service FORD E SERIES 2003 4.G Service Manual

emission control, such non-Ford parts should be equivalent to genuine
Ford Motor Company parts in performance and durability.
Do not park, idle, or drive your vehicle in dry grass or other dry
ground cover. The emission system heats up the engine
compartment and exhaust system, which can start a fire.
Illumination of the“Service Engine Soon”light, charging system warning
light or the temperature warning light, fluid leaks, strange odors, smoke
or loss of engine power, could indicate that the emission control system
is not working properly.
Exhaust leaks may result in entry of harmful and potentially
lethal fumes into the passenger compartment.
Do not make any unauthorized changes to your vehicle or engine. By
law, vehicle owners and anyone who manufactures, repairs, services,
sells, leases, trades vehicles, or supervises a fleet of vehicles are not
permitted to intentionally remove an emission control device or prevent
it from working. Information about your vehicle’s emission system is on
the Vehicle Emission Control Information Decal located on or near the
engine. This decal identifies engine displacement and gives some tune up
specifications.
Please consult yourWarranty Guidefor complete emission warranty
information.
Readiness for Inspection/Maintenance (I/M) testing
In some localities, it may be a legal requirement to pass an I/M test of
the on-board diagnostics system. If your“Check Engine/Service Engine
Soon”light is on, refer to the description in theWarning lights and
chimessection of theInstrument clusterchapter. Your vehicle may not
pass the I/M test with the“Check Engine/Service Engine Soon”light on.
If the vehicle’s powertrain system or its battery has just been serviced,
the on-board diagnostics system is reset to a“not ready for I/M test”
condition. To ready the on-board diagnostics system for I/M testing, a
minimum of 30 minutes of city and highway driving is necessary as
described below:
•First, at least 10 minutes of driving on an expressway or highway.
•Next, at least 20 minutes driving in stop-and-go, city-type traffic with
at least four idle periods.
Allow the vehicle to sit for at least eight hours without starting the
engine. Then, start the engine and complete the above driving cycle. The
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202

engine must warm up to its normal operating temperature. Once started,
do not turn off the engine until the above driving cycle is complete.
CHECKING AND ADDING POWER STEERING FLUID
Check the power steering fluid.
Refer to the scheduled maintenance
guide for the service interval
schedules. If adding fluid is
necessary, use only MERCON
AT F.
Check the fluid level when it is at ambient temperature, 20°–80°F (-7°
–25°C):
1. Check the fluid level on the dipstick. It should be between the arrows
in the FULL COLD range. Do not add fluid if the level is within this
range.
2. If the fluid level is low, start the engine.
3. While the engine idles, turn the steering wheel left and right several
times.
4. Turn the engine off.
For E-450 and E-550 vehicles with the Hydro-Boost Brake
System, do not press the brake pedal after the engine has been
turned off.
5. Recheck the fluid level on the dipstick. Do not add fluid if the level is
between the arrows in the FULL COLD range.
FULL COLD
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203

6. If the fluid is low, add fluid in small amounts, continuously checking
the level until it reaches the FULL COLD range. Be sure to put the
dipstick back in the reservoir.
BRAKE FLUID RESERVOIR
The fluid level will drop slowly as
the brakes wear, and will rise when
the brake components are replaced.
Fluid levels below the“MAX”line
that do not trigger the brake system
warning lamp are within the normal
operating range, there is no need to
add fluid. If the fluid levels are outside of the normal operating range,
the performance of your brake system could be compromised, seek
service from your dealer immediately.
DRIVELINE UNIVERSAL JOINT AND SLIP YOKE
Your vehicle may be equipped with universal joints that require
lubrication. Refer to the scheduled maintenance guide for maintenance
intervals. If the original universal joints are replaced with universal joints
equipped with grease fittings, lubrication will also be necessary.
TRANSMISSION FLUID
Checking automatic transmission fluid (if equipped)
Refer to your scheduled maintenance guide for scheduled intervals for
fluid checks and changes. Your transmission does not consume fluid.
However, the fluid level should be checked if the transmission is not
working properly, i.e., if the transmission slips or shifts slowly or if you
notice some sign of fluid leakage.
Automatic transmission fluid expands when warmed. To obtain an
accurate fluid check, drive the vehicle until it is at normal operating
temperature (approximately 30 km [20 miles]). If your vehicle has been
operated for an extended period at high speeds, in city traffic during hot
weather or pulling a trailer, the vehicle should be turned off for about 30
minutes to allow fluid to cool before checking.
1. Drive the vehicle 30 km (20 miles) or until it reaches normal operating
temperature.
2. Park the vehicle on a level surface and engage the parking brake.
3. With the parking brake engaged and your foot on the brake pedal,
start the engine and move the gearshift lever through all of the gear
ranges. Allow sufficient time for each gear to engage.
MAX
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204

government test course. For example, a tire graded 150 would wear one
and one-half (1 1/2) times as well on the government course as a tire
graded 100. The relative performance of tires depends upon the actual
conditions of their use, however, and may depart significantly from the
norm due to variations in driving habits, service practices, and
differences in road characteristics and climate.
Traction AA A B C
The traction grades, from highest to lowest are AA, A, B, and C. The
grades represent the tire’s ability to stop on wet pavement as measured
under controlled conditions on specified government test surfaces of
asphalt and concrete. A tire marked C may have poor traction
performance.
The traction grade assigned to this tire is based on
straight-ahead braking traction tests, and does not include
acceleration, cornering, hydroplaning or peak traction characteristics.
Temperature A B C
The temperature grades are A (the highest), B and C, representing the
tire’s resistance to the generation of heat and its ability to dissipate heat
when tested under controlled conditions on a specified indoor laboratory
test wheel. Sustained high temperature can cause the material of the tire
to degenerate and reduce tire life, and excessive temperature can lead to
sudden tire failure. The grade C corresponds to a level of performance
which all passenger car tires must meet under the Federal Motor Vehicle
Safety Standard No. 109. Grades B and A represent higher levels of
performance on the laboratory test wheel than the minimum required by
law.
The temperature grade for this tire is established for a tire that
is properly inflated and not overloaded. Excessive speed,
underinflation, or excessive loading, either separately or in
combination, can cause heat buildup and possible tire failure.
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208

SERVICING YOUR TIRES
Tire inflation information
The E550 vehicles are equipped with a tire that is an all-steel radial.
All-steel radial tires utilize steel cords in the sidewalls, and also require
increased inflation pressures of up to 95 psi. As such, they cannot be
treated like normal light truck tires. Tire service, including adjusting tire
pressure, must be performed by personnel trained, supervised and
equipped according to Federal Occupational Safety and Health
Administration (OSHA) regulations. For example, during any procedure
involving tire inflation, the technician or individual must utilize a remote
inflation device, and insure that all persons are clear of the trajectory
area.
WARNINGAn inflated tire and rim can be very dangerous if
improperly used, serviced or maintained. To reduce the risk of
serious injury, never attempt to re-inflate a tire which has been run flat
or seriously under-inflated without first removing the tire from the
wheel assembly for inspection. Do not attempt to add air to tires or
replace tires or wheels without first taking precautions to protect
persons and property.
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209

tires and chains. If you need to use chains, it is recommended that steel
wheels (of the same size and specifications) be used, as chains may chip
aluminum wheels.
Follow these guidelines when using snow tires and chains:
•Use only SAE Class S chains.
•Install chains securely, verifying that the chains do not touch any
wiring, brake lines or fuel lines.
•Drive cautiously. If you hear the chains rub or bang against your
vehicle, stop and re-tighten the chains. If this does not work, remove
the chains to prevent damage to your vehicle.
•If possible, avoid fully loading your vehicle.
•Remove the tire chains when they are no longer needed. Do not use
tire chains on dry roads.
•The suspension insulation and bumpers will help prevent vehicle
damage. Do not remove these components from your vehicle when
using snow tires and chains.
MOTORCRAFT PART NUMBERS
Component14.2L V6 engine 4.6L V8
engine5.4L V8
engine6.8L V10
engine
Air filter element FA-1634 FA-1634 FA-1634 FA-1634
Battery
(standard)BXT-65-750 BXT-65-750 BXT-65-750 BXT-65-750
Battery
(auxiliary)BH-65DC BH-65DC BH-65DC BH-65DC
Fuel filter FG-872 FG-872 FG-872 FG-872
Oil filter FL-400-S FL-820-S FL-820-S FL-820-S
PCV valve EV-251 EV-233 EV-233 EV-233
Spark plugs
2AGSF-34EEM3AWSF-32PP4AGSF-22W AGSF-22W
1Refer to the7.3 Liter Power Stroke Direct Injection Turbo Diesel
Owner’s Guide Supplementfor Motorcraft diesel engine service part
numbers.
2Refer to Vehicle Emissions Control Information (VECI) decal for spark
plug gap information.
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212

3If a spark plug is removed for inspection, it must be reinstalled in the
same cylinder. Cylinders No. 1, 2 and 3 have a“EGM”suffix. Cylinders
No. 4, 5 and 6 have a“EM”suffix. If a spark plug needs to be replaced,
use only spark plugs with the service part number suffix letterEEMas
shown on the engine decal.
4If a spark plug is removed for inspection, it must be reinstalled in the
same cylinder. Cylinders No. 1, 2, 3 and 4 have a“PG”suffix. Cylinders
No. 5, 6, 7 and 8 have a“P”suffix. If a spark plug needs to be replaced,
use only spark plugs with the service part number suffix letter as shown
on the engine decal.
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 Premium
Synthetic Blend
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.
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213

Fluid Ford Part
NameApplication Capacity
Transmission
fluid
6Motorcraft
MERCON
V
AT FAutomatic
(4R70W)13.2L (13.9
quarts)7
Motorcraft
MERCON
AT FAutomatic
(4R100 except
E-450)16.1L (17.0
quarts)7
Automatic
(4R100 E-450
and E-550)16.7L (17.7
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
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.
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 your scheduled maintenance guide to determine
the correct service interval.
Maintenance and Specifications
216

Item Ford part
nameFord part
numberFord
specification
Dana 9.75 inch
(M60–1U)
3Hypoid Gear Oil
SAE 90C6AZ-19580–E ESW-M2C105–E
10.5 inch
(M70–2U)
(M70–1HD)
(E-250/350/
450/550)
3
Motorcraft SAE
80W-90
Premium Rear
Axle LubricantXY-80W90-QL WSP-M2C197-A
Windshield
washer fluidMotorcraft
Premium
Windshield
Washer
ConcentrateZC-32–A WSB-M8B16–A2
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 your scheduled maintenance guide to determine
the correct service interval.
Some transmission fluids may be labeled as dual usage, such as
MERCON
and MERCON
V. These dual usage fluids are not to be used
in an automatic transmission that requires use of the MERCON
type
fluid. However, these dual usage fluids may be used in transmissions that
require the MERCON
V type fluid.
MERCON
and MERCON
V type fluids are not interchangeable.
DO NOT mix MERCON
and MERCON
V. Use of a transmission
fluid that indicates dual usage (MERCON
and MERCON
V) in
an automatic transmission application requiring MERCON
may
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 Traction-Lok rear axles.
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219

•When adding accessories, equipment, passengers and luggage to your
vehicle, do not exceed the total weight capacity of the vehicle or of
the front or rear axle (GVWR or GAWR as indicated on the Safety
compliance certification label). Consult your dealer for specific weight
information.
•The Federal Communications Commission (FCC) and Canadian Radio
Telecommunications Commission (CRTC) regulate the use of mobile
communications systems - such as two-way radios, telephones and
theft alarms - that are equipped with radio transmitters. Any such
equipment installed in your vehicle should comply with FCC or CRTC
regulations and should be installed only by a qualified service
technician.
•Mobile communications systems may harm the operation of your
vehicle, particularly if they are not properly designed for automotive
use or are not properly installed. When operated, such systems may
cause the engine to stumble or stall or cause the transmission to be
damaged or operate improperly. In addition, such systems may be
damaged or their performance may be affected by operating your
vehicle. (Citizens band [CB] transceivers, garage door openers and
other transmitters with outputs of five watts or less will not ordinarily
affect your vehicle’s operation.)
•Ford cannot assume responsibility for any adverse effects or damage
that may result from the use of such equipment.
Accessories
226