2004 FORD SUPER DUTY change time

The fuel injectors are located in the center of the combustion chambers
in the cylinder head between the rocker arm assemblies. The glow plug
system and fuel injection system are controlled through the Powertrain
Control Module (PCM) and Fuel Injection Control Module (FICM).
Fuel is drawn from the fuel tank by a frame-mounted electric fuel pump.
The fuel pump provides pressurized fuel to the engine and is
electronically controlled by the fuel pump PCM relay. The fuel pump
contains a pressure relief valve for overpressure protection in the event
of restricted flow.
Lubrication system
It is important to change the engine oil at the recommended service
intervals, because oil viscosity is important in maintaining the oil
pressure required to actuate the fuel injectors. Extended oil change
intervals can negatively affect engine performance, fuel economy and
engine life. Refer to the engine oil specification chart located under
Engine oil specificationsin theMaintenance and specifcations
chapter.
Fast start glow plug system
The glow plug system consists of:
•eight glow plugs
•the glow plug control module (GPCM)
•engine oil temperature (EOT) sensor
•barometric pressure (BARO) sensor
The glow plug system is
electronically controlled by the
PCM. The GPCM energizes the glow
plugs immediately after the ignition
is placed in the ON position, then determines how long the glow plugs
will be on according to the EOT and BARO sensors. The required time
for the glow plugs to be energized decreases as the engine oil
temperature and barometric pressure increase.
Engine cooling system
The cooling system contains an engine oil cooler which is mounted in the
center valley of the engine. The cooler’s function is to regulate engine oil
temperature.
Introduction
4

Do not blend used engine oil with Diesel fuel under any
circumstances.Blending used oil with the fuel will significantly increase
your vehicle’s exhaust emissions and reduce engine life due to increased
internal wear.
Do not crank the engine for more than 30 seconds at a time as
damage to the starter motor may result.
If the engine fails to start in 30 seconds, turn the key to the OFF
position and wait 30 seconds before trying again.
Truck stops have pumps and nozzles designed for larger, heavy-duty
trucks. When refueling at truck stops: if the nozzle shuts off repeatedly
when refueling, wait 5–10 seconds; then use a slower rate of flow (don’t
depress the nozzle trigger as far).
If air is allowed to enter the fuel system (during fuel filter change or if
you run out of fuel) the engine will purge the trapped air as it runs. The
engine may run rough and produce white smoke while air is in the
system. This is normal and should correct itself in a short time.
An engine that suddenly becomes noisy or operates poorly after a fuel fill
could be using substandard fuel (i.e., high water content, low cetane
rating or gasoline in the fuel). Diesel fuel should be purchased from a
reputable station which sells a large amount of Diesel fuel.
Care should be taken whenever Diesel fuel is stored. Use only clean,
approved containers which will prevent the entry of dirt or water.
Diesel fuel must not be stored in a galvanized container. The fuel will
dissolve the zinc in a galvanized container. The zinc will then remain in
solution until it is run through the engine where it will be deposited in
the fuel injectors causing expensive-to-repair damage.
Diesel fuel dispensing nozzle fill rate
This truck is equipped with a fuel fill pipe which is able to accept fuel up
to 20 gallons per minute from an 1 1/8 inch fuel dispensing nozzle.
Pumping fuel at greater flow rates may result in premature nozzle
shut-off or spitback.
HORIZONTAL FUEL CONDITIONING MODULE (HFCM)
(FUEL FILTER/WATER SEPARATOR)
The vehicle is equipped with a Horizontal Fuel Conditioning Module
(HFCM) located on the frame-rail under the driver-side floorboard near
the transmission.
Maintenance and specifications
25

Using a fuel which has more than average impurities may require
the fuel filter to be replaced more frequently than the service
interval specifies.
ENGINE OIL
Checking the engine oil level
Because it is normal to add some oil between oil changes, check your
engine oil level each time you stop for fuel. To check the engine oil level
consistently and accurately, the following procedure is recommended:
1. Have engine at normal operating temperature (at least into the
NORMAL range on the engine coolant temperature gauge).
2. Park the vehicle on a level surface, then turn off the engine and open
the hood.
3. Allow at least20 minutesafter engine shutdown to assure that the oil
contained in the upper parts of the engine has returned to the oil pan.
4. Protecting yourself from engine
heat, pull out the dipstick, wipe it
clean and reinsert fully.
5. Read oil level on both sides of dipstick and use highest level (reading)
for the actual engine oil level.
6. Maintain the oil level between ADD and OPERATING RANGE on the
dipstick by adding oil as required. The distance from ADD to
OPERATING RANGE on the dipstick represents 1.9L (2 quarts). Do not
overfill. If the oil level exceeds OPERATING RANGE, oil consumption
may result.
Engine oil specifications
To help achieve proper engine performance and durability, it is important
that only engine lubricating oils of the proper quality are used in your
Diesel engine and that the engine oil is changedno laterthan the
recommended interval. Diesel engines require specially formulated oil to
Maintenance and specifications
28

Changing engine oil and filter
Change your oil and filter according to the scheduled maintenance guide.
Change more frequently if your vehicle operation includes extended
periods of idling or low-speed operation, driving for a long time in cold
temperatures or driving short distances. See the following section
Engine lubrication for severe service operationfor all severe duty
restrictions.
Use Ford Engine Oil Filter Part No. 3C3Z-6731–AA (FL–2016) or
equivalent. These filters protect your engine by filtering harmful,
abrasive or sludge particles. The FL–2016 filters particles significantly
smaller than most available“will-fit”filters.
To replace the filter,
1. Unscrew the oil filter cap and wait a few seconds for the oil to drain
through the built-in drain valve.Note:The filter should be changed
before reinstalling the oil pan drain plug.
2. Reinstall and tighten the oil filter cap.
Do not handle a hot oil filter with bare hands.
Continuous contact with USED motor oil has caused cancer in
laboratory mice. Protect your skin by washing with soap and
water.
Engine lubrication for severe service operation
The following severe service operating conditions require unique engine
maintenance procedures:
•towing a trailer over 1,600 km (1,000 miles)
•sustained, high speed driving at Gross Vehicle Weight Rating
(maximum loaded weight for vehicle operation during hot
weather-above 32°C [90°F]).
•frequent or extended idling (over 10 minutes per hour of normal
driving).
•operating in severe dust conditions.
•frequent, short trips of 16 km (10 miles) or less during freezing
weather
Maintenance and specifications
30

If you experience difficult starting, rough idling, excessive exhaust
smoke, a decrease in engine performance or excess fuel consumption,
perform the following checks:
•a plugged air inlet system or engine air filter element.
•water in the fuel filter/water separator.
•a clogged fuel filter.
•contaminated fuel.
•air in the fuel system, due to loose connections.
•an open or pinched sensor hose.
•low engine oil level.
•wrong fuel or oil viscosity for climactic conditions.
If these checks do not help you correct the engine performance problem
you are experiencing, consult an authorized dealer.
FUELING
Do not use starting fluid such as ether or gasoline in the Diesel
air intake system. Such fluids can cause immediate explosive
damage to the engine and possible personal injury.
If you fuel your vehicle at a truck stop, you may notice that the fuel
nozzle may shut off every 5–10 seconds. This is due to the flow rates
being designed for larger heavy duty trucks. You may have to fuel at a
slower rate (don’t depress the nozzle trigger fully).
Do not run your Diesel vehicle out of fuel as this will allow air to enter
the fuel system which will make restarting difficult. Longer engine
cranking time may be required once air is in the fuel system. If air enters
the fuel system (either through running the fuel tank(s) empty or during
a fuel filter change), the engine will self-purge the trapped air once it
starts running. The engine may run roughly and produce white smoke
while air is in the fuel system; this is normal and should stop after a
short time.
MINOR TROUBLESHOOTING GUIDE
If the engine won’t crank
Turn on the headlights. If the lights are dim, do not go on at all or if
when the ignition is turned to START the lights become dim or go out,
the battery connections may be loose or corroded, or the battery may be
Maintenance and specifications
37

life. These lubricants are not to be checked or changed unless a leak is
suspected, service is required or the axle assembly has been submerged
in water. The axle and PTO lubricant should be changed anytime the
axle and PTO have been submerged in water. Non-synthetic rear axle
lubricants should be replaced every 3,000 miles or 3 months, whichever
occurs first, during extended trailer tow operation above 21 Celsius (70
degrees Fahrenheit) ambient and wide open throttle for extended
periods above 45 mph. The 3,000 mile lube change interval may be
waived if the axle was filled with 75W140 synthetic gear lubricant
meeting Ford specification WSL-M2C192-A, part number F1TZ-19580-B
or equivalent. Add four ounces of additive friction modifier
C8AZ-19B546-A (EST-M2C118-A) or equivalent for complete refill of
Traction-Lok rear axles. The axle lubricant should be changed anytime
an axle has been submerged in water.
F-450 and F-550 axle maintenance
Replace rear axle lubricant every 100,000 miles under normal driving
conditions on all F-450 and F-550 commercial applications. For F-450
and F-550 trucks operated at or near maximum Gross Vehicle Weights,
the rear axle lubricant should be replaced every 50,000 miles. In
addition, this 50,000 mile schedule should be observed when the vehicles
are operated under the Special Operating Conditions.
SPECIAL OPERATING CONDITIONS
Towing a trailer or using a camper or car-top carrier
Every 5,000 miles or 6 months:Change engine oil and replace filter
Every 15,000 miles:Inspect and lubricate 4x2 ball joints and steering
idler arms
Every 30,000 miles:Lubricate 4x4 hub needle bearings
Every 60,000 miles:Change transfer case fluid
As required:Change manual transmission fluid
Extensive idling and/or low-speed driving for long distances as in
heavy commercial use such as delivery, taxi, patrol or livery
Every 5,000 miles, 6 months or 200 hours (whichever comes
first):Change engine oil and replace filter
Every 5,000 miles:Inspect brake system. Inspect and lubricate 4x2 ball
joints and steering idler arms
30,000 miles and 90,000 miles:Lubricate 4x2 wheel bearings. Replace
wheel bearing grease seal.
General Owner’s Information
54

Every 60,000 miles:Change transfer case fluid
As required:Replace cabin air filter, if equipped
Off-road operation
Every 5,000 miles or 6 months:Change engine oil and replace filter
Every 15,000 miles:Lubricate 4x4 hub needle bearings
Every 60,000 miles:Change transfer case fluid
As required:Inspect and lubricate 4x2 ball joints and steering idler
arms. Replace cabin air filter, if equipped
Short trip in cold operating conditions
Every 15,000 miles:Inspect and lubricate 4x2 ball joints and steering
idler arms
Every 40,000 miles:Change transfer case fluid
MAINTENANCE AND SERVICE RECORD
See an authorized dealer
This section of the guide is designed to allow your Ford or Lincoln
Mercury dealer, or Ford or Lincoln Mercury Auto Care service center or
other qualified service technician to record that the recommended
service was completed at the appropriate mileage intervals. Be sure to
ask your service provider to record the type of service rendered (Normal
or Special Operating Conditions—SOC) each time service is performed.
Date:
Mileage:
Normal


SOC

Dealer’s Stamp:
See corresponding mileage in maintenance schedule for services performed.
General Owner’s Information
56