FORD SUPER DUTY 2002 1.G Owners Manual

•Four tire rotation
•Five tire rotation
Maintenance and Specifications
231

•DRW – Six tire rotation
If you vehicle is equipped with dual
rear wheels it is recommended that
front and rear tires (in pairs) be
rotated only side to side, with the
rear tires maintaining original
vehicle position. After tire rotation,
inflation pressures must be adjusted
for the tires new positions in
accordance with vehicle
requirements.
Replacing the tires
Replace the tires when the wear
band is visible through the tire
treads. Due to exposure to the
elements and exhaust you should
replace the spare tire when you
replace the other tires.
When replacing full size tires, never mix radial bias-belted, or
bias-type tires. Use only the tire sizes that are listed on the
Certification Label. Make sure that all tires are the same size, speed
rating, and load-carrying capacity. Use only the tire combinations
recommended on the label. If you do not follow these precautions,
your vehicle handling may be effected which can lead to loss of vehicle
control, vehicle rollover and/or personal injury.
Maintenance and Specifications
232

Make sure that all replacement tires are of the same size, type,
load-carrying capacity and tread design (e.g., “All Terrain”,
“Touring”, etc.), as originally offered by Ford.
Do not replace your tires with “high performance” tires or larger
size tires.
Failure to follow these precautions, your vehicle handling may be
adversely effected which can lead to loss of vehicle control,
vehicle rollover and/or personal injury.
Tires that are larger or smaller than your vehicle’s original tires may also
affect the accuracy of your speedometer.
SNOW TIRES AND CHAINS
Snow tires must be the same size and grade as the tires you
currently have on your vehicle.
The tires on your vehicle have all weather treads to provide traction in
rain and snow. However, in some climates, you may need to use snow
tires and chains. If you need to use chains, it is recommended that steel
wheels (of the same size and specifications) be used, as chains may chip
aluminum wheels.
Follow these guidelines when using snow tires and chains:
•Use only SAE Class S chains.
•Install chains securely, verifying that the chains do not touch any
wiring, brake lines or fuel lines.
•Drive cautiously. If you hear the chains rub or bang against your
vehicle, stop and re-tighten the chains. If this does not work, remove
the chains to prevent damage to your vehicle.
•If possible, avoid fully loading your vehicle.
•Remove the tire chains when they are no longer needed. Do not use
tire chains on dry roads.
•The suspension insulation and bumpers will help prevent vehicle
damage. Do not remove these components from your vehicle when
using snow tires and chains.
Maintenance and Specifications
233

MOTORCRAFT PART NUMBERS
Component* 5.4L V8 engine 6.8L V10 engine
Air filter element FA-1634 FA-1634
Fuel filter FG-986B FG-986B
Oil filter FL-820-S FL-820-S
PCV valve EV-233 EV-233
Battery (Standard) BXT-65-650 BXT-65-650
Battery (Optional) BXT-65-750 BXT-65-750
Spark plugs-platinum** AGSF-22W AGSF-22W
*Refer to the7.3 Liter Power Stroke Direct Injection Turbo Diesel
Owner’s Guide Supplementfor Motorcraft diesel engine service part
numbers.
**Refer to Vehicle Emissions Control Information (VECI) decal for spark
plug gap information.
REFILL CAPACITIES
FluidFord Part
NameApplication Capacity
Front axle Hypoid Gear Oil
SAE 90F-250/350
(Dana 60 axle)2.7L (5.8 pints)
F-350/450/550
(Dana 60 axle)2.7L (5.8 pints)
Rear axle
1,2Motorcraft SAE
75W-140
Synthetic Rear
Axle LubricantF-250 /350
(10.50 inch
axle)3.3L (6.9 pints)
Motorcraft SAE
75W-90
Synthetic Rear
Axle LubricantF-350/450
(DANA 80)4.0L (8.5 pints)
Motorcraft SAE
80W-90
Premium Rear
Axle LubricantF-550
(Dana 135)11.6L (24.5
pints)
Maintenance and Specifications
234

FluidFord Part
NameApplication Capacity
Brake fluid (and
clutch fluid-if
equipped)Motorcraft High
Performance
DOT 3 Motor
Vehicle Brake
FluidAll Fill to line or
step (for clutch)
on reservoir
Engine coolant
3Motorcraft
Premium Engine
Coolant
(green-colored)
orMotorcraft
Premium Gold
Engine Coolant
(yellow-colored)5.4L V8 engine
with A/C25.0L (26.4
quarts)
6.8L V10 engine 27.0L (28.5
quarts)
Engine oil
(includes filter
change)-Gas
enginesMotorcraft SAE
5W-20 Premium
Synthetic Blend
Motor OilAll 5.7L (6.0
quarts)
Engine oil
(includes filter
change)-Diesel
engineRefer to your 7.3L Diesel Supplement
Maintenance and Specifications
235

FluidFord Part
NameApplication Capacity
Fuel tank N/A Mid-ship tank
(optional on
Chassis Cab)71.9L (19.0
gallons)
Right side
saddle mounted
tank (optional
on Chassis Cab)87.1L (23.0
gallons)
Short box 109.8L (29.0
gallons)
Long box 143.9L (38.0
gallons)
Aft axle 151.4L (40.0
gallons)
Power steering
fluidMotorcraft
MERCON
AT FAll Fill to line on
reservoir
Transfer case
fluidMotorcraft
MERCON
AT F4x4 vehicles 1.9L (2.0
quarts)
Transmission
fluid
4Motorcraft
MERCON
AT F6-speed manual 5.5L (5.8
quarts)5
Automatic 16.7L (17.7
quarts)6
Windshield
washer fluidMotorcraft
Premium
Windshield
Washer
ConcentrateAll 4.0L (4.25
quarts)
1Your vehicle’s rear axle(s) may be filled with a synthetic lubricant that
may require a lubricant change. Refer to the scheduled maintenance
guide. Axle lubricant quantities should not need to be checked unless a
leak is suspected, service is required or the axle assembly has been
submerged in water. The axle lubricant should be changed any time the
rear axle has been submerged in water.
2Add 236 ml (8 oz.) of Additive Friction Modifier XL-3or equivalent
meeting Ford Specification EST-M2C118-A for complete refill of
Traction-Lok axles.
Maintenance and Specifications
236

3Add the coolant type originally equipped in your vehicle.
4Ensure the correct automatic transmission fluid is used. Transmission
fluid requirements are indicated on the dipstick or on the dipstick
handle. Check the container to verify the fluid being added is of the
correct type. Refer to your scheduled maintenance guide to determine
the correct service interval.
Some transmission fluids may be labeled as dual usage, such as
MERCON
and MERCON
V. These dual usage fluids are not to be used
in an automatic transmission that requires use of the MERCON
type
fluid. However, these dual usage fluids may be used in transmissions that
require the MERCON
V type fluid.
MERCON
and MERCON
V type fluids are not interchangeable.
DO NOT mix MERCON
and MERCON
V. Use of a transmission
fluid that indicates dual usage (MERCON
and MERCON
V) in
an automatic transmission application requiring MERCON
may
cause transmission damage. Use of any fluid other than the
recommended fluid may cause transmission damage.
5Service refill capacity is determined by filling the transmission to the
bottom of the filler hole with the vehicle on a level surface. The 6–speed
manual transmission is equipped with an in-tank cooler. Verify the fluid
level after operating vehicle to assure correct fluid level.
6Indicates 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.
LUBRICANT SPECIFICATIONS
ItemFord part
name or
equivalentFord part
numberFord
specification
Spindle bearingHigh
Temperature
4X4 Front Axle
and Wheel
Bearing GreaseE8TZ-19590–A ESA-M1C198–A
Front axle
(4X4)Hypoid Gear Oil
SAE 90C6AZ-19580–E ESW-M2C105–A
Maintenance and Specifications
237

ItemFord part
name or
equivalentFord part
numberFord
specification
Rear axleMotorcraft SAE
75W-140 High
Performance
Synthetic Rear
Axle Lube
1
XY-75W140–QL WSL-M2C192-A
Motorcraft SAE
75W-90
Synthetic Rear
Axle LubricantXY-75W90–GLS –
Motorcraft SAE
80W-90
Premium Rear
Axle Lubricant
(Dana 135
axles)
1
XY-80W90-QL WSP-M2C197-A
Brake fluid and
clutch fluid (if
equipped)Motorcraft High
Performance
DOT 3 Motor
Vehicle Brake
FluidPM-1 ESA-M6C25-A
and DOT 3
Engine coolant Motorcraft
Premium Engine
Coolant
(green-colored)VC-4–A (in
Canada,
Motorcraft
CXC-10)ESE-M97B44-A
Motorcraft
Premium Gold
Engine Coolant
(yellow-colored)VC-7–A WSS-M97B51-A1
Engine oilMotorcraft SAE
5W-20 Premium
Synthetic Blend
Motor OilXO-5W20-QSP WSS-M2C153-H
and API
Certification
Mark
Maintenance and Specifications
238

ItemFord part
name or
equivalentFord part
numberFord
specification
Hinges, latches,
striker plates,
fuel filler door
hinge and seat
tracksMulti-Purpose
GreaseXG—4 or XL-5 ESR-M1C159-A
or
ESB-M1C93–B
Lock cylindersMotorcraft
penetrating and
lock lubricantXL-1 none
Transmission
/steering/parking
brake linkages
and pivots,
brake and clutch
pedal shaft (if
equipped)Motorcraft
Premium
Long-Life GreaseXG-1-C or
XG-1-KESA-M1C75-B
Power steering
fluid and
transfer case
fluid (if
equipped)Motorcraft
MERCON
AT FXT-2-QDX MERCON

Manual
transmission
(6-speed)Motorcraft
MERCON
AT F
2
XT-2-QDX MERCON

Automatic
transmissionMotorcraft
MERCON
AT F
2
XT-2-QDX MERCON

Windshield
washer fluidMotorcraft
Premium
Windshield
Washer
ConcentrateZC-32–A ESR-M17P5-A
1Add 236 ml (8 oz.) of Additive Friction Modifier XL-3 or equivalent
meeting Ford specification EST-M2C118-A for complete refill of
Maintenance and Specifications
239

Traction-Lok axles. Ford design rear axles contain a synthetic lubricant
that does not require changing unless the axle has been submerged in
water. Dana rear axles also contain a synthetic lubricant butdorequire a
change. Refer to your “Service Guide” for change intervals on Dana rear
axles.
2Ensure the correct automatic transmission fluid is used. Transmission
fluid requirements are indicated on the dipstick or on the dipstick
handle. Check the container to verify the fluid being added is of the
correct type. Refer to your scheduled maintenance guide to determine
the correct service interval.
Some transmission fluids may be labeled as dual usage, such as
MERCON
and MERCON
V. These dual usage fluids are not to be used
in an automatic transmission that requires use of the MERCON
type
fluid. However, these dual usage fluids may be used in transmissions that
require the MERCON
V type fluid.
MERCON
and MERCON
V type fluids are not interchangeable.
DO NOT mix MERCON
and MERCON
V. Use of a transmission
fluid that indicates dual usage (MERCON
and MERCON
V) in
an automatic transmission application requiring MERCON
may
cause transmission damage. Use of any fluid other than the
recommended fluid may cause transmission damage.
ENGINE DATA
Engine 5.4L V8 engine 6.8L V10 engine
Cubic inches 330 415
Required fuel 87 octane 87 octane
Firing order 1-3-7-2-6-5-4-8 1-6-5-10-2-7-3-8-4-9
Spark plug gap1.3-1.4 mm
(0.052-0.056 inch)1.3-1.4 mm
(0.052-0.056 inch)
Ignition system Coil on plug Coil on plug
Compression ratio 9.0:1 9.0:1
Maintenance and Specifications
240