Assuming no outside factors like accidents or racing are involved, the life and death of a truck is based on maintenance. Good diesel truck maintenance is what keeps it on the road for several hundred thousand miles or more. Bad maintenance and it’ll feel like the truck never left the shop. Each truck and engine have their own common points that need a little more love than normal. We’ll touch on the necessary maintenance items, mainly in regards to fluids, for each diesel engine Ford used. Most will be obvious, oil changes, etc, but some will not be as well known. While we don't exactly consider 6.4's or 6.7's one of our main specialties, we included info for them as well. Here’s to keeping your Ford on the road for decades to come.

A few notes that impact fluid change intervals. If your vehicle experiences any of the below factors on a regular basis, you should be using the “extreme duty” schedule for oil changes.

• Excessive idling (defined as 10mins per hour of use or more)
• Biodiesel usage of 20% or more
• Frequent short trips where the engine does not reach operating temperature
• 1000 miles or more of offroad driving between oil changes
• Frequent hauling or towing of heavy loads

 

Engines and Fluid Information:

7.3L Power Stroke (1994.5-2003)

Oil Is Everything. Due to the HEUI injection system the 7.3L used, good fresh oil is extremely important. The HEUI system made the 7.3L oil system unlike any other light duty diesel (except the 6.0L) as the oil is used under extremely high pressures, no different than oil in a hydraulic system. Oil in a high pressure hydraulic system is designed to be sheared over and over by the high pressure pump. Normal engine oil is not designed for this abuse. So it is suggested to change the oil every 3000 miles like clockwork to keep its lubricating properties up to par. Adding extra filters helps, like bypass filters, but they do nothing for the shearing damage the oil sees from the HPOP.

Coolant Cavitation. The 7.3 is a coolant jacket engine. This means the cylinders are completely surrounded in coolant during normal operation. The pressure from the combustion event causes micro pulses or movements, in the walls of each cylinder. These small and fast movements cause cavitation of the coolant. Cavitation is a phenomenon that occurs due to a negative pressure, and it essentially makes little bubbles. We’re not going to go fully into what cavitation is here, but the issue with cavitation is that when these bubbles implode, they take tiny chunks of metal off the cylinder walls. Using the correct coolant, changing it regularly, and adding the recommended additives (SCA’s) to the coolant is important for a 7.3L.

Engine Oil:

Capacity: 15 quarts (with filter)

Type: 15W-40 (API CJ-4 or newer), 10W-30 can be used in colder climates

Frequency: 5000 miles standard duty / 3000 miles extreme duty

 

Coolant:

Capacity: 8.1 gallons (total system) – Varies slightly based on cooling system configuration

Type: Motorcraft VC-5 Premium Engine Coolant (Green)

Frequency: Every 30,000 miles or 36 months. Whichever comes first.

 

Automatic Transmission Fluid

Capacity:

4R100: 17 quarts (total system, dry fill), 7 quarts (drain and refill)

E4OD: 15.7 quarts (total system, dry fill), 7 quarts (drain and refill) – 4x4 uses half a quart more than 4x2

Type: Mercon V or Mercon 

Frequency: Every 30,000 miles

 

Manual Transmission Fluid (ZF5, ZF6):

Capacity:

ZF5: 3.4 quarts

ZF6: 5.8 quarts

Type: Mercon V or Mercon

Frequency: Every 60,000 miles

 

Power Steering Fluid:

Type: Mercon V

Frequency: Every 50,000 miles

 

Brake Fluid:

Type: DOT 3

Frequency: Every 60,000 miles or 3 years, whichever comes first

 

Axle Lubricant (Front and Rear) (check your axle tag for limited-slip requirements, which would need friction modifier):

Capacity:

Dana 50 TTB (Some OBS F250, front): 1.9 quarts

Dana 60 (All others, front): 2.9 quarts

Sterling 10.25 (1994-1997 rear): 3.75 quarts

Sterling 10.50 (1999-2003 rear): 3.45 quarts

Dana 80 (Some F450 and 350, rear): 4.15 quarts

Dana 135 (F550 rear): 12.25 quarts

Type:

Dana 50 TTB (Some OBS F250, front): 80W-90

Dana 60 (All others, front): 80W-90

Sterling 10.25 (1994-1997 rear): 75W-140

Sterling 10.50 (1999-2003 rear): 75W-140

Dana 80 (Some F450 and 350, rear): 75W-90

Dana 135 (F550 rear): 80W-90

Frequency: Every 100,000 miles standard service / 30,000 miles extreme duty

 

Transfer Case (4x4):

Capacity: 2 quarts

Type: Mercon ATF

Frequency: Every 60,000 miles

 

Fuel Filter:

Type: OE Motorcraft filter

Frequency: Every 15,000 miles, or as needed.

 

 

 

 

6.0L Power Stroke (2003-2007)

Coolant and Oil: The 6.0L, regarding oil and coolant maintenance, is similar to the 7.3L. The oil takes more abuse than with non-HEUI engines, so changing the oil frequently is very important, we recommend changes at 3,000 miles no matter the usage. We heavily recommend using a Motorcraft oil filter on the 6.0. Many aftermarket oil filter manufacturers didn’t build their oil filters large enough to depress the filter drain back valve in the base of the filter housing. If this valve is not depressed, the filter will be bypassed, meaning it won’t filter the oil.

And like the 7.3, it’s also a coolant jacket engine, so coolant changes are important. On top of the cavitation issues like the 7.3 has, the 6.0’s infamous oil cooler needs to be addressed. The oil cooler utilizes what is called a “stack plate heat exchanger” and has very small passageways for coolant and oil. When they clog, issues start. The issues run down stream of the oil cooler. Sure the oil coolers themselves fail on their own, but generally speaking, before that happens, the EGR, injectors, and turbo will have problems related to insufficient oil flow and cooling. Lifter failure is also common in the 6.0L and for the same reasons. All these issues can be avoided by keeping your oil and coolant fresh and clean. A coolant filter is also a good thing to add to 6.0’s.

 

Engine Oil:

Capacity: 15 quarts (with filter)

Type: 15W-40 (API CJ-4 or newer), 10W-30 can be used in colder climates

Frequency: 5000 miles standard duty / 3000 miles extreme duty

 

Coolant:

Capacity: 28 quarts (total system)

Type: Motorcraft Premium Gold Engine Coolant (Yellow) - Retrofit to Motorcraft VC-3 (Orange) Extended Life Coolant is highly recommended

Frequency: Every 30,000 miles or 36 months. Whichever comes first.

 

Automatic Transmission Fluid (5R110W TorqShift):

Capacity: 19 quarts (total system, dry fill), 7.4 quarts (drain and refill)

Type: Motorcraft MERCON SP (Later replaced by MERCON LV; check your manual)

Frequency: Every 45,000 miles

 

Power Steering Fluid:

Type: Motorcraft MERCON V

Frequency: Every 50,000 miles

 

Brake Fluid:

Type: DOT 3

Frequency: Every 60,000 miles or every 3 years, whichever comes first

 

Axle Lubricant (Front and Rear) (check your axle tag for limited-slip requirements, which would need friction modifier):

Capacity:

Dana 60 (super or standard) front: 2.9 quarts

Sterling 10.5 rear: 3.45 quarts

Dana 80 rear (some F350, all F450 and 550): 4.15 quarts

Type:

Dana 60 (super or standard) front: 80W-90

Sterling 10.5 rear: 75W-140

Dana 80 rear (some F350, all F450 and 550): 75W-90

Frequency: Every 100,000 miles standard service / 30,000 miles extreme duty

 

Transfer Case (4x4):

Capacity: 2 quarts

Type: Mercon SP

Frequency: Every 60,000 miles

 

Fuel Filter:

Type: OE Motorcraft

Frequency:  Every 10,000-15,000 miles, or as needed.

 

 

 

 

6.4L Power Stroke (2008-2010)

Oil: The 6.4L Powerstroke marked the first time Ford used a common rail injection system in their diesels. So, the oil doesn’t take as much abuse as a 6.0 or 7.3, but changing it regularly is almost as important. Turbocharger related failures often point to poor oil maintenance as the cause. Lifter failures are also common and almost always are due to poor oil maintenance, or high temperatures. Adding more emissions equipment to the 6.4 also contributes to dirtier oil. Keep up on your oil change intervals to avoid premature failure of these systems.

Fuel Filters: Clean fuel is much more important to a common rail system than it is to a HEUI system. Change your filters regularly and make sure you’re running good fuel from a reputable source. Also, additives are important to the fuel systems longevity because they add lubrication and help keep the system free from harmful deposits. We like Opti-Lube.

Cooling system: Cavitation is a common problem in regards to the water pump. Cavitation takes place on the front cover where the water pump impeller lives. It slowly eats away at the cover eventually requiring a new front cover be installed. Which is a huge job. Keep up on your coolant change intervals and we recommend using Ford’s specific additive as well (Motorcraft VC8).

 

Engine Oil:

Capacity: 15 quarts (with filter)

Type: 15W-40 (API CJ-4 or newer), 5W-40 can be used in colder climates

Frequency: 5000 miles standard duty / 3000 miles extreme duty

 

Coolant:

Capacity: 28 quarts (total system)

Type: Motorcraft VC-3 (Orange) Extended Life Coolant

Frequency: Every 45,000 miles or 36 months. Whichever comes first.

 

Automatic Transmission Fluid (5R110W TorqShift):

Capacity: 19 quarts (total system, dry fill), 7.4 quarts (drain and refill)

Type: Motorcraft Mercon LV

Frequency: Every 30,000 miles

 

Power Steering Fluid:

Type: Motorcraft MERCON V

Frequency: Every 40,000 miles

 

Brake Fluid:

Type: DOT 3

Frequency: Every 50,000 miles or 3 years, whichever comes first

 

Axle Lubricant (Front and Rear) (check your axle tag for limited-slip requirements, which would need friction modifier):

Capacity:

Dana Super 60 (F250 and F350, front): 2.9 quarts

Dana S110 (F450 and 550, front): 7 quarts

Sterling 10.5 (F250 and some F350, rear): 3.45 quarts

Dana 80 (F350 HD Tow Package, rear):  4.15 quarts

Dana M300 (F450 and 550, rear): 4.25 quarts

Type:

Dana Super 60 (F250 and F350, front): 80W-90

Dana S110 (F450 and 550, front): 75W-140

Sterling 10.5 (F250 and some F350, rear): 75W-140

Dana 80 (F350 HD Tow Package, rear): 75W-90

Dana M300 (F450 and 550, rear): 75W-140

Frequency: Every 100,000 miles standard service / 30,000 miles extreme duty

 

Transfer Case (4x4):

Capacity: 2 quarts

Type: Mercon SP

Frequency: Every 60,000 miles

 

Fuel Filter:

Type: 2x OE Motorcraft filter

Frequency: Every 10,000 miles or as needed.

 

 

 

 

6.7L Power Stroke (2011-Present)

Oil Type: Sticking to the correct oil type is pretty important for all engines, but even more so for later model year engines. Just throwing any 10W-30 in there like we’re used to with earlier engines is not going to cut it with today’s engines. The tolerances are just too tight. Lifter failures and bearing failures are common, and the cause almost always points to improper oil or poor oil maintenance.

Fuel System: Like the 6.4, the 6.7 is a common rail engine. Good clean fuel is extremely important and even more so for the 6.7 as it uses a CP4 high pressure fuel pump. The CP4 is a very common fail item and when it does fail, it takes the entire fuel system out with it. Repairs are commonly well over $10,000. Running an additive is important here. Additives help clean the system as well as add much needed lubricity to the fuel. Keep your fuel filters clean (there's two of them on these trucks), don’t run the tank lower than a quarter full, run an additive and get your fuel from a trustworthy source. Running with a low tank of diesel will increase fuel temperatures (which reduces lubrication to the system and increases harmful deposit formation) and increases the possibility of the pump sucking in contaminants that collect at the bottom of the tank.

CCV Filters: Crank Case Vapors (CCV) are fairly high on the 6.7L, and that’s completely normal. The 6.7L uses a CCV filtration system which helps pull oil from the crank case air/vapor. These filters clog fairly quickly and when they do, they cause elevated crank case pressures which wreak havoc on seals. Ford recommends changing your CCV filter every 60,000 miles, we recommend splitting that in half and changing it every 30-40,000 miles, or better yet, rerouting it into a catch can. The most common oil leak on a 6.7L is the upper pan, and it’s most commonly caused by clogged CCV systems. That leak requires pulling the engine to fix, so keeping your CCV filters clean is very important.

 

Engine Oil:

Capacity: 13 quarts (with filter)

Type: Check your manual, as the viscosity requirement changed over the years. All must meet API CK-4 or FA-4, Ford Specification WSS-M2C171-F1 or WSS-M2C171-F2.

15W-40 was generally used pre 2017

10W-30 was generally used post 2017

5W-40 synthetic can be used in colder climates 

Frequency: Per Ford, 10,000 miles for 2011-2022 / 15,000 miles for 2023+ (however we recommend splitting those intervals in half, changing closer to 5,000/7,500)

 

Coolant:

Capacity: 30 quarts (total system)

Type: Motorcraft VC-3DIL-B (Orange) or Motorcraft VC-13DL-G (Yellow) - Check your manual for the correct coolant. Newer models use the Yellow coolant

 

Automatic Transmission Fluid (6R140 TorqShift):

Capacity: 17.9 quarts (total system, dry fill), 7.5 quarts (drain and refill)

Type: Motorcraft Mercon ULV (Ultra Low Viscosity)

 

Power Steering Fluid:

Type: Motorcraft Mercon LV

Frequency: Every 50,000 miles 

 

Brake Fluid:

Type: DOT 4

Frequency: Every 50,000 miles or 3 years, whichever comes first

 

Axle Lubricant (Front and Rear)(Check your axle tag for limited-slip requirements, which would need friction modifier):

Type: 

Dana Super 60 (F250 and F350, front): 2.9 quarts

Dana S110 (F450 and F550, front): 7 quarts

Sterling 10.5 (F250 and some F350, rear): 3.45 quarts

Dana 80 (F350 HD Tow Package, rear): 4.15 quarts

Dana M300 (F450 and F550, rear): 4.25 quarts

Capacity:

Dana Super 60 (F250 and F350, front): 80W-90

Dana S110 (F450 and 550, front): 75W-140

Sterling 10.5 (F250 and some F350, rear): 75W-140

Dana 80 (F350 HD Tow Package, rear): 75W-90

Dana M300 (F450 and 550, rear): 75W-140

Frequency: Every 100,000 miles standard service / 30,000 miles extreme duty

 

Transfer Case (4x4):

Capacity: 2 quarts

Type: Mercon LV 

Frequency: Every 60,000 miles

 

Fuel Filter:

Type: 2x OE Motorcraft filters

Frequency: Every 10,000 miles or as needed.

 

 

***Disclaimer: The information provided on this blog is for informational purposes only. We share our knowledge and experience, but we are not liable for any damages, injuries, or losses that may occur as a result of using this information. Situations are rarely cut and dry in the automotive world. Your situation will likely be somewhat different than what we describe here.  Use your best judgment and always consult a qualified professional for automotive repairs and modifications. Your safety is your responsibility.