Fusion Gearbox Slipping

Alright, Ford Fusion gurus, I'm pulling my hair out. My 2018 Ford Fusion with the gasoline engine is giving me fits. I'm at 229258 km and the gearbox slips and shifts really uncleanly, especially between 2nd and 3rd. I'm getting a transfer case oil wear fault code. From what I've read, sounds like defective gears in the transfer case. Anyone else experienced this? Before I dive in, is there anything else I should check? I already did an oil change, replaced the transfer fluid, and no change. I'm dreading the sound of gear grinding I might hear if things get worse...

4 comment(s)

I had a similar issue with my Fusion. Same symptoms. Have you checked the transfer case oil itself for metal shavings?

Good point! I changed the transfer fluid, but didn't specifically check for shavings. Where exactly should I be looking? Is it obvious, or do I need to drain some fluid into a pan to really see it?

Draining into a pan is best. If you see anything that looks like glitter, that's bad news. Confirmed my suspicion - defective gears. Best take it to a workshop soon.

Thanks. That confirms my fear. I drained the fluid and sure enough, glitter everywhere! Ugh. Workshop it is. Ended up costing me 330€, but at least it's fixed.

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