Need Advice / Help - Random Bolt found in Transmission Tray when doing fluid / filter change - 2024 Expy Timberline

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Jozef Zoldos

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Hello All

Am in the middle of my first Transmission Fluid / Filter change on my 2024 Expedition Timberline. Has 30,000 Miles. So I drop the transmission pan and there is a random bolt in my pan (see picture). Obviously jiggled loose from someewhere during the initial 30,000 miles. Unfortunately, what is not obvious is where it jiggled loose from. There are no obvious missing bolts from inspection from below. Vehicle ran well.

Question is....What do I do from here??

Thanks in advance
 

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LanceExp2025

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WOW! That is very bazar, to say the least. I, like you, would be very concerned about finding this loose bolt in my transmission pan. Is it some random bolt that found its way into your trans oil pan on the assembly line which does NOT belong anywhere inside there? Or, is this a major, future, breakdown, just waiting to happen? I would send all your vehicle information and a picture of this bolt to your Ford Dealer with a letter of 'Great Concern' by Registered Mail to document this find and possible trans failure, just to CYA. Good luck with this. Hopefully someone on here who knows these 10 speed trans' like the back of their hand, can tell you exactly what's up with this bolt! Lance
 

Fastcar

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Find a trans rebuilder in your area and talk to the guy that does the rebuilding see what he has to offer.
 
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Jozef Zoldos

Jozef Zoldos

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So.....This is a preliminary update.

Transmission is still under warranty. Took it to the local dealer and got the runaround. I would go as far as to say that they were somewhat hostile and accusatory. They tried to spin it on me and accuse me of doing unnecessary work and, as a result, the problem would likely not be covered under warranty. Needless to say, I was not to pleased with them. Did a whole bunch of research about how they actually assemble tranmissions. Apparently, everything is done with robots and there are multiple inspection points in the process. Apparently, the chance of someone dropping a random bolt during the assembly process and just leaving it loose in the transmission pan is essentially 0%. I got Ford Corporate involved and they assured me that this is a problem that should be covered under the vehicle warranty and they gave me a claim number. Took it to a different dealership and they were significantly more friendly and reasonable. The vehicle is currently still in service with communications going back and forth between Ford Corporate and the Dealership as to what they are ultimately going to do. I will update you all when I get more info.

JZ
 
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Gary Waugh

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Fingers crossed Ford does right by you.. I would be very concerned to find a bolt like that in my transmission sump, on the bright side, there doesn’t appear to be any marks on the bolt, so it doesn’t look like it has collided with any gear teeth or rotating components. Just a concern as to what it was locating and what might happen now that the bolt is no longer present in the correct place.
 

LanceExp2025

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So.....This is a preliminary update.

Transmission is still under warranty. Took it to the local dealer and got the runaround. I would go as far as to say that they were somewhat hostile and accusatory. They tried to spin it on me and accuse me of doing unnecessary work and, as a result, the problem would likely not be covered under warranty. Needless to say, I was not to pleased with them. Did a whold bunch of research about how they actually assemble tranmissions. Apparently, everything is done with robots and there are multiple inspection points in the process. Apparently, the chance of someone dropping a random bolt during the assembly process and just leaving it loose in the transmission pan is essentially 0%. I got Ford Corporate involved and they assured me that this is a problem that should be covered under the vehicle warranty and they gave me a claim number. Took it to a different dealership and they were significantly more friendly and reasonable. The vehicle is currently still in service with communications going back and forth between Ford Corporate and the Dealership as to what they are ultimately going to do. I will update you all when I get more info.

JZ
YES, JZ! It sounds like you did the exact and correct procedure with Ford and both of your dealers.

When I had a major drive-line vibration problem with my Ford 1-Ton Transit Van when it was Brand New, my local dealer "Service Writer" was a complete dick and very condescending. I ended up leaving and called back to that dealership to speak with the OWNER of this dealership. Instead, a lady called me back who was very nice and also very knowledgeable about vehicles. She made arrangements for me to bring my Van back in the following day and instructed me to speak to a 'different Service Writer' there. Like you, I had done my on-line research and made copies of the high lights and a copy of the related TSB, all of which the 'first' Service Writer, refused to even look at. When I went back the following morning, the second "Very Courteous" Service Writer took my information, paperwork, pictures and TSB, read them over and asked me a few questions. After that, he had me walk back and talk with his heavy line mechanic, along with the mentioned, paperwork. His mechanic knew quickly and exactly what this problem was with many new T350 Transit Vans and said he had performed this TSB on a couple of vans, already, which solved the problem. My Van was fixed in 2 days and the major vibration was GONE!

The fact that Ford gave you a Warranty, claim number is a very Positive thing, in my opinion. One thing that I would advise you to do, is to stay on-top of this thing and get it done, inspected or fixed as quickly as possible. It seems like if too much time passes (like even 2-3 weeks) without this being taken care of by your dealer and Ford, interest is quickly lost by both the dealer & Ford and any warranty resolution or agreement to inspect or fix, may be lost forever. Then it's on you, which is NOT good.

You should be proud of yourself for pursuing this possible trans-failure problem and I would love to hear if there was a positive resolution here and "IF" that bolt belonged anywhere inside your transmission? Also, thanks for the robot assembly info. I had absolutely no idea that these transmissions, were assembled by a robot. Good to know. Best of luck, Lance
 

LanceExp2025

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So.....This is a preliminary update.

Transmission is still under warranty. Took it to the local dealer and got the runaround. I would go as far as to say that they were somewhat hostile and accusatory. They tried to spin it on me and accuse me of doing unnecessary work and, as a result, the problem would likely not be covered under warranty. Needless to say, I was not to pleased with them. Did a whole bunch of research about how they actually assemble tranmissions. Apparently, everything is done with robots and there are multiple inspection points in the process. Apparently, the chance of someone dropping a random bolt during the assembly process and just leaving it loose in the transmission pan is essentially 0%. I got Ford Corporate involved and they assured me that this is a problem that should be covered under the vehicle warranty and they gave me a claim number. Took it to a different dealership and they were significantly more friendly and reasonable. The vehicle is currently still in service with communications going back and forth between Ford Corporate and the Dealership as to what they are ultimately going to do. I will update you all when I get more info.

JZ
Hi again J. Zoldos:
Has there been any further resolution or repairs by Ford concerning your transmission "BOLT" discovery, yet? As you may have seen, I am fascinated by this potential trans problem and how Ford Corporate is going to handle it and make you feel comfortable with your Expy again. Thanks for any update, Lancee
 

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Hm. As long as there is no damage, who cares. If there is transmission damage, let warranty take care of it. I am actually more surprised the screw didn’t end up jammed in the filter! So is it a bummer, sure… but not something to really huff ‘n puff about… 30k is a bit early for a tranny fluid change in my mind, as I am doing mine more at 60k to 70k mile range. Not pulling trailer, but some very spirited driving.
 

LanceExp2025

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Hm. As long as there is no damage, who cares. If there is transmission damage, let warranty take care of it. I am actually more surprised the screw didn’t end up jammed in the filter! So is it a bummer, sure… but not something to really huff ‘n puff about… 30k is a bit early for a tranny fluid change in my mind, as I am doing mine more at 60k to 70k mile range. Not pulling trailer, but some very spirited driving.
Yes, agreed that there's NO DAMAGE 'so far' and that is good. But, if these trans' are assembled by a Ford robot, as JZ has found to be the case, I feel pretty certain that the robots are NOT given extra bolts in case one is dropped or misplaced per trans assembly. I would want a qualified Ford tech to inspect this trans thoroughly and determine if this bolt is missing within his trans or if it was from another trans, that found its way into his pan. The reason I would want this is because we depend so much on our vehicles that, to have your vehicle possible break down unexpectedly, at the worst time, (especially when there's a known potential failure) would give you NO peace of mind or confidence in your car. At least, not for me. Maybe just me?

I also agree that 30K is a little early to be doing a trans fluid change (I do my trans flushes and fluid changes at 50K) but I say to each his own judgement on these non-critical decisions. I'm not saying I am right and you are wrong, but being old, I have seen so many unnecessary problems, catastrophes and delays happen that sometimes being a little over-cautious would have been advantageous with a little extra effort and pre-planning on my part, it seems to me. My wife is the one who drives our Expy and I sure wouldn't want to put her at risk of an unnecessary breakdown. But, again, that's just me, I guess? Lance
 
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Jozef Zoldos

Jozef Zoldos

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As previously mentioned, I had a warranty claim opened up thru Ford Corporate. They were quite reasonable on the phone. Took it to the first dealership and got the runaround. Took it to a second dealership and got a better response (initially). They brought it in and did a "test drive" and said that it runs normally. They did not open up the transmission to look at the inner workings. I brought it in with the bolt in hand and with photos of the inner aspect of the transmission. They told me that there are only 3 bolts like the one that I brought in and they secure the pump. Since all three bolts were clearly visible in the pictures that I provided, they called it a "bonus bolt" that was inadvertently left in during the manufacturing process. Needless to say, I was not quite satisfied with that response either. At this juncture, however, it is a moot point. I was involved in a severe collision with that vehicle and it is no longer with us :sad72:. I was in the process of pursuing the issue thru Ford Corporate just before the collision. Fortunately, I walked away from this one without a scratch. I am a believer in the laws of physics in this regard. I only buy larger vehicles. Gonna wait for the '27s to come out and buy another one.

Joe Zoldos -
ex driver of a '24 Timberline Expy.
 

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LanceExp2025

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Quote; Fortunately, I walked away from this one without a scratch. I am a believer in the laws of physics in this regard. I only buy larger vehicles. Gonna wait for the '27s to come out and buy another one.

Joe Zoldos -
WOW! Jozef. That was a very serious hit and accident. Was that a rear-ender or did someone turn in front of you? I am so relieved to hear that you walked away from this one! I am hoping that the '27 Expy's have some improvements over the '26's but I'm thinking you've made a wise decision w/ 27's, anyway. It is good to hear that your transmission 'bolt' problem has been solved permanently, though. I appreciate the update and Best of Luck and Health to you, Lance
 
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