maintenance FORD SUPER DUTY 2003 1.G Diesel Supplement Manual

NOISE EMISSIONS WARRANTY, PROHIBITED TAMPERING ACTS
AND MAINTENANCE
On January 1, 1978, Federal regulation became effective governing the
noise emission on trucks over 4,536 kg (10,000 lbs.) GVWR (Gross
Vehicle Weight Rating). The following statements concerning prohibited
tampering acts and maintenance, and the noise warranty found in the
Warranty Facts Booklet, are applicable to complete chassis cabs over
4,536 (10,000 lbs.) GVWR.
Tampering with noise control system prohibited
Federal law prohibits the following acts or the causing thereof: (1) The
removal or rendering inoperative by any person other than for purposes
of maintenance, repair or replacement of any device or element of design
incorporated into any new vehicle for the purpose of noise control prior
to its sale or delivery to the ultimate purchaser or while it is in use, or
(2) the use of the vehicle after such device or element of design has
been removed or rendered inoperative by any person.
Among those acts which the U.S. Environmental Protection Agency may
presume to constitute tampering are the acts listed below:
•Removal of hood blanket, fender apron absorbers, fender apron
barriers, underbody noise shields or acoustically absorptive material.
•Tampering or rendering inoperative the engine speed governor, so as
to allow engine speed to exceed manufacturer’s specifications.
General maintenance information
37

ENGINE EMISSIONS LABEL
Emissions information appears on the Engine Emissions label on the
engine valve cover. This decal identifies engine displacement and
provides certain engine specifications.
Any modification of the emissions control system could create liability
under federal law (U.S.) if made prior to sale and registration, under the
laws of some states if made thereafter. Further, federal law prohibits
vehicle manufacturers, dealers and other persons engaged in the
business of repairing, servicing, selling, leasing or trading motor vehicles
as well as fleet operations from knowingly removing or rendering an
emissions control system inoperative after sale and delivery to an
ultimate purchaser. In Canada, modifications of the emissions control
system could create liability under applicable federal or provincial laws.
SCHEDULED MAINTENANCE SERVICES
Refer to your scheduled maintenance guide for details of maintenance on
your vehicle.
If you are using your vehicle in a manner in which it will remain
stationary (door to door service, taxi, etc.), then it is recommended that
you change the engine oil every 200 engine hours as opposed to a
mileage limit. Since most vehicles are not equipped with hourmeters, it
may be necessary for you to approximate your time and plan engine oil
and filter changes accordingly.
Scheduled maintenance
38

The complexity of the Diesel engine makes it so the owner is
discouraged from attempting to perform maintenance other than the
services described in this supplement.
If you experience difficult starting, rough idling, excessive exhaust
smoke, a decrease in engine performance or excess fuel consumption,
perform the following checks:
•a plugged air inlet system or engine air filter element.
•water in the fuel filter/water separator.
•a clogged fuel filter.
•contaminated fuel.
•air in the fuel system, due to loose connections.
•an open or pinched sensor hose.
•low engine oil level.
•wrong fuel or oil viscosity for climactic conditions.
If these checks do not help you correct the engine performance problem
you are experiencing, consult an authorized dealer.
FUELING
Do not use starting fluid such as ether or gasoline in the Diesel
air intake system. Such fluids can cause immediate explosive
damage to the engine and possible personal injury.
If you fuel your vehicle at a truck stop, you may notice that the fuel
nozzle may shut off every 5–10 seconds. This is due to the flow rates
being designed for larger heavy duty trucks. You may have to fuel at a
slower rate (don’t depress the nozzle trigger fully).
Do not run your Diesel vehicle out of fuel as this will allow air to enter
the fuel system which will make restarting difficult. Longer engine
cranking time may be required once air is in the fuel system. If air enters
the fuel system (either through running the fuel tank(s) empty or during
a fuel filter change), the engine will self-purge the trapped air once it
starts running. The engine may run roughly and produce white smoke
while air is in the fuel system; this is normal and should stop after a
short time.
Minor troubleshooting guide
39

LUBRICANT AND MAINTENANCE MATERIALS SPECIFICATIONS
ItemFord Part
NameFord Part
NumberFord
Specification
Engine OilMotorcraft Motor
Oil 15W40 Super
Duty, 10W30
Super Duty
1
XO-15W40-QSD,
XO-10W30-QSDWSS-M2C171-D,
CI-4/SL, DHD-1
Engine Oil Filter
(Use this filter
Only)-3C3Z-6731–AA
(FL–2016)-
Air Filter
2- FA-1680 ES-E95AE-9601-AA
Battery (2
Required)- BXT-65-750 -
Engine coolant Motorcraft
Premium Gold
Engine Coolant
(yellow-colored)VC-7–A WSS-M97B51–A1
Manual
TransmissionMotorcraft
MERCON
AT FXT-2–QDX MERCON

1Refer to the engine oil specification chart located underEngine oil
specificationsin theGeneral maintenance informationchapter.
2Always use the authorized Motorcraft air filter listed.Failure to use
the correct air filter may result in severe engine damage.
Capacities and specifications
43

FIND YOUR WAY
Symbol Key
Diesel
Towing a trailer or using a camper or car-top
carrier
Extensive idling and/or low-speed driving for long
distances as in heavy commercial use such as
delivery, taxi, patrol car or livery
Operating in dusty conditions such as unpaved or
dusty roads
Off-road operation
Short trip cold operating conditions
GENERAL MAINTENANCE INFORMATION
Why maintain your vehicle?
This guide describes the scheduled maintenance required for your
vehicle. Carefully following this schedule helps protect against major
repair expenses resulting from neglect or inadequate maintenance and
may also help to increase the value of your vehicle when you sell or
trade it.
It is your responsibility to see that all scheduled maintenance is
performed and that the materials used meet Ford engineering
specifications. Failure to perform scheduled maintenance specific in this
guide will invalidate warranty coverage on parts affected by the lack of
maintenance. Be sure receipts for completed maintenance are kept with
the vehicle and confirmation of the work performed is always recorded in
this guide.
Your Ford or Lincoln Mercury dealer, or Ford or Lincoln Mercury Quality
Care Center has factory trained technicians who can perform the
required maintenance using genuine Ford parts. They are committed to
meeting your service needs and to assuring your continuing satisfaction.
General Owner’s Information
47

Protecting your investment
Maintenance is an investment that will pay dividends in the form of
improved reliability, durability and resale value. To assure the proper
performance of your vehicle and its emission control systems, it is
imperative that scheduled maintenance be completed at the designated
intervals.
Ford strongly recommends the use of genuine Ford replacement parts.
Parts other than Ford, Motorcraft or Ford authorized remanufactured
parts that are used for maintenance replacement or for the service of
components affecting emission control must be equivalent to genuine
Ford Motor Company parts in performance and durability. It is the
owner’s responsibility to determine the equivalency of such parts. Please
consult your Warranty Guide for complete warranty information.
Quality Care - one stop for all your maintenance needs
When you need maintenance for your Ford, Lincoln or Mercury vehicle,
there’s only one name to remember: Quality Care, available at your Ford
and Lincoln Mercury dealership. From scheduled maintenance to more
complicated repair work, nobody knows your car or truck better. Protect
your investment by choosing Quality Care service.
The right people
The difference is factory training and equipment, which means nobody is
more qualified to work on your Ford, Lincoln or Mercury than our
Quality Care service technicians. They’ll fix it right the first time.
The right parts
From headlights to taillights and everything in between, nothing fits like
an original. With Quality Care service, you’ll get the parts made
especially for your car or truck–genuine Ford and Motorcraft
parts.
The right prices
Our commitment to quality extends to pricing as well as service. Your
Ford and Lincoln Mercury Dealership offers competitive prices on
Genuine Ford and Motorcraft
parts and services, making Quality Care a
great value.
WHICH MAINTENANCE SCHEDULE SHOULD YOU FOLLOW?
Owner Checks and Services
Refer to Mileage Intervals for Additional Checks and Services
Certain basic maintenance checks and inspections should be performed by
the owner or a service technician at the intervals indicated. Service
information and supporting specifications are provided in the Owner’s Guide.
General Owner’s Information
48

Any adverse condition should be brought to the attention of your dealer
or qualified service technician as soon as possible for the proper service
advice. The owner maintenance service checks are generally not covered
by warranties so you may be charged for labor, parts or lubricants used.
Maximum Oil Change Interval:
Normal Schedule: 7,500 miles or 6 months, whichever occurs first.
Special Operating Conditions: 5,000 miles or 6 months, see appropriate
schedule.
Check every month:
•Check function of all interior and exterior lights
•Check tires for wear and proper air pressure
•Check engine oil fluid level
•Check windshield washer solvent fluid level
•Check and drain fuel filter/water separator
Check every six months:
•Check lap/shoulder belts and seat latches for wear and function
•Check air pressure in spare tire
•Check that externally-mounted spare tire is tight (see Owner’s Guide)
•Check power steering fluid level
•Check washer spray, wiper operation and clean all wiper blades
•Check parking brake for proper operation
•Check and lubricate all hinges, latches and outside locks
•Check and lubricate door rubber weatherstrips
•Check and clean body and door drain holes
•Check safety warning lamps (brake, ABS, air bag, safety belt) for
operation
•Check cooling system fluid level and coolant strength
•Check battery connections and clean if necessary
•Check clutch fluid level, if equipped
General Owner’s Information
49

NORMAL SCHEDULE
The following section contains the“Normal Schedule.”This schedule is
presented at specific mileage intervals with exceptions noted.
Additional information available on the Web
To learn more about the importance of routine and dealer-performed
maintenance on your vehicle, please visit the Ford Customer Service
website. You’ll also find important warranty information, customer
assistance, technical expertise, frequently asked questions and much
more. The website location is at: www.ford.com/
Then go to the service pick at the web site.
12,000 km (7,500 miles)
•Change engine oil and replace oil filter
•Inspect tires for wear and measure tread depth
•Rotate tires
•Inspect engine air filter
24,000 km (15,000 miles)
•Change engine oil and replace oil filter
•Inspect tires for wear and measure tread depth
•Rotate tires
•Inspect engine air filter
•Replace engine- and frame-mounted fuel filters
•Inspect steering linkage, suspension and, if equipped, driveshaft and
ball joints
•Inspect engine cooling system and hoses
•Inspect brake system
•Inspect exhaust system and heat shields
•Check wheels for end play and noise
•Inspect and lubricate 4x2 ball joints (except F-450/F-550)
•Inspect and lubricate steering idler arms
•Replace cabin air filter, if equipped
•Inspect half-shaft boots, if equipped
36,000 km (22,500 miles)
•Change engine oil and replace oil filter
•Inspect engine air filter
General Owner’s Information
50

Exceptions
In addition, there are several exceptions to the Normal Schedule. They
are listed below:
Yellow coolant
•5 years or 100,000 miles - change yellow coolant (whichever comes
first)
•After initial change - change yellow coolant every 3 years or 50,000
miles
Normal vehicle axle maintenance
Rear axles and power take off (PTO) units containing synthetic lubricant
and light duty trucks equipped with Ford-design axles are lubricated for
life. These lubricants are not to be checked or changed unless a leak is
suspected, service is required or the axle assembly has been submerged
in water. The axle and PTO lubricant should be changed anytime the
axle and PTO have been submerged in water. Non-synthetic rear axle
lubricants should be replaced every 3,000 miles or 3 months, whichever
occurs first, during extended trailer tow operation above 21 Celsius (70
degrees Fahrenheit) ambient and wide open throttle for extended
periods above 45 mph. The 3,000 mile lube change interval may be
waived if the axle was filled with 75W140 synthetic gear lubricant
meeting Ford specification WSL-M2C192-A, part number F1TZ-19580-B
or equivalent. Add four ounces of additive friction modifier
C8AZ-19B546-A (EST-M2C118-A) or equivalent for complete refill of
Traction-Lok rear axles. The axle lubricant should be changed anytime
an axle has been submerged in water.
F-450 and F-550 axle maintenance
Replace rear axle lubricant every 100,000 miles under normal driving
conditions on all F-450 and F-550 commercial applications. For F-450
and F-550 trucks operated at or near maximum Gross Vehicle Weights,
the rear axle lubricant should be replaced every 50,000 miles. In
addition, this 50,000 mile schedule should be observed when the vehicles
are operated under the Special Operating Conditions, where noted,
beginning on page XX.
General Owner’s Information
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Short trip in cold operating conditions
Every 15,000 miles:Inspect and lubricate 4x2 ball joints and steering
idler arms
Every 40,000 miles:Change transfer case fluid
MAINTENANCE AND SERVICE RECORD
See an authorized dealer
This section of the guide is designed to allow your Ford or Lincoln
Mercury dealer, or Ford or Lincoln Mercury Auto Care service center or
other qualified service technician to record that the recommended
service was completed at the appropriate mileage intervals. Be sure to
ask your service provider to record the type of service rendered (Normal
or Special Operating Conditions—SOC) each time service is performed.
Date:
Mileage:
Normal


SOC

Dealer’s Stamp:
See corresponding mileage in maintenance schedule for services performed.
General Owner’s Information
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