2002 FORD SUPER DUTY oil change

Driving 101
Starting 101
Brakes 105
Transmission operation 109
Trailer towing 130
Roadside Emergencies 158
Getting roadside assistance 158
Fuses and relays 160
Changing tires 165
Jump starting 174
Wrecker towing 179
Customer Assistance 181
Reporting safety defects (U.S. only) 189
Cleaning 190
Maintenance and Specifications 196
Engine compartment 198
Engine oil 199
Battery 202
Fuel information 210
Air filter(s) 227
Part numbers 234
Refill capacities 234
Lubricant specifications 237
Accessories 251
Index 255
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notice and without incurring obligation.
Copyright © 2002 Ford Motor Company
Table of Contents
2

Improper removal/installation of the driveshaft can cause
transmission fluid loss, damage to the driveshaft and internal
transmission components.
RWD vehicles with 4x4 electronic shift transfer case or All Wheel
Drive (AWD) vehicles with automatic transmissions:
Regarding recreational towing or having your vehicle towed, 4x4 vehicles
with electronic shift on the fly and AWD vehicles cannot be towed with
any wheels on the ground (with the exception of moving it as a disabled
vehicle off the road out of traffic).
SNOWPLOWING
Note:Do not use your vehicle to snowplow until it has been driven at
least 800 km (500 miles). Follow the severe duty schedule in your
scheduled maintenance guide for engine oil and transmission fluid
change intervals.
Note:Ford does not install snowplows.
For low speed snow removal, Ford offers a Snowplow Package Option on
select 4x4 vehicles. To assist Ford dealers and equipment installers
further prepare the vehicle for snowplowing, Ford includes instructions
in theFord Truck Body Builders Layout BookandFord Truck Source
Book. These instructions are available through your Ford dealer; they
include the list of vehicle models recommended for snowplowing and
snowplow weight limits. Use of the Snowplow Package Option, or its
equivalent, along with these instructions will help avoid possible
powertrain and chassis damage from snowplowing.
The front and rear GAWR, GVWR, Total Accessory Reserve Capacity
(TARC) and tire inflation pressures are found on the Safety Compliance
Certification Label located on one of the vehicle’s door jambs. This label
is applied to all vehicles completed by Ford Motor Company. Incomplete
vehicles built by Ford Motor Company will have an Incomplete Vehicle
Label in place of the Safety Compliance Label. The TARC does not apply
to Incomplete Vehicles and will not be shown on the Incomplete Vehicle
Label. The weight of the vehicle with occupants must never exceed the
front and rear GAWR or the GVWR.
The TARC is the weight of the permanently attached equipment that can
be added to the vehicle without violating the vehicle’s Safety Compliance
Certification. This includes the snowplow mounting hardware but does
not include the removable portion of the snowplow assembly.
Driving
154

3. Recheck the engine oil level. Make sure the oil level is not above the
MAX mark on the engine oil level indicator (dipstick).
4. Install the indicator and ensure it is fully seated.
5. Fully install the engine oil filler cap by turning the filler cap clockwise
1/4 of a turn until three clicks are heard or until the cap is fully seated.
To avoid possible oil loss, DO NOT operate the vehicle with the
engine oil level indicator and/or the engine oil filler cap removed.
Engine oil and filter recommendations
Look for this certification
trademark.
SAE 5W-20 engine oil is recommended.
Only use oils “Certified For Gasoline Engines” by the American
Petroleum Institute (API). Use Motorcraft or an equivalent oil meeting
Ford specification WSS-M2C153–H.SAE 5W-20 oil provides optimum
fuel economy and durability performance meeting all
requirements for your vehicle’s engine.
Do not use supplemental engine oil additives, oil treatments or engine
treatments. They are unnecessary and could, under certain conditions,
lead to engine damage which is not covered by your warranty.
Change your engine oil and filter according to the appropriate schedule
listed in the scheduled maintenance guide.
Ford production and aftermarket (Motorcraft) oil filters are designed for
added engine protection and long life. If a replacement oil filter is used
that does not meet Ford material and design specifications, start-up
engine noises or knock may be experienced.
It is recommended you use the appropriate Motorcraft oil filter (or
another brand meeting Ford specifications) for your engine application.
Maintenance and Specifications
201

FluidFord Part
NameApplication Capacity
Brake fluid (and
clutch fluid-if
equipped)Motorcraft High
Performance
DOT 3 Motor
Vehicle Brake
FluidAll Fill to line or
step (for clutch)
on reservoir
Engine coolant
3Motorcraft
Premium Engine
Coolant
(green-colored)
orMotorcraft
Premium Gold
Engine Coolant
(yellow-colored)5.4L V8 engine
with A/C25.0L (26.4
quarts)
6.8L V10 engine 27.0L (28.5
quarts)
Engine oil
(includes filter
change)-Gas
enginesMotorcraft SAE
5W-20 Premium
Synthetic Blend
Motor OilAll 5.7L (6.0
quarts)
Engine oil
(includes filter
change)-Diesel
engineRefer to your 7.3L Diesel Supplement
Maintenance and Specifications
235

3Add the coolant type originally equipped in your vehicle.
4Ensure 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
MERCON
and MERCON
V. These dual usage fluids are not to be used
in an automatic transmission that requires use of the MERCON
type
fluid. However, these dual usage fluids may be used in transmissions that
require the MERCON
V type fluid.
MERCON
and MERCON
V type fluids are not interchangeable.
DO NOT mix MERCON
and MERCON
V. Use of a transmission
fluid that indicates dual usage (MERCON
and MERCON
V) in
an automatic transmission application requiring MERCON
may
cause transmission damage. Use of any fluid other than the
recommended fluid may cause transmission damage.
5Service refill capacity is determined by filling the transmission to the
bottom of the filler hole with the vehicle on a level surface. The 6–speed
manual transmission is equipped with an in-tank cooler. Verify the fluid
level after operating vehicle to assure correct fluid level.
6Indicates 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.
LUBRICANT SPECIFICATIONS
ItemFord part
name or
equivalentFord part
numberFord
specification
Spindle bearingHigh
Temperature
4X4 Front Axle
and Wheel
Bearing GreaseE8TZ-19590–A ESA-M1C198–A
Front axle
(4X4)Hypoid Gear Oil
SAE 90C6AZ-19580–E ESW-M2C105–A
Maintenance and Specifications
237

Traction-Lok 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 butdorequire a
change. Refer to your “Service Guide” for change intervals on Dana rear
axles.
2Ensure 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
MERCON
and MERCON
V. These dual usage fluids are not to be used
in an automatic transmission that requires use of the MERCON
type
fluid. However, these dual usage fluids may be used in transmissions that
require the MERCON
V type fluid.
MERCON
and MERCON
V type fluids are not interchangeable.
DO NOT mix MERCON
and MERCON
V. Use of a transmission
fluid that indicates dual usage (MERCON
and MERCON
V) in
an automatic transmission application requiring MERCON
may
cause transmission damage. Use of any fluid other than the
recommended fluid may cause transmission damage.
ENGINE DATA
Engine 5.4L V8 engine 6.8L V10 engine
Cubic inches 330 415
Required fuel 87 octane 87 octane
Firing order 1-3-7-2-6-5-4-8 1-6-5-10-2-7-3-8-4-9
Spark plug gap1.3-1.4 mm
(0.052-0.056 inch)1.3-1.4 mm
(0.052-0.056 inch)
Ignition system Coil on plug Coil on plug
Compression ratio 9.0:1 9.0:1
Maintenance and Specifications
240

Instrument panel
cleaning ...................................193
cluster ........................................10
lighting up panel and
interior .......................................38
J
Jump-starting your vehicle ......174
K
Keyless entry system
autolock .....................................63
Keys
positions of the ignition .........101
L
Lamps
autolamp system .......................36
bulb replacement
specifications chart ..................39
cargo lamps ...............................38
daytime running light ...............37
fog lamps ...................................37
headlamps .................................36
headlamps, flash to pass ..........38
instrument panel, dimming .....38
interior lamps ...........................39
replacing bulbs ...................39–44
Lane change indicator
(see Turn signal) ........................38
Lights, warning and indicator ....10
anti-lock brakes (ABS) ..........106
speed control ............................52
Load limits .................................128
GAWR ......................................128
GVWR ......................................128
trailer towing ..........................128
Loading instructions .................130Locks
autolock .....................................63
childproof ..................................59
Lubricant specifications ...237, 240
Lumbar support, seats ...............69
M
Manual transmission .................112
fluid capacities ........................234
lubricant specifications ..........240
reverse .....................................113
Message center ...........................53
english/metric button ...............54
menu button .............................54
Mirrors .........................................46
fold away ...................................49
side view mirrors (power) .......49
Motorcraft parts ................214, 234
O
Octane rating ............................213
Oil (see Engine oil) ..................199
P
Parking brake ............................107
Parts (see Motorcraft parts) ....234
Pedals (see Power adjustable
foot pedals) .................................49
Power distribution box
(see Fuses) ...............................161
Power door locks ..................58, 63
Power point .................................47
Power steering ..........................108
fluid, checking and adding ....220
fluid, refill capacity ................234
Index
258