5R110W Overhaul Kit 2005-2007

The 2005 to 2007 Super Duty trucks and Excursions with the 6.0L Power Stroke were bought to tow, and most of the TorqShift transmissions behind them have now done a lot of it. When one starts flaring between gears, slipping with a trailer behind it, leaking from more than one place or engaging slowly on a cold start, this new 5R110W overhaul kit for 2005-2007 is the soft-parts package for the rebuild. The product photo shows the gasket and seal set in its Precision bag, a boxed 5R110W friction set, steel plates, a filter and blue bonded pistons.

What the overhaul kit does in a 2005-2007 5R110W

In this transmission the computer applies the coast, overdrive, intermediate, direct and low/reverse clutches directly through individual pressure control solenoids, and it measures how long each apply takes. Nothing in the hydraulic circuit hides a leak. A piston seal that has taken a set, a cut sealing ring on the input shaft or a hardened case gasket shows up as a longer apply time, and once the frictions are glazed the clutch slips even with correct pressure. Replacing the seals, gaskets, frictions and steels together resets every pack at once, which is what a high-mileage towing unit needs.

Symptoms that send these years to the bench

• A flare on the 3-5 shift followed by a bang, often described by the driver as a 2-3 problem
• Slip under load in several gears rather than one
• Apply-time codes such as P2700 or P2701 that come back after the wiring and solenoids check out
• Burnt fluid and lining material on the pan magnet
• Reverse slip or no reverse, a known result of the low/reverse retaining ring working out of its groove
• Fluid weeping from the pan, case connector and output seal

How to confirm it before ordering

Record data before the transmission comes out. GEARS magazine documented a 2006 F-350 6.0L that arrived as a 2-3 slip after earlier repairs; recorded PIDs and a line pressure gauge showed the real fault was a 3-5 shift, and the cure was correct direct clutches, a new direct piston and factory fluid. Read codes, log shift data and verify pressure, then use our 5R110 TorqShift service guide to rule out the solenoid body. If pressure is right and the clutches still slip, overhaul the unit.

Fitment and the 2005 running change

This kit is listed for 2005, 2006 and 2007 5R110W transmissions in F-250 through F-550 Super Duty trucks and the Excursion. These years matter because Ford changed the rear of the unit for 2005. Transmission Digest lists different forward clutch friction teeth and different front planetary, ring gear and sun gear tooth counts compared with 2003-2004, and warns about shell interference when parts from the two designs are mixed. Frictions from an early kit can therefore be wrong for a 2005-up case. Match the kit to your year, compare the contents with your teardown, and send us your VIN if anything looks different. Trucks built in 2008 take the 2008 overhaul kit, and every TorqShift part we carry is on the 5R110W collection page.

Install notes

• Soak the frictions in Mercon SP ATF for at least the time the kit instructions call for and pre-lube the sealing rings with assembly gel.
• Air-check every clutch circuit on the bench and set clearances to Ford specification. The GEARS case shows how a wrong direct clutch stack produces a flare and bang.
• Replace the low/reverse retaining ring with an updated ring before the case is closed.
• Do not reuse a solenoid set that has been setting codes. Our 5R110W solenoid kit for 2004-2017 fits these years.
• Replace the pan if it is dented or the drain plug threads are damaged; the 5R110W oil pan with drain plug lets the next fluid service be a simple drain.
• Fill with Motorcraft Mercon SP, check the level hot, clear adaptive data and road test under load.

Our 5R110 rebuild wear points guide covers the pump, drums and planetaries to inspect while the unit is apart.

Does this kit fit a 2006 F-350 with the 6.0L Power Stroke?

Yes, it is listed for 2005-2007 5R110W TorqShift transmissions, which includes 6.0L and gas Super Duty trucks and the Excursion of those years. Send your VIN if you want us to confirm.

Can I use a 2003-2004 kit on my 2005 transmission?

No. Ford changed the rear section for 2005, including the forward clutch friction tooth count and the front planetary gearing, so early frictions may not fit. Use the kit for your model year.

What is in the box?

The product photo shows a gasket and seal set, a 5R110W friction set, steel plates, a filter and bonded pistons. Check the contents against your teardown before assembly.

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

Possibly, but record data first. On these units a 3-5 flare is often reported as a 2-3 slip, and a solenoid or pressure problem can mimic worn clutches.

Which fluid should I use after the rebuild?

Motorcraft Mercon SP ATF. Set the level at operating temperature and reset the adaptive data with a scan tool before the road test.

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