2002 Ford F 350 Owners Manual

It is important to note the box in the lower left corner of the window sticker. These numbers represent the Range of L/100 km (MPG) expected on the vehicle under optimum conditions. Your fuel economy may vary depending upon the method of operation and conditions. 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 the specified fuel listed. • Avoid running out of fuel. • Do not turn off the ignition while your vehicle is moving, especially at • Have the items listed in your scheduled maintenance guide performed

high speeds.

according to the specified schedule.

The scheduled maintenance items listed in the scheduled maintenance 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 “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.

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Maintenance and Specifications

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. 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 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.

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.

219

Maintenance and Specifications

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. 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.

220

Maintenance and Specifications

BRAKE FLUID Checking and adding brake fluid Brake fluid should be checked and refilled as needed. Refer to the scheduled maintenance 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 from a clean un-opened container until the level reaches MAX. Do not fill above this line. 4. Use only a DOT 3 brake fluid certified to meet Ford specification ESA-M6C25–A. Refer to Lubricant specifications in this chapter.

MAX

Brake fluid is toxic. If brake fluid contacts the eyes, flush eyes with running water for 15 minutes. Seek medical attention if

irritation persists. If taken internally, drink water and induce vomiting. Seek medical attention immediately.

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.

CLUTCH FLUID (IF EQUIPPED) Check the clutch fluid level. Refer to the scheduled maintenance guide for the service interval schedules. Use only a DOT 3 brake fluid designed to meet Ford specification ESA-M6C25–A. Refer to Lubricant Specifications in this chapter.

221

Maintenance and Specifications

Brake fluid is toxic. If brake fluid contacts the eyes, flush eyes with running water for 15 minutes. Seek medical if irritation persists. If taken internally, drink water and induce vomiting. Seek medical attention immediately.

During normal operation, the fluid level in the clutch reservoir should remain constant or rise slightly. If the fluid level drops, refill the fluid level to the step in the reservoir. 1. Clean the reservoir cap before removal to prevent dirt and water from entering the reservoir. 2. Remove cap and rubber diaphragm from reservoir. 3. Add fluid until the level reaches the step in the reservoir. 4. Reinstall rubber diaphragm and cap onto reservoir.

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

222

Maintenance and Specifications

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. 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).

DO NOT ADD

COLD

ADD

HOT

DON'T ADD IF IN CROSSHATCHED AREA (cid:127) CHECK WHEN HOT

IDLING IN PARK

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.

223

Maintenance and Specifications

The transmission fluid should be in this range if at normal operating temperature (66°C-77°C [150°F-170°F]).

ADD

COLD

HOT

DO NOT ADD

The transmission fluid should be in this range if at ambient temperature (10°C-35°C [50°F-95°F]).

ADD

COLD

HOT

DO NOT ADD

DON'T ADD IF IN CROSSHATCHED AREA (cid:127) CHECK WHEN HOT

IDLING IN PARK

DON'T ADD IF IN CROSSHATCHED AREA (cid:127) CHECK WHEN HOT

IDLING IN PARK

HOT

ADD

IDLING IN PARK

COLD

DO NOT ADD

DON'T ADD IF IN CROSSHATCHED AREA (cid:127) CHECK WHEN HOT

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.

DON'T ADD IF IN CROSSHATCHED AREA (cid:127) CHECK WHEN HOT

DO NOT ADD

COLD

IDLING IN PARK

ADD

HOT

224

Maintenance and Specifications

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.

Checking and adding manual transmission fluid (if equipped) 1. Clean the filler plug. 2. Remove the filler plug and inspect the fluid level.

3. Fluid level should be at the bottom of the opening. 4. Add enough fluid through the filler opening so that the fluid level is at the bottom of the opening. 5. Install and tighten the fill plug securely.

Use only fluid that meets Ford specifications. Refer to Lubricant Specifications in this chapter.

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Maintenance and Specifications

Checking and adding transfer case fluid (if equipped) 1. Clean the filler plug. 2. Remove the filler plug and inspect the fluid level.

3. Add only enough fluid through the filler opening so that the fluid level is at the bottom of the opening.

Use only fluid that meets Ford specifications. Refer to Lubricant Specifications in this chapter. 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. 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.

226

Maintenance and Specifications

Note: Do not start your engine with the air cleaner removed and do not remove it while the engine is running. Changing the air filter element (gasoline engines only) 1. Loosen the clamp that secures the air filter element in place.

2. Carefully separate the two halves of the air filter housing. 3. Remove the air filter element from the open end of the air filter housing.

4. Install a new air filter element, ensuring the arrow on the top half of the air filter housing lines up with the notch on the bottom half of air filter housing. Be careful not to crimp the filter element edges between the air filter housing. This could cause filter damage and allow unmetered air to enter the engine if not properly seated. 5. Replace the two halves of the air filter housing and secure the clamp. 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:

227

Maintenance and Specifications • Treadwear 200 Traction AA Temperature A 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 climates.

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

228

Maintenance and Specifications

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 Certification Label. Tire pressure information can also be found on the Tire Information label located on the inside of the fuel filler door.

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

rollover and/or personal injury.

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Maintenance and Specifications

Tire inflation information The F450 and F550 vehicles are equipped with a tire that is an all-steel radial. All-steel radial tires utilize steel cords in the sidewalls, and also require increased inflation pressures of up to 95 psi. 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.

WARNING An inflated tire and rim can be very dangerous if improperly used, serviced or maintained. To avoid 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 wheel.

230

Maintenance and Specifications

• Four tire rotation

• Five tire rotation

231

Maintenance and Specifications • DRW – Six tire rotation If you vehicle is equipped with dual rear wheels it is recommended that front and rear tires (in pairs) be rotated only side to side, with the rear tires maintaining original vehicle position. After tire rotation, inflation pressures must be adjusted for the tires new positions in accordance with vehicle requirements.

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 effected which can lead to loss of vehicle control, vehicle rollover and/or personal injury.

232

Maintenance and Specifications

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

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

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

Failure to follow these precautions, your vehicle handling may be adversely effected which can lead to 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.

233

Maintenance and Specifications

5.4L V8 engine FA-1634
FG-986B FL-820-S EV-233
BXT-65-650
BXT-65-750
AGSF-22W

MOTORCRAFT PART NUMBERS Component* Air filter element Fuel filter Oil filter PCV valve Battery (Standard) Battery (Optional) Spark plugs-platinum** *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.

6.8L V10 engine FA-1634
FG-986B FL-820-S EV-233
BXT-65-650
BXT-65-750
AGSF-22W

REFILL CAPACITIES

Ford Part

Name

Hypoid Gear Oil SAE 90

Motorcraft SAE 75W-140
Synthetic Rear Axle Lubricant Motorcraft SAE 75W-90
Synthetic Rear Axle Lubricant Motorcraft SAE 80W-90
Premium Rear Axle Lubricant

Application

Capacity

F-250/350
(Dana 60 axle) F-350/450/550
(Dana 60 axle) F-250 /350
(10.50 inch axle)

F-350/450
(DANA 80)

2.7L (5.8 pints)

2.7L (5.8 pints)

3.3L (6.9 pints)

4.0L (8.5 pints)

F-550
(Dana 135)

11.6L (24.5
pints)

Fluid

Front axle

Rear axle 1,2

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Maintenance and Specifications

Application

Capacity

All

Fill to line or step (for clutch) on reservoir

Fluid

Brake fluid (and clutch fluid-if equipped)

Ford Part

Name

Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid

Engine coolant 3 Motorcraft

5.4L V8 engine with A/C

25.0L (26.4
quarts)

6.8L V10 engine 27.0L (28.5

Premium Engine Coolant (green-colored) or Motorcraft Premium Gold Engine Coolant (yellow-colored) Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil Refer to your 7.3L Diesel Supplement

All

quarts)

5.7L (6.0
quarts)

Engine oil (includes filter change)-Gas engines Engine oil (includes filter change)-Diesel engine

235

Maintenance and Specifications

Fluid

Ford Part

Name

Fuel tank

N/A

Power steering fluid Transfer case fluid Transmission fluid 4

Motorcraft MERCON威 ATF Motorcraft MERCON威 ATF Motorcraft MERCON威 ATF

Windshield washer fluid

Motorcraft Premium Windshield Washer Concentrate

Application

Capacity

Mid-ship tank (optional on Chassis Cab) Right side saddle mounted tank (optional on Chassis Cab) Short box

Long box

Aft axle

All

4x4 vehicles

6-speed manual

Automatic

All

71.9L (19.0
gallons)

87.1L (23.0
gallons)

109.8L (29.0
gallons) 143.9L (38.0
gallons) 151.4L (40.0
gallons) Fill to line on reservoir 1.9L (2.0
quarts) 5.5L (5.8
quarts) 5
16.7L (17.7
quarts) 6
4.0L (4.25
quarts)

1Your vehicle’s rear axle(s) may be filled with a synthetic lubricant that may require a lubricant change. Refer to the scheduled maintenance guide. Axle lubricant quantities should not need to be checked 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. 2Add 236 ml (8 oz.) of Additive Friction Modifier XL-3or equivalent meeting Ford Specification EST-M2C118-A for complete refill of Traction-Lok axles.

236

Maintenance and Specifications

3Add the coolant type originally equipped in your vehicle. 4Ensure 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. 5Service refill capacity is determined by filling the transmission to the bottom of the filler hole with the vehicle on a level surface. The 6–speed manual transmission is equipped with an in-tank cooler. Verify the fluid level after operating vehicle to assure correct fluid level. 6Indicates 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.

LUBRICANT SPECIFICATIONS

Item

Spindle bearing

Front axle (4X4)

Ford part name or equivalent High Temperature 4X4 Front Axle and Wheel Bearing Grease Hypoid Gear Oil SAE 90

Ford part number

Ford specification

E8TZ-19590–A

ESA-M1C198–A

C6AZ-19580–E

ESW-M2C105–A

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Maintenance and Specifications

Item

Rear axle

Brake fluid and clutch fluid (if equipped)

Ford part name or equivalent Motorcraft SAE 75W-140 High Performance Synthetic Rear Axle Lube 1
Motorcraft SAE 75W-90
Synthetic Rear Axle Lubricant Motorcraft SAE 80W-90
Premium Rear Axle Lubricant (Dana 135
axles) 1
Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid

Engine coolant Motorcraft

Premium Engine Coolant (green-colored) Motorcraft Premium Gold Engine Coolant (yellow-colored) Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil

Engine oil

238

Ford part number

Ford specification

XY-75W140–QL WSL-M2C192-A

XY-75W90–GLS

–

XY-80W90-QL

WSP-M2C197-A

PM-1

ESA-M6C25-A and DOT 3

VC-4–A (in Canada, Motorcraft CXC-10) VC-7–A

ESE-M97B44-A

WSS-M97B51-A1

XO-5W20-QSP WSS-M2C153-H

and API Certification Mark

Item

Hinges, latches, striker plates, fuel filler door hinge and seat tracks

Lock cylinders

Transmission /steering/parking brake linkages and pivots, brake and clutch pedal shaft (if equipped) Power steering fluid and transfer case fluid (if equipped) Manual transmission (6-speed)

Automatic transmission

Windshield washer fluid

Maintenance and Specifications

Ford part name or equivalent Multi-Purpose Grease

Ford part number

XG—4 or XL-5

Ford specification

ESR-M1C159-A or ESB-M1C93–B

Motorcraft penetrating and lock lubricant Motorcraft Premium Long-Life Grease

XL-1

none

XG-1-C or XG-1-K

ESA-M1C75-B

Motorcraft MERCON威 ATF

XT-2-QDX

MERCON威

XT-2-QDX

MERCON威

XT-2-QDX

MERCON威

ZC-32–A

ESR-M17P5-A

Motorcraft MERCON威 ATF

Motorcraft MERCON威 ATF

Motorcraft Premium Windshield Washer Concentrate

1Add 236 ml (8 oz.) of Additive Friction Modifier XL-3 or equivalent meeting Ford specification EST-M2C118-A for complete refill of

239

Maintenance and Specifications

Traction-Lok axles. Ford design rear axles contain a synthetic lubricant that does not require changing unless the axle has been submerged in water. Dana rear axles also contain a synthetic lubricant but do require a change. Refer to your “Service Guide” for change intervals on Dana rear axles. 2Ensure 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.

ENGINE DATA Engine Cubic inches Required fuel Firing order

Spark plug gap

Ignition system Compression ratio

5.4L V8 engine 330
87 octane 1-3-7-2-6-5-4-8
1.3-1.4 mm (0.052-0.056 inch) Coil on plug 9.0:1

6.8L V10 engine 415
87 octane 1-6-5-10-2-7-3-8-4-9
1.3-1.4 mm (0.052-0.056 inch) Coil on plug 9.0:1

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Maintenance and Specifications

VEHICLE DIMENSIONS

F250–Regular and Super Cab Dimension

Body style

Regular Cab 4x2

1935 mm (76.2 in) 1 736 mm (68.3 in) / 1 729 mm (68 in) 2 031 mm (79.9 in)a 2426 mm (95.5 in)b 3 479.8 mm (137 in)

Regular Cab 4x4
2 005 mm (78.9 in) 1 736 mm (68.3 in) / 1 729.3 mm (68 in) 2 031 mm (79.9 in)a 2426 mm (95.5 in)b 3 479.8 mm (137 in)

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

(3) Overall width

(4) Wheelbase

(5) Overall length

5 756 mm (226.6 in)

5 756 mm (226.6 in)

aSingle rear wheel (SRW) bDual rear wheel (DRW) cShort Wheel Base (SWB) dLong wheel base (LWB)

Super Cab 4x2
1 943 mm (76.5 in)d 1 736 mm (68.3 in) / 1 729.3 mm (68 in) 2 031 mm (79.9 in)a 2426 mm (95.5 in)b 3 610.7 mm (141.8 in)c 4 013.2 mm (158 in)d 5 878 mm (231.4 in)c 6 289 mm (247.6 in)d

Super Cab 4x4
2 008 mm (79.0 in)d 1 736 mm (68.3 in) / 1 729.3 mm (68 in) 2 031 mm (79.9 in)a 2426 mm (95.5 in)b 3 610.7 mm (141.8 in)c 4 013.2 mm (158 in)d 5 878 mm (231.4 in)c 6 289 mm (247.6 in)d

241

Maintenance and Specifications

F250-Crew Cab Dimension

Body style

Crew Cab 4x2/ Short

Crew Cab 4x4/ Short

box 1960 mm (77.2 in) 1 736 mm (68.3 in) / 1 729 mm (68.1 in) 2 031 mm (79.9 in) 3 967 mm (156.2 in) 6 243 mm (245.8 in)

box 2 027 mm (79.8 in) 1 736 mm (68.3 in) / 1 729 mm (68.1 in) 2 031 mm (79.9 in) 3 967 mm (156.2 in) 6 243 mm (245.8 in)

Crew Cab 4x2/ Long box 1 957 mm (77.0 in) 1 736 mm (68.3 in) / 1 729 mm (68.1 in) 2 031 mm (79.9 in) 4 379 mm (172.4 in) 6 654 mm (262 in)

Crew Cab 4x4/ Long box 2 022 mm (76.6 in) 1 736 mm (68.3 in) / 1 729 mm (68.1 in) 2 031 mm (79.9 in) 4 379 mm (172.4 in) 6 654 mm (262 in)

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

(3) Overall width (4) Wheelbase (5) Overall length

242

Maintenance and Specifications

F350–except Crew Cab Dimension

(1) Overall height

(2a) Front Track

(2b) Rear Track

(3) Overall width

Chassis Cab — Regular Cab 1 924 mm (75.7 in)a 1 912 mm (75.2 in)b 2 028 mm (79.8 in)c 2 031 mm (80.0 in)d

1 736 mm (68.3 in)a,b / 1 736 mm (68.4 in)c,d 1 729 mm (68.1 in)a,c / 1 880 mm (74.0 in)b,d 2 031 mm (79.9 in)a,c / 2 304 mm (90.7 in)b 2 329 mm (91.7 in)d

Body style

Chassis Cab — Super Cab

Regular Cab Style Side

1 928 mm (75.9 in)a 1 931 mm (76.0 in)b 2 029 mm (79.9 in)c 2 019 mm (79.5 in)d

1 938 mm (76.3 in)a 1 976 mm (77.8 in)b 2 041 mm (80.3 in)c 2 018 mm (79.4in)d

1 736 mm (68.3 in)a,b / 1 736 mm (68.4 in)c,d 1 729 mm (68.1 in)a,c / 1 880 mm (74.0 in)b,d 2 031 mm (79.9 in)

1 736 mm (68.3 in)a,b / 1 736 mm (68.4 in)c,d 1 729 mm (68.1 in)a,c / 1 880 mm (74.0 in)b,d 2 031 mm (79.9 in)a,c 2 426 mm (95.5)b,d

Super Cab Style Side

1 952 mm (76.8 in)a,e 1 954 mm (76.9 in)a,f 1 939 mm (76.3 in)b 2 051 mm (80.7 in)c,e 2 039 mm (80.3 in)c,f 2 019 mm (79.5 in)d 1 736 mm (68.3 in)a,b / 1 736 mm (68.4 in)c,d 1 729 mm (68.1 in)a,c / 1 880 mm (74.0 in)b,d 2 031 mm (79.9 in)a,c 2 426 mm (95.5)b,d

243

Maintenance and Specifications

Dimension

(4) Wheelbase

(5) Overall length

Chassis Cab — Regular Cab 3 576 mm (140.8 in) 4 186 mm (164.8 in) 5 733 mm (225.7
in)a,b,c,d/ 6 343 (249.7
in)b,d

Body style

Chassis Cab — Super Cab

Regular Cab Style Side

4 110 mm (161.8 in)

3 480 mm (137.0 in)

6 267 mm (246.7 in)

5 756 mm (226.6 in)

Super Cab Style Side

3 602 mm (141.8 in)e/ 4 014 mm (158.0 in)f 5 878 mm (231.4 in)e/ 6 289 mm (247.6 in)f

a4x2 Single rear wheel (SRW) b4x2 Dual rear wheel (DRW) c4x4 Single rear wheel (SRW) d4x4 Dual rear wheel (DRW) eShort box fLong box

F350-Crew Cab

Dimension

Crew chassis

Cab 1 929 mm (75.9 in)a/ 1 941 mm (76.4 in)b/ 2 026 mm (79.8 in)c/ 2 038 mm (80.2 in)d 1 736 mm (68.3 in)

(1) Overall height

(2a) Track —Front

244

Body style

Crew cab-short box 1 955mm (77.0 in)a/ 1998 mm (78.6 in)b/ 1 958 mm (77.1 in)c/ 2 033 mm (80.0 in)d 1 736 mm (68.3 in)

Crew cab — long box 1 964 mm (77.3 in)a/ 1991 mm (75.2 in)b/ 1 957 mm (77.0 in)c/ 2 031 mm (80.0 in)d 1 736 mm (68.3 in)

Maintenance and Specifications

Body style

Crew cab-short box 1 729 mm (68.1 in)a,c/ 1 880 mm (74.0 in)b,d 2 031 mm (79.9 in)a,c 2 426 mm (95.5 in)b,d

Crew cab — long box 1 729 mm (68.1 in)a,c/ 1 880 mm (74.0 in)b,d 2 031 mm (79.9 in)a,c 2 426 mm (95.5 in)b,d

3 967 mm (156.2 in ) 6 243 mm (245.8 in)

4 379 mm (172.4 in) 6 654 mm (262.0 in)

Dimension

Crew chassis

(2b) Track — Rear

(3) Overall width

(4) Wheelbase

Cab 1 729 mm (68.1 in)a,c/ 1 803 mm (74.0 in)b,d 2 031 mm (79.9 in)a,c/ 2 304 mm (90.7 in)b/ 2 329 mm (91.7 in)d 4 475 mm (176.2 in ) 6 632 mm (261.1 in)

(5) Overall length a4x2 Single rear wheel (SRW) b4x2 Dual rear wheel (DRW) c4x4 Single rear wheel (SRW) d4x4 Dual rear wheel (DRW)

F450
Dimension

(1) Overall height

Body style

Super Cab Chassis 4x2/4x4
2 045 mm (80.5 in)

Regular

Cab

Chassis 4x2
2 048 mm (80.6 in)a 2 044 mm (80.5 in) b,c 2 038 mm (80.2 in)d

Regular Cab Chassis 4x4
2 051 mm (80.7 in)a 2 044 mm (80.5 in) b 2 033 mm (80.0 in)c,d

Crew Cab Chassis 4x2/4x4
2 053 mm (80.8 in) - 4x2
2 056 mm (80.9 in) - 4x4

245

Maintenance and Specifications

Dimension

Body style

(2) Track (Front / Rear)

(3) Overall width (4) Wheelbase

(5) Overall length

Super Cab Chassis 4x2/4x4
1 736 mm (68.4 in) / 1 889 mm (74.3 in) 2 386 mm (93.9 in) 4 110 mm (161.8 in)

Crew Cab Chassis 4x2/4x4
1 736 mm (68.4 in) / 1 880 mm (74.0 in) 2 377 mm (93.6 in) 4 475 mm (176.2 in) 5 085 (200.2
in)

6 267 mm (246.7 in)

6 632 mm (261.1 in)e 7 241 mm (285.1 in)f

Regular

Cab

Chassis 4x2
1 736 mm (68.4 in) / 1 880 mm (74.0 in) 2 377 mm (93.6 in) 3 576 mm (140.8 in) 4 186 mm (164.8 in) 4 795 mm (188.8 in) 5 100 mm (200.8 in) 5 733 mm (225.7 in)a 6 343 mm (249.7 in)b 6 952 mm (273.7 in)c 7 257 mm (285.7 in)d

Regular Cab Chassis 4x4
1 736 mm (68.4 in) / 1880 mm (74.0 in) 2 377 mm (93.6 in) 3 576 mm (140.8 in) 4 186 mm (164.8 in) 4 795 mm (188.8 in) 5 100 mm (200.8 in)

5 733 mm (225.7 in)a 6 343 mm (249.7 in)b 6 952 mm (273.7 in)c 7 257 mm (285.7 in)d

a 3 576 mm (140.8 in) wheel base b4 186 mm (164.8 in) wheel base c4 795 mm (188.8) wheel base d5 100 mm (200.8 in) wheel base e4 475 mm (176.2 in) wheel base f5 085 mm (200.2 in) wheel base

246

F550
Dimension

(1) Overall height

(2) Track (Front / Rear)

(3) Overall width (4) Wheelbase

Maintenance and Specifications

Body style

Crew Cab Chassis Cab 4x2

Crew Cab Chassis Cab 4x4

2 067 mm (81.4 in)

2 066 mm (81.3 in)

1 736 mm (68.4 in) / 1 880 mm (74.0 in) 2 377 mm (93.6 in) 4 475 mm (176.2 in) 5 085 (200.2
in)

1 736 mm (68.4 in) / 1 880 mm (74.0 in) 2 377 mm (93.6 in) 4 475 mm (176.2 in) 5 085 (200.2
in)

Regular

Cab

Chassis Cab 4x2
2 076 mm (81.7 in)a 2 068 mm (81.4 in) b,c 2 059 mm (81.1 in)d

1 736 mm (68.4 in) / 1 880 mm (74.0 in) 2 377 mm (93.6 in) 3 576 mm (140.8 in) 4 186 mm (164.8 in) 4 795 mm (188.8 in) 5 100 mm (200.8 in)

Regular Cab Chassis Cab 4x4
2 075 mm (81.7 in)a 2 063 mm (81.2 in) b 2 059 mm (81.1 in)c 2 049 mm (80.7 in)d 1 736 mm (68.4 in) / 1880 mm (74.0 in) 2 377 mm (93.6 in) 3 576 mm (140.8 in) 4 186 mm (164.8 in) 4 795 mm (188.8 in) 5 100 mm (200.8 in)

247

Maintenance and Specifications

Dimension

Body style

(5) Overall length

Crew Cab Chassis Cab 4x2

Crew Cab Chassis Cab 4x4

6 632 mm (261.1 in)e 7 241 mm (285.1 in)f

6 632 mm (261.1 in)e 7 241 mm (285.1 in)f

Regular

Cab

Chassis Cab 4x2
5 733 mm (225.7 in)a 6 343 mm (249.7 in)b 6 952 mm (273.7 in)c 7 257 mm (285.7 in)d

Regular Cab Chassis Cab 4x4

5 733 mm (225.7 in)a 6 343 mm (249.7 in)b 6 952 mm (273.7 in)c 7 257 mm (285.7 in)d

a 3 576 mm (140.8 in) wheel base b4 186 mm (164.8 in) wheel base c4 795 mm (188.8) wheel base d5 100 mm (200.8 in) wheel base e4 475 mm (176.2 in) wheel base f5 085 mm (200.2 in) wheel base

248

Maintenance and Specifications

IDENTIFYING YOUR VEHICLE

Certification label The National Highway Traffic Safety Administration Regulations require that a Certification label be affixed to a vehicle and prescribe where the Certification label may be located. The Certification label is located on the front door latch pillar on the driver’s side.

249

Maintenance and Specifications

Vehicle identification number (VIN) The vehicle identification number is attached to a metal tag and is located on the driver side instrument panel. (Please note that in the graphic XXXX is representative of your vehicle identification number.)

XXXXXXXXXXXXXXXXX

1. World manufacturer identifier 2. Brake type and gross vehicle weight rating (GVWR) 3. Vehicle line, series, body type 4. Engine type 5. Check digit 6. Model year 7. Assembly plant 8. Production sequence number

Engine number The engine number (the last eight numbers of the vehicle identification number) is stamped on the engine block, transmission, frame and transfer case (if equipped).

250

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.

Vehicle Security Remote keyless entry Styled wheel protector locks Vehicle security systems

Comfort and convenience Cargo organizers Cargo storage bin Cargo trays Cell phone holder Engine block heaters Manual sliding rear window Power sliding rear window Tire step

251

Accessories

Travel equipment Adjustable Towing System Auto headlamp system with Daytime Running Lights (DRL) Bed Tent Box Aluminum Rack cargo storage systems Daytime running lights (DRL) Electrochromic inside mirror with compass Electrochromic inside mirror with compass and temperature display Fog lights Battery Warmer Highway safety and first aid kit Off road lights Pickup box rails ROC2 hitch mounted bike courier Running boards and tubular running bars Running boards diamond plate Seatback organizer Speed control Towing mirrors Trailer hitch, Class IV Trailer hitch bars and balls Trailer hitch mounted bike carrier Trailer hitch wiring adaptor Trailer wiring harness Trailgate table

Protection and appearance equipment Air bag anti-theft locks All weather vinyl floor mats Bed mat/bedliner tailgate covers Bed hooks Bed mats Bedliners

252

Accessories

Carpet floor mats Cap (hard, color keyed – Leer supplier branded) Cap (commercial – Leer supplier branded) Cleaners, waxes and polishes Diamond plate bed rail caps Diamond plate front box protection Diamond plate splash guards Diamond plate tool box Door edge guards Fender flares Flat splash guards Front end covers (full) Hood deflectors Leather wrap steering wheel Locking gas cap Lubricants and oils Molded splash guards Rear window deflector Side window air deflectors Spare tire lock Stainless steel grill insert Step bumpers Tailgate covers (Diamond plate) Tonneau cover (soft) Tonneau cover (hard, color keyed – Leer supplier branded) Touch-up paint Truck cover Universal floor mats Wheels Wheel covers Wood trim

253

Accessories

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.

254

A

Accessory delay ..........................48
Air bag supplemental restraint system ..........................................82
and child safety seats ..............83
description ................................82
disposal ......................................86
driver air bag ............................84
indicator light ...........................85
operation ...................................84
passenger air bag .....................84
passenger deactivation switch ........................................86
Air cleaner filter .......226–227, 234
Ambulance packages ....................6
Antifreeze (see Engine coolant) ................204
Anti-lock brake system (see Brakes) ......................106–107
Audio system (see Radio) ................17, 19, 22, 26
Automatic transmission ............109

driving an automatic overdrive .................................110
fluid, adding ............................222
fluid, checking ........................222
fluid, refill capacities ..............234
fluid, specification ..................240
Auxiliary power point .................47
Axle

lubricant specifications ..237, 240
refill capacities ........................234
traction lok ..............................108

Battery .......................................202
acid, treating emergencies .....202

Index

jumping a disabled battery ....174
maintenance-free ....................202
replacement, specifications ...234
servicing ..................................202
BeltMinder ...................................77
Brakes ........................................105
anti-lock ...........................105–107
anti-lock brake system (ABS) warning light ...........................106
fluid, checking and adding ....221
fluid, refill capacities ..............234
fluid, specifications .........237, 240
lubricant specifications ..237, 240
parking ....................................107
pedals (see Power adjustable foot pedals) ...............................49
shift interlock ..........................109
Break-in period .............................4
Bulbs ............................................39

Capacities for refilling fluids ....234
Cassette tape player ...................26
CD changer .................................28
CD-single premium .........17, 19, 22
Certification Label ....................249
Child safety restraints ................91
child safety belts ......................91
Child safety seats ........................93
attaching with tether straps ....97
in front seat ..............................95
in rear seat ................................95

Cleaning your vehicle

engine compartment ..............191
instrument panel ....................193
interior .....................................193
plastic parts ............................192

255

Index

washing ....................................190
waxing .....................................190
wheels ......................................191
wiper blades ............................192
woodtone trim ........................193

Clutch

fluid ..........................................221
operation while driving ..........112
recommended shift speeds ....113
Compass, electronic ....................55
calibration .................................56
set zone adjustment .................56
Console ........................................53
overhead ....................................46

Controls

power seat .................................68

Coolant

checking and adding ..............204
refill capacities ................208, 234
specifications ..................237, 240
Customer Assistance ................158

Ford accessories for your vehicle .....................................194
Ford Extended Service Plan ..........................................183
Getting assistance outside the U.S. and Canada .....................187
Getting roadside assistance ...158
Getting the service you need .........................................181
Ordering additional owner’s literature .................................188
The Dispute Settlement Board .......................................183
Utilizing the Mediation/Arbitration Program ...................................186

256

Daytime running lamps (see Lamps) ................................37
Dipstick

automatic transmission fluid ..........................................222
engine oil .................................199

Doors

lubricant specifications ..........237

Driveline universal joint and slip yoke ....................................226
Driving under special conditions ..................112, 121, 124
sand .........................................123
snow and ice ...........................125
through water .................123, 128

Emergencies, roadside

jump-starting ..........................174
Emission control system ..........218
Engine ................................240–241
cleaning ...................................191
coolant .....................................204
diesel ...........................................5
fail-safe coolant ......................209
idle speed control ...................202
lubrication specifications ..................237, 240
refill capacities ........................234
service points ..........................198
starting after a collision .........159
Engine block heater .................105
Engine oil ..................................199
checking and adding ..............199
dipstick ....................................199
filter, specifications ........201, 234
recommendations ...................201

refill capacities ........................234
specifications ..................237, 240
Exhaust fumes ..........................105

Fail safe cooling ........................209
Fluid capacities .........................234
Foglamps .....................................37
Four-Wheel Drive vehicles .......116
driving off road .......................119
electronic shift ................118–119
indicator light .........................116
lever operated shift ................117
manual locking hubs ..............116
preparing to drive your vehicle .....................................108
Fuel ............................................210
calculating fuel economy .......215
cap ...........................................212
capacity ...................................234
choosing the right fuel ...........213
comparisons with EPA fuel economy estimates .................218
detergent in fuel .....................214
filling your vehicle with fuel ...........................210, 212, 215
filter, specifications ........214, 234
fuel pump shut-off switch .....159
improving fuel economy ........215
octane rating ...........213, 240–241
quality ......................................213
running out of fuel .................214
safety information relating to automotive fuels .....................210
Fuses ..................................160–161

Garage door opener ....................47

Index

Gas cap (see Fuel cap) ............212
Gas mileage (see Fuel economy) ...................................215
Gauges .........................................13
GAWR (Gross Axle Weight Rating) .......................................128
calculating ...............................130
definition .................................128
driving with a heavy load ......128
location ....................................128

GVWR (Gross Vehicle Weight Rating) .......................................128
calculating .......................128, 130
definition .................................128
driving with a heavy load ......128
location ....................................128

Headlamps ...................................36
aiming ........................................38
autolamp system .......................36
daytime running lights .............37
flash to pass ..............................38
high beam .................................37
replacing bulbs .........................40
turning on and off ....................36

Heating

heating and air conditioning system ...........33–34
Hood ..........................................197

Ignition .......................101, 240–241
Infant seats (see Safety seats) .......................93