I have a 2001 Expy 4x2 with the 4.6 liter engine. I started hearing a clunk/thump in the tranny or rear end last week and since it only has 10,000 miles on it, I took it back to the dealer. They say that there is a hard shift between first and second and from second to first. They are going to put in a "1-2 accumulator" which they say will soften the shift and eliminate the problem. I have insisted on documenting this with the service department in case of further tranny problems down the line, especially after the warranty runs out. Any advice? Is this a common problem? Previously owned a '97 Expy 4x4 that went over 100,000 miles and it had no problems whatsoever.

 

[updated:LAST EDITED ON 15-Jan-02 AT 10:56 AM (EST)]Sorry to hear that you have had a problem. I had the same thing happen. At 15,698 my tranny started to shutter when it would go into 2nd. It would bounce off the rev limiter before it would shift into second gear. As well, I was having issues with it going into Reverse. They did a diag test. The wds pinpoint test found "drum exwear" (on the notes from the service ticket). They removed the tranny, "mount in binch, fix overhaul trans, cleaned cooler lines, road test and verified ok."

However, it was taken back to the dealership @ 15,732 with the same issues. The cause here was Ford Code 7902 "Cameapart put metal in valve and stuck main reglator." They ran trans dianosis and Pin Point Test, removed trans, install reman trans and flushed cooler lines. Road test after repair. OK.

Long story short, it took 2 times to get them to put a new trans in the truck. And it was a remaned tranny at that. As well, get ready for one hell of a wait. My truck was in the shop for 29 days the 2nd time. The tranny had to be shipped from an assembly line (I think this was a line feed to me as I cannot see them installing remaned trannys at the assembly line, or that may explain why we are having these issues). I just find it funny that it takes soooo long to get something shipped by Ford. My last car was an Audi, and I had to have parts sent to my dealership many times. They usually arrived in fewer than 5 days, and those were from Germany!

I cannot figure out why the tranny crapped the bed like it did. I have a 2 wheel drive (so it only see the asphault). I have used it once to pull a trailer. It was a 6' covered trailer to move all of about 600lbs. I had a class 4 hitch installed, and traveled less the 25 miles with the trailer. What about you? Have you done alot of pulling, or off roading? Kinda funny how Ford states that there are no know issues with this tranny, but elected to install a totally new tranny in the new 2003 Expedition. They are using the same 4.6 and 5.4L engine.

Boxter

 

Aren't there two different transmissions for the Expy? Which one gave you the problem?

Patrick
2002 White Expedition
4x2 Limited Slip
4.6L