Comprehensive 90,000-mile maintenance service including engine oil change, transmission fluid exchange, differential service, spark plug replacement, air and cabin filter replacement, brake fluid flush, coolant flush, and full multi-point inspection.

Warnings

Tools required

Parts

• Engine oil filter × 1 — Motorcraft FL-500-S or equivalent
• Oil drain plug crush washer × 1 — Use OEM specification
• Spark plugs (6 required) × 6 — Motorcraft SP-546 or equivalent iridium
• Engine air filter × 1 — Motorcraft FA-1927 or equivalent
• Cabin air filter × 1 — Motorcraft FP-79 or equivalent
• Rear differential fill plug gasket × 1 — Use OEM specification

Fluids

• Motorcraft 0W-20 Full Synthetic engine oil — 6 qt
• Motorcraft MERCON LV ATF — 13 qt
• Motorcraft 75W-140 Synthetic Gear Oil — 2 qt
• Motorcraft DOT 4 LV Brake Fluid — 1 qt
• Motorcraft Orange Coolant (premixed) — 13 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Allow engine to cool completely (minimum 2 hours) before beginning spark plug service
3. Gather all fluids, filters, and parts before starting
4. Raise vehicle using floor jack at designated lift points and secure with jack stands at all four corners
5. Remove all four wheels and store safely
6. Remove engine under-shield or splash guards to access oil pan and transmission
7. Locate and photograph routing of any components to be removed for access

Procedure

1. 1

   Engine oil and filter service
   Place drain pan under oil pan. Remove oil drain plug and allow oil to drain completely (approximately 10 minutes). Remove oil filter using filter wrench and verify old gasket came off with filter. Install new crush washer on drain plug, reinstall and torque to specification. Apply thin film of clean oil to new filter gasket, install filter hand-tight plus 3/4 turn. Fill engine with 6 quarts of Motorcraft 0W-20 synthetic oil through filler cap.
2. 2

   Automatic transmission fluid exchange
   Locate transmission fluid pan. If using exchange machine, connect lines per machine instructions and perform fluid exchange per manufacturer procedure. If performing drain/refill method: remove transmission pan bolts in crisscross pattern, allow fluid to drain, replace pan gasket if equipped, reinstall pan. Add approximately 13 quarts Motorcraft MERCON LV through dipstick tube or fill port. Start engine, cycle through all gears, recheck level at operating temperature with engine running in Park.
   ⚠Transmission fluid must be checked at proper operating temperature (160-180°F). Cold fluid level checks will be inaccurate.
3. 3

   Rear differential service
   Locate rear differential on rear axle assembly. Place drain pan underneath. Remove fill plug first to ensure it's not seized (if seized, do not drain). Remove drain plug and allow gear oil to drain completely. Inspect magnetic drain plug for excessive metal particles (light coating is normal). Clean and reinstall drain plug with new gasket. Using fluid pump, fill differential with Motorcraft 75W-140 synthetic gear oil through fill hole until fluid reaches bottom of fill hole and begins to drip out. Install fill plug with new gasket.
   ℹ️Always remove fill plug before drain plug. If fill plug is seized and cannot be removed, you cannot refill the differential.
4. 4

   Spark plug replacement
   Remove engine cover by pulling upward on retaining clips. Disconnect ignition coil electrical connectors on all six cylinders. Remove coil mounting bolts and pull coils straight up from spark plug wells. Inspect spark plug wells for oil or coolant (indicates potential gasket issues). Using spark plug socket and extension, remove all six spark plugs. Verify new plugs are pre-gapped to 0.030-0.032 inches (verify specification in service manual). Install new spark plugs hand-tight, then torque to specification. Reinstall ignition coils and connect electrical connectors. Reinstall engine cover.
   ⚠EcoBoost engines have aluminum heads. Cross-threading or over-torquing spark plugs will cause expensive thread damage. Start plugs by hand and torque carefully.
5. 5

   Engine air filter replacement
   Open hood and locate air filter housing on passenger side of engine bay. Release air box clips and remove air box cover. Remove old air filter and inspect housing for debris, leaves, or rodent nests. Clean housing if needed. Install new air filter ensuring proper orientation and seal. Reinstall air box cover and secure clips.
6. 6

   Cabin air filter replacement
   Locate cabin air filter housing behind glove box. Open glove box and remove limiting stops on sides to allow box to drop down fully. Remove cabin air filter access door (typically push-tab release). Slide out old cabin air filter noting airflow direction arrow. Install new filter with airflow arrow pointing toward rear of vehicle. Reinstall access door and glove box.
7. 7

   Brake fluid flush
   Locate brake fluid reservoir under hood. Verify fluid level is at MAX line. Attach bleeder kit or vacuum pump to right rear brake caliper bleeder screw. Open bleeder screw and draw out old fluid until fresh fluid (lighter color) appears. Close bleeder screw and torque. Repeat process for left rear, right front, then left front (furthest to closest order). Continuously monitor reservoir level and refill with fresh Motorcraft DOT 4 LV brake fluid to prevent air entry. When complete, pump brake pedal to verify firm pedal and refill reservoir to MAX line.
   ⚠️Never allow brake fluid reservoir to run empty during bleeding or air will enter the system requiring extensive bleeding or ABS module service.
   ⚠DOT 4 brake fluid absorbs moisture and deteriorates paint. Wear gloves and immediately clean any spills.
8. 8

   Coolant system flush and refill
   With engine cold, locate radiator drain cock at bottom of radiator or remove lower radiator hose. Place large drain pan underneath and open drain to remove old coolant. Once drained, close drain cock. Fill cooling system with distilled water, run engine to operating temperature, allow to cool, and drain again (optional flush step for heavily contaminated systems). Fill system using coolant refill funnel or airlock tool with Motorcraft Orange premixed coolant. Fill until coolant is visible in funnel. Start engine and allow to reach operating temperature with funnel attached. As air bleeds from system, add additional coolant to maintain level. When no more air bubbles appear and level stabilizes, remove funnel and install radiator cap. Verify coolant level in overflow reservoir is at COLD FULL line.
   ⚠️Never open cooling system when hot. Pressurized coolant can cause severe burns. Allow engine to cool completely.
   ⚠EcoBoost engines are prone to airlock. Use proper filling procedure with airlock tool or extended funnel to ensure complete air purge.
9. 9

   Multi-point inspection
   Inspect all four brake pads and rotors for remaining thickness and condition. Check all tire tread depths and tire condition. Inspect all CV boots, ball joints, and tie rod ends for tears or excessive play. Check all fluid levels (engine oil, transmission, coolant, brake, windshield washer). Inspect serpentine belt for cracks, glazing, or fraying. Check battery terminals for corrosion and verify secure connections. Inspect exhaust system for leaks or damage. Test all exterior lights. Document findings and recommend any additional services needed.
10. 10

    Reinstall wheels and final checks
    Reinstall all four wheels, starting lug nuts by hand to avoid cross-threading. Lower vehicle partially so wheels contact ground but suspension is not loaded. Torque all lug nuts in star pattern to specification. Lower vehicle completely and remove jack stands. Start engine and verify no warning lights. Check for any fluid leaks under vehicle. Test drive vehicle to verify proper operation, smooth acceleration, and normal brake pedal feel. Recheck all fluid levels after test drive.
    ℹ️Always torque lug nuts in star pattern to ensure even wheel seating and prevent rotor warping.

Reassembly

1. Reinstall all removed shields, covers, and trim panels
2. Verify all electrical connectors are fully seated and locked
3. Double-check that all drain plugs and fill plugs are installed and torqued
4. Clean any spilled fluids from engine bay and undercarriage
5. Reset oil life monitoring system through vehicle information display or scan tool

Verification

• Start engine and verify smooth idle with no warning lights
• Check all previously serviced areas for leaks (oil, transmission, differential, coolant, brake fluid)
• Verify brake pedal is firm and at proper height
• Test drive vehicle for 10-15 minutes, reaching operating temperature
• After test drive, recheck all fluid levels and inspect for leaks
• Verify engine cooling fans cycle on at proper temperature
• Check transmission shifts smoothly through all gears
• Scan for diagnostic trouble codes using scan tool to verify no issues
• Document all service performed and reset maintenance reminders

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