5R55S harsh shifting; bump engaging reverse;

[tmarat]

I have a 2008 Ford Explorer V6 4.0L with 5R55S transmission. Vehicle is a middle east spec car, purchased in Dubai.

1) Most of the time shifts from 2nd to 3rd happen with a bump. I can't here any related noise, like clunk etc. Not sure if a flare is visible in the tachometer, but from what I can see and hear engine rpm does not increase, it falls during the shift without spiking.
2) If accelerating, let off the gas at around 2000-2200 rpm and start coasting, then transmission still does the upshift. Upshift usually happens when engine is at around 1600-1800rpm and falling. This happens with a slight bump in my back, not as hard as 2nd to 3rd shift, but still feel-able. This is true for both 2nd to 3rd and 3rd to 4th upshifts.
3) Engaging reverse from D happens with a very noticeable bump. I can hear the bump, but it is not a clunking sound (not hollow). Holding down the brake pedal more firmly makes the bump less noticeable, but it's still there. If engage the R from D right after the vehicle stops, then most of the time there is not bump, it goes smoothly.

I am not very hard on the gas pedal, shifts usually happen in the range of 2100-2300 rpm. If accelerate harder, then virtually all shifts are noticeable. It feels as if the transmission disengages the gear, car starts braking for a moment, then engages the next gear with a bump. I am not sure on the braking feeling, might be confusing sudden loss of the acceleration with braking, it might just be coasting at that moment.

Changed the oil and filter a month ago. Oil is Valvoline MaxLife ATF Multipurpose ATF (has Mercon V spec). Vehicle was refilled with engine on and transmission on P, cycled through other gears (D, 3,2,1, R; no actual wheel rotation). Old oil was in good condition. This issue was there before the oil change.

I have read about the flare issue and that most of the time this is solved by changing the solenoid block, or the EPC valve. But I am not seeing a flare in my case. Wonder if anybody could offer some advise on this?

 

[blacksnapon]

TSB
09-22-15 5R55S TRANSMISSION - CHECK ENGINE LIGHT ON - VARIOUS DTC'S - WATER INTRUSION FROM A/C DRAIN INTO TRANSMISSION SOLENOID BODY CONNECTOR - BUILT ON OR BEFORE 8/12/2009

Publication Date: November 2, 2009

FORD: 2006-2010 Explorer
2007-2010 Explorer Sport Trac
MERCURY: 2006-2010 Mountaineer


ISSUE:
Some 2006-2010 Explorer, Mountaineer and 2007-2010 Sport Trac vehicles built on or before 8/12/2009 and equipped with 5R55S transmission may exhibit a check engine light with diagnostic trouble code DTC P0713 and/or various transmission solenoid body connector related DTCs. This may be due to water traveling down from the A/C drain into the solenoid body connector on the left side of the transmission.

ACTION:
Follow the Service Procedure steps to correct the condition.

SERVICE PROCEDURE

Verify any transmission related symptoms or transmission related DTC's that are present.
Check the transmission solenoid connector for signs of water intrusion, corrosion, that may be coming from the A/C drain.

 

[blacksnapon]

TSB
09-12-12 5R55S/5R55N/5R55W TRANSMISSIONS - SHIFT CONCERNS, LOSS OF 2ND, 3RD AND 5TH GEAR, INCORRECT RATIO DTC'S - PROCEDURE TO INSPECT AND REPAIR SERVO PIN BORE WEAR

Publication Date: June 11, 2009

FORD: 2002-2005 Thunderbird
2005-2009 Mustang
2002-2009 Explorer
2007-2009 Explorer Sport Trac
LINCOLN: 2002-2006 Lincoln LS
2003-2005 Aviator
MERCURY: 2002-2009 Mountaineer


ISSUE:
Some 2002-2009 Explorer, Mountaineer, 2007-2009 Explorer Sport Trac, 2002-2006 Lincoln LS, 2005-2009 Mustang, 2002-2005 Thunderbird and 2003-2005 Aviator vehicles equipped with a 5R55S, 5R55W, and 5R55N transmission may experience shifting concerns. A loss of 2nd, 3rd and 5th gear, may have overdrive band or intermediate band failures due to servo pin case bore wear causing reduced apply pressure.

ACTION:
Follow the Service Procedure steps to correct the condition.

SERVICE PROCEDURE

For transmissions that have been determined to require an overhaul or rebuild and the overdrive band or intermediate band have excessive wear or burned/damaged band friction material, the cause maybe excessive servo pin case bore wear generally found on higher mileage vehicles, usually accompanied with incorrect ratio diagnostic trouble codes (DTCs), condition becomes worse when hot.



In our instructions, when we refer to the overdrive bore, we are talking about the smaller bore located closest to the bell housing. When we refer to the intermediate bore, we are talking about the larger bore located next to the line pressure tap.

Inspect and repair the worn-damaged transmission case servo pin bore utilizing the Rotunda Tool 5RW Master Kit part number NRL5RW servo pin bore repair system.

Install the drill jig into the case by setting the jig into the case servo bore. Retain the jig in the case with the servo's snap-ring.


Drop the 9/16" guide into the jig. It doesn't matter which one of the lands on the guide you use, as long as one of the lands is under the 3/8" Allen screw.
NOTE: CUTTING OIL MUST BE USED FOR LUBRICATION. THE USE OF SUBSTITUTES, PARTICULARLY ATF, MAY RESULT IN AN OVER-SIZED BORE.



Ream out the bore using the 9/16" reamer, applying ample lubrication.
NOTE: DO NOT REAM ABOVE 500 RPM.



Replace the 9/16" reamer guide with the 5/8" guide, and the 9/16" reamer with the 5/8" reamer.
Ream the bore out using the 5/8" reamer with ample lubrication. Take care not to either push too hard on the reamer or turn the reamer faster than 500 RPM when reaming. Either one can overly enlarge the bore, causing a loose bushing.
Clean the case before proceeding to Step 7. This kit utilizes two different bushings.
The shorter bushing is for the intermediate servo and is identified by a flat ground in the bushing's hat.
Overdrive servo bushing.


Both bushings are chamfered and need to be installed with the recessed edge up (away from the valve body).

Apply Loctite® 680 Retaining Compound or equivalent to the outside of the bushing and drive the bushing in by hitting the driver until the bushing bottoms. (Figure 5) The 5RW kit uses a smaller diameter installation tool identified by a groove cut in the handle.



After installing the bushing, using a 15/64" bit, drill a hole in the side of the bushing by following the servo apply holes in the case 5R55S case shown.
Overdrive servo.


Intermediate servo.


NOTE: FAILURE TO PERFORM CROSS DRILL STEP IN THE NEW BUSHING WILL RESULT IN A NO SHIFT CONDITION.



Insert the provided sizing pin into the bore. It maybe necessary to start the pin in the bushing with a rubber mallet. Once the pin is inside the bushing, use a punch to drive the pin all the way through the bushing. Repeat as necessary.


Correctly installed bushings will be flush inside of case.



The 9/16" and 5/8" reamers require typical maintenance and cleaning of aluminum build up on the cutting edges to help provide optimum bushing installation and increased tool life.

After bushing installation, thoroughly wash the case before rebuilding transmission.

 

[tmarat]

I don't have the check engine or the OD lights.

 

[blacksnapon]

Yours sounds like the second one.

 

[pb3]

any update on this problem? my 2010 w/ 52k miles is doing the same thing and this was the best google search result. it's not a flare, just a slam into gear.

 

[christes]

Transmission Failure

Sorry to break the news, it sounds like your transmission is failing. There are factory flaws in this transmission. Apparently its not unusal for them to fail between 50K and 100K.

I have an 08 Mountaineer 4.0 AWD with 85K I bought new. Mine is doing the same thing (although) not quite as bad. I'm having my transmission completely rebuilt this week. The shop should update the software and replace virtually everything with a combination of factory parts and upgraded aftermarket parts to correct the factory defects.

Expensive, Yes! However, my decision was to go through the whole transmission and fix/ugrade it now and not have to bring it back for something else in 6mos.

I'm going over to the shop tomorrow to take a look at the transmission when they get it apart. I'll let you know what they find and if it fixes the problems.