This procedure covers removal and replacement of the torque converter on a 2021-2024 Ford F-150 with 3.5L EcoBoost V6 engine and RWD configuration, requiring transmission separation from the engine.

Warnings

Tools required

Parts

• Torque converter × 1 — Use OEM Ford torque converter for 10R80 transmission
• Transmission drain plug washer × 1 — Use OEM specification
• Transmission pan gasket × 1 — Use OEM specification
• Transmission filter (if servicing) × 1 — Use OEM specification

Fluids

• Motorcraft MERCON LV ATF — 13 qt

Preparation

1. Park vehicle on level ground and engage parking brake
2. Disconnect negative battery terminal and wait 10 minutes for airbag system to deplete
3. Raise vehicle and support securely on jack stands at frame contact points
4. Remove skid plates or underbody panels if equipped
5. Mark driveshaft-to-flange orientation with paint marker for proper reinstallation
6. Take photos of all electrical connector locations and routing for reference during reassembly
7. Install engine support bar across engine bay or attach engine hoist to support engine weight

Procedure

1. 1

   Drain transmission fluid
   Position large drain pan under transmission. Remove the transmission drain plug and allow fluid to drain completely. Once drained, reinstall drain plug with NEW washer to prevent leaks during subsequent steps.
   Torque spec

   Drain Plug39 Nm (29 lb-ft)
2. 2

   Remove driveshaft
   Remove the four driveshaft flange bolts at the rear differential. Support driveshaft and remove front U-joint bolts or slip yoke from transmission tailshaft housing. Remove driveshaft from vehicle. Plug transmission output shaft opening with clean rag to prevent fluid loss and contamination.
3. 3

   Disconnect transmission electrical and cooler lines
   Disconnect all electrical connectors from transmission including main harness connector, solenoid body connector, output speed sensor, and any other sensors. Disconnect transmission cooler lines at transmission fittings using appropriate line disconnect tools. Cap or plug all open lines to prevent contamination. Remove shift cable from transmission lever and bracket.
4. 4

   Remove transmission crossmember and mount
   Support transmission with transmission jack positioned securely under transmission pan with safety chain in place. Remove transmission mount-to-crossmember fasteners, then remove crossmember-to-frame mounting bolts. Lower transmission jack slightly and remove crossmember from vehicle.
   Torque spec

   Mounting Bolts31 Nm (23 lb-ft)
5. 5

   Remove starter motor
   Disconnect electrical connections from starter motor. Remove starter motor mounting bolts and carefully remove starter from bellhousing. This provides access to lower torque converter and flexplate bolts.
6. 6

   Access and remove torque converter-to-flexplate bolts
   Working through starter motor opening and access holes in bellhousing, locate torque converter-to-flexplate bolts. Rotate crankshaft using 22mm socket on crankshaft pulley bolt to bring each torque converter bolt into view. Remove all torque converter-to-flexplate bolts (typically 4 bolts). Keep these bolts separate as they are specific to this application.
   ⚠Mark flexplate orientation to torque converter if reusing torque converter for balanced reassembly, though new torque converter installation is recommended.
   Torque spec

   Torque Converter Bolts50 Nm (37 lb-ft)
7. 7

   Remove bellhousing-to-engine bolts
   Remove all transmission bellhousing-to-engine block bolts. These bolts vary in length; note locations of each bolt length for proper reassembly. There are typically 6-8 bolts around the bellhousing perimeter including upper and lower bolts. Access upper bolts from engine bay.
8. 8

   Separate transmission from engine
   With transmission jack supporting full weight of transmission, carefully slide transmission rearward away from engine. Move transmission straight back to disengage input shaft from engine. As transmission separates, the torque converter will remain in the transmission bellhousing. Hold torque converter in place with one hand or use a strap to prevent it from sliding out and falling. Lower transmission carefully on jack and move clear of vehicle.
   ⚠️Transmission is extremely heavy. Ensure transmission jack is secure and use assistant if available. Never allow transmission to tilt excessively or torque converter will fall out.
9. 9

   Remove torque converter from transmission
   With transmission on bench or secure surface with front facing up, carefully pull torque converter straight out of transmission pump housing. Torque converter will contain residual fluid, so keep drain pan ready. Inspect torque converter hub for scoring, check transmission input shaft seals for damage, and examine flexplate for cracks or heat damage.
10. 10

    Prepare new torque converter for installation
    Verify new torque converter matches original in all dimensions and spline configuration. Pre-fill new torque converter with approximately 1 quart of fresh Motorcraft MERCON LV ATF through center hub. Coat torque converter hub and pump seal contact area with clean transmission fluid.
    ℹ️Pre-filling torque converter prevents dry start-up and ensures immediate lubrication upon first engine start.
11. 11

    Install torque converter into transmission
    Align torque converter splines with transmission pump. Carefully push torque converter into transmission while rotating it to engage pump drive. You should feel torque converter engage in three distinct stages as it seats into pump, input shaft, and stator support. Measure from bellhousing face to torque converter mounting lug; it should be recessed approximately 10-15mm indicating full engagement. Use straightedge across bellhousing to verify proper seating depth.
    ⚠Torque converter MUST be fully seated before transmission installation or transmission pump will be damaged during installation. Verify engagement depth before proceeding.
12. 12

    Install transmission to engine
    Apply thin film of high-temperature grease to transmission input shaft splines. Position transmission on jack and raise into position behind engine. Hold torque converter firmly in place during installation. Align transmission with engine dowel pins and carefully slide transmission forward. Ensure torque converter remains fully seated and does not slide out. Once transmission is flush with engine block, install all bellhousing-to-engine bolts in their original locations and tighten in star pattern.
    Torque spec

    Mounting Bolts31 Nm (23 lb-ft)
13. 13

    Install torque converter to flexplate
    Rotate crankshaft to align flexplate bolt holes with torque converter lugs. Install all torque converter-to-flexplate bolts and tighten evenly in star pattern to specified torque. Continue rotating crankshaft to access each bolt location through starter opening and bellhousing access holes.
    Torque spec

    Torque Converter Bolts50 Nm (37 lb-ft)

    Flexplate Bolts85 Nm (63 lb-ft)
14. 14

    Reinstall starter and transmission mount
    Install starter motor to bellhousing and connect electrical connections. Install transmission crossmember to frame, then install transmission mount between crossmember and transmission. Torque all mounting hardware to specification. Remove transmission jack.
    Torque spec

    Mounting Bolts31 Nm (23 lb-ft)
15. 15

    Reconnect driveshaft and all connections
    Remove rag from output shaft and install driveshaft, aligning marks made during disassembly. Reconnect all transmission cooler lines, electrical connectors, and shift cable. Verify all connections are secure and properly routed. Install any skid plates or underbody panels removed during preparation.
16. 16

    Fill transmission with fluid
    Lower vehicle to ground. Add approximately 6 quarts of Motorcraft MERCON LV ATF through dipstick tube. Start engine and allow to idle. With engine at idle and parking brake applied, move shift lever through all gear positions, pausing briefly in each position. Return to Park. Check fluid level with engine running at operating temperature and add fluid as needed to bring level to proper range. Total capacity is approximately 13 quarts but actual fill amount depends on fluid retained in system.
    ⚠10R80 transmission requires precise fluid level. Overfilling or underfilling can cause transmission damage or shifting issues. Check fluid at operating temperature per Ford procedure.

Reassembly

1. Reconnect negative battery terminal after all other work is complete
2. Reset transmission adaptive learning values using Ford IDS or compatible scan tool if available
3. Double-check all fasteners for proper torque specification
4. Verify no fluid leaks at cooler lines, drain plug, or transmission-to-engine mating surface

Verification

• Start engine and verify no abnormal noises from transmission or torque converter area
• Check for fluid leaks around all connections, particularly at torque converter-to-flexplate area and transmission cooler lines
• Perform test drive and verify smooth engagement in all gears with no slipping, shuddering, or delayed shifts
• Verify transmission fluid level is correct at operating temperature with engine running in Park
• Check for diagnostic trouble codes using scan tool; clear any codes related to battery disconnect but investigate any transmission-related codes
• Monitor fluid level and condition after first 100 miles and check for leaks

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