What fluids to run in ZF-5 , T-Case and Diffs - Ford Powerstroke Diesel Forum
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Old 03-08-2013, 01:40 PM
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What fluids to run in ZF-5 , T-Case and Diffs

Bought a 96 5 speed a while back and been searching on what fluids to run in the Diffs, T-Case and ZF-5. It's a 1996 4door longbox F350 SRW. I've found a lot of mixed opinions and what people run. Can I hear your thoughts?
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Old 03-08-2013, 01:57 PM
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ZF5 requires synthetic ATF. T-case takes ATF, synth or dino. Diffs take 75-90 gear oil any higher grade synth. Is your rear diff a limited-slip?

General rule with trannies / t-cases is that if the case is ferrous, it takes gear oil, and if not (magnesium/aluminum), it takes ATF.
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Old 03-08-2013, 03:12 PM
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Yeah i read they take ATF. Just not sure what kind. Mixed opinions on Mercon III, Redline, Royal Purple, Lucas etc. Not sure what to use. I bought the truck used so I dont have a manual, what's the fluid amounts if you don't mind me asking. For the T-Case, Trans. Front and rear Diff.
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Old 03-08-2013, 04:00 PM
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The trans came factory filled with Castrol SYNTHETIC ATF Mercon. It was green in color. It holds 6.8 Pints

The T-case used regular ATF Mercon 2 QUARTS

The rear diff(sterling 10.25) used 75w-90 or 75w-140

If you have a limited slip, add the friction modifier if using regular oil. If using synthetic, they typically have it in the oil already. 7.5 PINTS

Last edited by Diesel_brad; 03-08-2013 at 04:09 PM.
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Old 03-08-2013, 04:03 PM
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Quote:
Originally Posted by Diesel_brad View Post
The trans came factory filled with Castrol SYNTHETIC ATF Mercon. It was green in color. It holds 6.8 QUARTS

The T-case used regular ATF Mercon 2 QUARTS

The rear diff(sterling 10.25) used 75w-90 or 75w-140

If you have a limited slip, add the friction modifier if using regular oil. If using synthetic, they typically have it in the oil already. 7.5 PINTS
Thought the zf5 only held 3-4 quarts
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Old 03-08-2013, 04:08 PM
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My bad. Pints
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Old 03-08-2013, 04:14 PM
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^^^^^ All the above capacitites should bring you right up to the bottom of the fill hole in each case. If the clutch has been replaced and includes a single-mass flywheel, some fellas opt to overfill the tranny by a quart or so by filling it through the shifter, to reduce the gear rollover noise.
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Old 03-08-2013, 07:20 PM
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Quote:
Originally Posted by Buckhunter8813 View Post
Bought a 96 5 speed a while back and been searching on what fluids to run in the Diffs, T-Case and ZF-5. It's a 1996 4door longbox F350 SRW. I've found a lot of mixed opinions and what people run. Can I hear your thoughts?
Here is a list of fluid types/grades and capacities. Good info posted already too.

Engine Oil
Grade 1......CH-4
SAE 15W-40 Synthetic Heavy Duty Diesel and Marine Motor Oil (AMEQT)
Synthetic 15W-40 Diesel Oil (DMEQT)
Synthetic 15W40 OE Diesel Oil (OEDQT)
-9 To 90 F......10W-30 [1]
Above 0 F......15W-40 [1]
Below 50 F......5W-30
Manual Transmission,S5-42 (5-SPD)......SLF [2]
All TEMPS......
No AMSOIL Product Recommendation
Manual Transmission,S5-47 (5-SPD)......MA
All TEMPS......
Synthetic Multi-Vehicle Automatic Transmission Fluid (ATFQT)
Torque-Drive Synthetic Transmission Fluid (ATD1G)
Automatic Transmission,C6-Deep......MA
Synthetic Multi-Vehicle Automatic Transmission Fluid (ATFQT)
Torque-Drive Synthetic Transmission Fluid (ATD1G)
Automatic Transmission,E4OD......MA
Synthetic Multi-Vehicle Automatic Transmission Fluid (ATFQT)
Torque-Drive Synthetic Transmission Fluid (ATD1G)
Automatic Transmission,C6-Shallow......MA
Synthetic Multi-Vehicle Automatic Transmission Fluid (ATFQT)
Torque-Drive Synthetic Transmission Fluid (ATD1G)
Limited Slip Differential, Rear Dana 80......GL-5*
All TEMPS......80W-90
SAE 80W-90 Synthetic Gear Lube (AGLQT)
SEVERE GEAR 75W-90 Synthetic EP Lubricant (SVGQT)
75W-90 Synthetic Long Life Gear Lube (FGRQT)
SEVERE GEAR 75W-110 Synthetic EP Lubricant (SVTQT)
Limited Slip Differential, Rear Ford 10.25 RG......GL-5*
All TEMPS......80W-90
SAE 80W-90 Synthetic Gear Lube (AGLQT)
SEVERE GEAR 75W-90 Synthetic EP Lubricant (SVGQT)
75W-90 Synthetic Long Life Gear Lube (FGRQT)
SEVERE GEAR 75W-110 Synthetic EP Lubricant (SVTQT)
Standard Differential, Rear W/ 8.8 or 9 RG......GL-5
All TEMPS......80W-90
SAE 80W-90 Synthetic Gear Lube (AGLQT)
SEVERE GEAR 75W-90 Synthetic EP Lubricant (SVGQT)
75W-90 Synthetic Long Life Gear Lube (FGRQT)
SEVERE GEAR 75W-110 Synthetic EP Lubricant (SVTQT)
Standard Differential, Rear Ford 10.25 RG......GL-5
All TEMPS......80W-90
SAE 80W-90 Synthetic Gear Lube (AGLQT)
SEVERE GEAR 75W-90 Synthetic EP Lubricant (SVGQT)
75W-90 Synthetic Long Life Gear Lube (FGRQT)
SEVERE GEAR 75W-110 Synthetic EP Lubricant (SVTQT)
Standard Differential, Rear Dana 80......GL-5
All TEMPS......80W-90
SAE 80W-90 Synthetic Gear Lube (AGLQT)
SEVERE GEAR 75W-90 Synthetic EP Lubricant (SVGQT)
75W-90 Synthetic Long Life Gear Lube (FGRQT)
SEVERE GEAR 75W-110 Synthetic EP Lubricant (SVTQT)
Differential, Front Dana 60......GL-5*
All TEMPS......80W-90
SAE 80W-90 Synthetic Gear Lube (AGLQT)
SEVERE GEAR 75W-90 Synthetic EP Lubricant (SVGQT)
75W-90 Synthetic Long Life Gear Lube (FGRQT)
SEVERE GEAR 75W-110 Synthetic EP Lubricant (SVTQT)
Standard Differential, Rear Dana 70-2U......GL-5
All TEMPS......80W-90
SAE 80W-90 Synthetic Gear Lube (AGLQT)
SEVERE GEAR 75W-90 Synthetic EP Lubricant (SVGQT)
75W-90 Synthetic Long Life Gear Lube (FGRQT)
SEVERE GEAR 75W-110 Synthetic EP Lubricant (SVTQT)
Limited Slip Differential, Rear W/ 8.8 or 9 RG......GL-5*
All TEMPS......80W-90
SAE 80W-90 Synthetic Gear Lube (AGLQT)
SEVERE GEAR 75W-90 Synthetic EP Lubricant (SVGQT)
75W-90 Synthetic Long Life Gear Lube (FGRQT)
SEVERE GEAR 75W-110 Synthetic EP Lubricant (SVTQT)
Limited Slip Differential, Rear Dana 60-IU......GL-5*
All TEMPS......80W-90
SAE 80W-90 Synthetic Gear Lube (AGLQT)
SEVERE GEAR 75W-90 Synthetic EP Lubricant (SVGQT)
75W-90 Synthetic Long Life Gear Lube (FGRQT)
SEVERE GEAR 75W-110 Synthetic EP Lubricant (SVTQT)
Limited Slip Differential, Rear Dana 70 HD......GL-5*
All TEMPS......80W-90
SAE 80W-90 Synthetic Gear Lube (AGLQT)
SEVERE GEAR 75W-90 Synthetic EP Lubricant (SVGQT)
75W-90 Synthetic Long Life Gear Lube (FGRQT)
SEVERE GEAR 75W-110 Synthetic EP Lubricant (SVTQT)
Differential, Front Dana 50......GL-5*
All TEMPS......80W-90
SAE 80W-90 Synthetic Gear Lube (AGLQT)
SEVERE GEAR 75W-90 Synthetic EP Lubricant (SVGQT)
75W-90 Synthetic Long Life Gear Lube (FGRQT)
SEVERE GEAR 75W-110 Synthetic EP Lubricant (SVTQT)
Standard Differential, Rear Dana 70 HD......GL-5
All TEMPS......80W-90
SAE 80W-90 Synthetic Gear Lube (AGLQT)
SEVERE GEAR 75W-90 Synthetic EP Lubricant (SVGQT)
75W-90 Synthetic Long Life Gear Lube (FGRQT)
SEVERE GEAR 75W-110 Synthetic EP Lubricant (SVTQT)
Differential, Front Dana 44......GL-5*
All TEMPS......80W-90
SAE 80W-90 Synthetic Gear Lube (AGLQT)
SEVERE GEAR 75W-90 Synthetic EP Lubricant (SVGQT)
75W-90 Synthetic Long Life Gear Lube (FGRQT)
SEVERE GEAR 75W-110 Synthetic EP Lubricant (SVTQT)
Limited Slip Differential, Rear Dana 70-2U......GL-5*
All TEMPS......80W-90
SAE 80W-90 Synthetic Gear Lube (AGLQT)
SEVERE GEAR 75W-90 Synthetic EP Lubricant (SVGQT)
75W-90 Synthetic Long Life Gear Lube (FGRQT)
SEVERE GEAR 75W-110 Synthetic EP Lubricant (SVTQT)
Standard Differential, Rear Dana 60-IU......GL-5
All TEMPS......80W-90
SAE 80W-90 Synthetic Gear Lube (AGLQT)
SEVERE GEAR 75W-90 Synthetic EP Lubricant (SVGQT)
75W-90 Synthetic Long Life Gear Lube (FGRQT)
SEVERE GEAR 75W-110 Synthetic EP Lubricant (SVTQT)
Transfer Case,BW1356E W/ PTO......MA
Synthetic Multi-Vehicle Automatic Transmission Fluid (ATFQT)
Torque-Drive Synthetic Transmission Fluid (ATD1G)
Transfer Case,BW1356E/BW1356......MA
Synthetic Multi-Vehicle Automatic Transmission Fluid (ATFQT)
Torque-Drive Synthetic Transmission Fluid (ATD1G)
Fluids
Power Steering Fluid......FA
Synthetic Supershift Racing Transmission Fluid SAE 10W (ARTQT)
Clutch Fluid......HB
AMSOIL Brake Fluid DOT-3 (BF3SN)
Brake Fluid......HB
AMSOIL Brake Fluid DOT-3 (BF3SN)

[1] SAE 10W-30 is preferred -23 C (-10 F) to -1 C (31 F);
SAE 15W-40 is preferred above -1 C (31 F).
[2] Full Synthetic Manual Transmission Fluid, Part No. XT-5M-QS

FILTERS:
Oil Filter
25,000-Mile Ea Oil Filter (EAO99)
Oil Filter
WIX 51734 Oil Filter
Air Filter
Absolute Efficiency Air Filter (EAA103)
Fuel Filter
WIX 33817 Fuel Filter [1]
Transmission Filter
WIX 58968 Auto Tran Filter[2]
Transmission Filter
WIX 58967 Auto Tran Filter[3]

[1] Has Lid Attached
[2] 4WD
[3] 2WD

WIPER BLADES:
Blade Class
Driver
Passenger
ExactFit
T181
T181
NeoForm
T16180
T16180
Winter
T37180
T37180

CHASSIS LUBRICATION:

4WD
0-7 Fittings, 0 Plugs..........LM
Series 2000 Synthetic Racing Grease NLGI#2 GC/LB (GRGCR)
Synthetic Multi Purpose #2 (GLC3P)
Synthetic Water Resistant #2 (GWR3P)
2WD
4-10 Fittings, 0 Plugs..........LM
Series 2000 Synthetic Racing Grease NLGI#2 GC/LB (GRGCR)
Synthetic Multi Purpose #2 (GLC3P)
Synthetic Water Resistant #2 (GWR3P)

CAPACITIES:

Engine, with filter..........13.9 quarts [1]
Cooling System, Initial Fill..........22.7 quarts
AMSOIL Antifreeze and Engine Coolant
Automatic Transmission, E4OD Initial Fill..........6.4 quarts
Automatic Transmission, C6-Deep Pan Initial Fill..........5.9 quarts
Automatic Transmission, C6-Shallow Pan Initial Fill..........5 quarts
Automatic Transmission, Total Fill
4 speed E4OD..........Not Specified
3 speed C6-Shallow..........Not Specified
3 speed C6-Deep..........13.5 quarts
Manual Transmission, S5-42 (5-SPD)..........6.8 pints
Manual Transmission, S5-47 (5-SPD)..........6.8 pints
Differential, Dana 44 Front..........3.6 pints [2]
Differential, Dana 50 Front..........3.8 pints [2]
Differential, Dana 60 Front..........5.9 pints [2]
Differential, Dana 60-IU Rear..........6.3 pints [2]
Differential, Dana 70-2U Rear..........6.6 pints [2]
Differential, Dana 70 HD Rear..........7.4 pints [2]
Differential, Dana 80 Rear..........8.5 pints
Differential, Ford 10.25 RingGear Rear..........7.4 pints [2]
Differential, With 8.8 or 9 RingGear Rear..........5.5 pints [2]
Transfer Case, BW1356E W/ PTO..........12.3 pints
Transfer Case, BW1356E/BW1356..........4 pints

[1] When refilling, remove dipstick to provide adequate venting
and allow oil to flow into crankcase.
[2] Fill to no more than 1/4 to 9/16 inch below fill plug hole.

TORQUES:

Oil Drain Plug.....NA ft/lbs
Manual Transmission
Fill Plug 25-30 ft/lbs
Drain Plug 25-30 ft/lbs
Transfer Case
Fill Plug 12 ft/lbs
Drain Plug 12 ft/lbs
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  #9  
Old 05-20-2013, 10:54 AM
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After 2 or 3 days of research and a boat load of phone calls to: Ford Tech's, Veteran Transmission Builders, Royal Purp. Tech, Lucas Tech, Amsoil tech. Also reading countless charts, forum pages, user testimony.
This is what I came up with on the subject.

I had Rollover noise, 2nd & 3rd gear had typical grind.
The fluid I pulled out was: Burn, Dirty & 1/2 missing.

I pulled fill and drain plug.
Shot 1 full can parts cleaner into fill hole, for flush.

Filled from top w/ 3 quarts Lucas Simi-Syn ATF & 1 quart Lucas Oil Stabilizer.
Took around 150 miles, now it shifts like butter.
Cold/Hot, My pick up truck don't give a F*k. Shifts smooth and fast.
This is the 2nd Trans I Have used this on. It shut-up the ZF6 in my 99.5 350.

I made a Youtube for anyone who needs some extra instructions.
94 - 95 Powerstroke ZF5 Trans and Borg Warner 1356 T-Case Flush & Fill - YouTube

Hope this helps someone
-Joe
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