The Ford 5R55S: Engineering Evolution and Modern Solutions

The 5R55S transmission marked Ford's significant advancement into sophisticated electronic control for their rear-wheel-drive platforms. Introduced in the early 2000s for vehicles like the Ford Explorer, Mercury Mountaineer, Lincoln LS, and Ford Thunderbird, this five-speed automatic transmission brought refined shift control and overdrive efficiency to Ford's mid-size SUV and luxury car segments. Building upon its predecessor, the 5R55W, this transmission incorporated enhanced electronic control, updated solenoid design, and modified valve body architecture.

One of the most critical issues we address at Bench Built Transmissions is the notorious servo bore wear in the case. Our proprietary repair process involves precision boring of the worn servo bores and installing custom-machined aluminum sleeves. This restoration process not only repairs the wear but actually strengthens the case beyond its original specifications, preventing future servo-related failures. This attention to detail in case preparation sets the foundation for a reliable rebuild.

The 5R55S faces several common challenges that our rebuilds specifically address. Solenoid reliability issues often manifest as delayed engagement, erratic shifting, and inconsistent pressure control. Our solution includes installing updated solenoid packs with enhanced durability and more precise pressure control characteristics. Mechanical concerns such as input shaft wear, planetary gear set durability, and drum bearing failures are addressed through improved metallurgy and design modifications.

Electronic integration plays a crucial role in these transmissions. We've developed specific protocols for addressing solenoid pack failures, sensor malfunctions, and computer communication issues. Each rebuild receives a comprehensive electronic diagnostic evaluation, ensuring proper communication between the transmission and vehicle computer systems. Our valve body modifications improve hydraulic control while maintaining proper electronic feedback.

The rebuild process at Bench Built Transmissions goes beyond simple parts replacement. After the case receives our servo bore sleeve upgrade, we perform a complete disassembly and inspection. Every unit receives our modified valve body calibration, enhanced servo application, and updated friction materials. We've developed specific modifications to improve lubrication paths, addressing one of the original design's weaknesses. These improvements, combined with superior sealing technology and enhanced cooling provisions, result in a transmission that significantly outperforms the original.

5R55S Automatic Transmission (Rebuild)

  • ford-5r55s-transmission-rebuild-package-chevy-gm-automatic-transmission-service

    Carry Out Performance 5R55S (No Torque Converter) $2,750 Starting Price

    Our 12-month/12,000-mile limited warranty for the 5R55S transmission includes:

    Parts Coverage:
    • All internal soft parts
    • Friction clutch packs
    • Sealing rings
    • Gaskets and seals
    • Bushings
    • Thrust washers
    • Filter
    • Solenoid pack (when supplied by BBT)
    • Servo assemblies
    • Servo bore sleeve repair

    Warranty Exclusions:
    • Transmission case
    • Valve body
    • Pump housing
    • Planetary carriers
    • Output shaft
    • Input shaft
    • Customer-supplied torque converter
    • Labor costs
    • Fluids
    • Removal/installation expenses
    • Towing charges
    • Rental vehicle costs
    • Damage from overheating
    • Computer programming
    • Damage from external causes
    • Modifications after delivery

    Additional Cost Components:
    • Billet input shaft
    • Heavy-duty servo kit
    • Performance valve body modifications
    • High-capacity servo assemblies
    • Premium converter upgrades
    • Deep pan kit
    • Updated solenoid pack
    • Heavy-duty planetary components

    Note: All warranty coverage requires:
    • Proper transmission cooler operation
    • Maintenance of transmission fluid temperatures below 180°F
    • Servo bore sleeve repair is covered for warranty duration
    • Use of Mercon V transmission fluid
    • Proper converter installation
    • No external modifications
    • Core must be complete and rebuildable

  • 5r55s-ford-transmission-torque-converter-rebuild-package-complete-service

    Carry out 5R55S with Reman Torque Converter $3,050 Starting Price

    Our 12-month/12,000-mile limited warranty for the 5R55S transmission includes:

    Parts Coverage:
    • All internal soft parts
    • Friction clutch packs
    • Sealing rings
    • Gaskets and seals
    • Bushings
    • Thrust washers
    • Filter
    • Solenoid pack (when supplied by BBT)
    • Torque Converter (when supplied by BBT)
    • Servo bore sleeve repair

    Warranty Exclusions:
    • Transmission case
    • Valve body
    • Pump housing
    • Planetary carriers
    • Output shaft
    • Input shaft
    • Labor costs
    • Fluids
    • Removal/installation expenses
    • Towing charges
    • Rental vehicle costs
    • Damage from overheating
    • Computer programming
    • Damage from external causes
    • Modifications after delivery

    Additional Cost Components:
    • Billet input shaft
    • Heavy-duty servo kit
    • Performance valve body modifications
    • High-capacity servo assemblies
    • Premium converter upgrades
    • Deep pan kit
    • Updated solenoid pack
    • Heavy-duty planetary components

    Note: All warranty coverage requires:
    • Proper transmission cooler operation
    • Maintenance of transmission fluid temperatures below 180°F
    • Servo bore sleeve repair is covered for warranty duration
    • Use of Mercon V transmission fluid
    • Proper converter installation
    • No external modifications
    • Core must be complete and rebuildable

  • Ford-5R55s-e4od-rebuilt-transmissions-and-torque-converter

    Turn Key 5R55S Automatic Transmission Rebuild $3,650 Starting Price

    Our 24-month/24,000-mile Turn Key warranty for the 5R55S transmission includes:

    Parts Coverage:
    • All internal soft parts
    • Friction clutch packs
    • Sealing rings
    • Gaskets and seals
    • Bushings
    • Thrust washers
    • Filter
    • Solenoid pack
    • Torque converter (BBT supplied)
    • Servo assemblies

    Labor Coverage:
    • Removal and installation labor
    • Diagnostic time (if warranty-related)
    • Fluid replacement
    • Adjustments and updates
    • Test driving
    • Computer programming

    Additional Included Services:
    • Initial Mercon V transmission fluid
    • Filter service
    • Pan gasket
    • Cooler flush
    • Computer flash/updates
    • Test drive verification
    • Initial adjustments
    • Servo bore sleeve repair

    Warranty Exclusions:
    • Transmission case
    • Valve body
    • Pump housing
    • Planetary carriers
    • Output shaft
    • Input shaft
    • Damage from external causes
    • Modifications after delivery
    • Towing charges
    • Rental vehicle costs
    • Damage from overheating

    Additional Cost Components:
    • Billet input shaft
    • Heavy-duty servo kit
    • Performance valve body modifications
    • High-capacity servo assemblies
    • Premium converter upgrades
    • Deep pan kit
    • Updated solenoid pack
    • Heavy-duty planetary components

    Note: All warranty coverage requires proper transmission cooler operation and maintenance of transmission fluid temperatures below 180°F. Our servo bore sleeve repair is covered for the duration of the warranty period. Regular maintenance including fluid and filter services are required to maintain warranty coverage.