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  1. #1
    Join Date
    May 2003
    Location
    Cincinnati, Ohio
    Posts
    4,148

    Default 2002 Ford Explorer 4.0 AWD transmission slips

    Hey all,

    I'm gearing up to really dig in and trouble shoot my wife's explorer.

    2002, 4.0 AWD

    Basically it is very drive-able but it has a big problem.

    When driving the explorer when you start out its fine. Get to about 25 or 30 mph and it won't shift and will slip. I'm guessing its trying to get into 2nd or 3rd gear at this point. Now if you take your foot off the gas the car will shift and kind of hard and you can move on.

    When this first happened I figured we would just drive it until it blew up and I was forced to rebuild the tranny. Well that was a long time ago. We are talking years. I'm researching this and I'm 90% sure that the problem is in the transmission and not the transfer case.


    I'm also looking for a good book that will get me through the rebuild and have found this onehttp://www.amazon.com/5R55S-Techtran...=5R55++rebuild

    Any advice, suggestions or direction is greatly appreciated.

    Thanks.
    Richard.
    Richard
    aka rmousir
    1966 coupe

    My Toy - New web site, check it out

    lots of stuff done with lots more to do!

  2. #2
    Join Date
    Jul 2007
    Location
    C-BURG,PA.
    Posts
    4,015

    Default Could be

    I suspect the separator gasket ?


    Article No.
    02-13-8 TRANSMISSION - 4R44E - 4R55E - 5R44E - 5R55E - LOW LINE PRESSURE READING AT WIDE OPEN THROTTLE (WOT) - SLIPPING SHIFTS AND/OR DELAYED ENGAGEMENTS - POSSIBLE DIAGNOSTIC TROUBLE CODES P0732, P0733, P1762 SET - VEHICLES BUILT BEFORE 12/1/2001

    Publication Date: JULY 1, 2002

    FORD: 1995-2001 EXPLORER
    1995-2002 RANGER
    1996-97 AEROSTAR
    1999-2002 EXPLORER SPORT
    2001-2002 EXPLORER SPORT TRAC
    MERCURY: 1997-2001 MOUNTAINEER


    Article 02-8-2 is being republished in its entirety to update the DTC codes, build dates and to update the Service Procedure.

    ISSUE:
    Some vehicles built prior to 12/1/2001 may exhibit the following shift and engagement conditions:

    Low line pressure readings while in DRIVE at WOT
    No 2nd gear
    No 3rd gear
    No engine braking in Manual 1st
    Slipping shifts and/or delayed engagements
    DTCs P0732, P0733 or P1762 may be present
    This may be caused by improper pressures controlled by the Transmission Main Control assembly.

    ACTION:
    If the conditions described are verified, the Main Control may need to be updated to the latest level or completely replaced. Refer to the following Service Procedure for details.

    SERVICE PROCEDURE
    NOTE: THIS ARTICLE DOES NOT APPLY TO ANY OTHER CONDITIONS OR COMPONENTS THAT MAY CAUSE SIMILAR SYMPTOMS AND IS ONLY WRITTEN TO COVER THESE SPECIFIC CONDITIONS.



    NOTE: AN IN-LINE SERVICE FILTER IS NOT REQUIRED TO BE ADDED OR REPLACED FOR THIS TSB.



    Verify that one or more of the following conditions exist:

    Low line pressure while in Drive at WOT
    Slipping/delayed shifts
    Slipping/delayed engagements
    No 2nd and/or No 3rd gear
    No engine braking in Manual 1st
    OD Band failed OFF
    DTC P0732, P0733 or P1762 set
    Verify that one of the conditions listed above exist with the vehicle.
    If the condition exists, drain the transmission fluid from the pan.
    Remove the fluid pan and fluid pan gasket, discard the gasket. Refer to Workshop Manual, In-Vehicle Service, Fluid Pan And Gasket Procedure.
    Inspect the fluid in pan for major contamination.
    If major contamination IS present, refer to Procedure A, to replace the Main Control Assembly.
    If major contamination is NOT present, refer to Procedure B, to Update the Main Control Assembly.
    After completing procedure A or B, verify the condition has been corrected.
    Clear all DTCs.
    Procedure A:
    If major contamination is present, follow normal Workshop Manual procedures to repair internal transmission damage. If the transmission is repaired remember that the the Main Control (7A100), Fluid Pan Gasket (7A191) and Fluid Filter (7A098) must be replaced. Refer to the application chart for the correct Main Control assembly to use.
    Procedure B:
    CAUTION: A NEW SEPARATOR PLATE 7A008 OR 7Z490 MUST BE USED WHEN INSTALLING THE SPECIAL SERVICE KIT 7M203 OR ADDITIONAL TRANSMISSION DAMAGE MAY OCCUR.



    To UPDATE the main control to the new level, follow the steps listed in the Service Kit 1L5Z-7M203-JA (ALL KIT CONTENTS MUST BE USED). A new separator plate (7A008 or 7Z490), upper/lower separator plate gaskets (7C155 and 7D100 used only with a 7A008 plate), fluid pan gasket (7A191), and a fluid filter (7A098) must be used. ALL NEW PARTS MUST BE USED. Refer to Parts Application Chart for parts selection.
    Install the Special Service Tools 307-333 and 307-334 (1 each) onto the main control ( Figure 1 ).
    Install a new service Separator Plate (refer to chart), make sure that the new plate has hole #50 deleted, install the three (3) screw and tighten to 7 N-m (62 Lb-in).
    Install a new separator plate to case gasket (7C155) if installing the 7A008 style separator plate. DO NOT INSTALL a 7C155 GASKET IF USING A 7Z490 Separator Plate.
    Remove the special service tools.
    Continue to follow the assembly steps as found in the assembly of sub-assemblied, main control valve body.
    Reinstall the main control by continuing to follow the Installation steps listed in the Workshop Manual, In-Vehicle Service, Fluid Pan And Gasket Procedure.

    Procedure A - Parts Application Chart
    Vehicle Application Engineering Description Qty. New Service Part
    95/96 Models ONLY
    96 Aerostar 3.0L/4.0L Control Assy - Main 1 F5TZ-7A100-CB
    95/96 3.0L/4.0L Ranger/Explorer Control Assy - Main 1 F5TZ-7A100-CB
    95/96 2.3L Ranger Control Assy - Main 1 F57Z-7A100-RA

    97 Models ONLY 1
    97 2.3L Ranger Control Assy - Main 1 F77Z-7A100-FA
    97 3.0L OHV Ranger/Aerostar Control Assy - Main 1 F77Z-7A100-GA
    97 4.0L OHV Ranger/Aerostar Control Assy - Main 1 F79Z-7A100-AA
    97 4.0L OHV Explorer/Mountaineer Control Assy - Main 1 F77Z-7A100-HA
    97 4.0L SOHC Explorer/Mountaineer Control Assy - Main 1 F77Z-7A100-JA

    1998-2001 Models ONLY
    98/01 2.5L Ranger Control Assy - Main 1 XL2Z-7A100-AB
    98/00 3.0L Ranger Control Assy - Main 1 XL2Z-7A100-BB
    98/00 4.0L - EI Ranger Control Assy - Main 1 XL2Z-7A100-CB
    98/00 4.0L - EI Explorer Control Assy - Main 1 XL2Z-7A100-DB
    98/00 4.0L - SOHC Control Assy - Main 1 XL2Z-7A100-EB

    2001-2002 Models ONLY
    2001/2002 2.3L Ranger Control Assy - Main 1 1L5Z-7A100-AB
    2001/2002 3.0L Ranger Control Assy - Main 1 1L5Z-7A100-BC
    2001/2002 4.0L-SOHC Control Assy - Main 1 1L5Z-7A100-CC



    Procedure B - Parts Application Chart
    Vehicle Application Engineering Description Qty. New Service Part
    95/97 Models ONLY
    95/97 Models - ALL Separator Plate to Case Gasket 1 2L5Z-7C155-AA
    95/97 Models - ALL Separator Plate to Main Control Gasket 1 2L5Z-7D100-BA

    95/96 Models ONLY
    95/96 Models - ALL Plate - Valve Body Separator 1 F5TZ-7A008-CA
    1
    97 Models ONLY
    97 2.3L Ranger Plate - Valve Body Separator 1 F77Z-7A008-AB
    97 3.0L OHV Ranger/Aerostar Plate - Valve Body Separator 1 F77Z-7A008-AB
    97 4.0L OHV Ranger/Aerostar Plate - Valve Body Separator 1 F77Z-7A008-CB
    97 4.0L OHV Explorer/Mountaineer Plate - Valve Body Separator 1 F77Z-7A008-DB
    97 4.0L SOHC Explorer/Mountaineer Plate - Valve Body Separator 1 F77Z-7A008-EB

    1998-2001 Models ONLY
    98/01 2.5L Ranger Plate - Valve Body Separator 1 1L5Z-7Z490-DA
    98/00 3.0L Ranger Plate - Valve Body Separator 1 1L5Z-7Z490-EA
    98/00 4.0L - EI Ranger Plate - Valve Body Separator 1 1L5Z-7Z490-FA
    98/00 4.0L - EI Explorer Plate - Valve Body Separator 1 1L5Z-7Z490-GA
    98/00 4.0L - SOHC Plate - Valve Body Separator 1 1L5Z-7Z490-HA

    2001-2002 Models ONLY
    2001/2002 2.3L Ranger Plate - Valve Body Separator 1 1L5Z-7Z490-AA
    2001/2002 3.0L Ranger Plate - Valve Body Separator 1 1L5Z-7Z490-BA
    2001/2002 4.0L-SOHC Plate - Valve Body Separator 1 1L5Z-7Z490-CA



    LABOR OPERATION CLAIMING CHART
    Operation Labor Description Vehicle Time
    021308A Inspect, And Replace Transmission Main Control 1996-1997 Aerostar 4R44E
    2.1
    1996-1997 Aerostar 4.0L MFI 5R55E/5R44E
    2.2
    1995-2001 Ranger 4R44E 2.1
    1997-2000 Ranger 5R55E 2.2
    2001-2002 Ranger 5R55E 2.3
    1995-1996 Explorer 4R55E
    2.1
    1997-1999 Explorer 4.0L MFI 5R55E/5R44E
    2.2
    2000-2001 Explorer/Mountaineer 4.0L SOHC 5R55E/5R44E

    2.2
    1997-1999 Explorer 4.0L SOHC 5R44E/5R55E
    2.4
    2001-2002 Sport Trac 5R55E/5R44E
    2.2
    1998-1999 Mountaineer 4.0L SOHC 5R55E/5R44E
    2.4

    021308B Inspect And Install Service Kit In Transmission Main Control 1996-1997 Aerostar 4R44E
    3.9
    1996-1997 Aerostar 4.0L MFI 5R55E/5R44E
    4.0
    2001-2002 Ranger 5R55E 4.1
    1995-2001 Ranger 4R44E 3.9
    1997-2000 Ranger 5R55E 4.0
    1995-1996 Explorer 4R55E
    3.9
    2000-2001 Explorer/Mountaineer 4.0L SOHC 5R55E/5R44E

    4.0
    1997-1999 Explorer 4.0L SOHC 5R44E/5R55E
    4.2
    2001-2002 Sport Trac 5R55E/5R44E
    4.0
    1998-1999 Mountaineer 4.0L SOHC 5R55E/5R44E
    4.2
    1997-1999 Explorer 4.0L 5R55E/5R44E
    4.0




    PART NUMBER PART NAME
    1L5Z-7M203-JA Valve Body Service Kit


    OTHER APPLICABLE ARTICLES:
    02-8-3
    Phil
    Friends are like wedgies..They know your inner self..They're intimately close..And it feels great when you pick out a good one.
    RIP DAD 1/12/22-12/19/11

  3. #3
    Join Date
    May 2003
    Location
    Cincinnati, Ohio
    Posts
    4,148

    Default

    That is great info!!!
    Richard
    aka rmousir
    1966 coupe

    My Toy - New web site, check it out

    lots of stuff done with lots more to do!

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