Complete removal and reinstallation of the crankshaft, requiring engine removal from vehicle and complete disassembly of lower end including main bearings, connecting rods, and timing components.

Warnings

Tools required

Parts

• Main bearing set (standard or appropriate oversize) × 1 — Use OEM specification
• Connecting rod bearing set (standard or appropriate oversize) × 1 — Use OEM specification
• Front crankshaft seal × 1 — Use OEM specification
• Rear main seal × 1 — Use OEM specification
• Oil pan gasket × 1 — Use OEM specification
• Timing cover gasket × 1 — Use OEM specification
• Front cover seal housing gasket × 1 — Use OEM specification
• Rear main seal housing gasket × 1 — Use OEM specification
• Oil pump pickup tube O-ring × 1 — Use OEM specification
• Timing chain tensioner assembly × 2 — Use OEM specification
• Timing chain guide (if worn) × 2 — Use OEM specification
• Main bearing cap bolts (TTY) × 10 — Use OEM specification
• Connecting rod bolts (TTY) × 16 — Use OEM specification
• Harmonic balancer bolt (TTY) × 1 — Use OEM specification
• Cylinder head bolts (TTY) × 20 — Use OEM specification
• Head gasket set × 1 — Use OEM specification
• Flexplate or flywheel (inspect for cracks) × 1 — Use OEM specification
• Engine oil filter × 1 — Motorcraft FL-820-S
• Oil drain plug crush washer × 1 — Use OEM specification
• RTV silicone gasket maker (Motorcraft TA-31) × 1 — Motorcraft TA-31
• Engine assembly lube × 1 — Use OEM specification

Fluids

• Motorcraft 5W-20 Synthetic Blend engine oil — 7.5 qt
• Motorcraft Orange Coolant — 16 qt
• Motorcraft MERCON LV ATF — 11 qt
• Motorcraft Transfer Case Fluid — 2.5 qt
• Motorcraft 75W-140 Synthetic Gear Oil (rear differential) — 2 qt
• 75W-90 GL-5 Gear Oil (front differential) — 1.5 qt

Preparation

1. Park vehicle on level surface and engage parking brake. Chock rear wheels securely.
2. Disconnect negative battery cable and then positive battery cable. Remove battery from vehicle.
3. Drain engine coolant completely by opening radiator petcock and removing lower radiator hose.
4. Drain engine oil and remove oil filter. Install drain plug with new crush washer temporarily.
5. Remove engine cover and air intake assembly including air filter housing and intake tube.
6. Recover A/C refrigerant using proper recovery equipment. Do not vent refrigerant to atmosphere.
7. Drain transmission fluid by removing pan or using drain plug if equipped.
8. Mark hood hinge positions with paint marker, then remove hood with assistant and store safely.
9. Remove radiator, cooling fans, A/C condenser, and all coolant hoses from engine.
10. Disconnect all electrical connectors from engine including alternator, starter, sensors, and fuel injectors. Label for reassembly.
11. Disconnect fuel lines at fuel rail using proper disconnect tools. Relieve fuel pressure before disconnecting.
12. Remove serpentine belt, power steering pump (leave hoses attached and secure aside), and A/C compressor (leave hoses attached and secure aside).
13. Raise vehicle on lift or jack stands ensuring secure support at frame lift points.
14. Remove front wheels and skid plates if equipped.
15. Disconnect exhaust system at manifold flanges and remove Y-pipe assembly.
16. Remove starter motor and secure aside.
17. Support transmission with transmission jack before removing crossmember.
18. Remove transmission crossmember bolts and lower crossmember.
19. Mark driveshaft position at rear differential flange, then remove rear driveshaft.
20. Mark front driveshaft position at transfer case and front differential, then remove front driveshaft.
21. Disconnect shift linkage and all electrical connections from transmission and transfer case.
22. Remove transmission cooler lines from transmission.
23. Attach engine hoist chains to engine lifting points (cylinder head bolt locations front and rear). Balance engine on hoist before removing mounts.
24. Remove engine mount through-bolts on both sides.

Procedure

1. 1

   Remove engine and transmission assembly
   With engine properly balanced on hoist and all connections verified disconnected, slowly lift engine while guiding transmission tailshaft through firewall opening. Have assistant guide assembly to prevent damage to surrounding components. Once clear of vehicle, move assembly to clean workspace and lower onto engine stand mounting location. Verify all hoses, wiring, and lines are clear before lifting.
2. 2

   Separate transmission from engine
   With engine and transmission on ground or suitable support, remove torque converter dust cover. Mark torque converter to flexplate position. Remove flexplate to torque converter bolts by rotating crankshaft with socket on harmonic balancer bolt. Remove transmission to engine mounting bolts. Carefully separate transmission from engine, ensuring torque converter remains with transmission. Support transmission weight during separation to prevent input shaft damage.
   Torque spec

   Transmission-to-Engine Bolts55 Nm (41 lb-ft)
3. 3

   Mount engine on stand and remove flexplate
   Bolt engine securely to engine stand using proper adapter plate at bell housing bolt holes. Ensure stand is locked before releasing hoist. Use crankshaft holding tool or wooden block between crank counterweight and block to prevent rotation. Remove flexplate bolts in star pattern (reverse of tightening sequence). Inspect flexplate for cracks, heat checking, or damaged ring gear teeth. Mark flexplate orientation for reinstallation if reusing.
   ⚠Flexplate bolts may be TTY depending on production date. Replace if any doubt exists.
   Torque spec

   Flexplate Bolts85 Nm (63 lb-ft)
4. 4

   Remove cylinder heads
   Remove valve covers, ignition coils, and spark plugs. Remove exhaust manifolds if not already removed. Loosen cylinder head bolts in reverse of tightening sequence (outside to inside pattern) in multiple passes. Remove cylinder head bolts completely. Carefully lift cylinder heads from block using proper lifting points. Do not pry between head and block surfaces. Place heads on clean padded surface with combustion chambers facing up. Remove and discard head gaskets. Inspect head bolt holes in block for thread damage or debris.
   ⚠Cylinder head bolts are TTY and must be replaced. Do not reuse head bolts.
   Torque spec

   Cylinder Head Bolts65 Nm (48 lb-ft)
5. 5

   Remove timing cover and timing components
   Remove harmonic balancer bolt using impact wrench or breaker bar while preventing crankshaft rotation. Use harmonic balancer puller to remove balancer from crankshaft snout. Do not hammer on balancer. Remove timing cover bolts (note different sizes - 8mm and 10mm) in pattern from outside to inside. Carefully remove timing cover, noting RTV sealant locations. Remove timing chain tensioners by releasing locking mechanism and removing mounting bolts. Remove timing chains, guides, and sprockets. Mark all components for position and orientation. Inspect guides and tensioners for wear, scoring, or broken components.
   ⚠Harmonic balancer bolt is TTY and must be replaced. Timing chain tensioners must be replaced, not reused.
   Torque spec

   Harmonic Balancer Bolt180 Nm (133 lb-ft)

   Cover Bolts20 Nm (15 lb-ft)

   Timing Chain Tensioner Bolt25 Nm (18 lb-ft)

   Timing Chain Guide Bolts12 Nm (9 lb-ft)
6. 6

   Remove oil pan and oil pump
   Remove oil pan bolts in reverse of tightening sequence. Break oil pan seal using plastic gasket scraper, working carefully around perimeter. Remove oil pan and gasket. Remove oil pump pickup tube mounting bolt and separate pickup from pump. Remove oil pump mounting bolts and remove pump assembly from front of crankshaft. Inspect pump gears for scoring or excessive wear. Clean all RTV and old gasket material from oil pan and block mating surfaces using scraper and solvent.
   Torque spec

   Oil Pan Bolts12 Nm (9 lb-ft)

   Oil Pump Pickup Tube12 Nm (9 lb-ft)

   Oil Pump Bolts12 Nm (9 lb-ft)
7. 7

   Remove pistons and connecting rod assemblies
   Rotate engine so cylinder being serviced is at bottom dead center. Check connecting rod and cap for cylinder number stamps (should be numbered 1-8). If not marked, use number stamps to mark rod and cap with cylinder number and orientation before disassembly. Remove connecting rod cap bolts and carefully remove cap with bearing shell. Push piston and rod assembly up and out of cylinder bore from below. Remove upper bearing shell from rod. Install rod caps back on rods with bearings to keep pairs together. Repeat for all 8 cylinders. Keep all components organized by cylinder number.
   ⚠Connecting rod bolts are TTY and must be replaced. Rod caps must be reinstalled on correct rod in correct orientation. Mismatched caps will cause immediate failure.
   Torque spec

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

   Remove main bearing caps and crankshaft
   Check main bearing caps for position markings and orientation arrows. Main caps are numbered 1-5 from front to rear and have directional arrows pointing toward front of engine. Use number stamps to mark caps if markings are not clear. Remove main bearing cap bolts in sequence from outside caps (1 and 5) working toward center. Remove main bearing caps carefully, noting thrust bearing location (typically center main bearing position 3). With all caps removed, carefully lift crankshaft straight up and out of block. Remove upper bearing shells from block and lower bearing shells from caps. Keep bearings organized by position.
   ⚠️Main bearing caps MUST be installed in correct position and orientation. Caps are NOT interchangeable between positions. Incorrect installation will cause immediate catastrophic engine failure.
   ⚠Main bearing cap bolts are TTY and must be replaced with new bolts.
   Torque spec

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

   Inspect and measure crankshaft and block
   Clean crankshaft thoroughly with solvent and compressed air, ensuring all oil passages are clear. Inspect all journal surfaces for scoring, discoloration, or damage. Measure all main bearing journals and rod journals with micrometer at multiple points (90 degrees apart) to check for out-of-round and taper. Compare measurements to service specifications. Journal out-of-round exceeding 0.0002 inch or taper exceeding 0.0005 inch requires machining. Inspect thrust surfaces on center main journal for wear. Clean block main bearing saddles and measure bore diameter with telescoping bore gauge. Check block deck surfaces for warpage with straightedge.
   ℹ️Standard main journal diameter is 2.6568-2.6576 inches. Standard rod journal diameter is 2.0861-2.0867 inches. If journals are worn beyond specification, crankshaft must be machined for undersize bearings.
10. 10

    Install main bearings and verify clearances
    Ensure all bearing surfaces in block and caps are perfectly clean and oil-free. Install upper bearing shells into block saddles, ensuring tang engages notch in block. Place strip of Plastigage on each crankshaft journal parallel to crankshaft centerline. Carefully lower crankshaft into block. Install lower bearing shells in caps with tangs properly engaged. Install main caps in correct position and orientation with arrows pointing toward front. Install new main bearing cap bolts finger tight. Torque bolts to 75 Nm (55 lb-ft) in sequence from center main outward, then add angle per specification (typically 90 degrees additional). Do NOT rotate crankshaft. Carefully remove main caps and measure Plastigage width with scale on package. Clearance should be 0.0009-0.0019 inches. If clearance is out of specification, verify bearing size and journal diameter.
    ⚠️Do NOT rotate crankshaft with Plastigage installed. Rotation will give false readings and may damage bearings.
    ⚠Main bearing cap bolts are torque-to-yield. After measuring clearance, bolts must be removed and replaced with new bolts for final assembly.
    Torque spec

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

    Final crankshaft installation
    Remove crankshaft and all Plastigage residue from journals and bearings. Apply engine assembly lube generously to all bearing surfaces and crankshaft journals. Install upper bearing shells in block. Carefully lower crankshaft into position. Apply assembly lube to lower bearing shells and install in caps. Install main caps in correct position with arrows toward front. Install NEW main bearing cap bolts. Torque bolts to 75 Nm (55 lb-ft) in sequence from center outward, then rotate each bolt the specified additional angle (typically 90 degrees). Install dial indicator on front of engine with plunger against crankshaft snout. Pry crankshaft fully forward and zero dial indicator. Pry crankshaft fully rearward and note endplay reading. Endplay specification is typically 0.0051-0.0110 inches. If endplay is out of specification, verify thrust bearing installation.
    ⚠Excessive endplay indicates thrust bearing wear or incorrect installation. Insufficient endplay may indicate contamination between thrust surfaces.
    Torque spec

    Main Bearing Cap Bolts75 Nm (55 lb-ft)
12. 12

    Install piston and connecting rod assemblies
    Verify connecting rod bearing clearances using Plastigage method similar to main bearings. Target clearance is typically 0.0010-0.0020 inches. Clean all components thoroughly. Apply engine assembly lube to rod bearings, piston pins, and cylinder walls. Install upper bearing shells in connecting rods with tangs engaged. Ensure piston ring end gaps are properly staggered (120 degrees apart). Compress piston rings using ring compressor. Orient piston and rod assembly with markings facing forward (typically arrow on piston crown toward front and rod numbers toward outside of engine). Insert rod and piston into appropriate cylinder from top of block, tapping piston crown gently with wooden hammer handle while guiding rod into position. Install lower bearing shell in rod cap with assembly lube. Install rod cap in correct orientation matching cylinder number. Install NEW connecting rod bolts and torque to 45 Nm (33 lb-ft), then add specified angle (typically 90 degrees additional). Repeat for all cylinders.
    ⚠Connecting rod bolts are TTY and must be new. Piston orientation is critical - arrow on piston crown must face front of engine.
    Torque spec

    Connecting Rod Bolts45 Nm (33 lb-ft)
13. 13

    Install oil pump and front seal housing
    Clean crankshaft snout and front of block thoroughly. Install new front crankshaft seal in front seal housing using seal driver. Apply small bead of RTV sealant to seal housing mating surface per factory specifications. Align oil pump to crankshaft and install on engine front, ensuring pump drive engages properly with crankshaft. Install oil pump bolts and torque to 12 Nm (9 lb-ft). Install front seal housing over crankshaft snout, ensuring seal does not damage on splines. Install housing bolts and torque to 12 Nm (9 lb-ft) in crisscross pattern. Install new O-ring on oil pump pickup tube. Install pickup tube to oil pump and block, torquing bolt to 12 Nm (9 lb-ft). Verify pickup tube to oil pan clearance will be 0.197-0.354 inches when pan is installed.
    Torque spec

    Oil Pump Bolts12 Nm (9 lb-ft)

    Front Main Seal Housing12 Nm (9 lb-ft)

    Oil Pump Pickup Tube12 Nm (9 lb-ft)
14. 14

    Install timing components
    Install crankshaft timing sprockets ensuring alignment marks are visible and correct. Install camshaft sprockets if removed during head service. Route timing chains over sprockets according to factory timing mark alignment (typically marks at 12 o'clock position aligned). Install timing chain guides and torque bolts to 12 Nm (9 lb-ft). Compress timing chain tensioners and install retaining pins or clips to hold in compressed position. Install tensioners and torque bolts to 25 Nm (18 lb-ft). Verify timing marks are correctly aligned before removing tensioner pins. Remove pins and allow tensioners to load chains. Rotate crankshaft two complete revolutions by hand and recheck timing mark alignment.
    ⚠Incorrect timing chain installation will cause valve to piston contact and catastrophic engine damage. Verify all timing marks align before final assembly.
    Torque spec

    Timing Chain Guide Bolts12 Nm (9 lb-ft)

    Timing Chain Tensioner Bolt25 Nm (18 lb-ft)
15. 15

    Install timing cover and harmonic balancer
    Clean timing cover and block mating surfaces thoroughly. Remove all old RTV sealant. Apply continuous bead of RTV sealant (Motorcraft TA-31) to block mating surface and around coolant passages. Install timing cover within 10 minutes of RTV application. Install timing cover bolts finger tight. Note that 8mm and 10mm bolts are used in specific locations. Torque 8mm bolts to 25 Nm (18 lb-ft) and 10mm bolts to 45 Nm (33 lb-ft) in sequence from center outward. Apply engine oil to crankshaft snout and harmonic balancer bore. Install harmonic balancer using installation tool to prevent seal damage. Install NEW harmonic balancer bolt and torque to 180 Nm (133 lb-ft), then add additional angle if specified (verify if TTY). May require impact wrench for installation.
    ⚠Never hammer harmonic balancer onto crankshaft. Use proper installation tool to prevent seal damage and crankshaft damage.
    Torque spec

    Cover Bolts20 Nm (15 lb-ft)

    Harmonic Balancer Bolt180 Nm (133 lb-ft)
16. 16

    Install cylinder heads
    Clean block deck surfaces and cylinder head mating surfaces thoroughly. Ensure no debris remains in head bolt holes. Chase threads with tap if necessary and blow out with compressed air. Install new head gaskets on block with orientation marks UP and toward front. Verify coolant and oil passage holes align correctly. Carefully lower cylinder heads onto block over alignment dowels. Install NEW cylinder head bolts with light oil on threads and under bolt heads. Torque head bolts to 65 Nm (48 lb-ft) in sequence (center outward pattern) then add specified angle in multiple steps (typically 90 degrees, then additional 90 degrees, then final 45 degrees). Follow exact factory sequence and angle specifications. Install exhaust manifolds with new gaskets. Install valve covers with new gaskets, torquing bolts to specification.
    ⚠️Cylinder head bolts are TTY and must be replaced. Follow exact torque sequence and angle specifications. Incorrect torque will cause head gasket failure or bolt failure.
    Torque spec

    Cylinder Head Bolts65 Nm (48 lb-ft)
17. 17

    Install oil pan and rear main seal
    Install new rear main seal in seal housing using seal driver. Apply RTV sealant to housing mating surface. Install rear main seal housing and torque bolts to 12 Nm (9 lb-ft) in crisscross pattern. Clean oil pan and block mating surfaces completely. Install new oil pan gasket. Apply small dabs of RTV at front cover to block and rear seal housing to block corners. Install oil pan and hand tighten all bolts. Torque oil pan bolts to 12 Nm (9 lb-ft) in sequence from center outward. Allow RTV to cure per manufacturer specifications before filling with oil.
    Torque spec

    Rear Main Seal Housing12 Nm (9 lb-ft)

    Oil Pan Bolts12 Nm (9 lb-ft)
18. 18

    Install flexplate and transmission
    Clean flexplate and crankshaft flange surfaces. Install flexplate in original orientation (note offset bolt holes or alignment marks). Install flexplate bolts and torque in star pattern to 85 Nm (63 lb-ft). Verify flexplate rotates without runout or wobble. Position transmission on transmission jack and align with engine. Apply small amount of grease to torque converter hub splines. Carefully guide transmission into position, ensuring torque converter remains fully seated in transmission pump. Verify proper torque converter engagement depth before bolting transmission to engine. Install transmission to engine bolts and torque to 55 Nm (41 lb-ft). Align torque converter to flexplate and install mounting bolts through access holes. Install dust cover.
    Torque spec

    Flexplate Bolts85 Nm (63 lb-ft)

    Transmission-to-Engine Bolts55 Nm (41 lb-ft)
19. 19

    Install engine assembly in vehicle
    Attach engine hoist to lifting points on engine/transmission assembly. Ensure balance is correct with transmission weight. Carefully raise assembly and guide into engine bay, aligning engine mounts and ensuring transmission tailshaft passes through firewall opening. Have assistant guide and watch clearances. Lower engine onto engine mount brackets and install mount through-bolts, torquing to 59 Nm (44 lb-ft). Install transmission crossmember and torque mounting bolts to 59 Nm (44 lb-ft). Remove transmission jack and engine hoist.
    Torque spec

    Mounting Bolts59 Nm (44 lb-ft)
20. 20

    Reconnect all systems and fill fluids
    Reconnect exhaust Y-pipe to manifolds with new gaskets. Install starter motor. Install front and rear driveshafts in original orientation. Connect shift linkage and all electrical connections to transmission and transfer case. Install transmission cooler lines. Install power steering pump and A/C compressor. Install serpentine belt. Reconnect all engine electrical connectors including alternator, sensors, and fuel injectors. Reconnect fuel lines. Install radiator, cooling fans, and A/C condenser with all hoses. Install air intake system. Fill engine with 7.5 quarts of Motorcraft 5W-20 oil and install new oil filter. Fill cooling system with 16 quarts of Motorcraft Orange coolant. Fill transmission with 11 quarts of Motorcraft MERCON LV. Fill transfer case with 2.5 quarts of Motorcraft transfer case fluid. Fill rear differential with 2.0 quarts of Motorcraft 75W-140 synthetic gear oil. Fill front differential with 1.5 quarts of 75W-90 GL-5 gear oil. Reconnect battery cables (positive first, then negative).

Reassembly

1. Double-check all electrical connectors are fully seated and locked
2. Verify all ground straps are reinstalled to engine and transmission
3. Check all fluid levels including engine oil, coolant, transmission, transfer case, and differentials
4. Verify serpentine belt is properly routed and tensioned
5. Ensure all exhaust connections are secure and gaskets are properly seated
6. Install hood, aligning with marks made during removal
7. Install engine cover and air filter housing
8. Install front wheels and torque lug nuts to specification
9. Lower vehicle to ground

Verification

• Prime oil system by cranking engine with fuel pump fuse removed until oil pressure gauge shows pressure
• Perform initial start and verify oil pressure comes up immediately (within 5 seconds)
• Check for any fluid leaks around oil pan, timing cover, rear main seal, and all external gaskets
• Allow engine to reach operating temperature and verify cooling fans cycle properly
• Check for exhaust leaks at manifold connections
• Verify no unusual noises such as knocking, ticking, or rattling from engine
• Check transmission engagement in all gears and verify proper shift quality
• Test drive vehicle and verify normal operation with no warning lights
• Recheck all fluid levels after test drive when engine is at operating temperature
• Monitor oil pressure gauge during first 100 miles of operation to ensure bearing clearances are correct
• Perform oil and filter change after initial 500 miles of break-in period

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