FORD SUPER DUTY 2003 1.G Diesel Supplement Manual

48,000 km (30,000 miles)
•Change engine oil and replace oil filter
•Inspect tires for wear and measure tread depth
•Rotate tires
•Replace 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
•Change automatic transmission fluid and external filter element
•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
60,000 km (37,500 miles)
•Change engine oil and replace oil filter
•Inspect engine air filter
72,000 km (45,000 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
General Owner’s Information
51

•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
84,500 km (52,500 miles)
•Change engine oil and replace oil filter
•Inspect engine air filter
96,500 km (60,000 miles)
•Change engine oil and replace oil filter
•Inspect tires for wear and measure tread depth
•Rotate tires
•Replace 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
•Change automatic transmissio fluid and external filter element
•Change manual transmission fluid
•Check wheels for end play and noise
•Lubricate 4x4 hub needle bearings
•Lubricate 4x2 wheel bearings
•Replace wheel bearing grease seal
•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
108,000 km (67,500 miles)
•Change engine oil and replace oil filter
•Inspect engine air filter
General Owner’s Information
52

121,000 km (75,000 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
133,000 km (82,500 miles)
•Change engine oil and replace oil filter
•Inspect engine air filter
145,000 km (90,000 miles)
•Change engine oil and replace oil filter
•Inspect tires for wear and measure tread depth
•Rotate tires
•Replace 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
•Change automatic transmissio fluid and external filter element
•Check wheels for end play and noise
General Owner’s Information
53

•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
157,000 km (97,500 miles)
•Change engine oil and replace oil filter
•Inspect engine air filter
•Inspect accessory drive belt(s)
•Change rear wheel drive (RWD) axle fluid - DANA axles using
synthetic fluid only
170,000 km (105,000 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
•Change engine coolant
•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
181,000 km (112,500 miles)
•Change engine oil and replace oil filter
•Inspect engine air filter
193,000 km (120,000 miles)
•Change engine oil and replace oil filter
•Inspect tires for wear and measure tread depth
General Owner’s Information
54

•Rotate tires
•Replace 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
•Change automatic transmissio fluid and external filter element
•Change manual transmission fluid
•Check wheels for end play and noise
•Lubricate 4x4 hub needle bearings
•Lubricate 4x2 wheel bearings
•Replace wheel bearing grease seal
•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
205,000 km (127,500 miles)
•Change engine oil and replace oil filter
•Check air filter minder, replace filter as required
217,000 km (135,000 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
General Owner’s Information
55

•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
229,000 km (142,500 miles)
•Change engine oil and replace oil filter
•Check air filter minder, replace filter as required
241,000 km (150,000 miles)
•Change engine oil and replace oil filter
•Inspect tires for wear and measure tread depth
•Rotate tires
•Replace 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
•Replace accessory drive belt(s)
•Change engine coolant
•Change automatic transmission fluid and external filter element
•Change rear wheel drive (RWD) axle fluid - DANA axles using
synthetic fluid only
•Change transfer case fluid
•Check wheels for end play and noise
•Lubricate 4x2 wheel bearings
•Replace wheel bearing grease seal
•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
General Owner’s Information
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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
57

SPECIAL OPERATING CONDITIONS
Towing a trailer or using a camper or car-top carrier
Every 5,000 miles or 6 months:Change engine oil and replace filter
Every 15,000 miles:Inspect and lubricate 4x2 ball joints and steering
idler arms
Every 30,000 miles:Lubricate 4x4 hub needle bearings
Every 60,000 miles:Change transfer case fluid
As required:Change manual transmission fluid
Extensive idling and/or low-speed driving for long distances as in
heavy commercial use such as delivery, taxi, patrol or livery
Every 5,000 miles or 6 months:Change engine oil and replace filter
Every 5,000 miles:Inspect brake system. Inspect and lubricate 4x2 ball
joints and steering idler arms
30,000 miles and 90,000 miles:Lubricate 4x2 wheel bearings. Replace
wheel bearing grease seal.
Every 60,000 miles:Change transfer case fluid
As required:Replace cabin air filter, if equipped
Operating in dusty conditions such as unpaved or dusty roads
Every 5,000 miles or 6 months:Change engine oil and replace filter
Every 15,000 miles:Inspect and lubricate 4x2 ball joints and steering
idler arms
Every 60,000 miles:Change transfer case fluid
As required:Replace cabin air filter, if equipped
Off-road operation
Every 5,000 miles or 6 months:Change engine oil and replace filter
Every 15,000 miles:Lubricate 4x4 hub needle bearings
Every 60,000 miles:Change transfer case fluid
As required:Inspect and lubricate 4x2 ball joints and steering idler
arms. Replace cabin air filter, if equipped
General Owner’s Information
58

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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YELLOW COOLANT CHANGE RECORD
Date: \ \
3 Years + 3
Next Date
or
Current Mileage:
50,000 Miles + 50,000
Next Mileage:Dealer’s Stamp:
Date: \ \
3 Years + 3
Next Date
or
Current Mileage:
50,000 Miles + 50,000
Next Mileage:Dealer’s Stamp:
Date: \ \
3 Years + 3
Next Date
or
Current Mileage:
50,000 Miles + 50,000
Next Mileage:Dealer’s Stamp:
Date: \ \
3 Years + 3
Next Date
or
Current Mileage:
50,000 Miles + 50,000
Next Mileage:Dealer’s Stamp:
General Owner’s Information
60