2005 FORD SUPER DUTY maintenance

Cleaning 238
Maintenance and Specifications 245
Engine compartment 247
Engine oil 249
Battery 253
Fuel information 261
Air filter(s) 278
Part numbers 280
Refill capacities 281
Lubricant specifications 283
Accessories 296
Index 299
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Copyright © 2004 Ford Motor Company
Table of Contents
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SAFETY AND ENVIRONMENT PROTECTION
Warning symbols in this guide
How can you reduce the risk of personal injury to yourself or others? In
this guide, answers to such questions are contained in comments
highlighted by the warning triangle symbol. These comments should be
read and observed.
Warning symbols on your vehicle
When you see this symbol, it is
imperative that you consult the
relevant section of this guide before
touching or attempting adjustment
of any kind.
Protecting the environment
We must all play our part in
protecting the environment. Correct
vehicle usage and the authorized
disposal of waste, cleaning and
lubrication materials are significant
steps towards this aim. Information in this respect is highlighted in this
guide with the tree symbol.
BREAKING-IN YOUR VEHICLE
Your vehicle does not need an extensive break-in. Try not to drive
continuously at the same speed for the first 1,000 miles (1,600 km) of
new vehicle operation. Vary your speed frequently in order to give the
moving parts a chance to break in.
Drive your new vehicle for at least 500 miles (800 km) before towing a
trailer or snowplowing.
Do not add friction modifier compounds or special break-in oils during
the first few thousand miles (kilometers) of operation, since these
additives may prevent piston ring seating. SeeEngine oilin the
Maintenance and Specificationschapter for more information on oil
usage.
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Introduction
5

Notice to owners of diesel-powered vehicles
Read the6.0 Liter Power Stroke Direct Injection Turbo Diesel Owner’s
GuideSupplement for information regarding correct operation and
maintenance of your Diesel-powered light truck.
Notice to owners of pickup trucks and utility type vehicles
Utility vehicles have a significantly higher rollover rate than
other types of vehicles.
Before you drive your vehicle, please read this Owner’s Guide carefully.
Your vehicle is not a passenger car. As with other vehicles of this type,
failure to operate this vehicle correctly may result in loss of vehicle
control, vehicle rollover, personal injury or death.
Be sure to readDriving off roadin theDrivingchapter.
Using your vehicle with a snowplow
For more information and guidelines for using your vehicle with a
snowplow, refer to theDrivingchapter.
Using your vehicle as an ambulance
If your light truck is equipped with the Ford Ambulance Preparation
Package, it may be utilized as an ambulance. Ford urges ambulance
manufacturers to follow the recommendations of theFord Incomplete
Vehicle Manual, Ford Truck Body Builder’s Layout Bookand the
Qualified Vehicle Modifiers (QVM) Guidelinesas well as pertinent
supplements. For additional information, please contact the Truck Body
Builders Advisory Service at 1–877–840–4338.
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Introduction
8

Warning lights and gauges can alert you to a vehicle condition that may
become serious enough to cause expensive repairs. A warning light may
illuminate when a problem exists with one of your vehicle’s functions.
Many lights will illuminate when you start your vehicle to make sure the
bulbs work. If any light remains on after starting the vehicle, have the
respective system inspected immediately.
If your vehicle is equipped with a Diesel engine, it has a unique cluster,
refer toStarting the engine in your 6.0 Liter Power Stroke Direct
Injection Turbo Diesel Owner’s Guide Supplement.
Service engine soon:TheService
engine soonindicator light
illuminates when the ignition is first
turned to the ON position to check
the bulb. Solid illumination after the engine is started indicates the On
Board Diagnostics System (OBD-II) has detected a malfunction. Refer to
On board diagnostics (OBD-II)in theMaintenance and Specifications
chapter. If the light is blinking, engine misfire is occurring which could
damage your catalytic converter. Drive in a moderate fashion (avoid
heavy acceleration and deceleration) and have your vehicle serviced
immediately.
Under engine misfire conditions, excessive exhaust temperatures
could damage the catalytic converter, the fuel system, interior
floor coverings or other vehicle components, possibly causing a fire.
Electronic throttle control:
Illuminates when the engine has
defaulted to a ’limp-home’ operation.
Report the fault to a dealer at the
earliest opportunity.
On vehicles equipped with a message center, “ENGINE FAILSAFE
MODE” will be displayed, refer toMessage Centerin theDriver
Controlschapter.
Brake system warning light:To
confirm the brake system warning
light is functional, it will
momentarily illuminate when the
ignition is turned to the ON position
when the engine is not running, or in a position between ON and START,
or by applying the parking brake when the ignition is turned to the ON
P!
BRAKE
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Instrument Cluster
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Tachometer:Indicates the engine
speed in revolutions per minute.
Driving with your tachometer
pointer continuously at the top of
the scale may damage the engine.
Engine oil pressure gauge:
Indicates engine oil pressure. The
needle should stay in the normal
operating range (between “L” and
“H”). If the needle falls below the
normal range, stop the vehicle, turn
off the engine and check the engine
oil level. Add oil if needed. If the oil
level is correct, have your vehicle checked at your dealership or by a
qualified technician.
Fuel gauge:Indicates
approximately how much fuel is left
in the fuel tank (when the ignition
is in the ON position). The fuel
gauge may vary slightly when the
vehicle is in motion or on a grade.
Refer toFilling the tankin the
Maintenance and Specifications
chapter for more information.
Battery voltage gauge (manual
transmission only):Indicates the
battery voltage when the ignition is
in the ON position. If the pointer
moves and stays outside the normal
operating range (as indicated by
arrows), have the vehicle’s electrical
system checked as soon as possible.
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Instrument Cluster
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Transmission fluid temperature gauge (automatic transmission
only):If the gauge is in the:
Normal area(normal) - the
transmission fluid is within the
normal operating temperature
(between “H” and “C”).
Yellow area(warning) — the
transmission fluid is higher than
normal operating temperature. This
can be caused by special operation
conditions (i.e. snowplowing, towing
or off road use). Refer toSpecial
Operating Conditionsin the
Scheduled Maintenance Guidefor
instructions. Operating the transmission for extended periods of time
with the gauge in the yellow area may cause internal transmission
damage.
Altering the severity of the driving conditions is recommended to lower
the transmission temperature into the normal range.
Red area(over temperature) —
the transmission fluid is overheating.
Stop the vehicle to allow the
temperature to return to normal
range.
If the gauge is operating in the Yellow or Red area, stop the vehicle and
verify the airflow is not restricted such as snow or debris blocking airflow
through the grill. If the gauge continues to show high temperatures, see
your Ford dealer.
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Instrument Cluster
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Door ajar:Displays when the
ignition is in the ON position and
any door is open.
Check fuel cap:Displays when the
fuel cap may not be properly
installed. Continued driving with
this display on may cause the
Service engine soon warning light to
come on. Refer toFuel filler capunder theFuel Information sectionin
theMaintenance and Specificationschapter.
Trailer fault (if equipped):
Displayed if there is a short circuit
on the electric brake output wire or
the trailer brakes are drawing too
much current. Refer toIntegrated
trailer brake controllerin theTires, Wheels and Loadingchapter for
more information.
TBC fault (if equipped):Displays
in response to faults sensed by the
TBC. In the event this message is
seen, please take your vehicle to an
authorized Ford dealership for
diagnosis and repair. Refer toIntegrated trailer brake controllerin the
Tires, Wheels and Loadingchapter for more information.
Note:The following warning messages will reappear on the display every
ten minutes.
Low fuel:Displays when the fuel
level in the fuel tank is at or near
empty (refer toFuel gaugein this
chapter).
Check gauge:Displays when any of
the following conditions has
occurred:
•The engine coolant temperature
is high.
•The engine oil pressure is low.
•The fuel gauge is at or near empty.
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Driver Controls
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Warning display Status
Reduced engine power Warning cannot be reset
Stop engine safely
Low fuel level Warning returns after 10 minutes
Low brake fluid level
Low oil pressure
Check engine temperature
Trailer disconnected
Water in fuel (diesel only)
Check air filter (diesel only)
Door ajar Warning returns after the ignition key
is turned from OFF to ON.
Check fuel cap
Engine failsafe mode
Check compass module
Trailer fault
TBC fault
DOOR AJAR.Displayed when a door is not completely closed.
CHECK ENGINE TEMPERATURE.Displayed when the engine
coolant is overheating. Stop the vehicle as soon as safely possible, turn
off the engine and let it cool. Check the coolant and coolant level. Refer
toEngine coolantin theMaintenance and Specificationschapter. If
the warning stays on or continues to come on, contact your dealer as
soon as possible.
REDUCED ENGINE POWER.Displayed when the engine is
overheating. Stop the vehicle as soon as safely possible, turn off the
engine. If the warning stays on followed by an indicator chime or
continues to come on, contact your dealer as soon as possible.
STOP ENGINE SAFELY.Displayed when the engine is overheating.
Stop the vehicle as soon as safely possible, turn off the engine. If the
warning stays on followed by an indicator chime or continues to come
on, contact your dealer as soon as possible.
LOW FUEL LEVEL.Displayed as an early reminder of a low fuel
condition.
LOW BRAKE FLUID LEVEL.Indicates the brake fluid level is low and
the brake system should be inspected immediately. Refer toChecking
and adding brake fluidin theMaintenance and Specifications
chapter.
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Driver Controls
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