service FORD F150 2002 10.G Workshop Manual

Component4.2L V6
engine4.6L V8
engine5.4L V8
engine5.4LSuperchargedV8 engine
Battery
(heavy
duty)BXT-65-650 BXT-65-650 BXT-65-650
BXT-65-650
Spark
plugs-
platinum
1
AGSF-34EE2AWSF-32P AGSF-22W AGSF-12E or
AGSF-12FM1
2, 3
1
Refer to Vehicle Emissions Control Information (VECI) decal for spark
plug gap information.
2If a spark plug is removed for inspection and replaced, it must be
reinstalled in the same cylinder. If a spark plug needs to be replaced, use
only spark plugs with the service number suffix letter as shown above.
3Use only AGSF-12FM1 spark plugs for replacement.
REFILL CAPACITIES
Fluid Ford Part
NameApplication Capacity
Brake fluid
and clutch
fluidMotorcraft
High
Performance
DOT 3 Motor
Vehicle Brake
FluidAll Fill to line or step
(for clutch) on
reservoir
Engine
coolant
1Motorcraft
Premium
Engine
Coolant
(green-colored)orMotorcraft
Premium
Gold Engine
Coolant
(yellow-colored)
4.2L V6 engine with
1 row radiator19.0L (20.1 quarts)
4.2L V6 engine with
2 row radiator20.4L (21.6 quarts)
4.6L V8 engine with
1 row radiator19.5L (20.6 quarts)
4.6L V8 engine with
2 row radiator21.9L (23.1 quarts)
5.4L V8 engine with
1 row radiator22.6L (23.9 quarts)
5.4L V8 engine with
2 row radiator24.1L (25.5 quarts)
Maintenance and Specifications
295

Fluid Ford Part
NameApplication Capacity
Front axle Motorcraft
SAE 75W-90
Premium 4x4
Front Axle
Lubricant4x4 vehicles 2.0L (3.7 pints)
Rear axle
5Motorcraft
SAE 75W-140
Synthetic
Rear Axle
Lubricant8.8/9.75 inch axle 2.6L (5.5 pints)6
Rear axle5Motorcraft
SAE 75W-140
Synthetic
Rear Axle
Lubricant10.25 inch axle 3.3L (6.9 pints)7
Windshield
washer fluidUltra-Clear
Windshield
Washer
ConcentrateAll 4.0L (4.25 quarts)
1Add the coolant type originally equipped in your vehicle.
2Service refill capacity is determined by filling the transfer case to the
bottom of the filler hole with the vehicle on a level surface.
3Ensure 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
MERCONtand MERCONtV. These dual usage fluids are not to be used
in an automatic transmission that requires use of the MERCONttype
fluid. However, these dual usage fluids may be used in transmissions that
require the MERCONtV type fluid.
Maintenance and Specifications
297

MERCONtand MERCONtV type fluids are not interchangeable.
DO NOT mix MERCONtand MERCONtV. Use of a transmission
fluid that indicates dual usage (MERCONtand MERCONtV) in
an automatic transmission application requiring MERCONtmay
cause transmission damage. Use of any fluid other than the
recommended fluid may cause transmission damage.
4Approximate dry fill capacity including transmission fluid cooling
system, actual refill capacities will vary based on vehicle application and
transmission fluid cooling system (i.e. coolers size, cooling lines. auxiliary
cooler capacities). The amount of transmission fluid and fluid level
should be set by the indication on the dipstick's normal operating range.
5Your 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.
6Service refill capacity is determined by filling the axle to 6-14 mm
(1/4-9/16 inch) below the bottom of the filler hole with the vehicle on a
level surface.
Add 118 ml (4 oz.) of Additive Friction Modifier C8AZ-19B546-A or
equivalent meeting Ford specification EST-M2C118±A, for complete fill of
8.8 inch and 9.75 inch Traction-Lok axles.
7Service refill capacity is determined by filling the axle to the bottom of
the filler hole with the vehicle on a level surface.
For 10.25 inch Traction-Lok axles, use 3.1L (6.5 pints) of Motorcraft SAE
75W-140 Synthetic Rear Axle Lubricant and 236 ml (8 oz.) of Additive
Friction Modifier C8AZ-19B546-A or equivalent meeting Ford
Specification EST-M2C118-A.
Maintenance and Specifications
298

ItemFord part
name or
equivalentFord part
numberFord
specification
Transmission
/steering/parking
brake linkages
and pivots,
brake and clutch
pedal shaft (if
equipped)Premium
Long-Life GreaseXG-1-C or
XG-1-KESA-M1C75-B
Power steering
fluid, transfer
case fluid (4X4)
and transmission
fluid (manual)Motorcraft
MERCONtAT FXT-2-QDX MERCONt
Automatic
transmission
(4R100)
2
Motorcraft
MERCONtAT FXT-2-QDX MERCONt
Automatic
transmission
(4R70W)
2
Motorcraft
MERCONtV
AT FXT-5-QM
MERCONtV
Windshield
washer fluidUltra-clear
Windshield
Washer
ConcentrateC9AZ-19550-AC ESR-M17P5-A
1Add 118 ml (4 oz) of Additive Friction Modifier C8AZ-19B546-A or
equivalent meeting Ford specification EST-M2C118-A for complete refill
of Traction-Lok axles. Add 236 ml (8 oz.) of Additive Friction Modifier
C8AZ-19B546-A or equivalent meeting Ford specification EST-M2C118-A
for complete refill of 10.25 and 10.5 inch Traction-Lok axles.
2Ensure 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
300

1. World manufacturer identifier
2. Brake type and gross vehicle
weight rating (GVWR)
3. Vehicle line, series, body type
4. Engine type
5. Check digit
6. Model year
7. Assembly plant
8. Production sequence number
Engine number
The engine number (the last eight numbers of the vehicle identification
number) is stamped on the engine block and transmission.
Harley-Davidson serialization plate
The Harley-Davidson Edition contains a serialization plate that is unique
and custom made for each Harley-Davidson vehicle. The serialization
plate contains the model year, vehicle identification number and build
sequence number. This information is added to the plate at the time of
vehicle build. Since plate is custom made, it isnot a serviceable part.
Maintenance and Specifications
308

For maximum vehicle performance, keep the following information in
mind when adding accessories or equipment to your vehicle:
²When 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.
²The 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.
²Mobile 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.)
²Ford cannot assume responsibility for any adverse effects or damage
that may result from the use of such equipment.
Accessories
312

Child safety restraints ..............154
child safety belts ....................154
Child safety seats ......................155
attaching with tether
straps .......................................160
in front seat ............................157
in rear seat ..............157, 159±160
Cleaning your vehicle
engine compartment ..............244
exterior ....................................251
instrument cluster lens ..........248
instrument panel ....................248
interior .....................................248
plastic parts ....................246±247
safety belts ..............................251
washing ....................................243
waxing .....................................243
wheels ......................................244
windows ..................................250
wiper blades ............................247
woodtone trim ........................248
Clock ................................23, 31, 41
Clutch
fluid ..........................................283
operation while driving ..........178
recommended shift speeds ....180
Compass, electronic ..............80, 86
calibration .................................82
set zone adjustment .................81
Console ........................................84
overhead ....................................78
Controls
power seat ...............................123
Coolant
checking and adding ..............265
refill capacities ................269, 295
specifications ..................299, 301Cruise control
(see Speed control) ....................88
Customer Assistance ................210
Ford accessories for
your vehicle ............................251
Ford Extended
Service Plan ............................235
Getting assistance outside
the U.S. and Canada ..............239
Getting roadside
assistance ................................210
Getting the service
you need .................................233
Ordering additional
owner's literature ...................240
The Dispute Settlement
Board .......................................236
Utilizing the
Mediation/Arbitration
Program ...................................239
D
Daytime running lamps
(see Lamps) ................................66
Dipstick
automatic transmission
fluid ..........................................284
engine oil .................................258
Doors
door ajar warning .....................14
lubricant specifications ..........299
Driveline universal joint
and slip yoke .............................288
Driving under special
conditions ..........................190, 193
sand .........................................191
snow and ice ...........................194
through water .................192, 197
Index
314

E
Emergencies, roadside
jump-starting ..........................226
Emission control system ..........280
Engine ................................301±302
check engine/service
engine soon light ......................11
cleaning ...................................244
coolant .....................................265
fail-safe coolant ......................270
idle speed control ...................263
lubrication
specifications ..................299, 301
refill capacities ........................295
service points ..................255±257
starting after a collision .........211
Engine block heater .................169
Engine oil ..................................258
checking and adding ..............258
dipstick ....................................258
filter, specifications ........262, 294
recommendations ...................262
refill capacities ........................295
specifications ..................299, 301
Exhaust fumes ..........................169
F
Fail safe cooling ........................270
Floor mats ...................................97
Fluid capacities .........................295
Foglamps .....................................65
Four-Wheel Drive
vehicles ................................15, 184
description ..............................187
driving off road .......................188
electronic shift ........................187indicator light ...................15, 185
lever operated shift ................185
preparing to drive your
vehicle .....................................174
Fuel ............................................271
calculating fuel economy .......277
cap .....................................12, 273
capacity ...................................295
choosing the right fuel ...........274
comparisons with EPA
fuel economy estimates .........280
detergent in fuel .....................276
filling your vehicle
with fuel ..................271, 273, 277
filter, specifications ........276, 294
fuel pump shut-off switch .....211
gauge .........................................18
improving fuel economy ........277
low fuel warning light ..............13
octane rating ...274±275, 301±302
quality ......................................275
running out of fuel .................276
safety information relating
to automotive fuels ................271
Fuses ..................................213±214
G
Garage door opener ..............79, 93
Gas cap (see Fuel cap) ......12, 273
Gas mileage
(see Fuel economy) .................277
Gauges .........................................16
battery voltage gauge ...............18
engine coolant temperature
gauge .........................................17
engine oil pressure gauge ........17
fuel gauge ..................................18
odometer ...................................19
speedometer .............................18
Index
315

daytime running light ...............66
fog lamps ...................................65
headlamps .................................65
headlamps, flash to pass ..........66
instrument panel, dimming .....67
interior lamps .....................68±69
replacing bulbs .............69, 71±75
Lane change indicator
(see Turn signal) ........................67
Lights, warning and indicator ....10
air bag ........................................13
anti-lock brakes (ABS) ....12, 171
anti-theft ...................................15
brake ..........................................12
charging system ........................13
check coolant ............................13
cruise indicator .........................14
door ajar ....................................14
engine oil pressure ...................13
fuel cap light .............................12
high beam .................................14
low fuel ......................................13
low washer fluid .......................14
safety belt .................................13
service engine soon ..................11
speed control ............................92
turn signal indicator .................14
Load limits .................................197
GAWR ......................................197
GVWR ......................................197
trailer towing ..........................197
Loading instructions .................199
Locks
autolock ...................................113
childproof ................................107
Lubricant
specifications .....................299, 301
Lumbar support, seats .............123M
Manual transmission .................178
fluid capacities ........................295
lubricant specifications ..........301
reverse .....................................183
Mirrors .........................................78
automatic dimming rearview
mirror ........................................86
fold away ...................................88
side view mirrors (power) .......87
Moon roof ....................................92
Motorcraft parts ................276, 294
O
Octane rating ....................274±275
Odometer .....................................19
Oil (see Engine oil) ..................258
Overdrive .....................................84
P
Panic alarm feature, remote
entry system ..............................110
Parking brake ............................172
Parts (see Motorcraft parts) ....294
Pedals (see Power adjustable
foot pedals) .................................88
Power distribution box
(see Fuses) ...............................217
Power door locks ..............106, 113
Power steering ..........................173
fluid, checking and adding ....282
fluid, refill capacity ................295
fluid, specifications .........299, 301
Index
317