5R110W Sprag Clutch 2005-2007

Rebuilding a 2005, 2006 or 2007 Ford 5R110W TorqShift? This is the Raybestos RHT96-180 friction clutch pack, a one-box set of the lined plates for every clutch in the transmission. It suits the F-250 through F-550 Super Duty, the Excursion and the E-Series vans with the 6.0L Power Stroke or the gas V8 and V10, when the old unit is slipping, burning fluid or flaring between gears. Although it sits under our sprag clutch listing name, the box holds friction plates only. There is no one-way clutch inside, so if you are chasing a freewheeling overdrive one-way clutch, this is not that part.

What is in the box and where each plate works

Raybestos builds this module mostly from its HT (Hybrid Technology) material, an OE-grade lining with a groove pattern meant to run cooler through the shift. It is the stock-replacement choice for a daily-driven or moderately loaded truck. The count per pack:

• Overdrive: 3 High Energy plates
• Coast: 3 HT plates
• Forward: 4 HT plates
• Direct: 4 HT plates
• Intermediate: 3 HT plates
• Low/reverse: 6 tan plates

In the TorqShift, the overdrive and coast clutches live in the front overdrive section, and the forward, direct, intermediate and low/reverse clutches sit behind the center support in the 4R100-based geartrain. The computer runs each pack through its own solenoid, so when lining wears down, the complaint usually lands on one shift or one gear before the whole unit goes soft.

Signs the frictions are done

• RPM climbs during a shift before the next gear catches, often first on the 2-3 or 3-5 under a trailer
• Slip that only appears once the fluid is hot
• Soft or late engagement when you pull it into gear
• Black fluid with a burnt smell and lining debris on the pan magnet
• Stored gear-ratio or clutch apply-time codes (P0732, P2700, P2701, P2702) that return after a solenoid body has been ruled out

Rule out the cheap causes first

Clutch-slip complaints on this unit overlap with solenoid body faults. Field cases in Transmission Digest show apply-time codes set by a single bad solenoid while the clutches were healthy, so test the solenoids and check fluid level before you tear the transmission down. Our 5R110 TorqShift service guide walks through fluid checks and service, and the 5R110 rebuild wear points guide lists what else to inspect once the case is open.

Fitment and year breaks

Raybestos lists RHT96-180 for 2005-2007 5R110W units, and that window follows Ford's own changes. The 2005 update re-toothed the front planetary and moved the forward frictions from a 90-tooth spline to a 76-tooth spline, which locks 2003-2004 trucks out of this pack. After late 2008, Ford built the low/reverse plates into a rear planet and one-way clutch assembly, which changes how that pack is serviced on later trucks. A 5.4L gas truck runs one fewer low/reverse plate than the 6.8L and diesel units. If your build date is close to a break, compare an old forward friction to the new one or send us the year and VIN. More parts for this unit are on the 5R110W collection page.

Install notes

• Soak the plates in Mercon SP for at least the time the lining needs to fully wet out. Ford calls for Mercon SP in this transmission.
• Reuse steels only if they are flat and free of heat bluing. Otherwise replace them.
• Measure and set each pack's clearance. Too loose causes flare, too tight causes drag and heat.
• Fit the updated low/reverse retaining ring, which has rolled-out ends so it stays in its groove.
• Seals, gaskets and the filter are not in this box. Pair it with a 5R110W overhaul kit for 2005-2016, and check the pump bushing and stator while it is apart. A worn 2005-2010 5R110W pump will undo a fresh clutch job.

Building for heavy towing or added power instead? Look at the Raybestos GPZ performance pack for 2005-2007.

Does this include a one-way clutch or sprag?

No. It is the Raybestos RHT96-180 friction clutch pack only: overdrive, coast, forward, direct, intermediate and low/reverse friction plates. One-way clutches, steels, seals and the filter are sold separately.

Which trucks does it fit?

2005-2007 Ford vehicles with the 5R110W TorqShift: F-250 to F-550 Super Duty, Excursion and E-Series with the 6.0L Power Stroke or 5.4L/6.8L gas engines. It does not fit 2003-2004 units, which use a different forward friction spline.

HT or GPZ, which pack should I buy?

HT is Raybestos's OE-grade stock-replacement material and suits a daily driver or occasional tow rig. GPZ is a high-energy material for heavy towing, commercial duty or added power. Both cover 2005-2007 units.

Can I reuse my old steel plates?

Only if they are flat, smooth and not heat-blued. Glazed or warped steels will wear new frictions quickly, so most rebuilders replace any questionable steel.

What do I do after installing it?

Refill with Mercon SP, check the level hot as the service procedure describes, clear codes and drive gently through all gears so the computer can relearn shift timing before you tow.

• 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