26 GEARS October/November 2010

In this issue of Keep Those Trannies Rolling, we’re going to look at a 2006 Ford Fusion

equipped with the FNR5 automatic transmission. This unit was experienc-ing harsh 3-4 shifts after a rebuild.

Beginning at the EndOur story begins at the end of

the repair with a call to the ATRA Technical Hotline from Jeff Peacock of Peacock’s Transmissions in Cleburne, Texas. Jeff was working on a 2006 Ford Fusion equipped with Ford’s FNR5 five-speed automatic transmission. It had harsh 3-4 shifts after a rebuild. Jeff worked through the problem, and wanted to share his solution with the rest of ATRA.

Erratic ShiftsThe vehicle came into the shop

with erratic shifts. After test driving the vehicle and inspecting the transmission, Jeff determined the transmission had an internal problem and would have to be removed, disassembled, and inspected.

During disassembly and inspec-tion, Jeff noticed the 2/4 band was burnt. He air-checked and inspected the 2/4 servo circuit and discovered the servo seemed to be working properly.

He inspected the valve body for wear, knowing that these valvebodies have been known to experience pre-mature wear. This valve body looked okay. Jeff went ahead and rebuilt the transmission.

Harsh 3-4 Shift after Rebuild

After rebuilding and installing the transmission, Jeff took the car for a test drive. While driving, he noticed the transmission had harsh 3-4 shifts, but all other shifts seemed normal.

He brought the vehicle back to the shop and checked the computer system for codes: There were none. He then installed a pressure gauge on the line pressure tap and checked the line pres-sure during the shifts. The line pres-sure was steady during each shift, so the harsh 3-4 shifts weren’t caused by excessive pressure.

With no codes in the computer system and line pressure within specifi-cations, Jeff knew he was heading back inside the transmission.

Repeat 2/4 Band Failure

After removing and disassembling the transmission again, Jeff found the

by Pete Huschermembers.atra.com

www.atra.com

Ford Fusion, Harsh 3-4 Shift after Rebuild

Keep Those Trannies rolling

The Crew of Peacock Transmission

Shana Peacock Keeps it Running Smooth

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309-PRE-082 Transmission Digest....03/10/10 Gears Magazine APRIL 2010L: 7.375x10.125 T: 8.125x10.875 B: 8.375x11.125 4C

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28 GEARS October/November 2010

2/4 band had signs of slipping and was burnt again. With the repeat 2/4 band failure, Jeff was convinced he had a 2/4 servo circuit problem.

He checked the servo travel and found it was well within specifications. He inspected the servo bore for wear; it looked good.

Next he inspected the servo pin bore in the case and found evidence of excessive wear. He then removed the servo pin from the servo piston and inserted it into the servo pin bore. The servo pin had excessive movement in the bore, indicating the servo pin bore was worn.

Repair or Replace the Case

Because of the wear, Jeff knew he was going to have to repair the servo pin bore or replace the case.

Jeff was familiar with servo pin bore wear and the repair procedure for the 5R55W/S and N transmissions, so he was willing to try to repair this case. But his parts suppliers explained there were no servo pin bore repair kits avail-able for the FNR5 transmission.

After a little research, Jeff deter-mined that the servo pin bore repair kit for the 4F27E would work on the FNR5

transmission.He drilled, reamed, and installed

the bushing, then he rechecked the servo pin bore; the servo pin was now snug in the servo pin bore. The 4F27E servo pin bore kit seemed to work great on this transmission. The case was repaired and ready to reassemble.

Reassemble, Install, and Recheck

During the transmission reassem-bly, Jeff rechecked the 2/4 servo opera-tion: It worked perfectly. After reas-sembling and reinstalling the transmis-sion, Jeff was ready to go for another test drive.

During the test drive, the trans-mission worked great. The shifts were right on time and the 3-4 shifts felt like new. After several accelerations with no problems Jeff knew the transmission was fixed. The vehicle was ready to be delivered.

A Call to the ATRA Technical Hotline

After driving the vehicle several times and verifying the transmission was working properly, Jeff wanted to call the ATRA Technical Hotline to share his experience with ATRA.

While speaking with Jeff, I explained that servo pin bore wear is becoming a real problem in today’s automatic transmissions. We’re con-stantly getting calls on the Hotline related to erratic shifts caused by exces-sive servo pin bore wear. Servo pin bore repair kits are available from your local suppliers.

Thanks to Jeff for taking the time to share his experience with us. You did a great job, Jeff. Remember, with your help we can all keep those tran-nies rolling.

An Invitation…You, too, can share your experi-

ences with ATRA. If you have a unique problem and have come up with a working solution, we’d like to hear from you. Submit your stories to ATRA Technical Director Lance Wiggins at lwiggins@atra.com.

Ford Fusion, Harsh 3-4 Shift after Rebuild

Reaming the Servo Bore

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