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Old 03-30-2010, 12:28 PM
badcarma badcarma is offline
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5R110W direct clutch problems

Has anyone had a problem with 5R110W direct clutch problems, My nephew had his 2005 SD f 250 6.0 be told that 5R110W direct clutch problems. He was towing a trailer in tow mode and it started slipping in and out, so he took it to a dealer and they said that it was the direct clutch that was causing the problem and needed to be rebuilt, he only has 40000 miles on it but they said that it is out of warranty. What do you guys think that he should do?

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Old 08-21-2010, 07:17 PM
loepke72 loepke72 is offline
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Yes, I've seen this before, usually comes in as a 3-5 shift flare that's inconsistent. Every time I've found a slightly burnt direct clutch. My theory is that shift solenoid D gets a bit flaky and causes the burnt clutch. It's just enough to cause a problem, but no burnt fluid or debris in the pan. The 3-5 shift is a bit hard to get right because (I forgot which component now) goes from being driven to being held or vice versa, so it's really independent of whether someone is towing a load or not. Note that it's a 3-5 shift, not a 3-4 shift; fourth gear is only used when the transmission temperature is well below 0F (I think it's -20F, but I'd have to look it up to be sure). Anyway, replacing SSD and the direct clutch components fixes the problem, and this requires transmission teardown.
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Old 08-22-2010, 03:14 AM
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Mark Kovalsky Mark Kovalsky is offline
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Originally Posted by loepke72 View Post
The 3-5 shift is a bit hard to get right because (I forgot which component now) goes from being driven to being held or vice versa,
It's a difficult shift because the intermediate clutch has to release as the direct clutch applies. They have to be timed to both finish within 30 milliseconds of each other or things get ugly. If the direct applies before the intermediate releases you get a tie up, which makes the output shaft stop turning, and the output shaft is connected directly to the wheels. This puts an incredible load on the clutches, not to mention locking the rear wheels.
If the intermediate releases before the direct applies the trans shifts back to first gear, the engine races, and then it shifts 1-3. This puts a lot of energy into the direct clutch. A few of these shifts and the clutch will burnt.

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fourth gear is only used when the transmission temperature is well below 0F (I think it's -20F, but I'd have to look it up to be sure).
Fourth gear is used instead of fifth gear when the trans is colder than 0F. Fourth is also used on kickdowns from sixth gear at certain speeds.
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Old 08-23-2010, 06:16 PM
loepke72 loepke72 is offline
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That all makes sense. Even the instructor at the Ford training center was a bit vague about the fourth gear thing on these transmissions, saying something about it making the fluid warm up faster or something like that. I think it has to do with that difficult 3-5 shift, and maybe not wanting to do that with cold fluid and screwing up the precise timing needed.

I don't strive to memorize the clutch/band application charts; that's what the service manual is for. But I do remember the 3-5 shift involving holding or driving the same component depending on which gear it was in. Screw up the timing and either it's a shift flare or the thing tries to lock up. At this time it's the most common internal Torqshift problem I run across. I wasn't doing trans work when the planetary recall was going on years ago. This unit is one of the best I have seen from Ford, reliable, tough, and easy to work on if it does need repair.
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Old 08-23-2010, 06:34 PM
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I think it has to do with that difficult 3-5 shift, and maybe not wanting to do that with cold fluid and screwing up the precise timing needed.
That is exactly correct! When the ATF is below 0F we could not get the timing on the 3-5 shift to work correctly. It was MUCH easier to shift 3-4. The 3-4 shift is non-synchronous, all that happens on that shift is the overdrive clutch applies and the overdrive one way clutch overruns. If the clutch takes longer to apply all that happens is the one way clutch holds for a bit longer. The driver won't notice anything wrong.

The engine runs 9% faster in the fourth than fifth at the same vehicle speed. This has the added benefit of helping both the engine and trans warm up faster.
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Old 08-23-2010, 06:34 PM
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