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Solved Transmission servo piston shaft broke in the bore.

Discussion in 'Stock 2002 - 2005 Explorers' started by Shtiv, January 31, 2017.

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  1. Shtiv

    Shtiv New Member

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    Hi guys,
    To leave out a long story I was replacing servo bores, but had to remove the new ones because of a problem. So while trying to remove the piston broke its tip in the bore. I believe I have bought every tool imaginable to get the thing out. Due to the tight space and the exhaust in the way I cannot get my drill in to try and use screw extractors. Not sure why its so tight in there, but it is. Any ideas for extraction???? I then removed the pan, filter, and tried to remove solenoid pack, but the solenoid pack does not want to come free, seems to be stuck in the part where it attaches to some kind of bore? If I remove the solenoid pack could I access the broken tip?????Thanks for any help.

    [​IMG]
     
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  3. BrooklynBay

    BrooklynBay Moderator & long time member. Staff Member Moderator Elite Explorer

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  4. Shtiv

    Shtiv New Member

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    Thanks for your reply, thats one thing I have not thought of. I still have no way of grabbing a hold of it to extract.
     
  5. BrooklynBay

    BrooklynBay Moderator & long time member. Staff Member Moderator Elite Explorer

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  6. Shtiv

    Shtiv New Member

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    That I have not, its a good idea but the problem is I do have any bored holed left down the center of the piston. I broke in the worst spot possible.
     
  7. BrooklynBay

    BrooklynBay Moderator & long time member. Staff Member Moderator Elite Explorer

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  8. Shtiv

    Shtiv New Member

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    I will give it a try, I have exhausted all other efforts without removing exhaust/tranny altogether. Any more ideas please share them. Also, any ideas why I wouldn't be able to wiggle the solenoid pack free and off? Also, I was just locking up and my puddle lights (which I just changed to LED) and the interior lights were not going off after I locked it?.
    Thanks!!!
     
  9. BrooklynBay

    BrooklynBay Moderator & long time member. Staff Member Moderator Elite Explorer

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  10. imp

    imp Well-Known Member

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    @Shtiv
    Can you remove the valve body, consult appropriate diagrams to find the port which carries oil to the servo, apply air pressurte to that port, it might just push the piston out. imp

    PS: If you cannot find info determining ports, post that. I can post images of which are for what.
     
  11. BrooklynBay

    BrooklynBay Moderator & long time member. Staff Member Moderator Elite Explorer

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    I thought about suggesting compressed air, but he will need an air test plate, compressor, and a blow gun. Once the valve body & solenoid block are removed, the shaft should be easy to remove but there's a chance that the apply strut holding the band might come off. It might be better to leave the solenoid block & valve body alone since assembly will require a torque wrench, and new gaskets.

    Some other thoughts that I had were to use a slap hammer with a stud gun, but where could you get a stud gun just for one job? There's limited access with the transmission in the vehicle, so there's no room to get a stud gun or a slap hammer in there. It might be possible to use a small slap hammer with a screw driven into the broken shaft.
     
  12. Shtiv

    Shtiv New Member

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    I have the screws removed from solenoid pack, just cant get the solenoid pack out, it wont come free. Will get photos of the area of the solenoid pack that is catching in the morning. Wondering if anyone knows where I can find instructions on removing transmission? Thinking about picking one of these up and starting from scratch, http://www.ebay.com/itm/291705870463?item=291705870463&viewitem=&vxp=mtr. But feel like I would have to buy a lot of parts for this, and becoming expensive? Still hunting for more ideas on how to get current one working. Thanks for everything so far.
     
  13. Shtiv

    Shtiv New Member

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    This is the part of the solenoid pack that seems stuck, everything this feels free. All screws are out, but this part is not working free?
    [​IMG]
     
  14. transman304

    transman304 Elite Explorer

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    Did you take out the bolt that holds in the connector on the outside of transmission?
     
  15. Shtiv

    Shtiv New Member

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    Wasn't aware of bolt on outside of transmission, so probably not :). Could you possibly describe how or where to look for this bolt? Thanks
     
  16. transman304

    transman304 Elite Explorer

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    IMG_3072.JPG Where the connector on the outside plugs into solenoid pack there is a bolt with a 7 or 8 mm head dead center in the plug.
     
  17. Shtiv

    Shtiv New Member

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    THANK YOU!!!!!!! it was the connector. Is there any good free manuals online of how to remove the transmission? I might just do an overhaul since Im in here. This forum is awesome, thanks for the help again.
     
  18. Shtiv

    Shtiv New Member

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    So I got the solenoid pack off, was hoping I was going to see more, any ideas how to access the OD bore that has the piston stuck?
     
  19. Hugh Janus

    Hugh Janus Active Member

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  20. Shtiv

    Shtiv New Member

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    I thought about that and was looking neodynium magnets, was trying to decide it would be worth ordering and trying.
     
  21. Shtiv

    Shtiv New Member

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    This is where I'm at currently, still searching for what I believe is the OD bore with the piston stuck. [​IMG]
     

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