2004 FORD E SERIES brakes

Exceeding the Safety Certification Label axle weight rating limits
could result in substandard vehicle handling, performance,
engine, transmission and/or structural damage, serious damage to the
vehicle, loss of control and personal injury.
GCW (Gross Combined Weight)–is the weight of the loaded vehicle
(GVW) plus the weight of the fully loaded trailer.
GCWR (Gross Combined Weight Rating)–is the maximum allowable
weight of the vehicle and the loaded trailer–including all cargo and
passengers–that the vehicle can handle without risking damage.
(Important: The towing vehicle’s braking system is rated for operation at
GVWR, not at GCWR. Separate functional brakes should be used for safe
control of towed vehicles and for trailers weighing more than 680 kg
[1,500 lbs]).The GCW must never exceed the GCWR.
Maximum Loaded Trailer Weight–is the highest possible weight of a
fully loaded trailer the vehicle can tow. It assumes a vehicle with only
mandatory options, no cargo (internal or external), a tongue load of
10–15% (conventional trailer) or king pin weight of 15–25% (fifth wheel
trailer), and driver only (68 kg [150 lbs]).Consult your dealership (or
the RV and Trailer Towing Guide provided by your dealership) for
more detailed information.
Tongue Load or Fifth Wheel King Pin Weight–refers to the amount
of the weight that a trailer pushes down on a trailer hitch.
Examples:For a 2268 kg (5000 lbs.) conventional trailer, multiply 5000
by 0.10 and 0.15 to obtain a proper tongue load range of 227 to 340 kg
(500 to 750 lbs.). For an 5216 kg (11,500 lbs.) fifth wheel trailer,
multiply by 0.15 and 0.25 to obtain a proper king pin load range of 782
to 1304 kg (1,725 to 2,875 lbs.)
Do not exceed the GVWR or the GAWR specified on the
certification label.
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GCWR (Gross Combined Weight Rating)/Trailer Weights
EngineRear
axle
ratioMaximum
GCWR - kg
(lbs.)Maximum
Loaded Trailer
Weight - kg
(lbs.)Maximum
frontal area of
trailer - m
2(ft2)
E-450 Stripped Chassis (all wheelbases, all GVWRs)
5.4L 4.56 5897 (13000) 3719 (8200) 5.52 (60)
6.8L 4.56 8391 (18500) 4536 (10000) 5.52 (60)
Maximum trailer weight for all cutaway (E-350 and E-450) vehicles must
be calculated by subtracting the weight of the vehicle (including
incomplete vehicle weight and payload which includes second unit body
weight, cargo and passengers) from the GCW. Otherwise, maximum trailer
weight is 4536 kg (10000 lbs)
For high altitude operation reduce GCWR by 2% per 300 meters (1000 ft)
elevation.
To determine the maximum trailer weight designed for your particular
vehicle as equipped, follow the sectionCalculating the load your vehicle
can tow/carryearlier in this chapter.
Your vehicle’s load capacity is designated by weight, not by volume, so
you cannot necessarily use all available space when loading a vehicle.
Distribute the load so that only 10 to 15% of the total is on the tongue.
Tie down the load so that it does not shift and change the weight on the
hitch.
Towing a trailer places an additional load on your vehicle’s engine,
transmission, axle, brakes, tires and suspension. Inspect these
components carefully after any towing operation.
Note:Do not exceed the GVWR or the GAWR specified on the
certification label.
Towing trailers beyond the maximum recommended gross trailer
weight exceeds the limit of the vehicle and could result in
engine damage, transmission damage, structural damage, loss of vehicle
control, vehicle rollover and personal injury.
Preparing to tow
Use the proper equipment for towing a trailer and make sure it is
properly attached to your vehicle. See your dealer or a reliable trailer
dealer if you require assistance.
Hitches
Do not use or install hitches that clamp onto the bumper or to the axle.
Underbody hitches are acceptable if installed properly.
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Safety chains
Always connect the trailer’s safety chains to the frame or hook retainers
of the vehicle hitch. To connect the trailer’s safety chains, cross the
chains under the trailer tongue and allow slack for turning corners.
If you use a rental trailer, follow the instructions that the rental agency
gives to you.
Do not attach safety chains to the bumper.
Trailer brakes
Electric brakes and manual, automatic or surge-type trailer brakes are
safe if installed properly and adjusted to the manufacturer’s
specifications. The trailer brakes must meet local and Federal
regulations.
Do not connect a trailer’s hydraulic brake system directly to your
vehicle’s brake system. Your vehicle may not have enough
braking power and your chances of having a collision greatly increase.
The braking system of the tow vehicle is rated for operation at the
GVWR not GCWR.
Trailer lamps
Trailer lamps are required on most towed vehicles. Make sure all running
lights, brake lights, turn signals and hazard lights are working. See your
dealer or trailer rental agency for proper instructions and equipment for
hooking up trailer lamps.
Using a step bumper (if equipped)
The rear bumper is equipped with an integral hitch and only requires a
ball with a 25.4 mm (one inch) shank diameter. The bumper has a 2,270
kg (5,000 lb.) trailer weight and 227 kg (500 lb.) tongue weight capacity.
If it is necessary to relocate the trailer hitch ball position, a
frame-mounted trailer hitch must be installed.
Driving while you tow
When towing a trailer:
•Turn off the speed control. The speed control may shut off
automatically when you are towing on long, steep grades.
•Consult your local motor vehicle speed regulations for towing a trailer.
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•To eliminate excessive shifting, use a lower gear. This will also assist
in transmission cooling.
•Anticipate stops and brake gradually.
When descending long, steep downhill grades, always use a lower gear to
provide engine braking to save wear on brakes. Use Drive (Overdrive
OFF) on moderately steep hills, Second (2) on steep hills, and First (1)
on very steep hills.Do not apply your brakes continuously, as they
may overheat and become less effective.
Servicing after towing
If you tow a trailer for long distances, your vehicle will require more
frequent service intervals. Refer to your scheduled maintenance guide for
more information.
Trailer towing tips
•Practice turning, stopping and backing up before starting on a trip to
get the feel of the vehicle trailer combination. When turning, make
wider turns so the trailer wheels will clear curbs and other obstacles.
•Allow more distance for stopping with a trailer attached.
•The trailer tongue weight should be 10–15% of the loaded trailer
weight.
•If you will be towing a trailer frequently in hot weather, hilly
conditions, at GCW, or any combination of these factors, consider
refilling your rear axle with synthetic gear lube. Refer to the
Maintenance and specificationschapter for the lubricant
specification.
•After you have traveled 80 km (50 miles), thoroughly check your
hitch, electrical connections and trailer wheel lug nuts.
•When stopped in traffic for long periods of time in hot weather, place
the gearshift in P (Park) and increase idle speed. This aids engine
cooling and air conditioner efficiency.
•Vehicles with trailers should not be parked on a grade. If you must
park on a grade, place wheel chocks under the trailer’s wheels.
Launching or retrieving a boat
Disconnect the wiring to the trailer before backing the trailer
into the water. Reconnect the wiring to the trailer after the
trailer is removed from the water.
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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 RESERVOIR
The fluid level will drop slowly as
the brakes wear, and will rise when
the brake components are replaced.
Fluid levels below the“MAX”line
that do not trigger the brake system
warning lamp are within the normal
operating range, there is no need to
add fluid. If the fluid levels are outside of the normal operating range,
the performance of your brake system could be compromised, seek
service from your dealer immediately.
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.
M
AX
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Maintenance and Specifications
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A
Accessory delay ..........................63
Air bag supplemental restraint
system ..........................................89
and child safety seats ..............91
description ................................89
disposal ......................................93
driver air bag ............................91
indicator light ...........................93
operation ...................................91
passenger air bag .....................91
Air cleaner filter .......202–203, 217
Ambulance packages ....................7
Antifreeze
(see Engine coolant) ................184
Anti-lock brake system
(see Brakes) ..............................112
Audio system
(see Radio) ................15, 17, 19, 22
Automatic transmission
driving an automatic
overdrive .................................116
fluid, adding ............................200
fluid, checking ........................200
fluid, refill capacities ..............218
fluid, specification ..................225
Auxiliary power point .................62
Axle
lubricant specifications ..222, 225
refill capacities ........................218
traction lok ..............................113
B
Battery .......................................178
acid, treating emergencies .....178
disconnecting ..........................180
jumping a disabled battery ....151maintenance-free ....................178
replacement, specifications ...217
servicing ..................................178
BeltMinder ...................................84
Brakes ........................................111
anti-lock ...................................112
anti-lock brake system (ABS)
warning light ...........................112
fluid, checking and adding ....200
fluid, refill capacities ..............218
fluid, specifications .........222, 225
lubricant specifications ..222, 225
parking ....................................112
shift interlock ..........................115
Break-in period .............................5
Bulbs ............................................53
C
Calculating load ........................123
Capacities for refilling fluids ....218
Cassette tape player ...................22
CD-single premium .....................15
Cell phone use ............................62
Child safety restraints ................94
child safety belts ......................94
Child safety seats ........................97
in front seat ..............................98
in rear seat ................................98
tether anchorage hardware ...101
Cleaning your vehicle
engine compartment ..............167
exterior ....................................170
instrument panel ....................169
interior .....................................169
interior trim ............................169
plastic parts ............................168
safety belts ..............................169
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Index
Index
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K
Keys
positions of the ignition .........108
L
Lamps
bulb replacement
specifications chart ..................53
daytime running light ...............50
headlamps .................................50
headlamps, flash to pass ..........51
instrument panel, dimming .....51
interior lamps ...........................52
replacing bulbs ...................53–57
Lane change indicator
(see Turn signal) ........................52
Lights, warning and indicator ....10
anti-lock brakes (ABS) ..........112
Load limits .................................120
Loading instructions .................123
Lubricant specifications ...222, 225
Lumbar support, seats ...............74
M
Mirrors
fold away ...................................64
side view mirrors (power) .......63
Motorcraft parts ................193, 217
O
Octane rating ............................192
Oil (see Engine oil) ..................175
P
Parking brake ............................112Parts (see Motorcraft parts) ....217
Power distribution box
(see Fuses) ...............................139
Power door locks ........................68
Power point .................................62
Power steering ..........................113
fluid, checking and adding ....199
fluid, refill capacity ................218
fluid, specifications .........222, 225
Power Windows ...........................63
Preparing to drive your
vehicle ........................................113
R
Radio ..........................15, 17, 19, 22
Rear seat entertainment
system ..........................................26
Relays ................................135, 142
Remote entry system
illuminated entry ................50, 72
locking/unlocking doors ...........68
Roadside assistance ..................132
S
Safety Belt Maintenance ............88
Safety belts (see Safety
restraints) ..............................79–83
Safety defects, reporting ..........165
Safety restraints ....................79–83
belt minder ...............................84
extension assembly ..................88
for adults .............................80–82
for children .........................93–94
lap belt ......................................83
safety belt maintenance ...........88
warning light and chime ..........84
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Owners Guide (post-2002-fmt)
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Index
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