2002 Explorer with a 5R55S

[kcblakely]

Hi All:

First, lemme say what an awesome forum this is. I've spent the last three days reading intently and learning a ton. Thanx!

My GF has a 03 Explorer with a 5R55S tranny; about 180K miles. Over the past four months or so, I've noticed a shudder at about 55-60mph that occurs intermittently higher than that speed. It's gotten a lot worse and common lately, and the OD light has come on a few times, then gone away...

Took it to a shop and they came up with codes P735(Trans gear #5 incorrect ratio) and P1565(Speed control command switch out of range).

Car seems to shift normally and smoothly thru 1st, 2nd, 3rd and into 4th gear; it's the transition into the OD "5th gear" that seems to induce the shudder.

So I'm thinking there's an issue with OD...

Here's the deal: I'm a week away from stepping off on the Appalachian Trail for a big adventure, and I won't be back til NOV. Normally, I would dive into it, but I just don't have the time til I get back

Question 1: based on what I've said, any thoughts on the root problem(s)?
Question 2: How bad would it be to simply have GF take the car out of OD and keep driving it til I can get back and fix it? I have a spare car she can use. Will doing so turn a simple and cheap problem into a horrible and $$$ problem, or is it one of those things that can just be worked around until later?

Thanx in advance....

 

[BrooklynBay]

Welcome to this forum! These transmissions have known issues with worn servo bores, solenoid blocks, and bands breaking. A lot of these issues occur after 60K miles. You have 3X this amount of mileage. Check the band adjustment with a torque wrench before you replace parts.

 

[kcblakely]

Are those things that I can do with the trans still in the car?

 

[Number4]

I'd say try driving for now w/o overdrive. Try to not go higher than 45-50. See if symptoms are still present.

 

[BrooklynBay]

The solenoid block replacement, and the band adjustment are the only things that are easy to do with the transmission in the vehicle. Servo bore repair or band replacement require removing the transmission.

 

[fritz24]

Seriously? OD light came on and you want him to drive his car and suffer??? You could just be low on fluid.
I got the same experience last month with my 4.oL Sohc 180kmiles original tranny. Everytime i hit 80kph i can feel the hesitation or somewhat like a light misfire or starving with fuel but the OD light never came on. This happened 3days after adding trans fluid( 5.5L)and replacing the filter. So i got my suspect, the transmission could be low on fluid. Topped it with 1L of fluid and pumped still attached started the car idle until it reach desired operating temp then break engaged shift to reverse and drive 10 times with 5sec interval then shift to Neutral. Went under tried removing the pump but nothing drip so i pump another bottle remove the pump and starting to drip the extra fluid off. Went off and relearn the shifting strategy "et voila" the car shifts perfect.

 

[JoshMcMadMac]

There most likely will not be a cheap fix to the issues you describe. You can certainly toss a bit more fluid into it as fritz24 suggests, but do not going into it expecting magic.

Good luck on the A.T. I thru-hiked in 2005.

 

[Will319]

Had the same problem at 180k. It sounds like the OD servo bore is wearing out, the other one wont be long behind it. This is usually fixed as part of a rebuild. I looked at it as if it eventually needs to be rebuilt then ill just run it for awhile. I just had it rebuilt for $2200 in Baltimore. I drove it for several months with the shudder and slipping by avoiding putting it under load and punching it up hills and feathering the gas when it shifts. If you do this you can avoid the shudder.

 

[kcblakely]

Had the same problem at 180k. It sounds like the OD servo bore is wearing out, the other one wont be long behind it. This is usually fixed as part of a rebuild. I looked at it as if it eventually needs to be rebuilt then ill just run it for awhile. I just had it rebuilt for $2200 in Baltimore. I drove it for several months with the shudder and slipping by avoiding putting it under load and punching it up hills and feathering the gas when it shifts. If you do this you can avoid the shudder.

Hi Will: Thanx for the info. I'm in Springfield VA; just south of DC.

I called a reputable tranny shop here and they told me
1. Absolutely DO NOT flush and refill the tranny
2. They can put an additive in it that will "change the friction behavior of the transfer case and probably get it back to normal operation at least temporarily"

I'm not a mechanic, but I've worked on cars a lot, and I've never really had any luck with additives of any type. Any of that sound reasonable to anyone?

 

[BrooklynBay]

They are probably using Lubegard. That's the only OEM approved additive (at least that's what I've read).

 

[imp]

Hi Will: Thanx for the info. I'm in Springfield VA; just south of DC.

I called a reputable tranny shop here and they told me
1. Absolutely DO NOT flush and refill the tranny
2. They can put an additive in it that will "change the friction behavior of the transfer case and probably get it back to normal operation at least temporarily"

I'm not a mechanic, but I've worked on cars a lot, and I've never really had any luck with additives of any type. Any of that sound reasonable to anyone?

Why in the hell would the friction behavior of the transfer case affect the transmission??????? imp

 

[fritz24]

The fact that you have tranny issue, those guys want to add additive in your tcase(not found in service manual). Thought only differential need a friction modifier?? That tranny shop MUST be good. Bet your wallet is gonna leak.

 

[kcblakely]

Actually, now that I think about it....

This explorer is 2WD only. So it doesn't even *have* a transfer case, right?

 

[BrooklynBay]

Only 4WD uses a transfer case.

 

[gtbutler]

BrooklynBridge is right on target in his earlier post. Soleniod and servo bore are the most common issues with this tranny. Ford used the 5r55s on a bunch of vehicles (all the way up to and including Jaguar, yes Ford owned Jag during the early 2000's). I'm betting that in the end, it is the servos. The cause is that the servo Pistons metal are running through an aluminum case and they just get worn out. A transmission rebuild (via a reputable ARTA Shop) will include some type of sleeve (usually brass). Yes it may cost you $3500, but that is not a lot if it buys you another 180,000.

Now with all of that said, if you are mechanically inclined and you have a little time, here's what I'd recommend and it can buy you thousands of miles.
First, check out http://www.fordservoboretransmissionfixsolution.com/index.html. Read all of the articles. These folks KNOW there stuff on the 5r55 tranny. They have a bunch of YouTube vids on their Servo Kits which can be installed without removing the tranny. Basically the servos have o-rings on them (they have a patent for their designs). Yes the o-rings on their servos wear out, but you remove their servos and replace the o-rings. They also have phone support and they are VERY willing to talk with you and explain their product, HONESTLY.
Second, drop the pan and change the fluid. Yes, you'll have the don't flush vs. the flush debate, and you can do what you feel most comfortable with, I wouldonly change the fluid, (yes I know the torque converter will hold fluid, and the fluid is still in the lines with a flush), but dropping the pan is going to let you see what the condition of your fluid is, and if you have any other issues due to transmission parts/sediment in the bottom of the pan. This will also let you visually inspect the solenoid and replace if you feel necessary. If you aren't going to replace the solenoid, I would remove the solenoid and clean the screen/filter (it sits between the solenoid and the transmission). Be VERY careful not to break the little tabs that hold it on the solenoid. Replace the solenoid, put the pan and pump the fluid back into the transmission (there are tons of YouTube videos that show many ingenious pump methods DYI mechanics have "invented." Yes your baby is an "overfill the transmission and let it drain until it is full" design from Ford. It's a little messy, but it's actually a pretty ingenious design when done properly actually prevents overfilling.
Third, if you decide to go with replacing the servos (after reading about them in step one), go ahead and replace them now.

At the very least with all of this done, you are going to be a LOT more knowledgeble about your Explorer, I'm pretty confident that will get you back like your Explorer drove 100,000miles ago, while spending less money than a tranny rebuild.

Also, not knowing the vehicle history (towing, towing in the mountains, etc.) I would check the fan. Stock Explorers have a centrifugal fan clutch that can wear out over time. The fan may still turn but maybe not at a level efficient enough to cool the engine AND the tranny. Long term that can cause tranny issues. Transmission temperature is sent to the PCM via the solenoid we're talking about in step 2.

Good Luck and have fun!

 

[kcblakely]

You guys are awesome. I'm taking your advice and changing the fluid/filter today - without a flush - and I'll inspect the solenoid as you say. Then it's going back to the girlfriend to drive while i'm on the AT. She can drive my car while i'm gone if it really craps out, and I'll do the servo work when I get back in Nov.

Thanx all!