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Ford F-250 Super Duty Gen 2 Transmission Guide (2008-2010)

by | May 13, 2025 | Common Issues, DIY Repairs, F250, Preventative Maintenance, Shop Talk, Truck Maintenance

Experiencing Transmission Issues? You’re in the Right Place. This is part 2 of a 4 part series of blog posts where we dive deep into the F250 transmissions. At Hillbilly Auto Supply, our team loves to talk shop. So don’t be afraid to pick up the phone and contact us. I don’t want to call us die-hard, but we are damn close to it. In this post, we’ll walk you through everything you need to know about the different transmission options found in the Ford F-250 Super Duty over the generations—and how they’ve evolved.

Need replacement parts or looking to do a full transmission swap? Give us a call—we work hard to keep a wide selection in stock and ready to go.

Overview

The second-generation Ford F-250 Super Duty trucks, produced from 2008 to 2010, featured a range of transmissions designed to handle heavy-duty applications across both gas and diesel powertrains. For automatic options, while introduced in the Gen 1, the 5R110W TorqShift was primarily used by Ford in Gen 2 and thus will be discussed here. This transmission is a five-speed automatic transmission known for its robust design and electronic shift control, primarily paired with the 6.4L Power Stroke diesel engine. This transmission offered adaptive shifting and was well-suited for towing and hauling. Late 2007 into early 2008 Ford also introduced the 6R140 automatic transmission designed for heavy trucks.

On the manual side, Ford offered the ZF S6-650, a six-speed manual transmission commonly paired with diesel engines for buyers who preferred greater control in work-oriented environments. For gas-powered models like those equipped with the 5.4L Triton V8 or 6.8L V10, Ford used the 5R110W in most configurations but also retained some earlier versions of the 4R100 automatic in transitional production. As the 4r100 is primarily used in Gen1, please reference our F250 Super Duty Gen 1 Transmission Guide for further information.

These transmissions reflected Ford’s emphasis on durability, especially for commercial and towing use, and helped cement the Super Duty’s reputation for toughness during this era.

5R110W “TorqShift” (Automatic)

  • Type: 5-speed automatic (electronically controlled)
  • Introduced: Originally in 2003, continued into Gen 2

Key Features:

  • Tow/Haul mode for improved trailer handling
  • Adaptive shift logic based on load and driving conditions
  • Integrated transmission cooler

Paired With:

  • 5.4L Triton V8 (gas)
  • 6.8L Triton V10 (gas)
  • 6.4L Power Stroke V8 (diesel)

Strengths: Durable under heavy towing; good low-end torque handling
Common Issues: Torque converter wear, solenoid failure, overheating under heavy loads

ZF S6-650 (6 Speed)

  • Type: 6-speed manual transmission
  • Paired With: 6.4L Power Stroke diesel
  • Known For: High torque handling, strong for towing and hauling
  • Common Issues: Input shaft bearing noise, clutch wear

Engine Pairings

  • 5.4L Triton V8 (Gasoline) paired with 5R110W TorqShift 5-speed automatic transmission. Some early builds may have used the 4R100 4-speed automatic (rare; mostly phased out after Gen 1)
  • 6.8L Triton V10 (Gasoline) paired with 5R110W TorqShift 5-speed automatic transmission
  • 6.4L Power Stroke V8 Turbo Diesel paired with 5R110W TorqShift 5-speed automatic transmission (standard) and ZF S6-650 6-speed manual transmission (optional, typically for fleet/commercial or special order trucks)

Gen 2 Super Duty Transmission Specs

Here’s a detailed breakdown of the specs, gear ratios, and known issues for the transmissions used in the second-generation Ford F-250 Super Duty (2008-2010).

TorqShift 5R110W (5-Speed Automatic Transmission)

Engines Paired With:

  • 6.4L Power Stroke Diesel (2008-2010)
  • 6.8L V10 (2008-2010)

Specs:

  • 5-speed automatic transmission
  • Electronic control with adaptive shift strategy
  • Designed for heavy-duty trucks
  • Maximum torque capacity: 1,000 lb-ft
  • Fully electronic with adaptive shift logic for smooth shifting under load

Gear Ratios:

  • 1st Gear: 3.23
  • 2nd Gear: 2.14
  • 3rd Gear: 1.55
  • 4th Gear: 1.00
  • 5th Gear: 0.71
  • Reverse Gear: 3.23

Known Issues:

  • Torque Converter Failure: Premature torque converter failure, especially under heavy load and towing.
  • Transmission Overheating: Tendency to overheat under heavy towing conditions, especially in the 6.4L diesel.
  • Shift Solenoid Failures: Can cause hard shifts, slipping, or failure to shift.
  • Oil Cooler Leaks: Transmission oil coolers can develop leaks leading to fluid loss and overheating.

ZF S6-650 (6-Speed Manual Transmission)

Engines Paired With:

  • 6.4L Power Stroke Diesel (2008-2010)
  • 6.8L V10 (2008-2010)

Specs:

  • 6-speed manual transmission
  • Designed for high-torque applications and heavy-duty use
  • Synchromesh design with full electronic control
  • Maximum torque capacity: 650 lb-ft
  • Smooth and robust shifting under load

Gear Ratios:

  • 1st Gear: 5.00
  • 2nd Gear: 2.69
  • 3rd Gear: 1.69
  • 4th Gear: 1.00
  • 5th Gear: 0.74
  • 6th Gear: 0.50
  • Reverse Gear: 5.00

Known Issues:

  • Clutch Wear: Premature clutch wear, particularly under heavy towing conditions.
  • Difficulty Shifting: Some users report difficulty shifting into higher gears, particularly when under load.
  • Clutch Pedal Issues: Pedal feel can deteriorate, and clutch hydraulics may require replacement.
  • Flywheel Cracking: Occasional reports of flywheel cracking under high torque.

Manual Versus Automatic

When it comes to the manual versus automatic transmissions in the Ford F-250 Super Duty Gen 2 (2008-2010), each type offers distinct advantages and disadvantages based on driving preferences, use case, and long-term durability. Here’s a breakdown of the pros and cons of both types:

Manual Transmission ZF S6-650

Pros:

Durability:

  • Known for its rugged construction and high torque handling capabilities, making it well-suited for heavy-duty applications.
  • Can handle up to 650 lb-ft of torque, making it a good match for the Ford F-250 Super Duty, especially with the diesel engines.

Improved Driving Control:

  • Offers a more engaging driving experience for those who prefer a manual transmission over an automatic.
  • Provides direct power delivery with no automatic shifting, giving the driver more control over gear selection and vehicle performance.

Better Towing Experience:

  • Provides a strong and predictable powertrain when towing, particularly when drivers are experienced with manual shifting.
  • Allows for better engine braking control, reducing wear on the brakes when descending hills or towing heavy loads.

Simplicity:

  • Fewer electronic components compared to automatic transmissions, which can lead to less potential for failure and lower repair costs over time.
  • Lower maintenance cost in general (compared to automatic).

Cons:

Clutch Wear:

  • The manual transmission requires a clutch, which will wear out over time and need replacement.
  • Heavy towing or off-road driving can accelerate clutch wear.

Driving Difficulty:

  • Requires more skill to operate compared to an automatic, which could be less appealing to some drivers, particularly in heavy traffic or challenging terrain.
  • Difficult to drive for those not accustomed to manual transmissions.

Towing Limitations:

  • While it can handle heavy loads, the clutch can be strained under prolonged heavy towing, requiring more maintenance.

Potential for Gear Grinding:

  • If not properly operated, gear grinding can occur, especially if the driver is unfamiliar with the manual transmission or if the clutch is not fully disengaging.

Automatic Transmission 5R110W

Pros:

Smooth Shifting:

  • The 5R110W offers seamless shifting between gears, especially compared to older automatic transmissions.
  • Its adaptive shift logic adjusts the transmission’s behavior based on load, providing smoother shifts during heavy towing or off-road driving..

Enhanced Towing Capacity:

  • The 5R110W is rated to handle up to 1,000 lb-ft of torque, making it ideal for heavy-duty towing and hauling.
  • Provides smooth and consistent towing power with less effort from the driver.

Ease of Use:

  • Automatic shifting eliminates the need for manual gear changes, making it easier for drivers who prefer convenience, especially in stop-and-go traffic.
  • Less physically demanding than a manual transmission.

Durability and Strength:

  • Built for heavy-duty use, including frequent towing and off-road driving, with strong internal components designed to withstand high torque levels.
  • Can handle high-stress situations such as steep inclines and heavy payloads.

Cons:

Higher Maintenance Costs:

  • The 5R110W is more complex than a manual transmission, with a higher number of components such as solenoids, sensors, and hydraulic systems, which can increase repair costs.
  • Fluid changes, filter replacements, and potential issues like solenoid failure can be more expensive than manual transmission service.

Overheating Risk:

  • The 5R110W is susceptible to overheating, especially under heavy towing or in hot climates, which can cause transmission fluid breakdown and potential damage to internal components.
  • Additional cooling systems, like transmission coolers, may be required for heavy-duty applications.

Torque Converter Issues:

  • The torque converter may exhibit problems like shuddering, slipping, or hesitation during acceleration, especially when the truck is under load.
  • These issues can lead to a less smooth driving experience and require expensive repairs.

Less Driver Control:

  • Some drivers may prefer the control that comes with a manual transmission, especially when it comes to engine braking and gear selection under specific conditions (like off-roading).
  • Less involvement in the driving experience, which might be less appealing to enthusiasts.

Torque Converters

The following torque converters were being used in the Gen 2 F250.

Torque Converters by Transmission Type

5R110W (Automatic Transmission)

Engines Paired: Power Stroke Diesel (2008-2010) and 6.2L V8 Gas Engine (2010)

Torque Converter Features:

  • Heavy Duty Construction: Designed to handle the high torque output of the 6.4L Power Stroke Diesel engine, which can produce up to 650 lb-ft of torque.
  • Lockup Torque Converter: Offers a lock-up feature that improves fuel efficiency by reducing slip at higher speeds.
  • Enhanced Towing Capability: Built to handle heavy-duty towing demands with smooth power transfer.
  • High Durability: Designed for long-lasting performance under high load conditions, such as hauling heavy trailers or loads.
  • Fluid Coupling: Provides smooth acceleration and helps reduce engine strain during shifts and load changes.

Common Issues:

  • Torque Converter Clutch (TCC) Issues: The clutch may fail, causing slipping, overheating, and potentially a loss of engine power.
  • Shuddering or Vibration: Some owners reported shuddering or vibration during acceleration, particularly when the transmission is locking and unlocking the converter.
  • Overheating: Under heavy towing or high-stress driving, the torque converter may overheat, leading to transmission fluid breakdown.

Transfer Cases

The Ford F-250 Super Duty from 2008 to 2010 used different torque converters depending on the engine and transmission.

Transfer Cases Used in Gen 2 F-250 Super Duty

New Venture 271 (NV271)

  • Type: Part-time, chain-driven, 2-speed transfer case
  • Shift Type: Manual shift (some models may feature electronic shift)
  • Model: NV271

Engine Pairing:

  • 5.4L V8 Gas Engine
  • 6.4L Power Stroke Diesel Engine

Features:

  • Low Range: 2.64:1 for off-road capabilities, enabling superior torque multiplication when driving in challenging conditions.
  • Durable Design: Designed to handle high torque outputs, particularly the 6.4L Power Stroke Diesel engine.
  • Manual and Electronic Shift Options: Typically comes with a manual shift lever, but electronic versions were available in some configurations, particularly in newer models.
  • Part-time 4WD: Ideal for off-road or light towing, designed to be engaged only when necessary to preserve fuel economy.

Common Issues:

  • Shift Linkage Wear: Over time, the shift linkage may wear out, making it difficult to switch between 2WD and 4WD.
  • Chain Wear: The chain-driven system can wear out, leading to whining or grinding noises.

BorgWarner 44-06 (BW44-06)

  • Type: Part-time, chain-driven, 2-speed transfer case
  • Shift Type: Electronic Shift-On-The-Fly (ESOF)
  • Model: BW44-06

Engine Pairing:

  • 5.4L V8 Gas Engine
  • 6.2L V8 Gas Engine (Introduced in 2010)

Features:

  • Shift-On-The-Fly: The ESOF system allows for shifting between 2WD and 4WD while driving at speeds of up to 60 mph without stopping the vehicle, offering increased convenience.
  • 2.72:1 Low Range Ratio: Provides excellent off-road capability and better performance when towing or navigating rough terrain.
  • Electronic Actuator: The transfer case is controlled electronically by a switch inside the cabin, improving ease of use compared to older manual systems.

Common Issues:

  • Actuator Failures: The electronic actuator that controls the shifting of the transfer case may fail over time, leading to issues with engaging/disengaging 4WD.
  • Chain Stretch: The chain-driven system may experience wear, resulting in noise and potential power loss to the wheels.

Figuring Out Which Transmission You Have:

To determine which transmission your Gen 2 Ford F-250 Super Duty (2008–2010) has, follow these steps:

Check the VIN (Vehicle Identification Number)

  • Location: Found on the driver’s side dashboard (visible through the windshield) or inside the driver’s door jamb.

How to Use:

  • Decode your VIN using an online VIN decoder or Ford’s official parts website.
  • Look specifically for the “Transmission Type” or “Powertrain” field.
  • This will indicate if you have the 5R110W (automatic) or ZF S6-650 (manual).

Look at the Gear Shifter

  • Column Shifter (Automatic): Usually indicates the 5R110W automatic.
  • Floor Shifter with Clutch Pedal (Manual): Indicates the ZF S6-650 manual transmission.

Check the Door Sticker (Safety Certification Label)

  • Location: Inside the driver’s door frame.
  • Look for the Transmission Code, which might be listed under “TR” or similar.

Example codes:

  • 5 or P: 5R110W automatic
  • K or 6: ZF S6-650 manual

Inspect the Transmission Itself

If you can get under the truck safely:

  • The 5R110W automatic has a larger pan with a deep sump, electronic connectors, and cooler lines.
  • The ZF S6-650 manual has a ribbed aluminum case, a mechanical shifter linkage, and no transmission cooler lines.

Owner’s Manual or Original Window Sticker

These documents often list:

  • Engine
  • Transmission
  • Axle ratios

Use an OBD-II Scanner or Ford Dealer Lookup

  • Plug in an OBD-II scanner and access module info.
  • Or call a Ford dealer with your VIN — they can confirm your transmission type by pulling up the build sheet.

Parts of The Transmissions

Here is a detailed bullet-point list of major parts for each transmission used in the Gen 2 Ford F-250 Super Duty (2008–2010):

5R110W TorqShift Automatic Transmission (5-speed, electronically controlled)

Paired with: 6.4L Power Stroke Diesel V8

Internal Components:

  • Torque converter with lock-up clutch
  • Front pump (gear-type, driven by the torque converter)
  • Planetary gearsets
  • Input shaft
  • Intermediate and output shafts
  • Overdrive clutch assembly
  • Forward and direct clutch packs
  • Low/reverse clutch
  • Intermediate clutch
  • Coast clutch
  • One-way clutches (sprag and roller)
  • Bands (intermediate and overdrive)
  • Valve body (hydraulic control center)
  • Shift solenoids (electronic shift control)
  • Transmission fluid temperature sensor
  • Transmission range sensor (TRS)
  • Pressure control solenoids
  • Speed sensors (input/output)
  • Wiring harness (internal)

External/Serviceable Components:

  • Transmission fluid pan
  • Dipstick and filler tube
  • External transmission cooler and lines
  • Transmission mount
  • Bellhousing (integrated)
  • Output shaft yoke/flange
  • Fluid filter and gasket
  • Seals (front pump, input, output)
  • Vent tube
  • Transmission control module (TCM)

ZF S6-650 Manual Transmission (6-speed)

Paired with: 6.4L Power Stroke Diesel in fleet/commercial builds or chassis cabs.

Internal Components

  • Input shaft
  • Mainshaft (output shaft)
  • Countershaft
  • 6 gearsets + reverse
  • Synchro assemblies (6 total)
  • Synchronizer rings
  • Bearings
  • Shift rails and forks
  • Detent mechanisms
  • Reverse idler gear
  • Oil channels and guides

External/Serviceable Components:

  • Shift tower and stick
  • Clutch slave cylinder (external or concentric)
  • Transmission case
  • Fill and drain plugs
  • Vent tube
  • Output flange/yoke
  • Bellhousing
  • Seals (input/output)
  • Speed sensor

Transmission Maintenance

For the Gen 2 Ford F-250 Super Duty (2008–2010), the recommended maintenance intervals for both manual and automatic transmissions were generally outlined in the owner’s manual, but specific recommendations can vary slightly depending on the model year and driving conditions. Below are the typical maintenance intervals for the transmission types:

Automatic Transmission 5R110W TorqShift 5-Speed (Diesel Models)

Recommended Maintenance Intervals:

  • Fluid & filter change: Every 30,000 miles under severe duty (towing, off-road, high heat), or 60,000 miles under normal driving.
  • Check fluid level/condition: At every oil change or 5,000 miles.
  • Flush: Optional, but usually at 100,000 miles, only if fluid condition is poor or contaminated.

Fluid Type:

Motorcraft MERCON SP Automatic Transmission Fluid
(Do NOT substitute with MERCON V or LV)

Notes:

  • Always use the factory filter and fluid for longevity.
  • Don’t overfill—check level at operating temperature, with engine running and shifter in “Park”.
  • If towing frequently, consider an auxiliary transmission cooler to reduce heat stress.

ZF S6-650 6-Speed Manual Transmission (Diesel Fleets/Chassis Cabs)

Recommended Maintenance Intervals:

  • Fluid check: Every 15,000 miles
  • Fluid change: Every 60,000 miles under normal conditions, or 30,000 miles for towing/harsh environments.

Fluid Type:

Motorcraft Full Synthetic Manual Transmission Fluid
(SAE 75W-90, API GL-4 or GL-5 depending on model year specs)
(Check exact spec per build sheet or manual)

Notes:

  • Avoid using GL-5 fluids with high sulfur content if they aren’t specifically rated for synchros.
  • Watch for signs of gear grinding or difficulty engaging gears as early signs of fluid degradation.

Parts Prone to Fail

The Ford F-250 Super Duty, especially in the Gen 2 (2008–2010) models, had several known transmission maintenance issues across both automatic and manual transmissions. These issues varied depending on the transmission type and how the truck was used (e.g., heavy towing vs. light duty). Below is a list of common issues and concerns:

5R110W Transmission (Automatic)

The 5R110W is known for its heavy-duty performance, but certain components are more prone to failure over time, especially under high stress (towing, off-roading, etc.):

Torque Converter

  • Common Failure Mode: The torque converter can fail due to overheating or internal damage, leading to a slipping feeling, rough shifting, or shuddering.
  • Symptoms of Failure: You may notice shuddering during acceleration or deceleration, rough shifting, or slipping during high load conditions like towing.

Solenoids (Shift Solenoids)

  • Common Failure Mode: Solenoids control the transmission fluid flow, and they can fail due to electrical issues, clogging, or wear. When they fail, it can cause erratic or harsh shifting.
  • Symptoms of Failure: Harsh or delayed shifts, failure to engage certain gears, or difficulty shifting at all.

Pump Assembly

  • Common Failure Mode: The transmission pump could fail due to excessive wear, typically caused by dirty or low fluid levels, which reduces fluid pressure and prevents proper function.
  • Symptoms of Failure: Slipping, erratic shifting, overheating, or a whining noise coming from the transmission.

Valve Body

  • Common Failure Mode: The valve body, which regulates the flow of transmission fluid to various parts of the transmission, can become clogged or develop leaks.
  • Symptoms of Failure: Harsh shifting, slipping, or failure to engage certain gears.

Clutch Packs and Bands

  • Common Failure Mode: The clutch packs and bands can wear down over time, especially under heavy towing or load conditions, leading to a loss of friction and engagement.
  • Symptoms of Failure: Slipping or delayed shifts, especially during acceleration or deceleration.

Transmission Fluid Cooler Lines and Cooler

  • Common Failure Mode: Leaks can develop in the cooler lines or the transmission cooler itself, resulting in fluid loss and overheating.
  • Symptoms of Failure: A noticeable drop in transmission fluid, overheating, or slipping.

Transmission Pan Gasket and Seals

  • Common Failure Mode: The seals and gaskets can deteriorate over time, leading to fluid leaks.
  • Symptoms of Failure: Fluid leakage under the vehicle, low fluid levels, or erratic shifting.

ZF S6-650 Transmission (Manual)

The ZF S6-650 is a 6-speed manual transmission known for its durability, but it also has some components that are prone to failure over time, particularly under heavy load and aggressive driving.

Clutch

  • Common Failure Mode: The clutch can wear out over time, especially if subjected to excessive load or driving conditions such as towing or aggressive shifting.
  • Symptoms of Failure: Slipping clutch, difficulty engaging gears, or a spongy clutch pedal.

Slave Cylinder

  • Common Failure Mode: The slave cylinder is responsible for disengaging the clutch. Over time, it can develop leaks or fail entirely.
  • Symptoms of Failure: Difficulty engaging or disengaging the clutch, soft or spongy clutch pedal feel, or fluid leakage around the transmission area.

Input Shaft Bearing

  • Common Failure Mode: The input shaft bearing can wear out, causing a whining noise when the clutch is disengaged. This often happens due to poor maintenance or overloading.
  • Symptoms of Failure: A whining or grinding noise when the clutch is disengaged, difficulty engaging gears, or grinding during gear shifts.

Shift Forks

  • Common Failure Mode: The shift forks can wear out over time, especially under heavy use, and may cause misalignment or difficulty shifting.
  • Symptoms of Failure: Grinding noises during shifting, difficulty engaging or staying in gear, or poor gear selection.

Shift Linkage and Bushings

  • Common Failure Mode: The shift linkage can become worn, leading to loose or sloppy shifting. The bushings on the linkage can degrade over time.
  • Symptoms of Failure: Sloppy, loose feeling when shifting, difficulty engaging gears, or the transmission popping out of gear.

Output Shaft

  • Common Failure Mode: The output shaft can fail due to excessive torque or stress, especially when towing heavy loads or under aggressive driving conditions.
  • Symptoms of Failure: Vibration or shaking under load, noisy operation, or complete loss of power to the wheels.

Syncros

  • Common Failure Mode: The synchros, which help engage the gears smoothly, can wear out or fail over time due to high miles or improper shifting technique.
  • Symptoms of Failure: Grinding noises when shifting, difficulty shifting into certain gears, or gear popping.

Checking Fluid Levels

Here are the step-by-step instructions for checking the fluid levels on both the 5R110W (automatic) and the ZF S6-650 (manual) transmissions used in Ford F-250 Super Duty trucks.

Checking Fluid Levels on the 5R110W Transmission (Automatic)

Tools You Will Need:

  • Transmission fluid dipstick (for the 5R110W)
  • Funnel (if adding fluid)
  • Clean rag or paper towels

Step-by-Step Instructions:
1.Park the Vehicle on a Level Surface
Ensure the truck is parked on flat, level ground. This ensures you get an accurate reading.

2.Warm Up the Transmission

  • Start the engine and let it idle for at least 5 minutes. The transmission fluid needs to be at operating temperature for an accurate reading.
  • Shift through all gears (P, R, N, D) and then place the truck back in Park.

3.Locate the Transmission Dipstick

  • For the 5R110W transmission, the dipstick is typically located towards the back of the engine bay, near the engine block.
  • It should be labeled with a red or yellow handle for easy identification.

4.Remove and Clean the Dipstick
Pull out the dipstick and wipe it clean with a rag or paper towel to remove any excess fluid.

5.Reinsert the Dipstick Fully
Insert the dipstick back into the tube all the way, then pull it back out to check the fluid level.

6.Check Fluid Level

  • Look at the fluid level on the dipstick. There will be two marks: “Full” and “Add.” The fluid level should fall between these marks.
  • If the fluid is low, you’ll need to add the correct type of transmission fluid.

7.Inspect Fluid Condition

  • Healthy transmission fluid should be a bright red or pink color. If the fluid looks brown, dark, or smells burnt, it’s time for a fluid change.
  • If the fluid level is correct but the fluid appears bad, consider replacing the fluid and filter.

8.Add Fluid if Necessary

  • If the fluid is low, use a funnel to add the recommended fluid (Ford Motorcraft Mercon LV ATF) until the level reaches the “Full” mark.
  • Recheck the fluid level after adding, and make sure it’s within the acceptable range.

9.Reinsert the Dipstick
Once you’re done, fully reinsert the dipstick back into the tube.

Checking Fluid Levels on the ZF S6-650 Transmission (Manual)

Tools You Will Need:

  • Wrench or socket set
  • Clean rag or paper towels
  • Transmission fluid (if topping off)
  • Jack and jack stands (if needed)

Step-by-Step Instructions:
1.Park the Vehicle on a Level Surface
Park the truck on level ground to ensure accurate fluid reading.

2.Lift the Truck (If Necessary)
If the fill plug is not easily accessible, use a jack to lift the front end of the truck and secure it with jack stands. Ensure the vehicle is stable before working underneath.

3.Locate the Fill Plug

  • The ZF S6-650 has a fill plug on the side of the transmission housing, typically near the middle of the transmission.
  • It’s usually a large bolt that is marked for easy identification.

4.Remove the Fill Plug

  • Use a wrench or socket to remove the fill plug. You may need a bit of force if the plug is tight or rusty.
  • Keep a rag or container handy to catch any fluid that might spill out.

5.Check Fluid Level

  • Stick your finger into the fill hole. The fluid should be level with the bottom of the hole. If the fluid is low, you will need to add more.
  • If you can’t feel any fluid at the bottom of the hole, the fluid is low.

6.Inspect Fluid Condition
The fluid should be light red or amber and should not smell burnt. If it looks dark or has a burnt odor, it’s time to change the fluid.

7.Top Off Fluid if Necessary

  • If the fluid is low, add the recommended ZF S6-650 transmission fluid using a funnel and tube. Use the correct type of manual transmission fluid (MTF) as recommended by Ford.
  • Be sure not to overfill, as this can cause issues with shifting and damage the seals.

8.Reinstall the Fill Plug
Once the fluid is at the correct level, reinstall the fill plug. Make sure it’s tightly secured.

9.Check for Leaks
After adding fluid and reinstalling the plug, check for any leaks around the fill plug and under the truck to ensure the transmission is sealed properly.

Fluids & Filters

5R110W Transmission (Automatic)

Recommended Fluid:

Type: Mercon LV Automatic Transmission Fluid (ATF)

  • This is the recommended fluid type for the 5R110W transmission, as it is specially formulated for Ford’s automatic transmissions.
  • Capacity: Approx. 12-13 quarts, but always check the specific vehicle manual or dipstick for the exact capacity.

Important Notes:

  • Do NOT use Mercon V or any other fluid that isn’t Mercon LV. Using the wrong fluid type can cause severe damage to the transmission.
  • It is highly recommended to use Ford Motorcraft Mercon LV fluid to ensure compatibility with the 5R110W transmission.

Recommended Filter:

Transmission Fluid Filter (part number: F81Z-7A098-AA or 4C3Z-7A098-AA)

  • The filter is located inside the pan and helps catch any contaminants in the fluid.
  • It’s advisable to replace the filter when performing a fluid change to ensure proper filtration and smooth operation.

ZF S6-650 Transmission (Manual)

Recommended Fluid:

Type: ZF S6-650 Manual Transmission Fluid (MTF)

  • This specific fluid is designed for the ZF S6-650 manual transmission to provide smooth shifting and long-lasting protection.
  • Capacity: Typically around 2.5 – 3 quarts, but it’s always a good idea to check your vehicle’s manual or fill plug to ensure the correct amount of fluid is used.

Important Notes:

  • Do NOT use automatic transmission fluid (ATF) in the ZF S6-650. Manual transmission fluid (MTF) is required for proper performance and longevity.
  • ZF 75W-90 or similar synthetic transmission oils that meet the correct viscosity and performance requirements are suitable as well.

Recommended Filter:
Manual Transmission Filter (Typically, the ZF S6-650 does not use a traditional filter like an automatic transmission, but it is a good idea to inspect the transmission housing for debris and clean as needed during a fluid change.)

Note: While the ZF S6-650 does not use a filter in the same way automatic transmissions do, it is important to maintain clean fluid and replace the fluid at regular intervals (every 30,000 to 60,000 miles, or as recommended) to prevent contamination and ensure smooth shifting.

Signs You Need Service

5R110W (Automatic) Transmission:

Slipping or Delayed Shifting

  • What to look for: If the transmission slips between gears or delays in shifting (especially when accelerating), it could be a sign of low fluid, a faulty solenoid, or internal wear.
  • Action: Check fluid levels and condition. If the fluid is low or dirty, perform a fluid change. If the issue persists, it might be a sign of a more serious internal issue requiring further inspection.

Harsh or Rough Shifting

  • What to look for: Hard, jerky, or rough shifts between gears, which could indicate a problem with the solenoids, valve body, or friction components inside the transmission.
  • Action: A fluid change and filter replacement may help, but if the issue continues, the transmission control module (TCM) or internal components might need inspection.

Grinding or Unusual Noises

  • What to look for: Grinding noises when shifting gears or when the truck is in gear could be a sign of internal component failure, such as worn bearings, gears, or clutch packs.
  • Action: Immediately check the fluid level and condition; if it’s dark or burnt, replace the fluid and filter. If the noise continues, a more thorough inspection may be required.

Transmission Fluid Leaks

  • What to look for: Puddles of reddish fluid under the truck are a common sign of a transmission fluid leak. This could be due to a bad seal, gasket, or transmission cooler line.
  • Action: Inspect the seals and hoses for leaks. Replace damaged parts and refill the fluid. If you continue to lose fluid, the transmission might require more serious repairs.

Overheating

  • What to look for: Overheating signs include a burnt smell in the fluid, the temperature gauge running high, or slipping when the truck is under load (e.g., towing).
  • Action: Check the fluid level and condition. If the fluid is burnt or low, change it immediately. Make sure the transmission cooler is functioning correctly.

Check Engine Light or Transmission Warning Light

  • What to look for: If the transmission warning light or check engine light comes on, it could indicate a problem with the transmission control system, solenoids, or sensors.
  • Action: Use an OBD-II scanner to read any stored trouble codes. Based on the code, you may need to service the transmission or replace faulty sensors.

ZF S6-650 (Manual) Transmission:

Difficulty Shifting Gears

  • What to look for: If you experience resistance or difficulty when shifting, particularly into higher gears, this could be due to low fluid, worn synchronizers, or a problem with the clutch.
  • Action: Check the transmission fluid level. If it’s low or dirty, top off or change the fluid. If the issue persists, inspect the clutch system (master/slave cylinder, release bearing) for any problems.

Grinding Noises

  • What to look for: Grinding noises when shifting gears or when the truck is in gear could indicate worn synchronizers, damaged gears, or low fluid.
  • Action: Change the fluid and inspect the synchros and gears for damage. If the problem is severe, internal transmission parts might need replacement.

Clutch Pedal Issues
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  • What to look for: If the clutch pedal feels spongy, soft, or requires more effort to press, it could indicate a hydraulic issue (e.g., low fluid in the clutch master cylinder, air in the lines, or worn components).
  • Action: Inspect the clutch system for leaks or air bubbles. Bleed the hydraulic system or replace the clutch fluid if needed. If the issue persists, the clutch slave/master cylinder might need replacing.

Transmission Fluid Leaks

  • What to look for: Leaking transmission fluid can occur due to faulty seals or gaskets. This can cause low fluid levels and lead to internal damage if not addressed.
  • Action: Inspect the seals, gaskets, and drain plugs for leaks. Replace any damaged parts and top off the fluid.

Hard or Jerky Engagement

  • What to look for: If the transmission has trouble engaging smoothly when shifting into gear or the truck jerks when shifting, this could indicate an issue with the clutch, low fluid, or a worn synchro.
  • Action: Check fluid levels and condition. If the fluid is low or dirty, perform a fluid change. If the issue continues, inspect the clutch and synchros.

Unusual Noises When in Gear

  • What to look for: Any rattling, whining, or grinding noises while the truck is in gear could be a sign of bearing or gear wear, especially if the noise stops when the clutch is depressed.
  • Action: If noises persist after fluid change, the transmission may need to be inspected for worn bearings or gears, and internal components might need replacement.

Clutch Slippage

  • What to look for: If the engine revs but the truck doesn’t accelerate as expected, it could be a sign of a slipping clutch, which can be caused by worn-out clutch discs, pressure plates, or a malfunctioning hydraulic system.
  • Action: Inspect the clutch system for wear, and replace the clutch or hydraulic components if necessary.

For both the 5R110W and ZF S6-650 transmissions, regular maintenance (fluid changes, proper fluid levels) and early detection of symptoms (slipping, grinding, leaks) are key to ensuring longevity and preventing more expensive repairs. If you notice any of the signs mentioned above, it’s best to have your transmission inspected and serviced promptly.

Improving Reliability

Improving the reliability of your 5R110W (automatic) and ZF S6-650 (manual) transmissions in your Ford F-250 Super Duty involves a combination of regular maintenance, proper driving habits, and addressing any potential issues early on. Below are some specific actions you can take for each transmission to help prolong their lifespan and prevent common failures:

5R110W (Automatic) Transmission

Regular Fluid Changes

  • Why: Clean, fresh fluid helps maintain proper lubrication and cooling for internal components.
  • How: Change the transmission fluid and filter regularly—every 30,000 to 60,000 miles, depending on driving conditions (heavier towing or off-roading may require more frequent changes).
  • Tip: Use high-quality Ford-approved transmission fluid to ensure optimal performance.

Monitor Fluid Levels

  • Why: Low or dirty fluid can cause excessive wear on components, leading to overheating or slipping.
  • How: Regularly check fluid levels using the dipstick (if your model has one) or via the OBD-II system for newer models.
  • Tip: Top off the fluid as needed and inspect for leaks around the seals and cooler lines.

Upgrade the Transmission Cooler

  • Why: The 5R110W is prone to overheating, especially when towing heavy loads.
  • How: Consider upgrading to a high-performance transmission cooler or adding an auxiliary cooler if you frequently tow or drive in high-stress conditions.
  • Tip: Keep the transmission cooler lines free from debris and inspect them regularly.

Address Shifting Issues Early

  • Why: Delayed or harsh shifting can indicate problems with solenoids, valve body, or internal components.
  • How: If you notice rough shifts, delayed gear changes, or erratic behavior, have the solenoids and valve body checked early before internal damage occurs.
  • Tip: Using an OBD-II scanner to check for error codes can help pinpoint the exact issue.

Prevent Overheating

  • Why: The 5R110W transmission can overheat under heavy load, leading to serious damage.
  • How: Avoid excessive towing or load-bearing conditions in extreme temperatures. If your truck is used for heavy towing, consider using an auxiliary cooler and check for proper airflow to the cooler.
  • Tip: Keep an eye on the transmission temperature gauge if your truck has one, and take breaks during long-haul towing.

Regularly Inspect Seals and Gaskets

  • Why: Worn-out seals can cause fluid leaks, leading to low fluid levels and transmission issues.
  • How: Inspect seals and gaskets regularly and replace them at the first sign of wear or leakage.
  • Tip: If you notice puddles of red transmission fluid under your truck, address the issue immediately to prevent low fluid levels.

ZF S6-650 (Manual) Transmission

Regular Fluid Changes

  • Why: Like the 5R110W, clean fluid helps ensure proper lubrication and reduces wear on the gears and synchros.
  • How: Change the manual transmission fluid every 30,000 to 60,000 miles. Some drivers may prefer synthetic fluid for its higher performance, especially in extreme temperatures.
  • Tip: Always use the correct transmission fluid recommended for the ZF S6-650 to ensure optimal performance.

Check and Maintain Clutch System

  • Why: The clutch system (slave cylinder, master cylinder, release bearing) is critical to smooth operation of a manual transmission.
  • How: Inspect the clutch for smooth engagement and disengagement. If the clutch pedal feels soft, spongy, or if you experience difficulty shifting, have the clutch hydraulic system checked and bled.
  • Tip: Replace the clutch when it shows signs of excessive wear (e.g., slipping, difficulty engaging gears).

Avoid Riding the Clutch

  • Why: Riding the clutch (keeping the clutch partially engaged when driving) can lead to unnecessary wear on the clutch disc and pressure plate.
  • How: Always ensure you fully engage or disengage the clutch when shifting gears.
  • Tip: Avoid holding the clutch pedal down unnecessarily while driving (e.g., during long stops or on inclines).

Regularly Inspect the Shift Linkage

  • Why: Worn or loose shift linkages can cause poor shifting performance or difficulty engaging certain gears.
  • How: Inspect the shift linkage for any looseness, wear, or damage, and lubricate the components if necessary.
  • How: Inspect the shift linkage for any looseness, wear, or damage, and lubricate the components if necessary.
  • Tip: If you experience difficulty engaging or shifting into gears, inspect the linkage and adjust or replace worn parts.

Prevent Fluid Leaks

  • Why: Leaks can lead to low fluid levels, causing poor performance and even gear damage.
  • How: Regularly check for transmission fluid leaks around the seals, gaskets, and drain plugs.
  • Tip: If you notice fluid on the ground, inspect the transmission seals and gaskets and replace them promptly.

Avoid Overloading the Transmission

  • Why: Overloading the truck with heavy towing or off-roading stresses the transmission and clutch system.
  • How: Be mindful of your truck’s payload and towing capacity. Avoid excessive towing in extreme conditions that can overheat or wear down the clutch and transmission.
  • Tip: If you tow heavy loads regularly, consider installing a heavy-duty clutch or upgrading your transmission cooler.

Proper Driving Habits

  • Why: Aggressive driving can cause excessive wear on the manual transmission.
  • How: Avoid sudden starts, hard launches, and rapid downshifting. Smooth and controlled shifting helps preserve the transmission’s longevity.
  • Tip: Practice smooth throttle and clutch use, especially when driving in stop-and-go traffic or on inclines.

General Tips for Both Transmissions:

Avoid Towing Above Your Capacity

  • Why: Overloading your truck and towing beyond its capacity places a significant strain on the transmission, leading to premature wear and potential overheating.
  • How: Always adhere to the recommended towing capacity for your specific truck and use proper towing techniques.
  • Tip: If you tow heavy loads regularly, consider upgrading your transmission cooler and brakes to ensure smoother performance under load.

Keep the Truck Clean

  • Why: Dirt and grime can accumulate on transmission cooler lines and seals, leading to potential blockages or leaks.
  • How: Regularly clean the underside of your truck and keep the transmission area free from dirt and debris.
  • Tip: Regularly inspect for signs of leaks and any obstructions to airflow in the transmission cooler.

Use an OBD-II Scanner

  • Why: Regularly scanning your truck for error codes helps you catch transmission issues early.
  • How: If you notice any unusual behavior, such as shifting problems, perform a diagnostic scan to read trouble codes that could point to faulty solenoids, sensors, or internal components.
  • Tip: Use a high-quality OBD-II scanner for more detailed results, or have a professional perform the scan for you.

Replacement Costs

The average replacement costs for a Gen 2 Ford F-250 Super Duty transmission (covering model years 2008-2010) vary depending on several factors, including whether you’re replacing with a new, rebuilt, or used transmission, as well as labor costs, and the type of transmission in your truck.

Automatic Transmission (5R110W TorqShift)

New Transmission:

  • Price: $3,500 to $5,000
  • Details: A brand new automatic transmission will typically cost between $3,500 and $5,000, depending on whether it’s sourced directly from Ford or an aftermarket manufacturer. This price includes the cost of the transmission unit itself.

Rebuilt Transmission:

  • Price: $2,000 to $3,500
  • Details: Rebuilt transmissions are typically less expensive than new ones. Prices for these transmissions range from around $2,000 to $3,500, depending on the quality of the rebuild and warranty.

Used Transmission:

  • Price: $1,500 to $2,500
  • Details: A used transmission will be the most affordable option, though it may come with a shorter warranty and an increased risk of wear. Prices typically range from $1,500 to $2,500, depending on mileage and condition.

Labor Costs:

  • Price: $1,000 to $2,000
  • Details: Labor to remove and replace an automatic transmission generally takes between 8 and 12 hours, with labor rates ranging from $100 to $150 per hour, depending on the shop and location.

Total Cost (Parts + Labor):

  • New Transmission: $4,500 to $7,000
  • Rebuilt Transmission: $3,000 to $5,500
  • Used Transmission: $2,500 to $4,500

Manual Transmission ZF S6-650

New Transmission:

  • Price: $3,000 to $4,500
  • Details: A brand new manual transmission typically ranges from $3,000 to $4,500. These transmissions are generally more affordable than automatic ones, but you may find that they are less readily available from OEM sources.

Rebuilt Transmission:

  • Price: $2,000 to $3,500
  • Details: Rebuilt manual transmissions for the F-250 Super Duty will generally be less expensive than their new counterparts, ranging from about $2,000 to $3,500, depending on the shop and parts used.

Used Transmission:

  • Price: $1,200 to $2,000
  • Details: A used manual transmission may cost between $1,200 and $2,000, again depending on mileage, condition, and the source.

Labor Costs:

  • Price: $900 to $1,500
  • Details: Labor for a manual transmission replacement is typically a bit less than an automatic one due to simpler designs, but it will still take several hours (usually 6-10 hours). Labor costs will be in the range of $100 to $150 per hour.

Total Cost (Parts + Labor):

  • New Transmission: $3,900 to $6,000
  • Rebuilt Transmission: $2,900 to $5,000
  • Used Transmission: $2,100 to $3,500

Factors Affecting Costs:

  • Location: Labor rates can vary significantly based on geographic location (e.g., urban vs. rural areas). Shops in high-cost-of-living areas like New York or California may charge more for labor than those in other states.
  • Transmission Source: Choosing OEM (original equipment manufacturer) parts typically increases costs compared to aftermarket or rebuilt transmissions.
  • Additional Parts: If other components like the torque converter (automatic), clutch, flywheel, or seals need replacement, it will add to the total cost.
  • Warranty: A rebuilt or new transmission often comes with a warranty, typically ranging from 1 year to 5 years, which can add value to the investment.

Estimated Total Replacement Cost Summary:

Automatic Transmission (5R110W):

  • New: $4,500 to $7,000
  • Rebuilt: $3,000 to $5,500
  • Used: $2,500 to $4,500

Manual Transmission (ZF S6-650):

  • New: $3,900 to $6,000
  • Rebuilt: $2,900 to $5,000
  • Used: $2,100 to $3,500

The above costs are estimates and may vary depending on specific circumstances, such as the condition of your vehicle and where you source your parts and labor. Always get quotes from multiple shops to ensure you’re getting the best price for the work being done.