maintenance FORD F SERIES MOTORHOME AND COMMERCIAL CHASSIS 2002 10.G Service Manual

WARNINGAn inflated tire and rim can be very dangerous if
improperly used, serviced or maintained. To avoid 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.
Tire rotation
Because your vehicle’s tires perform different jobs, they often wear
differently. To make sure your tires wear evenly and last longer, rotate
them as indicated in the scheduled maintenance guide. If you notice that
the tires wear unevenly, have them checked.
Your front tires should be rotated from side to side. If the spare tire is
used in the rotation, the pattern should be; left front to right front; right
front to the spare and the spare to left front.
Do not rotate the dual tires.
Replacing the tires
Replace the tires when the wear
band is visible through the tire
treads.
When replacing full size tires, never mix radial bias-belted, or
bias-type tires. Use only the tire sizes that are listed on the
Certification Label. Make sure that all tires are the same size, speed
rating, and load-carrying capacity. Use only the tire combinations
recommended on the label. If you do not follow these precautions,
your vehicle may not drive properly and safely.
Make sure that all replacement tires are of the same size, type,
load-carrying capacity and tread design (e.g., “All Terrain”, etc.),
as originally offered by Ford.
Maintenance and specifications
93

Failure to follow these precautions may adversely affect the
handling of the vehicle and make it easier for the driver to lose
control and roll over.
Tires that are larger or smaller than your vehicle’s original tires may also
affect the accuracy of your speedometer.
The tires on your vehicle have been match mounted to the original
equipment wheels. Replacement tires should be mounted so that the
match mount mark on the tire aligns with the small dimple in the face of
the wheel rim.
SNOW TIRES AND CHAINS
Snow tires must be the same size and grade as the tires you
currently have on your vehicle.
The tires on your vehicle have all weather treads to provide traction in
rain and snow. However, in some climates, you may need to use snow
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.
Maintenance and specifications
94

MOTORCRAFT PART NUMBERS
Component 6.8L V10 engine
Air filter element FA-1634
Battery BXT-65-750
Fuel filter FG-986B
Oil filter FL-820-S
PCV valve EV-233
Spark plugs* AWSF-22E
*Refer to Vehicle Emissions Control Information (VECI) decal for spark
plug gap information.
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
(includes filter
change)Motorcraft SAE
5W-20 Super
Premium Motor
OilAll 5.7L
(6.0 quarts)
Engine coolant
1Motorcraft
Premium Engine
Coolant
(green-colored)
orMotorcraft
Premium Gold
Engine Coolant
(yellow-colored)All 29.0L
(30.6 quarts)
Maintenance and specifications
95

Fluid Ford Part
NameApplication Capacity
Power steering
fluidMotorcraft
MERCONAT FAll Keep in FULL
range on
dispstick
Rear axle
2Motorcraft SAE
75W-90
Synthetic Rear
Axle LubricantDana 80 3.9L
(4.0 quarts)3
Motorcraft SAE
80W-90
Synthetic Rear
Axle LubricantDana 135 11.7L
(12.0 quarts)3
Fuel tank N/A All 284.0L
(75 .0 gallons)
Transmission
4Motorcraft
MERCONAT FAll 16.8L
(17.7 quarts)5
Your vehicle’s rear axle is filled with a synthetic rear axle lubricant and 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.
1Add the coolant type originally equipped in your vehicle.
2Fill 6 mm to 14 mm (1/4 inch to 9/16 inch) below bottom of fill hole.
3Fill Dana rear axles to 6 mm to 14 mm (1/4 inch to 9/16 inch) below
bottom of fill hole.
4Ensure 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
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.
Maintenance and specifications
96

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.
5Indicates only approximate dry-fill capacity. Some applications may vary
based on cooler size and if equipped with in-tank cooler. The amount of
transmission fluid and fluid level should be set by the indication on the
dipstick’s normal operating range.
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
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 Motorcraft SAE
5W-20 Super
Premium Motor
OilXO-5W20-QSP WSS-M2C153-H
with API
Certification
Mark
Automatic
transmission
(4R100)
1
Motorcraft
MERCONAT FXT-2-QDX MERCON
Power steering
fluidMotorcraft
MERCONAT FXT-2-QDX MERCON
Maintenance and specifications
97

Item Ford part
nameFord part
numberFord
specification
Parking brake
assemblyMotorcraft
MERCONXT-2-QDX MERCON
Dana 80 Axle Motorcraft SAE
75W-90
Synthetic Rear
Axle LubricantXY-75W90–GLS —
Dana 135 Axle Motorcraft SAE
80W-90
Synthetic Rear
Axle LubricantXY-80W90–QL WSL-M2C197-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
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
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.
Maintenance and specifications
98

ENGINE DATA
Engine 6.8L V10 engine
Cubic inches 415
Required fuel 87 octane
Firing order 1-6-5-10-2-7-3-8-4-9
Spark plug gap 1.3-1.4 mm (0.052-0.056 inch)
Ignition system Coil on plug
Compression ratio 9.0:1
IDENTIFYING YOUR VEHICLE
Certification label for incomplete vehicles
On completed derivations of incomplete vehicles, the certification label is
affixed at a location determined by a subsequent stage manufacturer of
the completed vehicle. In these cases the completed vehicle is
manufactured in two or more stages by two or more separate
manufacturers.
Vehicle Identification Number
The vehicle identification number is attached to a metal tag and is
located on the front firewall to the right of the air filter.
If you ever find it necessary to communicate with Ford Motor Company
about your vehicle, always include the VIN in your communication.
Maintenance and specifications
99

A
Air cleaner filter .............88–89, 95
Ambulance packages ....................4
Antifreeze
(see Engine coolant) ..................65
Anti-lock brake system
(see Brakes) ................................27
Automatic transmission
driving an automatic
overdrive ...................................31
fluid, adding ..............................86
fluid, checking ..........................86
fluid, refill capacities ................95
fluid, specification ....................99
Axle
lubricant specifications ......97, 99
refill capacities ..........................95
B
Battery .........................................63
acid, treating emergencies .......63
charging system
warning light .............................10
jumping a disabled battery ......51
maintenance-free ......................63
replacement, specifications .....95
servicing ....................................63
voltage gauge ............................13
Brakes ....................................26, 28
anti-lock .....................................27
anti-lock brake system
(ABS) warning light .............9, 28
brake warning light ....................9
fluid, checking and adding ......85
fluid, refill capacities ................95
fluid, specifications .............97, 99
lubricant specifications ......97, 99
shift interlock ............................30Break-in period .............................4
C
Capacities for refilling fluids ......95
Cleaning your vehicle
engine compartment ................58
exterior ......................................58
wheels ........................................58
Coolant
checking and adding ................65
refill capacities ....................69, 95
specifications ......................97, 99
Cruise control
(see Speed control) ....................17
D
Daytime running lamps
(see Lamps) ................................15
Dipstick
automatic transmission fluid ...86
engine oil ...................................61
Doors
door ajar warning .....................11
lubricant specifications ............97
Driveline universal joint and
slip yoke ......................................88
Driving under special
conditions
through water ...........................33
E
Emergencies, roadside
jump-starting ............................51
Emission control system ............82
Engine ..........................................99
Index
101

I
Ignition ...................................22, 99
Inspection/maintenance
(I/M) testing ................................83
Instrument panel
cluster ..........................................7
lighting up panel
and interior ...............................16
J
Jack ..............................................48
positioning .................................48
storage .......................................48
Jump-starting your vehicle ........51
K
Keys
key in ignition chime ...............11
positions of the ignition ...........22
L
Lamps
cargo lamps ...............................16
daytime running light ...............15
headlamps .................................15
headlamps, flash to pass ..........16
instrument panel, dimming .....16
replacing bulbs .........................16
Lights, warning and indicator ......7
anti-lock brakes (ABS) ........9, 28
brake ............................................9
charging system ........................10
check coolant ............................10
door ajar ....................................11
engine oil pressure ...................10
fuel reset ...................................10high beam .................................11
low fuel ......................................10
safety belt ...................................9
service engine soon ....................7
turn signal indicator .................10
Load limits ...................................34
GAWR ........................................34
GVWR ........................................34
trailer towing ............................34
Lubricant specifications .......97, 99
M
Motorcraft parts ....................76, 95
O
Octane rating ..............................74
Odometer .....................................14
Oil (see Engine oil) ....................61
Overdrive .....................................21
P
Parking brake ..............................29
Parts (see Motorcraft parts) ......95
Power distribution box
(see Fuses) .................................44
Power steering
fluid, checking and adding ......84
fluid, refill capacity ..................95
fluid, specifications .............97, 99
R
Relays ....................................41, 48
Index
103