Sigh.... hard 1-2 shift on 2001

Ok, so there are three possiblities as to why I now have a high, hard 1-2 shift on our 'Star.
1. Trying to tow a 1000lb+ trailer up a 6% grade at 55+ mph.
2. Exchanging the fluid after 35k miles (yes, Mercon V).
3. It's old, and could be expected with over 190,000 miles on it.

It's worse when cold, and worse when pushing it. If I take it REAL easy once warm, it's not too bad.
So, doing a bit of research it's possible the 1-2 shift solenoid is bad. The question is, and I couldn't really find a straight answer for, how hard is it to get to? I understand there are 3 of them behind the cover at the end of the transmission (left side of car). I've read that the 1-2 is the easiest to get to, but I'm thinking if I'm doing one, I might as well do all three. Any tips from those that have actually done it. Some details would help too. For instance, do I need to get my 10 year old daughter in there for her small hands? Do I need to move the trans or engine for access? Do I need a young priest, an old priest and a goat?

Thanks for any help. I don't have my repair manual in front of me right now, but I could look there too. The bad thing about is that it covers all years, not just the 99-03's, so it can be kind of confiusing when it doesn't specify or cover the later model changes.

I have never done this repair.....and reading the alldatadiy manual for my '96.....and I think the same process would apply for all years......although parts will be different......
They have you remove the battery&tray, remove the air filter/MAF unit, upper transaxle side cover bolts...raise and support vehicle..... remove left tire....and inner spash shield....use a engine support unit to support engine/transaxle.....remove left motor mount and insulator.....put a drain pan under end of transaxle.....remove remaining side cover bolts.....and remove transmission side pan and gasket....

Then you are ready to start to get to the parts you need to change.

If you look, from under the left side of the vehicle....you will see a cross member that is right in front of that side pan......which is why all the extra work....just to get the cover off.

Of course.....you will need a good manual before starting the job....I just listed the steps to get the side cover off.....which is enough to have me take the vehicle to a shop to do the job.

There may be members who have done the repair job...hopefully they will chime in.

Hello-

Just did this job on a '99. I'm sure it's similar.

1- Disconnect and move air filter assembly out of the way.
2- Disconnect and remove battery.
3- Remove the battery tray. 2 screws on the bottom of tray you access from the top - 2 additional screws on bottom - you need to get from underneath. Also - you'll need to remove the cruise control unit from the battery tray and move it out of the way.
4- Remove left front tire and support with jack stands.
5- Remove the left side motor mount and frame support. YOU WILL NEED TO SUPPORT THE MOTOR AND TRANNY ASSEMBLY WITH A FLOOR JACK BEFORE REMOVING THE MOTOR MOUNT.
Furthermore - I found it easier to separate the motor mount itself from the frame support when removing it from the vehicle.
6- Remove the side plate screws from the valve body cover. IMPORTANT SUGGESTION - after you remove the battery tray - get a stiff brush - or with a blast of air clean the top surface of the side cover - it usually covered with sand and road dirt that you don't want falling in as you remove the cover.
7- Once the side cover is removed - you will see the the shift modules aligned vertically on the right hand side (look through the wheel opening).
8- SS1 1st - 2nd shift is in the middle.
SS2 2nd - 3rd shift is the top module.
SS3 3rd - 4th shift is the bottom module.
9- Remove the electrical connector from the affected module - push the module IN slightly and rotate about a 1/4 turn CCW and pull out. Mine was stuck and needed to use a pair of pliers.
10- Assembly is reverse.

On a scale of 1-10 I would give this a 3 in terms of difficulty.
On the muscle power scale I would give it a solid 8 if your using hand tools. Those motor mount frame bolts were a bear to break. An impact wrench would make the job much easier.

Good Luck-
Glenn

Glenn & wiswind, thanks so much for that. It helps alot. I'll tackle it this weekend. At least the solenoids are cheap, now I just have to find them.

Jeckler-

Forgot to mention - you will lose some transmission fluid as you loosen and remove the side cover - so have a pan handy. I lost less than 1/2 quart.

Glenn

I have an oil drain pan, about 15" diameter.
Called around today, 1 dealer had two solenoids, another had to order them and needed the trans. tag or VIN (now I remember why I hate that dealer, they ask some odd questions) and he'd have 'em Monday, and finally the 3rd said he could order them and have them tomorrow, and $5 cheaper than the other two places. Woot!

Last question... assuming there's some sort of gasket, is it reusable?

Jeckler-

I ordered mine from Rock Auto and received them in a few days. In thinking back - I also found them to be the least expensive.
As to the gasket - it is a metal/hard plastic gasket. I reused mine and haven't leaked a drop. Also - be careful not to overtighten the side pan screws. Those threaded bores in the transmission casting are very easy to strip out.

Glenn

I got them for $23ea from a local dealer, but wasn't able to get them Saturday. We went fishing instead. However, I unplugged the connector on top of the transmission Saturday morning and found a couple of the pins were real dirty. After cleaning them with a rolled up piece of sandpaper, the van's been running fine ever since.

So much for that.....
Yesterday my wife told my it was doing it all day, after I reported here that it was all better.
I took the day off (slow), so I tackled changing the solenoids this afternoon. Afterwards I took it for a drive and it was still doing it, and now there's a strange rubbing/squealing sound as the van shfts from 1st to 2nd. I drove around for about half an hour, and the hard shift got lots better, but still has the noise.
Any ideas?

All fixed....
By doing nothing. It stopped making noise, and is shifting great. Here's pics of the solenoids....
http://img13.imageshack.us/img13/6448/trans01q.jpg
http://img13.imageshack.us/img13/5799/trans02.jpg
http://img268.imageshack.us/img268/8610/trans03.jpg
http://img198.imageshack.us/img198/7027/trans04.jpg

Jeckler-

Nice Documentation !!
I'm thinking this thread will answer many questions for a lot of Windstar owners.

Good Luck-
Glenn