Another funky E4OD question

[direwulf23]

Yes, another E4OD question. The truck has 206k miles on it and I have no knowledge of whether the transmission has been rebuilt. I've had the truck for about 6 months and I've been battling the 62 code (? Torque converter slipping code) since I got it. The code was showing up on hills mostly. I've replaced the FIPL, because I didn't know how to properly pull codes at first. I've replaced the VSS as well. I've cleaned the plug to both the MLPS and solenoid pack thoroughly and packed with grease.
Now, I haven't had any code for a while, but the transmission acts like it's slipping; however, the slippage is hit and miss. It doesn't act life is always slipping. Some days it doesn't slip at all, and sometimes it does it a lot. Any thoughts or suggestions short of a rebuild?

1994 Ford F250, 2wd, 7.3L IDI, NA, E4OD

 

[trackspeeder]

Code 62 on a grade usually means the tranny is really slipping. At 204k I would assume the tranny was rebuilt.

How is the fluid. Brown or black, tranny is slipping. Red is good, should be at, not above the full mark.

TPS (FIPL) is correctly set. This will cause slipping and other funky stuff.

TRS (MLPS) is correctly set. If its out of alignment it can cause high gear starts. feels like its slipping because it is.

OD OFF light flashing pull the codes.

 

[direwulf23]

Oh yeah, meant to mention that.
The transmission fluid is normal red and no burnt smell.
Would over full fluid cause slippage?
There is no codes when it acts like it's slipping, which is what is really throwing me off. Of the four main sensors the tach sensor and MLPS are the ones I have not replaced. FIPL is in range (as I understand it), 1.1/ 4.1

1994 Ford F250, 2wd, 7.3L IDI, NA, E4OD

 

[trackspeeder]

Over filled can be worse the low. It causes foaming of the fluid. Foaming causes slippage and overheating.

 

[direwulf23]

I suppose the extra fluid and foaming would lower the pressure. Is that possible?

1994 Ford F250, 2wd, 7.3L IDI, NA, E4OD

 

[direwulf23]

Drained/dropped the pan. The fluid was over full but still red and doesn't smell burnt. The magnet had maybe an 1/8" of powdery metal residue on top and there were less than a dozen small, viable shavings. Anybody care to interpret?

1994 Ford F250, 2wd, 7.3L IDI, NA, E4OD

 

[direwulf23]

Okay, on further examine maybe 2 dozen small shavings

1994 Ford F250, 2wd, 7.3L IDI, NA, E4OD

 

[FORDF250HDXLT]

bright shiny aluminum shavings you mean or just black clutch material? snap a pic?

 

[direwulf23]

Damn, I cleaned the magnet off already. J

You must be registered for see images attach

This stuff, if you can tell. It's pretty well black.

1994 Ford F250, 2wd, 7.3L IDI, NA, E4OD

 

[FORDF250HDXLT]

yeah that's ok.good news.that's just normal clutch disc material ware.don't be alarmed.

so re-reading this,to help you figure out if the trans is slipping or not,turn the flashers on.this will unlock the converter.is that the exact "slip" feel you get when going uphill? can you start off going uphill and make the trans slip on purpose? if the trans doesn't always slip while under load,that isn't a "slip" a clutch disc worn out causing one of your forward gears to slip,would never recover on it's own and pull the same grade under the same load just fine the next time.it would always be a slip until you eventually lost that gear altogether.
intermittent issues like that,are almost always electrical related issues.not mechanical failures.

 

[direwulf23]

Awesome! Since I'm here I'm going to pull the solenoid pack and clean it. Then I'll install the 4R100 pan and flash/fill the fluid

1994 Ford F250, 2wd, 7.3L IDI, NA, E4OD

 

[direwulf23]

One thing I did notice is the o ring for the old filter is smooth whereas the new filter o ring has ribbing on the outside.

1994 Ford F250, 2wd, 7.3L IDI, NA, E4OD

 

[OLDBULL8]

I've cleaned the plug to both the MLPS and solenoid pack thoroughly and packed with grease.

If you used Dielectric grease to PACK the connectors, that's not good. Dielectric grease is an insulator, a thin coating will allow current to flow, a thick coating stops it. The electronic signals operate on low voltage (~5 VDC) thats a very small "push".
For an intermitent problem like you have, you would have to have a trans. connector breakout box to check the Solenoid #3 (Converter Clutch Lockup Sol.) or connect an LED to the Black and Green wires to monitor voltage to it. I think I'm correct on that, trackspeeder will verify. I'm not a tranny rebuilder, just info from my own experience's.
Check the connector on the EEC module and the grounding wire from it, also the bulkhead connector.

 

[direwulf23]

Okay. I currently have the solenoid pack out and cleaning the pins. So, I don't want to put dielectric grease in the plug when I put it back together?

1994 Ford F250, 2wd, 7.3L IDI, NA, E4OD

 

[OLDBULL8]

Ya don't really need any grease on the pins, smear some around the connector ribbed body to keep moisture out.