Transmission problems 1997 4r55e

zems · June 14, 2003

I have gotten some good advice from searching these forums but I haven't found a situation similiar to mine. I have a 1997 Explorer 4x4, 4.0 SOHC with the 4r55e transmission,145000 miles. The transmission has started to grind when you let off of the gas going 35mph or faster. I have noticed that the grind doesn't start until the engine rpms drop. When you let off of the gas the engine holds its rpms for a while then drops to 1000 rpms then the grind starts. If you bring the rpms back up to close to where they were, without accelerating, the grind goes away or shifting it into neutral will stop the grind noise. Also when you put it in reverse you get the same grinding noise until it goes into gear. The reverse thing only happens once in a while. Otherwise the transmission seems to shift fine through all gears and does not slip. There are no codes when I scan it. This noise started as a once in a while thing to all the time in a weeks time. I will be running a pressure test on it soon and I do have the ATSG manual. Does anyone think the valve body or its gaskets could cause the problem. A transmission shop said it was probably the overrun sprag, but I realize they are in the business of selling rebuilt transmissions. I can not afford the quoted rebuild ($2000) so I would have to do it myself. What do you guys think.
Sorry for the long post,
zems

TPLYNCH · June 16, 2003

From the description of the times it happens, I'm gonna have to think Torque Converter. Have you checked fluid level/condition? Done a fluid/filter change recently? There are tsb's on this tranny for loose valve bodies and other things, but those generally result in slow D/R engagement and/or no engine braking in 1.

zems · June 17, 2003

The fluid level was fine and the condition was good. It was do for a filter/fluid change, not sure of maintenance history on this transmission so assume the worst. The Torque Converter was my first thought but I was told that it would act up more on acceleration then deceleration. There was no noises on acceleration. I have done some tests, the stall speed tests fine (2550 rpms at WOT) in all ranges. I believe this would eliminate the Torque Converter as a problem. The pressure test is a little low at idle in all ranges by 5-10 psi but the WOT pressure is at the upper limit (within 10-20 psi) in all ranges but does not go over. I have had the pan off and the valve body seems to be tight. There also was not any large metal pieces in the pan just gray flake. So I am leaning towards a mechanical problem inside. It is on its way out for a rebuild. I will rebuild it myself so I open to any advice or suggestions for this transmission rebuild. If there is any incorrect assumptions that I have made based on the tests performed, please let me know.

BonesDT · June 19, 2003

um...are you sure you have a 4r55e? '97 with the SOHC, that sounds like you have a 5r55e.

fordkrazy · June 20, 2003

the 4r55e may have still been used that year since it was the first for the sohc....but i would run the part # on the tranny tag before i bought any parts....the case is the same i believe and its just electronics and some smaller pieces that are different...but im not sure

lonestar · June 20, 2003

There was someone here trying to sell a 4r55e tranny not to long ago. I think rebuilt and everything.

JMEJAMES · June 20, 2003

I had the same exact problem to the "t" with my 96 4.0 and could find no one in the industry or on the net with the same symptoms. After a complete trans rebuild and new valve body it turned out to be the transfer case. I'm not sure if it was a slipping pinion or what that was causing it not to mesh upon deceleration (in 2w dr. only). Anyway replaced all the gears in the transfer case after they eventually stripped from that slight buzzing noise you hear upon decel and occasional reverse, and it's better than new, but it took 3 different trips to the tranny shop to figure it out when the gears finally went and all I had was 4 wheel low (front wheels driving only!). Let me know how ya make out.

zems · June 21, 2003

I guess I never felt it shift more than 3 times so I just assumed it was a 4 speed automatic. The codes on the door show that it is a 1997 manufactured in 8/96 and that it should have a 5 speed. Tommorrow I will be calling Ford with the part number on the transmission just to double check. It is possible that this transmission has already been replaced once, since a few things didn't look quite right on removal. I will definately look at the transfer case, but I'm not sure the rpm's would drop (3000 down to 1000) if it was that. Did yours?
I have been turning wrenches at home too long to make that kind of an assumption. Thanks BonesDT for bringing it (5r55e) to my attention.

Zems

BonesDT · June 21, 2003

no problem. i wouldn't go by what you feel. i can't feel for the life of me some of the shifts, they can be really smooth. def check it out.

zems · June 21, 2003

It is definately a 5r55e transmission. Well I guess I'm only out the cost of a manual. I will have to get the new manual on its way for the 5r55e. Has anyone else rebuilt their own 5r55e Transmission.

Zems

Hoppy · July 9, 2003

I second that. Has anyone rebuilt a 5R55E?

BonesDT · July 9, 2003

theres a guy OperaHouse on this site. everyone says hes the pro with the rebuilds.

i have the 5r55e manual. thank god someone actually makes a fully detailed manual. you will be happy with it. i would like to rebuild mine, but it seems like you need dozens of special tools that cost thousands of dollars.

can someone tell me if its possible to rebuild the entire tranny with minimal tools? i obviously have the know how since i now have the manual, and the tranny is sitting in my garage, im just stuck with the tool problem.

Hoppy · July 9, 2003

I have heard that the 5r55e is based on the old A4LD tranny, and I have one apart at my workbench and I took it apart with simple tools. The only special tool I had to buy was a snap ring plier that was slender enough to work inside of the tranny case. If it is based on the A4LD, I would imagine that it is an easy tranny to rebuild.

Any more insight?

Hoppy

coled43 · July 9, 2003

I agree with JMEJAMES above, the symptoms you describe sound like the transfer case! I had the same grinding sound under the same conditions in my 97 SOHC when decelerating. It was the transfer case. I had it replaced with a used one and its all set. There is alot of information on this board about the control trac transfer case so its hard to search it, but when I was researching my problem I found a post where this problem repeated after rebuilding the transfer case. Dogfriend posted a link to an article in Gears magizine by someone from Rockland Standard Gear about troubleshooting the control trac t-case. He mentioned that these t-cases are prone to certain mechanical problems. The gears that are wearing are misaligned due to problems with the rails in the case itself. So if they are replaced without fixing the case, which requires special machining, the gears will fail again. I believe it also said that the gears are helical and stay engaged when under power but slip out when you let of the gas. I have a print out of the article somewhere, but maybe you or someone else can find the link in the old post. Rockland Standard sells rebuilds with the case repaired for around $1200, other generic rebuilds are around $750. I went for a used one for $600.

jknapp6 · July 12, 2003

just started having this same problem of "grinding while deaccelerating (sp)" so I need to know is this the transfer case? It does not seem to be the transmission!

Help... should I take it to a dealer or what?

Thanks!

zems · July 14, 2003

I have my 5r55e apart and did not need special tools to get it apart but it looks like I will need special tools to replace the overdrive sprag and align the front pump. There was nothing obviously wrong with the transmission. There was a lot of metal shavings. I will be replacing the overdrive sprag, overdrive planetary, overdrive adaptor washer, sunshell, and torque convertor. The overdrive sprag seems to be holding but will be replaced due to a recommendation by a transmission shop and cheap to replace. Overdrive planetary is wearing through the hard surfacing on the gears, so replace now than later. Overdrive adaptor washer is showing wear like it has been slipping but it is not warped. Sunshell was wearing so again because it was cheap. Torgue convertor is general procedure and using a rebuilt one. The only other thing that looked like a problem was one of the three bolts that holds the divider plate to the valve body was loose but all others were tight. It did look like fluid was leaking by the gasket where the bolt was loose. Again I didn't consider the transfer case because I lost engine braking or when I lost engine braking is when the noise started. But it could still be the problem. I will search the archives. Did anyone else lose engine braking with the transfer case problems. I still think it is a good time to rebuild the transmission at 145,000, with all the metal flake that I have found, and with the parts and kit I have only spent $500.

Hoppy · July 14, 2003

Zems,

This sounds like an excellent way to learn the ins and outs of the 5r55e. I have one in my 97 XLT as well, I am not having any trouble with it whatsoever, so far, but I also have a year and a half drivetrain warranty on the truck. I don't know if you have ever had an A4LD apart, I have one in my basement that I have dissassembled and it sounds from what you describe to be the same kind of setup that the 5R55E is.

Where did you purchase your kit from, and what all did you get with the kit? The price you quoted, is that in US dollars as well? The reason I ask is because I am in Ontario Canada and would like to price out how much it is here for the same kit.

What kind of special tool to you mean to get the overdrive sprag back together? Is this just to compress the return springs? The front pump, Is this the same alignment tool you would use for the A4LD?

Thanks,

Hoppy

BonesDT · July 14, 2003

what about alignment/gauge tools?

Hoppy · July 14, 2003

Any of the tools. Do you use the same alignment tools and spring compressors as you would on the A4LD?

Glacier991 · July 15, 2003

Amazingly enough... the tranny that started out with the pinto, still lives. Yes the Pump alignment tools are the same.... even been reissued, but are the 74 series. Gauge bar was in 93 and is still the same. I'd say the pump alignment tools are critical - still.

Happy Exploring

Chris

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