37S06T0 rear wheel drive automatic transmission repair 2004

5R55S synchronized with .71 Overdrive 2003 LS, Thunderbird, Aviator, Mountaineer and Explorer 5R55N non-synchronized with .75 Overdrive 2000-2002 LS, 2002 Thunderbird The 5R55E has the f

automatic transmission

rear-wheel drive automatic transmission

repair

student reference book

COURSE CODE: 37S06T0 ORDER NUMBER: FCS-13883-REF

September 2, 2004

Ford Customer Service Division

Course 37S06T0, Slide 1

Appropriate service methods and proper repair procedures are essential for the safe, reliable operation of all motor vehicles, as well as the personal safety of the individual doing the work

This document provides general directions for accomplishing service and repair work with tested, effective techniques Following them will help assure reliability There are numerous variations in procedures, techniques, tools, and parts for servicing vehicles, as well as in the skill of the individual doing the work This document cannot possibly anticipate all such variations and provide advice or cautions as to each Accordingly, anyone who departs from instructions provided in this document must first establish that he compromises neither his personal safety nor the vehicle integrity by his choice of methods, tools or parts

As you read through the shop manual procedures, you will come across NOTES, CAUTIONS, and WARNINGS Each one is there for a specific purpose NOTES give you added information that will help you to complete a particular procedure CAUTIONS are given to prevent you from making an error that could damage the

vehicle WARNINGS remind you to be especially careful in those areas where carelessness can cause personal injury The following list contains some general WARNINGS that you should follow when you work on a vehicle

Always wear safety glasses for eye protection

Use safety stands whenever a procedure requires you to be under the vehicle

Be sure that the ignition switch is always in the OFF position, unless otherwise required by the procedure

Set the parking brake when working on the vehicle If you have an automatic

transmission, set it in PARK unless instructed otherwise for a specific service

operation Operate the engine only in a well-ventilated area to avoid the danger of carbon monoxide

Keep yourself and your clothing away from moving part when the engine is running, especially the fan and belts

To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler

Do not smoke while working on the vehicle

To avoid injury, always remove rings, watches, loose hanging jewelry, and loose clothing before beginning to work on a vehicle Tie long hair securely behind your head

Keep hands and other objects clear of the radiator fan blades Electric cooling fans can start to operate at any time by an increase in under hood temperatures, even though the ignition is in the OFF position Therefore, care should be taken to ensure that the electric cooling fan is completely disconnected when working under the hood

Course 37S06T0, Slide 3

The Automatic Transmission Curriculum consists of 8 courses addressing automatic transmission theory of operation, diagnosis, and service Each course in the

curriculum is a “building block” for the next course in the curriculum

This curriculum is designed for technicians who want to learn the methods and techniques to properly diagnose and service automatic transmission systems and components The skills and knowledge gained from this curriculum will enable technicians to pursue training in other service specialty areas

The Automatic Transmission Update course is a Web-based Training (WBT) course

designed as an ongoing source of information on new transmissions/transaxles

The course is required for currently certified technicians New technicians do not have to take it

Currently this course addresses the TorqShift transmission Future versions of the course will cover new content

All technicians will be required to take future versions of the Automatic Transmission

Update course to remain certified

Technicians will be notified of need to take the course by electronic field

communication When technicians take the course, it sets the time clock for when they have to take the next update course

Course 37S06T0, Slide 5

The Automatic Transmission Curriculum consists of 8 courses addressing automatic transmission theory of operation, diagnosis, and service Each course in the

curriculum is a “building block” for the next course in the curriculum

This curriculum is designed for technicians who want to learn the methods and techniques to properly diagnose and service automatic transmission systems and components The skills and knowledge gained from this curriculum will enable technicians to pursue training in other service specialty areas

Course 37S06T0, Slide 6

Course 37S06T0, Slide 10

Course 37S06T0, Slide 19

Course 37S06T0, Slide 20

In a RWD vehicle, power flow starts at the input shaft and is selectively directed through various hydraulic apply components and into the planetary gear set elements After the gear set, the power flow passes through other apply

components, into the output shaft and then out of the transmission

5R55S (synchronized with 71 Overdrive) (2003 LS, Thunderbird, Aviator,

Mountaineer and Explorer)

5R55N (non-synchronized with 75 Overdrive) (2000-2002 LS, 2002 Thunderbird)

The 5R55E has the following features:

x five forward speeds

x electronic shift, pressure, and torque converter clutch controls

x three compound planetary gear sets

x three bands

x three multi-plate clutches

x two one-way clutches

All hydraulic functions are directed by electronic solenoids The solenoids control:

x engagement feel

x shift feel

x shift scheduling

x modulated torque converter clutch (TCC) applications

x timing of the 3-2 torque demand and kick-down shift

x engine braking (with O/D cancelled) utilizing the coast clutch

x manual 1st timing

x Clutch and damper assembly

The standard torque converter components operate as follows:

x Rotation of the converter housing and impeller set the fluid in motion

x The turbine reacts to the fluid motion from the impeller, transferring rotation to the gear train through the input shaft

x The reactor redirects fluid going back into the impeller, allowing for torque

Course 37S06T0, Slide 30

The main control valve body and related components are part of the pressure side of the hydraulic system It consists of the solenoids, the valve body assembly and the separator plate These components combine to convert electrical signals into

hydraulic actions

All valves in the main control assembly are anodized aluminum and cannot be

sanded, filed, or dressed in any other way Any damage to the valves, that prevents

or restricts their movement, requires replacement of the entire main control valve body

The valves are anodized to reduce corrosion and scuffing

Course 37S06T0, Slide 31

The 5R55E has three planetary gear sets

x The front planetary gear set

x The forward planetary gear set

x The low/reverse planetary gear set

The planetary gear front carrier is driven by the input shaft

x The front planetary gear set carrier drives the center shaft via the overdrive way clutch in 1st, 3rd and 4th gears

one-x In 2nd, the front sun gear is held causing the pinion gears to rotate around the front sun gear The pinion gears in turn drive the front ring gear and, with the front band applied, results in a 2nd gear ratio of 1.87 to 1

x In 5th, the front sun gear is held causing the pinion gears to rotate around the front sun gear

x The pinion gears in turn drive the front ring gear and, with the front band applied,results in a 5th (overdrive) gear ratio of 0.75 to 1

x The front planetary gear set is internally splined to the coast clutch for engine braking.

Course 37S06T0, Slide 32

The forward planetary gear set is splined to the output shaft

x The forward planetary gear set is driven by the forward ring gear when the forward clutch is applied

x The forward planetary gear set pinions drive the forward sun gear

x The forward sun gear is splined to the input shell

Course 37S06T0, Slide 34

The TorqShift automatic transmission is designed for high torque applications in rear wheel drive and four wheel drive vehicles It features:

x six forward speeds

x direct electronic shift control

x optional power take-off

The main operating components include:

x a torque converter clutch

x six multiple-disc friction clutches

x two mechanical diode one-way clutches (OWC)

x three planetary gear sets

This transmission is equipped with a remote transmission fluid filter This filter

passes ten percent of the transmission fluid from the transmission through a small orifice into a serviceable filter element The filtered fluid is then directed back into the rear lube circuit through the large opening in the remote manifold

Consult the owner’s manual for servicing intervals

x clutch and damper assembly

The standard torque converter components operate as follows:

x Rotation of the converter housing and impeller set the fluid in motion

x The turbine reacts to the fluid motion from the impeller, transferring rotation to the gear train through the input shaft

x The reactor redirects fluid going back into the impeller, providing for torque

Course 37S06T0, Slide 36

The Powertrain Control Module (PCM) controls transmission operation through:

x seven variable force solenoids (VFS)

x five pressure switches

x a transmission fluid temperature (TFT) sensor

x a manual valve

x an over-pressurization relief valve

These components are located on the solenoid body

Electronic solenoids placed close to the clutches, engage the clutch elements, reducing delays and variability common to more conventional hydraulic spring/valve systems

A solenoid and pressure switch is dedicated to the function of each of five clutches Line pressure and the torque converter clutch each have their own solenoid Four solenoids are directly proportional: the pressure output is directly proportional to the applied DC amps

Three solenoids are inversely proportional: pressure output is inversely proportional

to the applied DC current

Solenoids are keyed to prevent mistakes during assembly

There are separate connectors for the TFT sensor and for the Transmission Range Sensor (TRS)

The 24-pin bulkhead connector completes the serviceable harness assembly and has a serviceable O-ring seal The 24-pin connector uses gold plated pins

All solenoids except the line pressure solenoid can be serviced without removing the solenoid assembly from the transmission case The solenoid assembly holds the switches and solenoids The solenoid manifold is aligned with the solenoid ditch plate using permanent dowel pins

There is a filter-type gasket between the solenoid assembly and the transmission case It must be replaced if removed

Course 37S06T0, Slide 37

Gear Train Overview

Power is transmitted from the torque converter to the gear train components through the input shaft and forward clutch cylinder

By holding or driving certain members of the gear set, five forward ratios and one reverse ratio are obtained and transmitted to the output shaft

Input Shaft

The input shaft is supported by two bushings in the stator support End positioning of the input shaft is controlled by the splines in the converter turbine and the overdrive planet assembly

Output Shaft

The output shaft is supported by a press fit radial bearing in the extension housing It

is positioned by a bushing in the forward clutch cylinder, which in turn is positioned

by the case center support and the center shaft

Course 37S06T0, Slide 38

The overdrive (OD) and coast clutch system consists of the following:

x OD friction clutch assembly

x coast clutch cylinder

x overdrive sun gear

x coast clutch input hub

x coast clutch friction clutch assembly

The OD clutch separator plates and pressure plate are splined to the case The three OD friction plates are splined to the coast clutch cylinder The OD clutch

assembly is positioned between the pump face and a snap ring, and installed into

the case adjacent to the OD pressure plate The OD sun gear is pressed into the coast clutch cylinder

The coast clutch piston is also a bonded lip seal type The coast clutch piston is installed into the coast clutch cylinder and held to the cylinder along with the clutch return spring by a snap ring The separator plates are splined to the case

The coast clutch pressure plate is a mechanical diode one-way clutch (OWC) assembly The OWC is splined to the coast clutch cylinder and held in with a snap ring The coast clutch friction plates are internally splined to the coast clutch hub, which is held to the OD carrier by four bolts Absorbing the load between the OD carrier and the OD sun gear is the "captured" thrust bearing, part of the OD planet assembly

On the opposite side of the OD planet is a thrust bearing positioned between the carrier and the shaft, splined to the center shaft and retained by a snap ring is the

OD ring gear On the opposite side of the center shaft is a thrust bearing that separates it from the center support The overdrive/coast clutch system is driven clockwise by the input shaft, one end of which is splined to the torque converter turbine, and the other end is splined to the OD carrier

Course 37S06T0, Slide 39

The center support acts as the intermediate clutch cylinder piston bore, and also provides the snap ring groove to retain the bonded seal type intermediate clutch piston and the return spring

The center support is rigidly held to the case by a tapered snap ring The flat side faces toward the center support and the gap at 6 o'clock The center support is also retained to the case by two hollow feed bolts

Both the forward clutch feed bolt and the intermediate clutch feed bolt are installed through the solenoid body worm trail of the case The forward feed bolt has an orifice spacer installed on top of the bolt head

A black phenolic thrust washer is positioned by its two tabs into two holes in the center support A seal pack containing two Teflon® seals is pressed onto the center support hub below a pressed-on steel sleeve The sleeve acts as the journal for the direct clutch cylinder bushings

The intermediate clutch separator plates and pressure plate are externally splined to the case and the friction is internally splined to the direct clutch cylinder The case and the center support define and limit the stroke of the intermediate clutch

There is a 030 air bleed that allows air to bleed out the intermediate clutch There will be some air leakage during test plate checking The low/reverse clutch has an air bleed also

Course 37S06T0, Slide 40

The forward drive system consists of the following:

x Direct clutch assembly

x Forward clutch assembly

x Forward ring gear

x Forward planetary assembly

x Forward/reverse input shell assembly

The direct clutch cylinder contains the following:

x A bonded lip seal piston

x A direct clutch return spring

x A direct clutch bonded lip seal balance piston

These components are held in by a snap ring to the direct clutch cylinder

The direct clutch separator plates and pressure plate are splined to the direct clutch cylinder and held by a snap ring The direct clutch friction internally splined plates