1998 Transmission Failed

[DieselHilux]

I was on my way back to New York yesterday from PA.

The trans and engine were working perfectly for the entire trip, no slipping, no problems.

Then as I was almost home (about 40 miles) I went to pass someone and nothing.

The engine was still running fine but it was as though someone put the trans into neutral.

NO gears work, not even reverse or manual 2nd, 1st.

No check engine light or flashing O/D light.

I had to have the damn thing towed home to the tune of almost $300.

The trans was rebuilt about a year ago and it has been perfect up to this point........

I have a feeling it is the pump or its driveshaft but I wanted to see what you think.

[glennet404]

Hello-

Sorry to hear of your problem. I bought my '99 with a known bad tranny - and heard a story from the previous owner very similar to yours. The symptoms were identical. In my case - it turned out to be the pump. If you care to check this - you may want to disconnect the return line to the transmission from the tranny cooler in the radiator. If you get little if any pressure - it's most likely the pump.

Good Luck-
Glenn

[12Ounce]

Another way to check the pump: Normally a pump will prime and fill the upper area of the tranny. Therefore the fluid level should go from "too high" at engine off; ... to "normal" with engine running.

If the level doesn't change much when the engine is started, changes are you have a broken pump (shaft).

[garync1]

Just curious if you had a warranty with your trans...

[DieselHilux]

Even if it had a warranty I wouldnt let those retarts fix it, I will do it and I will do it correctly.

Most likley is the pump, but the trans is gonna have to come out one way or another.

[wiswind]

I would try the suggestion from 12ounce first....as it is the easiest.......the fluid should be "overfull" with the motor OFF......and will go down to "normal" with the motor running.

Of course......if the fluid is LOW with the motor off.....well that would be a problem.......too little fluid.

Next.....double check to see if the unit is under waranty.......and follow up there if it is.

Then.....you can try the pressure in the cooler line as suggested by glennet404.
I don't know how much pressure would be normal there.

[DieselHilux]

Ok so I FINALLY got a chance to yank the trans today (easier than it first appeared)

There is NO SPLINES what so ever left in the torque converter where the pump shaft is supposed to be driven from, I have no idea why those splines would get stripped out like that but the splines on the pump shaft its self were perfect so I'm lost as to what happened but the converter is now shot.

Just gotta tear into it and see what else got fucked up.

[glennet404]

Hello-

Given the fact that you had the transmission rebuilt a year ago - you may not want to go ripping into the case at all.

Do a search and you will find that the converter splines stripping out are a common problem with the AX4S transmission.

However it is surprising you would have the converter strip out so soon after a rebuild. Generally on a rebuilt tranny the converter is replace as a routine matter - given its failure history. .

If it were me - I'd probably check the pan to make sure there were no chips, etc. If not - I'd probably just replace the converter - if you really want to be through - maybe replace the pump shaft as well - its a pretty easy job with the transmission out of the vehicle.

Good Luck-
Glenn

[DieselHilux]

The DAMN converter was replaced!!!! With a BRAND NEW FORD ONE!!!!!

I have a feeling it was a combination of cheap, improperly cast and or machined splines along with a very small shaft to drive the pump which draws a consiterable amount of power.

[serge_saati]

Originally Posted by DieselHilux

I have a feeling it was a combination of cheap, improperly cast and or machined splines along with a very small shaft to drive the pump which draws a consiterable amount of power.

Well said. I agree with you, Ford got 12 years to revise their transmission design and they do it only once, to build the same thing. Almost.

They still keep the same trans in new Ford vehicle, they don't realize why they make rupt.

I don't know why they don't want to built something solid.
The trans is smaller than the fuel tank.

[glennet404]

DieselHilux-

It is unusual for the converter to strip out so soon. Also- the following statement I make is based upon MY previous experiences with transmission rebuilders.

Just because they say the converter was replaced and charged you for it - doesn't make it so.

Good Luck-
Glenn

[DieselHilux]

The converter was replaced because the other ones lockup clutch was shot and slipping BAD, overheated the trans and distroyed everything else in there.

I will get a junkyard converter and matching pump shaft and give that a shot, the van has 215k on the original engine so if I can get another 10-20k out of it i will be more than happy, I have no problem doing work, I have a problem spending money on parts.

[glennet404]

DieselHilux-

I'm a firm believer in used parts - and will buy at every sensible opportunity.

This may be one time where buying new over used makes more sense. While you can inspect the integrity of the splines on the shaft and converter. You don't really know the internal condition of the converter. Furthermore - the pump shaft is another high failure item on the converter end. The undercut radius where the splines meet the ground shaft is a failure area - and these shafts are known to snap clean at that location due to micro cracks caused by heat. These micro cracks can only be detected under magnaflux. On a used part these cracks would not be visible to the eye.

A new converter from NAPA runs about $160.00 and if I remember the pump shaft is about $40.00. So for $200.00 you have new parts. At todays prices I don't think you would get out of a salvage yard for under $100.00.
If the converter were an easily accessable item - maybe it would be worth the chance - but would you really want to be pulling the tranny again in a few weeks if the used part turned out bad ??

Also- don't forget to change the front transmission seal.

Good Luck-
Glenn

[DieselHilux]

Got a rebuilt converter, brand new improved pump shaft and new converter seal, got the trans re-installed and tomorrow I will try it out and see what I got.