5R55W Banner Rebuild Kit 2002-2007, new and ready to install. Fits the 5R55W. Ships fast from the USA.
A 2002-2003 Explorer or Mountaineer with the 5R55W that has started engaging late into Drive once it is warm, slipping on the takeoff, or showing dark fluid with clutch lining on the magnet is a teardown candidate. This banner kit is the mid-level parts package for that rebuild. It is catalogued as a Raybestos kit (W16004GP) for 2002-2007 5R55W and 5R55S units and contains two things: a complete overhaul kit (gaskets, seals, O-rings, sealing rings, lip seals and rubber components) with a bonded piston, and a Raybestos friction clutch pack module, RCP96-139. It costs less than a master kit because it skips the hard wear parts you may be able to reuse.
The W shifts with a mix of bands and multi-plate clutches, and the forward, direct and overrun packs are what wear first when the fluid has been cooked. Transmission Digest explains that the W and S engagements are managed by four on/off shift solenoids, a PWM converter clutch solenoid and three variable force solenoids, and that the PCM adapts the apply pressure as parts wear. When the clutches glaze and the piston seals start to bleed, the adaptive tables run out of correction and the slip shows up. Fresh frictions plus a full reseal restore the pack clearance and the sealing the controls were calibrated around. The bonded piston replaces a piston whose molded rubber hardens and leaks apply oil after years of heat.
Be clear about what is not in the box: the listing names no steel plates, no bands and no filter. If your steels are blued or the bands are down to the backing, add those or choose the 5R55W master rebuild kit for 2002-2007, which includes them.
The W has faults that copy worn clutches, so prove it first. GEARS Magazine documents a 2006 Explorer with severe delayed forward when warm where solenoid and sensor readings were normal and the forward clutch was the only damage inside, the exact job this kit is built for. Sonnax, on the other hand, shows that worn overdrive and intermediate servo pin bores in the case leak apply oil and upset shift timing; no seal kit fixes that, and the case needs a sleeve. Read the servo pin bore wear guide and work through the 5R55 harsh or delayed shift walkthrough before the transmission comes out. If the problem is electrical, a 5R55W solenoid kit may be the real fix.
This listing covers 5R55W transmissions from 2002 through 2007, and the same kit is applied to the 5R55S in that window. According to Sonnax, Ford used the W in 2002-2003 Explorers and Mountaineers, with the S taking over for 2004-up, so a 2004-2007 truck usually has an S even though this kit fits both. It does not fit the 5R55N used in 1999-2002 Lincoln LS, Thunderbird and Jaguar S-Type, or the older 5R55E. Check the code on the door-jamb label and the case tag, count the teeth on your old frictions against the new module, or send us your year and VIN. For 2008-up units see the 2008 5R55W banner kit, and browse everything for this family on our 5R55 parts page.
| Fits | 5R55W 2002-2007 |
| 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.
No. It contains the overhaul gasket and seal set with a bonded piston and the Raybestos RCP96-139 friction module. Steels, bands and the filter are separate; the 5R55W master kit includes them.
Most 2004-2007 Explorers and Mountaineers have the 5R55S, and this kit is applied to both the W and S for 2002-2007. Confirm the transmission code on the door-jamb label or send us your VIN.
Often, but not always. Worn servo pin bores, a sticking valve or a weak solenoid body can cause the same complaint, so check pressures and pull the pan before ordering a rebuild kit.
Mercon V. A dry unit behind the 4.0L or 4.6L takes about 12.4 to 12.7 quarts, and the level is checked hot at the fill plug because there is no dipstick.
Yes. The PCM uses adaptive shift control, so clear the adaptive values with a scan tool and drive it through all gears gently so it can relearn the new clutches.
