TSB 04-24-17
12/13/04
5R55W TRANSMISSION - NO 3RD GEAR OR
SLIPPING 2-3 SHIFT - DTCS P0733 AND P0745 -
VEHICLES BUILT PRIOR TO 3/4/2002
FORD:
2002 EXPLORER
MERCURY:
2002 MOUNTAINEER
This article supersedes TSB 03-25-4 to update the description for labor operation "B". There have been no changes made to the TSB procedure.
ISSUE
Some 2002 Explorer/Mountaineer vehicles built prior to 3/4/2002 with 5R55W transmission, may exhibit no 3rd gear or slipping 2-3 shift with diagnostic trouble codes (DTCs) P0733 and P0745 present. This may be due to a broken intermediate band.
ACTION
If the conditions described are verified:
^ Follow Service Procedure "A" to confirm band is broken.
^ Follow Service Procedure "B" after verifying a band is broken.
Per Procedure "B", if a broken band is found replacement of both the OD and intermediate bands and pistons will be necessary. However, only an inspection of the direct clutch drum may be necessary. The drum should not be replaced unless damage is found.
NOTE THIS ARTICLE DOES NOT APPLY TO ANY OTHER CONDITIONS OR COMPONENTS THAT MAY CAUSE SIMILAR SYMPTOMS AND IS ONLY WRITTEN TO COVER THESE SPECIFIC CONDITIONS.
SERVICE PROCEDURE
PROCEDURE "A" - BROKEN BAND VERIFICATION
CAUTION WHILE PERFORMING THE FOLLOWING PROCEDURE DO NOT ALLOW BAND ADJUSTMENT SCREW TO BACK OUT. BAND STRUT COULD FALL OUT OF POSITION.
1. Loosen the intermediate band locknut on the band adjustment screw.
2. Using the special service tool (307-5022), tighten the suspect band adjustment screw to 10 lb.ft (14 N.m).
a. If the band adjustment torque cannot be achieved, both bands will need to be replaced. Proceed to PROCEDURE "B".
b. If the proper torque is achieved, the band is OK and does not need to be replaced. Proceed to Step 3 of PROCEDURE "A".
3. Lubricate the locknut seal with petroleum jelly prior to installation.
a. Remove the band locknut and discard.
b. Install a NEW band locknut.
c. Using the special service tool (307-5022), tighten the band adjustment screw to 10 lb-ft (14 N.m).
d. Back off the screw exactly two (2) turns and hold that position.
e. Tighten the intermediate band locknut.
f. Hold the band adjustment screw stationary.
g. Tighten the band locknut to 40 lb-ft (54 N.m).
h. Continue with normal diagnosis and repair for the condition as outlined in the Workshop Manual.
PROCEDURE "B" - VERIFIED BROKEN BAND
NOTE REPLACEMENT OF THE EXTENSION HOUSING SEAL AND BUSHING ARE NOT REQUIRED. DO NOT DISASSEMBLE BEYOND THE DIRECT CLUTCH ASSEMBLY. ALL SUBASSEMBLY STEPS ARE NOT REQUIRED FOR THIS PROCEDURE.
Using the following procedure, replace the bands and servos. Inspect the direct clutch drum and replace ONLY IF DAMAGED.
1. Remove transmission assembly, refer to the Workshop Manual Section 307-01.
2. Following the Workshop Manual steps found in Section 307-01 remove and discard the front and intermediate bands and the front and intermediate servos.
3. Remove the direct clutch drum.
4. Inspect the direct clutch drum for scoring or damage, DO NOT REPLACE THE DRUM UNLESS IT IS DAMAGED. For replacement procedures, refer to the Workshop Manual Section 307-01 (Automatic Transmission, Disassembly and Assembly of Subassemblies Direct Clutch Drum Assembly).
NOTE DO NOT DISASSEMBLE BEYOND THE DIRECT CLUTCH ASSEMBLY. NO OTHER SUBASSEMBLIES NEED TO BE DISASSEMBLED.
5. Following the Workshop Manual, reassemble the transmission and install BOTH NEW service bands (7D034), a NEW intermediate servo piston and rod assembly (7D021), and a NEW front servo piston and rod assembly (7D021). ONLY IF DAMAGED INSTALL A NEW DIRECT CLUTCH DRUM ASSEMBLY (7D044).
6. Install the transmission assembly, refer to the Workshop Manual procedures found in 307-01.
7. Verify the condition has been corrected.
