This procedure covers the removal and replacement of the torque converter in a 2011-2014 Ford F-150 with the 3.5L EcoBoost V6 engine and 6R80 automatic transmission, requiring transmission removal.

Warnings

Tools required

Parts

• Torque converter assembly × 1 — Use OEM specification for 6R80 transmission
• Transmission pan gasket × 1 — Use OEM specification
• Transmission filter × 1 — Use OEM specification
• Front driveshaft U-joint strap bolts × 4 — Replace if corroded
• Rear driveshaft U-joint strap bolts × 4 — Replace if corroded
• Transfer case adapter gasket × 1 — Use OEM specification for 4WD models

Fluids

• Motorcraft MERCON LV ATF — 11 qt

Preparation

1. Disconnect negative battery cable and wait 5 minutes for airbag system to deplete
2. Raise vehicle on lift or securely support on jack stands at all four corners
3. Remove front skid plate if equipped
4. Mark front and rear driveshaft positions relative to differential flanges with paint pen
5. Drain transmission fluid by removing pan bolts and allowing fluid to drain into catch pan
6. Remove transmission fluid pan and filter
7. Place transmission jack under transmission with safety chains attached

Procedure

1. 1

   Remove driveshafts
   Remove front driveshaft by unbolting U-joint straps from transfer case output and front differential input. Remove rear driveshaft by unbolting U-joint straps from transfer case rear output and rear differential pinion flange. Support driveshafts and carefully lower them out. Cap open transfer case outputs with plastic bags and tape to prevent fluid loss.
2. 2

   Disconnect electrical and mechanical connections
   Disconnect transmission wiring harness connector on passenger side of transmission. Disconnect transmission cooler lines at radiator or transmission (plug openings immediately). Remove shift cable from transmission lever and bracket. Disconnect any ground straps attached to transmission case. On 4WD models, disconnect transfer case wiring harness and vent hose.
3. 3

   Remove transfer case (4WD models)
   Support transfer case with separate jack. Remove transfer case mounting bolts securing it to transmission adapter. Carefully slide transfer case rearward off transmission output shaft and lower from vehicle. Drain remaining transfer case fluid and set aside. Remove transfer case adapter from transmission if replacement is needed.
   Torque spec

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

   Support engine and remove crossmember
   Position engine support fixture or place jack with wood block under oil pan to support engine weight. Remove transmission crossmember mounting bolts and lower crossmember from vehicle. This allows transmission to pivot for removal.
   Torque spec

   Mounting Bolts70 Nm (52 lb-ft)
5. 5

   Remove transmission-to-engine bolts
   Remove all transmission bellhousing-to-engine block mounting bolts. There are typically 7-9 bolts of varying lengths around the perimeter. Note bolt locations and lengths for reinstallation. Remove starter motor mounting bolts and position starter aside without disconnecting wiring if access is needed.
6. 6

   Access torque converter bolts
   Through the starter motor opening or dedicated access hole in bellhousing, rotate engine crankshaft using breaker bar on crank pulley bolt to bring each torque converter-to-flexplate bolt into view. Remove all torque converter bolts (typically 4-6 bolts). Use torque converter holding tool or screwdriver to prevent converter rotation while loosening bolts.
   Torque spec

   Torque Converter Bolts50 Nm (37 lb-ft)
7. 7

   Remove transmission from vehicle
   Secure torque converter to transmission using C-clamp or retaining strap across bellhousing to prevent converter from sliding out during removal. Verify all connections are disconnected. With transmission securely supported on transmission jack, carefully slide transmission rearward away from engine ensuring it clears dowel pins. Lower transmission from vehicle. Keep transmission level to prevent torque converter from falling out.
   ⚠Transmission must slide straight back to avoid binding on input shaft or damaging pilot bushing. Do not allow transmission to hang on input shaft.
8. 8

   Remove torque converter
   Remove C-clamp or retaining strap. Carefully pull torque converter straight out from transmission input shaft. Torque converter is heavy and contains residual fluid. Have drain pan ready. Inspect torque converter hub, stator support, and pump drive for damage or wear. Inspect flexplate for cracks, damaged ring gear teeth, or elongated bolt holes.
9. 9

   Install new torque converter
   Add approximately 1 quart of clean MERCON LV ATF into new torque converter. Align torque converter tabs with transmission pump slots and insert converter while rotating slightly. Push converter fully onto input shaft. Converter must engage three times: pump drive gear, turbine shaft, and stator support. Measure from transmission bellhousing face to torque converter mounting pad - should be approximately 1.0 to 1.25 inches recessed. If converter is not fully seated, remove and reinstall.
   ⚠️Torque converter MUST be fully seated before transmission installation. Improper seating will cause pump failure when transmission is bolted to engine. Verify three distinct engagement clicks or drops as converter is installed.
10. 10

    Reinstall transmission to engine
    Apply thin film of high-temperature grease to torque converter pilot hub. Install C-clamp or retaining strap to secure converter. Raise transmission into position on transmission jack. Align transmission with engine dowel pins and carefully slide transmission forward. Ensure transmission mates flush with engine block before installing any bolts. Install all bellhousing bolts finger-tight, then torque to specification in a cross pattern.
    ⚠If transmission does not slide easily into place or bellhousing does not sit flush against engine block, torque converter may have fallen off input shaft. Do not force with bolts or transmission damage will result.
    Torque spec

    Mounting Bolts70 Nm (52 lb-ft)
11. 11

    Install torque converter to flexplate
    Remove converter retaining strap or C-clamp. Rotate crankshaft to align torque converter bolt holes with flexplate holes. Install all torque converter-to-flexplate bolts finger-tight. Use holding tool to prevent converter rotation. Torque bolts evenly in a cross pattern to specification. Rotate crankshaft two full revolutions and verify smooth rotation without binding.
    ℹ️Tighten torque converter bolts evenly to prevent flexplate warping or imbalanced torque converter operation.
    Torque spec

    Torque Converter Bolts50 Nm (37 lb-ft)
12. 12

    Reinstall crossmember and transfer case
    Install transmission crossmember and torque mounting bolts to specification. Remove engine support. On 4WD models, install new transfer case adapter gasket if removed. Raise transfer case into position and slide onto transmission output shaft splines. Install transfer case mounting bolts and torque to specification. Reconnect transfer case wiring and vent hose.
    Torque spec

    Mounting Bolts70 Nm (52 lb-ft)
13. 13

    Reconnect components and driveshafts
    Reconnect transmission wiring harness, shift cable, and ground straps. Install transmission cooler lines with new O-rings if applicable. Align driveshaft marks made during removal and install front and rear driveshafts to transfer case and differentials. Torque U-joint strap bolts to specification. Reconnect any vacuum lines or sensors disconnected during removal.
14. 14

    Install transmission pan and refill fluids
    Install new transmission filter. Clean pan and transmission mating surface thoroughly. Install new pan gasket and transmission pan. Torque pan bolts evenly in a cross pattern to specification starting from center and working outward. Refill transmission with 6 quarts of MERCON LV ATF through dipstick tube. On 4WD models, refill transfer case with 2.5 quarts Motorcraft transfer case fluid. Reconnect battery.
    Torque spec

    Pan Bolts19 Nm (14 lb-ft)
15. 15

    Complete fluid fill and perform initial checks
    Start engine and allow to idle. With parking brake applied and foot on brake pedal, shift through all gear ranges, pausing 3-5 seconds in each position. Return to Park. Check transmission fluid level with engine running and fluid at operating temperature. Add additional MERCON LV fluid as needed to bring to proper level on dipstick (typically 4-5 more quarts). Check for leaks around pan, cooler lines, and torque converter area.

Reassembly

1. Verify torque converter engagement depth before final transmission installation - must be recessed approximately 1.0 to 1.25 inches from bellhousing face
2. Apply thread locker to torque converter-to-flexplate bolts per manufacturer specifications
3. Replace transmission filter and pan gasket during reassembly as part of preventive maintenance
4. Use only Motorcraft MERCON LV automatic transmission fluid - other fluids may cause shifting issues or damage

Verification

• Start engine and verify no unusual noises from torque converter or transmission
• With engine at operating temperature, verify transmission fluid level is within proper range on dipstick in Park with engine running
• Test drive vehicle and verify smooth engagement in all gears with no slipping, shuddering, or delayed shifts
• Check for fluid leaks around transmission pan, cooler lines, converter seal area, and transfer case connections after test drive
• Verify no diagnostic trouble codes related to transmission operation using scan tool
• Recheck fluid level after test drive and top off if necessary - transmission may require up to 11 quarts total depending on cooler line volume

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