manual transmission FORD SUPER DUTY 2003 1.G 7.3L Diesel Engine Owners Manual

California Proposition 65 Warning: Diesel engine exhaust, some
of its constituents, and certain vehicle components contain or
may emit chemicals known to the State of California to cause cancer or
birth defects or other reproductive harm.
Your new Diesel engine will feel, drive and function somewhat differently
than a gasoline engine. Therefore it is very important that you read and
thoroughly familiarize yourself and others operating the vehicle with this
guide.
This guide will acquaint you with the Power Stroke (7.3L DIT) Diesel
engine. It provides recommendations on engine care and operating
procedures. For complete vehicle information, also refer to the Owner
Guide included with the vehicle. It also describes equipment and gives
specifications for equipment that was in effect when this guide was
approved for printing, and should be considered a permanent part of the
vehicle.
Some aftermarket products may cause severe engine and/or
transmission damage. There are various manufacturers offering
devices to increase turbocharger boost, exhaust brakes to
increase stopping/hauling capacity or other such devices to
increase the power/torque of the 7.3L engine. Many owners’ past
experience with these products has been very poor. Severe
powertrain damage may result from the use of these aftermarket
products which will not be covered by the Ford warranty.
Ford may discontinue models or change specifications without any notice
and without incurring obligations.
IMPORTANT NOTICE
Ford vehicles are suitable for producing ambulances only if equipped
with theFord Ambulance Preparation Package.In addition, Ford
urges ambulance manufacturers to follow the recommendation of the
Ford Incomplete Vehicle Manual, Ford Truck Body Builder’s Layout
Book(and pertinent supplements) and theQualified Vehicle Modifiers
Guidelines. Using a Ford vehicle without theFord Ambulance
Preparation Packageto produce an ambulance voids the Ford warranty
and could result in elevated underbody temperatures, fuel
overpressurization and the risk of fuel expulsion and fires. To determine
whether the vehicle is equipped with theFord Ambulance Preparation
Package,inspect the information plate on the driver’s side door pillar.
Contact the manufacturer of your vehicle to determine whether the
ambulance manufacturer’s followed Ford’s recommendations.
Introduction
2

•engine oil temperature (EOT) sensor
•barometric pressure (BARO) sensor
The glow plug system is electronically controlled by the PCM. The PCM
energizes the glow plugs immediately after the ignition is placed in the
ON position, then determines how long the glow plugs will be on
according to the EOT and BARO sensors. The required time for the glow
plugs to be energized decreases as the engine oil temperature and
barometric pressure increase.
Engine cooling system
The cooling system contains an engine oil cooler which is mounted to
the side of the cylinder block. The cooler’s function is to regulate engine
oil temperature.
Engine governed speed
The engine governor is controlled by the PCM. The PCM controls fuel
input to limit maximum engine speed. It will not, however, prevent
engine overspeeding resulting from downshifting at high vehicle speed or
by descending steep grades at too high a vehicle speed for the selected
transmission gear.
For maximum vehicle speed in various gears, refer toManual
transmission shift speedsin theDriving tipschapter. Do not exceed
3,600 rpm. Maximum engine governed speed is 3,000–4,000 rpm
depending on engine load. Excessive rpm can only be achieved by
manually downshifting at too high of a vehicle speed.
Operating the engine beyond the governed speed can cause severe
engine damage.
Air filter restriction gauge, E-Series
The restriction gauge, located on
the clean-air side of the air cleaner
upper housing, shows if the air filter
is clogged. Refer toEngine
CompartmentinService points
chapter.
AIRFILTERGAUGECHANGEFILTERCHANGEFILTER
Diesel information
5

STARTING THE ENGINE
Read all starting instructions carefully before you start your vehicle.
For temperatures below 0°C (32°F), the use of the correct grade engine
oil is essential for proper operation.
If your vehicle is equipped with a manual transmission, make sure the
parking brake is set fully before you turn the key. Depress the clutch
pedal and place the gearshift in the neutral position. The clutch must be
fully depressed in order to operate the starter. Do not press the
accelerator during starting.
If your vehicle is equipped with an automatic transmission, ensure the
gearshift lever is in P (Park) and the parking brake is set before you turn
the key. Do not press the accelerator during starting.
COLD WEATHER STARTING
Do not crank the engine for more than 30 seconds at a time as starter
damage may occur. If the engine fails to start, turn the key to OFF and
wait 30 seconds before trying again.
Do not use starting fluid such as ether in the air intake system (see Air
Cleaner Decal). Such fluid could cause immediate explosive damage to
the engine and possible personal injury.
Do not add gasoline, gasohol or alcohol to Diesel fuel. This practice
creates a serious fire hazard and causes engine performance problems.
1. Make sure all vehicle occupants have buckled their safety belts. For
more information on safety belts and their proper usage, refer toSeating
and safety restraintschapter in the owner guide.
2. Make sure the headlamps and vehicle accessories are off.
3. Turn the key to the ON position. When the WAIT TO START light
goes off, turn the key to START. (For Canadian vehicles, the daytime
running lamps will be on if the parking brake is not applied and the key
is turned to ON.)
•E-Series
•F-250/350/450/550, Excursion
Starting
10

DUAL FUEL TANK SELECTOR CONTROL (IF EQUIPPED)
If your vehicle is equipped with dual fuel tanks, you will have a selector
control, located to the right of the steering wheel, which allows you to
draw fuel from either tank. Your fuel gauge will display the amount of
fuel in the currently selected tank.
Fuel level indication is delayed for several minutes when the tank
selector switch is actuated. Fuel level indication can be obtained
immediately by turning off and restarting the engine.
MANUAL TRANSMISSION SHIFT SPEEDS
Do not overspeed the engine when going downhill or steep grades. If
equipped, use the tachometer and do not allow engine speed to exceed
the redline area. Operating the engine beyond the recommended speeds
can cause severe engine damage.
If your vehicle is an F-Series equipped with a manual
transmission, your vehicle has an electronic operating strategy
which protects the engine system when the engine is operating
with high coolant temperatures; fueling to the engine will be
modified to prevent damage to the engine. Some power loss may
be experienced if the vehicle is overloaded.
Driving tips
13

Trailer towing tables
F-250
Engine Rear axle
ratioMaximum GCWR -
kg (lbs.)Maximum
trailer weight -
kg (lbs.)
Vehicles without fifth wheel
7.3L All 9072 (20000) 5670 (12500)
Regular Cab Pickup 4x2 with manual transmission and fifth
wheel
7.3L All 9072 (20000) 6260 (13800)
Regular Cab Pickup 4x2 with automatic transmission and fifth
wheel
7.3L All 9072 (20000) 6305 (13900)
Regular Cab Pickup 4x4 with manual transmission and fifth
wheel
7.3L All 9072 (20000) 6033 (13300)
Regular Cab Pickup 4x4 with automatic transmission and fifth
wheel
7.3L All 9072 (20000) 6078 (13400)
SuperCab Pickup 4x2 with fifth wheel
7.3L All 9072 (20000) 6078 (13400)
SuperCab Pickup 4x4 with fifth wheel
7.3L All 9072 (20000) 5897 (13000)
Crew Cab Pickup 4x2 with manual transmission and fifth wheel
7.3L All 9072 (20000) 5942 (13100)
Crew Cab Pickup 4x2 with automatic transmission and fifth
wheel
7.3L All 9072 (20000) 5987 (13200)
Crew Cab Pickup 4x4 with fifth wheel
7.3L All 9072 (20000) 5806 (12800)
Driving tips
17

F-350 Regular Cab Single Rear Wheel Pickup
Fifth
Wheel
OptionRear axle
ratioMaximum GCWR -
kg (lbs.)Maximum
trailer weight -
kg (lbs.)
Vehicles without fifth wheel
7.3L All 9072 (20000) 5670 (12500)
4x2 with manual transmission and fifth wheel
7.3L All 9072 (20000) 6214 (13700)
4x2 with automatic transmission and fifth wheel
7.3L All 9072 (20000) 6260 (13800)
4x4 with manual transmission and fifth wheel
7.3L All 9072 (20000) 6033 (13300)
4x4 with automatic transmission and fifth wheel
7.3L All 9072 (20000) 6078 (13400)
F-350 Regular Cab Dual Rear Wheel Pickup
Fifth
Wheel
OptionRear axle
ratioMaximum GCWR -
kg (lbs.)Maximum
trailer weight -
kg (lbs.)
Vehicles without fifth wheel
7.3L All 9072 (20000) 5670 (12500)
4x2 with fifth wheel
7.3L All 9072 (20000) 6078 (13400)
4x4 with manual transmission and fifth wheel
7.3L All 9072 (20000) 5851 (12900)
4x4 with automatic transmission and fifth wheel
7.3L All 9072 (20000) 5897 (13000)
Driving tips
18

F-350 SuperCab Single Rear Wheel Pickup
Fifth
Wheel
OptionRear axle
ratioMaximum GCWR -
kg (lbs.)Maximum
trailer weight -
kg (lbs.)
Vehicles without fifth wheel
7.3L All 9072 (20000) 5670 (12500)
4x2 with fifth wheel
7.3L All 9072 (20000) 6078 (13400)
4x4 with fifth wheel
7.3L All 9072 (20000) 5897 (13000)
F-350 SuperCab Dual Rear Wheel Pickup
Fifth
Wheel
OptionRear axle
ratioMaximum GCWR -
kg (lbs.)Maximum
trailer weight -
kg (lbs.)
Vehicles without fifth wheel
7.3L All 9072 (20000) 5670 (12500)
4x2 with fifth wheel
7.3L All 9072 (20000) 5942 (13100)
4x4 with manual transmission and fifth wheel
7.3L All 9072 (20000) 5761 (12700)
4x4 with automatic transmission and fifth wheel
7.3L All 9072 (20000) 5806 (12800)
Driving tips
19

F-350 Crew Cab Single Rear Wheel Pickup
Fifth
Wheel
OptionRear axle
ratioMaximum GCWR -
kg (lbs.)Maximum
trailer weight -
kg (lbs.)
Vehicles without fifth wheel
7.3L All 9072 (20000) 5670 (12500)
4x2 with manual transmission and fifth wheel
7.3L All 9072 (20000) 5942 (13100)
4x2 with automatic transmission and fifth wheel
7.3L All 9072 (20000) 5987 (13200)
4x4 with fifth wheel
7.3L All 9072 (20000) 5806 (12800)
F-350 Crew Cab Dual Rear Wheel Pickup
Fifth
Wheel
OptionRear axle
ratioMaximum GCWR -
kg (lbs.)Maximum
trailer weight -
kg (lbs.)
4x2 without fifth wheel
7.3L All 9072 (20000) 5670 (12500)
4x2 with manual transmission and fifth wheel
7.3L All 9072 (20000) 5806 (12800)
4x2 with automatic transmission and fifth wheel
7.3L All 9072 (20000) 5851 (12900)
4x4
7.3L All 9072 (20000) 5625 (12400)
Driving tips
20

F-350 Regular Chassis Cab Single Rear Wheel
(Fifth Wheel Towing)
Fifth
Wheel
OptionRear axle
ratioMaximum GCWR -
kg (lbs.)Maximum
trailer weight -
kg (lbs.)
4x2 with manual transmission
7.3L All 9072 (20000) 5942 (13100)
4x2 with automatic transmission
7.3L All 9072 (20000) 5987 (13200)
4x4
7.3L All 9072 (20000) 5761 (12700)
F-350 Regular Chassis Cab Dual Rear Wheel
(Fifth Wheel Towing)
Fifth
Wheel
OptionRear axle
ratioMaximum GCWR -
kg (lbs.)Maximum
trailer weight -
kg (lbs.)
4x2
7.3L All 9072 (20000) 5806 (12800)
4x4
7.3L All 9072 (20000) 5579 (12300)
F-350 SuperCab Chassis Cab Single Rear Wheel
(Fifth Wheel Towing)
Fifth
Wheel
OptionRear axle
ratioMaximum GCWR -
kg (lbs.)Maximum
trailer weight -
kg (lbs.)
4x2
7.3L All 9072 (20000) 5806 (12800)
4x4 with manual transmission
7.3L All 9072 (20000) 5579 (12300)
4x4 with automatic transmission
7.3L All 9072 (20000) 5625 (12400)
Driving tips
21

F-350 SuperCab Chassis Cab Single Rear Wheel
(Fifth Wheel Towing)
Fifth
Wheel
OptionRear axle
ratioMaximum GCWR -
kg (lbs.)Maximum
trailer weight -
kg (lbs.)
4x2
7.3L All 9072 (20000) 5625 (12400)
4x4
7.3L All 9072 (20000) 5443 (12000)
F-350 Crew Cab Chassis Cab Single Rear Wheel
(Fifth Wheel Towing)
Fifth
Wheel
OptionRear axle
ratioMaximum GCWR -
kg (lbs.)Maximum
trailer weight -
kg (lbs.)
4x2
7.3L All 9072 (20000) 5715 (12600)
4x4 with manual transmission
7.3L All 9072 (20000) 5488 (12100)
4x4 with automatic transmission
7.3L All 9072 (20000) 5534 (12200)
F-350 Crew Cab Chassis Cab Dual Rear Wheel
(Fifth Wheel Towing)
Fifth
Wheel
OptionRear axle
ratioMaximum GCWR -
kg (lbs.)Maximum
trailer weight -
kg (lbs.)
4x2 with manual transmission
7.3L All 9072 (20000) 5534 (12200)
4x2 with automatic transmission
7.3L All 9072 (20000) 5579 (12300)
4x4
7.3L All 9072 (20000) 5352 (11800)
Driving tips
22