An exhaust brake is an auxiliary braking system that assists, but does
not replace, the primary service brake system. It is intended to help
control vehicle speed. It is not a vehicle stopping device.
A switch on the instrument panel,
in combination with the accelerator
and clutch pedal, allows the
operator to make maximum use of
the exhaust brake in the following
conditions:
•off-highway driving
•mountain driving
•heavy traffic
•high-speed highway driving.
To operate the brake, push the switch up to turn it on. Push the switch
down to turn it off.
While approaching a steep grade, make sure that the exhaust brake
switch is in the on position. The exhaust brake begins working as soon as
you remove your foot from the accelerator pedal.
Before descending a hill or steep grade, always select the proper gear. If
the transmission is taken out of gear while descending, it is possible that
you cannot select another gear because of maximum RPM being
governed.
Make sure the engine speed does not exceed the maximum allowable
engine RPM. Exceeding the maximum allowable engine RPM can result
in damage to the engine. Apply the service brakes to reduce the engine
RPM or make a slower descent by using a lower gear.
While going down the grade, use a low enough gear to descend safely
with a minimum application of the service brakes. As a general guideline,
use the same gear as you use to ascend the hill.
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Exhaust Brake Operating Characteristics
When you remove your feet from both the accelerator and clutch pedals
and the exhaust brake switch is in the on position, the exhaust brake is
activated. The following conditions exist if the brake is operating properly:
•A slight change in engine sound when the exhaust brake is activated.
•A smooth braking effect. Do not expect a retarding effect similar to
sudden, hard application of the service brakes.
•The retarding force possibly felt acting against your body when the
brake is applied (depending on the grade and vehicle load). This force
is actually preventing the vehicle from going much faster.
•Engine temperature remaining in the normal operating range.
•The tachometer showing a drop in engine RPM (depending on grade
and vehicle load) during a descent.
•A decrease in road speed when the exhaust brake is applied during a
descent, except when the vehicle is carrying a heavy load or the grade
is extremely steep. In these instances, you may need to apply the
service brakes occasionally.
TRAILER BRAKES
Trailer Brake Hand Control (If Equipped)
WARNING:The hand control should never be used to apply
the brakes when the tractor and trailer are parked unattended.
Air may leak from the system and the vehicle could possibly move,
resulting in possible property damage, personal injury or death.
The hand control is located on the
right-hand side of the instrument
panel. It is used to apply the
trailer service brakes which are
independent of the truck or tractor
service brakes.
It operates a valve that provides gradual control of air pressure applied.
When the valve is only partially applied, the trailer brakes can be
overridden by pressing fully on the brake pedal.
To apply the trailer brakes using the hand control, move the lever
downward. The further the lever is pushed down, the greater the air
pressure is applied to the brakes. The lever remains in place until
manually moved.
To release the trailer brakes, move the lever up completely.
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The upper portion of the switch must be pressed before operating with a
trailer or operating in the bobtail mode.
Suspension Conversions
WARNING:When operating a loaded vehicle, the driver must
keep all adjustable axles on the ground at all times, supporting
their share of the vehicle’s load. Failure to do so can overload other
axles, tires, wheels, springs, steering components, brakes and frames,
resulting in early component failure, loss of vehicle control, possible
property damage and personal injury.
It is not recommended, or approved, that suspension conversions be
performed. However, it is understood that, on occasion, aftermarket
add-on suspensions are installed by others on the truck chassis which
allow operator control for weight transfer from other axles (i.e., air lift
axles).
UPFITTER CONTROLS (IF EQUIPPED)
The upfitter option package
provides four switches, mounted in
the center of the instrument panel.
These switches are always on
whether the engine is running or
not. Make sure you put the switches
in the off position to avoid draining
the battery when the vehicle is not
being used. It is recommended that the engine remain running to
maintain battery charge when using the upfitter switches for extended
duration or higher current draws. (This is even more important for
vehicles with a diesel engine since the glow plugs are also draining
battery power when the ignition key is in the on position.)
Each switch provides 10 amps of electrical battery power for a variety of
personal or commercial uses.
There is also a relay box located on the passenger side end of the
instrument panel. See your authorized dealer for service.
Switch access location is in a connector located in the engine
compartment. More detailed information can be found at
https://www.fleet.ford.com/truck/bbas/.
AUX 1
AUX 2
AUX 3
AUX 4
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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.
To avoid damage to the vehicle’s electrical components prior to electric
welding:
•disconnect both battery cables.
•attach the welder ground cable as close as possible to the part being
welded.
•it is recommended that the component be temporarily removed if
welding close to an electrical component.
Follow the checks and services in theScheduled Maintenancechapter.
Have your dealer or service center inspect your vehicle at least once a
year. Remember that regular maintenance and inspections usually
prevent serious problems from developing later.
If the owner or operator of the vehicle is a skilled technician and intends
on performing the vehicle maintenance and service, he is strongly urged
to purchase a service manual.
Electrical System
Periodically inspect electrical connectors on the outside of the cab and
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 Motorcraft® Silicone 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. See theElectrical Circuit Diagram Manuals,available from your
vehicle’s manufacturer, to make sure 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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Replacing Brake/Tail/Rear Turn Signal/Reverse/License Plate Lamp
Bulbs
1. Remove the four screws and the
lamp lens from the lamp
assembly.
2. Carefully pull the bulb straight
out of the socket.
3. Reverse the procedure to install
the new bulb.
BULB SPECIFICATION CHART
Replacement bulbs are specified in the chart below. Headlamp bulbs
must be marked with an authorized D.O.T. for North America and an E
for Europe to make sure lamp performance, light brightness and pattern
and safe visibility. The correct bulbs will not damage the lamp assembly
or void the lamp assembly warranty and will provide quality bulb
illumination time.
Function Number of
BulbsTrade Number
Headlamps 2 H6054
Front turn signal lamps 2 1157
Front sidemarker lamps, parking
lamps2 (amber) 194
Brake lamps, tail lamps, stop lamps,
rear turn signals lamps, license plate
lamps1 (each side) 1157
Back up lamps 2 1156
Front clearance and identification
lamps5 194
Dome lamp 1 105
To replace all instrument panel lights, see your authorized dealer.
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CLEANING THE INSTRUMENT PANEL AND INSTRUMENT
CLUSTER LENS
WARNING:Do not use chemical solvents or strong detergents
when cleaning the steering wheel or instrument panel to avoid
contamination of the airbag system.
Clean the instrument panel and cluster lens with a clean, damp, white,
cotton cloth, then use a clean and dry, white, cotton cloth to dry these
areas.
•Avoid cleaners or polishes that increase the gloss of the upper portion
of the instrument panel. The dull finish in this area helps protect the
driver from undesirable windshield reflection.
•Be certain to wash or wipe your hands clean if you have been in
contact with certain products such as insect repellent and suntan
lotion in order to avoid possible damage to the interior painted
surfaces.
•Do not use household or glass cleaners as these may damage the
finish of the instrument panel, interior trim and cluster lens.
•Do not allow air fresheners and hand sanitizers to spill on interior
surfaces. If a spill occurs, wipe off immediately. Damage may not be
covered by your warranty.
If a staining liquid, like coffee or juice, has been spilled on the
instrument panel or on interior trim surfaces, clean as follows:
1. Wipe up spilled liquid using a clean, white, cotton cloth.
2. Wipe the surface with a damp, clean, white, cotton cloth. For more
thorough cleaning, use a mild soap and water solution. If the spot
cannot be completely cleaned by this method, the area may be
cleaned using a commercially available cleaning product designed for
automotive interiors.
3. If necessary, apply more soap and water solution or cleaning product
to a clean, white, cotton cloth and press the cloth onto the soiled
area. Allow this to set at room temperature for 30 minutes.
4. Remove the soaked cloth, and if it is not soiled badly, use this cloth
to clean the area by using a rubbing motion for 60 seconds.
5. Following this, wipe area dry with a clean, white, cotton cloth.
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Child safety seats - booster
seats .............................................31
Cleaning your vehicle ...............242
engine compartment ..............245
exterior ....................................242
instrument panel ....................247
interior .....................................246
plastic parts ............................244
washing ....................................242
waxing .....................................244
wheels ......................................248
wiper blades ............................245
Climate control (see Air
conditioning or Heating) ............88
Clock ......................................79–80
Clutch ................................133, 229
adjusting ..................................230
fluid ..........................................229
specifications ..........................264
Coolant ......................................219
checking and adding ..............219
refill capacities ........................277
specifications ..........................264
Cruise control ...........................166
Customer Assistance ................184
Getting assistance outside the
U.S. and Canada .....................191
Getting roadside assistance ...184
Getting the service you
need .................................189, 204
Ordering additional owner’s
literature .................................192
Utilizing the
Mediation/Arbitration
Program ...................................191
D
Daytime running lamps
(see Lamps) ................................57Defrost .........................................88
Diesel exhaust fluid (DEF) .....120
Diesel Particulate Filter
(DPF) ........................................106
Dipstick
automatic transmission fluid...223
engine oil .................................217
Doors
lubricant specifications ..........264
Drivebelt ....................................263
Driving under special
conditions
through water .........................183
E
Electronic message center .........74
Emergencies, roadside
jump-starting ..........................185
running out of fuel .................116
Emergency Flashers .................185
Emission control system ..130, 288
catalytic converter ..................213
End user license agreement ....364
Engine ........................................263
cleaning ...................................245
coolant .....................................219
fail-safe cooling .......................222
lubrication specifications .......264
Engine block heater .................111
Engine fan .................................219
Engine oil
checking and adding ......217–218
dipstick ....................................217
filter, specifications ................280
refill capacities ........................277
specifications ..........................264
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Exhaust fumes ..........................104
F
Fail safe cooling ........................222
Fan, Engine Cooling .................219
Filter
fuel ...........................................232
Fuel
cap ...........................................118
capacity ...................................277
filler funnel .............................116
filling your vehicle with fuel ..118
octane rating ...................116, 263
quality ......................................114
running out of fuel .................116
safety information relating to
automotive fuels .....................113
Fuses ..........................194–195, 203
G
Gas cap (see Fuel cap) ............118
Gauges ...................................64, 66
H
Hazard flashers .........................185
Headlamps ...................................56
aiming ......................................239
bulb specifications ..................241
daytime running lights .............57
flash to pass ..............................56
replacing bulbs .......................239
turning on and off ....................56
Head restraints ...........................92
Heating ........................................88
Hood ..........................................215I
Ignition ...............................103, 263
Information displays ...................74
Instrument panel
cleaning ...................................247
cluster ........................................68
lighting up panel and
interior .......................................57
J
Joining two calls
(multiparty/conference call) ....328
Jump-starting your vehicle ......185
K
Keys
positions of the ignition .........103
L
Lamps ..........................................56
bulb replacement
specifications chart ................241
daytime running light ...............57
headlamps .................................56
headlamps, flash to pass ..........56
instrument panel, dimming .....57
interior lamps .....................58–59
replacing bulbs .......................239
Lane change indicator
(see Turn signal) ........................58
LATCH anchors ...........................36
Lights, warning and indicator ....68
Load limits .................................174
Locks
childproof ..................................40
doors ..........................................53
374Index
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USA(fus)