2005 FORD SUPER DUTY Diesel Supplement Manual

The vehicle may be driven with the engine air filter warning light
illuminated/or when the underhood air filter restriction gauge has moved
to the CHANGE FILTER mark for up to 400 km (250 miles) without
damaging the engine or related components. However, the air filter
element must be replaced at the earliest opportunity. Refer toAir filter
restriction gauge (if equipped)in this section of the supplement for
more information.
Transmission Tow/Haul Feature
(if equipped):Illuminates when
the Tow/Haul feature has been
selected. Refer to theDriving
chapter for transmission function and operation. If the light flashes
steadily or does not illuminate, have the transmission serviced soon, or
damage may occur.
Air filter restriction gauge (if equipped)
The restriction gauge, located on
the upper housing of the air cleaner
assembly, monitors the condition of
the air filter element in two ways:
•First, the colored indictor inside
the gauge highlights the
percentage that the air filter
element is clogged with dust or
contaminants. Refer to
Maintenance and Specifications
section of this supplement.
•Second, the gauge contains an
electrical switch which illuminates
a warning light on the instrument
cluster when the air filter element
is 100% clogged. Refer to the
Engine air filterwarning light in
this section of the supplement.
Check the air filter restriction gauge
whenever the hood is raised to
perform general engine maintenance at least every 7,500 miles (12,000
km). If the vehicle is operated in extremely dusty conditions, check the
gauge at least every 500 miles (800 km), or two weeks, whichever comes
first.
AIRFILTERRESTAA
CHANGE FILTER
PUSH BUTTON RESET75%
50%65%
Instrumentation
9

The air filter element must be
replaced when the colored band on
the gauge reaches the CHANGE
FILTER mark. Engine performance
and fuel economy are adversely
affected when the maximum
restriction is reached.
Blowing-out the air filter
element with compressed air is
not recommended as the
compressed air may damage the
filter paper.
Note:It is not possible to determine
the level of filter clogging by visual
appearance alone. A filter which
appears to be dirty may actually
have several thousand miles
(kilometers) of life remaining.
Always use the underhood air
filter restriction gauge to
determine when the air filter element needs to be changed. The
warning light on the instrument cluster should not be used
exclusively for determining when the air filter element needs
changing.
AIRFILTERRESTAA
CHANGE FILTER
PUSH BUTTON RESET75%
50%65%
Instrumentation
10

After servicing the air filter element,
reset the restriction gauge by
pressing the button on the end of
the gauge.
Note:If the vehicle is operated in a
heavy snow storm, in blowing snow
or the vehicle is equipped with a
snowplow, the engine air filter
element may become partially
clogged with snow and/or ice. If this
occurs, the air filter restriction
gauge will move to the CHANGE FILTER mark and the engine may
experience a significant reduction in power output. The vehicle may be
driven under these conditions for up to 160 km (100 miles) without
damage to the engine or related components.
At the earliest opportunity, clear all snow and ice from the air induction
system and reset the restriction gauge by pressing the button on the end
of the gauge. If the air filter restriction gauge moves the CHANGE
FILTER mark after clearing snow and/or ice, then replace the filter.
Reset filter restriction gauge after changing the air filter element.
The air filter warning light on the instrument cluster may be used, in
addition to the underhood restriction gauge, to monitor the condition of
the air filter element. Refer to theEngine air filterwarning light in this
section of the supplement.
Engine boost gauge (if equipped)
Indicates the amount of pressure in
the engine. Driving with your
pointer continuously at the high end
of the scale may damage the engine.
Instrumentation
11

STARTING THE ENGINE
Read all starting instructions carefully before you start your vehicle.
For temperatures below 32°F(0°C), the use of the correct grade engine
oil is essential for proper operation.
If your vehicle is equipped with a manual transmission,make sure
the parking brake is set fully before you turn the key. Depress the clutch
pedal and place the gearshift in the neutral position. The clutch must be
fully depressed in order to operate the starter. Do not press the
accelerator during starting.
If your vehicle is equipped with an automatic transmission,ensure
the gearshift lever is in P (Park) and the parking brake is set before you
turn the key. Do not press the accelerator during starting.
Cold weather starting
When operating in cold weather, use a minimum of 45 Cetane Diesel fuel
or use Cetane Index improvers from a reputable manufacturer.
Do not crank the engine for more than 30 seconds as starter damage
may occur. If the engine fails to start, turn the key to 3 (OFF) and wait
30 seconds before trying again.
Do not use starting fluid, such as ether, in the air intake system
(see air cleaner decal). Such fluid could cause immediate
explosive damage to the engine and possible personal injury.
Note:Do not add gasoline, gasohol or alcohol to diesel fuel. This
practice creates a serious fire hazard and causes engine performance
problems.
1. Turn the key to 4 (ON) without
turning the key to 5 (START).Do
not start the engineuntil the
glow-plug pre-heat indicator
turns off.
3
2
1
5
4
Driving
Driving
12

2. When the glow plug pre-heat
indicator turns off, turn the key to 5
(START), then release the key as
soon as the engine starts. The glow
plugs will continue to be activated for two minutes after the glow plug
pre-heat indicator
has turned off. If the engine is not started
before the glow plug activation time ends, the glow plugs will need to be
reset by turning the key to 3 (OFF).
3. After the engine starts, allow it to idle for about 15 seconds. Do not
increase engine speed until the oil pressure gauge indicates normal
pressure.
STOPPING THE ENGINE
Turn the ignition to 3 (OFF). To prolong engine life (after extended high
speed or maximum GVW operation), it is recommended that a hot engine
be allowed to operate at low idle for about 7–10 minutes which would
allow sufficient time for the turbocharged engine to cool down.
COLD WEATHER OPERATION
Changing to a lighter grade engine oil also makes starting easier under
these conditions. Refer toEngine oil specificationsin theMaintenance
and Specificationssection of this supplement.
At temperatures below 20°F(–7°C), Number 2–D diesel fuel may thicken
enough to clog the fuel filter. Your vehicle is equipped with either an
FCM (E-Series) or an HFCM (F-Super Duty and Excursion) which acts
as a fuel filter/heater/water separator to keep the wax melted which will
help prevent fuel filter clogging. However, if the engine starts but stalls
after a short time and will not restart, the fuel filter(s) may be clogged.
For best results in cold weather, use Number 1–D diesel fuel or
“winterized”Number 2–D diesel fuel which has an additive to minimize
wax formation.
Your vehicle is also equipped with a bypass relief valve, located on the
fuel control module, which provides fuel flow to the engine if the fuel
pickup should become plugged by ice or wax. To allow this bypass valve
to function and avoid engine fuel starvation, it is recommended that,
during cold weather operation 32°F(0°C) or below, the fuel level in your
tank should not be allowed to drop below
1⁄4full. This will help prevent
air from entering the fuel system and stalling the engine.
In cold weather below 32°F (0°C) your diesel engine will slowly increase
to a higher idle speed if left idling in P (Park). As the engine warms-up,
Driving
13

the engine sound level will decrease due to the activation of
PCM-controlled sound reduction features.
If your vehicle is operated in a heavy snow storm or blowing snow
conditions, the engine air induction may become partially clogged with
snow and/or ice. If this occurs, the engine may experience a significant
reduction in power output. At the earliest opportunity, clear all the snow
and/or ice away from the air induction inlet.
Operation in snow
Vehicle operation in heavy snowfall or in dry loose snow that may swirl
around the front of the vehicle may feed excessive amounts of snow into
the air intake system. This could plug the air cleaner with snow and
cause the engine to stall and/or lose power.
Refer toAir filter restriction gaugeandEngine air filterin the
Instrumentationsection of this supplement for more information.
Operation in standing water
Ingestion of water into the diesel engine can result in immediate and
severe damage to the engine. If driving through water, slow down to
avoid splashing water into the intake. If the engine stalls, and ingestion
of water into the engine is suspected, do not try to restart the engine.
Consult your dealer for service immediately.
Engine block heater (if equipped)
Refer to theDrivingchapter in theOwner’s Guide.
DUAL FUEL TANK SELECTOR CONTROL (IF EQUIPPED)
If your vehicle is equipped with dual
fuel tanks, you will have a selector
control, located to the right of the
steering wheel, which allows you to
draw fuel from either tank. Your fuel
gauge will display the amount of
fuel in the currently selected tank.
Fuel level indication is delayed for several minutes when the tank
selector switch is actuated. Fuel level indication can be obtained
immediately by turning off and restarting the engine.
Driving
14

TRAILER TOWING
Refer to yourOwner’s Guidefor full details on towing a trailer.
Trailer towing tables - E-Series
Engine Rear axle
ratioMaximum GCWR -
lbs. (kg)Maximum
trailer weight -
lbs. (kg)
E-350 Regular Van (9500 GVWR)
6.0L 3.55 16000 (7257) 9700 (4400)
6.0L 4.10 20000 (9072) 10000 (4536)
E-350 Regular Van (Crew) (9500 GVWR)
6.0L 3.55 16000 (7257) 9400 (4264)
6.0L 4.10 20000 (9072) 10000 (4536)
E-350 Extended Van (9400 GVWR)
6.0L 3.55 16000 (7257) 9500 (4309)
6.0L 4.10 20000 (9072) 10000 (4536)
E-350 Extended Van (Crew) (9400 GVWR)
6.0L 3.55 16000 (7257) 9300 (4218)
6.0L 4.10 20000 (9072) 10000 (4536)
E-350 Regular Wagon (7–passenger) (8700 GVWR)
6.0L 3.55 16000 (7257) 9200 (4173)
6.0L 4.10 20000 (9072) 10000 (4536)
E-350 Regular Wagon (8–passenger) (8700 GVWR)
6.0L 3.55 16000 (7257) 9200 (4173)
6.0L 4.10 20000 (9072) 10000 (4536)
E-350 Regular Wagon (12–passenger) (8700 GVWR)
6.0L 3.55 16000 (7257) 9200 (4173)
6.0L 4.10 20000 (9072) 10000 (4536)
E-350 Extended Wagon (12–passenger) (9300 GVWR)
6.0L 3.55 16000 (7257) 9000 (4082)
6.0L 4.10 20000 (9072) 10000 (4536)
E-350 Extended Wagon (15–passenger) (9400 GVWR)
6.0L 3.55 16000 (7257) 9000 (4082)
6.0L 4.10 20000 (9072) 10000 (4536)
Driving
15

Engine Rear axle
ratioMaximum GCWR -
lbs. (kg)Maximum
trailer weight -
lbs. (kg)
E-350 Cutaway 138”wheelbase, single rear wheel) (9600
GVWR)
6.0L 4.10 20000 (9072) 10000 (4536)
E-350 Cutaway 138”wheelbase, dual rear wheel) (10700 GVWR)
6.0L 4.10 20000 (9072) 10000 (4536)
E-350 Cutaway 158”wheelbase, dual rear wheel) (11500 GVWR)
6.0L 4.10 20000 (9072) 10000 (4536)
E-350 Cutaway 176”wheelbase, dual rear wheel) (11500 GVWR)
6.0L 4.10 20000 (9072) 10000 (4536)
E-450 Cutaway 158”wheelbase) (14050 GVWR)
6.0L 4.10 20000 (9072) 10000 (4536)
E-350 Cutaway 176”wheelbase) (14050 GVWR)
6.0L 4.10 20000 (9072) 10000 (4536)
Trailer towing tables - Excursion & F-Super Duty
Excursion
Engine Rear axle
ratioMaximum GCWR -
lbs. (kg)Maximum
trailer weight -
lbs. (kg)
4x2
6.0L 3.73 20000 (9072) 11000 (4988)
4x4
6.0L 3.73 20000 (9072) 11000 (4988)
Driving
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