INTRODUCTION March, 2004 FORD 5R55S FORD 5R55W
INTRODUCTIONFORD 5R55SFORD 5R55WUpdatedMarch, 2004The Ford 5R55S and 5R55W transmissions are both very similar in design to the Ford 5R55N transmission anduse electronic shift controls. The 5R55S/W are both "Syncrounous" units, as they do not use the intermediateclutch and intermediate sprag that the 5R55N incorporates. The Ford 5R55S and 5R55W transmissions wereintroduced in 2002, found in the Ford Explorer and Mercury Mountaineer vehicles, and are available in both2WD and 4WD configurations. For model year 2003 they are also in the Lincoln LS, Lincoln Aviator and FordThunderbird. They are designed for operation in longitudinal powertrains for rear wheel drive vehicles.5R55SGear Ratios1st Gear 3.222nd Gear 2.293rd Gear 1.544th Gear 1.005th Gear 0.71Reverse 3.075R55WGear Ratios1st Gear 3.222nd Gear 2.413rd Gear 1.544th Gear 1.005th Gear 0.75Reverse 3.07We wish to thank Ford Motor Companyfor the information and illustrationsthat have made this booklet possible.No part of any ATSG publication may be reproduced, stored in any retrieval system or transmitted in any form orby any means, including but not limited to electronic, mechanical, photocopying, recording or otherwise,without written permission of Automatic Transmission Service Group. This includes all text illustrations,tables and charts.The information and part numbers contained in this booklet havebeen carefully compiled from industry sources known for theirreliability, but ATSG does not guarantee its accuracy.DALE ENGLANDFIELD SERVICE CONSULTANTCopyright ATSG 2004JIM DIALTECHNICAL CONSULTANTWAYNE COLONNAED KRUSETECHNICAL SUPERVISORTECHNICAL CONSULTANTPETER LUBANGREGORY LIPNICKTECHNICAL CONSULTANTTECHNICAL CONSULTANTJON GLATSTEINDAVID CHALKERTECHNICAL CONSULTANTTECHNICAL CONSULTANTJERRY GOTTSTANTON ANDERSONTECHNICAL CONSULTANTTECHNICAL CONSULTANTGERALD CAMPBELLROLAND ALVAREZTECHNICAL CONSULTANTTECHNICAL CONSULTANTMIKE SOUZATECHNICAL CONSULTANTAUTOMATIC TRANSMISSION SERVICE GROUP9200 S. DADELAND BLVD. SUITE 720MIAMI, FLORIDA 33156(305) 670-41611
FOR D MOTOR C O. 5R 55W /SGOTO PAGEINDEXPREVIOUS MENU5R55W/S TRANSMISSION IDENTIFICATION . 3COMPONENT APPLICATION CHART . 4SOLENOID APPLICATION AND RESISTANCE CHARTS . 5SOLENOID BODY PIN IDENTIFICATION . 6GENERAL DESCRIPTION AND OPERATION . 7MANUAL SHIFT SELECTOR OPERATION . 9BATTERY JUNCTION BOX FUSE AND RELAY LOCATIONS . 10CENTRAL JUNCTION BOX FUSE LOCATIONS . 10DIGITAL TRANSMISSION RANGE SENSOR . 11VARIOUS CONNECTOR AND PIN IDENTIFICATION . 12WIRING SCHEMATIC . 13PCM LOCATION . 15TRANSMISSION COMPONENT RESISTANCE CHART THROUGH PCM CONNECTOR . 16DIAGNOSTIC TROUBLE CODE CHART AND DESCRIPTION . 18LINE PRESSURE TESTS . 21CHECKING TRANSMISSION FLUID LEVEL . 22TRANSMISSION DISASSEMBLY . 24COMPONENT REBUILD SECTION.OIL PUMP ASSEMBLY . 39COAST CLUTCH HOUSING . 43OVERDRIVE CARRIER AND OVERDRIVE SPRAG ASSEMBLY . 47DIRECT CLUTCH HOUSING . 49FORWARD CLUTCH HOUSING . 52CENTER SUPPORT ASSEMBLY . 57LOW SPRAG AND REVERSE DRUM ASSEMBLY . 58REAR RING GEAR AND HUB ASSEMBLY . 58FRONT AND REAR PLANETARY CARRIER ASSEMBLY . 60SUN GEAR AND SHELL ASSEMBLY . 61FRONT RING GEAR AND HUB ASSEMBLY . 61VALVE BODY ASSEMBLY . 65CHECKBALL LOCATIONS . 66REVERSE SERVO ASSEMBLY . 68SOLENOID BODY DIFFERENCES . 72SOLENOID BODY ASSEMBLY . 734WD ADAPTER HOUSING AND PARKING PAWL ASSEMBLY . 74TRANSMISSION CASE ASSEMBLY . 76FINAL TRANSMISSION ASSEMBLY . 79REAR END CLEARANCE PROCEDURES . 84FRONT END CLEARANCE PROCEDURES . 932WD EXTENSION HOUSING ASSEMBLY SECTION . 100BOLT SIZE AND LENGTH CHART . 105SPECIAL SERVICE TOOLS . 106TORQUE SPECIFICATIONS . 1085R55N VERSUS 5R55W/S DIFFERENCES . 108AUTOMATIC TRANSMISSION SERVICE GROUP9200 S. DADELAND BLVD. SUITE 720MIAMI, FLORIDA 33156(305) 670-4161Copyright ATSG 20042
Technical Service InformationFORD 5R55W/S5 5 Forward SpeedsR Rear Wheel Drive5 Relative Torque Capacity5}S or W SyncrounousFord0061NTEURA1 L 2 P- 7 F 2 9 3 -A ArdFoLI.D. TAG INFORMATION FOUND ON RIGHT REAR SIDE OF TRANSMISSION2L2P-DABDX-A004361BD-2C171234P-DA2L2 -ABDX 613004 H179BD -BDX-A0 0 Part Number, Basic 7000 (Example 2L2Z-7000-DA)Transmission Model CodeSerial NumberBuild Date (YMDD)9 19990 20001 20012 20023 2003A JanB FebC MarD AprE MayF JunG JulH AugJ SepK OctL NovM DecCopyright 2004 ATSGFigure 1AUTOMATIC TRANSMISSION SERVICE GROUP3
Technical Service InformationFORD 5R55W/S COMPONENT APPLICATION CHARTRANGEFWDDIR COAST O/DINTL/RO/DCLUT CLUT CLUT BAND BAND BAND ParkReverseONONHOLDNeutral"D"-1st GearONHOLD"D"-2nd GearON"D"-3rd GearON"D"-4th GearONON"D"-5th GearONON"D"-1st GearON"D"-2nd GearON"D"-3rd GearON"D"-4th GearON"3"-3rd Hold *ON"2"-2nd Hold **ON"1"-1st Hold ONHOLD* Manual "3" is 3rd gear starts and hold.** Manual "2" is 2nd gear starts and hold.*** Manual "1" provides 1st gear operation ow/ReverseSpragCopyright 2004 ATSGFigure 24AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service InformationFORD 5R55W/S SOLENOID APPLY CHARTShiftShiftShiftShiftPres Cont Pres Cont Pres ContTCCRange And Gear Commanded Sol. "A" Sol. "B" Sol. "C" Sol. "D" Sol. "A" Sol. "B" Sol. "C" SolenoidPark/NeutralReverse"D" - 1st Gear"D" - 2nd Gear"D" - 3rd Gear"D" - 4th Gear"D" - 5th V""H""L""V""L""L""V""L""H""L""L""L""H""H""D" - 1st Gear"D" - 2nd Gear"D" - 3rd Gear"D" - 4th H"ON"3" - 3rd Gear (Hold)ONON"V""V""L""2" - 2nd Gear (Hold)ON"V""V""L""1" - 1st Gear (Hold)ON"V""V""L" Lower Line Pressure"V" Variable Line Pressure"H" Higher Line Pressure** TCC may be On, and is dependent on vehicle speed and throttle position"L"ONONONONON**************CASE CONNECTOR PIN IDENTIFICATIONAND RESISTANCE CHARTSSolenoid Resistance ChartConnectorTerminalsComponentResistanceIn OhmsShift Solenoid "A"Shift Solenoid "B"Shift Solenoid "C"Shift Solenoid "D"Pressure Control Solenoid "A"Pressure Control Solenoid "B"Pressure Control Solenoid "C"TCC Solenoid3 And 163 And 153 And 63 And 53 And 113 And 13 And 43 And 1416-4516-4516-4516-453.3-7.53.3-7.53.3-7.59-16TOT Sensor2 And 12See ChartTOT Sensor Resistance Chart0 F-31 F 284k - 100k Ohms32 F-68 F 100k - 37k Ohms69 F-104 F 37k - 16k Ohms105 F-158 F 16k - 5k Ohms159 F-194 F 5k - 2.7k Ohms195 F-230 F 2.7k - 1.5k Ohms231 F-266 F 1.5k - 0.8k Ohms267 F-302 F 0.8k - 0.54k OhmsRefer To Figure 4 ForCase Connector PinIdentificationCopyright 2004 ATSGFigure 3AUTOMATIC TRANSMISSION SERVICE GROUP5
Technical Service InformationCASE CONNECTOR PIN IDENTIFICATIONView Looking Into TransmissionCase Connector111166SOLENOID PACKASSEMBLYCopyright 2004 ATSGFigure 4"FAIL-SAFE" DESCRIPTION AND OPERATIONIf the Powertrain Control Module (PCM) detects aninput sensor or signal fault, it may use FailureManagement Effects Mode (FMEM) strategy andprovide a substitute signal or value.If the transmission totally loses electronic control, itwill operate in a Fail-Safe mode with all of thefollowing features:Maximum line pressure in all transmission shifterpositions.Fully functional "P", "R" and "N" transmissionshifter positions.Operation in 4th gear only with coast braking whenthe selector is in the "D", "3", "2", or "1" positions.Torque Converter Clutch (TCC) will be released inall positions.6AUTOMATIC TRANSMISSION SERVICE GROUP
Technical Service InformationGENERAL DESCRIPTION AND OPERATIONThe 5R55W/S is a fully automatic rear wheel drivetransmission. It provides Park, Reverse, Neutral, andfive forward speeds with 5th gear being overdriveInternally it looks similar to the previous 5R55Etransmission, but there are very few minorcomponents that are actually the same, so be verycautious during the rebuild process. The majorcomponents used in this unit are as follows:3 Multi-Plate Clutch PacksCoast ClutchDirect Clutch (Single Sided)Forward Clutch2 One-Way ClutchesOverdrive Sprag ClutchLow Sprag Clutch3 Brake BandsOverdrive BandIntermediate BandLow/Reverse Band3 Compound Planetary Gear SetsOverdrive Planetary SetForward Planetary SetRear Planetary SetThe shift pattern is controlled electronically withfour (On-Off) solenoids that recieve a ground signalfrom the PCM (Powertrain Control Module). ThePCM will vary shift points, as it is constantlyinterpreting numerous electronic signals from variousoperational sensors located on the vehicle and insidethe transmission.Line pressure and shift feel are also controlledelectronically with three Pressure Control solenoids,referred to as PCA, PCB, and PCC. The PCM variesthe current to the pressure control solenoids and Fordrefers to them as Variable Force Solenoids.The PCM also controls application of the converterclutch and apply feel electronically, with a TCCsolenoid, which is also Variable Force style.All solenoids are incorporated in the "SolenoidBody", located on the valve body, and are not servicedseperately. You must purchase the entire solenoidbody assembly, if necessary.ELECTRONIC COMPONENTSThe PCM also receives input signals from varioussensors and switches, located internally andexternally, that affect proper transmission operation.The following will provide a brief description of eachof the sensors and actuators used for transmissionoperations.AIR CONDITIONING CLUTCHThis switch is located on the suction accum/drier andwhen the A/C is engaged, operating pressures areadjusted to compensate for the additional engine load.BRAKE PEDAL POSITION (BPP) SWITCHThis switch is located on the brake pedal and tells thePCM when the brakes are applied. The TCC isdisengaged when the brakes are applied. The BPPswitch closes when the brakes are applied and openwhen they are released.ENGINE COOLANT TEMPERATURE (ECT) SENSORThis sensor detects temperature of engine coolantand supplies the information to the PCM. The PCMuses this information to control Torque ConverterClutch (TCC) operation.ELECTRONIC IGNITION (EI) SYSTEMThe ignition control module generates a ProfileIgnition Pickup (PIP) signal (engine rpm) and sends itto the PCM. The PCM uses PIP signal in thetransmission strategy for WOT shift control, TCCcontrol and operating pressures.INTAKE AIR TEMPERATURE (IAT) SENSORThe Intake Air Temperature (IAT) sensor, located inthe air cleaner outlet tube, is also used in thetransmission strategy to determine control pressures.MASS AIR FLOW (MAF) SENSORThe Mass Air Flow (MAF) sensor, located in the aircleaner inlet tube, measures the amount of air flowinginto the engine and sends this information (engineload) to the PCM. For transmission strategies theMAF is used to regulate electronic pressure control,shift timing and torque converter clutch scheduling.Continued On Next PageCopyright 2004 ATSGAUTOMATIC TRANSMISSION SERVICE GROUP7
Technical Service InformationELECTRONIC COMPONENTS (Cont'd)TRANSMISSION CONTROL SWITCH (TCS)The Transmission Control Switch (TCS), locatedwithin the manual shift selector assembly, as shown inFigure 5, is a momentary contact switch. When thisswitch is pressed, overdrive (5th gear) will becanceled. After the TCS has been pressed to requestoverdrive cancel, the PCM turns ON theTransmission Control Indicator Lamp (TCIL) toindicate that overdrive cancel mode is activated.TRANSMISSION CONTROL INDICATOR LAMP (TCIL)The Transmission Control Indicator Lamp (TCIL), islocated on the manual shift lever, as shown in Figure5, or in the instrument panel and illuminates when theTCS switch is pressed. When the TCIL is "ON",overdrive is OFF or canceled.The PCM will also "Flash" the TCIL when it detectsa fault in one of the solenoids or monitered sensors orswitches.THROTTLE POSITION SENSOR (TPS)The Throttle Position Sensor is a potentiometerlocated on the throttle body and is used to detectthrottle plate position and send this information to thePCM. The PCM uses this information for shiftscheduling, pressure control and TCC control.DIGITAL TRANSMISSION RANGE (TR) SENSORThe Digital Transmission Range (TR) sensor islocated on the outside of the transmission at themanual shift lever. The digital TR sensor completesthe start circuit in Park and Neutral, and the back-uplamp circuit in Reverse. The digital TR sensor alsoopens or closes a set of four switches that aremonitered by the PCM to determine the position ofthe manual lever (P, R, N, D, 3, 2, 1).TURBINE SHAFT SPEED (TSS) SENSORThe Turbine Shaft Speed (TSS) sensor is mountedexternally on the transmission case, and triggered bythe overdrive carrier. The PCM uses TSS to helpdetermine appropriate operating pressures and TCCoperation.INTERMEDIATE SHAFT SPEED (ISS) SENSORThe Intermediate Shaft Speed (ISS) sensor ismounted externally on the case, and triggered by thesun gear shell. The PCM uses ISS to aid indetermining appropriate pressure requirements.8OUTPUT SHAFT SPEED (OSS) SENSORThe Output Shaft Speed (OSS) sensor is mountedexternally on the transmission case, and triggered by aspeed rotor on the parking gear on the output shaft.The PCM uses OSS to determine appropriate shiftspeed scheduling, operating pressures and TCCoperation.PRESSURE CONTROL SOLENOIDS (PCA, PCB, PCC)The Pressure Control solenoids PCA, PCB and PCCare located in the solenoid body assembly and are avariable-force style (VFS) solenoid. The VFS typesolenoid is an electro-hydraulic actuator thatcombines a solenoid and a regulating valve. ThePCM varies the current to all three pressure controlsolenoids.The line pressure tap is used to verify output pressurefrom "PCA" or "PCB" by turning off either one, whileverifying the output from the other solenoid. Thesecond pressure tap is used to verify the outputpressure from "PCC" solenoid.SHIFT SOLENOIDS (SSA, SSB, SSC, SSD)The four On-Off Shift Solenoids are three-way,normally open style solenoids, and also located in thesolenoid body assembly. The four shift solenoids,(SSA, SSB, SSC, SSD), provide gear selection of 1stthrough 5th and reverse gears by directing controlpressures to the appropriate element. Coast brakingand manual gear selections are also controlled by theshift solenoids.TORQUE CONVERTER CLUTCH (TCC) SOLENOIDThe Torque Converter Clutch (TCC) solenoid is apulse width modulating type of solenoid and is used tocontrol the apply and release of the TCC. Like theothers, it is located in the solenoid body assembly.TRANSMISSION FLUID TEMPERATURE (TFT) SENSORThe Transmission Fluid Temperature (TFT) sensor,located in the solenoid body, is a thermister typesensor that varies a reference signal to the PCM. ThePCM uses this information to determine fluidtemperature. The shift schedule is changed whenfluid is cold. The PCM also inhibits TCC operation,and compensates pressure control solenoids whenfluid is cold. The PCM uses TFT signal to helpdetermine shift scheduling, TCC operation andpressure control requirements.AUTOMATIC TRANSMISSION SERVICE GROUPCopyright 2004 ATSG
Technical Service InformationINSTRUMENT PANEL RANGE SELECTOR INDICATORVehicles equipped with the 5R55W/S seriestransmissions have a Transmission Control Switch(TCS) and a Transmission Control Indicator Lamp(TCIL), as shown in Figure 5. The shift quadrant hasthe following positions P, R, D, 3, 2 and 1, as shown inFigure 5.P R N D 3 2 1INSTRUMENT PANEL RANGE SELECTOR INDICATOR"N" NeutralWhen in the Neutral position, there is no power flowthrough the transmission, the output shaft is not heldand is free to turn. T
clutch and intermediate sprag that the 5R55N incorporates. The Ford 5R55S and 5R55W transmissions were introduced in 2002, found in the Ford Explorer and Mercury Mountaineer vehicles, and are available in both 2WD and 4WD configurations. For model year 2003 they are also in the Lincoln LS, Lincoln Aviator and Ford Thunderbird.
The Ford 5R55S and 5R55W transmissions are both very similar in design to the Ford 5R55N transmission and use electronic shift controls. The 5R55S/W are both "Syncrounous" units, as they do not use the intermediate clutch and intermediate sprag that the 5R55N incorporates. The Ford 5R55S and 5R55W transmissions were
The Ford 5R55S and 5R55W transmissions are both very similar in design to the Ford 5R55N transmission and use electronic shift controls. The 5R55S/W are both "Syncrounous" units, as they do not use the intermediate clutch and intermediate sprag that the 5R55N incorporates. The Ford 5R55S and 5R55W transmissions were
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