clutch FORD SUPER DUTY 2003 1.G User Guide

•Manual transmission:
1. Set the parking brake, depress the clutch and place the gearshift in N
(Neutral).
2. Block the wheels.
Note:Do not start your engine with the air cleaner removed and do not
remove it while the engine is running.
OPENING THE HOOD
1. Inside the vehicle, pull the hood
release handle located under the
bottom left corner of the instrument
panel.
2. Go to the front of the vehicle and
release the auxiliarylatch located
under the right center of the hood.
Slide the handle to release the
auxiliarylatch.
3. Lift the hood until the lift
cylinders hold it open.
H
O
O
D
Maintenance and Specifications
192

IDENTIFYING COMPONENTS IN THE ENGINE COMPARTMENT
5.4L V8/6.8L V10 gasoline engines
Refer to the7.3 Liter Power Stroke Direct Injection Turbo Diesel
Owner’s Guide Supplementfor diesel engine component locations.
1. Engine oil dipstick
2. Clutch fluid reservoir (manual transmission)
3. Brake fluid reservoir
4. Power steering fluid reservoir
5. Air filter assembly
6. Engine coolant reservoir
7. Windshield washer fluid reservoir
8. Battery
9. Engine oil filler cap
10. Transmission fluid dipstick (automatic transmission)
Maintenance and Specifications
193

CLUTCH FLUID (IF EQUIPPED)
Check the clutch fluid level. Refer to the scheduled maintenance guide
for the service interval schedules.
Use onlya DOT 3 brake fluid designed to meet Ford specification
ESA-M6C25–A. Refer toLubricant Specificationsin this chapter.
Brake fluid is toxic. If brake fluid contacts the eyes, flush eyes
with running water for 15 minutes. Seek medical if irritation
persists. If taken internally, drink water and induce vomiting. Seek
medical attention immediately.
During normal operation, the fluid level in the clutch reservoir should
remain constant or rise slightly. If the fluid level drops, refill the fluid
level to the step in the reservoir.
1. Clean the reservoir cap before
removal to prevent dirt and water
from entering the reservoir.
2. Remove cap and rubber
diaphragm from reservoir.
3. Add fluid until the level reaches
the step in the reservoir.
4. Reinstall rubber diaphragm and
cap onto reservoir.
TRANSMISSION FLUID
Checking automatic transmission fluid (if equipped)
Refer to your scheduled maintenance guide for scheduled intervals for
fluid checks and changes. Your transmission does not consume fluid.
Maintenance and Specifications
216

FluidFord Part
NameApplication Capacity
Brake fluid (and
clutch fluid-if
equipped)Motorcraft High
Performance
DOT 3 Motor
Vehicle Brake
FluidAll Fill to line or
step (for clutch)
on reservoir
Engine coolant
3Motorcraft
Premium Engine
Coolant
(green-colored)
orMotorcraft
Premium Gold
Engine Coolant
(yellow-colored)5.4L V8 engine
with A/C25.0L (26.4
quarts)
6.8L V10 engine 27.0L (28.5
quarts)
Engine oil
(includes filter
change)-Gas
enginesMotorcraft SAE
5W-20 Premium
Synthetic Blend
Motor OilAll 5.7L (6.0
quarts)
Engine oil
(includes filter
change)-Diesel
engineRefer to your 7.3L Diesel Supplement
Maintenance and Specifications
229

LUBRICANT SPECIFICATIONS
ItemFord part
name or
equivalentFord part
numberFord
specification
Spindle bearingHigh
Temperature
4X4 Front Axle
and Wheel
Bearing GreaseE8TZ-19590–A ESA-M1C198–A
Front axle
(4X4)Hypoid Gear Oil
SAE 90C6AZ-19580–E ESW-M2C105–A
Rear axleMotorcraft SAE
75W-140 High
Performance
Synthetic Rear
Axle Lube
1
XY-75W140–QL WSL-M2C192-A
Motorcraft SAE
75W-90
Synthetic Rear
Axle LubricantXY-75W90–GLS –
Motorcraft SAE
80W-90
Premium Rear
Axle Lubricant
(Dana 135
axles)
1
XY-80W90-QL WSP-M2C197-A
Brake fluid and
clutch fluid (if
equipped)Motorcraft High
Performance
DOT 3 Motor
Vehicle Brake
FluidPM-1 ESA-M6C25-A
and DOT 3
Maintenance and Specifications
232

ItemFord part
name or
equivalentFord part
numberFord
specification
Engine coolant Motorcraft
Premium Engine
Coolant
(green-colored)VC-4–A (in
Canada,
Motorcraft
CXC-10)ESE-M97B44-A
Motorcraft
Premium Gold
Engine Coolant
(yellow-colored)VC-7–A WSS-M97B51-A1
Engine oilMotorcraft SAE
5W-20 Premium
Synthetic Blend
Motor OilXO-5W20-QSP WSS-M2C153-H
and API
Certification
Mark
Hinges, latches,
striker plates,
fuel filler door
hinge and seat
tracksMulti-Purpose
GreaseXG—4 or XL-5 ESR-M1C159-A
or
ESB-M1C93–B
Lock cylindersMotorcraft
penetrating and
lock lubricantXL-1 none
Transmission
/steering/parking
brake linkages
and pivots,
brake and clutch
pedal shaft (if
equipped)Motorcraft
Premium
Long-Life GreaseXG-1-C or
XG-1-KESA-M1C75-B
Power steering
fluid and
transfer case
fluid (if
equipped)Motorcraft
MERCON
AT FXT-2-QDX MERCON

Maintenance and Specifications
233

washing ....................................184
waxing .....................................184
wheels ......................................185
wiper blades ............................186
Clutch
fluid ..........................................216
operation while driving ..........109
recommended shift speeds ....110
Compass, electronic ....................53
calibration .................................54
set zone adjustment .................54
Console ........................................51
overhead ....................................45
Controls
power seat .................................66
Coolant
checking and adding ..............199
refill capacities ................203, 228
specifications ..................232, 235
Cruise control
(see Speed control) ....................48
Customer Assistance ................152
Ford accessories for your
vehicle .....................................190
Ford Extended Service
Plan ..........................................177
Getting assistance outside the
U.S. and Canada .....................181
Getting roadside assistance ...152
Getting the service you
need .........................................175
Ordering additional owner’s
literature .................................182
The Dispute Settlement
Board .......................................177
Utilizing the
Mediation/Arbitration
Program ...................................180D
Daytime running lamps
(see Lamps) ................................36
Dipstick
automatic transmission
fluid ..........................................216
engine oil .................................194
Doors
lubricant specifications ..........232
Driveline universal joint and
slip yoke ....................................220
Driving under special
conditions ..................109, 118, 121
sand .........................................120
snow and ice ...........................122
through water .................120, 125
E
Emergencies, roadside
jump-starting ..........................168
Emission control system ..........213
Engine ........................................235
cleaning ...................................185
coolant .....................................199
diesel ...........................................6
fail-safe coolant ......................204
idle speed control ...................197
lubrication
specifications ..................232, 235
refill capacities ........................228
service points ..........................193
starting after a collision .........153
Engine block heater .................102
Engine oil ..................................194
checking and adding ..............194
dipstick ....................................194
filter, specifications ........196, 228
recommendations ...................196
Index
250