2003 FORD SUPER DUTY maintenance

Seating and Safety Restraints 63
Seating 63
Safetyrestraints 68
Air bags 79
Child restraints 87
Driving 98
Starting 98
Brakes 102
Transmission operation 106
Trailer towing 127
Roadside Emergencies 152
Getting roadside assistance 152
Hazard flasher switch 153
Fuel pump shut-off switch 153
Fuses and relays 154
Changing tires 159
Jump starting 168
Wrecker towing 173
Customer Assistance 175
Reporting safetydefects (U.S. only) 183
Cleaning 184
Maintenance and Specifications 191
Engine compartment 193
Engine oil 194
Battery197
Fuel information 205
Air filter(s) 221
Part numbers 228
Refill capacities 228
Lubricant specifications 232
Table of Contents
2

This information maybe stored during regular operation or in a crash or
near crash event. This stored information maybe read out and used by:
•Ford Motor Company.
•service and repair facilities.
•law enforcement or government agencies.
•others who mayassert a right or obtain your consent to know such
information.
Special instructions
For your added safety, your vehicle is fitted with sophisticated electronic
controls.
Please read the sectionAir bagin theSeating and safety
restraintschapter. Failure to follow the specific warnings and
instructions could result in personal injury.
Front seat mounted rear facing child or infant seats should
NEVERbe used in front of a passenger side air bag unless the
air bag can be and is turned OFF.
Notice to owners of diesel-powered vehicles
Read the 7.3 Liter Power Stroke Direct Injection Turbo Diesel Owner’s
Guide Supplement for information regarding correct operation and
maintenance of your diesel-powered light truck.
Notice to owners of pickup trucks and utility type vehicles
Utilityvehicles have a significantlyhigher rollover rate than
other types of vehicles.
Before you drive your vehicle, please read this Owner’s Guide carefully.
Your vehicle is not a passenger car. As with other vehicles of this type,
failure to operate this vehicle correctlymayresult in loss of vehicle
control, vehicle rollover, personal injuryor death.
Be sure to readDriving off roadin theDrivingchapter.
Using your vehicle with a snowplow
For more information and guidelines for using your vehicle with a
snowplow, refer to theDrivingchapter.
Using your vehicle as an ambulance
If your light truck is equipped with the Ford Ambulance Preparation
Package, it maybe utilized as an ambulance. Ford urges ambulance
Introduction
6

Transmission fluid temperature gauge
(automatictransmission only):If the gauge is in the:
White area(normal) - the
transmission fluid is within the
normal operating temperature
(between “H” and “C”).
Yellow area(warning) — the
transmission fluid is higher than
normal operating temperature. This
can be caused byspecial operation
conditions (i.e. snowplowing, towing
or off road use). Refer toSpecial
Operating Conditionsin the
scheduled maintenance guide for
instructions. Operating the
transmission for extended periods of
time with the gauge in the yellow
area maycause internal transmission damage.
Altering the severityof the driving conditions is recommended to lower
the transmission temperature into the normal range.
Red area(over temperature) —
the transmission fluid is overheating.
Stop the vehicle to allow the
temperature to return to normal
range.
If the gauge is operating in the
Yellow or Red area, stop the vehicle
and verifythe airflow is not
restricted such as snow or debris
blocking airflow through the grill. If
the gauge continues to show high
temperatures, see your Ford or Lincoln Mercury dealer.
Instrument Cluster
16

pretensioner. Do NOT place objects between the seats, this could
interfere with the functioning of the pretensioner. For the SuperCab and
CrewCab base bench seats and all Regular Cab seating positions, the
safetybelts are equipped with a retractor pretensioner.
The safetybelt pretensioners are designed to activate onlyduring certain
frontal or near-frontal collisions with sufficient longitudinal deceleration.
A safetybelt pretensioner is a device which tightens the webbing of the
lap and shoulder belts during some collisions in such a waythat theyfit
more snuglyagainst the body.
The driver and front outboard passenger safetybelt system (including
retractors, buckles and height adjusters) must be replaced if the vehicle
is involved in a collision that results in the activation of the safetybelt
pretensioners. Refer to theSafety belt maintenancesection in this
chapter.
Failure to replace the safetybelt assemblyunder the above
conditions could result in severe personal injuries in the event of
a collision.
Front safety belt height adjustment
If your shoulder belts come out of the seatback, you will not have a
safetybelt height adjuster.
Adjust the height of the shoulder belt so the belt rests across the middle
of your shoulder.
•Regular Cab and 4–door CrewCab
Seating and Safety Restraints
73

Safety belt extension assembly
If the safetybelt is too short when fullyextended, there is a 20 cm
(8 inch) safetybelt extension assemblythat can be added (part number
611C22). This assemblycan be obtained from your dealer at no cost.
Use onlyextensions manufactured bythe same supplier as the safety
belt. Manufacturer identification is located at the end of the webbing on
the label. Also, use the safetybelt extension onlyif the safetybelt is too
short for you when fully extended.
Do not use extensions to change the fit of the shoulder belt
across the torso.
Safety belt maintenance
Inspect the safetybelt systems periodicallyto make sure theywork
properlyand are not damaged. Inspect the safetybelts to make sure
there are no nicks, tears or cuts. Replace if necessary. All safety belt
assemblies, including retractors, buckles, front seat belt buckle
assemblies, buckle support assemblies (slide bar-if equipped), shoulder
belt height adjusters (if equipped), shoulder belt guide on seatback (if
equipped), child safetyseat LATCH and tether anchors, and attaching
hardware, should be inspected after a collision. Ford Motor Company
recommends that all safetybelt assemblies used in vehicles involved in a
collision be replaced. However, if the collision was minor and a qualified
technician finds that the belts do not show damage and continue to
operate properly, theydo not need to be replaced. Safetybelt assemblies
not in use during a collision should also be inspected and replaced if
either damage or improper operation is noted.
Failure to inspect and if necessaryreplace the safetybelt
assemblyunder the above conditions could result in severe
personal injuries in the event of a collision.
Refer toInteriorin theCleaningchapter.
Seating and Safety Restraints
78

restrained or are otherwise out of position at the time of air bag
deployment. Thus, it is extremely important that occupants be properly
restrained as far awayfrom the air bag module as possible while
maintaining vehicle control.
Several air bag system components get hot after inflation. Do not
touch them after inflation.
If the air bag has deployed,the air bag will not function
again and must be replaced immediately.If the air bag is not
replaced, the unrepaired area will increase the risk of injuryin a
collision.
The SRS consists of:
•driver and passenger (if equipped) air bag modules (which include the
inflators and air bags),
•one or more impact and safing sensors,
•a readiness light and tone
•and the electrical wiring which connects the components.
The diagnostic module monitors its own internal circuits and the
supplemental air bag electrical system warning (including the impact
sensors), the system wiring, the air bag system readiness light, the air
bag back up power and the air bag ignitors.
Determining if the system is operational
The SRS uses a readiness light in the instrument cluster or a tone to
indicate the condition of the system. Refer toAir bag readinesssection
in theInstrument clusterchapter. Routine maintenance of the air bag is
not required.
A difficultywith the system is indicated byone or more of the following:
•The readiness light will either
flash or staylit.
•The readiness light will not
illuminate immediatelyafter
ignition is turned on.
•A series of five beeps will be heard. The tone pattern will repeat
periodicallyuntil the problem and/or light are repaired.
Seating and Safety Restraints
82

Vehicles with a higher center of gravitysuch as utilityand
four-wheel drive vehicles handle differentlythan vehicles with a
lower center of gravity. Utility and four-wheel drive vehicles arenot
designed for cornering at speeds as high as passenger cars anymore
than low-slung sports cars are designed to perform satisfactorilyunder
off-road conditions. Avoid sharp turns, excessive speed and abrupt
maneuvers in these vehicles. Failure to drive cautiouslycould result in
an increased risk of loss of vehicle control, vehicle rollover, personal
injuryand death.
•If the vehicle goes from one type of surface to another (i.e., from
concrete to gravel) there will be a change in the waythe vehicle
responds to a maneuver (steering, acceleration or braking). Again,
avoid these abrupt inputs.
Parking
On some 4WD vehicles, when the transfer case is in the N (Neutral)
position, the engine and transmission are disconnected from the rest of
the driveline. Therefore, the vehicle is free to roll even if the automatic
transmission is in P (Park) or the manual transmission is in gear. Do not
leave the vehicle unattended with the transfer case in the N (Neutral)
position. Always set the parking brake fully and turn off the ignition
when leaving the vehicle.
4WD Systems
4WD (when you select a 4WD mode), uses all four wheels to power the
vehicle. This increases traction, enabling you to drive over terrain and
road conditions that a conventional two-wheel drive vehicle cannot.
Power is supplied to all four wheels
through a transfer case. On 4WD
vehicles, the transfer case allows
you to select 4WD when necessary.
Information on transfer case
operation and shifting procedures
can be found in theDriving
chapter. Information on transfer
case maintenance can be found in theMaintenance and specifications
chapter. You should become thoroughlyfamiliar with this information
before you operate your vehicle.
Normal characteristics
On some 4WD models, the initial shift from two-wheel drive to 4x4 while
the vehicle is moving can cause some momentaryclunk and ratcheting
Driving
119

Each daybefore you drive, check
your tires. If one looks lower than
the others, use a tire gauge to check
pressure of all tires, and adjust if
required. Check tire pressure with a
tire gauge everyfew weeks
(including spare). Safe operation
requires tires that are neither
underinflated nor a vehicle which is
overloaded.
Periodicallyinspect the tire treads and remove stones, nails, glass or
other objects that maybe wedged in the tread grooves. Check for holes
or cuts that maypermit air leakage from the tire and make necessary
repairs.
Inspect the tire side walls for cuts, bruises and other damage. If internal
damage to the tire is suspected, have the tire demounted and inspected
in case it needs to be repaired or replaced.
Maintenance and Modifications
The suspension and steering systems on your vehicle have been designed
and tested to provide both reasonablysafe, predictable performance
whether loaded or emptyand durable load carrying capability. For this
reason, Ford Motor Companystronglyrecommends that you do not make
modifications such as adding or removing parts (such as lift kits or
stabilizer bars) or byusing replacement parts not equivalent to the
original factoryequipment.
Anymodifications to a vehicle that raise the center of gravitycan make
it more likelythe vehicle will roll over as a result of a loss of control.
Ford Motor Companyrecommends that caution be used with anyvehicle
equipped with a high load or device (such as ladder racks or pickup box
cover).
Failure to maintain your vehicle properlymayvoid the warranty, increase
your repair cost, reduce vehicle performance and operational capabilities
and adverselyaffect driver and passenger safety. Frequent inspection of
vehicle chassis components is recommended if the vehicle is subjected to
heavyoff-road usage.
POWER TAKE OFF (PTO) CAPABILITY (IF EQUIPPED)
Some vehicles maybe equipped with Power Take Off (PTO) capability.
These vehicles have a special transmission case, internal components and
calibration for PTO usage.
Driving
124