2008 FORD SUPER DUTY maintenance schedule

Introduction
2
Instrument Cluster
7
Driving
11
Roadside emergencies
19
Cleaning
25
Maintenance and Specifications
28
Scheduled Maintenance: General Information
55
Scheduled Maintenance: E-Series
62
Scheduled Maintenance: F-Super Duty
77
Scheduled Maintenance: Special Information
91
Exceptions 91
Motorcraft Premium Gold Coolant change record 93
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Copyright © 2006 Ford Motor Company
Table of Contents
1
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•On F-Super Duty vehicles (6.4L engine),a frame-mounted
Horizontal Fuel Conditioner Module (HFCM)
•an engine-mounted secondary fuel filter
•a unit injector for each cylinder
The FCM/HFCM acts as a primary fuel filter/water separator which
removes both water and impurities from the fuel. The engine-mounted
fuel filter and the FCM/HFCM filter should be changed at the
recommended service interval. Refer to thescheduled maintenance
informationin this supplement for more information.
The FCM/HFCM should be drained at regular intervals or when the
WATER IN FUEL light illuminates in the instrument cluster (E-Series) or
when the WATER IN FUEL message appears in the message center
(F-Super Duty).
The fuel injectors are located in the center of the combustion chambers
in the cylinder head between the rocker arm assemblies. The glow plug
system and fuel injection system are controlled through the Powertrain
Control Module (PCM) and Fuel Injection Control Module (FICM) (6.0L
engine only).
Fuel is drawn from the fuel tank by a frame-mounted electric fuel pump.
The fuel pump provides pressurized fuel to the engine and is
electronically controlled by the fuel pump PCM relay. The fuel pump
contains a pressure relief valve for overpressure protection in the event
of restricted flow.
Engine protection mode
Ford diesel engines are equipped with engine protection and emission
control systems. These systems monitor critical temperatures and
pressures and modify engine operation accordingly. These features are
intended to modify engine performance characteristics. If these modified
engine performance characteristics persist for an extended period or the
Check Engine (
) or Powertrain malfunction/Reduced
power/Electronic throttle control light (
) is illuminated, seek
service from your authorized dealer.
Lubrication system
Extended oil change intervals can negatively affect engine performance,
fuel economy and engine life. Refer to the engine oil specification chart
located underEngine oil specificationsin theMaintenance and
Specificationschapter of this supplement.
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Introduction
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FCM (E-Series) or an HFCM (F-Super Duty) which acts as a fuel
filter/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 the 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
14full. This will help prevent
air from entering the fuel system and stalling the engine.
In cold weather below 32°F (0°C), the engine will slowly increase to a
higher idle speed if left idling in P (Park). As the engine warms-up, 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 inside the air filter assembly. Take the top off the
assembly, leaving the air filter in, and remove any snow or ice.
In order to operate the engine in temperatures of 32°F (0°C) or lower,
read the following instructions:
•Make sure that the batteries are of sufficient size and are fully
charged. Check other electrical components to make sure they are in
optimum condition.
•Use Motorcraft Premium Gold Engine Coolant solution at the
concentration recommended to protect the engine against damage
from freezing.
•Try to keep the fuel tank full as much as possible at the end of
operation to prevent condensation in the fuel system.
•Make sure you use proper cold weather engine oil and that it is at its
proper level. Also, if necessary, make sure to follow the engine oil and
filter change schedule found under theSpecial Operating Conditions
section in theScheduled Maintenance Guidechapter.
•At temperatures of -10°F (-23°C) or below, it is recommended that
you use an engine block heater to improve cold engine starting.
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Driving
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The Horizontal Fuel Conditioner Module (HFCM) is located on the
frame-rail under the driver-side floorboard near the transmission.
SCHEDULED MAINTENANCE
The scheduled maintenance services in thescheduled maintenance
informationof this supplement are required because they are
considered essential to the life and performance of your vehicle.
Use only recommended fuel, lubricants, fluids and service parts
conforming to Ford specifications. Motorcraft parts are designed and
built for best performance in your vehicle.
FUEL REQUIREMENTS - CHOOSING THE RIGHT FUEL: VEHICLES
OPERATED WHERE ULTRA LOW SULFUR DIESEL FUEL IS
REQUIRED (UNITED STATES/CANADA/PUERTO RICO/U.S. VIRGIN
ISLANDS AND OTHER LOCALES)
Use only Ultra Low Sulfur (15 ppm Sulfur Maximum) number 1-D
or 2-D diesel fuel in your 6.0L or 6.4L diesel engine.The engine
and exhaust system were designed to only use this fuel. Look for the
ULTRA-LOW SULFUR HIGHWAY DIESEL FUEL (15 ppm Sulfur
Maximum)label on fuel pumps when purchasing your fuel.
Using low sulfur diesel fuel (16-500 ppm) or high sulfur diesel
fuel (greater than 500 ppm) in a 6.4L diesel engine designed to
use only Ultra Low Sulfur Diesel fuel will cause certain emission
components to malfunction which may also cause the Check
Engine(
)light to illuminate indicating an emissions-related
concern.
Number 1-D or winter blend number 2-D fuel is recommended at
temperatures below 20°F (-7°C) (seeCold weather operationin the
Drivingchapter of this supplement). Diesel fuel containing no more
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Maintenance and Specifications
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DRAINING THE FCM/HFCM AND CHANGING THE ENGINE AND
VEHICLE FUEL FILTERS
Your vehicle is equipped with two fuel filters; one is mounted on top of
the engine.On F-Super Duty,the second filter, inside the HFCM, is
mounted inside the frame rail under the driver-side floorboard near the
transmission.On E-Series,the second filter, inside the FCM, is mounted
on the driver-side of the vehicle next to the transmission case.On all
vehicles,both filters should be replaced at the same time. Regular fuel
filter changes are an important part of engine maintenance; failing to
keep with the scheduled maintenance could lead to engine performance
issues and/or fuel injection system damage. Refer to theScheduled
Maintenance Guidechapter of this supplement for more information.
Refer toMotorcraft Part Numberslater in this chapter for the fuel filter
replacement part number. This part number includes filters and seals for
both the engine-mounted and frame-mounted filters.
1. Stop the vehicle andshut offthe engine.
The vehicle must be stopped with the engine off when draining
the HFCM/FCM. Fuel may ignite if the separator is drained while
the engine is running or vehicle is moving.
2. Locate the HFCM and place an appropriate container under the drain
port (see illustration).
•E-Series
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Maintenance and Specifications
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F-Super Duty vehicles (6.4L engine):
•An engine block heater must be used at temperatures below
–10°F (–23°C).
•Use the same engine oil and filter change intervals when using
synthetic engine oil.
•Heavier 15W–40 and 5W–40 engine oils are recommended for
temperature over 50°F (10°C) and must be used for heavy duty
driving and trailer towing.
A symbol has been developed by the
American Petroleum Institute (API)
to help you select the proper engine
oil. It will be included on the oil
container you purchase. The top
section of the symbol shows the oil
performance by the API designation.
This should match the owner guide recommendation. The center section
will show the SAE viscosity grade
Changing engine oil and filter
Change your oil and filter according to thescheduled maintenance
informationin this supplement. Change more frequently if your vehicle
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Maintenance and Specifications
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SCHEDULED MAINTENANCE GUIDE
Vehicle Identification Number (VIN):
Owner Name:
Address:
Note:Use only a 6.4L diesel engine that has been configured for use with
high sulfur diesel fuel in markets with diesel fuel that has sulfur content
greater than 15 ppm. Using low sulfur diesel fuel (16–500 ppm) or high
sulfur diesel fuel (greater than 500 ppm) in a 6.4L diesel engine
designed to use only Ultra Low Sulfur Diesel fuel increases the likelihood
of engine oil dilution with fuel which may lead to major engine damage.
Vehicles that are operated in high sulfur diesel fuel markets must be
configured for the high sulfur fuel and require a different maintenance
schedule.
GENERAL MAINTENANCE INFORMATION
Why maintain your vehicle?
This guide describes the scheduled maintenance required for your
vehicle. Carefully following this schedule helps protect against major
repair expenses resulting from neglect or inadequate maintenance and
may also help to increase the value of your vehicle when you sell or
trade it.
It is your responsibility to see that all scheduled maintenance is
performed and that the materials used meet Ford engineering
specifications. Failure to perform scheduled maintenance in this guide
will invalidate warranty coverage on parts affected by the lack of
maintenance. Be sure receipts for completed maintenance are kept with
the vehicle and confirmation of the work performed is always recorded in
this guide.
Your Ford or Lincoln Mercury dealer, or Ford or Lincoln Mercury Quality
Care Center has factory trained technicians who can perform the
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required maintenance using genuine Ford parts. They are committed to
meeting your service needs and to assuring your continuing satisfaction.
Protecting your investment
Maintenance is an investment that will pay dividends in the form of
improved reliability, durability and resale value. To ensure the proper
performance of your vehicle and its emission control systems, it is
imperative that scheduled maintenance be completed at the designated
intervals.
Your vehicle is very sophisticated and built with multiple complex
performance systems. Every manufacturer develops these systems using
different specifications and performance features. That’s why it’s
important to rely upon your Ford or Lincoln Mercury dealership to
properly diagnose and repair your vehicle.
Ford Motor Company has recommended maintenance intervals for
various parts and component systems based upon engineering testing.
Ford Motor Company relies upon this testing to determine the most
appropriate mileage for replacement of oils and fluids to protect your
vehicle at the lowest overall cost to you and recommends against
maintenance schedules that deviate from the scheduled maintenance
information.
Ford strongly recommends the use of genuine Ford replacement parts.
Parts other than Ford, Motorcraft or Ford authorized remanufactured
parts that are used for maintenance replacement or for the service of
components affecting emission control must be equivalent to genuine
Ford Motor Company parts in performance and durability. It is the
owner’s responsibility to determine the equivalency of such parts. Please
consult yourWarranty Guidefor complete warranty information.
Non-Ford approved chemicals or additives are not required for factory
recommended maintenance. In fact, Ford Motor Company recommends
against the use of such additive products unless specifically
recommended by Ford for a particular application.
Oils, Fluids and Flushing
In many cases, fluid discoloration is a normal operating characteristic of
the chemical compound and may not necessarily demonstrate that a fluid
needs to be changed. Oils and fluids identified in this guide should be
changed at the specified interval or in conjunction with a repair. Flushing
is a viable way to change fluid for many vehicle sub-systems during
scheduled maintenance and should only be done using the same fluid
required to finish the maintenance procedure, or a Ford approved
flushing chemical.
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