2006 FORD SUPER DUTY maintenance schedule

Use only a DOT 3 brake fluid designed to meet Ford specification
ESA-M6C25–A. Refer toLubricant Specificationsin this chapter.
Brake fluid is toxic. If brake fluid contacts the eyes, flush eyes
with running water for 15 minutes. Seek medical attention if
irritation persists. If taken internally, drink water and induce vomiting.
Seek medical attention immediately.
During normal operation, the fluid level in the clutch reservoir should
remain constant or rise slightly. If the fluid level drops, refill the fluid
level to the step in the reservoir.
1. Clean the reservoir cap before
removal to prevent dirt and water
from entering the reservoir.
2. Remove cap and rubber
diaphragm from reservoir.
3. Add fluid until the level reaches
the step in the reservoir.
4. Reinstall rubber diaphragm and
cap onto reservoir.
TRANSMISSION FLUID
Checking automatic transmission fluid (if equipped)
Refer to yourscheduled maintenance informationfor scheduled
intervals for fluid checks and changes. Your transmission does not
consume fluid. However, the fluid level should be checked if the
transmission is not working properly, i.e., if the transmission slips or
shifts slowly or if you notice some sign of fluid leakage.
Automatic transmission fluid expands when warmed. To obtain an
accurate fluid check, drive the vehicle until it is at normal operating
temperature (approximately 20 miles [30 km]). If your vehicle has been
operated for an extended period at high speeds, in city traffic during hot
weather or pulling a trailer, the vehicle should be turned off for about
30 minutes to allow fluid to cool before checking.
1. Drive the vehicle 20 miles (30 km) or until it reaches normal operating
temperature.
2. Park the vehicle on a level surface and engage the parking brake.
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Automatic transmission fluid filter (if equipped)
The TorqShift automatic
transmission is equipped with a
serviceable external fluid filter
mounted on the frame rail. Refer to
thescheduled maintenance
informationfor service intervals.
To replace the transmission filter:
1. Shut off the engine.
2. Unscrew filter housing.
3. Replace filter with a new authorized Motorcraft filter element. Refer to
theMotorcraft part numberschart in this chapter.
4. Reinstall housing and check transmission fluid level using procedure in
this section.
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CHECKING AND ADDING TRANSFER CASE FLUID (IF EQUIPPED)
1. Clean the filler plug.
2. Remove the filler plug and
inspect the fluid level.
3. Add only enough fluid through
the filler opening so that the fluid
level is at the bottom of the
opening.
Use only fluid that meets Ford specifications. Refer toLubricant
specificationsin this chapter.
DRIVELINE UNIVERSAL JOINT AND SLIP YOKE
If the original universal joints are replaced with universal joints equipped
with grease fittings, lubrication will be necessary. Refer to thescheduled
maintenance informationfor maintenance intervals.
AIR FILTER MAINTENANCE
Refer to thescheduled maintenance informationfor the appropriate
intervals for changing the air filter element.
When changing the air filter element, use only the Motorcraft air filter
element listed. Refer toMotorcraft part numbersin this chapter.

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MOTORCRAFT PART NUMBERS
Component 5.4L V8 engine 6.8L V10 engine
Air filter element FA-1754 FA-1782
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 Filter3FT-145 FT–145
1The PCV valve is a critical emission component. It is one of the items
listed in thescheduled maintenance informationand is essential to
the life and performance of your vehicle and to its emissions system.
For PCV valve replacement, see your authorized dealer. Refer to the
scheduled maintenance informationfor 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.
2For spark plug replacement, see your authorized dealer. Refer to the
scheduled maintenance informationfor 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.
3Also available with 6.0L Diesel engine/TorqShift transmission. Part
number is FT-145.
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FluidFord Part
NameApplication Capacity
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 informationfor change intervals
on Dana rear axles.
2Add the coolant type originally equipped in your vehicle.3Ensure the correct automatic transmission fluid is used. Transmission
fluid requirements are indicated on the dipstick handle. Check the
container to verify the fluid being added is of the correct type. Refer to
yourscheduled maintenance informationto determine the correct
service interval.
MERCON, MERCONV and MERCONSP are not
interchangeable. DO NOT mix MERCON, MERCONV and
MERCONSP. Use of dual usage fluids in an automatic
transmission application requiring MERCONSP may cause
transmission damage. Use of a transmission fluid other than the
recommended fluid may cause transmission damage.
4Service 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 ensure correct fluid level.
5Indicates 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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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 butdorequire a change.
Refer to yourscheduled maintenance informationfor change intervals
on Dana rear axles.
2Ensure the correct automatic transmission fluid is used. Transmission
fluid requirements are indicated on the dipstick handle. Check the
container to verify the fluid being added is of the correct type. Refer to
yourscheduled maintenance informationto determine the correct
service interval.
MERCON, MERCONV and MERCONSP are not
interchangeable. DO NOT mix MERCON, MERCONV and
MERCONSP. Use of dual usage fluids in an automatic
transmission application requiring MERCONSP may cause
transmission damage. Use of a transmission fluid other than the
recommended fluid may cause transmission damage.
ENGINE DATA
Engine 5.4L V8 engine 6.8L V10 engine
Cubic inches 330 415
Required fuel 87 octane 87 octane
Firing order 1-3-7-2-6-5-4-8 1-6-5-10-2-7-3-8-4-9
Spark plug gap1.02–1.28mm
(0.040–0.050 inch)*1.02–1.28mm
(0.040–0.050 inch)*
Ignition system Coil on plug Coil on plug
Compression ratio 9.8:1 9.2:1
*The 5.4L 3V and 6.8L 3V spark plug gap CANNOT be adjusted.
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