2002 FORD E-450 brake fluid

2. If the fluid level is low, start the engine.
3. While the engine idles, turn the steering wheel left and right several
times.
4. Turn the engine off.
For E-450 and E-550 vehicles with the Hydro-Boost Brake
System, do not press the brake pedal after the engine has been
turned off.
5. Recheck the fluid level on the dipstick. Do not add fluid if the level is
between the arrows in the FULL COLD range.
6. 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
Checking and adding brake fluid
Brake fluid should be checked and
refilled as needed. Refer to the
scheduled maintenance guide for
the service interval schedules.
1. Clean the reservoir cap before
removal to prevent dirt or water
from entering the reservoir.
2. Visually inspect the fluid level.
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 specification ESA-M6C25–A. Refer toLubricant
specificationsin this chapter.
MAX
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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.
Do not let the reservoir for the master cylinder run dry. This
may cause the brakes to fail.
DRIVELINE UNIVERSAL JOINT AND SLIP YOKE
Your vehicle may be equipped with universal joints that require
lubrication. Refer to the scheduled maintenance guide for maintenance
intervals. If the original universal joints are replaced with universal joints
equipped with grease fittings, lubrication will also be necessary.
TRANSMISSION FLUID
Checking automatic transmission fluid (if equipped)
Refer to your scheduled maintenance guide for scheduled intervals for
fluid checks and changes. Your transmission does not consume fluid.
However, the fluid level should be checked if the transmission is not
working properly, i.e., if the transmission slips or shifts slowly or if you
notice some sign of fluid leakage.
Automatic transmission fluid expands when warmed. To obtain an
accurate fluid check, drive the vehicle until it is at normal operating
temperature (approximately 30 km [20 miles]). 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 30 km (20 miles) 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.
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No. 4, 5 and 6 have a“EM”suffix. If a spark plug needs to be replaced,
use only spark plugs with the service part number suffix letterEEMas
shown on the engine decal.
4If a spark plug is removed for inspection, it must be reinstalled in the
same cylinder. Cylinders No. 1, 2, 3 and 4 have a“PG”suffix. Cylinders
No. 5, 6, 7 and 8 have a“P”suffix. If a spark plug needs to be replaced,
use only spark plugs with the service part number suffix letter as shown
on the engine decal.
REFILL CAPACITIES
Fluid Ford Part
NameApplication Capacity
Brake fluid Motorcraft High
Performance
DOT 3 Motor
Vehicle Brake
FluidAll Fill to line on
reservoir
Engine
oil-gasoline
engine (includes
filter change)Motorcraft SAE
5W-20 Premium
Synthetic Blend
Motor OilAll 5.7L (6.0
quarts)
Engine oil-diesel
engine (includes
filter change)Refer to the7.3L Power Stroke Direct Injection
Turbo Diesel Owner’s Guide Supplement.
Maintenance and Specifications
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handle. Check the container to verify the fluid being added is of the
correct type. Refer to your scheduled maintenance guide to determine
the correct service interval.
Some transmission fluids may be labeled as dual usage, such as
MERCONand MERCONV. These dual usage fluids are not to be used
in an automatic transmission that requires use of the MERCONtype
fluid. However, these dual usage fluids may be used in transmissions that
require the MERCONV type fluid.
MERCONand MERCONV type fluids are not interchangeable.
DO NOT mix MERCONand MERCONV. Use of a transmission
fluid that indicates dual usage (MERCONand MERCONV) in
an automatic transmission application requiring MERCONmay
cause transmission damage. Use of any fluid other than the
recommended fluid may cause transmission damage.
7Approximate dry fill capacity including transmission fluid cooling
system, actual refill capacities will vary based on vehicle application and
transmission fluid cooling system (i.e. coolers size, cooling lines. auxiliary
cooler capacities). The amount of transmission fluid and fluid level
should be set by the indication on the dipstick’s normal operating range.
LUBRICANT SPECIFICATIONS
Item Ford part
nameFord part
numberFord
specification
Brake fluid Motorcraft High
Performance
DOT 3 Motor
Vehicle Brake
FluidPM-1 ESA-M6C25-A
and DOT 3
Door weatherstrips Silicone
Lubricant
F7AZ-19G208-BA
and
F5AZ-19553-AAESR-M13P4-A
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Item Ford part
nameFord part
numberFord
specification
Disc brake caliper
railsMotorcraft
Silicone Brake
Caliper Grease
and Dielectric
CompoundXG-4 ESE-M1C171-A
Parking brake
assembly
(E-450/550 Super
Duty)Motorcraft
MERCON
Automatic
Transmission
FluidXT-2-QDX MERCON
Visteon
conventional and
Traction-Lok axles
(E-150)
2
Motorcraft SAE
75W-140 High
Performance
Synthetic Rear
Axle LubricantXY-75W140–QL WSL-M2C192-A
Dana 9.75 inch
(M60–1U) 10.5 inch
(M70–2U)
(M70–1HD)
(E-250/350/450/550)
3
Motorcraft SAE
80W-90 Premium
Rear Axle
LubricantXY-80W90-QL WSP-M2C197-A
Windshield washer
fluidMotorcraft
Ultra-clear
Windshield
Washer
ConcentrateZC-18–A ESR-M17P5-A
1Ensure the correct automatic transmission fluid is used. Transmission
fluid requirements are indicated on the dipstick or on the dipstick
handle. Check the container to verify the fluid being added is of the
correct type. Refer to your scheduled maintenance guide to determine
the correct service interval.
Some transmission fluids may be labeled as dual usage, such as
MERCONand MERCONV. These dual usage fluids are not to be used
in an automatic transmission that requires use of the MERCONtype
fluid. However, these dual usage fluids may be used in transmissions that
require the MERCONV type fluid.
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A
ABS (see Brakes) .....................141
Air bag supplemental restraint
system ................................119–120
and child safety seats ............121
description ..............................120
disposal ....................................124
driver air bag ..........................122
indicator light ...................12, 123
operation .................................122
passenger air bag ...................122
Air cleaner filter ...............229, 235
Air conditioning
manual heating and air
conditioning system .................71
Ambulance packages ....................6
Antifreeze (see Engine
coolant) .....................................209
Anti-lock brake system
(see Brakes) ..............................141
Audio system
(see Radio) ................17, 22, 28, 36
Automatic transmission
driving an automatic
overdrive .................................146
fluid, adding ............................227
fluid, checking ........................227
fluid, refill capacities ..............236
fluid, specification ..................243
Auxiliary power point .................86
Axle
lubricant specifications ..240, 243
refill capacities ........................236
traction lok ..............................143
B
Battery .......................................204acid, treating emergencies .....204
charging system warning
light ............................................12
disconnecting ..........................206
jumping a disabled battery ....175
maintenance-free ....................204
replacement, specifications ...235
servicing ..................................204
voltage gauge ............................15
BeltMinder .................................115
Brakes ........................................140
anti-lock ...................................141
anti-lock brake system (ABS)
warning light .....................12, 142
brake warning light ..................11
fluid, checking and adding ....226
fluid, refill capacities ..............236
fluid, specifications .........240, 243
lubricant specifications ..240, 243
shift interlock ..........................145
Break-in period .............................5
Bulbs ............................................79
C
Capacities for refilling fluids ....236
CD-6 disc .....................................36
CD-single premium .....................28
Changing a tire .........................168
Child safety restraints ..............125
child safety belts ....................125
Child safety seats ......................127
in front seat ............................129
in rear seat ..............................129
tether anchorage hardware ...131
Cleaning your vehicle
engine compartment ..............192
exterior ....................................195
instrument panel ....................194
Index
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