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Ford Vehicle Manual

Ford motor company vehicle manual
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  • Page 1: Table Of Contents

    Introduction Instrumentation Warning and control lights Gauges Entertainment Systems AM/FM stereo AM/FM stereo cassette AM/FM stereo cassette with CD AM/FM stereo with CD Climate Controls Heater only Manual heating and air conditioning Lights Headlamps Turn signal control Driver Controls Windshield wiper/washer control Steering wheel adjustment Power windows Mirrors...
  • Page 2 Seating and Safety Restraints Seating Safety restraints Child restraints Driving Starting Brakes Transmission operation Vehicle loading Roadside Emergencies Hazard flasher switch Fuses and relays Jump starting Customer Assistance The dispute settlement board Getting assistance outside the U.S. and Canada Ordering additional owner’s literature...
  • Page 3 Ford Motor Company. Ford may change the contents without notice and without incurring obligation. Copyright © 2002 Ford Motor Company...

  • Page 4: Introduction

    Furthermore, due to printing cycles it may describe options before they are generally available. Remember to pass on the Owner’s Guide when reselling the vehicle. It is an integral part of the vehicle. SAFETY AND ENVIRONMENT PROTECTION...
  • Page 5 The New Vehicle Limited Warranty includes Bumper-to-Bumper Coverage, Safety Restraint Coverage, Corrosion Coverage, and 7.3L Power Stroke Diesel Engine Coverage. In addition, your vehicle is eligible for Emissions Defect and Emissions Performance Warranties. For a detailed description of what is covered and what is not covered, refer to the Warranty Guide that is provided to you along with your Owner’s...
  • Page 6 Introduction These are some of the symbols you may see on your vehicle. Safety Alert Fasten Safety Belt Air Bag-Side Child Seat Installation Warning Brake System Brake Fluid - Non-Petroleum Based AdvanceTrac Hazard Warning Flasher Fuse Compartment Windshield Wash/Wipe Rear Window...
  • Page 7 Interior Luggage Compartment Release Symbol Engine Oil Engine Coolant Temperature Battery Battery Acid Fan Warning Maintain Correct Fluid Level Engine Air Filter Jack Low tire warning Panic Alarm Engine Coolant Do Not Open When Hot Avoid Smoking, Flames, or Sparks Explosive Gas Power Steering Fluid Emission System...
  • Page 8 Occupational Safety and Health Act (OSHA), and/or state and local laws and regulations may require additional equipment for the way you intend to use the vehicle. It is the responsibility of the registered owner to determine the applicability of such laws and regulations to your intended use for the vehicle, and to arrange for the installation of required equipment.

  • Page 9: Instrumentation

    Instrumentation WARNING LIGHTS AND CHIMES Warning lights and gauges can alert you to a vehicle condition that may become serious enough to cause expensive repairs. A warning light may illuminate when a problem exists with one of your vehicle’s functions.
  • Page 10 Refer to Engine shutdown system in the Driving chapter. Drivers of electronically controlled engines should know the extent of warning engine shutdown system before operating the vehicle. This information can be obtained from your dealer. ENGINE PROTECT STOP...
  • Page 11 If the light remains on while the engine is running, this indicates inadequate hydraulic booster pressure or reserve pump system failure. Stop the vehicle safely as soon as possible and seek service immediately. Brake system warning Momentarily illuminates when the ignition is turned to the ON position and the engine is off.
  • Page 12 PLC trailer or a PLC diagnostic tool is connected. If the light remains on after the vehicle is started, continues to flash or fails to illuminate, have the system serviced immediately. Parking brake warning (Hydraulic brakes only)
  • Page 13 Range inhibit Illuminates when the transmission is not engaged in the selected gear. The warning light will go off when the gearshift lever is adjusted in to the appropriate gear. Refer to the Transmission Operator’s Manual for more information. Charging system (if equipped) Illuminates when the ignition is turned to the ON position and the engine is off, or an over voltage...
  • Page 14 START position. If the light illuminates when the engine is running, stop the vehicle as soon as safely possible, shut off the engine and drain the filter bowl. Allowing water to stay in the system could result in extensive damage to, or failure of, the fuel injection system.

  • Page 15: Gauges

    Instrumentation Safety belt warning chime Sounds to remind you to fasten your safety belts. BeltMinder chime Sounds intermittently to remind you to fasten your safety belts. Headlamps on warning chime Sounds when the headlamps or parking lamps are on, the key is removed from the ignition and the driver’s door is opened.
  • Page 16 Check the oil level. Add oil if needed (refer to Engine oil in the Maintenance and specifications chapter). If the oil level is correct, have your vehicle checked at your dealership or by a qualified technician.
  • Page 17 Vehicles equipped with rear air suspension also have a dual-pointer air pressure gauge. Do not drive the vehicle when the low air pressure buzzer is sounding or the warning light is lit. These warnings indicate there is not enough air pressure for the brake or suspension system to operate properly.
  • Page 18 The FUEL DOOR icon and arrow indicates which side of the vehicle the fuel filler door is located. Speedometer Indicates the current vehicle speed.
  • Page 19 Instrumentation Trip odometer Registers the kilometers (miles) of individual journeys. To reset, depress the control. Tachometer Indicates the engine speed in revolutions per minute. Driving with your tachometer DIESEL FUEL ONLY pointer in the red zone may damage the engine. 1000...

  • Page 20: Entertainment Systems

    Entertainment Systems AM/FM STEREO (WITH 2 SPEAKERS) PUSH AM/FM STEREO (WITH 4 SPEAKERS AND FADE CAPABILITY) PUSH AM / FM STEREO TONE TONE VOL TONE TONE VOL SEEK TUNE AM/FM SEEK TUNE AM/FM...
  • Page 21 Volume/power control Press the control to turn the audio system on or off. Turn the control to raise or lower volume. If the volume is set above a certain level and the ignition is turned off, the volume will come back on at a “nominal” listening level when the ignition switch is turned back on.
  • Page 22 Entertainment Systems Speaker balance adjust Speaker sound distribution can be adjusted between the right and left speakers. Press the TONE control three times, then use the volume knob to adjust the desired level. Speaker fade adjust (if equipped) Speaker sound can be adjusted between the front and rear speakers.
  • Page 23 Radio station memory preset The radio is equipped with four station memory preset controls. These controls can be used to select up to four preset AM stations and eight FM stations (four in FM1 and four in FM2). Setting memory preset stations 1.
  • Page 24 Entertainment Systems To set the minute, press and hold the CLK control until CLOCK SET appears in the display and press the TUNE control: • to decrease minutes and • to increase minutes. The CLK control will allow you to switch between media display mode (radio station, stereo information, etc.) and clock display mode (time).
  • Page 25 AM/FM STEREO CASSETTE VOL - PUSH ON SEEK TUNE Volume/power control Press the control to turn the audio system on or off. Turn the control to raise or lower volume. If the volume is set above a certain level and the ignition is turned off, the volume will come back on at a “nominal”...
  • Page 26 Entertainment Systems Bass adjust The bass adjust control allows you to increase or decrease the audio system’s bass output. BASS Treble adjust The treble adjust control allows you to increase or decrease the audio system’s treble output. TREB Speaker balance adjust Speaker sound distribution can be adjusted between the right and left speakers.
  • Page 27 Speaker fade adjust Speaker sound can be adjusted between the front and rear speakers. Seek function The seek function control works in radio mode. Seek function in radio mode • Press to find the next listenable station down the frequency band. •...
  • Page 28 Entertainment Systems AM/FM select The AM/FM select control works in radio and tape modes. AM/FM select in radio mode This control allows you to select AM or FM frequency bands. Press the AM control to select from AM selections, and press the FM control to select from FM1 or FM2 memory preset stations.
  • Page 29 Setting the clock Press CLK to toggle between listening frequencies and clock mode while in radio mode. To set the hour, press and hold the CLK control and press the SEEK control: • to decrease hours and • to increase hours. To set the minute, press and hold the CLK control and press the TUNE control:...
  • Page 30 Entertainment Systems Tune adjust in radio mode • Press to move to the next frequency down the band (whether or not a listenable station is located there). Hold the control to move through the frequencies quickly. • Press to move to the next frequency up the band (whether or not a listenable station is located there).
  • Page 31 Rewind The rewind control works in tape mode. To rewind in tape mode, press the REW control. Fast forward The fast forward control works in tape mode. To fast forward in tape mode, press the FF control. In the tape mode, tape direction will automatically reverse when the end of the tape is reached.

  • Page 32: Am/Fm Stereo Cassette With Cd

    Entertainment Systems PREMIUM AM/FM STEREO/CASSETTE/SINGLE CD VOL PUSH ON SEEK TUNE SCAN Volume/power control Press the control to turn the audio system on or off. Audio power can also be turned on by pressing the AM/FM select control or the TAPE/CD select control.
  • Page 33 Bass adjust The bass adjust control allows you to increase or decrease the audio system’s bass output. Press the BASS control then press: • to decrease the bass output • to increase the bass output. Treble adjust The treble adjust control allows you to increase or decrease the audio system’s treble output.
  • Page 34 Entertainment Systems Seek function in radio mode • Press to find the next listenable station down the frequency band. • Press to find the next listenable station up the frequency band. Seek function in tape mode • Press to listen to the previous selection on the tape. •...
  • Page 35 AM/FM select The AM/FM select control works in radio, tape and CD modes. AM/FM select in radio mode This control allows you to select AM or FM frequency bands. Press the control to switch between AM, FM1 or FM2 memory preset stations. AM/FM select in tape mode Press this control to stop tape play and begin radio play.
  • Page 36 Entertainment Systems Starting autoset memory preset 1. Select a frequency using the AM/FM select controls. 2. Press the control. 3. When the first six strong stations are filled, the station stored in memory preset control 1 will start playing. If there are less than six strong stations available on the frequency band, the remaining memory preset controls will all store the last strong station available.
  • Page 37 • to increase minutes. If your vehicle has a separate clock, (other than the digital radio display), the CLK control will not function in the above manner. The CLK control will allow you to switch between media display mode (radio station, stereo information, etc.) and clock display mode (time).
  • Page 38 Entertainment Systems • To begin CD play (if CD is loaded), press the CD control. The first track of the disc will begin playing. If returning from radio or tape mode, CD play will begin where it stopped last. Rewind The rewind control works in tape and CD modes.
  • Page 39 Dolby noise reduction Dolby noise reduction operates in tape mode. Dolby noise reduction reduces the amount of hiss and static during tape playback. Press the control to activate (and deactivate) the Dolby noise reduction. Dolby noise reduction is manufactured under license from Dolby Laboratories Licensing Corporation.

  • Page 40: Am/Fm Stereo With Cd

    Entertainment Systems AUDIOPHILE AM/FM STEREO IN DASH SIX CD RADIO PREMIUM AM/FM STEREO IN DASH SIX CD RADIO SHUF SCAN LOAD PUSH ON DISC SEEK TUNE COMP BASS TREB MUTE FADE MENU...
  • Page 41 Volume/power control Press the control to turn the audio system on or off. Turn the control to raise or lower volume. If the volume is set above a certain level and the ignition is turned off, the volume will come back on at a “nominal” listening level when the ignition switch is turned back on.
  • Page 42 Entertainment Systems Speaker fade adjust Speaker sound can be adjusted between the front and rear speakers. Press the FADE control. Use the SEL control to adjust the sound between the front and rear speakers. Seek function The seek function works in radio or CD mode. Seek function in radio mode •...
  • Page 43 AM/FM select The AM/FM select control works in radio and CD modes. AM/FM select in radio mode This control allows you to select AM or FM frequency bands. Press the control to switch between AM, FM1 or FM2 memory preset stations. AM/FM select in CD mode Press this control to stop CD play and begin radio play.
  • Page 44 Entertainment Systems 2. AUTOSET will flash in the display as the frequency band is scrolled through. 3. When the six strongest stations are filled, the station stored in memory preset control 1 will start playing. If there are fewer than six strong stations available on the frequency band, the remaining memory preset controls will all store the last strong station available.
  • Page 45 (that is currently empty) are pressed. The system will play the next available disc. If your vehicle is equipped with a CD changer, pressing the CD control again will allow you to toggle between accessing the multi disc system and the CD changer.
  • Page 46 Entertainment Systems Rewind The rewind control works in CD modes. Press and hold the REW control until the desired selection is reached. If the beginning of the disc is reached, the CD will begin play at the first track. Release the control to disengage rewind mode.
  • Page 47 Auto load This feature allows you to autoload up to 6 discs into the multi disc CD player internal to the radio. Press and hold the LOAD control until AUTOLOAD # is displayed. The CD door will open. Load the desired discs, one at a time. The CD is loaded into position and the audio system will display CD#.
  • Page 48 Entertainment Systems Compression feature (if equipped) The compression feature operates in CD mode and brings soft and loud MENU CD passages together for a more consistent listening level. On Audiophile audios, press the MENU control until compression status is displayed. Press the SEL control to enable the compression feature when COMP OFF is displayed.
  • Page 49 Entertainment Systems TRAFFIC ON/OFF— Traffic announcements can be programmed as local or distant. Refer to Traffic announcements. RDS ON/OFF— This feature allows your audio system to receive text information from RDS-equipped FM radio stations. Refer to Radio Data System feature. FIND type —...
  • Page 50 Entertainment Systems audio system will scan to all traffic capable frequencies. If no valid stations are found after one pass, the scan function is cancelled and NOT FOUND displays. Traffic announcements are not available in most U.S. markets. Radio data system (RDS) feature This feature allows your audio system to receive text information MENU...
  • Page 51 Program type This feature allows you to search for RDS stations selectively by their program type. Press the MENU control until FIND program type is displayed. Use the SEL control to select the program type. With the feature on, use the SEEK or SCAN control to find the desired program type from the following selections: •...
  • Page 52 • STADIUM—outdoor stadium with a capacity of about 30 000 Press the DSP control again to access the occupancy modes. Use the SEL control to optimize the sound based upon the occupants in the vehicle. The following occupancy modes can be selected: • ALL SEATS • DRIVER SEAT...
  • Page 53 • Press the phone/mute control again to send and end calls. This control will mute the playing media even if your vehicle is not equipped with a factory-installed cellular phone. Press the control again to return to the playing media.
  • Page 54 Due to technical incompatibility, certain recordable and re-recordable compact discs may not function correctly when used in Ford CD players. Irregular shaped CDs, CDs with a scratch protection film attached, and CDs with homemade paper (adhesive) labels should not be inserted into the CD player.
  • Page 55 • Terrain. Hills, mountains and tall buildings between your vehicle’s antenna and the radio station signal can cause FM reception problems. Static can be caused on AM stations by power lines, electric fences, traffic lights and thunderstorms.

  • Page 56: Climate Controls

    Mode selector control Controls the direction of the airflow to the inside of the vehicle. • (Panel) – Distributes outside air through the instrument panel registers. • OFF – Outside air is shut out and the fan will not operate. For short periods of time only, use this mode to prevent undesirable odors from entering the vehicle.

  • Page 57: Manual Heating And Air Conditioning

    This will reduce fogging on your windshield. Once the windshield has been cleared, select any desired position. • To reduce humidity buildup inside the vehicle, do not drive with the climate control system in the OFF position. • Under normal weather conditions, your vehicle’s climate control system should be left in any position other than OFF position when the vehicle is parked.
  • Page 58 • A/C – Uses outside air to cool the vehicle. It is quieter than MAX A/C but not as economical. Airflow will be from the instrument panel registers.
  • Page 59 Once the windshield has been cleared, operate the climate control system as desired. • To reduce humidity buildup inside the vehicle in cold weather conditions, don’t drive with the climate control system in the OFF or MAX A/C position.
  • Page 60 Climate Controls • Under snowy or dirty weather conditions, your vehicle’s climate control system should be left in the OFF position when the vehicle is parked. This allows the climate control system to be free from contamination of outside pollutants.

  • Page 61: Lights

    Lights HEADLAMP CONTROL Turns the lamps off. Turns on the parking lamps, instrument panel lamps, license plate lamps and tail lamps. Turns the headlamps on. High beams Push the lever toward the instrument panel to activate. Pull the lever towards you to deactivate. Flash to pass Pull toward you slightly to activate and release to deactivate.

  • Page 62: Headlamps

    AIMING THE HEADLAMPS The headlamps on your vehicle are properly aimed at the assembly plant. If your vehicle has been in an accident the alignment of your headlamps should be checked by a qualified service technician.

  • Page 63: Turn Signal Control

    TURN SIGNAL CONTROL • Push down to activate the left turn signal. • Push up to activate the right turn signal. • In DRL equipped vehicles, use of the turn signals will shut off the highbeams in daytime driving. INTERIOR LAMPS Map lamps (if equipped) To turn on the map lamps, press the control next to each lamp.
  • Page 64 Lights Using the right bulbs Function Headlamps Park/turn signal Sidemarker/rear marker lamp Tail/stop lamp Backup Foglamp Running board/courtesy lamp License plate lamp Cabmarker Exterior visor lamp (if equipped) Rear fender clearance Rear identification Dome lamp To replace all instrument panel lights - see your dealer Replace entire lamp assembly;...
  • Page 65 Lights 3. Remove four screws and the retaining bracket from the headlamp bulb. 4. Pull headlamp bulb out of the housing, disconnect the electrical connector and remove the headlamp bulb. 5. To complete installation, follow the removal procedure in reverse order.
  • Page 66 Lights Replacing visor/cab marker bulbs To change the cab marker bulbs: 1. Make sure the headlamp switch is in the OFF position and then remove the screw and lens from the lamp assembly. 2. Carefully pull the bulb straight out of the socket and push in the new bulb.
  • Page 67 Lights Replacing tail lamp/turn/backup lamp bulbs — F650 SuperCrewzer only The tail lamp/backup lamp bulbs are located in the same portion of the tail lamp assembly, one just below the other. Follow the same steps to replace either bulb: 1. Make sure the headlamp switch is in the OFF position and then remove the two screws holding the light cover to the light housing.

  • Page 68: Driver Controls

    Driver Controls WINDSHIELD WIPER/WASHER CONTROLS Rotate the windshield wiper control to the desired interval, low or high speed position. The bars of varying length are for intermittent wipers. When in this position rotate the control upward for fast intervals and downward for slow intervals.

  • Page 69: Steering Wheel Adjustment

    Driver Controls Changing the wiper blades To replace the wiper blades: 1. Pull the wiper arm away from the windshield and lock into the service position. 2. Turn the blade at an angle from the wiper arm. Push the lock pin manually to release the blade and pull the wiper blade down toward the windshield to remove it from the...
  • Page 70 The compass reading may be affected when you drive near large buildings, bridges, power lines and powerful broadcast antenna. Magnetic or metallic objects placed in or on the vehicle may also affect compass accuracy. Adjustments may need to be made to the zone and calibration of the compass.
  • Page 71 Usually, when something affects the compass readings, the compass will correct itself after a few days of operating your vehicle in normal conditions. If the compass still appears to be inaccurate, a manual calibration may be necessary. Refer to Compass calibration adjustment.
  • Page 72 CAL indicator will remain lit until the compass is sucessfully calibrated. 5. Slowly drive the vehicle in a circle (less than 5 km/h [3 mph]) until the CAL indicator turns off. It may take up to five circles to complete calibration.
  • Page 73 A driver’s first responsibility is the safe operation of the vehicle. The most important thing you can do to prevent a crash is to avoid distractions and pay attention to the road. Wait until it is safe to operate Mobile Communications Equipment.

  • Page 74: Power Windows

    Driver Controls POWER WINDOWS (IF EQUIPPED) Press and hold the rocker switches to open and close windows. • Press the top portion of the rocker switch to close. • Press the bottom portion of the rocker switch to open. One touch down •...

  • Page 75: Mirrors

    Driver Controls Window lock (if equipped) The window lock feature allows only the driver to operate the power windows. To lock out all the window controls except for the driver’s press the left side of the control. Press the right side to restore the window controls. MIRRORS With the doors closed and the seat adjusted for proper comfort, move...

  • Page 76: Speed Control

    To turn speed control on 7.3L Power Stroke engine • Press ON. Vehicle speed cannot be controlled until the vehicle is traveling at or above 48 km/h (30 mph). Do not shift the gearshift lever into N (Neutral) with the speed control on.
  • Page 77 Caterpillar/Cummins engines Press CRUISE RPM. If the vehicle is moving, speed control will be enabled; if the vehicle is stationary, engine RPM can be controlled. Do not use the speed control in heavy traffic or on roads that are winding, slippery, or unpaved.
  • Page 78 If the vehicle is stationary, this will set the vehicle idle RPM. If you drive up or down a steep hill, your vehicle speed may vary momentarily slower or faster than the set speed. This is normal. Speed control cannot reduce the vehicle speed if it increases above the set speed on a downhill.
  • Page 79 • Accelerate with your accelerator pedal. When the desired vehicle speed is reached, press and release SET ACCEL. You can accelerate with the accelerator pedal at any time during speed control usage. Releasing the accelerator pedal will return your vehicle to the previously programmed set speed. Caterpillar/Cummins engines Press and hold SET +.
  • Page 80 Driver Controls Caterpillar/Cummins engine Press and hold RESUME -. If the vehicle is moving, this will decrease vehicle speed by 1.6 km/h (1 mph) increments; if the vehicle is stationary, this will decrease engine RESUME RPM. Release the control when the desired vehicle speed/engine RPM is reached.
  • Page 81 RPM. To return to a previously set speed 7.3L Power Stroke engine • Press RES. For RES to operate, the vehicle speed must be faster than 48 km/h (30 mph). Caterpillar/Cummins engines Press RESUME -. For RESUME - to...

  • Page 82: Locks And Security

    Locks and Security KEYS The key operates all locks on your vehicle. In case of loss, replacement keys are available from your dealer. You should always carry a second key with you in a safe place in case you require it in an emergency.
  • Page 83 Locks and Security Unlocking the doors Press this control to unlock the driver’s door. The interior lamps will illuminate. Press the control a second time within five seconds to unlock all doors. Locking the doors Press this control to lock all doors. To confirm all doors are closed and locked, press the control a second time within five seconds.
  • Page 84 The remote transmitter is powered by one coin type three-volt lithium battery CR2032 or equivalent. Typical operating range will allow you to be up to 10 meters (33 feet) away from your vehicle. A decrease in operating range can be caused by the following factors: •...
  • Page 85 Programming remote transmitters It is necessary to have all (maximum of four — original and/or new) of your remote transmitters available prior to beginning this procedure. To program the transmitters yourself: • Place the key in the ignition and turn from 2 (LOCK) to 3 (OFF) and cycle between 3 (OFF) and 4(ON) eight times in rapid succession (within 10 seconds)

  • Page 86: Seating And Safety Restraints

    Seating and Safety Restraints SEATING Driver’s seat adjustment Never adjust the driver’s seat or seatback when the vehicle is moving. Always drive and ride with your seatback upright and the lap belt snug and low across the hips. Reclining the seatback can cause an occupant to slide under the seat’s safety belt, resulting in severe personal injuries in the...
  • Page 87 Seating and Safety Restraints Rotate control to adjust seatback. Easy-Aire seat (if equipped) Move handle to the left to move seat forward or backward. Rotate control to adjust seatback.
  • Page 88 Seating and Safety Restraints Pump handle to raise seat height. Push handle full down to lower. Always adjust the seat height before fastening seatbelt. Air-Ride seat (if equipped) Push up on the switch to raise the seat height. Press down on the switch to lower the seat height.
  • Page 89 • Push control to activate. • Push again to deactivate. Adjusting the front power seat (if equipped) Never adjust the driver’s seat or seatback when the vehicle is moving. Do not pile cargo higher than the seatbacks to avoid injuring people in a collision or sudden stop.
  • Page 90 Seating and Safety Restraints Press to raise or lower the front portion of the seat cushion. Press to raise or lower the rear portion of the seat cushion. Press the control to move the seat forward, backward, up or down.
  • Page 91 5. Rotate the seatback forward. RETURNING THE SEAT TO UPRIGHT Always latch the vehicle seat to the floor, whether the seat is occupied or empty. If not latched, the seat may cause injury during a sudden stop.

  • Page 92: Safety Restraints

    Do not allow people to ride in any area of your vehicle that is not equipped with seats and safety belts. Be sure everyone in your vehicle is in a seat and using a safety belt properly.
  • Page 93 2. To unfasten, push the release button and remove the tongue from the buckle. The front and rear outboard safety restraints in the vehicle are combination lap and shoulder belts. The front and rear seat passenger outboard safety belts have vehicle sensitive emergency locking retractors.
  • Page 94 Seating and Safety Restraints • 4–door SuperCab • 4–door CrewCab...
  • Page 95 To lower the shoulder belt height, push the button and slide the height adjuster down. To raise the height of the shoulder belt, slide the height adjuster up. Pull down on the height adjuster to make sure it is locked in place.
  • Page 96 Seating and Safety Restraints Shorten and fasten the belt when not in use. Safety belt warning light and indicator chime The seat belt warning light illuminates in the instrument cluster and a chime sounds to remind the occupants to fasten their safety belts. Conditions of operation If...
  • Page 97 If... The driver’s safety belt is not buckled before the vehicle has reached at least 5 km/h (3 mph) and 1-2 minutes have elapsed since the ignition switch has been turned to ON... The driver’s safety belt is buckled while the safety belt...
  • Page 98 45% in cars, and by 60% in light trucks. Nearly 1 of 2 deaths occur in single-vehicle crashes, many when no other vehicles are around. Possibly, but a serious crash can do much more than wrinkle your clothes, particularly if you are unbelted.
  • Page 99 • All vehicle doors are closed. • The driver’s safety belt is unbuckled. • The parklamps/headlamps are in OFF position (If vehicle is equipped with Autolamps, this will not affect the procedure). To reduce the risk of injury, do not deactivate/activate the Belt Minder feature while driving the vehicle.
  • Page 100 Ford Motor Company recommends that all safety belt assemblies used in vehicles involved in a collision be replaced. Safety belt assemblies not in use during a collision should also be inspected and replaced if either damage or improper operation is noted.

  • Page 101: Child Restraints

    Moving the child closer to the center of the vehicle may help provide a good shoulder belt fit.
  • Page 102 When children should use booster seats Children need to use booster seats from the time they outgrow the toddler seat until they are big enough for the vehicle seat and lap/shoulder belt to fit properly. Generally this is when they weigh about 80 lbs (about 8 to 12 years old).
  • Page 103 Both can be used in any vehicle in a seating position equipped with lap/shoulder belts if your child is over 40 lbs. The shoulder belt should cross the chest, resting snugly on the center of the shoulder.
  • Page 104 Use a safety seat that is recommended for the size and weight of the child. Carefully follow all of the manufacturer’s instructions with the safety seat you put in your vehicle. If you do not install and use the safety seat properly, the child may be injured in a sudden stop or...
  • Page 105 Attaching safety seats with tether straps. Carefully follow all of the manufacturer’s instructions included with the safety seat you put in your vehicle. If you do not install and use the safety seat properly, the child may be injured in a sudden stop or collision.
  • Page 106 Seating and Safety Restraints Installing child safety seats with combination lap and shoulder belts 1. Position the child safety seat in a seat with a combination lap and shoulder belt. Children under 12 are safer when properly restrained in the rear seat, to the extent this is possible.
  • Page 107 Rebuckle the belt. Obtain the locking clip kit (Part Number FO3Z-5461248–A) at no charge from an authorized Ford or Lincoln-Mercury dealer. 5. Before placing the child in the seat, forcibly tilt the seat forward and back to make sure the seat is securely held in place. To check this, grab the seat at the belt path and attempt to move it side to side and forward and back.
  • Page 108 Ford or Lincoln/Mercury dealer. If you have a Super Cab or Crew Cab, Ford recommends you attach tether safety seats in the rear seating position (if possible) with the tether strap attached to the tether anchorage bracket as shown in the instructions provided with the tether anchor kit.

  • Page 109: Driving

    The use of starting fluids (ether) in an engine equipped with an air intake heater could cause an explosion and result in vehicle damage, property damage and/or personal injury. 2. Do not depress the accelerator during starting the engine.
  • Page 110 Use of an engine block heater is strongly recommended if you live in a region where temperatures reach -23° C (-10° F) or below. For best results, plug the heater in at least three hours before starting the vehicle. The heater can be plugged in the night before starting the vehicle.
  • Page 111 If the gauges indicate any reading is not in the normal operating range, stop your vehicle as soon as possible, shut the engine off and check the appropriate fluid level. If an overheating condition starts to occur,...
  • Page 112 30 seconds. This is to allow time for the operator to move the vehicle off the road. If additional time is required, the engine can be restarted and run each time for approximately 30 seconds.

  • Page 113: Brakes

    • Set fan speed on high with function control to any position except OFF or MAX A/C and the temperature control on any desired position. • Adjust air control system to force outside air into the vehicle. Winter fronts If using an aftermarket winter front (not recommended), it must have a permanent opening directly in line with the center of the fan drive.
  • Page 114 Stop the vehicle safely as soon as possible and seek service immediately. If the yellow BRAKE RESERVE BRAKE...
  • Page 115 • The Anti-Lock system does not decrease the time necessary to apply the brakes or always reduce stopping distance. Always leave enough room between your vehicle and the vehicle in front of you to stop. • We recommend that you familiarize yourself with this braking technique.
  • Page 116 P (Park) (if equipped) or N (Neutral) for vehicles with automatic transmission. Use of wheel chocks is also recommended in hilly or off-road usage. Unexpected and possible sudden vehicle movement may occur if these precautions are not taken. BRAKE...
  • Page 117 Driving The parking brake is not recommended to stop a moving vehicle. However, if the normal brakes fail, the parking brake can be used to stop your vehicle in an emergency. Since the parking brake only applies retardation to the rear wheels, the vehicle’s stopping distance will increase greatly and the handling of your vehicle will be adversely affected.
  • Page 118 For optimal performance of a new parking brake system/new linings perform the following procedure: 1. While driving the vehicle at 40 km/h (20 mph) apply the parking brake (with applicable force to set to approximately 18kg [40 lbs.]). Allow the vehicle to come to a complete stop.
  • Page 119 • Check brake adjustment. • Check brake linings for excessive wear. • Check system air pressure. Air brakes After starting the engine, give the air compressor time to build up the air pressure to 414 kPa (60 psi) before moving the vehicle. Driving...
  • Page 120 ON position. This condition may be caused by excessive brake applications depleting the system air pressure. If this condition occurs, stop driving the vehicle until the compressor has fully recharged the air system. Do not move the vehicle in this condition because the brake system may be inoperative.
  • Page 121 These systems are all controlled by the brake pedal in the same manner as for normal stops. Do not continue to operate the vehicle with a failure of one of the systems. Take the vehicle to your dealer for service immediately.
  • Page 122 Unexpected and possible sudden vehicle movement may occur if these precautions are not taken. If the service brakes should fail to operate while the vehicle is in motion, you can make an emergency stop with the parking brake. The stopping distance, however, will be much greater than normal.
  • Page 123 Block the wheels to prevent the vehicle from moving. Unexpected and possibly sudden vehicle movement may occur if these precautions are not taken.
  • Page 124 Driving 4. Turn the release stud one-quarter turn to engage the stud tangs with the slot in the pressure plate. Keep the stud engaged and install the nut on the release stud. 5. Tighten the nut until the spring is fully caged and the brakes are released.
  • Page 125 When a trailer is hooked-up correctly and system pressure reaches 448 kPa (65 psi), the red control (trailer supply) may be pushed in and should stay in, charging the trailer system and releasing the trailer brakes. The yellow control (parking brake) may now be pushed in, which will supply air to the tractor spring brakes, releasing them.
  • Page 126 Trailer charge If both controls are out when parking the combination vehicle and it is desired to recharge the trailer (leaving the tractor spring brakes applied), the trailer air supply control may be pushed in, repressurizing the trailer supply line.
  • Page 127 This retarding action is carried through the engine and drivetrain, slowing the vehicle and reducing the need for frequent service brake applications. Exhaust brakes are not intended for use as the primary braking system...
  • Page 128 Apply the service brakes to reduce the engine RPM or make a slower descent by using a lower gear. The exhaust brake is not recommended for use on slippery or low traction road surfaces. Under these conditions a loss of vehicle control could possibly occur.
  • Page 129 The exhaust brake retards the vehicle with a smooth braking effect. • Depending on the grade and vehicle load, you may or may not feel the retarding force acting against your body when the brake is applied.
  • Page 130 STEERING Your vehicle is equipped with power steering. Power steering uses energy from the engine to decrease the driver’s effort in steering the vehicle. Never hold the steering wheel to the extreme right or the extreme left for more than a few seconds when the engine is running. This action could damage the power steering pump.
  • Page 131 Driving • Total vehicle out of alignment (i.e. rear axle[s] out of alignment with front axle) • Improper adjustment in the steering gear • Vehicle overloaded or unevenly loaded • High crosswinds • High crown in center of road • Components in steering linkage loose or worn •...

  • Page 132: Transmission Operation

    Do not allow your vehicle to coast in N (Neutral). Transmission braking is not available in N (Neutral). Allowing the vehicle to coast in N (Neutral) could result in loss of vehicle control and severe transmission damage. The Allison automatic transmissions are a torque converter type, full power shifting and fully automatic.
  • Page 133 R (Reverse) Use this position to back the vehicle. Completely stop the vehicle before shifting from R (Reverse) to any forward gear (1, 2, 3 or D). The reverse warning signal will sound when the selector is in R (Reverse). Reverse has only one gear and provides the greatest gear reduction.
  • Page 134 Driving The push button shifter has a R (Reverse), N (Neutral) and D (Drive) selections as well as a MODE button, up arrow (for upshifts) and a down arrow (downshift) and a digital display. When a range button is pressed, a tone will sound, the SELECT indicator displays a chosen operation (if the electronic control...
  • Page 135 (Neutral) to a drive range is made. The Select and Monitor indicators will display N. Do not allow your vehicle to coast in N (Neutral). Transmission braking is not available in N (Neutral). This practice can also result in transmission damage.
  • Page 136 Driving D (Drive) - The vehicle will attain first gear, and as the speed increases, the transmission will automatically upshift through each gear. As the vehicle slows down, the transmission will automatically downshift. The Select indicator will display the highest gear available.
  • Page 137 Do not allow your vehicle to coast in N (Neutral). Engine braking is not available in N (Neutral). Allowing your vehicle to coast in N (Neutral) may result in loss of vehicle control and severe internal transmission damage. D (Drive-Normal driving position)
  • Page 138 R (Reverse) Use this position to move the vehicle backwards. Completely stop the vehicle before shifting from a forward gear (1, 2, 4 or D) to R (Reverse), or from R (Reverse) to any forward gear. The reverse warning signal will sound when the selector is in R (Reverse).
  • Page 139 - then engage the PTO. If engagement is prevented by the gear teeth not meshing properly, release the brakes and allow the vehicle to creep slightly - or shift the selector to N (Neutral) and then back in gear. The PTO should never be engaged by clashing the gear teeth.
  • Page 140 Caterpillar 3126E engine If your vehicle is equipped with a Caterpillar 3126E engine, the PTO will only operate if the vehicle is in Neutral. This feature can be overriden by a special service tool; see your dealer or service representative for more...
  • Page 141 To avoid premature clutch wear and failure, do not drive with your foot resting on the clutch pedal or use it to hold the vehicle at a standstill on an upgrade as when waiting for a traffic light.
  • Page 142 5th gears are synchronized. The shift pattern is embossed on the gear shift knob. Do not shift the transmission into R (Reverse) while the vehicle is moving as this could damage the transmission. To go forward With the engine idling, depress the clutch pedal and shift into 1 (First).
  • Page 143 The shift pattern is embossed on the gear shift knob. Do not shift the transmission into 1 (First) or R (Reverse) while the vehicle is moving as this could damage the transmission. To go forward With the engine idling, depress the clutch pedal and shift into 1 (First).
  • Page 144 The shift pattern is embossed on the gear shift knob. Do not shift the transmission into 1 (First) or R (Reverse) while the vehicle is moving as this could damage the transmission. To go forward With the engine idling, depress the clutch pedal and shift into 1 (First).
  • Page 145 When operating the PTO unit with the vehicle stationary, first set the parking brake (chock the wheels if the vehicle is on a hill or other unlevel surface). BACKING UP To avoid the possibility of personal injury while backing the vehicle, always be sure your vehicle’s path is clear.
  • Page 146 TWO-SPEED REAR AXLE General Information A two-speed rear axle allows the vehicle operator to select LO range for good starting and pulling power. The operator may also select HI range which allows for greater road speed and economy.
  • Page 147 Shifting the axle from HI to LO range - vehicle stopped Place the transmission in N (Neutral), the press the upper part of the control. Note: Do not shift the axle to LO range with the vehicle in motion. Driving 2SPD...
  • Page 148 (for trucks) or the bottom of the wheel rims (for cars). Once through the water, always try the brakes. Wet brakes do not stop the vehicle as effectively as dry brakes. Drying can be improved by moving your vehicle slowly while applying light pressure on the brake pedal.

  • Page 149: Vehicle Loading

    (GAWR) at the tire to ground interface. Under no circumstances should your vehicle be loaded in excess of the GVWR or GAWR. It is the operator’s responsibility to assure that neither the axle capacities, spring capacities, tire capacities nor the vehicle rated GVWR is exceeded.

  • Page 150: Roadside Emergencies

    Roadside Emergencies GETTING ROADSIDE ASSISTANCE To fully assist you should you have a vehicle concern, Ford offers a complimentary roadside assistance program. This program is separate from the New Vehicle Limited Warranty and is not applicable to vehicles sold in Canada. The service is available: •...

  • Page 151: Fuses And Relays

    • Depress control again to turn the flashers off. FUSES AND RELAYS Fuses If electrical components in the vehicle are not working, a fuse may have blown. Blown fuses are identified by a broken wire within the fuse. Check the appropriate fuses before replacing any electrical components.

  • Page 152: Passenger Compartment Fuse Panel

    Roadside Emergencies Fuse Mini rating fuses Natural Green — — — — — Passenger compartment fuse panel The fuse panel is located below and to the left of the steering wheel by the brake pedal. Remove the panel cover to access the fuses. To remove a fuse use the fuse puller tool provided on the fuse panel cover.
  • Page 153 The fuses are coded as follows: Fuse/Relay Location Roadside Emergencies Fuse Amp Passenger Compartment Fuse Rating Horn Turn/Hazard lamps Cigar lighter Diagnostic connectors Back-up lamps, Daytime Running Lamps (DRL) relays, Blend door actuator, Heated seat module (SuperCrewzer only), On/Off fan clutch (SuperCrewzer only), Warning chime module (SuperCrewzer and Ambulance)
  • Page 154 Roadside Emergencies Fuse/Relay Location Fuse Amp Passenger Compartment Fuse Rating GEM, Interior lamp relay, Map lamps, Glove box lamps (SuperCrewzer only), Power mirrors (SuperCrewzer only), Warning chime module (SuperCrewzer only) Highbeams — Not used Headlamp switch, GEM Engine, Cluster, Cummins PCM, CAT PCM, 7.3L Power Stroke PCM (idle valid switch input), Alternator (Ambulance only)
  • Page 155 Power distribution box The power distribution box is located in the engine compartment. The power distribution box contains high-current fuses that protect your vehicle’s main electrical systems from overloads. Always disconnect the battery before servicing high current fuses. Always replace the cover to the power distribution box before...
  • Page 156 Roadside Emergencies The high-current fuses and relays are coded as follows. Fuse/Relay Location Fuse Amp Power Distribution Box Rating 15A* Park lamps, Roof lamps 25A* Cummins Powertrain Control Module (PCM) 15A* Foglamps (SuperCrewzer only) 10A* Generator 15A* Washer pump 15A* CAT air intake heater relay, Cummins PCM 20A*...
  • Page 157 Fuse/Relay Fuse Amp Location Roadside Emergencies Power Distribution Box Rating 20A* Allison MD transmission, Allison 2000/2400 transmission 10A* Keyless entry module (SuperCrewzer only) 10A* Park brake adjustment module (SuperCrewzer only) — Not used 7.5A* Body builder prep (hydraulic brake vehicles only) 10A* Allison 2000/2400 transmission (except F650 SuperCrewzer)
  • Page 158 Roadside Emergencies Fuse/Relay Location 119/120 121/122 Fuse Amp Power Distribution Box Rating 40A** Power windows 30A** Power seats (SuperCrewzer only) 30A** Body builder prep 40A** Blower motor 30A** Heated seats (SuperCrewzer only) 30A** E-brake (SuperCrewzer only) 40A** Ignition switch (Junction box fuses 5, 8, 9, 11, 21) 30A** Body builder prep...
  • Page 159 Fuse/Relay Location * Mini Fuses ** Maxi Fuses Relays The relay box is located on the rear crossmember. Air Brake Trailer Tow Relays (if equipped) Roadside Emergencies Fuse Amp Power Distribution Box Rating — Fuel heater relay (CAT and Cummins only)/7.3L Power Stroke PCM relay) —...
  • Page 160 Roadside Emergencies The relays are coded as follows: Fuse/Relay Location ** Maxi Fuse Fuse Amp Rating 30A** Trailer Tow Run Feed 30A** Trailer Tow Park/Marker Lamps 30A** Trailer Tow Stop Lamps 30A** Trailer Tow Turn/Stop Lamps — Not Used — Trailer Tow Run Relay —...
  • Page 161 SuperCrewzer (if equipped) HOOK LAMP RELAY N.U. The relays are coded as follows: Fuse/Relay Location Roadside Emergencies EXHAUST BRAKE USED RELAY#1 EXHAUST BRAKE USED RELAY#2 Fuse Amp Rating — Not Used — Not Used — Not Used — Not Used —...

  • Page 162: Jump Starting

    Preparing your vehicle Also see the label on the battery. 1. Use only a 12–volt supply to start your vehicle. If you connect your battery to a 24–volt power supply you can damage your starter, ignition system and other electrical components. Do not attach the jumper cables to the glow plug relay as this could severely damage the glow plugs, injector driver module and PCM.
  • Page 163 1. Start the booster vehicle and run the engine at moderately increased speed. 2. After a few minutes, start the engine of the vehicle with the discharged battery. 3. After starting, run the engine at about 1,000 RPM for 3–5 minutes.
  • Page 164 Always follow the outlined towing procedures. • To tow a vehicle on the front wheels, the steering wheel must be in the straight ahead position. Secure the steering wheel with a...
  • Page 165 • To tow a vehicle on the rear wheels, it will be necessary to remove the drive axles or disconnect the driveshaft. If the drive axles are removed, the ends of the axle housing must be sealed to prevent the loss of axle lubricant during towing.

  • Page 166: Customer Assistance

    Ford Customer Relationship Center. Away from home If you own a Ford or Mercury vehicle and are away from home when your vehicle needs service, or if you need more help than the dealership could provide, after following the steps described above, contact the Ford Customer Relationship Center to find an authorized dealership to help you.
  • Page 167 Oakville, Ontario L6J 5E4 1-800-565-3673 (FORD) www.ford.ca If you own a Lincoln vehicle and are away from home when your vehicle needs service, or if you need more help than the dealership could provide, after following the steps described above, contact the Ford Customer Relationship Center to find an authorized dealership to help you.

  • Page 168: The Dispute Settlement Board

    Customer Assistance In some states (in the U.S.) you must directly notify Ford in writing before pursuing remedies under your state’s warranty laws. Ford is also allowed a final repair attempt in some states. In the United States, a warranty dispute must be submitted to the...
  • Page 169 • The date of repair(s) and mileage at the time of occurrence(s). • The current mileage. • The name of the dealer(s) who sold or serviced the vehicle. • A brief description of your unresolved concern. Customer Assistance...
  • Page 170 Customer Assistance • A brief summary of the action taken by the dealer(s) and Ford Motor Company. • The names (if known) of all the people you contacted at the dealership(s). • A description of the action you expect to resolve your concern.

  • Page 171: Getting Assistance Outside The U.s. And Canada

    In the United States, using leaded fuel may also result in difficulty importing your vehicle back into the U.S. If your vehicle must be serviced while you are traveling or living in Central or South America, the Caribbean, or the Middle East, contact the nearest Ford dealership.

  • Page 172: Ordering Additional Owner's Literature

    18 months of ownership of a new vehicle or the first 29 000 km (18 000 miles), whichever occurs first: 1.

  • Page 173: Reporting Safety Defects (U.s. Only)

    To contact NHTSA, you may either call the Auto Safety Hotline toll-free at 1–800–424–9393 (or 366–0123 in the Washington D.C. area) or write NHTSA U.S. Department of Transportation Washington, D.C. 20590 You can also obtain other information about motor vehicle safety from the Hotline.

  • Page 174: Cleaning

    These products can discolor and spot painted surfaces. • Never wash a vehicle that is “hot to the touch” or during exposure to strong, direct sunlight. • Always use a clean sponge or carwash mitt with plenty of water for best results.
  • Page 175 • Do not use hydrofluoric acid-based or high caustic-based wheel cleaners, steel wool, fuels or strong household detergent. • To remove tar and grease, use Ford Extra Strength Tar and Road Oil Removal (B7A-19520–AA), available from your dealer. ENGINE Engines are more efficient when they are clean because grease and dirt buildup keep the engine warmer than normal.
  • Page 176 Use only approved products to clean plastic parts. These products are available from your dealer. • For routine cleaning, use Detail Wash (ZC-3–A). • If tar or grease spots are present, use Ford Extra Strength Tar and Road Oil Removal (B7A-19520–AA). INSTRUMENT PANEL AND CLUSTER LENS Clean the instrument panel with a damp cloth, then dry with a dry cloth.

  • Page 177: Underbody Preservation

    These products may cause premature wearing of the clear, protective coating. UNDERBODY Flush the complete underside of your vehicle frequently. Keep body and door drain holes free from packed dirt. Cleaning...

  • Page 178: Maintenance And Specifications

    Maintenance and Specifications OPENING THE HOOD The hood and fenders are held in position by a latch located on each fender. The parking brake must be fully set before opening the hood or possible personal injury may occur. If you must leave the engine running while checking under the hood, do not allow any loose clothing, jewelry, hair or other items to get near moving engine components or possible personal injury may occur.
  • Page 179 4. Tilt the hood forward until stopped by the retaining cables. To lower the hood: 1. Push the hood rearward at the top center of the hood above the grille until closed. 2. Engage the latch on each fender. 3. Push down on the bottom of each latch until locked. To avoid the possibility of personal injury, never stand beneath the hood when it is being raised or lowered.
  • Page 180 Washer fluids containing non-methanol antifreeze agents should be used only if they provide cold weather protection without damaging the vehicle’s paint finish, wiper blades or washer system. Do not put engine coolant or antifreeze in the washer fluid reservoir.
  • Page 181 3. Set the parking brake and shift into N (Neutral) (automatic transmission) or 1 (First) (manual transmission). 4. Turn off the engine and wait a few minutes for the oil to drain completely into the oil pan. 5. Open the hood. Protect yourself from engine heat. 6.
  • Page 182 Refer to the general maintenance information section for the appropriate intervals for changing the engine oil and filter. • Change your engine oil and filter more frequently if your vehicle operation includes extended periods of idling or low-speed operation, driving for a long time in cold temperatures or short driving distances.
  • Page 183 EXPECTED TEMPERATURE RANGE Using the chart, determine which SAE viscosity grade best suits the temperature range in which you expect to operate your vehicle. The use of the correct oil viscosity grade for diesel engines is important for satisfactory engine operation.
  • Page 184 Maintenance and Specifications BATTERY Your vehicle is equipped with two Motorcraft maintenance-free batteries which are mounted in a covered tray and located on the left frame rail. The covered battery tray, depending upon application, may also have one or two steps attached.
  • Page 185 When lifting a plastic-cased battery, excessive pressure on the end walls could cause acid to flow through the vent caps, resulting in personal injury and/or damage to the vehicle or battery. Lift the battery with a battery carrier or with your hands on opposite corners.
  • Page 186 If the level falls below, add coolant per the instructions in the Adding Engine Coolant section. Your vehicle was factory-filled with a 50/50 engine coolant and water concentration. If the concentration of coolant falls below 40% or above 60%, the engine parts could become damaged or not work properly.
  • Page 187 Vehicles with diesel engines typically are used to carry heavy loads and accumulate mileage rapidly. These two factors cause the additives in the coolant to “wear out” in a shorter time. Ford recommends an interim service interval performed at 12 months or 24 000 km (15 000 miles), whichever occurs first.
  • Page 188 Gold Engine Coolant (yellow-colored), VC-7–A (VC-7–B in Oregon), depending on the type of coolant originally equipped in your vehicle. If you are unsure which type of coolant your vehicle requires, check your coolant reservoir or contact your local dealer. Note: Use of Motorcraft Cooling System Stop Leak Pellets, VC-6, darkens the color of Motorcraft Premium Gold Engine Coolant from yellow to golden tan.
  • Page 189 Whenever coolant has been added, the coolant level in the coolant reservoir should be checked the next few times you drive the vehicle. If necessary, add enough 50/50 concentration of engine coolant and distilled water to bring the liquid level to the proper level.
  • Page 190 Maintenance and Specifications to determine the coolant type in your vehicle. Add 1.89L (4 pints) of Motorcraft Heavy Duty Cooling System Additive FW-16 or equivalent meeting Ford specification ESN-M99B169–A, directly to the cooling system. An additional 237–295 ml (8–10 oz.) of supplemental coolant additive FW-16 should be added at 24 000 km (15 000 mile) intervals to maintain proper concentration.
  • Page 191 • Refer to the chart on the coolant container to ensure the coolant concentration in your vehicle will provide adequate freeze protection at the temperatures in which you drive in the winter months.
  • Page 192 Maintenance and Specifications Fan clutches Your vehicle’s cooling system is equipped with a viscous variable speed fan clutch. • The fan clutch helps control cooling, increase performance, improve fuel economy and reduce noise. • The fan clutch is controlled by bimetallic spring sensors. Do not tamper with these sensors as this may change their calibration or keep the fan clutch from operating at all.
  • Page 193 If you must replace the fuel filler cap, replace it with a genuine Ford or Motorcraft part. The customer warranty may be void for any damage to the fuel tank or fuel system if a genuine Ford or Motorcraft fuel filler cap is not used.
  • Page 194 If you have run out of fuel: • If your vehicle is equipped with dual fuel tanks, add at least 15–19 liters (4–5 gallons) of fuel to each tank before attempting to restart the engine.
  • Page 195 Maintenance and Specifications Draining the fuel filter/water separator—Caterpillar 3126 B engine 1. With the engine off, open the drain valve located at the bottom of the fuel filter/water separator by turning it counterclockwise. 2. Drain the filter until clear fuel is visible. 3.
  • Page 196 Maintenance and Specifications Fuel filter replacement—Caterpillar 3126 B engine The fuel filter/water separator is located on the left side of the engine. Replace the fuel filter/water separator as recommended in the general maintenance information section, or sooner if it becomes plugged.
  • Page 197 Maintenance and Specifications Fuel filter replacement—7.3L Power Stroke engine The fuel filter/water separator is located on the right side of the engine. Replace the fuel filter/water separator as recommended in the general maintenance information section, or sooner if it becomes plugged.
  • Page 198 Your vehicle may be equipped with dual fuel tanks. If so, you will have a selector control. For information on the Dual Fuel Tank Selector Control refer to the Driving Tips section in the 7.3 Liter Power Stroke Direct...
  • Page 199 • Always use fuel of a known quality, preferably a national brand. • Have the vehicle loading and distribution the same every time. • When refueling a vehicle equipped with dual fuel tanks, if the two tanks are not filled equally, the fuel gauge reading may fluctuate slightly until the fuel level between the two tanks balance out and become equal.
  • Page 200 FUEL CONSUMPTION IMPROVEMENT MEASURES There are two important factors you can control to improve fuel economy: the mechanical condition of your vehicle and how you drive it. A properly maintained vehicle will deliver better performance than a neglected vehicle. Always follow your maintenance schedule to keep your vehicle in top operating condition.
  • Page 201 CHECKING AND ADDING POWER STEERING FLUID Checking power steering fluid level Check the power steering fluid level using the following procedure. Refer to the general maintenance information section for the recommended service intervals. If adding fluid is necessary, use only MERCON ATF. 1.
  • Page 202 If the fluid level drops, maintain the fluid level at the step in the reservoir. Use only a DOT 3 brake fluid designed to meet Ford specifications. Refer to Lubricant Specifications in this chapter. 1. Set the parking brake, shift into 1 (First) and turn the engine off.
  • Page 203 3. If necessary, add brake fluid from a clean un-opened container until the level reaches MAX. Do not fill above this line. 4. Use only a DOT 3 brake fluid certified to meet Ford specifications. Refer to Lubricant specifications in this chapter.
  • Page 204 Maintenance and Specifications Brake fluid is toxic. If brake fluid contacts the eyes, flush eyes with running water for 15 minutes. Seek medical attention if irritation persists. If taken internally, drink water and induce vomiting. Seek medical attention immediately. If you use a brake fluid that is not DOT 3, you will cause permanent damage to your brakes.
  • Page 205 A tag on the filler plug will identify the use of the synthetic fluid. Use only fluid that meets Ford specifications (refer to Lubricant specifications in this chapter. Use of a non-approved transmission fluid may cause internal transmission component damage.
  • Page 206 AIR FILTER When to service Your vehicle is equipped with an air filter restriction gauge to determine when to replace the air filter element. It is not possible to determine the need for service by visually inspecting the air filter.
  • Page 207 Servicing the air filter Your vehicle is equipped with a dry-type air cleaner element. When the yellow indicator on the air filter restriction indicator reaches the red line the air filter element should be replaced.
  • Page 208 Maintenance and Specifications • Cummins B engine • Caterpillar 3126 B engine Replace the air filter element using the following procedure: 1. Set the parking brake and shift into N (Neutral) (automatic transmission) or 1 (First) (manual transmission) and turn the engine off. 2.
  • Page 209 • If your vehicle is equipped with the Cummins B engine, a secondary air filter is located the bottom of the air filter housing to keep dirt and debris from falling into the engine when the air filter element is being removed.
  • Page 210 The disc wheel nuts on your vehicle were tightened before delivery. Recheck torque of nuts at 160 km (100 miles) and 800 km (500 miles) of new vehicle operation or any time a wheel is removed. Reset to recommended torque levels.
  • Page 211 Never run the engine with one wheel off the ground. Failure to retighten wheel lug nuts as required could allow the wheel to come off while the vehicle is in motion, possibly causing loss of vehicle control and collision. Loose wheel studs may also cause shimmy and vibration.
  • Page 212 Check the pressure regularly. Maintain the recommended air pressure for your vehicle, load, tires and rims or wheels. Check the tire valve for air leaks and replace the valve if necessary. If the valve cap is missing, install a new cap. Refer to Tire/Wheel Rim Selection and Inflation...
  • Page 213 Consult your dealer about the need to change the switch setting on the back of the speedometer. Front wheel alignment If abnormal tire wear or ride and handling characteristics such as vehicle lead or wander are experienced with properly inflated tires, the front end alignment should be checked.
  • Page 214 Maintenance and Specifications ADD and FULL marks indicated on the hub. Do not overfill. Overfilling can result in oil on brake linings. Refer to your general maintenance information section for fluid level checks and change intervals for the front hubs. Your front hubs may be filled with an optional synthetic fluid which allows use of the extended service intervals.
  • Page 215 Insert a second fuse or reset the breaker (if equipped). If this fuse immediately burns out or the breaker (if equipped) trips and you cannot locate the fuse, return your vehicle to your dealer for a circuit check.
  • Page 216 Maintenance and Specifications TRANSMISSION REFILL CAPACITIES Type and make 5-speed (Eaton FS-4205A) 5-speed (Eaton FS-5205A) 6-speed (Eaton FS-5306A and 1, 2 FS-6306A) 7-speed (Spicer ES52-7B and 1, 2 ES066-7B) Allison AT-545 2000/2400 Series-Standard sump 2000/2400 Series-Shallow sump MD series Quantity shown is nominal; fluid level should be at lower edge of fill hole.
  • Page 217 8585 (23000) Quantities listed are approximate. Fill axle until the lubricant level is at bottom of filler hole, with vehicle on level ground. If hubs have been removed, add an additional 0.75 liter (1.6 pints) of axle lubricant. Add lubricant through the axle vent.
  • Page 218 Maintenance and Specifications LUBRICANT SPECIFICATIONS Item Brake and clutch Motorcraft High fluid (if Performance DOT equipped) 3 Motor Vehicle Brake Fluid Body hinges, Multi-Purpose hood hinges and Grease latches. Lock cylinders Penetrating Lubricant Front axle Premium Long spindle pins, Life Grease...
  • Page 219 Item Ford Part Name Bushings, front Premium Long wheel bearings Life Grease (grease packed type)and seals, fuel shut-off solenoid linkage, air brake control valve, linkage, treadle hinge and roller, transmission and transmission cables, clutch release bearing hub, transmission shift lever pivot.
  • Page 220 Stroke engine Motorcraft SAE 0W-30 Super All Season Motor oil (synthetic) Engine oil Refer to the appropriate engine operator’s manual. -Cummins B and Caterpillar 3126 B engines Ford Part Name XY-80W90-QL XY-75W140 XO-30-QSD XO-15W40-QSD XO-10W30-QSD XO-0W30-LAS Ford Part Number Specification...
  • Page 221 Refer to your general maintenance information section to determine the correct service interval for the lubricant which you are using. Ford Motor Company currently does not offer a SAE 50 Motor oil. Ford Motor Company currently does not offer a synthetic based lubricant for this viscosity grade.

  • Page 222: Certification Label

    VEHICLE IDENTIFICATION NUMBER (VIN/SERIAL NUMBER) The Vehicle Identification Number (VIN) is printed on the Vehicle Rating Decal attached to the vehicle. The VIN also serves as the warranty number. The rating decal is attached to the front door latch pillar (B-pillar) on the driver’s side.
  • Page 223 Vehicle Rating Decal - Sample 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. Where Ford Motor Company is the sole manufacturer of the vehicle, the Certification Label is located on the front door latch pillar on the driver’s side.

  • Page 224: Accessories

    • the remainder of your new vehicle limited warranty. This means that genuine Ford accessories purchased along with your new vehicle and installed by the dealer are covered for the full length of your New Vehicle’s Limited Warranty — 3 years or 60 000 km (36 000 miles) (whichever occurs first).

  • Page 225: General Maintenance Information

    Ford Motor Company recommends you perform the Owner Maintenance Services listed in this section. These services are matters of day-to-day care that are important to the proper operation of your vehicle. In addition to the conditions described in the Owner Maintenance Checklist, be alert for any unusual noise, vibration or other indication that your vehicle may need service and attend to it promptly.
  • Page 226 You should avoid running out of fuel or turning off the ignition while the vehicle is in motion, especially at high speeds. Because of high engine compartment and exhaust system...
  • Page 227 (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.
  • Page 228 Required Maintenance Services and in the General Maintenance Checklist. To further help minimize noise emissions degradation throughout the life of the vehicle, Ford Motor Company recommends that this vehicle should be operated in the manner described within the Owner Guide.
  • Page 229 • Operating in severe dust conditions. • Extensive idling, or low speed operation such as door-to-door delivery service. • High speed operation with a fully loaded vehicle (max. GVW). • Snowplowing. Perform the following: • Change engine oil and oil filter every three months, 8 000 km (5 000 miles) or 125 hours of engine service.
  • Page 230 32 000 km (20 000 miles) whichever occurs first. However, more frequent inspection is required if your vehicle’s brakes are subjected to heavy use or adverse operating conditions such as: • Frequent brake applications while fully loaded.
  • Page 231 General Maintenance Information SCHEDULED MAINTENANCE GUIDE...
  • Page 232 Visually check the automatic transmission for fluid leakage Steering system Check the power steering pump fluid level and check the system for leaks Check the entire vehicle for evidence of fluid leaks U.S. Department of Transportation, Federal Highway Administration requirements (ensure that the entire...
  • Page 233 Check every oil change Oil change intervals are as follows: Powerstroke - 10 000 ; Caterpillar - 15 000 ; Cummins - 15 000 (refer to the Caterpillar and Cummins service manuals for further instructions and information) General Maintenance Information Engine system Check the engine cooling system - hoses, clamps and protection...
  • Page 234 If coolant is dirty or rusty in appearance, the system should be drained, flushed and refilled with the prescribed solution of cooling system fluid and water. Use only permanent type coolant that meets Ford specifications ESE-M97B18-C. See the engine manufacturer’s operating guide for supplimental corrosion inhibitor specifications.
  • Page 235 500 000 KM / 300 000 MILES • Disassemble the air dryer, replace the desiccant and check the mounting of the dryer to the vehicle (if equipped). Please continue with these scheduled maintenance intervals for your vehicle. * Shown intervals are for Powerstroke engine only. Refer to Caterpillar and Cummins Owner Manuals for intervals for their respective engines.
  • Page 236 General Maintenance Information 800 000 KM / 500 000 MILES • Change the lubricant in the manual shift transmission (all applications) when equipped with optional synthetic lubricant.
  • Page 237 (*c) General Maintenance Information Frequency - Observation Insufficient power shown in loaded practice stop Vehicle handling qualities not up to Excessive noise emanates from under the cab or engine compartment Excessive engine noise Engine overheats, fans runs at high speed constantly, excessive fan noise,...
  • Page 238 General Maintenance Information Maintenance Operation Check the transmission and engine mountings (*b) Check and adjust transmission controls (*b) Check fuel pump pressure Clean radiator cap seal. Clean and inspect the cap surface on the radiator Check the battery terminals for corrosion Tighten the wheel mounting nuts to the specified torque.
  • Page 239 General Maintenance Information...
  • Page 240 General Maintenance Information...
  • Page 241 General Maintenance Information...
  • Page 242 General Maintenance Information...

  • Page 243: Index

    ...101 Child safety seats ...104 attaching with tether straps ..108 in front seat ...106 in rear seat ...106 tether anchorage hardware ...108 Cleaning your vehicle engine compartment ...175 exterior ...177 instrument panel ...176 interior ...176 plastic parts ...176 washing ...174...
  • Page 244 ...181 Exhaust fumes ...112 Foglamps ...62 Fuel ...192 calculating fuel economy ...198, 200 choosing the right fuel ...193 filling your vehicle with fuel ...192 filter, specifications ...194–196 gauge ...18 improving fuel economy ...198, 200 safety information relating to automotive fuels ...192 Fuses ...151–152...
  • Page 245 Instrument panel cleaning ...176 lighting up panel and interior ...62 Jump-starting your vehicle ...165 Keys key in ignition chime ...15 removing from the ignition ...145 Lamps ...72 bulb replacement specifications chart ...64 cargo lamps ...62 daytime running light ...61 fog lamps ...62 headlamps ...61...
  • Page 246 ...12, 15, 96 Safety seats for children ...104 Seat belts (see Safety restraints) ...92 Seats ...86 child safety seats ...104 Servicing your vehicle ...229 Speed control ...76 Speedometer ...18 Starting your vehicle ...109 jump starting ...165 preparing to start your vehicle ...109...

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