transmission FORD SUPER DUTY 2009 2.G Workshop Manual

CLUTCH FLUID (IF EQUIPPED)
Check the fluid level. Refer toscheduled maintenance informationfor
the service interval schedules.
During normal operation, the fluid level in the clutch reservoir should
remain constant. If the fluid level drops, refill the fluid level to the step
in the reservoir.
Use only a DOT 3 brake fluid designed to meet Ford specifications. Refer
toMaintenance product specifications and capacitiesin this chapter.
WARNING:Carefully read cautionary information on product
label. For MEDICAL EMERGENCY INFORMATION contact a
physician or Poison Control Center immediately; on Ford-Motorcraft
products call: 1-800-959-3673 (FORD). Failure to follow these
instructions may result in personal injury.
1. Clean the reservoir cap before
removal to prevent dirt and water
from entering the reservoir.
2. Remove cap and rubber
diaphragm from reservoir.
3. Add fluid until the level reaches
the step in the reservoir.
4. Reinstall rubber diaphragm and
cap onto reservoir.
TRANSMISSION FLUID
Checking automatic transmission fluid (if equipped)
Refer to yourscheduled maintenance informationfor 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 20 miles [30 km]). 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.
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1. Drive the vehicle 20 miles (30 km) 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 50°F (10°C).
Correct fluid level
The transmission fluid should be checked at normal operating
temperature 150°F-170°F (66°C-77°C) on a level surface. The normal
operating temperature can be reached after approximately 20 miles
(30 km) of driving.
You can check the fluid without driving if the ambient temperature is
above 50°F (10°C). However, if fluid is added at this time, an overfill
condition could result when the vehicle reaches normal operating
temperature.
The transmission fluid should be in
this range if at normal operating
temperature (150°F-170°F
[66°C-77°C]).
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The transmission fluid should be in
this range if at ambient temperature
(50°F-95°F [10°C-35°C]).
High fluid level
Fluid levels above the safe range
may result in transmission failure.
An overfill condition of transmission
fluid may cause shift and/or
engagement concerns and/or possible damage.
High fluid levels can be caused by an overheating condition.
Adjusting automatic transmission fluid levels
Before adding any fluid, make sure the correct type is used. The type of
fluid used is normally indicated on the dipstick handle and also in the
Maintenance Product Specifications and Capacitiessection in this
chapter.
Use of a non-approved automatic transmission fluid may cause
internal transmission component damage.
If necessary, add fluid in 1/2 pint (250 ml) increments through the filler
tube until the level is correct.
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.
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Checking and adding manual transmission fluid (if equipped)
1. Clean the filler plug.
2. Remove the filler plug and
inspect the fluid level.
3. Fluid level should be at the
bottom of the opening.
4. Add enough fluid through the
filler opening so that the fluid level
is at the bottom of the opening.
5. Install and tighten the fill plug
securely.
Use only fluid that meets Ford specifications. Refer toMaintenance
Product Specifications and Capacitiesin this chapter.
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MOTORCRAFT PART NUMBERS
Component 5.4L V8/6.8L V10 engines
Air filter element FA-1883
Fuel filter FG-1083
Oil filter FL-820-S
PCV valve
1
Battery (Standard) BXT-65-650
Battery (Optional) BXT-65-750
Spark plugs-platinum
2
Remote Automatic Transmission Filter3, 4
1
The PCV valve is a critical emission component. It is one of the items
listed in thescheduled maintenance informationand is essential to
the life and performance of your vehicle and to its emissions system.
For PCV valve replacement, see your authorized dealer. Refer to the
scheduled maintenance informationfor the appropriate intervals for
changing the PCV valve.
Replace the PCV valve with one that meets Ford material and
design specifications for your vehicle, such as a Motorcraft or
equivalent replacement part. The customer warranty may be void
for any damage to the emissions system if such a PCV valve is not
used.
2For spark plug replacement, see your authorized dealer. Refer to the
scheduled maintenance informationfor the appropriate intervals for
changing the spark plugs.
Replace the spark plugs with ones that meet Ford material and
design specifications for your vehicle, such as Motorcraft or
equivalent replacement parts. The customer warranty may be
void for any damage to the engine if such spark plugs are not
used.
3Also available with 6.4L diesel engine and TorqShift transmission. Part
number is FT-176.
4Also available with 6.4L diesel engine and TorqShift transmission. Part
number is FT-175.
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Item Capacity Ford part nameFord part number /
Ford specification
Hinges, latches, striker
plates, fuel filler door
hinge and seat tracks— Multi-Purpose GreaseXG–4 or XL-5 /
ESB-M1C93–B
Lock cylinders —Motorcraft Penetrating
and Lock LubricantXL-1 / None
Transmission / parking
brake linkages and
pivots, brake and clutch
pedal shaft (if
equipped)—Motorcraft Premium
Long-Life GreaseXG-1-C or XG-1-K /
WSD-M1C227-A
Power steering fluidKeep fluid level
between MIN and
MAX on reservoirMERCON
V
Automatic Transmission
FluidXT-5-QM /
MERCON
V
Transfer case fluid 2.0 quarts (1.9L)Motorcraft Transfer Case
FluidXL-12 / —
Manual transmission
fluid (M60D)5.8 quarts (5.5L)
4
Motorcraft Full Synthetic
Manual Transmission
FluidXT-M5-QS /
WSS-M2C200–C
Automatic transmission
fluid (5R110)
3
17.5 quarts
(16.6L)
5(includes
remote filter
element change)Motorcraft
MERCON
LV AT FXT-10–QLV /
MERCON
LV
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Item Capacity Ford part nameFord part number /
Ford specification
Windshield washer fluid 3.5 quarts (3.3L)Motorcraft Premium
Windshield Washer
ConcentrateZC-32–A /
WSB-M8B16–A2
1Add 8 oz. (236 ml) of Additive Friction Modifier XL-3 or equivalent meeting Ford Specification
EST-M2C118–A for complete refill of limited slip Ford axles. Ford design rear axles contain a
synthetic lubricant that does not require changing unless the axle has been submerged in water.2Add the coolant type originally equipped in your vehicle.3Ensure the correct automatic transmission fluid is used. Transmission fluid requirements are
indicated on the dipstick blade or the dipstick handle. Check the container to verify the fluid being
added is of the correct type. Refer to yourscheduled maintenance informationto determine the
correct service interval.
Automatic transmissions that require MERCON
LV should only use MERCON
LV fluid.
Use of any fluid other than the recommended fluid may cause transmission damage.4Service 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 ensure correct fluid level.5Indicates 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.6Use of synthetic or synthetic blend motor oil is not mandatory. Engine oil need only meet the
requirements of Ford specification WSS-M2C930-A and the API Certification mark.
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The Vehicle Identification Number (VIN) contains the following
information:
1. World manufacturer identifier
2. Brake system / Gross Vehicle
Weight Rating (GVWR) / Restraint
System
3. Vehicle line, series, body type
4. Engine type
5. Check digit
6. Model year
7. Assembly plant
8. Production sequence number
TRANSMISSION CODE DESIGNATIONS
You can find a transmission code on
the Safety Compliance Certification
Label. The following table tells you
which transmission each code
represents.
Code Description
5 Six-speed manual, Dana (ZF S6–650)
7 Six-speed manual, Dana (Z/F M6HD-W)
T Five-speed automatic, TorqShift (gas engines)
B Five-speed automatic, TorqShift (diesel engine)
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A
Accessory delay ........................110
Air cleaner filter ...............401, 403
Air conditioning ..........................84
Airbag supplemental restraint
system ........................................190
and child safety seats ............192
description ..............................190
disposal ....................................195
driver airbag ............................193
indicator light .........................194
operation .................................193
passenger airbag .....................193
passenger deactivation
switch ......................................195
Ambulance packages ..................10
Antifreeze (see Engine
coolant) .....................................377
Anti-lock brake system
(see Brakes) ......................277–278
Anti-theft system ..............165, 168
arming the system ..........166, 168
disarming a triggered
system .....................................168
triggering .................................168
Audio system
(see Radio) ......................26, 28, 35
Automatic transmission ............282
driving an automatic
overdrive .................................284
fluid, adding ............................396
fluid, checking ........................396
fluid, refill capacities ..............404
Auxiliary Input Jack ...................42
Auxiliary power point ...............107
Axle
refill capacities ........................404B
Battery .......................................375
acid, treating emergencies .....375
jumping a disabled battery ....342
maintenance-free ....................375
replacement, specifications ...403
servicing ..................................375
Belt-Minder
.............................186
Booster seats .............................218
Brakes ........................................277
anti-lock ...........................277–278
anti-lock brake system (ABS)
warning light ...........................278
fluid, checking and adding ....395
fluid, refill capacities ..............404
parking ....................................278
shift interlock ..........................282
trailer .......................................264
Bulbs ............................................95
C
Capacities for refilling fluids ....404
Cassette tape player ...................26
Cell phone use ..............................9
Child safety seats ......................204
attaching with tether straps ..212
in front seat ....................204, 208
in rear seat ..............204, 208, 212
LATCH .....................................212
Child safety seats - booster
seats ...........................................218
Cleaning your vehicle
engine compartment ..............359
instrument panel ............361–362
interior .....................................363
plastic parts ............................360
safety belts ..............................363
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washing ....................................357
waxing .....................................358
wheels ......................................358
wiper blades ............................360
Climate control (see Air
conditioning or Heating) ......80, 84
Clock adjust
6-CD in dash .............................37
AM/FM/CD .................................30
Clutch
fluid ..........................................396
operation while driving ..........287
recommended shift speeds ....288
Compass, electronic
set zone adjustment ...............141
Console ......................................106
overhead ..................................105
Controls
power seat ...............................172
steering column ......................118
Coolant
checking and adding ..............377
refill capacities ................381, 404
Cruise control (see Speed
control) ......................................116
Customer Assistance ................313
Ford accessories for your
vehicle .....................................365
Ford Extended Service
Plan ..........................................353
Getting assistance outside the
U.S. and Canada .....................354
Getting roadside assistance ...313
Getting the service you
need .........................................349
Ordering additional owner’s
literature .................................355Utilizing the
Mediation/Arbitration
Program ...................................353
D
Daytime running lamps
(see Lamps) ................................90
Dipstick
automatic transmission
fluid ..........................................396
engine oil .................................372
Driving under special
conditions ..................286, 303, 306
sand .........................................305
snow and ice ...........................307
through water .................306, 309
DVD system .................................51
E
Electronic message
center .................................127, 136
Emergencies, roadside
jump-starting ..........................342
Emergency Flashers .................314
Emission control system ..........391
Engine ........................................408
cleaning ...................................359
coolant .....................................377
diesel .........................................10
fail-safe cooling .......................382
idle speed control ...................375
refill capacities ........................404
service points ..................369–370
starting after a collision .........315
Engine oil ..................................372
checking and adding ..............372
dipstick ....................................372
filter, specifications ........374, 403
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