service FORD SUPER DUTY 2003 1.G Workshop Manual

MOTORCRAFT PART NUMBERS
Component* 5.4L V8 engine 6.8L V10 engine
Air filter element FA-1634 FA-1634
Fuel filter FG-986B FG-986B
Oil filter FL-820-S FL-820-S
PCV valve EV-233 EV-233
Battery(Standard) BXT-65-650 BXT-65-650
Battery(Optional) BXT-65-750 BXT-65-750
Spark plugs-platinum** AGSF-22W AGSF-22W
*Refer to the7.3 Liter Power Stroke Direct Injection Turbo Diesel
Owner’s Guide Supplementfor Motorcraft diesel engine service part
numbers.
**Refer to Vehicle Emissions Control Information (VECI) decal for spark
plug gap information.
REFILL CAPACITIES
FluidFord Part
NameApplication Capacity
Front axle Hypoid Gear Oil
SAE 90F-250/350
(Dana 60 axle)2.7L (5.8 pints)
F-350/450/550
(Dana 60 axle)2.7L (5.8 pints)
Rear axle
1,2Motorcraft SAE
75W-140
Synthetic Rear
Axle LubricantF-250 /350
(10.50 inch
axle)3.3L (6.9 pints)
Motorcraft SAE
75W-90
Synthetic Rear
Axle LubricantF-350/450
(DANA 80)4.0L (8.5 pints)
Motorcraft SAE
80W-90
Premium Rear
Axle LubricantF-550
(Dana 135)11.6L (24.5
pints)
Maintenance and Specifications
228

FluidFord Part
NameApplication Capacity
Fuel tank N/A Mid-ship tank
(optional on
Chassis Cab)71.9L (19.0
gallons)
Right side
saddle mounted
tank (optional
on Chassis Cab)87.1L (23.0
gallons)
Short box 109.8L (29.0
gallons)
Long box 143.9L (38.0
gallons)
Aft axle 151.4L (40.0
gallons)
Power steering
fluidMotorcraft
MERCON
AT FAll Fill to line on
reservoir
Transfer case
fluidMotorcraft
MERCON
AT F4x4 vehicles 1.9L (2.0
quarts)
Transmission
fluid
4Motorcraft
MERCON
AT F6-speed manual 5.5L (5.8
quarts)5
Automatic 16.7L (17.7
quarts)6
Windshield
washer fluidMotorcraft
Premium
Windshield
Washer
ConcentrateAll 4.0L (4.25
quarts)
1Your vehicle’s rear axle(s) maybe filled with a synthetic lubricant that
mayrequire a lubricant change. Refer to the scheduled maintenance
guide. Axle lubricant quantities should not need to be checked unless a
leak is suspected, service is required or the axle assemblyhas been
submerged in water. The axle lubricant should be changed anytime the
rear axle has been submerged in water.
Maintenance and Specifications
230

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

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

Wood trim - interim applique
For maximum vehicle performance, keep the following information in
mind when adding accessories or equipment to your vehicle:
•When adding accessories, equipment, passengers and luggage to your
vehicle, do not exceed the total weight capacityof the vehicle or of
the front or rear axle (GVWR or GAWR as indicated on the Safety
compliance certification label). Consult your dealer for specific weight
information.
•The Federal Communications Commission (FCC) and Canadian Radio
Telecommunications Commission (CRTC) regulate the use of mobile
communications systems - such as two-way radios, telephones and
theft alarms - that are equipped with radio transmitters. Anysuch
equipment installed in your vehicle should comply with FCC or CRTC
regulations and should be installed onlybya qualified service
technician.
•Mobile communications systems may harm the operation of your
vehicle, particularlyif theyare not properlydesigned for automotive
use or are not properlyinstalled. When operated, such systems may
cause the engine to stumble or stall or cause the transmission to be
damaged or operate improperly. In addition, such sy stems may be
damaged or their performance maybe affected byoperating your
vehicle. (Citizens band [CB] transceivers, garage door openers and
other transmitters with outputs of five watts or less will not ordinarily
affect your vehicle’s operation.)
•Ford cannot assume responsibilityfor anyadverse effects or damage
that mayresult from the use of such equipment.
Accessories
248

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