My 2004 Explorer

[ANTHONY-GATLIN]

New clutches are soaking overnight.
One thing I thought was cool was how when the transfer case was removed, there was no fluid in between the transmission and transfercase. There is a plate with a rear seal that goes on the back of the trans.

go bro

 

[4pointslow]

5R55S rebuild

Got most of the transmission rebuilt today, I like using engine stands for working on the trans.

When reinstalling the out put shaft, you have to put a snap ring on (see second picture). Prying up on the reverse drum makes it possible (third pic).

Fourth pic is my home made compressor for drum piston springs/retainers.(fith pic)

Pump alignment tools help make pump installation easier. (Sixth pic).

Reman valve body, new solenoid pack. (7th pic).

Tomorrow I replace the seal in the rear plate, install that plate, and then bolt the transfer case up. Then it is ready for install.

 

[ANTHONY-GATLIN]

hey do you have repair shop ?

 

[4pointslow]

Repair Shop

hey do you have repair shop ?

No repair shop, just my garage and lots of tools.

 

[4pointslow]

Forward Clutch

This is air checking the forward clutch after replacing the bonded piston.

 

[4pointslow]

Direct Clutch clearance

The direct clutch was way to loose. This was before replacing the clutches and metals. The feeler gauges were .079 which is max spec. Way to much clearance.

 

[4pointslow]

Direct Clutch clearance 2

Checking Direct Clutch after replacing clutches and metals.
Feeler gauges were .052

 

[ANTHONY-GATLIN]

No repair shop, just my garage and lots of tools.

then I must ask you this
where did you get so much knowledge ?

 

[4pointslow]

then I must ask you this
where did you get so much knowledge ?

One of my first words was wheels, lol. Always had a thing for cars/trucks/engines.
Went to Lincoln Technical Institute for automotive when I was around 18.
I worked for a privately owned chain of Goodyear stores (they had 12) for over 16 years, and I have been an automotive instructor for the last 11. The last 10 I have been teaching Ford specific classes. I consider my self very lucky to be in a career that fuels my passion.

I don't know everything though.
If there is anything on my explorer I might be unsure of, I just come to Explorerforum and get info from all the other members, there really is a lot of very smart people here with lots of experience. Love this site!

 

[ANTHONY-GATLIN]

One of my first words was wheels, lol. Always had a thing for cars/trucks/engines.
Went to Lincoln Technical Institute for automotive when I was around 18.
I worked for a privately owned chain of Goodyear stores (they had 12) for over 16 years, and I have been an automotive instructor for the last 11. The last 10 I have been teaching Ford specific classes. I consider my self very lucky to be in a career that fuels my passion.

I don't know everything though.
If there is anything on my explorer I might be unsure of, I just come to Explorerforum and get info from all the other members, there really is a lot of very smart people here with lots of experience. Love this site!

Lots of respect to you

 

[4pointslow]

Secret admirer

I have a secret admirer in my garage.
It leaves me food surprises like old cookies and dried out bread.
Today I went out to the garage to find a cinnamon roll. lol

 

[4pointslow]

Lots of respect to you

Right back at you, takes a lot to put a supercharger on an Explorer!
By the way have you started on your build thread yet?

 

[4pointslow]

Ready to install

The used transmission is back out, and the rebuilt one is ready to go back in.
I hope to finish it tomorrow, we will see. ( I need to clean up that transfer case).

 

[4pointslow]

Transmission Rebuild Done and Installed

After 4 long days in the garage it is finally done!
Good thing I am not working flat rate, lol.

Mileage 100,868
Hope it lasts!

Notes:
I used a reman - pump(115.00), torque converter(134.68), and valve body(212.90).
New Ford OEM - solenoid pack(182.00), bonded overdrive and intermediate servo pistons(55.90), bonded reverse servo piston(19.95), bonded forward clutch piston(33.43).
New rebuild kit with seals/gaskets, 4wd filter, metal reinforced pan gasket, all 3 bands and Raybestos clutches(324.85)
12 quarts of Castrol Mercon V (5) (On sale at advanced auto parts for 2 for $8.00)
3 extra quarts for soaking bands/clutches.
1 Quart left over.

The servo bores already had brass inserts in them, as a matter of fact the trans had been rebuilt but the pump got trashed from the engine to transmission plate being missing from whoever installed the 2005 engine I suppose.

The original problem with this transmission was leaking out the front (pump damage), and shifted like crap.

Now it shifts fast and firm like it should and no leaks.

 

[Dono]

Wow. That's all I have to say. So apparently you can make a silk purse out of a sow's ear.
Impressive.

I don't understand how some people can do such crappy work. All those brackets loose, pieces missing....very sad.

I see you lift both the transfer case and trans up in one shot. I thought that would be too painful to do.

 

[4pointslow]

I see you lift both the transfer case and trans up in one shot. I thought that would be too painful to do.

I lift nothing, lol. I am too old.
I use an engine hoist to get the transmission on and off the transmission jack.

On my two 1998's I prefer to pull the transfer case off first, then pull the trans out. I have tried it both ways and it is real hard to get to the engine to trans bolts with the transfer case in the way.
It sucks because when you remove the transfer case fluid would come out since the transmission is open at the rear of it. So you have to drain the fluid first.

On the 2004 there is a lot more room to work on things, you can get to the engine/trans bolts pretty easy even with the transfercase in the way.
Funny too because there is a plate at the back of the transmission that seals it up, so if you want to drop the transfer case first there is no fluid loss. go figure.

 

[Joe in NY]

Can we have a video of driving to see how it shifts?

 

[4pointslow]

Video

Can we have a video of driving to see how it shifts?

I will try to make one, if the video comes out halfway decent I will post it. lol.
The exhaust is really quiet so I don't know if anything will be heard there.
I should be able to get the mph and tach in action.

One thing I have to note:
I am so used to the lockup torque converter in my other two trucks staying locked up even under heavy throttle, this truck seems as if it unlocks with very little throttle. I never liked lock up staying on so long but now I got used to it. I guess I will have to get un used to it in my 2004. lol.

 

[4pointslow]

Remote start finished

I finally finished the remote start installation.
Took way longer than I thought, and I have installed a few of these before.
I did spend a lot of time trying to figure out where to put the switches and LED.
One switch and the LED is for programming the unit, the other switch I added. The added one is a kill switch the opens the input circuit to the remote start.

I wanted the switches to be mounted in a way that if I had to remove panels or instrument panel parts, I would not have to disconnect them. I can access them by just reaching behind the knee bolster with very little effort. The LED can been seen if I look down through the knee bolster and steering column.

I hate the type of hood switch that comes with remote starts, they rust, lock up, and cause all kinds of problems. I will be looking for a different design later.

Pictures:
1. Remote start module
2. Transponder bypass module
3. Buttons and LED
4. Hood switch

 

[4pointslow]

D/S Door lock button

The drivers side door lock button has not worked since I got the truck. I did some tests a while back and found the switch to be good. I mentioned the problem to a guy I work with and he said to look for broken wires in the rubber from the door to the body. I saw that problem before years ago when vehicle manufacturers did not know how to make wiring harnesses. lol. That was a long time ago though, they should know better now. But they don't.

I pulled the door panel off and chased the wire, sure enough it was broken in the rubber piece between the door and body. I just ran another wire through and soldered/heat shrinked it.