Reply With QuoteStrange shifting can be caused by oil in the engine ecu harness - check the red connectors at the engine ecu for oil.
Fossicker
Hi guys I'm hoping somebody might be able to point me in the right direction with an issue that we're having without discovery 2
It's a td5 auto 1999.
Synopsis of issue;
When I pull up at lights, there are 2 loud clunks as it changes back to first. Under acceleration you can also notice the changes but not as badly.
Now the whole story;
We have been having our fair share of bad luck with this vehicle. It's the third up to 5 auto that we've owned and this one has been the worst, i'm going to all of the details but after three months of ownership we decided that we needed to replace the engine with a secondhand engine and replace the gearbox with a reconditioned unit.
The vehicle ran okay except the engine was a little bit smoky with a bit of blowback into the crankcase until the gearbox gave up, therefore when replacing the gearbox will also sourced a secondhand engine both were replaced at the same time.
After installation of the gearbox and engine, but before the auto was filled with fluid and before the auto with mated to the engine via the flexplate, The engine was started and run at idle for a short period. The torque converter see used to the flexplate and spun the input shaft for the gearbox which was not shifted through gears during this time.
On the advice of the autobox rebuilder The box was removed from the vehicle and taken to a local autobox rebuilder who was to check that no damage had been done to the box. They replaced the oil pump in the box which I believe was a precaution and returned the box to us.
Since refitting the box and engine, the gearbox is giving problems. When I pull up at lights, there are 2 loud clunks as it changes back to first. Under acceleration you can also notice the changes but not as badly. The original box and engine combo was changing smoothly despite the box been knackered.
The vehicle is now back at the local rebuilder, Who has changed the valve body for a another rebuilt one. The problem still persists.
Now I realise that the engine is also different meaning that the sensors fitted to this engine are not the same sensors that were with fitted with the original gearbox, is it likely or even possible that this could be the cause of my issue?
How would I check on the sensors, I do have a Nano-com available if this will help.
I have seen one previous post on what seems to be the same symptoms if not the same issue, however the resolution to the other users issue was a stuck valve was sticky valve in the valve body as mine has been replaced I think we should be able to discount this.
Other than that I'm really struggling for ideas so any help or suggestions would be greatly appreciated.
Regards.
Chris
Master
SupporterStrange shifting can be caused by oil in the engine ecu harness - check the red connectors at the engine ecu for oil.
Cheers
Simon
2003 D2a TD5, ACE, SLS, Vienna Green.
Also check that the wiring harness that goes over the top of the box is not frayed and the connections clean and tight. A faulty maf can sometimes cause the auto to behave erraticaly.
Cheers Scott
Master
Mine has started doing this too, AFTER having the gearbox rebuilt. Already taken it back once, but I don't think the mechanic is much chop, to be honest, and just said it was normal for 4WDs. Would be keen to find an actual cause myself if possible.
Found this on a Ford forum, suggesting it could be something in the driveline, rather than the box. My first thought was the front driveshaft, which I have already replaced a few years ago, but can't find any slip in that. Will spend a bit of time under it in the next few days to see if there is anything obvious.
Clunk when stopping and starting. Transmission? - The FORDification.com Forums
Master
And still reading, seeing a few sites mention a lack of grease in the rear driveshaft. An easy check if nothing else.
ChatterBox
SubscriberJust check for excessive backlash in diffs (especially front), and transfer case , as well as checking the shafts.
Fossicker
Thank you to all for your suggestions I will look into each of these when our vehicles back from the local gearbox bloke. I'll let you know how it all goes
Master
How do you check for backlash? Is it just spinning the propshaft with the gearbox in neutral?Originally Posted by discorevy
Master
Ok, so with the auto and the transfer box in N, front driveshaft and diff have movement, but little noise. Rear diff has a distinct clunk when the rear driveshaft is twisted. On inspection, the diff oil was the right level, but the consistency and colour of a caramel milkshake. No metal in the oil luckily, but I can't think of the last time I drove through water, so not sure how ling it's been like that for. Diff oils were changed about 33,000kms ago, so I've replaced it, and will check it again at Christmas when I do the front diff. Front diff oil is darkish, but clean.
I also greased the front and rear driveshafts, plus any unis that seem to have a nipple, and after a test drive, I can still feel a smaller clunk in the driveline as I roll to a stop, and take off again, but I don't hear the clunk. It's improved dramatically, and probably at an acceptable level for a 15 yr old car with 275kk on the clock.
Will be keen to hear how you go, Ceebrady.
Fossicker
The local auto box bloke swapped out the auto ECU which he reports has moved the upshifts. I think this is probably just a matter of the shifting parameters having moved due to this ECU been mated with the old gearbox, they probably could've been reset in the old ECU, nevermind.
However the downshift clunk still exists, he is obtaining a new sensor (MAF I think as the wrong one was delivered). I will report back tomorrow.
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