engine FORD SUPER DUTY 2010 2.G Workshop Manual

•Heavy or uneven efforts may be caused by low power steering fluid.
Check for low power steering pump fluid level before seeking service
by your dealer.
•Do not fill the power steering pump reservoir above the MAX mark on
the reservoir, as this may result in leaks from the reservoir.
If the power steering system breaks down (or if the engine is turned
off), you can steer the vehicle manually, but it takes more effort.
If the steering wanders or pulls, check for:
•an improperly inflated tire
•uneven tire wear
•loose or worn suspension components
•loose or worn steering components
•improper steering alignment
If any steering components are serviced or replaced, install new
fasteners (many are coated with thread adhesive or have prevailing
torque features which may not be re-used). Never re-use a bolt or nut.
Torque fasteners to specifications inWorkshop Manual.
A high crown in the road or high crosswinds may also make the steering
seem to wander/pull.
LIMITED-SLIP AXLE (IF EQUIPPED)
This axle provides added traction on slippery surfaces, particularly when
one wheel is on a poor traction surface. Under normal conditions, the
Limited-slip axle functions like a standard rear axle. The axle may
exhibit a slight noise or vibration in tight turns with low vehicle speed.
This is normal behavior and indicates the axle is working.
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AUTOMATIC TRANSMISSION OPERATION (IF EQUIPPED)
Understanding the shift positions of the 5–speed automatic
transmission
This vehicle is equipped with an adaptive Transmission Shift Strategy.
Adaptive Shift Strategy offers the optimal transmission operation and
shift quality. When the vehicle’s battery has been disconnected for any
type of service or repair, the transmission will need to relearn the normal
shift strategy parameters, much like having to reset your radio stations
when your vehicle battery has been disconnected. The Adaptive
Transmission Strategy allows the transmission to relearn these operating
parameters. This learning process could take several transmission
upshifts and downshifts; during this learning process, slightly firmer
shifts may occur. After this learning process, normal shift feel and shift
scheduling will resume.
P (Park)
This position locks the transmission and prevents the rear wheels from
turning.
To put your vehicle in gear:
•Start the engine
•Press the brake pedal
•Move the gearshift lever into the desired gear
To put your vehicle in P (Park):
•Come to a complete stop
•Move the gearshift lever and securely latch it in P (Park)
WARNING:Always set the parking brake fully and make sure
the gearshift is latched in P (Park). Turn the ignition to the off
position and remove the key whenever you leave your vehicle.
R (Reverse)
With the gearshift lever in R (Reverse), the vehicle will move backward.
Always come to a complete stop before shifting into and out of R
(Reverse).
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N (Neutral)
With the gearshift lever in N (Neutral), the vehicle can be started and is
free to roll. Hold the brake pedal down while in this position.
D (Overdrive) with Tow/Haul OFF
D (Overdrive) with Tow/Haul OFF is the normal driving position for the
best fuel economy. The overdrive function allows automatic upshifts and
downshifts through gears one through five.
D (Overdrive) with Tow/Haul ON
The Tow/Haul feature improves transmission operation when towing a
trailer or a heavy load. All transmission gear ranges are available when
using Tow/Haul.
To activate Tow/Haul, press the
button on the end of the gearshift
lever.
The TOW HAUL indicator light will
illuminate in the instrument cluster.
Tow/Haul delays upshifts to reduce frequency of transmission shifting.
Tow/Haul also provides engine braking in all forward gears when the
transmission is in the D (Overdrive) position; this engine braking will
slow the vehicle and assist the driver in controlling the vehicle when
descending a grade. Depending on driving conditions and load
conditions, the transmission may downshift, slow the vehicle and control
the vehicle speed when descending a hill, without the accelerator pedal
being pressed. The amount of downshift braking provided will vary based
upon the amount the brake pedal is depressed.
To deactivate the Tow/Haul feature and return to normal driving mode,
press the button on the end of the gearshift lever. The TOW HAUL light
will no longer be illuminated.
When you shut-off and restart the engine, the transmission will
automatically return to normal D (Overdrive) mode (Tow/Haul OFF).
WARNING:Do not use the Tow/Haul feature when driving in icy
or slippery conditions as the increased engine braking can cause
the rear wheels to slide and the vehicle to swing around with the
possible loss of vehicle control.
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3 (Third)
Transmission starts and operates in third gear only.
Used for improved traction on slippery roads. Selecting 3 (Third)
provides engine braking.
2 (Second)
Use 2 (Second) to start-up on slippery roads or to provide additional
engine braking on downgrades.
1 (First)
•Provides maximum engine braking.
•Allows upshifts by moving gearshift lever.
•The transmission will not downshift into 1 (First) at high speeds; it
will downshift to a lower gear and then shift into 1 (First) when the
vehicle reaches slower speeds.
Forced downshifts
•Allowed in D (Overdrive) or D (Drive).
•Press the accelerator to the floor.
•Allows transmission to select an appropriate gear.
If your vehicle gets stuck in mud or snow
If your vehicle gets stuck in mud or snow, it may be rocked out by
shifting between forward and reverse gears, stopping between shifts in a
steady pattern. Press lightly on the accelerator in each gear.
Do not rock the vehicle if the engine is not at normal operating
temperature or damage to the transmission may occur.
Do not rock the vehicle for more than a minute or damage to the
transmission and tires may occur, or the engine may overheat.
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MANUAL TRANSMISSION OPERATION (IF EQUIPPED)
Using the clutch
Manual transmission vehicles have a starter interlock that prevents
cranking the engine unless the clutch pedal is fully pressed.
To start the vehicle:
1. Make sure the parking brake is fully set.
2. Press the clutch pedal to the floor, then put the gearshift lever in the
neutral position.
3. Start the engine.
4. Press the brake pedal and move the gearshift lever to the desired
gear; 1 (First) or R (Reverse).
5. Release the parking brake, then slowly release the clutch pedal while
slowly pressing on the accelerator.
During each shift, the clutch pedal must be fully pressed to the floor.
Make sure the floor mat is properly positioned so it doesn’t interfere with
the full extension of the clutch pedal.
Failure to fully press the clutch pedal to the floor may cause
increased shift efforts, prematurely wear transmission
components or damage the transmission.
Do not drive with your foot resting on the clutch pedal or use the
clutch pedal to hold your vehicle at a standstill while waiting on a
hill. These actions will severely reduce the life of the clutch and
could nullify a clutch warranty claim.
Recommended shift speeds
Do not overspeed the engine when going downhill or steep grades. If
equipped, use the tachometer and do not allow engine speed to exceed
the redline area. Operating the engine beyond the recommended speeds
can cause severe engine damage.
1
24 R
L3D
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4WD system indicator lights
The 4WD system indicator lights illuminate only under the following
conditions. If these lights illuminate when driving in 2WD, contact your
authorized dealer as soon as possible.
•4x4 HIGH- momentarily
illuminates after the engine is
started. Illuminates when 4H (4x4
High) is engaged. Flashes when
shifting into or out of 4H (4x4 high) (ESOF systems only).
•4x4 LOW– momentarily
illuminates when the ignition is
turned to the ON position.
Illuminates when 4L (4x4 Low) is
engaged. Flashes when shifting into or out of 4L (4x4 Low) or if the
range shift conditions are not met (ESOF systems only).
Using a Manual Shift On Stop (MSOS) 4x4 system (if equipped)
Note: High shift efforts may be encountered when attempting to
shift into and out of 4x4 modes. It is recommended to allow the
vehicle to roll at a speed below 5 mph (8 km/h) when shifting.
Note:Some noise may be heard as the 4x4 system shifts or engages.
This is normal. In order to reduce engagement noise, it is recommended
that all shifts be performed at speeds below 5 mph (8 km/h).
2H (2WD)– For general on-road driving. Sends power to the rear
wheels only.
4H (4x4 High)– For winter and off-road conditions. Sends power to
front and rear wheels.This mode is not intended for use on dry
pavement.
N (Neutral)– Only used when towing the vehicle.
4L (4x4 Low)– For low-speed off-road applications that require extra
power such as steep grades, deep sand or pulling a boat out of the water.
Sends power to front and rear wheels.This mode is not intended for
use on dry pavement.
4x4
HIGH
4x4
LOW
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Basic operating principles
•Do not use 4WD on dry, hard surfaced roads. Doing so will produce
excessive noise, increase tire wear and may damage drive components.
4WD modes are only intended for consistently slippery or loose
surfaces.
•Drive slower in strong crosswinds which can affect the normal steering
characteristics of your vehicle.
•Be extremely careful when driving on pavement made slippery by
loose sand, water, gravel, snow or ice.
If your vehicle goes off the edge of the pavement
•If your vehicle goes off the edge of the pavement, slow down, but
avoid severe brake application, ease the vehicle back onto the
pavement only after reducing your speed. Do not turn the steering
wheel too sharply while returning to the road surface.
•It may be safer to stay on the apron or shoulder of the road and slow
down gradually before returning to the pavement. You may lose
control if you do not slow down or if you turn the steering wheel too
sharply or abruptly.
•It often may be less risky to strike small objects, such as highway
reflectors, with minor damage to your vehicle rather than attempt a
sudden return to the pavement which could cause the vehicle to slide
sideways out of control or roll over. Remember, your safety and the
safety of others should be your primary concern.
WARNING:Vehicles with a higher center of gravity such as
utility and four-wheel drive vehicles handle differently than
vehicles with a lower center of gravity. Utility and four-wheel drive
vehicles arenotdesigned for cornering at speeds as high as passenger
cars any more than low-slung sports cars are designed to perform
satisfactorily under off-road conditions. Avoid sharp turns, excessive
speed and abrupt maneuvers in these vehicles. Failure to drive
cautiously could result in an increased risk of loss of vehicle control,
vehicle rollover, personal injury and death.
If your vehicle gets stuck
If your vehicle gets stuck in mud or snow it may be rocked out by
shifting between forward and reverse gears, stopping between shifts, in a
steady pattern. Press lightly on the accelerator in each gear.
Do not rock the vehicle if the engine is not at normal operating
temperature or damage to the transmission may occur.
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Do not rock the vehicle for more than a few minutes or damage to
the transmission and tires may occur or the engine may overheat.
WARNING:Do not spin the wheels at over 35 mph (56 km/h).
The tires may fail and injure a passenger or bystander.
Refer toTransmission fluid temperature gaugein theInstrument
Clusterchapter for transmission fluid temperature information.
Emergency maneuvers
•In an unavoidable emergency situation where a sudden sharp turn
must be made, remember to avoid “over-driving” your vehicle, i.e.,
turn the steering wheel only as rapidly and as far as required to avoid
the emergency. Excessive steering will result in less vehicle control,
not more. Additionally, smooth variations of the accelerator and/or
brake pedal pressure should be utilized if changes in vehicle speed are
called for. Avoid abrupt steering, acceleration or braking which could
result in an increased risk of loss of vehicle control, vehicle rollover
and/or personal injury. Use all available road surface to return the
vehicle to a safe direction of travel.
•In the event of an emergency stop, avoid skidding the tires and do not
attempt any sharp steering wheel movements.
WARNING:Vehicles with a higher center of gravity such as
utility and four-wheel drive vehicles handle differently than
vehicles with a lower center of gravity. Utility and four-wheel drive
vehicles arenotdesigned for cornering at speeds as high as passenger
cars any more than low-slung sports cars are designed to perform
satisfactorily under off-road conditions. Avoid sharp turns, excessive
speed and abrupt maneuvers in these vehicles. Failure to drive
cautiously could result in an increased risk of loss of vehicle control,
vehicle rollover, personal injury and death.
•If the vehicle goes from one type of surface to another (i.e., from
concrete to gravel) there will be a change in the way the vehicle
responds to a maneuver (steering, acceleration or braking). Again,
avoid these abrupt inputs.
Parking
On some 4WD vehicles, when the transfer case is in the N (Neutral)
position, the engine and transmission are disconnected from the rest of
the driveline. Therefore, the vehicle is free to roll even if the automatic
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Driving on hilly or sloping terrain
Although natural obstacles may make it necessary to travel diagonally up
or down a hill or steep incline, you should always try to drive straight up
or straight down.Avoid driving crosswise or turning on steep
slopes or hills. A danger lies in losing traction, slipping sideways and
possibly rolling over. Whenever driving on a hill, determine beforehand
the route you will use. Do not drive over the crest of a hill without
seeing what conditions are on the other side. Do not drive in reverse
over a hill without the aid of an observer.
When climbing a steep slope or hill,
start in a lower gear rather than
downshifting to a lower gear from a
higher gear once the ascent has
started. This reduces strain on the
engine and the possibility of stalling.
If you do stall out, do not try to
turn around because you might roll
over. It is better to back down to a
safe location.
Apply just enough power to the
wheels to climb the hill. Too much
power will cause the tires to slip,
spin or lose traction, resulting in
loss of vehicle control.
Descend a hill in the same gear you
would use to climb up the hill to
avoid excessive brake application
and brake overheating. Do not
descend in neutral; instead,
manually shift to a lower gear. Your
vehicle has anti-lock brakes, apply
the brakes steadily. Do not “pump”
the brakes.
Driving on snow and ice
4WD vehicles have advantages over 2WD vehicles in snow and ice but
can skid like any other vehicle.
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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
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