Complete 90,000-mile maintenance service including engine oil change, air filter replacement, cabin filter replacement, differential service, brake fluid flush, coolant system service, spark plug replacement, and comprehensive fluid inspection.

Warnings

Tools required

Parts

• Engine oil filter × 1 — Motorcraft FL-910-S or equivalent
• Oil drain plug crush washer × 1 — Use OEM specification
• Engine air filter × 1 — Motorcraft FA-1927 or equivalent
• Cabin air filter × 1 — Motorcraft FP-67 or equivalent
• Spark plugs (6 required) × 6 — Motorcraft SP-546 or equivalent
• Rear differential fill plug gasket × 1 — Use OEM specification
• Rear differential drain plug gasket × 1 — Use OEM specification

Fluids

• Motorcraft 0W-20 Full Synthetic — 6 qt
• Motorcraft 75W-140 Synthetic Gear Oil — 2 qt
• Motorcraft DOT 4 LV Brake Fluid — 1 qt
• Motorcraft Orange Coolant — 1 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Allow engine to cool completely if recently operated (minimum 2 hours)
3. Gather all tools, parts, and fluids before beginning
4. Raise vehicle using appropriate lift points and support securely on jack stands
5. Remove all four wheels and set aside with lug nuts organized
6. Place oil drain pan beneath engine oil drain plug location
7. Open hood and ensure it is properly secured

Procedure

1. 1

   Drain engine oil
   Locate the oil drain plug on the oil pan at the rear of the engine. Clean area around drain plug. Using appropriate socket, loosen and remove the oil drain plug, allowing oil to drain completely into drain pan. This will take approximately 10-15 minutes for complete drainage. Inspect drain plug threads and oil pan threads for damage. Discard old crush washer.
2. 2

   Replace oil filter and drain plug
   While oil drains, locate the oil filter on the driver side of the engine block. Position drain pan beneath filter and remove old filter by turning counterclockwise. Allow filter to drain completely. Clean the filter mounting surface on the engine. Apply a thin film of fresh oil to the new filter gasket. Install new filter hand-tight, then turn an additional 3/4 turn. Install new crush washer on oil drain plug, then install and torque drain plug to specification.
3. 3

   Fill engine oil and verify
   Lower vehicle to ground. Remove engine oil fill cap located on passenger side valve cover. Using funnel, add 5.5 quarts of Motorcraft 0W-20 full synthetic oil. Install oil fill cap. Start engine and allow to run for 2 minutes, monitoring for leaks at drain plug and filter. Shut off engine, wait 5 minutes, then check oil level with dipstick. Add remaining oil as needed to bring level to full mark. Reset oil life monitor through instrument cluster menu.
4. 4

   Replace engine air filter
   Locate air filter housing on driver side of engine bay. Release air box clips securing the housing cover. Lift cover and remove old air filter element. Inspect housing for debris and clean if necessary. Install new air filter element ensuring proper orientation (airflow direction arrow pointing toward engine). Replace housing cover and secure all clips to specification.
   ℹ️Ensure air filter is properly seated to prevent unfiltered air from entering the engine.
5. 5

   Replace cabin air filter
   Open passenger door and locate cabin air filter access panel behind glove box. Remove glove box stops by squeezing sides inward and lowering glove box completely. Locate filter access door, press release tabs, and remove cover. Slide out old cabin filter noting airflow direction. Install new cabin filter with airflow arrow pointing in same direction as old filter (toward rear of vehicle). Reinstall access door and return glove box to normal position.
6. 6

   Drain rear differential
   Raise vehicle and support on jack stands. Locate rear differential at center of rear axle. Position drain pan beneath differential drain plug (lower plug). Clean area around drain plug. Remove drain plug and allow gear oil to drain completely (approximately 10 minutes). Inspect magnetic drain plug for excessive metal debris. Clean drain plug thoroughly. Remove fill plug (upper plug) to assist drainage and verify location.
   ⚠Gear oil has strong odor and can cause skin irritation. Use gloves and work in well-ventilated area.
7. 7

   Refill rear differential
   Install new gasket on drain plug and reinstall drain plug to mounting bolt torque specification. Using fluid transfer pump and appropriate hose, inject Motorcraft 75W-140 synthetic gear oil through fill hole until oil begins to seep out of fill hole (approximately 2 quarts). Install new gasket on fill plug and reinstall fill plug to mounting bolt torque specification. Wipe excess oil from differential housing.
8. 8

   Perform brake fluid flush
   Lower vehicle to ground. Locate brake fluid reservoir in engine bay on driver side near firewall. Using turkey baster or fluid extractor, remove as much old brake fluid as possible from reservoir. Refill with fresh Motorcraft DOT 4 LV brake fluid to MAX line. Beginning with right rear wheel, attach bleeder hose to bleeder valve. Have assistant pump brake pedal 5 times and hold. Open bleeder valve, allow fluid to drain until clear fluid appears, close valve before pedal reaches floor. Repeat process for left rear, right front, then left front wheels. Maintain reservoir level throughout process.
   ⚠️Do not allow brake fluid reservoir to run empty during bleeding process or air will enter system requiring complete bleeding restart.
   ⚠Brake fluid damages paint and finishes. Cover fender areas and wipe spills immediately.
9. 9

   Inspect and service cooling system
   Ensure engine is completely cool. Remove radiator cap slowly to release any residual pressure. Inspect coolant condition and level in overflow tank and radiator. Using refractometer or hydrometer, test coolant freeze protection (should be -34°F or better). If coolant appears contaminated or protection is inadequate, partial drain and refill is recommended. Remove radiator drain plug at bottom of radiator, drain 2-3 quarts into clean container, reinstall drain plug, and refill with 50/50 mix of Motorcraft Orange Coolant and distilled water. Bleed cooling system by running engine to operating temperature with heater on high, then top off coolant level.
   ⚠️Never remove radiator cap from hot engine. Pressurized coolant can cause severe burns.
10. 10

    Replace spark plugs
    Disconnect negative battery cable. The 3.5L EcoBoost has 6 spark plugs (3 per cylinder bank). Remove engine cover by lifting upward (secured by grommets). Locate ignition coils on top of each valve cover. Disconnect electrical connector from each coil. Remove coil mounting bolt and carefully pull coil straight up. Using compressed air, clean debris from spark plug wells. Using appropriate spark plug socket with extension, remove old spark plugs. Verify new spark plugs are gapped to specification (typically 0.035 inch for EcoBoost). Install new plugs hand-tight, then torque to specification if provided, or turn 1/16 turn beyond hand-tight if no torque spec. Reinstall ignition coils and electrical connectors. Reinstall engine cover.
    ⚠Do not over-torque spark plugs in aluminum cylinder heads. Excessive torque can strip threads requiring costly repairs.
    ℹ️Apply small amount of dielectric grease to inside of coil boots before reinstalling to prevent moisture intrusion.
11. 11

    Inspect all fluid levels
    Verify engine oil level is at full mark on dipstick. Check automatic transmission fluid level with engine running at operating temperature in Park (refer to dipstick or check plug procedure). Verify brake fluid is at MAX line in reservoir. Check power steering reservoir (this vehicle has electric power steering with no fluid). Verify windshield washer fluid level and top off if needed. Check coolant level in overflow tank (should be at FULL COLD line when engine is cold).
12. 12

    Reinstall wheels and perform final inspection
    Raise vehicle and remove jack stands. Reinstall all four wheels, starting lug nuts by hand to prevent cross-threading. Lower vehicle until wheels just touch ground (vehicle weight not fully on wheels). Torque lug nuts to specification in star pattern. Fully lower vehicle to ground. Reconnect negative battery cable if disconnected. Start engine and verify no warning lights remain illuminated. Check for any fluid leaks under vehicle. Test drive vehicle for 5-10 miles, verifying normal operation of all systems.

Reassembly

1. Ensure all drain plugs and fill plugs are properly torqued to specification
2. Verify all electrical connectors are fully seated and secured
3. Confirm engine cover and air filter housing are properly installed
4. Double-check that all fluid levels are correct and reservoirs are capped
5. Verify lug nuts are torqued in proper star pattern to prevent wheel warping

Verification

• Start engine and verify no warning lights remain illuminated on instrument cluster
• Check for leaks under vehicle after engine reaches operating temperature
• Verify brake pedal feels firm and responsive with no sponginess
• Confirm oil pressure gauge shows normal pressure after startup
• Test drive vehicle for 10 miles and verify smooth operation, normal operating temperature, and no unusual noises
• Re-check all fluid levels after test drive and top off if necessary
• Verify oil life monitor has been properly reset to 100%

More procedures for this vehicle