Page 3 of 274
Maintenance and Specifications 169
Hood 177
Engine oil 180
Battery 180
Engine coolant 183
Fuel information 184
Wheel lug nut torque 210
Tire information 210
Lubricant specifications 218
Refill capacities 230
Scheduled Maintenance Guide 235
Index 270
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system or translation in whole or part is not permitted without written
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Copyright © 2009 Ford Motor Company
Table of Contents
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These are some of the symbols you may see on your vehicle.
Vehicle Symbol Glossary
Safety Alert
See Owner’s Guide
Fasten Safety BeltAirbag - Front
Airbag - SideChild Seat Lower
Anchor
Child Seat Tether
AnchorBrake System
Anti-Lock Brake SystemParking Brake System
Brake Fluid -
Non-Petroleum BasedParking Aid System
Stability Control SystemSpeed Control
Master Lighting SwitchHazard Warning Flasher
Fog Lamps-FrontFuse Compartment
Fuel Pump ResetWindshield Wash/Wipe
Windshield
Defrost/DemistRear Window
Defrost/Demist
Introduction
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Vehicle Symbol Glossary
Power Windows
Front/Rear
Power Window Lockout
Child Safety Door
Lock/UnlockInterior Luggage
Compartment Release
Panic AlarmEngine Oil
Engine CoolantEngine Coolant
Temperature
Do Not Open When HotBattery
Avoid Smoking, Flames,
or SparksBattery Acid
Explosive GasFan Warning
Power Steering FluidMaintain Correct Fluid
LevelMAX
MIN
Service Engine SoonEngine Air Filter
Passenger Compartment
Air FilterJack
Check Fuel CapLow Tire Pressure
Warning
Introduction
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USA(fus)
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Driver/Fuel area
Fuel tank(s):Make sure the fuel tank(s) and cap(s) are
secure. Make sure there is no damage to the
tank(s).
Leaks:Check for any leaks from the fuel tank(s).
Underbody of vehicle
Driveshaft:Make sure that the driveshaft is not bent or
cracked. Ensure all driveshaft couplings are
secure.
Exhaust system:Make sure the outside visible parts are
securely mounted. Make sure there are no
cracks, holes or severe dents.
Frame:Check for cracks or bends in longitudinal
frame members. Make sure there are no loose,
cracked, bent, broken or missing
crossmembers or crossmember fasteners.
WARNING:Maintain adequate clearance between all parts of
the exhaust system and all hoses, wires and lines for engine
cooling, brake system, fuel system, power steering system and
electrical system, Heat damage to hoses, wires or lines may cause
vehicle malfunction that could result in property damage, personal
injury or death.
Vehicle Inspection Guide
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Water in fuel:During refueling, it
is possible for water-contaminated
diesel fuel to be pumped into your
tank. Your vehicle fuel system is
equipped with a fuel filter/water
separator to remove water from the fuel. The WATER IN FUEL light will
illuminate when the fuel filter/water separator has a significant quantity
of water in it.
If the light illuminates when the engine is running, stop the vehicle as
soon as safely possible, shut off the engine, then drain the fuel
filter/water separator. Refer to your engine operator’s manual for the
drain procedure. Allowing water to stay in the system could result in
extensive damage to, or failure of, the fuel injection system.
WARNING:Do not drain water separator while engine is
running. Fuel may ignite if separator is drained while engine is
running or vehicle is moving.
Traction control (if equipped):
Illuminates and flashes slowly if the
Off Road or Mud/Snow mode is
selected and flashes rapidly during a
traction control event.
Differential lock:Illuminates when
the main differential is locked
(engaged).
Parking brake warning:
Momentarily illuminates when the
ignition is turned to the on position
and the engine is off. Also
illuminates when the parking brake
is engaged. If the parking brake
warning lamp does not illuminate at
these times, seek service immediately.
Vehicles equipped with the Power Park Parking Brake option:If
after setting the parking brake on your vehicle the park brake warning
lamp begins to blink, this may indicate a failure in the parking brake
system. Seek service from your dealer immediately.
WATER
IN
FUEL
P
BRAKE
Instrument Cluster
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USA(fus)
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Trip odometer:Registers the miles
(kilometers) of individual journeys.
To reset, press the control.
Fuel gauge:Indicates
approximately how much fuel is left
in the fuel tank (when the ignition
is in the on position). If your vehicle
is equipped with dual fuel tanks, the
engine will draw fuel from the
driver-side fuel tank only. With dual
fuel tanks, the vehicle will be
equipped with a fuel transfer pump system that will draw fuel from the
passenger-side fuel tank and send fuel to the driver-side fuel tank. The
driver-side fuel tank must have fuel in it at all times otherwise the
vehicle may stall and may be difficult to re-start. The fuel gauge reads
the fuel level only from the driver-side fuel tank.
Engine coolant temperature
gauge:Indicates engine coolant
temperature. At normal operating
temperature, the needle will be in
the normal range (as indicated by
the arrows).If it enters the red
section, the engine is
overheating. Stop the vehicle as
soon as safely possible, switch
off the engine and let the engine
cool.
WARNING:Never remove the coolant reservoir cap while the
engine is running or hot. The contents may be under pressure,
and could cause burns or other serious injury.
H
C
Instrument Cluster
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STARTING
Positions of the ignition
1. ACCESSORY, allows the electrical
accessories such as the radio to
operate while the engine is not
running.
2. LOCK, locks the steering wheel,
automatic transmission gearshift
lever and allows key removal.
3. OFF, shuts off the engine and all
accessories without locking the
steering wheel.
4. ON, all electrical circuits operational. Warning lights illuminated. Key
position when driving.
5. START, cranks the engine. Release the key as soon as the engine
starts.
Starting the engine
WARNING:Operation of a diesel engine near flammable vapors
in the air may cause the engine speed to increase uncontrollably
and over speed. If this situation occurs, mechanical damage, fire,
explosion, personal injury or death could result.Turning off the
ignition key will not slow or stop the engine due to uncontrollable
fueling of the engine through flammable vapors being drawn into
the engine air inlet.Operation of components such as starter,
alternator, electric motors, etc. and static electricity could also ignite
flammable vapors.
Do not operate the truck in the possible presence of flammable vapors
unless both a complete hazard analysis is performed and necessary
additional safety processes and/or equipment such as vapor testing, air
intake shutoff devices, ventilation, etc. are utilized. The operator is
responsible for using those processes and/or equipment to ensure that
the diesel engine and all other components on the truck can be
operated safely under the specific conditions and hazards that may be
encountered.
Note:If equipped with Eaton UltraShift transmission, allow UltraShift to
power up before starting the engine. Engine cranking is delayed until the
transmission power up is complete and the gear display shows a solid N.
3
1
2
5
4
Driving
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•Do not increase engine speed
until the oil pressure gauge
indicates normal pressure (as
indicated by the arrows); this
should be indicated on the gauge
within 15 seconds after starting.
•Idle the engine for three to five
minutes before operating with a
full load.
•Try to limit engine idle to
10 minutes. Excessive idling reduces fuel economy.
•When starting a cold engine, increase the engine speed (RPM) slowly
to make sure adequate lubrication is available to the bearings.
Cold weather operation
WARNING:Do not use volatile starting aids such as ether,
propane or gasoline in the engine air intake system. Glow plugs
may ignite vapors which can cause engine damage or personal injury.
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’re in
optimum condition.
•Use a permanent-type engine coolant solution to protect the engine
against damage from freezing.
•If your vehicle is equipped with a water-fuel separator, drain it daily.
Fill the fuel tank at the end of daily 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.
•At temperatures of –4°F (–20°C) or below, it is recommended that you
use a crankcase-mounted coolant heater to improve cold engine
starting.
•If operating in arctic temperatures of –20°F (–29°C) or lower, consult
your truck dealer for information about special cold weather
equipment and precautions.
Driving
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