cooling FORD SUPER DUTY 2004 1.G Owners Manual

Failure to maintain your vehicle properly may void the warranty, increase
your repair cost, reduce vehicle performance and operational capabilities
and adversely affect driver and passenger safety. Frequent inspection of
vehicle chassis components is recommended if the vehicle is subjected to
heavy off-road usage.
POWER TAKE OFF (PTO) CAPABILITY (IF EQUIPPED)
Some automatic transmission vehicles may be equipped with a
Transmission Power Take-Off Provision, Option Code 62R. These
vehicles have a special transmission that includes a port on the left hand
side to mount an aftermarket PTO, an internal PTO gear, and calibration
for PTO usage. The actual PTO and related equipment is not offered by
Ford Motor Company, but is installed by the aftermarket.
The PTO gear in the transmission will drive the aftermarket PTO while
driving the vehicle. Therefore, some additional gear noise that may result
is normal. Also, the transmission upshift and downshift schedules will be
reduced by about 15% and may result in a firmer shift feel during PTO
mobile applications.
A more complete description of PTO operation is discussed in the Ford
Truck Body Builders Layout Book, found at
www.fleet.ford.com/truckbbas.
Note:PTO applications draw auxiliary horsepower from the powertrain,
often while the vehicle is stationary. In this condition there is limited
cooling air flow through the radiator and around the vehicle that
normally occurs when a vehicle is moving. Depending on the level of
auxiliary horsepower draw and for how long, vehicle and surrounding
environmental conditions, and other factors, this can contribute to
elevated transmission fluid temperatures and resultant accelerated fluid
aging, fuel vapor over-pressurization, and other concerns. Ford trucks are
fully qualified for stationary PTO operation for 10 minutes or less of
continuous operation. For extended duration stationary PTO operation
(beyond 10 minutes) diesel engine is recommended, and further consult
your aftermarket PTO installer.
DRIVING THROUGH WATER
If driving through deep or standing water is unavoidable, proceed very
slowly especially if the depth is not known. Never drive through water
that is higher than the bottom of the hubs (for trucks) or the bottom of
the wheel rims (for cars). Traction or brake capability may be limited
and your vehicle may stall. Water may also enter your engine’s air intake
and severely damage your engine.
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Do not connect a trailer’s hydraulic brake system directly to your
vehicle’s brake system. Your vehicle may not have enough
braking power and your chances of having a collision greatly increase.
The braking system of the tow vehicle is rated for operation at the
GVWR not GCWR.
Trailer lamps
Trailer lamps are required on most towed vehicles. Make sure all running
lights, brake lights, turn signals and hazard lights are working. See your
dealer or trailer rental agency for proper instructions and equipment for
hooking up trailer lamps.
Using a step bumper (if equipped)
The rear bumper is equipped with an integral hitch and only requires a
ball with a 25.4 mm (one inch) shank diameter. The bumper has a 2,270
kg (5,000 lb.) trailer weight and 227 kg (500 lb.) tongue weight capacity.
If it is necessary to relocate the trailer hitch ball position, a
frame-mounted trailer hitch must be installed.
Driving while you tow
When towing a trailer:
•Turn off the speed control. The speed control may shut off
automatically when you are towing on long, steep grades.
•Consult your local motor vehicle speed regulations for towing a trailer.
•If your vehicle is equipped with a 4–speed automatic
transmission:To eliminate excessive transmission shifting, use a
lower gear. This will also assist in transmission cooling. (For additional
information, refer to theUnderstanding the positions of the 4–speed
automatic transmissionsection in this chapter.
•If your vehicle is equipped with a 5–speed automatic
transmission:To eliminate excessive transmission shifting, activate
the Tow/Haul feature. This will also assist in transmission cooling. (For
additional information, refer to theUnderstanding the positions of
the 5–speed automatic transmissionsection in this chapter.
•Anticipate stops and brake gradually.
•Do not exceed the GCWR rating or transmission damage may occur.
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•Your vehicle may be equipped with a temporary or conventional spare
tire. If the spare tire is different in size (diameter and/or width), tread
type (All-Season or All-Terrain) or is from a different manufacturer
other than the road tires on your vehicle, your spare tire is considered
“temporary”. Consult information on the spare tire label for limitations
when using.
Servicing after towing
If you tow a trailer for long distances, your vehicle will require more
frequent service intervals. Refer to your scheduled maintenance guide for
more information.
Trailer towing tips
•Practice turning, stopping and backing up before starting on a trip to
get the feel of the vehicle trailer combination. When turning, make
wider turns so the trailer wheels will clear curbs and other obstacles.
•Allow more distance for stopping with a trailer attached.
•The trailer tongue weight should be 10–15% of the loaded trailer
weight.
•After you have traveled 80 km (50 miles), thoroughly check your
hitch, electrical connections and trailer wheel lug nuts.
•To aid in engine/transmission cooling and A/C efficiency during hot
weather while stopped in traffic, place the gearshift lever in P (Park)
(automatic transmission) or N (Neutral) (manual transmissions).
•Vehicles with trailers should not be parked on a grade. If you must
park on a grade, place wheel chocks under the trailer’s wheels.
Launching or retrieving a boat
When backing down a ramp during boat launching or retrieval,
•Do not allow the static water level to rise above the bottom edge of
the rear bumper.
•Do not allow waves to break higher than 15 cm (6 inches) above the
bottom edge of the rear bumper.
•Disconnect the trailer tow electrical connector to prevent blown fuses
caused by water entering into your trailer’s electrical wiring.
Exceeding these limits may allow water to enter critical vehicle
components, adversely affecting driveability, emissions and reliability.
Replace front and rear axle lubricants any time the axles have been
submerged in water. Axle lubricant quantities are not to be checked
unless a leak is suspected.
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When a wheel is installed, always remove any corrosion, dirt or
foreign materials present on the mounting surfaces of the wheel
or the surface of the front disc brake hub and rotor that contacts the
wheel. Installing wheels without correct metal-to-metal contact at the
wheel mounting surfaces can cause the wheel nuts to loosen and the
wheel to come off while the vehicle is in motion, resulting in loss of
control.
JUMP STARTING YOUR VEHICLE
The gases around the battery can explode if exposed to flames,
sparks, or lit cigarettes. An explosion could result in injury or
vehicle damage.
Batteries contain sulfuric acid which can burn skin, eyes and
clothing, if contacted.
Do not attempt to push-start your vehicle. Automatic
transmissions do not have push-start capability; doing so may
damage the catalytic converter.
Preparing your vehicle
When the battery is disconnected or a new battery is installed, the
transmission must relearn its shift strategy. As a result, the transmission
may have firm and/or soft shifts. This operation is considered normal and
will not affect function or durability of the transmission. Over time, the
adaptive learning process will fully update transmission operation.
1.Use only a 12–volt supply to start your vehicle.
2. Do not disconnect the battery of the disabled vehicle as this could
damage the vehicle’s electrical system.
3. Park the booster vehicle close to the hood of the disabled vehicle
making sure the two vehiclesdo nottouch. Set the parking brake on
both vehicles and stay clear of the engine cooling fan and other moving
parts.
4. Check all battery terminals and remove any excessive corrosion before
you attach the battery cables. Ensure that vent caps are tight and level.
5. Turn the heater fan on in both vehicles to protect any electrical
surges. Turn all other accessories off.
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WINDSHIELD WASHER FLUID
Add fluid to fill the reservoir if the
level is low. In very cold weather, do
not fill the reservoir completely.
Only use a washer fluid that meets
Ford specification WSB-M8B16–A2.
Refer toLubricant specifications
in this chapter.
State or local regulations on volatile organic compounds may restrict the
use of methanol, a common windshield washer antifreeze additive.
Washer fluids containing non-methanol antifreeze agents should be used
only if they provide cold weather protection without damaging the
vehicle’s paint finish, wiper blades or washer system.
If you operate your vehicle in temperatures below 4.5°C (40°
F), use washer fluid with antifreeze protection. Failure to use
washer fluid with antifreeze protection in cold weather could result in
impaired windshield vision and increase the risk of injury or accident.
Note:Do not put washer fluid in the engine coolant reservoir. Washer
fluid placed in the cooling system may harm engine and cooling system
components.
ENGINE OIL
Checking the engine oil
Refer to the scheduled maintenance guide for the appropriate intervals
for checking the engine oil.
1. Make sure the vehicle is on level ground.
2. Turn the engine off and wait a few minutes for the oil to drain into the
oil pan.
3. Set the parking brake and ensure the gearshift is securely latched in P
(Park) (automatic transmission) or 1 (First) (manual transmission).
4. Open the hood. Protect yourself from engine heat.
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When the engine is cold, check the
level of the engine coolant in the
reservoir.
•The engine coolant should be at the“cold fill level”or within the“cold
fill range”as listed on the engine coolant reservoir (depending upon
application).
•Refer to the Scheduled Maintenance Guide for service interval
schedules.
•Be sure to read and understandPrecautions when servicing your
vehiclein this chapter.
If the engine coolant has not been checked at the recommended interval,
the engine coolant reservoir may become low or empty. If the reservoir is
low or empty, add engine coolant to the reservoir. Refer toAdding
engine coolantin this chapter.
Note:Automotive fluids are not interchangeable; do not use engine
coolant, antifreeze or windshield washer fluid outside of its specified
function and vehicle location.
Adding engine coolant
When adding coolant, make sure it is a 50/50 mixture of engine coolant
and distilled water. Add the mixture to the coolant reservoir,when the
engine is cool, until the appropriate fill level is obtained.
Do not add engine coolant when the engine is hot. Steam and
scalding liquids released from a hot cooling system can burn you
badly. Also, you can be burned if you spill coolant on hot engine parts.
COLD FILL
RANGEMAX
MIN
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Do not put engine coolant in the windshield washer fluid
container. If sprayed on the windshield, engine coolant could
make it difficult to see through the windshield.
•Add Motorcraft Premium Gold Engine Coolant
(yellow-colored), VC-7–A (VC-7–B in Oregon), meeting Ford
Specification WSS-M97B51–A1.
Note:Use of Motorcraft Cooling System Stop Leak Pellets, VC-6, may
darken the color of Motorcraft Premium Gold Engine Coolant from
yellow to golden tan.
•Do not add/mix an orange-colored, extended life coolant such
as Motorcraft Speciality Orange Engine Coolant, VC-2 (US) or
CXC-209 (Canada), meeting Ford specification WSS-M97B44–D
with the factory-filled coolant.Mixing Motorcraft Speciality Orange
Engine Coolant or any orange-colored extended life product with your
factory filled coolant can result in degraded corrosion protection.
•A large amount of water without engine coolant may be added, in case
of emergency, to reach a vehicle service location. In this instance, the
cooling system must be drained and refilled with a 50/50 mixture of
engine coolant and distilled water as soon as possible. Water alone
(without engine coolant) can cause engine damage from corrosion,
overheating or freezing.
•Do not use alcohol, methanol, brine or any engine coolants
mixed with alcohol or methanol antifreeze (coolant).Alcohol
and other liquids can cause engine damage from overheating or
freezing.
•Do not add extra inhibitors or additives to the coolant.These
can be harmful and compromise the corrosion protection of the engine
coolant.
For vehicles with overflow coolant systems with a non-pressurized cap
on the coolant recovery system, add coolant to the coolant recovery
reservoir when the engine is cool. Add the proper mixture of coolant and
water to the“cold full”level. For all other vehicles, which have a coolant
degas system with a pressurized cap, or if it is necessary to remove the
coolant pressure relief cap on the radiator of a vehicle with an overflow
system, follow these steps to add engine coolant.
To reduce the risk of personal injury, make sure the engine is
cool before unscrewing the coolant pressure relief cap. The
cooling system is under pressure; steam and hot liquid can come out
forcefully when the cap is loosened slightly.
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1. Before you begin, turn the engine off and let it cool.
2. When the engine is cool, wrap a thick cloth around the coolant
pressure relief cap on the coolant reservoir (a translucent plastic bottle).
Slowly turn cap counterclockwise (left) until pressure begins to release.
3. Step back while the pressure releases.
4. When you are sure that all the pressure has been released, use the
cloth to turn it counterclockwise and remove the cap.
5. Fill the coolant reservoir slowly with the proper coolant mixture (see
above), to within the“cold fill range”or the“cold full”level on the
reservoir. If you removed the radiator cap in an overflow system, fill the
radiator until the coolant is visible and radiator is almost full.
6. Replace the cap. Turn until tightly installed. (Cap must be tightly
installed to prevent coolant loss.)
After any coolant has been added, check the coolant concentration, refer
toChecking Engine Coolantsection. If the concentration is not 50/50
(protection to–34°F/–36°C), drain some coolant and adjust the
concentration. It may take several drains and additions to obtain a 50/50
coolant concentration.
Whenever coolant has been added, the coolant level in the coolant
reservoir should be checked the next few times you drive the vehicle. If
necessary, add enough 50/50 concentration of engine coolant and
distilled water to bring the liquid level to the proper level.
If you have to add more than 1.0 liter (1.0 quart) of engine coolant per
month, have your dealer check the engine cooling system. Your cooling
system may have a leak. Operating an engine with a low level of coolant
can result in engine overheating and possible engine damage.
Recycled engine coolant
Ford Motor Company does NOT recommend the use of recycled engine
coolant in vehicles originally equipped with Motorcraft Premium Gold
Engine Coolant since a Ford-approved recycling process is not yet
available.
Used engine coolant should be disposed of in an appropriate
manner. Follow your community’s regulations and standards for recycling
and disposing of automotive fluids.
Coolant refill capacity
To find out how much fluid your vehicle’s cooling system can hold, refer
toRefill capacitiesin this chapter.
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Fill your engine coolant reservoir as outlined inAdding engine coolant
in this chapter.
Severe climates
If you drive in extremely cold climates (less than–36°C[–34°F]):
•It may be necessary to increase the coolant concentration
above 50%.
•NEVER increase the coolant concentration above 60%.
•Increased engine coolant concentrations above 60% will
decrease the overheat protection characteristics of the engine
coolant and may cause engine damage.
•Refer to the chart on the coolant container to ensure the
coolant concentration in your vehicle will provide adequate
freeze protection at the temperatures in which you drive in the
winter months.
If you drive in extremely hot climates:
•It is still necessary to maintain the coolant concentration
above 40%.
•NEVER decrease the coolant concentration below 40%.
•Decreased engine coolant concentrations below 40% will
decrease the corrosion protection characteristics of the engine
coolant and may cause engine damage.
•Decreased engine coolant concentrations below 40% will
decrease the freeze protection characteristics of the engine
coolant and may cause engine damage.
•Refer to the chart on the coolant container to ensure the
coolant concentration in your vehicle will provide adequate
protection at the temperatures in which you drive.
Vehicles driven year-round in non-extreme climates should use a 50/50
mixture of engine coolant and distilled water for optimum cooling system
and engine protection.
What you should know about fail-safe cooling (if equipped)
If the engine coolant supply is depleted, this feature allows the vehicle to
be driven temporarily before incremental component damage is incurred.
The“fail-safe”distance depends on ambient temperatures, vehicle load
and terrain.
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How fail-safe cooling works
If the engine begins to overheat:
•The engine coolant temperature
gauge will move to the red (hot)
area.
•The
andsymbol will
illuminate.
•TheService Engine Soon
indicator light will illuminate.
If the engine reaches a preset
over-temperature condition, the engine will automatically switch to
alternating cylinder operation. Each disabled cylinder acts as an air
pump and cools the engine.
When this occurs the vehicle will still operate. However:
•The engine power will be limited.
•The air conditioning system will be disabled.
Continued operation will increase the engine temperature and the engine
will completely shut down, causing steering and braking effort to
increase.
Once the engine temperature cools, the engine can be re-started. Take
your vehicle to a service facility as soon as possible to minimize engine
damage.
When fail-safe mode is activated
You have limited engine power when in the fail-safe mode, so drive the
vehicle with caution. The vehicle will not be able to maintain high-speed
operation and the engine will run rough. Remember that the engine is
capable of completely shutting down automatically to prevent engine
damage, therefore:
1. Pull off the road as soon as safely possible and turn off the engine.
2. Arrange for the vehicle to be taken to a service facility.
3. If this is not possible, wait a short period for the engine to cool.
4. Check the coolant level and replenish if low.
Never remove the coolant reservoir cap while the engine is
running or hot.
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