Complete 90,000 mile scheduled maintenance service including engine oil change, filter replacements, fluid inspections, drivetrain service, and full system inspection for the 3.5L EcoBoost V6 engine.

Warnings

Tools required

Parts

• Engine oil filter × 1 — Motorcraft FL-910-S or equivalent
• Engine air filter × 1 — Motorcraft FA-1927 or equivalent
• Cabin air filter × 1 — Motorcraft FP-67 or equivalent
• Oil drain plug crush washer × 1 — Use OEM specification
• Transfer case drain plug gasket × 1 — Use OEM specification
• Rear differential drain plug gasket × 1 — Use OEM specification
• Front differential drain plug gasket × 1 — Use OEM specification

Fluids

• Motorcraft 5W-20 Synthetic Blend engine oil — 6 qt
• Motorcraft Transfer Case Fluid — 2.5 qt
• Motorcraft 75W-140 Synthetic Gear Oil (rear differential) — 2 qt
• 75W-90 GL-5 Gear Oil (front differential) — 1.5 qt
• Motorcraft DOT 4 LV Brake Fluid — 0.5 qt
• Motorcraft MERCON LV power steering fluid — 0.25 qt

Preparation

1. Park vehicle on level surface and apply parking brake firmly
2. Place wheel chocks behind rear wheels
3. Ensure engine and drivetrain are cool to touch (minimum 2 hours after last operation)
4. Gather all fluids, filters, and gaskets before beginning
5. Verify you have the correct transfer case fluid (NOT ATF) for this application
6. Raise front of vehicle with floor jack and support on jack stands at manufacturer frame lift points
7. Remove front wheels and set aside in safe location
8. Install drain pans under engine oil pan, transfer case, and differentials

Procedure

1. 1

   Drain engine oil
   Locate the oil drain plug on the rear passenger side of the oil pan. Using appropriate socket, loosen the drain plug slowly. Once loose, quickly remove by hand while positioning drain pan to catch oil flow. Allow oil to drain completely for at least 10 minutes. Remove and discard old crush washer from drain plug. Clean drain plug threads and sealing surface with clean rag.
2. 2

   Replace oil filter and reinstall drain plug
   Locate oil filter on driver side of engine block. Using oil filter wrench, turn filter counterclockwise to remove. Verify old filter gasket came off with filter. Clean filter mounting surface on engine block. Apply thin film of new oil to new filter gasket. Hand-tighten new filter until gasket contacts mounting surface, then turn an additional 3/4 to 1 full turn. Install new crush washer on drain plug. Thread drain plug by hand first to avoid cross-threading, then torque to specification.
3. 3

   Drain and refill transfer case
   Locate transfer case between transmission and rear driveshaft (center-rear of vehicle). Clean area around drain and fill plugs. Remove fill plug first (upper plug) to verify it's not seized. Remove drain plug and allow fluid to drain completely into catch pan. Inspect drained fluid for metal particles or contamination. Clean and install drain plug with new gasket. Using fluid transfer pump, fill transfer case through fill hole until fluid begins to seep out. Install fill plug and torque to specification.
   ⚠Always remove fill plug before drain plug. If fill plug is seized and you've already drained the case, the transfer case will be inoperable.
4. 4

   Service rear differential
   Position drain pan under rear differential (rear axle center section). Clean area around drain and fill plugs. Remove fill plug first (located on front face of differential). Remove drain plug on bottom of differential and drain completely. Inspect for metal particles or excessive wear debris. Clean magnetic drain plug thoroughly. Install drain plug with new gasket. Using fluid transfer pump, add Motorcraft 75W-140 through fill hole until fluid level reaches bottom of fill hole threads. Install fill plug with new gasket and torque to specification.
5. 5

   Service front differential
   Position drain pan under front differential (front axle center section). Access may require turning steering wheel full lock. Clean area around drain and fill plugs. Remove fill plug first. Remove drain plug and drain fluid completely. Inspect drained fluid for contamination. Clean magnetic drain plug. Install drain plug with new gasket. Using fluid transfer pump, add 75W-90 GL-5 gear oil through fill hole until fluid reaches bottom of fill hole. Install fill plug with new gasket and torque to specification.
   ℹ️Front differential uses different fluid specification (75W-90) than rear differential (75W-140). Do not interchange.
6. 6

   Replace engine air filter
   Open hood and locate air filter housing on driver side of engine bay. Release air box clips (typically 4 clips). Carefully lift top of air box housing, disconnecting any attached hoses or sensors as needed. Remove old air filter element. Inspect housing for debris, leaves, or rodent activity and clean if necessary. Verify new filter orientation matches old filter. Install new air filter element ensuring proper seating. Reconnect any hoses or sensors. Close air box housing and secure all clips to specification.
7. 7

   Replace cabin air filter
   Locate cabin air filter access door behind glove box. Open glove box and remove contents. Squeeze sides of glove box inward to release stops and lower glove box fully. Locate cabin air filter cover (typically on right side of HVAC housing). Press release tabs and remove cover. Slide out old cabin air filter, noting airflow direction arrow. Inspect HVAC housing for debris. Install new cabin air filter with airflow arrow pointing toward rear of vehicle. Reinstall cover ensuring tabs lock properly. Return glove box to normal position.
8. 8

   Refill engine oil
   Remove engine oil fill cap on driver side valve cover. Using funnel, add 5.5 quarts of Motorcraft 5W-20 synthetic blend oil. Replace 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 with dipstick. Add remaining oil in small increments until level reaches full mark. Do not overfill.
9. 9

   Inspect and service brake system
   With wheels removed, inspect brake pads for remaining thickness (minimum 3mm). Inspect rotors for scoring, warping, or excessive wear. Check brake hoses for cracks, bulging, or fluid seepage. Inspect caliper pins for proper movement and lubrication. Check brake fluid level in master cylinder reservoir under hood. If level is low, top off with fresh Motorcraft DOT 4 LV brake fluid. Do not overfill. Inspect brake lines along frame rails for corrosion or damage.
   ⚠Use only DOT 4 LV brake fluid. Do not mix with DOT 3 or standard DOT 4 fluid. Keep brake fluid away from painted surfaces.
10. 10

    Inspect suspension and steering components
    Visually inspect all visible suspension components for damage, excessive wear, or leaking. Check ball joints for torn boots or excessive play. Inspect tie rod ends for loose boots or play. Check sway bar links and bushings for wear. Inspect shocks/struts for fluid leaks. Check CV axle boots for tears or grease leakage. Inspect power steering hoses and reservoir for leaks. Check power steering fluid level and top off with Motorcraft MERCON LV if needed.
11. 11

    Perform cooling system inspection
    With engine cool, inspect coolant level in overflow reservoir. Level should be between MIN and MAX marks. Inspect all visible coolant hoses for cracks, soft spots, or leaks. Check radiator for damage or leaks. Inspect water pump area for coolant seepage (located front of engine). Check radiator cap gasket condition. Inspect EcoBoost intercooler system for leaks or damage. Check intercooler coolant level in separate reservoir if equipped.
    ⚠️Never open radiator cap or coolant reservoir on hot engine. System is pressurized and can cause severe burns.
12. 12

    Inspect belts and turbocharger system
    Inspect serpentine belt for cracks, fraying, or glazing. Check belt tension and condition. Inspect belt tensioner for proper operation and no bearing noise. Visually inspect turbocharger inlet and outlet connections for loose clamps or damaged boots. Check intercooler piping connections for security. Inspect charge air cooler (CAC) for damage or debris. Look for any oil residue around turbo connections which may indicate seal issues.
13. 13

    Inspect exhaust and underbody
    Inspect entire exhaust system from manifolds to tailpipe for leaks, damage, or excessive corrosion. Check exhaust hangers for deterioration. Inspect catalytic converters for damage or heat discoloration. Check frame rails and crossmembers for rust or damage. Inspect fuel lines and tank for leaks or damage. Verify all underbody shields and covers are secure. Check driveshafts for proper U-joint condition and no excessive play.
14. 14

    Reinstall wheels and perform final checks
    Clean wheel mounting surfaces on hubs and wheels. Install wheels and hand-tighten lug nuts in star pattern. Lower vehicle until wheels just contact ground but vehicle weight is still on jack stands. Torque lug nuts to specification in star pattern using three passes (first pass 50%, second pass 75%, final pass 100%). Fully lower vehicle and remove jack stands. Perform final torque verification on all lug nuts in star pattern. Check all drain plugs and fill plugs for tightness and no leaks.
15. 15

    Reset maintenance reminder and test drive
    Turn ignition to ON position without starting. Navigate to Settings > Vehicle > Oil Life Reset on instrument cluster display. Confirm reset of oil life monitor to 100%. Start engine and verify no warning lights. Check for any fluid leaks under vehicle. Allow engine to reach operating temperature. Test drive vehicle for 10-15 minutes, operating in both 2WD and 4WD modes. Listen for any unusual noises from drivetrain. Verify smooth shifting and proper 4WD engagement. After test drive, recheck all fluid levels and inspect for leaks.

Reassembly

1. Verify all drain plugs and fill plugs are torqued to specification and not leaking
2. Confirm all air filter housings are properly secured with clips engaged
3. Verify oil fill cap is installed and tight
4. Double-check wheel lug nuts are torqued to specification in star pattern
5. Ensure all underbody shields and covers removed during service are reinstalled
6. Verify no tools or rags were left in engine bay or under vehicle

Verification

• Start engine and verify oil pressure warning light extinguishes within 2 seconds
• Check under vehicle immediately after start for any fluid leaks from drain plugs
• Verify oil level on dipstick shows FULL after engine has run and cooled
• Confirm no warning lights on instrument cluster after starting
• Test drive vehicle and verify smooth operation in 2WD, 4WD High, and 4WD Low
• After test drive, perform final leak inspection of all serviced components
• Verify oil life monitor shows 100% remaining
• Check tire pressures and adjust to door placard specification (typically 35 PSI front/rear)
• Document service date and mileage for maintenance records

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