brake FORD SUPER DUTY 2010 2.G Workshop 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.
VEHICLE USED AS A STATIONARY POWER SOURCE
Auxiliary equipment called power take-off, or PTO, is often added to the
engine or transmission to operate utility equipment. Examples include a
wheel-lift for tow trucks, cranes, tools for construction or tire service,
and pumping fluids. 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. The aftermarket
PTO system installer, having the most knowledge of the final application,
is responsible for determining whether additional chassis heat protection
or powertrain cooling is required, and alerting the user to the safe and
proper operation.
Ford Super Duty Vehicles are qualified for use as a stationary power
source, within limits detailed in theFord Truck Body Builders Layout
Book,found at www.fleet.ford.com/truckbbas, and through the Ford
Truck Body Builders Advisory Service.
Gas engine vehicles are qualified for up to 10 minutes of continuous
operation as a stationary power source, due to the potential for the
normal venting of fuel vapors. For stationary PTO operation of extended
duration (beyond 10 minutes), diesel engine is recommended. Further
consult your aftermarket PTO installer, since the duration of operation
limit for the aftermarket PTO may be less than the vehicle is capable of.
DRIVING THROUGH WATER
If driving through deep or standing
water is unavoidable, proceed very
slowly especially when the depth is
not known. Never drive through
water that is higher than the bottom
of the wheel rims (for cars) or the
bottom of the hubs (for trucks).
When driving through water, traction or brake capability may be limited.
Also, water may enter your engine’s air intake and severely damage your
engine or your vehicle may stall.Driving through deep water where
Driving
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the transmission vent tube is submerged may allow water into the
transmission and cause internal transmission damage.
Once through the water, always dry the brakes by moving your
vehicle slowly while applying light pressure on the brake pedal.
Wet brakes do not stop the vehicle as quickly as dry brakes.
SNOWPLOWING
Ford recommends that the Super Duty F-Series used for snow removal
include the Snow Plow Package Option.
Installing the snowplow
Weight limits and guidelines for selecting and installing the snowplow can
be found in theFord Truck Body Builders Layout Book,Snowplow
section, found at www.fleet.ford.com/truckbbas. A typical installation
affects the following:
•Certification to government safety laws such as occupant protection
and airbag deployment, braking, and lighting. Look for an “Alterer’s
Label” on the vehicle from the snowplow installer certifying that the
installation meets all applicable Federal Motor Vehicle Safety
Standards (FMVSS).
•The Total Accessory Reserve Capacity (TARC) is shown on the lower
right side of the vehicle’s Safety Compliance Certification Label. This
applies to Ford-completed vehicles of 10,000 lb. (4,536 kg) GVWR or
less. This is the weight of permanently-attached auxiliary equipment,
such as snowplow frame-mounting hardware, that can be added to the
vehicle and satisfy Ford compliance certification to FMVSS. Exceeding
this weight may require the auxiliary equipment installer additional
safety certification responsibility. The Front Accessory Reserve
Capacity (FARC) is added for customer convenience.
•Rear ballast weight behind the rear axle may be required to prevent
exceeding the FGAWR, and provide front-to-rear weight balance for
proper braking and steering.
•Front wheel toe may require re-adjustment to prevent premature
uneven tire wear. Specifications are found in the FordWorkshop
Manual.
•Headlight aim may require re-adjustment.
Driving
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The fuses are coded as follows.
Fuse/Relay
LocationFuse Amp
RatingProtected Circuits
1 30A Not used (spare)
2 15A Not used (spare)
3 15A Family entertainment system (FES)
4 30A Not used (spare)
5 10A Keypad illumination, Brake-shift
interlock (BSI), SPBJB
6 20A Turn signals
7 10A Left headlamp (Low beam)
8 10A Right headlamp (Low beam)
9 15A Interior lighting, Lighted running
boards
10 15A Cargo lamp, Puddle lamp, Switch
backlight
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Fuse/Relay
LocationFuse Amp
RatingProtected Circuits
33 10A Trailer tow brake controller, Trailer
tow battery charge relay coil
34 5A Not used (spare)
35 10A Reverse sensing system (RSS), 4x4
module, 4x4 solenoid, Traction
control switch, Tow/Haul switch
(Diesel engine)
36 5A Passive anti-theft system (PATS)
transceiver, Cluster control
37 10A Climate control, PTC control
38 20A Subwoofer
39 20A Radio, Navigation radio and amplifier
40 20A 4x4 module, Satellite radio module,
SYNC
, GPS
41 15A Radio, Auto dimming rear view
mirror, Lock switch illumination
42 10A Heated seat relay coil, Upfitter switch
relay coils, Heated mirror relay coil
43 10A Fuel tank selector switch, 4x4 module
44 10A Run customer access feed (PTO)
45 5A Front wiper logic, Blower motor relay
coil
46 7.5A Not used (spare)
47 30A Circuit
BreakerPower windows, Moon roof, Power
rear sliding window
48 Relay Delayed accessory
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Power distribution box
The power distribution box is located in the engine compartment. The
power distribution box contains high-current fuses that protect your
vehicle’s main electrical systems from overloads.
WARNING:Always disconnect the battery before servicing high
current fuses.
WARNING:To reduce risk of electrical shock, always replace
the cover to the Power Distribution Box before reconnecting the
battery or refilling fluid reservoirs.
If the battery has been disconnected and reconnected, refer to the
Batterysection of theMaintenance and Specificationschapter.
The high-current fuses are coded as follows:
Fuse/Relay
LocationFuse Amp
RatingProtected Circuits
1 Relay Blower motor/Variable blower control
(Dual zone climate control)
2 Relay Electronic shift-on-the-fly (ESOF)
Lo-Hi
3 Relay Heater mirror
4 — Not used
5 30A* Trailer brake controller (TBC)
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Fuse/Relay
LocationFuse Amp
RatingProtected Circuits
6 40A* Anti-lock brake system (ABS) module
(Pump)
7 30A* Upfitter auxiliary switch #1
8 30A* Upfitter auxiliary switch #2
9 40A* ABS module (Coil)
10 20A* Instrument panel power point/cigar
lighter
11 20A* Instrument panel power point
12 15A** Brake on/off (BOO) relay feed
13 5A** Brake switch, Brake switch relay coil,
SJB module, 4x4 module
14 — Not used
15 — Not used
16 Relay A/C clutch
17 Relay Wipers
18 Relay Fuel pump driver module (FPDM),
Fuel injectors (Gasoline engines),
Diesel fuel control module (DFCM)
(Diesel engine)
19 Relay Back-up lamps, Reverse sensing
system (RSS), Engine compartment
fuse 63
20 Relay Trailer stop/turn (Left)
21 Relay Trailer stop/turn (Right)
22 Relay Stop lamps, Center high-mounted
stop lamp (CHMSL), TBC, Customer
access
23 15A** Heater mirror, Heated spotted mirror
24 40A* Blower motor relay
25 — Not used
26 30A* ESOF relay lo-hi
27 50A* Glow plug control module (GPCM) #1
(Diesel engine only)
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Fuse/Relay
LocationFuse Amp
RatingProtected Circuits
74 20A**Gasoline engines:Vehicle power
(VPWR): Heated exhaust gas oxygen
sensor, CMS, Mass air flow sensor,
Electronic vapor management valve,
CMCV, Variable cam timing, IMTV
Diesel engine:VPWR: Engine loads
75 5A** Back-up relay coil power
76 20A**Gasoline engines:VPWR: PCM
Diesel engine:VPWR: ECM
77 10A** ABS module logic
* Cartridge fuses ** Mini fuses
CHANGING A FLAT TIRE
If you get a flat tire while driving:
•do not brake heavily.
•gradually decrease the vehicle’s speed.
•hold the steering wheel firmly.
•slowly move to a safe place on the side of the road.
Your vehicle may be equipped with a conventional spare tire that is
different in one or more of the following: type, brand, size, speed rating
and tread design. If this is the case, this dissimilar spare tire is still rated
for your vehicle loads (GAWR and GVWR).Temporary spare tires are not
equipped with Tire Pressure Monitor System (TPMS) sensors if the
system is present.
WARNING:The use of tire sealant may damage your Tire
Pressure Monitoring System (if equipped) and should not be
used.
WARNING:If your vehicle is equipped with a Tire Pressure
Monitoring System, refer toTire Pressure Monitoring System
(TPMS)in theTires, Wheels and Loadingchapter for more
information. If the tire pressure monitor sensor becomes damaged, it
will no longer function.
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Stopping and securing the vehicle
WARNING:To help prevent the vehicle from moving when you
change a tire, be sure the parking brake is set, then block (in
both directions) the wheel that is diagonally opposite to the tire being
changed.
Refer to the instruction sheet (located in the glove box) for detailed tire
change instructions.
Park on a level surface, activate
hazard flashers and set the parking
brake.
•Automatic transmission: Place
gearshift lever in P (Park).
•Manual transmission: Place
gearshift lever in R (Reverse).
•Electronic Shift-On-the-Fly
(ESOF) 4x4: Place transfer case
in 4x4 HIGH or 4x4 LOW before
turning off the engine.
•Manual shift transfer case 4x4: Place transfer case in 4H or 4L.
Location of the spare tire and tools
If your vehicle is equipped with a spare tire, jack and associated tools,
refer to the following table for their locations:
Tool Location
Spare tire (pick-up trucks only) Under the vehicle, just forward of
the rear bumper
Jack Regular cab and Crew Cab:
Fastened to floor pan behind
rearmost seat on passenger side
SuperCab: Under rear bench seat
on passenger side
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2. Attach the spare tire lock key (A)
to the jack handle (B).
3. Fully insert the jack handle (with
one extension) through the bumper
hole and into the guide tube. The
key and lock will engage with a
slight push and counterclockwise
turn. Some resistance will be felt
when turning the jack handle
assembly.
4. Turn the handle counterclockwise
and lower the spare tire until you
can slide the tire rearward and the
cable is slack.
5. Remove the retainer through the center of the wheel.
Tire change procedure
WARNING:When one of the rear wheels is off the ground, the
transmission alone will not prevent the vehicle from moving or
slipping off the jack, even if the transmission is in P (Park) (automatic
transmission) or R (Reverse) (manual transmission). To help prevent
the vehicle from moving when you change the tire, be sure that the
parking brake is set and the diagonally opposite wheel is blocked.
WARNING:To prevent the vehicle from moving when you
change a tire, be sure the parking brake is set, then block (in
both directions) the wheel that is diagonally opposite (other side and
end of the vehicle) to the tire being changed.
WARNING:If the vehicle slips off the jack, you or someone else
could be seriously injured.
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5. Repeat this tightness check procedure when servicing the spare tire
pressure (every six months, perscheduled maintenance information),
or at any time that the spare tire is disturbed through service of other
components.
6. If removed, install the spare tire lock (if equipped) into the bumper
drive tube with the spare tire lock key (if equipped) and jack handle.
WHEEL LUG NUT TORQUE SPECIFICATIONS
On vehicles equipped with single rear wheels, retighten the lug nuts to
the specified torque at 500 miles (800 km) after any wheel disturbance
(tire rotation, changing a flat tire, wheel removal, etc.).
On vehicles equipped with dual rear wheels, retighten the wheel lug nuts
to the specified torque at 100 miles (160 km), and again at 500 miles
(800 km) of new vehicle operation and after any wheel disturbance (tire
rotation, changing a flat tire, wheel removal, etc.).
Bolt size Wheel lug nut torque*
lb.ft. N•m
M14 x 1.5 165 224
* Torque specifications are for nut and bolt threads free of dirt and
rust. Use only Ford recommended replacement fasteners.
It is important to follow the proper wheel mounting and lug nut torque
procedures.
On all two-piece flat wheel nuts,
apply one drop of motor oil between
the flat washer and the nut.
WARNING: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 wheel hub, brake drum or
brake disc that contacts the wheel. Ensure that any fasteners that
attach the rotor to the hub are secured so they do not interfere with
the mounting surfaces of 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.
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