Complete 60,000 mile scheduled maintenance service including engine oil change, fluid inspections and replacements, filter replacements, spark plug replacement, and comprehensive inspection of all major systems.

Warnings

Tools required

Parts

• Engine oil filter × 1 — Motorcraft FL-820-S or equivalent
• Engine air filter × 1 — Motorcraft FA-1927 or equivalent
• Cabin air filter × 1 — Motorcraft FP-67 or equivalent
• Spark plugs (Motorcraft SP-520 or equivalent) × 8 — Pre-gapped to 0.054 inches
• Oil drain plug crush washer × 1 — Use OEM specification
• Front differential drain plug gasket × 1 — Use OEM specification
• Front differential fill plug gasket × 1 — Use OEM specification
• Rear differential drain plug gasket × 1 — Use OEM specification
• Rear differential fill plug gasket × 1 — Use OEM specification
• Transfer case drain plug gasket × 1 — Use OEM specification
• Transfer case fill plug gasket × 1 — Use OEM specification

Fluids

• Motorcraft 5W-20 Synthetic Blend Engine Oil — 7.5 qt
• Motorcraft 75W-90 GL-5 Front Differential Gear Oil — 1.5 qt
• Motorcraft 75W-140 Synthetic Rear Differential Gear Oil — 2 qt
• Motorcraft Transfer Case Fluid — 2.5 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Place wheel chocks behind rear wheels
3. Allow engine and drivetrain to cool completely to ambient temperature (minimum 2 hours after last operation)
4. Gather all required fluids, filters, and gaskets before beginning
5. Verify spark plug gap specification is 0.054 inches (1.37mm) for this engine

Procedure

1. 1

   Raise and support vehicle
   Raise vehicle using floor jack at front crossmember. Position jack stands under frame rails at manufacturer-recommended lift points. Lower vehicle onto stands. Raise rear of vehicle and position jack stands under rear axle housing or frame rails. Ensure vehicle is stable before working underneath.
2. 2

   Remove wheels for access
   Remove all four wheels to provide better access to differential and transfer case drain plugs. Store lug nuts in a safe location.
3. 3

   Drain engine oil
   Position drain pan under engine oil pan. Remove oil drain plug using appropriate socket and allow oil to drain completely (approximately 10 minutes). Inspect drain plug threads for damage. Remove old crush washer and install new crush washer on drain plug. Reinstall drain plug and torque to specification.
4. 4

   Replace engine oil filter
   Reposition drain pan under oil filter (located on driver side of engine block). Use oil filter wrench to remove old filter. Clean oil filter mounting surface on engine block with clean rag. Apply thin film of new engine oil to rubber gasket of new filter. Hand-tighten new filter until gasket contacts mounting surface, then turn an additional 3/4 to 1 full turn. Do not use filter wrench for installation.
5. 5

   Drain and refill front differential
   Locate front differential (front axle center section). Clean area around drain and fill plugs. Position drain pan under differential drain plug. Remove fill plug first (top plug) to ensure it can be removed. Remove drain plug and allow fluid to drain completely. Inspect magnetic drain plug for excessive metal debris. Install new drain plug gasket and reinstall drain plug. Using fluid transfer pump, refill differential through fill hole with 75W-90 GL-5 gear oil until fluid begins to seep from fill hole. Install new fill plug gasket and reinstall fill plug.
6. 6

   Drain and refill rear differential
   Locate rear differential drain plug on bottom of differential housing. Clean area around drain and fill plugs. Remove fill plug first (side of housing). Remove drain plug and allow fluid to drain completely. Inspect magnetic drain plug for excessive metal debris (some fine material is normal). Install new drain plug gasket and reinstall drain plug. Using fluid transfer pump, refill with Motorcraft 75W-140 synthetic gear oil through fill hole until fluid begins to seep from fill hole. Install new fill plug gasket and reinstall fill plug.
7. 7

   Drain and refill transfer case
   Locate transfer case behind transmission on driver side. Clean area around drain and fill plugs. Remove fill plug first (upper plug on rear of case). Remove drain plug and allow fluid to drain completely. Install new drain plug gasket and reinstall drain plug. Using fluid transfer pump, fill transfer case through fill hole with Motorcraft transfer case fluid until fluid begins to seep from fill hole. Install new fill plug gasket and reinstall fill plug.
8. 8

   Reinstall wheels and lower vehicle
   Reinstall all four wheels. Hand-tighten lug nuts in star pattern. Raise vehicle slightly off jack stands, remove stands, and lower vehicle to ground. Torque all lug nuts to specification in star pattern.
9. 9

   Refill engine oil
   Remove engine oil fill cap on driver side valve cover. Using funnel, add 7 quarts of Motorcraft 5W-20 synthetic blend engine oil. Reinstall oil fill cap. Start engine and allow to idle for 30 seconds, then shut off. Wait 2 minutes for oil to drain into pan. Check oil level on dipstick and add remaining oil as needed to bring level to full mark (do not overfill).
10. 10

    Disconnect battery and replace spark plugs
    Disconnect negative battery terminal. Remove engine cover by pulling upward (uses rubber grommets). Locate all 8 ignition coil-on-plug assemblies (4 per valve cover). Disconnect electrical connector from each coil by pressing release tab. Remove coil mounting bolt from each coil and carefully extract coils from spark plug wells. Use spark plug socket to remove all 8 spark plugs. Verify new spark plugs are gapped to 0.054 inches. Apply small amount of dielectric grease to inside of spark plug boots. Install new spark plugs hand-tight, then torque to 13 lb-ft (18 Nm) using care not to cross-thread. Reinstall ignition coils and torque mounting bolts to specification. Reconnect coil electrical connectors. Reinstall engine cover.
11. 11

    Replace engine air filter
    Locate air filter housing on driver side of engine compartment. Release clamps on air box cover (may be clips or screws depending on configuration). Remove air box cover and extract old air filter element. Clean debris from inside air box using clean rag. Install new air filter element ensuring proper seating. Reinstall air box cover and secure clamps.
12. 12

    Replace cabin air filter
    Open passenger door. Locate cabin air filter access door behind glove box (may require removing or lowering glove box). Remove access cover. Slide out old cabin air filter noting airflow direction arrow. Install new cabin air filter with airflow arrow pointing in same direction as original. Reinstall access cover and glove box if removed.
13. 13

    Inspect and top off all fluid levels
    Reconnect negative battery terminal. Check and top off the following fluids as needed: brake fluid (do not overfill, use only DOT 4 LV), power steering fluid (check with engine off, use MERCON LV), coolant reservoir (check cold level, use Motorcraft orange coolant only), windshield washer fluid. Check automatic transmission fluid level with engine at operating temperature in Park on level ground (check procedure requires running through all gears).
14. 14

    Perform comprehensive inspection
    Inspect the following systems and components: all belts for cracks or glazing (serpentine belt and accessory belts), all hoses for cracks or leaks (coolant, vacuum, brake), brake pads and rotors for wear (minimum thickness 3mm for pads), suspension components for damage or excessive wear, exhaust system for leaks or damage, battery terminals for corrosion (clean if needed), all lights for proper operation, tire tread depth (minimum 2/32 inch, replace if needed), tire pressures and adjust to door placard specification (typically 35 PSI front and rear).

Reassembly

1. Ensure all fluid fill caps are properly secured and drain plugs are torqued correctly
2. Reset oil life monitoring system: turn ignition to ON (engine off), fully depress and release accelerator pedal three times within 5 seconds, system will confirm reset
3. Verify no fluid leaks from any service points after first test drive
4. Record service date and mileage in vehicle maintenance log

Verification

• Start engine and verify no warning lights on instrument cluster
• Check for leaks under vehicle after engine has run for 5 minutes at operating temperature
• Verify engine oil level is at full mark on dipstick with engine off
• Test drive vehicle and verify smooth operation, proper shifting, and normal 4WD engagement
• After test drive, recheck all fluid levels and inspect service areas for leaks
• Verify proper tire pressures after driving (check warm)
• Confirm oil life monitoring system has been reset to 100%

More procedures for this vehicle