service FORD F250 2008 Repair Manual

How fail-safe cooling works
If the engine begins to overheat:
•The engine coolant temperature
gauge will move to the red (hot)
area.
•The message center will indicate
the engine is overheating.
•The
indicator will
illuminate.
If the engine reaches a preset over-temperature condition, the engine
will automatically switch to alternating cylinder operation. Each disabled
cylinder acts as an air pump and cools the engine.
When this occurs the vehicle will still operate. However:
•The engine power will be limited.
•The air conditioning system will be disabled.
Continued operation will increase the engine temperature and the engine
will completely shut down, causing steering and braking effort to
increase.
Once the engine temperature cools, the engine can be re-started. Take
your vehicle to a service facility as soon as possible to minimize engine
damage.
When fail-safe mode is activated
You have limited engine power when in the fail-safe mode, so drive the
vehicle with caution. The vehicle will not be able to maintain high-speed
operation and the engine will run rough. Remember that the engine is
capable of completely shutting down automatically to prevent engine
damage, therefore:
1. Pull off the road as soon as safely possible and turn off the engine.
2. Arrange for the vehicle to be taken to a service facility.
3. If this is not possible, wait a short period for the engine to cool.
4. Check the coolant level and replenish if low.
Never remove the coolant reservoir cap while the engine is
running or hot.
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5. Re-start the engine and take your vehicle to a service facility.
Driving the vehicle without repairing the engine problem
increases the chance of engine damage. Take your vehicle to a
service facility as soon as possible.
FUEL FILTER
For fuel filter replacement, see your authorized dealer. Refer to the
scheduled maintenance informationfor the appropriate intervals for
changing the fuel filter.
Replace the fuel filter with an authorized Motorcraft part. The
customer warranty may be void for any damage to the fuel system
if an authorized Motorcraft fuel filter is not used.
WHAT YOU SHOULD KNOW ABOUT AUTOMOTIVE FUELS
Important safety precautions
Do not overfill the fuel tank. The pressure in an overfilled tank
may cause leakage and lead to fuel spray and fire.
The fuel system may be under pressure. If the fuel filler cap is
venting vapor or if you hear a hissing sound, wait until it stops
before completely removing the fuel filler cap. Otherwise, fuel may
spray out and injure you or others.
If you do not use the proper fuel filler cap, excessive pressure or
vacuum in the fuel tank may damage the fuel system or cause
the fuel cap to disengage in a collision, which may result in possible
personal injury.
Automotive fuels can cause serious injury or death if misused or
mishandled.
Gasoline may contain benzene, which is a cancer-causing agent.
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If you have run out of fuel:
•You may need to cycle the ignition from OFF to ON several times after
refueling to allow the fuel system to pump the fuel from the tank to
the engine. On restarting, cranking time will take a few seconds longer
than normal.
•Normally, adding one gallon of fuel is enough to restart the engine. If
the vehicle is out of fuel and on a steep grade, more than one gallon
may be required.
•TheService engine soonindicator (
) may come on. For more
information on theService engine soonindicator, refer to the
Instrument Clusterchapter.
ESSENTIALS OF GOOD FUEL ECONOMY
Measuring techniques
Your best source of information about actual fuel economy is you, the
driver. You must gather information as accurately and consistently as
possible. Fuel expense, frequency of fill-ups or fuel gauge readings are
NOT accurate as a measure of fuel economy. We do not recommend
taking fuel economy measurements during the first 1,000 miles (1,600
km) of driving (engine break-in period). You will get a more accurate
measurement after 2,000 miles-3,000 miles (3,000 km–5,000 km).
Filling the tank
The advertised fuel capacity of the fuel tank on your vehicle is equal to
the rated refill capacity of the fuel tank as listed in theMaintenance
Product Specifications and Capacitiessection of this chapter.
The advertised capacity is the amount of the indicated capacity and the
empty reserve combined. Indicated capacity is the difference in the
amount of fuel in a full tank and a tank when the fuel gauge indicates
empty. Empty reserve is the small amount of fuel remaining in the fuel
tank after the fuel gauge indicates empty.
The amount of usable fuel in the empty reserve varies and should
not be relied upon to increase driving range. When refueling your
vehicle after the fuel gauge indicates empty, you might not be
able to refuel the full amount of the advertised capacity of the
fuel tank due to the empty reserve still present in the tank.
For consistent results when filling the fuel tank:
•Turn the engine/ignition off prior to refueling, an error in the reading
will result if the engine is left running.
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If other than Ford, Motorcraft or Ford-authorized parts are used for
maintenance replacements or for service of components affecting
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 theService engine soonlight (
), 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 also identifies engine displacement.
Please consult yourWarranty Guidefor complete emission warranty
information.
On board diagnostics (OBD-II)
Your vehicle is equipped with a computer that monitors the engine’s
emission control system. This system is commonly known as the On
Board Diagnostics System (OBD-II). The OBD-II system protects the
environment by ensuring that your vehicle continues to meet
government emission standards. The OBD-II system also assists your
authorized dealer in properly servicing your vehicle. When the
indicator illuminates, the OBD-II system has detected a malfunction.
Temporary malfunctions may cause the
indicator to illuminate.
Examples are:
1. The vehicle has run out of fuel - the engine may misfire or run poorly.
2. Poor fuel quality or water in the fuel - the engine may misfire or run
poorly.
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3. The fuel cap may not have been securely tightened. SeeFuel filler
capin this chapter.
4. Driving through deep water - the electrical system may be wet.
These temporary malfunctions can be corrected by filling the fuel tank
with good quality fuel, properly tightening the fuel cap or letting the
electrical system dry out. After three driving cycles without these or any
other temporary malfunctions present, the
indicator should stay off
the next time the engine is started. A driving cycle consists of a cold
engine startup followed by mixed city/highway driving. No additional
vehicle service is required.
If the
indicator remains on, have your vehicle serviced at the first
available opportunity. Although some malfunctions detected by the
OBD-II may not have symptoms that are apparent, continued driving
with the
indicator on can result in increased emissions, lower fuel
economy, reduced engine and transmission smoothness, and lead to more
costly repairs.
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 the
indicator is on, refer to the
description in the Warning lights and chimes section of the Instrument
Cluster chapter. Your vehicle may not pass the I/M test with the
indicator 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
engine must warm up to its normal operating temperature. Once started,
do not turn off the engine until the above driving cycle is complete.
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POWER STEERING FLUID
Check the power steering fluid. Refer to thescheduled maintenance
informationfor the service interval schedules. If adding fluid is
necessary, use only MERCON
AT F.
•Gasoline engine shown; diesel
engine similar. Refer to
Identifying components in the
engine compartmentin the6.0
and 6.4 Liter Power Stroke
Direct Injection Turbo Diesel
Owner Guide Supplement.
Check the fluid level when it is at ambient temperature, 20°F–80°F
(-7°C–25°C):
1. Check the fluid level in the reservoir. It should be between the MIN
and MAX range. Do not add fluid if the level is within this range.
2. If the fluid level is low. Add fluid to bring fluid level up to be between
the MIN and MAX range.
3. Start the engine.
4. While the engine idles, turn the steering wheel left and right several
times.
5. Turn the engine off.
6. Recheck the fluid level in the reservoir. Do not add fluid if the level is
between the MIN and MAX range.
7. If the fluid is low, add fluid in small amounts, continuously checking
the level until it is between the MIN and MAX range. Be sure to put the
cap back on the reservoir.
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The fluid level will drop slowly as the brakes wear, and will rise when the
brake components are replaced. Fluid levels between the “MIN” and
“MAX” lines 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 authorized dealer immediately.
CLUTCH FLUID (IF EQUIPPED)
Check the clutch fluid level. Refer to thescheduled maintenance
informationfor the service interval schedules.
Use only a DOT 3 brake fluid designed to meet Ford specifications. Refer
toMaintenance product specifications and capacitiesin this chapter.
Carefully read cautionary information on product label. For
MEDICAL EMERGENCY INFORMATION, contact a physician or
Poison Control Center immediately; on Ford-Motorcraft products call:
1-800-959-3673 (FORD). Failure to follow these instructions may result
in personal injury.
During normal operation, the fluid level in the clutch reservoir should
remain constant or rise slightly. If the fluid level drops, refill the fluid
level to the step in the reservoir.
1. Clean the reservoir cap before
removal to prevent dirt and water
from entering the reservoir.
2. Remove cap and rubber
diaphragm from reservoir.
3. Add fluid until the level reaches
the step in the reservoir.
4. Reinstall rubber diaphragm and
cap onto reservoir.
TRANSMISSION FLUID
Checking automatic transmission fluid (if equipped)
Refer to yourscheduled maintenance informationfor 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.
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Item Capacity Ford part nameFord part number /
Ford specification
Windshield washer fluid 3.5 quarts (3.3L)Motorcraft Premium
Windshield Washer
ConcentrateZC-32–A /
WSB-M8B16–A2
1Add 8 oz. (236 ml) of Additive Friction Modifier XL-3 or equivalent meeting Ford Specification
EST-M2C118–A for complete refill of limited slip Ford axles. Ford design rear axles contain a
synthetic lubricant that does not require changing unless the axle has been submerged in water.2Add the coolant type originally equipped in your vehicle.3Ensure the correct automatic transmission fluid is used. Transmission fluid requirements are
indicated on the dipstick blade or the dipstick handle. Check the container to verify the fluid being
added is of the correct type. Refer to yourscheduled maintenance informationto determine the
correct service interval.
Automatic transmissions that require MERCON
SP should only use MERCON
SP fluid.
Use of a dual usage fluid in an automatic transmission requiring MERCON
SP may cause
transmission damage. Use of any fluid other than the recommended fluid may cause
transmission damage.4Service refill capacity is determined by filling the transmission to the bottom of the filler hole with
the vehicle on a level surface. The 6–speed manual transmission is equipped with an in-tank cooler.
Verify the fluid level after operating vehicle to ensure correct fluid level.5Indicates only approximate dry-fill capacity. Some applications may vary based on cooler size and
if equipped with an in-tank cooler. The amount of transmission fluid and fluid level should be set
by the indication on the dipstick’s normal operating range.6Use of synthetic or synthetic blend motor oil is not mandatory. Engine oil need only meet the
requirements of Ford specification WSS-M2C930-A and the API Certification mark.
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Climate control (see Air
conditioning or Heating) ............80
Clock adjust
6-CD in dash .............................34
AM/FM/CD .................................28
Clutch
fluid ..........................................375
operation while driving ..........269
recommended shift speeds ....270
Compass, electronic
set zone adjustment
...............134
Console
......................................120
overhead
..................................100
Controls
power seat
...............................165
steering column
......................112
Coolant
checking and adding
..............356
refill capacities
................359, 383
Cruise control
(see Speed control)
..................109
Customer Assistance
................294
Ford accessories for your
vehicle
.....................................345
Ford Extended Service
Plan
..........................................333
Getting assistance outside the
U.S. and Canada
.....................334
Getting roadside assistance
...294
Getting the service you
need
.........................................329
Ordering additional owner’s
literature
.................................335
Utilizing the
Mediation/Arbitration
Program
...................................333D
Daytime running lamps
(see Lamps) ................................86
Dipstick
automatic transmission
fluid ..........................................375
engine oil .................................351
Driveline universal joint and
slip yoke ....................................380
Driving under special
conditions ..................269, 284, 288
sand .........................................286
snow and ice ...........................288
through water .................287, 290
DVD system .................................48
E
Electronic message
center .................................120, 129
Emergencies, roadside
jump-starting ..........................322
Emergency Flashers .................296
Emission control system ..........370
Engine ........................................387
cleaning ...................................338
coolant .....................................356
diesel ...........................................8
fail-safe cooling .......................360
idle speed control ...................354
refill capacities ........................383
service points ..................348–349
starting after a collision .........296
Engine oil ..................................351
checking and adding ..............351
dipstick ....................................351
filter, specifications ........353, 382
recommendations ...................353
refill capacities ........................383
Event data recording ....................6
Exhaust fumes ..........................258
F
Fail safe cooling ........................360
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