This inspection should be performed by a qualified technician and must
be in accordance with instructions provided by the service manual.
Note:Hydraulic brake systems are power assisted. Braking capabilities
will be greatly reduced without engine assist.
Fluid level
Fluid level should be at the bottom edge of the ring on each reservoir fill
port. Do not fill the master cylinder to the top of the reservoir.
Note:If brake fluid requires attention to maintain a proper master
cylinder level, this is an indication of either severe operation (pad wear)
or fluid system leakage. A more frequent and thorough brake inspection
will be required.
Brake lines, hoses and fittings
Inspect these components every 4,000 miles (6,000 km).
•Check lines for kinks, dents, corrosion or rupture.
•Check hoses for abrasions, kinks, soft spots or rupture, collapse,
cracks, twists or loose frame supports. When replacing a hose, be sure
there is adequate clearance to the hose to avoid an abrasion to the
new hose.
•Examine all connections for leaks.
•Repair or replace brake line tubes, hoses or fittings as required.
Driveline parking brake
Parking brake adjustment should only be performed by a qualified
technician, and in accordance with the instructions in the service
manual.
WARNING:Use wheel chocks and exercise caution when
inspecting under the vehicle. A vehicle roll-away could result in
property damage, personal injury or death.
Catalytic converter
If your diesel engine is equipped with a catalytic converter, it is
important to review the maintenance schedule to ensure proper
functioning of the catalytic converter. Also, take precautions not to
damage the catalytic converter when servicing your engine or storing
your vehicle.
Note:If your vehicle is equipped with a catalytic converter/muffler,do
notblend waste oil with Diesel fuel. Operate only on ultra low sulfur
(less than 15 parts per million sulfur) diesel fuel with a cetane value of
45 or higher.
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CHANGING THE WIPER BLADES
1. Pull the wiper arm away from the
vehicle. Pry open the lock cover
with your thumb (1) to release the
blade and pull the wiper blade down
toward the windshield to remove it
from the arm (2).
2. Insert the wiper arm hook into
the wiper arm (3).
Replace wiper blades at least once
per year for optimum performance.
Poor wiper quality can be improved by cleaning the wiper blades and the
windshield. Refer toWindows and wiper bladesin theCleaning
chapter.
To prolong the life of the wiper blades, it is highly recommended to
scrape off the ice on the windshield before turning on the wipers. The
layer of ice has many sharp edges and can damage the micro edge of the
wiper rubber element.
ENGINE OIL
Refer to your engine operator’s manual for information on checking and
adding engine oil as well as engine oil specifications, capacities and
required maintenance.
BATTERY
Your vehicle is equipped with two or three maintenance-free batteries
which are mounted in a covered tray and located on the left frame rail.
The covered battery tray, depending upon application, may also have one
or two steps attached.
WARNING:This vehicle is equipped with more than one
battery, removal of cable from only one battery does not
disconnect the vehicle electrical system. Be sure to disconnect cables
from all batteries when disconnecting power. Failure to do so may
cause serious personal injury or property damage.
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1. Bring the vehicle to a complete stop on level ground and safely off the
road with the exhaust system away from people, flammable materials,
vapors or structures. Ford recommends that you perform a walk-around
to check before commencing parked regeneration.
2. If your vehicle is equipped with an automatic transmission and a
steering column shift lever, place transmission in P (Park). Otherwise,
place the transmission in N (Neutral).
3. Remove feet from the accelerator pedal and clutch pedal (if
equipped).
4. Set the parking brake.
5.Within 5 seconds of setting the parking brake,remove foot from
the service brake pedal.
The engine speed may increase slightly. To allow parked regeneration to
continue uninterrupted:
1. The vehicle must remain parked
2. The transmission must remain in P (Park) or N (Neutral) (as
previously described in Step 2).
3. The accelerator pedal, service brake pedal, and clutch pedal (if
equipped) must not be pressed
4. The parking brake must remain set
On average (depending on filter level and other factors), the process will
take 20–30 minutes to complete. The DPF lamp will turn off when the
process is complete. Repeat Steps 1–5, if parked regeneration is
interrupted.
To discontinue parked regeneration
Press any of the floor pedals to discontinue parked regeneration.
Diesel particulate filter maintenance and service
The DPF is designed to retain a relatively large amount of residual ash
and provide many miles and hours of maintenance-free operation. At
some point, generally beyond 150,000 miles (240,000 km) or 5,000 hours
of operation (whichever comes first), the DPF will require professional
cleaning to remove the accumulated ash
The exact number of miles or hours of operation will vary greatly
depending upon vehicle/engine loading and operating conditions, ash
content of the engine oil, and quality of the diesel fuel used in your
truck. Adhering to your engine manufacturer’s recommended oil and fuel
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Cooling System
•Check the fan for damage to blades; replace, if damaged, with the
recommended parts. Inspect for fan to shroud interference, and any
damage to shroud such as cracks and holes.
•The fan ratio should not be changed and the fan spacer dimensions
and positions should not be altered.
•Inspect the fan clutch for proper operation, make sure that the fan is
disengaged when cooling of the engine is not required.
•Check for proper operation of radiator shutters, if equipped. The
shutters should be open during normal operating temperatures.
Engine and Driveline System
•Transmission Enclosure:inspect for cracks, holes, and tears. Clean
any deposits such as oil, dirt, and stones.
•Engine valve covers and block covers are made to damp out engine
mechanical noise and, if needed, should be replaced with
recommended parts. Check for mechanical isolations.
Exhaust System
•Inspect the exhaust system for leaks at various joint connections and
tighten the clamps.
•Do a visual inspection for cracks or holes in the muffler and tail pipe.
•Always use the recommended parts when items need to be replaced.
•The tail pipe elbow or offset tail pipe orientation must not be changed
from the standard position as originally received.
•To avoid abnormal changes in vehicle sound levels, it is necessary for
the owner to perform inspections and necessary maintenance at the
intervals shown in theScheduled Maintenance Guidechapter.
POWER STEERING FLUID
Check the power steering fluid level using the following procedure. If
adding fluid is necessary, refer toLubricant Specificationsin this
chapter for the proper fluid type. Refer to theScheduled Maintenance
Guidechapter for the recommended service intervals.
1. Set the parking brake, shift into N (Neutral) (automatic transmission)
or 1 (First) (manual transmission) and turn the engine off.
2. Open the hood.
3. Clean the top of the power steering fluid reservoir.
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SUSPENSION INSPECTION
Note:Do not adjust air suspension height to any setting other than the
specified setting. Altering the height setting will change the driveline
angle and may result in unwarrantable component damage, such as
transmission component damage.
Verify drive axle air suspension height and height control valve
performance at engine lube oil change intervals.
Periodically:
•Check condition of spring leaves for evidence of fatigue, bending or
breakage.
•Check condition of suspension mounting brackets and bushings.
•Check that torque rod mounting fasteners are tight.
•Check to be sure the suspension alignment is maintained at all times.
•Check U-bolts after the chassis has been operating under load for
1,000 miles (1,600 km) or six months, whichever comes first, the
U-bolt nuts must be re-torqued. The U-bolt nuts thereafter must be
re-torqued every 36,000 miles (58,000 km). The U-bolt and nut
threads and seats should be cleaned and lubricated to ensure a “like
new” condition when re-torquing.
Note:See theU-bolt nut torquechart later in this section.
Supporting your vehicle for service
When performing service repairs on your vehicle, first prepare the
vehicle by doing the following:
1. Park the vehicle on a level concrete floor.
2. Set the parking brake and block the wheels to prevent the vehicle
from moving.
3. Select a jack with a rated capacity sufficient to lift and hold up the
vehicle.
4. Raise the vehicle with the jack applied to the axle(s). DO NOT use the
bumper as a lifting point.
5. Support the vehicle with floor stands under the axle(s). If the axle or
the suspension are being serviced, support the vehicle with floor stands
under the frame side-members, preferably between the axles.
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Draining and refilling the rear axle lubricant
1. Drain the rear axle while the lubricant is warm.
2. Park the vehicle on level ground.
3. Set the parking brake and shift into N (Neutral) (automatic
transmission) or 1 (First) (manual transmission) and turn the engine off.
4. Clean any dirt from around the rear axle filler and drain plugs.
5. Remove the filler and drain plugs and drain the lubricant into a
suitable container. Dispose of all used automotive fluids in a responsible
manner following your local authorized standards.
6. Clean and install the drain plug securely.
7. Add enough lubricant through the filler plug opening so that the
lubricant level is up to the bottom of the opening.
8. Clean and install the filler plug securely.
WHEELS
General
Wheel bearings should be inspected, lubricated and adjusted at regular
intervals. This is especially important if operating in deep sand, mud, or
water. Refer toLubricant specificationsin this chapter.
When installing wheel balance weights, they must be mounted on the
dome-side of the wheel only. Failure to do so may result in loss of wheel
weight and/or damage to brakes or wheels.
Important:Remember to replace the wheel air valves when the road
tires are replaced at the end of their useful life.
Oil-lubricated front wheel bearings
During normal vehicle duty cycle, the lube and air inside the hub/wheel
cavity expands and if not vented, causes pressure build-up that could
cause accelerated seal wear.
There are two venting methods:
•a slit or small hole in the rubber check vent or
•the window
You can use either of these methods to prevent pressure build-up.
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Normal maintenance
Over a period of time, if not routinely cleaned, a slight film of oil can
collect dirt around the rubber fill plug and face, which could appear to
be a leak. Routine cleaning ensures that the lube level can be easily
observed through the clear window as intended. In situations where the
window is clean on the outside but discolored on the inside, the lube
level may be checked by inserting a finger through the rubber check
vent hole.
The specified lube level for a clear window type hubcaps is from the
minimum line to + 5/16 inch above the minimum line.
If the lube level should suddenly drop dramatically below the minimum
level, see theWorkshop Manualfor diagnostic procedure.
Installation, tightening and alignment
When installing wheels, be certain that the threads on studs and nuts are
clean to permit correct torque. The mounting surfaces of rims, wheels,
spacer rings and clamps must be free of dirt, rust, lubricants or damage.
Use a wire brush to clean the mounting contact surfaces. Do not use
lubricant on threads.
After the rim or wheel has been properly tightened, it should be checked
for alignment. Rotate the wheel with a piece of chalk attached to a
steady, firm surface, and placed to just barely clear the outside surface of
the tire bead seat. This procedure will point out the high spot. A high
spot does not necessarily mean that the lug nuts have been unevenly
tightened. This condition or misalignment could be caused by a bent
wheel.
Use the following installation procedure:
1. Slide inner rear or front tire and wheel in position over studs and push
it back as far as possible. Use care so that the threads on studs are not
damaged.
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Oils, fluids and flushing
In many cases, fluid discoloration is a normal operating characteristic
and, by itself, does not necessarily indicate a concern or that the fluid
needs to be changed. However, discolored fluids that also show signs of
overheating and/or foreign material contamination should be inspected
immediately by a qualified expert such as the factory-trained technicians
at your authorized servicing dealership. Your vehicle’s oils and fluids
should be changed at the specified intervals or in conjunction with a
repair. Flushing is a viable way to change fluid for many vehicle
sub-systems during scheduled maintenance. It is critical that systems are
flushed only with new fluid that is the same as that required to fill and
operate the system, or using a Ford-approved flushing chemical.
OWNER MAINTENANCE
You can do much of the maintenance your vehicle requires yourself, if
you have the time and a reasonable amount of mechanical ability. If you
prefer to have this work done professionally, your authorized dealer
stands ready to help you.
All mechanical components and attachments are important in that they
could affect the performance of vital components and systems. If
replacement becomes necessary, they must be replaced with parts having
the same part number or with equivalent parts. Torque values of the
attaching parts must be used as specified during any reassembly
procedure to ensure proper retention.
Daily owner checks
EngineAir filter restriction gauge
Engine oil level
Engine coolant level
Brake systemAir brake reservoir automatic drain valve
operation
Drain the air brake reservoir (manual valve)
TransmissionVisually check for fluid leakage
Steering systemPower steering pump fluid level and check the
system for leaks
Entire vehicle for evidence of fluid leaks
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