Advice Please - DIY torque converter or transmission replacement

[dhollow2]

Ok, the job is done and it's back on the road minus the shudders and surging from the old transmission. But all is not well with the new transmission. It is strong in 1st and 2nd gear with a smooth 1/2 shift but when it tries to shift to 3rd it seems to drop completely out of gear for about a second before 3rd engages. If I don't get off the gas in a hurry it slams into 3rd. If it's in 3rd and I accelerate to kick down to second, it acts like it goes into neutral and the engine revs until I let off the accelerator and it reengages back into 3rd. Once it's in third all is well and lockup is fine at higher speeds. I have driven it for a couple of days hoping it was a sticking valve or something that might loosen itself up but it's not getting better. I don't know enough about the inner workings of the transmission to know what is going on here so any help is appreciated. It seems like an internal problem to me that should be covered under the warranty. Is there anything I could have done that would cause this? Is there anything I should be checking before I take it to the dealer?

[12Ounce]

Sorry you have this concern ... I have little experience on this matter... would prob go to dealership that sold the part to see if you can get a customer-friendly inspection by their tranny jock.

BTW, did you check the rear axle to see if it has that rust area toward the LH end that others have written about?

[dhollow2]

We already received a new rear axle as a result of that recall. Had a nice crack that wasn't far from causing the axle to break. Ford provided us a rental for 6 months while they sorted out the parts sourcing. They offered to buy the van but we thought the offer was too low for its condition and I couldn't bear sending it to it's grave just so we could get a new(er) vehicle.

[wiswind]

The "new" unit should work.
While you may have some slight shifting issues while the computer re-learns the drive-ability information, like not shifting at exactly the ideal rpm/speed, etc.....major revving between gears and slamming into gear is not normal.
You most likely already did this.....verify the transmission fluid level.....slightly low fluid level can cause similar issues....and these units are really sensitive to even slightly low transmission fluid level.
Also, if the filter is not fully seated up into the fluid intake, it can also suck air in.
However, the replacement unit should have had this in place already.
I would return to the dealership with the vehicle to see what they can offer in terms of advice....Hopefully you don't have to change it out again, but if you do, you don't want to further damage the unit.

[dhollow2]

Just got a call from the service advisor at the dealership and the problem is definitely internal to the transmission and they are going to have to pull it out. I am REALLY glad I took the advice to go with a Ford rebuilt unit! The warranty will cover parts and labor. Had I bought the 3rd party rebuilt unit I was looking at and had this problem I would have been responsible for the labor.

[Plata]

if i were you, i will go on for the warranty my friend, that is not normal.


i'm thinking that maybe the oil pump pressure is not adecuate and when it tries to engage 3rd, it takes a time (because all clutch packages need to be engaged at the same time, that needs much pressure)

well, the problem should be covered by warranty, i rebuild mine twice, first time it dont do it properly, so the tranny wasnt engaging first and reverse, only from 2nd and up, i were using the tranny in that conditions for a time, but then, all the discs clutchtes were again burn, because it wasn't frictioning properly.

I'm telling to you, that if you continue using it in that way, maybe a rebuild will be necesary again in short time, because of burn discs, i hope dont, but if the clutches packages slips to much they burn very quickly, so just be carefull and try to dont make it slip to much until you could get a solution..

[12Ounce]

Good that Ford is stepping up to the plate. Its very likely that they are already familiar with this particular issue coming from the rebuild shop. Hopefully, the next unit you get will be as good as the one I just returned from 600 mile trip with .. today.

[12Ounce]

...BTW, between me and my kids, we have three Ford tranny remanufactures on the road ... 97 Tracer, 04 Tribute, 99 Windstar. Each has over 100K miles ... the Windstar is approaching 200K miles. I believe!

Just hope Ford does as good quality on the labor, as you did.

[dhollow2]

One final post to put close the loop on the thread. We picked up the van today after being out of town most of last week. The transmission feels great and the 2/3 shift issue is gone. Per the repair order: "Disassembled valve body and inspected, found scoring in 3-2 shift timing valve and gaskets out of position. Replaced valve body". Best of all: "Total Invoice $0.00".

So the project is finally complete and we have a new transmission, subframe, control arms, motor mounts, flex pipe, exhaust hangers, left side outer tire rod (my bad on that one), sway bar bushings, and tires. I have pictures from the project and I'll try and get them up in a new thread sometime this week. Thanks to the community for all the advice along the way!