engine FORD SUPER DUTY 2009 2.G Repair Manual

The 4WD system:
•provides 4x4 High engagement and disengagement while the vehicle is
moving.
•is operated by a rotary control located on the instrument panel that
allows you select 2WD, 4x4 High or 4x4 Low operation.
•uses auto-manual hub locks that can be engaged and disengaged
automatically based on the 4x4 mode selected.
•auto-manual hub locks can be
manually overridden by rotating
the hub lock control from AUTO
to LOCK if desired.
•automatic operation of the
hub locks is recommended,and
will increase fuel economy
•For proper operation, make
sure that each hub is fully
engaged and that both hub
locks are set to the same position (both set to LOCK or both
set to AUTO). To engage LOCK, turn the hub locks completely
clockwise; to engage AUTO, turn the hub locks completely
counterclockwise.
4WD system indicator lights
The 4WD system indicator lights illuminate only under the following
conditions. If these lights illuminate when driving in 2WD, contact your
authorized dealer as soon as possible.
•4x4 HIGH- momentarily
illuminates after the engine is
started. Illuminates when 4H (4x4
High) is engaged. Flashes when
shifting into or out of 4H (4x4 high) (ESOF systems only).
•4x4 LOW– momentarily
illuminates when the ignition is
turned to the ON position.
Illuminates when 4L (4x4 Low) is
engaged. Flashes when shifting into or out of 4L (4x4 Low) or if the
range shift conditions are not met (ESOF systems only).
4x4
HIGH
4x4
LOW
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•It often may be less risky to strike small objects, such as highway
reflectors, with minor damage to your vehicle rather than attempt a
sudden return to the pavement which could cause the vehicle to slide
sideways out of control or roll over. Remember, your safety and the
safety of others should be your primary concern.
WARNING:Vehicles with a higher center of gravity such as
utility and four-wheel drive vehicles handle differently than
vehicles with a lower center of gravity. Utility and four-wheel drive
vehicles arenotdesigned for cornering at speeds as high as passenger
cars any more than low-slung sports cars are designed to perform
satisfactorily under off-road conditions. Avoid sharp turns, excessive
speed and abrupt maneuvers in these vehicles. Failure to drive
cautiously could result in an increased risk of loss of vehicle control,
vehicle rollover, personal injury and death.
If your vehicle gets stuck
If your vehicle gets stuck in mud or snow it may be rocked out by
shifting between forward and reverse gears, stopping between shifts, in a
steady pattern. Press lightly on the accelerator in each gear.
Do not rock the vehicle if the engine is not at normal operating
temperature or damage to the transmission may occur.
Do not rock the vehicle for more than a few minutes or damage
to the transmission and tires may occur or the engine may
overheat.
WARNING:Do not spin the wheels at over 35 mph (56 km/h).
The tires may fail and injure a passenger or bystander.
Refer toTransmission fluid temperature gaugein theInstrument
Clusterchapter for transmission fluid temperature information.
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Emergency maneuvers
•In an unavoidable emergency situation where a sudden sharp turn
must be made, remember to avoid “over-driving” your vehicle, i.e.,
turn the steering wheel only as rapidly and as far as required to avoid
the emergency. Excessive steering will result in less vehicle control,
not more. Additionally, smooth variations of the accelerator and/or
brake pedal pressure should be utilized if changes in vehicle speed are
called for. Avoid abrupt steering, acceleration or braking which could
result in an increased risk of loss of vehicle control, vehicle rollover
and/or personal injury. Use all available road surface to return the
vehicle to a safe direction of travel.
•In the event of an emergency stop, avoid skidding the tires and do not
attempt any sharp steering wheel movements.
WARNING:Vehicles with a higher center of gravity such as
utility and four-wheel drive vehicles handle differently than
vehicles with a lower center of gravity. Utility and four-wheel drive
vehicles arenotdesigned for cornering at speeds as high as passenger
cars any more than low-slung sports cars are designed to perform
satisfactorily under off-road conditions. Avoid sharp turns, excessive
speed and abrupt maneuvers in these vehicles. Failure to drive
cautiously could result in an increased risk of loss of vehicle control,
vehicle rollover, personal injury and death.
•If the vehicle goes from one type of surface to another (i.e., from
concrete to gravel) there will be a change in the way the vehicle
responds to a maneuver (steering, acceleration or braking). Again,
avoid these abrupt inputs.
Parking
On some 4WD vehicles, when the transfer case is in the N (Neutral)
position, the engine and transmission are disconnected from the rest of
the driveline. Therefore, the vehicle is free to roll even if the automatic
transmission is in P (Park) or the manual transmission is in gear. Do not
leave the vehicle unattended with the transfer case in the N (Neutral)
position. Always set the parking brake fully and turn off the ignition
when leaving the vehicle.
WARNING:Always set the parking brake fully and make sure
the gearshift is latched in P (Park). Turn the ignition to the off
position and remove the key whenever you leave your vehicle.
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or straight down.Avoid driving crosswise or turning on steep
slopes or hills. A danger lies in losing traction, slipping sideways and
possibly rolling over. Whenever driving on a hill, determine beforehand
the route you will use. Do not drive over the crest of a hill without
seeing what conditions are on the other side. Do not drive in reverse
over a hill without the aid of an observer.
When climbing a steep slope or hill,
start in a lower gear rather than
downshifting to a lower gear from a
higher gear once the ascent has
started. This reduces strain on the
engine and the possibility of stalling.
If you do stall out, do not try to
turn around because you might roll
over. It is better to back down to a
safe location.
Apply just enough power to the
wheels to climb the hill. Too much
power will cause the tires to slip,
spin or lose traction, resulting in
loss of vehicle control.
Descend a hill in the same gear you
would use to climb up the hill to
avoid excessive brake application
and brake overheating. Do not
descend in neutral; instead,
manually shift to a lower gear. Your
vehicle has anti-lock brakes, apply
the brakes steadily. Do not “pump”
the brakes.
Driving on snow and ice
4WD vehicles have advantages over 2WD vehicles in snow and ice but
can skid like any other vehicle.
Should you start to slide while driving on snowy or icy roads, turn the
steering wheel in the direction of the slide until you regain control.
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VEHICLE USED AS A STATIONARY POWER SOURCE
Auxiliary equipment called power take-off, or PTO, is often added to the
engine or transmission to operate utility equipment. Examples include a
wheel-lift for tow trucks, cranes, tools for construction or tire service,
and pumping fluids. PTO applications draw auxiliary horsepower from
the powertrain, often while the vehicle is stationary. In this condition,
there is limited cooling air flow through the radiator and around the
vehicle that normally occurs when a vehicle is moving. The aftermarket
PTO system installer, having the most knowledge of the final application,
is responsible for determining whether additional chassis heat protection
or powertrain cooling is required, and alerting the user to the safe and
proper operation.
Ford Super Duty Vehicles are qualified for use as a stationary power
source, within limits detailed in theFord Truck Body Builders Layout
Book,found at www.fleet.ford.com/truckbbas, and through the Ford
Truck Body Builders Advisory Service.
Gas engine vehicles are qualified for up to 10 minutes of continuous
operation as a stationary power source, due to the potential for the
normal venting of fuel vapors. For stationary PTO operation of extended
duration (beyond 10 minutes), diesel engine is recommended. Further
consult your aftermarket PTO installer, since the duration of operation
limit for the aftermarket PTO may be less than the vehicle is capable of.
DRIVING THROUGH WATER
If driving through deep or standing
water is unavoidable, proceed very
slowly especially when the depth is
not known. Never drive through
water that is higher than the bottom
of the wheel rims (for cars) or the
bottom of the hubs (for trucks).
When driving through water, traction or brake capability may be limited.
Also, water may enter your engine’s air intake and severely damage your
engine or your vehicle may stall.Driving through deep water where
the transmission vent tube is submerged may allow water into the
transmission and cause internal transmission damage.
Once through the water, always dry the brakes by moving your
vehicle slowly while applying light pressure on the brake pedal.
Wet brakes do not stop the vehicle as quickly as dry brakes.
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•The snow plow prep package includes a unique powertrain control
strategy which is required for diesel engine cooling during highway
driving with the snowplow raised.
Operating the vehicle with the snowplow attached
Do not use your vehicle for snow removal until it has been driven at
least 500 miles (800 km).
The attached snowplow blade restricts airflow to the radiator, and may
cause the engine to run at a higher temperature: Attention to engine
temperature is especially important when outside temperatures are
above freezing. Angle the blade to maximize airflow to the radiator and
monitor engine temperature to determine whether a left or right angle
provides the best performance.
Follow the severe duty schedule in yourscheduled maintenance
informationfor engine oil and transmission fluid change intervals.
Snowplowing with your airbag-equipped vehicle
Your vehicle is equipped with a driver and passenger airbag
Supplemental Restraint System (SRS) The SRS is designed to activate in
certain frontal and offset frontal collisions when the vehicle sustains
sufficient longitudinal deceleration.
Careless or high speed driving while plowing snow which results in
sufficient vehicle decelerations can deploy the airbag. Such driving also
increases the risk of accidents.
WARNING:All occupants of the vehicle, including the driver,
should always properly wear their safety belts, even when an air
bag supplemental restraint system (SRS) is provided.
Never remove or defeat the “tripping mechanisms” designed into the
snow removal equipment by its manufacturer. Doing so may cause
damage to the vehicle and the snow removal equipment as well as
possible airbag deployment.
WARNING:Do not attempt to service, repair, or modify the air
bag supplemental restraint system (SRS) or its fuses. See your
Ford or Lincoln Mercury dealer.
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WARNING:Additional equipment such as snowplow equipment
may effect the performance of the airbag sensors increasing the
risk of injury. Please refer to theBody Builders Layout Bookfor
instructions about the appropriate installation of additional equipment.
Transmission operation while plowing
Operate the vehicle with the automatic transmission gearshift lever in
the D (Overdrive) position and Tow/Haul off.
•Shift transfer case to 4x4 LOW (4WD Low) when plowing in small
areas at speeds below 5 mph (8 km/h).
•Shift transfer case to 4x4 HIGH (4WD High) when plowing larger
areas or light snow at higher speeds. Do not exceed 15 mph
(24 km/h).
•Do not shift the transmission from a forward gear to R (Reverse) until
the engine is at idle and the wheels are stopped.
•If the vehicle is stuck, shift the transmission in a steady motion
between forward and reverse gears. Do not rock the vehicle for more
than a few minutes. The transmission and tires may be damaged or
the engine can overheat.
Do not rock the vehicle if the engine is not at normal operating
temperature. Do not rock the vehicle for more than a minute. The
transmission and tires may be damaged or the engine may
overheat.
Refer toTransmission temperature gaugein theInstrument Cluster
chapter for transmission fluid temperature information.
WARNING:Do not spin the wheels at over 35 mph (55 km/h).
The tires may fail and injure a passenger or bystander.
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FUEL PUMP SHUT-OFF SWITCH
This device stops the electric fuel pump from sending fuel to the engine
when your vehicle has had a substantial jolt.
After an accident, if the engine cranks but does not start, this switch
may have been activated.
This switch is located on the
passenger’s side of the instrument
panel. Open the front passenger
door and remove the small access
panel
The switch has a red button on top
of it.
To reset the switch:
1. Turn the ignition off.
2. Check the fuel system for leaks.
3. If no leaks are apparent, reset the switch by pushing in on the reset
button.
4. Turn the ignition on.
5. Wait a few seconds and return the key to off.
6. Make another check for leaks.
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Fuse/Relay
LocationFuse Amp
RatingProtected Circuits
10 15A Cargo lamp, Puddle lamp, Switch
backlight
11 10A Not used (spare)
12 7.5A Power mirror switch, Driver
power seat (Memory)
13 5A Not used (spare)
14 10A Upfitter relay #3 feed
15 10A Climate control head
16 15A Upfitter Relay #4 Feed
17 20A All lock motor feeds
18 20A Heated seat relay feed
19 25A Not used (spare)
20 15A Adjustable pedals, Datalink
21 15A Fog lamp relay feed, Cornering
lamps
22 15A Park lamp relay feed
23 15A High beam headlight relay feed
24 20A Horn relay feed
25 10A Power telescoping mirror switch
Demand lamps - underhood and
illuminated visor (battery saver)
26 10A Cluster
27 20A Ignition switch feed, Passenger
compartment fuses 28, 42, 43, 44,
and 45, Engine compartment
starter relay coil #57 (Diesel
engine), Accessory shutoff control
module (if equipped) (Diesel
engine), Engine compartment
starter relay diode (gasoline
engines)
28 5A Radio
29 5A Not used (spare)
30 5A Not used (spare)
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Fuse/Relay
LocationFuse Amp
RatingProtected Circuits
31 10A Not used (spare)
32 10A Restraints Control Module (RCM),
Passenger Airbag Deactivation
Indicator
33 10A Trailer tow brake controller,
Trailer tow battery charge relay
coil
34 5A Not used (spare)
35 10A Reverse Sensing System (RSS),
4x4 module, 4x4 solenoid,
Traction control switch, Tow/Haul
switch (Diesel engine)
36 5A Passive Anti-Theft System (PATS)
transceiver, Cluster control
37 10A Dual automatic or Manual climate
control, PTC control
38 20A Subwoofer
39 20A Radio, Navigation radio and
amplifier
40 20A 4x4 module, Satellite radio
module, SYNC
41 15A Radio, Electrochromatic rear view
mirror, Lock switch illumination
42 10A Heated seat relay coil, Upfitter
switch relay coils, Heated mirror
relay coil
43 10A Fuel tank selector switch, 4x4
module
44 10A Run customer access feed (PTO)
45 5A Front wiper logic, Blower motor
relay coil
46 7.5A Not used (spare)
47 30A Circuit
BreakerPower windows, Moon roof,
Power Sliding Backlite
48 Relay Delayed accessory
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