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Extremely Intermittent 2nd gear start

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3K later, a ton of work and dead pedal is back.

Pre-Wiring for Backup Camera

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Preface: 2nd performance trans in approx. 2/2021 (note info in signature). The 1st trans, DTT, lasted 2002 - 2021, roughly 110,000mi and was done by same builder as present trans. Anyhow, about a month or so after 2nd trans done it did a few 2nd gear starts. Oddly these happened after driving a few miles. You can tell if it doesn't shift down to low by watching the tachometer for that little blip up just before coming to a stop. I know 2nd gear starts ares very detrimental so a quick into "N", shut off and restart is what to do if it doesn't go into 1st when placing gear selector into "L". Understand the trans builder is in VA Beach and I'm in the Poconos, so driving 12 hours (round trip) for a simple warranty fix wasn't cost effective for me. In conversation with the builder it was determined to replace transducer/solenoid, which is fairly easy and I've had to do several times over the years with the old DTT, always used "quality" parts from TranStar with part numbers provided from builder so as to replace with same "updated" parts as used during build.

These 2nd gear starts are more of a nuisance than anything else, as I've learned to deal with to a point where (I feel) no damage is happening. As mentioned in the title these 2nd gear starts are "Extremely Intermittent", meaning this can go days and days without happening, or will happen after driving around town then getting on the highway for 20 or so miles and as soon as you come to a stop then go it'll be in 2nd. Most times just placing the gear selector in "L" get it into low, then I start out and shift into "D" and all is well for the rest of the day. This "rest of the day" can include; multiple stopping, shut downs, start ups, drive a few miles or many more and not occur again for days.

I'm thinking there's something electronically that happens, somewhere for some reason, but have yet to conjure what or where and how to try to troubleshoot.

So far, I've replaced the transducer/solenoid (around 4/2021), over the last several months looked at grounds (meaning removed screw cleaned both surfaces and re-scured) of course I have no idea where "all" the grounds can/could be - I do have FSM and am totally confused by the electrical diagrams as to where and how to locate "all the grounds", have removed and cleaned (with electrical contact cleaner + used dielectric grease to ward off corrosion) both male & female plug connections (including metal = not just rubber area connections) at the ECM, PCM, Trans and firewall to harness connections. Batteries are excellent, alternator and other accessories are excellent condition.

Just fishing for possible routes to follow that others having similar issues have tried.

Thanks in advance,

Joe
 
Just throwing this out there, Joe. I had a SIMILAR issue on my ‘98 that was cured by replacing the output speed sensor. Should be Mopar #4800879. It’s a simple job and the sensor’s relatively inexpensive.
 
BigPapa, thanks for your reply. The sensor you mentioned is it in the rear of the transmission (before x-fer case)?
On edit: just looked online and it is as I thought. I know I replaced that part before, but was years back on old DTT. Who's to say it wasn't re-used on the new build? You'd think not but... Will have to check when I get home in a few weeks.
I do recall when I replaced it before that it ohmed the same as the new one but was caked with fine metal. I cleaned it and put in the box the new one came in. Thanks again
 
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Yes, that’s where it is, driver side. Sensors aren’t normally replaced on a rebuild. It wouldn’t hurt to pull it out and clean it.
 
Thanks will definitely check it out. Cheap and if cleaning does it great, if not then nothing lost. It'll be a few weeks before I get home but will post outcome. Of course after a week of testing. Due to cost of fuel I typically drive it only on weekends. The Prius is much more efficient at 48-52mpg, unfortunately. Love my truck and after 21 years of ownership I can honestly say "it ain't going anywhere until I can no longer pull myself up behind the wheel".
 
It's a 20$ piece, i replace it regularly at the oil change as they tend to fail over time.

Best indicator for a failed one - switch to low range and drive, if it refuses a normal upshift and only shifts close to the red line - it's bad.
 
Ah, that could be my problem. For some time, the trans has shifted oddly now and again, before and after the rebuild (lost reverse, drum, and reverse light switch).
  • Sometimes doesn't shift 1-2 until around 2800 RPM (and 'freewheels' when coasting in this state which likely always happened unnoticed because it never stayed in 1st very long)
  • Sometimes downshifts to the state above around 20MPH when slowing down
  • Sometimes only gets to 2nd when stopping.
  • Sometimes stays in direct when stopping.
Most of the time, I can pop it into neutral, turn the key off/on a number of times, then restart and it's ok again. Sometimes it seems that moisture (rain, slush) makes it happen easier. It's been better since I sprayed contact cleaner in the TPS; it was begging for a cleaning for a long time. But it still happens once in a while. If this doesn't fix it, then it almost has to be the PCM which looked rather gnarly last time I had it open.
 
You can also put a noise suppressor to the APPS wiring, for some vehicles these work great and also not expensive, so, worth a shot.
 
Ozymandias, I have noise suppressor as well as a some little box from DTT to eliminate the OD hunting. Thanks.

Still haven't gotten around to cleaning the speed sensor in tail of trans yet...
 
Finally got around to cleaning the speed sensor in the trans today, because
-> see post https://www.turbodieselregister.com/threads/intermittent-rpm-fluctuation.274011/

Although I haven't driven it much lately (maybe 1X/week) it hasn't given any 2nd gear starts. I'm well tuned into watching the tach whenever I'm coming to a stop to make sure I see the little bump in RPMs indicating it went into 1st.

I love this old truck. Never thought I'd have a vehicle this long, 22 years now. I't isn't going anywhere, God willing, as long as I can still pull my self up behind the wheel anyway.
 
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