2004 Ford E 250 Owners Manual

60 (5.52)

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

5.4L

5.4L

3.55

4.10

12000
(5443) 13000
(5897)

5700 (2585)

60 (5.52)

6700 (3039)

60 (5.52)

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Driving

GCWR (Gross Combined Weight Rating)/Trailer Weights

Engine

6.8L

6.8L

Rear axle ratio

3.73

4.10

Maximum GCWR - lbs. (kg)

Maximum

Loaded

Trailer Weight

- lbs. (kg)

Maximum

frontal area of

trailer - ft2

(m2)

15000
(6804) 18500
(8391)

8400 (3810)

60 (5.52)

10000 (4536)

60 (5.52)

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

5.4L

5.4L

3.55

4.10

12000
(5443) 13000
(5897)

5600 (2540)

60 (5.52)

6600 (2994)

60 (5.52)

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

6.8L

6.8L

3.73

4.10

15000
(6804) 18500
(8391)

8400 (3810)

60 (5.52)

10000 (4536)

60 (5.52)

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

GVWR)

5.4L

6.8L

4.10

4.10

13000
(5897) 18500
(8391)

7900 (3583)

60 (5.52)

10000 (4536)

60 (5.52)

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

GVWR)

5.4L

6.8L

4.10

4.10

13000
(5897) 18500
(8391)

7800 (3538)

60 (5.52)

10000 (4536)

60 (5.52)

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GCWR (Gross Combined Weight Rating)/Trailer Weights

Driving

Engine

Rear axle ratio

Maximum GCWR - lbs. (kg)

Maximum

Loaded

Trailer Weight

- lbs. (kg)

Maximum

frontal area of

trailer - ft2

(m2)

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

GVWR)

5.4L

6.8L

4.10

4.10

13000
(5897) 18500
(8391)

7700 (3493)

60 (5.52)

10000 (4536)

60 (5.52)

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

GVWR)

5.4L

4.10

6.8L

4.10/4.56

13000
(5897) 18500
(8391)

7700 (3493)

60 (5.52)

10000 (4536)

60 (5.52)

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

GVWR)

5.4L

6.8L

4.10

4.10

13000
(5897) 18500
(8391)

7700 (3493)

60 (5.52)

10000 (4536)

60 (5.52)

E-350 Stripped Chassis (158” wheelbase, dual rear wheel)

(11500 GVWR)

5.4L

6.8L

4.10

4.10

13000
(5897) 18500
(8391)

7600 (3447)

60 (5.52)

10000 (4536)

60 (5.52)

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

GVWR)

5.4L

4.10

6.8L

4.10/4.56

13000
(5897) 18500
(8391)

7700 (3493)

60 (5.52)

10000 (4536)

60 (5.52)

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Driving

GCWR (Gross Combined Weight Rating)/Trailer Weights

Engine

Rear axle ratio

Maximum GCWR - lbs. (kg)

Maximum

Loaded

Trailer Weight

Maximum

frontal area of

trailer - ft2

(m2) E-350 Stripped Chassis (138” wheelbase) (9600 GVWR)

- lbs. (kg)

5.4L

3.55/4.10

6.8L

4.10

13000
(5897) 18500
(8391)

8800 (3992)

60 (5.52)

10000 (4536)

60 (5.52)

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

5.4L

3.55/4.10

6.8L

4.10

13000
(5897) 18500
(8391)

8700 (3946)

60 (5.52)

10000 (4536)

60 (5.52)

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

5.4L

6.8L

4.10

4.10

13000
(5897) 18500
(8391)

8500 (3856)

60 (5.52)

10000 (4536)

60 (5.52)

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

5.4L

6.8L

4.10

4.10

13000
(5897) 18500
(8391)

8400 (3810)

60 (5.52)

10000 (4536)

60 (5.52)

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

5.4L

6.8L

4.10

4.10

13000
(5897) 18500
(8391)

8400 (3810)

60 (5.52)

10000 (4536)

60 (5.52)

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

5.4L

4.10

13000
(5897)

8400 (3810)

60 (5.52)

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2004 Econoline (eco) Owners Guide (post-2002-fmt) USA English (fus)

GCWR (Gross Combined Weight Rating)/Trailer Weights

Driving

Engine

Rear axle ratio

Maximum GCWR - lbs. (kg)

6.8L

4.10

18500
(8391)

Maximum

Loaded

Trailer Weight

- lbs. (kg)

Maximum

frontal area of

trailer - ft2

(m2)

10000 (4536)

60 (5.52)

E-350 Stripped Chassis (176” wheelbase) (11000 GVWR)

5.4L

6.8L

4.10

4.10

13000
(5897) 18500
(8391)

8400 (3810)

60 (5.52)

10000 (4536)

60 (5.52)

E-450 Cutaway and Chassis Cab (all wheelbases, all GVWRs)

6.8L

4.56

20000
(9072)

10000 (4536)

60 (5.52)

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

5.4L

6.8L

4.56

4.56

13000
(5897) 18500
(8391)

8200 (3719)

60 (5.52)

10000 (4536)

60 (5.52)

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 10,000 lbs. (4536 kg). For high altitude operation reduce GCWR by 2% per 1,000 ft. (300
meters) 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 10–15% of the total is on the tongue. Tie down the load so that it does not shift and change the weight on the hitch.

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Driving

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.

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.

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Driving

Trailer lamps Trailer lamps are required on most towed vehicles. Make sure all running lights, brake lights, turn signals and hazard lights are working. See your dealer or trailer rental agency for proper instructions and equipment for hooking up trailer lamps.

Using a step bumper (if equipped) The rear bumper is equipped with an integral hitch and only requires a ball with a one inch (25.4 mm) shank diameter. The bumper has a 5,000
lbs. (2,270 kg) trailer weight and 500 lbs. (227 kg) 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. • Do not exceed 50 mph (80 km/h) for the first 500 miles (800 km) of towing and do not perform and fast accelerations from a stop during this time. • 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.

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weight.

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

the rear axle lube

• Do not tow a trailer for the first 500 miles (800 km) after changing • Do not exceed 50 mph (80 km/h) for the first 500 miles (800 km) of towing and do not perform and fast accelerations from a stop during this time.

• After you have traveled 50 miles (80 km), thoroughly check your • When stopped in traffic for long periods of time in hot weather, place

hitch, electrical connections and trailer wheel lug nuts.

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 6 inches (15 cm) 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.

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Driving

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 of 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 35 mph (56 km/h) • Maximum distance is 50 miles (80 km) If a distance of 50 miles (80 km) or a speed of 35 mph (56 km/h) 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 36,000

miles (60,000 km), whichever occurs first on Ford and Mercury vehicles, and four years or 50,000 miles (80,000 km) 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 35 miles (56.3 km) 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.

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Roadside Emergencies

Canadian customers who require roadside assistance, call 1–800–665–2006. 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 or if the key is not in the ignition. 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 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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Roadside Emergencies

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

On commercial 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 for leaks.

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Roadside Emergencies

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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Roadside Emergencies

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

13

19

25

31

37

14

20

26

32

38

15

21

27

33

39

10

16

22

28

34

40

11

17

23

29

35

41

42

43

44

12

18

24

30

36

The fuses are coded as follows.

Fuse/Relay Location

Fuse Amp

Rating

Passenger Compartment Fuse

Panel Description

5A

10A

15A

15A

4–Wheel Anti–lock Brake System (4WABS) module Remote Keyless Entry (RKE), O/D cancel, Low vacuum (Diesel engine only) Trip computer, Radio, Instrument illumination, Video Cassette Player (VCP) and video screens, Overhead console Modified vehicle, Courtesy lamps

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Fuse/Relay Location

Fuse Amp

Rating

10

11

12

13

14
15

16
17
18
19
20

30A

10A

10A 30A

30A

20A

15A

15A

15A

5A 5A

30A 5A — — 10A

Roadside Emergencies

Passenger Compartment Fuse

Panel Description

Power lock switches, Power locks without RKE Brake-shift interlock, Speed control (gasoline engine only) Multi-function switch, Turn signals Radio capacitor(s), Ignition coil, Powertrain Control Module (PCM) diode, PCM power relay, Auxiliary PCM (APCM) (Diesel engine only) Wiper control module, Windshield wiper motor Main light switch, Park lamps, License lamp (external lamps), Multi-function switch (flash-to-pass) Multi-function switch (hazards), Brake lamp switch, Brake lamps Back-up lamps, Auxiliary battery relay (gasoline engine only), Trailer tow relay Blend door actuator, A/C heater, Function selector switch Instrument cluster Trailer battery charge relay, Cluster, Daytime Running Lamps (DRL) module Power seats Power mirrors Not used Not used Restraints

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Passenger Compartment Fuse

Panel Description

Not used Memory power radio, Rear seat video control unit, Battery saver relay, Instrument cluster, Courtesy lamp relay, Accessory delay relay Power locks w/RKE Not used Left headlamp (low beam) Cigar lighter, Diagnostics Radio Not used Power point #4 (console) Headlamps (high beam indicator) Right headlamp (low beam) Power point #1 (instrument panel) Starter solenoid (gasoline engine only)/Start relay (diesel engine only) Power point #3 (console) Modified vehicle (Cluster, A/C, Illumination, Radio) Not used Not used Trailer tow electric brake, Center High-Mounted Stop Lamp (CHMSL), Brake lamps Power point #2 (2nd row seating position - driver side) Modified vehicle Not used

Roadside Emergencies

Fuse/Relay Location

Fuse Amp

Rating

21
22

23
24
25
26
27
28
29
30
31
32

33

34
35
36
37
38
39

40

41
42

— 15A

20A — 10A 20A 5A — 20A 15A 10A 20A

10A

20A 30A 5A — — 10A

20A

30A —

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Roadside Emergencies

Passenger Compartment Fuse

Panel Description

Power windows

Fuse Amp

Rating

20A circuit

breaker

—

Not used

Fuse/Relay Location

43

44

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

The high-current fuses are coded as follows.

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Roadside Emergencies

Fuse/Relay Location

Fuse Amp

Rating

Power Distribution Box

Description

10
11

12
13
14
15
16
17

18

19

—

—

10A*

20A*

15A* 2A* 60A**

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

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

—

50A**

60A**

50A**

Powertrain Control Module (PCM) diode Alternative Fuel Control Module (AFCM) diode (Natural gas vehicle only) Daytime Running Lamps (DRL) module, A/C clutch Natural Gas Vehicle (NGV) tank solenoids (natural gas vehicle only) Horn relay Brake pressure switch Ignition switch, Fuse panel, Accessory delay Trailer battery charge relay Modified vehicle power Electric brake controller 4-Wheel Anti-lock Brake System (4WABS) I/P fuses 29, 34, 35, 40 and 41
Fuel pump relay Auxiliary blower relay Main light switch Not used Blower motor relay (blower motor) Engine compartment fuses 3, 5, 23 and 26, Instrument panel fuses 26 and 32, Diesel start relay (Diesel engine only) IDM relay (Diesel engine only)

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Roadside Emergencies

Power Distribution Box

Description

Auxiliary battery relay (gasoline engine only), PDB fuses 8 and 24
(Diesel engine only) PCM power relay, PDB fuse 27
I/P fuses 4, 5, 10, 11, 16, 17, 22
and 23
Alternator Trailer tow running lamps and back-up lamp relays Not used Trailer tow turn signals PCM Not used Fuel pump relay Horn relay Trailer back-up lamps relay Trailer running lamps relay Trailer battery charge relay IDM relay (Diesel only) PCM relay Blower motor relay Accessory delay relay Start relay (Diesel only)

Fuse Amp

Rating 60A**

30A** 60A**

10A* 20A*

—

20A* 10A*

— — — — — — — — — — —

Fuse/Relay Location

20

21
22

23
24

25
26
27
28

* Mini fuses ** Maxi fuses

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Roadside Emergencies

Relay modules Instrument panel relay module

The instrument panel relay module is located behind the radio in the center of the instrument panel. Have a certified technician or your dealer service this module, if required. The relays are coded as follows:

Relay location

Description Interior lamps Open Roof marker lamps Battery saver Engine compartment relay module

The engine compartment relay module is located in one of two places depending on which type of engine your vehicle is equipped with: • Gasoline engine: driver side of the engine compartment above the

brake master cylinder.

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Roadside Emergencies • Diesel engine: passenger side of the engine compartment behind the

power distribution box.

Have a certified technician or your dealer service this module, if required. The relays are coded as follows:

Relay location

Description Trailer tow left turn A/C control PCM back-up lamp Trailer tow right turn

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 may damage your tires.

Dissimilar spare tire/wheel information

Failure to follow these guidelines could result in an increased risk of loss of vehicle control, injury or death.

Your vehicle may be equipped with a dissimilar spare tire/wheel. A dissimilar spare tire/wheel is defined as a spare tire and/or wheel that is different in brand, size or appearance from the road tires and wheels. If you have a dissimilar spare tire/wheel, then it is intended for temporary use only. This means that if you need to use it, you should replace it as soon as possible with a road tire/wheel that is the same size and type as the road tires and wheels that were originally provided by Ford. If the dissimilar spare tire or wheel is damaged, it should be replaced rather than repaired. When driving with the dissimilar spare tire/wheel, do not: • Exceed 70 mph (113 km/h)

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Roadside Emergencies • Use more than one dissimilar spare tire/wheel at a time • Use commercial car washing equipment • Use snow chains on the end of the vehicle with the dissimilar spare

tire/wheel

The usage of a dissimilar spare tire/wheel can lead to impairment of the following: • Handling, stability and braking performance • Comfort and noise • Ground clearance and parking at curbs • Winter weather driving capability • Wet weather driving capability • All-Wheel Driving Capability (if applicable) • Load Leveling Adjustment (if applicable) When driving with the dissimilar spare tire/wheel additional caution should be given to: • Towing a trailer • Driving vehicles equipped with a camper body • Driving vehicles with a load on the cargo rack Drive cautiously when using a dissimilar spare tire/wheel and seek service as soon as possible.

Spare tire information The spare tire for your vehicle is stowed under the rear of your vehicle (except cutaway and stripped chassis modelsor if equipped on E-350
Chassis Cab vehicles).

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Roadside Emergencies

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.

Tire change procedure

Preparing to change the tire

To help 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).

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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 (if equipped on E-350 chassis cab vehicles) from the storage location.

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

• E-350 Chassis cab vehicles (if equipped): jack is strapped to a bracket behind the driver’s seat.

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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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Rear axle jacking points - All models except E-350 Dual Rear Wheel (DRW) and E-450:

Rear axle jacking points - E-350
Dual Rear Wheel (DRW) and E-450:

Front axle jacking points: 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. • Raise the jack until the wheel is completely off the ground. (Turn jack handle clockwise if your vehicle is equipped with a screw-type jack or pump the jack if equipped with a hydraulic jack.)

• Remove the lug nuts with the lug • Replace the flat tire with the

nut wrench.

spare tire.

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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 (Refer to Wheel lug nut torque specifications later in this chapter for the proper lug nut torque specification): • 5-lug wheel

• 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. Stowing the flat/spare tire Note: Failure to follow spare tire stowage instructions may result in failure of cable or loss of spare tire.

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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.

WHEEL LUG NUT TORQUE SPECIFICATIONS On vehicles equipped with single rear wheels, retighten the lug nuts to the specified torque at 500 miles (800 km) after any wheel disturbance (tire rotation, changing a flat tire, wheel removal, etc.). On vehicles equipped with dual rear wheels, retighten the wheel lug nuts to the specified torque at 100 miles (160 km), and again at 500 miles (800 km) of new vehicle operation and after any wheel disturbance (tire rotation, changing a flat tire, wheel removal, etc.).

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Bolt size

Wheel lug nut torque*

N•m 135
190

lb.ft. 100
140

E-150: 1/2–20
E-250, E-350 and E-450: 9/16–18
* Torque specifications are for nut and bolt threads free of dirt and rust. Use only Ford recommended replacement fasteners. On all two-piece flat wheel nuts, apply one drop of motor oil between the flat washer and the nut. Do not apply motor oil to the wheel nut threads or the wheel stud threads.

When a wheel is installed, always remove any

corrosion, dirt or foreign materials present on the mounting surfaces of the wheel or the surface of the front disc brake hub and rotor that contacts the wheel. Installing wheels without correct metal-to-metal contact at the wheel mounting surfaces can cause the wheel nuts to loosen and the wheel to come off while the vehicle is in motion, resulting in loss of control.

JUMP STARTING YOUR VEHICLE The following procedure is for vehicles equipped with a gasoline engine; if your vehicle is equipped with a diesel engine, refer to the 6.0L Power Stroke Direct Injection Turbo Diesel Owner’s Guide Supplement for the proper jump starting procedure.

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

vehicle damage.

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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; doing so may damage the catalytic converter.

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

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Connecting the jumper cables

+–

+–

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

+–

+–

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

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+–

+–

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

+–

+–

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

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

explosion of the gases that surround the battery.

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

Jump starting 1. Start the engine of the booster vehicle and run the engine at moderately increased speed. 2. Start the engine of the disabled vehicle.

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3. Once the disabled vehicle has been started, run both engines for an additional three minutes before disconnecting the jumper cables.

Removing the jumper cables

+–

+–

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

+–

+–

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

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+–

+–

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

+–

+–

4. Remove the jumper cable from the positive (+) terminal of the disabled vehicle’s battery. After the disabled vehicle has been started and the jumper cables removed, allow it to idle for several minutes so the engine computer can relearn its idle conditions.

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WRECKER TOWING

If you need to have your vehicle towed, contact a professional towing service or, if you are a member of a roadside assistance program, your roadside assistance service provider. Ford recommends your vehicle be towed with a wheel lift or flatbed. Do not tow with a slingbelt. Ford Motor Company has not approved a slingbelt towing procedure. If your vehicle is equipped with an air dam and must be towed from the front, it is recommended that your vehicle be towed by wheel lift or flatbed equipment to prevent damage to the air dam. If the vehicle is towed by other means or incorrectly, vehicle damage may occur.

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Customer Assistance

GETTING THE SERVICES YOU NEED

At home You must take your Ford vehicle to an authorized Ford dealer for warranty repairs. While any Ford dealership handling your vehicle line will provide warranty service, we recommend you return to your selling dealer who wants to ensure your continued satisfaction. Please note that certain warranty repairs require special training and/or equipment, so not all dealers are authorized to perform all warranty repairs. This means that, depending on the warranty repair needed, you may have to take your vehicle to another dealer. A reasonable time must be allowed to perform a repair after taking your vehicle to the dealership. Repairs will be made using Ford or Motorcraft parts, or remanufactured or other parts that are authorized by Ford. If you have questions or concerns, or are unsatisfied with the service you are receiving, follow these steps: 1. Contact your Sales Representative or Service Advisor at your selling/servicing dealership. 2. If your inquiry or concern remains unresolved, contact the Sales Manager, Service Manager or Customer Relations Manager. 3. If you require assistance or clarification on Ford Motor Company policies or procedures, please contact the Ford Customer Relationship Center at the number below.

Away from home If you own a Ford or Mercury vehicle and are away from home when your vehicle needs service, or if you need more help than the dealership could provide, after following the steps described above, contact the Ford Customer Relationship Center to find an authorized dealership to help you. In the United States: Ford Motor Company Customer Relationship Center P.O. Box 6248
Dearborn, MI 48121
1-800-392-3673 (FORD) (TDD for the hearing impaired: 1-800-232-5952) www.customersaskford.com

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In Canada: Customer Relationship Centre Ford Motor Company of Canada, Limited P.O. Box 2000
Oakville, Ontario L6J 5E4
1-800-565-3673 (FORD) www.ford.ca Away from home–motorhome service If you own a motorhome built on a Ford Chassis and are away from home when your vehicle needs service, or if you need more help than the dealership could provide, after following the steps above, contact the Ford Motorhome Customer Assistance Center to find an authorized dealership or service location to help you. In the United States and Canada: Ford Motorhome Customer Assistance Center 900 N. Lake Havasu Avenue Lake Havasu City, AZ 86403
1-800-444-3311
Open 365/24/7
In order to help service your motorhome vehicle, please have the following information available when contacting the Motorhome Customer Assistance Center: • telephone number where you can be reached • vehicle location (city and state) • year and make of your vehicle • date of vehicle purchase • current odometer reading • vehicle identification number (VIN). Additional Assistance If you still have a complaint involving a warranty dispute, you may wish to contact the Dispute Settlement Board (U.S.). In some states (in the U.S.) you must directly notify Ford in writing before pursuing remedies under your state’s warranty laws. Ford is also allowed a final repair attempt in some states. In the United States, a warranty dispute must be submitted to the Dispute Settlement Board before taking action under the Magnuson-Moss Warranty Act, or to the extent allowed by state law, before pursuing

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replacement or repurchase remedies provided by certain state laws. This dispute handling procedure is not required prior to enforcing state created rights or other rights which are independent of the Magnuson-Moss Warranty Act or state replacement or repurchase laws.

FORD EXTENDED SERVICE PLAN You can get more protection for your new car or light truck by purchasing Ford Extended Service Plan (Ford ESP) coverage. It provides the following: • Benefits during the warranty period depending on the plan you

purchase (such as: reimbursement for rentals; coverage for certain maintenance and wear items).

• Protection against covered repair costs after your Bumper-to-Bumper

Warranty expires.

You may purchase Ford ESP from any participating Ford and Lincoln Mercury and Ford of Canada dealer. There are several plans available in various time, distance and deductible combinations which can be tailored to fit your own driving needs. Ford ESP also offers reimbursement benefits for towing and rental coverage. When you buy Ford ESP, you receive Peace-of-Mind protection throughout the United States and Canada, provided by a network of more than 5,000 participating Ford or Lincoln Mercury and Ford of Canada dealers. If you did not take advantage of the Ford Extended Service Plan at the time of purchasing your vehicle, you may still be eligible. Since this information is subject to change, please ask your dealer for complete details about Ford Extended Service Plan coverage options, or visit the Ford ESP website at www.ford-esp.com.

THE DISPUTE SETTLEMENT BOARD (U.S. ONLY) The Dispute Settlement Board is: • an independent, third-party arbitration program for warranty disputes. • available free to owners and lessees of qualifying Ford Motor Company

vehicles.

The Dispute Settlement Board may not be available in all states. Ford Motor Company reserves the right to change eligibility limitations, modify procedures and/or to discontinue this service without notice and without incurring obligations per applicable state law.

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What kinds of cases does the Board review? Unresolved warranty repair concerns or vehicle performance concerns as on Ford and Lincoln Mercury cars and Ford and Lincoln Mercury light trucks which are within the terms of any applicable written new vehicle warranty are eligible for review, except those involving: • a non-Ford product • a non-Ford dealership • sales disputes between customer and dealer except those associated with warranty repairs or concerns with the vehicle’s performance as designed

maintenance and wear items)

service or product concern is being reviewed

• a request for reimbursement of consequential expenses unless a • items not covered by the New Vehicle Limited Warranty (including • alleged personal injury/property damage claims • cases currently in litigation • vehicles not used primarily for family, personal or household purposes (except in states where the Dispute Settlement Board is required to review commercial vehicles)

• vehicles with non-U.S. warranties Concerns are ineligible for review if the New Vehicle Limited Warranty has expired at receipt of your application and, in certain states eligibility is dependent upon the customer’s possession of the vehicle. Eligibility may differ according to state law. For example, see the unique brochures for California, West Virginia, Georgia and Wisconsin purchasers/lessees.

Board membership The Board consists of: • Three consumer representatives • A Ford or Lincoln Mercury dealership representative Consumer candidates for Board membership are recruited and trained by an independent consulting firm. The dealership Board member is chosen from Ford and Lincoln Mercury dealership management, recognized for their business leadership qualities.

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