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Automatic Transmission Servicing - A/t Ford Explorer Sport Trac I

Automatic Trans 54 illustrations ~4243 words

APPLICATION

ApplicationTransmission Model
Explorer Sport & Explorer Sport Trac
4.0L5R55E
Ranger
2.3L & 3.0L5R44E
4.0L5R55E

TRANSMISSION APPLICATION

ApplicationTransfer Case Model
Explorer Sport, Explorer Sport Trac & RangerBorg-Warner 13-54

TRANSFER CASE APPLICATION

The 5R44E and 5R55E 5-speed automatic transmissions can be identified by the vehicle certification label, located on driver's door post. This label contains the transmission letter code under space marked TR (next to space marked AXLE). Letter code for 5R44E and 5R55E transmission is "D". Transmission can also be identified by service identification tag attached to transmission case. (Scheme 1)and (Scheme 2).

Scheme 1

Scheme 1: TRANSMISSION
Scheme 1: TRANSMISSION

Scheme 2

Scheme 2
Scheme 2

Scheme 3

Scheme 3: OIL PAN GASKET
Scheme 3: OIL PAN GASKET

Check transmission fluid level at every engine oil change. Under normal service, change transmission fluid and filter at 150,000-mile intervals. See DRAINING & REFILLING . Service all models at 30,000-mile intervals when used under the following conditions

  1. In hot weather with temperature greater than 90°F (32°C), carrying heavy loads and/or in hilly terrain.
  2. Towing a trailer or using a car top carrier.
  3. In police, taxi or door-to-door delivery service.
  4. Extreme dusty conditions or off-road use.

Transfer Case

Under normal driving conditions, replace transfer case fluid every 150,000 miles. Under severe driving conditions, replace transfer case fluid every 60,000 miles.

CHECKING FLUID LEVEL

To obtain an accurate transmission fluid level check, drive vehicle until it is at normal operating temperature, about 20 miles. If vehicle has been operated for an extended period at high speeds, in city traffic during hot weather or pulling a trailer, vehicle should be turned off for about 30 minutes to allow transmission fluid to cool down before checking.

  1. Drive vehicle for about 20 miles or until it reaches operating temperature 150-170°F (66-77°C). With vehicle on level ground, apply parking brake, and run engine at idle. Shift gear selector lever through all ranges, ending in Park.
  2. Check fluid level with dipstick. Transmission fluid level should be in crosshatch area on dipstick. If transmission is at room temperature, fluid level should be between 2 dimples on bottom of dipstick.
  3. Add fluid as necessary. See «RECOMMENDED FLUIDS»(/ford/explorer-sport-trac/i-2000-2005/remont/automatic-trans/#automatic-transmission-servicing-at__recommended-fluids) . DO NOT overfill. Check condition of fluid for contamination and burned smell. Ensure dipstick is fully installed.

Check fluid level at transfer case fill plug hole. Fluid should be level with bottom of fill plug hole. Add fluid as necessary. See RECOMMENDED FLUIDS .

RECOMMENDED FLUIDS

CAUTIONEnsure correct transmission and transfer case fluid is used. Mercon(R) V and Mercon(R) are not compatible.
ApplicationFluid Type
5R44E & 5R55EMercon(R) V (XT-5-QM)

TRANSMISSION FLUID APPLICATION

ApplicationFluid Type
5R44E & 5R55EMercon(R) (XT-2-QDX)

TRANSFER CASE FLUID APPLICATION

FLUID CAPACITIES

ApplicationQts. (L)
5R44E
2WD
2.3L9.9 (9.4)
3.0L & 4.0L10.0 (9.5)
4WD
3.0L & 4.0L10.3 (9.8)
5R55E
2WD10.0 (9.5)
4WD10.3 (9.8)
(1) Fluid capacities listed are approximate. Always fill to specified area on dipstick. See CHECKING FLUID LEVEL .
(1)Fluid capacities listed are approximate. Always fill to specified area on dipstick. See CHECKING FLUID LEVEL .

TRANSMISSION FLUID CAPACITIES (1)

ApplicationPts. (L)
Borg-Warner 13-542.5 (1.2)
(1) Fluid capacities listed are approximate. Always fill to specified area on dipstick. See CHECKING FLUID LEVEL .
(1)Fluid capacities listed are approximate. Always fill to specified area on dipstick. See CHECKING FLUID LEVEL .

TRANSFER CASE FLUID CAPACITIES (1)

DRAINING & REFILLING

  1. Position the vehicle on a hoist. Place gearshift selector lever in Neutral position. The transmission servo heat shield must be removed from the transmission oil pan rail and positioned aside for transmission oil pan removal. Loosen the nut and position the heat shield aside, if equipped. (Scheme 4)
  2. Place a drain pan under the transmission oil pan. Remove all the transmission oil pan bolts except for 2 in the front. Loosen the 2 front transmission oil pan bolts.
  3. Pry the rear of the transmission oil pan down and allow the fluid to drain. After the fluid is drained, remove the front 2 transmission oil pan bolts. Remove the transmission oil pan.
  4. Remove and discard the transmission oil pan gasket. Remove the transmission fluid filter screw. (Scheme 5) Remove the transmission fluid filter and discard. Clean and inspect the transmission oil pan and magnet.
  5. Clean all mating surfaces. Position a new transmission oil pan gasket on the transmission oil pan. Flush the transmission fluid cooler and transmission fluid cooler lines. See «BACK FLUSHING & CLEANING OIL COOLER»(/ford/explorer-sport-trac/i-2000-2005/remont/automatic-trans/#automatic-transmission-servicing-at__oil-cooler-flushing).
  6. Lube and install new O-ring seals onto the transmission fluid filter. (Scheme 6) Position the transmission fluid filter on the main control valve body. Install the transmission fluid filter. Position the oil pan magnet in the transmission oil pan. Install and align the transmission oil pan.
  7. Loosely install the transmission oil pan bolts. Tighten the transmission oil pan bolts in a crisscross sequence to specification. See «TORQUE SPECIFICATIONS»(/ford/explorer-sport-trac/i-2000-2005/remont/automatic-trans/#automatic-transmission-servicing-at__torque-specifications).
  8. Position the servo heat shield over the servos and clip it to the pan rail, if equipped. If the vehicle is equipped with an in-line fluid filter, install a new in-line fluid filter. Lower the vehicle. When filling a dry transmission and converter, start with a minimum of 4 Qts. (3.7 L).
  9. Fill the transmission with appropriate fluid to proper level and check for correct transmission operation. See «CHECKING FLUID LEVEL»(/ford/explorer-sport-trac/i-2000-2005/remont/automatic-trans/#automatic-transmission-servicing-at__checking-fluid-level). Apply the park brake, and start the engine. Move the gearshift selector lever through all the gears. Fill the transmission with appropriate fluid to proper level and check for correct transmission operation. See «CHECKING FLUID LEVEL»(/ford/explorer-sport-trac/i-2000-2005/remont/automatic-trans/#automatic-transmission-servicing-at__checking-fluid-level).

Scheme 4

Scheme 4
Scheme 4

Scheme 5

Scheme 5
Scheme 5

Scheme 6

Scheme 6
Scheme 6

OIL COOLER FLUSHING

CAUTIONWhenever a transmission has been disassembled to install new parts, or because the valve body sticks from foreign material, the transmission fluid cooler must be cleaned using a suitable torque converter/fluid cooler cleaner. Under no circumstances should torque converters be cleaned by hand agitation with solvent. When internal wear or damage has occurred in the transmission, metal particles, clutch plate material, or band material may have been carried into the transmission cooler. These contaminants are a major cause of recurring transmission concerns and must be removed from the system before the transmission is put back into service.
  1. Conduct back flushing with a suitable torque converter/transmission fluid oil cooler cleaner. Test the equipment to make sure that a vigorous fluid flow is present before proceeding. Install a new system filter if flow is weak or contaminated.
  2. To aid in attaching the cleaner to the transmission steel oil cooler lines, connect 2 additional rubber hoses to the transmission end of the steel transmission oil cooler lines as described.
  3. Connect the cleaner tank pressure line to the steel transmission oil cooler return line (longest line). Connect a tank return hose to the steel transmission oil cooler pressure line (shorter line). Place the outlet end of this hose in the solvent tank reservoir.
  4. Turn on solvent pump and allow the solvent to circulate a minimum of 5 minutes (cycling switch on and off will help dislodge contaminants in oil cooler system).
  5. Switch off the solvent pump and disconnect the solvent pressure hose from the transmission oil cooler return line. Use compressed air to blow out the oil cooler(s) and oil cooler lines (blow air into the transmission cooler return line) until all solvent is removed. Remove the rubber return hose from the remaining steel oil cooler line.

ON-VEHICLE REPAIRS

Various components may be serviced without transmission removal, depending on application. For servicing of these components, see appropriate component under ADJUSTMENTS and/or REMOVAL & INSTALLATION . For additional information on testing electrical components, see appropriate DIAGNOSIS article in AUTOMATIC TRANSMISSIONS.

ADJUSTMENTS

WARNINGVehicle is equipped with Supplemental Inflatable Restraint (SIR) system. When servicing vehicle, use care to avoid accidental air bag deployment. SIR system-related components are located in various locations throughout interior and exterior of vehicle, depending on application. Do not use electrical test equipment on or near these circuits. If necessary, deactivate SIR system before servicing components. See AIR BAG DEACTIVATION PROCEDURES article in GENERAL INFORMATION.

INTERMEDIATE & OVERDRIVE BANDS

CAUTIONDO NOT allow adjustment screw to back out of case. Band strut may fall inside transmission assembly.
  1. Raise the vehicle on a hoist. Disconnect the shift cable. Disconnect the shift cable (1) from the manual control lever. (Scheme 7) Disconnect the shift cable from the bracket (2).
  2. Remove the Transmission Range (TR) sensor. See «TRANSMISSION RANGE SENSOR»(/ford/explorer-sport-trac/i-2000-2005/remont/automatic-trans/#automatic-transmission-servicing-at) under REMOVAL & INSTALLATION.
  3. Remove and discard the intermediate and overdrive band lock nuts. (Scheme 8) The lock nuts are not reusable for assembly. Apply petroleum jelly to the lock nut seals.
  4. Using the Transmission Band Adjustment Set (307-S022), tighten overdrive band adjustment screw then, back off the overdrive band adjustment screw exactly 2 turns and hold that position. (Scheme 9)
  5. Using the transmission band adjustment set, tighten intermediate band adjustment screw then, back off the intermediate band adjustment screw exactly 2 turns and hold that position.
  6. Tighten the intermediate and overdrive band lock nuts to specification, by holding the band adjustment screw stationary and tightening the band lock nut. See «TORQUE SPECIFICATIONS»(/ford/explorer-sport-trac/i-2000-2005/remont/automatic-trans/#automatic-transmission-servicing-at__torque-specifications).
  7. Install the TR sensor. See «TRANSMISSION RANGE SENSOR»(/ford/explorer-sport-trac/i-2000-2005/remont/automatic-trans/#automatic-transmission-servicing-at) under REMOVAL & INSTALLATION. Install the shift cable to the manual control lever. (Scheme 7) Lower the vehicle.

Scheme 7

Scheme 7
Scheme 7

Scheme 8

Scheme 8
Scheme 8

Scheme 9

Scheme 9
Scheme 9

SHIFT CABLE

  1. Place gearshift lever in " D" position. Hang a 3 lb. (1.4 kg) weight from gearshift lever. Raise and support vehicle. Using a screwdriver, pry shift cable from shift control lever on transmission. Pull shift cable adjustment lock tab outward to unlock. (Scheme 10) Ensure adjuster body moves freely.
  2. Position shift control lever in "OD" position. "OD" position is obtained by rotating shift control lever clockwise until travel stops, and then turn shift control lever counterclockwise 2 detents. (Scheme 11) Connect cable to shift control lever. Push in lock tab to lock adjustment sleeve in position. Lower vehicle.
  3. Remove weight from gearshift lever. Check for park gear engagement. Start engine and ensure indicated gear positions match transmission response. Verify vehicle only starts in Park and Neutral, and back-up lights operate. If operation is not okay, check transmission range sensor adjustment. See «TRANSMISSION RANGE SENSOR»(/ford/explorer-sport-trac/i-2000-2005/remont/automatic-trans/#automatic-transmission-servicing-at__transmission-range-sensor).

Scheme 10

Scheme 10
Scheme 10

Scheme 11

Scheme 11
Scheme 11

TRANSMISSION RANGE SENSOR

  1. Place gearshift lever in Neutral position. Remove manual control lever. Loosen Transmission Range (TR) sensor retaining bolts. Using Range Sensor Adjuster (307-351), adjust TR sensor adjuster. (Scheme 12) Tighten TR sensor retaining bolts to specification. See «TORQUE SPECIFICATIONS»(/ford/explorer-sport-trac/i-2000-2005/remont/automatic-trans/#automatic-transmission-servicing-at__torque-specifications). Install shift control lever, and tighten nut.
  2. Check for park gear engagement. Start engine and ensure indicated gear positions match transmission response. If operation is not okay, check shift cable adjustment. See «SHIFT CABLE»(/ford/explorer-sport-trac/i-2000-2005/remont/automatic-trans/#automatic-transmission-servicing-at__shift-cable). Verify vehicle only starts in Park and Neutral, and back-up lights operate.

Scheme 12

Scheme 12
Scheme 12

REMOVAL & INSTALLATION

WARNINGVehicle is equipped with Supplemental Inflatable Restraint (SIR) system. When servicing vehicle, use care to avoid accidental air bag deployment. SIR system-related components are located in various locations throughout interior and exterior of vehicle, depending on application. Do not use electrical test equipment on or near these circuits. If necessary, deactivate SIR system before servicing components. See AIR BAG DEACTIVATION PROCEDURES article in GENERAL INFORMATION.
CAUTIONWhen battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. See COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION before disconnecting battery.

CONTROL VALVE BODY

Note. Note length and location of valve body bolts for reassembly reference. (Scheme 18)

Removal

  1. Disconnect the negative battery cable. Raise and support the vehicle. Place a drain pan under the transmission oil pan. Remove transmission oil pan and filter. See «DRAINING & REFILLING»(/ford/explorer-sport-trac/i-2000-2005/remont/automatic-trans/#automatic-transmission-servicing-at__draining-refilling) under LUBRICATION.
  2. Unclip main control valve body wire harness. Lift up on wire harness guide and protector and disengage the retaining pins from the solenoid clamps. Disconnect the 6 solenoid harness connectors. Disconnect the shift solenoids "A", "B", "C" and "D" harness connectors (1). (Scheme 13)
  3. Disconnect the Torque Converter Clutch (TCC) solenoid harness connector (2). Disconnect the Electronic Pressure Control (EPC) solenoid harness connector (3). Remove the manual control valve detent lever spring screw. Remove the manual control valve detent lever spring. (Scheme 14)
  4. Remove the low/reverse servo cover screws (1). (Scheme 15) Remove the low/reverse band servo cover (2) and gasket. Discard the low/reverse servo separator plate cover gasket. Remove the low/reverse band servo piston and rod. Support the main control valve body.
  5. Do not remove the 2 Gold colored screws specified. (Scheme 16) Support the main control valve body. Remove the screws. Remove the main control valve body.

Scheme 13

Scheme 13
Scheme 13

Scheme 14

Scheme 14
Scheme 14

Scheme 15

Scheme 15
Scheme 15

Scheme 16

Scheme 16
Scheme 16

Installation

  1. Install the Valve Body Alignment Pins (307-333) into the transmission case. (Scheme 17) Position the main control valve body with the 2 valve body alignment pins as a guide.
  2. Loosely install 4 M6 x 45 mm (1.8 in) screws. (Scheme 18) Loosely install 2 M6 x 35 mm (1.4 in) screws. Remove the 2 valve body alignment pins. Loosely install the M6 x 30 mm (1.2 in) screw. Loosely install the sixteen M6 x 40 mm (1.6 in) main control valve body screws.
  3. Tighten the main control valve body screws in the sequence shown. (Scheme 19) Rotate the manual lever into the Neutral position.
  4. Install the manual control valve detent lever spring. Install the low/reverse band servo piston and rod. Install the low/reverse band servo cover. Install the low/reverse band servo cover and gasket.
  5. Loosely install the low/reverse servo piston cover screws. Tighten the servo cover screws in the sequence shown. (Scheme 19)
  6. Connect shift solenoids "A", "B", "C", and "D" harness connectors. (Scheme 13) Connect the TCC solenoid harness connector. Connect the EPC solenoid harness connector.
  7. Install the main control valve body wire harness. Align the retaining pins to the holes in the solenoid clamps and press in the main control valve body wire harness guide and protector.
  8. If the vehicle was not equipped with a in-line transmission fluid filter, install a fluid filter kit. (Scheme 20) Follow the instructions supplied in the kit. If the vehicle was equipped with a in-line transmission fluid filter, install a new filter.
  9. Lower the vehicle. Connect the negative battery cable. Fill the transmission with appropriate fluid to proper level and check for correct transmission operation. See «LUBRICATION»(/ford/explorer-sport-trac/i-2000-2005/remont/automatic-trans/#automatic-transmission-servicing-at).

Scheme 17

Scheme 17
Scheme 17

Scheme 18

Scheme 18
Scheme 18

Scheme 19

Scheme 19
Scheme 19

Scheme 20

Scheme 20
Scheme 20

EXTENSION HOUSING

Note. For extension housing removal and installation procedures on 4WD models, see appropriate OVERHAUL article in AUTOMATIC TRANSMISSIONS.

Note. Parking pawl, return spring and shaft may fall during extension housing removal. Ensure parking pawl is installed correctly during reassembly. (Scheme 25)

  1. Raise and support the vehicle. Mark the rear driveshaft. (Scheme 21) Remove the rear driveshaft bolts. Remove the rear driveshaft. Remove the nuts. Raise and support the transmission.
  2. Remove the transmission mount bolts (1). (Scheme 22) Remove the transmission mount (2). Remove the extension housing screws and studs. (Scheme 23)
  3. Remove the extension housing. Discard the extension housing gasket. (Scheme 24) Inspect the parking pawl, parking pawl return spring and the parking pawl shaft. Install new components, if required.

Scheme 21

Scheme 21
Scheme 21

Scheme 22

Scheme 22
Scheme 22

Scheme 23

Scheme 23
Scheme 23

Scheme 24

Scheme 24
Scheme 24

Scheme 25

Scheme 25
Scheme 25

Note. Ensure the parking lever actuating rod is correctly seated into the case parking rod guide cup. Verify that the output shaft is locked in the Park position.

  1. Align the flats of the manual valve inner lever with the flats on the manual control lever shaft. Install the manual valve inner lever and parking lever actuating rod onto the manual control lever shaft.
  2. Clean the extension housing and install new extension housing gasket. (Scheme 24)
  3. Position the extension housing. Install the extension housing screws. (Scheme 23) Install the extension housing studs.
  4. Position the transmission mount on the extension housing. (Scheme 22) Install the transmission mount-to-extension housing bolts and tighten to specification. Install the transmission mount-to-extension housing bolts into the crossmember and tighten the transmission mount-to-extension housing bolts to specification. See «TORQUE SPECIFICATIONS»(/ford/explorer-sport-trac/i-2000-2005/remont/automatic-trans/#automatic-transmission-servicing-at__torque-specifications).
  5. Align and install the rear driveshaft. (Scheme 21) Tighten driveshaft bolts to specification. See «TORQUE SPECIFICATIONS»(/ford/explorer-sport-trac/i-2000-2005/remont/automatic-trans/#automatic-transmission-servicing-at__torque-specifications).
  6. Lower the vehicle. Fill the transmission with appropriate fluid to proper level and check for correct transmission operation. See «LUBRICATION»(/ford/explorer-sport-trac/i-2000-2005/remont/automatic-trans/#automatic-transmission-servicing-at).
CAUTIONUse the extension housing bushing remover carefully so that the seal area is not damaged.

Note. For extension housing seal and bushing removal and installation procedures on 4WD models, see appropriate OVERHAUL article in AUTOMATIC TRANSMISSIONS.

Note. To maintain initial driveshaft balance, mark the rear driveshaft yoke and axle flange so they can be installed in their original alignment.

Position the vehicle on a hoist. Place transmission in Neutral. Mark the rear driveshaft. (Scheme 21) Remove the rear driveshaft bolts. Remove the rear driveshaft. Using the Slide Hammer (100-001) and Seal Remover (307-309), remove the extension housing seal. (Scheme 26) Using the Bushing Remover (308-070), remove the extension housing bushing. (Scheme 27)

Scheme 26

Scheme 26
Scheme 26

Scheme 27

Scheme 27
Scheme 27
CAUTIONThe lube hole in the extension housing bushing must be aligned with the lube groove in the extension housing. This groove is located at the 3 o'clock position when viewed from the rear. (Scheme 28)
  1. Inspect the counterbore of the extension housing for burrs. Remove any burrs from the extension housing counterbore with an oil stone. Position the extension housing bushing into the extension housing.
  2. Using the Extension Housing Bushing Installer (307-065), install the extension housing bushing. (Scheme 29) Position new extension housing seal with drain hole in the 6 o'clock position. (Scheme 30) Using the Extension Housing Seal Installer (307-038), install the extension housing seal. (Scheme 31)
  3. Inspect the driveshaft slip-yoke for wear and damage. Install a new component if required. Align the driveshaft with the marks made during removal to make sure balance is correct. (Scheme 21) Install the rear driveshaft bolts.
  4. Lower the vehicle. Fill the transmission with appropriate fluid to proper level and check for correct transmission operation. See «LUBRICATION»(/ford/explorer-sport-trac/i-2000-2005/remont/automatic-trans/#automatic-transmission-servicing-at).

Scheme 28

Scheme 28
Scheme 28

Scheme 29

Scheme 29
Scheme 29

Scheme 30

Scheme 30
Scheme 30

Scheme 31

Scheme 31
Scheme 31

INTERMEDIATE & OVERDRIVE SERVOS

WARNINGServo covers are under spring tension. Use appropriate tools to disassemble.
  1. Disconnect the negative battery cable. Raise and support the vehicle. Disconnect the shift cable from the manual control lever. (Scheme 7) Remove the shift cable from the bracket.
  2. Remove the Transmission Range (TR) sensor. See «TRANSMISSION RANGE SENSOR»(/ford/explorer-sport-trac/i-2000-2005/remont/automatic-trans/#automatic-transmission-servicing-at). Remove the three-way Catalytic Converter (TWC).
  3. If equipped, the transmission servo heat shield needs to be unclipped from the fluid pan rail and positioned out of the way for fluid pan removal. Remove transmission oil pan and filter. See «DRAINING & REFILLING»(/ford/explorer-sport-trac/i-2000-2005/remont/automatic-trans/#automatic-transmission-servicing-at__draining-refilling) under LUBRICATION.
  4. Remove the control valve body. See «CONTROL VALVE BODY»(/ford/explorer-sport-trac/i-2000-2005/remont/automatic-trans/#automatic-transmission-servicing-at__control-valve-body). Remove the lock nut and unscrew the screw. (Scheme 8)
  5. Discard the lock nut after removal. Using the Servo Cover Compressor (307-340), remove the appropriate band servo cover retaining ring. (Scheme 32)or (Scheme 33). Slowly remove tension on the J-hook nut and remove the servo cover compressor.
  6. Insert the servo remover into the transmission case, and remove the servo cover, band servo piston and servo piston spring. (Scheme 34)

Scheme 32

Scheme 32
Scheme 32

Scheme 33

Scheme 33
Scheme 33

Scheme 34

Scheme 34
Scheme 34
  1. Assemble the band servo cover (1), band servo piston (2) and the servo piston spring (3). (Scheme 35)
  2. Lubricate band servo cover O-ring with petroleum jelly. Using the servo cover compressor, install the band servo cover retaining ring. (Scheme 32)or (Scheme 33).
  3. Adjust the appropriate band. See «INTERMEDIATE & OVERDRIVE BANDS»(/ford/explorer-sport-trac/i-2000-2005/remont/automatic-trans/#automatic-transmission-servicing-at__intermediate-overdrive-bands) under ADJUSTMENTS. Install the main control valve body. See «CONTROL VALVE BODY»(/ford/explorer-sport-trac/i-2000-2005/remont/automatic-trans/#automatic-transmission-servicing-at__control-valve-body).
  4. Install the TR sensor. See «TRANSMISSION RANGE SENSOR»(/ford/explorer-sport-trac/i-2000-2005/remont/automatic-trans/#automatic-transmission-servicing-at). If equipped, position the transmission servo heat shield on the transmission and install the nut.
  5. Install the shift cable to the manual control lever. (Scheme 7) Install the three-way catalytic converter. Lower the vehicle.
  6. Connect the negative battery cable. Fill the transmission with appropriate fluid to proper level and check for correct transmission operation. See «LUBRICATION»(/ford/explorer-sport-trac/i-2000-2005/remont/automatic-trans/#automatic-transmission-servicing-at).

Scheme 35

Scheme 35
Scheme 35

Raise and support the vehicle. Disconnect Intermediate Shaft Speed (ISS) sensor harness connector. Remove the ISS sensor screw (1). (Scheme 36) Remove the ISS sensor from the transmission (2). Inspect the ISS sensor O-ring for damage. If damaged, install a new O-ring.

Scheme 36

Scheme 36: Removal
Scheme 36: Removal

Inspect and lubricate O-ring with petroleum jelly. Install the ISS sensor into the transmission. Tighten ISS sensor screw (1). (Scheme 36) Connect ISS sensor harness connector. Lower the vehicle.

  1. Disconnect the negative battery cable. Raise and support the vehicle. Disconnect vehicle harness from transmission case harness connector. (Scheme 37) Drain the transmission fluid.
  2. Remove the transmission oil pan and filter. See «DRAINING & REFILLING»(/ford/explorer-sport-trac/i-2000-2005/remont/automatic-trans/#automatic-transmission-servicing-at__draining-refilling) under LUBRICATION. Carefully lift up on wire loom guide and protector and disengage the retaining pins from the solenoid clamps.
  3. Disconnect the solenoid harness connectors. (Scheme 13) Disconnect the shift solenoid harness connectors. Disconnect the Torque Converter Clutch (TCC) solenoid harness connector.
  4. Disconnect the Electronic Pressure Control (EPC) solenoid harness connector. Remove the solenoid clamp screws. Remove the solenoid clamp. Remove the EPC and shift solenoid "B".
  5. Do not pry on the other wires or damage the harness connector case surface. Disconnect the Turbine Shaft Speed (TSS) sensor harness connector from the transmission case harness connector (1). (Scheme 38)
  6. Remove from the TSS sensor wire locator (2). Do not overstretch the retaining spring. Remove the transmission case harness connector retaining spring. (Scheme 39)
  7. Do not damage the harness connector. Remove the transmission case harness connector. Compress the tabs on the transmission case harness connector. (Scheme 40) Push the transmission case harness connector out of transmission case.

Scheme 37

Scheme 37
Scheme 37

Scheme 38

Scheme 38
Scheme 38

Scheme 39

Scheme 39
Scheme 39

Scheme 40

Scheme 40
Scheme 40

Note. Make sure the tab is in the lock position. Install new O-rings on the transmission case harness connector

  1. Install the transmission case harness connector. Lubricate the transmission case harness connector O-rings with petroleum jelly. (Scheme 41)
  2. Press the transmission case harness connector through the case until a click is heard. (Scheme 42) Align the slot on the TSS sensor harness connector with the slot in the case harness connector.
  3. Install TSS sensor wire into transmission case harness connector (1). (Scheme 38) Install TSS sensor wire into the locator (2). Install the transmission case harness connector retaining spring, ensuring not to overstretch the retaining spring. (Scheme 39)
  4. Install the EPC and shift solenoid "B". The solenoid clamp must be installed in the TCC and EPC solenoid grooves, shift solenoid pockets and the No. 204 plug. Install the solenoid clamp. Position the solenoid clamp on the main control valve body.
  5. Install the solenoid clamp screws. Connect shift solenoids "A" and "C" harness connectors. (Scheme 13)
  6. Connect the TCC, shift solenoids "B" and "D" then the EPC solenoid harness connectors.
  7. Install the wire harness guide and protector. Align the retaining pins to the holes in the solenoid clamps and gently press in the wire harness guide and protector. Install the transmission fluid filter and pan. See «DRAINING & REFILLING»(/ford/explorer-sport-trac/i-2000-2005/remont/automatic-trans/#automatic-transmission-servicing-at__draining-refilling) under LUBRICATION
  8. Connect the negative battery cable. Fill the transmission with appropriate fluid to proper level and check for correct transmission operation. See «LUBRICATION»(/ford/explorer-sport-trac/i-2000-2005/remont/automatic-trans/#automatic-transmission-servicing-at).

Scheme 41

Scheme 41
Scheme 41

Scheme 42

Scheme 42
Scheme 42
  1. Position the vehicle on a hoist. Place transmission in Neutral. Disconnect the negative battery cable. If equipped, the transmission servo heat shield must be unclipped from the oil pan rail and positioned out of the way for transmission oil pan removal. (Scheme 4)
  2. Remove transmission oil pan and fluid filter. See «DRAINING & REFILLING»(/ford/explorer-sport-trac/i-2000-2005/remont/automatic-trans/#automatic-transmission-servicing-at__draining-refilling) under LUBRICATION.
  3. Remove the low/reverse band servo cover screws (1). (Scheme 43) Remove the low/reverse band servo cover and gasket (2).
  4. Discard the low/reverse servo separator plate cover gasket. Remove the low/reverse band servo piston and rod assembly. (Scheme 44)

Scheme 43

Scheme 43
Scheme 43

Scheme 44

Scheme 44
Scheme 44
  1. Clean and inspect the low/reverse band servo piston bore and the low/reverse band servo piston and rod.
  2. Install the low/reverse band servo piston and rod assembly (1). (Scheme 45) Install a new low/reverse band servo separator plate cover gasket (2).
  3. Install the low/reverse band servo cover (3). Loosely install the low/reverse band servo piston cover screws. Tighten the servo cover screws in the sequence shown. (Scheme 46)
  4. Lower the vehicle. Connect the negative battery cable. Fill the transmission with appropriate fluid to proper level and check for correct transmission operation. See «LUBRICATION»(/ford/explorer-sport-trac/i-2000-2005/remont/automatic-trans/#automatic-transmission-servicing-at).

Scheme 45

Scheme 45
Scheme 45

Scheme 46

Scheme 46
Scheme 46
  1. Disconnect the negative battery cable. Raise and support vehicle. Remove the transmission oil pan. See «DRAINING & REFILLING»(/ford/explorer-sport-trac/i-2000-2005/remont/automatic-trans/#automatic-transmission-servicing-at__draining-refilling) under LUBRICATION. Remove the Transmission Range (TR) sensor. See «TRANSMISSION RANGE SENSOR»(/ford/explorer-sport-trac/i-2000-2005/remont/automatic-trans/#automatic-transmission-servicing-at).
  2. Remove the manual control valve detent lever spring screw. (Scheme 14) Remove the manual control valve detent lever spring. Remove the manual valve inner lever nut. (Scheme 47)
  3. Separate the manual valve inner lever and the parking lever actuating rod. (Scheme 48) Remove the manual control lever shaft spring pin. (Scheme 49) Tap lightly on each side of the manual control lever shaft spring pin with a drift punch.
  4. Pry the spring pin out of its bore. Remove the manual control lever shaft. Do not damage the bore. Remove the manual control lever shaft seal. (Scheme 50)

Scheme 47

Scheme 47
Scheme 47

Scheme 48

Scheme 48
Scheme 48

Scheme 49

Scheme 49
Scheme 49

Scheme 50

Scheme 50
Scheme 50
  1. Using the Manual Control Lever Shaft Seal Installer (307-050), install the manual control lever shaft seal. (Scheme 51) Lubricate the manual control lever shaft seal with petroleum jelly. Install the manual control lever shaft. (Scheme 52)
  2. Align the manual control lever shaft alignment groove with the manual control lever shaft spring pin bore in the transmission case. (Scheme 49) Tap the manual control lever shaft spring pin into the transmission case.
  3. Align flats of the manual valve inner lever with flats on the manual control lever shaft. Install the manual valve inner lever and parking lever actuating rod onto the manual control lever shaft. (Scheme 48)
  4. Install the manual valve inner lever nut. (Scheme 47) Verify park linkage function. Verify that the output shaft is locked in the Park position. Rotate the manual lever into the Neutral position and install the manual valve detent spring. (Scheme 14)
  5. Install the transmission oil pan with new pan gasket. See «DRAINING & REFILLING»(/ford/explorer-sport-trac/i-2000-2005/remont/automatic-trans/#automatic-transmission-servicing-at__draining-refilling) under LUBRICATION. If equipped, position the servo heat shield over the servos and clip it to the pan rail.
  6. Install the TR sensor. See «TRANSMISSION RANGE SENSOR»(/ford/explorer-sport-trac/i-2000-2005/remont/automatic-trans/#automatic-transmission-servicing-at). Lower the vehicle. Connect the negative battery cable. Fill the transmission with appropriate fluid to proper level and check for correct transmission operation. See «LUBRICATION»(/ford/explorer-sport-trac/i-2000-2005/remont/automatic-trans/#automatic-transmission-servicing-at).

Scheme 51

Scheme 51
Scheme 51

Scheme 52

Scheme 52
Scheme 52

Raise and support the vehicle. Disconnect Output Shaft Speed (OSS) sensor harness connector. Remove the OSS sensor screw (1). (Scheme 53) Remove the OSS sensor (2) from the transmission. Inspect the OSS sensor O-ring for damage. If damaged, install a new O-ring.

Scheme 53

Scheme 53: Removal
Scheme 53: Removal

Inspect and lubricate O-ring with petroleum jelly. Install the OSS sensor into the transmission. Tighten OSS sensor screw. Connect OSS sensor harness connector. Lower the vehicle.

PARKING PAWL

Note. For parking pawl removal and installation procedures, see EXTENSION HOUSING .

SOLENOIDS

Note. It is not necessary to remove valve body to replace solenoids.

  1. Disconnect negative battery cable. Raise and support vehicle. Drain transmission fluid and remove transmission oil pan and filter. See «DRAINING & REFILLING»(/ford/explorer-sport-trac/i-2000-2005/remont/automatic-trans/#automatic-transmission-servicing-at__draining-refilling) under LUBRICATION.
  2. Lift up wire loom guide and protector to disengage retaining pins from solenoid brackets. Disconnect appropriate solenoid harness connector. (Scheme 13)
  3. Remove the solenoid(s) wire harness. Remove the solenoid clamp screws. Remove the solenoid clamp. Remove the appropriate solenoid(s).
CAUTIONThe solenoid clamp must be installed in the TCC and EPC solenoid grooves, shift solenoid pockets and the No. 204 plug.
  1. Install the new solenoid(s). Install the solenoid clamp. Position the solenoid clamp on the main control valve body. Install the solenoid clamp screws. Connect the 6 solenoid harness connectors.
  2. Connect shift solenoid harness connectors. (Scheme 13) Connect the TCC solenoid harness connector. Connect the EPC solenoid harness connector.
  3. Install the main control valve body wire loom. Align the retaining pins to the holes in the solenoid clamps and gently press in the main control valve body wire loom guide and protector.
  4. Install transmission filter and oil pan. See «DRAINING & REFILLING»(/ford/explorer-sport-trac/i-2000-2005/remont/automatic-trans/#automatic-transmission-servicing-at__draining-refilling) under LUBRICATION. Lower the vehicle.
  5. Connect the negative battery cable. Fill the transmission with appropriate fluid to proper level and check for correct transmission operation. See «LUBRICATION»(/ford/explorer-sport-trac/i-2000-2005/remont/automatic-trans/#automatic-transmission-servicing-at).

Disconnect negative battery cable. Place transmission in Neutral position. Raise and support vehicle. Disconnect shift cable from manual selector lever. Disconnect Transmission Range (TR) sensor harness connector. Remove manual selector lever nut and manual selector lever. Remove 2 screws and TR sensor. (Scheme 54)

Scheme 54

Scheme 54: Removal
Scheme 54: Removal

Install TR sensor on manual lever. Install TR sensor bolts and finger tighten them. (Scheme 54) Adjust TR sensor. See TRANSMISSION RANGE SENSOR under ADJUSTMENTS. Tighten TR sensor bolts to specification. See TORQUE SPECIFICATIONS. Install manual selector lever and nut and tighten to specification. See TORQUE SPECIFICATIONS. Connect TR sensor harness connector. Install shift linkage and adjust if necessary.

TORQUE SPECIFICATIONS

ApplicationFt. Lbs. (N.m)
Driveshaft Bolts70-95 (95-129)
Extension Housing Bolts27-39 (36-52)
Intermediate & Overdrive Band Lock nuts35-45 (47-61)
Manual Selector Lever Nut35 (47)
Transmission Mount Nuts64-81 (87-110)
Transmission Mount-To-Extension Housing Bolts64-81 (87-110)
INCH Lbs. (N.m)
Digital Transmission Range Sensor89 (10)
Oil Pan Bolts124 (14)

TORQUE SPECIFICATIONS

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