In April 2016, Ford issued a recall for over 202,000 vehicles including the F150 with the 6R80 transmission. The recall was described very commonly and generally but you could understand from the notice that Ford is concerned with the speed sensor output (the sensor in the lead frame, in your transmission).
Lead frame problems highlights
- Level of urgency:medium
- DIY inspection:impossible
- DIY repairs:impossible
- Can you drive?usually, no
- Price of repairs:$250 - $450
- If ignored:transmission not working
- Ways to fix:professional repair is needed
If your F150 transmission in 2011-2016 models freaks out, it may be the lead frame issue and it may even be covered by the extended warranty. So, keep reading to find out more.
The recall and the extended warranty
So, in 2016 Ford, most likely, found that they had been making faulty lead frames. The lead frame is the unit that holds transmission sensors and wiring, in simple words. And there were several sensors that could be damaged pretty quickly and lead to unpleasant symptoms.
Ford immediately issued a recall for "software update" and mentioned that if the issue with the lead frame was found, Ford would replace the entire part for free. Unfortunately, not all owners got the recall notice and not all of those who got it took it seriously.
So, even now a lot of F150 and other models with the 6R80 transmission experience this issue and pay hundreds or even thousands of dollars to shops to try and solve the problem.
Please be informed that Ford has issued an extended warranty on lead frames - 10 years or 150,000 miles, whatever comes first. So, if your car is still under 10 years old, you are likely to get the free lead frame replacement in a Ford dealership!
Later, Ford issued several other recalls for other transmission models, so you need to check it with the dealer or online using your VIN.
Why is the lead frame faulty in the F150?
The lead frames installed in Ford transmissions between 2011-2016 were faulty and could crack. This led to wrong signals and wrong sensor readings being sent to the ECU and other control modules.
Also, this could lead to complete loss of signal of several transmission sensors and this would light up several lights on the dash, throw the transmission into limp mode, and allow you to drive on one or two gears.
Actually, Ford never told us what was wrong with those lead frames and this is bad because you can't do anything to prevent the issue. They just seem to be faulty and that's all!
Can you repair the lead frame?
Well, no, repairing it is impossible. The only way is to replace the entire lead frame in your transmission. And it may sound like an easy task for a good mechanic. But there is one problem - no parts are available.
I was told about this problem by my friend who owned the 3.5L EcoBoost F-150 truck. His transmission did the same thing as described above and he was a good mechanic, so he called the dealer and tried to order the new lead frame.
He was told that the part was about $1100 (apparently, they named the price with labor for replacement) and that he would need to wait about 3-4 months before it arrived. This sounds ridiculous - the faulty part that is commonly cracked in thousands of Ford vehicles needs to be expected for almost half a year.
So, he decided to spin the wheel and check his luck with the aftermarket lead frame and eventually sold his truck shortly after replacing it.
There is a tricky question of whether you need to program the newly installed lead frame after installation. The answer is yes - it needs to be programmed as all the new sensors have to be calibrated to work well together with your control modules and the transmission. Otherwise, the warning lights may only multiply on the dash after repair.
So, you can replace the lead frame and this is not a task for a genius mechanic. But buying it new and OEM is almost impossible.
Who's eligible for free repairs?
My friend with the 3.5L EcoBoost F-150 tried to get the free repair using the extended lead frame warranty from Ford. However, it appeared that his truck model was not included in the recall list. So, not all affected cats are actually covered by this recall.
I recommend you go to the NHTSA website or to Ford's official website and check the recalls that you are eligible for. I strongly recommend you follow all the recalls because some of them cover safety issues that may save your life one day.
If the lead frame is broken suddenly, it may eventually lock up the wheels when downshifting at high speed and you may lose control over your car.
About the authors
The CarAraC research team is composed of seasoned auto mechanics and automotive industry professionals, including individuals with advanced degrees and certifications in their field. Our team members boast prestigious credentials, reflecting their extensive knowledge and skills. These qualifications include: IMI: Institute of the Motor Industry, ASE-Certified Master Automobile Technicians; Coventry University, Graduate of MA in Automotive Journalism; Politecnico di Torino, Italy, MS Automotive Engineering; Ss. Cyril and Methodius University in Skopje, Mechanical University in Skopje; TOC Automotive College; DHA Suffa University, Department of Mechanical Engineering
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