Systems Covered:
General Information, Chassis, Powertrain, Electrical, Body and Paint, Wiring Diagrams
Specific Chapters:
General Information, Service Information, Chassis Systems (Suspension, Brakes, Steering), Powertrain (Engine, Transmission, Exhaust, Fuel), Electrical Systems (Climate, Instrument Cluster, Charging, Audio, Lighting, Communications, Anti-Theft), Body & Paint, Wiring Diagrams.
Estimated Pages:
Detailed page count not specified, but indicated as a comprehensive workshop manual. Typically 1500-2500+ pages for this era of heavy-duty truck workshop manuals.
Type:
Workshop Service Repair Manual (OEM)
Engine Service:
Engine System, Cooling, Fuel Charging & Control, Accessory Drive, Starting System, Ignition, Emission Control, Intake Air, Evaporative Emissions, Electronic Engine Controls
Transmission Service:
Automatic Transaxle/Transmission, Manual Transaxle/Transmission
Chassis Service:
Suspension (Front & Rear), Wheels & Tires, Driveline, Rear Drive Axle/Differential, Brake System (Front/Rear Disc, Parking, Hydraulic Actuation, Power Brakes), Steering System (Power Steering, Gear, Pump, Hoses, Cooler, Module, Ignition Lock Cylinder, Air Bag Sliding Contact, Steering Shaft/Column Switches)
Electrical Service:
Climate Control, Instrument Cluster & Panel Illumination, Charging System, Entertainment System, Lighting, Module Communications Network, Anti-Theft System
Body Service:
Body Panels (Front End), Closures, Interior Trim, Exterior Trim, Mirrors, Seating, Glass, Instrument Panel, Console, Handles, Locks, Latches, Entry System, Wipers & Washers, Bumpers, Safety Belts, Supplemental Restraint System (SRS)
Wiring Diagrams:
Comprehensive wiring for Audio, Navigation, Charging, Climate, Seats, Cluster Illumination, Convertible Top, Cooling Fan, Electronic Engine Controls, Headlamps, Autolamps, Heated Window, Horn, Cigar Lighter, Instrument Cluster, Interior Lamps, Luggage Compartment, Manual Climate Control, Module Communications Network, Overhead Console, Parking/Rear/License Lamps, Passive Anti-Theft, Power Distribution, Power Door Locks, Power Mirrors, Power Window, Remote Keyless Entry, Reversing Lamps, Seating, Shift Interlock, Speed Control, SRS, Splice Locations
Emission Control Systems:
Evaporative emissions control (EVAP), exhaust gas recirculation (EGR), catalytic converters, oxygen sensors, and related electronic controls.
Diagnostic Procedures:
Diagnostic Trouble Codes (DTCs) for various systems, troubleshooting charts, component testing procedures
Maintenance Procedures:
Scheduled maintenance, lubrication, fluid changes, filter replacements, inspection routines
Repair Procedures:
Step-by-step repair instructions for all covered systems, including component removal, installation, and adjustment
Technical Specifications:
Torque specifications, clearances, fluid capacities, electrical data, component specifications
Troubleshooting Guides:
Included for various common and complex issues, often tied to diagnostic trouble codes.
Alignment Specifications:
Front and rear wheel alignment angles, caster, camber, toe settings.
Depth:
Complete factory-level repair information, suitable for DIY enthusiasts and professional technicians. Covers diagnostics, repair, and maintenance.
Component Replacement:
Detailed steps for replacing major components like engines, transmissions, axles, suspension parts, brake assemblies, and body panels.
Electrical Diagnostics:
In-depth coverage of electrical system diagnostics, including power distribution, grounding, sensor inputs, actuator outputs, and module communication.
Oil Change Interval:
Typically 5,000-7,500 miles for gasoline engines, and 5,000-10,000 miles for the 7.3L Power Stroke diesel (depending on duty cycle and oil type). Manual will provide specific OEM intervals.
Transmission Fluid Change:
Often recommended every 30,000-60,000 miles for automatic transmissions under normal use. Manual will specify.
Engine Oil:
e.g., 15W-40 (Power Stroke Diesel), 5W-30 or 10W-30 (Gasoline V8). Specific API service classification provided in the manual.
Coolant:
Ford Premium Gold Coolant or equivalent meeting Ford specification WSS-M97B51-A1.
Power Steering Fluid:
Typically MERCON or MERCON V automatic transmission fluid for Ford power steering systems of this era.
Differentials And Axles:
Specific gear oil weights (e.g., 75W-90, 75W-140) and friction modifiers if a limited-slip differential is equipped.
Common Wear Items:
Ball joints, tie rod ends, U-joints, brake components, fuel injectors (on diesel), glow plugs (on diesel).
Diesel Engine Considerations:
7.3L Power Stroke is known for reliability but can experience issues with injector o-rings, turbocharger wear, and fuel pressure regulator issues if not maintained.