This procedure covers removal and replacement of the transmission output shaft bearing on a 2011-2014 Ford F-150 with 5.0L V8 and 4WD, requiring transmission removal and partial disassembly.

Warnings

Tools required

Parts

• Transmission output shaft bearing × 1 — Use OEM specification
• Output shaft seal × 1 — Use OEM specification
• Transmission pan gasket × 1 — Use OEM specification
• Transmission filter × 1 — Use OEM specification
• Transmission drain plug crush washer × 1 — Use OEM specification
• Transfer case output seal (inspect and replace if needed) × 1 — Use OEM specification
• Driveshaft U-joint straps and bolts × 1 — Use OEM specification

Fluids

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

Preparation

1. Park vehicle on level surface and engage parking brake
2. Disconnect negative battery cable
3. Raise vehicle and support securely on jack stands at frame rails
4. Remove skid plates if equipped
5. Mark driveshaft-to-differential and driveshaft-to-transfer case alignment for reinstallation
6. Drain transmission fluid via drain plug and collect in appropriate container
7. Drain transfer case fluid and collect in appropriate container
8. Allow fluids to drain completely (15-20 minutes)

Procedure

1. 1

   Remove driveshafts and exhaust components
   Remove rear driveshaft by unbolting U-joint straps at rear differential and transfer case. Remove front driveshaft by unbolting U-joint straps at front differential and transfer case. Support and remove exhaust system from catalytic converters back to provide clearance for transmission removal. Label all components for proper reinstallation.
2. 2

   Disconnect transmission electrical connections and cooler lines
   Disconnect transmission range sensor connector, output speed sensor, and turbine speed sensor. Disconnect shift cable from transmission lever and bracket. Disconnect transmission cooler lines at transmission using appropriate line disconnect tools. Plug all openings to prevent contamination. Remove dipstick tube mounting bolt and set aside.
3. 3

   Support engine and remove crossmember
   Install engine support bar across engine compartment or use engine hoist to support engine weight. Position transmission jack under transmission and transfer case assembly. Secure transmission to jack with safety chains. Remove transmission crossmember mounting bolts and lower crossmember away from vehicle.
   Torque spec

   Mounting Bolts34 Nm (25 lb-ft)
4. 4

   Remove transfer case from transmission
   Remove transfer case-to-transmission mounting bolts. Carefully slide transfer case rearward off transmission output shaft while supporting weight with secondary jack or assistant. Lower transfer case from vehicle. Inspect transfer case output seal and replace if worn.
5. 5

   Separate transmission from engine
   Remove transmission-to-engine mounting bolts, noting different bolt lengths and positions. Verify all electrical connections, cooler lines, and mechanical linkages are disconnected. Carefully slide transmission rearward on transmission jack, ensuring torque converter remains fully seated in transmission. Once input shaft clears engine block, lower transmission from vehicle.
   ⚠Torque converter can fall out during removal. Secure with converter holding tool or strap before tilting transmission.
   Torque spec

   Mounting Bolts34 Nm (25 lb-ft)
6. 6

   Remove transmission pan and valve body
   With transmission on sturdy workbench, remove transmission pan bolts in criss-cross pattern. Remove pan and gasket. Remove transmission filter. Remove valve body mounting bolts and carefully lower valve body, noting position of check balls and springs. Set valve body aside in clean workspace.
   Torque spec

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

   Remove extension housing
   Remove output speed sensor from extension housing. Remove extension housing bolts and carefully slide housing rearward off output shaft. Inspect housing for cracks or damage. Remove output shaft seal from housing using seal puller.
8. 8

   Remove output shaft assembly
   Remove output shaft snap ring using snap ring pliers. Note orientation and position of all components. Carefully pull output shaft assembly from transmission case. Place output shaft in padded vise, protecting machined surfaces with soft jaws or aluminum blocks.
9. 9

   Remove and inspect old bearing
   Using dial indicator, measure output shaft endplay and bearing clearances before disassembly. Record measurements. Remove bearing retaining snap ring. Using appropriate bearing puller, remove output shaft bearing from shaft. Inspect bearing race in extension housing for scoring or pitting. Remove bearing race from housing using race puller or shop press if necessary.
   ⚠Do not reuse old bearing even if it appears serviceable. Always install new bearing during this repair.
10. 10

    Install new bearing and race
    If bearing race was removed from extension housing, press new race into housing using proper size race installer until fully seated. Verify race is square in bore. Place new output shaft bearing on shaft with manufacturer markings facing correct direction per service manual. Using bearing installer and shop press or bearing installation tool, press bearing onto shaft until it contacts shoulder. Install bearing retaining snap ring and verify it is fully seated in groove.
    ⚠Bearing must be pressed on squarely to avoid damage. Apply even pressure and verify alignment throughout installation process.
11. 11

    Verify bearing installation and clearances
    Using dial indicator, measure output shaft endplay with new bearing installed. Compare to factory specifications (typically 0.003-0.025 inches). Verify bearing rotates smoothly without binding or rough spots. Check that snap ring is properly seated and bearing cannot move axially on shaft.
12. 12

    Reinstall output shaft and extension housing
    Lubricate output shaft and bearing with clean ATF. Carefully install output shaft assembly into transmission case, ensuring all components are properly aligned. Install new output shaft seal in extension housing using seal driver, ensuring seal lip faces inward. Lubricate seal lip with ATF. Slide extension housing over output shaft, carefully guiding shaft through seal. Install and torque extension housing bolts evenly. Reinstall output speed sensor.
    Torque spec

    Sensor Bolts14 Nm (10 lb-ft)
13. 13

    Reinstall valve body and transmission pan
    Clean transmission pan thoroughly and inspect for metal particles. Clean transmission case mating surface. Position valve body in case, ensuring all check balls and springs are in correct positions. Install valve body bolts and torque evenly. Install new transmission filter. Install new pan gasket on pan, then position pan on case. Install pan bolts and torque in criss-cross pattern.
    Torque spec

    Pan Bolts20 Nm (15 lb-ft)
14. 14

    Reinstall transmission and transfer case
    Raise transmission into position using transmission jack. Align transmission to engine, ensuring torque converter pilot enters crankshaft properly and dowel pins engage. Install transmission-to-engine mounting bolts and torque to specification. Raise transfer case into position and align to transmission output shaft. Install transfer case mounting bolts and torque. Reinstall transmission crossmember and torque mounting bolts.
    Torque spec

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

    Reconnect all components and refill fluids
    Reconnect transmission cooler lines and torque fittings. Reconnect all electrical connectors to transmission sensors. Reconnect shift cable and adjust if necessary. Reinstall dipstick tube. Install front and rear driveshafts, aligning marks made during disassembly. Reinstall exhaust system. Install new drain plug crush washer and install drain plug. Fill transmission with 11 quarts MERCON LV ATF through dipstick tube. Fill transfer case with 2.5 quarts transfer case fluid. Reinstall skid plates if equipped.
    Torque spec

    Transmission Drain Plug30 Nm (22 lb-ft)

Reassembly

1. Verify all electrical connectors are fully seated and locked
2. Verify all driveshaft U-joint strap bolts are torqued to specification
3. Double-check transmission and transfer case fluid levels with engine running and transmission at operating temperature
4. Ensure shift cable adjustment allows proper engagement of all gear positions

Verification

• Lower vehicle and reconnect battery negative cable
• Start engine and verify no transmission fluid leaks at pan, cooler lines, or extension housing
• With foot on brake, shift through all gear positions and verify smooth engagement
• Check transmission fluid level with engine at operating temperature and adjust if necessary
• Test drive vehicle and verify smooth shifting, proper operation in all gears, and no unusual noises from transmission or transfer case
• Verify 4WD engagement works properly in both 4-High and 4-Low
• Re-check fluid levels after test drive and inspect for leaks

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