2005 FORD SUPER DUTY fuel cap

applications draw auxiliary horsepower from the powertrain, often while
the vehicle is stationary. In this condition, there is limited cooling air
flow through the radiator and around the vehicle that normally occurs
when a vehicle is moving. Depending on the level and duration of
auxiliary horsepower draw, vehicle conditions and surrounding
environmental conditions and other factors, this can contribute to
elevated transmission fluid temperatures and result in accelerated fluid
deterioration, fuel vapor over-pressurization, and other concerns. Ford
trucks are fully qualified for stationary PTO operation for 10 minutes or
less of continuous operation. For extended duration stationary PTO
operation (beyond 10 minutes), a diesel engine is recommended, and
further consult your aftermarket PTO installer.
Transmission Power Take-Off (PTO) Provision (if equipped)
Some vehicles with an automatic transmission may be equipped with a
“Transmission Power Take-Off Provision”, Option Code 62R. These
vehicles have a special transmission that includes a port on the left-hand
side to mount an aftermarket PTO, an internal PTO gear, and calibration
for PTO usage. The actual PTO and related equipment is not offered by
Ford Motor Company, but is installed by an aftermarket source. The PTO
gear in the transmission will drive the aftermarket PTO while driving the
vehicle. Therefore, some additional gear noise that may result is normal.
Also, the transmission upshift and downshift schedules will be reduced
by about 15% and may result in a firmer shift feel during PTO mobile
applications.
A more complete description of PTO operation is discussed in the Ford
Truck Body Builders Layout Book, found at
www.fleet.ford.com/truckbbas.
DRIVING THROUGH WATER
If driving through deep or standing water is unavoidable, proceed very
slowly especially when the depth is not known. Never drive through
water that is higher than the bottom of the hubs (for trucks) or the
bottom of the wheel rims (for cars). When driving through water,
traction or brake capability may be limited. Also, water may enter your
engine’s air intake and severely damage your engine or your vehicle may
stall.Driving through deep water where the transmission vent
tube is submerged may allow water into the transmission and
cause internal transmission damage.
Once through the water, always dry the brakes by moving your
vehicle slowly while applying light pressure on the brake pedal.
Wet brakes do not stop the vehicle as quickly as dry brakes.
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Batteries normally produce explosive gases which can cause
personal injury. Therefore, do not allow flames, sparks or lighted
substances to come near the battery. When working near the battery,
always shield your face and protect your eyes. Always provide proper
ventilation.
When lifting a plastic-cased battery, excessive pressure on the
end walls could cause acid to flow through the vent caps,
resulting in personal injury and/or damage to the vehicle or battery.
Lift the battery with a battery carrier or with your hands on opposite
corners.
Keep batteries out of reach of children. Batteries contain sulfuric
acid. Avoid contact with skin, eyes or clothing. Shield your eyes
when working near the battery to protect against possible splashing of
acid solution. In case of acid contact with skin or eyes, flush
immediately with water for a minimum of 15 minutes and get prompt
medical attention. If acid is swallowed, call a physician immediately.
Battery posts, terminals and related accessories contain lead and
lead compounds.Wash hands after handling.
For information on transmission operation after the battery has been
disconnected, refer toShift strategyin theDrivingchapter.
Because your vehicle’s engine is also electronically controlled by a
computer, some control conditions are maintained by power from the
battery. When the battery is disconnected or a new battery is installed,
the engine must relearn its idle and fuel trim strategy for optimum
driveability and performance. To begin this process:
1. With the vehicle at a complete stop, set the parking brake.
2. Put the gearshift in P (Park) (automatic transmission) or the neutral
position (manual transmission), turn off all accessories and start the
engine.
3. Run the engine until it reaches normal operating temperature.
4. Allow the engine to idle for at least one minute.
5. Turn the A/C on and allow the engine to idle for at least one minute.
6. Drive the vehicle to complete the relearning process.
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Never remove the coolant reservoir cap while the engine is
running or hot.
5. Re-start the engine and take your vehicle to a service facility.
Driving the vehicle without repairing the engine problem
increases the chance of engine damage. Take your vehicle to a
service facility as soon as possible.
WHAT YOU SHOULD KNOW ABOUT AUTOMOTIVE FUELS
Important safety precautions
Do not overfill the fuel tank. The pressure in an overfilled tank
may cause leakage and lead to fuel spray and fire.
The fuel system may be under pressure. If the fuel filler cap is
venting vapor or if you hear a hissing sound, wait until it stops
before completely removing the fuel filler cap. Otherwise, fuel may
spray out and injure you or others.
If you do not use the proper fuel filler cap, excessive pressure or
vacuum in the fuel tank may damage the fuel system or cause
the fuel cap to disengage in a collision, which may result in possible
personal injury.
Automotive fuels can cause serious injury or death if misused or
mishandled.
Gasoline may contain benzene, which is a cancer-causing agent.
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Use the following guidelines to avoid static build-up when filling an
ungrounded fuel container:
•Place approved fuel container on the ground.
•DO NOT fill a fuel container while it is in the vehicle (including the
cargo area).
•Keep the fuel pump nozzle in contact with the fuel container while
filling.
•DO NOT use a device that would hold the fuel pump handle in the fill
position.
Fuel Filler Cap
Your fuel tank filler cap has an indexed design with a 1/4 turn on/off
feature.
When fueling your vehicle:
1. Turn the engine off.
2. Carefully turn the filler cap counterclockwise 1/4 of a turn until it
stops.
3. Pull to remove the cap from the fuel filler pipe.
4. To install the cap, align the tabs on the cap with the notches on the
filler pipe.
5. Turn the filler cap clockwise 1/4 of a turn until it stops.
If the “Check Fuel Cap” indicator comes on and stays on after you start
the engine, the fuel filler cap may not be properly installed. Turn off the
engine, remove the fuel filler cap, align the cap properly and reinstall it.
If you must replace the fuel filler cap, replace it with a fuel filler
cap that is designed for your vehicle. The customer warranty may
be void for any damage to the fuel tank or fuel system if the
correct genuine Ford or Motorcraft fuel filler cap is not used.
The fuel system may be under pressure. If the fuel filler cap is
venting vapor or if you hear a hissing sound, wait until it stops
before completely removing the fuel filler cap. Otherwise, fuel may
spray out and injure you or others.
If you do not use the proper fuel filler cap, excessive pressure or
vacuum in the fuel tank may damage the fuel system or cause
the fuel cap to disengage in a collision, which may result in possible
personal injury.
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Filling the tank
The advertised fuel capacity of the fuel tank on your vehicle is equal to
the rated refill capacity of the fuel tank as listed in theRefill capacities
section of this chapter.
The advertised capacity is the amount of the indicated capacity and the
empty reserve combined. Indicated capacity is the difference in the
amount of fuel in a full tank and a tank when the fuel gauge indicates
empty. Empty reserve is the small amount of fuel remaining in the fuel
tank after the fuel gauge indicates empty.
The amount of usable fuel in the empty reserve varies and should
not be relied upon to increase driving range. When refueling your
vehicle after the fuel gauge indicates empty, you might not be
able to refuel the full amount of the advertised capacity of the
fuel tank due to the empty reserve still present in the tank.
For consistent results when filling the fuel tank:
•Turn the engine/ignition switch to the off position prior to refueling,
an error in the reading will result if the engine is left running.
•Use the same filling rate setting (low — medium — high) each time
the tank is filled.
•Allow no more than 2 automatic click-offs when filling.
•Always use fuel with the recommended octane rating.
•Use a known quality gasoline, preferably a national brand.
•Use the same side of the same pump and have the vehicle facing the
same direction each time you fill up.
•Have the vehicle loading and distribution the same every time.
Your results will be most accurate if your filling method is consistent.
Calculating fuel economy
1. Fill the fuel tank completely and record the initial odometer reading
(in miles or kilometers).
2. Each time you fill the tank, record the amount of fuel added (in
gallons or liters).
3. After at least three to five tank fill-ups, fill the fuel tank and record
the current odometer reading.
4. Subtract your initial odometer reading from the current odometer
reading.
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Please consult yourWarranty Guidefor complete emission warranty
information.
On board diagnostics (OBD-II)
Your vehicle is equipped with a computer that monitors the engine’s
emission control system. This system is commonly known as the On
Board Diagnostics System (OBD-II). This OBD-II system protects the
environment by ensuring that your vehicle continues to meet
government emission standards. The OBD-II system also assists the
service technician in properly servicing your vehicle. When theCheck
engine/Service engine soonlight illuminates, the OBD-II system has
detected a malfunction. Temporary malfunctions may cause yourCheck
engine/Service engine soonlight to illuminate. Examples are:
1. The vehicle has run out of fuel. (The engine may misfire or run
poorly.)
2. Poor fuel quality or water in the fuel.
3. The fuel cap may not have been securely tightened.
These temporary malfunctions can be corrected by filling the fuel tank
with good quality fuel and/or properly tightening the fuel cap. After three
driving cycles without these or any other temporary malfunctions
present, theCheck engine/Service engine soonlight should turn off. (A
driving cycle consists of a cold engine startup followed by mixed
city/highway driving.) No additional vehicle service is required.
If theCheck engine/Service engine soonlight remains on, have your
vehicle serviced at the first available opportunity.
Readiness for Inspection/Maintenance (I/M) testing
In some localities, it may be a legal requirement to pass an I/M test of
the on-board diagnostics system. If yourCheck engine/Service engine
soonlight is on, refer to the description in theWarning lights and
chimessection of theInstrument Clusterchapter. Your vehicle may not
pass the I/M test with theCheck engine/Service engine soonlight on.
If the vehicle’s powertrain system or its battery has just been serviced,
the on-board diagnostics system is reset to a “not ready for I/M test”
condition. To ready the on-board diagnostics system for I/M testing, a
minimum of 30 minutes of city and highway driving is necessary as
described below:
•First, at least 10 minutes of driving on an expressway or highway.
•Next, at least 20 minutes driving in stop-and-go, city-type traffic with
at least four idle periods.
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FluidFord Part
NameApplication Capacity
Engine oil
(includes filter
change)-Diesel
engineRefer 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
fluidMotorcraft
MERCONAT FAll Fill to FULL
COLD range on
dipstick
Transfer case
fluidMotorcraft
MERCONAT F4x4 vehicles 2.0 quarts
(1.9L)
Manual
transmission
fluidMotorcraft
MERCONAT F6-speed manual 5.8 quarts
(5.5L)
4
Automatic
transmission
fluid
3
Motorcraft
MERCONSP
AT FTorqShift
(5–speed)17.5 quarts
(16.6L)
5(includes
remote filter
element change)
Windshield
washer fluidMotorcraft
Premium
Windshield
Washer
ConcentrateAll 4.25 quarts
(4.0L)
1Add 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 yourScheduled Maintenance Guidefor change intervals on
Dana rear axles.
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filter, specifications ........252, 280
recommendations ...................252
refill capacities ........................281
specifications ..................283, 287
Exhaust fumes ..........................180
F
Fail safe cooling ........................260
Fluid capacities .........................281
Foglamps .....................................41
Four-Wheel Drive vehicles .......193
description ..............................197
driving off road .......................199
electronic shift ................193, 197
indicator light .........................194
lever operated shift ................195
manual locking hubs ..............193
preparing to drive your
vehicle .....................................184
Fuel ............................................261
calculating fuel economy .72, 265
cap ...........................................263
capacity ...................................281
choosing the right fuel ...........264
comparisons with EPA fuel
economy estimates .................268
detergent in fuel .....................265
filling your vehicle
with fuel ..................261, 263, 266
filter, specifications ........265, 280
fuel pump shut-off switch .....213
improving fuel economy ........265
octane rating ...................264, 287
quality ......................................264
running out of fuel .................265
safety information relating to
automotive fuels .....................261
Fuel pump shut-off switch .......213
Fuses ..................................213–214G
Gas cap (see Fuel cap) ............263
Gas mileage (see Fuel
economy) ...................................265
Gauges .........................................16
transmission fluid
temperature gauge ...................20
H
Hazard flashers .........................212
Head restraints ...........................90
Headlamps ...................................40
aiming ..................................42, 44
autolamp system .......................40
daytime running lights .............41
flash to pass ..............................42
high beam .................................41
replacing bulbs ...................48–51
turning on and off ....................40
Heating
heating and air conditioning
system ...........................34–35, 37
Hood ..........................................246
I
Ignition ...............................175, 287
Infant seats
(see Safety seats) .....................120
Inspection/maintenance
(I/M) testing ..............................270
Instrument panel
cleaning ...................................241
cluster ........................................12
lighting up panel and
interior .......................................42
J
Jump-starting your vehicle ......221
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