2007 4R75E rebuild

[88grandmarq]

Owner of this 2007 CVPI from Knoxville TN contacted me about a strange noise he was hearing from under his car. The transmission had recently been serviced and the noise started shortly after that. We both suspected a broken flexplate and with 140K on the odometer he wanted the transmission rebuilt while it was out of the car.

Doing a quick test drive, I was able to confirm the noise and also confirmed no Torque converter lock up in 3rd and 4th gear.

With the transmission removed, I confirmed the flex plate is broken and the torque converter rattles loudly when shaken. I am fairly certain the internal lock up clutch is broken some how.
http://i1033.photobucket.com/albums/a414/88grandmarq/2007%20Tungsten%20CVPI/IMG_0359_zps80184000.jpg
http://i1033.photobucket.com/albums/a414/88grandmarq/2007%20Tungsten%20CVPI/IMG_0360_zps2feab086.jpg
http://i1033.photobucket.com/albums/a414/88grandmarq/2007%20Tungsten%20CVPI/IMG_0370_zps4e7b5bf6.jpg

Once a complete tear down was done, I found the forward clutches were worn and starting to burn
http://i1033.photobucket.com/albums/a414/88grandmarq/2007%20Tungsten%20CVPI/IMG_0362_zps8466cb83.jpg
http://i1033.photobucket.com/albums/a414/88grandmarq/2007%20Tungsten%20CVPI/IMG_0363_zpse25cd0ee.jpg

the snap ring that holds the intermediate one way clutch on the reverse drum was distorted about about to come off
http://i1033.photobucket.com/albums/a414/88grandmarq/2007%20Tungsten%20CVPI/IMG_0367_zpsa4365452.jpg
http://i1033.photobucket.com/albums/a414/88grandmarq/2007%20Tungsten%20CVPI/IMG_0366_zps6f4048b0.jpg

the low/reverse band is worn
http://i1033.photobucket.com/albums/a414/88grandmarq/Transmissions/DSCF0014_zpsdf05c366.jpg

the o-rings that seal the EPC solenoid to the case are flat and brittle
http://i1033.photobucket.com/albums/a414/88grandmarq/2007%20Tungsten%20CVPI/IMG_0369_zps13a81b56.jpg

the pressure regulator valve in the valve body is worn

http://i1033.photobucket.com/albums/a414/88grandmarq/2007%20Tungsten%20CVPI/IMG_0364_zps76327cc7.jpg

The other clutches and OD band showed very little wear. Doing a full rebuild on this unit with new seals, gaskets, clutches and bands. I will perform some lubrication upgrades and install a spiral retaining ring on the intermediate one way clutch

[88grandmarq]

Today I picked up the replacement flex plate. Its a Pioneer unit from the local parts store. It appears to be a perfect match and its drilled for both torque converters.

http://i1033.photobucket.com/albums/a414/88grandmarq/2007%20Tungsten%20CVPI/IMG_0375_zpsff2b60d9.jpg
http://i1033.photobucket.com/albums/a414/88grandmarq/2007%20Tungsten%20CVPI/IMG_0374_zps192f132e.jpg

http://i1033.photobucket.com/albums/a414/88grandmarq/2007%20Tungsten%20CVPI/IMG_0373_zps8e7aa372.jpg

New flex plate is installed on the engine
http://i1033.photobucket.com/albums/a414/88grandmarq/2007%20Tungsten%20CVPI/IMG_0376_zps2c2723d3.jpg

[clmrt]

I find your posts very interesting. Please continue.

[Marauderjack]

GREAT write-up!!:beer:

What do you think broke the flexplate??:eek:

[88grandmarq]

Not sure what caused the flexplate to break like that. I have never seen a broken flexplate on a modular ford engine before, but I am told it happens frequently, particularly on Police cars.

[fireandice9008]

That's weird, usually Ford's don't break flexplates, especially like that. Is the rebuild done? If so, how does the guy like it? I've still got the one from my '07 sitting around...

[massacre]

Wow that flexplate is crazy, surprised it even held together at all....

[88grandmarq]

That's weird, usually Ford's don't break flexplates, especially like that. Is the rebuild done? If so, how does the guy like it? I've still got the one from my '07 sitting around...


Yeah, rebuild is done. I drove it around for a day before the owner came and got it. Transmission shifted perfectly, crisp and consistent with out being harsh or jerking.

[88grandmarq]

Wow that flexplate is crazy, surprised it even held together at all....

yeah, only 2" of solid material was holding it together.