This procedure covers complete removal and installation of the crankshaft from a 2015-2020 Ford F-150 with 3.5L EcoBoost V6 engine, requiring engine removal from vehicle and complete disassembly.

Warnings

Tools required

Parts

• Crankshaft (remanufactured or new) × 1 — Use OEM specification
• Main bearing set (standard or appropriate oversize) × 1 — Use OEM specification
• Rod bearing set (standard or appropriate oversize) × 1 — Use OEM specification
• Thrust bearing set × 1 — Use OEM specification
• Front crankshaft seal × 1 — Use OEM specification
• Rear crankshaft seal × 1 — Use OEM specification
• Front main seal housing gasket × 1 — Use OEM specification
• Rear main seal housing gasket × 1 — Use OEM specification
• Oil pan gasket × 1 — Use OEM specification
• Timing cover gasket × 1 — Use OEM specification
• Timing chain kit (chains, guides, tensioners) × 1 — Use OEM specification
• Cylinder head gasket set × 1 — Use OEM specification
• Connecting rod bolts (TTY) × 12 — Use OEM specification
• Main bearing cap bolts (TTY) × 10 — Use OEM specification
• Cylinder head bolts (TTY) × 20 — Use OEM specification
• Oil filter × 1 — FL-820S or equivalent
• Oil drain plug crush washer × 1 — Use OEM specification
• Engine assembly lubricant × 1 — Use OEM specification
• RTV silicone sealant (Motorcraft TA-30) × 1 — TA-30 or equivalent

Fluids

• Motorcraft 0W-20 Full Synthetic — 6 qt
• Motorcraft Orange Coolant — 13 qt
• Motorcraft MERCON LV ATF — 11 qt

Preparation

1. Park vehicle on level surface and engage parking brake. Disconnect negative battery cable, then positive cable.
2. Drain engine oil completely and remove oil filter. Drain cooling system from radiator and engine block drain plugs.
3. Remove engine cover, air intake system, and intercooler piping.
4. Relieve fuel system pressure and disconnect fuel lines. Cap all open fuel fittings.
5. Remove radiator, cooling fans, and A/C condenser (move aside without disconnecting refrigerant lines if possible).
6. Disconnect all electrical connectors from engine harness. Label connections for reassembly.
7. Remove exhaust manifolds and turbochargers as assemblies.
8. Support transmission with transmission jack. Remove transmission-to-engine bolts and separate transmission from engine.
9. Disconnect power steering lines if equipped, brake booster vacuum line, and all remaining hoses.
10. Attach engine hoist to factory lift points using appropriate chains or straps. Verify secure attachment.
11. Remove engine mount bolts and carefully lift engine from vehicle. Transfer to engine stand and secure properly.
12. Prepare clean workspace with organized parts storage. Have all measuring tools calibrated and ready.

Procedure

1. 1

   Remove accessory drive components
   Remove serpentine belt, alternator, A/C compressor (move aside), power steering pump bracket if applicable, and all accessory brackets from front of engine. Remove harmonic balancer bolt using impact wrench (180 Nm removal). Use harmonic balancer puller to remove balancer from crankshaft nose. Do not hammer on crankshaft.
   Torque spec

   Harmonic Balancer Bolt180 Nm (133 lb-ft)
2. 2

   Remove timing cover and timing components
   Remove all timing cover bolts (note locations of different length bolts). Separate timing cover from engine block - may require gentle prying. Rotate engine to TDM position for cylinder #1. Compress timing chain tensioners using tensioner compression tool and install retaining pins. Remove tensioner bolts, then remove tensioners, guides, and timing chains. Mark timing chain orientation before removal.
   Torque spec

   Cover Bolts19 Nm (14 lb-ft)

   Timing Chain Tensioner Bolt25 Nm (18 lb-ft)

   Timing Chain Guide Bolts12 Nm (9 lb-ft)
3. 3

   Remove cylinder heads
   Remove valve covers. Loosen cylinder head bolts in reverse of tightening sequence (outside to inside pattern). Remove all cylinder head bolts - these are TTY and must be discarded. Lift cylinder heads from block, keeping them upright to prevent valve damage. Place on padded surface. Remove and discard head gaskets.
   ⚠Cylinder heads are heavy (approximately 50 lbs each). Use proper lifting technique or assistance to prevent injury.
   Torque spec

   Cylinder Head Bolts65 Nm (48 lb-ft)
4. 4

   Remove oil pan and oil pump
   Remove all oil pan bolts in sequence and lower oil pan from engine. Remove oil pump pickup tube bolts and remove pickup tube. Remove oil pump mounting bolts and remove oil pump assembly from front of block. Inspect oil pump drive for wear.
   Torque spec

   Oil Pan Bolts12 Nm (9 lb-ft)

   Oil Pump Pickup Tube12 Nm (9 lb-ft)

   Oil Pump Bolts12 Nm (9 lb-ft)
5. 5

   Remove flexplate/flywheel and rear seal housing
   Lock crankshaft rotation using appropriate tool. Remove flexplate bolts (automatic transmission) in star pattern. Remove flexplate. Remove rear main seal housing bolts and separate housing from block. Remove and discard rear crankshaft seal.
   Torque spec

   Flexplate Bolts85 Nm (63 lb-ft)

   Rear Main Seal Housing12 Nm (9 lb-ft)
6. 6

   Remove pistons and connecting rods
   Use ridge reamer to remove any ridge at top of cylinder bores. Rotate engine so piston is at bottom of stroke. Mark connecting rod and cap with cylinder number and orientation using permanent marker or stamps. Remove connecting rod bolts (note these are TTY). Remove rod caps and push piston/rod assembly out through top of block. Install rod caps back on rods immediately to prevent mixing. Repeat for all six cylinders.
   ⚠Do not let connecting rods scratch cylinder walls during removal. Protect cylinder bores with shop towels.
   Torque spec

   Connecting Rod Bolts45 Nm (33 lb-ft)
7. 7

   Remove main bearing caps and crankshaft
   Verify all connecting rods are removed. Mark main bearing caps with position and orientation (they are not interchangeable). Remove main bearing cap bolts in sequence from outside to inside (note these are TTY bolts). Carefully remove main bearing caps, keeping bearing shells with their respective caps. Carefully lift crankshaft straight up from block. Remove upper bearing shells from block, keeping them organized by position.
   ⚠Crankshaft weighs approximately 60 lbs. Use proper lifting technique and have assistance available.
   Torque spec

   Main Bearing Cap Bolts75 Nm (55 lb-ft)
8. 8

   Inspect and measure crankshaft and block
   Clean crankshaft thoroughly with solvent and dry completely. Inspect all journals for scoring, heat discoloration, or damage. Use micrometer to measure all main and rod journals at multiple points to check for taper and out-of-round. Maximum taper: 0.0005 inch, maximum out-of-round: 0.0005 inch. Measure cylinder bores with dial bore gauge for taper and out-of-round. Clean all oil passages with rifle brush and compressed air. Inspect block bearing saddles for damage.
   ⚠If crankshaft journals are worn beyond specification, crankshaft must be replaced or professionally reground to undersize with matching undersize bearings installed.
9. 9

   Install new crankshaft and verify bearing clearances
   Clean all bearing surfaces in block with lint-free cloth and solvent. Install new upper main bearing shells in block (without sealant - bearings have locating tabs). Apply thin coat of assembly lubricant to bearings. Carefully lower crankshaft into position. Install lower bearing shells in main caps. Apply assembly lubricant to lower bearings. Place strips of Plastigage on each crankshaft journal. Install main caps in correct positions and orientation. Install NEW main bearing cap bolts and torque to 75 Nm, then tighten additional angle per manufacturer specification (typically +90 degrees). DO NOT rotate crankshaft with Plastigage installed.
   ⚠️Main bearing clearance specification is typically 0.0009-0.0019 inch. Clearances outside this range will cause bearing failure.
   Torque spec

   Main Bearing Cap Bolts75 Nm (55 lb-ft)
10. 10

    Verify clearances and torque main caps final
    Remove main bearing cap bolts and carefully remove caps without rotating crankshaft. Measure flattened Plastigage width using Plastigage envelope scale to determine bearing clearance. Record all clearances. Verify all clearances are within specification (typically 0.0009-0.0019 inch). If clearances are correct, remove Plastigage residue completely. Reapply assembly lubricant to all bearing surfaces. Reinstall main caps with NEW bolts. Torque main bearing cap bolts to final specification: 75 Nm plus angle as specified. Verify crankshaft rotates freely by hand with smooth resistance.
    ⚠️If any bearing clearance is out of specification, do not proceed. Determine cause and correct before final assembly.
    Torque spec

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

    Install pistons and connecting rods with bearing clearance check
    Install new rod bearing shells in connecting rods and caps. Apply assembly lubricant to bearings. Install piston ring compressor on piston (ensure piston is being installed in correct cylinder and correct orientation). Insert rod/piston assembly into cylinder from top, guiding rod onto crankshaft journal. Install rod bearing cap in correct orientation with Plastigage on journal. Install NEW rod bolts and torque to 45 Nm plus angle per specification. Remove caps, verify bearing clearance (typically 0.0008-0.0015 inch), reinstall with assembly lubricant and torque to final specification. Repeat for all cylinders.
    ⚠Verify piston orientation markings face front of engine and connecting rod orientation matches original installation before tightening.
    Torque spec

    Connecting Rod Bolts45 Nm (33 lb-ft)
12. 12

    Install rear main seal and housing
    Clean rear main seal housing and engine block mating surface thoroughly. Install new rear crankshaft seal into housing using seal driver (install from outside, seal lip facing inward toward engine). Apply thin bead of RTV sealant to housing mating surface per manufacturer specification. Position housing on block and install bolts. Torque rear main seal housing bolts to 12 Nm in sequence from center outward.
    Torque spec

    Rear Main Seal Housing12 Nm (9 lb-ft)
13. 13

    Install flexplate and front components
    Position flexplate on crankshaft flange in correct orientation (note offset bolt pattern). Apply threadlocker to flexplate bolts. Install and torque flexplate bolts to 85 Nm in star pattern. Install oil pump with new gasket, torque bolts to 12 Nm. Install oil pump pickup tube with new O-ring, torque to 12 Nm. Clean oil pan mating surface and install new gasket. Install oil pan and torque bolts to 12 Nm in sequence (center outward).
    Torque spec

    Flexplate Bolts85 Nm (63 lb-ft)

    Oil Pump Bolts12 Nm (9 lb-ft)

    Oil Pump Pickup Tube12 Nm (9 lb-ft)

    Oil Pan Bolts12 Nm (9 lb-ft)
14. 14

    Install cylinder heads
    Verify block deck surface is completely clean. Position new cylinder head gaskets on block (note orientation markings - 'TOP' or 'FRONT' indicators). Carefully lower cylinder heads into position. Install NEW cylinder head bolts (TTY). Torque cylinder head bolts in specified sequence: first pass to 65 Nm, then tighten additional angle per manufacturer specification (typically two stages of +90 degrees each for total of 180 degrees).
    ⚠Follow exact torque sequence provided in service manual. Improper sequence can warp cylinder heads.
    Torque spec

    Cylinder Head Bolts65 Nm (48 lb-ft)
15. 15

    Install timing components and front seal
    Rotate crankshaft to TDM position for cylinder #1. Install new timing chains with marks aligned per manufacturer specification. Install timing chain guides and torque bolts to 12 Nm. Install timing chain tensioners (compressed with pins installed) and torque bolts to 25 Nm. Install new front crankshaft seal into front seal housing using seal driver. Install housing with new gasket, torque bolts to 12 Nm. Apply RTV sealant to timing cover gasket surfaces as specified. Install timing cover with new gasket, torque 8mm bolts to 25 Nm and 10mm bolts to 45 Nm in sequence. Remove timing chain tensioner retaining pins.
    ⚠️Verify timing chain alignment marks are correct before installing timing cover. Incorrect timing will cause severe engine damage.
    Torque spec

    Timing Chain Guide Bolts12 Nm (9 lb-ft)

    Timing Chain Tensioner Bolt25 Nm (18 lb-ft)

    Front Main Seal Housing12 Nm (9 lb-ft)

    Cover Bolts19 Nm (14 lb-ft)
16. 16

    Install harmonic balancer and complete engine assembly
    Clean crankshaft nose and harmonic balancer bore. Apply thin coat of clean engine oil to crankshaft nose and balancer bore. Install harmonic balancer onto crankshaft, aligning keyway. Install NEW harmonic balancer bolt if TTY type. Torque harmonic balancer bolt to 180 Nm using impact wrench or by locking crankshaft. Install all remaining external engine components in reverse order of removal. Install new oil filter.
    Torque spec

    Harmonic Balancer Bolt180 Nm (133 lb-ft)

Reassembly

1. Reinstall engine into vehicle in reverse order of removal, ensuring all engine mount bolts are torqued to specification.
2. Reconnect transmission using NEW transmission-to-engine bolts if TTY type, torque to 55 Nm.
3. Reconnect all exhaust components, electrical connectors, fuel lines, and cooling hoses.
4. Install intercooler piping, air intake system, and engine cover.
5. Fill cooling system with 13 quarts of Motorcraft Orange Coolant (50/50 mixture).
6. Fill engine with 6 quarts of Motorcraft 0W-20 Full Synthetic engine oil.
7. Fill transmission with 11 quarts of Motorcraft MERCON LV ATF (check level per procedure).
8. Reconnect battery cables (positive first, then negative).

Verification

• Verify no tools or parts are left in engine compartment. Check all fluid levels are correct.
• Perform initial start with oil pressure gauge monitoring. Oil pressure should register within 5 seconds. If no pressure, shut down immediately and investigate.
• Allow engine to reach normal operating temperature while monitoring for leaks (oil, coolant, fuel).
• Check for unusual noises, vibrations, or smoke during warm-up period.
• Verify timing by scanning for diagnostic trouble codes and checking engine performance.
• After initial warm-up, shut down engine and recheck all fluid levels. Add as necessary.
• Road test vehicle under light load, gradually increasing to normal driving conditions.
• Perform final inspection after 50-100 miles of driving. Recheck all fluid levels and inspect for leaks.
• Follow engine break-in procedure: avoid full throttle and sustained high RPM for first 500 miles. Change oil and filter at 500 miles.

More procedures for this vehicle