2002LSV8
LVC Member
"Problem - Hard Shifting (Park to Reverse, Reverse to Drive, Park to Drive) - New Solenoid Pack fixed it"
Removing Transmission Pan and Solenoid Pack - Part 1 of 3
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Watch YouTube video to get general idea - Ford Explorer 5R55S Transmission Solenoid Pack Replace
Check this post (first five pictures for a visual of what the parts look like) -
Lifting car up on jack stands -
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Tools Needed for this part:
** DISCONNECT Negative Battery Cable **
Put car on 4 Jacks Stands (Leveled)
LEVEL FOR FILLING "A MUST" - Put a level on the frame under door where a lift would lift car
** Fluid Level - Too Low or Too High - Will cause hard shift problems - MUST BE JUST RIGHT
Drain Transmission Fluid - remove Drain Plug on transmission pan, not inner Fluid Level Plug - 7/8 or 22mm Socket
Remove - the shift cable bracket 2 Bolts - 11mm Wrench
Disconnect the digital transmission range (TR) sensor connector - unplugs
Remove - The plastic wire harness that attaches to the front of the transmission pan
Remove - 1 Bolt (10mm - Gear Wrench with Flex Head) on top of Solenoid Pack, holding the electrical connection on.
Remove - Transmission Pan and Gasket - 16 Bolts - 8mm Socket
Remove - Transmission Filter - 2 Bolts - 8mm Socket
Disconnect - the Reverse Pressure Switch from the bottom of the Solenoid Pack - unplugs
Remove - Solenoid Pack - 8 Bolts - T-30 Torx Bit - (7 long bolts, 1 short bolt)
***
Clean - inside of Transmission Pan, Gasket Rim, and Magnet inside of pan
Installing Solenoid and Transmission Pan - Part 2 of 3
Tools Needed for this part:
(Lubricate the O-ring seals on Solenoid Pack with clean automatic transmission fluid)
Install Solenoid Pack - Make sure the Solenoid Pack is properly seated where the electrical connection goes in
Bolt Solenoid Pack - 8 Bolts - T-30 Torx Bit - Torque 71 in/lbs
Install - 1 Bolt to top of Solenoid Pack, electrical connection - 10mm - Gear Wrench with Flex Head
Plug-in ** Plug in the Reverse Pressure Switch in to the bottom of the Solenoid Pack
Install - NEW Transmission Filter - 2 Bolts - 8mm Socket - Torque 89 in/lbs
Install the Transmission Pan and Gasket (Cleaned - NEW Drain Plug & Fluid Level Plug)
Reconnect - the shift cable bracket 2 Bolts - 11mm Wrench - Torque 216 in/lbs
Reconnect - the digital transmission range (TR) sensor connector - Plugs in
Reconnect - the plastic wire harness that attaches to the front of the transmission pan
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Filling Transmission Fluid - Part 3 of 3
Tools Needed for this part:
Reconnect The Negative Battery Cable
LEVEL - Recheck Car Is Level - Use Leveler.
Remove Fill Plug at rear of transmission - T-50 Torx Bit
Pump Fluid into Fill Plug at rear of transmission -
Torque Fill Plug at rear of transmission - T-50 Torx Bit - Torque 180 in/lbs
Loosen - center Fluid Level Plug from the Drain Plug on the Transmission Pan - T-30 Torx Bit
Start car - Keep Foot On Brake (with emergency brake on) while shifting thru gears
Let car idle for about 10 minutes, depending on your ambient temperature
Remove center Fluid Level Plug on Transmission Pan and watch for correct fluid drip - Add more fluid if needed
Tighten center Fluid Level Plug - T-30 Torx Bit - Torque 89 in/lbs
Turn car off
Lower car from jacks
Discounted Negative Battery Cable for 10 minutes to reset PCM
Do the KAM Reset for the PCM (per Owner's Guide, page 228)
Test Drive Car.............................................
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Parts List with Part Numbers:
Purchased from:
AutoNation Ford White BearLake, MN - (online) - Friendly company, Fast shipping
Cost:
Transmission Fluid:
Removing Transmission Pan and Solenoid Pack - Part 1 of 3
----
Watch YouTube video to get general idea - Ford Explorer 5R55S Transmission Solenoid Pack Replace
Check this post (first five pictures for a visual of what the parts look like) -
Lifting car up on jack stands -
----
Tools Needed for this part:
7/8 or 22mm Socket
8mm Socket
10mm - Gear Wrench with Flex Head
11mm Wrench
T-30 Torx Bit
** DISCONNECT Negative Battery Cable **
Put car on 4 Jacks Stands (Leveled)
LEVEL FOR FILLING "A MUST" - Put a level on the frame under door where a lift would lift car
** Fluid Level - Too Low or Too High - Will cause hard shift problems - MUST BE JUST RIGHT
Drain Transmission Fluid - remove Drain Plug on transmission pan, not inner Fluid Level Plug - 7/8 or 22mm Socket
*Replace Drain Plug after drain fluid to prevent leaking
Remove - the shift cable bracket 2 Bolts - 11mm Wrench
Disconnect the digital transmission range (TR) sensor connector - unplugs
Remove - The plastic wire harness that attaches to the front of the transmission pan
Remove - 1 Bolt (10mm - Gear Wrench with Flex Head) on top of Solenoid Pack, holding the electrical connection on.
Note: I cut my "Gear Wrench with Flex Head" down to 3 5/8" total length
** This is a Very tight area to get at with a wrench
Remove - Transmission Pan and Gasket - 16 Bolts - 8mm Socket
Note: The front of pan needs to be lowered first to clear the crossmember at the back of the pan.
**Careful - there is still about a quart of fluid left in the pan, some WILL spill out.
Remove - Transmission Filter - 2 Bolts - 8mm Socket
Disconnect - the Reverse Pressure Switch from the bottom of the Solenoid Pack - unplugs
Remove - Solenoid Pack - 8 Bolts - T-30 Torx Bit - (7 long bolts, 1 short bolt)
***
Clean - inside of Transmission Pan, Gasket Rim, and Magnet inside of pan
Install New Drain Plug & center Fluid Level Plug
Torque Drain Plug - 7/8 or 22mm Socket - Torque 228 in/lbs
New Transmission Pan Gasket is optional (they are reusable, inspect gasket for damage)
---------------------------------------------------------------------------------------------------------------------------------Installing Solenoid and Transmission Pan - Part 2 of 3
Tools Needed for this part:
T-30 Torx Bit
8mm Socket
10mm - Gear Wrench with Flex Head
11mm Wrench
Torque Wrench
(Lubricate the O-ring seals on Solenoid Pack with clean automatic transmission fluid)
Install Solenoid Pack - Make sure the Solenoid Pack is properly seated where the electrical connection goes in
Bolt Solenoid Pack - 8 Bolts - T-30 Torx Bit - Torque 71 in/lbs
Note: 7 Long Bolts & 1 Short Bolt (#7 in the Torque Pattern is the short bolt)
*** Torque Bolts In Correct Torque Pattern
Install - 1 Bolt to top of Solenoid Pack, electrical connection - 10mm - Gear Wrench with Flex Head
Hand Tighten 1/4 to 1/2 turn after bottoming out - Unable to Torque, no room
Plug-in ** Plug in the Reverse Pressure Switch in to the bottom of the Solenoid Pack
Install - NEW Transmission Filter - 2 Bolts - 8mm Socket - Torque 89 in/lbs
(Lubricate the 2 new seals with clean automatic transmission fluid)
Install the Transmission Pan and Gasket (Cleaned - NEW Drain Plug & Fluid Level Plug)
Loosely install the bolts, do 1 bolt in the 4 corners first to hold pan up, then the other bolts
Torque Bolts -16 Bolts - 8mm Socket - Using a crisscross sequence, Torque 96 in/lbs
Reconnect - the shift cable bracket 2 Bolts - 11mm Wrench - Torque 216 in/lbs
Reconnect - the digital transmission range (TR) sensor connector - Plugs in
Reconnect - the plastic wire harness that attaches to the front of the transmission pan
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Filling Transmission Fluid - Part 3 of 3
Tools Needed for this part:
T-30 Torx Bit
T-50 Torx Bit
Attwood Gear Lube Pump (WalMart $6.98) - Bought two, just in case the 1st one broke (it didn't)
Reconnect The Negative Battery Cable
LEVEL - Recheck Car Is Level - Use Leveler.
Remove Fill Plug at rear of transmission - T-50 Torx Bit
* This picture is from a post on this forum, but can not recall who posted it
Pump Fluid into Fill Plug at rear of transmission -
Put in same amount that you drained out (plus a 1/2 a quart)
* took 1-2 minutes pumping per bottle, with the Gear Lube Pump
Torque Fill Plug at rear of transmission - T-50 Torx Bit - Torque 180 in/lbs
Loosen - center Fluid Level Plug from the Drain Plug on the Transmission Pan - T-30 Torx Bit
Start car - Keep Foot On Brake (with emergency brake on) while shifting thru gears
Shift thru all gears, Pause (5 seconds) between shifts
Let car idle for about 10 minutes, depending on your ambient temperature
Need transmission fluid temp to be between 80°F - 120°F
* My ambient temperature was about 80°F, took about 10 minutes of idle time to get to 100°F
Remove center Fluid Level Plug on Transmission Pan and watch for correct fluid drip - Add more fluid if needed
*Picture shows the "Fill Adaptor" being used, so disregard that part, fluid will drip from the center Fluid Level hole
*Fluid Level - Too Low or Too High - Will cause hard shift problems - MUST BE JUST RIGHT
Tighten center Fluid Level Plug - T-30 Torx Bit - Torque 89 in/lbs
Turn car off
Lower car from jacks
Discounted Negative Battery Cable for 10 minutes to reset PCM
Do the KAM Reset for the PCM (per Owner's Guide, page 228)
Test Drive Car.............................................
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Parts List with Part Numbers:
Solenoid Pack (XW4Z-7G391-AF)
Trans Oil Pan Drain Plug (includes Fluid Level Plug) (4W4Z-7A010-AA)
Trans Filter (XW4Z-7A098-BB)
Purchased from:
AutoNation Ford White BearLake, MN - (online) - Friendly company, Fast shipping
*Note: Call them for parts availability before ordering (1-800-328-9552)
Cost:
Solenoid Pack $241.10
Drain/Fluid Level Plugs $8.10
Trans Filter $23.82
Shipping (USPS) $14.36
Total $287.38
Transmission Fluid:
Mercon V ATF - $7.25 a quart at local Ford Dealership