This procedure covers the replacement of the starter solenoid on a 2015-2020 Ford F-150 with the 3.5L EcoBoost V6 engine. The solenoid is integral to the starter assembly and requires starter removal for replacement.

Warnings

Tools required

Parts

• Starter motor assembly with integrated solenoid × 1 — Use OEM Motorcraft SA-1065-RM or equivalent
• Anti-seize compound × 1 — Use copper-based anti-seize

Preparation

1. Park vehicle on level ground and engage parking brake
2. Place wheel chocks behind rear wheels
3. Allow engine to cool completely if recently operated
4. Raise front of vehicle and support securely on jack stands
5. Ensure adequate working clearance beneath vehicle

Procedure

1. 1

   Disconnect battery
   Open the hood and locate the battery in the engine bay. Using a 10mm socket, loosen and remove the negative battery cable from the battery terminal. Move the cable away from the terminal and secure it to prevent accidental contact. Wait at least 5 minutes for any residual electrical charge to dissipate.
   Torque spec

   Battery Terminal Bolts6 Nm (4 lb-ft)
2. 2

   Access starter from below
   Position yourself under the vehicle with adequate lighting. The starter is located on the passenger side of the engine block, between the engine and transmission bellhousing. Remove any splash shields or undertray panels if equipped using 10mm fasteners to improve access.
3. 3

   Disconnect starter electrical connections
   Locate the two electrical connections on the starter solenoid. The larger cable is the battery positive feed with a protective rubber boot. Slide the boot back and use a 13mm socket to remove the nut securing the cable to the solenoid stud. For the smaller trigger wire connector, press the release tab and pull straight off. Do not pull on the wire itself.
   ⚠Mark or photograph wire positions before removal to ensure correct reinstallation.
   Torque spec

   Battery Terminal Bolts6 Nm (4 lb-ft)
4. 4

   Remove starter mounting bolts
   Locate the two starter mounting bolts that secure the starter to the transmission bellhousing. These are 15mm bolts accessed from below. The upper bolt may require a longer extension to reach. Remove both bolts completely while supporting the starter weight with your free hand. Apply penetrating oil if bolts are corroded.
   ⚠Support the starter before removing the second bolt to prevent it from falling.
   Torque spec

   Mounting Bolts39 Nm (29 lb-ft)
5. 5

   Remove starter assembly
   With both mounting bolts removed, carefully maneuver the starter out of the bellhousing. The starter may need to be tilted or rotated to clear the engine and chassis components. Lower the starter carefully and move it away from the work area. Note the position of any shims or spacers that may be present between the starter and bellhousing.
6. 6

   Inspect mounting surface and components
   Clean the starter mounting surface on the bellhousing with a wire brush. Inspect the ring gear on the flywheel/flexplate for damage or missing teeth by rotating the crankshaft if necessary. Check that any shims or alignment components are in good condition. Clean all electrical connection points with electrical contact cleaner or wire brush.
7. 7

   Prepare new starter assembly
   Remove the new starter from packaging and verify it matches the old unit in mounting configuration and electrical connections. Apply a thin coat of anti-seize compound to the mounting bolt threads. Verify that the solenoid plunger moves freely by pressing it by hand (it should spring back).
8. 8

   Install new starter assembly
   Position the new starter into the bellhousing opening, ensuring any shims or alignment components are in their original positions. Align the mounting holes while supporting the starter weight. Thread both mounting bolts by hand to ensure proper thread engagement before tightening. Verify the starter nose is fully seated into the bellhousing bore.
9. 9

   Torque starter mounting bolts
   Using a torque wrench and 15mm socket, tighten both starter mounting bolts to specification in a cross-pattern (alternate between upper and lower bolt). Ensure the starter is properly aligned and seated before final torque. Verify there is no gap between the starter and bellhousing.
   Torque spec

   Mounting Bolts39 Nm (29 lb-ft)
10. 10

    Reconnect electrical connections
    Connect the small trigger wire to the solenoid terminal by pushing firmly until the connector clicks into place. Position the large battery positive cable onto the solenoid stud, ensuring the cable terminal is clean and sits flat. Install the nut and tighten to specification using a 13mm socket and torque wrench. Slide the protective rubber boot back over the connection.
    ⚠Ensure the battery positive cable does not contact the engine block or chassis to prevent short circuit.
    Torque spec

    Battery Terminal Bolts6 Nm (4 lb-ft)
11. 11

    Reinstall underbody panels
    If any splash shields or undertray panels were removed, reinstall them using the original fasteners. Ensure all clips and bolts are properly secured. Lower the vehicle from jack stands carefully.
12. 12

    Reconnect battery
    Clean the negative battery terminal and cable end with a wire brush if corrosion is present. Reconnect the negative battery cable to the battery terminal and tighten the bolt to specification using a 10mm socket and torque wrench. Ensure the connection is secure.
    Torque spec

    Battery Terminal Bolts6 Nm (4 lb-ft)

Reassembly

1. Verify all electrical connections are secure and properly routed away from heat sources and moving parts
2. Confirm no tools or parts were left in the engine compartment or under the vehicle
3. Double-check that both starter mounting bolts are torqued to specification

Verification

• Turn the ignition key to the START position and verify the engine cranks smoothly without grinding or clicking noises
• Start the engine and let it idle briefly, listening for any unusual sounds from the starter area
• Turn off the engine and restart it 2-3 times to confirm consistent operation
• Verify there are no warning lights on the instrument cluster related to charging system
• Inspect underneath the vehicle for any loose fasteners or leaking fluids
• Test that the starter disengages immediately when the key is released from START position

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