Early 07 5.9 hesitation

[Redemption]

I have an early 07 with the 5.9...recently had truck in for preparation for future serious Rv-ing...discovered a shot transmission so my Deisel shop installed a SunCoast transmission rebuild kit. During this shop visit I had the crankshaft seal and pinion shaft seal replaced, a new transmission line installed, a Timbren Kit installed, PAC brake installed, a new trans shift interlock solenoid added, a new overdrive housing, the Sun Coast bill it input shaft/hub, a Sun Coast flex plate, Sun Coast triple disc torque converter, a new trans filter kit installed and had a Fluidmaster damper installed! Since all that work has been done, my truck now has a serious hesitation! The very first day after getting my truck back, when I started to back out of my driveway, it would barely move...as I pushed on the accelorator, nothing happened....it barely moved. Shifted into drive and same thing for maybe 5 seconds...then took off. That was three weeks ago and the problem still exists intermittently. Sometimes it happens when I pull out to merge into traffic...it just sits there with no excelleration, no boost, no engine revs, nothing for several seconds before taking off. Happens daily...replaced the MAP sensor with no change. My mechanic is out of ideas! Since I am preparing to full time haul my 39 ft 5th wheel...I need help?? Sorry for the long post but want to give all info! Any ideas???
thanks
Bob

 

[cerberusiam]

If the engine does not rev the APPS is not telling it to, or, the engine is slow receiving the signal.. Either because it is bad or a connection is loose. Since they did a major amount of work in that rear I would look for some loose connections or scuffed wires.

 

[Redemption]

Thanks! I will check for loose or frayed wires. It doesn't happen at highway speeds which is one reason I have not thought of a wire being messed up...but often when I am trying to accelerate to get onto the freeway, the hesitation can get real "dicey"!

 

[Redemption]

Well a lot has happened since my last call for help! I checked for some loose or frayed wires and found nothing suspicious. I was going to take it back to the shop when the injectors let me know they had other plans. So had the injectors replaced along with the cross tubes. After getting truck back, it seemed to run a bit better...hesitation didn't seem as pronounced. Then the 4WD system began having issues....4WD Low light blinking off and on, truck going into 4-low at slow speeds...especially while parking, backing up or turning sharpe! Back to mechanic and after checking EVERYTHING he could think of...read a post on a forum and found another Dodge owner who had had same issue and discovered a broken in the back of the TIPM! Had the new installed today...4WD ISSUE SEEMS TO BE SOLVED!! But the hesitation is still there! I forgot to mention that I have installed a tuner...if that helps any? We are at a loss as to what else to try? Any thoughts Cerberusiam or any one?
Thanks!

 

[cerberusiam]

Is the hesitation rpm or boost dependent, ie lower numbers make it worse? What tuner do you have? If you roll into the throttle rather than stab it does it change?

 

[Redemption]

The hesitation can come during a har acceleration or when I "gently" roll into a throttle...when I am up above 50mph and punch it, it usually responds just fine and gives good results with a moderate throttle at speeds higher than 50mph....often if I am cruising at 50-ish and slow down coming to a stop light and then accelerate as the light changes....it lags....often when pulling out into traffic after coming to a complete stop I get out into the lane and sit with no acceleration until it catches at which point it REALLY takes off under a full throttle like surge....if I am cruising in town around 35-50 mph and accelerate it may respond normally and just as often will lag. Today I had the Throttle Valve Actuator replaced with NO difference...the tuner I have is an EFI Live by Starlight Deisel....? Really appreciate your help....I'm wondering if it could be tuner related.....? Thanks

 

[cerberusiam]

With any tuner anything is possible, just not probable. I would set truck back to stock and to validate it is NOT the tuner to start with.

If the engine was revving and just going no where that would be transmission controls. If you are getting no engine revs it is either APPS or an ECM problem.

Did the problem JUST start with the trans rebuild or ????

 

[Redemption]

Lugging/hesitation started immediately after transmission work...seems to hesitate more if I accelerate aggressively vs slowly...if I am slightly lugging as if I'm slowing down to come to a stop and accelerate aggressively...almost sure to lug/hesitate....if I am driving under a load such as climbing up an incline I can accelerate aggressively with no lugging/hesitating...from a dead stop, any heavy foot almost guarantees a hesitation...if I pull out of a dead stop easily, slight or no hesitation. Tonight had codes PO477, PO 633 and P1740 showed up...clue or coincidence? Thanks for your time...I really appreciate it!

 

[cerberusiam]

The P1740 is TCC error, it could show if you have too tight a TC in the trans. The 633 is SKIM key nuisance, the 4777 doesn't make sense on a diesel. It would not be unusual to have a harness pinched somewhere, possibly a connector on the firewall was disconnected and not set correctly when connected, it would also not be unusual that there is a problem with the trans. Any of those could generate the problems you describe. Since it happened with trans over haul I would take it back to the builder and see if they can test drive it to have ideas.

 

[Redemption]

The one code was not 4777 but PO477.... All the work was done at same diesel shop and because it started lugging/hesitating right after they did the transmission work, I have assumed it was transmission related...but as they have checked that out finding nothing, I have been questioning the tuner since it is one I have never heard of...but I have kept you thoughts on loose or frayed wires or connections in the back of my mind.....so just went out and checked battery terminal connections......loose! So after tightening them, the trouble code disappeared!....although the engine light remains on. I will take out for a test drive and see if it lugs.....my truck seems to be VERY SENSITIVE to loose batter connections.....stay tuned!

 

[cerberusiam]

Ummm, yeah it is lucky it ran at all with a loose cable. They want to quit when that happens and it will throw all manner of codes and weird behavior into things. Might want to clean all the posts and connections now also.