Bucking/Surging Epidemic

[colin39]

I would check the MAP Sensor and Circuit as well as the (Diesel Variant of the DPFE is the DPF) and circuit.

With it shifting to (neutral) and (downshifting to 1st) on its own

I would check this circuit for the 3.2 with the 6R80, it should be similar except you have a TCM in the system for the transmission - the US Version uses the PCM for Transmission control.

Note: This is for a 10R80 and this uses a 9 Volt (VREF) circuit

Your mentioned issues Buck/Surge - Shifting to (N) etc may tie into this specific VREF Circuit



Take a look at the (2) TR Sensor PIDs A&B, anything look abnormal?
Plus you might try checking on the selector cable adjustment, it may be slightly out of adjustment.

Should be similar to this: Note the (100%) Total above (TR Sensor)
Note: PWM = The Duty Cycle (PID)

Again - I have a hunch that your issue is here and needs to be checked.

Thanks dude I will check that later today , that's real helpful

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[RangerBill]

The differential sensor on the petrol? I've read about these buddy , it creates a similar problem, that's the reason I changed my 6r80 box as when it stutters the gearbox calls for a neutral,bor worst still 1st gear, and when slowing from 60mph and it calls for first it makes ya bum pucker a bit

See if this TSB for NA 6R80 transmissions would give any insight. It references the molded leadframe and output shaft speed sensor causing sudden downshifts into first gear.

https://static.nhtsa.gov/odi/tsbs/2019/MC-10159510-0001.pdf

 

[colin39]

See if this TSB for NA 6R80 transmissions would give any insight. It references the molded leadframe and output shaft speed sensor causing sudden downshifts into first gear.

https://static.nhtsa.gov/odi/tsbs/2019/MC-10159510-0001.pdf

Replaced it, and the gearbox and torque converter and the wiring loom
I've even carried out the tsb regarding prop to pinion angle

 

[RangerBill]

Replaced it, and the gearbox and torque converter and the wiring loom
I've even carried out the tsb regarding prop to pinion angle

Did you have the sudden downshifting with the original transmission? I am thinking that your sudden shift into first at higher speeds is related to the transmission speed sensor or wiring. Does your speedometer read correctly when this happens?

 

[colin39]

Did you have the sudden downshifting with the original transmission? I am thinking that your sudden shift into first at higher speeds is related to the transmission speed sensor or wiring. Does your speedometer read correctly when this happens?

I've had it with both, what ever I do that fault isn't changing.
Speedo reads right too.

Tomorrow I'm going to check through what @airline_tech said and report back, he has given the wiring for the 10r80 but I have found 6r80 I'm my ford computer

 

[My12SecRanger]

Decided to replace the EGR tube assembly like ford recommends for the surging issues, notice the small fitting in the picture goes inside the intake manifold (make sure to clean this )

 

[RangerBill]

Decided to replace the EGR tube assembly like ford recommends for the surging issues, notice the small fitting in the picture goes inside the intake manifold (make sure to clean this )

Just curious, but where did you find the info that Ford recommends the EGR tube replacement? Is it available in a document (TSB)?

 

[My12SecRanger]

That came directly from Ford tech line, we had two rangers here that received transmission replacements and still had the surge/bucking issue, after sending tech line live data they recommended egr tube and egr sensors to be replaced due to moisture in the tube causing sensors to read out of spec

 

[RangerBill]

That came directly from Ford tech line, we had two rangers here that received transmission replacements and still had the surge/bucking issue, after sending tech line live data they recommended egr tube and egr sensors to be replaced due to moisture in the tube causing sensors to read out of spec

Thanks. Did the EGR tube replacement finally solve the issue on those trucks? Has it been re-designed?

 

[airline tech]

Decided to replace the EGR tube assembly like ford recommends for the surging issues, notice the small fitting in the picture goes inside the intake manifold (make sure to clean this )

Curious if you can fit a borescope inside the old tube and inspect the orifice area for buildup and blockage

 

[airline tech]

Thanks. Did the EGR tube replacement finally solve the issue on those trucks? Has it been re-designed?

As far as the redesigns, I do not see any revisions to the part number (supersedes), if my hunch is correct the tube is building up carbon deposits and creating a blockage at the (orifice) limiting its ability to push the (inherent) moisture into the intake flow.
This MAY account for repeated failures of the sensor, again at this point it's just my theory and why I am wanting to see a (failed tube) to confirm if I (correct or incorrect)

We know that moisture is considered normal, it's when it becomes overly abundant and accumulating in the module that creates the issue and if Ford is recommending replacing the tube along with the sensor points that somewhere in the field techs are finding these tubes clogged.
I have yet to see one, that's why I am so curious to see how bad they are clogging up, if this is a true finding in the field or is this simply a (Recommendation) to replace both to address possible comeback returns.

My main focus on this issue is that the majority of those who only replace the DPFE and report good results, there are a few who ask what else can it be, the Tube is a good possibility (IF) it is clogging up or restricting flow.
There is no easy way to test it - without pulling it off and inspecting it or cut it open and for me if going through the labor to pull it off, might as well replace it due to the limitation of actually inspecting it as I am unsure if a scope will fit in the tube.
Can they be properly cleaned to like new condition? IDK it depends on how bad they are clogged up. But you need a way to view that orifice to verify you have it cleaned as that is the most likely spot for the clog / restriction.

If I had a Pick N Pull type yard where I could pick one of these up (Cheap) I would already have the answer - I would get one and cut it open. (No 5G Rangers easily found on these types of yards)

 

[Motorpsychology]

As far as the redesigns, I do not see any revisions to the part number (supersedes), if my hunch is correct the tube is building up carbon deposits and creating a blockage at the (orifice) limiting its ability to push the (inherent) moisture into the intake flow.
This MAY account for repeated failures of the sensor, again at this point it's just my theory and why I am wanting to see a (failed tube) to confirm if I (correct or incorrect)

We know that moisture is considered normal, it's when it becomes overly abundant and accumulating in the module that creates the issue and if Ford is recommending replacing the tube along with the sensor points that somewhere in the field techs are finding these tubes clogged.
I have yet to see one, that's why I am so curious to see how bad they are clogging up, if this is a true finding in the field or is this simply a (Recommendation) to replace both to address possible comeback returns.

My main focus on this issue is that the majority of those who only replace the DPFE and report good results, there are a few who ask what else can it be, the Tube is a good possibility (IF) it is clogging up or restricting flow.
There is no easy way to test it - without pulling it off and inspecting it or cut it open and for me if going through the labor to pull it off, might as well replace it due to the limitation of actually inspecting it as I am unsure if a scope will fit in the tube.
Can they be properly cleaned to like new condition? IDK it depends on how bad they are clogged up. But you need a way to view that orifice to verify you have it cleaned as that is the most likely spot for the clog / restriction.

If I had a Pick N Pull type yard where I could pick one of these up (Cheap) I would already have the answer - I would get one and cut it open. (No 5G Rangers easily found on these types of yards)

Mine had a coolant leak from the EGR Cooler that caused the sensor to fail. I'm not familiar with how the system is laid out, but I would do what I could to make double plus sure that coolant won't come in contact with the EGR valve or enter the tube and fail the sensor.

 

[My12SecRanger]

Update, ran my bore scope down the tube and saw no blockages with normal EGR buildup until I got to the small hose for the DPFE sensor which had quite a bit of buildup on it (50 % blockage) at this point I do not believe the tube replacement is necessary, but I would recommend cleaning both dpfe sensor ports

 

[TJC]

Update, ran my bore scope down the tube and saw no blockages with normal EGR buildup until I got to the small hose for the DPFE sensor which had quite a bit of buildup on it (50 % blockage) at this point I do not believe the tube replacement is necessary, but I would recommend cleaning both dpfe sensor ports

Just so I understand, the small hose had the build up, not the tube or the tube bungs.

 

[My12SecRanger]

correct, find something bendable and ream the inside of the small hose for the DPFE port on the tube assembly

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