Complete removal, disassembly, inspection, rebuild, and reinstallation of the 6R80 automatic transmission in a 2011-2014 Ford F-150 3.5L EcoBoost 4WD.

Warnings

Tools required

Parts

• 6R80 master rebuild kit × 1 — Use OEM or quality aftermarket kit
• Torque converter (remanufactured or new) × 1 — Verify stall speed for EcoBoost
• Transmission pan gasket × 1 — Reusable rubber or new
• Transmission filter × 1 — Internal filter
• Transfer case output shaft seal × 1 — Use OEM specification
• Front driveshaft CV boot (if damaged) × 1 — Inspect during removal
• Transmission cooler line O-rings × 4 — Use OEM specification
• Transmission mount × 1 — Replace if worn
• Flexplate bolts (if TTY) × 6 — Check for single-use designation
• Transmission drain plug crush washer × 1 — Use OEM specification

Fluids

• Motorcraft MERCON LV ATF — 14 qt
• Motorcraft Transfer Case Fluid — 2.5 qt

Preparation

1. Position vehicle on level surface and engage parking brake
2. Disconnect negative battery cable and wait 10 minutes for airbag system to discharge
3. Raise vehicle on lift or jack stands to comfortable working height (minimum 36 inches)
4. Remove skid plates and belly pans to access transmission
5. Drain transmission fluid from pan drain plug, then remove pan for complete drainage
6. Drain transfer case fluid into separate container
7. Remove front and rear driveshafts, marking orientation for reinstallation
8. Support engine with support bar across engine bay or overhead hoist
9. Clean work area and prepare transmission rebuild stand with all necessary tools and parts

Procedure

1. 1

   Disconnect transmission electrical and cooling connections
   Disconnect transmission range sensor connector, output shaft speed sensor, turbine shaft speed sensor, solenoid body connector, and transmission fluid temperature sensor. Label each connection. Disconnect and plug transmission cooler lines at transmission using line disconnect tools. Cap all openings immediately to prevent contamination.
2. 2

   Separate transfer case from transmission
   Remove transfer case mounting bolts and carefully separate transfer case from transmission. Support transfer case weight during removal. Inspect transfer case output shaft seal and replace if necessary. Set transfer case aside on clean surface.
   Torque spec

   Mounting Bolts70 Nm (52 lb-ft)
3. 3

   Remove transmission crossmember and mount
   Support transmission securely with transmission jack. Remove transmission mount bolts from crossmember and frame. Remove crossmember bolts and lower crossmember away from vehicle. Inspect transmission mount for damage or deterioration.
   ⚠️Transmission must be securely supported on jack before removing mount. Transmission can shift suddenly causing injury.
   Torque spec

   Mounting Bolts70 Nm (52 lb-ft)
4. 4

   Disconnect shift linkage and starter
   Disconnect shift cable from transmission manual lever and remove cable bracket bolts. Remove starter motor mounting bolts and position starter aside without disconnecting wiring. Access to flexplate bolts is through starter opening.
5. 5

   Remove torque converter and separate transmission from engine
   Mark flexplate-to-torque converter relationship for reinstallation. Remove flexplate bolts by rotating engine via crankshaft bolt. Ensure torque converter is fully pushed into transmission. Remove bell housing bolts and carefully slide transmission rearward on jack, ensuring torque converter stays with transmission. Lower transmission from vehicle.
   ⚠Torque converter contains approximately 2 quarts of fluid and weighs 40+ lbs. Secure with strap or holder to prevent falling during removal.
   Torque spec

   Flywheel Bolts95 Nm (70 lb-ft)
6. 6

   Mount transmission on rebuild stand and begin disassembly
   Secure transmission to rebuild stand. Remove transmission pan bolts in criss-cross pattern and remove pan. Remove filter and inspect for debris (metal particles indicate internal damage). Remove valve body bolts carefully noting different bolt lengths and locations. Remove valve body assembly and set aside on clean surface. Remove solenoid pack.
   ℹ️Photograph valve body bolt locations as they vary in length. Incorrect bolt placement can cause case damage.
   Torque spec

   Pan Bolts19 Nm (14 lb-ft)
7. 7

   Disassemble transmission case and remove clutch assemblies
   Remove pump assembly bolts and extract pump with slide hammer if necessary. Remove forward clutch assembly, intermediate clutch assembly, and reverse clutch assembly. Use dial indicator to measure end play of each component before removal. Remove snap rings retaining each clutch pack and carefully extract planetary gear sets. Keep components organized by location.
   ⚠Springs in clutch assemblies are under tension. Use appropriate spring compressor to prevent components from flying out.
8. 8

   Inspect and measure all components
   Inspect all clutch plates, steel plates, and friction surfaces for wear, burning, or glazing. Measure clutch pack clearances and compare to Ford specifications. Inspect all bushings for wear or scoring. Check all planetary gear teeth for damage. Inspect case for cracks or porosity. Check all fluid passages for blockage. Measure all bearing surfaces with micrometer. Replace any components not meeting specifications.
9. 9

   Clean and prepare components for reassembly
   Thoroughly clean all metal components in solvent. Blow out all case passages with compressed air. Clean valve body in dedicated solvent ensuring all passages are clear. Inspect valve body separator plate and gaskets for damage. Soak new clutch friction plates in MERCON LV for minimum 30 minutes before installation. Organize all new seals, gaskets, and wear components from rebuild kit.
10. 10

    Reassemble transmission internal components
    Install new bushings and seals in case using appropriate seal drivers. Lubricate all components with MERCON LV during assembly. Install planetary gear sets in correct order with new thrust washers. Install clutch assemblies with new friction plates, steel plates, and seals. Install snap rings ensuring full seating in grooves. Measure and verify clutch pack clearances meet Ford specifications using feeler gauges. Install pump assembly with new seal and gasket.
    ⚠Clutch plate installation order is critical. Forward clutch uses specific waved plate sequence. Refer to rebuild kit instructions.
11. 11

    Install valve body and solenoid pack
    Install new valve body gaskets and separator plate ensuring proper alignment. Install solenoid pack with new O-rings and seals. Carefully install valve body assembly ensuring manual valve aligns with detent lever. Install valve body bolts in correct locations and torque in sequence from center outward. Install new transmission filter. Verify all check balls are in correct locations per service manual.
    Torque spec

    Sensor Bolts12 Nm (9 lb-ft)

    Cover Screws12 Nm (9 lb-ft)
12. 12

    Install transmission pan and prepare for installation
    Clean pan mating surface thoroughly. Install new pan gasket or apply RTV sealant per Ford specifications. Install pan and torque bolts in criss-cross pattern. Install and torque drain plug with new crush washer. Verify all electrical connectors are clean and undamaged. Install new torque converter with fresh fluid, ensuring proper engagement (should click three times as it seats into pump, stator support, and input shaft).
    ⚠Verify torque converter is fully seated by measuring from bell housing face to converter mounting lug. Should be minimum 0.75 inches recessed.
    Torque spec

    Pan Bolts19 Nm (14 lb-ft)

    Transmission Drain Plug30 Nm (22 lb-ft)
13. 13

    Install transmission into vehicle
    Raise transmission into position using transmission jack. Align torque converter with flexplate marks made during removal. Slide transmission forward onto engine, ensuring alignment dowels engage properly. Install bell housing bolts and torque to specification. Rotate engine and install flexplate bolts in star pattern to specification. Install starter motor.
    Torque spec

    Mounting Bolts70 Nm (52 lb-ft)

    Flywheel Bolts95 Nm (70 lb-ft)
14. 14

    Reconnect all systems and install transfer case
    Install transmission mount and crossmember, torquing bolts to specification. Connect shift cable and adjust per Ford procedure. Reconnect all electrical connectors ensuring positive engagement. Install new O-rings on cooler lines and connect to transmission. Install transfer case with new output shaft seal, torquing mounting bolts to specification. Refill transfer case with Motorcraft Transfer Case Fluid to proper level.
    ℹ️Transfer case bolts have different torque values. Verify which bolts use 23 lb-ft versus 52 lb-ft specification.
    Torque spec

    Mounting Bolts70 Nm (52 lb-ft)
15. 15

    Fill transmission and perform initial startup procedure
    Add approximately 6 quarts MERCON LV through dipstick tube. Start engine and allow to idle. With foot on brake, shift through all gear ranges, pausing 3 seconds in each. Return to Park. Check fluid level with engine running and at operating temperature. Add fluid to bring level into crosshatch area. Total capacity is approximately 14 quarts including torque converter and cooler. Use scan tool to perform transmission relearn procedure per Ford IDS instructions. Check for leaks at all connections.

Reassembly

1. Install front and rear driveshafts in original orientation, torquing U-joint straps and CV flange bolts to specification
2. Install skid plates and belly pans
3. Reconnect negative battery cable
4. Lower vehicle to ground

Verification

• Verify no fluid leaks at pan, cooler lines, transfer case junction, or front pump seal after initial startup
• Perform test drive including multiple acceleration and deceleration cycles through all gears
• Verify smooth shifts in all ranges without slipping, flaring, or harsh engagement
• Check for proper shift points and verify speedometer accuracy
• Monitor transmission fluid temperature during test drive (should not exceed 200°F under normal driving)
• Recheck fluid level after test drive with transmission at operating temperature
• Use scan tool to verify no transmission-related DTCs are present
• Verify proper Park pawl engagement by attempting to push vehicle while in Park on incline

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