2005 Ford F 250 Owners Manual

Your vehicle is designed to use “Regular” unleaded gasoline with pump (R+M)/2 octane rating of 87. We do not recommend the use of gasolines labeled as “Regular” that are sold with octane ratings of 86 or lower in high altitude areas. Do not be concerned if your engine sometimes knocks lightly. However, if it knocks heavily under most driving conditions while you are using fuel with the recommended octane rating, see your dealer or a qualified service technician to prevent any engine damage.

87(R+M)/2 METHOD

Fuel quality If you are experiencing starting, rough idle or hesitation driveability problems, try a different brand of unleaded gasoline. “Premium” unleaded gasoline is not recommended for vehicles designed to use “Regular” unleaded gasoline because it may cause these problems to become more pronounced. If the problems persist, see your dealer or a qualified service technician. It should not be necessary to add any aftermarket products to your fuel tank if you continue to use high quality fuel of the recommended octane rating. Aftermarket products could cause damage to the fuel system. Repairs to correct the effects of using an aftermarket product in your fuel may not be covered by your warranty.

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Many of the world’s automakers approved the World-wide Fuel Charter that recommends gasoline specifications to provide improved performance and emission control system protection for your vehicle. Gasolines that meet the World-wide Fuel Charter should be used when available. Ask your fuel supplier about gasolines that meet the World-wide Fuel Charter.

Cleaner air Ford endorses the use of reformulated “cleaner-burning” gasolines to improve air quality.

Running out of fuel Avoid running out of fuel because this situation may have an adverse affect on powertrain components. If you have run out of fuel: • You may need to cycle the ignition from OFF to ON several times after

refueling, to allow the fuel system to pump the fuel from the tank to the engine.

• Your Service engine soon indicator may come on. For more information on the Service engine soon indicator, refer to the Instrument cluster chapter.

Fuel Filter For fuel filter replacement, see your dealer or a qualified service technician. Refer to the scheduled maintenance guide for the appropriate intervals for changing the fuel filter. Replace the fuel filter with an authorized Motorcraft part. The customer warranty may be void for any damage to the fuel system if an authorized Motorcraft fuel filter is not used.

ESSENTIALS OF GOOD FUEL ECONOMY

Measuring techniques Your best source of information about actual fuel economy is you, the driver. You must gather information as accurately and consistently as possible. Fuel expense, frequency of fill-ups or fuel gauge readings are NOT accurate as a measure of fuel economy. We do not recommend taking fuel economy measurements during the first 1,000 miles (1,600
km) of driving (engine break-in period). You will get a more accurate measurement after 2,000 miles-3,000 miles (3,000 km–5,000 km).

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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 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.

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

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 miles or kilometers). 2. Each time you fill the tank, record the amount of fuel added (in gallons or liters). 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.

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5. Follow one of the simple calculations in order to determine fuel economy:

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

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 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 55 mph [88 km/h] 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 65 mph [105 km/h]).

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.

economy.

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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 • Perform all regularly scheduled maintenance items. Follow the

this chapter.

economy.

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

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

driving on hilly terrain.

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

8–10 miles (12–16 km) 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 • Four-wheel-drive operation (if equipped) is less fuel efficient than • 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 MPG (L/100 km) expected on the vehicle under optimum conditions. Your fuel economy may vary depending upon the method of operation and conditions.

two-wheel-drive operation.

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EMISSION CONTROL SYSTEM Your vehicle is equipped with various emission control components and a catalytic converter which will enable your vehicle to comply with applicable exhaust emission standards. To make sure that the catalytic converter and other emission control components continue to work properly: • Use only the specified fuel listed. • Avoid running out of fuel. • Do not turn off the ignition while your vehicle is moving, especially at • Have the items listed in your Scheduled Maintenance Guide

high speeds.

performed 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.

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Please consult your Warranty Guide for complete emission warranty information.

On board diagnostics (OBD-II) Your vehicle is equipped with a computer that monitors the engine’s emission control system. This system is commonly known as the On Board Diagnostics System (OBD-II). This OBD-II system protects the environment by ensuring that your vehicle continues to meet government emission standards. The OBD-II system also assists the service technician in properly servicing your vehicle. When the Check engine/Service engine soon light illuminates, the OBD-II system has detected a malfunction. Temporary malfunctions may cause your Check engine/Service engine soon light to illuminate. Examples are: 1. The vehicle has run out of fuel. (The engine may misfire or run poorly.) 2. Poor fuel quality or water in the fuel. 3. The fuel cap may not have been securely tightened. These temporary malfunctions can be corrected by filling the fuel tank with good quality fuel and/or properly tightening the fuel cap. After three driving cycles without these or any other temporary malfunctions present, the Check engine/Service engine soon light should turn off. (A driving cycle consists of a cold engine startup followed by mixed city/highway driving.) No additional vehicle service is required. If the Check engine/Service engine soon light remains on, have your vehicle serviced at the first available opportunity.

Readiness for Inspection/Maintenance (I/M) testing In some localities, it may be a legal requirement to pass an I/M test of the on-board diagnostics system. If your Check engine/Service engine soon light is on, refer to the description in the Warning lights and chimes section of the Instrument Cluster chapter. Your vehicle may not pass the I/M test with the Check engine/Service engine soon light on. If the vehicle’s powertrain system or its battery has just been serviced, the on-board diagnostics system is reset to a “not ready for I/M test” condition. To ready the on-board diagnostics system for I/M testing, a minimum of 30 minutes of city and highway driving is necessary as described below: • First, at least 10 minutes of driving on an expressway or highway. • Next, at least 20 minutes driving in stop-and-go, city-type traffic with

at least four idle periods.

Allow the vehicle to sit for at least eight hours without starting the engine. Then, start the engine and complete the above driving cycle. The

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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. 2. If the fluid level is low. Add fluid to bring fluid level up to be between the arrows in the FULL COLD range. 3. Start the engine. 4. While the engine idles, turn the steering wheel left and right several times. 5. Turn the engine off. 6. Recheck the fluid level on the dipstick. Do not add fluid if the level is between the arrows in the FULL COLD range. 7. 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.

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BRAKE FLUID RESERVOIR The fluid level will drop slowly as the brakes wear, and will rise when the brake components are replaced. Fluid levels between the “MIN” and “MAX” lines are within the normal operating range; there is no need to add fluid. If the fluid levels are outside of the normal operating range the performance of your brake system could be compromised; seek service from your dealer immediately.

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

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.

During normal operation, the fluid level in the clutch reservoir should remain constant or rise slightly. If the fluid level drops, refill the fluid level to the step in the reservoir.

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1. Clean the reservoir cap before removal to prevent dirt and water from entering the reservoir. 2. Remove cap and rubber diaphragm from reservoir. 3. Add fluid until the level reaches the step in the reservoir. 4. Reinstall rubber diaphragm and cap onto reservoir.

TRANSMISSION FLUID

Checking automatic transmission fluid (if equipped) Refer to your Scheduled Maintenance Guide for scheduled intervals for fluid checks and changes. Your transmission does not consume fluid. However, the fluid level should be checked if the transmission is not working properly, i.e., if the transmission slips or shifts slowly or if you notice some sign of fluid leakage. Automatic transmission fluid expands when warmed. To obtain an accurate fluid check, drive the vehicle until it is at normal operating temperature (approximately 20 miles [30 km]). 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 20 miles (30 km) or until it reaches normal operating temperature. 2. Park the vehicle on a level surface and engage the parking brake. 3. With the parking brake engaged and your foot on the brake pedal, start the engine and move the gearshift lever through all of the gear ranges. Allow sufficient time for each gear to engage. 4. Latch the gearshift lever in P (Park) and leave the engine running. 5. Remove the dipstick, wiping it clean with a clean, dry lint free rag. If necessary, refer to Identifying components in the engine compartment in this chapter for the location of the dipstick. 6. Install the dipstick making sure it is fully seated in the filler tube. 7. Remove the dipstick and inspect the fluid level. The fluid should be in the designated area for normal operating temperature or ambient temperature.

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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 50°F (10°C). Correct fluid level The transmission fluid should be checked at normal operating temperature 150°F-170°F (66°C-77°C) on a level surface. The normal operating temperature can be reached after approximately 20 miles (30
km) of driving. You can check the fluid without driving if the ambient temperature is above 50°F (10°C). 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 (150°F-170°F [66°C-77°C]). The transmission fluid should be in this range if at ambient temperature (50°F-95°F [10°C-35°C]).

High fluid level Fluid levels above the safe range may result in transmission failure. An overfill condition of transmission fluid may cause shift and/or engagement concerns and/or possible damage. High fluid levels can be caused by an overheating condition. Adjusting automatic transmission fluid levels Before adding any fluid, make sure the correct type is used. The type of fluid used is normally indicated on the dipstick and also in the Lubricant specifications section in this chapter. Use of a non-approved automatic transmission fluid may cause internal transmission component damage. If necessary, add fluid in 1/2 pint (250 ml) increments through the filler tube until the level is correct.

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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.

Automatic transmission fluid filter (if equipped) The TorqShift automatic transmission is equipped with a serviceable external fluid filter mounted on the frame rail. Refer to the Scheduled Maintenance Guide for service intervals.

To replace the transmission filter: 1. Shut off the engine. 2. Unscrew filter housing. 3. Replace filter with a new authorized Motorcraft filter element. Refer to the Motorcraft part numbers chart in this chapter. 4. Reinstall housing and check transmission fluid level using procedure in this section.

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

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

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

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

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

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

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

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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 in this chapter. 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 • 5.4L Engine 1. Release two retainer clamps.

2. Pull air filter tray assembly out toward front of vehicle and lift air filter element up and out of housing.

The air filter box needs to be free of any debris before installing a new air filter.

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3. Install a new air filter element into the tray assembly. 4. Return air filter tray to original position by pressing firmly on the handle until all rearward movement stops and secure the two clamps.

• 6.8L Engine 1. Loosen the clamps that secures the air filter cover in place.

2. Carefully separate the two halves of the air filter housing. 3. Remove the air filter element from the air filter housing. 4. Install a new air filter element. 5. Reassemble the two halves of the air filter housing, aligning the notchs and slots. Secure the clamps, making sure not to crimp the air filter edges between the two halves of the air filter housing. This could cause filter damage and allow unmetered air to enter the engine if not properly seated.

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FT-145

FT–145

BXT-65-650
BXT-65-750

BXT-65-650
BXT-65-750

6.8L V10 engine FA-1634
FG-1011
FL-820-S

5.4L V8 engine FA-1634
FG-1011
FL-820-S

MOTORCRAFT PART NUMBERS Component Air filter element Fuel filter Oil filter PCV valve Battery (Standard) Battery (Optional) Spark plugs-platinum Remote Automatic Transmission Filter 3
1The PCV valve is a critical emission component. It is one of the items listed in the Scheduled Maintenance Guide and is essential to the life and performance of your vehicle and to its emissions system. For PCV valve replacement, see your dealer or a qualified service technician. Refer to the Scheduled Maintenance Guide for the appropriate intervals for changing the PCV valve. Replace the PCV valve with one that meets Ford material and design specifications for your vehicle, such as a Motorcraft or equivalent replacement part. The customer warranty may be void for any damage to the emissions system if such a PCV valve is not used. 2For spark plug replacement, see your dealer or a qualified service technician. Refer to the Scheduled Maintenance Guide for the appropriate intervals for changing the spark plugs. Replace the spark plugs with ones that meet Ford material and design specifications for your vehicle, such as Motorcraft or equivalent replacement parts. The customer warranty may be void for any damage to the engine if such spark plugs are not used. 3Also available with 6.0L Diesel engine/TorqShift transmission. Part number is FT-145.

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REFILL CAPACITIES

Fluid

Front axle

Rear axle

Brake fluid (and clutch fluid-if equipped)

Ford Part

Name

Motorcraft SAE 80W-90
Premium Rear Axle Lubricant Motorcraft SAE 75W-140
Synthetic Rear Axle Lubricant Motorcraft SAE 75W-90
Synthetic Rear Axle Lubricant Motorcraft SAE 75W–140
Synthetic Rear Axle Lubricant Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid

Application

Capacity

F-250/350
(Dana 60 axle) F-350/450/550
(Dana 60 axle) F-250 /350
(10.50 inch axle) 1

F-350 (DANA 80)1

6.3 pints (3.0L)

6.3 pints (3.0L)

6.9 pints (3.3L)

8.5 pints (4.0L)

F-450/550
(Dana S110)

14.0 pints (6.6L)

All

Fill to line or step (for clutch) on reservoir

Engine coolant 2 Motorcraft

Premium Gold Engine Coolant (yellow-colored)

5.4L V8 engine with A/C 6.8L V10 engine 27.5 quarts

26.4 quarts (25.0L)

(26.0L)

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Ford Part

Name

Application

Capacity

7.0 quarts (6.6L)

5.4L V8 and 6.8L V10
engines

Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil (US) Motorcraft SAE 5W-20 Super Premium Motor Oil (Canada) Refer to your 6.0L Diesel Supplement

Fluid

Engine oil (includes filter change)-Gas engines6

Engine oil (includes filter change)-Diesel engine Fuel tank

19.0 gallons (71.9L )

30.5 gallons (115.5L) 38.0 gallons (143.9L) 40.0 gallons (151.4L) Fill to FULL COLD range on dipstick 2.0 quarts (1.9L) 5.8 quarts (5.5L) 4

N/A

Mid-ship tank (optional on Chassis Cab) Short box

Long box

Aft axle

Power steering fluid

Motorcraft MERCON威 ATF

All

Transfer case fluid Manual transmission fluid

Motorcraft MERCON威 ATF Motorcraft MERCON威 ATF

4x4 vehicles

6-speed manual

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Fluid

Automatic transmission fluid 3

Windshield washer fluid

Ford Part

Name Motorcraft MERCON威 SP ATF

Motorcraft Premium Windshield Washer Concentrate

Application

Capacity

TorqShift (5–speed)

All

17.5 quarts (16.6L) 5(includes remote filter element change) 4.25 quarts (4.0L)

1Add 8 oz. (236 ml) of Additive Friction Modifier XL-3 or equivalent meeting Ford Specification EST-M2C118–A for complete refill of limited slip axles. Ford design rear axles contain a synthetic lubricant that does not require changing unless the axle has been submerged in water. Dana rear axles also contain a synthetic lubricant but do require a change. Refer to your Scheduled Maintenance Guide for change intervals on Dana rear axles. 2Add the coolant type originally equipped in your vehicle. 3Ensure the correct automatic transmission fluid is used. Transmission fluid requirements are indicated on the end of the dipstick. 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. MERCON威, MERCON威 V and MERCON威 SP are not interchangeable. DO NOT mix MERCON威, MERCON威 V and MERCON威 SP. Use of dual usage fluids in an automatic transmission application requiring MERCON威 SP may cause transmission damage. Use of a transmission fluid other than the recommended fluid may cause transmission damage. 4Service refill capacity is determined by filling the transmission to the bottom of the filler hole with the vehicle on a level surface. The 6–speed manual transmission is equipped with an in-tank cooler. Verify the fluid level after operating vehicle to assure correct fluid level. 5Indicates only approximate dry-fill capacity. Some applications may vary based on cooler size and if equipped with an in-tank cooler. The amount of transmission fluid and fluid level should be set by the indication on the dipstick’s normal operating range.

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6Use of synthetic or synthetic blend motor oil is not mandatory. Engine oil need only meet the requirements of Ford specification WSS-M2C930-A and the API Certification mark.

LUBRICANT SPECIFICATIONS

Ford part number

E8TZ-19590–A XG-11 (FAD)

Ford specification

ESA-M1C198–A

XY-80W-90–QL WSP-M2C197–A

XY-75W140–QL WSL-M2C192-A

XY-75W90–QLS WSS–M2C918–A

XY-75W140-QL WSL–M2C192–A

PM-1

ESA-M6C25-A and DOT 3

Ford part name or equivalent High Temperature 4X4 Front Axle and Wheel Bearing Grease Motorcraft SAE 80W-90
Premium Rear Axle Lubricant Motorcraft SAE 75W-140
Synthetic Rear Axle Lubricant (10.5 inch)1
Motorcraft SAE 75W-90
Synthetic Rear Axle Lubricant (Dana 80)1
Motorcraft SAE 75W–140Synthetic Rear Axle Lubricant (Dana S110 axles) Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid

Item

Spindle bearing

Front axle (4X4)

Rear axle

Brake fluid and clutch fluid (if equipped)

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Item

Ford part name or equivalent Engine coolant Motorcraft

Premium Gold Engine Coolant (yellow-colored)

Maintenance and Specifications

Ford part number

Ford specification

VC-7-A (U.S., except CA, OR and NM), VC-7-B (CA, OR and NM) XO-5W20-QSP (US) CXO-5W20–LSP12
(Canada)

WSS-M97B51-A1

WSS-M2C930-A and API Certification Mark

XG–4 or XL-5

ESR-M1C159-A or ESB-M1C93–B

XL-1

none

XG-1-C or XG-1-K

ESA-M1C75-B

Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil (US) Motorcraft SAE 5W-20 Super Premium Motor Oil (Canada) Multi-Purpose Grease

Motorcraft penetrating and lock lubricant Motorcraft Premium Long-Life Grease

Motorcraft Premium Long-Life Grease

XG-1-C or XG-1-K

WSD-M1C227-A

287

Engine oil

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

Lock cylinders

Transmission /parking brake linkages and pivots, brake and clutch pedal shaft (if equipped)

Steering linkage

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Item

Power steering fluid and transfer case fluid (if equipped) Manual transmission (6-speed) Automatic transmission TorqShift (5–speed)

Windshield washer fluid

Ford part name or equivalent Motorcraft MERCON威 ATF

Motorcraft MERCON威 ATF

Motorcraft MERCON威 SP ATF 2

Motorcraft Premium Windshield Washer Concentrate

Ford part number

XT-2-QDX

Ford specification

MERCON威

XT-2-QDX

MERCON威

XT-6–QSP

MERCON威 SP

ZC-32–A

WSB-M8B16–A2

1Add 8 oz.(236 ml) of Additive Friction Modifier XL-3 or equivalent meeting Ford specification EST-M2C118-A for complete refill of limited slip axles. Ford design rear axles contain a synthetic lubricant that does not require changing unless the axle has been submerged in water. Dana rear axles also contain a synthetic lubricant but do require a change. Refer to your Scheduled Maintenance Guide for change intervals on Dana rear axles. 2Ensure the correct automatic transmission fluid is used. Transmission fluid requirements are indicated on the end of the dipstick. 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. MERCON威, MERCON威 V and MERCON威 SP are not interchangeable. DO NOT mix MERCON威, MERCON威 V and MERCON威 SP. Use of dual usage fluids in an automatic transmission application requiring MERCON威 SP may cause transmission damage. Use of a transmission fluid other than the recommended fluid may cause transmission damage.

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Maintenance and Specifications

ENGINE DATA Engine Cubic inches Required fuel Firing order

Spark plug gap

5.4L V8 engine 330
87 octane 1-3-7-2-6-5-4-8
1.02–1.28mm (0.040–0.050 inch)** Coil on plug 9.8:1

6.8L V10 engine 415
87 octane 1-6-5-10-2-7-3-8-4-9
1.02–1.28mm (0.040–0.050 inch)** Coil on plug 9.2:1

Ignition system Compression ratio *Refer to the 6.0 Liter Power Stroke Direct Injection Turbo Diesel Owner’s Guide Supplement for Motorcraft diesel engine service part numbers. **The 5.4L 3V and 6.8L 3V spark plug gap CANNOT be adjusted.

VEHICLE DIMENSIONS

F–250 Regular Cab and SuperCab Dimension

Body style

Regular Cab 4x2 – inches

Regular Cab 4x4 – inches

SuperCab

SuperCab

4x2 – inches

4x4 – inches

(mm)

(mm)

(mm)

(mm)

76.5 (1943)

79.1 (2009)

76.8 (1951)b

79.4 (2017)b

68.3

(1734)/67.2

(1706)

68.3 (1736) / 67.2 (1706)

68.3 (1734) / 67.2 (1706)

68.3 (1736) / 67.2 (1706)

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

79.9 (2029)

79.9 (2029)

79.9 (2029)

79.9 (2029)

(3) Overall width (4) Wheelbase 137.0 (3480)

137.0 (3480) 141.8 (3602)a 158.0 (4013)b

226.4 (5751)

226.4 (5751)

231.2
(5872)a

247.4 (6284)b

(5) Overall length

aShort Box bLong Box

2005 F250/350/450/550 (f23) Owners Guide (post-2002-fmt) USA_English (fus)

141.8 (3602)a 158.0 (4013)b 231.2 (5872)a 247.4 (6284)b

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F–250 Crew Cab Dimension

Crew Cab 4x2, Short

box - inches (mm)

Body style

Crew Cab 4x4, Short box - inches

Crew Cab 4x2, Long box - inches

(mm)

(mm)

Crew Cab 4x4, Long box - inches (mm)

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

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

77.5 (1969) 80.0 (2032)

77.3 (1963)

79.9 (2029)

68.3 (1736)/ 67.2 (1706)

68.3
(1734)/ 67.2 (1706) 79.9 (2029) 79.9 (2029)

68.3 (1734)/ 67.2 (1706)

68.3 (1736)/ 67.2 (1706)

79.9 (2029)

79.9 (2029)

156.2
(3967) 245.6
(6238)

156.2 (3967) 172.4 (4379) 172.4 (4379)

245.6 (6238) 261.8 (6650) 261.8 (6650)

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Maintenance and Specifications

F–350 (except Crew Cab) Dimension

Body style

(1) Overall height

(2a) Track - Front

(2b) Track - Rear

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

Regular Cab Chassis Cab - inches (mm) 76.9 (1953)a 77.1 (1958)b 81.6 (2073)c 80.0 (2032)d

SuperCab

Chassis Cab - inches (mm) 77.4 (1966)a 77.4 (1966)b 81.5 (2070)c 80.2 (2037)d

Regular Cab Style Side - inches (mm) 76.8 (1951)a 76.7 (1948)b 80.8 (2052)c 79.6 (2022)d

68.3 (1734)a / 68.9 (1751)b/ 68.3 (1736)c / 69.0 (1753)d 68.1 (1730)a,c / 71.0 (1803)b,d

68.3 (1734)a / 68.9 (1751)b/ 68.3 (1736)c / 69.0 (1753)d 68.1 (1730)a,c / 71.0 (1803)b,d

68.3 (1734)a / 68.9 (1751)b/ 68.3 (1736)c / 69.0 (1753)d 67.2 (1706)a,c / 74.6 (1896)b,d

79.9 (2029)a,c / 92.2 (2342)b,d 161.8 (4110)

79.9 (2029)a,c / 95.5 (2426)b,d 137.0 (3480)

246.6 (6264)

226.4 (5751)

79.9 (2029)a,c / 92.2 (2342)b, d 140.8 (3576) 164.8 (4186) 225.6
(5730)a,b,c,d/ 249.6
(6340)b,d

SuperCab Style Side - inches (mm) 77.3 (1963)a,e 77.1 (1958)a,f 77.0 (1956)b 81.4 (2068)c,e 81.2 (2062)c,f 79.6 (2022)d 68.3 (1734)a / 68.9 (1751)b/ 68.3 (1736)c / 69.0 (1753)d 67.2 (1706)a, c 74.6 (1896)b, d 79.9 (2029)a,c / 95.5 (2426)b, d 141.8 (3602)e/ 158.0 (4013)f 231.2 (5872)e/ 247.4 (6284)f

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

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Maintenance and Specifications

F–350 Crew Cab

Body style

Crew Cab, Short box - inches (mm) 77.8 (1976)a/ 77.6 (1971)b/ 81.8 (2078)c/ 80.1 (2035)d 68.3 (1734)a / 68.9 (1751)b / 68.3 (1736)c / 69.0 (1753) d 67.2 (1706)a,c/ 74.6 (1896)b,d 79.9 (2029)a,c/ 95.5 (2426)b, d 156.2 (3967) 245.6 (6238)

Crew Cab, Long box - inches (mm) 77.6 (1971)a/ 77.4 (1966)b/ 81.7 (2075)c/ 80.0 (2032)d 68.3 (1734)a / 68.9 (1751)b / 68.3 (1736)c / 69.0 (1753) d 67.2 (1706)a,c/ 74.6 (1896)b,d 79.9 (2029)a,c 95.5 (2426)b,d 172.4 (4379) 261.8 (6650)

Dimension

Crew Cab

Chassis Cab - inches (mm)

(1) Overall height

(2a) Track - Front

77.9 (1979)a/ 77.9 (1979)b/ 81.8 (2078)c/ 80.8 (2052)d 68.3 (1734)a / 68.9 (1751)b / 68.3 (1736)c / 69.0 (1753) d 68.1 (1730)a,c/ 71.0 (1803)b,d 79.9 (2029)a,c/ 92.2 (2342)b, d 176.2 (4475) 261.60 (6629)

(2b) Track - Rear (3) Overall width (4) Wheelbase (5) Overall length a4x2 Single Rear Wheel (SRW) b4x2 Dual Rear Wheel (DRW) c4x4 Single Rear Wheel (SRW) d4x4 Dual Rear Wheel (DRW)

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Maintenance and Specifications

F–450
Dimension

Body style

(1) Overall height

(2) Track - Front / Rear (3) Overall width (4) Wheelbase

(5) Overall length

SuperCab Chassis 4x2/4x4 –

inches (mm)

80.5 (2045)

74.8 (1900) / 74.0 (1880) 93.6 (2377)

Crew Cab Chassis 4x2/4x4 –

inches (mm)

80.8 (2052) - 4x2
80.9 (2055) - 4x4
74.8 (1900) / 74.0 (1880) 93.6 (2377)

161.8 (4110) 176.2 (4475) 200.2 (5085)

246.6 (6264) 261.0

(6629)e 285.0
(7239)f

Regular

Cab

Regular

Cab

Chassis 4x2

Chassis 4x4

– inches

(mm)

80.6 (2047)a 80.5
(2045)b,c 80.2 (2037)d 74.8 (1900) / 74.0 (1880) 93.6 (2377)

– inches

(mm)

80.7 (2050)a 80.5 (2045)b 80.0
(2032)c,d 74.8 (1900) / 74.0 (1880) 93.6 (2377)

140.8 (3576) 164.8 (4186) 188.8 (4796) 200.8 (5100) 225.6
(5730)a 249.6
(6340)b 273.6
(6949)c 285.6
(7254)d

140.8 (3576) 164.8 (4186) 188.8 (4796) 200.8 (5100) 225.6
(5730)a 249.6
(6340)b 273.6
(6949)c 285.6
(7254)d

a140.8” (3576 mm) wheel base b164.8” (4186 mm) wheel base c188.8” (4795 mm) wheel base d200.8” (5100 mm) wheel base e176.2” (4475 mm) wheel base f200.2” (5085 mm) wheel base

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Maintenance and Specifications

F–550
Dimension

Body style

(1) Overall height

(2) Track - Front / Rear (3) Overall width (4) Wheelbase

(5) Overall length

Crew Cab Chassis Cab 4x2 –

inches (mm)

Crew Cab Chassis Cab 4x4 –

inches (mm)

81.5 (2070)

81.4 (2068)

74.8 (1900) / 74.0 (1880) 93.6 (2377)

74.8 (1900) / 74.0 (1880) 93.6 (2377)

161.8 (4110) 176.2 (4475) 200.2 (5085)

246.6
(6264)e

261.0
(6629)e 285.0
(7239)f

Regular

Cab

Chassis Cab 4x2 –

inches (mm)

Regular

Cab

Chassis Cab 4x4 –

inches (mm)

81.7 (2075)a 81.4
(2068)b,c 81.1 (2060)d 74.8 (1900) / 74.0 (1880) 93.6 (2377)

81.7 (2075)a 81.2 (2062)b 81.1 (2060)c 80.7 (2050)d 74.8 (1900) / 74.0 (1880) 93.6 (2377)

140.8 (3576) 164.8 (4186) 188.8 (4796) 200.8 (5100) 225.6
(5730)a 249.6
(6340)b 273.6
(6949)c 285.6
(7254)d

140.8 (3576) 164.8 (4186) 188.8 (4796) 200.8 (5100) 225.6
(5730)a 249.6
(6340)b 273.6
(6949)c 285.6
(7254)d

a140.8” (3576 mm) wheel base b164.8” (4186 mm) wheel base c188.8” (4795 mm) wheel base d200.8” (5100 mm) wheel base e176.2” (4475 mm) wheel base f200.2” (5085 mm) wheel base

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Maintenance and Specifications

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Maintenance and Specifications

IDENTIFYING YOUR VEHICLE

Certification label The National Highway Traffic Safety Administration Regulations require that a Certification label be affixed to a vehicle and prescribe where the Certification label may be located. The Certification label is located on the structure by the trailing edge of the driver’s door or the edge of the driver’s door.

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

XXXXXXXXXXXXXXXXX

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Maintenance and Specifications

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

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

Transmission/Transaxle code designations

You can find a transmission/transaxle code on the vehicle certification label. The following table tells you which transmission or transaxle each code represents.

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Maintenance and Specifications

Code

Description Five-speed manual (TR4050) Six-speed manual, Dana (ZF S6–650) Six-speed manual, Dana (ZF M6HD-W) Five-speed automatic, TorqShift

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Accessories

Accessories

GENUINE FORD ACCESSORIES FOR YOUR VEHICLE A wide selection of Genuine Ford Accessories are available for your vehicle through your local authorized Ford 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 Genuine 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 12,000 miles (20,000 km) (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 36,000 miles (60,000
km) (whichever occurs first). Contact your dealer for details and a copy of the warranty. Not all accessories are available for all models. The following is a list of several Genuine Ford Accessory products for your vehicle. Not all accessories are available for all models. For a complete listing of the accessories that are available for your vehicle, please contact your dealer or visit our online store at: www.fordaccessoriesstore.com.

Exterior style Bug shields Chrome exhaust tip Deflectors Exterior trim Fender flares Front end covers Grille inserts Fog lights and Daytime Running Lamps (DRLs) Running boards

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Accessories

Sliding rear windows - manual and power Splash guards Step bars Tonneau covers Wheels

Interior style Consoles Electrochromatic compass/temperature interior mirrors Floor mats Leather wrapped steering wheels Scuff plates Speed control

Lifestyle Bedliners and bedmats Bed tents Bike racks Cargo organization and management Diamond plate accessories Rear seat entertainment systems Toolboxes Towing mirrors TracRac and accessories Trailer hitches, wiring harnesses and accessories

Peace of mind First aid and highway safety kits Full vehicle covers Locking gas cap Navigation systems Remote start Vehicle security systems

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Accessories

For maximum vehicle performance, keep the following information in mind when adding accessories or equipment to your vehicle: • When adding accessories, equipment, passengers and luggage to your vehicle, do not exceed the total weight capacity of the vehicle or of the front or rear axle (GVWR or GAWR as indicated on the Safety Compliance Certification label). Consult your dealer for specific weight information. • The Federal Communications Commission (FCC) and Canadian Radio Telecommunications Commission (CRTC) regulate the use of mobile communications systems — such as two-way radios, telephones and theft alarms - that are equipped with radio transmitters. Any such equipment installed in your vehicle should comply with FCC or CRTC regulations and should be installed only by a qualified service technician.

• Mobile communications systems may harm the operation of your

vehicle, particularly if they are not properly designed for automotive use. • To avoid interference with other vehicle functions, such as anti-lock braking systems, amateur radio users who install radios and antennas onto their vehicle should not locate the Amateur Radio Antennas in the area of the driver’s side hood.

• Electrical or electronic accessories or components that are

non-Genuine Ford Accessories added to the vehicle by the dealer or the owner may adversely affect battery performance and durability.

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Index

Index

Accessory delay ..........................59
Air bag supplemental restraint system ................................107–108
and child safety seats ............109
description ..............................108
disposal ....................................111
driver air bag ..........................110
indicator light .........................111
operation .................................110
passenger air bag ...................110
passenger deactivation switch ......................................112
Air cleaner filter ...............280, 282
Air conditioning ..........................36
Ambulance packages ....................8
Antifreeze (see Engine coolant) ................257
Anti-lock brake system (see Brakes) ......................183–184
Audio system (see Radio) ................20, 22, 25, 28
Automatic transmission ............187

driving an automatic overdrive .................................188
fluid, adding ............................275
fluid, checking ........................275
fluid, refill capacities ..............283
fluid, specification ..................289
Auxiliary power point .................57
Axle

lubricant specifications ..286, 289
refill capacities ........................283
traction lok ..............................186

Battery .......................................255

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acid, treating emergencies .....255
jumping a disabled battery ....224
maintenance-free ....................255
replacement, specifications ...282
servicing ..................................255
BeltMinder .................................103
Brakes ........................................183
anti-lock ...........................183–184
anti-lock brake system (ABS) warning light ...........................183
fluid, checking and adding ....274
fluid, refill capacities ..............283
fluid, specifications .........286, 289
lubricant specifications ..286, 289
parking ....................................184
shift interlock ..........................187
trailer .......................................171
Break-in period .............................5
Bulbs ............................................45

Capacities for refilling fluids ....283
Cassette tape player .......20, 22, 25
Cell phone use ............................66
Certification Label ....................296
Child safety restraints ..............117
child safety belts ....................117
Child safety seats ......................119
attaching with tether straps ..123
in front seat ............................121
in rear seat ..............................121

Cleaning your vehicle

engine compartment ..............241
instrument panel ....................243
interior .....................................244
interior trim ............................243
plastic parts ............................242
safety belts ..............................244

Index

Daytime running lamps (see Lamps) ................................40
Dipstick

automatic transmission fluid ..........................................275
engine oil .................................251

Doors

lubricant specifications ..........286

Driveline universal joint and slip yoke ....................................279
Driving under special conditions ..................190, 203, 207
sand .........................................205
snow and ice ...........................208
through water .................206, 209

Electronic message center ...66, 68
Emergencies, roadside

jump-starting ..........................224
Emergency Flashers .................214
Emission control system ..........271
Engine ........................................289
cleaning ...................................241
coolant .....................................257
diesel ...........................................7
fail-safe coolant ......................262
idle speed control ...................255
lubrication specifications ......286, 289
refill capacities ........................283
service points ..................249–250
starting after a collision .........214
Engine block heater .................182
Engine oil ..................................251
checking and adding ..............251

303

washing ....................................240
waxing .....................................240
wheels ......................................241
wiper blades ............................243

Climate control (see Air conditioning or Heating) ............36
Clutch

fluid ..........................................274
operation while driving ..........191
recommended shift speeds ....191

Compass, electronic

set zone adjustment .................70
Console ........................................66
overhead ....................................56

Controls

steering column ........................65

Coolant

checking and adding ..............257
refill capacities ................261, 283
specifications ..................286, 289

Cruise control (see Speed control) ....................62
Customer Assistance ................213

Ford accessories for your vehicle .....................................246
Ford Extended Service Plan ..........................................237
Getting assistance outside the U.S. and Canada ..............238
Getting roadside assistance ...213
Getting the service you need .........................................231
Ordering additional owner’s literature .................................238
The Dispute Settlement Board .......................................234
Utilizing the Mediation/Arbitration Program ...................................236

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Index

dipstick ....................................251
filter, specifications ........254, 282
recommendations ...................254
refill capacities ........................283
specifications ..................286, 289
Exhaust fumes ..........................183

safety information relating to automotive fuels .....................263
Fuel pump shut-off switch .......214
Fuses ..................................215–216

Gas cap (see Fuel cap) ............265
Gas mileage (see Fuel economy) .................267
Gauges .........................................16

transmission fluid temperature gauge ...................20

Hazard flashers .........................214
Head restraints ...........................89
Headlamps ...................................39
aiming ..................................41, 43
autolamp system .......................39
daytime running lights .............40
flash to pass ..............................41
high beam .................................41
replacing bulbs .............46, 48–49
turning on and off ....................39

Heating

heating and air conditioning system ...........................33–34, 36
Hood ..........................................248

Ignition ...............................178, 289
Infant seats (see Safety seats) .....................119
Inspection/maintenance (I/M) testing ........................................272

Fail safe coolant ........................262
Fluid capacities .........................283
Foglamps .....................................40
Four-Wheel Drive vehicles .......195
description ..............................200
driving off road .......................202
electronic shift ................196, 200
indicator light .........................197
lever operated shift ................197
manual locking hubs ..............196
preparing to drive your vehicle .....................................186
Fuel ............................................263

calculating fuel economy ............................71, 267
cap ...........................................265
capacity ...................................283
choosing the right fuel ...........266
comparisons with EPA fuel economy estimates .................270
detergent in fuel .....................267
filling your vehicle with fuel ...........................263, 265, 268
filter, specifications ........267, 282
fuel pump shut-off switch .....214
improving fuel economy ........267
octane rating ...................266, 289
quality ......................................266
running out of fuel .................267

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Index

Manual transmission .................191
fluid capacities ........................283
lubricant specifications ..........289
reverse .....................................192
Message center ...............66, 68–69
english/metric button ...............73
system check button ................72
warning messages .....................74
Mirrors ...................................55, 59

automatic dimming rearview mirror ........................................59
fold away ...................................61
heated ........................................60
side view mirrors (power) .......59
.........................................60
signal Moon roof ....................................56
Motorcraft parts ................267, 282

Octane rating ............................266
Oil (see Engine oil) ..................251
Overdrive .....................................55

Parking brake ............................184
Parts (see Motorcraft parts) ....282
Pedals (see Power adjustable