5R55W Help!

[Hannie]

Ok, I have a 2002 Ford Explorer XLT with the 4.0 V6 and 5R55W automatic transmission. Had a flashing O/D Off light, delayed drive engagement, and a sloppy 1-2 shift, would have to back off the gas and tip back in slowly for it to take 2nd. Once it's in gear it seems relatively ok. I replaced the O/D servo with a machined servo w/ o-rings from http://www.fordservoboretransmissionfixsolution.com , installed a TransGo shift kit, replaced the bonded separator plate, tried to get as much atf out as possible and replace with synthetic, cleared the computer of codes with a jumper from battery positive to the negative cable for 10 minutes, and adjusted the O/D band to spec (1 1/2 turns back rather than 2, this was suggested by the owner of the servo shop). Got everything done tonight, went for a test drive and I still have the exact same issues going on. I had performed a pin-out test of the solenoid pack and the resistances were all within spec. Fluid I pulled out when disassembling was pretty dark but no metal, magnet was coated with friction, but not the worst I've seen. I'm stuck and need some help. I don't have the money to take it in for a rebuild, I can rebuild it myself but really am not set up well to do it. Is there something I might be missing that could be causing this, or do you think the bands/discs are fried and I need to gut it? Any help you could give would be greatly appreciated. I need to get this thing back on the road as soon as possible.

 

[Number4]

There's a post on this forum where either a college or high school kid rebuilt his.

 

[gsbarry]

Additional Diagnostic Information

1) How does the trans perform in manual 1 and manual 2? If manual 2 functions correctly, can you shift to D from manual 2 while moving? Does this seem to work smoothly?

2) Do you have any codes? You will need a slightly more advanced code reader than just the basic to read the TCM - try a friendly mechanic that might hook it up.

3) Can you perform a pressure test? You need a trans pressure gauge. This may be helpful, but may not be.

4) Is the updated servo you installed meant to correct for a worn servo bore? The W, N, S models typically have issues with worn servo bores, which typically requires either sleeving or a new case, but there may a be another solution I'm not aware of.

Not sure what you mean by not being setup well to rebuild... if you don't have a garage, that would make it cumbersome. If your talking lack of tools and lift, well it doesn't take much of an investment in tools to get by. To do a completely thorough rebuild - and to do it by the book - takes more investment in tools, but you can cut corners that will likely not impact longevity and save $$ on tools. Essential tools on my list would be: trans jack - harbor freight for $50 (unless ur an animal on the bench), in-lb torque wrench (for VB), snap ring pliers, clutch piston compressor tool OTC-7024(ebay for $38) if you have fried clutches then the piston seals likely need it requiring this tool - if clutches are good then seals are probably fine.

If manual 1 and 2 work, my gut says its not the valve body and it probably has to come out. When troubleshooting my E, I replaced the valve body as a last ditch attempt before pulling my trans - that didn't work and it had to come out. Not a complete waste of money, but probably not necessary in my case. I ended up with a jammed OD sprag (which damaged the OD planetary, center shaft, and sun gear) and toasted OD clutches.

My (lengthy) post here:http://www.explorerforum.com/forums/showthread.php?t=428970

 

[Hannie]

There's a post on this forum where either a college or high school kid rebuilt his.

Good for him. I have no problem doing it, the problem is money and time.

 

[Hannie]

GSBarry -

1) o/d servo seems to have fixed the 1-2, now noticing the delayed shift is 2-3. Once I back off and lightly accelerate it takes 3rd and drives fine. I can manually shift but the delay/slip still occurs.

2) no codes pulled yet, o/d Off light flashes intermittently when hot.

3) don't have a pressure gauge

4) yes, the modified servo is meant to prevent pressure bleed due to a worn bore

By not being set up I meant I don't have the money, time or space for a rebuild. I'm just looking for ideas on what could be failed so I can weigh my options. I think I am going to replace the IM servo with the modified o-ring type, adjust the IM band, and see what happens.

 

[gsbarry]

That may solve it. OD band is applied in 2nd and intermediate band is applied in 3rd. That would be the next logical step given your constraints. It's risk and value based guesswork w/o pulling, which is what I started with too.

 

[gsbarry]

Not having time AND money is a tough spot to be in. Another possible approach if the servo doesn't help is to find a junk yard trans and slap it in. This is a gamble of course, and may just be temporary, but it will take LESS time and money in general. To that end, you could take your time (what little you have available) to rebuild ur current trans while the junker holds you over.

Just trying to come up w/ alternatives for you, sounds like your in a tough situation.