I thought about putting this in the Blow-Off Valve, but I'm not really blowing off any steam on this one. Rather, it's general documentation of the on-going saga called "Katie" - aka my 04 FX4 Level II. I just dropped the truck off for the 5th time regarding a transmission leak between the rear main transmission housing and the extension housing. Leak is along the seal. (Photos will be in a reply post).

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R. O. DATE: 10/20/05
INVOICE DATE: 10/27/05
MILEAGE: 19,949

ISSUE: Thursday Oct 20, 2005 I get into my truck to go to work in the morning. I go to throw the clutch so that I can start truck and can't engage clutch. Clutch is stiff as can be.

Job #1: Wont move in gear
- Customer states clutch inop. Won't move into gear, check and advise
- Confirmed concern found slave cylinder leaking. R&R transmis. Installed new slave cylinder and master cylinder. Still slip R&R trans. Installed new pressure plate. Normal operation at this time.

Job #2: Noise/rattles/ squeak
- customer state rattle in front hub. Check and advise
- not confirmed (verbally stated, not on invoice)

Job #3: Perform QCM Insp.
- completed QCM inspection report card

Job #4: Sublet
-customer req enterprise rental 10/26. Auth 1 day
-sublet complete

Personal note: vehicle tower to Borman Autoplex dealership through Ford roadside assistance. All work done under warranty.

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R. O. DATE: 02/06/06
INVOICE DATE: 02/09/06
MILEAGE: 24,397

ISSUE: Having transmission problems and loud squeal from fan belt area.

Job #1: Perform QCM Insp

Job #2: Signal/flasher/lamps
- Customer state signal lights intermitantly will not work, check & advise
- Could not confirm normal: op noted

Job #3: Wont move in gear
- Customer states will not go into 2nd and 4th gear and sometimes 3rd will shoot out of gear. Check & advise (Personal note: 2nd and 4th became difficult to get into gear with clutch pedal fully depressed, I'd have to gently force it into gear)
- Could not confirm road test normal

Job #4: Other trans concerns
- Customer requests check transmission due to possible problems with previous work
- Normal op noted

Job #5: noise/moving
- Customer states squealing noise at start up, check & advise
- Could not confirm at this time

Job #6: Other driveability
-Customer states high idle, RPMS stick at 2000-3000 when vehicle has been driven 1-2 miles, check & advise
-no response on invoice, verbally told not confirmed

Job #7:
- Customer states pulls to right, check & advise
- confirm concern needs camber kit...on order
- customer need to reschedule and will owe 1 hours (80.00)

Job #8: sublet
- customer request enterprise rental
- sublet complete

Job #9: brake pad inspection
- Customer req brake inspection
-inspection brakes ok rear 5mm front 6mm

Job #10: rotate tires
-customer req rotate tires
-did not rotate tires customer need to call back (I don't remember why they didn't rotate)

Job #11: QC
-perform quality control insp and/or test drive
-completed QC

Billed: 82.45 (labor), 75.36 (parts), 7.89 (misc chg), 11.60 (tax) = $177.30 total. I was billed for Job #7 and Job #9.

 

R. O. DATE: 03/20/06
INVOICE DATE: 03/20/06
MILEAGE: 25,542

ISSUES: Installed camber kit (it took them this long to get the kit, which they lost in the parts dept, which is why it took so long to get kit), squeal still coming from fan belt area at start-up in mornings, slow tire leak

Job #1: Wheels/tires
- customer req install camber kit
- inst camber kit and asligned as needed

Job #2: noise/rattle/squeak
-customer states squeaking noise at start up. suspects surpentine (serpentine) belt, check & advis, while driving.
- could not confirm concern started repeatedly no noise heard

Job #3: Perform QCM insp
-perform multipoint qcm insp report card
- completed qcm insp report card

Job #4: tires replacement
- customer states LF tire has slow leak, check & advise (I looked over tire and never found the screw they found)
-confirmed concern repaired leak due to nail puncture

Billed: 92.95 (labor), 6.51 (tax) = 99.46. Billed for Job #1 and Job #4

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R. O. DATE: 05/25/06
INVOICE DATE: 06/12/06
MILEAGE: 29,906

ISSUE & NOTE: Tranny leak - initial discovery. Switched Service Dept Advisors

Job #1: Auto transmission (auto??????)
- customer states rear seal on trans leaking, check & advise
-run black light oil leak test. Sealer skipped between M5OD trans case & ext HSNG. R&R trans & transfer case. Mount on bench fixture. Disassemble ext hsng from case & reseal. Roadtest. No leaks found

Job #2: Perform QCM

Job #3 Gone-vehicle
-vehicle has been released to customer...waiting for parts

NOTE: everything warrantied - The next invoices get REALLY good.

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R. O. DATE: 06/27/06
INVOICE DATE: 06/30/06
MILEAGE: 33,639

ISSUE: tranny leak #2, the serpentine belt squeak has returned (never actually went away just became intermitent in it's occurrance).

Job #1: Safety checks & insp
- customer states: there is a leak at top of shifter. Confirm by Henry S. Trans shifter housing leaking
- RR trans reseal shifter housing cover complete

Job #2: Steering
- customer states: front suspension feels a little loose some noise noted, ck and advise (control arm ? ball joint)
- Upper ball joints loose out of specs, replace both upper ball joints align frt end to specs
- attached align specs to RO

Job #3: 30,000 mile service

Job #4: Noise/rattle/squeak
- cust states: on first start there is a squealing noise noted from pulleys / ck and advise on idler and tensioner
- belt tensioner out of range causing excessive scuffing to idler pulley
- replaced belt tensioner and idler pulley, belt looks ok

Job #5: Gone - vehicle
- vehicle has been released to customer...waiting for parts...

Billed:
- for 30K mile service 65.06 total
- everything else warranty

Personal note: I specified for this check (see job #4) after reading on here, RPS, and ORR about the tensioner pulley squeal! AND had been requesting it and the idler pulleys be inspected since I first got the noise! Original service advisor refused to inspect and just listened for noise. I was also told by new (current advisor for this invoice) that she was going to warranty the tensioner and idler pulleys, but only because I had a documented known issue and to not mention that she had this job warrantied.

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3 more invoices to go!

 

R. O. DATE: 07/12/06
INVOICE DATE: 07/14/06
MILEAGE: 35,384

ISSUE: Trans leak #3 - woohoo!, pinging from engine (thanks to rwenzing on this one - noted TSB on PCM reflash)

Job #1: manual transmission (WTF was that auto crap about on earlier invoice)
-customer states: trans fluid leak - ref history and Adv
-performed inspection. rechecked previous repairs, only noted residual oil from previous repairs
- cleaned and road tested vehicle, rechecked, no leaks present at this time

Job #2: perform QCM insp

Job #3: gasoline engine
- pinging noise when underload with a/c on any incline, check & advise on possible PCM update (THANK YOU rwenzing!)
-confirmed customer concern
-reprogram PCM update 7-13-06

Job #4: sublet
- rental - ford tap, 2 days
-sublet complete

Job #5: QC

Personal note: tranny leak was cleaned, site of leak was bone dry for 2 or 3 whole days after this invoice. I bit the bullet and said F*** it regarding the leak, opting not to go back. Pulled aside by Serv Advisor from when I had my 93. She tells me she's tired of seeing me here and requests that I come see her next time.

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R. O. DATE: 01/03/07
INVOICE DATE: 01/09/07
MILEAGE: 46,011

ISSUE: clutch feels unusually soft after truck sits for a week at El Paso Int'l Airport from 12/12/06 to 12/18/06. I stop by Borman and talk with old 93 ranger advisor. She askes me if I can nurse it until after the new year due to holidays, etc. Trans still leaking from last invoice (above) and after dropping off truck to her I request for it to be addressed while they have the tranny out for the clutch and pressure plate install. This is not noted on invoice!

Job #1: clutch
- customer requests to install center clutch dual friction (her wording- i stated center force)
-customer providing parts
-save old parts
-verified concern (soft clutch) installed slave cylinder and customer purchased parts dual friction
- test drove, normal operation noted

Job #2: QCM insp

Job #3: battery test
-ok

Job #4: tires check
-ok

Note: Now wait a damn minute. I just had a new slave put in at 19,949 (20K) and now I'm needing a 2nd salve cylinder at 46,011, or 26K miles later!!!! I was called and told the slave was leaking and needed to be replaced.

Billed: 547.64 for clutch install, and new slave cylinder

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R. O. DATE: 01/24/07
INVOICE DATE: 01/24/07
MILEAGE: 46,565

ISSUE: CEL code P0446

Job #1: customer states ck engine light on found code P0446
-first extended warranty (1-800-XXX-XXXX)
-verified concern, performed eec tests P0446 verified
-performed pinpiont test. Circuit 140 black/pink impact damage. repaired circuit, retested. passsed
-retested evap system. passed

Job #2: QCM insp

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Which all this now brings me to today.

The truck was dropped off as of 8:20 this morning. 8 times out of 10, I have to pump the clutch to get into 1st when cranking over the engine (I don't leave the vehicle in 1st when I cut engine, I apply e-brake and leave in neutral). I sometimes have to muscle into 1st and 2nd and now 4th is acting up. When I shift I depress clutch wait about a second for clutch to disengage and then shift. AND the transmission leak is back after having been resealed from the dual friction clutch install. I only have 800 and something miles on the truck since the clutch install; I'm at approx. 46,900 miles. I babied the hell out of the truck while in the 500 mile break in period and still baby it (shifting between 2k-2.5k RPM, whereas I use to shift between 2.5K and 3K).

All I want is this damned thing to work properly. I actually sat at home last night from about 9pm to 12am just reading various consumer reports about the ranger and other vehicles of interest, as a replacement to this ranger of mine. Oddly enough, putting all the rankings, ratings, and reports on the ranger together it stacks up to be the better vehicle so far vs the nissan frontier, nissan x-terra, toyota FJ cruiser, and toyota tacoma (both late 90s [onset of TRD pacakge] and newer models). Couple this with the fact that my monthly payments are only $173.22 on this ranger and I have an extended warranty of 60 mos/75K miles it's not really worth the vehicle loan payment increase to get a brand new or newer-used (newer than 04) different vehicle.

EDIT: pictures from an older post

 

Well, the 5SP automatic in my 2004 FX4 LII has performed well and I do not regret passing on a manual tranny
consider the auto before switching brands

 

I've thought about it. I won't be switching brands, not for a while. I thought about the auto too and if I could get an auto with a manual t-case I think I might be happy. I found that configuration in a 2001 F-150. Honestly though, I really hate driving autos. I feel like I just put it into gear, point and go. With a manual I feel like I'm driving, I have to be alert to my surroundings, both other vehicles or traffic signals and signs. If I don't then I either lug the engine or stall. It keeps you aware and not mindless, IMHO.

 

People always bag on the autos, but I see more slave/master cylinders issues than anything else. My auto has been trouble free for 36K.

 

not necessarily bagging on it, just all I've ever known in a ford is manual. Only automatics I've ever driven have been my old 81 celica and rental cars. I almost got that 01 F150. It was at 53K with the 5.4 V8, ex cab, short bed. They wanted 12.8K for it. I REALLY thought about getting it.

 

I guess im pretty lucky that I haven't had any problems with mine....I've had it for about 6-7 months now, and its got 141k miles on it. And as far as I know, It doesn't leak anywhere, and doesn't use any oil.

 

No not you, just the general opinion that ford autos suck. I hardly have enough miles on mine to prove any point, but I'm glad I have the auto.

 

x2

 

my auto gave me problems.... mainly in the torque converter, be cruising along and the TC would lock up for a second, and release. I also had an isssue with that additive they added as a recall, after they added that, my truck stalled in reverse 2x, and would slip out of gear ALL the time.... they finally flushed the fluid, but the question remains, how much damage was done to the transmission? at 8,000K they rebuiult my tranny. and im still having issues with the TC however it only locks up about once a week and its not as bad as it used to be

other problems, well my power window on the driver side stopped working, the replacement motor isnt as 'fast' or 'powerful' as the original one, but it works... driverside power locks still dont work, they have been replaced 3x had a wheel replaced under warrnty due to corrosion around center cap, had idle issues, time chain rattle, 4wd no engaging, rear brakes locking up on wet pavement, they replaced driverside rear - truck has never stopped as fast as it used to.

ongoing issues with abs, truck doesnt stop with abs, so i disabled it after ford refused to do something with it.

 

FMD, my 2000 has the same problem with the torque converter. Where you ever able to correct that problem? No error codes show up to reflect this problem and my indie doesn't know what to do with it.

 

I think my clutch is going out @ 56k miles. No biggie, time for a spec 2 that's all. =]

My auto in the '03 fx4(that burnt) blew! It had zero power or acceleration compared to my 03 LII manual. The gear shifting was rough! I'd say one out of ten times I drove it, it shifted okay. Most of the time it bucked through the gears. Everytime I brought it in to the dealer they just scratched their heads and said "I dunno, we'll make a note of it on your file".

 

Ford....do something that makes sense? Good one, I needed a laugh.

 

I got off the phone about 4 hours ago with Ford. I called some 800 number my service advisor gave me. I told the guy everything that I listed above from my dealership invoices. I also mentioned my frustration with having a slave cylinder die at 19,949 (as well as the pressure plate - main cause) and then when I put the dual friction in at 46,011 they had to replace the slave again because it was leaking.

Right now I'm pushing for a brand new transmission. I told the guy I was on the phone with that I have no idea what damage has been done from this reoccurring leak at my extension housing. I said I honestly don't know if this is a valid request, but this is where I'm at with this vehicle. I started from the beginning and kept it brief, about how I had a 93 4.0L 5 spd and lost it to a 16 y.o. kid. I was on the phone with this Ford guy for almost 52 minutes. He placed me on hold and supposedly called the dealership to confirm my claims and my statement that my vehicle is currently up there for the 5th time to "fix" this leak. He has escalated the issue to higher ups that have more power into looking at my request. He outlined that given the age of the vehicle, mileage, my concern for the fact that I don't know what kind of damage has been done for continual "band-aid fixing" a possibly larger problem, and that this problem has been a multiple issue occurance since I was still well within my 36/36 warranty that my request is valid enough. Basically both he, the local dealership rep he talked to, and his boss feel that my vehicle has been in for repairs too much for the same issue.

I'm suppose to get a phone call for the next step in this saga with 48 hours. Good thing I work 8-5 tomorrow and 10:30-8 on Friday! Oh, and I haven't heard from the dealership about current leak and difficulty of shifting, so I'm currently without a vehicle. Not that the 1-1.5 mile oneway trip to work is gonna kill me, but I'd prefer not to ride my bike tomorrow morning given our recent "cold" snap. Hell, back in January I rode my bike in the snow to work but I shouldn't have to do that. If I was wise I would have asked for a rental today when I dropped my truck off.

Long story short, Ford has documentation now through another concerned customer regarding "common" issues with their newer ranger vehicle.
1. weak slave cylinders
2. idler and tensioner pulleys
3. some sort of transmission fault yet to be determined.

I'm going to greatly push the slave cylinder and tranny issues when I get my within 48 hours phone call.

 

Ford Owner Relations? 1-800-392-3673?

They did the same exact thing you described, was on the phone with them for almost an hour giving them my truck's(and burnt truck's) life story. Put me on hold while they called the dealer. I was treated much better(by my dealer's service dept) after talking to Ford @ that 800 number.

 

That'd be it. And x2!

 

reading this thread makes me sad, as my 05 Lvl II with 19k on it is starting to have the same exact problems, its a getting a little hard to shift, the clutch will slip for absolutley no reason (like in 5th gear on the highway, i give it some gas and it just revs up). And my clutch pedal lets out at pretty much the last centimeter or so of pedal travel at the top. Im going to have to bring it in and let them deal with it, which im not looking forward to.

 

I have not had much of any issues with my auto, 80k here and most of that was not easy for it.

I like my auto for alot of things but at the same time i would love to have a manual back. the power is just there with the manual, the auto eh its ok.

Bill doesnt have too many issues with his manual trans.

sucks about your issues hope it gets fixed!

 

i like my auto tranny.....not a single problem with it.....she has 90,500 miles on her and is 10 years old....runs just as strong as the day i got her (at 40,000 miles)

i wanted a manual when i got my truck but couldn't find one in good shape......ooo well if i want a manual i will swap one in...

i would be pissed if i were you and kept having the tranny problem....

 

I was fuming mad the time I was told it was residual/excess oil. I pretty much can't do anything though. I have just enough control of the situation to get the necessary steps in place to get the ball rolling. From there it's up to the mechanic(s), service advisor(s), and service dept manager. If I don't like it I just keep going back and that's what I've done. I've become a fly in their ointment.

Back to the excess oil thing. Since I was still within my 36/36 warranty and knew that I had an extended drivetrain warranty I just basically told myself, ya know what. They did the work on it, it's documented by my invoices so there's a paper trail. If the tranny blows, not my fault.

Andrew, don't let my post worry you, but be aware. I didn't have this type of issue with my old transmission (93 ranger). The current problems I'm having, that are reoccurring and have gotten worse, were developing before and got worse after my center force DF kit install. I hope to god they don't tell me it's the 33 inch tires or the CF DF kit. I'll blow up. FWIW though, at 800 something miles after the dual friction install my clutch pedal was back to a high release point. Clutch wasn't slipping, but I didn't like where the release point was. All manual vehicles I've driven before this 04 have the clutch grabbing and engaging at about 1/2 way through releasing the pedal. This truck grabs at a little beyond half way and completely engages at almost the top of pedal release.

I'll keep everyone informed on how this goes.

......this is the main reason why the beautiful RCD kit and deaver leaf springs are sitting in my kitchen not installed on my truck!

 

have you ever thought about taking it to another dealer? that would be my choice....kinda like when your health insurance wants a second opinion before a major procedure...

 

3 dealerships in El Paso, TX anywhere from 42-60+ miles away.
1 dealership in Alamogordo, NM (where I'm originally since moving to NM in 95) approximately 55-60 miles away
1 dealership in Deming, NM approximately 65-70 miles away.

But yes, I've threatened to go to another dealership. Pending the results of the truck being in right now will decide if I go to another dealership. I have Mon-Wed off next week and my mom still owns a house in Alamogordo. I'll just have to bring my camping gear as no utilities are on at the house, I think. We also know the tranny mechanic over there.

 

i would go ahead and plan on taking it to another dealership.....stop playing games with the dealership that you are going to now.......they are screwing you.....

figure out which dealership is the LARGEST out of those, and take it to them.....then find out which one is the smallest and take it to them also....since you have 3 days off it would be worth it......