3. Remove the jumper cable from the positive (+) terminal of the booster
vehicle’s battery.
4. Remove the jumper cable from the positive (+) terminal of the
disabled vehicle’s battery.
After the disabled vehicle has been started and the jumper cables
removed, allow it to idle for several minutes so the engine computer can
relearnits idle conditions.
WRECKER TOWING INSTRUCTIONS
Before moving the disabled vehicle, check for adequate road clearance of
vehicle components. It is recommended the disabled vehicle be unloaded
prior to being towed to reduce any abnormal load to the vehicle
components resulting from the towing procedures. Before towing, be
sure to fully release the parking brake. The spring-actuated type parking
brake can be reset by recharging the air system with at least 64 psi
(441 kPa) of air. If the brake system will not retain air pressure, then the
spring brakes must be released manually. Refer toParking brakein the
Drivingchapter.
Note:For towing, make sure the vehicle is securely connected to the
tow vehicle and the tow vehicle’s parking brakes are applied before
releasing the disabled vehicle’s spring brakes.
+–+–
+–+–
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GENERAL SERVICING GUIDELINES AND PRECAUTIONS
As with any machine, care should be taken to avoid being injured when
performing maintenance, repairs or system checks. Improper or
incomplete service could result in the vehicle not working properly
which, in turn, may result in personal injury or damage to the vehicle or
equipment. It is the operator’s responsibility to see that the vehicle
receives proper care and maintenance. If you have any questions about
performing some service, have the service done by a qualified technician.
Servicing guidelines
When servicing your vehicle, always:
•turn off the ignition unless the particular procedure calls for the
engine to be running.
•set the parking brake or chock the wheels.
•use support stands, not a jack, whenever you must be under a raised
vehicle.
•do not smoke.
•wear safety glasses for eye protection.
•operate the engine in a well-ventilated area
•do not work on the brakes or the clutch unless the proper precautions
are taken to avoid inhaling friction material dust.
•do not wear loose-fitting clothing, hanging jewelry, watches or rings.
•avoid contact with hot metal parts. Allow the hot components to cool
before working with, or around them.
Quality service parts are available through your dealer. If dealer parts are
not used, the owner must make sure that the parts that are being used
are equivalent quality to dealer parts.
WARNING:The use of inferior parts can adversely affect the
quality and reliability of your vehicle which, in turn, can result in
property damage, personal injury or death.
Note:To avoid damage to the vehicle’s electrical components, disconnect
the positive (+) and negative (-) battery cables prior to electric welding.
Attach the welder ground cable as close as possible to the part being
welded. If it is necessary to weld close to an electrical component, it is
recommended that the electronic component be temporarily removed.
Follow the periodic lubrication procedures and regular inspection
intervals as outlined. Have your dealer or service center inspect your
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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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•Covered battery tray shown.
Battery tray with steps similar.
The two rubber straps on top of
the cover must be pulled up and
moved to the side of the battery
in order to remove the lid.
•Battery tray with cover removed.
Maintenance-free batteries do not normally require adding additional
water.
Make sure the battery cover/shield is reinstalled after the battery
has been cleaned or replaced.
For longer, trouble-free operation, keep the top of the batteries clean
and dry. Also, make certain the battery cables are always tightly fastened
to the battery terminals.
If you see any corrosion on the battery or terminals, remove the cables
from the terminals and clean with a wire brush. You can neutralize the
acid with a solution of baking soda and water.
It is recommended that the negative battery cable terminal be
disconnected from the battery if you plan to store your vehicle for an
extended period of time. This will minimize the discharge of your battery
during storage.
If the engine cranks but does not start, remove the battery box cover
and check the 40A inline fuse located on the battery cable above the
battery.
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WARNING:Batteries normally produce explosive gases which
can cause personal injury. Therefore, do not allow flames, sparks
or lighted substances to come near the battery. When working near the
battery, always shield your face and protect your eyes. Always provide
proper ventilation.
WARNING:When lifting a plastic-cased battery, excessive
pressure on the end walls could cause acid to flow through the
vent caps, resulting in personal injury and/or damage to the vehicle or
battery. Lift the battery with a battery carrier or with your hands on
opposite corners.
WARNING:Keep batteries out of reach of children. Batteries
contain sulfuric acid. Avoid contact with skin, eyes or clothing.
Shield your eyes when working near the battery to protect against
possible splashing of acid solution. In case of acid contact with skin or
eyes, flush immediately with water for a minimum of 15 minutes and
get prompt medical attention. If acid is swallowed, call a physician
immediately.
WARNING:Battery posts, terminals and related accessories
contain lead and lead compounds.Wash hands after handling.
Always dispose of automotive
batteries in a responsible manner.
Follow your local authorized
standards for disposal. Call your
local authorized recycling center to
find out more about recycling
automotive batteries.
LEAD
RETURN
RECYCLE
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7. Clean and install the filler plug securely.
CHASSIS-MOUNTED CHARGE AIR COOLER
Inspect charge air cooler daily
With the engine off, visually inspect the charge air cooler core assembly
for debris and clogging of external fins. Prior to engine operation,
remove any debris blocking the core.
•Turbocharger-to-charge air cooler
•Charge air cooler-to-intake manifold pipe
•Mounting bracket
•Chassis-mounted charge air cooler core
Inspect air intake piping
•Check for accumulation of salt deposits (where applicable). If present,
disassemble and clean the complete air intake piping system. If the
intake piping is pitted, use MotorcraftSilicone Gasket and Sealant
TA-30 to seal joints against leakage.
•Check for loose hoses and clamps.
•Check for ruptured or collapsed hoses.
•Check air cleaner housing for cracks.
ELECTRICAL SYSTEM INSPECTIONS
Periodically inspect electrical connectors on the outside of the cab, on
the engine and frame for corrosion and tightness. Exposed terminals
such as the fuel sender, cranking motor, alternator and feed-through
studs should be cleaned and re-coated with a lubricant sealing grease
such as MotorcraftSilicone Brake Caliper Grease and Dielectic
Compound XG-3, or equivalent. This should include the ground cable
connector for batteries, engine and cab as well as the jump starting stud.
Accessory feed connections
Vehicle electrical systems are complex and often include powertrain
components such as engine and transmission controls, instrument panels,
ABS, etc. While most systems operate on battery voltage (12 volts),
some systems can be as high as 90 volts or as low as five volts. Refer to
the Electrical Circuit Diagram Manuals, available from your vehicle’s
manufacturer, to ensure that any additional body lights and accessories
are connected to circuits that are both appropriate and not overloaded.
No modification should be made to any vehicle control system without
first contacting your dealer.
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Maintenance operation Frequency/Observation
Check the transmission and
engine mountings
(2)Hard shifting or excessive vibration.
Check and adjust transmission
controls
(2)High effort to shift or noisy
transmission.
Check fuel pump pressure Insufficient full-throttle power or
backfiring.
Clean radiator cap seal. Clean
and inspect the cap surface on
the radiatorWhen the cap does not hold pressure.
Check the battery terminals for
corrosionWhenever electrical power supply has
diminished.
Tighten the wheel mounting
nuts to the specified torque.
Refer toWheelsin the
Maintenance and
SpecificationschapterRequired initially at 500 and
1000 miles (800 and 1600 km).
Perform again at 500 and 1000 mile
(800 and 1600 km) intervals after
each tire removal/replacement.
Clean body/door drain holes At least twice annually.
Clean windshield wiper blades As required.
Replace windshield wiper
bladesIf wiping the blades with a clean cloth
and mild detergent and washing with
a cleaner does not restore a clean
wipe.
Lubricate body lock cylinders Noisy or difficult to operate.
Check headlamp alignment Lamp beams in wrong position when
vehicle operating loaded.
Check windshield washer fluid
level; add fluid if requiredIf washes do not spray when operated.
1During maintenance and repair, protect the fuel tube and the hose
assemblies, the power steering lines, and the brake lines from the
external heat, the acids and the abrasion that could damage the lines.
2Check for (free) linkage action and ensure that (return) spring force
is adequate to maintain pedal free play.
3Adjust, repair or replace as required with the same or equivalent
parts.
Scheduled Maintenance Guide
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A
Air conditioning ..........................48
manual heating and air
conditioning system .................48
Air suspension ...........................132
Anti-lock brake system
(see Brakes) ..............................130
Audio system (see Radio) ...36, 38
Automatic transmission ............134
fluid, adding ............................218
fluid, checking ........................218
fluid, refill capacities ..............252
fluid, specification ..................237
Auxiliary Input Jack ...................45
Auxiliary power point .................57
Axle ............................143, 184, 223
lubricant specifications ..........237
refill capacities ........................250
B
Battery .......................................193
charging system warning
light ............................................23
jumping a disabled battery ....162
voltage gauge ............................31
Belt-Minder...............................84
Booster seats ...............................99
Brakes ........................111, 116, 185
adjustment ..............................187
anti-lock ...................................130
anti-lock brake system (ABS)
warning light .....................23, 130
brake warning light ..................23
fluid, checking and adding ....215
fluid, specifications .................237
parking ....................112, 119, 188
Bulbs ............................................53C
Cassette tape player ...................36
Catalytic converter
(see Emission control) .............188
Cell phone use ..............................8
Child safety seats ........................92
attaching with tether straps ....96
in front seat ..............................93
in rear seat ..........................93, 95
tether anchorage hardware .....96
Child safety seats - booster
seats .............................................99
Cleaning your vehicle
engine compartment ..............176
exterior ....................................181
instrument panel ....................178
interior .....................................179
plastic parts ............................177
safety belts ..............................179
washing ....................................175
waxing .....................................175
wheels ......................................176
wiper blades ............................177
Climate control (see Air
conditioning or Heating) ............48
Clock adjust
AM/FM/CD .................................45
Clutch ................................137, 216
adjusting ..................................217
fluid ..........................................216
operation while driving ..........137
specifications ..........................237
Console
overhead ....................................57
Controls
power seat .................................76
Coolant ......................................196
Index
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