  1. Accelerate to 40 km/h (25 mph) and select 3rd gear.

  1. Accelerate to 56-72 km/h (35-45 mph) and select 4th gear.

  1. Reverse the order to downshift.

  1. Does the transmission pass these tests? If not refer to Diagnosis by Symptom in the Diagnosis and Testing portion of this section.

Torque Converter Clutch (TCC) Engagement

  1.  CAUTION: Do not depress torque converter clutch solenoid switch with transmission in gear and the vehicle at a stop. Damage to torque converter clutch may result.

    NOTE: This test should be performed on the road. If performed on a hoist, feeling the torque converter clutch engage may not be possible.

    Accelerate and shift vehicle up into third gear. Hold speed steady and depress the torque converter clutch solenoid switch.

  1. Holding speed steady, release switch.

  1. Does the transmission pass these tests? If not, refer to Diagnosis by Symptom in the Diagnosis and Testing portion of this section.

Coast Clutch Engagement

  1. NOTE: This test should be performed on the road. If performed on the hoist the technician may not feel the coast clutch engage.

    Accelerate and shift vehicle up into third gear. Depress the coast clutch solenoid switch and immediately back off the throttle.

  1. Release the CCS switch.

  1. Does the transmission pass these tests? If not, refer to Diagnosis by Symptom in the Diagnosis and Testing portion of this section.

 

Transmission Range (TR) Sensor Testing

Introduction

The Rotunda Transmission Tester 007-00085 or equivalent allows a technician to operate the electrical portion of the manual Transmission Range sensor. Usage of the Transmission Range (TR) Sensor Cable "B" (MLPS Manual Lever Position Sensor Cable) 007-00086 or equivalent is divided into five steps:

  1. Preliminary testing and diagnosis.

  1. Installation Procedures.

  1. Resistance/Continuity Tests.

  1. Voltage Tests Park/Neutral, Backup Lamp and Optional Circuits.

  1. Disconnecting the tester.

Preliminary Testing and Diagnosis

Before any diagnostic testing is done on a vehicle some preliminary checks must be performed, as outlined below. Be sure to write down your findings, especially any DTCs found, for future reference.

Installation Procedures

Installing Rotunda Transmission Tester 007-00085, Cable and Overlay 007-00107 and Transmission Range (TR) Sensor Cable "B" (MLPS Manual Lever Position Sensor Cable) 007-00086 or equivalents at the Transmission Range (TR) sensor allows the separation of the vehicle electronics from the TR sensor electronics.

During tester usage additional DTCs may be set. Therefore, it is important that all codes are erased after service has been made. To verify elimination of all DTCs, rerun On-Board Diagnostic.

The Powertrain Control/Emissions Diagnosis Manual and Transmission Tester Manual (provided with tester) should be available to assist in diagnosis of electronically controlled transmissions.

TR Tester Instructions, TR/MLP Tester 007-00086




  1.  CAUTION: Do not attempt to pry off connectors with a screwdriver. This will damage the connector and could result in a transmission concern. Route all cables away from HEAT SOURCES.

    Disconnect vehicle harness at Transmission Range (TR) sensor connector.

  1. Set Bench/Drive switch to DRIVE mode. Install Transmission Range (TR) sensor overlay onto tester.

  1. Connect interface cable A for 1989-94 models or cable B for 1995 and newer models to transmission tester and then to the TR sensor connector.

  1. Turn test select dial to the TR/MLP SENSOR TEST position.

  1. Plug transmission tester power supply plug into cigar lighter.

At this time, all LEDs should illuminate for a short period and then turn off. This is the tester internal circuit check.

Resistance/Continuity Tests

Static testing procedures allow for shop testing of the transmission in the vehicle or on the bench. Completion of these tests prove out the Transmission Range (TR) sensor electronically.

  1.  CAUTION: For resistance checks, be sure that the tester selector switch is set to the TR SENSOR TEST position or damage to the ohmmeter may result.

    Using a digital volt-ohmmeter, Rotunda Transmission Tester 007-00085, Cable and Overlay 007-00107 and Transmission Range (TR) Sensor Cable "B" (MLPS Manual Lever Position Sensor Cable) 007-00086 or equivalents, perform Pinpoint Test D based on the DTCs that were displayed.

  1. Perform services as indicated by the pinpoint tests. Always retest and road test vehicle after any service.

  1. Set ohmmeter to 1000 ohm range.

  1. Connect the positive lead of the ohmmeter to the TR/MLP jack.

  1. Connect the negative lead of the ohmmeter to the SIGRTN jack.

  1. Move transmission gearshift selector lever into each gear position.

  1. Record resistance at each position.

  1. Refer to the following chart for values.

If out of range, refer to Pinpoint Test D under Pinpoint Tests in the Diagnosis and Testing portion of this section.

TR SENSOR RESISTANCE SPECIFICATIONS
Transmission Gear Selector Lever PositionResistance (Ohms)
MinimumMaximum
PARK37704607
REVERSE13041593
NEUTRAL660807
OVERDRIVE361442
MANUAL SECOND190232
MANUAL 17895

Voltage Test Park/Neutral, Backup Lamp and Optional Circuits

  1. Tester selector switch to the TR SENSOR TEST position.

  1. Press and HOLD each button while moving the transmission range selector lever through EACH gear position.

  1. Monitor each LED.

  1. NOTE: LED will turn red when the circuit closes and turn OFF when the circuit is open.

    The status LED should indicate red only in the indicated position. Refer to overlay.

  1. If the LED does NOT indicate red in the desired position, or indicates red in another position, first verify Transmission Range (TR) sensor alignment and then retest. If the sensor fails, replace.

 

Disconnecting the Tester

  1.  CAUTION: Do not attempt to pry off connectors with a screwdriver. This will damage the connector and could result in a transmission concern.

    Disconnect transmission tester from the Transmission Range (TR) sensor connector.

  1. Reinstall vehicle wiring harness. Verify connection by pulling up on the harness.

  1. Disconnect transmission tester power lead from vehicle.

  1. Erase all DTCs using the procedures in the Powertrain Control/Emissions Diagnosis Manual OBDI or OBDII.

  1. Rerun On-Board Diagnostic Tests to receive a pass code (P1111 or 111).

  1. Verify that the customer concern has been eliminated.