check engine FORD SUPER DUTY 2004 1.G Owner's Manual

3. The fuel cap may not have been securely tightened.
These temporary malfunctions can be corrected by filling the fuel tank
with good quality fuel and/or properly tightening the fuel cap. After three
driving cycles without these or any other temporary malfunctions
present, theCheck Engine/Service Engine Soonlight should turn off.
(A driving cycle consists of a cold engine startup followed by mixed
city/highway driving.) No additional vehicle service is required.
If theCheck Engine/Service Engine Soonlight remains on, have your
vehicle serviced at the first available opportunity.
Readiness for Inspection/Maintenance (I/M) testing
In some localities, it may be a legal requirement to pass an I/M test of
the on-board diagnostics system. If your“Check Engine/Service Engine
Soon”light is on, refer to the description in theWarning lights and
chimessection of theInstrument clusterchapter. Your vehicle may not
pass the I/M test with the“Check Engine/Service Engine Soon”light on.
If the vehicle’s powertrain system or its battery has just been serviced,
the on-board diagnostics system is reset to a“not ready for I/M test”
condition. To ready the on-board diagnostics system for I/M testing, a
minimum of 30 minutes of city and highway driving is necessary as
described below:
•First, at least 10 minutes of driving on an expressway or highway.
•Next, at least 20 minutes driving in stop-and-go, city-type traffic with
at least four idle periods.
Allow the vehicle to sit for at least eight hours without starting the
engine. Then, start the engine and complete the above driving cycle. The
engine must warm up to its normal operating temperature. Once started,
do not turn off the engine until the above driving cycle is complete.
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Maintenance and Specifications
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CHECKING AND ADDING POWER STEERING FLUID
Check the power steering fluid.
Refer to the scheduled maintenance
guide for the service interval
schedules. If adding fluid is
necessary, use only MERCONAT F.
Check the fluid level when it is at ambient temperature, 20°–80°F (-7°
–25°C):
1. Check the fluid level on the dipstick. It should be between the arrows
in the FULL COLD range. Do not add fluid if the level is within this
range.
2. If the fluid level is low. Add fluid to bring fluid level up to be between
the arrows in the FULL COLD range.
3. Start the engine.
4. While the engine idles, turn the steering wheel left and right several
times.
5. Turn the engine off.
6. Recheck the fluid level on the dipstick. Do not add fluid if the level is
between the arrows in the FULL COLD range.
7. If the fluid is low, add fluid in small amounts, continuously checking
the level until it reaches the FULL COLD range. Be sure to put the
dipstick back in the reservoir.
BRAKE FLUID RESERVOIR
The fluid level will drop slowly as
the brakes wear, and will rise when
the brake components are replaced.
Fluid levels below the“MAX”line
that do not trigger the brake system
warning lamp are within the normal
operating range, there is no need to
add fluid. If the fluid levels are outside of the normal operating range,
the performance of your brake system could be compromised, seek
service from your dealer immediately.
M
AX
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Maintenance and Specifications
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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.
However, the fluid level should be checked if the transmission is not
working properly, i.e., if the transmission slips or shifts slowly or if you
notice some sign of fluid leakage.
Automatic transmission fluid expands when warmed. To obtain an
accurate fluid check, drive the vehicle until it is at normal operating
temperature (approximately 30 km [20 miles]). If your vehicle has been
operated for an extended period at high speeds, in city traffic during hot
weather or pulling a trailer, the vehicle should be turned off for about 30
minutes to allow fluid to cool before checking.
1. Drive the vehicle 30 km (20 miles) or until it reaches normal operating
temperature.
2. Park the vehicle on a level surface and engage the parking brake.
3. With the parking brake engaged and your foot on the brake pedal,
start the engine and move the gearshift lever through all of the gear
ranges. Allow sufficient time for each gear to engage.
4. Latch the gearshift lever in P (Park) and leave the engine running.
5. Remove the dipstick, wiping it clean with a clean, dry lint free rag. If
necessary, refer toIdentifying components in the engine compartment
in this chapter for the location of the dipstick.
6. Install the dipstick making sure it is fully seated in the filler tube.
7. Remove the dipstick and inspect the fluid level. The fluid should be in
the designated area for normal operating temperature or ambient
temperature.
Low fluid level
Do not drive the vehicle if the fluid
level is at the bottom of the dipstick
and the ambient temperature is
above 10°C (50°F).
ADD COLD HOT DO NOT ADD
DON'T ADD IF IN CROSSHATCHED AREA  CHECK WHEN HOT IDLING IN PARK
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If an overfill occurs, excess fluid
should be removed by a qualified
technician.
An overfill condition of
transmission fluid may cause
shift and/or engagement
concerns and/or possible
damage.
Do not use supplemental transmission fluid additives, treatments or
cleaning agents. The use of these materials may affect transmission
operation and result in damage to internal transmission components.
Automatic transmission fluid filter (if equipped)
The TorqShift automatic
transmission is equipped with a
serviceable external fluid filter
mounted on the frame rail. Refer to
the Scheduled Maintenance Guide
for service intervals.
To replace the transmission filter:
1. Shut off the engine.
2. Unscrew filter housing.
3. Replace filter with a new authorized Motorcraft filter element. Refer to
theMotorcraft Part Numberschart in this chapter.
4. Reinstall housing and check transmission fluid level using procedure in
this section.
ADD COLD HOT DO NOT ADD
DON'T ADD IF IN CROSSHATCHED AREA  CHECK WHEN HOT IDLING IN PARK
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1Your vehicle’s rear axle(s) may be filled with a synthetic lubricant that
may require 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 assembly has been
submerged in water. The axle lubricant should be changed any time the
rear axle has been submerged in water.
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 end of the dipstick. Check the
container to verify the fluid being added is of the correct type. Refer to
your scheduled maintenance guide to determine the correct service
interval.
Some transmission fluids may be labeled as dual usage, such as
MERCONand MERCONV. These dual usage fluids are not to be used
in an automatic transmission that requires use of the MERCONtype
fluid. However, these dual usage fluids may be used in transmissions that
require the MERCONV type fluid.
MERCON, MERCONV and MERCONSP are not
interchangeable. DO NOT mix MERCON, MERCONV and
MERCONSP. Use of dual usage fluids in an automatic
transmission application requiring MERCONSP may cause
transmission damage. Use of a transmission fluid other than the
recommended fluid may cause transmission damage.
5Service refill capacity is determined by filling 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. Verify the fluid
level after operating vehicle to assure correct fluid level.
6Indicates only approximate dry-fill capacity. Some applications may vary
based on cooler size and if equipped with an in-tank cooler. The amount
of transmission fluid and fluid level should be set by the indication on
the dipstick’s normal operating range.
7Use of synthetic or synthetic blend motor oil is not mandatory. Engine
oil need only meet the requirements of Ford specification
WSS-M2C153–H and the API Certification mark.
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Vehicle identification number (VIN)
The vehicle identification number is
attached to a metal tag and is
located on the driver side
instrument panel. (Please note that
in the graphic XXXX is
representative of your vehicle
identification number.)
1. World manufacturer identifier
2. Brake type and gross vehicle
weight rating (GVWR)
3. Vehicle line, series, body type
4. Engine type
5. Check digit
6. Model year
7. Assembly plant
8. Production sequence number
Engine number
The engine number (the last eight numbers of the vehicle identification
number) is stamped on the engine block, transmission, frame and
transfer case (if equipped).
XXXXXXXXXXXXXXXXX
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USA English(fus)
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293

A
Accessory delay ..........................56
Air bag supplemental restraint
system ........................................104
and child safety seats ............106
description ..............................104
disposal ....................................108
driver air bag ..........................106
indicator light .........................108
operation .................................106
passenger air bag ...................106
passenger deactivation
switch ......................................109
Air cleaner filter ...............263, 277
Ambulance packages ....................8
Antifreeze
(see Engine coolant) ................240
Anti-lock brake system
(see Brakes) ..............................129
Audio system
(see Radio) ..........19, 21, 23, 26, 30
Automatic transmission ............132
driving an automatic
overdrive .........................133, 135
fluid, adding ............................258
fluid, checking ........................258
fluid, refill capacities ..............278
fluid, specification ..................284
Auxiliary power point .................55
Axle
lubricant specifications ..281, 284
refill capacities ........................278
traction lok ..............................131
B
Battery .......................................238
acid, treating emergencies .....238jumping a disabled battery ....209
maintenance-free ....................238
replacement, specifications ...277
servicing ..................................238
BeltMinder ...................................99
Brakes ........................................128
anti-lock ...................................129
anti-lock brake system (ABS)
warning light ...........................129
fluid, checking and adding ....256
fluid, refill capacities ..............278
fluid, specifications .........281, 284
lubricant specifications ..281, 284
parking ....................................129
shift interlock ..........................132
Bulbs ............................................44
C
Calculating load ........................162
Capacities for refilling fluids ....278
Cassette tape player ...................30
CD changer .................................33
Cell phone use ............................67
Certification Label ....................292
Child safety restraints ..............113
child safety belts ....................113
Child safety seats ......................116
attaching with tether straps ..120
in front seat ............................118
in rear seat ..............................118
Cleaning your vehicle
engine compartment ..............226
instrument panel ....................228
interior .....................................228
interior trim ............................228
plastic parts ............................227
safety belts ..............................228
washing ....................................225
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USA English(fus)
Index
Index
299

waxing .....................................225
wheels ......................................226
wiper blades ............................227
Clock ............................................33
Clock adjust
AM/FM .................................21, 23
AM/FM Stereo ...........................23
AM/FM/CD ...........................26, 33
AM/FM/Tape/CD .......................30
Clutch
fluid ..........................................257
operation while driving ..........138
recommended shift speeds ....139
Compass, electronic ....................69
calibration .................................71
set zone adjustment .................70
Console ........................................67
overhead ....................................52
Coolant
checking and adding ..............240
refill capacities ................243, 278
specifications ..................281, 284
Cruise control
(see Speed control) ....................59
Customer Assistance ................191
Ford accessories for your
vehicle .....................................230
Ford Extended Service
Plan ..........................................218
Getting assistance outside the
U.S. and Canada .....................222
Getting roadside assistance ...191
Getting the service you
need .........................................216
Ordering additional owner’s
literature .................................223
The Dispute Settlement
Board .......................................218Utilizing the
Mediation/Arbitration
Program ...................................221
D
Daytime running lamps
(see Lamps) ................................41
Dipstick
automatic transmission
fluid ..........................................258
engine oil .................................235
Doors
lubricant specifications ..........281
Driveline universal joint and
slip yoke ....................................262
Driving under special
conditions ..................138, 151, 154
sand .........................................153
snow and ice ...........................155
through water .................153, 158
E
Emergencies, roadside
jump-starting ..........................209
Emergency Flashers .................192
Emission control system ..........253
Engine ........................................284
cleaning ...................................226
coolant .....................................240
diesel ...........................................7
fail-safe coolant ......................244
idle speed control ...................238
lubrication
specifications ..................281, 284
refill capacities ........................278
service points ..........................234
starting after a collision .........192
Engine block heater .................128
Engine oil ..................................235
checking and adding ..............235
dipstick ....................................235
filter, specifications ........237, 277
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Owners Guide (post-2002-fmt)
USA English(fus)
Index
300