5R110W Master Rebuild Kit 2005-2007

A 2005, 2006 or 2007 Super Duty with the 6.0L Power Stroke has usually spent its life towing, and by now the TorqShift behind it is often on its original clutches. If yours flares on the 3-5 shift, slips under a trailer, or the pan comes off coated in friction material, this master rebuild kit is built for the middle years of the 5R110W. The product photos show full friction and steel packs, bonded pistons and a boxed 5R110W kit, so the whole unit can be overhauled in one pass instead of chasing one clutch at a time.

What a master kit renews in a 2005-2007 5R110W

The 5R110W applies its coast, overdrive, intermediate, direct and low/reverse clutches through their own pressure control solenoids, while the forward clutch is fed straight from the manual valve. There are no shift valves left to blame, so when a pack is glazed the computer simply watches the apply take too long. This kit replaces the frictions, steels, seals and gaskets for every one of those packs, which is the only way to put all six clutches back on equal footing after high-mileage towing.

Symptoms that point to a rebuild on these years

• A 3-5 flare followed by a bang, often reported by the driver as a 2-3 problem
• Slip in more than one gear when loaded or hot
• Burnt-smelling fluid and friction debris on the pan magnet
• Apply-time codes P2700 through P2704 that stay after the solenoids test good
• No reverse or a reverse slip on a unit that has lost its low/reverse retaining ring

How to confirm it before you order

Record data before you pull the unit. GEARS magazine documented a 2006 F-350 6.0L that came in as a 2-3 slip after two transmissions and two computers; a line pressure transducer and recorded PIDs showed the real fault was a 3-5 flare-bang, traced to aftermarket direct clutches, a molded direct piston and the wrong fluid. Factory-spec direct clutches and the correct fluid fixed it. Our 5R110 solenoid symptoms guide shows how to separate a solenoid fault from a burnt pack, and the 5R110 rebuild wear points guide covers what to check on the bench.

Fitment: why 2005 starts a new kit

This kit is listed for 2005-2007 5R110W units in the F-250 through F-550 Super Duty and Excursion, behind the 6.0L diesel and the 5.4L and 6.8L gas engines. Ford reworked the rear half of the transmission for 2005: Transmission Digest reports the forward frictions went from 90 teeth to 76 teeth, the front planet pinions from 18 to 23 teeth, the front ring gear from 78 to 101 teeth and the front sun gear from 42 to 55. That forward spline change is why a 2003-2004 kit will not fit a 2005-up drum. Ford also changed the overdrive section again in 2007, with separate gas and diesel packages, and a transmission that has already been rebuilt may carry updated parts from either era. Count the forward friction teeth on your old plates, check the build tag, or send us your year and VIN before ordering. Browse every part for this unit on our 5R110 TorqShift parts page.

Install notes

• Inspect the hard parts the kit does not include. Do not mix a first-design rear planet with a 2005-up sun shell; Transmission Digest warns the combination can interfere. Our 2005 5R110W planetary and 5R110W sun shell cover worn gear sets.
• Fit the upgraded low/reverse retaining ring with the rolled-out ends while the case is open.
• Match the pump to the cooler filtration on the truck. These years used the external bypass filter, so do not install the non-bypass pump cover meant for later trucks.
• Replace the remote bypass filter and the oil-to-air cooler rather than reusing debris-filled parts.
• Fill with Mercon SP or the Mercon LV Ford later authorized for these units, never Mercon V, and run the engagement relearn with the fluid warm.

On a 6.0L that is getting a rebuilt transmission and more power, the ATS billet 6.0L flexplate is worth installing while the transmission is out. Our TorqShift service guide covers fluid and filter service after the rebuild.

Will this kit fit a 2003 or 2004 5R110W?

Not as a rule. Ford changed the forward clutch from 90-tooth to 76-tooth frictions in 2005 along with the front planet and sun gear, so 2003-2004 units use their own kit. If your early unit was already rebuilt with 2005-up parts, count the teeth on the old forward frictions or send us your VIN.

Does a master rebuild kit include drums, planets or the pump?

No. It covers frictions, steels, seals, gaskets and the bonded pistons shown in the photos. Drums, planets, one-way clutches, bushings and the pump are inspected and replaced separately if they are worn.

My truck flares on the 2-3 shift. Is it the direct clutch?

Possibly. On the 5R110W a flare the driver feels as 2-3 is often the 3-5 shift, which applies the direct clutch. Record PIDs and line pressure on a road test before you decide, and test the solenoids so a stuck one is not mistaken for a worn pack.

What fluid goes in a rebuilt 2005-2007 5R110W?

These units were built for Mercon SP, and Ford later authorized Mercon LV for them. Do not use Mercon V or a generic multi-vehicle ATF.

What should I replace with the kit?

Plan on testing or replacing the solenoids, an upgraded low/reverse retaining ring, the remote bypass filter, the oil-to-air cooler and any worn bushings, and inspect the pump regulator bore.

• 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