2003 7.3 4R100 issues - Ford Powerstroke Diesel Forum
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Old 12-19-2013, 09:50 AM
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2003 7.3 4R100 issues

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, PSN, powerstrokearmy, 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 Dacco 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.
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  #2  
Old 01-15-2014, 09:14 AM
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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?
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