Very intermittent transmission issue

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LoneMustang

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Three times in the last 3 months, the transmission in my 2014 Expedition Limited (112k mi) has spontaneously shifted into a high gear while at a stop. The only thing that resolved it was turning off the engine completely and then restarting, after which all was well for about a month.

The first time it happened, I *think* I noticed the speedometer wasn't moving, but not entirely sure. Hard to say since it was so hard to get any speed. lol

Any hunches? Feels like some kind of an electronics issue, maybe a sensor somewhere or something?

Thanks in advance!
 
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LoneMustang

LoneMustang

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UPDATE: Sharing a bunch of learned info in case it's useful to anyone else.

After extensive additional research, Google pointed me to a forum post here that I hadn't previously found that appeared to describe *somewhat* similar issues.

A response therein pointed to this FordTechMakuloco video which describes known issues with the electronics within the 6R80 transmissions that seem to track, and how to fix them:


In between then and now, I had new, different symptoms emerge that appear to confirm it:

1) Transmission failed to shift out of 1st gear upon gentle acceleration from a stop (speedometer was working). Pulled over, turned off the ignition and restarted to resolve.

2) A single somewhat-hard upshift a few miles later (speedo still working).

Days later (today), things got worse:

1) Transmission shifted up and down erratically a few times at slow speed, then went into top gear as before. Speedometer was at zero. Restart didn't fix, at least not for long.

2) Between then and when I found a place to pull over again, I got a "_ _ miles to empty" warning on the center display (tank was half full).

3) Restart resolved it and I got home without any additional problems.

After my original post, I did check for any related OBD codes, and found none. Checked again after today's experiences and found two, both related to the Output Shaft Speed Sensor Circuit -- P0720 and P0722 -- the first of which was called out in the forum post I found.

I also found a second forum post here that described symptoms more similar to mine (including the out-of-fuel warning) that the OP resolved himself by following Makuloco's video.

Bottom line: The OSS sensor is part of a one-piece electronics component bolted atop the R680 transmission's valve body called a "Molded Lead Frame." It also houses the transmission range sensor, which could explain the shifting issues seen today that didn't coincide with a zeroed speedo.

Replacement part supposedly addresses both sensor issues, and includes an added rubber seal that keeps metal particles from creating conductivity between the transmissions solenoid connectors the Molded Lead Frame mates with (another known issue).

Additional notes:

I did check for TSBs related to the issue; found none pointing to my model. Odd given that Makuloco said Ford updated PCM software to keep OSS sensor issues from resulting in a dangerous rear-wheel-locking sudden downshift at high speed.

One comment in the aforementioned forum posts reported similar issues caused by trans fluid getting past the bulkhead seal for the electrical connector. I will check that, but the only way to replace the seal is to drop the pan (also part of Makuloco's fix). May as well replace the Molded Lead Frame while there.

The process is the same as doing a fluid & filter change, with added steps to drop the valve body to replace the Molded Lead Frame along with a couple of seals.

Makuloco recommends doing it proactively if you have an affected transmission (at your next fluid & filter change perhaps?), as encountering these problems seems inevitable.

The two related earlier threads can be found by searching for the YouTube video link listed above.
 
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LoneMustang

LoneMustang

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UPDATE:

I replaced the Molded Lead Frame in the transmission three weeks ago today. Pretty much went exactly as outlined in Makuloco's videos, except the dipstick in mine's a tad different than the one shown in his fluid-level check video (has two zones, that I ultimately figured out and adapted to).

Since then, I've taken 22 relatively short trips for a total of 192 miles, with zero recurrence of symptoms and zero new DTCs. Some other seemingly coincidental symptoms I was having -- intermittent freezing of the Sync touchscreen and an occasional TPS system fault warning among them -- have also not returned.

There was no fluid buildup in the electrical connector, by the way, so my troubles were indeed related to the Molded Lead Frame itself. The bulkhead seal was replaced nonetheless as suggested to keep it that way.

Totally worthwhile endeavor -- a few hundred dollars and the better part of a day in the garage netted a seemingly good-as-new transmission.
 
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LoneMustang

LoneMustang

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It's been over a year, now, since I replaced the molded lead frame in my 2014 Limited's tranny, thought I'd pop in for an update.

Bottom line: No issues at all to report.

I towed a fairly heavy travel trailer with it through 5 states and back in the spring (1,000s of miles), and towed the same trailer up a steep climb from Denver to a campground near Rocky Mountain National Park in the fall.

The problem issues never returned, and the transmission with 118k miles on it now is still operating perfectly. Definitely a worthwhile DIY project that probably saved me thousands of dollars.
 
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