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.

 

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.

 

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

 

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

 

My bad. Pints

 

^^^^^ 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.

 

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

 

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:ford:
-Joe

 

Thanks Irish95. I am a subcriber on your YouTube channel and plan on doing the same in my tranny. Thanks for the helpful info in your videos.

 

My rear end took 75w-190 synthetic and the front took 70w-90. I just ran synthetic ATF in the tranny and t-case. Now all the gearboxes and engine has synthetic oil of some form in it which is a good thing! Synthetic is superior to dino oils.

 

I overfill my zf to quite the gear rollover.

 

Here is the TSB for Mercon to Mercon V for Auto Trans

 

Here is the tsb for Mercon to Mercon V for manual trans ZF-5

 

pennzoil synchromesh does wonders for the ZF5 or ZF6 compared to ATF