brake FORD SUPER DUTY 2000 1.G Workshop Manual

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.
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181

5. Recheck the fluid level on the dipstick. Do not add fluid if the level is
between the arrows in the FULL COLD range.
6. If the fluid is low, add fluid in small amounts, continuously checking
the level until it reaches the FULL COLD range. Be sure to put the
dipstick back in the reservoir.
TRANSMISSION FLUID
Checking automatic transmission fluid
Refer to your Scheduled Maintenance Guide for 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.
Automatic transmission fluid expands when warmed. To obtain an
accurate fluid check, drive the vehicle until it is at normal operating
temperature (approximately 30 km [20 miles]). If your vehicle has been
operated for an extended period at high speeds, in city traffic during hot
weather or pulling a trailer, the vehicle should be turned off for about 30
minutes to allow fluid to cool before checking.
1. Drive the vehicle 30 km (20 miles) or until it reaches normal operating
temperature.
2. Park the vehicle on a level surface and engage the parking brake.
3. With the parking brake engaged and your foot on the brake pedal,
start the engine and move the gearshift lever through all of the gear
ranges. Allow sufficient time for each gear to engage.
4. Latch the gearshift lever in P (Park) and leave the engine running.
5. Remove the dipstick, wiping it clean with a clean, dry lint free rag. If
necessary, refer toIdentifying components in the engine compartment
in this chapter for the location of the dipstick.
6. Install the dipstick making sure it is fully seated in the filler tube.
7. Remove the dipstick and inspect the fluid level. The fluid should be in
the designated area for normal operating temperature or ambient
temperature.
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189

Because your vehicle's engine is also electronically controlled by a
computer, some control conditions are maintained by power from the
battery. When the battery is disconnected or a new battery is installed,
the engine must relearn its idle and fuel trim strategy for optimum
driveability and performance. To begin this process:
1. With the vehicle at a complete stop, set the parking brake.
2. Put the gearshift in P (Park) (automatic transmission) or the neutral
position (manual transmission), turn off all accessories and start the
engine.
3. Run the engine until it reaches normal operating temperature.
4. Allow the engine to idle for at least one minute.
5. Turn the A/C on and allow the engine to idle for at least one minute.
6. Drive the vehicle to complete the relearning process.
²The vehicle may need to be driven 16 km (10 miles) or more to
relearn the idle and fuel trim strategy.
²If you do not allow the engine to relearn its idle trim, the idle
quality of your vehicle may be adversely affected until the idle
trim is eventually relearned.
If the battery has been disconnected or a new battery has been installed,
the clock and the preset radio stations must be reset once the battery is
reconnected.
²Always dispose of automotive
batteries in a responsible manner.
Follow your local authorized
standards for disposal. Call your
local authorized recycling center
to find out more about recycling
automotive batteries.
WINDSHIELD WIPER BLADES
Check the wiper blades at least twice a year or when they seem less
effective. Substances such as tree sap and some hot wax treatments used
by commercial car washes reduce the effectiveness of wiper blades.
LEAD
RETURN
RECYCLE
Maintenance and care
196

The tires on your vehicle have all weather treads to provide traction in
rain and snow. However, in some climates, you may need to use snow
tires and chains. If you need to use chains, it is recommended that steel
wheels (of the same size and specifications) be used as chains may chip
aluminum wheels.
Follow these guidelines when using snow tires and chains:
²Use only SAE Class S chains.
²Install chains securely, verifying that the chains do not touch any
wiring, brake lines or fuel lines.
²Drive cautiously. If you hear the chains rub or bang against your
vehicle, stop and re-tighten the chains. If this does not work, remove
the chains to prevent damage to your vehicle.
²If possible, avoid fully loading your vehicle.
²Remove the tire chains when they are no longer needed. Do not use
tire chains on dry roads.
²The suspension insulation and bumpers will help prevent vehicle
damage. Do not remove these components from your vehicle when
using snow tires and chains.
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 system to work improperly in a collision, which may result in
possible personal injury.
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202

²Using the air conditioner or defroster may reduce fuel economy.
²You may want to turn off the speed control in hilly terrain if
unnecessary shifting between third and fourth gear occurs.
Unnecessary shifting of this type could result in reduced fuel
economy.
²Warming up a vehicle on cold mornings is not required and may
reduce fuel economy.
²Resting your foot on the brake pedal while driving may reduce fuel
economy.
²Combine errands and minimize stop-and-go driving.
Maintenance
²Keep tires properly inflated and use only recommended size.
²Operating a vehicle with the wheels out of alignment will reduce fuel
economy.
²Use recommended engine oil. Refer toLubricant Specifications.
²Perform all regularly scheduled maintenance items. Follow the
recommended maintenance schedule and owner maintenance checks
found in your vehicle Scheduled Maintenance Guide.
Conditions
²Heavily loading a vehicle or towing a trailer may reduce fuel economy
at any speed.
²Carrying unnecessary weight may reduce fuel economy (approximately
0.4 km/L [1 mpg] is lost for every 180 kg [400 lb] of weight carried).
²Adding certain accessories to your vehicle (for example bug
deflectors, rollbars/light bars, running boards, ski/luggage racks) may
reduce fuel economy.
²Using fuel blended with alcohol may lower fuel economy.
²Fuel economy may decrease with lower temperatures during the first
12±16 km (8±10 miles) of driving.
²Driving on flat terrain offers improved fuel economy as compared to
driving on hilly terrain.
²Transmissions give their best fuel economy when operated in the top
cruise gear and with steady pressure on the gas pedal.
Maintenance and care
209

BULBS
Replacing exterior bulbs
Check the operation of the following lamps frequently:
²Headlamps
²High-mount brakelamp
²Brakelamps
²Turn signals
²License plate lamp
²Tail lamps
²Back-up lamps
Do not remove lamp bulbs unless they can be replaced immediately with
new ones. If a bulb is removed for an extended period of time,
contaminants may enter the lamp housings and affect lamp performance.
Replacing headlamp bulbs (aerodynamic)
1. Make sure that the headlamp control is in the OFF position.
2. Open the hood.
3. Disconnect the electrical connector from the bulb by pulling rearward.
4. Remove bulb retainer ring by
turning it counterclockwise, then
slide the ring off the plastic base.
5. Without turning, carefully pull
bulb out of headlamp assembly.
Handle a halogen headlamp bulb carefully and keep out of
children's reach. Grasp the bulb only by its plastic base and do
not touch the glass. The oil from your hand could cause the bulb to
break the next time the headlamps are operated.
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212

Replacing brake/tail/backup lamp bulbs Ð F450/F550 only
The brake/tail/backup lamp bulbs
are located in the same portion of
the tail lamp assembly. Follow the
same steps to replace either bulb:
1. Remove the four screws and the
lamp lens from lamp assembly.
2. Carefully pull the bulb straight
out of the socket and push in the
new bulb.
3. Install the lens on the lamp
assembly with the four screws.
Replacing cargo lamp and high-mount brakelamp bulbs
To remove the lamp assembly:
1. Remove the two screws and lamp
assembly from vehicle as wiring
permits.
2. Remove the bulb socket by
rotating counterclockwise and
pulling it out of the lamp assembly.
3. Pull the bulb straight out of the
socket and push in the new bulb.
To install the brakelamp assembly:
1. Install the bulb into the lamp
assembly and rotate clockwise.
2. Install the lamp assembly on the vehicle with two screws.
Maintenance and care
215

Washing your vehicle
Wash your vehicle regularly with
cold or lukewarm water. Never use
strong detergents or soap. If your
vehicle is particularly dirty, use a
quality car wash detergent. Always
use a clean sponge, washing glove
or similar device and plenty of water
for best results. To avoid spots,
avoid washing when the hood is still
warm, immediately after or during
exposure to strong sunlight.
During winter months, it is especially important to wash the vehicle on a
regular basis. Large quantities of dirt and road salt are difficult to
remove and also cause damage to the vehicle.
Any gasoline spilled on the vehicle or deposits such as bird droppings
should be washed and sponged off as soon as possible. Deposits not
removed promptly can cause damage to the vehicle's paintwork.
Remove any exterior accessories (such as antennas) and fold in the side
view mirrors before entering a car wash. If you have wax applied to the
vehicle at a commercial car wash, it is recommended that you clean the
wiper blades and windshield as described inCleaning the wiper blades
and windshield.
After washing, apply the brakes several times to dry them.
Waxing your vehicle
Waxing your vehicle on a regular basis will reduce minor scratches and
paint damage.
Wax when water stops beading on the surface. This could be every three
or four months, depending on operating conditions.
Use only carnauba or synthetic-based waxes. Use a cleaning fluid with a
clean cloth to remove any bugs before waxing your vehicle. Use tar
remover to remove any tar spots.
Avoid getting wax on the windshield, or on any surfaces which appear
coarse or bumpy. If you have wax applied at a commercial car wash, it is
recommended that you clean the wiper blades and windshield as
described inCleaning the wiper blades and windshield.
Maintenance and care
218

MOTORCRAFT PART NUMBERS
Component* 5.4L V8 engine 6.8L V10 engine
Air filter element FA-1634 FA-1634
Fuel filter FG-986B FG-986B
Oil filter FL-820-S FL-820-S
PCV valve EV-233 EV-233
Battery (Standard) BXT-65-650 BXT-65-650
Battery (Optional) BXT-65-750 BXT-65-750
Spark plugs-platinum** AWSF-22E AWSF-22E
*Refer to the7.3 Liter Power Stroke Direct Injection Turbo Diesel
Owner's Guide Supplementfor Motorcraft diesel engine service part
numbers.
**Refer to Vehicle Emissions Control Information (VECI) decal for spark
plug gap information.
REFILL CAPACITIES
FluidFord Part
NameApplication Capacity
Front axle Motorcraft SAE
75W-90
Premium 4x4
Front Axle
LubricantF-250/350 Dana
50 axle1.8L (3.8 pints)
F-350/450/550
Dana 60 axle2.7L (5.8 pints)
Rear axle
1,2Motorcraft SAE
75W-140
Synthetic Rear
Axle LubricantF-250 /350
(10.50 inch
axle)3.3L (6.9 pints)
Motorcraft SAE
80W-90
Premium Rear
Axle LubricantF-550 Dana 135 11.6L
(24.5 pints)
Brake fluid High
Performance
DOT 3 Motor
Vehicle Brake
FluidAll Fill to line on
reservoir
Capacities and specifications
222

fluid that indicates dual usage (MERCONtand MERCONtV) in
an automatic transmission application requiring MERCONtmay
cause transmission damage. Use of any fluid other than the
recommended fluid may cause transmission damage.
5Service refill capacity is determined by filling the transmission to the
bottom of the filler hole with the vehicle on a level surface.
6Indicates 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.
LUBRICANT SPECIFICATIONS
ItemFord part name
or equivalentFord part
numberFord
specification
Front axle
(4X4)Motorcraft SAE
75W-90 Premium
4x4 Front Axle
LubricantXY-75W90-TQL WSP-M2C201-A
Rear axleMotorcraft SAE
75W-140 High
Performance
Synthetic Rear
Axle Lube
1
F1TZ-19580-B WSL-M2C192-A
Motorcraft SAE
80W-90 Premium
Rear Axle
Lubricant (Dana
135 axles)
1
XY-80W90-QL WSP-M2C197-A
Brake fluid
and clutch
fluid (if
equipped)High Performance
DOT 3 Motor
Vehicle Brake
FluidC6AZ-19542-AB ESA-M6C25-A
and DOT 3
Engine coolant Ford Premium
Engine CoolantE2FZ-19549-AA
(in Canada,
Motorcraft
CXC-8-B)ESE-M97B44-A
Capacities and specifications
225