P0722 on 2011-2013 Lincoln Navigator: Output Speed Sensor Failure Causes and Fixes

What's Unique About the 2011-2013 Lincoln NAVIGATOR

The 2011-2013 Lincoln Navigator uses the Ford 6R80 automatic transmission, which is based on a ZF design. For this specific platform, the P0722 code is not due to a simple, external sensor. The Output Shaft Speed (OSS) sensor is integrated into a larger internal component called the 'molded lead frame' or 'conductor plate'. This part is a known weak point due to internal circuit cracks from thermal stress and vibration, and its failure is so common that Lincoln issued Customer Satisfaction Program 19N01, extending the warranty for this specific part. The primary symptom is a sudden, dangerous downshift to a low gear at speed, which prompted NHTSA Safety Recall 16V-248.

Diagnostic Flowchart

Tap your situation to follow the diagnostic path that matches what you're seeing on this vehicle.

Symptoms You May Notice

• Sudden, violent downshift to a low gear (often first gear) while driving.
• Illuminated Malfunction Indicator Light (MIL/Check Engine Light) and/or a wrench warning light.
• Speedometer reads zero or behaves erratically.
• Harsh, erratic, or delayed shifting.
• Transmission gets stuck in one gear (limp mode), often 3rd or 5th.
• Odometer displays dashes (----) instead of mileage.
• Cruise control will not engage.
• Tire Pressure Monitoring System (TPMS) light may illuminate.

Most Likely Causes

1. Failed Molded Lead Frame 🔴 High Probability This is a well-documented, widespread failure on the 6R80 transmission. Heat and vibration cause cracks in the lead frame's internal circuitry, specifically for the OSS sensor. Ford/Lincoln acknowledged this with Customer Satisfaction Program 19N01, which extended the warranty for this specific part to 10 years or 150,000 miles.
   How to confirm: Scan the PCM for code P0722, often accompanied by P0720, P0731, and/or P1500. The presence of these codes combined with the symptoms is a definitive diagnosis for a failed lead frame.
   Typical fix: Replace the entire molded lead frame assembly inside the transmission. This also requires replacing the transmission fluid, filter, pan gasket, and the bulkhead connector sleeve.
   Est. part cost: $200-$400

Rare But Worth Checking

• Wiring Harness Damage: While less common than lead frame failure, damage to the main transmission wiring harness or the large, round bulkhead connector at the transmission case can cause a loss of signal. This should be visually inspected for fluid intrusion or physical damage before condemning the internal lead frame.
• Powertrain Control Module (PCM) Failure: In very rare cases, the fault can be with the PCM itself. This should only be considered after the lead frame and wiring have been ruled out. One user on a forum replaced nearly every other component before suspecting the computer.
• Sticking Thermal Bypass Valve: During the lead frame replacement, the transmission thermal bypass valve and spring can fall out. It is crucial to inspect, clean, and correctly reinstall this valve. A stuck valve can cause overheating issues which may contribute to electronic failures.

Diagnosis Steps

1. Confirm the presence of code P0722 using an OBD-II scanner. Check for related codes like P0720, P0731, or P1500.
2. Contact a Lincoln dealer with your Vehicle Identification Number (VIN) to check the status of Customer Satisfaction Program 19N01 and Safety Recall 16V248. Although the warranty extension period (10 years/150,000 miles) may have expired, it confirms the known issue and some owners have received refunds for prior repairs.
3. Visually inspect the main transmission wiring harness and the large round bulkhead connector on the side of the transmission for any signs of damage, corrosion, or fluid intrusion from a leaking connector sleeve.
4. If wiring appears intact, the diagnosis is a failed internal molded lead frame.
5. The repair involves draining the transmission fluid, removing the transmission pan, and removing the main valve body assembly to access and replace the lead frame.
6. While the valve body is out, it is critical to replace the bulkhead connector sleeve and ensure the small thermal bypass valve and spring are accounted for and reinstalled correctly.
7. Install the new lead frame, valve body, transmission filter, and pan, torquing bolts to specification.
8. Refill the transmission with the correct type and amount of MERCON LV fluid.
9. Clear all DTCs and perform a transmission adaptive learning drive cycle.

Parts You'll Likely Need

• Molded Lead Frame (OEM #AL3Z-7G276-D) — This is the component that houses the failing Output Shaft Speed (OSS) sensor and is the root cause of code P0722 on this vehicle. The -D revision replaces earlier, failure-prone versions like AL3Z-7G276-A and AL3Z-7G276-B.
  Trusted brands: Motorcraft, Dorman, NAPA Echlin
  OEM price range: $250-$450
  Aftermarket price range: $150-$300
• Transmission Fluid (MERCON LV) (OEM #XT-10-QLVC) — The transmission must be drained to perform the repair. Approximately 9-10 quarts are needed for a pan drop and fill.
  Trusted brands: Motorcraft
  OEM price range: $80-$120
  Aftermarket price range: $60-$90
• Transmission Filter Kit (OEM #BL3Z-7A098-A) — The filter should always be replaced whenever the transmission pan is removed.
  Trusted brands: Motorcraft
  OEM price range: $30-$50
  Aftermarket price range: $20-$40
• Transmission Bulkhead Connector Sleeve (OEM #6L2Z-7G276-AA) — This seal for the main electrical connector is inexpensive and prone to leaking transmission fluid, which can damage the external harness connection. It is highly recommended to replace it while the valve body is removed.
  Trusted brands: Motorcraft, Dorman
  OEM price range: $15-$25
  Aftermarket price range: $10-$20

Related Codes That Often Appear With This One

• P0720 — P0720 indicates a general or intermittent circuit malfunction for the Output Speed Sensor, while P0722 indicates a complete loss of signal. They are often triggered together by the same failing lead frame and are both listed in TSB 19N01.
• P0731 — This code means 'Gear 1 Incorrect Ratio'. The PCM sets this when it commands first gear but the speed sensor data doesn't match the expected engine RPM and gear ratio, a direct consequence of the OSS failure.
• P1500 — This manufacturer-specific code for intermittent vehicle speed sensor failure is also listed in TSB 19N01 as being related to the lead frame failure.

Technical Service Bulletins (TSBs) & Recalls

• 19N01-S3: Outlines the extended warranty coverage for replacing the molded leadframe on vehicles exhibiting DTCs P0720, P0722, P0731, and/or P1500. It confirms the specific fix for the OSS sensor failure.
• TSB 13-6-8: An earlier TSB that identified the issue on 2011-2013 F150s and 2012-2013 Navigators, instructing technicians to update the molded lead frame for symptoms including a speedometer at zero and codes P0720/P0722.

Platform-Specific Known Issues

• Lincoln issued Customer Satisfaction Program 19N01, which extended the warranty on the molded lead frame to 10 years or 150,000 miles due to the high failure rate. For vehicles already past the limits, the program ended on October 31, 2019.
• An earlier safety recall (NHTSA 16V-248, Ford recall 16S19) involved a software update to prevent the sudden downshift to first gear, but this did not fix the underlying hardware failure of the lead frame. Subsequent actions were required because the software patch was not a sufficient remedy.

Mechanic-Grade Diagnostic Values

• OSS Sensor Signal (Hall-effect type) — expected: A clean 0-5V square wave that increases in frequency as the output shaft rotates.. Failure: No waveform or an erratic, inconsistent waveform when back-probed with an oscilloscope.
• Valve Body-to-Case Bolt Torque — expected: 71 inch-pounds. Failure: Incorrect torque can cause internal pressure leaks or damage to the valve body.
• Transmission Pan Bolt Torque — expected: 98 inch-pounds. Failure: Improper or uneven torque can lead to fluid leaks from the pan gasket.
• Bulkhead Connector Sleeve Seating Depth — expected: Approximately 15 to 16 millimeters from the edge of the sleeve to the transmission case.. Failure: A measurement greater than 16mm indicates the sleeve is not fully seated, which can lead to limp mode or other DTCs.

Scan Tool Commands That Help

• Ford IDS (or equivalent professional scanner): Reset Transmission Adaptive Memory / TCM Keep-Alive Memory (KAM) Reset — This must be performed after replacing the molded lead frame. It clears the old, learned shift strategies, allowing the transmission to relearn shift points and pressures with the new component. Failure to do this can result in continued harsh or erratic shifting.
• Ford IDS (or equivalent professional scanner): Transmission Adaptive Learning Drive Cycle — After resetting the adaptive memory, a specific drive cycle must be performed to allow the PCM to learn the characteristics of the new lead frame and solenoids for smooth shifting.

Wiring & Ground Locations

• PCM Connector C175T, Pin 25 — This is one of the main connectors at the Powertrain Control Module (PCM).. Pin 25 is the specific input for the Output Shaft Speed (OSS) sensor signal, circuit RET04 (YE-OG). A continuity test between this pin and the corresponding pin at the transmission bulkhead connector can isolate a wiring fault from an internal transmission issue.
• Transmission Bulkhead Connector (C1575) — The large, round, external electrical connector on the passenger side of the 6R80 transmission case.. This is the main connection point between the vehicle's wiring harness and the internal lead frame. It's a common point for testing and is susceptible to fluid leaks from the internal sleeve, which can cause connection issues.

Real Owner Repair Stories

• f150forum.com user (2014 Ford Expedition, 83k miles) — Check engine light with code P0720, transmission went into limp mode, 'Miles to Empty' display went blank, and the TPMS warning light came on.
  ❌ Tried (didn't work) The dealer initially wanted to replace the entire transmission for $5,000 and did not consider the lead frame despite the owner mentioning the known recalls.
  ✅ What actually fixed it The owner performed a DIY replacement of the molded lead frame, transmission fluid, gasket, and bulkhead connector sleeve. The total cost for parts was approximately $275, and the repair resolved all symptoms.
• f150forum.com user 'electrotyper' (2013 F-150 5.0L) — Error codes P0720, P0722, and P0731 were present.
  ✅ What actually fixed it The dealer replaced the molded lead frame, 11 quarts of transmission fluid, and the bulkhead connector sleeve. The repair was covered financially by Ford under a TSB (likely 19N01).

When the Usual Fixes Don't Work

• In one documented case, a technician performed electrical checks for shorts and opens on the OSS circuit and found nothing wrong, yet the P0722 code persisted intermittently. This highlights that the failure within the lead frame is often an internal, intermittent open circuit caused by thermal expansion or vibration, which may not be detectable with a simple static continuity or voltage test from the external connector. The problem was only resolved by replacing the lead frame assembly.

OEM Part Supersession History

• AL3Z-7G276-A, AL3Z-7G276-B → AL3Z-7G276-D — The earlier revisions of the lead frame were prone to internal circuit failure for the OSS and transmission range sensors. The 'D' revision is the updated design intended to fix these quality control issues.
  Heads up: The 'D' revision is the correct and recommended replacement for all 2011-2013 models. While older stock of 'A' or 'B' may be found, they should be avoided as they contain the original design flaw.

Model Year Variations Within This Range

• 2011+: Unlike the 2009-2010 6R80 transmissions where the Transmission Control Module (TCM) was integrated with the lead frame inside the transmission, the 2011+ models have a separate lead frame. The TCM functions were moved to the main Powertrain Control Module (PCM). This makes the lead frame a separately replaceable (and less expensive) part.