Ford F550 Super Duty Transmission Problems & Cost | 4R100 | 5R110W | 6R140

The Ford F550 4-speed 4R100 and 5-speed 5R110W and 6-speed 6R140 were able to handle the monster torque of the 6.0L and 7.3L Power Stroke Diesel engine, while providing impressive fuel economy. They also were equipped with a PTO (power-take-off) option. But they aren’t without their problems though, so let’s look at some of the most common Ford F550 Super Duty transmission problems, and figure out what you can do about them.

Need a replacement transmission? Get an estimate for replacement transmissions and local installation. Look up your transmission model by vehicle make and model.

What Transmission Do I Have?

Ford F550 Transmission Models

1999-2004 Ford F550 Super-Duty: 4R100 Transmission
2003-2010 Ford F550 Super-Duty: 5R110W Transmission
2011+ Ford F550 Super-Duty: 6R140 Transmission

F550 Transmission Replacement Cost Estimate

These are the most current prices for a remanufactured replacement Ford F550 transmission.

Replacement F550 Transmission:

What are the DTC codes related to Ford F-550 transmission problems?

Tow/Haul Light Flashing – A flashing Tow Haul light on the Ford F-250 Super Duty acts as sort of a warning light to let you know that something is wrong with your 5R110W transmission. It can be as simple as a failed temperature sensor, or the valve body could be cracked in half. But you won’t know unless there was a DTC stored in the computer.

Ford F550 Transmission Technical Service Bulletins | TSBs

TSB 02–21–1 – 4R100 Transmission – Torque converter access plug may become dislodged
1989 – 1997 Ford Super Duty – 1989 – 1998 Ford F250 – 1989 – 1998 Ford F53 Motorhome – 1989 – 2003 Ford E-Series – 1989 – 2003 Ford F150 – 1999 – 2003 Ford Super Duty – 2000 – 2003 Ford Excursion – 1998 – 2003 Lincoln Navigator – 2002 – 2003 Lincoln Blackwood
Problem – Due to extreme load and material shrinkage, the torque converter external access dust plug may fall out during severe duty use.
Solution – Install new plug (part number E9TZ-7N171-A) with a 1/4 inch bead of silicone sealant around the plug.

TSB 98-20-9 – Ticking noise on initial startup when the selector is in park or neutral – 4R100 Transmission
1998 Ford Econoline – 1998 Ford Expedition – 1998 Ford F150 – 1998 Ford F250 – 1998 Lincoln Navigator – 1999 Ford F250 HD – 1999 Ford F350 – 1999 Ford Super Duty
Problem – A ticking noise may be hard when the vehicle is first started and the shifter is in the ‘P’ or ‘N’ position. In some cases, the noise may also be heard after the vehicle has warmed up. This can be caused by the overdrive clutch steel separator plate(s) hitting against the case internal spline.
Solution – Install new OD friction plates and accumulator assembly

TSB 08-26-4 – 5R110W transmission failure in cold weather
2008 – 2009 Ford E-Series – 2008 – 2009 Ford Super Duty
Problem – Vehicles built between 5/18/2007-11/1/2008, which are driven in cold climates (i.e. 35°F and below) may experience complete transmission failure due to the lack of an in-line transmission filter, which causes a lack of lubrication to the low/reverse one way clutch.
Solution – Rebuild or install a remanufactured 5R110W transmission with an updated transmission pump and external in-line transmission filter.

05-25-4: 2005-2006 Ford Super Duty 6.0L – Some models equipped with the 5R110W transmission may experience erratic shifting in Tow/Haul Mode, a late 5-6 shift in Tow/Haul Mode, a harsh 3-2 engine braking downshift, and potentially a harsh 5-2 downshift.
Solution: The powertrain control module (PCM) needs to be reprogrammed (WDS release B39.15 and higher or B40.2 and higher).

TSB 11-7-10 – 2-3 shift flare with P0733 DTC and or delayed reverse engagement – 6R140 transmission
2011 Ford Super Duty 6.7L Powerstroke \ 6R140 transmission
Problem – On vehicles built on or before 4/11/2011, drivers may experience a 2-3 shift flare (unusual RPM fluctuation), along with a P0733 diagnostic trouble code, and possibly a reverse gear engagement delay.
Solution – Replace the three normally high solenoids

TSB 16-0057 – P0751, P0730 and/or P2700 DTCs – 6R140 Torqshift 6 Transmission & 5R110W Torqshift 5 Transmission
2009 – 2016 Ford E-Series – 2009 – 2016 Ford Super Duty – 2009 Ford F53 Motorhome – 2011 – 2015 Ford F53 Motorhome – 2011 – 2015 Ford commercial stripped chassis
Problem – Vehicles built before 12/15/2015 may experience the P0751, P0730 and/or P2700 diagnostic trouble codes
Solution – Replace the coast clutch cylinder and coast one-way clutch mechanical diode assembly.

Common Problems with the F550 4R100 Transmission (1999-2004)

Poor performance with DTCs P0715, P0716 & P0717 – 4R100 Transmission
Problem – Poor engine performance and acceleration may be due to a sticking solenoid regulator valve
Solution – If the solenoid regulator valve cannot be repaired, the valve body will have to be replaced

1) Faulty Shift Solenoids

Heat and vibration are the natural enemy of car parts, and they’re the main cause of premature solenoid failure on the Ford 4R100 transmission. These little plunger mechanisms route pressurized ATF through the valve body to actuate a shift. Over time, the heat and vibration can short out the wiring on a 4R100 solenoid, leading to delayed shifts, or no shift at all.

2) Failed Forward Clutch Drum

Controlling hydraulic pressure is the key to creating a durable transmission. Unfortunately, an OE design flaw in the accumulator pistons and snap ring can cause the 4R100 forward clutch drum to fail prematurely. Leading to no forward gears, or severe slipping in 1st, 2nd, or 3rd gears. To solve this problem, each SST remanufactured 4R100 transmission gets upgraded (see: Stronger) 1-2 and 2-3 accumulator pistons, a more robust spiral-lock snap ring, and a staked retainer for the intermediate clutch.

Common Problems with the F550 5R110W Transmission (2003-2010)

The Ford 5R110W TorqShift transmission is a five-speed automatic transmission that replaced the aging 4-speed 4R100 transmission. Although it was considered to be a 5-speed automatic, it actually had a 6th overdrive ratio that allowed for an alternate shift pattern in cold weather. At temperatures below 5°F, 5th gear would be skipped in order to increase engine RPM and bring the transmission up to operating temperature. The Ford 5R110W transmission also had full electronic controls, which allowed the computer to lockup the torque converter when the 5R110W Tow/Haul Mode or PTO was in use. Some of the highlights included an integrated trailer brake control system, and the optional Torqshift 5R110W transmission which was fitted with a groundbreaking Tow/Haul Mode that minimized upshifts to keep the engine in the power band, and automatically downshifted to provide engine braking when descending a hill. The Ford 5R110W transmission could also be outfitted with a PTO to power accessories like a snowplow or external hydraulics.

1) Reverse Planetary Assembly

A common 5R110W transmission problem has to do with the low/reverse planetary gear pinions. An OE design flaw allowed the gear set pinion shafts to back themselves out of the carrier, resulting in slipping, and harsh or delayed forward/reverse gear engagement.

2) Transmission Pump

The Ford F-350 5R110W transmission transfers engine power to the wheels through hydraulic pressure. This pressure is created by the transmission pump, which has a tendency to fail prematurely. If this happens, you’ll experience a pronounced delay in forward and reverse gear engagement, or the transmission could just “slam” into gear.

Can I drive with a transmission problem?

Okay, if your truck can still make it up and down the road, you might say “It’s fine, I’ll just drive it until I can get it fixed”. But that is not always a good idea. You see, there are a lot of (very expensive) moving parts inside of a transmission, and if something isn’t right, continuing to drive with a transmission problem could damage something else.

How often does a F550 transmission need to be replaced?

The overall lifespan of a Ford F-350 transmission largely depends on how well it was maintained. Factory design flaws also factor into this equation, along with how/how hard you drive. But on average, we’ve seen the OE Ford F-350 5R110W transmission last for between 130,000-220,000 miles. A high quality replacement Ford 5R110W transmission however, can last considerably longer if all of the factory design flaws have been addressed and the vehicle has been maintained.

How are Ford F550 SD transmission issues diagnosed?

It is fairly easy to guesstimate what the root cause of your Ford F550 transmission problems might be, but you won’t truly know unless you have the right tools and experience. A good mechanic or transmission repair center will be able to connect your Ford Super Duty to a computer and find out which diagnostic trouble codes (DTC’s) have been stored. Once they know what to look for, they can perform a visual inspection to verify the problem.

How is a Ford F550 transmission replaced?

In order to replace your Ford F-350 transmission, the truck has to be lifted from the ground in order to gain access to all of the parts that will need to be unbolted. Then the transmission can be lowered to the ground (typically with a transmission jack), so the new 5R110W transmission can be installed. Once it is in place, the ECU will have to be reprogrammed to accept the new gearbox.

Recommendations for F550 transmission issues?

To save time and get back on the road faster, you can get an online quote for a replacement Ford F-350 transmission here, then find a local shop using our Find a Shop guide to install it for you.

How to Solve Ford F550 Transmission Problems

Solution A: Buy a Used Ford F550 Transmission

The quickest way to fix your transmission problems is to simply buy a used 4R100 transmission or used 5R110W transmission. These can be found at most junk yards, and they often come with a 30-90 day warranty. However, there’s no way to determine the actual condition of the internal components, so you could be spending a bunch of money to have the exact same problems. Plus, that warranty only covers the transmission if it’s defective, not the labor costs that you’ll have to pay.

Solution B: Buy a Rebuilt Ford F550 Transmission

Another option would be a rebuilt 4R100 transmission or rebuilt 5R110W transmission. A local repair shop will remove your F550 transmission, then install a bunch of new parts during the rebuild. The problem here is, the skills and experience of each transmission rebuilder will vary widely from shop to shop, so you could have problems from something that wasn’t adjusted properly. And the 1-2 year warranty might only cover you at certain transmission repair shops, in a specific geographical area.

Solution C: Buy a Remanufactured Ford F550 Transmission

Need a replacement transmission? Get an estimate for replacement transmissions and local installation. Look up your transmission model by vehicle make and model.

What Transmission Do I Have?

Many owners depend on their Ford F-350 to make a living and get things done. Their gasoline and PowerStroke diesel engines are designed to go 100’s of thousands of miles, so it makes sense to invest in a remanufactured 4R100 transmission or remanufactured 5R110W transmission.