View
631
Download
37
Category
Preview:
Citation preview
8/17/2019 5R110W Problems Fixes
1/63
8/17/2019 5R110W Problems Fixes
2/63
8/17/2019 5R110W Problems Fixes
3/63
8/17/2019 5R110W Problems Fixes
4/63
Free Webinar Schedu
8/17/2019 5R110W Problems Fixes
5/63
8/17/2019 5R110W Problems Fixes
6/63
SEPTEM
9/19/15
9/26/15
OCTOBE
ATRA's POctober
NOVEM
11/7/15
http://members.atra.com/events/event_details.asp?id=573594&group=http://members.atra.com/events/event_details.asp?id=574310&group=http://members.atra.com/events/event_details.asp?id=573603&group=http://members.atra.com/events/event_details.asp?id=573603&group=http://members.atra.com/events/event_details.asp?id=574310&group=http://members.atra.com/events/event_details.asp?id=573594&group=
8/17/2019 5R110W Problems Fixes
7/63
5R110W “TorqShift” Problem
Presented by :
Mike Souza
ATRA Senio r
Research Technic ian5R110W Problems & Fixes Webin
8/17/2019 5R110W Problems Fixes
8/63
No Move After Rebuild
The problem is mismatched pump parts. The change occurs in 2005 and is
with the earlier 2004-04 parts. The 2005 and later pump will retro back as a
interchange of parts between early and late are possible.
The early 2003-04 can be identified by the rough forged date found on the
Early 2003-2004Body
Stator Sup
Casting #3C3P
8/17/2019 5R110W Problems Fixes
9/63
No Move After Rebuild
The 2005 & later pump assembly can be identified by the rough fothe castings shown here.
2005 & Later Body
Stator SupCasting #RF5C3P
C
N M Aft R b ild
8/17/2019 5R110W Problems Fixes
10/63
No Move After Rebuild
The difference between the oil circuit worm tracks found in the puare shown here.
2005 & La2003 - 2004
N M Aft R b ild
8/17/2019 5R110W Problems Fixes
11/63
No Move After Rebuild
The difference between the oil circuit worm tracks found in the puhere.
2005 &2003 - 2004
No Mo e After Reb ild
8/17/2019 5R110W Problems Fixes
12/63
No Move After Rebuild
The difference between the oil circuits found in the pump wear pla
2005 2003 - 2004
2 Slots No Slots
TorqShift Pump Failures
8/17/2019 5R110W Problems Fixes
13/63
TorqShift Pump Failures
Spun pump bushing and/or pump gear welded to the pump plate. These pr
occurring quite often on the technical hotline lately.
We have seen this in the past on other vehicles such as the Aisin Seiki and
couple of examples.
There have been articles written in Gears on the 722.9 with this problem.
Here are some tips that will help prevent these issues:• The converter pilot is a tight fit with the crankshaft, so make sure it doesn’t have a
the journal is smooth and free of any burrs or nicks.
• Check the crankshaft, make sure it’s clean and free of any corrosion or debris tha
• Take some extra time to slide the converter up to the flexplate and make sure the
crankshaft.
• When you bolt up the converter to the flexplate during installation, make sure you
way toward the crankshaft, and then tighten the converter bolts gradually as you t
sure the converter pilot doesn’t bind as you tighten the bolts.
• Clean the engine block and bellhousing of any paint, debris or corrosion.
• Check the dowel pins, make sure their extended out far enough.
• Check the dowel pin holes on the bellhousing, make sure they are not worn out.
• Add a ground strap from the engine block to the battery to prevent electrolysis.
• When your putting the pump together instead of squirting oil onto the pump gears
Here are a couple of tips that were used back when the Aisin Seiki units w• With the engine off and the first 4 quarts or so have been poured into the unit. Hav
Don’t wait, have someone ready to add it right away after you start the vehicle.
• If it fills too slow it may be better to turn off the engine and add more and then res
• You can also start out with more than 4 quarts instead start out with 8 quarts or m
Delays in Reverse Worse when Hot
8/17/2019 5R110W Problems Fixes
14/63
Delays in Reverse, Worse when Hot
A delayed reverse that gets worse when hot can be caused by direct drum
This concern especially with high mileage vehicles can be caused by the c
ring lands.
Wear in the ring lands will cause major pressure leaks.
To test this you can try using string behind the sealing rings to get a bette
works replace the center support and use factory rings. Do not install it th
Bind In Reverse D3 and Low D2 Is Okay After
8/17/2019 5R110W Problems Fixes
15/63
Bind In Reverse, D3 and Low, D2 Is Okay After
The transmission may exhibit an unusual bind in Reverse, Drive 3, and Ma
working fine. The transmission may feel like it’s taking off in a higher gear
position.
In 2006-and-later model 5R110W, the O/D pressure plate has a raised, step
one side with an extended tab toward one lug. These plates are found mos
5R110W with the PTO setup. These plates according to Ford are “NOT” int
But, most suppliers only carry the less expensive flat plate that has not ha
Bind In Reverse D3 and Low D2 Is Okay After
8/17/2019 5R110W Problems Fixes
16/63
After taking a close look at the transmission clutch apply chart, the one co
for a bind in all these ranges would be if the overdrive clutches were stayi
The coast clutch is on in Reverse, Manual 3 and Manual 1, causing the bin
But it’s not on in Manual 2 or the Drive range so it’ll move, even though fe
gear.
Bind In Reverse, D3 and Low, D2 Is Okay After
Bind In Reverse D3 and Low D2 Is Okay After
8/17/2019 5R110W Problems Fixes
17/63
When you install the plate in the case, the extended tab is supposed to fac
6 o’clock position with the flat side up.
If you don’t place the snap ring opening in the proper location during a reb
installation shown below), the O/D clutches will mechanically lock when y
case.
If you make this mistake, you’ll have no choice but to remove the transmis
and correct it.
In
Bind In Reverse, D3 and Low, D2 Is Okay After
Bind In Reverse D3 and Low D2 Is Okay After
8/17/2019 5R110W Problems Fixes
18/63
You can see the clutches through a small opening in the main cas
removed. You can check the clutches for free play through this op
or thin screwdriver.
You should feel noticeable movement in the clutches and steels to
aren’t clamped down when the pump is in place and bolted down.
Bind In Reverse, D3 and Low, D2 Is Okay After
Engagement Issues
8/17/2019 5R110W Problems Fixes
19/63
Engagement Issues
A complaint of a delay and/or intermittent no reverse or forward concern m
faulty Internal Range Sensor.
After inspecting the linkage and shifter assembly. Remove the pan and ins
sensor.
With the rooster comb pushed away from the sensor. A clearer view revea
follows the worm track in the rooster comb is worn paper thin.
New
Engagement Issues
8/17/2019 5R110W Problems Fixes
20/63
The other item that was noticeable on the new sensor was the retu
sensor pin cam.
The newer sensor had a different spring configuration that placed
pin to rooster comb contact.
g g
Newer Sensor
New
Old
8/17/2019 5R110W Problems Fixes
21/63
Swapping Solenoids
8/17/2019 5R110W Problems Fixes
22/63
g
In most cases swapping a solenoid with one that looks just like it is usual
case of the 5R110W there can be an issue.
The solenoids all look the same even after they are removed from the sole
always mean if it looks like a duck that it will quack like a duck, the soleno
SSPC-C
SSPC-D
SSPC-E
PC-A
TCC
SSPC-B
SSPC-A
SSPC-C
SSPC-D
SSPC-E
Swapping Solenoids
8/17/2019 5R110W Problems Fixes
23/63
TCC, SSPC-B, SSPC-C & SSPC-E
"Directly" Proportional Solenoids
(1 Amp = Maximum Pressure)
PC-A, SSPC-A
"Inversely" Proport
(0 Amp = Maximu
The TCC, SSPC-B, SSPC-C and the SSPC-E are all directly proportional sol
controlled amperage is high the solenoid regulates maximum pressure.
The PC-A, SSPC-A and the SSPC-D are all inversely proportional solenoids
controlled amperage is low the solenoid regulates maximum pressure.
From the back of the solenoid you can easily identify which is directly prop
inversely proportional.
Swapping Solenoids
8/17/2019 5R110W Problems Fixes
24/63
On the front of the solenoids you can also see the 3 different tab l
On the inversely proportional solenoids the PC-A tab (line) is in a
than the others.
"Directly" Pr"Inversely" Proportional Solenoids
PC-A
Center
SSPC-A & SSPC-D
Low
TCC, SS
&
High
Swapping Solenoids
8/17/2019 5R110W Problems Fixes
25/63
So, if that’s the case then we should be able to swap any directly or invers
solenoid with another just like it.
Yes you can, but the exception to the rule is the PC-A solenoid (line). This
next to another directly proportional solenoid you can see a difference.
The inversely proportional PC-A (line) has a smaller orifice near the tip of t
at approximately 190 psi while the others like it only regulate at 140 psi.
When swapping the PC-A solenoid with SSPC-D may
result in a firmer upshift or downshift complaint.
The shifts are synchronized so engine tune and clutch
clearances may be a factor.
On 2008 is some cases has set code P2703 (Direct clutch
failed on of off) for clutch apply too fast.
Swapping it the other way would cause low max line.
PC-A, SSPC-A & SSPC-D
"Inversely" Proportional Solenoids
(0 Amp = Maximum Pressure)
Understanding Clutch Apply
8/17/2019 5R110W Problems Fixes
26/63
It’s much easier to repair a transmission when you know how it works. The 5R110W i
speeds at times but only utilizes 5 speeds.
Looking at the chart below you can see that the 4th gear ratio is only commanded bel
Now this may not be an issue here in south Florida where I live but it can be confusin
this same vehicle for the first time in the northern states of the U.S. or Canada
(a) PCM calibr
pressure se
(b) Cold strateg
(c) 30 psi until 3
(d) Clutch appl
MIL Light On, Codes P0751, P0730 and/or P2
8/17/2019 5R110W Problems Fixes
27/63
While working on a 2009-2011 Ford E350, E450, F-Super Duties, F53 Stripp
Motorhomes equipped with the Torqshift transmission, you may experien
codes P0751 SSPCA circuit coast cutch solenoid failure, P0730 gear ratio
coast clutch failed on or off stored in the computer system.
It has been determined that the coast clutch drum weld may be cracked an
recommends replacing the coast clutch drum with part # 7C3Z-7G387-B.
These drums may air check well cold on the bench but
once they heat up that’s when the leak will appear. Added Weld To Pr
Sets DTC’s P2700 & P0751, No Movemen
8/17/2019 5R110W Problems Fixes
28/63
Coast clutch drum failure is common on the Torqshift. A cracked drum or
circuit is will set P2700 and P0751 DTC’s.
There may not be any driveability symptoms other than code setting. If the
broken as shown, you will have no movement forward or reverse. A broke
P0730 stored.
The P2700 sets when the TCM sees the incorrect
engine RPM vs road speed during coast down whenTCM is commanding the coast clutch on.
The P2700 is a gear ratio error code. When the coast clutch
does not apply the TCM also sets P0751, SSPC-A
coast clutch solenoid stuck off.
When diagnosing codes P2700 and P0751 install new
SSPC-A solenoid, clear codes and road test.
If the codes still set, expect to find a cracked drum ormolded piston problem.
Manual Code Retrieval On LCF Trucks
8/17/2019 5R110W Problems Fixes
29/63
If you do not have the scan tool or software that can communicat
Series truck.
Just use the following procedure for manual flash code retrieval.
1. Turn the key to ON but do not start the engine.
2. Place the shifter in the 2 position.
3. Press the Tow/Haul switch 4 times within 4 seconds, this will inretrieval.
Manual Code Retrieval On LCF Trucks
8/17/2019 5R110W Problems Fixes
30/63
Once the process is initiated the following sequence will communicate an
1 The Check Trans, Trans Temp and Tow/Haul indicator lamps all turn on a
indicate the diagnostic mode has been entered.
2 The Check Trans and Trans Temp indicators turn off. The Tow/Haul indic
3 The Check Trans indicator will then communicate each digit of any fault
Tr
Tem
Example 1 flash = 1, 3 flashes = 3. There will be a pause between each of tcode. 1 flash pause 2 flashes pause 2 flashes pause = code 122 / P0711 T
4 If more than one fault code is present the Trans Temp indicator will flash
fault code.
5 When all fault codes have been flashed the Trans Temp indicator will flas
Tow/Haul indicator will turn off.
Check
Trans !
Tow
Haul
Manual Code Clearing On LCF Trucks
Th t d f lt d b l d f ll
8/17/2019 5R110W Problems Fixes
31/63
The stored fault codes can be cleared as follows:
1 Turn the key to On but do not start the engine.
2 Place the shift selector in the D position and push the Tow/Haul
3 Pace the shift selector in the N position and push the Tow/Haul s
4 Place the shift selector in the R position and push the Tow/Haul
5 Place the shift selector in the P position and push the Tow/Haul
6 The Check Trans, Trans Temp and Tow/Haul indicators will then
indicate that all codes have been cleared.
Ford LCF Trucks 3 Digit Flash/OBD2 Code Lis
8/17/2019 5R110W Problems Fixes
32/63
Ford LCF Trucks 3 Digit Flash/OBD2 Code Lis
8/17/2019 5R110W Problems Fixes
33/63
Ford LCF Trucks 3 Digit Flash/OBD2 Code Lis
8/17/2019 5R110W Problems Fixes
34/63
Ford LCF Trucks 3 Digit Flash/OBD2 Code Lis
8/17/2019 5R110W Problems Fixes
35/63
Ford LCF Trucks 3 Digit Flash/OBD2 Code Lis
8/17/2019 5R110W Problems Fixes
36/63
Ford LCF Trucks 3 Digit Flash/OBD2 Code Lis
8/17/2019 5R110W Problems Fixes
37/63
Transmission OverheatingTransmission overheating issues check the cooler bypass thermal elemen
8/17/2019 5R110W Problems Fixes
38/63
Transmission overheating issues check the cooler bypass thermal elemen
stator support.
Hold the element with a pair of needle nose pliers and heat it up with a lig
protrude out as seen below.
Blocking the valve inward with a spacer that measures the same length as
extended is fine in some warm areas but not recommended for colder area
.190”
F
Low Diode FailureTrucks that do NOT have an external filter may experience low diode failure during ex
di i ( 10º l ) i d l di i Th d l WITH
8/17/2019 5R110W Problems Fixes
39/63
1. Remote Filter adapter assembly with cooler bypass
2. Oil-to-air (OTA) auxiliary cooler
3. Radiator-in-tank cooler
4. Transmission
5. Transmission fluid cooler fitting (fluid flowing out)
6. Transmission fluid cooler fitting (fluid flowing in)
7. Transmission fluid cooler fitting (fluid flowing into remote
8. Transmission fluid cooler line (fluid flowing into radiator-
9. Transmission fluid cooler line (fluid flowing into oil-to-air
10. Transmission fluid cooler line (fluid flowing from OTA in
11. Transmission fluid cooler fitting (fluid flowing from remo
Cooler BypassRemote Filter
Assembly
conditions (-10º or lower) or a restricted cooler condition. The models WITH an exter
bypass circuit built in to provide lube flow in the event of any cooler flow problem.
With the external filter removed this failure can occur because there is no safety oil f
lubrication flow if the cooler flow becomes restricted or plugged.
2006-07 Ford trucks that are equipped
with an external inline filter can be
identified by the stator casting number
RF5C3P-7B324-AB.2008-2009 Trucks that are NOT equipped
with an external inline filter can be
identified by stator number
RF5C3P-7B324-AC.
2006-07
2008-09
Low Diode FailureDuring extreme cold temperatures, cooler flow may become restricted as
8/17/2019 5R110W Problems Fixes
40/63
g y
increased fluid viscosity. The bypass orifice located within the external fi
lube flow during these conditions.2006-07
Low Diode FailureThere is new design pump cover assembly that has an orifice feed
8/17/2019 5R110W Problems Fixes
41/63
RF5C3P-7B324-AC
2008-09 WithoutExternal Filter
g p p y
passage and the lube passage. This will provide cold lube flow to
extreme cold climates or with a restricted cooler on all models.
RF5C3P-7B324-AB
2006-07 WithExternal Filter
Low Diode Failure
8/17/2019 5R110W Problems Fixes
42/63
The new design pump assembly
will provide low diode lube flow in
extreme cold situations and/or
with a restricted cooler.
The width of the orifice is .078”wide and the depth is .050” deep.
2008-09
Leaking out of the vent can be caused by dipstick hitting valve body and n
d t th b tt f th
Venting Issues
8/17/2019 5R110W Problems Fixes
43/63
down to the bottom of the pan.
This would give a false reading on the dipstick and too much fluid would b
transmission.
A bracket could be made from some thin sheet metal and bolted to the val
prevent the dipstick from contacting the valve body and stop this from occ
Note: some dipsticks have been known to be too short right from the factory. Check leaving the pan off with the dipstick inserted the full mark should be even with the pa
Bracket
Venting IssuesThe pump is cross leaking between the halves. The options to correct this
8/17/2019 5R110W Problems Fixes
44/63
new pump or have the existing pump machined.
A new pump is flat however it may develop the same problem down the ro
through some hot and cold cycles.
A used pump that has been machined will be
more stable and is less likely develop the problemagain. The key to using the old pump is having it
machined correctly.
Talk to your local machinist, explain the complaint
and express your concerns about the pump being
flat.
There is one more less costly alternative to this
problem a fix by TransGo shown on the followingpages.
Venting Issues TransGo Fix (Kit # 5R110 VeMake a new vent circuit. Using suitable bolts and washers; bolt the Guide
the stator
8/17/2019 5R110W Problems Fixes
45/63
the stator.
Line up the center hole of the guide plate with the left side of the vent hole
Using the plate as a guide use a 1/4” drill (.250) and remove approx. 1/2 of
wall. When done, it will look like the picture on the right. It’s not fussy.
Remove burrs with a small file.
Kit # 5R1
Guide Plate
Venting Issues TransGo Fix (Kit # 5R110 Ve
Then install the tapered cup (freeze) plug into the vent hole from the other
8/17/2019 5R110W Problems Fixes
46/63
p p ( ) p g
This will reroute the vent into an area of the pump stator with no pressure
cross leaks inside the pump. This will prevent any accidental venting.
Special thanks to Mark Puc
for the information
Shift / Engagement Complaints Solenoid PerformaAll these issue can be caused by a worn solenoid body. There is only the o
valve body so it’s really nothing more than an aluminum solenoid block
8/17/2019 5R110W Problems Fixes
47/63
valve body so it s really nothing more than an aluminum solenoid block.
The problem is on vehicles with high mileage the bores that hold the solen
leak. The complaints may only show up when hot.
Always check to see if there is any play between the bore for the solenoid
the solenoid. The solenoid body will have to be replaced.
Manual Valve
Checked the PCM and MLPS could not find a problem. Replaced both and
There was also a complaint of an intermittent no start condition
Falling Out Of Gear / Limp Mode At Startup / MLP
8/17/2019 5R110W Problems Fixes
48/63
There was also a complaint of an intermittent no start condition.
Only code found was for the electronic fan clutch. At times when the elect
on it caused erratic range switch data on the scan tool. Unplugged the fan
went back to normal.
A closer look revealed the pigtail wires run down the fan shroud had worn
these problems.
After changing the fan clutch and (pigtail attached) everything worked oka
The complaint has appeared on our tech line a few times with a few F250/3
high gear while driving down the highway Also a complaint of intermittent
Rear Tires Locking Up While Driving Down The H
8/17/2019 5R110W Problems Fixes
49/63
high gear while driving down the highway. Also a complaint of intermittent
There is no TSB or recall on this problem. After chasing several things suc
possible cross leak issues.
It was finally fixed by replacing the PCM.
It’s a lot to ask a tech to take a movie snap shot with a scan tool while slid
at 60-70 mph to see what the PCM was possibly commanding.
2005-06 Models
On late model units 2008 and up, if the Low/Reverse clutches are burnt or
planet assembly must be replaced The planet can be purchased from the
Low/Reverse Planetary Gear Set Interchan
8/17/2019 5R110W Problems Fixes
50/63
planet assembly must be replaced. The planet can be purchased from the
The alternative is to use the earlier Low/Reverse clutches and steels, Plan
assembly. The early Low/Reverse clutch pack only has a five (5) clutch pa
You must use six (6) clutch fibers and six (6) steels to complete the interch
Early Pre-2008 Low/Reverse
planet with separate clutches
and sprag assembly Late 2008-up Lo
planet with integ
and sprag a
Low/Reverse Planetary Gear Set InterchanThe late and the early planet/clutch assemblies have the same clearance a
between years
8/17/2019 5R110W Problems Fixes
51/63
between years.
Just by replace the .220”
thick bottom plate on the
early Low/Reverse clutch
pack with a steel, clutch
and another steel.
Early L/R Clutch La
8/17/2019 5R110W Problems Fixes
52/63
Low/Reverse Planetary Gear Set Interchan You must place the two thrust washers on both sides of the plane
l th l t it th t d t th th t h
8/17/2019 5R110W Problems Fixes
53/63
clearance on the late units that do not carry the thrust washer.
Low/Reverse Planet
Clearance
8/17/2019 5R110W Problems Fixes
54/63
This could be caused by the wrong TCC control valve being installed into
two different lengths for the TCC control valve, the early 2003-04 and the 2
Intermittent No Movement After Rebuild
8/17/2019 5R110W Problems Fixes
55/63
g , y
With the early 2003-04 valve (shorter) installed into a 2005 and later pump
spring tension on TCC control valve spring. There will be approximately 1
valve.
The over all difference in length between the two valves is 0.200” almost a
2003-04
2005
Over All Length 3.770”
Over All Length 3.570”
If the valves are different then there must be something different in the sta
TCC control valve bore is .200” deeper on the 2005 and later stator suppo
Intermittent No Movement After Rebuild
8/17/2019 5R110W Problems Fixes
56/63
p pp
Intermittent No Movement After RebuildThis will allow the shorter valve to intermittently move into a position that
feed oil.
8/17/2019 5R110W Problems Fixes
57/63
ConverterFeed
2003-04 2005
2005 Pump Stator
8/17/2019 5R110W Problems Fixes
58/63
8/17/2019 5R110W Problems Fixes
59/63
8/17/2019 5R110W Problems Fixes
60/63
8/17/2019 5R110W Problems Fixes
61/63
5R110W Problems & Fixes Webin
If you see material that is not shown in your handout just double cicon at the top right of your screen and it will leave a picture (jpg.
8/17/2019 5R110W Problems Fixes
62/63
When you received the emailinvitation to the webinar, there
should be a place to click and
8/17/2019 5R110W Problems Fixes
63/63
should be a place to click and
download the Adobe (pdf file) of
the presentation handout material.
Also there is an icon that you can
click on to be placed onto theemail list for future webinars. An
invitation will be emailed
automatically when future
webinars are scheduled.
You can also invite a friend.
Recommended