Freeze Plugs - All

Complete replacement of all engine block freeze plugs on the 5.0L Coyote V8, requiring engine removal from the vehicle to access all plugs on both sides of the block and rear locations.

Warnings

Tools required

Parts

• Engine freeze plug set (cup type, various sizes for 5.0L Coyote) × 1 — Use OEM specification
• Engine oil filter × 1 — FL-820S or equivalent
• Engine coolant drain plug gasket × 1 — Use OEM specification
• Oil pan gasket × 1 — Use OEM specification
• Front cover gasket × 1 — Use OEM specification
• Thermostat housing gasket × 1 — Use OEM specification
• Exhaust manifold gaskets (both sides) × 2 — Use OEM specification
• Engine mount bolts × 6 — Use OEM specification
• RTV silicone sealant (high-temp, compatible with aluminum) × 2 — Motorcraft TA-357 or equivalent
• Anaerobic sealant for freeze plugs × 1 — Permatex 51813 or equivalent

Fluids

• Motorcraft Orange Coolant — 16 qt
• Motorcraft 5W-20 Synthetic Blend — 7.5 qt

Preparation

1. Park vehicle on level surface and engage parking brake. Chock rear wheels securely.
2. Disconnect negative battery cable, then positive cable. Remove battery from vehicle.
3. Remove engine cover and air intake system completely from throttle body to air filter box.
4. Drain engine coolant completely from radiator petcock and block drain plugs into appropriate containers.
5. Drain engine oil and remove oil filter.
6. Remove radiator upper and lower hoses, heater hoses, and all coolant lines from engine.
7. Remove serpentine belt and all accessory drive components (alternator, A/C compressor, power steering pump) - support A/C compressor without disconnecting refrigerant lines.
8. Tag and disconnect all electrical connectors including ignition coils, fuel injectors, sensors, and engine harness connections.
9. Relieve fuel system pressure and disconnect fuel lines at fuel rail.
10. Remove exhaust manifolds or disconnect exhaust at manifold flanges.
11. Raise vehicle on lift or jack stands to access underside components.
12. Support transmission with transmission jack.
13. Remove starter motor.
14. Mark driveshaft position and remove from transmission/transfer case.

Procedure

1. 1

   Disconnect transmission from engine
   Remove transmission bellhousing bolts connecting transmission to engine block. On 4WD models, remove transfer case if necessary for clearance. Support transmission securely on transmission jack before removing final bolts. Remove flexplate/flywheel to torque converter bolts through inspection cover if equipped with automatic transmission.
2. 2

   Remove engine mounting hardware
   Remove bolts securing engine mounts to frame brackets on both driver and passenger sides. Remove through-bolts from engine mounts. Verify all electrical connections, hoses, and mechanical connections have been disconnected from engine.
   Torque spec

   Mounting Bolts34 Nm (25 lb-ft)
3. 3

   Lift engine from vehicle
   Attach engine hoist with chains or straps to factory lift points on cylinder heads or engine block. Use load leveler to balance engine. Carefully lift engine, tilting as necessary to clear firewall, radiator support, and front crossmember. Have assistant guide engine clear of vehicle. Transfer engine to engine stand once clear of vehicle.
   ⚠️Ensure engine is balanced and hoist is positioned directly over lift point before raising. Clear area of personnel during lift operation.
4. 4

   Mount engine on stand and position for access
   Secure engine to engine stand using bellhousing bolt holes. Tighten stand mounting bolts securely. Rotate engine on stand to inspect all sides of block and identify all freeze plug locations. The 5.0L Coyote has freeze plugs on both sides of the block, front, and rear.
5. 5

   Remove oil pan for access to lower plugs
   Remove oil pan mounting bolts and carefully separate oil pan from engine block. Some lower freeze plugs may require oil pan removal for proper access and installation clearance. Clean oil pan gasket surfaces thoroughly with gasket scraper.
6. 6

   Remove front timing cover if necessary
   If front freeze plugs are not accessible, remove timing cover bolts and separate cover from block. This provides access to front freeze plug locations. Clean gasket surfaces if cover is removed.
   Torque spec

   Cover Bolts20 Nm (15 lb-ft)
7. 7

   Remove all freeze plugs
   Using freeze plug removal tool or slide hammer with hook, carefully extract each freeze plug from block. Alternative method: punch a hole in center of freeze plug with pointed tool, insert slide hammer hook, and pull plug from bore. For stubborn plugs, use a large screwdriver or pry bar to collapse plug inward, then pry out. Remove all old sealant residue from freeze plug bores.
   ⚠Avoid damaging freeze plug bores in block during removal. Do not gouge or scratch the bore surfaces as this will prevent proper seal of new plugs.
8. 8

   Clean and inspect freeze plug bores
   Thoroughly clean each freeze plug bore with wire brush and solvent. Remove all rust, corrosion, old sealant, and debris. Inspect bore surfaces for damage, cracks, or excessive corrosion. Bores must be smooth and clean for new plugs to seal properly. Dry bores completely with compressed air or clean rags.
9. 9

   Install new freeze plugs
   Apply anaerobic sealant around outer edge of each new freeze plug as specified. Position freeze plug squarely in bore with cup side facing outward (convex side into engine). Using appropriately sized freeze plug installation tool and hammer, drive plug into bore evenly until seated flush or slightly below block surface. Ensure plug is not cocked or tilted during installation. Install all freeze plugs in this manner.
   ⚠Use correct size installation tool for each plug to prevent distortion. Drive plug in straight and evenly to prevent cocking which will cause leaks.
   Torque spec

   Freeze Plug10 Nm (7 lb-ft)
10. 10

    Reinstall front timing cover
    If timing cover was removed, install new gasket with appropriate sealant per manufacturer specifications. Position cover onto block and install cover bolts finger-tight. Torque cover bolts in sequence from center outward to specification.
    Torque spec

    Cover Bolts20 Nm (15 lb-ft)

    Gasket Bolts25 Nm (19 lb-ft)
11. 11

    Reinstall oil pan
    Install new oil pan gasket with RTV sealant at corners where gasket meets front cover and rear main seal retainer. Position oil pan and install bolts finger-tight. Torque oil pan bolts in crisscross pattern from center outward to specification. Allow sealant to cure per manufacturer recommendations before adding oil.
    Torque spec

    Gasket Bolts25 Nm (19 lb-ft)
12. 12

    Prepare engine for reinstallation
    Install new oil drain plug gasket and tighten drain plug. Rotate engine on stand to position for installation back into vehicle. Verify all freeze plugs are properly seated and sealant has set. Remove engine from stand and attach to engine hoist with load leveler.
13. 13

    Lower engine into vehicle
    Carefully lower engine into engine bay, using load leveler to angle engine as needed to clear firewall and radiator support. Guide engine onto engine mounts. Align engine with transmission bellhousing. Install engine mount through-bolts and mounting bolts finger-tight initially.
    ⚠️Ensure no wiring, hoses, or body parts are pinched between engine and frame during installation.
14. 14

    Reconnect transmission to engine
    Align transmission bellhousing to engine block, ensuring alignment dowels engage properly. Install bellhousing bolts and torque to specification. For automatic transmission, install torque converter to flexplate bolts through inspection cover. Remove transmission jack once secured. Reinstall transfer case if removed.
    Torque spec

    Mounting Bolts34 Nm (25 lb-ft)
15. 15

    Torque engine mounts and reconnect components
    Torque all engine mount bolts to specification. Reconnect exhaust manifolds with new gaskets. Reinstall starter motor. Reconnect driveshaft with alignment marks matched. Lower vehicle and reconnect all accessories, electrical connectors, fuel lines, coolant hoses, serpentine belt, air intake system, and battery cables.
    Torque spec

    Mounting Bolts34 Nm (25 lb-ft)

    Sensor Bolts14 Nm (10 lb-ft)

Reassembly

1. Reinstall all components in reverse order of removal, using new gaskets where required
2. Ensure all electrical connectors are properly seated and secured with locking tabs engaged
3. Verify all coolant hoses are properly clamped and fuel lines are securely connected
4. Double-check that all fasteners are tightened to proper torque specifications
5. Install new engine oil filter and fill engine with correct quantity and specification of engine oil
6. Fill cooling system with proper coolant mixture, bleeding air from system per factory procedure

Verification

• With engine cold, verify all freeze plugs are properly seated and show no signs of leakage around edges
• Check that all hose connections, electrical connectors, and mechanical linkages are properly reconnected
• Verify correct oil level on dipstick and proper coolant level in overflow reservoir
• Start engine and allow to reach operating temperature while monitoring for any coolant or oil leaks around freeze plugs
• Check for leaks at all freeze plug locations both cold and at operating temperature
• Verify cooling system maintains proper pressure and temperature without overheating
• Inspect underneath vehicle for any fluid leaks from oil pan or other disturbed components
• Test drive vehicle and recheck all freeze plug locations for leaks after engine has fully heat cycled

More procedures for this vehicle