e4od Electronic Controls Testing

E4OD ELECTRONIC CONTROLS

APPLICATION

E4OD APPLICATIONS

Models Engine

E150/250 4.9L PFI

Bronco & "F" Series 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 & 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 fromvarious sensors and switches. Based on information received, the ECA generates output signals to controlengine and transmission operation. The EEC-IV system controls 3 major areas of engine operation: air/fuelmixture, ignition, and emission control. In addition. the system controls A/C compressor clutch operation, idlespeed, and transmission solenoids. The system has self-diagnostic capabilities.

The engine control system consists of the ECA, sensors, switches, and solenoids. In order for the ECA toperform properly, it must be kept constantly informed of engine operating conditions. It is the task of the enginesensors to supply the ECA, via electrical signals, with specific information required to determine engineoperating conditions. The ECA will then send out electrical signals to control air/fuel ratio, emission controls,idle speed, ignition timing, and transmission solenoids.

Perform all possible test steps under TROUBLE SHOOTING in the AUTO TRANS OVERHAUL - FORD E40Darticle. If referred here by trouble shooting charts or testing procedure, proceed with self-diagnostics. Somecircuit tests in this article may also be used by the experienced technician to help bench test and diagnosesolenoids. 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 QUICKTEST procedure. These fault codes pertain to engineperformance and must be repaired first, as engineperformance will greatly affect transmission operation.For information and testing procedures of enginerelated fault codes and components, see appropriateTESTS W/CODES - EEC-IV article in the ENGINEPERFORMANCE section.

SELF-DIAGNOSTIC SYSTEM

DIAGNOSTIC FORMATS

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

1992 Ford Pickup 7.3L Eng F350

Printer Friendly View http://www1.prodemand.com/Print/Index?content=article&module=...

1 of 57 12/12/2014 11:46 AM

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 passesQUICK TEST and no driveability symptoms or intermittent faults exist, EEC-IV system is okay.

SERVICE CODES

During QUICK TEST , 3 types of service codes are retrieved: KOEO, KOER and Continuous Memory codes.See QUICK TEST for self-test procedures. Codes may be cleared from ECA memory after they have beenrecorded 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 orMALFUNCTION INDICATOR LIGHT (MIL) to glow and remain on until fault is repaired. If KOEO or KOERcodes 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 todiagnose intermittent problems. Continuous Memory Codes are retrieved during KOEO SELF-TEST. Somecodes may turn on MIL or CHECK ENGINE light. Corresponding soft trouble code will be retained in ECAmemory. If fault does not reoccur within 40 warm-up cycles (80 cycles on some models), ECA will automaticallyclear code. Technician may clear service codes from memory. See CLEARING CODES . Intermittent faults maybe caused by a sensor, connector or wiring-related problem.

CAUTION: Continuous Memory Codes should berecorded when retrieved during KOEO SELF-TEST.These codes may be used to identify intermittentproblems that exist after all KOEO and KOER codeshave been repaired and a Code 11 or 111 (pass code)has been obtained. Failure to follow this procedure mayresult in unnecessary testing. Some ContinuousMemory Codes faults may not be valid after KOEO andKOER codes are repaired.

RETRIEVING CODES

Service codes are retrieved from EEC-IV system through self-test connector. Various methods and testequipment may be used to access these codes:

Analog Volt-Ohmmeter (VOM)

Scan tester

In-Dash Malfunction Indicator Light (MIL) or CHECK ENGINE light.

SELF-TEST CONNECTOR LOCATIONS

Application Location

Bronco & "F" Series Left Front Inner Fender Panel

"E" Series Right Front Inner Fender Panel

READING CODES


2 of 57 12/12/2014 11:46 AM

KOEO & KOER SELF-TEST Codes

Question: 1992 f-150 4x4

All service codes are 2 or 3-digit numbers. Some vehicles may output a 2 or 3 digit code for the same fault. SeeSERVICE CODE REFERENCE & DEFINITION CHARTS . ECA outputs codes one digit at a time. These codesindicate current faults in system and should be serviced in order of appearance. Codes are shown as voltagepulses (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 pauseoccurs between number of sweeps in a digit, and a 2-second pause occurs between digits in a code. A4-second pause occurs between each code. KOEO codes are separated from Continuous Memory codes by a6-second delay, a single 1/2-second sweep (Separator) and another 6-second delay. Record codes in orderreceived.

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 displayedin KOER SELF-TEST. See Fig 1. If using CHECK ENGINE light, service codes are displayed as flashes.

Separator Pulse

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 maydisplay separator code as "10" instead of "1".

Pass Codes

A Code 11 or 111 indicates no service codes were recorded in that portion of test; system passes that portion oftest. If Code 11 or 111 is not retrieved in KOEO SELF-TEST, codes retrieved during KOER SELF-TEST maynot be valid. Code 11 or 111 (pass code) must be obtained in KOEO SELF-TEST. A Code 11-1-11or 111-1-111output 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 Codes

These codes result from information stored by ECA during continuous self-test monitoring. Codes are displayedafter separator pulse code in KOEO SELF-TEST. Use these codes for diagnosis only when KOEO SELF-TESTand KOER SELF-TEST result in Code 11 or 111 (pass code) and all steps under QUICK TEST are successfullycompleted. (A few codes are exceptions which may be checked after KOEO codes have been repaired). Thesecodes indicate faults recorded within last 40 engine starts (80 engine starts on some models). Fault may or maynot be currently present. See SERVICE CODE REFERENCE & DEFINITION CHARTS .

Fast Codes

At start of KOEO SELF-TEST and after Wide Open Throttle (WOT) request in KOER SELF-TEST, ECA outputsshort bursts of information, known as FAST CODES, which were used by manufacturer during assembly. Withmost equipment, these code bursts are not visible; an entire code sequence lasts less than 1/2 second. If thisfluctuation is visible on test equipment, ignore it.


3 of 57 12/12/2014 11:46 AM

CLEARING CODES

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

CAUTION: DO NOT disconnect vehicle battery toclear codes. This will erase stored operatinginformation from Keep-Alive Memory (KAM). To clearKAM, disconnect negative battery terminal for at least 5minutes.

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

QUICK TEST

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

Courtesy of FORD MOTOR CO.


4 of 57 12/12/2014 11:46 AM

DESCRIPTION

Following procedures are functional tests of EEC-IV system. The following 5 basic test steps must be carefullyfollowed 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 Aids

Question: 1/2 shift

After each service or repair procedure has been completed, repeat QUICK TEST to ensure all EEC-IV systemswork properly and service codes are no longer present.

VISUAL CHECK & EQUIPMENT HOOKUP

Complete a basic inspection of engine compartment and all components before proceeding to self-diagnostictests. Ensure vacuum hoses and EEC-IV wiring harnesses are properly connected.

Apply parking brake, and place shift lever in "P" position. Block drive wheels. Turn off all electrical loads.Connect appropriate test equipment to vehicle as follows:

Analog Volt-Ohmmeter (VOM)

Turn ignition switch to OFF position. Set VOM at 0-15V DC range. Connect positive lead of VOM topositive battery terminal.

1.

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 connectingjumper wire from Self-Test Input (STI) pigtail to signal return terminal of self-test connector withignition on.

2.

Scan Tester

Follow manufacturer's instructions to hook up equipment and record service codes.

STAR Series Tester

Turn ignition switch to OFF position. Connect color-coded adapter cable leads to diagnostic tester. Connect 2service connectors of adapter cable to vehicle self-test connector and STI pigtail connector. Connect timinglight. Go to KOEO SELF-TEST.


5 of 57 12/12/2014 11:46 AM

KOEO SELF-TEST

Ensure engine is at normal operating temperature. If engine does not start (or stalls after starting), continueKOEO SELF-TEST. DO NOT depress throttle on gasoline engines. Turn ignition off. Wait 10 seconds. Ensuretest equipment is properly attached. Turn ignition on (engine off). Record all KOEO and Continuous MemoryCodes.

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 ECAwill not output codes, see appropriate TESTS W/CODES article in the ENGINE PERFORMANCE section.

Fig 2: Connecting Self-Test Diagnostic Equipment



6 of 57 12/12/2014 11:46 AM

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 TESTSarticle or SYSTEM/COMPONENT TESTS - DIESEL article in the ENGINE PERFORMANCE sectionif Continuous Memory Code 45, 46, 48, 215, 216, 217, 232 or 238 is retrieved during KOEOSELF-TEST. Repair ignition system as necessary.

If vehicle has a no-start condition, go to appropriate no-start CIRCUIT TESTS in appropriate TESTSW/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 inprevious 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. Ifengine 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 2minutes after last code has been retrieved unless self-test is deactivated.

Computed timing, at crankshaft, should equal base timing (see vehicle emission decal) plus 20degrees 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 ENGINEPERFORMANCE section.

KOER SELF-TEST

Diagnostic Aids

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 inuse. 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 appropriateprocedure 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 inFMEM 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 andreleased after ID code portion of test.

On vehicles with Power Steering Pressure Switch (PSPS), turn steering wheel at least 1/2 turn andrelease 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


7 of 57 12/12/2014 11:46 AM

WOT unless requested.

If a Code 11 or 111 (pass code) is retrieved during KOER SELF-TEST, service Continuous MemoryCodes retrieved in KOEO SELF-TEST. See TESTS W/CODES - EEC-IV article in the ENGINEPERFORMANCE section.

If a Code 11 or 111 (pass code) is retrieved during Continuous Memory Code portion of KOEOSELF-TEST (Code 11-1-11 or Code 111-1-111) and no driveability problem exists, EEC-IV testing iscomplete. If driveability problems are still present, go to TROUBLE SHOOTING in the AUTO TRANSOVERHAUL - FORD E40D article.

If KOER codes are present, see SERVICE CODE REFERENCE & DEFINITION CHARTS . If systemwill not output codes, go to CIRCUIT TEST QA. See appropriate TESTS W/CODES article in theENGINE 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. Circuittests specify use of this procedure to identify intermittent faults in specific circuits or components.

KOEO Wiggle Test Procedure

Connect test equipment. See Fig 2. Turn ignition on, and activate self-test using jumper lead or diagnostictester. 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 inmemory and indicated at diagnostic tester or scan tester. Retrieve code, and perform appropriate test. SeeSERVICE CODE REFERENCE & DEFINITION CHARTS .

KOER Wiggle Test Procedure

Connect test equipment. See Fig 2. Turn ignition off, and wait 10 seconds. Start engine. Activate self-test usingjumper lead or diagnostic tester. Wait 10 seconds, and then deactivate and reactivate self-test. DO NOT turnengine off. KOER wiggle test mode is now activated. Tap, move and wiggle suspect sensor and/or harnessarea. If a fault is detected, a service code may be stored in memory and indicated at diagnostic tester or scantester. Retrieve code, and perform appropriate test. See SERVICE CODE REFERENCE & DEFINITIONCHARTS .

ADDITIONAL SYSTEM FUNCTIONS

Additional diagnostic system features are available to help diagnose driveability problems and service EEC-IVsystems.

FUNCTIONS

CHECK ENGINE Light & Malfunction Indicator Light (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 orKOER SELF-TEST, light will display all codes which turn on light during vehicle operation, not just ContinuousMemory Codes.

If light comes on during vehicle operation, vehicle should be inspected as soon as possible. Immediatelyturning 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 ECAmemory 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


8 of 57 12/12/2014 11:46 AM

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-IVsystem. It allows technicians to energize and de-energize most system output actuators on command. Thismode is entered from KOEO SELF-TEST after all codes have been retrieved. Leave KOEO SELF-TESTactivated, and depress throttle to initiate test sequence. Each time throttle is depressed and released, outputactuators 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 operatingrange. During FMEM mode, ECA substitutes a mid-range signal for defective sensor while continuing tomonitor sensor. If faulty sensor's signals return to normal operating range, ECA will use those signals. A Code98 or 998 will be displayed when FMEM mode is in effect.

Hardware Limited Operational 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 concernswill be present. ECA will not output service codes in this mode.

Cylinder Balance Test

This test helps identify a weak or non-contributing cylinder in engines with sequential PFI fuel systems. ECAshuts off fuel supply to each injector and measures RPM drop. It computes variation between cylinders andidentifies 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 isrequired, not a wide open throttle). After a brief stabilizing period, ECA will activate test procedure. Test will berepeated 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 testidentify weak or non-contributing cylinder. See CYLINDER BALANCE TEST SERVICE CODES table. If Code90 is displayed during this test, system has passed test. If Code 77 is displayed, repeat cylinder balance test. Ifthrottle is moved during this test, Code 77 will appear, indicating test is not completed. Total test time is about 3minutes.

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


9 of 57 12/12/2014 11:46 AM

SUMMARY

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

SERVICE CODE REFERENCE & DEFINITION CHARTS

CODE REFERENCE & DEFINITION CHART (1991)

Fault CodeCode Definition

Circuit Test &Step

KOEO Codes

91/621 Shift Solenoid No. 1 (SS1) Circuit Failure 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


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


29/452 Insufficient Input From Vehicle Speed Sensor (VSS) DP1

49/617 1-2 Shift Error TC90




62/628 Converter Clutch Error TC90

67/634 Manual Lever Position (MLP) Sensor Voltage Out Of Range TC90

56/637 Transmission Oil Temp (TOT) Circuit Open TC90

66/638 Transmission Oil Temp (TOT) Circuit Grounded TC90

KOER Codes

65/632 Overdrive Cancel Switch (OCS) Not Changing State TC10

26/636 Transmission Oil Temp (TOT) Sensor Voltage Out Of Self-TestRange

TC30

(1)


10 of 57 12/12/2014 11:46 AM

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

CODE REFERENCE & DEFINITION CHART (1992)

Fault CodeCode Definition

Circuit Test &Step

KOEO Codes

49/617 1-2 Shift Error TG90






98/625 Electronic Pressure Control (EPC) Driver Circuit Open In ECA TC10



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-TestRange

TE1

56/637 Transmission Oil Temp (TOT) Circuit Open TE10

66/638 Transmission Oil Temp (TOT) Circuit Grounded TE20

00/654 Manual Lever Position (MLP) Sensor Not In Park Position TD1


29/452 Insufficient Input From Vehicle Speed Sensor (VSS) DS1

99/624 Electronic Pressure Control (EPC) Circuit Failure TG90

62/628 Converter Clutch Error TG90

67/634 Manual Lever Position (MLP) Sensor Voltage Out Of Self-TestRange

TD1

56/637 Transmission Oil Temp (TOT) Circuit Open TG91

66/638 Transmission Oil Temp (TOT) Circuit Grounded TG91

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

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

CIRCUIT TESTS (1991)

(1)

(1)

(1)


11 of 57 12/12/2014 11:46 AM

CIRCUIT TEST - VEHICLE SPEED SENSOR (VSS)

Diagnostic Aids

Perform this test when directed by QUICK TEST . This CIRCUIT TEST is intended to diagnose:

Vehicle Speed Sensor (VSS).

VSS wiring harness circuits.

ECA.

VSS WIRE COLOR IDENTIFICATION

Application Wire Color Pin 3 (+) Wire Color Pin 6 (-)

"E" Series Dark Green/White Orange/Yellow

All Others Gray/Black Pink/Orange

Preliminary Instructions

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.

Continuous Memory Code 29/452 Code 29/452 indicates there is insufficient input to ECA from VSS.Possible causes for this code are:

Faulty VSS.1.

Open or shorted circuit.2.

Faulty ECA.3.

Perform appropriate drive cycle procedure. If Code 29/452 is still present, go to step 2). If code is notpresent or complaint cannot be verified, fault cannot be duplicated at this time. Clear codes, and seeTROUBLE SHOOTING in the AUTO TRANS OVERHAUL - FORD E40D article.

1.

Fig 3: Vehicle Speed Sensor Circuit



12 of 57 12/12/2014 11:46 AM

Check VSS Circuit Continuity Turn ignition off and wait 10 seconds. Remove ECA 60-pin connectorand 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 pinNo. 3 at breakout box and VSS DIF (+) circuit at VSS vehicle harness connector. See Fig 4. Alsomeasure resistance between test pin No. 6 at breakout box and VSS DIF (-) circuit vehicle harnessconnector. 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 step1).

2.

Check VSS Circuits For Shorts To Power Or Ground Turn ignition off. With ECA and VSSdisconnected, install breakout box. Set DVOM on 200-k/ohm scale. Measure resistance between testpin No. 3 and test pins No. 37, 40 and 6. If all readings are greater than 500 ohms, remove breakoutbox, reconnect components and go to step 4). If any reading is less than 500 ohms, repair short(s) inVSS wiring harness and reconnect components. After repairs, repeat step 1).

3.

Checking VSS Resistance Turn ignition off and wait 10 seconds. Disconnect VSS. Set DVOM on2-k/ohm scale. Measure resistance across vehicle speed sensor. If reading is 190-250 ohms, replaceECA. Remove breakout box, reconnect components and repeat step 1). If reading is NOT 190-250ohms, replace vehicle speed sensor and repeat appropriate drive cycle procedure.

4.

CIRCUIT TEST TC - E4OD AUTOMATIC TRANSMISSION

Diagnostic Aids

Perform this test only when directed by QUICK TEST. To prevent replacing good components, be awarefollowing 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 4: Checking VSS Circuits



13 of 57 12/12/2014 11:46 AM

Fig 5: E4OD & MLP Circuit



14 of 57 12/12/2014 11:46 AM

1) Code 634, 654 & 67: Check Resistance Through MLP Sensor Code 67/634 indicates that totalresistance in the MLP sensor is out of Self-Test range when the selector lever is in "P" (correct rangeis 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 keyoff and wait 10 seconds. Disconnect ECA 60-pin connector and inspect for corroded or damagedpins. 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 selectorfrom "P" to "L" and back to "P". Record specifications and compare to specification table. See MLPRESISTANCE SPECIFICATIONS table. If resistance is within specification, go to step 3). Ifresistance is not as specified, go to next step.

Fig 6: 4WD Low & Overdrive Cancel Harness Schematic



15 of 57 12/12/2014 11:46 AM

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 fromharness. Use a mirror to inspect ends of transmission harness connector at MLP sensor for damageor corrosion. Repair as necessary. Install breakout box, leaving ECA disconnected. Measureresistance between test pin No. 30 at the breakout box and corresponding pin at the MLP sensorvehicle harness connector. Measure resistance between test pin No. 46 at the breakout box andcorresponding pin at the MLP sensor vehicle harness connector. If both resistances are less than 5ohms, 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 isdisconnected. 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 resistancesare 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. Installbreakout box and connect ECA. With KOEO, set DVOM on 20-volt scale. Measure voltage betweentest pins No. 30 and 46 at the breakout box. If voltage is 4.75-5.25 volts, service or adjust MLPsensor. If voltage is not as specified, replace ECA, reconnect components and rerun QUICK TEST .

NOTE: A break in step numbering sequenceoccurs 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 selectorlever is not in 2WD or 4WD High position during KOEO Self-Test. This condition may be accompaniedby 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 97/631indicates an Overdrive Cancel Indicator Light (OCIL) fault during KOEO Self-Test. Possible causes forthis fault are: faulty 4WD LOW switch, faulty OCS switch, burned out bulb, open harness, shortedharness or faulty ECA. Rerun QUICK TEST . If none of the above codes are present and fault cannotbe duplicated at this time, testing is complete. If Code 97/631 is present, go to step 12). If any othercodes are present, go to next step.

11) Cycle 4WD LOW Or Overdrive Cancel Switch Circuit Turn key off and wait 10 seconds.Disconnect ECA 60-pin connector, and inspect for corroded or damaged pins. Service or repair asnecessary. Install break-out box, leaving 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 thebreakout box while cycling the Overdrive Cancel Switch (OCS). Move transfer case lever between


16 of 57 12/12/2014 11:46 AM

4WD and 2WD positions several times.

OVERDRIVE CANCEL SWITCH (OCS) CIRCUIT - Measure voltage between test pin No. 41 andtest pins No. 40 and 60 at the breakout box while cycling the Overdrive Cancel Switch. Toggle theswitch on the dash several times.

If voltage cycles, remove breakout box. Replace ECA and rerun QUICK TEST. If voltage does notcycle, 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 isdisconnected. Set DVOM on 200-k/ohm scale.

4WD LOW CIRCUIT - Disconnect 4WD LOW switch. Measure resistance between test pin No. 12and test pins No. 40 and 60 at the breakout box.

OVERDRIVE CANCEL SWITCH (OCS) CIRCUIT - Disconnect Overdrive Cancel Switch. Measureresistance 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 forCode 97/631. If resistance is less than 10 k/ohms for Code 47 or 633, repair short circuit and rerunKOEO Self-Test; for Code 65/632, repair short circuit and rerun KOER Self-Test. If Code 65 or 632 isstill 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 andECA is disconnected. Set DVOM on 20-volt scale. Measure voltage between test pin No. 32 and testpins 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, disconnectECA 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 LOWswitch.

4WD LOW CIRCUIT - Measure voltage between Key Power Circuit at the fuse No. 18 (+ probe) andtest pin No. 12 (- probe) at the breakout box.

OCS-OCIL CIRCUIT - Measure voltage between Key Power Circuit at the fuse No. 5 (+ probe) andtest pin No. 32 (- probe) at the breakout box.

If voltage is greater than 2 volts, go to next step. If voltage is 2 volts or less, check for a faultyindicator bulb (4WD LOW LED or OCIL) or defective fuse in fuse panel. If fuse is okay, repair opencircuit. 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 4WDLOW circuit at the 4WD LOW switch vehicle harness.

OCS-OCIL CIRCUIT - Measure resistance between KEY PWR at fuse panel (ohmmeter positivelead) and power side of OCS harness connector (ohmmeter negative probe). Measure resistancebetween test pin No. 41 at breakout box and signal side of OCS harness connector. If resistance isless 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 isdisconnected. Set DVOM on 200-k/ohm scale.

4WD LOW CIRCUIT - Disconnect 4WD LOW switch. Measure resistance between test pin No. 12and test pins No. 37 and 57 at the breakout box.


17 of 57 12/12/2014 11:46 AM

OCS-OCIL CIRCUIT - Disconnect OCS switch. Measure resistance between test pin No. 41 and testpins No. 37 and 57 at the breakout box. Measure resistance between test pin No. 32 and test pinsNo. 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, repairshort circuit(s). Remove breakout box, reconnect ECA and rerun QUICK TEST.


18) Service Code 91/621, 92/622, 93/626, 94/627, 998 & 99/624 Circuit Identification These servicecodes 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. Code98 indicates Electronic Pressure Control (EPC) solenoid may have a faulty driver in the ECA. Code99/624 indicates a faulty EPC circuit which may cause harsh shifting and clutch wear. Code 89/629should be tested the same as 94/627. Possible causes for these codes are: solenoid resistance is outof limits, harness circuit is open or grounded, or faulty ECA.

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

Fig 7: Solenoid & Circuit Identification Chart


18 of 57 12/12/2014 11:46 AM

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

CAUTION: DO NOT perform Output StateCheck on 7.3L Diesel-E4OD vehicles, or damageto transmission may occur. This check is for4.9L/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 tobattery positive. Jumper STI circuit to SIG RTN at the Self-Test connector. Perform KOEOSELF-TEST until all Continuous Codes have been displayed. DVOM will indicate less than 1.0 voltwhen test is complete. Depress and release throttle. If voltage increases, remain in Output StateCheck and go to next step. If voltage does not increase, depress throttle to WOT and release. If STOvoltage does not increase, go to CIRCUIT TEST QC in appropriate TESTS W/CODES article in theENGINE PERFORMANCE section. Leave test equipment hooked up.

19) Check Suspect E4OD Solenoid Electrical Operation With KOEO, disconnect transmissionsolenoid 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 testlead to ECA signal test pin at bulkhead connector (see step 18). Set DVOM on 20-volt scale. Whileobserving DVOM, depress and release throttle several times to cycle output on and off. If suspectedsolenoid output circuit voltage change is 1.0 volt or more, service or repair solenoid. If voltage changeis 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 connectorfor damage or corrosion. Service or repair as necessary. With KOEO, measure voltage betweenVPWR circuits test pins No. 37 and 57, (EPC power pin 35 on Diesel) at E4OD transmission harnessconnector and ground. Ensure voltage is greater than 10.5 volts. If voltage is within specification, goto 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. DisconnectECA 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. SetDVOM 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, replaceECA, remove breakout box and rerun QUICK TEST . See Fig 8. If resistance is not as specified, go tonext step.


19 of 57 12/12/2014 11:46 AM

22) Checking Continuity Of E4OD Solenoid Harness Turn key off and wait 10 seconds. Installbreakout box, leaving ECA disconnected. Disconnect transmission bulkhead connector. Measureresistance 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) atthe breakout box and EPC PWR and VPWR pins at the E4OD transmission bulkhead connector. SeeFig 9. If all resistances are less than 5 ohms, go to next step. If resistance is 5 ohms or more, removebreakout 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. Installbreakout 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 atthe breakout box and chassis ground. If all resistances are 10 k/ohms or more, go to next step. Ifresistances are less than 10 k/ohms, repair short circuit(s), remove breakout box, and reconnect ECAand solenoid(s). Rerun QUICK TEST .

24) Checking E4OD Solenoid Harness For Short To Power Turn key off and wait 10 seconds. Installbreakout 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. 37and 57 at breakout box. See Fig 7. If all resistances are 10 k/ohms or more, repair or replacesolenoids as necessary. If resistances are less than 10 k/ohms, repair short circuit(s), removebreakout 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 andthe ECA signal test pin at the breakout box. See Fig 7. With KOEO, wait 10 seconds. Initiate KOEOSelf-Test. If test light flashes momentarily and then stays off, repair transmission solenoids as

Fig 8: Solenoid Resistance Chart


20 of 57 12/12/2014 11:46 AM

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


30) Code 26/636: Check Transmission Oil Operating Temperature Code 26/636 indicatesTransmission 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 vehiclenormally in city traffic for 20-30 minutes to bring transmission oil temperature to at least 50 F (10C).In extremely cold weather, a longer warm-up drive may be necessary. Rerun QUICK TEST . If code26/636 is still present, go to next step. If code 26/636 is no longer present, service or repair othercodes as necessary.

31) Checking For VREF At Throttle Position Sensor (TPS) Refer to wiring circuit diagrams in VREFchecks. Turn key off and wait 10 seconds. Disconnect ECA 60-pin connector and inspect for corrodedor damaged pins. Service or repair as necessary. Install breakout box and connect ECA to breakoutbox. Disconnect TPS (FIPL on 7.3L Diesel) and set DVOM on 20-volt scale. With KOEO, measurevoltage between VREF and SIG RTN at the TPS (or FIPL) vehicle harness connector. If voltage is4.0-6.0 volts, reconnect TPS (or FIPL) and go to next step. If voltage is not as specified, go toCIRCUIT 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 (10C). Iftransmission has cooled down, repeat test drive. Turn key off and wait 10 seconds. Ensure breakoutbox 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 sideaway from exhaust manifold. Measure resistance between test pin No. 42 (test pin No. 7 on 7.3LDiesel) 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.


21 of 57 12/12/2014 11:46 AM

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


40) Code 56/637: Attempt To Generate Code 66/638 Code 56/637 indicates TOT signal is greaterthan 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 transmissionbulkhead connector from TOT sensor. Inspect for corroded or damaged pins. Service or repair asnecessary. Insert a jumper wire at the bulkhead connector between TOT SIGNAL and SIG RTN. RunKOEO SELF-TEST . If Code 66/638 is present, remove jumper wire and service or replace TOTsensor. 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. Ensurebulkhead connector is disconnected at transmission. Disconnect ECA 60-pin connector and inspectfor corroded or damaged pins. Service or repair as necessary. Install break-out box, leaving ECAdisconnected. 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 atthe 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 . Ifresistances are 5 ohms or more, repair open circuits, remove breakout box and reconnect ECA.

Fig 9: TOT Resistance Chart


22 of 57 12/12/2014 11:46 AM

Rerun QUICK TEST.


50) Code 66/638: Attempt To Generate Code 56/637 Code 66/638 indicates that TOT signal is lessthan 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 transmissionconnector from bulkhead connector. Inspect for corroded or damaged pins. Service or repair asnecessary. Run KOEO Self-Test. If Code 56/637 is present, service or replace TOT sensor. If Code56/637 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 10seconds. Disconnect ECA 60-pin connector and inspect for corroded or damaged pins. Service orrepair as necessary. Install breakout box and connect ECA to breakout box. Disconnect TPS (FIPL on7.3L Diesel) and set DVOM on 20-volt scale. With KOEO, measure voltage between VREF and SIGRTN at the TPS (or FIPL) vehicle harness connector. If voltage is 4.0-6.0 volts, reconnect TPS (orFIPL) and go to next step. If voltage is not as specified, go to CIRCUIT TEST C in appropriate TESTSW/CODES article in the ENGINE PERFORMANCE section.

52) Checking TOT Signal For Short To Ground Turn key off and wait 10 seconds. Ensure bulkhead isdisconnected at transmission. With breakout box installed and ECA disconnected, set DVOM on200-k/ohm scale. Measure resistance between test pin No. 42 (test pin No. 7 on 7.3L Diesel) and testpins No. 40, 46 and 60 at the breakout box. If all resistances are 10 k/ohms or more, replace ECAand remove breakout box. Reconnect components and rerun QUICK TEST . If resistances are lessthan 10 k/ohms, repair short circuit, remove breakout box and reconnect components. Rerun QUICKTEST.


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 andrecord Continuous Memory Codes. If Codes 49/617, 59/618 or 69/619 are present, go to step 96). IfCodes 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 whiletransmission 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 drivestep. 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 Beforeperforming any procedures in this step, complete the drive cycle test. Drive vehicle approximately 15minutes over a rough road to simulate road shock. Observe MIL LED while driving for indication of afault. If MIL flashes ON and OFF, go to next step. If light does not flash, fault may not be duplicated atthis 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


23 of 57 12/12/2014 11:46 AM

connector at MLP sensor. Go to next step.

TRANSMISSION SOLENOIDS (CODES 62/628 OR 99/624) AND TOT SENSOR (CODES 56/637OR 66/638) - Wiggle transmission bulkhead connector. If a fault is indicated, isolate fault and serviceor repair as necessary. Clear Continuous Memory Codes and rerun QUICK TEST . If a fault is notindicated, go to step 95).

93) Checking EEC-IV Harness Ensure vehicle is still in KOEO Continuous Monitor Mode. ObserveVOM for an indication of a fault while performing the following: using illustration in step 94), graspharness close to sensor or transmission connector and perform "Wiggle" test while working fromtransmission 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.


24 of 57 12/12/2014 11:46 AM

95) Checking ECA & Harness Connectors Turn key off and wait 10 seconds. Disconnect ECA 60-pinconnector. Disconnect ECA 60-pin connector and inspect for corroded or damaged pins. Service orrepair 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, 59/618or 69/619 indicate that the transmission went through 4 consecutive incorrect shifts in an upward ordownward shift sequence. When changing a gear, the SS1 or SS2 solenoid remained ON or OFF anextended amount of time. Possible causes for these faults are: intermittent harness continuity or stuckshift solenoid. Rerun KOEO SELF-TEST . If any other codes appear during the KOEO Self-Test inaddition to Codes 49/617, 59/618, 69/619, service other codes first. If other codes do not appear, go

Fig 10: E4OD Vehicle Harness Circuit


25 of 57 12/12/2014 11:46 AM

to next step.

97) Checking Circuits Using KOEO Continuous Monitor Mode Enter KOEO Continuous MonitorMode. 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 totransmission bulkhead connector. If a fault is indicated, disconnect connectors and inspect connectorsand harness for damage. Clear codes and rerun QUICK TEST . If a fault is not indicated, service orreplace SS1 and SS2 solenoids as necessary.

CIRCUIT TESTS (1992)

CIRCUIT TEST DS PROGRAMMABLE SPEEDOMETER/ODOMETER MODULE (PSOM)

Diagnostic Aids

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 maybe cause of problem:

Cruise control system.

Rear anti-lock brake system.

Instrumentation system.

Fig 11: Programmable Speedometer/Odometer Module (PSOM) Circuit



26 of 57 12/12/2014 11:46 AM

1) Continuous Memory Code 29/452 Code 29/452 indicates ECA detected incorrect output from VSSsometime 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 repair if damaged. InstallEEC-IV Breakout Box (T83L-50-EEC-IV), leaving ECA disconnected. Measure resistance betweentest pins No. 3and 6 at breakout box. If resistance is 21-55 k/ohms, go to step 4). If resistance is not21-55 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 wiringharness connector. If resistance is less than 5 ohms, repair open circuit and repeat QUICK TEST . Ifresistance 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. 3and test pins No. 6, 37 and 40 at breakout box. If resistance is 10 k/ohms or less, repair open circuitand 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 toPSOM. 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 ismore than 4.5 volts, replace ECA.

CIRCUIT TEST TB 4X4 LOW & OVERDRIVE CANCEL SWITCH (OCS)

Diagnostic Aids

Perform this test only when directed by QUICK TEST . To prevent replacing good components, be awarefollowing non-EEC areas may be at fault:


Brakes.


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



27 of 57 12/12/2014 11:46 AM

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)



28 of 57 12/12/2014 11:46 AM

1) Code 47/633, 65/632 Or 97/631 Code 47/633 indicates 4x4 Low selector lever is not in 4x2 or 4x4HIGH position during KOEO Self-Test. Code 65/632 indicates Overdrive Cancel Switch (OCS) is notcycled between engine ID code and WOT check during KOER Self-Test. Code 97/631 indicates OCScircuit 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 thistime. See TROUBLE SHOOTING in the AUTO TRANS OVERHAUL - FORD E40D article. If Code47/633 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. Inspectterminals, and repair if damaged. Install EEC-IV Breakout Box (T83L-50-EEC-IV), leaving ECAdisconnected. Turn ignition on. To check 4x4 LOW circuit, measure voltage between test pin No. 12and test pins No. 40 and 60 at breakout box. To check OCS circuit, measure voltage between test pinNo. 41 and test pins No. 40 and 60 at breakout box while cycling overdrive cancel switch. If voltagecycles, 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 testpins No. 40 and 60 at breakout box. To check OCS circuit, measure resistance between test pin No.

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



29 of 57 12/12/2014 11:46 AM

41 and pins No. 40 and 60 at breakout box. If resistance is more than 10 k/ohms, go to step 4) (Code97/631) 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 ismore than 10.5 volts, replace ECA and repeat QUICK TEST . If voltage is 10.5 volts or less, go tonext step.

5) Check Output Driver Voltage Signal Turn ignition off. Leave ECA disconnected from breakoutbox. Disconnect OCS. To check 4x4 LOW circuit, connect DVOM positive lead on KEY POWERterminal of fuse panel and negative lead on test pin No. 12 at breakout box. See Fig 15. To checkOCS circuit, connect DVOM positive lead on KEY POWER terminal of fuse panel and negative leadon test pin No. 32 at breakout box. If either voltage reading is less than 2 volts, check bulb and fuse. Ifbulb and fuse are okay, repair open circuit and repeat QUICK TEST . If both voltage readings are 2volts or more, go to next step.


30 of 57 12/12/2014 11:46 AM

6) Check Circuit Continuity Turn ignition off. Leave ECA disconnected from breakout box. DisconnectOCS. To check 4x4 LOW circuit, connect DVOM positive lead on KEY POWER terminal of fuse paneland negative lead on test pin No. 12 at breakout box. To check OCS circuit, connect DVOM positivelead on KEY POWER terminal of fuse panel and negative lead on power side of OCS wiring harnessconnector. Connect DVOM positive lead on test pin No. 41 at breakout box and negative lead onpower side of OCS wiring harness connector. If either resistance reading is 5 ohms or more, repairopen circuit and repeat QUICK TEST . If both resistance readings are less than 5 ohms, go to nextstep.

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

Fig 15: Identifying KEY POWER Terminal in Fuse Panel



31 of 57 12/12/2014 11:46 AM

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 testpins No. 37 and 57 at breakout box. If resistances are more than 10 k/ohms, replace switch andrepeat QUICK TEST . If any resistance is 10 k/ohms or less, repair short circuit and repeat QUICKTEST.

CIRCUIT TEST TC - TRANSMISSION SOLENOIDS

Question: CODE 624 ELETRONIC PRESSURE CONTROLL

Diagnostic Aids



Brakes.



Wiring harness circuits M/CCC, CCO, CCS, EPC, SS3/4, SS1, SS2, SS3, SIG RTN, EPC PWR andVPWR.

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


32 of 57 12/12/2014 11:46 AM

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 solenoiddid 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 STOterminal at self-test connector. Connect positive lead to positive battery terminal. Install a jumper wirebetween SIG RTN terminal at self-test connector and STI terminal. Perform KOEO SELF-TEST until

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



33 of 57 12/12/2014 11:46 AM

continuous memory test is complete. DVOM will read less than 1.0 volt when test is complete toindicate 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 WOTand release. If STO voltage goes high, go to step 2). If STO voltage does not go high, leave testequipment connected. Check and repair throttle linkage as necessary or disconnect cruise control (ifequipped). Go to next step.

2) Check Solenoid Electrical Condition Turn ignition off. Disconnect transmission wiring harnessconnector. Inspect terminals, and repair if damaged. Connect VOM or DVOM positive test lead tosolenoid VPWR connector. Connect negative test lead to appropriate solenoid terminal attransmission wiring harness connector. Cycle solenoid output on and off by depressing and releasingthrottle 3-5 times. If voltage output changes 0.5 volt or more, fault is in transmission. If voltage outputdoes not change 0.5 volt or more, go to next step.

3) Check Continuity Between Solenoid & VPWR Circuits Turn ignition off. Leave transmission wiringharness 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 resistancebetween ECA output signal terminal at ECA wiring harness connector and output signal terminal attransmission wiring harness connector. Measure resistance between breakout box test pins No. 37and 57 and VPWR terminal at transmission wiring harness connector. If either resistance is less than5 ohms, repair open circuit and repeat QUICK TEST . If both resistances are 5 ohms or more, go tonext step.

4) Check Solenoid Circuit For Short To Power Or Ground Turn ignition off. Leave ECA disconnectedfrom breakout box. Leave transmission wiring harness disconnected. Measure resistance betweenECA output signal test pin and test pins No. 37 and 57 at breakout box. Measure resistance betweenECA output signal test pin and pins No. 40, 46 and 60 at breakout box. Measure resistance betweenECA output signal test pin and chassis ground. If either resistance is less than 10 k/ohms, repair shortcircuit and repeat QUICK TEST . If all resistances are 10 k/ohms or more, replace ECA and repeatQUICK TEST.


10) Check VPWR To Solenoid Code 86/566 or 89/629 indicates shift solenoid did not respond to ECAcommand. Code 99/624 indicates failure of EPC circuit. Code 98/625 indicates EPC driver failure.Possible causes for these faults are:

Faulty solenoid.


Faulty ECA.

Turn ignition off. Disconnect transmission wiring harness connector. Turn ignition on. Measureresistance between VPWR and EPC PWR terminal at transmission wiring harness connector andchassis ground. If voltage is less than 10.5 volts, repair open circuit and repeat QUICK TEST . Ifvoltage is 10.5 volts or more, go to step 11).

11) Check Solenoid Resistance Turn ignition off. Leave transmission wiring harness connectordisconnected. Measure resistance between VPWR and EPC PWR terminal and suspect componentterminal at transmission wiring harness connector. If resistance is not 3-7 ohms, fault is intransmission. If resistance is 3-7 ohms, go to step 12).

12) Check Solenoid Signal & VPWR Circuit Continuity Turn ignition off. Disconnect 60-pin ECAconnector. Inspect terminals, and repair if damaged. Install EEC-IV Breakout Box (T83L-50-EEC-IV),


34 of 57 12/12/2014 11:46 AM

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. Measureresistance between test pin No. 32 at breakout box and EPC solenoid terminal at transmission wiringharness connector. If resistance is 5 ohms or more, repair open circuit and repeat QUICK TEST . Ifresistance is more than 5 ohms, go to next step.

13) Check Circuit For Short To Power Or Ground Turn ignition off. Leave ECA disconnected frombreakout box. Leave transmission wiring harness connector disconnected. Measure resistancebetween 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 eitherresistance is less than 10 k/ohms, repair short circuit and repeat QUICK TEST . If all resistances are10 k/ohms or more, replace ECA and repeat QUICK TEST.


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.


Faulty ECA.

Turn ignition off. Disconnect transmission wiring harness connector. Measure resistance betweensuspect shift solenoid at transmission wiring harness connector and chassis ground. If resistance is13-17 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 wiringharness connector. Disconnect 60-pin ECA connector. Inspect terminals, and repair if damaged. Turnignition on. Measure voltage between suspect shift solenoid at transmission wiring harness connectorand chassis ground. If voltage is more than 0.5 volt, repair short to power and repeat QUICK TEST . Ifvoltage is 0.5 volt or less, go to next step.

22) Check Shift Solenoid For Short To Ground Turn ignition off. Leave transmission wiring harnessconnector disconnected. Measure resistance between suspect shift solenoid at transmission wiringharness connector and chassis ground. Measure resistance between suspect shift solenoid and othercircuits at transmission wiring harness connector. If either resistance is less than 10 k/ohms, repairshort 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 harnessconnector 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 solenoidterminal at transmission wiring harness connector. If resistance is 5 ohms or more, repair open circuitand 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 ECAdisconnected from breakout box. Reconnect transmission wiring harness connector. Measure voltagebetween test pin No. 60 and suspect shift solenoid terminal at breakout box. If voltage is 0.5 volt ormore, replace or repair solenoid short to power. If voltage is less than 0.5 volt, replace ECA andrepeat QUICK TEST .

NOTE: A break in step numbering sequence


35 of 57 12/12/2014 11:46 AM

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 80warm-up cycles. Possible causes for these faults are:

Faulty shift solenoid.


Turn ignition off. Check shift solenoid circuit between ECA and transmission. Repair or replace asnecessary. If circuits are okay, go to next step.

31) Check For Intermittent Short Or Open Turn ignition off. Disconnect 60-pin ECA connector. Inspectterminals, and repair if damaged. Install EEC-IV Breakout Box (T83L-50-EEC-IV), leaving ECAdisconnected. Turn ignition on. Connect test light between test pin No. 37 and suspect shift solenoidterminal at breakout box. See IDENTIFYING SHIFT SOLENOID TEST CIRCUITS table. Test lightshould be at partial brightness. Observe test light while wiggling and bending shift solenoid circuitbetween transmission and ECA. An open or short to power will be indicated by light going off. A shortto ground will be indicated by light getting bright. Repeat procedure for all solenoids. If fault isindicated, 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 breakoutbox. Disconnect transmission wiring harness connector. Turn ignition on. Connect test light betweentest pin No. 37 and suspect shift solenoid terminal at breakout box. Test light should be off. Observetest light while wiggling and bending shift solenoid circuit between transmission and ECA. A short toground 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 beduplicated at this time.

CIRCUIT TEST TD - MANUAL LEVER POSITION (MLP) SENSOR

Diagnostic Aids



Electrical (alternator, battery, add-on devices, etc.).

Transmission shift linkage.


Wiring harness circuits MLP, TSR, TSL, TSD, TSOD and SIG RTN.

ECA.


36 of 57 12/12/2014 11:46 AM

TEST PIN NO. 30 (MLP) WIRE COLOR IDENTIFICATION


Bronco, "E" Series & "F" Series Light Blue/White

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


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 ofself-test range (3770-4607 ohms) when gear selector is in Park position. Possible causes for thesefaults are:

Linkage not adjusted correctly.

Faulty Manual Lever Position (MLP) sensor.


Faulty ECA.

Turn ignition off. Apply parking brake. Place transmission gear selector in Neutral position. PlaceManual Lever Position (MLP) sensor gauge in sensor slot. If gauge does not fit, loosen MLP mountingbolts 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 harnessconnector. Disconnect 60-pin ECA connector. Inspect terminals, and repair if damaged. Install EEC-IVBreakout Box (T83L-50-EEC-IV), leaving ECA disconnected. Measure resistance between MLPterminal at MLP sensor wiring harness connector and test pin No. 30 at breakout box. Measureresistance between SIG RTN terminal at MLP sensor wiring harness connector and test pin No. 46 atbreakout 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 sensordisconnected. Measure resistance between test pin No. 30 and test pins No. 40, 46 and 60 atbreakout box. Measure resistance between test pin No. 30 and chassis ground. If resistance is less

Fig 17: Manual Lever Position (MLP) Sensor Circuit



37 of 57 12/12/2014 11:46 AM

than 10 k/ohms, repair short circuit and repeat QUICK TEST . If resistance is 10 k/ohms or more, goto next step.

4) Check MLP Sensor Resistance Turn ignition off. Connect MLP sensor. Leave ECA disconnectedfrom breakout box. Measure resistance between test pins No. 30 and 46 at breakout box while cyclinggear selector. See MLP SENSOR RESISTANCE table. If resistance is within specification, replaceECA and repeat QUICK TEST . If resistance is not within specification, replace MLP sensor andrepeat 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


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 gearwhen vehicle is operated with shift lever in Drive or Overdrive position, go to step 10). If transmissiondoes not remain in 3rd gear, go to next step.

8) Visual Inspection Visually check select switch and solenoid wiring harness between ECA andtransmission. Repair or replace wiring harness as necessary. If wiring harness is okay, go to nextstep.

9) Diagnose Transmission Shift Patterns If transmission upshifts and downshifts correctly, EEC-IVsystem is okay. Fault is in transmission. If transmission does not shift correctly, check harness andconnectors for intermittent opens and shorts.

10) Code 634 Code 634 indicates ECA has received incorrect voltage signals from gear selectsensors. Clear continuous memory codes. Start engine. Shift gear selector to each position, leavingselector in each gear for 10 seconds. Turn ignition off. Shift gear selector to PARK position. PerformKOEO Self-Test. If Code 634 is not present, fault is intermittent. Go to next step. If Code 634 ispresent, go to next step.


20) Recheck For Code 634 Clear continuous memory codes. Turn ignition on. Shake, wiggle andbend select switch wiring harness circuit between ECA and transmission. Verify Shift gear selectorthrough entire range and then place in PARK position. Perform KOEO SELF-TEST . If Code 634 ispresent, isolate fault and repair as necessary. If Code 634 is not present, go to next step.


38 of 57 12/12/2014 11:46 AM

21) Inspect Circuit Turn ignition off. Inspect transmission switches and harness connectors forcorrosion 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 atthis time.

CIRCUIT TEST TE - TRANSMISSION OIL TEMPERATURE (TOT) SENSOR

Diagnostic Aids


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.

TOT SENSOR SPECIFICATIONS

Temperature F (C) Volts 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

(1) (1)

Fig 18: Transmission Oil Temperature (TOT) Sensor Circuit



39 of 57 12/12/2014 11:46 AM

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

Value may vary by 15 percent.

1) KOEO Code 26/636 KOEO Code 26/636 indicate TOT sensor is out of self-test range. Possiblecauses for these faults are:

Transmission fluid incorrect temperature.

Incorrect sensor resistance.

Faulty ECA.

Ensure transmission fluid temperature is more than 50F (10C). Repeat QUICK TEST . If Code26/636 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 wiringharness 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 voltageis 4-6 volts, go to step 3). If voltage is not 4-6 volts, there is a fault in the 5-volt reference circuit. Seewiring diagram or go to CIRCUIT TEST C in appropriate TESTS W/CODES article in the ENGINEPERFORMANCE section.

3) Check TOT Sensor Resistance Turn ignition off. Disconnect ECA from breakout box. Allowtransmission to cool. Turn ignition on. Measure and record voltage between test pin No. 46 and TOTtest 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 atbreakout box. If voltage is within specification, replace ECA and repeat QUICK TEST . If voltage isnot within specification, fault is in transmission.


10) KOEO Code 56 Or 637 KOEO Code 56 and 637 indicate TOT sensor output exceeds self-test

(1)


40 of 57 12/12/2014 11:46 AM

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 Code66/638 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 BreakoutBox (T83L-50-EEC-IV), leaving ECA disconnected. Measure resistance between TOT circuit at TOTwiring harness connector and TOT test pin at breakout box. Measure resistance between SIG RTNcircuit at TOT wiring harness connector and TOT test pin at breakout box. If either resistance is morethan 5 ohms, repair open circuit and repeat QUICK TEST . If each resistance is 5 ohms or less, go tostep 12).

12) Check TOT Sensor For Short To VPWR Turn ignition off. Leave ECA and TOT sensordisconnected. 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 10k/ohms or less, repair short circuit and repeat QUICK TEST.


20) KOEO Code 66 Or 638 KOEO Code 66 and 638 indicate TOT sensor output is lower thanself-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 ifdamaged. Perform KOEO Self-Test. If Code 56 or 637 is present, fault is in transmission. If Code66/638 is not present, go to step 21).

21) Check VREF At Throttle Position Sensor (TPS) Turn ignition off. Disconnect TPS sensor wiringharness 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 Fig19. If voltage is 4-6 volts, go to step 22). If voltage is not 4-6 volts, there is a fault in the 5-voltreference circuit. See wiring diagram or go to CIRCUIT TEST C in appropriate TESTS W/CODESarticle in the ENGINE PERFORMANCE section.


41 of 57 12/12/2014 11:46 AM

22) Check TOT Sensor Resistance Turn ignition off. Disconnect ECA from breakout box. Measureresistance between TOT test pin at breakout box and test pins No. 40, 46 and 60. If resistance ismore 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.


25) Check Transmission Wiring Harness Turn ignition off. Check transmission internal and externalwiring 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

Documents

e4od Electronic Controls Testing