Suncoast 5R110 Cat 2 500 HP Transmission with Converter 2003-2004 4WD

Product Name: SunCoast Category 2 500HP+ SunCoast 5R110 Transmission 4WD
Manufacturer: SunCoast
Manufacture Part #: SC-5R110CAT2
Thoroughbred Diesel Part #: SUNSC-5R110CAT2-CRE
Fitment Notes: 2003-2004 4WD Powerstroke 5R110

5R110 transmission includes the following:

• SunCoast Low/Reverse Clutch Pack with 6 Clutches & 6 Kolene Steels
• SunCoast Overdrive Clutch Pack with 5 Clutches & 4 Kolene Steels
• SunCoast Overdrive Piston
• SunCoast Overdrive Pressure Plate
• SunCoast Intermediate Clutch Pack with 5 Clutches & 5 Kolene Steels
• SunCoast Intermediate Pressure Plate
• SunCoast Forward Clutch Pack with 5 Frictions & 5 Steels
• SunCoast Forward Pressure Plate
• SunCoast Wide Load Direct Clutch Pack with 5 Frictions & 5 Steels
• SunCoast Direct Pressure Plate
• SunCoast Direct Piston
• SunCoast Direct Snap Ring
• SunCoast No Walk Center Support
• SunCoast Overhaul Kit
• SunCoast Valve Body Calibration Kit
• Billet Vascomax Input Shaft
• Billet Rear Ring Gear Hub
• Mag-Hytec Deep Pan
• SunCoast Triple-Disc Billet Torque Converter

The SunCoast Category 2 5R110 transmission takes another step forward in power handling with the addition of the billet rear ring gear hub in conjunction with the billet input shaft. The SunCoast Category 2 5R110 upgraded transmission also gets our proprietary pump and valve body modifications ensuring clean, crisp, and accurate shifts. At this power level a billet flexplate is recommended to ensure reliability.

Tales from the 5R110

The TorqShift 5-speed 5R110 transmission replaces the old faithful 4-speed 4R100 in the 2003 model year with the introduction of the new 6.0L diesel engine. The TorqShift design, in fact, has a total of six forward gears ratios; however, only five are advertised, with the hidden gear only being used in very cold weather. The five forward ratios are: 3.11, 2.22, 1.55, 1.00, andfinallyoverdrive is 0.71. The TorqShift also utilizes an optional 4th gear at 1.10, which is used in cold start conditions to aid in engine and transmission warm up.

With the TorqShift, once the Tow/Haul mode is activated, it can help increase driver control when towing large loads up and down steep grades. It will also minimize shifts and maximize the available torque. Upon descent, the tow/haul feature utilizes engine braking to help extend the life of the transmission and improves driver control.

The TorqShift was also Fords first attempt at adaptive control. The adaptive control shift function monitors the performance over its lifetime and adjusts shift times in real time to ensure consistency and compensate for wear. The TorqShift was also used with the 6.4L. This particular transmission was later replaced with the much larger and more robust 6R140 when the 6.7L PowerStroke was released by Ford.

Walking Away from the Center Support

The center support on a transmission is a critical component that could make the difference between success or failure. The center support acts as a stabilizer, just as our lower back and abdominal muscles support us. With the TorqShift being such a long unit, over time, the torsional flexing distorts the case, and the center support can sag and become displaced. The TorqShift relies on the center support to also apply fluid feed to the direct and forward clutches. When this distortion occurs, the fluid feed holes for direct and forward can become misaligned. This is especially true when towing heavy loads or under moderate-to-hard acceleration. This will also lead to premature failure and burnt clutches.

SunCoast has developed a new No Walk Center Support to correct this issue, which we include in this kit. We also go a step further with this and make a new Mag-Hytec pan standard to increase the rigidity of the case and reduce torsional flexing.

With this now being corrected, the need for the direct solid modification is no longer needed. We originally created this modification before learning about the torsional effect.

The 'Wide Load" Direct Clutch

The direct clutch pack has been a problem child for some time now. With the center support now being corrected, we move your attention to the most problematic area of the 5R110: the direct clutch. In the 5R110, the direct clutch pack has been the topic of so many discussions. In the beginning, we modified the direct clutch solenoid as a result of the fluid flow issues we were seeing and trying to compensate for what we would later find out was the center support walking. Today, many companies still sell these altered solenoids to try to correct a direct clutch issue. We have alleviated this with our new no walk center support.

The direct clutch pack is still one of the most abused clutch packs within the transmission. The direct clutch pack is constantly subjected to conditions that can prematurely wear. To alleviate this, SunCoast has developed our new wide load direct clutch pack. These new clutches are not only made from our SunCoast SCZ carbon graphitic material, but also a larger, wider clutch.

Making the clutch wider effectively increases the mean radius of a clutch, which in turn increases the torque capacity of said clutch. What this means is the larger the mean effective radius, the more torque load capacity the friction plate can handle.

This new wider clutch is also combined with the new wider steel and new wider apply plate. This combination, along with the new and improved No Walk center support, makes this the most loudly engineered kit on the market today.

The Billet Ring Gear Hub

The Ford factory ring gear hub has many issues, even in stock form. When we start increasing load on the driveline via additional torque, larger wheels and tires, towing heavy loads or aftermarket tuning, this piece becomes very susceptible to catastrophic failure.

This unit comes with a new billet one-piece ring gear hub. This new billet hub is precision machined out of 4140 HTSR steel. This not only withstands the additional torque, but is also perfect for heavy duty towing applications.

The Input Shaft

The factory Ford input shaft is one of the smallest input shafts on the market today. Its lack of size makes for a sore subject with many of our customers after a simple programmer has proven to be too much. With factory wheels and tires, this is a standard replacement for all of our builds. With larger wheels and tire combinations, this becomes essential at stock horsepower/torque.

Tire size, gear ratio, and reciprocating mass can all play a role in the amount of torsional fatigue that can occur. Torsional fatigue is one of the largest contributors to premature failure. Fatigue is something that occurs over time after repeated stress. So torsional fatigue is something that occurs over time after repeated stress. It is not so much the overall torque but the accumulation or sum of all the torque that the object has seen over time. SunCoast uses a new billet input shaft that is heat treated and precision ground from 300 maraging steel for maximum held strength. This shaft is a 100% drop-in assembly.

Mean effective radius is the distance from the theoretical center of the friction plate to the center of the friction material. What this means is the larger the mean effective radius, the more torque load capacity the friction plate can handle.

Information such as tire size, gear ratio, and reciprocating mass can all play a role in the torsional fatigue that occurs on these shafts. Torsional fatigue is one of the largest contributors to premature failure that we see. Fatigue is something that occurs over time after repeated stress. It is not so much the overall torque but the "accumulation" or "sum" of all the torque that the object has been exposed to over time. When you examine the different materials for making these shafts, you will see they come in a variety of grades with a variety of prices. While the more expensive grades such a Maraging, Vascomax, or even the much coveted Aeromet, have a stronger yield rate, they are much more resistant to fatigue.