2003 7.3 4R100 issues

[Goober1979]

I am trying to diagnose and fix trans issues for a 2003 7.3 F250.

I have done a good bit of forum research here, powerstrokenation, and FTE. I have come up with some helpful info but nothing conclusive.

The truck:

-2003 7.3 f250

-410,000 miles

-Trans rebuilt approx. 3 years ago and Dayco triple disc converter installed

-Stock programming/no chip

-Beans injectors installed early this year and are stock size


Symptoms:

-When in D, the truck will not move and will roll back if on a grade.

-When manually shifted into 1st the truck will shudder and ease forward like it as if the friction clutches are not totally engaged.

-When in R there is a hesitation and then the trans slams hard into gear.

-The OD light is NOT flashing.

-Will not start in D sometimes. Must be shifted into N.

-Trans fliud is at appropriate level and looks/smells fine.

Codes:

P0605: internal ctrl module ROM error - i think this could be related
P0733: Gear 3 incorrect ratio - almost certainly related
P0541: Manifold intake air heater - i do not think this is related
P0476: exh press ctrl valve perform - i do not think thisis related
P1780: trans ctrl sw out of range - armost certainly related

My plan:

-Clear all codes and attempt to drive. See what codes return.

-Calibrate the trans range sensor

-Check the TSS and OSS sensor and harness.

-Check all underhood connections.

-Check column shifter wiring for wear.

-Drop pan and look for clutch material.

-Flush with Cooler Cleaner, change filter and refill.

-Check PCM grounds.

Ideas/other:

-Accumulator related?

-Sticky valve?

-Sticky solenoid?

-PCM not grounded well?

-PCM need reflash?

-VSS?

-If there is slippage, why is there no P1728?

I consider the shop that rebuilt the trans to be reputable. They rebuilt the E4OD in my 97 (mods in sig) in 2006, gave me a 3 year warranty and let me watch them rebuild it (just wanted to see how it was done). He upgraded the E4OD with 4R100 parts. I have since beat the crap out of the trans in my 97 with no issues whatsoever.

Please let me know if you see anything I should add/delete/modify in my current plan.

 

[David N]

You've said everything but the pump. Have you checked/looked into that?

 

[Goober1979]

No. I really haven't DONE anything yet but hook it to a scanner. is there a way to test the pump without pulling the trans down? Thanks.

 

[Mark Kovalsky]

-When in D, the truck will not move and will roll back if on a grade.

There is NOTHING electronic that can do that. It MUST be a mechanical failure in the transmission.

-When manually shifted into 1st the truck will shudder and ease forward like it as if the friction clutches are not totally engaged.

Could be a low pressure problem. You should get a pressure gauge and find out what the trans pressures are doing.

-When in R there is a hesitation and then the trans slams hard into gear.

Ditto.

-Will not start in D sometimes. Must be shifted into N.

Do you mean the engine will not start in D? That's good! It should only start in P or N. If you meant it won't start in P, then you need to see about tightening two bolts on the steering column that can loosen and cause this.

Lay under the dash looking up the steering column. There are two #30 Torx head bolts that hold the shift cable bracket to the shift tube.

P0605: internal ctrl module ROM error - i think this could be related

I don't.

P0733: Gear 3 incorrect ratio - almost certainly related

Usually indicates a problem with the direct clutch, which is also used for reverse.

P0541: Manifold intake air heater - i do not think this is related

I agree.

P0476: exh press ctrl valve perform - i do not think thisis related

I agree.

P1780: trans ctrl sw out of range - armost certainly related

No, it is not. It means you didn't press the OD OFF button while running self test, or the button isn't working. Either way it doesn't affect your problem.

-Clear all codes and attempt to drive. See what codes return.

Good.

-Calibrate the trans range sensor

Waste of time.

-Check the TSS and OSS sensor and harness.

Waste of time.

-Check all underhood connections.

Waste of time.

-Check column shifter wiring for wear.

Good idea. See above where I described what to look for.

-Drop pan and look for clutch material.

My guess is that you'll find the direct clutch friction material in the pan.

-Flush with Cooler Cleaner, change filter and refill.

Won't fix it.

-Check <acronym title="Powertrain Control Module">PCM</acronym> grounds.

Waste of time.

-Accumulator related?

No.

-Sticky valve?

No.

-Sticky solenoid?

No.

-PCM not grounded well?

No.

-PCM need reflash?

No.

-VSS?

No.

-If there is slippage, why is there no P1728?

It won't detect no drive engagement. The test doesn't do that.

 

[Goober1979]

Ok. Here is a an update. Took it to the trans shop that did the original rebuild. He pulled it apart and it turns out that the center support "exploded" (his term). The "explosion" took out the front drum and poluted the pump with debris. The center support was the upgraded roller bearing type. All the clutches look good. So, my questions are:

-As far as keeping this from happening aain in the future, I assume an beefier center support like the one from Suncoast. Is that the one to go with? Are there better options?

-Is beefing up the center support the solution or could thius failure be the result of some other part/system?