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4R100/E4OD Installation Guide

Read This Entire Document Before Installing Your Transmission

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BEFORE REMOVING THE OLD TRANSMISSION You MUST have a scanner and scan the vehicle for any codes. All codes MUST be fixed BEFORE installing the new transmission.

INSTALLATION SUGGESTIONS

1. The cooling system on this vehicle MUST be replaced. The plate cooler in this vehicle cannot be properly flushed and is a non-serviceable component which must be replaced with new.

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Transmission: Subject:

Issue Date:

4R100 Bypass valve December 2013

Technical Bulletin #416 4R100 Transmission – Bypass Valve in cooler line

Vehicles affected: Ford Super Duty, F150, Expedition, Excursion, and Econoline

Issue: This Transmission is equipped with a bypass tube from the factory. In this tube is a “bypass valve”, this valve is designed to open in the event of Transmission cooler blockage (Like when a transmission has

catastrophic failure and contaminates the system) when this happens fluid is allowed to flow from the cooler supply line directly to the return line “Bypassing” the transmission cooler. This will cause the transmission to

overheat and fail prematurely.

Solution: Replacement bypass tubes are still available from the OEM, the tube comes with a new valve built in. The aftermarket has rebuild kits that come with the parts shown below. If reusing the original bypass tube you must disassemble the valve and remove all debris that remains. Failure to do so may hold the valve in the “Bypass” position causing an overheat condition.

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Pro Tip #1:

There have been lots of updates to PCM programming in vehicles equipped with a 4R100 Transmission. It is highly recommended that the OEM programming is updated to the newest version.

All aftermarket tunes / “Chips” must be removed from the Engine and Transmission. Not all tunes are Transmission friendly. Most increase power levels from stock which increases stress on the transmission. This added stress can cause the transmission to fail prematurely.

Pro Tip #2:

Low fluid level in this transmission will typically cause the Torque Converter Clutch to lock up in reverse. You

will notice the engine struggle to stay running or stall at idle while the vehicle is stationary. Try adding 1 or

2qts of fluid to see if the issue goes away.

Pre Powerstroke Diesels (1993 and older):

Use a sensor similar to a TPS called a FIPL(Fuel Injection Position Lever). It is critical that this is adjusted

correctly. There have been updates to the design as well so it is recommended to be replaced with a new

version from Ford. In many cases this switch can be blamed for the actual failure of the Transmission.

Wire C Orange and white wire leading to pin 47 on the PCM is the throttle-opening signal sent to the computer from the FIPL sensor (figure 2). TEST: With the KEY ON, ENGINE OFF, and the throttle at idle position, voltage should be TEST: approximately 1.2 volts. With the throttle wide-open voltage should be approximately 4.5 TEST: volts. The sweep should be smooth A meter with a snapshot or min/max capture mode is useful to catch intermittent ‘opens’. If the previously described range cannot be attained, FIPL adjustment can be done by rotating the sensor (on its bracket) one way or the other until the voltage values are satisfactory.

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Adjust the range sensor

1. Best done before installing the manual shaft

linkage. If the linkage has been bolted on, it may

be necessary to remove it to see the alignment

marks.

2. Loosen the 2 bolts which hold the range sensor

to the case. The Inner part turns with the linkage

shaft, and has a score mark on it. The outer body

which bolts to the transmission case also has a

score mark. These score marks need to be

aligned perfectly when the vehicle is in neutral.

3. Tighten the bolts when score marks are aligned.

4. Move the shift lever back and forth and recheck to insure that the score marks are still aligned. Repeat

if necessary.

Range sensor and

shifter cable

adjustments are very

critical with this

transmission.

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Verify proper shifter cable adjustment:

• Disconnect the cable from the transmission

• Set the transmission to park and attempt to turn the wheels. If

the wheels DO NOT turn then you are in park.

• Now rotate the linkage two detents(clicks) in the opposite

direction of park (this verifies you are in neutral).

The cable end and

manual lever should

line up. If not then

the cable end needs

to be adjusted.

• Push the lock up to free

the cable end.

• Now you can slide the

cable end back and

forth to line it up with

the manual shaft pin.

• Now pull the lock down

and connect the cable

end to the manual shaft.

N

P

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s

h

t

h

e

l

o

c

k

Now have an assistant select

neutral with the shift lever

hold steady pressure upward

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Filling the 4R100:

Relearn:

Adaptive shift data should be cleared by either disconnecting the battery or using a scan tool to erase Keep

Alive Memory (KAM) any time:

Major transmission repair

Transmission replacement

TCM calibration changed

After this procedure it still will take several days of driving the vehicle for the transmission to fully adapt

and begin to shift properly. You MUST DRIVE EASY for the first 200miles after clearing the shift adapts. This

includes no towing or accelerations above ½ throttle.

Perform a thorough test drive with multiple accelerations and from a stop with light to medium throttle

application.

Rescan the vehicle. If codes are present, compare these to the original codes. Use a scan tool to erase the

codes and re-road test the vehicle.

This transmission

requires:

Mercon V

1. Make sure the fluid is touching the bottom of the stick. 2. Start the engine. 3. Move the transmission range selector lever through all

the gear ranges pausing for 3 seconds in each, check for good engagements

4. With the engine running and the transmission at normal operating temperature 150 - 170°F, check and adjust the transmission fluid level, and check for any leaks. If fluid is needed, add fluid in increments of ½qt until the correct level is achieved (fluid should be in the cross-hatched area of the fluid level indicator).

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INSTALLATION CHECKLIST

o Scan vehic le and f ix a l l codes

o Replace the cool ing system (Radiator) and replace or clean cool ing l ines

o Inspect f lex plate for cracks or breakage. Damaged f lex plates are common

o Compare bolt pattern on flex plate to bolt pattern on new torque converter

o Inspect crankshaft pilot bore for wear and apply grease to aid with installation

o C om p a re r e p la cem e nt t r a n s m i ss io n a n d t o r q ue converter to original before installation

o Verify all dowel pins are present, clean, and in good condition – these are critical for proper alignment

o Do not t ighten bell housing bolts with force; may damage torque converter if shifted in t ransit

o Inspect wiring harness and connector for damage and /or corrosion

o Inspect entire electrical system including ground, battery, alternator, mass air flow sensor and throttle position sensor.

o Inspect axle shaft splines and check transmission/engine mounts

o Install supplied tai l shaft housing gaskets and seals

o If 4WD application, replace transfer case input shaft seal

o Inspect transmission mounts, carrier bearing, driveshaft, yoke and U-joints. Excessive vibration due to defective mounts and other faulty driveline parts is the main cause of broken cases.

Road Test Check list

o Does vehicle hold in park

o Engagement into reverse

o Acceleration in reverse

o Does engine free spin in neutral

o Engagement into Over Drive

o Acceleration in Over Drive

o 1-2 shift in Over Drive

o 2-3 shift in Over Drive

o 3-4 shift in Over Drive

o 4-5 shift in Over Drive

o 5-4 downshift in Over Drive

o 4-3 downshift in Over Drive

o 3-2 downshift in Over Drive

o 2-1 downshift in Over Drive

o Engine braking in manual 1

o Engine braking in manual 2

o Torque Converter lock up and release