96, shudder at 40-45 MPH?

Hello, been long time since I posted on here, but anyway. I have a 96, 3.8 155K. At around 40 MPH, there is a shudder/vibration from the front end. I took off the tires and inspected the suspendtion, CV rubber boots, and all seems to be OK. Trans oil is OK. Is the trans ready to go? or any help from anyone that may help me look into this problem. Thanks.

Is there a check engine light coming on?......like from a misfire?
Clogged EGR ports could be a cause of misfire.
To verify, remove and plug the vaccum line that goes to the top of the EGR valve.
Start motor and drive the vehicle.
If the problem does NOT happen, then the problem is likely the EGR system.
If the problem still happens, then the problem is not likely the EGR system.
Reconnect the vaccum line to the top of the EGR valve.
This test will cause the Check Engine Light (CEL) to come on because you have disabled the EGR valve from being able to open during this test.

No CEL on, but I will pull the codes to see if any are there. I will try the test with the EGR system. Thanks.

I also have a '96. Is the shudder intermittent? I've had one from my transmission that occurs when the TCC locks up. Watch the tachometer.... if it drops during (or just after) the shudder, then it's a good chance your TCC chattering during lockup.

I started seeing this at around 60k miles. It has done it ever since, even after replacing the transmission with a rebuilt one.

I've had trouble getting mine fixed, so if this is the problem and you're able to get it repaired, I'd like to know the ultimate cause.

I googled torque converter shudder, and it sounds like what my promblem is. About the only thing I can do now is to change the trans fluid. The article on google mentions when have this shudder, replacing the trans may not cure it.I'm not going to replace the trans do to its age, going on 16 years old.

I googled torque converter shudder, and it sounds like what my promblem is. About the only thing I can do now is to change the trans fluid. The article on google mentions when have this shudder, replacing the trans may not cure it.I'm not going to replace the trans do to its age, going on 16 years old.
I went through all of this with my 95 a couple of years ago. It would feel as if you were running across speed bumps at around 55 MPH. I automatically assumed that it was torque converter shudder. I brought it into a transmission shop in Atlanta, and was told that they could rebuild it with a TC for about $1400.00. They did the job, I paid and got the car back and it was still doing the same thing. Long story short, after several trips back to the transmission shop and them lying to me. They kept telling my wife when she'd pick it up that they replaced the tranny. The third time we brought it back I put some white out on one of the tranny bolts. I showed it to my wife and told her that if the white out was still on the bolt and they said that they replaced the tranny, then they were lying. Well that's exactly what happened and when my wife called the guy out on it, he got very angry. So I basically filed a small claims suit against the guy but in my letter to him. I said that if he wanted to make it right, I would drop the suit. But that he would be responsible for getting the car to Atlanta. He sent a wrecker after it and sent it to one of his other locations. The manager there called me and told me that he thought it was an ignition problem. I said that's impossible, I just replaced all the plugs and wires a couple of months ago. He asked me where I bought the wires and I told him from advance auto. He told me to go get a better set of wires. So I did and was still having the same problem and another trip to Atlanta ensued. Round and round we went, some jackass took my autolite platinum plugs out and replaced them with regular autolites. Still the same problem, I went all over it again. Outside in the middle of the night letting it run to see if I could see anything arcing, nothing. I called a friend of mine that's a ford mechanic, he said to change the coil pack. I told him that it wasn't arcing out anywhere, he said change it anyway. I did that, I've had no more problems whatsoever, so much for trying to keep this condensed eh? I still left a lot out, but it's something I would check on before I went and had the tranny done.

Uzzo2, thanks for the info. I can not imagine that the coil pac can do something like that. This shudder I have can be more like a short shudder/ trans shifting alittle hard? Wiswind reconmended the EGR, I have not played around with anything yet. I would not have the trans replaced do to 16 years old now.

Uzzo2, thanks for the info. I can not imagine that the coil pac can do something like that. This shudder I have can be more like a short shudder/ trans shifting alittle hard? Wiswind reconmended the EGR, I have not played around with anything yet. I would not have the trans replaced do to 16 years old now.
Well, I never would have imagined it either, I kind of felt bad after it was all over and I had spent all of this time, effort and money fooling with the tranny. I had to call and apologize to the guy at the shop that rebuilt it. He apologized to me for his employees lying to me. It's just hard to find trustworthy auto repair shops these days. That's why I try and do as much of it myself as I can. I would definitely follow Wiswinds advice, he's been fooling with these things for a long time. The only thing I would add as far as the EGR goes was a lot of info I found out here. When I first got the car, the CEL was on, lean codes, EGR codes. Here are a couple of old threads of mine that really helped me diagnose what the problem actually was.

http://www.automotiveforums.com/vbulletin/showthread.php?t=711481

http://www.automotiveforums.com/vbulletin/showthread.php?t=717786

http://www.automotiveforums.com/vbulletin/showthread.php?t=900292

None of this may apply to you at all, I've heard that the 95's were a beast all of their own. I figured that it wouldn't hurt to post it though just in case, hope it helps!

OK, what I did so far was disconnect the vac line to the EGR valve. And it seems that the problem/shutter is still there. Its hard to look for when I am waiting for the shutter. I had the vac line off for 2 days,and drove all over the place. I reconnected the EGR vac line and i will still look for the shutter. I did not have the CEL light turn on with the vac line disconnected, and no codes stored. I want to know if anyone cleaned out the EGR ports a second time?I have done it and it was along time ago. Im not to sure what to do next.

Well this is was has happened so far. Friday morning started the the van and right away I smelled a burning/burnt smell. It was 5 above out side and the van was cold. Drove it to work and the smell lasted about 15 minutes. Then, I drove home and still right away the burnt smell. Then the tach jumped up and down, the oil,battery,park lights came on. The tach was on zero but I can still rev the engine. Then the engine died and the van bucked to a stop. No restart, battery dead. Towed home. Replaced the battery and she came to life. Still have that burnt/burning smell even outside the van. Drove the van, and it seemed to labor when at idle and driving. I checked the trans fluid and did not smell burnt. I think maybe its the torque converter? or the cat.converter is going bad?So now Im thinking its time to donate her and part with her. I dont want to put any money into it.

Battery died?......How is the alternator?, sometimes they go out together......battery dies, pulling a LOT of current and burning out alternator.
Or.....Alternator dies and battery discharges.
Anyhow, I would verify that the battery is getting charged.......

I don't see the problems you mention causing the battery to suddenly die or cause some sudden current draw that kills the electrical system.

There is no vibration at all during accelerating. I will check to see if the alternator is charging.

I checked the alternator for charging. The voltage with van off from the battery is 12.5 volts. Started van and went up to 13.5 to 14 and came down to 12.5. Turned on the head lights and jumped up to 14.5 and the came down. After about a minute of running the alternator housing got very hot, almost enough to sizzle spit. And it smelled with that burnt smell. Alt. bad? most likely.