This procedure covers the removal and replacement of the transmission output shaft bearing on a 2021-2024 Ford F-150 with 3.5L EcoBoost and RWD transmission, requiring transmission removal and partial disassembly.

Warnings

Tools required

Parts

• Transmission output shaft bearing × 1 — Use OEM specification
• Output shaft seal × 1 — Use OEM specification
• Transmission pan gasket × 1 — Use OEM specification
• Transmission filter × 1 — Use OEM specification
• Drain plug washer × 1 — Use OEM specification
• Transmission mounting hardware (as needed) × 1 — Use OEM specification

Fluids

• Motorcraft MERCON LV ATF — 13 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Disconnect negative battery terminal and wait 10 minutes for airbag system deactivation
3. Raise vehicle on lift or properly supported jack stands to working height
4. Remove engine skid plate/splash shield if equipped
5. Remove rear driveshaft and mark orientation for reinstallation
6. Disconnect shift linkage and all electrical connectors from transmission
7. Mark transmission-to-engine orientation for proper reinstallation alignment
8. Have clean workspace prepared for transmission disassembly

Procedure

1. 1

   Drain transmission fluid
   Place drain pan under transmission. Remove drain plug from transmission pan and allow fluid to drain completely. Remove fill plug to aid drainage. Inspect drained fluid for metal particles or debris indicating additional internal damage. Once drained, reinstall drain plug with new washer.
   Torque spec

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

   Remove transmission pan and filter
   Remove all transmission pan bolts in criss-cross pattern working from outside to center. Lower pan carefully as residual fluid will be present. Remove transmission filter by pulling straight down. Inspect pan for metal debris or clutch material. Clean pan and magnet thoroughly.
   Torque spec

   Pan Bolts19 Nm (14 lb-ft)
3. 3

   Support engine and transmission
   Install engine support bar across engine compartment or attach overhead hoist to engine lifting points. Position transmission jack under transmission with adapter plate. Adjust jack to just contact transmission without bearing weight. Ensure transmission is properly balanced on jack.
4. 4

   Remove transmission crossmember and mounts
   Remove transmission crossmember mounting bolts. Remove transmission mount bolts connecting transmission to crossmember. Lower transmission jack slightly to access upper mounting bolts. Note location of different length bolts for reinstallation.
   Torque spec

   Mounting Bolts70 Nm (52 lb-ft)
5. 5

   Disconnect torque converter
   Remove torque converter access cover from bellhousing. Rotate engine via crankshaft bolt to access each torque converter-to-flexplate bolt. Remove all torque converter bolts. Mark torque converter position relative to flexplate for balanced reinstallation. Push torque converter back into transmission bell housing to ensure it does not come out with transmission.
6. 6

   Remove transmission from vehicle
   Remove all bellhousing-to-engine bolts. Note locations of different bolt sizes. Carefully pull transmission straight back away from engine using transmission jack. Ensure torque converter remains in transmission. Once input shaft clears engine, lower transmission and remove from under vehicle. Place on clean workbench.
   ⚠Keep transmission level during removal to prevent torque converter from sliding out and spilling fluid.
   Torque spec

   Mounting Bolts70 Nm (52 lb-ft)
7. 7

   Remove transmission extension housing
   With transmission on workbench, remove extension housing bolts. Note bolt locations as some may be different lengths. Carefully pry extension housing away from transmission case using appropriate pry points. Remove housing and gasket. Inspect housing for cracks or damage.
   Torque spec

   Cover Screws12 Nm (9 lb-ft)
8. 8

   Remove output shaft components
   Remove output shaft snap ring using snap ring pliers. Slide output shaft yoke or companion flange off shaft if still attached. Note position and orientation of all components for reassembly. Remove any spacers or thrust washers behind bearing and keep in order.
9. 9

   Extract output shaft bearing
   Install internal bearing puller into bearing bore. Attach slide hammer to puller. Use slide hammer action to extract bearing from transmission case. If bearing is severely damaged or seized, may require careful use of bearing splitter or cutting tool. Inspect bearing bore in transmission case for scoring, wear, or damage. Measure bore diameter to verify within specification.
   ⚠Do not damage bearing bore surface during extraction. Scoring or gouging will cause new bearing to fail.
10. 10

    Prepare bearing bore and new bearing
    Clean bearing bore thoroughly with brake cleaner and lint-free cloth. Remove any burrs with fine emery cloth. Inspect output shaft for wear, scoring, or damage where bearing rides. Measure shaft diameter to ensure within specification. Clean new bearing and verify correct part number. Apply thin coat of clean ATF to bearing outer diameter and bore.
11. 11

    Install new output shaft bearing
    Position new bearing at bore opening with manufacturer markings facing outward. Using appropriate size bearing driver or installation tool that contacts only outer bearing race, carefully drive bearing squarely into bore. Drive until bearing is fully seated to proper depth (flush or to specification per service manual). Verify bearing is fully seated and rotates smoothly without binding.
    ⚠Never drive on inner race or rolling elements. Only apply installation force to outer race to prevent bearing damage.
12. 12

    Install new output shaft seal
    Remove old output shaft seal from extension housing using seal puller or screwdriver. Clean seal bore in housing. Apply thin coat of ATF to new seal outer diameter and lip. Using seal driver of appropriate size, drive new seal squarely into housing bore until fully seated. Seal lip should face inward toward transmission.
13. 13

    Reassemble transmission output components
    Install any spacers, thrust washers, or shims on output shaft in original order and orientation. Install output shaft snap ring ensuring it is fully seated in groove. Check output shaft endplay with dial indicator if specifications are available. Verify all components rotate freely without binding.
14. 14

    Reinstall extension housing
    Install new gasket on transmission case. Apply small amount of ATF to output shaft seal lip. Carefully slide extension housing over output shaft, ensuring shaft does not damage seal lip. Align housing with case and install all bolts finger tight. Torque bolts in criss-cross pattern to specification.
    Torque spec

    Cover Screws12 Nm (9 lb-ft)
15. 15

    Install transmission in vehicle
    Secure transmission to transmission jack ensuring it is properly balanced. Raise transmission into position under vehicle. Align torque converter with flexplate using alignment marks made during removal. Carefully slide transmission forward onto engine dowel pins. Install all bellhousing bolts and torque in sequence. Verify torque converter rotates freely and is fully seated. Install torque converter-to-flexplate bolts and torque in star pattern.
    ⚠Verify torque converter is fully seated in pump before bolting transmission to engine. Converter should be recessed into bellhousing and rotate freely.
    Torque spec

    Mounting Bolts70 Nm (52 lb-ft)

    Flywheel Bolts95 Nm (70 lb-ft)
16. 16

    Install mounts and crossmember
    Raise transmission jack to align transmission mounts. Install transmission mount bolts. Position crossmember and install crossmember mounting bolts. Torque all mounting hardware to specification. Remove transmission jack once all mounts are secure.
    Torque spec

    Mounting Bolts70 Nm (52 lb-ft)
17. 17

    Reconnect components
    Reconnect all electrical connectors to transmission ensuring they click fully into place. Reconnect shift linkage and adjust if necessary. Install rear driveshaft aligning marks made during removal. Torque driveshaft bolts to specification. Install torque converter access cover.
18. 18

    Install filter and pan
    Install new transmission filter pressing firmly until seated. Clean transmission pan mating surface thoroughly. Install new pan gasket. Position pan and install all bolts finger tight. Torque pan bolts in criss-cross pattern from center outward to specification.
    Torque spec

    Pan Bolts19 Nm (14 lb-ft)
19. 19

    Refill transmission fluid
    Remove fill plug. Using fluid pump or funnel with hose, add approximately 10 quarts of Motorcraft MERCON LV ATF through fill hole. Reinstall fill plug with new washer and torque to specification. Connect negative battery terminal. Start engine and allow to idle. Check fluid level with engine running in Park after transmission reaches operating temperature. Add fluid as needed to bring to proper level on dipstick. Total capacity is approximately 13 quarts.
    Torque spec

    Fill Plug39 Nm (29 lb-ft)

Reassembly

1. Reinstall engine skid plate/splash shield if equipped
2. Torque all fasteners to specified values in proper sequence
3. Verify all electrical connectors are fully seated and locked
4. Double-check driveshaft U-joint bolts are torqued and safety wired if applicable
5. Ensure no tools or parts are left in engine bay or under vehicle

Verification

• Start engine and verify no fluid leaks from transmission pan, extension housing, or mounting points
• With engine at operating temperature, shift through all gear ranges and verify smooth engagement
• Test drive vehicle and verify all gears engage properly with no abnormal noise from output shaft area
• Recheck transmission fluid level after test drive and top off if necessary
• Inspect for leaks after test drive, paying special attention to output shaft seal area
• Verify no abnormal vibrations during acceleration which could indicate improper driveshaft installation
• Scan for transmission codes with scan tool to verify no faults present

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