Vehicle Class:
Heavy-duty commercial vehicle / Medium-duty truck
Target Audience:
Businesses requiring reliable work trucks for hauling, construction, delivery, etc.
Competitors:
Chevrolet Kodiak, GMC Topkick, Freightliner FL Series, International S-Series
Vehicle Durability:
Built for demanding commercial applications, known for robustness and longevity.
Customization:
Offered in various configurations (chassis cab, stake bed, box truck, etc.) to suit diverse business needs.
Engine Options:
Availability of powerful diesel engines designed for towing and continuous operation.
Primary Coverage:
Comprehensive Service and Repair
Additional Coverage:
Troubleshooting, Diagnostics, Maintenance, Component Overhaul
Estimated Page Count:
1500+
Type:
Factory Service Manual / Workshop Manual
Powertrain:
Engine mechanical, fuel system, ignition system, cooling system, lubrication system, exhaust system
Drivetrain:
Transmission (manual and automatic), drivetrain components (driveshafts, U-joints, axles)
Chassis:
Suspension (front and rear), steering system, braking system (hydraulic and air, where applicable)
Electrical:
12V and 24V electrical systems, charging system, starting system, lighting, instrumentation, body electronics, wiring diagrams
Body:
Body panels, doors, glass, interior trim, HVAC system, body hardware
Maintenance:
Scheduled maintenance, fluid changes, filter replacements, lubrication
Diagnostics:
Troubleshooting charts, diagnostic trouble codes (DTCs), component testing procedures
Repair:
Component removal and installation, overhaul procedures for major assemblies, specific repair techniques
Specifications:
Torque specifications, clearances, tolerances, electrical resistance values, pressure readings
Depth:
Expert-level, suitable for professional technicians and advanced DIYers
Detail Level:
Detailed step-by-step instructions, exploded views, service bulletins
Engine Family:
Ford/Navistar Power Stroke Diesel (various displacements)
Engine Type:
Turbocharged Direct Injection Diesel
Common Displacements:
7.3L (444 cubic inches), potentially 5.9L Cummins (for certain applications/conversions if specified)
Horsepower Range:
Approx. 210-275 hp (depending on specific engine and tune)
Torque Range:
Approx. 450-520 lb-ft (depending on specific engine and tune)
Injection System:
HEUI (Hydraulically Actuated Electronically Controlled Unit Injector) for Power Stroke
Oil Capacity:
15 quarts (check manual for exact capacity and specific engine)
Oil Type:
API CD, CE, or CF-4 rated diesel engine oil, SAE 15W-40 recommended (verify specific viscosity for ambient temperature)
Coolant Type:
E.L.C. (Extended Life Coolant) or equivalent, orange-colored ethylene glycol based coolant
Type:
Heavy-duty manual transmission (e.g., Eaton Fuller, Spicer, New Process Gear)
Type:
Heavy-duty automatic transmission (e.g., Allison MD Series, Ford/Caterpillar)
Manual Gears:
Typically 5, 6, 8, 9, 10, or 13-speed configurations
Automatic Gears:
Typically 4 or 6-speed configurations
Manual Transmission Fluid:
GL-4 or GL-5 gear oil, SAE 75W-90 or 80W-90 (verify specific type based on transmission model)
Automatic Transmission Fluid:
Mercon, Mercon V, or Allison C-4/TES 295 (verify specific type based on transmission model)
Classification:
Class 4-7 Medium Duty Truck
Wheelbase Options:
Highly variable, depending on application (e.g., 130-250 inches)
Cab Configurations:
Regular Cab, Crew Cab (potential)
Gvwr Range:
14,050 lbs - 33,000 lbs (Class 4-6 typical), up to 54,000 lbs (Class 7)
Gcwr Range:
Significantly higher than GVWR, dependent on powertrain and chassis rating
Crash Test Data:
N/A (Commercial vehicles are typically rated differently than passenger vehicles; focus is on structural integrity and driver protection)
Brakes:
Hydraulic disc brakes front, drum brakes rear; optional air brakes on heavier GVWR models
ABS:
Anti-lock Braking System (standard or optional depending on GVWR and year)
Airbags:
Driver airbag; Passenger airbag may be optional or not available on all configurations
Seatbelts:
Three-point seatbelts for outboard occupants
Radio System:
Basic AM/FM radio, potentially with cassette player. CD player might be an option on later models.
Speakers:
Typically 2 or 4 speakers, focused on functionality over audio fidelity.
Cruise Control:
Available as an option on many models.
Trailer Brake Controller:
Integrated or aftermarket trailer brake controllers are common for towing applications.
Phone Integration:
No integrated smartphone connectivity or Bluetooth for this era; aftermarket solutions would be required.
Oil Change Interval:
Every 5,000-10,000 miles or 6-12 months (diesel, depending on duty cycle and oil type - refer to specific manual)
Fuel Filter Replacement:
Every 15,000-30,000 miles (diesel, depending on fuel quality and conditions)
Air Filter Replacement:
Every 15,000-30,000 miles or as needed based on visual inspection
Coolant Flush:
Every 30,000-50,000 miles or 2-3 years (conventional coolant); Extended Life Coolant may extend this interval significantly.
Brake Fluid:
DOT 3 or DOT 4 (verify based on system, especially if air brakes are present)
Power Steering Fluid:
Ford ESW-M2C195-A or equivalent power steering fluid
Engine Components:
Potential for injector issues (HEUI systems), turbocharger wear, EGR valve problems (later models).
Transmission Wear:
Heavy-duty transmissions can experience wear with high mileage and improper fluid maintenance; clutch wear in manuals.
Electrical Gremlins:
Corrosion on connectors, aging wiring harnesses, and issues with body control modules can arise with age.
Frame And Suspension:
Rust on frame rails, wear in suspension bushings and ball joints due to heavy loads and use.
Ford Commercial:
Ford has a long history of producing commercial and heavy-duty vehicles, establishing a reputation for reliability and capability.
Louisville Lineup:
The 'Louisville' designation refers to Ford's line of medium-duty trucks, succeeding previous models and setting the stage for the F-650/F-750 series.
Manufacturing Plant:
Ford Kentucky Truck Plant, Louisville, Kentucky
Production Period:
The Louisville line was produced roughly from the mid-1980s to the early 2000s, with the 1996-1998 range being part of a significant generation.
