My 1993 Aerostar has an intermittent transmission problem with the front seal.

[Tapemeasureman]

this is now the 4th time in last couple of years that all the fluid leaks out from the front of the bell housing, and it dumps fast. After engine cools off, it holds ATF just fine, so its NOT the front seal. Any help will be most appreciated.

 

[wood1]

Search in the trans section, one of two problems. If you are lucky, your coolant level is getting low enough to cause the transmission to overheat (rad has a tranny cooler in it) and it pukes it's fluid out. If you're unlucky the machined bushing in your bell housing is worn out of spec and it is allowing the torque converter to overheat the front seal...

 

[Tapemeasureman]

I have been through all 20 pages of threads, and it does seem most plausible to me that it is a temperature related issue, maybe from clogged veins in radiator? If worn bushing in bell housing, would it not be a more regular occurrence ? I have had this issue 4 times now in the last couple of years, generally months and months apart. last time in the mountains, a month ago, this time hauling heavy load. Thanks BTW, for the speedy reply !

 

[wood1]

Sounds like overheating to me too. I would install a nice big tranny cooler/temp gauge and stop hauling heavy loads. I wouldn't think you'll keep getting away with that over and over... you don't tow or drive up mountains in OD do you? Recipe for disaster with an A4LD. You might even think of installing an electric fan over that external cooler you should install. Have you adjusted the bands in the last 20 K miles? It will help prevent slippage and unnecessary heat in your tranny too.

 

[Tapemeasureman]

It has an aux trans cooler, temp gauge sounds like it is in order. Another thread suggests removal of tank from radiator and reaming tubes, believe I will do that in am. Also suggested is checking the back pressure on exhaust sys. Thought I had problem solved a couple of weeks ago when I replaced thermostat, fixed very minor leak in hose and flushed sys. was fine until today. Thanx for your rapid replies and continued advice ! Gregg

 

[wood1]

Oh no problem, glad to help out. If your cooling system isn't up to snuff that'll definitely add to your woes. Clutch fan working right etc?

 

[Tapemeasureman]

tested fan clutch by holding piece of folded cardboard to blades, and it didnt seem to impede turning at all, so.....That was my first guess....and it doesnt overheat to the point of boilover. Today was the first time needle on temp gauge was "out of place" since thermostat replaced, today went to straight up and down, and no still loss of coolant. Am leaning towards clogged radiator at the moment, will know more manyana. Thanx

 

[BrooklynBay]

Welcome to this forum! I've renamed your thread, and moved it into the Aerostar section. Which engine do you have?

 

[Tapemeasureman]

4 l

 

[BrooklynBay]

The 4.0L sometimes develops a problem that the 3.0L doesn't. There is a part called a crankshaft to flexplate spacer which is made out of powdered iron. It eventually cracks, and causes the front seal to leak. Sonnax made an improved version out of billet steel. Check WWW.Sonnax.Com or my list of useful threads for more information. WWW.TransmissionPartsUSA.Com sells it. Your 1993 uses the 6 hole design.

 

[Tapemeasureman]

This is a very intermittent issue, and I believe it is temperature related

 

[BrooklynBay]

A low coolant level in the radiator could prevent the internal transmission cooler in the radiator from cooling properly. Did you ever flush the cooling system?

 

[Tapemeasureman]

yes, not loosing coolant

 

[Tapemeasureman]

overheating tranny hemorrhages fluid

it is now end of July, after replacing fan clutch all was well until this week, when I believe ive blown front seal out completely. Even after allowing engine to cool down completely it will not retain ATF at all for any amount of time once engine is cranked. It hemorrhages fluid in a stream as big around as my finger.

Now, I have a new dilemma regarding removal of trannny, specifically regards to un- doing bolts that connect TC to flywheel, there is NO access cover ..I can see tip of the bolts showing through to the front of the flywheel, (through the starter hole) but not on the rear of the TC where the HEADS of the bolts are. Is this a standard set up? It is totally NOT like described in Haynes book....