Complete 60,000-mile scheduled maintenance service including oil change, fluid inspections, filter replacements, and multi-point inspection per Ford maintenance schedule.

Warnings

Tools required

Parts

• Engine oil filter × 1 — Motorcraft FL-820S or equivalent
• Engine air filter × 1 — Motorcraft FA-1883
• Cabin air filter × 1 — Motorcraft FP-67
• Oil drain plug crush washer × 1 — Use OEM specification
• Front differential fill plug gasket × 1 — Use OEM specification
• Rear differential fill plug gasket × 1 — Use OEM specification
• Transfer case fill plug gasket × 1 — Use OEM specification

Fluids

• Motorcraft 5W-20 Synthetic Blend engine oil — 6 qt
• Motorcraft 75W-140 Synthetic rear differential oil — 2 qt
• 75W-90 GL-5 front differential gear oil — 1.5 qt
• Motorcraft Transfer Case Fluid — 2.5 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Allow engine and exhaust system to cool completely (minimum 2 hours)
3. Gather all required tools, parts, and fluids before beginning
4. Loosen wheel lug nuts on all four wheels while vehicle is on ground
5. Raise vehicle using floor jack at manufacturer-specified lift points and secure on jack stands
6. Remove all four wheels for brake and tire inspection
7. Place oil drain pan under engine oil drain plug location

Procedure

1. 1

   Drain engine oil and remove filter
   Locate oil drain plug on passenger side of oil pan. Clean area around drain plug. Remove drain plug using socket wrench and allow oil to drain completely into pan (approximately 5-7 minutes). While draining, locate oil filter on driver side of engine near firewall. Use oil filter wrench to remove filter, allowing remaining oil to drain. Inspect drain plug threads and oil pan threads for damage.
2. 2

   Install new oil filter and drain plug
   Install new crush washer on oil drain plug. Clean drain plug threads and oil pan mating surface. Install drain plug and torque to specification. Apply thin film of clean oil to new oil filter gasket. Install new oil filter hand-tight, then turn an additional 3/4 turn. Do not use filter wrench for installation.
   ⚠Always use a new crush washer on drain plug to prevent leaks. Reusing old washers will cause oil seepage
3. 3

   Replace engine air filter
   Open hood and locate air filter housing on driver side of engine bay. Release clips securing air box cover (typically 4-6 clips). Lift cover and remove old engine air filter. Inspect air box housing for debris and clean if necessary. Install new air filter ensuring proper seating in housing. Replace cover and secure all clips.
4. 4

   Replace cabin air filter
   Open passenger door. Remove glove box by pressing sides inward to release stops and lowering fully. Locate cabin air filter housing behind glove box. Remove cover by pressing release tabs or removing screws. Slide old cabin filter out noting airflow direction arrow. Install new cabin filter with airflow arrow pointing toward rear of vehicle. Reinstall cover and glove box.
5. 5

   Drain and refill rear differential
   Locate rear differential fill plug (upper) and drain plug (lower) on rear axle housing. Clean area around both plugs thoroughly. Remove fill plug first to ensure it is not seized. Remove drain plug and allow gear oil to drain completely into clean drain pan. Inspect drained fluid for metal particles or unusual debris. Clean magnetic drain plug of any metal shavings. Install drain plug with new gasket. Using fluid transfer pump, fill differential through fill hole until fluid reaches bottom of fill hole threads. Install fill plug with new gasket.
   ℹ️Always remove fill plug before drain plug to ensure you can refill the differential. A seized fill plug with drained oil creates a critical problem
6. 6

   Drain and refill front differential
   Locate front differential on driver side of vehicle under engine. Identify fill plug (upper side) and drain plug (lower). Clean area around both plugs. Remove fill plug first, then remove drain plug and drain gear oil into clean pan. Inspect fluid for contamination. Clean drain plug and install with new gasket. Use transfer pump to add 1.5 quarts of 75W-90 GL-5 gear oil through fill hole until fluid level reaches bottom of fill plug threads. Install fill plug with new gasket.
7. 7

   Drain and refill transfer case
   Locate transfer case mounted to transmission on passenger side. Identify fill plug on side and drain plug on bottom of case. Clean both plug areas thoroughly. Remove fill plug first to verify access. Remove drain plug and drain fluid into clean pan. Inspect drained fluid condition. Install drain plug with new gasket. Using transfer pump, add 2.5 quarts of Motorcraft Transfer Case Fluid through fill hole until fluid begins to drip from fill opening. Install fill plug with new gasket.
8. 8

   Inspect brake system
   With wheels removed, inspect brake pads on all four corners for remaining thickness (minimum 3mm). Inspect brake rotors for scoring, heat cracks, or excessive wear. Check brake caliper slides for proper movement and lubrication. Inspect brake lines and hoses for cracks, damage, or fluid seepage. Verify brake fluid level in master cylinder reservoir is between MIN and MAX marks. Test brake fluid condition using brake fluid tester or test strips if available.
   ℹ️Ford recommends DOT 4 LV brake fluid. Do not mix with DOT 3 or standard DOT 4 fluids
9. 9

   Inspect suspension and steering components
   Visually inspect all suspension components for damage, excessive wear, or leaks. Check ball joints for excessive play or torn boots. Inspect tie rod ends for looseness or damaged boots. Check control arm bushings for cracking or separation. Inspect shock absorbers for fluid leakage. Examine CV axle boots for tears or grease leakage. Check power steering fluid level in reservoir and top off with MERCON LV if needed. Inspect power steering hoses for leaks or damage.
10. 10

    Inspect drivetrain and exhaust
    Inspect driveshaft U-joints for excessive play or wear. Check driveshaft boots for damage. Verify transfer case and transmission are not leaking from seals or gaskets. Inspect exhaust system from manifolds to tailpipe for damage, excessive rust, or loose connections. Pay special attention to exhaust manifold studs which are common failure points on EcoBoost engines. Check exhaust hangers for deterioration.
11. 11

    Inspect cooling system and hoses
    Visually inspect coolant level in overflow reservoir (should be at FULL COLD mark when engine is cold). Check coolant condition for proper color (orange) and clarity. Inspect all coolant hoses for cracks, soft spots, or swelling. Check hose clamps for tightness. Inspect radiator for damage or leaks. Check intercooler and charge air cooler hoses specific to EcoBoost system for proper connection and condition. Inspect turbocharger oil feed and return lines for leaks.
12. 12

    Inspect belts and engine accessories
    Inspect serpentine belt for cracks, glazing, fraying, or missing ribs. Check belt tensioner for proper operation and signs of wear. Verify belt routing matches underhood diagram. Inspect all accessible engine hoses for condition. Check battery terminals for corrosion and tightness. Verify battery hold-down is secure. Inspect engine air intake system from air box to turbochargers for loose connections or damage.
13. 13

    Fill engine with oil and verify level
    Lower vehicle enough to access engine oil fill cap on driver side valve cover. Remove oil fill cap and insert funnel. Add 5.5 quarts of Motorcraft 5W-20 Synthetic Blend oil. Install oil fill cap. Start engine and allow to run for 30 seconds, then shut off. Wait 2 minutes for oil to drain to pan. Check oil level on dipstick and add remaining oil to bring level to FULL mark (typically 0.5 quart additional). Verify no leaks at drain plug or oil filter.
    ⚠Do not overfill engine oil. Overfilling can cause seal damage and increased crankcase pressure in turbocharged engines
14. 14

    Reinstall wheels and perform final checks
    Inspect tires for tread depth (minimum 2/32 inch), uneven wear patterns, and sidewall damage. Rotate tires if wear is uneven or per maintenance schedule. Clean wheel mounting surfaces on hub and wheel. Install wheels and hand-thread all lug nuts. Lower vehicle until tires just touch ground but weight is still on jack stands. Torque lug nuts to specification in star pattern. Fully lower vehicle and remove jack stands. Perform final torque verification of all lug nuts in star pattern.
    ⚠Always torque lug nuts in star pattern to prevent wheel distortion and ensure even clamping force
15. 15

    Reset maintenance reminder and document service
    Turn ignition to ON position without starting engine. Using steering wheel controls, navigate to Settings > Vehicle > Oil Life Reset. Select Reset and confirm. Verify oil life shows 100%. Check tire pressures when cold and adjust to specification on door jamb sticker (typically 35 PSI front and rear). Document all service performed, fluid conditions observed, and any items requiring future attention. Update vehicle maintenance records.

Reassembly

1. Verify all drain plugs and fill plugs are properly installed with new gaskets
2. Confirm all fluid levels are correct and no leaks are present
3. Ensure all clips, covers, and access panels are properly secured
4. Verify glove box operates normally after cabin filter replacement
5. Double-check that all wheels are torqued to specification in star pattern

Verification

• Start engine and verify oil pressure light extinguishes within 2-3 seconds
• Allow engine to reach operating temperature and verify no leaks from oil filter, drain plug, or differential/transfer case plugs
• Test drive vehicle 5-10 miles and recheck all fluid levels when engine is at operating temperature
• Verify no unusual noises from differentials or transfer case during turns and acceleration
• Recheck wheel lug nut torque after test drive
• Verify oil life monitor has been reset to 100%
• Check tire pressures when cold and confirm all are at specification

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