maintenance FORD E-150 2004 Repair Manual

Refer to Vehicle Emissions Control Information (VECI) decal for spark
plug gap information.
4Only available with 6.0L Diesel engine/TorqShift transmission. Part
number is FT-145.
REFILL CAPACITIES
Fluid Ford Part
NameApplication Capacity
Brake fluid Motorcraft High
Performance
DOT 3 Motor
Vehicle Brake
FluidAll Fill to line on
reservoir
Engine
oil-gasoline
engine (includes
filter change)
9
Motorcraft SAE
5W-20 Premium
Synthetic Blend
Motor Oil (US)
Motorcraft SAE
5W-20 Super
Premium Motor
Oil (Canada)All 5.7L (6.0
quarts)
Engine oil-diesel
engine (includes
filter change)Refer to thePower Stroke Direct Injection Turbo
Diesel Owner’s Guide Supplement.
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Fluid Ford Part
NameApplication Capacity
Engine
coolant-gasoline
engine
1
Motorcraft
Premium Gold
Engine Coolant
(yellow-colored)4.6L V8 engine 23.7L (25.0
quarts)
1 row–22.6L
(23.8 quarts)
8
4.6L V8 engine
with aux rear
heat25.7L (27.2
quarts)
1 row–24.6L
(26.0 quarts)
8
5.4L V8 engine 27.4L (29.0
quarts)
1 row–26.3L
(27.8 quarts)
8
5.4L V8 engine
with aux rear
heat29.4L (31.0
quarts)
1 row–28.3L
(29.8 quarts)
8
6.8L V10 engine 29.0L (30.6
quarts)
1 row–27.9L
(29.4 quarts)
8
6.8L V10 engine
with aux rear
heat31.0L (32.8
quarts)
1 row–29.9L
(31.6 quarts)
8
Engine
coolant-diesel
engineRefer to thePower Stroke Direct Injection Turbo
Diesel Owner’s Guide Supplement.1
Power steering
fluidMotorcraft
MERCONAT FAll Keep in FULL
range on
dipstick
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Fluid Ford Part
NameApplication Capacity
Rear axle
4Motorcraft SAE
75W-90 Fuel
Efficient High
Performance
Synthetic rear
axle lubricant
2
Visteon 8.8/9.75
inch
conventional and
Traction-Lok2.6 (5.5 pints)3
SAE 75W-140
Synthetic Rear
Axle Lubricant
2
Dana M70HD
(M273HD)
E-350 DSO3.5L (7.4 pints)3
Dana M60
(M248)
E-250/350 DSO
limited slip
4
3.0L (6.3 pints)3
SAE 90 Hypoid
Gear Oil (axles
shown are all
limited slip)
4
Dana Limited
Slip Axles
M60 (M248)
E250/3503.0L (6.3 pints)3
M70FF
(M267FF)
E-3503.2L (6.8 pints)3
M70HD
(M273HD)
E-4503.9L (8.3 pints)3
SAE 80W-90
Premium Rear
Axle LubricantDana
conventional
axles
M60 (M248)
E250/3503.0L (6.3 pints)3
M70FF
(M267FF)
E-3503.1L (6.6 pints)3
M70HD
(M273HD)
E-4503.9L (8.3 pints)3
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Fluid Ford Part
NameApplication Capacity
Fuel tank N/A All regular and
extended length
vans and wagons132.4L (35.0
gallons)
138 inch
wheelbase
(except E-Super
Duty)140.0L (37.0
gallons)
158 inch
wheelbase
(except E-Super
Duty)140.0L (37.0
gallons)
5
176 inch
wheelbase
(except E-Super
Duty)140.0L (37.0
gallons)
158 inch and
176 inch
wheelbase
(E-Super Duty)208.0L (55 .0
gallons)
Transmission
fluid
6Motorcraft
MERCONV
AT FAutomatic
(4R70/75 E-W)13.2L (13.9
quarts)7
Motorcraft
MERCONAT FAutomatic
(4R100 except
E-450)16.1L (17.0
quarts)7
Automatic
(4R100 E-450)16.7L (17.7
quarts)7
Motorcraft
MERCONSP
AT FTorqShift
(5–speed)16.6L (17.5
quarts)7
Windshield
washer fluidMotorcraft
Premium
Windshield
Washer
ConcentrateAll 4.0L (4.2
quarts)
1Add the coolant type originally equipped in your vehicle.2If your vehicle’s rear axle is filled with a synthetic rear axle lubricant it
is considered lubricated for life. These lubricants do not need to be
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checked or changed 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.
Fill 6 mm to 14 mm (1/4 inch to 9/16 inch) below bottom of fill hole.
Add 118 ml (4 oz.) of Additive Friction Modifier XL-3 or equivalent
meeting Ford specification EST-M2C118–A, for complete refill of 8.8 inch
and 9.75 inch Traction-Lok axles.
3Fill Dana rear axles to 6 mm to 19 mm (1/4 inch to 3/4 inch) below
bottom of fill hole. Fill Visteon axles 6 mm to 14 mm (1/4 inch to 9/16
inch) below bottom of fill hole.
4Visteon Traction-Lok axles require 118 ml (4 oz.) of Additive Friction
Modifier XL—3 or equivalent meeting Ford specification EST-M2C118–A.
Dana limited-slip axles (E250/350/450/550) require 237ml (8 oz.) of
Additive Friction Modifier C8AZ—19B546–A or equivalent meeting Ford
specification EST-M2C118-A.
5Optional fuel tank 208L (55 gallon).
6Ensure 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 yourScheduled Maintenance Guideto determine
the correct service interval.
Some transmission fluids may be labeled as dual usage, such as
MERCONand MERCONV. These dual usage fluids are not to be used
in an automatic transmission that requires use of the MERCONtype
fluid. However, these dual usage fluids may be used in transmissions that
require the MERCONV type fluid.
MERCON, MERCONV and MERCONSP are not
interchangeable. DO NOT mix MERCON, MERCONV and
MERCONSP. Use of dual usage fluids in an automatic
transmission application requiring MERCONSP may cause
transmission damage. Use of a transmission fluid other than the
recommended fluid may cause transmission damage.
7Indicates only approximate dry-fill capacity. Some applications may vary
based on cooler size, if equipped with an in-tank cooler, if equipped an
oil to air cooler and if equipped with a remote filter assembly. The
amount of transmission fluid and fluid level should be set by the
indication on the dipstick’s normal operating range.
8If your vehicle is equipped with a single row radiator, there will be a
label on the top side of the radiator indicating“1 Row Radiator”.
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9Use of synthetic or synthetic blend motor oil is not mandatory. Engine
oil need only meet the requirements of Ford specification
WSS-M2C153–H and the API Certification mark.
LUBRICANT SPECIFICATIONS
Item Ford part
nameFord part
numberFord
specification
Brake fluid Motorcraft High
Performance
DOT 3 Motor
Vehicle Brake
FluidPM-1 ESA-M6C25-A
and DOT 3
Door
weatherstripsSilicone
LubricantXL-6 ESR-M13P4-A
Engine coolant Motorcraft
Premium Gold
Engine Coolant
(yellow-colored)VC-7-A (U.S.,
except CA and
OR), VC-7-B
(CA and OR
only)WSS
-M97B51-A1
Engine
oil-gasoline
engineMotorcraft SAE
5W-20 Premium
Synthetic Blend
Motor Oil (US)
Motorcraft SAE
5W-20 Super
Premium Motor
Oil (Canada)XO-5W20-QSP
(US)
CXO-5W20–
LSP12 (Canada)WSS-M2C153-
HWSS-M2C930-A
with API
Certification
Mark
Engine oil-diesel
engineRefer to thePower Stroke Direct Injection Turbo
Diesel Owner’s Guide Supplement.
Hinges, latches,
Striker plates,
fuel filler door
hinge, and seat
tracksMotorcraft
Multi-Purpose
GreaseXG–4 or XL-5 ESR-M1C159-A
or
ESB-M1C93–B
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Item Ford part
nameFord part
numberFord
specification
Lock cylinders Motorcraft
Penetrating and
Lock LubricantMotorcraft XL-1 none
Power steering
fluidMotorcraft
MERCONAT FXT-2-QDX MERCON
Automatic
transmission
(4R100)
1
Motorcraft
MERCONAT FXT-2-QDX MERCON
Automatic
transmission
(4R70/75 E-W)
1
Motorcraft
MERCONV
AT FXT-5-QM MERCONV
Automatic
transmission
TorqShift
(5–speed)
1
Motorcraft
MERCONSP
AT FXT-6–QSP MERCONSP
WSS-M2C919–D
Disc brake
caliper railsMotorcraft
Silicone Brake
Caliper Grease
and Dielectric
CompoundXG-3-A ESE-M1C171-A
Parking brake
assembly (E-450
Super Duty)Motorcraft
MERCON
Automatic
Transmission
FluidXT-2-QDX MERCON
Visteon
conventional and
Traction-Lok
axles
2
Motorcraft SAE
75W-90 Fuel
Efficient High
Performance
Synthetic Rear
Axle LubricantXY-75W90–
QFEHPMeets API GL-5
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Item Ford part
nameFord part
numberFord
specification
Dana M70HD
(M273HD)
E-350 DSO
Dana M60
(M248)
E-250/350 DSO
limited slip
3
SAE 75W-140
Synthetic Rear
Axle LubricantXY-75W140–QL WSL-M2C192–A
Dana Limited
Slip Axles
3
M60 (M248)
E-250/350
M70FF
(M267FF)
E-350
M70HD
(M273HD)
E-450SAE 90 Hypoid
Gear OilC6AZ-19580–E ESW-M2C105–E
Dana
conventional
axles
M60 (M248)
E-250/350
M70FF
(M267FF)
E-350
M70HD
(M273HD)
E-450SAE 80W-90
Premium Rear
Axle LubricantXY-80W90–QL WSP-M2C197–A
Windshield
washer fluidMotorcraft
Premium
Windshield
Washer
ConcentrateZC-32–A WSB-M8B16–A2
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1Ensure 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 yourScheduled Maintenance Guideto determine
the correct service interval.
Some transmission fluids may be labeled as dual usage, such as
MERCONand MERCONV. These dual usage fluids are not to be used
in an automatic transmission that requires use of the MERCONtype
fluid. However, these dual usage fluids may be used in transmissions that
require the MERCONV type fluid.
MERCONand MERCONV type fluids are not interchangeable.
DO NOT mix MERCONand MERCONV. Use of a transmission
fluid that indicates dual usage (MERCONand MERCONV) in
an automatic transmission application requiring MERCONmay
cause transmission damage. Use of any fluid other than the
recommended fluid may cause transmission damage.
2Add 118 ml (4 oz.) of Additive Friction Modifier XL-3 or equivalent
meeting Ford specification EST-M2C118-A for complete refill of Visteon
Traction-Lok rear axles.
3Add 237 ml (8 oz.) of Additive Friction Modifier C8AZ-19B546-A or
equivalent meeting Ford specification EST-M2C118-A for complete refill
of Dana Limited Slip rear axles.
ENGINE DATA
Engine*4.6L V8 engine 5.4L V8 engine 6.8L V10 engine
Cubic inches 281 330 415
Required fuel 87 octane 87 octane 87 octane
Firing order 1-3-7-2-6-5-4-8 1-3-7-2-6-5-4-8 1-6-5-10-2-7-3-8-4-9
Ignition
systemCoil on plug Coil on plug Coil on plug
Compression
ratio9.4:1 9.0:1 9.0:1
*Refer to thePower Stroke Direct Injection Turbo Diesel Owner’s
Guide Supplementfor diesel engine information.
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VEHICLE DIMENSIONS
Van/wagon models
E-150–Inches
(mm)E-250–Inches
(mm)E-350–
Inches
(mm)
(1) Overall height 80.7 (2050) 83.4 (2118) 84.1 (2136)
(2) Track front/rear 69.4 (1763)/
67.2(1707)69.4 (1763)/
66.6 (1692)69.4 (1763)/
66.4 (1687)
(3) Overall width
(excluding mirrors)79.3 (2014)
(4) Wheelbase 138.0 (3505)
(5) Overall length Regular van: 211.8. (5381)
Extended van: 231.8 (5889)
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