Ford Windstar transmission problem

My diagnosis of our 2000 Ford Windstar AX4S Transmission problem. I could have repaired this failure without removing the transaxle. Just recently a comment-er to this video confirmed you do not have to remove the transaxle to replace the pump shaft.
Ford Part Numbers for Pump Shaft Replacement
Pump Shaft Bearing = XF2Z-7G184-AA
Pump Shaft = E6DZ-7B328-AB
Pump Shaft Seals 2 ea = E6DZ-7G092-A
Pump Shaft Seals 2ea = E6DZ-7G093-A
Also go to www.sonnax.com to look for sonnax parts.

[@JuanGonzalez-es6tw]

I seen your video and it was very helpful. This is the 3rd time my transmission failed for the same reason as yours did and finally decided to look it up on KZbin and walla found the problem. I was ripped off 3 times by the mechanics and wished I would have checked sooner on KZbin for the problem.

[@ranxceroxcallixte9262]

Dan, you've the patience of a saint to answer all these comment & do that job. my hats off to you. I just acquired a Windstar free due to a trans problem & I did many trans. on carbed vehicles. My fav. was a Cordoba. 4 bolts also held up the front end, although that wasn't needed to change the trans. Watching how removal of these is akin to watching a scary movie. Should I render it scrap metal, I'll at least learn my lesson. Happy motoring to you.

[@amt1298]

If the rest of the vehicle and engine are in good shape, I would swap out the transmission with a remanufactured unit. You should take a look at what maintenance has been done to the engine and see if there are any leaks or things that need to be done. That will help you decide to drop the engine and transaxle as one unit with the subframe or not. A whole lot easier to do all of your repairs to the engine when it is out of the vehicle.

[@ranxceroxcallixte9262]

@@amt1298 I wondered if dropping the 2 , eng. & trans. would be possible while still attached to th k frame. I was jus wonderin, not gonna try it. Don't have too many resources but might be a hobby. Used vehicle $ said to be goin' up :P

[@ranxceroxcallixte9262]

@@amt1298 Thank you Dan.

[@kazparzyxzpenualt8111]

Hi Dan, Just wanted to say up front this is one of the most friendly and helpful vehicle help you tube comment sections I have EVER read though! You are a true prince of the internet! Your patience and explanatory skill shines through and through. The video is very helpful too. I myself am on the outside edge of a Windstar problem. So anyway, my friend and business partner has suddenly encountered trouble with his '03.Windstar. I think but am not sure that his issue sounds very early in the failure mode you described.It drops into neutral suddenly while trying to climb hills or accelerate. (And the van is full of heavy constructuon debris right now too.) I believe it then recovers. It was still on the road yesterday and a he took it to a local mechanic who looked at the fluid level and condition and said it was ok. The nearest transmission shop won't even look at it. They say it is too old to get parts for any problem they might find. Kind of discouraging. Your youtube gives me some hope though. So thank you for being the kind of person that the world needs more of these days! I am going to follow up and see what we can do about this because without some fix we won't be able to move stuff around for the next job we have lined up very easily. Thanks again Dan! I will probably be back to consult if this looks like the way to go. Take care!

[@amt1298]

Do you get any flashing amber OD light? It sounds like your transmission might be slipping and would have to be torn down to identify the problem. I can narrow it down if you can let me know which gear it slips in.

[@kazparzyxzpenualt8111]

@@amt1298 wow! Thanks for asking! And very much for replying to my inquiry. Actually my friends van may not get the attention you might be able to help him with. I will check with him the next time we get together for work. He seemed like he may just give up on the van when we sorted out how to still work around not having his van to use. We managed to move the ladders we needed with my vehicle. Since he has a small car he is using that to get around now. The van has a number of other things he said it would also need so I guess he thinks it isn't worth kicking a dead horse. And like a lot of drivers he may have been ignoring any dashboard warning lights over the years. Seems I think I saw the check engine light on last time I ride with him. He has a mechanic that might tell him what it was and not to worry about it. I don't know about anything flashing though. I will ask him. Thanks again Dan. Take care!

[@CimarronyAtigrado]

Hi Dan, Thanks for sharing. I had a similar issue with my windstar 2003. I didn't have any lights or alarm going off though, the transmission just died while I was driving. I took it to the shop and I was told that the problem was coolant leaking into the transmission through some crack on the transmission coolant line. I noticed that the coolant level went down a bit a while ago before the van died but I never thought it was leaking into the transmission. I never noticed any coolant leaking underneath the van either. Two thousands and four hundred dollars later I got it back in the road but leaving a big empty space in my wallet.

[@abelpostman9049]

[+Dan Weston] You may have saved us thousands of dollars on a 2002 Windstar!!! I am crossing my fingers. My story: While driving @ 70mph north on IH35 headed to San Marcos, suddenly the engine revved up while on cruise control. I noticed NO noise other than the engine revving and no lights. I tapped the brakes only to discover while in drive it felt as if I shifted to neutral. I luckily got it to the shoulder where I discovered I had only PARK and NEUTRAL. I had to be towed home. The next day I stumbled onto your video, while getting quotes from transmission shops, some close to $3,000. That was a week ago. For a week it has perplexed me. With your comment about repairing without having to remove transmission. I revisited your video at least a dozen times questioning "MY" diagnosis,when I found another video about flushing the trans. I realized the fluid should tell me something confirming your diagnosis. I checked the fluid and was surprised it was relatively clean and no signs of leaks. I wound expect the fluid to be burnt had I had a catastrophic failure. I want to drain the fluid. pull the pan and inspect what filings are on the magnet. What do you think?

[@amt1298]

abel postman You are on the right track. These are all things to check and properly diagnose the problem. I would also removed the transaxle cooler lines and place them in a bucket or other suitable container. Then have someone else start the engine, if you get ATF flow then your pump shaft might be ok but I doubt you will. The symtoms you described lead me to believe the splines in the torque converter where the pump shaft is meshed with are stripped. This failure will not give you any lights and will act like you are in neutral. The down side is you will need to remove the transmission to replace the torque converter. All of witch you can do with time and some equipment. Let me know and I will fill you in on some tip and tricks I learned. Fellow DIYer, Dan

[@abelpostman9049]

abel postman THE VERDICT IS IN!!! The torque converter was stripped. Apparently over time at light duty use the TC can, un-noticed, wear until it fails. The "shortcut" however was not an option as just to get to that point required 75% of the labor that was needed to just pull the transmission. Immediately the TC was apparent but for good measure the pump was opened the impeller carefully removed to expose the shaft. Counter rotating the two end was impossible concluding the shaft entact. All the pains did save the vehicle from the $3000 shop. Some money was spent on tools. After all was said done TC=$120. Labor (undisclosed). THIS JOB WAS NOT FOR THE HOBBYIST!!!

[@BobKontak]

Thank you, Dan, Best vid I have seen for isolating a hard parts problem for the the blinking OD light. It makes sense. I have a P0734, Gear 4 incorrect. Only after fluid temp reaches about 205-210F degrees (45 mins or so) - AND under load. Was watching my spiffy but old Snap-On scanner while owner was driving it. Suspect viscosity drops with heat and the floppity-flop from the needle bearing failure does not drive the thinner fluid to the degree needed. No fluid stink at all. Drops to direct drive (3rd gear) instantly and must not give it time to burn friction surfaces. Don't understand torque converters but 3rd must require a little less pressure than 4th. You may become my new best friend. :-) Thanks again.

[@amt1298]

Bob Kontak What did you find out on your transaxle problem?

[@BobKontak]

Dan Weston This is embarrassing. I had used Mercon and not Mercon V when changing the fluid out several weeks prior. Asked counter guy what fluid. He said Mercon. So I got the Mercon/Dexron combination stuff. Wrong answer. Fail as the kids say. I called the parts place you mentioned and customer service spent 1/2 hour with me on the phone. E-mailed me diagrams, etc. They were outstanding. Then found a thread where they mention Mercon V as the required fluid. Argh. I'm in Summit County, Ohio so drove to Summit Racing and grabbed an $8 drain plug kit and did it right. 11 quarts of Castrol Mercon V. Smells like dead fish. It has to be good. A bit of Sea Foam Trans Tune - one cup. Drove a bit. Dropped pan. A bit more Seafoam and five quarts to get the trans to engage then drove it for five miles. Pan off, filter change, drain plug installed. Six quarts plus a 20 oz of Lucas AT "conditioner". OD flashing gone and shifts are nearly imperceptible. Lucas stuff was on a whim. The full fluid change out is expensive. Same ballpark price as the the shaft and bearing you bought.

[@hatmakerronald]

Dan, thanks for answering. I have more information about the windstar. Last week, I replaced the engine with a rebuilt engine. Before I had this done, the transmission worked just fine and very smoothly. Except it would leak a bit of fluid when I went up a long steep hill (mountain). I kept a close eye on the fluid level. But after the engine change, it flashes the O/D light and says check transmission. It still runs very smoothly, no shudder, no hard shifting at all. It does not give the error indication often, and must warn up a bit and turning engine off and right back on clears the problem for a while. I have two codes, P1744- torq conv. clutch stuck and Po742 - torq conv solenoid stuck. However, I am also getting wheel speed codes missing. C1233, c1235 & c1236. I suspect the transmission is OK but the mechanic may have caused this. I have checked all connectors on the transmission and changed the TPS sensor. One other item, All the sensors on the new engine were already on the new engine. One of the sensors on the new engine could be bad. I just added shudder stop and I will see if this helps. If it does, then the transmission is bad. Thanks for any advice you can give me. ron

[@BobKontak]

Hi Dan, Just pulled the pan off the side of the transmission with it in the car (2002 Windstar). I did it without the engine holder and I have a two post lift. This can be done on jack stands. Just more fiddling. In short, Drain radiator. Remove trans motor mount completely. Remove motor mount nut on front passenger side. Engine now can float on sub-frame cradle. Remove trans cover bolts (8 & 10MM). Remove air snorkle, battery, battery tray to get to the top bolts. Lift engine/trans from the cradle just enough to where the bottom of the side pan clears the cradle. Use blocks to wedge engine into place relative to cradle so distance between will not change. Place a 2X8 under cradle - across left and right side - eyeball center of engine/trans assemble to balance. Lift with floor jack until pressure is felt. Remove all four cradle bolts (19MM). Remove lower passenger side radiator hose from pipe that fits into water pump. Drop cradle and engine (6-8") until trans cover clears the car's frame removing it upwards and towards the drivers side top of the radiator.

[@amt1298]

Bob Kontak Thank you for posting your project on this video and confirming my hypothosis that this repair can be done with out pulling the transmission out.. I am very glad that this video is helping out others with the same problem. Thanks again, Dan.

[@BobKontak]

Dan Weston One thing I did not mention. When you drop the saddle the steering shaft will separate (thankfully by design, just for fools like me) right at the floor. Best bet is to remove pinch bolt at the column universal joint about 10 inches above the floor boards, Ummmmm, before dropping. :-)

[@BobKontak]

Dan Weston FWIW - removed side pan after finding the trans would still intermittently flutter between OD and third on the highway (if you remember my Mercon vs Mercon V discussion). No OD malfunction light, just a 1000 change in RPM. Changed 3-4 solenoid and torque converter clutch solenoid as well as inspected the pump shaft. Will advise as to how it performs after a strut change. Thanks again for the video

[@amt1298]

Bob Kontak I actually left the steering rack in the van by removing the two nuts mounting it to the engine cradle and tied both ends up with small diameter rope to support it. Thanks for posting.

[@BobKontak]

Dan Weston That was a lesson learned on the column. No change in symptoms. Shifts like butter though. Climbs to 3200 rpm on highway WHILE scanner says it's still in overdrive. Let off gas and RPM drops to the 2200 rpm (at 70mph) it should be. Any additional load - e.g., slight incline, and creeps up to 3300 rpm but w/o gear change. I am becoming more certain the torque converter mechanical lock up mechanism is failing. Going to buy the support bar for the engine and get on it. Thanks again for your video.

[@oljames1687]

Howdy Dan, just found your video. The wifey's 2005 Freestar suffered the same fate. I rebuilt the motor 1 1/2 years ago. Then Ford sent a recall about the pump shaft and got it done. Cross your fingers, cause now the adventure begins. Good thing i'm about bald cause i would have pulled my hair out...

[@amt1298]

Let us know what you find. Thanks for posting.

[@tarajunky]

Thanks for the video. I have a 1998 Windstar with ~160k miles on it. About 9 months ago, the transmission slipped for the first time while driving up a hill near our home. Since then it has gotten progressively worse. Now it has two obvious problems. If I park it facing downhill and try to back up the hill in reverse the transmission will not engage. Also, if I am coasting or braking to slow down the transmission seems to get stuck in neutral, like if I try to accelerate again it will not engage. If I brake to a complete stop I hear a clunk as it shifts, then I can accelerate again as normal. The Overdrive light did blinked on one trip, but hasn't done any other times before or since. It hasn't had routine transmission maintenance. Today I checked the fluid level and it is normal so there doesn't seem to be any leak but the fluid was dark/black instead of pink. We're not planning to do any major repairs to the van, since we figure it is only worth ~$500-800 in good condition in our area and we don't rely on it for daily transportation. If you have any ideas about what I could try as far as troubleshooting or repairs, let me know.

[@amt1298]

tarajunky I am afraid the damage has been done since the fluid is black. I have had success in the past with performing a transmission flush and filter change. This is where I would start, it is a fairly simple procedure that can be done at home. The main thing is dropping the transmission pan to look at the magnets in the bottom. This will provide you will valuable information regarding the condition of the transmission. If you would like more info let me know.

[@ericreedy5668]

Thank you Dan. You're the best to help out strangers.

[@amt1298]

After working on my van when I could, I have it back on the road. So far I have not had any issues but I will keep you all posted on the status. I go apologize though, I was unable to take the time to verify whether the pump shaft could be replaced with the transmission in the vehicle or not. I do know that due to the lack of clearance with the side pan the transmission mount, as seen through the drivers wheel well, it will need to be removed. This will require a carefully placed jack or the use of a support bar. If you are going to give it a try, please post back to let everyone know how it turns out. Thank you for watching and I will try updating the video as soon as I can.

[@amt1298]

RAUL ROLA It sounds to me that you are having a different problem. Firstly, start by getting the Power-train code out of the ECM by going to an auto-parts store and see if their scanner will read the Power-train Codes. I the behavior of the Overdrive flashing light at high speeds is consistent with my failure but the oil leak has me puzzled. Has the transmission fluid level been decreasing? If not then the oil is from something else. Check you other fluids to see what is low. Then I would service and check it regularly to verify what is leaking. Let me know what you find out. I will help as much as I can.

[@mandyantonacci998]

Can I check this problem the pump shaft without touching or pulling the transmission at all in my Windstar van

[@mandyantonacci998]

Can I check this problem the pump shaft without touching or pulling the transmission at all in my Windstar van

[@amt1298]

+Mandy Antonacci If you have a repair shop or someone with a professional scantool, you can retrieve codes from the Powertrain Control Module. If the shaft or solenoid is having issues, the code till be TCC performance low. I will dig through my notes on my project to find the code I got.

[@rameshpatnaikuni7622]

Hi Dan I have the same O/D problem on highways and since 2 days I am getting check transmission message, its a 2000 windstar 3.8L, about 80k miles, I am in a wheelchair with handcontrols, please advice me on how do I proceed to fix this with a mechanic

[@ericreedy5668]

Hi Dan No errors on the dash, it never stalled, but was still able to roll in park. I didn't hook it up for any error codes, due to thinking it was transmission, but now have the transmission completely out.

[@amt1298]

I see. Well the parking pawl is probably broken. I will send you a link to the IPC of the transmission. I will see what I can dig up for you. drive.google.com/open?id=0BzpVC0nsNqDpeWtaYjVBS2gwVmc

[@MsDjodi]

Thank you again. I think we have a handle on things now. I'll probably order the parts next week, so if I run into any problems I'll let you know. In addition, I'll let you know once we get it fixed how it all worked out! Many thanks.

[@amt1298]

Djodi Deutsch Your welcome and good luck.

[@amt1298]

Djodi Deutsch How is the repair going?

[@MsDjodi]

Dan Weston Hi Dan. Just returned from a vacation, so that is why you heard nothing for a while. I am going to go ahead and order the parts we discussed. Not sure about ordering the torque converter or not. So far we decided the filter, pan and gasket, and torque converter seal if I can find it on Tasca. Not sure what number it is. Then we have to take it to the mechanic for repairs.

[@jamessowards3822]

I had the same issue with the transmission in a 2005 Ford Taurus. I believe that has a transmission of the same design. The pump shaft was the problem and failed without warning. PS, I like Dan's CX500, great bikes.

[@amt1298]

Thanks for the like on my 1980 Honda CX500 Deluxe. I have been riding it since I was 16. And you are correct, the Taurus and Windstar have the same transmissions but there are differences in some of the valve body plates.

[@ericreedy5668]

Thank you Dan, you confirmed what my wife and I thought.

[@bradcarter7388]

Thanks for this video! Rock auto is the best place to buy transmission parts got the clutches drive chain and all the pumps seals for $130.00

[@MrDane1876]

Our 2000 windstar is losing transmission fluid also but only does it sometimes while driving. This helps some for research.

[@MsDjodi]

Okay, so based on all this conversation, we will order the filter and the pan and gasket for the pan, and probably the torque converter and its seal. We can change the transmission fluid too, if it has not been done for a while. We don't drive the car on a regular basis. You mentioned the seal where the drive axle goes into the transaxle - that it might be worn due to normal wear and tear. Is this one of the seals I highlighted to purchase? If not, what is it called and what am I looking to buy. One of the problems is that all this is taking place in two languages, and even though my husband speaks Arabic fluently (as does the mechanic) he does not speak auto parts Arabic, I think you all have a special language. Again, I thank you, you have been really really helpful.

[@amt1298]

Before you go to the expense of removing the transmission to replace the torque converter seal, remove the starter and check for transmission fluid inside the bell housing. If it is dry then the seal is fine and the leak is somewhere else. The reason for asking where the fluid was dripping on the ground was to aid in finding the leaks. On to the drive axles, if fluid is dripping from either drive axle (also known as cv shafts) closest to the transmission then those axle seals should be replaced. I will try to put together a PDF for you to see what I am referring to.

[@amt1298]

Djodi DeutschHere is the PDF I said I would send to you. I have highlighted the items that I think might need to be replaced due to our conversations. Follow this link to "My Drive" and the PDF should open. @file/d/0BzpVC0nsNqDpdlJSSjVxSHRFSlk/edit?usp=sharing Thank you, Dan

[@amt1298]

Djodi Deutsch @file/d/0BzpVC0nsNqDpdlJSSjVxSHRFSlk/edit?usp=sharing

[@amt1298]

Djodi Deutsch Not sure why this link is being a pain but copy and past the address below into your browser. drive.google.com/file/d/0BzpVC0nsNqDpdlJSSjVxSHRFSlk/edit?usp=sharing

[@pissedcitizen1081]

I have a 98 Windstar that only has 1st and 2nd gear. .won't shift into drive...is your issue my issue?

[@bradleykline7937]

thanks, u just saved me a ton of work and money, u rock !!!!!!!

[@hatmakerronald]

When driving up a steep and lengthy mountain, my 2001 windstar o/d light started flashing and dash panel said check transmission. I pulled over as soon as possible and all the transmission fluid started running out on the ground. Vehicle would not drive forward or backward, like in neutral but would roll all by itself. I had no transmission fluid so was stranded at the top of blueridge mountains in Tennessee. AAA hauled me 200 miles at midnight. Transmission was fine until this. I replaced the transmission fluid and every thing was ok but still when I drive up a steep and extensive mountain, some fluid leaks out of a vent on top of transmission. this incident happened over a year ago. The transmission still runs good but today, the o/d light flashed and said check transmission. Did this 3 times so far. Still runs good and shifts smooth. Turning the vehicle off and back on clears the indication. I changed the fluid (mercon V) and filter after problem occurred last year . Any suggestions please.You are the most knowledgeable person on youtube. thanks . ron

[@amt1298]

Ronald Hatmaker Ron, my apologies for taking so long to reply to your comment, my 8 to 5 has had me quite busy this past week. This is a new one for me and I will have to get back to you after I contemplate over a schematic. The fact that is operates fine but vents fluid under load is....interesting.

[@uawsux]

Swage lock

[@MTzombieKill]

Can you pull the pump shaft through the side of the valve body with out having to worry about torque converter or clutch plates?

[@amt1298]

Yes. The clutches are in a different section of the transaxle. You are just removing it from the valve body side.

[@MTzombieKill]

Ok. Im just having problems with 1st to 2nd. It has a hickup for half a second. If you get on it and go through all gears it dose fine but if you drive like a grandma from firat to second then it dose its thing. Do you think it be the TCC?

[@luaryarfo1427]

I have the same problem now

[@hkk3656]

It's a shame Ford didn't do a recall on this problem. My Mercury Sable (same transmission) had the same problem with the shaft and torque stripping out. Mine totally failed on a busy freeway, couldn't get over and came to a rolling stop in my lane. People were mad as hell I wouldn't move. What a mess!!!

[@amt1298]

My van quit on my wife while driving on the interstate.

[@alanhoggard4554]

Hello, so can you replace the pump shaft without removing the transmission? Thanks

[@amt1298]

It has been done by another KZbinr.

[@djfastfreddy8949]

Thanks for you video. i too have the overdrive light flashing when i go uphill. also the trans shifts hard from 1st to 2nd. any other ideas you can share?

[@amt1298]

First you need to have someone with a good scantool see what codes are in the ECM. Then we can start looking in to the causes.

[@KDsGpapa]

Dan, I hope I'm not asking any stupid questions as I am an intermediate mechanic but here goes. 200 Tauras AX4S. If pulling the torque converter shaft out with the engine/transmission still in the car, will I be able to see or feel the splines on the torque converter? Also, when replacing the shaft with new o-rings/seals, is there any problem with dislodging them? Will codes still be in the PCM if the battery negative cable was removed and even if the transmission doesn't work? Thanks so much for the excellent video! It gives me hope.

[@lylejessicawells2622]

we use a 98 as a taxi (ugh) anywho at 104 degrees outside it decided to just give up at a red light in bfe.. So mine is doing what you described but I had a few extra question/symptoms to ask. it nudges forward and back ever so briefly and acts as if the brakes are engaged, the engine even bogs as if it has a load. I had to push it and it was impossible to push backwards, but forward i was able to push it with one hand… trans fluid was at the bottom on the circles and not bright red. when i rev the engine up while in gear I get the nudge, which seems like pressure… thanks!

[@amt1298]

Lyle Jessica Wells I sounds to me that you have something broken in the trans-axle. I would recommend replacing it with a re-manufactured one from www.moveras.com. Re-manufactured transmissions are a great way to go for transmissions with extensive problems. You will need to replace the transmission cooler if so equipped.

[@Hiffewiffe]

My 2004 Ford freestar gear box neon light blinks when going 80-90mph… let it sit cool down and goes away . I have to drive 65-70 and light stays off I wonder if this is what happening to my Ford Freestar . Great information.

[@garyjenkins6629]

I had same problem. There was a recall about 10 years ago. They replaced the torque converter.

[@scottmiller3025]

were there any check ball in the valve body?my filter stopped up causing a no go.changed filter and fluid and now it's shifting really hard from 1st to2nd but normal through the other gears. I thought about pulling the valve body.

[@amt1298]

+Scott Miller There are check valves in the valve body but I would check resistance of the 1-2 shift solenoid at the plug on top of the transmission first before pulling the value body off the side pan. Click this link to view a diagram and resistance values. drive.google.com/file/d/0BzpVC0nsNqDpWjRHVS1raXl3Mkk/view?usp=sharing

[@KDsGpapa]

Dan, I also was wondering where the stripped-out torque converter splines go. Do the larger pieces stay in the torque converter or get passed on to other parts of the trans to cause more damage? Thanks again.

[@amt1298]

+Luis DelValle If the splines in the torque converter did strip the metal will be pushed around the transmission until the pan if the particles are small but the larger chunks will remain in the torque converter. You will know which failure you had when the pump shaft is removed. If the shaft is not broken then the splines are stripped and you will see wear on the splines of the shaft. When you complete your repair and before you had fluid, disconnect the transmission cooler lines and flush it out. Also, remove the pan, clean it (including the magnets) and replace the filter.

[@MsDjodi]

My husband says it is coming from under the pan and from the side where the oil seal is. Kind of sounds like those might be the problems then. If that is the case, I wonder if we should still get the torque converter and not just the converter seal. Since it is not all that easy for us to get the parts, I'd rather invest a bit and be safe rather than sorry. Any thoughts?

[@amt1298]

Ok, sounds like the pan is leaking due to being hit and the seal where the drive axle goes into the transaxle is due to normal wear. If that is the case then the transmission does not need to come out. You can support the front end and do the job on a Saturday. You had asked if the filter should be changed while you have the pan off, you should indeed. The fluid is recommend to be changed every 30,000 miles (48300 kilometers).

[@robertford5987]

hey Dan thinking my 2003 might have the stripped splines on the Torque Converter. Driving home when I got into our neighborhood at about 20mph it acted like tranny quit working. let off the Gas and then it started working again but quickly did same thing. I was able to drop it into 2nd gear and make it home. No codes, No flashing lights. Would this indicate Torque Converter? Unfortunately about 1,000 miles ago I had Ford dealer flush the tranny. also noticed at highway speeds prior to this every once in a while it would shudder for about 2 seconds then be fine. wasn't sure if it was the transmission or the road. Pretty sure it was the Transmission causing it now. Before I drop the tranny and replace the TC thought I would check to see if anyone might have idea of simpler fix.

[@serenapark629]

so how is the van running since the repair? I'm having a similar issue with my 2000 Windstar. I had the blinking OD light days before, the check transmission, I smelled burning tranny oil...about 2 days after all this I was driving the van and heard a pop from the tranny and it seemed to go into neutral. I'm a fairly good mechanic doing work by the book (ex-military) and I want to make this repair on my own, I do need to know which bolts I don't remove on the valve body and where I can purchase that support bar. Thanks for any help you can provide

[@amt1298]

The van has been running great since I got it back on the road. I have not had any flashing OD lights and it has been functioning normally. Planning to tow a car with it in a few days to really put it to the test.

[@amt1298]

Manny Perez How is your repair to your van going?

[@joshpatrow5895]

Dan, we recently just started having the same problem with our 2000 ford windstar. The thing is- the overdrive off light and check transmission message only show up when the vehicle is running and you put it into park. The message and light will go away when you shift back into gear and drive. Then when you park again it will come on. Is this the same issue or just a sensor going bad?

[@amt1298]

Josh Patrow This is strange and I do not have an answer for you. My first thought is the position switch on top of the transaxle where the shift cable connects has gone bad and the PCM is probably throwing a code. These are fairly inexpensive ($20) and would be where I would start. If you are good with a multimeter and a wiring diagram, I would check this switch out first.

[@CajunCarpenter]

hey would this cause the fluid to just pour out the bottom as well? mines doing the same thing sorta

[@amt1298]

+Aaron Bertoniere I am afraid not. If transmission fluid is leaking onto the ground then you have a leak. Check your fluid and fluid level before driving. Determine where the leak is coming from and repair immediately.

[@davegregory6622]

thanks Dan, got that part fixed. now it acts like the trans is shuttering at take off. once stopped, it won't engage even revving doesn't help. but if you push the car past a few mph it'll pick up and shifts out fine. so what's going on?

[@amt1298]

+Dave Gregory Shift the transmission into low at a stop and see if it pulls away fine. I am thinking a shift 1-2 shift solenoid.

[@danbrown6002]

Great Video Dan, I have a 2003 Limited Windstar with the same symptoms. Drove it a few miles from home parked it, came out an hour later started right up but nothin wouldn't move in any gear. Towed it to a shop they want mega bucks to replace the tranny with a used or rebuilt. I want to give it a try. Is the shaft still available from Tasca Parts? How will I know if the Tourque Converter also needs to be replaced? I want to get started next week. Is this a suitable engine support? Astro Pneumatic Transverse Engine Support Bar 31"-64" .Any additional tips would be greatly appreciated. Thanks, Dan

[@amt1298]

***** Dan, the parts listed below are still available. Tasca and eBay is were I acquired my parts from. First thing is getting to the side cover of the transaxle and then removing the valve body. Not all of the bolt that you see need to come out to remove it. For example the pump housing cover can stay in place. Once the valve body is removed the pump shaft will be able to come out. Check to see if it is broken but if it is not then put it back in and rotate the shaft to verify the torque converter splines are stripped. If the converter splines are stripped, removal of the transaxle will be required. Do not man handle the transaxle down but use a transmission jack or a floor jack with a wide piece 2x6 or 2x8 to distribute the weight of the transaxle. I also used a piece of foam. The Astro support you mentioned is the same as the one I bought for the job but I went to the hardware store and bought metric bolts and chains to hang the engine from. Also, I bought some coupling nuts for the j-hooks of the support bar to spread the weight of the engine over more threads of the j-hook. You will also need a long 3/8 extension (24") or enough extensions to reach one transaxle bolt that is sort of hidden between the transaxle and the back of the engine (as viewed in the engine compartment). Ford Part Numbers for Pump Shaft Replacement Pump Shaft Bearing = XF2Z-7G184-AA Pump Shaft = E6DZ-7B328-AB Pump Shaft Seals 2 ea = E6DZ-7G092-A Pump Shaft Seals 2ea = E6DZ-7G093-A Valve Body Sleeve = Sonnax PN is 96201-18 go to www.sonnax.com and find a distributor closest to you. (I bought this on eBay)

[@matthewbrown5481]

+Dan Weston Thanks Dan. Just an update I finally got started and was able to get the transmission out on Saturday. Like most of us my torque converter was stripped out. The shaft was not broken and the bearing and sleeve were intact and looked good. I have the new sleeve and bearing I was just going swap the converter and be done but the engine appears to have shifted somewhat from its original location. What do you think about the bearing and sleeve? Do you have any suggestions on repositioning the engine? I’ll try again later this week maybe try 2 floor jacks and a 2X12? Thanks for the good advice.

[@amt1298]

A shift in the location of the engine is not really an issue. Basicly you just want the engine to be supported and not putting strain on wiring, hoses and etcetera. Once you get the transmission back in place with a few bolts then you can start putting the subframe back in to support the engine and transmission. As for the bearing and sleeve, would replace them while making sure the shaft bearing surface is not grooved or worn.

[@matthewbrown5481]

+Dan Weston Hi Dan, I sent a photo of the pump shaft, what do you think? Turns out I need to order a larger bearing. The part number was correct but the actual bearing was smaller than mine. I am hoping to just remove the cover replace the bearing and shaft when they come in as I have the transmission back in place. Also, in the replacement instructions that i have read they mention lining up the flex plate with a certain stud on the converter? Do you know why? Thanks again, Dan

[@danbrown6002]

+Dan Weston Hi Dan, I sent a photo of the pump shaft, what do you think? Turns out I need to order a larger bearing. The part number was correct but the actual bearing was smaller than mine. I am hoping to just remove the cover replace the bearing and shaft when they come in as I have the transmission back in place. Also, in the replacement instructions that i have read they mention lining up the flex plate with a certain stud on the converter? Do you know why? Thanks again, Dan

[@shanerobinson4549]

Thanks for sharing Dan. I've had my 2000 3.8 for about 3 1/2 years and whenever I drive longer than 5 or 10 minutes my OD light flashes. I read somewhere back when I got it that it was probably a speed sensor and that I should get it fix asap because it could lead to costly repairs. I only drive around town a little, I work from home so I've put about 25Kmi on it. 93k when I bought it and I'm at around 120kmi now. Besides an occasional slightly rough feeling shift, there's been no other problems. My past exp. with a number of chrysler minivans (3 of which the trans went out on) is that I've done better when I don't try to intervene (changing fluid/additives etc.). Is this my future here? Transmission tore apart on my floor, seems impossible to get the shaft out from the bottom but I would try none the less. How long did it take your's to finally break? Do you think I can just slip on another collar and prevent the shaft from breaking (maybe 3 years ago huh). Besides being stranded was there any collateral damage done from the break? Knowing what you know now what would you do in my situation? Just to reiterate the cost of a diy repair- $80 for the shaft, then the collar which is what? $10-20 bucks I would guess. Fluid, filter (probably get the pan gasket with the filter), $150 or so and a Saturday and the OD light will not flash anymore and I can put this all behind me? Did your OD light come on right away or after a few minutes of driving? I just noticed on one of my repairs that the cruise control module located beneath the air filter pipe wasn't plugged in (seemed intensional) and looked like it had been that way for a while. I plugged it back in after cleaning the contacts but it didn't change anything or fix the OD light. Just holding out hope that my situation isn't as serious. Sorry for so many questions, again thanks for your time in putting this together for everyone.

[@amt1298]

Shane Robinson Shane, the Ford recommends to change the fluid and filter every 30,000 miles but I cannot say that would have prevented my shaft bearing and pump shaft from failing. Your transaxle does have issues but the two most common failures are the pump shaft failing due to worn support bearing and the torque converter Splines stripping. Most shops will quote a full transmission overhaul but I fixed my van for a couple hundred bucks and some time. It will take longer than a weekend unless you can devote 100% of your time for the repair. I have 5 kids so frequent interruptions were plentiful. As for just replacing the sleeve (collar) will not foot the bill. The core issue is the bearing and Shaft wear. As you can see from the video the machined groove in the pump shaft was created by the failing pump shaft bearing and the only fix for that was replacement. The sleeve (collar) is the sealing surface for the fluid passage that controls the lockup torque converter function and the light is most likely for this performance being low. The pan gasket on the AX4S Transaxle is reusable but the filter might come with a new one. I used the original rubber seal instead of the cork gasket I got and yes, no leaks. So in the end it is up to you, wait till the shaft fails and tow it home or preventatively check or replace the shaft. I drove for about 1 year or so before the shaft failed but the light would only come on after being on the highway for several miles. Hope this helps, Dan.

[@ericreedy5668]

Hi DanWell everything looks good in the transmission, torque converter, pump shaft and chain. The main drive axle also appears to be intact. I forgot to mention that the car tolls in park. Any thoughts?

[@amt1298]

Does the van stall when to come to a stop?

[@amt1298]

Are there any Ford PowerTrain codes?

[@JesterStrike]

Excellent video. My issue is when it's warmed up the van won't go into reverse or Low 1.

[@amt1298]

JesterStrike Are you getting the flashing O/D light? Have you retrieved any transmission codes from the vehicle?

[@JesterStrike]

Dan Weston No flashing OD light. Didn't check for any codes. The van had been sitting for a couple years when the original owner went to move it and discovered no reverse. He put some Lucas oil in there and got it to go into reverse,but not consistently. I bought it and hoping it just needed to be driven. I never say the OD light ever flash or light up unless I pushed in the button. I tried flushing and changing the filter, but it did not help. Nothing out of the ordinary in the pan. The van only has 51,xxx miles on it.

[@danbrown6002]

Hello Dan, Just wanted to let you know that i got it all put back togehter last weekend and it's moving again. I can't say for sure yet that it's 100 % but it shifts and drives. I have experienced a few jerks when it shifts out of the lower gears after stopping at traffic lights but I haven't driven too much yet. I am wondering if you have any suggestions about how to test or make sure all transmission parts that I replaced are working as they should? Is there a way to check it out? My project dragged out over the winter due to a bathroom remodel but it's great to have it out of the garage. Do I need to get it aligned? I only ask because the engine looks a little crooked in the sub-frame very close but not perfect and very close on the passenger side of the van. Thanks for all your help!

[@amt1298]

+Dan Brown It depends on what you replaced. If it was just the shaft, shaft bearing, bearing bushing and shaft seals then by driving you have checked out those parts. As for the alignment, is it pulling? Is the steering wheel straight? As for the engine placement, it is a tight fit and there is probably less than a 1/2 inch of gap on that passenger side.

[@danbrown6002]

Yes, I did replace all those parts. It is not pulling but I do find myself tilting the steering wheel a little more than I remember. If the engine/transmission is off a little would that affect the transmission? I would say that I have about 3/4" to 1/2 " on the passenger side and front to back there might be a 1/4" difference. I am hearing some noise but I am pretty sure it's comming from the front brakes (this weekends project) and the yellow temp warning light is on but I haven't quite figured that out yet. Otherwise, seems promising I don't know if you ran into any of these issues but as always thanks for your advise and help. I know it's comming up on two years now is your van still going strong?

[@amt1298]

+Dan Brown If it is not pulling then the alignment is fine but the sub member is off to one side just a bit. Did you leave the steering rack in the van or removed it with the sub-member? And my van is still truckn'. Just normal maintenance.

[@danbrown6002]

+Dan Weston I Just removed the nuts and bolts from the steering rack and tied it with wire to support it. Update: I replaced the front brakes this weekend but it was still making noise. Turns out that it was just still low on transmission fluid. All together it took about 13 quarts - no more slipping or noises. The "temp light" on was from the coolant sensor - the wires had pulled out from the connector but I was able to repair it. I am excited to have it back on the road! Do you think adding a Magnefine inline filter is a good idea? That's the last thing I am thinking about doing. Otherwise, mission accomplished! Thanks again I learned a lot and it was a worthwhile challenge.

[@amt1298]

+Dan Brown I use the Magnafine filter on my vehicles but be sure not to forget about changing it.

[@amt1298]

+Dan Weston Also, don't forget to change the transmission fluid in your Windstar every 30,000 miles.

[@danbrown6002]

+Dan Weston Do you have any tips for installing the filter? Does it need to be secured to the van somewhere or do you just cut out part of the return hose and clamp it back together? Where did you put yours?

[@bjodaddyo]

Hi Dan. I have a 2001 windstar and I dropped the trans pan to do a filter change and found some needles from a bearing and a small piece of what looks like the bearing cage. Is there any other needle bearings besides the pump shaft bearing? Trans works fine without any problems but I'm thinking this might be the pump shaft bearing coming apart and will attempt to do that repair if you believe there's no other possibility of another bearing. I'm not experienced enough to go any deeper then the pump shaft bearing. Thank You in advance.

[@amt1298]

I seriously doubt these pieces are from the pump shaft bearing. I am thinking you have bearing out in the rotating assembly in the lower part of the transaxle. There are more needle bearings than just the pump shaft bearing.

[@Wayne_M_JR]

Hi Dan. Just had this issue last night on my 2001 Windstar. Driving along highway with cruise on. Tapped the brake and when I tried to accelerate again there was nothing there. Checked the fluid level, on and off, and it did not seem to change levels. So, my question is, can I tell if the shaft is broken or if the torque converter is bad with out tearing something apart? Thanks

[@amt1298]

+Wayne M Sorry Wayne, you will need to take the side pan and valve body off to find out if you have a broken pump shaft or stripped splines in the torque converter. You will need to access it from the driver's wheel well and removed the mount to get the side pan off. Once you remove the correct bolts the valve body can be removed and you can pull the pump shaft out to see if it is broken. If it is not then the torque converter is likely stripped.

[@Wayne_M_JR]

+Dan Weston Thanks Dan. I did end up doing that last night. Shaft was fine. Now to drop the trans out and swap the TC.

[@richardboussatta343]

Very nice video . Thank you. My car is 1995 Windstar. Changed the Torque converter because I thought it was the problem. However, Mine drives fine once its out of first gear. However, when I come to a complete stop (Stop light or stop sign), the van wouldn't move. It goes to neutral. When I rev the engine, in about 2-3 sec, it jerks and get into gear. Do you think I have the same issue as you have described on your video. Appreciate your answer

[@amt1298]

Rich, I am afraid your clutches are worn out. If you want to take on this project, I can recommend a parts supplier for you.

[@justingeraldi2304]

Your forward clutch piston is cracked!!!!!!!

[@grandvalleyfishslayers1279]

How did you get the old pump shaft bearing out? Press?

[@amt1298]

After taking the valve body off I used a properly fitting socket and tapped it out with a hammer. It is not a supper tight Press fit that would require a press.

[@amberclark6668]

Dan Weston we are having the same problem with our 2003 ford windstar I was wondering could you give us a idea of how to go about trying to replace it without pulling the transmission?

[@amt1298]

amber clark The transmission does not need to come out to diagnose or replace a broken pump shaft. Read the posts from Frank Fox and others under this video. I have parts listed, links to diagrams and places I purchased parts. Thank you and let me know if you need additional information.

[@amt1298]

amber clark Are you finding all of the information you need?

[@eddievannewkirk4458]

Hey Dan I have a 2001 Windstar and was driving while speeding up it went into 2nd gear but never went into 3rd. Now it goes inton drive, park, reverse, and neutral just fine but in drive it seems to be stuck in 2nd gear. The over drive light is flashing on the dash. No trans fluid leaking and fluid is full. Any suggestions the vehicle has 185,000 on it and i dont believe the transmission has ever been rebuilt at least not to my knowledge. Any thoughts? Is it most likely going to need a transmission rebuild? Thanks for your help.

[@amt1298]

Eddie VanNewkirk Firstly, I would get the powertrain transmission codes from the PCM. My guess is you have a shift solenoid stuck open. These can be access from the side cover in the Drivers Wheel Well. Not the easiest of jobs but it can be done.

[@brownbear041]

hey about to purchase saturday a 2003 or 2005 ford windstar at dealership near me should I ask them when the pump shaft was last replaced

[@amt1298]

+Bruce Brown Sorry about the late reply. I have been terribly busy at work. But yes I would ask if the pump shaft and bearing were replaced. Also ask if the transmission was serviced every 30,000 miles per Fords Maintenance recommendations.

[@brownbear041]

OK THANKS

[@frankfox6328]

ive got a 99 windstar that is doing the same thing. after about 15 to 20 min of highway driving the OD light blinks on and off and it says check tranny. was it ur torque converter that was bad also or just the pump shaft? i would just like to kno the parts u replaced bc i just got the van for my wife and i do not want to shell out 1500 for a rebuild when i can do it myself. also about how long did it take u? i kno u took it out but im gonna try to see if i can leave it in to save a little time.

[@amt1298]

I originally thought the torque converter had bad splines for the pump and is why i took the transmission out. After I got the torque converter off I needed to remove the pump shaft from the transmission in order to check and found the broken pump shaft instead. I would recommend taking it to someone who can pull codes out of the ECU for you as this will help direct you in your repairs. I replaced the pump shaft, pump shaft bearing, shaft nylon seals and the valve body bushing.

[@frankfox6328]

As for getting the codes I'll have to have someone do that but I've been doing all my own work on cars since I was young, learned from my father and brother. I've got the tools, jacks and stands. Just wanted to make sure that yours was doing the same things as mine is. It's real common for the shafts to do that, or so I've heard from multiple ppl. I Appreciate the video. When I replace mine I'll upload it as well.

[@amt1298]

I purchased online an engine support bar that worked very well and cost about $70 shipped to my door. Hope all goes well and I look forward to your video.

[@hectorestrada5751]

Was your original code p0741 with the over drive light turning on and off ? What where the part #s . Thanks for the help.

[@amt1298]

Sorry for the late reply but yes, that was the code. The part numbers are below in the comments. I will try and update the video with links and additional information to make it easier to find the information you and so many others are looking for.

[@forestspinner9711]

Do they make a permant fix to the torque converter in these so this issue doesn't keep happening?

[@amt1298]

My issue was not a torque converter issue but a pump shaft seal and bearing issue.

[@ericreedy5668]

Hi DanMy 2000 Windstar made a loud pop/bang noise, lost power in the transmission and now only grinds when trying to engage or disengage the transmission. Do you think that it is the pump shaft?

[@amt1298]

+Eric Reedy I am afraid not. There is something else going on and I have a hunch the chain has broken. This repair will require the Transaxle to be removed and probably a donor transmission depending on how much damage was done to the transmission case. If you want to repair or replace the transmission yourself, it can be done but look at what you are able to spend and decide on a remain or salvage transmission.

[@chadboling6075]

hey Dan, When your van transmission starting acting up did you have any forward gears at all? My 2003 ford Taurus has 1st and 2nd but then acts like it goes into neutral. Plus mine will go in reverse. Please let me know what your experience was with your tranny.

[@amt1298]

I had no issues with the fwd or rev gears but got the flashing "O/D" Light. Then one day the van just seamed to go into neutral on the Interstate.

[@donaldrichardson52]

I have an 03 windstar and the od light was blinking off and when I let off the gas it just revs down and stops the van and it has to rev up high before it will move....and the reverse doesn't work at all...is this the same problem u had the transmission shop said it needs a rebuild but I can't afford it so I found a used one for 450 bit I would rayher fix mine because it still has low miles on it

[@amt1298]

Does the van rev high when in Low? Did you take the van to a shop to pull codes or use a coder reader? How many miles and what kind of miles are they? Has the transmission fluid been changed every 30,000 miles? Thank you for posting. Dan

[@danielarey6304]

can I get to the pump shaft from taking off the pan without having to take the whole transmission out? my van would / overdrive off and onand then I tried to leave the store and it wouldn't even go in to a gear. do you think it could be the same problem ?

[@amt1298]

If your van is acting like it is in neutral all the time then yes you probably have the same problem has I had. The good news is is that you can check to see if the pump shaft is broken though having to take the transmission out of the vehicle. What you will need to do is gain access to the site cover of the transmission is seen through the drivers wheel well. The transmission stabilizer mount assembly will be in the way of getting the side pan off but once you have it off you be able to see the pump. Take the cover off and see of the pump rotor turns. If it does then it is one of two things; pump shaft is broken or the splines in the torque converter are stripped.

[@nicoleolson1347]

Dan Weston Hey. First off thank you for your VERY informational video. My van: 2001 Windstar 3.8L. I've had the "flashing over/drive" which was soon followed by "no-gears". It all seems like neutral. I watched your video to get an idea of what I'd be working on, because $1700 replacement is out of the question for us. I've taken the outer-most parts off to reveal the end of the pump shaft(nearest to the pump). I cannot spin this shaft. MY QUESTION: Should I continue to remove the entire transmission and see if the torque converter is stripped on the inside? Is it possible that the torque converter is stripped, but still holding on enough to where the pump shaft cant be turned? Any other ideas to what it may be. All the shifter linkeages are in working order. Thank you for taking the time to read this, I look forward to your educated respone. -Ryan

[@amt1298]

Nicole Olson I would take a couple of pictures and send them to [e-mail]. I would go ahead and remove the valve body in order to remove the pump shaft This will give you a better idea of where to go from here.

[@terryiverson8355]

Was fluid pouring out? My daughters van I just brought to the shop and it pours out as fast as we put it in once you start the engine. I was thinking torque converter but not sure. It is pouring out by where you said the pump was. I have it on the lift but have not done anything yet.

[@amt1298]

There was no fluid leaking from the transmission. I bet yours is a leaking transmission cooler hose.

[@Jeffcatbuckeye]

I don't have a Windstar, but I have a 2000 Taurus with the AX4S tranny and it has symptoms of accelerating fine up until about 25mph, when it's supposed to shift from 1st to 2nd. At that point, it just falls into neutral and does nothing at that shift point. DId your tranny make any other noises from the broken shaft or anything, because mine doesn't. I know it could be multiple things like the Vehicle Speed Sensor, shift solenoid, and multiple other things like this pump shaft, so I'm trying to get a better idea what's worth while before just tossing money at it.

[@amt1298]

My transaxle did not make any noise but that is not the problem you are having. Is your O/D Off light blinking? Have you pulled codes? I would guess that our 1-2 Shift solenoid has gone bad. These can be checked from the plug on top of the transaxle.

[@stephaniejackson1167]

hi,my windstar will drive fine,just will not go into overdrive unless you give more rpm than it should,what problem do you think i have,thanks

[@amt1298]

Stephanie Jackson Are you getting the flashing overdrive light?

[@amt1298]

Stephanie Jackson My first thought is the #3 shift solenoid is going bad but resistance checking of the solenoid would need to be performed to verify this. If you have a multi-meter and some tools you could do this yourself.

[@anulloarev]

Good afternoon. I have a 2005 ford freestar transmission problem. Sometimes when drive the van it gets kind of stuck in the first gearvit hesitates to shift but when I let the gas pedal go it shifts with no problem to the other up gears. what do you think can be causing this problem or what are the steps to approach thsi problem. My last experience with a transmission place in a other van was that i need it a new transmission when in reality all i needed was a sensor. thanks for time

[@amt1298]

+alejandro ulloa I do believe you are having a similar problem. Let me check my sources and see what the most likely issue might be.

[@amt1298]

+Dan Weston There is a plug on top of the Transaxle, disconnect and check the resistance of the Shift Solenoids. Refer to this link: drive.google.com/file/d/0BzpVC0nsNqDpWjRHVS1raXl3Mkk/view?usp=sharing.

[@1percenterRebel]

Hello Dan, I've got kinda the same thing going on on my Fiance's 02 Windstar I think, it has 180,000 miles on it but she said it had started slipping for a minute then after her calling me Zi had her check the fluid and it was a couple quarts low but after her limping it on home and me looking it over the OD light flashes and it won't upshift from 1st gear and feels like its in neutral after lifting off the throttle, although when manually putting it into 1st gear it does have deceleration pull when lifting off the throttle, being unfortunately educated on this situation does it sound to you like this shaft could be our problem also?

[@amt1298]

+1percenterRebel In my opinion the transmission needs to be rebuilt or replaced with a Remanufactured Unit. Since the transmission was low on fluid and slipping. The fact that you still have first says the pump shaft in still turning the pump.

[@Adam19832]

Good job! Did you have any shifting symptoms before it failed?

[@amt1298]

Just the flashing OD light.....then it stopped going in gear at all.

[@Adam19832]

@@amt1298 I had same symptoms as you but mine get stuck in second gear for wile before shifting to other gear my CEL shows Output Sensor Transmission was bad I changed it and now the problem is fix. The only thing I have is a very very slight jerks between 3rd and 4th gear at 80km/h , would you know what could be? Thank you

[@twllmscttn1]

my 1999 ford windstar has 74,000 miles. It recently started to have an occasional 2-3 (?) flare & OD flashing at 65 mph or greater (no OD flashing under 65 mph). Do you think I have the shaft or converter problem or do I need to change the fluid and filter (since this may have not been performed in the past)?

[@amt1298]

I would change the fluid and filter as it should be done every 30,000 miles per Ford. The flare of the 2-3 could be a failing 2-3 Shift solenoid. A resistance check of these can be performed from the plug on top of the transaxle.

[@ricks.8522]

Great video, Dan ... on my Windstar ( same exact transmission ) it works fine. Fluid is clean. But lately when I start-up first thing in the morning my transmission acts like it has no fluid pressure, thus when you go to put it into gear nothing happens. However, by waiting only about 4 or 5 seconds the pressure does come up and then everything works fine ... no shifting problems ... no weird sounds ... goes into each gear quickly .... no lag ... no clunking ... no hard shifts ... and no slipping. No check engine light, either. Fluid level is correct ( and has correct fluid ). It is only if the car sits for say about 12 hours that I have this issue ...... Dan ... what do you think? Is there an "o" ring I could easily replace to solve the problem ... or something like that? Maybe a solenoid someplace ... or .....??? It's gotta be something pretty simple ... seems like. I really hope I might hear back from you ..... really, really appreciate ... and thanks again for the great video.

[@amt1298]

+Rick S. When was the transmission last serviced and how many miles are on it?

[@ricks.8522]

+Dan Weston Hi ... actually the trans had been rebuilt about 4 years ago ... probably has about 20,000 miles on the rebuild. Total milage on the car is 135,000 miles. Trans was rebuilt due to bad slipping in 2nd and 3rd gears. It was my Dad's car ... he no longer drives ... these days I do the driving for him and my driving style is rather conservative; no hard stops or fast take-off from a stop .... not much highway driving either. The fluid is pink and does not stink ..... and like I say, I do not drive it hard .....

[@amt1298]

+Rick S. I would drop the pan and change the filter. This should be done every 30,000 miles and if that does not fix the problem. You most likely have and issue with a seal. Last ditch effort would be to use a transmission seal conditioner. I would hope they replaced these seal when the unit was rebuilt. Also, adding High Mileage ATF will add a conditioner lubricant package to the transaxle to help the seals.

[@ricks.8522]

Hey Dan ... thanks .. appreciate. Yeah ... I had the same idea ... the fluid in my trans really looks / smells good; however I know it is not a synthetic fluid. I have been thinking about doing a total flush / filter and using Schaeffer AllTrans fluid in it just for the heck of it ... see what happens. This Windstar is so old ... I think I can afford to experiment a little and see what happens. I have read that this Schaeffer fluid is pretty darn good .... I got the idea from Monster Transmission out in Florida

[@amt1298]

Let me know how it goes.

[@christophergentry8929]

I just bought a 2002 Windstar SE for my family of 8... Times have been hard, and I got the van for only $500 from a friend. When driving after about 10-15 the O/D light comes on and the Check Transmission message pops up. Other than the lights, it seems to shift ok. There is also an emissions system warning light, a tire pressure light and the gauges seem to act all crazy sometimes.... I'm hoping it's just the pump shaft because I can't afford to throw $1500 in it.... Is your Van still doing well?

[@amt1298]

It sounds like you have multiple problems but for the transmission, sounds like you are on the beginning stages of shaft failure. You have some time before it fails but when it does it will leave you stranded.

[@christophergentry8929]

+Dan Weston so I got the transmission part and removed the pump shaft... It definitely has some wear on it and appears to be what the problem is... The shaft didn't come with the little nylon pressure seals so now I gotta order them. My question today is about the valve body sleeve... Do I need that? Did you find a part number?

[@amt1298]

Christopher GentryChris, I would definitely replace the valve Body Sleeve (bushing). I used a threaded rod, coupling nuts, fender washers and sockets to press the sleeve out and in. I also went a step further and put the sleeve in the freezer overnight. Ford Part Numbers for Pump Shaft Replacement Pump Shaft Bearing = XF2Z-7G184-AA Pump Shaft = E6DZ-7B328-AB Pump Shaft Seals 2 ea = E6DZ-7G092-A Pump Shaft Seals 2ea = E6DZ-7G093-A Valve Body Sleeve = Sonnax PN is 96201-18 go to www.sonnax.com and find a distributor closest to you.

[@jefferycorbin9176]

@@amt1298 I am having some of the same problem LK 2004 freestar minivan drove to work one mornin started after work no reverse dash gauges doing crazy I can't figure out what's wrong with it

[@MsDjodi]

The other question - are the parts interchangeable in newer models. if the 1996 part is obsolete, could we use a later model. Do you know?

[@amt1298]

Djodi Deutsch Refer to my reply in our other post for details.

[@richbunting169]

can you replace the pump shaft without removing the transmission?

[@amt1298]

I think it is possible. I did not take the time to try removing the new pump shaft I had installed when the transmission was out. You will need to support the engine and transmission with a support bar or hoist because you will need to removed the sub frame from the vehicle in order to make clearance to remove the side pan from the transmission. After the clearance is made to remove the side pan, it is a simple procedure to replace the pump shaft. Remove bolts from the valve body and remove, the pump will stay in the valve body. Note, there are some bolt you need to leave in. There are PDFs available on the web to aid in the removal process and identify which bolts to leave.

[@amt1298]

Rich Bunting Another comment-er has confirmed that the pump shaft can be replaced without removing the transmission. Hope your repairs are or did go smoothly.

[@TheLeosk2003]

hello dan im having a problem with 2002 windstar the over drive light is blinking can it be a bad range sensor or would that be the best place to start ?????

[@amt1298]

The best place to start is to pull codes from the PCM and a generic code reader will not due. This will lead you in the right direction.

[@lar4305]

Dan , before it quit, did it make a whining noise that go got loader as the engine rpm went up? My wife's 07 freestar did the same thing as yours.

[@amt1298]

I was not in the Windstar when it happened but she was on the I-70 when it just felt like it went into neutral. When I got there I tried all the gears and had nothing. I had AAA tow it home so I could get to work on it. The Freestar was the short lived renamed version of the Windstar. It sounds like you have a similar situation and the transmission has not changed in basic design. This should be the latest version of the AX4S and AX4N, the 4F50N.

[@lar4305]

Thanks Dan.

[@513mark]

I have a 1999 Ford Windstar I was driving yesterday truck off at the light and it made a loud pop and wouldn't go nowhere the van will go in reverse fine and if you roll the van till about 25 miles an hour it will catch and go do you think that could be the same as you you had

[@amt1298]

I am afraid not. Sounds like something let go in your transmission.

[@justingeraldi2304]

Mark Johnson listen to me,,sounds like you either broke the low/intermediate band and or the low/intermediate sungear drum weld broken,,,if you unplug the trans electrical pass through connector the white one,,the trans will default to 3rd gear and you can drive it around.. reverse will work too by the way

[@justin83101]

hi dan, my question is that my 2002 van is having kinda that same thing.. i start it with out problems..i can put it into drive and revers, and it works ok in first gear..but when it goes to 2 gear it dos nothing, like its in neutral. but if i down shift to drive 2 or drive 1..i can drive it. the o/d light is flashing and the check engine light is on. do i have the same problem as you do... i asked a friend that works on cars and he told me i would need a whole new transmission, which would be 2500.00 or so.. any help would be great thank you

[@amt1298]

george poulin I do not think you need a whole new transmission and depending on where you live a Re-manufactured Transmission from Moveras would cost less than that. In my opinion you have a solenoid that has gone bad and can be replaced through the driver side wheel well under the side pan of the transmission. I would recommend getting codes from the vehicle first and starting there. You will need to take it some where to read the powertrain codes if you do not have a high dollar scantool. Also, you may have multiple problems since you have a Flashing O/D Light and a Check Engine Light. Hope this gives you a good place to start and sorry for taking so long to respond.

[@lammyde2566]

Dan Weston Hi Dan. I seem to have a similar problem on my ford windstar 2002. I was on the highyway when i found the o/d flashing and message on my dashboard which says 'check transmission'. The is still moving but just want to see what could be done to fix the problem before it stops on me who knows maybe on the highway. Also being a lady,i really dont know the parts of a car so well and can afford the prices an being charged to repair it. What are the steps i need to take. Am willing to learn as i cant afford the prices am getting. Thanks

[@amandabunac8245]

Hey Dan, I'm getting p0743 and p0755 error codes, the van will jerk sometimes and act like slipping. Thoughts?

[@amt1298]

Amanda Bunac The first code you have is electrical. The P0743 is "Torque Converter Clutch System Electrical" but the P0755 is "Shift Solenoid B Malfunction" is most likely a bad Solenoid. Firstly, I would disconnect the large plug on top of the transaxle and use electric parts cleaner to clean the plug and socket. Then reconnect and see if that fixes the issue. The solenoid could be faulty and can be replaced by removing the side pan of the transaxle. Hope this helps and let me know the out come of your repair and feel free to ask questions.

[@jamescudaback732]

my 2000 Ford Windstar van its shifting fine its just when I go to take off its like in neutral then pops into gear and its making a noise when I start it what could it be?

[@whitneeclary1576]

Did you have to replace any of the seals? I have the same problem with my 2000 Windstar except no lights.

[@amt1298]

The transmission is fitted with reusable rubber gaskets on the lower and side pan. The seals I replaced were the nylon split rings on the pump shaft itself due to wear and the new pump shaft bearing has an internal seal, ensure you install it correctly. I also needed to replace other items. Hope this helps and feel free to ask more questions.

[@whitneeclary1576]

What other items did you have to replace? I am mechanically ignorant. I have a friend who is doing the job I just have to purchase all the parts. So I am trying to get everything together now to get the job done as quickly as possible.

[@anitahemphill3670]

Hi my name is Anita.And I have a 2005 Ford Freestar van and my van did the same thing that you van did while I was driving it just stop pulling.I need to know if you have the part number for the parts that you replaced?

[@tteuvky]

Part Number: 86671 also watch this video: kzbin.info/www/bejne/iJSoZpl-j96haK8

[@daxcastro]

Do you happen to have the part numbers you ordered. Having trouble finding the right parts.

[@amt1298]

Dax Castro Here are the Part numbers. My appologies for taking so long, I have just been busy lately. Thanks for posting and let me know how your repair goes. Ford Part Numbers for Pump Shaft Replacement Pump Shaft Bearing = XF2Z-7G184-AA Pump Shaft = E6DZ-7B328-AB Pump Shaft Seals 2 ea = E6DZ-7G092-A Pump Shaft Seals 2ea = E6DZ-7G093-A Valve Body Sleeve = Sonnax PN is 96201-18 go to www.sonnax.com and find a distributor closest to you.

[@davegregory6622]

Just got our 2000 ford Taurus S.E. flexfuel. the gear shift selector will not shift into reverse or park. can't take the key out. what do I need to do????

[@amt1298]

+Dave Gregory Sound like the brake interlock solenoid failed. There should be a cover at the Shifter Quadrant to move the interlock. Your Owners Manual will have information on this.

[@richardroldan9634]

Do you have a video on how to change it out step by step

[@amt1298]

I do not but send me a Meet invite to [e-mail] and I will be happy to discuss this process with you.

[@superdave3558]

Hi I too have a Windstar only mine s a 98 3.0 v6 and like you my van was working fine then my wife was in the way home from shopping stop at a stop sign and it was as if it was stuck in neutral and iv been told a few different possible reason for this the tourqu converter ,the silinoed pack , and the pump is there any way to see if it is the pump for sure with our have to tear into it limited on space to work on it so if I can find problem and fix it fast would be sweet . Any help is better then no help

[@amt1298]

Well Super Dave, I would recommend removing the side pan of the transmission. This will require you to support the engine and transmission because the subframe will need to be lowered some in order to remove the side transmission mount. This is seen from the driver's wheel well. This is how you would go about determining if the pump shaft is broken like mine was. If the bearing and shaft are fine then the transmission will need to be removed to the torque converter can be replaced due to worn splines in the torque converter.

[@genarogarcia6719]

hy i just saw ur video and had a couple of questions i have a 99 ford windstar my problem with my transmission is that it starts working fine but the third gear i belive it doesnt kick in and sometimes it does and when it starts getting hot the over drive light starts flashing. do u thing it might be the same problem shes been working like this for almost two years already and havent fix it thinking well just let the transmission give up but its still working and havent change a bit. do u think it might also be that same part that u change on urs that its bad on mine? hope u understand what i wrote and hope u can help out thank you

[@amt1298]

Sounds like you might have multiple problems. The 3rd gear issue is probably a solenoid. To a resistance check of all the solenoids at the plug on top of the transmission. Search the comments for more information. As for the flashing O/D light, that is what mine was doing for about a year or so whenever it got driven on the highway. If you know someone that has a professional scantool, they can pull out codes pertaining to the transmission or you will need to take it to a shop to pull out the codes. What you are looking for is the TCC performance low. This pertains to the lockup torque converter. Thanks for posting.

[@olowoyeyelawrenvelawrenceo4910]

pls,l need to buy compete engine and gear of Windstar limited, how murch

[@Biggman1611]

I have a 1998 Windstar with around 180K miles About 8 months ago I pulled up to a crossroads and it just dropped out of gear, like it was in neutral. I put it in park and then back to drive and it seemed to work fine and hasn't missed a lick until yesterday when the same thing happened. This time I tried shifting through the gears in addition to putting it in park and then back in drive, still no cigar. Then I put it in park and back in drive and it worked fine again and has been fine since.....I've driven probably 50 miles since then. Any ideas? Your input would surely be appreciated. Thank You much.

[@amt1298]

Biggman1611 Interesting. I will need to do some research and think about your issue. I will respond back as soon as I can.

[@Biggman1611]

Dan Weston Thank you Dan.......I do appreciate your thoughts on this.

[@amt1298]

Biggman1611 Are you getting a flashing "OD OFF" light? Are there any powertrain codes? You have not mentioned any other problems like slipping or erratic shifting. Before you start taking the transmission apart I would barrow a good scantool to read any powertrain codes stored in the PCM. A cheap code reader will not get the job done. If you decide dive into the transmission, I would recommend checking the Transmission Range Sensor on top of the transmission first. You move this sensor every time you move the shift lever. Make sure the connector is not corroded or dirty. Check the sensor for proper operation with a multimeter or spend the $20 to replace it. If it is faulty, the computer might think you are in park instead of in drive and there would not be a flashing "OD Off" light or a Powertrain Code. On another note, have you been performing the recommended 30,000 mile transmission filter and fluid changes? The filter and fluid change is difficult but a little more time consuming and more of a mess that an oil change. I have devised ways to limit the mess.

[@crystaljones9642]

Hi Dan I have a 2001 windstar lx and my o/d light is blinking and my engine light is on and when I put it in drive it kicks in gear. The people said it is because my transmission is getting over heated a P1783 and then they said it really could be the transmission sensor is not working and that's a P0172 . what do you think please let me know they are going to try and fix it tomorrow they said also I need a transmission filter and gauge replaced also. It will all cost they said almost $300 or maybe more. Please let me know what you think ??????

[@amt1298]

I would honestly start by cleaning the electrical connector on the top of the transmission with Electrical Contact Cleaner and compressed air. If you have not been changing the transmission filter and fluid every 30,000 miles, I would do that as well. "THIS IS A MERCRON V TRANSMISSION FLUID ONLY." Is the cooling system clean? Is the engine getting hot? Are the cooling fans operating properly? The P1783 and P0172 are not related. They are two different issues. The P0172 code is a fuel mixture code. Are you having poor gas milage? I assume you are not having hesitation issues since you are not getting any misfire codes. Have the O2 sensors ever been replaced?

[@leboon3843]

How many bolts did you need to remove to drop the undercarriage? How did you secure the engine to the support?

[@amt1298]

There are 4 bolts that hold the engine subframe in the van. I used an engine support bar and chains bolted to the ends of the heads. Removed the alternator support bracket in the front left and the ignition block on the back right.

[@jefffuehr366]

i have a 2006 Pontiac Grand Prix GT supercharged 3800 engine with 60,000 miles on it. and the other day may transmission stopped shifting into 2nd, 3rd, unless i let up on the gas pedal. and it won't go into overdrive at all. so what do you suppose the problem is?

[@amt1298]

I am not a GM guy but I have been doing some research when I can. Hang in there and if you already have solution to the issue, let us know. Thanks

[@dumpgodby1874]

I like this video. I got same problem did you have any other issues with the transmission after you got it back together sir. And what parts did you replace..

[@amt1298]

I have not had any other transmission issues. I only changed the Pump Shaft and the Bearing in the valve body.

[@frankfox6328]

i have a question? u say the overdrive light was blinking on and off and it said check transmission right?

[@amt1298]

Correct.

[@frankfox6328]

Dan Weston ive got a 99 windstar that is doing the same thing. after about 15 to 20 min of highway driving the OD light blinks on and off and it says check tranny. was it ur torque converter that was bad also or just the pump shaft? i would just like to kno the parts u replaced bc i just got the van for my wife and i do not want to shell out 1500 for a rebuild when i can do it myself. also about how long did it take u? i kno u took it out but im gonna try to see if i can leave it in to save a little time.

[@ghostryder0079]

My 2000 Ford Windstar will go in reverse but won't go forward. Can you tell me if a linkage broke???

[@amt1298]

My apologies for the late reply but to answer your question, it is not a linkage issue but a transmission issue. I will research to see if there are any specific failures that are tied to your description.

[@amt1298]

If there were not other issues with the transmission prior to this failure, my opinion would be a problem in the Valve Body. More specifically the forward clutch control valve may have a broken retaining clip.

[@garyjenkins6629]

Some people say never change fluid and filter in an old transmission. What are your thoughts?

[@amt1298]

Well I disagree. The Ford manual for my Windstar states to change the transmission fluid every 30,000 miles. Other than this design flaw which caused this pump shaft failure, I have not had any problems with my transmission. I have an upgraded bearing and seal set where this old shaft failed. I have almost 185,000 on my wife’s Windstar. I would say this, perform maintenance and recommend by the manufacturer and ensure you use the fluid recommended.

[@garyjenkins6629]

@@amt1298 mine has 286,000. I changed mine several times over the years.

[@amt1298]

It also depends if you are currently experiencing shifting issues and how long the problem as been going.

[@ZemTours1]

my 2000 automatic windstar o/d light come on when going up hill and check transmission, is this the same problem, and some times 4th gear does not select

[@amt1298]

ZemTours1 My apologies for taking so long to respond to your post. Let's make sure we are talking about the same thing. It does not want to go into Overdrive or you don't feel that the torque converter is going into lockup?

[@CurlyQLink]

How difficult was it to drop your Windstar's subframe? Did you run into any issues dropping the subframe?

[@amt1298]

It was not too bad. I removed the two large nuts holding the power steering rack and supported it with rope. I also used PB Blaster on the sub-frame blind nuts. I live I the rust area and the front bolts proved to be challenging. With some help I was able to hold the blind nuts with a pry bar while the bolts were removed. I also used straps to hold the subframe while the bolts were removed. When I was ready to man handle the frame out, I had help remove the straps.

[@fabianfrenchman5842]

Hello dan i have 1993 ford taurus when i put in to gear it jerks at first than its ok than when i put in park why is that

[@Molinajme]

i have 99 windstar se i was driving 55 mph one day and out of no ware my transmisdmsion went from o/d to 1st and shudderd bad since then i been having 2 to 3rd flare ups and my transmission barely moves and shakes in D and in second gear it moves more forward in drive but i feel ike its trying to grab. reverse is ok! is it possible that torque converter is gone, o hear a whineing sound when dribe is ungaged

[@ritamesser3803]

Jaime let me known what you do to get it fix , am having the same problem

[@josephbohme7917]

how long to take the trans out put in main seal and reinstall. + My idiot factor

[@anthonyyoung3341]

My transmission is slipping sometimes do you think that is the pump shaft????? Help please

[@amt1298]

Anthony Young Probably not. Two questions...has the transmission fluid been changed every 30,000 miles and is the transmission fluid dark or smell burnt? If so then the friction packs and bands are probably worn out. How many miles are on the van and what kind of miles are they, hwy or city driving?

[@jeremymatha946]

Wat kind of transmission was in your 04 windstar I have an 03 windstar with same problems

[@amt1298]

Jeremy Matha I actually have a 2000 Windstar and it has an AX4S transaxle Your 2003 Windstar has a AX4N (4F50N) transaxle but the problem, replacement parts and repair remain the same at it pertains to the hydraulic pump.

[@laccanvas]

our 2000 windstar van only moves in reverse...no leaks and trans fluid is good, no smoke etc. made some very quiet grinding sounds a few times then stopped, then it stopped going mid drive, but we can back up fine. When you start it up everything sounds normal...if we could only get it to drive forward.

[@amt1298]

Since your van only moves in reverse then it is not the pump shaft but something else. I will look into it and let you know.

[@laccanvas]

thanks!

[@jonathanhurtado9279]

Where did.you purchase those parts and what are they called apparently autozone doesn't carry them

[@amt1298]

Jonathan Hurtado Sorry for the late reply. I purchased my parts thru www.tascaparts.com, www.sonnax.com, www.ebay.com and other transmission parts suppliers. I will try to locate my information but in the meantime, look through the postings on this video as may part numbers and suppliers have been mentioned. Thank you.

[@asalasch]

very good video man

[@mzsassy21223]

So I have the same car!!! My car only goes in reverse!!! Can I replace this without taking the trans out

[@amt1298]

I am afraid you are having a different issue. I will see what information I can send your way.

[@dougjstl1]

Nieemah Peterson sounds like you have a different problem you may want to ask somebody who knows a little bit more about it can look at it first hand