Check the TCM for water damage. (inside left kick panel)
The TCM needs a good tach signal in order to work correctly. No signal or erratic signal will cause shift issues.
Starting in a higher gear is usually no power to the TCM. Check the TCM relay. (under hood left fender)
I wouldn't worry about the max spec. Don't exceed 4.5 volts. When setting the TPS stay within the min/max spec. Do a test drive, if it shifts good leave it. If you don't like it, give it a little adjustment. Most times it can take a couple of tries to get it right.
CPS is on a PSD. IDI uses a tach sensor.
The TPS could could develop dead spots causing shift issues up or down range.
To test for this, use the volt meter and test the full sweep. There should be no jumps or erratic changes on the meter.
If it does lock it should unlock fairly quick. The TCM is programed to keep the engine from bogging down and burning up the converter clutch.
Reset the TPS and try again. Hit the OD OFF button before you hit the grade. Sometimes this helps. The TCM program isn't the greatest.
ATS is a decent converter, it should be a multi disk unit with a billet cover.
A converter will run locked or unlocked. Never half locked. If it did run half locked the disk will fail quickly.
The converter should lock when cruising. Unless the RPM is below 1200. Climbing a steady grade...
Unwanted things would be aluminum planetary carriers. Early center support bushing. Non hardened sun shell to list a few things. There are a number of upgrades for the 89 model year. enough to warrant a book of updates.
Yes for a stock converter. With a multi disk billet cover this is optional. A quality after market converter will take a much larger load than a single disk stock unit.
Before going crazy with the tranny. Fix the electrical issue first. Any voltage drops will make the E4 go nuts. The TCM is not tolerant of fluctuating voltage. I would start with the alternator because the TCM or solenoid pack are not able to draw down that kind of power.
The 5th gear feeling is the TC locking. The go peddle isn't slammed to the floor, you will get this response.
When setting the TPS. Set it to spec first. Then test drive. You will end up resetting it, because the factory TCM tuning sucks.LOL
Any diesel two wheel drive E4OD from 89-94 will work. The only catch is the manual lever might have to be swapped out. 89-91 are the rod type linkage.92 on are cable driven.
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