05 Ranger TDI conversion

[RonD]

CKP(crank position) sensor reads a tone ring with 36 "teeth" minus 1, the ring has 1 "tooth" every 10deg(360deg / 36) then 1 missing "tooth" at TDC for #1 piston.
I think that's the same for all Ford CKP sensor setups, engine size wouldn't matter.

So technically it would have 35 pulses per 1 revolution of the crank, but not sure what it's reaction would be without a TDC gap, it might even be the RPM reference.

Yes, Ford TPS is a variable resistor, it gets 5volts from computer and sends back .6-.9volts(under 1 volt) when throttle is closed.
Wide open throttle sends computer above 4.5volts, because this is a variable resistor the computer "learns" closed throttle voltage and WOT voltage, so there are no specific voltages, under 1 volt closed and above 4.5v wide open is range.

 

[Evguy1]

Thanks for the info RonD.
I have spent all day trying to get my speedo working.
I have the gray/black coming from the VSS on the back of the trans but not sure what the other side of the VSS should be.
Have tried grounding it and get nothing.
Tried 5V and it jumps up pretty quick to 30mph in my driveway.
I'm cobbling this together with scrounged parts so nothing is plug and play.

The ECU now gets a TPS signal and I have a module coming on Tues to give me a crank signal.

 

[Ranger Kip]

I am loving this build, I have been wanting to do a diesel conversion myself but only see swaps Im not interested in.

 

[RonD]

3.0l should have the 5R44E trans
It has 2 speed sensors
Output shaft sensor(OSS)
Intermediate shaft sensor(ISS)

OSS
Grey/red to pin 91(PCM)
Dark Blue/yellow to pin 84

ISS
Grey/red to pin 91
grey/orange to pin 59

The grey/red is basically the PCM ground for these sensors and the TPS and ECT sensors, all 4 would have the grey/red going to pin 91

Here are the wiring diagrams for 2005 Ranger 3.0l automatic

 

[Evguy1]

Tried 12V as well and got nothing.
Where can I get the transmission pin outs for the main connector?
Turns out this transmission is from an 08 3L.
I don't know if the wiring is the same as the 05?
Maybe its time to throw the standard trans in and give up on the automatic.

 

[RonD]

Manual would probably be better because it doesn't need computer and also the driver can chose shift points for the diesel power curve.

But you do need to get rid of automatic column shifter and add clutch pedal assembly.

An A4LD from a 1991 - 1994 Ranger 3.0l only has the TCC and 3-4(OD) shift to deal with.
These are both just Ground activated so can be controlled via buttons on dash.

1991 was first year of the 3.0l engine in a Ranger, and as you know it has unique bell housing pattern you made the adapter for.

http://www.therangerstation.com/tech_library/a4ld.shtml

 

[Evguy1]

Thanks for the schematics.
I'll print them BIG and see if I can see my problem.
As long as the 08 trans is the same I may have a hope.

 

[RonD]

Yes, it is the same, Ranger with 3.0l used 5R44E from 2001 to at least 2009

 

[chucky2]

Hope you can figure it out, that way there is hope for others with these and the 5R55E!

 

[Evguy1]

Spent a bit of time on this tonight.
Trucks drives great in REVERSE. ;>)
Still no shifting in forward.
If I sit on a hill in any forward gear facing up the hill the truck wont roll back, its like the park brake is on but its not. Sit on the same hill facing the other way and in reverse the truck will roll forward down the hill.
I have a good signals on turbine input shaft and output shaft and the ECM is calculating speed correctly via my laptop scanner software but no signal out to the speedo.
No idea why I'm not getting the speedo signal when the ECM is seeing a speed.
ANY ideas are appreciated.

 

[RonD]

Do you have or can you get an OBD II reader, computer probably has set some transmission codes and that may point you to a circuit that needs to be connected to get TCC(torque converter clutch) to engage in Drive.
I assume other forward gears were tested

TCC circuit used to just be a Ground, that the computer controlled

 

[Evguy1]

I will check for codes.
Why does it feel like the brakes are on in forward?
Its pretty much locked when you come to a stop and takes quite a bit of throttle to get it moving. In reverse its easy to start rolling.
In a stock truck does the speedo work if you are rolling down a hill with the engine off?
If it does that would take all the engine sensors out of the system and narrow down my search.

 

[RonD]

With key on and output shaft(OSS) moving speedometer would/should show the speed.

Just asking so don't shot me
You did drive this ranger into the shop powered by the 3.0l, so the transmission was working fine.

Not an automatic trans guy, but....................
Just doing a little reading about it and even without any computer controls hooked up trans should work, forward and reverse, forward it will shift oddly but will shift.
And speed sensor is not needed for forward motion with trans, it is only for shifting to second, third, ect...

No forward or having to use high RPMs to get any forward movement means trans is bad, it would be forward clutch issue since reverse works, and not a pressure issue since reverse works.

I know when I did my first automatic swap I screwed up by not seating the torque converter in all the way into the front pump, after getting all together I had no movement, forward or reverse, expensive lesson learned

Since you made an adapter plate and I assume a flexplate adapter could the torque convert not be seated correctly or damaged in some way, the TC or the trans.

 

[Evguy1]

It shifts!
Turns out what I thought was 12 volt power to the 02 sensors was actually shift solenoid power.
I jumpered power to that wire and it now shifts.
Still have no speedo and it is shifting at way to high of an RPM but I'll keep working on it.

 

[Evguy1]

I must have posted more info on the TDI forum as I thought I have given the back story on this truck.
This Ranger is left over from a company R&D project where it was converted to an EV about 4 years ago and a number of electric drive system were tested in it.
ALL of the engine wiring and trans were scrapped as we never thought it would be running an infernal combustion engine again.
So you can see why I'm having so many problems. The truck is an 05, the wiring harness was out of a mid 90's and the trans is out of an 08.
The wiring diagram you posted for the 05 was a huge help and solved a few problems where harness pins were in the wrong locations for my ECU and trans years.
Anyway its nice to get it shifting and thanks again for the help.