2003 Ford E 150 Owners Manual

Illumination of the “Service Engine Soon” light, charging system warning light or the temperature warning light, fluid leaks, strange odors, smoke or loss of engine power, 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, services, 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 engine. This decal identifies engine displacement and gives some tune up specifications.

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Please consult your Warranty Guide for complete emission warranty information.

On board diagnostics (OBD-II) Your vehicle is equipped with a computer that monitors the engine’s emission control system. This system is commonly known as the On Board Diagnostics System (OBD-II). This OBD-II system protects the environment by ensuring that your vehicle continues to meet government emission standards. The OBD-II system also assists the service technician in properly servicing your vehicle. When the Check Engine/Service Engine Soon light illuminates, the OBD-II system has detected a malfunction. Temporary malfunctions may cause your Check Engine/Service Engine Soon light to illuminate. Examples are: 1. The vehicle has run out of fuel. (The engine may misfire or run poorly.) 2. Poor fuel quality or water in the fuel. 3. The fuel cap may not have been securely tightened. These temporary malfunctions can be corrected by filling the fuel tank with good quality fuel and/or properly tightening the fuel cap. After three driving cycles without these or any other temporary malfunctions present, the Check Engine/Service Engine Soon light should turn off. (A driving cycle consists of a cold engine startup followed by mixed city/highway driving.) No additional vehicle service is required. If the Check Engine/Service Engine Soon light remains on, have your vehicle serviced at the first available opportunity.

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 diagnostics system. If your “Check Engine/Service Engine Soon” light is on, refer to the description in the Warning lights and chimes section of the Instrument cluster 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 on-board diagnostics system is reset to a “not ready for I/M test” condition. To ready the on-board diagnostics 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.

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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. CHECKING AND ADDING POWER STEERING FLUID Check the power steering fluid. Refer to the scheduled maintenance guide for the service interval schedules. If adding fluid is necessary, use only MERCON威 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-450 and E-550 vehicles with the Hydro-Boost Brake System, do not press the brake pedal after the engine has been

turned off.

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

BRAKE FLUID RESERVOIR The fluid level will drop slowly as the brakes wear, and will rise when the brake components are replaced. Fluid levels below the “MAX” line that do not trigger the brake system warning lamp are within the normal operating range, there is no need to add fluid. If the fluid levels are outside of the normal operating range, the performance of your brake system could be compromised, seek service from your dealer immediately.

MAX

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

TRANSMISSION FLUID

Checking automatic transmission fluid (if equipped) Refer to your scheduled maintenance 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 at normal operating temperature (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.

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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. If necessary, refer to Identifying components in the engine compartment in this chapter for the location of the dipstick. 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 area for normal operating temperature or ambient temperature. Low fluid level Do not drive the vehicle if the fluid level is at the bottom of the dipstick and the ambient temperature is above 10°C (50°F). Correct fluid level The transmission fluid should be checked at normal operating temperature 66°C-77°C (150°F-170°F) on a level surface. The normal operating temperature can be reached after approximately 30 km (20
miles) of driving. You can check the fluid without driving if the ambient temperature is above 10°C (50°F). However, 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 ambient temperature (10°C-35°C [50°F-95°F]).

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High fluid level 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. Adjusting automatic transmission fluid levels Before adding any fluid, make sure the correct type is used. The type of fluid used is normally indicated on the dipstick and also in the Lubricant specifications section in this 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. Do not use supplemental transmission fluid additives, treatments or cleaning agents. The use of these materials may affect transmission operation and result in damage to internal transmission components.

AIR FILTER MAINTENANCE Refer to the scheduled maintenance guide for the appropriate intervals for changing the air filter element. When changing the air filter element, use only the Motorcraft air filter element listed. Refer to Motorcraft Part Numbers. Note: Do not start your engine with the air cleaner removed and do not remove it while the engine is running.

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Changing the air filter element 1. Disconnect the fresh air inlet tube from the radiator support. 2. Loosen the clamp that secures the two halves of the air filter housing together.

3. Carefully separate the two halves of the air filter housing. 4. Remove the air filter element from the housing.

5. Install a new air filter element. Be careful not to crimp the filter element edges between the air filter housing. This could cause filter damage and allow unfiltered air to enter the engine if not properly seated. 6. Replace the two halves of the air filter housing and secure the clamp. 7. Connect the fresh air inlet tube to the radiator support.

INFORMATION ABOUT UNIFORM TIRE QUALITY GRADING New vehicles are fitted with tires that have a rating on them called Tire Quality Grades. The Quality grades can be found where applicable on the tire sidewall between tread shoulder and maximum section width. For example: • Treadwear 200 Traction AA Temperature A

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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 graded 150 would wear one and one-half (1 1/2) times as well on the government course as a tire graded 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. The 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.

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.

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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

Tire inflation information All tires with Steel Carcass Plies (if equipped): This type of tire utilizes steel cords in the sidewalls. As such, they cannot be treated like normal light truck tires. Tire service, including adjusting tire pressure, must be performed by personnel trained, supervised and equipped according to Federal Occupational Safety and Health Administration (OSHA) regulations. For example, during any procedure involving tire inflation, the technician or individual must utilize a remote inflation device, and insure that all persons are clear of the trajectory area.

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WARNING An inflated tire and rim can be very dangerous if improperly used, serviced or maintained. To reduce the risk of

serious injury, never attempt to re-inflate a tire which has been run flat or seriously under-inflated without first removing the tire from the wheel assembly for inspection. Do not attempt to add air to tires or replace tires or wheels without first taking precautions to protect persons and property.

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 scheduled maintenance 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). • Four tire rotation

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Maintenance and Specifications • Five tire rotation

Replacing the tires Replace the tires when the wear band is visible through the tire treads. Due to exposure to the elements and exhaust you should replace the spare tire when you replace the other tires.

When replacing full size tires, never mix radial bias-belted, or bias-type tires. Use only the tire sizes that are listed on the

Certification Label. Make sure that all tires are the same size, speed rating, and load-carrying capacity. Use only the tire combinations recommended on the label. If you do not follow these precautions, your vehicle handling may be affected which can lead to loss of vehicle control, vehicle rollover and/or personal injury.

Make sure that all replacement tires are of the same size, type, speed rating, load-carrying capacity and tread design (e.g., “All

Terrain”, “Touring”, etc.), as originally offered by Ford.

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Do not replace your tires with “high performance” tires or larger size tires.

Failure to follow these precautions may adversely affect the handling of the vehicle, and increase the risk of loss of vehicle

control, vehicle rollover and/or personal injury.

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. • 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.

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MOTORCRAFT PART NUMBERS Component1 4.2L V6
engine FA-1634

4.6L V8
engine FA-1634

5.4L V8
engine FA-1634

6.8L V10
engine FA-1634

BH-65DC

BH-65DC

BH-65DC

BH-65DC

BXT-65-750

BXT-65-750

BXT-65-750

BXT-65-750

FG-872
FL-820-S EV-233

FG-872
FL-820-S EV-233
AGSF-22W

FG-872
FL-820-S EV-233
AGSF-22W

FG-872
FL-400-S EV-251
AGSF-34EEM3 AWSF-32PP4

Air filter element Battery (standard) Battery (auxiliary) Fuel filter Oil filter PCV valve Spark plugs2
1Refer to the 7.3 Liter Power Stroke Direct Injection Turbo Diesel Owner’s Guide Supplement for Motorcraft diesel engine service part numbers. 2Refer to Vehicle Emissions Control Information (VECI) decal for spark plug gap information. 3If a spark plug is removed for inspection, it must be reinstalled in the same cylinder. Cylinders No. 1, 2 and 3 have a “EGM” suffix. Cylinders No. 4, 5 and 6 have a “EM” suffix. If a spark plug needs to be replaced, use only spark plugs with the service part number suffix letter ⬙EEM⬙ as shown on the engine decal. 4 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.

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REFILL CAPACITIES Fluid

All

Capacity

Application

Fill to line on reservoir

Ford Part Name Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil (US) Motorcraft SAE 5W-20 Super Premium Motor Oil (Canada) Refer to the 7.3L Power Stroke Direct Injection Turbo Diesel Owner’s Guide Supplement.

5.7L (6.0 quarts)

All

Brake fluid

Engine oil-gasoline engine (includes filter change)9

Engine oil-diesel engine (includes filter change)

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Application

Capacity

Fluid

Engine coolant-gasoline engine 1

Ford Part Name Motorcraft Premium Gold Engine Coolant (yellow-colored)

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) 1 row – 20.9L (22.1
quarts)8
24.0L (25.4 quarts) 1 row – 22.9L (24.2
quarts)8
23.7L (25.0 quarts) 1 row – 22.6L (23.8
quarts)8
25.7L (27.2 quarts) 1 row – 24.6L (26.0
quarts)8
27.4L (29.0 quarts) 1 row – 26.3L (27.8
quarts)8
29.4L (31.0 quarts) 1 row – 28.3L (29.8
quarts)8

5.4L V8 engine with aux rear heat 6.8L V10 engine 29.0L (30.6 quarts) 1 row – 27.9L (29.4
quarts)8
31.0L (32.8 quarts) 1 row – 29.9L (31.6
quarts)8

6.8L V10 engine with aux rear heat

Engine coolant-diesel engine Power steering fluid

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

Motorcraft MERCON威 ATF

All

Keep in FULL range on dispstick

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Fluid

Rear axle4

Ford Part Name Motorcraft SAE 75W-90 Fuel Efficient High Performance Synthetic rear axle lubricant Hypoid Gear Oil SAE 90
Motorcraft 80W-90
Premium rear axle lubricant

Fuel tank

N/A

Application

Capacity

Visteon 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 135 (E-550
only) 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) E-550

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

11.6L (24.5 pints) 3

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)

208.0L (55.0
gallons)

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Fluid

Transmission fluid 6

Ford Part Name Motorcraft MERCON威V ATF Motorcraft MERCON 威 ATF

Windshield washer fluid

Motorcraft Premium Windshield Washer Concentrate

Application

Capacity

Automatic (4R70W)

13.2L (13.9 quarts)

Automatic (4R100 except E-450) Automatic (4R100 E-450
and E-550) All

16.1L (17.0 quarts)

16.7L (17.7 quarts)

4.0L (4.2 quarts)

1Add the coolant type originally equipped in your vehicle. 2If 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. 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 XL-3 or equivalent meeting Ford specification EST-M2C118–A, for complete refill of 8.8 inch and 9.75 inch Traction-Lok axles. 3Fill Dana rear axles to 6 mm to 19 mm (1/4 inch to 3/4 inch) below bottom of fill hole. 4Visteon Traction-Lok axles require 118 ml (4 oz.) of Additive Friction Modifier XL—3 or equivalent meeting Ford specification EST-M2C118–A. Dana limited-slip axles (E250/350/450/550) require 237ml (8 oz.) of Additive Friction Modifier C8AZ—19B546–A or equivalent meeting Ford specification EST-M2C118-A. 5Optional fuel tank 208L (55 gallon). 6Ensure the correct automatic transmission fluid is used. Transmission fluid requirements are indicated on the dipstick or on the dipstick handle. Check the container to verify the fluid being added is of the correct type. Refer to your scheduled maintenance guide to determine the correct service interval.

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Some transmission fluids may be labeled as dual usage, such as MERCON威 and MERCON威 V. These dual usage fluids are not to be used in an automatic transmission that requires use of the MERCON威 type fluid. However, these dual usage fluids may be used in transmissions that require the MERCON威 V type fluid. MERCON威 and MERCON威 V type fluids are not interchangeable. DO NOT mix MERCON威 and MERCON威 V. Use of a transmission fluid that indicates dual usage (MERCON威 and MERCON威 V) in an automatic transmission application requiring MERCON威 may cause transmission damage. Use of any fluid other than the recommended fluid may cause transmission damage. 7Approximate dry fill capacity including transmission fluid cooling system, actual refill capacities will vary based on vehicle application and transmission fluid cooling system (i.e. coolers size, cooling lines. auxiliary cooler capacities). The amount of transmission fluid and fluid level should be set by the indication on the dipstick’s normal operating range. 8If your vehicle is equipped with a single row radiator, there will be a label on the top side of the radiator indicating “1 Row Radiator”. 9Use of synthetic or synthetic blend motor oil is not mandatory. Engine oil need only meet the requirements of Ford specification WSS-M2C153–H and the API Certification mark.

LUBRICANT SPECIFICATIONS Item

Brake fluid

Door weatherstrips Silicone

Engine coolant

Ford part name Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid

Lubricant Motorcraft Premium Gold Engine Coolant (yellow-colored)

Ford part number PM-1

Ford specification ESA-M6C25-A and DOT 3

F5AZ-19553-AA

ESR-M13P4-A

VC-7–A

WSS -M97B51-A1

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Ford specification WSS-M2C153-H with API Certification Mark

Ford part number XO-5W20-QSP (US) CXO-5W20–LSP12
(Canada)

Ford part name Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil (US) Motorcraft SAE 5W-20 Super Premium Motor Oil (Canada) Refer to the 7.3 Liter Power Stroke Direct Injection Turbo Diesel Owner’s Guide Supplement. Motorcraft Multi-Purpose Grease

ESR-M1C159-A or ESB-M1C93–B

XG–4 or XL-5

Motorcraft XL-1

none

XT-2-QDX

MERCON威

XT-2-QDX

MERCON威

XT-5-QM

MERCON威V

XG-4

ESE-M1C171-A

XT-2-QDX

MERCON威

Motorcraft Penetrating and Lock Lubricant Motorcraft MERCON威 ATF Motorcraft MERCON威 ATF

Motorcraft MERCON威V ATF Motorcraft Silicone Brake Caliper Grease and Dielectric Compound Motorcraft MERCON威 Automatic Transmission Fluid

Item

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 transmission (4R100) 1
Automatic tranmission (4R70W) 1
Disc brake caliper rails

Parking brake assembly (E-450/550 Super Duty)

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Item

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

Dana 9.75 inch (M60–1U) 3
10.5 inch (M70–2U) (M70–1HD) (E-250/350/450/550)3

Windshield washer fluid

Ford part name Motorcraft SAE 75W-90 Fuel Efficient High Performance Synthetic Rear Axle Lubricant Hypoid Gear Oil SAE 90
Motorcraft SAE 80W-90
Premium Rear Axle Lubricant Motorcraft Premium Windshield Washer Concentrate

Ford part number XY-75W90–QFEHP Meets API GL-5

Ford specification

C6AZ-19580–E

ESW-M2C105–E

XY-80W90-QL

WSP-M2C197-A

ZC-32–A

WSB-M8B16–A2

1Ensure the correct automatic transmission fluid is used. Transmission fluid requirements are indicated on the dipstick or on the dipstick handle. Check the container to verify the fluid being added is of the correct type. Refer to your scheduled maintenance guide to determine the correct service interval. Some transmission fluids may be labeled as dual usage, such as MERCON威 and MERCON威 V. These dual usage fluids are not to be used in an automatic transmission that requires use of the MERCON威 type fluid. However, these dual usage fluids may be used in transmissions that require the MERCON威 V type fluid. MERCON威 and MERCON威 V type fluids are not interchangeable. DO NOT mix MERCON威 and MERCON威 V. Use of a transmission fluid that indicates dual usage (MERCON威 and MERCON威 V) in an automatic transmission application requiring MERCON威 may cause transmission damage. Use of any fluid other than the recommended fluid may cause transmission damage. 2Add 118 ml (4 oz.) of Additive Friction Modifier XL-3 or equivalent meeting Ford specification EST-M2C118-A for complete refill of Visteon Traction-Lok rear axles.

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3Add 237 ml (8 oz.) of Additive Friction Modifier C8AZ-19B546-A or equivalent meeting Ford specification EST-M2C118-A for complete refill of Dana Traction-Lok rear axles.

ENGINE DATA

Engine*

4.2L V6
engine 256

Cubic inches Required fuel 87 octane 1-4-2-5-3-6

Firing order

4.6L V8
engine 281
87 octane 1-3-7-2-6-5-4-8 1-3-7-2-6-5-4-8 1-6-5-10-2-7-

6.8L V10
engine 415
87 octane

5.4L V8
engine 330
87 octane

Spark plug gap

1.3-1.4 mm (0.052-0.056
inch) EDIS

1.3-1.4 mm (0.052-0.056
inch) Coil on plug

1.3-1.4 mm (0.052-0.056
inch) 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

9.4:1

3-8-4-9
1.3-1.4 mm (0.052-0.056
inch) Coil on plug

VEHICLE DIMENSIONS

Van/wagon models

(1) Overall height

2050 mm (80.7

2118 mm (83.4

in)

in)

E-150

E-250

E-350

2136 mm (84.1 in)

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

1763 mm (69.4 in)/ 1 702 mm (67.0 in)

2014 mm (79.3 in)

3505 mm (138 in) Regular van, 5382 mm (211.9 in)

Extended, 5890 mm (231.9 in)

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Cutaway/commercial stripped chassis models Body style Dimension E-450
Super Duty Refer to Body Builder for specifications.

E-250

E-350

E-550
Super Duty

(1) Overall height (2) Track (Front / Rear)

1 763 mm (69.4 in)/ 1 689 mm (66.5 in)

1 763 mm (69.4 in)/ SRW 1689
mm (66.5
in), DRW 1 859
mm (73.2 in)

1 763 mm (69.4 in)/ 1 973 mm (77.7 in)

1 999 mm (78.7 in)/ 1 970 mm (77.5 in)

(3) Overall width (4) Wheelbase

Refer to Body Builder for specifications.

3 149.6 mm (124 in)

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

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

4 051 mm (159.5 in) 4 508 mm (177.5 in) 4 864 mm (191.5 in) 5 321 mm (209.5 in) 5 930 mm (233.5 in)

(5) Overall length

Refer to Body Builder for 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

driver’s side.

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Maintenance and Specifications

• On the 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.

Certification label for incomplete vehicles On completed derivations of incomplete vehicles, the 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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Accessories

Accessories

FORD ACCESSORIES FOR YOUR VEHICLE A wide selection of genuine Ford accessories are available for your vehicle through your local authorized Ford, Lincoln, Mercury or Ford of Canada dealer. These quality accessories have been specifically engineered to fulfill your automotive needs; they are custom designed to complement the style and aerodynamic appearance of your vehicle. In addition, each accessory is made from high quality materials and meets or exceeds Ford’s rigorous engineering and safety specifications. Ford Motor Company will repair or replace any properly dealer-installed Ford accessory found to be defective in factory-supplied materials or workmanship during the warranty period, as well as any component damaged by the defective accessory. The accessory will be warranted for whichever provides you the greatest benefit: • 12 months or 20,000 km (12,000 miles) (whichever occurs first), or • the remainder of your new vehicle limited warranty. This means that genuine Ford accessories purchased along with your new vehicle and installed by the dealer are covered for the full length of your New Vehicle’s Limited Warranty — 3 years or 60,000 km (36,000
miles) (whichever occurs first). Contact your dealer for details and a copy of the warranty. Not all accessories are available for all models. Following is a list of several Ford Genuine Accessory products. Not all accessories are available for all models. To find out what accessories are available for your vehicle, please contact your dealer or visit our online store at: www.fordaccessories.com.

Vehicle Security Styled wheel locks Vehicle security systems

Comfort and convenience Engine block heaters Remote start Tire step

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Accessories

Travel equipment Auto head lamps with DRL Bicycle rack Cell phone holder Console (Engine cover) Daytime running lights (DRL) First aid and highway kits Fog lights Hitch mount bicycle carrier Inside mirror, electrochromic with compass (with and without temperature display) Removable roof rack Running boards — Aluminum and Platinum elliptical Speed control Tailgate table TracRac Trailer hitch (Class III) Trailer hitch bars and balls Trailer hitch wiring adaptor

Protection and appearance equipment Air bag anti-theft locks Battery warmer Carpet floor mats Cleaners, waxes and polishes Door edge guards Flat splash guards Front end covers (full) Hood deflector Rear step bumpers Side window air deflectors

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For maximum vehicle performance, keep the following information in mind when adding accessories or equipment to your vehicle: • When adding accessories, equipment, passengers and luggage to your vehicle, do not exceed the total weight capacity of the vehicle or of the front or rear axle (GVWR or GAWR as indicated on the Safety compliance certification label). Consult your dealer for specific weight information. • The Federal Communications Commission (FCC) and Canadian Radio Telecommunications Commission (CRTC) regulate the use of mobile communications systems - such as two-way radios, telephones and theft alarms - that are equipped with radio transmitters. Any such equipment installed in your vehicle should comply with FCC or CRTC regulations and should be installed only by a qualified service technician.

• Mobile communications systems may harm the operation of your

vehicle, particularly if they are not properly designed for automotive use or are not properly installed. When operated, such systems may cause the engine to stumble or stall or cause the transmission to be damaged or operate improperly. In addition, such systems may be damaged or their performance may be affected by operating your vehicle. (Citizens band [CB] transceivers, garage door openers and other transmitters with outputs of five watts or less will not ordinarily affect your vehicle’s operation.) • Ford cannot assume responsibility for any adverse effects or damage

that may result from the use of such equipment.

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Index

Air bag supplemental restraint system ..........................................93
and child safety seats ..............95
description ................................93
disposal ......................................97
driver air bag ............................95
indicator light ...........................97
operation ...................................95
passenger air bag .....................95
Air cleaner filter .......203–204, 210
Ambulance packages ....................6
Antifreeze (see Engine coolant) ................184
Anti-lock brake system (see Brakes) ......................116–117
Audio system (see Radio) ................16, 18, 21, 25
Automatic transmission

driving an automatic overdrive .................................120
fluid, adding ............................201
fluid, checking ........................201
fluid, refill capacities ..............211
fluid, specification ..................218
Auxiliary power point .................67
Axle

lubricant specifications ..215, 218
refill capacities ........................211
traction lok ..............................118

Battery .......................................179
acid, treating emergencies .....179
disconnecting ..........................181
jumping a disabled battery ....152
maintenance-free ....................179

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Index

replacement, specifications ...210
servicing ..................................179
BeltMinder ...................................89
Brakes ........................................116
anti-lock ...........................116–117
anti-lock brake system (ABS) warning light ...........................117
fluid, checking and adding ....201
fluid, refill capacities ..............211
fluid, specifications .........215, 218
lubricant specifications ..215, 218
parking ....................................117
shift interlock ..........................119
Break-in period .............................5
Bulbs ............................................57

Calculating load ........................126
Capacities for refilling fluids ....211
Cassette tape player ...................25
CD-single premium .........16, 18, 21
Cell phone use ............................67
Child safety restraints ................98
child safety belts ......................98
Child safety seats ......................101
in front seat ............................103
in rear seat ..............................103
tether anchorage hardware ...105

Cleaning your vehicle

engine compartment ..............168
exterior ....................................171
instrument panel ....................170
interior .....................................170
interior trim ............................170
plastic parts ............................169
safety belts ..............................170
washing ....................................167

225

Dipstick

automatic transmission fluid ..........................................201
engine oil .................................176

Doors

lubricant specifications ..........215

Driveline universal joint and slip yoke ....................................201
Driving under special conditions ..................................123
through water .........................123

Emergencies, roadside

jump-starting ..........................152
Emergency Flashers .................136
Emission control system ..........198
Engine ........................................218
cleaning ...................................168
coolant .....................................184
diesel ...........................................6
fail-safe coolant ......................189
idle speed control ...................179
lubrication specifications ..................215, 218
refill capacities ........................211
service points ..........................174
starting after a collision .........136
Engine block heater .................116
Engine oil ..................................176
checking and adding ..............176
dipstick ....................................176
filter, specifications ........178, 210
recommendations ...................178
refill capacities ........................211
specifications ..................215, 218
Exhaust fumes ..........................116

Index

waxing .....................................167
wheels ......................................168
wiper blades ............................169

Climate control (see Air conditioning or Heating) ......51, 53
Compass, electronic ....................65
calibration .................................66
set zone adjustment .................66

Console

overhead ....................................64

Controls

power seat .................................78

Coolant

checking and adding ..............184
refill capacities ................188, 211
specifications ..................215, 218

Cruise control (see Speed control) ....................69
Customer Assistance ................135

Ford accessories for your vehicle .....................................171
Ford Extended Service Plan ..........................................160
Getting assistance outside the U.S. and Canada ..............164
Getting roadside assistance ...135
Getting the service you need .........................................158
Ordering additional owner’s literature .................................165
The Dispute Settlement Board .......................................161
Utilizing the Mediation/Arbitration Program ...................................164

Daytime running lamps (see Lamps) ................................54

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F

Fail safe cooling ........................189
Fluid capacities .........................211
Four-Wheel Drive vehicles

preparing to drive your vehicle .....................................118
Fuel ............................................190
calculating fuel economy .......194
cap ...........................................192
capacity ...................................211
choosing the right fuel ...........193
comparisons with EPA fuel economy estimates .................197
detergent in fuel .....................194
filling your vehicle with fuel ...........................190, 192, 195
filter, specifications ........194, 210
fuel pump shut-off switch .....136
improving fuel economy ........194
octane rating ...................193, 218
quality ......................................193
running out of fuel .................194
safety information relating to automotive fuels .....................190
Fuses ..........................................138

Index

driving with a heavy load ......124
location ....................................124

GVWR (Gross Vehicle Weight Rating) .......................................124
calculating .......................124, 126
definition .................................124
driving with a heavy load ......124
location ....................................124

Hazard flashers .........................136
Headlamps ...................................54
aiming ........................................55
bulb specifications ....................57
daytime running lights .............54
flash to pass ..............................55
high beam .................................54
replacing bulbs ...................58–59
turning on and off ....................54

Heating

heater only system .............51, 53
heating and air conditioning system .......................................52
Hood ..........................................174

Garage door opener ....................65
Gas cap (see Fuel cap) ............192
Gas mileage (see Fuel economy) .................194
Gauges .........................................13
GAWR (Gross Axle Weight Rating) .......................................124
calculating ...............................126
definition .................................124

Ignition ...............................113, 218
Infant seats (see Safety seats) .....................101
Inspection/maintenance (I/M) testing ........................................199
Instrument panel

cleaning ...................................170
cluster ........................................10
lighting up panel and interior .......................................55

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O

Octane rating ............................193
Oil (see Engine oil) ..................176

Parking brake ............................117
Parts (see Motorcraft parts) ....210
Power distribution box (see Fuses) ...............................141
Power door locks ........................73
Power point .................................67
Power steering ..........................118
fluid, checking and adding ....200
fluid, refill capacity ................211
fluid, specifications .........215, 218
Power Windows ...........................68
Preparing to drive your vehicle ........................................118

Radio ..........................16, 18, 21, 25
Relays ................................138, 143
Remote entry system

illuminated entry ......................76
locking/unlocking doors ...........73
Roadside assistance ..................135

Safety Belt Maintenance ............92
Safety belts (see Safety restraints) ........................83–85, 87
Safety defects, reporting ..........166

Index

Jump-starting your vehicle ......152

Keys

positions of the ignition .........113

Lamps

bulb replacement specifications chart ..................57
cargo lamps ...............................55
daytime running light ...............54
headlamps .................................54
headlamps, flash to pass ..........55
instrument panel, dimming .....55
interior lamps ...........................56
replacing bulbs ...................57–61

Lane change indicator (see Turn signal) ........................55
Lights, warning and indicator ....10
anti-lock brakes (ABS) ..........117
Load limits .................................124
GAWR ......................................124
GVWR ......................................124
trailer towing ..........................124
Loading instructions .................126
Lubricant specifications ...215, 218
Lumbar support, seats ...............78

Mirrors

fold away ...................................69
side view mirrors (power) .......68
Motorcraft parts ................194, 210

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Index

rotating ....................................207
snow tires and chains ............209
tire grades ...............................205
treadwear ................................205
Towing .......................................126
recreational towing .................134
trailer towing ..........................126
wrecker ....................................157
Traction-lok rear axle ...............118
Transmission .............................119

fluid, checking and adding (automatic) .............................201
fluid, refill capacities ..............211
lubricant specifications ..215, 218
Trunk ...........................................72
Turn signal ..................................55

Vehicle dimensions ...................218
Vehicle Identification Number (VIN) ..........................................220
Vehicle loading ..........................124
Ventilating your vehicle ...........116

Warning lights (see Lights) .......10
Washer fluid ..............................175
Water, Driving through .............123
Windows

power .........................................68

Windshield washer fluid and wipers ..........................................63
checking and adding fluid .....175
replacing wiper blades .............63
Wrecker towing .........................157

229

Safety restraints ....................83–87
belt minder ...............................89
extension assembly ..................92
for adults .............................84–85
for children .........................97–98
lap belt ......................................87
safety belt maintenance ...........92
warning light and chime ..........88
Safety seats for children ..........101
Seat belts (see Safety restraints) ...............83
Seats ............................................77
child safety seats ....................101
Servicing your vehicle ..............173
Spare tire (see Changing the Tire) ....................................144
Spark plugs, specifications .....................210, 218
Special notice

ambulance conversions ..............6
diesel-powered vehicles .............6
utility-type vehicles ....................6

Specification chart, lubricants ...........................215, 218
Speed control ..............................69
Starting your vehicle ........113–115
jump starting ..........................152

Steering wheel

tilting .........................................64

Temperature control (see Climate control) ...........51, 53
Tilt steering wheel ......................64
Tires ...................................204–206
changing ..........................144–145
replacing ..........................147, 208

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230

231

232

Table of Contents

Table of Contents

10

10
13
16

16
18
25
51

51
52
54

54
55
57
63

63
64
68
68
69
73

73
73

Introduction

Instrument Cluster

Warning and control lights Gauges

Entertainment Systems

AM/FM stereo cassette with CD AM/FM stereo cassette AM/FM stereo with CD

Climate Controls

Heater only Manual heating and air conditioning

Lights

Headlamps Turn signal control Bulb replacement Driver Controls

Windshield wiper/washer control Steering wheel adjustment Power windows Mirrors Speed control

Locks and Security

Keys Locks

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77

77
83
93
97
113

113
116
119
126
135

135
136
136
138
144
152
157
158

166
167

171

Table of Contents

Seating and Safety Restraints

Seating Safety restraints Air bags Child restraints

Driving

Starting Brakes Transmission operation Trailer towing

Roadside Emergencies

Getting roadside assistance Hazard flasher switch Fuel pump shut-off switch Fuses and relays Changing tires Jump starting Wrecker towing

Customer Assistance

Reporting safety defects (U.S. only)

Cleaning

Underbody preservation

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Maintenance and Specifications

Engine compartment Engine oil Battery Fuel information Air filter(s) Part numbers Refill capacities Lubricant specifications

Accessories

Index

Table of Contents

173

174
176
179
190
204
210
211
215
222

225

All rights reserved. Reproduction by any means, electronic or mechanical including photocopying, recording or by any information storage and retrieval system or translation in whole or part is not permitted without written authorization from Ford Motor Company. Ford may change the contents without notice and without incurring obligation.

Copyright © 2002 Ford Motor Company

2003 Econoline (eco) Owners Guide (post-2002-fmt) USA English (fus)

Introduction

Introduction

CALIFORNIA Proposition 65 Warning

WARNING: Engine exhaust, some of its constituents, and certain vehicle components contain or emit chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. In addition, certain fluids contained in vehicles and certain products of component wear contain or emit chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.

CONGRATULATIONS Congratulations on acquiring your new Ford. Please take the time to get well acquainted with your vehicle by reading this handbook. The more you know and understand about your vehicle the greater the safety and pleasure you will derive from driving it. For more information on Ford Motor Company and its products visit the following website: • In the United States: www.ford.com • In Canada: www.ford.ca • In Australia: www.ford.com.au • In Mexico: www.ford.com.mx Additional owner information is given in separate publications. This Owner’s Guide describes every option and model variant available and therefore some of the items covered may not apply to your particular vehicle. Furthermore, due to printing cycles it may describe options before they are generally available. Remember to pass on the Owner’s Guide when reselling the vehicle. It is an integral part of the vehicle.

Fuel pump shut-off switch In the event of an accident the safety switch will automatically cut off the fuel supply to the

engine. The switch can also be activated through sudden vibration (e.g. collision when parking). To reset the switch, refer to the Fuel pump shut-off switch in the Roadside emergencies chapter.

SAFETY AND ENVIRONMENT PROTECTION

Warning symbols in this guide

How can you reduce the risk of personal injury and prevent possible damage to others, your vehicle and its equipment? In this guide, answers to such questions are contained in comments highlighted by the warning triangle symbol. These comments should be read and observed.

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Introduction

Warning symbols on your vehicle

When you see this symbol, it is imperative that you consult the relevant section of this guide before touching or attempting adjustment of any kind.

Protecting the environment We must all play our part in protecting the environment. Correct vehicle usage and the authorized disposal of waste cleaning and lubrication materials are significant steps towards this aim. Information in this respect is highlighted in this guide with the tree symbol.

BREAKING-IN YOUR VEHICLE There are no particular guidelines for breaking-in your vehicle. During the first 1,600 km (1,000 miles) of driving, vary speeds frequently. This is recommended to give the moving parts a chance to break in.

SPECIAL NOTICES

Emission warranty The New Vehicle Limited Warranty includes Bumper-to-Bumper Coverage, Safety Restraint Coverage, Corrosion Coverage, and 7.3L Power Stroke Diesel Engine Coverage. In addition, your vehicle is eligible for Emissions Defect and Emissions Performance Warranties. For a detailed description of what is covered and what is not covered, refer to the Warranty Guide that is provided to you along with your Owner’s Guide.

Data Recording Computers in your vehicle are capable of recording detailed data potentially including but not limited to information such as: • the use of restraint systems including seat belts by the driver and • information about the performance of various systems and modules in • information related to engine, throttle, steering, brake or other system

the vehicle, and

passengers,

status.

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Introduction

Any of this information could potentially include information regarding how the driver operates the vehicle potentially including but not limited to information regarding vehicle speed, brake or accelerator application or steering input. This information may be stored during regular operation or in a crash or near crash event. This stored information may be read out and used by: • Ford Motor Company. • service and repair facilities. • law enforcement or government agencies. • others who may assert a right or obtain your consent to know such

information.

Special instructions For your added safety, your vehicle is fitted with sophisticated electronic controls.

Please read the section Supplemental Restraint System (SRS) in the Seating and safety restraints chapter. Failure to follow the specific warnings and instructions could result in personal injury.

Front seat mounted rear facing child or infant seats should NEVER be used in front of a passenger side air bag unless the

air bag can be and is turned OFF.

Notice to owners of diesel-powered vehicles Read the 7.3 Liter Power Stroke Direct Injection Turbo Diesel Owner’s Guide Supplement for information regarding correct operation and maintenance of your diesel-powered light truck. Notice to owners of pickup trucks and utility type vehicles

Utility vehicles have a significantly higher rollover rate than other types of vehicles.

Before you drive your vehicle, please read this Owner’s Guide carefully. Your vehicle is not a passenger car. As with other vehicles of this type, failure to operate this vehicle correctly may result in loss of vehicle control, vehicle rollover, personal injury or death. Using your vehicle as an ambulance If your light truck is equipped with the Ford Ambulance Preparation Package, it may be utilized as an ambulance. Ford urges ambulance

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Introduction

manufacturers to follow the recommendations of the Ford Incomplete Vehicle Manual, Ford Truck Body Builder’s Layout Book and the Qualified Vehicle Modifiers (QVM) Guidelines as well as pertinent supplements. For additional information, please contact the Truck Body Builders Advisory Service 1–877–840–4338. Use of your Ford light truck as an ambulance, without the Ford Ambulance Preparation Package voids the Ford New Vehicle Limited Warranty and may void the Emissions Warranties. In addition, ambulance usage without the preparation package could cause high underbody temperatures, overpressurized fuel and a risk of spraying fuel which could lead to fires. If your vehicle is equipped with the Ford Ambulance Preparation Package, it will be indicated on the Certification label. The label is located on the driver’s side door pillar or on the rear edge of the driver’s door. You can determine whether the ambulance manufacturer followed Ford’s recommendations by directly contacting that manufacturer. Ford Ambulance Preparation Package is only available on certain 7.3L Diesel engine equipped vehicles.

Notice to owners of natural gas fueled vehicles Before you drive your vehicle, be sure to read the Dedicated Natural Gas Vehicle supplement. This book contains important operation and maintenance information.

Middle East/North Africa vehicle specific information For your particular global region, your vehicle may be equipped with features and options that are different from the ones that are described in this Owner Guide; therefore, a supplement has been supplied that complements this book. By referring to the pages in the provided supplement, you can properly identify those features, recommendations and specifications that are unique to your vehicle. Refer to this Owner Guide for all other required information and warnings.

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Introduction

These are some of the symbols you may see on your vehicle.

Vehicle Symbol Glossary

Safety Alert

See Owner’s Guide

Fasten Safety Belt

Air Bag-Front

Air Bag-Side

Child Seat

Child Seat Installation Warning

Child Seat Tether Anchor

Anti-Lock Brake System

Child Seat Lower Anchor

Brake System

Brake Fluid - Non-Petroleum Based

Traction Control

AdvanceTrac娂

Master Lighting Switch

Hazard Warning Flasher

Fog Lamps-Front

Fuse Compartment

Fuel Pump Reset

Windshield Wash/Wipe

Windshield Defrost/Demist

Rear Window Defrost/Demist

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Introduction

Vehicle Symbol Glossary

Power Windows Front/Rear

Child Safety Door Lock/Unlock

Power Window Lockout

Interior Luggage Compartment Release Symbol

Panic Alarm

Engine Oil

Engine Coolant

Engine Coolant Temperature

Do Not Open When Hot

Battery

Avoid Smoking, Flames, or Sparks

Battery Acid

Explosive Gas