Hi Guys,

I have a 2002 Explorer EB 4.6L 4x4 Automatic Transmission.

Just performed a transmission service today as general maintenance.

The transmission was rebuilt 3 years ago, and valve body was supposedly replaced too. Had a transmission flush done every year to extend the life of the transmission by a transmission specialty shop. This truck was not used for towing or anything, just regular commuting. I decided this year to do it myself, and do it right. Just cant trust anyone anymore.

some notes:
-Only 3L of oil was drained out. fluid was still red, no burnt smell or anything.
-Filter was replaced with an OEM one - old one looked a little dirty
-OEM Ford Mercon V was used only.
-Pan was clean, no metal, magnet was cleaned, everything was cleaned.
-3L was filled into the trans. while doing the check level procedure: warm up to certain temp, run through gears, etc, i found myself adding another 2L+ so a total of over 5L. I guess the fluid was low from the last service.

Improvements:
-I guess no slipping. used to have a minor slip out of 3rd gear.
-no hard/clunking downshifts
-less transmission noise/groaning noise (torque converter noise)

I guess there are a few clunks that are my concern. Sometimes (mainly when cold) when a gear is engaged (Reverse or Drive), it engages and clunks, and another is when slowing down to a very low speed/coming to a stop. It sometimes clunks on the downshift. Otherwise the transmission has no other issues I suppose. Don't recall last time I had a transmission software update on this vehicle. I am hoping to do it later.

Any comments/suggestions on the clunks I am experiencing? Solenoid Pack?

Thanks in advance.

 

I noticed some harsh downshifting and harsh reverse engagement shortly after getting my (used) 2004 Aviator a couple years ago. With 83k miles on the odometer, I took it to the transmission shop to let them have a look. They were surprised that with less than 100k miles the bores were worn, which I think was the likely cause of the harsh downshifts. The valve body was the culprit for the harsh reverse engagement (there's a TSB for that). For somewhere around $600 I had a new valve body, the cylinders bored and sleeved, and fresh fluid and new filter. The Aviator drives like I imagine it did new now.

-Rod

 

Some of that clunk when coming to a stop, downshifting or taking off can be attributed to slip yoke movement in your drive shaft as well, be sure to check you rear driveshaft and lube the slip yoke!

 

yikes! worn bores. i hope mines not like that considering its had an overhaul and new valve body.

I was going to disconnect the main valve body harness and try to clean up the electrical contacts, and put some di-electric grease. they seem to have put it in a pretty bad place.

also for the slip yoke. is that the u-joint? I believe the u-joints do not have a grease nipple on these models.

Thanks for the comments guys.

 

The slip joint is on your drive shaft and allows for the movement of the axle an slides in and out as the axle moves up and down, typically most slip yokes will be on the transfer case/transmission end of the rear drive shaft!