Hey all, new to the forums, Any assistance is greatly appreciated. I have a 1991 F150 xlt, 5.0l with a E4OD. Little back story, Truck was stalling intermittently during hard stops, or if you bumped the throttle. pulled, cleaned and rebuilt clutch packs, seals, steels. reinstalled and started having excessively hard shifts, and she required high rpms to even consider moving. Round two. Pulled tranny and found two solenoids on the pack were toast. and took the torque convert in to have it checked out. Was recommended to replace it, This is my business truck so, figured ok,.. won't hurt to have a new TC, Got a new TC, found a Solenoid pack at pick n pull from a '94. Solenoids ohm'd out ok at 20-25ohm. Now, the actual problem.
Truck runs like a Dream, smooth, powerful, until 55ish. it shudders, struggles and requires extra throttle to clear the area. at 60ish the transmission starts smoking, and loosing fluid, actually bubbling through the pan gasket. I don't have a Transmission temp sensor, but I'm assuming she's getting quite hot. now, i read the e40d new models have a pwm TC lock up,.. and mine should be a on/off TC. could i have inadvertently got a hold of a PWM,? and if so could that cause this issue?

 

So after much head scratching hopefully this may help someone else, The Transmission pan wasn't torqued down properly, letting the fluid drain seep out, causing the smoking as it got on the Catalytic converter. the shuttering at 55, was the overdrives tearing them selves apart, (this is a assumption based on the OD steels and frictions being torn, litteraly) Now what i found, was the OD planetary Race.."center" was up side down not seating on the machined shoulder, the pump gear was turned over so not seating on the TC properly, (observation/assumption from the machined shoulder again) new OD frictions, and steels, new planetary as a few teeth were broken off the previous one, and the truck runs great with mild temperamental issues im more then happy to deal with now. only took a 6 hour drive an a bit of destruction, to figure out something i should have noticed on the initial rebuild.

 

Good posts. I would like to work on an auto trans myself one day.

 

they aren't as scary as some make it sound, this was my first attempt at doing one out side of schooling, my recommendation is,. pictures,..lots of pictures. and pay attention to the direction parts were facing as they come out, even if you have to make a little mark to let you know which side is the bell housing side.