Manual Coverage
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Systems Covered
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Powertrain:
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Engine (gasoline and diesel), transmission (automatic and manual), drivetrain (4x4 systems, axles)
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Chassis:
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Suspension, steering, brakes (hydraulic, ABS), wheels and tires
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Electrical:
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Starting and charging system, lighting, instruments and gauges, body control modules, infotainment, diagnostic systems (OBD-II)
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Body:
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Exterior body panels, interior trim, doors, windows, seats, HVAC system
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Procedures Included
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Routine Maintenance:
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Oil changes, filter replacements, fluid checks and changes, lubrication
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Diagnostics Troubleshooting:
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Step-by-step diagnostic procedures, common fault finding, electrical troubleshooting charts
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Repair Rebuild:
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Complete disassembly, assembly, repair, and reinstallation of all major components and systems
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Special Procedures:
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Torque specifications, alignment procedures, specific tool requirements, diagnostic connector pinouts
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Engine Mechanical:
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Engine assembly, disassembly, cylinder head service, piston and rod installation, crankshaft service, timing component replacement.
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Transmission Mechanical:
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Transmission removal and installation, internal component inspection and repair, torque converter service, clutch service (for manual transmissions).
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Brake System:
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Brake pad and rotor replacement, caliper service, brake line repair, ABS component testing and replacement, parking brake adjustment.
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Suspension Steering:
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Front and rear suspension component replacement (shocks, springs, bushings), steering gear service, power steering system maintenance, wheel alignment procedures.
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Electrical Diagnostics:
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Diagnostic procedures for starting and charging systems, lighting circuits, instrument cluster issues, body electrical faults, diagnostic trouble code (DTC) interpretation and resolution.
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Technical Depth
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Diagnostic Capability:
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Advanced diagnostics, including detailed explanations of sensor operations, module functions, and troubleshooting strategies
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Rebuild Level:
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Complete engine and transmission rebuild procedures with detailed specifications
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Electrical Diagrams:
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Comprehensive wiring diagrams for all vehicle systems
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Specific Torques:
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Detailed torque specifications for all critical fasteners, including cylinder head bolts, main bearing caps, and suspension components.
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Diagnostic Charts:
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Component testing procedures, resistance values, voltage readings, and diagnostic flowcharts for various systems.
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Schematics:
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Detailed electrical schematics and vacuum diagrams for troubleshooting and repair.
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Engine Specifications
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Primary Engine Options
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Gasoline Engine:
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6.8L Triton V10 (362 hp @ 4,750 rpm, 457 lb-ft torque @ 3,250 rpm)
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Diesel Engine:
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6.0L Power Stroke V8 Turbo Diesel (325 hp @ 3,300 rpm, 560 lb-ft torque @ 2,000 rpm)
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Performance
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Towing Capacity Max:
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Up to 15,000 lbs (conventional), up to 21,500 lbs (5th-wheel/gooseneck) - varies by configuration
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Payload Capacity Max:
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Up to 5,700 lbs - varies by configuration
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Fuel System
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Diesel Injection Type:
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Common Rail Direct Injection (CRDI)
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Gasoline Fuel Delivery:
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Electronic Fuel Injection (EFI)
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Maintenance
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Service Intervals
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Oil Change Interval Gasoline:
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Every 5,000-7,500 miles or 6 months (whichever comes first), depending on usage and oil type
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Oil Change Interval Diesel:
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Every 5,000-7,500 miles or 6 months (whichever comes first), depending on usage and oil type, with diligent use of the tow/haul mode requiring more frequent changes.
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Fluid Specifications
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Engine Oil Gasoline:
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SAE 5W-20 (API Service SG or higher) for 6.8L V10
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Engine Oil Diesel:
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Ford Specification FSK-621 (e.g., 15W-40, or 5W-40 synthetic for cold weather) - meeting API CI-4 or CI-4 PLUS
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Transmission Fluid Auto:
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Mercon V (for TorqShift automatic)
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Coolant:
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Ford Premium Engine Coolant (Yellow) or equivalent, 50/50 mix with distilled water
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Known Issues
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Diesel Glow Plugs:
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Glow plug failures and FICM (Fuel Injection Control Module) issues are known on the 6.0L Power Stroke.
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Gasoline Spark Plugs:
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Erosion of spark plug tips and potential breakage on the 6.8L V10 can occur if not replaced per Ford's recommended interval or if wrong plugs are used.
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Suspension Wear:
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Front end component wear (ball joints, tie rods) is common on heavy-duty trucks subjected to heavy use and towing.
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