This procedure covers the replacement of connecting rod bearings on the 2021-2024 Ford F-150 3.5L EcoBoost V6 engine, requiring engine removal and complete disassembly of the lower end.

Warnings

Tools required

Parts

• Connecting rod bearing set (all 6 cylinders) × 1 — Motorcraft or OEM specification
• Engine oil and filter × 1 — Motorcraft FL500S filter
• Oil pan gasket × 1 — Use OEM specification
• Timing cover gasket × 1 — Use OEM specification
• Engine coolant × 1 — Motorcraft Orange
• RTV silicone sealant × 1 — Motorcraft TA-357
• Engine mounting hardware as needed × 1 — Inspect during removal

Fluids

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

Preparation

1. Ensure vehicle is on a level surface with adequate overhead clearance for engine removal
2. Disconnect negative battery cable and wait 10 minutes for airbag system to discharge
3. Remove engine cover and label all electrical connections with tape and marker
4. Drain engine oil completely and remove oil filter
5. Drain cooling system into appropriate container
6. Remove air intake system from turbochargers to throttle body
7. Discharge A/C system using approved recovery equipment (if equipped)
8. Support transmission with jack and remove transmission-to-engine bolts
9. Remove radiator, cooling fans, and intercooler assembly
10. Disconnect all fuel lines after relieving fuel system pressure
11. Remove exhaust manifolds and turbocharger assemblies
12. Label and disconnect all engine harness connectors
13. Remove accessory drive belts and accessories (alternator, A/C compressor, power steering pump)
14. Attach engine hoist with load leveler to factory lifting points

Procedure

1. 1

   Remove engine from vehicle
   Remove engine mount bolts and carefully lift engine from vehicle. Use load leveler to balance engine during removal. Once clear of engine bay, lower engine onto engine stand and secure with appropriate bolts through bellhousing mounting points.
2. 2

   Remove external components
   With engine on stand, remove remaining external components: oil filter adapter, oil cooler, dipstick tube, knock sensors, coolant temperature sensors, and any remaining brackets. Remove valve covers and set aside. Remove timing chain cover after removing all mounting bolts and carefully prying at designated pry points.
3. 3

   Remove timing components
   Rotate crankshaft to TDC cylinder #1 and verify timing marks align. Mark timing chain position on sprockets with paint marker. Remove timing chain tensioners, guides, and chains. Remove camshaft sprockets. Note the EcoBoost has dual overhead cams per bank - keep all components organized by cylinder bank.
4. 4

   Remove cylinder heads
   Remove cylinder head bolts in reverse of tightening sequence (consult service manual for pattern). Lift cylinder heads off block and place on clean surface with combustion chambers facing up. Do not lay heads on gasket surface. Remove and discard head gaskets.
5. 5

   Remove oil pan and pickup
   Rotate engine on stand to access oil pan. Remove all oil pan bolts and carefully separate pan from block using plastic pry tool at designated points. Remove oil pickup tube and set aside. Clean all RTV residue from block mating surface using plastic scraper.
6. 6

   Inspect and mark connecting rods
   Using permanent marker or metal stamps, clearly mark each connecting rod and cap with cylinder number (1-6) and orientation arrow pointing toward front of engine. Verify factory marks are visible. Rotate crankshaft to bring cylinder #1 to bottom dead center.
   ⚠Improper marking or mixing of rod caps will cause immediate engine failure. Triple-check all markings before disassembly.
7. 7

   Remove connecting rod caps - Cylinders 1-3
   Starting with cylinder #1, remove connecting rod bolts and carefully remove rod cap. Keep bolts with their respective cap. Push piston/rod assembly up into cylinder bore and install rod cap back on rod loosely to keep pairs together. Repeat for cylinders 2 and 3. Inspect bearing surfaces for wear, scoring, or discoloration.
   ℹ️Examine old bearings carefully for wear patterns - this indicates crankshaft condition and potential machining needs.
8. 8

   Remove connecting rod caps - Cylinders 4-6
   Rotate crankshaft 360 degrees to bring cylinders 4-6 to bottom dead center. Remove rod caps for cylinders 4, 5, and 6 using same procedure as cylinders 1-3. Keep all caps with their respective rods. Place removed rod/piston assemblies in numbered containers or labeled areas.
9. 9

   Measure crankshaft journals
   Using micrometer, measure all six connecting rod journals in multiple positions (front-to-back and side-to-side) to check for taper, out-of-round, and proper sizing. Journals must be within 0.0002 inch of specification. Record all measurements. If journals are scored or out of specification, crankshaft must be reground or replaced.
   ⚠Crankshaft journal out-of-round exceeding 0.001 inch requires professional machining. Do not install new bearings on damaged journals.
10. 10

    Clean all components
    Thoroughly clean crankshaft journals with lint-free cloth and solvent. Clean connecting rod bores with solvent and compressed air. Ensure all oil passages in crankshaft and rods are clear. Wipe down block bearing saddles. All surfaces must be completely clean and dry before bearing installation.
11. 11

    Install new bearings in rods
    Install new bearing inserts into connecting rods and caps, ensuring bearing tangs engage notches properly. Do not use force - bearings should snap into place. Apply light coat of clean engine oil to bearing surfaces. Never interchange upper and lower bearings.
    ℹ️Bearings are directional and have specific upper/lower positioning. Verify correct orientation before installation.
12. 12

    Check bearing clearance
    Place Plastigage strip on each crankshaft journal parallel to crankshaft centerline. Install piston/rod assemblies back into cylinders with bearings dry (no oil for this check). Install rod caps with new bolts and torque to Step 1 specification only (18 lb-ft). Do not rotate crankshaft. Remove caps and measure Plastigage width using scale on package. Clearance should be 0.0008-0.0022 inches. Record measurements for all six cylinders.
    ⚠Do not rotate crankshaft with Plastigage installed - this will give false readings.
    Torque spec

    Connecting Rod Bolts25 Nm (18 lb-ft) + 90°
13. 13

    Final bearing installation
    Remove rod caps and clean all Plastigage residue from bearings and journals using lint-free cloth. Coat all bearing surfaces with clean engine assembly lube or 0W-20 oil. Install piston/rod assemblies into cylinders, ensuring ring gaps are properly staggered. Orient connecting rods with marks toward front of engine.
14. 14

    Torque connecting rod bolts - Cylinders 1-3
    Install NEW connecting rod bolts into caps for cylinders 1-3. Torque in three steps: Step 1 to 18 lb-ft, Step 2 to 33 lb-ft, Step 3 additional 90 degrees using torque angle gauge. Ensure cap orientation matches marks made during disassembly. After torquing, verify rod side clearance is 0.006-0.015 inches using feeler gauge.
    ⚠Rod bolts are torque-to-yield. Use NEW bolts only. Reusing old bolts will cause catastrophic failure.
    Torque spec

    Connecting Rod Bolts25 Nm (18 lb-ft) + 90°
15. 15

    Torque connecting rod bolts - Cylinders 4-6
    Rotate crankshaft to position cylinders 4-6 at bottom dead center. Install NEW connecting rod bolts and torque caps using same three-step procedure: 18 lb-ft, 33 lb-ft, then additional 90 degrees. Check rod side clearance. Rotate crankshaft by hand through two complete rotations to verify smooth operation with no binding.
    ℹ️Crankshaft should rotate smoothly with consistent resistance. Any binding indicates misassembly or clearance problem.
    Torque spec

    Connecting Rod Bolts25 Nm (18 lb-ft) + 90°
16. 16

    Install oil pan and pickup
    Clean oil pan thoroughly and inspect for cracks. Apply continuous 3mm bead of RTV silicone to oil pan mating surface, circling all bolt holes on inside. Install oil pickup tube and torque mounting bolts. Position oil pan and install all bolts hand-tight, then torque in crisscross pattern. Allow RTV to cure for 1 hour minimum before adding oil.
    Torque spec

    Mounting Bolts54 Nm (40 lb-ft)
17. 17

    Reinstall cylinder heads
    Install new head gaskets on block with orientation marks visible. Carefully lower cylinder heads onto block, aligning dowel pins. Install head bolts and torque in proper sequence per service manual (multi-stage torque-to-yield procedure). Reinstall camshafts if removed, ensuring proper timing position.
18. 18

    Reinstall timing components and front cover
    Install crankshaft and camshaft sprockets. Route timing chains per service manual specifications, aligning all timing marks precisely. Install chain guides and tensioners. Verify timing marks alignment by rotating crankshaft two full revolutions. Apply RTV to timing cover mating surfaces and install cover with all mounting bolts. Torque cover bolts and electrical connector bolts per specifications.
    ⚠️Incorrect timing chain installation will cause valve-to-piston contact and catastrophic engine damage. Verify all timing marks multiple times.
    Torque spec

    Cover Bolts19 Nm (14 lb-ft)

    Electrical Connector Bolts8 Nm (6 lb-ft)
19. 19

    Reinstall external components
    Install valve covers with new gaskets. Install all sensors including knock sensors and coolant temperature sensors using proper torque specifications. Reinstall oil filter adapter, dipstick tube, and all brackets. Mount accessories including alternator, A/C compressor, and install serpentine belt.
    Torque spec

    Sensor Bolts12 Nm (9 lb-ft)

    Mounting Bolts54 Nm (40 lb-ft)
20. 20

    Install engine in vehicle
    Carefully lift engine with hoist and load leveler. Guide engine into engine bay, aligning with transmission and engine mounts. Install engine mount bolts and torque to specification. Connect transmission to engine and torque bolts per service manual. Remove engine hoist.
    Torque spec

    Mounting Bolts54 Nm (40 lb-ft)

Reassembly

1. Reconnect all engine harness connectors per labels applied during disassembly
2. Install turbocharger assemblies and exhaust manifolds with new gaskets
3. Install intercooler, radiator, and cooling system components
4. Reconnect all fuel lines and ensure connections are secure
5. Install air intake system from turbochargers to throttle body
6. Recharge A/C system if equipped
7. Fill cooling system with Motorcraft Orange Coolant to proper level
8. Install new oil filter and fill engine with 6 quarts Motorcraft 0W-20 synthetic oil
9. Reinstall engine cover and all remaining components
10. Reconnect battery negative cable

Verification

• Prime oil system by cranking engine with fuel pump fuse removed until oil pressure gauge shows pressure
• Reinstall fuel pump fuse and start engine - monitor for unusual noises or vibrations during first start
• Allow engine to reach operating temperature while monitoring for leaks at oil pan, timing cover, and all gasket surfaces
• Check oil pressure at idle and 2000 RPM - should be within factory specifications (typically 25+ PSI at idle warm)
• Perform test drive and monitor engine behavior under various loads
• Recheck oil level after test drive and top off if needed
• Monitor oil consumption over first 500 miles - excessive consumption may indicate ring seating issues
• Change oil and filter at 500 miles to remove assembly lube and break-in debris
• Scan for any diagnostic trouble codes and address if present

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