5R55W Overhaul Kit 2002-2008, new and ready to install. Fits the 5R55W. Ships fast from the USA.
This overhaul kit, part number T16002G, is aimed at the 2002-2008 run of the Ford 5R55W and 5R55S, the five-speed automatic found in that era's Explorer and Mercury Mountaineer and in the 5R55S-equipped Lincoln and Ford cars of the same years. Shoppers usually reach it with a high-mileage truck that has started leaking, engaging slowly when cold, or flaring between gears, and a plan to pull the transmission and reseal it properly. It is the gasket and seal portion of a rebuild. It does not contain frictions, steels, bands or a filter, so it suits a unit whose clutch packs are still serviceable or a rebuild where those parts are bought separately.
The 5R55W reached the Explorer and Mountaineer for 2002, and Sonnax notes that the 5R55S took over in later trucks and replaced the older 5R55N in the Lincoln LS and Thunderbird from 2003. Both share the same case and soft parts. Inside, clutch and band apply is managed by solenoids, and each apply circuit depends on a rubber seal to hold that pressure: the drum piston seals, the servo piston and cover seals, and the O-rings at the solenoid body. The gaskets and the front and rear seals keep the fluid in the case. By the time one of these early trucks has passed 150,000 miles, years of heat have hardened most of that rubber at once, which is why rebuilders reseal the whole unit rather than chasing one seal.
On 2002-2008 trucks, rule out the common hard-part failures before blaming the rubber. Sonnax ties worn overdrive and intermediate servo pin bores to flares, burned band linings and ratio codes 732, 733 and 735, and new seals will not seal a worn bore. Our servo pin bore wear guide explains how to check it, and the 5R55W Explorer common problems page covers the other weak spots. If the pan holds clean fluid and the only complaint is a leak or a soft engagement, a reseal with this kit is a reasonable plan.
T16002G is listed for the 5R55W and 5R55S from 2002 to 2008. That covers 2002-2008 Explorers and Mountaineers with either the 4.0L V6 or 4.6L V8, plus 5R55S cars of those years. One thing to watch on these trucks is the solenoid pack: ATRA documents an early pack (1L2Z-7G391-AG) and a later pack (4L2Z-7G391-AA, updated to 9L2Z-7G391-A) used by year, so do not assume a pack swapped from another truck is correct. If your vehicle is a 2009 or 2010, choose the 5R55W overhaul kit for 2002-2010 instead. The kit does not fit the 5R55N or 5R55E. Read the transmission code on the door-jamb label, compare the pan gasket outline with your pan, or send us your year and VIN. The full range is on the 5R55 transmission parts page.
| Fits | 5R55W 2002-2008 |
| Part type | Overhaul 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. T16002G is a gasket and seal overhaul kit. Frictions, steels, bands and the filter are sold separately, or you can choose a master rebuild kit that bundles them.
This listing is for 2002-2008. For a 2009 or 2010, use our 2002-2010 5R55W overhaul kit so the fitment range covers your year.
Yes for soft parts. The W and S share the case and seals, and the kit is listed for both. The overdrive sun gear and some hard parts differ, which does not affect this kit.
Only if seal leakage caused it. Worn servo pin bores in the case are a documented cause of P0735 on this unit and new seals will not fix them. Check the bores during the teardown.
A remanufacturer installation guide lists about 12.4 to 12.7 quarts dry behind the 4.0L and 4.6L. Use Mercon V and set the final level at the check plug with the engine running and the fluid hot.
