Engine Mechanical:
Complete engine disassembly, assembly, inspection, diagnosis, and repair for all gasoline and diesel variants.
Engine Performance:
Fuel injection, ignition system diagnosis and repair, emissions control systems, turbocharging (if applicable).
Transmission Manual:
Repair and overhaul procedures for manual transmissions (e.g., ZF S6-650).
Transmission Automatic:
Repair and overhaul procedures for automatic transmissions (e.g., TorqShift 5R110W).
Drivetrain:
Driveshaft, universal joints, rear axle, differential service and repair, 4WD system (transfer case).
Suspension Front:
Leaf spring system, axle alignment, shock absorbers, steering linkage.
Suspension Rear:
Leaf spring system, axle components, shock absorbers.
Brakes Hydraulic:
Hydraulic system diagnosis, master cylinder, brake lines, wheel cylinders/calipers, brake fluid flush and bleeding.
Brakes Parking:
Parking brake system operation, adjustment, and repair.
Steering System:
Power steering pump, steering gear/rack, steering column, alignment specifications.
Electrical System Battery:
Battery service, testing, and charging system diagnosis (alternator, voltage regulator).
Electrical System Lighting:
Headlights, taillights, interior lighting, diagnostic procedures.
Electrical System Accessories:
Wiper system, horn, power windows/locks (if equipped), trailer wiring.
Climate Control HVAC:
Air conditioning system diagnosis, refrigerant handling, heater core service, blower motor.
Safety Airbags:
Airbag system diagnosis, SRS module, component replacement (cautionary procedures highly detailed).
Body Exterior:
Door panel removal, hood repair, grille, bumpers, tailgate/bed removal and installation.
Body Interior:
Seat removal, dashboard trim, headliner, carpet replacement.
Diagnostics OBD:
On-Board Diagnostics (OBD-II) codes, diagnostic trouble codes (DTCs) and their meaning, diagnostic flowcharts.
Routine Maintenance:
Oil changes, filter replacements (oil, fuel, air), fluid level checks and top-offs, tire rotation.
Component Replacement:
Step-by-step guides for replacing virtually all mechanical and electrical components.
Troubleshooting:
Diagnostic trees and symptom-based troubleshooting for common and uncommon problems.
Engine Rebuild:
Detailed procedures for engine disassembly, cleaning, inspection, measurement, and reassembly.
Transmission Overhaul:
Comprehensive guides for disassembling, inspecting, repairing, and reassembling both manual and automatic transmissions.
Brake Service:
Brake pad and rotor replacement, caliper service, brake line repair, bleeding procedures.
Electrical Diagnostics:
Wiring diagrams for all circuits, component testing procedures, voltage drop testing.
Suspension Alignment:
Front and rear wheel alignment specifications and adjustment procedures.
Diagnostics Testing:
Procedures for testing sensors, actuators, control modules, and other electronic components.
Depth:
OEM level detail, suitable for professional technicians and experienced DIYers.
Diagnostics:
In-depth diagnostic strategies, including use of scan tools, oscilloscopes, and multimeter testing.
Torque Specifications:
Precise torque values for all fasteners, critical for proper assembly and safety.
Clearances Tolerances:
Specific measurement ranges for engine and transmission components during rebuilds.
Wiring Diagrams:
Comprehensive, color-coded wiring schematics for all electrical systems.
Schematics:
Vacuum, hydraulic, and pneumatic schematics as applicable.
Oil Change Interval:
7,500 miles or 6 months for gasoline, 5,000 miles or 6 months for diesel (under severe use conditions, consult manual for specific recommendations).
Transmission Fluid Change:
Manual: Inspect periodically, change as needed. Automatic: 30,000-60,000 miles (severe use may require more frequent changes).
Engine Oil Gasoline:
API SG/SH/SJ certified, SAE 5W-30 or 5W-40 (refer to manual for exact spec).
Engine Oil Diesel:
API CH-4 or CI-4 certified, SAE 15W-40 (preferred) or 5W-40 synthetic for cold weather.
Coolant:
Ford Premium Engine Coolant (Gold Color) or equivalent; a 50/50 mix of antifreeze and distilled water.
Brake Fluid:
DOT 3 Motor Vehicle Brake Fluid.
7.3L Diesel Glow Plugs:
Glow plug failure leading to hard starting in cold weather.
7.3L Diesel Oil Cooler:
Potential leaks or failures in the oil cooler lines.
Torqshift Transmission Isar:
Intermittent problems with the Input Shaft/Accessory Ratio (ISAR) assembly in earlier TorqShift transmissions.
Rear Axle Bearings:
In some heavy-duty applications, rear axle bearing wear can occur under extreme load.
