
Jump Starting the Vehicle ........................190
Transporting the Vehicle ...........................192
Towing Points ...............................................193
Customer Assistance
Getting the Services You Need ..............194
In California (U.S. Only) ............................195
The Better Business Bureau (BBB) Auto
Line Program (U.S. Only) .....................196
Getting Assistance Outside the U.S. and
Canada ........................................................197
Ordering Additional Owner's Literature
........................................................................1 9 8
Reporting Safety Defects (U.S. Only)
........................................................................1 9 8
Reporting Safety Defects (Canada Only)
........................................................................1 9 9
Fuses
Fuse Specification Chart .........................200
Changing a Fuse .........................................208
Vehicle Inspection Guide
Vehicle Inspection Information ..............210
Maintenance
General Information ...................................219
Opening and Closing the Hood .............220
Under Hood Overview - 6.7L Diesel ......222
Under Hood Overview - 7.3L ...................223
Engine Oil Dipstick - 6.7L Diesel ............224
Engine Oil Dipstick - 7.3L ..........................224
Engine Oil Check - 6.7L Diesel ...............224
Engine Oil Check - 7.3L .............................225
Changing the Engine Oil and Oil Filter
........................................................................226
Oil Change Indicator Reset ......................227
Changing the Engine Air Filter - 6.7L
Diesel ...........................................................228
Changing the Engine Air Filter - 7.3L .....230Draining the Fuel Filter Water Trap - 6.7L
Diesel ...........................................................232
Engine Coolant Check - 6.7L Diesel ......233
Engine Coolant Check - 7.3L ...................238
Automatic Transmission Fluid Check
........................................................................242
Brake Fluid Check .......................................244
Power Steering Fluid Check ....................245
Changing the 12V Battery ........................246
Adjusting the Headlamps ........................247
Washer Fluid Check ...................................249
Fuel Filter - 7.3L ...........................................249
Checking the Wiper Blades ....................249
Changing the Wiper Blades ....................249
Removing a Headlamp ............................250
Changing a Bulb .........................................250
Changing the Engine-Mounted and
Diesel Fuel Conditioner Module Fuel
Filters - 6.7L Diesel ..................................251
Electrical System Inspection ..................254
Air Induction System Inspection ...........254
Exhaust System Inspection ....................255
Brake System Inspection .........................255
Axle Inspection ............................................258
Steering System Inspection ...................259
Suspension System Inspection .............259
Frame and Tow Hook Inspection .........260
Rear Axle Fluid Check ...............................260
Spring U-Bolt Check .................................260
Vehicle Care
General Information ..................................262
Cleaning Products ......................................262
Cleaning the Exterior .................................263
Waxing ............................................................264
Cleaning the Engine ..................................264
Cleaning the Windows and Wiper Blades
........................................................................265
Cleaning the Interior ..................................265
Cleaning the Instrument Panel and
Instrument Cluster Lens ......................266
4
Table of Contents

VEHICLE INSPECTION
INFORMATION
To make sure your vehicle is ready to
operate, conduct a pre-trip inspection at
the beginning of each work period. Follow
the steps listed in this section to verify a
proper vehicle inspection procedure.
WARNING: Exercise great caution
when working on a vehicle equipped with
an automatic fan clutch. The fan starts
in motion only after the engine coolant
reaches a predetermined temperature
or the refrigerant pressure (if equipped
with air conditioning) reaches a
predetermined setting. The fan starts at
this point with no advance warning.
Never reach near, or permit objects to
protrude into, the fan blade radius while
the engine is running as this could result
in vehicle damage, personal injury or
death.
WARNING: Do not operate the
vehicle if any suspension conditions
listed in the following charts are evident.
Loss of steering or suspension could
result in property damage, personal injury
or death.
WARNING: If a wheel must be
changed, obtain expert tire service help.
Mounting and un-mounting of tires
should only be performed by a qualified
technician using necessary safety
procedures and equipment, otherwise
the result could be property damage,
personal injury or death.
Note:Always make sure you apply the
parking brake before starting the engine.
Engine compartment (with engine off)
Use the dipstick to verify the oil level is in the proper operating
range. See Engine Oil Dipstick (page 224). Engine oil
Look through the plastic reservoir and verify the coolant level
is within the proper operating range. Do not remove the
pressure cap until the coolant has cooled. See Engine
Coolant Check (page 238). Engine coolant
Verify that the fluid level is in the proper operating range. See
Power Steering Fluid Check (page 245). Power steering fluid
Remove the master cylinder caps and inspect the fluid level.
See Brake Fluid Check (page 244). Brake fluid
210
Vehicle Inspection Guide

UNDER HOOD OVERVIEW - 6.7L DIESEL
E313700E313700
Engine compartment fuse box. See Fuses (page 200). A
Windshield washer fluid reservoir. See Washer Fluid Check (page 249). B
Automatic transmission fluid dipstick. See Automatic Transmission Fluid
Check (page 242). C
Secondary Cooling System Reservoir. See Engine Coolant Check (page 233). D
Engine coolant reservoir. See Engine Coolant Check (page 233). E
Secondary fuel filter. See Draining the Fuel Filter Water Trap (page 232). F
Engine oil separator. See Changing the Engine Oil and Oil Filter (page 226). G
Engine oil filler cap. See Engine Oil Check (page 224). H
Brake fluid reservoir. See Brake Fluid Check (page 244). I
Power steering fluid reservoir. See Power Steering Fluid Check (page 245). J
Air brake compressor. See Brake System Inspection (page 255). K
Engine oil dipstick. See Engine Oil Dipstick (page 224). L
Air cleaner assembly. See Changing the Engine Oil and Oil Filter (page 226). M
222
Maintenance

UNDER HOOD OVERVIEW - 7.3L
E330964E330964
Engine compartment fuse box. See Fuses (page 200). A
Engine oil dipstick. See Engine Oil Dipstick (page 224). B
Windshield washer fluid reservoir. See Washer Fluid Check (page 249). C
Automatic transmission fluid dipstick. See Automatic Transmission Fluid
Check (page 242). D
Engine coolant reservoir. See Engine Coolant Check (page 238). E
Engine oil filler cap. See Engine Oil Check (page 225). F
Brake fluid reservoir. See Brake Fluid Check (page 244). G
Power steering fluid reservoir. See Power Steering Fluid Check (page 245). H
Air cleaner assembly. See Changing the Engine Air Filter (page 230). I
223
Maintenance

ENGINE OIL DIPSTICK - 6.7L
DIESEL
E249448
Minimum. A
Nominal. B
Maximum. C
ENGINE OIL DIPSTICK - 7.3L
E250320E250320
Minimum. A
Nominal. B
Maximum. C
ENGINE OIL CHECK - 6.7L
DIESEL
To check the engine oil level consistently
and accurately, do the following:1. Make sure the parking brake is on. Make
sure the transmission is in park (P) or
neutral (N).
2. Run engine until it reaches normal
operating temperature.
3. Make sure that your vehicle is on level
ground.
4. Switch the engine off and wait 15
minutes for the oil to drain into the oil
pan. Checking the engine oil level too
soon after you switch the engine off
may result in an inaccurate reading.
5. Open the hood. See Opening and
Closing the Hood (page 220).
6. Remove the dipstick and wipe it with
a clean, lint-free cloth. See Under
Hood Overview (page 222).
7. Replace the dipstick and remove it
again to check the oil level. See
Engine Oil Dipstick (page 224).
8. Make sure that the oil level is between
the maximum and minimum marks. If
the oil level is at the minimum mark,
add oil immediately. See Engine Oil
Capacity and Specification (page
292).
9. If the oil level is correct, replace the
dipstick and make sure it is fully seated.
Note:Do not remove the dipstick when the
engine is running.
Note: If the oil level is between the
maximum and minimum marks, the oil level
is acceptable. Do not add oil.
Note:The oil consumption of new engines
reaches its normal level after approximately
3,000 mi (5,000 km).
Adding Engine Oil
WARNING: Do not remove the filler
cap when the engine is running.
224
Maintenance

Do not use supplemental engine oil
additives because they are unnecessary
and could lead to engine damage that may
not be covered by the vehicle Warranty.
To top up the engine oil level do the
following:
1. Clean the area surrounding the engine
oil filler cap before you remove it.
2. Remove the engine oil filler cap. See
Under Hood Overview (page 222).
Turn it counterclockwise and remove
it.
3. Add engine oil of the proper viscosity
and grade that meets Ford
specifications. See Engine Oil
Capacity and Specification (page
292). You may have to use a funnel to
pour the engine oil into the opening.
4. Recheck the oil level.
5. If the oil level is correct, replace the
dipstick and make sure it is fully seated.
6. Replace the engine oil filler cap. Turn
it clockwise until you feel a strong
resistance.
Note: Do not add oil further than the
maximum mark. Oil levels above the
maximum mark may cause engine damage.
Note:Make sure you install the oil filler cap
correctly.
Note:Soak up any spillage with an
absorbent cloth immediately.
Engine lubrication for severe
service operation
The following conditions define severe
operation for which engine operation with
SAE 5W-40 oil which meets Ford
specification, WSS-M2C171-F1, is
recommended. Oil and oil filter change
intervals will be determined by the
Intelligent Oil Life Monitor™ as noted
previously.
ENGINE OIL CHECK - 7.3L
1. Make sure that your vehicle is on level
ground.
2. Check the oil level before starting the
engine, or switch the engine off after
warm up and wait 10 minutes for the
oil to drain into the oil pan.
3. Remove the dipstick and wipe it with
a clean, lint-free cloth.
4. Reinstall the dipstick and make sure it
is fully seated.
5. Remove the dipstick again to check the
oil level.
Note: If the oil level is between the
maximum and minimum marks, the oil level
is acceptable. Do not add oil.
6. If the oil level is at the minimum mark,
immediately add oil.
7. Reinstall the dipstick. Make sure it is
fully seated.
Note:The oil consumption of new engines
reaches its normal level after approximately
3,000 mi (5,000 km).
Adding Engine Oil
WARNING: Do not add engine oil
when the engine is hot. Failure to follow
this instruction could result in personal
injury.
WARNING: Do not remove the filler
cap when the engine is running.
Do not use supplemental engine oil
additives because they are unnecessary
and could lead to engine damage that the
vehicle warranty may not cover.
1. Clean the area surrounding the engine
oil filler cap before you remove it.
2. Remove the engine oil filler cap.
225
Maintenance

Engine Oil Capacity and Specification -
7.3L.................................................................295
Engine Oil Check - 6.7L Diesel.................224
Engine Oil Check - 7.3L..............................225
Engine Oil Dipstick - 6.7L Diesel.............224
Engine Oil Dipstick - 7.3L...........................224
Engine Specifications - 6.7L
Diesel............................................................288
Engine Specifications - 7.3L....................289
Entering, Exiting or Climbing on This
Vehicle.............................................................20
Environment......................................................21
Essential Towing Checks..........................180
Event Data Recording
See: Data Recording.............................................13Exhaust Brake................................................143
Exhaust System Inspection.....................255
Export Unique Options................................20
Exterior Mirrors...............................................60
F
Fastening the Seatbelts..............................38
Federal Highway Administration
Regulation......................................................20
Fifth Wheel Operation.................................181
Flat Tire
See: Changing a Road Wheel.......................284Ford Credit..........................................................17
Ford Protect....................................................317
Frame and Tow Hook Inspection..........260
Front Seat Armrest........................................94
Fuel and Refueling.......................................105
Fuel Consumption.........................................113
Fuel Filter - 7.3L............................................249
Fuel Quality - Diesel....................................106
Fuel Quality - Gasoline..............................109
Fuel Shutoff...................................................189
Fuel Tank Capacity - Diesel.....................298
Fuel Tank Capacity - Gasoline...............299
Fuel Tank Selector Switch..........................114
Fuses................................................................200
Fuse Specification Chart..........................200
G
Gauges...............................................................63Gearbox
See: Transmission..............................................128General Driving Points................................183
General Information on Radio
Frequencies...................................................45
General Maintenance Information........319
Getting Assistance Outside the U.S. and
Canada..........................................................197
Getting the Services You Need...............194
H
HandbrakeSee: Parking Brake.............................................138Hazard Flashers............................................189
Headlamp Adjusting
See: Adjusting the Headlamps.....................247Headlamp Exit Delay....................................55
Headlamp Removal
See: Removing a Headlamp..........................250HeadrestSee: Head Restraints..........................................88Head Restraints..............................................88
Heated Exterior Mirrors................................87
Heating
See: Climate Control...........................................85Hill Start Assist...............................................141
Hints on Controlling the Interior
Climate...........................................................86
Hints on Driving With Anti-Lock
Brakes............................................................138
Hood Lock
See: Opening and Closing the Hood..........220Horn.....................................................................52
How Does the Pneumatic Locking
Differential Work........................................135
Hydraulic Power Steering Fluid Capacity
and Specification.....................................306
I
Ignition Switch..............................................100
In California (U.S. Only).............................195
Information Display Control.......................52
Information Displays.....................................70
General Information............................................70Information Messages..................................74
Installing Child Restraints...........................26
371
Index