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E4OD Free Tips Ebook

Version 1.09

Revised: Jan 24, 2015
This program is free software: you can redistribute it and/or modify it under the terms of the GNU General Public License as published by the Free Software Foundation version 3 of the License. This program is distributed in the hope that it will be useful, but WITHOUT ANY WARRANTY; without even the implied warranty of MERCHANTABILITY or FITNESS FOR A PARTICULAR PURPOSE. See the GNU General Public License for more details. You should have received a copy of the GNU General Public License along with this program. If not, see http://www.gnu.org/licenses/.

COPYRIGHT NOTICE © 2006-2015 E4OD.COM
This ebook is supplied FREE of charge for your personal use only. No other use, reproduction or electronic transmission in part may be done without the express written permission of Bobby Cooper. YOU CAN, however, send the whole ebook to anyone you wish, or make it available for download on the internet and without charge.
 

DISCLAIMER NOTICE
Information contained in the E4OD Free Tips ebook is from best available sources, personal experience and is accurate at the time of publication. However, www.myfsbo.net, and Robert J. Cooper and their agents ASSUMES NO RESPONSIBILITY and cannot be held liable for any results or consequences regarding the use of this information.

 Jack's Backyard Sales

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E4OD.com is open to anyone who is intereseted in the E4OD automatic transmission or who would like to share their knowledge or experience working on the E4OD and 4R100.

We aret not a repair or diagnosic site. Contained on www.e4od.com is basic information about the E4OD Transmission. 

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E4OD Transmission

Diagnosis Form

Done

1. Check Fluid level at normal operating temperature. (Do not over fill !).

If fluid appears to roll off dipstick and smells sweet,

and does not feel slippery when rubbed between fingers

"Immediately Change Fluid and Filter" !

This is a contamination problem that is happening nationwide.

2. Checked for vehicle computer error codes:

Using engine light blink test and/or OBD-I scan tool (1989 - 1995); (can also use test light)

Using OBD-II Scan Tool (1996 - 1998).

3. Resolved all computer codes which are related to the transmission.

4. Changed transmission fluid & filter, inspected for metal in pan and tested again.

5. Asked questions at various transmission help forums.

6. Purchased E4OD Rebuilding manual or other manual for diagnostic help.

7. Performed in vehicle tests and diagnostics.
8. Email E4OD transmission problems to Bobby Cooper for assistance.

9. Decided to have transmission overhauled.

 

 

Computer Codes:

Diagnosis: EEC-IV .

(Transmission Related)
11 - Computer Self Test passed.
15 - PCM self test of Read Only Memory has failed.
15 - PCM self test of Keep Alive Memory has failed.
23 - TPS sensor out of self-test range
26 - TOT sensor out of self-test range (E4OD)
29 - No signal from VSS
45 - Coil 1 2 or 3 failure.
47 - 4WD switch closed (E4OD)
49 - 1-2 shift error (E4OD)
53 - TPS circuit above maximum voltage
56 - TOT reads -40°F or circuit open (E4OD)
59 - 2-3 shift error (E4OD)
63 - TPS circuit below minimum voltage
65 - Overdrive cancel switch open and no change seen by computer (E4OD)
66 - TOT grounded or reads Max Temperature (E4OD)
67 - Neutral Switch open or A/C is on (turn off A/C during Tests.
67 - Clutch switch circuit failure
67 - MLP sensor out of range or A/C on (E4OD)
69 - 3-4 shift error
73 - Insufficient TPS change during dynamic test
88 - Loss of dual plug input control
91 - Shift solenoid 1 circuit failure (E4OD)
92 - Shift solenoid 2 circuit failure (E4OD)
93 - Coast clutch solenoid circuit failure (E4OD)
94 - Converter clutch solenoid circuit failure (E4OD)
97 - Overdrive cancel indicator light - circuit failure (E4OD)
98 - Electronic pressure control driver open in PCM (E4OD)
98 - Hard fault present
99 - Electronic pressure control circuit failure (E4OD)
111 - System pass
121 - Closed throttle voltage higher or tower than expected
167 - TPS change during dynamic response test is beyond specifications
452 - Insufficient input from vehicle speed sensor
511 - EEC processor ROM test failed
512 - EEC processor Keep Alive Memory test failed
513 - Failure in EEC processor internal voltage
617 - 1-2 shift error (E4OD)
618 - 2-3 shift error (E4OD)
619 - 3-4 shift error (E4OD)
626 - Coast clutch solenoid circuit failure (E4OD)
627 - Converter clutch solenoid circuit failure (E4OD)
628 - Converter clutch error (E4OD)
629 - Converter clutch control circuit failure
631 - Overdrive cancel indicator light circuit failure
632 - Overdrive cancel switch not changing states (E4OD)
633 - 4WD switch is closed
634 - MLP sensor voltage out of self-test range A/C on
636 - TOT sensor voltage out of self-test range
637 - TOT sensor circuit above maximum voltage
638 - TOT sensor circuit below minimum voltage
654 - MLP sensor not in park position
998 - Hard fault present
Abbreviations Defined -
EEC = Electronic Engine Control System
KOEO = Key On Engine Off
KOER = Key On Engine Running
MLP = Manual Lever Position Sensor
PCM = Powertrain Control Module
TPS = Throttle Position Sensor
VSS = Vehicle Speed Sensor
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E4OD Transmission

Disassembly Procedure
   

Done

  

1. Fabricate or purchase transmission stand or use a sturdy workbench with transmission adapter.
   

2. Locate a large drain pan. (I use a large trash can lid with no holes)
   

3. Rotate the transmission to allow any fluid to drain from filler tube in to the drain pan.
   

4. Rotate transmission upside down.
   

5. Use a 10 mm socket to remove remaining pan bolts.
   

6. Remove pan.
   

7. Remove pan magnet, clean, and reinstall back in pan for safe keeping.
   

8. Grasp "FILTER" and rock it end to end as you pull to remove. (remove seal if it stays in pump)
   

9 CAUTION: Protect Valve body mating surfaces at all times. - Always!!!!
   

9. Remove LOWER CONTROL VALVE BODY nuts and bolts. (Bolted on top of largest valve body).
   

10. Remove lower control valve body and small separator plate.
   

11. Remove Check Balls from top of Main Control Valve Body. (record number of check balls)


These check balls will be either made of rubber or plastic:

1989-1995 2 each check balls

1996-1998 (3) each 1/4" check balls; and (2) each 5/16" check balls
   

12. Remove ACCUMULATOR VALVE BODY nuts and bolts. (very front valve body).
   

13. Remove Accumulator Valve Body.
   

14. Remove screen in separator plate under Accumulator Valve Body. (Rotate counter-clockwise)
   

15. Remove Main Control Valve Body bolts & nuts. (Largest valve body)
   

16. Remove Main Control Valve Body
   

17. Remove "SOLENOID VALVE BODY" nuts & bolts.
   

18. Remove Solenoid Valve Body
   

19. CAUTION: Locate EPC 1/4" metal check ball & Spring under separator plate

(EPC 1/4" metal check ball & spring are located near round hole hole in case for solenoid connector).
   

19. Remove 3 bolts on Valve Body separator Retaining Plate.
   

21a. CAUTION: Keep Steel Valve Body plate with gaskets for now to protect plate from damage.
   

20. Remove large Valve Body Separator Plate and EPC 1/4" metal check ball and spring.
   

21b. CAUTION: Do not use solvent to clean rubber or plastic check balls.
   

21. Remove remaining 5/16" Check Balls. Record number of check balls.

(14) each 5/16" Early 1989 + EPC Metal 1/4" relief valve & spring

(11) each 5/16" Late 1989 + EPC metal 1/4" relief valve & spring

(9) each 5/16" 1990-1995 + EPC metal 1/4" relief valve & spring

(8) each 5/16" 1996-1998 + EPC metal 1/4" relief valve & spring

1991-1998 Models:

Also Remove Accumulator Regulator Filter Screen (very small with spring)

(located near single bolt fluid feed bolt in worm tracks.)
   

22. Remove snap ring and plate securing band apply "SERVO" (if applicable) & discard both.

(updated servo in new kit does not use plate and snap ring).
   

23. Remove band apply servo by using high power magnet. (or wait until band is removed later).
   

24. Remove "INPUT SHAFT" - Note: Long spline goes inside transmission:

('96 Updated input shaft (center shaft kit) has groove mark at outer end of input shaft)
   

25. Remove (9) pump bolts using 10mm socket.
   

Special Tools: Front pump 8 MM x 1.25 adapters & slide hammer.
   

26. Thread 8mm adapters in the two 8 mm threaded bolt holes in pump.

Pump bolt holes at 2 and 8 o'clock from bottom / top of case.
   

27. Attach slide hammers to 8 mm adapters.
   

28 CAUTION: Do not nick or mar the pump surface and edges (ever)
   

28. Slide hammer weight outward until pump is popped loose of case.
   

29. Lift pump out of case. (PROTECT EDGE SURFACES)
   

30. Remove plastic trust washer - usual stuck to back of stator flange. (pump back side)
   

31. Remove bearing - usually on coast clutch sun gear. (use magnet if necessary)
   

32. Remove case to pump gasket and discard.
   

33. Remove Coast Clutch assembly and sun gear.
   

34. Remove "CENTER SHAFT" assembly. (Lift Device Available from www.tranYshop.com
   

36. Remove bearing if not on Center Shaft. (use magnet if necessary).
   

37. Remove large Overdrive Clutch Pack snap ring.
   

38. Remove Overdrive pressure plate / clutch pack. (Record number of friction discs).
   

39. Using a 13 mm socket remove 1 Bolt retaining OD Cylinder at worm tracks.

This bolt is the single bolt nearest front of transmission.
   

Special Tool: OD / Intermediate Cylinder compressor cage and jack screw.
   

40 CAUTION: Do not mar pump to case flange area when attaching compressor.
   

40. Install OD Cylinder compressor removal tool and compress 1 revolution of screw.
   

41. See if OD Cylinder snap ring can be spun in case using flathead screwdriver.

IF NOT, repeat 1 complete turn of jack screw until snap ring can be spun easily.

Remove snap ring from case slot.

Back off jack screw until loose.

Then remove compressor cage tool.
   

42. Remove Snap Ring retaining OD cylinder Assembly from case.
   

43. Remove OD / Intermediate Cylinder Assembly.
   

44. Remove Intermediate Cylinder diaphragm return spring. (large wafer spring)
   

42. Using a 13 mm socket remove 2 bolts retaining Center Support at worm tracks.
   

43. Remove "CENTER SUPPORT" by grasping cross bar and pulling up.
   

44. Remove plastic trust washer.
   

45. Remove band apply servo, if not already removed, then remove BAND from case.
   

46. Remove bearing in top of drum opening. (use magnet if necessary)
   

Specialty Tool: Needed to vertically lift drum assembly from transmission.
   

47 CAUTION: Shell / Direct Drum / Forward Hub is very heavy.

Remove Direct Drum / Forward Hub / and Shell as an assembly.
   

47. Tighten handle on the E4OD Drum Lift Tool until cables are tight.

(If no lift tool is available, lay transmission horizontal and carefully remove assembly)
   

48. Lift Direct Drum / Forward Drum / Shell assembly from case.
   

49. Remove metal Trust Washer laying on Reverse Planet if not on bottom of shell.
   

50. Remove Snap Ring from Reverse Hub assembly securing Reverse Planet.
   

51. Remove Reverse Planet.
   

52. Remove metal Thrust Washer from Output Hub if not on bottom of Reverse Planet.
   

53. Remove Extension Housing bolts and remove housing.
   

54 CAUTION: Place rubber bun gee cord from case around end of output shaft to case

This will prevent shaft from falling out of case when c-ring is removed from output shaft.
   

54. Remove small c-ring from output shaft.

NOTE: Replace this c-ring - DO NOT REUSE !
   

55. Remove Output Ring Gear/Hub assembly from output shaft.
   

56. Remove bearing from inner race if not on the back of Ring Gear / output hub.
   

57 CAUTION: The Reverse Hub has a one-way clutch.

Be careful to pull the Reverse Hub off the Inner Race parallel to case. (do not wobble it)
   

57. Remove Reverse Hub and sprag one-way clutch assembly.
   

58. Remove Bun gee cord, Output shaft / Park Gear / Trust Washer. (from rear of case)
   

59. Remove Large Snap Ring retaining Reverse Clutch Pack.
   

60. Remove Reverse Clutch Pack. (record number of friction disc)
   

61 CAUTION: if tear down is on a bench use 2 each 5/16" x 3" long guide bolts with
   
  heads cut off to prevent Reverse one-way sprag Inner Race from falling in case.
   

61. Remove 5 bolts retaining Reverse Sprag Inner Race.
   

62. Remove Reverse sprag Inner Race and Reverse Piston Return Spring assembly.
   

63. Reinstall Pressure Plate & Snap Ring for piston removal process:

1st - Reinstall Reverse Clutch Pressure Plate in Case; and then

2nd - Reinstall Reverse Clutch Snap Ring.
   

  64a WARNING: Precaution Check before applying air to case:

1. Verify Pressure Plate is behind Snap Ring.

2. Verify Reverse Clutch Pack Snap Ring is completely in case groove.

3. DO NOT Place Hands in transmission when air pressure is applied !!!

3. Use no more air pressure than necessary to remove Reverse Piston.

4. Start with 30 pounds and go up from there, never go over 60 pounds.
   

64b CAUTION: You will here a pop-sound and hiss when Reverse Piston is removed.
   

64. SEE 64a WARNING & 64b CAUTION above BEFORE APPLYING air to case:

1. Apply air pressure to Reverse Piston apply at worm track.

(this hole is about center of case and is the 2nd hole from the rear of case.
   

65. Remove Reverse Clutch Pack Snap Ring.
   

66. Remove Reverse Clutch Pack Pressure Plate.
   

67. Remove Reverse Clutch Piston.
   

68. Reinstall pan back on case to protect valve body studs.
   

69. Late 1990-1998, remove rear cooling line tap from transmission and

Check Converter Anti-drain back check valve.:

Check for spring back of ball; and

Fill back side fitting with light oil (such as 3-in-1 oil) to verify check valve is sealing.
   
  NOTE: I usually don't remove the following unless there is an obvious problem(s):

» Manual lever from case if the seal is not leaking and it feels good.

» Parking pawl & parking pawl arm to manual lever if visually looks good.

» Lower filler tube going in to case.
 
  1. Evaluation
  2. Introduction
  3. GNU License
  4. Testing