Complete removal, disassembly, inspection, rebuild, and reinstallation of the 10R80 10-speed automatic transmission in a 2015-2020 Ford F-150 with 3.5L EcoBoost V6 engine.

Warnings

Tools required

Parts

• 10R80 master rebuild kit with clutches and seals × 1 — Use OEM or Transtar specification
• Torque converter (if damaged or high mileage) × 1 — OEM BC3Z-7902-F or equivalent
• Transmission filter and seal kit × 1 — Motorcraft FT-182 or equivalent
• Transmission pan gasket × 1 — Fel-Pro TOS18767 or OEM
• Transmission cooler line O-rings × 1 — Use OEM specification
• Transmission drain plug crush washer (if equipped) × 1 — Use OEM specification
• Solenoid body gaskets and seals × 1 — Included in master kit or separate
• Valve body separator plate and gaskets × 1 — Included in master kit
• New flywheel bolts (if TTY) × 8 — Use OEM specification
• Transmission mount (if worn) × 1 — Inspect before ordering

Fluids

• Motorcraft MERCON LV ATF — 16 qt

Preparation

1. Position vehicle on level ground and engage parking brake
2. Disconnect negative battery cable and secure away from terminal
3. Raise vehicle on lift or jack stands to comfortable working height with adequate clearance underneath
4. Remove engine cover and air intake system for access
5. Install engine support fixture across engine bay to support engine weight
6. Drain transmission fluid completely using drain plug or removing pan. Collect fluid for inspection
7. Remove driveshaft after marking yoke-to-flange alignment
8. Disconnect shift linkage, electrical connectors, and transmission cooler lines from transmission
9. Remove exhaust system components as needed for transmission clearance
10. Remove starter motor for access to torque converter bolts
11. Set up clean, organized workspace with parts bins for disassembly
12. Have transmission rebuild manual and specifications available for reference

Procedure

1. 1

   Remove transmission from vehicle
   Support transmission securely with transmission jack. Remove crossmember and transmission mount. Remove bellhousing-to-engine mounting bolts. Carefully separate transmission from engine, ensuring torque converter remains with transmission. Use pry bar if needed but avoid damaging alignment dowels. Lower transmission carefully and move to rebuild stand.
   Torque spec

   Mounting Bolts31 Nm (23 lb-ft)
2. 2

   Remove external components and pan
   Remove torque converter and inspect for debris or damage. Mount transmission on rebuild stand. Remove all external sensors, solenoids, and wiring harness. Remove transmission pan bolts in criss-cross pattern and remove pan. Inspect pan for metal debris, clutch material, or damage. Remove transmission filter. Photograph valve body and solenoid locations before removal.
   Torque spec

   Pan Bolts19 Nm (14 lb-ft)

   Sensor Bolts12 Nm (9 lb-ft)
3. 3

   Remove valve body and control components
   Carefully disconnect all internal wiring harnesses from valve body. Remove valve body bolts in sequence per service manual (typically inside-out pattern). Carefully lift valve body straight up to avoid damaging check balls or separator plate. Keep separator plate, gaskets, and check balls in order. Inspect valve body for wear, scoring, or debris. Clean thoroughly with brake cleaner and compressed air.
4. 4

   Disassemble transmission case and remove clutch packs
   Remove pump bolts and carefully extract pump assembly using slide hammers or pry technique. Remove front snap rings and wave plates. Use clutch pack compressor to compress clutch assemblies and remove snap rings. Carefully extract each clutch pack assembly, keeping components in order. Label each pack (A, B, C, D, E clutches) and document plate sequence with photos. Remove planetary gear sets and internal snap rings. Extract shafts carefully to avoid damaging bushings or sealing surfaces.
5. 5

   Inspect all components for wear and damage
   Measure all clutch plates for thickness and warpage using micrometer. Check clearances against service specifications (typically 0.025-0.045 inch per pack). Inspect friction plates for glazing, burning, or delamination. Check steel plates for discoloration or warping. Inspect all bushings for wear using inside micrometer. Check all sealing surfaces for scoring or damage. Inspect planetary gears for wear, pitting, or broken teeth. Check shafts for scoring, wear, or cracks. Measure all end play specifications with dial indicator. Replace any worn components per rebuild kit and specifications.
6. 6

   Clean and prepare all hard parts for reassembly
   Thoroughly clean all metal components in parts washer. Use compressed air to blow out all oil passages in case, shafts, and pump. Inspect case for cracks, especially around bolt holes and bearing bores. Clean valve body separator plate and verify all check ball locations per service manual. Soak new clutch friction plates in MERCON LV ATF for minimum 30 minutes before installation. Layout all new seals, gaskets, and O-rings from rebuild kit. Verify all components match specifications before proceeding.
7. 7

   Rebuild pump assembly and install new seals
   Disassemble pump and install new seal rings, O-rings, and bushings from rebuild kit. Check pump body and gears for wear or scoring. Measure pump clearances per specifications (typically 0.001-0.003 inch). Install new pump seal using seal driver. Lubricate all components with ATF during assembly. Test pump gear rotation for smoothness. Apply thin coat of petroleum jelly to new pump O-ring and install carefully into case bore.
8. 8

   Reassemble internal components and clutch packs
   Install new bushings in case if worn beyond specification. Install rear planetary assembly and thrust washers with proper lubrication. Begin installing clutch packs starting from rear, alternating steel and friction plates per rebuild kit specifications. Use air pressure to verify check ball operation in case passages. Install wave springs and snap rings, ensuring proper seating in grooves. Measure each clutch pack clearance with feeler gauge and verify against specifications. Install intermediate shaft and verify proper engagement with planetary sets.
9. 9

   Install forward clutch assemblies and measure end play
   Install forward clutch drum assembly with new seals lubricated with ATF. Install proper sequence of clutch plates per specifications. Compress clutch pack and install retaining snap ring. Measure clutch pack clearance and adjust with selective snap rings if needed. Install input shaft and verify smooth rotation through all gear sets. Set up dial indicator on output shaft and measure total end play. Adjust end play to specification (typically 0.008-0.028 inch) using selective thrust washers.
10. 10

    Install pump assembly to transmission case
    Install new pump O-ring and gasket. Apply thin coat of ATF to pump bore and O-ring. Carefully align pump with case, ensuring proper engagement with forward clutch hub. Tap pump into case using soft mallet if needed, ensuring even seating. Install pump bolts finger-tight initially, then torque in star pattern to specification per service manual (typically 15-20 Nm). Verify input shaft rotates freely after pump installation.
11. 11

    Install valve body and separator plate assembly
    Install new separator plate gaskets on valve body. Verify all check balls are in correct positions per service manual diagram (typically 15-20 balls in specific locations). Carefully position separator plate and upper gasket. Align valve body to case, ensuring all fluid passages align correctly. Install valve body bolts finger-tight, then torque in sequence per service manual (typically inside-out pattern) to specification. Connect all internal wiring harnesses and solenoid connectors. Verify all connectors are fully seated.
12. 12

    Install transmission filter and pan
    Install new transmission filter and O-ring seal. Torque filter bolts to specification. Clean pan mating surface on case thoroughly. Install new pan gasket (do not use RTV unless specified). Position pan carefully to avoid shifting gasket. Install pan bolts finger-tight, then torque in criss-cross pattern from center outward to specification. Do not overtighten as this can distort pan and cause leaks.
    Torque spec

    Pan Bolts19 Nm (14 lb-ft)
13. 13

    Install external components and prepare for installation
    Install all external sensors and solenoids with new O-rings lubricated with ATF. Torque sensor bolts to specification. Install wiring harness and verify all connections. Install new transmission cooler line O-rings and connect lines. Install new drain plug crush washer if equipped and torque drain plug to specification. Inspect torque converter for damage, replace if needed. Install new torque converter seal in pump. Verify torque converter hub engages fully with pump (should seat with 2-3 distinct clicks).
    Torque spec

    Sensor Bolts12 Nm (9 lb-ft)

    Transmission Drain Plug30 Nm (22 lb-ft)
14. 14

    Install transmission into vehicle
    Apply small amount of grease to torque converter hub and input shaft splines. Carefully raise transmission into position using transmission jack. Rotate torque converter while aligning to ensure proper engagement with flexplate. Align transmission to engine using dowel pins. Push transmission forward until bellhousing is flush with engine block. Install bellhousing mounting bolts and torque to specifications (two different torque values used for different bolt sizes). Install transmission mount and crossmember. Remove transmission jack and engine support fixture.
    Torque spec

    Mounting Bolts31 Nm (23 lb-ft)
15. 15

    Complete installation and initial fluid fill
    Rotate engine and access torque converter bolts through starter opening. Install flywheel bolts (use new TTY bolts if specified) and torque in star pattern to specification. Install starter motor. Reconnect shift linkage and adjust per service manual. Reconnect all electrical connectors. Install driveshaft aligned with marks made during removal. Install exhaust components. Lower vehicle. Fill transmission with approximately 6 quarts MERCON LV ATF initially through dipstick tube. Reconnect battery.
    Torque spec

    Flywheel Bolts95 Nm (70 lb-ft)

Reassembly

1. Follow steps in reverse order for any components removed during preparation
2. Replace air intake system and engine covers
3. Verify all electrical connections are secure and properly routed
4. Double-check all fasteners are torqued to specification
5. Ensure transmission cooler lines are properly secured with no kinks

Verification

• With engine off and parking brake set, cycle shifter through all gear positions to verify linkage operation
• Start engine and verify no leaks from pan, cooler lines, or seals
• With foot on brake, shift through all gears and verify engagement (P-R-N-D-M)
• Check ATF level with engine at operating temperature and add fluid as needed to bring to proper level on dipstick
• Perform initial test drive at moderate speeds, verifying smooth shifts in all gears with no slipping or harsh engagement
• Check for trouble codes using scan tool and verify transmission control module recognizes all sensors
• Perform transmission relearn procedure using Ford IDS scan tool or equivalent if required by service manual
• Recheck fluid level after test drive and top off as needed
• Inspect for leaks after test drive and verify no drips from pan or seals
• Monitor shift quality over first 100 miles and recheck fluid level at 500 miles

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