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How to replace valve body on 2006 Fusion V6?

34K views 42 replies 14 participants last post by  klitch 
#1 ·
My sister's 2006 Fusion seems to be in need of a valve body. It's suffering from problems described in TSB 08-24-1

I don't have the car here to get an idea of how hard it is since she lives six hours away, but I told her I should be able to replace it. Has anybody replaced the valve body in their 2006-2009 V6? Before I ordered a $925 part, figured I should check in just to make sure it can be done without pulling the trans or any other weirdness.
 
#3 ·
That would have been my suggestion...service manuals are a must have.
 
#4 ·
[quote author=HALOREALM link=topic=189146.msg3992446#msg3992446 date=1302672809]
That would have been my suggestion...service manuals are a must have.
[/quote]

Best $50 I spent on the Fusion!
 
#5 ·
And just a follow-up in case somebody else wants to tackle this job. It's not bad. Got it done in a few hours, and it shifts like new.
 
#6 ·
[quote author=EsJayEs link=topic=189146.msg4001481#msg4001481 date=1303449632]
And just a follow-up in case somebody else wants to tackle this job. It's not bad. Got it done in a few hours, and it shifts like new.
[/quote]

Total cost?
 
#8 ·
[quote author=HALOREALM link=topic=189146.msg4001495#msg4001495 date=1303452852]
[quote author=EsJayEs link=topic=189146.msg4001481#msg4001481 date=1303449632]
And just a follow-up in case somebody else wants to tackle this job. It's not bad. Got it done in a few hours, and it shifts like new.
[/quote]

Total cost?
[/quote]

About $1,280 with shipping for the valve body from TascaParts.com, minus a $275 core charge. One can of Permatex Right Stuff for the side pan, and 5 quarts of Castrol import transmission fluid. I initially put 4.75 quarts in, and it was overfilled. So I drained out about a half quart and it was perfect. Not a cheap repair, but it would've much more if the dealer did it.
 
#9 ·
[quote author=Gilbertsville PA link=topic=189146.msg4001525#msg4001525 date=1303473375]
I would get a diagnosis and a estimate. What if it is not the valve body?
[/quote]

No need. It's fixed! The problem described was exactly as the TSB stated and could easily be replicated. Shifts perfectly now. TSB attached.
 

Attachments

#10 ·
One last thing to post for the benefit of everybody. Attached is the replacement procedure for the valve body on 2006-2009 Fusion V6.
 

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#12 ·
[quote author=fyannju link=topic=189146.msg4054426#msg4054426 date=1308679605]
Thanks for sharing. I have trouble to download the attached replacement procedure. Do you mind sending another copy to me? I will try to PM you my email. My 05 Mercury Montego has the same hard shifting problem. I am thinking about changing the valve body, too.
[/quote]

Hi fyannnju. :wavey: There is a chance your 2005 Montego has a different transmission model than the Aisin model being referred to here. For example the Montego also came equipped with a CVT trans (which is a whole other "ball of wax" concerning "shifting"). Anyway, if you have not already done so, check which model transmission your vehicle actually has before purchasing parts and proceeding.

You can do so by finding the Transmission code listed on the Manufacturers plate located on the drivers side door sill. Compare that code to the list of transmission codes listed in your Owners Manual.

Let us know how you make out.

Good luck. :cheers:
 
#13 ·
Hi bbf2530, thanks for the reply. My 05 Montego has a 6 speed Aisin AW F21 transmission, which I believe, is the same as what in 06 Fusion V6. Both the Fusion and 05 Montego are included in TSB 08-24-1 from Ford. That TSB is the reason why I am looking into replacing the valve body. Actually, I am still debating whether I should simply get rid of the car instead of trying to repair it. I like the car, but the transmission problem is just a real pain ...
 
#14 ·
Were you able to download the procedure? I just checked the link above and it's working. It's not bad if you take your time, and are mechanically confident. The worst part of it is the cost of the part. I ordered it from Tascaparts.com and was very pleased with the transaction. The TSB states to have the computer updated to the latest calibration. I didn't do that on the Fusion and it works excellent still.

Before diving into such an expensive fix, make sure that the TSB describes your issue exactly. I could easily replicate the issue by driving at 50 mph+ and gradually giving the car more throttle until it would downshift into 3rd. It was an extremely harsh shift. Sometimes the transmission wouldn't engage when downshifting and the engine would just rev. When that happened, I'd have to pull over, shut off the engine, and start it up again to get rolling.
 
#15 ·
[quote author=fyannju link=topic=189146.msg4055126#msg4055126 date=1308755767]
Hi bbf2530, thanks for the reply. My 05 Montego has a 6 speed Aisin AW F21 transmission, which I believe, is the same as what in 06 Fusion V6. Both the Fusion and 05 Montego are included in TSB 08-24-1 from Ford. That TSB is the reason why I am looking into replacing the valve body. Actually, I am still debating whether I should simply get rid of the car instead of trying to repair it. I like the car, but the transmission problem is just a real pain ...
[/quote]

Hi fyannju. :wavey: Okay, understood. Just wanted to be sure you were aware that the Montego did have more than one available transmission, before you purchased parts.

In that case, as long as the TSB concerning the throttle body applies to your particular vehicle build date, it may be helpful to you. However, as EsJayEs stated, just be sure you follow the correct troubleshooting steps before you move forward to avoid unnecessary expenses.

Keep us updated and good luck. :cheers:
 
#17 ·
[quote author=oi1022 link=topic=189146.msg4078824#msg4078824 date=1311640219]
i cant find a valve body anywhere can someone post a link or anything even a part number would help thanks
[/quote]

Hi oi1022. :wavey: You don't give much information (model year, transmission model etc.). However, among many places, you can obtain Ford parts at your local Ford/Lincoln Dealer or any online Ford Parts sellers, such as Team Ford Parts Online www.teamfordparts.com/partlocator/index.cfm?siteid=214270, Silver State Ford Parts www.silverstatefordparts.com/oem-Ford-parts.html etc.

It is not the type of part I would purchase on eBay, from a Salvage yard, etc..

Good luck. :cheers:
 
#20 ·
[quote author=bsnelson link=topic=189146.msg4087750#msg4087750 date=1312558105]
This sounds like the exact problem my '06 Fusion SEL V-6 is having. Any chance that the CPO extended powertrain warranty might cover some or all of this repair?

Brad
[/quote]

Hi Brad. :wavey: Maybe. It would depend on the type of "CPO Extended Powertrain Warranty" the Dealer gave you and whether your vehicle is still within the Warranty limitations. Your best course of action at this point would be to contact the Dealers Service Department and ask.

Keep us updated.

Good luck. :cheers:
 
#21 ·
Well, here's update number one: Even though I know some will say this is the WORST way to handle it, I went to the dealership with TSB printout in hand and said "I'm 99% certain my car has this issue". He asked what my symptoms were and I say "It does exactly what it says there". I did, however, add some specifics of how I can easily recreate the problem. He seemed to take it well. I also needed an oil change, so I requested "The Works Fuel Saver Package".

Long story short, I spoke to them late in the afternoon and the tech was able to recreate the problem, dropped the pan and found metal in it :shock:. He said it needs an "overhaul" (his words) and yes, all covered under the extended powertrain warranty, only a $100 deductable owed by me. Even better, they spring for a rental, and after agreeing to a $5 per day upcharge, I'm sporting a shiny new Hyundai Sonata (my original option was an Accent; too small!) while my Fusion gets fixed. Very good on you, Ford, for making good on the warranty!

One question that someone might be able to answer: Would a transaxle (do they still call them that) overhaul involve dropping the whole thing out of the car, and if so, would it necessitate an alignment job upon re-installation? Obviously, if it did, it'd be included in the repair, but the reason I ask is because I almost got them to look into the pull that the car's had for a while (despite an alignment at a different dealership), but if they'll have to do it anyway, I might have saved some money. :)

Although it's a topic for a different thread, though, I must say that the Sonata is a very impressive car. The hardest thing for me to get used to is that it has to have the world's tightest torque converter. Honestly, the throttle feel is almost exactly like a manual trans, except you don't have to push in the clutch when you stop. It's almost annoying in a way, but at the same time, it gives it better throttle response than my Fusion. But I digress. :)

I'll report back when I get the Fusion back.

Brad
 
#22 ·
[quote author=bsnelson link=topic=189146.msg4091970#msg4091970 date=1313158231]
Well, here's update number one: Even though I know some will say this is the WORST way to handle it, I went to the dealership with TSB printout in hand and said "I'm 99% certain my car has this issue". He asked what my symptoms were and I say "It does exactly what it says there". I did, however, add some specifics of how I can easily recreate the problem. He seemed to take it well. I also needed an oil change, so I requested "The Works Fuel Saver Package".

Long story short, I spoke to them late in the afternoon and the tech was able to recreate the problem, dropped the pan and found metal in it :shock:. He said it needs an "overhaul" (his words) and yes, all covered under the extended powertrain warranty, only a $100 deductable owed by me. Even better, they spring for a rental, and after agreeing to a $5 per day upcharge, I'm sporting a shiny new Hyundai Sonata (my original option was an Accent; too small!) while my Fusion gets fixed. Very good on you, Ford, for making good on the warranty!

One question that someone might be able to answer: Would a transaxle (do they still call them that) overhaul involve dropping the whole thing out of the car, and if so, would it necessitate an alignment job upon re-installation? Obviously, if it did, it'd be included in the repair, but the reason I ask is because I almost got them to look into the pull that the car's had for a while (despite an alignment at a different dealership), but if they'll have to do it anyway, I might have saved some money. :)

Although it's a topic for a different thread, though, I must say that the Sonata is a very impressive car. The hardest thing for me to get used to is that it has to have the world's tightest torque converter. Honestly, the throttle feel is almost exactly like a manual trans, except you don't have to push in the clutch when you stop. It's almost annoying in a way, but at the same time, it gives it better throttle response than my Fusion. But I digress. :)

I'll report back when I get the Fusion back.

Brad
[/quote]

Yes, the transmission needs to come out of the car.

If done properly, the alignment should not be effected, but it would not hurt to ask before the work is done. If you feel a steering pull immediately after getting the car back, you should return immediately a demonstrate the problem. They should align it if they cause it.
 
#23 ·
I wish this was the final update for me, but alas...

We had a delay due to parts availability, so I didn't get the car back until Friday morning. The good news that I noticed immediately: The front end alignment is better, but I've had the "pull" change when I rotated tires, so I don't know that I can attribute it directly to the repair.

Now, the bad news: After putting about 150 miles on it hauling my stepdaughter back and forth this weekend, it's clear that the transmission is actually WORSE than it was before. I don't see how that's possible, but it is. Very harsh downshifts (intermittent) under deceleration, very hesitant to downshift under acceleration, and two big episodes where it just completely came out of gear under acceleration, including once where I was merging on to the interstate and just about ended up with the back end of my car becoming one with an 18 wheeler. Each time, I had to completely let off the accelerator and wait for it to lurch back in gear before I could continue on.

Surely, they wouldn't have rebuilt the tranny and put in the old valve body (whether my actual old one or a new one with the old part number)? They never actually admitted that it was the valve body TSB, and I don't have the paperwork yet (they're mailing it to me). So, I guess it's back to the dealership tomorrow; maybe I'll get that sweet Sonata again as a rental.

More updates as they become available. If I need to move this to it's own thread, please feel free to say so.

Brad
 
#25 ·
Took it back to the dealer this morning as soon as they opened, and the service advisor didn't even bat an eye when I explained what happened. He sent me to the Enterprise Rent-A-Car counter, and I was even able to score that same sweet Hyundai Sonata.

He called later this afternoon and said that they verified the fix "didn't work", and that Ford had authorized them to replace the entire transmission. So, I guess I won't have a "numbers matching" car anymore; hope it never gets on Barrett Jackson. :)

I should get it back on Friday, or so they say. As an aside, the Hyundai still had my same XM presets and the bluetooth was even still paired with my phone. I think it likes me. :)

Brad
 
#26 ·
I didn't mention before, but wanted to ask the opinion of the folks here: The replacement transmission I'm getting is a rebuilt unit (as opposed to new). Should this give me pause, or not? Obviously, reman techniques and quality vary, but I'd like to hope that a unit that was remanufactured for Ford would at least be decent.

Has anyone else had Ford install a remanufactured tranny in one of these cars?

Brad
 
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