Complete removal and replacement of the crankshaft on a 2011-2014 Ford F-150 3.5L EcoBoost, requiring engine removal, complete disassembly, and precision reassembly with new bearings and seals.

Warnings

Tools required

Parts

• Crankshaft (remanufactured or new) × 1 — Use OEM Ford specification
• Main bearing set (standard or oversized as measured) × 1 — Mahle or Clevite OEM equivalent
• Connecting rod bearing set (standard or oversized as measured) × 1 — Mahle or Clevite OEM equivalent
• Thrust bearing set × 1 — Use OEM specification
• Front crankshaft seal × 1 — Use OEM Ford seal
• Rear main seal × 1 — Use OEM Ford seal
• Timing chain kit (complete with tensioners and guides) × 1 — Use OEM Ford EcoBoost kit
• Oil pump (recommended replacement) × 1 — Use OEM specification
• Oil pan gasket × 1 — Use OEM Ford gasket
• Timing cover gasket × 1 — Use OEM Ford gasket
• Cylinder head gasket set × 1 — Fel-Pro or OEM Ford
• Valve cover gaskets × 2 — Use OEM Ford gaskets
• Water pump gasket or O-rings × 1 — Use OEM specification
• Intake manifold gasket set × 1 — Use OEM Ford gaskets
• Exhaust manifold gaskets × 2 — Use OEM Ford gaskets
• Turbocharger mounting gaskets × 2 — Use OEM Ford gaskets
• Oil filter × 1 — Motorcraft FL-500S or equivalent
• Oil drain plug crush washer × 1 — Use OEM specification
• Main bearing cap bolts (TTY) × 1 — Use OEM Ford bolts
• Connecting rod bolts (TTY) × 1 — Use OEM Ford bolts
• Cylinder head bolts (TTY) × 1 — Use OEM Ford bolts
• Harmonic balancer bolt (TTY) × 1 — Use OEM Ford bolt
• Flexplate bolts (if automatic) × 1 — Use OEM Ford bolts
• RTV silicone sealant (Motorcraft TA-357) × 2 — Motorcraft TA-357
• Engine assembly lubricant × 1 — Motorcraft XL-3 or equivalent

Fluids

• Motorcraft 5W-20 Synthetic Blend engine oil — 6 qt
• Motorcraft Orange Coolant — 13 qt
• Motorcraft MERCON LV ATF (if drained) — 11 qt
• Motorcraft Transfer Case Fluid (if drained) — 2.5 qt
• Motorcraft 75W-140 Synthetic Gear Oil (rear diff) — 2 qt
• 75W-90 GL-5 Gear Oil (front diff) — 1.5 qt

Preparation

1. Park vehicle on level surface, set parking brake, and place wheel chocks at all four wheels
2. Disconnect both battery terminals (negative first) and remove battery
3. Drain engine oil completely and remove oil filter
4. Drain cooling system at radiator petcock and block drain plugs
5. Recover A/C refrigerant using approved recovery equipment
6. Remove engine cover and air intake system completely
7. Remove both turbochargers with all associated piping and intercooler system
8. Raise and support vehicle on jack stands at frame rails, remove front wheels
9. Remove front skid plate and lower engine splash shields
10. Support transmission with transmission jack before removing engine mounts
11. Label and photograph all electrical connectors, vacuum lines, and hose connections for reassembly reference
12. Have clean workspace prepared for engine disassembly with organized parts storage

Procedure

1. 1

   Remove engine from vehicle
   Disconnect all engine wiring harnesses, fuel lines (relieve fuel pressure first), coolant hoses, power steering lines, A/C lines, and exhaust system at manifolds. Remove radiator and cooling fan assembly. Disconnect transmission cooler lines if automatic. Remove driveshaft and mark position for reinstallation. Support transmission with jack, then remove transmission-to-engine mounting bolts. Attach engine hoist with load leveler to lifting points on engine. Remove engine mount bolts and carefully lift engine from vehicle, tilting as needed to clear firewall and body. Transfer engine to engine stand and secure with grade 8 bolts.
   ⚠️Fuel system is under pressure. Relieve fuel pressure by removing fuel pump fuse and running engine until it stalls before disconnecting fuel lines.
   ⚠Engine weighs approximately 450 lbs. Use proper lifting equipment and have assistant guide engine during removal.
   Torque spec

   Transmission-to-Engine Bolts55 Nm (41 lb-ft)
2. 2

   Remove external engine components
   With engine on stand, remove alternator, A/C compressor (if still attached), power steering pump, starter motor, all accessory brackets, and wiring harnesses. Remove both valve covers, intake manifold assembly, fuel rail, and ignition coils. Remove exhaust manifolds if still attached. Remove water pump and thermostat housing. Remove oil filter housing and oil cooler assembly. Tag and store all hardware separately by component.
3. 3

   Remove cylinder heads
   Remove all cylinder head bolts in reverse of tightening sequence (consult Ford service manual for specific sequence). Use breaker bar as these are TTY bolts torqued to high specification. Carefully lift cylinder heads from block, using pry points if necessary (never pry between sealing surfaces). Place heads on clean surface with combustion chambers facing up. Remove and inspect head gaskets. Clean all gasket surfaces thoroughly but do not damage aluminum surfaces.
   ⚠Cylinder heads are heavy (approximately 40 lbs each). Get assistance when removing to avoid dropping and damaging valve train components.
   Torque spec

   Cylinder Head Bolts65 Nm (48 lb-ft)
4. 4

   Remove timing components
   Rotate engine to TDC on cylinder #1. Using crankshaft pulley holding tool, remove harmonic balancer bolt with breaker bar or impact wrench. Use harmonic balancer puller to remove balancer from crankshaft snout. Remove timing cover bolts in sequence and carefully remove timing cover (may require gentle prying). Remove timing chain tensioners (both primary and secondary). Remove timing chain guides. Remove timing chains from crankshaft and camshaft sprockets. Remove crankshaft timing gear. Inspect all timing components for wear and replace as needed.
   ℹ️Mark timing chain orientation and sprocket positions with paint marker before removal for reference during reassembly.
   Torque spec

   Harmonic Balancer Bolt180 Nm (133 lb-ft)

   Cover Bolts19 Nm (14 lb-ft)

   Timing Chain Tensioner Bolt25 Nm (18 lb-ft)

   Timing Chain Guide Bolts12 Nm (9 lb-ft)
5. 5

   Remove oil pan and oil pump
   Remove all oil pan bolts in crisscross pattern. Carefully break oil pan seal using gasket scraper or thin pry tool at designated pry points. Remove oil pan and gasket. Remove oil pump pickup tube bolts and remove pickup tube. Remove oil pump mounting bolts and remove oil pump assembly from front of engine block. Inspect oil pump for wear; replacement is strongly recommended during crankshaft R&R.
   Torque spec

   Oil Pan Bolts12 Nm (9 lb-ft)

   Oil Pump Pickup Tube12 Nm (9 lb-ft)

   Oil Pump Bolts12 Nm (9 lb-ft)
6. 6

   Remove flexplate and rear main seal housing
   If equipped with automatic transmission, remove flexplate bolts using star pattern. Remove flexplate from crankshaft flange. Remove rear main seal housing bolts and carefully remove housing with seal. Clean all sealing surfaces on block and inspect for damage.
   ℹ️Use thread locking compound on flexplate bolts during reassembly as specified by Ford.
   Torque spec

   Flexplate Bolts85 Nm (63 lb-ft)

   Rear Main Seal Housing12 Nm (9 lb-ft)
7. 7

   Remove pistons and connecting rods
   Rotate engine so cylinder #1 is at bottom dead center. Using paint marker or permanent marker, mark each connecting rod and cap with cylinder number and orientation (they must be reinstalled in exact same position). Check for existing marks from factory. Remove connecting rod cap bolts and carefully remove caps, keeping them with their respective rods. Push piston and rod assembly up and out through top of cylinder bore. Use wooden dowel or plastic hammer handle to gently tap rod out if needed. Repeat for all six cylinders. Keep pistons, rods, caps, and bearings organized by cylinder number.
   ⚠Do not let connecting rods contact cylinder walls or crankshaft journals during removal. Cover rod bolts with protective caps or rubber hose to prevent damage to cylinder walls.
   Torque spec

   Connecting Rod Bolts45 Nm (33 lb-ft)
8. 8

   Remove main bearing caps and crankshaft
   Verify all main bearing caps are marked for position and orientation (factory marks should be present - front of engine and numbered 1-4). Remove all main bearing cap bolts, keeping hardware organized by cap number. Carefully remove main bearing caps, keeping upper and lower bearings with their respective caps. With all caps removed, carefully lift crankshaft straight up and out of engine block. This is a heavy component requiring two people. Place crankshaft on padded surface or V-blocks. Remove thrust bearings from block (typically on center main journal). Remove all bearing shells from caps and block, inspecting for wear patterns, scoring, or embedded debris.
   ⚠️Crankshaft weighs approximately 60 lbs and is awkward to handle. Use two people and proper lifting technique to avoid injury or dropping the crankshaft.
   ⚠Main bearing caps are machined as matched pairs with the block and are NOT interchangeable. Installing caps in wrong positions will cause immediate engine failure.
   Torque spec

   Main Bearing Cap Bolts75 Nm (55 lb-ft)
9. 9

   Inspect and measure all components
   Thoroughly clean engine block, crankshaft, and all bearing surfaces with solvent and compressed air. Inspect block main bearing bores for scoring, out-of-round, or damage. Use inside dial bore gauge to measure each main bearing bore at multiple points - record all measurements. Inspect crankshaft journals for scoring, heat discoloration, or wear. Use micrometer to measure all main and rod journals in multiple orientations (check for taper and out-of-round) - record all measurements. Calculate bearing clearances using journal and bore measurements. Typical clearances: main bearings 0.0010-0.0018 inches, rod bearings 0.0010-0.0026 inches. Check crankshaft end play specification. Inspect cylinder bores for scoring, glazing, or wear. If any components are out of specification, block may need machine work or crankshaft may need grinding, requiring undersized bearings.
   ⚠Accurate measurements are critical. If you do not have proper measuring tools or experience, have a qualified machine shop perform inspection and provide bearing size recommendations.
10. 10

    Install new crankshaft and main bearings
    Ensure all bearing bores and crankshaft journals are spotlessly clean and dry. Install upper main bearing shells into engine block, ensuring bearing tangs engage locating slots. Do not force bearings. Lubricate all bearing surfaces with assembly lubricant or engine oil. Carefully lower new or machined crankshaft into block, aligning with bearing shells. Install thrust bearings on center main journal. Install lower bearing shells into main bearing caps, again ensuring tangs engage slots. Lubricate lower bearings. Install main bearing caps in correct positions with factory marks aligned (typically toward front of engine). Install NEW main bearing cap bolts and hand tighten all bolts. Torque main bearing cap bolts in sequence from center outward: first to 75 Nm (55 lb-ft), then tighten an additional 90 degrees using torque angle gauge. Check crankshaft rotational resistance - should turn freely by hand. Measure crankshaft endplay using dial indicator - should be within specification (typically 0.0035-0.0106 inches).
    ⚠Verify bearing clearances using Plastigage before final torquing if measurements were borderline. Improper clearances will cause immediate bearing failure.
    ℹ️Main bearing cap bolts are TTY and single-use only. Using old bolts will result in inadequate clamping force and bearing failure.
    Torque spec

    Main Bearing Cap Bolts75 Nm (55 lb-ft)
11. 11

    Install pistons and connecting rods
    Install connecting rod bearing shells into rods and caps, ensuring tangs engage slots properly. Lubricate bearings, piston pins, and cylinder walls with assembly lubricant. Ensure piston ring gaps are properly positioned (stagger 120 degrees apart, not aligned with pin bore). Install piston ring compressor on piston #1. Insert rod and piston assembly into cylinder #1 from top of block, ensuring directional marking on piston faces front of engine. Gently tap piston down into bore using wooden hammer handle while guiding connecting rod onto crankshaft journal. Install connecting rod cap in correct orientation (match marks aligned). Install NEW connecting rod bolts and torque to 45 Nm (33 lb-ft), then tighten an additional 90 degrees. Verify rod rotates freely on crankshaft. Repeat for all remaining cylinders in order. After all rods are installed, rotate crankshaft several complete revolutions to verify smooth rotation without binding.
    ⚠Do not force pistons into bores. If excessive force is needed, remove and check for proper ring compression and ring gap positioning.
    Torque spec

    Connecting Rod Bolts45 Nm (33 lb-ft)
12. 12

    Install front and rear seals and housings
    Install new front crankshaft seal into front main seal housing using seal driver or appropriate socket. Ensure seal is seated flush and square. Apply thin bead of RTV silicone to housing mating surface as specified in service manual. Install front seal housing to block and torque bolts to 12 Nm (9 lb-ft). Install new rear main seal into rear seal housing using seal installation tool. Apply RTV to housing mating surface. Install rear seal housing and torque bolts to 12 Nm (9 lb-ft). Allow RTV to cure per manufacturer specifications before adding oil.
    Torque spec

    Front Main Seal Housing12 Nm (9 lb-ft)

    Rear Main Seal Housing12 Nm (9 lb-ft)
13. 13

    Install oil pump and oil pan
    Install new or inspected oil pump to front of engine block. Ensure pump drive engages crankshaft properly. Torque oil pump mounting bolts to 12 Nm (9 lb-ft). Install oil pump pickup tube with new O-ring or gasket and torque bolts to 12 Nm (9 lb-ft). Ensure pickup tube clearance to bottom of pan is within specification. Clean oil pan and block mating surfaces thoroughly. Apply new oil pan gasket or RTV silicone as specified by Ford (EcoBoost typically uses formed gasket with RTV at specific corners). Position oil pan and install all bolts hand tight. Torque oil pan bolts in crisscross sequence from center outward to 12 Nm (9 lb-ft). Do not overtighten as this can distort pan and cause leaks.
    Torque spec

    Oil Pump Bolts12 Nm (9 lb-ft)

    Oil Pump Pickup Tube12 Nm (9 lb-ft)

    Oil Pan Bolts12 Nm (9 lb-ft)
14. 14

    Install timing components
    Install crankshaft timing sprocket onto crankshaft snout, ensuring keyway is aligned. Install timing chain guides and torque bolts to 12 Nm (9 lb-ft). Rotate crankshaft to TDC position for cylinder #1. Install primary timing chain over crankshaft sprocket. Install camshaft sprockets (camshafts should be in heads already) with timing chains routed correctly. Verify all timing marks align per Ford specifications - this is critical. Install timing chain tensioners with locking pins installed to compress tensioners. Clean timing cover and block mating surfaces thoroughly. Install new timing cover gasket or apply RTV as specified. Install timing cover and torque 8mm bolts to 25 Nm (18 lb-ft) and 10mm bolts to 45 Nm (33 lb-ft) in proper sequence. Install new harmonic balancer onto crankshaft snout (may require gentle tapping with rubber mallet). Install NEW harmonic balancer bolt and torque to 180 Nm (133 lb-ft), then tighten additional degrees as specified (consult service manual for TTY procedure). Remove timing chain tensioner locking pins to activate tensioners.
    ⚠️Incorrect timing chain installation will cause piston-to-valve contact and catastrophic engine damage. Triple-check all timing marks before installing timing cover.
    ⚠Do not rotate crankshaft or camshafts after timing chains are installed until timing is verified correct and tensioners are released.
    Torque spec

    Timing Chain Guide Bolts12 Nm (9 lb-ft)

    Timing Chain Tensioner Bolt25 Nm (18 lb-ft)

    Cover Bolts19 Nm (14 lb-ft)

    Harmonic Balancer Bolt180 Nm (133 lb-ft)
15. 15

    Install cylinder heads and reassemble engine
    Clean cylinder head and block mating surfaces thoroughly. Inspect surfaces for warpage using straightedge and feeler gauge. Install new head gaskets onto block, ensuring correct orientation (TOP marking faces up). Carefully position cylinder heads onto block, aligning dowel pins. Install NEW cylinder head bolts finger tight. Torque cylinder head bolts in proper sequence (consult Ford service manual): first pass to 65 Nm (48 lb-ft), then loosen all bolts one full turn, re-torque to 65 Nm (48 lb-ft), then tighten 90 degrees, then tighten additional 90 degrees. Install flexplate with NEW bolts, torque to 85 Nm (63 lb-ft) in star pattern. Reinstall all external components: water pump, thermostat housing, exhaust manifolds, intake manifold with new gaskets, fuel rail, ignition coils, valve covers with new gaskets, and all accessory components. Torque all fasteners to specifications. Install new oil filter.
    ⚠Cylinder head bolt tightening sequence is critical and uses multi-step torque-to-yield procedure. Follow Ford specifications exactly.
    Torque spec

    Cylinder Head Bolts65 Nm (48 lb-ft)

    Flexplate Bolts85 Nm (63 lb-ft)
16. 16

    Reinstall engine in vehicle
    Using engine hoist with load leveler, carefully lower engine into engine bay, aligning with transmission. Install transmission-to-engine bolts and torque to 55 Nm (41 lb-ft). Install engine mount bolts and torque mounting bolts to 55 Nm (40 lb-ft) for critical mounts. Remove transmission jack. Reconnect all wiring harnesses, fuel lines, coolant hoses, A/C lines, power steering lines, and exhaust system. Install radiator and cooling fan assembly. Reinstall driveshaft in original marked position. Reconnect transmission cooler lines. Install turbochargers with new gaskets and all associated piping. Install intake system and engine cover. Reinstall front wheels and lower vehicle. Reinstall battery and connect terminals (positive first).
    Torque spec

    Transmission-to-Engine Bolts55 Nm (41 lb-ft)

    Mounting Bolts31 Nm (23 lb-ft)
17. 17

    Fill fluids and perform initial start
    Install oil drain plug with NEW crush washer and torque to 35 Nm (26 lb-ft). Fill engine with 6 quarts of Motorcraft 5W-20 synthetic blend oil. Fill cooling system with 13 quarts of Motorcraft Orange coolant (purge air from system using bleeder valves). Check and fill transfer case with 2.5 quarts Motorcraft transfer case fluid if drained. Check and fill front differential with 1.5 quarts 75W-90 GL-5 gear oil if drained. Check and fill rear differential with 2.0 quarts Motorcraft 75W-140 synthetic gear oil if drained. If transmission was drained, fill with approximately 11 quarts Motorcraft MERCON LV ATF and check level per procedure. Double-check all connections, hoses, and fasteners. Remove spark plugs and disable fuel system. Crank engine with starter to build oil pressure (watch for oil pressure gauge or light). Reinstall spark plugs. Prime fuel system. Start engine and immediately check for leaks, unusual noises, or warning lights. Allow engine to idle and warm up, monitoring temperature and oil pressure closely.
    ⚠️Do not run engine without oil pressure. If oil pressure does not register within 10 seconds of cranking, shut down immediately and investigate.
    ⚠Monitor for coolant, oil, or fuel leaks during initial start. Shut down immediately if any leaks are detected.
    Torque spec

    Oil Drain Plug35 Nm (26 lb-ft)

Reassembly

1. Torque all fasteners to specifications using proper sequences where applicable
2. All TTY (torque-to-yield) bolts including main bearing cap bolts, connecting rod bolts, cylinder head bolts, and harmonic balancer bolt must be replaced with new bolts
3. Apply assembly lubricant to all bearing surfaces, piston rings, and cylinder walls during assembly
4. Use new gaskets and seals throughout - do not reuse any gaskets
5. Apply RTV silicone only where specified by Ford service procedures
6. Verify timing chain alignment at least three times before installing timing cover
7. Ensure all piston ring gaps are properly staggered and not aligned
8. Check crankshaft rotation by hand at multiple points during assembly - should rotate freely without binding
9. Verify all electrical connectors are fully seated and locked

Verification

• Check engine oil level and condition - should be at full mark on dipstick
• Check coolant level in reservoir - should be at cold full mark
• Verify no oil, coolant, or fuel leaks around engine after initial warm-up cycle
• Check oil pressure gauge reads within normal range (typically 25-80 PSI depending on RPM and temperature)
• Verify engine idles smoothly without unusual noises, vibrations, or misfires
• Check for proper operation of all accessories (alternator charging, A/C compressor, power steering)
• Scan for diagnostic trouble codes using OBD-II scanner - should have no codes related to engine mechanical issues
• Perform test drive and verify normal power delivery, smooth acceleration, and no unusual noises under load
• Recheck all fluid levels after test drive and top off as needed
• After 500 miles, recheck oil level and inspect for any new leaks. Consider oil and filter change at 500-1000 miles to remove assembly lubricants and any initial wear particles
• Monitor oil pressure and engine temperature for first several hundred miles to ensure proper break-in

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