Torque Converter Clutch Operation Concerns: Always Applied/Stalls Vehicle

WARNING: This page is about a different car, the 2005 Ford RV Cutaway, 2005 Ford Econoline, and 2005 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.

TORQUE CONVERTER CLUTCH OPERATION CONCERNS: ALWAYS APPLIED/STALLS VEHICLE

Possible Component	Reference/Action
241 - ELECTRICAL ROUTINE
Powertrain Control System
Electrical inputs/outputs, vehicle wiring harnesses, PCM, torque converter clutch (TCC) solenoid, TFT sensor	Carry out Self-Test. See INTRODUCTION - GASOLINE and/or INTRODUCTION -- 6.0L DIESEL articles for diagnosis and testing of the Powertrain Control System. GO to PINPOINT TEST B or GO to PINPOINT TEST A . Repair as required. Clear DTCs, road test and repeat Self-Test.
341 - HYDRAULIC/MECHANICAL ROUTINE
Main Control
Drain back valve, torque converter clutch (TCC) and plunger stuck, damaged or assembled incorrectly	Inspect for damage. Repair as required.
Bolts not tightened to specifications	Tighten bolts to specifications.
TCC solenoid malfunction	Activate solenoid using diagnostic tool. If solenoid operation cannot be felt when placing hand on solenoid, install a new solenoid. Inspect O-rings for damage. Repair as required.
No. 7 ball incorrect seating	Inspect for damage. Repair as required.
Gaskets damaged	Inspect for damage and install a new gasket.
Pump Assembly
Bolts not tightened to specifications	Tighten bolts to specifications.
Ball missing, leaking, porosity/cross leaks	Inspect for porosity/leaks, balls missing. Install a new pump as required.
Gaskets damaged	Inspect for damage and install a new gasket.
Input Shaft
Seals damaged	Inspect for damage. Repair as required.
Torque Converter Assembly
No end clearance	Inspect converter and install a new or remanufactured torque converter as required.
Piston plate damaged or stuck to cover	If cover is heat-stained, install a new converter and determine the cause of the overheat condition.