Engine Rear Cover: Removal

WARNING: This page is about a different variant/trim than selected.

Vehicles with automatic transmission

Remove the starter. For additional information, refer to STARTERS - EXCURSION & F250-550 SUPER DUTY PICKUPS - DIESEL .

All vehicles

Remove the transmission. For additional information, refer to REMOVAL & INSTALLATION - EXCURSION & F250-550 SUPER DUTY PICKUPS for automatic transmission or MANUAL TRANSAXLE/TRANSMISSION - ZF 6 SPEED for manual transmission.

Vehicles with manual transmission

Remove the clutch disc and pressure plate. For additional information, refer to CLUTCH .

All vehicles

Remove the bolts and the flexplate or flywheel.

Fig 1: Identifying Flexplate/Flywheel Bolts
Courtesy of FORD MOTOR CO.

NOTE: Use extreme care when removing the flywheel front adapter to prevent damage to the alignment dowel pin.

Fig 2: Identifying Flywheel Adapter

Courtesy of FORD MOTOR CO.

Remove the flywheel front adapter.

CAUTION: To prevent engine damage, do not remove the rear primary crankshaft flange bolts under any circumstances. If the flange is removed and reinstalled, it will result in engine vibration and premature transmission component wear.

NOTE: The drill bit used must be the appropriate size for the body dent puller used in the following step.

Fig 3: View Of Holes On RH and LH Side of Seal

Courtesy of FORD MOTOR CO.

Using the appropriate drill bit, drill a hole on the RH side of the seal and another directly across from it on the LH side of the seal, as shown.

NOTE: It will be necessary to alternate between the two holes, drilled in the previous step, to walk the seal out of the engine rear cover.

Fig 4: Removing Rear Main Seal Using Special Tool

Courtesy of FORD MOTOR CO.

Using the special tool and a commercially available body dent puller attachment, remove and discard the rear main seal.

NOTE: Production engines will not have a wear sleeve.

Fig 5: Removing Crankshaft Rear Wear Sleeve

Courtesy of FORD MOTOR CO.

If equipped with a crankshaft wear sleeve, use the special tool to remove the crankshaft rear wear sleeve.
Clean and inspect the crankshaft sealing surface.

Fig 6: Identifying Crankshaft Sealing Surface
Courtesy of FORD MOTOR CO.
Remove the bolts and the turbocharger heat shield.

Fig 7: Locating Turbocharger Heat Shield And Bolts
Courtesy of FORD MOTOR CO.

CAUTION: To prevent engine damage, replace damaged or missing dowel pins before installing the rear engine cover.

Fig 8: Locating Rear Engine Cover Bolts

Courtesy of FORD MOTOR CO.

Remove the 11 bolts from the rear engine cover.

NOTE: Use care when removing the engine rear cover so that the oil pump cover gasket does not get pulled out on removal.

Fig 9: Cutting Sealant

Courtesy of FORD MOTOR CO.

Using a thin blade scraper cut the sealant at the oil pump cover joint.

CAUTION: Sealant is used where the crankcase and the lower crankcase meet. Failure to cut the sealant could result in pulling the lower crankcase seal out while removing the rear cover.

NOTE: A 51/2 inch long thin blade scraper will be needed to properly cut the sealant.

Fig 10: Cutting Sealant Where Crankcase And Lower Crankcase Meet

Courtesy of FORD MOTOR CO.

Use a thin blade scraper cut the sealant where the crankcase and the lower crankcase meet.

CAUTION: Sealant is used where the crankcase and the lower crankcase meet. Failure to cut the sealant could result in pulling the lower crankcase seal out while removing the rear cover.

NOTE: A 51/2 inch long thin blade scraper will be needed to properly cut the sealant.

Use a thin blade scraper cut the sealant where the crankcase and the lower crankcase meet. Remove the rear cover.
- Remove and discard the press-in-place gasket.
- Clean and inspect the sealing surfaces.
  
  Fig 11: Cutting Sealant Where Crankcase And Lower Crankcase Meet
  Courtesy of FORD MOTOR CO.