5R55W Banner Rebuild Kit 2002-2005, new and ready to install. Fits the 5R55W. Ships fast from the USA.
When a 2002-2005 Ford Explorer or Mercury Mountaineer with the 4.0L starts slipping on the upshifts, takes a second or two to grab Drive, or shows dark, burnt fluid at the check plug, the clutch packs are usually cooked and the seals have gone hard. This 5R55W banner rebuild kit is the soft-parts package for that overhaul. It contains a complete transmission overhaul kit (gaskets, seals and O-rings), a full set of friction clutch plates and a set of steel clutch plates, so every pack in the unit goes back together with new frictions running against fresh, flat steels instead of heat-marked originals.
The 5R55W gets its five forward speeds from a mix of multi-plate clutches and bands. The clutches handle the forward, direct and coast work while the overdrive and intermediate bands, applied by servos in the case, hold drums for second, third and fifth. Every clutch pack depends on its piston seals holding apply oil; once those seals harden, the pack applies slowly and slips, which generates heat that glazes the frictions. A banner kit addresses exactly that wear: it reseals every circuit and renews the friction and steel stack. What it does not include is bands, a bonded piston or a pan filter, so plan those separately if your teardown shows they are worn.
Drop the pan before ordering anything. Bronze-colored fines and fiber on the magnet mean the clutch packs are worn and a kit like this is the right call. Black band lining points at the servos, and on this case that often means oval servo pin bores, which Sonnax describes as a root cause of slipping and ratio codes that new frictions will not cure. Our guide to 5R55W/5R55S servo pin bore wear explains how to check them. If the fluid is clean and the complaint is a harsh or late shift, work through the 5R55 harsh or delayed shift walkthrough first, because a worn valve body or solenoid block can mimic a slipping clutch.
This listing is for 5R55W transmissions from 2002-2005, and the kit is listed for 4.0L Explorer and Mountaineer applications. Sonnax places the W in 2002-2003 Explorers and Mountaineers, with the 5R55S taking over in 2004-2005 trucks, and notes the two share many soft parts but differ in hard parts such as the overdrive sun gear (24 teeth in the W, 38 in the S). Read the transmission code on the door-jamb label and the tag on the case, and if your vehicle is a V8, a Lincoln or anything other than a 4.0L, send us the year and VIN before ordering. Every 5R55 part we carry, sorted by version, is on the 5R55 transmission parts page.
For a 2002-2007 unit where you want the forward clutch bonded piston in the box, compare the 5R55W banner kit for 2002-2007; if the drums and bands are worn too, a 5R55S master rebuild kit covers more of the unit in one order.
| Fits | 5R55W 2002-2005 |
| Part type | Banner Rebuild Kit |
| Condition | New |
| 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.
Yes. It includes the overhaul gasket and seal kit, a full set of friction clutch plates and a set of steel clutch plates. Bands, a bonded piston and a pan filter are not listed as included.
Many 2004-2005 Explorers and Mountaineers came with the 5R55S rather than the W. The soft parts are largely shared, but check the code on the door-jamb label and the case tag, or send us your VIN so we can confirm.
Use Mercon V. Behind the 4.0L the installation guide lists roughly 12.4 to 12.7 quarts dry, with the final level set at the T30 Torx check plug, engine running and fluid at operating temperature.
Only if worn fifth-gear components are the cause. On the 5R55W, P0735 is often tied to overdrive servo pin bore wear, so measure the bores and inspect the overdrive band before you assume new frictions alone will cure it.
Clear the PCM's adaptive tables after the rebuild if your scan tool supports it, then drive with light and moderate throttle through every gear so the computer relearns the new clutch fill times.
