2001 Ford E 250 Owners Manual

light (TCIL) (the word OFF) on the end of the gearshift lever will illuminate.

OVERDRIVE OFF

OVERDRIVE

position. The TCIL (the word OFF) will illuminate on the

Drive – Not shown on the display. Activate by pressing the transmission control switch (TCS) on the end of the gearshift lever with the gearshift in the gearshift lever. Transmission operates in gears one through three. (Drive) provides more engine braking than when: † driving with a heavy load. † towing a trailer up or down steep hills. † additional engine downhill braking is desired. If towing a trailer, refer

(Overdrive) and is useful

to Driving while you tow in the Trailer towing section.

(Overdrive) mode, press the transmission control switch

To return to (TCS). The TCIL (the word OFF) will no longer be illuminated. Each time the vehicle is started, the transmission will automatically return to normal overdrive mode. Every time the vehicle is shut off and restarted, you must press the transmission control switch to cancel overdrive operation if driving in overdrive is not desired. 2(Second) Use 2 (Second) to start-up on slippery roads or to provide additional engine braking on downgrades.

108

Driving

(Overdrive) or Drive (O/D OFF) when

1(First) Use 1 (Low) to provide maximum engine braking on steep downgrades. Upshifts can be made by shifting to 2 (Second) or to (Overdrive). Selecting 1 (Low) at higher speeds causes the transmission to shift to a lower gear, and will shift to 1 (Low) after vehicle decelerates to the proper speed. ForcedDownshifts To gain acceleration in passing another vehicle, push the accelerator to the floor. The transmission will downshift to the appropriate gear: third, second or first gear. Shiftstrategy(4R100automatictransmission) To account for customer driving habits and conditions, your 4R100
automatic transmission electronically controls the shift quality by using an adaptive learning strategy. The adaptive learning strategy is maintained by power from the battery. When the battery is disconnected or a new battery is installed, the transmission must relearn its adaptive strategy. Optimal shifting will resume within a few hundred kilometers (miles) of operation. If the shift quality does not improve within a few hundred kilometers (miles) of operation, or if the downshifts and other throttle conditions do not function normally, see your dealer or a qualified service technician as soon as possible.

VEHICLE LOADING Before loading a vehicle, familiarize yourself with the following terms: † Base Curb Weight: Weight of the vehicle including any standard equipment, fluids, lubricants, etc. It does not include passengers or aftermarket equipment. † Payload: Combined maximum allowable weight of cargo, passengers and optional equipment. The payload equals the gross vehicle weight rating minus base curb weight.

† GVW (Gross Vehicle Weight): Base curb weight plus payload

weight. The GVW is not a limit or a specification.

109

Driving † GVWR (Gross Vehicle Weight Rating): Maximum total weight of

the base vehicle, passengers, optional equipment and cargo. The GVWR is specific to each vehicle and is listed on the Safety Certification Label on the driver’s door pillar.

† GAWR (Gross Axle Weight Rating): Carrying capacity for each axle

system. The GAWR is specific to each vehicle and is listed on the Safety Certification Label on the driver’s door pillar. † GCW (Gross Combined Weight): The combined weight of the towing vehicle (including passengers and cargo) and the trailer. † GCWR (Gross Combined Weight Rating): Maximum combined weight of towing vehicle (including passengers and cargo) and the trailer. The GCWR indicates the maximum loaded weight that the vehicle is designed to tow.

† Maximum Trailer Weight Rating: Maximum weight of a trailer the

vehicle is permitted to tow. The maximum trailer weight rating is determined by subtracting the vehicle curb weight for each engine/transmission combination, any required option weight for trailer towing and the weight of the driver from the GCWR for the towing vehicle. † Maximum Trailer Weight: Maximum weight of a trailer the loaded

vehicle (including passengers and cargo) is permitted to tow. It is determined by subtracting the weight of the loaded trailer towing vehicle from the GCWR for the towing vehicle.

† Trailer Weight Range: Specified weight range that the trailer must fall within that ranges from zero to the maximum trailer weight rating.

Remember to figure in the tongue load of your loaded trailer when figuring the total weight.

Do not exceed the GVWR or the GAWR specified on the certification label.

Do not use replacement tires with lower load carrying capacities than the originals because they may lower the vehicle’s GVWR and GAWR limitations. Replacement tires with a higher limit than the originals do not increase the GVWR and GAWR limitations. The Safety Certification Label, found on the driver’s door pillar, lists several important vehicle weight rating limitations. Before adding any additional equipment, refer to these limitations. If you are adding weight

110

Driving

to the front of your vehicle, (potentially including weight added to the cab), the weight added should not exceed the front axle reserve capacity (FARC). Additional frontal weight may be added to the front axle reserve capacity provided you limit your payload in other ways (i.e. restrict the number of passengers or amount of cargo carried). Always ensure that the weight of passengers, cargo and equipment being carried is within the weight limitations that have been established for your vehicle including both gross vehicle weight and Front and rear gross axle weight rating limits. Under no circumstance should these limitations be exceeded. Exceeding any vehicle weight rating limitation could result in serious damage to the vehicle and/or personal injury.

Special loading instructions for owners of pickup trucks and utility-type vehicles

For important information regarding safe operation of this type of vehicle, see the Preparing to drive your vehicle section in

the Driving chapter of this owner guide.

Loaded vehicles, with a higher center of gravity, may handle differently than unloaded vehicles. Extra precautions, such as

slower speeds and increased stopping distance, should be taken when driving a heavily loaded vehicle.

Your vehicle has the capability to haul more cargo and people than most passenger cars. Depending upon the type and placement of the load, hauling cargo and people may raise the center of gravity of the vehicle.

Calculating the load your vehicle can carry/tow 1. Use the appropriate maximum gross combined weight rating (GCWR) chart to find the maximum GCWR for your type engine and rear axle ratio.

111

Driving

2. Weigh your vehicle as you customarily operate the vehicle without cargo. To obtain correct weights, try taking your vehicle to a shipping company or an inspection station for trucks. 3. Subtract your loaded vehicle weight from the maximum GCWR on the following charts. This is the maximum trailer weight your vehicle can tow and must fall below the maximum shown under maximum trailer weight on the chart.

TRAILER TOWING Refer to 7.3 Liter Power Stroke Direct Injection Turbo Diesel Owner’s Guide Supplement for diesel engine towing information. Your vehicle may tow a class I, II or III trailer provided the maximum trailer weight is less than or equal to the maximum trailer weight listed for your engine and rear axle ratio on the following charts.

GCWR (Gross Combined Weight Rating)/Trailer Weights Maximum

Rear axle ratio

Maximum GCWR - kg

(lbs.)

Trailer weight range - kg (lbs.)

(0-Maximum)

Frontal Area Of Trailer - m2 (ft2)

Engine

Regular Van E-150

4.2L

3.55

4.6L

3.55

5.4L

3.55

4 536

(10 000)

5 216

(11 500)

5 443

(12 000)

2 313 (5 100)

5.52 (60)

2 993 (6 600)

5.52 (60)

3 130 (6 900)

5.52 (60)

Regular Van E-250

4.2L

3.73

5.4L

3.73

4 763

(10 500)

5 897

(13 000)

2 359 (5 200)

5.52 (60)

3 402 (7 500)

5.52 (60)

Regular Van E-250 HD

(3 901 kg [8 600 lb.]-3 924 kg [8 650 lb.] GVW)

4.2L

4.09

5.4L

3.73

4 990

(11 000)

5 897

(13 000)

2 586 (5 700)

5.52 (60)

3 402 (7 500)

5.52 (60)

112

Driving

GCWR (Gross Combined Weight Rating)/Trailer Weights Maximum

Rear axle ratio

Maximum GCWR - kg

(lbs.)

Trailer weight range - kg (lbs.)

(0-Maximum)

Frontal Area Of Trailer - m2 (ft2)

Engine

Super Van E-250

4.2L

3.73

5.4L

3.73

4 763

(10 500)

5 897

(13 000)

2 313 (5 100)

5.52 (60)

3 357 (7 400)

5.52 (60)

(3 901 kg [8 600 lb.]-3 924 kg [8 650 lb.] GVW)

Super Van E-250 HD

4.2L

4.09

5.4L

3.73

4 990

(11 000)

5 897

(13 000)

2 540 (5 600)

5.52 (60)

3 356 (7 400)

5.52 (60)

Regular Van E-350

5.4L

3.55

5.4L

4.10

6.8L

3.73

6.8L

4.10

5.4L

3.55

5.4L

4.10

6.8L

3.73

6.8L

4.10

5 443

(12 000)

5 897

(13 000)

6 804

(15 000)

8 392

(18 500)

2 948 (6 500)

5.52 (60)

3 402 (7 500)

5.52 (60)

4 218 (9 300)

5.52 (60)

4 536 (10 000)

5.52 (60)

Super Van E-350

5 443

(12 000)

5 897

(13 000)

6 804

(15 000)

8 392

(18 500)

2 858 (6 300)

5.52 (60)

3 311 (7 300)

5.52 (60)

4 173 (9 200)

5.52 (60)

4 536 (10 000)

5.52 (60)

113

Driving

GCWR (Gross Combined Weight Rating)/Trailer Weights Maximum

Maximum GCWR - kg

Trailer weight range - kg (lbs.)

Engine

Frontal Area Of Trailer - m2 (ft2)

Rear axle ratio

(0-Maximum) (lbs.) E-150 8 passenger Wagon

4.2L

3.55

4.6L

3.55

5.4L

3.55

4 536

(10 000)

5 216

(11 500)

5 443

(12 000)

2 132 (4 700)

5.52 (60)

2 767 (6 100)

5.52 (60)

2 948 (6 500)

5.52 (60)

E-350 7 passenger Wagon

5.4L

3.73

6.8L

3.73

6.8L

4.10

5 443

(12 000)

6 804

(15 000)

8 392

(18 500)

2 812 (6 200)

5.52 (60)

3 992 (8 800)

5.52 (60)

4 536 (10 000)

5.52 (60)

E-350 8 passenger Wagon

5.4L

3.73

6.8L

3.73

6.8L

4.10

5 443

(12 000)

6 804

(15 000)

8 392

(18 500)

2 858 (6 300)

5.52 (60)

4 037 (8 900)

5.52 (60)

4 536 (10 000)

5.52 (60)

E-350 12 passenger Wagon

5.4L

3.55

5.4L

4.10

5.4L

3.73

6.8L

3.73

6.8L

4.10

5 443

(12 000)

5 897

(13 000)

5 443

(12 000)

6 804

(15 000)

8 392

(18 500)

2 722 (6 000)

5.52 (60)

3 175 (7 000)

5.52 (60)

2 812 (6 200)

5.52 (60)

4 037 (8 900)

5.52 (60)

4 536 (10 000)

5.52 (60)

114

Driving

GCWR (Gross Combined Weight Rating)/Trailer Weights Maximum

Rear axle ratio

Maximum GCWR - kg

(lbs.)

Trailer weight range - kg (lbs.)

(0-Maximum)

Frontal Area Of Trailer - m2 (ft2)

Engine

5.4L

3.55

5.4L

4.10

6.8L

3.73

6.8L

4.10

5.4L

4.10

6.8L

4.10

6.8L

4.63

Super E-350 15 passenger Wagon 5 443

2 586 (5 700)

(12 000)

5.52 (60)

5 897

(13 000)

6 804

(15 000)

8 392

(18 500)

3 039 (6 700)

5.52 (60)

3 901 (8 600)

5.52 (60)

4 536 (10 000)

5.52 (60)

E-350 Cutaway (dual rear wheel) 5 897

(13 000)

8 392

(18 500)

E-450 Cutaway (dual rear wheel) 9 072

(20 000)

5.52 (60)

5.52 (60)

5.52 (60)

E-250/350 Stripped Chassis (single rear wheel-124(wheelbase

for E-250 only)

4.2L

4.09

5.4L

4.10

4 990

(11 000)

5 897

(13 000)

1 090 (2 400)

5.52 (60)

1 542 (3 400)

5.52 (60)

E-350 Stripped Chassis (dual rear wheel)

5.4L

4.10

5 897

(13 000)

1 361 (3 000)

5.52 (60)

115

Driving

GCWR (Gross Combined Weight Rating)/Trailer Weights Maximum

Rear axle ratio

Maximum GCWR - kg

(lbs.)

Trailer weight range - kg (lbs.)

(0-Maximum)

Frontal Area Of Trailer - m2 (ft2)

Engine

E-450 Stripped Chassis (dual rear wheel)

5.4L

4.10

6.8L

4.63

5 897

(13 000)

9 072

(20 000)

1 361 (3 000)

5.52 (60)

5.52 (60)

* Maximum trailer weight for all cutaway (E-350 and E-450) vehicles must be calculated by subtracting the weight of the vehicle (including incomplete vehicle weight, and payload which includes second unit body weight, cargo, and passengers) from the GCW. Otherwise, maximum trailer weight is 4 536 kg (10 000 lbs). For high altitude operation reduce GCWR by 2% per 300 meters (1 000
ft) elevation. To determine the maximum trailer weight designed for your particular vehicle as equipped, follow the section Calculating the load your vehicle can tow/carry earlier in this chapter. Your vehicle’s load capacity is designated by weight, not by volume, so you cannot necessarily use all available space when loading a vehicle. Distribute the load so that only 10 to 15% of the total is on the tongue. Tie down the load so that it does not shift and change the weight on the hitch. Towing a trailer places an additional load on your vehicle’s engine, transmission, axle, brakes, tires and suspension. Inspect these components carefully after any towing operation.

Do not exceed the GVWR or the GAWR specified on the certification label.

Towing trailers beyond the maximum recommended gross trailer weight could result in engine damage, transmission/axle damage,

structural damage, loss of control, and personal injury.

116

Driving

Preparing to tow Use the proper equipment for towing a trailer, and make sure it is properly attached to your vehicle. See your dealer or a reliable trailer dealer if you require assistance. Hitches Do not use or install hitches that clamp onto the bumper or to the axle. Underbody hitches are acceptable if installed properly. Safetychains Always connect the trailer’s safety chains to the frame or hook retainers of the vehicle. To connect the trailer’s safety chains, cross the chains under the trailer tongue and allow slack for turning corners. If you use a rental trailer, follow the instructions that the rental agency gives to you. Do not attach safety chains to the bumper. Trailerbrakes Electric brakes and manual, automatic or surge-type trailer brakes are safe if installed properly and adjusted to the manufacturer’s specifications. The trailer brakes must meet local and Federal regulations.

Do not connect a trailer’s hydraulic brake system directly to your vehicle’s brake system. Your vehicle may not have enough

braking power and your chances of having a collision greatly increase.

The braking system of the tow vehicle is rated for operation at the GVWR not GCWR. Trailerlamps Trailer lamps are required on most towed vehicles. Make sure your trailer lamps conform to local and Federal regulations. See your dealer or trailer rental agency for proper instructions and equipment for hooking up trailer lamps. Usingastepbumper(ifequipped) The rear bumper is equipped with an integral hitch and only requires a ball with a 25.4 mm (one inch) shank diameter. The bumper has a 2 270
kg (5 000 lb.) trailer weight and 227 kg (500 lb.) tongue weight capacity.

117

Driving

If it is necessary to relocate the trailer hitch ball position, a frame-mounted trailer hitch must be installed.

Driving while you tow When towing a trailer: † Ensure that you turn off your speed control. The speed control may shut off automatically when you are towing on long, steep grades. † Consult your local motor vehicle speed regulations for towing a trailer. † Use D (Drive) or a lower gear when towing up or down steep hills.

This will eliminate excessive downshifting and upshifting for optimum fuel economy and transmission cooling.

† Anticipate stops and brake gradually. When descending long, steep downhill grades, always use a lower gear to provide engine braking to save wear on brakes. Use Drive (Overdrive OFF) on moderately steep hills, Second (2) on steep hills, and First (1) on very steep hills. Servicingaftertowing If you tow a trailer for long distances, your vehicle will require more frequent service intervals. Refer to your scheduled maintenance guide for more information.

Trailer towing tips † Practice turning, stopping and backing up before starting on a trip to get the feel of the vehicle trailer combination. When turning, make wider turns so the trailer wheels will clear curbs and other obstacles.

† Allow more distance for stopping with a trailer attached. † The trailer tongue weight should be 10–15% of the loaded trailer † If you will be towing a trailer frequently in hot weather, hilly conditions, at GCW, or any combination of these factors, consider refilling your rear axle with synthetic gear lube. Refer to the Capacities and specifications chapter for the lubricant specification.

† After you have traveled 80 km (50 miles), thoroughly check your

weight.

hitch, electrical connections and trailer wheel lug nuts.

118

Driving † When stopped in traffic for long periods of time in hot weather, place

the gearshift in P (Park) and increase idle speed. This aids engine cooling and air conditioner efficiency. † Vehicles with trailers should not be parked on a grade. If you must

park on a grade, place wheel chocks under the trailer’s wheels.

Launching or retrieving a boat When backing down a ramp during boat launching or retrieval, † Do not allow the static water level to rise above the bottom edge of † Do not allow waves to break higher than 15 cm (6 inches) above the

the rear bumper and

bottom edge of the rear bumper.

Exceeding these limits may allow water to enter critical vehicle components, adversely affecting driveability, emissions, reliability and causing internal transmission damage. Replace the rear axle lubricant anytime the axle has been submerged in water. Rear axle lubricant quantities are not to be checked or changed unless a leak is suspected or repair required. Disconnect the wiring to the trailer before backing the trailer into the water. Reconnect the wiring to the trailer after the trailer is removed from the water.

Recreational towing (all wheels on the ground) An example of recreational towing would be towing your vehicle on a trip behind a Motorhome. Follow these guidelines if you have the need for recreational towing your vehicle with all four wheels on the ground. These guidelines are designed to ensure that your transmission is not damaged. 2WD vehicles (with automatic transmissions) † Place the transmission in N (Neutral) † Maximum speed is 56 km (35 mph) † Maximum distance is 80 km (50 miles) If a distance of 80 km (50 miles) or a speed of 56 km (35 mph) must be exceeded, the drive shaft will have to be removed. Ford recommends the driveshaft be removed/installed only by a qualified technician. See your local dealer for driveshaft removal/installation.

119

Driving

Improper removal/installation of the driveshaft can cause transmission fluid loss, damage to the driveshaft and internal transmission components.

DRIVING THROUGH WATER Do not drive quickly through standing water, especially if the depth is unknown. Traction or brake capability may be limited and if the ignition system gets wet, your engine may stall. Water may also enter your engine’s air intake and severely damage your engine. If driving through deep or standing water is unavoidable, proceed very slowly. Never drive through water that is higher than the bottom of the hubs (for trucks) or the bottom of the wheel rims (for cars). Once through the water, always try the brakes. Wet brakes do not stop the vehicle as effectively as dry brakes. Drying can be improved by moving your vehicle slowly while applying light pressure on the brake pedal. Driving through deep water where the transmission vent tube is submerged may allow water into the transmission and cause internal transmission damage.

120

Roadside emergencies

GETTING ROADSIDE ASSISTANCE To fully assist you should you have a vehicle concern, Ford offers a complimentary roadside assistance program. This program is separate from the New Vehicle Limited Warranty. The service is available: † 24–hours, seven days a week † for the Basic warranty period (Canada) or New Vehicle Limited

Warranty period (U.S.) of three years or 60 000 km (36 000 miles), whichever comes first on Ford and Mercury vehicles, and four years or 80 000 km (50 000 miles) on Lincoln vehicles

Roadside assistance will cover: † changing a flat tire † jump-starts † lock-out assistance † limited fuel delivery* † towing of your disabled vehicle to the nearest Ford dealership, or your

selling dealer if within 25 kms (15.5 miles) of the nearest Ford Dealership (one tow per disablement). Even non-warranty related tows, like accidents or getting stuck in the mud or snow, are covered (some exclusions apply, such as impound towing or repossession).

* Canadian customers refer to your Roadside Assistance supplement for exact fuel amounts.

Using roadside assistance Complete the roadside assistance identification card and place it in your wallet for quick reference. In the United States, this card is found in the Owner Guide portfolio in the glove compartment in Ford vehicles and is mailed to you if you own a Mercury or Lincoln. In Canada, the card is found in the Roadside Assistance book in the glove compartment. To receive roadside assistance in the United States: † Ford or Mercury vehicle customers call 1-800-241-3673. † Lincoln vehicle customers call 1–800–521–4140
To receive roadside assistance in Canada, customers call 1–800–665–2006.

121

Roadside emergencies

If you need to arrange roadside assistance for yourself, Ford will reimburse a reasonable amount. To obtain reimbursement information in the United States: † Ford or Mercury vehicles customers call 1-800-241-3673
† Lincoln vehicle customers call 1–800–521–4140
To obtain reimbursement information in Canada, customers call 1–800–665–2006.

Roadside coverage beyond basic warranty In the United States, you may purchase additional roadside assistance coverage beyond this period through the Ford Auto Club by contacting your Ford or Lincoln Mercury dealer. Similarly in Canada, you may purchase additional coverage beyond the basic coverage period by consulting the Ford Roadside Assistance Club brochure or by calling 1–877–294–CLUB (1–877–294–2582).

HAZARD FLASHER Use only in an emergency to warn traffic of vehicle breakdown, approaching danger, etc. The hazard flashers can be operated when the ignition is off. † The hazard lights control is

located on top of the steering column.

† Depress hazard lights control to

activate all hazard flashers simultaneously.

† Depress control again to turn the

flashers off.

RESETTING THE FUEL PUMP SHUT-OFF SWITCH FUEL RESET The fuel pump shut-off switch is a device intended to stop the electric fuel pump when your vehicle has been involved in a substantial jolt. After a collision, if the engine cranks but does not start, the fuel pump shut-off switch may have been activated.

122

Roadside emergencies

The fuel pump shut-off switch is located in the passenger’s foot well, behind the kick panel, except for commercial stripped chassis vehicles.

For commercial stripped chassis vehicles, the fuel pump shut-off switch is located on a bracket above the brake pedal.

123

Roadside emergencies

Use the following procedure to reset the fuel pump shut-off switch. 1. Turn the ignition to the OFF position. 2. Check the fuel system for leaks. 3. If no fuel leak is apparent, reset the fuel pump shut-off switch by pushing in on the reset button. 4. Turn the ignition to the ON position. Pause for a few seconds and return the key to the OFF position. 5. Make a further check for leaks in the fuel system.

FUSES AND RELAYS

Fuses If electrical components in the vehicle are not working, a fuse may have blown. Blown fuses are identified by a broken wire within the fuse. Check the appropriate fuses before replacing any electrical components.

15

Always replace a fuse with one that has the specified amperage rating. Using a fuse with a higher amperage rating can cause

severe wire damage and could start a fire.

124

Roadside emergencies

Standardfuseamperageratingandcolor

Fuse Rating

2A 3A 4A 5A 7.5A 10A 15A 20A 25A 30A 40A 50A 60A 70A 80A

Mini Fuses

Grey Violet Pink Tan

Brown

Red Blue Yellow Natural Green

— — — — —

COLOR

Standard

Fuses

Maxi Fuses

Grey Violet Pink Tan

Brown

Red Blue Yellow Natural Green

— — — — —

— — — — — — —

Yellow

—

Green Orange

Red Blue Tan

Natural

Cartridge

Maxi Fuses

— — — — — — — Blue — Pink Green Red — — —

Fuse Link Cartridge

— — — — — — — Blue — Pink Green Red Yellow Brown Black

Passenger compartment fuse panel The fuse panel is located below and to the left of the steering wheel by the brake pedal. Remove the panel cover to access the fuses. To remove a fuse use the fuse puller tool provided on the fuse panel cover.

125

Roadside emergencies

13

19

25

31

37

14

20

26

32

38

15

21

27

33

39

10

16

22

28

34

40

11

17

23

29

35

41

42

43

44

12

18

24

30

36

The fuses are coded as follows.

Fuse/Relay Location

Fuse Amp

Rating

Passenger Compartment Fuse Panel Description

20A 15A

15A

15A

20A

4WABS Module Brake Warning Lamp, Instrument Cluster, Warning Chime, 4WABS Relay, Warning Indicators, Low Vacuum Warning Switch (Diesel Only) Main Light Switch, RKE Module, Radio, Instrument Illumination, E Traveler VCP and video screen. Power Locks w/RKE, Illuminated Entry, Warning Chime, Modified Vehicle, Main Light Switch, Courtesy Lamps RKE Module, Power Lock Switches, Memory Lock, Power Locks with RKE

126

Roadside emergencies

Fuse/Relay Location

Fuse Amp

Rating

Passenger Compartment Fuse Panel Description

10

11

12

13

14

15
16
17
18
19
20
21
22
23

24
25
26

10A

10A 30A

30A

20A

15A

15A

15A

5A

5A 30A — — 10A 5A 30A 15A 20A

— 10A 20A

Brake Shift Interlock, Speed Control, DRL Module Multi-Function Switch, Turn Signals Radio Capacitor(s), Ignition Coil, PCM Diode, PCM Power Relay, Fuel Heater (Diesel Only), Glow Plug Relay (Diesel Only) Wiper Control Module, Windshield Wiper Motor Main Light Switch, Park Lamps, License Lamp,(External Lamps) Multi-Function Switch (Flash-to-pass) Brake Pressure Switch, Multi-Function Switch (Hazards), Brake Lamp Switch, Brake Lamps Transmission Range (TR) Sensor, Backup Lamps, Auxiliary Battery Relay Blend Door Actuator, A/C Heater, Function Selector Switch Instrument Cluster (Air Bag and Charge Indicator) Trailer Battery Charge Relay Power Seats Not Used Not Used Air Bag Diagnostic Monitor Overdrive Cancel Switch Power Windows* Memory Power Radio, E Traveler Radio Cigar Lighter, Data Link Connector (DLC) Not Used Left Headlamp (Low Beam) Rear Power Point

127

Roadside emergencies

Fuse/Relay Location

Fuse Amp

Rating

Passenger Compartment Fuse Panel Description

27
28
29
30

31
32
33
34
35
36

37
38
39
40
41
42
43
44

5A 20A — 15A

10A 5A 20A 10A 30A 5A

20A 10A 20A 30A 30A —

20A C.B.

—

Radio Power Plug Not Used Headlamps (High Beam Indicator), DRL10A Right Headlamp (Low Beam), DRL Power Mirrors E Traveler Power Point #2
Transmission Range (TR) Sensor RKE Module (Cluster, A/C, Illumination, Radio), Steering Column Assembly Power Plug Air Bag Diagnostic Monitor E Traveler Power Point #1
Modified Vehicle Modified Vehicle Not Used Power Windows* Not Used

* Either Fuse 21 or Circuit breaker 43 will be present for power windows.

Power distribution box The power distribution box is located in the engine compartment. The power distribution box contains high-current fuses that protect your vehicle’s main electrical systems from overloads.

Always disconnect the battery before servicing high current fuses.

128

Roadside emergencies

Always replace the cover to the Power Distribution Box before reconnecting the battery or refilling fluid reservoirs.

If the battery has been disconnected and reconnected, refer to the Battery section of the Maintenance and care chapter.

32

The high-current fuses are coded as follows.

Fuse/Relay Location

Fuse Amp

Rating

Power Distribution Box Description

— — —

10A*

10A* 10A*

—

60A**

Not Used Not Used Not Used PCM Keep Alive Memory, Instrument Cluster, Voltmeter Right Trailer Turn Signal Left Trailer Turn Signal Not Used I/P Fuses 5, 11, 23, 38, 4, 10, 16, 22, 28, 32

129

Roadside emergencies

Fuse Amp

Rating 30A**

60A**

30A** 60A** 50A** 30A**

40A**

50A** 30A** 60A** 60A** 20A** 50A** 40A**

60A**

—

20A* 10A* 15A*

— — — — — — —

Power Distribution Box Description

PCM Power Relay, Engine Compartment Fuse 4
Auxiliary Battery Relay, Engine Compartment Fuses 14, 22
IDM Relay (Diesel Only) Engine Compartment Fuses 25, 27
Blower Motor Relay (Blower Motor) Trailer Running Lamps Relay, Trailer Backup Lamps Relay Main Light Switch, Daytime Running Lights (DRL) Auxiliary Blower Motor Relay Fuel Pump Relay I/P Fuses 40, 41,26, 33, 39
4WABS Module Electric Brake Controller Modified Vehicle Power Trailer Battery Charge Relay, Modified Vehicles Ignition Switch, Fuse Panel Not Used NGV Module (Natural Gas Only) A/C Clutch (4.2L Only) DRL Module, Horn Relay PCM Diode Not Used Not Used Stop Lamp Relay Trailer Backup Lamps Relay Trailer Running Lamps Relay Trailer Battery Charge Relay

Fuse/Relay Location

10

11
12
13
14

15

16
17
18
19
20
21
22

23
24
25
26
27
28
29

130

Roadside emergencies

Fuse/Relay Location

Fuse Amp

Rating

Power Distribution Box Description

—

— — — —

IDM Relay (Diesel Only), A/C Clutch Relay (4.2L Only) PCM Relay Blower Motor Relay Horn Relay Fuel Pump Relay

* Mini Fuses ** Maxi Fuses

Relays Relays are located in the power distribution box and should be replaced by qualified technicians.

CHANGING THE TIRES If you get a flat tire while driving, do not apply the brake heavily. Instead, gradually decrease your speed. Hold the steering wheel firmly and slowly move to a safe place on the side of the road.

Spare tire information The spare tire for your vehicle is stowed under the rear of your vehicle (except cutaway and stripped chassis models). Toremovethesparetire: 1. Open both rear doors and remove thumb screw and anti-theft bracket. If finger pressure will not remove the thumb screw, use the lug wrench to loosen the screw. 2. Remove the access cover from the rubber strip behind the left door.

131

Roadside emergencies

3. Remove the jack handle from the right side compartment and insert the tip of the jack handle through the access hole and into the tube. 4. Turn the jack handle counterclockwise until the cable is slack and the tire can be slid rearward from under the vehicle. 5. Remove the retainer from the spare tire. To stow the cable retainer with the spare removed, turn the jack handle clockwise until all slack is removed. Tostowthesparetire: 1. Lay the tire on the ground under the rear of the vehicle with the valve stem facing up. Stow aluminum wheels with valve stem facing down. 2. Install the retainer through the wheel center. 3. Raise the tire by turning the jack handle clockwise. Continue until the lift mechanism “clicks.” 4. Check that the tire is tightly seated under the vehicle by pushing against the tire. Retighten as necessary. 5. Replace the access cover, anti-theft bracket and thumb screw. Use finger pressure only to secure the thumb screw.

Make sure the spare tire and jacking equipment are stowed and secured in the proper storage location.

Never run the engine with one wheel off the ground.

132

Roadside emergencies

Tire change procedure Preparingtochangethetire

To prevent the vehicle from moving when you change a tire, be sure the parking brake is set, then block (in both directions) the wheel that is diagonally opposite (other side and end of the vehicle) to the tire being changed.

1. Park on a level surface. 2. Activate the warning flashers. 3. Place the gearshift in P (Park)(automatic transmission). 4. Apply the parking brake and turn engine OFF.

5. Block the wheel that is diagonally opposite the tire you are changing. On E-450 vehicles, the parking brake is on the transmission. Therefore, the vehicle will not be prevented from moving when a rear wheel is lifted, even if the parking brake is applied. Be sure to block both directions of the wheel that is diagonally opposite to the wheel that is being lifted.

If the vehicle slips off the jack, you or someone else could be seriously injured.

133

Roadside emergencies

6. Remove the spare tire and jack from the storage location. 7. Use the tapered end of the lug nut wrench to unscrew wheel ornaments attached by retaining screws. Remove any wheel trim. Insert the tapered end of the lug nut wrench behind wheel covers or hubcaps and twist off. 8. Loosen the wheel nut by pulling up on the handle of the lug nut wrench about one-half turn (counterclockwise). Do not remove the wheel lug nuts until you raise the tire off the ground.

Replacingthetire 1. Assemble the jack handle sections together and lock into jack. Use the jack handle to slide the jack under the vehicle.

To lessen the risk of personal injury, do not put any part of your body under the vehicle while changing a tire. Do not start the engine when your vehicle is on the jack. The jack is only meant for changing the tire.

2. Position the jack to raise the front or rear wheel.

134

† Never use the front or rear

differential as a jacking point.

Roadside emergencies

Rear axle jacking points: † All models except E-Super Duty

† E-Super Duty

135

Roadside emergencies

Front axle jacking points: † All models Place the jack under the pin on the front surface of the front axle. Do not place the jack under or on the steering linkage. 3. Turn the jack handle clockwise until the wheel is completely off the ground. 4. Remove the lug nuts with the lug nut wrench. 5. Replace the flat tire with the spare tire.

If your vehicle has single rear wheels, thread the lug nuts on the studs with the beveled face toward the wheel. If your vehicle has dual rear wheels, thread the two element swiveling lug nuts on the studs with the flange facing toward the wheel. 6. Use the lug nut wrench to screw the lug nut snugly against the wheel. 7. Lower the vehicle by turning the jack handle counterclockwise. 8. Remove the jack and fully tighten the lug nuts in the following pattern: † 5-lug wheel

136

† 8-lug wheel

Never use wheels or lug nuts different than the

original equipment as this could damage the wheel or mounting system. This damage could allow the wheels to come off while the vehicle is being driven.

Roadside emergencies

9. Replace any wheel covers, ornaments or hub caps. Make sure they are screwed or snapped in place. 10. Stow the jack, handle and lug wrench. 11. Unblock the wheels. On vehicles equipped with dual rear wheels, retighten the wheel lug nuts to the specified torque at 160 km (100 miles), and again at 800 km (500
miles) of new vehicle operation. On vehicles equipped with single rear wheels, retighten the lug nuts to the specified torque at 800 km (500 miles) of operation after any wheel change or any time the lug nuts are loosened.

Model

Bolt Size

Wheel Lug nut Torque*

Nm 135
190

Lb-ft 100
140

1/2-20
9/16-18

E-150
E-250, E-350 and E-Super Duty * Torque specifications are for nut and bolt threads free of dirt and rust. Do not use oil or grease on threads. Use only Ford recommended replacement fasteners.

137

Roadside emergencies

JUMP STARTING YOUR VEHICLE

The gases around the battery can explode if exposed to flames, sparks, or lit cigarettes. An explosion could result in injury or

vehicle damage.

Do not push start your vehicle. You could damage the catalytic converter.

Batteries contain sulfuric acid which can burn skin, eyes, and clothing, if contacted.

Do not attempt to push start your vehicle. Automatic transmissions do not have push-start capability.

Preparing your vehicle When the battery is disconnected or a new battery is installed, the transmission must relearn its adaptive strategy. As a result of this, the transmission may shift firmly. This operation is considered normal and will not effect function or durability of the transmission. Over time, the adaptive learning process will fully update transmission operation to its optimum shift feel. 1. Use only a 12–volt supply to start your vehicle. 2. Do not disconnect the battery of the disabled vehicle as this could damage the vehicle’s electrical system. 3. Park the booster vehicle close to the hood of the disabled vehicle making sure the two vehicles do not touch. Set the parking brake on both vehicles and stay clear of the engine cooling fan and other moving parts. 4. Check all battery terminals and remove any excessive corrosion before you attach the battery cables. Ensure that vent caps are tight and level. 5. Turn the heater fan on in both vehicles to protect any electrical surges. Turn all other accessories off.

138

Connecting the jumper cables

Roadside emergencies

+–

+–

1. Connect the positive (+) booster cable to the positive (+) terminal of the discharged battery. Note: In the illustrations, lightning bolts are used to designate the assisting (boosting) battery.

+–

+–

2. Connect the other end of the positive (+) cable to the positive (+) terminal of the assisting battery.

139

Roadside emergencies

+–

+–

3. Connect the negative (-) cable to the negative (-) terminal of the assisting battery.

+–

+–

4. Make the final connection of the negative (-) cable to an exposed metal part of the stalled vehicle’s engine, away from the battery and the carburetor/fuel injection system. Do not use fuel lines, engine rocker covers or the intake manifold as grounding points.

Do not connect the end of the second cable to the negative (-) terminal of the battery to be jumped. A spark may cause an

explosion of the gases that surround the battery.

5. Ensure that the cables are clear of fan blades, belts, moving parts of both engines, or any fuel delivery system parts.

140

Roadside emergencies

Jump starting 1. Start the engine of the booster vehicle and run the engine at moderately increased speed. 2. Start the engine of the disabled vehicle. 3. Once the disabled vehicle has been started, run both engines for an additional three minutes before disconnecting the jumper cables.

Removing the jumper cables

+–

+–

Remove the jumper cables in the reverse order that they were connected. 1. Remove the jumper cable from the ground metal surface. Note: In the illustrations, lightning bolts are used to designate the assisting (boosting) battery.

+–

+–

2. Remove the jumper cable on the negative (-) connection of the booster vehicle’s battery.

141

Roadside emergencies

+–

+–

3. Remove the jumper cable from the positive (+) terminal of the booster vehicle’s battery.

+–

+–

4. Remove the jumper cable from the positive (+) terminal of the disabled vehicle’s battery. After the disabled vehicle has been started and the jumper cables removed, allow it to idle for several minutes so the engine computer can relearn its idle conditions. When the battery is disconnected or a new battery is installed, the transmission must relearn its adaptive strategy. As a result of this, the transmission may shift firmly. This operation is considered normal and will not effect function or durability of the transmission. Over time, the adaptive learning process will fully update transmission operation to its optimum shift feel.

142

WRECKER TOWING

Roadside emergencies

If you need to have your vehicle towed, contact a professional towing service or, if you are a member, your roadside assistance center. It is recommended that your vehicle be towed by wheel lift or flatbed equipment. However, a slingbelt with T-hooks can also be used. If your vehicle is equipped with an air dam and must be towed from the front, it is recommended that your vehicle be towed by wheel lift or flatbed equipment to prevent damage to the air dam. If the vehicle is towed by other means or incorrectly, vehicle damage may occur. Ford Motor Company provides a towing manual for all authorized tow truck operators. Have your tow truck operator refer to this manual for proper hook-up and towing procedures for your vehicle.

143

Maintenance and care

SERVICE RECOMMENDATIONS To help you service your vehicle: † We highlight do-it-yourself items in the engine compartment for easy † We provide a scheduled maintenance guide which makes tracking

location.

routine service easy.

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

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

space, unless you are sure you have enough ventilation.

long hair does not get caught up in moving parts.

the battery and all fuel related parts.

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

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

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

144

Maintenance and care

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

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

HOOD

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

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

145

Maintenance and care

IDENTIFYING COMPONENTS IN THE ENGINE COMPARTMENT

Engine compartment component locations Refer to the 7.3 Liter Power Stroke Direct Injection Turbo Diesel Owner’s Guide Supplement for diesel engine component locations.

10

1. Windshield washer fluid reservoir 2. Engine oil filler cap (except 4.2L V6 engine) 3. Automatic transmission fluid dipstick 4. Air filter assembly 5. Engine oil dipstick 6. Engine oil filler cap (4.2L V6 engine only) 7. Power steering fluid reservoir 8. Brake fluid reservoir 9. Engine coolant reservoir 10. Battery

ENGINE OIL

Checking the engine oil