Complete removal and reinstallation of the 3.5L EcoBoost V6 engine from a 2021-2024 Ford F-150 RWD, including disconnection of all systems, transmission separation, and engine extraction.

Warnings

Tools required

Parts

• Engine oil and filter × 1 — FL-910S or equivalent
• Oil drain plug crush washer × 1 — Use OEM specification
• Coolant (concentrate or premixed) × 1 — Motorcraft Orange VC-7-B
• Transmission-to-engine gasket/seal × 1 — Use OEM specification
• Exhaust manifold gaskets × 2 — Use OEM specification
• Engine mount hardware (if reusing mounts) × 1 — Inspect and replace as needed
• Miscellaneous hose clamps × 1 — Assorted sizes

Fluids

• Motorcraft 0W-20 Full Synthetic — 6 qt
• Motorcraft Orange Coolant — 13 qt

Preparation

1. Position vehicle on level surface with adequate overhead clearance for engine removal (minimum 8 feet recommended)
2. Disconnect negative battery cable, then positive cable. Remove battery from vehicle
3. Remove engine cover and air intake assembly completely
4. Drain engine coolant completely by opening radiator drain and removing lower radiator hose
5. Drain engine oil through drain plug into appropriate container
6. Remove front grille and radiator support components for access
7. Remove hood completely by marking hinge positions and unbolting from hinges with assistance
8. Relieve fuel system pressure by removing fuel pump fuse and cranking engine until it stalls
9. Raise and support vehicle on jack stands at frame points if additional underside access is needed

Procedure

1. 1

   Remove cooling system components
   Remove upper and lower radiator hoses from engine. Disconnect coolant bypass hoses and heater hoses at firewall, labeling each connection. Remove radiator, cooling fans, and fan shroud assembly as a unit. Disconnect and remove coolant reservoir. On models with engine oil cooler, disconnect oil cooler lines.
2. 2

   Disconnect fuel and EVAP systems
   Using fuel line disconnect tools, separate fuel supply and return lines at engine-mounted connections. Cap all open fuel lines immediately. Disconnect EVAP purge line and canister vent line from intake and valve cover areas. Secure all lines away from engine.
   ⚠️Have fire extinguisher nearby. Work in well-ventilated area away from ignition sources.
3. 3

   Remove intake and throttle body assembly
   Disconnect throttle body electrical connector and all intake manifold-mounted sensors including MAP sensor and intake air temperature sensor. Remove PCV hoses and breather tubes. Unbolt and remove intake manifold assembly with throttle body attached. Cover intake ports with clean shop towels to prevent debris entry.
4. 4

   Disconnect engine electrical systems
   Disconnect all engine wiring harness connectors including: both ignition coil connectors, fuel injector harness, camshaft position sensors, crankshaft position sensor, oil pressure sensor, coolant temperature sensors, oxygen sensors, and knock sensors. Disconnect alternator power cable and mounting bolts. Remove alternator. Disconnect starter power cables and remove starter motor. Unbolt main engine harness from engine and position aside.
   Torque spec

   Alternator Mounting Bolts50 Nm (37 lb-ft)

   Mounting Bolts55 Nm (40 lb-ft)

   Electrical Connector Bolts8 Nm (6 lb-ft)
5. 5

   Remove accessory drive components
   Release serpentine belt tensioner and remove drive belt. Remove power steering pump with lines attached and secure to frame with wire (do not disconnect lines). Remove A/C compressor mounting bolts and secure compressor to frame with lines attached. Remove belt tensioner assembly.
   Torque spec

   AC Compressor Bolts25 Nm (18 lb-ft)

   Power Steering Pump Bolts25 Nm (18 lb-ft)
6. 6

   Disconnect exhaust system
   From underneath vehicle, disconnect exhaust Y-pipe from both exhaust manifolds. May require cutting exhaust if rusted. Support exhaust system and remove hangers as necessary to lower front section away from engine. Inspect manifold studs for damage.
   ⚠Exhaust fasteners are frequently corroded. Apply penetrating oil 24 hours before removal if possible. Replacement studs may be required.
   Torque spec

   Exhaust Manifold Nuts30 Nm (22 lb-ft)
7. 7

   Support and separate transmission
   Place transmission jack under transmission pan with wooden block to distribute load. Remove transmission bellhousing inspection covers. Mark flexplate-to-torque converter position. Remove all torque converter-to-flexplate bolts by rotating crankshaft with breaker bar on crankshaft pulley bolt. Remove all transmission-to-engine mounting bolts. Carefully pull transmission jack rearward approximately 2 inches to separate transmission from engine dowels while ensuring torque converter remains with transmission.
   ⚠Torque converter must remain fully seated in transmission during separation. Secure converter with wire or bracket to prevent falling.
   Torque spec

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

   Flywheel Bolts95 Nm (70 lb-ft)
8. 8

   Disconnect engine mounts
   Support engine weight using engine hoist with lifting chains attached to factory lifting eyes on cylinder heads. Apply slight upward tension. Remove both engine mount-to-frame bolts. Remove engine mount-to-block bolts on both driver and passenger side mounts. Verify all hoses, wires, and connections are clear of engine.
   ⚠️Ensure hoist is properly centered and engine is balanced before unbolting mounts. Engine can shift suddenly when mounts are released.
   Torque spec

   Engine Mount-to-Block Bolts65 Nm (48 lb-ft)

   Engine Mount-to-Frame Bolts75 Nm (55 lb-ft)
9. 9

   Extract engine from vehicle
   Perform final inspection to verify all connections, hoses, and wiring are disconnected. Slowly raise engine with hoist while simultaneously using pry bar to separate engine from transmission if needed. Use engine leveler to adjust angle, tilting front of engine upward approximately 15-20 degrees. Carefully raise and maneuver engine forward and upward out of engine bay, watching clearances at firewall, fender aprons, and radiator support. Once clear of vehicle, lower onto engine stand or suitable support.
   ⚠️Never work beneath unsupported engine. Ensure area beneath engine is clear of personnel during extraction.
10. 10

    Prepare engine for reinstallation or service
    If reinstalling existing engine, inspect and clean all mounting surfaces, replace all gaskets including exhaust manifold gaskets. Check engine mounts for deterioration and replace if necessary. If installing replacement engine, transfer all necessary components including sensors, fuel rails, exhaust manifolds, and accessories. Clean transmission bellhousing and inspect pilot bearing/bushing. Clean flexplate and torque converter mating surfaces.
    ℹ️This is ideal time to replace water pump, timing components, rear main seal, and other difficult-to-access components.

Reassembly

1. Installation is reverse of removal with the following critical points:
2. Apply thin film of high-temperature grease to transmission input shaft splines and torque converter pilot
3. Verify torque converter is fully seated in transmission pump (should be recessed approximately 1/2 inch from bellhousing face)
4. Align engine to transmission dowels carefully, ensuring no binding. Use transmission jack to fine-tune alignment
5. Torque all fasteners to specification in proper sequence. Flywheel/flexplate bolts must be torqued in star pattern
6. Apply anti-seize compound to exhaust manifold studs before installing nuts, torque from center outward
7. Route all wiring harnesses in original locations using factory clips and ties to prevent contact with hot or moving components
8. Install new oil drain plug crush washer before filling with oil
9. Refill cooling system with proper Motorcraft Orange coolant mixture, bleed air from system per Ford procedure
10. Reinstall serpentine belt ensuring proper routing per underhood diagram
11. Double-check that all sensors, connectors, hoses, and grounds are reconnected before first start attempt

Verification

• Perform visual inspection of entire engine bay to confirm all connections, no tools left behind, and no loose fasteners
• Verify all fluid levels are correct: engine oil at full mark on dipstick, coolant at proper level in reservoir
• Reconnect battery cables (positive first, then negative) and verify no warning lights are illuminated before starting
• Prime fuel system by cycling ignition on/off three times without cranking
• Start engine and immediately verify oil pressure light extinguishes within 2-3 seconds
• Monitor for any fluid leaks while engine warms to operating temperature, checking all connection points
• Verify cooling fans engage at proper temperature and no overheating occurs
• Check for unusual noises, vibrations, or exhaust leaks during initial run period
• Allow engine to reach full operating temperature, then shut off and recheck all fluid levels after cool-down
• Test drive vehicle to verify proper operation, smooth acceleration, no warning lights, and normal transmission engagement
• Perform final torque verification on all critical fasteners after heat cycle, particularly exhaust manifold nuts and engine mount bolts

More procedures for this vehicle