2010 FORD SUPER DUTY maintenance schedule

Introduction
2
Instrument Cluster
7
Driving
11
Roadside Emergencies
24
Cleaning
30
Maintenance and Specifications
33
Scheduled Maintenance: General Information
61
Scheduled Maintenance: E-Series
67
Scheduled Maintenance: F-Super Duty
84
Scheduled Maintenance: Special Information
101
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Table of Contents
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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
filter filters finer impurities from the diesel 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.
F-Super Duty
E-Series
The FCM/HFCM should be drained at regular intervals or when the
WATER IN FUEL light illuminates in the instrument cluster.
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
service engine soon
or powertrain malfunction/reduced
power/electronic throttle control light
is illuminated, seek service
from your authorized dealer.
Introduction
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•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 guideinformation.
•At temperatures of -10°F (-23°C) or below, it is recommended that
you use an engine block 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.
Note:Idling in cold weather will not heat the engine to its normal
operating temperature. Long periods of idling in cold weather can cause
a buildup of heavy deposits of carbon and rust on valve stems causing
them to stick, which in turn, can cause valve train damage.
The following cold weather idling guidelines must be followed:
•Avoid idling the engine for more than 10 minutes at a time.
•Use Motorcraft Cetane improvers or non alcohol-based cetane
improvers from a reputable manufacturer.
•Maintain the engine cooling system properly.
•Do not shut the engine down after an extensive idling period
(10 minutes or more). Drive the vehicle for several miles with the
engine at normal operating temperatures under a moderate load to
burn off any accumulated carbon and varnish.
•Consider using an engine block heater.
•For extended idle times use an approved idle speed increase device.
Winter operating tips for Arctic operation -20°F (-29°C) and below
The following information is provided as a guideline only, and is not
intended to be the only source of possible solutions in resolving extreme
cold temperature issues.
Starting aids:
The use of the factory engine block heater (refer toEngine block heater
[if equipped]in theDrivingchapter of theOwner’s Guide) and oil pan
heaters (aftermarket) will assist in engine starting, in extreme cold
ambient temperatures.
WARNING:Do not use starting fluid, such as ether, in the air
intake system (see air filter decal). Such fluid could cause
immediate explosive damage to the engine and possible personal injury.
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 (also known as ULSD) in your 6.4L diesel
engine.The engine and exhaust system were designed to only use this
fuel. Look for theULTRA-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 Service
Engine Soon(
)light to illuminate indicating an
emissions-related concern.
Maintenance and Specifications
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(exhaust catalyst and particulate filter) failures. Concentrations greater
than 5% can also cause fuel filter restrictions that may result in a lack of
power and or damage to components such as fuel tank, fuel lines, fuel
pump, fuel sender and fuel injectors fuel pump and fuel injector failures.
Look for a label on the fuel pump to confirm the amount of biodiesel
contained in a diesel fuel. Biodiesel content is often indicated with the
letter “B” followed by the percent of biodiesel in the fuel. For example,
B5 indicates a fuel containing 5% biodiesel. Ask the service station
attendant to confirm the biodiesel content of a diesel fuel if you do not
see a label on the fuel pump.
Biodiesel should not be stored in the fuel tank for more than three
months. If your vehicle will be parked or stored for more than three
months, then your vehicle should be drained and filled with a diesel fuel
not containing biodiesel.
During cold weather, if you have problems operating on biodiesel, you
may need to use a diesel fuel with lower biodiesel content, try another
brand, or discontinue the use of biodiesel.
Biodiesel use may affect the recommended oil change intervals. Refer to
theSpecial operating conditionssection in theschedule maintenance
guidefor more information about oil change intervals and other
maintenance when operating on biodiesel.
Biodiesel fuel is a product that has been converted from renewable fuel
sources, including vegetable oil, animal fat and cooking oil. Raw or
refined vegetable oil, animal fat, cooking oil or recycled greases should
NOTbe used.
WARNING:Do not use home heating oil, agricultural fuel or any
diesel fuel not intended for highway use. Damage to the fuel
injection system, engine and exhaust catalyst can occur if an improper
fuel is used. Do not add gasoline, gasohol or alcohol to diesel fuel. This
practice creates a serious fire hazard and engine performance
problems.
Fuel quality
It should not be necessary to add any aftermarket additives to your fuel
tank if you use a properly formulated diesel fuel that meets the ASTM D
975 industry specification. Aftermarket additives can damage the injector
system or engine. Repairs to correct the effects of using an aftermarket
product in your fuel may not be covered by your warranty.
Maintenance and Specifications
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FUEL FILTER/WATER SEPARATOR
Fuel Conditioner Module (FCM - E-Series)
The vehicle is equipped with a Fuel Conditioning Module (FCM) located
on the driver-side of the vehicle next to the transmission case.
Water should be drained from the
module assembly whenever the
warning light comes on. The WATER
IN FUEL light will come on when
approximately 0.2 pints (100 ml) of water accumulates in the module. If
water level is allowed to exceed this level, the water may be passed
through to the engine and may cause FIE (Fuel Injection Equipment)
damage.
Horizontal Fuel Conditioner Module (HFCM - F-Super Duty)
The vehicle is equipped with a Horizontal Fuel Conditioning Module
(HFCM) located on the frame-rail under the driver-side floorboard near
the transmission
Water should be drained from the
module assembly whenever the
warning light comes on. The WATER
IN FUEL light will come on when
approximately 0.13–0.16 pints (60–75 ml) of water accumulates in the
module. If water level is allowed to exceed this level, the water may be
passed through to the engine and may cause FIE (Fuel Injection
Equipment) damage.
DRAINING THE 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.
Maintenance and Specifications
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Changing engine oil and filter
Change your oil and filter according to thescheduled maintenance
informationin this supplement. Change more frequently if your vehicle
operation includes extended periods of idling or low-speed operation,
driving for a long time in cold temperatures or driving short distances.
See the following sectionEngine lubrication for severe service
operationfor all severe duty restrictions.
Refer toMotorcraft part numberslater in this chapter for the engine oil
filter part number. This filter protects your engine by filtering harmful,
abrasive or sludge particles and particles significantly smaller than most
available “will-fit” filters.
To replace the filter,
1. Unscrew the oil filter cap and wait a few seconds for the oil to drain
through the built-in drain valve.Note:The filter should be changed
before reinstalling the oil pan drain plug.
2. Reinstall and tighten the oil filter cap.
WARNING:Do not handle a hot oil filter with bare hands.
WARNING:Continuous contact with USED motor oil has caused
cancer in laboratory mice. Protect your skin by washing with
soap and water.
Engine lubrication for severe service operation
The following severe service operating conditions require unique engine
maintenance procedures:
•frequent or extended idling (over 10 minutes per hour of normal
driving).
•if vehicle is operated in sustained ambient temperatures below -10°F
(-23°C) or above 100°F (38°C)
•frequent low speed operation, consistent heavy traffic less than
25 mph (40 km/h)
•operating in severe dust conditions.
•towing a trailer over 1,000 miles (1,600 km)
•sustained, high speed driving at Gross Vehicle Weight Rating
(maximum loaded weight for vehicle operation)
Maintenance and Specifications
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Item Capacity Ford part nameFord part number /
Ford specification
Manual transmission
fluid5 .8 quarts (5.5L) Full Synthetic OilXT-M5-QS /
WSS-M2C200-C
Automatic transmission
fluid
4
17.5 quarts
(16.6L)
5
Motorcraft MERCON
LV AT FXT-10-QLV / MERCON
LV
1Includes heater and 5.0 quarts (4.7L) in coolant recovery.2Includes 1 quart (1.0L) in oil filter.3Only use coolant meeting Ford specifications for topping off and coolant changes. Using any
other coolant may result in vehicle damage.4Ensure the correct automatic transmission fluid is used. Transmission fluid requirements are
indicated on the dipstick blade or the dipstick handle. Check the container to verify the fluid being
added is of the correct type. Refer to your scheduled maintenance information to determine the
correct service interval.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.
Maintenance and Specifications
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