engine FORD SUPER DUTY 2015 3.G Service Manual

On-Board Diagnostics (OBD-II)
Your vehicle is equipped with an on-boarddiagnostics system (OBD-II) that monitorsthe engine’s emission control system. Thissystem protects the environment byensuring that your vehicle continues tomeet government emission standards. TheOBD-II system also assists your authorizeddealer in properly servicing your vehicle.
When the service engine soonindicator illuminates, the OBD-IIsystem has detected amalfunction. Temporary malfunctions maycause the service engine soon indicator toilluminate.
Examples of temporary malfunctions are:
•the vehicle has run out of fuel—theengine may misfire or run poorly
•poor fuel quality or water in thefuel—the engine may misfire or runpoorly
•the fuel fill inlet may not have beenproperly closed See Refueling (page138).
•driving through deep water—theelectrical system may be wet.
You can correct these temporarymalfunctions by filling the fuel tank withgood quality fuel, properly closing the fuelfill inlet or letting the electrical system dryout. After three driving cycles without theseor any other temporary malfunctionspresent, the service engine soon indicatorshould stay off the next time you start theengine. A driving cycle consists of a coldengine startup followed by mixedcity/highway driving. No additional vehicleservice is required.
If the service engine soon indicator remainson, have your vehicle serviced at the firstavailable opportunity. Although somemalfunctions detected by the OBD-II maynot have symptoms that are apparent,continued driving with the service enginesoon indicator on can result in increasedemissions, lower fuel economy, reducedengine and transmission smoothness, andlead to more costly repairs.
Readiness forInspection/Maintenance (I/M)Testing
Some state/provincial and localgovernments may haveInspection/Maintenance (I/M) programsto inspect the emission control equipmenton your vehicle. Failure to pass thisinspection could prevent you from gettinga vehicle registration.
If the service engine soonindicator is on or the bulb doesnot work, you may need to havethe vehicle serviced. See On-BoardDiagnostics (OBD-II).
Your vehicle may not pass the I/M test ifthe service engine soon indicator is on ornot working properly (bulb is burned out),or if the OBD-II system has determinedthat some of the emission control systemshave not been properly checked. In thiscase, your vehicle is not ready for I/Mtesting.
If the vehicle’s engine or transmission hasjust been serviced, or the battery hasrecently run down or been replaced, theOBD-II system may indicate that thevehicle is not ready for I/M testing. Todetermine if the vehicle is ready for I/Mtesting, turn the ignition key to the onposition for 15 seconds without cranking
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the engine. If the service engine soonindicator blinks eight times, it means thatthe vehicle is not ready for I/M testing; ifthe service engine soon indicator stays onsolid, it means that the vehicle is ready forI/M testing.
The OBD-II system monitors the emissioncontrol system during normal driving. Acomplete check may take several days. Ifthe vehicle is not ready for I/M testing, youmay need to perform the following drivingcycle consisting of mixed city and highwaydriving:
Drive on an expressway or highway for asteady 15 minutes, followed by 20 minutesof stop-and-go driving with at least four30-second idle periods.
Allow the vehicle to sit for at least eighthours without starting the engine. Then,start the engine and complete the abovedriving cycle. The engine must warm up toits normal operating temperature. Oncestarted, do not turn off the engine until theabove driving cycle is complete. If thevehicle is still not ready for I/M testing, youwill have to repeat the above driving cycle.
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AUTOMATIC TRANSMISSION
WARNING
Always set the parking brake fullyand make sure the gearshift islatched in P (Park). Turn the ignitionto the off position and remove the keywhenever you leave your vehicle.
Understanding the Shift Positionsof the 5–Speed AutomaticTransmission (If Equipped)
Putting your vehicle in or out of gear:
1.Fully press down the brake pedal.
2.Move the gearshift lever into thedesired gear.
3.Come to a complete stop.
4.Move the gearshift lever and securelylatch it in P (Park)
P (Park)
This position locks the transmission andprevents the rear wheels from turning.
R (Reverse)
With the gearshift lever in R (Reverse), thevehicle will move backward. Always cometo a complete stop before shifting into andout of R (Reverse).
N (Neutral)
With the gearshift lever in N (Neutral), thevehicle can be started and is free to roll.Hold the brake pedal down while in thisposition.
D (Overdrive) with tow/haul off
D (Overdrive) with tow/haul off is thenormal driving position for the best fueleconomy. The overdrive function allowsautomatic upshifts and downshifts throughgears one through five.
D (Overdrive) with tow/haul on
The tow/haul feature improvestransmission operation when towing atrailer or a heavy load. All transmissiongear ranges are available when usingtow/haul.
To activate tow/haul, press thebutton on the end of thegearshift lever. The TOW HAULindicator light will illuminate in theinstrument cluster.
Tow/haul delays upshifts to reducefrequency of transmission shifting.Tow/haul also provides engine braking inall forward gears when the transmission isin the D (Overdrive) position; this enginebraking will slow the vehicle and assist thedriver in controlling the vehicle whendescending a grade. Depending on drivingconditions and load conditions, the
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transmission may downshift, slow thevehicle and control the vehicle speed whendescending a hill, without the acceleratorpedal being pressed. The amount ofdownshift braking provided will vary basedupon the amount the brake pedal ispressed.
To deactivate the tow/haul feature andreturn to normal driving mode, press thebutton on the end of the gearshift lever.The TOW HAUL light will no longer beilluminated.
When you shut-off and restart the engine,the transmission will automatically returnto normal D (Overdrive) mode (tow/hauloff).
WARNING
Do not use the tow/haul or enginebrake features when driving in icy orslippery conditions as the increasedengine braking can cause the rear wheelsto slide and your vehicle to swing aroundwith the possible loss of vehicle control.
3 (Third)
Transmission starts and operates in thirdgear only
Used for improved traction on slipperyroads. Selecting 3 (Third) provides enginebraking.
2 (Second)
Use 2 (Second) to start-up on slipperyroads or to provide additional enginebraking on downgrades.
1 (First)
•Provides maximum engine braking
•Allows upshifts by moving gearshiftlever
•The transmission will not downshiftinto 1 (First) at high speeds; it willdownshift to a lower gear and thenshift into 1 (First) when the vehiclereaches slower speeds.
Forced downshifts
•Allowed in D (Overdrive) with thetow/haul feature on or off
•Press the accelerator to the floor
•Allows transmission to select anappropriate gear
Understanding the Shift Positionsof a 6–Speed AutomaticTransmission (If Equipped)
Putting your vehicle in or out of gear:
1.Fully press down the brake pedal.
2.Move the gearshift lever into thedesired gear.
3.Come to a complete stop.
4.Move the gearshift lever and securelylatch it in P (Park)
P (Park)
This position locks the transmission andprevents the rear wheels from turning.
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R (Reverse)
With the gearshift lever in R (Reverse), thevehicle will move backward. Always cometo a complete stop before shifting into andout of R (Reverse).
N (Neutral)
With the gearshift lever in N (Neutral), thevehicle can be started and is free to roll.Hold the brake pedal down while in thisposition.
D (Overdrive) with tow/haul off
D (Overdrive) with tow/haul off is thenormal driving position for the best fueleconomy. The overdrive function allowsautomatic upshifts and downshifts throughgears one through six.
D (Overdrive) with tow/haul on
The tow/haul feature improvestransmission operation when towing atrailer or a heavy load. All transmissiongear ranges are available when usingtow/haul.
To activate tow/haul, press thebutton on the end of thegearshift lever. The TOW HAULindicator light will illuminate in theinstrument cluster.
Tow/haul delays upshifts to reducefrequency of transmission shifting.Tow/haul also provides engine braking inall forward gears when the transmission isin the D (Overdrive) position; this enginebraking will slow the vehicle and assist thedriver in controlling the vehicle whendescending a grade. Depending on drivingconditions and load conditions, thetransmission may downshift, slow thevehicle and control the vehicle speed whendescending a hill, without the acceleratorpedal being pressed. The amount ofdownshift braking provided will vary basedupon the amount the brake pedal ispressed.
Tow/haul may be automatically activated(without pressing the tow/haul button).This provides engine braking to assist thevehicles braking system when goingdownhill and repetitive braking is sensed.Once the tow/haul mode has beenautomatically activated it will notautomatically deactivate.
To deactivate the tow/haul feature andreturn to normal driving mode, press thebutton on the end of the gearshift lever.The TOW HAUL light will no longer beilluminated.
Tow/haul will also deactivate when thevehicle is powered down for a few minutes.
WARNING
Do not use the tow/haul or enginebrake features when driving in icy orslippery conditions as the increasedengine braking can cause the rear wheelsto slide and your vehicle to swing aroundwith the possible loss of vehicle control.
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M (Manual) without Overdrive
With the gearshift lever in M (Manual), thedriver can change gears up or down asdesired. This is called SelectShiftAutomatic™ transmission (SST) mode.By moving the gearshift lever from driveposition D (Overdrive) to M (Manual) younow have control of selecting the gear youdesire using buttons on the shift lever.
To return to normal D (Overdrive) position,move the shift lever back from M to D.
The transmission will operate in gears onethrough six.
2 (Second)
Use 2 (Second) to start-up on slipperyroads or to provide additional enginebraking on downgrades.
1 (First)
•Provides maximum engine braking
•Allows upshifts by moving gearshiftlever
•The transmission will not downshiftinto 1 (First) at high speeds; it willdownshift to a lower gear and thenshift into 1 (First) when the vehiclereaches slower speeds.
Forced downshifts
•Allowed in D (Overdrive) with thetow/haul feature on or off
•Press the accelerator to the floor
•Allows transmission to select anappropriate gear
Understanding your SelectShiftAutomatic® transmission (If Equipped)
Your vehicle is equipped with a SelectShiftAutomatic transmission gearshift lever.SelectShift Automatic transmission givesyou the ability to change gears up or down(without a clutch) as desired.
Use the buttons on the shifter to lock orunlock gears and manually select gears.Press the + button to upshift or the –button to downshift.
With the gearshift lever in D (Drive), pressthe – button to activate SelectShift. Theavailable and selected gears will beindicated on the instrument cluster.
All available gears will be displayed withthe current gear indicated. Press the –button again to lock out gears beginningwith the highest gear. Example: press the– button twice to lock out 6th and 5thgears. Only the available gears will bedisplayed and the transmission willautomatically shift between the availablegears. Press the + button to unlock gears.
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By moving the gearshift lever from the D(Drive) position to the M (Manual) positionyou may now manually select the gear youdesire. Only the current gear will bedisplayed. Press the + button or the –button to upshift or downshift. If the –button is pressed at a vehicle speed that
would cause an engine overspeed, therequested gear will flash then disappearand the transmission will remain in thecurrent gear.
Recommended shift speeds
Upshift according to the following chart:
Upshifts when accelerating (recommended for best fuel economy)
Diesel enginesGasoline enginesShift from:
12 mph (19 km/h)15 mph (24 km/h)1 – 2
19 mph (31 km/h)25 mph (40 km/h)2 – 3
26 mph (42 km/h)40 mph (64 km/h)3 – 4
34 mph (55 km/h)45 mph (72 km/h)4 – 5
46 mph (74 km/h)50 mph (80 km/h)5 – 6
In order to prevent the engine from runningat too low an RPM, which may cause it tostall, SelectShift will still automaticallymake some downshifts if it has determinedthat you have not downshifted in time.Although SelectShift will make somedownshifts for you, it will still allow you todownshift at any time as long as theSelectShift determines that the engine willnot be damaged from over-revving.
SelectShift will not automatically upshift,even if the engine is approaching the RPMlimit. It must be shifted manually bypressing the + button.
Note:Engine damage may occur ifexcessive engine revving is held withoutshifting.
Automatic Transmission AdaptiveLearning
This feature is designed to increasedurability and provide consistent shift feelover the life of the vehicle. A new vehicleor transmission may have firm shifts, softshifts or both. This operation is considerednormal and will not affect function ordurability of the transmission. Over time,the adaptive learning process will fullyupdate transmission operation.Additionally, whenever the battery isdisconnected or a new battery installed,the strategy must be relearned.
Brake-Shift Interlock
WARNINGS
Do not drive your vehicle until youverify that the brake lamps areworking.
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9.Start the vehicle.
Perform Steps 4 through 8 in reverse order,making sure to engage the hinge pivotsbetween the upper and lower halves of theshroud. Keep slight pressure in the forwarddirection as the halves are rotatedtogether.
If Your Vehicle Gets Stuck In Mudor Snow
Note:Do not rock the vehicle if the engineis not at normal operating temperature ordamage to the transmission may occur.
Note:Do not rock the vehicle for more thana minute or damage to the transmission andtires may occur, or the engine may overheat.
If your vehicle gets stuck in mud or snow,it may be rocked out by shifting betweenforward and reverse gears, stoppingbetween shifts in a steady pattern. Presslightly on the accelerator in each gear.
POWER TAKE-OFF
Auxiliary equipment called power take-off,or PTO, is often added to the engine ortransmission to operate utility equipment.Examples include a wheel-lift for towtrucks, cranes, tools for construction or tireservice, and pumping fluids. PTOapplications draw auxiliary horsepowerfrom the powertrain, often while thevehicle is stationary. In this condition, thereis limited cooling air flow through theradiator and around the vehicle thatnormally occurs when a vehicle is moving.The aftermarket PTO system installer,having the most knowledge of the finalapplication, is responsible for determiningwhether additional chassis heat protectionor powertrain cooling is required, andalerting the user to the safe and properoperation.
Ford Super Duty Vehicles are approved foruse as a stationary (including split shaftcapability) or mobile power source, withinlimits and operating guidelines detailed inthe Ford Truck Body Builders Layout Book,found at www.fleet.ford.com/truckbbas,and through the Ford Truck Body BuildersAdvisory Service.
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Four-wheel drive (when you select a 4WDmode) uses all four wheels to power thevehicle. This increases traction, enablingyou to drive over terrain and roadconditions that a conventional two-wheeldrive vehicle cannot.
Basic Operating Principles
•Drive slower in strong crosswinds whichcan affect the normal steeringcharacteristics of your vehicle.
•When driving your vehicle on surfacesmade slippery by loose sand, water,gravel, snow or ice proceed with care.
•Do not use Four-wheel drive on dry,hard surfaced roads. Doing so willproduce excessive noise, increase tirewear and may damage drivecomponents. Four-wheel drive modesare only intended for consistentlyslippery or loose surfaces.
If Your Vehicle leaves the Road
If your vehicle leaves the road, reduce yourvehicle speed and avoid severe braking.When your vehicle speed has been reducedease your vehicle back onto the road. Donot turn the steering wheel sharply whilereturning your vehicle to the road.
It may be safer to stay on the shoulder ofthe road and slow down gradually beforereturning to the road. You may lose controlif you do not slow down or if you turn thesteering wheel too sharply or abruptly.
It may be less risky to strike small objects,such as freeway reflectors, with minordamage to your vehicle rather thanattempt a sudden return to the road whichcould cause your vehicle to slide sidewaysout of control or roll over. Remember, yoursafety and the safety of others should beyour primary concern.
Emergency Maneuvers
In an unavoidable emergency situationwhere a sudden sharp turn must be made,remember to avoid over-driving yourvehicle (i.e. turn the steering wheel only asrapidly and as far as required to avoid theemergency). Excessive steering can resultin loss of vehicle control. Apply smoothpressure to the accelerator pedal or brakepedal when changes in vehicle speed arerequired. Avoid abrupt steering,acceleration and braking. This could resultin an increased risk of vehicle roll over, lossof vehicle control and personal injury. Useall available road surface to bring yourvehicle to a safe direction of travel.
In the event of an emergency stop, avoidskidding the tires and do not attempt anysharp steering wheel movements.
If your vehicle goes from one type ofsurface to another (i.e. from concrete togravel) there will be a change in the wayyour vehicle responds to a maneuver (i.e.steering, acceleration or braking).
Sand
When driving over sand, try to keep all fourwheels on the most solid area of the trail.Avoid reducing the tire pressures but shiftto a lower gear and drive steadily throughthe terrain. Apply the accelerator slowlyand avoid excessive wheel slip.
When driving at slow speeds in deep sandunder high outside temperatures, use a lowgear when possible. Low gear operationwill maximize the engine and transmissioncooling capability.
Avoid driving at excessive speeds, thiscauses vehicle momentum to work againstyou and your vehicle could become stuckto the point that assistance may berequired from another vehicle. Remember,you may be able to back out the way youcame if you proceed with caution.
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Mud and Water
Mud
Be cautious of sudden changes in vehiclespeed or direction when you are driving inmud. Even four-wheel drive vehicles canlose traction in slick mud. If your vehicledoes slide, steer in the direction of the slideuntil you regain control of your vehicle.
After driving through mud, clean off residuestuck to rotating driveshafts and tires.Excess mud stuck on tires and rotatingdriveshafts can cause an imbalance thatcould damage drive components.
Water
If you must drive through high water, driveslowly. Traction or brake capability maybe limited.
When driving through water, determine thedepth and avoid water higher than thebottom of the hubs. If the ignition systemgets wet, your vehicle may stall.
Once through water, always try the brakes.Wet brakes do not stop your vehicle aseffectively as dry brakes. Drying can beimproved by applying light pressure to thebrake pedal while moving slowly.
Note:Driving through deep water maydamage the transmission. If the front or rearaxle is submerged in water, the axlelubricant and power transfer unit lubricantshould be checked and changed ifnecessary.
Driving on Hilly or Sloping Terrain
Although natural obstacles may make itnecessary to travel diagonally up or downa hill or steep incline, you should alwaystry to drive straight up or straight down.
Note:Avoid turning on steep slopes or hills.A danger lies in losing traction, slippingsideways and possible vehicle roll over.Whenever driving on a hill, determinebeforehand the route you will use. Do notdrive over the crest of a hill without seeingwhat conditions are on the other side. Donot drive in reverse over a hill without theaid of an observer.
When climbing a steep slope or hill, startin a lower gear rather than downshifting toa lower gear from a higher gear once theascent has started. This reduces strain onthe engine and the possibility of stalling.
If your vehicle stalls, do not try to turnaround because this could cause vehicleroll over. It is better to reverse back to asafe location.
Apply just enough power to the wheels toclimb the hill. Too much power will causethe tires to slip, spin or lose traction,resulting in loss of vehicle control.
Descend a hill in the same gear you woulduse to climb up the hill to avoid excessivebrake application and brake overheating.Do not descend in neutral. Disengageoverdrive or move the transmissionselector lever to a lower gear. Whendescending a steep hill, avoid sudden hardbraking as you could lose control. The frontwheels have to be turning in order to steeryour vehicle.
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