2005 FORD E SERIES service

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 theScheduled Maintenance Guidefor
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 yourScheduled Maintenance Guidefor 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.
Automatic transmission fluid expands when warmed. To obtain an
accurate fluid check, drive the vehicle until it is at normal operating
temperature (approximately 30 km [20 miles]). If your vehicle has been
operated for an extended period at high speeds, in city traffic during hot
weather or pulling a trailer, the vehicle should be turned off for about 30
minutes to allow fluid to cool before checking.
1. Drive the vehicle 30 km (20 miles) or until it reaches normal operating
temperature.
M
AX
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Automatic transmission fluid filter (if equipped)
The TorqShift automatic
transmission is equipped with a
serviceable external fluid filter
mounted on the driver’s side of the
transmission. Refer to the
Scheduled Maintenance Guidefor
service intervals.
To replace the transmission filter:
1. Shut off the engine.
2. Unscrew remote filter housing.
3. Replace filter with a new authorized Motorcraft filter element. Refer to
theMotorcraft part numberschart in this chapter.
4. Reinstall housing and check transmission fluid level using procedure in
this section.
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MOTORCRAFT PART NUMBERS
Component14.6L V8
engine5.4L V8
engine6.8L V10
engine
Air filter element FA-1634 FA-1634 FA-1634
Battery (standard) BXT-65-750 BXT-65-750 BXT-65-750
Battery (auxiliary) BH-65DC BH-65DC BH-65DC
Fuel filter FG-872 FG-872 FG-872
Oil filter FL-820-S FL-820-S FL-820-S
PCV valve
2
Spark plugs-platinum3
Automatic
transmission filter4— FT-145 FT-145
1Refer to thePower Stroke Direct Injection Turbo Diesel Owner’s
Guide Supplementfor Motorcraft diesel engine service part numbers.
2The PCV valve is a critical emission component. It is one of the items
listed in theScheduled Maintenance Guideand is essential to the life
and performance of your vehicle and to its emissions system.
For PCV valve replacement, see your dealer or a qualified service
technician. Refer to theScheduled Maintenance Guidefor the
appropriate intervals for changing the PCV valve.
Replace the PCV valve with one that meets Ford material and
design specifications for your vehicle, such as a Motorcraft or
equivalent replacement part. The customer warranty may be void
for any damage to the emissions system if such a PCV valve is not
used.
3For spark plug replacement, see your dealer or a qualified service
technician. Refer to theScheduled Maintenance Guidefor the
appropriate intervals for changing the spark plugs.
Replace the spark plugs with ones that meet Ford material and
design specifications for your vehicle, such as Motorcraft or
equivalent replacement parts. The customer warranty may be
void for any damage to the engine if such spark plugs are not
used.
4Also available with 6.0L Diesel engine/TorqShift transmission. Part
number is FT-145.
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Fluid Ford Part
NameApplication Capacity
Fuel tank N/A All regular and
extended length
vans and wagons35.0 gallons
(132.4L)
138 inch
wheelbase
(except E-Super
Duty)37.0 gallons
(140.0L)
158 inch
wheelbase
(except E-Super
Duty)37.0 gallons
(140.0L)
5
176 inch
wheelbase
(except E-Super
Duty)37.0 gallons
(140.0L)
158 inch and
176 inch
wheelbase
(E-Super Duty)55 .0 gallons
(208.0L)
Transmission
fluid
6Motorcraft
MERCON
V
AT FAutomatic
(4R70/75 E)13.9 quarts
(13.2L)7
Motorcraft
MERCON
SP
AT FTorqShift
(5–speed)17.5 quarts
(16.6L)7
Windshield
washer fluidMotorcraft
Premium
Windshield
Washer
ConcentrateAll 4.2 quarts
(4.0L)
1Add the coolant type originally equipped in your vehicle.2If your vehicle’s rear axle is filled with a synthetic rear axle lubricant it
is considered lubricated for life. These lubricants do not need to be
checked or changed unless a leak is suspected, service is required or the
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axle assembly has been submerged in water. The axle lubricant should
be changed any time the rear axle has been submerged in water.
Fill 1/4 inch to 9/16 inch (6 mm to 14 mm) below bottom of fill hole.
Add 4 oz. (118 ml) of Additive Friction Modifier XL-3 or equivalent
meeting Ford specification EST-M2C118–A, for complete refill of 8.8 inch
and 9.75 inch Traction-Lok axles.
3Fill Dana rear axles to 1/4 inch to 9/16 inch (6 mm to 14 mm) below
bottom of fill hole. Fill Visteon axles 1/4 inch to 9/16 inch (6 mm to 14
mm) below bottom of fill hole.
4Visteon Traction-Lok axles require 4 oz. (118 ml) of Additive Friction
Modifier XL—3 or equivalent. Dana limited-slip axles (E250/350/450/550)
require 8 oz. (237ml) of Additive Friction Modifier XL—3 or equivalent
meeting Ford specification EST-M2C118-A.
5Optional fuel tank 208L (55 gallon).6Ensure 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 yourScheduled Maintenance Guideto 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
, MERCON
V and MERCON
SP are not
interchangeable. DO NOT mix MERCON
, MERCON
V and
MERCON
SP. Use of dual usage fluids in an automatic
transmission application requiring MERCON
SP may cause
transmission damage. Use of a transmission fluid other than the
recommended fluid may cause transmission damage.
7Indicates only approximate dry-fill capacity. Some applications may vary
based on cooler size, if equipped with an in-tank cooler, if equipped an
oil to air cooler and if equipped with a remote filter assembly. The
amount of transmission fluid and fluid level should be set by the
indication on the dipstick’s normal operating range.
8If your vehicle is equipped with a single row radiator, there will be a
label on the top side of the radiator indicating “1 Row Radiator”.
9Use of synthetic or synthetic blend motor oil is not mandatory. Engine
oil need only meet the requirements of Ford specification
WSS-M2C930-A and the API Certification mark.
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Item Ford part
nameFord part
numberFord
specification
Dana Limited
Slip Axles
3
M60 (M248)
E-250/350
M70FF
(M267FF)
E-350
M70HD
(M273HD)
E-450SAE 90 Hypoid
Gear OilC6AZ-19580–E ESW-M2C105–E
Dana
conventional
axles
M60 (M248)
E-250/350
M70FF
(M267FF)
E-350
M70HD
(M273HD)
E-450SAE 80W-90
Premium Rear
Axle LubricantXY-80W90–QL WSP-M2C197–A
Windshield
washer fluidMotorcraft
Premium
Windshield
Washer
ConcentrateZC-32–A WSB-M8B16–A2
1Ensure 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 yourScheduled Maintenance Guideto 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.
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Vehicle security systems
For maximum vehicle performance, keep the following information in
mind when adding accessories or equipment to your vehicle:
•When adding accessories, equipment, passengers and luggage to your
vehicle, do not exceed the total weight capacity of the vehicle or of
the front or rear axle (GVWR or GAWR as indicated on the Safety
Compliance Certification label). Consult your dealer for specific weight
information.
•The Federal Communications Commission (FCC) and Canadian Radio
Telecommunications Commission (CRTC) regulate the use of mobile
communications systems — such as two-way radios, telephones and
theft alarms - that are equipped with radio transmitters. Any such
equipment installed in your vehicle should comply with FCC or CRTC
regulations and should be installed only by a qualified service
technician.
•Mobile communications systems may harm the operation of your
vehicle, particularly if they are not properly designed for automotive
use.
•To avoid interference with other vehicle functions, such as anti-lock
braking systems, amateur radio users who install radios and antennas
onto their vehicle should not locate the Amateur Radio Antennas in
the area of the driver’s side hood.
•Electrical or electronic accessories or components that are
non-Genuine Ford Accessories added to the vehicle by the dealer or
the owner may adversely affect battery performance and durability.
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Accessories
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Climate control (see Air
conditioning or Heating) ......39, 41
Clock adjust
6-CD in dash .................27, 30, 34
AM/FM .......................................19
AM/FM/CD .................................23
AM/FM/Tape ..............................20
Compass, electronic ....................54
calibration .................................55
set zone adjustment .................55
Console
overhead ....................................53
Controls
power seat .................................68
Coolant
checking and adding ..............205
refill capacities ................209, 228
specifications ..................233, 236
Cruise control
(see Speed control) ....................59
Customer Assistance ................165
Ford accessories for your
vehicle .....................................196
Ford Extended Service
Plan ..........................................188
Getting assistance outside the
U.S. and Canada .....................188
Getting roadside assistance ...165
Getting the service you
need .........................................182
Ordering additional owner’s
literature .................................189
The Dispute Settlement
Board .......................................184
Utilizing the
Mediation/Arbitration
Program ...................................187D
Daytime running lamps
(see Lamps) ................................42
Dipstick
automatic transmission
fluid ..........................................222
engine oil .................................200
Doors
lubricant specifications ..........233
Driveline universal joint and
slip yoke ....................................222
Driving under special
conditions
through water .........................164
E
Emergencies, roadside
jump-starting ..........................176
Emergency Flashers .................166
Emission control system ..........219
Engine ................................236–237
cleaning ...................................193
coolant .....................................205
diesel ...........................................7
fail-safe coolant ......................210
idle speed control ...................203
lubrication
specifications ..................233, 236
refill capacities ........................228
service points ..........................199
starting after a collision .........166
Engine block heater .................150
Engine oil ..................................200
checking and adding ..............200
dipstick ....................................200
filter, specifications ........202, 227
recommendations ...................202
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Index
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