2003 Ford F250 Diesel Supplement 2nd Printing
2003 Ford F250 Manual
2003 Ford F250 manual content summary:
- 2003 Ford F250 | Diesel Supplement 2nd Printing - Page 1
Table of contents Introduction Diesel information Warning lights Starting Driving tips General maintenance information Scheduled maintenance Minor troubleshooting guide Capacities and specifications Service points General Owner's Information 2 4 8 10 13 23 38 39 42 44 46 All rights reserved. - 2003 Ford F250 | Diesel Supplement 2nd Printing - Page 2
may cause severe engine and/or transmission damage. There are various manufacturers offering devices to increase turbocharger boost, exhaust brakes to increase stopping/hauling capacity or other such devices to increase the power/torque of the Power Stroke engine. Many owners' past experience with - 2003 Ford F250 | Diesel Supplement 2nd Printing - Page 3
Manual, Ford Truck Body Builder's Layout Book (and pertinent supplements) and the Qualified Vehicle Modifiers Guidelines. Using a Ford vehicle without the Ford Ambulance Preparation Package to produce an ambulance voids the Ford warranty and could result in elevated underbody temperatures, fuel - 2003 Ford F250 | Diesel Supplement 2nd Printing - Page 4
filter should be changed at the recommended service interval. Refer to the Scheduled maintenance guide section of this manual for more information. The HFCM should be drained at regular intervals or when the WATER IN FUEL light illuminates in the instrument cluster. The fuel injectors are located - 2003 Ford F250 | Diesel Supplement 2nd Printing - Page 5
Diesel information Fast start glow plug system The glow plug system consists of: • eight glow plugs • the glow plug control module (GPCM) • engine oil temperature (EOT) sensor • barometric pressure (BARO) sensor The glow plug system is electronically controlled by the PCM. The GPCM energizes the - 2003 Ford F250 | Diesel Supplement 2nd Printing - Page 6
gauge contains an electrical switch which illuminates a warning light on the instrument cluster when the air filter element is 100% clogged. Refer to the Warning lights chapter. Check the air filter restriction gauge whenever the hood is raised to perform general engine maintenance at least every - 2003 Ford F250 | Diesel Supplement 2nd Printing - Page 7
Diesel information Always use the underhood air filter restriction gauge to determine when the air filter element needs to be changed. The warning light on the instrument cluster should not be used exclusively for determining when the air filter element needs changing. After servicing the air filter - 2003 Ford F250 | Diesel Supplement 2nd Printing - Page 8
the ON position. If the light does not illuminate, there may be a problem. Refer to the Starting chapter in this guide. After the engine starts, the light should remain off. WATER IN FUEL During refueling, it is possible for water-contaminated diesel fuel to be pumped into your tank. Your vehicle - 2003 Ford F250 | Diesel Supplement 2nd Printing - Page 9
drain the HFCM 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 The engine air filter warning light illuminates when the air filter restriction gauge reaches the CHANGE FILTER mark. The condition should - 2003 Ford F250 | Diesel Supplement 2nd Printing - Page 10
before you start your vehicle. For temperatures below 0°C (32°F), the use of the correct grade engine oil is essential for proper operation. If your vehicle is equipped with a manual transmission, make sure the parking brake is set fully before you turn the key. Depress the clutch pedal and place - 2003 Ford F250 | Diesel Supplement 2nd Printing - Page 11
WEATHER OPERATION Changing to a lighter grade engine oil also makes starting easier under these conditions. Refer to Engine oil specifications in the General maintenance information chapter. At temperatures below -7°C (20°F), Number 2-D Diesel fuel may thicken enough to clog the fuel filter. Your - 2003 Ford F250 | Diesel Supplement 2nd Printing - Page 12
, slow down to avoid splashing water into the intake. If the engine stalls, and ingestion of water into the engine is suspected, do not try to restart the engine. Consult your dealer for service immediately. Engine block heater (if equipped) Refer to the Starting chapter in your Owner Guide. 12 - 2003 Ford F250 | Diesel Supplement 2nd Printing - Page 13
is delayed for several minutes when the tank selector switch is actuated. Fuel level indication can be obtained immediately by turning off and restarting the engine. MANUAL TRANSMISSION SHIFT SPEEDS Do not overspeed the engine when going downhill or steep grades. If equipped, use the tachometer - 2003 Ford F250 | Diesel Supplement 2nd Printing - Page 14
(11000) 4x4 9072 (20000) 4990 (11000) 6.0L 6.0L Engine 3.73 3.73 Rear axle ratio F-250 Maximum GCWR Maximum kg (lbs.) trailer weight kg (lbs.) Vehicles without fifth wheel 6.0L All 9072 (20000) 5670 (12500) Regular Cab Pickup 4x2 with manual transmission and fifth wheel 6.0L All 9072 (20000) 6167 - 2003 Ford F250 | Diesel Supplement 2nd Printing - Page 15
Crew Cab Pickup 4x2 with automatic transmission and fifth wheel 6.0L All 9072 (20000) 5941 (13100) Crew Cab Pickup 4x4 with manual transmission and fifth wheel 6.0L All 9072 (20000) 4671 (10300) Crew Cab Pickup 4x4 with automatic transmission and fifth wheel 6.0L All 9072 (20000) 4807 (10600) Engine - 2003 Ford F250 | Diesel Supplement 2nd Printing - Page 16
(20000) 5670 (12500) 4x2 with manual transmission and fifth wheel 6.0L All 9072 (20000) 6167 (13600) 4x2 with automatic transmission and fifth wheel 6.0L All 9072 (20000) 6213 (13700) 4x4 with fifth wheel 6.0L All 9072 (20000) 6033 (13300) Engine F-350 Regular Cab Dual Rear Wheel Pickup Rear axle - 2003 Ford F250 | Diesel Supplement 2nd Printing - Page 17
F-350 Crew Cab Single Rear Wheel Pickup Engine Rear axle Maximum GCWR Maximum ratio kg (lbs.) trailer weight kg (lbs.) Vehicles without fifth wheel 6.0L All 9072 (20000) 5670 (12500) 4x2 with manual transmission and fifth wheel 6.0L All 9072 (20000) 5850 (12900) 4x2 with automatic transmission and - 2003 Ford F250 | Diesel Supplement 2nd Printing - Page 18
kg (lbs.) 4x2 6.0L All 9072 (20000) 5759 (12700) 4x4 6.0L All 9072 (20000) 5532 (12200) F-350 SuperCab Chassis Cab Single Rear Wheel (Fifth Wheel Towing) Engine Rear axle Maximum GCWR Maximum ratio kg (lbs.) trailer weight kg (lbs.) 4x2 with manual transmission 6.0L All 9072 (20000) 5759 (12700) 18 - 2003 Ford F250 | Diesel Supplement 2nd Printing - Page 19
6.0L All 9072 (20000) 5668 (12500) 4x4 with manual transmission 6.0L All 9072 (20000) 5442 (12000) 4x4 with automatic transmission 6.0L All 9072 (20000) 5487 (12100) F-350 Crew Cab Chassis Cab Single Rear Wheel (Fifth Wheel Towing) Engine Rear axle Maximum GCWR Maximum ratio kg (lbs.) trailer - 2003 Ford F250 | Diesel Supplement 2nd Printing - Page 20
.) trailer weight kg (lbs.) 4x4 with automatic transmission 6.0L All 9072 (20000) 5534 (12200) F-350 Crew Cab Chassis Cab Dual Rear Wheel (Fifth Wheel Towing) Engine Rear axle Maximum GCWR Maximum ratio kg (lbs.) trailer weight kg (lbs.) 4x2 with manual transmission 6.0L All 9072 (20000) 5534 (12200 - 2003 Ford F250 | Diesel Supplement 2nd Printing - Page 21
) 7981 (17600) Regular Chassis Cab 4x4 with automatic transmission 6.0L All 11793 (26000) 8029 (17700) SuperCab Chassis Cab 4x2 6.0L All 11793 (26000) 8029 (17700) SuperCab Chassis Cab 4x4 6.0L All 11793 (26000) 7802 (17200) Crew Cab Chassis Cab 4x2 with manual transmission 6.0L All 11793 (26000 - 2003 Ford F250 | Diesel Supplement 2nd Printing - Page 22
(26000) 7891 (17400) 6.0L (with 4.88 13608 (30000) 9705 (21400) high capacity trailer tow package) Crew Cab Chassis Cab 4x4 with manual transmission 6.0L All 11793 (26000) 7709 (17000) Crew Cab Chassis Cab 4x4 with automatic transmission 6.0L All 11793 (26000) 7756 (17100) Engine Rear axle ratio 22 - 2003 Ford F250 | Diesel Supplement 2nd Printing - Page 23
the life and performance of your vehicle. 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 - 2003 Ford F250 | Diesel Supplement 2nd Printing - Page 24
heating oil or any Diesel fuel not intended for highway use. Damage to the fuel injection system, engine and exhaust catalyst can occur if an improper fuel is used. Do not add gasoline, gasohol or alcohol to Diesel fuel. This practice creates a serious fire hazard and engine performance problems. It - 2003 Ford F250 | Diesel Supplement 2nd Printing - Page 25
in the module. Replace the fuel filters with Ford Part No. 3C3Z-9N184-CA. This part number includes filters and seals for both the engine-mounted and frame-mounted filters. DRAINING THE HFCM AND CHANGING THE FUEL FILTERS Your vehicle is equipped with two fuel filters; one mounted on top of - 2003 Ford F250 | Diesel Supplement 2nd Printing - Page 26
information HFCM drain procedure 1. Stop the vehicle and shut off the engine. The vehicle must be stopped with the engine off when draining the HFCM. Fuel may ignite if separator is drained while the engine is running or vehicle is moving. 2. Locate the HFCM and place an appropriate container under - 2003 Ford F250 | Diesel Supplement 2nd Printing - Page 27
the new fuel filter and cap seal (from Ford Part No. 3C3Z-9N184-CA) into the fuel filter housing. 2. Tighten cap onto fuel filter housing slowly, allowing fuel to soak into the fuel filter element. Tighten cap until it contacts the housing. After replacing the fuel filter, the engine will purge - 2003 Ford F250 | Diesel Supplement 2nd Printing - Page 28
maintenance information ENGINE OIL Checking the engine oil level Because it is normal to add some oil between oil changes, check your engine oil level each time you stop for fuel. To check the engine oil level consistently and accurately, the following procedure is recommended: 1. Have engine at - 2003 Ford F250 | Diesel Supplement 2nd Printing - Page 29
the owner guide recommendation. The center section will show the SAE viscosity grade. The lower section will state energy conserving if the oil has proven fuel saving capabilities. Changing engine oil and filter Change your oil and filter according to the scheduled maintenance guide. Change more - 2003 Ford F250 | Diesel Supplement 2nd Printing - Page 30
of 16 km (10 miles) or less during freezing weather If you are operating your vehicle under any of these conditions, observe the following service procedures: • Change engine oil and filter every 8,000 km (5,000 miles). • Use Motorcraft oil or an equivalent oil conforming to Ford Specification WSS - 2003 Ford F250 | Diesel Supplement 2nd Printing - Page 31
to ensure good sealing. 3. Install a new air filter element. Be careful not to crimp the filter edges between the air filter housing and cover. This could cause damage to the air filter element and possible severe damage to the engine. When servicing the air filter, always be sure that the auxiliary - 2003 Ford F250 | Diesel Supplement 2nd Printing - Page 32
in this chapter. Note: Automotive fluids are not interchangeable; do not use engine coolant or windshield washer fluid outside of its specified function and vehicle location. Vehicles with Diesel engines typically are used to carry heavy loads and accumulate mileage rapidly. These two factors cause - 2003 Ford F250 | Diesel Supplement 2nd Printing - Page 33
large amount of water without engine coolant may be added, in case of emergency, to reach a vehicle service location. In this instance, the full" level. For all other vehicles, which have a coolant degas system with a pressurized cap, or if it is necessary to remove the coolant pressure relief cap - 2003 Ford F250 | Diesel Supplement 2nd Printing - Page 34
To avoid damaging the engine and radiator, the coolant concentrate should not exceed 60%. When refilling the coolant system either as part of the regular maintenance (refer to the scheduled maintenance guide), or due to service performed, adhere to the following instructions: 1. Drain and flush the - 2003 Ford F250 | Diesel Supplement 2nd Printing - Page 35
Motorcraft Premium Gold Engine Coolant since a Ford-approved recycling process is not yet available. Used engine coolant should be disposed of in an appropriate manner. Follow your community's regulations and standards for recycling and disposing of automotive fluids. Coolant refill capacity To find - 2003 Ford F250 | Diesel Supplement 2nd Printing - Page 36
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 - 2003 Ford F250 | Diesel Supplement 2nd Printing - Page 37
General maintenance information to its sale or delivery to the ultimate purchaser or while it is in use, Agency may presume to constitute tampering are the acts listed below: • Removal of hood blanket, fender apron absorbers, fender apron barriers, underbody noise shields or acoustically absorptive - 2003 Ford F250 | Diesel Supplement 2nd Printing - Page 38
stationary (door to door service, taxi, etc.), then it is recommended that you change the engine oil every 200 engine hours as opposed to a mileage limit. Since most vehicles are not equipped with hourmeters, it may be necessary for you to approximate your time and plan engine oil and filter changes - 2003 Ford F250 | Diesel Supplement 2nd Printing - Page 39
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, - 2003 Ford F250 | Diesel Supplement 2nd Printing - Page 40
the Roadside emergencies chapter of your owner guide. IF ENGINE CRANKS BUT WON'T START Prolonged starter cranking (in excess of 30 seconds) could cause damage to the starter motor. • Check the fuel gauge. You may be out of fuel. If the gauge shows that there is fuel in the tank, the trouble may be - 2003 Ford F250 | Diesel Supplement 2nd Printing - Page 41
Minor troubleshooting guide • Plugged radiator fins, charge air cooler, A/C condenser and/or oil cooler. • Driving with frozen coolant. • Sticking thermostat. • Overloading or pulling heavy trailers during hot weather. • Grill or radiator air blockage. • Slipping or missing drive belt. • Plugged or - 2003 Ford F250 | Diesel Supplement 2nd Printing - Page 42
and specifications Capacities and specifications REFILL CAPACITIES Component Cooling system Engine oil 2 Fuel tank (F-250/350/450/550) Fuel tank (Excursion) Radiator cap Manual transmission 3 Automatic transmission 1 2 1 Capacity 26.0L (27.5 quarts) 14.2L (15.0 quarts) Refer to Owner Guide 166.6L - 2003 Ford F250 | Diesel Supplement 2nd Printing - Page 43
- - Engine Oil Engine Oil Filter (Use this filter Only) Air Filter2 Battery (2 Required) Engine coolant VC-7-A WSS-M97B51-A1 Manual Transmission Automatic transmission 1 XT-2-QDX MERCON Refer to Owner Guide Refer to the engine oil specification chart located under Engine oil specifications - 2003 Ford F250 | Diesel Supplement 2nd Printing - Page 44
Service points 1. Battery (dual batteries shown) 2. Air filter assembly 3. Power steering fluid reservoir 4. Clutch fluid reservoir (if equipped) 5. Brake fluid reservoir 6. Engine coolant reservoir 7. Engine oil dipstick 8. Engine-mounted fuel filter assembly 9. Engine oil filter 10. Engine oil - 2003 Ford F250 | Diesel Supplement 2nd Printing - Page 45
Service points The Horizontal Fuel Conditioner Module (HFCM) located on the frame-rail under the driver-side floorboard near the transmission. 45 - 2003 Ford F250 | Diesel Supplement 2nd Printing - Page 46
inquiry or concern remains unresolved, contact the Sales Manager or Service Manager at the dealership. 3. If the inquiry or concern cannot be resolved at the dealership level, please contact the Ford Customer Assistance Center. In the US, contact: Ford Motor Company Customer Assistance Center 16800 - 2003 Ford F250 | Diesel Supplement 2nd Printing - Page 47
General Owner's Information In Puerto Rico and Virgin Islands, contact: Ford Motor Company Caribbean Inc. P.O. Box 11957, Caparra Heights Station San Juan, PR 00922-1957 Telephone: (787) 782-5959 Fax: (787) 781-8975 E-mail: [email protected] In Caribbean, Central America, Israel and Sub-Saharan Africa, - 2003 Ford F250 | Diesel Supplement 2nd Printing - Page 48
General Owner's Information FIND YOUR WAY Symbol Key Diesel Towing a trailer or using a camper or car-top carrier Extensive idling and/or low- meet Ford engineering specifications. Failure to perform scheduled maintenance specific in this guide will invalidate warranty coverage on parts affected - 2003 Ford F250 | Diesel Supplement 2nd Printing - Page 49
fix it right the first time. The right parts From headlights to taillights and everything in between, nothing fits like an original. With Quality Care service, you'll get the parts made especially for your car or truck - genuine Ford and Motorcraft parts. The right prices Our commitment to quality - 2003 Ford F250 | Diesel Supplement 2nd Printing - Page 50
every month: • Check function of all interior and exterior lights • Check tires for wear and proper air pressure • Check engine oil fluid level • Check windshield washer solvent fluid level • Check and drain fuel filter/water separator Check every six months: • Check lap/shoulder belts and seat - 2003 Ford F250 | Diesel Supplement 2nd Printing - Page 51
much more. The website location is at: www.ford.com/ Then go to the service pick at the web site. 12,000 km (7,500 miles) • Change engine oil and replace oil filter • Inspect tires for wear and measure tread depth • Rotate tires • Inspect engine air filter minder, replace filter as required 24,000 - 2003 Ford F250 | Diesel Supplement 2nd Printing - Page 52
filter as required • Replace engine- and frame-mounted fuel filters • Inspect steering linkage, suspension and, if equipped, driveshaft and ball joints • Inspect engine cooling system and hoses • Inspect brake system • Inspect exhaust system and heat shields • Change automatic transmission fluid - 2003 Ford F250 | Diesel Supplement 2nd Printing - Page 53
fuel filters • Inspect steering linkage, suspension and, if equipped, driveshaft and ball joints • Inspect engine cooling system and hoses • Inspect brake system • Inspect exhaust system and heat shields • Change automatic transmission fluid and external filter element • Change manual transmission - 2003 Ford F250 | Diesel Supplement 2nd Printing - Page 54
Change engine oil and replace oil filter • Inspect tires for wear and measure tread depth • Rotate tires • Inspect engine air filter minder, replace filter as required • Replace engine- and frame-mounted fuel filters • Inspect steering linkage, suspension and, if equipped, driveshaft and ball joints - 2003 Ford F250 | Diesel Supplement 2nd Printing - Page 55
General Owner's Information Inspect engine cooling system and hoses Inspect brake system Inspect exhaust system and heat shields Change automatic transmission fluid and external filter element Check wheels for end play and noise Inspect and lubricate 4x2 ball joints (except F-450/F-550) Inspect - 2003 Ford F250 | Diesel Supplement 2nd Printing - Page 56
fuel filters • Inspect steering linkage, suspension and, if equipped, driveshaft and ball joints • Inspect engine cooling system and hoses • Inspect brake system • Inspect exhaust system and heat shields • Change automatic transmission fluid and external filter element • Change manual transmission - 2003 Ford F250 | Diesel Supplement 2nd Printing - Page 57
fuel filters • Inspect steering linkage, suspension and, if equipped, driveshaft and ball joints • Inspect engine cooling system and hoses • Inspect brake system • Inspect exhaust system and heat shields • Replace accessory drive belt(s) • Change engine coolant • Change automatic transmission fluid - 2003 Ford F250 | Diesel Supplement 2nd Printing - Page 58
axles and power take off (PTO) units containing synthetic lubricant and light duty trucks equipped with Ford-design axles are lubricated for life. These lubricants are not to be checked or changed unless a leak is suspected, service is required or the axle assembly has been submerged in water. The - 2003 Ford F250 | Diesel Supplement 2nd Printing - Page 59
6 months: Change engine oil and replace filter Every 15,000 miles: Inspect and lubricate 4x2 ball joints and steering idler arms Every 30,000 miles: Lubricate 4x4 hub needle bearings Every 60,000 miles: Change transfer case fluid As required: Change manual transmission fluid Extensive idling and/or - 2003 Ford F250 | Diesel Supplement 2nd Printing - Page 60
General Owner's Information Off-road operation Every 5,000 miles or 6 months: Change engine oil and replace filter Every 15,000 miles: Lubricate 4x4 hub needle bearings Every 60,000 miles: Change transfer case fluid As required: Inspect and lubricate 4x2 ball joints and steering idler arms. Replace - 2003 Ford F250 | Diesel Supplement 2nd Printing - Page 61
General Owner's Information YELLOW COOLANT CHANGE RECORD Date: 3 Years \ \ + Dealer's Stamp: 3 Next Date or Current Mileage: 50,000 Miles + 50,000 Next Mileage: Date: 3 Years \ \ + Dealer's Stamp: 3 Next Date or Current Mileage: 50,000 Miles + 50,000 Next Mileage: Date: 3 Years \ \ + 3 - 2003 Ford F250 | Diesel Supplement 2nd Printing - Page 62
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Introduction
2
Diesel information
4
Warning lights
8
Starting
10
Driving tips
13
General maintenance information
23
Scheduled maintenance
38
Minor troubleshooting guide
39
Capacities and specifications
42
Service points
44
General Owner’s Information
46
All rights reserved. Reproduction by any means, electronic or mechanical
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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 © 2003 Ford Motor Company
Table of contents
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