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Discussion Starter #1
Background: I have a '95 TBird. It was a 4.6LX. I replaced it with an '03 Explorer 4.6, replaced the induction with '96 TBird rails and TB. Transmission is from a '99 Mustang GT. I did the repin of the bulkhead connector. Also new MLPS. After initial startup had some sensor issues and normal gremlins. Once all worked out turned car off and refused to restart. Could start by jumpering battery to starter hot, but transmission now was stuck in limp home mode. (2nd only) Turns out starting issue was bad ignition switch. Now starts fine.

Parts replaced in attempt to fix: MLPS x2, TPS, Speed Sensor and gear, Tranny Bulkhead Connector and hard wire inside tranny. (and of course the ignition switch for the starting issue)

Current issues: CE light on, only code is for EGR (since I didn't put back the after CAT O2 sensors) Go and clear the code, drove car with same result, after a start and restart tranny shifted perfect. Stopped and put car in park (engine on), shifted back into D and back in limp home. Cleared code this morning, no CE light, drove 20+ miles, perfect shifting, 90+ on the highway and tons of stop and go, stopped at store, came back out, restarted, CE is back and no shifting.:confused:

ANY thoughts would be greatly appreciated.
 

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Throttle body position sensor is bad? Or, after the shifter locks in D, pull it back just a tad more and it will probably shift then... If that's the case, ull have to re-adjust the nss..
 

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Discussion Starter #3
I have replaced TPS. At tranny shop on there tester it showed it was getting voltage even when no throttle applied. Hmm.

But I was able to reproduce symptoms while in D going down the road if I pull back on shifter there is some slop, and the car will stop shifting. If I then push forward on the shifter and wiggle from side to side it will begin shifting normally again. I took the shifter apart this morning and there seems to be play in it when in D. Going to go to junk yard later and take apart another one for comparison.

Thanks for the reply :)

Still rattle chasing
 

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I say MLPS is not correctly aligned / installed - I use my Headband mounted LED & a GOOD mirror - These Shift Cables have been known to break interrnally also - & Did'nt you have to backfit old style TCC into 99 Tranny to mate with your old ECM ?... did'nt see that on your very detailed OP.
 

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Discussion Starter #5
Went to junkyard and found '94 Cougar. Shifter was very tight (unlike mine). Took whole shifter unit out to replace. Yes Buck, MLPS is bang on the mark. I have 3 of them I have tried in chasing this, the original, brand new Motorcraft, and a junkyard one. May not have time to get it in and test tonight, but think it may solve the movement issue.

Also yes, I repinned the bulkhead connector to the tranny to match EEC with the new sensors.
 

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& Attaching Cable correctly affects MLPS position too - I did some tweaks to Shifter Cable Bracket at Tranny so Bracket is now out the way (barely) when dropping Pan for maintenance... Also Bracket is slighly angled now so Cable is aligned best at middle position of the "Arch" it makes thru it's travel.
 

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Discussion Starter #7
:D Good news! I got the shifter in and after having to readjust the MLPS and re attaching the cable on the bottom of the shifter that came loose while installing :-( I got it on the road and all seems good!

Thanx guys for all your input! Hope this helps someone else with an issue like this. Guess I should not push on shifter as I have had this car since 96 and 230,000 of the 250,000 miles are mine, I can only blame me.

Keep these 'Birds runnin'
 
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