307-01-1 Automatic Transmission — 5R55S 307-01-1

SPECIFICATIONS
General Specifications (Continued)
Item Specification
General Specifications
Approximate dry capacity, includes cooler and tubes.
Item Specification Fluid level procedures in this section should be used to
Fluid determine actual fluid requirements and fluid
specification. DO NOT OVERFILL. If it is necessary to
CAUTION: Use only MERCON V transmission add or change fluid, use only fluid that has been
fluid. Use of any other fluids may result in certified by the supplier as meeting the Ford Motor
transmission failure. Company specification shown.
• Normal maintenance;
— Fluid change not necessary, filled for life. Aviator 4.6L engine 12.0L (12.7 Quarts)
• Severe duty maintenance; Fluid Filter
— Change the fluid at 48,000 km (30,000 miles)
intervals. In-Line Fluid Filter Kit 7B155

Motorcraft MERCON  MERCON  V In-Line Fluid Filter 7B155

V Automatic Transmission Lubricant
Fluid XT-5-QM Ford Multi-Purpose ESR-M19159-A
Fluid Capacity Grease XG-4

End Play Specifications

Transmission Overdrive End Select Thrust Washer (No. 1 Nylon)

Play Dimension D Part Number Thickness ID: Color
38.05-38.13 mm (1.50 in) F7TZ-TA 1.55-1.60 mm (0.061-0.063 in) White
38.14-38.28 mm (1.50-1.51 in) F7TZ-MA 1.75-1.80 mm (0.069-0.071 in) Green
38.29-38.42 mm (1.51-1.52 in) F7TZ-NA 1.85-1.90 mm (0.073-0.075 in) Red
38.43-38.61 mm (1.51-1.52 in) F7TZ-RA 2.05-2.10 mm (0.081-0.083 in) Black
38.62-38.74 mm (1.52-1.53 in) F7TZ-SA 2.15-2.20 mm (0.095-0.097 in) Yellow

End Play Specifications

Selective Needle Bearings (No. 4) ID:
Rear (No. 4) Dimension E Part Number Thickness Notches
1.69-1.87 mm (0.066-0.074 in) XW4Z-7D014-CA 2.65-2.80 mm (0.104-0.110 in) 0
1.88-2.04 mm (0.074-0.080 in) XW4Z-7D014-DA 2.83-2.98 mm (0.110-0.116 in) 1
2.05-2.22 mm (0.081-0.087 in) XW4Z-7D014-EA 3.01-3.16 mm (0.118-0.124 in) 2
2.23-2.43 mm (0.088-0.096 in) XW4Z-7D014-FA 3.21-3.36 mm (0.126-0.132 in) 3

Band Adjustment and Torque Chart

No. of Turns Locknut Adjusting Screw

Description to Back Off Nm Lb-Ft Nm Lb-Ft
Intermediate Band 2.0 54 40 14 10
Overdrive Band 2.0 54 40 14 10

Copyright  2004, Ford Motor Company

Last updated: 06/29/2004 2005 Aviator, 09/2004
307-01-2 Automatic Transmission — 5R55S 307-01-2
SPECIFICATIONS (Continued)
Selective Snap Rings
Coast and Direct Clutch Drum Forward Clutch Cylinder
Thickness Diameter Thickness Diameter
Part Number mm inch mm inch Part Number mm inch mm inch
E860126-S 1.37 0.0539 130.1 5.122
E860127-S 1.73 0.0681 130.1 5.122 XW4Z-7D483-AB 1.73 0.0681 141.45 5.56
E860128-S 2.08 0.0819 130.1 5.122 XW4Z-7D483-AC 2.08 0.0819 141.45 5.56
E860129-S 2.44 0.0961 130.1 5.122 XW4Z-7D483-AD 2.44 0.0961 141.45 5.56

Service Identification Model Chart

Vehicle Application
7000 Prefix and Suffix C=Column F=Floor Engine Displacement Vehicle Application
4L2P-EC F 4.6L-V8 4x2
4L2P-FC F 4.6L-V8 4x4 or AWD

Solenoid Operation Chart — 5R55W and 5R55S Truck Only

Shift Selector Normal Mode Normal Mode

Lever Position Gear SSA SSB SSC SSD PC A PC B PC C
P On Off Off On L H/L L
N On Off Off On L H/L L
R On Off Off On L/H L H
OD 1 On Off Off On H H/L L
2 On Off On On L/H H L
3 On On Off On H L/H L
4 Off Off Off On H L/H H
5 Off Off On On H H H
OD (Cancelled) 1 On Off Off On H H/L L
2 On Off On On L/H H L
3 On On Off On H L/H L
4 Off Off Off Off L/H H H
MANUAL 3 3 On On Off Off H L H/L
MANUAL 2 2 On Off On Off H L H/L
MANUAL 1 1 On Off Off Off H L H/L

H = High
L = Low
H/L = is PCM controlled

2005 Aviator, 09/2004

307-01-3 Automatic Transmission — 5R55S 307-01-3
SPECIFICATIONS (Continued)
Band and Clutch Application Chart A
Overdrive Intermediate Reverse Forward Direct Coast
Band Band Band Clutch Clutch Clutch
REVERSE Aa Aa
1st Aa
2nd Aa Aa
3rd Aa Aa
4th Aa Aa
5th Aa Aa Aa
1stb Aa
2ndb Aa Aa
3rdb Aa Aa
4thb Aa Aa Acc
MAN. 3rd Acb Aa Acc
MAN. 2nd Aa Acc Aa
MAN. 1st Acc Aa Acc
a A = Applied
b (D) Position (overdrive canceled)
c Ac = Applied to carry coast torque

Band and Clutch Application Chart B

Direct One-Way Clutch Low One-Way Clutch Engine
Drive Coast Drive Coast Braking
REVERSE Ha ORb NEc NO
1st Ha OR b Ha OR b NO
2nd OR b OR b Ha OR b NO
3rd Ha OR b OR b OR b NO
4th Ha OR b OR b OR b NO
5th OR b OR b OR b OR b YES
1st d Ha OR b Ha OR b YES
2nd d OR b OR b Ha OR b YES
3rd d Ha OR b OR b OR b YES
4th d Ha OR b OR b OR b Yes
MAN. 3rd Ha OR b OR b OR b YES
MAN. 2ND OR b OR b Ha OR b YES
MAN. 1ST Ha OR b Ha OR b YES
a H = Hold
b OR = Overrunning
c NE = No Effect
d (D) Position (overdrive canceled)

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307-01-4 Automatic Transmission — 5R55S 307-01-4
SPECIFICATIONS (Continued)
Line Pressure Chart

Transmission Idle WOT Stall

Trans. Model/Application Range PC C Line PC C Line
5R55S 4.6L R 621-827 621-827 772-924 1,944-2,620
kPa kPa kPa kPa
(90-120 (90-120 (112-134 (282-380
psi) psi) psi) psi)
N 0-103 kPa 621-827
(0-15 psi) kPa
(90-120
psi)
(D) 3, 2, 1 0-103 kPa 552-758 0-103 kPa 1,572-1,813
(0-15 psi) kPa (0-15 psi) kPa
(80-110 (228-263
psi) psi)

Stall Speed Chart

Vehicle Engine RPM
Aviator 4.6L 2,597-3,045

Shift Speeds
(D) Speed km/h (mph)
Vehicle Information Throttle Position Shift 5R55S Axle Ratio All
4.6L Closed 5-4 40-47 (25-29)
4-3 24-29 (15-18)
3-1 10-13 (6-8)
Minimum 1-2 14-18 (9-11)
Monitor PID: 2-3 26-32 (16-20)
TP volt-1.25 3-4 34-40 (21-25)
4-5 60-66 (37-42)
Wide Open 1-2 53-66 (33-37)
2-3 79-87 (49-54)
3-4 124-133 (77-83)

Torque Specifications Torque Specifications (Continued)

Description Nm lb-ft lb-in Description Nm lb-ft lb-in
Case-to-center support 11 8 — Fluid pan drain plug 26 19 —
bolt Fluid pump housing 25 18 —
Converter drain plug 10 — 89 screws to case
Digital transmission 10 — 89 Locknut for band 54 40 —
range (TR) sensor adjustment screw
screws Main control-to-case 10 — 89
Extension housing 25 18 — screws (all)
screws Main control separator 7 — 62
Fluid level indicator 10 — 89 plate bolts
plug-to-drain pipe Manual control valve 10 — 89
assembly detent spring screw

2005 Aviator, 09/2004

307-01-5 Automatic Transmission — 5R55S 307-01-5
SPECIFICATIONS (Continued)
Torque Specifications (Continued) Torque Specifications (Continued)
Description Nm lb-ft lb-in Description Nm lb-ft lb-in
Manual control lever 48 35 — Transmission cooler 47 35 —
shaft nut fitting-to-case
Band adjustment screw 14 10 — Transmission cooler 30 22 —
Pressure tap plug to 14 10 — tube nut-to-case fitting
case Transmission fluid 10 — 89
Fill plug 20 15 — filter screws

Reverse servo assembly 11 8 — Transmission fluid 11 8 —

screws pan-to-case screws

Separator-to-main 7 — 62 Transmission 90 66 —
control screws mount-to-extension
housing screws
Shift cable bracket 40 30 —
screws Transmission 90 66 —
mount-to-crossmember
Solenoid body screws 8 — 71 nuts
Speed sensor screws 14 10 — Transmission-to-engine 48 35 —
Torque converter 44 32 — screws
adapter Vehicle 5 — 44
plate-to-converter nuts harness-to-solenoid
Torque converter 35 26 — body screw
adapter
plate-to-flexplate nuts

2005 Aviator, 09/2004

307-01-1 Automatic Transmission — 5R55S 307-01-1

DESCRIPTION AND OPERATION

Transmission Description Transmission View

This transmission has the following features:

• 5 forward speeds
• Electronic shift, pressure and torque converter
clutch controls
• 3 compound planetary gearsets
• 3 bands
• 3 multi-plate clutches
• 2 one-way clutches
All hydraulic functions are directed by electronic
solenoids. The solenoids control:
• static engagement feel.
• shift feel.
• shift scheduling.
• modulated torque converter clutch (TCC)
applications.
• engine braking utilizing the coast clutch and band.
• manual 1st and 2nd timing.
• reverse inhibit timing.

Copyright  2004, Ford Motor Company

Last updated: 06/29/2004 2005 Aviator, 09/2004
307-01-1 Automatic Transmission — 5R55S 307-01-1

DESCRIPTION AND OPERATION

Identification Tags
ID Tag Located on Transmission Case

Item Description
1 Transmission part number
2 Bar code 1
3 Transmission plant model code part 1
4 Transmission plant model code part 2
5 Bar code 2
6 Transmission serial number
7 Transmission build date (DD MM YY)
8 Assembly plant line shift

All vehicles are equipped with a Vehicle

Certification Label, located on the driver side door
lock post. Refer to the code in the space marked
TR. For model, service ID level or build date
information, refer to the transmission service ID tag
located on the transmission case.

Copyright  2004, Ford Motor Company

Last updated: 06/29/2004 2005 Aviator, 09/2004
307-01-1 Automatic Transmission — 5R55S 307-01-1

DESCRIPTION AND OPERATION

Range Selection The OVERDRIVE ((D)) position provides:
The transmission has 7 range positions: P, R, N, • automatic shifts 1-5 and 5-1.
(D), 3, 2 and 1. • apply and release of the torque converter clutch.
• maximum fuel economy during normal operation.
• engine braking in 5th gear.
Drive — Overdrive Canceled
The OVERDRIVE position provides:
• automatic shifts 1-4 and 4-1.
• apply and release of the torque converter clutch.
• maximum fuel economy during normal operation.
• engine braking in 4th gear.
3rd Position — 3rd Gear
Park The 3rd position provides:
In the PARK position: • 3rd gear start and hold.
• there is no power flow through the transmission. • torque converter clutch apply and release.
• the parking pawl locks the output shaft to the • improved traction on slippery roads.
case. • engine braking.
• the engine may be started.
2nd Position — 2nd Gear
• the ignition key may be removed.
If this position is selected at normal road speeds,
Reverse the transmission will downshift into the next lower
gear and continue downshifting until the vehicle
In the REVERSE position:
reaches 2nd gear.
• the vehicle may be operated in a rearward The 2nd position provides:
direction, at a reduced gear ratio.
• 2nd gear start and hold.
Neutral
• torque converter clutch apply and release.
In the NEUTRAL position:
• improved traction on slippery roads.
• there is no power flow through the transmission. • engine braking.
• the output shaft is not held and is free to turn.
Manual Low Position
• the engine may be started.
If this position is selected at normal road speeds,
Overdrive the transmission will downshift into the next lower
Overdrive is the normal position for most forward gear and continue downshifting until the vehicle
driving. reaches 1st gear.
This position provides:
• 1st gear operation only.
• engine braking for descending steep grades.

Copyright  2004, Ford Motor Company

Last updated: 06/29/2004 2005 Aviator, 09/2004
307-01-1 Automatic Transmission — 5R55S 307-01-1

DESCRIPTION AND OPERATION

Shift Patterns Coastdown
The coastdown downshift occurs when the vehicle
Upshifts is coasting down to a stop.
Transmission upshifting is controlled by the
powertrain control module (PCM). The PCM Torque Demand
receives inputs from various engine or vehicle The torque demand downshift occurs (automatically)
sensors and driver demands to control shift during part throttle acceleration when the demand
scheduling, shift feel and torque converter clutch for torque is greater than the engine can provide at
(TCC) operation. that gear ratio. If applied, the transmission will
The PCM has an adaptive learn strategy to disengage the TCC to provide added acceleration.
electronically control the transmission which will
Kickdown
automatically adjust the shift feel. When the battery
has been disconnected or a new battery installed, For maximum acceleration, the driver can force a
certain transmission operating parameters may be downshift by pressing the accelerator pedal to the
lost. The PCM must relearn these parameters. floor. A forced downshift into a lower gear is
During this learning process you may experience possible below calibrated speeds. Specifications for
slightly firm shifts, delayed or early shifts. This downshift speeds are subject to variations due to
operation is considered normal and will not affect tire size and engine and transmission calibration
the function of the transmission. Normal operation requirements.
will return once these parameters are stored by the
PCM.
Downshifts
Under certain conditions the transmission will
downshift automatically to a lower gear range
(without moving the range selector lever). There are
3 categories of automatic downshifts: coastdown,
torque demand and forced or kickdown shifts.

Copyright  2004, Ford Motor Company

Last updated: 06/29/2004 2005 Aviator, 09/2004
307-01-1 Automatic Transmission — 5R55S 307-01-1

DESCRIPTION AND OPERATION

Torque Converter • The turbine reacts to the fluid motion from the
impeller, transferring rotation to the geartrain
The torque converter transmits and multiplies
through the input shaft.
torque. The torque converter is a 4-element device:
• The reactor redirects fluid going back into the
• Impeller assembly impeller, allowing for torque multiplication.
• Turbine and damper assembly • The clutch and damper assembly dampens
• Reactor assembly powertrain torsional vibration and provides a
• Clutch direct mechanical connection for improved
efficiency.
The standard torque converter components operate
as follows: • Power is transmitted from the torque converter to
the planetary gearsets and other components
• Rotation of the converter housing and impeller set through the input shaft.
the fluid in motion.

Copyright  2004, Ford Motor Company

Last updated: 06/29/2004 2005 Aviator, 09/2004
307-01-1 Automatic Transmission — 5R55S 307-01-1

DESCRIPTION AND OPERATION

Geartrain • The forward planetary gearset pinions drive the
forward sun gear.
Power is transmitted from the torque converter to
the planetary gearsets through the input shaft. Bands • The forward sun gear is splined to the input shell.
and clutches are used to hold and drive certain • The forward carrier is splined to the output shaft.
combinations of gearsets. This results in 5 forward
ratios and 1 reverse ratio, which are transmitted to Planetary Gearset — Low/Reverse
the output shaft and differential. For component location, refer to Transmission in the
Assembly portion of this section.
Gear Ratio
The low/reverse planetary gearset is connected to
1st 3.22 to 1
the reverse brake drum by lugs from the low/reverse
2nd 2.29 to 1 brake drum to the lugs of the low/reverse planetary
3rd 1.55 to 1 gearset.
4th 1.00 to 1 • The low/reverse planetary gearset is driven by the
5th 0.71 to 1 forward sun gear which is splined to the input
Reverse 3.07 to 1 shell.
• The forward sun gear drives the pinions in the
low/reverse planetary gearset.
Planetary Gearset — Overdrive
• The pinions of the low/reverse planetary gearset
For component location, refer to Transmission in drive the output shaft ring gear and output shaft
this section. hub which is splined to the output shaft.
The planetary gear overdrive carrier is driven by the • The low/reverse planetary gearset can be held by
input shaft. the low one-way clutch in the low/reverse brake
• The overdrive planetary gearset carrier drives the drum or by the low/reverse band.
center shaft via the overdrive one-way clutch in
Input Shaft
1st, 3rd, 4th and reverse gears.
For component location, refer to Transmission in the
• In 2nd and 5th gears the overdrive sun gear is
Assembly portion of this section.
held causing the pinion gears to rotate around the
overdrive sun gear. • The radial positioning of the input shaft is
• The pinion gears, in turn, drive the overdrive ring controlled by 2 bushings in the stator support.
gear resulting in the 5th (overdrive) gear ratio. • Axial positioning of the input shaft is controlled
• The overdrive planetary gearset is internally by the splines in the converter turbine hub and the
splined to the coast clutch for engine braking. retaining ring in the overdrive planetary carrier.

Planetary Gearset — Forward Output Shaft

For component location, refer to Transmission in the For component location, refer to Transmission in
Assembly portion of this section. this Assembly portion of this section.
The forward planetary gearset is splined to the The output shaft is supported by a bearing in the
output shaft. case and by a bearing in the extension housing. End
positioning is controlled by the parking gear and by
• The forward planetary gearset is driven by the the reverse ring gear hub and snap ring.
forward ring gear when the forward clutch is
applied.

Copyright  2004, Ford Motor Company

Last updated: 06/29/2004 2005 Aviator, 09/2004
307-01-1 Automatic Transmission — 5R55S 307-01-1

DESCRIPTION AND OPERATION

Apply Components The direct clutch is a multi-disc clutch made up of
steel and friction plates.
Band — Overdrive
• The direct clutch is applied with hydraulic
For component location, refer to Transmission in the pressure and disengaged by return springs and the
Assembly portion of this section. exhaust of the hydraulic pressure.
During 2nd and 5th gear operation, hydraulic • It is housed in the direct clutch drum.
pressure is applied to the overdrive servo.
• During 4th, 5th and reverse gear application, the
• This pressure causes the piston to move and apply direct clutch is applied transferring torque from
force to the band. the forward clutch cylinder to the direct clutch
• This action causes the overdrive band to hold the drum.
overdrive drum. • This action causes the forward sun gear to drive
• This causes the overdrive sun gear to be held the pinions of the low/reverse planetary carrier.
stationary through the adapter plate and the
Clutches — Forward
overdrive drum.
For component location, refer to Transmission in the
Band — Low/Reverse Assembly portion of this section.
For component location, refer to Transmission in the The forward clutch is a multi-disc clutch made up
Assembly portion of this section. of steel and friction plates.
During 2nd operation, 1st gear operation and • The forward clutch is applied with hydraulic
reverse, hydraulic pressure is applied to the pressure and disengaged by return springs and the
low/reverse servo. exhaust of the hydraulic pressure.
• This pressure causes the servo to move and apply • The forward clutch is applied in all forward gears.
force to the low/reverse band.
• When applied, the forward clutch provides a
• This action causes the low/reverse brake drum to direct mechanical coupling between the center
be held. shaft and the forward ring gear and hub.
• This action causes the low/reverse planetary
Clutches — Coast
assembly to be held stationary.
For component location, refer to Transmission in the
Band — Intermediate Assembly portion of this section.
For component location, refer to Transmission in the The coast clutch is a multi-disc clutch made up of
Assembly portion of this section. steel and friction plates.
During 3rd gear operation, hydraulic pressure is • The coast clutch is applied with hydraulic
applied to the intermediate servo. pressure and disengaged by return springs and the
• This pressure causes the servo to move and apply exhaust of the hydraulic pressure.
force to the intermediate band. • The coast clutch is housed in the overdrive drum.
• This action causes the direct clutch drum to be • The coast clutch is applied when in 1st, 3rd, D
held. and reverse positions.
• The intermediate band holds the intermediate • When applied, the coast clutch locks the overdrive
brake and direct clutch drum to the case in 3rd sun gear to the overdrive planetary carrier, thus
gear. preventing the one-way clutch from overrunning
• This causes the input shell and forward sun gear when the vehicle is coasting.
to be held stationary. — This allows the use of engine compression to
help slow the vehicle and provide engine
Clutches — Direct
braking.
For component location, refer to Transmission in the
Assembly portion of this section.

Copyright  2004, Ford Motor Company

Last updated: 06/29/2004 2005 Aviator, 09/2004
307-01-2 Automatic Transmission — 5R55S 307-01-2
DESCRIPTION AND OPERATION (Continued)
One-Way Clutch — Direct One-Way Clutch — Low/Reverse
For component location, refer to Transmission in For component location, refer to Transmission in
this section. this section.
The direct one-way clutch is a sprag-type one-way The low/reverse one-way clutch is a sprag-type
clutch that is pressed into the center shaft. one-way clutch.
• The direct one-way clutch is driven by the ring • The low/reverse one-way clutch holds the
gear of the overdrive planetary carrier. low/reverse drum and low/reverse planetary
• The direct one-way clutch holds and drives the assembly to the case in 1st and 2nd gear.
outer splines of the center shaft in 1st, 3rd, 4th • In all other gears the low/reverse one-way clutch
and reverse gears. overruns.
• The direct one-way clutch overruns during all
coast operations and at all times in 2nd and 5th
gear.

2005 Aviator, 09/2004

307-01-1 Automatic Transmission — 5R55S 307-01-1

DESCRIPTION AND OPERATION

Hydraulic System Main Control
For component location, refer to Transmission in the
Fluid Pump Assembly portion of this section.
For component location, refer to Transmission in the
Assembly portion of this section. • The main control assembly and related
components are part of the pressure side of the
• The fluid pump provides the fluid pressure hydraulic system.
necessary to charge the torque converter, main • The main control assembly consists of the
control assembly, transmission cooling system, solenoids, the valve body assembly and the
lubrication system and apply devices. separator plate.
• The fluid pump is a positive displacement, • These components combine to convert electrical
gear-type pump. signals into hydraulic actions.
— The fluid pump is driven by the torque — All valves in the main control assembly are
converter impeller hub. anodized aluminum and cannot be sanded,
Filter filed or dressed in any other way. If there is
any damage to the valves that prevents or
For component location, refer to Transmission in the restricts their movement, install a new main
Assembly portion of this section. control assembly.
• All fluid drawn from the transmission fluid pan
by the fluid pump passes through the fluid filter.
• The transmission fluid filter and its accompanying
seals are part of the fluid path from the sump
(pan) to the fluid pump.
— The transmission fluid filter has a bypass
section which allows fluid vented at the main
regulator valve to be recirculated to the fluid
pump, without passing through the
transmission fluid filter.

Copyright  2004, Ford Motor Company

Last updated: 06/29/2004 2005 Aviator, 09/2004
307-01-1 Automatic Transmission — 5R55S 307-01-1

DESCRIPTION AND OPERATION

Transmission Electronic Control Air Conditioning (A/C) Clutch
System An electromagnetic clutch is energized when the
clutch cycling pressure switch closes. The switch is
Electronic System Description located on the suction accumulator/drier. The
The powertrain control module (PCM) and its closing of the switch completes the circuit to the
input/output network control the following clutch and draws it into engagement with the
transmission operations: compressor driveshaft. When the A/C is engaged,
operating pressures are adjusted to compensate for
• Shift timing additional load on the engine.
• Line pressure (shift feel)
Brake Pedal Position (BPP) Switch
• Torque converter clutch
The brake pedal position (BPP) switch tells the
The transmission control strategy combined with the
powertrain control module (PCM) when the brakes
engine control provides optimum powertrain
are applied. The torque converter clutch disengages
operation under all conditions. When determining
when the brakes are applied. The BPP switch closes
the best operating strategy for transmission
when the brakes are applied and opens when they
operation, the PCM uses input information from
are released. The BPP is also used to disengage the
certain engine-related and driver-demand related
brake shift interlock.
sensors and switches.
In addition, the PCM receives input signals from Engine Coolant Temperature (ECT) Sensor
certain transmission-related sensors and switches. The engine coolant temperature (ECT) sensor
The PCM also uses these signals when determining detects temperature of engine coolant and supplies
transmission operating strategy. the information to the powertrain control module
Using all of these input signals, the PCM can (PCM). The ECT sensor is used to control torque
determine when the time and conditions are right converter clutch (TCC) operation.
for a shift or when to apply or release the torque
Electronic Ignition (EI) System
converter clutch. It will also determine the pressure
needed to optimize shift feel. To accomplish this The electronic ignition consists of a crankshaft
the PCM uses 3 pressure controls, 1 torque position sensor, 2 4-tower ignition coils and the
converter clutch and 4 shift solenoids to control powertrain control module (PCM). The ignition
transmission operation. control module operates by sending crankshaft
position information from the crankshaft position
The following provides a brief description of each
sensor to the ignition control module. The ignition
of the sensors and actuators used to control
control module generates a profile ignition pickup
transmission operation.
(PIP) signal (engine rpm) and sends it to the PCM.
Powertrain Control Module (PCM) The PCM uses PIP signal in the transmission
strategy, wide-open throttle (WOT) shift control,
The operation of the transmission is controlled by
torque converter clutch control and operating
the powertrain control module (PCM). Many input
pressures.
sensors provide information to the PCM. The PCM
then controls the actuators which determine Intake Air Temperature (IAT) Sensor
transmission operation.
The intake air temperature (IAT) sensor provides
the sequential fuel injection (SFI) system mixture
temperature information. The IAT sensor is used
both as a density corrector for air flow calculation
and to proportion cold enrichment fuel flow. The
IAT sensor is installed in the air cleaner outlet tube.
The IAT sensor is also used in determining control
pressures.

Copyright  2004, Ford Motor Company

Last updated: 06/29/2004 2005 Aviator, 09/2004
307-01-2 Automatic Transmission — 5R55S 307-01-2
DESCRIPTION AND OPERATION (Continued)
Mass Air Flow (MAF) Sensor Accelerator Pedal Position (APP) Sensor
The mass air flow (MAF) sensor measures the mass The accelerator pedal position (APP) sensor is
of air flowing into the engine. The MAF sensor mounted on the accelerator pedal. The APP sensor
output signal is used by the powertrain control detects the position of the accelerator pedal and
module (PCM) to calculate injector pulse width. For inputs this information as a voltage to the
transmission strategies the MAF sensor is used to powertrain control module (PCM). The PCM uses
regulate electronic pressure control, shift and torque the APP sensor information to aid in determining
converter clutch scheduling. shift scheduling, electronic pressure control (EPC)
and torque converter (TCC) control.
Transmission Control Switch (TCS)
The transmission control switch (TCS) is a Digital Transmission Range (TR) Sensor
momentary contact switch that allows the driver to The digital transmission range (TR) sensor is
cancel operation of 5th (D) gear. located on the outside of the transmission at the
The TCS is located on the end of the selector lever. manual lever. The digital TR sensor completes the
start circuit in PARK, NEUTRAL and the back-up
When the driver initially presses the TCS a signal is lamp circuit in REVERSE. The digital TR sensor
sent to the powertrain control module (PCM). also opens and closes a set of 4 switches that are
The PCM uses the shift solenoids to monitored by the powertrain control module (PCM)
disengage/disable 5th gear operation and activate the to determine the position of the manual lever (P, R,
coast clutch. N, (D), 3, 2, 1).
At the same time, the PCM illuminates the
Turbine Shaft Speed (TSS) Sensor
transmission control indicator lamp (TCIL) to notify
the driver that 5th gear is canceled. The turbine shaft speed (TSS) sensor is a magnetic
pickup that sends the powertrain control module
When the TCS is pressed again, 5th (D) gear
(PCM) torque converter turbine speed information.
operation is enabled, the coast clutch is released and
the TCIL is turned off. The TSS sensor is mounted externally on the case.
Whenever the ignition is cycled (vehicle shut off, The PCM uses TSS information to help determine
then started again), the TCS is turned off and 5th appropriate operating pressures and torque converter
gear will be enabled, even if the TCS had been on clutch (TCC) operation.
when the ignition was shut off.
Output Shaft Speed (OSS) Sensor
Transmission Control Indicator Lamp (TCIL) The output shaft speed (OSS) sensor is a magnetic
The transmission control indicator lamp (TCIL) is pickup, located at the park gear trigger wheel
located in the instrument panel and is labeled O/D assembly, that sends a signal to the powertrain
OFF. It is illuminated in conjunction with the control module (PCM) to indicate transmission
transmission control switch (TCS). output shaft speed. The OSS sensor is mounted
externally on the case. The OSS is used for torque
The TCIL will flash if the electronic pressure
converter clutch control, shift scheduling and to
control (EPC) solenoid circuit is open, shorted to
determine pressure control (PC).
battery, ground or a fault has been detected in a
monitored sensor used for transmission operation. Intermediate Shaft Speed Sensor
Throttle Position (TP) Sensor The intermediate shaft speed sensor is a magnetic
pickup that sends planetary sun gear speed
The throttle position (TP) sensor is a potentiometer
information to the powertrain control module
mounted on the throttle body. The TP sensor detects
(PCM). It is mounted externally on the center of the
the position of the throttle plate and sends this
case.
information to the powertrain control module
(PCM). The TP sensor is used for shift scheduling, The PCM uses the intermediate shaft speed sensor
electronic pressure control (EPC) and torque information to aid in determining pressure
converter clutch (TCC) control. requirements.

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307-01-3 Automatic Transmission — 5R55S 307-01-3
DESCRIPTION AND OPERATION (Continued)
Pressure Control Solenoids (PCA, PCB, Shift Solenoids — (SSA, SSB, SSC, SSD)
PCC) Four On/Off shift solenoids allow the powertrain
The pressure control (PC) solenoids are a control module (PCM) to control shift scheduling.
variable-force style (VFS) solenoid. The VFS-type
solenoid is an electrohydraulic actuator combining a • The solenoids are 3-way, normally open style.
solenoid and a regulating valve. • The shift solenoids SSA, SSB, SSC and SSD
The line pressure tap is used to verify output provide gear selection of 1st through 5th and
pressure from PC A or PC B by turning either one reverse gears by directing PC pressures to the
appropriate elements.
off while verifying the output from the other
solenoid. The 2nd pressure tap is used to verify the Coast braking and manual gears are also controlled
output from the PC C solenoid. by the shift solenoids.
There are 3 PC solenoids located in the solenoid Transmission Fluid Temperature (TFT)
body assembly used to control line pressure, band Sensor
and clutch application pressure within the
transmission. • The transmission fluid temperature (TFT) sensor
is a thermistor-type sensor that varies a reference
The powertrain control module (PCM) varies the voltage signal. The resistance in the TFT varies
current to the PC solenoid. with temperature. The powertrain control module
The PCM has an adaptive learn strategy to (PCM) monitors the voltage signal across the
electronically control the transmission which will TFT and uses this information to determine the
automatically adjust the shift feel. When the battery transmission fluid temperature.
has been disconnected or a new battery installed, • The TFT is located on the solenoid body.
certain transmission operating parameters may be
lost. The PCM must relearn these parameters. • The PCM uses the TFT signal to help determine
During this learning process you may experience shift scheduling, torque converter clutch operation
slightly firm shifts, delayed or early shifts. This and pressure control requirements.
operation is considered normal and will not affect It sends a voltage signal to the PCM. The voltage
the function of the transmission. Normal operation signal varies with transmission fluid temperature.
will return once these parameters are stored by the The PCM uses this signal to determine whether a
PCM. cold start shift schedule is necessary. The shift
schedule is compensated when the transmission
Torque Converter Clutch (TCC) Solenoid fluid temperature is cold. The PCM also inhibits
The torque converter clutch (TCC) solenoid is a torque converter clutch (TCC) operation at low
pulse width modulating type solenoid which is used transmission fluid temperatures and use to determine
to control the apply and release of the TCC. pressure control (PC) solenoid operations.

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307-01-1 Automatic Transmission — 5R55S 307-01-1

DIAGNOSIS AND TESTING

Preliminary Inspection • Noise/vibration — check for dependencies, either
rpm dependent, vehicle speed dependent, shift
The following items must be checked prior to
dependent, gear dependent, range dependent or
beginning the diagnostic procedures:
temperature dependent.
Know and Understand the Concern
Check Fluid Level and Condition
In order to correctly diagnose a concern, 1st
understand the customer complaint or condition. CAUTION: The vehicle should not be
Customer contact may be necessary in order to driven if the fluid level is low or internal failure
begin to verify the concern. Understand the can result.
condition as to when the concern occurs, for NOTE: If the vehicle has been operated for an
example: extended period of time at highway speeds, in city
• Hot or cold vehicle temperature traffic, in hot weather or while pulling a trailer, the
fluid needs to cool down 30 minutes to obtain an
• Hot or cold ambient temperature accurate reading.
• Vehicle driving conditions This vehicle is not equipped with a fluid level
• Vehicle loaded/unloaded indicator. An incorrect level may affect the
After understanding when and how the concern transmission operation and could result in
occurs, proceed to verify the concern. transmission damage. To correctly check and add
fluid to the transmission, refer to Transmission
Verification of Condition Fluid Level Check in this section.
This section provides information that must be used High Fluid Level
in both determining the actual cause of customer
concerns and executing the appropriate procedures. A fluid level that is too high may cause the fluid to
become aerated due to the churning action of the
The following procedures must be used when
rotating internal parts. This will cause erratic control
verifying customer concerns for the engine.
pressure, foaming, loss of fluid from the vent tube
Determine Customer Concern and possible transmission damage. Refer to
Transmission Fluid Level Check in this section to
NOTE: Some transmission conditions can cause
correct a possible overfill condition.
engine concerns. An electronic pressure control
short circuit can cause engine misfiring. The torque Low Fluid Level
converter clutch not disengaging will stall the
A low fluid level can result in poor transmission
engine.
engagement, slipping or damage. This can also
Determine customer concerns relative to vehicle use indicate a leak in one of the transmission seals or
and dependent driving conditions, paying attention gaskets.
to the following items:
Adding Fluid
• Hot or cold vehicle operating temperature
CAUTION: The use of any type of
• Hot or cold ambient temperatures
transmission fluid other than specified could
• Type of terrain result in transmission damage.
• Vehicle loaded/unloaded If fluid needs to be added, add fluid in 0.25L (1/2
• City/highway driving pint) increments through the fluid level plug in the
• Upshift bottom of the pan. Do not overfill the fluid. For
fluid filling, refer to Transmission Fluid Level
• Downshift Check in this section. For fluid type, refer to the
• Coasting General Specification chart in this section.
• Engagement Fluid Condition Check
1. Check the fluid level. Only remove the small
(center) plug for this procedure.
Copyright  2004, Ford Motor Company
Last updated: 06/29/2004 2005 Aviator, 09/2004
307-01-2 Automatic Transmission — 5R55S 307-01-2
DIAGNOSIS AND TESTING (Continued)
2. Observe the color and the odor of the fluid. 5. If fluid contamination or transmission failure is
Under normal circumstances the color should be confirmed by the sediment in the bottom of the
dark reddish, not brown or black. transmission fluid pan, the transmission must be
3. Allow the fluid to drip onto a facial tissue and disassembled and completely cleaned.
examine the stain. 6. Carry out diagnostic checks and adjustments.
4. If evidence of solid material is found, the Refer to Diagnosis By Symptom in this section.
transmission fluid pan should be removed for
further inspection.

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307-01-1 Automatic Transmission — 5R55S 307-01-1

DIAGNOSIS AND TESTING

Road Testing Vehicle
NOTE: Always drive the vehicle in a safe manner
according to driving conditions and obey all traffic
laws.
NOTE: When the battery has been disconnected or
a new battery installed certain transmission
operating parameters may be lost. The powertrain
control module (PCM) must relearn these
parameters. During this learning process you may
experience slightly firm shifts, delayed or early
shifts. This operation is considered normal and will
not affect the function of the transmission. Normal
operation will return once these parameters are
stored by the PCM.
The Shift Point Road Test and Torque Converter
Clutch Operation Test provide diagnostic
information on transmission shift controls and
torque converter operation.

Copyright  2004, Ford Motor Company

Last updated: 06/29/2004 2005 Aviator, 09/2004
307-01-1 Automatic Transmission — 5R55S 307-01-1

DIAGNOSIS AND TESTING

Shift Point Road Test 5. Press the accelerator pedal to the floor, wide
open throttle (WOT). The transmission should
This test verifies that the shift control system is
shift from 3rd to 2nd or 3rd to 1st, depending
operating correctly.
on vehicle speed and torque converter clutch
1. Bring engine and transmission up to normal should release.
operating temperature.
6. With vehicle speed above 48 km/h (30 mph),
2. Operate the vehicle with the selector lever in move the transmission range selector lever from
the (D) position. D position to 1st position and release the
3. Apply minimum throttle and observe the speeds accelerator pedal. The transmission should
at which upshift occurs and torque converter immediately downshift to 3rd gear. When
engages. Refer to the following Shift Speeds vehicle speed drops below 32 km/h (20 mph),
chart. (Also refer to the Automatic the transmission should downshift into 1st gear.
Transmission Specifications Issue.) 7. If transmission fails to upshift/downshift or
4. Stop the vehicle. Depress transmission control torque converter clutch does not apply/release,
switch (TCS) to activate D range. Repeat Step refer to Diagnosis By Symptom in this section
3. Transmission will make all upshifts except for possible causes.
4-5 and torque converter clutch apply should
occur above 46 km/h (29 mph).
Shift Speeds
(D) Speed km/h (mph)
Vehicle Information Throttle Position Shift 5R55S Axle Ratio All
4.6L Closed 5-4 40-47 (25-29)
4-3 24-29 (15-18)
3-1 10-13 (6-8)
Minimum 1-2 15-18 (9-11)
Monitor PID: 2-3 26-32 (16-20)
TP volt-1.25 3-4 33-40 (21-25)
4-5 60-68 (37-42)
Wide Open 1-2 53-60 (33-37)
2-3 79-87 (49-54)
3-4 123-134 (77-83)

Copyright  2004, Ford Motor Company

Last updated: 06/29/2004 2005 Aviator, 09/2004
307-01-1 Automatic Transmission — 5R55S 307-01-1

DIAGNOSIS AND TESTING

Torque Converter Diagnosis Torque Converter Operation Test
Prior to installing a new torque converter, all This test verifies that the torque converter clutch
diagnostic procedures must be followed. This is to control system and the torque converter are
prevent the unnecessary installation of good torque operating correctly.
converters. Only after a complete diagnostic 1. Carry out the Quick Test. See On-Board
evaluation can the decision be made to install a Diagnostics with NGS. Refer to Diagnostics in
new or remanufactured torque converter. this section. Check for DTCs. Refer to the
Begin with the normal diagnostic procedures as Diagnostic Trouble Code Charts in this section.
follows: 2. Connect a tachometer to the engine.
1. Preliminary Inspection. 3. Bring the engine to normal operating
2. Know and Understand the Customer Concern. temperature by driving the vehicle at highway
speeds for approximately 15 minutes in (D)
3. Verify the Concern — Carry out the Torque
position.
Converter Clutch Operation Test. Refer to
Torque Converter Operation Test in this section. 4. After normal operating temperature is reached,
maintain a constant vehicle speed of about 80
4. Carry out Diagnostic Procedures.
km/h (50 mph) and tap brake pedal with the
• Run on-board diagnostics. See On-Board left foot.
Diagnostics with NGS. Refer to Diagnostics 5. The engine rpm should increase when the brake
in this section. pedal is tapped and decrease about 5 seconds
— Repair all non-transmission related DTCs after the pedal is released. If this does not
1st. occur, refer to Torque Converter Operation
— Repair all transmission DTCs. Concerns in Diagnosis By Symptom.
— Rerun on-board diagnostic to verify repair. 6. If the vehicle stalls in (D) or MANUAL 2 at
idle with vehicle at a stop, move the
• Carry out the Line Pressure Test. Refer to transmission range selector lever to MANUAL
Special Testing Procedures in this section. 1 position. If the vehicle stalls, refer to
• Carry out the Stall Speed Test. Refer to Diagnosis By Symptom, Torque Converter
Special Testing Procedures in this section. Operation Concerns in this section. Repair as
• Carry out the Diagnosis by Symptom Index. necessary. If the vehicle does not stall in (D),
Refer to Diagnosis By Symptom in this refer to Diagnosis By Symptom in this section.
section.
— Use the index to locate the appropriate
routine that best describes the symptom(s).
The routine will list all possible
components that may cause or contribute
to the symptom. Check each component
listed, diagnose and service as necessary
before servicing the torque converter.

Copyright  2004, Ford Motor Company

Last updated: 06/29/2004 2005 Aviator, 09/2004
307-01-1 Automatic Transmission — 5R55S 307-01-1

DIAGNOSIS AND TESTING

Visual Inspection Shift Linkage Check
This inspection will identify modifications or Check for a misadjustment in shift linkage by
additions to the vehicle operating system that may matching the detents in the transmission range
affect diagnosis. Inspect the vehicle for non-Ford selector lever with those in the transmission. If they
factory add-on devices such as: match, the misadjustment is in the indicator. Do not
adjust the shift linkage.
• Electronic add-on items:
Hydraulic leakage at the manual control valve can
— air conditioning cause delay in engagements and/or slipping while
— generator (alternator) operating if the linkage is not correctly adjusted.
— engine turbo Refer to Section 307-05 for shift linkage
adjustment.
— cellular telephone
— cruise control Check TSBs and OASIS
— CB radio Refer to all Technical Service Bulletins and OASIS
messages which pertain to the transmission concern
— linear booster and follow the procedure as outlined.
— backup alarm signal
Carry Out On-Board Diagnostics (KOEO,
— computer KOER)
• Vehicle modification: After a road test, with the vehicle warm and before
These items, if not installed correctly, will affect the disconnecting any connectors, carry out the Quick
powertrain control module (PCM) or transmission Test using a diagnostic scan tool. Refer to the
function. Pay particular attention to add-on wiring Powertrain Control/Emissions Diagnosis (PC/ED)
splices in the PCM harness or transmission wiring manual for diagnosis and testing of the powertrain
harness, abnormal tire size or axle ratio changes. control system.
• Leaks; refer to Leakage Inspection in this section.
• Correct linkage adjustments; refer to Section
307-05.

Copyright  2004, Ford Motor Company

Last updated: 06/29/2004 2005 Aviator, 09/2004
307-01-1 Automatic Transmission — 5R55S 307-01-1

DIAGNOSIS AND TESTING

Diagnostics Special Tool(s)
Worldwide Diagnostic System
Special Tool(s) (WDS)
UV Leak Detector Vehicle Communication Module
164-R0756 or equivalent (VCM) with appropriate
adapters or equivalent diagnostic
tool

MLP-TR Cable
418-F107 (007-00111) or
Pressure Gauge, Transmission equivalent
Fluid
307-004 (T57L-77820-A)

Transmission Tester
307-F016 (007-00130) or
Alignment Gauge, TR Sensor equivalent
307-351 (T97L-70010-A)

Diagnosing electronically controlled automatic

transmissions is simplified using the following
Transmission Test Plate and procedures. It is important to remember that there is
Gasket a definite procedure to follow. Do not take shortcuts
307-433-01, 307-433-02,
307-433-03 or assume that critical checks or adjustments have
already been made. Follow the procedures as written
to avoid missing critical components or steps. By
following the diagnostic sequence, the technician
will be able to diagnose and repair the concern the
73 III Automotive Meter 1st time.
105-R0057 or equivalent
On-Board Diagnostics with WDS
NOTE: For detailed instruction and other diagnostic
methods using the WDS, refer to the WDS tester
and thePowertrain Control/Emissions Diagnosis
(PC/ED) manual.
Trans Tester TR/MLP Overlay These quick tests should be used to diagnose the
and Manual
007-00131 or equivalent powertrain control module (PCM) and should be
carried out in order.
• Quick Test 1.0 — Visual Inspection
• Quick Test 2.0 — Set Up
(Continued)
• Quick Test 3.0 — Key On, Engine Off
• Quick Test 4.0 — Continuous Memory
• Quick Test 5.0 — Key On, Engine Running

Copyright  2004, Ford Motor Company

Last updated: 06/29/2004 2005 Aviator, 09/2004
307-01-2 Automatic Transmission — 5R55S 307-01-2
DIAGNOSIS AND TESTING (Continued)
• Special Test Mode For further information on other diagnostic testing
— Wiggle Test Mode features using the WDS or generic diagnostic tool,
refer to the Powertrain Control/Emissions Diagnosis
— Output Test Mode (PC/ED) manual. Other diagnostic methods include
• PCM Reset Mode the following:
• Clearing DTCs — Parameter Identification (PID) Access Mode
• OBD II Drive Cycle — Freeze Frame Data Access Mode
• Other WDS Features — Oxygen Sensor Monitor Mode

2005 Aviator, 09/2004

307-01-1 Automatic Transmission — 5R55S 307-01-1

DIAGNOSIS AND TESTING

Output State Control (OSC) Mode • Carry out test and record DTCs.
Output state control (OSC) allows the technician to • Repair all NON-Transmission DTCs.
take control of certain parameters to function the • Repair all VSS and digital TR sensor DTCs.
transmission. For example, OSC allows the
• Make sure that VSS/digital TR sensors are
technician to shift the transmission only when
functional.
commanding a gear change. If the technician
commands 1st gear in OSC, the transmission will • Select ‘‘Active Command Modes.’’
remain in 1st gear until the technician commands • Select ‘‘Output State Control.’’
the next gear. For another example, the technician • Select ‘‘Trans - Bench Mode or Trans - Drive
can command a shift solenoid to turn ON or OFF Mode.’’
when carrying out an electrical circuit check. OSC
has 2 modes of operation for transmission, the OSC — Transmission Bench Modes
BENCH MODE and the DRIVE MODE. Each The following Transmission Bench Modes may be
mode/parameter has a unique set of vehicle used as necessary during diagnostics.
operating requirements that the technician must meet
before being allowed to operate OSC. SSA, SSB, SSC, SSD and TCC in BENCH
NOTE: To operate OSC the digital transmission MODE
range (TR) sensor and the vehicle speed sensor CAUTION: The parking brake must be set
(VSS) must be operational. No diagnostic trouble prior to carrying out this procedure.
codes (DTCs) related to the digital TR sensor or the
The BENCH MODE allows the technician to carry
VSS can be present.
out electrical circuit checks on the following
• The vehicle requirements MUST BE MET when components:
SENDING the OSC value. Refer to vehicle
• SSA - Activates SS A OFF or ON.
requirements for each individual test.
• SSB - Activates SS B OFF or ON.
• If the vehicle requirements are NOT MET when
SENDING the OSC value, an ERROR • SSC - Activates SS C OFF or ON.
MESSAGE will appear. When the ERROR • SSD - Activates SS D OFF or ON.
MESSAGE is received, OSC is aborted and must
• TCC - Activates TCC OFF or ON.
be restarted.
OSC ‘‘SSA, SSB, SSC, SSD, TCC’’ BENCH
• If after a sent value is substituted and the vehicle
MODE Operates ONLY when:
requirements are no longer met, the PCM will
cancel the OSC value and resume normal • VSS and digital TR sensor are operational.
operation. No error message will be sent. • No VSS and digital TR sensor DTCs.
• The OSC value XXX may be sent anytime to • Transmission range selector lever in P or N.
cancel OSC.
• Key ON.
Output State Control (OSC) Procedures • Engine OFF.
• Carry out visual inspection and vehicle OSC Command Values
preparation as necessary.
• OFF - turns solenoid OFF.
• Select ‘‘Vehicle and Engine Selection’’ menu.
• ON - turns solenoid ON.
• Select appropriate vehicle and engine.
• XXX - cancels OSC value sent.
• Select ‘‘Diagnostic Data Link.’’
• SEND - sends the values to PCM.
• Select ‘‘Powertrain Control Module.’’
BENCH MODE Procedure for SSA, SSB, SSC,
• Select ‘‘Diagnostic Test Mode.’’ SSD and TCC
• Select ‘‘KOEO On-Demand Self Test and KOER
On-Demand Self Tests.’’

Copyright  2004, Ford Motor Company

Last updated: 06/29/2004 2005 Aviator, 09/2004
307-01-2 Automatic Transmission — 5R55S 307-01-2
DIAGNOSIS AND TESTING (Continued)
Follow operating instructions from the NGS menu • Transmission range selector lever in P or N.
screen: • Pressure gauge installed.
• Select ‘‘Output State Control.’’ • Key ON.
• Select ‘‘Trans - Bench Mode.’’ • Engine ON.
• Select ‘‘PIDs’’ to be monitored. • Engine rpm at least 1500.
• Monitor all selected PIDs during test. OSC ‘‘PCx’’ Bench Mode should ONLY be
• Select ‘‘Parameters - SSA, SSB, SSC, SSD or operated to complete PCx SOLENOID CIRCUIT
TCC.’’ PINPOINT TESTS when:
• Select ‘‘ON’’ to turn solenoid ON. • VSS and Digital TR Sensor are operational.
• Press ‘‘SEND’’ to send command ON. • No VSS and Digital TR Sensor DTCs are present.
• Select ‘‘OFF’’ to turn solenoid OFF. • Transmission range selector lever is in ‘‘P’’ or
• Press ‘‘SEND’’ to send command OFF. ‘‘N’’.
• Select ‘‘XXX’’ to cancel at any time. • Key ‘‘ON’’.
• Press ‘‘SEND.’’ • Engine ‘‘OFF’’.
OSC Command Values
PCA, PCB, PCC in BENCH MODE
• 00 - sets PCx pressure to 00 psi.
CAUTION: The parking brake must be set
prior to carrying out this procedure. • 15 - sets PCx pressure to 15 psi.
The BENCH MODE is also used to test the • 30 - sets PCx pressure to 30 psi.
functionality of the transmission electronic pressure • 45 - sets PCx pressure to 45 psi.
control. During BENCH MODE, the PCx solenoids • 60 - sets PCx pressure to 60 psi.
can be commanded in increments of 15 psi from 0
• 75 - sets PCx pressure to 75 psi.
to 90 psi and 90 to 0 psi.
• 90 - sets PCx pressure to 90 psi.
The line pressure tap is used to verify output
pressure from PC A or PC B by turning either one • XXX - cancels OSC value sent.
off while verifying the output from the other • SEND - sends the values to PCM.
solenoid. The 2nd pressure tap is used to verify the
output from the PC C solenoid. BENCH MODE Procedure for PCx
The OSC functions for the parameter PCx allows Following operating instructions from the NGS
the technician to choose the following options: menu screen:
• PCx - Activates PCx to selected values. • Select ‘‘Output State Control.’’
• 00 - sets PCx pressure to 00 psi. • Select ‘‘Trans - Bench Mode.’’
• 15 - sets PCx pressure to 15 psi. • Select ‘‘PIDs’’ to be monitored.
• 30 - sets PCx pressure to 30 psi. • Monitor all selected PIDs during test.
• 45 - sets PCx pressure to 45 psi. • Select ‘‘Parameters - PCx.’’
• 60 - sets PCx pressure to 60 psi. • Select Value ‘‘0 - 90 psi.’’
• 75 - sets PCx pressure to 75 psi. • Press ‘‘SEND’’ to send command.
• 90 - sets PCx pressure to 90 psi. • Select ‘‘XXX’’ to cancel at any time.
OSC ‘‘PCx’’ Bench Mode should ONLY be • Press ‘‘SEND.’’
operated to check PRESSURE FUNCTIONALITY
using an installed pressure gauge (300 psi) when:
• VSS and digital TR sensor are operational.
• No VSS and digital TR sensor DTCs.

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307-01-3 Automatic Transmission — 5R55S 307-01-3
DIAGNOSIS AND TESTING (Continued)
OSC — Transmission DRIVE MODES • 5 - PCM selects 5th gear.
The DRIVE MODE allows control of 3 • XXX - cancels OSC value sent.
transmission parameters. Each mode/parameter has a • SEND - sends the values to PCM.
unique set of vehicle operating requirements that the
technician must meet before being allowed to DRIVE MODE Procedure for GEAR
operate OSC. The recommended procedure, when Follow operating instructions from the NGS menu
using the DRIVE MODE, is to control one screen.
parameter at a time.
The DRIVE MODE allows the technician to carry • Select ‘‘Output State Control.’’
out the following functions on the transmission: • Select ‘‘Trans - DRIVE MODE.’’
• GEAR - allows upshifts or downshifts. • Select ‘‘PIDs’’ to be monitored.
• TCC - engages or disengages the torque converter • Monitor all selected PIDs during test.
clutch. • Select ‘‘Parameters - GEAR.’’
• FIRM SFT - Commands a higher control • Select Value ‘‘1-5.’’
pressure during upshift. • Press ‘‘SEND’’ to send command.
The pressure control (PCx) solenoids for this • Reselect Value ‘‘1-5.’’
transmission are not directly controlled during
DRIVE MODE testing. Pressures may be raised • Press ‘‘SEND’’ to send command.
during an upshift via the harsh shift control channel • Select ‘‘XXX’’ to cancel at any time.
(FIRM SFT) • Press ‘‘SEND.’’
GEAR in DRIVE MODE TCC in DRIVE MODE
This OSC function is used to test the transmission This OSC function is used to test whether the
shift functions. torque converter clutch is engaging and disengaging
The OSC functions for the GEAR parameter allow correctly.
the technician to choose the following options: The OSC functions for the TCC parameter allows
• 1 - PCM selects 1st gear. the technician to choose the following:
• 2 - PCM selects 2nd gear. • TCC - activates TCC OFF and ON.
• 3 - PCM selects 3rd gear. • ON - turns TCC solenoid ON.
• 4 - PCM selects 4th gear. • OFF - turns TCC solenoid OFF.
• 5 - PCM selects 5th gear. OSC ‘‘TCC OFF’’ DRIVE MODE operates ONLY
OSC ‘‘GEAR’’ Mode operates ONLY when: when:

• VSS and digital TR sensor are operational. • VSS and digital TR sensors are operational.
• No VSS and digital TR sensor DTCs. • No VSS and digital TR sensor DTCs present.
• Engine ON. • Engine ON.
• TCC ‘‘OFF’’ (TCC cannot be engaged) • Transmission range selector lever in (D).
• Transmission range selector lever in (D). • Vehicle speed is greater than 3 km/h (2 mph).
• Vehicle speed is greater than 3 km/h (2 mph). OSC ‘‘TCC ON’’ DRIVE MODE operates ONLY
when:
OSC Command Values
• VSS and digital TR sensors are operational.
• 1 - PCM selects 1st gear.
• No VSS and digital TR sensor DTCs present.
• 2 - PCM selects 2nd gear.
• Engine ON.
• 3 - PCM selects 3rd gear.
• Transmission range selector lever in (D).
• 4 - PCM selects 4th gear.
• Vehicle speed is greater than 3 km/h (2 mph).

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307-01-4 Automatic Transmission — 5R55S 307-01-4
DIAGNOSIS AND TESTING (Continued)
• Transmission in 2nd gear or higher. OSC ‘‘FIRM SFT’’ DRIVE MODE operates
• TFT is between 33-153°C (60-275° F). ONLY when:
• Brake not applied ‘‘OFF’’ below 32 km/h (20 • VSS and digital TR sensor are operational.
mph). • No VSS and digital TR sensor DTCs.
• Maintain steady speed. • Transmission range selector lever in O/D.
OSC Command Values • Pressure gauge installed (optional).
• OFF - turns TCC OFF. • Key ON.
• ON - turns TCC ON. • Engine ON.
• XXX - cancels OSC value sent. • Vehicle speed greater than 3 km/h (2 mph).
• SEND - sends the values to PCM. • TCC is OFF (TCC is not engaged).
Drive Mode Procedures for TCC OSC Command Values
Follow operating instructions from the NGS menu • ON - sets control pressure high for all upshifts
screen. (determined by the PCM)
• Select ‘‘Output State Control.’’ • OFF- sets control pressure to normal for all
upshifts (determined by the PCM)
• Select ‘‘Trans-drive Mode.’’
• XXX - cancel OSC for FIRM SFT
• Select ‘‘PIDs’’ to be monitored.
• SEND - sends the values to the PCM
• Monitor all selected PIDs during test.
DRIVE MODE Procedure for FIRM SFT
• Select ‘‘Parameters - TCC.’’
Follow operating instructions from the NGS menu
• Select ‘‘ON’’ to turn solenoid ON. screen.
• Press ‘‘SEND’’ to send command ON.
• Select ‘‘Output State Control.’’
• Select ‘‘OFF’’ to turn solenoid OFF.
• Select ‘‘Trans - Drive Mode.’’
• Press ‘‘SEND’’ to send command OFF.
• Select ‘‘PIDs’’ to be monitored.
• Select ‘‘XXX’’ to cancel at any time.
• Monitor all selected PIDs during test.
• Press ‘‘SEND.’’
• Select ‘‘Parameters - FIRM SFT.
FIRM SFT in DRIVE MODE • Press ‘‘SEND’’ to send command.
This OSC function is used to raise pressure during • Select ‘‘XXX’’ to cancel at any time.
an upshift to determine whether the pressure control
• Press ‘‘SEND.’’
system is functioning correctly. Harsher shifts
indicate that the pressure control system works at Using Output State Control (OSC) and
higher pressure. The best test for isolating pressure Accessing PIDs
control system problems is to carry out the PCA, To confirm that the OSC value was sent by the
PCB, PCC in BENCH MODE using a hydraulic NGS and the PCM has accepted the OSC
pressure gauge. substitution, a corresponding PID for each OSC
The OSC functions for the parameter FIRM SFT parameter must be monitored. Additional PIDs
allows the technician to choose the following should be monitored to help the technician
options: adequately diagnose the transmission.
• FIRM SFT - activates the harsh shift channel. The following is a list of OSC parameters and their
corresponding PID:
— ON - sets control pressure higher for all
upshifts (determined by the PCM)
— OFF- sets control pressure to normal for all
upshifts (determined by the PCM)
— XXX - cancel OSC for FIRM SFT

2005 Aviator, 09/2004

307-01-5 Automatic Transmission — 5R55S 307-01-5
DIAGNOSIS AND TESTING (Continued)
Corresponding PID PID Description Corresponding PID PID Description
BPP Brake pedal position SSA Shift solenoid A
switch ON/OFF commanded ON
PCA Pressure control solenoid SSB Shift solenoid B
A — commanded pressure commanded ON
PCB Pressure control solenoid SSC Shift solenoid C
B — commanded pressure commanded ON
PCC Pressure control solenoid SSD Shift solenoid D
C — commanded pressure commanded ON
FIRMST Firm shift control (FMC) TCC Torque converter
status requested by OSC; commanded duty cycles
0 = FSC not commanded (%)
by OSC, NGS PID output TCCRAT Torque converter speed
= OFF; 1 = FSC ratio (RPM and or TSS)
commanded by OSC,
NGS PID output = ON TFT Transmission fluid
temperature (degrees F)
GEAR Commanded transmission
gear (use in DRIVE only) VSS Vehicle speed (mph)
RPS Pinpoint test for
REVERSE pressure To confirm that the OSC substitution occurred,
switch; 0 = closed, 1 =
open SEND the OSC value and monitor the
corresponding PID value. If no ERROR MESSAGE
FFG RPS Instantaneous failure flag was received and the value of the corresponding
for REVERSE pressure
switch; Failure = 1 PID is the same as the value sent from OSC, then
the OSC substitution was successful.
RPM Engine revolutions per
minute

2005 Aviator, 09/2004

307-01-1 Automatic Transmission — 5R55S 307-01-1

DIAGNOSIS AND TESTING

Transmission Drive Cycle Test After On-Board Diagnostics
NOTE: Always drive the vehicle in a safe manner NOTE: The vehicle wiring harness, powertrain
according to driving conditions and obey all traffic control module (PCM) and non-transmission sensors
laws. may affect transmission operations. Repair these
concerns 1st.
NOTE: The Transmission Drive Cycle Test must be
followed exactly. Transmission failure must occur 4 After the on-board diagnostic procedures are
times consecutively for shift error DTC code to be completed, repair all DTCs.
set and 5 times consecutively for continuous torque Begin with non-transmission related DTCs, then
converter clutch code to set. repair any transmission related DTCs. Refer to the
NOTE: When carrying out the Transmission Drive Diagnostic Trouble Code Charts in this section for
Cycle Test, use the Solenoid Operation Chart for information on condition and symptoms. This chart
proper solenoid operation. Refer to Pinpoint Tests will be helpful in referring to the correct manual(s)
— OSC Equipped Vehicles in this section. and aids in diagnosing internal transmission
concerns and external non-transmission inputs. The
After carrying out the Quick Test, use the
pinpoint tests are used in diagnosing transmission
Transmission Drive Cycle Test for checking
electrical concerns. Make sure that the vehicle
continuous codes.
wiring harness and the PCM are diagnosed as well.
1. Record and then erase Quick Test codes. The Powertrain Control/Emissions Diagnosis
2. Warm engine to normal operating temperature. (PC/ED) manual will aid in diagnosing
non-transmission electronic components.
3. Make sure transmission fluid level is correct.
4. With transmission in (D) position, moderately Before Pinpoint Tests
accelerate from stop to 80 km/h (50 mph). This NOTE: Prior to entering pinpoint tests, check the
allows the transmission to shift into 5th gear. powertrain control module (PCM) wiring harness for
Hold speed and throttle open steady for a correct connections, bent or broken pins, corrosion,
minimum of 15 seconds. loose wires, correct routing, correct seals and their
5. With transmission in 5th gear and maintaining condition. Check the PCM, sensors and actuators
steady speed and throttle opening, lightly apply for damage. Refer to the Powertrain
and release brake to operate stop lamps. Then Control/Emissions Diagnosis (PC/ED) manual.
hold speed and throttle steady for a minimum NOTE: If a concern still exists after electrical
of 5 seconds. diagnosis, refer to Diagnosis By Symptom in this
6. Brake to a stop and remain stopped for a section.
minimum of 20 seconds. If DTCs appear while carrying out the on-board
7. Repeat Steps 4 through 6 at least 5 times. diagnostics, refer to the Diagnostic Trouble Code
8. Carry out Quick Test and record continuous Charts in this section for the appropriate repair
DTCs. procedure. Prior to entering pinpoint tests, refer to
any TSBs and OASIS messages for transmission
concerns.

Copyright  2004, Ford Motor Company

Last updated: 06/29/2004 2005 Aviator, 09/2004
307-01-1 Automatic Transmission — 5R55S 307-01-1

DIAGNOSIS AND TESTING

Diagnostic Trouble Code Charts
Diagnostic Trouble Code Chart
**May also be generated by some other non-electric transmission hardware system.
*Output circuit check, generated only by electrical symptoms.
Five
Digit Compon-
DTC ent Description Condition Symptom Action
P0102, MAF MAF concerns MAF system High/low EPC REFER to the
P0103, inoperative which pressure, incorrect Powertrain
P1100, may cause a shift schedule. Control/Emissions
P1101 transmission Incorrect torque Diagnosis (PC/ED)
concern. converter clutch manual.
engagement
scheduling.
Symptoms similar
to a TP failure.
P0112 IAT IAT indicates Voltage drop across Incorrect EPC REFER to the
125°C (254°F) IAT exceeds scale pressure. Either Powertrain
(grounded) set for temperature high or low which Control/Emissions
125°C (254°F). will result in harsh Diagnosis (PC/ED)
or soft shifts. manual.
P0113 IAT IAT indicates -40°C Voltage drop across Incorrect EPC REFER to the
(-40°F) (open IAT exceeds scale pressure. Either Powertrain
circuit) set for temperature high or low which Control/Emissions
-40°C (-40°F). will result in harsh Diagnosis (PC/ED)
or soft shifts. manual.
P0114 IAT IAT out of IAT temperature Rerun on-board REFER to the
on-board diagnostic higher or lower diagnostic at normal Powertrain
range than expected operating Control/Emissions
during KOEO and temperature. Diagnosis (PC/ED)
KOER. manual.
P1116 ECT ECT out of ECT temperature Rerun on-board REFER to the
on-board diagnostic higher or lower diagnostic at normal Powertrain
range than expected operating Control/Emissions
during KOEO and temperature. Diagnosis (PC/ED)
KOER. manual.
P0117 ECT ECT indicates Voltage drop across Torque converter REFER to the
125°C (254°F) ECT exceeds scale clutch will always Powertrain
set for temperature be OFF, resulting in Control/Emissions
125°C (254°F) reduced fuel Diagnosis (PC/ED)
(grounded). economy. manual.
P0118 ECT ECT indicates Voltage drop across Torque converter REFER to the
-40°C (-40°F) ECT exceeds scale clutch will always Powertrain
set for temperature be OFF, resulting in Control/Emissions
-40°C (-40°F) (open reduced fuel Diagnosis (PC/ED)
circuit). economy. manual.

Copyright  2004, Ford Motor Company

Last updated: 8/18/2004 2005 Aviator, 09/2004
307-01-2 Automatic Transmission — 5R55S 307-01-2
DIAGNOSIS AND TESTING (Continued)
Diagnostic Trouble Code Chart (Continued)
**May also be generated by some other non-electric transmission hardware system.
*Output circuit check, generated only by electrical symptoms.
Five
Digit Compon-
DTC ent Description Condition Symptom Action
P0121, TP TP concern PCM has detected Harsh engagements, REFER to the
P0122, an error. This error firm shift feel, Powertrain
P0123, may cause a abnormal shift Control/Emissions
P1120, transmission schedule, torque Diagnosis (PC/ED)
P1121, concern. converter clutch manual.
P1125, does not engage.
P1124 Torque converter
clutch cycling.
P0121- APP APP concern PCM has detected Harsh engagements, REFER to the
P0124, an error. This error firm shift feel, Powertrain
P0221- may cause a abnormal shift Control/Emissions
P0224, transmission schedule, torque Diagnosis (PC/ED)
P2100- concern. converter clutch manual.
P2107, does not engage.
P2110- Torque converter
P2112, clutch cycling.
P2121-
P2124,
P2126-
P2129,
P2121-
P2135,
P2138-
P2140
P0300- EI EI concerns EI system is Harsh engagements REFER to the
P0308, inoperative which and shifts, late Powertrain
P0320, may cause a WOT shifts, no Control/Emissions
P0340, transmission torque converter Diagnosis (PC/ED)
P1351- concern. clutch engagement. manual.
P1364
P0503, ABS Insufficient VSS PCM detected a No transmission REFER to the
P0500, input from ABS loss of vehicle symptom. I.P. Powertrain
U1039 through SCP link speed signal speedometer may Control/Emissions
through SCP link be affected. Diagnosis (PC/ED)
from ABS. manual.
P0715 TSS Insufficient input PCM detected a May turn on MIL. GO to Pinpoint Test E.
from turbine shaft loss of TSS signal
speed sensor during operation.
P0717 TSS Insufficient input PCM detected a May flash TCIL. GO to Pinpoint Test E.
from turbine shaft loss of TSS signal
speed sensor during operation.
P0718 TSS Turbine shaft speed PCM has detected a May flash TCIL. GO to Pinpoint Test E.
sensor signal noisy noisy TSS signal.
P0720 OSS Insufficient input PCM detected a Abnormal shift GO to Pinpoint Test E.
from OSS sensor loss of OSS signal schedule, harsh
during operation. shifts. Will turn on
MIL.

2005 Aviator, 09/2004

307-01-3 Automatic Transmission — 5R55S 307-01-3
DIAGNOSIS AND TESTING (Continued)
Diagnostic Trouble Code Chart (Continued)
**May also be generated by some other non-electric transmission hardware system.
*Output circuit check, generated only by electrical symptoms.
Five
Digit Compon-
DTC ent Description Condition Symptom Action
P0721 OSS Output shaft speed PCM has detected Abnormal shift GO to Pinpoint Test E.
sensor signal noisy an erratic OSS schedule, harsh
signal. shifts. May flash
TCIL.
P0722 OSS Insufficient input PCM detected a Abnormal shift GO to Pinpoint Test E.
from OSS sensor loss of OSS signal schedule, harsh
during operation. shifts. May flash
TCIL.
P0791 Intermed- Insufficient input PCM has detected a Harsh shifts. May GO to Pinpoint Test E.
iate shaft from the loss of the flash TCIL.
speed intermediate shaft intermediate shaft
sensor speed sensor speed sensor signal
during operation.
P0794 Intermed- Intermediate shaft PCM has detected Harsh shifts. May GO to Pinpoint Test E.
iate shaft speed sensor signal an erratic flash TCIL.
speed noisy intermediate shaft
sensor speed sensor signal.
P0731** SSA, 1st gear ratio error 1st gear, not Correct gear ratio REFER to the Solenoid
SSB, SSC commanded. not achieved for On/Off Charts. Then
or commanded gear. GO to Pinpoint Test A.
internal Shift errors may
parts also be due to other
transmission
concerns (stuck
valves, damaged
friction material).
Engine rpm could
be higher or lower
than expected. May
flash TCIL.
P0732** SSA, 2nd gear ratio error 2nd gear not Correct gear ratio REFER to the Solenoid
SSB, SSC commanded. not achieved for On/Off Charts. Then
or commanded gear. GO to Pinpoint Test A.
internal Shift errors may
parts also be due to other
transmission
concerns (stuck
valves, damaged
friction material).
Engine rpm could
be higher or lower
than expected. May
flash TCIL.

2005 Aviator, 09/2004

307-01-4 Automatic Transmission — 5R55S 307-01-4
DIAGNOSIS AND TESTING (Continued)
Diagnostic Trouble Code Chart (Continued)
**May also be generated by some other non-electric transmission hardware system.
*Output circuit check, generated only by electrical symptoms.
Five
Digit Compon-
DTC ent Description Condition Symptom Action
P0733** SSA, 3rd gear ratio error 3rd gear not Correct gear ratio REFER to the Solenoid
SSB, SSC commanded. not achieved for On/Off Charts. Then
or commanded gear. GO to Pinpoint Test A.
internal Shift errors may
parts also be due to other
transmission
concerns (stuck
valves, damaged
friction material).
Engine rpm could
be higher or lower
than expected. May
flash TCIL.
P0734** SSA, 4th gear ratio error 4th gear not Correct gear ratio REFER to the Solenoid
SSB, SSC commanded. not achieved for On/Off Charts. Then
or commanded gear. GO to Pinpoint Test A.
internal Shift errors may
parts also be due to other
transmission
concerns (stuck
valves, damaged
friction material).
Engine rpm could
be higher or lower
than expected. May
flash TCIL.
P0735 SSA, 5th gear ratio error 5th gear not Correct gear ratio REFER to the Solenoid
SSB, commanded. not achieved for On/Off Chart. Then GO
SSC, commanded gear. to Pinpoint Test A.
SSD or Shift errors may
internal also be due to other
parts transmission
concerns (stuck
valves, damaged
friction material).
Engine rpm could
be higher or lower
than expected. May
flash TCIL.

2005 Aviator, 09/2004

307-01-5 Automatic Transmission — 5R55S 307-01-5
DIAGNOSIS AND TESTING (Continued)
Diagnostic Trouble Code Chart (Continued)
**May also be generated by some other non-electric transmission hardware system.
*Output circuit check, generated only by electrical symptoms.
Five
Digit Compon-
DTC ent Description Condition Symptom Action
P1740** TCC TCC solenoid TCC not Stuck OFF: Harsh GO to Pinpoint Test A
inoperative commanded. shifts or and GO to Pinpoint
Mechanical failure engagements, Test D.
of the solenoid engine rpm higher
detected. than expected.
Stuck ON: Vehicle
stall when in drive
gear at idle, harsh
shifts or
engagements,
engine rpm lower
than expected. May
turn on MIL.
P0741** TCC TCC solenoid or The PCM picked up Harsh shifts or REFER to Diagnosis
clutch circuit an excessive engagements. By Symptom in this
performance or amount of TCC Engine RPM may section.
stuck OFF. slippage during be higher than
normal vehicle expected. May flash
operation. TCIL.
P0743* TCC TCC solenoid TCC solenoid Open or short to GO to Pinpoint Test A.
circuit failure circuit fails to battery power:
during on-board provide voltage harsh shifts or
diagnostic drop across engagements,
solenoid. Circuit engine rpm higher
open or shorted or than expected. Short
PCM driver failure to ground: Vehicle
during on-board stall when in
diagnostics. DRIVE gear at idle,
harsh shifts or
engagements,
engine rpm lower
than expected. May
turn on MIL.
P0740* TCC TCC solenoid TCC solenoid Open or short to GO to Pinpoint Test A.
circuit failure circuit fails to battery power:
during on-board provide voltage harsh shifts or
diagnostic drop across engagements,
solenoid. Circuit engine rpm higher
open or shorted or than expected. Short
PCM driver failure to ground: Vehicle
during on-board stall when in
diagnostics. DRIVE gear at idle,
harsh shifts or
engagements,
engine rpm lower
than expected. May
turn on TCIL.

2005 Aviator, 09/2004

307-01-6 Automatic Transmission — 5R55S 307-01-6
DIAGNOSIS AND TESTING (Continued)
Diagnostic Trouble Code Chart (Continued)
**May also be generated by some other non-electric transmission hardware system.
*Output circuit check, generated only by electrical symptoms.
Five
Digit Compon-
DTC ent Description Condition Symptom Action
P0962 PCA PCA solenoid Voltage through Short circuit — GO to Pinpoint Test D.
circuit failure, PCA solenoid is causes minimum
shorted to ground checked. An error PCA pressure
will be noted if (minimum capacity)
tolerance is and limits engine
exceeded. torque (alternate
firm). Slips in gear
and no 3rd gear.
May turn on MIL.
P0750* SSA SSA solenoid SSA circuit failed Open or short to GO to Pinpoint Test A.
circuit failure to provide voltage battery power: 1st
drop across gear ratio incorrect
solenoid. Circuit or no gear ratio
open or shorted or errors, no 1st gear.
PCM driver failure Short to ground: no
during on-board 4th or 5th gear.
diagnostic. May turn on MIL.
P0753* SSA SSA solenoid SSA circuit failed Open or short to GO to Pinpoint Test A.
circuit failure to provide voltage battery power: 1st
drop across gear ratio incorrect
solenoid. Circuit or no gear ratio
open or shorted or errors, no 1st gear.
PCM driver failure Short to ground: no
during on-board 4th or 5th gear.
diagnostic. May turn on TCIL.
P1714 SSA SSA inoperative Mechanical failure Stuck OFF: Open GO to Pinpoint Test F.
of the solenoid or short to battery
detected. power: 1st gear
ratio incorrect or no
gear ratio errors, no
1st gear. Stuck ON:
no 4th or 5th gear.
May turn on MIL.
P0755* SSB SSB solenoid SSB circuit failed Open or short to GO to Pinpoint Test A.
circuit failure to provide voltage battery power: no
drop across 3rd gear. Short to
solenoid. Circuit ground: no 1st gear.
open or shorted or May turn on MIL.
PCM driver failure
during on-board
diagnostic.
P0758* SSB SSB solenoid SSB circuit failed Open or short to GO to Pinpoint Test A.
circuit failure to provide voltage battery power: 3rd
drop across gear ratio incorrect
solenoid. Circuit or no gear ratio
open or shorted or errors, no 3rd gear.
PCM driver failure Short to ground: no
during on-board 1st gear. May flash
diagnostic. TCIL.

2005 Aviator, 09/2004

307-01-7 Automatic Transmission — 5R55S 307-01-7
DIAGNOSIS AND TESTING (Continued)
Diagnostic Trouble Code Chart (Continued)
**May also be generated by some other non-electric transmission hardware system.
*Output circuit check, generated only by electrical symptoms.
Five
Digit Compon-
DTC ent Description Condition Symptom Action
P1715 SSB SSB inoperative Mechanical failure Stuck OFF: 3rd GO to Pinpoint Test F.
of the solenoid gear ratio incorrect
detected. or no gear ratio
errors, no 3rd gear.
Stuck ON: 1st gear
ratio incorrect or no
gear ratio errors, no
1st gear. May turn
on MIL.
P0760* SSC SSC solenoid SSC circuit failed Open or short to GO to Pinpoint Test A.
circuit failure to provide voltage battery power: 2nd
drop across and 5th gear ratio
solenoid. Circuit incorrect. Short to
open or shorted or ground: 1st gear
PCM driver failure ratio incorrect or no
during on-board gear ratio errors.
diagnostic. May turn on MIL.
P0763* SSC SSC solenoid SSC circuit failed Open or short to GO to Pinpoint Test A.
circuit failure to provide voltage battery power: 2nd
drop across and 5th gear ratio
solenoid. Circuit incorrect. Short to
open or shorted or ground: 1st gear
PCM driver failure ratio incorrect or no
during on-board gear ratio errors.
diagnostic. May flash TCIL.
P1716 SSC SSC inoperative Mechanical failure Stuck OFF: 2nd and GO to Pinpoint Test F.
of the solenoid 5th gear ratio
detected. incorrect. Stuck
ON: 1st gear ratio
incorrect or no gear
ratio errors. May
turn on MIL.
P0768 SSD SSD solenoid SSD circuit failed Short to ground: No GO to Pinpoint Test A.
circuit failure to provide voltage engine braking.
drop across May flash TCIL.
solenoid. Circuit
open, shorted or
PCM driver circuit
failure during
on-board
diagnostics.
P0765 SSD SSD solenoid SSD circuit failed Short to ground: No GO to Pinpoint Test A.
circuit failure to provide voltage engine braking.
drop across May turn on MIL.
solenoid. Circuit
open, shorted or
PCM driver circuit
failure during
on-board
diagnostics.

2005 Aviator, 09/2004

307-01-8 Automatic Transmission — 5R55S 307-01-8
DIAGNOSIS AND TESTING (Continued)
Diagnostic Trouble Code Chart (Continued)
**May also be generated by some other non-electric transmission hardware system.
*Output circuit check, generated only by electrical symptoms.
Five
Digit Compon-
DTC ent Description Condition Symptom Action
P1717 SSD SSD inoperative Mechanical failure Stuck ON: No GO to Pinpoint Test F.
of the solenoid engine braking.
detected. May turn on MIL.
P0966** PCB PCB solenoid Voltage through Short circuit, short GO to Pinpoint Test D.
circuit failure, PCB solenoid is to ground. No 2nd
shorted circuit to checked. An error and 5th gear. May
ground will be noted if turn on MIL.
tolerance is
exceeded.
P0967 PCB PCB solenoid Voltage through Short to battery GO to Pinpoint Test D.
intermittent short to PCB solenoid is power: harsh shift
battery voltage checked. An error and engagements.
will be noted if May flash TCIL.
tolerance is
exceeded.
P0970** PCC PCC solenoid Voltage through No 4th and 5th GO to Pinpoint Test D.
circuit failure, PCC solenoid is gear. May turn on
shorted circuit to checked. An error MIL.
ground will be noted if
tolerance is
exceeded.
P0968** PCC PCC solenoid Voltage through Open circuit — GO to Pinpoint Test D.
circuit open PCC solenoid is causes maximum
checked. Error is PCC pressure, harsh
noted if tolerance is engagements and
exceeded. shifts. May flash
TCIL.
P0971 PCC PCC solenoid short Voltage through Short to battery GO to Pinpoint Test D.
to power PCC solenoid is power: harsh shift
checked. An error and engagements.
will be noted if May flash TCIL.
tolerance is
exceeded.
P0745 PCA PCA solenoid or PCA functional Incorrect shift GO to Pinpoint Test D.
circuit fault fault — low pattern indicating
pressure. mechanical or
hydraulic failure of
the transmission.
Will turn on MIL.
P0748 PCA PCA solenoid Electrical failure of Possible slip in gear GO to Pinpoint Test D.
inoperative the solenoid and/or 3rd gear
detected. ratio. May turn on
TCIL.
P0960 PCA PCA solenoid Voltage through Open circuit — GO to Pinpoint Test D.
circuit open PCA solenoid is causes maximum
checked. Error is PCA pressure, harsh
noted if tolerance is engagements and
exceeded. shifts. May flash
TCIL.

2005 Aviator, 09/2004

307-01-9 Automatic Transmission — 5R55S 307-01-9
DIAGNOSIS AND TESTING (Continued)
Diagnostic Trouble Code Chart (Continued)
**May also be generated by some other non-electric transmission hardware system.
*Output circuit check, generated only by electrical symptoms.
Five
Digit Compon-
DTC ent Description Condition Symptom Action
P0963 PCA PCA solenoid short Voltage through Short to power — GO to Pinpoint Test D.
to power PCA solenoid is causes maximum
checked. An error PCA pressure, harsh
will be noted if engagements and
tolerance is shifts. May flash
exceeded. TCIL.
P0964 PCB PCB solenoid Voltage through Open circuit — GO to Pinpoint Test D.
circuit open PCB solenoid is causes maximum
checked. Error is PCB pressure, harsh
noted if tolerance is engagements and
exceeded. shifts. May flash
TCIL.
P0775 PCB PCB solenoid or PCB functional Incorrect shift GO to Pinpoint Test D.
circuit fault fault — low pattern indicating
pressure. mechanical or
hydraulic failure of
the transmission.
Will turn on MIL.
P0778 PCB PCB solenoid Electrical failure of No 2nd and 5th GO to Pinpoint Test D.
inoperative the solenoid gear. Will turn on
detected. TCIL.
P0795 PCC PCC solenoid or PCC functional Incorrect shift GO to Pinpoint Test D.
circuit fault fault — low pattern indicating
pressure. mechanical or
hydraulic failure of
the transmission.
Will turn on MIL.
P0798 PCC PCC solenoid Electrical failure of Incorrect gear ratio GO to Pinpoint Test D.
inoperative the solenoid in 4th and 5th gear.
detected. Will turn on TCIL.
P1124 TP TP voltage high/low TP was not in the Rerun at REFER to the
for on-board correct position for appropriate throttle Powertrain
diagnostic on-board diagnostic. position per Control/Emissions
application. Diagnosis (PC/ED)
manual.
P1460 A/C A/C clutch cycling A/C or defrost ON DTC set during REFER to the
pressure switch condition may on-board diagnostic Powertrain
error result from A/C — rerun with A/C Control/Emissions
clutch being ON OFF. Failed ON — Diagnosis (PC/ED)
during on-board EPC pressure manual.
diagnostic. slightly low with
A/C OFF.
P1636 SSx SSx ISIG PCM has detected May turn on MIL. INSTALL a new PCM.
communication an error with the
error ISIG chip.

2005 Aviator, 09/2004

307-01-10 Automatic Transmission — 5R55S 307-01-10
DIAGNOSIS AND TESTING (Continued)
Diagnostic Trouble Code Chart (Continued)
**May also be generated by some other non-electric transmission hardware system.
*Output circuit check, generated only by electrical symptoms.
Five
Digit Compon-
DTC ent Description Condition Symptom Action
P1700 TRANS Transmission Internal component FMEM becomes If other solenoid DTCs
undetermined failure. Direct active — engine are present, diagnose
failure one-way clutch rpm limited to and repair them 1st.
failure. 4,000 rpms. Failed CLEAR DTCs and
a NEUTRAL drive vehicle. If P1700
condition in 1st, 3rd returns, disassemble
or 4th gear in transmission and
automatic mode. INSPECT the direct
Only 2nd and 5th one-way clutch.
gear available. REPAIR as required.
Other DTCs that CLEAR DTC. Drive
may set P1700: vehicle and verify
P0745, P1747, repair.
P1760, P1714,
P1715, P0750,
P0755.
P0705 Digital Digital TR circuit Digital TR circuits, Harsh engagements GO to Pinpoint Test C.
TR sensor failure indicating an or wrong gear
invalid pattern in commanded.
TR D. Condition Defaults to (D) or
caused by a short to invalid position.
ground or an open May turn MIL ON.
in TR4, TR3A, TR2
and or TR1 circuits.
This DTC cannot
be set by an
incorrectly adjusted
digital TR sensor.
P0708 Digital Digital TR sensor Digital TR sensor Harsh engagements GO to Pinpoint Test C.
TR sensor circuit TR3A open circuit TR3A or wrong gear
reading 2.6v - 5.0v commanded.
(open circuit). This Defaults to (D) or
DTC cannot be set invalid position.
by an incorrectly May turn MIL ON.
adjusted digital TR
sensor.
P1702 Digital Digital TR signal See P0705, P0708 See P0705, P0708 GO to Pinpoint Test C.
TR intermittent, code conditions. symptoms. May
P0705, P0708 are flash TCIL.
set
P1704 Digital Digital TR not in P Digital TR sensor DTC is set. GO to Pinpoint Test C.
TR or N positions or shift cable
during incorrectly adjusted
KOEO/KOER or digital TR circuit
failure.
P1705 Digital Digital TR not in P KOEO/KOER not DTC is set. RERUN KOEO/KOER
TR or N during run in P or N or in P or N or GO to
KOEO/KOER digital TR circuit Pinpoint Test C.
failure.

2005 Aviator, 09/2004

307-01-11 Automatic Transmission — 5R55S 307-01-11
DIAGNOSIS AND TESTING (Continued)
Diagnostic Trouble Code Chart (Continued)
**May also be generated by some other non-electric transmission hardware system.
*Output circuit check, generated only by electrical symptoms.
Five
Digit Compon-
DTC ent Description Condition Symptom Action
P1703 BPP Brake not actuated Brake not cycled Failed ON or not REFER to the
during on-board during KOER. connected — torque Powertrain
diagnostic KOER converter clutch Control/Emissions
will not engage at Diagnosis (PC/ED)
less than 1/3 manual.
throttle. Failed OFF
or not connected —
torque converter
clutch will not
disengage when
brake is applied.
P1703 BPP BPP switch circuit Brake ON circuit Failed ON or not REFER to the
failed failure during connected — torque Powertrain
KOEO. converter clutch Control/Emissions
will not engage at Diagnosis (PC/ED)
less than 1/3 manual.
throttle. Failed OFF
or not connected —
torque converter
clutch will not
disengage when
brake is applied.
P1572 BPP BPP switch circuit Brake ON circuit Failed ON or not REFER to the
failed failure during connected — torque Powertrain
normal operation. converter clutch Control/Emissions
will not engage at Diagnosis (PC/ED)
less than 1/3 manual.
throttle. Failed OFF
or not connected —
torque converter
clutch will not
disengage when
brake is applied.
P0712 TFT 157°C (315°F) Voltage drop across DTC set. May flash GO to Pinpoint Test B.
indicated TFT TFT sensor exceeds TCIL.
sensor circuit scale set for
grounded temperature of
157°C (315°F).
P0713 TFT -40°C (-40°F) Voltage drop across DTC set. May flash GO to Pinpoint Test B.
indicated TFT TFT sensor exceeds TCIL.
sensor circuit open scale set for
temperature -40°C
(-40°F).
P1711 TFT TFT out of Transmission not at DTC set — vehicle Warm or cool vehicle
on-board diagnostic operating cold or overheated. to normal operating
range temperature during temperature. GO to
on-board diagnostic. Pinpoint Test B.
P0711 TFT No change in TFT PCM has detected DTC is set. May GO to Pinpoint Test B.
no TFT change flash TCIL.
during operation.

2005 Aviator, 09/2004

307-01-12 Automatic Transmission — 5R55S 307-01-12
DIAGNOSIS AND TESTING (Continued)
Diagnostic Trouble Code Chart (Continued)
**May also be generated by some other non-electric transmission hardware system.
*Output circuit check, generated only by electrical symptoms.
Five
Digit Compon-
DTC ent Description Condition Symptom Action
P1783 TFT Transmission Transmission fluid Increase in control GO to Pinpoint Test B.
overtemp condition temperature pressure. May flash
indicated exceeded 127°C TCIL.
(270°F).
P1780 TCS TCS not changing TCS not cycled No (D) cancel when RERUN on-board
states during OBD test. switch is cycled. diagnostic and cycle
TCS circuit or switch. REFER to
switch open or Section 307-05.
shorted.
P1501 VSS VSS input high PCM had detected a Cannot run KOER. STOP vehicle. RERUN
input during self test VSS input signal KOER — Self Test. If
during KOER — KOER cannot be
Self Test. carried out, REFER to
the Powertrain
Control/Emissions
Diagnosis (PC/ED)
manual.

Rotunda Transmission Tester

The Rotunda Transmission Tester is used to
diagnose electronically controlled transmissions and
is used in conjunction with the pinpoint tests. The
tests should be carried out in order. Installing the
Rotunda Transmission Tester allows separation of
the vehicle electronics from transmission electronics.
Refer to the Rotunda Transmission Tester manual
for these tests.
• Digital Transmission Range (TR) Sensor Testing
• Resistance/Continuity Test
• Switch Test — PARK/NEUTRAL, Backup Lamp
and Optional Circuits

2005 Aviator, 09/2004

307-01-1 Automatic Transmission — 5R55S 307-01-1

DIAGNOSIS AND TESTING

Transmission Connector Layouts
Connector Reference

Powertrain Control Module (PCM)

Pin Number Circuit Description

1 Shift solenoid A (SSA)
2 Shift solenoid B (SSB)
3 Shift solenoid C (SSC)
4 Shift solenoid D (SSD)
5 Torque converter clutch (TCC) solenoid
7 Pressure control solenoid A (PC A)
9 Digital transmission range sensor TR3A to (PCM)
10 Digital transmission range sensor TR4 to (PCM)
12 Pressure control solenoid C (PC C)
13 Pressure control solenoid B (PC B)
17 Signal return
18 Digital transmission range sensor TR2 to (PCM)
21 Intermediate shaft speed sensor signal input
22 Digital transmission range sensor TR1 to (PCM)
23 Transmission fluid temperature (TFT) sensor
26 Powertrain control module (PCM) to output shaft speed (OSS) sensor signal input
27 Powertrain control module (PCM) to turbine shaft speed (TSS) sensor signal input

Copyright  2004, Ford Motor Company

Last updated: 06/29/2004 2005 Aviator, 09/2004
307-01-2 Automatic Transmission — 5R55S 307-01-2
DIAGNOSIS AND TESTING (Continued)
Transmission Vehicle Harness

Pin Number Circuit Description

1 Pressure control (PCB) solenoid B
2 Transmission fluid temperature (TFT) sensor input
3 Solenoid power
4 Pressure control (PCC) solenoid C
5 Shift solenoid D (SSD)
6 Shift solenoid C (SSC)
11 Pressure control (PCA) solenoid A
12 Signal return
14 Torque converter clutch (TCC) solenoid
15 Shift solenoid B (SSB)
16 Shift solenoid A (SSA)

Digital Transmission Range (TR) Sensor

Pin Number Circuit Description

2 Signal return
3 Digital transmission range (TR) sensor TR3A
4 Digital transmission range (TR) sensor TR1
5 Digital transmission range (TR) sensor TR2
6 Digital transmission range (TR) sensor TR4

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307-01-3 Automatic Transmission — 5R55S 307-01-3
DIAGNOSIS AND TESTING (Continued)
Pin Number Circuit Description
7 Ground
8 Neutral switch sense input
9 Fused power feed
10 Starter solenoid control power
11 Reverse backup lamps
12 Start (overload protected) to starter relay

Turbine Shaft Speed (TSS) Sensor

Pin Number Circuit Description

1 Turbine shaft speed (TSS) sensor signal
2 Signal return

Output Shaft Speed (OSS) Sensor

Pin Number Circuit Description

1 Output shaft speed (OSS) sensor signal
2 Signal return

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307-01-4 Automatic Transmission — 5R55S 307-01-4
DIAGNOSIS AND TESTING (Continued)
Intermediate Shaft Speed Sensor Harness Connector

Pin Number Circuit Description

1 Intermediate shaft speed sensor signal
2 Signal return

Digital Transmission Range (TR) Sensor Diagnosis Chart

PID: TR V
PID: TR D (volts)
TR3A (PCM
Selector pin 64 to
Position PID: TR TR4 TR3A TR2 TR1 sigrtn)
PARK P/N 0 0 0 0 0.0 Volts
REVERSE REV 1 1 0 0 1.3 - 1.8 Volts
NEUTRAL NTRL 0 1 1 0 1.3 - 1.8 Volts
OVERDRIVE O/Da 1 1 1 1 1.3 - 1.8 Volts
MANUAL 3 Man 3 1 0 1 0 0.0 Volts

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307-01-5 Automatic Transmission — 5R55S 307-01-5
DIAGNOSIS AND TESTING (Continued)
Digital Transmission Range (TR) Sensor Diagnosis Chart (Continued)
PID: TR V
PID: TR D (volts)
TR3A (PCM
Selector pin 64 to
Position PID: TR TR4 TR3A TR2 TR1 sigrtn)
MANUAL 2 Man 2 1 0 0 1 0.0 Volts
MANUAL 1 Man 1 0 0 1 1 0.0 Volts

A. TR V is the voltage at the PCM pin 64 (TR3A Circuit) to signal return.

B. ‘‘In Between’’ reading could be caused by a shift cable or digital TR sensor misaligned or a digital TR sensor
circuit failure of TR1, TR2, TR3A or TR4.
C. TR D: 1= Open digital TR switch, 0= Closed digital TR switch.
D. EEC-V Control System Breakout Box Readings: Taken from PCM signal pins for TR1, TR2, TR3A, TR4 to signal
return.
•Voltages for TR1, TR2, TR4:
•0 = 0.0 volts.
•1 = 9.0 - 14.0 volts.
•Voltage for TR3A:
•0 = 0.0 volts.
•1 = 1.3 - 1.8 volts.
Wiggle Test Information for Open/Shorts
A. TR4, TR3A, TR2 and TR1 are all closed in PARK. PARK is a good position to check for intermittent open circuits
(with scan tool monitoring TR D).
B. TR4, TR3A, TR2 and TR1 are all open in OVERDRIVE, so OVERDRIVE is a good position to check for shorts to
ground. To determine the shorted components while observing TR D, unplug the TR and see if the short goes
away. If the short is still present unplug the transmission harness and see if the short goes away. If the short is still
present, then the short is in the PCM or vehicle harness. Remove the suspect circuit(s) wire terminal from the PCM
connector. If the short is still present, then the PCM has an internal failure, otherwise the failure is in the vehicle
harness.

2005 Aviator, 09/2004

307-01-1 Automatic Transmission — 5R55S 307-01-1

DIAGNOSIS AND TESTING

Pinpoint Tests — OSC Equipped Special Tool(s)
Vehicles MLP-TR Cable
418-F107 (007-00111) or
Special Tool(s) equivalent

Pressure Gauge, Transmission

Fluid
307-004 (T57L-77820-A)

Transmission Tester
307-F016 (007-00130) or
equivalent

73 III Automotive Meter

105-R0057 or equivalent

Shift Solenoid Pre-Diagnosis

Any time an electrical connector or solenoid body is
disconnected, inspect the connector for terminal
Trans Tester TR/MLP Overlay
and Manual condition, corrosion and contamination. Also inspect
007-00131 or equivalent the connector seal for damage. Clean, repair or
install new as necessary.
Use the following shift solenoid operation
information when carrying out Pinpoint Test A.

Worldwide Diagnostic System

(WDS)
Vehicle Communication Module
(VCM) with appropriate
adapters or equivalent diagnostic
tool

(Continued)

Solenoid Operation Chart

Shift Selector Normal Mode Normal Mode

Lever Position Gear SSA SSB SSC SSD PC A PC B PC C
P On Off Off On L H/L L
N On Off Off On L H/L L
R On Off Off On L/H L H
OD 1 On Off Off On H H/L L
2 On Off On On L/H H L
3 On On Off On H L/H L
4 Off Off Off On H L/H H
5 Off Off On On H H H
OD (Cancelled) 1 On Off Off On H H/L L

Copyright  2004, Ford Motor Company

Last updated: 4/11/2005 2005 Aviator, 09/2004
307-01-2 Automatic Transmission — 5R55S 307-01-2
DIAGNOSIS AND TESTING (Continued)
Solenoid Operation Chart (Continued)

Shift Selector Normal Mode Normal Mode

Lever Position Gear SSA SSB SSC SSD PC A PC B PC C
2 On Off On On L/H H L
3 On On Off On H L/H L
4 Off Off Off Off L/H H H
MANUAL 3 3 On On Off Off H L H/L
MANUAL 2 2 On Off On Off H L H/L
MANUAL 1 1 On Off Off Off H L H/L

H = High SSC, SSD

L = Low O/D
H/L = is PCM controlled Position Actual Gear
SSC SSD
Shift Solenoid Failure Mode Chart Gear ON OFF ON OFF
Failed ON or OFF due to powertrain control module 1 2 1 1 1/M1
(PCM) and/or vehicle wiring concerns, solenoid
2 2 1 2 M2
electrically, mechanically or hydraulically stuck on
or off. 3 3 3 3 3/M3
4 4/5 4 4 4/M4
SSA, SSB
5 5 4 5 5
O/D R R R R R
Position Actual Gear
O/D Canceled Position
SSA SSB
Gear
Gear ON OFF ON OFF
1M M2 M1 1 M1
1 1 1 3 1
2M M2 M1 2 M2
2 2 2 2 2
3M 1.1 M3 3 M3
3 3 3 3 1
4M 5 M4 4 M4
4 1 4 4 4
5 2 5 5 5
1.1 = Actual ratio with Forward Clutch, Intermediate
R R R N R Clutch and O/D Band applied.
O/D Canceled Position
PC A, PC B, PC C
Gear
1M M1 M1 M3 M1 O/D
Posi-
2M M2 M2 1.1 M2 tion Actual Gear
3M M3 M3 M3 M1 PC A PC B PC C
4M M1 M4 M4 M4 Gear L H L H L H
1 1/S 1 1 1 1 1
1.1 = Actual ratio with Forward Clutch, Intermediate 2 2 2 1 2 2 2
Clutch and O/D Band applied.
3 1/S 3 3 3 3 3
4 4 4 4 4 1 4
5 5 5 4 5 2 5
R R/S R R/S R R R
O/D Canceled Position

2005 Aviator, 09/2004

307-01-3 Automatic Transmission — 5R55S 307-01-3
DIAGNOSIS AND TESTING (Continued)
PC A, PC B, PC C (Continued) PC A, PC B, PC C (Continued)
O/D O/D
Posi- Posi-
tion Actual Gear tion Actual Gear
PC A PC B PC C PC A PC B PC C
Gear L H L H L H Gear L H L H L H
Gear 3M 1 M3 3 M3 M3 M3
1M 1 M1 1 M1 M1 M1 4M M4 M4 4 M4 1 M4
2M M2 M2 1 M2 M2 M2
H = High
L = Low
Slip = Slip due to low line pressure
1.1 = Actual ratio with Forward Clutch, Intermediate
Clutch and O/D Band applied.

Pinpoint Tests

PINPOINT TEST A: SHIFT AND TORQUE CONVERTER CLUTCH SOLENOIDS

NOTE: Refer to the Transmission Vehicle Harness Connector illustration preceding these
pinpoint tests.
NOTE: Refer to the Internal Harness Diagram illustration preceding these pinpoint tests.
NOTE: Read and record all DTCs. All Digital TR Sensor and VSS DTCs must be repaired
before entering Output State Control (OSC).
Test Step Result / Action to Take
A1 ELECTRONIC DIAGNOSTICS
• Key in OFF position.
• Select PARK.
• Check to make sure the transmission harness connector is fully
seated, terminals are fully engaged in connector and in good
condition before proceeding.
• Connect the diagnostic tool.
• Key in ON position.
• Enter the following diagnostic mode on the diagnostic tool:
Diagnostic Data Link.
• Enter the following diagnostic mode on the diagnostic tool: PCM. Yes
• Enter the following diagnostic mode on the diagnostic tool: REMAIN in Trans-Bench Mode. GO to A2.
Active Command Modes. No
• Enter the following diagnostic mode on the diagnostic tool: REPEAT procedure to enter Trans-Bench
Output State Control (OSC). Mode. If vehicle did not enter Trans-Bench
• Enter the following diagnostic mode on the diagnostic tool: Mode, REFER to the Powertrain
Trans-Bench Mode. Control/Emissions Diagnosis (PC/ED)
• Does vehicle enter Trans-Bench Mode? manual for diagnosis of PCM or NGS.
A2 WIGGLE TEST
• Remain in Trans-Bench Mode.
• Select PIDs to be monitored.

PID Command PID Actual

SSA SSA
SSB SSB
SSC SSC
SSD SSD
TCC TCC

(Continued)

2005 Aviator, 09/2004

307-01-4 Automatic Transmission — 5R55S 307-01-4
DIAGNOSIS AND TESTING (Continued)
PINPOINT TEST A: SHIFT AND TORQUE CONVERTER CLUTCH SOLENOIDS (Continued)
Test Step Result / Action to Take
A2 WIGGLE TEST (Continued)
• Select ‘‘ON’’ to turn suspect solenoid on.
• Press ‘‘SEND’’.
• Wiggle all wiring and connectors to the transmission. Monitor the Yes
solenoid state for changes. REPAIR the circuit. TEST the system for
• Select ‘‘OFF’’ to turn solenoid off. normal operation.
• Press ‘‘SEND’’. No
• Does the suspect solenoid(s) fault state change? GO to A3.
A3 SOLENOID FUNCTIONAL CHECK
• Monitor each solenoid state. Yes
• Turn each solenoid ON and OFF. GO to A4.
• Does the solenoid turn ON and OFF when commanded and No
can solenoid activation be heard? GO to A5.
A4 OSC TRANS-DRIVE MODE (GEAR OR TCC)
• Carry out OSC Trans-Drive Mode. Yes
• Select GEAR for shift solenoids or follow procedures for GEAR CLEAR all DTCs. ROAD TEST to verify if
as listed in this section. concern is still present. If concern is still
• Select TCC for Torque Converter Clutch Solenoid. Follow present, REFER to Diagnosis By Symptom
procedures of TCC in Drive Mode as listed in this section. in this section to diagnose shift or torque
• Does the transmission upshift and downshift or torque converter concern.
converter engage/disengage when commanded? No
GO to A5.
A5 CHECK FOR BATTERY VOLTAGE
• Disconnect: Transmission Vehicle Harness Connector.
• Visually inspect all wires and connectors for damage.
• Key in ON position.
• Measure the voltage on pin 3 harness side and ground.

Yes
GO to A6.
No
REPAIR the circuit. TEST for normal
• Is the voltage greater than 10 volts? operation.
A6 ELECTRICAL SIGNAL CHECK
• Leave positive lead connected to pin 3 and connect negative
lead to pins 5, 6, 14, 15 and 16.

(Continued)

2005 Aviator, 09/2004

307-01-5 Automatic Transmission — 5R55S 307-01-5
DIAGNOSIS AND TESTING (Continued)
PINPOINT TEST A: SHIFT AND TORQUE CONVERTER CLUTCH SOLENOIDS (Continued)
Test Step Result / Action to Take
A6 ELECTRICAL SIGNAL CHECK (Continued)
• Enter the following diagnostic mode on the diagnostic tool:
Trans-Bench Mode.
• Select Parameter SSA, SSB, SSC, SSD or TCC.
• Select ‘‘ON’’. Yes
• Press ‘‘SEND’’. GO to A7.
• Measure the voltage while cycling the solenoids ON and OFF. No
• Select ‘‘OFF’’, press ‘‘SEND’’. REPAIR the circuit. TEST the system for
• Does the voltage change? normal operation.
A7 CHECK SOLENOID RESISTANCE AT SOLENOID
• Measure the resistance between pin 3 and pins 5, 6, 14, 15 and
16 solenoid side.

Solenoid Resistance (ohms)

SSA 16-45
SSB 16-45
SSC 16-45
SSD 16-45
TCC 9-16

Yes
GO to A8.
No
INSTALL a new solenoid body assembly.
• Is the resistance within specification? TEST the system for normal operation.
A8 CHECK SOLENOID FOR SHORT TO GROUND
• Measure the resistance between pin 3 and pins 5, 6, 14, 15 and
16 solenoid side and ground.

Yes
INSTALL a new solenoid body assembly.
No
REFER to Diagnosis By Symptom in this
section for diagnosis of shift or torque
• Is the resistance less than 5 ohms? converter concerns.

2005 Aviator, 09/2004

307-01-6 Automatic Transmission — 5R55S 307-01-6
DIAGNOSIS AND TESTING (Continued)
PINPOINT TEST B: TRANSMISSION FLUID TEMPERATURE (TFT) SENSOR
NOTE: Refer to the Transmission Vehicle Harness Connector illustration preceding these
pinpoint tests.
Test Step Result / Action to Take
B1 ELECTRONIC DIAGNOSTICS
• Key in OFF position.
• Select PARK.
• Check to make sure the transmission harness connector is fully
seated, terminals are fully engaged in connector and in good
condition before proceeding.
• Connect the diagnostic tool.
• Key in ON position.
• Enter the following diagnostic mode on the diagnostic tool: Yes
Diagnostic Data Link. REMAIN in PID/Data Control. GO to B2.
• Enter the following diagnostic mode on the diagnostic tool: PCM. No
• Enter the following diagnostic mode on the diagnostic tool: REPEAT procedure to enter PID. If vehicle
PID/Data Monitor and Record. did not enter PID, REFER to
• Enter the following diagnostic mode on the diagnostic tool: PIDs; thePowertrain Control/Emissions Diagnosis
TFT, TFTV. (PC/ED) manual for diagnosis of PCM and
• Does the vehicle enter PID/Data Monitor and Record? NGS.
B2 WARM-UP/COOL-DOWN CYCLE
• While monitoring the TFT PIDs, carry out the following test: If Yes
transmission is cold, run transmission to warm it up. If If the TFT PIDs increase as the
transmission is warm, allow transmission to cool down. transmission is warmed or decrease as
• Do the TFT PIDs increase as the transmission is warmed up the transmission is cooled, CLEAR all
or decrease as the transmission is cooled or does the TFT DTCs. Road test to verify if concern is still
or TFTV drop in and out of range? present. If concern is still present, REFER
to Diagnosis By Symptom in this section
to diagnose transmission overheating.
If the TFT or TFTV drop in and out of
range, INSPECT for intermittent concern in
the internal/external harness, sensor or
connector.
No
GO to B3.
B3 ELECTRICAL SIGNAL CHECK
• Disconnect: Transmission Harness Connector.
• Visually inspect all wires and connectors for damage.
• Measure the voltage between pin 2 harness side and ground.

Yes
GO to B4.
No
REPAIR the circuit. TEST the system for
• Is the voltage between 4.5 and 5.5 volts? normal operation.
(Continued)

2005 Aviator, 09/2004

307-01-7 Automatic Transmission — 5R55S 307-01-7
DIAGNOSIS AND TESTING (Continued)
PINPOINT TEST B: TRANSMISSION FLUID TEMPERATURE (TFT) SENSOR (Continued)
Test Step Result / Action to Take
B4 CHECK RESISTANCE OF TFT SENSOR
• Measure the resistance between pin 2 and 12 at the solenoid
body connector.

• Record the resistance.

• Resistance should be approximately in the following ranges:

Transmission Fluid Temperature

°C °F Resistance (Ohms)
-40 to -20 -40 to -4 967K - 284K
-19 to -1 -3 - 31 284K - 100K
0 - 20 32 - 68 100K - 37K
21 - 40 69 - 104 37K - 16K
41 - 70 105 - 158 16K - 5K
71 - 90 159 - 194 5K - 2.7K
91 - 110 195 - 230 2.7K - 1.5K Yes
111 - 130 231 - 266 1.5K - 0.8K REFER to Diagnosis By Symptom in this
section to diagnose an overheating
131 - 150 267 - 302 0.8K - 0.54K concern.
No
• Is the resistance in the range? INSTALL a new solenoid body assembly.

PINPOINT TEST C: DIGITAL TRANSMISSION RANGE (TR) SENSOR

NOTE: Refer to the Digital Transmission Range (TR) Sensor Connector illustration and Digital
Transmission Range TR) Sensor Diagnosis Chart preceding these pinpoint tests.
Test Step Result / Action to Take
C1 VERIFY DIAGNOSTIC TROUBLE CODES
• Key in OFF position. Yes
• Select PARK. GO to C4.
• Carry out on-board diagnostic test. No
• Are only DTC codes P0705, P0708 present? GO to C2.
C2 VERIFY DIGITAL TRANSMISSION RANGE SENSOR ALIGNMENT
• Key in OFF position.
(Continued)

2005 Aviator, 09/2004

307-01-8 Automatic Transmission — 5R55S 307-01-8
DIAGNOSIS AND TESTING (Continued)
PINPOINT TEST C: DIGITAL TRANSMISSION RANGE (TR) SENSOR (Continued)
Test Step Result / Action to Take
C2 VERIFY DIGITAL TRANSMISSION RANGE SENSOR ALIGNMENT
(Continued)
• Select PARK.
• Check to make sure the digital TR sensor harness connector is Yes
fully seated, terminals are fully engaged in connector and in GO to C3.
good condition before proceeding. No
• Apply the parking brake. ADJUST the digital TR sensor. REFER to
• Select NEUTRAL. Transmission Range (TR) Sensor
• Disconnect the shift cable/linkage from the manual lever. Adjustment in this section. PLACE
• Verify that the TR Sensor Alignment Gauge fits in the transmission range selector lever into
appropriate slots. PARK and CLEAR DTCs. RERUN OBD
• Is the digital TR sensor correctly adjusted? Tests. GO to C3.
C3 VERIFY SHIFT CABLE/LINKAGE ADJUSTMENT
• Select DRIVE. Yes
• Connect the shift cable/linkage. GO to C4.
• Verify that the shift cable/linkage is correctly adjusted. Refer to No
Section 307-05. ADJUST the shift cable/linkage. REFER to
• Is the shift cable/linkage is correctly adjusted? Section 307-05. GO to C4.
C4 CHECK ELECTRICAL SIGNAL OPERATION
• Select PARK.
• Disconnect: Digital TR Sensor. Yes
REPAIR as necessary. CLEAR DTCs and
RERUN OBD Tests.
CAUTION: Do not pry on connector. This will damage
the connector and result in a transmission concern. No
• Inspect both ends of the connector for damage or pushed out If diagnosing a DTC, GO to C5.
pins, corrosion, loose wires and missing or damaged seals. If diagnosing a starting concern or a
• Is there damage to the connector, pins or harness? backup lamp concern, GO to C10.
C5 CHECK ELECTRICAL SYSTEM OPERATION (TR AND PCM)
• Key in OFF position.
• Connect the diagnostic tool.
• Connect: Digital TR Sensor.
• Key in ON position.
• Enter the following diagnostic mode on the diagnostic tool: TR
PIDs TR D, TR V.
• Move transmission range selector lever into each gear and stop.
• Observe the PIDs, TR D and TR V (vehicle-dependent) while Yes
wiggling harness, tapping on sensor or driving the vehicle. Use The problem is not in the digital TR sensor
PIDs TR D for DTCs P0705, P1704 and P1705. Use PIDs system. REFER to Diagnosis By Symptom
TR V for DTC P0708. for further diagnosis.
• Compare the PIDs to the Digital Transmission Range (TR)
Sensor Diagnosis Chart. No
• Do the PIDs TR D and TR V match the Digital If TR D changes when wiggling harness,
Transmission Range (TR) Sensor Diagnosis chart and does tapping on the sensor or driving the
the TR D PID remain steady when the harness is wiggled, vehicle, the problem may be intermittent.
the sensor is tapped on or the vehicle driven? GO to C6.
C6 CHECK DIGITAL TRANSMISSION RANGE SENSOR OPERATION
• Disconnect: Digital TR Sensor. Yes
• Connect: TR-E Cable to Transmission Tester. Concern is not in the digital TR sensor.
• Connect: TR-E Cable to Digital TR Sensor. GO to C7.
• Place the DIGITAL TR Overlay onto Transmission Tester. No
• Carry out SENSOR Test as instructed on the digital TR Overlay. INSTALL a new digital TR sensor and
• Does the status lamp on the tester TRS-E cable match the ADJUST. REFER to Digital Transmission
selected gear positions? Range (TR) Sensor in this section. CLEAR
DTCs and RERUN OBD Tests.
C7 CHECK PCM HARNESS CIRCUITS FOR OPENS
• Key in OFF position.
• Disconnect: 150-Pin PTEC Module Connector ‘‘B’’.
• Disconnect: Digital TR Sensor.

CAUTION: Do not pry the connector. This will damage

the connector and result in a transmission concern.
(Continued)

2005 Aviator, 09/2004

307-01-9 Automatic Transmission — 5R55S 307-01-9
DIAGNOSIS AND TESTING (Continued)
PINPOINT TEST C: DIGITAL TRANSMISSION RANGE (TR) SENSOR (Continued)
Test Step Result / Action to Take
C7 CHECK PCM HARNESS CIRCUITS FOR OPENS (Continued)
• Measure the resistance between pin 2 harness side and signal
return pin 17 harness side.

• Measure the resistance between pin 22 and pin 4 harness side.

• Measure the resistance between pin 18 and pin 5 harness side.

(Continued)

2005 Aviator, 09/2004

307-01-10 Automatic Transmission — 5R55S 307-01-10
DIAGNOSIS AND TESTING (Continued)
PINPOINT TEST C: DIGITAL TRANSMISSION RANGE (TR) SENSOR (Continued)
Test Step Result / Action to Take
C7 CHECK PCM HARNESS CIRCUITS FOR OPENS (Continued)
• Measure the resistance between pin 10 and pin 6 harness side.

• Measure the resistance between pin 9 and pin 3 harness side.

Yes
GO to C8.
No
REPAIR the circuits. TEST the system for
• Are the resistances less than 5 ohms? normal operation.
C8 CHECK PCM HARNESS CIRCUITS FOR SHORT TO GROUND
OR POWER
• Measure the resistance between pin 17 and pin 10 harness side
and pin 12 harness side.

(Continued)

2005 Aviator, 09/2004

307-01-11 Automatic Transmission — 5R55S 307-01-11
DIAGNOSIS AND TESTING (Continued)
PINPOINT TEST C: DIGITAL TRANSMISSION RANGE (TR) SENSOR (Continued)
Test Step Result / Action to Take
C8 CHECK PCM HARNESS CIRCUITS FOR SHORT TO GROUND
OR POWER (Continued)
• Measure the resistance between pin 22 harness side and
ground; and pin 17 harness side and ground.

• Measure the resistance between pin 18 harness side and

ground; and pin 17 harness side and ground.

• Measure the resistance between pin 10 harness side and

ground; and pin 17 harness side and ground.

(Continued)

2005 Aviator, 09/2004

307-01-12 Automatic Transmission — 5R55S 307-01-12
DIAGNOSIS AND TESTING (Continued)
PINPOINT TEST C: DIGITAL TRANSMISSION RANGE (TR) SENSOR (Continued)
Test Step Result / Action to Take
C8 CHECK PCM HARNESS CIRCUITS FOR SHORT TO GROUND
OR POWER (Continued)
• Measure the resistance between pin 9 harness side and ground;
and pin 17 harness side and ground.

Yes
GO to C9.
No
REPAIR the circuits. TEST the system for
normal operation. CLEAR DTCs. RERUN
• Are the resistances greater than 10,000 ohms? OBD Tests.
C9 CHECK FOR SHORT BETWEEN TR/PCM INPUT SIGNAL
CIRCUITS
• Measure the resistance between pin 9 harness side and pins 22,
18 and 10 harness side.

• Measure the resistance between pin 22 harness side and pins 9,

18 and 10 harness side.

(Continued)

2005 Aviator, 09/2004

307-01-13 Automatic Transmission — 5R55S 307-01-13
DIAGNOSIS AND TESTING (Continued)
PINPOINT TEST C: DIGITAL TRANSMISSION RANGE (TR) SENSOR (Continued)
Test Step Result / Action to Take
C9 CHECK FOR SHORT BETWEEN TR/PCM INPUT SIGNAL
CIRCUITS (Continued)
• Measure the resistance between pin 18 harness side and pins
22, 9 and 10 harness side.

• Measure the resistance between pin 10 harness side and pins

22, 18 and 9 harness side.

Yes
INSTALL a new PCM. TEST the system
for normal operation.
No
REPAIR the circuit. TEST the system for
• Are the resistances greater than 10,000 ohms? normal operation.
C10 CHECK THE NON-PCM INTERNAL CIRCUITS OF SENSOR
• Connect: TRS-E Cable to Transmission. Yes
• Connect: TRS-E Cable to Digital TR Sensor. Concern is not in the digital TR sensor.
• Place the Digital TR Overlay onto Transmission Tester. For start system concerns, REFER to
• Carry out Switch Test as instructed on the Digital TR Overlay. Section 303-04 or Section 303-04. For
• Does the status lamp on the tester indicate RED for the backup lamp concerns, REFER to Section
correct gear position? 417-01.
No
INSTALL a new digital TR sensor and
ADJUST. REFER to Digital Transmission
Range (TR) Sensor in this section. CLEAR
DTCs and RERUN OBD Tests.

PINPOINT TEST D: PRESSURE CONTROL (PC) SOLENOIDS (PCA, PCB, PCC)

NOTE: Refer to the Transmission Vehicle Harness Connector illustration preceding these
pinpoint tests.
NOTE: Read and record all DTCs. All digital TR Sensor and VSS DTCs must be repaired
before entering Output State Control (OSC).
Test Step Result / Action to Take
D1 ELECTRONIC DIAGNOSTICS
• Key in OFF position.
• Select PARK.
(Continued)

2005 Aviator, 09/2004

307-01-14 Automatic Transmission — 5R55S 307-01-14
DIAGNOSIS AND TESTING (Continued)
PINPOINT TEST D: PRESSURE CONTROL (PC) SOLENOIDS (PCA, PCB, PCC) (Continued)
Test Step Result / Action to Take
D1 ELECTRONIC DIAGNOSTICS (Continued)
• Check to make sure the transmission harness connector is fully
seated, terminals are fully engaged in the connector and in good
condition before proceeding.
• Install 300 psi pressure gauges into Line and PC C tap.
• Connect the diagnostic tool.
• Key in ON position.
• Enter the following diagnostic mode on the diagnostic tool:
Diagnostic Data Link.
• Enter the following diagnostic mode on the diagnostic tool: PCM. Yes
• Enter the following diagnostic mode on the diagnostic tool: REMAIN in Trans-Bench Mode. GO to D2.
Active Command Modes. No
• Enter the following diagnostic mode on the diagnostic tool: REPEAT procedure to ENTER
Output State Control (OSC). Trans-Bench Mode. If vehicle did not enter
• Enter the following diagnostic mode on the diagnostic tool: OSC, REFER to Powertrain
Trans-Bench Mode. Control/Emissions Diagnosis (PC/ED)
• Does the vehicle enter the Trans-Bench Mode? manual for diagnosis of PCM or NGS.
D2 SOLENOID FUNCTIONAL TEST
• Monitor pressure gauges.
• Enter the following diagnostic mode on the diagnostic tool:
Parameter; PCx.
• NOTE: Make sure that the solenoids not being tested are off or
at zero.
Select PC A, PC B or PC C.
• Select value - 15, 30, 45, 60, 70 or 90 psi.
• Press ‘‘SEND’’.
• Select another value ‘‘0-90 psi’’.
• Press ‘‘SEND’’.
• Enter the following diagnostic mode on the diagnostic tool: XXX.
• Press ‘‘SEND’’.
• For PC A and PC B — Does the pressure reading for A or B
follow the commanded pressure, (actual A and B pressure Yes
will be higher than the commanded pressure)? For PC C — CLEAR DTCs.
Does the pressure reading match the commanded No
pressure? GO to D3.
D3 CHECK FOR BATTERY VOLTAGE
• Disconnect: Transmission Harness Connector.
• Visually inspect all wires and connectors for damage.
• Key in ON position.
• Measure the voltage between pin 3 harness side and ground.

Yes
GO to D4.
No
REPAIR the circuit. TEST the system for
• Is the voltage greater than 10 volts? normal operation.
(Continued)

2005 Aviator, 09/2004

307-01-15 Automatic Transmission — 5R55S 307-01-15
DIAGNOSIS AND TESTING (Continued)
PINPOINT TEST D: PRESSURE CONTROL (PC) SOLENOIDS (PCA, PCB, PCC) (Continued)
Test Step Result / Action to Take
D4 ELECTRICAL SIGNAL CHECK
• Leave the positive lead connected to pin 3 and connect the
negative lead to pins 1, 4 and 11 harness and ground.

• Activate solenoids (ON and OFF) while monitoring the voltage

reading.
• Enter the following diagnostic mode on the diagnostic tool:
Trans-Bench Mode.
• Enter the following diagnostic mode on the diagnostic tool:
Parameter; PCx.
• Select a value ‘‘0-90 psi’’.
• Press ‘‘SEND’’.
• Select another value ‘‘0-90 psi’’. Yes
• Press ‘‘SEND’’. GO to D5.
• Enter the following diagnostic mode on the diagnostic tool: XXX. No
• Press ‘‘SEND’’. CHECK for open or short circuit in
• Does the voltage and solenoid state change? harness or PCM.
D5 CHECK SOLENOID RESISTANCE AT SOLENOID
• Measure and record the resistance between PC solenoid pin 3
and pins 1, 4 and 11. Resistance should be between 3.3 and
7.5 ohms.

Yes
GO to D6.
No
• Is the resistance within specifications? INSTALL a new solenoid body assembly.
(Continued)

2005 Aviator, 09/2004

307-01-16 Automatic Transmission — 5R55S 307-01-16
DIAGNOSIS AND TESTING (Continued)
PINPOINT TEST D: PRESSURE CONTROL (PC) SOLENOIDS (PCA, PCB, PCC) (Continued)
Test Step Result / Action to Take
D6 CHECK SOLENOID FOR SHORT TO GROUND
• Measure and record the resistance between the PC solenoid
pins 1, 4, 11 and ground, solenoid side.

Yes
INSTALL a new solenoid body assembly.
TEST the system for normal operation.
No
REFER to Diagnosis By Symptom in this
section for diagnosis of pressure concerns.
• Is the resistance less than 10,000 ohms? TEST the system for normal operation.

PINPOINT TEST E: TURBINE SHAFT SPEED (TSS), INTERMEDIATE SHAFT SPEED, AND OUTPUT
SHAFT SPEED (OSS) SENSORS
NOTE: Refer to the turbine shaft speed (TSS), intermediate shaft speed and output shaft speed
(OSS) sensor connector illustrations preceding these pinpoint tests.
Test Step Result / Action to Take
E1 ELECTRONIC DIAGNOSTICS
• Check to make sure the transmission harness connectors are
fully seated, terminals are fully engaged in connector and in
good condition before proceeding.
• Connect the diagnostic tool.
• Key in ON position. Yes
• Enter the following diagnostic mode on the diagnostic tool: REMAIN in PID/Data. GO to E2.
Diagnostic Data Link. No
• Enter the following diagnostic mode on the diagnostic tool: PCM. REPEAT procedure to ENTER PID. If
• Select PID/Data Monitor and Record. vehicle did not enter PID, REFER to
• Select the following PIDs: TSS, Intermediate shaft speed sensor thePowertrain Control/Emissions Diagnosis
or OSS. (PC/ED) manual for diagnosis of PCM or
• Does vehicle enter PID/Data Monitor and Record? NGS.
E2 DRIVE CYCLE TEST
• While monitoring the appropriate sensor PID, drive the vehicle Yes
so that the transmission upshifts and downshifts through all GO to E3.
gears. No
• Does the TSS, Intermediate shaft speed sensor or OSS If the TSS, Intermediate shaft speed
Speed PID increase and decrease with engine and vehicle sensor or OSS Speed PID does not
speed? increase and decrease with engine and
vehicle speed, INSPECT for open or short
in vehicle harness, sensor, a PCM
concern or internal hardware concern. GO
to E4.
E3 DRIVE CYCLE TEST ERRATIC
• While monitoring the appropriate sensor PID, drive the vehicle Yes
so that the transmission upshifts and downshifts through all If the sensor signal is erratic, INSPECT for
gears. intermittent concern in the harness, sensor
• Is the TSS, Intermediate shaft speed sensor or OSS Speed or connector. GO to E4.
PID signal erratic (drop to zero or near zero and return to No
normal operation)? CLEAR all DTCs. RERUN OBD test.
E4 CHECK PCM HARNESS CIRCUITS FOR OPENS
• Key in OFF position.
• Disconnect: 150 Pin PTEC Module Connector ‘‘B’’.
(Continued)

2005 Aviator, 09/2004

307-01-17 Automatic Transmission — 5R55S 307-01-17
DIAGNOSIS AND TESTING (Continued)
PINPOINT TEST E: TURBINE SHAFT SPEED (TSS), INTERMEDIATE SHAFT SPEED, AND OUTPUT
SHAFT SPEED (OSS) SENSORS (Continued)
Test Step Result / Action to Take
E4 CHECK PCM HARNESS CIRCUITS FOR OPENS (Continued)
• For OSS, measure the resistance between pin 17 and the
appropriate sensor connector pin 2 harness side.

• For intermediate shaft speed sensor, measure the resistance

between pin 17 and the appropriate sensor connector pin 2
harness side.

• For TSS, measure the resistance between pin 17 and the

appropriate sensor connector pin 2 harness side.

(Continued)

2005 Aviator, 09/2004

307-01-18 Automatic Transmission — 5R55S 307-01-18
DIAGNOSIS AND TESTING (Continued)
PINPOINT TEST E: TURBINE SHAFT SPEED (TSS), INTERMEDIATE SHAFT SPEED, AND OUTPUT
SHAFT SPEED (OSS) SENSORS (Continued)
Test Step Result / Action to Take
E4 CHECK PCM HARNESS CIRCUITS FOR OPENS (Continued)
• For intermediate shaft speed sensor, measure the resistance
between pin 21 and the appropriate sensor connector pin 1
harness side.

• For TSS, measure the resistance between pin 27 and the

appropriate sensor connector pin 1 harness side.

• For OSS, measure the resistance between pin 26 and the

appropriate connector sensor pin 1 harness side.

Yes
GO to E5.
No
REPAIR the circuit. TEST the system for
• Are all resistances less than 5 ohms? normal operation.
(Continued)

2005 Aviator, 09/2004

307-01-19 Automatic Transmission — 5R55S 307-01-19
DIAGNOSIS AND TESTING (Continued)
PINPOINT TEST E: TURBINE SHAFT SPEED (TSS), INTERMEDIATE SHAFT SPEED, AND OUTPUT
SHAFT SPEED (OSS) SENSORS (Continued)
Test Step Result / Action to Take
E5 CHECK PCM HARNESS CIRCUITS FOR SHORT TO GROUND
• For OSS, measure the resistance between pin 26 and sensor
connector pin 1 harness side and ground.

• For intermediate shaft speed sensor, measure the resistance

between pin 21 and sensor connector pin 1 harness side and
ground.

• For TSS, measure the resistance between pin 27 and sensor

connector pin 1 harness side and ground.

Yes
GO to E6.
No
REPAIR the circuits. TEST the system for
normal operation. CLEAR DTCs. RERUN
• Are the resistances greater than 10,000 ohms? OBD Tests.
E6 CHECK RESISTANCE OF TSS, INTERMEDIATE SHAFT SPEED
SENSOR OR OSS SENSOR
• Disconnect the appropriate vehicle harness connector from the
TSS, intermediate shaft speed sensor or OSS sensor.
(Continued)

2005 Aviator, 09/2004

307-01-20 Automatic Transmission — 5R55S 307-01-20
DIAGNOSIS AND TESTING (Continued)
PINPOINT TEST E: TURBINE SHAFT SPEED (TSS), INTERMEDIATE SHAFT SPEED, AND OUTPUT
SHAFT SPEED (OSS) SENSORS (Continued)
Test Step Result / Action to Take
E6 CHECK RESISTANCE OF TSS, INTERMEDIATE SHAFT SPEED
SENSOR OR OSS SENSOR (Continued)
• Connect ohmmeter negative lead to one pin of the sensor and
the positive lead to the other pin on the sensor.

• Record the resistance. Resistance should be as follows:

Resistance (ohms) Temperature °C (°F)

266-390 -20° (4°)
325-485 21° (70°)
492-738 150° (302°) Yes
GO to E7.
• Is the resistance within specification for the appropriate No
sensor? INSTALL a new sensor.
E7 CHECK SENSORS FOR SHORT TO GROUND
• Measure the resistance between pin 1 and 2 of each sensor and
ground.

Yes
INSTALL a new sensor.
No
REFER to Diagnosis By Symptom in this
section for diagnosis of shift or torque
• Is the resistance less than 10,000 ohms? converter concerns.

2005 Aviator, 09/2004

307-01-21 Automatic Transmission — 5R55S 307-01-21
DIAGNOSIS AND TESTING (Continued)
PINPOINT TEST F: SOLENOID MECHANICAL FAILURE
NOTE: Repair all other DTCs before repairing the following DTCs: P1714, P1715, P1716,
P1717, P1740.
Test Step Result / Action to Take
F1 ELECTRONIC DIAGNOSIS
• Connect the diagnostic tool. Yes
• Select PARK. REPAIR the DTCs for TFT or shift
• Key in ON position. solenoids first. CLEAR DTCs and CARRY
• Carry out KOEO test until continuous DTCs have been OUT transmission drive cycle test. RERUN
displayed. Quick Test.
• If any of the following DTCs are present, continue with this test: No
P1714, P1715, P1716, P1717, P1740. INSTALL a new solenoid and/or body.
• Are other DTCs present for TFT or shift solenoids? REFER to Diagnostic Trouble Code Charts
in this section for code description. GO to
F2.
F2 TRANSMISSION DRIVE CYCLE TEST
• Carry out transmission drive cycle test; refer to Transmission Yes
Drive Cycle Test in this section. GO to F3.
• Does the vehicle upshift and downshift OK? No
REFER to Diagnosis By Symptom in this
section to diagnose shift concerns.
F3 RETRIEVE DTCs
• Connect the diagnostic tool. Yes
• Select PARK. INSTALL a new PCM. ROAD TEST and
• Key in ON position. RERUN Quick Test.
• Carry out KOEO test until continuous DTCs have been No
displayed. Testing completed. If a concern still exists,
• Are DTCs P1714, P1715, P1716, P1717 and P1740 still REFER to Diagnosis By Symptom in this
present? section for concern diagnosis.

2005 Aviator, 09/2004

307-01-1 Automatic Transmission — 5R55S 307-01-1

DIAGNOSIS AND TESTING

Special Testing Procedures
Special Tool(s)
Pressure Gauge, Transmission
Fluid
307-004 (T57L-77820-A)

Transmission Test Plate and

Gasket
307-433-01, 307-433-02,
307-433-03 Item Part Number Description
1 — Line pressure tap

1. Connect the pressure gauge to the line pressure

tap.
The special tests are designed to aid the technician 2. Start the engine and check the line pressures.
in diagnosing the hydraulic and mechanical portion Refer to the following Line Pressure Chart for
of the transmission. the correct specification.
Engine Idle Speed Check
Refer to the Powertrain Control/Emissions Diagnosis
(PC/ED) manual for diagnosis and testing of the
engine idle speed.
Line Pressure Test
CAUTION: Carry out Line Pressure Test
prior to carrying out Stall Speed Test. If line
pressure is low at stall, do not carry out the Stall
Speed Test or further transmission damage will
occur. Do not maintain wide open throttle in any
gear range for more than 5 seconds.
NOTE: Certain sensor failures may cause high PC,
FMEM (Failure Mode Effect Management) actions.
Be sure that self test and electrical repairs have
been carried out or test results may be incorrect.
NOTE: The line pressure tap is used to verify
output pressure from PC A or PC B by turning
either one off while verifying the output from the
other solenoid. The 2nd pressure tap is used to
verify the output from the PC C solenoid.
This test verifies that the line pressure is within
specifications.

Copyright  2004, Ford Motor Company

Last updated: 06/29/2004 2005 Aviator, 09/2004
307-01-2 Automatic Transmission — 5R55S 307-01-2
DIAGNOSIS AND TESTING (Continued)
Line Pressure Chart
Idle WOT Stall
Transmission Model/Application Range PC C Line PC C Line
4.6L R 621-827 kPa 621-827 kPa 772-924 kPa 1,944-2,620
(90-120 psi) (90-120 psi) (112-134 kPa
psi) (282-380
psi)
N 0-103 kPa 621-827 kPa
(0-15 psi) (90-120 psi)
(D) 3, 2, 1 0-103 kPa 522-758 kPa 0-103 kPa 1,572-1,813
(0-15 psi) (80-110 psi) (0-15 psi) kPa
(228-263
psi)

3. If the line pressure is not within specifications, 4. Connect the pressure gauge to the PC C
check the PC C pressure. pressure tap.
5. Start the engine and check the PC C pressure.
Refer to Line Pressure Diagnosis Chart for the
correct specification.
6. If the PC C pressure is not within specification,
GO to Pinpoint Test D to diagnose PC C
operation. If PC C operation is OK, refer to
Line Pressure Diagnosis Chart in this section
for line pressure concern causes.

Item Part Number Description

1 — Pressure control (PC C) tap

Line Pressure Diagnosis Chart

Test Results Possible Source
High at Idle — All Ranges • Wiring harnesses
• PC C boost valve
• PC C solenoid
• Main regulator valve
Low at Idle — All Ranges • Low fluid level
• Fluid inlet filter/seal
• Main control body
• Cross leaks
• Gaskets
• Pump
• Separator plate
Low — All Forward Ranges • Forward clutch
• Main control
• Overdrive servo
• Intermediate servo
Low in PARK Only • Valve body

2005 Aviator, 09/2004

307-01-3 Automatic Transmission — 5R55S 307-01-3
DIAGNOSIS AND TESTING (Continued)
Line Pressure Diagnosis Chart (Continued)
Test Results Possible Source
Low in REVERSE Only • Separator plate
• Reverse servo piston, cover seal
• Reverse clutch
• Overdrive servo
• Intermediate servo
• Valve body
• Forward clutch
Low in NEUTRAL Only • Valve body
• Overdrive servo
• Intermediate servo
Low in OVERDRIVE Only • Forward clutch
• Overdrive servo
• Intermediate servo
• Valve body
Low in DRIVE Only (O/D Cancelled) • Forward clutch
• Overdrive servo
• Intermediate servo
• Valve body
Low in 1st Position • Forward clutch
• Valve body
Low in 2nd Position • Intermediate servo
• Overdrive servo
• Forward clutch
Low in 3rd Position • Intermediate servo
• Overdrive servo
• Forward clutch

Stall Speed Test 2. CAUTION: After testing each of the

This test checks operation of the following items: following ranges (D), D, 3, 2, 1 and R, move
the transmission range selector lever to N
• Torque converter clutch
(NEUTRAL) and run the engine at 1,000
• Forward clutch rpm for about 15 seconds to allow the torque
• Low-one way clutch (OWC) assembly converter to cool before testing the next
range.
• Engine driveability concerns
• Overdrive one-way clutch assembly CAUTION: Do not maintain wide open
throttle in any range for more than 5
WARNING: Apply the parking brake seconds.
firmly while carrying out each Stall Speed Test.
CAUTION: If the engine rpm recorded
CAUTION: Always carry out the Line by the tachometer exceeds maximum
Pressure Test procedures prior to carrying out specified rpm, release the accelerator pedal
the Stall Speed Test. If line pressure is low at immediately. Clutch or band slippage is
stall, do not carry out the Stall Speed Test or indicated.
further transmission damage will occur.
NOTE: Prolonged use of this procedure may
NOTE: The Stall Speed Test should be carried out set Diagnostic Trouble Code P0712 or P1783.
with the engine and transmission at normal After carrying out Stall Speed Test, run OBD
operating temperatures. Test and clear DTCs from memory.
1. Connect tachometer to the engine. Press the accelerator pedal to floor (WOT) in
each range. Record rpm reached in each range.
Stall speeds should be as follows:

2005 Aviator, 09/2004

307-01-4 Automatic Transmission — 5R55S 307-01-4
DIAGNOSIS AND TESTING (Continued)
Stall Speed Chart
Vehicle Engine RPM
Aviator 4.6L 2,597-3,045

If stall speeds were too high, refer to the following

Stall Speed Diagnosis Chart. If stall speeds were too
low, first check the engine idle speed. If engine idle
is OK, remove torque converter and check the
torque converter one-way clutch for slippage.

Stall Speed Diagnosis Chart

Transmission Range Selector Lever Stall Speeds
Position Stall Speeds High Low
(D), D and 1 Overdrive one-way clutch, rear one-way clutch —
D, 2 and 1 Forward clutch, overdrive one-way clutch —
(D) Forward clutch, overdrive one-way clutch —
(D), D, 2, 1 and R General pressure concerns, forward clutch, Converter
overdrive one-way clutch one-way clutch
or engine
driveability
concerns
R Only High/reverse, high clutch, low and reverse —
band/servo
2 Only Intermediate band/servo —
1 Only Low/reverse band/servo —

Air Pressure Tests A no-drive or erratic shift condition may be due to

inoperative bands and clutches. To diagnose these
conditions a series of checks can be made by
substituting air pressure for fluid to determine the
location of the damaged or obstructed component.
Follow the procedure to determine the location of
the inoperative clutch or band by substituting air
pressure into the various test plate passages.
NOTE: Use only dry, regulated air pressure, 276
kPa (40 psi) maximum.
1. Remove the main control valve body. Refer to
Main Control Valve Body in this section
2. Install the transmission test plate and gasket.
Item Part Number Description Tighten bolts to 10 Nm (89 lb-in).
1 — Reverse servo 3. NOTE: Do not apply air to the test plate vent
2 — Intermediate servo hole.
3 — Overdrive servo Apply air to the appropriate clutch or servo port
4 — Coast clutch (refer to plate layout diagram). Refer to the Air
5 — Forward clutch Pressure Test Diagnostic Chart for conditions,
6 — Direct clutch possible causes and actions.
7 — Reverse servo modulator 4. After the testing is completed, remove the air
test plate and gasket and proceed with any
repairs that are needed.

2005 Aviator, 09/2004

307-01-5 Automatic Transmission — 5R55S 307-01-5
DIAGNOSIS AND TESTING (Continued)
5. After the repairs are completed, install the main
control valve body. Refer to Main Control
Valve Body in this section.
Air Pressure Test Diagnostic Chart
Condition Possible Causes Actions
Dull Thud Heard or Movement Felt Clutches, bands and fluid passages Concerns may not be in the
When Air is Applied and Released are OK. transmission. Check the powertrain
control module (PCM), wiring
harness and non-transmission related
components.
No Drive Clutches and bands inoperative. Disassemble the transmission, clean
and inspect to locate area of concern.
Erratic Shifts Clutches and bands inoperative due to Disassemble the transmission, clean
incorrect pressures. and inspect to locate area of concern.
No Dull Thud Heard Clutches, bands and fluid passages Disassemble the transmission, clean
may be damaged or obstructed. and inspect to locate area of concern.
No Movement Felt Clutches, bands and fluid passages Disassemble the transmission, clean
may be damaged or obstructed. and inspect to locate area of concern.
Hissing Sound Heard Clutch seals or check ball may be Disassemble the transmission, clean
damaged or leaking. and inspect to locate area of concern.
Servos Do Not Operate Seals and pistons may be damaged. Disassemble the transmission, clean
Supply and release ports may be and inspect to locate area of concern.
obstructed. Spring may be broken.
Multiple Clutches Are Applied Fluid passages in center support or Disassemble the transmission, clean
clutch cylinders may be obstructed. and inspect to locate area of concern.
Check fluid passages in the center
support for obstructions.

2005 Aviator, 09/2004

307-01-1 Automatic Transmission — 5R55S 307-01-1

DIAGNOSIS AND TESTING

Leakage Inspection 2. Start and run the engine. Shift the transmission
through all the gears several times to make sure
NOTE: An ultra violet light (164-R0756 or
the fluorescent dye has had enough time to
equivalent) must be used to detect the fluorescent
circulate. Observe the back of the engine
dye solution.
cylinder block and the top of the converter
1. Add UV Fluorescent Tracer dye (164-R3706 or housing part of the case for evidence of
equivalent specifically formulated for ATF) for leakage. Turn off the engine.
automatic transmission fluid. Use 1 ounce of
3. Position the vehicle on a hoist. For additional
dye solution for every 4 quarts of ATF
information, refer to Section 100-02.
capacity. Add any transmission fluid, designated
for the transaxle/transmission, to bring the unit 4. NOTE: The leak source will probably be above
to its correct fluid level. and/or forward of the actual leak indications
due to airflow and/or gravity.
Using an ultraviolet light, observe the
transmission. Follow the leak back to its source
point. Repair as required.
External Fluid Leaks
Leak Path Possible source
Leaks at the fluid pan-to-case • Pan bolts not tightened to specification.
• Case pan rail damaged.
• Pan gasket damaged.
Fluid cooler lines of fittings leaking • Cooler line(s), cooler line fitting(s) damaged.
• Cooler line fittings-to-case union damaged.
• Case damage at case fitting.
• Fittings not tightened to specifications.
Fluid cooler line nut-to-case fittings leaking • Damaged or missing O-ring seals.
• Fittings not tightened to specifications.
Leaks at the fluid cooler • Fluid cooler damage.
• Fitting(s) damaged or not tightened to specifications.
Leaks at the external sensors • Damaged or missing O-ring seals.
• Screw not tightened to specifications.
Leaks at the manual control lever seal • Damaged or missing lever seal.
Leaks at the solenoid body harness connector • Install a new solenoid body harness connector O-ring
seal. Either on the harness end or the solenoid body.
Fluid leakage in the torque converter area • For possible sources refer to Fluid Leakage In Torque
Converter Area Chart.

External Sealing • O-ring seals

CAUTION: Do not try to stop a fluid leak • Seal rings
by increasing the torque beyond specifications. • Seal grommets
This may cause damage to the transmission case
• Thread sealant
threads.
The transmission has the following parts to prevent
external fluid leakage:
• Gaskets
• Lip-type seals

Copyright  2004, Ford Motor Company

Last updated: 06/29/2004 2005 Aviator, 09/2004
307-01-2 Automatic Transmission — 5R55S 307-01-2
DIAGNOSIS AND TESTING (Continued)
External Sealing

Item Part Number Description Item Part Number Description

1 7902 Torque converter assembly 18 7060 Output shaft assembly
2 7902 Torque converter assembly 19 7086 Extension housing gasket
3 6730 Torque converter drain plug 20 7A039 Extension housing (4x2)
4 7A248 Front pump fluid seal 21 7052 Extension housing seal (4x2)
5 7D441 Front pump fluid seal 22 W500311-S1427 Extension housing-to-case
6 W704892-S1300 Screw and washer assembly screw
7 7G187 Cover assembly fluid pump 23 7A039 Extension housing (4x4)
8 7A136 Gasket front fluid pump 24 7052 Extension housing seal (4x4)
9 7D027 Overdrive servo cover 25 W500224-S1309 Extension housing-to-case
screw
10 W703119-S300 Overdrive servo cover seals
(2 required) 26 7005 Case
11 W702969-S300 Intermediate servo cover seal 27 7B498 Manual control lever seal
(1 required) 28 7C493 Manual control lever
12 7D027 Intermediate servo cover 29 3888307-S100 locking nut
13 390318-S2 Pipe plug 30 7C492 Band adjuster lock screw
14 W702981-S300 Speed sensor O-ring seal 31 W705928-S300 Solenoid body connector
15 7H103 Turbine shaft speed, O-ring seal
intermediate shaft speed and 32 7A191 Fluid pan gasket
output shaft speed sensors 33 7A194 Fluid pan
16 6026 Fluid fill access plug 34 W500213-S1309 Fluid pan screws
17 7034 Vent assembly (4x2) 35 7A010 Fluid fill drain tube
(Continued)
36 W704999-S309 Short hex plug

2005 Aviator, 09/2004

307-01-3 Automatic Transmission — 5R55S 307-01-3
DIAGNOSIS AND TESTING (Continued)
Fluid Leakage in Torque Converter Area Possible
Leak Path Symptom Source
In diagnosing and correcting fluid leaks in the front
pump support and gear and torque converter area, 1, 2 and 4 Leak at front of Pump lip seal
transmission
use the following procedures to locate the exact
cause of the leakage. Leakage at the front of the 1, 2 and 4 Leak at front of Vent
transmission, as evidenced by fluid around the transmission
torque converter housing, may have several sources. 1, 2 and 4 Leak at front of Converter hub
By careful observation it is possible, in many transmission weld
instances, to pinpoint the source of leak before 1, 2 and 4 Leak at front of External pump
removing the transmission from the vehicle. The transmission seal (large)
paths which the fluid takes to reach the bottom of 1, 2 and 4 Leak at front of Pump-to-case
the torque converter housing are shown in the transmission screws
illustration. 1, 2 and 4 Leak at front of Pump gasket
transmission
3 Leak at front of Torque
transmission converter seal
weld
3 Leak at front of Torque
transmission converter stud
5 Leak at front of Engine oil leak
transmission — rear main
seal
5 Leak at front of Engine valve
transmission cover
5 Leak at front of Oil galley
transmission
5 Leak at front of Engine oil
transmission pressure sensor

2005 Aviator, 09/2004

307-01-1 Automatic Transmission — 5R55S 307-01-1

DIAGNOSIS AND TESTING

Transmission Fluid Cooler Transmission Fluid Cooler Flow Test
NOTE: The following components should be
Special Tool(s) checked and should be within specification prior to
Adapter, Fluid Level and Fill carrying out this test:
Plug
307-437 • Engine idle; refer to the Powertrain
Control/Emissions Diagnosis (PC/ED) manual.
• Transmission fluid level; refer to Transmission
Fluid Level Check in this section.
• Line pressure; refer to Special Testing Procedures
in this section.
Material
Item Specification • Transmission fluid must be at normal operating
temperature, 66°C - 77°C (150°F - 170°F)
MERCON V Automatic MERCON V
Transmission Fluid 1. Place the transmission range selector lever into
XT-5-QM PARK.
CAUTION: Whenever a transmission has 2. Position the vehicle on a hoist. For additional
been disassembled to install new parts or a new information, refer to Section 100-02.
or remanufactured transmission has been 3. Prior to carrying out this test, check to see if
installed, a new transmission fluid coolers (either the vehicle is equipped with a transmission
in-tank, auxiliary or OTA) if equipped will need fluid in-line fluid filter. If the vehicle is
to be installed. Using a suitable torque equipped with a transmission fluid in-line fluid
converter/fluid cooler cleaner, clean and filter, it must be removed and discarded.
backflush the transmission fluid cooler tubes.
CAUTION: Use only clean automatic
transmission fluid specified for this transmission.
Do not use supplemental fluid additives,
treatments or cleaning agent. The use of these
materials may affect transmission operation and
result in internal damage to the transmission
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 fluid cooler. These contaminants are a
major cause of recurring transmission concerns and
must be removed from the system before the
transmission is put back in use.
When evidence of transmission fluid contamination
(i.e., metal particles, clutch plate material or band
material) is found in the cooling system, the
transmission fluid cooler flow test should be carried
out.
If the transmission cooling system fails the
transmission fluid cooler flow test install a new
transmission fluid cooler and flush out the fluid
cooler lines. If installing a new transmission fluid
cooler, use only factory approved components.

Copyright  2004, Ford Motor Company

Last updated: 06/29/2004 2005 Aviator, 09/2004
307-01-2 Automatic Transmission — 5R55S 307-01-2
DIAGNOSIS AND TESTING (Continued)
4. Using a 3/16 inch Allen key, hold the large 9. Start the engine and run it at idle.
drain plug with a wrench and remove the small 10. With the engine running, place the vehicle in
(center) fluid level indicating plug. PARK and position the vehicle on a hoist. For
additional information, refer to Section 100-02.
11. Once a steady flow of fluid (without air
bubbles) is observed, remove the hose from the
special tool and place the hose in a measuring
container for 15 seconds. After 15 seconds,
place the hose back onto the special tool.
Lower the vehicle and turn the engine off.
Measure the amount of fluid in the container. If
adequate flow is observed, approximately 208
ml (7 oz) will be in the measuring container.
The test is now complete. Reconnect the cooler
line and install the fluid fill plug.
5. Install the special tool into the pan. 12. If the flow is not adequate 208 ml (7 oz) in 15
seconds, disconnect the hose from the cooler
return line and connect the hose to the cooler
inlet (lower fitting) on the transmission case.
Reconnect the cooler return line to the case
(upper fitting) and continue with this
procedure.
13. Repeat Steps 10-11 to see if the flow is now
adequate.
• If the flow is now approximately 208 ml (7
oz) in 15 seconds, install a new transmission
fluid cooler and flush out the fluid cooler
tubes. Test is complete.
6. Remove the cooler return line (upper line) from • If the flow is still not adequate 208 ml (7 oz)
the fitting on the transmission case. in 15 seconds the pump and/or torque
converter may be at fault. Carry out the
following procedures and checks:
— Carry out the torque converter diagnosis.
Refer to Torque Converter Diagnosis in
this section.
— Carry out the main control valve body
procedure. Refer to Main Control Valve
Body in this section.
— Carry out the fluid pump procedure. Refer
to Fluid Pump in this section.
14. Once the procedure has been completed and
adequate flow has been established, a new
7. Connect one end of a clear hose to the cooler transmission in-line filter will need to be
return line and route the other end of the hose installed. For the filter installation procedure,
to the special tool in the pan. refer to Transmission Fluid In-Line Filter in
this section.
8. Lower the vehicle.

2005 Aviator, 09/2004

307-01-1 Automatic Transmission — 5R55S 307-01-1

DIAGNOSIS AND TESTING

Diagnosis By Symptom Special Tool(s)
Pressure Gauge, Transmission
Special Tool(s) Fluid
307-004 (T57L-77820-A)
Transmission Test Plate and
Gasket
307-433-01, 307-433-02,
307-433-03

UV Leak Detector
164-R0756 or equivalent
73 III Automotive Meter
105-R0057 or equivalent

The Diagnosis by Symptom Index gives the

technician diagnostic information, direction and
Trans Tester TR/MLP Overlay suggests possible components, using a symptom as a
and Manual starting point.
007-00131 or equivalent
Diagnosis by Symptom Index — Directions
1. Using the Symptom Index, select the
Concern/Symptom that best describes the
condition.
Worldwide Diagnostic System 2. Refer to the routine indicated in the Diagnosis
(WDS) by Symptom Index.
Vehicle Communication Module
(VCM) with appropriate 3. Always begin diagnosis of a symptom with:
adapters or equivalent diagnostic 1 Preliminary inspections.
tool
2 Verifications of condition.
3 Checking the fluid levels.
MLP-TR Cable
418-F107 (007-00111) or 4 Carrying out other test procedures as
equivalent directed.

Transmission Tester
307-F016 (007-00130) or
equivalent

(Continued)

Copyright  2004, Ford Motor Company

Last updated: 4/11/2005 2005 Aviator, 09/2004
307-01-2 Automatic Transmission — 5R55S 307-01-2
DIAGNOSIS AND TESTING (Continued)
4. NOTE: Not all concerns and conditions with 5. These components are listed in the removal
electrical components will set a diagnostic sequence and by most probable cause. All
trouble code (DTC). Be aware that the components listed must be inspected to make
components listed may still be the cause. sure of correct repair.
NOTE: When the battery is disconnected or a
new battery installed, certain transmission
operating parameters can be lost. The
powertrain control module (PCM) must relearn
these parameters. During this learning process,
you may experience slightly firm shifts,
delayed or early shifts. This operation is
considered normal and will not affect the
function of the transmission. Normal operation
will return once these parameters are stored by
the PCM.
Begin with the ROUTINE, if indicated. Follow
the reference or action statements. Always carry
out the On-Board Diagnostic Tests as necessary.
Never skip steps. Repair as necessary.

Diagnosis by Symptom Index

Diagnosis by Symptom Index

5R55S Routines
Engagement Concerns:
• No Forward in (D) Only 201A
• No Forward Only (All Positions) 201B
• No Reverse Only 202
• Harsh Reverse Only 203
• Harsh Forward Only 204A
• Harsh Manual 1st Gear Only 204B
• Delayed/Soft Reverse Only 205
• Delayed/Soft Forward Only 206
• No Forward and No Reverse 207
• Harsh Forward and Harsh Reverse 208
• Delayed Forward and Delayed Reverse 209
Shift Concerns:
• Some/All Shifts Missing (Automatic Mode Only) 210
• Timing Concern
— Early/Late (Some/All) 211
— Erratic/Hunting (Some/All) 212
• Feel Concerns
— Soft/Slipping (Some/All) 213
— Harsh (Some/All) 214
• No 1st Gear in Drive, Engages in a Higher Gear 215

2005 Aviator, 09/2004

307-01-3 Automatic Transmission — 5R55S 307-01-3
DIAGNOSIS AND TESTING (Continued)
Diagnosis by Symptom Index (Continued)
5R55S Routines
• No 1st Gear in Manual 1st 216
• No 2nd Gear In Manual 2 Position 217
Torque Converter Operation Concerns:
• Does Not Apply 240
• Always Applied/Stalls Vehicle 241
• Cycling/Shudder/Chatter 242
Other Concerns:
• Shift Lever Efforts High 251
• External Leaks 252
• Noise/Vibration — Forward or Reverse 254
• Engine Will Not Crank 255
• No Park Range 256
• Transmission Overheating 257
• No Engine Braking in Manual 2nd Position 258
• No Engine Braking in Manual 1st Position 259
• Fluid Venting or Foaming 261
• Vehicle Movement with Gear Selector in ‘‘N’’ 262
• Slips/Chatters in Manual 1st Gear 263
• Slips/Chatters in Manual 2nd Gear 264
• No Engine Braking in Manual 3rd Position 280
• No Engine Braking in Manual 4th (D) Position 281
• Slips/Chatters in Manual 3rd Gear 282
• Engine Braking in All Gears 283
• No 2nd and 5th Gears 284
• No 3rd, 4th and 5th Gears 285

Diagnostic Routines

Engagement Concern: No Forward in (D) Only

Possible Component Reference/Action
201A — ROUTINE
Powertrain Control System
• PCM, vehicle wiring harnesses, pressure control • Carry out On-Board Diagnostic Tests. Refer to the
solenoid B Powertrain Control/Emissions Diagnosis (PC/ED)
manual for diagnosis and testing of the PCM.
• GO to Pinpoint Test D.
• Repair as required. Clear DTCs, road test and rerun
On-Board Diagnostic Test.
Main Control
• Screw not tightened to specification • Tighten to specification.

2005 Aviator, 09/2004

307-01-4 Automatic Transmission — 5R55S 307-01-4
DIAGNOSIS AND TESTING (Continued)
Engagement Concern: No Forward in (D) Only (Continued)
Possible Component Reference/Action
• Separator plate damaged • Inspect for damage. If damaged, install a new
separator plate.
• Contamination • Disassemble and clean.
• Valves, springs damaged, misassembled, missing, • If damaged or parts are missing, install a new main
stuck or bore damaged control assembly. If misassembled, reassemble
correctly. DO NOT stone, file or sand valves. This
will remove the anodized finish and may result in
further main control or transmission damage.
• Filter damaged or missing • Inspect for damage. Repair as necessary.
Center Support
• Screw not tightened to specification • Tighten to specification.
• Seal rings or bearing damaged • Inspect for damage. Repair as necessary.
• Outside diameter of case bore damaged • Inspect for damage. Repair as necessary.
• Support damaged or leaking • Inspect for damage. Repair as necessary.
Forward Clutch Assembly
• Seals, piston damaged • Inspect for damage. Repair as necessary.
• Check ball damaged, missing, not seating, off location • Inspect for mislocation, poor seating, damage. Install
a new cylinder.
• Friction elements damaged or worn • Inspect for damage. Repair as necessary.
• Return springs damaged • Inspect for damage. Repair as necessary.
• Bronze seal ring on bearing damaged • Inspect for damage. Repair as necessary.
Forward Planetary Assembly
• Planetary damage • Inspect for damage. Repair as necessary.
Low One-Way Clutch
• Worn, damaged or assembled incorrectly • Inspect for damage. Repair as necessary.

Engagement Concern: No Forward

Possible Component Reference/Action
201B — ROUTINE
Powertrain Control System
• PCM, vehicle wiring harnesses, pressure control • Carry out On-Board Diagnostic Tests. Refer to the
solenoid B Powertrain Control/Emissions Diagnosis (PC/ED)
manual for diagnosis and testing of the PCM.
• GO to Pinpoint Test D.
• Repair as required. Clear DTCs, road test and rerun
On-Board Diagnostic Test.
Fluid
• Incorrect level • Adjust fluid to the correct level. Refer to
Transmission Fluid Level Check in this section.
• Condition • Carry out the Fluid Condition Check in this section.
Main Control
• Screw not tightened to specification • Tighten to specification.

2005 Aviator, 09/2004

307-01-5 Automatic Transmission — 5R55S 307-01-5
DIAGNOSIS AND TESTING (Continued)
Engagement Concern: No Forward (Continued)
Possible Component Reference/Action
• Separator plate damaged • Inspect for damage. If damaged, install a new
separator plate.
• Contamination • Disassemble and clean.
• Valves, springs damaged, misassembled, missing, • If damaged or parts are missing, install a new main
stuck or bore damaged control assembly. If misassembled, reassemble
correctly. DO NOT stone, file or sand valves. This
will remove the anodized finish and may result in
further main control or transmission damage.
• Filter damaged or missing • Inspect for damage. Repair as necessary.
Forward Clutch Assembly
• Seals, piston damaged • Inspect for damage. Repair as necessary.
• Check ball damaged, missing, not seating, off location • Inspect for mislocation, poor seating, damage. Install
a new cylinder.
• Friction elements damaged or worn • Inspect for damage. Repair as necessary.
• Return springs damaged • Inspect for damage. Repair as necessary.
• Bronze seal ring on bearing damaged • Inspect for damage. Repair as necessary.
OD Servo
• Servo retaining screws damaged • Inspect for damage. Repair as necessary.
• Seals (piston and cover) damaged • Inspect for damage. Repair as necessary.
OD Band
• Band damaged • Inspect for damage. Repair as necessary.
• Servo worn or damaged • Inspect for damage. Repair as necessary.
• Not adjusted correctly • Inspect for damage. Repair as necessary.
Case
• Damaged • Inspect for damage. Repair as necessary.

Engagement Concern: No Reverse

Possible Component Reference/Action
202 — ROUTINE
Powertrain Control System
• PCM, vehicle wiring harnesses, pressure control • Carry out On-Board Diagnostic Tests. Refer to the
solenoid C (PC C), shift solenoid B (SSB) Powertrain Control/Emissions Diagnosis (PC/ED)
manual for diagnosis and testing of the PCM.
• GO to Pinpoint Test A and GO to Pinpoint Test D.
• Repair as required. Clear DTCs, road test and rerun
On-Board Diagnostic Test.
Main Control
• Screws not tightened to specification • Tighten to specification.
• Separator plate damaged • Inspect for damage. If damaged, install a new
separator plate.
• Contamination • Disassemble and clean.

2005 Aviator, 09/2004

307-01-6 Automatic Transmission — 5R55S 307-01-6
DIAGNOSIS AND TESTING (Continued)
Engagement Concern: No Reverse (Continued)
Possible Component Reference/Action
• Valves, springs damaged, misassembled, missing, • If damaged or parts are missing, install a new main
stuck or bore damage control assembly. If misassembled, reassemble
correctly. DO NOT stone, file or sand valves. This
will remove the anodized finish and may result in
further main control or transmission damage.
• Filter damaged or missing • Inspect for damage. Repair as necessary.
Direct Clutch Assembly
• Seals, piston damaged • Inspect or damage. Repair as necessary.
• Check ball damaged, missing, not seating, off location • Inspect for mislocation, poor seating, damage. Install
a new cylinder.
• Friction elements damaged or worn • Inspect for damage. Repair as necessary.
• Return springs damaged • Inspect for damage. Repair as necessary.
Reverse Servo
• Servo retaining screws damaged • Inspect for damage. Repair as necessary.
• Seals (piston and cover) damaged • Inspect for damage. Repair as necessary.
Reverse Band
• Band damaged • Inspect for damage. Repair as necessary.
• Servo worn or damaged • Inspect for damage. Repair as necessary.
Reverse Drum Assembly
• One-way clutch damaged • Inspect for damage. Install a new drum assembly.
• Bearing damaged • Inspect for damage. Install a new drum assembly.
Torque Converter
• Internal component damage • Remove transmission. Inspect for damage. Refer to
Torque Converter in this section. If the torque
converter fails to pass the checks or is damaged,
install a new or remanufactured torque converter.

Engagement Concern: Harsh Reverse Only

Possible Component Reference/Action
203 — ROUTINE
Powertrain Control System
• PCM, vehicle wiring harnesses, pressure control • Carry out On-Board Diagnostic Tests. Refer to the
solenoid C (PC C) Powertrain Control/Emissions Diagnosis (PC/ED)
manual for diagnosis and testing of the PCM.
• GO to Pinpoint Test D.
• Repair as required. Clear DTCs, road test and rerun
On-Board Diagnostic Test.
Incorrect Pressures
• High pressures • Check pressure at line and PC C taps.
• Carry out Line Pressure Test, refer to procedure in
this section. Follow pressure diagnosis and repair as
required.
Main Control

2005 Aviator, 09/2004

307-01-7 Automatic Transmission — 5R55S 307-01-7
DIAGNOSIS AND TESTING (Continued)
Engagement Concern: Harsh Reverse Only (Continued)
Possible Component Reference/Action
• Screws not tightened to specification • Tighten to specification.
• Separator plate damaged • Inspect for damage. If damaged, install a new
separator plate.
• Contamination • Disassemble and clean.
• Valves, spring damaged, misassembled, missing, stuck • If damaged or parts are missing, install a new main
or bore damaged control assembly. If misassembled, reassemble
correctly. DO NOT stone, file or sand valves. This
will remove the anodized finish and may result in
further main control or transmission damage.
• Filter damaged or missing • Inspect for damage. Repair as necessary.
Direct Clutch Assembly
• Seals, piston damaged • Inspect for damage. Repair as necessary.
• Check ball damaged, missing not seating, off location • Inspect for mislocation, poor seating, damage. Install
a new cylinder.
• Friction elements damaged or worn • Inspect for damage. Repair as necessary.
• Return springs damaged • Inspect for damage. Repair as necessary.
Forward Clutch Assembly
• Seals, piston damaged • Inspect for damage. Repair as necessary.
• Check ball damaged, missing, not seating, off location • Inspect for mislocation, poor seating, damage. Install
a new cylinder.
• Friction elements damaged or worn • Inspect for damage. Repair as necessary.
• Return springs damaged • Inspect for damage. Repair as necessary.
• Bronze seal ring on bearing damaged • Inspect for damage. Repair as necessary.
Reverse Servo
• Servo retaining screws damaged • Inspect for damage. Repair as necessary.
• Seals (piston and cover) damaged • Inspect for damage. Repair as necessary.
Reverse Band
• Band damaged • Inspect for damage. Repair as necessary.
• Servo worn or damaged • Inspect for damage. Repair as necessary.
Reverse Drum Assembly
• One-way clutch damaged • Inspect for damage. Install a new drum assembly.
• Bearing damaged • Inspect for damage. Install a new drum assembly.

Engagement Concern: Harsh Forward Only

Possible Component Reference/Action
204A — ROUTINE
Powertrain Control System
• PCM, vehicle wiring harnesses, pressure control • Carry out On-Board Diagnostic Tests. Refer to the
solenoid A (PC A), pressure control solenoid C (PC Powertrain Control/Emissions Diagnosis (PC/ED)
C) manual for diagnosis and testing of the PCM.
• GO to Pinpoint Test D.

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307-01-8 Automatic Transmission — 5R55S 307-01-8
DIAGNOSIS AND TESTING (Continued)
Engagement Concern: Harsh Forward Only (Continued)
Possible Component Reference/Action
• Repair as required. Clear DTCs, road test and rerun
On-Board Diagnostic Test.
Incorrect Pressures
• High pressures • Check pressure at line and PC C taps.
• Carry out Line Pressure Test. Refer to Special Testing
Procedures in this section.
Main Control
• Screws not tightened to specification • Tighten to specification.
• Separator plate damaged • Inspect for damage. If damaged, install a new
separator plate.
• Contamination • Disassemble and clean.
• Valves, springs damaged, misassembled, missing, • If damaged or parts are missing, install a new main
stuck or bore damaged control assembly. If misassembled, reassemble
correctly. DO NOT stone, file or sand valves. This
will remove the anodized finish and may result in
further main control or transmission damage.
• Filter damaged or missing • Inspect for damage. Repair as necessary.
Center Support
• Screw not tightened to specification • Tighten to specification.
• Seal rings or bearing damaged • Inspect for damage. Repair as necessary.
• Outside diameter of case bore damaged • Inspect for damage. Repair as necessary.
• Support damaged or leaking • Inspect for damage. Repair as necessary.
Forward Clutch Assembly
• Seals, piston damaged • Inspect for damage. Repair as necessary.
• Check ball damaged, missing, not seating, off location • Inspect for mislocation, poor seating, damage. Install
a new cylinder.
• Friction elements damaged or worn • Inspect for damage. Repair as necessary.
• Return springs damaged • Inspect for damage. Repair as necessary.
• Bronze seal ring on bearing damaged • Inspect for damage. Repair as necessary.

Engagement Concern: Harsh Manual 1st Gear Only

Possible Component Reference/Action
204B — ROUTINE
Powertrain Control System
• PCM, vehicle wiring harnesses, pressure control • Carry out On-Board Diagnostic Tests. Refer to the
solenoid B (PC B), turbine shaft speed (TSS) sensor Powertrain Control/Emissions Diagnosis (PC/ED)
manual for diagnosis and testing of the PCM.
• GO to Pinpoint Test D and GO to Pinpoint Test E.
• Repair as necessary. Clear DTCs, road test and rerun
On-Board Diagnostic Test.

2005 Aviator, 09/2004

307-01-9 Automatic Transmission — 5R55S 307-01-9
DIAGNOSIS AND TESTING (Continued)
Engagement Concern: Delayed or Soft Reverse Only
Possible Component Reference/Action
205 — ROUTINE
Powertrain Control System
• PCM, vehicle wiring harnesses, pressure control • Carry out On-Board Diagnostic Tests. Refer to the
solenoid C (PC C) Powertrain Control/Emissions Diagnosis (PC/ED)
manual for diagnosis and testing of the PCM.
• GO to Pinpoint Test D.
• Repair as required. Clear DTCs, road test and rerun
On-Board Diagnostic Test.
Incorrect Pressures
• Low pressure • Check pressure at line and PC C taps.
• Carry out Line Pressure Test. Refer to Special Testing
Procedures in this section.
Main Control
• Screws not tightened to specification • Tighten to specification.
• Separator plate damaged • Inspect for damage. If damaged, install a new
separator plate.
• Contamination • Disassemble and clean.
• Valves, springs damaged, misassembled, missing, • If damaged or parts are missing, install a new main
stuck or bore damaged control assembly. If misassembled, reassemble
correctly. DO NOT stone, file or sand valves. This
will remove the anodized finish and may result in
further main control or transmission damage.
• Filter damaged or missing • Inspect for damage. Repair as necessary.
Direct Clutch Assembly
• Seals, piston damaged • Inspect for damage. Repair as necessary.
• Check ball damaged, missing not seating, off location • Inspect for mislocation, poor seating, damage. Install
a new cylinder.
• Friction elements damaged or worn • Inspect for damage. Repair as necessary.
• Return springs damaged • Inspect for damage. Repair as necessary.
Reverse Servo
• Servo retaining screws damaged • Inspect for damage. Repair as necessary.
• Seals (piston and cover) damaged • Inspect for damage. Repair as necessary.
Reverse Band
• Band damaged • Inspect for damage. Repair as necessary.
• Servo worn or damaged • Inspect for damage. Repair as necessary.

Engagement Concern: Delayed/Soft Forward Only

Possible Component Reference/Action
206 — ROUTINE
Powertrain Control System
• PCM, vehicle wiring harnesses, pressure control • Carry out On-Board Diagnostic Tests. Refer to the
solenoid B (PC B) Powertrain Control/Emissions Diagnosis (PC/ED)
manual for diagnosis and testing of the PCM.

2005 Aviator, 09/2004

307-01-10 Automatic Transmission — 5R55S 307-01-10
DIAGNOSIS AND TESTING (Continued)
Engagement Concern: Delayed/Soft Forward Only (Continued)
Possible Component Reference/Action
• GO to Pinpoint Test D.
• Repair as necessary. Clear DTCs, road test and rerun
On-Board Diagnostic Test.
Incorrect Pressures
• Low pressures • Check pressure at line and PC C taps.
• Carry out Line Pressure Test. Refer to Special Testing
Procedures in this section.
Main Control
• Screws not tightened to specification • Tighten to specification.
• Separator plate damaged • Inspect for damage. If damaged, install a new
separator plate.
• Contamination • Disassemble and clean.
• Valves, spring damaged, misassembled, missing, stuck • If damaged or parts are missing, install a new main
or bore damaged control assembly. If misassembled, reassemble
correctly. DO NOT stone, file or sand valves. This
will remove the anodized finish and may result in
further main control or transmission damage.
• Filter damaged or missing • Inspect for damage. Repair as necessary.
OD Servo
• Servo retaining screws damaged • Inspect for damage. Repair as necessary.
• Seals (piston and cover) damaged • Inspect for damage. Repair as necessary.
OD Band
• Band damaged. • Inspect for damage. Repair as necessary.
• Servo worn or damaged • Inspect for damage. Repair as necessary.
• Not adjusted correctly • Inspect for damage. Repair as necessary.
Center Support
• Screw not tightened to specification • Tighten to specification.
• Seal rings or bearing damaged • Inspect for damage. Repair as necessary.
• Outside diameter of case bore damage • Inspect for damage. Repair as necessary.
• Support damaged or leaking • Inspect for damage. Repair as necessary.
Forward Clutch Assembly
• Seals, piston damaged • Inspect for damage. Repair as necessary.
• Check ball damaged, missing, not seating, off location • Inspect for mislocation, poor seating, damage. Install
a new cylinder.
• Friction element damaged or worn • Inspect for damage. Repair as necessary.
• Return springs damaged • Inspect for damage. Repair as necessary.
• Bronze seal ring on bearing damaged • Inspect for damage. Repair as necessary.

Engagement Concern: No Forward and No Reverse

Possible Component Reference/Action
207 — ROUTINE
Powertrain Control System

2005 Aviator, 09/2004

307-01-11 Automatic Transmission — 5R55S 307-01-11
DIAGNOSIS AND TESTING (Continued)
Engagement Concern: No Forward and No Reverse (Continued)
Possible Component Reference/Action
• PCM, vehicle wiring harnesses, pressure control • Carry out On-Board Diagnostic Tests. Refer to the
solenoid B (PC B) Powertrain Control/Emissions Diagnosis (PC/ED)
manual for diagnosis and testing of the PCM.
• GO to Pinpoint Test D.
• Repair as required. Clear DTCs, road test and rerun
On-Board Diagnostic Test.
Fluid
• Incorrect level • Adjust to the correct level. Refer to Transmission
Fluid Level Check in this section.
• Condition • Carry out Fluid Condition Check. Refer to
Preliminary Inspection in this section.
Shift Cable/Digital TR Sensor
• Cable system or digital TR sensor damaged, • Inspect and repair as necessary. Refer to Transmission
misaligned Range (TR) Sensor Adjustment or Section 307-05.
Main Control
• Screws not tightened to specification • Tighten screws to specification.
• Separator plate damaged • Inspect for damage. If damaged, install a new
separator plate.
• Contamination • Disassemble and clean.
• Valve, springs damaged, misassembled, missing, stuck • If damaged or parts are missing, install new main
or bore damaged control assembly. If misassembled, reassemble
correctly. DO NOT stone, file or sand valves. This
will remove the anodized finish and may result in
further main control or transmission damage.
• Filter damaged or missing • Inspect for damage. Repair as necessary.
Input Shaft
• Damaged • Inspect for damage. Repair as necessary.
Fluid Pump Assembly
• Screws not tightened to specification • Tighten screws to specification.
• Gasket damaged • Inspect for damage. If damaged, install a new gasket.
• Porosity, cross leaks, ball missing, plugged hole • Inspect for damage. If damaged, repair as necessary.
• Pump gears cracked and/or seized • Inspect for damage. Install a new pump.
• Flow control valves, springs or seals damaged, stuck • Inspect for damage. Install a new seal or flow control
or not assembled correctly valve.
OD Planetary Assembly
• Planetary damaged • Inspect for damage. Repair as necessary.
Center Shaft Assembly
• Damaged. One-way clutch damaged • Inspect for damage. Repair as necessary.
Forward Clutch Assembly
• Seals, piston damaged • Inspect for damage. Repair as necessary.
• Check ball damaged, missing, not seating, off location • Inspect for mislocation, poor seating, damage. Install
a new cylinder.
• Friction elements damaged or worn • Inspect for damage. Repair as necessary.
• Return springs damaged • Inspect for damage. Repair as necessary.

2005 Aviator, 09/2004

307-01-12 Automatic Transmission — 5R55S 307-01-12
DIAGNOSIS AND TESTING (Continued)
Engagement Concern: No Forward and No Reverse (Continued)
Possible Component Reference/Action
• Bronze seal ring on bearing damaged • Inspect for damage. Repair as necessary.
Forward Planetary Assembly
• Planetary damaged • Inspect for damage. Repair as necessary.
Reverse Planetary Assembly
• Planetary damaged • Inspect for damage. Repair as necessary.
Output Shaft
• Damage • Inspect for damage. Repair as necessary.
Torque Converter
• Damaged flexplate or adapter plate • Inspect for damage. Remove transmission. Refer to
Torque Converter in this section. If the torque
converter fails to pass the checks or is damaged,
install a new or remanufactured torque converter.
• Damaged impeller hub
• Damaged turbine hub
Direct One-Way Clutch
• Worn, damaged or assembled incorrectly • Inspect for damage. Repair as necessary.

Engagement Concern: Harsh Forward and Harsh Reverse

Possible Component Reference/Action
208 — ROUTINE
Powertrain Control System
• PCM, vehicle wiring harnesses, digital TR sensor, • Carry out On-Board Diagnostic Tests. Refer to the
transmission fluid (TFT) sensor Powertrain Control/Emissions Diagnosis (PC/ED)
manual for diagnosis and testing of the PCM.
• GO to Pinpoint Test B and GO to Pinpoint Test C.
• Repair as necessary. Clear DTCs, road test and rerun
On-Board Diagnostic Test.
Fluid
• Incorrect level • Adjust to the correct level. Refer to Transmission
Fluid Level Check in this section.
• Condition • Carry out Fluid Condition Check. Refer to
Preliminary Inspection.
Incorrect Pressures
• High pressures • Check line pressure at line and PC C taps.
• Carry out Line Pressure Test. Refer to Special Testing
Procedures in this section. Follow pressure diagnosis
and repair as required.
Main Control
• Screws not tightened to specification • Tighten to specification.
• Separator plate damaged • Inspect for damage. If damaged, install a new
separator plate.
• Contamination • Disassemble and clean.

2005 Aviator, 09/2004

307-01-13 Automatic Transmission — 5R55S 307-01-13
DIAGNOSIS AND TESTING (Continued)
Engagement Concern: Harsh Forward and Harsh Reverse (Continued)
Possible Component Reference/Action
• Valves, springs damaged, misassembled, missing, • If damaged or parts are missing, install new main
stuck or bore damaged control assembly. If misassembled, reassemble
correctly. DO NOT stone, file or sand valves. This
will remove the anodized finish and may result in
further main control or transmission damage.
• Filter damaged or missing • Inspect for damage. Repair as necessary.
Forward Clutch Assembly
• Seals, piston damaged • Inspect for damage. Repair as necessary.
• Check ball damaged, missing, not seating, off location • Inspect for mislocation, poor seating, damage. Install
a new cylinder.
• Friction elements damaged or worn • Inspect for damage. Repair as necessary.
• Return springs damaged • Inspect for damage. Repair as necessary.
• Bronze seal ring on bearing damaged • Inspect for damage. Repair as necessary.

Engagement Concern: Delayed Forward and Delayed Reverse

Possible Component Reference/Action
209 — ROUTINE
Powertrain Control System
• PCM, vehicle wiring harnesses, transmission fluid • Carry out On-Board Diagnostic Tests. Refer to the
temperature (TFT) sensor Powertrain Control/Emissions Diagnosis (PC/ED)
manual for diagnosis and testing of the PCM.
• GO to Pinpoint Test B.
• Repair as necessary. Clear DTCs, road test and rerun
On-Board Diagnostic Test.
Fluid
• Incorrect level • Adjust to the correct level. Refer to Transmission
Fluid Level Check in this section.
• Condition • Carry out Fluid Condition Check. Refer to
Preliminary Inspection.
Incorrect Pressures
• High pressures • Check line pressure at line and PC C taps.
• Carry out Line Pressure Test. Refer to Special Testing
Procedures in this section. Follow pressure diagnosis
and repair as required.
Main Control
• Screws not tightened to specification • Tighten to specification.
• Separator plate damaged • Inspect for damage. If damaged, install a new
separator plate.
• Contamination • Disassemble and clean.
• Valves and springs damaged, misassembled, missing, • If damaged or parts are missing, install a new main
stuck or bore damaged control assembly. If misassembled, reassemble
correctly. DO NOT stone, file or sand valves. This
will remove the anodized finish and may result in
further main control or transmission damage.
• Filter damaged or missing • Inspect for damage. Repair as necessary.

2005 Aviator, 09/2004

307-01-14 Automatic Transmission — 5R55S 307-01-14
DIAGNOSIS AND TESTING (Continued)
Engagement Concern: Delayed Forward and Delayed Reverse (Continued)
Possible Component Reference/Action
Fluid Pump Assembly
• Screws not tightened to specification • Tighten screws to specification.
• Gasket damaged • Inspect for damage. If damaged, install a new gasket.
• Porosity, cross leaks, ball missing, plugged hole • Inspect for damage. If damaged, repair as necessary.
• Pump gears cracked and/or seized • Inspect for damage. Install a new pump.
• Flow control valves, springs or seals damaged, stuck • Inspect for damage. Install a new seal or flow control
or not assembled correctly valve.

Shift Concern: Some/All Shifts Missing (Automatic Mode Only)

Possible Component Reference/Action
210 — ROUTINE
Powertrain Control System
• PCM, vehicle wiring harnesses, shift solenoids A, B, • Carry out On-Board Diagnostic Tests. Refer to the
C, torque converter clutch (TCC) solenoid, pressure Powertrain Control/Emissions Diagnosis (PC/ED)
control solenoids A, B, C, output shaft speed (OSS) manual for diagnosis and testing of the PCM, IAT
sensor, digital TR sensor, IAT sensor, VSS input and VSS.
• GO to Pinpoint Test A, GO to Pinpoint Test C, GO
to Pinpoint Test D and GO to Pinpoint Test E.
• Repair as necessary. Clear DTCs, road test and rerun
On-Board Diagnostic Test.
Some Shifts Missing Only
• If only some shifts are missing, determine which
shift(s) is missing.
• Refer to the following routine(s) for further No Shift
concerns:
— No 1-2 Shift, Routine 220
— No 2-3 Shift, Routine 221
— No 3-4 Shift, Routine 222
— No 4-5 Shift, Routine 270
— No 5-4 Shift, Routine 271
— No 4-3 Shift, Routine 223
— No 3-2 Shift, Routine 224
— No 2-1 Shift, Routine 225
Fluid
• Incorrect level • Adjust fluid to correct level, refer to the in this
section.
• Condition • Carry out Fluid Condition Check. Refer to
Preliminary Inspection in this section.
Shift Cable/Digital TR Sensor
• Cable system or digital TR sensor damaged, • Inspect and repair as necessary. Refer to Section
misaligned 307-05.
Incorrect Pressures
• High/low pressures • Check pressure at line and PC C taps.
• Carry out Line Pressure Test. Refer to Special Testing
Procedures in this section.

2005 Aviator, 09/2004

307-01-15 Automatic Transmission — 5R55S 307-01-15
DIAGNOSIS AND TESTING (Continued)
Shift Concern: Some/All Shifts Missing (Automatic Mode Only) (Continued)
Possible Component Reference/Action
Main Control
• Screws not tightened to specification • Tighten to specification.
• Separator plate damaged • Inspect for damage. If damaged, install a new
separator plate.
• Contamination • Disassemble and clean.
• Valve, springs damaged, misassembled, missing, stuck • If damaged or parts are missing, install new main
or bore damaged control assembly. If misassembled, reassemble
correctly. DO NOT stone, file or sand valves. This
will remove the anodized finish and may result in
further main control or transmission damage.
• Filter damaged or missing • Inspect for damage. Repair as necessary.
Fluid Pump Assembly
• Screws not tightened to specification • Tighten screws to specification.
• Gasket damaged • Inspect for damage. If damaged, install a new gasket.
• Porosity, cross leaks, ball missing, plugged hole • Inspect for damage. If damaged, repair as necessary.
• Pump gears cracked and/or seized • Inspect for damage. Install a new pump.
• Flow control valves, springs or seals damaged, stuck • Inspect for damage. Install a new seal or flow control
or not assembled correctly valve.
OD Planetary Assembly
• Planetary damaged • Inspect for damage. Repair as necessary.
Center Support
• Screw not tightened to specification • Tighten to specification.
• Seal rings or bearing damaged • Inspect for damage. Repair as necessary.
• Outside diameter of case bore damaged • Inspect for damage. Repair as necessary.
• Support damaged or leaking • Inspect for damage. Repair as necessary.
Direct Clutch Assembly
• Seals, piston damaged • Inspect for damage. Repair as necessary.
• Check ball damaged, missing, not seating, off location • Inspect for mislocation, poor seating, damage. Install
a new cylinder.
• Friction elements damaged or worn • Inspect for damage. Repair as necessary.
• Return springs damaged • Inspect for damage. Repair as necessary.

Shift Concern: Timing Concerns—Early/Late

Possible Component Reference/Action
211— ROUTINE
Powertrain Control System
• PCM, vehicle wiring harnesses, output shaft speed • Carry out On-Board Diagnostic Tests. Refer to the
(OSS) sensor, IAT sensor Powertrain Control/Emissions Diagnosis (PC/ED)
manual for diagnosis and testing of the PCM and
IAT.
• GO to Pinpoint Test E.
• Repair as necessary. Clear DTCs, road test and rerun
On-Board Diagnostic Test.

2005 Aviator, 09/2004

307-01-16 Automatic Transmission — 5R55S 307-01-16
DIAGNOSIS AND TESTING (Continued)
Shift Concern: Timing Concerns—Early/Late (Continued)
Possible Component Reference/Action
Some Shifts Early/Late Only
• If only some shifts are early/late, determine which
shift(s) is missing.
• Refer to the following routine(s) for further No Shift
concerns:
— Soft/Slipping 1-2 Shift, Routine 226
— Soft/Slipping 2-3 Shift, Routine 227
— Soft/Slipping 3-4 Shift, Routine 228
— Soft/Slipping 4-5 Shift, Routine 272
— Soft/Slipping 5-4 Shift, Routine 273
— Soft/Slipping 4-3 Shift, Routine 229
— Soft/Slipping 3-2 Shift, Routine 230
— Soft/Slipping 2-1 Shift, Routine 221
Fluid
• Incorrect level • Adjust to the correct level. Refer to Transmission
Fluid Level Check in this section.
• Condition • Carry out Fluid Condition Check. Refer to
Preliminary Inspection in this section.
Main Control
• Screws not tightened to specification • Tighten to specification.
• Separator plate damaged • Inspect for damage. If damaged, install a new
separator plate.
• Contamination • Disassemble and clean.
• Valve, springs damaged, misassembled, missing, stuck • If damaged or parts are missing, install new main
or bore damaged control assembly. If misassembled, reassemble
correctly. DO NOT stone, file or sand valves. This
will remove the anodized finish and may result in
further main control or transmission damage.
• Filter damaged or missing • Inspect for damage. Repair as necessary.
OD Servo
• Servo retaining screws damaged • Inspect for damage. Repair as necessary.
• Seals (piston and cover) damaged • Inspect for damage. Repair as necessary.
OD Band
• Band damaged • Inspect for damage. Repair as necessary.
• Servo worn or damaged • Inspect for damage. Repair as necessary.
• Not adjusted correctly • Inspect for damage. Repair as necessary.

Shift Concern: Timing Concerns—Erratic/Hunting (Some/All)

Possible Component Reference/Action
212 — ROUTINE
Powertrain Control System
• PCM, vehicle wiring harnesses, output shaft speed • Carry out On-Board Diagnostic Tests. Refer to the
(OSS) sensor, IAT sensor Powertrain Control/Emissions Diagnosis (PC/ED)
manual for diagnosis and testing of the PCM and
IAT.

2005 Aviator, 09/2004

307-01-17 Automatic Transmission — 5R55S 307-01-17
DIAGNOSIS AND TESTING (Continued)
Shift Concern: Timing Concerns—Erratic/Hunting (Some/All) (Continued)
Possible Component Reference/Action
• GO to Pinpoint Test E.
• Repair as necessary. Clear DTCs, road test and rerun
On-Board Diagnostic Test.
Fluid
• Incorrect level • Adjust to the correct level. Refer to Transmission
Fluid Level Check in this section.
• Condition • Carry out Fluid Condition Check. Refer to
Preliminary Inspection in this section.
Main Control
• Screws not tightened to specification • Tighten to specification.
• Separator plate damaged • Inspect for damage. If damaged, install a new
separator plate.
• Contamination • Disassemble and clean.
• Valve, springs damaged, misassembled, missing, stuck • If damaged or parts are missing, install new main
or bore damaged control assembly. If misassembled, reassemble
correctly. DO NOT stone, file or sand valves. This
will remove the anodized finish and may result in
further main control or transmission damage.
• Filter damaged or missing • Inspect for damage. Repair as necessary.
OD Servo
• Servo retaining screws damaged • Inspect for damage. Repair as necessary.
• Seals (piston and cover) damaged • Inspect for damage. Repair as necessary.
Further Diagnosis
• For further diagnosis for timing issues, refer to • Refer to the following routine(s) for specific
Reference/Actions diagnosis:
• No 1-2 Shift, Routine 220
• No 2-3 Shift, Routine 221
• No 3-4 Shift, Routine 222
• No 4-5 Shift, Routine 270
• No 5-4 Shift, Routine 271
• No 4-3 Shift, Routine 223
• No 3-2 Shift, Routine 224
• No 2-1 Shift, Routine 225
• Soft/Slip 1-2 Shift, Routine 226
• Soft/Slip 2-3 Shift, Routine 227
• Soft/Slip 3-4 Shift, Routine 228
• Soft/Slip 4-5 Shift, Routine 272
• Soft/Slip 5-4 Shift, Routine 273
• Soft/Slip 4-3 Shift, Routine 229
• Soft/Slip 3-2 Shift, Routine 230
• Soft/Slip 2-1 Shift, Routine 231
• Harsh 1-2 Shift, Routine 232
• Harsh 2-3 Shift, Routine 233
• Harsh 3-4 Shift, Routine 234
• Harsh 4-5 Shift, Routine 274
• Harsh 5-4 Shift, Routine 275
• Harsh 4-3 Shift, Routine 235
• Harsh 3-2 Shift, Routine 236
• Harsh 2-1 Shift, Routine 237

2005 Aviator, 09/2004

307-01-18 Automatic Transmission — 5R55S 307-01-18
DIAGNOSIS AND TESTING (Continued)
Engagement Concern: Feel—Soft/Slipping (Some/All)
Possible Component Reference/Action
213 — ROUTINE
Powertrain Control System
• PCM, vehicle wiring harnesses, shift solenoids A, B, • Carry out On-Board Diagnostic Tests. Refer to the
C, pressure control solenoids A, B, C, D, intermediate Powertrain Control/Emissions Diagnosis (PC/ED)
shaft speed sensor, transmission fluid temperature manual for diagnosis and testing of the PCM, IAT
(TFT) sensor, IAT sensor, VSS input and VSS.
• GO to Pinpoint Test A, GO to Pinpoint Test B, GO
to Pinpoint Test D and GO to Pinpoint Test E.
• Repair as necessary. Clear DTCs, road test and rerun
On-Board Diagnostic Test.
Some Shifts Soft/Slipping Only
• If only some of the shifts are soft/slipping, determine
which shift(s) is missing.
• Refer to the following routine(s) for further
Soft/Slipping concerns:
— Soft/Slipping 1-2 Shift, Routine 226
— Soft/Slipping 2-3 Shift, Routine 227
— Soft/Slipping 3-4 Shift, Routine 228
— Soft/Slipping 4-5 Shift, Routine 272
— Soft/Slipping 5-4 Shift, Routine 273
— Soft/Slipping 4-3 Shift, Routine 229
— Soft/Slipping 3-2 Shift, Routine 230
— Soft/Slipping 2-1 Shift, Routine 231
Fluid
• Incorrect level • Adjust to the correct level. Refer to Transmission
Fluid Level Check in this section.
• Condition • Carry out Fluid Condition Check. Refer to
Preliminary Inspection in this section.
Incorrect Pressures
• High/low pressures • Check pressure at line and PC C taps.
• Carry out Line Pressure Test. Refer to Special Testing
Procedures in this section.
Main Control
• Screws not tightened to specification • Tighten to specification.
• Separator plate damaged • Inspect for damage. If damaged, install a new
separator plate.
• Contamination • Disassemble and clean.
• Valves, springs damaged, misassembled, missing, • If damaged or parts are missing, install new main
stuck or bore damaged control assembly. If misassembled, reassemble
correctly. DO NOT stone, file or sand valves. This
will remove the anodized finish and may result in
further main control or transmission damage.
• Filter damaged or missing • Inspect for damage. Repair as necessary.
Fluid Pump Assembly
• Screws not tightened to specification • Tighten screws to specification.
• Gasket damaged • Inspect for damage. If damaged, install a new gasket.
• Porosity, cross leaks, ball missing, plugged hole • Inspect for damage. If damaged, repair as necessary.

2005 Aviator, 09/2004

307-01-19 Automatic Transmission — 5R55S 307-01-19
DIAGNOSIS AND TESTING (Continued)
Engagement Concern: Feel—Soft/Slipping (Some/All) (Continued)
Possible Component Reference/Action
• Pump gears cracked and/or seized • Inspect for damage. Install a new pump.
• Flow control valves, springs or seals damaged, stuck • Inspect for damage. Install a new seal or flow control
or not assembled correctly valve.
Coast Clutch Assembly
• Seals, piston damaged • Inspect for damage. Repair as necessary.
• Check ball damaged, missing, not seating, off location • Inspect for mislocation, poor seating, damage. Install
a new cylinder.
• Friction elements damaged or worn • Inspect for damage. Repair as necessary.
• Return springs damaged • Inspect for damage. Repair as necessary.
Center Support
• Screw not tightened to specification • Tighten to specification.
• Seal rings or bearings damaged • Inspect for damage. Repair as necessary.
• Outside diameter of case bore damage • Inspect for damage. Repair as necessary.
• Support damaged or leaking • Inspect for damage. Repair as necessary.
Intermediate Servo
• Servo retaining screws damaged • Inspect for damage. Repair as necessary.
• Seals (piston and cover) damaged • Inspect for damage. Repair as necessary.
Intermediate Band
• Band damaged • Inspect for damage. Repair as necessary.
• Servo worn or damaged • Inspect for damage. Repair as necessary.
• Not adjusted correctly • Inspect for damage. Repair as necessary.
Direct Clutch Assembly
• Seals, piston damaged • Inspect for damage. Repair as necessary.
• Check ball damaged, missing, not seating, off location • Inspect for mislocation, poor seating, damage. Install
a new cylinder.
• Friction elements damaged or worn • Inspect for damage. Repair as necessary.
• Return springs damaged • Inspect for damage. Repair as necessary.
Forward Clutch Assembly
• Seals, piston damaged • Inspect for damage. Repair as necessary.
• Check ball damaged, missing, not seating, off location • Inspect for mislocation, poor seating, damage. Install
a new cylinder.
• Friction elements damaged or worn • Inspect for damage. Repair as necessary.
• Return springs damaged • Inspect for damage. Repair as necessary.
• Bronze seal ring on bearing damaged • Inspect for damage. Repair as necessary.
Reverse Servo
• Servo retaining screws damaged • Inspect for damage. Repair as necessary.
• Seals (piston and cover) damaged • Inspect for damage. Repair as necessary.
Reverse Band
• Band damaged • Inspect for damage. Repair as necessary.
• Servo worn or damaged • Inspect for damage. Repair as necessary.
• Not adjusted correctly • Inspect for damage. Repair as necessary.

2005 Aviator, 09/2004

307-01-20 Automatic Transmission — 5R55S 307-01-20
DIAGNOSIS AND TESTING (Continued)
Engagement Concern: Feel—Soft/Slipping (Some/All) (Continued)
Possible Component Reference/Action
Case
• Damaged • Inspect for damage. Repair as necessary.
Torque Converter
• Internal component damage • Remove transmission. Inspect for damage. Refer to
Torque Converter in this section. If the torque
converter fails to pass the criteria or is damaged,
install a new or remanufactured torque converter.

Shift Concern: Feel—Harsh (Some/All)

Possible Component Reference/Action
214— ROUTINE
Powertrain Control System
• PCM, vehicle wiring harnesses, shift solenoids A, B, • Carry out On-Board Diagnostic Tests. Refer to the
C, pressure control solenoids A, B, C, D, intermediate Powertrain Control/Emissions Diagnosis (PC/ED)
shaft speed sensor, digital TR sensor, transmission manual for diagnosis and testing of the PCM, IAT
fluid temperature (TFT) sensor, IAT sensor, VSS and VSS.
input
• GO to Pinpoint Test A, GO to Pinpoint Test B, GO
to Pinpoint Test D and GO to Pinpoint Test E.
• Repair as necessary. Clear DTCs, road test and rerun
On-Board Diagnostic Test.
Some Shifts Harsh Only
• If only some of the shifts are harsh, determine which
shift(s) is missing.
• Refer to the following routine(s) for further No Shift
concerns:
— Harsh 1-2 Shift, Routine 232
— Harsh 2-3 Shift, Routine 233
— Harsh 3-4 Shift, Routine 234
— Harsh 4-5 Shift, Routine 274
— Harsh 5-4 Shift, Routine 275
— Harsh 4-3 Shift, Routine 235
— Harsh 3-2 Shift, Routine 236
— Harsh 2-1 Shift, Routine 237
Fluid
• Incorrect level • Adjust to the correct level. Refer to Transmission
Fluid Level Check in this section.
Incorrect Pressures
• High/low pressures • Check pressure at line and PC C taps.
• Carry out Line Pressure Test. Refer to Special Testing
Procedures in this section. Follow pressure diagnosis
and repair as required.
Main Control
• Screws not tightened to specification • Tighten to specification.
• Separator plate damaged • Inspect for damage. If damaged, install a new
separator plate.

2005 Aviator, 09/2004

307-01-21 Automatic Transmission — 5R55S 307-01-21
DIAGNOSIS AND TESTING (Continued)
Shift Concern: Feel—Harsh (Some/All) (Continued)
Possible Component Reference/Action
• Contamination • Disassemble and clean.
• Valves, springs damaged, misassembled, missing, • If damaged or parts are missing, install new main
stuck or bore damaged control assembly. If misassembled, reassemble
correctly. DO NOT stone, file or sand valves. This
will remove the anodized finish and may result in
further main control or transmission damage.
• Filter damaged or missing • Inspect for damage. Repair as necessary.
Input Shaft
• Damaged • Inspect for damage. Install new as necessary.
OD Servo
• Servo retaining screws damaged • Inspect for damage. Repair as necessary.
• Seals (piston and cover) damaged • Inspect for damage. Repair as necessary.
OD Band
• Band damaged • Inspect for damage. Repair as necessary.
• Servo worn or damaged • Inspect for damage. Repair as necessary.
• Not adjusted correctly • Inspect for damage. Repair as necessary.
Center Shaft Assembly
• Center shaft assembly damaged • Inspect for damage. Repair as necessary.
• One-way clutch damaged • Inspect for damage. Repair as necessary.
Center Support
• Screw not tightened to specification • Tighten to specification.
Intermediate Servo
• Servo retaining screws damaged • Inspect for damage. Repair as necessary.
• Seals (piston and cover) damaged • Inspect for damage. Repair as necessary.
Intermediate Band
• Band damaged • Inspect for damage. Repair as necessary.
• Servo worn or damaged • Inspect for damage. Repair as necessary.
• Not adjusted correctly • Inspect for damage. Repair as necessary.
Forward Clutch Assembly
• Seals, piston damaged • Inspect for damage. Repair as necessary.
• Check ball damaged, missing, not seating, off location • Inspect for mislocation, poor seating, damage. Install
a new cylinder.
• Friction elements damaged or worn • Inspect for damage. Repair as necessary.
• Return springs damaged • Inspect for damage. Repair as necessary.
• Bronze seal ring on bearing damaged • Inspect for damage. Repair as necessary.
Reverse Servo
• Servo retaining screws damaged • Inspect for damage. Repair as necessary.
• Seals (piston and cover) damaged • Inspect for damage. Repair as necessary.
Reverse Band
• Band damaged • Inspect for damage. Repair as necessary.
• Servo worn or damaged • Inspect for damage. Repair as necessary.

2005 Aviator, 09/2004

307-01-22 Automatic Transmission — 5R55S 307-01-22
DIAGNOSIS AND TESTING (Continued)
Shift Concern: Feel—Harsh (Some/All) (Continued)
Possible Component Reference/Action
• Not adjusted correctly • Inspect for damage. Repair as necessary.
Output Shaft
• Damaged • Inspect for damage. Install new as necessary.
Case
• Damaged • Inspect for damage. Repair as necessary.

Shift Concern: No 1st Gear in Drive, Engages in a Higher Gear

Possible Component Reference/Action
215 — ROUTINE
Powertrain Control System
• PCM, vehicle wiring harnesses, shift solenoids A, B, • Carry out On-Board Diagnostic Tests. Refer to the
C, digital TR sensor Powertrain Control/Emissions Diagnosis (PC/ED)
manual for diagnosis and testing of the PCM.
• GO to Pinpoint Test A and GO to Pinpoint Test C.
• Repair as necessary. Clear DTCs, road test and rerun
On-Board Diagnostic Test.
Incorrect Pressures
• High/low pressures • Check which pressures are on at line and PC C taps.
• Refer to the Band/Clutch Chart in this section to
determine which gears are on. Follow the diagnostic
routines to repair the missing gears.
Main Control
• Screws not tightened to specification • Tighten to specification.
• Separator plate damaged • Inspect for damage. If damaged, install a new
separator plate.
• Contamination • Disassemble and clean.
• Valves/springs damaged, misassembled, missing, stuck • If damaged or parts are missing, install new main
or bore damaged control assembly. If misassembled, reassemble
correctly. DO NOT stone, file or sand valves. This
will remove the anodized finish and may result in
further main control or transmission damage.
• Filter damaged or missing • Inspect for damage. Repair as necessary.
OD Servo
• Servo retaining screws damaged • Inspect for damage. Repair as necessary.
• Seals (piston and cover) damaged • Inspect for damage. Repair as necessary.
Direct One-Way Clutch
• Worn, damaged or assembled incorrectly • Inspect for damage. Repair as necessary.
Low One-Way Clutch
• Worn, damaged or assembled incorrectly • Inspect for damage. Repair as necessary.

2005 Aviator, 09/2004

307-01-23 Automatic Transmission — 5R55S 307-01-23
DIAGNOSIS AND TESTING (Continued)
Engagement Concern: No 1st Gear in Manual 1 Position
Possible Component Reference/Action
216 — ROUTINE
Powertrain Control System
• PCM, vehicle wiring harnesses, shift solenoids A, B, • Carry out On-Board Diagnostic Tests. Refer to the
pressure control solenoids B, C Powertrain Control/Emissions Diagnosis (PC/ED)
manual for diagnosis and testing of the PCM.
• GO to Pinpoint Test A and GO to Pinpoint Test D.
• Repair as necessary. Clear DTCs, road test and rerun
On-Board Diagnostic Test.
Incorrect Pressures
• High/low pressures • Carry out Line Pressure Test. Refer to Special Testing
Procedures in this section.
Main Control
• Screws not tightened to specification • Tighten to specification.
• Separator plate damaged • Inspect for damage. If damaged, install a new
separator plate.
• Contamination • Disassemble and clean.
• Valves, springs damaged, misassembled, missing, • If damaged or parts are missing, install new main
stuck or bore damaged control assembly. If misassembled, reassemble
correctly. DO NOT stone, file or sand valves. This
will remove the anodized finish and may result in
further main control or transmission damage.
• Filter damaged or missing • Inspect for damage. Repair as necessary.
OD Planetary Assembly
• Planetary damaged • Inspect for damage. Repair as necessary.
Direct One-Way Clutch
• Worn, damaged or assembled incorrectly • Inspect for damage. Repair as necessary.
Low One-Way Clutch
• Worn, damaged or assembled incorrectly • Inspect for damage. Repair as necessary.

Shift Concern: No 2nd Gear in Manual 2 Position

Possible Component Reference/Action
217 — ROUTINE
Powertrain Control System
• PCM, vehicle wiring harnesses, shift solenoids A, B, • Carry out On-Board Diagnostic Tests. Refer to the
C, pressure control solenoid B Powertrain Control/Emissions Diagnosis (PC/ED)
manual for diagnosis and testing of the PCM.
• GO to Pinpoint Test A and GO to Pinpoint Test D.
• Repair as necessary. Clear DTCs, road test and rerun
On-Board Diagnostic Test.
Incorrect Pressures
• High/low pressures • Check pressure at line and PC C taps.
• Carry out Line Pressure Test. Refer to Special Testing
Procedures in this section.

2005 Aviator, 09/2004

307-01-24 Automatic Transmission — 5R55S 307-01-24
DIAGNOSIS AND TESTING (Continued)
Shift Concern: No 2nd Gear in Manual 2 Position (Continued)
Possible Component Reference/Action
Main Control
• Screws not tightened to specification. • Tighten to specification.
• Separator plate damaged • Inspect for damage. If damaged, install a new
separator plate.
• Contamination • Disassemble and clean.
• Valves, springs damaged, misassembled, missing, • If damaged or parts are missing, install a new main
stuck or bore damaged control assembly. If misassembled, reassemble
correctly. DO NOT stone, file or sand valves. This
will remove the anodized finish and may result in
further main control or transmission damage.
• Filter damaged or missing • Inspect for damage. Repair as necessary.
OD Servo
• Servo retaining screws damaged • Inspect for damage. Repair as necessary.
• Seals (piston and cover) damaged • Inspect for damage. Repair as necessary.
• Not adjusted correctly • Inspect for damage. Repair as necessary.
OD Band
• Band damaged • Inspect for damage. Repair as necessary.
• Servo worn or damaged • Inspect for damage. Repair as necessary.
• Not adjusted correctly • Inspect for damage. Repair as necessary.
Direct One-Way Clutch
• Worn, damaged or assembled incorrectly • Inspect for damage. Repair as necessary.
Low One-Way Clutch
• Worn, damaged or assembled incorrectly • Inspect for damage. Repair as necessary.

Torque Converter Operation Concerns: Does Not Apply

Possible Component Reference/Action
240 — ROUTINE
Powertrain Control System
• PCM, vehicle wiring harnesses, torque converter • Carry out On-Board Diagnostic Tests. Refer to the
clutch (TCC) solenoid, transmission fluid temperature Powertrain Control/Emissions Diagnosis (PC/ED)
(TFT) sensor and engine coolant temperature (ECT) manual for diagnosis and testing of the PCM.
sensor
• GO to Pinpoint Test A and GO to Pinpoint Test B.
• Repair as necessary. Clear DTCs, road test and rerun
On-Board Diagnostic Test.
Incorrect Pressures
• High/low pressures • Check pressure at line and PC C taps.
• Carry out Line Pressure Test. Refer to Special Testing
Procedures in this section.
Main Control
• Screws not tightened to specification • Tighten to specification.
• Separator plate damaged • Inspect for damage. If damaged, install a new
separator plate.

2005 Aviator, 09/2004

307-01-25 Automatic Transmission — 5R55S 307-01-25
DIAGNOSIS AND TESTING (Continued)
Torque Converter Operation Concerns: Does Not Apply (Continued)
Possible Component Reference/Action
• Contamination • Disassemble and clean.
• Valve, springs damaged, misassembled, missing, stuck • If damaged or parts are missing, install new main
or bore damaged control assembly. If misassembled, reassemble
correctly. DO NOT stone, file or sand valves. This
will remove the anodized finish and may result in
further main control or transmission damage.
• Filter damaged or missing • Inspect for damage. Repair as necessary.
Fluid Pump Assembly
• Screws not tightened to specification • Tighten screws to specification.
• Gasket damaged • Inspect for damage. If damaged, install a new gasket.
• Porosity, cross leaks, ball missing, plugged hole • Inspect for damage. If damaged, repair as necessary.
• Pump gears cracked and/or seized • Inspect for damage. Install a new pump.
• Flow control valves, springs or seals damaged, stuck • Inspect for damage. Install a new seal or flow control
or not assembled correctly valve.
Torque Converter Assembly
• Torque Converter internal failure preventing • Remove transmission. Inspect for damage. Refer to
engagement, piston application Torque Converter in this section. If the torque
converter fails to pass the criteria or is damaged,
install a new or remanufactured torque converter.

Torque Converter Operation Concern: Always Applied/Stalls Vehicle

Possible Component Reference/Action
241 — ROUTINE
Powertrain Control System
• PCM, vehicle wiring harnesses, torque converter • Carry out On-Board Diagnostic Tests. Refer to the
clutch (TCC) solenoid Powertrain Control/Emissions Diagnosis (PC/ED)
manual for diagnosis and testing of the PCM.
• GO to Pinpoint Test A.
• Repair as necessary. Clear DTCs, road test and rerun
On-Board Diagnostic Test.
Main Control
• Screws not tightened to specification • Tighten to specification.
• Separator plate damaged • Inspect for damage. If damaged, install a new
separator plate.
• Contamination • Disassemble and clean.
• Valve, springs damaged, misassembled, missing, stuck • If damaged or parts are missing, install new main
or bore damaged control assembly. If misassembled, reassemble
correctly. DO NOT stone, file or sand valves. This
will remove the anodized finish and may result in
further main control or transmission damage.
• Filter damaged or missing • Inspect for damage. Repair as necessary.
Low One-Way Clutch
• Worn, damaged or assembled incorrectly • Inspect for damage. Repair as necessary.

2005 Aviator, 09/2004

307-01-26 Automatic Transmission — 5R55S 307-01-26
DIAGNOSIS AND TESTING (Continued)
Torque Converter Operation Concern: Always Applied/Stalls Vehicle (Continued)
Possible Component Reference/Action
Torque Converter Assembly
• Torque Converter internal failure preventing • Remove transmission. Inspect for damage. Refer to
engagement, piston release Torque Converter in this section. If the torque
converter fails to pass the criteria or is damaged,
install a new or remanufactured torque converter.

Torque Converter Operation Concern: Cycling/Shudder/Chatter

Possible Component Reference/Action
242 — ROUTINE
Powertrain Control System
• PCM, vehicle wiring harnesses, torque converter • Carry out On-Board Diagnostic Tests. Refer to the
clutch (TCC) solenoid Powertrain Control/Emissions Diagnosis (PC/ED)
manual for diagnosis and testing of the PCM.
• GO to Pinpoint Test A.
• Repair as necessary. Clear DTCs, road test and rerun
On-Board Diagnostic Test.
Fluid
• Condition—contaminated, degraded • Carry out Fluid Condition Check. Refer to
Preliminary Inspection in this section. If
contaminated, locate source of contamination. If
burnt, inspect mechanical bands, clutches. Repair as
necessary. Change fluid. Carry out drain and refill
procedure. Refer to Transmission Fluid Drain and
Refill — Without Torque Converter Drain Plug in
this section. Carry out fluid cooler and torque
converter cleaning procedure. Refer to Transmission
Fluid Cooler — Backflushing and Cleaning in this
section.
Main Control
• Screws not tightened to specification • Tighten to specification.
• Separator plate damaged • Inspect for damage. If damaged, install a new
separator plate.
• Contamination • Disassemble and clean.
• Valve, springs damaged, misassembled, missing, stuck • If damaged or parts are missing, install new main
or bore damaged control assembly. If misassembled, reassemble
correctly. DO NOT stone, file or sand valves. This
will remove the anodized finish and may result in
further main control or transmission damage.
• Filter damaged or missing • Inspect for damage. Repair as necessary.
Torque Converter Assembly
• Torque converter internal leakage, clutch material • Remove transmission. Inspect for damage. Refer to
damaged Torque Converterin this section. If torque converter
fails to pass the criteria or is damaged, install a new
or remanufactured converter.

2005 Aviator, 09/2004

307-01-27 Automatic Transmission — 5R55S 307-01-27
DIAGNOSIS AND TESTING (Continued)
Other Concerns: Shift Lever Efforts High
Possible Component Reference/Action
251 — ROUTINE
Powertrain Control System
• PCM, vehicle wiring harnesses, digital TR sensor • Carry out On-Board Diagnostic Tests. Refer to the
Powertrain Control/Emissions Diagnosis (PC/ED)
manual for diagnosis and testing of the PCM.
• GO to Pinpoint Test C.
• Repair as required. Clear DTCs, road test and rerun
On-Board Diagnostic Test.
Shift Cable, Digital TR sensor
• Cable system or digital TR sensor damaged, • Inspect and repair as necessary. Refer to Transmission
misaligned Range (TR) Sensor Adjustment or Section 307-05.
Main Control
• Screws not tightened to specification • Tighten to specification.
• Separator plate damaged • Inspect for damage. If damaged, install a new
separator plate.
• Contamination • Disassemble and clean.
• Valve/springs damaged, misassembled, missing, stuck • If damaged or parts are missing, install new main
or bore damaged control assembly. If misassembled, reassemble
correctly. DO NOT stone, file or sand valves. This
will remove the anodized finish and may result in
further main control or transmission damage.
• Filter damaged or missing • Inspect for damage. Repair as necessary.
Case
• Manual control lever assembly damage, manual valve • Inspect for damage. If damaged, install a new part.
inner lever pin bent, manual valve inner lever
damaged, spring rod damaged
• Manual valve lever shaft retaining pin damaged • Inspect for damage. If damaged, repair as necessary.

Other Concerns: External Leaks

Possible Component Reference/Action
252 — ROUTINE
Powertrain Control System
• Output shaft speed (OSS) sensor, intermediate shaft • Inspect for leakage. If areas around sensor show signs
speed, turbine shaft speed (TSS) sensor, digital TR of leakage, install a new sensor O-ring seal. If area
sensor behind digital TR sensor shows signs of a leak, a new
manual lever shaft seal may need to be installed.
Fluid
• Incorrect level • Adjust to correct level. Refer to Transmission Fluid
Level Check in this section.
Case
• Case vent damaged, output shaft flange damaged • Inspect for damage. If damaged, repair as necessary.
Seals/Gaskets

2005 Aviator, 09/2004

307-01-28 Automatic Transmission — 5R55S 307-01-28
DIAGNOSIS AND TESTING (Continued)
Other Concerns: External Leaks (Continued)
Possible Component Reference/Action
• Leakage at gaskets, seals, cooler lines, torque • Refer to Leakage Inspection in this section for
converter studs, venting, etc. potential leak locations.
• Remove all traces of lubricant on exposed surfaces of
the transmission. Check vent for free breathing.
Operate the vehicle at normal temperatures and carry
out leak check test. Refer to Leakage Inspection in
this section. Repair as necessary.

Other Concern: Noise/Vibration—Forward or Reverse

Possible Component Reference/Action
254 — ROUTINE
Powertrain Control System
• PCM, vehicle wiring harnesses, torque converter • Carry out On-Board Diagnostic Tests. Refer to the
clutch (TCC) solenoid, pressure control solenoids A, Powertrain Control/Emissions Diagnosis (PC/ED)
B, C manual for diagnosis and testing of the PCM.
• GO to Pinpoint Test A and GO to Pinpoint Test D.
• Repair as required. Clear DTCs, road test and rerun
On-Board Diagnostic Test.
Shift Cable/Digital TR Sensor
• Cable or digital TR Sensor damaged, misaligned • Inspect and repair as necessary. Refer to Transmission
Range (TR) Sensor Adjustment orSection 307-05.
Main Control
• Screws not tightened to specification • Tighten to specification.
• Separator plate damaged • Inspect for damage. If damaged, install a new
separator plate.
• Contamination • Disassemble and clean.
• Valves/springs damaged, misassembled, missing, stuck • If damaged or parts are missing, install new main
or bore damaged, thermostatic bypass valve damaged control assembly. If misassembled, reassemble
correctly. DO NOT stone, file or sand valves. This
will remove the anodized finish and may result in
further main control or transmission damage.
• Filter damaged or missing • Inspect for damage. Repair as necessary.
Fluid Pump Assembly
• Screws not tightened to specification • Tighten screws to specification.
• Gasket damaged • Inspect for damage. If damaged, install a new gasket.
• Porosity, cross leaks, ball missing, plugged hole • Inspect for damage. If damaged, repair as necessary.
• Pump gears cracked and/or seized • Inspect for damage. Install a new pump.
• Flow control valves, springs or seals damaged, stuck • Inspect for damage. Install a new seal or flow control
or not assembled correctly valve.
Low One-Way Clutch
• Worn, damaged or assembled incorrectly • Inspect for damage. Repair as necessary.
Flexplate or Adapter Plate
• Damaged • Inspect for damage. Repair as necessary.
• Nuts not tightened to specification • Tighten nuts to specification.

2005 Aviator, 09/2004

307-01-29 Automatic Transmission — 5R55S 307-01-29
DIAGNOSIS AND TESTING (Continued)
Other Concern: Noise/Vibration—Forward or Reverse (Continued)
Possible Component Reference/Action
• Adapter plate not aligned correctly • Remove transmission and, using special service tool
and procedure in this section, align adapter plate.
Torque Converter Assembly
• Damaged • Remove transmission. Inspect for damage. Refer to
Torque Converter in this section. If the torque
converter fails to pass the checks or is damaged,
install a new or remanufactured torque converter.
Clutch Assemblies
• Seals, piston damaged • Inspect for damage. Repair as necessary.
• Check ball damaged, missing, not seating, off location • Inspect for mislocation, poor seating, damage. Install
a new cylinder.
• Friction elements damaged or worn • Inspect for damage. Repair as necessary.
• Return springs damaged • Inspect for damage. Repair as necessary.

Other Concern: Engine Will Not Crank

Possible Component Reference/Action
255 — ROUTINE
Powertrain Control System
• PCM, vehicle wiring harnesses, digital TR sensor • Carry out On-Board Diagnostic Tests. Refer to the
Powertrain Control/Emissions Diagnosis (PC/ED)
manual for diagnosis and testing of the PCM.
• GO to Pinpoint Test C.
• Repair as required. Clear DTCs, road test and rerun
On-Board Diagnostic Test.
Shift Cable/Digital TR Sensor
• Cable or digital TR Sensor damaged, misaligned • Inspect and repair as necessary. Refer to Transmission
Range (TR) Sensor Adjustment or Section 307-05.
Main Control/Park System/TR Sensor Alignment
• Detent spring, rooster comb, manual lever and TR • Disconnect TR sensor electrical connector. Remove
sensor are not correctly aligned together outer manual lever nut. Loosen TR sensor screws.
Loosen detent spring screw. Move manual lever
through all gear ranges. Place manual lever into the
NEUTRAL position. Tighten the detent spring screw
to correct specification. Install TR sensor alignment
tool. Tighten the TR sensor screws alternating
sequence until correct tightening specification is
obtained. Remove tool. Install outer manual lever and
nut. Tighten nut to correct specification. Install TR
sensor connector. Verify that the vehicle will start in
PARK and NEUTRAL. Verify that the reverse
backup lamps illuminate in REVERSE.
Fluid Pump Assembly
• Screws not tightened to specification • Tighten screws to specification.
• Gasket damaged • Inspect for damage. If damaged, install a new gasket.
• Porosity, cross leaks, ball missing, plugged hole • Inspect for damage. If damaged, repair as necessary.
• Pump gears cracked and/or seized • Inspect for damage. Install a new pump.

2005 Aviator, 09/2004

307-01-30 Automatic Transmission — 5R55S 307-01-30
DIAGNOSIS AND TESTING (Continued)
Other Concern: Engine Will Not Crank (Continued)
Possible Component Reference/Action
• Flow control valves, springs or seals damaged, stuck • Inspect for damage. Install a new seal or flow control
or not assembled correctly valve.
Flexplate or Adapter Plate
• Damaged • Inspect for damage. Repair as necessary.

Other Concern: No Park Range

Possible Component Reference/Action
256 — ROUTINE
Shift Cable/Digital TR sensor
• Cable system or digital TR sensor damaged, • Inspect and repair as necessary. Refer to Transmission
misaligned Range (TR) Sensor Adjustment or Section 307-05.
Case
• Manual control lever assembly damage, manual valve • Inspect for damage. If damaged, repair as necessary.
inner lever pin bent, manual valve inner lever
damaged, spring rod damaged
• Manual valve lever shaft retaining pin damaged • Inspect for damage. If damaged, repair as necessary.
Park System
• Park gear, parking pawl, parking pawl return spring, • Inspect for damage. If damaged, repair as necessary.
park or guide plate, parking actuating rod, parking
pawl shaft, manual lever, manual lever detent spring
damaged or misassembled
• External linkages/brackets damaged • Inspect for damage. If damaged, repair as necessary.

Other Concern: Transmission Overheating

Possible Component Reference/Action
257 — ROUTINE
Powertrain Control System
• PCM, vehicle wiring harnesses, torque converter • Carry out On-Board Diagnostic Tests. Refer to the
clutch (TCC) solenoid, pressure control solenoids A, Powertrain Control/Emissions Diagnosis (PC/ED)
B, C, transmission fluid temperature (TFT) sensor manual for diagnosis and testing of the PCM.
• GO to Pinpoint Test A, GO to Pinpoint Test B and
GO to Pinpoint Test D.
• Repair as required. Clear DTCs, road test and rerun
On-Board Diagnostic Test.
Fluid
• Incorrect level • Adjust to correct level. Refer to Transmission Fluid
Level Check in this section.
Incorrect Pressures
• High/low pressures • Check pressure at line and PC C taps.
• Carry out Line Pressure Test. Refer to Special Testing
Procedures in this section.
Main Control
• Screws not tightened to specification • Tighten to specification.

2005 Aviator, 09/2004

307-01-31 Automatic Transmission — 5R55S 307-01-31
DIAGNOSIS AND TESTING (Continued)
Other Concern: Transmission Overheating (Continued)
Possible Component Reference/Action
• Separator plate damaged • Inspect for damage. If damaged, install a new
separator plate.
• Contamination • Disassemble and clean.
• Valves/springs damaged, misassembled, missing, stuck • If damaged or parts are missing, install new main
or bore damaged, thermostatic bypass valve damaged control assembly. If misassembled, reassemble
correctly. DO NOT stone, file or sand valves. This
will remove the anodized finish and may result in
further main control or transmission damage.
• Filter damaged or missing • Inspect for damage. Repair as necessary.
Fluid Pump Assembly
• Screws not tightened to specification • Tighten screws to specification.
• Gasket damaged • Inspect for damage. If damaged, install a new gasket.
• Porosity, cross leaks, ball missing, plugged hole • Inspect for damage. If damaged, repair as necessary.
• Pump gears cracked and/or seized • Inspect for damage. Install a new pump.
• Flow control valves, springs or seals damaged, stuck • Inspect for damage. Install a new seal or flow control
or not assembled correctly valve.
Case
• Case vent damaged • Inspect for damage. If damaged, repair as necessary.
Torque Converter Assembly
• Seized torque converter one-way clutch • Remove transmission. Inspect for damage. Refer to
Torque Converter in this section. If torque converter
fails to pass the criteria or is damaged, install a new
or remanufactured converter.
• Excessive slip detected
Other
• Restriction in the transmission cooling system • Refer to Section 307-02 in this section for
information and diagnosis of cooling issues.
• Excessive trailer tow load • Refer to the owner guide for specifications on trailer
towing.
• Engine driveability concerns • Check engine. Refer to Section 303-00.

Other Concern: No Engine Braking in Manual 3rd Position

Possible Component Reference/Action
280 — ROUTINE
Powertrain Control System
• PCM, vehicle wiring harnesses, shift solenoids A, B, • Carry out On-Board Diagnostic Tests. Refer to the
C, reverse pressure (RP) switch, pressure control Powertrain Control/Emissions Diagnosis (PC/ED)
solenoids A, B manual for diagnosis and testing of the PCM.
• GO to Pinpoint Test A, GO to Pinpoint Test D.
• Repair as required. Clear DTCs, road test and rerun
On-Board Diagnostic Test.
Fluid
• Incorrect level • Adjust fluid to correct level. Refer to Transmission
Fluid Level Check in this section.

2005 Aviator, 09/2004

307-01-32 Automatic Transmission — 5R55S 307-01-32
DIAGNOSIS AND TESTING (Continued)
Other Concern: No Engine Braking in Manual 3rd Position (Continued)
Possible Component Reference/Action
Incorrect Pressures
• High/low pressures • Check pressure at line and PC C taps.
• Carry out Line Pressure Test. Refer to Special Testing
Procedures in this section.
Main Control
• Screws not tightened to specification • Tighten to specification.
• Separator plate damaged • Inspect for damage. If damaged, install a new
separator plate.
• Contamination • Disassemble and clean.
• Valve/springs damaged, misassembled, missing, stuck • If damaged or parts are missing, install new main
or bore damaged control assembly. If misassembled, reassemble
correctly. DO NOT stone, file or sand valves. This
will remove the anodized finish and may result in
further main control or transmission damage.
• Filter damaged or missing • Inspect for damage. Repair as necessary.
Coast Clutch Assembly
• Seals, piston damaged • Inspect for damage. Repair as necessary.
• Check ball damaged, missing, not seating, off location • Inspect for mislocation, poor seating, damage. Install
a new cylinder.
• Friction elements damaged or worn • Inspect for damage. Repair as necessary.
• Return springs damaged • Inspect for damage. Repair as necessary.
Center Support
• Screw not tightened to specification • Tighten to specification.
• Seals rings or bearing damaged • Inspect for damage. Repair as necessary.
• Outside diameter of case bore damaged • Inspect for damage. Repair as necessary.
• Support damaged or leaking • Inspect for damage. Repair as necessary.
Intermediate Servo
• Servo retaining screws damaged • Inspect for damage. Repair as necessary.
• Seals (piston and cover) damaged • Inspect for damage. Repair as necessary.
Intermediate Band
• Band damaged • Inspect for damage. Repair as necessary.
• Servo worn or damaged • Inspect for damage. Repair as necessary.
• Not adjusted correctly • Inspect for damage. Repair as necessary.

Other Concern: No Engine Braking in Manual 4th (D) Position

Possible Component Reference/Action
281 — ROUTINE
Powertrain Control System
• PCM, vehicle wiring harnesses, shift solenoid D, • Carry out On-Board Diagnostic Tests. Refer to the
reverse pressure (RP) switch, pressure control Powertrain Control/Emissions Diagnosis (PC/ED)
solenoid B manual for diagnosis and testing of the PCM.
• GO to Pinpoint Test A, GO to Pinpoint Test D.

2005 Aviator, 09/2004

307-01-33 Automatic Transmission — 5R55S 307-01-33
DIAGNOSIS AND TESTING (Continued)
Other Concern: No Engine Braking in Manual 4th (D) Position (Continued)
Possible Component Reference/Action
• Repair as required. Clear DTCs, road test and rerun
On-Board Diagnostic Test.
Fluid
• Incorrect level • Adjust fluid to correct level. Refer to Transmission
Fluid Level Check in this section.
Main Control
• Screws not tightened to specification • Tighten to specification.
• Separator plate damaged • Inspect for damage. If damaged, install a new
separator plate.
• Contamination • Disassemble and clean.
• Valve/springs damaged, misassembled, missing, stuck • If damaged or parts are missing, install new main
or bore damaged control assembly. If misassembled, reassemble
correctly. DO NOT stone, file or sand valves. This
will remove the anodized finish and may result in
further main control or transmission damage.
• Filter damaged or missing • Inspect for damage. Repair as necessary.
Coast Clutch Assembly
• Seals, piston damaged • Inspect for damage. Repair as necessary.
• Check ball damaged, missing, not seating, off location • Inspect for mislocation, poor seating, damage. Install
a new cylinder.
• Friction elements damaged or worn • Inspect for damage. Repair as necessary.
• Return springs damaged • Inspect for damage. Repair as necessary.

Other Concerns: No Engine Braking in Manual 2nd Position

Possible Component Reference/Action
258 — ROUTINE
Powertrain Control System
• PCM, vehicle wiring harnesses, shift solenoids A, C, • Carry out On-Board Diagnostic Tests. Refer to the
D, pressure control solenoid A Powertrain Control/Emissions Diagnosis (PC/ED)
manual for diagnosis and testing of the PCM.
• GO to Pinpoint Test A and GO to Pinpoint Test D.
• Repair as required. Clear DTCs, road test and rerun
On-Board Diagnostic Test.
Fluid
• Incorrect level • Adjust fluid to correct level. Refer to Transmission
Fluid Level Check in this section.
Incorrect Pressures
• High/low pressures • Check pressure at line and PC C taps.
• Carry out Line Pressure Test. Refer to Special Testing
Procedures in this section.
OD Servo
• Servo retaining screws damaged • Inspect for damage. Repair as necessary.
• Seals (piston and cover) damaged • Inspect for damage. Repair as necessary.

2005 Aviator, 09/2004

307-01-34 Automatic Transmission — 5R55S 307-01-34
DIAGNOSIS AND TESTING (Continued)
Other Concerns: No Engine Braking in Manual 2nd Position (Continued)
Possible Component Reference/Action
OD Band
• Band damaged • Inspect for damage. Repair as necessary.
• Servo worn or damaged • Inspect for damage. Repair as necessary.
• Not adjusted correctly • Inspect for damage. Repair as necessary.

Other Concern: No Engine Braking in Manual 1st Position

Possible Component Reference/Action
259 — ROUTINE
Powertrain Control System
• PCM, vehicle wiring harnesses, shift solenoids A, C, • Carry out On-Board Diagnostic Tests. Refer to the
D, pressure control solenoids A, B Powertrain Control/Emissions Diagnosis (PC/ED)
manual for diagnosis and testing of the PCM.
• GO to Pinpoint Test A and GO to Pinpoint Test D.
• Repair as required. Clear DTCs, road test and rerun
On-Board Diagnostic Test.
Fluid
• Incorrect level • Adjust fluid to the correct level, refer to Transmission
Fluid Level Check in this section.
Incorrect Pressures
• High/low pressures • Check pressure at line and PC C taps.
• Carry out Line Pressure Test. Refer to Special Testing
Procedures in this section.
Reverse Servo
• Servo retaining screws damaged • Inspect for damage. Repair as necessary.
• Seals (piston and cover) damaged • Inspect for damage. Repair as necessary.
Reverse Band
• Band damaged • Inspect for damage. Repair as necessary.
• Servo worn or damaged • Inspect for damage. Repair as necessary.

Other Concerns: Fluid Venting/Foaming

Possible Component Reference/Action
261 — ROUTINE
Fluid
• Incorrect level • Adjust fluid to correct level. Refer to Transmission
Fluid Level Check in this section.
• Condition • Carry out Fluid Condition Check. Refer to
Preliminary Inspection in this section.
Fluid Pump Assembly
• Screws not tightened to specification • Tighten screws to specification.
• Gasket damaged • Inspect for damage. If damaged, install a new gasket.
• Porosity, cross leaks, ball missing, plugged hole • Inspect for damage. If damaged, repair as necessary.

2005 Aviator, 09/2004

307-01-35 Automatic Transmission — 5R55S 307-01-35
DIAGNOSIS AND TESTING (Continued)
Other Concerns: Fluid Venting/Foaming (Continued)
Possible Component Reference/Action
Case
• Case vent damaged • Inspect for damage. If damaged, repair as necessary.
Other
• Transmission overheating • Refer to 257 routine in this section.

Other Concern: Vehicle Movement with Gear Selector in ‘‘N’’ Position

Possible Component Reference/Action
262 — ROUTINE
Fluid
• Incorrect level • Adjust fluid to correct level. Refer to Transmission
Fluid Level Check in this section.
Shift Cable/Digital TR sensor
• Cable system or digital TR sensor damaged, • Inspect and repair as necessary. Refer to Transmission
misaligned Range (TR) Sensor Adjustment or Section 307-05.
Incorrect Pressures
• High/low pressures • Check pressure at line and PC C taps.
• Carry out Line Pressure Test. Refer to Special Testing
Procedures in this section.
Main Control
• Screws not tightened to specification • Tighten to specification.
• Separator plate damaged • Inspect for damage. If damaged, install a new
separator plate.
• Contamination • Disassemble and clean.
• Valve/springs damaged, misassembled, missing, stuck • If damaged or parts are missing, install new main
or bore damaged control assembly. If misassembled, reassemble
correctly. DO NOT stone, file or sand valves. This
will remove the anodized finish and may result in
further main control or transmission damage.
Clutch Assemblies
• Seals, piston damaged • Inspect for damage. Repair as necessary.
• Check ball damaged, missing, not seating, off location • Inspect for mislocation, poor seating, damage. Install
a new cylinder.
• Friction elements damaged or worn • Inspect for damage. Repair as necessary.
• Return springs damaged • Inspect for damage. Repair as necessary.
Case
• Manual control lever assembly damage, manual valve • Inspect for damage. If damaged, repair as necessary.
inner lever pin bent, manual valve inner lever
damaged, spring rod damaged
• Manual valve lever shaft retaining pin damaged • Inspect for damage. If damaged, repair as necessary.

2005 Aviator, 09/2004

307-01-36 Automatic Transmission — 5R55S 307-01-36
DIAGNOSIS AND TESTING (Continued)
Other Concern: Slips/Chatters in Manual 1st Position
Possible Component Reference/Action
263 — ROUTINE
Powertrain Control System
• PCM, vehicle wiring harnesses, pressure control • Carry out On-Board Diagnostic Tests. Refer to the
solenoids A, B Powertrain Control/Emissions Diagnosis (PC/ED)
manual for diagnosis and testing of the PCM.
• GO to Pinpoint Test D.
• Repair as required. Clear DTCs, road test and rerun
On-Board Diagnostic Test.
Fluid
• Incorrect level • Adjust fluid to the correct level. Refer to
Transmission Fluid Level Check in this section.
• Condition • Carry out Fluid Condition Check. Refer to
Preliminary Inspection in this section.
Incorrect Pressures
• High/low pressures • Check pressure at line and PC C taps.
• Carry out Line Pressure Test. Refer to Special Testing
Procedures in this section.
Main Control
• Screws not tightened to specification • Tighten to specification.
• Separator plate damaged • Inspect for damage. If damaged, install a new
separator plate.
• Contamination • Disassemble and clean.
• Valve/springs damaged, misassembled, missing, stuck • If damaged or parts are missing, install new main
or bore damaged control assembly. If misassembled, reassemble
correctly. DO NOT stone, file or sand valves. This
will remove the anodized finish and may result in
further main control or transmission damage.
• Filter damaged or missing • Inspect for damage. Repair as necessary.
Fluid Pump Assembly
• Screws not tightened to specification • Tighten screws to specification.
• Gasket damaged • Inspect for damage. If damaged, install a new gasket.
• Porosity, cross leaks, ball missing, plugged hole • Inspect for damage. If damaged, repair as necessary.
• Pump gears cracked and/or seized • Inspect for damage. Install a new pump.
• Flow control valves, springs or seals damaged, stuck • Inspect for damage. Install a new seal or flow control
or not assembled correctly valve.
Forward Clutch Assembly
• Seals, piston damaged • Inspect for damage. Repair as necessary.
• Check ball damaged, missing, not seating, off location • Inspect for mislocation, poor seating, damage. Install
a new cylinder.
• Friction elements damaged or worn • Inspect for damage. Repair as necessary.
• Return springs damaged • Inspect for damage. Repair as necessary.
• Bronze seal ring on bearing damaged • Inspect for damage. Repair as necessary.
Reverse Servo
• Servo retaining screws damaged • Inspect for damage. Repair as necessary.

2005 Aviator, 09/2004

307-01-37 Automatic Transmission — 5R55S 307-01-37
DIAGNOSIS AND TESTING (Continued)
Other Concern: Slips/Chatters in Manual 1st Position (Continued)
Possible Component Reference/Action
• Seals (piston and cover) damaged • Inspect for damage. Repair as necessary.
Reverse Band
• Band damaged • Inspect for damage. Repair as necessary.
• Servo worn or damaged • Inspect for damage. Repair as necessary.
Direct One-Way Clutch
• Worn, damaged or assembled incorrectly • Inspect for damage. Repair as necessary.

Other Concern: Slips/Chatters in Manual 2nd Position

Possible Component Reference/Action
264 — ROUTINE
Powertrain Control System
• PCM, vehicle wiring harnesses, pressure control • Carry out On-Board Diagnostic Tests. Refer to the
solenoids A, B Powertrain Control/Emissions Diagnosis (PC/ED)
manual for diagnosis and testing of the PCM.
• GO to Pinpoint Test D.
• Repair as required. Clear DTCs, road test and rerun
On-Board Diagnostic Test.
Fluid
• Incorrect level • Adjust fluid to the correct level. Refer to
Transmission Fluid Level Check in this section.
• Condition • Carry out Fluid Condition Check. Refer to
Preliminary Inspection in this section.
Incorrect Pressures
• High/low pressures • Check pressure at line and PC C taps.
• Carry out Line Pressure Test. Refer to Special Testing
Procedures in this section.
OD Servo
• Servo retaining screws damaged • Inspect for damage. Repair as necessary.
• Seals (piston and cover) damaged • Inspect for damage. Repair as necessary.
OD Band
• Band damaged • Inspect for damage. Repair as necessary.
• Servo worn or damaged • Inspect for damage. Repair as necessary.
• Not adjusted correctly • Inspect for damage. Repair as necessary.
OD Planetary Assembly
• Planetary damaged • Inspect for damage. Repair as necessary.
Forward Clutch Assembly
• Seals, piston damaged • Inspect for damage. Repair as necessary.
• Check ball damaged, missing, not seating, off location • Inspect for mislocation, poor seating, damage. Install
a new cylinder.
• Friction elements damaged or worn • Inspect for damage. Repair as necessary.
• Return springs damaged • Inspect for damage. Repair as necessary.
• Bronze seal ring on bearing damaged • Inspect for damage. Repair as necessary.

2005 Aviator, 09/2004

307-01-38 Automatic Transmission — 5R55S 307-01-38
DIAGNOSIS AND TESTING (Continued)
Other Concern: Slip/Chatters in Manual 3rd Position
Possible Component Reference/Action
282 — ROUTINE
Powertrain Control System
• PCM, vehicle wiring harnesses, pressure control • Carry out On-Board Diagnostic Tests. Refer to the
solenoids A, B Powertrain Control/Emissions Diagnosis (PC/ED)
manual for diagnosis and testing of the PCM.
• GO to Pinpoint Test D.
• Repair as required. Clear DTCs, road test and rerun
On-Board Diagnostic Test.
Fluid
• Incorrect level • Adjust fluid to the correct level. Refer to
Transmission Fluid Level Check in this section.
• Condition • Carry out Fluid Condition Check. Refer to
Preliminary Inspection in this section.
Incorrect Pressures
• High/low pressures • Check pressure at line and PC C taps.
• Carry out Line Pressure Test. Refer to Special Testing
Procedures in this section.
OD Servo
• Servo retaining screws damaged • Inspect for damage. Repair as necessary.
• Seals (piston and cover) damaged • Inspect for damage. Repair as necessary.
OD Band
• Band damaged • Inspect for damage. Repair as necessary.
• Servo worn or damaged • Inspect for damage. Repair as necessary.
• Not adjusted correctly • Inspect for damage. Repair as necessary.
Intermediate Servo
• Servo retaining screws damaged • Inspect for damage. Repair as necessary.
• Seals (piston and cover) damaged • Inspect for damage. Repair as necessary.
Intermediate Band
• Band damaged • Inspect for damage. Repair as necessary.
• Servo worn or damaged • Inspect for damage. Repair as necessary.
• Not adjusted correctly • Inspect for damage. Repair as necessary.
Forward Clutch Assembly
• Seals, piston damaged • Inspect for damage. Repair as necessary.
• Check ball damaged, missing, not seating, off location • Inspect for mislocation, poor seating, damage. Install
a new cylinder.
• Friction elements damaged or worn • Inspect for damage. Repair as necessary.
• Return springs damaged • Inspect for damage. Repair as necessary.
• Bronze seal ring on bearing damaged • Inspect for damage. Repair as necessary.
Direct One-Way Clutch
• Worn, damaged or assembled incorrectly • Inspect for damage. Repair as necessary.
Low One-Way Clutch
• Worn, damaged or assembled incorrectly • Inspect for damage. Repair as necessary.

2005 Aviator, 09/2004

307-01-39 Automatic Transmission — 5R55S 307-01-39
DIAGNOSIS AND TESTING (Continued)
Other Concern: Engine Braking in ALL Gears
Possible Component Reference/Action
283 — ROUTINE
Powertrain Control System
• PCM, vehicle wiring harnesses, shift solenoid D • Carry out On-Board Diagnostic Tests. Refer to the
Powertrain Control/Emissions Diagnosis (PC/ED)
manual for diagnosis and testing of the PCM.
• GO to Pinpoint Test A.
• Repair as required. Clear DTCs, road test and rerun
On-Board Diagnostic Test.
Main Control
• Screws not tightened to specification • Tighten to specification.
• Separator plate damaged • Inspect for damage. If damaged, install a new
separator plate.
• Contamination • Disassemble and clean.
• Valve, springs damaged, misassembled, missing, stuck • If damaged or parts are missing, install new main
or bore damaged control assembly. If misassembled, reassemble
correctly. DO NOT stone, file or sand valves. This
will remove the anodized finish and may result in
further main control or transmission damage.
• Filter damaged or missing • Inspect for damage. Repair as necessary.
Low One-Way Clutch
• Worn, damaged or assembled incorrectly • Inspect for damage. Repair as necessary.
Torque Converter Assembly
• Torque Converter internal failure preventing • Remove transmission. Inspect for damage. Refer to
engagement, piston release Torque Converter in this section. If the torque
converter fails to pass the criteria or is damaged,
install a new or remanufactured torque converter.

Other Concern: No 2nd and 5th Gears

Possible Component Reference/Action
284 — ROUTINE
Powertrain Control System
• PCM, vehicle wiring harnesses, pressure control • Carry out On-Board Diagnostic Tests. Refer to the
solenoids B, C Powertrain Control/Emissions Diagnosis (PC/ED)
manual for diagnosis and testing of the PCM.
• GO to Pinpoint Test D.
• Repair as required. Clear DTCs, road test and rerun
On-Board Diagnostic Test.

Other Concern: No 3rd, 4th and 5th Gears

Possible Component Reference/Action
285 — ROUTINE
Powertrain Control System

2005 Aviator, 09/2004

307-01-40 Automatic Transmission — 5R55S 307-01-40
DIAGNOSIS AND TESTING (Continued)
Other Concern: No 3rd, 4th and 5th Gears (Continued)
Possible Component Reference/Action
• PCM, vehicle wiring harnesses, pressure control • Carry out On-Board Diagnostic Tests. Refer to the
solenoids A, B Powertrain Control/Emissions Diagnosis (PC/ED)
manual for diagnosis and testing of the PCM.
• GO to Pinpoint Test D.
• Repair as required. Clear DTCs, road test and rerun
On-Board Diagnostic Test.
OD Servo
• Servo retaining screws damaged • Inspect for damage. Repair as necessary.
• Seals (piston and cover) damaged • Inspect for damage. Repair as necessary.
OD Band
• Band damaged • Inspect for damage. Repair as necessary.
• Servo worn or damaged • Inspect for damage. Repair as necessary.
• Not adjusted correctly • Inspect for damage. Repair as necessary.
OD Planetary Assembly
• Planetary damaged • Inspect for damage. Repair as necessary.
Intermediate Servo
• Servo retaining screws damaged • Inspect for damage. Repair as necessary.
• Seals (piston and cover) damaged • Inspect for damage. Repair as necessary.
Intermediate Band
• Band damaged • Inspect for damage. Repair as necessary.
• Servo worn or damaged • Inspect for damage. Repair as necessary.
• Not adjusted correctly • Inspect for damage. Repair as necessary.

Shift Concern: Harsh 1-2 Shift

Possible Component Reference/Action
232 — ROUTINE
Powertrain Control System
• PCM, vehicle wiring harnesses, shift control solenoid • Carry out On-Board Diagnostic Tests. Refer to the
C, pressure control solenoids B, turbine shaft speed Powertrain Control/Emissions Diagnosis (PC/ED)
(TSS) sensor, digital TR sensor, transmission fluid manual for diagnosis and testing of the PCM.
temperature (TFT) sensor
• GO to Pinpoint Test A, GO to Pinpoint Test B, GO
to Pinpoint Test C, GO to Pinpoint Test D and GO to
Pinpoint Test E.
• Repair as required. Clear DTCs, road test and rerun
On-Board Diagnostic Test.
Incorrect Pressures
• High/low pressures • Check pressure at line and PC C taps.
• Carry out Line Pressure Test. Refer to Special Testing
Procedures in this section.
Main Control
• Screws not tightened to specification • Tighten to specification.

2005 Aviator, 09/2004

307-01-41 Automatic Transmission — 5R55S 307-01-41
DIAGNOSIS AND TESTING (Continued)
Shift Concern: Harsh 1-2 Shift (Continued)
Possible Component Reference/Action
• Separator plate damaged • Inspect for damage. If damaged, install a new
separator plate.
• Contamination • Disassemble and clean.
• Valve/springs damaged, misassembled, missing, stuck • If damaged or parts are missing, install new main
or bore damaged control assembly. If misassembled, reassemble
correctly. DO NOT stone, file or sand valves. This
will remove the anodized finish and may result in
further main control or transmission damage.
• Filter damaged or missing • Inspect for damage. Repair as necessary.
OD Servo
• Servo retaining screws damaged • Inspect for damage. Repair as necessary.
• Seals (piston and cover) damaged • Inspect for damage. Repair as necessary.
OD Band
• Band damaged • Inspect for damage. Repair as necessary.
• Servo worn or damaged • Inspect for damage. Repair as necessary.
• Not adjusted correctly • Inspect for damage. Repair as necessary.

Shift Concern: Harsh 2-3 Shift

Possible Component Reference/Action
233 — ROUTINE
Powertrain Control System
• PCM, vehicle wiring harnesses, shift control solenoid • Carry out On-Board Diagnostic Tests. Refer to the
B, pressure control solenoids A, turbine shaft speed Powertrain Control/Emissions Diagnosis (PC/ED)
(TSS) sensor, intermediate shaft speed sensor, digital manual for diagnosis and testing of the PCM.
TR sensor, transmission fluid temperature (TFT)
sensor
• GO to Pinpoint Test A, GO to Pinpoint Test B, GO
to Pinpoint Test C, GO to Pinpoint Test D and GO to
Pinpoint Test E.
• Repair as required. Clear DTCs, road test and rerun
On-Board Diagnostic Test.
Incorrect Pressures
• High/low pressures • Check pressure at line and PC C taps.
• Carry out Line Pressure Test. Refer to Special Testing
Procedures in this section.
Main Control
• Screws not tightened to specification • Tighten to specification.
• Separator plate damaged • Inspect for damage. If damaged, install a new
separator plate.
• Contamination • Disassemble and clean.
• Valve/springs damaged, misassembled, missing, stuck • If damaged or parts are missing, install new main
or bore damaged control assembly. If misassembled, reassemble
correctly. DO NOT stone, file or sand valves. This
will remove the anodized finish and may result in
further main control or transmission damage.

2005 Aviator, 09/2004

307-01-42 Automatic Transmission — 5R55S 307-01-42
DIAGNOSIS AND TESTING (Continued)
Shift Concern: Harsh 2-3 Shift (Continued)
Possible Component Reference/Action
• Filter damaged or missing • Inspect for damage. Repair as necessary.
OD Servo
• Servo retaining screws damaged • Inspect for damage. Repair as necessary.
• Seals (piston and cover) damaged • Inspect for damage. Repair as necessary.
OD Band
• Band damaged • Inspect for damage. Repair as necessary.
• Servo worn or damaged • Inspect for damage. Repair as necessary.
• Not adjusted correctly • Inspect for damage. Repair as necessary.
Direct Clutch Assembly
• Seals, piston damaged • Inspect for damage. Repair as necessary.
• Check ball damaged, missing, not seating, off location • Inspect for mislocation, poor seating, damage. Install
a new cylinder.
• Friction elements damaged or worn • Inspect for damage. Repair as necessary.
• Return springs damaged • Inspect for damage. Repair as necessary.
Intermediate Servo
• Servo retaining screws damaged • Inspect for damage. Repair as necessary.
• Seals (piston and cover) damaged • Inspect for damage. Repair as necessary.
Intermediate Band
• Band damaged • Inspect for damage. Repair as necessary.
• Servo worn or damaged • Inspect for damage. Repair as necessary.
• Not adjusted correctly • Inspect for damage. Repair as necessary.
Direct One-Way Clutch
• Worn, damaged or assembled incorrectly • Inspect for damage. Repair as necessary.

Shift Concern: Harsh 3-4 Shift

Possible Component Reference/Action
234 — ROUTINE
Powertrain Control System
• PCM, vehicle wiring harnesses, shift control solenoid • Carry out On-Board Diagnostic Tests. Refer to the
A, pressure control solenoids C, digital TR sensor, Powertrain Control/Emissions Diagnosis (PC/ED)
transmission fluid temperature (TFT) sensor manual for diagnosis and testing of the PCM.
• GO to Pinpoint Test A, GO to Pinpoint Test B, GO
to Pinpoint Test C and GO to Pinpoint Test D.
• Repair as required. Clear DTCs, road test and rerun
On-Board Diagnostic Test.
Incorrect Pressures
• High/low pressures • Check pressure at line and PC C taps.
• Carry out Line Pressure Test. Refer to Special Testing
Procedures in this section.
Main Control
• Screws not tightened to specification • Tighten to specification.

2005 Aviator, 09/2004

307-01-43 Automatic Transmission — 5R55S 307-01-43
DIAGNOSIS AND TESTING (Continued)
Shift Concern: Harsh 3-4 Shift (Continued)
Possible Component Reference/Action
• Separator plate damaged • Inspect for damage. If damaged, install a new
separator.
• Contamination • Disassemble and clean.
• Valve/springs damaged, misassembled, missing, stuck • If damaged or parts are missing, install new main
or bore damaged control assembly. If misassembled, reassemble
correctly. DO NOT stone, file or sand valves. This
will remove the anodized finish and may result in
further main control or transmission damage.
• Filter damaged or missing • Inspect for damage. Repair as necessary.
Center Support
• Screws not tightened to specification • Tighten to specification.
• Seal rings or bearing damaged • Inspect for damage. Repair as necessary.
• Outside diameter of case bore damaged • Inspect for damage. Repair as necessary.
• Support damaged or leaking • Inspect for damage. Repair as necessary.
Direct Clutch Assembly
• Seals, piston damaged • Inspect for damage. Repair as necessary.
• Check ball damaged, missing, not seating, off location • Inspect for mislocation, poor seating, damage. Install
a new cylinder.
• Friction elements damaged or worn • Inspect for damage. Repair as necessary.
• Return springs damaged • Inspect for damage. Repair as necessary.
Intermediate Servo
• Seals (piston and cover) damaged • Inspect for damage. Repair as necessary.

Shift Concerns: Harsh 4-5 Shift

Possible Component Reference/Action
274 — ROUTINE
Powertrain Control System
• PCM, vehicle wiring harnesses, shift solenoid C, • Carry out On-Board Diagnostic Tests. Refer to the
pressure control solenoid B, turbine shaft speed (TSS) Powertrain Control/Emissions Diagnosis (PC/ED)
sensor, digital TR sensor, transmission fluid manual for diagnosis and testing of the PCM.
temperature (TFT) sensor
• GO to Pinpoint Test A, GO to Pinpoint Test B, GO
to Pinpoint Test C, GO to Pinpoint Test D and GO to
Pinpoint Test E.
• Repair as required. Clear DTCs, road test and rerun
On-Board Diagnostic Test.
Incorrect Pressures
• High/low pressures • Check pressure at line and PC C taps.
• Carry out Line Pressure Test. Refer to Special Testing
Procedures in this section.
Main Control
• Screws not tightened to specification • Tighten to specification.
• Separator plate damaged • Inspect for damage. If damaged, install a new
separator.

2005 Aviator, 09/2004

307-01-44 Automatic Transmission — 5R55S 307-01-44
DIAGNOSIS AND TESTING (Continued)
Shift Concerns: Harsh 4-5 Shift (Continued)
Possible Component Reference/Action
• Contamination • Disassemble and clean.
• Valve/springs damaged, misassembled, missing, stuck • If damaged or parts are missing, install new main
or bore damaged control assembly. If misassembled, reassemble
correctly. DO NOT stone, file or sand valves. This
will remove the anodized finish and may result in
further main control or transmission damage.
• Filter damaged or missing • Inspect for damage. Repair as necessary.
OD Servo
• Servo retaining screws damaged • Inspect for damage. Repair as necessary.
• Seal (piston and cover) damaged • Inspect for damage. Repair as necessary.
OD Band
• Band damaged • Inspect for damage. Repair as necessary.
• Servo worn or damaged • Inspect for damage. Repair as necessary.
• Not adjusted correctly • Inspect for damage. Repair as necessary.

Shift Concern: Harsh 5-4 Shift

Possible Component Reference/Action
275 — ROUTINE
Powertrain Control System
• PCM, vehicle wiring harnesses, shift control solenoid • Carry out On-Board Diagnostic Tests. Refer to the
C, pressure control solenoid C, turbine shaft speed Powertrain Control/Emissions Diagnosis (PC/ED)
(TSS) sensor, digital TR sensor, transmission fluid manual for diagnosis and testing of the PCM.
temperature (TFT) sensor
• GO to Pinpoint Test A, GO to Pinpoint Test B, GO
to Pinpoint Test C, GO to Pinpoint Test D and GO to
Pinpoint Test E.
• Repair as required. Clear DTCs, road test and rerun
On-Board Diagnostic Test.
Incorrect Pressures
• High/low pressures • Check pressure at line and PC C taps.
• Carry out Line Pressure Test. Refer to Special Testing
Procedures in this section.
Main Control
• Screws not tightened to specification • Tighten to specification.
• Separator plate damaged • Inspect for damage. If damaged, install a new
separator plate.
• Contamination • Disassemble and clean.
• Valve/springs damaged, misassembled, missing, stuck • If damaged or parts are missing, install new main
or bore damaged control assembly. If misassembled, reassemble
correctly. DO NOT stone, file or sand valves. This
will remove the anodized finish and may result in
further main control or transmission damage.
• Filter damaged or missing • Inspect for damage. Repair as necessary.
OD Servo

2005 Aviator, 09/2004

307-01-45 Automatic Transmission — 5R55S 307-01-45
DIAGNOSIS AND TESTING (Continued)
Shift Concern: Harsh 5-4 Shift (Continued)
Possible Component Reference/Action
• Servo retaining screws damaged • Inspect for damage. Repair as necessary.
• Seals (piston and cover) damaged • Inspect for damage. Repair as necessary.
OD Band
• Band damaged • Inspect for damage. Repair as necessary.
• Servo worn or damaged • Inspect for damage. Repair as necessary.
• Not adjusted correctly • Inspect for damage. Repair as necessary.
Direct One-Way Clutch
• Worn , damaged or assembled incorrectly • Inspect for damage. Repair as necessary.

Shift Concern: Harsh 4-3 Shift

Possible Component Reference/Action
235 — ROUTINE
Powertrain Control System
• PCM, vehicle wiring harnesses, shift solenoid A, • Carry out On-Board Diagnostic Tests. Refer to the
pressure control solenoid A, digital TR sensor, Powertrain Control/Emissions Diagnosis (PC/ED)
transmission fluid temperature (TFT) sensor manual for diagnosis and testing of the PCM.
• GO to Pinpoint Test A, GO to Pinpoint Test B, GO
to Pinpoint Test C and GO to Pinpoint Test D.
• Repair as required. Clear DTCs, road test and rerun
On-Board Diagnostic Test.
Incorrect Pressures
• High/low pressures • Check pressure at line and PC C taps.
• Carry out Line Pressure Test. Refer to Special Testing
Procedures in this section.
Main Control
• Screws not tightened to specification • Tighten to specification.
• Separator plate damaged • Inspect for damage. If damaged, install a new
separator plate.
• Contamination • Disassemble and clean.
• Valves, springs damaged, misassembled, missing, • If damaged or parts are missing, install new main
stuck or bore damaged control assembly. If misassembled, reassemble
correctly. DO NOT stone, file or sand valves. This
will remove the anodized finish and may result in
further main control or transmission damage.
• Filter damaged or missing • Inspect for damage. Repair as necessary.
Direct Clutch Assembly
• Seals, piston damaged • Inspect for damage. Repair as necessary.
• Check ball damaged, missing, not seating, off location • Inspect for mislocation, poor seating, damage. Install
a new cylinder.
• Friction elements damaged or worn • Inspect for damage. Repair as necessary.
• Return springs damaged • Inspect for damage. Repair as necessary.
Intermediate Servo
• Servo retaining screws damaged • Inspect for damage. Repair as necessary.

2005 Aviator, 09/2004

307-01-46 Automatic Transmission — 5R55S 307-01-46
DIAGNOSIS AND TESTING (Continued)
Shift Concern: Harsh 4-3 Shift (Continued)
Possible Component Reference/Action
• Seals (piston and cover) damaged • Inspect for damage. Repair as necessary.
Intermediate Band
• Band damaged • Inspect for damage. Repair as necessary.
• Servo worn or damaged • Inspect for damage. Repair as necessary.
• Not adjusted correctly • Inspect for damage. Repair as necessary.

Shift Concern: Harsh 3-2 Shift

Possible Component Reference/Action
236 — ROUTINE
Powertrain Control System
• PCM, vehicle wiring harnesses, shift control solenoid • Carry out On-Board Diagnostic Tests. Refer to the
C, pressure control solenoid B, turbine shaft speed Powertrain Control/Emissions Diagnosis (PC/ED)
(TSS) sensor, intermediate shaft speed sensor, digital manual for diagnosis and testing of the PCM.
TR sensor, transmission fluid temperature (TFT)
sensor
• GO to Pinpoint Test A, GO to Pinpoint Test B, GO
to Pinpoint Test C, GO to Pinpoint Test D and GO to
Pinpoint Test E.
• Repair as required. Clear DTCs, road test and rerun
On-Board Diagnostic Test.
Incorrect Pressures
• High/low pressures • Check pressure at line and PC C taps.
• Carry out Line Pressure Test. Refer to Special Testing
Procedures in this section.
Main Control
• Screws not tightened to specification • Tighten to specification.
• Separator plate damaged • Inspect for damage. If damaged, install a new
separator plate.
• Contamination • Disassemble and clean.
• Valve/springs damaged, misassembled, missing, stuck • If damaged or parts are missing, install new main
or bore damaged control assembly. If misassembled, reassemble
correctly. DO NOT stone, file or sand valves. This
will remove the anodized finish and may result in
further main control or transmission damage.
• Filter damaged or missing • Inspect for damage. Repair as necessary.
OD Servo
• Servo retaining screws damaged • Inspect for damage. Repair as necessary.
• Seals (piston and cover) damaged • Inspect for damage. Repair as necessary.
OD Band
• Band damaged • Inspect for damage. Repair as necessary.
• Servo worn or damaged • Inspect for damage. Repair as necessary.
• Not adjusted correctly • Inspect for damage. Repair as necessary.
Intermediate Servo

2005 Aviator, 09/2004

307-01-47 Automatic Transmission — 5R55S 307-01-47
DIAGNOSIS AND TESTING (Continued)
Shift Concern: Harsh 3-2 Shift (Continued)
Possible Component Reference/Action
• Servo retaining screws damaged • Inspect for damage. Repair as necessary.
• Seals (piston and cover) damaged • Inspect for damage. Repair as necessary.
Intermediate Band
• Band damaged • Inspect for damage. Repair as necessary.
• Servo worn or damaged • Inspect for damage. Repair as necessary.
• Not adjusted correctly • Inspect for damage. Repair as necessary.

Shift Concern: Harsh 2-1 Shift

Possible Component Reference/Action
237 — ROUTINE
Powertrain Control System
• PCM, vehicle wiring harnesses, shift control solenoid • Carry out On-Board Diagnostic Tests. Refer to the
C, pressure control solenoid B, turbine shaft speed Powertrain Control/Emissions Diagnosis (PC/ED)
(TSS) sensor, digital TR sensor, transmission fluid manual for diagnosis and testing of the PCM.
temperature (TFT) sensor
• GO to Pinpoint Test A, GO to Pinpoint Test B, GO
to Pinpoint Test C, GO to Pinpoint Test D and GO to
Pinpoint Test E.
• Repair as required. Clear DTCs, road test and rerun
On-Board Diagnostic Test.
Incorrect Pressures
• High/low pressures • Check pressure at line and PC C taps.
• Carry out Line Pressure Test. Refer to Special Testing
Procedures in this section.
Main Control
• Screws not tightened to specification • Tighten to specification.
• Separator plate damaged • Inspect for damage. If damaged, install a new
separator plate.
• Contamination • Disassemble and clean.
• Valve/springs damaged, misassembled, missing, stuck • If damaged or parts are missing, install new main
or bore damaged control assembly. If misassembled, reassemble
correctly. DO NOT stone, file or sand valves. This
will remove the anodized finish and may result in
further main control or transmission damage.
• Filter damaged or missing • Inspect for damage. Repair as necessary.
OD Servo
• Servo retaining screws damaged • Inspect for damage. Repair as necessary.
• Seals (piston and cover) damaged • Inspect for damage. Repair as necessary.
OD Band
• Band damaged • Inspect for damage. Repair as necessary.
• Servo worn or damaged • Inspect for damage. Repair as necessary.
• Not adjusted correctly • Inspect for damage. Repair as necessary.
Direct One-Way Clutch
• Worn, damaged or assembled incorrectly • Inspect for damage. Repair as necessary.

2005 Aviator, 09/2004

307-01-48 Automatic Transmission — 5R55S 307-01-48
DIAGNOSIS AND TESTING (Continued)
Shift Concern: No 1-2 Shift
Possible Component Reference/Action
220 — ROUTINE
Powertrain Control System
• PCM, vehicle wiring harnesses, shift solenoid C, • Carry out On-Board Diagnostic Tests. Refer to the
pressure control solenoid B, output shaft speed (OSS) Powertrain Control/Emissions Diagnosis (PC/ED)
sensor, digital TR sensor, VSS input manual for diagnosis and testing of the PCM and
VSS.
• GO to Pinpoint Test A, GO to Pinpoint Test C, GO
to Pinpoint Test D and GO to Pinpoint Test E.
• Repair as required. Clear DTCs, road test and rerun
On-Board Diagnostic Test.
Fluid
• Incorrect level • Adjust to correct level. Refer to Transmission Fluid
Level Check in this section.
Incorrect Pressures
• High/low pressures • Check pressure at line and PC C taps.
• Carry out Line Pressure Test. Refer to Special Testing
Procedures in this section.
Main Control
• Screws not tightened to specification • Tighten to specification.
• Separator plate damaged • Inspect for damage. If damaged, install a new
separator plate.
• Contamination • Disassemble and clean.
• Valve/springs damaged, misassembled, missing, stuck • If damaged or parts are missing, install new main
or bore damaged control assembly. If misassembled, reassemble
correctly. DO NOT stone, file or sand valves. This
will remove the anodized finish and may result in
further main control or transmission damage.
• Filter damaged or missing • Inspect for damage. Repair as necessary.
OD Servo
• Servo retaining screws damaged • Inspect for damage. Repair as necessary.
• Seals (piston and cover) damaged • Inspect for damage. Repair as necessary.
OD Band
• Band damaged • Inspect for damage. Repair as necessary.
• Servo worn or damaged • Inspect for damage. Repair as necessary.
• Not adjusted correctly • Inspect for damage. Repair as necessary.
OD Planetary Assembly
• Planetary damaged • Inspect for damage. Repair as necessary.

Shift Concern: No 2-3 Shift

Possible Component Reference/Action
221 — ROUTINE
Powertrain Control System

2005 Aviator, 09/2004

307-01-49 Automatic Transmission — 5R55S 307-01-49
DIAGNOSIS AND TESTING (Continued)
Shift Concern: No 2-3 Shift (Continued)
Possible Component Reference/Action
• PCM, vehicle wiring harnesses, shift solenoid B, • Carry out On-Board Diagnostic Tests. Refer to the
torque converter clutch (TCC) solenoid, pressure Powertrain Control/Emissions Diagnosis (PC/ED)
control solenoid A, output shaft speed (OSS) sensor, manual for diagnosis and testing of the PCM.
digital TR sensor
• GO to Pinpoint Test A, GO to Pinpoint Test C, GO
to Pinpoint Test D and GO to Pinpoint Test E.
• Repair as required. Clear DTCs, road test and rerun
On-Board Diagnostic Test.
Incorrect Pressures
• High/low pressures • Check pressure at line and PC C taps.
• Carry out Line Pressure Test. Refer to Special Testing
Procedures in this section.
Main Control
• Screws not tightened to specification • Tighten to specification.
• Separator plate damaged • Inspect for damage. If damaged, install a new
separator plate.
• Contamination • Disassemble and clean.
• Valve/springs damaged, misassembled, missing, stuck • If damaged or parts are missing, install new main
or bore damaged control assembly. If misassembled, reassemble
correctly. DO NOT stone, file or sand valves. This
will remove the anodized finish and may result in
further main control or transmission damage.
• Filter damaged or missing • Inspect for damage. Repair as necessary.
Forward Clutch Assembly
• Seals, piston damaged • Inspect for damage. Repair as necessary.
• Check ball, damaged, missing, not seating, off • Inspect for mislocation, poor seating, damage. Install
location a new cylinder.
• Friction elements damaged or worn • Inspect for damage. Repair as necessary.
• Return springs damaged • Inspect for damage. Repair as necessary.
• Bronze seal ring on bearing damaged • Inspect for damage. Repair as necessary.
Intermediate Servo
• Servo retaining screws damaged • Inspect for damage. Repair as necessary.
• Seals (piston and cover) damaged • Inspect for mislocation, poor seating, damage. Install
a new cylinder.
Intermediate Band
• Band damaged • Inspect for damage. Repair as necessary.
• Servo worn or damaged • Inspect for damage. Repair as necessary.
• Not adjusted correctly • Inspect for damage. Repair as necessary.

Shift Concern: No 3-4 Shift

Possible Component Reference/Action
222 — ROUTINE
Powertrain Control System

2005 Aviator, 09/2004

307-01-50 Automatic Transmission — 5R55S 307-01-50
DIAGNOSIS AND TESTING (Continued)
Shift Concern: No 3-4 Shift (Continued)
Possible Component Reference/Action
• PCM, vehicle wiring harnesses, shift solenoid A, • Carry out On-Board Diagnostic Tests. Refer to the
pressure control solenoid C, output shaft speed (OSS) Powertrain Control/Emissions Diagnosis (PC/ED)
sensor, digital TR sensor manual for diagnosis and testing of the PCM.
• GO to Pinpoint Test A, GO to Pinpoint Test C, GO
to Pinpoint Test D and GO to Pinpoint Test E.
• Repair as required. Clear DTCs, road test and rerun
On-Board Diagnostic Test.
Incorrect Pressures
• High/low pressures • Check pressure at line and PC C taps.
• Carry out Line Pressure Test. Refer to Special Testing
Procedures in this section.
Main Control
• Screws not tightened to specification • Tighten to specification.
• Separator plate damaged • Inspect for damage. If damaged, install a new
separator plate.
• Contamination • Disassemble and clean.
• Valve/springs damaged, misassembled, missing, stuck • If damaged or parts are missing, install new main
or bore damaged control assembly. If misassembled, reassemble
correctly. DO NOT stone, file or sand valves. This
will remove the anodized finish and may result in
further main control or transmission damage.
• Filter damaged or missing • Inspect for damage. Repair as necessary.
Center Support
• Screws not tightened to specification • Tighten to specification.
• Seal rings or bearing damaged • Inspect for damage. Repair as necessary.
• Outside diameter of case bore damaged • Inspect for damage. Repair as necessary.
• Support damaged or leaking • Inspect for damage. Repair as necessary.
Direct Clutch Assembly
• Seals, piston damaged • Inspect for damage. Repair as necessary.
• Check ball damaged, missing, not seating, off location • Inspect for mislocation, poor seating, damage. Install
a new cylinder.
• Friction elements damaged or worn • Inspect for damage. Repair as necessary.
• Return springs damaged • Inspect for damage. Repair as necessary.
Forward Clutch Assembly
• Seals, piston damaged • Inspect for damage. Repair as necessary.
• Check ball damaged, missing, not seating, off location • Inspect for mislocation, poor seating, damage. Install
a new cylinder.
• Friction elements damaged or worn • Inspect for damage. Repair as necessary.
• Return springs damaged • Inspect for damage. Repair as necessary.
• Bronze seal ring on bearing damaged • Inspect for damage. Repair as necessary.
Intermediate Servo
• Servo retaining screws damaged • Inspect for damage. Repair as necessary.
• Seals (piston and cover) damaged • Inspect for mislocation, poor seating, damage. Install
a new cylinder.

2005 Aviator, 09/2004

307-01-51 Automatic Transmission — 5R55S 307-01-51
DIAGNOSIS AND TESTING (Continued)
Shift Concern: No 4-5 Shift
Possible Component Reference/Action
270 — ROUTINE
Powertrain Control System
• PCM, vehicle wiring harnesses, shift solenoid C, • Carry out On-Board Diagnostic Tests. Refer to the
pressure control solenoid B, output shaft speed (OSS) Powertrain Control/Emissions Diagnosis (PC/ED)
sensor, digital TR sensor manual for diagnosis and testing of the PCM.
• Transmission Control Switch (TCS) • GO to Pinpoint Test A, GO to Pinpoint Test C, GO
to Pinpoint Test D and GO to Pinpoint Test E.
• Repair as required. Clear DTCs, road test and rerun
On-Board Diagnostic Test.
• For TSC diagnosis, refer to Section 307-05.
Incorrect Pressures
• High/low pressures • Check pressure at line and PC C taps.
• Carry out Line Pressure Test. Refer to Special Testing
Procedures in this section.
Main Control
• Screws not tightened to specification • Tighten to specification.
• Separator plate damaged • Inspect for damage. If damaged, install a new
separator plate.
• Contamination • Disassemble and clean.
• Valve/springs damaged, misassembled, missing, stuck • If damaged or parts are missing, install new main
or bore damaged control assembly. If misassembled, reassemble
correctly. DO NOT stone, file or sand valves. This
will remove the anodized finish and may result in
further main control or transmission damage.
• Filter damaged or missing • Inspect for damage. Repair as necessary.
OD Servo
• Servo retaining screws damaged • Inspect for damage. Repair as necessary.
• Seals (piston and cover) damaged • Inspect for damage. Repair as necessary.
OD Band
• Band damaged • Inspect for damage. Repair as necessary.
• Servo worn or damaged • Inspect for damage. Repair as necessary.
• Not adjusted correctly • Inspect for damage. Repair as necessary.

Shift Concern: No 5-4 Shift

Possible Component Reference/Action
271 — ROUTINE
Powertrain Control System
• PCM, vehicle wiring harnesses, shift solenoid C, • Carry out On-Board Diagnostic Tests. Refer to the
pressure control solenoid C, output shaft speed (OSS) Powertrain Control/Emissions Diagnosis (PC/ED)
sensor, digital TR sensor manual for diagnosis and testing of the PCM.
• Transmission Control Switch (TCS) • GO to Pinpoint Test A, GO to Pinpoint Test C, GO
to Pinpoint Test D and GO to Pinpoint Test E.
• Repair as required. Clear DTCs, road test and rerun
On-Board Diagnostic Test.

2005 Aviator, 09/2004

307-01-52 Automatic Transmission — 5R55S 307-01-52
DIAGNOSIS AND TESTING (Continued)
Shift Concern: No 5-4 Shift (Continued)
Possible Component Reference/Action
• For TSC diagnosis, refer to Section 307-05.
Incorrect Pressures
• High/low pressures • Check pressure at line and PC C taps.
• Carry out Line Pressure Test. Refer to Special Testing
Procedures in this section.
Main Control
• Screws not tightened to specification • Tighten to specification.
• Separator plate damaged • Inspect for damage. If damaged, install a new
separator plate.
• Contamination • Disassemble and clean.
• Valves/springs damaged, misassembled, missing, stuck • If damaged or parts are missing, install new main
or bore damaged control assembly. If misassembled, reassemble
correctly. DO NOT stone, file or sand valves. This
will remove the anodized finish and may result in
further main control or transmission damage.
• Filter damaged or missing • Inspect for damage. Repair as necessary.
OD Servo
• Servo retaining screws damaged • Inspect for damage. Repair as necessary.
• Seals (piston and cover) damaged • Inspect for damage. Repair as necessary.
OD Band
• Band damaged • Inspect for damage. Repair as necessary.
• Servo worn or damaged • Inspect for damage. Repair as necessary.
• Not adjusted correctly • Inspect for damage. Repair as necessary.

Shift Concern: No 4-3 Shift

Possible Component Reference/Action
223 — ROUTINE
Powertrain Control System
• PCM, vehicle wiring harnesses, shift solenoid A, B, • Carry out On-Board Diagnostic Tests. Refer to the
pressure control solenoid A, output shaft speed (OSS) Powertrain Control/Emissions Diagnosis (PC/ED)
sensor, digital TR sensor manual for diagnosis and testing of the PCM.
• GO to Pinpoint Test A, GO to Pinpoint Test C, GO
to Pinpoint Test D and GO to Pinpoint Test E.
• Repair as required. Clear DTCs, road test and rerun
On-Board Diagnostic Test.
Incorrect Pressures
• High/low pressures • Check pressure at line and PC C taps.
• Carry out Line Pressure Test. Refer to Special Testing
Procedures in this section.
Main Control
• Screws not tightened to specification • Tighten to specification.
• Separator plate damaged • Inspect for damage. If damaged, install a new
separator plate.

2005 Aviator, 09/2004

307-01-53 Automatic Transmission — 5R55S 307-01-53
DIAGNOSIS AND TESTING (Continued)
Shift Concern: No 4-3 Shift (Continued)
Possible Component Reference/Action
• Contamination • Disassemble and clean.
• Valves/springs damaged, misassembled, missing, stuck • If damaged or parts are missing, install new main
or bore damaged control assembly. If misassembled, reassemble
correctly. DO NOT stone, file or sand valves. This
will remove the anodized finish and may result in
further main control or transmission damage.
• Filter damaged or missing • Inspect for damage. Repair as necessary.
Intermediate Servo
• Servo retaining screws damaged • Inspect for damage. Repair as necessary.
• Seals (piston and cover) damaged • Inspect for damage. Repair as necessary.
Intermediate Band
• Band damaged • Inspect for damage. Repair as necessary.
• Servo worn or damaged • Inspect for damage. Repair as necessary.
• Not adjusted correctly • Inspect for damage. Repair as necessary.

Shift Concern: No 3-2 Shift

Possible Component Reference/Action
224 — ROUTINE
Powertrain Control System
• PCM, vehicle wiring harnesses, shift solenoid C, • Carry out On-Board Diagnostic Tests. Refer to the
pressure control solenoid B, output shaft speed (OSS) Powertrain Control/Emissions Diagnosis (PC/ED)
sensor, digital TR sensor manual for diagnosis and testing of the PCM.
• GO to Pinpoint Test A, GO to Pinpoint Test C, GO
to Pinpoint Test D and GO to Pinpoint Test E.
• Repair as required. Clear DTCs, road test and rerun
On-Board Diagnostic Test.
Incorrect Pressures
• High/low pressures • Check pressure at line and PC C taps.
• Carry out Line Pressure Test. Refer to Special Testing
Procedures in this section.
Main Control
• Screws not tightened to specification • Tighten to specification.
• Separator plate damaged • Inspect for damage. If damaged, install a new
separator plate.
• Contamination • Disassemble and clean.
• Valves/springs damaged, misassembled, missing, stuck • If damaged or parts are missing, install new main
or bore damaged control assembly. If misassembled, reassemble
correctly. DO NOT stone, file or sand valves. This
will remove the anodized finish and may result in
further main control or transmission damage.
• Filter damaged or missing • Inspect for damage. Repair as necessary.
OD Servo
• Servo retaining screws damaged • Inspect for damage. Repair as necessary.
• Seals (piston and cover) damaged • Inspect for damage. Repair as necessary.

2005 Aviator, 09/2004

307-01-54 Automatic Transmission — 5R55S 307-01-54
DIAGNOSIS AND TESTING (Continued)
Shift Concern: No 3-2 Shift (Continued)
Possible Component Reference/Action
OD Band
• Band damaged • Inspect for damage. Repair as necessary.
• Servo worn or damaged • Inspect for damage. Repair as necessary.
• Not adjusted correctly • Inspect for damage. Repair as necessary.
Forward Clutch Assembly
• Seals, piston damaged • Inspect for damage. Repair as necessary.
• Check ball damaged, missing, not seating, off location • Inspect for mislocation, poor seating, damage. Install
a new cylinder.
• Friction elements damaged or worn • Inspect for damage. Repair as necessary.
• Return springs damaged • Inspect for damage. Repair as necessary.
• Bronze seal ring on bearing damaged • Inspect for damage. Repair as necessary.

Shift Concern: No 2-1 Shift

Possible Component Reference/Action
225 — ROUTINE
Powertrain Control System
• PCM, vehicle wiring harnesses, shift solenoid C, • Carry out On-Board Diagnostic Tests. Refer to the
pressure control solenoid B, output shaft speed (OSS) Powertrain Control/Emissions Diagnosis (PC/ED)
sensor, digital TR sensor manual for diagnosis and testing of the PCM.
• GO to Pinpoint Test A, GO to Pinpoint Test C, GO
to Pinpoint Test D and GO to Pinpoint Test E.
• Repair as required. Clear DTCs, road test and rerun
On-Board Diagnostic Test.
Incorrect Pressures
• High/low pressures • Check pressure at line and PC C taps.
• Carry out Line Pressure Test. Refer to Special Testing
Procedures in this section.
Main Control
• Screws not tightened to specification • Tighten to specification.
• Separator plate damaged • Inspect for damage. If damaged, install a new
separator plate.
• Contamination • Disassemble and clean.
• Valves/springs damaged, misassembled, missing, stuck • If damaged or parts are missing, install new main
or bore damaged control assembly. If misassembled, reassemble
correctly. DO NOT stone, file or sand valves. This
will remove the anodized finish and may result in
further main control or transmission damage.
• Filter damaged or missing • Inspect for damage. Repair as necessary.
Forward Clutch Assembly
• Seals, piston damaged • Inspect for damage. Repair as necessary.
• Check ball damaged, missing, not seating, off location • Inspect for mislocation, poor seating, damage. Install
a new cylinder.
• Friction elements damaged or worn • Inspect for damage. Repair as necessary.

2005 Aviator, 09/2004

307-01-55 Automatic Transmission — 5R55S 307-01-55
DIAGNOSIS AND TESTING (Continued)
Shift Concern: No 2-1 Shift (Continued)
Possible Component Reference/Action
• Return springs damaged • Inspect for damage. Repair as necessary.
• Bronze seal ring on bearing damaged • Inspect for damage. Repair as necessary.
OD Servo
• Servo retaining screws damaged • Inspect for damage. Repair as necessary.
• Seals (piston and cover) damaged • Inspect for damage. Repair as necessary.
OD Band
• Band damaged • Inspect for damage. Repair as necessary.
• Servo worn or damaged • Inspect for damage. Repair as necessary.
• Not adjusted correctly • Inspect for damage. Repair as necessary.

Shift Concern: Soft/Slipping 1-2 Shift

Possible Component Reference/Action
226 — ROUTINE
Powertrain Control System
• PCM, vehicle wiring harnesses, shift solenoid C, • Carry out On-Board Diagnostic Tests. Refer to the
pressure control solenoid B, transmission fluid Powertrain Control/Emissions Diagnosis (PC/ED)
temperature (TFT) sensor, VSS input manual for diagnosis and testing of the PCM.
• GO to Pinpoint Test A, GO to Pinpoint Test B and
GO to Pinpoint Test D.
• Repair as required. Clear DTCs, road test and rerun
On-Board Diagnostic Test.
Fluid
• Incorrect level • Adjust fluid to correct level. Refer to Transmission
Fluid Level Check in this section.
• Condition • Carry out Fluid Condition Check. Refer to
Preliminary Inspection in this section.
Incorrect Pressures
• High/low pressures • Check pressure at line and PC C taps.
• Carry out Line Pressure Test. Refer to Special Testing
Procedures in this section.
Main Control
• Screws not tightened to specification • Tighten to specification.
• Separator plate damaged • Inspect for damage. If damaged, install a new
separator plate.
• Contamination • Disassemble and clean.
• Valve/springs damaged, misassembled, missing, stuck • If damaged or parts are missing, install new main
or bore damaged control assembly. If misassembled, reassemble
correctly. DO NOT stone, file or sand valves. This
will remove the anodized finish and may result in
further main control or transmission damage.
• Filter damaged or missing • Inspect for damage. Repair as necessary.
OD Servo
• Servo retaining screws damaged • Inspect for damage. Repair as necessary.

2005 Aviator, 09/2004

307-01-56 Automatic Transmission — 5R55S 307-01-56
DIAGNOSIS AND TESTING (Continued)
Shift Concern: Soft/Slipping 1-2 Shift (Continued)
Possible Component Reference/Action
• Seals (piston and cover) damaged • Inspect for damage. Repair as necessary.
OD Band
• Band damaged • Inspect for damage. Repair as necessary.
• Servo worn or damaged • Inspect for damage. Repair as necessary.
• Not adjusted correctly • Inspect for damage. Repair as necessary.

Shift Concern: Soft/Slipping 2-3 Shift

Possible Component Reference/Action
227 — ROUTINE
Powertrain Control System
• PCM, vehicle wiring harnesses, shift solenoid A, • Carry out On-Board Diagnostic Tests. Refer to the
pressure control solenoid A, intermediate shaft speed Powertrain Control/Emissions Diagnosis (PC/ED)
sensor, transmission fluid temperature (TFT) sensor manual for diagnosis and testing of the PCM.
• GO to Pinpoint Test A, GO to Pinpoint Test B, GO
to Pinpoint Test D and GO to Pinpoint Test E.
• Repair as required. Clear DTCs, road test and rerun
On-Board Diagnostic Test.
Incorrect Pressures
• High/low pressures • Check pressure at line and PC C taps.
• Carry out Line Pressure Test. Refer to Special Testing
Procedures in this section.
Main Control
• Screws not tightened to specification • Tighten to specification.
• Separator plate damaged • Inspect for damage. If damaged, install a new
separator plate.
• Contamination • Disassemble and clean.
• Valve/springs damaged, misassembled, missing, stuck • If damaged or parts are missing, install new main
or bore damaged control assembly. If misassembled, reassemble
correctly. DO NOT stone, file or sand valves. This
will remove the anodized finish and may result in
further main control or transmission damage.
• Filter damaged or missing • Inspect for damage. Repair as necessary.
Intermediate Servo
• Servo retaining screws damaged • Inspect for damage. Repair as necessary.
• Seals (piston and cover) damaged • Inspect for mislocation, poor seating, damage. Install
a new cylinder.
Intermediate Band
• Band damaged • Inspect for damage. Repair as necessary.
• Servo worn or damaged • Inspect for damage. Repair as necessary.
• Not adjusted correctly • Inspect for damage. Repair as necessary.
Direct One-Way Clutch
• Worn, damaged or assembled incorrectly • Inspect for damage. Repair as necessary.

2005 Aviator, 09/2004

307-01-57 Automatic Transmission — 5R55S 307-01-57
DIAGNOSIS AND TESTING (Continued)
Shift Concern: Soft/Slipping 3-4 Shift
Possible Component Reference/Action
228 — ROUTINE
Powertrain Control System
• PCM, vehicle wiring harnesses, shift solenoid A, • Carry out On-Board Diagnostic Tests. Refer to the
pressure control solenoid C, transmission fluid Powertrain Control/Emissions Diagnosis (PC/ED)
temperature (TFT) sensor manual for diagnosis and testing of the PCM.
• GO to Pinpoint Test A, GO to Pinpoint Test B and
GO to Pinpoint Test D.
• Repair as required. Clear DTCs, road test and rerun
On-Board Diagnostic Test.
Incorrect Pressures
• High/low pressures • Check pressure at line and PC C taps.
• Carry out Line Pressure Test. Refer to Special Testing
Procedures in this section.
Main Control
• Screws not tightened to specification • Tighten to specification.
• Separator plate damaged • Inspect for damage. If damaged, install a new
separator plate.
• Contamination • Disassemble and clean.
• Valves/springs damaged, misassembled, missing, stuck • If damaged or parts are missing, install new main
or bore damaged control assembly. If misassembled, reassemble
correctly. DO NOT stone, file or sand valves. This
will remove the anodized finish and may result in
further main control or transmission damage.
• Filter damaged or missing • Inspect for damage. Repair as necessary.
Center Support
• Screw not tightened to specification • Tighten to specification.
• Seal rings or bearing damaged • Inspect for damage. Repair as necessary.
• Outside diameter of case bore damaged • Inspect for damage. Repair as necessary.
• Support damaged or leaking • Inspect for damage. Repair as necessary.
Direct Clutch Assembly
• Seals, piston damaged • Inspect for damage. Repair as necessary.
• Check ball damaged, missing, not seating, off location • Inspect for mislocation, poor seating, damage. Install
a new cylinder.
• Friction elements damaged or worn • Inspect for damage. Repair as necessary.
• Return springs damaged • Inspect for damage. Repair as necessary.
Intermediate Servo
• Servo retaining screws damaged • Inspect for damage. Repair as necessary.
• Seals (piston and cover) damaged • Inspect for damage. Repair as necessary.

Shift Concern: Soft/Slipping 4-5 Shift

Possible Component Reference/Action
272 — ROUTINE
Powertrain Control System

2005 Aviator, 09/2004

307-01-58 Automatic Transmission — 5R55S 307-01-58
DIAGNOSIS AND TESTING (Continued)
Shift Concern: Soft/Slipping 4-5 Shift (Continued)
Possible Component Reference/Action
• PCM, vehicle wiring harnesses, shift solenoid C, • Carry out On-Board Diagnostic Tests. Refer to the
pressure control solenoid B, transmission fluid Powertrain Control/Emissions Diagnosis (PC/ED)
temperature (TFT) sensor manual for diagnosis and testing of the PCM.
• GO to Pinpoint Test A, GO to Pinpoint Test B and
GO to Pinpoint Test D.
• Repair as required. Clear DTCs, road test and rerun
On-Board Diagnostic Test.
Incorrect Pressures
• High/low pressures • Check pressure at line and PC C taps.
• Carry out Line Pressure Test. Refer to Special Testing
Procedures in this section.
Main Control
• Screws not tightened to specification • Tighten to specification.
• Separator plate damaged • Inspect for damage. If damaged, install a new
separator plate.
• Contamination • Disassemble and clean.
• Valves/springs damaged, misassembled, missing, stuck • If damaged or parts are missing, install new main
or bore damaged control assembly. If misassembled, reassemble
correctly. DO NOT stone, file or sand valves. This
will remove the anodized finish and may result in
further main control or transmission damage.
• Filter damaged or missing • Inspect for damage. Repair as necessary.
OD Servo
• Servo retaining screws damaged • Inspect for damage. Repair as necessary.
• Seals (piston and cover) damaged • Inspect for damage. Repair as necessary.
OD Band
• Band damaged • Inspect for damage. Repair as necessary.
• Servo worn or damaged • Inspect for damage. Repair as necessary.
• Not adjusted correctly • Inspect for damage. Repair as necessary.

Shift Concern: Feel — Soft/Slipping 5-4 Shift

Possible Component Reference/Action
273 — ROUTINE
Powertrain Control System
• PCM, vehicle wiring harnesses, shift solenoid C, • Carry out On-Board Diagnostic Tests. Refer to the
pressure control solenoid C, transmission fluid Powertrain Control/Emissions Diagnosis (PC/ED)
temperature (TFT) sensor manual for diagnosis and testing of the PCM.
• GO to Pinpoint Test A, GO to Pinpoint Test B and
GO to Pinpoint Test D.
• Repair as required. Clear DTCs, road test and rerun
On-Board Diagnostic Test.
Incorrect Pressures
• High/low pressures • Check pressure at line and PC C taps.

2005 Aviator, 09/2004

307-01-59 Automatic Transmission — 5R55S 307-01-59
DIAGNOSIS AND TESTING (Continued)
Shift Concern: Feel — Soft/Slipping 5-4 Shift (Continued)
Possible Component Reference/Action
• Carry out Line Pressure Test. Refer to Special Testing
Procedures in this section.
Main Control
• Screws not tightened to specification • Tighten to specification.
• Separator plate damaged • Inspect for damage. If damaged, install a new
separator plate.
• Contamination • Disassemble and clean.
• Valves/springs damaged, misassembled, missing, stuck • If damaged or parts are missing, install new main
or bore damaged control assembly. If misassembled, reassemble
correctly. DO NOT stone, file or sand valves. This
will remove the anodized finish and may result in
further main control or transmission damage.
• Filter damaged or missing • Inspect for damage. Repair as necessary.
Direct Clutch Assembly
• Seals, piston damaged • Inspect for damage. Repair as necessary.
• Check ball damaged, missing, not seating, off location • Inspect for mislocation, poor seating, damage. Install
a new cylinder.
• Friction elements damaged or worn • Inspect for damage. Repair as necessary.
• Return springs damaged • Inspect for damage. Repair as necessary.
Direct One-Way Clutch
• Worn, damaged or assembled incorrectly • Inspect for damage. Repair as necessary.

Shift Concern: Feel — Soft/Slipping 4-3 Shift

Possible Component Reference/Action
229 — ROUTINE
Powertrain Control System
• PCM, vehicle wiring harnesses, shift solenoid A, • Carry out On-Board Diagnostic Tests. Refer to the
pressure control solenoid A, transmission fluid Powertrain Control/Emissions Diagnosis (PC/ED)
temperature (TFT) sensor manual for diagnosis and testing of the PCM.
• GO to Pinpoint Test A, GO to Pinpoint Test B and
GO to Pinpoint Test D.
• Repair as required. Clear DTCs, road test and rerun
On-Board Diagnostic Test.
Incorrect Pressures
• High/low pressures • Check pressure at line and PC C taps.
• Carry out Line Pressure Test. Refer to Special Testing
Procedures in this section.
Main Control
• Screws not tightened to specification • Tighten to specification.
• Separator plate damaged • Inspect for damage. If damaged, install a new
separator plate.
• Contamination • Disassemble and clean.

2005 Aviator, 09/2004

307-01-60 Automatic Transmission — 5R55S 307-01-60
DIAGNOSIS AND TESTING (Continued)
Shift Concern: Feel — Soft/Slipping 4-3 Shift (Continued)
Possible Component Reference/Action
• Valves/springs damaged, misassembled, missing, stuck • If damaged or parts are missing, install new main
or bore damaged control assembly. If misassembled, reassemble
correctly. DO NOT stone, file or sand valves. This
will remove the anodized finish and may result in
further main control or transmission damage.
• Filter damaged or missing • Inspect for damage. Repair as necessary.
Intermediate Servo
• Servo retaining screws damaged • Inspect for damage. Repair as necessary.
• Seals (piston and cover) damaged • Inspect for damage. Repair as necessary.
Intermediate Band
• Band damaged • Inspect for damage. Repair as necessary.
• Servo worn or damaged • Inspect for damage. Repair as necessary.
• Not adjusted correctly • Inspect for damage. Repair as necessary.

Shift Concern: Soft/Slipping 3-2 Shift

Possible Component Reference/Action
230 — ROUTINE
Powertrain Control System
• PCM, vehicle wiring harnesses, shift solenoid C, • Carry out On-Board Diagnostic Tests. Refer to the
pressure control solenoid B, intermediate shaft speed Powertrain Control/Emissions Diagnosis (PC/ED)
sensor, transmission fluid temperature (TFT) sensor manual for diagnosis and testing of the PCM.
• GO to Pinpoint Test A, GO to Pinpoint Test B, GO
to Pinpoint Test D and GO to Pinpoint Test E.
• Repair as required. Clear DTCs, road test and rerun
On-Board Diagnostic Test.
Incorrect Pressures
• High/low pressures • Check pressure at line and PC C taps.
• Carry out Line Pressure Test. Refer to Special Testing
Procedures in this section.
Main Control
• Screws not tightened to specification • Tighten to specification.
• Separator plate damaged • Inspect for damage. If damaged, install a new
separator plate.
• Contamination • Disassemble and clean.
• Valves/springs damaged, misassembled, missing, stuck • If damaged or parts are missing, install new main
or bore damaged control assembly. If misassembled, reassemble
correctly. DO NOT stone, file or sand valves. This
will remove the anodized finish and may result in
further main control or transmission damage.
• Filter damaged or missing • Inspect for damage. Repair as necessary.
OD Servo
• Servo retaining screws damaged • Inspect for damage. Repair as necessary.
• Seals (piston and cover) damaged • Inspect for damage. Repair as necessary.
OD Band

2005 Aviator, 09/2004

307-01-61 Automatic Transmission — 5R55S 307-01-61
DIAGNOSIS AND TESTING (Continued)
Shift Concern: Soft/Slipping 3-2 Shift (Continued)
Possible Component Reference/Action
• Band damaged • Inspect for damage. Repair as necessary.
• Servo worn or damaged • Inspect for damage. Repair as necessary.
• Not adjusted correctly • Inspect for damage. Repair as necessary.
Direct One-Way Clutch
• Worn, damaged or assembled incorrectly • Inspect for damage. Repair as necessary.

Shift Concern: Feel — Soft/Slipping 2-1 Shift

Possible Component Reference/Action
231 — ROUTINE
Powertrain Control System
• PCM, vehicle wiring harnesses, shift solenoid C, • Carry out On-Board Diagnostic Tests. Refer to the
pressure control solenoid B, transmission fluid Powertrain Control/Emissions Diagnosis (PC/ED)
temperature (TFT) sensor manual for diagnosis and testing of the PCM.
• GO to Pinpoint Test A, GO to Pinpoint Test B and
GO to Pinpoint Test D.
• Repair as required. Clear DTCs, road test and rerun
On-Board Diagnostic Test.
Incorrect Pressures
• High/low pressures • Check pressure at line and PC C taps.
• Carry out Line Pressure Test. Refer to Special Testing
Procedures in this section.
Main Control
• Screws not tightened to specification • Tighten to specification.
• Separator plate damaged • Inspect for damage. If damaged, install a new
separator plate.
• Contamination • Disassemble and clean.
• Valves/springs damaged, misassembled, missing, stuck • If damaged or parts are missing, install new main
or bore damaged control assembly. If misassembled, reassemble
correctly. DO NOT stone, file or sand valves. This
will remove the anodized finish and may result in
further main control or transmission damage.
• Filter damaged or missing • Inspect for damage. Repair as necessary.

2005 Aviator, 09/2004

307-01-1 Automatic Transmission — 5R55S 307-01-1

GENERAL PROCEDURES
Transmission Fluid Level Check Fluid Fill Reference
NOTE: Left side of case shown.
Special Tool(s)
Rubber Tip Air Nozzle
100-D009 (D93L-7000-A)

Vacuum Pump Kit

416-D002 (D95L-7559-A)

Item Part Number Description

1 — Fluid level
2 7A010 Fluid level tube
Fluid Transporter/Evacuator/
Injector 3 W704999-S309 Fluid level and fill plug
307-D465 (small) (in-vehicle)
4 7A010 Fluid drain plug (large)

1. Using the diagnostic tool (WDS), monitor the

transmission fluid temperature (TFT) using PID:
Worldwide Diagnostic System TFT.
(WDS)
Vehicle Communication Module 2. Start the vehicle.
(VCM), with appropriate
adapters or equivalent diagnostic 3. NOTE: Engine idle speed is approximately 650
tool rpm.
While proceeding with this procedure, run the
Adapter, Fluid Level and Fill engine until the transmission fluid temperature
Plug is between 27-49°C (80-120°F).
307-437
4. Move the range selector lever slowly through
each gear, stopping in each position and
allowing the transmission to engage.

Material
Item Specification
MERCON V Automatic MERCON V
Transmission Fluid
XT-5-QM

Copyright  2004, Ford Motor Company

Last updated: 06/29/2004 2005 Aviator, 09/2004
307-01-2 Automatic Transmission — 5R55S 307-01-2
GENERAL PROCEDURES (Continued)
5. Place the range selector lever in the PARK
position.

6. With the engine running and the vehicle set as

close to level as possible, position it on a hoist.
For additional information, refer to Section
100-02.

7. Hold the larger drain plug with a wrench and

remove the small (center) fluid level indicating
plug.

10. Hang the special tool under the vehicle.

Position it upright and close to the transmission.

8. Install the special tool into the pan.

11. Connect the special tools.

• Connect the open end of the fluid hose from
the Fluid Transporter/Evacuator/Injector to
the Fluid Level and Fill Plug Adapter at the
bottom of the transmission fluid pan.

9. NOTE: Prior to filling the special tool with

clean transmission fluid, make sure that the
canister is clean.
Fill the special tool with clean automatic
transmission fluid.

2005 Aviator, 09/2004

307-01-3 Automatic Transmission — 5R55S 307-01-3
GENERAL PROCEDURES (Continued)
12. Apply a maximum of 206.85 kPa (30 psi) to 16. Allow the fluid to drain. Make sure that the
the open end of the vacuum/pressure hose from fluid temperature is between 27-49°C
the special tool. Fluid will immediately start (80-120°F). When the fluid comes out as a thin
flowing out of the special tool into the stream or drip, the fluid is at the correct level.
transmission fluid pan.

17. Reinstall the small (center) fluid level indicating

13. Add one pint of transmission fluid into the fluid plug using a 3/16-inch Allen key.
pan. Stop the process by releasing the air • Tighten to 10 Nm (89 lb-in).
pressure and removing the air nozzle from the
end of the hose.

14. Inspect the fluid level in the special tool. If the

fluid drains back into the canister, the
transmission is full. If no fluid drains back,
more fluid will need to be added. Repeat Steps
12 and 13.

15. Once the transmission is full, place a hand

vacuum pump on the open end of the hose of
the special tool and apply vacuum to the
system. This will pull out any extra fluid
trapped in the system and direct it into the
container. 18. Check the operation of the transmission by
moving the range selector lever slowly through
each gear, stopping in each position and
allowing the transmission to engage.

2005 Aviator, 09/2004

307-01-1 Automatic Transmission — 5R55S 307-01-1

GENERAL PROCEDURES
Transmission Fluid Drain and Refill — 3. When connecting the flush and fill machine,
Automated Equipment connect the machine to the fluid cooler tube
after the fluid cooler on the cooler return line.
This will help remove any foreign material
Special Tool(s)
trapped in the fluid coolers.
Automatic Transmission Flush
and Fill Machine Refill
211-00018
Automatic Transmission Flush 1. Use only clean automatic transmission fluid.
and Fill Machine
199-00010 or equivalent
2. Once the fluid exchange has been completed,
disconnect the flush and fill machine.
Reconnect any disconnected fluid cooler tubes.
Material
Item Specification 3. Lower the vehicle. For additional information,
refer to Section 100-02.
MERCON V Automatic MERCON V
Transmission Fluid
XT-5-QM 4. With the engine running, check and adjust the
transmission fluid level and check for any
Draining leaks. If fluid is needed, add fluid in increments
of 0.24-liter (0.5-pint) until the correct level is
CAUTION: Use only clean automatic achieved. For additional information, refer to
transmission fluid specified for this transmission. Transmission Fluid Level Check in this section,
Do not use supplemental transmission fluid
additives, treatments or clean agents. The use of
these materials may affect transmission operation
and result in damage to internal transmission
components.

CAUTION: Always refer to the

instructions supplied with the flush and fill
machine.

1. With the vehicle in PARK, position it on a

hoist. For additional information, refer to
Section 100-02.

2. Use a suitable flush and fill machine to change

the fluid.

Copyright  2004, Ford Motor Company

Last updated: 06/29/2004 2005 Aviator, 09/2004
307-01-1 Automatic Transmission — 5R55S 307-01-1

GENERAL PROCEDURES
Transmission Fluid Drain and Refill — Fluid Fill Reference
Without Torque Converter Drain Plug NOTE: Left side of case shown.

Special Tool(s)
Rubber Tip Air Nozzle
100-D009 (D93L-7000-A)

Vacuum Pump Kit

416-D002 (D95L-7559-A)

Item Part Number Description

1 — Fluid level
2 7A010 Fluid level tube
3 W704999-S309 Fluid level and fill plug
Fluid (small) (in-vehicle)
Transporter/Evacuator/Injector
307-D465 4 7A010 Fluid drain plug (large)

Draining

1. With the vehicle in PARK, position it on a

Adapter, Fluid Level and Fill hoist. Set the vehicle as close to level as
Plug possible. For additional information, refer to
307-437 Section 100-02.

2. Remove the drain plug (large plug) and allow

the fluid to drain.

Worldwide Diagnostic System

(WDS)
Vehicle Communication
Module, with appropriate
adapters or equivalent diagnostic
tool

Material
Item Specification
MERCON V Automatic MERCON V
Transmission Fluid
XT-5-QM

Copyright  2004, Ford Motor Company

Last updated: 06/29/2004 2005 Aviator, 09/2004
307-01-2 Automatic Transmission — 5R55S 307-01-2
GENERAL PROCEDURES (Continued)
Refill 4. NOTE: Prior to filling the special tool with
clean transmission fluid, make sure that the
1. Install the fluid drain plug. canister is clean.
• Tighten to 26 Nm (19 lb-ft). Fill the special tool with clean automatic
transmission fluid.

2. Hold the larger drain plug with a wrench and

remove the small (center) fluid level indicating 5. Hang the special tool under the vehicle, upright
plug. and close to the transmission.

3. Install the special tool into the pan.

2005 Aviator, 09/2004

307-01-3 Automatic Transmission — 5R55S 307-01-3
GENERAL PROCEDURES (Continued)
6. Connect the special tools. 10. Inspect the fluid level in the special tool. If the
• Connect the open end of the fluid hose from fluid drains back into the canister, the
the Fluid Transporter/Evacuator/Injector to transmission is full. If no fluid drains back,
the, Fluid Level and Fill Plug Adapter at the more fluid will need to be added. Repeat Steps
bottom of the transmission fluid pan. 9 and 10.

11. Once the transmission is full, place a hand

vacuum pump on the open end of the
vacuum/pressure hose of the special tool and
apply vacuum to the system. This will pull out
any extra fluid trapped in the system and direct
it into the container.

7. Apply a maximum of 206.85 kPa (30 psi) to

the open end of the vacuum/pressure hose from
the special tool. Fluid will immediately start
flowing out of the special tool into the
transmission fluid pan.

12. Allow the fluid to drain. When the fluid comes

out as a thin stream or drip, the fluid is at the
correct level.

8. Add 2 or 3 quarts of transmission fluid into the

fluid pan. Stop the process by releasing the air
pressure and removing the air nozzle from the
end of the hose.

9. NOTE: Engine idle speed is approximately 650

rpm.
Start and run the engine until the transmission
fluid temperature is between 27°C - 49°C (80°F
- 120°F).

2005 Aviator, 09/2004

307-01-4 Automatic Transmission — 5R55S 307-01-4
GENERAL PROCEDURES (Continued)
13. Reinstall the small (center) fluid level indicating
plug.
• Tighten to 10 Nm (89 lb-in).

2005 Aviator, 09/2004

307-01-1 Automatic Transmission — 5R55S 307-01-1

GENERAL PROCEDURES
Transmission Fluid In-Line Filter

Special Tool(s)
Disconnect Tool, Transmission
307-441

Material
Item Specification 3. Loosen the bolts and position the power
MERCON V Automatic MERCON V steering cooler aside.
Transmission Fluid
XT-5-QM

NOTE: Use the following guidelines for installing

the transmission fluid in-line filter:
• If the transmission was overhauled and the vehicle
was equipped with an in-line fluid filter, install a
new in-line fluid filter.
• If the transmission was overhauled and the vehicle
was not equipped with an in-line fluid filter,
install a new in-line fluid filter kit.
• If the transmission is being installed for a
non-internal repair, do not install an in-line filter
or filter kit. 4. Remove the safety retainer from the fluid cooler
• If installing a Ford-authorized remanufactured connector.
transmission, install the in-line transmission fluid
filter that is supplied.

1. With the vehicle in NEUTRAL, position it on a

hoist. For additional information, refer to
Section 100-02.

2. Remove the push pins and remove the lower air

dam.

Copyright  2004, Ford Motor Company

Last updated: 06/29/2004 2005 Aviator, 09/2004
307-01-2 Automatic Transmission — 5R55S 307-01-2
GENERAL PROCEDURES (Continued)
5. Using the special tool, disconnect the fluid
cooler connector.

9. CAUTION: The filter has a bypass

valve in it. The red arrow on the filter
indicates the direction of fluid flow through
6. Remove the section of the steel tube at the 2nd the filter. The filter must be installed in the
flare. fluid cooler return line with the red arrow
• Clean and deburr the cut end of the steel on the filter pointing away from the
tube. transmission fluid cooler and toward the
transmission (the return line has fluid
7. NOTE: Be sure the cooler tube is fully seated coming out of the cooler going to the
in the body of the fitting before final tightening transmission). If the fluid filter is not
of the ferrule nut. installed correctly, it will cause internal
Install the tubing ferrule hose assembly transmission damage.
connector onto the end of the steel fluid cooler CAUTION: Do not install any rubber
tube. Finger-tighten the ferrule nut, then tighten hoses or steel tubing with a bend entering
the nut an additional 1-1/2 turns to seat the the filter greater than 60 degrees.
ferrule in the connector.
Install the one end of the filter into the rubber
hose with a clamp.
• Tighten the hose clamp.

8. Remove the section of the rubber hose as

illustrated.

2005 Aviator, 09/2004

307-01-3 Automatic Transmission — 5R55S 307-01-3
GENERAL PROCEDURES (Continued)
10. Using a suitable length of hose, install the other
end of the filter into the tubing ferrule hose
assembly with 2 clamps.
• Tighten the hose clamps.

13. Clean a section of the transmission fluid pan,

then install the sticker.

11. Install the power steering fluid cooler.

• Tighten to 11 Nm (8 lb-ft).

14. Fill the transmission with clean automatic

transmission fluid.
• Verify for correct operation.
• Check the filter for leaks.

12. Install the lower air dam and install the push
pins.

2005 Aviator, 09/2004

307-01-1 Automatic Transmission — 5R55S 307-01-1

GENERAL PROCEDURES
Transmission Fluid Cooler — 2. Remove and discard the in-line transmission
Backflushing and Cleaning fluid filter, if equipped.

Material
Item Specification
MERCON V Automatic MERCON V
Transmission Fluid
XT-5-QM

CAUTION: Whenever a transmission has

been disassembled to install new parts or a new
or remanufactured transmission has been
installed, a new transmission fluid cooler, either
in-tank, auxiliary or oil to air (OTA), if equipped
will need to be installed. Using a suitable torque
converter/fluid cooler cleaner, clean and 3. To aid in attaching the cleaner to the
backflush the transmission fluid cooler tubes. transmission steel cooler lines, connect 2
additional rubber hoses to the transmission end
CAUTION: Use only clean automatic of the steel transmission cooler lines as
transmission fluid specified for this transmission. described.
Do not use supplemental fluid additives, • Connect the cleaner tank pressure line to the
treatments or cleaning agent. The use of these steel transmission cooler return line (longest
materials may affect transmission operation and line).
result in internal damage to the transmission.
• Connect a tank return hose to the steel
When internal wear or damage has occurred in transmission cooler pressure line (shorter
the transmission, metal particles, clutch plate line). Place the outlet end of this hose in the
material or band material may have been carried solvent tank reservoir.
into the transmission fluid cooler. These
contaminants are a major cause of recurring 4. Turn on the pump and allow the transmission
transmission concerns and must be removed fluid to circulate a minimum of 5 minutes
from the system before the transmission is put (cycling switch on and off will help dislodge
back in use. contaminants in the cooler system).

NOTE: Do not use any solvents while carrying out 5. Switch off the pump and disconnect the
this procedure. Only use clean automatic pressure hose from the transmission cooler
transmission fluid. return line.

1. Conduct backflushing with a suitable torque 6. Use compressed air to blow out the cooler(s)
converter/transmission fluid cooler cleaner. Test and lines (blow air into the transmission cooler
the equipment to make sure that a vigorous return line) until all the fluid is removed.
fluid flow is present before proceeding. Install a
new system filter if flow is weak or 7. Remove the rubber return hose from the
contaminated. remaining steel cooler line.

Copyright  2004, Ford Motor Company

Last updated: 06/29/2004 2005 Aviator, 09/2004
307-01-1 Automatic Transmission — 5R55S 307-01-1

GENERAL PROCEDURES
Transmission Range (TR) Sensor
Adjustment

Special Tool(s)
Alignment Gauge, TR Sensor
307-351 (T97L-70010-A)

Adjust 5. Remove the outer manual control lever.

1. With the vehicle in the NEUTRAL, position it

on a hoist For additional information, refer to
Section 100-02.

2. Move the rubber boot back to gain access to

the connector.

6. Loosen but do not remove the digital TR sensor

screws.

3. Disconnect the digital TR sensor connector.

4. Remove the range selector lever cable end from

the manual control lever.

Copyright  2004, Ford Motor Company

Last updated: 06/29/2004 2005 Aviator, 09/2004
307-01-2 Automatic Transmission — 5R55S 307-01-2
GENERAL PROCEDURES (Continued)
7. Using the special tool, align the digital TR 10. Reconnect the digital TR sensor electrical
sensor and tighten the screws in an alternating connector.
sequence.
• Tighten to 10 Nm (89 lb-in).

11. Move the rubber boot back over the connector.

8. Install the outer manual lever.

• Tighten to 48 Nm (35 lb-ft).

12. Verify that the range selector lever cable is

adjusted correctly.

13. Verify that the vehicle will start in PARK and

9. Install the range selector lever cable end onto NEUTRAL and that the reverse lamps
the manual control lever. illuminate in REVERSE.

2005 Aviator, 09/2004

307-01-1 Automatic Transmission — 5R55S 307-01-1

GENERAL PROCEDURES
Torque Converter

1. A new or remanufactured torque converter must

be installed if one or more of the following
statements is true:
• A torque converter malfunction has been
determined based on complete diagnostic
procedures.
• Converter stud or studs, impeller hub or
bushing are damaged.
• Discoloration (due to overheating).
• Evidence of transmission assembly or fluid
contamination due to the following
transmission or converter failure modes:
X Major metallic failure.
X Multiple clutches or clutch plate failures.
X Sufficient component wear which results
in metallic contamination.
X Internal torque converter contamination
present. For additional information refer
to Torque Converter Contamination
Inspection in this section.

Copyright  2004, Ford Motor Company

Last updated: 06/29/2004 2005 Aviator, 09/2004
307-01-1 Automatic Transmission — 5R55S 307-01-1

GENERAL PROCEDURES
Torque Converter Contamination 3. Observe the color and odor of the fluid. The
Inspection fluid should be red, not brown or black. Odor
may indicate an overheating condition such as
clutch disc or band failure.
CAUTION: Do not use water-based
cleaners or mineral spirits to clean or flush the 4. Examine the stain on the tissue for evidence of
torque converter or transmission damage will particles (spec of any kind). Examine the fluid
occur. Use only clean automatic transmission level indicator for signs of antifreeze (gum or
fluid designated for the transmission and varnish). If particles are present in the fluid or
converter being serviced. there is evidence of engine coolant or water, a
new torque converter must be installed.
CAUTION: The torque converter drain
plug and seal are not reusable. If equipped, 5. If there are no particles or contamination
discard the drain plug and seal, then install a present, drain the remainder of the transmission
new drain plug assembly. fluid from the torque converter.

1. If a new or remanufactured torque converter is 6. Add 1.9 liter (2 qt.) of clean automatic
not being installed, the following steps must be transmission fluid into the converter and agitate
completed. by hand.

2. With the torque converter on a bench, pour a 7. Thoroughly drain the fluid.
small amount of transmission fluid from the
torque converter onto an absorbent white tissue
or through a paper filter and examine the fluid.

Copyright  2004, Ford Motor Company

Last updated: 06/29/2004 2005 Aviator, 09/2004
307-01-1 Automatic Transmission — 5R55S 307-01-1

IN-VEHICLE REPAIR
Fluid Pan, Gasket and Filter 5. Remove and discard the transmission fluid
filter.
Material
Item Specification
MERCON V Automatic MERCON V
Transmission Fluid
XT-5-QM, XT-5-DM

Removal

1. Raise and support the vehicle. For additional

information, refer to Section 100-02.

2. Place a drain pan under the transmission fluid

pan.
6. Clean and inspect the transmission fluid pan
3. Remove the drain plug and drain the fluid.
and magnet.

4. NOTE: The transmission fluid pan gasket is

reusable, clean and inspect for damage. If not
damaged, the gasket should be reused.
Remove the 16 transmission fluid pan screws,
fluid pan and gasket.

Copyright  2004, Ford Motor Company

Last updated: 06/29/2004 2005 Aviator, 09/2004
307-01-2 Automatic Transmission — 5R55S 307-01-2
IN-VEHICLE REPAIR (Continued)
Installation

1. CAUTION: Damage may occur to fluid

filter seals if they are not lubricated with
clean automatic transmission fluid.
NOTE: Make sure that the fluid filter seals are
correctly seated on the filter.
Lubricate the seals and install the transmission
fluid filter.
• Tighten to 10 Nm (89 lb-in).

4. Install the transmission fluid pan and gasket and

loosely install the screws.

2. Install the fluid pan magnet in the transmission

fluid pan.

5. Tighten the screws in a crisscross sequence.

• Tighten to 10 Nm (89 lb-in).

3. NOTE: The transmission fluid pan gasket is

reusable, clean and inspect for damage. If not
damaged, the gasket should be reused.
Install the fluid pan gasket on the pan.

2005 Aviator, 09/2004

307-01-3 Automatic Transmission — 5R55S 307-01-3
IN-VEHICLE REPAIR (Continued)
6. Install the fluid drain plug. 7. Partially fill the transmission. For additional
• Tighten to 26 Nm (19 lb-ft). information, refer to Transmission Fluid Drain
and Refill — Automated Equipment or
Transmission Fluid Drain and Refill — Without
Torque Converter Drain Plug in this section.

2005 Aviator, 09/2004

307-01-1 Automatic Transmission — 5R55S 307-01-1

IN-VEHICLE REPAIR
Main Control Valve Body

Special Tool(s)
Aligner, Valve Body (2
required)
307-334 (T95L-70010-C)

Material
Item Specification 4. NOTE: The transmission fluid pan gasket is
MERCON V Automatic MERCON V reusable. Clean and inspect for damage. If not
Transmission Fluid damaged, the gasket should be reused.
XT-5-QM
Remove the 16 transmission fluid pan screws,
Removal fluid pan and gasket.

1. Raise and support the vehicle. For additional

information, refer to Section 100-02.

2. If equipped, remove the drain plug and drain

the fluid.

5. Remove the transmission fluid filter.

3. NOTE: Clean the area around connector to

prevent contamination of the solenoid body
connector.
Disconnect the solenoid body harness
connector.

Copyright  2004, Ford Motor Company

Last updated: 06/29/2004 2005 Aviator, 09/2004
307-01-2 Automatic Transmission — 5R55S 307-01-2
IN-VEHICLE REPAIR (Continued)
6. Remove the solenoid body.

Installation

7. Remove the reverse servo. 1. Install the special tools into the transmission
case.

8. Remove the manual control valve detent spring.

2. Using the special tools, install the main control
valve body and loosely install the screws.

9. Remove the main control valve body.

2005 Aviator, 09/2004

307-01-3 Automatic Transmission — 5R55S 307-01-3
IN-VEHICLE REPAIR (Continued)
3. Remove the special tools and loosely install the 4. Tighten the screws in the sequence shown.
screw. • Tighten to 10 Nm (89 lb-in).

2005 Aviator, 09/2004

307-01-4 Automatic Transmission — 5R55S 307-01-4
IN-VEHICLE REPAIR (Continued)
5. Install the manual control valve detent spring. 8. CAUTION: Inspect the transmission
• Tighten to 10 Nm (89 lb-in). case bore to make sure it is free of foreign
material and not damaged. If it is damaged,
transmission leak may occur.
Install the solenoid body. Tighten the bolts in
the sequence shown.
• Tighten to 8 Nm (71 lb-in).

6. Install the reverse servo. Tighten the screws in

2 stages, in the sequence shown.
• Stage 1: Tighten to 5 Nm (44 lb-in).
• Stage 2: Tighten to 10 Nm (89 lb-in).

9. CAUTION: Damage may occur to fluid

filter seals if they are not lubricated with
clean automatic transmission fluid.
NOTE: Make sure that the fluid filter seals are
correctly seated on the filter.
Lubricate the seals and install the transmission
fluid filter.
• Tighten to 10 Nm (89 lb-in).

7. Install new O-ring seals on the solenoid body

connector. Lubricate the O-ring seals with clean
automatic transmission fluid.

2005 Aviator, 09/2004

307-01-5 Automatic Transmission — 5R55S 307-01-5
IN-VEHICLE REPAIR (Continued)
10. NOTE: The transmission fluid pan gasket is 13. CAUTION: Damage will occur to the
reusable, clean and inspect for damage. If not solenoid body assembly if the screw is
damaged, the gasket should be reused. tightened above specification.
Install the fluid pan gasket on the pan. NOTE: Always install new O-ring seals on
vehicle harness connector.
NOTE: Clean the area around connector to
prevent contamination of the solenoid body
connector.
NOTE: Use petroleum jelly to lubricate the
O-ring seals to aid in the installation process.
Install and lubricate new O-ring seals on the
transmission connector and connect the
connector.
• Tighten to 5 Nm (44 lb-in).

11. Install the transmission fluid pan and gasket and

loosely install the screws.

14. Fill the transmission. For additional

information, refer to Transmission Fluid Drain
and Refill — Automated Equipment in this
section.
12. Tighten the screws in a crisscross sequence.
• Tighten to 10 Nm (89 lb-in).

2005 Aviator, 09/2004

307-01-1 Automatic Transmission — 5R55S 307-01-1

IN-VEHICLE REPAIR
Extension Housing Seal — 4x2

Special Tool(s)
Slide Hammer
100-001 (T50T-100-A)

Remover, Torque Converter

Fluid Seal
307-309 (T94P-77001-BH) Installation

1. NOTE: Make sure the extension housing seal is

correctly installed onto the special tool and the
garter spring is in the correct position.
Installer, Transmission Using the special tool, install the extension
Extension Housing Oil Seal
308-002 (T61L-7657-A) housing seal.

Removal

1. Raise and support the vehicle. For additional

information, refer to Section 100-02.

2. Remove the driveshaft. For additional

information, refer to Section 205-01.

3. Using the special tools, remove the extension

2. Install the driveshaft. For additional
housing seal.
information, refer to Section 205-01.

3. Carry out fluid level check. For additional

information, refer to Transmission Fluid Level
Check in this section.

Copyright  2004, Ford Motor Company

Last updated: 06/29/2004 2005 Aviator, 09/2004
307-01-1 Automatic Transmission — 5R55S 307-01-1

IN-VEHICLE REPAIR
Extension Housing Seal — 4x4

Special Tool(s)
Slide Hammer
100-001 (T50T-100-A)

Installer, Transmission
Extension Housing Fluid Seal
307-435 Installation

1. NOTE: Make sure the extension housing seal is

correctly installed onto the special tool and the
garter spring is in the correct position.
Remover, Input Shaft Oil Seal Using the special tool, install the extension
308-375
housing seal.

Removal

1. Raise and support the vehicle. For additional

information, refer to Section 100-02.

2. Remove the transfer case assembly. For

additional information, refer to Section
308-07B.
2. Install the transfer case assembly. For additional
3. Using the special tools, remove the extension
information, refer to Section 308-07B.
housing seal.
3. Lower the vehicle.

4. Carry out fluid level check. For additional

information, refer to Transmission Fluid Level
Check in this section.

Copyright  2004, Ford Motor Company

Last updated: 06/29/2004 2005 Aviator, 09/2004
307-01-1 Automatic Transmission — 5R55S 307-01-1

IN-VEHICLE REPAIR
Extension Housing Gasket — 4x2

Removal

1. Raise and support the vehicle. For additional

information, refer to Section 100-02.

2. Remove the driveshaft. For additional

information, refer to Section 205-01.

3. Support the transmission with a suitable jack.

4. Remove the transmission support insulator nuts.

7. CAUTION: The parking pawl, parking
pawl return spring and parking pawl shaft
could fall out during removal of the
extension housing.
Remove the extension housing.

5. Remove the bolts from the transmission support

insulator.

8. Remove and discard the extension housing

gasket.

6. Raise the transmission and remove the

transmission support insulator.

Copyright  2004, Ford Motor Company

Last updated: 06/29/2004 2005 Aviator, 09/2004
307-01-2 Automatic Transmission — 5R55S 307-01-2
IN-VEHICLE REPAIR (Continued)
Installation

1. Clean the extension housing and install new

extension housing gasket. Make sure that the
park pawl is installed correctly.

4. Install the transmission support insulator bolts.

• Tighten to 90 Nm (66 lb-ft).

2. CAUTION: Make sure the parking

lever actuating rod is correctly seated into
the case parking rod guide cup.
Install the extension housing.
• Tighten to 30 Nm (22 lb-ft).

5. Install the transmission support insulator nuts.

• Tighten to 90 Nm (66 lb-ft).

3. Install the transmission support insulator and

lower the transmission onto the transmission
support insulator.

6. Install the driveshaft. For additional

information, refer to Section 205-01.

2005 Aviator, 09/2004

307-01-3 Automatic Transmission — 5R55S 307-01-3
IN-VEHICLE REPAIR (Continued)
7. Carry out fluid level check. For additional
information, refer to Transmission Fluid Level
Check in this section.

2005 Aviator, 09/2004

307-01-1 Automatic Transmission — 5R55S 307-01-1

IN-VEHICLE REPAIR
Extension Housing Gasket — 4x4 Installation

Removal 1. Clean the extension housing and install new

extension housing gasket. Make sure that the
1. Raise and support the vehicle. For additional park pawl is installed correctly.
information, refer to Section 100-02.

2. Support the transmission with a suitable jack.

3. Remove the transfer case. For additional

information, refer to Section 308-07B.

4. CAUTION: The parking pawl, parking

pawl return spring and parking pawl shaft
could fall out during removal of the
extension housing.
Remove the extension housing.

2. CAUTION: Make sure the parking

lever actuating rod is correctly seated into
the case parking rod guide cup.
Install the extension housing.
• Tighten to 24 Nm (18 lb-ft).

5. Remove and discard the extension housing

gasket.

3. Install the transfer case. For additional

information, refer to Section 308-07B.

4. Remove the transmission support.

5. Carry out fluid level check. For additional

information, refer to Transmission Fluid Level
Check in this section.

Copyright  2004, Ford Motor Company

Last updated: 06/29/2004 2005 Aviator, 09/2004
307-01-1 Automatic Transmission — 5R55S 307-01-1

IN-VEHICLE REPAIR
Solenoid Body Assembly 4. NOTE: The transmission fluid pan gasket is
reusable, clean and inspect for damage. If not
Material damaged, the gasket should be reused.
Item Specification Remove the 16 transmission fluid pan screws,
fluid pan and gasket.
MERCON V Automatic MERCON V
Transmission Fluid
XT-5-QM

Removal

1. Raise and support the vehicle. For additional

information, refer to Section 100-02.

2. Remove the drain plug and drain the fluid.

5. Remove the transmission fluid filter.

3. NOTE: Clean the area around connector to

prevent contamination of the solenoid body
connector.
Disconnect the solenoid body harness
connector.
6. Remove the solenoid body.

Copyright  2004, Ford Motor Company

Last updated: 06/29/2004 2005 Aviator, 09/2004
307-01-2 Automatic Transmission — 5R55S 307-01-2
IN-VEHICLE REPAIR (Continued)
Installation

1. Install new O-ring seals on the solenoid body

connector. Lubricate the O-ring seals with clean
automatic transmission fluid.

4. NOTE: The transmission fluid pan gasket is

reusable, clean and inspect for damage, if not
damaged, the gasket should be reused.
Install the transmission fluid pan and gasket and
loosely install the screws.

2. CAUTION: Inspect the transmission

case bore to make sure it is free of foreign
material and not damaged. If damaged, a
transmission leak may occur.
Install the solenoid body. Tighten the bolts in
sequence shown.
• Tighten to 10 Nm (89 lb-in).

5. Tighten the screws in a crisscross sequence.

• Tighten to 10 Nm (89 lb-in).

3. CAUTION: Lubricate the fluid filter

seals with clean automatic transmission fluid
or they may be damaged.
NOTE: Make sure that the fluid filter seals are
correctly seated on the filter.
Lubricate the seals and install the transmission
fluid filter.
• Tighten to 10 Nm (89 lb-in).

2005 Aviator, 09/2004

307-01-3 Automatic Transmission — 5R55S 307-01-3
IN-VEHICLE REPAIR (Continued)
6. CAUTION: Damage will occur to the
solenoid body assembly if the screw is
tightened above the specification.
NOTE: Always install new O-ring seals on
vehicle harness connector.
NOTE: Clean the area around connector to
prevent contamination of the solenoid body
connector.
NOTE: Use petroleum jelly to lubricate the
O-ring seals to aid in the installation process.
Install and lubricate new O-ring seals on the
transmission connector and connect the
7. Fill the transmission. For additional
connector.
information, refer to Transmission Fluid Drain
• Tighten to 5 Nm (44 lb-in). and Refill — Automated Equipment or
Transmission Fluid Level Check in this
section.

2005 Aviator, 09/2004

307-01-1 Automatic Transmission — 5R55S 307-01-1

IN-VEHICLE REPAIR
Digital Transmission Range (TR)
Sensor

Special Tool(s)
Alignment Gauge, TR Sensor
307-351 (T97L-70010-A)

Removal 5. Remove the outer manual control lever.

1. Raise and support the vehicle. For additional

information, refer to Section 100-02.

2. Move the rubber boot back to gain access to

the connector.

6. Remove the digital TR sensor.

3. Disconnect the digital TR sensor connector.

4. Remove the shift cable from the manual control

lever.

Copyright  2004, Ford Motor Company

Last updated: 06/29/2004 2005 Aviator, 09/2004
307-01-2 Automatic Transmission — 5R55S 307-01-2
IN-VEHICLE REPAIR (Continued)
Installation

1. CAUTION: The digital transmission

range sensor must fit flush against the boss
on the case to prevent damage to the sensor.
Install the digital TR sensor and loosely install
the screws.

4. Install the shift cable to the manual control

lever.

2. CAUTION: Tightening one screw

before tightening the other may cause the
sensor to bind or become damaged.
NOTE: The manual lever must be in the
NEUTRAL position.
Using the special tool, align the digital TR
sensor and tighten the screws in an alternating 5. Reconnect the digital TR sensor connector.
sequence.
• Tighten to 10 Nm (89 lb-in).

3. Install the outer manual lever.

• Tighten to 48 Nm (35 lb-ft).

2005 Aviator, 09/2004

307-01-3 Automatic Transmission — 5R55S 307-01-3
IN-VEHICLE REPAIR (Continued)
6. Move the rubber boot back over the connector. 7. Verify that the shift cable is adjusted correctly.
For additional information, refer to Section
307-05.

2005 Aviator, 09/2004

307-01-1 Automatic Transmission — 5R55S 307-01-1

IN-VEHICLE REPAIR
Transmission Support Insulator —
4x2

Removal

1. Raise and support the vehicle. For additional

information, refer to Section 100-02.

2. Support the transmission with a transmission

jack.

3. Remove the transmission support insulator nuts.

Installation

1. Install the transmission support insulator and

lower the transmission onto the transmission
support insulator.

4. Remove the 2 transmission support insulator

bolts.

2. Install the transmission support insulator bolts.

• Tighten to 90 Nm (66 lb-ft).

5. Raise the transmission and remove the

transmission support insulator.

Copyright  2004, Ford Motor Company

Last updated: 06/29/2004 2005 Aviator, 09/2004
307-01-2 Automatic Transmission — 5R55S 307-01-2
IN-VEHICLE REPAIR (Continued)
3. Install the transmission support insulator nuts.
• Tighten to 90 Nm (66 lb-ft).

2005 Aviator, 09/2004

307-01-1 Automatic Transmission — 5R55S 307-01-1

IN-VEHICLE REPAIR
Transmission Support Insulator — Installation
4x4
1. Install the rear transmission support and bolts.
Removal • Tighten to 90 Nm (66 lb-ft).

1. With the vehicle in NEUTRAL, position on a

hoist. For additional information, refer to
Section 100-02.

2. Support the transmission with a transmission

jack.

3. Remove the 2 nuts from the rear transmission

support.

2. Lower the rear mount onto the crossmember

and tighten the rear transmission support nuts.
• Tighten to 90 Nm (66 lb-ft).

4. Remove the 2 bolts and remove the rear

transmission support.

Copyright  2004, Ford Motor Company

Last updated: 06/29/2004 2005 Aviator, 09/2004
307-01-1 Automatic Transmission — 5R55S 307-01-1

IN-VEHICLE REPAIR
Turbine Shaft Speed (TSS) Sensor

Removal

All vehicles

1. Raise and support the vehicle. For additional

information, refer to the Section 100-02.

4x4 vehicles

2. Disconnect the front driveshaft from the transfer

case. All vehicles

5. Remove the shift cable and bracket.

3. Disconnect the front driveshaft from the front

differential.
6. Disconnect the turbine shaft speed (TSS) sensor
electrical connector.

4. Remove the front driveshaft from the vehicle.

Copyright  2004, Ford Motor Company

Last updated: 06/29/2004 2005 Aviator, 09/2004
307-01-2 Automatic Transmission — 5R55S 307-01-2
IN-VEHICLE REPAIR (Continued)
7. Remove the TSS sensor.
1 Remove the TSS sensor screw.
2 Remove the TSS sensor from the
transmission.
• Inspect the TSS sensor O-ring for damage.
If damaged, install a new O-ring.

3. Install the shift cable and bracket.

• Tighten to 40 Nm (30 lb-ft).

Installation

All vehicles

1. Inspect the O-ring seal for damage. Install a

new seal if damaged. Lubricate the O-ring seal
with petroleum jelly to prevent damage to the
O-ring seal.
1 Install the TSS sensor into the transmission. 4x4 vehicles
2 Tighten the TSS sensor screw.
4. Install the front driveshaft in the vehicle.
• Tighten to 10 Nm (89 lb-in).

2. Connect the TSS sensor electrical connector.

2005 Aviator, 09/2004

307-01-3 Automatic Transmission — 5R55S 307-01-3
IN-VEHICLE REPAIR (Continued)
5. Install the front driveshaft to the transfer case. 6. Install the front driveshaft to the front
• Tighten to 30 Nm (22 lb-ft). differential.
• Tighten to 18 Nm (13 lb-ft).

2005 Aviator, 09/2004

307-01-1 Automatic Transmission — 5R55S 307-01-1

IN-VEHICLE REPAIR
Output Shaft Speed (OSS) Sensor

Removal

All vehicles

1. Raise and support the vehicle. For additional

information, refer to the Section 100-02.

4x4 vehicles

2. Disconnect the front driveshaft from the transfer

case. All vehicles

5. Remove the shift cable and bracket.

3. Disconnect the front driveshaft from the front

differential.
6. Disconnect the HO2S sensor connector from the
transmission case.

4. Remove the front driveshaft from the vehicle.

Copyright  2004, Ford Motor Company

Last updated: 06/29/2004 2005 Aviator, 09/2004
307-01-2 Automatic Transmission — 5R55S 307-01-2
IN-VEHICLE REPAIR (Continued)
7. Disconnect the output shaft speed (OSS) sensor
electrical connector.

2. Connect the OSS sensor electrical connector.

8. Remove the OSS sensor.

1 Remove the OSS sensor screw.
2 Remove the OSS sensor from the
transmission.
• Inspect the OSS sensor O-ring for damage.
If damaged, install a new O-ring.

3. Connect the HO2S sensor connector to the

transmission case.

Installation

All vehicles

1. Inspect the O-ring seal for damage. Install a

new seal if damaged. Lubricate the O-ring seal
with petroleum jelly to prevent damage to the
O-ring seal.
1 Install the OSS sensor into the transmission.
2 Tighten the OSS sensor screw.
• Tighten to 10 Nm (89 lb-in).

2005 Aviator, 09/2004

307-01-3 Automatic Transmission — 5R55S 307-01-3
IN-VEHICLE REPAIR (Continued)
4. Install the shift cable and bracket. 6. Install the front driveshaft to the transfer case.
• Tighten to 40 Nm (30 lb-ft). • Tighten to 30 Nm (22 lb-ft).

4x4 vehicles 7. Install the front driveshaft to the front

differential.
5. Install the front driveshaft in the vehicle. • Tighten to 18 Nm (13 lb-ft).

2005 Aviator, 09/2004

307-01-1 Automatic Transmission — 5R55S 307-01-1

IN-VEHICLE REPAIR
Intermediate Shaft Speed Sensor

Removal

All vehicles

1. Raise and support the vehicle. For additional

information, refer to the Section 100-02.

4x4 vehicles

2. Disconnect the front driveshaft from the transfer

case. All vehicles

5. Remove the shift cable and bracket.

3. Disconnect the front driveshaft from the front

differential.
6. Disconnect the intermediate shaft speed (ISS)
sensor electrical connector.

4. Remove the front driveshaft from the vehicle.

Copyright  2004, Ford Motor Company

Last updated: 06/29/2004 2005 Aviator, 09/2004
307-01-2 Automatic Transmission — 5R55S 307-01-2
IN-VEHICLE REPAIR (Continued)
7. Remove the ISS sensor.
1 Remove the ISS sensor screw.
2 Remove the ISS sensor from the
transmission.
• Inspect the ISS sensor O-ring for damage. If
damaged, install a new O-ring.

3. Install the shift cable and bracket.

• Tighten to 40 Nm (30 lb-ft).

Installation

All vehicles

1. Inspect the O-ring seal for damage. Install a

new seal if damaged. Lubricate the O-ring seal
with petroleum jelly to prevent damage to the
O-ring seal.
1 Install the ISS sensor into the transmission. 4x4 vehicles
2 Tighten the ISS sensor screw.
4. Install the front driveshaft in the vehicle.
• Tighten to 10 Nm (89 lb-in).

2. Connect the ISS sensor electrical connector.

2005 Aviator, 09/2004

307-01-3 Automatic Transmission — 5R55S 307-01-3
IN-VEHICLE REPAIR (Continued)
5. Install the front driveshaft to the transfer case. 6. Install the front driveshaft to the front
• Tighten to 30 Nm (22 lb-ft). differential.
• Tighten to 18 Nm (13 lb-ft).

2005 Aviator, 09/2004

307-01-1 Automatic Transmission — 5R55S 307-01-1

REMOVAL
Transmission — 4x2 6. NOTE: LH side shown, RH side similar.
Disconnect the 2 heated oxygen sensor
Special Tool(s) electrical connectors.
Retainer, Torque Converter
307-346 (T97T-7902-A)

1. NOTE: When the battery has been

disconnected and reconnected, some abnormal
drive symptoms can occur while the vehicle
relearns its adaptive strategy. The customer
needs to be notified that they can experience
slightly different upshifts either (soft or firm)
7. NOTE: LH side shown, RH side similar.
and that this is a temporary condition and will
eventually return to normal operating condition. Disconnect the 2 catalyst monitor sensor
electrical connectors.
Disconnect the battery ground cable. For
additional information, refer to Section 414-01.

2. Remove the fan shroud bolts. Do not remove

the fan shroud.

3. Raise and support the vehicle. For additional

information, refer to Section 100-02.

4. If transmission disassembly or installation of a

new transmission is necessary, drain the
transmission fluid. Install the drain plug when
finished.

5. Remove the 2 RH heat shield bolts and position

the shield aside. 8. Remove the RH heat shield bolts.

Copyright  2004, Ford Motor Company

Last updated: 06/29/2004 2005 Aviator, 09/2004
307-01-2 Automatic Transmission — 5R55S 307-01-2
REMOVAL (Continued)
9. Remove the RH heat shield bolt and remove the
heat shield.

13. Remove the bolts, springs, flag nuts and

separate the muffler from the converter.
• Discard the gasket.
10. Remove the LH heat shield bolt.
• Discard the flag nuts.

11. Remove the 2 nuts and the plastic shield on the

right side of the crossmember near the fuel 14. NOTE: LH side shown, RH side similar.
tank. Remove the 4 converter-to-manifold nuts.
Remove the jackstand and lower the converter
assembly with the heat shield.

12. NOTE: RH side shown, LH side similar.

Remove the 4 upper crossmember bolts (2 on
each side).

2005 Aviator, 09/2004

307-01-3 Automatic Transmission — 5R55S 307-01-3
REMOVAL (Continued)
15. WARNING: Secure the transmission to 19. Remove the transmission support insulator nuts
the transmission jack with a safety chain. and remove the crossmember.
Failure to follow these instructions can result
in personal injury.
Install a suitable jack under the transmission.

16. Remove the RH side crossmember bolts.

20. NOTE: This step may require an assistant.

Remove the transmission mounted exhaust
hanger and the 3-way converter assembly.
1 Remove the bolt and 3-way system.
2 If required, remove the other bolt and the
17. Remove the LH side crossmember bolts.
mount.

18. Remove the 2 bolts on the bracket and position

aside.

2005 Aviator, 09/2004

307-01-4 Automatic Transmission — 5R55S 307-01-4
REMOVAL (Continued)
21. Remove the shift cable and bracket and position
out of PARK.
1 Disconnect the cable from the lever.
2 Position the manual lever out of PARK.
3 Remove the bolts and the shift cable and
bracket and position aside.

24. Index-mark the driveshaft and the extension

housing. Remove the driveshaft from the
vehicle.

22. Remove the rear driveshaft pinion flange bolts.

1 Index-mark the location of the rear flange
and pinion flange.
2 Remove the 4 bolts.

25. Remove the electrical connector cover.

23. NOTE: Do not use a hammer.

Remove the driveshaft flange from the pinion
flange, using a pry bar.

2005 Aviator, 09/2004

307-01-5 Automatic Transmission — 5R55S 307-01-5
REMOVAL (Continued)
26. Remove the starter wire and positive battery
cable.

30. NOTE: Make an identifying mark on the nut,

stud and flexplate to allow for correct
installation.
27. Remove the starter motor bolts and starter. Remove the 4 torque converter nuts.

28. Remove the flexplate cover. 31. Lower the transmission to gain access to the
sensor connectors and the transmission bolts.

32. Disconnect the RH catalyst monitor connector

and the fuel lines from the bracket.

29. Remove the access cover.

2005 Aviator, 09/2004

307-01-6 Automatic Transmission — 5R55S 307-01-6
REMOVAL (Continued)
33. Disconnect the RH heated oxygen sensor from
the transmission.

37. Disconnect the digital transmission range (TR)

sensor connector.

34. Disconnect the LH heated oxygen sensor and

the harness clip from the transmission.

38. Disconnect the turbine shaft speed (TSS)

sensor, output shaft speed (OSS) sensor and
intermediate shaft speed (ISS) sensor electrical
35. Disconnect the LH catalyst monitor connector connectors.
from the transmission.

36. Move the rubber boot back to gain access to

the connector.

2005 Aviator, 09/2004

307-01-7 Automatic Transmission — 5R55S 307-01-7
REMOVAL (Continued)
39. NOTE: Clean the area around connector to 42. Remove the front crossmember.
prevent contamination of the solenoid body
connector.
Remove the screw from the solenoid body
connector and disconnect the connector.

43. Remove the 7 engine-to-transmission retaining

bolts.

40. Disconnect the harness retainers.

44. Lower the transmission assembly from the

vehicle.

45. Install the special tool.

41. CAUTION: Do not damage the cooler
tubes.
Disconnect the transmission cooler tubes.

2005 Aviator, 09/2004

307-01-8 Automatic Transmission — 5R55S 307-01-8
REMOVAL (Continued)
46. Carry out the transmission fluid cooler
backflushing and cleaning if the transmission is
being overhauled or installing a new or
remanufactured transmission. For additional
information, refer to Transmission Fluid Cooler
— Backflushing and Cleaning in this section.

2005 Aviator, 09/2004

307-01-1 Automatic Transmission — 5R55S 307-01-1

REMOVAL
Transmission — 4x4 6. Disconnect the 2 heated oxygen sensor
electrical connectors.
Special Tool(s)
Retainer, Torque Converter
307-346 (T97T-7902-A)

1. NOTE: When the battery has been

disconnected and reconnected, some abnormal
drive symptoms can occur while the vehicle
relearns its adaptive strategy. The customer
needs to be notified that they can experience 7. Disconnect the 2 catalyst monitor sensor
slightly different upshifts either (soft or firm) electrical connectors.
and that this is a temporary condition and will
eventually return to normal operating condition.
Disconnect the battery ground cable. For
additional information, refer to Section 414-01.

2. Remove the fan shroud bolts. Do not remove

the fan shroud.

3. Raise and support the vehicle. For additional

information, refer to Section 100-02.

4. If transmission disassembly or installation of

new transmission is necessary, drain the
transmission fluid.
• Install the drain plug when finished. 8. Remove the RH heat shield bolts.

5. Remove the 2 RH heat shield bolts and position

the RH heat shield aside.

Copyright  2004, Ford Motor Company

Last updated: 06/29/2004 2005 Aviator, 09/2004
307-01-2 Automatic Transmission — 5R55S 307-01-2
REMOVAL (Continued)
9. Remove the RH heat shield bolt and remove the
heat shield.

13. Remove the bolts, springs, flag nuts and

separate the muffler from the converter.
• Discard the gasket.
10. Remove the LH heat shield bolt.
• Discard the flag nuts.

11. Remove the plastic shield on the right side of

the crossmember near the fuel tank. 14. NOTE: LH side shown, RH similar.
Remove the 4 converter-to-manifold nuts.

12. NOTE: RH side shown, LH side similar.

Remove the 4 upper crossmember bolts (2 on
each side).

2005 Aviator, 09/2004

307-01-3 Automatic Transmission — 5R55S 307-01-3
REMOVAL (Continued)
15. Install a suitable jackstand under the transfer
case.

19. NOTE: This step may require an assistant.

Remove the transmission mounted exhaust
hanger and the 3-way converter system.
16. Remove the RH side crossmember bolts.
1 Remove the bolt and converter assembly.
2 If required, remove the 2nd bolt and mount.

17. Remove the LH side crossmember bolts.

20. Remove the shift cable and bracket.

18. Remove the transmission support insulator nuts

and remove the crossmember.

2005 Aviator, 09/2004

307-01-4 Automatic Transmission — 5R55S 307-01-4
REMOVAL (Continued)
21. Position the manual lever out of park. 24. Remove and discard the bolts and washers.

22. Index-mark the front axle pinion flange and the 25. Remove and discard the bolts and universal
front driveshaft. joint retainers.

23. Index-mark the front output shaft assembly and

the front driveshaft constant velocity (CV) joint.

2005 Aviator, 09/2004

307-01-5 Automatic Transmission — 5R55S 307-01-5
REMOVAL (Continued)
26. CAUTION: Always disconnect the
front driveshaft from the transfer case first.
Otherwise, the weight of the driveshaft can
pinch the boot between the shaft and the
boot can and cause the boot to tear.
CAUTION: Tape the bearing cups to
the driveshaft to prevent them from falling
off of the spider.
NOTE: The front driveshaft CV joint is not
repairable.
Remove the driveshaft.
29. Remove the electrical connector cover.

27. NOTE: Pinion flange shown, transfer case

flange similar.
30. Remove the starter wire and the positive battery
Remove the rear driveshaft bolts. cable.
1 Mark the location of the flanges.
2 Remove the 4 bolts.

28. NOTE: Do not use a hammer.

Remove the driveshaft from the flange using a
pry bar.

2005 Aviator, 09/2004

307-01-6 Automatic Transmission — 5R55S 307-01-6
REMOVAL (Continued)
31. Remove the starter motor bolts and starter.

35. Lower the transmission to gain access to the

sensor connectors and the transmission bolts.
32. Remove the flexplate cover.
36. Disconnect the RH catalyst monitor connector
and the fuel lines from the bracket.

33. Remove the access cover.

37. Disconnect the RH heated oxygen sensor from

the transmission.

34. NOTE: Make an identifying mark on the nut,

stud and flexplate to allow for correct
installation.
Remove the 4 torque converter nuts.

2005 Aviator, 09/2004

307-01-7 Automatic Transmission — 5R55S 307-01-7
REMOVAL (Continued)
38. If equipped, disconnect the shift motor electrical
connector.

42. Disconnect the digital transmission range (TR)

sensor connector.

39. Disconnect the LH heated oxygen sensor and

the harness clip from the transmission.

43. Disconnect the turbine shaft speed (TSS)

sensor, output shaft speed (OSS) sensor and
intermediate shaft speed (ISS) sensor electrical
40. Disconnect the LH catalyst monitor connector connectors.
from the transmission.

41. Move the rubber boot back to gain access to

the connector.

2005 Aviator, 09/2004

307-01-8 Automatic Transmission — 5R55S 307-01-8
REMOVAL (Continued)
44. NOTE: Clean the area around connector to 47. WARNING: Secure the transmission to
prevent contamination of the solenoid body the transmission jack with a safety chain.
connector. Failure to follow these instructions can result
Remove the screw from the solenoid body in personal injury.
connector and disconnect the connector. Support the transmission with a transmission
jack.

48. Remove the jackstand from under the transfer

case.

45. Disconnect the harness retainers.

49. NOTE: RH side shown, LH side similar.

Remove the 4 front crossmember bolts and the
crossmember.

46. CAUTION: Do not damage the cooler

tubes. Hold the transmission case fittings
with a wrench.
Disconnect the transmission cooler tubes.

2005 Aviator, 09/2004

307-01-9 Automatic Transmission — 5R55S 307-01-9
REMOVAL (Continued)
50. Remove the 7 engine-to-transmission retaining 53. NOTE: If the transmission is being serviced,
bolts. the transfer case will need to be removed.
Remove the transfer case from the back of the
transmission.
• Remove the bolts and the bracket.
• Disconnect the vent hose.

51. Lower the transmission and transfer case as an

assembly from the vehicle.

52. Install the special tool.

54. Carry out the transmission fluid cooler

backflushing and cleaning if the transmission is
being overhauled or installing a new or
remanufactured transmission. For additional
information, refer to Transmission Fluid Cooler
— Backflushing and Cleaning in this section.

2005 Aviator, 09/2004

307-01-1 Automatic Transmission — 5R55S 307-01-1

DISASSEMBLY
Transmission Special Tool(s)
Compressor, Servo Cover
Special Tool(s) 307-402

Air Test Plate and Gaskets

307-433-1, 307-433-2,
307-433-3

Handle, Torque Converter

307-091 (T81P-7902-C)

Remover, Input Shaft Oil Seal

308-375

All vehicles

Remover, Transmission Fluid 1. Place the transmission on a workbench.

Pump
307-397

Holding Fixture, Transmission

307-003 (T57L-500-B)

Slide Hammer
100-001 (T50T-100-A) 2. If vehicle is equipped and installation of a new
or remanufactured torque converter is necessary,
remove the torque converter adapter plate.

Remover, Torque Converter

Fluid Seal
307-309 (T94P-77001-BH)

(Continued)

Copyright  2004, Ford Motor Company

Last updated: 06/29/2004 2005 Aviator, 09/2004
307-01-2 Automatic Transmission — 5R55S 307-01-2
DISASSEMBLY (Continued)
3. If the adapter plate has been removed use the 6. Remove the sensors.
special tools to remove the torque converter.

7. Remove the outer manual control lever.

4. WARNING: The torque converter is
heavy, especially when full of fluid.
NOTE: If not installing a new torque converter
leave the adapter plate bolted to the torque
converter.
Using the special tools, remove the torque
converter and adapter plate as an assembly.

8. Remove the digital transmission range (TR)

sensor.

5. Remove the input shaft.

2005 Aviator, 09/2004

307-01-3 Automatic Transmission — 5R55S 307-01-3
DISASSEMBLY (Continued)
4x2 applications 4x4 applications

9. Using the special tools, remove the extension 11. Using the special tools, remove the extension
housing seal. housing seal.

10. CAUTION: The parking pawl, parking 12. CAUTION: The parking pawl, parking
pawl return spring and parking pawl shaft pawl return spring and parking pawl shaft
could fall out during removal of the could fall out during removal of the
extension housing. extension housing.
Remove the extension housing. Remove the extension housing.

2005 Aviator, 09/2004

307-01-4 Automatic Transmission — 5R55S 307-01-4
DISASSEMBLY (Continued)
All applications

13. NOTE: 4x2 shown, 4x4 similar.

Remove the parking pawl assembly and discard
the gasket.
1 Remove the parking pawl shaft.
2 Remove the parking pawl.
3 Remove the parking pawl return spring.
4 Remove and discard the gasket.

16. Remove the manual control valve detent spring.

14. NOTE: The transmission fluid pan gasket is

reusable. Clean and inspect the gasket for
damage. If not damaged, the gasket should be
reused. 17. WARNING: The upper and lower
Remove the 16 transmission fluid pan screws, servo covers are under spring tension. Use
fluid pan and gasket. care when removing the piston and cover
assembly. Failure to follow these instructions
can result in personal injury.
Remove the reverse servo assembly.

15. Remove the transmission fluid filter and seal

assembly and discard.

2005 Aviator, 09/2004

307-01-5 Automatic Transmission — 5R55S 307-01-5
DISASSEMBLY (Continued)
18. CAUTION: Do not damage solenoid 21. CAUTION: Failure to loosen the OD
body connector pins. band adjusting screw prior to pump removal
Remove the solenoid body assembly by lifting may cause damage to the pump and OD
on the body and pushing the connector from the band.
other side of the case. CAUTION: Throw the locknuts away.
The locknuts are not reusable for assembly.
Remove the locknuts and loosen the OD band
adjusting screw.

19. Remove the main control valve body, separator

plate and gasket.

22. Remove and tag the overdrive anchor strut for

assembly.

20. Using the special tools, remove the converter

hub seal.

2005 Aviator, 09/2004

307-01-6 Automatic Transmission — 5R55S 307-01-6
DISASSEMBLY (Continued)
23. CAUTION: The screws are not 26. CAUTION: Servo cover is under
reusable for assembly. Discard the screws. If spring tension.
the screws are reused, the housing may Using the special tool, remove the intermediate
become separated from the transmission. servo cover retaining ring and cover.
Remove and discard the screws.

27. Remove the intermediate band servo piston and

24. Install the special tool. spring.

25. Using the special tools, remove the pump. 28. CAUTION: Servo cover is under
spring tension.
Using the special tool, remove the overdrive
servo cover retaining ring and cover.

2005 Aviator, 09/2004

307-01-7 Automatic Transmission — 5R55S 307-01-7
DISASSEMBLY (Continued)
29. Remove the front band servo piston and spring. 32. CAUTION: Identify the anchor and
apply ends of the overdrive band.
NOTE: The new overdrive band is dark in
color. This is a normal condition of the band.
Hairline cracks in the band are also considered
normal. Do not install a new band based solely
on the color.
Remove and inspect the overdrive band. Check
the following conditions for installing a new
band:
• Inspect for glazing.
• Inspect for missing friction material.
• Inspect for material flaking.
30. Remove the screw. • Inspect for damage to the anchor pins.

31. NOTE: Tag and identify parts for reassembly. 33. Remove the overdrive brake and coast clutch
Compress the overdrive band and remove the drum.
apply strut.

2005 Aviator, 09/2004

307-01-8 Automatic Transmission — 5R55S 307-01-8
DISASSEMBLY (Continued)
34. CAUTION: Do not bend the trigger 37. NOTE: Tag and identify the center shaft thrust
wheel. bearing (No. 3) for assembly.
NOTE: The No. 12 thrust bearing is in this Remove the No. 3 center shaft thrust bearing.
assembly.
Remove the planetary gear overdrive carrier.

38. CAUTION: The center support locknut

could fall into the remaining assembly if not
35. Remove the overdrive planet thrust bearing (No. removed.
2). Remove the screw.

36. Remove the overdrive ring gear, overdrive 39. Remove the locknut and cage.
one-way clutch assembly and center shaft as an
assembly.

2005 Aviator, 09/2004

307-01-9 Automatic Transmission — 5R55S 307-01-9
DISASSEMBLY (Continued)
40. Remove the center support retaining ring.

43. Inspect the seal rings for damage.

41. NOTE: The center support is repaired as an

assembly. Any damage requires installing a new
component.
NOTE: When removing the center support, pull
evenly around the center support web.
Remove the center support.

44. Inspect the bearing for missing rollers or

damage.

42. Inspect the center support assembly for wear or

damage.
1 Inspect the thrust surfaces for wear or
damage.
2 Inspect the center support sealing surface.
3 Inspect the fluid passage for blockage or
damage.

2005 Aviator, 09/2004

307-01-10 Automatic Transmission — 5R55S 307-01-10
DISASSEMBLY (Continued)
45. Inspect the direct clutch feed hole for blockage
or damage.
1 Rotate the center support bearing to locate
the direct clutch feed hole.
2 Inspect the direct clutch feed hole for
blockage or damage.

48. CAUTION: Identify the anchor and

apply ends of the intermediate band.
NOTE: The new intermediate band is dark in
color. This is a normal condition of the band.
Hairline cracks in the band are also considered
normal. Do not install a new band based solely
on the color.
46. NOTE: Tag and identify the No. 4 intermediate Remove and inspect the intermediate band.
brake drum thrust bearing. Check the following conditions for installing a
Remove the intermediate brake drum thrust new band:
bearing (No. 4). • Inspect for glazing.
• Inspect for missing friction material.
• Inspect for material flaking.
• Inspect for damage to the anchor pins.

47. Remove and tag the intermediate band anchor

strut for assembly.

2005 Aviator, 09/2004

307-01-11 Automatic Transmission — 5R55S 307-01-11
DISASSEMBLY (Continued)
49. Remove and tag the intermediate band apply
strut for assembly.

53. NOTE: The No. 6A thrust bearing may come

out with the cylinder. Tag for reassembly.
Remove the forward clutch cylinder.
50. Remove the screw.

54. NOTE: The No. 6A forward ring gear hub

51. NOTE: The No. 5 forward clutch cylinder thrust bearing may have come out with the
thrust bearing may come out with the forward clutch cylinder.
intermediate brake and direct clutch drum.
Remove the No. 6A forward ring gear hub
Remove the direct clutch drum. thrust bearing.

52. Remove the No. 5 forward clutch cylinder

thrust bearing, tag and identify.

2005 Aviator, 09/2004

307-01-12 Automatic Transmission — 5R55S 307-01-12
DISASSEMBLY (Continued)
55. NOTE: The No. 7 forward planet thrust
bearing may come out with the forward ring
gear and hub assembly.
Remove the forward ring gear and hub as an
assembly.

58. Remove the forward planetary assembly.

56. Remove the No. 6B forward clutch thrust

washer from the forward ring gear hub.

59. Remove the input shell and sun gear assembly.

57. NOTE: The No. 7 forward planet thrust

bearing may come out with the forward ring
gear and hub assembly.
Remove the No. 7 forward planet thrust
bearing.

2005 Aviator, 09/2004

307-01-13 Automatic Transmission — 5R55S 307-01-13
DISASSEMBLY (Continued)
60. Remove the spacer.

64. NOTE: Tag and identify the No. 9 low/reverse

planetary carrier thrust bearing.
61. NOTE: Tag and identify the No. 8 low/reverse Remove the thrust bearing.
planetary carrier thrust bearing.
Remove the thrust bearing.

65. NOTE: Use slots located around the outside of

the sleeve.
62. Remove the retaining ring. Using a small pick, remove the output shaft
sleeve.

63. Remove low/reverse planetary assembly.

2005 Aviator, 09/2004

307-01-14 Automatic Transmission — 5R55S 307-01-14
DISASSEMBLY (Continued)
66. WARNING: The output shaft may fall
out after removing the snap ring. Failure to
follow these instructions may result in
personal injury.
CAUTION: Discard the output shaft
retaining ring. A new retaining ring must be
used for assembly.
While holding the output shaft, remove and
discard the output shaft retaining ring.

69. CAUTION: Do not pry on the outer

edge of the case damage to the gasket sealing
surface could occur.
NOTE: It may be necessary to grind flat spots
on the edges of the reverse band actuating lever
shaft in order to remove it.
Using a pair of vice grips, hold the flat spots
on the reverse band actuating lever shaft,
wiggle it back and forth and remove the reverse
band actuating lever shaft.
67. Remove the output shaft ring gear and hub.

70. Remove the reverse band actuating lever

68. Remove the No. 10 low intermediate sun gear assembly.
bearing.

2005 Aviator, 09/2004

307-01-15 Automatic Transmission — 5R55S 307-01-15
DISASSEMBLY (Continued)
71. NOTE: The inner race of the rear one-way
clutch is not removable. It is repaired in the
case.
Remove the low/reverse brake drum and
one-way clutch assembly by rotating it
clockwise.

74. Remove the output shaft and park gear.

72. NOTE: The reverse one-way clutch is part of

the reverse brake drum assembly. Install a new
reverse brake drum as an assembly only.
Inspect the reverse brake drum assembly and
install a new reverse brake drum assembly if
damaged.
1 Inspect the reverse brake drum sprags.
2 Inspect the reverse brake drum rollers. 75. NOTE: Tag and identify the No. 11 output
shaft thrust washer.
3 Inspect the reverse brake drum.
Remove the output shaft thrust washer.

73. Remove the reverse band.

2005 Aviator, 09/2004

307-01-16 Automatic Transmission — 5R55S 307-01-16
DISASSEMBLY (Continued)
76. CAUTION: To avoid damage, make 79. Disconnect the manual valve inner lever from
sure the wrench does not strike the manual the parking lever actuating rod.
valve inner lever pin.
Remove the nut.

80. Remove the manual valve inner lever.

77. Remove the manual lever shaft retaining pin.

81. Remove the parking lever actuating rod.

78. Remove the manual control lever shaft.

2005 Aviator, 09/2004

307-01-17 Automatic Transmission — 5R55S 307-01-17
DISASSEMBLY (Continued)
82. CAUTION: Do not damage the bore.
Remove the manual control lever seal.

2005 Aviator, 09/2004

307-01-1 Automatic Transmission — 5R55S 307-01-1

DISASSEMBLY AND ASSEMBLY

OF SUBASSEMBLIES
Main Control Valve Body

Special Tool(s)
Aligner, Valve Body (2
required)
307-334 (T95L-70010-C)

Item Part Number Description Item Part Number Description

1 — Clip — retainer 8 — Spring — converter clutch
2 — Plug — retainer control valve
3 — Valve assembly — thermo 9 — Valve — converter clutch
control
4 — Valve — fluid cooler bypass
10 — Plate
5 — Spring — fluid cooler bypass
11 — Spring — coast clutch control
6 — Clip — retainer
12 — Valve — coast clutch control
7 — Plug — retainer
13 — Clip — retainer
(Continued)
(Continued)

Copyright  2004, Ford Motor Company

Last updated: 06/29/2004 2005 Aviator, 09/2004
307-01-2 Automatic Transmission — 5R55S 307-01-2
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)
Item Part Number Description Item Part Number Description
14 — Plug — retainer 48 — Clip — retainer
15 — Valve — converter clutch 49 — Plug — retainer
back pressure 50 — Spring — converter limit
16 — Spring — converter clutch 51 — Valve — converter limit
back pressure
52 — Plate
17 — Clip — retainer
53 — Spring — solenoid regulator
18 — Plug — retainer valve
19 — Valve — VFS2 modulator 54 — Valve — solenoid regulator
20 — Spring — VFS2 modulator 55 — Valve — manual
valve
56 — Clip — retainer
21 — Clip — retainer
57 — Plug — retainer
22 — Plug — retainer
58 — Spring — rear servo control
23 — Valve — intermediate servo valve
release
59 — Valve — rear servo control
24 — Spring — intermediate servo
release valve 60 — Clip — retainer
25 — Plate 61 — Plug — retainer
26 — Spring — high clutch control 62 — Spring — RS ISA select
valve
27 — Valve — high clutch control
63 — Valve — RS ISA select
28 — Plug — Retainer
64 — Clip — Retainer
29 — Clip — Retainer
65 — Plug — Retainer
30 — Valve — reverse modulator
66 — Spring — forward
31 — Spring — reverse modulator engagement control valve
valve
67 — Valve — forward engagement
32 — Clip — retainer control
33 — Plug — retainer 68 — Plate
34 — Valve — reverse engagement 69 — Spring — OD servo control
35 — Spring — reverse engagement 70 — Valve — OD servo control
valve
71 — Retainer — clip
36 — Clip — retainer
72 — Sleeve — converter clutch
37 — Plug — retainer modulator control
38 — Valve — VFS1 modulator 73 — Valve — converter clutch
39 — Spring —VFS1 modulator modulator control
valve 74 — Valve — converter clutch
40 — Clip — retainer modulator
41 — Sleeve 75 — Spring — converter clutch
42 — Valve — booster modulator control
43 — Valve — booster 76 7Z490 Plate assembly — main
control valve body separator
44 — Spring — inner
77 7E195 Ball — lubrication check
45 — Spring — outer
78 7E195 Ball — shuttle valve
46 — Spring — retainer
79 7A101 Body — control valve lower
47 — Valve — main regulator
80 W701099-S430 Screw — separator plate
(Continued)

2005 Aviator, 09/2004

307-01-3 Automatic Transmission — 5R55S 307-01-3
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)
Disassembly 2. CAUTION: Do not stone, file or sand
the valves. This will remove the anodized
1. NOTE: The valve body separator plate has a finish and may result in further main control
bonded gasket. Do not reuse. Discard the plate. or transmission damage.
Remove and discard the valve body separator After cleaning the main control valve body,
plate. carry out the following.
• Inspect all valve and plug bores for scoring
or burrs.
• Check all fluid passages for obstructions.
• Inspect all valves and plugs for burrs.
• Inspect all mating surfaces for burrs or
distortion.
• Inspect all springs for distortion.
• Check all valves and plugs for free
movement in their respective bores.
X Valves and plugs, when dry, must fall
from their own weight into their
respective bores.
2. Remove the check balls.
• Roll the manual valve on a flat surface to
check for a bent condition.

3. Assemble the main control valve body.

4. Install the main control valve body check balls.

3. NOTE: Refer to the disassembled view.

Disassemble the main control valve body only
if cleaning is required.
Assembly

1. CAUTION: Do not lose parts when

cleaning or repairing.
Thoroughly clean all parts in solvent and blow
dry with moisture-free compressed air.

2005 Aviator, 09/2004

307-01-4 Automatic Transmission — 5R55S 307-01-4
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)
5. NOTE: Use a new valve body separator plate
for main control valve body installation.
Using the special tools, install a new main
control valve body separator plate.
• Tighten to 7 Nm (62 lb-in).

2005 Aviator, 09/2004

307-01-1 Automatic Transmission — 5R55S 307-01-1

DISASSEMBLY AND ASSEMBLY

OF SUBASSEMBLIES
Fluid Pump Special Tool(s)
Transmission Fluid Pump Seal
Special Tool(s) Aligner
307-451/1
Installer, Torque Converter
Fluid Seal
307-349 (T97T-77000-A)

Transmission Fluid Pump Seal

Sizer
307-451/2
Alignment Set, Fluid Pump
307-S039 (T74P-77103-X)

Transmission Fluid Pump Seal

Installer
307-451/3
Aligner, Fluid Pump Handle
307-431

Material
Item Specification
Aligner, Fluid Pump Pilot
307-432 Multi-Purpose Grease ESR-M1C159-A
XG-4

Disassembly

1. Remove the fluid pump gasket, fluid pump seal

ring and the No.1 thrust washer.
Sizer, Piston Seal
307-338 (T95L-70010-G) 1 Remove and discard the fluid pump gasket.
2 Remove and discard the fluid pump seal
ring (square cut).
3 Remove and tag the No.1 thrust washer.

Alignment Pins, Transmission

Pump
307-398

(Continued)

Copyright  2004, Ford Motor Company

Last updated: 06/29/2004 2005 Aviator, 09/2004
307-01-2 Automatic Transmission — 5R55S 307-01-2
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)
2. Remove the fluid pump support seal ring.

6. Remove the drive gear O-ring seal and discard.

Inspect the fluid pump gears for cracks and
3. Remove the seal rings. scoring.

4. Remove the fluid pump housing. 7. Inspect the overdrive pump.

• Inspect the overdrive pump support gear
pockets for scoring and wear.
• Clean and inspect the overdrive and rear
input shaft bushings.

5. NOTE: A rough casting on the pump surface

crescent is not a flaw.
NOTE: The fluid pump gears are part of the
pump assembly and are not repaired separately.
Remove the fluid pump gears.

2005 Aviator, 09/2004

307-01-3 Automatic Transmission — 5R55S 307-01-3
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)
8. Inspect the fluid pump adapter plate for scoring 11. Inspect the fluid pump to converter housing
and wear. bushing.

9. Remove the valve. Assembly

1. NOTE: Minor burrs and scoring may be

removed with crocus cloth. If damage is found,
install a new assembly.
Inspect the fluid pump components for the
following:
• Pump body and case for burrs.
• Fluid passages for obstructions.

2. NOTE: Check and make sure that the garter

spring in the seal has not popped off of the
converter hub seal.
Install a new seal onto the special tool.
10. Remove and discard the seal.

2005 Aviator, 09/2004

307-01-4 Automatic Transmission — 5R55S 307-01-4
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)
3. Using the special tool, install the converter hub 6. CAUTION: The chamber on the inside
seal. edge of the small gear must be UP when in
the pump housing gear pocket. The dimple
on the larger gear must be DOWN when in
the pump housing gear pocket.
Install the pump gears into the fluid pump
housing. Apply multi-purpose grease to pump
gear to prevent scoring at start up.

4. Install a new O-ring seal in fluid pump drive

gear.

7. Install a new seal on the valve.

5. CAUTION: Lubricate the special tool

with multi-purpose grease.
Using the special tool, seat the O-ring seal in
the pump gear.

8. Install the valve with the tab facing down.

2005 Aviator, 09/2004

307-01-5 Automatic Transmission — 5R55S 307-01-5
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)
9. First install the fluid pump adapter plate and 12. Loosely install the fluid pump housing screws
then the alignment pins in their correct location. in their correct location and remove the special
tools.

10. CAUTION: The special tools must be

used to correctly align the pump with the 13. Install the 2 remaining screws and tighten all
adapter plate to reduce gear noise, bushing the screws in a star pattern.
failure and leakage. • Tighten to 25 Nm (18 lb-ft).
Using the special tool, align the fluid pump to
the adapter plate.

14. Install a new fluid pump seal ring.

11. Using the special tools, assemble the pump.

2005 Aviator, 09/2004

307-01-6 Automatic Transmission — 5R55S 307-01-6
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)
15. Install 2 new seal rings.

18. CAUTION: Failure to correctly size

the seal will cause damage to the seal when
16. CAUTION: Be careful not to the torque converter is installed.
overstretch the seal ring past the seal ring Using the special tool, size the seal to the
groove. Damage to the seal will occur. correct size. Leave the special tool on the seal
Using the special tools, install the fluid pump ring for 2 minutes to obtain the correct seal
seal ring. size.

17. CAUTION: Verify correct seal

installation. Make sure seal grooves are clean
and free of burrs.
Verify that the seal is installed correctly.

2005 Aviator, 09/2004

307-01-1 Automatic Transmission — 5R55S 307-01-1

DISASSEMBLY AND ASSEMBLY

OF SUBASSEMBLIES
Overdrive Brake and Coast Clutch
Drum Assembly

Special Tool(s)
Compressor, Clutch Spring
307-015 (T65L-77515-A)

Protector, Piston Seal

307-049 (T74P-77404-A)

Material
Item Specification
MERCON V Automatic MERCON V
Transmission Fluid
XT-5-QM

Overdrive Brake and Coast Clutch Drum Assembly

Copyright  2004, Ford Motor Company

Last updated: 06/29/2004 2005 Aviator, 09/2004
307-01-2 Automatic Transmission — 5R55S 307-01-2
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)
Item Part Number Description
1 7L669 Coast clutch drum
2 7A548 Overdrive piston outer seal
ring
3 7D404 Overdrive piston inner seal
ring
4 7A262 Overdrive clutch piston
5 7A480 Overdrive piston spring (20
required)
6 7A527 Coast clutch piston spring
retainer
7 E860125-S Retaining ring
8 7B442 Coast clutch external plate — 3. WARNING: Use caution when
steel (2 required)
releasing tool pressure on the rear clutch
9 7B164 Coast clutch internal plate — piston spring. Failure to follow these
friction (2 required)
instructions may result in personal injury.
10 7B066 Coast clutch pressure plate
11 E860126S/129S Retaining ring (select fit) CAUTION: Do not fully compress the
special tool or damage to the spring retainer
Disassembly may occur.
Using the special tool, remove the coast clutch
1. Remove the coast clutch pressure plate. piston retaining ring.
1 Remove the coast clutch retaining ring.
2 Remove the coast clutch pressure plate.

4. Relieve the coast clutch spring tension and

remove the special tool.

2. Remove the coast clutch disc pack.

• Inspect for wear, install a new pack as
necessary.

2005 Aviator, 09/2004

307-01-3 Automatic Transmission — 5R55S 307-01-3
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)
5. Remove the coast clutch piston springs.
1 Remove the coast clutch piston retainer.
2 Remove the clutch piston springs.

Assembly

1. CAUTION: The lip seals must be

positioned as shown. Care must be taken to
prevent rollover of the lip seal.
6. WARNING: Air pressure must not
exceed 138 kPa (20 psi). Wear safety glasses Install the new coast clutch piston inner and
when using compressed air and make sure outer seal.
the drum is facing down as shown. Failure to
follow these instructions may result in
personal injury.
Remove the coast clutch piston.
• Apply air pressure to the hole in the drum
to remove the coast clutch piston while
blocking the other hole with a finger.

2. Verify the check ball is free to move.

7. Remove and discard the coast clutch piston

inner seal and the coast clutch piston outer seal.

2005 Aviator, 09/2004

307-01-4 Automatic Transmission — 5R55S 307-01-4
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)
3. CAUTION: Care must be taken to
prevent damage to the seals during
installation.
Using the special tool, install the coast clutch
piston.
• Lubricate the seals with transmission fluid.

6. CAUTION: Coast clutch friction plates

are directional and must be installed with
grooves clockwise (ID to OD). The word
‘‘TOP’’ should face up.
CAUTION: If new clutch plates are
being used, they should be soaked in clean
automatic transmission fluid before assembly.
4. Install the coast clutch piston springs. When installing friction plates, the word
1 Install the coast clutch piston springs. ‘‘TOP’’ should face up. If reusing plates,
2 Install the coast clutch spring retainer. grooves must be installed clockwise. Install the
coast clutch disc pack.

5. CAUTION: Do not fully compress the

special tool or damage to the coast clutch
piston spring retainer may occur.
Using the special tool, install the coast clutch
piston spring retainer ring.

2005 Aviator, 09/2004

307-01-5 Automatic Transmission — 5R55S 307-01-5
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)
7. Install the 2 steel clutch plates and 2 friction
clutch plates in alternating order starting with a
steel clutch plate.

10. Check the coast clutch disc pack free play.

1 Push down on the coast pressure plate.
2 Check clearance between the coast clutch
retaining ring and coast pressure plate.
8. CAUTION: The retaining ring is select
Clearance should be 1.3-2.0 mm (.051-.079
fit.
in). If clearance is not within the
Install the coast clutch pressure plate. specification, install a correct coast clutch
1 Install the coast clutch pressure plate. retaining ring that will provide the correct
free play adjustment.
2 Install the original coast clutch retaining
ring. Thickness Diameter
Part Number mm In mm In
E860126-S 1.37 0.0539 130.1 5.122
E860127-S 1.73 0.0681 130.1 5.122
E860128-S 2.08 0.0819 130.1 5.122
E860129-S 2.44 0.0961 130.1 5.122

9. WARNING: Air pressure must not

exceed 138 kPa (20 psi). Wear safety glasses
when using compressed air and make sure
drum is facing down as shown. Failure to
follow these instructions may result in
personal injury.
Air check the assembly.
• Apply air pressure to the hole in the drum
while blocking the other hole with a finger.

2005 Aviator, 09/2004

307-01-1 Automatic Transmission — 5R55S 307-01-1

DISASSEMBLY AND ASSEMBLY

OF SUBASSEMBLIES
Direct Clutch Drum Assembly

Special Tool(s)
Compressor, Clutch Spring
307-015 (T65L-77515-A)

Protector, Piston Seal

307-049 (T74P-77404-A)

Material
Item Specification
MERCON V Automatic MERCON V
Transmission Fluid
XT-5-QM

Direct Clutch Drum Assembly

Copyright  2004, Ford Motor Company

Last updated: 06/29/2004 2005 Aviator, 09/2004
307-01-2 Automatic Transmission — 5R55S 307-01-2
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)
Item Part Number Description
1 7D044 Intermediate brake drum
assembly
2 7A548 Direct piston outer seal ring
3 7D404 Direct piston inner seal ring
4 7A262 Direct clutch piston
5 7A480 Direct piston spring (20
required)
6 7A527 Direct clutch piston spring
retainer
7 E860125-S Retaining ring
8 7B442 Direct clutch external spline
plate
9 7B164 Direct clutch internal spline
plate
10 7B066 Direct clutch pressure plate
11 E860126S/129S Retaining ring (select fit)

Disassembly

1. Remove the direct clutch retaining ring and the

direct clutch pressure plate.
1 Remove the direct clutch retaining ring.
2 Remove the direct clutch pressure plate.
3. WARNING: After removing the
retaining ring, use care when releasing the
pressure on the springs. Failure to follow
these instructions may result in personal
injury.
CAUTION: Do not fully compress the
special tool or damage to the spring retainer
may occur.
Using the special tool, remove the direct clutch
piston retaining ring.

2. Remove the direct clutch disc pack.

• Inspect and install new friction plates if
worn, damaged or overheated.

2005 Aviator, 09/2004

307-01-3 Automatic Transmission — 5R55S 307-01-3
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)
4. Relieve the direct clutch spring tension and 7. Remove and discard the direct clutch piston
remove the special tool. inner and outer seal.
1 Remove and discard the direct clutch piston
5. Remove the direct clutch piston spring retainer inner seal.
and the direct clutch piston springs.
2 Remove and discard the direct clutch piston
1 Remove the direct clutch piston spring outer seal.
retainer.
• Clean the components as necessary.
2 Remove the direct clutch piston springs.

Assembly
6. WARNING: Air pressure must not
exceed 138 kPa (20 psi). Wear safety glasses 1. Inspect the clutch components for damage or
when using compressed air and make sure wear. Install new components as necessary.
the drum is facing down as shown. Failure to
• Inspect the drum surface for damage.
follow these instructions may result in
personal injury. • Inspect the clutch piston bore and piston.
Using compressed air, remove the direct clutch • Check the fluid passages for obstructions.
piston from the direct clutch drum. All fluid passages must be clean and free of
obstructions.
• Apply air pressure to the hole in the drum
while blocking the other hole with a finger. • Inspect the clutch plates for damage.
• Inspect the clutch springs.

2005 Aviator, 09/2004

307-01-4 Automatic Transmission — 5R55S 307-01-4
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)
2. CAUTION: The lip seals must be
positioned as shown. Care must be taken to
prevent rollover of the lip seal.
NOTE: Use new seals to help prevent seal
failures.
Install the new direct clutch piston inner seal
and the direct clutch piston outer seal.

5. Install the direct clutch piston springs and the

retainer.

3. Verify the check ball is free to move.

6. WARNING: After removing the

retaining ring, use care when releasing the
pressure on the springs. Failure to follow
these instructions may result in personal
injury.
CAUTION: Do not fully compress the
special tool or damage to the spring retainer
4. CAUTION: Care must be taken to may occur.
prevent damage to the seals during Using the special tool, install the direct clutch
installation. piston retaining ring.
Using the special tool, install the direct clutch
piston.
• Lubricate the seals with transmission fluid
before installing.

2005 Aviator, 09/2004

307-01-5 Automatic Transmission — 5R55S 307-01-5
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)
7. CAUTION: The direct clutch friction
plates are directional and must be installed
correctly. Alternate the internally splined
(clockwise) and the externally splined
(counterclockwise) clutch plates.
CAUTION: If new plates are used,
they should be soaked in clean automatic
transmission fluid before assembly.
When installing friction plates, alternate the
internally splined (clockwise) and the externally
splined (counterclockwise) clutch plates. Install
the direct clutch disc pack.

8. Install the friction plates alternating the 9. CAUTION: The retaining ring is a
internally splined (clockwise) and the externally select fit.
splined (counterclockwise) clutch plates starting Install the direct clutch pressure plate using the
with an externally splined (counterclockwise) original direct clutch retaining ring.
clutch plate.

2005 Aviator, 09/2004

307-01-6 Automatic Transmission — 5R55S 307-01-6
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)
10. WARNING: Air pressure must not 11. Push down on direct clutch disc pack and check
exceed 138 kPa (20 psi). Wear safety glasses gap between the direct clutch retaining ring and
when using compressed air and make sure the direct clutch pressure plate with a feeler
drum is facing down as shown. Failure to gauge.
follow these instructions may result in • If specifications do not match, use a select
personal injury. fit direct clutch retaining ring to match
Air check the assembly. specifications and verify with a feeler gauge.
• Apply air pressure to the hole in the drum Direct Clutch
while blocking the other hole with a finger.
Thickness Diameter
Part Number mm In mm In
E860126-S 1.37 0.0539 130.1 5.122
E860127-S 1.73 0.0681 130.1 5.122
E860128-S 2.08 0.0819 130.1 5.122
E860129-S 2.44 0.0961 130.1 5.122

2005 Aviator, 09/2004

307-01-1 Automatic Transmission — 5R55S 307-01-1

DISASSEMBLY AND ASSEMBLY

OF SUBASSEMBLIES
Forward Clutch

Special Tool(s)
Compressor, Clutch Spring
307-015 (T65L-77515-A)

Protector, Piston Seal

307-051 (T74P-77548-A)

Bonded Piston Seal Sizer

307-434

Material
Item Specification
MERCON V Automatic MERCON V
Transmission Fluid
XT-5-QM

Copyright  2004, Ford Motor Company

Last updated: 06/29/2004 2005 Aviator, 09/2004
307-01-2 Automatic Transmission — 5R55S 307-01-2
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)
Forward Clutch Assembly

Item Part Number Description

1 7D483 Forward clutch retaining ring
(select fit)
2 7B066 Forward clutch pressure plate
3 7B164 Forward clutch internal plate
— friction
(vehicle-dependent)
4 7B442 Forward clutch external plate
— steel (vehicle-dependent)
5 E860109-S Forward clutch retaining ring
6 7G229 Forward clutch spring
assembly
7 7A262 Forward clutch piston
8 7A360 Forward clutch cylinder
assembly

Disassembly

1. Remove the pressure plate.

1 Remove the forward clutch retaining ring.
2 Remove the pressure plate.

2005 Aviator, 09/2004

307-01-3 Automatic Transmission — 5R55S 307-01-3
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)
2. Remove the forward clutch disc pack.
• Inspect the forward clutch plates for wear,
damage or overheating.

4. Relieve the forward clutch spring tension and

remove the tool.

5. Remove the forward clutch piston spring

assembly.

3. WARNING: Use caution when

releasing tool pressure on the clutch piston
springs. Failure to follow these instructions
may result in personal injury.
CAUTION: Do not fully depress the
special tool or damage to the spring retainer
may occur.
Using the special tool, remove the forward
clutch piston retaining ring.

2005 Aviator, 09/2004

307-01-4 Automatic Transmission — 5R55S 307-01-4
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)
6. WARNING: Air pressure must not 2. NOTE: If the seals on the forward clutch
exceed 138 kPa (20 psi). Wear safety glasses piston show any signs of damage, a new
when using compressed air. Make sure the forward clutch piston will need to be installed.
cylinder is facing down as shown. Failure to Inspect the forward clutch piston and seals.
follow these instructions may result in
personal injury.
Remove the forward clutch piston.
1 Place the forward clutch cylinder with
forward clutch piston facing down.
2 Install the center support on the forward
clutch cylinder.
3 Apply air pressure to the left port of the
center support.

3. Inspect the forward clutch drum assembly.

1 Inspect the forward clutch cylinder surfaces
for scores or burrs.
2 Inspect the forward clutch piston for scores
or burrs.
3 Verify the check ball is free to move in the
piston.

Assembly

1. Inspect the clutch components for damage or

wear. Install new components as necessary.
• Check the fluid passages for obstructions.
All fluid passages must be clean and free of
obstructions.
• Inspect the clutch plates for damage.
• Inspect the clutch springs.
• Inspect the needle bearing and seal rings for
damage.
• Check clutch hub thrust surfaces for
damage.
• Check clutch plates for flatness and fit on
the clutch hub serrations.

2005 Aviator, 09/2004

307-01-5 Automatic Transmission — 5R55S 307-01-5
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)
4. NOTE: The special tool must be installed on 6. Install the forward clutch piston spring
the forward clutch piston for a couple of assembly.
minutes prior to installing it into the forward
clutch cylinder.
Install the special tool on the forward clutch
piston.

7. CAUTION: Do not fully depress the

clutch spring compressor or damage to the
spring retainer may occur.
Using the special tool, install the forward clutch
5. CAUTION: Care must be taken to piston spring retaining ring.
prevent damage to the seals.
NOTE: Lubricate the forward clutch piston
inner and outer seal with clean automatic
transmission fluid.
Using the special tool, install the forward clutch
piston assembly into the forward clutch
cylinder.

2005 Aviator, 09/2004

307-01-6 Automatic Transmission — 5R55S 307-01-6
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)
8. CAUTION: The forward clutch friction
plates are directional and must be installed
with grooves pointing counterclockwise.
CAUTION: If new plates are used,
they should be soaked in clean automatic
transmission fluid before assembly.
If reusing plates, grooves must be installed
counterclockwise. Install the direct clutch disc
pack.

9. Install the steel clutch plates and friction clutch

plates in alternating order starting with a steel
clutch plate.
10. CAUTION: The retaining ring is a
select fit.
Install the original selective retaining ring.
1 Install the forward clutch pressure plate.
2 Install the original selective retaining ring.

2005 Aviator, 09/2004

307-01-7 Automatic Transmission — 5R55S 307-01-7
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)
11. WARNING: Air pressure must not 12. Check the forward clutch disc pack free play.
exceed 138 kPa (20 psi). Wear safety glasses 1 Press down on the forward clutch disc pack.
when using compressed air. Make sure the 2 Using a feeler gauge, check the gap
cylinder is facing down as shown. Failure to between the forward clutch retaining ring
follow these instructions may result in and the forward clutch pressure plate.
personal injury.
• If the clearance is not within specifications,
Air check the forward clutch piston. install the correct size retaining ring.
1 Place the forward clutch cylinder with
forward clutch piston facing down. Thickness Diameter
2 Install the transmission center support on Part Number mm In mm In
the forward clutch cylinder. XW4Z-7D483-AB 1.73 0.0681 141.45 5.65
in
3 Apply air pressure to the left port of the
center support. XW4Z-7D483-AC 2.08 0.0819 141.45 5.65
in
XW4Z-7D483-AD 2.44 0.0961 141.45 5.65
in

2005 Aviator, 09/2004

307-01-1 Automatic Transmission — 5R55S 307-01-1

DISASSEMBLY AND ASSEMBLY

OF SUBASSEMBLIES
Overdrive Planetary and One-Way
Clutch Assembly

2. CAUTION: Do not remove the

overdrive one-way clutch. Damage to the
clutch may occur if it is removed.
Item Part Number Description Clean and inspect the overdrive one-way clutch
1 W702037-S300 Retaining ring and center shaft.
2 7A658 Center shaft • Inspect for cracks in the roller cage and
3 7653 Overdrive ring gear wear on the roller clutch and the press fit of
4 7L495 No. 2 overdrive planetary the one-way clutch to the center shaft.
thrust bearing
5 7B446 Overdrive planetary gear
carrier assembly
6 7D063 Overdrive sun gear
7 7660 Coast clutch adapter

Disassembly

1. NOTE: The overdrive one-way clutch is

serviced with the center shaft assembly.
Remove the center shaft from the overdrive ring
gear.
1 Remove the overdrive center shaft retaining
ring.
2 While rotating counterclockwise remove the
center shaft from the ring gear.

Copyright  2004, Ford Motor Company

Last updated: 06/29/2004 2005 Aviator, 09/2004
307-01-2 Automatic Transmission — 5R55S 307-01-2
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)
3. Inspect the one-way clutch. Assembly
• Temporarily insert the overdrive planetary
gear carrier assembly into the one-way 1. Install the center shaft and one-way clutch.
clutch rollers for verification of the one-way 1 Install the center shaft and one-way clutch.
clutch.
2 Install the center shaft retaining ring.
• The planetary gear must rotate
counterclockwise and hold when rotated
clockwise.
• Remove the planetary gear carrier assembly.

2005 Aviator, 09/2004

307-01-1 Automatic Transmission — 5R55S 307-01-1

DISASSEMBLY AND ASSEMBLY

OF SUBASSEMBLIES
Overdrive Planetary Gears

Disassembly

1. NOTE: Individual parts of the planetary

carriers are not serviceable.
Before installing a planetary assembly, the shaft
retaining pins should be checked for adequate
staking. Check the pins and shafts in the
planetary assemblies for loose fit and/or
complete disengagement. Install a new planetary
assembly if necessary.
4. Remove and inspect the No. 2 overdrive
planetary thrust bearing on the nose of the
overdrive planetary gear carrier assembly.

2. Inspect the pinion gears for damaged or

excessively worn teeth and for free rotation.

5. NOTE: Inspect the sun gear for damaged or

worn teeth.
Remove the coast clutch-to-overdrive carrier
adapter.

3. Inspect the overdrive one-way clutch inner race

and the inner and outer races for scored or
damaged surface areas where the rollers contact
the races.

Copyright  2004, Ford Motor Company

Last updated: 06/29/2004 2005 Aviator, 09/2004
307-01-2 Automatic Transmission — 5R55S 307-01-2
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)
6. Remove and inspect the overdrive sun gear.

2. Install the overdrive planetary gear carrier into

the center shaft and overdrive.
7. CAUTION: Do not attempt to remove
the No. 12 bearing from behind the pinion
gears.
Inspect the No. 12 bearing for damage.

3. CAUTION: Make sure that the No. 12

bearing is in place in the overdrive planetary
prior to installing the overdrive sun gear.
Install the overdrive sun gear with the recessed
Assembly gear teeth facing toward the adapter.

1. NOTE: Thoroughly clean all parts and blow

dry with moisture-free compressed air.
NOTE: Use petroleum jelly to hold the No. 2
overdrive planetary thrust bearing in place.
Install the No. 2 overdrive planetary thrust
bearing.

2005 Aviator, 09/2004

307-01-3 Automatic Transmission — 5R55S 307-01-3
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)
4. CAUTION: Adapter part number must
not be visible after installation.
NOTE: Inspect the sun gear for damaged or
worn teeth.
Install the coast clutch-to-overdrive carrier
adapter.

2005 Aviator, 09/2004

307-01-1 Automatic Transmission — 5R55S 307-01-1

DISASSEMBLY AND ASSEMBLY

OF SUBASSEMBLIES
Output Shaft Ring Gear and Hub
Shaft Assembly

Disassembly

Assembly

1. Install the output shaft ring gear onto the output

shaft hub.
1 Install the output shaft ring gear.
Item Part Number Description 2 Install the retaining ring.
1 7A153 Output shaft ring gear
2 7D164 Output shaft hub
3 7C122 Retaining ring
4 7D019 Output shaft hub seal

1. Inspect the output shaft ring gear and hub shaft

assembly for damage. If repair is necessary, use
the following procedure.

2. Remove the seal.

3. Remove the output shaft ring gear from the

output shaft hub.
1 Remove the retaining ring.
2 Remove the output shaft ring gear.

Copyright  2004, Ford Motor Company

Last updated: 06/29/2004 2005 Aviator, 09/2004
307-01-2 Automatic Transmission — 5R55S 307-01-2
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)
2. Install the seal.

2005 Aviator, 09/2004

307-01-1 Automatic Transmission — 5R55S 307-01-1

DISASSEMBLY AND ASSEMBLY

OF SUBASSEMBLIES
Reverse Servo Assembly

Disassembly

Item Part Number Description

1 7D321 Control valve spring retainer
2 7A270 Fluid pressure regulator valve
spring
3 7D488 Reverse servo check valve
4 7D372 Reverse servo plate
5 7D466 Reverse servo accumulator
spring
6 7D189 Reverse servo piston and seal
7 7423 Reverse servo piston O-ring
8 7D036 Reverse servo cover

1. Remove the control valve spring retainer.

Copyright  2004, Ford Motor Company

Last updated: 06/29/2004 2005 Aviator, 09/2004
307-01-2 Automatic Transmission — 5R55S 307-01-2
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)
2. Remove the reverse servo spring and check
valve.

5. Remove the reverse servo piston and seal

assembly.
• Inspect the seal for damage, install new
3. WARNING: The upper and lower reverse servo piston if necessary.
servo covers are under spring tension. Use
care when separating the 2 halves. Failure to
follow these instructions can result in
personal injury.
NOTE: Tabs on servo plate mate with slots on
cover every 120 degrees.
Remove the reverse servo plate by turning in
either direction to release.
• Align arrow on servo plate with any slot on
cover.

6. Remove and discard the reverse servo piston

seal.

4. Remove the reverse servo spring.

2005 Aviator, 09/2004

307-01-3 Automatic Transmission — 5R55S 307-01-3
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)
Assembly 4. WARNING: The upper and lower
servo covers are under spring tension. Use
1. NOTE: Try not to roll the seal onto the care when assembling the 2 halves. Failure to
housing when installing the seal or damage to follow these instructions can result in
the seal can occur. personal injury.
Lubricate and install a new reverse servo piston CAUTION: The arrow on the servo
seal. plate must be aligned evenly between any 2
slots on the cover.
Install the reverse servo plate.

2. Lubricate and install the reverse servo piston

and seal assembly.
5. Install the reverse servo spring and check valve.

3. Install the reverse servo spring.

2005 Aviator, 09/2004

307-01-4 Automatic Transmission — 5R55S 307-01-4
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)
6. Install the control valve spring retainer.
• Tighten to 10 Nm (89 lb-in).

2005 Aviator, 09/2004

307-01-1 Automatic Transmission — 5R55S 307-01-1

ASSEMBLY
Transmission Special Tool(s)
Sizer, Piston Seal
Special Tool(s) 307-338 (T95L-70010-G)

Adjustment Set, Transmission

Band
307-S022 (T71P-77370-A)

Alignment Set, Fluid Pump

307-S039 (T74P-77103-X)

Holding Fixture, Transmission

307-003 (T57L-500-B)

Aligner, Fluid Pump Handle

307-431

Depth Micrometer
303-D026 (D80P-4201-A) or
equivalent

Aligner, Fluid Pump Pilot

307-432

Dial Indicator with Holding

Fixture
100-002 (TOOL-4201-C) or
equivalent

Gauge Bar
307-400

Alignment Gauge, TR Sensor

307-351 (T97L-70010-A)

Compressor, Servo Cover

307-402

Installer, Transmission
Extension Housing Oil Seal
(4x2)
308-002 (T61L-7657-A)

Installer, Shift Shaft Fluid Seal

307-050 (T74P-77498-A)

(Continued)

(Continued)

Copyright  2004, Ford Motor Company

Last updated: 06/29/2004 2005 Aviator, 09/2004
307-01-2 Automatic Transmission — 5R55S 307-01-2
ASSEMBLY (Continued)
Special Tool(s) Special Tool(s)
Handle, Torque Converter Installer, Transmission
307-091 (T81P-7902-C) Extension Housing Fluid Seal
(4x4)
307-435

Compressor, Cushion Spring Air Test Plate

307-401 307-0433/01, 307-433/02,
307-433/03

Aligner, Valve Body

307-334 (T95L-70010-C) Material
Item Specification
MERCON V Automatic MERCON V
Transmission Fluid
XT-5-QM
Multi-Purpose Grease ESR-M1C159-A
Alignment Pins, Transmission XG-4
Pump
307-399

Aligner, Flex Plate

307-403

(Continued)

2005 Aviator, 09/2004

307-01-3 Automatic Transmission — 5R55S 307-01-3
ASSEMBLY (Continued)
Disassembled Views

2005 Aviator, 09/2004

307-01-4 Automatic Transmission — 5R55S 307-01-4
ASSEMBLY (Continued)
Disassembled Views

2005 Aviator, 09/2004

307-01-5 Automatic Transmission — 5R55S 307-01-5
ASSEMBLY (Continued)
Disassembled Views

2005 Aviator, 09/2004

307-01-6 Automatic Transmission — 5R55S 307-01-6
ASSEMBLY (Continued)
Item Part Number Description Item Part Number Description
1 379299-S2 Converter-to-flexplate nut 28 71000 Overdrive/intermediate
(attaches the converter locking nut
assembly to the flexplate) 29 7L669 Overdrive brake band drum
2 7902 Converter assembly assembly
3 6441 Converter-to-adapter plate nut 30 7A548 Direct and overdrive piston
(attaches the converter outer seal
assembly to the adapter plate) 31 7D404 Direct and overdrive piston
4 6441 Adapter plate-to-flexplate nut inner seal
(attaches adapter plate to the 32 7A262 Direct and overdrive clutch
flexplate) piston
5 6K374 Adapter plate assembly 33 7A480 Direct and overdrive clutch
6 7902 Converter assembly piston spring
7 6730 Torque converter drain plug 34 7A527 Clutch piston spring retainers
8 7017 Input shaft (2 required)
9 7A248 Front fluid pump seal 35 E860125-S Retaining rings (retains
assembly 7D041 to drum) (2 required)
10 7A248 Front fluid pump seal 36 7B442 Coast clutch external splined
plates (steel) (2 required)
11 W704892-S300 M8 x 35 internal lobe screw
and washer assembly 37 7B164 Coast clutch internal splined
(attaches pump-to-case) (8 friction plates (2 required)
required) 38 7B066 Coast and direct clutch
12 7G178 Fluid pump cover assembly pressure plates (2 required)
13 7B472 Fluid pump adapter plate 39 E860126- Coast and direct clutch plates
S/129-S retaining rings (select fit) (2
14 7A136 Front fluid pump gasket required)
15 W701431-S300 Fluid pump shaft-to-inner 40 7660 Coast clutch-to-overdrive
gear O-ring seal (also in carrier adapter
pump assembly)
41 7D063 Overdrive sun gear
16 7L323 Stator support seal
42 7B446 Overdrive planetary gear
17 7A108 Front pump support assembly carrier (with trigger wheel)
18 7H416 O-ring 43 7L495 Overdrive planet thrust
19 7H411 Fluid pump control valve bearing No. 2
20 7A103 Fluid pump assembly 44 7A153 Overdrive ring gear
21 W701429- M8 x 1 x 35 internal lobe 45 7A089 Center shaft one-way clutch
S309M screw (attaches pump support assembly
to pump assembly) (8 46 7A658 Overdrive center shaft
required)
47 W702037-S300 Retaining ring (retains 7686
22 7D025 Overdrive brake drum seal to 7653)
23 7D014 Fluid pump input thrust 48 7L678 Hub and ring gear assembly
washer No. 1 (includes 7C109, 7A153,
24 7D029 Intermediate and overdrive 7A658, W702037-S300)
brake band anchor strut (2 49 7M153 Center shaft and forward
required) clutch cylinder bearing
25 7D034 Intermediate and overdrive assembly No. 3, No. 5, No. 8
brake band (2 required) and No. 9 (4 required)
26 7D029 Intermediate and overdrive 50 W702465-S300 Retaining ring
brake band apply struts (2 51 7A130 Center support assembly
required)
52 E826160-S76 Nut and cage assembly
27 7C492 Overdrive/intermediate band (attaches center support to
adjusting screw case)
(Continued) (Continued)

2005 Aviator, 09/2004

307-01-7 Automatic Transmission — 5R55S 307-01-7
ASSEMBLY (Continued)
Item Part Number Description Item Part Number Description
53 E804373-S Bolt 83 7H027 Low/intermediate sun gear
54 7D014 Intermediate clutch drum bearing assembly
bearing No. 4 84 7C498 Reverse brake drum and
55 7D044 Intermediate brake drum clutch assembly (includes
assembly OWC)
56 7B442 Direct clutch external splined 85 7D095 Low/reverse band assembly
steel plates (5 required) bearing
57 7B164 Direct clutch internal splined 86 7B368 Output shaft thrust washer
friction plates (5 required) No. 11
58 7A360 Forward clutch cylinder 87 7C058 Deflector assembly
59 7A262 Forward clutch piston 88 7A233 Transmission parking gear
assembly assembly
60 7G299 Forward clutch support and 89 7060 Output shaft
spring assembly 90 7A441 Parking pawl
61 E860109-S Forward clutch piston and 91 7D070 Parking pawl return spring
spring retaining ring in 92 7D071 Parking pawl shaft
forward clutch cylinder
93 7086 Extension housing gasket
62 7B442 Forward clutch external spline
steel plates (5 required) 94 7A039 Extension housing (4x2)
63 7B164 Forward clutch internally 95 W500311-S309 M8 x 1.25 extension
spline friction plates (5 housing-to-case screws (5
required) required)
64 7B066 Forward clutch pressure plate 96 7052 Extension housing seal (4x2)
65 7D483 Retaining ring 141.45 x 1.37 97 7060 Output shaft assembly
internal (select fit) 98 7A039 Extension housing (4x4)
66 7D234 Forward ring gear hub thrust 99 7052 Extension housing seal (4x4)
bearing No. 6A 100 W500224-S309 Extension housing-to-case
67 7D090 Forward clutch thrust washer screw
No. 6B 101 7D273 Fluid tube connector
68 7G375 Forward clutch hub retainer assembly (2 required)
ring 102 7H074 Ring overdrive servo retainer
69 7B067 Forward ring gear hub 103 W703119-S300 Overdrive servo cover seals
70 7D392 Forward ring gear (2 required)
71 7F374 Forward planet thrust bearing 104 7D027 Overdrive servo cover
No. 7 105 7D021 Overdrive servo piston and
72 7A398 Forward planetary rod
73 7A019 Shell and sun gear assembly 106 7D028 Intermediate/overdrive servo
74 7C176 Low and reverse spacer gear piston springs (2 required)
75 W702775-S300 Reverse carrier drum snap 107 W702777-S300 Ring intermediate servo
ring retainer
76 7D006 Reverse planet assembly 108 W702969-S300 Intermediate servo cover seal
(1 required)
77 7B167 Output shaft sleeve
109 7D027 Intermediate servo cover
78 E860527-S External retainer ring
110 7D021 Intermediate servo piston and
79 7A153 Output shaft ring gear rod
80 7D164 Output shaft hub 111 7005 Case assembly
81 7C122 Output shaft ring gear 112 7H103 Output shaft speed, turbine
retaining ring shaft speed and intermediate
82 7D019 Output shaft hub seal shaft speed sensors
(Continued) (Continued)

2005 Aviator, 09/2004

307-01-8 Automatic Transmission — 5R55S 307-01-8
ASSEMBLY (Continued)
Item Part Number Description Item Part Number Description
113 W702981-S300 Speed sensor-to-case O-ring 141 7Z490 Main control valve body
seal separating plate (bonded)
114 W705534-S309 Speed sensor-to-case screw 142 7A101 Lower main control valve
(M6 x 19) body
115 7034 Case vent (4x2) 143 W500102-S1300 Main control valve body
116 7A179 Reverse brake drum lever screws
117 7D433 Reverse band actuating lever 144 W500102-S300 Main control valve body
shaft screws
118 390318-S2 Pipe plug 145 7E332 Manual valve detent spring
119 6026 Fluid fill plug 146 W500100-S300 Screw detent spring
120 7B210 Manual lever shaft retaining 147 7A100 Main control valve body
pin 148 W705928-S300 Solenoid body connector
121 7N171 Converter drain access plug O-ring seal
122 7A232 Parking pawl actuating rod 149 7G391 Transmission control solenoid
body
123 W703001-S309 Manual lever shaft outer and
inner nut 150 W702921-S300 Transmission control solenoid
body screw
124 7A115 Manual valve inner lever
151 W702921-S1300 Transmission control solenoid
125 7B498 Manual control lever seal body screws (7 required)
126 7C493 Manual lever shaft 152 7A098 Transmission fluid pan filter
127 7F293 Digital transmission range 153 7A191 Transmission fluid pan gasket
(TR) sensor
154 7L027 Transmission fluid pan
128 W500015-S309 Digital transmission range magnet
(TR) sensor screw and washer
(2 required) 155 W705559-S300 Transmission fluid pan filter
screws
129 7A256 Manual control lever
156 7A194 Transmission fluid pan
130 7B193 Reverse servo assembly
157 7A010 Transmission fluid pan drain
131 7D372 Reverse servo plate tube
132 7D466 Reverse servo accumulator 158 W500213-S1309 Transmission fluid pan screw
spring
159 W704999-S309 Transmission fluid pan drain
133 7D189 Reverse servo piston and seal tube plug (short hex)
134 7423 Reverse servo piston O-ring A — Overdrive/coast clutch
seal assembly
135 7D036 Reverse servo cover B — Direct clutch assembly
136 W702359-S309 Reverse servo piston-to-case C — Forward clutch assembly
screws (4 required)
137 7D321 Control valve spring retainer All vehicles
138 7A270 Main fluid pressure spring
regulator valve
1. Thoroughly clean the transmission case and
139 7D488 Reverse servo check valve
extension housing in solvent and blow dry with
140 W701099-S1430 Main control valve body compressed air.
separating plate screw
(Continued)

2005 Aviator, 09/2004

307-01-9 Automatic Transmission — 5R55S 307-01-9
ASSEMBLY (Continued)
2. Inspect the transmission case for the following:
• Stripped bolt hole threads.
• Gasket and mating surfaces for burrs or
nicks.
• Obstructions to vent and fluid passages.
• Cracks or warpage.

All vehicles

5. Inspect the case bearing for damage. If damage

to the case bearing is indicated, install a new
case.

4x2 vehicles

3. Inspect the extension housing for cracks, burrs

or warpage.

6. WARNING: Make sure the lock pin on

bench-mounted holding fixture is secure.
Failure to follow these instructions may
result in personal injury.
Using the special tool, install the transmission
into the bench with the converter housing
facing up.
4x4 vehicles

4. Inspect the extension housing for cracks, burrs

or warpage.

2005 Aviator, 09/2004

307-01-10 Automatic Transmission — 5R55S 307-01-10
ASSEMBLY (Continued)
7. Using the special tool, install the manual
control lever shaft seal and lubricate it with
petroleum jelly.

11. CAUTION: Align the flats on the

manual valve inner lever with the flats on
the manual control lever shaft.
8. Install the parking lever rod. Install the manual control lever shaft.

9. Install the manual control lever. 12. Install the manual valve inner lever onto the
manual shaft and loosely install the nut.

10. Assemble the manual valve inner lever and

parking lever actuating rod as shown.

2005 Aviator, 09/2004

307-01-11 Automatic Transmission — 5R55S 307-01-11
ASSEMBLY (Continued)
13. CAUTION: Use care not to damage
the fluid pan rail surface when installing the
retaining pin.
NOTE: Align the manual control lever shaft
alignment groove with the manual control lever
shaft spring pin bore in the transmission case.
Install the manual control lever shaft spring pin.
• Tap the manual control lever shaft spring
pin into the transmission case.

16. Install the park gear on the output shaft.

14. CAUTION: To avoid damage, do not

allow the wrench to strike the manual valve
inner lever pin.
Tighten the nut. 17. Install the output shaft and park gear.
• Tighten to 48 Nm (35 lb-ft)

15. CAUTION: The tabs on the output

shaft thrust washer (No. 11) point into the
case. Make sure the thrust washer is
correctly seated.
Install the output shaft thrust washer (No. 11).
• Coat the output shaft thrust washer with
petroleum jelly.

2005 Aviator, 09/2004

307-01-12 Automatic Transmission — 5R55S 307-01-12
ASSEMBLY (Continued)
18. Install the low/reverse brake drum. 21. Install the reverse band actuating lever shaft
• Rotate the low/reverse brake drum clockwise into the case and into the reverse band actuating
to install. lever.

22. Install the No.10 needle bearing into the case.

19. CAUTION: Make sure band is resting
on the 2 anchor pins in the case.
Install the low/reverse band over the reverse
drum.

23. CAUTION: Do not damage the seal

against the case during assembly.
Install the output shaft ring gear, hub and seal.
20. NOTE: The reverse band actuating lever must
fit into the notches in the band.
Install the reverse band actuating lever into the
reverse band.

2005 Aviator, 09/2004

307-01-13 Automatic Transmission — 5R55S 307-01-13
ASSEMBLY (Continued)
24. CAUTION: Always install a new 27. CAUTION: Make sure the needle
output shaft retaining ring. bearings stay in place.
Install a new output shaft retaining ring. Install the low/reverse planetary assembly.

25. NOTE: Install the output shaft sleeve with the 28. CAUTION: The low/reverse brake
cone facing up. This sleeve will snap into place drum must be pulled forward to install the
when correctly installed. low/reverse planet retaining ring.
Install the output shaft sleeve. Install the retaining ring.

26. Install low/reverse planetary carrier needle 29. Install the No. 8 thrust bearing.
bearing (No. 9) onto the output shaft ring gear
and hub assembly.

2005 Aviator, 09/2004

307-01-14 Automatic Transmission — 5R55S 307-01-14
ASSEMBLY (Continued)
30. Install the spacer on the input shell, using 33. Install the No. 7 forward planet thrust bearing
petroleum jelly to hold it in place. into the forward ring gear and hub assembly.
Use petroleum jelly to hold the bearing in
place.

31. Install the input shell and sun gear assembly.

34. Install the No. 6B forward clutch thrust washer

onto the forward ring gear hub.

32. NOTE: The No. 13 bearing must be correctly

seated in the forward planet assembly so the
sun gear can be installed correctly.
Install the forward planetary assembly. 35. Install the forward ring gear and hub as an
assembly.

2005 Aviator, 09/2004

307-01-15 Automatic Transmission — 5R55S 307-01-15
ASSEMBLY (Continued)
36. Install the No. 6A forward ring gear hub thrust
bearing into the forward ring gear and hub.

40. Using the special tool, install the retaining ring.

37. Install the forward clutch cylinder.

41. Install the direct clutch drum.

38. Install the No. 5 thrust bearing.

39. Install the intermediate servo piston and spring.

• Lubricate the servo bore with clean
automatic transmission fluid.

2005 Aviator, 09/2004

307-01-16 Automatic Transmission — 5R55S 307-01-16
ASSEMBLY (Continued)
42. Using a depth micrometer with an 8-inch
extension, measure from the top of the gauge
bar to center support ledge in case at 4 places
90 degrees apart.
• Add the 4 measurements, divide by 4 and
record as dimension A.

44. NOTE: Align the disc holes on special tool

with the slot in gauge bar for correct
measurement.
Measure the distance from the top of the gauge
bar to the drum bearing surface through the
hole in the disc and record as dimension B.
Repeat measurement 180 degrees opposite side
43. CAUTION: The torque specifications of the special tool and record as dimension C.
are critical for this procedure. Failure to use
the correct torque specifications may cause
transmission damage.
Install the special tool.
1 Install the special tool and the bolts using
the 2 pump screw locations at
approximately 6 and 12 o’clock positions.
X Tighten to 15 Nm (11 lb-ft).
2 Tighten the center screw.
X Tighten to 1 Nm (10 lb-in).

45. Add dimension B to C, divide by 2 and record

as dimension D.

46. Subtract A from D and record as dimension E.

47. Select bearing from the following chart, using

dimension E.

Service Part Number

Dimension E (7D014) Bearing Thickness Identification (Notches)
1.69-1.87 mm XW4Z-CA 2.65-2.80 mm None
(0.066-0.074 in) (0.104-0.110 in)
1.88-2.04 mm XW4X-DA 2.83-2.98 mm One
(0.073-0.080 in) (0.111-0.116 in)

2005 Aviator, 09/2004

307-01-17 Automatic Transmission — 5R55S 307-01-17
ASSEMBLY (Continued)
Service Part Number
Dimension E (7D014) Bearing Thickness Identification (Notches)
2.05-2.22 mm XW4Z-EA 3.01-3.16 mm 2
(0.081- 0.088 in) (0.118-0.124 in)
2.23-2.43 mm XW4Z-FA 3.21-3.36 mm 3
(0.088-0.096 in) (0.126-0.132 in)

48. NOTE: Make sure that the intermediate band

apply strut is aligned with the band notch.
NOTE: If the intermediate band is reused, it
must be installed in the same position as when
removed.
NOTE: The new intermediate band is dark in
color. This is a normal condition of the band.
Hairline cracks in the band are also considered
normal. Do not install a new band based solely
on the color.
Install the intermediate band.

49. CAUTION: To avoid a fall out

condition of the strut from the screw during 50. CAUTION: If the strut is installed
assembly and function, the small U-shaped incorrectly, transmission damage will occur.
notch should be toward the band and the Check to make sure that the intermediate band
large U-shaped notch toward the main anchor strut is installed in the correct
control side. orientation to the case and adjustment screw.
Install the intermediate band anchor strut.
1 Small ‘‘U’’ notch.
2 Large ‘‘U’’ notch.

2005 Aviator, 09/2004

307-01-18 Automatic Transmission — 5R55S 307-01-18
ASSEMBLY (Continued)
51. Loosely install the screw.

55. NOTE: Align the center support screw hole

with correct case hole.
52. Install the intermediate band apply strut. Install the center support.

53. CAUTION: If the strut is installed 56. Install the center support locknut and cage.
incorrectly, transmission damage will occur.
Check to make sure that the intermediate band
apply strut is installed in the correct orientation
to the case and piston rod.

54. Install the selected No. 4 thrust washer on the

direct clutch drum.
• Coat the thrust washer with petroleum jelly.

2005 Aviator, 09/2004

307-01-19 Automatic Transmission — 5R55S 307-01-19
ASSEMBLY (Continued)
57. Loosely install the screw.

58. CAUTION: Install the center support

retaining ring with the tapered side facing
up.
CAUTION: Make sure the notch
opening is not obstructed by the center
support retaining ring.
Install the center support retaining ring.
1 Make sure the center support retaining ring
is installed with the tapered side facing up.
2 Make sure the opening of the center support
retaining ring is positioned correctly. 59. Install the center shaft thrust bearing (No. 3).

2005 Aviator, 09/2004

307-01-20 Automatic Transmission — 5R55S 307-01-20
ASSEMBLY (Continued)
60. Install the overdrive ring gear, overdrive 63. Install the overdrive band servo piston and
one-way clutch and center shaft assembly. spring.
• Lubricate the servo bore with clean
automatic transmission fluid.

61. CAUTION: Do not bend the trigger

wheel. Make sure that the No. 2 thrust
bearing is in this assembly. 64. Using the special tools, install the retaining
Install the planetary gear overdrive carrier. ring.

62. Install the overdrive brake drum and coast

clutch drum assembly.

2005 Aviator, 09/2004

307-01-21 Automatic Transmission — 5R55S 307-01-21
ASSEMBLY (Continued)
65. NOTE: If the overdrive band is reused, it must
be installed in the same position as when
removed.
NOTE: Make sure that the overdrive band
apply strut is aligned with the band notch.
NOTE: The new overdrive band is dark in
color. This is a normal condition of the band.
Hairline cracks in the band are also considered
normal. Do not install a new band based solely
on the color.
Install the overdrive band.

67. CAUTION: If the strut is installed

incorrectly, transmission damage will occur.
Check to make sure that the overdrive band
anchor strut is installed in the correct
orientation to the case and adjustment screw.

66. CAUTION: To avoid a fall out

condition of the strut from the screw during
assembly and function, the small U-shaped
notch should be toward the band and the
large U-shaped notch toward the main
control side.
Install the overdrive anchor strut. 68. Loosely install the screw.
1 Small ‘‘U’’ notch.
2 Large ‘‘U’’ notch.

2005 Aviator, 09/2004

307-01-22 Automatic Transmission — 5R55S 307-01-22
ASSEMBLY (Continued)
69. Install the overdrive apply strut.

72. NOTE: Align the disc holes on special tool

with the slot in gauge bar for correct
70. CAUTION: If the strut is installed measurement.
incorrectly, transmission damage will occur. Measure the distance from the top of the gauge
Check to make sure that the overdrive band bar to the drum bearing surface through the
apply strut is installed in the correct orientation hole in the disc and record as dimension A.
to the case and piston rod. Repeat measurement 180 degrees opposite side
of the special tool and record as dimension B.

71. CAUTION: The torque specifications

are critical for this procedure. Failure to use 73. Add dimension A to B, divide by 2 and record
the correct torque specifications may cause as dimension C.
transmission damage.
74. Subtract the thickness of the gauge bar 17.78
Install the special tool. mm (0.71 in) from dimension C and record as
1 Install the special tool and the bolts using dimension D.
the 2 pump screw locations at
approximately 6 and 12 o’clock positions. 75. Select the No.1 thrust bearing from the
following chart using dimension D.
X Tighten to 15 Nm (11 lb-ft).
2 Tighten the center screw.
X Tighten to 1 Nm (10 lb-in).

2005 Aviator, 09/2004

307-01-23 Automatic Transmission — 5R55S 307-01-23
ASSEMBLY (Continued)
Service Part Number
Dimension D (7D014) Bearing Thickness Identification (Color/ID)
38.05-38.13 mm F7TZ-TA 1.55-1.60 mm (0.061-0.063 White
(1.50 in) in)
38.14-38.28 mm (1.50-1.51 F7TZ-MA 1.75-1.80 mm (0.069-0.071 Green
in) in)
38.29-38.42 mm F7TZ-NA 1.85-1.90 mm (0.073-0.075 Red
(1.51 in) in)
38.43-38.61 mm F7TZ-RA 2.05-2.10 mm (0.081-0.083 Black
(1.51-1.52 in) in)
38.63-38.74 mm (1.52-1.53 F7TZ-SA 2.15-2.20 mm (0.095-0.097 Yellow
in) in)

76. Install the selected No. 1 fluid pump input

thrust washer.
• Coat the fluid pump input thrust washer
with petroleum jelly.

79. CAUTION: Make sure that the fluid

pump inlet thrust washer (No. 1), selective
thrust washer, fluid pump gasket and the
fluid pump-to-case O-ring seal remain in the
correct position throughout this step.
77. Install the special tools into the transmission Install the fluid pump.
case.

78. Install the pump gasket.

2005 Aviator, 09/2004

307-01-24 Automatic Transmission — 5R55S 307-01-24
ASSEMBLY (Continued)
80. CAUTION: The special tools must be
used to correctly align the pump with the
adapter plate to reduce gear noise, bushing
failure and leakage.
Using the special tool, align the fluid pump to
the adapter plate.

83. CAUTION: Do not allow overdrive

band adjustment screw to back out. Band
strut could fall out of position.
CAUTION: Install, but do not tighten,
a new locknut on the band adjustment screw.
Apply petroleum jelly to the locknut seal.
81. Install 6 screws. Tighten the screws in a star Install a new locknut on the band adjustment
pattern. screw.
• Tighten to 25 Nm (18 lb-ft).

82. Remove the special tools and install the 2

remaining screws.
• Tighten to 25 Nm (18 lb-ft).

2005 Aviator, 09/2004

307-01-25 Automatic Transmission — 5R55S 307-01-25
ASSEMBLY (Continued)
84. CAUTION: The overdrive servo must
be installed prior to band adjustment.
Using the special tool, tighten the overdrive
band adjustment screw. Then back off the
screw exactly (2) turns and hold that position.
• Tighten to 14 Nm (10 lb-ft).

87. CAUTION: The intermediate servo

must be installed prior to band adjustment.
Tighten the intermediate band adjustment screw.
Then back off the screw exactly (2) turns and
hold that position.
• Tighten to 14 Nm (10 lb-ft).

85. Tighten the overdrive band locknut.

1 Hold the overdrive band adjustment screw
stationary.
2 Tighten the overdrive band locknut.
• Tighten to 54 Nm (40 lb-ft).

88. Tighten the intermediate band locknut.

1 Hold the intermediate band adjustment
screw stationary.
2 Tighten the intermediate band locknut.
• Tighten to 54 Nm (40 lb-ft).

86. CAUTION: Do not allow the

intermediate band adjusting screw to back
out. Band strut could fall out of position.
CAUTION: Install, but do not tighten,
a new locknut on the band adjustment screw.
Apply petroleum jelly to the locknut seal.
Install new nut on the band adjustment screw.

2005 Aviator, 09/2004

307-01-26 Automatic Transmission — 5R55S 307-01-26
ASSEMBLY (Continued)
89. Tighten the center support screw. 92. Using the special tools, install the main control
• Tighten to 11 Nm (8 lb-ft). valve body and loosely install the screws.
1 Install the short screw.
2 Install the screw with the larger head.
3 Install the remaining screws.

90. Using the special tools, carry out the air

pressure test procedure. For additional
information, refer to Special Testing Procedures
in this section.
93. Remove the special tools and loosely install the
screw.

91. Install the special tools into the transmission

case.

2005 Aviator, 09/2004

307-01-27 Automatic Transmission — 5R55S 307-01-27
ASSEMBLY (Continued)
94. Tighten the screws in the sequence shown.
• Tighten to 10 Nm (89 lb-in).

95. With the manual lever in the NEUTRAL 96. Install new O-ring seals on the solenoid body
position, install the manual valve detent spring. connector. Lubricate the O-ring seals with clean
• Tighten to 10 Nm (89 lb-in). automatic transmission fluid.

2005 Aviator, 09/2004

307-01-28 Automatic Transmission — 5R55S 307-01-28
ASSEMBLY (Continued)
97. CAUTION: Inspect the transmission
case bore to make sure it is free of foreign
material and not damaged. If damaged,
transmission leak may occur.
Install the solenoid body. Tighten bolts in the
sequence shown.
• Tighten to 8 Nm (71 lb-in).

100. NOTE: The transmission fluid pan gasket is

reusable. Clean and inspect for damage. If not
damaged, the gasket should be reused.
Install the transmission fluid pan and gasket
and loosely install the screws.

98. Install the reverse servo. Tighten the bolts in

the sequence shown in 2 stages.
• Stage 1: Tighten bolts to 5 Nm (44 lb-in).
• Stage 2: Tighten bolts to 11 Nm (8 lb-ft).

101. Tighten the 16 screws in a crisscross

sequence.
• Tighten to 11 Nm (8 lb-ft).

99. CAUTION: Lubricate the fluid filter

seals with clean automatic transmission fluid
or they may be damaged.
NOTE: Make sure that the fluid filter seals are
correctly seated on the filter.
Lubricate the seals and install the transmission
fluid filter.
• Tighten to 10 Nm (89 lb-in).

2005 Aviator, 09/2004

307-01-29 Automatic Transmission — 5R55S 307-01-29
ASSEMBLY (Continued)
102. NOTE: 4x2 shown, 4x4 similar.
Install the parking pawl assembly and gasket.
1 Install the parking pawl shaft.
2 Install the parking pawl return spring.
3 Install the parking pawl.
4 Install a new gasket.

4x4 vehicles

105. Install the extension housing.

• Tighten to 25 Nm (18 lb-ft).

4x2 vehicles

103. Install the extension housing.

• Tighten to 25 Nm (18 lb-ft).

106. Using the special tool, install the extension

housing seal.

104. Using the special tool, install the extension

housing seal.

2005 Aviator, 09/2004

307-01-30 Automatic Transmission — 5R55S 307-01-30
ASSEMBLY (Continued)
All vehicles

107. CAUTION: The digital transmission

range sensor must fit flush against the boss
on the case to prevent damage to the
sensor.
Install the digital transmission range (TR)
sensor and loosely install the screws.

110. CAUTION: The splines of the input

shaft are not the same length on both ends.
The shaft end with the shorter splines goes
into the fluid pump.
Install the input shaft.

108. CAUTION: Tightening one screw

before tightening the other may cause the
sensor to bind or become damaged.
NOTE: The manual lever must be in the
NEUTRAL position.
Using the special tool, align the digital TR
sensor and tighten the screws in an alternating
sequence.
• Tighten to 10 Nm (89 lb-in).
111. Using the special tool, make sure that the fluid
pump gear seal ring is fully seated.

109. Install the outer manual lever.

• Tighten to 48 Nm (35 lb-ft).

2005 Aviator, 09/2004

307-01-31 Automatic Transmission — 5R55S 307-01-31
ASSEMBLY (Continued)
112. Remove the special tool. 114. WARNING: The torque converter can
fall out if the transmission is tipped. Failure
to follow these instructions may cause
personal injury.
Using the special tools, install the torque
converter by pushing and rotating.

113. CAUTION: Do not damage the fluid

pump gear O-ring seal when installing
torque converter.
CAUTION: Make sure the converter
hub is fully engaged in the pump support
and gear and rotates freely. Do not damage 115. Lubricate the torque converter pilot hub with
the hub seal. multi-purpose grease.

CAUTION: If the torque converter

slides out, the hub seal may be damaged.
Lubricate the converter hub with clean
automatic transmission fluid.

2005 Aviator, 09/2004

307-01-32 Automatic Transmission — 5R55S 307-01-32
ASSEMBLY (Continued)
116. CAUTION: The special tool must be 118. Using one of the speed sensor holes, fill the
used to correctly align the adapter plate to transmission with 8.5L (9 quarts) of automatic
the converter or transmission damage could transmission fluid.
occur.
In order to correctly install the special
service tool, it must be installed using 1
round and 1 oblong hole. Using 2 oblong
holes will cause damage to the transmission.
NOTE: Position the adapter plate on the
torque converter and identify the position of
the orange or green paint daub on the
converter face.
If the vehicle is equipped, use the special tool
to install the torque converter flex plate
adapter assembly and 8 nuts.
• Tighten to 44 Nm (33 lb-ft). 119. NOTE: Inspect O-ring seals for damage.
Install new seals if damaged. Lubricate the
O-ring seals with petroleum jelly to prevent
damage to the O-ring seals.
Install the sensors.
• Tighten to 10 Nm (89 lb-in).

117. Install 2 torque converter flex plate adapter

nuts.

2005 Aviator, 09/2004

307-01-1 Automatic Transmission — 5R55S 307-01-1

INSTALLATION
Transmission — 4x2

Special Tool(s)
Retainer, Torque Converter
307-346 (T97T-7902-A)

1. WARNING: Secure the transmission to

the transmission jack with a safety chain. 5. Install the access cover.
Failure to follow these instructions can result
in personal injury.
Secure the transmission to the transmission jack
with a safety chain.

2. NOTE: Rotate the torque converter so the

orange or green paint daub is in the 12 o’clock
position.
Raise and position the transmission to the back
of the engine.

3. Install the 7 engine-to-transmission retaining

bolts.
• Tighten to 48 Nm (35 lb-ft). 6. Install the flexplate cover.
• Tighten to 34 Nm (25 lb-ft).

4. Install the 4 torque converter nuts.

• Tighten to 38 Nm (28 lb-ft).

Copyright  2004, Ford Motor Company

Last updated: 06/29/2004 2005 Aviator, 09/2004
307-01-2 Automatic Transmission — 5R55S 307-01-2
INSTALLATION (Continued)
7. Install the starter.
• Tighten to 24 Nm (18 lb-ft).

11. CAUTION: Use care not to bend or

force the cooler tubes otherwise damage to
the cooler tubes and the transmission can
8. Install the starter motor electrical connectors. result.
• Tighten to 13 Nm (10 lb-ft). Install the transmission fluid cooler tubes.
• Tighten to 30 Nm (22 lb-ft).

9. Install the starter motor electrical connector

cover. 12. Connect the digital transmission range (TR)
sensor connector.

10. NOTE: RH side shown, LH side similar.

Install the front crossmember.
• Tighten to 70 Nm (62 lb-ft).

2005 Aviator, 09/2004

307-01-3 Automatic Transmission — 5R55S 307-01-3
INSTALLATION (Continued)
13. Move the rubber boot back over the connector. 16. CAUTION: Damage will occur to the
solenoid body assembly if the screw is
tightened above the specification.
NOTE: Always install new O-ring seals on the
vehicle harness connector.
NOTE: Clean the area around connector to
prevent contamination of the solenoid body
connector.
NOTE: Use petroleum jelly to lubricate the
O-ring seals to aid in the installation process.
Install and lubricate new O-ring seals on the
transmission connector and connect the
connector.
14. Connect the LH heated oxygen sensor (HO2S) • Tighten to 5 Nm (44 lb-in).
to the transmission and install the wire harness
retainer.

17. Connect the LH catalyst monitor connector to

the transmission.
15. Position the wire harness and install the
retainers.

2005 Aviator, 09/2004

307-01-4 Automatic Transmission — 5R55S 307-01-4
INSTALLATION (Continued)
18. Connect the RH heated oxygen sensor (HO2S) 21. NOTE: This step may require an assistant. LH
to the transmission. side shown, RH side similar.
Position the catalytic converter assembly with
heat shield and loosely install the 4
converter-to-manifold nuts.

19. Connect the fuel lines and the RH catalyst

monitor connector to the bracket.

22. Install the rear transmission mount bolts.

• Tighten to 90 Nm (66 lb-ft).

20. Connect the turbine shaft speed (TSS) sensor,

output shaft speed (OSS) sensor and
intermediate shaft speed (ISS) sensor electrical
connectors.
23. NOTE: RH side shown, LH side similar.
Connect the 2 heated oxygen sensor electrical
connectors.

2005 Aviator, 09/2004

307-01-5 Automatic Transmission — 5R55S 307-01-5
INSTALLATION (Continued)
24. NOTE: RH side shown, LH side similar. 27. Install the LH side crossmember bolts.
Connect the 2 catalyst monitor sensor electrical • Tighten to 70 Nm (52 lb-ft).
connectors.

28. Remove the transmission jack.

25. Position the crossmember in place and loosely
install the 2 nuts to hold up the crossmember. 29. NOTE: RH side shown, LH side similar.
Install the 4 upper crossmember bolts (2 on
each side).
• Tighten to 70 Nm (52 lb-ft).

26. NOTE: Using a transmission jack, raise the

crossmember into place.
Install the RH side crossmember bolts.
• Tighten to 70 Nm (52 lb-ft). 30. Tighten the rear transmission mount nuts.
• Tighten to 90 Nm (66 lb-ft).

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307-01-6 Automatic Transmission — 5R55S 307-01-6
INSTALLATION (Continued)
31. Install the cable bracket and 2 bolts.
• Tighten to 40 Nm (30 lb-ft).

35. Install the plastic shield on the right side of the

crossmember near the fuel tank.
• Tighten to 9 Nm (80 lb-in).
32. Install the heat shield bolts.
• Tighten to 20 Nm (15 lb-ft).

36. Tighten the 4 converter-to-manifold nuts.

• Tighten to 40 Nm (30 lb-ft).
33. Install the RH heat shield and 2 bolts.
• Tighten to 20 Nm (15 lb-ft).

34. Install the LH heat shield bolts.

• Tighten to 20 Nm (15 lb-ft).

2005 Aviator, 09/2004

307-01-7 Automatic Transmission — 5R55S 307-01-7
INSTALLATION (Continued)
37. Using a new gasket install the
converter-to-muffler pipe. Install the bolts,
springs and flag nuts.
• Tighten to 40 Nm (30 lb-ft).

40. Install the shift cable and bracket.

• Tighten to 40 Nm (30 lb-ft).

38. Align the marks made during removal. Install

the front portion of the driveshaft into the
transmission.

41. Use the following guidelines for installing the

in-line transmission fluid filter:
• If the transmission was overhauled and the
vehicle was equipped with an in-line fluid
filter, install a new in-line fluid filter.
• If the transmission was overhauled and the
39. CAUTION: If new bolts to retain the
vehicle was not equipped with an in-line
driveshaft to the axle are not available, coat
fluid filter, install a new in-line fluid filter
the threads of the original bolts with
kit.
Threadlock and Sealer TA-25 or equivalent
meeting Ford specification • If the transmission is being installed for a
WSK-M2G351-A5. non-internal repair, do not install an in-line
filter or filter kit.
CAUTION: The driveshaft flange fits
• If installing a new or a Ford-authorized
tightly on the rear axle pinion flange pilot.
remanufactured transmission, install the
To make sure that the driveshaft flange seats
in-line transmission fluid filter that is
squarely on the pinion flange, tighten the
supplied.
bolts evenly in a cross pattern as shown.
X Prior to lowering the vehicle, install a
Align the marks made during removal. Install
new in-line transmission filter or a filter
the rear driveshaft and bolts.
kit. For additional information, refer to
• Tighten to 112 Nm (83 lb-ft). Transmission Fluid In-Line Filter in this
section.

2005 Aviator, 09/2004

307-01-8 Automatic Transmission — 5R55S 307-01-8
INSTALLATION (Continued)
42. NOTE: When the battery has been 44. Carry out the fluid level check. For additional
disconnected and reconnected, some abnormal information, refer to Transmission Fluid Level
drive symptoms can occur while the vehicle Check in this section.
relearns its adaptive strategy. The customer
needs to be notified that they can experience 45. Verify that the shift cable is correctly adjusted.
slightly different upshifts (either soft or firm) For additional information, refer to Section
and that this is a temporary condition and will 307-05.
eventually return to normal operating condition.
46. Check the operation of the transmission and
Connect the battery ground cable. For additional
inspect for leaks.
information, refer to Section 414-01.

43. Position the fan shroud and install the bolts.

2005 Aviator, 09/2004

307-01-1 Automatic Transmission — 5R55S 307-01-1

INSTALLATION
Transmission — 4x4 3. WARNING: Make sure that the
transmission and transfer case assembly are
Special Tool(s) secured to the transmission jack with a
safety chain. Failure to follow these
Retainer, Torque Converter
307-346 (T97T-7902-A) instructions can result in personal injury.
NOTE: Rotate the torque converter so the
orange or green paint daub is in the 12 o’clock
position.
Raise and position the transmission and transfer
case to the back of the engine.

1. WARNING: Secure the transmission to 4. Install the 7 engine-to-transmission retaining

the transmission jack with a safety chain. bolts.
Failure to follow these instructions can result • Tighten to 48 Nm (35 lb-ft).
in personal injury.
If removed, install the transfer case to the back
of the transmission, install the bracket and
connect the vent hose.
• Tighten to 41 Nm (30 lb-ft).

5. Install the 4 torque converter nuts.

• Tighten to 38 Nm (28 lb-ft).

2. Remove the special tool.

Copyright  2004, Ford Motor Company

Last updated: 06/29/2004 2005 Aviator, 09/2004
307-01-2 Automatic Transmission — 5R55S 307-01-2
INSTALLATION (Continued)
6. Install the access cover.

10. Install the starter motor electrical connector

cover.
7. Install the flexplate cover.
• Tighten to 34 Nm (25 lb-ft).

11. NOTE: RH side shown, LH side similar.

Install the front crossmember and the 4 bolts (2
8. Install the starter. on each side).
• Tighten to 24 Nm (18 lb-ft). • Tighten to 70 Nm (52 lb-ft).

9. Install the starter motor electrical connectors.

• Tighten to 13 Nm (10 lb-ft).

2005 Aviator, 09/2004

307-01-3 Automatic Transmission — 5R55S 307-01-3
INSTALLATION (Continued)
12. Install a jackstand under the transfer case.

16. Move the rubber boot back over the connector.

13. Remove the transmission jack from under the

transmission.

14. CAUTION: Use care not to bend or

force the cooler tubes otherwise damage to
the cooler tubes and the transmission can
result.
Install the transmission fluid cooler tubes.
• Tighten to 30 Nm (22 lb-ft).

17. Connect the LH heated oxygen sensor (HO2S)

to the transmission and install the wire harness
retainer.

15. Connect the digital transmission range (TR)

sensor connector.

2005 Aviator, 09/2004

307-01-4 Automatic Transmission — 5R55S 307-01-4
INSTALLATION (Continued)
18. Position the wire harness and install the
retainers.

21. Connect the RH heated oxygen sensor (HO2S)

to the transmission.

19. CAUTION: Damage will occur to the

solenoid body assembly if the screw is
tightened above the specification.
NOTE: Always install new O-ring seals on the
vehicle harness connector.
NOTE: Clean the area around connector to
prevent contamination of the solenoid body
connector.
NOTE: Use petroleum jelly to lubricate the
O-ring seals to aid in the installation process.
Install and lubricate new O-ring seals on the
transmission connector and connect the
22. Connect the fuel lines and the RH catalyst
connector.
monitor connector to the bracket.
• Tighten to 5 Nm (44 lb-in).

20. Connect the LH catalyst monitor connector to

the transmission.

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307-01-5 Automatic Transmission — 5R55S 307-01-5
INSTALLATION (Continued)
23. Connect the turbine shaft speed (TSS) sensor, 26. NOTE: LH side shown, RH side similar.
output shaft speed (OSS) sensor and Connect the 2 heated oxygen sensor electrical
intermediate shaft speed (ISS) sensor electrical connectors.
connectors.

27. Connect the 2 catalyst monitor sensor electrical

24. NOTE: This step may require an assistant. connectors.
Position the catalytic converter assembly with
heat shield and loosely install the 4
converter-to-manifold nuts.

28. Position the crossmember in place and loosely

install the 2 nuts to hold up the crossmember.

25. Install the rear transmission mount bolts.

• Tighten to 90 Nm (66 lb-ft).

2005 Aviator, 09/2004

307-01-6 Automatic Transmission — 5R55S 307-01-6
INSTALLATION (Continued)
29. Install the RH side crossmember bolts.
• Tighten to 70 Nm (52 lb-ft).

33. Tighten the rear transmission mount nuts.

• Tighten to 90 Nm (66 lb-ft).

30. Install the LH side crossmember bolts.

• Tighten to 70 Nm (52 lb-ft).

34. Install the RH heat shield and bolts.

• Tighten to 20 Nm (15 lb-ft).

31. Remove the jackstand.

32. NOTE: RH side shown, LH side similar.

Install the 4 upper crossmember bolts (2 on
each side).
• Tighten to 70 Nm (52 lb-ft).

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307-01-7 Automatic Transmission — 5R55S 307-01-7
INSTALLATION (Continued)
35. Install the LH heat shield bolts. 38. Using a new gasket, install the
• Tighten to 20 Nm (15 lb-ft). converter-to-muffler pipe and the heat shield.
Install the bolts, springs and flag nuts.
• Tighten to 40 Nm (30 lb-ft).

36. Install the plastic shield on the right side of the

crossmember near the fuel tank.
• Tighten to 9 Nm (80 lb-in). 39. If equipped, connect the shift motor electrical
connector.

37. Tighten the 4 converter-to-manifold nuts.

• Tighten to 40 Nm (30 lb-ft).

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307-01-8 Automatic Transmission — 5R55S 307-01-8
INSTALLATION (Continued)
40. CAUTION: The can (domed CV joint
housing cover) is pressed into the CV joint
housing at the factory. When housed
correctly, the can will appear as shown in
the cut-away illustration, top box. Do not
reseat the can in the CV joint housing if the
can’s flange is above the CV joint housings
shown in the cut-away illustration, bottom
box. Install a new driveshaft.
Verify that the can flange is housed correctly in
the CV joint housing as shown in the cut-away
illustration, top box. Install a new driveshaft if
the can flange is not housed correctly. 43. Verify that the CV joint has seated squarely in
the transfer case flange.
• Check that the space between the end of the
CV joint cap and the end of the transfer
case flange is equal from the top to the
bottom of the 2 components.
• Rotate the driveshaft 1/4 turn.
• Check that the space between the end of the
CV joint cap and the end of the transfer
case flange is equal from the top to the
bottom of the 2 components.
• Repeat this procedure several times.
• If the space if not equal at any point in the
41. CAUTION: Always connect the front attachment, remove and reinstall the
driveshaft to the axle first. Otherwise, the driveshaft as described in this procedure.
weight of the driveshaft can pinch the boot
between the shaft and the boot can and cause
the boot to tear.
NOTE: Align the index marks.
Install the driveshaft.

42. CAUTION: Tighten the bolts evenly in

a cross pattern or damage will occur to the
CV joint.
NOTE: Install new washers and bolts. If new
bolts are not available, coat the threads of the
original bolts with threadlock and sealer.
Install the new washers and bolts. Tighten the
bolts evenly in a cross pattern as shown.
• Tighten to 30 Nm (22 lb-ft).

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307-01-9 Automatic Transmission — 5R55S 307-01-9
INSTALLATION (Continued)
44. NOTE: Install new universal joint retainers and
bolts. If new bolts are not available, coat the
threads of the original bolts with threadlock and
sealer.
Align the index marks and install the new
universal joint retainer and bolts.
• Tighten to 18 Nm (13 lb-ft).

47. Use the following guidelines for installing the

in-line transmission fluid filter:
• If the transmission was overhauled and the
vehicle was equipped with an in-line fluid
filter, install a new in-line fluid filter.
• If the transmission was overhauled and the
vehicle was not equipped with an in-line
fluid filter, install a new in-line fluid filter
45. CAUTION: If new bolts to retain the kit.
driveshaft to the axle are not available, coat • If the transmission is being installed for a
the threads of the original bolts with non-internal repair, do not install an in-line
Threadlock and Sealer TA-25 or equivalent filter or filter kit.
meeting Ford specification
• If installing a new or a Ford-authorized
WSK-M2G351-A5.
remanufactured transmission, install the
CAUTION: The driveshaft flange fits in-line transmission fluid filter that is
tightly on the rear axle pinion flange pilot. supplied.
To make sure that the driveshaft flange seats X Prior to lowering the vehicle, install a
squarely on the pinion flange, tighten the new in-line transmission filter or a filter
bolts evenly in a cross pattern as shown. kit. For additional information, refer to
Install the rear driveshaft and the 8 bolts. Transmission Fluid In-Line Filter in this
• Tighten to 112 Nm (83 lb-ft). section.

48. NOTE: When the battery has been

disconnected and reconnected, some abnormal
drive symptoms can occur while the vehicle
relearns its adaptive strategy. The customer
needs to be notified that they can experience
slightly different upshifts (either soft or firm)
and that this is a temporary condition and will
eventually return to normal operating condition.
Connect the battery ground cable. For additional
information, refer to Section 414-01.

49. Position the fan shroud and install the bolts.

46. Install the shift cable and bracket. 50. Carry out the fluid level check. For additional
• Tighten to 40 Nm (30 lb-ft). information, refer to Transmission Fluid Level
Check in this section.
2005 Aviator, 09/2004
307-01-10 Automatic Transmission — 5R55S 307-01-10
INSTALLATION (Continued)
51. Verify that the shift cable is correctly adjusted. 52. Check the operation of the transmission and
For additional information, refer to Section inspect for leaks.
307-05.

2005 Aviator, 09/2004

307-02-1 Transaxle/Transmission Cooling 307-02-1

SPECIFICATIONS
General Specifications (Continued)
Item Specification
General Specifications
In-Line Fluid Filter Kit 7B155
Item Specification
In-Line Fluid Filter 7B155
Fluid
Lubricant
CAUTION: Use only MERCON V transmission
fluid. Use of any other fluids may result in Ford Multi-Purpose ESR-M19159-A
transmission failure. Grease XG-4
• Normal maintenance;
— Fluid change not necessary, filled for life.
• Severe duty maintenance; Torque Specifications
— Change the fluid at 48,000 km (30,000 miles) Description Nm lb-ft lb-in
intervals.
A/C condenser 10 — 89
Motorcraft MERCON V MERCON V mounting bracket
Automatic Transmission
Fluid XT-5-QM Fill plug 20 15 —
Fluid Capacity Lower fan shroud bolts 7 — 62
NOTE: Approximate dry capacity, includes cooler and Radiator support 12 9 —
tubes. Fluid level procedures in this section should be bracket bolts
used to determine actual fluid requirements and fluid Transmission cooler 10 — 89
specification. DO NOT OVERFILL. If it is necessary to bolts
add or change fluid, use only fluid that has been
certified by the supplier as meeting the Ford Motor Transmission cooler 10 — 89
Company specification shown. line nut
5R55S 12.0L (12.7 Quarts) Transmission fluid 35 26 —
cooler return line
Fluid Filter fitting

Copyright  2004, Ford Motor Company

Last updated: 06/29/2004 2005 Aviator, 09/2004
307-02-1 Transaxle/Transmission Cooling 307-02-1

DESCRIPTION AND OPERATION

Transmission Cooling
Vehicles equipped with automatic transmissions
have a transmission auxiliary fluid cooler which is
mounted between the radiator and the A/C
condenser. In operation, transmission fluid travels
from the transmission to the auxiliary transmission
fluid cooler then back to the transmission. The
transmission auxiliary fluid cooler transfers heat
from the transmission fluid to the outside air.

Copyright  2004, Ford Motor Company

Last updated: 06/29/2004 2005 Aviator, 09/2004
307-02-1 Transaxle/Transmission Cooling 307-02-1

DIAGNOSIS AND TESTING

Transmission Cooling
CAUTION: Whenever a transmission has
been disassembled to install new parts, a new
transmission fluid cooler must be installed and
the transmission fluid cooler tubes must be
cleaned and backflushed.
NOTE: Cleaning and backflushing the transmission
fluid cooling system, along with normal cleaning
and inspection procedures as outlined in this section
during disassembly and assembly, will keep
contamination from reentering the transmission and
causing a repeat repair.
When internal wear or damage has occurred in the
transmission, metal particles, clutch plate material,
or band material may have been carried into the
torque converter and transmission fluid cooler.
These contaminants are a major cause of recurring
transmission troubles and must be removed from the
system before the transmission is put back in use.
Inspection and Verification
When fluid leakage is found in the fluid cooler,
install a new fluid cooler.
When there is evidence of transmission assembly or
fluid contamination due to the following
transmission failure modes, install a new fluid
cooler.
• Major metallic failure
• Multiple clutches or clutch plate failure
• Sufficient component wear which results in
metallic contamination

Copyright  2004, Ford Motor Company

Last updated: 06/29/2004 2005 Aviator, 09/2004
307-02-2 Transaxle/Transmission Cooling 307-02-2
DIAGNOSIS AND TESTING (Continued)
Symptom Chart

Symptom Chart
Condition Possible Sources Action
• Transmission overheating • Damaged radiator. • REPAIR or INSTALL a new
radiator. REFER to Section
303-03.
• Plugged auxiliary fluid cooler. • INSPECT auxiliary fluid
cooler for blockage.
INSTALL new if required.
REFER to Auxiliary
Transmission Fluid Cooler in
this section.
• System leaks. • INSPECT for leaks. REPAIR
as required.
• System leaks. • INSPECT transmission fluid
cooler and tubes for leaks.
REPAIR as required.
• Incorrect fluid level. • ADJUST to correct level.
• Fluid condition. • INSPECT according to
instructions under Check
Fluid Level and Condition.
REFER to Section 307-01.
• Damaged, blocked, reversed, • INSPECT cooler lines and
leaking or restricted cooler tubes. REPAIR or FLUSH as
lines or cooler tubes. necessary.
• Engine concerns causing • INSPECT engine cooling
transmission to overheat. system. REFER to Section
303-03.
• Excessive towing loads. • CHECK gross vehicle weight.
• Incorrect idle or driveability • REFER to the Powertrain
concerns. Control/Emissions Diagnosis
(PC/ED) manual.

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307-02-1 Transaxle/Transmission Cooling 307-02-1

GENERAL PROCEDURES
Transmission Fluid Cooler Flow Test NOTE: If the transmission cooling system fails the
transmission fluid cooler flow test, install a new
Special Tool(s) transmission fluid cooler and flush out the fluid
cooler lines. If installing a new transmission fluid
Adapter, Fluid Level and Fill cooler, use only factory approved components.
Plug
307-437 NOTE: The following components should be
checked and should be within specification prior to
carrying out this test:
• Engine idle. For additional information, refer to
the Powertrain Control/Emissions Diagnosis
Material (PC/ED) manual.
Item Specification • Transmission fluid level. For additional
MERCON V Automatic MERCON V information, refer to Section 307-01.
Transmission Fluid • Line pressure. For additional information, refer to
XT-5-QM Section 307-01.
• Transmission fluid must be at normal operating
CAUTION: Whenever a transmission has
temperature, 66°C - 77°C (150°F - 170°F)
been disassembled to install new parts or a new
or remanufactured transmission has been
1. Place the transmission range selector lever into
installed, a new transmission fluid cooler (either
PARK.
in-tank, auxiliary or OTA) if equipped will need
to be installed. Using a suitable torque 2. With the vehicle in NEUTRAL, position it on a
converter/fluid cooler cleaner, clean and hoist. For additional information, refer to
backflush the transmission fluid cooler tubes. Section 100-02.
CAUTION: Use only clean automatic 3. Prior to carrying out this test, check to see if
transmission fluid specified for this transmission. the vehicle is equipped with a transmission
Do not use supplemental fluid additives, fluid in-line fluid filter. If the vehicle is
treatments or cleaning agent. The use of these equipped with a transmission fluid in-line fluid
materials may affect transmission operation and filter, it must be removed and discarded.
result in internal damage to the transmission
4. Using a 3/16 inch Allen key, hold the large
NOTE: When internal wear or damage has occurred
drain plug with a wrench and remove the small
in the transmission, metal particles, clutch plate
(center) fluid level indicating plug.
material, or band material may have been carried
into the transmission fluid cooler. These
contaminants are a major cause of recurring
transmission concerns and must be removed from
the system before the transmission is put back in
use.

NOTE: When evidence of transmission fluid

contamination (i.e., metal particles, clutch plate
material or band material) is found in the cooling
system, the transmission fluid cooler flow test
should be carried out.

Copyright  2004, Ford Motor Company

Last updated: 06/29/2004 2005 Aviator, 09/2004
307-02-2 Transaxle/Transmission Cooling 307-02-2
GENERAL PROCEDURES (Continued)
5. Install the special tool into the pan. 9. Start the engine and run it at idle.

10. With the engine running, place the vehicle in

PARK and position the vehicle on a hoist. For
additional information, refer to Section 100-02.

11. Once a steady flow of fluid (without air

bubbles) is observed, remove the hose from the
special tool and place the hose in a measuring
container for 15 seconds. After 15 seconds,
place the hose back onto the special tool.
Lower the vehicle and turn the engine OFF.
Measure the amount of fluid in the container. If
adequate flow is observed, approximately 208
ml (7 oz) will be in the measuring container.
6. Remove the cooler return line (upper line) from The test is now complete. Reconnect the cooler
the fitting on the transmission case. line.
• To install, tighten to 35 Nm (26 lb-ft). • Tighten to 35 Nm (26 lb-ft).

7. Connect one end of a clear hose to the cooler 12. Install the fluid level indicating plug.
return line and route the other end of the hose • Tighten to 10 Nm (89 lb-in).
to the special tool in the pan.

8. Lower the vehicle.

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307-02-3 Transaxle/Transmission Cooling 307-02-3
GENERAL PROCEDURES (Continued)
13. If the flow is not adequate 208 ml (7 oz) in 15 15. Once the procedure has been completed and
seconds, disconnect the hose from the cooler adequate flow has been established, a new
return line and connect the hose to the cooler transmission in-line filter will need to be
inlet (lower fitting) on the transmission case. installed. For the filter installation procedure,
Reconnect the cooler return line to the case refer to Section 307-01.
(upper fitting) and continue with this
procedure.

14. Repeat Steps 10-11 to see if the flow is now

adequate.
• If the flow is now approximately 208 ml (7
oz) in 15 seconds, install a new transmission
fluid cooler and flush out the fluid cooler
tubes. Test is complete.
• If the flow is still not adequate 208 ml (7
oz) in 15 seconds the pump and/or torque
converter may be at fault. Carry out the
following procedures and checks:
X Carry out the torque converter diagnosis.
For additional information, refer to
Section 307-01.
X Carry out the main control valve body
procedure. For additional information,
refer to Section 307-01.
X Carry out the fluid pump procedure. For
additional information, refer to Section
307-01.

2005 Aviator, 09/2004

307-02-1 Transaxle/Transmission Cooling 307-02-1

GENERAL PROCEDURES
Transmission Fluid Cooler — 2. Remove and discard the in-line transmission
Backflushing and Cleaning fluid filter, if equipped.

Material
Item Specification
MERCON V Automatic MERCON V
Transmission Fluid
XT-5-QM

CAUTION: Whenever a transmission has

been disassembled to install new parts or a new
or remanufactured transmission has been
installed, a new transmission fluid cooler, either
in-tank, auxiliary or oil to air (OTA), if equipped
will need to be installed. Using a suitable torque
converter/fluid cooler cleaner, clean and 3. To aid in attaching the cleaner to the
backflush the transmission fluid cooler tubes. transmission steel cooler lines, connect 2
additional rubber hoses to the transmission end
CAUTION: Use only clean automatic of the steel transmission cooler lines as
transmission fluid specified for this transmission. described.
Do not use supplemental fluid additives, • Connect the cleaner tank pressure line to the
treatments or cleaning agent. The use of these steel transmission cooler return line (longest
materials may affect transmission operation and line).
result in internal damage to the transmission.
• Connect a tank return hose to the steel
When internal wear or damage has occurred in transmission cooler pressure line (shorter
the transmission, metal particles, clutch plate line). Place the outlet end of this hose in the
material, or band material may have been solvent tank reservoir.
carried into the transmission fluid cooler. These
contaminants are a major cause of recurring 4. Turn on the pump and allow the transmission
transmission concerns and must be removed fluid to circulate a minimum of 5 minutes
from the system before the transmission is put (cycling switch ON and OFF will help dislodge
back in use. contaminants in the cooler system).

NOTE: Do not use any solvents while carrying out 5. Switch OFF the pump and disconnect the
this procedure. Only use clean automatic pressure hose from the transmission cooler
transmission fluid. return line.

1. Conduct backflushing with a suitable torque 6. Use compressed air to blow out the cooler(s)
converter/transmission fluid cooler cleaner. Test and lines (blow air into the transmission cooler
the equipment to make sure that a vigorous return line) until all the fluid is removed.
fluid flow is present before proceeding. Install a
new system filter if flow is weak or 7. Remove the rubber return hose from the
contaminated. remaining steel cooler line.

Copyright  2004, Ford Motor Company

Last updated: 06/29/2004 2005 Aviator, 09/2004
307-02-1 Transaxle/Transmission Cooling 307-02-1

REMOVAL AND INSTALLATION

Auxiliary Transmission Fluid Cooler

Special Tool(s)
Holding Wrench, Fan Pulley
303-239 (T84T-6312-C)

Wrench, Fan Clutch Nut

303-240 (T84T-6312-D)
3. Remove the degas bottle cap.

Disconnect Tool, Transmission

307-441

Removal

1. Remove the upper air deflector. 4. Remove and discard the screws. Remove the
bolt from the left side of the fan shroud.

2. Remove the inner air deflector.

Copyright  2004, Ford Motor Company

Last updated: 4/8/2005 2005 Aviator, 09/2004
307-02-2 Transaxle/Transmission Cooling 307-02-2
REMOVAL AND INSTALLATION (Continued)
5. Remove and discard the screws. Remove the 8. With the vehicle in NEUTRAL, position the
bolt from the right side of the fan shroud. vehicle on a hoist. For additional information,
refer to Section 100-02.

9. Drain the engine coolant. For additional

information, refer to Section 303-03.

10. NOTE: If equipped, remove the safety retainer

from the connector.
Disconnect the cooler line.
• If equipped, use the special tool to
disconnect the quick connect coupler.
• If equipped, loosen and remove the screw
clamp from the hose.

6. Remove the upper radiator fan shroud.

11. Remove the right lower radiator hose from the

radiator, remove the hose from the retainer and
7. Using the special tools, remove the cooling fan. position it aside.

2005 Aviator, 09/2004

307-02-3 Transaxle/Transmission Cooling 307-02-3
REMOVAL AND INSTALLATION (Continued)
12. Remove the left lower radiator hose from the 16. Remove the degas bottle hose and upper
radiator and position it aside. radiator hose.

13. Remove the bolts and the lower fan shroud. 17. Remove the right radiator support bracket.

14. Disconnect the lower air dam push pins. 18. Remove the A/C line retainer clip.

15. Position the vehicle.

2005 Aviator, 09/2004

307-02-4 Transaxle/Transmission Cooling 307-02-4
REMOVAL AND INSTALLATION (Continued)
19. Remove the left radiator support bracket. 22. NOTE: It will be necessary to lift the radiator
assembly from the mounts and set it on the
frame in order to separate the A/C condenser
from the radiator. Right side shown; left side
similar.
Remove the radiator from the mount and set it
on the frame.

20. Remove the right A/C condenser support

bracket.

23. Remove the left inner air deflector from the

A/C condenser.

21. Remove the left A/C condenser support bracket.

24. Remove the right inner air deflector from the

A/C condenser.

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307-02-5 Transaxle/Transmission Cooling 307-02-5
REMOVAL AND INSTALLATION (Continued)
25. NOTE: It is not necessary to evacuate the A/C
system, the A/C condenser can remain in the
vehicle.
NOTE: It will be necessary to lift the A/C
condenser from the lower support. Move the
A/C condenser toward the front of the vehicle.
Remove the radiator and transmission cooler as
an assembly and place it on a bench.

Installation

1. Install the transmission cooler lines.

26. CAUTION: Do not allow the A/C

condenser to hang freely or damage to the
A/C lines can occur.
Using mechanic’s wire, support the A/C
condenser to the frame.

27. Remove the bolts and the transmission cooler.

2. Install the transmission cooler and bolts.
• Tighten to 10 Nm (89 lb-in).

28. Remove the transmission cooler lines.

2005 Aviator, 09/2004

307-02-6 Transaxle/Transmission Cooling 307-02-6
REMOVAL AND INSTALLATION (Continued)
3. NOTE: Remove the mechanic’s wire from the
A/C condenser.
NOTE: Do not set the radiator assembly in the
mounts at this time. Set the radiator assembly
on the frame.
Install the radiator and transmission cooler into
the vehicle as an assembly.

7. Set the radiator assembly onto the support

mounts.

4. Set the lower A/C condenser mounts into the

radiator assembly.

5. Install the right inner A/C air deflector shield.

8. Install the right A/C condenser mounting

bracket.
• Tighten to 10 Nm (89 lb-in).

6. Install the left inner A/C air deflector shield.

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307-02-7 Transaxle/Transmission Cooling 307-02-7
REMOVAL AND INSTALLATION (Continued)
9. Install the left A/C condenser mounting bracket.
• Tighten to 10 Nm (89 lb-in).

13. With the range selector in NEUTRAL, position

the vehicle on a hoist. For additional
information, refer to Section 100-02.
10. Install the right radiator support bracket and
bolt. 14. Install the lower front air dam push pins.
• Tighten to 12 Nm (9 lb-ft).

15. Install the lower fan shroud and bolts.

11. Install the left radiator support bracket and bolt. • Tighten to 7 Nm (62 lb-in).
• Tighten to 12 Nm (9 lb-ft).

12. Install the A/C line retainer.

2005 Aviator, 09/2004

307-02-8 Transaxle/Transmission Cooling 307-02-8
REMOVAL AND INSTALLATION (Continued)
16. Connect the left lower radiator hose. 19. Using the special tools, install the fan.
• Tighten to 55 Nm (41 lb-ft).

17. Connect the right lower radiator hose to the

radiator and position it into the retainer. 20. Install the upper fan shroud.

18. Connect the transmission cooler lines. 21. Install the bolt and screws on the left side of
• If equipped, install the safety retainer on the the fan shroud.
connector. • Tighten to 7 Nm (62 lb-in).
• If equipped, install the screw clamp on the
hose.

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307-02-9 Transaxle/Transmission Cooling 307-02-9
REMOVAL AND INSTALLATION (Continued)
22. Install the bolt and screws on the right side of
the fan shroud.
• Tighten to 7 Nm (62 lb-in).

25. Install the upper air deflector.

23. Connect the upper radiator hose and the degas

bottle hose.

26. Fill the cooling system. For additional

information, refer to Section 303-03.

27. Fill and check the transmission fluid. For

additional information, refer to Section 307-01.
24. Install the inner air deflector.

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307-02-1 Transaxle/Transmission Cooling 307-02-1

REMOVAL AND INSTALLATION

Transmission Fluid Cooler Tubes

Special Tool(s)
Disconnect Tool, Transmission
307-441

Removal
4. Remove the transmission cooler line bracket
1. With the vehicle in NEUTRAL, position it on a nut.
hoist. For additional information, refer to
Section 100-02.

2. Use a backup wrench to hold the case fitting

securely. Disconnect the fluid cooler fittings.

5. Remove the transmission cooler line bracket

from the stud.

3. NOTE: If equipped, remove the safety retainer

from the connector.
Disconnect the cooler line.
• If equipped, use the special tool to
disconnect the quick connect coupler.
• If equipped, loosen and remove the screw
clamp from the hose.

Copyright  2004, Ford Motor Company

Last updated: 06/29/2004 2005 Aviator, 09/2004
307-02-2 Transaxle/Transmission Cooling 307-02-2
REMOVAL AND INSTALLATION (Continued)
6. NOTE: 4x4 vehicle shown; 4x2 vehicle similar. Installation
Remove both transmission cooler lines from the
vehicle. 1. Install the fluid cooler tube bracket.

7. Remove the fluid cooler tube brackets. 2. Install the fluid cooler tube brackets.
1 Bend the tabs open to remove the bracket. 1 Install the bracket, bend the tabs closed.
2 Remove the bracket. 2 Install the bracket.

8. Remove the fluid cooler tube bracket. 3. NOTE: 4x4 vehicle shown; 4x2 vehicle similar.
Install the transmission fluid cooler tubes into
the vehicle.

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307-02-3 Transaxle/Transmission Cooling 307-02-3
REMOVAL AND INSTALLATION (Continued)
4. Install the transmission cooler line bracket. 6. CAUTION: To prevent cross
threading, all tube nuts must be hand started
before being torqued to specification.
Use a backup wrench to hold the case fittings
securely, install the transmission fluid cooler
tubes.
• Tighten to 30 Nm (22 lb-ft).

5. Install the transmission cooler lines.

• Install the cooler line hoses.
• Install the nut.
• Tighten to 10 Nm (89 lb-in).
• If equipped, install the safety retainer on the
connector.
7. Position the vehicle.

8. Fill transmission fluid to the correct level using

clean automatic transmission fluid and inspect
for leaks. For additional information, refer to
Section 307-01.

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307-02-1 Transaxle/Transmission Cooling 307-02-1

REMOVAL AND INSTALLATION

Transmission Fluid Cooler Hoses

Special Tool(s)
Disconnect Tool, Transmission
307-441

Removal
Installation
1. With the vehicle in NEUTRAL, position the
vehicle on a hoist. For additional information, 1. Install new fluid cooler hoses to the fluid
refer to Section 100-02. cooler. Install new screw clamps to secure the
hoses to the fluid cooler.
2. NOTE: If equipped, remove the safety retainer
from the connector.
Disconnect the cooler line.
• If equipped, use the special tool to
disconnect the quick connect coupler.
• If equipped, loosen and remove the screw
clamp from the hose.

2. Connect the transmission cooler hoses to the

cooler tubes.

3. NOTE: Use side cutter pliers to cut the hose

clamps.
Remove the fluid cooler hoses from the fluid
cooler.

3. If equipped, install the safety retainer on the

connector.

4. Position the vehicle.

Copyright  2004, Ford Motor Company
Last updated: 06/29/2004 2005 Aviator, 09/2004
307-02-2 Transaxle/Transmission Cooling 307-02-2
REMOVAL AND INSTALLATION (Continued)
5. Fill transmission fluid to the correct level using
clean automatic transmission fluid and inspect
for leaks. For additional information, refer to
Section 307-01.

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307-05-1 Automatic Transaxle/Transmission External Controls 307-05-1

SPECIFICATIONS

Torque Specifications
Description Nm lb-ft lb-in
Digital transmission 10 — 89
range (TR) sensor
screws
Fluid level indicator 10 — 89
plug-to-drain pipe
assembly
Shift cable bracket 40 30 —
screws

Copyright  2004, Ford Motor Company

Last updated: 6/29/2004 2005 Lincoln Aviator, 09/2004
307-05-1 Automatic Transaxle/Transmission External Controls 307-05-1

DESCRIPTION AND OPERATION

External Controls If the selector lever will not move out of park with
the key in the ON position, it will need to be
The transmission shift cable transfers the
unlocked manually.
transmission operating mode from the shift control
selector lever to the transmission. The indicated Transmission Control Switch (TCS)
position of the shift control selector lever is
The transmission control switch (TCS) is a
transferred to the transmission through the
momentary contact switch located on the floor
transmission floor shifter linkage, then to the shift
shifter knob. Pushing the transmission control
cable and bracket, and down to the manual control
switch (TCS) will either disengage or engage the
lever on the transmission.
overdrive function of the transmission. If the
Shift Interlock System overdrive (D) is disengaged, the message O/D OFF
will illuminate on the instrument panel.
The shift interlock system prevents the shifting from
PARK unless the brake pedal is depressed. The shift
interlock system consists of a shift lock actuator
mounted on the floor shifter. If the ignition switch
is in the RUN position, the shift lock actuator is
continually on unless the brake pedal is depressed.

Copyright  2004, Ford Motor Company

Last updated: 6/29/2004 2005 Lincoln Aviator, 09/2004
307-05-1 Automatic Transaxle/Transmission External Controls 307-05-1

DIAGNOSIS AND TESTING

External Controls Transmission Control Switch (TCS)
Refer to Wiring Diagrams Cell 29 for schematic and The transmission control switch (TCS) is a
connector information. momentary contact switch that is located on the
console-mounted transmission range selector lever.
Special Tool(s) Pushing the TCS will either disengage or engage the
73 III Automotive Meter overdrive function of the automatic transmission. If
105-R0057 or equivalent the OVERDRIVE is disengaged, the word O/D OFF
will illuminate on the instrument cluster.
Inspection and Verification
1. Verify the customer concern by operating the
transmission external control.
Breakout Box, EEC-V Control 2. Visually inspect for obvious signs of
System mechanical and electrical damage; refer to the
418-049 (014-00950) or
equivalent following chart:
Visual Inspection Chart
Mechanical Electrical
• Damaged shift lock • Failed fuse(s)
Shift Interlock System actuator • Damaged wiring harness
• Damaged transmission • Loose or corroded
The brake/shift interlock system prevents the control switch (TCS) connections
shifting from PARK unless the brake pedal is • Damaged shift interlock • Damaged shift interlock
depressed. The brake/shift interlock system consists switch switch
of a shift lock actuator mounted at the base of the
console-mounted transmission range selector lever. 3. If the fault is not visually evident, determine
the symptom. GO to Symptom Chart.

Symptom Chart

Symptom Chart
Condition Possible Sources Action
• Shift interlock system does • Shift interlock switch. • GO to Pinpoint Test A.
not release/lock correctly • Circuit(s).
• Fuse(s).
• Shift lock actuator.
• Brake pedal position (BPP)
switch.
• Shift control out of correct • Transmission shift cable and • GO to Pinpoint Test B.
gear relationship bracket.
• Retainer bracket.
• Shift control linkage.

Copyright  2004, Ford Motor Company

Last updated: 6/29/2004 2005 Lincoln Aviator, 09/2004
307-05-2 Automatic Transaxle/Transmission External Controls 307-05-2

DIAGNOSIS AND TESTING (Continued)

Symptom Chart (Continued)
Condition Possible Sources Action
• Transmission range indicator • Transmission shift cable • TIGHTEN the screws holding
does not correspond to the bracket. the transmission shift cable
gear bracket.
• Transmission control indicator • VERIFY transmission shift
linkage. cable adjustment. REFER to
Selector Lever Cable
Adjustment in this section.
ADJUST transmission shift
cable if necessary.
• Transmission shift cable loose • TIGHTEN the transmission
from the transmission retainer shift cable screws.
bracket.
• Shift linkage. • VERIFY transmission shift
cable adjustment. REFER to
Selector Lever Cable
Adjustment in this section.
ADJUST transmission shift
cable if necessary. VERIFY
digital transmission range
(TR) sensor for correct
adjustment. REFER to
Section 307-01.
• Transmission range indicator • Bulb. • REFER to Section 413-00.
lamp does not illuminate • Circuit(s).
• Transmission control switch • Fuse. • GO to Pinpoint Test C.
(TCS) is not operating • TCS not cycled during self
correctly test.
• Powertrain control module
(PCM).
• Circuit(s).
• Transmission control indicator • Bulb. • GO to Pinpoint Test D.
lamp (TCIL) does not • Circuit(s).
illuminate • Powertrain control module
(PCM).
• Transmission control indicator • Circuit(s). • GO to Pinpoint Test E.
lamp (TCIL) stays illuminated • Powertrain control module
(PCM).
• Water enters inside the • Cable assembly grommet. • SECURE grommet to dash
vehicle panel.
• Torn cable assembly • INSTALL new transmission
grommet. shift cable.
• Excessive shift effort • Transmission shift cable. • INSTALL a new transmission
shift cable.
• Cable bracket. • ADJUST cable. TIGHTEN
cable bracket screws.
• Transmission range selector • Transmission shift cable. • REINSTALL transmission
lever will not shift from range shift cable.
• Lock tab. • REPAIR or INSTALL a new
lock tab.
• Broken transmission shift • INSTALL a new transmission
cable. shift cable.

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307-05-3 Automatic Transaxle/Transmission External Controls 307-05-3

DIAGNOSIS AND TESTING (Continued)

Connector Circuit Reference

Brake Pedal Position (BPP) Switch

Pin Number Circuit Description

1 Brake pedal position switch output
2 Voltage supplied at all times

Brake Shift Interlock Switch

Pin Number Circuit Description

1 Voltage in run
2 Brake Pedal Position Switch Input
3 Ground
6 Key lock

Transmission Control Switch (TCS)

Pin Number Circuit Description

1 Transmission Overdrive Cancel Switch to PCM
2 Voltage in run

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307-05-4 Automatic Transaxle/Transmission External Controls 307-05-4

DIAGNOSIS AND TESTING (Continued)

Instrument Cluster

Pin Number Circuit Description

16 SCP Bus positive
17 SCP Bus negative

Instrument Cluster C220a

Pin Number Circuit Description

17 Voltage supplied at all times

Battery Junction Box C1117

Pin Number Circuit Description

10 Voltage supplied at all times
11 Voltage supplied at all times

Pinpoint Tests Pinpoint Tests A: Shift Interlock System

Refer to Wiring Diagrams Cell 37 for schematic and Does Not Release/Lock Correctly
connector information. Normal Operation
Refer to Wiring Diagrams Cell 29 for schematic and The shift lever will not come out of PARK unless
connector information. the key is in the ON position and the brake pedal is
depressed.

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307-05-5 Automatic Transaxle/Transmission External Controls 307-05-5

DIAGNOSIS AND TESTING (Continued)

Possible Causes • Short to ground
If the range selector lever does not release or lock,
• Short to open
the cause may be:
• Faulty shift lock actuator
• Faulty brake pedal position (BPP) switch
• Wiring, terminals or connectors
• Blown fuse
PINPOINT TEST A: SHIFT INTERLOCK SYSTEM DOES NOT RELEASE/LOCK CORRECTLY
Test Step Result / Action to Take
A1 TEST BRAKE LIGHTS
• Apply brake pedal and view brake lights. Yes
• Do brake lights illuminate? GO to A7.
No
GO to A2.
A2 TEST FUSE 30 (15A)
• Key in OFF position. Yes
• Check fuse: BJB Fuse 50 (15A). GO to A4.
• Is resistance of fuse 5 ohms or less? No
GO to A3.
A3 TEST CIRCUIT FOR SHORT TO GROUND
• Key in OFF position.
• Disconnect: Brake Pedal Position (BPP) Switch.
• Measure the resistance pin 2 and ground.

Yes
REPAIR circuit for short to ground. TEST
the system for normal operation.
No
• Is the resistance 10 ohms or less? GO to A4.
A4 TEST CIRCUIT FOR OPEN
• Measure the resistance between output side of Fuse 50 (15A)
and brake pedal position switch connector Pin 2.

Yes
GO to A5.
No
REPAIR circuit for open. TEST the system
• Is the resistance 5 ohms or less? for normal operation.
(Continued)

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307-05-6 Automatic Transaxle/Transmission External Controls 307-05-6

DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST A: SHIFT INTERLOCK SYSTEM DOES NOT RELEASE/LOCK CORRECTLY (Continued)
Test Step Result / Action to Take
A5 TEST BRAKE PEDAL POSITION (BPP) SWITCH
• Measure resistance of brake pedal position switch while open
(OFF) and closed (ON).

Yes
GO to A6.
No
• Is resistance of switch greater than 10 ohms while OFF and INSTALL a new switch. TEST the system
5 ohms or less while ON? for normal operation.
A6 TEST CIRCUIT FOR SHORT TO GROUND
• Disconnect: Shift Lock Actuator.
• Measure resistance of Pin 2 and ground.

Yes
REPAIR circuit for short to ground. TEST
the system for normal operation.
No
• Is resistance 10 ohms or less? GO to A7.
A7 TEST CIRCUIT 810 FOR OPEN
• Measure resistance between shift lock actuator Pin 2 and brake
pedal position switch connector Pin 1.

Yes
GO to A8.
No
REPAIR circuit for open. TEST the system
• Is resistance 5 ohms or less? for normal operation.
A8 TEST FOR B+
• Key in ON position.
(Continued)

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307-05-7 Automatic Transaxle/Transmission External Controls 307-05-7

DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST A: SHIFT INTERLOCK SYSTEM DOES NOT RELEASE/LOCK CORRECTLY (Continued)
Test Step Result / Action to Take
A8 TEST FOR B+ (Continued)
• Measure voltage at shift lock actuator Pins 1 and 5 and ground.

Yes
GO to A12.
No
• Is the voltage greater than 10 volts? GO to A9.
A9 TEST FUSE 15 (7.5A)
• Key in OFF position. Yes
• Check fuse: Fuse 15 (7.5A). GO to A11.
• Is resistance of fuse 5 ohms or less? No
GO to A10.
A10 TEST CIRCUIT FOR SHORT TO GROUND
• Measure resistance at Pins 1 and 5 and ground.

Yes
REPAIR circuit for short to ground. TEST
the system for normal operation.
No
• Is resistance 10 ohms or less? GO to A11.
A11 TEST CIRCUIT FOR OPEN
• Measure resistance between output side of Fuse 15 (7.5A) and
shift lock actuator Pins 1 and 5.

Yes
GO to A12.
No
REPAIR circuit for open. TEST the system
• Is resistance 5 ohms or less? for normal operation.
(Continued)

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307-05-8 Automatic Transaxle/Transmission External Controls 307-05-8

DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST A: SHIFT INTERLOCK SYSTEM DOES NOT RELEASE/LOCK CORRECTLY (Continued)
Test Step Result / Action to Take
A12 CHECK CIRCUIT FOR OPEN
• Measure the resistance of shift lock actuator Pin 3 and ground.

Yes
Shift lock actuator is not serviced.
INSTALL a new Transmission Selector
Level REFER to Transmission Selector
Lever in this section. TEST the system for
normal operation.
No
REPAIR circuit for open. TEST the system
• Is the resistances less than 5 ohms? for normal operation.

Pinpoint Test B: Shift Control is Out of Possible Causes

Correct Gear Relationship When placing the range selector lever in a selected
gear (P, R, N, D, or (D) ) and the transmission is
Normal Operation
not in the corresponding gear for what was selected,
When placing the range selector lever in a selected
the cause could be:
gear (P, R, N, D, or (D) ) the transmission will be
in the correct gear for what was selected. • Shift linkage out of adjustment
• Worn or broken shift cable
• Wiring, terminals or connectors
PINPOINT TEST B: SHIFT CONTROL IS OUT OF CORRECT GEAR RELATIONSHIP
Test Step Result / Action to Take
B1 CHECK SHIFT CONTROL LINKAGE
• Key in ON position.
• Apply the brake pedal. Yes
• Gain access to the shift control linkage. INSTALL new shift control linkage. TEST
• Actuate the transmission range selector lever in all ranges. the system for normal operation.
• Observe all linkages during operation. No
• Is the linkage damaged? GO to B2.
B2 CHECK TRANSMISSION SHIFT CABLE
• Check transmission shift cable and bracket installation and Yes
tightness. VERIFY the transmission shift cable
• Is the transmission shift cable correctly installed and adjustment. REFER to Selector Lever
adjusted? Cable Adjustment in this section. ADJUST
the transmission shift cable if necessary.
VERIFY the digital transmission range
(TR) sensor for correct adjustment.
REFER to Section 307-01 in this section.
ADJUST the TR sensor if necessary. GO
to B3.
No
REPAIR as necessary. TEST the system
for normal operation.
(Continued)

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307-05-9 Automatic Transaxle/Transmission External Controls 307-05-9

DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST B: SHIFT CONTROL IS OUT OF CORRECT GEAR RELATIONSHIP (Continued)
Test Step Result / Action to Take
B3 CHECK LINKAGE/CABLE FOR CORRECT GEAR
RELATIONSHIP
• Apply the brake pedal. Yes
• Actuate the transmission range selector lever in all ranges. System OK. TEST the system for normal
• Does the indicator match the gear selection? operation.
No
REFER to Selector Lever Cable
Adjustment in this section. TEST the
system for normal operation.

Pinpoint Test C: Transmission Control Possible Causes

Switch (TCS) Is Not Operating Correctly When the TCS switch is depressed and the
transmission will not disengage or engage the
Normal Operation
overdrive function, the possible causes are:
When the TCS switch is depressed, the transmission
will either disengage or engage the overdrive • Blown fuse
function. • Short to ground
• Short to open
• Faulty switch
• Wiring, terminals or connectors
PINPOINT TEST C: TRANSMISSION CONTROL SWITCH (TCS) IS NOT OPERATING CORRECTLY
Test Step Result / Action to Take
C1 CHECK I/P FUSE 26
• Key in OFF position. Yes
• Check fuse: I/P Fuse 2.13 (5A). REINSTALL the fuse. GO to C3.
• Is the resistance 5 ohms or less? No
INSTALL a new fuse. TEST the system for
normal operation. If the fuse fails again,
GO to C2.
C2 CHECK CIRCUIT FOR SHORT TO GROUND
• Disconnect: Powertrain Control Module (PCM). Yes
• Inspect for damaged or pushed out pins, corrosion, loose wires, GO to C3.
etc. Repair as necessary. No
• Measure the resistance between Pin 41 and ground. REPAIR circuit. TEST the system for
• Is the resistance greater than 10,000 ohms? normal operation.
C3 CHECK TRANSMISSION CONTROL SWITCH (TCS) CIRCUIT
FOR VOLTAGE
• Disconnect: Powertrain Control Module (PCM).
• Inspect for damaged or pushed out pins, corrosion, loose wires,
etc. Repair as necessary.
• Leave PCM disconnected. Yes
• Key in ON position. INSTALL a new PCM. TEST the system
• Measure the voltage between Pin 41 and ground while cycling for normal operation.
the TCS switch several times. No
• Does the voltage cycle? GO to C4.
C4 CHECK CIRCUIT FOR OPEN
• Key in OFF position.
• Disconnect: Central Junction Box (CJB).
• Disconnect: Transmission Control Switch (TCS).
Inspect both ends for damaged or pushed out pins, moisture,
corrosion, loose wires, etc. Repair as necessary.
• Measure the resistance between the CJB fuse 2.13 (5A) Pin 10
and the power side of the TCS Pin 2 vehicle harness connector. Yes
• Measure the resistance between the CJB fuse 2.13 (5A) Pin 10 GO to C5.
and the power side of the TCS Pin 1 vehicle harness connector No
circuit. REPAIR open circuit. TEST the system for
• Is the resistance less than 5 ohms for both circuits? normal operation.
(Continued)

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307-05-10 Automatic Transaxle/Transmission External Controls 307-05-10

DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST C: TRANSMISSION CONTROL SWITCH (TCS) IS NOT OPERATING CORRECTLY
(Continued)
Test Step Result / Action to Take
C5 CHECK CIRCUIT FOR SHORT TO POWER
• Measure the resistance between pin 41 and pin 1. Yes
• Is the resistance greater than 10,000 ohms? INSTALL a new selector level knob.
RECONNECT all components. TEST the
system for normal operation.
No
REPAIR circuit. TEST the system for
normal operation.

Pinpoint Test D: Transmission Control Possible Causes

Indicator Lamp (TCIL) Does Not Illuminate If the TCS switch is depressed and the does not
illuminate, the possible causes could be:
Normal Operation
When the TCS switch is depressed, a light on the • Faulty PCM
dash will illuminate O/D OFF. When the TCS • Short to ground
switch is depressed a second time, the lamp will go
off. • Short to open
• Faulty TCS switch
• Wiring, terminals or connectors
PINPOINT TEST D: TRANSMISSION CONTROL INDICATOR LAMP (TCIL) DOES NOT ILLUMINATE
Test Step Result / Action to Take
D1 CHECK TRANSMISSION CONTROL INDICATOR LAMP (TCIL)
CIRCUIT 915 FOR VOLTAGE
• Key in OFF position. Yes
• Disconnect: Powertrain Control Module (PCM). INSTALL a new PCM. CYCLE the
• Inspect for damaged or pushed out pins, corrosion, loose wires, transmission control switch (TCS) to check
etc. Repair as necessary. the operation of the TCIL. TEST the
• Key in ON position. system for normal operation.
• Measure the voltage at Pin 4 and ground No
• Is the voltage reading greater than 10 volts? CHECK the indicator bulb and the fuse. If
OK, GO to D2.
D2 CHECK TRANSMISSION CONTROL INDICATOR LAMP (TCIL)
CIRCUIT 729 FOR VOLTAGE
• Disconnect the instrument cluster. Yes
• Key in ON position. INSTALL a new PCM. CYCLE the
• Measure the voltage at Pin 17 and ground transmission control switch (TCS) to check
• Is the voltage greater than 10 volts? the operation of the TCIL. TEST the
system for normal operation.
No
REPAIR circuit. TEST the system for
normal operation.

Pinpoint Test E: Transmission Control Possible Causes

Indicator Lamp (TCIL) Stays Illuminated If the TCS switch is depressed and the light does
not turn off, the possible causes could be:
Normal Operation
When the TCS switch is depressed, a light on the • Faulty PCM
dash will illuminate O/D OFF. When the TCS • Short to ground
switch is depressed a second time, the lamp will go
off. • Short to open
• Faulty TCS switch
• Wiring, terminals or connectors

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307-05-11 Automatic Transaxle/Transmission External Controls 307-05-11

DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST E: TRANSMISSION CONTROL INDICATOR LAMP (TCIL) STAYS ILLUMINATED
Test Step Result / Action to Take
E1 CYCLE TRANSMISSION CONTROL SWITCH (TCS)
• Key in ON position. Yes
• Cycle the transmission control switch (TCS). OK at this time. Concern may be
• Does the transmission control indicator lamp (TCIL) intermittent.
illuminate and then go off? No
GO to E2.
E2 CHECK CIRCUIT FOR SHORT TO GROUND
• Key in OFF position. Yes
• Disconnect: Powertrain Control Module (PCM). REPAIR circuit. RECONNECT all
• Inspect both ends for damage or pushed out pins, moisture, components. TEST the system for normal
corrosion, loose wires, etc. Repair as necessary. operation.
• Key in ON position. No
• Does the TCIL remain on? INSTALL a new PCM. TEST the system
for normal operation.

2005 Lincoln Aviator, 09/2004

307-05-1 Automatic Transaxle/Transmission External Controls 307-05-1

GENERAL PROCEDURES
Selector Lever Cable Adjustment

1. Place the transmission range selector lever in

the 1st position all the way toward the rear of
the vehicle.

2. Move the transmission range selector lever

forward 3 detents. This should be the (D)
position.

3. Position the vehicle on a hoist. For additional

information, refer to Section 100-02.

4. Disconnect the shift cable from the manual 7. Carry out the following:
lever. 1 Make sure that the shift cable slides forward
and backward.
2 Connect the shift cable to the manual
control lever, making sure not to move the
lever. Move the cable to match the position
of the manual lever.
3 Press the shift cable adjustment lock
downward to the lock position.

5. Rotate the manual lever forward until the travel

stops. Then rotate the manual lever back 3
detents to the (D) position.

6. NOTE: The tab will need to be pried up to

unlock the shift cable.
Using a suitable tool, unlock tab on the shift
cable. With the cable unlocked, make sure the
cable slides forward and backward.

Copyright  2004, Ford Motor Company

Last updated: 6/29/2004 2005 Lincoln Aviator, 09/2004
307-05-2 Automatic Transaxle/Transmission External Controls 307-05-2

GENERAL PROCEDURES (Continued)

8. Verify that the engine will start in PARK and
NEUTRAL. Verify that the reverse lamps will
illuminate in the REVERSE position. If not,
check the adjustment of the transmission range
TR sensor. For additional information on the
TR sensor adjustment, refer to Section 307-01
in this section.

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307-05-1 Automatic Transaxle/Transmission External Controls 307-05-1

REMOVAL AND INSTALLATION

Brake Shift Interlock Actuator

Removal and Installation

NOTE: If installation of a new brake shift interlock

actuator is required, a new transmission selector
lever must be installed.
For additional information, refer to Transmission
Selector Lever in this section.

Copyright  2004, Ford Motor Company

Last updated: 6/29/2004 2005 Lincoln Aviator, 09/2004
307-05-1 Automatic Transaxle/Transmission External Controls 307-05-1

REMOVAL AND INSTALLATION

Selector Lever Cable

Removal

1. With the vehicle in PARK, position it on a

hoist. For additional information, refer to
Section 100-02.

2. Remove the left console access panel.

5. Push the rubber grommet through the bulkhead.

3. Disconnect the shift cable from the transmission

selector lever.

6. Remove the shift cable from the vehicle.

1 Disconnect the shift cable from the manual
control lever.
2 Disconnect the shift cable from the shift
cable bracket.
3 Remove the shift cable from the vehicle.

4. Disconnect the shift cable from the transmission

selector lever bracket.

Copyright  2004, Ford Motor Company

Last updated: 6/29/2004 2005 Lincoln Aviator, 09/2004
307-05-2 Automatic Transaxle/Transmission External Controls 307-05-2

REMOVAL AND INSTALLATION (Continued)

7. Remove the 2 bolts and the shift cable bracket. 4. Connect the shift cable to the transmission
selector lever.

Installation
5. Seat the rubber grommet in the bulkhead.
1. Install new shift cable retainers on both ends of
the shift cable.

6. Install the left console access panel.

2. Position the shift cable through the opening of

the bulkhead. Do not seat the rubber grommet
in the bulkhead at this time.

3. Connect the shift cable to the transmission

selector lever bracket.

7. Rotate the gearshift lever rearward until it

bottoms out in 1st gear, then rotate it forward 3
detents to the (D) position.

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307-05-3 Automatic Transaxle/Transmission External Controls 307-05-3

REMOVAL AND INSTALLATION (Continued)

8. Position the shift cable bracket on the
transmission and install the 2 bolts.
• Tighten to 40 Nm (30 lb-ft).

11. Connect the shift cable to the manual lever.

1 Position the shift cable on the manual lever.
2 Push the shift cable adjustment lock
downward to the lock position.
9. Rotate the manual lever forward until travel
stops, then rotate the manual lever rearward 3
detents to the (D) position.

12. Verify the engine will start in PARK and

NEUTRAL and the reversing lamps illuminate
in REVERSE. If not, readjust the shift cable.
10. Connect the shift cable to the shift cable For additional information, refer to Selector
bracket. Lever Cable Adjustment in this section.

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307-05-1 Automatic Transaxle/Transmission External Controls 307-05-1

REMOVAL AND INSTALLATION

Transmission Selector Lever 4. Remove the screw and remove the console
finish plate.
1. Remove the left and right console access • Feed the shift bezel through the hole in the
panels. finish panel.

2. Remove the switch module from the console 5. Remove the rear half of the center console. For
finish plate and disconnect the electrical additional information, refer to Section 501-05.
connectors.
6. Disconnect the shift cable from the transmission
selector lever arm.

3. Lift the front of the bezel to separate the bezel

from the console finish plate.
7. Disconnect the shift cable from the transmission
selector lever bracket.

Copyright  2004, Ford Motor Company

Last updated: 6/29/2004 2005 Lincoln Aviator, 09/2004
307-05-2 Automatic Transaxle/Transmission External Controls 307-05-2

REMOVAL AND INSTALLATION (Continued)

8. Disconnect the electrical connector. 10. Remove the 2 bolts retaining the right side of
the shifter.
• To install, tighten to 7 Nm (62 lb-in).

9. Remove the 2 bolts retaining the left side of the

shifter.
• To install, tighten to 7 Nm (62 lb-in). 11. Remove the transmission selector lever
assembly from the vehicle.

12. To install, reverse the removal procedure.

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REMOVAL AND INSTALLATION

Transmission Control Switch

Removal and Installation

NOTE: If installation of a new transmission control

switch is required, a new selector lever knob must
be installed.
For additional information, refer to Selector Lever
Knob in this section.

Copyright  2004, Ford Motor Company

Last updated: 6/29/2004 2005 Lincoln Aviator, 09/2004
307-05-1 Automatic Transaxle/Transmission External Controls 307-05-1

REMOVAL AND INSTALLATION

Selector Lever Knob

Removal

1. Remove the transmission selector lever. For

additional information, refer to Transmission
Selector Lever in this section.

2. Using a small screwdriver, carefully lift the

front of the knob bezel.
• Do not bend the bezel.

5. With the horseshoe clip removed, lift up and

remove the knob bezel and shift knob.

3. Pull down on the knob shroud and boot.

Remove the knob locating screw.

6. NOTE: The spring may dislodge from the shift

rod pocket. Locate and retain the spring for
installation.
Remove the spring from the top of the shift
rod.

4. Carefully remove the horseshoe clip from the

rear of the knob.

Copyright  2004, Ford Motor Company

Last updated: 6/29/2004 2005 Lincoln Aviator, 09/2004
307-05-2 Automatic Transaxle/Transmission External Controls 307-05-2

REMOVAL AND INSTALLATION (Continued)

7. Remove the electrical connector from the wiper 3. Verify the horseshoe clip is fully seated.
switch pocket and disconnect the connector.
4. Position the wires to the front of the shift knob
for clearance and extend the release button.

8. Remove the shift knob assembly.

Installation 5. With the spring inserted in the shift rod pocket,
position the knob on the shift rod.
1. Install the knob bezel into the bottom of the
shift knob until the retainer snaps in place.

6. Install the knob screw.

2. Install the horseshoe clip in the shift knob.

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REMOVAL AND INSTALLATION (Continued)

7. Position the wires through the knob shroud and 10. Pull up on the knob shroud and boot until the
through the front of the boot. retainers are seated.

8. Wrap the wires around the lever 2 times from 11. Strike the top of the knob bezel with the palm
left to right. of your hand to seat the bezel in the knob.

9. Connect the electrical connector and position it 12. Install the transmission selector lever assembly.
in the wiper switch pocket. For additional information, refer to
Transmission Selector Lever in this section.

2005 Lincoln Aviator, 09/2004