1999 Ford E 150 Owners Manual

+–

4. Remove the jumper cable from the positive (+) terminal of the disabled vehicle’s battery. After the disabled vehicle has been started and the jumper cables removed, allow it to idle for several minutes so the engine computer can relearn its idle conditions.

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Roadside emergencies

WRECKER TOWING

If you need to have your vehicle towed, contact a professional towing service or, if you are a member, your roadside assistance center. It is recommended that your vehicle be towed with a wheel lift or flatbed equipment. A towing manual is available from Ford Motor Company for all authorized tow truck operators. Have your tow truck driver refer to this manual for proper hook-up and towing procedures for your vehicle.

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SERVICE RECOMMENDATIONS To help you service your vehicle: † We highlight do-it-yourself items in the engine compartment for easy † We provide a “Service Guide” which makes tracking routine service

location.

easy.

If your vehicle requires professional service, your dealership can provide necessary parts and service. Check your “Warranty Guide” to find out which parts and services are covered. Use only recommended fuels, lubricants, fluids and service parts conforming to specifications. Motorcraft parts are designed and built to provide the best performance in your vehicle.

PRECAUTIONS WHEN SERVICING YOUR VEHICLE Be especially careful when inspecting or servicing your vehicle. † Do not work on a hot engine. † When the engine is running, make sure that loose clothing, jewelry or † Do not work on a vehicle with the engine running in an enclosed † Keep all lit cigarettes, open flames and other lit material away from

space, unless you are sure you have enough ventilation.

long hair does not get caught up in moving parts.

the battery and all fuel related parts.

If you disconnect the battery, the engine must “relearn” its idle conditions before your vehicle will drive properly, as explained in Battery in this chapter.

Working with the engine off 1. Set the parking brake and ensure the gearshift is securely latched in P (Park). 2. Turn off the engine and remove the key. 3. Block the wheels to prevent the vehicle from moving unexpectedly.

Working with the engine on 1. Set the parking brake and ensure the gearshift is securely latched in P (Park). 2. Block the wheels to prevent the vehicle from moving unexpectedly.

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Do not start your engine with the air cleaner removed and do not remove it while the engine is running.

OPENING THE HOOD 1. Inside the vehicle, pull the hood release handle located under the bottom left corner of the instrument panel.

PUSH

ON

PUSH OFF

HOOD

2. Go to the front of the vehicle and release the auxiliary latch that is located in the center top of the grill.

3. Lift the hood and secure it with the prop rod.

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Maintenance and care

IDENTIFYING COMPONENTS IN THE ENGINE COMPARTMENT

Engine compartment component locations

1. Windshield washer fluid reservoir 2. Engine oil filler cap 3. Automatic transmission fluid dipstick 4. Air filter assembly 5. Engine oil dipstick 6. Power steering fluid reservoir 7. Brake fluid reservoir 8. Engine coolant reservoir 9. Battery

ENGINE OIL

Checking the engine oil Refer to the maintenance guide and or service guide for the appropriate intervals for checking the engine oil. 1. Make sure the vehicle is on level ground. 2. Turn the engine off and wait a few minutes for the oil to drain into the oil pan.

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3. Set the parking brake and ensure the gearshift is securely latched in P (Park). 4. Open the hood. Protect yourself from engine heat. 5. Locate and carefully remove the engine oil level indicator (dipstick).

MIN

MAX

6. Wipe the indicator clean. Insert the indicator fully, then remove it again. † If the oil level is between the MIN and MAX marks, the oil level is acceptable. DO NOT ADD OIL. † If the oil level is below the MIN mark, add enough oil to raise the level within the MIN-MAX range.

† Oil levels above the MAX mark may cause engine damage. Some oil

must be removed from the engine by a service technician.

7. Put the indicator back in and ensure it is fully seated.

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Maintenance and care

Adding engine oil 1. Check the engine oil. For instructions, refer to Checking the engine oil in this chapter. 2. If the engine oil level is not within the MIN and MAX ranges, add only certified engine oil of the recommended viscosity. Remove the engine oil filler cap and use a funnel to pour the engine oil into the opening. 3. Recheck the engine oil level. Make sure the oil level is not above the MAX mark on the dipstick.

Engine oil and filter recommendations Look for this certification mark.

Ford oil specification is WSS-M2C153-G. Use SAE 5W-30 motor oil certified for gasoline engines by the American Petroleum Institute. Do not use supplemental engine oil additives, oil treatments or engine treatments. They are unnecessary and could, under certain conditions, lead to engine damage which is not covered by your warranty. Change your engine oil and filter according to the appropriate schedule listed in the maintenance guide and or service guide. Ford production and aftermarket (Motorcraft) oil filters are designed for added engine protection and long life. If a replacement oil filter is used that does not meet Ford material and design specifications, startup engine noises or knock may be experienced. It is recommended you use the appropriate Motorcraft oil filter (or another brand meeting Ford specifications) for your engine application.

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Maintenance and care

BRAKE FLUID

Checking and adding brake fluid Brake fluid should be checked and refilled as needed. Refer to the maintenance guide and or service guide for the service interval schedules: 1. Clean the reservoir cap before removal to prevent dirt or water from entering the reservoir.

2. Visually inspect the fluid level. 3. If necessary, add brake fluid until the level reaches MAX. Do not fill above this line. 4. Use only a DOT 3 brake fluid certified to meet Ford specifications. Refer to Lubricant specifications in the Capacities and specifications chapter.

MAX

Brake fluid is toxic.

If you use a brake fluid that is not DOT 3, you will cause permanent damage to your brakes.

Do not let the reservoir for the master cylinder run dry. This may cause the brakes to fail.

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Maintenance and care

WINDSHIELD WASHER FLUID

Checking and adding washer fluid Check the washer fluid whenever you stop for fuel. The reservoir is highlighted with a If the level is low, add enough fluid to fill the reservoir. In very cold weather, do not fill the reservoir all the way.

symbol.

Do not put engine coolant in the container for the windshield washer fluid.

ENGINE COOLANT Check the level of the engine coolant in the reservoir. Refer to the maintenance guide and or service guide for service interval schedules. Be sure to read and understand Precautions when servicing your vehicle in this chapter.

COLD FILL LEVEL

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Maintenance and care

If the engine coolant has not been checked at the recommended interval, the engine coolant reservoir may become empty. If this occurs, add engine coolant to the reservoir. For more information on engine coolant maintenance, refer to Adding engine coolant in this chapter. Automotive fluids are not interchangeable; do not use engine coolant, antifreeze or windshield washer fluid outside of its specified function and vehicle location.

Adding engine coolant

Do not put engine coolant in the container for the windshield washer fluid.

Do not mix conventional green coolant, orange coolant or recycled coolants together in your vehicle. Use only the type of coolant that your vehicle was originally equipped with. If you are unsure which type of coolant your vehicle requires, contact your local dealer. If sprayed on the windshield, engine coolant could make it difficult to see through the windshield. When the engine is cool, add a 50/50 mixture of engine coolant and water to the engine coolant reservoir-DO NOT ADD DIRECTLY TO THE RADIATOR. Add straight water only in an emergency, but you should replace it with a 50/50 mixture of coolant and distilled water as soon as possible. Check the coolant level in the coolant reservoir the next few times you drive the vehicle. If necessary, add enough of a 50/50 mixture of coolant and water to bring the liquid level to the fill line on the reservoir.

Never remove the coolant reservoir cap while the engine is running or hot.

If you must remove the coolant reservoir cap, follow these steps to avoid personal injury: 1. Before you remove the cap, turn the engine off and let it cool. 2. When the engine is cool, wrap a thick cloth around the cap. Slowly turn cap counterclockwise until pressure begins to release. 3. Step back while the pressure releases.

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4. When you are sure that all the pressure has been released, use the cloth to turn it counterclockwise and remove the cap. Change your engine coolant according to the appropriate schedule listed in the maintenance guide and or service guide. Before adding engine coolant, check the color of the coolant in your vehicle. For vehicles with green coolant, use Ford Premium Cooling System Fluid E2FZ-19549–AA (in Canada, Motorcraft CXC-8–B) or an equivalent premium engine coolant that meets Ford specification ESE-M97B44–A. Do not add orange coolant or recycled coolant to your vehicle originally equipped with conventional green coolant. For vehicles with orange coolant, use Ford Extended Life Engine Coolant F6AZ-19544–AA or a DEX-COOLt equivalent that meets Ford specification WSS-M97B44–D. Do not add conventional green coolant or recycled coolant to your vehicle originally equipped with orange coolant. Do not use alcohol or methanol antifreeze or any engine coolants mixed with alcohol or methanol antifreeze. Do not use supplemental coolant additives in your vehicle. These additives may harm your engine cooling system. The use of an improper coolant may void your warranty of your vehicle’s engine cooling system.

Recycled engine coolant Ford Motor Company recommends that Ford and Lincoln-Mercury dealers use recycled engine coolant produced by Ford-approved processes. For vehicles with green coolant, not all coolant recycling processes produce coolant which meets Ford specification ESE-M97B44–A, and use of such coolant may harm engine and cooling system components. For vehicles with orange coolant, no recycling process has been approved at this time and use of such coolant may harm engine and cooling system components.

Always dispose of used automotive fluids in a responsible manner.

Follow your community’s regulations and standards for recycling and disposing of automotive fluids.

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Maintenance and care

Coolant refill capacity To find out how much fluid your vehicle’s cooling system can hold, refer to Refill capacities in the Capacities and specifications chapter. Have your dealer check the engine cooling system for leaks if you have to add more than 1.0 liter (1.0 quart) of engine coolant per month.

Severe winter climate If you drive in extremely cold climates (less than –36°C [–34°F]), it may be necessary to increase the coolant concentration above 50%. Refer to the chart on the coolant container to ensure the coolant concentration in your vehicle is such that the coolant will not freeze at the temperature level in which you drive during winter months. Never increase the engine coolant concentration above 60%. Leave a 50/50 mixture of engine coolant and water in your vehicle year-round in non-extreme climates.

What you should know about fail-safe cooling (if equipped) If the engine coolant supply is depleted, this feature allows the vehicle to be driven temporarily before incremental component damage is incurred. The “fail-safe” distance depends on ambient temperatures, vehicle load and terrain. Howfail-safecoolingworks If the engine begins to overheat: † the engine coolant temperature gauge will move to the red (hot) area. † the † the † the Service Engine Soon

symbol will illuminate.

symbol will illuminate.

indicator light will illuminate.

If the engine reaches a preset over-temperature condition, the engine will automatically switch to alternating cylinder operation. Each disabled cylinder acts as an air pump and cools the engine. When this occurs the vehicle will still operate, however: † the engine power will be limited. † the air conditioning system will be disabled.

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Continued operation will increase the engine temperature and the engine will completely shut down, causing steering and braking effort to increase. Once the engine temperature cools, the engine can be re-started. Take your vehicle to a service facility as soon as possible to minimize engine damage. Whenfail-safemodeisactivated You have limited engine power when in the fail-safe mode, so drive the vehicle with caution. The vehicle will not be able to maintain high-speed operation and the engine will run rough. Remember that the engine is capable of completely shutting down automatically to prevent engine damage, therefore: 1. Pull off the road as soon as safely possible and turn off the engine. 2. Arrange for the vehicle to be taken to a service facility. 3. If this is not possible, wait a short period for the engine to cool. 4. Check the coolant level and replenish if low.

Never remove the coolant reservoir cap while the engine is running or hot.

5. Re-start the engine and take your vehicle to a service facility.

Driving the vehicle without repairing the engine problem increases the chance of engine damage. Take your vehicle to a

service facility as soon as possible.

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Maintenance and care

CHECKING AND ADDING POWER STEERING FLUID Check the power steering fluid. Refer to the maintenance guide and or service guide for the service interval schedules. If adding fluid is necessary, use only MERCONt ATF.

Check the fluid level when it is at ambient temperature, 20° – 80° F (-7° – 25° C): 1. Check the fluid level on the dipstick. It should be between the arrows in the FULL COLD range. Do not add fluid if the level is within this range. 2. If the fluid level is low, start the engine. 3. While the engine idles, turn the steering wheel left and right several times. 4. Turn the engine off.

For E-SuperDuty vehicles with the Hydro-Boost Brake System, do not press the brake pedal after the engine has been turned

off.

5. Recheck the fluid level on the dipstick. Do not add fluid if the level is between the arrows in the FULL COLD range.

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Maintenance and care

6. If the fluid is low, add fluid in small amounts, continuously checking the level until it reaches the FULL COLD range. Be sure to put the dipstick back in the reservoir.

TRANSMISSION FLUID

Checking automatic transmission fluid Refer to your maintenance guide and or service guide for scheduled intervals for fluid checks and changes. Your transmission does not consume fluid. However, the fluid level should be checked if the transmission is not working properly, i.e., if the transmission slips or shifts slowly or if you notice some sign of fluid leakage. Automatic transmission fluid expands when warmed. To obtain an accurate fluid check, drive the vehicle until it is warmed up (approximately 30 km [20 miles]). If your vehicle has been operated for an extended period at high speeds, in city traffic during hot weather or pulling a trailer, the vehicle should be turned off for about 30 minutes to allow fluid to cool before checking. 1. Drive the vehicle 30 km (20 miles) or until it reaches normal operating temperature. 2. Park the vehicle on a level surface and engage the parking brake. 3. With the parking brake engaged and your foot on the brake pedal, start the engine and move the gearshift lever through all of the gear ranges. Allow sufficient time for each gear to engage. 4. Latch the gearshift lever in P (Park) and leave the engine running. 5. Remove the dipstick, wiping it clean with a clean, dry lint free rag. 6. Install the dipstick making sure it is fully seated in the filler tube. 7. Remove the dipstick and inspect the fluid level. The fluid should be in the designated areas for normal and room temperature. Lowfluidlevel Do not drive the vehicle if the fluid level is at the bottom of the dipstick and the outside temperatures are above 10°C (50°F). Correctfluidlevel The transmission fluid should be checked at normal operating temperatures 66°C-77°C (150°F-170°F) on a level surface. The normal

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Maintenance and care

operating temperature can be reached after approximately 30 km (20 miles) of driving. However, you can check the fluid without driving if the outside temperatures are above 10°C (50°F). If fluid is added at this time, an overfill condition could result when the vehicle reaches normal operating temperature. The transmission fluid should be in this range if at normal operating temperature (66°C-77°C [150°F-170°F]). The transmission fluid should be in this range if at room temperature (10°C-35°C [50°F-95°F]).

Highfluidlevel Fluid levels above the safe range may result in transmission failure. An overfill condition of transmission fluid may cause shift and/or engagement concerns and/or possible damage. High fluid levels can be caused by an overheating condition. Adjustingautomatictransmissionfluidlevels Before adding any fluid, make sure the correct type is used. The type of fluid used is normally indicated on the dipstick and/or dipstick handle and also in the Lubricant specifications section in the Capacities and specifications chapter. Use of a non-approved automatic transmission fluid may cause internal transmission component damage. If necessary, add fluid in 250 mL (1/2 pint) increments through the filler tube until the level is correct. If an overfill occurs, excess fluid should be removed by a qualified technician. An overfill condition of transmission fluid may cause shift and/or engagement concerns and/or possible damage.

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Maintenance and care

DRIVELINE UNIVERSAL JOINT AND SLIP YOKE Your vehicle may be equipped with universal joints that require lubrication. Refer to the maintenance guide and or service guide for maintenance intervals. If the original universal joints are replaced with universal joints equipped with grease fittings, lubrication will also be necessary.

BATTERY Your vehicle is equipped with a Motorcraft maintenance-free battery which normally does not require additional water during its life of service.

However, for severe usage or in high temperature climates, check the battery electrolyte level. Refer to the maintenance guide and or service guide for the service interval schedules. Keep the electrolyte level in each cell up to the “level indicator”. Do not overfill the battery cells. If the electrolyte level in the battery is low, you can add plain tap water to the battery, as long as you do not use hard water (water with a high mineral or alkali content). If possible, however, try to only fill the battery cells with distilled water. If the battery needs water often, have the charging system checked. If your battery has a cover/shield, make sure it is reinstalled after the battery has been cleaned or replaced. For longer, trouble-free operation, keep the top of the battery clean and dry. Also, make certain the battery cables are always tightly fastened to the battery terminals. If you see any corrosion on the battery or terminals, remove the cables from the terminals and clean with a wire brush. You can neutralize the acid with a solution of baking soda and water.

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Maintenance and care

Batteries normally produce explosive gases which can cause personal injury. Therefore, do not allow flames, sparks or lighted

substances to come near the battery. When working near the battery, always shield your face and protect your eyes. Always provide proper ventilation.

When lifting a plastic-cased battery, excessive pressure on the end walls could cause acid to flow through the vent caps,

resulting in personal injury and/or damage to the vehicle or battery. Lift the battery with a battery carrier or with your hands on opposite corners.

Keep batteries out of reach of children. Batteries contain sulfuric acid. Avoid contact with skin, eyes or clothing. Shield your eyes when working near the battery to protect against possible splashing of acid solution. In case of acid contact with skin or eyes, flush immediately with water for a minimum of 15 minutes and get prompt medical attention. If acid is swallowed, call a physician immediately.

Because your vehicle’s engine is electronically controlled by a computer, some control conditions are maintained by power from the battery. When the battery is disconnected or a new battery is installed, the engine must relearn its idle and fuel trim strategy for optimum driveability and performance. To begin this process: 1. Set your parking brake. 2. Put the gearshift in P (Park), turn off all accessories and start the engine. 3. Let the engine idle for at least one minute. 4. The relearning process will automatically complete as you drive the vehicle. † The vehicle may need to be driven 16 km (10 miles) or more to † If you do not allow the engine to relearn its idle trim, the idle quality

relearn the idle and fuel trim strategy.

of your vehicle may be adversely affected until the idle trim is eventually relearned.

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Maintenance and care

If the battery has been disconnected or a new battery has been installed, the clock and the preset radio stations must be reset once the battery is reconnected. † Always dispose of automotive batteries in a responsible manner. Follow your local authorized standards for disposal. Call your local authorized recycling center to find out more about recycling automotive batteries.

Disconnecting dual batteries (if equipped) The primary battery is located under the hood.

RECYCLE

The auxiliary battery is located on the passenger side frame rail.

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Maintenance and care

Gasolineengines Disconnect: 1. Disconnect the primary battery ground cable.

2. Disconnect the auxiliary battery frame ground. † Remove the ground bolt. † Pull the cable away from the frame and make sure that the cable does not contact the frame.

Connect: 1. Reconnect the auxiliary battery frame ground.

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Maintenance and care

2. Reconnect the primary battery ground cable.

Dieselengines Disconnect:

Secondary positive cable remains energized after disconnection. make sure the tool does not contact any ground surface.

1. Disconnect the secondary positive cable from the primary battery terminal.

2. Wrap the secondary positive cable with a non-conductive material to insulate.

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Maintenance and care

3. Disconnect the primary battery ground cable. 4. Disconnect the primary battery positive cable.

Connect:

Secondary positive cable remains energized after disconnection. make sure the tool does not contact any ground surface.

1. Reconnect the primary battery positive cable. 2. Reconnect the primary battery ground cable.

3. Unwrap the secondary positive cable and reconnect to the primary battery terminal.

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Maintenance and care

WINDSHIELD WIPER BLADES Check the wiper blades at least twice a year or when they seem less effective. Substances such as tree sap and some hot wax treatments used by commercial car washes reduce the effectiveness of wiper blades.

Checking the wiper blades If the wiper blades do not wipe properly, clean both the windshield and wiper blades using undiluted windshield wiper solution or a mild detergent. Rinse thoroughly with clean water. To avoid damaging the blades, do not use fuel, kerosene, paint thinner or other solvents.

Changing the wiper blades To replace the wiper blades: 1. Pull the wiper arm away from the windshield and lock into the service position. 2. Turn the blade at an angle from the wiper arm. Push the lock pin manually to release the blade and pull the wiper blade down toward the windshield to remove it from the arm. 3. Attach the new wiper to the wiper arm and press it into place until a click is heard.

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Maintenance and care

INFORMATION ABOUT TIRE QUALITY GRADES New vehicles are fitted with tires that have their Tire Quality Grade (described below) molded into the tire’s sidewall. These Tire Quality Grades are determined by standards that the United States Department of Transportation has set. Tire Quality Grades apply to new pneumatic tires for use on passenger cars. They do not apply to deep tread, winter-type snow tires, space-saver or temporary use spare tires, tires with nominal rim diameters of 10 to 12 inches or limited production tires as defined in Title 49 Code of Federal Regulations Part 575.104(c)(2). U.S. Department of Transportation-Tire quality grades: The U.S. Department of Transportation requires Ford to give you the following information about tire grades exactly as the government has written it.

Treadwear The treadwear grade is a comparative rating based on the wear rate of the tire when tested under controlled conditions on a specified government test course. For example, a tire grade 150 would wear one and one-half (1 1/2) times as well on the government course as a tire grade 100. The relative performance of tires depends upon the actual conditions of their use, however, and may depart significantly from the norm due to variations in driving habits, service practices, and differences in road characteristics and climate.

Traction AA A B C The traction grades, from highest to lowest are AA, A, B, and C. Those grades represent the tire’s ability to stop on wet pavement as measured under controlled conditions on specified government test surfaces of asphalt and concrete. A tire marked C may have poor traction performance.

The traction grade assigned to this tire is based on straight-ahead braking traction tests, and does not include

acceleration, cornering, hydroplaning or peak traction characteristics.

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Maintenance and care

Temperature A B C The temperature grades are A (the highest), B, and C, representing the tire’s resistance to the generation of heat and its ability to dissipate heat when tested under controlled conditions on a specified indoor laboratory test wheel. Sustained high temperature can cause the material of the tire to degenerate and reduce tire life, and excessive temperature can lead to sudden tire failure. The grade C corresponds to a level of performance which all passenger car tires must meet under the Federal Motor Vehicle Safety Standard No. 109. Grades B and A represent higher levels of performance on the laboratory test wheel than the minimum required by law.

The temperature grade for this tire is established for a tire that is properly inflated and not overloaded. Excessive speed,

underinflation, or excessive loading, either separately or in combination, can cause heat buildup and possible tire failure.

SERVICING YOUR TIRES

Checking the tire pressure † Use an accurate tire pressure gauge. † Check the tire pressure when tires are cold, after the vehicle has been

parked for at least one hour or has been driven less than 5 km (3 miles).

† Adjust tire pressure to recommended specifications found on the Tire

Pressure Label.

Improperly inflated tires can affect vehicle handling and can fail suddenly, possibly resulting in loss of vehicle control.

Tire rotation Because your vehicle’s tires perform different jobs, they often wear differently. To make sure your tires wear evenly and last longer, rotate them as indicated in the maintenance guide and or service guide. If you notice that the tires wear unevenly, have them checked. The following procedure applies to vehicles equipped with single rear wheels, if your vehicle is equipped with dual rear wheels it is recommended that only the front wheels be rotated (side to side).

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Maintenance and care † Four tire rotation

† Five tire rotation

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Maintenance and care

Replacing the tires Replace the tires when the wear band is visible through the tire treads.

Failure to follow these precautions may adversely affect the handling of the vehicle and make it easier for the driver to lose

control and roll over.

Tires that are larger or smaller than your vehicle’s original tires may also affect the accuracy of your speedometer.

SNOW TIRES AND CHAINS

Snow tires must be the same size and grade as the tires you currently have on your vehicle.

The tires on your vehicle have all weather treads to provide traction in rain and snow. However, in some climates, you may need to use snow tires and chains. If you need to use chains, it is recommended that steel wheels (of the same size and specifications) be used as chains may chip aluminum wheels. Follow these guidelines when using snow tires and chains: † Use only SAE Class S chains. † Install chains securely, verifying that the chains do not touch any † Drive cautiously. If you hear the chains rub or bang against your

wiring, brake lines or fuel lines.

vehicle, stop and re-tighten the chains. If this does not work, remove the chains to prevent damage to your vehicle.

† If possible, avoid fully loading your vehicle.

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Maintenance and care † Remove the tire chains when they are no longer needed. Do not use † The suspension insulation and bumpers will help prevent vehicle damage. Do not remove these components from your vehicle when using snow tires and chains.

tire chains on dry roads.

WHAT YOU SHOULD KNOW ABOUT AUTOMOTIVE FUELS

Important safety precautions

Do not overfill the fuel tank. The pressure in an overfilled tank may cause leakage and lead to fuel spray and fire.

If you do not use the proper fuel cap, the pressure in the fuel tank can damage the fuel system or cause it to work improperly

in a collision.

The fuel system may be under pressure. If the fuel cap is venting vapor or if you hear a hissing sound, wait until it stops before

completely removing the cap.

Automotive fuels can cause serious injury or death if misused or mishandled.

Observe the following guidelines when handling automotive fuel: † Extinguish all smoking materials

and any open flames before fueling your vehicle.

fueling.

† Always turn off the vehicle before † Automotive fuels can be harmful or fatal if swallowed. Fuel such as gasoline is highly toxic and if swallowed can cause death or permanent injury. If fuel is swallowed, call a physician immediately, even if no symptoms are immediately apparent. The toxic effects of fuel may not be visible for hours.

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Maintenance and care † Avoid inhaling fuel vapors. Inhaling too much fuel vapor of any kind

can lead to eye and respiratory tract irritation. In severe cases, excessive or prolonged breathing of fuel vapor can cause serious illness and permanent injury.

† Avoid getting fuel liquid in your eyes. If fuel is splashed in the eyes, remove contact lenses (if worn), flush with water for 15 minutes and seek medical attention. Failure to seek proper medical attention could lead to permanent injury.

† Fuels can also be harmful if absorbed through the skin. If fuel is

splashed on the skin and/or clothing, promptly remove contaminated clothing and wash skin thoroughly with soap and water. Repeated or prolonged skin contact with fuel liquid or vapor causes skin irritation. † Be particularly careful if you are taking “Antabuse” or other forms of disulfiram for the treatment of alcoholism. Breathing gasoline vapors, or skin contact could cause an adverse reaction. In sensitive individuals, serious personal injury or sickness may result. If fuel is splashed on the skin, promptly wash skin thoroughly with soap and water. Consult a physician immediately if you experience an adverse reaction.

Choosing the right fuel Use only UNLEADED FUEL. The use of leaded fuel is prohibited by law and could damage your vehicle. Do not use gasolines containing methanol. It can damage critical fuel systems components. Vehicles certified to meet California emission standards (indicated on the underhood Vehicle Emissions Control Information label) are designed to operate on California cleaner-burning, low-sulfur gasolines. If you have a California-certified vehicle and California cleaner—burning gasoline is not available when you refuel, your engine should perform adequately. However, the performance of the emission control devices and systems may be adversely affected. In New York and Massachusetts, which have adopted California’s emission standards without requiring the sale of California cleaner-burning gasoline, repairs to correct the effects of using non-California fuel may not be covered by the emissions warranty. Your vehicle was not designed to use fuel or fuel additives with metallic compounds, including manganese-based compounds containing (MMT). Repairs to correct the effects of using a fuel for which your vehicle was not designed may not be covered by your warranty.

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Maintenance and care

Octane recommendations Your vehicle is designed to use “Regular” unleaded gasoline with an (R+M)/2 octane rating of 87. We do not recommend the use of gasolines labeled as “Regular” that are sold with octane ratings of 86 or lower in high altitude areas. Do not be concerned if your engine sometimes knocks lightly. However, if it knocks heavily under most driving conditions while you are using fuel with the recommended octane rating, see your dealer or a qualified service technician to prevent any engine damage.

87(R+M)/2 METHOD

Fuel quality If you are experiencing starting, rough idle or hesitation driveability problems during a cold start, try a different brand of “Regular” unleaded gasoline. “Premium” unleaded gasoline is not recommended (particularly in the United States) because it may cause these problems to become more pronounced. If the problems persist, see your dealer or a qualified service technician. The American Automobile Manufacturers Association (AAMA) issued a fuel specification to provide information on high quality fuels that optimize the performance of your vehicle. We recommend the use of fuels that meet the AAMA specification if they are available. It should not be necessary to add any aftermarket products to your fuel tank if you continue to use a high-quality fuel.

Cleaner air Ford approves the use of gasolines to improve air quality, including reformulated gasolines that contain oxygenates up to 10% ethanol or 15% MTBE.

Running out of fuel Avoid running out fuel because this situation may have an adverse affect on modern powertrain components. If you have run out of fuel: † You may need to crank the engine several times before the system

starts to pump fuel from the tank to the engine.

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Maintenance and care † Your “Service Engine Soon” light may come on. For more information

on the “Service Engine Soon” light, refer to the Instrumentation chapter.

Fuel Filler Cap Your fuel tank filler cap has an indexed design with a one-eighth turn on/off feature. When fueling your vehicle: 1. Turn the engine off. 2. Carefully turn the filler cap counterclockwise 1/8 of a turn until it stops. 3. Pull to remove the cap from the fuel filler pipe. 4. To install the cap, align the tabs on the cap with the notches on the filler pipe. 5. Turn the filler cap clockwise 1/8 of a turn until it stops. If the “Service Engine Soon/Check Engine “ indicator comes on and stays on when you start the engine, the fuel filler cap may not be properly installed. Turn off the engine, remove the fuel filler cap and reinstall it being careful to align the cap properly. If you must replace the fuel filler cap, replace it with a genuine Ford or Motorcraft part. The customer warranty may be void for any damage to the fuel tank or fuel system if a genuine Ford or Motorcraft fuel filler cap is not used.

The fuel system may be under pressure. If the fuel filler cap is venting vapor or if you hear a hissing sound, wait until it stops

before completely removing the fuel filler cap. Otherwise, fuel may spray out and injure you or others.

If you do not use the proper fuel filler cap, the pressure in the fuel tank can damage the fuel system or cause it to work

improperly in a collision.

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Fuel Filter Your vehicle is equipped with a fuel filter that is mounted on the underbody. For fuel filter replacement, see your dealer or a qualified service technician. Refer to the maintenance guide and or service guide for the appropriate intervals for changing the fuel filter. If you replace the fuel filter, replace it with an authorized Motorcraft part. The customer warranty may be void for any damage to the fuel system if an authorized Motorcraft fuel filter is not used.

ESSENTIALS OF GOOD FUEL ECONOMY

Measuring techniques Your best source of information about actual fuel economy is you, the driver. You must gather information as accurately and consistently as possible. Fuel expense, frequency of fillups or fuel gauge readings are NOT accurate as a measure of fuel economy. We do not recommend taking fuel economy measurements during the first 1 600 km (1 000 miles) of driving (engine break-in period). You will get a more accurate measurement after 3 000 km–5 000 km (2 000 miles– 3 000 miles). The advertised fuel capacity of the fuel tank on your vehicle is equal to the rated refill capacity of the fuel tank as listed in the Refill Capacities chart in this “Owner Guide.” The advertised capacity is the amount of the Indicated Capacity and the Empty Reserve combined. Indicated Capacity is the difference in the amount of fuel in a full tank and a tank when the fuel gauge indicates empty. Empty Reserve is the small amount of usable fuel remaining in the fuel tank after the fuel gauge indicates empty. The amount of Empty Reserve varies and should not be relied upon to increase driving range. When refueling your vehicle after the fuel gauge indicates empty, you might not be able to refuel the full amount of the advertised capacity of the fuel tank due to the empty reserve still present in the tank.

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Maintenance and care

the tank is filled.

Filling the tank For consistent results: † Use the same filling rate setting (low — medium — high) each time † Allow three automatic click-offs when filling. † Always use the recommended octane rating of a known quality † Use the same side of the same pump and have the vehicle facing the † Have the vehicle loading and distribution the same every time. Your results will be most accurate if your filling method is consistent.

gasoline, preferably a national brand.

same direction each time you fill up.

Calculating fuel economy 1. Fill the fuel tank completely and record the initial odometer reading. 2. Each time you fill the tank, record the amount of fuel added (in liters or gallons). 3. After at least three to five tank fill-ups, fill the fuel tank and record the current kilometer (mileage) reading. 4. Follow one of the simple calculations in order to determine fuel economy: Multiply liters used by 100, then divide by total kilometers traveled. Divide total miles traveled by total gallons used. Keep a record for at least one month and record the type of driving (city or highway). This will provide an accurate estimate of the vehicle’s fuel economy. Additionally, keeping records during summer and winter will show how temperature impacts fuel economy. In general, lower temperatures give lower fuel economy.

Driving style — good driving and fuel economy habits Give consideration to the lists that follow and you may be able to change a number of variables and improve your fuel economy.

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Maintenance and care

fuel.

economy.

Habits † Smooth, moderate operation can yield up to 10% savings in fuel. † Steady speeds without stopping will usually give the best fuel † Idling for long periods of time (greater than one minute) may waste † Anticipate stopping; slowing down may eliminate the need to stop. † Sudden or hard accelerations may reduce fuel economy. † Slow down gradually. † Drive at reasonable speeds (traveling at 105 km/h [65 mph] uses 15% † Revving the engine before turning it off may reduce fuel economy. † Use of the air conditioner or defroster may reduce fuel economy. † Use of speed control (if equipped) may improve fuel economy. Speed control can help maintain a constant speed and reduce speed changes. You may want to turn off the speed control in hilly terrain as unnecessary shifting between third and fourth gears may occur and could result in reduced fuel economy.

more fuel than traveling at 88 km/h [55 mph]).

economy.

reduce fuel economy.

† Warming up a vehicle on cold mornings is not required and may † Resting your foot on the brake pedal while driving may reduce fuel † Combine errands and minimize stop-and-go driving. Maintenance † Keep tires properly inflated and use only recommended size. † Operating a vehicle with the wheels out of alignment will reduce fuel † Use recommended engine oil. Refer to Lubricant Specifications. † Perform all regularly scheduled maintenance items. Follow the recommended maintenance schedule and owner maintenance checks found in your vehicle maintenance guide and or service guide.

economy.

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Maintenance and care

at any speed.

Conditions † Heavily loading a vehicle or towing a trailer may reduce fuel economy † Carrying unnecessary weight may reduce fuel economy (approximately † Adding certain accessories to your vehicle (for example bug

2 km/h [1 mpg] is lost for every 180 kg [400 lb] of weight carried).

deflectors, rollover/light bars, running boards, ski/luggage racks) may reduce fuel economy.

two-wheel-drive operation.

12–16 km (8–10 miles) of driving.

cruise gear and with steady pressure on the gas pedal.

† Use of fuel blended with alcohol may lower fuel economy. † Fuel economy may decrease with lower temperatures during the first † Flat terrain driving improves fuel economy over hilly roads. † Transmissions give their best fuel economy when operated in the top † Four-wheel-drive operation (if equipped) is less fuel efficient than † Close windows for high speed driving. EPA window sticker Every new vehicle should have the EPA window sticker. Contact your dealer if the window sticker is not supplied with your vehicle. The EPA window sticker should be your guide for the fuel economy comparisons with other vehicles. It is important to note the box in the lower left corner of the window sticker. These numbers represent the Range of Km/L (MPG) expected on the vehicle, depending upon the driver’s method of operation and conditions.

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Maintenance and care

EMISSION CONTROL SYSTEM Your vehicle is equipped with various emission control components and a catalytic converter which will enable your vehicle to comply with applicable exhaust emission standards. To make sure that the catalytic converter and other emission control components continue to work properly: † Use only unleaded fuel. † Avoid running out of fuel. † Do not turn off the ignition while your vehicle is moving, especially at † Have the items listed in your maintenance guide and or service guide

high speeds.

performed according to the specified schedule.

The scheduled maintenance items listed in the maintenance guide and or service guide are essential to the life and performance of your vehicle and to its emissions system. If other than Ford, Motorcraft or Ford-authorized parts are used for maintenance replacements or for service of components affecting emission control, such non-Ford parts should be equivalent to genuine Ford Motor Company parts in performance and durability.

Do not park, idle, or drive your vehicle in dry grass or other dry ground cover. The emission system heats up the engine

compartment and exhaust system, which can start a fire.

Illumination of the charging system warning light, “Service Engine Soon” light or the temperature warning light, fluid leaks, strange odors, smoke or loss of oil pressure, could indicate that the emission control system is not working properly.

Exhaust leaks may result in entry of harmful and potentially lethal fumes into the passenger compartment.

Do not make any unauthorized changes to your vehicle or engine. By law, vehicle owners and anyone who manufactures, repairs, items, sells, leases, trades vehicles, or supervises a fleet of vehicles are not permitted to intentionally remove an emission control device or prevent it from working. Information about your vehicle’s emission system is on the Vehicle Emission Control Information Decal located on or near the

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Maintenance and care

engine. This decal identifies engine displacement and gives some tune up specifications. Please consult your “Warranty Guide” for complete emission warranty information.

Readiness for inspection/maintenance (I/M) testing In some localities, it may be a legal requirement to pass an I/M test of the on-board diagnostic (OBD-II) system. If your “Check Engine/Service Engine Soon” light is on, refer to the description in the Warning Lights and Chimes section of the Instrumentation chapter. Your vehicle may not pass the I/M test with the “Check Engine/Service Engine Soon” light on. If the vehicle’s powertrain system or its battery has just been serviced, the OBD-II system is reset to a “not ready for I/M test” condition. To ready the OBD-II system for I/M testing, a minimum of 30 minutes of city and highway driving is necessary as described below: † First, at least 10 minutes of driving on an expressway or highway. † Next, at least 20 minutes driving in stop-and-go, city-type traffic with

at least four idle periods.

Allow the vehicle to sit for at least eight hours without starting the engine. Then, start the engine and complete the above driving cycle. The engine must warm up to its normal operating temperature. Once started, do not turn off the engine until the above driving cycle is complete.

EXTERIOR BULBS

Replacing exterior bulbs Check the operation of the following lamps frequently: † Headlamps † Tail lamps † Brakelamps † High-mount brakelamp † Turn signals † Backup lamps † License plate lamp

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Maintenance and care

Do not remove lamp bulbs unless they will be replaced immediately. If a bulb is removed for an extended period of time, contaminants may enter the lamp housings and affect performance.

Replacing headlamp bulbs (aerodynamic)

Handle a halogen headlamp bulb carefully and keep out of children’s reach. Grasp the bulb only by its plastic base and do not touch the glass. The oil from your hand could cause the bulb to break the next time the headlamps are operated.

To remove the headlamp bulb: 1. Make sure headlamp switch is in OFF position. 2. Open the hood. 3. Push each clip tab toward the engine compartment and lift upward to the stop position. 4. Remove the headlamp assembly.

5. Release clip and disconnect the electrical connector from the bulb.

6. Remove the bulb retaining ring by rotating it counterclockwise (when viewed from the rear) about 1/8 turn to free it from the bulb socket, and slide the ring off the plastic base. Keep the ring to retain the new bulb. 7. Without turning, remove the old bulb from lamp assembly by gently pulling it straight back out of the lamp assembly and replace.

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Maintenance and care

To install the new bulb: 1. With the flat side of the bulb’s plastic base facing upward, insert the glass end of the bulb into the lamp assembly. You may need to turn the bulb left or right to align the grooves in the plastic base with the tabs in the lamp assembly. When the grooves are aligned, push the bulb into the socket until the plastic base contacts the rear of the lamp assembly. 2. Install the bulb retaining ring over the plastic base until it contacts the rear of the lamp assembly by rotating clockwise until you feel a “stop.” 3. Install the electrical connector into the rear of the plastic base until it snaps, locking it into position. 4. Install the headlamp assembly into the vehicle and secure it with the clip tabs. 5. Turn the headlamps on and make sure they work properly. If the headlamp was correctly aligned before you changed the bulb, you should not need to align it again. Replacingfrontparkinglamp/turnsignalbulbs 1. Make sure the headlamp control is in the OFF position. 2. Open the hood. 3. Rotate the bulb socket counterclockwise about ¼ turn and remove. 4. Carefully pull out the bulb straight out of the socket and push in new bulb.

5. To complete installation, follow the removal procedures in reverse order.

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Maintenance and care

High-mountbrakelampbulbs The interior cargo lamp (if equipped) will have to be removed from under the high-mount brakelamp assembly located inside the vehicle. To change the high-mount brakelamp bulbs: 1. Remove the two screws from the high-mount brakelamp assembly. 2. Remove the bulb from the lamp assembly by turning counterclockwise. 3. Carefully pull the bulb straight out of the socket and push in the new bulb. 4. Install bulb socket in lamp assembly by turning clockwise. 5. Install brakelamp assembly on the vehicle with two screws. Licenseplatelampbulbs To change the license plate bulbs: 1. Remove two screws and the license plate lamp assembly from the rear door. 2. Remove bulb socket from lamp assembly by turning counterclockwise. 3. Pull the bulb out from socket and push in the new bulb. 4. Install the bulb socket in lamp assembly turning it clockwise, 5. Install the lamp assembly on rear door with two screws.

Replacingtaillamp/backupbulbs For bulb replacement, see a dealer or qualified technician.

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Maintenance and care

Using the right bulbs

Function

Number of

Trade number

bulbs

Headlamps (low series) Headlamps (high series) Park lamp and turn signal (front) Back-up lamps License plate lamps Stop/tail/side marker lamp Turn lamp (rear) High-mount brakelamp Cargo lamp Dome lamp (standard) Map/reading lamp To replace all instrument panel lights - see your dealer

H5054
9007

3157 NAK

3156K

168

3357 K 3156K

912
211-2
912
211-2

AIMING THE HEADLAMPS The alignment of your headlamps should be checked by a qualified service technician if: † Oncoming motorists frequently signal you to deactivate your high † The headlamps do not seem to provide enough light for clear night † The headlamp beams are pointed substantially away from a slightly

beams, and your high beams are not activated.

vision.

down and to the right position.

CLEANING AND CARING FOR YOUR VEHICLE Refer to the “Customer Assistance Guide” for a list of Ford-approved cleaners, polishes and waxes.

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Maintenance and care

Washing your vehicle Wash your vehicle regularly with cold or lukewarm water. Never use strong detergents or soap. If your vehicle is particularly dirty, use a quality car wash detergent. Always use a clean sponge, washing glove or similar device and plenty of water for best results. To avoid spots, avoid washing when the hood is still warm, immediately after or during exposure to strong sunlight. During winter months, it is especially important to wash the vehicle on a regular basis. Large quantities of dirt and road salt are difficult to remove and also cause damage to the vehicle. Remove any exterior accessories, such as antennas, before entering a car wash. If you have wax applied to the vehicle at a commercial car wash, it is recommended that you clean the wiper blades and windshield as described in Cleaning the wiper blades and windshield. After washing, apply the brakes several times to dry them.

Waxing your vehicle Wax when water stops beading on the surface. This could be every three or four months, depending on operating conditions. Use only carnauba or synthetic-based waxes. Use cleaning fluid or alcohol with a clean cloth to remove any bugs and tar before waxing vehicle. Use tar remover to remove any tar spots. Avoid getting wax on the windshield. If you have wax applied at a commercial car wash, it is recommended that you clean the wiper blades and windshield as described in Cleaning the wiper blades and windshield.

Repairing paint chips Minor scratches or paint damage from road debris may be repaired with touch-up paint, repair foil or aerosol paint spray from the Ford accessory line. Observe the application instructions on the products. Remove particles such as bird droppings, tree sap, insect remains, tar spots, road salt and industrial fallout immediately.

184

Maintenance and care

Cleaning the wheels Wash with the same detergent as the body of your vehicle. Do not use acid-based or alcohol-based wheel cleaners, steel wool, fuel or strong detergents. Never use abrasives that will damage the finish of special wheel surfaces. Use a tar remover to remove grease and tar.

Cleaning the engine Engines are more efficient when they are clean because grease and dirt buildup keep the engine warmer than normal. When washing: † Take care when using a power washer to clean the engine. The high pressure fluid could penetrate the sealed parts and cause damage. † Do not spray with cold water to avoid cracking the engine block or

other engine components.

† Cover the highlighted areas to prevent water damage when cleaning † Never wash or rinse the engine while it is running; water in the

the engine.

running engine may cause internal damage.

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Maintenance and care

Cleaning plastic exterior parts Use vinyl cleaner for routine cleaning. Clean with a tar remover if necessary. Do not clean plastic parts with thinners, solvents or petroleum-based cleaners.

Cleaning the exterior lamps Wash with the same detergent as the exterior of your vehicle. Use glass cleaner or tar remover if necessary. To avoid scratching the lamps, do not use a dry paper towel, chemical solvents or abrasive cleaners.

Cleaning the wiper blades and windshield If the wiper blades do not wipe properly, clean the wiper blade rubber element with undiluted windshield washer solution or a mild detergent. To avoid damaging the blades, do not use fuel, kerosene, paint thinner or other solvents. If the wiper still does not wipe properly, this could be caused by substances on the windshield such as tree sap and some hot wax treatments used by commercial car washes. Clean the outside of the windshield with a non-abrasive cleanser such as the non-abrasive Bon-Amit powder. Rinse thoroughly with clean water. Do not use abrasive cleansers on glass as they may cause scratches. The windshield is clean if beads do not form when you rinse it with water. The windshield and wiper blades should be cleaned on a regular basis, and blades or rubber elements replaced when worn.

Cleaning the instrument panel Clean with a damp cloth, then dry with a dry cloth. Avoid cleaner or polish that increases the gloss of the upper portion of the instrument panel. The dull finish in this area helps protect the driver from undesirable windshield reflection.

Cleaning the interior fabric Remove dust and loose dirt with a whisk broom or a vacuum cleaner. Remove fresh spots immediately. Do not use household or glass cleaners. These agents can stain and discolor the fabric. Use a mild soap and water solution if necessary.

186

Maintenance and care

Cleaning and maintaining the safety belts Clean the safety belts with a mild soap solution recommended for cleaning upholstery or carpets. Do not bleach or dye the belts, because these actions may weaken the belt webbing. Check the safety belt system periodically to make sure there are no nicks, wear or cuts. If your vehicle has been involved in an accident, refer to the Safety belt maintenance section in the Seating and safety restraints chapter.

Underbody Flush the complete underside of vehicle frequently. Keep body drain holes unplugged. Inspect for road damage.

Inside windows Use glass cleaner for the inside windows if they become fogged.

187

Capacities and specifications

BH-65DC

BH-65DC

BH-65DC

BH-65DC

BXT-65-750

BXT-65-750

BXT-65-750 BXT-65-750

6.8L V10
engine FA-1634

FG-872
FL-400-S EV-152
AGSF- 34EE***

4.2L V6
engine FA-1634
BXT-65-650

4.6L V8
engine FA-1634
BXT-65-650

FG-872
FL-820-S EV-233
AWSF- 32PP****

5.4L V8
engine FA-1634
BXT-65-650 BXT-65-650

MOTORCRAFT PART NUMBERS Com- ponent* Air filter Battery (standard) Battery (optional) Battery (auxiliary) Fuel filter Oil filter PCV valve Spark plugs** *Refer to the 7.3 Liter Power Stroke Direct Injection Turbo Diesel Owner’s Guide Supplement for Motorcraft diesel engine service part numbers. **Refer to Vehicle Emissions Control Information (VECI) decal for spark plug gap information. ***If a spark plug is removed for inspection, it must be reinstalled in the same cylinder. Cylinders No. 1, 2 and 3 have a “EG” suffix. Cylinders No. 4, 5 and 6 have a “E” suffix. If a spark plug needs to be replaced, use only spark plugs with the service part number suffix letter “EE” as shown on the engine decal. **** If a spark plug is removed for inspection, it must be reinstalled in the same cylinder. Cylinders No. 1, 2, 3 and 4 have a “PG” suffix. Cylinders No. 5, 6, 7 and 8 have a “P” suffix. If a spark plug needs to be replaced, use only spark plugs with the service part number suffix letter as shown on the engine decal.

FG-872
FL-820-S EV-233
AWSF-22E

FG-872
FL-820-S EV-233
AWSF-22E

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Capacities and specifications

Ford Part Name High Performance DOT 3 Motor Vehicle Brake Fluid Motorcraft 5W30
Super Premium Motor Oil

Application

Capacity

All

All

Fill to line on reservoir

5.7L (6.0 quarts)

Refer to the 7.3L Power Stroke Direct Injection Turbo Diesel Owner’s Supplement.

REFILL CAPACITIES Fluid

Brake fluid

Engine oil-gasoline engine (includes filter change) Engine oil-diesel engine (includes filter change) Engine coolant-gasoline engine

4.2L V6 engine

4.2L V6 engine with aux rear heat 4.6L V8 engine

4.6L V8 engine with aux rear heat 5.4L V8 engine

22.0L (23.3 quarts) 24.0L (25.4 quarts)

23.7L (25.0 quarts) 25.7L (27.2 quarts)

27.4L (29.0 quarts) 29.4L (31.0 quarts)

(30.6 quarts) 31.0L (32.8 quarts)

5.4L V8 engine with aux rear heat 6.8L V10 engine 29.0L

6.8L V10 engine with aux rear heat

Engine coolant-diesel engine

Refer to the 7.3L Power Stroke Direct Injection Turbo Diesel Owner’s Supplement. 1

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Capacities and specifications

Fluid

Power steering fluid

Rear axle

Ford Part Name Motorcraft MERCONt ATF

Refer to footnote 4

Fuel tank

N/A

Application

Capacity

All

Ford 8.8/ 9.75 inch conventional and Traction-Lok Dana 9.75 inch (M60-IU) Dana 10.5 inch (M70-2U) Dana 10.5 inch (M70-1HD) Dana 11.25 inch (model 80) All regular and extended length vans and wagons 138 inch wheelbase (except E-Super Duty) 158 inch wheelbase (except E-Super Duty) 176 inch wheelbase (except E-Super Duty) 158 inch and 176 inch wheelbase (E-Super Duty)

Keep in FULL range on dispstick 2.6-2.7L (5.5-5.8 pints)2

3.0L (6.3 pints)3

3.1L (6.6 pints)3

3.5L (7.5 pints)3

3.9L (8.25 pints)4
132.4L (35.0 gallons)

140.0L (37.0 gallons)

140.0L (37.0 gallons)5

140.0L (37.0 gallons)

208.0L (55.0 gallons)

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Capacities and specifications

Fluid

Transmission6

Windshield washer fluid

Ford Part Name Motorcraft MERCONtV ATF Motorcraft MERCONt ATF Ultra-Clear Windshield Washer Concentrate

Application

Capacity

Automatic (4R70W)

Automatic (4R100)7
All

13.1L (13.9 quarts)

15.0L (15.9 quarts)8
Fill to line on reservoir

If your vehicle’s rear axle is filled with a synthetic rear axle lubricant it is considered lubricated for life. These lubricants do not need to be checked or changed unless a leak is suspected, service is required or the axle assembly has been submerged in water. The axle lubricant should be changed any time the rear axle has been submerged in water. 1 If your engine coolant is green in color, use Ford Premium Cooling System Fluid. If your coolant is orange in color, use Ford Extended Life Engine Coolant. Refer to Adding engine coolant, in the Maintenance and Care chapter. 2 Fill 6 mm to 14 mm (1/4 inch to 9/16 inch) below bottom of fill hole. Add 118 ml (4 oz.) of additive friction modifier C8AZ-19B546-A, Ford specification EST-M2C118–A, for complete refill of 8.8 inch and 9.75 inch Traction-Lok axles. 3 Fill Dana rear axles to 6 mm to 19 mm (1/4 inch to 3/4 inch) below bottom of fill hole. 4 Ford conventional and Traction-Lok axles, Dana 80 axle (E-Super Duty) and Dana axles on E-350 vans/wagons with 4.10:1 ratio require Motorcraft SAE 75W140 Synthetic Rear Axle Lubricant (part number F1TZ-19580–B). Add 118 ml (4 oz.) of friction modifier C8AZ-19B546-A, Ford specification EST-M2C118–A. Dana conventional and limited-slip axles require Motorcraft SAE 80W90 Premium Rear Axle Lubricant. Add 177ml (6 oz.) of additive friction modifier C8AZ-19B546-A, Ford specification EST-M2C118–A. 5 Optional fuel tank 208.0L (55 gallon). 6 Always use dipstick to determine exact fluid requirement.

191

Capacities and specifications

7 Ensure the correct automatic transmission fluid is used for a specific application. Check the container to verify the fluid is MERCONt approved. Transmission fluid requirements are indicated on the dipstick handle. Refer to the maintenance guide and or service guide. Do NOT use any non-approved automatic transmission fluid for an application specifying MERCONt. Use of a non-approved fluid may cause internal transmission component damage. 8 Indicates only approximate dry-fill capacity. Some applications may vary based on cooler size and if equipped with an in-tank cooler. The amount of transmission fluid and fluid level should be set by the indication on the dipstick’s normal operating range.

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Capacities and specifications

Ford Ford part number specification C6AZ-19542-AB ESA-M6C25-A

and DOT 3

LUBRICANT SPECIFICATIONS Item

Ford part name High Perfor- mance DOT 3
Motor Vehicle Brake Fluid Silicone Lubricant

Brake fluid

Door weatherstrips

Engine coolant

Engine oil-gasoline engine Engine oil-diesel engine Hinges, latches, Striker plates, fuel filler door hinge, and seat tracks Lock cylinders

Power steering fluid Automatic trans- mission (4R100)1
Automatic trans- mission (4R70W) Disc brake caliper rails

ESR-M13P4-A

C0AZ-19553-AA and F5AZ-19553-AA E2FZ-19549-AA ESE-M97B44-A

F6AZ-19544-AA WSS-M97B44-D or DEX-COOLt equivalent

Ford Premium Engine Coolant (green in color) Ford Extended Life Engine Coolant (orange in color) Motorcraft 5W30
Super Premium Motor Oil Refer to the 7.3 Liter Power Stroke Direct Injection Turbo Diesel Owner’s Guide Supplement. Multi-Purpose ESB-M1C93-B or ESR-M1C159-A Grease

XO-5W30-QSP WSS-M2C153-G with API Certi- fication Mark

D0AZ-19584-AA or F5AZ-19G209-AA

Penetrating Lubricant Motorcraft MERCONt ATF Motorcraft MERCONt ATF Motorcraft MER- CONtV ATF Silicone Brake Caliper and Dielectric compound

E8AZ-19501-B

none

XT-2-QDX

MERCONt

XT-2-QDX

MERCONt

XT-5-QM

MERCONtV

D7AZ-19A331-A WA-10

ESE-M1C171-A

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Capacities and specifications

Item

Parking brake assembly (E-Super Duty)

Ford conventional and Traction-Lok axles (E-150)2

Dana conven- tional and Traction-Lok axles (E-250/350) Dana 80 Axle (E-Super Duty)3

Windshield washer fluid

Ford part name Motorcraft MERCONt Automatic Transmission Fluid Motorcraft SAE 75W140 High Performance Synthetic rear axle lubricant Motorcraft SAE 80W90 Premium rear axle lubricant Motorcraft SAE 75W140 High Performance Synthetic rear axle lubricant Ultra-Clear Wind- shield Washer Concentrate

Ford part number XT-2-QDX

Ford specification MERCONt

F1TZ-19580-B

WSL-M2C192-A

XY-80W90-QL

WSP-M2C197-A

F1TZ-19580-B

WSL-M2C192-A

C9AZ-19550-AB ESR-M17P5-A

1 Refer to the dipstick for the type of transmission fluid required. Some fluid labels may indicate dual usage such as MERCONt and MERCON Vt. These dual usage fluids are not to be used in transmissions that use only the MERCONt type fluid. These dual usage fluids may be used in transmissions that require MERCONt V use. Using a transmission fluid that indicates a dual usage (MERCONt and MERCON Vt) in a transmission application requiring MERCONt may cause transmission damage. Use of any fluid other than the recommended fluid may cause transmission damage. 2 Add 118 ml (4 oz.) of EST-M2C118–A (friction modifier Part No. C8AZ-19B546–A) for complete refill of Ford Traction-Lok rear axles. 3 Add 237 ml (6 oz.) of EST-M2C118–A (friction modifier Part No. C8AZ-19B546–A) for complete refill of Dana Traction-Lok rear axles.

194

ENGINE DATA

Engine*

4.2L V6
engine

Cubic inches 256

Horsepower

Torque

Recom- mended fuel

Firing order

Spark plug gap

200 @ 4800 rpm 250 lb.-ft. @ 2800 rpm 87 octane

1-4-2-5-3-6

1.3-1.4 mm (0.052- 0.056 inch) EDIS

Capacities and specifications

4.6L V8
engine 281
215 @ 4500 rpm 290 lb.-ft. @ 3250 rpm 87 octane

5.4L V8
engine 330
235 @ 4450 rpm 335 lb.-ft. @ 3000 rpm 87 octane

6.8L V10
engine 415
265 @ 4250 rpm 405 lb.-ft. @ 2750 rpm 87 octane

1-3-7-2- 6-5-4-8
1.3-1.4 mm (0.052- 0.056 inch) EDIS

1-6-5-10-2- 1-3-7-2- 7-3-8-4-9
6-5-4-8
1.3-1.4 mm 1.3-1.4 mm (0.052- (0.052- 0.056 inch) 0.056 inch) Coil on plug Coil on plug

Ignition system Compression ratio *Refer to the 7.3 Liter Power Stroke Direct Injection Turbo Diesel Owner’s Guide Supplement for diesel engine information.

9.0:1

9.3:1

9.0:1

9.0:1

VEHICLE DIMENSIONS

Van/wagon models

(1) Overall height

(2) Track front/rear (3) Overall width (excluding mirrors) (4) Wheelbase (5) Overall length

E-250

E-150

2 054.8 mm

E-350
2 136.1
(84.1 in) 1 762.8 mm (69.4 in)/ 1 701.8 mm (67.0 in)

2 118.4 mm

(80.9 in)

(83.4)

2 014.2 mm (79.3 in)

3 505 mm (138 in)

Regular van, 5 379.7 mm (211.8 in) Supervan, 5 892.8 mm (232.0 in)

195

Capacities and specifications

196

Capacities and specifications

Cutaway/commercial stripped chassis models

(1) Overall height (2) Track front/rear

(3) Overall width (excluding mirrors) (4) Wheelbase

E-250
Refer to Body Builder for specifications

E-350

E-Super Duty

1 762.8 mm (69.4 in)/ 1 701.8 mm (67.0 in)

1 762.8 mm (69.4 in.)/ SRW 1 701.8
mm (67.0 in.), DRW 1 859.3
mm (73.2 in.)

1 762.8 mm (69.4 in.)/ 1 973.6 mm (77.7 in.)

Refer to Body Builder for specifications.

3 149.6 mm (124 in)

3 505 mm (138 in.) 4 013 mm (158 in.) 4 470 mm (176 in.)

4 013 mm (158 in.) 4 470 mm (176 in.)

(5) Overall length

Refer to Body Builder for specifications.

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Capacities and specifications

VEHICLE IDENTIFICATION NUMBER

Complete Ford built vehicles The vehicle identification number is attached to your vehicle in the following places: † On the metal tag attached to the top of the instrument panel on the † On the safety compliance

driver’s side.

certification label. This label is required by the National Highway Traffic Safety Administration and is made of special material. If it is tampered with, it will be destroyed or a destruction pattern will appear.

Incomplete vehicles On completed derivations of incomplete vehicles, the safety compliance certification label is affixed at a location determined by a subsequent stage manufacturer of the completed vehicle. In these cases the completed vehicle is manufactured in two or more stages by two or more separate manufacturers.

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Reporting safety defects

REPORTING SAFETY DEFECTS (U.S. ONLY) If you believe that your vehicle has a defect that could cause a crash, or could cause injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying Ford Motor Company.

If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety defect exists in a group of vehicles, it may order a recall and remedy campaign. However, NHTSA cannot become involved in individual problems between you, your dealer or Ford Motor Company. To contact NHTSA, you may either call the Auto Safety Hotline toll-free at 1–800–424–9393 (202–366–0123 in the Washington D.C. area) or write to: NHTSA U.S. Department of Transportation 400 Seventh Street Washington D.C. 20590
You can also obtain other information about motor vehicle safety from the Hotline.

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Index

Air bag supplemental restraint system ..........................................83
and child safety seats ..............84
description ................................83
disposal ......................................87
indicator light ...........................86
passenger air bag .....................85

Automatic transmission

driving an automatic overdrive ...................109,110,111