This procedure covers replacement of the transmission output shaft bearing on a 2015-2020 Ford F-150 with 3.5L EcoBoost engine and RWD configuration, requiring transmission removal and partial disassembly.

Warnings

Tools required

Parts

• Transmission output shaft bearing × 1 — Use OEM specification
• Transmission rear seal × 1 — Use OEM specification
• Transmission pan gasket × 1 — Use OEM specification
• Transmission filter × 1 — Use OEM specification
• Driveshaft flange bolts × 4 — Use OEM specification
• Transmission drain plug crush washer × 1 — Use OEM specification if equipped
• Extension housing gasket × 1 — Use OEM specification
• Thread locker (medium strength) × 1 — Loctite 243 or equivalent

Fluids

• Motorcraft MERCON LV ATF — 11 qt

Preparation

1. Park vehicle on level surface and set parking brake firmly
2. Disconnect negative battery cable and secure away from terminal
3. Raise vehicle on lift or secure on jack stands at manufacturer-specified lift points with wheels off ground
4. Remove rear wheels if additional clearance is needed for access
5. Allow transmission and exhaust system to cool completely if vehicle was recently operated
6. Place drain pan under transmission and drain fluid via drain plug if equipped, or prepare to drain from pan removal
7. Clean area around transmission pan, driveshaft connections, and transmission mounting points
8. Install engine support fixture across engine bay or attach engine hoist to support engine weight
9. Mark driveshaft and rear flange orientation for correct reinstallation
10. Photograph electrical connector locations and routing on transmission for reference

Procedure

1. 1

   Remove driveshaft and crossmember
   Remove the four bolts securing rear driveshaft flange to transmission output flange. Support driveshaft and slide rearward to remove from transmission output shaft. Mark orientation before removal. Remove transmission crossmember mounting bolts and carefully lower crossmember away from transmission. Transmission will now be supported only by jack.
2. 2

   Disconnect transmission connections
   Disconnect transmission cooler lines at transmission using line disconnect tools. Cap open lines immediately to prevent contamination. Disconnect all electrical connectors from transmission including speed sensors, solenoid body connector, and range sensor. Remove wire harness from transmission mounting clips. Disconnect shift cable at transmission lever and cable bracket.
3. 3

   Remove transmission from vehicle
   Position hydraulic transmission jack under transmission and secure with safety chains. Remove transmission-to-engine mounting bolts, noting different lengths and locations. Carefully slide transmission rearward on jack, ensuring torque converter stays with transmission. Guide transmission down and out from under vehicle. Transport to clean workbench and secure in transmission holding fixture.
   ⚠Keep transmission level during removal to prevent torque converter from sliding out. If converter slides forward, fluid will drain and converter must be reinstalled properly.
   Torque spec

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

   Remove transmission pan and valve body
   With transmission secured in fixture, remove transmission pan bolts in criss-cross pattern working from outside toward center. Lower pan and drain remaining fluid. Remove transmission filter. Remove valve body bolts and carefully lower valve body assembly, keeping solenoids and springs organized. Set valve body aside in clean area covered with lint-free cloth.
   ℹ️Keep all valve body components in order and protected from contamination. Any debris entering valve body will cause transmission failure.
   Torque spec

   Pan Bolts19 Nm (14 lb-ft)
5. 5

   Remove extension housing
   Remove extension housing mounting bolts securing rear housing to transmission case. Carefully tap housing with soft mallet to break gasket seal. Slide extension housing rearward off output shaft. Remove and discard gasket. The output shaft bearing is now accessible in the extension housing bore.
   Torque spec

   Mounting Bolts31 Nm (23 lb-ft)
6. 6

   Remove output shaft rear seal and measure bearing
   Using seal puller, remove rear seal from extension housing. Before removing bearing, install dial indicator on output shaft and measure shaft endplay by moving shaft in and out. Record measurement for reassembly reference. Normal endplay specification is 0.005-0.025 inches. This measurement is critical for proper bearing preload during reassembly.
   ⚠Endplay measurement must be recorded accurately. Incorrect bearing preload will cause premature bearing failure or transmission binding.
7. 7

   Remove output shaft bearing
   Using appropriate bearing puller, carefully extract output shaft bearing from extension housing bore. Inspect housing bore for scoring, damage, or discoloration. Clean bore thoroughly with solvent and lint-free cloth. Measure housing bore diameter with micrometer at multiple points to verify it is within specification and not worn oversize.
8. 8

   Install new output shaft bearing
   Using bearing installation tool matched to bearing outer race diameter, carefully drive new bearing into extension housing bore. Bearing must be installed to correct depth - typically flush with housing shoulder or as specified by service information. Ensure bearing is square during installation and seats completely. Inspect bearing for smooth rotation after installation.
   ⚠Apply installation force only to bearing outer race, never to inner race or rolling elements. Driving on wrong race will destroy bearing immediately.
9. 9

   Install new rear seal and reinstall extension housing
   Install new rear seal into extension housing using seal driver, ensuring seal is square and seated to proper depth with lip facing inward. Apply thin coat of ATF to seal lip. Install new extension housing gasket on transmission case. Apply thin bead of thread locker to extension housing mounting bolts. Carefully slide extension housing over output shaft and onto transmission case. Install mounting bolts and torque in criss-cross pattern.
   Torque spec

   Mounting Bolts31 Nm (23 lb-ft)
10. 10

    Verify bearing endplay
    With extension housing installed, reinstall dial indicator on output shaft and measure endplay again. Compare to initial measurement recorded during disassembly. Endplay should be within 0.005-0.025 inches. If endplay is excessive, bearing may not be seated properly or housing requires selective shims. If too tight, verify bearing installation depth and housing gasket is correct thickness.
    ⚠Do not proceed if endplay is outside specification. Incorrect preload will cause bearing failure and require repeating this entire procedure.
11. 11

    Reinstall valve body and pan
    Clean transmission case mating surface thoroughly. Position valve body assembly carefully into case, ensuring all passages align and no gaskets are pinched. Install valve body bolts and torque evenly. Install new transmission filter. Install new pan gasket and position pan on case. Install pan bolts and torque in criss-cross pattern from center outward.
    Torque spec

    Pan Bolts19 Nm (14 lb-ft)
12. 12

    Reinstall transmission in vehicle
    Position transmission on transmission jack and raise into position under vehicle. Align transmission with engine and carefully slide forward, ensuring torque converter hub engages pump correctly. Install transmission mounting bolts with appropriate thread locker and torque to specification. Install transmission crossmember and torque mounting bolts.
    Torque spec

    Mounting Bolts31 Nm (23 lb-ft)
13. 13

    Reconnect all components
    Reconnect all electrical connectors to transmission using photos taken during disassembly as reference. Reconnect transmission cooler lines and ensure fittings are secure. Reconnect shift cable to lever and bracket. Align driveshaft to transmission output flange using alignment marks made during removal. Install new driveshaft flange bolts with thread locker and torque in star pattern to manufacturer specification.
14. 14

    Fill transmission with fluid
    Remove transmission dipstick tube or fill plug. Using transmission fill pump and clean funnel, add 10 quarts of Motorcraft MERCON LV ATF through fill tube. With engine off, check fluid level. Start engine and allow to idle, shifting through all gear ranges with foot on brake. Recheck fluid level with engine at operating temperature and add fluid to bring to proper level on dipstick. Install drain plug with new crush washer if equipped and torque to specification.
    Torque spec

    Transmission Drain Plug30 Nm (22 lb-ft)

Reassembly

1. Torque all fasteners to specifications using criss-cross or star patterns where applicable
2. Ensure all electrical connectors are fully seated with locking tabs engaged
3. Verify transmission cooler lines are properly routed and secured away from exhaust components
4. Double-check that driveshaft is installed in original orientation to prevent driveline vibration
5. Reconnect negative battery cable and clear any diagnostic codes that may have set
6. Reinstall rear wheels if removed and torque lug nuts to specification

Verification

• With engine running and transmission in Park, check for fluid leaks around pan, extension housing, cooler lines, and all seal areas
• Test drive vehicle and verify smooth shifting through all gear ranges with no abnormal noise from transmission
• Listen specifically for bearing noise from transmission rear area during acceleration and deceleration
• Verify speedometer and all transmission-related functions operate correctly
• Recheck transmission fluid level after test drive with fluid at operating temperature and engine idling
• Check for diagnostic trouble codes related to transmission speed sensors or other transmission components
• Verify no fluid leaks are present after test drive, particularly at extension housing seal

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