Mercon V is actually what is specified for 2008 & up M5OD, so in theory that should be fine in a '10 (a synthetic like Royal Purple or Redline should be fine also... I put RP in my '90 and it seemed like maybe I picked up a teensy bit more power to the wheels in all gears but 4th, but it could also be placebo effect, I'm not sure... I've not dyno'ed it).
The fill & drain plugs on the M5OD do use crush washers. I've reused them at least half-dozen times w/o issue (my factory Ford service books also make no mention of needing to replace any washers or seals on the M5OD when changing fluid). The only NPT plugs that come to mind are fill plugs for the axles, and the t-case fill & drain.
Not NPT on the trans. Got it.
I find it weird that the books dont advise to replace crush washers. They only crush once and that's it. Like stretch bolts. They can only get so tight until they give and over stretch which decreases the clamping/fastening capabilities.
I have that book too. All of them in fact. If you want to get out the torque wrench for every tiny fastener and replace the drain plug every time, more power to you.
I also have over a decade of day-in day-out practical experience that tells me most of those torque specs were issued because the legal department said to and not because it is critical to torque them exactly to spec each time, and that those drain plugs can go 100K miles or more before they start to leak.
If it is an electric shift transfer case I'd use actual transfer case fluid. If it is manual either t-case fluid or Mercon are OK.
For the diffs just use a high quality gear oil of the correct weight, and a factory diff cover. The shape of the cover makes large contributions to the oil flow and heating/cooling characteristics of the diff, and many after-market covers give up that flow characteristic in favor of a larger sump, and end up working the oil harder and running the diff hotter.
So not NPT on the trans. Got it.
I dont use tq specs on ever nut and bolt. I'm not going to use it for the windshield wiper fluid reservoir.
But something that holds in crucial oil, I'm willing to follow the book.
You have the book? I'm a VW mechanic. Ford is kinda new to me. Is the aforementioned book a good starting point or did I waste my money?
This is where I need my hand held and Explain it like I'm 5.
What do you mean by "Electric shifter"? I have a 5speed manual transmission. Do you mean to put it into 4x4? For that, I have a dial in the cab. I'm going to assume that's what you're talking about. "2hi(?)", "4hi" & "4low". I think that is electric, unless its turning cable and pulleys to change between them.
Assuming it is electric, what brand do you recommend I go with? Do you know if Redline sells something for it?
Diff cover. I watched a thing by Banks about diff cover shapes. All the big names with larger capacity having flat plains making the oil work harder and whatnot. So I've been looking into rounder ones.
The G2 is pretty round. You dont think it's good enough?
If not that then how about the mustang "Ford Performance" diff cover. That's aluminum and finned and round.
If I'm just trying to re-invent the wheel, and all of this has been covered in depth in another thread, please let me know and share a link. I'll just go read that. But I dont see how atleast the "Ford Performance" cover is not better.
Diff oil. What do you mean by "high quality"? Like redline 75w90 full synethic gear oil? Or is OEM Ford fluid quality?
One more thing. Diff cover sealant. Or is it a gasket? I looked around and, I'm trying to keep up on different codes and MY they were on, but I read some 8.8 covers used a gasket from the factory while other used a clear silicone and yet OTHERS use the same OEM grey silicone that is used on the (I think) 12" diff for the 7.3 international engine(?). I dont know. 12" different sounds freaking huge so I'm probably wrong on that. However, that 7.3 is a beast.
Not to blow my own horn but I'm pretty mechanical savy. I've been doing the VW thing since I was a wee lad. My dad brought me up on aircooled VWs. I learned how to adjust valves on them when I was 10 or 11 and it's been down hill from there lol. I rebuilt a 5 speed tranny, from an '88 Ranger XLT with the 2.9 V6, my Junior year in hs. I've built 4bangers and big blocks. Petrol and diesel. 5 and 6 speed, FWD, RWD, AWD. Hadn't touched autos (other than DSG fluid changes). Now I have my own house and a 2 car garage that's filled with tools. I have a 30g air tank with 1" hose, 1/2" and 3/4" IR impacts, 20ton hydraulic press, engine hoist and stand, 4 tool boxes. The list goes on. Now. I'm not claiming to be a professional and it seems you're the real deal. Im just letting you know, I can do work and I take pride in my work manship. Now, I know these are apples and nazi oranges, (Ford and VW) but there are a good handful of OEM VW/Audi fluids are quality and hard to beat. Just a little insight why I'm going down this rabbit hole of oils and whatnot.