3.5L V6 Engine Complete Assembly for 2024-2025 Ford Expedition, F-150

A quick look at your own vehicle makes sure the right engine shows up:

• Verify the 8th digit of the VIN is either 8 or G. If it is D, the vehicle is a PowerBoost Hybrid and this engine will not fit.
• Confirm the vehicle has a longitudinal (RWD/4WD) drivetrain layout, not a transverse layout.
• Locate the Engine ID Tag on the front timing cover or valve cover and compare it with the replacement engine.

What the install really takes — plan and budget with confidence:

Special tools this job needs:

• Camshaft Holding Tool Kit (OEM 303-1655 / Lisle 37350)
• Crankshaft Vibration Damper Remover/Installer (OEM 303-1521)
• Quick-Disconnect Tool Set
• High-Quality Scan Tool (with FORScan or Ford FDRS)
• Vacuum Coolant Filler

Budget for these consumables at install:

• Engine Oil (5W-30 Full Synthetic or Synthetic Blend)
• Motorcraft Oil Filter (FL-500S)
• Motorcraft Yellow Prediluted Antifreeze/Coolant (WSS-M97B57-A2)
• Spark Plugs (Motorcraft SP-580 or equivalent, pre-gapped to 0.030" - 0.032")
• Intake manifold gaskets (upper and lower)
• Turbocharger mounting gaskets, oil feed/drain line O-rings, and coolant line seals
• Exhaust manifold gaskets and new mounting studs/nuts
• Crankshaft pulley bolt (one-time use TTY)
• Flexplate-to-crankshaft bolts (one-time use TTY)
• Torque converter nuts (one-time use TTY)

What your vehicle’s computers will need after the swap:

What’s involved: Crankshaft Position (CKP) Sensor Relearn, Injector Flow Code (IQA) Programming, Idle Relearn

A Crankshaft Position (CKP) variation relearn and Idle Relearn are required to prevent false misfire codes (P0300) and rough running. If using the direct fuel injectors included with the replacement engine, their unique calibration codes must be programmed into the PCM. If the PCM itself is replaced, a PATS security re-marriage and VIN programming are required.

Pro tips for a smooth first start-up — hand them to whoever does the install:

• Turbocharger line seals must be replaced with brand-new O-rings and backing spacers to prevent leaks.
• Crankshaft pulley bolt is torque-to-yield and must be replaced; failure to follow the multi-stage torque sequence can cause catastrophic engine failure.
• Direct injector Teflon seals must be replaced using a special expander/compressor tool if injectors are transferred.
• Starter motor must be completely flush with the engine-to-transmission spacer plate before tightening to prevent bending the plate and causing a scraping noise.
• Exhaust manifold studs frequently warp or snap; extract carefully and use brand new OEM hardware.
• Mechanical vacuum pump at the rear of the passenger-side cylinder head is prone to oil leaks; replace its seal while the engine is out.
• Cooling system is difficult to bleed; use a vacuum coolant filling tool to prevent air pockets.

Easy to get right once you know them:

• Ordering for a Hybrid (PowerBoost) vehicle; the hybrid block, crankshaft, and flywheel configurations are completely different.
• Reusing old turbocharger mounting hardware, studs, and oil/coolant line seals, leading to exhaust or fluid leaks.
• Skipping the mandatory Crankshaft Position (CKP) sensor relearn, resulting in phantom misfire codes (P0300) and harsh shifting.
• Mixing up or pinching the port and direct injector wiring harnesses during installation.
• Ignoring the transmission separator plate alignment when mating the engine to the 10-speed transmission.

Not issues with the units on this page — the manufacturer documented these for every engine of this family, wherever you buy one. Handy for your installer: