2005 FORD F250 SUPER DUTY Owners Manual

3. Install a new air filter element
into the tray assembly.
4. Return air filter tray to original
position by pressing firmly on the
handle until all rearward movement
stops and secure the two clamps.
• 6.8L Engine
1. Loosen the clamps that secures
the air filter cover in place.
2. Carefully separate the two halves of the air filter housing.
3. Remove the air filter element from the air filter housing.
4. Install a new air filter element.
5. Reassemble the two halves of the air filter housing, aligning the notchs
and slots. Secure the clamps, making sure not to crimp the air filter edges
between the two halves of the air filter housing. This could cause filter
damage and allow unmetered air to enter the engine if not properly seated.
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MOTORCRAFT PART NUMBERS
Component 5.4L V8 engine 6.8L V10 engine
Air filter element FA-1634 FA-1634
Fuel filter FG-1011 FG-1011
Oil filter FL-820-S FL-820-S
PCV valve 1
Battery (Standard) BXT-65-650 BXT-65-650
Battery (Optional) BXT-65-750 BXT-65-750
Spark plugs-platinum 2
Remote Automatic
Transmission Filter 3
FT-145 FT–1451
The PCV valve is a critical emission component. It is one of the items
listed in the Scheduled Maintenance Guide and 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 the Scheduled Maintenance Guide for 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. 2
For spark plug replacement, see your dealer or a qualified service
technician. Refer to the Scheduled Maintenance Guide for 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. 3
Also available with 6.0L Diesel engine/TorqShift transmission. Part
number is FT-145.
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REFILL CAPACITIES
Fluid Ford Part
Name Application Capacity
Front axle Motorcraft SAE
80W-90
Premium Rear
Axle Lubricant F-250/350
(Dana 60 axle) 6.3 pints (3.0L)
F-350/450/550
(Dana 60 axle) 6.3 pints (3.0L)
Rear axle Motorcraft SAE
75W-140
Synthetic Rear
Axle Lubricant F-250 /350
(10.50 inch
axle) 1
6.9 pints (3.3L)
Motorcraft SAE
75W-90
Synthetic Rear
Axle Lubricant F-350 (DANA
80) 1
8.5 pints (4.0L)
Motorcraft SAE
75W–140
Synthetic Rear
Axle Lubricant F-450/550
(Dana S110) 14.0 pints (6.6L)
Brake fluid (and
clutch fluid-if
equipped) Motorcraft High
Performance
DOT 3 Motor
Vehicle Brake
Fluid All Fill to line or
step (for clutch)
on reservoir
Engine coolant 2
Motorcraft
Premium Gold
Engine Coolant
(yellow-colored) 5.4L V8 engine
with A/C 26.4 quarts
(25.0L)
6.8L V10 engine 27.5 quarts
(26.0L)
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Fluid Ford Part
Name Application Capacity
Engine oil
(includes filter
change)-Gas
engines 6
Motorcraft SAE
5W-20 Premium
Synthetic Blend
Motor Oil (US)
Motorcraft SAE
5W-20 Super
Premium Motor
Oil (Canada) 5.4L V8 and
6.8L V10
engines 7.0 quarts
(6.6L)
Engine oil
(includes filter
change)-Diesel
engine Refer to your 6.0L Diesel Supplement
Fuel tank N/A Mid-ship tank
(optional on
Chassis Cab) 19.0 gallons
(71.9L )
Short box 30.5 gallons
(115.5L)
Long box 38.0 gallons
(143.9L)
Aft axle 40.0 gallons
(151.4L)
Power steering
fluid Motorcraft
MERCON  AT F All Fill to FULL
COLD range on
dipstick
Transfer case
fluid Motorcraft
MERCON  AT F 4x4 vehicles 2.0 quarts
(1.9L)
Manual
transmission
fluid Motorcraft
MERCON  AT F 6-speed manual 5.8 quarts
(5.5L) 4
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Fluid Ford Part
Name Application Capacity
Automatic
transmission
fluid 3
Motorcraft
MERCON  SP
AT F TorqShift
(5–speed) 17.5 quarts
(16.6L) 5
(includes
remote filter
element change)
Windshield
washer fluid Motorcraft
Premium
Windshield
Washer
Concentrate All 4.25 quarts
(4.0L)1
Add 8 oz. (236 ml) of Additive Friction Modifier XL-3 or equivalent
meeting Ford Specification EST-M2C118–A for complete refill of limited
slip axles. Ford design rear axles contain a synthetic lubricant that does
not require changing unless the axle has been submerged in water. Dana
rear axles also contain a synthetic lubricant but do require a change.
Refer to your Scheduled Maintenance Guide for change intervals on
Dana rear axles. 2
Add the coolant type originally equipped in your vehicle. 3
Ensure the correct automatic transmission fluid is used. Transmission
fluid requirements are indicated on the end of the dipstick. Check the
container to verify the fluid being added is of the correct type. Refer to
your Scheduled Maintenance Guide to determine the correct service
interval.
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. 4
Service refill capacity is determined by filling the transmission to the
bottom of the filler hole with the vehicle on a level surface. The 6–speed
manual transmission is equipped with an in-tank cooler. Verify the fluid
level after operating vehicle to assure correct fluid level. 5
Indicates only approximate dry-fill capacity. Some applications may vary
based on cooler size and if equipped with an in-tank cooler. The amount
of transmission fluid and fluid level should be set by the indication on
the dipstick’s normal operating range.
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6
Use 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.
LUBRICANT SPECIFICATIONS
Item Ford part
name or
equivalent Ford part
number Ford
specification
Spindle bearing High
Temperature
4X4 Front Axle
and Wheel
Bearing Grease E8TZ-19590–A
XG-11 (FAD) ESA-M1C198–A
Front axle
(4X4) Motorcraft SAE
80W-90
Premium Rear
Axle Lubricant XY-80W-90–QL WSP-M2C197–A
Rear axle Motorcraft SAE
75W-140
Synthetic Rear
Axle Lubricant
(10.5 inch) 1
XY-75W140–QL WSL-M2C192-A
Motorcraft SAE
75W-90
Synthetic Rear
Axle Lubricant
(Dana 80) 1
XY-75W90–QLS WSS–M2C918–A
Motorcraft SAE
75W–140Synthetic
Rear Axle
Lubricant (Dana
S110 axles) XY-75W140-QL WSL–M2C192–A
Brake fluid and
clutch fluid (if
equipped) Motorcraft High
Performance
DOT 3 Motor
Vehicle Brake
Fluid PM-1 ESA-M6C25-A
and DOT 3
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Item Ford part
name or
equivalent Ford part
number Ford
specification
Engine coolant Motorcraft
Premium Gold
Engine Coolant
(yellow-colored) VC-7-A (U.S.,
except CA, OR
and NM),
VC-7-B (CA, OR
and NM) WSS-M97B51-A1
Engine oil Motorcraft SAE
5W-20 Premium
Synthetic Blend
Motor Oil (US)
Motorcraft SAE
5W-20 Super
Premium Motor
Oil (Canada) XO-5W20-QSP
(US)
CXO-5W20–LSP12
(Canada) WSS-M2C930-A
and API
Certification
Mark
Hinges, latches,
striker plates,
fuel filler door
hinge and seat
tracks Multi-Purpose
Grease XG–4 or XL-5 ESR-M1C159-A
or
ESB-M1C93–B
Lock cylinders Motorcraft
penetrating and
lock lubricant XL-1 none
Transmission
/parking brake
linkages and
pivots, brake
and clutch pedal
shaft (if
equipped) Motorcraft
Premium
Long-Life Grease XG-1-C or
XG-1-K ESA-M1C75-B
Steering linkage Motorcraft
Premium
Long-Life Grease XG-1-C or
XG-1-K WSD-M1C227-A
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Item Ford part
name or
equivalent Ford part
number Ford
specification
Power steering
fluid and
transfer case
fluid (if
equipped) Motorcraft
MERCON  AT F XT-2-QDX MERCON 
Manual
transmission
(6-speed) Motorcraft
MERCON  AT F 2
XT-2-QDX MERCON 
Automatic
transmission
TorqShift
(5–speed) Motorcraft
MERCON  SP
AT F 2
XT-6–QSP MERCON  SP
Windshield
washer fluid Motorcraft
Premium
Windshield
Washer
Concentrate ZC-32–A WSB-M8B16–A21
Add 8 oz.(236 ml) of Additive Friction Modifier XL-3 or equivalent
meeting Ford specification EST-M2C118-A for complete refill of limited
slip axles. Ford design rear axles contain a synthetic lubricant that does
not require changing unless the axle has been submerged in water. Dana
rear axles also contain a synthetic lubricant but do require a change.
Refer to your Scheduled Maintenance Guide for change intervals on
Dana rear axles. 2
Ensure the correct automatic transmission fluid is used. Transmission
fluid requirements are indicated on the end of the dipstick. Check the
container to verify the fluid being added is of the correct type. Refer to
your Scheduled Maintenance Guide to determine the correct service
interval.
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.
2005 F250/350/450/550 (f23)
Owners Guide (post-2002-fmt)
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