engine FORD F150 2002 10.G Service Manual

Engine Rear axle
ratio/tire size -
cm (inches)Maximum
GCWR-kg (lbs.)Maximum
trailer
weight-kg (lbs.)
5.4L 3.73/40.6 (16) 6 124 (13 500) 3 810 (8 400)
SuperCab/Super Crew 4x4 w/automatic transmission
4.6L 3.31/40.6 (16) 4 763 (10 500) 2 540 (5 600)
4.6L 3.55/40.6 (16) 5 216 (11 500) 2 994 (6 600)/
2 812 (6 200)
4.6L 3.55/43.2 (17) 4 990 (11 000) 2 767 (6 100)/
2 585 (5 700)
5.4L 3.31/40.6 (16) 5 443 (12 000) 3 175 (7 000)
5.4L 3.55/40.6 (16) 5 897 (13 000) 3 628 (8 000)/
3 447 (7 600)
5.4L 3.55/43.2 (17) 5 670 (12 500) 3 401 (7 500)/
3 221 (7 100)
5.4L 3.73/40.6 (16) 6 124 (13 500) 3 719 (8 200)
Engine Rear axle ratio Maximum GCWR
- kg (lbs.)Maximum
trailer weight -
kg (lbs.)
Regular Cab 4x4 w/manual transmission
4.2L 3.31 3 265 (7 200) 1 179 (2 600)
4.2L 3.55 3 538 (7 800) 1 452 (3 200)
4.6L 3.31 3 265 (7 200) 1 134 (2 500)
4.6L 3.55 3 538 (7 800) 1 406 (3 100)
SuperCab 4x4 w/manual transmission
4.6L 3.31 3 265 (7 200) 1 043 (2 300)
4.6L 3.55 3 533 (7 800) 1 315 (2 900)
Trailer frontal area considerations:
²Not to exceed towing vehicle frontal area without Class III trailer
towing package
²Not to exceed 5.52 square meters (60 square feet) with Class III
trailer towing package
Driving
202

Servicing after towing
If you tow a trailer for long distances, your vehicle will require more
frequent service intervals. Refer to your scheduled maintenance guide for
more information.
Trailer towing tips
²Practice turning, stopping and backing up before starting on a trip to
get the feel of the vehicle trailer combination. When turning, make
wider turns so the trailer wheels will clear curbs and other obstacles.
²Allow more distance for stopping with a trailer attached.
²The trailer tongue weight should be no more than 10±15% of the
loaded trailer weight.
²After you have traveled 80 km (50 miles), thoroughly check your
hitch, electrical connections and trailer wheel lug nuts.
²When stopped in traffic for long periods of time in hot weather, place
the gearshift in P (Park) (automatic transmissions) or N (Neutral)
(manual transmissions). This aids engine cooling and air conditioner
efficiency.
²Vehicles with trailers should not be parked on a grade. If you must
park on a grade, place wheel chocks under the trailer's wheels.
Launching or retrieving a boat
When backing down a ramp during boat launching or retrieval:
²do not allow the static water level to rise above the bottom edge of
the rear bumper.
²do not allow waves to break higher than 15 cm (6 inches) above the
bottom edge of the rear bumper.
Exceeding these limits may allow water to enter critical vehicle
components, adversely affecting driveability, emissions, reliability and
causing internal transmission damage.
Replace the rear axle lubricant any time the axle has been submerged in
water. Rear axle lubricant quantities are not to be checked or changed
unless a leak is suspected or repair required.
Disconnect the wiring to the trailer before backing the trailer into the
water. Reconnect the wiring to the trailer after the trailer is removed
from the water.
Driving
205

RECREATIONAL TOWING (ALL WHEELS ON THE GROUND)
An example of recreational towing would be towing your vehicle behind a
motorhome. Follow these guidelines if you have the need for recreational
towing your vehicle with all four wheels on the ground. These guidelines are
designed to ensure that your transmission is not damaged.
2WD vehicles (with automatic transmissions)
²Place the transmission in N (Neutral)
²Maximum speed is 56 km (35 mph)
²Maximum distance is 80 km (50 miles)
If a distance of 80 km (50 miles) or a speed of 56 km (35 mph) must be
exceeded, the drive shaft will have to be removed before the vehicle is towed.
Ford recommends the driveshaft be removed/installed only by a qualified
technician. See your local dealer for driveshaft removal/installation.
Improper removal/installation of the driveshaft can cause
transmission fluid loss, damage to the driveshaft and internal
transmission components.
4WD vehicles electronic shift transfer case (with automatic
transmissions)
4x4 vehicles with electronic shift on the fly cannot be towed with any
wheels on the ground.
SNOWPLOWING
Ford recommends the following specifications for low speed, personal
use snow removal:
²
F-150 4x4 (except F-150 Supercrew, ªLightningº and ªHarley-Davidsonº)
²5.4L engine
²Heavy duty service package
²Super engine cooling
²Heavy duty front suspension package
²Automatic transmission with auxiliary automatic transmission fluid
cooling
²All-terrain tires
²Limited slip and optional axle ratio.
Do not install a snowplow and plow with your vehicle until it has been
driven at least 800 km (500 miles).
Driving
206

Installing the snowplow
Removing the blocker beam without installing snowplow
attachment hardware may affect air bag deployment in a crash.
Do not operate the truck unless either the blocker beam or snowplow
attachment hardware is installed on the vehicle.
Read the following instructions before installing a snowplow:
²Front GAWR must not exceed 63% of the GVW. Add ballast weight to
the back of the vehicle, if necessary. Refer to the Safety Compliance
Certification Label to find Front GAWR.
²The Front Axle Accessory Reserve Capacity and the Total Accessory
Reserve Capacity listed on the bottom right of the Safety Compliance
Certification Label will determine whether or not the addition of a
snowplow will overload your vehicle.
²The weight of the snowplow and supporting components distributed to
the front axle must not exceed the front accessory reserve capacity.
²The total weight of the snowplow and aftermarket equipment must
not exceed the Total Accessory Reserve Capacity.
²The weight of the installed snowplow and aftermarket equipment must
not load the vehicle beyond the GAWR (front/rear) and GVWR listed
on the Safety Compliance Certification Label.
²The total weight of the snowplow and aftermarket equipment must be
considered part of the payload and must not exceed the Gross
Combined Weight Rating (GCWR) for towing.
²Federal and most local regulations require additional exterior lamps
for snowplow-equipped vehicles. Consult your dealer for additional
information.
²After installing a snowplow to the vehicle, ensure the vehicle's front
toe alignment and front ride height are within specification (reset if
required). These specifications are located in the vehicle's Workshop
Manual. Adherence to the toe, tire pressures and ride height
specification is important for proper tire wear, ride, handling and
headlight aim. Also, maintain the engine oil and transmission fluid
change intervals following the severe duty schedule.
Do not exceed the GVWR or the GAWR specified on the
certification label.
Driving
207

Engine temperature while plowing
When driving with a plow, your
engine may run at a higher
temperature than normal because
the attached snowplow blade will
restrict airflow to the radiator.
If you are driving more than 24 km (15 miles) at temperatures above
freezing, angle the plow blade either full left or full right to provide
maximum airflow to the radiator.
If you are driving less than 24 km (15 miles) at speeds up to 64 km/h
(40 mph) in cold weather, you will not need to worry about blade
position to provide maximum airflow.
Transmission operation while plowing
²Shift transfer case to 4L (4WD Low) when plowing in small areas at
speeds below 8 km/h (5 mph).
²Shift transfer case to 4H (4WD High) when plowing larger areas or
light snow at higher speeds. Do not exceed 24 km/h (15 mph).
²Do not shift the transmission from a forward gear to R (Reverse) until
the engine is at idle and the wheels are stopped.
²If the vehicle is stuck, shift the transmission in a steady motion
between forward and reverse gears. Do not rock the vehicle for more
than a few minutes. The transmission and tires may be damaged or
the engine can overheat.
Do not rock the vehicle if the engine is not at operating
temperature. Do not rock the vehicle for more than a few
minutes. The transmission and tires may be damaged or the
engine may overheat.
Do not spin the wheels at over 35 mph (55 km/h). The tires may
fail and injure a passenger or bystander.
H
C
Driving
209

Canadian customers who need to obtain reimbursement information, call
1±800±665±2006.
ROADSIDE COVERAGE BEYOND BASIC WARRANTY
In the United States, you may purchase additional roadside assistance
coverage beyond this period through the Ford Auto Club by contacting
your Ford or Lincoln Mercury dealer.
Similarly in Canada, for uninterrupted Roadside Assistance coverage, you
may purchase extended coverage prior to your Basic Warranty's Roadside
Assistance expiring. For more information and enrollment, contact
1±877±294±2582 or visit our website at www.ford.ca.
HAZARD FLASHER
Use only in an emergency to warn traffic of vehicle breakdown,
approaching danger, etc. The hazard flashers can be operated when the
ignition is off.
²The hazard lights control is
located on top of the steering
column.
²Depress hazard lights control to
activate all hazard flashers
simultaneously.
²Depress control again to turn the
flashers off.
FUEL PUMP SHUT-OFF SWITCH
FUEL
RESET
The fuel pump shut-off switch is a device intended to stop the electric
fuel pump when your vehicle has been involved in a substantial jolt.
After a collision, if the engine cranks but does not start, the fuel pump
shut-off switch may have been activated.
Roadside Emergencies
211

Power distribution box
The power distribution box is located in the engine compartment. The
power distribution box contains high-current fuses that protect your
vehicle's main electrical systems from overloads.
Always disconnect the battery before servicing high current
fuses.
Always replace the cover to the power distribution box before
reconnecting the battery or refilling fluid reservoirs
If the battery has been disconnected and reconnected, refer to the
Batterysection of theMaintenance and specificationschapter.
The high-current fuses are coded as follows.
Fuse/Relay
LocationFuse Amp
RatingPower Distribution Box
Description
1 20A * Power Point
2 30A* Powertrain Control Module
MAXI
FUSE
115MAXI
FUSE
116MAXI
FUSE
117
MAXI
FUSE
118
MAXI
FUSE
111MAXI
FUSE
112MAXI
FUSE
113
MAXI
FUSE
114
MAXI
FUSE
107MAXI
FUSE
108MAXI
FUSE
109
MAXI
FUSE
110
MAXI
FUSE
103MAXI
FUSE
104MAXI
FUSE
105
MAXI
FUSE
106
MAXI
FUSE
101MAXI
FUSE
102 CB601 CB602 FUSE 17 FUSE 18FUSE 21 FUSE 22
FUSE 19 FUSE 20FUSE 23
FULL
RELAY 302R 401
D 501 FUSE 24
FUSE 15 FUSE 16
FUSE 13 FUSE 14
FUSE 11 FUSE 12
FUSE 9 FUSE 10
FUSE 7 FUSE 8
FUSE 5 FUSE 6
FUSE 3 FUSE 4
FUSE 1 FUSE 2
D 503 D 502
FULL
RELAY 301HALF
RELAY
207
FULL
RELAY 305FULL
RELAY 306
FULL
RELAY 303
FULL
RELAY 304
HALF
RELAY
201
HALF
RELAY
202HALF
RELAY 208
HALF
RELAY 209
HALF
RELAY 205
HALF
RELAY 206
HALF
RELAY
203
HALF
RELAY
204
Roadside Emergencies
217

Fuse/Relay
LocationFuse Amp
RatingPower Distribution Box
Description
102 50/20A** Four Wheel Antilock Brake
Module/Rear Wheel Antilock
Brake Module, Ignition Switch
103 50A** Central Junction Box
104 30A** 4x4 Shift Motor & Clutch
105 40A** Climate Control Front Blower
106 20A** Inter Cooler Pump (Supercharged
engine only)
107 Ð Not Used
108 30A** Trailer Tow Electric Brake
109 Ð Not Used
110 30A** ACC Delay Relay
111 40A** Ignition Switch Battery Feed
(Start and Run Circuits)
112 30A** Drivers Power Seat, Adjustable
Pedal switch
113 40A** Ignition Switch Battery Feed (Run
and Accessory Circuits)
114 Ð Not Used
115 20A** Power Door Locks
116 Ð Not Used
117 Ð Not Used
118 30A** Heated Seats
201 Ð Trailer Tow Park Lamp Relay
202 Ð Front Wiper Run/Park Relay
203 Ð Trailer Tow Backup Lamp Relay
204 Ð A/C Clutch Relay
205 Ð Horn Relay
206 Ð Fog Lamp Relay
207 Ð Front Washer Pump Relay
208 Ð Inter Cooler Pump Relay
(Supercharged engine only)
Roadside Emergencies
219

Fuse/Relay
LocationFuse Amp
RatingPower Distribution Box
Description
209 Ð Front Wiper Hi/Lo Relay
301 Ð Fuel Pump Relay
302 Ð Trailer Tow Battery Charge Relay
303 Ð Not Used
304 Ð Powertrain Control Module Relay
305 Ð Fuel Pump Hi/Lo Relay
(Supercharged engine only)
306 Ð Inertia Switch Relay
(Supercharged engine only)
401 Ð Not Used
501 Ð Powertrain Control Module Diode
502 Ð A/C Compressor Diode
503 Ð Not Used
601 CB Power Windows, Moonroof
602 Ð Not Used
*Mini fuses **Maxi fuses
CHANGING THE TIRES
If you get a flat tire while driving, do not apply the brake heavily.
Instead, gradually decrease your speed. Hold the steering wheel firmly
and slowly move to a safe place on the side of the road.
Spare tire information
Your vehicle is equipped with a spare tire that may be used as a spare or
a regular tire. The spare tire wheel may not match the road wheel, and is
not equipped with wheel trim. The wheel trim from the wheel/tire may
be used on the spare if the wheels match.
If your vehicle is equipped with 4WD, a spare tire of a different
size than the road tires should not be used. Such a tire could
result in damage to driveline components and make the vehicle
difficult to control.
Roadside Emergencies
220

Location of the spare tire and tools
The spare tire and tools for your vehicle are stowed in the following
locations:
Tool Location
Spare tire Under the vehicle, just forward of
the rear bumper
Jack, lug nut wrench Regular cab: Under the seat on the
passenger side
Super Cab: Under the front or rear
seat on the passenger side
Super Crew cab: In the passenger
side rear storage compartment
Jack handle On top of the radiator support at
the front of the engine
compartment
Key, spare tire lock In the glove box
Removing the spare tire
1. If equipped with a two piece lug wrench, assemble the lug wrench as
shown in the illustration.
²To assemble, screw the parts
together. To disassemble,
unscrew.
2. Attach the spare tire lock key (A)
to the jack handle (B).
Roadside Emergencies
221