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I'm guessing they pulled a P1744 code. Have you had any probelms with the engine stalling or stumbling when you shift into REVERSE?
If so, there are several things in the E40D that can cause this.
The line-lube pressure regulator valve may be intermittently sticking due to bore or valve wear. This is located in the pump body and requires that the front end of the tranny be disassembled.
The line pressure modulator valve may be sticking. This one is in the valve body.
The TCC valve in the pump housing may be worn and oscillating/sticking. This causes a loss of hydraulic pressure for the TC clutch and causes the TC to slip.
These conditions are often detected by the computer. It responds by maxing out EPC pressure which causes the harsh shifts, hopefully allowing the vehicle to limp to a service facility before it self destructs.
I can guaratantee that if you take the truck to AAMCO, they'll find something that will require a rebuild. AAMCO= All Automatics Must Come Out....
You could get by with a new TC, a rebuilt VB with Sonnax valves, and a few Sonnax items in the pump assy. This is still going to be expensive since the tranny has to be pulled. Of course, the rest of the tranny has 116k of miles on it so this might result in having to rebuild the whole thing anyway a few miles down the road. That's why the Ford dealer suggested a complete rebuild.
In order to diagnose the fault, a transmission shop will need to catch it in the act most likely. You may be able to find a very experienced specialist who can likely diagnose it specifically based on hydraulic pressure readings and diagnostic tests.
In any event, your transmission is not going to be cheap. Let us know what happens.
Steve
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1994 Taurus SHO 3.2/ATX
1989 Taurus SHO What a project! Retired at 249K.
1997 Ford F150 SC 5.4L New Work Truck
1998 Ford Contour Wifey's old daily driver
2007 Mercury Mariner AWD
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