light FORD F150 2003 10.G Repair Manual

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 (PCM)
3 30A* Main light switch, Headlamp relay,
Multifunction switch
4 20A* Console power point (Harley
Davidson only)
5 20A* Trailer tow back-up/park lamps
6 15A* Main light switch, Park lamp relay
7 20A* Horn
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
181

Fuse/Relay
LocationFuse Amp
RatingPower Distribution Box
Description
102 50/20A** Four-wheel Anti-lock Brake
System (4WABS)
module/Rear-wheel Anti-lock
Brake System (RABS) module,
Ignition switch
103 50A** Central junction box
104 30A** 4x4 shift motor & clutch
105 40A** Climate control front blower
106 20A** Intercooler pump (supercharged
engine only)
107—Not used
108 30A** Trailer tow electric brake
109—Not used
110 30A** Accessory delay relay (Not used
on SuperCrew)
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—Not used
115 20A** Power door locks (SuperCrew
only)
116 40A** Heated backlight
117 40A** Audiophile radio (SuperCrew
only)
118 30A** Heated seats
201—Trailer tow park lamp relay
202—Front wiper run/park relay
203—Trailer tow backup lamp relay
204—A/C clutch relay
Roadside Emergencies
183

Fuse/Relay
LocationFuse Amp
RatingPower Distribution Box
Description
205—Horn relay
206—Fog lamp relay
207—Front washer pump relay
208—Intercooler pump relay
(supercharged engine only)
209—Front wiper HI/LO relay
301—Fuel pump relay
302—Trailer tow battery charge relay
303—Heated backlight relay
(SuperCrew only)
304—PCM relay
305—Fuel pump HI/LO relay
(supercharged engine only)
306—Inertia switch relay (supercharged
engine only)
401—Not used
501—PCM diode
502—A/C compressor diode
503—Not used
601 CB Power windows, Moonroof
(SuperCrew only)
602—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.
Harley-Davidson vehicles are equipped with a spare tire with a different
speed rating than the road tires. It is not recommended that you exceed
112 km/h (70 mph) when the spare tire is in use. Though the spare tire
is rated for 112 km/h (70 mph), always obey the local speed limits.
Roadside Emergencies
184

Tool Location
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.
•To assemble, screw the parts
together. To disassemble,
unscrew.
2. Attach the spare tire lock key (A)
to the jack handle (B).
3. Fully insert the jack handle
through the bumper hole and into
the guide tube. The key and lock
will engage with a slight push and
counterclockwise turn. Some
resistance will be felt when turning
the jack handle assembly.
4. Turn the handle counterclockwise
until tire is lowered to the ground,
the tire can be slid rearward and the
cable is slightly slack.
5. Remove the retainer from the spare tire.
Roadside Emergencies
186

Preparing your vehicle
When the battery is disconnected or a new battery is installed, the
transmission must relearn its shift strategy. As a result, the transmission
may have firm and/or soft shifts. This operation is considered normal and
will not affect function or durability of the transmission. Over time, the
adaptive learning process will fully update transmission operation.
1.Use only a 12–volt supply to start your vehicle.
2. Do not disconnect the battery of the disabled vehicle as this could
damage the vehicle’s electrical system.
3. Park the booster vehicle close to the hood of the disabled vehicle
making sure the two vehiclesdo nottouch. Set the parking brake on
both vehicles and stay clear of the engine cooling fan and other moving
parts.
4. Check all battery terminals and remove any excessive corrosion before
you attach the battery cables. Ensure that vent caps are tight and level.
5. Turn the heater fan on in both vehicles to protect any electrical
surges. Turn all other accessories off.
Connecting the jumper cables
1. Connect the positive (+) booster cable to the positive (+) terminal of
the discharged battery.
Note:In the illustrations,lightning boltsare used to designate the
assisting (boosting) battery.
+–+–
Roadside Emergencies
192

Removing the jumper cables
Remove the jumper cables in the reverse order that they were
connected.
1. Remove the jumper cable from thegroundmetal surface.
Note:In the illustrations,lightning boltsare used to designate the
assisting (boosting) battery.
2. Remove the jumper cable on the negative (-) connection of the
booster vehicle’s battery.
+–+–
+–+–
Roadside Emergencies
195

In some states (in the U.S.) you must directly notify Ford in writing
before pursuing remedies under your state’s warranty laws. Ford is also
allowed a final repair attempt in some states.
In the United States, a warranty dispute must be submitted to the
Dispute Settlement Board before taking action under the Magnuson-Moss
Warranty Act, or to the extent allowed by state law, before pursuing
replacement or repurchase remedies provided by certain state laws. This
dispute handling procedure is not required prior to enforcing state
created rights or other rights which are independent of the
Magnuson-Moss Warranty Act or state replacement or repurchase laws.
FORD EXTENDED SERVICE PLAN
You can get more protection for your new car or light truck by
purchasing Ford Extended Service Plan (Ford ESP) coverage. Ford ESP
is an optional service contract which is backed by Ford Motor Company
or Ford Motor Service Company (in the U.S.) and Ford of Canada (in
Canada). It provides the following:
•Benefits during the warranty period depending on the plan you
purchase (such as: reimbursement for rentals; coverage for certain
maintenance and wear items).
•Protection against covered repair costs after your Bumper-to-Bumper
Warranty expires.
You may purchase Ford ESP from any participating Ford and Lincoln
Mercury and Ford of Canada dealer. There are several plans available in
various time, distance and deductible combinations which can be tailored
to fit your own driving needs. Ford ESP also offers reimbursement
benefits for towing and rental coverage.
When you buy Ford ESP, you receive Peace-of-Mind protection
throughout the United States and Canada, provided by a network of
more than 5,000 participating Ford or Lincoln Mercury and Ford of
Canada dealers.
If you did not take advantage of the Ford Extended Service Plan at the
time of purchasing your vehicle, you may still be eligible. Please contact
your dealer for further information. Since this information is subject to
change, please ask your dealer for complete details about Ford Extended
Service Plan coverage options, or visit the Ford ESP website at
www.ford-esp.com.
Customer Assistance
200

THE DISPUTE SETTLEMENT BOARD (U.S. ONLY)
The Dispute Settlement Board is:
•an independent, third-party arbitration program for warranty disputes.
•available free to owners and lessees of qualifying Ford Motor Company
vehicles.
The Dispute Settlement Board may not be available in all states. Ford
Motor Company reserves the right to change eligibility limitations, modify
procedures and/or to discontinue this service without notice and without
incurring obligations per applicable state law.
What kinds of cases does the Board review?
Unresolved warranty repair concerns or vehicle performance concerns as
on Ford and Lincoln Mercury cars and Ford and Lincoln Mercury light
trucks which are within the terms of any applicable written new vehicle
warranty are eligible for review, except those involving:
•a non-Ford product
•a non-Ford dealership
•sales disputes between customer and dealer except those associated
with warranty repairs or concerns with the vehicle’s performance as
designed
•a request for reimbursement of consequential expenses unless a
service or product concern is being reviewed
•items not covered by the New Vehicle Limited Warranty (including
maintenance and wear items)
•alleged personal injury/property damage claims
•cases currently in litigation
•vehicles not used primarily for family, personal or household purposes
(except in states where the Dispute Settlement Board is required to
review commercial vehicles)
•vehicles with non-U.S. warranties
Concerns are ineligible for review if the New Vehicle Limited Warranty
has expired at receipt of your application and, in certain states eligibility
is dependent upon the customer’s possession of the vehicle.
Eligibility may differ according to state law. For example, see the unique
brochures for California, West Virginia, Georgia and Wisconsin
purchasers/lessees.
Customer Assistance
201

WASHING THE EXTERIOR
Wash your vehicle regularly with cool or lukewarm water and a neutral
Ph shampoo, such as Motorcraft Detail Wash (ZC-3–A), which is available
from your dealer.
•Never use strong household detergents or soap, such as dish washing
or laundry liquid. These products can discolor and spot painted
surfaces.
•Never wash a vehicle that is“hot to the touch”or during exposure to
strong, direct sunlight.
•Always use a clean sponge or carwash mitt with plenty of water for
best results.
•Dry the vehicle with a chamois or soft terry cloth towel in order to
eliminate water spotting.
•It is especially important to wash the vehicle regularly during the
winter months, as dirt and road salt are difficult to remove and cause
damage to the vehicle.
•Immediately remove items such as gasoline, diesel fuel, bird droppings
and insect deposits because they can cause damage to the vehicle’s
paintwork and trim over time.
•Remove any exterior accessories, such as antennas, before entering a
car wash.
•Suntan lotions and insect repellents can damage any painted
surface; if these substances come in contact with your vehicle,
wash off as soon as possible.
•If your vehicle is equipped with running boards, do not use
rubber, plastic and vinyl protectant products on the running
board surface, as the area may become slippery.
WAXING
Applying a polymer paint sealant to your vehicle every six months will
assist in reducing minor scratches and paint damage.
•Wash the vehicle first.
•Do not use waxes that contain abrasives.
•Do not allow paint sealant to come in contact with any non-body
(low-gloss black) colored trim, such as grained door handles, roof
racks, bumpers, side moldings, mirror housings or the windshield cowl
area. The paint sealant will“gray”or stain the parts over time.
Cleaning
208

PAINT CHIPS
Your dealer has touch-up paint and sprays to match your vehicle’s color.
Take your color code (printed on a sticker in the driver’s door jam) to
your dealer to ensure you get the correct color.
•Remove particles such as bird droppings, tree sap, insect deposits, tar
spots, road salt and industrial fallout before repairing paint chips.
•Always read the instructions before using the products.
ALUMINUM WHEELS AND COVERS
Aluminum wheel rims or covers are coated with a clearcoat paint finish.
In order to maintain their shine:
•Clean weekly with Motorcraft Wheel and Tire Cleaner (ZC-37–A),
which is available from your dealer. Heavy dirt and brake dust
accumulation may require agitation with a sponge. Rinse thoroughly
with a strong stream of water.
•Never apply any cleaning chemical to hot or warm wheel rims or
covers.
•Some automatic car washes may cause damage to the finish on your
wheel rims or covers. Chemical-strength cleaners, or cleaning
chemicals, in combination with brush agitation to remove brake dust
and dirt, could wear away the clearcoat finish over time.
•Do not use hydrofluoric acid-based or high caustic-based wheel
cleaners, steel wool, fuels or strong household detergent.
•To remove tar and grease, use Ford Extra Strength Tar and Road Oil
Removal (B7A-19520–AA), available from your dealer.
ENGINE
Engines are more efficient when they are clean because grease and dirt
buildup keep the engine warmer than normal. When washing:
•Take care when using a power washer to clean the engine. The
high-pressure fluid could penetrate the sealed parts and cause
damage.
•Do not spray a hot engine with cold water to avoid cracking the
engine block or other engine components.
•Spray Motorcraft Engine Shampoo and Degreaser (ZC-20) on all parts
that require cleaning and pressure rinse clean.
•Cover the highlighted areas to prevent water damage when cleaning
the engine.
Cleaning
209