brake FORD E SERIES 2002 4.G Service Manual

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)Motorcraft SAE
5W-20 Super
Premium Motor
OilAll 5.7L (6.0
quarts)
Engine oil-diesel
engine (includes
filter change)Refer to the7.3L Power Stroke Direct Injection
Turbo Diesel Owner's Guide Supplement.
Engine
coolant-gasoline
engine
1
Motorcraft
Premium Engine
Coolant
(green-colored)
orMotorcraft
Premium Gold
Engine Coolant
(yellow-colored)4.2L V6 engine 22.0L (23.3
quarts)
4.2L V6 engine
with aux rear
heat24.0L (25.4
quarts)
4.6L V8 engine 23.7L (25.0
quarts)
4.6L V8 engine
with aux rear
heat25.7L (27.2
quarts)
5.4L V8 engine 27.4L (29.0
quarts)
5.4L V8 engine
with aux rear
heat29.4L (31.0
quarts)
6.8L V10 engine 29.0L (30.6
quarts)
6.8L V10 engine
with aux rear
heat31.0L (32.8
quarts)
Maintenance and specifications
254

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
LubricantF7AZ-19G208-BA
and
F5AZ-19553-AAESR-M13P4-A
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
oil-gasoline
engineMotorcraft SAE
5W-20 Super
Premium Motor
OilXO-5W20-QSP WSS-M2C153-H
with API
Certification
Mark
Engine oil-diesel
engineRefer to the7.3 Liter Power 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
F5AZ-19G209-AAESR-M1C159-A
Lock cylinders Motorcraft
Penetrating and
Lock LubricantMotorcraft XL-1 none
Power steering
fluidMotorcraft
MERCONtAT FXT-2-QDX MERCONt
Maintenance and specifications
258

Item Ford part
nameFord part
numberFord
specification
Automatic
transmission
(4R100)
1
Motorcraft
MERCONtAT FXT-2-QDX MERCONt
Automatic
tranmission
(4R70W)
1
Motorcraft
MERCONtV
AT FXT-5-QM MERCONtV
Disc brake
caliper railsMotorcraft
Silicone Brake
Caliper Grease
and Dielectric
CompoundXG-4 ESE-M1C171-A
Parking brake
assembly
(E-Super Duty)Motorcraft
MERCONt
Automatic
Transmission
FluidXT-2-QDX MERCONt
Visteon
conventional and
Traction-Lok
axles (E-150)
2
Motorcraft SAE
75W-140 High
Performance
Synthetic Rear
Axle LubricantXY-75W140±QL WSL-M2C192-A
Dana 9.75 inch
(M60±1U) 10.5
inch (M70±2U)
(M70±1HD)
(E-250/350/450)
3
Motorcraft SAE
80W-90
Premium Rear
Axle LubricantXY-80W90-QL WSP-M2C197-A
Windshield
washer fluidUltra-clear
Windshield
Washer
ConcentrateC9AZ-19550-AC ESR-M17P5-A
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
Maintenance and specifications
259

A
Air bag supplemental restraint
system ........................................132
and child safety seats ............134
description ..............................132
disposal ....................................137
driver air bag ..........................135
indicator light ...................14, 136
operation .................................135
passenger air bag ...................135
Air cleaner filter ...............247, 253
Air conditioning
manual heating and air
conditioning system .................79
Ambulance packages ....................7
Antifreeze (see Engine
coolant) .....................................226
Anti-lock brake system (see
Brakes) ..............................152±153
Audio system (see Radio) ...20, 41
Automatic transmission
driving an automatic
overdrive .................................157
fluid, adding ............................245
fluid, checking ........................245
fluid, refill capacities ..............254
fluid, specification ..................260
Auxiliary power point .................96
Axle
lubricant specifications ..258, 260
refill capacities ........................254
traction lok ..............................155
B
Battery .......................................220
acid, treating emergencies .....220charging system warning light 14
disconnecting ..........................222
jumping a disabled battery ....191
maintenance-free ....................220
replacement, specifications ...253
servicing ..................................220
voltage gauge ............................18
Belt minder ...............................127
Brakes ........................................152
anti-lock ...........................152±153
anti-lock brake system (ABS)
warning light .....................13, 153
brake warning light ..................13
fluid, checking and adding ....244
fluid, refill capacities ..............254
fluid, specifications .........258, 260
lubricant specifications ..258, 260
shift interlock ..........................156
Break-in period .............................5
C
Capacities for refilling fluids ....254
Child safety restraints ..............138
child safety belts ....................138
Child safety seats ......................139
in front seat ............................140
in rear seat ..............................140
tether anchorage hardware ...143
Cleaning your vehicle
engine compartment ..............209
exterior ....................................212
instrument cluster lens ..........211
instrument panel ....................211
interior .....................................211
plastic parts ............................210
safety belts ..............................212
washing ....................................207
waxing .....................................207
Index
267

I
Ignition .......................148, 260±261
Infant seats
(see Safety seats) .....................139
Inspection/maintenance (I/M)
testing ........................................242
Instrument panel
cleaning ...................................211
cluster ................................12, 211
lighting up panel and
interior .......................................86
J
Jack ............................................184
positioning ...............................184
storage .....................................184
Jump-starting your vehicle ......191
K
Keys
key in ignition chime ...............16
positions of the ignition .........148
L
Lamps
bulb replacement
specifications chart ..................88
cargo lamps ...............................86
daytime running light ...............85
headlamps .................................85
headlamps, flash to pass ..........86
instrument panel, dimming .....86
interior lamps ...........................87
replacing bulbs ...................88±93
Lane change indicator (see
Turn signal) .................................86Lights, warning and indicator ....12
air bag ........................................14
anti-lock brakes (ABS) ....13, 153
brake ..........................................13
charging system ........................14
check coolant ............................14
cruise indicator .........................14
door ajar ....................................15
engine oil pressure ...................14
high beam .................................15
low fuel ......................................14
safety belt .................................13
service engine soon ..................12
turn signal indicator .................15
Load limits .................................160
GAWR ......................................160
GVWR ......................................160
trailer towing ..........................160
Loading instructions .................162
Lubricant specifications ...258, 260
Lumbar support, seats .............114
M
Mirrors
fold away ...................................98
side view mirrors (power) .......97
Motorcraft parts ................238, 253
O
Octane rating ............................236
Odometer .....................................19
Oil (see Engine oil) ..................217
Overdrive ...................................102
Index
270

P
Panic alarm feature, remote
entry system ..............................110
Parking brake ............................154
Parts (see Motorcraft parts) ....253
Power distribution box (see
Fuses) ........................................181
Power door locks ......................108
Power steering ..........................155
fluid, checking and adding ....243
fluid, refill capacity ................254
fluid, specifications .........258, 260
Preparing to drive your
vehicle ........................................156
R
Radio ............................................20
Relays ................................177, 184
Remote entry system .......109±110
illuminated entry ....................112
locking/unlocking
doors ................................108±110
panic alarm .............................110
replacement/additional
transmitters .............................111
replacing the batteries ...........110
S
Safety belts (see Safety
restraints) ....................16, 121±125
Safety defects, reporting ..........206
Safety restraints ................121±125
belt minder .............................127
cleaning the safety
belts .................................131, 212extension assembly ................131
for adults .........................122±124
for children .....................137±138
lap belt ....................................125
warning light and
chime ...................13, 15, 126±127
Safety seats for children ..........139
Seat belts (see Safety
restraints) ..................................121
Seats ..........................................113
child safety seats ....................139
Servicing your vehicle ..............214
Spark plugs,
specifications .............253, 260±261
Special notice
ambulance conversions ..............7
diesel-powered vehicles .............6
utility-type vehicles ....................7
Specification chart,
lubricants ...........................258, 260
Speed control ..............................98
Speedometer ...............................18
Starting your vehicle ........148±150
jump starting ..........................191
Steering wheel
controls ................................95, 98
tilting .........................................95
T
Temperature control (see
Climate control) ..........................78
Tires ...........................184, 248±250
changing ..........................184, 186
checking the pressure ............250
replacing ..........................187, 251
rotating ....................................250
Index
271