I have a 2007 F150 Regular Cab 4X4; 4.6 V-8; 3.55 Non-LS; Automatic; 58,000 miles.

A couple of months ago, it started to shudder at 25 mph when I slow down to stop. Not bad, but noticeable. Then I experienced a harsh downshift clunk and also a clunk when moving at 40+ mph and letting my foot off the accelerator and reapplying the gas.

I took it to the dealer, and although there were no codes stored, they drove the truck and agreed that there was a problem. They ended up installing a complete new (Ford ReMan) tranny with torque converter under warranty. The dealer has bee great - very focused on getting this fixed and making me happy. The new transmission fixed the higher speed clunk, but I still feel a slight (noticeable) shudder at 25 mph when slowing to a stop. I can't figure it out.

I doubt that it's the driveshaft lube problem because I don't feel anything when I start to accelerate from a stop other than an occasional shudder at 25 mph as I speed up. Emergency brake doesn't seem to be binding and I don't have limited slip, so I don't think its rear end clutch pack problems.

Don't know what else to try. Any comments?

 

brake rotor

 

Sounds like TSB 09-20-14, which would mean the TCC is locking when it is not commanded.

 

TSB 09-20-14
10/19/09
UN-COMMANDED TCC APPLY ON THE 1-2 SHIFT
CAUSING PERCEPTION OF HESITATION AND/OR
LACK OF POWER DURING SHIFT FORD:
2005-2010 Crown Victoria
2005-2006 Expedition
2005-2010 E-150, E-250, E-350, F-150 LINCOLN: 2005-2010 Town Car 2006-2008 Mark LT MERCURY:
2005-2010 Grand Marquis This article supersedes TSB 6-22-7 to update the Issue Statement, vehicle model years and model line covered.
ISSUE
Some 2005-2010 vehicles equipped with a 4R70/75E-W transmission may experience an un-commanded torque converter clutch (TCC) apply or TCC partial apply immediately after the 1-2 shift. This may result in the perception that the vehicle lacks power or that the transmission is up-shifting too early. Additional symptoms of uncommanded TCC apply when coming to a stop (before the 2-1 downshift is commanded), are engine stalling or lugging when engaging manual 2nd while at a stop and code P1742 may be present in continuous memory. However, the vehicle should operate normally in park, reverse, neutral and manual 1st gear. ACTION
Follow the Service Procedure for verification and repair. SERVICE PROCEDURE
1. Monitor (TCC %) solenoid command state - duty cycle and (TC SLIP ACT) torque converter clutch slippage - RPM, while in 2nd, 3rd or 4th gear with a TCC % reading 0.

a. If TCC % = 0 and TC SLIP ACT = less than 20 RPM then inspect the number 7 check ball in the main control valve body for damage. Replace as required following the appropriate Workshop Manual (WSM) under Disassembly and Assembly of Subassemblies - Main Control Valve Body. (Figure 1) NOTE THIS PROCEDURE IS PERFORMED IN 2ND GEAR AUTO (NOT MANUAL 2). MONITOR (TC SLIP ACT) AFTER THE POWERTRAIN CONTROL MODULE (PCM) COMMANDS 2ND GEAR AND BEFORE THE VEHICLE SPEED SENSOR (VSS) READS 35 MPH (56 KM/H). b. If you receive any other reading, this procedure does not apply; follow normal diagnostic procedures as outlined in the appropriate WSM. NOTE IT IS NORMAL FOR THE PCM TO COMMAND 4TH GEAR AT SPEEDS AS LOW AS 19 MPH (30 KM/H) WITH LIGHT ACCELERATION WHEN THE THROTTLE POSITION IS LESS THEN 20%.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT : Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME

092014A 2005-2010 Crown Victoria, 2.3 Hrs.
Grand Marquis, Town Car,
Econoline 150/250/350,
2005-2006 Expedition:
Includes Time To Perform
The Diagnosis Outlined In
This Article And Repair
(Do Not Use With Any
Other Labor Operations)

092014A 2005-2010 F-150, 2.2 Hrs.
2006-2008 Mark LT:
Includes Time To Perform
The Diagnosis Outlined In
This Article And Repair
(Do Not Use With Any
Other Labor Operations) DEALER CODING CONDITION
BASIC PART NO. CODE
7E195 01