Bits of Bronze
......The solonoid bushings were pretty decent the bands were in good shape.
The rebuild included the bronze solonoid inserts, a rebuild (new bands) and hard parts.
(no warranty:
)
Hey, above caught my eye! '04 Explorer, 96K, 5R55S trans., O/D light started flashing while we were on vacation in Laughlin, NV. I noted symptom of eng. rpm increase with slight pedal pressure @50mph, guessed Torque Converter Clutch (TCC) was not engaging. Worried, Ford Dealer pulled code P-1744 "TCC solenoid error or stuck OFF". He recommended replace transmission, based on high miles, or try flushing it ($300); I gave him the $75, and we drove it back home to Missouri, 1600 miles, light flashing all the way!
Now, I believe in fixing things when possible, like the guy in Indiana (my wife's from there), rather than throwing them away. So I did the tests I knew how, lacking the big diagnostic equipment. Checked solenoid coil resistance and resistance to ground, both good. 12V. applied to the solenoid at it's terminals produced audible "click". Now suspecting the clutch itself, I grounded the proper PCM lead up in the eng. compartment, with eng. idling, to see if clutch would apply (eng. would stall), thus proving computer at fault, result negative.
I ordered a new solenoid block, meanwhile today I took down the valve body to check TCC-related valves for possible sticking. The pics show what I found sitting on top of the valve body as I lowered it out: small pieces of bronze in a neat little pile directly below a dime-sized hole in the trans. case above, no matching hole for flow in the valve body.
Dunwood's mention of bronze bushings, or guides, in these solenoids prompted me to post. Perhaps someone else viewing this thread, now over 2 years old, might shed some light on this with their own thoughts/knowledge. I figgered the clicking of the sol. indicated it was good; I could be dead wrong on that. Still do not know the true mechanical nature of the clutch in these torque converters; Ford mechanic claimed it is a splined coupling which is shifted to lock the members together; Shop Manual mentions "clutch material". I wonder if the bronze pieces came from the clutch itself? The proof of solenoid failure, or not, will come in the mail maybe Monday. Meanwhile, any thoughts would be greatly appreciated.
I posted several new threads in the "Transmissions" section, lots of views, but no replies, though. Any thoughts greatly appreciated! imp
Below, the top of the valve body, with separator plate still installed. Little heap of bronze bits visible right where I found them.
Close-up of the bad stuff. The pieces appear to be flat chunks about 1/16-inch thick, like one might find used as a thrust washer............
