Ford - Low Cab Forward - Owners Manual - 2008 - 2008

Table of Contents Introduction 4 Vehicle Inspection Guide 11 Instrument Cluster 18 Warning lights and chimes Gauges 18 23 Entertainment Systems 26 AM/FM stereo AM/FM stereo with CD 26 28 Climate Controls Heater only Manual heating and air conditioning Lights Headlamps Turn signal control Bulb replacement Driver Controls Windshield wiper/washer control Steering wheel adjustment Power windows Mirrors Speed control Locks and Security Keys Locks 33 33 34 37 37 43 44 50 50 50 50 52 52 56 56 56 1 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Table of Contents Seating and Safety Restraints Seating Safety restraints Child restraints Driving 59 59 60 65 71 Starting Brakes Transmission operation Vehicle loading Trailer towing 71 74 77 84 87 Roadside Emergencies 90 Getting roadside assistance Hazard flasher switch Fuses and relays Changing tires Jump starting Wrecker towing Customer Assistance Reporting safety defects (U.S. only) 90 90 90 98 98 103 105 109 Cleaning 110 Maintenance and Specifications 116 Tilting/Lowering the cab Engine oil Battery Engine coolant Fuel information Air filter(s) Lug nut torque Lubricant specifications Refill capacities 2 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) 121 124 127 128 135 153 162 171 176 Table of Contents Scheduled Maintenance Guide Normal scheduled maintenance and log Motorcraft Premium Gold Coolant change record Index 178 189 199 201 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 © 2007 Ford Motor Company 3 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Introduction CALIFORNIA Proposition 65 Warning 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. In addition, certain fluids contained in vehicles and certain products of component wear contain or emit chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. PERCHLORATE MATERIAL Certain 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 disposal. See www.dtsc.ca.gov/hazardouswaste/perchlorate. CONGRATULATIONS Congratulations on acquiring your new Ford. Please take the time to get well acquainted with your vehicle by reading this handbook. The more you know and understand about your vehicle, the greater the safety and pleasure you will derive from driving it. For more information on Ford Motor Company and its products visit the following website: • In the United States: www.ford.com • In Canada: www.ford.ca • In Mexico: www.ford.com.mx • In Australia: www.ford.com.au Additional owner information is given in separate publications. This Owner’s Guide describes every option and model variant available and therefore some of the items covered 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 reselling the vehicle. It is an integral part of the vehicle. 4 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Introduction SAFETY AND ENVIRONMENT PROTECTION Warning symbols in this guide How can you reduce the risk of personal injury and prevent possible damage to others, your vehicle and its equipment? In this guide, answers to such questions are contained in comments highlighted by the warning triangle symbol. These comments should be read and observed. Warning symbols on your vehicle When you see this symbol, it is imperative that you consult the relevant section of this guide before touching or attempting adjustment of any kind. Protecting the environment We must all play our part in protecting the environment. Correct vehicle usage and the authorized disposal of waste cleaning and lubrication materials are significant steps towards this aim. Information in this respect is highlighted in this guide with the tree symbol. SPECIAL NOTICES New Truck Limited Warranty For a detailed description of what is covered and what is not covered by your vehicle’s New Truck Limited Warranty, refer to the Warranty Guide that is provided to you along with your Owner’s Guide. Special instructions For your added safety, your vehicle is fitted with sophisticated electronic controls. 5 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Introduction Service Data Recording Service data recorders in your vehicle are capable of collecting and storing diagnostic information about your vehicle. This potentially includes information about the performance or status of various systems and modules in the vehicle, such as engine, throttle, steering or brake systems. In order to properly diagnose and service your vehicle, Ford Motor Company, Ford of Canada, and service and repair facilities may access vehicle diagnostic information through a direct connection to your vehicle when diagnosing or servicing your vehicle. Event Data Recording Other modules in your vehicle - event data recorders - are capable of collecting and storing data during a crash or near crash event. The recorded information may assist in the investigation of such an event. The modules may record information about both the vehicle and the occupants, potentially including information such as: • how various systems in your vehicle were operating; • whether or not the driver and passenger seatbelts were buckled; • how far (if at all) the driver was depressing the accelerator and/or the brake pedal; • how fast the vehicle was traveling; and • where the driver was positioning the steering wheel. To access this information, special equipment must be directly connected to the recording modules. Ford Motor Company and Ford of Canada do not access event data recorder information without obtaining consent, unless pursuant to court 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 Motor Company and Ford of Canada. 6 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Introduction Cell phone use The use of Mobile Communications Equipment has become increasingly important in the conduct of business and personal affairs. However, drivers must not compromise their own or others’ safety when using such equipment. Mobile Communications can enhance personal safety and security when appropriately used, particularly in emergency situations. Safety must be paramount when using mobile communications equipment to avoid negating these benefits. Mobile Communication Equipment includes, but is not limited to cellular phones, pagers, portable email devices, in-vehicle communications systems, telematics devices and portable two-way radios. Driving while distracted can result in loss of vehicle control, accident and injury. Ford strongly recommends that drivers use extreme caution when using any device that may take their focus off the road. The driver’s 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. 7 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Introduction These are some of the symbols you may see on your vehicle. Vehicle Symbol Glossary Safety Alert See Owner’s Guide Fasten Safety Belt Airbag - Front Airbag - Side Child Seat Lower Anchor Child Seat Tether 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 Flasher Fog Lamps-Front Fuse Compartment Fuel Pump Reset Windshield Wash/Wipe Windshield Defrost/Demist Rear Window Defrost/Demist 8 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Introduction Vehicle Symbol Glossary Power Windows Front/Rear Power Window Lockout Child Safety Door Lock/Unlock Interior Luggage Compartment Release Panic Alarm Engine Oil Engine Coolant 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 Service Engine Soon Engine Air Filter Passenger Compartment Air Filter Jack Check Fuel Cap Low Tire Pressure Warning MAX MIN 9 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Introduction FEDERAL HIGHWAY ADMINISTRATION REGULATION Regulations such as those issued by the Federal Highway Administration or issued pursuant to the Occupational Safety and Health Act (OSHA), and/or state and local laws and regulations may require additional equipment or require other restrictions for the way you intend to use the vehicle. It is the responsibility of the registered owner and driver to determine the applicability of such laws and regulations to your intended use for the vehicle, and to arrange for the installation of any required equipment and meet the requirements of any other restrictions. Your dealer has information about the availability of equipment which may be ordered for your vehicle. ENTERING, EXITING AND/OR CLIMBING ON THIS VEHICLE You 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 climbing. Do not skip any steps or assist handles. Use three point contact at all times with at least two feet and one hand or two hands and one foot firmly placed during all phases of entering, exiting and/or climbing. Always keep your shoe soles and hands clean. Keep the steps and assist handles free of snow, ice, oil, grease, substances or debris. Be sure to use extra care in bad weather. Avoid wearing thick gloves. Do not carry items while entering, exiting, and/or climbing. Make sure you keep a firm grip. Always FACE the VEHICLE STEP and HANDLE SYSTEM while climbing up and down. Do not climb behind the cab unless you have three point contact with a step and handle system at all times. 10 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Vehicle Inspection Guide To be sure your vehicle is ready to operate, conduct a pre-trip inspection at the beginning of each work period. Follow the steps listed in this section to ensure a proper vehicle inspection procedure. The pages in this section may be produced locally and used on a regular basis. VEHICLE INSPECTION INFORMATION Note: Always make sure the parking brake is applied before starting the engine. Engine compartment (with engine stopped) Belts (Fan, Check for glazing, fraying or cracking. alternator, water pump and A/C compressor): Any leaks: Check for signs of fluid puddles, dripping fluid on the ground under the engine or the underside of the engine. HVAC air 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 Periodically check the HVAC fresh air filter for (if equipped): cleanliness. Exercise great caution when working on vehicle equipped with an automatic fan clutch. The fan starts in motion only after the engine coolant reaches a predetermined temperature or the refrigerant pressure (if equipped with air conditioning) reaches a predetermined setting. The fan will start at these points with no advance warning. Never reach near, or permit objects to protrude into the fan blade radius while the engine is running, as this could result in vehicle damage, personal injury or death. 11 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Vehicle Inspection Guide Engine starting (parking brake applied) Safety/Emergency Prior to entering the cab, verify that the vehicle is equipment: equipped with spare electrical fuses (if used), three red reflective triangles, a properly charged and rated fire extinguisher and wheel chocks. Walk around the vehicle and check that all steps and grab handles, inside and out as well as behind, are tight and clean. Use extreme caution and a three-point stance at all times. Check door latches for positive closing, latching and locking. Starting the engine: Verify the parking brake is set and the transmission is in P (Park). When the WAIT TO START indicator light in the instrument cluster turns off, turn the key to START. Accelerator: With the engine running and the transmission in P (Park), depress the accelerator and verify that it operates smoothly without any binding or irregular feel. Remove your foot from the pedal and make sure the engine returns to idle speed immediately. Steering linkage Check for excessive free play in the steering free play: linkages. The steering wheel should have less than two inches (five centimeters) of free play at rim of steering wheel. Brake check: Pump the brake pedal three times, then apply firm pressure to the pedal and hold it for five seconds. Once applied, the pedal should not move; if it does, there may be a leak or another problem. Do not drive the vehicle until the problem is fixed. Parking brake: Check that the parking brake will hold the vehicle by gently trying to pull forward with the parking brake applied. Transmission fluid: With the engine idling at normal operating temperature and the parking brake applied, check the automatic transmission fluid. If fluid needs to be added, refer to Transmission fluid in the Maintenance and Specifications chapter. 12 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Vehicle Inspection Guide Lights: Steering gear: Steering linkage: Tow hooks: Spring: Spring mount: Torsion bar, Shock absorber: Front of vehicle Make sure all exterior lights illuminate and are clean. Make sure headlights function on both high and low beams. Make 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. Look for missing or loose fasteners, power steering fluid leaks and damage to power steering hoses. Make sure connecting links, arms and rods are not worn or cracked; joints, sockets and boot seals are not worn or loose and that there are no loose or missing cotter keys, nuts or bolts. Front tow hooks should be inspected for damage or loose mounting. This is particularly important on vehicles where tow hooks are frequently used. Front suspension Inspect for missing, broken or shifted leaves or leaves that are in contact, or nearly contacting a tire, rim, brake drum, frame or body components. Inspect spring hangers, bolts, bushings, axle mounting bolts and nuts for cracks, breaks, wear, damage and tightness. Make sure torsion arm is not cracked, broken or missing. Inspect for cracks, leaks and missing or broken bolts or bushings. Note: Never apply grease to spring pads. Do not operate the vehicle if any suspension conditions listed in the Front suspension chart are evident. Loss of steering or suspension could result in property damage, personal injury or death. 13 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Vehicle Inspection Guide Hoses: Rims: Lug nuts: Hub oil seal: Oil-lubricated front wheel bearing: Front brakes Check for cracked, worn or frayed hoses. Make sure all couplings are secured. Front wheels Check for damaged or bent rims. Rims should not have welding repairs and no rust trails that indicate it is loose on the wheel. Make sure all lug nuts are present and not loose (look for rust trails around the lug nuts). There should be no cracks radiating from the lug bolt holes or distortion of the bolt holes. Check wheel hub oil seal for leaks, and if sight glass is present, check to see that the oil level is adequate. If the hubcap has a transparent window, check for proper lubrication level. If the hubcap does not have a transparent window, remove the rubber fill-plug and check for proper level. If a wheel must be changed, obtain expert tire service help. Mounting and dismounting of tires should only be performed by a qualified technician using necessary safety procedures and equipment, otherwise the result could be property damage, personal injury or death. 14 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Vehicle Inspection Guide Driver area Use the engine oil dipstick to verify that the engine oil level is in the operating range. Engine coolant: Look through the see-through level indicators on the reservoir and make sure the fluid is in the proper operating range as marked on the reservoir. Do not remove pressure cap until the coolant has cooled. Power steering fluid: Verify that the fluid level is between the ADD and FULL marks on the reservoir. Windshield washer Make sure the reservoir is full. fluid: Brake fluid: Make sure the fluid level is between the MIN/MAX lines as marked on the reservoir. Fuel tank: Make sure the fuel tank(s) and cap(s) are secure. Make sure there is no damage to the tank(s) and no leaks from the tank(s). Engine oil: Driveshaft: Exhaust system: Frame: Underbody of vehicle Make sure that the driveshaft is not bent or cracked. Ensure all driveshaft couplings are secure. Make sure the outside visible parts are securely mounted. Make sure there are no cracks, holes or severe dents. Check for cracks or bends in longitudinal frame members. Make sure there are no loose, cracked, bent, broken or missing crossmembers or crossmember fasteners. Maintain adequate clearance between all parts of the exhaust system and all hoses, wires and lines for engine cooling, brake system, fuel system, power steering system and electrical system. Heat damage to hoses, wires or lines may cause vehicle malfunction that could result in property damage, personal injury or death. 15 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Vehicle Inspection Guide Electrical lines: Turn signals/Brake lights: Lights, reflectors: Springs: Spring mounts: Shock absorber (if equipped): Rear of vehicle Make sure electrical lines are not tangled, crimped or pinched or being dragged against any truck parts. Electrical line insulation should not be cut, cracked, chafed or worn. None of the electrical lines should be spliced or taped. Check for corrosion on pins and in electrical sockets to ensure continuity and reduced heat build-up potential. Make sure both brake lights illuminate when the brake pedal is applied and each turn signal flashes. Make sure that the four-way flashers work properly. Make sure all exterior lights illuminate and are clean. Make 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 turn signal, flasher and brake lights. Rear springs Check for broken or shifted leaves or leaves that are in contact, or nearly contacting a tire, rim, brake drum, frame or body components. Check for missing or broken leaves in the leaf spring. Check for cracked or broken spring hangers, broken, missing or loose bolts, missing or damaged bushings, broken, loose or missing axle mounting parts. Check the shock absorber for cracks or leaks; there should be no missing or broken mounting bolts or worn bushings. 16 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Vehicle Inspection Guide Hoses: Spacers: Rims: Lug nuts: Rear brakes Check for cracked, worn or frayed hoses. Make sure all couplings are secured. Rear wheels Make sure dual wheels are evenly separated and that tires are not touching one another. Check for damaged or bent rims. Rims should not have welding repairs and no rust trails that indicate it is loose on the wheel. Make sure all lug nuts are present and not loose (look for rust trails around the lug nuts). There should be no cracks radiating from the lug bolt holes or distortion of the bolt holes. Transmission Check the transmission fluid level and shift linkage for proper operation. 17 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Instrument Cluster WARNING LIGHTS AND CHIMES Warning lights and gauges can alert you to a vehicle condition that may become serious enough to cause expensive repairs. A warning light may illuminate when a problem exists with one of your vehicle’s functions. Many lights will illuminate when you start your vehicle to make sure the bulb works. If any light remains on after starting the vehicle, have the respective system inspected immediately. Note: The instrument cluster will self-test when the ignition 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 coolant temperature/low coolant level, low engine oil pressure or high diesel particulate filter soot loading may exist. An audible tone will also sound when this light is illuminated. Safely pull off the road as soon as possible and stop the engine. Continuing to drive while this light is illuminated may result in extensive engine damage. Contact your dealership or authorized service center as soon as possible. 18 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Instrument Cluster Check engine: If this yellow warning light illuminates while driving, a problem in the electronic engine controls has been detected or the Diesel Particulate Filter (DPF) needs a parked regeneration (refer to Diesel Particulate Filter [DPF] in the Maintenance and Specifications chapter for more information). Contact your dealership or authorized service center as soon as possible. Service Engine Soon: This yellow warning light will illuminate to display any emissions-related issues. Contact your dealership or authorized service center as soon as possible. Wait to start: With the key in the ON position, this yellow light will illuminate if the 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. Refer to Starting the engine and Cold weather operation in the Driving chapter. After the engine starts, the light should remain off. The light should always illuminate at least momentarily when the engine is cold and the ignition is turned to ON. If it does not illuminate, the glow plug system should be checked and repaired promptly to avoid difficulty in cold starting. To reduce the risk of death or personal injury and the potential for damage to the engine, do not use volatile starting aids such as ether, propane or gasoline in the air intake system. The glow plugs will ignite any of the vapors. 19 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Instrument Cluster Water in fuel: During refueling, it is possible for water-contaminated diesel fuel to be pumped into your tank. Your vehicle fuel system is equipped with a fuel filter/water separator to remove water from the fuel. The yellow WATER IN FUEL light will illuminate when the fuel filter/water separator has a significant quantity of water in it. If the light illuminates when the engine is running, stop the vehicle as soon as safely possible, shut off the engine, then drain the fuel filter/water separator. Refer to Fuel filter/water separator in the Maintenance and Specifications section for the drain procedure. Allowing water to stay in the system could result in extensive damage to, or failure of, the fuel injection system. Do not drain water separator while engine is running. Fuel may 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 illuminated. Check the brake master cylinder reservoir to make sure the fluid level is OK, add if necessary (refer to Brake fluid in the Maintenance and Specifications chapter for proper checking and adding procedure). If the level is OK, but the light stays illuminated, do not drive the vehicle as loss of braking ability may occur. Have the vehicle towed to your local dealership or authorized service center. Driving a vehicle with the brake fluid warning light on is dangerous. A significant decrease in braking performance may occur. It will take you longer to stop the vehicle. Have the vehicle checked by your dealer immediately. Parking brake warning: This red light illuminates when the parking brake is engaged. 20 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Instrument Cluster Anti-lock brake system: This yellow light momentarily illuminates ABS when the ignition is in the ON position. If the light stays illuminated or continues to flash, a malfunction has been detected; have the system serviced immediately. Normal braking is still functional unless the brake fluid warning light also is illuminated. If the ABS light is not functioning, the trip odometer display will show “No ABS Ind”. Check trans: This yellow light momentarily illuminates when the ignition is in the ON position. If this light stays illuminated, a problem has been detected and the shift pattern may be in default operation (starts in 5th gear). Operating limitations may be placed on the transmission upshifting and downshifting patterns. 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 seconds to remind you to fasten your safety belt. Diesel Particulate Filter (DPF): Illuminates if the soot level in the DPF has reached to a level where it requires cleaning or service. Trans temp: This red light momentarily illuminates when the ignition is in the ON position. This light will stay illuminated when the transmission temperature is too high. An audible tone will also sound when this light is illuminated. Normal transmission fluid operating temperature is 70°F–248°F (21°C–120°C ). Fluid temperatures above 275°F (135°C) can cause transmission fluid to break down and result in internal component damage. Have the system serviced immediately. 21 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Instrument Cluster Check electrical system: This yellow light will momentarily illuminate when the ignition is in the ON position. If this light stays illuminated, there is a communication problem between the cluster and an electrical module. A message will be displayed on the trip odometer. Change oil: This yellow light will momentarily illuminate when the ignition is in the ON position. If activated, this light illuminates when the engine oil life is low and requires changing. To reset the indicator, perform the following (this procedure must be completed within 12 seconds from starting it): 1. Set the parking brake, then turn 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. Release cruise buttons. Tow/Haul: This green light illuminates when the Tow/Haul feature has been activated. Refer to the Driving chapter for transmission function and operation. PTO enable: This yellow light illuminates when power take-off (PTO) mode is being used. Charging system: This red light illuminates when the battery is not charging properly. Turn signal: The(se) green light(s) illuminates when the left or right turn signal or the hazard lights are turned on. If the indicator(s) stay(s) on or flash(es) faster, check for a burned out bulb. 22 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Instrument Cluster High beams: This blue light illuminates when the high beam headlamps are turned on. Safety belt not fastened warning chime: Sounds for five seconds each time the ignition is turned to the ON position and the safety belt is not fastened. Key-in-ignition warning 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 when the headlamps or parking lamps are on, the ignition is off (the key is not in the ignition) and the driver’s door is opened. The trip odometer display will show “Lights ON”. GAUGES 23 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Instrument Cluster Speedometer: Indicates the current vehicle speed. If there is an electrical problem between the gauge and the engine control module, the gauge pointer will fall below the “0” position and rest on the pointer stop. Note: This vehicle’s speed is limited to 75 mph (120 km/h). Tachometer: Indicates the engine speed in revolutions per minute. Driving with your tachometer pointer continuously at the top of the scale may damage the engine. If there is an electrical 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 (kilometers) of the vehicle. The trip odometer registers the miles (kilometers) of individual journeys. There are two modes for the trip odometer, Trip 1 and Trip 2. Pressing Select/Reset for less than two seconds will switch between Trip 1 and Trip 2. Pressing and holding Select/Reset for longer than two seconds will clear the trip odometer for the setting it is on (Trip 1 or Trip 2). 24 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Instrument Cluster Fuel gauge: Indicates approximately how much fuel is left in the fuel tank (when the ignition is in the ON position). If your vehicle is equipped with dual fuel tanks, the engine will draw fuel from the driver-side fuel tank only. With dual fuel tanks, the vehicle will be equipped with a fuel transfer pump system that will draw fuel from the passenger-side fuel tank and send fuel to the driver-side fuel tank. The driver-side fuel tank must have fuel in it at all times otherwise the vehicle may stall and may be difficult to re-start. The fuel gauge reads the fuel level only from the driver-side fuel tank. Ensure only the proper type diesel fuel is added to the fuel tank(s). When the fuel level reaches 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 electrical problem between the gauge and the engine control module, the gauge pointer will drop to the six o’clock position and the red warning light will flash. Engine coolant temperature gauge: Indicates engine coolant temperature. Readings above 230°F (110°C) indicate the engine may be overheating; a red warning light will illuminate on the gauge indicating this condition. If there is an electrical problem between the gauge and the engine control module, the gauge pointer will drop to the six o’clock position and the red warning light will flash. Never remove the coolant reservoir cap while the engine is running or hot. 25 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Entertainment Systems AUDIO SYSTEMS AM/FM Stereo (if equipped) Driving while distracted can result in loss of vehicle control, accident and injury. Ford strongly recommends that drivers use extreme caution when using any device that may take their focus 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: Press to turn the radio on/off and turn to adjust the volume. 2. PWR: Press to turn the radio on and off. 3. BAND: Press to alternate between AM, FM1, FM2 and Weatherband. 26 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Entertainment Systems 4. DSPL TM SET: Press to display the time or to set the clock. To set the clock: • Turn the ignition on. • Press and hold the DSPL TM SET button until the hours digits flash, then press either the TUNE or SEEK buttons to set the hour. • Press the DSPL TM SET button again and the minutes digits will flash. Press either the TUNE or SEEK buttons to set the minutes. • After five seconds, the display will show the time. 5. AUTO: Press to automatically set the strongest stations to presets. 6. DIM: Press to 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 frequency band AM/FM; tune to a station, press and hold a preset button until sound returns. For the TUNE and SEEK buttons, press and hold both TUNE and BAND for two seconds to switch between manual tune and seek modes. The display will show either “MANUAL” or “SEEK” to indicate the mode. 9. TUNE: Press to manually change radio frequency up or down. 10. SEEK: Press to find the next strong station up or down the frequency band. 27 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Entertainment Systems AM/FM Stereo/CD (if equipped) Driving while distracted can result in loss of vehicle control, accident and injury. Ford strongly recommends that drivers use extreme caution when using any device that may take their focus 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. BAND: In radio mode, press to change the band (AM/FM1/FM2/WB). In CD/MP3 mode: press to pause and play a track/file. 2. SRC: Turns radio power on and off. To turn power off, press and hold for more than one second. Press to change the listening source (Radio, XM/Sirius receiver [if equipped], CD/MP3 player [if CD/MP3 disc is loaded] or CD changer [if equipped]). 28 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Entertainment Systems 3. DISP: Press to switch between Radio/CD/MP3/Clock display. In CD mode, pressing DISP will display the disc title and track title. To set the clock: Press and hold DISP for more than two seconds; the hours will flash to indicate time setting mode is activated. / to set the hour ahead/back. Press DISP; the minutes will Press / to set flash to indicate time setting mode is activated. Press the minutes ahead/back. Press DISP to end the time setting adjustment. Note: Press and hold 4. TUNE/SEEK / to change the numbers rapidly. : In radio mode: Press to manually go up or down the radio frequency. Hold down for more than 1⁄2 second to find the next/previous strongest broadcast station. 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. TUNE/SEEK to manually find a station Manual preset: Press to be stored, then press and hold one of the preset station buttons until the display blinks once. Auto Preset Memory (APM): Press and hold BAND for more than two seconds. The six strongest stations will be stored in presets 1–6. The presets will then be scanned for five seconds each. Press BAND again to stop the scan. Tuning in a Weather Band (WB) station: Press BAND to select WB, then press any of the memory presets to monitor that preset station. FOLDER/DISC : Select 6. the next/previous folder on an MP3 disc or the next CD track on a disc. 29 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Entertainment Systems 7. SCROLL: Scrolls the information on the display on an MP3 disc. If there is no information on the disc to display, NO TEXT will be displayed. 8. SCAN: In radio mode, press and hold for a brief sampling of radio stations. Press again to cancel the operation. In CD mode, press to scan the first 10 seconds of each track on the CD. Press again to cancel the operation. In MP3 mode, press and hold for more than two seconds to scan the first 10 seconds of each file in each album. Hold down again to cancel the operation 9. REPEAT: Press to repeat a CD track/MP3 file. 10. RANDOM: In CD/MP3 mode, press 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 counterclockwise to decrease volume. Press the control to switch between Bass, Treble, Balance and Fade. Bass: Increase or decrease bass by turning the control left or right. Treble: Increase or decrease treble by turning the control left or right. Balance: Adjust the audio between left and right speakers by turning the control left or right. Fader: Adjust the audio between front and rear speakers by turning the control left or right. Note: If no action takes place after five seconds, the display returns to regular mode. 30 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Entertainment Systems 12. MUTE/SQ (Sound Quality): Press to mute the playing media; press again to cancel. Press and hold for more than two seconds to enhance various sound types at low or medium volumes. The different sound types are FLAT, ROCK, POP and VOCAL. Press and hold MUTE for more than two seconds to deactivate this feature if it is not desired at higher volumes. 13. : Press to eject a CD. 14. CD door: Insert a CD into the CD door. Radio power will automatically turn on when a disc is inserted. GENERAL AUDIO INFORMATION Radio frequencies AM and FM frequencies are established 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 reception factors There are three factors that can effect radio reception: • Distance/strength: The further you travel from an FM station, the weaker the signal and the weaker the reception. • Terrain: Hills, mountains, tall buildings, power lines, electric fences, traffic lights and thunderstorms can interfere with your reception. • Station overload: When you pass a broadcast tower, a stronger signal may overtake a weaker one and play while the weak station frequency is displayed. 31 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Entertainment Systems CD/CD player care Do: • Handle discs by their edges only. Never touch the playing surface. • Inspect discs before playing. Clean only with an approved CD cleaner and wipe from the center out. Don’t: • Expose discs to direct sunlight or heat sources for extended periods of time. • Clean using a circular motion. CD units are designed to play commercially pressed 4.75 inch (12 cm) audio compact discs only. Due to technical incompatibility, certain recordable and re-recordable compact discs may not function 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. The label may peel and cause the CD to become jammed. It is recommended that homemade CDs be identified with permanent felt tip marker rather than adhesive labels. Ball point pens may damage CDs. Please contact your dealer for further information. Audio system warranty and service Refer to the Warranty Guide for audio system warranty information. If service is necessary, see your dealer or qualified technician. 32 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Climate Controls HEATER ONLY SYSTEM (IF EQUIPPED) 1. Temperature selection: Controls the temperature of the airflow in the vehicle. 2. Fan speed adjustment: Controls the volume of air circulated in the vehicle. / : Used to manually enable or disable recirculated air 3. operation. When activated (control moved all the way to the left), may help reduce undesired outside odors from reaching the interior of the off (control vehicle. To reduce humidity inside the vehicle, turn 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 description on each control. : Distributes air through the instrument panel vents. : Distributes air through the instrument panel vents and the floor vents. : Distributes air through the floor vents. : Distributes air through the windshield defroster vents and floor vents. : Distributes air through the windshield defroster vents. 33 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Climate Controls Operating tips • To reduce fog build up on the windshield during humid weather, place position. the air flow selector in the off (control moved • To reduce humidity inside the vehicle, turn all the way to the right). • Under normal weather conditions, leave the recirculated air selector when the vehicle is parked. This allows the vehicle to in “breathe” using the outside 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 panel vents towards the side windows To increase airflow to the outer instrument panel vents, close the vents located in the middle of the instrument panel. Do not place objects on top of the instrument panel as these objects may become projectiles in a collision or sudden stop. MANUAL HEATING AND AIR CONDITIONING SYSTEM (IF EQUIPPED) 34 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Climate Controls 1. Temperature selection: Controls the temperature of the airflow in the vehicle. 2. A/C: Uses outside air to cool the vehicle. Air flows from the instrument panel vents only. 3. Fan speed adjustment: Controls the volume of air circulated in the vehicle. / : Used to manually enable or disable recirculated air 4. operation. When activated (control moved all the way to the left), recirculates air in the cabin thereby reducing the amount 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 interior of the vehicle. To off (control moved all the reduce humidity inside the vehicle, turn way to the right. 5. Air flow selections: Controls the direction of the airflow in the vehicle. See the following for a brief description on each control. : Distributes air through the instrument panel vents. : Distributes air through the instrument panel vents and the floor vents. : Distributes air through the floor vents. : Distributes air through the windshield defroster vents and floor vents. : Distributes air through the windshield defroster vents. Operating tips • To reduce fog build up on the windshield during humid weather, place position. the air flow selector in the off (control moved • To reduce humidity inside the vehicle, turn all the way to the right). • Under normal weather conditions, leave the recirculated air selector when the vehicle is parked. This allows the vehicle to in “breathe” using the outside air inlet vents. 35 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Climate Controls To aid in side window defogging/demisting in cold weather: 1. Select 2. Press A/C 3. Modulate the temperature control to maintain comfort. 4. Set the fan speed to its highest setting 5. Direct the outer instrument panel vents towards the side windows To increase airflow to the outer instrument panel vents, close the vents located in the middle of the instrument panel. Do not place objects on top of the instrument panel as these objects may become projectiles in a collision or sudden stop. 36 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Lights HEADLAMP CONTROL OFF: Turns the lamps off. : Turns on the parking lamps, instrument panel lamps, license plate lamps and tail lamps. : Turns the headlamps on. Fog lamps Turn the ring on the headlamp control to turn the fog lamps on and off. Note: The fog lamps will only operate with the low beam headlamps activated. When the highbeams are activated, the foglamps will not operate. High beams/Flash-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 deactivate. Daytime Running Lamps (DRL) (if equipped) Turns the headlamps on with a reduced output. To activate: • the ignition must be in the ON position and (parking lamp) • the headlamp control is in the OFF or position. • the parking brake must be released (the parking brake warning light in the instrument cluster is not illuminated) 37 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Lights Always remember to turn on your headlamps at dusk or during inclement weather. The Daytime Running Lamp (DRL) system does not activate your tail lamps and generally may not provide adequate lighting during these conditions. Failure to activate your headlamps under these conditions may result in a collision. PANEL DIMMER CONTROL The panel dimmer control is located to the left of the steering wheel on the 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 HEADLAMPS Place the vehicle with the following conditions: 1. The area around the headlamp is not deformed. 2. The unloaded vehicle is parked on a flat level surface. 3. Tire inflation pressure is at the specified value. 4. The vehicle is in a state ready for driving (with a full tank of fuel, oil level, and coolant). 5. The vehicle has been bounced several times. 38 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Lights Checking headlamp aim 90 2 1. Prepare a thick white paper. 2. Stand the paper 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 illustration). 39 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Lights 4. Draw a horizontal line (#3 in the illustration) on the paper at the same height from ground as the headlamp bulb center, which is marked on the headlamp lens by a 2 mm x 2 mm square. 5. Draw a horizontal line (#4 in the illustration) parallel to the headlamp bulb center line (#3 in the illustration) but 0.82 inches (20.9 mm) (#5 in the illustration) below it. 6. Take appropriate measures to prevent any influence of other lights. 7. Start the engine. 8. Turn the low beam of the 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 line (#4 in illustration) and below the cross-hatched area shown in the illustration. If it isn’t, adjust the headlamps in the vertical direction. Use this illustration to check the headlamp aim pattern as it should appear on the paper. 3. Horizontal line at headlamp bulb center. 4. Horizontal lines for headlamps, 0.82 inch (20.9 mm) below bulb center. 5. 0.82 inch (20.9 mm). 6. High intensity area of light pattern. 40 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Lights Adjusting the headlamp aim IMPORTANT: Both the inboard and outboard vertical aim screws must be turned the same amount in the same direction. Do NOT turn the screws different amounts or in different directions. Note: Do not finish the aiming 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 turn the screwdriver clockwise one full turn, so you finish the adjustment in the clockwise direction and still line up with the vertical aiming line. This applies to both screws. 41 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Lights 1. Use a #2 Phillips screwdriver with at least a six inch (150 mm) long shaft. 2. Insert the screwdriver in the inboard aiming hole (#1 in the illustration) until it engages the gear at the back of the headlamp (#3 in the illustration). Always start with the inboard aiming screw. 3. Turn the screwdriver in the counterclockwise direction to move the headlamp aim upward or in the clockwise direction to move the headlamp aim downward, while counting the number of turns made. Continue turning this screw until the vertical aim is properly adjusted, but make sure you finish in the clockwise screwdriver direction. If you are adjusting in the counterclockwise screwdriver movement, overshoot the adjustment by one full turn 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 (#2 in the illustration) until it engages the gear at the back of the headlamp (#3 in the illustration). 5. Turn the screwdriver the same number of turns in the same direction as was done in the inboard aiming hole, but make sure you finish in the clockwise screwdriver direction. If you are adjusting in the counterclockwise screwdriver direction overshoot the adjustment by one full turn and then turn it back one full turn, so you finish the adjustment in the clockwise direction and still line up with the vertical aiming line. Do NOT turn this outboard screw in a different direction or a different amount than was done with the inboard aiming screw. 42 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Lights TURN SIGNAL CONTROL • Push down to activate the left turn signal. • Push up to activate the right 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 either side of the dome lamp. 43 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Lights EXTERIOR BULBS Bulb inspection It is a good safety practice to check operation of headlamps, parking lamps, turn signals, clearance and marker lamps, instrument panel and control lamps each day. Using the right bulbs Function Headlamps Front park/turn signal lamps Front sidemarker Front clearance and identification lamps Fog lamps Brake/Tail/Stop/Rear turn signal/License lamps Back-up lamps Dome lamp Number of bulbs 2 2 2 Trade number 9007LL 1157A 168 5 194 2 64151 2 1157 1156 DE3175 (single 2 bulb lamp) or 212 (dual bulb lamp) To replace all instrument panel lights - see your dealer Bulb replacement Dome lamp - Type A To replace the dome lamp, pull the lamp cover off by disengaging the tabs and pulling the cover down; pull the bulb down to remove it. Replace the bulb and cover. 44 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) 2 Lights Dome lamp - Type B To replace the dome lamp, pull the lamp cover off by disengaging the tabs on the long end of the lens and pulling it down; pull the bulb(s) out. Replace the bulb and lens. Replacing headlamp and fog lamp bulbs Handle a halogen headlamp bulb carefully and keep out of children’s reach. Grasp the bulb only by its plastic base and do not touch the glass. The oil from your hand could 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 cab in the Maintenance and Specifications chapter) and reaching in the back of the headlamp assemblies to remove the bulbs. If you find replacing the headlamp or fog lamp bulbs too difficult without removing the headlamp assemblies, see the following procedure. To remove the headlamp bulbs: 1. Make sure headlamp switch is in the OFF position. 45 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Lights 2. Open the door and, from inside the vehicle, remove the screw from the front turn signal/parking light assembly by inserting a screwdriver through the gap 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 front turn signal/parking lamp assembly. 4. Detach the electrical connector from the assembly. 46 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Lights 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. 47 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Lights 8. Remove the screws (1) from the headlight, then disconnect the electrical connectors (2). 9. Pull off the sealing cover, unhook the bulb spring, then carefully remove the headlight 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 parking lamp/turn signal lamps, refer to Steps 1 through 3 in the Replacing headlamp bulbs procedure. • Front parking lamp 48 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Lights • Front turn signal lamp Replacing front clearance and identification lamp bulbs To change the cab marker bulbs: 1. Make sure the headlamp control is in the OFF position and then remove the screw and lens from the lamp assembly. 2. Carefully pull the bulb straight out of the socket and push in the new bulb. 3. Install lens on lamp assembly with screw. Replacing 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 same steps to replace any of these bulbs: 1. Make sure the headlamp and turn signal controls are in the OFF position and then remove the trim cover around the bulb to be replaced. 2. Carefully pull the bulb out, unplug the bulb and plug in the new bulb. 3. Install the trim cover on the lamp assembly. 49 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Driver Controls WINDSHIELD WIPER/WASHER CONTROLS • MIST: For a single wipe (without washer), push the control up once. • OFF: Wipers off. • INT: Interval wiper operation. • 1: Low-speed wiper operation. • 2: High-speed wiper operation : Pull the control toward you to activate washer. Pull and hold for a longer wash cycle. Note: Do not operate the washer for more than 10 seconds as damage to the washer motor may occur. TILT/TELESCOPE STEERING Pull the tilt steering control toward you 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. Never adjust the steering wheel when the vehicle is moving. POWER WINDOWS (IF EQUIPPED) Do not leave children unattended in the vehicle and do not let children play with the power windows. They may seriously injure themselves. When closing the power windows, you should verify they are free of obstructions and ensure that children and/or pets are not in the proximity of the window openings. 50 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Driver Controls Push the switches down to open the windows and pull the switches up to close the windows. One-touch down driver’s window To open the driver window without holding the control, press the control marked AUTO completely down and 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 from operating for both driver and passenger. To prevent power window operation, press the control down. Press the control again to restore the window controls. 51 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Driver Controls EXTERIOR MIRRORS With the doors closed, move the mirrors to maximize rear viewing area by adjusting the mirrors left or right as required. Adjust the auxiliary convex mirrors. Convex mirrors are a ball-stud design for precise adjustment to maximize viewing area. The mirror arms can be manually folded forward or backwards for narrow spaces like driving through an automatic car wash or backing 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 If the vehicle is moving, speed control will be enabled; if the vehicle is stationary, engine RPM can be controlled. Do not use the speed control in heavy traffic or on roads that are winding, slippery, or unpaved. Do not shift the gearshift lever into N (Neutral) with the speed control on. 52 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Driver Controls To turn speed control off Press CRUISE THRTL or turn off the ignition. Once speed control is switched off, the previously programmed engine RPM will be erased. Do not use the speed control in heavy traffic or on roads that are winding, slippery, or unpaved. To set a speed Turn the speed control on. Press SET COAST. If the vehicle is moving, this will set the vehicle speed. If the vehicle is stationary, this will set the vehicle idle RPM. If you drive up or down a steep hill, your vehicle speed 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 than the set speed while driving on a downhill, you may want to shift to the next lower gear or apply the brakes to reduce your vehicle speed. If the vehicle speed falls below a predetermined speed or engine RPM falls below 1,000 RPM, your speed control will disengage; this is normal. Pressing RESUME ACCEL will re-engage it. Do not use the speed control in heavy traffic or on roads that are winding, slippery, or unpaved. 53 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Driver Controls To set a higher set speed Press and hold RESUME ACCEL. If the vehicle is moving, this will increase vehicle speed; if the vehicle is stationary, this will increase engine RPM. Release the control when the desired vehicle speed/engine RPM is reached. Press and release RESUME ACCEL to operate the tap-up function. Each press will increase the set speed by 1 mph (1.6 km/h) or engine RPM in idle mode. To set a lower set speed Press and hold SET COAST. If the vehicle is moving, 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 COAST to operate the tap-down function. Each press will decrease the set speed in increments of 1 mph (1.6 km/h) or engine RPM in idle mode. To disengage speed control Depress the brake pedal or press CRUISE THRTL. Disengaging the speed control will not erase the previously programmed set speed or engine RPM. Turning off the ignition will erase the previously programmed set speed or engine RPM. 54 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Driver Controls To return to a previously set speed Press RESUME ACCEL. 55 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Locks and Security KEYS The key operates all locks on your vehicle. In case of loss, replacement keys are available from your dealer. You should always carry a second key with you in a safe place in case you require it in an emergency. POWER DOOR LOCKS (IF EQUIPPED) Both doors lock and unlock automatically when the driver’s door is locked or unlocked with a key. Both doors lock automatically when the driver’s door lock button is pushed down and unlock when it is pulled up. Manually locking the vehicle without the key Depress the door locks button(s). When closing the door(s), lift the door handle, then release the door handle once the door is 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 cause harmful interference, and (2) This device must accept any interference received, including interference that may cause undesired operation. Changes or modifications not expressly approved by the party responsible for compliance could void the user’s authority to operate the equipment. The typical operating range for your remote entry transmitter is approximately 33 feet (10 meters). A decrease in operating range could be caused by: • weather conditions, • nearby radio towers, • structures around the vehicle, or • other vehicles parked next to your vehicle. 56 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Locks and Security Your vehicle has an all-door remote entry system. The all-door remote entry system allows you to: • lock or unlock both vehicle doors without a key. • activate the panic alarm. The remote entry features only operate with the ignition in the 1 (LOCK) position. If there are problems with the remote entry system, make sure to take ALL remote entry transmitters with you to the dealership in order to aid in troubleshooting the problem. Unlocking the doors 1. Press UNLOCK to unlock the driver’s door. 2. Press UNLOCK again within three seconds to unlock both doors. Note: The vehicle doors may be unlocked by using the remote entry transmitter, however, in the event of a low battery charge, the 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 second time will sound the horn to confirm the doors are locked. Sounding a panic alarm to activate the alarm. Press again, or turn the ignition to the Press 3 (ON) position to deactivate. Note: The panic alarm will only operate when the ignition is in the 1 (LOCK) position. Replacing the battery The remote entry transmitter uses one button type three-volt lithium battery CR2025 or equivalent. To replace the battery: 1. Twist a thin coin between the two halves of the remote entry transmitter near the key ring. DO NOT TAKE THE RUBBER COVER AND CIRCUIT BOARD OFF THE FRONT HOUSING OF THE REMOTE ENTRY TRANSMITTER. 57 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Locks and Security 2. Do not wipe off any grease on the battery terminals on the back surface of the circuit board. 3. Remove the old battery. Note: Please refer to local regulations when disposing of transmitter batteries. 4. Insert the new battery. Refer to the diagram inside the remote entry transmitter for the correct orientation of the battery. Press the battery down to ensure that the battery is fully seated 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 should operate normally after battery replacement. Replacing lost remote entry transmitters If you would like to have your remote entry transmitter reprogrammed because you lost one, or would like to buy additional remote entry transmitters, take all remote entry transmitters to your authorized dealer for reprogramming. 58 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Seating and Safety Restraints SEATING 40/20/40 split bench seat The driver seat can be adjusted forward or backward by lifting the lever (1) located under the seat. The driver seat back angle can be adjusted by lifting the lever (2) located on 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 while pulling the loop to flip the seat down. When pushing the seat back to its upright position, make sure it latches securely. 59 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Seating and Safety Restraints Pull the right-hand passenger seatback down while pulling the latch handle to flip the seatback down flat. When pushing the seatback to its upright position, make sure it latches securely. Before returning the seatback to its original position, make sure that cargo or any objects are not trapped underneath the seatback. After returning the seatback to its original position, pull on the seatback to ensure that it has fully latched. An unlatched seat may become dangerous in the event of a sudden stop or collision. SAFETY RESTRAINTS Safety restraints precautions Always drive and ride with your seatback upright and the lap belt snug and low across the hips. To reduce the risk of injury, make sure children sit where they can be properly restrained. All occupants of the vehicle, including the driver, should always properly wear their safety belts. Never let a passenger hold a child on his or her lap while the vehicle is moving. The passenger cannot protect the child from injury in a collision. 60 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Seating and Safety Restraints It is extremely dangerous to ride in a cargo area, inside or outside of a vehicle. In a collision, people riding in these areas are more likely to be seriously injured or killed. Do not allow people to ride in any area of your vehicle that is not equipped with seats and safety belts. Be sure everyone in your vehicle is in a seat and using a safety belt properly. In a rollover crash, an unbelted person is significantly more likely to die than a person wearing a safety belt. Each 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 shoulder only. Never wear the shoulder belt under the arm. 2) Never swing the safety belt around your neck over the inside shoulder. 3) Never use a single belt for more than one person. Combination lap and shoulder belts 1. Insert the belt tongue into the proper buckle (the buckle closest to the direction the tongue is coming from) until you hear a snap and feel it latch. Make sure the tongue is securely fastened in the buckle. 61 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Seating and Safety Restraints 2. To unfasten, push the release button and remove the tongue from the buckle. The front outboard safety restraints in the vehicle are combination lap and shoulder belts. The passenger outboard safety belt has vehicle sensitive emergency locking retractors. Lap belts The front center lap belt does not adjust automatically. The lap belt 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 belt, turn the tongue at a right angle to the belt and pull across your lap until it reaches the buckle. To tighten the belt, pull the loose end of the belt through the tongue until it fits snugly across the hips. Shorten and fasten the belt when not in use. 62 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Seating and Safety Restraints Vehicle sensitive retractor The vehicle sensitive retractor allows free shoulder belt length adjustment to your movements and locks in response to vehicle movement. For example, if the driver brakes suddenly or turns a corner sharply, or the vehicle receives an impact of approximately 5 mph (8 km/h) or more, the combination safety belts will lock to help reduce forward movement of the driver and passengers. Front safety belt height adjustment Vehicles have safety belt height adjustments for the driver. Adjust the height of the shoulder belt so the belt rests across the middle of your shoulder. To lower the shoulder belt height, push the button and slide the height adjuster down. To raise the height of the shoulder belt, slide the height adjuster up. Pull down on the height adjuster to make sure it is locked in place. Position the safety belt height adjuster so that the belt rests across the middle of your shoulder. Failure to adjust the safety belt properly could reduce the effectiveness of the seat belt and increase the risk of injury in a collision. Safety belt extension assembly If the safety belt is too short when fully extended, there is an eight inch (20 cm) safety belt extension assembly that can be added (part number 611C22). This assembly can be obtained from your dealer at no cost. Use only extensions manufactured by the same supplier as the safety belt. Manufacturer identification is located at the end of the webbing on the label. Also, use the safety belt extension only if the safety belt is too short for you when fully extended. Do not use extensions to change the fit of the shoulder belt across the torso. 63 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Seating and Safety Restraints Safety belt maintenance Inspect the safety belt systems periodically to make sure they work properly and are not damaged. Inspect the safety belts to make sure there are no nicks, tears or cuts. Replace if necessary. All safety belt assemblies, including retractors, buckles, front seat belt buckle assemblies, buckle support assemblies (slide bar-if equipped), shoulder belt height adjusters (if equipped), shoulder belt guide on seatback (if equipped), child safety seat tether anchors, and attaching hardware, should be inspected after a collision. Ford Motor Company recommends that all safety belt assemblies used in vehicles involved in a collision be inspected for proper function and replaced, if necessary. Safety belt assemblies not in use during a collision should also be inspected and replaced if either damage or improper operation is noted. 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 Interior in the Cleaning chapter. Safety belt warning light and indicator chime The safety belt warning light illuminates in the instrument cluster and a chime sounds to remind the driver to fasten their safety belt. Conditions of operation If... The driver’s safety belt is not buckled before the ignition switch is turned to the ON position... The driver’s safety belt is buckled while the indicator light is illuminated and the warning chime is sounding... The driver’s safety belt is buckled before the ignition switch is turned to the ON position... Then... The safety belt warning light illuminates and the warning chime sounds 4–8 seconds. The safety belt warning light and warning chime turn off. The safety belt warning light and indicator chime remain off. 64 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Seating and Safety Restraints SAFETY RESTRAINTS FOR CHILDREN Important child restraint precautions You are required by law to use safety restraints for children in the U.S. and Canada. If small children (generally children who are four years old or younger and who weigh 40 lb. [18 kg] or less) ride in your vehicle, you must put them in safety seats made especially for children. Many states require that children use approved booster seats until they are eight years old. Check your local and state or provincial laws for specific requirements regarding the safety of children in your vehicle. Never let a passenger hold a child on his or her lap while the vehicle is moving. The passenger cannot protect the child from injury in a collision. Always follow the instructions and warnings that come with any infant or child restraint you might use. Children and safety belts If the child is the proper size, restrain the child in a safety seat. Children who are too large for child safety seats (as specified by your child safety seat manufacturer) should always wear safety belts. Follow all the important safety restraint precautions that apply to adult passengers in your vehicle. If the shoulder belt portion of a combination lap and shoulder belt can be positioned so it does not cross or rest in front of the child’s face or neck, the child should wear the lap and shoulder belt. Moving the child closer to the center of the vehicle may help provide a good shoulder belt fit. Do not leave children, unreliable adults, or pets unattended in your vehicle. Safety belts and seats can become hot in a vehicle that has been closed up in sunny weather; they could burn a small child. Check seat covers and buckles before you place a child anywhere near them. 65 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Seating and Safety Restraints Child booster seats Children outgrow a typical convertible or toddler seat when they weigh 40 pounds and are around 4 years of age. Although the lap/shoulder belt will provide some protection, these children are still too small for lap/shoulder belts to fit properly, which could increase the risk of serious injury. To improve the fit of both the lap 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 safety belts fit better. They lift the child up so that the lap belt rests low across the hips and the knees bend comfortably. Booster seats also make the shoulder belt fit better and more comfortably for growing children. When children should use booster seats Children need to use booster seats from the time they outgrow the toddler seat until they are big enough for the vehicle seat and lap/shoulder belt to fit properly. Generally this is when they weigh about 80 lb. (36 kg) (about 8 to 12 years old). Booster seats should be used until you can answer YES to ALL of these questions: • Can the child sit all the way back against the vehicle seat back with knees bent comfortably at the edge of the seat without slouching? • Does the lap belt rest low across the hips? • Is the shoulder belt centered on the shoulder and chest? • Can the child stay seated like this for the whole trip? 66 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Seating and Safety Restraints Types of booster seats There are two types of belt-positioning booster seats: • Those that are backless. If your backless booster seat has a removable shield, remove the shield and use the lap/shoulder belt. If a seating position has a low seat back and no head restraint, a backless booster seat may place your child’s head (top of ear level) above the top of the seat. In this case, move the backless booster to another seating position with a higher seat back and lap/shoulder belts. • Those with a high back. If, with a 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. Both can be used in any vehicle in a seating position equipped with lap/shoulder belts if your child is over 40 lbs (18 kg). The shoulder belt should cross the chest, resting snugly on the center of the shoulder. The lap belt should rest low and snug across the hips, never up high across the stomach. If the booster seat slides on the vehicle seat, placing a rubberized mesh sold as shelf or carpet liner under the booster seat may improve this condition. The importance of shoulder belts Using a booster without a shoulder belt increases the risk of a child’s head hitting a hard surface in a collision. For this reason, you should never use a booster seat with a lap belt only. It is best to use a booster seat with lap/shoulder belts in the back seat- the safest place for children to ride. 67 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Seating and Safety Restraints Follow all instructions provided by the manufacturer of the booster seat. Never put the shoulder belt under a child’s arm or behind the back because it eliminates the protection for the upper part of the body and may increase the risk of injury or death in a collision. Never use pillows, books, or towels to boost a child. They can slide around and increase the likelihood of injury or death in a collision. SAFETY SEATS FOR CHILDREN Child and infant or child safety seats Use a safety seat that is recommended for the size and weight of the child. Carefully follow all of the manufacturer’s instructions with the safety seat you put in your vehicle. If you do not install and use the safety seat properly, the child may be injured in a sudden stop or collision. When installing a child safety seat: • Use the correct safety belt 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 release button pointing up and away from the safety seat, with the tongue between the child seat and the release button, to prevent accidental unbuckling. • Place seat back in upright position. 68 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Seating and Safety Restraints Carefully follow all of the manufacturer’s instructions included with the safety seat you put in your vehicle. If you do not install and use the safety seat properly, the child may be injured in a sudden stop or collision. Installing child safety seats with combination lap and shoulder belts 1. Position the child safety seat in a seat with a combination lap and shoulder belt. 2. While holding the shoulder and lap belt portions together, route the tongue through the child seat according to the child seat manufacturer’s instructions. Be sure the belt webbing is not twisted. 69 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Seating and Safety Restraints 3. Buckle the seat belt. Push down on the child seat and pull on the shoulder portion of the belt to snug the lap belt. Hold the lap and shoulder belts next to the tongue and unbuckle the belt. 4. Install a locking clip over both lap and shoulder belt portions next to the sliding tongue. Buckle the belt. Note: Obtain the locking clip kit (part number FO3Z-5461248–A) at no charge from an authorized dealer. 5. Before placing the child in the seat, forcibly tilt the seat forward and back to make sure the seat is securely held in place. To check this, grab the seat at the belt path and attempt to move it side to side and forward and back. There should be no more than one inch of movement for proper installation. 6. If the child seat is not tight enough, unbuckle the seat belt, move the tongue and locking clip to shorten the lap portion and push down hard on the child seat while you buckle the belt. 7. Check to make sure the child seat is properly secured before each use. 70 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Driving STARTING Positions of the ignition 1. LOCK, shuts off the engine and all accessories, locks the steering wheel, gearshift lever and allows key removal. 2. ACC, allows the electrical accessories such as the radio to operate while the engine is not running. This position also unlocks the steering wheel. 3. ON, all electrical circuits operational. Warning lights illuminated. Key position when driving. 4. START, cranks the engine. Release the key as soon as the engine starts. Starting the engine Diesel engine vapors are combustible. Do not operate the engine in an enclosed area. These vapors can be sucked through the air intake system and cause an explosion 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 accessories are turned off, the parking brake is applied and the transmission is in the P (Park) position. 2. Turn the key to ON, but do not start the engine. In cooler weather, the air intake heater may activate the WAIT TO START light in the instrument cluster. If the WAIT TO START light illuminates, do not crank the engine until the light goes off. If equipped with an air intake heater, DO NOT use ether or any other starting fluids. The use of starting fluids (ether) in an engine equipped with an air intake heater could cause an explosion and result in property damage and/or personal injury. 71 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Driving 3. When the WAIT TO START light turns off, turn the key to START; when the engine starts, release the key If the engine does not start within 20 seconds of cranking, release the key and allow two or three minutes for the starter to cool before trying again. Excessive cranking may damage the starter and/or engine. After the engine starts: • Idle the engine for at least five minutes before operating with a full load. • Try to limit engine idle to 10 minutes. Excessive idling reduces fuel economy. • When starting a cold engine, increase the engine speed (RPM) slowly to make sure adequate lubrication is available to the bearings. Cold weather operation 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 cause engine damage or personal injury. In order to operate the engine in temperatures of 32°F (0°C) or lower, read the following instructions: • Make sure that the batteries are of sufficient size and are fully charged. Check other electrical components to make sure they’re in optimum condition. • Use a permanent-type engine coolant solution to protect the engine against damage from freezing. • Drain the fuel/water separator daily; refer to Draining the fuel filter/water separator in the Maintenance and Specifications chapter. Fill the fuel tank at the end of daily operation to prevent condensation in the fuel system. • Make sure you use proper cold weather engine oil and that it is at its proper level. • At temperatures of –4°F (–20°C) or below, it is recommended that you use an engine block heater to improve cold engine starting. • If operating in arctic temperatures of –20°F (–29°C) or lower, consult your truck dealer for information about special cold weather equipment and precautions. Note: Idling in cold weather will not heat the engine to its normal operating temperature. Long periods of idling in cold weather can cause 72 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Driving a buildup of heavy deposits of carbon and rust on valve stems causing them to stick, which in turn, can cause valvetrain damage. The following cold weather idling guidelines must be followed: • Avoid idling the engine for more than 10 minutes at a time. • Use a minimum of 42 Cetane Diesel fuel or use Cetane Index improvers from a reputable manufacturer. • Maintain the engine cooling system properly. • Do not shut the engine down after an extensive idling period (10 minutes or more). Drive the vehicle under load for several miles at normal operating temperatures to burn off any accumulated 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 daily operation to prevent condensation in the fuel system. • Keep external surfaces of the engine, radiator, charge air cooler, A/C condenser and accessories clean to avoid dirt build-up. Restarting after running out of fuel The fuel system may need to be purged of air, refer to Running out of fuel in the Maintenance and Specifications chapter. GENERAL OPERATING INSTRUCTIONS • Accelerate smoothly and evenly; rapid acceleration increases fuel consumption without increasing engine performance. • When approaching a hill, depress the accelerator smoothly to start the incline at full power, then shift down as needed to maintain vehicle speed. • When going down a hill, or long steep grades, prevent over-speeding of the engine. The engine governor has no control over engine speed when it is being pushed by a loaded vehicle. All vehicles have blind spots. To reduce the risk of severe injury or property damage, never move your vehicle to the side or rear or change lanes without being sure your way is clear on both sides and to your rear. 73 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Driving Backing up/Electric back-up alarm To reduce the risk of the possibility of personal injury while backing the vehicle, always be sure your vehicle’s path is clear. Before backing your vehicle, be sure you can do so safely. If anything behind the cab limits your view, do not rely on mirrors alone to ensure that your intended path is clear. If other people are in the vicinity, have someone standing well behind your vehicle and outside of your intended path (visible through an exterior mirror) guide you as you back up. Although OSHA or some governmental regulations may require the use of an electrical or mechanical back-up alarm to warn bystanders, such an alarm does not ensure that the intended path is clear. When in doubt, get out of the vehicle and visually check the intended 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 side so that if the vehicle rolls, the front tires will act against the curb to stop the vehicle. The front wheels will be more effective at stopping a rolling vehicle than the rear wheels. Driving through water If driving through deep or standing water is unavoidable, proceed very slowly especially if the depth is not known. Never drive through water that is higher than the bottom of the hubs. Traction or brake capability may be limited and your vehicle may stall. Water may also enter your engine’s air intake and severely damage your engine, rear axle or transmission (through the breather ports). If the transmission is submerged in water, the transmission fluid should be checked and changed, if necessary. Driving through deep water may damage the transmission Once through the water, always dry the brakes by moving your vehicle slowly while applying light pressure on the brake pedal. Wet brakes do not stop the vehicle as quickly as dry brakes. BRAKES Your service brakes are self-adjusting. Refer to the Scheduled Maintenance Guide chapter for scheduled maintenance. Occasional brake noise is normal and often does not indicate a performance concern with the brake system. In normal operation, brake 74 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Driving systems may emit occasional or intermittent squeal or groan noises when the brakes are applied. Such noises are usually heard during the first few brake applications in the morning; however, they may be heard at any time while braking and can be aggravated by environmental conditions such as cold, heat, moisture, road dust, salt or mud. If a “metal-to-metal,” “continuous grinding” or “continuous squeal” sound is present while braking, the brake linings may be worn-out and should be inspected by a qualified service technician. If you are driving down a long or steep hill, shift to a lower gear. Do not apply your brakes continuously, as they may overheat and become less effective. If brakes do not grip well • If you have been driving through deep water, gently apply the brakes several times while the vehicle is moving slowly. • Let the brakes cool if you have been using them excessively, as in mountain driving or after several fast, high-speed stops. • Check brake linings for excessive wear. Hydraulic brake booster system (HydroBoost) The HydroBoost systems receive fluid pressure from the power steering pump to provide power assist during braking. The HydroBoost booster includes a pneumatic accumulator that holds a reserve of power steering fluid under pressure that will provide two or more power-assisted brake applications in the event of power steering fluid pressure loss. The accumulator will also deliver a limited number of power-assisted brake 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 applications), so the vehicle should be operated under these conditions with caution, and only to seek service repair and remove the vehicle from the roadway. Under normal operating conditions, noise of the fluid flowing through the booster may be heard whenever the brake is applied. This is normal and should be no reason for concern. If braking performance or pedal response becomes very poor, even when the pedal is strongly applied, this may indicate the presence of air in the hydraulic system or fluid leakage. Safely stop the vehicle as soon as possible and seek service immediately. 75 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Driving If the brake fluid warning light in the instrument cluster remains illuminated after engine start-up, and an audible tone is heard while the light is illuminated, this indicates a system failure in the brake system. Stop the vehicle as soon as safely possible and seek service immediately. Parking brake Apply the parking brake whenever the vehicle is parked. To set the parking brake, pull the handle (1) up until it stops. Always set the parking brake fully and make sure that the transmission is securely latched in P (Park). To release the parking brake, pull the handle up slightly, push the button (2) on the end of the handle, then push the handle down to its original position. Driving with the parking brake on will cause the brakes to wear out quickly and reduce fuel economy. The parking brake warning light in the instrument cluster illuminates, and remains illuminated (when the ignition is turned on), until the parking brake is released. If the parking brake is fully released, but the parking brake warning lamp remains illuminated, the brakes may not 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 to stop your vehicle in an emergency. Since the parking brake only applies braking power to the rear wheels, the vehicle’s stopping distance will increase greatly and the handling of your vehicle will be adversely affected. 76 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Driving ANTI-LOCK BRAKE SYSTEM (ABS) Your vehicle is equipped with an Anti-lock Braking System (ABS). This system helps you maintain steering control during emergency stops by keeping the brakes from locking. Noise from the ABS pump motor and brake pedal pulsation may be observed during ABS braking and the brake pedal may suddenly travel a little further as soon as ABS braking is done and normal brake operation resumes. These are normal characteristics of the ABS and should be no reason for concern. ABS warning lamp The ABS lamp in the instrument cluster momentarily illuminates ABS when the ignition is turned on. If the light does not illuminate during start up, remains on or flashes, the ABS may be disabled and may need to be serviced. Even when the ABS is disabled, normal braking is still effective. (If your BRAKE FLUID warning lamp illuminates, have your brake system serviced immediately.) Using ABS When hard braking is required, apply continuous force on the brake pedal; do not 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 control during hard braking and on slippery surfaces. AUTOMATIC TRANSMISSION Brake-shift interlock This vehicle is equipped with a brake-shift interlock feature that prevents the gearshift lever from being moved from P (Park) when the ignition is in the ON position unless brake pedal is depressed. 77 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Driving If you cannot move the gearshift lever out of P (Park) with ignition in the ON position and the brake pedal depressed: 1. Apply the parking brake, turn ignition key to LOCK, then remove the key. 2. Remove 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 the bottom fastener. 78 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Driving 3. Remove the shifter shroud, then depress the override mechanism as shown in the illustration. 4. While depressing the override mechanism, apply the brake pedal and shift to N (Neutral). 5. Start the vehicle. If it is necessary to use the above procedure to move the gearshift lever, it is possible that a fuse has blown or the vehicle’s brakelamps are not operating properly. Refer to Fuses in the Roadside Emergencies chapter. Do not drive your vehicle until you verify that the brakelamps are working. Always set the parking brake fully and make sure the gearshift is latched in P (Park). Turn the ignition to the LOCK position and remove the key whenever you leave your vehicle. If the parking brake is fully released, but the brake warning lamp remains illuminated, the brakes may not be working properly. See your dealer or a qualified service technician as soon as possible. 79 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Driving Understanding the shift positions of the 5–speed automatic transmission This vehicle is equipped with an adaptive Transmission Shift Strategy. Adaptive Shift Strategy offers the optimal transmission operation and shift quality. When the vehicle’s battery has been disconnected for any type of service or repair, the transmission will need to relearn the normal shift strategy parameters, much like having to reset your radio stations when your vehicle battery 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; during this learning process, slightly firmer shifts may occur. After this learning process, normal shift feel and shift scheduling will resume. P (Park) This position locks the transmission and prevents the rear wheels from turning. To put your vehicle in gear: • Start the engine • Depress the brake pedal • Move the gearshift lever into the desired gear To put your vehicle in P (Park): • Come to a complete stop 80 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Driving • Move the gearshift lever and securely latch it in P (Park) Always set the parking brake fully and make sure the gearshift is latched in P (Park). Turn the ignition to the LOCK position and remove the key whenever you leave your vehicle. R (Reverse) With the gearshift lever in R (Reverse), the vehicle will move backward. Always come to a complete stop before shifting into and out of R (Reverse). N (Neutral) With the gearshift lever in N (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 the best fuel economy. The overdrive function allows automatic upshifts and downshifts through gears one through five. D (Overdrive) with Tow/Haul ON The Tow/Haul feature improves transmission operation when towing a trailer or a heavy load. All transmission gear ranges are available when using Tow/Haul. To activate Tow/Haul, press the button on the side of the gearshift lever. 81 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Driving The TOW HAUL indicator light will illuminate in the instrument cluster. Tow/Haul delays upshifts to reduce frequency of transmission shifting. Tow/Haul also provides engine braking in all forward gears when the transmission is in the D (Overdrive) position; this engine braking will slow the vehicle and assist the driver in controlling the vehicle when descending a grade. Depending on driving conditions and load conditions, the transmission may downshift, slow the vehicle and control the vehicle speed when descending a hill, without the accelerator pedal being pressed. The amount of downshift braking provided will vary based upon the amount the brake pedal is depressed. To deactivate the Tow/Haul feature and return to normal driving mode, press the button on the side of the gearshift lever. The TOW HAUL light will no 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 deactivate when ABS braking is required. Do not use the Tow/Haul feature when driving in icy or slippery conditions as the increased engine braking can cause the rear wheels to slide and the vehicle to swing around with the possible loss of vehicle control. 3 (Third) Transmission starts and operates in third gear only. Used for improved traction on slippery roads. Selecting 3 (Third) provides engine braking. 2 (Second) Use 2 (Second) to start-up on slippery roads or to provide additional engine braking on downgrades. 1 (First) • Provides maximum engine braking. • Allows upshifts by moving gearshift lever. • The transmission will not downshift into 1 (First) at high speeds; it will downshift to a lower gear and then shift into 1 (First) when the vehicle reaches slower speeds. 82 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Driving Forced downshifts • Allowed in (Overdrive) or Drive. • Depress the accelerator to the floor. • Allows transmission to select an appropriate gear. If your vehicle gets stuck in mud or snow If your vehicle gets stuck in mud or snow, it may be rocked out by shifting between forward and reverse gears, stopping between shifts in a steady pattern. Press lightly on the accelerator in each gear. Do not rock the vehicle if the engine is not at normal operating temperature or damage to the transmission may occur. Do not rock the vehicle for more than a minute or damage to the transmission and tires may occur, or the engine may overheat. VEHICLE USED AS A STATIONARY POWER SOURCE Auxiliary equipment called power take-off, or PTO, is often added to the engine or transmission to operate utility equipment. Examples include a wheel-lift for tow trucks, tools for construction and cranes. PTO applications draw auxiliary horsepower from the powertrain, often while the vehicle is stationary. In this condition, there is limited cooling air flow through the radiator and around the vehicle that 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 contribute to elevated transmission fluid temperatures and result in accelerated fluid deterioration, fuel vapor over-pressurization, and other concerns. Ford trucks are fully qualified for stationary PTO operation for 10 minutes or less of continuous operation. Transmission Power Take-Off (PTO) Provision (if equipped) Some vehicles with an automatic transmission may be equipped with a “Transmission Power Take-Off Provision”. These vehicles have a special transmission that includes a port on the left-hand side to mount an aftermarket PTO, an internal PTO gear, and calibration for PTO usage. The actual PTO and related equipment is not offered by Ford Motor Company, but is installed by an aftermarket source. The PTO gear in the transmission will drive the aftermarket PTO while driving the vehicle. Therefore, some additional gear noise that may result is normal. Also, the transmission upshift and downshift schedules will be reduced by about 15% and may result in a firmer shift feel during PTO mobile applications. 83 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Driving A more complete description of PTO operation is discussed in the Ford Truck Body Builders Layout Book, found at www.fleet.ford.com/truckbbas. REAR AXLE INFORMATION Axle operating temperature normally will not exceed 100°F (38°C). If the operating temperature exceeds 230°F (110°C), the rate of axle lubrication oxidation will increase and shorten the life of the lubricant and seals, requiring axle lubrication changes to become more frequent to preserve the axle. Extreme Pressure (EP) lubricants should not be run consistently above 230°F (110°C). Gross axle weight Your truck has gross axle weight, gross vehicle weight and gross combination weight ratings. Do not exceed these ratings. Exceeding these ratings by overloading can cause component failure resulting in property damage, personal injury or death. Axle conversions It is not recommended, or approved, for axle conversions to be 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 lift axles). When operating a loaded vehicle, the driver must keep all adjustable axles on the ground at all times, supporting their share of the vehicle’s load. Failure to do so can overload other axles, tires, wheels, springs, steering components, brakes and frames, resulting in early component failure, loss of vehicle control, possible property damage and personal injury. VEHICLE LOADING This section will guide you in the proper loading of your vehicle and/or trailer, to keep your loaded vehicle weight within its design rating capability, with or without a trailer. Properly loading your vehicle will provide maximum return of vehicle design performance. Before loading your vehicle, familiarize yourself with the following terms for determining your vehicle’s weight ratings, with or without a trailer, from the vehicle’s Vehicle Rating Decal. Every vehicle manufactured by Ford Motor 84 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Driving Company is supplied with information on the Vehicle Rating Decal, located on either the B-pillar or the driver’s door edge, listing the maximum loading for the vehicle (GVWR), and its axle systems (GAWR) at the tire-to-ground interface. GAWR (Gross Axle Weight Rating) – is the maximum allowable weight that can be carried by a single axle (front or rear). These numbers are shown on the Vehicle Rating Decal located on the B-Pillar or the edge of the driver’s door. The total load on each axle must never exceed its GAWR. Exceeding the axle weight rating limits listed on the Vehicle Rating Decal could result in substandard vehicle handling or performance, engine, transmission and/or structural damage, serious damage to the vehicle, loss of control and personal injury. Note: For trailer towing information refer to Trailer towing found in this chapter or the RV and Trailer Towing 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, spring capacities, tire capacities nor the vehicle rated GVWR is exceeded. For tire capacities, refer to Maintenance and Specifications chapter. Vehicle Curb Weight – is the weight of your new vehicle when you picked it up from your dealer plus any aftermarket equipment. GVW (Gross Vehicle Weight) – is the Vehicle Curb Weight + cargo + passengers. 85 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Driving GVWR (Gross Vehicle Weight Rating) – is the maximum allowable weight of the fully loaded vehicle (including all options, equipment, passengers and cargo). The GVWR is shown on the Vehicle Rating Decal located on the B-Pillar or the edge of the driver’s door. The GVW must never exceed the GVWR. Exceeding the vehicle weight rating limits listed on the Vehicle Rating Decal could result in substandard vehicle handling or performance, engine, transmission and/or structural damage, serious damage to the vehicle, loss of control and personal injury. GCW (Gross Combined Weight) – is the weight of the loaded vehicle (GVW) plus the weight of the fully loaded trailer. GCWR (Gross Combined Weight Rating) – is the maximum allowable weight of the vehicle and the loaded trailer – including all cargo and passengers – that the vehicle can handle without risking damage. (Important: The towing vehicles’ braking system is rated for operation at GVWR, not at GCWR. Separate functional brakes should be used for safe control of towed vehicles and for trailers where the GCW of the towing vehicle plus the trailer exceed the GVWR of the towing vehicle. The GCW must never exceed the GCWR. Maximum Loaded Trailer Weight – 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 lb. [68 kg]). Consult your dealership (or the RV and Trailer Towing Guide provided by your dealership) for more detailed information. Tongue Load – refers to the amount of the weight that a trailer pushes down on a trailer hitch. Example: For a 5,000 lb. (2,268 kg) conventional trailer, multiply 5,000 by 0.10 and 0.15 to obtain a proper tongue load range of 500 to 750 lb. (227 to 340 kg). Do not exceed the GVWR or the GAWR specified on the Vehicle Rating Decal. Do not use replacement tires with lower load carrying capacities than the originals because they may lower the vehicle’s GVWR and GAWR limitations. Replacement tires with a higher limit than the originals do not increase the GVWR and GAWR limitations. 86 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Driving Exceeding any vehicle weight rating limitation could result in serious damage to the vehicle and/or personal injury. TRAILER TOWING Towing a trailer places an additional load on your vehicle’s engine, transmission, axle, brakes, tires and suspension. Inspect these components carefully prior to and after any towing operation. Your vehicle’s load capacity is designated by weight, not by volume, so you cannot necessarily use all available space when loading a vehicle. 2nd unit bodies are not included in maximum trailer weight ratings. The weight of the additional “body” must be subtracted from the maximum trailer weight. Provided the vehicle’s GAWR, GVWR and GCWR are not exceeded, your vehicle may tow a Conventional/Class IV trailer or fifth wheel trailer of up to 12,500 lbs. To calculate the maximum trailer weight your vehicle can tow, subtract the towing vehicle’s actual loaded weight from its GCWR. For example, if your vehicle has a 26,000 lbs. (11,794 kg) GCWR and your loaded 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 kg). There may be some instances where your vehicle is lightly loaded or empty and the calculated maximum trailer weight exceeds 12,500 lbs (5,670 kg). In these instances, the maximum allowable trailer weight is limited to a maximum of 12,500 lbs (5,670 kg). Note: Do not exceed the GVWR or the GAWR specified on the Vehicle Rating Decal. Towing trailers beyond the maximum recommended gross trailer weight exceeds the limit of the vehicle and could result in engine damage, transmission damage, structural damage, loss of vehicle control, vehicle rollover and personal injury. 87 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Driving Maximum GVWR - lbs. (kg)* 15000 (6804) 16000 (7258) LCF 17950 (8142) 17999 (8164) 19500 (8845) * Refer to your Vehicle Rating Decal for your vehicle’s Model Maximum GCWR - lbs. (kg) 26000 (11794) 26000 (11794) 26000 (11794) 26000 (11794) 26000 (11794) GVWR. Preparing to tow Use the proper equipment for towing a trailer and make sure it is properly attached to your vehicle. See your dealer or a reliable trailer dealer if you require assistance. Hitches Do not use hitches that clamp onto the vehicle’s bumper or attach to the axle. You must distribute the load in your trailer so that 10–15% of the total weight of the trailer is on the tongue. Safety chains Always connect the trailer’s safety chains to the frame or hook retainers of the vehicle hitch. To connect the trailer’s safety chains, cross the chains under the trailer tongue and allow slack for turning corners. If you use a rental trailer, follow 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 installed properly and adjusted to the manufacturer’s specifications. The trailer brakes must meet local and Federal regulations. Do not connect a trailer’s hydraulic brake system directly to your vehicle’s brake system. Your vehicle may not have enough braking power and your chances of having a collision greatly increase. 88 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Driving Trailer lamps Trailer lamps are required on most towed vehicles. Make sure all running lights, brake lights, turn signals and hazard lights are working. See your dealer or trailer rental agency for proper instructions and equipment for hooking up trailer lamps. Driving while you tow When towing a trailer: • Turn off the speed control. The speed control may shut off automatically when you are towing on long, steep grades. • Consult your local motor vehicle speed regulations for towing a trailer. • To eliminate excessive transmission shifting, activate the Tow/Haul feature; this will also assist in transmission cooling. (For additional information, refer to the Understanding the positions of the 5–speed automatic transmission section in this chapter. • Anticipate stops and brake gradually. • Do not exceed the GCWR rating or transmission damage may occur. Servicing after towing If you tow a trailer for long distances, your vehicle will require more frequent service 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 vehicle trailer combination. When turning, make wider turns so the trailer wheels will clear curbs and other obstacles. • Allow more distance for stopping with a trailer attached. • The trailer tongue weight should be 10–15% of the loaded trailer weight. • After you have traveled 50 miles (80 km), thoroughly check your hitch, electrical connections and trailer wheel lug nuts. • To aid in engine/transmission cooling and A/C efficiency during hot weather while stopped in traffic, place the gearshift lever in P (Park). • Vehicles with trailers should not be parked on a grade. If you must park on a grade, place wheel chocks under the trailer’s wheels. 89 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Roadside Emergencies GETTING ROADSIDE ASSISTANCE To fully assist you should you have a vehicle concern, Ford offers a complimentary roadside assistance program. This program is separate from the New Vehicle Limited Warranty and is not applicable to vehicles sold in Canada. The service is available: • 24–hours, seven days a week • for the New Vehicle Limited Warranty period (U.S.) of two years (unlimited miles) Roadside assistance will cover: • jump-starts. • lock-out assistance. • towing to the nearest Ford Motor Company dealership, or towing to your selling dealership if within 35 miles (56 km). Even non-warranty related tows, like accidents or getting stuck in the mud or snow, are covered (some exclusions apply, such as impound towing or repossession). Using roadside assistance Complete the roadside assistance identification card and place it in your wallet for quick reference. This 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, Ford will reimburse a reasonable amount. To obtain information about reimbursement, call 1-800-241-3673. HAZARD FLASHER The hazard flasher control is located on the instrument panel, to the right of the steering wheel. The hazard flashers will operate when the ignition is off. Push in the flasher control and all front and rear direction signals will flash. Press the flasher control again to turn them off. Use it when your vehicle is disabled and is creating a safety hazard for other motorists. Note: With extended use, the flasher may run down your battery. FUSING If electrical components in the vehicle are not working, a fuse may have blown. Blown fuses are identified by a broken wire within the fuse. Check the appropriate fuses before replacing any electrical components. 90 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Roadside Emergencies Note: Always replace a fuse with one that has the specified amperage rating. Using a fuse with a higher amperage rating can cause severe wire damage and could start a fire. Power distribution box (PDB) The PDB is located behind the cab on the right-hand frame rail, behind a 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 cover carefully so that no wires or cables become disconnected or damaged. Note: Always re-install the protective cover to avoid water or fluids from damaging the PDB or other electrical components. 91 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Roadside Emergencies Once the cover has been removed, simply lift the tab on the PDB cover to access the fuses and relays. Always disconnect the battery before servicing high current fuses. 92 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Roadside Emergencies The fuses and relays are coded as follows: Fuse/Relay Fuse Amp Location Rating 1 — 2 30A* 3 20A* 4 50A* 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30A* 40A* 25A* 30A* 20A* 20A* 20A* 20A* 20A* 15A** 10A** 15A** 15A** 15A** 20A* 60A* 20A* 40A* 20A** 20A** 15A** 10A** 10A** 60A* Fuse Description Not used Starter Park lamps Injector Driver Module (IDM)/Powertrain Control Module (PCM) Headlamps Blower motor Wipers Electric brakes Door locks Stoplamps Fuel pump RUN/ACC feed RUN/START feed Horn Cluster Back-up lamps Fog lamps Transmission Fuel heater Anti-lock Brake System (ABS) module Trailer lighting circuit Not used Trailer battery charge Cigar lighter Hazard flasher Remote Keyless Entry (RKE) Radio Dome lamp ABS pump 93 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Roadside Emergencies Fuse/Relay Location 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 Fuse Amp Rating 30A* 20A* 40A* 25A* 20A* 20A* — 10A** — 10A** 10A** — — — 20A** Micro relay Micro relay Micro relay Micro relay Micro relay Micro relay Micro relay Full ISO relay Full ISO relay Full ISO relay Fuse Description HVAC pusher fan Diagnostic connector Power windows Body builder prep A/C clutch Cluster Not used Turn signals Not used Cornering lamps Not used Not used Radio Not used Not used Not used PCM key power Body builder prep Fuel pump Back-up lamps Not used Fuel heater Transmission A/C clutch Fog lamps ECM Wiper Starter 94 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Roadside Emergencies Fuse/Relay Fuse Amp Fuse Description Location Rating 58 — Not used 59 Micro relay Park lamps 60 — Transmission relay diode 61 — 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 plastic rivet from the driver side of the trim panel. 95 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Roadside Emergencies Remove the two screws on the passenger side bottom of the panel, then the 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. 96 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Roadside Emergencies The relays are coded as follows: Relay location A/C DEMAND HORN RT FRONT TURN SIGNAL IGN. PUSHER FAN LEFT FRONT DOME LAMP RT REAR HEADLAMP BLOWER MOTOR LEFT REAR HIGH/LOW POWER WINDOWS Description Climate control Horn Right front turn signal Turn signals Ignition HVAC pusher fan Left front turn signal Dome lamp Right rear turn signal Headlamps Climate control blower motor Left rear turn signal Headlamp high/low beams Power windows 97 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Roadside Emergencies CHANGING A FLAT TIRE, IF EQUIPPED WITH THE OPTIONAL SPARE TIRE If you get a flat tire while driving: • do not brake heavily. • gradually decrease the vehicle’s speed. • hold the steering wheel firmly. • slowly move to a safe place on the side of the road. For tire changing instructions refer to the Ford Work Shop Manual. Note: Remember to replace the spare tire when you replace the road tires at the end of their useful life. Even if it has never been used, the spare tire should be replaced because tires degrade over time. Note: Remember to replace the wheel air valves when the road tires are replaced at the end of their useful life. JUMP STARTING The gases around the battery can explode if exposed to flames, sparks, or lit cigarettes. An explosion could result in injury or vehicle damage. Batteries contain sulfuric acid which can burn skin, eyes and clothing, if contacted. Do not attempt to push-start your automatic transmission vehicle. Automatic transmissions do not have push-start capability. Attempting to push-start a vehicle with an automatic transmission may cause transmission damage. Preparing your vehicle When the battery is disconnected or a new battery is installed, the transmission must relearn its shift strategy. As a result, the transmission may have firm and/or soft shifts. This operation is considered normal and will not affect function or durability of the transmission. Over time, the adaptive learning process will fully update transmission operation. 1. Use only a 12–volt supply to start your vehicle. 2. Do not disconnect the battery of the disabled vehicle as this could damage the vehicle’s electrical system. 98 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Roadside Emergencies 3. Park the vehicles close to one another, making sure they do not touch, so the batteries on the right-hand frame rail behind the cab of your vehicle can be accessed for jump starting. Set the parking brake on both vehicles and stay clear of the engine cooling fan and other moving parts. 4. Check all battery terminals and remove any excessive corrosion before you 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 cables + + – – 1. Connect the positive (+) jumper cable to the positive (+) terminal of the discharged battery. Note: In the illustrations, lightning bolts are used to designate the assisting (boosting) battery. + + – – 2. Connect the other end of the positive (+) cable to the positive (+) terminal of the assisting battery. 99 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Roadside Emergencies + + – – 3. Connect the negative (-) cable to the negative (-) terminal of the assisting battery. + + – – 4. Make the final connection of the negative (-) cable to an exposed metal part of the stalled vehicle’s engine, away from the battery and the carburetor/fuel injection system. Do not use fuel lines, engine rocker covers or the intake manifold as grounding points. Do not connect the end of the second cable to the 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 engines, or any fuel delivery system parts. Jump starting 1. Start the engine of the booster vehicle and run the engine at moderately increased speed. 2. Start the engine of the disabled vehicle. 3. Once the disabled vehicle has been started, run both engines for an additional three minutes before disconnecting the jumper cables. 100 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Roadside Emergencies Removing the jumper cables + + – – Remove the jumper cables in the reverse order that they were connected. 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. + + – – 3. Remove the jumper cable from the positive (+) terminal of the booster vehicle’s battery. 101 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Roadside Emergencies + + – – 4. Remove the jumper cable from the positive (+) terminal of the disabled 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. 102 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Roadside Emergencies WRECKER TOWING If you need to have your vehicle towed, contact a professional towing service or, if you are a member of a roadside assistance program, your roadside assistance service provider. The following methods are recommended for towing: • Vehicle towed from the front using a 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 equipment as doing so may damage your vehicle. When it is necessary to tow a vehicle with the front wheels suspended, extra precautions must be taken to avoid transmission damage. The driveshafts must be removed from between the transmission and the axle assembly to prevent the wheels from driving the differential and the transmission. 103 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Roadside Emergencies Note: To avoid transmission damage, vehicles should not be towed even a short distance without suspending rear wheels or removing the driveshaft. If the vehicle is towed by other means or incorrectly, vehicle damage may occur. When calling for a tow truck, tell the operator what kind of vehicle you have. Tow hooks Your vehicle is equipped with front tow hooks. The tow hooks should only be used in case of an emergency (retrieving a vehicle out of a ditch or snow bank, for example). When using the tow hooks, always pull the lead or chains in a straight direction with respect to the hook; do not apply sideways force. 104 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Customer Assistance GETTING THE SERVICES YOU NEED At home Ford Motor Company and Ford of Canada have authorized dealerships to service your vehicle. It is preferred that you return to the authorized dealer where your vehicle was purchased when warranty repairs are needed. However, you may also take your vehicle to another Ford Motor Company or Ford of Canada dealership authorized for warranty repairs. Please note that certain warranty repairs require special training and/or equipment, so not all dealers are authorized to perform all warranty repairs. That means that depending on the warranty repair needed, the vehicle may need to be taken to another dealer. If a particular dealership cannot assist you, then contact the Commercial Vehicle Hotline. If you have questions or concerns, or are 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 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 Commercial Vehicle Hotline. Away from home If you need more help than the dealership can provide after following the steps provided above call the Ford Fleet and Commercial Vehicle Hotline. In the United States: Ford Motor Company Commercial Vehicle Hotline 1655 Fairlane Circle Allen Park, MI 48101 800-782-8627 (option #3) (TDD for the hearing impaired: 1-800-232-5952) www.fleet.ford.com In Canada: Customer Relationship Centre Ford Motor Company of Canada, Limited P.O. Box 2000 Oakville, Ontario L6J 5E4 1-800-565-3673 (FORD) www.ford.ca 105 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Customer Assistance In order to help you service your Ford vehicle, please have the following information available when contacting the Commercial Vehicle Hotline: • Your telephone number (home and business) • The name of the dealer and the city where the dealership is located • The year and make of your vehicle • The date of vehicle purchase • The current odometer reading • The vehicle identification number (VIN) Additional assistance If you still have a complaint involving a warranty dispute, you must directly notify Ford in writing before pursuing remedies under your state’s warranty laws. Ford is also allowed a final repair attempt in some states. IN CALIFORNIA (U.S. ONLY) California Civil Code Section 1793.2(d) requires that, if a manufacturer or its representative is unable to repair a motor vehicle to conform to the vehicle’s applicable express warranty after a reasonable number of attempts, the manufacturer shall be required 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 reasonable allowance for consumer use). The consumer has the right to choose whether to receive a refund or replacement vehicle. California Civil Code Section 1793.22(b) presumes that the manufacturer has had a reasonable number of attempts to conform the vehicle to its applicable express warranties if, within the first 18 months of ownership of a new vehicle or the first 18,000 miles (29,000 km), whichever occurs first: 1. Two or more repair attempts are made on the same nonconformity likely to cause death or serious bodily injury OR 2. Four or more repair attempts are made on the same nonconformity (a defect or condition that substantially impairs the use, value or safety of the vehicle) OR 3. The vehicle is out of service for repair of nonconformities for a total of more than 30 calendar days (not necessarily all at one time) 106 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Customer Assistance In the case of 1 or 2 above, the consumer must also notify the manufacturer of the need for the repair of the nonconformity at the following address: Ford Motor Company 16800 Executive Plaza Drive Mail Drop 3NE-B Dearborn, MI 48126 GETTING ASSISTANCE OUTSIDE THE U.S AND CANADA Before exporting your vehicle to a foreign country, contact the appropriate foreign embassy or consulate. These officials can inform you of local vehicle registration regulations and where to find diesel fuel. If you cannot find diesel fuel or can only get fuel with an anti-knock index lower than is recommended for your vehicle, contact a regional office or owner relations/customer relationship office. The use of low quality diesel fuel may affect your emissions control system and may cause engine damage. Ford Motor Company/Ford of Canada is not responsible for any damage caused by use of improper fuel. 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 specialized training and servicing requirements of these vehicles. If your vehicle must be serviced while you are traveling or living in Central or South America, the Caribbean, or the Middle East, contact the nearest Ford dealership. If the dealership cannot help you, write or call: FORD MOTOR COMPANY FORD EXPORT OPERATIONS 1555 Fairlane Drive Fairlane Business Park #3 Allen Park, Michigan 48101 U.S.A. Telephone: (313) 594-4857 FAX: (313) 390-0804 If you are in another foreign country, contact the nearest Ford dealership. If the dealership employees cannot help you, they can direct you to the nearest Ford affiliate office. If you buy your vehicle in North America and then relocate outside of the U.S. or Canada, register your vehicle identification number (VIN) and new address with Ford Motor Company Export Operations. 107 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Customer Assistance ORDERING ADDITIONAL OWNER’S LITERATURE To order the publications in this portfolio, contact Helm, Incorporated at: HELM, INCORPORATED P.O. Box 07150 Detroit, Michigan 48207 Or call: For a free publication catalog, order toll free: 1-800-782-4356 Monday-Friday 8:00 a.m. - 6:00 p.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 Guides can be obtained from your authorized dealer or by writing to: Ford Motor Company of Canada, Limited Service Publications CHQ202 The Canadian Road P.O. Box 2000 Oakville, ON, Canada L6J 5E4 108 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Customer Assistance REPORTING SAFETY DEFECTS (U.S. ONLY) If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying Ford Motor Company. If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety defect exists in a group of vehicles, it may order a recall and remedy campaign. However, NHTSA cannot become involved 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.gov; or write to: NHTSA 400 Seventh Street, SW. Washington, D.C. 20590 You can also obtain other information about motor vehicle safety from http://www.safercar.gov. REPORTING SAFETY DEFECTS (CANADA ONLY) If your believe your vehicle has a defect which could cause a crash or could cause injury or death, you should immediately inform Transport Canada, using their toll-free number: 1–800–333–0510. 109 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Cleaning WASHING THE EXTERIOR Wash your vehicle regularly with cool or lukewarm water and a neutral pH shampoo, such as Motorcraft Detail Wash (ZC-3–A), which is available from your dealer. • Never use strong household detergents or soap, such as dish washing or laundry liquid. These products can discolor and spot painted surfaces. • Never wash a vehicle that is “hot to the touch” or during exposure to strong, direct sunlight. • Always use a clean sponge or car wash mitt with plenty of water for best results. • Dry the vehicle with a chamois or soft terry cloth towel in order to eliminate water spotting. • It is especially important to wash the vehicle regularly during the winter months, as dirt and road salt are difficult to remove and cause damage to the vehicle. • Immediately remove items 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 your authorized dealer. • Remove any exterior accessories, such as antennas, before entering a car wash. • Suntan lotions and insect repellents can damage any painted surface; if these substances come in contact with your vehicle, wash off as soon as possible. WAXING • Wash the vehicle first. • Do not use waxes that contain abrasives. Use Motorcraft Premium Liquid Wax, ZC-53-A, which is available from your authorized dealer, or an equivalent quality product. • Do not allow paint sealant to come in contact with any non-body (low-gloss black) colored trim, such as grained door handles, roof racks, bumpers, side moldings, mirror housings or the windshield cowl area. The paint sealant will “gray” or stain the parts over time. 110 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Cleaning PAINT CHIPS In order to ensure a proper color match, paint purchased for service and second-unit body paints may need to be ordered from Akzo Nobel/Sikkens using the seven-digit NAVxxxx paint code. Paint purchased from the Ford (or Ford paint suppliers) service system using the two-digit Ford paint code may not provide an acceptable color match for your vehicle. • Remove particles such as bird droppings, tree sap, insect deposits, tar spots, road salt and industrial fallout before repairing paint chips. • Always read the instructions before using the products. ALUMINUM WHEELS AND COVERS • Clean with Motorcraft Wheel and Tire Cleaner (ZC-37–A), which is available from your dealer. • Never apply any cleaning chemical to hot or warm wheel rims or covers. • Some automatic car washes may cause damage to the finish on your wheel rims or covers. 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 high caustic-based wheel cleaners, steel wool, fuels or strong household detergent. • To remove tar and grease, use Motorcraft Bug and Tar Remover (ZC-42), available from your dealer. ENGINE Engines are more efficient when they are clean because grease and dirt buildup keep the engine warmer than normal. When washing: • Take care when using a power washer to clean the engine. The high-pressure fluid could penetrate the sealed parts and cause damage. • Do not spray a hot engine with cold water to avoid cracking the engine block or other engine components. • Spray Motorcraft Engine Shampoo and Degreaser (ZC-20) 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. 111 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Cleaning PLASTIC (NON-PAINTED) EXTERIOR PARTS Use only approved products to clean plastic parts. These products are available from your dealer. • For routine cleaning, use Motorcraft Detail Wash (ZC-3–A). • If tar or grease spots are present, use Motorcraft Bug and Tar Remover (ZC-42). • For plastic headlamp lenses, use Motorcraft Ultra Clear Spray Glass Cleaner (ZC-23). WINDOWS AND WIPER BLADES The windshield, rear and side windows and the wiper blades should be cleaned regularly. If the wipers do not wipe properly, substances on the vehicle’s glass or the wiper blades may be the cause. These may include hot wax treatments used by commercial car washes, water repellent coatings, tree sap, or other organic contamination; these contaminants may cause squeaking or chatter noise from the blades, and streaking and smearing of the windshield. 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 from your authorized dealer. • The wiper blades can be cleaned with isopropyl (rubbing) alcohol or Motorcraft Premium Windshield Washer Concentrate (ZC-32–A), available from your authorized dealer. This washer fluid contains special solution in addition to alcohol which helps to remove the hot wax deposited on the wiper blade and windshield from automated car wash facilities. Be sure to replace wiper blades when they appear worn or do not function properly. • Do not use abrasives, as they may cause scratches. • Do not use fuel, kerosene, or paint thinner to clean any parts. Do not use sharp objects, such as a razor blade, to clean the inside of the rear window or to remove decals, as it may cause damage to the rear window defroster’s heated grid lines. INSTRUMENT PANEL AND CLUSTER LENS Clean the instrument panel, interior trim areas and cluster lens with a clean and damp, white cotton cloth, then with a clean and dry, white cotton cloth; you may also use Motorcraft Dash & Vinyl Cleaner (ZC-38-A) on the instrument panel and interior trim areas. • Avoid cleaners or polish that increase the gloss of the upper portion of the instrument panel. The dull finish in this area helps protect the driver from undesirable windshield reflection. 112 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Cleaning • Be certain to wash or wipe your hands clean if you have been in contact with certain products such as insect repellent and suntan lotion in order to avoid possible damage to the painted surfaces. • Do not use household or glass cleaners as these may damage the finish of the instrument panel, 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 white cotton cloth. 2. Apply Motorcraft Deluxe Leather and Vinyl Cleaner (ZC-11-A) [In Canada use Motorcraft Multi-Purpose Cleaner (CXC-101)] to the wiped area and spread around evenly. 3. Apply more Motorcraft cleaner to a clean white cotton cloth and press the cloth onto the soiled area–allow this to set at room temperature for 30 minutes. 4. Remove the soaked cloth, and if it is not soiled badly, use this cloth to clean the area by using a rubbing motion for 60 seconds. 5. Following this, wipe area dry with a clean white cotton cloth. INTERIOR TRIM • Clean the interior trim areas with a damp cloth, then dry by wiping with a dry, soft, clean cloth. • Do not use household or glass cleaners as these may damage the finish. INTERIOR For fabric, carpets, cloth seats and safety belts: • Remove dust and loose dirt with a vacuum cleaner. • Remove light stains and soil with Motorcraft Professional Strength Carpet & Upholstery Cleaner (ZC-54). • If grease or tar is present on the material, spot-clean the area first with Motorcraft Spot and Stain Remover (ZC-14). • Never saturate the seat covers with cleaning solution. • Do not use household cleaning products or glass cleaners, which can stain and discolor the fabric and affect the flame retardant abilities of the seat materials. 113 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Cleaning Do not use cleaning solvents, bleach or dye on the vehicle’s seat belts, as these actions may weaken the belt webbing. UNDERBODY Flush the complete underside of your vehicle frequently. Keep body and door drain holes free from 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 quality products have been specifically engineered to fulfill your automotive needs; they are custom designed to complement the style and appearance of your vehicle. Each product is made from high quality materials that meet or exceed rigid specifications. For best results, use the following products or products of equivalent quality: Motorcraft Bug and Tar Remover (ZC-42) Motorcraft Car Wash (Canada only) (CXC-21) Motorcraft Multi-Purpose Cleaner (Canada only) (CXC-101) Motorcraft Custom Bright Metal Cleaner (ZC-15) Motorcraft Custom Clear Coat Polish (ZC-8-A) Motorcraft Custom Vinyl Protectant (U.S. only) (ZC-40-A) Motorcraft Dash and Vinyl Cleaner (ZC-38–A) Motorcraft Deluxe Leather and Vinyl Cleaner (U.S. only) (ZC-11-A) Motorcraft Leather Care Kit (ZC-11-D) Motorcraft Detail Wash (ZC-3-A) Motorcraft Dusting Cloth Mitt (ZC-47) Motorcraft Dusting Cloth (ZC-24) Motorcraft Engine Shampoo and Degreaser (U.S. only) (ZC-20) Motorcraft One Step Wash and Wax Concentrate (ZC-6-A) Motorcraft Premium Glass Cleaner (Canada only) (CXC-100) Motorcraft Premium Liquid Wax (ZC-53-A) Motorcraft Premium Windshield Washer Concentrate (ZC-32-A) Motorcraft Professional Strength Carpet & Upholstery Cleaner (ZC-54) 114 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Cleaning Motorcraft Motorcraft Motorcraft Motorcraft Motorcraft Motorcraft Spot and Stain Remover (U.S. only) (ZC-14) Tire Clean and Shine (ZC-28) Triple Clean (U.S. only) (ZC-13) Ultra-Clear Spray Glass Cleaner (ZC-23) Vinyl Cleaner (Canada only) (CXC-93) Wheel and Tire Cleaner (ZC-37-A) 115 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Maintenance and Specifications GENERAL SERVICING GUIDELINES AND PRECAUTIONS As with any machine, care should be taken to avoid being injured when performing maintenance, repairs or system checks. Improper or incomplete service could result in the vehicle not working properly which, in turn, may result in personal injury or damage to the vehicle or equipment. It is the operator’s responsibility to see that the vehicle receives proper care and maintenance. If you have any questions about performing some service, have the service done by a qualified technician. Servicing guidelines When servicing your vehicle, always: • turn off the ignition unless the particular procedure calls for the engine to be running. • if the procedure requires the engine to be running, operate the engine in a well-ventilated area • set the parking brake or chock the wheels. • use support stands, not a jack, whenever you must be under a raised vehicle. • do not smoke. • wear 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, watches or rings. • avoid contact with hot metal parts. Allow the hot components to cool before working with, or around them. Quality service parts are available through your dealer. If dealer parts are not used, the owner must make sure that the parts that are being used are equivalent quality to dealer parts. The use of inferior parts can adversely affect the quality and reliability of your vehicle which, in turn, can result in property damage, personal injury or death. Note: To avoid damage to the vehicle’s electrical components, disconnect the positive (+) and negative (-) battery cables prior to electric welding. Attach the welder ground cable as close as possible to the part being welded. If it is necessary to weld close to an electrical component, it is recommended that the electronic component be temporarily removed. 116 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Maintenance and Specifications Follow the periodic lubrication procedures and regular inspection intervals as outlined. Have your dealer or service center inspect your vehicle at least once a year. Remember that regular maintenance and replacement of worn components will usually prevent serious problems from developing later. Making modifications to various parts, components and systems of the vehicle, such as brake and steering systems can adversely affect the quality, reliability and operation of your vehicle and could result in property damage, personal injury or death. Such modifications must be avoided. The lubrication intervals present a good opportunity to inspect the vehicle. It is suggested that the various points listed herein be checked at the lubrication or other recommended intervals. Failure to properly perform maintenance and servicing procedures could result in vehicle damage, personal injury or death. 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. Take care when performing any maintenance, system check or service on your vehicle. Some of the materials may also be hazardous if used, serviced or handled improperly and could result in property damage, personal injury or death. Supporting your vehicle for service When performing service repairs on your vehicle, first prepare the vehicle by doing the following: 1. Park the vehicle on a level concrete floor. 2. Set the parking brake and block the wheels to prevent the vehicle from moving. 3. Select a jack with a rated capacity sufficient to lift and hold up the vehicle. 4. Raise the vehicle with the jack applied to the axle. DO NOT use the bumper as a lifting point. 5. Support the vehicle with floor stands under the axle(s). If the axle or the suspension are being serviced, support the vehicle with floor stands under the frame side-members. 117 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Maintenance and Specifications Do not use a jack when working under a vehicle. It may give way, causing the vehicle to fall and result in property damage, personal injury or death. Always use floor stands to support the vehicle. Air conditioning system checks Have your air conditioning system checked each spring. The refrigerant charge, cleanliness of the condenser-evaporator cores and belt condition is essential to air conditioning performance. When the air conditioning system is being used daily, remove the fresh air filter (if equipped) once each season and check for dirt, lint, etc. Replace the filter if necessary. Vehicles operating in unusually dusty conditions may require inspecting and replacing the fresh air filter more often. Front axle - general service information Maintaining the front axle alignment to specifications is very important and should only be performed by a qualified technician. Toe-in adjustment is particularly important with radial tires. Check to make sure that the axle mounting U-bolt nuts, attaching or mounting bolts and nuts are securely 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, alignment, etc.) the kingpins should be checked for excessive wear. Refer to the service manual for proper procedures. Toe-in setting - general inspection Inspecting steer axle tires in the first 3,000–10,000 miles (4,800–16,000 km) will generally show if tires are wearing normally. Rapid outside shoulder wear on both tires indicates too much toe-in. Rapid inside shoulder wear on both tires indicates too much toe-out. In P&D-type service, left-to-right steer tire tread life differentials up to 40% can be observed depending on routes and other variables. Follow the tire manufacturer’s recommended cold inflation pressure for the tire size, load range (ply rating) and steer axle loading typical for their operation (each steer axle tire will equal 1⁄2 steer axle loading). Special applications may warrant a setting based on past experience with the type of tire operating loads and conditions. Radial tires are more sensitive to toe-in setting than bias ply tires. 118 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Maintenance and Specifications It is essential that correct toe-in and tire pressure be maintained for optimum tire wear. Rear axle - general inspection Check to make sure that the axle mounting U-bolts, attaching or mounting bolts and nuts are securely tightened. Refer to the U-bolt nut torque chart in this chapter. Regularly check the rear axle for damaged, binding or worn parts. Brake system - general inspection Your vehicle is equipped with non-asbestos brake linings. However, exposure to excessive amounts of brake material (whether asbestos or non-asbestos, fiberglass, mineral wool, aramid or carbon) may be a potentially serious health hazard. Avoid breathing brake lining fiber dust as it may be extremely hazardous to your health. Always use a respirator during brake maintenance. Note: Persons handling brake linings should follow all precautions listed below: 1. Always wear a respirator approved by the National Institute of Occupational Studies of Health (NIOSH) or Mine Safety and Appliance (MSA) during 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 assemblies in a well ventilated area. During assembly, carefully place all parts on the floor to avoid getting dust in the air. Use an industrial vacuum cleaner with a HEPA filter system to clean dust from the brake drums, backing plates and other brake parts. After using the vacuum, remove any remaining dust with a rag soaked in water and wrung until nearly dry. 4. Never use compressed air or dry sweeping to clean the work area. Use an industrial vacuum cleaner with a HEPA filter system and rags soaked in water until wrung until nearly dry. Dispose of used rags with care to avoid getting dust in the air. Use an approved respirator when emptying vacuum cleaners and handling used rags. 5. Worker clean-up: Wash your hands before eating, drinking or smoking. Vacuum your work clothes after use and then launder them separately, without shaking them, to prevent fiber dust getting into the air. 119 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Maintenance and Specifications General inspection and adjustment A regular schedule for periodic cleaning, lubrication, adjustment and inspection should be established based on the type of vehicle operation. It is difficult to predetermine an exact maintenance interval (time or mileage), since vehicles will be used in a wide variety of applications and conditions. If you are uncertain of the proper schedule and procedures for your vehicle, contact your dealer. Inspect the brake lining every maintenance interval. Establish inspection intervals that provide for lining replacement before damage to the disc occurs. Excessive lining wear may expose the backing plate to the disc causing scoring of the disc faces. This inspection should be performed by a qualified technician and must be in accordance with instructions provided by the service manual. Fluid level Fluid level should be between the MIN and MAX lines as marked on the reservoir. Do not fill the master cylinder to the top of the reservoir. Note: If brake fluid requires attention to maintain a proper master cylinder level, this is an indication of either 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 systems operating with two different and incompatible fluids; power steering fluid and hydraulic brake fluid. Failure to observe precautions preventing the contamination of either system with fluid from the other will result in swelling and deterioration of rubber parts leading to reduced brake performance and eventual brake failure. To avoid fluid contamination, the following should always be observed: 1. Use only fluids specified (or equivalent) and properly identified. 2. Add fluids only to the following locations: • Power steering fluid to the power steering fluid pump reservoir • Brake fluid to the brake master cylinder Note on brake fluid usage: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford-Motorcraft products call: 1-800-959-3673. For additional information consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in personal injury. 120 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Maintenance and Specifications Brake lines, hoses and fittings Inspect these components every 4,000 miles (6,000 km). • Check lines for kinks, dents, corrosion or rupture. • Check hoses for abrasions, kinks, soft spots or rupture, collapse, cracks, twists or loose frame supports. When replacing a hose, be sure there is adequate clearance to the hose to avoid an abrasion to the new hose. • Examine all connections for leaks. • Repair or replace brake line tubes, hoses or fittings as required. Parking brake Parking brake adjustment should only be performed by a qualified technician, and in accordance with the instructions in the service manual. Use wheel chocks and exercise caution when inspecting under the vehicle. A vehicle roll-away could result in property damage, personal injury or death. TILTING/LOWERING THE CAB Before titling the cab: • Make sure the vehicle is parked on a level surface. • Make sure the parking brake is fully set. • Turn the engine off (unless it is required to be running for inspection) • Make sure all doors are closed tightly. Note: Never lower handle B when cab is tilted (see illustration). 121 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Maintenance and Specifications Tilting Remove all loose objects from cab, close doors, and chock wheels. Refer to the accompanying illustration when following these directions: 1. Raise lever A then raise handle B until it comes to a stop. 2. Pull lever C toward you. Tilt the cab while holding grip E. 3. After 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 grip E. Pull handle G rearward while holding grip E. 2. With handle B raised fully, hold grip E and lower the cab until hook D is locked. 3. Lower handle B securely to its original position. 122 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Maintenance and Specifications WINDSHIELD WASHER FLUID The fluid reservoir is located on the far right side of the instrument panel, accessible by opening the passenger’s door. Add fluid to fill the reservoir if the level is low. In very cold weather, do not fill the reservoir completely. Only use a washer fluid that meets Ford specification WSB-M8B16–A2. Refer to Lubricant specifications in this chapter. State or local regulations on volatile organic compounds may restrict the use of methanol, a common windshield washer antifreeze additive. Washer fluids containing non-methanol antifreeze agents should be used only if they provide cold weather protection without damaging the vehicle’s paint finish, wiper blades or washer system. If you operate your vehicle in temperatures below 40°F (4°C), use washer fluid with antifreeze protection. Failure to use washer fluid with antifreeze protection in cold weather could result in impaired windshield vision and increase the risk of injury or accident. CHANGING THE WIPER BLADES To prolong the life of the wiper blades, it is highly recommended to scrape off the ice on the windshield before turning on the wipers. The layer of ice has many sharp edges and can damage the micro edge of the wiper element. The wiper blades should be replaced every six months for optimum performance. 123 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Maintenance and Specifications 1. Pull the wiper arm away from the windshield and lock into the service position. 2. Turn the blade at an angle from the wiper arm. Push the lock pin manually to release the blade and pull the wiper blade down toward the windshield to remove it from the arm. 3. Attach the new wiper to the wiper arm and press it into place until a click is heard. ENGINE OIL Checking 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 brake and shift into P (Park). 3. Locate and carefully remove the engine oil dipstick. The dipstick is located between the air filter housing and the back of the cab; you do not need to tilt the cab to access it. 4. Wipe the dipstick clean. Insert the dipstick fully, then remove it again. 124 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Maintenance and Specifications • If the oil level is between ADD and OPERATING RANGE, the oil level is acceptable. DO NOT ADD OIL. • Maintain the oil level between ADD and OPERATING RANGE on the dipstick by adding oil as required. • The distance from ADD to OPERATING RANGE on the dipstick represents 1.0 quart (1.0L). • Oil levels above OPERATING RANGE may cause engine damage. Some oil must be removed from the engine by a qualified service technician. 5. Put the dipstick back into the engine and ensure it is fully seated. Engine oil and filter recommendations To help achieve proper engine performance and durability, it is important that you: • Use only engine oil and oil filters of the proper quality. • Change the engine oil and filter no later than the recommended service interval. Refer to the scheduled maintenance information for the appropriate intervals for changing 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 temperatures or short driving distances. Diesel engines require specially formulated oil to resist contamination. Proper quality oils also provide maximum efficiency of the crankcase ventilation system which reduces air pollution. To help achieve acceptable engine performance and durability, it is important that only engine oils of good quality are used in your diesel engine and it is changed at the recommended interval. For normal or severe service, use Motorcraft oil or an equivalent oil conforming to Ford specification WSS-M2C171–E or API service categories CJ-4 or CJ-4/SM. It is important to use these oils because they are compatible with the emission control equipment of your vehicle to meet the more stringent emission standards. 125 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Maintenance and Specifications * Heavy duty trailer towing with ambient temperatures above 50°F (10°C) requires 15W-40 engine oil. Using the chart, determine which SAE viscosity grade best suits the temperature range in which you expect to operate your vehicle. The use of the correct oil viscosity grade for diesel engines is important for satisfactory engine operation. A symbol has been developed 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 service category designation; this should be CJ-4 or CJ-4/SM. The center section of the API symbol shows the SAE viscosity grade. Use a Ford engine oil filter, part number FL-1995, or equivalent. This filter protects your engine by filtering harmful, abrasive or sludge particles. 126 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Maintenance and Specifications BATTERY Your vehicle is equipped with two Motorcraft maintenance-free batteries which are mounted in a covered tray and located on the right frame rail. Maintenance-free batteries do not normally require adding additional water. If the batteries have a cover or shield, make sure the cover or shield is reinstalled after the battery has been cleaned or replaced. For longer, trouble-free operation, keep the top of the batteries clean and dry. Also, make certain the battery cables are always tightly fastened to the battery terminals. It is recommended 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 storage. If you see any corrosion on the battery or terminals, remove the cables from the terminals and clean with a wire brush. You can neutralize the acid with a solution of baking soda and water. Batteries normally produce explosive gases which can cause personal injury. Therefore, do not allow flames, sparks or lighted substances to come near the battery. When working near the battery, always shield your face and protect your eyes. Always provide proper ventilation. When lifting a plastic-cased battery, excessive pressure on the end walls could cause acid to flow through the vent caps, resulting in personal injury and/or damage to the vehicle or battery. Lift the battery with a battery carrier or with your hands on opposite corners. Keep batteries out of reach of children. Batteries contain sulfuric acid. Avoid contact with skin, eyes or clothing. Shield your eyes when working near the battery to protect against possible splashing of acid solution. In case of acid contact with skin or eyes, flush immediately with water for a minimum of 15 minutes and get prompt medical attention. If acid is swallowed, call a physician immediately. 127 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Maintenance and Specifications Battery posts, terminals and related accessories contain lead and lead compounds. Wash hands after handling. R TU LE AD RE N Always dispose of automotive batteries in a responsible manner. Follow your local authorized standards for disposal. Call your local authorized recycling center to find out more about recycling automotive batteries. RECYCLE ENGINE COOLANT Checking engine coolant The concentration and 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 to a freeze point of -34°F (-36°C). Coolant concentration testing is possible with a hydrometer or antifreeze tester. The level of coolant should be maintained at the full mark in the coolant reservoir. If the level falls below, add coolant per the instructions in the Adding engine coolant section. Your vehicle was factory-filled with a 50/50 engine coolant and water concentration. If the concentration of coolant falls below 40% or above 60%, the engine parts could become damaged or not work properly. A 50–50 mixture of coolant and water provides the following: • Freeze protection down to -34°F (-36°C). • Boiling protection up to 265°F (129°C). • Protection against rust and other forms of corrosion. • Enables calibrated gauges to work properly. 128 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Maintenance and Specifications The engine coolant reservoir is located behind the passenger side of the cab. When the engine is cold, check the level of the engine coolant in the reservoir. The reservoir has two see-through level indicators on it. The top indicator is the full mark; the bottom indicator is the ADD mark. If engine coolant is visible through either indicator it will appear as yellow (or gold) in color. The reservoir level should be kept so that engine coolant is visible at the top indicator (full mark). • The engine coolant should be at the full mark as shown on the engine coolant reservoir (depending upon application). • 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 been checked at the recommended interval, the engine coolant reservoir may become low or empty. If the reservoir is low or empty, add engine coolant to the reservoir. Refer to Adding engine coolant in this chapter. Note: Automotive fluids are not interchangeable; do not use engine coolant, antifreeze or windshield washer fluid outside of its specified function and vehicle location. Adding engine coolant Note: The engine coolant reservoir requires air space for expansion volume. The proper fill level is identified on the reservoir; do not overfill the reservoir. 129 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Maintenance and Specifications Note: If the coolant should get extremely low and the engine very hot, let the engine cool for approximately 15 minutes before adding coolant. After the engine has cooled, start the engine and add coolant slowly. Adding coolant to a hot engine may crack the cylinder head or crankcase. Never use only water to fill the cooling system. When adding coolant, make sure it is a 50/50 mixture of engine coolant and distilled water. Add the mixture to the coolant reservoir, when the engine is cool, until the appropriate fill level is obtained. Do not add engine coolant when the engine is hot. Steam and scalding liquids released from a hot cooling system can burn you badly. Also, you can be burned if you spill coolant on hot engine parts. Do not put engine coolant in the windshield washer fluid container. If sprayed on the windshield, engine coolant could make it difficult to see through the windshield. The cooling system in your vehicle is filled with yellow-colored Motorcraft Premium Gold 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 Specification WSS-M97B51–A1. Note: Use of Motorcraft Cooling System Stop Leak Pellets, VC-6, may darken the color of Motorcraft Premium Gold Engine Coolant from yellow to golden tan. • Do not add/mix extended life coolants such as Motorcraft Specialty Orange Engine Coolant meeting Ford specification WSS-M97B44–D, or DEX-COOL威 brand, with the factory-fill coolant. Mixing Motorcraft Specialty Orange Engine Coolant or any orange-colored extended life product such as DEX-COOL威 brand with your factory filled coolant can result in degraded corrosion protection. • A large amount of water without engine coolant may be added, in case of 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. 130 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Maintenance and Specifications • Do not use alcohol, methanol or brine or any engine coolants mixed with alcohol or methanol antifreeze (coolant). Alcohol and other liquids can cause engine damage from overheating or freezing. • Do not add extra inhibitors or additives to the coolant. These can be harmful and compromise the corrosion protection of the engine coolant. • Do not mix with recycled coolant unless from a Ford-approved recycling process (see Use of Recycled Engine Coolant section). To reduce the risk of personal injury, make sure the engine is cool before unscrewing the coolant pressure relief cap. The cooling system is under pressure; steam and hot liquid can come out forcefully when the cap is loosened slightly. 1. Before you begin, turn the engine off and let it cool. 2. When the engine is cool, wrap a thick cloth around the coolant pressure relief cap on the coolant reservoir (an opaque plastic bottle). 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 counterclockwise and remove the cap. 5. Fill the coolant reservoir slowly with the proper coolant mixture (see above), to the top indicator (full mark) on the reservoir. If you removed the radiator cap in an overflow system, fill the radiator until the coolant is visible and radiator is almost full. 6. Replace the cap. Turn until tightly installed to prevent coolant loss. After any coolant has been added, check the coolant concentration (refer to Severe climates later in this chapter). If the concentration is not 50/50 (protection to –34°F [–36°C]), drain some coolant and adjust the concentration. It may take several drains and additions to obtain a 50/50 coolant concentration. 131 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Maintenance and Specifications Whenever coolant has been added, the coolant level in the coolant reservoir should be checked the next few times you drive the vehicle. If necessary, add enough 50/50 concentration of engine coolant and distilled water to bring the liquid level to the proper level. If you have to add more than 1.0 quart (1.0L) of engine coolant per month, have your dealer check the engine cooling system for leaks. 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 engine coolant in vehicles originally equipped with 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. Engine coolant capacities and part numbers For cooling system capacities, refer 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 necessary to increase the coolant concentration above 50%. • NEVER increase the coolant concentration above 60%. • Engine coolant concentrations above 60% will decrease the overheat protection characteristics of the engine coolant and may cause engine damage. • If available, refer to the chart on the coolant container to ensure the coolant concentration in your vehicle will provide adequate freeze protection at the temperatures in which you drive in the winter months. If you drive in extremely hot climates: • It is still necessary to maintain the coolant concentration above 40%. 132 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Maintenance and Specifications • NEVER decrease the coolant concentration below 40%. • Engine coolant concentrations below 40% will decrease the corrosion protection characteristics of the engine coolant and may cause engine damage. • Engine coolant concentrations below 40% will decrease the freeze protection characteristics of the engine coolant and may cause engine damage. • If available, refer to the chart on the coolant container to ensure the coolant concentration in your vehicle will provide adequate protection at the temperatures in which you drive. Vehicles driven year-round in non-extreme climates should use a 50/50 mixture of engine coolant and distilled water for optimum cooling system and engine protection. FUEL FILTER/WATER SEPARATOR Your vehicle is equipped with two fuel filters; one is mounted on top of the engine, the second one is mounted inside the Horizontal Fuel Conditioner Module (HFCM) on the inside of the left frame rail by the transmission. The fuel filter/water separator removes any contaminated particles and/or water from the fuel before 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 drained from the module assembly whenever the warning light comes on or every 5,000 miles (8,000 km). The WATER IN FUEL light will come on when approximately 0.13 pints (60 cc) of water accumulates in the module. 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. 133 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Maintenance and Specifications 2. Locate the module drain plug cap on the outside of the left frame rail and place an appropriate container under the drain plug. 3. Loosen the drain plug by turning it counterclockwise. Allow to drain for approximately 25 seconds or until clean fuel is observed. Install the drain plug by turning it clockwise until it is firmly seated. 4. Verify that the drain plug is closed and sealed, then remove the container from under the vehicle. 5. Restart the engine and check the WATER IN FUEL indicator light; it should not be illuminated. If it continues to illuminate, have the fuel system checked and repaired. Fuel filter replacement Both filters 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) 134 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Maintenance and Specifications • Frame-mounted filter (36 mm socket required) 1. Place an appropriate container under the filter assembly, then remove the fuel filter cap by turning counterclockwise. 2. Remove and discard the old fuel filter element. 3. Carefully clean the mating surfaces. Installation The engine will not run properly if the fuel filter is not installed in housing. 1. Install new fuel filter 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 as it runs. The engine may run roughly and smoke until the air is completely eliminated. Using 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 Do not overfill the fuel tank. The pressure in an overfilled tank may cause leakage and lead to fuel spray and fire. The fuel system may be under pressure. If the fuel cap is venting vapor or if you hear a hissing sound, wait until it stops before completely removing the cap. 135 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Maintenance and Specifications Automotive fuels can cause serious injury or death if misused or mishandled. Observe the following guidelines when handling fuel: • Extinguish all smoking materials and any open flames before fueling your vehicle. • Always turn off the vehicle before fueling. • Automotive fuels can be harmful or fatal if swallowed. If fuel is swallowed, call a physician immediately, even if no symptoms are immediately apparent. The toxic effects of fuel may not be visible for hours. • Avoid inhaling fuel vapors. Inhaling too much fuel vapor of any kind can lead to eye and respiratory tract irritation. In severe cases, excessive or prolonged breathing of fuel vapor can cause serious illness and permanent injury. • Avoid getting fuel liquid in your eyes. If fuel is splashed in the eyes, remove contact lenses (if worn), flush with water for 15 minutes and seek medical attention. Failure to seek proper medical attention could lead 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 and water. Repeated or prolonged skin contact with fuel liquid or vapor causes skin irritation. When refueling always shut the engine off and never allow sparks or open flames near the filler neck. Never smoke while refueling. Fuel vapor is extremely hazardous under certain conditions. Care should be taken to avoid inhaling excess fumes. The flow of fuel through a fuel pump nozzle can produce static electricity, which can cause a fire if fuel is pumped into an ungrounded fuel container. If you must replace the fuel filler cap, replace it with a genuine Ford or Motorcraft part. The customer warranty may be void for any damage to the fuel tank or fuel system if a genuine Ford or Motorcraft fuel filler cap is not used. 136 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Maintenance and Specifications Refueling • • • • • • Fuel vapor burns violently and a fuel fire can cause severe injuries. To help avoid injuries to you and others: Read and follow all the instructions on the pump island; Turn off your engine when you are refueling; Do not smoke if you are near fuel or refueling your vehicle; Keep sparks, flames and smoking materials away from fuel; Stay outside your vehicle and do not leave the fuel pump unattended when refueling you vehicle — this is against the law in some places; Keep children away from the fuel pump; never let children pump fuel Use the following guidelines to avoid static build-up when filling an ungrounded fuel container: • Place approved fuel container on the ground. • DO NOT fill a fuel container while it is in the vehicle (including the cargo area). • Keep the fuel pump nozzle in contact with the fuel container while filling. • DO NOT use a device that would hold the fuel pump handle in the fill 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. Look for the ULTRA-LOW SULFUR HIGHWAY DIESEL FUEL (15 ppm Sulfur Maximum) label on fuel pumps when purchasing your fuel. Number 1-D or winter blend number 2-D fuel is recommended at temperatures below 20°F (-7°C) (see Cold weather operation in the Driving chapter. Diesel fuel containing no more than 5% biodiesel may be used. Biodiesel fuel is a product that has been converted from renewable fuel sources, including vegetable oil, animal fat and cooking oil. Raw or refined vegetable oil, animal fat, cooking oil or recycled greases should not be used. Since it is normal for a small amount of unburned fuel to enter the crankcase and mix with the engine oil, the use of biodiesel requires that the engine oil and filter be changed more often. Refer to the Exceptions section of the Scheduled Maintenance Guide chapter for more information. 137 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Maintenance and Specifications Do not use home heating oil or any diesel fuel not intended for highway use. Red dye is used to identify fuels intended for agricultural and non-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. Using low sulfur (16-500 ppm) or high sulfur (greater than 500 ppm) diesel fuel in a diesel engine designed to use only Ultra Low Sulfur Diesel fuel increases the likelihood of engine oil dilution with fuel which may lead to major engine damage. Using low sulfur (16-500 ppm) or high sulfur (greater than 500 ppm) diesel fuel in a diesel engine designed to use only 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. Do not mix diesel fuel with gasoline, gasohol or alcohol. This could cause an explosion resulting in personal injury. Do not use starting fluid such as ether or gasoline. Such fluids can cause immediate explosive damage to the engine and possible personal injury. Fuel quality It should not be necessary to add any aftermarket additives to your fuel tank if you use a properly formulated diesel fuel that meets ASTM D 975 specification. Aftermarket additives can damage the injector system or engine. Repairs to correct the effects of using an aftermarket product in your fuel may not be covered by your warranty. Do not blend used engine oil with diesel fuel under any circumstances. Blending used oil with the fuel will significantly increase your vehicle’s exhaust emissions and reduce engine life due to increased internal wear. 138 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Maintenance and Specifications Many of the world’s automakers approved the World-wide Fuel Charter that recommends diesel fuel specifications to provide improved performance and emission control system protection for your vehicle. Diesel fuel that meet the World-wide Fuel Charter should be used when available. Ask your fuel supplier about fuel that meet the World-Wide Fuel Charter. Running out of fuel Avoid running out of fuel as this will allow air to enter the fuel system, which will make restarting the vehicle difficult. If you have run out of fuel: • If your vehicle is equipped with dual fuel tanks, add at least 4–5 gallons (15–19 liters) of fuel to each tank before attempting to restart the engine. • The fuel system must be primed before attempting to restart the engine. Refer to the engine operator’s manual for instructions on priming the engine. • Use caution not to overheat and damage the starter by cranking the engine for an excessive period of time. You 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. • Any remaining trapped air will self-purge from the fuel system once the engine starts running. • The engine may run rough and produce white smoke while air is in the fuel system. This is normal and should stop after a short period of time. FUEL CONSUMPTION IMPROVEMENT MEASURES There are two important factors you can control to improve fuel economy: the mechanical condition of your vehicle and how you drive it. A properly maintained vehicle will deliver better performance than a neglected vehicle. Always follow your maintenance schedule to keep your vehicle in top operating condition. Also, your driving habits have a significant influence on use of fuel. By following these suggestions, you can stretch your fuel use: • Avoid changes in speed as much as possible. • Anticipate changing traffic conditions. Sudden stops and fast acceleration waste fuel. 139 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Maintenance and Specifications • Avoid extensive idling. • Do not drive with your foot resting on the brake pedal. Essentials of good fuel economy Measuring techniques Your best source of information about actual fuel economy is you, the driver. You must gather information as accurately and consistently as possible. Fuel expense, frequency of fill-ups or fuel gauge readings are NOT accurate as a measure of fuel economy. We do not recommend taking fuel economy measurements during the first 1,000 miles (1,600 km) of driving. You will get a more accurate measurement after 2,000–3,000 miles (3,000 km–5,000 km). The advertised fuel capacity of the fuel tank(s) on your vehicle is equal to the rated refill capacity of the fuel tank(s) as listed in Refill capacities in this chapter. The advertised capacity is the amount of the Indicated Capacity and the Empty Reserve combined. Indicated Capacity is the difference in the amount of fuel in a full tank and a tank when the fuel gauge indicates empty. Empty Reserve is the 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 your vehicle after the fuel gauge indicates empty, you might not be able to refuel the full amount of the advertised capacity of the fuel tank due to the empty reserve still present in the tank. Filling the tank For consistent results: • Use the same fill rate setting (low - medium - high) each time during filling. • Allow three automatic click-offs when filling. • Always use fuel of a known quality, preferably a national brand. • Have the vehicle loading and distribution the same every time. • When refueling a vehicle equipped with dual fuel tanks, if the two tanks are not filled equally, the fuel gauge reading may fluctuate slightly until the fuel level between the two tanks balance out and become equal. Your results will be most accurate if your filling method is consistent. Note: For vehicles equipped with dual fuel tanks, engine performance may degrade if fuel is not added to both tanks when refueling. 140 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Maintenance and Specifications Calculating fuel economy 1. Fill the fuel tank(s) completely and record the initial odometer reading (in miles or kilometers). 2. Each time you fill the tank(s), record the amount of fuel added (in gallons or liters). 3. After at least three to five tank fill-ups, fill the fuel tank(s) and record the current odometer reading. 4. Subtract your initial odometer reading from the current odometer reading. 5. Follow one of the simple calculations in order to determine fuel economy: • Divide total miles traveled by total gallons used. • Multiply liters used by 100, then divide by total kilometers traveled. Keep a record for at least one month and record the type of driving (city or highway). This will provide an accurate estimate of the vehicle’s fuel economy under current driving 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 fuel economy habits Give consideration to the lists that follow and you may be able to change a number of variables and improve your fuel economy. Habits • Smooth, moderate operation can yield up to 10% savings in fuel. • Steady speeds without stopping will usually give the best fuel economy. • Anticipate stopping; slowing down may eliminate the need to stop. • Slow down gradually. • Sudden or hard accelerations may reduce fuel economy. • Driving at reasonable speeds (traveling at 55 mph [88 km/h] uses 15% less fuel than traveling at 65 mph [105 km/h]). • Using the air conditioner or defroster may reduce fuel economy. • Resting your foot on the brake pedal while driving may reduce fuel economy. 141 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Maintenance and Specifications Conditions • Carrying unnecessary weight may reduce fuel economy. • Fuel economy may decrease with lower temperatures during the first 8–10 miles (12–16 km) of driving. • Flat terrain driving improves fuel economy over hilly roads. • Transmissions give their best fuel economy when operated in the top cruise gear and with steady pressure on the accelerator. • Close windows for highway driving. DIESEL PARTICULATE FILTER (DPF) Your vehicle is equipped with a diesel particulate filter (DPF), as part of the after-treatment exhaust system, to trap soot and other large particles produced by the engine combustion process. The soot that accumulates in the filter must be periodically reduced to ash to prevent excessive exhaust restriction. The soot reduction process, also known as “filter regeneration,” is generally performed automatically by your engine and after-treatment system. The normal operating temperature of the exhaust system 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 high temperature after only a short period of engine operation, and can remain hot even after the engine is turned off. Failure to follow these instructions may result in personal injury. Diesel particulate filter regeneration Under most operating conditions, DPF regeneration will be transparent to the operator. A small increase in engine/turbo sound-level is normal during filter regeneration. If, however, your engine is operated for extended periods of time under one of the following conditions, operator assistance may be required to facilitate the filter regeneration process: • Vehicle is operated in stop-and-go traffic and/or maintains low speeds as in a city/delivery driving • Engine is started and shut-off frequently • Vehicle payload is relatively light • Vehicle is regularly operated in cold ambient temperatures (i.e. below 0°F [-18°C]) 142 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Maintenance and Specifications Diesel Particulate Filter Four–Level Loading Chart Level/Lamp status Filter status Requested action Level 1 Regeneration required. Drive on highway at DPF lamp solid highway speeds OR start “parked Level 2 Nearly full. Engine regeneration” to DPF lamp flashing performance is limited. prevent loss of engine (once per second) performance. Level 3 Full. Engine is Perform “parked DPF lamp flashing + increasingly limited. regeneration” to Check Engine lamp prevent loss of engine solid performance. Pull vehicle safely off Level 4 Over full. Engine performance is highly roadway, turn on Stop Engine lamp solid limited. Continued hazard flashers and shut down engine as operation may result in irreparable damage soon as possible. Seek to the filter. service immediately. Instrument cluster lamp(s) will illuminate and/or flash when operator assistance is required. In addition, engine performance will become increasingly limited above Level 1. At Levels 1 and 2, two courses of action may be taken by the operator to facilitate filter regeneration: 1. The vehicle may be driven on the highway at highway speeds, 2. The operator may perform a parked regeneration by following the steps in Parked regeneration procedure. At Level 3, performing a parked regeneration is the only available course of action (short of professional servicing) available to the operator for regenerating the filter. At Level 4, professional servicing is the only way to regenerate the filter. 143 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Maintenance and Specifications Parked regeneration procedure When performing the parked regeneration procedure, make certain the vehicle is safely off roadway, and the exhaust system is away from people, or any flammable materials, vapors, or structures. Engine speed may increase during parked regeneration. Note: Parked regeneration is only available when the DPF lamp on the instrument cluster is illuminated (solid or flashing). 1. Bring the vehicle to a complete stop on level ground and safely off the road with the exhaust system away from people, flammable materials, vapors or structures. 2. Place transmission in P (Park). 3. Remove foot from the accelerator pedal. 4. Set the parking brake. 5. Within 5 seconds of setting 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 seconds. The engine speed may also increase slightly. To allow parked regeneration to continue uninterrupted: 1. The vehicle must remain parked. 2. The transmission must remain in P (Park). 3. The accelerator pedal and service brake pedal must not be depressed. 4. The parking brake must remain set. On average (depending on filter level and other factors), the process will take 20–30 minutes to complete. The DPF lamp will turn off when the process is complete. Repeat Steps 1–5, if parked regeneration is interrupted. To discontinue parked regeneration Depress any of the floor pedals to discontinue parked regeneration. Diesel particulate filter maintenance and service The DPF is designed to retain a relatively large amount of residual ash and provide many miles and hours of maintenance-free operation. At some point, generally beyond 150,000 miles (240,000 km) or 5,000 hours of operation (whichever comes first), the DPF will require professional cleaning to remove the accumulated ash 144 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Maintenance and Specifications The exact number of miles or hours of operation will vary greatly depending upon vehicle/engine loading and operating conditions, ash content of the engine oil, and quality of the diesel fuel used in your truck. Adhering to recommended oil and fuel specifications will maximize the miles and hours of operation before a DPF professional cleaning is required. Exhaust outlet assembly The normal operating temperature of the exhaust system is very high. Never work around or attempt to repair any part of the exhaust system until it has cooled. Failure to follow these instructions may result in personal injury. The exhaust outlet assembly on your vehicle 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. Modification of the system and/or additions of aftermarket devices can reduce the effectiveness of the system, as well as cause damage to the exhaust system and/or engine. Any modifications may also invalidate the vehicle and/or engine warranties. See the vehicle warranty guide for more information. The inlet holes in the side of the assembly are functional. These holes allow outside air to be drawn into the outlet assembly. The holes need to be kept clear of mud and other foreign material to maintain proper functionality of the system. One way to keep the holes clear is to spray the outlet assembly with a hose when washing the vehicle. Failure to keep the functional holes clear of foreign material may result in the holes becoming blocked or plugged. Blocked/plugged holes or modification/removal of the outlet assembly could result in elevated exhaust temperatures which may result in vehicle/property damage and/or personal injury. NOISE EMISSIONS – EXTERIOR In order to comply with the federal exterior noise regulations, your vehicle may be equipped with noise emission items. Depending on the vehicle configuration, it may have all or some of the following items: Air Intake System • Air Filter: should be inspected and its location should not be altered. Do not alter inlet and outlet piping. 145 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Maintenance and Specifications Body • Wheel Well: splash shields, cab shields and under-cab insulation should be inspected for deterioration, dislocation, and orientation. Cooling System • Check the fan for damage to blades; replace, if damaged, with the recommended parts. Inspect for fan to shroud interference, and any damage to shroud such as cracks and holes. • The fan ratio should not be changed and the fan spacer dimensions and positions should not be altered. • Inspect the fan clutch for proper operation, make sure that the fan 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 Driveline System • Transmission Enclosure: inspect for cracks, holes, and tears. Clean any deposits such as oil, dirt, and stones. • Engine valve covers and block covers are made to damp out engine mechanical noise and, if needed, should be replaced with recommended parts. Check for mechanical isolations. Exhaust System • Inspect the exhaust system for leaks at various joint connections and tighten the clamps. • Do a visual inspection for cracks or holes in the muffler and tail pipe. • Always use the recommended parts when items need to be replaced. • Exhaust After Treatment module must not be changed or moved from the standard position as originally received. • The tail pipe elbow or offset tail pipe orientation must not be changed from the standard position as originally received. • To avoid abnormal changes in vehicle sound levels, it is necessary for the owner to perform inspections and necessary maintenance at the intervals shown in the scheduled maintenance information. 146 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Maintenance and Specifications STEERING - GENERAL INSPECTION • Ask your service technician to examine the steering mechanism. Only minor adjustments may be necessary. • Check tie rod, drag link end clamp bolts and ball joints for proper tightness. • Check for installation and spread of cotter pins and tightness of nuts at both ends of the tie rod and drag link. • Check that pitman arm (steering arm at steering gear) mounting is tight and locked. Check system for leaks or hose chafing. Repair at once, if necessary. • Maintain proper steering gear and power steering pump lubricant levels. • Regularly inspect steering column joint bolts and steering linkage, particularly for body-to-chassis clearance. Note: Have any steering problems corrected at once by a qualified service technician. Failure to maintain the steering system in proper condition can cause reduced steering ability resulting in property damage, personal injury or death. Tightening steering column joint bolts As a good maintenance practice, it is recommended that steering column joint bolts be checked for tightness. Refer to the Scheduled Maintenance Guide chapter for service intervals. Power steering Whenever the power steering system has been drained and refilled for any reason, air must be bled from the system before returning the vehicle to service. Failure to properly bleed the system can result in degradation of power steering performance. Consult your dealer who is aware of the proper procedures for filling and bleeding the system. 147 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Maintenance and Specifications POWER STEERING FLUID Check the power steering fluid level by looking at the see-through plastic reservoir. Make sure that the fluid is within the FULL and ADD range as marked on the reservoir. If the fluid level is below the ADD line, add fluid in small amounts, continuously checking the level until it reaches the proper level. If adding fluid is necessary, refer to Lubricant Specifications in this chapter for the proper fluid type. Refer to the scheduled maintenance 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 or a qualified service technician. To avoid damage to the power steering system, do not operate the vehicle with a low power steering fluid level. BRAKE FLUID The reservoir is located behind a panel on the far left side of the instrument panel, accessible by opening the driver’s door and removing the end panel. Check and refill the brake fluid reservoir using the following procedure. 148 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Maintenance and Specifications 1. Clean the reservoir cap before removal to prevent dirt or water from entering the reservoir. 2. Visually inspect the fluid level; the level should be between the MIN/MAX marks on the reservoir. 3. If necessary, add brake fluid from a clean unopened container until the level reaches the MAX mark. Do not fill above this line. 4. Use only a DOT 3 brake fluid certified to meet manufacturer specifications. Refer to Lubricant specifications in this chapter. Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford-Motorcraft products call: 1-800-959-3673. For additional information consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in personal injury. If you use a brake fluid that is not DOT 3, you will cause permanent damage to your brakes. Do not let the reservoir for the master cylinder run dry. This may cause the brakes to fail. TRANSMISSION FLUID Checking automatic transmission fluid Refer to the scheduled maintenance information for scheduled intervals for fluid checks and changes. Your transmission does not consume fluid. However, the fluid level should be checked if the transmission is not working properly, i.e., if the transmission slips or shifts slowly or if you notice some sign of fluid leakage. Automatic transmission fluid expands when warmed. To obtain an accurate fluid check, drive the vehicle until it is at normal operating temperature (approximately 20 miles [30 km]). If your vehicle has been operated for an extended period at high speeds, in city traffic during hot weather or pulling a trailer, the vehicle should be turned off for about 30 minutes to allow fluid to cool before checking. 149 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Maintenance and Specifications 1. Drive the vehicle 20 miles (30 km) or until it reaches normal operating temperature. 2. Park the vehicle on a level surface and engage the parking brake. 3. With the parking brake engaged and your foot on the brake pedal, start the engine and move the gearshift lever through all of the gear ranges. Allow sufficient time for each gear to engage. 4. Latch the gearshift lever in P (Park) and leave the engine running. 5. Remove the dipstick, and wipe it clean with a clean, dry lint free rag. 6. Install the dipstick making sure it is fully seated in the tube. 7. Remove the dipstick and inspect the 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 dipstick and the ambient temperature is above 50°F (10°C). Correct fluid level The transmission fluid should be checked at normal operating temperature 150°F-170°F (66°C-77°C) on a level surface. The normal operating temperature can be reached after approximately 20 miles (30 km) of driving. You can check the fluid without driving if the ambient temperature is above 50°F (10°C). However, if fluid is added at this time, an overfill condition could result when the vehicle reaches normal operating temperature. 150 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Maintenance and Specifications The transmission fluid should be in this range if at normal operating temperature (150°F-170°F [66°C-77°C]). The transmission fluid should be in this range if at ambient temperature (50°F-95°F [10°C-35°C]). High fluid level Fluid levels above the safe range may result in transmission failure. An overfill condition of transmission fluid may cause shift and/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 type is used. The type of fluid used is indicated on a tag located on the transmission fill tube and also in the Lubricant specifications section in this chapter. Use of a non-approved automatic transmission fluid may cause internal transmission component damage. 151 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Maintenance and Specifications If necessary, add fluid in 1⁄2 pint (250 ml) increments through the filler tube until the level is correct. If an overfill occurs, excess fluid should be removed by a qualified technician. An overfill 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 these materials may affect transmission operation and result in damage to internal transmission components. 152 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Maintenance and Specifications AIR FILTER REPLACEMENT The air filter should be replaced any time the air filter restriction gauge reads 25 inches (635 mm) or as indicated by the maintenance intervals in the scheduled maintenance information. 1. Remove the cover by releasing the clamp and turning the cover counterclockwise and pulling it off. 2. Remove the dirty filter and discard it. 3. Clean any accumulation of dirt from the housing using a damp rag. Do not use 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, then turn it clockwise and close the clamp. After replacing the filter, reset the gauge by pressing the reset button on top of the gauge. Air filter restriction gauge This gauge, located on top of the air filter housing, measures the vacuum inside the air cleaner. The more the air cleaner is restricted (dirty, clogged), the higher the vacuum reading. 153 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Maintenance and Specifications Change the air filter when the gauge reads 25 inches (635 mm). After installation of the new filter element, reset the gauge by pressing the reset button on top of the gauge. ENGINE AND SUBSYSTEM MAINTENANCE Note: To prevent damage to the engine control module or any parts of the electrical system, never spray-wash the parts directly. For effective emissions control and low operating cost, it is important that maintenance operations listed in this section be performed at the specified periods or mileage intervals indicated (kilometers, miles, hours, or months, whichever comes first). Service intervals are based upon average operating conditions. Where dusty, frequent start-and-stop or heavily laden operations are encountered, more frequent servicing will be required. As the vehicle owner, you are responsible for the performance of all scheduled maintenance. The required maintenance operations may be performed by the owner at a service 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 performance to genuine manufacturer service parts. Use of inferior parts hinders operations of the engine and emissions controls and can reduce engine life and/or jeopardize the warranty. Receipts covering the performance of regular maintenance should be retained in the event questions arise concerning maintenance. The receipts should be transferred to each subsequent owner of the vehicle. Catalytic converter If your vehicle is equipped with a catalytic converter, it is important to review the scheduled maintenance information to ensure proper functioning of the catalytic converter. Also, take precautions not to damage the catalytic converter when servicing your engine or storing your vehicle. Do not blend waste oil with diesel fuel. Operate only on ultra low sulfur diesel fuel (less than 15 parts per million) with a Cetane value of 42 or higher. 154 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Maintenance and Specifications Air induction system Once each year, perform a complete inspection of the air induction system. In areas where road salt is used, the inspection consists of disassembling the joints of each aluminum component and inspecting for salt build-up and presence of chlorine that can cause aluminum particles to flake off and enter the engine combustion chambers. If evidence of corrosion is found (usually at the pipe connections), use a wire brush to clean the inside of the pipes and inside the rubber hoses. If the intake pipes are pitted at the joint ends, use RTV silicone to seal the joints. Be certain that no excess material is on the inside of the pipes that can be pulled into the engine. If the service condition of the pipes, hoses or clamps is questionable, replace the defective part(s). Be sure that prior to reassembly all dust and debris has been cleaned out of the pipes and couplings with a clean, damp rag. 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 inlet protective shield should be installed over the turbocharger air inlet. CHASSIS-MOUNTED CHARGE AIR COOLER The charge air cooler should be inspected daily. With the engine off, visually inspect the charge air cooler core assembly for debris and clogging of external fins. Prior to engine operation, remove any debris blocking the core. • Turbocharger-to-charge air cooler • Charge air cooler-to-intake manifold pipe • Mounting bracket • Chassis-mounted charge air cooler core Air intake piping inspection • Check for accumulation of salt deposits (where applicable). If present, disassemble and clean the complete air intake piping system. If the intake piping is pitted, use RTV silicone to seal joints against leakage. • Check for loose hoses and clamps. • Check for ruptured or collapsed hoses. • Check air filter housing for cracks. 155 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Maintenance and Specifications ELECTRICAL SYSTEM INSPECTIONS Periodically inspect electrical connectors on the outside of the cab, on the engine and frame for corrosion and tightness. Exposed terminals such as the fuel sender, cranking motor, alternator and feed-through studs should be cleaned and re-coated with a lubricant sealing grease such as Motorcraft XG-3, or equivalent. This should include the ground cable connector for batteries, engine and cab. Accessory feed connections Vehicle electrical systems are complex and often include electronic components such as engine and transmission controls, instrument panels, ABS, etc. While most systems operate on battery voltage (12 volts), some systems can be as high as 90 volts or as low as five volts. Refer to the Electrical Circuit Diagram Manuals, available from your vehicle’s manufacturer, to 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 first contacting your dealer. SUSPENSION INSPECTION Periodically: • Check condition of spring leaves for evidence of fatigue, bending or breaks. • Check condition of suspension mounting brackets and bushings. • Check that torque rod mounting fasteners are tight. • Check to be sure the suspension alignment is maintained at all time. • Check U-bolts after the chassis has been operating under load for 1,000 miles (1,600 km) or six months, whichever comes first, the U-Bolt nuts must be re-torqued. The U-Bolt nuts thereafter must be re-torqued every 30,000 miles (48,000 km). The U-Bolt and nut threads and seats should be cleaned and lubricated to ensure a “like new” condition when re-torquing. Note: See the U-Bolt Nut Torque chart in this chapter. 156 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Maintenance and Specifications U-BOLT NUT TORQUE Axle type All U-bolt torque Ft. lb. N•m 260–300 353–407 Spring U-bolt checks Check U-bolt nuts and re-torque every 30,000 miles (48,000 km) after initial 1,000 miles (1,600 km) re-torque. The U-bolt and nut threads and seats should be cleaned and lubricated to ensure peak condition when re-torqued. FRAME AND TOW HOOKS Your vehicles chassis is manufactured with frame rails of either mild carbon steel, or HSLA steel. Each must be handled in a specific manner to ensure maximum service life. Before attempting frame repair or modification, consult the service manual or your dealer. It is important, particularly on vehicles where the tow hooks are used frequently to inspect the front and rear tow hooks for damage or a loose mounting. DRIVESHAFT 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 hazardous consequences or damage to other components. REAR AXLE LUBRICANT Refer to the scheduled maintenance information for rear axle lubricant level checks and lubricant change intervals. The rear axle may be filled with an optional synthetic lubricant which allows the use of extended service intervals. A tag on the filler plug will identify the use of synthetic lubricant. Use only a lubricant that meets manufacturer specifications (refer to Lubricant specifications in this chapter). Use of a non-approved rear axle lubricant may cause internal axle component damage. Check your rear axle lubricant level using the following procedure: 1. Park the vehicle on level ground. 157 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Maintenance and Specifications 2. Set the parking brake and shift into P (Park) and turn the engine off. 3. Clean any dirt from around the rear axle filler plug. 4. Remove the filler plug and inspect the lubricant level. 5. The lubricant level should be up to the bottom of the filler plug opening. 6. If necessary, add enough lubricant through the filler plug opening so that the lubricant level is at the bottom of the opening. 7. Clean and install the filler plug securely. Drain and refill your rear axle lubricant using the following procedure: Note: The rear axle lubricant should only be drained when the lubricant is warm. 1. Park the vehicle on level ground. 2. Set the parking brake and shift into P (Park) and turn the engine off. 3. Clean any dirt from around the rear axle filler plug and drain bolt. 4. Remove the filler plug and drain bolt, then drain the lubricant into a suitable container. Dispose all used automotive fluids in a responsible manner 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 bottom of the opening. 7. Clean and install the filler plug securely. WHEELS General Wheel bearings should be inspected, lubricated and adjusted at regular intervals. This is especially important if operating in deep sand, mud, or water. Refer to Lubricant specifications in this chapter. When installing wheel balance weights, they must be mounted on the dome-side of the wheel only. Failure to do so may result in loss of wheel weight and/or damage to brakes or wheels. Wheel bearings Your vehicle is equipped with grease-packed front wheel bearings and oil-lubricated rear wheel bearings. Normal maintenance Over a period of time, if not routinely cleaned, a slight film of oil/grease can collect dirt around the gasket, which could appear to be a leak. Routine cleaning ensures that leaks can be easily observed before damage occurs. 158 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Maintenance and Specifications Installation, tightening and alignment Tighten the lug nuts in the order shown. When installing wheels, be certain that the threads on studs and nuts are clean to permit correct torquing of nuts. The mounting surfaces of rims, wheels, spacer rings and clamps must be free of dirt, rust, lubricants or damage. Use a wire brush to clean the mounting contact surfaces. 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, and placed to just barely clear the outside surface of the tire bead seat. This procedure will point out the high spot. A high spot does not necessarily mean that the lug nuts have been unevenly tightened. This condition or misalignment could be caused by a bent wheel. 159 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Maintenance and Specifications Wheel mounting Disc wheel with flange nuts (hub-piloted) Front wheel mounting of flange nut system 1. Flange nut 2. Wheel(s) 3. Brake drum 4. Wheel stud (M14) 5. Wheel hub Rear wheel mounting of flange nut system 1. Flange nut 2. Wheel(s) 3. Brake drum 4. Wheel stud (M14) 5. Wheel hub 1. Slide inner rear or front tire and wheel in position over studs and push it back as far as 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 studs are not damaged. 3. Run the nuts on the studs until they contact the wheel(s). Rotate the wheel assembly a half-turn to permit the parts to seat. 160 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Maintenance and Specifications 4. Draw up the nuts alternately following the crisscross sequence illustrated under Installation, tightening and alignment. Do not fully tighten the nuts. This will allow uniform seating of the nuts and ensure even face-to-face contact of the wheel and hub. 5. Continue tightening the nuts to the torque specifications in the Wheel Lug Nut Torque chart, later in this chapter, using the same crisscross sequence shown. 6. After operating the vehicle approximately 50 miles (80 km), check the nuts for tightness. 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 wheel with flange nuts (hub-piloted) 2 3 1 4 5 6 1. 2. 3. 4. 5. 6. Flange nut Wheel(s) Brake drum Wheel stud (M14) Wheel hub Wheel locator pad 161 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Maintenance and Specifications Prior to re-installing rear aluminum hub-piloted wheels, clean each wheel locator pad on the hub from all dirt, rust and foreign material. Apply a light coat of chassis grease, never-seize or disc brake corrosion control grease, only to the wheel locator pad. When installing the tire and rim assembly on disc-brake equipped axles, make sure the tire valve stem clears the brake caliper. The use of a tire manufacturer’s stem forming tool is the only acceptable method of obtaining clearance when necessary. Note: Always observe the following instructions: Failure to follow these instructions could result in property damage, personal injury or death • Never use cracked, bent or badly rusted parts. • Always inflate tires in a safety cage. Proper torque It is important to tighten and maintain wheel mounting nuts to the proper torque. Loose nuts or overtightened nuts can lead to premature wear and possible failure of the wheel and/or mounting hardware. Wheel lug nut torque Size Nut mounting M14 Flange Torque Ft. lb. 140–160 N•m 189–217 Note: Do not use lubrication on dry threads. Where excessive corrosion exists, a light coat of lubricant on the first three threads of the stud bolt is permitted. Keep lubricant away from flange nut washer surface and flat on the disc wheel. Changing wheel types Consult your dealer or wheel/rim distributor before attempting any wheel or fastener changes. Use only the same type and style wheels and mounting hardware to replace original parts. Failure to do so may result in an assembly that looks fine, but does not fit together properly. This could possibly cause wheel or fastener failures which could result in property damage, personal injury or death. 162 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Maintenance and Specifications Note: Do not attempt to mix stud-piloted wheels or fasteners with hub-piloted wheels or fasteners. Note: Do not change from aluminum wheels to steel wheels or vice-versa without changing the mounting hardware required or, with flange-nut mounting systems, changing the hub and stud assembly. Tire rotation Rotating your tires will help your tires wear more evenly, providing better tire performance and longer tire life. Six tire rotation It is recommended that front and rear tires (in 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 vehicle requirements. Sometimes irregular tire wear can be corrected by rotating the tires. Note: If your tires show uneven wear ask a qualified technician at a reputable repair facility to check for and correct any wheel misalignment, tire imbalance or mechanical problem involved before tire rotation. 163 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Maintenance and Specifications TIRE INFORMATION Inflation Always maintain your tires in good condition. Frequently check and maintain correct inflation pressures as specified by tire manufacturers. Inspect periodically for abnormal wear patterns and repair/replace cut or broken tire casing. Always use experienced, trained personnel with proper equipment and correct procedures to mount or remove tires and wheels. Failure to adhere to these warnings could result in wheel or tire malfunction, damage to your vehicle, personal injury, or death. • • • • • • • • To avoid personal injury or death, always follow these instructions when mounting radial tires on wheels: Only personnel that have had proper training and experience should mount or remove tires from rims or wheels. Use only heavy-duty rims or approved rims for radial tires. It may be necessary to contact your wheel and rim distributor to determine if your rims are approved for radial tires. If a tube is to be used, make sure special radial tire tubes are 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 used as an aid for mounting tires. Always inflate tires in a safety cage. Do not attempt to mix stud piloted wheels or fasteners with hub piloted wheels or fasteners. To do so may cause premature wheel failure resulting in property damage, personal injury, or death. Do no mix foreign (not made in North America) wheel mounting parts with domestic (made in North America) parts. Many foreign wheel components look similar to, but not exactly the same as domestic made components. Mixing components could cause wheel or fastener failures and result in property damage, personal injury, or death. Do not change from aluminum wheels to steel wheels or vice-versa without changing the mounting hardware where required or, in some cases with flange nut mounting systems, changing the hub and stud assembly. Mixing components could cause wheel or fastener failures and result in property damage, personal injury, or death. 164 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Maintenance and Specifications Do not mount tube type tires on tubeless wheels or tubeless tires on tube type wheels. To do so could result in tire or wheel failure and cause property damage, personal injury or death. Preserving proper inflation pressure is a very important maintenance practice to insure safe vehicle operation and long life for the tires. Failure to maintain correct inflation pressure may result in sudden tire destruction, improper vehicle handling, and may cause rapid and irregular tire wear. Therefore, inflation pressures should be checked daily and always before long distance trips. Follow the tire manufacturer’s recommended cold inflation pressure for the tire size, type, load range (ply rating) and axle loading typical for your operation. (Each steer axle tire load will equal 1⁄2 steer axle loading; each drive tire load will be 1⁄4 the axle loading if fitted with four tires). Checking inflation Always check inflation pressure when tires are cold. Never bleed air from hot tires to relieve 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 of tires, and proper selection of air compressor equipment, proper air line routing, and the use of shop air dryers is strongly recommended to avoid moisture in the high pressure air used for tire inflation. Under inflation Tires should not be permitted to become under-inflated. Increased flexing due to under-inflation causes heat build-up within the tire components. This leads to reduced strength, breakdown of the rubber compounds, and possible separation of the tire components (i.e., ply and tread separation and reduced retreadability). Under inflation is the primary cause of premature tire concerns including sudden loss of air. In addition, low inflation causes an increase in rolling resistance. This results in reduced fuel mileage, a loss in tread mileage, and uneven wear due to increased tread movement. To determine proper inflation refer to the tire inflation range stated on the tire sidewall. Inspection Check condition of tires for abnormal wear patterns, and proper inflation pressures. Cut or broken tire casing must be repaired or replaced. 165 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Maintenance and Specifications Tires should be inspected for the following conditions. If any are present, the tire should be removed and repaired, retreaded or scrapped as the condition indicates. • Any blister, bump or raised portion anywhere on the surface of the tire tread or sidewall (other than a bump made by a repair). These indicate the start of internal separation. • Any cut that reaches to the belt or ply cords, or any cut that is large enough to grow in size and depth. • Any nail or puncturing object. • If any stone or object is held by a tread groove and is starting to drill into the tread base, remove the object. Proper tire inflation, toe-in adjustment, loads, and road speeds are important factors governing tire mileage, steering ease and maneuverability. Loads Loading tires beyond their rated capacity 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 cause property damage, personal injury or death. Note: Your GAW/GVW rating is correct at the time of your vehicle production, and reflects the exact rating of the tires specified. When replacing tires be sure that the replacement tire load rating (listed in pounds and kilograms on the tire sidewall) is the same or higher than the tire that is removed. Failure to do so will adversely affect maximum load carrying capacity. Tires with the same size specification do not always have the same load specification. Matching Dual Tires: Dual tires should be matched using tires of equivalent size. Tires which differ more than 1⁄4 inch (6 mm) in diameter or 3⁄4 inch (19 mm) in circumference should not be mounted on the same dual wheel assembly. Mixing: Never mix bias and radial tires on this vehicle. Never mix different tire sizes or constructions on the same axle. Note: Never mix bias and radial tires on this vehicle. 166 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Maintenance and Specifications Rotation: Rotation is always advisable: 1. If front (steering) axle tires become irregularly worn, move to rear position. 2. In a dual assembly, reverse the position of the tires if one tire wears much faster than its mate. 3. On the drive axle, if heel and toe wear or alternate lug wear occurs, rotating the tires from one end of the axle to the other end of the axle may help even out this wear. Rotation may not advisable: 1. Front (Steering) Axle: Tires must be removed when tread is worn to 4/32 inch (3 mm) or less. Retread or rotate worn tires to drive position. Retreaded tires are not recommended to be used on steering axles. 2. Rear Axles: Tires must be removed when tread is worn to 2/32 inch (2 mm). If rib tire is used on front axle and lug or off-road type on rear axle positions: 1. Front (Steering) Axle: Replace tires at front wheels 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 can be re-grooved. A minimum of 3/32 inch (2.5 mm) of under-tread must be left at the bottom of the grooves. Wheel and tire balancing Out-of-round or out-of-balance wheels or tires can cause vehicle vibration, bounce and shimmy. Replace damaged or out-of-round wheels. Out-of-round tires and wheel assemblies can be corrected by re-clocking the tire relative to the wheel. The tire and wheel assembly should then be dynamically balanced. Wear Radial tires can exhibit three types of normal wear patterns: 1) Even, 2) Erosion, 3) Chamfer. Even wear is a sign that the tire is being properly used and maintained. 167 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Maintenance and Specifications Erosion wear has also been called rolling wear, channel or river wear. Erosion wear is found more often at free rolling tires. This is an indication that the tire is being used in a slow wearing operation. What happens is that the belt plies are held very rigid and the tread is not allowed to distort as it passes through the contact area. Wear will only occur at the edge of the tread. No corrective action required. If erosion gets to be 1/16 inch (2 mm) or more, the tire may be rotated to a drive axle. Chamfer or shoulder wear, with tires inflated properly, is a normal tendency of most radial tire designs. If both inside and outside shoulders are wearing evenly around the tire, no further action is required. Over-inflation is not effective in correcting this effect. Tires: Irregular Wear If irregular wear is present, check the axle alignment, tire pressure, wheel balancing, shock and suspension component condition, and wheel bearing end play. This condition not only shortens tire life, but will adversely affect the handling of your vehicle, which is dangerous. Rotating tires from one wheel position to another is a way often used to even out many types of irregular wear or to 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 on all wheel positions. Applying steer tires to a drive position will often clean them and they can be moved back to the steer axles or run out to re-tread stage on the rear axle. • Another rotation possibility for fleets with rib tires in all wheel positions is to break in the new steer tires in the drive axle positions, then move them to steer axles. This will wear away tread rubber relatively quickly in the early life of a tire when it is most likely to develop an unusual wear pattern. • Drive axle tires may be placed on the other end of the same axle so that direction of rotation is reversed. This is often helpful if a heel and toe or alternate lug wear pattern has developed. Irregular wear can be minimized by: • Using the right inflation pressure for the load being carried. • Maintaining proper front wheel alignment - especially toe-in - to specifications. • Maintaining proper tire and wheel balance. 168 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Maintenance and Specifications • Maintaining shock absorbers and suspension components. Use of tire chains Refer to chain manufacturer’s recommendation for correct tire chain usage, installation and removal. Tire inflation information All tires with Steel Carcass Plies (if equipped): This type of tire utilizes steel cords in the sidewalls. As such, they cannot be treated like normal light truck tires. Tire service, including adjusting the air pressure, must be performed by personnel trained, supervised and equipped according to Federal Occupational Safety and Health Administration (OSHA) regulations. 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. WARNING An inflated tire and rim can be very dangerous if improperly used, serviced or maintained. To reduce the risk of serious injury, never attempt to re-inflate a tire which has been run flat or seriously under-inflated without first removing the tire from the wheel assembly for inspection. Do not attempt to add air to tires or replace tires or wheels without first taking precautions to protect persons and property. 169 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Maintenance and Specifications Stay out of the trajectory (1) as indicated in the illustration. Under some circumstances, the trajectory may deviate from the suspected path. LUBRICATION AND MAINTENANCE INTERVALS New vehicles are lubricated at the factory. After the vehicle is placed in operation, regular lubrication intervals, based on the type of service and road conditions, should be established. Thorough lubrication at the specified intervals will ensure outstanding life cycle value and will reduce overall expense. The lubrication intervals specified should be performed at whatever interval occurs 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 the service life of the vehicle or result in failure of its components. Unless otherwise specified, never add lubricant unless it is the same grade as that which is already being used. If the grade is not known or not available, drain, flush and refill with new lubricant. The interval between lubrication periods, oil changes, etc. depends entirely upon operating conditions. The loads carried, speeds, road and weather conditions all contribute to the frequency of lubrication periods. 170 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Maintenance and Specifications In some types of operation, and where operating conditions are extremely severe (such as in deep water, mud or unusually dusty conditions), the vehicle may require lubrication after every 24 hours of operation. LUBRICANT SPECIFICATIONS Viscosity / Ambient Component Lubricant temperature / Notes Front axle Front axle wheel EP2 Lithium Note: With chassis load on bearing grease, complex-based tie rod ends, moly grease (or axle, force equivalent) grease through drag link, kingpin and GC/LB NLGI #2 thrust bearings; bushing multi-purpose then with axle lithium complex lifted clear of grease the floor, force grease between kingpin and bushing surfaces. Rear axle Dana-Spicer rear Motorcraft SAE All applications axle 75W-140 Synthetic Rear Axle Lubricant Equivalent Ford part name / number Motorcraft Premium Long Life Grease / XG-1-C XY-75W140–QL 171 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Maintenance and Specifications Viscosity / Equivalent Ambient Component Lubricant Ford part temperature / name / number Notes Steering Power steering MERCON 威 V — MERCON 威 V / fluid Automatic XT-5-QMC Transmission Fluid Steering gear GC/LB NLGI #2 — Motorcraft Ross lithium Premium Long Life Grease / TAS-Output Seal complex-based moly grease or XG-1-C multi-purpose lithium complex grease Steering column GC/LB NLGI #2 — Motorcraft Premium Long U-joints / slip lithium joint complex-based Life Grease / moly grease or XG-1-C multi-purpose lithium complex grease Driveshaft U-joint GC/LB NLGI #2 — Motorcraft lithium Premium Long complex-based Life Grease / moly grease or XG-1-C multi-purpose lithium complex grease 172 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Maintenance and Specifications Component Engine coolant (1) Washer fluid TorqShift Viscosity / Equivalent Ambient Lubricant Ford part temperature / name / number Notes Cooling system WSS-M97B51-A1 — Motorcraft Premium Gold Engine Coolant / VC-7-B Windshield washer WSB-M8B16-A2 — Motorcraft Premium Windshield Washer Concentrate / ZC-32-A Transmission Motorcraft MERCON威 SP XT-6–QSP MERCON威 SP ATF ATF 173 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Maintenance and Specifications Viscosity / Equivalent Ambient Component Lubricant Ford part temperature / name / number Notes Cab components Cab latch, lock GC/LB NLGI #2 — Motorcraft levers and lithium Premium Long complex-based Life Grease / pivots, Door check, hinges, moly grease (or XG-1-C latches and equivalent) or strikers; Seat multi-purpose adjuster slides lithium complex grease Door lock Lock oil — Motorcraft cylinders Penetrating and Lock Lubricant / XL-1 — Motorcraft Door window NGLI #2 regulators multipurpose Multi-Purpose Grease Spray / lithium complex grease XL-5 or Motorcraft Multi-Purpose Grease / XG-4 Weatherstripping Silicone — Motorcraft lubricant Silicone Spray / XL-6 174 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Maintenance and Specifications Component 4.5L Power Stroke engine Master cylinder Caliper slide pins and bushings (1) Viscosity / Ambient Lubricant temperature / Notes Engine oil Motorcraft SAE SAE 15W–40 15W-40 Super above 10°F Duty Motor Oil (–12°C) Motorcraft SAE SAE 10W-30 10W-30 Super –10°F to 90°F Duty Motor Oil (–23°C to 32°C) Motorcraft SAE SAE 0W–30 0W-30 Super All below 0°F Season Motor (–18°C) Oil Brake system DOT 3, — WSS-M6C62–A Caliper Grease and Dielectic Compound ESE-M1C171–A — Equivalent Ford part name / number XO-15W40-QSD XO-10W30-QSD XO-0W30-LAS Motorcraft High Performance Motor Vehicle Brake Fluid / PM-1–C XG-3–A Add the coolant type originally equipped in your vehicle. 175 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Maintenance and Specifications REFILL CAPACITIES Fluid (1) Engine coolant Engine oil Transmission fluid(2) Rear axle Power steering fluid Washer fluid Ford Part Name Motorcraft Premium Gold Engine Coolant (yellow-colored) Motorcraft SAE 15W-40 Super Duty Motor Oil / Motorcraft SAE 10W-30 Super Duty Motor Oil / Motorcraft SAE 0W-30 Super All Season Motor Oil Motorcraft MERCON威 SP ATF Capacity 21.5 quarts (20.3L) Without filter change: 14 quarts (13.0L) With filter change: 15 quarts (14.0L) 17.5 quarts (16.6L)(3) (Includes remote filter change) Motorcraft SAE 23.4 pints 80W-90 Premium (12.0L)(4)(5) Rear Axle Lubricant Motorcraft Keep level MERCON威 V between ADD ATF and FULL marks as shown on reservoir Motorcraft 4.25 quarts Premium (4.0L) Windshield Washer Concentrate 176 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Maintenance and Specifications Fluid Fuel tank - Single tank, mounted on left side Fuel tank - Single tank mounted between frame sidemembers and behind rear axle Fuel tanks - Dual Ford Part Name — — — Capacity 35 gallons (132.0L) 40 gallons (151.4L) 35 gallons (132.0L) each (1) Add the coolant type originally equipped in your vehicle. Ensure the correct automatic transmission fluid is used. Transmission fluid type requirements are indicated on the tag located on the transmission fill tube. Check the container to verify the fluid being added is of the correct type. Refer to the scheduled maintenance information to determine the correct service interval. MERCON威, MERCON威 V and MERCON威 SP are not interchangeable. DO NOT mix MERCON威, MERCON威 V and MERCON威 SP. Use of dual usage fluids in an automatic transmission application requiring MERCON威 SP may cause transmission damage. 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 equipped with an in-tank cooler. The amount of transmission fluid and fluid level should be set by the indication on the dipstick’s normal operating range. (4) Quantities listed are approximate. Fill axle until the lubricant level is at the bottom of the filler hole, with the vehicle on level ground. (5) If hubs are removed, add an additional 1.6 pints (0.75L) of axle lubricant. Add lubricant through the axle vent. (2) VEHICLE IDENTIFICATION NUMBER (VIN) The VIN is printed on the Vehicle Rating Decal attached to the vehicle. The VIN also serves as the warranty number. If you ever find it necessary to communicate with Ford Motor Company about your vehicle, always include the VIN in your communication. 177 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Scheduled Maintenance Guide GENERAL MAINTENANCE INFORMATION The scheduled maintenance services listed in this section are required because they are considered essential to the life and performance of your vehicle. Ford Motor Company recommends you perform the Owner Maintenance Services listed in this section. These services are matters of day-to-day care that are important to the proper operation of your vehicle. In addition to the conditions described in the Daily Owner Checks, be alert for any unusual noise, vibration or other indication that your vehicle may need service and attend to it promptly. Your vehicle is very sophisticated and built with multiple complex performance systems. Every manufacturer develops these systems using different specifications and performance features. That’s why it’s important to rely upon your Ford dealership to properly diagnose and repair your vehicle. Use only recommended fuels, lubricants, fluids and service parts conforming to Ford specifications. Motorcraft parts are designed and built for best performance in your vehicle. Using these parts for replacement is your assurance 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 use of such additive products unless specifically recommended by Ford for a particular application. SCHEDULED MAINTENANCE Ford Motor Company has recommended maintenance intervals for various parts and component systems based upon engineering testing. Ford Motor Company relies upon this testing to determine the most appropriate mileage for replacement of oils and fluids to protect your vehicle at the lowest overall cost to you and recommends against maintenance schedules that deviate from the scheduled maintenance information. The maintenance or replacement of the emission control devices (or systems) in your new Ford Motor Company vehicle (or engine) may be performed at your expense. These services may be performed by any automotive repair establishment or individual using automotive parts equivalent to those with which your vehicle or engine was originally equipped. If any parts other than Ford, Motorcraft, or Ford authorized, remanufactured parts are used for maintenance replacements (or for the 178 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Scheduled Maintenance Guide service) of components effecting the emission control, the owner should be ensured that such parts are warranted by their manufacturer to be equivalent to genuine Ford Motor Company Parts in performance and durability. Please consult your warranty information booklet for complete warranty information. Authorized dealer maintenance Your authorized dealer specializes in knowing all about Ford Motor Company vehicles rather than knowing a little about all makes. There are Ford or Ford of Canada dealer service shops ready to serve you wherever you drive in the U.S. or Canada. They stock Ford and Motorcraft parts, and Ford Chemicals and lubricants. You can be confident that these meet the same exacting design and quality standards as those used to build the vehicle originally. Dealer service technicians have available training in the latest product developments and service techniques. Oils, Fluids and Flushing In many cases, fluid discoloration is a normal operating characteristic of the chemical compound and in itself does not demonstrate that a fluid needs to be changed. Oils and Fluids identified in the 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 maintenance and should only be done using the same fluid required to finish the maintenance procedure, or a Ford approved flushing chemical. OWNER MAINTENANCE You can do much of the maintenance your vehicle requires yourself, if you have the time and a reasonable amount of mechanical ability. If you prefer to have this work done professionally, your authorized dealer stands ready to help you. All mechanical components and attachments are important in that they could affect the performance of vital components and systems. If replacement becomes necessary, they must be replaced with parts having the same part number or with equivalent parts. Torque values of the attaching parts must be used as specified during any reassembly procedure to ensure proper retention. FACTORY AUTHORIZED SYSTEMS CHECKS In the event that your vehicle experiences a component related concern, please contact your Ford dealership. The Ford Motor Company Trained Technicians who work at Ford dealerships are specifically trained to understand your vehicle. 179 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Scheduled Maintenance Guide A proper repair begins with a thorough system check. A Factory Authorized Systems Check can ONLY be found at a Ford dealership. In some circumstances, the technician may need to request your authorization to perform additional operations to determine the final diagnosis. The technician’s goal is to ensure that your vehicle is fixed right the first time, at the best value to you. The following list represents several of the Factory Authorized Systems Checks available at participating Ford dealers: • Air Conditioning • Service Engine Soon Light • All Wheel Drive and 4 X 4 • Automatic Transmission • Engine Cooling and Cabin Heating • Steering and Suspension • Charge/Start/Battery • Wheel Alignment • Anti-Lock Brake System EMISSIONS CONTROL SYSTEM To ensure the emissions control systems operate effectively, you should have the services listed in the maintenance schedule 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. Because of high engine compartment and exhaust system temperatures resulting from emissions equipment, do not park, idle or operate your vehicle in dry grass or other dry ground cover where the possibility of ground fire exists. Do not make unauthorized modifications to the engine or vehicle. Modifications causing increased amounts of unburned fuel to reach the exhaust system can significantly increase the temperature of the engine compartment and/or the exhaust system. Avoid driving your vehicle if it does not operate properly. If the engine diesels (more than five seconds of engine run-on after shut-off), misfires, surges, stalls or backfires, see your dealer. Be alert for fluid leakage, odor, smoke, loss of oil pressure, or charge indicator or over temperature warning. 180 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Scheduled Maintenance Guide Do NOT use diesel fuel blended with waste oil in engines equipped with a catalytic converter-muffler. Waste lube oil blending in fuel will plug the catalytic converter-muffler, resulting in a significant loss of engine power. Emissions control system(s) laws Federal law prohibits vehicle manufacturers, dealers and other persons engaged in the business of repairing, servicing, selling, leasing or trading motor vehicles, as well as fleet operators from knowingly removing or rendering an emissions control device or system inoperative. Further, modifications of the emissions control system(s) could create liability on the part of individual owners under the laws of some states. In Canada, modification of the emissions control system could create liability under applicable Federal or Provincial laws. NOISE EMISSIONS WARRANTY, PROHIBITED 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 prohibited tampering acts and maintenance and the noise warranty are found in the Warranty Guide, and are applicable to completed trucks. Tampering with noise control system prohibited Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative, by any person other than for purposes of maintenance, repair or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person. 181 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Scheduled Maintenance Guide Among those acts presumed to constitute tampering are the following acts listed: Vehicle System Acoustical Shielding Engine Engine Air Induction System Exhaust System Engine Cooling System Acts Removal of noise shields, hood blanket, tunnel liner or acoustical absorptive material. Removal or rendering inoperative the engine speed governor so as to allow engine speed to exceed manufacturer specifications. Removal of engine mounted noise shield or oil pan enclosure. Removal of the air duct, silencer, air cleaner, and/or air cleaner element and baffle in air cleaner; re-indexing of air cleaner. Removal or rendering inoperative exhaust system components including the catalytic converter muffler assembly, inlet pipe, outlet pipe, resonator and flexpipe. Rotation of horizontal exhaust system directional outlet pipe to cause the exhaust to be emitted in a direction other than the orientation the vehicle was originally produced with. Removal or rendering inoperative the fan clutch. Removal or modification of the fan shroud. Replacing a fixed fan with a fan of increased diameter, different number of blades or different pitch width. 182 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Scheduled Maintenance Guide MAINTENANCE Instructions for maintenance and service of the noise control system have been included in the scheduled maintenance services listed later in this section. To further help minimize noise emissions degradation throughout the life of the vehicle, Ford Motor Company recommends that this vehicle should be operated in the manner described within the Owner’s Guide. Caution should be exercised by the owner when installing replacement parts to be sure that a tampering act (as outlined above) is not committed. Note any inspection and service performed in the Maintenance Record. EMISSIONS INFORMATION LABEL Emissions information appears on the Important Engine Information Decal located on 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. The following services are to be performed at scheduled intervals because they are considered essential to the life and performance of your vehicle. Ford recommends that you perform maintenance on all designated items to achieve best vehicle operation. GENERAL MAINTENANCE SERVICES The following are vehicle checks that should be made periodically either by the owner or a qualified technician. It is recommended that deficiencies be brought to the attention of your dealer or another qualified service outlet as soon as possible in order that advice regarding the need for service or replacement can be obtained. 183 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Scheduled Maintenance Guide Maintenance Operation Check the operation of the brakes and the steering(1,2) Inspect the vehicle for missing, damaged, or mislocated noise shields Check the engine performance and the engine governor Inspect the fan, the fan shroud, and the fan clutch Check for operation of ABS warning lamp Inspect the entire exhaust system (including inlet pipe, muffler, outlet pipe and all exhaust clamps and fasteners) for holes, leakage, breakage, looseness and corrosive damage Inspect the engine air induction system (including the air ducts, the air cleaner, and the air cleaner element) for loose fitting, damaged or missing components Inspect the tires and check the air pressure(3) Balance the wheels and the tires Frequency - Observation Vehicle handling qualities not up to par. Excessive noise emanates from under the cab or engine compartment. Excessive engine noise. Engine overheats, fans runs at high speed constantly, excessive fan noise, or fan wobble due to worn bearings. At each engine start up. Excessive noise or the smell of fumes is experienced. Excessive noise emanates from the engine compartment. Poor steering, wandering or excessive tire wear. Vibration or abnormal tire wear indicates imbalance. Poor steering, wandering or Check the front end alignment(3) excessive tire wear. Check the transmission and engine Excessive vibration. mountings High effort to shift or noisy Check and adjust transmission transmission. controls(2) 184 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Scheduled Maintenance Guide Maintenance Operation Drain the fuel filter/water separator (HFCM) Check fuel pump pressure Clean radiator cap seal. Clean and inspect the cap surface on the radiator Check the battery terminals for corrosion Re-torque suspension U-bolts Frequency - Observation Every oil change or as required when WATER IN FUEL light ) in instrument cluster ( illuminates Insufficient full-throttle power. When the cap does not hold pressure. Whenever electrical power supply has diminished. Re-torque at 1000 miles (1600 km), and every 30000 miles (48000 km) thereafter. Tighten the wheel mounting nuts Required initially at 500 and 1000 to the specified torque. Refer to miles (800 and 1600 km). Perform Servicing your wheels and tires again at 500 and 1000 mile (800 and 1600 km) intervals after each tire 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 detergent and washing with a cleaner does not restore a clean wipe. Lubricate body lock cylinders Noisy or difficult to operate. Check headlamp alignment Lamp beams in wrong position when vehicle operating loaded. Check windshield washer fluid If washes do not spray when level; add fluid if required operated. (1) During maintenance and repair, protect the fuel tube and the hose assemblies, the power steering lines, and the brake lines from the external heat, the acids and the abrasion that could damage the lines. (2) Check for (free) linkage action and ensure that (return) spring force is adequate to maintain pedal free play. (3) Adjust, repair or replace as required with the same or equivalent parts. 185 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) 186 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) IMPORTANT — This document should remain with the vehicle at all times. Warranty Start Date ______________________________________ Engine Displacement ______________________________________ Vehicle Identification Number _________________________________________ Owner Name ___________________________________________ Maintenance Record The maintenance record form which follows is for your convenience. In addition to recording the services performed, you should retain copies of your receipts for the services. You also should keep records of any emission control systems maintenance services performed on your vehicle. MAINTENANCE SERVICES AND RECORD RETENTION Scheduled Maintenance Guide SCHEDULED MAINTENANCE GUIDE Scheduled Maintenance Guide Daily owner checks Check the air filter restriction gauge Check the engine oil level Inspect the engine coolant level Transmission Visually check the automatic transmission for fluid leakage Steering system Check the power steering pump fluid level and check the system for leaks Check the entire vehicle for evidence of fluid leaks U.S. Department of Check the service brakes Transportation, Federal Check the parking brake Highway Administration Check the steering mechanism requirements (ensure that Check the lighting devices and the entire system is reflectors functioning properly) Check the tires Check the horn Check the windshield wipers and windshield washer fluid level Check the rear vision mirrors Check the wheels and rims Check the emergency equipment Engine 187 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Scheduled Maintenance Guide Check every oil change (six months, 10,000 miles [16,000 km] or 400 engine hours, whichever comes first) Engine Check the engine cooling hoses, clamps and protection* Inspect the drive belts Exhaust system Inspect the entire exhaust system including the inlet pipe(s), muffler(s), outlet pipe(s), clamps and fasteners, for holes, leaks, breaks, corrosive damage and separation from other components. Adjust, service or replace with the same or the equivalent part. (Also a noise emission control service.) Driveline and rear axle Lubricate the U-joints and the slip yoke Brake system Inspect the disc brake pads and the piston boots. Inspect the parking brake system; adjust if necessary Fuel 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 splines when equipped with grease fittings * Coolant protection checks should be made just prior to the onset of freezing weather, where applicable. If coolant is dirty or rusty in appearance, the system should be drained, flushed and refilled with the prescribed solution of engine coolant and water. Use only permanent type coolant that meets Ford specifications WSS-M97B51-A1 or add the coolant type originally equipped in your vehicle. In addition to the items to be performed daily or at each oil change, the services listed in General Maintenance Services need to be completed as specified. 188 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Scheduled Maintenance Guide Maximum oil change interval ❑ Normal schedule: 10,000 miles (16,000 km), 6 months or 400 engine hours whichever occurs first. ❑ Special Operating Conditions: 5,000 miles (8,000 km), 6 months or 200 hours of engine operation, see appropriate schedule. Maximum fuel filter change interval ❑ Normal schedule: 20,000 miles (32,000 km) or 12 months, whichever occurs first. ❑ Special Operating Conditions: 10,000 miles (16,000 km) or 400 hours of engine operation, see appropriate schedule. Motorcraft Premium Gold Engine Coolant change 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 50,000 miles (80,000 km) NORMAL SCHEDULED MAINTENANCE AND LOG The following section contains the “Normal Schedule”. This schedule is presented at specific mileage (kilometer) intervals with exceptions noted. 1,000 miles (1,600 km) ❑ Inspect tires for wear and measure tread depth ❑ Inspect air filter restriction gauge, replace filter as required ❑ Torque suspension U-bolts DEALER VALIDATION: RO#: P&A CODE: DATE: MILEAGE: 10,000 miles (16,000 km) ❑ ❑ ❑ ❑ ❑ ❑ Change engine oil and replace oil filter Inspect 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 Inspect exhaust system and heat shields Inspect accessory drive belt DEALER VALIDATION: RO#: P&A CODE: DATE: MILEAGE: 189 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Scheduled Maintenance Guide 20,000 miles (32,000 km) ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ Change engine oil and replace oil filter Inspect tires for wear and measure tread depth Inspect air filter restriction gauge, replace filter as required Replace engine- and frame-mounted fuel filters Inspect and lubricate steering linkage, suspension, driveshaft, cab latch, door hinges, latches and strikers (door checks, locks and seals) Inspect engine cooling system 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 DEALER VALIDATION: RO#: P&A CODE: DATE: MILEAGE: 30,000 miles (48,000 km) ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ Change engine oil and replace oil filter Inspect 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 Inspect exhaust system and heat shields Inspect accessory drive belt Torque suspension U-bolts Replace front wheel bearing grease and seals DEALER VALIDATION: RO#: P&A CODE: DATE: MILEAGE: 40,000 miles (64,000 km) ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ Change engine oil and replace oil filter Inspect tires for wear and measure tread depth Inspect air filter restriction gauge, replace filter as required Replace engine- and frame-mounted fuel filters Inspect and lubricate steering linkage, suspension, driveshaft, cab latch, door hinges, latches and strikers (door checks, locks and seals) Inspect engine cooling system 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 190 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) DEALER VALIDATION: RO#: P&A CODE: DATE: MILEAGE: Scheduled Maintenance Guide 50,000 miles (80,000 km) ❑ ❑ ❑ ❑ ❑ ❑ Change engine oil and replace oil filter Inspect 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 Inspect exhaust system and heat shields Inspect accessory drive belt DEALER VALIDATION: RO#: P&A CODE: DATE: MILEAGE: 60,000 miles (96,000 km) ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ Change engine oil and replace oil filter Inspect tires for wear and measure tread depth Inspect air filter restriction gauge, replace filter as required Replace engine- and frame-mounted fuel filters Inspect and lubricate steering linkage, suspension, driveshaft, cab latch, door hinges, latches and strikers (door checks, locks and seals) Inspect engine cooling system 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 automatic transmission fluid and filter Change rear axle fluid (every three years or 250,000 miles [400,000 km] for axles filled with synthetic fluid. If axle is filled with non-synthetic fluid, the interval is every year or 100,000 miles [160,000 km]) Torque suspension U-bolts Replace front wheel bearing grease and seals DEALER VALIDATION: RO#: P&A CODE: DATE: MILEAGE: 70,000 miles (112,000 km) ❑ ❑ ❑ ❑ ❑ ❑ Change engine oil and replace oil filter Inspect 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 Inspect exhaust system and heat shields Inspect accessory drive belt DEALER VALIDATION: RO#: P&A CODE: DATE: MILEAGE: 191 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Scheduled Maintenance Guide 80,000 miles (128,000 km) ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ Change engine oil and replace oil filter Inspect tires for wear and measure tread depth Inspect air filter restriction gauge, replace filter as required Replace engine- and frame-mounted fuel filters Inspect and lubricate steering linkage, suspension, driveshaft, cab latch, door hinges, latches and strikers (door checks, locks and seals) Inspect engine cooling system 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 DEALER VALIDATION: RO#: P&A CODE: DATE: MILEAGE: 90,000 miles (144,000 km) ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ Change engine oil and replace oil filter Inspect 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 Inspect exhaust system and heat shields Inspect accessory drive belt Torque suspension U-bolts Replace front wheel bearing grease and seals 192 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) DEALER VALIDATION: RO#: P&A CODE: DATE: MILEAGE: Scheduled Maintenance Guide 100,000 miles (160,000 km) ❑ Change engine oil and replace oil filter ❑ Inspect tires for wear and measure tread depth ❑ Replace engine air filter every five years or 100,000 miles (160,000 km) if not replaced sooner ❑ Replace engine- and frame-mounted fuel filters ❑ Replace rear axle lubricant (Refer to Special Operating Condi- ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ tions later in this chapter for more information.) If rear axle is filled with synthetic lubricant, replace lubricant every five years or 250,000 miles (400,000 km), whichever comes first. Inspect and lubricate steering linkage, suspension, driveshaft, cab latch, door hinges, latches and strikers (door checks, locks and seals) Inspect cooling system 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 Engine Coolant Change power steering fluid (every five years or 100,000 miles [160,000 km], whichever comes first) Replace power steering fluid filter DEALER VALIDATION: RO#: P&A CODE: DATE: MILEAGE: 110,000 miles (176,000 km) ❑ ❑ ❑ ❑ ❑ ❑ Change engine oil and replace oil filter Inspect 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 Inspect exhaust system and heat shields Inspect accessory drive belt DEALER VALIDATION: RO#: P&A CODE: DATE: MILEAGE: 193 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Scheduled Maintenance Guide 120,000 miles (192,000 km) ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ Change engine oil and replace oil filter Inspect tires for wear and measure tread depth Inspect air filter restriction gauge, replace filter as required Replace engine- and frame-mounted fuel filters Inspect and lubricate steering linkage, suspension, driveshaft, cab latch, door hinges, latches and strikers (door checks, locks and seals) Inspect engine cooling system 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 automatic transmission fluid and filter Torque suspension U-bolts Replace front wheel bearing grease and seals DEALER VALIDATION: RO#: P&A CODE: DATE: MILEAGE: 130,000 miles (208,000 km) ❑ ❑ ❑ ❑ ❑ ❑ Change engine oil and replace oil filter Inspect 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 Inspect exhaust system and heat shields Inspect accessory drive belt DEALER VALIDATION: RO#: P&A CODE: DATE: MILEAGE: 140,000 miles (224,000 km) ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ Change engine oil and replace oil filter Inspect tires for wear and measure tread depth Inspect air filter restriction gauge, replace filter as required Replace engine- and frame-mounted fuel filters Inspect and lubricate steering linkage, suspension, driveshaft, cab latch, door hinges, latches and strikers (door checks, locks and seals) Inspect engine cooling system 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 194 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) DEALER VALIDATION: RO#: P&A CODE: DATE: MILEAGE: Scheduled Maintenance Guide 150,000 miles (240,000 km) ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ ❑ Change engine oil and replace oil filter Inspect 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 Inspect exhaust system and heat shields Replace accessory drive belt if not replaced in the last 100,000 miles (160,000 km) Change Motorcraft Premium Gold Engine Coolant Torque suspension U-bolts Replace front wheel bearing grease and seals DEALER VALIDATION: RO#: P&A CODE: DATE: MILEAGE: SPECIAL OPERATING CONDITIONS Operating extensively on dirt roads or in dusty conditions Every 5,000 miles (8,000 km) Inspect and lubricate steering and suspension Inspect brake system and tires Every 5,000 miles (8,000 km) or Change engine oil and replace filter 200 hours Every 10,000 miles (16,000 km) or Change engine-mounted fuel filter and chassis-mounted 400 hours of engine operation (HFCM) fuel filter (whichever comes first) As required Check air filter restriction gauge, replace air filter as required Frequent stops and starts or driven extensively at speeds below 25 mph (40 km/h) Every 5,000 miles (8,000 km) Inspect and lubricate steering and suspension Inspect brake system and tires Every 5,000 miles (8,000 km) or Change engine oil and replace filter 200 hours Every 10,000 miles (16,000 km) or Change engine-mounted fuel filter and chassis-mounted 400 hours of engine operation (HFCM) fuel filter (whichever comes first) For engines idled daily for more than 10 minutes at a time, change engine oil and replace filter every 125 hours of engine operation 195 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Scheduled Maintenance Guide Sustained driving at or near Gross Vehicle Weight Rating (maximum loaded weight for vehicle operation) Every 5,000 miles (8,000 km) Every 5,000 miles (8,000 km) or 200 hours Every 10,000 miles (16,000 km) or 400 hours of engine operation (whichever comes first) Every 50,000 miles (80,000 km) Inspect brake system and tires Change engine oil and replace filter Change engine-mounted fuel filter and chassis-mounted (HFCM) fuel filter Replace non-synthetic rear axle lubricant Use of Biodiesel, up to and including 5% Biodiesel (B5) Every 10,000 miles (16,000 km), 6 Replace engine-mounted fuel filter and chassis-mounted months or 400 hours of operation (HFCM) fuel filter (which ever comes first) 196 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Scheduled Maintenance Guide Special Operating Conditions Log DEALER VALIDATION: DEALER VALIDATION: RO#: DATE: P&A CODE: MILEAGE: DEALER VALIDATION: RO#: DATE: P&A CODE: MILEAGE: DEALER VALIDATION: RO#: DATE: P&A CODE: MILEAGE: DEALER VALIDATION: RO#: DATE: P&A CODE: MILEAGE: DEALER VALIDATION: RO#: DATE: P&A CODE: MILEAGE: DEALER VALIDATION: RO#: DATE: P&A CODE: MILEAGE: DEALER VALIDATION: RO#: DATE: P&A CODE: MILEAGE: DEALER VALIDATION: RO#: DATE: P&A CODE: MILEAGE: DEALER VALIDATION: RO#: DATE: P&A CODE: MILEAGE: RO#: DATE: P&A CODE: MILEAGE: 197 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Scheduled Maintenance Guide Special Operating Conditions Log DEALER VALIDATION: DEALER VALIDATION: RO#: DATE: P&A CODE: MILEAGE: DEALER VALIDATION: RO#: DATE: P&A CODE: MILEAGE: DEALER VALIDATION: RO#: DATE: P&A CODE: MILEAGE: DEALER VALIDATION: RO#: DATE: P&A CODE: MILEAGE: DEALER VALIDATION: RO#: DATE: P&A CODE: MILEAGE: DEALER VALIDATION: RO#: DATE: P&A CODE: MILEAGE: DEALER VALIDATION: RO#: DATE: P&A CODE: MILEAGE: DEALER VALIDATION: RO#: DATE: P&A CODE: MILEAGE: DEALER VALIDATION: RO#: DATE: P&A CODE: MILEAGE: RO#: DATE: 198 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) P&A CODE: MILEAGE: Scheduled Maintenance Guide MOTORCRAFT PREMIUM GOLD COOLANT CHANGE RECORD The charts below will help you calculate your next service interval for your engine coolant change. Your first engine coolant change should occur at six years or 100,000 miles (160,000 km), whichever comes first. After the first coolant change the coolant should be changed every three years or 50,000 miles (80,000 km) whichever comes first. Current mileage goes here => Add 50,000 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 Current mileage goes here => Add 50,000 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 Current mileage goes here => Add 50,000 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 + 50,000 + 00 / 00 / 03 P & A CODE R.O.# Dealer Stamp + 50,000 + 00 / 00 / 03 P & A CODE R.O.# Dealer Stamp + 50,000 + 00 / 00 / 03 P & A CODE R.O.# 199 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Scheduled Maintenance Guide Current mileage goes here => Add 50,000 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 + 50,000 + 00 / 00 / 03 200 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) P & A CODE R.O.# Index A ABS (see Brakes) .......................77 Air cleaner filter .......................153 Air conditioning ..........................34 manual heating and air conditioning system .................34 Air filter restriction gauge .........23 Anti-lock brake system (see Brakes) ................................77 Automatic transmission ..............77 driving an automatic overdrive ...................................77 fluid, adding ............................151 fluid, checking ........................149 fluid, refill capacities ..............176 fluid, specification ..................171 Axle ..............................84, 119, 157 lubricant specifications ..........171 refill capacities ........................176 B Battery .......................................127 how to service ........................127 jumping a disabled battery ......98 maintenance-free ....................127 proper disposal, recycling ......128 servicing ..................................127 Brakelamp bulb replacement ......................49 Brakes ..................................74, 119 anti-lock .....................................77 anti-lock brake system (ABS) warning light .............................77 fluid, checking and adding ....148 if brakes do not grip well ........75 lubricant specifications ..........171 parking ......................................76 servicing ..................................119 shift interlock ............................77 Bulbs ............................................44 C Cell phone use ..............................7 Changing a tire ...........................98 Child safety restraints ................65 child safety belts ......................65 Child safety seats ........................68 in front seat ..............................69 in rear seat ................................69 Child safety seats - booster seats .............................................66 Chimes (warning) .......................18 Cleaning your vehicle ...............110 CD player and discs .................31 exterior ....................................110 exterior lamps .........................112 instrument cluster lens ..........112 instrument panel ....................112 interior .....................................113 interior trim ............................113 plastic parts ............................112 safety belts ..............................113 washing ....................................110 waxing .....................................110 wheels ......................................111 Climate control (see Air conditioning or Heating) ......33–34 Clock adjust AM/FM Stereo ...........................26 AM/FM/CD .................................28 Coolant ......................................128 checking and adding ......128–129 disposal ....................................132 recovery reservoir ..................128 refill capacities ........................176 specifications ..........................171 201 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Index temperature gauge ...................23 Customer Assistance ................105 Getting assistance outside the U.S. and Canada .............105, 107 Getting the service you need .........................................105 Ordering additional owner’s literature .................................108 D Daytime running lamps (see Lamps) ................................37 Defects, reporting .....................109 Defrost ...................................33–34 with heating and air conditioning system .................34 with standard heating system .......................................33 Diesel Particulate Filter (DPF) ........................................142 Dipstick automatic transmission fluid ..........................................149 engine oil .................................124 Door locks ...................................56 Driving under special conditions ....................................83 through water ...........................74 E Emergencies, roadside assistance ..................................90 jump-starting ............................98 towing ......................................103 Emergency brake (see Parking brake) ....................76 Emergency Flashers ...................90 Emission control system ............................5, 145, 180 catalytic converter ..................154 Engine coolant .....................................128 lubrication specifications .......171 preparing to start .....................71 refill capacities ........................176 starting ......................................71 Engine oil ..................................124 checking and adding ..............124 dipstick ....................................124 filter, specifications ................125 recommendations ...................125 refill capacities ........................176 specifications ..................125, 171 Event data recording ....................6 F Flashers, hazard ..........................90 Fluid capacities .........................176 Fuel ............................................135 calculating fuel economy .......141 capacity ...................................176 choosing the right fuel ...........137 filling your vehicle with fuel ...................................135, 140 filter, specifications ................133 gauge .........................................23 improving fuel economy ..........................139, 141 running out of fuel ...........73, 139 safety information relating to automotive fuels .....................135 Fuses ............................................90 G Gauges .........................................23 202 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Index air filter restriction ...................23 engine coolant temperature gauge .........................................23 fuel gauge ..................................23 odometer ...................................23 speedometer .............................23 tachometer ................................23 trip odometer ............................23 GAWR (Gross Axle Weight Rating) .......84 driving with a heavy load ........84 GVWR (Gross Vehicle Weight Rating) ..84 H Hazard flashers ...........................90 Headlamps ...................................37 aiming ............................38–39, 41 bulb specifications ....................44 flash to pass ..............................37 high beam .................................37 replacing bulbs .........................44 turning on and off ....................37 warning chime ..........................18 Heating ..................................33–34 heater only system ...................33 manual heating and air conditioning system .................34 I Ignition .........................................71 chime .........................................18 positions of the ignition ...........71 Infant seats (see Safety seats) ..68 Instrument panel cleaning ...................................112 cluster ......................................112 J Jump-starting your vehicle ........98 K Keys .............................................56 key in ignition chime ...............18 positions of the ignition ...........71 L Lamps bulb replacement specifications chart ..................44 cargo lamps ...............................38 daytime running light ...............37 hazard flashers ..........................90 headlamps .................................37 headlamps, flash to pass ..........37 high beams ................................37 instrument panel, dimming .....38 interior lamps .....................43–45 replacing bulbs .......44–45, 48–49 Lights, warning and indicator ....18 anti-lock brakes (ABS) ......18, 77 brake fluid .................................18 brake pressure ..........................18 change oil ..................................18 charging system ........................18 check electrical system ............18 check engine .............................18 check transmission ...................18 engine warning .........................18 high beam .................................18 parking brake ............................18 PTO enable .........................18, 83 safety belt .................................18 tow/haul .....................................18 transmission temperature ........18 turn signal indicator .................18 warn engine ..............................18 water in fuel ..............................18 Load limits GAWR ........................................84 GVWR ........................................84 203 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Index Locks ............................................56 doors ..........................................56 Lubricant specifications ...........171 Roadside assistance ....................90 M Safety Belt Maintenance ..........113 Safety belts (see Safety restraints) ...60–61, 63 Safety defects, reporting ..........109 Safety restraints ..............60–61, 63 cleaning the safety belts ........113 extension assembly ..................63 for adults .............................61, 63 for children ...............................65 lap belt ......................................62 safety belt maintenance ...64, 113 warning light and chime ..........64 Safety seats for children ............68 Safety Compliance Certification Label ......................84 Scheduled Maintenance Guide .........................................178 Coolant Change Record .........199 General Maintenance Information .............................178 Normal Scheduled Maintenance and Log .............189 Seat belts (see Safety restraints) ...............60 Seats ............................................59 child safety seats ......................68 cleaning ...................................113 Serial number (VIN) .................177 Servicing your vehicle ..............116 Setting the clock AM/FM stereo ...........................26 AM/FM stereo CD .....................28 Spare tire (see Changing the Tire) .............98 Mileage, calculating fuel economy ....................................141 Mirrors .........................................52 fold away ...................................52 Motorcraft parts ........................114 O Odometer .....................................23 Oil (see Engine oil) ..................124 P Parking .........................................74 Parking brake ..............................76 warning light .............................76 Power distribution box (see Fuses) .................................91 Power steering ..........................147 fluid, checking and adding ....148 fluid, refill capacity ................176 fluid, specifications .................171 Power Take-Off (PTO) indicator light ...........................83 operation ...................................83 Power Windows ...........................50 R Radio reception ...........................31 Refill capacities for fluids ........176 Remote entry system .................56 S 204 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) Index Special notice ................................5 Specification chart, lubricants ...................................171 Speed control ..............................52 Speedometer ...............................23 Starting your vehicle ..................71 jump starting ............................98 preparing to start your vehicle .......................................71 Steering .....................................147 Steering wheel tilting .........................................50 Suspension ................................156 T Tachometer .................................23 Tail lamps bulb replacement ......................49 Tilt steering wheel ......................50 Tires changing ....................................98 rotating ....................................163 spare tire ...................................98 Tow hooks .................................104 Towing .................................87, 103 trailer towing ............................87 wrecker ....................................103 Transmission ...............................77 automatic operation .................80 brake-shift interlock (BSI) ......77 fluid, refill capacities ..............176 Trip odometer .............................23 Turn signal ..................................43 V Vehicle Identification Number (VIN) ..........................................177 Vehicle loading ............................84 W Warning chimes ...........................18 Warning lights (see Lights) .......18 Warranty coverage ........................5 Washer fluid ..............................123 reservoir ..................................123 Washing your vehicle ................110 Water, Driving through ...............74 Waxing your vehicle .................110 Weight limits (GAWR, GVWR) ...84 Wheels .......................................158 cleaning ...................................111 Windows ......................................50 power .........................................50 Windshield washer fluid and wipers ..........................................50 checking and adding fluid .....123 checking and cleaning ............112 operation ...................................50 replacing wiper blades ...........123 reservoir ..................................123 Wrecker towing .........................103 205 2008 Low Cab Forward Truck (lcf) Supplement USA (fus) 206