Complete disassembly, inspection, rebuild and reinstallation of the 10R80 10-speed automatic transmission in a 2021-2024 Ford F-150 with 3.5L EcoBoost engine.

Warnings

Tools required

Parts

• 10R80 transmission rebuild kit (clutches, steels, gaskets, seals) × 1 — Use OEM specification
• Transmission filter × 1 — Use OEM specification
• Torque converter (if worn or contaminated) × 1 — Use OEM specification
• Transmission pan gasket × 1 — Use OEM specification
• Valve body gasket set × 1 — Use OEM specification
• Drain plug crush washer × 1 — Use OEM specification
• Flywheel bolts (if TTY) × 8 — Use OEM specification
• Transmission mount × 1 — Inspect and replace if worn
• Input shaft seal × 1 — Use OEM specification
• Output shaft seal × 1 — Use OEM specification
• Selective thrust washers (measured to spec) × 1 — Use OEM specification
• Solenoid body gaskets × 1 — Use OEM specification

Fluids

• Motorcraft MERCON LV ATF — 13 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Disconnect negative battery cable and wait 10 minutes for airbag system deactivation
3. Raise vehicle on lift or support securely on jack stands at manufacturer specified lift points
4. Remove transmission skid plate if equipped
5. Place large drain pan under transmission
6. Remove driveshaft and mark orientation for reinstallation
7. Disconnect transmission cooler lines and cap openings
8. Disconnect all electrical connectors from transmission and transfer case (if equipped)
9. Remove exhaust system components as needed for transmission clearance
10. Support engine with engine support bar or jack with wood block under oil pan
11. Label and photograph all connections before disassembly

Procedure

1. 1

   Remove transmission from vehicle
   Support transmission with transmission jack. Remove transmission crossmember mounting bolts. Remove bellhousing to engine mounting bolts. Carefully separate transmission from engine, ensuring torque converter stays with transmission. Lower transmission from vehicle and secure to work stand.
   Torque spec

   Mounting Bolts71 Nm (52 lb-ft)
2. 2

   Remove torque converter and external components
   Remove torque converter from transmission input shaft and inspect for damage, debris, or metal contamination. If metal is present, converter must be replaced. Remove transmission pan bolts in reverse of tightening pattern. Remove pan and drain remaining fluid. Remove transmission filter and inspect for metal particles.
   ⚠Metal particles in pan or filter indicate internal damage. Document findings before proceeding.
   Torque spec

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

   Remove valve body and solenoid pack
   Disconnect internal wiring harness connectors. Remove valve body bolts in proper sequence (refer to service manual for specific pattern). Carefully lower valve body assembly and remove gaskets. Remove solenoid body and inspect for damage. Mark all check ball locations with photos or diagram.
   Torque spec

   Sensor Bolts12 Nm (9 lb-ft)
4. 4

   Disassemble clutch packs and planetary gear sets
   Remove pump assembly from front of case. Use snap ring pliers to remove retaining rings for each clutch pack. Document order of all components as removed. Remove clutch packs A, B, C, D, E, and F in sequence. Remove planetary gear assemblies and inspect for wear, broken teeth, or bearing damage. Measure all end play with dial indicator before disassembly.
   ⚠Clutch pack components must be reinstalled in exact order. Label or photograph each pack during removal.
   ℹ️10R80 uses six clutch packs with specific clearance requirements. Consult service manual for specifications.
5. 5

   Inspect and measure all internal components
   Clean all hard parts in solvent and dry with compressed air. Inspect all clutch drums for scoring, heat damage, or cracks. Measure all bushings and bearing surfaces with micrometer. Check all snap ring grooves for damage. Inspect case for cracks, porosity, or stripped threads. Measure all shafts for wear and runout using dial indicator and V-blocks.
   ℹ️Replace any component that is out of specification. Reusing worn parts will cause premature failure.
6. 6

   Measure and select thrust washers
   Measure endplay requirements for each gear set and clutch pack assembly using dial indicator. Select appropriate selective thrust washers to achieve specified endplay (typically 0.010-0.030 inches depending on location). Record all measurements and washer thicknesses for verification.
   ⚠Incorrect endplay will cause bearing failure, noise, or loss of drive. Verify all measurements twice.
7. 7

   Install new seals and bearings
   Install new input and output shaft seals using proper seal driver tools. Replace all case bushings if worn beyond specification. Install new bearings using bearing driver set. Lubricate all seals with MERCON LV before installation. Install new pump bushing and seal.
8. 8

   Reassemble clutch packs with new components
   Soak all new friction clutches in MERCON LV ATF for minimum 30 minutes before installation. Install clutch packs in reverse order of removal, alternating friction discs and steel plates per rebuild kit instructions. Install pressure plates and snap rings. Use clutch spring compressor to install retaining rings. Measure each clutch pack clearance with feeler gauge and verify against specifications (typically 0.030-0.080 inches depending on pack).
   ⚠Each clutch pack has specific clearance requirements. Do not proceed until all clearances are verified correct.
9. 9

   Reassemble planetary gear sets and internal components
   Install selected thrust washers with petroleum jelly to hold in place. Install planetary gear assemblies in correct orientation. Install all shafts and verify rotation is smooth with no binding. Verify all snap rings are fully seated in grooves. Check total endplay of complete assembly.
10. 10

    Install pump assembly
    Install new pump gasket or seal. Install pump assembly to case, ensuring alignment with torque converter hub. Tighten pump bolts to specification in criss-cross pattern. Verify pump rotates freely and check converter hub engagement depth.
    Torque spec

    Cover Screws12 Nm (9 lb-ft)
11. 11

    Install valve body and solenoid pack
    Install all check balls in correct locations per service manual diagram. Install new valve body gaskets. Position solenoid body and install new gaskets. Carefully install valve body assembly, ensuring all passages align. Install valve body bolts in proper sequence and torque to specification. Connect all internal wiring harnesses.
    ⚠Missing or misplaced check balls will cause incorrect hydraulic operation and transmission failure.
    Torque spec

    Sensor Bolts12 Nm (9 lb-ft)
12. 12

    Install transmission pan and filter
    Install new transmission filter. Clean pan mating surface thoroughly and install new gasket. Install pan and tighten bolts in criss-cross pattern to specification. Install drain plug with new crush washer if equipped.
    Torque spec

    Pan Bolts19 Nm (14 lb-ft)

    Drain Plug39 Nm (29 lb-ft)
13. 13

    Install transmission in vehicle
    Install torque converter onto transmission input shaft, ensuring fully seated (check depth measurement per service manual). Mount transmission on transmission jack. Raise transmission into position, aligning with engine. Install bellhousing mounting bolts and tighten to specification. Install transmission crossmember and mounting bolts.
    ⚠️Ensure torque converter is fully seated before mating transmission to engine. Improper seating will cause catastrophic failure on startup.
    Torque spec

    Mounting Bolts71 Nm (52 lb-ft)
14. 14

    Reconnect all external components
    Install driveshaft in original orientation. Connect transmission cooler lines and tighten fittings. Reconnect all electrical connectors to transmission and sensors. Install exhaust components. Install transmission skid plate if equipped. Remove engine support.
15. 15

    Fill transmission and perform initial setup
    Add approximately 6 quarts of Motorcraft MERCON LV ATF through fill tube. Reconnect battery. Start engine and check for leaks. With engine at idle and parking brake applied, shift through all gear positions, pausing 3 seconds in each. Check fluid level with engine running at operating temperature and add fluid to bring to proper level (approximately 13 quarts total). Connect Ford IDS scan tool and perform transmission adaptive learning reset and clutch calibration procedure.
    ⚠Do not overfill transmission. Overfilling will cause aeration, overheating, and seal damage.
    ℹ️Transmission requires scan tool adaptive learning procedure after rebuild for proper shift quality.

Reassembly

1. Transmission fluid level must be checked with engine running at normal operating temperature (180-200°F)
2. Perform complete road test including all shift points, kickdown, and manual mode operation
3. Recheck fluid level after road test and adjust as necessary
4. Reset transmission adaptive tables using Ford IDS scan tool per manufacturer procedure
5. Verify no diagnostic trouble codes are present after initial drive cycle
6. Torque converter bolts to flexplate must be torqued in star pattern if accessible (not included in removal steps above)

Verification

• Verify no fluid leaks from pan, cooler lines, seals, or case after initial operation
• Confirm all forward gears (1-10) engage smoothly without slipping or harsh shifts
• Verify reverse gear engages firmly without delay
• Check that transmission shifts occur at correct speeds and engine RPM
• Scan for diagnostic trouble codes and verify none are present
• Verify fluid level is correct with engine at operating temperature
• Confirm no abnormal noises, vibrations, or whining from transmission
• Verify proper operation of manual shift mode and all gear selections
• Road test vehicle at highway speeds and verify smooth operation under load
• Recheck all mounting bolt torque values after first 50 miles of operation

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