fordhead!
Member
- Joined
- April 16, 2014
- Messages
- 22
- Reaction score
- 1
- City, State
- Atlanta
- Year, Model & Trim Level
- 2002 Explorer XLT
Hello everyone,
I recently rebuilt the transmission on my 165k 2002 Ford Explorer, saving around $2000. I have taken videos on the entire process, and I have all the information needed. I will be updating this post as I edit the videos and upload them.
I don't know how many people are interested in such complex repair. Please post any question or interest in the subject.
Transmission types:
Ford Explorers come with the 5R55S and 5R55W. These two transmissions are almost exactly the same, only having small size difference in two internal gears, which does not affect any of the procedures necessary for rebuild. These transmissions are also found in Mustangs and Rangers.
The 5R55N and 5R55E are very similar to S/W but have different valve body and therefore cases. Some Lincoln and Jaguar have this transmission. Do not buy anything that is specific for these two.
Symptoms:
- The car took a long time to shift to most gears, specially 2nd and 5th.
- Took around 10 seconds to engage to D and R, unless I got to 3000 RPM, engaging very violently.
- I would randomly lose power, just like if I changed to N in the middle of the road.
- Absolutely no codes or engine light.
The problem:
- No transmission flush (at least to my knowledge) after 165k miles.
- All gaskets and rubbers were hardened and shattered because of the very old burnt fluid.
- Worn servo bores responsible for shifting problems, (fixed with new case).
- Sticky oil pump valve responsible for delayed engagement, (redesigned replacement came with Transgo kit).
- Internal clutches although none were burnt, the friction material was almost gone in all of them.
These transmissions all have the same "servo bore problem". The servos are metal pieces shaped like an umbrella. They move in and out thanks to fluid pressure. After years of use the servo carves a bigger hole in the aluminum case, allowing oil to scape through the bigger hole.
To solve this problem:
you can re-sleeve the case which requires you to take the case out.
In this video a professional drills and installs the only sleeve kit sold on eBay for $380.
Instead, I bought a case that was already re-sleeved for $265. I took no risk in drilling my case and it is cheaper than doing it yourself.
OR
you can buy modified servos with a o-ring installed around them, which can be done from the outside.
Ford Lincoln Mercury Explorer Mountaineer Navigator Servo Bore Fix
This solution does not last forever, and does not fix any other internal problem.
PDFs:
Rebuild:
http://downloads.bustedfingermotorsports.com/Ford Transmission Manuals/5R55W.pdf
All parts:
http://www.atpnz.co.nz/admin/uploads/5R55W.pdf
Necessary parts:
Ford 5R55W 5R55S Transmission Overhaul Deluxe Rebuild Kit 02-ON Mercury Lincoln $275 on eBay
Rebuilt Torque Converter $170-$30=$140returning the old one on Autozone
Transgo Shift Kit $65 on eBay
5R55S 5R55W Ford/Mercury UPDATED Transmission Case $256 from eBay's powertrainpartsplus
Transjel $11
MerconV Transmission Fluid 12x$6=$72
+$275
+$140
+$65
+$256
+$11
+$72
= $819
Necessary tools: (that you get to keep)
Socket kit, of course.
Torque wrench.
Pick set.
WD-40
Snap Ring Pliers $7
Dial Indicator $12
Transmission adapter for jack $65
Videos:
The car has been working PERFECTLY 100%. It feels really good knowing that I was able to fix it. ^^
I recently rebuilt the transmission on my 165k 2002 Ford Explorer, saving around $2000. I have taken videos on the entire process, and I have all the information needed. I will be updating this post as I edit the videos and upload them.
I don't know how many people are interested in such complex repair. Please post any question or interest in the subject.
Transmission types:
Ford Explorers come with the 5R55S and 5R55W. These two transmissions are almost exactly the same, only having small size difference in two internal gears, which does not affect any of the procedures necessary for rebuild. These transmissions are also found in Mustangs and Rangers.
The 5R55N and 5R55E are very similar to S/W but have different valve body and therefore cases. Some Lincoln and Jaguar have this transmission. Do not buy anything that is specific for these two.
Symptoms:
- The car took a long time to shift to most gears, specially 2nd and 5th.
- Took around 10 seconds to engage to D and R, unless I got to 3000 RPM, engaging very violently.
- I would randomly lose power, just like if I changed to N in the middle of the road.
- Absolutely no codes or engine light.
The problem:
- No transmission flush (at least to my knowledge) after 165k miles.
- All gaskets and rubbers were hardened and shattered because of the very old burnt fluid.
- Worn servo bores responsible for shifting problems, (fixed with new case).
- Sticky oil pump valve responsible for delayed engagement, (redesigned replacement came with Transgo kit).
- Internal clutches although none were burnt, the friction material was almost gone in all of them.
These transmissions all have the same "servo bore problem". The servos are metal pieces shaped like an umbrella. They move in and out thanks to fluid pressure. After years of use the servo carves a bigger hole in the aluminum case, allowing oil to scape through the bigger hole.
To solve this problem:
you can re-sleeve the case which requires you to take the case out.
In this video a professional drills and installs the only sleeve kit sold on eBay for $380.
Instead, I bought a case that was already re-sleeved for $265. I took no risk in drilling my case and it is cheaper than doing it yourself.
OR
you can buy modified servos with a o-ring installed around them, which can be done from the outside.
Ford Lincoln Mercury Explorer Mountaineer Navigator Servo Bore Fix
This solution does not last forever, and does not fix any other internal problem.
PDFs:
Rebuild:
http://downloads.bustedfingermotorsports.com/Ford Transmission Manuals/5R55W.pdf
All parts:
http://www.atpnz.co.nz/admin/uploads/5R55W.pdf
Necessary parts:
Ford 5R55W 5R55S Transmission Overhaul Deluxe Rebuild Kit 02-ON Mercury Lincoln $275 on eBay
Rebuilt Torque Converter $170-$30=$140returning the old one on Autozone
Transgo Shift Kit $65 on eBay
5R55S 5R55W Ford/Mercury UPDATED Transmission Case $256 from eBay's powertrainpartsplus
Transjel $11
MerconV Transmission Fluid 12x$6=$72
+$275
+$140
+$65
+$256
+$11
+$72
= $819
Necessary tools: (that you get to keep)
Socket kit, of course.
Torque wrench.
Pick set.
WD-40
Snap Ring Pliers $7
Dial Indicator $12
Transmission adapter for jack $65
Videos:
The car has been working PERFECTLY 100%. It feels really good knowing that I was able to fix it. ^^