5R110W Master Rebuild Kit 2003-04

The first two model years of the Ford 5R110W TorqShift, 2003 and 2004, went into the debut of the 6.0L Power Stroke as well as 5.4L and 6.8L gas Super Duty trucks and the Excursion. Twenty-plus years on, a lot of these units are slipping, leaking or full of burnt fluid. This master rebuild kit is for those first-design transmissions. The photos show the friction packs, steel plates, bonded pistons, seal rings and gaskets for a full teardown, so every clutch in the unit is renewed at the same time.

Why the first-design 5R110W needs its own kit

The 2003-2004 unit is not just an older version of the same parts. Transmission Digest reports that for 2005 Ford changed the forward clutch frictions from 90 teeth to 76 teeth and redesigned the front planet, ring gear, sun gear and shell around them. An original 2003-2004 transmission still runs the 90-tooth forward drum and the original front gear set, and the forward plates in this kit are meant for that design. Put a later kit in an early drum and the forward pack simply will not go together.

Symptoms on high-mileage early units

• Slipping in several gears, worst when towing or after the fluid is hot
• Dark fluid, a burnt smell and clutch material on the magnet
• Reverse that slips or disappears, the classic sign of a low/reverse retaining ring that has walked out
• Noise or loss of drive from a rear planet whose pinion pins are walking out, a problem Ford addressed with an updated planet by 2004
• Apply-time codes P2700 to P2704 that remain after the solenoid body checks out

How to confirm a rebuild is the answer

Make sure you are not about to rebuild around an electrical fault. Every clutch except forward is applied by its own solenoid, so scan for codes, test the solenoids and connector, and record line pressure and slip data on a road test. If one shift is bad and the rest are crisp, the problem may be a single solenoid; our 5R110 solenoid symptoms guide walks through that test. If several packs slip and the fluid is burnt, plan the overhaul and read the 5R110 rebuild wear points guide before teardown.

Fitment

This kit is listed for 2003-2004 5R110W transmissions in the Ford F-250 to F-550 Super Duty and the Excursion with the 6.0L diesel or the 5.4L and 6.8L gas engines. Because many early units have already been rebuilt or had 2005-up retrofit packages installed, do not assume by model year alone. Pull an old forward friction and count the teeth: 90 teeth matches this kit, 76 teeth means the unit was updated and needs the later kit. Check the transmission tag as well, or send us your year and VIN and we will confirm. Every part for this unit is on our 5R110 TorqShift parts page.

Install notes

• Inspect the rear planet. Transmission Digest says the 2003 version should not be reused at all; the updated 2004 design limits pinion pin walk-out.
• Check the pump bushing and the pressure regulator bore before reassembly. These trucks use the external bypass cooler filter, so a replacement must be the bypass-type pump; our 2003-2004 5R110W pump is listed for these years.
• Install the upgraded low/reverse retaining ring with the rolled-out ends.
• Test or replace the solenoids before the unit goes back in; a remanufactured 5R110W solenoid set saves a second teardown if a 20-year-old solenoid sticks.
• Change the remote bypass filter element, replace the oil-to-air cooler, and fill with Mercon SP or the Mercon LV Ford later authorized. Run the engagement relearn with warm fluid.

For fluid capacity and service intervals after the rebuild, see our 5R110 TorqShift service guide.

How do I tell if my unit is a first-design 2003-2004 5R110W?

Count the teeth on a forward clutch friction. Original 2003-2004 units use 90-tooth forward frictions; Ford switched to 76 teeth in 2005. A rebuilt early unit may already have the later parts, so the plates tell you more than the model year.

Can I use this kit on a 2005 or later 5R110W?

No. The 2005 and later forward clutch, front planet and sun gear are different, so those units need the 2005-up kit.

Is the rear planet included?

No. A master kit covers frictions, steels, seals, gaskets and the bonded pistons shown in the photos. Inspect the rear planet carefully; the original 2003 design is known for pinion pins walking out and should be replaced.

What fluid does a 2003-2004 5R110W use?

It was designed for Mercon SP, and Ford later authorized Mercon LV as its replacement. Do not fill it with Mercon V.

Do I need to keep the external bypass filter?

Yes, on trucks built with it. The 2003-2004 trucks use the external bypass cooler filter, and the pump must match that system. Replace the filter element during the rebuild.

• 5R110 TorqShift Rebuild Guide: Known Wear Points and Upgrades
• 5R110 TorqShift Shift Solenoid Symptoms, Testing and Replacement
• Ford 5R110 TorqShift Service Guide: What Every Super Duty Tech Needs to Know