light FORD SUPER DUTY 2000 1.G Service Manual

²The Front Axle Accessory Reserve Capacity and the Total Accessory
Reserve Capacity listed on the bottom right of the Safety Compliance
Certification Label will determine whether or not the addition of a
snowplow will overload your vehicle.
²The weight of the snowplow and supporting components distributed to
the front axle must not exceed the front accessory reserve capacity.
²The total weight of the snowplow and aftermarket equipment must
not exceed the Total Accessory Reserve Capacity.
²The weight of the installed snowplow and aftermarket equipment must
not load the vehicle beyond the GAWR (front/rear) and GVWR listed
on the Safety Compliance Certification Label.
²The total weight of the snowplow and aftermarket equipment must be
considered part of the payload and must not exceed the Gross
Combined Weight Rating (GCWR) for towing.
²Federal and most local regulations require additional exterior lamps
for snowplow-equipped vehicles. Consult your dealer for additional
information.
²After installing a snowplow to the vehicle, ensure the vehicle's front
toe alignment and front ride height are within specification (reset if
required). These specifications are located in the vehicle's Workshop
Manual. Adherence to the toe, tire pressures and ride height
specification is important for proper tire wear, ride, handling and
headlight aim. Also, maintain the engine oil and transmission fluid
change intervals following the severe duty schedule.
Do not exceed the GVWR or the GAWR specified on the
certification label.
Removing snowplow
Read the following instructions before removing a snowplow:
²After removing a snowplow from the vehicle, ensure the vehicle's front
toe alignment and front ride height are within specification (reset if
required). These specifications are located in the vehicle's Workshop
Manual. Adherence to the toe and ride height specification is
important for proper tire wear, ride, handling and headlight aim.
Driving
142

If you are driving more than 24 km (15 miles) at temperatures above
freezing, angle the plow blade either full left or full right to provide
maximum airflow to the radiator.
If you are driving less than 24 km (15 miles) at speeds up to 64 km/h
(40 mph) in cold weather, you will not need to worry about blade
position to provide maximum airflow.
4WD operation while plowing
²Shift transfer case to 4x4 LOW (4WD Low) when plowing in small
areas at speeds below 8 km/h (5 mph).
²Shift transfer case to 4x4 HIGH (4WD High) when plowing larger
areas or light snow at higher speeds. Do not exceed 24 km/h (15
mph).
²Do not shift the transmission from a forward gear to R (Reverse) until
the engine is at idle and the wheels are stopped.
²If the vehicle is stuck, shift the transmission in a steady motion
between forward and reverse gears. Do not rock the vehicle for more
than a few minutes. The transmission and tires may be damaged or
the engine can overheat.
It is the owner's responsibility to avoid engine overheating which
can cause damage.
Do not spin the wheels at over 35 mph (55 km/h). The tires may
fail and injure a passenger or bystander.
Driving
144

Roadside coverage beyond basic warranty
In the United States, you may purchase additional roadside assistance
coverage beyond this period through the Ford Auto Club by contacting
your Ford or Lincoln Mercury dealer.
Similarly in Canada, you may purchase additional coverage beyond the
basic coverage period by consulting the Ford Roadside Assistance Club
brochure or by calling 1±877±294±CLUB (1±877±894±2582).
HAZARD FLASHER
Use only in an emergency to warn traffic of vehicle breakdown,
approaching danger, etc. The hazard flashers can be operated when the
ignition is off.
²The hazard lights control is
located on top of the steering
column.
²Depress hazard lights control to
activate all hazard flashers
simultaneously.
²Depress control again to turn the
flashers off.
RESETTING THE FUEL PUMP SHUT-OFF SWITCH
The fuel pump shut-off switch is a device intended to stop the electric
fuel pump when your vehicle has been involved in a substantial jolt.
After a collision, if the engine cranks but does not start, the fuel pump
shut-off switch may have been activated.
Roadside emergencies
146

The fuses are coded as follows.
Fuse/Relay
LocationFuse Amp
RatingPassenger Compartment
Fuse Panel Description
1 20A Turn/Hazard Lamps
2 10A Airbag Module
3 20A Cigar Lighter, Data Link Connector
4 10A Glove Box Lamp, Map Lamps, Power
Mirrors, Underhood Lamp
5 Ð Not Used
6 Ð Not Used
7 5A Power Window/Lock Switch Illumination
8 5A Radio, Headlamp Switch Illumination
9 Ð Not Used
10 15A Dual Fuel Tanks
11 30A Wiper Motor, Wiper Run/Park Relay Coil,
Wiper Hi/LO Relay Coil, Washer Pump
Relay Coil
12 15A Horn
13 20A Stop Lamps, Center High-mount Stop
Lamp, Trailer Tow Stop Lamp, Speed
Control
14 10A Dome Lamp, Cargo Lamp, Courtesy Lamps,
Running Board Lamps
15 5A Stop Lamp Switch (Logic): Generic
Electronic Module (GEM), Powertrain
Control Module (PCM), Four Wheel
Anti-lock Brake System (4WABS) Module,
Brake Shift Interlock, Cluster and PCM
Keep Alive Memory
16 15A Instrument Cluster, Hi-beam Headlamps
17 Ð Not Used
18 Ð Not Used
Roadside emergencies
150

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.
2. Connect the other end of the positive (+) cable to the positive (+)
terminal of the assisting battery.
+–+–
+–+–
Roadside emergencies
167

SERVICE RECOMMENDATIONS
To help you service your vehicle:
²We highlight do-it-yourself items in the engine compartment for easy
location.
²We provide a Scheduled Maintenance Guide which makes tracking
routine service easy.
If your vehicle requires professional service, your dealership can provide
necessary parts and service. Check your ªWarranty Guideº to find out
which parts and services are covered.
Use only recommended fuels, lubricants, fluids and service parts
conforming to specifications. Motorcraft parts are designed and built to
provide the best performance in your vehicle.
PRECAUTIONS WHEN SERVICING YOUR VEHICLE
Be especially careful when inspecting or servicing your vehicle.
²Do not work on a hot engine.
²When the engine is running, keep loose clothing, jewelry or long hair
away from moving parts.
²Do not work on a vehicle with the engine running in an enclosed
space, unless you are sure you have enough ventilation.
²Keep all lit cigarettes, open flames and other lit material away from
the battery and all fuel related parts.
If you disconnect the battery, the engine must ªrelearnº its idle
conditions before your vehicle will drive properly, as explained in the
Batterysection in this chapter.
Working with the engine off
²Automatic transmission:
1. Set the parking brake and ensure the gearshift is securely latched in P
(Park).
2. Turn off the engine and remove the key.
3. Block the wheels to prevent the vehicle from moving unexpectedly.
²Manual transmission:
1. Set the parking brake.
2. Depress the clutch and place the gearshift in 1 (First).
Maintenance and care
172

CLUTCH FLUID (IF EQUIPPED)
Check the clutch fluid level. Refer to the Scheduled Maintenance Guide
for the service interval schedules.
Use only a DOT 3 brake fluid designed to meet Ford specifications. Refer
toCapacities and specifications.
Brake fluid is toxic. If brake fluid contacts the eyes, flush eyes
with running water for 15 minutes. Seek medical if irritation
persists. If taken internally, drink water and induce vomiting. Seek
medical attention immediately.
For vehicles equipped with the 6±speed manual transmission,
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.
For vehicles equipped with the 5±speed manual transmission,
during normal operation, the fluid level in the clutch reservoir will drop
slightly. As this occurs, 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.
Maintenance and care
181

WINDSHIELD WASHER FLUID
Checking and adding washer fluid
Check the washer fluid whenever
you stop for fuel. The reservoir is
highlighted with a
symbol.
If the level is low, add enough fluid
to fill the reservoir. In very cold
weather, do not fill the reservoir all
the way.
Only use a washer fluid that meets Ford specifications. Refer to
Lubricant specificationsin theCapacities and specificationschapter.
State or local regulations on volatile organic compounds may restrict the
use of methanol, a common windshield washer antifreeze additive.
Washer fluids containing non-methanol antifreeze agents should be used
only if they provide cold weather protection without damaging the
vehicle's paint finish, wiper blades or washer system.
Do not put washer fluid in the engine coolant reservoir. Washer
fluid placed in the cooling system may harm engine and cooling
system components.
ENGINE COOLANT
Checking engine coolant
Your engine's cooling system has been factory-filled with a 50/50 mixture
of distilled water and Ford Premium Engine Coolant E2FZ-19549-AA (in
Canada, Motorcraft CXC-10), or an equivalent premium engine coolant
that meets Ford specification ESE-M97B44-A.
A50/50 mixtureof distilled water and Ford Premium Engine Coolant
provides:
²maximum cooling system efficiency.
²freeze protection down to -36É C (-34É F).
²boiling protection up to 129É C (265É F).
Maintenance and care
182

How fail-safe cooling works
If the engine begins to overheat:
²the engine coolant temperature
gauge will move to the red (hot)
area.
²the
andsymbol will
illuminate.
²theService Engine Soon
indicator light 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:
²the engine power will be limited.
²the 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.
H
C
Maintenance and care
187

However, for severe usage or in high temperature climates, check the
battery electrolyte level. Refer to the Scheduled Maintenance Guide for
the service interval schedules.
Keep the electrolyte level in each cell up to the ªlevel indicatorº.
Do not overfill the battery cells.
If the electrolyte level in the battery is low, you can add plain tap water
to the battery, as long as you do not use hard water (water with a high
mineral or alkali content). If possible, however, try to only fill the battery
cells with distilled water. If the battery needs water often, have the
charging system checked.
If your battery has a cover/shield, make sure it is reinstalled
after the battery has been cleaned or replaced.
For longer, trouble-free operation, keep the top of the battery clean and
dry. Also, make certain the battery cables are always tightly fastened to
the battery terminals.
If you see any corrosion on the battery or terminals, remove the cables
from the terminals and clean with a wire brush. You can neutralize the
acid with a solution of baking soda and water.
Batteries normally produce explosive gases which can cause
personal injury. Therefore, do not allow flames, sparks or lighted
substances to come near the battery. When working near the battery,
always shield your face and protect your eyes. Always provide proper
ventilation.
When lifting a plastic-cased battery, excessive pressure on the
end walls could cause acid to flow through the vent caps,
resulting in personal injury and/or damage to the vehicle or battery.
Lift the battery with a battery carrier or with your hands on opposite
corners.
Keep batteries out of reach of children. Batteries contain sulfuric
acid. Avoid contact with skin, eyes or clothing. Shield your eyes
when working near the battery to protect against possible splashing of
acid solution. In case of acid contact with skin or eyes, flush
immediately with water for a minimum of 15 minutes and get prompt
medical attention. If acid is swallowed, call a physician immediately.
Maintenance and care
195