6R60 Bulkhead Connector Sleeve leak

[Ornery]

Changed the oil in the truck today, and finally took a good look at where our transmission fluid was seeping from. Not sure how serious this is, but it seems to be coming from around the electrical connector. My repair manual labels this as the "bulkhead electrical connector". Searching the Web for more info keeps bringing up TSB's for the 6R80:

TSB 11-3-25 - Transmission bulkhead connector sleeve leaking transmission fluid.​

This is for the 2009-2010 6 speeds, but I guess it could surely effect the earlier ones.

Anyway, I don't get how the sleeve can be removed, without having a bundle of wiring come out with it? Has anybody else done this repair? Don't feel too enthused about dropping the pan, although I guess a fluid and filter change wouldn't hurt. I don't own a fancy trans fluid filling device either. Even with that, it must be a pain when you have to add several quarts!

I'll bet there are quicker, easier ways to deal with this...

 

[makuloco2000]

Changed the oil in the truck today, and finally took a good look at where our transmission fluid was seeping from. Not sure how serious this is, but it seems to be coming from around the electrical connector. My repair manual labels this as the "bulkhead electrical connector". Searching the Web for more info keeps bringing up TSB's for the 6R80:

TSB 11-3-25 - Transmission bulkhead connector sleeve leaking transmission fluid.​

This is for the 2009-2010 6 speeds, but I guess it could surely effect the earlier ones.

Anyway, I don't get how the sleeve can be removed, without having a bundle of wiring come out with it? Has anybody else done this repair? Don't feel too enthused about dropping the pan, although I guess a fluid and filter change wouldn't hurt. I don't own a fancy trans fluid filling device either. Even with that, it must be a pain when you have to add several quarts!

Flip up the lever on bulkhead connector to pull harness outta the way, drop pan, pull down on retaining tab and then the sleeve pulls right out. I knew I should have done a video on this.

 

[Ornery]

How is there not a bunch of wires on that sleeve? If the socket for that plug is separate from the sleeve, then there has to be another gap for fluid to seep past.

I want to see a video of how a shade tree mechanic puts that fluid back in!

By the time I buy the fluid, filter, new sleeve and fluid injecting device, I'll be out about $100.00 and couple hours effort. On the other hand, I can epoxy that mess in about ten minutes. (Yeah, I can be a butcher sometimes!)

Edit: Somebody already gave this a shot with silicone:

If you read the thread, these guys were quoted from $400-$600 for this repair!

 

[makuloco2000]

there are no wires just on the outside flick that lever up and its out of the way. Very easy repair, you could even catch the fluid and reuse if you are tight on money. Only part needed is that sleeve. I would fix it right. I have a video on filling the r680. it can be done with a suction gun, a messy pain but it can.

 

[makuloco2000]

Recently made a video for this concern, take a look and you will see how easy it is to change that out.

 

[Ornery]

Thanks loads Maku, but I still don't get what is sealing the inner part of that sleeve. What keeps fluid from coming out the center? There are no O-Rings that I can see in the video, and if there is a seal around that male pin connector, it may need attention as well...

No wait, I'll guess the smaller diameter orange seal is doing that job, eh?

So, now I have to decide if I want to do the fluid & filter change on this puppy. It won't be till spring and either way, I still have to find a simple refilling container for topping off the fluid lost through the current seepage. I put a third of a quart in by squeezing a quart of trans fluid with a small hose passed through its lid. There must be a cheap better way. My vacuum brake bleeder may be able to do this for me, I'll have to try it.

Thanks again for that video!

And this one too:

​

I subscribed! Oh, and don't forget your safety glasses!

 

[makuloco2000]

Yes it is the smaller O-rings that seal the connector part. If your are over 60k I would change the filter while you are in there. The last one I did had about 60k and it was definitely due. What is the glasses all about? You have a little accident?

 

[Ornery]

Morning Maku. I'll do this chore in the spring. It's 24 degrees here now, and I'm broke anyway. Christmas will be pretty spartan, but at least all the vehicles are rolling.

I was watching some videos, and was cringing when you used the compressed air and grinder with no eye protection. I hate wearing mine, but still try and make a habit of it. Forgot to put them on last week when working on the leaking gas tank, and managed to get rust in my eye. Brilliant! Swore again to wear them from now on.

Wacked myself in the eyebrow while doing the Explorer hub. Pure genius!

Thanks again for posting all the videos. What do you use for a camera and editing software?

 

[makuloco2000]

Morning Maku. I'll do this chore in the spring. It's 24 degrees here now, and I'm broke anyway. Christmas will be pretty spartan, but at least all the vehicles are rolling.

I was watching some videos, and was cringing when you used the compressed air and grinder with no eye protection. I hate wearing mine, but still try and make a habit of it. Forgot to put them on last week when working on the leaking gas tank, and managed to get rust in my eye. Brilliant! Swore again to wear them from now on.

Wacked myself in the eyebrow while doing the Explorer hub. Pure genius!

Thanks again for posting all the videos. What do you use for a camera and editing software?

Yeah I am bad about wearing safety glasses. I did the other day though cutting a shock bushing in half large shower of sparks, and guess what one went right by the safety glasses and into the corner of my eye. They are the fancy wrap around glasses too, so it's hit or miss it seems I am more careless with them on then this happens where if I had them off I would be squinting and my head partially turned away and further away.

 

[vipersinu2]

is there a dorman part number?
or aftermarket parts number,
I am having trouble finding the orings

 

[Trainmaster]

Ford sells a kit with the proper "o"rings. They had a problem with these and were originally replacing the entire connector, then they came out with the o-ring kit. Call the dealer. They'll know very well about it. Mine was covered under warranty.

 

[Trainmaster]

I'd avoid the Dorman. My experience with them is that they sell Chinese garbage.

 

[vipersinu2]

I found ford parts new orings were 10.bucks
the job took about 2 hrs. a bit messy.
7quarts sp oil, filter, about 100 bucks total
i made a miastake 2 years ago, i should of changed these orings when I changed the fluid.2 years ago I though it was going to be hard.or that I would mess something up. but it was super easy.