6R140 Banner Rebuild Kit

This is the diesel-application 6R140 banner rebuild kit, part number T236004AAW from Toledo Trans-Kit, for Ford Super Duty F-250 through F-550 trucks with the 6.7L Power Stroke. Shops order a banner kit when a TorqShift that has pulled a lot of weight starts slipping out of a gear, flares on upshifts, engages slowly after sitting, or shows burnt fluid with friction material in the pan. It is the lower-cost route to a proper overhaul: the gasket and seal set plus new friction clutch plates, without the extra pistons and hard parts of a larger master kit.

What a banner kit renews in a 6R140

The 6R140 is a Lepelletier-style six speed. A simple planetary in front feeds a Ravigneaux gearset, and five clutches, A through E, are applied in pairs to make each gear. Friction plates in those packs wear first on a diesel truck because of the torque they carry, and the lip seals and sealing rings that hold each clutch's apply pressure harden with heat. A banner kit replaces both groups. That is exactly what a unit with worn frictions and tired seals needs, and nothing it does not: steels, drums, the pump and the valve body are reused if they inspect good.

Symptoms that call for a banner kit

• Slip in one or more gears, usually first under heavy throttle or while towing
• Flare on upshifts, where the engine revs up before the next gear takes hold
• Slow engagement into Drive or Reverse that gets worse over time
• Fluid that smells burnt or has turned dark, with clutch material on the magnet
• Seal leaks that keep returning on a high-mileage unit

Valve body and solenoid faults, harsh shifts that need an adaptive relearn, and converter clutch wear are the other common 6R140 failures, and none of them are cured by new frictions. Those need their own diagnosis.

How to confirm before buying

Before pulling the transmission, make sure the problem is mechanical. Read codes and live data for ratio errors versus solenoid circuit faults; our 6R140 shift solenoid guide covers that split. Check the fluid hot and look at its color and smell. Then gauge line pressure. A truck with good pressure that still slips has worn clutches and is a banner kit candidate. If speed sensor readings look erratic, read the 6R140 speed sensor guide first, because a bad sensor can trigger slip codes on a healthy unit.

Fitment

The source listing identifies this as the diesel version of the kit and does not narrow it to a year range. The 6R140 changed during production, including a 2015 valve body redesign and 2017 and later diesel updates, and friction and seal packages can differ between units. Match part number T236004AAW against your rebuild reference, or send us your year and VIN and we will confirm it fits before you order. Owners of gas-engine trucks should not assume this kit fits. If you want a kit already split by year that also includes pistons, a filter and valve body repair parts, see the 2015 and up 6R140 banner kit. All 6R140 parts are listed on the 6R140 collection page.

Install notes

• Pre-soak the new frictions in Mercon LV, then measure each clutch pack clearance. Heat-marked steels should be replaced, not reused.
• Size the new sealing rings correctly before assembly; the 6R140 seal ring expander and downsizer tool kit makes that much easier.
• Inspect drums for cracks and worn ring lands. A damaged 6R140 clutch drum will leak past even brand-new rings.
• Replace bushings while the unit is apart, and install a new filter with its neck seal fully seated.
• Refill with Mercon LV, set the level hot, and clear the adaptive tables so the computer relearns clutch fill.

Does this kit fit the 6.2L or 7.3L gas engine 6R140?

The listing identifies this kit as the diesel version. Do not assume it fits a gas truck. Send us your year and VIN and we will tell you which kit to use.

What is the difference between a banner kit and a master kit?

A banner kit is the overhaul gasket and seal set plus friction plates. A master kit usually adds more parts such as steels, pistons or a filter. This kit is the banner level, so plan to buy steels, bushings or a filter separately if needed.

What part number is this kit?

It is T236004AAW. Use that number to match the kit against your rebuild reference or parts catalog.

Will a rebuild fix harsh shifts?

Only if worn clutches are the cause. Harsh shifts on the 6R140 often come from valve body wear, solenoid faults or adaptive tables that need a reset, so diagnose those first.

What fluid goes in after the rebuild?

Mercon LV. Ford lists the 6R140 at about 4 gallons total. Check the level hot using the factory procedure after the first drive.

• 6R140 Shift Solenoid Symptoms and Replacement
• 6R140 Input/Output Speed Sensor Symptoms
• Ford 6R140 TorqShift Problems and Service: A Rebuilder's Guide
• 6R140 Delayed Engagement: Causes and Fix