5R55W Disassembly

[ScottBowden]

Well, I found this forum after my Mom's 2002 Mercury Mountaineer 2wd transmission started having shifting problems.
Long story short; you guys gave me just enough courage to pull the pan. Pulled it and found a broken intermediate(?) band (2nd from the front). I have removed the trans from the truck and it is on the bench.
Of course, I was figuring this would just be an easy pull, replace broken parts, ream servo bores if needed and put back in (even the most well intentioned plans of men...).

What type of puller do I use to get the pump out? I found a couple of artists renderings of a puller from an online store. I built one that looked similar and modified it several times, even tapping on the outside of the case while applying tension. It wont come out.

PLEASE, I NEED SOME HELP!


Thanks,
Scott Bowden

 

[whitestang04gt]

Well, I found this forum after my Mom's 2002 Mercury Mountaineer 2wd transmission started having shifting problems.
Long story short; you guys gave me just enough courage to pull the pan. Pulled it and found a broken intermediate(?) band (2nd from the front). I have removed the trans from the truck and it is on the bench.
Of course, I was figuring this would just be an easy pull, replace broken parts, ream servo bores if needed and put back in (even the most well intentioned plans of men...).

What type of puller do I use to get the pump out? I found a couple of artists renderings of a puller from an online store. I built one that looked similar and modified it several times, even tapping on the outside of the case while applying tension. It wont come out.

PLEASE, I NEED SOME HELP!


Thanks,
Scott Bowden

That trans has a special tool to realign the pump also on assembly..Are you experience with transmissions? If not i would highly recommend a tranny shop doing the work there are alot of internals that have been replaced with new & improved redesigned parts & fixes, sonnax makes alot of these parts & tools. You can get a 5r55w manual off ebay fairly cheap, its like $40-50 but it shows you "everything" even part numbers & tools needed, its very indepth, one of the better manuals I've purchased http://cgi.ebay.com/ebaymotors/Ford-5R55W-S-5R55-5R55N-Transmission-Reference-Manual_W0QQcmdZViewItemQQ_trkparmsZ72Q3a1205Q7c39Q3a1Q7c66Q3a2Q7c65Q3a12Q7c240Q3a1318QQ_trksidZp3286Q2ec0Q2em14QQhashZitem250299092182QQitemZ250299092182

 

[BrooklynBay]

Welcome to this forum! I have a PDF on the 5R55W. Send me your email address if you want me to send it to you.

 

[Hitchhikingmike]

How would you guys rate ATSG?

http://www.atsg.biz/cgi-bin/shopper...es/SearchResult.html&category=CFRD&pricecode=

Do you think their manuals are very helpful?

Does ATSG research and explain any upgrades or modifications to be done while rebuilding in their manuals?

 

[BrooklynBay]

ATSG sells update manuals for certains transmission like the A4LD. I've caught some mistakes in the regular ATSG manual on the A4LD. The Ford 3 ring binder pretty much covers everything. The ATSG is good for reference while doing an entire rebuild.

 

[ScottBowden]

Welcome to this forum! I have a PDF on the 5R55W. Send me your email address if you want me to send it to you.

Thanks, email sent.

 

[BrooklynBay]

Let me know when you get it. It was just sent to your email address.

 

[Glacier991]

The FORD tool attaches to the pump input shaft and connects to a slide hammer puller.

I have generally found that in a one piece case a slide hammer puller works best on removing pumps.

 

[Hitchhikingmike]

I don't mean to go too off topic, but do you know if Ford or any other company ever published a service rebuild manual for the transfer cases? I know ford didn't make the transfer case, did Borg Warner ever publish a rebuild manual that you know of?

Thanks.

 

[CDW6212R]

How would you guys rate ATSG?...

Those ATSG manuals are short but great, you get almost every picture you might need. They used to be $14 each, so call your local trans parts store and see what they charge, they all will have it. Regards,

 

[ScottBowden]

Let me know when you get it. It was just sent to your email address.

Received and saved

Thank You

 

[ScottBowden]

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Thanks everyone for you past, present and future support!



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[ScottBowden]

..Are you experience with transmissions?

I have not pulled a trans apart in about 20 years, so I am a little rusty.

 

[Glacier991]

To HitchhikingMike: Not a manual per se, but they have detailed instructions on disassembly and reassembly available. The FORD MANUALS on CD contains that.

 

[ScottBowden]

Thanks Glacier, Bay and others.
I will post some photos of the puller I made to take the pump out. The slide hammer is definately the key.
I did pull out the 1st servo piston to look at the bore and it does have the ridge.
So far I know that I will be replacing the 2 front bands, both servo pistons and ream and install bushings. I will also do the valve body shift kit but need to go back through the threads to get the preferred one.
What are any other "weak links" that need to be addressed while I'm in here?

 

[CDW6212R]

Do the EPC solenoid absolutely, and the shift solenoids if you any mileage over about 100k. Regards,

 

[ScottBowden]

Photos

Well I have the trans torn down completely.

I finally got the right combination for the pump puller: I cut a 3" section out of 2" x 6" rectangle tubing. Used a 1 1/4" hole saw in the drill press. Cut a slot and relief notch for tightening, and just welded an oversized nut to one side with a bolt running through it to clamp down on the pump stator. Used my small Harbor Freight slide hammer and it came off in about 15 whacks.

 

[ScottBowden]

Broken Parts

The intermediate band is broken and also the intermediate planetary assy. radial roller bearing cage.

 

[ScottBowden]

I could not find the definitive answers on the valve body upgrades.
Which brand "shift kit", other valves, separater plate and and other mods are recommended?

 

[jrford]

This looks/sounds like what happen to my '04, 51k miles. I have the 5r55s, lost the 3rd gear. I had a code P0733. Its been in the shop now for a week.
What were the symtoms?
Thanks
Jim