Hey y'all.
I could've sworn I registered last year and uploaded photos, but my email address didn't kick back a login. I guess I meant to, but never got around to it. In any case, I'm now registered and here to post in hopes of getting some help.

On June 6th, 2006 (I know. I know. 6/6/6), I purchased a lovely 5.4XLT SuperCab from World Ford in Brandon, Florida. I later found out that while it has a 4.10 rear, it lacks a differential. One wheel power! Anyway. This last September (2007), the truck suffered catastrophic transmission failure.

After approaching a red light, the truck faltered. During an attempt at accelerating, it refused to shift and the check engine light came on. It was promptly taken to the nearest Ford dealer (Suncoast of New Port Richey). I'm also going to take a moment to say that this truck has always been babied. Regular oil/maintenance work (albeit off dealership, but with trusted family mechanic), regular washings and detailings. In other words, we're not casual owners. We're car people and we're always very aware of our vehicles and as hands on as our schedules will allow.

Three days later, it was ready to be picked up and the dealership explained that the truck was defective from the factory. The "behaviour" that happened days earlier were as a result of the defective manufacturing. What happened was that the baring of the system that allows the transmission to transfer from reverse to drive essentially "exploded" which, sent metal shavings and other materials into the gears breaking teeth, et cetera. With a rebuilt tranny, we were on our way.

Basically, all of my family members, plus our regular mechanic drove this truck for a year and a half and none of us "noticed" that there was a long running "mechanical issue" with our tranny. I'm 21 and it's my first truck, but I'd like to think I can tell if something is amiss.

I told you guys all that.. to tell you this..

This morning, I received a call from a family member that the truck started acting up again after 20 minutes of driving. Five seconds into accelerating, the truck wigged out as it was pulling away from a red light. The dash flashed off and it was as if the truck lost power but the steering was still active. A second or so later, the wrench light came on and entered (what I figured to be) Limp Home Mode rather than the Engine Fail Safe Mode or whatever its called. The driver pulled into a lot, turned it off, and started it again 15 minutes later. No wrench/LHM restriction or other symptoms. The driver elected to continue on in the vehicle for what would be about 75 miles without any other issue.

Fast forward to fifteen minutes ago after calls to two separate service managers at two different dealerships. They're both saying that because it happened out of the blue, cleared up, and it was a 38 degree morning in Florida, it's probably a "fluke". Both guys said to drive it until a) something happens or b) the warning lights trip again. Not very comforting when you have to drive through woodland Pasco county where mobile phone coverage can be spotty.

Sorry if that's a lot to read.. but here are my questions.

1) Has anyone else bought/acquired a truck with a "Defective from the factory" transmission?

2) Has anyone bought/acquired a truck that later threw a baring causing internal damage to their transmission?

3) Has anyone experienced a similar PCM response?

4) With such a rear end as a 4.10, is it normal for it to groan 25 -/+mph or coasting? (Coming from someone who has mostly handled cars with sub 3.55 gearing, I haven't a clue.)

5) While it was uncharacteristically cold this morning, is it likely that it was in fact the temperature even though this occurred well after the engine had a chance to reach normal operating temperature?

6) Could this be an indicator that there's an issue with the rebuilt transmission or a related component?

I've looked through all the TSB/areas of complaint on this generation of F150, and while it occasionally shares similar issues.. nothing quite fits. Sooner rather than later, it will be sent in for a major check up (par for the course), but any help would be greatly appreciated.

Perhaps if there are others that have had such severe issues, a pattern might develop that could help us as well as others.

Happy/Safe motoring in the mean time!

 

This is probably not the first transmission ever built that had a failure. It probably is also not the last. It can happen with any transmission in any make of vehicle.

I've never seen a trans fail from someone taking off their clothes, which is what I imagine a baring would be. Sometimes they do fail when a bearing fails, though.

This is one of those problems that would be REALLY hard to find. It probably is a fluke, but if it starts happening more often a good tech should be able to find it.

Since I haven't heard the noise I can't comment on this one.

No, these trucks will run well down to -40. Once it's at normal temps the truck doesn't really care what the outside temperature is.

It doesn't sound like anything related to the transmission to me.

 

Thanks for the replies! Excuse me while I cringe from embarrassment over the baring/bearing issue LOL.

I probably should have phrased my first question better by stating that it was mainly aimed at this particular generation of F150 and/or with this combination of train components.

It's got extra warranty protection.. so.. if anything happens.. I'll post an update here I guess.