5R55 Product Issues/Updates

Presented by:
Steve Garrett
ATRA

Connections
Handout
Questions
Survey

Note: The 5R55N was only

used in 1999-2001

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 5R55W/S
eer

V6-4.0L V8-4.6L

2003-2005

Explorer/Mountain 5R55S
eer

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

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 XL2Z-7017AA
5R55W/S/N ------- 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.

38 tooth Sun Gear

94 teeth Ring Gear
0.71:1 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

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

24 tooth Sun Gear

72 teeth Ring Gear
0.75:1 Ratio

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

5R55N

Check Ball Locations

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.

5R55W/S

Check Ball Locations

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).

5R55W/S
Erratic Transmission Operation
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

5R55W/S
Erratic Transmission Operation
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.

O/D Servo
Fwd & Dir Clutch
Coast
Clutch

VFS2
Mod Valve

5R55W/S

Erratic Transmission Operation

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.

Direct Clutch
Reverse
Mod Valve

Reverse
Engagement
Control Valve

5R55W/S

Erratic Transmission Operation

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

Transmissi
on

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# 2W477A100-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

2003 2004 Valve

T-Bird
(5R55S)
2003 2005
Lincoln LS
(5R55S)
3W4Z-7Z490-AA

No holes
here

Body Separator Plate Identification

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

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

Slipping 2nd/5th Gears, Binds on 2-3 Shift

Servo Pin Wear as seen from the Field

Drive Cycle Procedure

Erratic Shifts

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 1L2Z7C078-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.
4/5R55E Thermal Bypass Valve

5R55W/S Thermal Bypass Valve

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

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

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

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
Auto ECMs 1-877-687-3267
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

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

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