Ford F-250 Owner's Manual
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Ford F-250 Owner's Manual

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See also: Shop Manual , Owner's Manual
All rights reserved. Reproduction by any means, electronic 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 Company. Ford may change the contents without
notice and without incurring obligation.
Copyright © 2002 Ford Motor Company

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  • Page 1: Table Of Contents

    Ford Motor Company. Ford may change the contents without notice and without incurring obligation. Copyright © 2002 Ford Motor Company...

  • Page 2: Introduction

    Severe powertrain damage may result from the use of these aftermarket products which will not be covered by the Ford warranty. Ford may discontinue models or change specifications without any notice and without incurring obligations.
  • Page 3 Introduction WARNING: Engine exhaust, some of its constituents, and certain vehicle components contain or emit chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Certain fluids contained in vehicles and certain products of components contain or emit chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.

  • Page 4: Diesel Information

    Diesel information DIESEL ENGINE INFORMATION The Diesel engine fuel system consists of: • a frame-mounted electric fuel supply pump • an engine mounted fuel filter/water separator • a fuel restriction sensor • a unit injector for each cylinder The combination fuel filter/water separator removes both water and impurities from the fuel.
  • Page 5 Diesel information • engine oil temperature (EOT) sensor • barometric pressure (BARO) sensor The glow plug system is electronically controlled by the PCM. The PCM energizes the glow plugs immediately after the ignition is placed in the ON position, then determines how long the glow plugs will be on according to the EOT and BARO sensors.
  • Page 6 Second, the gauge contains an electrical switch which illuminates a warning light on the instrument cluster when the air filter element is 100% clogged. Refer to F-250/350/450/550, Excursion in Warning Lights chapter. Check the air filter restriction gauge whenever the hood is raised to perform general engine maintenance.
  • Page 7 Diesel information Blowing-out the air filter element with compressed air is not recommended as the compressed air may damage the filter paper. Note: It is not possible to determine the level of filter clogging by visual appearance alone. A filter which appears to be dirty may actually have several thousand kilometers (miles) of life remaining.

  • Page 8: Warning Lights

    F–250/350/450/550, EXCURSION WAIT TO START • E-Series • F-250/350/450/550, Excursion With the key in the ON position, the WAIT TO START light will illuminate if glow plug 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.
  • Page 9 Do not drain the water separator while the engine is running. Fuel may ignite if the separator is drained while the engine is running or the vehicle is moving. ENGINE AIR FILTER (F-250/350/450/550 & EXCURSION) The engine air filter warning light illuminates when the air filter restriction gauge reaches the CHANGE FILTER mark.

  • Page 10: Starting

    3. Turn the key to the ON position. When the WAIT TO START light goes off, turn the key to START. (For Canadian vehicles, the daytime running lamps will be on if the parking brake is not applied and the key is turned to ON.) • E-Series • F-250/350/450/550, Excursion...
  • Page 11 Starting 4. When the engine starts, release the key. The glow plugs will continue to be activated for up to two minutes. If the engine is not started before the activation ceases, the glow plug system must be reset by turning the ignition key to OFF.
  • Page 12 Starting Operation in snow Vehicle operation in heavy snowfall or in dry loose snow that may swirl around the front of the vehicle may feed excessive amounts of snow into the air intake system. This could plug the air cleaner with snow and cause the engine to stall.

  • Page 13: Driving Tips

    Driving tips DUAL FUEL TANK SELECTOR CONTROL (IF EQUIPPED) If your vehicle is equipped with dual fuel tanks, you will have a selector control, located to the right of the steering wheel, which allows you to draw fuel from either tank. Your fuel gauge will display the amount of fuel in the currently selected tank.
  • Page 14 Driving tips Upshift and downshift according to the following shift speed charts: Upshifts when accelerating (recommended for best fuel economy) 6-speed transmission Shift from: Transfer case position (if equipped) 2H or 4H LO-1 8 km/h (5 mph) 3 km/h (2 mph) 16 km/h (10 mph) 6 km/h (4 mph) 32 km/h (20 mph)
  • Page 15 Driving tips TRAILER TOWING Refer to your Owner Guide for full details on towing a trailer. E-Series trailer towing tables Your vehicle may tow a class I, II or III trailer provided the maximum trailer weight is less than or equal to the maximum trailer weight listed for your engine and rear axle ratio on the following charts.
  • Page 16 Driving tips GCWR (Gross Combined Weight Rating)/Trailer Weights Maximum Trailer Loaded Maximum Frontal Rear axle GCWR-kg Trailer Weight - Area Of ratio (lbs.) kg (lbs.) Trailer-m 4.10 9072 (20000) 4536 (10000) 5.52 (60) E-350 Cutaway and Chassis Cab (all wheelbases, all GVWRs) 4.10 9072 (20000) 4536 (10000)
  • Page 17 Driving tips Trailer towing tables F-250 Engine Rear axle Maximum GCWR - Maximum ratio kg (lbs.) trailer weight - kg (lbs.) Vehicles without fifth wheel 7.3L 9072 (20000) 5670 (12500) Regular Cab Pickup 4x2 with manual transmission and fifth wheel 7.3L...
  • Page 18 Driving tips F-350 Regular Cab Single Rear Wheel Pickup Fifth Rear axle Maximum GCWR - Maximum Wheel ratio kg (lbs.) trailer weight - Option kg (lbs.) Vehicles without fifth wheel 7.3L 9072 (20000) 5670 (12500) 4x2 with manual transmission and fifth wheel 7.3L 9072 (20000) 6214 (13700)
  • Page 19 Driving tips F-350 SuperCab Single Rear Wheel Pickup Fifth Rear axle Maximum GCWR - Maximum Wheel ratio kg (lbs.) trailer weight - Option kg (lbs.) Vehicles without fifth wheel 7.3L 9072 (20000) 5670 (12500) 4x2 with fifth wheel 7.3L 9072 (20000) 6078 (13400) 4x4 with fifth wheel 7.3L...
  • Page 20 Driving tips F-350 Crew Cab Single Rear Wheel Pickup Fifth Rear axle Maximum GCWR - Maximum Wheel ratio kg (lbs.) trailer weight - Option kg (lbs.) Vehicles without fifth wheel 7.3L 9072 (20000) 5670 (12500) 4x2 with manual transmission and fifth wheel 7.3L 9072 (20000) 5942 (13100)
  • Page 21 Driving tips F-350 Regular Chassis Cab Single Rear Wheel (Fifth Wheel Towing) Fifth Rear axle Maximum GCWR - Maximum Wheel ratio kg (lbs.) trailer weight - Option kg (lbs.) 4x2 with manual transmission 7.3L 9072 (20000) 5942 (13100) 4x2 with automatic transmission 7.3L 9072 (20000) 5987 (13200)
  • Page 22 Driving tips F-350 SuperCab Chassis Cab Single Rear Wheel (Fifth Wheel Towing) Fifth Rear axle Maximum GCWR - Maximum Wheel ratio kg (lbs.) trailer weight - Option kg (lbs.) 7.3L 9072 (20000) 5625 (12400) 7.3L 9072 (20000) 5443 (12000) F-350 Crew Cab Chassis Cab Single Rear Wheel (Fifth Wheel Towing) Fifth Rear axle...
  • Page 23 Driving tips F-450 Fifth Rear axle Maximum GCWR - Maximum Wheel ratio kg (lbs.) trailer weight - Option kg (lbs.) Regular Chassis Cab 4x2 7.3L 11793 (26000) 8210 (18100) Regular Chassis Cab 4x4 7.3L 11793 (26000) 8074 (17800) SuperCab Chassis Cab 4x2 with manual transmission 7.3L 11793 (26000) 8029 (17700)
  • Page 24 Driving tips F-550 Fifth Rear axle Maximum GCWR - Maximum Wheel ratio kg (lbs.) trailer weight - Option kg (lbs.) Regular Chassis Cab 4x2 7.3L 11793 (26000) 8165 (18000) Regular Chassis Cab 4x4 7.3L 11793 (26000) 8029 (17700) SuperCab Chassis Cab 4x2 7.3L 11793 (26000) 8029 (17700)

  • Page 25: General Maintenance Information

    Use only recommended fuel, lubricants, fluids and service parts conforming to Ford specifications. Motorcraft parts are designed and built for best performance in your vehicle. CLEANING THE ENGINE Engines are more efficient when they are clean because grease and dirt buildup keep the engine warmer than normal.
  • Page 26 General maintenance information • E-Series • F-250/350/450/550 & Excursion FUEL REQUIREMENTS The engine is designed to use low sulfur number 1–D or 2–D Diesel fuel only. At temperatures below -7°C (20°F), number 1–D or winter blend number 2–D fuel is recommended. (See Cold Weather Operation in the...
  • Page 27 General maintenance information Do not use fuel intended for agricultural use (agricultural fuel is dyed red), home heating oil or any Diesel fuel not intended for highway use. Damage to the fuel injection system or engine can occur if an improper fuel is used. Do not add gasoline, gasohol or alcohol to Diesel fuel.
  • Page 28 General maintenance information CHANGING FUEL FILTER Removal — F-250/350/450/550 and Excursion 1. Remove the engine appearance cover. 2. Remove the fuel filter cap by turning counterclockwise. 3. Remove and discard old fuel filter element and fuel filter o-ring. 4. Carefully clean the mating surfaces.
  • Page 29 9. Carefully clean the mating surfaces. Installation — F-250/350/450/550 and Excursion The engine will not run properly if the fuel filter is not installed in housing. 1. Apply a coating of clean Diesel fuel to the new fuel filter o-ring.
  • Page 30 General maintenance information 1. Apply a coating of clean Diesel fuel to the new fuel filter o-ring. 2. Install new fuel filter o-ring onto fuel filter element. 3. Install new fuel filter and o-ring into the fuel filter housing. 4. Tighten cap onto fuel filter housing slowly, allowing fuel to soak into the fuel filter element.
  • Page 31 Engine oils with improved fuel economy properties (energy conserving) are currently available. If you use an energy conserving oil, be sure it meets the recommended Ford Specification, API service categories and SAE viscosity grades listed in the Lubricant and Maintenance Materials Specifications chart.
  • Page 32 See the following section Engine Lubrication for Severe Service Operation for all severe duty restrictions. Use Ford Engine Oil Filter Part No. F4TZ-6731–A (FL–1995) or equivalent. These filters protect your engine by filtering harmful, abrasive or sludge particles. The FL–1995 filters particles significantly smaller than most available “will fit”...
  • Page 33 • Change engine oil and filter every 5,000 km (3,000 miles). • Use Motorcraft oil or an equivalent oil conforming to Ford Specification WSS-M2C171–C or API categories CH-4, CH-4/SJ, CH-4/SL or DHD-1. If CH-4 oil is not available, CG-4 is acceptable..
  • Page 34 (5 000 miles). The WATER IN FUEL light will come on when approximately 100 cc (0.2 pints) of water accumulates in the separator. Replace the fuel filter with Motorcraft Part No. FD-4596 (Ford Part No. F81Z-9N184–AA). Fuel filter/water separator drain procedure 1.
  • Page 35 General maintenance information 2. Open the hood. Place an appropriate container under the filter drain under the vehicle. 3. Locate the fuel filter drain valve. If necessary, remove the engine appearance cover. Refer to Engine Compartment in the Service points chapter.
  • Page 36 General maintenance information 4. On E-Series models, open fuel filter drain valve by pulling on the release handle. Allow to drain for approximately 25 seconds or until clean fuel is observed. Close filter drain valve by resetting handle to original position. 5.
  • Page 37 These two factors cause the additives in the coolant to “wear out” in a shorter time. For vehicles equipped with green coolant, Ford recommends an interim service interval performed at 12 months or 24,000 km (15,000 miles), whichever occurs first. Add 237–295 ml (8–10 oz.) of supplemental coolant additive FW-16 to the...
  • Page 38 The cooling system in your vehicle is filled with either green-colored Motorcraft Premium Engine Coolant meeting Ford specification ESE-M97B44–A or yellow-colored Motorcraft Premium Gold Engine Coolant meeting Ford Specification WSS-M97B51–A1. To determine your vehicle’s coolant type (color), check your coolant reservoir. • Add Motorcraft Premium Engine Coolant (green-colored), VC-4–A (U.S.) or CXC-10 (Canada) or Motorcraft Premium...
  • Page 39 • Do not mix with recycled coolant unless from a Ford-approved recycling process (see Use of Recycled Engine Coolant section). For vehicles with overflow coolant systems with a non-pressurized cap on the coolant recovery system, add coolant to the coolant recovery reservoir when the engine is cool.
  • Page 40 Adding Coolant section to determine the coolant type in your vehicle. Add 1.89L (4 pints) of Motorcraft Heavy Duty Cooling System Additive FW-16 or equivalent meeting Ford specification ESN-M99B169–A, directly to the cooling system. An additional 237–295 ml (8–10 oz.) of supplemental coolant additive FW-16 should be added at 24,000 km (15,000 mile) intervals to maintain proper concentration.
  • Page 41 General maintenance information Recycled engine coolant Ford Motor Company recommends the use of a recycled engine coolant produced by Ford-approved processes in vehicles originally equipped with Motorcraft Premium Engine Coolant (green-colored). However, not all coolant recycling processes produce coolant that meets Ford specification ESE-M97B44–A.
  • Page 42 Coolant conditioner (liquid) For engines filled with green-colored Motorcraft Premium Engine Coolant, a supplemental coolant additive FW-16 meeting Ford specification ESN-M99B169–A has been added to the coolant in this engine. This additive aids in the prevention of rust and scale buildup on the internal parts of the cooling system.
  • Page 43 General maintenance information NOISE EMISSIONS WARRANTY, PROHIBITED TAMPERING ACTS AND MAINTENANCE On January 1, 1978, Federal regulation became effective governing the noise emission on trucks over 4,536 kg (10,000 lbs.) GVWR (Gross Vehicle Weight Rating). The following statements concerning prohibited tampering acts and maintenance, and the noise warranty found in the Warranty Facts Booklet, are applicable to complete chassis cabs over 4,536 (10,000 lbs.) GVWR.

  • Page 44: Scheduled Maintenance

    Scheduled maintenance VEHICLE EMISSIONS CONTROL INFORMATION (VECI) Emissions information appears on the VECI decal on the engine valve cover. This decal identifies engine displacement and provides certain engine specifications. SCHEDULED MAINTENANCE SERVICES Refer to your scheduled maintenance guide for details of maintenance on your vehicle.

  • Page 45: Minor Troubleshooting Guide

    Minor troubleshooting guide The complexity of the Diesel engine makes it so the owner is discouraged from attempting to perform maintenance other than the services described in this supplement. If you experience difficult starting, rough idling, excessive exhaust smoke, a decrease in engine performance or excess fuel consumption, perform the following checks: •...
  • Page 46 Minor troubleshooting guide IF THE ENGINE WON’T CRANK Turn on the headlights. If the lights are dim, do not go on at all or if when the ignition is turned to START the lights become dim or go out, the battery connections may be loose or corroded, or the battery may be discharged.
  • Page 47 Minor troubleshooting guide IF THE ENGINE RUNS HOT The following could cause the engine to overheat: • Lack of coolant. • Dirty cooling system. • Plugged radiator fins, charge air cooler, A/C condenser and/or oil cooler. • Driving with frozen coolant. •...

  • Page 48: Capacities And Specifications

    Includes 1.9L (2 quarts) in engine oil filter. Optional DRW cutaway and all standard E-450 models are 208.2L (55.0 gallons). Use Motorcraft MERCON ATF, Motorcraft part number XT-2–QDX, meeting Ford specification MERCON . BULB SPECIFICATIONS Number of bulbs Trade number...
  • Page 49 Capacities and specifications LUBRICANT AND MAINTENANCE MATERIALS SPECIFICATIONS Ford Part Ford Part Item Ford Specification Name Number Motorcraft Motor Oil XO-15W40-QSD, WSS-M2C171-C, Engine Oil 15W40 Super XO-10W30-QSD CH-4/SJ/SL, DHD-1 Duty, 10W30 Super Duty Engine Oil F4TZ-6731-A Filter (Use this (FL-1995)

  • Page 50: Service Points

    Service points E-SERIES ENGINE COMPARTMENT 1. Battery 2. Windshield washer fluid reservoir 3. Engine oil dipstick 4. Fuel filter/water separator drain valve release handle 5. Automatic transmission fluid dipstick 6. Air filter assembly 7. Engine oil filler 8. Air filter restriction gauge 9.
  • Page 51 Service points F-SERIES AND EXCURSION ENGINE COMPARTMENT 1. Battery (dual batteries shown) 2. Engine coolant recovery reservoir 3. Engine oil filler 4. Engine oil dipstick 5. Automatic transmission dipstick (if equipped) 6. Fuel filter drain valve 7. Clutch fluid reservoir (if equipped) 8.

This manual is also suitable for:

F-350F-450F-550ExcursionPower stroke 7.3l dit

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