From: Andrew Cohen <cohen@cubic.com>
Subject: Need Help: Ford Bronco Transmission (long)
Organization: Cubic Toll Systems (Tolls R Us)
Date: Wed, 26 Aug 92 09:49:26 GMT
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X-Xxdate: Wed, 26 Aug 92 17:47:50 GMT

I need help and/or advice from someone out there with experience relating
to the problem I am about to describe.  This is long and detailed, but I
felt that would be more help to a knowledgable reader.

I own a 1989 Bronco, equipped with the 302 EFI and the AOD Automatic 4
speed overdrive transmission.  The towing package is installed, including
the transmission cooler.

The problem I had at the end of 1991 was that the shifts were erratic. 
When entering the highway under WOT, the transmission would sometimes
jump from 1st to 3rd and then bang into 4th.  In addition to this, the
2nd to 3rd gear shift would take place either too early or too late.  All
of these problems were much more prevalent when the truck had been driven
in either stop and go or highway speed traffic.

I went to various truck shops (ATV and others) and asked if any Bronco
owners had problems with this type of transmission.  To my amazement, I
learned that not only were there many complaints, but that Ford was
failing to acknowledge the problem.

I took it to a local dealer with a list of the symptoms and explained
that I had heard that there was a problem with this type of transmission.
 He (adamantly) denied any knowledge of any problem, and after a "strong"
discussion he agreed to look at it.

I was then told that they couldn't duplicate the symptoms, but there are
only 2 items which could cause it; the governor and the valve body, and
they were going to replace both.  I figured "Great, it's going to get
fixed!"

This appeared to correct the problem, and I was happy because there is
nothing worse than making payments on a declining asset like a car and
having heartache over getting dealers to honor their own warranties. 
When I was picking up the truck, the service manager candidly told me
that there was a problem with the first design of the valve bodies in
these transmissions which caused burning of the clutches.  He assured me
that the revised design would stop this from happening.

So, I drive the truck for a few months and guess what... The problem
starts to come back again.  Now, it doesn't appear to jump from 1st to
3rd, but when it gets hot after traffic or highway driving the 2nd to 3rd
shift is either early or late.  When it's early, the shift occurs and the
truck just "plops" because there's no momentum.  I have to mash on the
gas pedal to make it downshift back to 2nd because it won't go back to
2nd with just some additional pedal pressure.  When it shifts too late,
2nd stays in and the engine revs to about 3100 RPM before it will shift
to 3rd (normally around 2200 average).  If during this time, I let off of
the gas pedal it feels as if the transmission had completely disengaged
and when I step on the gas again, it revs up like it is in neutral until
the engine reaches around 2900 RPM and then it grabs and the truck starts
to move again.  It seems like something is sticking.  Again, it only
happens with the 2nd to 3rd shift.

I brought the truck back to the same dealer that fixed it the first time.
 I gave them a list of the symptoms as before.  I got a call at the end
of the day that the throttle valve cable was broken, and since that is
not a warranty item, they would have to charge me $150 to fix it.  I went
down there and asked them to show me where the cable was broken.  The
service manager walked me out to the truck, lifted the hood and pointed
to a cable connected to the throttle body.  He explained that the cable
was no good and needed replacement.  Needless to say, he was pointing to
the cruise control cable.  When I brought this to his attention he turned
red with embarrassment, double talked me, and blamed it on the mechanic's
diagnosis.

Apprehensive as I was to leave it, I did.  I felt that now they were on
notice that they couldn't snow me.  Well, it turns out that they claimed
the problem was due to improper throttle valve pressure and they would
have to charge me $40 to adjust it.  I let them.

The end result is this;  All they did was change the times at which all
shifts occur.  The 2-3 problem is still there.  I brought it back to them
and all I get now is a flippantly-toned; "It shifts fine.  Nothing wrong
with it.  You can pick up your car now."

I have a call in to Ford customer service in Detroit, but I doubt that
will do much of anything because I'm already getting the old "Well, it
seems like they just can't duplicate the problem."

So, here I am today.  I want to get the transmission fixed properly so
that I can get these people out of my life.  Does anyone have any
suggestions on how to proceed?

Thanks.