96 Windstar transaxle issues... HELP???

[Stites]

Hey, y'all.

What started out as a leak in our trans has evolved into a complete overhaul... twice. The latest diagnosis is that the PCM is telling the trans to go to 2nd gear ALL THE TIME. Whether it's in park, neutral, even with the switch on and not running, the PCM is telling the trans to engage 2nd gear. This is apparently what caused the trans to go bad in the first place. After the 1st rebuild, the guys put it on their scanner and noticed what the PCM was doing. They took it up the road a short distance, and managed to fry O/D and 2nd again. Has this happened to anyone before? Does anyone know what could be the cause of this???

One thing I might look at... it has a factory burglar alarm installed on it, but it was installed sometime after the previous owner took delivery. Could there be a wire crossed up or shorting out on a trans circuit somewhere???

[Stites0518]

We talked with the mechanic today, and he showed us on his scanner where the computer was acting up. With the switch on, engine not running, and PCM connector unhooked from the trans, we put the shift lever in P, R, N, D, and 1, and the computer still shows to be in 2nd gear. In 2 however, the computer shows to be in 3rd. So, somewhere in the wiring lies a mean little gremlin.

It also showed to have a problem in the ignition switch, as the key was obviously in, but the PCM said it wasn't. We cleared the code, and it came right back as soon as we turned the switch on again. Can ANYONE help us???

[12Ounce]

Have you already tested/replaced the Transmission Digital Range (TDR) switch?

[CoachKarl]

Yeah. 12Oz, the "Transmission Range Sensor (TRS), I believe it is also referred to as. My advice is . . . 1. Go after the harness connection to the TSR. Pull it, Spray it with carb cleaner, Bend all the posts a tiny bit, grease it, and plug it back in. If that don't work. . . 2. Replace the TRS. 3. Post Back here. Details about what you're into grease the wheels here.

Karl

[Stites0518]

Before we took it to the garage, we put a new TRS in. The garage also put ANOTHER new TRS in. The codes that they get deal with the ignition now. The key can be in and it says it isn't. Also when you turn the van on the PCM is commanding 2nd gear. No matter if you're in park, neutral or some other gear. They seem to think that whoever hooked up the aftermarket burglar alarm has messed some wires up. They're trying to find somebody with electrical knowledge to come to their garagage and take a look at it. Any ideas people??

[wiswind]

Keep following the electrical trail.
I can see how someone could tap into the wrong wire....easy to do.
Also, look for any signs of a pinched or worn wiring harness.....as that happens from time to time.

[Stites0518]

I'll be removing the alarm system Saturday morning... doubt there'd be anyone around here wanting to steal a minivan, let alone one with who it belongs to on the door.

I've read on here that where the wiring harness goes into the firewall near the AC lines is prone to chaffing, so I'll check that out, too. Also, we have a Haynes manual with electrical diagrams in it, so I'm prepared to beat this gremlin provided the manual shows all of the wiring.

[Stites0518]

Welp, I went down to the shop today to check out the wiring. I ohm'd out the wires on the PCM plug going into the trans, and checked voltage with switch on(in both cases, I went from solenoid wires to ground, and from hot wire in plug to solenoid wires). During the ordeal, I picked up a signal in solenoid 2 for only a moment, as in putting the probe in the lead and getting a momentary reading that disappeared shortly. Other'n that, there was no continuity from any source other than the hot leads in the plug, and the trans temp sensor lead. With the switch on though, I picked up a reading from solenoid 2 to ground. That told me the PCM was still requesting 2nd gear, which sucks when you really want reverse.
I broke from that, and proceeded to take out the alarm system. I pulled the hot battery terminal before clipping wires, and figured it'd help to reset the PCM. Once I got the alarm out and all molested wires back to normal, I ohm'd the plug out the same as before, and got no signal from any wires except for the hot feed to the temp sensor again, which made sense. With the switch on, battery reconnected, I got 11.35V at both hot leads, and .03V from all solenoid wires to ground. From the hot lead to the solenoid wires, I got 13ish volts. So, I dunno if all's well or not, but it's looking like everything's the same now. Maybe someone with more expertise than me could chime in and tell me if all's well, how stupid I must be to do such a thing, or something inbetween???

Either way, the trans man'll be back in Monday to run his scanner on it and let me know if I've helped matters any.

I also attempted to address the issure with the PCM showing the keey not in when it obviously is. Pulled the key cylinder, tweaked the conductors for a tighter connection, checked both switches, all was well, and reinstalled the cylinder. We'll see on Monday.

[C. Cleve]

Hi, Have you considerd obtaining a ford shop manual with the diagnotic flow charts? I am sure by useing them in their proper sequence and not skipping any steps you should be able to solve your problem if you have the proper ford scan tool to guide you thru the process, This really the only way to go. Let me know how you make out if you choose to use this method..See Ya, Clay..

[Stites0518]

Thanks for the help, Clay. I don't have any shop manuals, though, nor do I have any scan tool of any sort. So, I'm more or less dead in the water without my transmission man(he has about a $4500 MAC scanner).