Engine:
Detailed coverage of all gasoline and diesel engine options, including diagnostics, repair, and overhaul.
Fuel System:
Fuel delivery, injection systems (gasoline and diesel), fuel filters, fuel pumps, and evaporative emission controls.
Cooling System:
Radiator, coolant flow, water pump, thermostat, hoses, and fan clutch operation.
Lubrication System:
Oil pump, oil filter, oil cooler, lubrication passages, and oil specifications.
Ignition Charging Starting:
Spark plug service, ignition coils, battery, alternator, starter motor, and related circuits.
Automatic Transmission:
Service, diagnostics, repair, and overhaul for applicable automatic transmissions (e.g., 4R100, 5R110W).
Manual Transmission:
Service, diagnostics, repair, and overhaul for applicable manual transmissions (e.g., ZF6).
Transfer Case:
Operation, service, and repair of four-wheel-drive transfer cases (e.g., BW 4406, BW 4407).
Driveshaft Axle:
U-joints, CV joints, driveshafts, axle housing service, and differential repair.
Suspension:
Front and rear suspension components, shock absorbers, springs, bushings, and alignment specifications.
Steering:
Steering column, power steering system, steering gear, and linkage repair.
Brakes:
Front and rear brake systems (disc/drum), hydraulic components, ABS, and parking brake service.
Electrical System:
Complete wiring diagrams, component locations, diagnostics, and repair for all electrical systems.
Multiplex Communication:
CAN bus communication systems, diagnostic protocols, and related component service.
HVAC:
Air conditioning system service, refrigerant handling, heating system, and climate controls.
Restraint Systems:
Supplemental Restraint System (SRS) components, airbags, seat belts, and diagnostics.
Interior Trim:
Removal and installation procedures for interior panels, seats, dashboard, and console components.
Exterior Body:
Hood, doors, fenders, bumpers, tailgate, and glass service and replacement.
Cruise Control:
System operation, diagnostics, and repair for the factory cruise control system.
Wiper Washer:
Wiper motor, linkage, washer pump, and fluid reservoir service.
Instrument Panel:
Instrument cluster, gauges, warning lights, and related diagnostics.
Audio Visual:
Factory radio, speaker systems, and related electrical connections.
Security Immobilizer:
Engine immobilizer system operation and troubleshooting.
Diagnostics:
Comprehensive diagnostic procedures, including symptom-based troubleshooting and OBD-II code interpretation.
Maintenance:
Scheduled maintenance tasks, fluid changes, filter replacements, and inspections.
Repair:
Step-by-step instructions for virtually all mechanical and electrical repairs.
Overhaul:
Detailed procedures for engine, transmission, and axle overhauls.
Component Replacement:
Instructions for the removal, installation, and adjustment of all vehicle components.
Depth:
Factory-level technical depth, suitable for professional technicians and experienced DIY enthusiasts.
Troubleshooting:
In-depth troubleshooting guides with flowcharts and diagnostic trees.
Specifications:
Extensive technical specifications, torque values, clearances, and tolerances for all components.
Illustrations:
Numerous diagrams, illustrations, and exploded views to aid in understanding procedures.
Wiring Schematics:
Complete and detailed electrical wiring schematics for all systems.
Available Engines:
4.2L V6 Triton, 5.4L V8 Triton, 6.8L V10 Triton (Gasoline); 7.3L V8 Power Stroke Turbo Diesel.
4.2L V6 Hp:
Approx. 202 hp @ 4000 rpm (Specific output can vary slightly by sub-model and year variations).
4.2L V6 Torque:
Approx. 250 lb-ft @ 2500 rpm (Specific output can vary slightly by sub-model and year variations).
5.4L V8 Hp:
Approx. 235 hp @ 4500 rpm (Specific output can vary slightly by sub-model and year variations).
5.4L V8 Torque:
Approx. 330 lb-ft @ 3000 rpm (Specific output can vary slightly by sub-model and year variations).
6.8L V10 Hp:
Approx. 275 hp @ 4400 rpm (Specific output can vary slightly by sub-model and year variations).
6.8L V10 Torque:
Approx. 410 lb-ft @ 3200 rpm (Specific output can vary slightly by sub-model and year variations).
7.3L Powerstroke Hp:
Approx. 250 hp @ 2600 rpm (Specific output can vary slightly by sub-model and year variations).
7.3L Powerstroke Torque:
Approx. 500 lb-ft @ 1600 rpm (Specific output can vary slightly by sub-model and year variations).
Fuel Delivery Gas:
Electronic Fuel Injection (EFI) with sequential multiport injection.
Fuel Delivery Diesel:
HEUI (Hydraulically Actuated Electronically Controlled Unit Injector) system.
Oil Change Interval:
Typically 3,000-5,000 miles for conventional oil, or 5,000-7,500 miles for synthetic oil, depending on driving conditions and engine type.
Transmission Fluid Change:
Recommended every 30,000-60,000 miles for automatic transmissions, depending on towing and load usage. Manual transmission fluid checks are less frequent.
Engine Oil Gasoline:
API Service SG, SH, SJ, or SL rated oil, SAE 5W-30 or 10W-30 depending on temperature. Consult manual for specific engine.
Engine Oil Diesel:
API Service CH-4 or CI-4 rated synthetic diesel engine oil, SAE 15W-40 or 5W-40. Consult manual for specific engine.
Coolant:
Ford Premium Long Life Coolant (Green) or equivalent with a 50/50 mix of coolant and distilled water.
Transmission Fluid Auto:
MERCON V (for 4R100 and potentially 5R110W). Check manual for exact specification.
Transfer Case Fluid:
Mercon Automatic Transmission Fluid or specified manual transmission fluid depending on transfer case type.
Power Stroke Injector Issues:
Some 7.3L Power Stroke engines can experience injector seal leaks or injector control pressure (ICP) sensor issues. The manual details diagnostic procedures for these.
U Joint Wear:
Heavy-duty use can lead to accelerated wear of universal joints, requiring regular lubrication and inspection. Manual covers replacement.
Diesel Glow Plugs:
Glow plug failure can lead to hard starting in cold weather. Manual provides testing and replacement procedures.