manual transmission FORD SUPER DUTY 2007 1.G Diesel Supplement Manual

California Proposition 65 Warning
WARNING:Engine exhaust, some of its constituents, and
certain vehicle components contain or emit chemicals known to
the State of California to cause cancer and birth defects or other
reproductive harm. Certain fluids contained in vehicles and certain
products of components contain or emit chemicals known to the State
of California to cause cancer and birth defects or other reproductive
harm.
Your new diesel engine will feel, drive and function somewhat differently
than a gasoline engine. Therefore it is very important that you read and
thoroughly familiarize yourself and others operating the vehicle with this
guide.
This guide will acquaint you with the 6.0L Power Stroke diesel engine. It
provides recommendations on engine care and operating procedures. For
complete vehicle information, also refer to theOwner’s Guideincluded
with the vehicle. It also describes equipment and gives specifications for
equipment that was in effect when this guide was approved for printing,
and should be considered a permanent part of the vehicle.
Some aftermarket products may cause severe engine and/or
transmission damage; refer to theWhat is not coveredsection in
The new vehicle limited warranty for your vehiclechapter of your
vehicle’sWarranty Guidefor more information. Your vehicle’s
Powertrain Control Systems can detect and store information
about vehicle modifications that increase horsepower and torque
output. This information cannot be erased and will stay in the
system’s memory even if the modification is removed. The
Information can be retrieved by Ford Motor Company, Ford of
Canada, and service and repair facilities when servicing your
vehicle. This information may be used to determine if repairs will
be covered by warranty.
Ford may discontinue models or change specifications without any notice
and without incurring obligations.
Important notice
Ford vehicles are suitable for producing ambulances only if equipped
with the Ford ambulance preparation package. In addition, Ford urges
ambulance manufacturers to follow the recommendation of theFord
Incomplete Vehicle Manual, Ford Truck Body Builder’s Layout Book
(and pertinent supplements) and theQualified Vehicle Modifiers
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Introduction
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Engine cooling system
The cooling system contains an engine oil cooler which is mounted in the
center valley of the engine. The cooler’s function is to regulate engine oil
temperature.
Engine governed speed
The engine governor is controlled by the PCM. The PCM controls fuel
input to limit maximum engine speed. It will not, however, prevent
engine overspeeding resulting from downshifting at high vehicle speed or
by descending steep grades at too high a vehicle speed for the selected
transmission gear.
On F-Super Duty vehicles equipped with a manual transmission,
refer toManual transmission shift speedsin theDrivingchapter of
yourOwner’s Guidefor maximum vehicle speed in various gears. Do not
exceed 3,600 rpm. Maximum engine governed speed is 4,000 rpm
depending on engine load. Excessive rpm can only be achieved by
manually downshifting at too high of a vehicle speed.
Operating the engine beyond the governed speed can cause
severe engine damage.
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Introduction
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STARTING THE ENGINE
Read all starting instructions carefully before you start your vehicle.
For temperatures below 32°F (0°C), the use of the correct grade engine
oil is essential for proper operation.
If your vehicle is equipped with a manual transmission,make sure
the parking brake is set fully before you turn the key. Depress the clutch
pedal and place the gearshift in the neutral position. The clutch must be
fully depressed in order to operate the starter. Do not press the
accelerator during starting.
If your vehicle is equipped with an automatic transmission,ensure
the gearshift lever is in P (Park) and the parking brake is set before you
turn the key. Do not press the accelerator during starting.
Cold weather starting
The engine block heater must be used for starting when the temperature
is -20°F (-29°C) or colder. Refer toUsing the engine block heater (if
equipped)in theDrivingchapter of theOwner’s Guide.
When operating in cold weather, use a minimum of 45 Cetane Diesel fuel
or use Cetane Index improvers from a reputable manufacturer.
Do not crank the engine for more than 30 seconds as starter damage
may occur. If the engine fails to start, turn the key to 3 (OFF) and wait
30 seconds before trying again.
Do not use starting fluid, such as ether, in the air intake system
(see air cleaner decal). Such fluid could cause immediate
explosive damage to the engine and possible personal injury.
Do not add gasoline, gasohol or alcohol to diesel fuel. This
practice creates a serious fire hazard and causes engine
performance problems.
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Driving
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The following cold weather idling guidelines must be followed:
•Avoid idling the engine for more than 10 minutes at a time.
•Use Motor Craft Cetane Index improvers of a non-alcohol based from a
reputable manufacturer.
•Maintain the engine cooling system properly.
•Do not shut the engine down after an extensive idling period (10
minutes or more). Drive the vehicle for several miles with the engine
at normal operating temperatures under a moderate load to burn off
any accumulated carbon and varnish.
•Consider using an engine block heater.
•For extended idle times use an approved idle speed increase device.
Winter operating tips for Arctic operation -20°F (-29°C) and below
The following information is provided as a guideline only, and is not
intended to be the only source of possible solutions in resolving extreme
cold temperature issues.
Starting Aids:
The use of the factory engine block heater (refer toUsing the engine
block heater (if equipped)in theDrivingchapter of theOwner’s
Guide) and oil pan heaters (aftermarket) will assist in engine starting, in
extreme cold ambient temperatures.
Do not use starting fluid, such as ether, in the air intake system
(see air cleaner decal). Such fluid could cause immediate
explosive damage to the engine and possible personal injury.
Idle control:
For periods of extended idle, the throttle should be set at an rpm, which
is sufficient to keep the engine at normal operating temperatures. This
action can reduce the amount of engine damaging deposits.
•The 6.0L diesel engine contains a unique
Cold Weather – Idle up
feature
calibration strategy within the Powertrain Control Module
(PCM). Under the appropriate conditions, the strategy will
automatically elevate the engine idle speed after 130 seconds of idling
in cold ambient temperatures. For this feature to be activated the
truck must be in P (Park) (for automatic transmission), in neutral (for
manual transmission) with the park brake applied and engine oil
temperature below 158°F (70°C). This strategy raises the rpm to a
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Driving
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Engine Rear axle
ratioMaximum GCWR -
lbs. (kg)Maximum
trailer weight -
lbs. (kg)
E-350 Cutaway 158” wheelbase, (dual rear wheel) (11500
GVWR)
6.0L 4.10 20000 (9072) 10000 (4536)
E-350 Cutaway 176” wheelbase, (dual rear wheel) (11500
GVWR)
6.0L 4.10 20000 (9072) 10000 (4536)
E-450 Cutaway 158” wheelbase (14050 GVWR)
6.0L 4.10 20000 (9072) 10000 (4536)
E-350 Cutaway 176” wheelbase (14050 GVWR)
6.0L 4.10 20000 (9072) 10000 (4536)
Trailer towing tables - F-Super Duty
Maximum GCWR - lbs (kg.)
Engine Rear axle
ratioManual
transmissionAutomatic
transmission
F–250/F–350 Single Rear Wheel (SRW)
6.0L 3.73 23000 (10433) 23000 (10433)
F–350 Dual Rear Wheel (DRW)
6 .0L 3.73 23500 (10659) 23500 (10659)
4.10 23500 (10659) 23500 (10659)
4.30 — 26000 (11793)
F–450
6.0L 4.30/4.88 26000 (11793) 26000 (11793)
6.0L* 4.88 28000 (12701) 30000 (13608)
F–550
6.0L 4.30/4.88 26000 (11793) 26000 (11793)
6.0L* 4.88 28000 (12701) 33000 (14969)
*With high capacity trailer tow package, see rear axle label to identify
actual vehicle content.
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Driving
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If you fuel your vehicle at a truck stop, you may notice that the fuel
nozzle may shut off every 5–10 seconds. This is due to the flow rates
being designed for larger heavy duty trucks. You may have to fuel at a
slower rate (don’t depress the nozzle trigger fully).
Do not run your diesel vehicle out of fuel as this will allow air to enter
the fuel system which will make restarting difficult. Longer engine
cranking time may be required once air is in the fuel system. If air enters
the fuel system (either through running the fuel tank(s) empty or during
a fuel filter change), the engine will self-purge the trapped air once it
starts running. The engine may run roughly and produce white smoke
while air is in the fuel system; this is normal and should stop after a
short time.
MINOR TROUBLESHOOTING GUIDE
If the engine won’t crank
Turn on the headlights. If the lights are dim, do not go on at all or when
the ignition is turned to 5 (START) the lights become dim or go out, the
battery connections may be loose or corroded, or the battery may be
discharged. If there is a clicking or stuttering sound coming from the
engine compartment when you turn the key to 5 (START), this may also
indicate a loose or corroded battery connection.
Check the battery connections at the battery posts, cable connection to
the engine grounding point and at the starter connection.
If a discharged battery is suspected, have it checked and corrected.
Battery posts, terminals and related accessories contain lead and
lead compounds.Wash hands after handling.
•For vehicles with manual transmissions,the clutch pedalmustbe
fully depressed in order for the starter to operate.
•For vehicles with automatic transmissions,the gearshift lever
must be in P (Park) or N (Neutral) in order for the starter to operate.
•Try operating the starter switch several times. Should the switch be
corroded, this operation may clean the contacts or make the switch
temporarily operable until you can reach the dealer.
•If all electrical connections are tight and you need assistance to start,
refer toJump startingin theRoadside Emergencieschapter of your
Owner’s Guide(F-Super Duty ) or refer to theJump starting
section in theRoadside Emergencieschapter of this supplement
(E-Series).
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Maintenance and Specifications
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MOTORCRAFT PART NUMBERS
Item Ford Part Number
Engine oil filter FL-2016
Air Filter – Super Duty
14C3Z-9601-AA
Air Filter – E-series1FA-1804
Fuel filter (2 required) FD-4604
Battery (2 Required) BXT-65-750
1Always use the authorized Motorcraft air filter listed.Failure to use
the correct air filter may result in severe engine damage.
REFILL CAPACITIES
Component Capacity
Cooling system127.5 quarts (26.0L)
Engine oil215.0 quarts (14.2L)
Fuel tankRefer to yourOwner’s
Guide
Radiator cap 16 psi (110 kPa)
Manual transmission
35.8 quarts (5.5L)
Automatic transmissionRefer to yourOwner’s
Guide
1Includes heater and 5.0 quarts (4.7L) in coolant recovery.
2Includes 1 quart (1.0L) in engine oil filter.
3Use Motorcraft MERCONATF, Motorcraft part number XT-2–QDX,
meeting Ford specification MERCON.
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Maintenance and Specifications
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LUBRICANT SPECIFICATIONS
ItemFord Part
NameFord Part
NumberFord
Specification
Engine OilMotorcraft
Motor Oil 15W40
Super Duty,
10W30 Super
Duty
1
XO-15W40-QSD,
XO-10W30-QSDWSS-M2C171-D
Engine coolant Motorcraft
Premium Gold
Engine Coolant
(yellow-colored)VC-7-B WSS-M97B51–A1
Manual
TransmissionMotorcraft
MERCONAT FXT-2–QDX MERCON
Automatic
transmissionRefer to Owner’s Guide
1Refer to the engine oil specification chart located underEngine oil
specificationsin this chapter.
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Maintenance and Specifications
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Multi-point Inspection
In order to keep your vehicle running right, it is important that you have
the systems on your vehicle checked regularly. This can help identify any
potential issue before there are any problems. Ford Motor Company
suggests the following multi-point inspection to be performed at every
scheduled maintenance interval as the way to ensure your vehicle keeps
running right.
NORMAL SCHEDULED MAINTENANCE AND LOG
The following section contains the “Normal Schedule.” This schedule is
presented at specific mileage intervals with exceptions noted.
Additional information available on the Web
To learn more about the importance of routine and dealer-performed
maintenance on your vehicle, please visit the Ford Customer Service
website. You’ll also find important warranty information, customer
assistance, technical expertise, frequently asked questions and much
more. The website location is at: www.ford.com/
Then go to the vehicles and service pick at the web site.
Multi-point inspection - recommended at every visit
❑Check and top up fluid levels:❑brake
❑coolant recovery reservoir
❑manual and automatic transmission
❑power steering
❑window washer
❑Inspect tires for wear and check air pressure, including spare.
❑Check exhaust system for leaks, damage, loose parts and foreign materials.
❑Check battery performance.
❑Check operation of horn, exterior lamps, turn signals and hazard warning lights.
❑Check radiator, coolers and heater and air conditioning hoses.
❑Inspect windshield washer spray and wiper operation.
❑Check windshield for cracks, chips and pitting.
❑Inspect for oil and fluid leaks.
❑Inspect air cleaner filter.
❑Check shocks and struts and other suspension components for leaks and damage.
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Scheduled Maintenance Guide
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52,500 miles (84,500 km)
❑Change engine oil and replace oil filter❑Perform multi-point inspection (recommended)❑Inspect tires for wear.❑Inspect air filter restriction gauge, replace filter as required
DEALERVALIDATION:
RO#: P&A C
ODE:
D
ATE:MILEAGE:
60,000 miles (96,500 km)
❑Change engine oil and replace oil filter❑Replace engine- and frame-mounted fuel filters❑Change automatic transmission fluid and external filter ele-
ment
❑Change manual transmission fluid❑Lubricate 4x2 front wheel bearings, adjust wheel bearings
and replace grease seals (if non-sealed bearings)
❑Perform multi-point inspection (recommended)❑Inspect tires for wear and rotate❑Inspect air filter restriction gauge, replace filter as required❑Inspect and lubricate steering linkage, ball joints, suspension,
driveshaft and u-joints
❑Inspect engine cooling system and hoses❑Inspect brake pads, shoes, rotors, drums, brake lines and
hoses and parking brake system.
❑Inspect exhaust system and heat shields❑Check wheels for end play and noise❑Inspect and lubricate 4x4 front axle u-joints
DEALERVALIDATION:
RO#: P&A C
ODE:
D
ATE:MILEAGE:
67,500 miles (108,000 km)
❑Change engine oil and replace oil filter❑Perform multi-point inspection (recommended)❑Inspect tires for wear.❑Inspect air filter restriction gauge, replace filter as required
DEALERVALIDATION:
RO#: P&A C
ODE:
D
ATE:MILEAGE:
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