How to: 5R55E Valve Body Rebuild Diary

[CDW6212R]

Interesting yes, but it brings a question to mind. I know that the first 5R55E has little PCM adaptive control, but the later 2002+ models have greater PCM control. How much difference is there, and is it worth having, or obtaining?

I'd still rather have AWD in my 99 Explorer, but that would require a 2002+ 5R55E and AWD, plus the 2002+ PCM, harness, etc. Too much work for now. Regards,

 

[Allbert]

The solenoid blocks in the 5R55 variants use EPC solenoids that are very similar to the ones used in the 5R55E in that they are direct acting and I think most of the "motor" design is the same. Some minor differences are that the block solenoids use o-rings to seal in their bores, and of course the connectors are redesigned to accomodate different plug styles.

As a footnote to my earlier post, I just read an article specifically about the 2-3 flare issue in the 5R55E which said it's the result of the OD band beginning to slip before the intermediate band applies firmly enough, so the Ford programming fix is probably more involved than just specifying a shorter ideal shift time.

From what I understand of how transmissions that use "clutch to clutch" shifting* work, the task of releasing one clutch while applying another is usually done with solenoids that can vary the pressure to the clutches (PWM or other styles of variable pressure solenoids) rather than with ON-OFF type solenoids. If anyone can direct me to a source of more information on the strategy the 5R55 uses to balance between bind-ups and horrible flares, I'd be very interested in reading that.

*applying one clutch while releasing another instead of keeping the lower range clutch applied and letting a one way clutch resolve the ratio disagreement that would otherwise cause a bind-up.

 

[Allbert]

Interesting yes, but it brings a question to mind. I know that the first 5R55E has little PCM adaptive control, but the later 2002+ models have greater PCM control. How much difference is there, and is it worth having, or obtaining?

I'd still rather have AWD in my 99 Explorer, but that would require a 2002+ 5R55E and AWD, plus the 2002+ PCM, harness, etc. Too much work for now. Regards,

I don't know much at all about the evolution of the 5R55... I recall seeing another post mentioning the addition of another speed sensor (ISS) at some point, and that may have something to do with the answer to your question, but I'd only be guessing at this point. As for the task of updating a transmission's hardware and software to a later level... I've never personally loved a car so much that I've been willing to pioneer anything like that. But if it were something more than a few people agreed would be worthwhile, there'd probably be some aftermarket company offering a DIY kit for the update.

 

[BrooklynBay]

This thread is probably the one you are referring to about the extra sensor.

 

[Glacier991]

It is my understanding that the Shift solenoids in the 5R are mainly just on off types. I'd like to know if that is not correct. I think the only solenoids what modulate or regulate pressures ate the TCC and EPC.

 

[Allbert]

It is my understanding that the Shift solenoids in the 5R are mainly just on off types. I'd like to know if that is not ocrrect. I think the only solenoids what modulate or regulate pressures ate the TCC and EPC.

You're right about the 5R55 having on-off types for shifting. That's why I'm interested in learning more about Ford's strategy for the 2-3 upshift in those transmissions. How do they do it with just one line pressure control and some On-Offs when most everyone else (that I know about) uses variable solenoids to control the release of one clutch during the apply of another in a clutch to clutch shift??? [:thumbdwn: wrongo!... see edit below]. Chrysler uses PWM solenoids (for the modules we presently sell), and some of the newer transmissions use other kinds of variable force solenoids (e.g., we're presently working on a control module for the upcoming Ford 6F-Mid transmission that will use "low-leak variable bleed solenoids").

I'll post some photos of sectioned 5R55 solenoids that some others in our company have prepared.

EDIT: Apparently, the synchronized release of one element during the apply of another for a shift is not as rare as I was led to believe... the 2-3 upshift in the GM 4L60E (not many of those out there ) is done by releasing the 2-4 band while applying the 3-4 clutch, and that's done with on-off solenoids too.

 

[Runnin'OnEmpty]

So debris is clogging the EPC and contributing to the 2-3 flare?

I'm wondering if an external ATF filter would help in this regard?

BTW, I have about 36K on the flare fix and it's still shifting fine. (I installed the Ford separator plate/valve kit, Superior shift kit, and new EPC.)

 

[Allbert]

So debris is clogging the EPC and contributing to the 2-3 flare?

I'm wondering if an external ATF filter would help in this regard?

BTW, I have about 36K on the flare fix and it's still shifting fine. (I installed the Ford separator plate/valve kit, Superior shift kit, and new EPC.)

I'm hesitant to state specific cause and effect relationships without knowing more about the particular application, but in general, contaminants can be driven (by pressure differentials) into the clearances between spools and their bores such that they interfere with smooth motion of the spool either by directly binding the part or by degrading the surface finish of the sleeve and/or the spool over time such that the friction would be higher even if the contaminants were removed. Once the friction is high enough to slow or stop the spool from moving where it needs to for the output pressure to respond correctly, all the bad things that result from incorrect pressures can happen.

Being that a smooth 2-3 upshift in the 5R55 is a neat trick under the best conditions, I think the probability of a 2-3 flare would probably be increased by the poor pressure control that might result from an EPC that is impaired by contamination or wear.

In my opinion, one of those magnetic in-line filters (like from SPX Filtran or Magnefine) is good insurance for any transmission that has solenoids that are not exceedingly robust against contamination. In fact, I believe one of our OE customers intends to use a filter from one of those companies to guard the operation of the solenoids in an upcoming 6 speed. And if I had a vehicle that had a sensitive solenoid, I'd probably get one for my transmission.

Very glad to hear that your transmission is doing well . Tranny problems give me a stomach-ache.

 

[Allbert]

If interested, here is a link to an image of a sectioned (and mounted in Gloopstick) Bosch EPC from a 5R55 module.

 

[Allbert]

...and here is a better one with some labeling of the subcomponents.

 

[BrooklynBay]

I'm going to link these pictures below to make it easier to view. Thanks for the pictures Allbert!

 

[whoathere]

To help with a little bit of the confusion as to what "fixes" the 2-3 flare, I'm going to do the Ford TSB and the Superior Kit to my 5R55E, which is experiencing the flare. I will wait to do the EPC, to see if it actually needs it. Hopefully I'll be able to do this next week, and report back to you guys and let you know how it goes. I'll be sure to take pics to add to this diary.

Anyway, I was just on FPN, and was a little confused. I went to order a filter and gasket, but they don't show the part #'s, and they didn't ask if I have the 5R55E, it just asked 4x4 or 4x2. Maybe all 4x2 Ex's have the 5R, I dont know... Anyway, here is my parts list as of right now, can someone correct me if I'm wrong? THat would be great.

I have a 2000 Explorer Sport, 4.0L OHV. 5R55E.

Valve Body Service Kit - 3L5Z-7M203-JA
Revized Bracket - XL2Z-7L491-AA (taken from Glacier's pic)
Vavle Body Seperator Plate - 1L5Z-7Z490-GA
Superior Shift Kit - K4R/5R55E
EPC Solenoid - XL2Z7G383AA
IIRC, the pan gasket and filter were about $30 from FPN
And then the Mercon V to fill it up.

Those are the part #'s I have gathered throughout this thread. I'm hoping that without doing the EPC, the problem will be solved, but if not then I'll just have to get more fluid and drop the pan. Hopefully doing it this way will help others. Any input on the part #'s would be appreciated.

 

[Runnin'OnEmpty]

Mr Whoathere, I have the exact same year, model, engine, and maybe color (Medium Wedgewood Blue). I had the exact same flare, and replaced the exact same parts you have listed. According to my old parts invoices, your parts numbers are all:

CORRECT

I did this fix about 3 years ago, when not much info was available on it, replacing everything including the sol bracket and EPC. I did NOT want to pull the pan again, so I threw every part I had available in it (All those on your list). These fixed the flare, and I've had about 40K miles of trouble-free shifting since.

I omitted some of the Superior kit parts; using only the ones that were valve-body related. I omitted the 'Pressure Riser'. I also poured a bottle of LubeGard RED in it.

The difference in the filters (4x4 vs 2x4) is that the 4x4 uses an extension to fit the filter to the deeper 4x4 pan.

I didn't have the time nor inclination to experiment with mine to see which part cured the flare, so it'll be interesting to see if the EPC affects the flare in yours.

GOOD LUCK!
ROE

 

[whoathere]

So, does the gasket come with the seperator plate, or the service kit? Or do I need to order that as well. I'm finally getting around to this, need to sell the X now that I have my 5.0 AWD mounty! Anyway, do I also need to order a gasket or no?

 

[Glacier991]

This a 00 5R55E SOHC ? If so the gaskets come "bonded" to the plate.

Now there was a DUH moment, it says right under your post in your sig it is OHV. Answer is the same. Sorry.

You can also try www.transmissionpartsUSA.com.

 

[whoathere]

Its an OHV...

And why is FPN so bloody hard to navigate? I tried to find my pan gasket and filter, but instead of having 5R55E, it has 5R55w/s. What does that mean, and is it the same thing?

 

[BrooklynBay]

Those are the newer models with the unitary case (bellhousing is connected to the case as opposed to being separate, and bolted on).

 

[whoathere]

well, FPN lists that as the only option other than the 4R55E and the 4R70W. So will that kit work for me as well? If you look under 2000 Ford Explorer, then Maintenance -> Transmissions -> Automatic Transmission -> Pan Gasket... it says that it is the filter, pan gasket and o rings, and then it says for the A4LD Only... This makes me confused??? All I have left to order is the pan gasket and the filter. and the fluid, any recommendations?

 

[Glacier991]

The filter you want is made by Fram. Any auto parts house that carries FRAM will carry one, and it comes with a pan gasket inside the box. Your old one can usually be reused. Just clean the mating surface carefully and make sure the old gasket and the mating surfaces are clean and dry before putting it back on.

 

[divolfish]

Hi, the information you guys give is just tremendous. I would like to get the VB upgrade that you guys have been talking about. I have a 96 XLT 6 cyc 4 wd AT. It has 115 K miles and is starting to flare when I go into 3 rd gear. I am a little intimidated by the thought of going into a transmission. Do you have any suggestions as far as finding a good mechanic that would do the mods.
Fbbeale also suggested getting the servos redone also. I am within an hour of Brooklyn, if BrooklynBay knows anyone good mechanics.Thanks.