for access to Reviews and Discussion of the 2016 and 2017 Ford Explorer Tech Tips, How to Articles, Off-Road Modification, Events, and more!

Register Today It's free! This box will disappear once registered!

5R55W Solenoid Block Replacement w/photos.

Discussion in 'Explorer & Ranger Transmissions, Transfer Cases, &' started by borland, August 4, 2006.

  • Searches ExplorerForum.com
    1. borland

      borland New Member

      Joined:
      July 4, 2006
      Messages:
      47
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      Camarillo, CA
      Year and Model:
      2002 XLT
      5R55W Solenoid Pack Replacement on 2002 Explorer XLT

      Here’s the procedure.

      Placed all fours on 4”x12” wooden blocks.

      [​IMG]

      [​IMG]

      Disconnect the battery neg terminal

      [​IMG]

      Draining ATF with 22mm wrench. Only about 4 qts drained.

      [​IMG]

      Next evening, removed plug again another 3 qts drained.

      Disconnecting the harness using a 10mm wrench. Note in the photo, the connector w/bolt is seen in the inspection mirror.

      [​IMG]

      Lay down a plastic drop cloth under a metal drip pan.
      Remove drained pan using 8mm socket wrench, ¼”swivel and extension.

      [​IMG]

      Using the tranny pan to catch fluids, unbolt solenoid pack using T-30 wrench.

      [​IMG]

      Solenoid body removed. Note the solenoid connector in photo.

      [​IMG]

      Install new solenoid body pack and tighten bolts to 71 in-lbs. Coat harness plug o-rings with dielectric grease and reinstall/tighten harness plug

      Install tranny pan, reusing gasket, tighten pan bolts to 96 in-lbs. Tighten drain plug to 19 ft-lbs.

      Degrease exhaust pipe under drain pan to remove any ATF.

      At pan drain plug, Remove inner plug using T-30 wrench (counter hold drain plug with 22mm wrench). Install temporary fill brass hose barb (1/8” NPT x ¼” hose). Install hand pump (valvoline fluid lubricant pump, fits most standard quart bottles, about $7 at Kragen Auto) and suitable pinch clamp.

      [​IMG]

      Remove pinch clamp, and refill with new Mercor V. Start by adding with 5 qts. Without disconnecting the pump, switch between fresh quart bottles.

      Reconnect battery. Run engine for a 30 seconds.

      Add remainder ATF. Install pinch clamp, remove pump.

      Restart engine and cycle tranny between reverse and drive gears. Let engine idle in "Park" and remove pinch clamp to drain excess fluids. Excess should flow until a very small stream or drip is observed.

      Add more fluid if necessary, but install pinch clamp before shutting off engine.

      With engine still running, reinstall inner plug. Tighten inner plug to 89 in-lbs.

      Test drive.
       
      Last edited: July 1, 2009
    2. Support EF


      Join the Elite Explorers for $20 a year

      Explorer Forum has probably saved you that much already, and will continue to save you money as you learn how to diagnose and fix problems yourself, and learn which modifications work without having to experiment on your own. Elite Explorer members see practically no ads, add your own profile photo, upload photo attachments directly to your posts and Media Gallery, create more private Conversations, and more. Join Today. Your support is greatly appreciated.



      to hide adverts.
    3. BrooklynBay

      BrooklynBay Staff Member Moderator Elite Explorer

      Joined:
      November 11, 2005
      Messages:
      50,870
      Likes Received:
      18
      Trophy Points:
      58
      City, State:
      Brooklyn, NY
      Year and Model:
      88 89 93 95 96 Aerostars
    4. borland

      borland New Member

      Joined:
      July 4, 2006
      Messages:
      47
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      Camarillo, CA
      Year and Model:
      2002 XLT
      Looks like the photos are still showing up in my above post. I've added some updating information in post #5 below.
       
      Last edited: June 24, 2011
    5. mikephotos

      mikephotos Active Member

      Joined:
      July 6, 2004
      Messages:
      105
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      Queens, NY
      Year and Model:
      '02 Eddie Bauer
      Great photos, thanks! I actually just got back from my friends place where we did the same. But the replacement didn't help, my tranny is still having shift problems between 2nd-3rd. Maybe someone here can help/give advice. Here's the deal (sorry if this sorta hijacks the thread a bit but I figured since we're on the same topic there was no need to start another thread..hope you don't mind)

      Ok, so the tranny is acting up. O/D light flashing and slow/very difficult shifting from 2nd to 3rd. SES light goes on. Checked the codes and get P0745 - Pres Cntrl Sol. A Circuit Malf. Reading up here and elsewhere on the web suggest replace the solenoid block. It's a 2002 Eddy V6 4x4 with 64,000. AFAIK, never had a trans filter or fluid change.

      Basically did the exact same procedure as listed above (great write-up BTW, thanks). Everything went well, filter change, about 4-4.5 qts ATF M-V came out, replaced same and of course the solenoid. Torqued everything to spec. All was actually fairly simple, no complications.

      Test drove the vehicle afterwards (about an hour ago) and it's still behaving exactly as before. Slow shifting 2nd to 3rd, revving high between 2-3 and then sometimes shifts with a slight clunk (nothing too loud) or perfectly if you let off the gas slightly and then reapply. Once in 3rd it drives like a dream until slowing down again. If I let it rev too high or if it doesn't shift correctly the O/D light starts flashing but no SES yet.

      Now, after reading borland's post I noticed I forget a step. We did not disconnect the battery before the procedure. Did do it afterwards to reset the SES but didn't even think about it beforehand. Was that a big mistake? Would that be the cause of the solenoid replacement to not correct the problem? Or (which is what I am leaning towards) is it another problem, poss. valve body or worse?

      Any help would be greatly appreciated. I spent about $250 so far, got the solenoid and filter at a discount via a friend. Should I continue with replacing other parts or just give in and bring it to the dealership and expect to pay $$$.

      Mike
       
    6. borland

      borland New Member

      Joined:
      July 4, 2006
      Messages:
      47
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      Camarillo, CA
      Year and Model:
      2002 XLT
      Mike,

      Maybe one of the experts can give you some recommendations. Glad you posted your problem, as wouldn't want anyone to think this procedure will fix all.

      A pressure gage would tell if the pressures are good. It might be your valve body separator plate that needs replacing. There's also a pressure relief valve at the main pump that could be leaking off pressure.

      My symptoms were harsh up-shifting. No flashing OD light. Never read the OBD codes to see if there were any. But replacing the solenoid body seems to have fixed it.

      A little history on my truck. Current mileage is 75K miles. Dealer replaced the solenoid body at 51K miles with the exact same symptoms (harsh up-shifting) [Repair bill was $616 total]. They said it had an erratic modulation pressure. Immediately after that repair, the truck developed a leak at the converter housing (apparently the fluid was foaming). Remedy for that was to pull the tranny and replace the vent tubing [Repair bill was $131, some of the labor was absorbed by the dealer]. So, total for those repairs was $747.

      Why the second solenoid body would go bad after 18 months and only 24K miles? I really don't know. The dealer never replaced the filter; that might have attributed to the early failure. I took the dealer installed solenoid body apart and found no apparent damage. There was some micro fines/particles on one of the internal plastic filters, but certainly not clogged. So, it's a mistery to me.

      -----------------
      Update: June 23, 2011

      Everyone,

      I still own this 2002 Explorer XLT.

      After almost 5 years and 50K miles (now 125K miles), the truck developed the same hard shifting symtoms, but only after driving several freeway miles (fully warm transmission). So I replaced the solenoid block again.

      Only thing I have to add on this replacement procedure is the center plug on the drain plug stripped out with the T-30 wrench. The factory spec of 89 in-lbs may be too much. It might be a good idea to replace the drain plug each time, as the part (part number 6L2Z7A010AA) is only $7.50 (plus shipping) from Ford and this part also includes the pipe, o-ring (W705355 S300), and center plug. I installed the center plug this time at only 80 in-lbs of torque.

      I also reduce the pan bolt torque from the factory recommended 96 in-lbs to 80 in-lbs.
       
      Last edited: June 24, 2011
    7. BrooklynBay

      BrooklynBay Staff Member Moderator Elite Explorer

      Joined:
      November 11, 2005
      Messages:
      50,870
      Likes Received:
      18
      Trophy Points:
      58
      City, State:
      Brooklyn, NY
      Year and Model:
      88 89 93 95 96 Aerostars
      Why would the dealer replace the solenoid block, and ATF without replacing the filter? Maybe they just did a flush from the cooler lines. Does the 5R55W use bonded gaskets on separator plates like the previous 5R55E model?
       
    8. borland

      borland New Member

      Joined:
      July 4, 2006
      Messages:
      47
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      Camarillo, CA
      Year and Model:
      2002 XLT
      Yes, the 5R55W has a bonded separator plate gasket too.

      Invoice showed only parts replaced were the solenoid pack and 6 quarts Mercon V. They couldn't do a flush with only 6 quarts.
       
    9. BrooklynBay

      BrooklynBay Staff Member Moderator Elite Explorer

      Joined:
      November 11, 2005
      Messages:
      50,870
      Likes Received:
      18
      Trophy Points:
      58
      City, State:
      Brooklyn, NY
      Year and Model:
      88 89 93 95 96 Aerostars
      At least they used Mercon V. A lot of people have posted that these shops used Dexron III with the Lubegard additive. Some people posted having slippage problems until they added the Lubegard.
       
    10. BrooklynBay

      BrooklynBay Staff Member Moderator Elite Explorer

      Joined:
      November 11, 2005
      Messages:
      50,870
      Likes Received:
      18
      Trophy Points:
      58
      City, State:
      Brooklyn, NY
      Year and Model:
      88 89 93 95 96 Aerostars
    11. mikephotos

      mikephotos Active Member

      Joined:
      July 6, 2004
      Messages:
      105
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      Queens, NY
      Year and Model:
      '02 Eddie Bauer
      Borland, thanks for the reply. I'll look into those suggestions. If anyone else has suggestions/advice I'd love to hear it.

      Mike
       
    12. mikephotos

      mikephotos Active Member

      Joined:
      July 6, 2004
      Messages:
      105
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      Queens, NY
      Year and Model:
      '02 Eddie Bauer
      Was searching for more info on the 5R55W and came across this .pdf. Some nice detail pics and info.
      http://www.ratiotek.com/tmp/5r55w-complete.pdf

      Still looking for more advice on what to do...is Glacier991 still around?


      Mike
       
    13. BrooklynBay

      BrooklynBay Staff Member Moderator Elite Explorer

      Joined:
      November 11, 2005
      Messages:
      50,870
      Likes Received:
      18
      Trophy Points:
      58
      City, State:
      Brooklyn, NY
      Year and Model:
      88 89 93 95 96 Aerostars
    14. fatdad461

      fatdad461 New Member

      Joined:
      June 10, 2006
      Messages:
      10
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      somerset kentucky
      Year and Model:
      2002 xlt
      The thread on solenoid replacement is very helpful to me because I have the some problem with my 02 Explorer.Did the powertrain control module need to be re-progamed? I have seen other threads that state this might in to be done
       
    15. BrooklynBay

      BrooklynBay Staff Member Moderator Elite Explorer

      Joined:
      November 11, 2005
      Messages:
      50,870
      Likes Received:
      18
      Trophy Points:
      58
      City, State:
      Brooklyn, NY
      Year and Model:
      88 89 93 95 96 Aerostars
      I don't think it's necessary to flash, and reprogram the PCM with a new tune when you replace the solenoid block, but according to some threads, a lot of people experienced better shifting with the new tune, so it's optional, but recommended.
       
      Last edited: November 7, 2008
    16. Glacier991

      Glacier991 EF Tranny Guru Moderator Emeritus

      Joined:
      February 8, 2003
      Messages:
      9,830
      Likes Received:
      4
      Trophy Points:
      38
      City, State:
      Sacramento, CA 95827
      Year and Model:
      1992 XLT
      Sorry guys... been away a bit on and off plus really busy at work and missed this thread.

      I liked the pix and always think pic threads are the best of all, wish you might had had a few more of the removal and re-install od the block, but that's ok.

      When FORD went to "blocks" they more or less mandated replacing everything when just ONE thing went bad. EPC or shift, didn't matter. The EPC was a low mileage failure component, and 75K is about right for that to occur, low end. I have sold a few blocks, and in every case they have solved the problem. I am interested that yours did not.

      PO745 is either a mechanical OR hydraulic failure. Pinpoint Test D for the solenoids is the textbook method... requires a NGS tester (every FORD dealer has one).

      I am very curious to know ifthe harnesses are ok....In this day and age, transmissions are as much electrical as transmission.

      Not much help here, I know... but I am researching, and when I can add something i will.
       
    17. fatdad461

      fatdad461 New Member

      Joined:
      June 10, 2006
      Messages:
      10
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      somerset kentucky
      Year and Model:
      2002 xlt
      Well it took me about 2+ hours to swap solenoids,but as of right now [knock wood] the tranny shifts great,very smooth. The only hard part for me was getting that 10mm bolt loose from the top of the pack.I have rather large hands, and laying on the ground working in a very small space just about got the best of me, but I won this one! The best part was I found a guy online that sold me a brand new soleoid for $55, the dealer was asking $275.THANKS to all who post the threads and links that got me through this.
       
      Last edited: October 29, 2006
    18. Glacier991

      Glacier991 EF Tranny Guru Moderator Emeritus

      Joined:
      February 8, 2003
      Messages:
      9,830
      Likes Received:
      4
      Trophy Points:
      38
      City, State:
      Sacramento, CA 95827
      Year and Model:
      1992 XLT
      Success stories are always welcome! Thanks for sharing yours. Especially with the W's (and S's and N's) Block replacement is going to become a big event.... and easy to DIY. I appreciate you taking the time to share your story with us.
       
    19. walterZ

      walterZ New Member

      Joined:
      October 12, 2007
      Messages:
      3
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      miami.fl
      Year and Model:
      2002
      5r55w Replaced solenoid following the procedure but still have the problem

      Hello Friends: first at all, Thank you for the Great info at this forum.
      A week ago i've started to have problems with my 2002 explorer, Trans failed to change from 2nd to 3rd, I've read the post here and everything pointed to the solenoid pack, so i got a new one, and replaced with a new filter and gasket, the procedure went pretty smooth (about 2 hours to replace it), when i went to test it, trans shifted better but i was still having trouble betwen 2nd and 3rd , i having even no shift or a very delayed shift and when the 3rd is finally engaged at high rpm the shift is kinda rough (but i think is because is not doing it at the proper rpm) , I found some others users wuth the same 5r55w trans that have had the same problem, any ideas about where i have to look?. everything was clean when i took off the pan, no metal pieces,no burned smell , oil was little bit darker than the new one but it was 65000 old. I'd really appreciate any input , i'm already out of ideas (and money BTW) . Thank you.
       
    20. BrooklynBay

      BrooklynBay Staff Member Moderator Elite Explorer

      Joined:
      November 11, 2005
      Messages:
      50,870
      Likes Received:
      18
      Trophy Points:
      58
      City, State:
      Brooklyn, NY
      Year and Model:
      88 89 93 95 96 Aerostars
    21. walterZ

      walterZ New Member

      Joined:
      October 12, 2007
      Messages:
      3
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      miami.fl
      Year and Model:
      2002
      Thaks for the prompt response!!. i didn't have the torque specs for the T30 from the solenoid but i took care not to overtight them. All the problem started with a 745 OBD code, and the shifting issue, now after a test road, again got the 745 , it's shifting but when it does i hear like a strong hissing coming from the trans, like a valve releasing pressure, could it be a broken valve plate related? , i'm suspecting also from a servo because of the rough shifting. some ideas of how to do a checkout in order to discard options?. Thank you.
       
    22. walterZ

      walterZ New Member

      Joined:
      October 12, 2007
      Messages:
      3
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      miami.fl
      Year and Model:
      2002
      Hello: Thanks for the promp reply: I did't have the torque specs for the solenoid but i took care not to overtight, The problem started with a 745 code and the shifting issue, right after i replace the solenoid i have shifting delay but no code, after a few miles finally the 745 showed again, now it's doing something little bit different, instaed of shift at 3000 rpm , it's doing the 2nd to 3rd at 4000 rpm (aprox) , and i can hear a hissing coming from the trans like a valve releasing pressure, but it does the shift, i'm wondering if could it be a broken valve plate , or may be a servo , there's some way to test to discard options?.Thank you.
       
    23. tmiddendorf

      tmiddendorf New Member

      Joined:
      November 4, 2007
      Messages:
      3
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      Melbourne, FL
      Year and Model:
      2002 Explorer Limited RWD
      5R55W Solenoid Body Replacement found Overdrive Anchor Strut in pan

      Hello,
      THis is my first post here. I want to thank you all for posting such helpful and detailed information.
      I found a bulk buy Solenoid Pack on the web for $85 shipped. I did the replacement. All seemed to go well. When I drained the last of the old ATF from the pan before reinstalling the pan, I discovered a metal part sitting in the bottom of the pan. I later learned it is the Overdrive Anchor Strut! Yes, sitting nt he bottom of the transmission pan. So while I have the Solenoid Pack job done it looks like I have another job ahead of me. By the way , the transmission acts the same after the installation of the "new" Solenoid Pack. It seems likely to me that the Overdrive Anchor Strut would be a causing factor in the transmissions behavior. Does anyone have any information or experience with this part and how to reinstall it? Thanks.
       
    24. BrooklynBay

      BrooklynBay Staff Member Moderator Elite Explorer

      Joined:
      November 11, 2005
      Messages:
      50,870
      Likes Received:
      18
      Trophy Points:
      58
      City, State:
      Brooklyn, NY
      Year and Model:
      88 89 93 95 96 Aerostars
      Welcome to this forum! You could reinstall it by dropping the valve body for clearance. Make sure that both sides of the band are connected. It's possible that it either fell out because somebody tried to adjust the band, but didn't do it correctly, or the band might be broken. Where did you find a solenoid block at that price? Check this link for band adjustment, and installation pictures: http://www.explorerforum.com/forums/showpost.php?p=1436286&postcount=4
       
    25. tmiddendorf

      tmiddendorf New Member

      Joined:
      November 4, 2007
      Messages:
      3
      Likes Received:
      0
      Trophy Points:
      0
      City, State:
      Melbourne, FL
      Year and Model:
      2002 Explorer Limited RWD
      5R55W Solenoid Body Replacement found Overdrive Anchor Strut in pan

      Thanks for the reply BrooklynBay. I found it at: http://bulk-surplus.com/bulk.aspx . Just scroll to the bottom of the page. I paid via Paypal and he shipped quickly.

      I have the Ford Service Publication CD, but the images are not esy to read. If you have a link to a better diagram I would appreciate it so that I can see the Valve Body you referred to. If the band is broken, I assume that is a bad thing as in costly. If I can get teh strut back in place myself, will I need to adjust the band? If so is that procedure in the service pub CD?
      Thanks,
      Tim
       
    26. BrooklynBay

      BrooklynBay Staff Member Moderator Elite Explorer

      Joined:
      November 11, 2005
      Messages:
      50,870
      Likes Received:
      18
      Trophy Points:
      58
      City, State:
      Brooklyn, NY
      Year and Model:
      88 89 93 95 96 Aerostars
      If you could get the parts in place from underneath, then you could adjust the band when you are finished. A broken band requires opening the transmission to get to it. This link has pretty much everything you would want to know about the 5R55W: http://ratstangrestoration.com/5r55w-complete.pdf
       
      Last edited: November 16, 2008

    Share This Page









    We Support Our Troops!