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Home >> Ford >> 2001 >> Explorer Chassis >> Repair and Diagnosis >> Transmission >> Automatic Trans >> Automatic Transmission - Overhaul - 5R55E >> Transmission Disassembly >> Disassembly

Transmission Disassembly: Disassembly

    WARNING: Do not remove the torque converter from the transmission while still on the jack. Doing so could cause the transmission to fall. Failure to follow these instructions may result in personal injury.
    Fig 1: Identifying Transmission
    G02045815
  1. Place the transmission on a workbench.
  2. Remove the special tool.
    Fig 2: Installing Torque Converter Retainer
    G02045816
    3. WARNING: The torque converter is heavy, especially when full of fluid. Failure to follow these instructions may result in personal injury.
    Fig 3: Removing Torque Converter
    G02045817
  3. Using the special tool, remove the torque converter.
    4. NOTE: The splines on the input shaft are not the same on both ends. The end with the shorter spline goes into the assembly.
    Fig 4: Removing Input Shaft
    G02045818
  4. Remove the input shaft.
  5. Remove output shaft speed (OSS) sensor.
    1. Remove the OSS screw.
    2. Remove OSS sensor.
    Fig 5: Removing Output Shaft Speed (OSS) Sensor
    G02045819
  6. If equipped, remove the intermediate shaft speed (ISS) sensor.
    1. Remove the ISS screw.
    2. Remove ISS sensor.
    Fig 6: Removing Intermediate Shaft Speed (ISS) Sensor
    G02045820
  7. If equipped, remove the heat shield.
    1. Remove the nut.
    2. Remove the heat shield.
    Fig 7: Removing Servo Heat Shield
    G02045821
  8. Remove manual control outer lever nut and manual control outer lever.
    Fig 8: Removing Manual Control Outer Lever Nut & Manual Control Outer Lever
    G02045822
  9. Remove the digital transmission range (TR) sensor.
    1. Remove the screws.
    2. Remove the digital TR sensor.
    Fig 9: Removing Digital Transmission Range (TR) Sensor
    G02045823
  10. Using the special tools, remove the extension housing seal.
    Fig 10: Removing Extension Housing Seal
    G02045824
    11. NOTE: Remove the extension housing bushing only if service is required.
    Fig 11: Removing Extension Housing Bushing
    G02045825
  11. Using the special tool, remove the extension housing bushing.
    • Inspect the extension housing bushing and driveshaft slip yoke for nicks, gauges, scoring and wear.
    12. CAUTION: The parking pawl, parking pawl return spring and parking pawl shaft could fall out during removal of the extension housing.
    Fig 12: Removing Extension Housing
    G02045826
  12. Remove the screws, studs, and the extension housing.
    • Discard the extension housing gasket.
  13. Remove the parking pawl assembly.
    1. Remove the parking pawl shaft.
    2. Remove the parking pawl.
    3. Remove the parking pawl return spring.
    Fig 13: Removing Parking Pawl Assembly
    G02045827
    14. CAUTION: The parking pawl actuating rod must slip freely into the clearance hole in the adapter plate.
    Fig 14: Installing Transmission Holding Fixture
    G02045828
  14. Install the special tool.
  15. Assemble the special tools.
    Fig 15: Installing Transmission Holding Fixtures
    G02045829
    16. WARNING: Make sure the lock pin on the special tool is secure. Failure to follow these instructions may result in personal injury.
    Fig 16: Repositioning Transmission
    G02045830
  16. Install the transmission into the special tool. Rotate the transmission so the fluid pan is facing up.
    17. CAUTION: Do not reuse the fluid pan gasket.
    Fig 17: Removing Transmission Fluid Pan
    G02045831
  17. Remove the transmission fluid pan and transmission pan gasket and then discard gasket.
  18. Remove the transmission fluid filter and discard.
    1. Remove the screw.
    2. Remove the transmission fluid filter.
    Fig 18: Removing Transmission Fluid Filter
    G02045832
  19. Carefully lift up on the wire loom guide and protector. Disengage the retaining pins from the solenoid clamps.
    Fig 19: Disengaging Retaining Pins From Solenoid Clamps
    G02045833
  20. Disconnect the solenoid electrical connectors.
    1. Disconnect the SSA, SSB, SSC, and the SSD electrical connectors.
    2. Disconnect the torque converter clutch (TCC) solenoid electrical connector.
    3. Disconnect the electronic pressure control (EPC) solenoid electrical connector.
    Fig 20: Disconnecting Solenoid Electrical Connectors
    G02045834
  21. Remove the manual control valve detent lever spring.
    1. Remove the screw.
    2. Remove the manual control valve detent lever spring.
    Fig 21: Removing Manual Control Valve Detent Lever Spring
    G02045835
  22. Remove the low/reverse band servo cover.
    1. Remove the screws.
    2. Remove the low/reverse band servo cover and the low/reverse servo separator plate cover gasket.
      • Discard the low/reverse servo separator plate cover gasket.
    Fig 22: Removing Low/Reverse Band Servo Cover
    G02045836
  23. Remove the low/reverse band servo piston and rod assembly.
    Fig 23: Removing Low/Reverse Band Servo Piston & Rod Assembly
    G02045837
    24. CAUTION: To prevent solenoid valves from falling out, do not remove the two screws shown below.
    Fig 24: Identifying Two (Gold Colored) Screws
    G02045838
  24. Do not remove the two (gold colored) screws specified.
  25. Remove the twenty-three valve body screws.
    Fig 25: Removing Twenty-Three Valve Body Screws
    G02045839
  26. Remove the main control valve body, valve body separator plate and main control to separator plate gasket.
    • Discard gaskets.
    Fig 26: Removing Main Control Valve Body, Valve Body Separator Plate & Main Control-To-Separator Plate Gasket
    G02045840
    27. CAUTION: Throw the locknuts away. The locknuts are not reusable for assembly.
    Fig 27: Removing Locknuts
    G02045841
  27. Remove the locknuts. Back off the screws.
    28. CAUTION: The servo cover is under spring tension.
    Fig 28: Removing Intermediate Servo Cover Retaining Ring
    G02045842
  28. Using the special tool, remove the intermediate servo cover retaining ring.
    • Remove the special tool.
    29. NOTE: Tag the servo cover, piston and spring. Label accordingly for assembly. The covers have letters cast on the outer surface for identification.
    NOTE: Use the special tool to prevent damage to the servo, cover and bore.
    Fig 29: Releasing Intermediate Band Servo Piston
    G02045843
  29. Using the special tool, release the intermediate band servo piston.
  30. Remove the intermediate band servo cover, piston and spring.
    Fig 30: Removing Intermediate Band Servo Cover, Piston & Spring
    G02045844
    31. CAUTION: Servo cover is under spring tension.
    Fig 31: Removing Overdrive Servo Retaining Ring & Cover
    G02045845
  31. Using the special tool, remove the overdrive servo retaining ring and cover.
    32. NOTE: Tag the servo cover, piston and servo piston spring. Label accordingly for assembly. The covers have letters cast on the outer surface for identification.
    NOTE: Use the special tool to prevent damage to the servo piston and bore.
    Fig 32: Releasing Overdrive Band Servo Piston
    G02045846
  32. Using the special tool, release the overdrive band servo piston.
  33. Remove the overdrive band servo cover, piston and spring.
    Fig 33: Removing Overdrive Band Servo Cover, Piston & Spring
    G02045847
    34. WARNING: Make sure the lock pin on the Holding Fixture is secure. Failure to follow these instructions may result in personal injury.
  34. Rotate the transmission so the converter housing faces up.
    35. CAUTION: Discard the screws. The screws are not reusable for assembly.
    Fig 34: Removing Converter Housing Screws
    G02045848
  35. Remove and discard the screws.
  36. Remove the converter housing and fluid pump support.
    • Turn and lift the converter housing and fluid pump support from the case.
    Fig 35: Removing Converter Housing & Fluid Pump Support
    G02045849
  37. Remove the fluid pump input thrust washer (No. 1).
    • Tag and identify the thrust washer.
    Fig 36: Removing Fluid Pump Input Thrust Washer (No. 1)
    G02045850
  38. Remove the front band adjusting screw.
    Fig 37: Removing Front Band Adjusting Screw
    G02045851
  39. Compress the front band around the front brake and coast clutch drum and remove the front band anchor strut.
    Fig 38: Removing Front Band Anchor Strut
    G02045852
    40. CAUTION: Identify the anchor and apply ends of the front band.
    Fig 39: Removing Front Band
    G02045853
  40. Remove the front band.
  41. Remove the front brake and coast clutch drum.
    Fig 40: Removing Front Brake & Coast Clutch Drum
    G02045854
  42. Remove the front band apply strut.
    Fig 41: Removing Front Band Apply Strut
    G02045855
    43. NOTE: The front band lever shaft is longer than the intermediate band lever shaft.
    Fig 42: Removing Front Band Actuating Lever Shaft
    G02045856
  43. Remove the front band actuating lever shaft.
    44. CAUTION: Do not bend trigger wheel.
    NOTE: The No. 2 thrust bearing is in this assembly.
    Fig 43: Removing Planetary Gear Overdrive Carrier
    G02045857
  44. Remove the planetary gear overdrive carrier.
    45. NOTE: Tag and identify the front band servo lever. The front band servo lever has a letter stamped on the side.
    Fig 44: Removing Front Band Servo Lever & Front Band Lever-To-Case Bracket
    G02045858
  45. Remove the front band servo lever and front band lever to case bracket.
  46. Remove the front planet thrust bearing (No. 2).
    Fig 45: Removing Front Planet Thrust Bearing (No. 2)
    G02045859
  47. Remove the front ring gear, front one-way clutch assembly, and center shaft as an assembly.
    Fig 46: Removing Front Ring Gear, Front One-Way Clutch Assembly & Center Shaft
    G02045860
    48. NOTE: Tag and identify the center shaft thrust bearing (No. 3) for assembly.
    Fig 47: Removing No. 3 Center Shaft Thrust Bearing
    G02045861
  48. Remove the No. 3 center shaft thrust bearing.
    49. CAUTION: The center support locknut can fall into the remaining assembly if not removed.
    Fig 48: Removing Center Support Cap Screw
    G02045862
  49. Remove the center support cap screw.
  50. Remove the locknut and cage.
    Fig 49: Removing Locknut & Cage
    G02045863
    51. CAUTION: Do not pry on other wires or damage the connector or case surface.
    Fig 50: Disconnecting Turbine Shaft Speed (TSS) Sensor Electrical Connector
    G02045864
  51. Disconnect the turbine shaft speed (TSS) sensor electrical connector.
    1. Remove the TSS sensor electrical connector from the transmission case (16-pin) electrical connector.
    2. Remove the TSS sensor connector wires from wire locator.
    52. CAUTION: Carefully route the TSS connector and wiring into the transmission through the opening in the case.
    Fig 51: Removing TSS Sensor
    G02045865
  52. Remove the TSS sensor.
    1. Remove the screw.
    2. Remove the TSS sensor.
    53. CAUTION: Do not overstretch the retaining spring.
    Fig 52: Removing Transmission Case (16-Pin) Electrical Connector Retaining Spring
    G02045866
  53. Remove the transmission case (16-pin) electrical connector retaining spring.
    54. CAUTION: Do not damage the connector or harness.
    Fig 53: Removing Transmission Case (16-Pin) Electrical Connector
    G02045867
  54. Compress the tabs on the transmission case (16-pin) electrical connector. Push the transmission case (16-pin) electrical connector out of transmission case.
  55. Remove the center support retaining ring.
    Fig 54: Removing Center Support Retaining Ring
    G02045868
    56. NOTE: When removing the center support, pull evenly around the center support web.
    Fig 55: Removing Center Support
    G02045869
  56. Remove the center support.
    57. NOTE: Tag and identify the No. 4 intermediate brake drum thrust bearing.
    Fig 56: Removing Intermediate Brake Drum Thrust Bearing (No. 4)
    G02045870
  57. Remove the intermediate brake drum thrust bearing (No. 4).
  58. Remove the intermediate band anchor strut and adjusting screw.
    Fig 57: Removing Intermediate Band Anchor Strut & Adjusting Screw
    G02045871
    59. CAUTION: Identify the anchor and apply ends of the intermediate band.
    Fig 58: Removing Intermediate Band
    G02045872
  59. Remove the intermediate band.
  60. Remove the intermediate band apply strut.
    Fig 59: Removing Intermediate Band Apply Strut
    G02045873
    61. NOTE: The intermediate band lever shaft is shorter than the front band lever shaft.
    Fig 60: Removing Intermediate Band Actuating Lever Shaft
    G02045874
  61. Remove the intermediate band actuating lever shaft.
    62. NOTE: Tag and identify the intermediate servo band lever. The intermediate servo band lever has a letter stamped into its side.
    Fig 61: Removing Intermediate Servo Actuating Lever
    G02045875
  62. Remove the intermediate servo actuating lever.
    63. WARNING: Make sure the lock pin on the Holding Fixture is secure. Failure to follow these instructions may result in personal injury.
    Fig 62: Positioning Transmission Fluid Pan With Surface Facing Up
    G02045876
  63. Rotate the transmission so the transmission fluid pan surface is facing up.
    64. NOTE: The forward clutch cylinder thrust bearing (No. 5) may come out with the intermediate brake and direct clutch drum.
    Fig 63: Removing Intermediate Brake & Direct Clutch Drum
    G02045877
  64. Remove the intermediate brake and direct clutch drum.
  65. Remove the forward clutch cylinder thrust bearing (No. 5) tag and identify.
    Fig 64: Remove The Forward Clutch Cylinder Thrust Bearing (No. 5) Tag
    G02045878
  66. Remove the forward clutch cylinder.
    Fig 65: Removing Forward Clutch Cylinder
    G02045879
  67. Remove the forward ring gear hub thrust bearing (No. 6A).
    Fig 66: Removing Forward Ring Gear Hub Thrust Bearing (No. 6A)
    G02045880
  68. Remove the forward ring gear and forward ring gear hub as an assembly.
    Fig 67: Removing Forward Ring Gear & Forward Ring Gear Hub
    G02045881
  69. Remove forward clutch thrust washer (No. 6B) from the forward ring gear hub.
    Fig 68: Removing Forward Clutch Thrust Washer (No. 6B)
    G02045882
    70. NOTE: Check black oxidized side during removal to ensure correct placement during reassembly. Black oxidized side must be toward planetary assembly. The uncoated side must face up.
    Fig 69: Removing Forward Planet Thrust Bearing (No. 7)
    G02045883
  70. Remove the forward planet thrust bearing (No. 7).
  71. Remove the forward planetary assembly.
    Fig 70: Removing Forward Planetary Assembly
    G02045884
  72. Remove input shell with the forward sun gear.
    Fig 71: Removing Input Shell With Forward Sun Gear
    G02045885
    73. NOTE: Tag and identify the low/reverse planetary carrier thrust bearing (No. 8).
    Fig 72: Removing Low/Reverse Planetary Carrier Thrust Bearing (No. 8)
    G02045886
  73. Remove the low/reverse planetary carrier thrust bearing (No. 8).
  74. Remove the low/reverse planetary retaining ring.
    Fig 73: Removing Low/Reverse Planetary Retaining Ring
    G02045887
  75. Remove low/reverse planetary assembly.
    Fig 74: Removing Low/Reverse Planetary Assembly
    G02045888
    76. NOTE: Tag and identify the low/reverse planetary carrier thrust bearing (No. 9).
    Fig 75: Removing Low/Reverse Planetary Carrier Thrust Bearing (No. 9)
    G02045889
  76. Remove the low/reverse planetary carrier thrust bearing (No. 9).
  77. Remove the output shaft sleeve.
    Fig 76: Removing Output Shaft Sleeve
    G02045890
    78. CAUTION: Discard the output shaft retaining ring. A new retaining ring must be used for assembly.
    Fig 77: Removing Output Shaft Retaining Ring
    G02045891
  78. Remove and discard the output shaft retaining ring.
  79. Remove the output shaft ring gear and the output shaft hub.
    Fig 78: Removing Output Shaft Ring Gear & Output Shaft Hub
    G02045892
    80. NOTE: Tag and identify the output shaft hub thrust bearing (No. 10).
    Fig 79: Removing Output Shaft Thrust Bearing (No. 10)
    G02045893
  80. Remove the output shaft thrust bearing (No. 10).
    81. NOTE: The inner race of the rear one-way clutch is not removable. It is serviced in the case.
    Fig 80: Removing Low/Reverse Brake Drum & One-Way Clutch Assembly
    G02045894
  81. Remove the low/reverse brake drum and one-way clutch assembly.
  82. Remove the reverse band.
    Fig 81: Removing Reverse Band
    G02045895
  83. Remove the output shaft.
    Fig 82: Removing Output Shaft
    G02045896
  84. Remove the park gear.
    Fig 83: Removing Park Gear
    G02045897
    85. NOTE: Tag and identify the output shaft thrust washer (No. 11).
    Fig 84: Removing Output Shaft Thrust Washer (No. 11)
    G02045898
  85. Remove the output shaft thrust washer (No. 11).
    86. CAUTION: To avoid damage, make sure wrench does not strike the manual valve inner lever pin.
    Fig 85: Removing Manual Control Valve Inner Lever Nut
    G02045899
  86. Remove the manual control valve inner lever nut.
  87. Remove the manual control valve inner lever and the parking lever actuating rod.
    Fig 86: Removing Manual Control Valve Inner Lever & Parking Lever Actuating Rod
    G02045900
    88. CAUTION: Do not damage the case fluid pan rail.
    Fig 87: Removing Manual Control Lever Shaft Spring Pin
    G02045901
  88. Remove the manual control lever shaft spring pin.
    • Tap lightly on each side of the manual control lever shaft spring pin with a drift punch.
    • Pry the spring pin out of its bore.
  89. Remove the manual control lever shaft.
    Fig 88: Removing Manual Control Lever Shaft
    G02045902
    90. CAUTION: Do not damage the bore.
    Fig 89: Removing Manual Control Lever Seal
    G02045903
  90. Remove the manual control lever seal.
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