brake FORD E SERIES 1996 4.G Workshop Manual

327
*
[SV36850( ALL)12/91]
NOTE: If brake fluid is spilled on painted
surfaces, it must be flushed and wiped
away immediately. Brake fluid may
dissolve the paint finish on your
vehicle.
*
[SV36900( ALL)01/95]
RWARNING
If you use a brake fluid that is not DOT
3, you will cause permanent damage to
your brakes.
*
[SV37000( ALL)01/95]
Do not fill the reservoir above the MAX line.
*
[SV37100( ALL)01/95]
If you find that the fluid level is excessively low
Ð below the seam or ridge on the outside of the
plastic reservoir Ð have the brake system
inspected.
*
[SV37200( ALL)01/95]
RWARNING
Do not let the reservoir for the master
cylinder run dry. This may cause the
brakes to fail.
*
[SV37400(BEF )01/89]
quarter page art:0020381-A
Brake master cylinder
File:14ltsve.ex
Update:Wed Apr 17 08:40:13 1996

340
*
[SV44600(BEF )03/95]
Lights and Bulb Replacement
*
[SV44700(BEF )01/95]
It is a good idea to check the operation of the
following lights frequently:
*
[SV44800(BEF )01/95]
q
headlamps
*
[SV44900(BEF )01/95]
q
tail lamps
*
[SV45000(BEF )01/95]
q
brakelamps
*
[SV45050(BEF )02/95]
q
high-mount brakelamp
*
[SV45100(BEF )01/95]
q
hazard flasher
*
[SV45200(BEF )01/95]
q
turn signals
*
[SV45300(BEF )01/95]
q
license plate lamp
%*
[SV45400(BEF )01/95]
The alignment of your headlamps should be
checked if:
*
[SV45500(BEF )01/95]
q
oncoming motorists frequently signal you to
turn off your vehicle's high beams when you
do not have the high beams on
*
[SV45600(BEF )01/95]
q
the headlamps do not seem to give you
enough light to see clearly at night
*
[SV45700(BEF )01/95]
q
the headlamp beams are pointed substantially
away from a position slightly down and to
the right
File:14ltsve.ex
Update:Wed Apr 17 08:40:13 1996

343
*
[SV46900(BEF )03/95]
Installing the headlamp bulb
*
[SV47000(BEF )02/95]
1. With the flat side of the bulb's plastic base
facing upward, insert the glass end of the
bulb into the socket. You may need to turn
the bulb left or right to line up the grooves
in the plastic base with the tabs in the
socket. When the grooves are aligned, push
the bulb into the socket until the plastic base
contacts the rear of the socket.
*
[SV47100(BEF )02/95]
2. Slip the bulb retaining ring over the plastic
base until it contacts the rear of the socket.
Lock the ring into the socket by rotating it
clockwise until you feel a ªstopº.
[SV47250( E )12/91]
3. Reposition the three adjuster screws into the
retaining holes and hold while pushing the
two black tabs downward to engage the
ends of the adjuster screws. You will hear a
ªsnapº when the tabs are properly engaged.
Make sure lamp is secured properly by
pulling it forward. If it is loose, remove
lamp and reinstall.
*
[SV47300(BEF )02/95]
4. Turn the headlamps on and make sure that
they work properly. If the headlamp was
correctly aligned before you changed the
bulb, you should not need to align it again.
*
[SV47406( E )02/95]
High-Mount Brakelamp Bulbs
[SV47410( E )03/91]
E-150 Ð E-350 without cargo lamp attached
[SV47420( E )03/91]
To remove/install or replace a bulb:
[SV47430( E )03/91]
1. Remove the two screws that secure the lamp
and lift up from the vehicle.
[SV47440( E )03/91]
2. Remove the socket that contains the
burned-out bulb and replace the bulb.
[SV47450( E )03/91]
3. To install a bulb, reverse the procedures
above.
File:14ltsve.ex
Update:Wed Apr 17 08:40:13 1996

362 %
*
[SV57350( ALL)01/95]
Engine
*
[SV57400( ALL)01/95]
q
Start engine every 15 days. Run at fast idle
until it reaches normal operating temperature.
*
[SV57500( ALL)01/95]
q
With your foot on the brake, shift through all
the gears while the engine is running.
%*
[SV57600( ALL)01/95]
Fuel system
%*
[SV57700( ALL)07/94]
q
Fill fuel tank with high-quality unleaded fuel
until the first automatic shutoff of the fuel
pump nozzle.
*
[SV57900( ALL)03/95]
NOTE: During extended periods of vehicle
storage (60 days or more), fuel may
deteriorate due to oxidation. This can
damage rubber and other polymers in
the fuel system and may also clog
small orifices.
*
[SV58000( ALL)01/95]
Ford Gas Stabilizer should be added whenever
actual or expected storage periods exceed 60
days. Follow the instructions on the label. The
vehicle should then be operated at idle speed to
circulate the additive throughout the fuel system.
*
[SV58050( EF )05/94]
NOTE: Read the7.3L Diesel Engine Owner
Guide Supplementfor information
regarding vehicle storage for your
diesel-powered vehicle.
*
[SV58100( ALL)01/95]
A volatile corrosion inhibitor added to the fuel
system will protect the fuel system's inner
surfaces from corrosion. Follow the instructions
packaged with the product.
%*
[SV58200( ALL)01/95]
Cooling system
*
[SV58300( ALL)01/95]
q
Protect against freezing temperatures.
File:14ltsve.ex
Update:Wed Apr 17 08:40:13 1996

363 %
*
[SV58400( ALL)01/95]
Battery
*
[SV58500( ALL)01/95]
q
Check and recharge as necessary.
*
[SV58600( ALL)01/95]
q
Keep connections clean and covered with a
light coat of grease.
%*
[SV58700( ALL)01/95]
Brakes
*
[SV58800( ALL)01/95]
q
Make sure brakes and parking brake are fully
released.
%*
[SV58900( ALL)01/95]
Tires
[SV59000( ALL)10/95]
q
Maintain recommended air pressures.
*
[SV59100( ALL)01/95]
Miscellaneous
*
[SV59200( ALL)01/95]
q
Make sure all linkages, cables, levers and
clevis pins under vehicle are covered with
grease to prevent rust.
*
[SV59300( ALL)05/95]
q
Move vehicles at least 25 feet (10 m) every 15
days to lubricate working parts to prevent
corrosion.
File:14ltsve.ex
Update:Wed Apr 17 08:40:13 1996

Index 379
Brake fluid
brake warning light........... 69
checking and adding......... 326
description.............. 326
specifications............. 326
Brakelamp, high-mount brakelamp . . . 96, 343
Brakes
adjustment.............. 206
anti-lock............... 206
anti-lock brake system (ABS)
warning light............ 70
applying the brakes.......... 212
brake warning light........... 69
fluid, checking and adding...... 326
fluid, refill capacities......... 353
fluid, specifications.......... 326
front disc.............. 206
if brakes do not grip well....... 211
master cylinder............ 326
new brake linings............ 8
noise................ 206
parking............... 212
power braking............ 206
rear anti-lock............. 208
servicing............... 211
stopping distances.......... 212
trailer................ 238
when storing your vehicle....... 363
Brake-shift interlock....... 60,196, 202
Break-in period.............. 8
Brights (high beams)........... 77
Bulbs, replacing............. 340
halogen............... 341
headlamps.............. 341
high-mount brakelamp........ 343
C
Canada, customer assistance....... 268
Canada, warranty information....... 4
Canadian Motor Vehicle Arbitration Plan
(CAMVAP).............. 269
File:ltixe.ex
Update:Wed Apr 17 08:36:26 1996

Index 383
Electronic stereo radio
(see Electronic sound system)..... 178
Emergencies, roadside
assistance.............. 259
battery acid spills.........243, 321
jump-starting............. 243
towing................ 258
Emergency brake (parking brake)..... 212
Emission control system......... 346
catalytic converter.......... 346
emissions warranty....... 4,346, 349
Engine
check engine warning light....... 71
diesel................. 6
fuel injected engine, starting..... 57,59
fuel pump shut-off switch........ 63
preparing to start............ 58
refill capacities............ 353
service points............ 283
starting.............. 55,59
starting after a collision......... 63
storing your vehicle........361±362
Engine block heater............ 62
Engine coolant
checking and adding......... 301
checking hoses............ 305
disposal...........301, 304, 324
drain and flush............ 306
preparing for storage......... 362
proper solution............ 303
recovery reservoir........283, 302
refill capacities............ 353
refill procedure............ 306
specifications............. 304
temperature gauge........... 78
Engine coolant temperature gauge..... 78
File:ltixe.ex
Update:Wed Apr 17 08:36:26 1996

Index 387
Heating (continued)
standard heater system......... 83
High beams
indicator light............. 77
operation............. 92,100
High-mount brakelamp
description.............. 343
replacing the bulb.......... 343
High-mount brakelamp:location...... 96
Hitch................. 237
Hood
latch location............. 281
release lever............. 281
working under the hood....... 280
Horn.................. 104
Hoses, checking............. 305
I
Identification Number, Vehicle (VIN).... 6
Idle, relearning......... 57,247, 280
Ignition
chime................. 56
positions of the ignition......... 55
removing the key............ 56
Indicator lights and chimes (see Lights) . . . 67
Infant seats (see Safety seats)...... 38,41
Instrument cluster............. 67
mechanical............... 69
Instrument panel
cleaning................ 97
lighting up panel and interior...... 94
location of components......... 81
registers................ 83
Interval wipers...........101±102
J
Jack
operation............250, 252
positioning.............. 252
File:ltixe.ex
Update:Wed Apr 17 08:36:26 1996

388 Index
Jump-starting your vehicle
attaching cables............ 245
disconnecting cables.......... 247
K
Keys
key in ignition chime.......... 56
positions of the ignition......... 55
removing from the ignition....... 56
stuck in lock position........55±56
L
Lamps
cargo lamps.............. 94
checking............... 340
courtesy lamps............. 94
daytime running light system...... 93
dome lamps.............. 94
flashing the lamps........... 101
hazard flashers............ 103
headlamps............... 92
high beams.............. 100
high-mount brakelamp...... 96,343
illuminated entry system........ 120
illuminated mirrors.......... 143
instrument panel, dimming....... 94
interior lamps............ 92,94
replacing bulbs............ 340
Lane change indicator (see Turn signal) . . . 99
Lap belts................. 22
Lights, warning and indicator
airbag................. 74
anti-lock brakes (ABS).......... 70
anti-theft................ 75
brake................. 69
charging system............. 74
check engine.............. 71
engine oil pressure........... 76
hazard warning light......... 103
File:ltixe.ex
Update:Wed Apr 17 08:36:26 1996

Index 389
Lights, warning and indicator (continued)
high beam............... 77
overdrive off............. 201
rear ABS................ 70
safety belt............... 71
testing the warning lights........ 58
theft system.............. 75
turn signal indicator.......... 99
Load limits
GAWR................ 218
GVWR................ 218
trailer towing............. 220
Lubricant specifications......... 357
Lug nuts
standard............... 252
tightening sequence.......... 255
Lumbar support, seats.......... 141
M
Maintenance schedule and record
(see separate Maintenance Schedule
and Record booklet).......... 3
Maintenance (see Servicing)....... 279
Master cylinder, brakes......... 326
Mileage, calculating fuel economy.... 295
Mirrors
dual electric remote control...... 146
rearview............... 143
side view mirrors (manual)...... 144
side view mirrors (power)....... 146
vanity mirror............. 143
vanity mirror, illuminated....... 143
Motorcraft parts............. 356
File:ltixe.ex
Update:Wed Apr 17 08:36:26 1996