5R110W Sun Shell 2009, used and ready to install. Fits the 5R110W. Ships fast from the USA.
A 2009 Ford F-250, F-350, F-450 or F-550 with the 5R110W TorqShift that suddenly loses drive in some gears, makes a grinding or clicking noise under load, or comes back from a teardown with a cracked shell or stripped splines needs a correct-year sun gear shell. This listing is a used, take-out 5R110W sun shell for the 2009 model year. Used is the honest way to buy this part on a late unit: the 2008-later shell differs from the early design, so a correct-year original part is often the cleanest match for a 6.4L Power Stroke or gas Super Duty transmission.
The sun shell is the stamped steel drum that carries drive from the clutch drums down to the sun gear for the front and rear planetary sets behind the center support. When the intermediate and direct clutches apply, the shell is what turns or holds that sun gear, so it takes the full reaction load of second, third and the higher gears. The tabs or lugs around its rim and the splines in its hub are its wear points. On a diesel that tows, a shell that has been hammered by a slipping clutch can crack at the hub weld or round off the drive lugs.
Transmission Digest's history of the 5R110W explains that Ford changed the front sun gear and shell in 2005, raising the sun gear tooth count from 42 to 55 and changing the overall shell length. Then, when the rear planet without planet washers went into production with the one-way clutch bonded to it, the shell was revised again: with no planet washers there was no need for a washer surface, so the shell collar was left off. A 2009 transmission uses this late-design gear train. That is why an early 2003-2004 shell is not a substitute here, and why a 2009 shell should be checked against the rear planet it will run next to.
Most shells fail as collateral damage from a clutch that slipped and burned, so start with the hydraulic side. The direct clutch is the known weak point on this unit and usually shows up as a 3-5 flare or a flare followed by a bang. Our 5R110 rebuild wear points guide covers that failure and the parts that prevent it. If the scan tool shows a solenoid fault, work through the 5R110 shift solenoid testing guide first. Once the unit is apart, inspect the shell lugs, the hub weld and the splines, and compare the old part side by side with this one.
This listing is for 2009 5R110W TorqShift transmissions, which in that year were behind the 6.4L Power Stroke diesel and the gas V8 and V10 in Ford Super Duty trucks. Because Ford changed the shell more than once, match the shell length, the hub spline and sun gear tooth count, and the presence or absence of the washer collar to the part you removed. If your unit has been rebuilt with a mix of parts, check what is in the case rather than going by the truck's year. If you are unsure, send us your year and VIN and we will help confirm the fit. Every TorqShift part we carry is on the 5R110W parts page, and a later-design alternative is listed as the 5R110W sun shell for 2008-later units.
| Fits | 5R110W 2009 |
| Part type | Sun Shell |
| Condition | Used |
| Brand | OEM |
| Ships | From the USA |
| Warranty | 1-year |
Doing this repair right usually means replacing these at the same time. Same transmission, ships together.
It is not a recommended swap. Ford changed the sun gear and shell in 2005 and again with the later washer-less rear planet. Use a shell that matches the rear planet and sun gear in your unit, and send us your year and VIN if you are not sure.
For a stamped part with no friction surfaces, a clean used shell in the correct design is a practical repair. Inspect the lugs, hub weld and splines before installing, and check that the sun gear turns smoothly.
Usually overload from a slipping clutch, most often the direct clutch, which hammers the shell lugs and hub. Heavy towing on worn clutches and debris-filled fluid speed it up.
Ford's 2009 Super Duty owner guide specifies Motorcraft Mercon LV for the 5R110W. Check the level hot, in Park, with the engine running after cycling through the ranges.
Replacing the shell is part of a teardown, so reset the transmission adaptive values with a scan tool after the rebuild and road test the truck through every gear so the computer can relearn shift timing.
