2005 6.0 Excursion 4x4 Torqshift Output Case Cracked

robby830

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So I was driving home to South Florida from the Smokies and transmission went out on me on the highway in South Carolina. Wouldn’t move in drive or reverse and has a grinding noise when put back into park. Towed it to a local shop. They noticed the torqshift output assembly is cracked and broken into a few pieces. Does anyone know what would cause this? Could there be other issues with either the transfer case or transmission?


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Loose driveshaft, failing ujoints, or loose tcase bolts. Seen a handful of each cause breakages like that.

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robby830

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Loose driveshaft, failing ujoints, or loose tcase bolts. Seen a handful of each cause breakages like that.

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Thanks for the quick reply! I’ll have them check for those issues. I was hearing a grunting/popping sound during the trip when I would let go of the gas. Same sound happened right before transmission lost all gears. Not sure if that means anything or helps determine which part was at fault.


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Mark Kovalsky

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I was hearing a grunting/popping sound during the trip when I would let go of the gas. Same sound happened right before transmission lost all gears.
That doesn't help me determine which part was loose, but it does pretty well confirm that SOMETHING was loose and caused this failure.
 

robby830

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The shop called and said the truck is ready. Mechanic said the tow/haul light is blinking though, but it’s driving and shifting with no issues. He’s not sure if it needs to be programmed now or if it’ll go away after a while. Does this sound like a common issue after it’s been replaced?


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No, that sounds like there is still an issue. If the tow haul light is flashing there should be a code

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robby830

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No, that sounds like there is still an issue. If the tow haul light is flashing there should be a code

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They told me there’s no check engine light on and they apparently can’t check trouble codes. I’m on my way up there now and should be there in about 5 hours. I brought my scanner with me to see if I get anything regarding the tow light flashing.

Just curious, does $1200 for labor seem fair for this job? I purchased the part separately and shipped it to them.


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The tow haul light flashing is basically the check engine light for the trans, it wont set a check engine light.

1200 seems about right, to a little low to replace the output shaft, as the trans has to come apart if I remember right to replace the output shaft
 
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robby830

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The tow haul light flashing is basically the check engine light for the trans, it wont set a check engine light.

1200 seems about right, to a little low to replace the output shaft, as the trans has to come apart if I remember right to replace the output shaft


They actually told me they didn’t need to touch the trans.


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They actually told me they didn’t need to touch the trans.


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Well, that seems high then. I think transfer case r&r is only like 4 or 4.5 hours. Then maybe an hour or 2 to replace that housing, 4 more at the most. So unless their labor rate is 150 bucks an hour, that seems high.

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Mark Kovalsky

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Mechanic said the tow/haul light is blinking though, but it’s driving and shifting with no issues. He’s not sure if it needs to be programmed now or if it’ll go away after a while. Does this sound like a common issue after it’s been replaced?
It is a common issue when you have an incompetent shop.

No, it doesn't need to be programmed. It needs the codes to be read and the issue that it has fixed before it causes damage, such as destroying the transmission. I suggest you read the codes while you are there and leave the truck with them to fix what's wrong with it. Or even pay a good shop to fix it. I would NOT drive it home the way it is now.

It is a big red flag to me that an auto repair shop (even if they are not transmission specialists) cannot read the codes. With all newer (less than 25 years old) vehicles being run by computers, it is unforgivable to be attempting to repair vehicles when you can't read codes.
 

robby830

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It is a common issue when you have an incompetent shop.

No, it doesn't need to be programmed. It needs the codes to be read and the issue that it has fixed before it causes damage, such as destroying the transmission. I suggest you read the codes while you are there and leave the truck with them to fix what's wrong with it. Or even pay a good shop to fix it. I would NOT drive it home the way it is now.

It is a big red flag to me that an auto repair shop (even if they are not transmission specialists) cannot read the codes. With all newer (less than 25 years old) vehicles being run by computers, it is unforgivable to be attempting to repair vehicles when you can't read codes.


Totally agree with you. I just made it here. I just took it for a drive and it doesn’t go past 3rd gear from what I could tell. No way I can make it home over 500 miles away in this. Goes 40mph max. And it jerks when going into reverse. Here are the codes I’m getting with my scanner. Any additional help would be appreciated!

P0720
P0722
P1876
P1832


Thanks!


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robby830

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Quick update: Apparently, the mechanic from the local Ford dealer is the one who did the work. He’s on his way now to look at it. Said it was driving fine before. He’s thinking the sensor from the used case that was put in is bad or the tow/haul button is stuck. Not sure about the sensor being bad, but doubtful it’s the button. With it off, it should still drive past 40mph.


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Mark Kovalsky

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The tow/haul button cannot cause these codes. P0720 and P0722 tell me that either the output sensor is damaged or the wires to the sensor are damaged, or he forgot to plug them in. The other two codes indicate the same thing with the transfer case sensors.

P0700 just says that the PCM recognizes something is wrong with the transmission, but it can't figure out what's wrong.
 

robby830

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The tow/haul button cannot cause these codes. P0720 and P0722 tell me that either the output sensor is damaged or the wires to the sensor are damaged, or he forgot to plug them in. The other two codes indicate the same thing with the transfer case sensors.

P0700 just says that the PCM recognizes something is wrong with the transmission, but it can't figure out what's wrong.


I just left the place. He tried removing the sensor and putting my original one back on, but both are stuck. My original one broke off and now he’s going to try to remove the one in the truck tomorrow morning without breaking it inside the case. Hopefully I can find the sensor locally tomorrow.


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robby830

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Welp, he broke that sensor too. Had to take it apart to remove. Luckily Parks Auto Parts had it in stock. Just had to deliver it from another location. New sensor is in now and he’s putting the case back on now. Let’s hope that does it


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robby830

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Thank you guys for your help! With the new sensor in, it now shifts like normal. Made it home last night with the truck. Only thing I noticed is that the truck now vibrates between certain mileage (30-35, 50-55 and 65-70). They’re all between 1500-1800 RPMs. Other than that it drives normal. Any idea what that could be? Is it related?


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