light FORD F450 SUPER DUTY 2016 Workshop Manual

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

Tow/Haul Mode
To activate tow/haul, press thebutton on the gearshift leveronce. The TOW HAUL indicatorlight illuminates in the instrument cluster.
The tow/haul feature:
•Delays upshifts to reduce the frequencyof transmission shifting.
•Provides engine braking in all forwardgears, which slows your vehicle andassists you in controlling your vehiclewhen descending a grade.
•Depending on driving conditions andload conditions, may downshift thetransmission, slow your vehicle andcontrol your vehicle speed whendescending a hill, without pressing theaccelerator pedal. The amount ofdownshift braking provided variesbased upon the amount you press thebrake pedal.
The tow/haul feature improvestransmission operation when towing atrailer or a heavy load. All transmissiongear ranges are available when usingtow/haul.
To deactivate the tow/haul feature andreturn to normal driving mode, press thebutton on the gearshift lever twice. TheTOW HAUL light deactivates. Tow/haulalso deactivates when you power downyour vehicle.
WARNING
Do not use the tow/haul featurewhen driving in icy or slipperyconditions as the increased enginebraking can cause the rear wheels to slideand your vehicle to swing around with thepossible loss of vehicle control.
Understanding the Shift Positionsof a 6–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 six.
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M (Manual)
With the gearshift lever in manual (M), thedriver can change gears up or down asdesired. By moving the gearshift lever fromdrive position drive (D) to manual (M) younow have control of selecting the gear youdesire using buttons on the shift lever. SeeUnderstanding your SelectShiftAutomatic™ transmission later in thissection.
To return to normal drive (D) position,move the shift lever back from manual (M)to drive (D).
The transmission operates in gears onethrough six.
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.
Tow/Haul Mode
To activate tow/haul, press thebutton on the gearshift leveronce. The TOW HAUL indicatorlight illuminates in the instrument cluster.
The tow/haul feature:
•Delays upshifts to reduce the frequencyof transmission shifting.
•Provides engine braking in all forwardgears, which slows your vehicle andassists you in controlling your vehiclewhen descending a grade.
•Depending on driving conditions andload conditions, may downshift thetransmission, slow your vehicle andcontrol your vehicle speed whendescending a hill, without pressing theaccelerator pedal. The amount ofdownshift braking provided will varybased upon the amount you press thebrake pedal.
The tow/haul feature improvestransmission operation when towing atrailer or a heavy load. All transmissiongear ranges are available when usingtow/haul.
To deactivate the tow/haul feature andreturn to normal driving mode, press thebutton on the gearshift lever twice. TheTOW HAUL light deactivates. Tow/haulalso deactivates when you power downyour vehicle.
WARNING
Do not use the tow/haul featurewhen driving in icy or slipperyconditions as the increased enginebraking can cause the rear wheels to slideand your vehicle to swing around with thepossible loss of vehicle control.
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TransmissionE161509

4. Place fingers into hole where youremoved the gearshift lever boot andpull top half of shroud up and forwardto separate it from the lower half of theshroud. There is a hinge at the forwardedge of the top shroud. Roll the tophalf of the shroud upward on the hingepoint to clear the hazard flasher button,then pull straight rearward toward thedriver’s seat to remove.
5. Remove the top half of the shroud.
6. Remove the three fasteners under thecolumn that secure the lower shroudhalf to the column.
7.Pull the lock lever into the full unlockedposition and remove the lower shroudcover by pulling the lever handlethrough the slot in the cover.
8.Apply the brake. Gently lift the overridedisk and move the gearshift lever intoneutral (N).
9. Start your vehicle.
Perform Steps 4 through 8 in reverse order,making sure to engage the hinge pivotsbetween the upper and lower halves of theshroud. Keep slight pressure in the forwarddirection as you rotate the halves together.
If Your Vehicle Gets Stuck In Mudor Snow
Note:Do not rock your vehicle if the engineis not at normal operating temperature ordamage to the transmission may occur.
Note:Do not rock your vehicle for morethan a minute or damage to thetransmission and tires may occur, or theengine may overheat.
If your vehicle is stuck in mud or snow, youmay rock it out by shifting between forwardand reverse gears, stopping between shiftsin a steady pattern. Press lightly on theaccelerator in each gear.
POWER TAKE-OFF
Auxiliary equipment called power take-off,or PTO, is often added to the engine ortransmission to operate utility equipment.Examples include a wheel-lift for towtrucks, cranes, tools for construction or tireservice, and pumping fluids. PTOapplications draw auxiliary horsepowerfrom the powertrain, often while the
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TransmissionE163185 E163186

•provides 4x4 High engagement anddisengagement while the vehicle ismoving.
•is operated by a rotary control locatedon the instrument panel that allowsyou select 4x2, 4x4 High or 4x4 Lowoperation.
•uses auto-manual hub locks that canbe engaged and disengagedautomatically based on the 4x4 modeselected.
•will increase fuel economy when usedin the recommended AUTO lock mode.
4WD Indicator Lights
Note:When a 4X4 system fault is present,the system will typically remain in whichever4X4 mode was selected prior to the faultcondition occurring. It will not default to 4X2in all circumstances. When this warning isdisplayed, have your vehicle serviced by anauthorized dealer.
4X2
Momentarily illuminates when2H is selected.
4X4 HIGH
Continuously illuminates when4H is selected.
4X4 LOW
Continuously illuminates when4L is selected.
CHECK 4X4
Displays when a 4X4 fault ispresent.
Using a Manual Shift On Stop(MSOS) 4WD system (If Equipped)
Note:High shift efforts may be encounteredwhen attempting to shift into and out of 4x4modes. It is recommended to allow thevehicle to roll at a speed below 3 mph(5 km/h) when shifting between modes.
2H (2WD)
For general on-road driving. Sends powerto the rear wheels only and should be usedfor street and highway driving. Providesoptimal smoothness and fuel economy athigh speeds
4H (4x4 High)
Used for extra traction such as in snow oricy roads or in off road situations. Thismode is not intended for use on drypavement.
N (Neutral)
Only used when towing the vehicle. Nopower to front or rear wheels.
4L (4x4 Low)
Uses extra gearing to provide maximumpower to all four wheels at reducedspeeds. Intended only for off roadapplications such as deep sand, steepgrades or pulling heavy objects.
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Four-Wheel Drive (If Equipped)E163173 E163175 E163174 E163189

Mud and Water
Mud
Be cautious of sudden changes in vehiclespeed or direction when you are driving inmud. Even four-wheel drive vehicles canlose traction in slick mud. If your vehicledoes slide, steer in the direction of the slideuntil you regain control of your vehicle.
After driving through mud, clean off residuestuck to rotating driveshafts and tires.Excess mud stuck on tires and rotatingdriveshafts can cause an imbalance thatcould damage drive components.
Water
If you must drive through high water, driveslowly. Traction or brake capability maybe limited.
When driving through water, determine thedepth and avoid water higher than thebottom of the hubs. If the ignition systemgets wet, your vehicle may stall.
Once through water, always try the brakes.Wet brakes do not stop your vehicle aseffectively as dry brakes. Drying can beimproved by applying light pressure to thebrake pedal while moving slowly.
Note:Driving through deep water maydamage the transmission. If the front or rearaxle is submerged in water, the axlelubricant and power transfer unit lubricantshould be checked and changed ifnecessary.
Driving on Hilly or Sloping Terrain
Although natural obstacles may make itnecessary to travel diagonally up or downa hill or steep incline, you should alwaystry to drive straight up or straight down.
Note:Avoid turning on steep slopes or hills.A danger lies in losing traction, slippingsideways and possible vehicle roll over.Whenever driving on a hill, determinebeforehand the route you will use. Do notdrive over the crest of a hill without seeingwhat conditions are on the other side. Donot drive in reverse over a hill without theaid of an observer.
When climbing a steep slope or hill, startin a lower gear rather than downshifting toa lower gear from a higher gear once theascent has started. This reduces strain onthe engine and the possibility of stalling.
If your vehicle stalls, do not try to turnaround because this could cause vehicleroll over. It is better to reverse back to asafe location.
Apply just enough power to the wheels toclimb the hill. Too much power will causethe tires to slip, spin or lose traction,resulting in loss of vehicle control.
Descend a hill in the same gear you woulduse to climb up the hill to avoid excessivebrake application and brake overheating.Do not descend in neutral. Disengageoverdrive or move the transmissionselector lever to a lower gear. Whendescending a steep hill, avoid sudden hardbraking as you could lose control. The frontwheels have to be turning in order to steeryour vehicle.
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Four-Wheel Drive (If Equipped)E143949

If your vehicle has anti-lock brakes, applythe brakes steadily. Do not pump thebrakes.
Driving on Snow and Ice
WARNING
If you are driving in slipperyconditions that require tire chains orcables, then it is critical that you drivecautiously. Keep speeds down, allow forlonger stopping distances and avoidaggressive steering to reduce the chancesof a loss of vehicle control which can leadto serious injury or death. If the rear end ofyour vehicle slides while cornering, steer inthe direction of the slide until you regaincontrol of your vehicle.
Note:Excessive tire slippage can causetransmission damage.
Four-wheel drive vehicles have advantagesover two-wheel drive vehicles in snow andice but can skid like any other vehicle.Should you start to slide while driving onsnowy or icy roads, turn the steering wheelin the direction of the slide until you regaincontrol.
Avoid sudden applications of power andquick changes of direction on snow andice. Apply the accelerator slowly andsteadily when starting from a full stop.
Avoid sudden braking. Although afour-wheel drive vehicle may acceleratebetter than a two-wheel drive vehicle insnow and ice, it will not stop any faster asbraking occurs at all four wheels. Do notbecome overconfident as to roadconditions.
Make sure you allow sufficient distancebetween you and other vehicles forstopping. Drive slower than usual andconsider using one of the lower gears. Inemergency stopping situations, apply thebrake steadily. Do not pump the brakepedal. See Hints on Driving WithAnti-Lock Brakes (page 169).
If Your Vehicle Gets Stuck In Mud orSnow
WARNING
Do not spin the wheels at over35 mph (56 km/h). The tires may failand injure a passenger or bystander.
If your vehicle gets stuck in mud or snow,it may be rocked out by shifting betweenforward and reverse gears, stoppingbetween shifts in a steady pattern. Presslightly on the accelerator in each gear.
Note:Do not rock your vehicle if the engineis not at normal operating temperature,damage to the transmission may occur.
Note:Do not rock your vehicle for morethan a minute, damage to the transmissionand tires may occur or the engine mayoverheat.
Parking
WARNINGS
If the parking brake is fully released,but the brake warning lamp remainsilluminated, the brakes may not beworking properly. See your authorizeddealer.
Always set the parking brake fullyand make sure the gearshift islatched in P (Park). Turn the ignitionto the off position and remove the keywhenever you leave your vehicle.
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Four-Wheel Drive (If Equipped)

LIMITED SLIP DIFFERENTIAL
This axle provides added traction onslippery surfaces, particularly when onewheel is on a poor traction surface. Undernormal conditions, the limited-slip axlefunctions like a standard rear axle. The axlemay exhibit a slight noise or vibrationduring tight turns with low vehicle speed.This is normal behavior and indicates theaxle is working.
ELECTRONIC LOCKING
DIFFERENTIAL (If Equipped)
Note:The electronic locking differential isfor off-road use only and is not for use ondry pavement. Using the electronic lockingdifferential on dry pavement will result inincreased tire wear, noise and vibration.
The electronic locking differential is adevice housed in the rear axle that allowsboth rear wheels to turn at the samespeed. The electronic locking differentialcan provide additional traction should yourvehicle become stuck. You can activatethe differential electronically and shift iton the fly within the differential operatingspeed range. The differential is for use inmud, rocks, sand, or any off-road conditionwhere you need maximum traction. It isnot for use on dry pavement.
The following conditions will affect theelectronic locking differential:
•On 2WD vehicles and 4WD vehicles in2H (4X2) or 4H (4X4 High), the ELDwill not engage if the vehicle speed isabove 20 mph (32 km/h).
•On 2WD vehicles and 4WD vehicles in2H (4X2) or 4H (4X4 High), the ELDwill automatically disengage at speedsabove 25 mph (40 km/h) and willautomatically reengage at speedsbelow 20 mph (32 km/h).
•On 4WD vehicles in 4L (4X4 Low), theELD can be engaged at any speed andwill not automatically disengage.
Activating the Electronic LockingDifferential
Note:Do not use electronic lockingdifferential on dry, hard surfaced roads.Doing so will produce excessive noise,vibration and increase tire wear.
Note:If the electronic locking differentialhas difficulty disengaging, release theaccelerator pedal and turn the steeringwheel in the opposite direction while rolling.
For vehicles equipped with anelectronic shift 4WD system
Pull the 4WD control knob toward you.
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Rear AxleE172924

For 2WD vehicles and vehiclesequipped with a manual shift 4WDsystem
Turn the control to ON.
Once the indicator lightilluminates in the informationdisplay, both rear wheel axleshafts will be locked together providingadded traction.
If the indicator does not come on, or theindicator turns off while driving, one of thefollowing has occurred:
•The vehicle speed is too high.
•The left and right rear wheel speeddifference is too high during anengagement attempt.
•The system has malfunctioned and isaccompanied by CHECK LOCKINGDIFFERENTIAL in the informationdisplay. See your authorized Forddealer for assistance.
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GENERAL INFORMATION
Note:Occasional brake noise is normal. Ifa metal-to-metal, continuous grinding orcontinuous squeal sound is present, thebrake linings may be worn-out. Have thesystem checked by an authorized dealer. Ifyour vehicle has continuous vibration orshudder in the steering wheel while braking,have it checked by an authorized dealer.
Note:Brake dust may accumulate on thewheels, even under normal drivingconditions. Some dust is inevitable as thebrakes wear and does not contribute tobrake noise. See Cleaning the AlloyWheels (page 261).
See Warning Lamps andIndicators (page 84).
Wet brakes result in reduced brakingefficiency. Gently press the brake pedal afew times when driving from a car wash orstanding water to dry the brakes.
Brake Over Accelerator
In the event the accelerator pedalbecomes stuck or entrapped, apply steadyand firm pressure to the brake pedal toslow the vehicle and reduce engine power.If you experience this condition, apply thebrakes and bring your vehicle to a safestop. Move the transmission to park (P),switch the engine off and apply the parkingbrake. Inspect the accelerator pedal forany interference. If none are found and thecondition persists, have your vehicle towedto the nearest authorized dealer.
Brake Assist
Brake assist detects when you brakerapidly by measuring the rate at which youpress the brake pedal. It providesmaximum braking efficiency as long as youpress the pedal, and can reduce stoppingdistances in critical situations.
Anti-lock Brake System
This system helps you maintain steeringcontrol during emergency stops by keepingthe brakes from locking.
This lamp momentarilyilluminates when you turn theignition on. If the light does notilluminate during start up, remains on orflashes, the system may be disabled. Havethe system checked by an authorizeddealer. If the anti-lock brake system isdisabled, normal braking is still effective.
If the brake warning lampilluminates when you release theparking brake, have the systemchecked by an authorized dealer.
HINTS ON DRIVING WITH
ANTI-LOCK BRAKES
Note:When the system is operating, thebrake pedal will pulse and may travelfurther. Maintain pressure on the brakepedal. You may also hear a noise from thesystem. This is normal.
The anti-lock braking system will noteliminate the risks when:
•You drive too closely to the vehicle infront of you.
•Your vehicle is hydroplaning.
•You take corners too fast.
•The road surface is poor.
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