2012 Fusion 2.5L, 127K miles.
This is now the 5th time I have to take the car to my independent shop to fix the leak. They used original Ford parts (shaft, bushing, seal) and the leak comes back almost immediately. I watched FordTechMakuloco's video and I feel an experienced tech should have no problem fixing this issue.
What could they have missed?
Thanks in advance!

 

Now that you have some idea of what is involved, you might ask your shop what they might have missed.
OR ,,,you could always consider having a different shop look at it. Without actually looking at the parts, not a good idea to try to diagnose over the net..

Glad to see you are back !

 

Thanks, Hanky!
I hoped you'd reply.
I had the Ford Dealer look at the situation and they gave me an estimate for doing the same job for more than a grand. The service manager also suggested to go back to the shop because warranty.
I do have a theory: the ATF the shop uses is too viscous. that raises the pressure and the seal can't hold it. I will take it back for a seal replacement and insist they completely flush the transmission, torque converter, and cooling loop with original Ford Motorcraft Mercon LV. If it leaks again after that I will look for a different shop or spend the grand for the Ford dealer.

How is your wife's wheel barrow holding up?

 

Regarding the seal leak,,,there is a vent on the top of the trans that should be checked to make sure it is clear. As to why it always leaks from the same place tells us there is something not right with the installation process .

Regarding the wheelbarrow,,,,she bought me a set of chains to put on it so I could continue working it even in the snow. Something about that picture just bothers me and yet she won't let me do any of the repairs. You know if she ever gets to read my posts I will be in big trouble ,lol
I believe you were the person that posted what became one of my favorite sayings,
Good judgement comes from experience,
Experience comes from bad judgement.
Just so true !
Wishing you and our Ford family A healthy and happy New Year.

 

This wheelbarrow must be a monster!
Thanks for the hint on the tranny vent!
Wishing you a happy new year as well!

 

Update: I went back to the shop that did the repair. They said that something must be wrong with the transmission and suggested to go to a local transmission shop. I called them and they gave me a 3 week waiting time but also suggested to go to the Ford dealer. I mulled it over and decided to go back to the Ford dealer. They found that the replaced drive shaft was an aftermarket unit, not Ford. I let them redo the whole repair using nothing but Ford parts for about $1200 total. That was on January 30,three weeks ago. So far no leak has returned and I feel it is fixed correctly this time. I figure that there was to much of a mismatch between the aftermarket shaft and the Ford seal and as a result it kept blowing out. It's nice to drive with confidence again.

 

Thanks for getting back to us.
Glad all is well and you are back to help, thanks.


As I am sure you are aware by now, there is a reason we try to stay with OEM.