2002 FORD F150 manual transmission

SERVICE RECOMMENDATIONS
To help you service your vehicle:
²We highlight do-it-yourself items in the engine compartment for easy
location.
²We provide a scheduled maintenance guide which makes tracking
routine service easy.
If your vehicle requires professional service, your dealership can provide
the necessary parts and service. Check yourWarranty Guideto find out
which parts and services are covered.
Use only recommended fuels, lubricants, fluids and service parts
conforming to specifications. Motorcraft parts are designed and built to
provide the best performance in your vehicle.
PRECAUTIONS WHEN SERVICING YOUR VEHICLE
Be especially careful when inspecting or servicing your vehicle.
²Do not work on a hot engine.
²When the engine is running, keep loose clothing, jewelry or long hair
away from moving parts.
²Do not work on a vehicle with the engine running in an enclosed
space, unless you are sure you have enough ventilation.
²Keep all lit cigarettes, open flames and other lit material away from
the battery and all fuel related parts.
If you disconnect the battery, the engine must ªrelearnº its idle
conditions before your vehicle will drive properly, as explained in the
Batterysection in this chapter.
Working with the engine off
²Automatic transmission:
1. Set the parking brake and ensure the gearshift is securely latched in P
(Park).
2. Turn off the engine and remove the key.
3. Block the wheels to prevent the vehicle from moving unexpectedly.
²Manual transmission:
1. Set the parking brake.
2. Depress the clutch and place the gearshift in 1 (First).
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253

3. Turn off the engine and remove the key.
4. Block the wheels to prevent the vehicle from moving unexpectedly.
Working with the engine on
²Automatic transmission:
1. Set the parking brake and ensure the gearshift is securely latched in P
(Park).
2. Block the wheels to prevent the vehicle from moving unexpectedly.
Note:Do not start your engine with the air cleaner removed and do not
remove it while the engine is running.
²Manual transmission:
1. Set the parking brake, depress the clutch and place the gearshift in
neutral.
2. Block the wheels to prevent the vehicle from moving unexpectedly.
Note:Do not start your engine with the air cleaner removed and do not
remove it while the engine is running.
The cooling fan is automatic and may come on at any time.
Always disconnect the negative terminal of the battery before
working near the fan.
OPENING THE HOOD
1. Inside the vehicle, pull the hood
release handle located under the
bottom of the instrument panel.
2. Go to the front of the vehicle and
release the auxiliary latch that is
located under the front center of
the hood.
3. Lift the hood until the lift
cylinders hold it open.
BRAKE
HOOD
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254

IDENTIFYING COMPONENTS IN THE ENGINE COMPARTMENT
4.2L V6 engine
1. Battery
2. Engine oil filler cap
3. Engine oil dipstick
4. Clutch fluid reservoir (manual transmission)
5. Brake fluid reservoir
6. Power distribution box
7. Engine coolant reservoir
8. Air filter assembly
9. Power steering fluid reservoir
10. Transmission fluid dipstick (automatic transmission)
11. Windshield washer fluid reservoir
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255

4.6L V8/5.4L V8 engines
1. Power steering fluid reservoir
2. Clutch fluid reservoir (manual transmission)
3. Engine oil dipstick
4. Brake fluid reservoir
5. Power distribution box
6. Air filter assembly
7. Engine coolant reservoir
8. Windshield washer fluid reservoir
9. Battery
10. Transmission fluid dipstick (automatic transmission)
11. Engine oil filler cap
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256

WINDSHIELD WASHER FLUID
Washer fluid
Check the washer fluid whenever
you stop for fuel. The reservoir is
highlighted with a
symbol.
If the level is low, add enough fluid
to fill the reservoir. In very cold
weather, do not fill the reservoir all
the way.
Only use a washer fluid that meets Ford specification ESR-M17P5±A.
Refer toLubricant specificationsin this chapter.
State or local regulations on volatile organic compounds may restrict the
use of methanol, a common windshield washer antifreeze additive.
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.
Note:Do not put washer fluid in the engine coolant reservoir. Washer
fluid placed in the cooling system may harm engine and cooling system
components.
ENGINE OIL
Checking the engine oil
Refer to the scheduled maintenance guide for the appropriate intervals
for checking the engine oil.
1. Make sure the vehicle is on level ground.
2. Turn the engine off and wait a few minutes for the oil to drain into the
oil pan.
3. Set the parking brake and ensure the gearshift is securely latched in P
(Park) (automatic transmission) or 1 (First) (manual transmission).
4. Open the hood. Protect yourself from engine heat.
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258

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.
Keep batteries out of reach of children. Batteries contain sulfuric
acid. Avoid contact with skin, eyes or clothing. Shield your eyes
when working near the battery to protect against possible splashing of
acid solution. In case of acid contact with skin or eyes, flush
immediately with water for a minimum of 15 minutes and get prompt
medical attention. If acid is swallowed, call a physician immediately.
Battery posts, terminals and related accessories contain lead and
lead compounds.Wash hands after handling.
Because your vehicle's engine is also electronically controlled by a
computer, some control conditions are maintained by power from the
battery. When the battery is disconnected or a new battery is installed,
the engine must relearn its idle and fuel trim strategy for optimum
driveability and performance. To begin this process:
1. With the vehicle at a complete stop, set the parking brake.
2. Put the gearshift in P (Park) (automatic transmission) or the neutral
position (manual transmission), turn off all accessories and start the
engine.
3. Run the engine until it reaches normal operating temperature.
4. Allow the engine to idle for at least one minute.
5. Turn the A/C on and allow the engine to idle for at least one minute.
6. Drive the vehicle to complete the relearning process.
²The vehicle may need to be driven 16 km (10 miles) or more to
relearn the idle and fuel trim strategy.
²If you do not allow the engine to relearn its idle trim, the idle
quality of your vehicle may be adversely affected until the idle
trim is eventually relearned.
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264

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.
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 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 toLubricant
Specificationsin this chapter.
DON’T ADD
ADD COLD HOT DO NOT ADD
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287

Fluid Ford Part
NameApplication Capacity
Intercooler
coolant
1Motorcraft
Premium
Engine
Coolant
(green-colored)orMotorcraft
Premium
Gold Engine
Coolant
(yellow-colored)
5.4L Supercharged
V8 engine4.0L (4.2 quarts)
Engine oil
(includes
filter
change)Motorcraft
SAE 5W-20
Super
Premium
Motor OilAll 5.7L (6.0 quarts)
Fuel tank N/A 4x4 Reg. Cab with
short wheelbase92.7L (24.5 gallons)
4x2 Regular Cab,
SuperCab and
SuperCrew with
short wheelbase94.6L (25.0 gallons)
All long Wheelbase 113.6L (30.0
gallons)
Power
steering
fluidMotorcraft
MERCONt
AT FAll Fill to line on
reservoir
Transfer
case fluidMotorcraft
MERCONt
AT F4x4 vehicles 1.9L (2.0 quarts)
2
Transmission
fluid3Motorcraft
MERCONt
AT F5-speed manual 3.5L (3.75 quarts)4
Automatic- 4R100
(4x2)16.1L (17.0 quarts)4
Automatic- 4R100
(4x4)16.7L (17.7 quarts)4
Motorcraft
MERCONtV
AT FAutomatic- 4R70W 13.2L (13.9 quarts)4
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296