2003 Ford E 250 Owners Manual

control if you do not slow down or if you turn the steering wheel too sharply or abruptly.

• It often may be less risky to strike small objects, such as highway

reflectors, with minor damage to your vehicle rather than attempt a sudden return to the pavement which could cause the vehicle to slide sideways out of control or roll over. Remember, your safety and the safety of others should be your primary concern.

Vehicles with a higher center of gravity such as utility and four-wheel drive vehicles handle differently than vehicles with a

lower center of gravity. Utility and four-wheel drive vehicles are not designed for cornering at speeds as high as passenger cars any more than low-slung sports cars are designed to perform satisfactorily under off-road conditions. Avoid sharp turns, excessive speed and abrupt maneuvers in these vehicles. Failure to drive cautiously could result in an increased risk of loss of vehicle control, vehicle rollover, personal injury and death.

If your vehicle gets stuck in mud or snow If your vehicle gets stuck in mud or snow, it may be rocked out by shifting from forward and reverse gears, stopping between shifts in a steady pattern. Press lightly on the accelerator in each gear. Do not rock the vehicle if the engine is not at normal operating temperature or damage to the transmission may occur. Do not rock the vehicle for more than a minute or damage to the transmission and tires may occur, or the engine may overheat.

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

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EMERGENCY MANEUVERS • In an unavoidable emergency situation where a sudden sharp turn must be made, remember to avoid “over-driving” your vehicle, i.e., turn the steering wheel only as rapidly and as far as required to avoid the emergency. Excessive steering will result in less vehicle control, not more. Additionally, smooth variations of the accelerator and/or brake pedal pressure should be utilized if changes in vehicle speed are called for. Avoid abrupt steering, acceleration or braking which could result in an increased risk of loss of vehicle control, vehicle rollover and/or personal injury. Use all available road surface to return the vehicle to a safe direction of travel.

• In the event of an emergency stop, avoid skidding the tires and do not

attempt any sharp steering wheel movements.

Vehicles with a higher center of gravity such as utility and four-wheel drive vehicles handle differently than vehicles with a

lower center of gravity. Utility and four-wheel drive vehicles are not designed for cornering at speeds as high as passenger cars any more than low-slung sports cars are designed to perform satisfactorily under off-road conditions. Avoid sharp turns, excessive speed and abrupt maneuvers in these vehicles. Failure to drive cautiously could result in an increased risk of loss of vehicle control, vehicle rollover, personal injury and death. • If the vehicle goes from one type of surface to another (i.e., from concrete to gravel) there will be a change in the way the vehicle responds to a maneuver (steering, acceleration or braking). Again, avoid these abrupt inputs.

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 occupants or aftermarket equipment. • Payload: Combined maximum allowable weight of cargo, occupants 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.

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Driving • GVWR (Gross Vehicle Weight Rating): Maximum allowable total weight of the base vehicle, occupants, 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

towing vehicle (including occupants and cargo) and the loaded trailer.

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 • GCWR (Gross Combined Weight Rating): Maximum allowable combined weight of towing vehicle (including occupants and cargo) and the loaded trailer. • 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 occupants 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 range of trailer weight from zero to

the maximum trailer weight rating.

Remember to figure in the tongue load of your loaded trailer when figuring the total weight. The Safety Certification Label, located on the driver’s door pillar, lists vehicle weight rating limitations. Before adding any additional equipment, refer to these limitations. Always ensure that the weight of occupants, cargo and equipment is within the weight limitations, including both gross vehicle weight and front and rear gross axle weight rating limits. Note: Do not exceed the GVWR or the GAWR specified on the certification label.

Exceeding any vehicle weight rating limitation could result in serious damage to the vehicle, loss of vehicle control, vehicle

rollover, and/or personal injury.

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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.

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

this chapter.

Loaded vehicles 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 can 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 GCWR chart (in the Trailer Towing section in this chapter) for your type of engine and rear axle ratio. 2. Weigh your vehicle without cargo. To obtain correct weights, take your vehicle to a shipping company or an inspection station for trucks. 3. Subtract your loaded weight from the maximum GCWR in the chart. This is the maximum trailer weight your vehicle can tow. It must be below the maximum trailer weight shown in 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.

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Driving

Engine

Rear axle ratio

Maximum GCWR - kg

(lbs.)

Maximum

Loaded Trailer

Weight - kg

(lbs.)

Maximum

frontal area of trailer - m2 (ft2)

4.2L 4.6L 5.4L

4.2L 4.6L 5.4L

4.6L 5.4L

4.2L 4.6L 5.4L

4.2L

5.4L

4.2L 5.4L

4.2L 5.4L

4.2L

5.4L

E-150 Regular Van (6700 GVWR)

2268 (5000) 2903 (6400) 3084 (6800)

4536 (10000) 5216 (11500) 5443 (12000)

3.55
3.55
3.55
E-150 Regular Van (Crew) (6700 GVWR) 3.55
3.55
3.55

4536 (10000) 5216 (11500) 5443 (12000)

2178 (4800) 2812 (6200) 2994 (6600)

5.52 (60) 5.52 (60) 5.52 (60)

5.52 (60) 5.52 (60) 5.52 (60)

E-150 Regular Van (Conversion) (7000 GVWR)

3.55
3.55

5216 (11500) 5443 (12000)

2858 (6300) 3039 (6700)

5.52 (60) 5.52 (60)

E-150 Regular Van (7– and 8–passenger) (7000 GVWR)

3.55
3.55
3.55

4536 (10000) 5216 (11500) 5443 (12000)

2132 (4700) 2767 (6100) 2948 (6500)

E-250 Regular Van (7200 GVWR)

5.52 (60) 5.52 (60) 5.52 (60)

3.73

4763 (10500)

2313 (5100)

5.52 (60)

E-250 Regular Van (Conversion) (7900 GVWR)

3.73

5897 (13000)

3402 (7500)

5.52 (60)

.E-250 Regular Van (8600 GVWR)

2540 (5600) 3402 (7500)

4990 (11000) 5897 (13000)

4.10
3.73
E-250 Regular Van (Crew) (8600 GVWR) 4.10
3.73

4990 (11000) 5897 (13000)

2449 (5400) 3311 (7300)

5.52 (60) 5.52 (60)

5.52 (60) 5.52 (60)

E-250 Extended Van (7300 GVWR)

3.73

4763 (10500)

2268 (5000)

5.52 (60)

E-250 Extended Van (Conversion) (7500 GVWR)

3.73

5897 (13000)

3266 (7200)

5.52 (60)

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GCWR (Gross Combined Weight Rating)/Trailer Weights

Engine

Rear axle ratio

Maximum GCWR - kg

(lbs.)

Maximum

Loaded Trailer

Weight - kg

(lbs.)

Maximum

frontal area of trailer - m2 (ft2)

E-250 Extended Van (8600 GVWR)

2449 (5400) 3311 (7300)

4990 (11000) 5897 (13000)

4.10
3.73
E-250 Extended Van (Crew) (8600 GVWR) 4.10
3.73

4990 (11000) 5897 (13000)

2449 (5400) 3311 (7300)

E-350 Regular Van (9500 GVWR)

5443 (12000) 5897 (13000) 6804 (15000) 8391 (18500)

2858 (6300) 3311 (7300) 4173 (9200) 4536 (10000)

3.55
4.10
3.73
4.10
E-350 Regular Van (Crew) (9500 GVWR) 3.55
4.10
3.73
4.10

2767 (6100) 3221 (7100) 4082 (9000) 4536 (10000)

5443 (12000) 5897 (13000) 6804 (15000) 8391 (18500)

E-350 Extended Van (9400 GVWR)

5443 (12000) 5897 (13000) 6804 (15000) 8391 (18500)

2812 (6200) 3266 (7200) 4082 (9000) 4536 (10000)

3.55
4.10
3.73
4.10
E-350 Extended Van (Crew) (9250 GVWR) 3.55
4.10
3.73
4.10

2676 (5900) 3130 (6900) 3992 (8800) 4536 (10000)

5443 (12000) 5897 (13000) 6804 (15000) 8391 (18500)

5.52 (60) 5.52 (60)

5.52 (60) 5.52 (60)

5.52 (60) 5.52 (60) 5.52 (60) 5.52 (60)

5.52 (60) 5.52 (60) 5.52 (60) 5.52 (60)

5.52 (60) 5.52 (60) 5.52 (60) 5.52 (60)

5.52 (60) 5.52 (60) 5.52 (60) 5.52 (60)

E-350 Regular Wagon (8 passenger) (8600 GVWR)

3.73/4.10

3.73

5897 (13000) 6804 (15000)

3175 (7000) 3992 (8800)

5.52 (60) 5.52 (60)

4.2L 5.4L

4.2L 5.4L

5.4L 5.4L 6.8L 6.8L

5.4L 5.4L 6.8L 6.8L

5.4L 5.4L 6.8L 6.8L

5.4L 5.4L 6.8L 6.8L

5.4L 6.8L

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Driving

Engine

6.8L

Rear axle ratio

4.10

Maximum GCWR - kg

(lbs.)

Maximum

Loaded Trailer

Weight - kg

(lbs.)

Maximum

frontal area of trailer - m2 (ft2)

8391 (18500)

4536 (10000)

5.52 (60)

E-350 Regular Wagon (12 passenger) (8600 GVWR)

5.4L

3.73/4.10

5897 (13000)

3130 (6900)

5.52 (60)

E-350 Regular Wagon (12 passenger) (8600 GVWR)

6.8L 6.8L

5.4L 5.4L 6.8L 6.8L

5.4L 5.4L

6.8L 6.8L

3.73
4.10

6804 (15000) 8391 (18500)

3992 (8800) 4536 (10000)

5.52 (60) 5.52 (60)

E-350 Extended Wagon (12 passenger) (9300 GVWR)

3.55
4.10
3.73
4.10

5443 (12000) 5897 (13000) 6804 (15000) 8391 (18500)

2585 (5700) 3039 (6700) 3901 (8600) 4536 (10000)

5.52 (60) 5.52 (60) 5.52 (60) 5.52 (60)

E-350 Extended Wagon (15 passenger) (9100 GVWR)

3.55
4.10

5443 (12000) 5897 (13000)

2540 (5600) 2994 (6600)

5.52 (60) 5.52 (60)

E-350 Extended Wagon (15 passenger) (9300 GVWR)

3.73
4.10

6804 (15000) 8391 (18500)

3856 (8500) 4536 (10000)

5.52 (60) 5.52 (60)

E-350 Cutaway (138” wheelbase, single rear wheel) (9600 GVWR)

5.4L 6.8L

4.10
4.10

5897 (13000) 8391 (18500)

3629 (8000) 4536 (10000)

5.52 (60) 5.52 (60)

E-350 Cutaway (138” wheelbase, dual rear wheel) (10700 GVWR)

5.4L 6.8L

4.10
4.10

5897 (13000) 8391 (18500)

3583 (7900) 4536 (10000)

5.52 (60) 5.52 (60)

E-350 Cutaway (158” wheelbase, dual rear wheel) (11500 GVWR)

5.4L 6.8L

4.10
4.10

5897 (13000) 8391 (18500)

3538 (7800) 4536 (10000)

5.52 (60) 5.52 (60)

E-350 Cutaway (176” wheelbase, dual rear wheel) (11500 GVWR)

5.4L 6.8L

4.10/4.56
4.10/4.56

5897 (13000) 8391 (18500)

3538 (7800) 4536 (10000)

5.52 (60) 5.52 (60)

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GCWR (Gross Combined Weight Rating)/Trailer Weights

Engine

Rear axle ratio

Maximum GCWR - kg

(lbs.)

Maximum

Loaded Trailer

Weight - kg

(lbs.)

Maximum

frontal area of trailer - m2 (ft2)

E-350 Cutaway (138” wheelbase, dual rear wheel) (10000 GVWR)

5.4L 6.8L

4.10
4.10

5897 (13000) 8391 (18500)

3583 (7900) 4536 (10000)

5.52 (60) 5.52 (60)

E-350 Chassis Cab (138” wheelbase, dual rear wheel) (10700 GVWR)

5.4L 6.8L

4.10
4.10

5897 (13000) 8391 (18500)

3583 (7900) 4536 (10000)

5.52 (60) 5.52 (60)

E-350 Chassis Cab (158” wheelbase, dual rear wheel) (11500 GVWR)

5.4L 6.8L

4.10
4.10

5897 (13000) 8391 (18500)

3538 (7800) 4536 (10000)

5.52 (60) 5.52 (60)

E-350 Chassis Cab (176” wheelbase, dual rear wheel) (11500 GVWR)

5.4L 6.8L

4.10/4.56
4.10/4.56

5897 (13000) 8391 (18500)

5.52 (60) 5.52 (60) E-250 Stripped Chassis (Single rear wheel) (8600 GVWR) 5.52 (60)

3538 (7800) 4536 (10000)

4990 (11000)

3311 (7300)

4.09

4.2L

E-350 Stripped Chassis (138” wheelbase) (9600 GVWR)

5.4L 6.8L

3.55/4.10

4.10

5897 (13000) 8391 (18500)

3992 (8800) 4536 (10000)

5.52 (60) 5.52 (60)

E-350 Stripped Chassis (158” wheelbase) (9600 GVWR)

5.4L 6.8L

3.55/4.10

4.10

5897 (13000) 8391 (18500)

3946 (8700) 4536 (10000)

5.52 (60) 5.52 (60)

E-350 Stripped Chassis (138” wheelbase) (10000 GVWR)

5.4L 6.8L

4.10
4.10

5897 (13000) 8391 (18500)

3856 (8500) 4536 (10000)

5.52 (60) 5.52 (60)

E-350 Stripped Chassis (158” wheelbase) (10000 GVWR)

5.4L 6.8L

5.4L 6.8L

4.10
4.10

5897 (13000) 8391 (18500)

3856 (8500) 4536 (10000)

5.52 (60) 5.52 (60)

E-350 Chassis Cab (158” wheelbase) (11000 GVWR)

4.10
4.10

5897 (13000) 8391 (18500)

3856 (8500) 4536 (10000)

5.52 (60) 5.52 (60)

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Driving

Engine

Rear axle ratio

Maximum GCWR - kg

(lbs.)

Maximum

Loaded Trailer

Weight - kg

(lbs.)

Maximum

frontal area of trailer - m2 (ft2)

E-350 Stripped Chassis (176” wheelbase) (10000 GVWR)

4.10
4.10

5.4L 5.52 (60) 6.8L 5.52 (60) E-450 Cutaway and Chassis Cab (all wheelbases, all GVWRs) 6.8L 5.52 (60)

3810 (8400) 4536 (10000)

5897 (13000) 8391 (18500)

4536 (10000)

9072 (20000)

4.10/4.56

E-450 Stripped Chassis (all wheelbases, all GVWRs)

5.4L 6.8L

6.8L

4.56
4.56

5897 (13000) 8391 (18500)

3719 (8200) 4536 (10000)

E-550 (all wheelbases, all GVWRs)

5.52 (60) 5.52 (60)

4.88

9072 (20000)

4536 (10000)

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 4536 kg (10000 lbs)

For high altitude operation reduce GCWR by 2% per 300 meters (1000 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. Note: Do not exceed the GVWR or the GAWR specified on the certification label.

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Towing trailers beyond the maximum recommended gross trailer weight exceeds the limit of the vehicle and could result in

engine damage, transmission damage, structural damage, loss of vehicle control, vehicle rollover and personal injury.

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.

Safety chains Always connect the trailer’s safety chains to the frame or hook retainers of the vehicle hitch. 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.

Trailer brakes 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.

Trailer lamps 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.

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Using a step bumper (if equipped) 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. If it is necessary to relocate the trailer hitch ball position, a frame-mounted trailer hitch must be installed.

in transmission cooling.

Driving while you tow When towing a trailer: • Turn off the 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. • To eliminate excessive shifting, use a lower gear. This will also assist • 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. Do not apply your brakes continuously, as they may overheat and become less effective. Servicing after towing 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 weight. • 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 Maintenance and specifications chapter for the lubricant specification.

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

hitch, electrical connections and trailer wheel lug nuts.

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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 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. 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.

bottom edge of the rear bumper.

Exceeding these limits may allow water to enter vehicle components: • causing internal damage to the components. • affecting driveability, emissions and reliability. Replace the rear axle lubricant any time 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.

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

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Roadside Emergencies

Roadside Emergencies

GETTING ROADSIDE ASSISTANCE To fully assist you should you have a vehicle concern, Ford Motor Company 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 New Vehicle Limited Warranty period of three years or 60,000

km (36,000 miles), whichever occurs 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 Motor Company dealership, or your selling dealer if within 56.3 km (35 miles) of the nearest Ford Motor Company 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 Owner Information Guide for information on: • coverage period • exact fuel amounts • towing of your disabled vehicle • emergency travel expense reimbursement • travel planning benefits 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 Owner Information Guide in the glove compartment. U.S. Ford or Mercury vehicle customers who require roadside assistance, call 1–800–241–3673; Lincoln vehicle customers call 1–800–521–4140. Canadian customers who require roadside assistance, call 1–800–665–2006.

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If you need to arrange roadside assistance for yourself, Ford Motor Company will reimburse a reasonable amount. To obtain reimbursement information, U.S. Ford or Mercury vehicles customers call 1-800-241-3673; Lincoln vehicle customers call 1–800–521–4140. Canadian customers who need to obtain reimbursement information, 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, for uninterrupted Roadside Assistance coverage, you may purchase extended coverage prior to your Basic Warranty’s Roadside Assistance expiring. For more information and enrollment, contact 1–877–294–2582 or visit our website at www.ford.ca.

HAZARD FLASHER The hazard flasher is located on the steering column, just behind the steering wheel. The hazard flashers will operate when the ignition is in any position. Push in the flasher control and all front and rear direction signals will flash. Press the flasher control again to turn them off. Use it when your vehicle is disabled and is creating a safety hazard for other motorists. Note: With extended use, the flasher may run down your battery.

FUEL PUMP SHUT-OFF SWITCH FUEL RESET This device stops the electric fuel pump from sending fuel to the engine when your vehicle has had a substantial jolt. After an accident, if the engine cranks but does not start, this switch may have been activated.

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Except for commmercial stripped chassis vehicles, this switch is located in the passenger’s footwell, by the kick panel.

On commmercial stripped chassis vehicles, this switch is located on a bracket above the brake pedal. To reset the switch: 1. Turn the ignition OFF. 2. Check the fuel system for leaks. 3. If no leaks are apparent, reset the switch by pushing in on the reset button. 4. Turn the ignition ON. 5. Wait a few seconds and return the key to OFF. 6. Make another check of leaks.

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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. Note: 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. Standard fuse amperage rating and color

15

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

Grey Violet Pink Tan

Brown

Red Blue Yellow Natural Green

— — — — —

Maxi fuses

— — — — — — —

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.

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To remove a fuse use the fuse puller tool provided on the fuse panel cover.

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

Passenger Compartment Fuse

Panel Description

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, VCP and video screens, Overhead console 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

139

The fuses are coded as follows. Fuse Amp

Fuse/Relay Location

Rating

20A 15A

15A

15A

20A

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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

10A

10A 30A

30A

20A

15A

15A

15A

5A

5A 30A — — 10A 5A 30A 15A

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, Rear seat control unit, Video screen Cigar lighter, Data Link Connector (DLC) Not used

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Roadside Emergencies

Fuse/Relay Location

Fuse Amp

Rating

Passenger Compartment Fuse

Panel Description

25
26
27
28
29
30

31
32
33
34
35
36

37
38
39
40
41
42
43
44

10A — 5A 20A — 15A

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

20A 10A 20A 30A 30A —

20A C.B.

—

Left headlamp (low beam) Not used Radio Power plug Not used Headlamps (high beam indicator), DRL10A Right Headlamp (Low Beam), DRL Power mirrors Power point #2
Transmission Range (TR) sensor RKE module (Cluster, A/C, Illumination, Radio), Steering column assembly Rear power point Air bag diagnostic monitor 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.

Always replace the cover to the power distribution box before reconnecting the battery or refilling fluid reservoirs

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Roadside Emergencies

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

32

The high-current fuses are coded as follows.

Fuse/Relay Location

Fuse Amp

Rating

Power Distribution Box Description

10

11
12
13

142

— — — 10A*

10A* 10A* 20A* 60A** 30A** 60A**

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

Not used Not used Not used Powertrain Control Module (PCM) Keep Alive Memory, Instrument cluster, Voltmeter Right trailer turn signal Left trailer turn signal Clearance lamps I/P fuses 4, 5, 10, 11, 16, 22, 23, 28, 32, 38
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)

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

Roadside Emergencies

Power Distribution Box Description

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 33, 37, 39, 40, 41
4WABS module Electric brake controller Modified vehicle power Trailer battery charge relay, Modified vehicles Ignition switch, Fuse panel Natural gas tank valves (NGV only) NGV module (NGV only) A/C clutch (4.2L only) DRL module, Horn relay PCM diode Not used Marker lamps relay Stop lamp relay Trailer backup lamps relay Trailer running lamps relay Trailer battery charge relay IDM relay (Diesel only), A/C clutch relay (4.2L only) PCM relay Blower motor relay Horn relay Fuel pump relay

Fuse Amp

Rating 30A**

40A**

50A** 30A** 60A** 60A** 20A** 50A** 40A** 60A** 20A* 20A* 10A* 15A* — — — — — — — —

— — — —

Fuse/Relay Location

14

15

16
17
18
19
20
21
22
23
24
25
26
27
28
29

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

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Roadside Emergencies

CHANGING A FLAT TIRE If you get a flat tire while driving: • do not brake heavily. • gradually decrease the vehicle’s speed. • hold the steering wheel firmly. • slowly move to a safe place on the side of the road.

The use of tire sealants is not recommended and may compromise the integrity of your tires.

Spare tire information The spare tire for your vehicle is stowed under the rear of your vehicle (except cutaway and stripped chassis models). To remove the spare tire: 1. Open the rear doors and remove the 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.

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 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.

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Roadside Emergencies

Tire change procedure

Preparing to change the tire

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). 4. Apply the parking brake and turn the 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.

6. Remove the spare tire and jack from the storage location.

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Roadside Emergencies • non-chassis cab vehicles: jack is located in the rear right-hand side of the cargo area.

• E-350 chassis cab vehicles: jack is strapped to a bracket behind the driver’s seat.

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Roadside Emergencies

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. Replacing the tire 1. Assemble the jack handle sections together and lock into the 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. • Never use the front or rear

differential as a jacking point.

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Roadside Emergencies

Rear axle jacking points - All models except E-450 and E-550:

Rear axle jacking points - E-450
and E-550:

Front axle jacking points - All models except E-550: • All models except E-550
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. • Turn the jack handle clockwise until the wheel is completely off the ground. • Remove the lug nuts with the lug • Replace the flat tire with the

nut wrench.

spare tire.

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Roadside Emergencies

Front axle jacking points - E-550: Place the jack under the front axle directly below the springs. Do not place the jack under or on the steering linkage. • Slide the notched end of the jack

pump linkage.

• Insert the jack handle into the • Use an up-and-down motion with the jack handle to raise the wheel completely off the ground.

handle over the release valve and use the handle to slide the jack under the vehicle. Make sure the valve is closed by turning it clockwise.

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. 3. Use the lug nut wrench to screw the lug nut snugly against the wheel. 4. Lower the vehicle by turning the jack handle counterclockwise. 5. Remove the jack and fully tighten the lug nuts in the following pattern: • 5-lug wheel

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Roadside Emergencies • 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.

6. Install any wheel covers, ornaments or hub caps. Make sure they are screwed or snapped in place. 7. Stow the jack, handle and lug wrench. 8. Unblock the wheels. 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. 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. Bolt size

Wheel lug nut torque*

Model

Nm 135
190

Lb-ft 100
140

1/2-20
9/16-18

E-150
E-250, E-350
and E-450
E-550
* Torque specifications are for nut and bolt threads free of dirt and rust. Do not use oil or grease on threads (E-550 vehicles, refer to following Note). Use only Ford recommended replacement fasteners.

M14x1.5

200–225

150–165

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Roadside Emergencies

Note: For E-550 vehicles, on all two-piece flat wheel nuts, apply motor oil between the flat washer and the nut. Do not apply motor oil to the wheel nut threads or the wheel stud threads.

Stowing the flat/spare tire 1. Lay the tire on the ground with the valve stem facing in the direction specified on the Tire Changing Instructions located with the jack hardware. 2. Slide the wheel partially under the vehicle and install the retainer through the wheel center. Pull on the cable to align the components at the end of the cable. 3. Turn the jack handle clockwise until the tire is raised to its stowed position underneath the vehicle. The effort to turn the jack handle increases significantly and the spare tire carrier ratchets or slips when the tire is raised to the maximum tightness. Tighten to the best of your ability, to the point where the ratchet/slip occurs, if possible. The spare tire carrier will not allow you to overtighten. If the spare tire carrier ratchets or slips with little effort, take the vehicle to your dealer for assistance at your earliest convenience. 4. Check that the tire lies flat against the frame and is properly tightened. Try to push or pull, then turn the tire to be sure it will not move. Loosen and retighten, if necessary. Failure to properly stow the spare tire may result in failure of the winch cable and loss of the tire. 5. Repeat this tightness check procedure when servicing the spare tire pressure (every six months, per scheduled maintenance guide), or at any time that the spare tire is disturbed through service of other components. 6. If removed, install the spare tire lock (if equipped) into the bumper drive tube with the spare tire lock key (if equipped) and jack handle.

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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.

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; also, the