Its always something - even something as simple as changing the MT fluid. I can not remove the upper fill bolt on my 96R not even with a 16" extension. Lower drain bolt - no problem. Question - I have a shifter rebuild kit that I plan on installing. Can I pour the fluid down through the shifter hole? Also, can someone confirm that the bolt is 24mm?

Appreciate any help.

Glenn

 

I always put mine down through the shift hole.
It's a real PITA pumping it up into the filler hole.
Make sure it's in neutral before pulling the shift lever. VERT IMPORTANT

 

Thanks for the advise. Any reason I can't put some heat on the bolt to loosen it?

 

By the way - is it 2 1/2 or 3 quarts to fill the transmission? Can I use Mercon or should it only be Mercon V?

 

Here's the issue, the measured amount isn't what i needed, it was less than the 2.5 i think it's specced for.

I do believe it's a 24mm fill bolt, do you have a 6 sided socket for it, that'll be best to use on a 1/2 inch breaker bar, no issues here - i don't think heat will help though.

 

I used this.

As for the drain plug, sounds like someone may have used an impact wrench on it.
Mine was tight too, I put a 12 pointed wrench on it, used my hand to tension the wrench on the nut and gave it a sharp tap with a rather large ball-peen hammer.
Note that I was wearing some thick heavy welding gloves.

Dex/Merc ATF - Automatic Transmission Fluid | United States

 

Sorry, forgot to answer the Mercon part - for me, i know Ford specifies MerconV (not Mercon) - For some reason i can't find a Penzoil product that clearly replaces that, however i'll be dropping mine again in the next 6 months and replacing it with this:

PENNZOIL SYNCHROMESH MANUAL TRANSMISSION FLUID

 

But Ford clearly lists ATF for their manual transmissions.
Putting in an oil that may be to thick and or sticky, that the transmission wasn't designed for, may damage the trans.

If the manual trans has an internal oil pump, then the oil in your link may be too thick.

If you're were in California, it probably wouldn't be an issue, but it can get quite cold where you are.

 

Ford do state ATF, but they did change it from Mercon, to MerconV about 10 years ago (roughly)

I have considered the oil type change, and honestly i'm still mulling it over some, however it's not a thicker MT fluid and i've seen several good reports from using it. Still, it's running clean MerconV right now, so no rush.

 

Mercon-V is still ATF.
I would just stick with that.

 

There are equivalent gear lubes to ATF. I use Royal Purple Synchromax which is designed for transmissions that call out ATF. It has additives that, in my opinion, improves shifting. I was not happy with the way the Mazda transmission shifted and switched to Synchromax at around 50K miles. I liked the improvement and am still using it at 225K miles (with a couple drain and refills of course).