FORD SUPER DUTY 2003 1.G Owners Manual

2Add 236 ml (8 oz.) of Additive Friction Modifier XL-3or equivalent
meeting Ford Specification EST-M2C118-A for complete refill of
Traction-Lok axles.
3Add the coolant type originally equipped in your vehicle.
4Ensure the correct automatic transmission fluid is used. Transmission
fluid requirements are indicated on the dipstick or on the dipstick
handle. Check the container to verifythe fluid being added is of the
correct type. Refer to your scheduled maintenance guide to determine
the correct service interval.
Some transmission fluids maybe labeled as dual usage, such as
MERCON
and MERCON
V. These dual usage fluids are not to be used
in an automatic transmission that requires use of the MERCON
type
fluid. However, these dual usage fluids maybe used in transmissions that
require the MERCON
V type fluid.
MERCON
and MERCON
V type fluids are not interchangeable.
DO NOT mix MERCON
and MERCON
V. Use of a transmission
fluid that indicates dual usage (MERCON
and MERCON
V) in
an automatictransmission application requiring MERCON
may
cause transmission damage. Use of any fluid other than the
recommended fluid may cause transmission damage.
5Service refill capacityis determined byfilling the transmission to the
bottom of the filler hole with the vehicle on a level surface. The 6–speed
manual transmission is equipped with an in-tank cooler. Verifythe fluid
level after operating vehicle to assure correct fluid level.
6Indicates onlyapproximate dry-fill capacity. Some applications mayvary
based on cooler size and if equipped with an in-tank cooler. The amount
of transmission fluid and fluid level should be set bythe indication on
the dipstick’s normal operating range.
Maintenance and Specifications
231

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

ItemFord part
name or
equivalentFord part
numberFord
specification
Manual
transmission
(6-speed)Motorcraft
MERCON
AT F
2
XT-2-QDX MERCON

Automatic
transmission
4R100
(4–speed)Motorcraft
MERCON
AT F
2
XT-2-QDX MERCON

Automatic
transmission
5R110W
(5–speed)Motorcraft
MERCON
SP
AT F
2
— WSS-M2C919–D
Windshield
washer fluidMotorcraft
Premium
Windshield
Washer
ConcentrateZC-32–A ESR-M17P5-A
1Add 236 ml (8 oz.) of Additive Friction Modifier XL-3 or equivalent
meeting Ford specification EST-M2C118-A for complete refill of
Traction-Lok axles. Ford design rear axles contain a synthetic lubricant
that does not require changing unless the axle has been submerged in
water. Dana rear axles also contain a synthetic lubricant butdorequire a
change. Refer to your “Service Guide” for change intervals on Dana rear
axles.
2Ensure the correct automatic transmission fluid is used. Transmission
fluid requirements are indicated on the dipstick or on the dipstick
handle. Check the container to verifythe fluid being added is of the
correct type. Refer to your scheduled maintenance guide to determine
the correct service interval.
Some transmission fluids maybe labeled as dual usage, such as
MERCON
and MERCON
V. These dual usage fluids are not to be used
in an automatic transmission that requires use of the MERCON
type
fluid. However, these dual usage fluids maybe used in transmissions that
require the MERCON
V type fluid.
MERCON
and MERCON
V type fluids are not interchangeable.
DO NOT mix MERCON
and MERCON
V. Use of a transmission
Maintenance and Specifications
234

fluid that indicates dual usage (MERCON
and MERCON
V) in
an automatictransmission application requiring MERCON
may
cause transmission damage. Use of any fluid other than the
recommended fluid may cause transmission damage.
ENGINE DATA
Engine 5.4L V8 engine 6.8L V10 engine
Cubic inches 330 415
Required fuel 87 octane 87 octane
Firing order 1-3-7-2-6-5-4-8 1-6-5-10-2-7-3-8-4-9
Spark plug gap1.3-1.4 mm
(0.052-0.056 inch)1.3-1.4 mm
(0.052-0.056 inch)
Ignition system Coil on plug Coil on plug
Compression ratio 9.0:1 9.0:1
VEHICLE DIMENSIONS
F250–Regular and Super Cab
Dimension Body style
Regular
Cab 4x2Regular
Cab 4x4Super Cab
4x2Super Cab
4x4
(1) Overall
height1935 mm
(76.2 in)2 005 mm
(78.9 in)1 943 mm
(76.5 in)
d2 008 mm
(79.0 in)d
(2) Track
(Front /
Rear)1 736 mm
(68.3 in) /
1 729 mm
(68 in)1 736 mm
(68.3 in) /
1 729.3 mm
(68 in)1 736 mm
(68.3 in) /
1 729.3 mm
(68 in)1 736 mm
(68.3 in) /
1 729.3 mm
(68 in)
(3) Overall
width2 031 mm
(79.9 in)
a
2426 mm
(95.5 in)b
2 031 mm
(79.9 in)a
2426 mm
(95.5 in)b
2 031 mm
(79.9 in)a
2426 mm
(95.5 in)b
2 031 mm
(79.9 in)a
2426 mm
(95.5 in)b
(4)
Wheelbase3 479.8 mm
(137 in)3 479.8 mm
(137 in)3 610.7 mm
(141.8 in)c
4 013.2 mm
(158 in)d
3 610.7 mm
(141.8 in)c
4 013.2 mm
(158 in)d
Maintenance and Specifications
235

Dimension Body style
Regular
Cab 4x2Regular
Cab 4x4Super Cab
4x2Super Cab
4x4
(5) Overall
length5 756 mm
(226.6 in)5 756 mm
(226.6 in)5 878 mm
(231.4 in)
c
6 289 mm
(247.6 in)d
5 878 mm
(231.4 in)c
6 289 mm
(247.6 in)d
a
Single rear wheel (SRW)bDual rear wheel (DRW)cShort Wheel Base (SWB)dLong wheel base (LWB)
F250-Crew Cab
Dimension Body style
Crew Cab
4x2/ Short
boxCrew Cab
4x4/ Short
boxCrew Cab
4x2/ Long
boxCrew Cab
4x4/ Long
box
(1) Overall
height1960 mm
(77.2 in)2 027 mm
(79.8 in)1 957 mm
(77.0 in)2 022 mm
(76.6 in)
(2) Track
(Front /
Rear)1 736 mm
(68.3 in) /
1 729 mm
(68.1 in)1 736 mm
(68.3 in) /
1 729 mm
(68.1 in)1 736 mm
(68.3 in) /
1 729 mm
(68.1 in)1 736 mm
(68.3 in) /
1 729 mm
(68.1 in)
(3) Overall
width2 031 mm
(79.9 in)2 031 mm
(79.9 in)2 031 mm
(79.9 in)2 031 mm
(79.9 in)
(4)
Wheelbase3 967 mm
(156.2 in)3 967 mm
(156.2 in)4 379 mm
(172.4 in)4 379 mm
(172.4 in)
(5) Overall
length6 243 mm
(245.8 in)6 243 mm
(245.8 in)6 654 mm
(262 in)6 654 mm
(262 in)
Maintenance and Specifications
236

F350–except Crew Cab
Dimension Body style
Chassis
Cab —
Regular
CabChassis
Cab —
Super CabRegular
Cab Style
SideSuper Cab
Style Side
(1) Overall
height1 924 mm
(75.7 in)
a
1 912 mm
(75.2 in)b
2 028 mm
(79.8 in)c
2 031 mm
(80.0 in)d
1 928 mm
(75.9 in)a
1 931 mm
(76.0 in)b
2 029 mm
(79.9 in)c
2 019 mm
(79.5 in)d
1 938 mm
(76.3 in)a
1 976 mm
(77.8 in)b
2 041 mm
(80.3 in)c
2 018 mm
(79.4in)d
1 952 mm
(76.8 in)a,e
1 954 mm
(76.9 in)a,f
1 939 mm
(76.3 in)b
2 051 mm
(80.7 in)c,e
2 039 mm
(80.3 in)c,f
2 019 mm
(79.5 in)d
(2a) Front
Track1 736 mm
(68.3 in)a,b/
1 736 mm
(68.4 in)
c,d
1 736 mm
(68.3 in)a,b/
1 736 mm
(68.4 in)
c,d
1 736 mm
(68.3 in)a,b/
1 736 mm
(68.4 in)
c,d
1 736 mm
(68.3 in)a,b/
1 736 mm
(68.4 in)
c,d
(2b) Rear
Track1 729 mm
(68.1 in)a,c/
1 880 mm
(74.0 in)
b,d
1 729 mm
(68.1 in)a,c/
1 880 mm
(74.0 in)
b,d
1 729 mm
(68.1 in)a,c/
1 880 mm
(74.0 in)
b,d
1 729 mm
(68.1 in)a,c/
1 880 mm
(74.0 in)
b,d
(3) Overall
width2 031 mm
(79.9 in)a,c/
2 304 mm
(90.7 in)
b
2 329 mm
(91.7 in)d
2 031 mm
(79.9 in)2 031 mm
(79.9 in)a,c
2 426 mm
(95.5)b,d
2 031 mm
(79.9 in)a,c
2 426 mm
(95.5)b,d
Maintenance and Specifications
237

Dimension Body style
Chassis
Cab —
Regular
CabChassis
Cab —
Super CabRegular
Cab Style
SideSuper Cab
Style Side
(4)
Wheelbase3 576 mm
(140.8 in)
4 186 mm
(164.8 in)4 110 mm
(161.8 in)3 480 mm
(137.0 in)3 602 mm
(141.8 in)
e/
4 014 mm
(158.0 in)
f
(5) Overall
length5 733 mm
(225.7
in)
a,b,c,d/
6 343 (249.7
in)
b,d
6 267 mm
(246.7 in)5 756 mm
(226.6 in)5 878 mm
(231.4 in)e/
6 289 mm
(247.6 in)
f
a
4x2 Single rear wheel (SRW)b4x2 Dual rear wheel (DRW)c4x4 Single rear wheel (SRW)d4x4 Dual rear wheel (DRW)eShort boxfLong box
F350-Crew Cab
DimensionBody style
Crew chassis
CabCrew cab-short
boxCrew cab —
long box
(1) Overall
height1 929 mm
(75.9 in)
a/
1 941 mm
(76.4 in)
b/
2 026 mm
(79.8 in)
c/
2 038 mm
(80.2 in)
d
1 955mm
(77.0 in)a/
1998 mm
(78.6 in)
b/
1 958 mm
(77.1 in)
c/
2 033 mm
(80.0 in)
d
1 964 mm
(77.3 in)a/
1991 mm
(75.2 in)
b/
1 957 mm
(77.0 in)
c/
2 031 mm
(80.0 in)
d
(2a) Track
—Front1 736 mm
(68.3 in)1 736 mm
(68.3 in)1 736 mm
(68.3 in)
Maintenance and Specifications
238

DimensionBody style
Crew chassis
CabCrew cab-short
boxCrew cab —
long box
(2b) Track —
Rear1 729 mm
(68.1 in)
a,c/
1 803 mm
(74.0 in)
b,d
1 729 mm
(68.1 in)a,c/
1 880 mm
(74.0 in)
b,d
1 729 mm
(68.1 in)a,c/
1 880 mm
(74.0 in)
b,d
(3) Overall
width2 031 mm
(79.9 in)a,c/
2 304 mm
(90.7 in)
b/
2 329 mm
(91.7 in)
d
2 031 mm
(79.9 in)a,c
2 426 mm
(95.5 in)b,d
2 031 mm
(79.9 in)a,c
2 426 mm
(95.5 in)b,d
(4) Wheelbase 4 475 mm
(176.2 in )3 967 mm
(156.2 in )4 379 mm
(172.4 in)
(5) Overall
length6 632 mm
(261.1 in)6 243 mm
(245.8 in)6 654 mm
(262.0 in)
a4x2 Single rear wheel (SRW)b4x2 Dual rear wheel (DRW)c4x4 Single rear wheel (SRW)d4x4 Dual rear wheel (DRW)
F450
Dimension Body style
Regular
Cab
Chassis 4x2Regular
Cab
Chassis 4x4Super Cab
Chassis
4x2/4x4Crew Cab
Chassis
4x2/4x4
(1) Overall
height2 048 mm
(80.6 in)
a
2 044 mm
(80.5 in)b,c
2 038 mm
(80.2 in)d
2 051 mm
(80.7 in)a
2 044 mm
(80.5 in)b
2 033 mm
(80.0 in)c,d
2 045 mm
(80.5 in)2 053 mm
(80.8 in) -
4x2
2 056 mm
(80.9 in) -
4x4
Maintenance and Specifications
239

Dimension Body style
Regular
Cab
Chassis 4x2Regular
Cab
Chassis 4x4Super Cab
Chassis
4x2/4x4Crew Cab
Chassis
4x2/4x4
(2) Track
(Front /
Rear)1 736 mm
(68.4 in) /
1 880 mm
(74.0 in)1 736 mm
(68.4 in) /
1880 mm
(74.0 in)1 736 mm
(68.4 in) /
1 889 mm
(74.3 in)1 736 mm
(68.4 in) /
1 880 mm
(74.0 in)
(3) Overall
width2 377 mm
(93.6 in)2 377 mm
(93.6 in)2 386 mm
(93.9 in)2 377 mm
(93.6 in)
(4)
Wheelbase3 576 mm
(140.8 in)
4 186 mm
(164.8 in)
4 795 mm
(188.8 in)
5 100 mm
(200.8 in)3 576 mm
(140.8 in)
4 186 mm
(164.8 in)
4 795 mm
(188.8 in)
5 100 mm
(200.8 in)4 110 mm
(161.8 in)4 475 mm
(176.2 in)
5 085 (200.2
in)
(5) Overall
length5 733 mm
(225.7 in)
a
6 343 mm
(249.7 in)b
6 952 mm
(273.7 in)c
7 257 mm
(285.7 in)d
5 733 mm
(225.7 in)a
6 343 mm
(249.7 in)b
6 952 mm
(273.7 in)c
7 257 mm
(285.7 in)d
6 267 mm
(246.7 in)6 632 mm
(261.1 in)e
7 241 mm
(285.1 in)f
a
3 576 mm (140.8 in) wheel baseb4 186 mm (164.8 in) wheel basec4 795 mm (188.8) wheel based5 100 mm (200.8 in) wheel basee4 475 mm (176.2 in) wheel basef5 085 mm (200.2 in) wheel base
Maintenance and Specifications
240