I have a 2005 f150 (130,000 on the clock) with the 5.4 and 4x4. The tires are stock, I have an edge programmer that I used on setting 2, the tow performance one, with a custom tune that slightly advanced spark and firmed up the shifts. I don't tow and have only don't some light off-roading but nothing in the last couple months. I use the edge to monitor the transmission temperature; I've never seen it get over 180 with the norm around 150-160 degrees F. Since it got cold out my truck has had a whine that I thought sounded like it was coming from the engine bay. It progressively got worse until it was always there but would get quieter when the motor warmed up.

A couple days ago I experienced what felt like a loss of power then the motor would rev up. The transmission would shudder and then it would be fine to drive. This happened 5 or 6 times in the 3 mile trip back to my house. I checked the tranny fluid, which was good, and put the edge back to stock and pulled the batter to reset the system.

That night I decided to try to drive it to the supermarket down the street to see if the problem persisted and if turning od on/off changed anything. It started fine then when I got about a mile from my house it started slipping again and revving up. It would barely move so I decided to turn around and go back home. I limped it a couple hundred feet before the transmission dash light came on and said transmission failure. I got it towed back to my house then used the edge to pull the codes. I got

p0720 - output speed shaft sensor
p0722 - output speed shaft sensor no signal
p0731 - incorrect first gear ratio
p1000 - OBD system readiness test not complete
p2106 - throttle actuator control system - forced limited power

Upon start-up the motor idled at 1500 rpm and the transmission whine was very loud. Neither drive or reverse worked but I didn't rev it up above 2000 rpm, I've read it might engage at a higher rpm in 3rd or 4th so I put it in D and revved the truck up to 4k. It started to move forward but it didn't have enough to go up the hill. After a second or two the engine went into fail safe mode and the od light began flashing.

I dropped the transmission pan to change the filter and fluid. I have another oss sensor but I didn't install it. Upon dropping the pan I found the fluid was very dark and had metal flakes in it. There were no pieces of metal larger than dust but the magnet was completely covered and the bottom of the pan had a layer of black crap that had a consistency closer to grease than tranny fluid.

Any ideas what I should do? Should I install the new filter, clean the pan and install the new oss sensor or is it time to have the transmission replaced/rebuilt?

 

That transmission will have to be rebuilt, that is not what you want to see in the pan. Not sure at this point what failed but it really doesn't matter, there is damage that can only be repaired by removing the transmission and rebuilding it. You will want to replace the converter also.

 

I talked to a couple shops today and found that I can get the transmission rebuilt for $23-2500 or I can have Ford put in a re-manufactured unit for $3100. All the shops had a warranty of around 12 months and 12k miles while the Ford unit has their 3 year unlimited warranty. There aren't any Jasper transmission installers anywhere near me, otherwise I would go that route. I would love a BTS or equivalent but the cost puts that out of the picture. I won't tow often but I do plan to get 285/70/18 KM2's so it will have more tire weight than stock. Which is the best option? Are there alternatives I haven't thought of?

 

Make sure you have a inline filter installed in the return line between trans cooler and transmission.
What ever is in your trans pan is also in the trans cooler and flushing the cooler will not get it all out.
Ford has a part number for this filter.

Did you ever have the trans fluid replaced?
I have 185 thousand miles on my 08, all stock with 3:73 gears and exchange fluid every 30 thousand. I only have them exchange fluid no cleaner used ever.
Good luck!

 

Based on the fluid it looked like it had never been changed. The filter was completely blocked. I've only owned the vehicle for the last 6k and the previous owner put 20 some thousand miles on it. The original owner is the one who had it for over 100k, I have no way of contacting them to know if they did any maintenance. If I get the trans replaced I'll also have the cooler replaced at the same time.

 

If finances are driving the train, perhaps a salvage replacement?