5R110W Master Rebuild Kit 2003-2004, new and ready to install. Fits the 5R110W. Ships fast from the USA.
When a 2003 or 2004 Super Duty or Excursion with the 6.0L Power Stroke is slipping in more than one gear, the pan is full of friction material, or the fluid smells burnt and it is leaking from several places at once, patching one clutch pack rarely holds. This master rebuild kit is built for the early 5R110W TorqShift and gives you the frictions, steels, seals, gaskets and filter to overhaul the whole unit in one pass. The photos show the bonded pistons and full friction and steel packs that come in the box.
The 5R110W is a five-speed that runs six forward ratios depending on fluid temperature, with separate coast, overdrive, intermediate, direct, low/reverse and forward clutches. A master kit renews every one of those packs and reseals the case, pump and drums, so you are not reusing a single friction surface. On a high-mileage first-generation unit that matters, because these trucks have now been through two decades of towing on the original clutches.
Make sure the problem is in the clutches and not the solenoid body. On this unit every apply is metered by a solenoid, so a single stuck solenoid can look like a slipping pack. Scan for codes, record PIDs on a road test and, if you can, put a gauge on the line pressure port; a well-known ATRA case on a 6.0L F-350 reported as a 2-3 slip turned out to be a 3-5 fault once the data was recorded. Our 5R110 rebuild guide covers each wear point and the order they usually fail in.
This kit is listed for the 2003-2004 5R110W in the F-250 through F-550 Super Duty and the Excursion with the 6.0L diesel, and the same unit behind the 5.4L and 6.8L gas engines. The early transmissions differ from later ones in ways a rebuilder has to respect. Ford widened the overdrive one-way clutch early in production and updated the rear planet in 2004 to stop the pinion pins walking out, so check the hard parts you are reusing. These years also used the external bypass cooler filter system, and the pump that matches it is the bypass version; the later non-bypass pump should not go into a truck that still has the factory bypass filter. Check the build date on the tag, or send us your year and VIN and we will confirm it. Everything else for this unit is on the 5R110 TorqShift parts page.
For clearances and torque values on the bench, the ATSG 5R110W rebuild manual is the reference most shops keep next to this kit, and a 5R110W shift kit can go in during the same job if the truck is stock.
| Fits | 5R110W 2003-2004 |
| Part type | Master Rebuild Kit |
| Condition | New |
| Brand | OEM |
| Ships | From the USA |
| Warranty | 1-year |
Doing this repair right usually means replacing these at the same time. Same transmission, ships together.
It is listed for 2003-2004. Ford made hard-part and pump changes after 2004, so a 2005 and later unit should use the matching later kit. Send us your year and VIN if you are not sure which you have.
Frictions, steel plates, seals, gaskets and a filter for a complete overhaul, and the product photos show bonded pistons included. Hard parts such as drums, planets and bushings are not part of the kit and should be inspected separately.
Plan on solenoids, an upgraded low/reverse retaining ring, the oil-to-air cooler, the remote bypass filter and a torque converter service. Check the pump pressure regulator bore and the bushings for wear.
It was designed for Mercon SP. Ford later authorized Mercon LV for complete refill on these units. Do not use Mercon V or a generic ATF.
Yes. Warm the fluid to 130 F and perform five engagements each of Park to Reverse, Drive to Reverse, Reverse to Drive and Neutral to Drive, five seconds apart, so the PCM adapts engagement pressure.
