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TSB 02-21-01 E4OD/4R100 Torque Converter Access External Dust Plug May Become Dislodged
Publication Date: October 11, 2002

Applicability:
1989-1996 BRONCO
1989-1997 F SUPER DUTY
1989-1998 F-250 LD, F-53 MOTORHOME
1989-2003 E SERIES, F-150
1997-2003 EXPEDITION
1999-2003 SUPER DUTY F SERIES, SUPER DUTY F-53 STRIPPED CHAS.
2000-2003 EXCURSION
LINCOLN: 1998-2003 NAVIGATOR
2002-2003 BLACKWOOD

ISSUE: Some vehicles equipped with the E4OD/4R100 transmission may exhibit the torque converter external access dust plug dislodging and falling out during severe duty use. This may be caused by a combination of stack up tolerance, material shrinkage over time, and loading being applied to the plug during usage or cleaning of the underside of the vehicle.

ACTION: Obtain new plug (E9TZ-7N171-A) and apply 1/4" bead of silicone sealant around entire perimeter of part and install plug into transmission case. The silicone is to be applied in the groove of the part such that when it is installed, the sealant will fill any gaps between the transmission case and the plug.

SERVICE PROCEDURE
Obtain service part E9TZ-7N171-A, F7TZ-19554-AA and general purpose degreaser such as Motorcraft Brake Parts Cleaner, PM-4. Clean transmission case casting in the area of the plug using general purpose degreaser making sure the area is free from grease and other contaminants. Apply a 1/4" bead of silicone sealant F7TZ-19554-AA to plug E9TZ-7N171-A making sure that the groove in the plug is filled with silicone sealant. Immediately install plug into the transmission case casting smoothing out any overflow that may occur during installation.

PART NUMBER PART NAME
PM-4 Motorcraft Brake Parts Cleaner
E9TZ-7N171-A Plug - Converter Access
F7TZ-19554-AA Ultra Silicone Sealant

OTHER APPLICABLE ARTICLES: NONE

WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage

OPERATION: 022101A
DESCRIPTION: Install Torque Converter Access External Dust Plug - 1989-1996 Bronco, 1989-1997 F-150, F250LD, F-Super Duty, E-Series, 1998-2003 F-150, Lightning, Harley Davidson, F-250LD, Super Duty F-Series, E-Series, 2000-2003 Excursion, 1989-2003 Motor Home Stripped Chassis, 1997-2003 Expedition, Navigator, 2002-2003 Blackwood
TIME: 0.2 Hr.

For other TSBs, check here.


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OASIS 3866 1989-2003 VARIOUS VEHICLES - TRANSMISSION - 4R100/E4OD - TORQUE CONVERTER ACCESS EXTERNAL DUST PLUG MAY BECOME DISLODGED

SOME VEHICLES EQUIPPED WITH THE E4OD/4R100 TRANSMISSION MAY EXHIBIT THE TORQUE CONVERTER EXTERNAL ACCESS DUST PLUG DISLODGING AND FALLING OUT DURING SEVERE DUTY USE. THIS MAY BE CAUSED BY A COMBINATION OF STACK UP TOLERANCE, MATERIAL SHRINKAGE OVER TIME, AND LOADING BEING APPLIES TO THE PLUG DURING USAGE OR CLEANING OF THE UNDERSIDE OF THE VEHICLE. SEE TSB 02-21-01 ON OASIS AND QCDEALER.COM FOR DETAILS.
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THE DANGER OF CHANGING THE ATF

I'm no slushbox expert, but this is how I understand it:

A) Starting with a good trans & the right fluid, over time, debris is generated in the trans due to normal wear & contamination. The fluid contains detergent additives that keep this debris suspended in the fluid until it can flow back to the filter to be removed.

B) But the fluid only contains SO MUCH detergent. So if it's not changed on-schedule, the debris doesn't get suspended, and it settles out all over the trans. But this alone doesn't cause any immediate problems, which is why so many people neglect the trans fluid for so long.

C) Eventually, someone realizes how old the fluid is, and changes it with fresh detergent-rich fluid. This begins to break up the deposits, but it also loosens large chunks, which can block up the valve body's fine passages & ports, causing MAJOR damage.

D) From what I've seen, there are 2 possible ways to avoid this damage:
1) rebuild the trans
2) change the filter & fluid once, using decent aftermarket ATF. It's also a good time to add the drain plug kit. Then drive 50-200 miles to break up most of the deposits. Then change the fluid & filter again, using MotorCraft Mercon. If the trans goes out after that, it was going out anyway.

http://www.fcsdchemicalsandlubricants.com/Main/quickref/atf.pdf