This procedure covers replacement of the torque converter clutch solenoid on a 2015-2020 Ford F-150 with 3.5L EcoBoost V6, requiring transmission pan removal and internal valve body access.

Warnings

Tools required

Parts

• Torque converter clutch solenoid × 1 — Use OEM Ford part BC3Z-7G391-F or equivalent
• Transmission pan gasket × 1 — Use OEM specification
• Transmission fluid drain plug crush washer × 1 — Use OEM specification if equipped
• Shop towels and degreaser × 1 — Generic

Fluids

• Motorcraft MERCON LV ATF — 11 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Allow transmission to cool completely (minimum 2 hours after operation)
3. Disconnect negative battery cable to prevent electrical faults
4. Raise vehicle and support securely on jack stands at frame rails
5. Remove skid plates or undertray panels if equipped
6. Clean transmission pan and surrounding area with degreaser to prevent contamination
7. Position large drain pan beneath transmission pan

Procedure

1. 1

   Drain transmission fluid
   If equipped with drain plug, remove transmission drain plug and allow fluid to drain completely. If no drain plug is present, carefully loosen transmission pan bolts in a criss-cross pattern starting at one corner, allowing fluid to drain as pan tilts. Keep drain pan positioned to catch approximately 6-8 quarts of fluid during initial drain.
   Torque spec

   Transmission Drain Plug30 Nm (22 lb-ft)
2. 2

   Remove transmission pan
   Remove all transmission pan bolts in reverse criss-cross pattern. Carefully lower pan, being aware remaining fluid (2-3 quarts) will spill. Remove pan completely and pour remaining fluid into drain pan. Inspect pan for metal debris or clutch material that may indicate other transmission issues.
   Torque spec

   Pan Bolts19 Nm (14 lb-ft)
3. 3

   Remove and clean transmission filter
   Locate transmission filter assembly attached to valve body. Remove filter mounting bolts and carefully pull filter straight down. Some fluid will drain from filter cavity. Inspect old filter for debris. Clean filter mounting surface on valve body with brake cleaner and lint-free cloth.
   ℹ️The 10R80 transmission filter is typically reusable unless damaged. Inspect O-ring seal for damage.
   Torque spec

   Mounting Bolts31 Nm (23 lb-ft)
4. 4

   Access solenoid pack
   Locate the transmission solenoid pack/valve body assembly on the passenger side of the transmission case. The solenoid pack is secured by multiple bolts. Identify and label all electrical connectors before disconnection. Disconnect the main transmission control module connector and individual solenoid connectors by pressing release tabs.
   ⚠Do not pull on wires. Press connector release tabs firmly and pull on connector bodies only.
5. 5

   Remove solenoid pack cover
   Remove the solenoid pack cover screws in a criss-cross pattern. Carefully lift cover away, being aware of any remaining fluid in the cavity. Inspect cover gasket and replace if damaged or compressed.
   Torque spec

   Cover Screws12 Nm (9 lb-ft)
6. 6

   Identify and remove torque converter clutch solenoid
   The torque converter clutch (TCC) solenoid is typically located in the upper section of the solenoid pack. It is identified by its specific connector configuration and position. Remove the solenoid mounting bolts and carefully wiggle the solenoid to break the seal. Pull solenoid straight out to avoid damaging valve body bores. Note orientation and position of O-rings.
   ⚠Do not pry on solenoid body. This can damage valve body casting or solenoid mounting surfaces.
   Torque spec

   Sensor Bolts12 Nm (9 lb-ft)
7. 7

   Clean solenoid bore and inspect valve body
   Use brake cleaner and compressed air to thoroughly clean the solenoid mounting bore. Inspect bore for scoring, debris, or damage. Check valve body passages for blockages. Inspect all visible check balls and springs for proper position. Any debris or damage to the valve body requires additional diagnosis.
   ⚠Do not lose check balls or springs. Use low pressure compressed air only to avoid dislodging internal components.
8. 8

   Install new torque converter clutch solenoid
   Lubricate new solenoid O-rings with clean MERCON LV transmission fluid. Verify O-rings are properly seated in solenoid grooves. Carefully insert solenoid into valve body bore, ensuring proper alignment. Push solenoid fully seated and install mounting bolts finger-tight, then torque to specification.
   ℹ️Do not use petroleum-based lubricants on O-rings. Use only MERCON LV ATF or approved assembly lube.
   Torque spec

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

   Reinstall solenoid pack cover
   Clean cover gasket surface and install new gasket if needed. Position cover onto solenoid pack and install cover screws. Torque screws in criss-cross pattern to specification to ensure even gasket compression.
   Torque spec

   Cover Screws12 Nm (9 lb-ft)
10. 10

    Reconnect electrical connectors
    Reconnect all solenoid electrical connectors and main transmission control module connector. Ensure all connectors click firmly into place and locking tabs are fully engaged. Verify no wires are pinched or in contact with sharp edges.
    ℹ️Incorrect connector installation can cause transmission shifting issues or fault codes.
11. 11

    Reinstall transmission filter
    Install new or cleaned filter with new O-ring seal lubricated with MERCON LV. Align filter to valve body and install mounting bolts. Torque bolts to specification in a criss-cross pattern.
    Torque spec

    Mounting Bolts31 Nm (23 lb-ft)
12. 12

    Clean and prepare transmission pan
    Thoroughly clean transmission pan interior with brake cleaner. Remove all old gasket material from pan and transmission case mating surfaces using razor blade or gasket scraper. Ensure surfaces are completely clean and dry. Clean magnet in pan if equipped.
    ⚠Any debris or old gasket material left on mating surfaces will cause leaks.
13. 13

    Install transmission pan with new gasket
    Position new gasket on transmission pan or transmission case according to gasket design. Carefully raise pan into position, ensuring gasket stays aligned. Install all pan bolts finger-tight. Torque pan bolts in criss-cross pattern starting from center and working outward to specification.
    ⚠Do not overtighten pan bolts. Excessive torque will distort pan and cause leaks.
    Torque spec

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

    Refill transmission with fluid
    Locate transmission fluid fill tube. Using fluid pump or funnel, add approximately 6 quarts of Motorcraft MERCON LV ATF initially. Start engine and allow to idle in Park. With engine running and transmission at operating temperature (160-180°F), check fluid level using dipstick or fill plug procedure per Ford specification. Add fluid as needed to reach proper level. Total capacity is approximately 11 quarts, but actual fill amount depends on what drained.
    ⚠️Engine must be running and transmission in Park during fluid level check on 10R80 transmission. Follow exact Ford procedure for accurate fluid level.
    ⚠Overfilling transmission can cause foaming, overheating, and shifting issues. Add fluid in small increments.
15. 15

    Clear diagnostic codes and verify operation
    Reconnect negative battery cable. Use scan tool to clear any stored transmission diagnostic trouble codes. Start engine and verify no warning lights on instrument cluster. With brake pedal applied, shift through all gear ranges (P-R-N-D) pausing 3 seconds in each position. Check for leaks around transmission pan. Perform test drive with multiple acceleration and deceleration cycles to verify proper torque converter clutch lockup.
    ℹ️Transmission may exhibit slightly delayed shifts for first 5-10 shift cycles as adaptive learning resets.

Reassembly

1. Ensure all electrical connectors are fully seated and locked
2. Verify transmission pan bolts are torqued in proper criss-cross sequence
3. Double-check transmission fluid level at operating temperature with engine running
4. Reinstall any skid plates or undertray panels removed during preparation
5. Verify no tools or parts were left in engine bay or under vehicle

Verification

• Start engine and verify no transmission warning lights or check engine light
• With engine at idle and transmission in Park, verify smooth operation and no unusual noises
• Perform test drive with multiple shifts through all gears including highway speeds to verify torque converter lockup
• Monitor transmission temperature during test drive - should stabilize between 175-200°F
• Use scan tool to verify no active or pending transmission codes
• Check for fluid leaks around transmission pan and all service areas after test drive
• Verify proper shift quality and torque converter lockup engagement at cruising speeds (typically 40+ mph)
• Re-check transmission fluid level after test drive and top off if necessary

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