5R110W Overhaul Kit 2005-2016

Owners of a 2005 or newer TorqShift usually start looking for an overhaul kit after the same handful of complaints: a 6.0L or 6.4L Super Duty that slips with a trailer on, an E-450 bus or ambulance that bangs into gear after sitting overnight, or a V10 motorhome that leaves a puddle wherever it parks. This new 5R110W overhaul kit is aimed at the second-generation units built from 2005 on. The product photo shows a boxed kit with the gasket sheets, rubber seals and sealing rings laid out in front of it, so you can see what you are getting before the order arrives.

What the overhaul kit does in a 2005-and-later 5R110W

Ford built the 5R110W to apply each clutch directly from its own pressure control solenoid, and the computer times every apply. On the later units that system is unchanged, but the hardware around it changed a great deal, which means a tight hydraulic seal matters even more. Worn piston seals and sealing rings let pressure bleed away, the computer stretches the apply, and the result is a flare, a harsh bump or an apply-time code. Replacing every gasket, piston seal, sealing ring and O-ring during the teardown puts each circuit back to factory tightness.

Symptoms on later units

• External leaks combined with a fluid level that keeps dropping
• Delayed engagement on cold starts, a known sensitivity on the later sump-filter design
• Slip or flare under load in more than one gear
• Apply-time codes P2700 through P2704 that come back after solenoid work
• Loss of coast braking or a coast clutch noise, which on 2009-2015 E-Series vans can trace back to a coast clutch cylinder weld failure

How to confirm before ordering

Scan for codes and check the solenoid side first. The 5R110 solenoid testing guide explains how the solenoid body can produce the same symptoms as a leaking clutch. Then check the fluid level hot, pull the pan and read the debris. A circuit that will not hold an air check, or clutch material on the magnet, confirms the rebuild. Our TorqShift service guide covers the service steps, and the cooler lines are worth checking on any unit that failed in cold weather.

Fitment and what changed after 2005

The listing covers 5R110W units from 2005 through 2016. That takes in 2005-2010 Super Duty trucks with the 6.0L, 6.4L, 5.4L or 6.8L, the 2005 Excursion, and the E-Series vans and cutaways and V10 stripped chassis that kept the 5R110W after the pickups moved to the 6R140 for 2011. Inside the case, 2005 brought a new front planetary and a forward clutch with 76-tooth frictions in place of the earlier 90-tooth design, so do not mix these with 2003-2004 parts. From 2008 the external bypass filter began giving way to a sump filter, and Ford released separate pumps for each layout, 9C3Z-7A103A for bypass-filter units and 9C3Z-7A103B for the rest. In late 2008 the low one-way clutch was attached to the rear planet. Match your old kit number or send us your year and VIN, and see every compatible part on the 5R110W parts collection.

Install notes

• Install the pump that matches your filter system. A non-bypass pump on a bypass-filter unit starves lubrication.
• Soak lip seals, gel the sealing rings and air-check every clutch before the valve body goes on.
• On E-Series units inspect the coast clutch cylinder welds while the front section is apart.
• Fill with Mercon SP and set the level hot with the engine running.
• Worth replacing alongside: a 5R110W pump for 2005-2010 if the bushing or gears are scored, and a 5R110W solenoid kit if testing flagged weak solenoids.

Will this kit work on a 2004 5R110W?

It is listed for 2005 through 2016. Ford changed the front planetary and forward clutch for 2005, so a 2003-2004 unit should use a kit listed for those years. If you are unsure which build you have, send us the year and VIN.

Does the kit include frictions and steels?

The photo shows the gasket and seal side of a rebuild: gaskets, rubber seals and sealing rings. Plan on frictions, steels and a filter separately unless your teardown shows they can be reused.

Which pump should I use with my 2008 or later truck?

It depends on the filter system. Ford lists 9C3Z-7A103A for units with the external bypass filter and 9C3Z-7A103B for units with the sump filter only. Use the one that matches your truck.

What fluid do I refill with?

Mercon SP. Check the level hot, in Park with the engine running, and recheck after the first drive.

My E-Series van lost engine braking on downhills. Is that the seals?

Possibly, but check the coast clutch cylinder first. Ford addressed coast clutch cylinder weld failures on 2009-2015 E-Series TorqShift vans. If the cylinder is cracked, replace it during the overhaul.

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