service FORD SUPER DUTY 2004 1.G Repair Manual

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.
2004 F250/350/450/550(f23)
Owners Guide (post-2002-fmt)
USA English(fus)
Maintenance and Specifications
280

ItemFord part
name or
equivalentFord part
numberFord
specification
Automatic
transmission
4R100
(4–speed)Motorcraft
MERCONAT F
2
XT-2-QDX MERCON
Automatic
transmission
TorqShift
(5–speed)Motorcraft
MERCONSP
AT F
2
XT-6–QSP MERCONSP
Windshield
washer fluidMotorcraft
Premium
Windshield
Washer
ConcentrateZC-32–A WSB-M8B16–A2
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 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.
2004 F250/350/450/550(f23)
Owners Guide (post-2002-fmt)
USA English(fus)
Maintenance and Specifications
283

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
*Refer to the6.0 Liter Power Stroke Direct Injection Turbo Diesel
Owner’s Guide Supplementfor Motorcraft diesel engine service part
numbers.
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)2005 mm
(78.9 in)1943 mm
(76.5 in)
b2008 mm
(79.0 in)b
(2) Track
(Front /
Rear)1736 mm
(68.3 in) /
1729 mm
(68 in)1736 mm
(68.3 in) /
1729.3 mm
(68 in)1736 mm
(68.3 in) /
1729.3 mm
(68 in)1736 mm
(68.3 in) /
1729.3 mm
(68 in)
(3) Overall
width2031 mm
(79.9 in)2031 mm
(79.9 in)2031 mm
(79.9 in)2031 mm
(79.9 in)
(4)
Wheelbase3479.8 mm
(137 in)3479.8 mm
(137 in)3610.7 mm
(141.8 in)
a
4013.2 mm
(158 in)b
3610.7 mm
(141.8 in)a
4013.2 mm
(158 in)b
(5) Overall
length5767 mm
(227 in)5767 mm
(227 in)5889 mm
(231.9 in)a
6300 mm
(248 in)b
5889 mm
(231.9 in)a
6300 mm
(248 in)b
a
Short Wheel Base (SWB)bLong wheel base (LWB)
2004 F250/350/450/550(f23)
Owners Guide (post-2002-fmt)
USA English(fus)
Maintenance and Specifications
284

Peace of mind
Airbag anti-theft locks
First aid and safety kits
Full vehicle covers
Locking gas cap
Navigation systems
Remote start
Vehicle security systems
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 capacity of 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. Any such
equipment installed in your vehicle should comply with FCC or CRTC
regulations and should be installed only by a qualified service
technician.
•Mobile communications systems may harm the operation of your
vehicle, particularly if they are not properly designed for automotive
use.
2004 F250/350/450/550(f23)
Owners Guide (post-2002-fmt)
USA English(fus)
Accessories
298

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
2004 F250/350/450/550(f23)
Owners Guide (post-2002-fmt)
USA English(fus)
Index
300