engine FORD SUPER DUTY 2023 Repair Manual

FOUR-WHEEL DRIVE
PRECAUTIONS
WARNING: Vehicles with a highercenter of gravity (utility and four-wheeldrive vehicles) handle differently thanvehicles with a lower center of gravity(passenger cars). Avoid sharp turns,excessive speed and abrupt steering inthese vehicles. Failure to drive cautiouslyincreases the risk of losing control of yourvehicle, vehicle rollover, personal injuryand death.
WARNING: Do not becomeoverconfident in the ability of four-wheeldrive vehicles. Although a four-wheeldrive vehicle may accelerate better thana two-wheel drive vehicle in low tractionsituations, it won't stop any faster thantwo-wheel drive vehicles. Always driveat a safe speed.
Truck and utility vehicles can differ fromsome other vehicles. Your vehicle could behigher to allow it to travel over roughterrain without getting stuck or damagingunderbody components. The differencesthat make your vehicle so versatile alsomake it handle differently than an ordinarypassenger car. Always maintain steeringwheel control, especially in rough terrain.Since sudden changes in terrain can resultin abrupt steering wheel motion, make sureyou grip the steering wheel from theoutside. Do not grip the spokes. Drivecautiously to avoid vehicle damage fromconcealed objects such as rocks andstumps. Drive slower in strong crosswindswhich can affect the normal steeringcharacteristics of your vehicle. Beextremely careful when driving onpavement made slippery by loose sand,water, gravel, snow or ice.
Note:Your vehicle may come with a frontair dam that can become damaged (due toreduced ground clearance) when taking yourvehicle off-road. This air dam can be takenoff by removing 15 bolts.
Parking
WARNING: If the parking brake isfully released, but the brake warninglamp remains illuminated, the brakesmay not be working properly. Have yourvehicle checked as soon as possible.
WARNING: Apply the parkingbrake, shift into park (P), switch theignition off and remove the key beforeyou leave your vehicle. Failure to followthis instruction could result in personalinjury or death.
On some four-wheel drive vehicles, whenthe transfer case is in the neutral (N)position, the engine and transmissiondisconnects from the rest of the driveline.Therefore, your vehicle is free to roll evenif the automatic transmission is in park (P).Do not leave the vehicle unattended withthe transfer case in the neutral (N)position. Always set the parking brake fullyand turn off the ignition when leaving yourvehicle.
FOUR-WHEEL DRIVE
LIMITATIONS
Do not use four-wheel drive high orfour-wheel drive low mode on dry, hardsurface roads. Doing so can produceexcessive noise, increase tire wear and candamage drive components. Four-wheeldrive high or four-wheel drive low modesare intended for consistently slippery orloose surfaces. Use of four low mode onthese surfaces could produce some noise,such as occasional clunks, but should not
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BRAKE PRECAUTIONS
Wet brakes result in reduced brakingefficiency. Gently press the brake pedal afew times when leaving a car wash ordriving from standing water to dry thebrakes.
Note:Depending on applicable laws andregulations in the country where your vehiclewas originally built, the stoplamps couldflash during heavy braking. The hazardwarning flashers could also turn on whenyour vehicle comes to a stop.
ANTI-LOCK BRAKING SYSTEM
ANTI-LOCK BRAKING SYSTEMLIMITATIONS
The anti-lock braking system does noteliminate the risk of crash when:
•You drive too closely to the vehicle infront of you.
•Your vehicle is hydroplaning.
•You take corners too fast.
•The road surface is poor.
Note: If the system activates, the brakepedal could pulse and travel further.Maintain pressure on the brake pedal.
BRAKE OVER ACCELERATOR
In the event the accelerator pedalbecomes stuck or entrapped, apply steadyand firm pressure to the brake pedal toslow the vehicle and reduce engine power.If you experience this condition, apply thebrakes and bring your vehicle to a safestop. Move the transmission to park (P),switch the engine off and apply the parkingbrake. Inspect the accelerator pedal forany interference. If none are found and thecondition persists, have your vehicle towedto the nearest authorized dealer.
LOCATING THE BRAKE FLUID
RESERVOIR
See Under Hood Overview (page 441).
CHECKING THE BRAKE FLUID
WARNING: Do not use any fluidother than the recommended brake fluidas this will reduce brake efficiency. Useof incorrect fluid could result in the lossof vehicle control, serious personal injuryor death.
WARNING: Only use brake fluidfrom a sealed container. Contaminationwith dirt, water, petroleum products orother materials may result in brakesystem damage or failure. Failure toadhere to this warning could result in theloss of vehicle control, serious personalinjury or death.
WARNING: Do not allow the fluidto touch your skin or eyes. If thishappens, rinse the affected areasimmediately with plenty of water andcontact your physician.
WARNING: The brake systemcould be affected if the brake fluid levelis below the MIN mark or above the MAXmark on the brake fluid reservoir.
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WHAT IS THE ELECTRIC
PARKING BRAKE
The electric parking brake is used to holdyour vehicle on slopes and flat roads.
APPLYING THE ELECTRIC
PARKING BRAKE
WARNING: Apply the parkingbrake, shift into park (P), switch theignition off and remove the key beforeyou leave your vehicle. Failure to followthis instruction could result in personalinjury or death.
WARNING: If you drive extendeddistances with the parking brake applied,you could cause damage to the brakesystem.
WARNING: The electric parkingbrake does not operate if the vehiclebattery has run out of charge.
The switch is on the lower partof the instrument panel.
Pull the switch up to apply the electricparking brake. The red warning lampflashes, then steadily illuminates when theparking brake is applied.
Note:You can apply the electric parkingbrake when the ignition is off.
Note:The electric parking brake couldautomatically apply when park (P) isselected. See Park (P) (page 234).
APPLYING THE ELECTRIC
PARKING BRAKE IN AN
EMERGENCY
You can use the electric parking brake toslow or stop your vehicle in an emergency.
Pull the switch up and hold it.
The red warning lamp illuminates, a tonesounds and the stoplamps turn on whenyou use the electric parking brake in anemergency.
The electric parking brake continues toslow your vehicle down unless you releasethe switch.
Note:Do not apply the electric parkingbrake when your vehicle is moving, exceptin an emergency. If you repeatedly use theelectric parking brake to slow or stop yourvehicle, you could cause damage to thebrake system.
MANUALLY RELEASING THE
ELECTRIC PARKING BRAKE
1.Switch the ignition on.
2.Press and hold the brake pedal.
3.Push the switch down.
The red warning lamp turns off.
Pulling Away on a Hill When Towing aTrailer
1.Press and hold the brake pedal.
2.Pull the switch upward and hold it.
3.Shift into gear.
4.Press the accelerator pedal until enginehas developed sufficient torque toprevent your vehicle from rolling downthe hill.
5.Release the switch and pull away in anormal manner.
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DIESEL ENGINE EXHAUST
BRAKE – PRECAUTIONS
WARNING: Do not use tow/haulwhen the road surface is slippery. Failureto follow this instruction could result inthe loss of control of your vehicle.
WARNING: Do not use dieselengine exhaust braking when the roadsurface is slippery. Failure to follow thisinstruction could result in the loss ofcontrol of your vehicle.
USING THE DIESEL ENGINE
EXHAUST BRAKE
This feature increases engine braking athigher engine speeds to provide bettergrade descent control with less brake andtransmission wear and tear.
Note:Use this when driving downhill andcarrying heavy loads or trailering.
Benefits of engine braking are:
•Lower brake temperature.
•Reduced brake fade.
•Longer brake life.
•Improved driving and trailering control.
Press the button on the switchbank next to the audio unit toswitch the system on or off.
There are two engine brake modes, manualand automatic.
The following conditions must be met touse exhaust brake:
•Your vehicle is in a forward gear.
•The engine speed is above 1300 RPM.
•Your foot is off the accelerator.
You can use this feature with tow/haul orprogressive range selection to providefurther increased engine braking. Thetransmission upshifts to prevent the enginefrom entering the red zone on thetachometer.
Manual Engine Braking
1.Press the button to switch on manualengine braking.
2.Release the accelerator pedal tomaximize engine braking.
3.Apply the brakes. The transmissiondownshifts to lower gears.
Note:The engine braking feature onlyfunctions when you release the accelerator.
Note:You can shift the transmission tolower gears with progressive range selectionor manual shifting independent of pressingthe brakes.
Note:You can also use manual enginebraking with cruise control to improve gradedescent control.
Note:If your vehicle has adaptive cruisecontrol, the speed control system uses theselected engine brake mode, transmissiongears, and brakes to maintain the set speedand distance to the vehicle being followed.
Automatic Engine Braking
1.Press the button twice to switch onautomatic engine braking.
2.Release the accelerator or brake pedal.The system remembers your vehiclespeed.
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Note:This feature offers smoother, lessaggressive engine braking during downhilldescents. It may not apply braking if thevehicle speed is not increasing, although itapplies full engine braking force whenneeded to prevent acceleration. The systemautomatically activates the engine brakeand, if necessary, downshifts thetransmission to lower gears to not exceedyour vehicle's set speed when the brake oraccelerator were last released.
DIESEL ENGINE EXHAUST
BRAKE INDICATORS
DIESEL ENGINE EXHAUST
BRAKE GAUGE
Displays the diesel engine exhaust brakepower in the form of a percentage. A fullfill or 100% represents the total dieselengine exhaust brake power available.
The gauge displays zero to 100%depending on the engine brake powerprovided by the system.
Note:When the diesel engine exhaust brakeis switched off, the gauge displays zero.
Accessing the Diesel EngineExhaust Brake Gauge
You can access the diesel engine exhaustbrake gauge in the instrument cluster usingthe instrument cluster display control onthe steering wheel:
•Press the menu button.
•Select Gauges.
•Select Diesel Gauges.
DIESEL ENGINE EXHAUST
BRAKE – TROUBLESHOOTING
DIESEL ENGINE EXHAUST BRAKE– WARNING LAMPS
•Illuminates when this feature isswitched on and the system isoperating properly.
•Flashes when the engine brake isdisabled due to a fault.
•Does not illuminate when the switchor indicator is faulty.
You can switch the system on at any time.The braking system becomes active oncethe braking conditions are met.
DIESEL ENGINE EXHAUST
BRAKE VIDEOS
Diesel Engine Exhaust Braking Video Link
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WHAT IS TRACTION CONTROL
The traction control system helps to avoiddrive wheel spin and loss of traction.
HOW DOES TRACTION
CONTROL WORK
If your wheels begin to spin, the loss oftraction can compromise steering controland stability of the vehicle. The tractioncontrol system applies the brakes toindividual wheels and when needed,reduces engine power at the same time toincrease traction.
SWITCHING TRACTION
CONTROL ON AND OFF
WARNING: Operating your vehiclewith the traction control disabled couldlead to an increased risk of loss of vehiclecontrol, vehicle rollover, personal injuryand death.
The traction control system turns on eachtime you switch the ignition on.
The button for the stability and tractioncontrol system is on the instrument panel.
Press and release the button to switchtraction control off. The stability controlsystem remains fully active, to switch it off,press and hold the button for a fewseconds, then release.
When you switch traction control off, amessage and an illuminated icon appearon the instrument cluster.
Press the switch again to turn the tractioncontrol system back on to normaloperation.
If your vehicle is stuck in mud or snow,switching traction control off may bebeneficial as this allows the wheels to spin.
TRACTION CONTROL
INDICATOR
Stability and Traction ControlIndicator
If the indicator does notilluminate when you switch theignition on, or remains on whenthe engine is running, this indicates amalfunction. Have your vehicle checkedby an authorized dealer as soon aspossible.
The traction control off indicatorilluminates when you switch thetraction control system off, orwhen an alternative stability control modeis selected that requires the tractioncontrol off depending on the drive modeselected.
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HOW DOES STABILITY
CONTROL WORK
WARNING: Vehicle modificationsinvolving braking system, aftermarketroof racks, suspension, steering system,tire construction and wheel and tire sizemay change the handling characteristicsof your vehicle and may adversely affectthe performance of the electronicstability control system. In addition,installing any stereo speakers mayinterfere with and adversely affect theelectronic stability control system.Reducing the effectiveness of theelectronic stability control system couldlead to an increased risk of loss of vehiclecontrol, vehicle rollover, personal injuryand death.
WARNING: Remember that evenadvanced technology cannot defy thelaws of physics. It's always possible tolose control of a vehicle due toinappropriate driver input for theconditions. Aggressive driving on anyroad condition can cause you to losecontrol of your vehicle increasing the riskof personal injury or property damage.Activation of the electronic stabilitycontrol system is an indication that atleast some of the tires have exceededtheir ability to grip the road; this couldreduce the operator's ability to controlthe vehicle potentially resulting in a lossof vehicle control, vehicle rollover,personal injury and death.
If a driving condition activates either thestability control or traction control you mayexperience the following conditions:
•The stability and traction control lightflashes.
•Your vehicle slows down.
•Reduced engine power.
The stability control system has severalfeatures built into it to help you maintaincontrol of your vehicle:
Electronic Stability Control
Electronic stability control enhances yourvehicle’s ability to prevent skids or lateralslides by applying brakes to one or moreof the wheels individually and, if necessary,reducing engine power.
Roll Stability Control
Roll stability control enhances yourvehicle’s ability to prevent rollovers bydetecting your vehicle’s roll motion andthe rate at which it changes by applyingthe brakes to one or more wheelsindividually.
Curve Control
Curve control enhances your vehicle’sability to follow the road when corneringseverely or avoiding objects in the roadway.Curve control operates by reducing enginepower and, if necessary, applying brakesto one or more of the wheels individually.
Side Wind Stabilization
Side wind stabilization is an advancedfeature that works by carefully applyingthe brakes on one side of the vehicle toreduce the effect of a side wind gust onthe vehicle's path.
Traction Control
Traction control enhances your vehicle’sability to maintain traction of the wheelsby detecting and controlling wheel spin.See What Is Traction Control (page 268).
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HYDRAULIC POWER
STEERING
HYDRAULIC POWER STEERINGGUIDELINES
To help prevent damage to the powersteering system:
•Do not hold the steering wheel at itsfurthest turning points for more thanthree to five seconds when the engineis running.
•Avoid continuously steering back andforth with elevated engine RPM as thismay overheat the system. If trying tofree a stuck vehicle, pause betweenattempts to allow the power steeringsystem to cool or seek assistance.Typical steering and driving maneuversallow the system to cool.
•Do not operate the vehicle if the powersteering pump fluid level is below theMIN mark on the reservoir.
•Some noise is normal during operation.If excessive, check for low powersteering pump fluid level beforeseeking service by your dealer.
•Heavy or uneven efforts may be causedby low power steering fluid. Check forlow power steering pump fluid levelbefore seeking service by your dealer.
•Do not fill the power steering pumpreservoir above the MAX mark on thereservoir, as this may result in leaksfrom the reservoir.
If the power steering system breaks downor if you switch the engine off, you cansteer the vehicle manually, but it takesmore effort.
If you have any steering componentsserviced or replaced, install new fasteners.Many fasteners have coatings with threadadhesive, or have prevailing torquefeatures you cannot reuse. Do not reuse abolt or nut. Torque fasteners tospecifications.
Steering Tips
If the steering wanders or pulls, check for:
•An improperly inflated tire.
•Uneven tire wear.
•Loose or worn suspensioncomponents.
•Loose or worn steering components.
•Improper vehicle alignment.
Note:A high crown in the road or highcrosswinds may also make the steeringseem to wander or pull.
Electronic Torque Overlay Steering
(If Equipped)
WARNING: The electric powersteering system has diagnostic checksthat continuously monitor the system. Ifa fault is detected, a message displaysin the information display. Stop yourvehicle as soon as it is safe to do so.Switch the ignition off. After at least 10seconds, switch the ignition on andwatch the information display for asteering system warning message. If asteering system warning messagereturns, have the system checked assoon as possible.
WARNING: If the system detectsan error, you may not feel a difference inthe steering, however a serious conditionmay exist. Have your vehicle checked assoon as possible. Failure to do so mayresult in loss of steering control.
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The electronic torque overlay steeringsystem adds supplemental steering assistto the hydraulic gear when needed,dependent on vehicle conditions such asvehicle speed, steering wheel angle, andsteering wheel torque. The hydraulicsteering system provides the majority ofsteering assistance. The electronic torqueoverlay enables features such as pro trailerbackup assistance and lane departurewarning.
If your vehicle loses electrical power whileyou are driving, your vehicle loses electricpower steering assistance. The steeringsystem still operates, and you can steeryour vehicle with hydraulic assist. Steeringyour vehicle with only hydraulic assistrequires more effort.
Extreme continuous steering may increasethe effort required for you to steer yourvehicle. This increased effort preventsoverheating and permanent damage tothe steering system. You do not lose theability to steer your vehicle manually.Typical steering and driving maneuversallow the system to cool and return tonormal operation.
LOCATING THE HYDRAULICPOWER STEERING FLUIDRESERVOIR
The hydraulic power steering fluid reservoiris found in the engine compartment. SeeUnder Hood Overview (page 441).
CHECKING THE HYDRAULICPOWER STEERING FLUID
Check the power steering fluid. SeeScheduled Maintenance (page 591). Ifadding fluid is necessary, use onlyMERCON LV ATF.
Check the fluid level when it is at ambienttemperature.
1.Check the fluid level in the reservoir. Itshould be between the MIN and MAXrange. Do not add fluid if the level iswithin this range.
2.If the fluid level is low, add fluid to bringthe fluid level up to between the MINand MAX range.
3.Switch the engine on.
4.While the engine idles, turn the steeringwheel left and right several times.
5.Switch the engine off.
6.Recheck the fluid level in the reservoir.Do not add fluid if the level is betweenthe MIN and MAX range.
7.If the fluid is low, add fluid in smallamounts, continuously checking thelevel until it is between the MIN andMAX range. For proper fluid type, SeeCapacities and Specifications (page520). Be sure to put the cap back on thereservoir.
STEERING –
TROUBLESHOOTING
STEERING – WARNINGINDICATORS
The electric power steeringsystem indicator illuminates ifthe system detects a fault duringthe continuous diagnostic checks.
Note:If a red warning message displays,stop your vehicle as soon as it is safe to doso.
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HOW DOES ADAPTIVE CRUISE
CONTROL WITH STOP AND GO
WORK
Adaptive cruise control with stop and gouses radar and camera sensors to maintaina set gap between your vehicle and thevehicle in front of you while following it toa complete stop. Stop and go can also beset to follow a vehicle directly in front ofyou and adjust the set speed, while you areat a complete stop.
ADAPTIVE CRUISE CONTROL
PRECAUTIONS
WARNING: You are responsible forcontrolling your vehicle at all times. Thesystem is designed to be an aid and doesnot relieve you of your responsibility todrive with due care and attention. Failureto follow this instruction could result inthe loss of control of your vehicle,personal injury or death.
WARNING: Do not use adaptivecruise control on winding roads, in heavytraffic or when the road surface isslippery. This could result in loss ofvehicle control, serious injury or death.
WARNING: Pay close attention tochanging road conditions such asentering or leaving a highway, on roadswith intersections or roundabouts, roadswithout visible lanes of travel, roads thatare winding, slippery, unpaved, or steepslopes.
WARNING: The system is not acrash warning or avoidance system.
WARNING: Do not use the systemwhen towing a trailer that hasaftermarket electronic trailer brakecontrols. Failure to follow this instructioncould result in the loss of control of yourvehicle, personal injury or death.
WARNING: Do not use tire sizesother than those recommended becausethis can affect the normal operation ofthe system. Failure to do so may resultin a loss of vehicle control, which couldresult in serious injury.
WARNING: Do not use the systemwith a snow plow blade installed.
WARNING: Do not use the systemin poor visibility, for example fog, heavyrain, spray or snow.
When Following a Vehicle
WARNING: When following avehicle that is braking, your vehicle doesnot always decelerate quickly enough toavoid a crash without driver intervention.Apply the brakes when necessary. Failureto follow this instruction could result inpersonal injury or death.
Hilly Condition and Trailer TowUsage
You should select a lower gear when thesystem is active in situations such asprolonged downhill driving on steep slopes,for example in mountainous areas. Thesystem needs additional engine braking inthese situations to reduce the load on thevehicle’s regular brake system to preventit from overheating.
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