A/T - E40D No Converter Engage, 2nd and 4th Gear Starts

TECHNICAL BULLETIN # 216

DATE 1994

TRANSMISSION: E40D

SUBJECT:
High line pressure, 4th gear starts, 2nd gear starts in manual low, No TCC engagement

APPLICATION: Ford

E40D

Solenoid Harness Connector Problems





Improper installation of the solenoid harness connector can cause high line pressure, fourth gear starts, second gear starts in manual low, and no torque converter clutch engagement. The proper way to install the harness connector is shown in figure # 1.





Figure # 2 shows how the harness connector can be plugged in wrong and cause the problems stated earlier. You will notice that the harness connector in figure 2 looks different than the one shown in figure # 1. That's because: when the harness connector was removed from the solenoid body, a piece of the solenoid body was removed with the harness connector. It is now stuck to the harness connector. If you replace the solenoid body, the harness connector won't fit properly.

NOTE:
If your harness connector lock is broken like the ones shown, you should replace it. Many parts suppliers offer repair kits for this.





If you get lucky while reinstalling the plug, and the piece or insert happens to fall out it may look something like figure # 3.








The insert may not come out on all solenoid body connectors, It's purpose is to provide the top of the groove for the "O" ring seal inside the connector. Figure # 4 shows how the solenoid connector should look, and figure # 5 shows how the harness connector looks with the insert from the solenoid body connector stuck to it.