2003 FORD SUPER DUTY battery

IDENTIFYING COMPONENTS IN THE ENGINE COMPARTMENT
5.4L V8/6.8L V10 gasoline engines
Refer to the7.3 Liter Power Stroke Direct Injection Turbo Diesel
Owner’s Guide Supplementfor diesel engine component locations.
1. Engine oil dipstick
2. Clutch fluid reservoir (manual transmission)
3. Brake fluid reservoir
4. Power steering fluid reservoir
5. Air filter assembly
6. Engine coolant reservoir
7. Windshield washer fluid reservoir
8. Battery
9. Engine oil filler cap
10. Transmission fluid dipstick (automatic transmission)
Maintenance and Specifications
193

BATTERY
Your vehicle is equipped with a
Motorcraft maintenance-free battery
which normallydoes not require
additional water during its life of
service.
However, for severe usage or in high temperature climates, check the
batteryelectrolyte level. Refer to the scheduled maintenance guide for
the service interval schedules.
Keep the electrolyte level in each cell up to the “level indicator”.
Do not overfill the battery cells.
If the electrolyte level in the battery is low, you can add plain tap water
to the battery, as long as y ou do not use hard water (water with a high
mineral or alkali content). If possible, however, tryto onlyfill the battery
cells with distilled water. If the batteryneeds water often, have the
charging system checked.
If your battery has a cover/shield, make sure it is reinstalled
after the battery has been cleaned or replaced.
For longer, trouble-free operation, keep the top of the batteryclean and
dry. Also, make certain the batterycables are always tightlyfastened to
the batteryterminals.
If you see any corrosion on the battery or terminals, remove the cables
from the terminals and clean with a wire brush. You can neutralize the
acid with a solution of baking soda and water.
When the batteryis disconnected or a new batteryinstalled, the
transmission must learn its adaptive strategy. As a result of this, the
transmission mayshift firmly. This operation is considered normal and
will fullyupdate transmission operation to its optimum shift feel.
Batteries normallyproduce explosive gases which can cause
personal injury. Therefore, do not allow flames, sparks or lighted
substances to come near the battery. When working near the battery,
always shield your face and protect your eyes. Always provide proper
ventilation.
Maintenance and Specifications
197

When lifting a plastic-cased battery, excessive pressure on the
end walls could cause acid to flow through the vent caps,
resulting in personal injuryand/or damage to the vehicle or battery.
Lift the batterywith a batterycarrier 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 batteryto protect against possible splashing of
acid solution. In case of acid contact with skin or eyes, flush
immediatelywith water for a minimum of 15 minutes and get prompt
medical attention. If acid is swallowed, call a physician immediately.
Batteryposts, terminals and related accessories contain lead and
lead compounds.Wash hands after handling.
For information on transmission operation after the batteryhas been
disconnected see “Shift strategy” in the driving section.
Because your vehicle’s engine is also electronicallycontrolled bya
computer, some control conditions are maintained bypower from the
battery. When the batteryis disconnected or a new batteryis installed,
the engine must relearn its idle and fuel trim strategyfor optimum
driveabilityand 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.
•The vehicle mayneed to be driven 16 km (10 miles) or more to
relearn the idle and fuel trim strategy.
•If 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.
If the batteryhas been disconnected or a new batteryhas been installed,
the clock and the preset radio stations must be reset once the batteryis
reconnected.
Maintenance and Specifications
198

•Always dispose of automotive
batteries in a responsible manner.
Follow your local authorized
standards for disposal. Call your
local authorized recycling center
to find out more about recycling
automotive batteries.
ENGINE COOLANT
Checking engine coolant
The concentration and level of engine coolant should be checked at the
mileage intervals listed in the scheduled maintenance guide. The coolant
concentration should be maintained at 50/50 coolant and distilled water,
which equates to a freeze point of -36° C (-34° F). Coolant concentration
testing is possible with a hydrometer or antifreeze tester (such as the
Rotunda Batteryand Antifreeze Tester, 014–R1060). The level of coolant
should be maintained at the “cold full” of “cold fill range” level in the
coolant reservoir. If the level falls below, add coolant per the instructions
in theAdding engine coolantsection.
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.A
50–50 mixture of coolant and water provides the following:
•Freeze protection down to -36° C (-34° F).
•Boiling protection up to 129° C (265° F).
•Protection against rust and other forms of corrosion.
•Enables calibrated gauges to work properly.
L
E
A
D
R
E
T
U
R
N
RECYCLE
Maintenance and Specifications
199

Exhaust leaks mayresult in entryof harmful and potentially
lethal fumes into the passenger compartment.
Do not make anyunauthorized changes to your vehicle or engine. By
law, vehicle owners and anyone who manufactures, repairs, services,
sells, leases, trades vehicles, or supervises a fleet of vehicles are not
permitted to intentionallyremove an emission control device or prevent
it from working. Information about your vehicle’s emission system is on
the Vehicle Emission Control Information Decal located on or near the
engine. This decal identifies engine displacement and gives some tune up
specifications.
Please consult yourWarranty Guidefor complete emission warranty
information.
Readiness for Inspection/Maintenance (I/M) testing
In some localities, it maybe a legal requirement to pass an I/M test of
the on-board diagnostics system. If your “Check Engine/Service Engine
Soon” light is on, refer to the description in theWarning lights and
chimessection of theInstrument clusterchapter. Your vehicle maynot
pass the I/M test with the “Check Engine/Service Engine Soon” light on.
If the vehicle’s powertrain system or its battery has just been serviced,
the on-board diagnostics system is reset to a “not ready for I/M test”
condition. To readythe on-board diagnostics system for I/M testing, a
minimum of 30 minutes of cityand highwaydriving is necessaryas
described below:
•First, at least 10 minutes of driving on an expresswayor highway.
•Next, at least 20 minutes driving in stop-and-go, city-type traffic with
at least four idle periods.
Allow the vehicle to sit for at least eight hours without starting the
engine. Then, start the engine and complete the above driving cycle. The
engine must warm up to its normal operating temperature. Once started,
do not turn off the engine until the above driving cycle is complete.
Maintenance and Specifications
214

MOTORCRAFT PART NUMBERS
Component* 5.4L V8 engine 6.8L V10 engine
Air filter element FA-1634 FA-1634
Fuel filter FG-986B FG-986B
Oil filter FL-820-S FL-820-S
PCV valve EV-233 EV-233
Battery(Standard) BXT-65-650 BXT-65-650
Battery(Optional) BXT-65-750 BXT-65-750
Spark plugs-platinum** AGSF-22W AGSF-22W
*Refer to the7.3 Liter Power Stroke Direct Injection Turbo Diesel
Owner’s Guide Supplementfor Motorcraft diesel engine service part
numbers.
**Refer to Vehicle Emissions Control Information (VECI) decal for spark
plug gap information.
REFILL CAPACITIES
FluidFord Part
NameApplication Capacity
Front axle Hypoid Gear Oil
SAE 90F-250/350
(Dana 60 axle)2.7L (5.8 pints)
F-350/450/550
(Dana 60 axle)2.7L (5.8 pints)
Rear axle
1,2Motorcraft SAE
75W-140
Synthetic Rear
Axle LubricantF-250 /350
(10.50 inch
axle)3.3L (6.9 pints)
Motorcraft SAE
75W-90
Synthetic Rear
Axle LubricantF-350/450
(DANA 80)4.0L (8.5 pints)
Motorcraft SAE
80W-90
Premium Rear
Axle LubricantF-550
(Dana 135)11.6L (24.5
pints)
Maintenance and Specifications
228

Travel equipment
Adjustable Towing System
Auto headlamp system with Daytime Running Lights (DRL)
Bed Tent
Box Aluminum Rack cargo storage systems (Trac Rac)
Daytime running lights (DRL)
Electrochromic inside mirror with compass
Electrochromic inside mirror with compass and temperature display
Fog lights
BatteryWarmer
Highwaysafetyand first aid kit
Off road lights
Pickup box rails
ROC2 hitch mounted bike courier
Running boards and tubular running bars
Running boards diamond plate
Seatback organizer
Speed control
Towing mirrors
Trailer hitch, Class IV
Trailer hitch bars and balls
Trailer hitch mounted bike carrier
Trailer hitch wiring adaptor
Trailer wiring harness
Trailgate table
Protection and appearance equipment
Air bag anti-theft locks
All weather vinyl floor mats
Bed mat
Bed hooks
Bed mats
Accessories
246

A
Accessorydelay ..........................47
Air bag supplemental restraint
system ..........................................79
and child safetyseats ..............80
description ................................79
disposal ......................................83
driver air bag ............................81
indicator light ...........................82
operation ...................................81
passenger air bag .....................81
passenger deactivation
switch ........................................83
Air cleaner filter .......220–221, 228
Ambulance packages ....................6
Antifreeze
(see Engine coolant) ................199
Anti-lock brake system
(see Brakes) ......................103–104
Audio system
(see Radio) ................17–18, 21, 25
Automatic transmission ............106
driving an automatic
overdrive .................................107
fluid, adding ............................216
fluid, checking ........................216
fluid, refill capacities ..............228
fluid, specification ..................235
Auxiliarypower point .................46
Axle
lubricant specifications ..232, 235
refill capacities ........................228
traction lok ..............................105
B
Battery.......................................197
acid, treating emergencies .....197jumping a disabled battery....168
maintenance-free ....................197
replacement, specifications ...228
servicing ..................................197
BeltMinder ...................................74
Brakes ........................................102
anti-lock ...........................102–104
anti-lock brake system (ABS)
warning light ...........................103
fluid, checking and adding ....215
fluid, refill capacities ..............228
fluid, specifications .........232, 235
lubricant specifications ..232, 235
parking ....................................104
shift interlock ..........................106
Break-in period .............................5
Bulbs ............................................38
C
Calculating load ........................127
Capacities for refilling fluids ....228
Cassette tape player ...................25
CD changer .................................28
CD-single premium .........17–18, 21
Certification Label ....................243
Child safetyrestraints ................88
child safetybelts ......................88
Child safetyseats ........................90
attaching with tether straps ....94
in front seat ..............................92
in rear seat ................................92
Cleaning your vehicle
engine compartment ..............185
instrument panel ....................187
interior .....................................187
interior trim ............................187
plastic parts ............................186
Index
249