Check Fluid Level and Condition
NOTE: MERCON Automatic Transmission Fluid is being replaced by MERCON V as a service fluid.
Check Fluid Level and Condition Fluid Level Check
NOTE: If the vehicle has been operating for an extended period at high speeds in city traffic during hot weather or pulling a trailer, the vehicle should be turned off for about 30 minutes to allow the oil to cool before checking.
Under normal circumstances, check the transmission fluid level during normal maintenance and change the fluid at 48,000 km (30,000 miles), since the vehicle does not use up transmission fluid. If the transmission is not working properly, or if there is some sign of fluid leakage, the fluid level should be checked.
It is preferable to check the transmission fluid level at normal operating temperature after approximately 32 km (20 miles) of driving. The fluid level can be checked without driving the vehicle if the outside temperature is above 10°C(50°F).
With the vehicle on a level surface, start the engine and move the transmission range selector lever through all of the gear ranges, allowing sufficient time for each position to engage. Securely engage the transmission range selector lever in the Park position, fully set the parking brake control (2780) and leave the engine running.
Wipe off the fluid level indicator cap, pull the fluid level indicator (7A020) out and wipe the indicator end clean. Insert the fluid level indicator back into the oil filler tube (7A228) and make sure it is fully seated. Pull the fluid level indicator out and read the fluid level.
CAUTION: The vehicle should not be driven if the fluid level is below the bottom hole on the fluid level indicator and outside temperature is above 1O°C (5O°F).
When checking fluid at normal operating temperature, the fluid level should be within the crosshatched area on the fluid level indicator. When the vehicle has not been driven, and outside temperature is above 10°C (50°F), the fluid level should be between the holes in the fluid level indicator.
High or Low Fluid Level
CAUTION: If the fluid level is high, damage to the vehicle may occur. Excess fluid must be removed.
A fluid level that is too high may cause the fluid to become aerated due to the churning action of the rotating parts of the transmission. Aerated fluid will cause erratic line pressure, which may result in harsh/soft shifts or engagements, damage to the clutch materials, improper torque converter operation, and fluid coming out of the vent.
A fluid level that is too low will affect transmission operation, causing slipping, slow engagements, or damage to internal hardware. Low levels may also indicate that a leak is present in the fluid system. If the fluid level is low, add fluid using the procedures shown in Adding Fluid in this section.
Adding Fluid
CAUTION: Use of any fluid other than specified could result in transmission malfunction or failure.
Before adding any fluid, be sure that the correct type is used. MERCON is stamped on the container.
Add fluid in 0.25L (1/2 pint) increments through the filler tube to bring the level to the correct area on the dipstick. If an overfill occurs, excess fluid must be removed.
Fluid Change - Drain/Refill
Normal maintenance and lubrication necessitate periodic automatic transmission fluid changes at 48,000km (30,000 miles) or 33,800 km (21,000 miles) for severe duty applications.
To remove excess fluid, disconnect the cooler feed line at the cooler. Attach a rubber hose to the line and insert the other end into a drain pan. Crank the engine for a short period of time (do not allow the engine to start) to remove a quantity of transmission fluid. Reattach the cooler line to the cooler. Start the engine. Move the transmission range selector lever through all gear ranges. Recheck the fluid for the proper level. Continue to add or subtract fluid until the proper level is reached. If a major service (e.g., clutch, band, bearing, etc.) is required, the unit will have to be removed. At this time, the torque converter (7902), transmission cooler, and cooler lines must be flushed to remove any contaminates.
When used under severe duty conditions the transmission fluid filter/screen assembly should be replaced. The transmission fluid should be drained from the transmission and torque converter and refilled with MERCON or MERCON V Automatic Transmission Fluid or equivalent FORD approved fluid as specified to the proper level every 33,800 km (21,000 miles).
When filling a dry transmission and torque converter, refer to Specifications for capacity. Check the fluid level as outlined.
Procedures for Drain and Refill
Normal Maintenance
- Change fluid at 48,000 km (30,000 miles) intervals.
Severe Duty Maintenance
- Change fluid at 33,800 km (21,000 miles) intervals.
CAUTION: Use only MERCON or MERCON V transmission fluid. Use of any other fluids may result in a transmission malfunction or failure.
Maintenance Procedure
1. Loosen, then remove, the transmission fluid pan attaching screws to drain the fluid.
2. Remove and discard old pan gasket.
3. Thoroughly clean the pan and the transmission case pan rail surface.
4. Install new pan gasket onto pan and install pan to case with screws. Tighten screws to 11-13 Nm (8-10 lb. ft.).
5. Add 2.8 liters (3 quarts) of MERCON or MERCON V Automatic Transmission Fluid or equivalent FORD approved fluid to transmission through the fill tube.
6. Start the engine. Move transmission range selector lever through all gear ranges, checking for engagements.
7. Check and adjust transmission fluid in 0.25 liter (1 12 pint) increments to proper level (cross-hatched area of fluid level indicator at normal operating temperature).
Major Service/Overhaul
1. Loosen, then remove, the transmission fluid pan attaching bolts to drain fluid.
2. Remove and discard old pan gasket.
3. Perform required internal repair and cleaning.
4. Thoroughly flush torque converter, cooler lines and transmission in-tank radiator cooler and auxiliary cooler (if equipped).
5. Replace fluid filter and seal assembly.
6. Install cleaned pan and new pan gasket with screws. Tighten screws to 11-13 Nm (8-10 lb. ft.).
7. Add 3.7 liters (4 quarts) of MERCON or MERCON V Automatic Transmission Fluid or equivalent FORD approved fluid to the transmission through the fill tube.
8. Start engine. Move the transmission range selector lever through all gear ranges, checking for engagements.
9. Check and adjust the transmission fluid level in 0.25 liter (1/2 pint) increments to the proper level (cross-hatched area of the fluid level indicator at normal operating temperature).
Fluid Condition Check
1. Check the fluid level. Refer to the Fluid Level Check for proper procedure.
2. Observe color and odor of the fluid. It should be red, not brown or black. Odor may indicate an overheating condition, clutch disc or band failure.
3. Use an absorbent white facial tissue and wipe the fluid level indicator. Examine the stain for evidence of solid particles and for engine coolant signs (gum or varnish on fluid level indicator).
If particles are present in the fluid or there is evidence of engine coolant or water, the transmission fluid pan (7A194) must be removed for further inspection.
If fluid contamination or transmission failure is confirmed by further evidence of coolant or excessive particles in the transmission fluid pan, the transmission must be disassembled and completely cleaned and serviced. This includes cleaning and flushing the torque converter and transmission cooling system.
During disassembly and assembly, all overhaul checks and adjustments of clearances and end play must be made.
After the transmission has been serviced, all diagnostic tests and adjustments listed in the Diagnosis by Symptom charts must be completed to make sure that the problem has been corrected.