[CR_Magruder]

Before I get to my AE question, I must give some background to the application. Sorry it is a bit lengthly, but the details seem to be where the devil is hiding.

I have swapped a 4BT Cummins into my 2003 Expedition. The stock Expy had a 2v 5.4L and 4R70W transmission. If you want to read the whole saga, I have a thread on the 4BTswaps.com site here . You have to create a user name and login if you want see the pictures.

I replaced the auto transmission with a M5R2 5-speed manual which bolted directly to the stock transfer case.

I kept the following sensors on the diesel engine:

• Cylinder head temperature sensor (mounted in the water jacket and not contacting metal on the end of the probe like it did in the V8).
• Oil pressure sensor (switch)
• Throttle position sensor. I left this in since the PCM is looking for an idle position to shift into 4L. Presently the sensor is just connected to the harness and not rotated. That part of the project will come later when I add the TPS and cruise control to a dummy throttle body.
• Crank Position Sensor. I have 35 ridges machined into my vibration dampener on a 360° pattern, just like on the 5.4L crank.
• Cam Position Sensor. There is one rib machined on the vibration dampner for this sensor, so the PCM gets one pulse for each crankshaft revolution. On the 5.4L engine, the sensor got one pulse for every two revs of the crank.

All of the wires leading to the other devices connected to the 5.4L engine were separated from the harness and cut about 6" from the PCM connector. I put a piece of shrink-tube on each cut end.

The harness from the transmission was also stripped out in a similar way. I connected the former park/neutral start circuit in series with the clutch pedal position switch so it won't start without the clutch pedal depressed. This circuit does not run through the PCM though. I also connected the reverse switch on the manual transmission to the reverse light circuit; and this circuit does not run through the PCM.

I hard-wired the transmission range switch wires to the PCM so they are reporting a neutral condition. This was so I could shift into 4L.

The 4BT has a mechanical fuel pump, so it does not need the PCM to run; only a throttle cable, a 12v source for the fuel shutoff solenoid and the starter solenoid.

The truck runs and drives (a hoot to drive I might add! I went from 16mpg hiway to an estimated 25mpg using google maps on a couple of 300 mile trips), but all the devices that communicate with the PCM are not working. The following devices are not working:

• ABS system
• AWD module/ system, although I can manuall shift to 4H
• Engine temperature gauge
• Tachometer
• Speedometer

The radio, heater, fuel gauge, battery voltage and oil pressure gauge all work. I have not tried to use the AC because I still need to re-route the compressor tubes and re-charge the system. On top of that it is the middle of winter, so that part of the project can wait a bit.

So I bought the AE tool with the Ford Bundle to interrogate the PCM and begin to figure out what signals are being reported to the PCM and begin to sort out the electrical issues. I connected to the OBD-II plug in the usual way, but the software does not recognize the PCM. I tried "autodetect", J1850 PWM CAN interfaces; and OBD-II Compliant and CAN Physical Addressing for Initialization types.

I then connected the tool to our 1996 Lincoln Town Car, and it recognized the PCM and began reporting values, so I think I can assume the software and hardware are working.

So I have a couple of questions:

1. Am I missing something in connecting to the PCM on the 2003 Expy
2. Are there any other settings I should try?
3. I am wondering if by cutting the wires to the COPs, Injectors, IAC, MAF, IAT sensors that there is some powered loop that causes the PCM to be "dead"? This last question is outside the scope of the AE forum, but maybe someone at PHP has some ideas for me?

Thanks in advance for your time.

CR