Torque Converter Operation Concerns: Clutch Always Applied/Stalls Vehicle - 241/341

WARNING: This page is about a different car, the 2004 Ford Ranger. However, it is still accessible from the selected car via links, so may be relevant.

TORQUE CONVERTER OPERATION CONCERNS: CLUTCH ALWAYS APPLIED/STALLS VEHICLE -241/341

Possible Component	Reference/Action
241 - ELECTRICAL ROUTINE
Powertrain Control System
Low engine idle	Verify engine idle speed is within specification.
Electrical inputs/outputs, vehicle wiring harnesses, internal transmission wiring harnesses, PCM, TCC	Carry out TCC tests. Run on -board diagnostics. REFER to the INTRODUCTION - CNG, FLEX-FUEL & GASOLINE article for diagnosis. Use scan tool to carry out Pinpoint Test. Repair as required, clear codes, road test and rerun on-board diagnostics.
341 - HYDRAULIC/MECHANICAL ROUTINE
Main Control Assembly
Screw out of torque specification	Tighten to specification.
Gasket damaged, off location	Inspect and install a new gasket.
Separator plate damaged	Inspect for damage. Repair as required.
TCC, solenoid stuck, damaged, O-ring damaged or out of bore	Inspect for damage. Carry out solenoid function test as listed in electrical routine. Repair as required.
TCC solenoid and valve (200), TCC control valve (201), spring, damaged, missing, misassembled, stuck, bore damaged	Inspect for damage. If damaged, install a new main control, If parts are missing, install new parts or main control. If misassembled, reassemble correctly. Do not stone, file or sand valves. This will remove the anodized finish and result in further main control or transmission damage.
Wrong components used in rebuild	Verify that correct components were used.
Torque Converter Clutch Assembly
Torque converter internal malfunction preventing lockup piston application	Remove transmission. Inspect for damage. Install a new or remanufactured torque converter if required.