Oil Plug Gasket Washer/Crush Washer

[Meelaan]

According to Ford's maintenance documentation for the 2.3L four cylinder equipped Ford Fusion and Mercury Milan vehicles, during each oil change, a washer on the oil drain plug must be changed. Ready for the bad part? My dealer--and I suspect most dealers--have no idea such a requirement exists.

 

Prior to my first oil change for my 2007 Mercury Milan, I emailed my dealership's service department to ensure they were aware of the washer requirement. They replied that it was optional and could be added for an $8.00 charge at each service. I was surprised that the manual would indicate it is a requiped part of the service, but my dealer considered it optional.

 

Well, yesterday I got the car down to the dealership for the oil change. I spoke to the on hand service manager and asked about the washer requirement. He had no idea what I was talking about, but referenced an email that was circulated about such an issue (my email). They were simply amazed that I'd even read the owners manual.

 

The service rep called the parts desk to ask them about the washer. Parts looked it up and said it was only available along with a new oil drain plug (!) for $14.00. I said hell-no and pushed them to look deeper. Finally, the parts guy located the washer by itself. Total cost: $7.30 each.

 

If they'd even known it was something that should be changed each service I would have been shocked by this price, but honestly, I was still having trouble getting over the fact that they were completely oblivious to this information I was telling them about an oil gasket washer.

 

Honda has been requiring this practice for years. My 2002 Civic Si required a new "crush" washer during each change. Easy enough... any auto parts store has packs of four aluminum oil drain washers for about $1.25.

 

But does anyone remember the debacle that hit Honda about a year ago?

 

Hondas began catching fire after being parked and it was attributed to oil leaking onto the hot exhaust header. My theory: mechanics and service departments were either not aware, or not actively changing the crush washer during maintenance.

 

In my personal experience, I installed a washer that had a deformity on its surface. This caused a very slow oil leak that after one week had coated the bottom of my car--including exhaust components.

 

Consider that the Fusion/Milan have been in production now for well over a year. How many four cylinder models are on the road? Ford could be setting themselves up for disaster with this issue... and it's such a little thing to overlook. That's what blows me away.

 

I went ahead and got my oil changed since they showed records of other four cylinders they'd serviced without changing the oil gasket washer. But I assured them that I would be contacting Ford--which I did about an hour ago--to get the word out. It's not so much my dealer's fault (although it would make me feel better if they were as familiar with the owners manual of my car as I was) as it is Ford's for simply not educating their dealer network on this.

 

I wanted to bring this issue up so other owners could provide their input on the matter and maybe even bring it up with their dealer--if not FoMoCo.

[mtl1977]

These Al crush washers/gaskets are common it seems with Japanese parts. My company (Japanese) insisted the service manual called for replacement of the drain plug washer on the product I work on too. The dealers don't stock them.

 

My Escort GT (Mazda 1.8L DOHC I-4) and Honda motorcycle both use Al washers. Neither have ever leaked.

 

My Mustang and F-150 have drain bolts with a rubber ring under the head to seal against the pan. I wonder if the thread pitch/diameter is the same...

[ctrcbob]

Meelaan,

 

I had almost the same thing happen with me the last time I changed the oil on my Continental. I asked for a new Crush Washer. Was told they don't have such a thing and I would have to go with the Drain Plug that has a built in washer.

 

Next time I get the oil changed, I will bring a variaty of crush washers with me. I have both aluminum and copper crush washers. I can buy the aluminum ones cheap, but the copper ones I still have from my BMW Motorcycle days, back when they used the copper washers. (They now use aluminum washers - the copper washers are better).

 

BTW, I never changed the washers on either of my other FoMoCo cars in the past and never had any leaks, so changing the washer may just be hype. I always change it on my motorcycles, but then we always take better care of our bikes than we do our cars, don't we! :rolleyes:

[eiching1]

Meelan, Is this the part of the owners manual you are speaking about?

 

When changing the oil filter on the 2.3L engine you must also replace

the filter cap O-ring. The oil filter drain plug O-ring must also be

replaced whenever the oil filter drain plug is removed. Reuse of the

O-rings may cause engine oil leakage and may result in severe engine

damage. The customer warranty may be void for any damage to the

engine if the O-rings are not replaced.

 

This is from the Milan owner's manual

[akirby]

Meelan, Is this the part of the owners manual you are speaking about?

 

When changing the oil filter on the 2.3L engine you must also replace

the filter cap O-ring. The oil filter drain plug O-ring must also be

replaced whenever the oil filter drain plug is removed. Reuse of the

O-rings may cause engine oil leakage and may result in severe engine

damage. The customer warranty may be void for any damage to the

engine if the O-rings are not replaced.

 

This is from the Milan owner's manual

 

No, he's talking about the oil pan drain plug.

[Meelaan]

Meelan, Is this the part of the owners manual you are speaking about?

 

When changing the oil filter on the 2.3L engine you must also replace

the filter cap O-ring. The oil filter drain plug O-ring must also be

replaced whenever the oil filter drain plug is removed. Reuse of the

O-rings may cause engine oil leakage and may result in severe engine

damage. The customer warranty may be void for any damage to the

engine if the O-rings are not replaced.

 

This is from the Milan owner's manual

 

The "O-ring" they are referring to is a washer.

 

As for the one referenced on the filter, that's the rubber ring built into an oil filter.

 

UPDATE:

Got a voice mail from Ford yesterday afternoon regarding the situation. It continues to make little sense how they are proceeding.

 

The caller informed me that my dealer operates under the policy that the washer is a "replace by request" item only and is available for an additional fee during service. This contradicts Ford's own maintenance documentation where it clearly states that the washer must be replaced--not reused--during each oil change.

 

What's more baffling is that Ford isn't stepping up to the plate and enforcing its own directives. Instead, they are apparently letting dealers pick and choose how they service vehicles.

 

Nevermind that when I DID request the washer change, no one in the service or parts department had any clue as to what I was talking about--and the part wasn't even in stock, so how would I have even gotten the "replace by request" fullfilled?

 

Nuts.

[urnews]

Does this situation only apply to the I4 or is it recommended for the V6 too?

[mtl1977]

What's more baffling is that Ford isn't stepping up to the plate and enforcing its own directives. Instead, they are apparently letting dealers pick and choose how they service vehicles.

 

 

Bureaucracy at its finest. Engineering and FCSD...

[Meelaan]

UPDATE #2:

Ford's representative called me again today. I was glad because I needed to get the importance of this issue out loud and clear. She said usually a customer would only get one call back but due to the nature of my complaint, they wanted to make sure they spoke to me.

 

To sum it up, Ford apparently really downplays the usefulness of their owners manual(s). The rep at one point suggested that the directives concerning the required replacement of the O-ring at each oil service may have been an error that should have been cut from the text.

 

I fired back with the fact that Mercury just sent me an entirely new owners manualonly a month ago (a new warranty manual followed a couple weeks later). When I received it, the letter stated that the only change to the manual content was to language regarding fuses... nothing else. If other content was changed, customers should have been made aware of it.

 

The rep further informed me that Ford's service technicians are instructed to inspect the O-ring at each service and replace only if damaged. Now, why would I be mandated under threat of voided warranty to change the O-ring if I serviced the car myself--but the Ford tech doesn't have to?

 

In the end, the choice Ford has is simple: either remove the language from the manual requiring the replacement of the O-ring... or enforce the policy as stated in the manual throughout their dealer network. They'll probably go with the first option, even if it means sending out yet ANOTHER replacement copy of their owners manual.

 

It makes you wonder... if the rep I spoke to downplays the importance and relevance of the car's owners manual so much, why the hell did they bother to send out revised copies to all current owners?

 

To some people, it may seem a petty thing... but I value my warranty and to forfeit it less than 5,000 miles into the purchase would be tragic to say the least. That's why I think this is such a big deal. Beyond that, I have concerns over the truth in the manual that could lead to oil leaks which can (but rarely does) lead to an engine fire or even failure. And if the language in the manual on this issue really is B.S., what other parts of the manual could be inaccurate?

 

Someone at Ford decided it was a pretty important issue... important enough to put in the manual and important enough to threaten loss of warranty if not abided by. I just want to know who's rules do we as consumers need to follow here to keep the vehicle on the road and keep the warranty coverage running.

 

Rather than sending out new revised manuals every two months, Ford needs to be accountable here.

[eiching1]

I am aware of the "o" ring vs. crush washer. The reason I asked was that I cannot find any reference to the crush washer in my owner's manual. 2006 Mercury Milan 3rd. printing.

[Meelaan]

I am aware of the "o" ring vs. crush washer. The reason I asked was that I cannot find any reference to the crush washer in my owner's manual. 2006 Mercury Milan 3rd. printing.

 

The language I'm referring to is in the 2007 model year owner's manual. I don't think they refer to it as a crush washer (that's really a Honda term), but rather a gasket, or O-ring.

 

They printed the 2006 manual THREE TIMES??? I'm on my second '07 one already. Geez...

[akirby]

The language I'm referring to is in the 2007 model year owner's manual. I don't think they refer to it as a crush washer (that's really a Honda term), but rather a gasket, or O-ring.

 

They printed the 2006 manual THREE TIMES??? I'm on my second '07 one already. Geez...

 

According to the 2007 Milan owner's manual, both of these O rings are part of the Oil filter, not the oil pan drain plug. One is the oil filter cap o-ring and the other is the oil filter drain plug o-ring.

 

Just wanted to make sure this was clear.

[urnews]

According to the 2007 Milan owner's manual, both of these O rings are part of the Oil filter, not the oil pan drain plug. One is the oil filter cap o-ring and the other is the oil filter drain plug o-ring.

 

Just wanted to make sure this was clear.

I'm more confused than ever. Does the crankcase oil plug need to have a washer replaced with each oil change or not? Does this apply to the V6 as well as the I4?

[eiching1]

That's exactly my point. The reference in the owner's manual is for the "o" rings as stated by akirby. Both pertain to the oil filter not the oil pan drain plug. What seems really interesting is, if this is the case, where are these dealers coming up with a "washer" for the oil drain pan plug. Other than the one that is part of the plug itself.

[Meelaan]

That's exactly my point. The reference in the owner's manual is for the "o" rings as stated by akirby. Both pertain to the oil filter not the oil pan drain plug. What seems really interesting is, if this is the case, where are these dealers coming up with a "washer" for the oil drain pan plug. Other than the one that is part of the plug itself.

 

This is exactly the problem. The language is confusing and Ford has not communicated properly with dealers who service these vehicles. It's a recipe for disaster.

 

Can anyone please tell me exactly what an "oil filter drain plug" is? I've been changing my oil for over ten years and there are two parts that get removed during an oil change: 1.) the filter and 2.) the drain plug.

 

The language in the manual confused the hell out of me because they've effectively merged the two into one by saying the O-ring on the oil filter drain plug has to be replaced. What the hell is that?

 

This is where my issue arose.

 

The drain plug is the drain plug. The oil filter is the oil filter. If you say "drain plug" there is only one possible thing that can be.

 

Ford did a great job confusing something so simple. Now they need to address this language. I fully anticipate such an event happening.

[eiching1]

This is exactly the problem. The language is confusing and Ford has not communicated properly with dealers who service these vehicles. It's a recipe for disaster.

 

Can anyone please tell me exactly what an "oil filter drain plug" is? I've been changing my oil for over ten years and there are two parts that get removed during an oil change: 1.) the filter and 2.) the drain plug.

 

The language in the manual confused the hell out of me because they've effectively merged the two into one by saying the O-ring on the oil filter drain plug has to be replaced. What the hell is that?

 

This is where my issue arose.

 

The drain plug is the drain plug. The oil filter is the oil filter. If you say "drain plug" there is only one possible thing that can be.

 

Ford did a great job confusing something so simple. Now they need to address this language. I fully anticipate such an event happening.

[eiching1]

Meelaan, Due to the design of the "filter system" on the Fusion and Milan, there is an "oil filter drain plug" Our cars do not use a cartridge filter like most other cars do. There is a canister that has a cap (cover) that screws on from the bottom which houses a filter "cartridge" (paper filter, looks kind of like a small, tall air filter). The oil filter drain plug at the bottom of this cover allows you to drain the oil out of the filter canister before removing it. Otherwise when removing the cap the oil; would spill out all over the place. So, the "o" rings in the note in the manual are for the "oil filter drain plug" and the "oil filter cap"Check this link for the Mazda's that show it pretty clearly. Hope this helps. Ford should just put a standard filter on like the rest of the world!

 

http://www.mazda6tech.com/articles/mainten...4&Itemid=51

[Meelaan]

Meelaan, Due to the design of the "filter system" on the Fusion and Milan, there is an "oil filter drain plug" Our cars do not use a cartridge filter like most other cars do. There is a canister that has a cap (cover) that screws on from the bottom which houses a filter "cartridge" (paper filter, looks kind of like a small, tall air filter). The oil filter drain plug at the bottom of this cover allows you to drain the oil out of the filter canister before removing it. Otherwise when removing the cap the oil; would spill out all over the place. So, the "o" rings in the note in the manual are for the "oil filter drain plug" and the "oil filter cap"Check this link for the Mazda's that show it pretty clearly. Hope this helps. Ford should just put a standard filter on like the rest of the world!

 

http://www.mazda6tech.com/articles/mainten...4&Itemid=51

 

My God...

What the hell is that?

 

I had no idea. Why would Ford choose to do this? It's the 21st century. Are they aware that oil filters for every other car in production come complete and in one box? Yeah... you just take the old one off and screw the new one on. Done.

 

Here we have six different pieces that require assembly. I'm changing oil, not getting a mechanical engineering degree.

 

The manual makes no reference to this bizarre and unecessary elaborate setup. And there's the whole story. If they would have just shown a damn illustration like that one (http://www.wam.umd.edu/~greghess/scans/oilchange/6ioilchange.gif) I'd have been able to draw conclusions.

 

This doesn't change the fact that Ford's dealer network has not been made aware of the required O-ring change.

[eiching1]

My God...

What the hell is that?

 

I had no idea. Why would Ford choose to do this? It's the 21st century. Are they aware that oil filters for every other car in production come complete and in one box? Yeah... you just take the old one off and screw the new one on. Done.

 

Here we have six different pieces that require assembly. I'm changing oil, not getting a mechanical engineering degree.

 

The manual makes no reference to this bizarre and unecessary elaborate setup. And there's the whole story. If they would have just shown a damn illustration like that one (http://www.wam.umd.edu/~greghess/scans/oilchange/6ioilchange.gif) I'd have been able to draw conclusions.

 

This doesn't change the fact that Ford's dealer network has not been made aware of the required O-ring change.

[eiching1]

I believe they are well aware of the "o" rings requiring replacement. However, as I stated before the "o" ring or crush washer for the oil drain pan plug is a different issue. Again, it is quite interesting that the dealer found a solution for this replacement since it is a integeral part of the oil pan drain plug. Other than the parts guy that stated it is "optional " and you need to replace the oil pan drain plug, I think the others should be shot! If it's the same parts guy that found a replacement washer, I would be interested in what he found. Sounds like the dealership needs to have their "o" rings replaced due to some oil loss.

[akirby]

Isn't it a Mazda thing?

[Meelaan]

Isn't it a Mazda thing?

 

Same motors. Fusion/Milan/MKZ share the Mazda 6 platform. Fusion and Milan also share the same powertrain configurations.

[akirby]

Same motors. Fusion/Milan/MKZ share the Mazda 6 platform. Fusion and Milan also share the same powertrain configurations.

 

I know all about the platform sharing. The Fusion/Milan/MKZ platform is a modified Mazda6 platform that was further modified for the MKX and Edge. Fusion and Milan have the exact same engines and Fusion/Milan/MKZ all use the same Aisin 6 speed automatic tranny. They also share engines with Mazda. I believe the cartridge type oil filter was a Mazda invention that Ford decided to use on the I4 for whatever reason. I don't think any other FoMoCo products use it.

[mtl1977]

Fusion/Milan/MKZ all use the same Aisin 6 speed automatic tranny.

 

So does the Mazda6 and some Volvos...

[tapadav]

Ford Fusion and Mercury Milan require oil drain plug washer changes during each oil change but many dealerships are unaware of the requirement leading to potential issues with oil leaks and fires. The washer is available separately for $7.30 but dealerships often charge $8.00 to add it on as an optional service. Honda had a similar issue leading to car fires and Ford could be setting themselves up for disaster if the issue is not addressed.