ignition FORD F450 SUPER DUTY 2016 Service Manual

When the indicator light on the power pointis:
•On, the power point is working, theignition is on and a device is pluggedin.
•Off, the power point is off, the ignitionis off or no device is plugged in.
•Flashing, the power point is in faultmode.
The power outlet temporarily turns offpower when in fault mode if the deviceexceeds the 150 watt limit. Unplug yourdevice and switch the ignition off. Switchthe ignition back on, but do not plug yourdevice back in. Let the system cool off andswitch the ignition off to reset the faultmode. Switch the ignition back on andmake sure the indicator light remains on.
The power point is not designed for electricdevices such as:
•Cathode-ray, tube-type televisions.
•Motor loads, such as vacuum cleaners,electric saws and other electric powertools or compressor-drivenrefrigerators.
•Measuring devices, which processprecise data, such as medicalequipment or measuring equipment.
•Other appliances requiring anextremely stable power supply such asmicrocomputer-controlled electricblankets or touch-sensor lamps.
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Auxiliary Power Points

GENERAL INFORMATION
WARNINGS
Extended idling at high enginespeeds can produce very hightemperatures in the engine andexhaust system, creating the risk of fire orother damage.
Do not park, idle or drive your vehicleon dry grass or other dry groundcover. The emission system heats upthe engine compartment and exhaustsystem, creating the risk of fire.
Do not start the engine in a closedgarage or in other enclosed areas.Exhaust fumes can be toxic. Alwaysopen the garage door before you start theengine.
If you smell exhaust fumes insideyour vehicle, have your vehiclechecked by your authorized dealerimmediately. Do not drive your vehicle ifyou smell exhaust fumes.
If you disconnect the battery, your vehiclemay exhibit some unusual drivingcharacteristics for approximately 5 miles(8 kilometers) after you reconnect it. Thisis because the engine management systemmust realign itself with the engine. You candisregard any unusual drivingcharacteristics during this period.
The powertrain control system meets allCanadian interference-causing equipmentstandard requirements regulating theimpulse electrical field or radio noise.
When you start the engine, avoid pressingthe accelerator pedal before and duringoperation. Only use the accelerator pedalwhen you have difficulty starting theengine.
If your vehicle is operated in a heavy snowstorm or blowing snow conditions, theengine air induction may become partiallyclogged with snow and ice. If this occurs,the engine may experience a significantreduction in power output. At the earliestopportunity, clear all the snow and iceaway from the air induction inlet.
IGNITION SWITCH
A (off) - The ignition is off.
Note:When you switch the ignition off andleave your vehicle, do not leave your key inthe ignition. This could cause your vehiclebattery to lose charge.
B (accessory) - Allows the electricalaccessories, such as the radio, to operatewhile the engine is not running.
Note:Do not leave the ignition key in thisposition for too long. This could cause yourvehicle battery to lose charge.
C (on) - All electrical circuits areoperational and the warning lamps andindicators illuminate.
D (start) - Cranks the engine.
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Starting and Stopping the EngineC
D
B
A
E163165

STARTING A GASOLINE
ENGINE
When you start the engine, the idle speedincreases, this helps to warm up theengine. If the engine idle speed does notslow down automatically, have yourvehicle checked by an authorized dealer.
Before starting the engine check thefollowing:
•Make sure all occupants have fastenedtheir safety belts.
•Make sure the headlamps andelectrical accessories are off.
•Make sure the parking brake is on.
•Move the transmission selector leverto position P.
•Turn the ignition key to the on position.
Note:Do not touch the accelerator pedal.
1. Fully press the brake pedal.
2. Turn the key to the start position tostart the engine. Release the key whenthe engine starts.
Note:The engine may continue crankingfor up to 15 seconds or until it starts.
Note:If you cannot start the engine on thefirst try, wait for a short period and try again.
Failure to Start
If you cannot start the engine after threeattempts, wait 10 seconds and follow thisprocedure:
1. Fully press the brake pedal.
2. Fully press the accelerator pedal andhold it there.
3. Start the engine.
Stopping the Engine When YourVehicle is Stationary
1. Move the transmission selector leverto position P.
2. Turn the key to the off position.
3. Apply the parking brake.
Stopping the Engine When YourVehicle is Moving
WARNING
Switching off the engine when thevehicle is still moving will result in aloss of brake and steering assistance.The steering will not lock, but higher effortwill be required. When the ignition isswitched off, some electrical circuits,including air bags, warning lamps andindicators may also be off. If the ignitionwas turned off accidentally, you can shiftinto neutral (N) and re-start the engine.
1. Move the transmission selector leverto position N and use the brakes tobring your vehicle to a safe stop.
2. When your vehicle has stopped, movethe transmission selector lever toposition P and turn the key to the offposition.
3. Apply the parking brake.
Cold Weather Starting (FlexibleFuel Vehicles Only)
The starting characteristics of all gradesof E85 ethanol make it unsuitable for usewhen ambient temperatures fall below0°F (-18°C). Consult your fuel distributorfor the availability of winter grade ethanol.As the outside temperature approachesfreezing, ethanol fuel distributors shouldsupply winter grade ethanol (same as withunleaded gasoline). If summer gradeethanol is used in cold weather conditions,0°F to 32°F (-18°C to 0°C), you mayexperience increased cranking times, roughidle or hesitation until the engine haswarmed up.
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Starting and Stopping the Engine

We recommend regular unleaded gasolinewith a pump (R+M)/2 octane rating of 87.Some stations offer fuels posted as regularwith an octane rating below 87, particularlyin high altitude areas. We do notrecommend fuels with an octane ratingbelow 87.
Do not be concerned if your enginesometimes knocks lightly. However, if itknocks heavily under most drivingconditions while you are using fuel with therecommended octane rating, see yourauthorized dealer to prevent any enginedamage.
RUNNING OUT OF FUEL
Avoid running out of fuel because thissituation may have an adverse effect onengine components.
If you have run out of fuel:
•You may need to cycle the ignition fromoff to on several times after refuelingto allow the fuel system to pump thefuel from the tank to the engine. Onrestarting, cranking time will take a fewseconds longer than normal. Withkeyless ignition, just start the engine.Crank time will be longer than usual.
•Normally, adding 1.06 gal (4 L) of fuelis enough to restart the engine. If thevehicle is out of fuel and on a steepgrade, more than 1.06 gal (4 L) may berequired.
REFUELING
WARNINGS
Fuel vapor burns violently and a fuelfire can cause severe injuries.
Read and follow all the instructionson the pump island.
WARNINGS
Turn off your engine when you arerefueling.
Do not smoke if you are near fuel orrefueling your vehicle.
Keep sparks, flames and smokingmaterials away from fuel.
Stay outside your vehicle and do notleave the fuel pump unattendedwhen refueling your vehicle. This isagainst the law in some places.
Keep children away from the fuelpump; never let children pump fuel.
Do not use personal electronicdevices while refueling.
Wait at least 10 seconds beforeremoving the fuel pump nozzle toallow any residual fuel to drain intothe fuel tank.
Stop refueling after the fuel pumpnozzle automatically shuts off for thesecond time. Failure to follow thiswill fill the expansion space in the fuel tankand could lead to fuel overflowing.
Do not remove the fuel pump nozzlefrom its fully inserted position whenrefueling.
Use the following guidelines to avoidelectrostatic charge build-up when fillingan ungrounded fuel container:
•Place approved fuel container on theground.
•Do not fill a fuel container while it is inthe vehicle (including the cargo area).
•Keep the fuel pump nozzle in contactwith the fuel container while filling.
•Do not use a device that would holdthe fuel pump handle in the fill position.
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Fuel and Refueling

Fuel Filler Cap
WARNINGS
The fuel system may be underpressure. If you hear a hissing soundnear the fuel filler door, do not refueluntil the sound stops. Otherwise, fuel mayspray out, which could cause seriouspersonal injury.
If you do not use the proper fuel fillercap, excessive pressure or vacuumin the fuel tank may damage the fuelsystem or cause the fuel cap to disengagein a collision, which may result in possiblepersonal injury.
Note:If you must replace the fuel filler cap,replace it with a fuel filler cap that isdesigned for your vehicle. The customerwarranty may be void for any damage to thefuel tank or fuel system if the correctgenuine Ford, Motorcraft or other certifiedfuel filler cap is not used.
Your fuel tank filler cap has an indexeddesign with a 1/4th turn on and off feature.When fueling your vehicle:
1. Put your vehicle in park (P).
2. Switch the engine off.
3. Carefully turn the filler capcounterclockwise until it spins off.
4. Pull to remove the cap from the fuelfiller pipe.
5.To install the cap, align the tabs on thecap with the notches on the filler pipe.
6. Turn the filler cap clockwise 1/4 of aturn clockwise until it clicks at leastonce.
If the Check Fuel Cap light or a Check FuelCap message appears in the instrumentcluster and stays on after you start theengine, you may not have installed the fuelfiller properly.
If the fuel cap light remains on, at the nextopportunity, safely pull off of the road,remove the fuel filler cap, align the capproperly and reinstall it. The check fuel caplight or Check fuel cap message may notreset immediately. It may take severaldriving cycles for the indicators to turn off.A driving cycle consists of an enginestart-up (after four or more hours with theengine off) followed by normal city andhighway driving.
FUEL CONSUMPTION
Empty reserve is the amount of fuelremaining in the tank after the fuel gaugeindicates empty. The amount of usablefuel in the empty reserve varies and shouldnot be relied upon to increase driving range.
•The usable capacity of the fuel tank isthe amount of fuel that can be addedinto the tank after the gauge indicatesempty
•The advertised capacity is the total fueltank size. See Capacities andSpecifications (page 303). It is thecombined usable capacity plus theempty reserve.
•Due to the empty reserve, you may notbe able to refuel the full amount of theadvertised capacity of the fuel tankeven when the fuel gauge reads empty.
Filling the Tank
For consistent results when filling the fueltank:
•Turn the ignition off before fueling; aninaccurate reading results if the engineis left running.
•Use the same fill rate(low-medium-high) each time the tankis filled.
•Allow no more than two automaticclick-offs when filling.
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Fuel and Refueling

Your vehicle is equipped with variousemission control components and acatalytic converter that will enable yourvehicle to comply with applicable exhaustemission standards. To make sure that thecatalytic converter and other emissioncontrol components continue to workproperly:
•Use only the specified fuel listed.
•Avoid running out of fuel.
•Do not turn off the ignition while yourvehicle is moving, especially at highspeeds.
•Have the items listed in scheduledmaintenance information performedaccording to the specified schedule.
The scheduled maintenance items listedin scheduled maintenance information areessential to the life and performance ofyour vehicle and to its emissions system.
If you use parts other than Ford, Motorcraftor Ford-authorized parts for maintenancereplacements, or for service ofcomponents affecting emission control,such non-Ford parts should be theequivalent to genuine Ford Motor Companyparts in performance and durability.
Illumination of the service engine soonindicator, charging system warning light orthe temperature warning light, fluid leaks,strange odors, smoke or loss of enginepower could indicate that the emissioncontrol system is not working properly.
An improperly operating or damagedexhaust system may allow exhaust toenter the vehicle. Have a damaged orimproperly operating exhaust systeminspected and repaired immediately.
Do not make any unauthorized changes toyour vehicle or engine. By law, vehicleowners and anyone who manufactures,repairs, services, sells, leases, tradesvehicles, or supervises a fleet of vehiclesare not permitted to intentionally remove
an emission control device or prevent itfrom working. Information about yourvehicle’s emission system is on the VehicleEmission Control Information Decallocated on or near the engine. This decalalso lists engine displacement
Please consult your warranty informationfor complete details.
On-Board Diagnostics (OBD-II)
Your vehicle has a computer known as theon-board diagnostics system (OBD-II) thatmonitors the engine’s emission controlsystem. The system protects theenvironment by making sure that yourvehicle continues to meet governmentemission standards. The OBD-II systemalso assists a service technician in properlyservicing your vehicle.
When the service engine soonindicator illuminates, the OBD-IIsystem has detected amalfunction. Temporary malfunctions maycause the service engine soon indicator toilluminate.
Examples of temporary malfunctions are:
•the vehicle has run out of fuel—theengine may misfire or run poorly
•poor fuel quality or water in thefuel—the engine may misfire or runpoorly
•the fuel fill inlet may not have closedproperly. See Refueling (page 146).
•driving through deep water—theelectrical system may be wet.
You can correct these temporarymalfunctions by filling the fuel tank withgood quality fuel, properly closing the fuelfill inlet or letting the electrical system dryout. After three driving cycles without theseor any other temporary malfunctions
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Fuel and Refueling

present, the service engine soon indicatorshould stay off the next time you start theengine. A driving cycle consists of a coldengine startup followed by mixedcity/highway driving. No additional vehicleservice is required.
If the service engine soon indicator remainson, have your vehicle serviced at the firstavailable opportunity. Although somemalfunctions detected by the OBD-II maynot have symptoms that are apparent,continued driving with the service enginesoon indicator on can result in increasedemissions, lower fuel economy, reducedengine and transmission smoothness, andlead to more costly repairs.
Readiness forInspection/Maintenance (I/M)Testing
Some state/provincial and localgovernments may haveInspection/Maintenance (I/M) programsto inspect the emission control equipmenton your vehicle. Failure to pass thisinspection could prevent you from gettinga vehicle registration.
If the service engine soonindicator is on or the bulb doesnot work, you may need to havethe vehicle serviced. See On-BoardDiagnostics (OBD-II).
Your vehicle may not pass the I/M test ifthe service engine soon indicator is on ornot working properly (bulb is burned out),or if the OBD-II system has determinedthat some of the emission control systemshave not been properly checked. In thiscase, your vehicle is not ready for I/Mtesting.
If the vehicle’s engine or transmission hasjust been serviced, or the battery hasrecently run down or been replaced, theOBD-II system may indicate that thevehicle is not ready for I/M testing. Todetermine if the vehicle is ready for I/Mtesting, turn the ignition key to the onposition for 15 seconds without crankingthe engine. If the service engine soonindicator blinks eight times, it means thatthe vehicle is not ready for I/M testing; ifthe service engine soon indicator stays onsolid, it means that the vehicle is ready forI/M testing.
The OBD-II system monitors the emissioncontrol system during normal driving. Acomplete check may take several days. Ifthe vehicle is not ready for I/M testing, youmay need to perform the following drivingcycle consisting of mixed city and highwaydriving:
Drive on an expressway or highway for asteady 15 minutes, followed by 20 minutesof stop-and-go driving with at least four30-second idle periods.
Allow the vehicle to sit for at least eighthours without starting the engine. Then,start the engine and complete the abovedriving cycle. The engine must warm up toits normal operating temperature. Oncestarted, do not turn off the engine until theabove driving cycle is complete. If thevehicle is still not ready for I/M testing, youwill have to repeat the above driving cycle.
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Fuel and Refueling

AUTOMATIC TRANSMISSION
WARNING
Always set the parking brake fullyand make sure the gearshift islatched in park (P). Turn the ignitionto the off position and remove the keywhenever you leave your vehicle.
Understanding the Shift Positionsof the 5–Speed AutomaticTransmission (If Equipped)
Putting your vehicle in or out of gear:
1. Fully press down the brake pedal.
2. Move the gearshift lever into thedesired gear.
3. Come to a complete stop.
4. Move the gearshift lever and securelylatch it in park (P).
Park (P)
This position locks the transmission andprevents the rear wheels from turning.
Reverse (R)
With the gearshift lever in reverse (R), yourvehicle moves backward. Always come toa complete stop before shifting into andout of reverse (R).
Neutral (N)
With the gearshift lever in neutral (N), youcan start your vehicle and it is free to roll.Hold the brake pedal down while in thisposition.
Drive (D)
Drive (D) is the normal driving position forthe best fuel economy. The overdrivefunction allows automatic upshifts anddownshifts through gears one through five.
Third (3)
Transmission operates in third (3) gearonly. Use third (3) gear for improvedtraction on slippery roads.
Second (2)
Transmission operates in second (2) gearonly. Use second (2) gear to start-up onslippery roads.
First (1)
•Transmission operates in first (1) gearonly.
•Provides maximum engine braking.
•Allows upshifts by moving gearshiftlever.
•Does not downshift into first (1) gearat high speeds; allows for first (1) gearwhen vehicle reaches slower speeds.
Forced downshifts
•Allowed in drive (D) with the tow/haulfeature on or off.
•Press the accelerator to the floor.
•Allows transmission to select anappropriate gear.
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TransmissionE161511
P R N D 3 2 1

Upshifts when accelerating (recommended for best fuel economy)
Diesel enginesGasoline enginesShift from:
12 mph (19 km/h)15 mph (24 km/h)1 – 2
19 mph (31 km/h)25 mph (40 km/h)2 – 3
26 mph (42 km/h)40 mph (64 km/h)3 – 4
34 mph (55 km/h)45 mph (72 km/h)4 – 5
46 mph (74 km/h)50 mph (80 km/h)5 – 6
Automatic Transmission AdaptiveLearning
This feature's design is to increasedurability and provide consistent shift feelover the life of your vehicle. A new vehicleor transmission may have firm shifts, softshifts or both. This operation is normal anddoes not affect function or durability of thetransmission. Over time, the adaptivelearning process fully updates transmissionoperation. Additionally, whenever youdisconnect the battery or install a newbattery, the system must relearn thestrategy.
Brake-Shift Interlock
WARNINGS
Do not drive your vehicle until youverify that the brake lamps areworking.
When doing this procedure, you willbe taking your vehicle out of parkwhich means your vehicle can rollfreely. To avoid unwanted vehiclemovement, always fully set the parkingbrake prior to doing this procedure. Usewheel chocks if appropriate.
WARNINGS
If the parking brake is fully released,but the brake warning lamp remainsilluminated, the brakes may not beworking properly. See your authorizeddealer.
Your vehicle is equipped with a brake-shiftinterlock feature that prevents thegearshift lever from moving from park (P)when the ignition is in the 3 (on) positionand the brake pedal is not pressed.
If you cannot move the gearshift lever outof park (P) position with the ignition in the4 (on) position and the brake pedalpressed, a malfunction may have occurred.It is possible that a fuse has blown or yourvehicle’s brake lamps are not operatingproperly. See Fuse Specification Chart(page 223).
If the fuse is not blown and the brakelamps are working properly, the followingprocedure allows you to move the gearshiftlever from park (P):
1. Apply the parking brake. Switch theignition key to 1 (off), then remove thekey.
2. Move the steering column to the fulldown and full rearward position(toward the driver’s seat).
3. Remove the gearshift lever boot.
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Transmission

Shifting between system modes
Note:Do not perform these operations ifthe rear wheels are slipping.
Note:Some noise may be heard as the 4x4system shifts or engages. This is normal. Inorder to reduce engagement noise, it isrecommended that all shifts be performedat speeds below3 mph (5 km/h).
Note:The vehicle should not be driven in4X4 High with the hub locks disengaged asthis condition may damage driveline systemcomponents.
Engage the locking hubs by rotating thehub lock control from FREE to LOCK, thenmove the transfer case lever from 2H(2WD) to 4H (4x4 High) at a stop or avehicle speed below 3 mph (5 km/h).
Move the transfer case lever from 4H (4x4High) to 2H (2WD) at a stop or a vehiclespeed below 3 mph (5 km/h), thendisengage the locking hubs (optional) byrotating the hub lock control from LOCKto FREE.
For proper operation, make sure that bothindicator arrows on the hub are aligned,and that both hubs are set to either FREEor LOCK.
Shifting to/from 4L (4x4 Low)
1. Bring the vehicle to a stop or a speedbelow 3 mph (5 km/h).
2. Place the transmission in N (Neutral).
3. Move the transfer case shift leverthrough N (Neutral) directly to thedesired position.
4. If the transfer case does not, or onlypartially moves to the desired position,perform a shift with the transmissionin N (Neutral) and the vehicle rolling ata speed below 3 mph (5 km/h).
5.If shifting to 2H (2WD) with the vehicleat a complete stop, disengage thelocking hubs (optional) by rotating thehub lock control from LOCK to FREE.
Using the N (Neutral) position
WARNING
Do not leave the vehicle unattendedwith the transfer case in the N(Neutral) position. Always set theparking brake fully and turn off the ignitionwhen leaving the vehicle.
The transfer case neutral position overridesthe transmission and puts the vehicle inneutral regardless of transmission gearshiftlever position. The vehicle can moveforward or backwards.
This position should only be used whentowing the vehicle.
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Four-Wheel Drive (If Equipped)E163189