Whilst researching your test procedure I found this information. Perhaps this could be the cause of your problem?
NOTE:Adjustment of manual shift linkage/cable is critical. Ensure "D" or (Overdrive) detent in transmission corresponds exactly with stop in console.
All Except Aerostar, Bronco II & Ranger
Move selector lever rearward against stop in "D" position. On models with column mounted shift levers, hold lever against stop by hanging an 8 lb. (3.6 kg) weight from selector lever.
Loosen manual lever-to-control cable (or rod) retaining nut. Move transmission manual lever to drive position (second detent from rear). Hold selector against rear of "D" position and tighten retaining nut. Check for normal operation in all selected positions.
From inside vehicle, place gearshift lever in "Overdrive" position. From under vehicle, loosen adjustment screw on shift cable and remove end fitting from manual lever ball stud.
Position manual lever in "Overdrive" position by moving lever all the way rearward, then moving it 3 detents forward. Connect cable end fitting to manual lever.
NOTE:Excessive arm pressure can move shifter to "D" position. Apply pressure only until resistance of detent nib is felt.
Tighten adjusting screw to 45-60 INCH lbs. (5-7 N.M). After adjustment of shift linkage, check for "P" position engagement. Control lever must move to right when engaged in "P" detent.
Check control lever corresponds in all detent positions with engine running to ensure correct detent/transmission action.
Bronco II & Ranger
With engine off and parking brake applied, place shift lever in "D". Loosen trunnion bolt. Move shift lever at transmission all the way to the rear, then forward 4 steps. This places lever in "D" position.
Apply light forward pressure on shift control lever (at transmission) and tighten trunnion bolt to 18-31 ft. Lbs. (13-23 N.M). Move lever through all positions making sure transmission is at full detent in each position.
NEUTRAL SAFETY SWITCH
NOTE:AOD and A4LD switches are not adjustable. If necessary, use Neutral Start Switch Socket (T74P-77247-A) to replace switch. If any other socket is used, damage to switch may occur.
With transmission shift linkage properly adjusted, loosen the 2 switch attaching bolts. Place transmission manual lever in neutral position. Rotate switch and insert a gauge pin (No. 43 drill bit) into gauge pin hole of switch.
Gauge pin must be inserted completely through all 3 holes of switch. Tighten switch attaching bolts and remove gauge pin. Check operation of switch. Engine should start in "N" or "P" positions, only.
Saturday, November 8th, 2008 AT 5:53 PM