2010 Expy. Fun Transmission troubles

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LukeWarner

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Hi y'all,

New member to the forum but been reading daily for about a month now since I got my new (to me) 2010 Expy XLT. It was previously a retired law enforcement vehicle for a small county that was purchased by a dealer at auction. It had all the service records since the day it was bought and it checked out for me once a pre-purchase inspection gave me the A-ok.

The fun Transmission problems arise about the second week of use. First the CEL, which just gave me the P0420 for the cat. I used an OBD to see if the oxygen sensors are working properly and they seem to be doing so. Not a big deal.

But then started the hard downshifting between first and second. Whenever you're cruising for a parking spot speed. Took it to a shop which told me I had low transmission fluid along with a leak. They topped me off and said if the problem persists go find a dealer or ford specialist.

Problem still persisted. Did some research and narrowed it down to TSB 08 22 7 which detailed a fix regarding hard downshifts in first and second gear. Need to flash the TCM using Ford software.

Scheduled an appointment with a dealer for an inspection. Dealer says I have a leak in the trans and for them to diagnose further, it'll be $1k to fix the leak then they'll diagnose the trans issue. They also mentioned my cam phasers may be failing and that it was indicative of 'entire engine failure' but I'm not swayed.

Decided to try and find Ford specialists in my area.

I'll skip the part where an ASE certified shop told me disconnecting the battery is the same as a TCM flash.

Found a Ford Specialist in my area who would take a look at it. Didn't mentioned that I had previously taken it to a dealer to see what conclusion they would come to. They found all of the leaks that the dealership had mentioned. Mentioned that the previous shop that did my transmission fluid overfilled it slightly. Diagnosed me with the following TSBs

14-0069 connector
13-11 3 high elevation downshift
11-8 12 2-1 downshift

Paid for the TSB fixes, PCM reprogram, and a new belt change.

On the report tech writes ' Could try updates first but seeing how this is an old Law enforcement vehicle most likely the transmission has been abused and will need to be replaced in the future.'

At this point in the there is no hard downshift in first to second. There is a clunk around 5-6 with deceleration. My question to you is if this car is still worth investing in at this point or will it be a money pit until a new transmission is put in. The car itself is fun to drive and fits my lifestyle of towing with the 4x4 and space capacity. However, I can't see myself dropping 5k for a new trans so soon after I bought it.

Any help/advice is always appreciated thanks

Luke
 

Trainmaster

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I've driven police fleet vehicles all my life and many were Fords. If your downshift isn't so rough it loosens your teeth or you think it's doing damage, I'd leave the thing alone. You don't say how many miles are on that transmission. I'd fix the bulkhead connector leak, which is only an O-ring replacement, make sure the fluid is somewhat fresh and of the right type and proper level and drive the thing. These are very robust units. Most last the life of the truck, even in police service.
 
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LukeWarner

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I've driven police fleet vehicles all my life and many were Fords. If your downshift isn't so rough it loosens your teeth or you think it's doing damage, I'd leave the thing alone. You don't say how many miles are on that transmission. I'd fix the bulkhead connector leak, which is only an O-ring replacement, make sure the fluid is somewhat fresh and of the right type and proper level and drive the thing. These are very robust units. Most last the life of the truck, even in police service.

Sorry for not mentioning the mileage, I thought I threw that in there somewhere. It's currently at 155k. It's definitely been had it's share of fun on the road. Also looks like the trans was flushed around 90k for those wondering.

What makes you think bulkhead?
 

JExpedition07

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5th to 6th is torque converter lockup...I just replaced mine in my 2007 recently because lockup failed all together (piston that engages converter clutch inside converter seized for some reason). These transmissions are heavily solenoid based and they are sensitive to fluid cleanliness and level. There is a bridge seal that commonly goes bad above the valve body and causes issues. Do you have any delayed engagement when cold?
 

Trainmaster

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What makes you think bulkhead?

The bulkhead connector is a known problem and there have been recalls for many versions of the transmission. Some of the original O-ring seals were Chinese and leaked after a few years. The leak runs down around the pan edge and looks like the pan gasket is leaking. An easy fix after dropping the pan.
 
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LukeWarner

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5th to 6th is torque converter lockup...I just replaced mine in my 2007 recently because lockup failed all together (piston that engages converter clutch inside converter seized for some reason). These transmissions are heavily solenoid based and they are sensitive to fluid cleanliness and level. There is a bridge seal that commonly goes bad above the valve body and causes issues. Do you have any delayed engagement when cold?

I haven't noticed any difference between a cold run and it being ran all day in terms of it hard downshifting.

In terms of sensitivity to fluid changes, I noticed in the history report that the transmission fluid was flushed around 90k miles and that was last time the fluid had been changed. Both the dealer and the past shop said the fluid was 'alright' (as in not great but okay). My top priority right now is a transmission filter and change. I think that should be in order regardless of it helps or not.

I also noticed around 98k miles that the vehicle was brought in to have the transmission checked. Hoping that wasn't when the hard downshifting started and the TSB had been going on since then. Ouch.
 

TDBDLB

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Sorry for not mentioning the mileage, I thought I threw that in there somewhere. It's currently at 155k. It's definitely been had it's share of fun on the road. Also looks like the trans was flushed around 90k for those wondering.

What makes you think bulkhead?
 

TDBDLB

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Bulkhead connector common issue on this ford trans. Changed mine in an hour, $100 total. 180k on my 2010 Limited 4x4 runs great, pulls 4K lbs boat well.
 

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