Complete removal and replacement of the crankshaft in a 2021-2024 Ford F-150 with 3.5L EcoBoost V6 engine, requiring engine removal from vehicle and complete disassembly.

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
• Thrust bearing set × 1 — Use OEM specification
• Front crankshaft seal × 1 — Use OEM specification
• Rear crankshaft seal × 1 — Use OEM specification
• Timing chain kit (chains, guides, tensioners) × 1 — Use OEM specification
• Oil pump assembly × 1 — Use OEM specification
• Oil pan gasket × 1 — Use OEM specification
• Timing cover gasket × 1 — Use OEM specification
• Cylinder head gaskets × 2 — Use OEM specification
• Valve cover gaskets × 2 — Use OEM specification
• Connecting rod bolts (TTY) × 12 — Use OEM specification
• Main bearing cap bolts (TTY) × 10 — Use OEM specification
• Cylinder head bolts (TTY) × 20 — Use OEM specification
• Harmonic balancer bolt (TTY) × 1 — Use OEM specification
• Exhaust manifold gaskets × 2 — Use OEM specification
• Turbocharger gaskets and seals × 2 — Use OEM specification
• Coolant thermostat and gasket × 1 — Use OEM specification
• Oil filter × 1 — Motorcraft FL-500S
• Oil drain plug crush washer × 1 — Use OEM specification
• RTV silicone gasket maker (high-temp) × 1 — Motorcraft TA-357
• Engine assembly lubricant × 1 — Use OEM specification
• Thread locker (medium strength) × 1 — Use OEM specification

Fluids

• Motorcraft 0W-20 Full Synthetic Engine Oil — 6 qt
• Motorcraft Orange Coolant — 13 qt
• Motorcraft MERCON LV ATF — 13 qt

Preparation

1. Position vehicle on level surface with parking brake engaged and wheel chocks in place
2. Disconnect negative battery cable and wait 10 minutes for capacitor discharge
3. Disconnect positive battery cable and remove battery from vehicle
4. Drain engine oil completely and remove oil filter
5. Drain engine coolant from radiator and block drain plugs into appropriate containers
6. Relieve fuel system pressure using fuel pressure relief valve on fuel rail
7. Raise vehicle on lift to comfortable working height
8. Remove front skid plate and engine under-covers
9. Mark hood hinge positions and remove hood with assistance
10. Remove air intake system completely including intercooler piping
11. Disconnect all engine wiring harness connectors and label positions
12. Remove radiator, cooling fans, and upper/lower radiator hoses
13. Disconnect transmission cooler lines and plug openings
14. Remove drive belt(s) and belt tensioner assemblies
15. Tag and photograph all vacuum lines, fuel lines, and coolant hoses before disconnection
16. Support transmission with transmission jack before removing engine mounts

Procedure

1. 1

   Remove exhaust system and turbochargers
   Disconnect oxygen sensors and unbolt exhaust system from turbocharger outlets. Remove heat shields surrounding turbochargers. Disconnect oil feed and drain lines from both turbochargers. Unbolt turbochargers from exhaust manifolds and remove as assemblies. Cap all oil passages to prevent debris entry.
2. 2

   Separate transmission from engine
   Support transmission securely with transmission jack. Remove starter motor. Remove flexplate inspection cover. Unbolt torque converter from flexplate (mark position for reassembly). Remove all transmission-to-engine mounting bolts. Carefully separate transmission from engine dowel pins and lower transmission away. Ensure torque converter remains with transmission.
   ⚠Transmission weighs approximately 200 lbs. Ensure transmission jack is properly positioned and secure before removing mounting bolts.
   Torque spec

   Transmission-to-Engine Bolts55 Nm (41 lb-ft)
3. 3

   Disconnect engine mounts and remove engine
   Attach engine hoist with load leveler to engine lifting eyes (located on cylinder heads). Apply slight tension to hoist. Remove engine mount bolts from frame brackets. Disconnect remaining fuel lines, coolant hoses, and electrical connections. Slowly lift engine while guiding clear of transmission and chassis components. Use load leveler to maintain balance. Transfer engine to engine stand and secure with grade 8 bolts.
   ⚠️Verify all connections are disconnected before lifting. Engine can swing unpredictably if connections are still attached.
   Torque spec

   Mounting Bolts55 Nm (40 lb-ft)
4. 4

   Remove valve covers and cylinder heads
   Remove ignition coils and spark plugs. Unbolt and remove both valve covers. Rotate engine to TDC on cylinder #1 using harmonic balancer mark. Remove camshaft position sensors. Loosen cylinder head bolts in reverse of tightening sequence (spiral pattern from outside to inside). Remove cylinder heads with camshafts installed. Place heads on clean surface with combustion chambers facing up.
   ℹ️Keep cylinder head bolts organized by position. These are TTY and must be replaced, but organization helps identify any damaged bolt holes.
   Torque spec

   Cylinder Head Bolts65 Nm (48 lb-ft)

   Mounting Bolts55 Nm (40 lb-ft)
5. 5

   Remove timing components and front cover
   Remove harmonic balancer using appropriate puller tool. Remove timing cover bolts in sequence and remove timing cover. Compress timing chain tensioners and lock with retention pins. Mark timing chain positions relative to camshaft and crankshaft sprockets with paint. Remove timing chain tensioner bolts, then remove tensioners, guides, and chains. Remove crankshaft timing sprocket using appropriate puller.
   ⚠Timing chain tensioners are spring-loaded. Control removal carefully to prevent components from ejecting.
   Torque spec

   Harmonic Balancer Bolt180 Nm (133 lb-ft)

   Cover Bolts19 Nm (14 lb-ft)

   Timing Chain Tensioner Bolt25 Nm (18 lb-ft)

   Timing Chain Guide Bolts12 Nm (9 lb-ft)
6. 6

   Remove oil pan and oil pump
   Remove oil pan bolts in reverse sequence and carefully separate oil pan from block using plastic scraper. Remove oil pump pickup tube bolt and remove pickup tube. Unbolt oil pump assembly from engine block and remove. Remove front main seal housing bolts and separate housing from block.
   Torque spec

   Oil Pan Bolts12 Nm (9 lb-ft)

   Oil Pump Pickup Tube12 Nm (9 lb-ft)

   Oil Pump Bolts12 Nm (9 lb-ft)

   Front Main Seal Housing12 Nm (9 lb-ft)
7. 7

   Remove flexplate and rear main seal housing
   Install flywheel holding tool to lock flexplate. Remove flexplate bolts in star pattern and remove flexplate. Unbolt rear main seal housing from engine block and carefully remove housing with seal installed.
   ℹ️Mark flexplate orientation to crankshaft before removal to maintain balance during reassembly.
   Torque spec

   Flexplate Bolts85 Nm (63 lb-ft)

   Rear Main Seal Housing12 Nm (9 lb-ft)
8. 8

   Remove pistons and connecting rods
   Mark each connecting rod and cap with cylinder number and orientation using permanent marker. Remove connecting rod cap bolts (discard TTY bolts). Remove rod caps and set aside with corresponding rod. Push each piston/rod assembly up and out through top of cylinder bore. Install rod caps back on rods immediately to prevent mixing. Place piston assemblies in numbered order on clean workbench.
   ⚠Protect crankshaft journals by covering with shop towels while removing pistons. Do not allow connecting rods to contact crankshaft.
   Torque spec

   Connecting Rod Bolts45 Nm (33 lb-ft)
9. 9

   Mark and remove main bearing caps
   Using permanent marker, clearly mark each main bearing cap with position number (1-5) and directional arrow pointing toward front of engine. Verify factory markings are visible. Loosen main bearing cap bolts in sequence from outside caps to center, one turn at a time. Remove main bearing cap bolts completely (discard TTY bolts). Carefully remove main bearing caps using appropriate puller tool if necessary. Keep thrust bearings with center main cap.
   ⚠Main bearing caps must be installed in exact original positions and orientations. Installation errors will cause immediate engine failure.
   Torque spec

   Main Bearing Cap Bolts75 Nm (55 lb-ft)
10. 10

    Remove crankshaft from engine block
    Carefully lift crankshaft straight up out of engine block using assistance or lifting straps. Place crankshaft on padded supports (V-blocks) to prevent journal damage. Remove upper main bearings from block and keep with corresponding cap bearings. Inspect crankshaft journals for scoring, discoloration, or damage using micrometers.
    ⚠Crankshaft weighs approximately 60 lbs. Use proper lifting technique and get assistance to prevent injury or dropping crankshaft.
11. 11

    Clean and inspect engine block and crankshaft
    Thoroughly clean all engine block surfaces, main bearing bores, and cylinder bores. Remove all old gasket material using plastic scrapers. Clean crankshaft with solvent and compressed air, ensuring all oil passages are clear. Measure crankshaft main journal diameters and rod journal diameters with micrometer at multiple points. Measure main bearing bore diameters with dial bore gauge. Check crankshaft straightness using V-blocks and dial indicator. Verify all measurements are within factory specifications before proceeding.
    ℹ️If crankshaft journals are worn beyond specification, crankshaft must be reground and undersize bearings used, or crankshaft must be replaced.
12. 12

    Install new crankshaft and verify bearing clearances
    Lubricate main bearing bores with clean engine oil. Install new upper main bearings into block, ensuring bearing tabs engage notches properly. Coat bearing surfaces with assembly lubricant. Carefully lower new/remanufactured crankshaft into position. Install Plastigage strips on each main journal. Install lower main bearings into caps with assembly lubricant. Install main bearing caps in correct positions and orientations. Install new TTY main bearing cap bolts and torque to specification in sequence (center to outer, 75 Nm plus specified angle). Remove caps and measure Plastigage to verify bearing clearance is within 0.0011-0.0018 inches specification.
    ⚠Do not rotate crankshaft with Plastigage installed. This will invalidate clearance measurements.
    ⚠If bearing clearances are not within specification, determine cause before proceeding. Improper clearance will cause bearing failure.
    Torque spec

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

    Install pistons and connecting rods
    Verify piston ring end gaps are correct and install rings on pistons if removed. Lubricate cylinder walls with clean engine oil. Install piston ring compressor on piston #1. Lubricate connecting rod bearing with assembly lubricant. Guide piston into cylinder #1 bore with orientation mark toward front of engine. Tap piston gently into bore using wooden hammer handle. Install rod bearing on cap with assembly lubricant. Install rod cap in correct orientation and install new TTY connecting rod bolts. Torque connecting rod bolts to 45 Nm plus specified angle in procedure. Repeat for all remaining cylinders.
    ⚠Verify piston orientation marks face forward. Reversed pistons will cause severe engine damage.
    Torque spec

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

    Install rear main seal housing and flexplate
    Install new rear main seal into seal housing using appropriate seal driver. Apply thin bead of RTV silicone to housing mating surface per factory specifications. Install seal housing onto engine block and torque bolts to specification. Allow RTV to cure per manufacturer instructions. Install flexplate onto crankshaft in original orientation. Apply thread locker to new flexplate bolt threads. Install flexplate bolts and torque to 85 Nm in star pattern using flywheel holding tool.
    Torque spec

    Rear Main Seal Housing12 Nm (9 lb-ft)

    Flexplate Bolts85 Nm (63 lb-ft)
15. 15

    Install oil pump and front seal housing
    Install new front crankshaft seal into front seal housing using seal driver. Prime new oil pump by filling with clean engine oil and rotating by hand. Install oil pump onto crankshaft and align with block. Torque oil pump bolts to specification. Install oil pump pickup tube with new O-ring and torque bolt to specification. Apply RTV silicone to oil pan gasket surfaces per factory specification. Install new oil pan gasket and oil pan. Torque oil pan bolts to 12 Nm in sequence.
    Torque spec

    Front Main Seal Housing12 Nm (9 lb-ft)

    Oil Pump Bolts12 Nm (9 lb-ft)

    Oil Pump Pickup Tube12 Nm (9 lb-ft)

    Oil Pan Bolts12 Nm (9 lb-ft)
16. 16

    Install timing components
    Install crankshaft timing sprocket onto crankshaft. Install new timing chain guides and torque bolts to specification. Install timing chains with alignment marks on crankshaft and camshaft sprockets (refer to service manual for specific alignment marks). Install timing chain tensioners compressed and locked with retention pins. Torque tensioner bolts to 25 Nm. Clean timing cover mating surfaces and install new gasket. Install timing cover and torque 8mm bolts to 25 Nm and 10mm bolts to 45 Nm in sequence. Install harmonic balancer onto crankshaft using installation tool. Install new TTY harmonic balancer bolt and torque to 180 Nm plus specified angle.
    ⚠Verify timing chain alignment marks are correct before releasing tensioners. Incorrect timing will cause catastrophic piston-to-valve contact.
    Torque spec

    Timing Chain Guide Bolts12 Nm (9 lb-ft)

    Timing Chain Tensioner Bolt25 Nm (18 lb-ft)

    Cover Bolts19 Nm (14 lb-ft)

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

    Install cylinder heads and valve train
    Clean cylinder head and block mating surfaces thoroughly. Verify block deck surface is flat and undamaged. Install new head gaskets with orientation marks UP and toward front of engine. Carefully position cylinder heads onto block, aligning dowel pins. Install new TTY cylinder head bolts with light oil on threads. Torque cylinder head bolts to 65 Nm in sequence (spiral pattern from inside to outside) plus specified angle in service manual. Install valve covers with new gaskets and torque cover bolts to 19 Nm. Install camshaft position sensors and torque sensor bolts to 12 Nm.
    Torque spec

    Cylinder Head Bolts65 Nm (48 lb-ft)

    Cover Bolts19 Nm (14 lb-ft)

    Mounting Bolts55 Nm (40 lb-ft)
18. 18

    Reinstall engine and reconnect transmission
    Remove engine from engine stand and attach to engine hoist. Carefully lower engine into vehicle, aligning with transmission and engine mounts. Install engine mount bolts and torque mounting bolts to specification (31 Nm or 55 Nm depending on location). Reconnect transmission to engine ensuring proper dowel pin alignment. Install transmission-to-engine bolts and torque to 55 Nm. Align torque converter to flexplate using alignment marks and install bolts (torque during final assembly). Install starter motor.
    Torque spec

    Mounting Bolts55 Nm (40 lb-ft)

    Transmission-to-Engine Bolts55 Nm (41 lb-ft)
19. 19

    Reinstall turbochargers and exhaust system
    Install new exhaust manifold gaskets. Install turbochargers onto exhaust manifolds with new gaskets and torque mounting bolts to specification. Reconnect turbocharger oil feed and drain lines with new gaskets. Install heat shields. Connect exhaust system to turbocharger outlets with new gaskets. Reconnect oxygen sensors and torque sensor bolts to 12 Nm.
    Torque spec

    Mounting Bolts55 Nm (40 lb-ft)

    Sensor Bolts12 Nm (9 lb-ft)
20. 20

    Complete final assembly and fill fluids
    Reconnect all engine wiring harness connectors per documentation. Install new coolant thermostat and housing. Reconnect all coolant hoses, vacuum lines, and fuel lines. Install radiator, cooling fans, and transmission cooler lines. Install drive belt tensioners and drive belts. Install air intake system and intercooler piping. Install new oil filter and torque oil drain plug with new crush washer to 35 Nm. Fill engine with 6 quarts Motorcraft 0W-20 synthetic oil. Fill cooling system with 13 quarts Motorcraft Orange coolant and bleed air. Check and fill transmission with Motorcraft MERCON LV ATF to proper level. Install hood using alignment marks. Reconnect battery cables (positive first, then negative).
    Torque spec

    Oil Drain Plug35 Nm (26 lb-ft)

Reassembly

1. All torque-to-yield (TTY) fasteners must be replaced with new parts: connecting rod bolts, main bearing cap bolts, cylinder head bolts, and harmonic balancer bolt
2. Follow all torque sequences precisely as specified in service manual, particularly for main bearing caps and cylinder heads
3. Release timing chain tensioners only after confirming all timing marks are properly aligned
4. Verify crankshaft rotates freely by hand after main bearing installation and before piston installation
5. Check crankshaft endplay after installation should be 0.0035-0.0098 inches using dial indicator
6. Use only specified Motorcraft RTV silicone for gasket applications where indicated
7. Prime oil system before starting engine by cranking with fuel pump fuse removed until oil pressure registers

Verification

• Perform leak-down test or compression test on all cylinders to verify ring sealing and valve seating
• Check for oil leaks around all gasket surfaces with engine running at operating temperature
• Verify proper oil pressure at idle (minimum 10 psi) and at 2000 RPM (40-70 psi typical)
• Listen for abnormal engine noises including knocking, ticking, or rattling that could indicate bearing or timing issues
• Check for coolant leaks at head gaskets, thermostat housing, and all coolant connections
• Verify no exhaust leaks at turbocharger connections and exhaust manifolds
• Scan for diagnostic trouble codes using OBD-II scanner and address any stored codes
• Road test vehicle under various load conditions and verify smooth operation with no detonation or misfires
• Re-check all fluid levels after test drive and inspect for any new leaks
• Monitor oil pressure and coolant temperature during first 500 miles of operation

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