transmission FORD SUPER DUTY 2003 1.G Diesel Supplement Manual

California Proposition 65 Warning
WARNING:Engine exhaust, some of its constituents, and
certain vehicle components contain or emit chemicals known to
the State of California to cause cancer and birth defects or other
reproductive harm. Certain fluids contained in vehicles and certain
products of components contain or emit chemicals known to the State
of California to cause cancer and 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 6.0L Power Stroke 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 Power Stroke 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.
Introduction
2

Fast start glow plug system
The glow plug system consists of:
•eight glow plugs
•the glow plug control module (GPCM)
•engine oil temperature (EOT) sensor
•barometric pressure (BARO) sensor
The glow plug system is
electronically controlled by the
PCM. The GPCM 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 in the
center valley of the engine. 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 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.
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.
Note: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.)
4. When the engine starts, release
the key. The glow plugs will
continue to be activated for up to
two minutes after the WAIT TO
START light turns off. If the engine is not started before the activation
ceases, the glow plug system must be reset by turning the ignition key to
OFF.
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.
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.
Upshift and downshift according to the following shift speed charts:
Upshifts when accelerating (recommended for best fuel
economy)
6-speed transmission
Shift from: Transfer case position
1(if equipped)
2H or 4H 4L
LO-1 8 km/h (5 mph) 3 km/h (2 mph)
1-2 16 km/h (10 mph) 6 km/h (4 mph)
2-3 32 km/h (20 mph) 13 km/h (8 mph)
3-4 48 km/h (30 mph) 19 km/h (12 mph)
4
-
D(Overdrive)64 km/h (40 mph) 24 km/h (15 mph)
Driving tips
13

Maximum downshift speeds1
6-speed transmission
Shift from: Transfer case position (if equipped)2
2H or 4H 4L
D(Overdrive) -
472 km/h (45 mph) 26 km/h (16 mph)
4-3 56 km/h (35 mph) 19 km/h (12 mph)
3-2 32 km/h (20 mph) 13 km/h (8 mph)
2-1 8 km/h (5 mph) 3 km/h (2 mph)
1-LO Only shift to LO when at a stop.
1Use 2H or 4H for 4WD equipped vehicles.2Downshift at lower speeds when driving on slippery surfaces.
TRAILER TOWING
Refer to your Owner Guide for full details on towing a trailer.
Trailer towing tables
Excursion
Engine Rear axle
ratioMaximum GCWR -
kg (lbs.)Maximum
trailer weight -
kg (lbs.)
4x2
6.0L 3.73 9072 (20000) 4988 (11000)
4x4
6.0L 3.73 9072 (20000) 4990 (11000)
F-250
Engine Rear axle
ratioMaximum GCWR -
kg (lbs.)Maximum
trailer weight -
kg (lbs.)
Vehicles without fifth wheel
6.0L All 9072 (20000) 5670 (12500)
Regular Cab Pickup 4x2 with manual transmission and fifth wheel
6.0L All 9072 (20000) 6167 (13600)
Driving tips
14

F-250
Engine Rear axle
ratioMaximum GCWR -
kg (lbs.)Maximum
trailer weight -
kg (lbs.)
Regular Cab Pickup 4x2 with automatic transmission and fifth
wheel
6.0L All 9072 (20000) 6213 (13700)
Regular Cab Pickup 4x4 with manual transmission and fifth wheel
6.0L All 9072 (20000) 6033 (13300)
Regular Cab Pickup 4x4 with automatic transmission and fifth
wheel
6.0L All 9072 (20000) 6033 (13300)
SuperCab Pickup 4x2 with fifth wheel
6.0L All 9072 (20000) 6033 (13300)
SuperCab Pickup 4x4 with manual transmission and fifth wheel
6.0L All 9072 (20000) 5396 (11900)
SuperCab Pickup 4x4 with automatic transmission and fifth wheel
6.0L All 9072 (20000) 5578 (12300)
Crew Cab Pickup 4x2 with manual transmission and fifth wheel
6.0L All 9072 (20000) 5850 (12900)
Crew Cab Pickup 4x2 with automatic transmission and fifth wheel
6.0L All 9072 (20000) 5941 (13100)
Crew Cab Pickup 4x4 with manual transmission and fifth wheel
6.0L All 9072 (20000) 4671 (10300)
Crew Cab Pickup 4x4 with automatic transmission and fifth wheel
6.0L All 9072 (20000) 4807 (10600)
Driving tips
15

F-350 Regular Cab Single Rear Wheel Pickup
Engine Rear axle
ratioMaximum GCWR -
kg (lbs.)Maximum
trailer weight -
kg (lbs.)
Vehicles without fifth wheel
6.0L All 9072 (20000) 5670 (12500)
4x2 with manual transmission and fifth wheel
6.0L All 9072 (20000) 6167 (13600)
4x2 with automatic transmission and fifth wheel
6.0L All 9072 (20000) 6213 (13700)
4x4 with fifth wheel
6.0L All 9072 (20000) 6033 (13300)
F-350 Regular Cab Dual Rear Wheel Pickup
Engine Rear axle
ratioMaximum GCWR -
kg (lbs.)Maximum
trailer weight -
kg (lbs.)
Vehicles without fifth wheel
6.0L All 9072 (20000) 6031 (13300)
4x2 with manual transmission and fifth wheel
6.0L All 9072 (20000) 6031 (13300)
4x2 with automatic transmission and fifth wheel
6.0L All 9072 (20000) 6078 (13400)
4x4 with manual transmission and fifth wheel
6.0L All 9072 (20000) 5851 (12900)
4x4 with automatic transmission and fifth wheel
6.0L All 9072 (20000) 5897 (13000)
Driving tips
16

F-350 SuperCab Single Rear Wheel Pickup
Engine Rear axle
ratioMaximum GCWR -
kg (lbs.)Maximum
trailer weight -
kg (lbs.)
Vehicles without fifth wheel
6.0L All 9072 (20000) 5670 (12500)
4x2 with fifth wheel
6.0L All 9072 (20000) 6031 (13300)
4x4 with manual transmission and fifth wheel
6.0L All 9072 (20000) 5850 (12900)
4x4 with automatic transmission and fifth wheel
6.0L All 9072 (20000) 5897 (13000)
F-350 SuperCab Dual Rear Wheel Pickup
Engine Rear axle
ratioMaximum GCWR -
kg (lbs.)Maximum
trailer weight -
kg (lbs.)
Vehicles without fifth wheel
6.0L All 9072 (20000) 5895 (13000)
4x2 with fifth wheel
6.0L All 9072 (20000) 5895 (13000)
4x4 with fifth wheel
6.0L All 9072 (20000) 5714 (12600)
F-350 Crew Cab Single Rear Wheel Pickup
Engine Rear axle
ratioMaximum GCWR -
kg (lbs.)Maximum
trailer weight -
kg (lbs.)
Vehicles without fifth wheel
6.0L All 9072 (20000) 5670 (12500)
4x2 with manual transmission and fifth wheel
6.0L All 9072 (20000) 5850 (12900)
4x2 with automatic transmission and fifth wheel
6.0L All 9072 (20000) 5941 (13100)
Driving tips
17

F-350 SuperCab Chassis Cab Single Rear Wheel (Fifth Wheel
Towing)
Engine Rear axle
ratioMaximum GCWR -
kg (lbs.)Maximum
trailer weight -
kg (lbs.)
4x2 with manual transmission
6.0L All 9072 (20000) 5759 (12700)
4x2 with automatic transmission
6.0L All 9072 (20000) 5804 (12800)
4x4
6.0L All 9072 (20000) 5579 (12300)
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
6.0L All 9072 (20000) 5623 (12400)
4x2 with automatic transmission
6.0L All 9072 (20000) 5668 (12500)
4x4 with manual transmission
6.0L All 9072 (20000) 5442 (12000)
4x4 with automatic transmission
6.0L All 9072 (20000) 5487 (12100)
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
6.0L All 9072 (20000) 5668 (12500)
4x2 with automatic transmission
6.0L All 9072 (20000) 5715 (12600)
Driving tips
19

F-350 Crew Cab Chassis Cab Single Rear Wheel (Fifth Wheel
Towing)
Engine Rear axle
ratioMaximum GCWR -
kg (lbs.)Maximum
trailer weight -
kg (lbs.)
4x4 with manual transmission
6.0L All 9072 (20000) 5488 (12100)
4x4 with automatic transmission
6.0L All 9072 (20000) 5534 (12200)
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
6.0L All 9072 (20000) 5534 (12200)
4x2 with automatic transmission
6.0L All 9072 (20000) 5579 (12300)
4x4 with manual transmission
6.0L All 9072 (20000) 5306 (11700)
4x4 with automatic transmission
6.0L All 9072 (20000) 5352 (11800)
F-450
Engine Rear axle
ratioMaximum GCWR -
kg (lbs.)Maximum
trailer weight -
kg (lbs.)
Regular Chassis Cab 4x2 with manual transmission
6.0L All 11793 (26000) 8163 (18000)
Regular Chassis Cab 4x2 with automatic transmission
6.0L All 11793 (26000) 8210 (18100)
Regular Chassis Cab 4x4 with manual transmission
6.0L All 11793 (26000) 8027 (17700)
Driving tips
20