2005 FORD SUPER DUTY manual transmission

California Proposition 65 Warning
WARNING:Engine exhaust, some of its constituents, and
certain vehicle components contain or emit chemicals known to
the State of California to cause cancer and birth defects or other
reproductive harm. Certain fluids contained in vehicles and certain
products of components contain or emit chemicals known to the State
of California to cause cancer and birth defects or other reproductive
harm.
Your new diesel engine will feel, drive and function somewhat differently
than a gasoline engine. Therefore it is very important that you read and
thoroughly familiarize yourself and others operating the vehicle with this
guide.
This guide will acquaint you with the 6.0L Power Stroke diesel engine. It
provides recommendations on engine care and operating procedures. For
complete vehicle information, also refer to theOwner’s Guideincluded
with the vehicle. It also describes equipment and gives specifications for
equipment that was in effect when this guide was approved for printing,
and should be considered a permanent part of the vehicle.
Some aftermarket products may cause severe engine and/or
transmission damage. There are various manufacturers offering
devices to increase turbocharger boost, exhaust brakes to
increase stopping/hauling capacity or other such devices to
increase the power/torque of the Power Stroke engine. Many
owners’ past experience with these products has been very poor.
Severe powertrain damage may result from the use of these
aftermarket products which will not be covered by the Ford
warranty.
Ford may discontinue models or change specifications without any notice
and without incurring obligations.
IMPORTANT NOTICE
Ford vehicles are suitable for producing ambulances only if equipped
with the Ford ambulance preparation package. In addition, Ford urges
ambulance manufacturers to follow the recommendation of theFord
Incomplete Vehicle Manual, Ford Truck Body Builder’s Layout Book
(and pertinent supplements) and theQualified Vehicle Modifiers
Guidelines. Using a Ford vehicle without the Ford ambulance
preparation package to produce an ambulance voids the Ford warranty
and could result in elevated underbody temperatures, fuel
Introduction
Introduction
2

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.
Engine governed speed
The engine governor is controlled by the PCM. The PCM controls fuel
input to limit maximum engine speed. It will not, however, prevent
engine overspeeding resulting from downshifting at high vehicle speed or
by descending steep grades at too high a vehicle speed for the selected
transmission gear.
On F-Super Duty vehicles equipped with a manual transmission,
refer toManual transmission shift speedsin theDrivingsection of
yourOwner’s Guidefor maximum vehicle speed in various gears. Do not
exceed 3,600 rpm. Maximum engine governed speed is 4,000 rpm
depending on engine load. Excessive rpm can only be achieved by
manually downshifting at too high of a vehicle speed.
Operating the engine beyond the governed speed can cause
severe engine damage.
Introduction
5

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

F-Super Duty
Maximum GCWR - lbs (kg.)
Engine Rear axle
ratioManual
transmissionAutomatic
transmission
F–250/F–350 Single Rear Wheel (SRW)
6.0L 3.73 23000 (10433) 23000 (10433)
F–350 Dual Rear Wheel (DRW)
6.0L 3.73 23500 (10659) 23500 (10659)
4.10 23500 (10659) 23500 (10659)
F–450
6.0L 4.30/4.88 26000 (11793) 26000 (11793)
6.0L* 4.88 28000 (12701) 30000 (13608)
F–550
6.0L 4.30/4.88 26000 (11793) 26000 (11793)
6.0L* 4.88 28000 (12701) 33000 (14969)
*With high capacity trailer tow package, see rear axle label to identify
actual vehicle content.
Integrated hitch rating
The standard integrated hitch has two ratings depending on mode of
operation:
•Weight carrying- requires a draw bar and hitch ball. The draw bar
supports all the vertical tongue load of the trailer.
•Weight distributing- requires an aftermarket weight distributing
system which includes draw bar, hitch ball, spring bars and snap-up
brackets. The vertical tongue load of the trailer is distributed between
the truck and the trailer by this system.
Driving
17

out, the battery connections may be loose or corroded, or the battery
may be discharged. If there is a clicking or stuttering sound coming from
the engine compartment when you turn the key to 5 (START), this may
also indicate a loose or corroded battery connection.
Check the battery connections at the battery posts, cable connection to
the engine grounding point and at the starter connection.
If a discharged battery is suspected, have it checked and corrected.
•For vehicles with manual transmissions,the clutch pedalmustbe
fully depressed in order for the starter to operate.
•For vehicles with automatic transmissions,the gearshift lever
must be in P (Park) or N (Neutral) in order for the starter to operate.
•Try operating the starter switch several times. Should the switch be
corroded, this operation may clean the contacts or make the switch
temporarily operable until you can reach the dealer.
•If all electrical connections are tight and you need assistance to start,
refer toJump startingin theRoadside Emergencieschapter of your
Owner Guide(F-Super Duty and Excursion) or refer to theJump
startingsection of this supplement (E-Series).
If engine cranks but won’t start
Prolonged starter cranking (in excess of 30 seconds) could cause
damage to the starter motor.
•Check the fuel gauge. You may be out of fuel. If the gauge shows that
there is fuel in the tank, the trouble may be in the electrical system or
the fuel system. If equipped with an auxiliary tank, be sure that the
tank control switch is set for the tank with fuel and not on an empty
tank.
•Leaving the ignition key turned to 4 (ON) for over two minutes
without starting may make starting difficult because the glow plugs
will cease activation. Reset the system by turning the ignition key to 3
(OFF) and then back to 4 (ON) again.
If the engine runs hot
The following could cause the engine to overheat:
•Lack of coolant.
•Dirty cooling system.
•Plugged radiator fins, charge air cooler, A/C condenser and/or oil
cooler.
Maintenance and Specifications
46

REFILL CAPACITIES
Component Capacity
Cooling system127.5 quarts (26.0L)
Engine oil215.0 quarts (14.2L)
Fuel tank (F-250/350/450/550) Refer to yourOwner’s
Guide
Fuel tank (Excursion) 44.0 gallons (166.6L)
Fuel tank (E-Series) Refer to yourOwner’s
Guide
Radiator cap 16 psi (110 kPa)
Manual transmission
35.8 quarts (5.5L)
Automatic transmission Refer to yourOwner’s
Guide
1Includes heater and 5.0 quarts (4.7L) in coolant recovery.
2Includes 1 quart (1.0L) in engine oil filter.
3Use Motorcraft MERCON
ATF, Motorcraft part number XT-2–QDX,
meeting Ford specification MERCON
.
BULB SPECIFICATIONS
Lamp descriptionNumber of bulbs
requiredTrade number
Wait to Start Light 1 194
Water-in-Fuel Light 1 194
Engine Temp. Light 1 194
Maintenance and Specifications
48

LUBRICANT SPECIFICATIONS
ItemFord Part
NameFord Part
NumberFord
Specification
Engine OilMotorcraft
Motor Oil 15W40
Super Duty,
10W30 Super
Duty
1
XO-15W40-QSD,
XO-10W30-QSDWSS-M2C171-D,
CI-4/SL, DHD-1
Engine coolant
Motorcraft
Premium Gold
Engine Coolant
(yellow-colored)VC-7-A (U.S.,
except CA and
OR), VC-7-B
(CA and OR
only)WSS-M97B51–A1
Manual
TransmissionMotorcraft
MERCON
AT FXT-2–QDX MERCON

Automatic
transmissionRefer to Owner Guide
1Refer to the engine oil specification chart located underEngine oil
specificationsin theMaintenance and Specificationssection of this
supplement.
Maintenance and Specifications
49

•Check power steering fluid level
•Check washer spray, wiper operation and clean all wiper blades
(replace as necessary)
•Check parking brake for proper operation
•Check and lubricate all hinges, latches and outside locks
•Check and lubricate door rubber weatherstrips
•Check and clean body and door drain holes
•Check safety warning lamps (brake, ABS, air bag, safety belt) for
operation
•Check cooling system fluid level and coolant strength
•Check battery connections and clean if necessary
•Check clutch fluid level, if equipped
Multi-point Inspection
In order to keep your vehicle running right, it is important that you have
the systems on your vehicle checked regularly. This can help identify any
potential issue before there are any problems. Ford Motor Company
suggests the following multi-point inspection to be performed at every
scheduled maintenance as the way to ensure your vehicle keeps running
right.
Multi-point inspection - Recommended at every visit
•Check and top up fluid levels: brake, coolant recovery reservoir,
manual and automatic transmission, power steering and window
washer.
•Inspect tires for wear and check air pressure, including spare.
•Check exhaust system for leaks, damage, loose parts and foreign
materials.
•Check battery performance.
•Check operation of horn, exterior lamps, turn signals and hazard
warning lights.
•Check radiator, coolers and heater and air conditioning hoses.
•Inspect windshield washer spray and wiper operation.
•Check windshield for cracks, chips and pitting.
•Inspect for oil and fluid leaks.
•Inspect air cleaner filter.
General Owner’s Information
53