🔧 Fusion - Automatic Transmission Fluid Change

This procedure drains and refills the 6F35 automatic transmission in your Fusion. A simple drain removes only part of the old fluid, so this is a service exchange—not a complete flush.

Difficulty Level: Intermediate | Estimated Time: 1.5-2.5 hours

Assumption: This procedure is for the factory-installed 6F35 six-speed automatic transmission.

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⚠️ Safety & Precautions

• ⚠️ Support your Fusion level on four jack stands. Never work beneath a vehicle supported only by a jack.
• 🔥 Transmission fluid and nearby exhaust parts become hot. Wear gloves and safety glasses.
• ⚙️ The final fluid-level check requires the engine to run while the vehicle is raised. Keep hands, clothing, and tools away from moving parts.
• 🛢️ Use only fluid meeting Ford MERCON LV. MERCON ULV, MERCON V, and universal fluids are not substitutes unless the label explicitly lists Ford MERCON LV approval.
• 🚫 Do not use a pressurized transmission-flush machine or add transmission cleaners.
• 🔋 Battery disconnection is not required.

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🔧 Required Tools

You'll need the following tools for this repair:

• Low-profile floor jack rated 2-ton minimum
• Jack stands rated 2-ton minimum, set of four
• Wheel chocks, pair
• 7mm socket
• 11mm socket
• 14mm socket
• 3/8-inch-drive ratchet
• 3/8-inch-drive extension, 6-inch
• Torque wrench rated 5-30 Nm
• Fluid transfer pump with 3/8-inch hose
• Drain pan with 10-quart capacity
• Graduated measuring container with 5-quart capacity
• OBD-II scan tool with transmission-fluid-temperature data (specialty)
• Digital level, 9-inch minimum
• Shop light
• Nitrile gloves
• Safety glasses
• Shop towels

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🔩 Required Parts

HowToo sells all the parts you need for this repair:

• Automatic transmission fluid meeting Ford MERCON LV - Qty: 5 quarts
• Transmission drain-plug sealing washer - Qty: 1
• Transmission level-plug sealing washer - Qty: 1

A typical drain releases approximately 4-4.5 quarts, but the measured amount and final level check determine the correct refill.

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📋 Before You Begin

• 📍 Park on firm, level ground. Apply the parking brake and chock the rear wheels.
• 🌡️ Drive for approximately 10 minutes so the fluid is warm, but not extremely hot.
• 📱 Connect the OBD-II scan tool and confirm it can display transmission fluid temperature, abbreviated TFT.
• 📏 Raise and support all four corners. Use the digital level on a door sill to make sure your Fusion remains level front-to-rear and side-to-side.
• 🧪 Transmission fluid expands as it warms. The final level must be checked at the specified temperature with the engine running.
• 🗑️ Arrange for the drained fluid to be recycled. Do not pour it onto the ground or into household drains.

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🔨 Step-by-Step Instructions

Follow these steps in order:

Step 1: Raise and secure the vehicle

• Use the low-profile floor jack at the approved lifting points, then place all four jack stands under the reinforced support points.
• Lower your Fusion onto the stands and gently push the body to confirm it is stable.
• Use the digital level on a door sill. Adjust the stand heights until the vehicle is level.
• Keep the jack nearby as backup support.

Step 2: Remove the lower splash shield

• Put on the safety glasses and nitrile gloves.
• Use the 7mm socket, 6-inch extension, and 3/8-inch-drive ratchet to remove the splash-shield fasteners beneath the engine and transmission.
• Support the shield with one hand while removing its final fastener, then set it aside.

Step 3: Identify the service plugs

• Use the shop light to locate the drain plug at the bottom of the transmission case.
• Locate the fluid-level plug on the side of the transmission case. The level plug establishes the correct fluid height when the transmission is warm and running.
• Clean around both plugs with shop towels so dirt cannot enter the transmission.

Step 4: Drain and measure the old fluid

• Position the 10-quart drain pan beneath the transmission drain plug.
• Use the 11mm socket and 3/8-inch-drive ratchet to loosen and remove the drain plug carefully.
• Allow the transmission to drain until it slows to an occasional drip.
• Pour the used fluid into the graduated measuring container and record the exact quantity.
• Inspect the fluid. A dark color can be normal, but metallic debris, a strong burned smell, or chunks of clutch material indicate that professional diagnosis is needed.

Step 5: Reinstall the drain plug

• Install a new drain-plug sealing washer and thread the drain plug into the case by hand.
• Use the 11mm socket and torque wrench to tighten the drain plug to 12 Nm (106 in-lbs).
• Do not overtighten it because the transmission housing is aluminum.

Step 6: Add the initial refill

• Remove the transmission fill cap at the top of the transmission by hand. If access is too restricted, refill through the side level opening using the fluid transfer pump.
• Use the fluid transfer pump and 3/8-inch hose to add the same quantity of new MERCON LV fluid that was measured during draining.
• Start with approximately 4 quarts if the drained quantity could not be measured, then set the exact amount during the level check.
• Reinstall the fill cap by hand until fully seated.
• Add slowly to prevent trapped air and spills.

Step 7: Circulate the new fluid

• Confirm the parking brake is applied and all four wheels are securely supported.
• Start the engine and keep your foot firmly on the brake pedal.
• Move the selector slowly through P-R-N-D, pausing approximately five seconds in each position.
• Return the selector to Park and leave the engine idling.
• Use the OBD-II scan tool to monitor transmission fluid temperature.

Step 8: Set the fluid level

• Wait until the scan tool shows a transmission fluid temperature of 85-93°C (185-200°F).
• With the engine still idling and your Fusion level, position the drain pan below the side level plug.
• Use the 14mm socket, 6-inch extension, and 3/8-inch-drive ratchet to remove the level plug carefully.
• If a thin stream slows to a drip, the level is correct.
• If no fluid emerges, use the fluid transfer pump and 3/8-inch hose to add MERCON LV through the level opening until a thin stream begins, then wait until it becomes a slow drip.
• If fluid pours out heavily, allow the excess to drain until only a slow drip remains.
• Install a new level-plug sealing washer. Use the 14mm socket and torque wrench to tighten the level plug to 8 Nm (71 in-lbs).
• Switch off the engine after the plug has been installed.

Step 9: Check for leakage

• Use the shop light and shop towels to inspect the drain plug and level plug.
• Verify that neither plug is leaking.
• Clean any spilled fluid from the transmission and nearby exhaust components with shop towels.

Step 10: Reinstall the splash shield

• Position the lower splash shield beneath your Fusion.
• Start every fastener by hand to avoid cross-threading.
• Use the 7mm socket and 3/8-inch-drive ratchet to tighten the fasteners until snug. Do not overtighten the plastic retainers.

Step 11: Lower the vehicle

• Use the low-profile floor jack to raise one end slightly and remove the jack stands.
• Repeat at the opposite end, then lower your Fusion slowly to the ground.
• Remove the wheel chocks after the vehicle is fully lowered.

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✅ After Repair

• 🚗 Drive gently for 10-15 minutes and confirm that engagement and shifts feel normal.
• 🔍 Park on clean, level pavement and inspect underneath for leaks.
• 📊 No transmission adaptive reset or programming is required for a routine drain and refill.
• 🧰 If the transmission slips, delays engagement, or shifts abnormally, stop driving and recheck the fluid level at the specified temperature.
• ♻️ Take the used fluid to an authorized oil-recycling or automotive service facility in Panipat.
• 🔄 For badly discolored fluid, a second drain and refill after several hundred kilometers is safer than a pressurized flush.

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💰 DIY vs Shop Cost

Shop Cost: ₹8,000-₹15,000 (parts + labor)

DIY Cost: ₹4,000-₹7,000 (fluid and seals only)

You Save: ₹4,000-₹8,000 by doing it yourself!

Local labor rates vary. This repair takes a shop approximately 1-1.5 hours.

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🎯 Ready to get started?

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