engine FORD SUPER DUTY 2002 1.G Service Manual

F-350 SuperCab Chassis Cab Single Rear Wheel
(Fifth Wheel Towing)
Engine Rear axle
ratioMaximum GCWR -
kg (lbs.)Maximum
trailer weight -
kg (lbs.)
4x4 with manual transmission
5.4L 3.73 6123 (13500) 2903 (6400)
5.4L 4.10 6804 (15000) 3583 (7900)
6.8L 3.73 7484 (16500) 4218 (9300)
4x4 with automatic transmission
5.4L 3.73 6123 (13500) 2948 (6500)
5.4L 4.10 6804 (15000) 3629 (8000)
6.8L 3.73 7711 (17000) 4445 (9800)
F-350 SuperCab Chassis Cab Dual Rear Wheel (Fifth Wheel
Towing)
Engine Rear axle
ratioMaximum GCWR -
kg (lbs.)Maximum
trailer weight -
kg (lbs.)
4x2 with manual transmission
6.8L 3.73 7484 (16500) 4264 (9400)
6.8L 4.30 9072 (20000) 5851 (12900)
4x2 with automatic transmission
6.8L 3.73 7711 (17000) 4491 (9900)
6.8L 4.30 9072 (20000) 5851 (12900)
4x4 with manual transmission
6.8L 3.73 7484 (16500) 4082 (9000)
6.8L 4.30 9072 (20000) 5670 (12500)
4x4 with automatic transmission
6.8L 3.73 7711 (17000) 4309 (9500)
6.8L 4.30 9072 (20000) 5670 (12500)
Driving
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F-350 Crew Cab Chassis Cab Single Rear Wheel
(Fifth Wheel Towing)
Engine Rear axle
ratioMaximum GCWR -
kg (lbs.)Maximum
trailer weight -
kg (lbs.)
4x2 with manual transmission
5.4L 3.73 6123 (13500) 3039 (6700)
5.4L 4.10 6804 (15000) 3719 (8200)
6.8L 3.73 7484 (16500) 4309 (9500)
4x2 with automatic transmission
5.4L 3.73 6123 (13500) 3039 (6700)
5.4L 4.10 6804 (15000) 3719 (8200)
6.8L 3.73 7711 (17000) 4536 (10000)
4x4 with manual transmission
5.4L 3.73 6123 (13500) 2812 (6200)
5.4L 4.10 6804 (15000) 3493 (7700)
6.8L 3.73 7484 (16500) 4128 (9100)
4x4 with automatic transmission
5.4L 3.73 6123 (13500) 2858 (6300)
5.4L 4.10 6804 (15000) 3538 (7800)
6.8L 3.73 7711 (17000) 4354 (9600)
F-350 Crew Cab Chassis Cab Dual Rear Wheel
(Fifth Wheel Towing)
Engine Rear axle
ratioMaximum GCWR -
kg (lbs.)Maximum
trailer weight -
kg (lbs.)
4x2 with manual transmission
6.8L 3.73 7484 (16500) 9200 (4173)
6.8L 4.30 9072 (20000) 5761 (12700)
4x2 with automatic transmission
6.8L 3.73 7711 (17000) 4400 (9700)
6.8L 4.30 9072 (20000) 5761 (12700)
Driving
147

F-350 Crew Cab Chassis Cab Dual Rear Wheel
(Fifth Wheel Towing)
Engine Rear axle
ratioMaximum GCWR -
kg (lbs.)Maximum
trailer weight -
kg (lbs.)
4x4 with manual transmission
6.8L 3.73 7484 (16500) 3946 (8700)
6.8L 4.30 9072 (20000) 5534 (12200)
4x4 with automatic transmission
6.8L 3.73 7711 (17000) 4218 (9300)
6.8L 4.30 9072 (20000) 5579 (12300)
F-450 Regular Chassis Cab Dual Rear Wheel
(Fifth Wheel Towing)
Engine Rear axle
ratioMaximum GCWR -
kg (lbs.)Maximum
trailer weight -
kg (lbs.)
4x2 with manual transmission
6.8L 4.88/5.38 9979 (22000) 6577 (14500)
4x2 with automatic transmission
6.8L 4.88 10886 (24000) 7530 (16600)
6.8L 5.38 11793 (26000) 8437 (18600)
4x4 with manual transmission
6.8L 4.88/5.38 9979 (22000) 6441 (14200)
4x4 with automatic transmission
6.8L 4.88 10886 (24000) 7394 (16300)
6.8L 5.38 11793 (26000) 8301 (18300)
Driving
148

F-450 SuperCab Chassis Cab Dual Rear Wheel
(Fifth Wheel Towing)
Engine Rear axle
ratioMaximum GCWR -
kg (lbs.)Maximum
trailer weight -
kg (lbs.)
4x2 with manual transmission
6.8L 4.88/5.38 9979 (22000) 6441 (14200)
4x2 with automatic transmission
6.8L 4.88 10886 (24000) 7348 (16200)
6.8L 5.38 11793 (26000) 8255 (18200)
4x4 with manual transmission
6.8L 4.88/5.38 9979 (22000) 6260 (13800)
4x4 with automatic transmission
6.8L 4.88 10886 (24000) 7167 (15800)
6.8L 5.38 11793 (26000) 8074 (17800)
F-450 Crew Cab Chassis Cab Dual Rear Wheel
(Fifth Wheel Towing)
Engine Rear axle
ratioMaximum GCWR -
kg (lbs.)Maximum
trailer weight -
kg (lbs.)
4x2 with manual transmission
6.8L 4.88/5.38 9979 (22000) 6350 (14000)
4x2 with automatic transmission
6.8L 4.88 10886 (24000) 7257 (16000)
6.8L 5.38 11793 (26000) 8165 (18000)
4x4 with manual transmission
6.8L 4.88/5.38 9979 (22000) 6214 (13700)
4x4 with automatic transmission
6.8L 4.88 10886 (24000) 7121 (15700)
6.8L 5.38 11793 (26000) 8029 (17700)
Driving
149

F-550 Regular Cab Chassis Cab Dual Rear Wheel
(Fifth Wheel Towing)
Engine Rear axle
ratioMaximum GCWR -
kg (lbs.)Maximum
trailer weight -
kg (lbs.)
4x2 with automatic transmission
6.8L 4.88 10886 (24000) 7484 (16500)
6.8L 5.38 11793 (26000) 8391 (18500)
4x4 with automatic transmission
6.8L 4.88 10886 (24000) 7348 (16200)
6.8L 5.38 11793 (26000) 8255 (18200)
F-550 SuperCab Chassis Cab Dual Rear Wheel
(Fifth Wheel Towing)
Engine Rear axle
ratioMaximum GCWR -
kg (lbs.)Maximum
trailer weight -
kg (lbs.)
4x2 with automatic transmission
6.8L 4.88 10886 (24000) 7348 (16200)
6.8L 5.38 11793 (26000) 8255 (18200)
4x4 with automatic transmission
6.8L 4.88 10886 (24000) 7121 (15700)
6.8L 5.38 11793 (26000) 8029 (17700)
F-550 Crew Cab Chassis Cab Dual Rear Wheel
(Fifth Wheel Towing)
Engine Rear axle
ratioMaximum GCWR -
kg (lbs.)Maximum
trailer weight -
kg (lbs.)
4x2 with automatic transmission
6.8L 4.88 10886 (24000) 7212 (15900)
6.8L 5.38 11793 (26000) 8119 (17900)
4x4 with automatic transmission
6.8L 4.88 10886 (24000) 7076 (15600)
6.8L 5.38 11793 (26000) 7983 (17600)
Driving
150

•Allow more distance for stopping with a trailer attached.
•The trailer tongue weight should be 10–15% of the loaded trailer
weight.
•After you have traveled 80 km (50 miles), thoroughly check your
hitch, electrical connections and trailer wheel lug nuts.
•To aid in engine/transmission cooling and A/C efficiency during hot
weather while stopped in traffic, place the gearshift lever in P (Park)
(automatic transmission) or N (Neutral) (manual transmissions).
•Vehicles with trailers should not be parked on a grade. If you must
park on a grade, place wheel chocks under the trailer’s wheels.
Launching or retrieving a boat
When backing down a ramp during boat launching or retrieval,
•Do not allow the static water level to rise above the bottom edge of
the rear bumper.
•Do not allow waves to break higher than 15 cm (6 inches) above the
bottom edge of the rear bumper.
•Disconnect the trailer tow electrical connector to prevent blown fuses
caused by water entering into your trailer’s electrical wiring.
Exceeding these limits may allow water to enter critical vehicle
components, adversely affecting driveability, emissions and reliability.
Replace front and rear axle lubricants any time the axles have been
submerged in water. Axle lubricant quantities are not to be checked
unless a leak is suspected.
ALL REAR WHEEL DRIVE (RWD) VEHICLES
This applies to all cars and 4x2 trucks/sport utilities with rear wheel
drive capability.
An example of recreational towing is towing your vehicle behind a
motorhome. The following recreational towing guidelines are designed to
ensure that your transmission is not damaged.
•Place the transmission in N (Neutral).
•Maximum speed is 56 km/h (35 mph).
•Maximum distance is 80 km (50 miles).
If a distance of 80 km (50 miles) or a speed of 56 km/h (35 mph) must
be exceeded, you must disconnect the driveshaft. Ford recommends the
driveshaft be removed/installed only by a qualified technician. See your
local dealer for driveshaft removal/installation.
Driving
153

Improper removal/installation of the driveshaft can cause
transmission fluid loss, damage to the driveshaft and internal
transmission components.
RWD vehicles with 4x4 electronic shift transfer case or All Wheel
Drive (AWD) vehicles with automatic transmissions:
Regarding recreational towing or having your vehicle towed, 4x4 vehicles
with electronic shift on the fly and AWD vehicles cannot be towed with
any wheels on the ground (with the exception of moving it as a disabled
vehicle off the road out of traffic).
SNOWPLOWING
Note:Do not use your vehicle to snowplow until it has been driven at
least 800 km (500 miles). Follow the severe duty schedule in your
scheduled maintenance guide for engine oil and transmission fluid
change intervals.
Note:Ford does not install snowplows.
For low speed snow removal, Ford offers a Snowplow Package Option on
select 4x4 vehicles. To assist Ford dealers and equipment installers
further prepare the vehicle for snowplowing, Ford includes instructions
in theFord Truck Body Builders Layout BookandFord Truck Source
Book. These instructions are available through your Ford dealer; they
include the list of vehicle models recommended for snowplowing and
snowplow weight limits. Use of the Snowplow Package Option, or its
equivalent, along with these instructions will help avoid possible
powertrain and chassis damage from snowplowing.
The front and rear GAWR, GVWR, Total Accessory Reserve Capacity
(TARC) and tire inflation pressures are found on the Safety Compliance
Certification Label located on one of the vehicle’s door jambs. This label
is applied to all vehicles completed by Ford Motor Company. Incomplete
vehicles built by Ford Motor Company will have an Incomplete Vehicle
Label in place of the Safety Compliance Label. The TARC does not apply
to Incomplete Vehicles and will not be shown on the Incomplete Vehicle
Label. The weight of the vehicle with occupants must never exceed the
front and rear GAWR or the GVWR.
The TARC is the weight of the permanently attached equipment that can
be added to the vehicle without violating the vehicle’s Safety Compliance
Certification. This includes the snowplow mounting hardware but does
not include the removable portion of the snowplow assembly.
Driving
154

Removing snowplow
After removing a snowplow from the vehicle, ensure the vehicle’s front
toe alignment and front ride height are within specification (reset if
required).
Snowplowing with your air bag-equipped vehicle
Your vehicle is equipped with a driver and passenger air bag
Supplemental Restraint System (SRS) The SRS is designed to activate in
certain frontal and offset frontal collisions when the vehicle sustains
sufficient longitudinal deceleration.
Careless or high speed driving while plowing snow which results in
sufficient vehicle decelerations can deploy the air bag. Such driving also
increases the risk of accidents.
All occupants of the vehicle, including the driver, should always
properly wear their safety belts, even when an air bag (SRS) is
provided.
Never remove or defeat the “tripping mechanisms” designed into the
snow removal equipment by its manufacturer. Doing so may cause
damage to the vehicle and the snow removal equipment as well as
possible air bag deployment.
Do not attempt to service, repair, or modify the Air Bag
Supplemental Restraint System or its fuses. See your Ford or
Lincoln Mercury dealer.
Additional equipment such as snowplow equipment may effect
the performance of the air bag sensors increasing the risk of
injury. Please refer to the Body Builders Layout Book for instructions
about the appropriate installation of additional equipment.
Engine temperature while plowing
When driving with a snowplow, your engine may run at a higher
temperature than normal because the attached snowplow blade will
restrict airflow to the radiator.
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.
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4WD operation while plowing
•Shift transfer case to 4x4 LOW (4WD Low) when plowing in small
areas at speeds below 8 km/h (5 mph).
•Shift 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).
•Do not shift the transmission from a forward gear to R (Reverse) until
the engine is at idle and the wheels are stopped.
•If 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.
Refer toTransmission temperature gaugein theInstrument cluster
chapter for transmission fluid temperature information.
Do not spin the wheels at over 35 mph (55 km/h). The tires may
fail and injure a passenger or bystander.
Driving
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U.S. Ford or Mercury vehicle customers who require roadside assistance,
call 1–800–241–3673; Lincoln vehicle customers call 1–800–521–4140.
Canadian customers who require roadside assistance, call
1–800–665–2006.
If you need to arrange roadside assistance for yourself, Ford Motor
Company will reimburse a reasonable amount. To obtain reimbursement
information, U.S. Ford or Mercury vehicles customers call
1-800-241-3673; Lincoln vehicle customers call 1–800–521–4140.
Canadian customers who need to obtain reimbursement information, call
1–800–665–2006.
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, for uninterrupted Roadside Assistance coverage, you
may purchase extended coverage prior to your Basic Warranty’s Roadside
Assistance expiring. For more information and enrollment, contact
1–877–294–2582 or visit our website at www.ford.ca.
HAZARD FLASHER
The hazard flasher is located on the
steering column, just behind the
steering wheel. The hazard flashers
will operate when the ignition is off.
Push in the flasher control and all
front and rear direction signals will
flash. Press the flasher control again
to turn them off. Use it when your
vehicle is disabled and is creating a
safety hazard for other motorists.
Note:With extended use, the flasher may run down your battery.
FUEL PUMP SHUT-OFF SWITCH
FUEL
RESET
This device stops the electric fuel pump from sending fuel to the engine
when your vehicle has had a substantial jolt.
After an accident, if the engine cranks but does not start, this switch
may have been activated.
Roadside Emergencies
159