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The fuel system may be under pressure. If the fuel filler cap is venting vapor or if you hear a hissing sound, wait until it stops

before completely removing the fuel filler cap. Otherwise, fuel may spray out and injure you or others.

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If you do not use the proper fuel filler cap, excessive pressure or vacuum in the fuel tank may damage the fuel system or cause the fuel cap to disengage in a collision, which may result in possible personal injury.

Automotive fuels can cause serious injury or death if misused or mishandled.

Gasoline may contain benzene, which is a cancer-causing agent.

Observe the following guidelines when handling automotive fuel: • Extinguish all smoking materials

and any open flames before refueling your vehicle.

• Always turn off the vehicle before • Automotive fuels can be harmful

refueling.

or fatal if swallowed. Fuel such as gasoline is highly toxic and if swallowed can cause death or permanent injury. If fuel is swallowed, call a physician immediately, even if no symptoms are immediately apparent. The toxic effects of fuel may not be visible for hours. • Avoid inhaling fuel vapors. Inhaling too much fuel vapor of any kind

can lead to eye and respiratory tract irritation. In severe cases, excessive or prolonged breathing of fuel vapor can cause serious illness and permanent injury.

• Avoid getting fuel liquid in your eyes. If fuel is splashed in the eyes, remove contact lenses (if worn), flush with water for 15 minutes and seek medical attention. Failure to seek proper medical attention could lead to permanent injury.

• Fuels can also be harmful if absorbed through the skin. If fuel is

splashed on the skin and/or clothing, promptly remove contaminated clothing and wash skin thoroughly with soap and water. Repeated or prolonged skin contact with fuel liquid or vapor causes skin irritation.

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Maintenance and Specifications • Be particularly careful if you are taking “Antabuse” or other forms of disulfiram for the treatment of alcoholism. Breathing gasoline vapors, or skin contact could cause an adverse reaction. In sensitive individuals, serious personal injury or sickness may result. If fuel is splashed on the skin, promptly wash skin thoroughly with soap and water. Consult a physician immediately if you experience an adverse reaction.

When refueling always shut the engine off and never allow sparks or open flames near the filler neck. Never smoke while

refueling. Fuel vapor is extremely hazardous under certain conditions. Care should be taken to avoid inhaling excess fumes.

The flow of fuel through a fuel pump nozzle can produce static electricity, which can cause a fire if fuel is pumped into an

ungrounded fuel container.

Use the following guidelines to avoid static build-up when filling an ungrounded fuel container: • Place approved fuel container on the ground. • DO NOT fill a fuel container while it is in the vehicle (including the • Keep the fuel pump nozzle in contact with the fuel container while filling. • DO NOT use a device that would hold the fuel pump handle in the fill

cargo area).

position. Refueling

Fuel vapor burns violently and a fuel fire can cause bad injuries. To help avoid injuries to you and others: • Read and follow all the instructions on the pump island; • Turn off your engine when you are refueling; • Do not smoke if you are near fuel or refueling your vehicle; • Keep sparks, flames and smoking materials away from fuel; • Stay outside your vehicle and do not leave the fuel pump unattended when refueling you vehicle — this is against the law in some places; • Keep children away from the fuel pump; never let children pump fuel.

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Fuel filler cap Your fuel tank filler cap has an indexed design with a 1/4 turn on/off feature. When fueling your vehicle: 1. Turn the engine off. 2. Carefully turn the filler cap counterclockwise until it stops. 3. Pull to remove the cap from the fuel filler pipe. 4. To install the cap, align the tabs on the cap with the notches on the filler pipe. 5. Turn the filler cap clockwise until it clicks. If the “Check Fuel Cap” indicator comes on and stays on after you start the engine, the fuel filler cap may not be properly installed. Turn off the engine, remove the fuel filler cap, align the cap properly and reinstall it. If you must replace the fuel filler cap, replace it with a fuel filler cap that is designed for your vehicle. The customer warranty may be void for any damage to the fuel tank or fuel system if the correct genuine Ford or Motorcraft fuel filler cap is not used.

The fuel system may be under pressure. If the fuel filler cap is venting vapor or if you hear a hissing sound, wait until it stops

before completely removing the fuel filler cap. Otherwise, fuel may spray out and injure you or others.

If you do not use the proper fuel filler cap, excessive pressure or vacuum in the fuel tank may damage the fuel system or cause the fuel cap to disengage in a collision, which may result in possible personal injury.

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Choosing the right fuel Use only UNLEADED FUEL. The use of leaded fuel is prohibited by law and could damage your vehicle. Your vehicle was not designed to use fuel or fuel additives with metallic compounds, including manganese-based additives. Studies indicate that these additives can cause your vehicle’s emission control system to deteriorate more rapidly. In Canada, premium grade fuel generally contains more metallic additives than regular fuel. We recommend using regular grade fuel. In Canada, many fuels contain metallic additives, but fuels free of such additives may be available; check with your local fuel dealer. Do not use fuel containing methanol. It can damage critical fuel system components. Repairs to correct the effects of using a fuel for which your vehicle was not designed may not be covered by your warranty.

Octane recommendations 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 authorized dealer 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 authorized dealer. 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.

• The Service engine soon indicator (

) may come on. For more

information on the Service engine soon indicator, refer to the Instrument Cluster chapter.

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).

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.

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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 off prior to refueling, an error in the reading • Use the same filling rate setting (low-medium-high) each time the • 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.

will result if the engine is left running.

same direction each time you fill up.

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. 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.

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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.

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 economy. • Idling for long periods of time (greater than one minute) may waste fuel. • 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

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

economy.

reduce fuel economy.

shifting between third and fourth gear occurs. Unnecessary shifting of this type could result in reduced fuel economy.

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

economy.

this chapter.

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Maintenance and Specifications • Perform all regularly scheduled maintenance items. Follow the recommended maintenance schedule and owner maintenance checks found in your vehicle’s scheduled maintenance information.

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.

two-wheel-drive operation.

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 authorized 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.

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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 information

high speeds.

performed according to the specified schedule.

The scheduled maintenance items listed in the scheduled maintenance information 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 ( 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.

), charging system

Exhaust leaks may result in entry of harmful and potentially lethal fumes into the passenger compartment.

Do not make any unauthorized changes to your vehicle or engine. By law, vehicle owners and anyone who manufactures, repairs, services, sells, leases, trades vehicles, or supervises a fleet of vehicles are not permitted to intentionally remove an emission control device or prevent it from working. Information about your vehicle’s emission system is on the Vehicle Emission Control Information Decal located on or near the engine. This decal identifies engine displacement and gives some tune up specifications. Please consult your Warranty Guide for complete emission warranty information.

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light illuminates, the

light to illuminate. Examples are:

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 OBD-II system has detected a malfunction. Temporary malfunctions may cause your 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 cold engine startup followed by mixed city/highway driving.) No additional vehicle service is required. If the available opportunity.

light remains on, have your vehicle serviced at the first

light should turn off. (A driving cycle consists of a

light on.

Readiness for Inspection/Maintenance (I/M) testing In some localities, it may be a legal requirement to pass an I/M test of light is on, refer to the the on-board diagnostics system. If your description in the Warning lights and chimes section of the Instrument Cluster chapter. Your vehicle may not pass the I/M test with the 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.

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Allow the vehicle to sit for at least eight hours without starting the engine. Then, start the engine and complete the above driving cycle. The engine must warm up to its normal operating temperature. Once started, do not turn off the engine until the above driving cycle is complete.

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°F–80°F (-7°C–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.

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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.

BRAKE FLUID 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 authorized dealer immediately.

CLUTCH FLUID (IF EQUIPPED) Check the clutch fluid level. Refer to the scheduled maintenance information 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 information 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 handle 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 information 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 If the original universal joints are replaced with universal joints equipped with grease fittings, lubrication will be necessary. Refer to the scheduled maintenance information for maintenance intervals.

AIR FILTER MAINTENANCE Refer to the scheduled maintenance information 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.

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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. 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.

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• 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 notches 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

5.4L V8 engine FA-1754
FG-1011
FL-820-S

6.8L V10 engine FA-1782
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 information and is essential to the life and performance of your vehicle and to its emissions system. For PCV valve replacement, see your authorized dealer. Refer to the scheduled maintenance information 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 authorized dealer. Refer to the scheduled maintenance information 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

Application

Capacity

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

5.8 pints (2.8L)

5.8 pints (2.8L)

6.9 pints (3.3L)

F-350
(DANA 80)1

F-450/550
(Dana S110/S130)1

All

8.5 pints (4.0L)

14.0 pints (6.6L)

Fill to line or step (for clutch) on reservoir

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

26.4 quarts (25.0L) 27.5 quarts (26.0L)

Refer to your 6.0 Liter Power Stroke Direct Injection Turbo Diesel Owner’s Guide Supplement

5.4L V8 and 6.8L V10 engines

7.0 quarts (6.6L)

Fluid

Front axle

Rear axle

Brake fluid (and clutch fluid-if equipped)

Engine coolant - gas engines2

Engine coolant - diesel engine2

Engine oil (includes filter change) - gas engines6

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 Motorcraft Premium Gold Engine Coolant (yellow-colored) Motorcraft Premium Gold Engine Coolant (yellow-colored) Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil (US) Motorcraft SAE 5W-20 Super Premium Motor Oil (Canada)

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Ford Part Name Refer to your 6.0 Liter Power Stroke Direct Injection Turbo Diesel Owner’s Guide Supplement

Application

Capacity

Fluid

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

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 Automatic transmission fluid 3

Motorcraft MERCON威 ATF Motorcraft MERCON威 ATF Motorcraft MERCON威 SP ATF

4x4 vehicles

6-speed manual

TorqShift (5–speed)

Windshield washer fluid

All

Motorcraft Premium Windshield Washer Concentrate

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
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 information for change intervals on Dana rear axles. 2Add the coolant type originally equipped in your vehicle.

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3Ensure the correct automatic transmission fluid is used. Transmission fluid requirements are indicated on the dipstick handle. Check the container to verify the fluid being added is of the correct type. Refer to your scheduled maintenance information 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 ensure 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. 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.

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LUBRICANT SPECIFICATIONS

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–140
Synthetic Rear Axle Lubricant (Dana S110/S130
axles) 1
Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid Motorcraft Premium Gold Engine Coolant (yellow-colored)

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 or WSS-M6C62-A

WSS-M97B51-A1

VC-7-A (U.S., except CA, OR and NM), VC-7-B (CA, OR and NM)

Item

Spindle bearing

Front axle (4X4)

Rear axle

Brake fluid and clutch fluid (if equipped)

Engine coolant

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Ford part name or equivalent 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

Ford part number XO-5W20-QSP (US) CXO-5W20–LSP12
(Canada)

Ford specification WSS-M2C930-A and API Certification Mark

XG–4 or XL-5

ESB-M1C93–B

XL-1

none

XG-1-C or XG-1-K

ESA-M1C75-B

Motorcraft Premium Long-Life Grease

XG-1-C or XG-1-K

WSD-M1C227-A

Motorcraft MERCON威 ATF

XT-2-QDX

MERCON威

Motorcraft MERCON威 ATF 2

XT-2-QDX

MERCON威

Item

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, knuckle ball joints (F-450/550) and trackbar ball joint (F-450/550) Power steering fluid and transfer case fluid (if equipped) Manual transmission (6-speed)

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Item

Automatic transmission TorqShift (5–speed)

Windshield washer fluid

Ford part name or equivalent Motorcraft MERCON威 SP ATF 2

Motorcraft Premium Windshield Washer Concentrate

Ford part number XT-6–QSP

Ford specification 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 information for change intervals on Dana rear axles. 2Ensure the correct automatic transmission fluid is used. Transmission fluid requirements are indicated on the dipstick handle. Check the container to verify the fluid being added is of the correct type. Refer to your scheduled maintenance information 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 *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 (mm)

Regular Cab 4x4 –

inches (mm)

SuperCab

4x2 – inches (mm)

SuperCab

4x4 – inches (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)

79.9 (2029)

79.9 (2029)

79.9 (2029)

79.9 (2029)

137.0
(3480)

137.0 (3480)

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

(3) Overall width (4) Wheelbase

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

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

293

(5) Overall length

226.4
(5751)

226.4 (5751)

aShort Box bLong Box

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Maintenance and Specifications

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

Regular Cab Style Side - inches (mm)

SuperCab Style Side - inches (mm)

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

76.8 (1951)a 76.7 (1948)b 80.8 (2052)c 79.6 (2022)d

(1) Overall height

(2a) Track - Front

(2b) Track - Rear

(3) Overall width

(4) Wheelbase (5) Overall length

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 161.8 (4110)

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 137.0 (3480)

246.6 (6264)

226.4 (5751)

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

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

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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) 261.0 (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) 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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IDENTIFYING YOUR VEHICLE

Safety Compliance Certification Label The National Highway Traffic Safety Administration Regulations require that a Safety Compliance Certification Label be affixed to a vehicle and prescribe where the Safety Compliance Certification Label may be located. The Safety Compliance 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

TRANSMISSION/TRANSAXLE CODE DESIGNATIONS

You can find a transmission/transaxle code on the vehicle Safety Compliance Certification Label. The following table tells you which transmission or transaxle each code represents. Code

Description Six-speed manual, Dana (ZF S6–650) Six-speed manual, Dana (ZF M6HD-W) Five-speed automatic, TorqShift (gas engines) Five-speed automatic, TorqShift (diesel engine)

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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 authorized 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 authorized 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 authorized 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 authorized 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 authorized dealer or visit our online store at: www.fordaccessoriesstore.com.

Exterior style Bug shields Chrome exhaust tip Daytime Running Lamps (DRLs) Deflectors Front end covers Running boards Sliding rear windows - manual and power Splash guards Step bars

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Accessories

Tonneau covers Wheels

Interior style Electrochromatic compass/temperature interior mirrors Floor mats Speed control

Lifestyle Bedliners and bedmats Bed tents Bike racks Sport Liner娂 Toolboxes Towing mirrors Trailer hitches, wiring harnesses and accessories

Peace of mind First aid and highway safety kits Full vehicle covers Keyless entry Locking gas cap Mobile-Ease娂 hand-free communication system Remote start Vehicle security systems 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 authorized dealer for specific weight information.

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Accessories • 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 your authorized dealer. • 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 added to

the vehicle by the authorized dealer or the owner may adversely affect battery performance and durability.

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Index

jumping a disabled battery ....226
maintenance-free ....................258
replacement, specifications ...286
servicing ..................................258
BeltMinder .................................104
Brakes ........................................172
anti-lock ...........................172–173
anti-lock brake system (ABS) warning light ...........................173
fluid, checking and adding ....278
fluid, refill capacities ..............287
fluid, specifications .................290
lubricant specifications ..........290
parking ....................................173
shift interlock ..........................176
trailer .......................................159
Break-in period .............................5
Bulbs ............................................45

Capacities for refilling fluids ....287
Cassette tape player .......20, 22, 25
Cell phone use ..............................7
Child safety restraints ..............118
child safety belts ....................118
Child safety seats ......................121
attaching with tether straps ..124
in front seat ............................122
in rear seat ..............................122

Cleaning your vehicle

engine compartment ..............242
instrument panel ....................244
interior .....................................245
interior trim ............................245
plastic parts ............................244
safety belts ..............................245
washing ....................................241
waxing .....................................241

305

Accessory delay ..........................58
Air cleaner filter .......283–284, 286
Air conditioning ..........................36
Airbag supplemental restraint system ................................108–109
and child safety seats ............110
description ..............................109
disposal ....................................112
driver airbag ............................111
indicator light .........................112
operation .................................111
passenger airbag .....................111
passenger deactivation switch ......................................113
Ambulance packages ....................8
Antifreeze (see Engine coolant) ................260
Anti-lock brake system (see Brakes) ......................172–173
Audio system (see Radio) ................20, 22, 25, 28
Automatic transmission ............176

driving an automatic overdrive .................................177
fluid, adding ............................279
fluid, checking ........................279
fluid, refill capacities ..............287
Auxiliary power point .................56
Axle

lubricant specifications ..........290
refill capacities ........................287
traction lok ..............................175

Battery .......................................258
acid, treating emergencies .....258

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Dipstick

automatic transmission fluid ..........................................279
engine oil .................................254

Doors

lubricant specifications ..........290

Driveline universal joint and slip yoke ....................................283
Driving under special conditions ..................179, 192, 196
sand .........................................194
snow and ice ...........................196
through water .................195, 198

Electronic message center ...68–69
Emergencies, roadside

jump-starting ..........................226
Emergency Flashers .................204
Emission control system ..........275
Engine ........................................293
cleaning ...................................242
coolant .....................................260
diesel ...........................................8
fail-safe cooling .......................265
idle speed control ...................258
lubrication specifications .......290
refill capacities ........................287
service points ..................251–252
starting after a collision .........204
Engine block heater .................172
Engine oil ..................................254
checking and adding ..............254
dipstick ....................................254
filter, specifications ........257, 286
recommendations ...................257
refill capacities ........................287
specifications ..........................290

Index

wheels ......................................242
wiper blades ............................244

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

fluid ..........................................278
operation while driving ..........180
recommended shift speeds ....180

Compass, electronic

set zone adjustment .................71
Console ........................................67
overhead ..............................55–56

Controls

steering column ........................66

Coolant

checking and adding ..............260
refill capacities ................264, 287
specifications ..........................290

Cruise control (see Speed control) ....................61
Customer Assistance ................202

Ford accessories for your vehicle .....................................248
Ford Extended Service Plan ..........................................238
Getting assistance outside the U.S. and Canada ..............239
Getting roadside assistance ...202
Getting the service you