Freeze Plugs - All

Complete replacement of all freeze plugs (core plugs) on the 3.5L EcoBoost V6 engine, requiring engine removal for full access to all plug locations in the block.

Warnings

Tools required

Parts

• Engine freeze plug set (6 plugs) × 1 — Use OEM specification
• Engine oil filter × 1 — FL-500S or equivalent
• Engine oil drain plug washer × 1 — Use OEM specification
• Transmission mounting bolts (if reusable) × 6 — Use OEM specification
• Engine mount hardware × 1 — Use OEM specification
• Exhaust gaskets × 2 — Use OEM specification
• Various gaskets and O-rings × 1 — Use OEM specification

Fluids

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

Preparation

1. Park vehicle on level ground and engage parking brake
2. Disconnect negative battery cable and secure away from battery terminal
3. Allow engine to cool completely for at least 2 hours
4. Remove engine cover and air intake system
5. Drain engine coolant completely into appropriate container by opening radiator drain and removing lower radiator hose
6. Drain engine oil and remove oil filter
7. Raise vehicle on lift or support securely on jack stands at all four corners
8. Remove front skid plate if equipped
9. Take photos of all electrical connections, hoses, and cable routing for reinstallation reference

Procedure

1. 1

   Disconnect engine peripherals and electrical connections
   Disconnect all electrical connectors from engine including alternator, starter, fuel injectors, ignition coils, sensors (MAF, IAT, CMP, CKP, ECT, oil pressure, knock sensors), and main engine harness connectors. Label each connection with tape for reassembly. Disconnect throttle body connector and all PCM-related connections.
   Torque spec

   Electrical Connector Bolts8 Nm (6 lb-ft)
2. 2

   Disconnect cooling system and fuel lines
   Remove upper and lower radiator hoses, heater hoses, and coolant bypass hoses from engine. Relieve fuel system pressure by removing fuel pump fuse and cranking engine briefly. Disconnect fuel supply and return lines using proper disconnect tools. Cap all open fuel lines immediately to prevent contamination.
   ⚠️Fuel system is under high pressure. Failure to relieve pressure before disconnecting lines can cause fuel spray and fire hazard.
3. 3

   Remove exhaust system connections
   Disconnect exhaust Y-pipe from both turbocharger downpipes at the flange connections. Remove exhaust manifold to turbocharger connections if necessary for clearance. Support exhaust system with wire or stands to prevent damage to catalytic converters.
   Torque spec

   Gasket Bolts23 Nm (17 lb-ft)
4. 4

   Disconnect transmission from engine
   Support transmission with transmission jack. Remove transmission bell housing to engine block bolts. For RWD configuration, mark driveshaft to pinion flange orientation, then remove driveshaft. Remove torque converter to flexplate bolts through starter opening. Carefully separate transmission approximately 2 inches rearward but keep supported.
   Torque spec

   Mounting Bolts54 Nm (40 lb-ft)
5. 5

   Remove accessory drive components
   Remove serpentine belt. Remove power steering pump and secure to frame without disconnecting hydraulic lines (if hydraulic-assist equipped). Remove A/C compressor and secure to frame without disconnecting refrigerant lines. Remove alternator and mounting brackets.
   Torque spec

   Mounting Bolts54 Nm (40 lb-ft)
6. 6

   Prepare engine for removal
   Attach engine hoist with lifting chains to factory lifting eyes on engine block. Apply slight tension to take weight off engine mounts but do not lift yet. Remove engine mount through-bolts on both driver and passenger sides. Remove front engine mount bracket bolts.
   ⚠Ensure lifting chains are properly rated and securely attached to both lifting points before removing mount bolts.
   Torque spec

   Mounting Bolts54 Nm (40 lb-ft)
7. 7

   Remove engine from vehicle
   With all connections verified disconnected and transmission separated, slowly lift engine while using engine leveler to maintain proper angle. Tilt engine as needed to clear radiator support and body components. Lift engine completely out of engine bay and position on engine stand or secure work surface. Double-check no hoses, wires, or cables are still attached.
   ⚠️Have an assistant guide engine during removal to prevent contact with vehicle body or components. Sudden shifts in weight can cause loss of control.
8. 8

   Remove old freeze plugs
   Locate all six freeze plugs on engine block (typically 3 per side). Clean area around each freeze plug. Using freeze plug removal tool or drift punch, strike one edge of freeze plug to rotate it inward, then pry out with pliers or pry bar. Alternatively, drill small hole in center of plug and use slide hammer with screw attachment. Remove all old plugs completely and inspect block for corrosion or damage.
   ⚠Be careful not to damage freeze plug bore in block when removing old plugs. Gouges or damage may prevent proper seal of new plugs.
9. 9

   Prepare freeze plug bores and install new plugs
   Clean each freeze plug bore thoroughly with wire brush, removing all rust, old sealant, and debris. Inspect bore for damage or excessive corrosion. Apply thin bead of high-temp RTV silicone sealant around outer edge of new freeze plug as specified. Position new freeze plug in bore with convex side facing outward. Using appropriately sized freeze plug driver and hammer, tap plug evenly into bore until seated flush with block surface or slightly recessed per manufacturer specification.
   ℹ️Freeze plugs must be driven in straight to avoid cocking which will cause leaks. Use proper size driver that contacts outer rim only.
   Torque spec

   Freeze Plug10 Nm (7 lb-ft)
10. 10

    Verify freeze plug installation
    Inspect each installed freeze plug to ensure it is seated evenly and flush with block surface all around perimeter. Check that sealant has formed proper bead around edges. Allow RTV sealant to cure per manufacturer instructions (typically 15-30 minutes) before proceeding. Clean any excess sealant from block surface.
    Torque spec

    Freeze Plug10 Nm (7 lb-ft)
11. 11

    Reinstall engine into vehicle
    Attach lifting chains to engine and carefully lower engine into engine bay using hoist. Use engine leveler to maintain proper angle for clearance. Guide engine into position aligning with transmission bell housing. Install engine mount bolts finger-tight initially. Align engine to transmission and slide together, ensuring torque converter pilot engages flexplate center. Install bell housing bolts and torque to specification.
    Torque spec

    Mounting Bolts54 Nm (40 lb-ft)
12. 12

    Reconnect transmission and torque all engine mounts
    Install torque converter to flexplate bolts through starter opening and torque to specification. Install all transmission bell housing bolts and torque to specification. With engine and transmission properly aligned, torque all engine mount bolts to specification in sequence: front mount, then passenger side, then driver side. Remove engine hoist.
    Torque spec

    Mounting Bolts54 Nm (40 lb-ft)
13. 13

    Reinstall exhaust and accessory components
    Reconnect exhaust Y-pipe to turbocharger downpipes using new gaskets. Torque exhaust flange bolts to specification. Reinstall A/C compressor, power steering pump, and alternator with all mounting brackets. Install and tension serpentine belt per routing diagram.
    Torque spec

    Gasket Bolts23 Nm (17 lb-ft)

    Mounting Bolts54 Nm (40 lb-ft)
14. 14

    Reconnect all electrical, fuel, and cooling system connections
    Reconnect all electrical connectors to sensors, injectors, coils, alternator, starter, and main harness connections using photos and labels from removal. Reconnect fuel supply and return lines ensuring proper connection. Install all coolant hoses including radiator hoses, heater hoses, and bypass hoses. Secure all hose clamps properly.
    Torque spec

    Electrical Connector Bolts8 Nm (6 lb-ft)

    Sensor Bolts12 Nm (9 lb-ft)

    Mounting Bolts54 Nm (40 lb-ft)
15. 15

    Refill fluids and prepare for startup
    Install new oil filter and drain plug with new washer. Fill engine with 6 quarts of Motorcraft 0W-20 synthetic oil. Fill cooling system with 13 quarts of Motorcraft Orange coolant, following proper bleeding procedure to remove air pockets. Double-check all connections, bolts, and hoses. Reconnect negative battery cable. Reinstall skid plate, air intake system, and engine cover.
    Torque spec

    Cover Bolts19 Nm (14 lb-ft)

Reassembly

1. Verify all electrical connectors are fully seated and locked
2. Ensure all hose clamps are properly positioned and tightened
3. Confirm no tools or parts are left in engine bay
4. Verify serpentine belt is properly routed and tensioned
5. Check that transmission is fully engaged with engine and all bolts are torqued

Verification

• Start engine and allow to idle, monitoring for any unusual noises or vibrations
• Check for coolant leaks around all freeze plug locations while engine warms up
• Monitor coolant level and add as needed during warm-up cycle as air purges from system
• Allow engine to reach full operating temperature and verify cooling fans cycle properly
• Check for any oil leaks from drain plug and filter
• Verify all electrical systems function properly (charging system, sensors, etc.)
• Test drive vehicle to confirm normal operation and recheck fluid levels after drive
• After 24 hours, recheck freeze plug areas for any seepage or wetness indicating leaks

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