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Dp, thats cause most shop mechanics are dipsticks themselves.

Jb, I hate to be the pessimist, but welcome to the wonderful world of auto trannies. You may well have noticed my post on "auto to manual swap. " This is because a year ago I was where you are now, and it only got worse from there.

My first transmission blew, not due to power, but from a bad U-joint. It was so bad of a vibration that it finally cracked the tailhousing in half at 70, and in one swift stroke leaked all the fluid thus torching the whole innards of the transmission.

Had it rebuilt. Blew up 6 months later. My motor had ripped through the torque convertor and sprayed pieces of it into the rest of the transmission. Once again, torched. Covered under warranty, rebuilt it again. "All new parts. "

Another 6 months or so, truck stops moving after getting on the freeway. Big red puddle. Hmm... chalk another one up. Took it to a different shop. They did a pretty good job all in all. The replaced it with a reman unit from their warehouse as opposed to rebuilding my POS.

Here I am now and its acting up again. Still driveable... only a matter of time though.

Now that that's out of the way, though. Lets try to make sure you don't end up that way.

First off, as DP said, "tuning for longevity" is absolute horse apples. One big enemy of auto trannies is gear overlap. What the means is on a stock transmission when it shifts from 2nd to 3rd, the clutches don't release for 2nd right away, but the clutches for 3rd do engage, thus causing overlap. Something has to slip, of course, so both sets of clutches slip and cause heat buildup and wear material in the fluid. The point of overlap is smooth shifts, for a smooth ride. If you ask me, if you were lookin for a smooth ride, why would you buy a 15+ year old, leaf sprung, solid front axle, heavy duty truck?

What they do is reduce the amount of overlap in the clutches, causing a harder shift, but actually improving performance of the transmission by reducing slippage, and extend the life.

The slipping you talk about is a problem I have fought with for 3 years. Its generally a 2nd to 3rd shift, it feels like it hits neutral somewhere in between the two gears. With all I've done to my motor, the truck moves out pretty good, and when that slip happens you literally get thrown forward in your seat, and then thrown back again when it finally decides to hit 3rd. My newest transmission, the one in right now, doesn't do that. So let that speak for itself on the thought that the problem cant be fixed.

I cant figure out exactly what the issue is, if the transmission can't decide between which gear to be in, or if its something worse like gears not engaging right or something. If it is that the transmission can't decide, I have a thought that maybe you could try adjusting the throttle position sensor, "tps. " Which is actually an instrument of satan charged with the job of making you use many many profanities.
 
thanks dp and tpc but ummm where is the throttle position sensor? can i adjust it myself? and if so, how can i do it without breaking stuff? im also really confused about installing a tach because i was on the phone ordering my gauges from pdr on thursday and i couldnt decide on one because on my truck i havent been able to locate the factory plug for the tachometer(4 pin)ive read all the threads on installing one but nobody has posted a picture of where its located, and ive only found a three pin plug and the wires are red/yellow orange and black... what am i looking at? well gentlemen thanks again...
 
TPS is on top of the injection pump. It's the black plastic thing. The plug is under the dash, slightly left of the steering wheel, taped to the harness or column. Gray plastic, 4 wire, flat. About 3/4 inch square and 3/16's thick.
 
thanks pete im gonna look again... and as for the tps what or how do i adjust it,or i have to remove the sensor itself? or does it have to be replaced???
 
JB, I have a stick, so I don't have one. :D

I have seen threads about cleaning the contacts, or replacing it with a potentiometer. The best bet for you is to "search" for the info. The potentiometer is good because you can set it and it will shift the same everytime.
 
thanks pete, i'll look into the potentiometer... but hey i still cant locate the tachometer harness... i looked EVERYWHERE under there the only thing down there is a three pin connector and its in the spot you guys said it would be... it has a red/yellow orange and black, taped to the main harness could my truck be different? is there a picture of the harness location?
 
You do have an older truck, I have a slight worry that you have a different hook up for the tach. The sensor will still be on the motor, but Dodge may not have put the harness under the dash on your truck. There is a kit from Isspro for the 89-91 Dodges to hook into the factory Cummins tach sensor, and that kit is different than the 92-93, which hooks into the harness under the dash. I would assume the 89-91 kit would come with some form of instruction as to where and how to hook it in. Look on the piers diesel website, they have the kit. PDR Diesel Performance
 
JB, you have a 91, does it have an Intercooler? If not, you probably don't have the plug.

91. 5 and up had an I/C, PCM controls charging, (no voltage regulator on firewall), and ready wired for the tach, amongst other things.
 
yes sir, my truck is a 91. 5 ic'd. . all right lets say im looking under the hood for the sensor where should i be looking? and what am i looking for? wow, im green sorry. . but thanks again, you guys are great
 
JB - I think you are looking at the tach wires. I dont know if you checked out the link i posted a few posts back, for you. on where to get a tach and harness. they have a harness for your year. do you have an FSM? if soo, check your wire diagrams, theyll show you right where your tach lead is.



i had a lot of trouble finding my tach hook up too, dont worry its a pain to find sometimes. mine was taped over, onto the main cluster. but i think the 3 wire lead youve described is the tach hook up. . the colors sound right.
 
Before hooking anything up, I'd test voltage on the leads. I'm not sure exatly what the reading should be, but it should obviously change on one lead as the motor winds up. Another lead should change voltage as you turn the dimmer switch. Another lead should get a constant stream of power when the ignition switch is turned to "on. " The last lead is a ground wire.



If this three prong deal is really the right harness, I would imagine that you the lead your missing would wind up either being your ground or your dimmer lead. The other two are absolutely neccessary for the operation of the switch. Yes, the ground is also neccessary, but look around, anything metal basically is ground.



I'd definitely test that thing before hooking anything up, I'm a little weary about hooking up wires to things I don't know.
 
If you have a 91, period, you need the magnetic sensor on the harmonic balancer. I'm fairly sure the tach harness didnt come along til the 92 model year. Look on the harmoic balancer, about the 11 o'clock position when looking at it, and see if there is a sensor there. If not, you definitely need the magnetic pickup.



PDR's website has a page on adjusting the TPS, under their "technical" section.

DP
 
hey daniel, your probly right, but im just curious... why would USDieselparts sell a harness for pre-92 trucks? ive never seen one myself, so i cant say what it looks like, but it did seem strange to me the first time i saw they had one for the pre-92 trucks, but im just wondering what the deal is here?
 
It's not a harness as much as it is a kit- magnets sensor, mounting bracket and some 18ga wire. glue the magnets to the h-balancer in the slots (glue included), mount the sensor under an oil pan bolt, and run the wire to the tach.



DP
 
thanks, ill check this out and let you guys know for future refrence. as for the FSM... factory service manual, correct? where can i order one? ill bet there a fortune...
 
ohh also im going to take a picture under the dash ill post it... and im checking into the harness for the pre 92. . anyhow... have a good one.
 
JB - you got it, FSM = Factory Service Manual. Got mine from Genos. was $90+ i think. but it will pay it self off in no time at all. they are a life saver.



ill be very interested to see your pictures and hear what you find with the pre-92 harness. thanks and best of luck
 
Jimmy, I can't tell ya. ;) Weelllll, I could tell ya, but then I'd haveta kill ya. Then I'd go to jail and never get my cab swap done. So I can't tell ya. :p
 
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