Crankshaft R&R

Complete removal and replacement of the crankshaft, including engine removal, disassembly of rotating assembly, main bearings, and timing components.

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
• Front crankshaft seal × 1 — Use OEM specification
• Rear main seal × 1 — Use OEM specification
• Oil pump × 1 — Use OEM specification
• Timing chain kit (chains, guides, tensioners) × 1 — Use OEM specification
• Oil pan gasket × 1 — Use OEM specification
• Timing cover gasket × 1 — Use OEM specification
• Front cover seal × 1 — Use OEM specification
• Valve cover gaskets × 2 — Use OEM specification
• Intake manifold gaskets × 1 — Use OEM specification
• Exhaust manifold gaskets × 2 — Use OEM specification
• Head gaskets × 2 — Use OEM specification
• Main cap bolts (TTY) × 10 — Use OEM specification
• Rod bolts (TTY) × 16 — Use OEM specification
• Cylinder head bolts (TTY) × 20 — Use OEM specification
• Harmonic balancer bolt (TTY) × 1 — Use OEM specification
• Flexplate or flywheel bolts × 8 — Use OEM specification
• Oil filter × 1 — FL-820S or equivalent
• Oil drain plug washer × 1 — Use OEM specification
• RTV silicone sealant (Motorcraft TA-31) × 1 — Use OEM specification
• Engine assembly lube × 1 — Use OEM specification

Fluids

• Motorcraft 0W-20 Full Synthetic — 7.5 qt
• Motorcraft Orange Coolant — 16 qt
• Motorcraft MERCON LV ATF — 11 qt

Preparation

1. Verify replacement crankshaft has been inspected, measured, and machined if necessary by qualified machine shop
2. Ensure workspace has adequate overhead clearance for engine removal (minimum 10 feet)
3. Disconnect negative battery cable and isolate
4. Relieve fuel system pressure by removing fuel pump fuse and cranking engine until it stalls
5. Drain engine oil completely and remove oil filter
6. Drain cooling system completely from radiator petcock and block drains
7. Remove engine cover and air intake system
8. Remove radiator, cooling fans, and upper/lower radiator hoses
9. Label and disconnect all engine wiring harnesses, vacuum lines, and fuel lines
10. Remove serpentine belt and accessories (alternator, A/C compressor, power steering pump)
11. Remove exhaust manifolds or Y-pipe from manifolds
12. Support transmission with transmission jack
13. Remove transmission-to-engine bolts and separate transmission (or remove complete assembly)
14. Attach engine hoist with load leveler to engine lift points
15. Remove engine mount bolts
16. Carefully lift engine from vehicle and mount securely on engine stand

Procedure

1. 1

   Remove external engine components
   With engine on stand, remove valve covers, intake manifold, fuel rails, ignition coils, and spark plugs. Remove oil dipstick tube. Remove accessory brackets still attached to engine. Label all components for proper reinstallation.
2. 2

   Remove cylinder heads
   Loosen cylinder head bolts in reverse of tightening sequence (consult Ford service manual for exact sequence). Remove cylinder head bolts completely. Carefully lift cylinder heads off block using proper lifting points. Place heads on clean work surface with combustion chambers facing up. Keep head bolts separated and labeled by position if reusing (not recommended for TTY bolts).
   ⚠Cylinder heads are heavy (approximately 50 lbs each). Use proper lifting technique or assistance to avoid injury.
   Torque spec

   Cylinder Head Bolts65 Nm (48 lb-ft)
3. 3

   Remove timing components
   Remove harmonic balancer using puller (do not hammer). Remove timing cover bolts in sequence and remove cover. Release timing chain tensioners using appropriate tool. Remove timing chains, guides, and tensioners. Mark camshaft and crankshaft positions before removal. Remove crankshaft timing gear/sprocket.
   ⚠Do not rotate crankshaft or camshafts independently once timing components are removed to prevent valve-to-piston contact.
   Torque spec

   Harmonic Balancer Bolt180 Nm (133 lb-ft)

   Cover Bolts20 Nm (15 lb-ft)

   Timing Chain Tensioner Bolt25 Nm (18 lb-ft)

   Timing Chain Guide Bolts12 Nm (9 lb-ft)
4. 4

   Remove oil pan and oil pump
   Remove oil pan bolts in reverse sequence and remove oil pan. Remove oil pump pickup tube. Remove oil pump mounting bolts and remove oil pump assembly. Clean all gasket surfaces thoroughly.
   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 main seal housing
   Remove flexplate (automatic) or flywheel (manual) bolts in star pattern. Remove flexplate/flywheel. Remove rear main seal housing bolts and carefully remove housing. Note orientation of housing for reinstallation.
   ⚠Flexplate/flywheel may have balance marks or specific orientation. Mark position before removal.
   Torque spec

   Flexplate Bolts85 Nm (63 lb-ft)

   Flywheel Bolts95 Nm (70 lb-ft)

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

   Remove pistons and connecting rods
   Rotate engine so cylinders 1 and 2 are at bottom dead center. Check connecting rods and caps for cylinder number stamps. If not marked, mark with permanent marker or punch. Remove connecting rod cap bolts. Remove rod caps and place with corresponding rod. Push piston/rod assembly up and out through top of cylinder bore. Place assemblies on clean surface in order. Repeat for all eight cylinders.
   ⚠Do not allow connecting rod to contact crankshaft journal during removal. Cover rod bolts with rubber hose to prevent damage to journals.
   Torque spec

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

   Check main bearing cap orientation and remove
   Verify main bearing caps are numbered 1-5 from front to back and marked for direction (arrow pointing toward front). If not marked, mark them clearly. Loosen main bearing cap bolts evenly in reverse sequence, working from outer caps toward center. Remove all main cap bolts. Carefully remove main bearing caps and set aside in order with upper and lower bearing shells kept together.
   ⚠Main caps must be reinstalled in exact same position and orientation. Improper installation will cause immediate engine failure.
   Torque spec

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

   Remove crankshaft
   Carefully lift crankshaft straight up out of engine block. Use assistance or lifting strap as crankshaft weighs approximately 60 lbs. Place crankshaft on clean protected work surface. Remove upper main bearing shells from block and keep with corresponding cap bearings. Remove front crankshaft seal from timing cover if not already done.
   ⚠Do not drop or impact crankshaft. Even minor impacts can cause internal stress cracks.
9. 9

   Inspect and measure crankshaft journals
   Thoroughly clean crankshaft with solvent and compressed air. Inspect all journal surfaces for scoring, discoloration, or damage. Using precision micrometer, measure all main bearing journals and rod journals in multiple positions (check for taper and out-of-round). Main journals should measure 2.7170-2.7178 inches. Rod journals should measure 2.0866-2.0874 inches. Out-of-spec measurements require machining to next undersize. Check crankshaft runout with dial indicator (max 0.002 inch TIR). Inspect oil passages for debris.
   ⚠Journals out of specification must be machined by qualified shop. Using out-of-spec crankshaft will result in bearing failure.
10. 10

    Prepare engine block and install new main bearings
    Clean engine block main bearing saddles thoroughly with solvent and compressed air. Inspect bearing saddles for damage. Ensure all oil passages are clear. Install new upper main bearing shells into block saddles, ensuring bearing tangs are properly seated in notches. Do not mix bearing positions. Apply thin coat of assembly lube to bearing surfaces. Install new lower main bearing shells into main caps with tangs properly seated.
    ℹ️Bearings must match crankshaft journal size. Use standard size for standard journals or appropriate undersize for machined journals.
11. 11

    Install crankshaft and check bearing clearances
    Carefully lower crankshaft into block, aligning with main bearing saddles. Place strips of Plastigage across each crankshaft main journal (do not rotate crankshaft). Install main bearing caps in correct position and orientation with arrows pointing forward. Install NEW main cap bolts and torque in sequence from center outward to 75 Nm (55 lb-ft), then tighten additional angle per Ford specification (typically 90 degrees). Do NOT rotate crankshaft. Remove caps one at a time and measure Plastigage width. Clearance should be 0.0009-0.0019 inches. If out of spec, diagnose bearing or journal issue before proceeding.
    ⚠Do not rotate crankshaft with Plastigage installed. This will give false readings.
    ⚠Bearing clearances outside specification will cause immediate bearing failure. Do not proceed until corrected.
    Torque spec

    Main Bearing Cap Bolts75 Nm (55 lb-ft)
12. 12

    Final crankshaft installation
    Remove main caps and clean all Plastigage residue from bearings and journals. Reapply assembly lube to all bearing surfaces. Reinstall main caps in correct order and orientation. Install NEW main cap bolts. Torque main cap bolts in sequence from center outward: first to 75 Nm (55 lb-ft), then tighten additional angle per Ford specification (typically 90 degrees). Verify crankshaft rotates smoothly by hand with no binding or tight spots. Check crankshaft endplay with dial indicator (specification 0.0051-0.0118 inches).
    ⚠If crankshaft does not rotate freely, disassemble and diagnose issue. Forcing rotation will cause damage.
    Torque spec

    Main Bearing Cap Bolts75 Nm (55 lb-ft)
13. 13

    Install connecting rod bearings and pistons
    Install new rod bearing shells in connecting rods and caps, ensuring tangs are seated. Apply assembly lube to bearings. Check bearing clearances using Plastigage (specification 0.0010-0.0018 inches). Install piston rings on pistons with gaps properly staggered. Lubricate piston rings, pins, and cylinder walls with engine oil. Install piston ring compressor on piston. Insert piston/rod assemblies into cylinders from top, ensuring connecting rod orientation is correct (oil squirt hole toward camshaft side). Guide rod onto crankshaft journal. Install rod caps in correct position. Install NEW rod bolts and torque to 45 Nm (33 lb-ft), then tighten additional angle per Ford specification (typically 90 degrees). Repeat for all cylinders.
    ⚠Piston orientation is critical. Install with notch or arrow on piston crown pointing toward front of engine.
    Torque spec

    Connecting Rod Bolts45 Nm (33 lb-ft)
14. 14

    Install rear main seal and flexplate/flywheel
    Install new rear main seal into seal housing using proper seal driver. Apply small bead of RTV sealant to housing corners as specified. Install rear main seal housing with new gasket and torque bolts to 12 Nm (9 lb-ft). Install flexplate (automatic) or flywheel (manual) in original position, aligning any balance marks. Apply threadlocker to bolts. Torque flexplate bolts to 85 Nm (63 lb-ft) in star pattern, or flywheel bolts to 95 Nm (70 lb-ft) in star pattern.
    Torque spec

    Rear Main Seal Housing12 Nm (9 lb-ft)

    Flexplate Bolts85 Nm (63 lb-ft)

    Flywheel Bolts95 Nm (70 lb-ft)
15. 15

    Install oil pump and oil pan
    Install new oil pump with new gasket. Torque oil pump bolts to 12 Nm (9 lb-ft). Install oil pump pickup tube with new O-ring and torque to 12 Nm (9 lb-ft). Clean oil pan and block mating surfaces thoroughly. Apply new oil pan gasket or RTV sealant per Ford specification. Install oil pan and torque bolts in sequence to 12 Nm (9 lb-ft). Install new oil drain plug with new washer and torque to 35 Nm (26 lb-ft).
    Torque spec

    Oil Pump Bolts12 Nm (9 lb-ft)

    Oil Pump Pickup Tube12 Nm (9 lb-ft)

    Oil Pan Bolts12 Nm (9 lb-ft)

    Oil Drain Plug35 Nm (26 lb-ft)
16. 16

    Install timing components
    Install crankshaft timing gear/sprocket. Install new front crankshaft seal into timing cover using seal driver. Clean timing cover and block surfaces. Install new timing cover gasket and apply RTV to corners as specified. Install timing cover and torque 8mm bolts to 25 Nm (18 lb-ft) and 10mm bolts to 45 Nm (33 lb-ft) in sequence. Rotate crankshaft to TDC cylinder #1. Install camshafts (if removed) in timed position. Install new timing chain guides and torque to 12 Nm (9 lb-ft). Install timing chains per Ford procedure. Compress timing chain tensioners with tool and install, torquing to 25 Nm (18 lb-ft). Release tensioners. Verify timing marks alignment. Install harmonic balancer using NEW bolt, torquing to 180 Nm (133 lb-ft) plus angle per specification.
    ⚠Incorrect cam timing will cause valve-to-piston contact and catastrophic engine damage. Triple-check timing mark alignment.
    Torque spec

    Timing Chain Guide Bolts12 Nm (9 lb-ft)

    Timing Chain Tensioner Bolt25 Nm (18 lb-ft)

    Cover Bolts20 Nm (15 lb-ft)

    Harmonic Balancer Bolt180 Nm (133 lb-ft)
17. 17

    Install cylinder heads
    Clean cylinder head and block mating surfaces thoroughly. Install new head gaskets with proper orientation (typically marked TOP or FRONT). Carefully position cylinder heads onto block. Install NEW cylinder head bolts with light oil on threads. Torque head bolts in proper sequence: first to 65 Nm (48 lb-ft), then tighten additional angle per Ford specification (typically 90 degrees, then additional 90 degrees). Install all remaining cylinder head components (camshafts if removed, rockers, etc.).
    ⚠Head bolt tightening sequence is critical. Follow Ford specified sequence exactly.
    Torque spec

    Cylinder Head Bolts65 Nm (48 lb-ft)
18. 18

    Complete engine reassembly
    Install intake manifold with new gaskets. Install exhaust manifolds with new gaskets. Install valve covers with new gaskets. Install all sensors, wiring harnesses, fuel system components, and accessories in reverse order of removal. Install new oil filter.
19. 19

    Install engine in vehicle
    Carefully lower engine into engine bay using hoist. Align engine mounts and install mount bolts, torquing to 60 Nm (44 lb-ft). Reconnect transmission and torque transmission-to-engine bolts to 55 Nm (41 lb-ft). Reconnect all wiring harnesses, vacuum lines, fuel lines, and coolant hoses. Install exhaust system. Install serpentine belt and accessories. Install radiator and cooling system components. Install air intake system.
    Torque spec

    Mounting Bolts60 Nm (44 lb-ft)

    Transmission-to-Engine Bolts55 Nm (41 lb-ft)
20. 20

    Fill fluids and perform initial start
    Fill engine with 7.5 quarts Motorcraft 0W-20 Full Synthetic oil. Fill cooling system with 16 quarts Motorcraft Orange Coolant (50/50 mix). Refill transmission with 11 quarts Motorcraft MERCON LV ATF if drained. Reconnect battery. Turn ignition to ON position without starting to prime fuel system (repeat 3-4 times). Disable ignition system and crank engine for 10 seconds to build oil pressure. Verify oil pressure is present. Enable ignition and start engine. Monitor for leaks, unusual noises, and proper oil pressure (minimum 20 psi at idle when warm). Allow engine to reach operating temperature. Check for coolant and oil leaks.
    ⚠️Do not run engine without oil pressure. Shut down immediately if oil pressure warning remains on.
    ⚠Monitor engine closely during first start. Unusual noises may indicate assembly errors requiring immediate shutdown.

Reassembly

1. All TTY bolts (main caps, rod bolts, head bolts, harmonic balancer) must be new and torqued to specification plus angle
2. Tighten all fasteners in specified sequences from center outward where applicable
3. Verify timing chain alignment marks before completing reassembly
4. Prime oil system before starting engine
5. Double-check all sensor connections and harness routing
6. Verify all fluid levels before starting engine

Verification

• Engine starts and runs smoothly without unusual noises (knocking, ticking, grinding)
• Oil pressure reaches minimum 20 psi at idle when warm, 40-60 psi at 2000 rpm
• No oil leaks from pan, timing cover, rear main seal, or valve covers
• No coolant leaks from timing cover, head gaskets, or hose connections
• Engine reaches normal operating temperature (195-220°F) without overheating
• Transmission shifts properly through all gears
• Perform test drive and verify no warning lights, proper power delivery, and smooth operation
• Recheck all fluid levels after test drive
• Monitor oil pressure and temperature during first 500 miles of operation
• Perform oil and filter change after initial 500-mile break-in period

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