service FORD SUPER DUTY 1996 1.G Workshop Manual

327
*
[SV19801( ALL)02/95]
Ford Premium Cooling System Fluid is an
optimized formula that will protect all metals
and rubber elastomers used in Ford engines for
four years or 50,000 miles (80,000 km). It is not
necessary and not recommended to use
supplemental coolant additives in your gasoline
powered vehicle. These additives may harm
your engine cooling system. Follow the
recommended service interval for changing your
engine coolant.
*
[SV19851( ALL)04/94]
NOTE: When you change or add engine
coolant, it is important to maintain
your engine coolant concentration
between 40%(-11ÊF [-24ÊC]) and 60%
(-62ÊF [-52ÊC]),depending on your local
climate conditions. Below 40% you will
lose freeze protection and above 60%
your engine may overheat on a warm
day.
*
[SV19950( ALL)03/95]
NOTE: Do not use an engine coolant that does
not meet all 14 requirements of Ford
Specification ESE-M97B44-A. The use
of an improper coolant may void your
warranty for the engine cooling system.
Use only a premium nationally
recognized brand name engine coolant.
*
[SV19960( ALL)05/95]
Ford Motor Company expressly authorizes the
Ford Rotunda engine coolant recycling process
and chemicals. Use only Ford Rotunda recycled
engine coolant or an equivalent recycled engine
coolant that is certified by the supplier to meet
Ford specification ESE-M97B44-A.
%*
[SV19980( ALL)04/95]
NOTE: Always dispose of used automotive
fluids in a responsible manner. Follow
your community's standards for
disposing of these types of fluids. Call
your local recycling center to find out
about recycling automotive fluids.
File:ltsvf.ex
Update:Thu May 9 15:30:19 1996

329
*
[SV20700( ALL)05/95]
Engine coolant drain and flush
*
[SV20800( ALL)10/89]
To drain your vehicle's engine coolant:
*
[SV20900( ALL)03/94]
1. Turn off the engine and let it cool. Fully
depressurize the engine cooling system by
covering the radiator cap with a thick cloth
and turning it slowly counterclockwise to the
first stop. Step back while the pressure
releases.
*
[SV20950( ALL)05/90]
2. Remove the cap.
*
[SV21000(B FM)05/90]
3. Attach a small hose to the drain tube at the
bottom of the radiator.
*
[SV21200( ALL)05/90]
4. Let the engine coolant drain into a suitable
container. Disconnect the lower radiator hose
at the radiator connector and drain any
remaining engine coolant into a container.
*
[SV21225( ALL)05/94]
5. Reconnect the lower radiator hose and close
the radiator drain cock.
*
[SV21250( ALL)10/94]
Proper procedures for flushing the cooling
system can be found in theTruck Service Manual.
*
[SV21300( ALL)02/95]
Engine coolant refill procedure
*
[SV21400( ALL)10/89]
After you have drained the engine cooling
system:
*
[SV21500( ALL)01/89]
1. Fill the radiator with a 50/50 mixture of the
specified engine coolant concentrate and
water. Allow several minutes for trapped air
to escape (bubble out) and for engine coolant
to flow through the radiator.
*
[SV21900( ALL)03/94]
2. Replace the radiator cap to its fully installed
position, then back off to the first stop. This
will prevent high pressure from building up
in the cooling system during this part of the
fill procedure.
File:ltsvf.ex
Update:Thu May 9 15:30:19 1996

344 %
*
[SV33400( ALL)05/95]
RWARNING
Applying too much pressure on the ends
when lifting a battery could cause acid to
spill. Lift the battery with a carrier or
with your hands on the opposite corners.
*
[SV33500( ALL)01/95]
Automatic Transmission Fluid
*
[SV33601( ALL)04/95]
Under normal driving conditions automatic
transmission fluid should be changed every
30,000 miles (48,000 km) or 21,000 miles
(34,000 km) if under severe duty conditions.
However, if the transmission is not working
properly, for instance, the transmission may slip
or shift slowly, or you may notice some sign of
fluid leakage, the fluid level should be checked.
[SV33605( ALL)04/95]
NOTE: Except E4OD transmission, there is no
30,000 mile (48,000 km) sheduled
transmission fluid change requirement.
[SV33615( ALL)05/95]
Transmission fluid, filter and seal assembly
should be changed every 21,000 miles
(34,000 km) only under any of the following
conditions.
[SV33620( ALL)04/95]
q
Extended periods of high speed driving
during hot weather at/or above+90ÊF
(+30ÊC).
[SV33625( ALL)04/95]
q
Towing a trailer for distances over 1,000 miles
(1,600 km) per trip.
[SV33630( ALL)04/95]
q
Accumulating 5,000 miles (8,000 km) or more
per month.
[SV33635( ALL)04/95]
q
Continuous operation and/or extensive idling
(a delivery service as an example).
[SV33640( ALL)04/95]
q
Operating in severe dust conditions.
File:ltsvf.ex
Update:Thu May 9 15:30:19 1996

348
*
[SV35000(B F )03/91]
2. Replace the filler plug in its original
position, making sure it is fully seated.
%
*
[SV35100(B F )02/95]
The Clutch
*
[SV35200(B F )03/91]
The clutch on your vehicle is automatically
self-adjusting and should not require any routine
service.
*
[SV35301(B F )03/91]
During normal operation the fluid level in the
clutch reservoir will slowly rise. If for any
reason the fluid level drops, maintain the fluid
level at the step in the reservoir body.
%*
[SV35400(B F )03/94]
If it becomes necessary to remove the reservoir
cap, thoroughly clean the reservoir cap before
removing it to prevent dirt or water from
entering the reservoir. Remove the internal
diaphragm and then add only a DOT 3 brake
fluid such as Ford High Performance DOT 3
Brake Fluid, meeting Ford specification
ESA-M6C25-A.
*
[SV35600(B F )03/90]
one third page art:0020377-A
Clutch fluid reservoir
File:ltsvf.ex
Update:Thu May 9 15:30:19 1996

371
*
[SV48800(BEF )05/95]
To make sure that the catalytic converter and the
other emission control parts continue to work
properly:
*
[SV48900( ALL)01/95]
q
Use only unleaded fuel.
*
[SV49000( ALL)01/95]
q
Avoid running out of fuel.
*
[SV49100( ALL)01/95]
q
Do not turn off the ignition while your
vehicle is moving, especially at high speeds.
*
[SV49200( ALL)03/95]
q
Have the services listed in theMaintenance
Schedule and Recordbooklet performed
according to the specified schedule. The
scheduled maintenance services are required
because they are considered essential to the
life and performance of your vehicle and to
its emissions system.
*
[SV49250( ALL)03/95]
In general, maintenance, replacement, or service
of the emissions control devices or systems in
your new Ford Motor Company vehicle or
engine may be performed at your expense by
any automotive repair establishment or
individual using automotive parts equivalent to
those which your vehicle or engine was
originally equipped.
*
[SV49300( ALL)05/95]
RWARNING
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.
*
[SV49400(BEF )05/95]
RWARNING
On vehicles without original equipment
floor covering or insulation, do not let
passengers ride in your truck in a manner
that allows contact between skin and the
metal floor.
File:ltsvf.ex
Update:Thu May 9 15:30:19 1996

372
*
[SV49450( ALL)05/95]
If other than Ford or Motorcraft or Ford
authorized remanufactured parts are used for
maintenance, replacement, or for the service of
components affecting emissions control, the
owner should be assured that such parts are
warranted by their manufacturer to be
equivalent to genuine Ford Motor Company
parts in performance and durability. Please
consult your warranty information booklet for
complete warranty information.
*
[SV49500(BEF )05/95]
Watch for fluid leaks, strange odors, smoke, loss
of oil pressure, the charge warning light, the
check engine light, or the temperature warning
light. These sometimes indicate that the emission
system is not working properly.
*
[SV49600( ALL)01/95]
Do not make any unauthorized changes to your
vehicle or engine. Changes that cause more
unburned fuel to reach the exhaust system can
increase the temperature of the engine or
exhaust system.
*
[SV49700( ALL)01/95]
By law, anyone who manufactures, repairs,
services, sells, leases, trades vehicles, or
supervises a fleet of vehicles is not permitted to
intentionally remove an emission control device
or prevent it from working. In some of the
United States and in Canada, vehicle owners
may be liable if their emission control device is
removed or is prevented from working.
*
[SV49900( ALL)01/95]
Do not drive your vehicle if it does not operate
properly. See your dealer if the engine runs on
for more than five seconds after you shut it off
or if it misfires, surges, stalls, or backfires.
%*
[SV50000( ALL)05/95]
Information about your vehicle's emission
control system is on the Vehicle Emission
Control Information decal located on or near the
engine. This decal identifies engine displacement
and gives some tune-up specifications.
File:ltsvf.ex
Update:Thu May 9 15:30:19 1996

374
*
[SV50800( EFM)01/89]
The following are some of the acts that are
considered tampering:
*
[SV50900( FM)01/89]
q
Removing the hood blanket, fender apron
absorbers, fender apron barriers, underbody
noise shields or material constructed to
absorb noise output.
*
[SV51100( EFM)01/89]
q
Removing or dismantling the engine speed
governor, so that the engine's speed exceeds
the manufacturer's specifications.
*
[SV51200( EFM)01/89]
q
Removing the air duct, air intake choke or
silencer, air cleaner and/or air cleaner
element.
*
[SV51300( EFM)01/89]
q
Removing or dismantling any of the exhaust
system components including the catalyst
inlet pipe, muffler, outlet pipe, resonator or
diffuser.
*
[SV51400( EFM)01/89]
q
Removing the fan shroud. Removing or
dismantling the fan clutch so that it no longer
functions properly.
*
[SV51450( EFM)04/89]
Maintenance
*
[SV51455( EFM)06/93]
Instructions for maintenance and service of the
noise control system have been included in the
Maintenance Schedule and Recordbooklet and in
the ªGeneral Maintenance Checklist.º To aid the
noise control system throughout the life of the
vehicle, Ford Motor Company recommends that
this vehicle should be operated according to the
Owner's Guide. When installing replacement
parts, use caution not to violate the tampering
act as described above. Use the Maintenance
Record Log to list any inspections and services
performed on the vehicle.
File:ltsvf.ex
Update:Thu May 9 15:30:19 1996

375 %
*
[SV51456( ALL)05/95]
Readiness for Inspection/Maintenance
Testing
*
[SV51457( ALL)05/95]
In some localities it may become a legal
requirement to pass an
Inspection/Maintenance (I/M) test of the
On-Board Diagnostic (OBD) II system. If the
vehicle's powertrain system or its battery has
just been serviced, the OBD II system is reset to
a not ready for I/M testing condition. To
prepare for I/M testing, the law specifies a
ªneed for additional mixed city and highway
driving to complete the checkº of the OBD II
system. As soon as all of the OBD II system
checks are successfully completed, the OBD II
system is set to the ready condition. The amount
of driving required to reach the ready condition
varies with individual driving patterns. To
complete this requirement in the minimum
amount of time, refer to the OBD II Drive Cycle
defined below. If the vehicle owner cannot or
does not want to do the additional driving
required by law, a service center can perform
this drive cycle as it would any other type of
repair work.
[SV51458( ALL)05/95]
OBD II Drive Cycle
[SV51459( ALL)04/95]
The engine must be warmed up and at
operating temperature before proceeding with
the drive modes of the following OBD II Drive
Cycle.
[SV51461( ALL)04/95]
1. Start the engine. Drive or idle (in neutral)
the vehicle for 4 minutes.
[SV51463( ALL)04/95]
2. Idle the vehicle in drive (neutral for manual
transmission) for 40 seconds.
*
[SV51465( ALL)05/95]
3. Accelerate the vehicle to 45 mph (72 km/h)
at 1/4 to 1/2 throttle for 10 seconds.
File:ltsvf.ex
Update:Thu May 9 15:30:19 1996