Ford Low Cab Forward (Ford year). Manual — part 38

Change the air filter when the gauge
reads 25 inches (635 mm). After
installation of the new filter
element, reset the gauge by pressing
the reset button on top of the
gauge.

ENGINE AND SUBSYSTEM MAINTENANCE

Note: To prevent damage to the engine control module or any parts of
the electrical system, never spray-wash the parts directly.

For effective emissions control and low operating cost, it is important
that maintenance operations listed in this section be performed at the
specified periods or mileage intervals indicated (kilometers, miles, hours,
or months, whichever comes first).

Service intervals are based upon average operating conditions. Where
dusty, frequent start-and-stop or heavily laden operations are
encountered, more frequent servicing will be required.

As the vehicle owner, you are responsible for the performance of all
scheduled maintenance. The required maintenance operations may be
performed by the owner at a service establishment of the owner’s
choosing. Any replacement parts used for required maintenance services
or repairs should be genuine manufacturer service parts or equivalent in
quality and performance to genuine manufacturer service parts. Use of
inferior parts hinders operations of the engine and emissions controls
and can reduce engine life and/or jeopardize the warranty.

Receipts covering the performance of regular maintenance should be
retained in the event questions arise concerning maintenance. The
receipts should be transferred to each subsequent owner of the vehicle.

Catalytic converter

If your vehicle is equipped with a catalytic converter, it is important to
review the scheduled maintenance information to ensure proper
functioning of the catalytic converter. Also, take precautions not to
damage the catalytic converter when servicing your engine or storing
your vehicle. Do not blend waste oil with diesel fuel. Operate only on
ultra low sulfur diesel fuel (less than 15 parts per million) with a Cetane
value of 42 or higher.

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154

Air induction system

Once each year, perform a complete inspection of the air induction
system. In areas where road salt is used, the inspection consists of
disassembling the joints of each aluminum component and inspecting for
salt build-up and presence of chlorine that can cause aluminum particles
to flake off and enter the engine combustion chambers.

If evidence of corrosion is found (usually at the pipe connections), use a
wire brush to clean the inside of the pipes and inside the rubber hoses.

If the intake pipes are pitted at the joint ends, use RTV silicone to seal
the joints. Be certain that no excess material is on the inside of the pipes
that can be pulled into the engine. If the service condition of the pipes,
hoses or clamps is questionable, replace the defective part(s).

Be sure that prior to reassembly all dust and debris has been cleaned out
of the pipes and couplings with a clean, damp rag.

To reduce the risk of personal injury or death when performing
maintenance to any turbocharged engine with engine air inlet

piping disconnected, a turbocharger compressor air inlet protective
shield should be installed over the turbocharger air inlet.

CHASSIS-MOUNTED CHARGE AIR COOLER

The charge air cooler should be inspected daily. With the engine off,
visually inspect the charge air cooler core assembly for debris and
clogging of external fins. Prior to engine operation, remove any debris
blocking the core.
• Turbocharger-to-charge air cooler
• Charge air cooler-to-intake manifold pipe
• Mounting bracket
• Chassis-mounted charge air cooler core

Air intake piping inspection
• Check for accumulation of salt deposits (where applicable). If present,

disassemble and clean the complete air intake piping system. If the
intake piping is pitted, use RTV silicone to seal joints against leakage.

• Check for loose hoses and clamps.
• Check for ruptured or collapsed hoses.
• Check air filter housing for cracks.

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155

ELECTRICAL SYSTEM INSPECTIONS

Periodically inspect electrical connectors on the outside of the cab, on
the engine and frame for corrosion and tightness. Exposed terminals
such as the fuel sender, cranking motor, alternator and feed-through
studs should be cleaned and re-coated with a lubricant sealing grease
such as Motorcraft XG-3, or equivalent. This should include the ground
cable connector for batteries, engine and cab.

Accessory feed connections

Vehicle electrical systems are complex and often include electronic
components such as engine and transmission controls, instrument panels,
ABS, etc. While most systems operate on battery voltage (12 volts),
some systems can be as high as 90 volts or as low as five volts. Refer to
the Electrical Circuit Diagram Manuals, available from your vehicle’s
manufacturer, to ensure that any additional body lights and accessories
are connected to circuits that are both appropriate and not overloaded.
No modification should be made to any vehicle control system without
first contacting your dealer.

SUSPENSION INSPECTION

Periodically:
• Check condition of spring leaves for evidence of fatigue, bending or

breaks.

• Check condition of suspension mounting brackets and bushings.
• Check that torque rod mounting fasteners are tight.
• Check to be sure the suspension alignment is maintained at all time.
• Check U-bolts after the chassis has been operating under load for

1,000 miles (1,600 km) or six months, whichever comes first, the
U-Bolt nuts must be re-torqued. The U-Bolt nuts thereafter must be
re-torqued every 30,000 miles (48,000 km). The U-Bolt and nut
threads and seats should be cleaned and lubricated to ensure a “like
new” condition when re-torquing.

Note: See the U-Bolt Nut Torque chart in this chapter.

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156

U-BOLT NUT TORQUE

Axle type

U-bolt torque

Ft. lb.

N

•m

All

260–300

353–407

Spring U-bolt checks

Check U-bolt nuts and re-torque every 30,000 miles (48,000 km) after
initial 1,000 miles (1,600 km) re-torque. The U-bolt and nut threads and
seats should be cleaned and lubricated to ensure peak condition when
re-torqued.

FRAME AND TOW HOOKS

Your vehicles chassis is manufactured with frame rails of either mild
carbon steel, or HSLA steel. Each must be handled in a specific manner
to ensure maximum service life. Before attempting frame repair or
modification, consult the service manual or your dealer.

It is important, particularly on vehicles where the tow hooks are used
frequently to inspect the front and rear tow hooks for damage or a loose
mounting.

DRIVESHAFT SHAFT

At the regular lubrication interval, check the universal joints for any
evidence of wear or looseness. Should driveshaft vibrations occur, stop
the vehicle immediately to avoid possible hazardous consequences or
damage to other components.

REAR AXLE LUBRICANT

Refer to the scheduled maintenance information for rear axle
lubricant level checks and lubricant change intervals.

The rear axle may be filled with an optional synthetic lubricant which
allows the use of extended service intervals. A tag on the filler plug will
identify the use of synthetic lubricant.

Use only a lubricant that meets manufacturer specifications (refer to
Lubricant specifications in this chapter).

Use of a non-approved rear axle lubricant may cause internal axle
component damage.

Check your rear axle lubricant level using the following procedure:

1. Park the vehicle on level ground.

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157