Ford E-250 (2009 year). Manual — part 19

• Driving on flat terrain offers improved fuel economy as compared to

driving on hilly terrain.

• Transmissions give their best fuel economy when operated in the top

cruise gear and with steady pressure on the gas pedal.

• Close windows for high speed driving.

EPA fuel economy estimates

Every new vehicle should have a window sticker containing EPA fuel
economy estimates. Contact your authorized dealer if the window sticker
is not supplied with your vehicle. The EPA fuel economy estimates
should be your guide for the fuel economy comparisons with other
vehicles. Your fuel economy may vary depending upon the method of
operation and conditions.

Note: Vehicles over 8,500 GVW (Gross Vehicle Weight) will not have fuel
economy information printed on the window sticker.

EMISSION CONTROL SYSTEM

Your vehicle is equipped with various emission control components and a
catalytic converter which will enable your vehicle to comply with
applicable exhaust emission standards. To make sure that the catalytic
converter and other emission control components continue to work
properly:
• Use only the specified fuel listed.
• Avoid running out of fuel.
• Do not turn off the ignition while your vehicle is moving, especially at

high speeds.

• Have the items listed in scheduled maintenance information

performed according to the specified schedule.

The scheduled maintenance items listed in scheduled maintenance
information are essential to the life and performance of your vehicle
and to its emissions system.

If other than Ford, Motorcraft or Ford-authorized parts are used for
maintenance replacements or for service of components affecting
emission control, such non-Ford parts should be equivalent to genuine
Ford Motor Company parts in performance and durability.

WARNING: Do not park, idle, or drive your vehicle in dry grass
or other dry ground cover. The emission system heats up the

engine compartment and exhaust system, which can start a fire.

Maintenance and Specifications

293

Illumination of the Service engine soon

indicator, charging system

warning light or the temperature warning light, fluid leaks, strange odors,
smoke or loss of engine power could indicate that the emission control
system is not working properly.

An improperly operating or damaged exhaust system may allow exhaust
to enter the vehicle. Have a damaged or improperly operating exhaust
system inspected and repaired immediately.

WARNING: Exhaust leaks may result in entry of harmful and
potentially lethal fumes into the passenger compartment.

Do not make any unauthorized changes to your vehicle or engine. By
law, vehicle owners and anyone who manufactures, repairs, services,
sells, leases, trades vehicles, or supervises a fleet of vehicles are not
permitted to intentionally remove an emission control device or prevent
it from working. Information about your vehicle’s emission system is on
the Vehicle Emission Control Information Decal located on or near the
engine. This decal also lists engine displacement.

On board diagnostics (OBD-II)

Your vehicle is equipped with a computer that monitors the engine’s
emission control system. This system is commonly known as the On
Board Diagnostics System (OBD-II). The OBD-II system protects the
environment by ensuring that your vehicle continues to meet
government emission standards. The OBD-II system also assists your
authorized dealer in properly servicing your vehicle. When the Service
engine soon

indicator illuminates, the OBD-II system has detected

a malfunction. Temporary malfunctions may cause the Service engine
soon

indicator to illuminate. Examples are:

1. The vehicle has run out of fuel—the engine may misfire or run poorly.

2. Poor fuel quality or water in the fuel—the engine may misfire or run
poorly.

3. The fuel cap may not have been securely tightened. See Fuel filler
cap in this chapter.
4. Driving through deep water—the electrical system may be wet.

These temporary malfunctions can be corrected by filling the fuel tank
with good quality fuel, properly tightening the fuel cap or letting the

Maintenance and Specifications

294

electrical system dry out. After three driving cycles without these or any
other temporary malfunctions present, the Service engine soon
indicator should stay off the next time the engine is started. A driving
cycle consists of a cold engine startup followed by mixed city/highway
driving. No additional vehicle service is required.

If the Service engine soon

indicator remains on, have your vehicle

serviced at the first available opportunity. Although some malfunctions
detected by the OBD-II may not have symptoms that are apparent,
continued driving with the Service engine soon

indicator on can

result in increased emissions, lower fuel economy, reduced engine and
transmission smoothness, and lead to more costly repairs.

Readiness for Inspection/Maintenance (I/M) testing

Some state/provincial and local governments may have
Inspection/Maintenance (I/M) programs to inspect the emission control
equipment on your vehicle. Failure to pass this inspection could prevent
you from getting a vehicle registration. Your vehicle may not pass the I/M
test if the Service engine soon

indicator is on or not working

properly (bulb is burned out), or if the OBD-II system has determined
that some of the emission control systems have not been properly
checked. In this case, the vehicle is considered not ready for I/M testing.

If the Service engine soon

indicator is on or the bulb does not

work, the vehicle may need to be serviced. Refer to the On board
diagnostics (OBD-II) description in this chapter.

If the vehicle’s engine or transmission has just been serviced, or the
battery has recently run down or been replaced, the OBD-II system may
indicate that the vehicle is not ready for I/M testing. To determine if the
vehicle is ready for I/M testing, turn the ignition key to the on position
for 15 seconds without cranking the engine. If the Service engine
soon

indicator blinks eight times, it means that the vehicle is not

ready for I/M testing; if the Service engine soon

indicator stays on

solid, it means that the vehicle is ready for I/M testing.

The OBD-II system is designed to check the emission control system
during normal driving. A complete check may take several days. If the
vehicle is not ready for I/M testing, the following driving cycle consisting
of mixed city and highway driving may be performed:

15 minutes of steady driving on an expressway/highway followed by
20 minutes of stop-and-go driving with at least four 30-second idle
periods.

Maintenance and Specifications

295

Allow the vehicle to sit for at least eight hours without starting the
engine. Then, start the engine and complete the above driving cycle. The
engine must warm up to its normal operating temperature. Once started,
do not turn off the engine until the above driving cycle is complete. If
the vehicle is still not ready for I/M testing, the above driving cycle will
have to be repeated.

POWER STEERING FLUID

Check the power steering fluid.
Refer to the scheduled maintenance
guide for the service interval
schedules.

Check the fluid level when it is at ambient temperature, 20° – 80° F (-7°
– 25° C):

1. Check the fluid level on the dipstick. It should be between the arrows
in the FULL COLD range. Do not add fluid if the level is within this
range.

2. If the fluid level is low, start the engine.

3. While the engine idles, turn the steering wheel left and right several
times.

4. Turn the engine off.

FULL COLD

Maintenance and Specifications

296

WARNING: For E-350 and E-450 vehicles with the Hydro-Boost
Brake System, do not press the brake pedal after the engine has

been turned off. Pressing the brake pedal after the engine has been
turned off will give a false power steering fluid level reading.

5. Recheck the fluid level on the dipstick. Do not add fluid if the level is
between the arrows in the FULL COLD range.

6. If the fluid is low, add fluid in small amounts, continuously checking
the level until it reaches the FULL COLD range. Be sure to put the
dipstick back in the reservoir. Refer to Maintenance product
specifications and capacities in this chapter for the proper fluid type.

BRAKE FLUID
• E-150/E-350 Single Rear Wheel

• E-350/E-450 Dual Rear Wheel

The fluid level will drop slowly as the brakes wear, and will rise when the
brake components are replaced. Fluid levels between the “MIN” and
“MAX” lines are within the normal operating range; there is no need to
add fluid. If the fluid levels are outside of the normal operating range the
performance of the system could be compromised; seek service from
your authorized dealer immediately.

Maintenance and Specifications

297

DRIVELINE UNIVERSAL JOINT AND SLIP YOKE

Your vehicle may be equipped with universal joints that require
lubrication. Refer to the scheduled maintenance information for
maintenance intervals. If the original universal joints are replaced with
universal joints equipped with grease fittings, lubrication will also be
necessary.

TRANSMISSION FLUID

Checking automatic transmission fluid (if equipped)

Refer to your scheduled maintenance information for scheduled
intervals for fluid checks and changes. Your transmission does not
consume fluid. However, the fluid level should be checked if the
transmission is not working properly, i.e., if the transmission slips or
shifts slowly or if you notice some sign of fluid leakage.

Automatic transmission fluid expands when warmed. To obtain an
accurate fluid check, drive the vehicle until it is at normal operating
temperature (approximately 20 miles [30 km]). If your vehicle has been
operated for an extended period at high speeds, in city traffic during hot
weather or pulling a trailer, the vehicle should be turned off for about
30 minutes to allow fluid to cool before checking.

1. Drive the vehicle 20 miles (30 km) or until it reaches normal operating
temperature.

2. Park the vehicle on a level surface and engage the parking brake.

3. With the parking brake engaged and your foot on the brake pedal,
start the engine and move the gearshift lever through all of the gear
ranges. Allow sufficient time for each gear to engage.

4. Latch the gearshift lever in P (Park) and leave the engine running.

5. Remove the dipstick, wiping it clean with a clean, dry lint free rag. If
necessary, refer to Identifying components in the engine compartment
in this chapter for the location of the dipstick.

6. Install the dipstick making sure it is fully seated in the filler tube.

7. Remove the dipstick and inspect the fluid level. The fluid should be in
the designated area for normal operating temperature or ambient
temperature.

Maintenance and Specifications

298

Low fluid level

Do not drive the vehicle if the fluid level is at the bottom of the dipstick
and the ambient temperature is above 50°F (10°C).

Correct fluid level

The transmission fluid should be checked at normal operating
temperature 150°F-170°F (66°C-77°C) on a level surface. The normal
operating temperature can be reached after approximately 20 miles
(30 km) of driving.

You can check the fluid without driving if the ambient temperature is
above 50°F (10°C). However, if fluid is added at this time, an overfill
condition could result when the vehicle reaches normal operating
temperature.

ADD

COLD

HOT

DO NOT ADD

Maintenance and Specifications

299

The transmission fluid should be in this range if at normal operating
temperature (150°F-170°F [66°C-77°C]).

The transmission fluid should be in this range if at ambient temperature
(50°F-95°F [10°C-35°C]).

ADD

COLD

HOT

DO NOT ADD

DON'T ADD IF IN CROSSHATCHED AREA • CHECK WHEN HOT

IDLING IN PARK

ADD

COLD

HOT

DO NOT ADD

Maintenance and Specifications

300

High fluid level

Fluid levels above the safe range may result in transmission failure.
An overfill condition of transmission fluid may cause shift and/or
engagement concerns and/or possible damage.
High fluid levels can be caused by an overheating condition.

Adjusting automatic transmission fluid levels

Before adding any fluid, make sure the correct type is used. The type of
fluid used is normally indicated on the dipstick. Refer to Maintenance
product specifications and capacities in this chapter.

Use of a non-approved automatic transmission fluid may cause
internal transmission component damage.
If necessary, add fluid in 1/2 pint (250 ml) increments through the filler
tube until the level is correct.

If an overfill occurs, excess fluid should be removed by an authorized
dealer.

DON'T ADD IF IN CROSSHATCHED AREA • CHECK WHEN HOT

IDLING IN PARK

ADD

COLD

HOT

DO NOT ADD

DON'T ADD IF IN CROSSHATCHED AREA • CHECK WHEN HOT

IDLING IN PARK

ADD

COLD

HOT

DO NOT ADD

Maintenance and Specifications

301

An overfill condition of transmission fluid may cause shift and/or
engagement concerns and/or possible damage.

Do not use supplemental transmission fluid additives, treatments or
cleaning agents. The use of these materials may affect transmission
operation and result in damage to internal transmission components.

Automatic transmission fluid filter

The Torqshift automatic
transmission is equipped with a
serviceable transmission fluid filter
located inside the transmission
bottom pan.

Refer to scheduled maintenance
information for service intervals for
automatic transmission fluid and
transmission filter.

For transmission filter maintenance,
see your authorized dealer.

AIR FILTER

Refer to scheduled maintenance information for the appropriate
intervals for changing the air filter element.

When changing the air filter element, use only the Motorcraft air filter
element listed. Refer to Motorcraft part numbers in this chapter.

WARNING: To reduce the risk of vehicle damage and/or
personal burn injuries do not start your engine with the air

cleaner removed and do not remove it while the engine is running.

Maintenance and Specifications

302

Changing the air filter element

1. Disconnect the fresh air inlet tube
from the radiator support.

2. Open the clamp that secures the
two halves of the air filter housing
together.

3. Carefully separate the two halves
of the air filter housing.

4. Remove the air filter element
from the housing.

5. Install a new air filter element. Be careful not to crimp the filter
element edges between the air filter housing. This could cause filter
damage and allow unfiltered air to enter the engine if not properly
seated.

6. Replace the two halves of the air filter housing and secure the clamp.

7. Connect the fresh air inlet tube to the radiator support.

Note: Failure to use the correct air filter element may result in severe
engine damage. The customer warranty may be void for any damage to
the engine if the correct air filter element is not used.

Maintenance and Specifications

303

MOTORCRAFT PART NUMBERS

Component

1

4.6L V8 engine

5.4L V8

engine

6.8L V10

engine

Air filter element

FA-1632

FA-1632

FA-1632

Battery- standard /

(auxiliary)

BXT-65-650 /

(BXT-65-750)

BXT-65-650 /

(BXT-65-750)

BXT-65-650 /

(BXT-65-750)

Oil filter

FL-820-S

FL-820-S

FL-820-S

PCV valve

2

Spark plugs

3

Torqshift automatic

transmission

internal bottom–pan

filter

4

—

FT-180

FT-180

1

Refer to the 6.0 and 6.4 Liter Power Stroke Direct Injection Turbo

2

The PCV valve is a critical emission component. It is one of the items

listed in scheduled maintenance information and is essential to the
life and performance of your vehicle and to its emissions system.

For PCV valve replacement, see your authorized dealer. Refer to
scheduled maintenance information for the appropriate intervals for
changing the PCV valve.

Replace the PCV valve with one that meets Ford material and
design specifications for your vehicle, such as a Motorcraft or
equivalent replacement part. The customer warranty may be void
for any damage to the emissions system if such a PCV valve is not
used.

3

For spark plug replacement, see your authorized dealer. Refer to

scheduled maintenance information for the appropriate intervals for
changing the spark plugs.

Replace the spark plugs with ones that meet Ford material and
design specifications for your vehicle, such as Motorcraft or
equivalent replacement parts. The customer warranty may be
void for any damage to the engine if such spark plugs are not
used.

4

Also available with 6.0L Diesel engine/TorqShift transmission.

Maintenance and Specifications

304

MAINTENANCE

PRODUCT

SPECIFICATIONS

AND

CAPACITIES

Item

Capacity

Ford

part

name

Ford

part

number

/

Ford

specification

Brake

fluid

Between

MIN

and

MAX

on

reservoir

Motorcraft

H

igh

Performance

DOT

3

Motor

V

ehicle

Brake

Fluid

PM-1-C

/

WSS-M6C62-A

o

r

WSS-M6C65-A1

Door

weatherstrips

—

Silicone

Spray

Lubricant

XL-6

/

ESR-M13P4-A

Hinges,

latches,

Striker

plates,

fuel

filler

door

hinge,

and

seat

tracks

—

Motorcraft

Multi-Purpose

Grease

XG-4

o

r

XL-5

/

ESB-M1C93-B

Lock

cylinders

—

Motorcraft

Penetrating

and

Lock

Lubricant

XL-1

/

None

Engine

coolant

4.6L

engine

23.8

quarts

(22.6L)

Motorcraft

Premium

Gold

Engine

Coolant

with

bittering

agent

(yellow-colored)

1

VC-7-B

/

WSS-M97B51-A1

Engine

coolant

4.6L

engine

with

aux

rear

heat

26.0

quarts

(24.6L)

Engine

coolant

5.4L

engine

28.8

quarts

(27.2L)

Engine

coolant

5.4L

engine

with

aux

rear

heat

30.8

quarts

(29.1L)

Engine

coolant

6.8L

engine

30.4

quarts

(28.8L)

Engine

coolant

6.8L

engine

with

aux

rear

heat

32.6

quarts

(30.8L)

Engine

coolant-diesel

engine

1

Refer

to

the

6.0L

and

6.4L

Power

Stroke

Direct

Injection

T

urbo

Diesel

Owner’

s

Guide

Supplement.

Maintenance and Specifications

305

Item

Capacity

Ford

part

name

Ford

part

number

/

Ford

specification

Cooling

system

stop

leak

pellets

—

Motorcraft

Cooling

System

Stop

Leak

Pellets

VC-6

/

WSS-M99B37-B6

Engine

oil

6

.0

quarts

(5.7L)

Motorcraft

SAE

5W

-20

Premium

Synthetic

B

lend

Motor

Oil

(US)

Motorcraft

SAE

5W

-20

Super

Premium

Motor

Oil

(Canada)

2

XO-5W20-QSP

(US)

CXO-5W20-

LSP12

(Canada)

/

WSS-M2C930-A

w

ith

API

Certification

Mark

Engine

oil-diesel

engine

Refer

to

the

6.0L

and

6.4L

Power

Stroke

Direct

Injection

T

urbo

Diesel

Owner’

s

Guide

Supplement.

Power

steering

fluid

Keep

in

FULL

range

on

dipstick

Motorcraft

MERCON

威

VA

T

F

XT

-5-QM

/

MERCON

威

V

Automatic

transmission

fluid

(4R75E)

13.9

quarts

(13.1L)

3

Motorcraft

MERCON

威

LV

AT

F

4

XT

-10-QL

V

/

MERCON

威

LV

Automatic

transmission

fluid

T

orqShift

(5–speed)

18.8

quarts

(17.7L)

3

Motorcraft

MERCON

威

LV

AT

F

4

XT

-10-QL

V

/

MERCON

威

LV

Limited

S

lip

axle

fluid

M60

(M248)

E-350

with

4.10

axle

ratio

5.9

p

ints

(2.8L)

5,7

SAE

75W

-140

Synthetic

Rear

Axle

Lubricant

6

XY

-75W140-QL

/

WSL-M2C192-A

Maintenance and Specifications

306

Item

Capacity

Ford

part

name

Ford

part

number

/

Ford

specification

Dana

Limited

S

lip

Axle

fluid

M60

(M248)

E–250/E–350

5.9

p

ints

(2.8L)

5,7

SAE

90

Hypoid

Gear

Oil

XY–90–GL

/

ESW

-M2C105-E

Dana

Limited

S

lip

Axle

fluid

M70FF

(M267FF)

E-350

6.6

p

ints

(3.1L)

7

Dana

Limited

S

lip

Axle

fluid

M70HD

(M273HD)

E-450

8.3

p

ints

(3.9L)

7

Dana

conventional

axle

fluid

M60

(M248)

E-350

with

4.10

axle

ratio

6.2

p

ints

(2.9L)

7

SAE

75W

-140

Synthetic

Rear

Axle

Lubricant

6

XY

-75W140-QL

/

WSL-M2C192-A

Dana

conventional

axle

fluid

M60

(M248)

E-150/E-350

6.2

p

ints

(2.9

L

)

7

SAE

80W

-90

Premium

Rear

Axle

Lubricant

XY

-80W90-QL

/

WSP-M2C197-A

Dana

conventional

axle

fluid

M70FF

(M267FF)

E-350

6.6

p

ints

(3.1L)

7

Dana

conventional

axle

fluid

M70HD

(M273HD)

E-450

8.3

p

ints

(3.9L)

7

W

indshield

washer

fluid

4.2

quarts

(4.0L)

Motorcraft

Premium

W

indshield

W

asher

Concentrate

ZC-32-A

/

WSB-M8B16-A2

Maintenance and Specifications

307

Item

Capacity

Ford

part

name

Ford

part

number

/

Ford

specification

Fuel

tank–all

regular

and

extended

length

vans

and

wagons

35.0

gallons

(132.4L)

——

Fuel

tank–138

inch

wheelbase

(except

E-Super

Duty)

40.0

gallons

(151.0L)

Fuel

tank–158

inch

wheelbase

(except

E-Super

Duty)

40.0

gallons

(151.0L)

8

Fuel

tank–176

inch

wheelbase

(except

E-Super

Duty)

40.0

gallons

(151.0L)

8

Fuel

tank–158

inch

and

176

inch

wheelbase

(E-Super

Duty)

55.0

gallons

(208.0L)

1

Add

the

coolant

type

originally

equipped

in

your

vehicle.

2

Use

of

synthetic

or

synthetic

blend

motor

oil

is

not

mandatory

.

Engine

oil

need

only

meet

the

requirements

o

f

Ford

specification

WSS-M2C930-A

and

the

API

Certification

mark.

3

Indicates

only

approximate

dry-fill

capacity

.

Some

applications

may

vary

based

on

cooler

size,

if

equipped

with

an

in-tank

cooler

,

if

equipped

with

an

oil

to

a

ir

cooler

and

if

equipped

with

a

remote

filter

assembly

.

The

amount

of

transmission

fluid

and

fluid

level

should

b

e

set

by

the

indication

o

n

the

d

ipstick’

s

normal

operating

range.

4

Automatic

transmissions

that

require

MERCON

威

L

V

should

only

use

MERCON

威

L

V

fluid.

Refer

to

scheduled

maintenance

information

to

determine

the

correct

service

interval.

Use

of

any

fluid

other

than

the

recommended

fluid

may

cause

transmission

damage.

5

Dana

limited-slip

axle

(M60)

requires

8

oz.

(228

ml)

o

f

Additive

Friction

Modifier

XL-3

o

r

equivalent

meeting

Ford

specification

EST

-M2C118-A.

6

If

your

vehicle’

s

rear

axle

is

filled

w

ith

a

synthetic

rear

axle

lubricant

it

is

considered

lubricated

for

life.

These

lubricants

d

o

not

need

to

be

checked

or

changed

unless

a

leak

is

suspected,

service

is

required

or

the

axle

assembly

has

been

submerged

in

water

.

The

axle

lubricant

should

b

e

changed

any

time

the

rear

axle

has

been

submerged

in

water

.

7

Fill

Dana

rear

axles

to

1/4

inch

to

9/16

inch

(6

mm

to

14

mm)

below

bottom

o

f

fill

hole.

8

Optional

fuel

tank

55.0

gallons

(208.0L).

Maintenance and Specifications

308