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1997-2003 Ford/Lincoln Full Size Truck and SUV Routine Maintenance Reference Guide

(Covers 1997-03 Ford F-150 pickup, 2004 F-150 Heritage, 1997-99 F-150 based Ford F-250 pickup, and 1997-03 Ford Expedition/Lincoln Navigator SUVs,  Two- and four-wheel drive, with gas engines. Excludes F-250 and F-350 Super Duty Trucks, SVT Lightning and other supercharged models)

Ford F150 26666 front cover FullModern Ford F-150 trucks do not need as much maintenance as the vehicles of 25 years ago, but they still need periodic checks and inspections. You no longer have to tune and adjust the engine every six months or change the oil every three months/3,000 miles, but to protect your investment and ensure years of service, regular fluid changes and tire rotations are essential. Catching a problem before it happens, through regular inspections, will save you hundreds of dollars and countless time.

This quick reference guide answers many questions that occur during routine maintenance tasks. With this chart and a set of common tools, you can perform the majority of regular service yourself at home. This page covers the 10th generation Ford F-150 pickup truck, 2004 F-150 Heritage, the F-150 based 1997-1999 Ford F-250 (non-Super Duty), and Ford Expedition and Lincoln Navigator. For more information and step by step instruction, refer to the relevant section of Chilton manual 26666.

Engine Oil Change

Engine Oil Type 5W-30 (1997-99)
5W-20 (2000-newer)
Engine Oil Capacity 6.0 quarts (1997-2004)
7.0 quarts (2005-newer SUVs)
Oil Drain Plug Torque 96-144 in-lbs(1997-2006)

Transmission Fluid Change

Transmission Fluid Type Mercon ATF(E4OD, 4R100, manual)
Mercon V ATF (4R70W, 4R70E, 4R75E)
Mercon SP STF (6HP26, 6R75)
Mercon LV ATF (6R80)
Transmission Fluid Capacity 6-7.5 quarts (E4OD, 4R100)
(when changing filter) 4.5-5 quarts (4R70W, 4R70E, 4R75E)
5 quarts (6HP26)
about 7 quarts (6R75, 6R80)
3.75 quarts (manual)
Transmission Fluid Capacity 15.9/16.4 quarts (E4OD 2WD/4WD)
(total including converter) 13.9 quarts (4R70W, 4R70E, 4R75E)
17.1/17.7 quarts (4R100 F150 2WD/4WD)
15.9/16.4 quarts (4R100 Expedition/Navigator 2WD/4WD)
9.5 quarts (6HP26)
11 quarts (6R75)
13.0 quarts (6R80)
Transmission Drain Plug Torque 18 ft-lbs (4R100)
71 in-lbs (6HP26)
30-43 ft-lbs (manual)
Transmission Check/Fill Plug Torque 26 ft-lbs (E4OD, 4R70W, 4R100)
Transmission Pan Bolts Torque 108-132 in-lbs
Torque Converter Drain Plug Torque 22 ft-lbs (E4OD, 4R70W)
19 ft-lbs (4R100)

Transfer Case Fluid Change

Transfer Case Fluid Type Mercon ATF (1997-2006)
Transfer Case Capacity 2.0 pints (1997-2006)
Transfer Case Drain Plug Torque 80-203 in-lbs (1997-2002)
132 in-lbs (2003-up)

Differential Oil Change

Differential Oil Type 75W-90 GL-5 gear oil (front – all with 4WD)
75W-140 GL-5 synthetic gear oil (rear)
* plus 4 oz Ford XL-3 friction modifier (8.8″ and 9.75″ axles)
* plus 8 oz Ford XL-3 friction modifier (10.25″ axle)
Differential Oil Capacity 3.6 pints (front)
5.5-6.9 pints (F-150)
7.8 pints (F-250)
5.7 pints (1997-2003 Expedition/Navigator)
4.5 pints (2004-up Expedition/Navigator)
Differential Drain Plug Torque 15-22 ft-lbs (front)
15-30 ft-lbs (rear)
Differential Cover Bolts Torque 20-27 ft-lbs (front)
28-38 ft-lbs (1997-2002 rear)
24 ft-lbs (2003-up rear)

Cooling System Flush and Fill

Coolant Type Motorcraft Premium (green) or Premium Gold (yellow) coolant
mixed 50/50 with water (match color already installed)
Cooling System Capacity 15.7-20.1 quarts (V6 F-150)
17.9-23.9 quarts (1997-2003 V8)
18.0-20.8 quarts (2004-2006 V8)

Other Miscellaneous Fluid Types

Power Steering Fluid Mercon auto transmission fluid (1997-2005)
Mercon V auto transmission fluid (2006-later)
Brake Fluid DOT 3 brake fluid
Clutch Fluid DOT 3 brake fluid

Other Miscellaneous Torque Specs

Wheel Lug Nuts 100 ft-lbs (12mm wheel studs)
150 ft-lbs (14mm wheel studs)
Brake Caliper Bolts 21-26 ft-lbs (1997-2002 All front)
(front) 21-26 ft-lbs (2003 F-150 and F-250 front)
41 ft-lbs (2003-2006 Expedition/Navigator front)
(rear) 20 ft-lbs (1997-2002 All rear)
20 ft-lbs (2003 F-150 and F-250 rear)
26 ft-lbs (2003-2006 Expedition/Navigator rear)
Caliper Bracket Bolts 136 ft-lbs (1997-2002 All front)
(front) 136 ft-lbs (2003 F-150 and F-250 front)
148 ft-lbs (2003-2006 Expedition/Navigator front)
(rear) 80 ft-lbs (1997-2003 F-150 and F-250 rear)
70 ft-lbs (1997 Expedition/Navigator rear)
40 ft-lbs (1998-2002 Expedition/Navigator rear)
140 ft-lbs (2003-2006 Expedition/Navigator rear)

MAINTENANCE SCHEDULE

Ford F150 stepsideWhat follows is our recommended minimum maintenance intervals for daily driven Ford F-150 trucks and Expedition SUVs, based on our years of experience and the factory schedule. We encourage you to use our schedule and perform the maintenance yourself, to save money and needless trips to the dealer. In many cases, our intervals are shorter than the factory’s recommendations, but frequent maintenance will improve the service life of your vehicle, as well as enhance the efficiency, and improve the resale value. If your vehicle is frequently driven in dusty areas, driven at low speeds for extended periods, allowed to idle at length, used to tow a trailer, or used often for short trips (less than four miles at a time) in below freezing temperatures, even smaller intervals are recommended.

When you purchase the vehicle, follow this maintenance schedule and keep a written record and receipts to protect the warranty and resale value. If you buy the vehicle new, an initial maintenance check is often included at no cost (check with the service department for more information).

Every 250 miles or weekly

  • Check the engine oil level
  • Check the coolant level
  • Check the windshield washer fluid level
  • Check the brake and clutch fluid levels
  • Check the tires and tire pressures

Every 3,000 miles or 3 months
…all items listed above, as well as

  • Change engine oil and filter
  • Check the power steering fluid level
  • Check the automatic transmission fluid level
  • Lubricate the chassis

Every 6,000 miles or 6 months
…all items listed above, as well as

  • Rotate the tires
  • Inspect/replace the windshield wiper blades
  • Inspect exhaust system
  • Check and service the battery
  • Check the seat belts

Every 15,000 miles or 12 months
…all items listed above, as well as

  • Replace fuel filter
  • Replace air filter*
  • Inspect all underhood hoses
  • Inspect engine accessory drive belt
  • Inspect cooling system
  • Inspect steering and suspension
  • Inspect the brakes
  • Check fuel system
  • Check the differential oil level in the front (4×4) and rear
  • Check the transfer case oil level (4×4)
  • Check manual transmission fluid level

Every 30,000 miles or 30 months
…all items listed above, as well as

  • Inspect/repack front wheel bearings (2WD)
  • Flush and refill cooling system
  • Change the brake fluid
  • Change the automatic transmission fluid and filter**
  • Check the steering, suspension and drive axle boots
  • Inspect evaporative emissions control system

Every 60,000 miles or 48 months
…all items listed above, as well as

  • Check the PCV valve
  • Replace the spark plugs
  • Inspect/replace the spark plug wires
  • Change the differential oil
  • Change transfer case fluid
  • Change manual transmission fluid

* Replace more often if the vehicle is driven in dusty areas.

** If the vehicle is operated in continuous stop-and-go traffic or mountainous areas, change at 15,000 miles.

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