This procedure covers removal and replacement of the torque converter on a 2015-2020 Ford F-150 with 5.0L V8 Coyote engine and RWD configuration, including transmission separation and converter installation.

Warnings

Tools required

Parts

• Torque converter × 1 — Use OEM specification or quality aftermarket for 6R80 transmission
• Transmission pan gasket × 1 — BC3Z-7A191-A or equivalent
• Drain plug washer × 1 — Use new copper washer
• Transmission filter × 1 — Motorcraft FT185 or equivalent
• Transmission cooler line O-rings × 1 — Replace if damaged

Fluids

• Motorcraft MERCON LV ATF — 11 qt

Preparation

1. Disconnect negative battery cable and wait 5 minutes for airbag system to discharge
2. Raise vehicle on lift or secure on jack stands at frame contact points, ensuring adequate working height
3. Remove skid plate if equipped
4. Place drain pan under transmission and remove drain plug to drain fluid
5. Mark driveshaft-to-axle flange orientation for reinstallation alignment
6. Support engine with engine support bar or chain hoist to prevent sagging when transmission is removed

Procedure

1. 1

   Remove driveshaft and exhaust components
   Remove the four driveshaft flange bolts at the rear differential. Lower driveshaft and slide rearward out of transmission extension housing. Remove exhaust crossover pipe and support brackets as needed for transmission clearance. Cap transmission output shaft opening to prevent fluid leakage.
2. 2

   Disconnect transmission cooler lines and electrical connections
   Using transmission line disconnect tool, release cooler line fittings at transmission case. Disconnect transmission wiring harness connector on driver side of transmission. Disconnect output speed sensor and turbine speed sensor connectors. Label all connections for reassembly.
3. 3

   Remove transmission pan and filter
   Remove all pan bolts in reverse of tightening sequence (work from ends toward center). Lower pan and allow remaining fluid to drain completely. Remove filter by pulling straight down from valve body. Clean pan and magnet thoroughly, inspect for metal debris indicating internal damage.
   Torque spec

   Pan Bolts20 Nm (15 lb-ft)
4. 4

   Remove starter motor
   Disconnect starter electrical connections. Remove the three starter mounting bolts and lower starter motor from bell housing. Set aside in safe location. This provides access to flexplate and torque converter bolts.
5. 5

   Access and remove torque converter-to-flexplate bolts
   Rotate crankshaft using breaker bar on front crank bolt to access each torque converter bolt through starter opening. Remove all four torque converter bolts. Mark flexplate position relative to crankshaft if not already indexed. Keep torque converter pushed rearward into transmission while working.
   ⚠Do not use impact wrench on crankshaft bolt as this can damage crankshaft position sensor tone ring.
   Torque spec

   Torque Converter Bolts50 Nm (37 lb-ft)
6. 6

   Remove crossmember and transmission mount
   Support transmission with transmission jack positioned at pan rail. Remove crossmember-to-frame bolts. Remove transmission mount-to-crossmember nuts. Lower crossmember slightly and slide rearward to remove.
   Torque spec

   Mounting Bolts76 Nm (56 lb-ft)
7. 7

   Remove bell housing bolts
   Remove all bell housing-to-engine block bolts. There are typically 7-9 bolts of varying lengths around the perimeter. Note bolt locations and lengths for reinstallation. Ensure transmission jack is securely supporting transmission weight before removing final bolts.
8. 8

   Separate and lower transmission
   Carefully slide transmission rearward approximately 2 inches to clear engine dowel pins. Ensure torque converter remains fully seated in transmission pump during separation. Slowly lower transmission on jack, tilting as needed to clear body and frame components. Have helper secure torque converter to prevent it from falling out during removal.
   ⚠️Torque converter is only held by pump engagement and will fall when transmission is tilted. Use retention strap or have helper hold converter.
9. 9

   Remove old torque converter
   With transmission on bench or secure stand, pull torque converter straight out from transmission pump. Inspect pump bushing and seal for wear or damage. Clean transmission input shaft and pump housing mating surface thoroughly.
10. 10

    Install new torque converter and verify seating depth
    Apply thin coat of MERCON LV ATF to torque converter hub and pump seal area. Insert converter into transmission while rotating slightly. Push converter in until first engagement (pump drive gear), then rotate and push until second engagement (turbine shaft), then rotate and push until third engagement (stator support). Converter should seat approximately 0.75-1.0 inch behind bell housing face. Use dial indicator or straight edge to verify proper seating depth before installation.
    ⚠️Improperly seated torque converter will cause immediate transmission failure. Verify three distinct engagements and proper depth measurement before proceeding.
11. 11

    Install transmission to engine
    Raise transmission into position with torque converter secured. Align transmission with engine dowel pins and carefully slide forward. Ensure torque converter remains fully seated and does not contact flexplate during alignment. Bell housing should mate flush with engine block with minimal force. If resistance is felt, stop and verify converter position and dowel alignment.
12. 12

    Install bell housing bolts
    Install all bell housing-to-engine block bolts in their original locations. Tighten bolts in a cross pattern to pull transmission evenly to engine block. Verify bell housing is fully seated before final tightening.
13. 13

    Install torque converter to flexplate
    Rotate crankshaft to align first flexplate bolt hole with torque converter. Install bolt finger-tight. Rotate crankshaft to access remaining holes and install all four bolts. Tighten bolts evenly in a star pattern to specified torque. Rotate crankshaft two full revolutions and verify smooth rotation with no binding.
    Torque spec

    Torque Converter Bolts50 Nm (37 lb-ft)
14. 14

    Reinstall crossmember and mount
    Position crossmember and loosely install all mounting hardware. Align transmission mount and install to specified torque. Verify transmission is properly positioned before final tightening of all crossmember fasteners. Remove transmission jack.
    Torque spec

    Mounting Bolts76 Nm (56 lb-ft)
15. 15

    Complete final assembly and fill transmission
    Reinstall starter motor with all electrical connections. Install new transmission filter and pan with new gasket. Tighten pan bolts in proper sequence to specified torque. Reconnect cooler lines, driveshaft, and all electrical connections. Install drain plug with new washer. Fill transmission with MERCON LV ATF through fill tube until fluid reaches proper level on dipstick (cold reading). Reconnect battery.
    Torque spec

    Pan Bolts20 Nm (15 lb-ft)

    Sensor Bolts14 Nm (10 lb-ft)

    Drain Plug42 Nm (31 lb-ft)

Reassembly

1. Verify all electrical connectors are fully seated and locked
2. Ensure driveshaft alignment marks are matched to prevent vibration
3. Double-check that all bell housing bolts are installed and properly torqued
4. Confirm transmission cooler lines are fully seated with audible click

Verification

• With engine running and brake applied, shift through all gear ranges and verify smooth engagement
• Check for fluid leaks at pan, cooler lines, drain plug, and front pump seal
• Verify proper transmission fluid level with engine at operating temperature in Park on level surface
• Road test vehicle through all gears, verify proper shift points and torque converter lockup operation
• Scan for transmission diagnostic codes and verify no fault codes are present
• Recheck fluid level after road test and top off if necessary

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