2006—2009 Ford Fusion & Mercury Milan Transmission Fluid Change

2.3l Engine with Five-Speed Automatic Transmission

Introduction: This guide will show you in detail all the steps needed to change the transmission fluid on your 2006 — 2009 Ford Fusion or Mercury Milan with the 2.3l four cylinder engine and five-speed (FNR5)

automatic transmission. Read these instructions thoroughly before completing the procedure and have them

handy during the procedure. Troubleshooting is available at the end of this document for specific steps where

you may encounter problems. More images for reference are also available at the end of this document. Pay

attention to the WARNING, CAUTION, and NOTE mentions in steps where they occur for best results and safety.

Materials Needed:

Jack

Jack stand

Flathead screwdriver

Wheel chocks

Wide-grip pliers

10mm socket and ratchet

A bucket or graduated container; graduated every three

quarts

Funnel with long and thin neck

Nine quarts of Mazda M5 Automatic Transmission Fluid or

Motorcraft FNR5 Automatic Transmission Fluid; This can be

purchased from a Mazda or Ford dealership. CAUTION: For

your safety, please follow all warnings and precautions listed

on the transmission fluid bottle.

A helper

Procedure:

1. Park the car on level ground, set the parking brake, and block the

front of rear of each rear wheel, on both sides of the car.

2. On your bucket or container, mark three quart intervals up to nine

quarts on the inside of the bucket. This is important.

3. Removing the air filter box:

A. Open the hood. If you are facing the front of the car, the air

filter box is on the right side of the engine bay. The air filter

box is in two pieces. (Image 3A)

B. The Mass Airflow Sensor (MAS) is on the back (facing the

interior of the car) of the air filter box. Disconnect the wire

that runs to the MAS by pulling the red tab out, then sliding

the connector off. (Image 3B) . NOTE: disconnecting the MAS

will cause the car to idle roughly, but it will not harm the car.

The check engine light will illuminate if it is left disconnected.

C. Loosen the hose clamp on the side of the hose that connects

to the left side of the air filter box, then slide the hose off.

(Image 3B). Undo the clasps on the front of the air filter box.

(Image 3C). Lift the air filter box cover on the side where the

clamps are and pull towards you to remove it. Remove the air

filter.

D. The bottom part of the air filter box is secured with plastic

pegs that mount into rubber mountings; there are no bolts. Pull

the air filter box up to remove the pegs from their mountings

and then pull to the left to remove it; it may take some force

but it will come out. The air filter box is now removed.

NOTE: You should reconnect the MAS wire to the MAS in

the top of the air filter box so the check engine light does not

illuminate. The car will however still idle roughly.

Image 3A

Image 3B

Image 3C

4. Raising the Car & Removing the Underbody Panel

A. Using the jack, raise the left side of the car high enough so

that you can fit the bucket underneath then place a jack stand

underneath the car for safety. A safe location for the jack stand

is shown in Image 4A. WARNING: Do not rely on the jack to

support the car. Use a jack stand for safety.

B. Underneath the car, remove the seven 10mm bolts that hold

the underbody panel in place. Set the panel and bolts to one

side. Image 4B shows the location of the bolts that need to be

removed.

5. Changing the fluid

A. Back under the hood, locate the transmission fluid cooler

hose under where the air filter box was (Image 5A). It runs from

the radiator into the transmission. Place your bucket on the

ground under this hose.

B. Use the pliers to pinch the clamp on the transmission cooler

hose and slide it down the hose (Image 5B). Remove the cooler

hose from the transmission and aim it into the bucket. A small

amount of fluid may run out.

C. Have your helper start the car. Watch the fluid flow into the

bucket and have them turn the car off when the fluid reaches

the three quart mark; this takes about 30 seconds. Place the

cooler hose back on the transmission to prevent drips.

WARNING: Keep away from moving parts while the engine

Image 4A

Image 4B

Image 5A Image 5B

FRONT OF VEHICLE

REAR OF VEHICLE

is running.

D. Remove the red transmission fluid dipstick and place the

funnel in the tube. Add three quarts of the transmission fluid

(Image 5D).

E. Remove and re-aim the cooler hose back at the bucket and

repeat steps 5C through 5D for the second three quarts (six

total so far).

F. After you have removed the last three quarts (nine quarts

total), it is time to reassemble things. Do not add the last three

quarts yet.

G. Place the cooler hose back on the transmission firmly and

using the pliers, slide the clamp back in place. Go under the car

and replace the underbody panel. Remove the jack stand and

lower the car. It will need to be level for step 5J.

H. Replace the bottom of the air filter box and the air filter. If

you reconnected the MAS wire, disconnect it again to avoid

damaging the wire. Replace the top of the air filter box and

secure the clamps. Reinstall the MAS wire and the hose; tighten

the hose clamp.

I. With the car reassembled and at operating temperature, add

one quart of fluid then shift through each position on the gear

selector, staying in each position for a few seconds. Check the

fluid level, then repeat this step for the second quart. The

acceptable range for the transmission fluid is between the

two indents on the dipstick, shown in Image 5E. CAUTION:

Overfilling the transmission with fluid can cause damage to the

transmission. Do not overfill. WARNING: Do not drive the car

while it is significantly low on transmission fluid.

J. Now you will add the third quart in small parts. First, check

the fluid level to get an idea of where it is. Pour a little bit

at a time, then check the transmission fluid level using the

dipstick. After each addition, shift through each position on the

gear selector, staying in each position for a few seconds then

check the fluid level before adding more.

Image 5D

Image 5E

L. Drive the vehicle for a short distance and recheck the fluid. Add fluid if it is needed until it is in

the acceptable range on the dipstick.

You have now completed the transmission fluid change on your vehicle.

Troubleshooting for specific steps:

2. If your bucket or container does not have graduations on it, you can make the graduations yourself by

pouring three quarts of water into the container at a time and mark the level on the container.

3B. If it is hard to slide the hose off of the air filter box, you may not have loosened the hose clamp enough even

though it appears to be loose. Loosen the hose clamp more, but not so much that the clamp comes apart. Use the

flathead screwdriver to pry the hose up some while you try to slide it off the top of the air filter box.

3D. If after you have completed the procedure the check engine light is illuminated, you will need to check the

code with a Diagnostic Trouble Code Reader, check that the part that the trouble code is related to is installed

and operating correctly, and clear the trouble code.

5B. If you cannot easily move the clamp on the transmission fluid cooler hose, you may need a bigger set of

pliers.

5G. If reinstalling the underbody panel is difficult, you may need have your helper help since the panel is large.