Ford 2007 Low Cab Forward Truck Supplement Manual Download

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The fuses and relays are coded as follows:

Fuse/Relay

Location

Fuse Amp

Rating

Fuse Description

—

Not used

30A*

Starter

20A*

Park lamps

50A*

Injector Driver Module (IDM)/Powertrain
Control Module (PCM)

30A*

Headlamps

40A*

Blower motor

25A*

Wipers

30A*

Electric brakes

20A*

Door locks

20A*

Stoplamps

20A*

Fuel pump

20A*

RUN/ACC feed

20A*

RUN/START feed

15A**

Horn

10A**

Cluster

15A**

Back-up lamps

15A**

Fog lamps

15A**

Transmission

20A*

Fuel heater

60A*

Anti-lock Brake System (ABS) module

20A*

Trailer lighting circuit

Not used

40A*

Trailer battery charge

20A**

Cigar lighter

20A**

Hazard flasher

15A**

Remote Keyless Entry (RKE)

10A**

Radio

10A**

Dome lamp

60A*

ABS pump

2009 Low Cab Forward Truck

(lcf)

Supplement
USA

(fus)

Roadside Emergencies

Summary of Contents for 2007 Low Cab Forward Truck

Page 1: ...2 20 AM www carburetor manual com Would you like some Free Manuals http carburetor manual com free shop manual club t 13 html Also visit http freeshopmanual com for more Free Manuals Also Visit my web...

Page 2: ...ate Controls 33 Heater only 33 Manual heating and air conditioning 35 Lights 37 Headlamps 37 Turn signal control 43 Bulb replacement 44 Driver Controls 50 Windshield wiper washer control 50 Steering w...

Page 3: ...nging tires 104 Jump starting 104 Wrecker towing 109 Customer Assistance 111 Reporting safety defects U S only 115 Reporting safety defects Canada only 115 Cleaning 116 Maintenance and Specifications...

Page 4: ...nic or mechanical including photocopying recording or by any information storage and retrieval system or translation in whole or part is not permitted without written authorization from Ford Motor Com...

Page 5: ...red may not apply to your particular vehicle Furthermore due to printing cycles the Owner s Guide may describe options before they are generally available Remember to pass on the Owner s Guide when re...

Page 6: ...n components of this vehicle such as airbag modules seat belt pretensioners and button cell batteries may contain Perchlorate Material Special handling may apply for service or vehicle end of life dis...

Page 7: ...order or where required by law enforcement other government authorities or other third parties acting with lawful authority Other parties may seek to access the information independently of Ford Moto...

Page 8: ...2009 Low Cab Forward Truck lcf Supplement USA fus Introduction 7...

Page 9: ...ether Anchor Brake System Anti Lock Brake System Parking Brake System Brake Fluid Non Petroleum Based Parking Aid System Stability Control System Speed Control Master Lighting Switch Hazard Warning Fl...

Page 10: ...lant Engine Coolant Temperature Do Not Open When Hot Battery Avoid Smoking Flames or Sparks Battery Acid Explosive Gas Fan Warning Power Steering Fluid Maintain Correct Fluid Level MAX MIN Service Eng...

Page 11: ...must be careful and deliberate to minimize the possibility of personal injury from a slip and fall when entering exiting and or climbing on this vehicle Always use the steps and assist handles when c...

Page 12: ...ir inlet Check for debris leaves etc that may have collected on the HVAC air inlet grille or inside the exterior module as this may cause reduced system performance HVAC fresh air filter if equipped P...

Page 13: ...any binding or irregular feel Remove your foot from the pedal and make sure the engine returns to idle speed immediately Steering linkage free play Check for excessive free play in the steering linka...

Page 14: ...or loose mounting This is particularly important on vehicles where tow hooks are frequently used Front suspension Spring Inspect for missing broken or shifted leaves or leaves that are in contact or n...

Page 15: ...b oil seal for leaks and if sight glass is present check to see that the oil level is adequate Oil lubricated front wheel bearing If the hubcap has a transparent window check for proper lubrication le...

Page 16: ...amage to the tank s and no leaks from the tank s Underbody of vehicle Driveshaft Make sure that the driveshaft is not bent or cracked Ensure all driveshaft couplings are secure Exhaust system Make sur...

Page 17: ...ake sure reflectors are clean and unbroken and of proper color red on rear amber elsewhere Make sure the running lights are also clean and unbroken Rear running lights must be checked separately from...

Page 18: ...ould not have welding repairs and no rust trails that indicate it is loose on the wheel Lug nuts Make sure all lug nuts are present and not loose look for rust trails around the lug nuts There should...

Page 19: ...nition is turned on During this self test you may hear an audio buzz and or the gauges will sweep This is normal operation Stop engine If this red warning light illuminates while driving a high coolan...

Page 20: ...heat is necessary as a starting aid Wait until the light goes off before starting The light should always illuminate briefly when the ignition key is in the ON position Refer to Starting the engine a...

Page 21: ...y ignite if separator is drained while engine is running or vehicle is moving Brake fluid This red light illuminates when the brake fluid is low An audible tone will also sound when this light is illu...

Page 22: ...rns Have the system serviced immediately as transmission damage may occur Safety belt This red light illuminates to remind you to fasten your safety belt A chime will sound for approximately two secon...

Page 23: ...rn the ignition to ON 2 Press and release the Cruise RPM and Resume buttons simultaneously four 4 times within 6 seconds 3 Press and hold the Cruise RPM and Resume buttons for three 3 seconds 4 Releas...

Page 24: ...rning chime if equipped Sounds when the key is left in the ignition in the ON or ACC position and either door is opened The trip odometer display will show Key In IGN Headlamps on warning chime Sounds...

Page 25: ...al problem between the gauge and the engine control module the gauge pointer will fall below the 0 position and rest on the pointer stop Odometer Trip odometer The odometer registers the total miles k...

Page 26: ...eaches 1 8 full a red warning light on the fuel gauge will illuminate and an audible alarm will sound This warning light will stay on until the tank s is filled above 1 8 full If there is an electrica...

Page 27: ...off the road The drivers primary responsibility is the safe operation of their vehicle Only use cell phones and other devices not essential to the driving task when it is safe to do so 1 ON AUDIO Pre...

Page 28: ...adjust the brightness of the radio display 7 SCAN Press to search the current band for all listenable stations Press again to stop the scan 8 Memory preset buttons 1 6 To set a station Select frequen...

Page 29: ...ly use cell phones and other devices not essential to the driving task when it is safe to do so 1 BAND In radio mode press to change the band AM FM1 FM2 WB In CD MP3 mode press to pause and play a tra...

Page 30: ...ion In CD MP3 mode Skip to the next previous track file Hold down for more than 1 2 second to fast reverse fast forward 5 Radio preset stations 1 6 Press BAND to select the desired frequency band Manu...

Page 31: ...RANDOM to play the tracks in random order In MP3 folder mode the system will randomly play all files within the current folder 11 VOLUME PUSH SEL Turn the knob clockwise to increase volume and counte...

Page 32: ...tablished by the Federal Communications Commission FCC and the Canadian Radio and Telecommunications Commission CRTC Those frequencies are AM 530 540 1700 1710 kHz FM 87 7 87 9 107 7 107 9 MHz Radio r...

Page 33: ...unction correctly when used in Ford CD players Irregular shaped CDs CDs with a scratch protection film attached and CDs with homemade paper adhesive labels should not be inserted into the CD player Th...

Page 34: ...cle To reduce humidity inside the vehicle turn off control moved all the way to the right 4 Air flow selections Controls the direction of the airflow in the vehicle See the following for a brief descr...

Page 35: ...e air inlet vents To aid in side window defogging demisting in cold weather 1 Select 2 Set the temperature control to full heat 3 Set the fan speed to its highest setting 4 Direct the outer instrument...

Page 36: ...ount of time to cool down the interior of the vehicle when used with the A C control air flows from the instrument panel vents only May also help reduce undesired outside odors from reaching the inter...

Page 37: ...This allows the vehicle to breathe using the outside air inlet vents To aid in side window defogging demisting in cold weather 1 Select 2 Press A C 3 Modulate the temperature control to maintain comf...

Page 38: ...lash to pass To turn on the high beams push the lever away from you Pull the lever towards you to deactivate For flash to pass operation pull the lever toward you slightly to activate and release to d...

Page 39: ...he bottom edge of the instrument panel Use the dimmer to adjust the brightness of the instrument panel and all applicable switches in the vehicle during headlamp and parklamp operation AIMING THE HEAD...

Page 40: ...r perpendicular to the ground at a position 9 84 ft 3 m 1 in the illustration away from the headlamps 3 Ensure that the centerline of the vehicle and the paper face forms a 90 angle 2 in the illustrat...

Page 41: ...headlamps on 9 On the paper observe the portion of the light pattern with a distinct area of higher intensity light Check that the top edge of this high intensity area is at the horizontal reference...

Page 42: ...ng procedure by turning the screws in the counterclockwise screwdriver direction If you are adjusting in the counterclockwise screwdriver direction overshoot the adjustment by one full turn and then t...

Page 43: ...n and then turn it clockwise one full turn so you finish the adjustment in the clockwise direction and still line up with the vertical aiming line 4 Insert the screwdriver in the outboard aiming hole...

Page 44: ...ight turn signal INTERIOR LAMPS Dome lamp Type A 1 OFF Light always off 2 DOOR Light turns on when either door is open 3 ON Light always on Dome lamp Type B Press where the arrows indicate to turn on...

Page 45: ...arker 2 168 Front clearance and identification lamps 5 194 Fog lamps 2 64151 Brake Tail Stop Rear turn signal License lamps 2 1157 Back up lamps 2 1156 Dome lamp 2 DE3175 single bulb lamp or 212 dual...

Page 46: ...cause the bulb to break the next time the headlamps are operated The headlamp and fog lamp bulbs can be replaced without removing the headlight assemblies just by tilting the cab refer to Tilting the...

Page 47: ...ap in the opened door 3 With the door still open go around the door to the light assembly and insert a blunt object such as a screwdriver through the gap in the door and push the clip to release the f...

Page 48: ...5 Remove the grille screw then the grille 6 Remove the bezel from the top of the headlamp 7 Remove the bezel from below the headlamp 2009 Low Cab Forward Truck lcf Supplement USA fus Lights 47...

Page 49: ...bulb from the socket by pulling it straight back Replace the bulb then install the components in the reverse order of removal Replacing front parking lamp turn signal lamps To replace the front parkin...

Page 50: ...ing brake tail rear turn signal back up license plate lamp bulbs The brake tail rear turn signal back up license plate lamp bulbs are located in the same portion of the rear lamp assembly Follow the s...

Page 51: ...to move the steering wheel up or down or to push pull the steering wheel toward away from you Push the control back down fully to lock the steering wheel in position WARNING Never adjust the steering...

Page 52: ...d release quickly The driver s window will open fully To stop the window partway down pull the control up then release it Window lock if equipped The window lock feature prevents the power windows fro...

Page 53: ...king out of a garage with the trailer tow mirror The mirrors also can be folded forward in front of the vehicle to fit within the cab width SPEED CONTROL IF EQUIPPED To turn speed control on Press the...

Page 54: ...may vary momentarily slower or faster than the set speed this is normal Speed control cannot reduce the vehicle speed if it increases above the set speed on a downhill If your vehicle speed is faster...

Page 55: ...ing this will decrease vehicle speed if the vehicle is stationary this will decrease engine RPM Release the control when the desired vehicle speed engine RPM is reached Press and release SET to operat...

Page 56: ...a previously set speed Press RESUME For RESUME to operate the vehicle speed must be above 35 mph 56 km h or engine speed must be above 1 000 RPM 2009 Low Cab Forward Truck lcf Supplement USA fus Drive...

Page 57: ...closed REMOTE ENTRY SYSTEM IF EQUIPPED This device complies with part 15 of the FCC rules and with RS 210 of Industry Canada Operation is subject to the following two conditions 1 This device may not...

Page 58: ...door can be manually unlocked and opened by inserting the key into the driver s door lock cylinder and turning counter clockwise Locking the doors Press LOCK once to lock both doors Pressing LOCK a s...

Page 59: ...in the battery housing cavity 5 Snap the two halves back together Note Replacement of the battery will not cause the remote transmitter to become deprogrammed from your vehicle The remote transmitter...

Page 60: ...n the side of the seat The driver seat back can also be flipped forward by lifting lever 2 When pushing the seat back to its upright position make sure it latches securely Pull the center seat down wh...

Page 61: ...ay become dangerous in the event of a sudden stop or collision SAFETY RESTRAINTS Safety restraints precautions WARNING Always drive and ride with your seatback upright and the lap belt snug and low ac...

Page 62: ...seating position in your vehicle has a specific safety belt assembly which is made up of one buckle and one tongue that are designed to be used as a pair 1 Use the shoulder belt on the outside should...

Page 63: ...lt should fit snugly and as low as possible around the hips not across the waist Insert the tongue into the correct buckle the buckle closest to the direction the tongue is coming from To lengthen the...

Page 64: ...the height adjuster to make sure it is locked in place WARNING Position the safety belt height adjuster so that the belt rests across the middle of your shoulder Failure to adjust the safety belt pro...

Page 65: ...ation is noted WARNING Failure to inspect and if necessary replace the safety belt assembly under the above conditions could result in severe personal injuries in the event of a collision Refer to Int...

Page 66: ...d Passenger Safety Technician CPST and your pediatrician to make sure your child seat is appropriate for your child and is compatible with and properly installed in the vehicle To locate a child seat...

Page 67: ...ommended by child restraint manufacturer Use a vehicle safety belt having the lap belt snug and low across the hips shoulder belt centered across the shoulder and chest and seatback upright You are re...

Page 68: ...ehicle manufacturer A safety seat that is improperly installed or utilized is inappropriate for your child s height age or weight or does not properly fit the child may increase the risk of serious in...

Page 69: ...elt buckle for that seating position Insert the belt tongue into the proper buckle until you hear a snap and feel it latch Make sure the tongue is securely fastened in the buckle Keep the buckle relea...

Page 70: ...er route the tongue through the child seat according to the child seat manufacturer s instructions Be sure the belt webbing is not twisted 3 Buckle the seat belt Push down on the child seat and pull o...

Page 71: ...a NHTSA Certified Child Passenger Safety Technician CPST to make certain the child restraint is properly installed Installing child safety seats in the lap belt seating positions 1 Lengthen the lap b...

Page 72: ...and shoulder belt on children who have outgrown child safety seats Ford Motor Company recommends use of a belt positioning booster Booster seats position a child so that vehicle lap shoulder safety b...

Page 73: ...types of belt positioning booster seats backless and high back Always use booster seats in conjunction with the vehicle lap shoulder belt Backless booster seats If your backless booster seat has a re...

Page 74: ...backless booster seat you cannot find a seating position that adequately supports your child s head a high back booster seat would be a better choice 2009 Low Cab Forward Truck lcf Supplement USA fus...

Page 75: ...tably close to the neck and a shoulder belt that could slip off the shoulder The drawings below also show how the lap belt should be low and snug across the child s hips If the booster seat slides on...

Page 76: ...t Move a child to a different seating location if the shoulder belt does not stay positioned on the shoulder during use Follow all instructions provided by the manufacturer of the booster seat WARNING...

Page 77: ...sion which may result in severe bodily injury and extensive property damage Note When starting the engine do not press the accelerator as engine damage may result 1 Ensure headlamps and all accessorie...

Page 78: ...onomy nor engine performance Cold weather operation WARNING Do not use volatile starting aids such as ether propane or gasoline in the engine air intake system Glow plugs may ignite vapors which can c...

Page 79: ...ted carbon and varnish Hot weather operation Keep the engine cooling system filled with a clean permanent coolant solution to protect against damage from overheating Fill the fuel tank at the end of d...

Page 80: ...path is clear back up slowly as to allow others time to move if necessary Parking your vehicle Always use the parking brake When parking on a grade block the wheels and turn the front wheels to one s...

Page 81: ...position to reset the system before restarting the engine Note The engine idle shutdown timer will not start if The engine is operating in power take off PTO mode The engine coolant temperature is bel...

Page 82: ...ake applications when the engine is off The HydroBoost s accumulator reserve provides reduced braking power and the number of stops is limited depending on the severity and duration of the brake appli...

Page 83: ...ot be working properly See your dealer or a qualified service technician The parking brake is not recommended to stop a moving vehicle However if the normal brakes fail the parking brake can be used t...

Page 84: ...pump the brake pedal since this will reduce the effectiveness of the ABS and will increase your vehicle s stopping distance The ABS will be activated immediately allowing you to retain full steering...

Page 85: ...ve the three fasteners as shown in the illustration there is one at the bottom of the gearshift console and one on both sides of the console Note You may need to roll back the floor cover to access th...

Page 86: ...o Fuses in the Roadside Emergencies chapter WARNING Do not drive your vehicle until you verify that the brakelamps are working WARNING Always set the parking brake fully and make sure the gearshift is...

Page 87: ...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 du...

Page 88: ...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 t...

Page 89: ...longer be illuminated When you shut off and restart the engine the transmission will automatically return to normal D Overdrive mode Tow Haul OFF Note The Tow Haul feature will automatically deactivat...

Page 90: ...at normally occurs when a vehicle is moving Depending on the level and duration of auxiliary horsepower draw vehicle conditions and surrounding environmental conditions and other factors this can cont...

Page 91: ...e performed However it is understood that on occasion aftermarket add on axles are installed by others on the truck chassis which allow operator control for weight transfer from other axles i e air li...

Page 92: ...g Guide provided by your dealership Under no circumstances should your vehicle be loaded in excess of the GVWR or GAWR It is the operator s responsibility to ensure that neither the axle capacities sp...

Page 93: ...is the highest possible weight of a fully loaded trailer the vehicle can tow It assumes a vehicle with only mandatory options no cargo internal or external a tongue load of 10 15 and driver only 150 l...

Page 94: ...vehicle s actual weight is 16 000 lbs 7 258 kg then the maximum trailer weight your vehicle can tow is 10 000 lbs 4 536 kg Note The maximum allowable trailer weight is not to exceed 12 500 lbs 5 670 k...

Page 95: ...ollow the instructions that the rental agency gives to you Do not attach safety chains to the bumper Trailer brakes Electric brakes and manual automatic or surge type trailer brakes are safe if instal...

Page 96: ...rvice intervals Refer to the Scheduled Maintenance Guide chapter for more information Trailer towing tips Practice turning stopping and backing up before starting on a trip to get the feel of the vehi...

Page 97: ...is card is found in the Owner Guide portfolio in the glove compartment To receive roadside assistance in the United States call 1 800 241 3673 If you need to arrange roadside assistance for yourself F...

Page 98: ...protective cover To access the PDB the protective cover must be taken off the vehicle by removing the two screws shown in illustration then gently pulling the cover off Note Remove and install the co...

Page 99: ...removed simply lift the tab on the PDB cover to access the fuses and relays WARNING Always disconnect the battery before servicing high current fuses 2009 Low Cab Forward Truck lcf Supplement USA fus...

Page 100: ...0 20A Stoplamps 11 20A Fuel pump 12 20A RUN ACC feed 13 20A RUN START feed 14 15A Horn 15 10A Cluster 16 15A Back up lamps 17 15A Fog lamps 18 15A Transmission 19 20A Fuel heater 20 60A Anti lock Brak...

Page 101: ...s 40 Not used 41 Not used 42 10A Radio 43 Not used 44 Not used 45 Not used 46 20A PCM key power 47 Micro relay Body builder prep 48 Micro relay Fuel pump 49 Micro relay Back up lamps 50 Not used 51 Mi...

Page 102: ...Not used Cartridge fuse Mini fuse Relays The relay box is located under the center of the instrument panel The instrument panel lower trim panel must be removed to access the relays Remove the plasti...

Page 103: ...he plastic rivets on the top end Push the panel up slightly to disengage the locking tabs then pull the panel toward you and off Reinstall the panel in the reverse order of the removal procedure 2009...

Page 104: ...IGN Ignition PUSHER FAN HVAC pusher fan LEFT FRONT Left front turn signal DOME LAMP Dome lamp RT REAR Right rear turn signal HEADLAMP Headlamps BLOWER MOTOR Climate control blower motor LEFT REAR Left...

Page 105: ...lt in injury or vehicle damage WARNING Batteries contain sulfuric acid which can burn skin eyes and clothing if contacted Do not attempt to push start your automatic transmission vehicle Automatic tra...

Page 106: ...attach the battery cables Ensure that vent caps are tight and level 5 Turn the heater fan on in both vehicles to protect from any electrical surges Turn all other accessories off Connecting the jumper...

Page 107: ...e negative terminal of the battery to be jumped A spark may cause an explosion of the gases that surround the battery 5 Ensure that the cables are clear of fan blades belts moving parts of both engine...

Page 108: ...rface Note In the illustrations lightning bolts are used to designate the assisting boosting battery 2 Remove the jumper cable on the negative connection of the booster vehicle s battery 3 Remove the...

Page 109: ...bled vehicle s battery After the disabled vehicle has been started and the jumper cables removed allow it to idle for several minutes so the engine computer can relearn its idle conditions 2009 Low Ca...

Page 110: ...wheel lift with dollies under the rear wheels Vehicle towed from the rear using a wheel lift with the front wheels on the ground Vehicle towed using flatbed equipment Note Do not tow with slingbelt e...

Page 111: ...ard facing Place the transmission in N Neutral Maximum speed of 35 mph 56 km h Maximum distance of 50 miles 80 km Tow hooks Your vehicle is equipped with front tow hooks The tow hooks should only be u...

Page 112: ...e unsatisfied with the service you are receiving follow these steps 1 Contact your Sales Representative or Service Advisor at your selling servicing dealership 2 If your inquiry or concern remains unr...

Page 113: ...uired to either replace the vehicle with one substantially identical or repurchase the vehicle and reimburse the buyer in an amount equal to the actual price paid or payable by the consumer less a rea...

Page 114: ...l In the United States using leaded fuel may also result in difficulty importing your vehicle back into the U S Ford dealerships outside of the US Canada may be unable to support the LCF due to the sp...

Page 115: ...m EST Helm Incorporated can also be reached by their website www helminc com Items in this catalog may be purchased by credit card check or money order Obtaining a French owner s guide French Owner s...

Page 116: ...in individual problems between you your dealer or Ford Motor Company To contact NHTSA you may call the Vehicle Safety Hotline toll free at 1 888 327 4236 TTY 1 800 424 9153 go to http www safercar go...

Page 117: ...tems such as gasoline diesel fuel bird droppings and insect deposits because they can cause damage to the vehicle s paintwork and trim over time Motorcraft Bug and Tar Remover ZC 42 is available from...

Page 118: ...Chemical strength cleaners or cleaning chemicals in combination with brush agitation to remove brake dust and dirt could wear away the clearcoat finish over time Do not use hydrofluoric acid based or...

Page 119: ...shield To clean these items follow these tips The windshield rear windows and side windows may be cleaned with a non abrasive cleaner such as Motorcraft Ultra Clear Spray Glass Cleaner ZC 23 available...

Page 120: ...interior trim and cluster lens If a staining liquid like coffee juice has been spilled on the instrument panel or on interior trim surfaces clean as follows 1 Wipe up spilled liquid using a clean whit...

Page 121: ...rom packed dirt FORD AND LINCOLN MERCURY CAR CARE PRODUCTS Your Ford or Lincoln Mercury authorized dealer has many quality products available to clean your vehicle and protect its finishes These quali...

Page 122: ...100 Motorcraft Premium Liquid Wax ZC 53 A Motorcraft Premium Windshield Washer Concentrate ZC 32 A Motorcraft Professional Strength Carpet Upholstery Cleaner ZC 54 Motorcraft Spot and Stain Remover U...

Page 123: ...ar safety glasses for eye protection do not work on the brakes unless the proper precautions are taken to avoid inhaling friction material dust do not wear loose fitting clothing hanging jewelry watch...

Page 124: ...If the owner operator of the vehicle is a skilled technician and intends on performing the vehicle maintenance and service it is strongly advisable to purchase a service manual WARNING Take care when...

Page 125: ...urely tightened Regularly check front axle for damage binding worn parts and adequate lubrication At regular intervals or during other scheduled maintenance tire rotation service wheel bearing service...

Page 126: ...uring all brake service procedures Wear the respirator from removal of the wheels through assembly 2 Never use compressed air or dry brushing to clean brake parts or assemblies 3 Clean brake parts and...

Page 127: ...her severe brake pad wear or fluid leakage A more frequent and thorough brake inspection will be required Fluid precautions The HydroBoost brake system consists of two completely separate hydraulic sy...

Page 128: ...tment should only be performed by a qualified technician and in accordance with the instructions in the service manual WARNING Use wheel chocks and exercise caution when inspecting under the vehicle A...

Page 129: ...er tilting ensure pin on rod F is seated in groove Note Never lower handle B when cab is tilted Lowering Refer to the accompanying illustration when following these directions 1 Push the cab up using...

Page 130: ...ey provide cold weather protection without damaging the vehicle s paint finish wiper blades or washer system WARNING If you operate your vehicle in temperatures below 40 F 4 C use washer fluid with an...

Page 131: ...the engine oil Refer to the scheduled maintenance information for the appropriate intervals for checking the engine oil 1 Park the vehicle on level ground and shut the engine off 2 Set the parking br...

Page 132: ...nging the engine oil and filter Change your engine oil and filter more frequently if your vehicle operation includes extended periods of idling or low speed operation driving for a long time in cold t...

Page 133: ...eveloped by the American Petroleum Institute API to help you select the proper engine oil The symbol will be included on the oil container you purchase The top section of the symbol shows the API serv...

Page 134: ...nded that the negative battery cable terminal be disconnected from the battery if you plan to store your vehicle for an extended period of time This will minimize the discharge of your battery during...

Page 135: ...d level of engine coolant should be checked twice a year to ensure proper glycol water concentrations The coolant concentration should be maintained at 50 50 coolant and distilled water which equates...

Page 136: ...n Refer to the scheduled maintenance information for service interval schedules Be sure to read and understand Precautions when servicing your vehicle in this chapter If the engine coolant has not bee...

Page 137: ...d Engine Coolant meeting Ford Specification WSS M97B51 A1 Note Add the coolant type originally equipped in your vehicle Add Motorcraft Premium Gold Engine Coolant VC 7 B yellow colored meeting Ford Sp...

Page 138: ...tle Slowly turn cap counterclockwise until pressure begins to release 3 Step back while the pressure releases 4 When you are sure that all the pressure has been released use the cloth to turn it count...

Page 139: ...to Refill capacities in this chapter For coolant part numbers refer to Lubricant specifications in this chapter Severe climates If you drive in extremely cold climates less than 34 F 36 C It may be ne...

Page 140: ...ore the fuel enters the engine The fuel filter water separator should be drained as recommended in the scheduled maintenance information Draining the fuel filter water separator Water should be draine...

Page 141: ...s should be replaced at the same time Replace the fuel filters with Motorcraft Part No FD 4596 Removal Engine mounted filter 15 16 socket or 1 2 square drive required Frame mounted filter 36 mm socket...

Page 142: ...ng a fuel which has more than average impurities may require the fuel filter to be replaced more frequently than the service interval specifies FUEL INFORMATION Important safety precautions WARNING Do...

Page 143: ...ead to permanent injury Fuels can also be harmful if absorbed through the skin If fuel is splashed on the skin and or clothing promptly remove contaminated clothing and wash skin thoroughly with soap...

Page 144: ...position Choosing the right fuel Use only Ultra Low Sulfur 15 ppm Sulfur Maximum number 1 D or 2 D diesel fuel in your diesel engine The engine and exhaust system were designed to only use this fuel...

Page 145: ...y Ultra Low Sulfur Diesel fuel will cause certain emission components to malfunction which may also cause the Service Engine Soon light to illuminate indicating an emissions related concern WARNING Do...

Page 146: ...ou may need to crank the engine for a longer time than normal If the engine fails to start in 30 seconds turn the ignition to the OFF position and wait for two minutes before cranking the engine again...

Page 147: ...small amount of usable fuel remaining in the fuel tank after the fuel gauge indicates empty The amount of Empty Reserve varies and should not be relied upon to increase driving range When refueling yo...

Page 148: ...ng conditions Additionally keeping records during summer and winter will show how temperature impacts fuel economy In general lower temperatures give lower fuel economy Driving style good driving and...

Page 149: ...stem is very high Never work around or attempt to repair any part of the exhaust system until it has cooled Use special care when working around the diesel particulate filter The DPF heats up to a hig...

Page 150: ...turn on hazard flashers and shut down engine as soon as possible Seek service immediately Instrument cluster lamp s will illuminate and or flash when operator assistance is required In addition engin...

Page 151: ...ing the parking brake remove foot from the service brake pedal When these steps are performed successfully in the order outlined above the DPF lamp will begin flashing at a rate of once every 10 secon...

Page 152: ...is a uniquely functioning device that accompanies the DPF assembly It is designed to help control the temperature of the exhaust during the DPF regeneration process Do not modify or remove this device...

Page 153: ...is disengaged when cooling of the engine is not required Check for proper operation of radiator shutters if equipped The shutters should be open during normal operating temperatures Engine and Driveli...

Page 154: ...nt bolts and steering linkage particularly for body to chassis clearance Note Have any steering problems corrected at once by a qualified service technician WARNING Failure to maintain the steering sy...

Page 155: ...information for the recommended service intervals A low fluid level may indicate a leak in the power steering system Inspect the power steering system and repair the leak If necessary see your dealer...

Page 156: ...id that is not DOT 3 you will cause permanent damage to your brakes WARNING Do not let the reservoir for the master cylinder run dry This may cause the brakes to fail TRANSMISSION FLUID Checking autom...

Page 157: ...e 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 dip...

Page 158: ...d 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...

Page 159: ...rfill 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 th...

Page 160: ...e compressed air to clean the housing 4 Inspect the housing for damage or distortion which would allow unfiltered air to enter the engine 5 Install the new filter Install the cover onto the housing th...

Page 161: ...rvice establishment of the owner s choosing Any replacement parts used for required maintenance services or repairs should be genuine manufacturer service parts or equivalent in quality and performanc...

Page 162: ...lean damp rag WARNING To reduce the risk of personal injury or death when performing maintenance to any turbocharged engine with engine air inlet piping disconnected a turbocharger compressor air inle...

Page 163: ...o ensure that any additional body lights and accessories are connected to circuits that are both appropriate and not overloaded No modification should be made to any vehicle control system without fir...

Page 164: ...HAFT SHAFT At the regular lubrication interval check the universal joints for any evidence of wear or looseness Should driveshaft vibrations occur stop the vehicle immediately to avoid possible hazard...

Page 165: ...nner following your local authorized standards 5 Clean the drain area then install the bolt securely 6 Add enough lubricant through the filler plug opening so that the lubricant level is up to the bot...

Page 166: ...rfaces Do not use lubricant on threads After the rim or wheel has been properly tightened it should be checked for alignment Rotate the wheel with a piece of chalk attached to a steady firm surface an...

Page 167: ...possible Use care so that the threads on studs are not damaged 2 Position the outer rear tire and wheel in place over the studs and push it back as far as possible Use care so that the threads on stud...

Page 168: ...ess Some natural seating of parts may be encountered and the torque on the nuts will drop Retighten all nuts to specifications Once a week inspect and retighten the wheel stud nuts Aluminum rear disc...

Page 169: ...e of the wheel and or mounting hardware Wheel lug nut torque Size Nut mounting Torque Ft lb N m M14 Flange 140 160 189 217 Note Do not use lubrication on dry threads Where excessive corrosion exists a...

Page 170: ...pairs be rotated only side to side with the rear tires maintaining original vehicle position After tire rotation inflation pressures must be adjusted for the tires new positions in accordance with veh...

Page 171: ...used because of the increased flexing of the sidewalls on radial tires Never use anti freeze silicones or petroleum based lubricants when mounting radial tires Only an approved lubricant should be use...

Page 172: ...eve normal pressure build up Normal increases in pressure due to service conditions will be 10 to 15 psi which is allowable in truck tires It is particularly important to keep moisture from the inside...

Page 173: ...decreases tire life requiring more frequent replacement of tires Overloading creates an unsafe condition that may result in sudden air loss from a tire failure resulting in an accident that could caus...

Page 174: ...eels when tread is worn to 4 32 inch 3 mm or less 2 Rear Axles Tires must be removed when the tread is worn to 2 32 inch 2 mm or less Tires identified with the word re groovable molded on the sidewall...

Page 175: ...avoid it altogether Some of the more effective tire rotation programs are Steer tires that have developed some type of irregular wear pattern can be rotated to drive axles if rib tires are being used...

Page 176: ...lations For example during any procedure involving tire inflation the technician or individual must utilize a remote inflation device and ensure that all persons are clear of the trajectory area WARNI...

Page 177: ...ccurs first whether it is months miles kilometers or hours of engine operation Only lubricants of superior quality such as Motorcraft lubricants should be used The use of inferior products will reduce...

Page 178: ...grease tie rod ends drag link kingpin and bushing EP2 Lithium complex based moly grease or equivalent GC LB NLGI 2 multi purpose lithium complex grease Note With chassis load on axle force grease thr...

Page 179: ...ose lithium complex grease Motorcraft Premium Long Life Grease XG 1 C Steering column U joints slip joint GC LB NLGI 2 lithium complex based moly grease or multi purpose lithium complex grease Motorcr...

Page 180: ...1 WSS M97B51 A1 Motorcraft Premium Gold Engine Coolant VC 7 B Windshield washer Washer fluid WSB M8B16 A2 Motorcraft Premium Windshield Washer Concentrate ZC 32 A Transmission TorqShift Motorcraft MER...

Page 181: ...r multi purpose lithium complex grease Motorcraft Premium Long Life Grease XG 1 C Door lock cylinders Lock oil Motorcraft Penetrating and Lock Lubricant XL 1 Door window regulators NGLI 2 multipurpose...

Page 182: ...F to 90 F 23 C to 32 C XO 10W30 QSD Motorcraft SAE 0W 30 Super All Season Motor Oil SAE 0W 30 below 0 F 18 C XO 0W30 LAS Brake system Master cylinder DOT 3 WSS M6C62 A Motorcraft High Performance Mot...

Page 183: ...nge 14 quarts 13 0L With filter change 15 quarts 14 0L Transmission fluid 2 Motorcraft MERCON SP ATF 17 5 quarts 16 6L 3 Includes remote filter change Rear axle Motorcraft SAE 80W 90 Premium Rear Axle...

Page 184: ...mage Use of a transmission fluid other than the recommended fluid may cause transmission damage 3 Indicates only approximate dry fill capacity Some applications may vary based on cooler size and if eq...

Page 185: ...ssurance that Ford Built quality stays in your vehicle Non Ford approved chemicals or additives are not required for factory recommended maintenance In fact Ford Motor Company recommends against the u...

Page 186: ...scheduled maintenance information should be changed at the specified interval or in conjunction with a repair Flushing is a viable way to change fluid for many vehicle sub systems during scheduled mai...

Page 187: ...edule performed at the specified time and mileage kilometer intervals You should avoid running out of fuel or turning off the ignition while the vehicle is in motion especially at high speeds WARNING...

Page 188: ...BITED TAMPERING ACTS AND MAINTENANCE On January 1 1978 Federal regulations became effective governing the noise emissions on trucks over 10 000 lb 4 536 kg GVWR The following statements concerning pro...

Page 189: ...r cleaner Exhaust System Removal or rendering inoperative exhaust system components including the catalytic converter muffler assembly inlet pipe outlet pipe resonator and flexpipe Rotation of horizon...

Page 190: ...n or near the engine SCHEDULED MAINTENANCE SERVICES Maintenance service adjustments must conform to specifications contained in this manual and those shown on the Important Engine Information Decal Th...

Page 191: ...and all exhaust clamps and fasteners for holes leakage breakage looseness and corrosive damage Excessive noise or the smell of fumes is experienced Inspect the engine air induction system including t...

Page 192: ...re removal replacement Clean body door drain holes At least twice annually Clean windshield wiper blades As required Replace windshield wiper blades If wiping the blades with a clean cloth and mild de...

Page 193: ...ssion control systems maintenance services performed on your vehicle Maintenance Record Warranty Start Date ______________________________________ Engine Displacement _________________________________...

Page 194: ...f fluid leaks U S Department of Transportation Federal Highway Administration requirements ensure that the entire system is functioning properly Check the service brakes Check the parking brake Check...

Page 195: ...system Drain the fuel filter water separator HFCM at this time or as required when WATER IN FUEL light in instrument cluster illuminates Steering system Lubricate the steering shaft s U joints and sp...

Page 196: ...e interval 6 years or 100 000 miles 160 000 km change Motorcraft Premium Gold Engine Coolant whichever comes first After initial change change Motorcraft Premium Gold Engine Coolant every 3 years or 5...

Page 197: ...s required Inspect brake pads shoes rotors fluid drums brakes lines hoses and parking brake system Inspect exhaust system and heat shields Inspect accessory drive belt Torque suspension U bolts Replac...

Page 198: ...t brake pads shoes rotors fluid drums brakes lines hoses and parking brake system Inspect exhaust system and heat shields Inspect accessory drive belt Change automatic transmission fluid and filter Ch...

Page 199: ...parking brake system Inspect exhaust system and heat shields Inspect accessory drive belt DEALER VALIDATION RO P A CODE DATE MILEAGE 90 000 miles 144 000 km Change engine oil and replace oil filter In...

Page 200: ...em and hoses Inspect brake pads shoes rotors fluid drums brakes lines hoses and parking brake system Inspect exhaust system and heat shields Inspect accessory drive belt Change Motorcraft Premium Gold...

Page 201: ...ect tires for wear and measure tread depth Inspect air filter restriction gauge replace filter as required Inspect brake pads shoes rotors fluid drums brakes lines hoses and parking brake system Inspe...

Page 202: ...oil and replace filter Every 10 000 miles 16 000 km or 400 hours of engine operation whichever comes first Change engine mounted fuel filter and chassis mounted HFCM fuel filter For engines idled dail...

Page 203: ...of engine operation whichever comes first Change engine mounted fuel filter and chassis mounted HFCM fuel filter Every 50 000 miles 80 000 km Replace non synthetic rear axle lubricant Use of Biodiese...

Page 204: ...IDATION RO P A CODE DATE MILEAGE DEALER VALIDATION RO P A CODE DATE MILEAGE DEALER VALIDATION RO P A CODE DATE MILEAGE DEALER VALIDATION RO P A CODE DATE MILEAGE DEALER VALIDATION RO P A CODE DATE MIL...

Page 205: ...IDATION RO P A CODE DATE MILEAGE DEALER VALIDATION RO P A CODE DATE MILEAGE DEALER VALIDATION RO P A CODE DATE MILEAGE DEALER VALIDATION RO P A CODE DATE MILEAGE DEALER VALIDATION RO P A CODE DATE MIL...

Page 206: ...hange due at this mileage Or Today s date goes here Add 3 years 00 00 03 Date of next change whichever comes first Dealer Stamp P A CODE R O Current mileage goes here Add 50 000 miles to the current m...

Page 207: ...current miles 50 000 Next change due at this mileage Or Today s date goes here Add 3 years 00 00 03 Date of next change whichever comes first Dealer Stamp P A CODE R O 2009 Low Cab Forward Truck lcf S...

Page 208: ...ABS warning light 83 fluid checking and adding 154 if brakes do not grip well 81 lubricant specifications 177 parking 82 servicing 125 shift interlock 83 Bulbs 44 C Cell phone use 6 Changing a tire 10...

Page 209: ...82 Emergency Flashers 96 Emission control system 5 152 186 catalytic converter 160 Engine coolant 134 idle shutdown 80 lubrication specifications 177 preparing to start 76 refill capacities 182 start...

Page 210: ...r 119 J Jump starting your vehicle 104 K Keys 56 key in ignition chime 18 positions of the ignition 76 L Lamps bulb replacement specifications chart 44 cargo lamps 38 daytime running light 37 hazard f...

Page 211: ...120 Safety belts see Safety restraints 60 61 63 Safety defects reporting 115 Safety restraints 60 61 63 cleaning the safety belts 120 extension assembly 63 for adults 61 63 for children 65 lap belt 6...

Page 212: ...n 86 brake shift interlock BSI 83 fluid refill capacities 182 Trip odometer 23 Turn signal 43 V Vehicle Identification Number VIN 183 Vehicle loading 90 W Warning chimes 18 Warning lights see Lights 1...

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