2005 Ford F350 Diesel Supplement 3rd Printing

2005 Ford F350 Manual

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  • 2005 Ford F350 | Diesel Supplement 3rd Printing - Page 1
    Introduction Instrumentation Driving Roadside emergencies Cleaning Maintenance and Specifications Engine Coolant 2 6 12 19 25 27 41 Scheduled storage and retrieval system or translation in whole or part is not permitted without written authorization from Ford Motor Company. Ford may change the
  • 2005 Ford F350 | Diesel Supplement 3rd Printing - Page 2
    part of the vehicle. Some aftermarket products may cause severe engine and/or transmission damage; refer to the "What is not covered" section in "The new vehicle limited warranty for your vehicle" chapter of your vehicle's "Warranty Guide" for more information. Your vehicle's Powertrain Control
  • 2005 Ford F350 | Diesel Supplement 3rd Printing - Page 3
    The Diesel engine fuel system consists of: • On F-Super Duty and Excursion vehicles, a frame-mounted Horizontal Fuel Conditioner Module (HFCM) • On E-Series vehicles, a Fuel Conditioner Module (FCM) mounted on the driver-side of the transmission case • an engine-mounted secondary fuel filter
  • 2005 Ford F350 | Diesel Supplement 3rd Printing - Page 4
    plug system and fuel injection system are controlled through the Powertrain Control Module (PCM) and Fuel Injection Control Module (FICM). Fuel is drawn from the fuel tank by a frame-mounted electric fuel pump. The fuel pump provides pressurized fuel to the engine and is electronically controlled
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    The PCM controls fuel input to limit maximum engine speed. It will not, however, prevent engine overspeeding resulting from downshifting at high vehicle speed or by descending steep grades at too high a vehicle speed for the selected transmission gear. On F-Super Duty vehicles equipped with a manual
  • 2005 Ford F350 | Diesel Supplement 3rd Printing - Page 6
    Instrumentation E-SERIES EXCURSION H 40 60 80 00 20 40 60 KM/H RPMX1000 H C H C L F E DIESEL FUEL ONLY 20 0 MPH SELECT RESET TOW HAUL PRN D 321 F-SUPER DUTY CLUSTER (EXCEPT HARLEY-DAVIDSON) 6 2005 Econoline (eco) Supplement USA (fus)
  • 2005 Ford F350 | Diesel Supplement 3rd Printing - Page 7
    F-SUPER DUTY HARLEY-DAVIDSON 2 H 3 RPMX1000 50 60 40 4 30 20 20 160 0 180 km/h MPH 60 80 100 70 120 1 L TURBO PSI 20 0 40 40 140 80 90 L H 0 F E DIESEL FUEL ONLY 5 10 0 100 km/h 110 C H D 32 P RN D SELECT/RESET Glow plug pre-heat indicator With the key in the ON position, light
  • 2005 Ford F350 | Diesel Supplement 3rd Printing - Page 8
    the vehicle is moving. Engine air filter (if equipped) The engine air filter warning light illuminates when the air filter restriction gauge reaches the CHANGE FILTER mark. Type A Type B Type C The condition should be verified by inspecting the underhood air filter restriction gauge; the warning
  • 2005 Ford F350 | Diesel Supplement 3rd Printing - Page 9
    vehicle may be driven with the engine air filter warning light illuminated/or when the underhood air filter restriction gauge has moved to the CHANGE FILTER mark for up to 250 miles (400 km) without damaging the engine or related components. However, the air filter element must be replaced at the
  • 2005 Ford F350 | Diesel Supplement 3rd Printing - Page 10
    . 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. 10 2005 Econoline (eco) Supplement USA
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    of the air filter element. Refer to the Engine air filter warning light in this chapter of the supplement. Engine boost gauge (if equipped) Indicates the amount of pressure in the engine. Driving with your pointer continuously at the high end of the scale may damage the engine. 11 2005 Econoline
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    or colder. Refer to Using the engine block heater (if equipped) in the Driving chapter of the Owner's Guide. When operating in cold weather, use a minimum of 45 Cetane Diesel fuel or use Cetane Index improvers from a reputable manufacturer. Do not crank the engine for more than 30 seconds as starter
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    2-D diesel fuel may thicken enough to clog the fuel filter. Your vehicle is equipped with either an FCM (E-Series) or an HFCM (F-Super Duty and Excursion) which acts as a fuel filter/heater/water separator to keep the wax melted which will help prevent fuel filter clogging. However, if the engine
  • 2005 Ford F350 | Diesel Supplement 3rd Printing - Page 14
    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 Driving chapter in the Owner's Guide. 14 2005 Econoline (eco) Supplement USA
  • 2005 Ford F350 | Diesel Supplement 3rd Printing - Page 15
    ) 4.10 20000 (9072) 10000 (4536) E-350 Extended Van (9400 GVWR) 3.55 16000 (7257) 9500 (4309) 4.10 20000 (9072) 10000 (4536) E-350 Extended Van (Crew) (9400 GVWR) 3.55 16000 (7257) 9300 (4218) 4.10 20000 (9072) 10000 (4536) Rear axle ratio 6.0L 6.0L 6.0L 6.0L 6.0L 6.0L 6.0L 6.0L 15 2005 Econoline
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    , dual rear wheel) (11500 GVWR) 6.0L 4.10 20000 (9072) 10000 (4536) E-450 Cutaway 158" wheelbase) (14050 GVWR) 6.0L 4.10 20000 (9072) 10000 (4536) E-350 Cutaway 176" wheelbase) (14050 GVWR) 6.0L 4.10 20000 (9072) 10000 (4536) Engine Rear axle ratio 16 2005 Econoline (eco) Supplement USA (fus)
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    F-Super Duty Excursion Engine Rear axle ratio Maximum GCWR Maximum lbs. (kg) trailer weight lbs. (kg) 4x2 20000 (9072) 11000 (4988) 4x4 20000 (9072) 11000 (4988) 6.0L 6.0L F-Super Duty 3.73 3.73 Maximum GCWR - lbs (kg.) Rear axle Manual Automatic ratio transmission transmission F-250/F-350 Single
  • 2005 Ford F350 | Diesel Supplement 3rd Printing - Page 18
    hitch ball, spring bars and snap-up brackets. The vertical tongue load of the trailer is distributed between the truck and the trailer by this system. F-Super Duty Maximum Gross Trailer Weight - lb. (kg) 6000 (2721) 15000 (6804) Maximum Tongue Weight - lb. (kg) 600 (272) 1500 (680) Hitch Type 6.0L
  • 2005 Ford F350 | Diesel Supplement 3rd Printing - Page 19
    STARTING YOUR VEHICLE (E-SERIES ONLY) F-Super Duty and Excursion vehicles equipped with the 6.0L diesel engine can be jump started using the same procedure as a gasoline engine; refer to your Owner's guide for the jump starting procedure. The gases around the battery can explode if exposed to flames
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    other accessories off. Connecting the jumper cables 1. Connect the positive (+) jumper cable to the positive (+) jumper stud located on the passenger side frame rail of the disabled vehicle. Note: In the illustrations, lightning bolts are used to designate the assisting (boosting) battery. 20 2005
  • 2005 Ford F350 | Diesel Supplement 3rd Printing - Page 21
    Roadside emergencies 2. Connect the other end of the positive (+) cable to the positive (+) terminal of the assisting battery. 3. Connect the negative (-) cable to the negative (-) terminal of the assisting battery. 21 2005 Econoline (eco) Supplement USA (fus)
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    cause an explosion of the gases that surround the battery. 5. Ensure that the cables are clear of moving parts or any fuel delivery system, brake system or exhaust system parts. Jump starting 1. Start the engine of the booster vehicle and run the engine at moderately increased speed. 2. Start the
  • 2005 Ford F350 | Diesel Supplement 3rd Printing - Page 23
    . 1. Remove the jumper cable from the ground metal surface. 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. 23 2005 Econoline (eco) Supplement USA (fus)
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    Remove the jumper cable from the positive (+) terminal of the booster vehicle's battery. 4. Remove the jumper cable from the positive (+) jumper stud of the allow it to idle for several minutes so the engine computer can relearn its idle conditions. 24 2005 Econoline (eco) Supplement USA (fus)
  • 2005 Ford F350 | Diesel Supplement 3rd Printing - Page 25
    on all parts that require cleaning and pressure rinse clean. • Never wash or rinse the engine while it is running; water in the running engine may cause internal damage. • Cover the highlighted areas to prevent water damage when cleaning the engine. • F-Super Duty and Excursion 25 2005 Econoline
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    Cleaning • E-Series 26 2005 Econoline (eco) Supplement USA (fus)
  • 2005 Ford F350 | Diesel Supplement 3rd Printing - Page 27
    3. Engine oil filler cap 4. Secondary fuel filter assembly 5. Power steering fluid reservoir 6. Brake fluid reservoir 7. Engine coolant reservoir 8. Air filter assembly The Fuel Conditioner Module (FCM) is located on the driver-side of the vehicle next to the transmission case. 27 2005 Econoline
  • 2005 Ford F350 | Diesel Supplement 3rd Printing - Page 28
    fuel filter assembly 5. Engine coolant reservoir 6. Brake fluid reservoir 7. Clutch fluid reservoir (if equipped) 8. Underhood relay box 9. Battery (dual batteries shown) 10. Power steering fluid reservoir 11. Air filter assembly 12. Engine oil dipstick 13. Windshield washer fluid reservoir 28 2005
  • 2005 Ford F350 | Diesel Supplement 3rd Printing - Page 29
    . 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. FUEL REQUIREMENTS Choosing the right fuel The engine is designed to use low sulfur number 1-D or 2-D Diesel fuel only. At
  • 2005 Ford F350 | Diesel Supplement 3rd Printing - Page 30
    have pumps and nozzles designed for larger, heavy-duty trucks. When refueling at truck stops: if the nozzle shuts off repeatedly when refueling, wait 5-10 seconds; then use a slower rate of flow (don't depress the nozzle trigger as far). If air is allowed to enter the fuel system (during fuel filter
  • 2005 Ford F350 | Diesel Supplement 3rd Printing - Page 31
    the fuel filters with Ford Part No. FD-4604. This part number includes filters and seals for both the engine-mounted filter and the FCM filter. DRAINING THE FCM/HFCM AND CHANGING THE FUEL FILTERS Your vehicle is equipped with two fuel filters; one is mounted on top of the engine. On F-Super Duty
  • 2005 Ford F350 | Diesel Supplement 3rd Printing - Page 32
    off when draining the HFCM/FCM. Fuel may ignite if the separator is drained while the engine is running or vehicle is moving. 2. Locate the HFCM and place an appropriate container under the drain port (see illustration). • F-Super Duty /Excursion • E-Series 3. Rotate drain lever to the outward
  • 2005 Ford F350 | Diesel Supplement 3rd Printing - Page 33
    HFCM filter (F-Super Duty/Excursion) 1. Remove the fuel filter cap by turning counterclockwise. 2. Remove and discard the old fuel filter element. 3. Carefully clean the mating surfaces. Removal - FCM filter (E-Series) 1. Remove the fuel filter cap by turning counterclockwise. 33 2005 Econoline
  • 2005 Ford F350 | Diesel Supplement 3rd Printing - Page 34
    and Specifications 2. Remove and discard the old fuel filter element. 3. Carefully clean the mating surfaces. Removal - Engine-mounted fuel filter • F-Super Duty/Excursion • E-Series 1. Remove the fuel filter cap by turning counterclockwise. 34 2005 Econoline (eco) Supplement USA (fus)
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    fuel filter and cap seal (from Ford Part No. FD-4604) 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 the trapped air
  • 2005 Ford F350 | Diesel Supplement 3rd Printing - Page 36
    Ford Specification, API service categories and SAE viscosity grades listed in the Lubricant and Maintenance Materials Specifications chart. Some energy conserving oils do not meet the requirements necessary for your diesel engine. * Heavy duty trailer towing with ambient temperatures above 50°F (10
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    vehicle operation includes extended periods of idling or low-speed operation, driving for a long time in cold temperatures or driving short distances. See the following section Engine lubrication for severe service operation for all severe duty restrictions. Use Ford Engine Oil Filter Part No. 3C3Z
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    scheduled maintenance information section of this supplement. AIR FILTER When replacing the air filter element, use the Motorcraft air filter element listed. Refer to the Motorcraft part numbers chart in this chapter. Note: Do not start your engine with the air cleaner removed and do not remove it
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    the electrical connector.) 4. Disconnect the three latches and remove the air cleaner cover 5. Remove the air cleaner element. 6. To install, reverse the removal procedure. • F-Super Duty air filter element: 1. Release and flip the toggle clamps back. 39 2005 Econoline (eco) Supplement USA (fus)
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    pulling up to disengage the tabs on the cover from the slots on the filter element while pulling up on the rear of the filter element. Front cover tabs must be disengaged from the slots before pulling it or damage to the air cleaner element will occur. 40 2005 Econoline (eco) Supplement USA (fus)
  • 2005 Ford F350 | Diesel Supplement 3rd Printing - Page 41
    removal. When servicing the air filter, always be sure that the auxiliary hose is not kinked or obstructed and that it is placed back into the hole in the front cowl near the back of the headlamp. Check all hose and wiring positions. Failure to do so may result in severe engine damage when driving
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    coolant reservoir (depending upon application). • Refer to the General Owner's Information for service interval schedules. • Be sure to read and understand Precautions when servicing your vehicle in your Owner's Guide. If the engine coolant has not been checked at the recommended interval, the
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    emergency, to reach a vehicle service location. In this instance, the cooling system must be drained and refilled with a 50/50 mixture of engine coolant and distilled water as soon as possible. Water alone (without engine coolant) can cause engine damage from corrosion, overheating or freezing. • Do
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    coolant per month, have your dealer check the engine cooling system. Your cooling system may have a leak. Operating an engine with a low level of coolant can result in engine overheating and possible engine damage. Recycled engine coolant Ford Motor Company does NOT recommend the use of recycled
  • 2005 Ford F350 | Diesel Supplement 3rd Printing - Page 45
    repairing, servicing, selling, leasing or trading motor vehicles as well as fleet operations from unknowingly removing or rendering emission control system(s) inoperative. Further, modifications of the emission control system(s) could create liability on the part of the individual owners under the
  • 2005 Ford F350 | Diesel Supplement 3rd Printing - Page 46
    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: • a plugged air inlet system or engine air filter element. • water in the fuel filter
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    or during a fuel filter change), the engine will self-purge the trapped air once it starts running. The engine may run roughly and produce white smoke while air is in the fuel system; this is normal and should stop after a short time. MINOR TROUBLESHOOTING GUIDE If the engine won't crank Turn on the
  • 2005 Ford F350 | Diesel Supplement 3rd Printing - Page 48
    Owner's Guide (F-Super Duty and Excursion) or refer to the Jump starting section in the Roadside Emergencies chapter of this supplement (E-Series). 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
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    5.8 quarts (5.5L) Manual transmission3 Automatic transmission Refer to your Owner's Guide 1 Includes heater and 5.0 quarts (4.7L) in coolant recovery. 2 Includes 1 quart (1.0L) in engine oil filter. 3 Use Motorcraft MERCON௡ ATF, Motorcraft part number XT-2-QDX, meeting Ford specification MERCON௡. 49
  • 2005 Ford F350 | Diesel Supplement 3rd Printing - Page 50
    ) and NM) Motorcraft XT-2-QDX MERCON௡ MERCON௡ ATF Refer to Owner's Guide Engine Oil Engine coolant Manual Transmission Automatic transmission 1 Refer to the engine oil specification chart located under Engine oil specifications in this chapter. 50 2005 Econoline (eco) Supplement USA (fus)
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    Ford engineering specifications. Failure to perform scheduled maintenance in this guide will invalidate warranty coverage on parts affected and its emission control systems, it is imperative that scheduled maintenance be completed at the designated intervals. 51 2005 Econoline (eco) Supplement
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    service of components affecting emission control must be equivalent to genuine Ford Motor Company parts in performance and durability. It is the owner's responsibility to determine the equivalency of such parts. Please consult your Warranty Guide for complete warranty information. Engine Emissions
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    for wear and adjust air pressure (including spare tire) • Check engine oil level • Check windshield washer fluid level • Check and drain fuel filter/water separator Check every six months: • Check lap/shoulder belts and seat latches for wear and function 53 2005 Econoline (eco) Supplement USA (fus
  • 2005 Ford F350 | Diesel Supplement 3rd Printing - Page 54
    up fluid levels: brake, coolant recovery reservoir, manual and automatic transmission, power steering and window washer. • Inspect tires for wear and check air pressure, including spare. • Check exhaust system for leaks, damage, loose parts and foreign materials. • Check battery performance. • Check
  • 2005 Ford F350 | Diesel Supplement 3rd Printing - Page 55
    engine- and frame-mounted fuel filters • Perform multi-point inspection (recommended) • Inspect tires for wear and rotate • Inspect air filter restriction gauge, replace filter as required • Inspect and lubricate steering linkage, ball joints, suspension, driveshaft and u-joints 55 2005 Econoline
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    ) • Inspect tires for wear and rotate • Inspect air filter restriction gauge, replace filter as required • Inspect and lubricate steering linkage, ball joints, suspension, driveshaft and u-joints • Inspect engine cooling system and hoses • Inspect brake pads, shoes, rotors, drums, brake lines and
  • 2005 Ford F350 | Diesel Supplement 3rd Printing - Page 57
    -mounted fuel filters • Perform multi-point inspection (recommended) • Inspect tires for wear and rotate • Inspect air filter restriction gauge, replace filter as required • Inspect and lubricate steering linkage, ball joints, suspension, driveshaft and u-joints • Inspect engine cooling system and
  • 2005 Ford F350 | Diesel Supplement 3rd Printing - Page 58
    filter • Replace engine- and frame-mounted fuel filters • Change automatic transmission fluid and external filter element • Change manual transmission fluid • Lubricate 4x4 front hub needle bearings (Excursion only) • Lubricate 4x2 front wheel bearings, adjust wheel bearings and replace grease seals
  • 2005 Ford F350 | Diesel Supplement 3rd Printing - Page 59
    -mounted fuel filters • Perform multi-point inspection (recommended) • Inspect tires for wear and rotate • Inspect air filter restriction gauge, replace filter as required • Inspect and lubricate steering linkage, ball joints, suspension, driveshaft and u-joints • Inspect engine cooling system and
  • 2005 Ford F350 | Diesel Supplement 3rd Printing - Page 60
    ) • Inspect tires for wear and rotate • Inspect air filter restriction gauge, replace filter as required • Inspect and lubricate steering linkage, ball joints, suspension, driveshaft and u-joints • Inspect engine cooling system and hoses • Inspect brake pads, shoes, rotors, drums, brake lines and
  • 2005 Ford F350 | Diesel Supplement 3rd Printing - Page 61
    ) • Inspect tires for wear and rotate • Inspect air filter restriction gauge, replace filter as required • Inspect and lubricate steering linkage, ball joints, suspension, driveshaft and u-joints • Inspect engine cooling system and hoses • Inspect brake pads, shoes, rotors, drums, brake lines and
  • 2005 Ford F350 | Diesel Supplement 3rd Printing - Page 62
    filter • Replace engine- and frame-mounted fuel filters • Change automatic transmission fluid and external filter element • Change manual transmission fluid • Lubricate 4x4 front hub needle bearings (Excursion only) • Lubricate 4x2 front wheel bearings, adjust wheel bearings and replace grease seals
  • 2005 Ford F350 | Diesel Supplement 3rd Printing - Page 63
    -mounted fuel filters • Perform multi-point inspection (recommended) • Inspect tires for wear and rotate • Inspect air filter restriction gauge, replace filter as required • Inspect and lubricate steering linkage, ball joints, suspension, driveshaft and u-joints • Inspect engine cooling system and
  • 2005 Ford F350 | Diesel Supplement 3rd Printing - Page 64
    grease seals (if non-sealed bearings) • Perform multi-point inspection (recommended) • Inspect tires for wear and rotate • Inspect air filter restriction gauge, replace filter as required • Inspect and lubricate steering linkage, ball joints, suspension, driveshaft and u-joints 64 2005 Econoline
  • 2005 Ford F350 | Diesel Supplement 3rd Printing - Page 65
    vehicle axle maintenance Rear 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
  • 2005 Ford F350 | Diesel Supplement 3rd Printing - Page 66
    ): Change engine oil and replace filter Every 5,000 miles (8,000 km): Check air filter restriction gauge (replace air filter as required or when air filter restriction gauge indicates) Every 5,000 miles (8,000 km): Inspect brake system. Inspect and lubricate 4x2 ball joints and steering idler arms
  • 2005 Ford F350 | Diesel Supplement 3rd Printing - Page 67
    or 6 months: Change engine oil and replace filter Every 5,000 miles (8,000 km): Check air filter restriction gauge (replace air filter as required or when air filter restriction gauge indicates) Every 15,000 miles (24,000 km): Inspect and lubricate 4x2 ball joints and steering idler arms and linkage
  • 2005 Ford F350 | Diesel Supplement 3rd Printing - Page 68
    case fluid Date: Odometer reading: R.O.# Dealer's Stamp: See corresponding mileage in maintenance schedule for services performed. Short trip in cold operating conditions Every 5,000 miles (8,000 km): Inspect and lubricate 4x2 ball joints and steering idler arms Every 60,000 miles (96,000 km
  • 2005 Ford F350 | Diesel Supplement 3rd Printing - Page 69
    . Date: Odometer reading: R.O.# Dealer's Stamp: See corresponding mileage in maintenance schedule for services performed. Date: Odometer reading: R.O.# Dealer's Stamp: See corresponding mileage in maintenance schedule for services performed. 69 2005 Econoline (eco) Supplement USA (fus)
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    guide is designed to allow your Ford or Lincoln Mercury dealer, or Ford or Lincoln Mercury Auto Care service center or other qualified service technician to record that the recommended service was completed at the appropriate mileage intervals. Be sure to ask your service provider to record the type
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    R.O.# Current mileage goes here => Add 45,000 miles to the current miles Next change due at this mileage => Or Today's date goes here => Add 3 years Date of next change => whichever comes first Dealer Stamp + 45,000 + 00 / 00 / 03 P & A CODE R.O.# 71 2005 Econoline (eco) Supplement USA (fus
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Introduction
2
Instrumentation
6
Driving
12
Roadside emergencies
19
Cleaning
25
Maintenance and Specifications
27
Engine Coolant
41
Scheduled Maintenance Information
51
Normal Scheduled Maintenance and Log
55
Exceptions
65
Special Operating Conditions and Log
66
Motorcraft Premium Gold Coolant Change Record
70
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 © 2004 Ford Motor Company
Table of Contents
1
2005 Econoline
(eco)
Supplement
USA
(fus)