Improving the transmission in any vehicle is a sure-fire way to get all the power you're making down the path of the driveline and to the pavement. Beefing up your transmission is not only good for performance, but in the case of the 6.0L Power Stroke diesels, it is also key to making the transmission last while towing your race car, boat, or trailer.
Level 10 Performance Transmission Systems has stepped up to fill the void of beefing up the 5R110 transmission with its new PTS Stage 3 kit, better known as the Animal. The kit contains Animal clutches, which hold extra power without burning up; a solenoid that firms up the shifts; and a super pump to flow more transmission fluid to cool the tranny. The keys to the kit, however, are the billet torque converter and programmer with a custom Level 10 tune.
 The first thing you do with...  The first thing you do with any transmission rebuild or upgrade is remove it from the vehicle. To do this, we removed the driveshaft, unbolted the starter and got it out of the way, then loosened up the bellhousing bolts, trans lines, electrical connections, and crossmember before lowering it with a jack. |  With the trans out of the...  With the trans out of the truck, it was off to the bench where we'd gut it and beef it up with better clutches, a higher-volume pump, and a better solenoid. Take a long look at the stock converter because it won't be on the trans when it's reinstalled. |  We'll be replacing the stock...  We'll be replacing the stock converter with a billet one, so we took off the converter before we put the trans on the shelf. Be careful when pulling off the converter because it's filled with transmission fluid that could spill out and make a mess. |
 When the trans made it to...  When the trans made it to the bench, the first thing we did was take off the input and output sensors on top of the case. |  To get to the pan and valvebody,...  To get to the pan and valvebody, we had to flip the trans on its side. If you leave the sensors on, they could break when you flip over the transmission. |  Next, disconnect all the valvebody's...  Next, disconnect all the valvebody's wires. Once unclipped, hit the valvebody bolts with an impact wrench, then carefully take it off. |
"The problem with upgrading the transmission internals and not the converter is that the converter will slip more with more power you put through it," says Level 10's Pat Barrett. "The converter flat-lines at 2,800 rpm, for example, and it doesn't matter if you put 500 lb-ft of torque or 1,000 lb-ft of torque through it at that point. It will slip and keep the torque level constant. At that point, you are wasting power."
 Before we turned over the...  Before we turned over the trans, we decided to take off the pump. Once we had the bolts out, we used a specialty puller to remove it. If using the puller, go slowly and be careful because you could crack the pump. Even though we were going to replace the pump, we still wanted to keep it in one piece. |  Next up was removal of the...  Next up was removal of the pan to get at the valvebody. While not included in the Stage 3 Animal kit, the Level 10 deep pan is a good item to pick up and install. Our truck already had one installed, but even if it didn't, we would have put one on. The pan gives the case strength, which reduces flex in the case itself. It also has a magnetic drain plug to make fluid changes easy, and it holds a few extra quarts of transmission fluid, improving the longevity of the trans. |  The super pump (top left),...  The super pump (top left), the super solenoid (bottom left), and the Animal clutches were put into the transmission. These components team up to ensure the trans's reliability and to handle the higher power level of the truck's 6.0L Power Stroke. |
The converter that comes with the Stage 3 Animal kit has a lower stall speed. This lowered stall speed is used to calibrate the computer for the truck's use and to compensate for modifications done to the engine to improve power. That way, you get all the power through the converter and down the line.
 With the valvebody out, you...  With the valvebody out, you can right the trans and start taking out the innards. Remove the sprag first, then the input shaft and the clutch packs. We replaced the clutches in each of the clutch packs, so everything was taken out. |  Once the case was empty, we...  Once the case was empty, we cleaned it up. After we used some mineral spirits and flushed out all the trans fluid we could, we wiped down the case with a lint-free rag. A paper towel would also work in this scenario. |  With the clutch packs installed,...  With the clutch packs installed, it was time to install the pump. We replaced the factory pump with the super pump. Once it was in place, we tightened the bolts before torquing them down (Ford recommends 20 lb-ft). |
The programmer is the other key component to the kit. "In the past, you bought a valvebody or a shift kit to firm and calibrate shifts," Barrett says. "Nowadays, all the transmissions are electronically controlled through the computer-not of manual origin like a C6 tranny, for example. With today's transmissions, all the calibration has to be done through the computer. If you have a special use for your truck or have added power, you must have the computer reprogrammed for better driveability, performance, and durability. Also, what people fail to realize is that when you reprogram the computer, you cannot go out there and hammer the truck. You need to have the truck shift through 20 light shifts before the computer learns the programs. By going out there and planting the throttle right after the tune is uploaded, premature wear of components (particularly the clutches) occurs, and durability and reliability are diminished."
 With everything cleaned out,...  With everything cleaned out, it was time for the clutch packs to go back in. Before we put each pack in, we replaced the stock parts with the new Animal clutches. Once they were swapped, we put the clutch packs in the case. Make sure each pack goes all the way down into the case. A few tips here: First, when you have the first clutch pack in, install the input shaft because it will be a guide to getting each clutch pack in the right position. Second, keep a tight grip on the packs so they do not fall apart as you install them. Once all the clutch packs are in place, spin the input shaft to make sure everything turns freely. |  Next, we reinstalled the valvebody....  Next, we reinstalled the valvebody. Before we did, we had to reinstall and torque down the center support feed bolts. Once we torqued them down to 24 lb-in, the valvebody was slapped on and we torqued them to 89 lb-in. Before we put the valvebody on, we switched the factory solenoid for the super solenoid. This is a much easier task to perform when the valvebody is off the trans. Also, when you put the valvebody back on, don't forget to hook up all the electrical connections you undid when you took it off. If you don't, the computer won't recognize the transmission changing gears from Park to Reverse or Drive, and you won't be going anywhere. |  When we finished reassembling...  When we finished reassembling the transmission, we rolled it underneath the truck, which was still on the lift in the Level 10 shop. Before we started putting it back in, we installed the billet torque converter. In preparation for installing it, we used a sander to take off the paint around the snout of the converter, then filled it with 1 quart of transmission fluid. When the converter was filled, we quickly pushed the converter on the input shaft, lined it up, and jiggled it around to make sure it was all the way on. |
While you can buy a complete transmission with all the kit's components, we decided to take a 500-mile-old '07 F-350 Lariat Super Duty equipped with the 6.0L Power Stroke and the 5R110 and rebuild the transmission. Follow along as we show you how to get it done.
 When the valvebody was on,...  When the valvebody was on, we cleaned up the pan and bolted it back on. Don't forget to put on a new gasket before you wrench down the pan. |  The final piece of the puzzle...  The final piece of the puzzle is the handheld tuner that's loaded with the accompanying tune. Level 10 custom-tunes the transmission settings in its shop then uploads them to the SCT tuner. |  When the trans install was...  When the trans install was complete, we dropped down the truck and loaded up the accompanying tune. Just like loading an engine tune, plug the tuner into the serial port under the dash and follow the instructions. When the tune is loaded, run the truck through around 20 light shifts, then hammer away. |
Tracking Down Trouble
Anytime the service-engine-soon light comes on, we know something is wrong with our truck. The problem is, unless you have a diagnostic tool, it's a guess as to why the light came on. Thanks to Level 10, you can dial up its Web site (www.level10power.net) and check out what some codes mean when you do run a diagnostic check.