2002 Ford E 250 Owners Manual

miles) of driving (engine break-in period). You will get a more accurate measurement after 3,000 km–5,000 km (2,000 miles-3,000 miles).

Filling the tank The advertised fuel capacity of the fuel tank on your vehicle is equal to the rated refill capacity of the fuel tank as listed in the Refill capacities section of this chapter. The advertised capacity is the amount of the indicated capacity and the empty reserve combined. Indicated capacity is the difference in the

220

Maintenance and Specifications

an error in the reading will result if the engine is left running.

amount of fuel in a full tank and a tank when the fuel gauge indicates empty. Empty reserve is the small amount of fuel remaining in the fuel tank after the fuel gauge indicates empty. The amount of usable fuel in the empty reserve varies and should not be relied upon to increase driving range. When refueling your vehicle after the fuel gauge indicates empty, you might not be able to refuel the full amount of the advertised capacity of the fuel tank due to the empty reserve still present in the tank. For consistent results when filling the fuel tank: • Turn the engine/ignition switch to the off position prior to refueling, • Use the same filling rate setting (low — medium — high) each time • Allow no more than 2 automatic click-offs when filling. • Always use fuel with the recommended octane rating. • Use a known quality gasoline, preferably a national brand. • Use the same side of the same pump and have the vehicle facing the • Have the vehicle loading and distribution the same every time. Your results will be most accurate if your filling method is consistent.

same direction each time you fill up.

the tank is filled.

Calculating fuel economy 1. Fill the fuel tank completely and record the initial odometer reading (in kilometers or miles). 2. Each time you fill the tank, record the amount of fuel added (in liters or gallons). 3. After at least three to five tank fill-ups, fill the fuel tank and record the current odometer reading. 4. Subtract your initial odometer reading from the current odometer reading. 5. Follow one of the simple calculations in order to determine fuel economy:

Calculation 1: Multiply liters used by 100, then divide by total kilometers traveled. Calculation 2: Divide total miles traveled by total gallons used.

Keep a record for at least one month and record the type of driving (city or highway). This will provide an accurate estimate of the vehicle’s fuel

221

Maintenance and Specifications

economy under current driving conditions. Additionally, keeping records during summer and winter will show how temperature impacts fuel economy. In general, lower temperatures give lower fuel economy.

fuel.

economy.

Driving style — good driving and fuel economy habits Give consideration to the lists that follow and you may be able to change a number of variables and improve your fuel economy. Habits • Smooth, moderate operation can yield up to 10% savings in fuel. • Steady speeds without stopping will usually give the best fuel • Idling for long periods of time (greater than one minute) may waste • Anticipate stopping; slowing down may eliminate the need to stop. • Sudden or hard accelerations may reduce fuel economy. • Slow down gradually. • Driving at reasonable speeds (traveling at 88 km/h [55 mph] uses 15% • Revving the engine before turning it off may reduce fuel economy. • Using the air conditioner or defroster may reduce fuel economy. • You may want to turn off the speed control in hilly terrain if unnecessary shifting between third and fourth gear occurs. Unnecessary shifting of this type could result in reduced fuel economy.

less fuel than traveling at 105 km/h [65 mph]).

reduce fuel economy.

• Warming up a vehicle on cold mornings is not required and may • Resting your foot on the brake pedal while driving may reduce fuel • Combine errands and minimize stop-and-go driving. Maintenance • Keep tires properly inflated and use only recommended size. • Operating a vehicle with the wheels out of alignment will reduce fuel • Use recommended engine oil. Refer to Lubricant specifications in

economy.

economy.

this chapter.

222

Maintenance and Specifications

• Perform all regularly scheduled maintenance items. Follow the

recommended maintenance schedule and owner maintenance checks found in your vehicle scheduled maintenance guide.

at any speed.

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

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

driving on hilly terrain.

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

12–16 km (8–10 miles) of driving.

cruise gear and with steady pressure on the gas pedal.

• Using fuel blended with alcohol may lower fuel economy. • Fuel economy may decrease with lower temperatures during the first • Driving on flat terrain offers improved fuel economy as compared to • Transmissions give their best fuel economy when operated in the top • Close windows for high speed driving. EPA window sticker Every new vehicle should have the EPA window sticker. Contact your dealer if the window sticker is not supplied with your vehicle. The EPA window sticker should be your guide for the fuel economy comparisons with other vehicles. It is important to note the box in the lower left corner of the window sticker. These numbers represent the Range of 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.

223

Maintenance and Specifications • 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.

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.

224

Maintenance and Specifications

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.

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.

225

Maintenance and Specifications

2. If the fluid level is low, start the engine. 3. While the engine idles, turn the steering wheel left and right several times. 4. Turn the engine off.

For E-450 and E-550 vehicles with the Hydro-Boost Brake System, do not press the brake pedal after the engine has been

turned off.

5. Recheck the fluid level on the dipstick. Do not add fluid if the level is between the arrows in the FULL COLD range. 6. If the fluid is low, add fluid in small amounts, continuously checking the level until it reaches the FULL COLD range. Be sure to put the dipstick back in the reservoir.

BRAKE FLUID

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

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Maintenance and Specifications

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.

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

TRANSMISSION FLUID

Checking automatic transmission fluid (if equipped) Refer to your scheduled maintenance guide for scheduled intervals for fluid checks and changes. Your transmission does not consume fluid. However, the fluid level should be checked if the transmission is not working properly, i.e., if the transmission slips or shifts slowly or if you notice some sign of fluid leakage. Automatic transmission fluid expands when warmed. To obtain an accurate fluid check, drive the vehicle until it is at normal operating temperature (approximately 30 km [20 miles]). If your vehicle has been operated for an extended period at high speeds, in city traffic during hot weather or pulling a trailer, the vehicle should be turned off for about 30
minutes to allow fluid to cool before checking. 1. Drive the vehicle 30 km (20 miles) or until it reaches normal operating temperature. 2. Park the vehicle on a level surface and engage the parking brake. 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.

227

Maintenance and Specifications

5. Remove the dipstick, wiping it clean with a clean, dry lint free rag. If necessary, refer to Identifying components in the engine compartment in this chapter for the location of the dipstick. 6. Install the dipstick making sure it is fully seated in the filler tube. 7. Remove the dipstick and inspect the fluid level. The fluid should be in the designated area for normal operating temperature or ambient temperature. Low fluid level Do not drive the vehicle if the fluid level is at the bottom of the dipstick and the ambient temperature is above 10°C (50°F). Correct fluid level The transmission fluid should be checked at normal operating temperature 66°C-77°C (150°F-170°F) on a level surface. The normal operating temperature can be reached after approximately 30 km (20
miles) of driving. You can check the fluid without driving if the ambient temperature is above 10°C (50°F). However, if fluid is added at this time, an overfill condition could result when the vehicle reaches normal operating temperature. The transmission fluid should be in this range if at normal operating temperature (66°C-77°C [150°F-170°F]). The transmission fluid should be in this range if at ambient temperature (10°C-35°C [50°F-95°F]).

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.

228

Maintenance and Specifications

Adjusting automatic transmission fluid levels Before adding any fluid, make sure the correct type is used. The type of fluid used is normally indicated on the dipstick and also in the Lubricant specifications section in this chapter. Use of a non-approved automatic transmission fluid may cause internal transmission component damage. If necessary, add fluid in 250 ml (1/2 pint) increments through the filler tube until the level is correct. If an overfill occurs, excess fluid should be removed by a qualified technician. An overfill condition of transmission fluid may cause shift and/or engagement concerns and/or possible damage. Do not use supplemental transmission fluid additives, treatments or cleaning agents. The use of these materials may affect transmission operation and result in damage to internal transmission components.

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

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

229

Maintenance and Specifications

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

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

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

230

Maintenance and Specifications

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 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.

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Maintenance and Specifications

SERVICING YOUR TIRES

Tire inflation information The E550 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 reduce the risk of

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

232

Maintenance and Specifications

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

• Five tire rotation

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Maintenance and Specifications

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

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

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

Make sure that all replacement tires are of the same size, type, 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

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Maintenance and Specifications

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.

MOTORCRAFT PART NUMBERS Component1 4.2L V6
engine FA-1634

4.6L V8
engine FA-1634

5.4L V8
engine FA-1634

6.8L V10
engine FA-1634

BH-65DC

BH-65DC

BH-65DC

BH-65DC

BXT-65-750

BXT-65-750

BXT-65-750

BXT-65-750

FG-872
FL-400-S EV-251

Air filter element Battery (standard) Battery (auxiliary) Fuel filter Oil filter PCV valve Spark plugs2 AGSF-34EEM3AWSF-32PP4 AGSF-22W AGSF-22W 1Refer to the 7.3 Liter Power Stroke Direct Injection Turbo Diesel Owner’s Guide Supplement for Motorcraft diesel engine service part numbers. 2Refer to Vehicle Emissions Control Information (VECI) decal for spark plug gap information. 3If a spark plug is removed for inspection, it must be reinstalled in the same cylinder. Cylinders No. 1, 2 and 3 have a “EGM” suffix. Cylinders

FG-872
FL-820-S EV-233

FG-872
FL-820-S EV-233

FG-872
FL-820-S EV-233

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Maintenance and Specifications

No. 4, 5 and 6 have a “EM” suffix. If a spark plug needs to be replaced, use only spark plugs with the service part number suffix letter ⬙EEM⬙ as shown on the engine decal. 4 If a spark plug is removed for inspection, it must be reinstalled in the same cylinder. Cylinders No. 1, 2, 3 and 4 have a “PG” suffix. Cylinders No. 5, 6, 7 and 8 have a “P” suffix. If a spark plug needs to be replaced, use only spark plugs with the service part number suffix letter as shown on the engine decal.

All

Capacity

Application

Fill to line on reservoir

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

5.7L (6.0
quarts)

All

REFILL CAPACITIES Fluid

Brake fluid

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

236

Fluid

Engine coolant-gasoline engine 1

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

Maintenance and Specifications

Application

Capacity

4.2L V6 engine

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

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

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

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

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

5.4L V8 engine with aux rear heat 6.8L V10 engine 29.0L (30.6

6.8L V10 engine with aux rear heat

quarts) 31.0L (32.8
quarts)

Engine coolant-diesel engine Power steering fluid

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

Motorcraft MERCON威 ATF

All

Keep in FULL range on dispstick

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Maintenance and Specifications

Fluid

Rear axle4

Ford Part Name Motorcraft SAE 75W-140
Synthetic rear axle lubricant Motorcraft 80W-90
Premium rear axle lubricant

Fuel tank

N/A

Application

Capacity

Visteon 8.8/9.75
inch conventional and Traction-Lok Dana 9.75 inch (M60-IU) Dana 10.5 inch (M70-2U) Dana 10.5 inch (M70-1HD) Dana 135
(E-550 only) All regular and extended length vans and wagons 138 inch wheelbase (except E-Super Duty) 158 inch wheelbase (except E-Super Duty) 176 inch wheelbase (except E-Super Duty) 158 inch and 176 inch wheelbase (E-Super Duty) E-550

2.6-2.7L (5.5-5.8
pints) 2

3.0L (6.3 pints)

3.1L (6.6 pints)

3.5L (7.5 pints)

11.6L (24.5
pints) 3
132.4L (35.0
gallons)

140.0L (37.0
gallons)

140.0L (37.0
gallons) 5

140.0L (37.0
gallons)

208.0L (55 .0
gallons)

208.0L (55.0
gallons)

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Maintenance and Specifications

Fluid

Transmission fluid 6

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

Windshield washer fluid

Motorcraft Ultra-Clear Windshield Washer Concentrate

Application

Capacity

Automatic (4R70W)

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

13.2L (13.9
quarts) 7

16.1L (17.0
quarts) 7

16.7L (17.7
quarts) 7

4.0L (4.2
quarts)

1Add the coolant type originally equipped in your vehicle. 2If your vehicle’s rear axle is filled with a synthetic rear axle lubricant it is considered lubricated for life. These lubricants do not need to be checked or changed unless a leak is suspected, service is required or the axle assembly has been submerged in water. The axle lubricant should be changed any time the rear axle has been submerged in water. Fill 6 mm to 14 mm (1/4 inch to 9/16 inch) below bottom of fill hole. Add 118 ml (4 oz.) of Additive Friction Modifier XL-3 or equivalent meeting Ford specification EST-M2C118–A, for complete refill of 8.8 inch and 9.75 inch Traction-Lok axles. 3Fill Dana rear axles to 6 mm to 19 mm (1/4 inch to 3/4 inch) below bottom of fill hole. 4Visteon Traction-Lok axles require 118 ml (4 oz.) of Additive Friction Modifier XL—3 or equivalent meeting Ford specification EST-M2C118–A. Dana limited-slip axles (E250/350/450/550) require 237ml (8 oz.) of Additive Friction Modifier C8AZ—19B546–A or equivalent meeting Ford specification EST-M2C118-A. 5Optional fuel tank 208L (55 gallon). 6Ensure the correct automatic transmission fluid is used. Transmission fluid requirements are indicated on the dipstick or on the dipstick

239

Maintenance and Specifications

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. 7Approximate dry fill capacity including transmission fluid cooling system, actual refill capacities will vary based on vehicle application and transmission fluid cooling system (i.e. coolers size, cooling lines. auxiliary cooler capacities). The amount of transmission fluid and fluid level should be set by the indication on the dipstick’s normal operating range.

LUBRICANT SPECIFICATIONS Item

Brake fluid

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

Ford part number PM-1

Ford specification ESA-M6C25-A and DOT 3

Door weatherstrips Silicone

Lubricant

F7AZ-19G208-BA and F5AZ-19553-AA

ESR-M13P4-A

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Item

Engine coolant

Engine oil-gasoline engine

Engine oil-diesel engine

Hinges, latches, Striker plates, fuel filler door hinge, and seat tracks Lock cylinders

Power steering fluid Automatic transmission (4R100) 1
Automatic tranmission (4R70W) 1

Maintenance and Specifications

Ford specification ESE-M97B44-A

WSS -M97B51-A1

WSS-M2C153-H with API Certification Mark

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

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

XG–4 or F5AZ-19G209-AA

XO-5W20-QSP

ESR-M1C159-A

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

Motorcraft MERCON威V ATF

Motorcraft XL-1

none

XT-2-QDX

MERCON威

XT-2-QDX

MERCON威

XT-5-QM

MERCON威V

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Maintenance and Specifications

Item

Disc brake caliper rails

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

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

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

Ford part name Motorcraft Silicone Brake Caliper Grease and Dielectric Compound Motorcraft MERCON威 Automatic Transmission Fluid Motorcraft SAE 75W-140 High Performance Synthetic Rear Axle Lubricant Motorcraft SAE 80W-90 Premium Rear Axle Lubricant

Motorcraft Ultra-clear Windshield Washer Concentrate

Ford part number XG-4

Ford specification ESE-M1C171-A

XT-2-QDX

MERCON威

XY-75W140–QL WSL-M2C192-A

XY-80W90-QL

WSP-M2C197-A

ZC-18–A

ESR-M17P5-A

1Ensure the correct automatic transmission fluid is used. Transmission fluid requirements are indicated on the dipstick or on the dipstick handle. Check the container to verify the fluid being added is of the correct type. Refer to your scheduled maintenance guide to determine the correct service interval. Some transmission fluids may be labeled as dual usage, such as MERCON威 and MERCON威 V. These dual usage fluids are not to be used in an automatic transmission that requires use of the MERCON威 type fluid. However, these dual usage fluids may be used in transmissions that require the MERCON威 V type fluid.

242

Maintenance and Specifications

MERCON威 and MERCON威 V type fluids are not interchangeable. DO NOT mix MERCON威 and MERCON威 V. Use of a transmission fluid that indicates dual usage (MERCON威 and MERCON威 V) in an automatic transmission application requiring MERCON威 may cause transmission damage. Use of any fluid other than the recommended fluid may cause transmission damage. 2Add 118 ml (4 oz.) of Additive Friction Modifier XL-3 or equivalent meeting Ford specification EST-M2C118-A for complete refill of Visteon Traction-Lok rear axles. 3Add 237 ml (8 oz.) of Additive Friction Modifier XL-3 or equivalent meeting Ford specification EST-M2C118-A for complete refill of Dana Traction-Lok rear axles.

ENGINE DATA

Engine*

4.2L V6
engine

Cubic inches 256
Required fuel

87 octane

Firing order

1-4-2-5-3-6

Spark plug gap

1.3-1.4 mm (0.052-0.056
inch) EDIS

4.6L V8
engine 281
87 octane

5.4L V8
engine 330
87 octane

6.8L V10
engine 415
87 octane

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

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

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

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

9.3:1

9.4:1

9.0:1

9.0:1

243

Maintenance and Specifications

VEHICLE DIMENSIONS

Van/wagon models

(1) Overall height

2055 mm (80.9

2118 mm (83.4

in)

in)

E-150

E-250

E-350

2136 mm (84.1 in)

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

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

2014 mm (79.3 in)

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

Extended, 5890 mm (231.9 in)

244

Maintenance and Specifications

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

E-250

E-350

E-550
Super Duty

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

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

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

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

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

(3) Overall width

Refer to Body Builder for specifications.

245

Maintenance and Specifications

Dimension

E-250

E-350

(4) Wheelbase

3 149.6 mm (124 in)

Body style E-450
Super Duty 4 013 mm (158 in) 4 470 mm (176 in)

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

E-550
Super Duty 4 051 mm (159.5 in) 4 508 mm (177.5 in) 4 864 mm (191.5 in) 5 321 mm (209.5 in) 5 930 mm (233.5 in)

(5) Overall length

Refer to Body Builder for specifications.

VEHICLE IDENTIFICATION NUMBER

driver’s side.

Complete Ford built vehicles The vehicle identification number is attached to your vehicle in the following places: • On the metal tag attached to the top of the instrument panel on the • On the certification label. This label is required by the National Highway Traffic Safety Administration and is made of special material. If it is tampered with, it will be destroyed or a destruction pattern will appear.

246

Maintenance and Specifications

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

247

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 Styled wheel locks Vehicle security systems

Comfort and convenience Engine block heaters Remote start Tire step

Travel equipment Auto head lamps with DRL Bicycle rack Cell phone holder Console (Engine cover) Daytime running lights (DRL)

248

Accessories

First aid and highway kits Fog lights Hitch mount bicycle carrier Inside mirror, electrochromic with compass (with and without temperature display) Removable roof rack Running boards — Aluminum and Platinum elliptical Speed control Tailgate table TracRac Trailer hitch (Class III) Trailer hitch bars and balls Trailer hitch wiring adaptor

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

249

Accessories

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.

250

A

ABS (see Brakes) .....................141
Air bag supplemental restraint system ................................119–120
and child safety seats ............121
description ..............................120
disposal ....................................124
driver air bag ..........................122
indicator light ...................12, 123
operation .................................122
passenger air bag ...................122
Air cleaner filter ...............229, 235
Air conditioning

manual heating and air conditioning system .................71
Ambulance packages ....................6
Antifreeze (see Engine coolant) .....................................209
Anti-lock brake system (see Brakes) ..............................141
Audio system (see Radio) ................17, 22, 28, 36
Automatic transmission

driving an automatic overdrive .................................146
fluid, adding ............................227
fluid, checking ........................227
fluid, refill capacities ..............236
fluid, specification ..................243
Auxiliary power point .................86
Axle

lubricant specifications ..240, 243
refill capacities ........................236
traction lok ..............................143

Battery .......................................204

Index

acid, treating emergencies .....204
charging system warning light ............................................12
disconnecting ..........................206
jumping a disabled battery ....175
maintenance-free ....................204
replacement, specifications ...235
servicing ..................................204
voltage gauge ............................15
BeltMinder .................................115
Brakes ........................................140
anti-lock ...................................141
anti-lock brake system (ABS) warning light .....................12, 142
brake warning light ..................11
fluid, checking and adding ....226
fluid, refill capacities ..............236
fluid, specifications .........240, 243
lubricant specifications ..240, 243
shift interlock ..........................145
Break-in period .............................5
Bulbs ............................................79

Capacities for refilling fluids ....236
CD-6 disc .....................................36
CD-single premium .....................28
Changing a tire .........................168
Child safety restraints ..............125
child safety belts ....................125
Child safety seats ......................127
in front seat ............................129
in rear seat ..............................129
tether anchorage hardware ...131

Cleaning your vehicle

engine compartment ..............192
exterior ....................................195
instrument panel ....................194

251

Index

interior .....................................195
plastic parts ............................193
washing ....................................191
waxing .....................................191
wheels ......................................192
wiper blades ....................193–194
woodtone trim ........................195

Climate control (see Air conditioning or Heating) ......70–71
Clock ..........................20, 25, 32, 40
Compass, electronic ....................94
calibration .................................95
set zone adjustment .................95

Console

overhead ....................................93

Daytime running lamps (see Lamps) ................................76
Dipstick

automatic transmission fluid ..........................................227
engine oil .................................201

Doors

lubricant specifications ..........240

Driveline universal joint and slip yoke ....................................227
Driving under special conditions

through water .........................148

Controls

power seat ...............................102

Coolant

checking and adding ..............209
refill capacities ................213, 236
specifications ..................240, 243

Cruise control (see Speed control) ........................................88
Customer Assistance ................158

Ford accessories for your vehicle .............................195–196
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 .......................................184
Utilizing the Mediation/Arbitration Program ...................................187

252

Emergencies, roadside

jump-starting ..........................175
Emission control system ..........223
Engine ................................243–244

check engine/service engine soon light ..................................10
cleaning ...................................192
coolant .....................................209
diesel ...........................................6
fail-safe coolant ......................214
idle speed control ...................204
lubrication specifications ..................240, 243
refill capacities ........................236
service points ..........................199
starting after a collision .........160
Engine block heater .................139
Engine oil ..................................201
checking and adding ..............201
dipstick ....................................201
filter, specifications ........203, 235
recommendations ...................203

refill capacities ........................236
specifications ..................240, 243
Exhaust fumes ..........................140

Fail safe cooling ........................214
Fluid capacities .........................236
Four-Wheel Drive vehicles

preparing to drive your vehicle .....................................144
Fuel ............................................216
calculating fuel economy .......220
cap ...........................................218
capacity ...................................236
choosing the right fuel ...........218
comparisons with EPA fuel economy estimates .................223
detergent in fuel .....................220
filling your vehicle with fuel ...........................216, 218, 220
filter, specifications ........220, 235
fuel pump shut-off switch .....160
gauge .........................................16
improving fuel economy ........220
low fuel warning light ..............12
octane rating ...........219, 243–244
quality ......................................219
running out of fuel .................220
safety information relating to automotive fuels .....................216
Fuses ..................................161–162

Garage door opener ....................93
Gas cap (see Fuel cap) ............218
Gas mileage (see Fuel economy) ...................................220
Gauges .........................................14

Index

battery voltage gauge ...............15
engine coolant temperature gauge .........................................14
engine oil pressure gauge ........15
fuel gauge ..................................16
odometer ...................................16
speedometer .............................16
trip odometer ............................16

GAWR (Gross Axle Weight Rating) .......................................149
calculating ...............................151
definition .................................149
driving with a heavy load ......149
location ....................................149

GVWR (Gross Vehicle Weight Rating) .......................................149
calculating .......................149, 151
definition .................................149
driving with a heavy load ......149
location ....................................149

Hazard flashers .........................159
Headlamps ...................................76
aiming ........................................77
bulb specifications ....................79
daytime running lights .............76
flash to pass ..............................77
high beam ...........................13, 76
replacing bulbs ...................80–81
turning on and off ....................76
warning chime ..........................14

Heating

auxiliary heater and air conditioner ................................75
heater only system ...................70
heating and air conditioning system .......................................71
Hood ..........................................199
Ignition .......................136, 243–244

253

Index

Infant seats (see Safety seats) .....................127
Inspection/maintenance (I/M) testing ........................................224
Instrument panel

cleaning ...................................194
cluster ........................................10
lighting up panel and interior .......................................77

Jack ............................................168
positioning ...............................168
storage .....................................168
Jump-starting your vehicle ......175

Keys

key in ignition chime ...............14
positions of the ignition .........136

Lamps

bulb replacement specifications chart ..................79
cargo lamps ...............................77
daytime running light ...............76
headlamps .................................76
headlamps, flash to pass ..........77
instrument panel, dimming .....77
interior lamps ...........................78
replacing bulbs ...................79–83

Lane change indicator (see Turn signal) ........................77
Lights, warning and indicator ....10
air bag ........................................12
anti-lock brakes (ABS) ....12, 142
brake ..........................................11

254

charging system ........................12
check coolant ............................13
cruise indicator .........................13
engine oil pressure ...................13
high beam .................................13
low fuel ......................................12
safety belt .................................12
service engine soon ..................10
speed control ............................92
turn signal indicator .................13

Limited slip axle (see Traction Loc) ............................................143
Load limits .................................149
GAWR ......................................149
GVWR ......................................149
trailer towing ..........................149
Loading instructions .................150
Lubricant specifications ...240, 243
Lumbar support, seats .............102

Mirrors

fold away ...................................88
side view mirrors (power) .......87
Motorcraft parts ................220, 235

Octane rating ............................219
Odometer .....................................16
Oil (see Engine oil) ..................201
Overdrive .....................................92

Panic alarm feature, remote entry system ................................99
Parking brake ............................142

Parts (see Motorcraft parts) ....235
Power distribution box (see Fuses) ...............................165
Power door locks ........................97
Power mirrors .............................87
Power point .................................86
Power steering ..........................143
fluid, checking and adding ....225
fluid, refill capacity ................236
fluid, specifications .........240, 243
Power Windows ...........................86
Preparing to drive your vehicle ........................................144

Radio ..........................17, 22, 28, 36
Radio reception ...........................69
Relays ................................161, 168
Remote entry system ...........97, 99
illuminated entry ....................100
locking/unlocking doors .....97–98
panic alarm ...............................99
replacement/additional transmitters .............................100
replacing the batteries .............99
Roadside assistance ..................158

Index

for children .....................124–125
lap belt ....................................113
warning light and chime ...........................12–14, 114
Safety seats for children ..........127
Seat belts (see Safety restraints) ..................................109
Seats ..........................................101
child safety seats ....................127
Servicing your vehicle ..............198
Spare tire (see Changing the Tire) ...........................................168
Spark plugs, specifications .............235, 243–244
Special notice

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

Specification chart, lubricants ...........................240, 243
Speed control ..............................88
Speedometer ...............................16
Starting your vehicle ........136–138
jump starting ..........................175

Steering wheel

controls ................................85, 88
tilting .........................................85

Safety belts (see Safety restraints) ....................14, 109–113
Safety defects, reporting ..........190
Safety restraints ................109–113
belt minder .............................115
cleaning the safety belts ........118
extension assembly ................118
for adults .........................110–112

Temperature control (see Climate control) .................70
Tires ...........................168, 230–232
changing ..........................168, 170
replacing ..........................171, 234
rotating ....................................233
snow tires and chains ............234
tire grades ...............................231

255

Index

treadwear ................................231
Towing .......................................151
recreational towing .................157
trailer towing ..........................151
wrecker ....................................180
Traction-lok rear axle ...............143
Transmission .............................145

fluid, checking and adding (automatic) .............................227
fluid, refill capacities ..............236
lubricant specifications ..240, 243

Transmission control indicator light ..............................................13
Trip odometer .............................16
Trunk ...........................................96
Turn signal ............................13, 77

Vehicle dimensions ...................244

Vehicle Identification Number (VIN) ..........................................246
Vehicle loading ..........................149
Ventilating your vehicle ...........140

Warning chimes .....................13–14
Warning lights (see Lights) .......10
Washer fluid ..............................200
Water, Driving through .............148
Windows

power .........................................86

Windshield washer fluid and wipers

checking and adding fluid .....200
checking and cleaning ..............84
operation ...................................84
replacing wiper blades .............85
Wrecker towing .........................180

256