Nov 102012
 

Ford Falcon & Territory Automatic Transmission Problems & Fixes Introduction…

When ford released the falcon & territory with the 6 speed ZF gearbox it was a step in the right direction for the reliability. However there still lies a problematic part that could cost you your transmission if not attended to.

The Problem…

Ford Falcon and Territory 6 Speed ZF6HP26 Water Damage Sump

Ford Falcon & Territory 6 Speed ZF6HP26 Water Damage Sump

Its known as the “Transmission Milk Shake” and although it may sound appealing to those milk lovers out there this shake will set you back into the Thousands of Dollars to repair. The shake accrues when the transmission cooling system fails by allowing coolant into the transmission and transmission fluid into the cooling system. When this accrues the transmission is a write off and no amount of flushing will allow the transmission to recover.  The engine will not be damaged it will most like be better off due to the lower boiling point of the water oil mixture but all your rubber hoses will be effected.

The Culprit…

Ford Falcon & Territory 6 Speed ZF6HP26 Water Damage Internals

Ford Falcon & Territory 6 Speed ZF6HP26 Water Damage Internals

Automatic transmission need to keep cool and maintain and operating temperature and to achieve both they need to run the ATF through a Heat Exchanger normally fitted to one or both of the radiator tanks. These days vehicle’s use a new external Heat Exchanger which is hooked into the coolant lines around the heater hose circuit. Both types are know for failing and from when the BA falcon was released they suffered radiator problems then from 2004 most of fords had switched from the radiator style to the external style. Still there are issues with both of these units and with no alternative or know fix. or is there?

The Fix

Normally you would eliminate the water and oil cooling system and fit an external air to oil cooling unit. But with fords using 3 different transmissions and turbo models with front mount intercoolers it makes it hard for one kit to fit all models.

4 Speed Automatic 6 Cylinder Models…
From 2004 on the 4 speed models changed over to plastic cooling lines and the Heat Exchanger bolted under the inlet manifold. The plastic lines have female 1/2″ quick release fitting on each end which makes adapting to regular transmission hose difficult. As the transmission is the same as earlier models with steel lines your could source some from a wrecker and use them to connect to a Air/Oil Cooler suited to a AU Falcon. Alternatively you could use a Male 1/2″ Quick Connect to Push On hose adapter fitting and use the original Plastic lines.

5 Speed Automatic 6 Cylinder Models…
Mostly fitted to the Commercial Ute’s they also use the Heat Exchanger under the inlet manifold however they use Steel lines with a pipe  thread fitting. As this is a limited run at this time there is no known fittings that will connect easily. Its more common to Cut and Flare the lines and connect transmission hose.

6 Speed Automatic 6 Cylinder Models…
The 6 Speed has always had plastic lines with the heat exchanger under the inlet manifold which leaves only one choice as to fittings. They need a Male 1/2″ Quick Connect to Push On hose adapter fitting to allow an Air/Oil cooler to be connected.

6 Speed Ford FG XT Falcon 6 Cylinder Models…
When offered the XT Falcon with a 6 Speed transmission upgrade the Heat Exchanger was still suited to the 5 speed lines. This meant that a new set of lines where produced just for that model to suit a 5 speed exchanger and a 6 speed transmission. So if you want to run a bypass cooler its needs to fit directly to the transmission with custom fittings.

6 Speed Automatic 6 Cylinder Turbo Models…
With the turbo models running a front mount intercooler there is no room for a transmission oil cooler in the traditional position in front of the radiator. An alternative location for the cooler is under the drivers side head light behind the front bumper bar. Although the airflow is less in this location a Fan can be fitted to the oil cooler which can run through a temperature switch. Currently to our knowledge there is only one kit available from Furious Performance which uses braided lines from the transmission to the cooler.

XR8 Models…
Due to the V8 engine there is no suitable place to mount the heat exchanger to the engine like on the 6 cylinder models. So the transmission oil is cooler through the radiator similar to most vehicles. External oil cooler kits can be fitted if the lines attaching to the radiator are plastic. They still use a Male 1/2″ Quick Connect to Push On hose adapter fitting to allow an Air/Oil cooler to be connected using 3/8″ Hose. Some Late Model V8’s have a Male Steel pipe connecting into a female radiator connections. This setup would need a custom fitting to adapt to an external oil cooler.

Flushing Transmission Fluid…

Don’t wast your time if the oil has gone milky as its past the point of no return. Sure the transmission may still be working but having water in the oil raises the boiling point and also causes a reaction to the glue holding the friction material to the clutch plates and also causes the rubber seals to swell making the pistons jam in the clutch drums. Ones the water has entered no amount of flushing will reverse the affects it has on the internals.

Ford Falcon & Territory 6 Speed ZF6HP26 Water Damage Mechatronics

Ford Falcon & Territory 6 Speed ZF6HP26 Water Damage Mechatronics

Mechatronics Unit (6 Speed Transmission)

Due to warranty issues with transmission shops it is common to swap out the Mechatronics Unit during a water effected rebuild. This increases the rebuild costs by over $3000 and can really hurt your pocket but to cover the warranty issues it does need to be replaced. If your happy to try your luck with your original unit stripped and rebuilt it will save you some big bucks but may effect you warranty. If you have any DTC’s logged which relate to the TCM your out of luck and it will need to be swapped over.

Radiator Flushing…

Radiator hoses and transmission fluid don’t mix and depending on how long the fluids have been mixed it is common to changer over all the hoses. If you service your car regularly you may try changing one at a time as they go soft and swollen. Most cases its in there to long and you have repeated trips your mechanic with burst hoses so best get it sorted.

Ford Falcon & Territory 6 Speed ZF6HP26 Water Damage Prevention Cooler Kit

Ford Falcon & Territory 6 Speed ZF6HP26 Water Damage Prevention Cooler Kit

External Oil Cooler Kits…

We found a great kit from a business called Furious Performance best not wait until you need one and get it fitted ASAP!

See Also…





Nov 102012
 

Ford Territory ZF 6 Speed Automatic Transmission Oil Cooler Kit Introduction…

If you have read our post about the Heat Exchanger Failures with the Ford Falcons & Territories this post may provide an alternative cooling option to eliminate the contamination risk. The alternative cooling unit is an air to oil cooler mounted in the traditional location in front of the radiator. The kit we will be installing is from a local business called Furious Performance.

The Kit…

The kits completely bypasses the original Heat Exchanger by running new hoses to the front and installing a Air to Oil cooler in front of the A/C Condenser. There is even a brass fitting to allow the removal of the Heat exchanger completely so there is better flow for the cooling system. (added bonus for LPG vehicles)

The Contents…

1 x 280mm x 255mm x 10mm PWR fin oil cooler with 3/8″ Barbs.Furious Performance TCK-T25513 Cooler Kit
1 x Pair of steel mounting brackets.
1 x Adapter bracket to suit the Territory or FG Falcon.
2 x 1.6 meter lengths of 3/8″  Transmission cooling hose. 1 x Fittings Kit – including Hose clamps, CNC alloy bypass fittings, Bolts, Nuts & Hose holders brackets.
1 x Coolant bypass fitting with clamps.
1 x Set of Instructions.

The Tools You Will Need For Installation…

1 x Philips Head Screw DriverInternal Parts of Furious Performance Ford Territory Transmission Heat Exchanger Bypass Oil Cooler Kit
1 x Socket Set (3/8″ & 1/4″ Drive is preferred)
1 x Hose Cutters
1 x Drill
1 x Set of Drill Bits
1 x 8mm Hex Drill Socket (Optional)
1 x Large Lever Bar
2 x Pointy Nosed Vice Grips (Clamp Coolant Lines)
1 x 8mm Allen Key (Transmission Filler Plug)

The Installation…

We had a Customer who wanted an external oil cooler & steel sump conversion fitted to there 2006 Ford Territory 6 Speed ZF6HP26. If fitting to a falcon there will be some variations to these instructions so always refer to the instructions provided with the kit.

Step 1:  First thing to do is remove the Grill and the cover clips holding the radiator support cover in place.  Once they are removed you can pull the grill forward to gain access to the clips underneath and if your lucky it might just pope out in out hand.

Grill Removal of Furious Performance Ford Territory Transmission Heat Exchanger Bypass Oil Cooler KitGrill Removal of Furious Performance Ford Territory Transmission Heat Exchanger Bypass Oil Cooler Kit

 

 

 

 

 

Territory Bracket Modification…Bracket Modification of Furious Performance Ford Territory Transmission Heat Exchanger Bypass Oil Cooler Kit
           After some information found on the net you can modify the longer bracket by straitening the small bend it has. (Bend is to suit BF Falcon)

 

 

Step 2: PWR Cooler & Brackets fitted on Furious Performance Ford Territory Transmission Heat Exchanger Bypass Oil Cooler Kit The brackets can now be fitted to the cooler as per the instructions provided  The cooler hose connections need to be pointing towards the passengers side of the vehicle. The Longer bracket also needs to be on on the same side with the top holes facing towards the front. The additional bracket can also be fitted as per instructions provided.

Step 3:  Now you can now drill and mark the top holes for the brackets on the radiator support. The instructions provided are spot on and once you have drilled the first hole simply mark and drill the second hole.

Location of Piliot Hole of Furious Performance Ford Territory Transmission Heat Exchanger Bypass Oil Cooler KitLocation of Piliot Hole of Furious Performance Ford Territory Transmission Heat Exchanger Bypass Oil Cooler Kit

Alignment Hole of Furious Performance Ford Territory Transmission Heat Exchanger Bypass Oil Cooler KitLocation of Second Hole of Furious Performance Ford Territory Transmission Heat Exchanger Bypass Oil Cooler Kit

 

 

 

 

 

 

 

 

 

Airbag Sensor…Location of Airbag Sensor on Furious Performance Ford Territory Transmission Heat Exchanger Bypass Oil Cooler Kit
The airbag sensor is close to the bracket fitment just make sure its not damaged while drilling or installing cooler & bolts.

 

 

 

Step 4: Horn Removal on Furious Performance Ford Territory Transmission Heat Exchanger Bypass Oil Cooler Kit The cooler is now ready to be fitted to the vehicle but before you do its a good idea to loosen the bolts holding the brackets to the cooler.  This will allow you to maneuver the brackets if needed to allow the top and bottom holes to line up. You may also find the horn will be in your way so it can be removed for this installation. It does fit back into that location once cooler is installed.

Step 6:PWR Cooler with Hoses fitted on Furious Performance Ford Territory Transmission Heat Exchanger Bypass Oil Cooler Kit  With the cooler in place we found that it would be difficult to install the cooler hose once bolted up. We chose to remove the cooler and fit both lengths of hose with clamps and reinstall the cooler feeding the hose around the radiator and under the air box. We then where able to bolt the brackets into place as per instructions and tighten it all up.

 

Step 7:  Fitment of the cooler is straight forward remove the bottom bolt holding the power steer cooler. Then install the top bolts loose and align the bottom and install the bolt, tighten them all and refit horn. The hoses are all that’s left to complete the cooler the installation.


 

 


Territory Special Notes…Air Box Removed on Furious Performance Ford Territory Transmission Heat Exchanger Bypass Oil Cooler Kit
 

Due to the territory having the AWD option the heat exchanger is positioned closer to the front of the engine compared to a falcon. This is to allow clearance for the Front Differential if fitted. We found that if you remove the air box and engine oil filter it allow easy access to the heat exchanger unit.

 

Step 8:Location of Factory Heat Exchanger on Furious Performance Ford Territory Transmission Heat Exchanger Bypass Oil Cooler Kit  To disconnect the cooler lines can be tricky so take your time. The key is to push the connection on then press in the unlocking tabs and lever the fitting off. We did find that we could remove the fitting by pulling on it once the tabs where compressed but it took a few goes. The lever option may take a few goes but it was easier.

Step 9: Now we removed the heat exchanger which is held on with 3 x  13mm bolts, only one needed to be completely removed as the other two we just loosened. We used some pointy nosed vice grips to clamp the coolant Hoses and removed the Exchanger. Now the kit instructions don’t mention removing the exchanger or joining the hoses. However the kit does include a fitting and clamps to alloy you to do this.

 

Coolant Thermostat…
          On the Territory we where working on it had an auxiliary thermostat on the coolant hoses going to the heat exchanger. We chose to completely remove this unit as the purpose of it being there was no longer needed due to the removal of the Transmission Heat Exchanger. The only problem we ran into was we needed a 3/4″ ID Heater Hose section to loop the pipes together, which we purchased from our local Repco.

Coolant Thermostat Update…
          There is an optional silicone hose available from Furious Performance and can be added to the kit.  The optional hose is a 90 Degree Silicone Bend which can be purchased separately if needed (Part No: SMS 90075BLK).

Step 10:  With the Cooler fitted and the Heat Exchanger removed and the coolant system bypassed we only need to connect up the External Oil Cooler hoses to the Standard Transmission cooler lines. The aluminium adapters supplied need the to be assembled and tightened before installation. We installed the adapter but not fully until they locked into place. We then cut the rubber hoses to length making sure that where routed with no strain on them. We then removed the adapter and fitted them to the rubber hose with clamps. This allowed us to just then clip them into place once the rubber hose was fitted and tight.

Adapter Fitting Notes…
          The standard plastic lines can go hard with heat & age and could break easily if not handled with care. The O-Ring seals @ both ends can also leak due to heat & age so if any leaks after the install from these areas we recommend buying a new set of Factory Lines. They range from about $80 – $140 depending on 4 speed & 6 Speed transmissions.

Step 11:  The job is almost complete, double check all mounting bracket bolts, Hose clamps & connectors. Also you can secure the rubber hoses using the mounts provided in the kit. Check your coolant level and refit your engine oil filter if removed (Replace if  Required).

Time To Start Engine…
You can now start the engine and check for leaks, if you have access to a hoist you can check the transmission fluid level (Check Our other Post if not sure). If you don’t have access to a hoist and cant top up the fluid make sure you make a booking with your local mechanic to have it done. We do not recommend driving it low on oil as it could cause problems but consult your local mechanic.

Step 12: With the installation now complete all the removed body work & air box etc can be refitted.

Step 13:  Your done! Complete a Test Drive and recheck for leaks. If your doing the install @ home allow a day but if your handy you should have it completed by lunch time. If your paying a workshop look to pay at least 3 hours labour plus fluids. Also it might be an idea to complete a coolant flush while doing this install if needed.

Our Testing Results…
While we had a scanner plug into the vehicle to check oil level we decided to log the trans fluid temp sensor on our test drive. We found it does take about 5 minutes driving to get up to a decent temperature  and the low speed cooling fan kept it under control. We also did an over heat test and found when the transmission temp reached 110 degrees the Hi Speed engine fan kicked in and allowed the transmission to cool to a stable temp.

Conclusion…
The main reason we fitted this kit was to eliminate the risk of water contamination in the transmission. The other reason was to help prolong the life of the transmission by lowing the temp of the fluid during towing. We feel the kit achieved both these objectives.