🔧 Fusion Energi - Transmission Fluid Drain & Fill

On your Fusion Energi, the “transmission” is a hybrid eCVT transaxle. The fluid lubricates and cools the gears and electric drive components, and a drain-and-fill refreshes the fluid without taking the unit apart.

Difficulty Level: Intermediate | Estimated Time: 1.5-3 hours

Assumption: Hybrid eCVT (HF35-style) with drain/fill plugs that accept a 3/8" square drive. Verify plug shape before you start.

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⚠️ Safety & Precautions

• ⚠️ Support the car with jack stands on a level surface; never work under a jack-only vehicle.
• ⚠️ The hybrid system can start the gas engine automatically when in “READY.” Keep hands/tools clear of belts and fans.
• ⚠️ Transmission fluid can be hot. Wear gloves and safety glasses.
• ⚠️ Do not touch or unplug any orange high-voltage cables (these carry high voltage).
• ⚠️ No battery disconnect is required for a basic drain/fill, but keep the key fob at least 15 ft away when the car is OFF.

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🔧 Required Tools

You'll need the following tools for this repair:

• Floor jack (rated 2-ton minimum)
• Jack stands (rated 2-ton minimum)
• Wheel chocks
• Safety glasses
• Nitrile gloves
• Drain pan (8-quart minimum)
• 3/8" drive ratchet
• 3/8" drive extension (6")
• Torque wrench (10–100 Nm range)
• 8mm socket
• 10mm socket
• Trim clip tool
• Fluid transfer pump
• OBD2 scan tool with Transmission Fluid Temperature PID (specialty)
• Shop rags

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🔩 Required Parts

HowToo sells all the parts you need for this repair:

• Automatic transmission fluid (MERCON LV) - Qty: 5 quarts
• Transmission drain/fill plug seal washers - Qty: 2
• Brake cleaner spray - Qty: 1

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📋 Before You Begin

• Park on a level surface, set the parking brake, and place wheel chocks behind the rear tires.
• Plan to keep the car level on jack stands (front and rear at similar height). Fluid level checks are very sensitive to tilt.
• Install your OBD2 scan tool and confirm you can view Transmission Fluid Temperature (TFT) before you drain anything.
• Make sure the car is fully OFF before crawling underneath (no “READY” light).

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🔨 Step-by-Step Instructions

Follow these steps in order:

Step 1: Raise and secure the car

• Use a floor jack to lift the front, then place jack stands under the proper front lift points.
• Lift the rear slightly (if needed) and place jack stands so the car sits level.
• Give the car a firm shake to confirm it is stable.

Step 2: Remove the lower splash shield (if equipped)

• Use an 8mm socket and 10mm socket to remove the fasteners.
• Use a trim clip tool to pop any plastic clips without breaking them.
• Set the shield and hardware aside in order.

Step 3: Locate the transaxle drain and fill plugs

• Look at the transaxle case on the driver side area. Typically:
• One plug is low (drain) and one is higher (fill/level reference).
• Many Ford units use a plug that takes a 3/8" drive ratchet directly (square drive into the plug).
• If the fill plug won’t loosen, stop. Don’t drain first.

Step 4: Crack the fill plug loose first

• Place the drain pan underneath the transaxle area.
• Use a 3/8" drive ratchet and extension to loosen the fill plug.
• Leave it threaded in a few turns for now.

Step 5: Drain the old fluid

• Move the drain pan directly under the drain plug.
• Use a 3/8" drive ratchet to remove the drain plug.
• Let the fluid drain until it slows to an occasional drip (usually 10–20 minutes).
• Clean the drain plug with shop rags and spray with brake cleaner.
• Install a new seal washer if your plug uses one.

Step 6: Reinstall the drain plug

• Thread the drain plug in by hand to avoid cross-threading.
• Use a torque wrench to tighten the drain plug: Torque to 35 Nm (26 ft-lbs).

Step 7: Fill with fresh MERCON LV

• Remove the loosened fill plug using the 3/8" drive ratchet.
• Insert the hose from your fluid transfer pump into the fill port.
• Pump in MERCON LV until fluid begins to weep back out of the fill opening.
• Install the fill plug finger-tight for now (you’ll do the final level check next).

Step 8: Set the fluid level at the correct temperature

• Lower the car enough to safely start it, or keep it safely supported and clear of moving parts.
• Connect the OBD2 scan tool and monitor Transmission Fluid Temperature (TFT).
• Start the car to “READY” (foot on brake, press Start) and keep it in P.
• With foot on brake, slowly move the shifter through R → N → D → L, pausing 2–3 seconds each, then back to P.
• When TFT reaches about 40–50°C (104–122°F), remove the fill/level plug using the 3/8" drive ratchet.
• Correct level is when fluid drips out in a thin steady drip (not a heavy stream). Let excess drain until it becomes a drip.
• Install a new seal washer if required, then tighten the fill plug with a torque wrench: Torque to 35 Nm (26 ft-lbs).
• Keep the car level during this check.

Step 9: Reinstall the splash shield

• Reinstall the shield using the 8mm socket, 10mm socket, and trim clip tool.
• Snug fasteners evenly (do not over-tighten plastic).

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✅ After Repair

• Start the car and let it idle in “READY” for 1–2 minutes. Check underneath for leaks.
• Take a short 10–15 minute drive. Confirm smooth operation and no new warnings.
• Park on level ground and do a quick re-check for leaks around the fill and drain plugs.
• Dispose of used ATF properly (most parts stores accept waste fluids).

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💰 DIY vs Shop Cost

Shop Cost: ₹8,000-₹18,000 (parts + labor)

DIY Cost: ₹2,500-₹6,000 (parts only)

You Save: ₹5,500-₹12,000 by doing it yourself!

Shop labor rates vary but typically run ₹1,000-₹2,500/hour. This repair takes a shop approximately 1.5-2.5 hours.

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🎯 Ready to get started?

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