Transmission Hell

[wjamaica4]

98 windstar, I have a lifetime warranty with AAMCO, having the train rebuilt for the 3rd time now! Are there any high performance parts available, or any way to beef up the train so that it can hold up better?

[tomj76]

Sometime around 2008 I had my first transmission problem on my '96 Windstar. The housing cracked and hydraulic fluid from the transmission poured out. This happened in a fairly remote location far from home, so I left the vehicle with a local repair shop. They replaced the failed transmission with a used one.

A short time after that, it was clear that this used transmission needed to be rebuilt or replaced. I took it to several repair shops (including an AAMCO franchise) and settle on one that I felt was the most honest and competent. However, this rebuild never quite worked right, despite multiple returns to have the remaining issues resolved, even to the point where the rebuilder repeated the rebuild, but with no success.

In the mean time the vehicle mileage piled up to about 300,000 mile, engine began to consume large quantities of motor oil, and finally the transmission stopped shifting above 2nd gear. I decided that I would DIY the engine AND transmission rebuilds (despite being a novice), and although it took a fair amount of time (many months) to complete, I was very happy to find that not only did I resolve the engine issues, but the transmission problems were completely resolved.

During my work I found a couple of issues with the transmission that I believe the rebuilder failed to address that might have been the cause of the unresolved problems. First, I believe there were some areas that the rebuilder did not apply strict enough criteria for the decisions on which "hard" parts to replaced. For example there were several bushings that I replaced based on measurements of rather large clearances. Ford did not specify wear limits in any of my service/repair documentation, so it was left to a judgment call. I replaced several only because I though large clearance would degrade the oil pressure in the clutches. I also replaced several parts "just in case" such as solenoids, sensors, wiring, etc. I spent also significant time working on the valve body to make sure everything moved smoothly. A also found an error in the assembly done by the rebuilder, although I can't really argue that it caused my problems.

As I mentioned, I was able to get the transmission working well, despite being a novice, while my professional shop (who I still believe is reasonably competent and honest) could not. I'd guess that AAMCO is having trouble because they are not being careful enough or they are do not apply strict enough criteria when evaluating wear on the hard parts.

I doubt you can get AAMCO to do a better job. However, you have the option to purchase a factory rebuilt transmission. 12Ounce has done that and saw great results.

[12Ounce]

My Ford re-manufactured tranny cost less than $3K, exchange, (way back when) came with all new solenoids and full of synthetic fluid. It has lasted, to date, over 200k miles and is still going strong. I have replaced fluid with Mobil1 one, perhaps two, times. Fluid now stays clear, may never be replaced again.

[wiswind]

I bought my '96 Windstar in '99. at about 39K miles
About 2 years later..at 100K miles...I was faced with major transmission issue.
I bought a FORD remanufactured unit and had it installed through a dealership...
Cost was just over $2860.00
Lasted until well after I sold the car at 13 years old with over 229K miles on it.
As far as I know, it is still out there.

The FORD remanufactured unit had a number of "updates" done to it to improve the reliability over the one that was replaced.
I had been having the dealership replace the fluid and filter every other year.

After having the unit replaced....
I installed a auxillary transmission fluid cooler and also installed a Magnefine inline filter in the return line INTO the transmission.
I also changed the fluid every year and the internal filter every other year.

Each summer, I took the vehicle on a youth mission trip.....pulling a trailer.
I think that what finished my tranny off was an hour of stop and go traffic in Nashville with the temperature over 100 degrees (while pulling trailer).

The other factor......the radiator fan low speed dropping resistor was open.....so I had no low speed radiator fan operation.
All of this is hind sight........I had to learn from experience.

In my case, I planned to drive the vehicle for quite some time.
So I spent the extra $$$ and time.

In your case......I would CERTAINLY verify low speed radiator fan operation and also install a filter, as I did. Many shops will install this filter as part of their process (at least they used to).
Also, you MUST verify transmission fluid flow through the cooling lines.....if they have become clogged with junk from the failed transmission, it is CERTAIN that the new transmission will overheat.

You will need to look at the overall condition of the vehicle and determine how long you will have it....
That will help you to determine what route to take.
A junk yard transmission is a crap shoot as the transmission is a high failure item on the Windstar.

Rebuilt units sourced locally will be dependent upon the local business doing the rebuild work.

Again, I stress the radiator fan (fans should run always when the A/C is on) and fluid flow through the cooler so that whatever replacement unit you may install will have a fighting chance.

[wjamaica4]

Will do, thanks!