Complete removal and reinstallation of the 6R80 automatic transmission from a 2011-2014 Ford F-150 with 3.5L EcoBoost engine and 4WD.

Warnings

Tools required

Parts

• Transmission pan gasket or RTV sealant × 1 — Use OEM specification
• Transmission filter (if servicing) × 1 — Motorcraft FT-195
• Crush washers for drain plug × 2 — Use OEM specification
• Flywheel bolts (if TTY) × 8 — Check for stretch before reuse
• Transfer case gasket/seal × 1 — Use OEM specification
• Transmission cooler line O-rings × 4 — Use OEM specification

Fluids

• Motorcraft MERCON LV ATF — 11 qt
• Motorcraft Transfer Case Fluid — 2.5 qt

Preparation

1. Disconnect negative battery cable and wait 5 minutes for airbag system to discharge
2. Raise vehicle on lift or securely support on jack stands at manufacturer specified lift points
3. Remove skid plates and exhaust heat shields if equipped
4. Drain transmission fluid via drain plug using new crush washer on reinstallation
5. Remove both front wheels to access crossmember bolts
6. Install engine support bar across engine bay or attach hoist to engine lift points to support engine weight

Procedure

1. 1

   Remove exhaust components
   Disconnect both catalytic converters from exhaust manifolds. Remove Y-pipe assembly from behind transmission crossmember. On EcoBoost models, take care not to damage oxygen sensor wiring or turbocharger downpipes. Support exhaust components to prevent damage during removal.
2. 2

   Remove transfer case
   Disconnect front and rear driveshafts at transfer case flanges, marking orientation. Remove transfer case shift motor electrical connector. Disconnect vent hose. Support transfer case with jack and remove mounting bolts. Carefully separate transfer case from transmission extension housing. Drain remaining fluid into pan.
   Torque spec

   Mounting Bolts31 Nm (23 lb-ft)
3. 3

   Disconnect transmission cooler lines and electrical connections
   Using line wrenches, disconnect transmission cooler lines at transmission fittings. Cap all openings immediately to prevent contamination. Disconnect transmission range sensor, turbine shaft speed sensor, output shaft speed sensor, and solenoid body electrical connectors. Remove wiring harness from retaining clips along transmission case.
4. 4

   Remove torque converter access cover and mark converter
   Remove torque converter inspection cover from bellhousing. Mark torque converter to flexplate relationship with paint pen. Rotate crankshaft using 22mm socket on crankshaft bolt to access all converter-to-flexplate bolts through inspection opening. Remove all converter mounting bolts.
   Torque spec

   Cover Screws12 Nm (9 lb-ft)

   Flywheel Bolts95 Nm (70 lb-ft)
5. 5

   Support transmission and remove crossmember
   Position transmission jack under transmission pan with proper adapter. Secure transmission to jack with safety chains or straps. Remove rear transmission mount bolts. Remove transmission crossmember mounting bolts and carefully lower crossmember away from vehicle. Support weight of transmission on jack.
   ⚠️Transmission must be securely strapped to jack before removing crossmember. Weight shift can cause transmission to fall.
   Torque spec

   Mounting Bolts31 Nm (23 lb-ft)
6. 6

   Disconnect shift linkage and starter
   Disconnect shift cable from transmission manual lever. Remove shift cable bracket from transmission case. Remove starter motor mounting bolts and secure starter aside without disconnecting battery cable. On EcoBoost models, starter is accessed from underneath.
7. 7

   Remove transmission-to-engine mounting bolts
   Remove dust cover if not already removed. Locate and remove all transmission-to-engine mounting bolts. EcoBoost models typically have 8-10 bolts of varying lengths. Note bolt locations as lengths differ. Remove upper bellhousing bolts last while ensuring transmission is fully supported on jack.
   ⚠Upper and lower bellhousing bolts are different lengths. Mark or organize bolts by location for correct reinstallation.
   Torque spec

   Mounting Bolts31 Nm (23 lb-ft)
8. 8

   Separate transmission from engine
   Verify all connections are removed. Using transmission jack, carefully slide transmission straight back from engine, ensuring torque converter remains fully seated in transmission pump. Move slowly and keep transmission level. Once input shaft clears bellhousing, lower transmission jack and remove from under vehicle. Keep torque converter tilted upward to prevent falling out.
   ⚠️Transmission weighs over 215 lbs. Ensure secure footing and adequate clearance when lowering. Have assistant help guide transmission if possible.
   ⚠Torque converter must stay engaged in pump during removal. If converter slides forward, it will dump fluid and require reseating before installation.
9. 9

   Inspect and prepare transmission for installation
   If installing remanufactured or used transmission, verify torque converter is fully seated by measuring from bellhousing mating surface to converter pilot - should be recessed approximately 11mm or more. Inspect flexplate for cracks or damaged ring gear teeth. Replace flywheel bolts if they are torque-to-yield type or show thread stretch. Clean all mating surfaces on engine block.
10. 10

    Install transmission to engine
    Apply small amount of high-temp grease to torque converter pilot hub. Ensure torque converter is fully seated in pump. Raise transmission into position, keeping level and aligned. Rotate converter to align with flexplate while sliding transmission forward. Do not allow transmission weight to hang on input shaft - keep supported with jack. Verify converter pilot engages flexplate center before mating bellhousing surfaces. Install all bellhousing bolts finger tight, then torque in sequence.
    ⚠Never draw transmission to engine using mounting bolts. Bellhousing should mate with minimal force if properly aligned.
    Torque spec

    Mounting Bolts31 Nm (23 lb-ft)
11. 11

    Install torque converter bolts and starter
    Align torque converter to flexplate using marks made during removal. Rotate crankshaft to access bolt holes through inspection cover. Install and torque all converter-to-flexplate bolts in star pattern. Reinstall starter motor and torque converter inspection cover.
    Torque spec

    Flywheel Bolts95 Nm (70 lb-ft)

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

    Reinstall crossmember and connect linkages
    Raise transmission slightly with jack to align with crossmember mounts. Install crossmember and torque all mounting bolts. Install rear transmission mount. Connect shift cable and adjust if necessary. Remove transmission jack once all mounts are secured.
    Torque spec

    Mounting Bolts31 Nm (23 lb-ft)
13. 13

    Reconnect electrical and cooler lines
    Install all electrical connectors to their original locations using reference marks. Route wiring harness through clips. Install new O-rings on transmission cooler line fittings, lubricate with ATF, and connect lines using line wrenches. Do not overtighten quick-connect fittings.
14. 14

    Reinstall transfer case
    Clean transfer case and transmission mating surfaces. Install new gasket or seal. Apply transfer case fluid to input splines. Align transfer case with transmission extension housing and install. Torque mounting bolts to specification. Connect shift motor, vent hose, and both driveshafts in their original orientation.
    Torque spec

    Mounting Bolts31 Nm (23 lb-ft)
15. 15

    Reinstall exhaust and fill fluids
    Reinstall Y-pipe and connect to catalytic converters using new gaskets. Install skid plates and heat shields. Install transmission drain plug with new crush washer. Fill transmission with correct amount of Motorcraft MERCON LV through dipstick tube or fill plug. Fill transfer case to specification. Reinstall wheels and torque lug nuts.
    Torque spec

    Transmission Drain Plug30 Nm (22 lb-ft)

Reassembly

1. Reconnect negative battery cable
2. Start engine and allow to idle, checking for leaks at all connection points
3. With engine at operating temperature and vehicle on level ground, shift through all gear ranges while holding brake
4. Check and adjust transmission fluid level per Ford procedure - fluid must be checked at specific temperature range
5. Road test vehicle to verify proper shifting in all gears and transfer case operation
6. Recheck fluid levels after road test and inspect for leaks

Verification

• Verify no fluid leaks from transmission pan, cooler lines, transfer case, or bellhousing
• Confirm transmission shifts smoothly through all gears without slipping or harsh engagement
• Verify proper operation of transfer case 4WD engagement and disengagement
• Check that shift indicator in instrument cluster matches actual gear position
• Verify no warning lights or transmission-related DTCs stored in system
• Confirm transmission fluid is at proper level when checked at operating temperature per manufacturer procedure

More procedures for this vehicle