5R110W Overhaul Kit 2003-2004

A 2003 or 2004 Super Duty or Excursion with the original TorqShift that now leaks, engages late when cold, or slips under load has usually reached the point where patching one circuit is false economy. This new 5R110W overhaul kit for 2003-2004 is built for that full rebuild. The listing photo shows a complete box: friction and steel plates, a filter, and the gasket and seal set for the unit, so the frictions and the sealing parts are replaced in one order instead of being collected piece by piece.

What an overhaul kit restores in the 5R110W

Every shift in this transmission depends on pressure staying where the computer sends it. Five shift solenoids, a TCC solenoid and a line pressure solenoid command each clutch directly, with no shift valves in between, so a hardened piston seal or a worn sealing ring shows up immediately as slip, flare or a long apply time. The gaskets and seals in an overhaul kit reseal every one of those circuits, and the new frictions and steels give each pack its full holding capacity back. On a high-mileage early unit that is what returns firm, consistent shifts.

Symptoms that point to a full overhaul

• Fluid leaks at the pan, case or front seal combined with worn, dark fluid
• Slow engagement into Drive or Reverse on a cold morning that improves once warm
• Slip or flare in more than one gear, which points to worn frictions across several packs rather than one solenoid
• Debris and friction material on the pan magnet
• Reverse slip or no manual first, a sign the low/reverse retaining ring may be walking out of the case

Confirm before you tear it down

Check the easy things first. Early 2003-2004 solenoid bodies used pressure switches whose rubber boots can rupture and leak control pressure, and a weak line pressure solenoid causes harsh, not soft, engagement because it is inversely proportional. Read codes, record road-test data, and check line pressure. Our 5R110 TorqShift service guide walks through those checks. If pressure is correct and the unit still slips in several gears, it needs this kit.

Fitment and early-unit differences

This kit is listed for 2003-2004 5R110W transmissions. Those years used the original pressure-switch solenoid body and the external bypass cooler filter, and Ford released two different pumps later that are not interchangeable, so a rebuilder should confirm which components are in the unit before ordering hard parts. Kit contents can differ from one supplier revision to the next, so check the contents against your teardown and send us your year and VIN if you want us to confirm. For later trucks we carry a 2008 overhaul kit, and every TorqShift part is on the 5R110W collection page.

Rebuild notes

• Soak new frictions in Mercon SP ATF before assembly and lube every sealing ring with assembly gel.
• Air-check each clutch circuit before the case is closed and set clearances to Ford spec.
• Inspect the pump, including the pressure regulator bore and bushing. Worn bores drop line pressure and cause TCC complaints; replace the 2003-2004 pump if needed.
• Inspect each drum for scored ring lands and cracked splines, and replace any damaged one, such as the 2003-04 clutch drum.
• Install an upgraded low/reverse retaining ring; the original is documented to pop out and damage case lugs.
• Fill with Motorcraft Mercon SP and set the level hot, then clear adaptive data and road test.

Our 5R110 rebuild guide lists every known wear point to check during the overhaul.

Which trucks does this overhaul kit fit?

It is listed for 2003-2004 5R110W TorqShift transmissions, used in F-250 to F-550 Super Duty trucks and the Excursion of those years. Send us your VIN if you want fitment confirmed.

Does it include frictions and steels?

The kit shown includes friction and steel plates along with the filter, gaskets and seals. Compare the contents against your teardown before you start assembly.

What hard parts should I check while rebuilding?

Check the pump pressure regulator bore and bushing, every drum for worn ring lands, the planetary sets, and the low/reverse retaining ring, which is known to walk out of its groove.

What fluid do I use after the rebuild?

Motorcraft Mercon SP ATF. Check the level hot with the engine running.

Do I need to reset anything after installation?

Yes. Clear codes and reset the transmission adaptive data with a scan tool, then road test so the computer can relearn shift timing on the new clutches.

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