5r55 Product Issues

Presented by: Steve Garrett

ATRA

5R55 Product Issues/Updates

Connections Handout Questions Survey

Vehicle Application Chart Year Model Transmission Engine 2000-2002(late 2001)

T-Bird 5R55N V8-3.9L

2002-2005 T-Bird 5R55S V8-3.9L 1999-2001 S-Type Jaguar 5R55N V6-3.0L V8-4.0L 2002 Explorer/Mountain

eer 5R55W/S V6-4.0L V8-4.6L

2003-2005 Explorer/Mountaineer

5R55S V6-4.0L V8-4.6L

2000-2001 Lincoln LS 5R55N V6-3.0L V8-3.9L 2002-2005 Lincoln LS 5R55S V6-3.0L V8-3.9L 2005 Mustang 5R55S V6-4.0L V8-4.6L

Note: The 5R55N was only used in 1999-2001

5R55N/W/S Oil Fill Procedure The N/W/S transmissions do not have a dip stick. When filling the transmission after repairs or service the level must be set when the transmission is between 80F to 120F. If level is set while hot, when the unit cools down the level will be low and can cause failure. It is best after repairs to do a re-check for proper fluid level when the vehicle has had time to cool down.

Turbine Shafts

5R55W/S model Turbine shafts are 10.230 The 5R55N use a 10.030 length shaft from

1999-2001. 2002 and later 5R55N uses a 10.230 shaft

5R55 Engine Stall After Rebuild

4/5R55E 5R55N/W/S

5R55 Engine Stall After Rebuild

Part Numbers 4R44E & 5R55E 5R55W/S/N -------

XL2Z-7017AA XW4Z-7017AA

5R55W Gear Ratios 1st 3.22 2nd 2.41 3rd 1,55 4th 1.00 5th 0.75 Rev. 3.07 5R55S Gear Ratios 1st 3.22 2nd 2.29 3rd 1,55 4th 1.00 5th 0.71 Rev. 3.07

5R55W/S sun gear has 38 teeth. 5R55N sun gear has 24 teeth. 5R55W/S overdrive carrier pinions have 28 teeth. 5R55N has 25 teeth on the pinion gears 5R55W/S ring gear has 94 teeth. 5R55N has 72 ring gear teeth

5R55W/S and the 02 and later 5R55N forward ring gear uses 101 teeth. The 5R55N has 85 teeth from 1999-01 on the forward ring gear 5R55W/S and the 2002 and later 5R55N forward planetary has 23 teeth pinion gears The 5R55N uses 19 tooth gears on the forward planetary pinions up to the 2001 model year.

5R55W/S and 1999 and later 5R55N reaction sun gear has 55 teeth and no roller bearing in bore. The 5R55N has 47 teeth and uses a roller bearing in the bore.

5R55N/W/S Harsh 2-3 Shifts The 5R55N/W/S units have two different gear ratios available. Depending on the unit being worked on it is important to install the correct replacement parts when the OD planetary has failed. This can be an issue especially when working with the 5R55N as early production vs. late production could have either ratio. 5R55W OD ratio 0.75:1 5R55S OD ratio 0.71:1 5R55N - INT. ratio 2.41:1 early INT. ratio 2.29:1 late OD ratio 0.75:1 early OD ratio 0.71:1 late 38 tooth Sun Gear 94 teeth Ring Gear 0.71:1 Ratio 24 tooth Sun Gear 72 teeth Ring Gear 0.75:1 Ratio Note: Large Sun Gear = Small pinions on the OD Planet Small Sun Gear = Large pinions on the OD Planet 2004 and later is all S

Coast Clutch and Direct Clutch Thickness /Part # .054 E8601126-S .068 E8601127-S .082 E8601128-S .096 E8601129-S

Forward Clutch Selective Snap Rings Thickness/Part# .068 XW4Z-7D483-AB .082 XW4Z-7D483-AC .096 XW4Z-7D483-A

5R55N Intermediate Sprag Rotation

A damaged intermediate sprag will cause a bind in 3rd and 4th or no 3rd or 4th.

ROTATES CLOCKWISE

HOLD

ROTATE

Check Ball Locations 5R55N Check ball locations. All 5R55N transmissions will have 2 check balls and one limit valve. Always install new check balls when servicing the valve body.

Check Ball Locations 5R55W/S Check ball locations. All 5R55W/S uses at least 2 check balls (some models have 3 check balls, use separator plate to ID for the third check ball in the bath tub. Two holes = ball, 1 hole = no ball). Always install new check balls when servicing the valve body.

Solenoid Applications

Solenoid Bodies are NOT the same When servicing a solenoid body, make sure to reference the following part numbers with the correct model. 5R55N Only: (2000 2002) XW4Z-7G391-AE

5R55W/S (2002 2003 ONLY) 1L2Z-7G391-AE

5R55S (2004) 4L2Z-7G391-AE

5R55W/S Erratic Transmission Operation

Solenoid Operation: To get a handle on the problem with using the wrong solenoid pack, you need to understand how the system uses these solenoids to control the transmission operation. The pressure regulator setup in the valve body is typical.

There are three boost passages in the boost sleeve. In the earlier units the three passages were TV, cutback, and reverse boost.

In the later units the passages are TV1 (controlled by PCA), TV2 (controlled by PCB), and reverse boost (controlled by the manual valve).


These solenoids are used for more than just controlling pressure. PCA is also used for the VFS1 modulator valve. VFS1 pressure applies the intermediate servo in 3rd gear, and applies the low/reverse servo in manual 1 and 2.

Intermediate Servo L/R Servo

VFS1 Mod Valve


PCB also controls the VFS2 modulator valve, and forward and reverse engagement valves.

The VFS2 pressure indirectly affects the feel of forward engagement and the direct clutch engagement in reverse, and it directly applies the overdrive servo and the coast clutch.

Coast Clutch

O/D Servo

VFS2 Mod Valve

Fwd & Dir Clutch


PCC regulates the reverse pressure modulator and reverse engagement control valves. The solenoid indirectly affects the feel of the direct clutch engagement in reverse, and directly applies the direct clutch in 4th and 5th gears.

Reverse Mod Valve

Direct Clutch Reverse

Engagement Control Valve


After many tests and countless hours reading hydraulic schematics, measuring valves, and applying the math.

We discovered; theres a slight difference in solenoid output. When we tested the PCA solenoids from the different solenoid packs, we found that at 0.6 amps, there was a 4 psi difference.

That doesnt sound like much but it becomes a big deal when it comes to overall pressure in the system.

The 4 psi difference equates to about 30 psi of mainline pressure, enough to cause the problems weve been encountering.

In nearly every case, replacing the solenoid pack corrects the problem.

Solenoid Failure

The plastic block covering the solenoid circuit board rubs through solenoid wire strips. Multiple codes may set when this happens.

Valve Body Separator Plate Identification Vehicle Application Chart

Year Model Transmission

Engine Separator Plate Part Number

2002 T-Bird 5R55N V8-3.9L XW4Z-7Z490-AA

2002-2004 T-Bird 5R55S V8-3.9L 3W4Z-7Z490-AA (11/18/02-07/14/03)

2004-2005 T-Bird 5R55S V8-3.9L 4W4Z-7Z490-AA (AFTER 07/14/03)

2005 MUSTANG 5R55S V6-4.0L V8-4.6L 4W4z-7Z490-AA (AFTER 07/14/03)

1999-2001 S-TYPE JAGUAR 5R55N V6-3.0L V8-4.0L

2002-2003 EXPLORER/MOUNTAINEER 5R55W/S V6-4.0L V8-4.6L 1L2Z-7Z490-AB

2004-2005 EXPLORER/MOUNTAINEER 5R55S V6-4.0L V8-4.6L 4L2Z-7Z490-AA

2003-2005 AVIATOR 5R55S TRANS ID (3L2P-E, 3L2P-F) 1L2Z-7Z490-AB

2004-2005 AVIATOR 5R55S TRANS ID (4L2P-E, 4L2P-F) 4L2Z-7Z490-AB

2003-2005 LINCOLN LS 5R55S V6-3.0L V8-3.9L 3W4Z-7Z490-AA

2000-2002 LIINCOLN LS 5R55N V6-3.0L V8-3.9L XW4Z-7Z490-AB

2000 LINCOLN LS 5R55N TRANS ID (XW4PA-A, XW4P-B)

XW4Z-7Z490-AA (REPLACED BY A NEW VALVE BODY PER FORD PART# 2W47-7A100-AA)

Valve Body Separator Plate Identification 2000 T-Bird 2000 2002 Lincoln LS (5R55N Only) XW4Z-7Z490-AB

Valve Body Separator Plate Identification

2002 2003 Explorer/Mountaineer (5R55W/S) 2003 2005 Aviator (5R55S) IL2Z-7G490-AB

Valve Body Separator Plate Identification 2004 2005 Explorer/Mountaineer (5R55S) 2004 2005 Aviator (5R55S) 4L2Z-7Z490-AA

Valve Body Separator Plate Identification 2003 2004 T-Bird (5R55S) 2003 2005 Lincoln LS (5R55S) 3W4Z-7Z490-AA

No holes here

Note: Valves that commonly wear: 3, 6, 10, and 14. Pay close attention for wear when servicing. Valve 3 is also called PCA or VS1 Valve10 is also called PCB or VS2 Valve 14 (Rev. Mod. Valve) controls direct clutch feed

Note: Valves that commonly wear: 3, 6, 9, 12,and 14. Pay close attention for wear when servicing. Valve 9 is also called PCB Valve 12 (Rev. Mod. Valve) controls direct clutch feed Valve 14 is also called PCA

Slipping 2nd/5th Gears, Binds on 2-3 Shift Overdrive Servo Bore Wear Symptoms may be erratic! Before removal of transmission, always check pressure. If pressures are normal, make sure to check the servo PIN BORE for wear.

Slipping 2nd/5th Gears, Binds on 2-3 Shift Servo Pin Wear as seen from the Field

Erratic Shifts Drive Cycle Procedure Erratic shifts after an overhaul are quite normal. Most times you will need to drive the vehicle for over 4 hours in order to get the system to relearn shift values. Do not remove the transmission after repairs for erratic shifting until you have gone through a complete drive cycle. Many concerns will be associated with the transmission: No up shift without lifting throttle 2-3 flair 3-4 and 4-5 ok 1-2 shift late and harsh 2-3 flair and on time These are the common concerns that are normal after transmission repair and or battery disconnect. During the learning process you will experience slightly firm shifts, delayed, or early shifts. Normal operation will return once these parameters are restored by the PCM

Multiple Solenoid Codes Loose Case Connector The harness connector must be completely bottomed into the solenoid pack after repair. Failure to do this can cause any one of a number of solenoids codes.

The Depth of the Solenoid bolt hole Is 0.470

TCIL Illuminated, Code P0713, Multiple Codes 2002 Explorer/Mountaineer Solenoid Harness and Water Intrusion: Vehicles equipped with a 5R55W experiencing multiple codes, or just P0713 may have a wire harness that has water intrusion. This is a common concern. Check the solenoid harness for evidences of water. If water is found replace the entire wire loom part number 1L2Z-7C078-AB. Follow procedures laid out on page 154 in doing this. Important to string with a old harness on the way out to assure assembly of the new harness. Note: The drive cycle procedure will need to be preformed as in previous slide

to assure shift quality

No Fourth Gear and No Fifth Gear . The 4-3 pre-stroke intermediate band control valve spring may break.

Many springs were machined incorrectly. May set code P0795 (Pressure Control Solenoid C circuit failure or Shorted)

No / or Slow Engagement Concerns

5R55N/W/S Flow Control Valve

The Flow Control Valve is used to help control the volume output of the pump. Control Valve And O-ring

Broken Flex plate, Vibrations A special tool (Rotunda Part #307-403) must be used to align the adapter plate to the torque converter. When using the tool it is important to note: Use one round hole and one oblong hole before tightening the nuts holding the adaptor to the converter.

OTC and MILLER tools can be ordered from www.spxmiller.com or www.spxotc.com

5R55N/W/S 4R/5R44/55E Thermal Element Function

The Thermal Element opens at an operating temperature between 150F and 170F. The thermal element or fluid cooler bypass sleeve may stick causing internal components to fail without setting any temperature related codes.

Note: This problem may also cause an intermittent lockup code P0741

4/5R55E Thermal Bypass Valve

5R55W/S Thermal Bypass Valve

5R55N/W/S 4R/5R44/55E Thermal Element Function

5R55N Thermal Bypass Valve

Note: This problem may also cause an intermittent lockup code P0741

5R55N/W/S Metal in the Pan

Three repair options: One; Replace the assembly or replace the retaining ring from another used 5R55N/W/S transmission

Broken Snap Ring There may be no particular symptom other then metal in the pan. This is something that may only be noticed on a teardown for a normal rebuild for other reasons.

5R55S Harsh Shifts, Engagements and/or Erratic Shuttle Shifts

On 2003-04 Lincoln LS and Aviators only. There may or may not be codes set, such as P1744. The ECMs have been re-flashed on several of these vehicles but it doesnt fix the problem. The module connections were inspected closely for corrosion and no problems were found. The valve bodies were also changed without any luck.

When line pressure was checked on the drivers side tap it was extremely high. In some cases the module may be TAP TESTED to make the condition come and go. At times the pressure may only drop and rise back up. In these cases only a new module corrected the problem.

No TSB From Ford At This Time

Auto ECMs 1-877-687-3267

5R55E No 3rd or 5th after repair 4R44E: No 2nd - No 4th After Rebuild 5R55E: No 3rd - No 5th After Rebuild

This condition can be caused by installing the Plug between the EPC Boost valve and the Forward modulator valve backwards

5R55E low Line Rise Low Line Pressure/No Line Rise

Soft Shifts Slips on Acceleration Ratio Error Codes Burned Clutchs and Bands

Possible Cause Weak EPC Bracket, Allows the EPC to move

Questions Survey Thanks For Attending, See you during our Next ATRA webinar

ATRA [email protected]/W/SSlide Number 45R55 DifferencesSlide Number 6Slide Number 75R55 Differences5R55 Planetary Differences5R55 Planetary Differences5R55 Planetary DifferencesSlide Number 12Selective Snap RingsSelective Snap RingsSlide Number 155R55N5R55W/S5R55N/W/SSlide Number 19Slide Number 20Slide Number 21Slide Number 22Slide Number 235R55N/W/S5R55N/W/S5R55N/W/S5R55N/W/S5R55N/W/S5R55N/W/S5R55N5R55W/S5R55W5R55W5R55W5R55N/W/S5R55W5R55N/W/S5R55N/W/S5R55N/W/SSlide Number 40Slide Number 41Slide Number 42Slide Number 43Slide Number 44Slide Number [email protected]

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5r55 Product Issues