FORD SUPER DUTY 2009 2.G Diesel Supplement Manual

If vehicle is operated in sustained ambient temperatures below -10°F
(-23°C) or above 100°F (38°C)
Every 5,000 miles (8,000 km)Rotate tires, inspect tires for wear and measure tread
depth and inspect wheel ends for endplay and noise
Every 5,000 miles (8,000 km),
3 months or 200 hoursChange engine oil and replace filter
Inspect and lubricate steering and suspension ball joints
and tie rod ends (if equipped with zerk fittings)
Every 10,000 miles (16,000 km),
6 months or 400 hours of engine
operation (whichever comes first)Change engine-mounted fuel filter and chassis-mounted
(HFCM) fuel filter
Every 30,000 miles (48,000 km)Replace wheel bearing grease and grease seals on 4x2
wheel bearings (if non-sealed bearings)
Every 60,000 miles (96,000 km)Change transfer case fluid (4x4 only)
2009 Econoline(eco)
Supplement, 1st Printing
USA(fus)
Scheduled Maintenance: F-Super Duty
91

Frequent low speed operation, consistent heavy traffic less than 25 mph
(40 km/h) and/or long rush hour traffic
Every 5,000 (8,000 km) milesRotate tires, inspect tires for wear and measure tread
depth and inspect wheel ends for endplay and noise
Check air filter restriction gauge (replace air filter as
required or when air filter restriction gauge indicates)
Inspect brake system pads and rotors
Inspect and lubricate steering and suspension ball joints
and tie rod ends (if equipped with zerk fittings)
Every 5,000 miles (8,000 km),
6 months or 200 hours of engine
operation (whichever comes first)Change engine oil and replace filter
Every 10,000 miles (16,000 km),
6 months or 400 hours of engine
operation (whichever comes first)Change engine-mounted fuel filter and chassis-mounted
(HFCM) fuel filter
Every 20,000 miles (32,000 km) or
800 hours of engine operation
(whichever comes first)Check the Nitrite level of the coolant using Fleetguard

DCA4 Test Strip Kit CC2602A to determine if recharge is
required. If the Nitrite level is above 800 ppm no action
is required. If the Nitrite level is 800 ppm or lower add
32 fl. oz. (946 mL). of Supplemental Coolant Additive
Motorcraft VC-8 or equivalent.
Every 40,000 miles (64,000 km) or
1600 hours of engine operation
(whichever comes first)Check the Nitrite level of the coolant using Fleetguard

DCA4 Test Strip Kit CC2602A to determine if recharge is
required. If the Nitrite level is above 800 ppm no action
is required. If the Nitrite level is 800 ppm or lower add
32 fl. oz. (946 mL). of Supplemental Coolant Additive
Motorcraft VC-8 or equivalent.
Every 60,000 miles (96,000 km)Change transfer case fluid (4x4 only)
Every 60,000 miles (96,000 km) or
2400 hours of engine operation
(whichever comes first)Flush & refill engine coolant (refer to Motorcraft Premium
Gold Engine Coolant Change Record) – Do not add
Supplemental Coolant Additive
Note:When adding supplemental coolant additive, do not exceed the
specified maximum of 32 fl. oz. (946 mL). Operating the engine with
excessive supplemental coolant additive can cause severe engine
damage.
2009 Econoline(eco)
Supplement, 1st Printing
USA(fus)
Scheduled Maintenance: F-Super Duty
92

Frequent low speed operation if vehicle is used for stationary operation
Every 5,000 miles (8,000 km),
3 months or 200 hours of engine
operation (whichever comes first) if
vehicle is used for stationary
operationChange engine oil and replace filter
Note:For vehicles that operate under severe service conditions such as
frequent or extended idle (over 10 minutes per hour of normal driving),
maintenance requirements need to be adjusted. This needs to be
considered when determining vehicle service intervals.
Operating in dusty conditions such as unpaved or dusty roads
Every 5,000 miles (8,000 km)Check air filter restriction gauge (replace air filter as
required or when air filter restriction gauge indicates)
Inspect and lubricate steering and suspension ball joints
and tie rods (if equipped with zerk fittings)
Inspect brake system pads and rotors
Rotate tires, inspect tires for wear and measure tread
depth and inspect wheel ends for endplay and noise
Every 5,000 miles (8,000 km) or
6 monthsChange engine oil and replace filter
Inspect and lubricate U-joints
Every 10,000 miles (16,000 km) or
400 hours of engine operation
(whichever comes first)Change engine-mounted fuel filter and chassis-mounted
(HFCM) fuel filter
Every 30,000 miles (48,000 km)Replace wheel bearing grease and grease seals on 4x2
wheel bearings (if non-sealed bearings)
2009 Econoline(eco)
Supplement, 1st Printing
USA(fus)
Scheduled Maintenance: F-Super Duty
93

Off-road operation
Every 5,000 miles (8,000 km)Check air filter restriction gauge (replace air filter as
required or when air filter restriction gauge indicates)
Rotate tires, inspect tires for wear and measure tread
depth and inspect wheel ends for endplay and noise
Inspect brake system pads and rotors
Every 5,000 miles (8,000 km) or
6 monthsChange engine oil and replace filter
Inspect and lubricate U-joints
Every 10,000 miles (16,000 km) or
400 hours of engine operation
(whichever comes first)Change engine-mounted fuel filter and chassis-mounted
(HFCM) fuel filter
Every 30,000 miles (48,000 km)Replace wheel bearing grease and grease seals on 4x2
wheel bearings (if non-sealed bearings)
Every 50,000 miles (80,000 km)Check front axle lubricant (4x4 only)
Change rear axle lubricant (if equipped with a Dana rear
axle, some F-350s, all 450–550)
Every 50,000 miles (80,000 km)Change transfer case fluid (4x4 only)
As requiredInspect and lubricate steering and suspension ball joints
and tie rod ends (if equipped with zerk fittings)
Check that the functional holes in each leg of the twin tip
and the holes under the shield just inboard of the right
rear tire are kept clean/clear of debris or foreign materials
(clean/remove debris as required). Refer to the
Cleaningchapter for more information.
2009 Econoline(eco)
Supplement, 1st Printing
USA(fus)
Scheduled Maintenance: F-Super Duty
94

Towing a trailer or using a camper or car-top carrier
Every 5,000 miles (8,000 km)Check air filter restriction gauge (replace air filter as
required or when air filter restriction gauge indicates)
Rotate tires, inspect tires for wear and measure tread
depth and inspect wheel ends for endplay and noise
Inspect brake system pads and rotors
Every 5,000 miles (8,000 km) or
6 monthsChange engine oil and replace filter
Inspect and lubricate U-joints
Every 10,000 miles (16,000 km) or
400 hours of engine operation
(whichever comes first)Change engine-mounted fuel filter and chassis-mounted
(HFCM) fuel filter
Every 20,000 miles (32,000 km) or
800 hours of engine operation
(whichever comes first)Check the Nitrite level of the coolant using Fleetguard

DCA4 Test Strip Kit CC2602A to determine if recharge is
required. If the Nitrite level is above 800 ppm no action
is required. If the Nitrite level is 800 ppm or lower add
32 fl. oz. (946 mL). of Supplemental Coolant Additive
Motorcraft VC-8 or equivalent.
Every 30,000 miles (48,000 km)Replace wheel bearing grease and grease seals on 4x2
wheel bearings (if non-sealed bearings)
Every 40,000 miles (64,000 km) or
1600 hours of engine operation
(whichever comes first)Check the Nitrite level of the coolant using Fleetguard

DCA4 Test Strip Kit CC2602A to determine if recharge is
required. If the Nitrite level is above 800 ppm no action
is required. If the Nitrite level is 800 ppm or lower add
32 fl. oz. (946 mL). of Supplemental Coolant Additive
Motorcraft VC-8 or equivalent.
Every 60,000 miles (96,000 km)Change transfer case fluid (4x4 only)
Every 60,000 miles (96,000 km) or
2400 hours of engine operation
(whichever comes first)Flush & refill engine coolant (refer to Motorcraft Premium
Gold Engine Coolant Change Record) – Do not add
Supplemental Coolant Additive
As requiredChange manual transmission fluid
Note:When adding supplemental coolant additive, do not exceed the
specified maximum of 32 fl. oz. (946 mL). Operating the engine with
excessive supplemental coolant additive can cause severe engine
damage.
2009 Econoline(eco)
Supplement, 1st Printing
USA(fus)
Scheduled Maintenance: F-Super Duty
95

Sustained high-speed driving at Gross Vehicle Weight Rating (maximum
loaded weight for vehicle operation)
Every 5,000 miles (8,000 km) or
6 monthsChange engine oil and replace filter
Every 5,000 miles (8,000 km)Rotate tires, inspect tires for wear and measure tread
depth and inspect wheel ends for endplay and noise
Inspect and lubricate steering and suspension ball joints
and tie rod ends (if equipped with zerk fittings)
Inspect brake system pads and rotors
Every 10,000 miles (16,000 km) or
400 hours of engine operation
(whichever comes first)Change engine-mounted fuel filter and chassis-mounted
(HFCM) fuel filter
Every 20,000 miles (32,000 km) or
800 hours of engine operation
(whichever comes first)Check the Nitrite level of the coolant using Fleetguard

DCA4 Test Strip Kit CC2602A to determine if recharge is
required. If the Nitrite level is above 800 ppm no action
is required. If the Nitrite level is 800 ppm or lower add
32 fl. oz. (946 mL). of Supplemental Coolant Additive
Motorcraft VC-8 or equivalent.
Every 30,000 miles (48,000 km)Replace wheel bearing grease and grease seals on 4x2
wheel bearings (if non-sealed bearings)
Every 40,000 miles (64,000 km) or
1600 hours of engine operation
(whichever comes first)Check the Nitrite level of the coolant using Fleetguard

DCA4 Test Strip Kit CC2602A to determine if recharge is
required. If the Nitrite level is above 800 ppm no action
is required. If the Nitrite level is 800 ppm or lower add
32 fl. oz. (946 mL). of Supplemental Coolant Additive
Motorcraft VC-8 or equivalent.
Every 50,000 miles (80,000 km)Change rear axle lubricant (if equipped with a Dana rear
axle, some F-350s, all 450–550)
Every 50,000 miles (80,000 km)Change transfer case fluid (4x4 only)
Every 60,000 miles (96,000 km) or
2400 hours of engine operation
(whichever comes first)Flush & refill engine coolant (refer to Motorcraft Premium
Gold Engine Coolant Change Record) – Do not add
Supplemental Coolant Additive
Note:When adding supplemental coolant additive, do not exceed the
specified maximum of 32 fl. oz. (946 mL). Operating the engine with
excessive supplemental coolant additive can cause severe engine
damage.
2009 Econoline(eco)
Supplement, 1st Printing
USA(fus)
Scheduled Maintenance: F-Super Duty
96

Use of Biodiesel, up to and including 5% Biodiesel (B5)
Every 10,000 miles (16,000 km),
6 months or 400 hours of operation
(which ever comes first)Replace engine-mounted fuel filter and chassis-mounted
(HFCM) fuel filter
Use of non-Ultra Low Sulfur Diesel (ULSD) fuel - Vehicles operated where
ultra low sulfur diesel fuel is not required/not available
Every 2,500 miles (4,000 km) or
3 months (If using high sulfur fuel
with more than 3000 ppm sulfur)Change engine oil and replace filter
Every 5,000 miles (8,000 km) or
6 months (If using high sulfur fuel
with less than 3000 ppm sulfur)Change engine oil and replace filter
2009 Econoline(eco)
Supplement, 1st Printing
USA(fus)
Scheduled Maintenance: F-Super Duty
97

Special Operating Conditions Log
DEALERVALIDATION:
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2009 Econoline(eco)
Supplement, 1st Printing
USA(fus)
Scheduled Maintenance: F-Super Duty
98

Special Operating Conditions Log
DEALERVALIDATION:
RO#: P&A C
ODE:
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EALERVALIDATION:
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2009 Econoline(eco)
Supplement, 1st Printing
USA(fus)
Scheduled Maintenance: F-Super Duty
99

EXCEPTIONS
In addition, there are several exceptions to the Normal Schedule. They
are listed below:
MAINTENANCE AND SERVICE RECORD
See an authorized dealer
This section of the guide is designed to allow your Ford dealer, or Ford
Auto Care service center or other qualified service technician to record
that the recommended service was completed at the appropriate mileage
intervals. Be sure to ask your service provider to record the type of
service rendered (Normal or Special Operating Conditions - SOC) each
time service is performed.
Normal Vehicle Axle Maintenance
❑Rear axles and power take-off (PTO) units containing synthetic lubricant and light duty trucks equipped with Ford-design
axles are lubricated for life. These lubricants are not to be checked or changed unless a leak is suspected, service is re-
quired or the axle assembly has been submerged in water. The axle and PTO lubricant should be changed anytime the axle
and PTO have been submerged in water. Non-synthetic rear axle lubricants should be replaced every 3,000 miles
(5,000 km) or 3 months, whichever occurs first, during extended trailer tow operation above 70°F (21°C) ambient and
wide open throttle for extended periods above 45 mph (72 km/h). The 3,000 mile (5,000 km) lube change interval may
be waived if the axle was filled with 75W140 synthetic gear lubricant meeting Ford specification WSL-M2C192-A, part
number F1TZ-19580-B or equivalent. Add four ounces (118 mL) of additive friction modifier C8AZ-19B546-A (EST-
M2C118-A) or equivalent for complete refill of Traction-Lok rear axles. The axle lubricant should be changed anytime an
axle has been submerged in water.
E-450, F-450 and F-550 Axle Maintenance
❑Replace rear axle lubricant every 100,000 miles (160,000 km) under normal driving conditions on all F-450 and F-550
commercial applications. For F-450 and F-550 trucks operated at or near maximum Gross Vehicle Weights, the rear axle
lubricant should be replaced every 50,000 miles (80,000 km). In addition, this 50,000 mile (80,000 km) schedule
should be observed when the vehicles are operated under the Special Operating Conditions, where noted.
Diesel Particulate Filter (DPF)
❑The DPF may need to be removed for ash cleaning at approximately 120,000 miles (192,000 km) or greater (actual
mileage can vary greatly depending upon engine/vehicle operating conditions) and replaced with a new or remanufactured
(ash cleaned) part. The filter may need to be replaced at approximately 250,000 miles (400,000 km) depending upon
engine/vehicle operating conditions. In both cases the engine control system will set a service light (
) to inform
you to bring the vehicle to the dealer for service. If there are any issues with the oxidation catalyst/DPF system a service
light (
or) will be set by the engine control system to inform you to bring the vehicle into a dealership
for service.
2009 Econoline(eco)
Supplement, 1st Printing
USA(fus)
Scheduled Maintenance: Special Information
100