Engine Systems:
6.4L Power Stroke V8 Diesel, 5.4L Triton V8 Gasoline, 6.8L Triton V10 Gasoline - including: Engine mechanical, lubrication, cooling, fuel, ignition, exhaust, emission controls, turbocharger systems.
Transmission Systems:
6R140 TorqShift Heavy Duty Automatic Transmission, ZF6-650 6-Speed Manual Transmission - including: Overhaul, diagnostics, fluid specifications, torque converter, clutch systems, shift controls.
Drivetrain Systems:
4x2 and 4x4 drivetrain, front axle, rear axle ( Dana 80/Super 60), drive shafts, universal joints, axle ratios, differential maintenance.
Suspension Steering:
Front Twin-I Beam Independent Front Suspension (IFS) with leaf springs, Rear leaf spring solid axle, power steering system, steering gear, linkage, wheel alignment specifications.
Brake Systems:
Front and rear disc brakes, ABS (Anti-lock Braking System), hydraulic systems, parking brake, master cylinder, brake booster, caliper and rotor specifications.
Electrical Systems:
12V electrical system, battery, alternator, starter motor, lighting, fuses, relays, wiring diagrams, instrument cluster, trailer wiring harness, Powertrain Control Module (PCM), Body Control Module (BCM).
HVAC Systems:
Heating, Ventilation, and Air Conditioning (HVAC) system, refrigerant, compressor, evaporator, condenser, climate controls.
Body Chassis:
Frame construction, body panels, doors, tailgate, interior trim, glass, bumpers, towing equipment, underbody coatings.
Maintenance:
Scheduled maintenance intervals, oil changes, filter replacements, fluid checks and top-offs, tire rotation, brake inspection, battery maintenance.
Troubleshooting:
Diagnostic trouble codes (DTCs), symptom-based troubleshooting charts, electrical diagnostic procedures, engine performance diagnostics.
Repair:
Detailed step-by-step repair procedures for all major components and systems, including engine rebuilds, transmission overhauls, suspension and brake component replacement, electrical component diagnosis and replacement.
Diagnostics:
OBD-II diagnostic procedures, scan tool usage, live data interpretation, circuit testing, sensor testing.
Installation:
Installation procedures for common accessories and replacement parts, such as trailer hitches, auxiliary lighting, and aftermarket components.
Depth:
Comprehensive, covering everything from basic scheduled maintenance to complete engine and transmission rebuilds, including detailed wiring diagrams and diagnostic flowcharts.
Diesel Engine:
6.4L Power Stroke V8 Turbo Diesel
Diesel Power Output:
350 HP @ 3,000 RPM (approx.)
Diesel Torque Output:
650 lb-ft @ 1,600 RPM (approx.)
Gasoline Engine:
5.4L Triton V8 SOHC
Gasoline Power Output:
310 HP @ 5,000 RPM (approx.)
Gasoline Torque Output:
395 lb-ft @ 3,500 RPM (approx.)
Gasoline Engine:
6.8L Triton V10 SOHC
Gasoline Power Output:
362 HP @ 4,750 RPM (approx.)
Gasoline Torque Output:
457 lb-ft @ 3,250 RPM (approx.)
Diesel Fuel System:
Common Rail Diesel Injection (CRDI), High-Pressure Fuel Pump (HPFP), Diesel Particulate Filter (DPF), Selective Catalytic Reduction (SCR) with Diesel Exhaust Fluid (DEF).
Gasoline Fuel System:
Electronic Fuel Injection (EFI), Sequential Fuel Injection.
Transmission Standard:
6R140 TorqShift 6-Speed Automatic (standard on most models)
Transmission Optional:
ZF6-650 6-Speed Manual (available on select configurations)
Automatic Transmission Features:
Selectable Tow/Haul mode, electronic shift control, integrated transmission temperature gauge.
Automatic Transmission Fluid:
Mercon LV (Manual specifies Motorcraft ZD-10 or equivalent)
Manual Transmission Fluid:
Motorcraft SAE 75W-90 Synthetic Gear Lubricant (GL-5)
Wheelbase Options:
137.1" (Regular Cab), 153.1" (SuperCab), 172.4" (Crew Cab)
Bed Length Options:
6.75 ft (short box), 8.0 ft (long box)
Gvwr Range:
9,900 - 12,500 lbs (depending on configuration)
Curb Weight Range:
6,000 - 7,500 lbs (approx.)
Max Conventional Towing:
Up to 11,700 lbs (approx.)
Max 5Th Wheel Gooseneck Towing:
Up to 21,600 lbs (approx.)
Max Payload:
Up to 6,870 lbs (approx.)
Oil Change Interval Gasoline:
Every 5,000 - 7,500 miles or 6 months (depending on usage)
Oil Change Interval Diesel:
Every 5,000 - 10,000 miles or 6 months (depending on usage, oil quality, and DPF regeneration cycles)
Engine Air Filter Replacement:
Every 15,000 - 30,000 miles (or as needed based on driving conditions)
Fuel Filter Replacement Diesel:
Every 15,000 - 30,000 miles (critical for diesel engine health)
Engine Oil Gasoline 5W20:
API SN/SP, ILSAC GF-5, SAE 5W-20 (e.g., Motorcraft SAE 5W-20 Premium Synthetic Blend)
Engine Oil Gasoline 5W30:
API SN/SP, ILSAC GF-5, SAE 5W-30 (for towing or heavy loads, consult manual)
Engine Oil Diesel 15W40:
API CJ-4 or CK-4, ACEA E9, SAE 15W-40 (e.g., Motorcraft Power Stroke Diesel Engine Oil SAE 15W-40)
Coolant:
Ford Premium Gold Coolant (VC-7-B) or equivalent, 50/50 mixture with distilled water.
Brake Fluid:
DOT 3 (e.g., Motorcraft DOT 3 High Performance Synthetic Brake Fluid)
Diesel Particulate Filter Clogging:
Common issue with soot buildup if regeneration cycles are interrupted or insufficient; often requires manual or forced regeneration.
Fuel Injector Problems Diesel:
Some owners report premature injector failure, particularly with the 6.4L Power Stroke.
Rear Main Seal Leaks:
Reported on some diesel models, particularly under heavy use.
Transmission Cooler Leaks:
Concerns about potential leaks from the transmission cooler lines, especially with heavy towing.
Glow Plug Issues Diesel:
Glow plugs and their control module can fail, leading to hard starting in cold weather.