Ford F 53 Motorhome Chassis 1996 Owner's Manual

Table of Contents

Introductory Information................................ 1

Starting Your Motorhome............................... 9

Warning Lights and Gauges........................ 21

Instrument Panel Controls ........................... 33

Steering Column Controls............................ 35

Driving Your Motorhome............................. 47

Roadside Emergencies................................... 79

Customer Assistance ...................................... 91

Accessories...................................................... 103

Servicing Your Motorhome........................ 109

Index ................................................................ 209

Introductory Information

At Ford Motor Company, excellence is the
continuous commitment to achieve the best
result possible. It is dedication to learning what
you want, determination to develop the right
concept, and execution of that concept with care,
precision, and attention to detail. In short,
excellence means being the standard by which
others are judged.

Our Guiding Principles

Quality comes first. For your satisfaction, the

❑

quality of our products and services must be
our number one priority.

You are the focus of everything we do. Our

❑

work must be done with you in mind,
providing better products and services than
our competition.

Continuous improvement is essential to our

❑

success. We must strive for excellence in
everything we do: in our products — in their
safety and value — and in our services, our
human relations, our competitiveness, and
our profitability.

Employee involvement is our way of life.

❑

We are a team. We must treat one another
with trust and respect.

Dealers and suppliers are our partners. We

❑

must maintain mutually beneficial
relationships with dealers, suppliers, and our
other business associates.

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Integrity is never compromised. Our conduct

❑

worldwide must be pursued in a manner that
is socially responsible and commands respect
for its integrity and for its positive
contributions to society.

This Guide

This guide will familiarize you with operational,
maintenance and safety information about your
new vehicle. It is supplemented by a Warranty
Information Booklet. We urge you to read these
publications carefully and follow the
recommendations to help assure enjoyable and
safe operation of your new vehicle.

This chassis is designed to fulfill an infinite
variety of personal and business transportation
needs. Of necessity, a vehicle capable of such a
multitude of functions is much more than a
passenger vehicle and will therefore look, feel,
drive and function somewhat differently from a
passenger vehicle. These characteristics will also,
in part, be a result of the equipment you have
chosen for your particular vehicle application(s).
Therefore, it is very important that you read and
thoroughly familiarize yourself and others
operating your vehicle with this guide.

NOTES and WARNINGS

NOTES give you additional information about

the subject matter you are referencing.
WARNINGS remind you to be especially careful

in those areas where carelessness can cause
damage to your vehicle or personal injury to
yourself, your passengers or other people. Please
read all WARNINGS carefully.

2

RWARNING

Finding Information in This Guide

After you have read this guide once, you will
probably return to it when you have a specific
question or need additional information. To help
you find specific information quickly, you can
use the table of contents or the index.

This guide has a table of contents at the
beginning of the book to show chapter titles.

To use the Index, turn to the back of the book
and search in the alphabetical listing for the
word that best describes the information you
need. If the word you chose is not listed, think
of other related words and look them up. We
have designed the Index so that you can find
information under a technical term.

Canadian Owners — French Version

French Owner Guides can be obtained from your
dealer or by writing to Ford Motor Company of
Canada, Limited, Service Publications, P.O. Box
1580, Station B, Mississauga, Ontario L4Y 4G3.

Record Booklet

The Maintenance Schedule and Record booklet lists
the services that are most important for keeping
your vehicle in good condition. A record log is
also provided to help you keep track of all
services performed.

3

Your vehicle is covered by four types of
warranties:

Basic Vehicle Warranty

❑

Extended Warranties on certain parts

❑

Emissions Warranties

❑

Noise Emissions Warranty Coverage;

❑

applicable only on vehicles over 10,000 GVW
— Gross Vehicle Weight — in pounds.

Read your Warranty Information Booklet carefully
to find out about your vehicle’s warranties and
your basic rights and responsibilities.

If you lose your Warranty Information Booklet, you
can get a new one free of charge. Contact any
Ford or Lincoln-Mercury dealer, or refer to the
addresses and phone numbers on the first page
of this owner guide.

Buying a Ford Extended Service Plan

If you bought your vehicle in the U.S., you can
buy a Ford Extended Service Plan for your
vehicle. This optional contract provides service
protection for a longer period of time than the
basic warranty that comes with your vehicle.

You do not have to buy this option when you
buy your vehicle. However, your option to
purchase the Ford Extended Service Plan runs
out after 18 months or 18,000 miles. See your
dealer for more details about the Ford Extended
Service Plan.

If you purchased a Canadian vehicle and did not
take advantage of the Ford Extended Service
Plan at the time of purchase, you may still be
eligible. See your dealer for the details.

4

The Ford F-Super Duty Motorhome Chassis is
not suitable for producing ambulances or school
buses. In addition, Ford urges manufacturers to
follow the recommendations of the Ford

Incomplete Vehicle Manual and the Ford Truck
Body Builder’s Layout Book (and other

pertinent supplements).

Number (VIN)

Your Vehicle Identification Number (VIN) is the
same as the warranty number that appears on
your owner card. You should include this
number any time you write to Ford Motor
Company about your vehicle.

5

The Vehicle Identification (VIN) is stamped on a
metal tag attached to the chassis front end
structure. It is visible from outside the vehicle
under the hood.

Safety Compliance Certification Label

You’ll also find the VIN and other important
information on the Safety Compliance
Certification Label. It is required by the National
Highway Traffic Safety Administration and is
made of special material. If someone tampers
with it, it will be destroyed and/or a destruction
pattern will appear.

The label contains the name of the manufacturer,
the month and year of manufacture, the
certification statement and the Vehicle
Identification Number. The label also contains
Gross Vehicle Weight Rating and Gross Axle
Weight Ratings, wheel and tire data and
information codes for additional vehicle data.
For further information about the Safety
Compliance Certification Label and the
information contained on it, refer to the Index.

Incomplete Vehicles

On completed derivations of incomplete vehicles,
the Safety Compliance Certification Label is
affixed at a location determined by a subsequent
stage manufacturer of the completed vehicle. In
these cases the completed vehicle is
manufactured in two (or more) stages by two (or
more) separate manufacturers, with the
manufacture of the completed vehicle occurring
at a later date than the manufacture of the
incomplete vehicle. Consequently, the model
year of the completed vehicle may be later than
the model year of its chassis.

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Federal Highway Administration
Regulation

Regulations such as those issued by the Federal
Highway Administration or issued pursuant to
the Occupational Safety and Health Act (OSHA),
and/or state and local laws and regulations may
require additional equipment for the way you
intend to use the vehicle. It is the responsibility
of the registered owner to determine the
applicability of such laws and regulations to
your intended use for the vehicle, and to
arrange for the installation of required
equipment. Your Ford dealer has information
about the availability of many items of
equipment which may be ordered for your
vehicle.

Your new vehicle goes through an adjustment or
break-in period during the first 1,000 miles
(1,600 km) that you drive it. During the break-in
period, you need to pay careful attention to how
you drive your vehicle.

Avoid sudden stops. Because your vehicle

❑

has new brake linings, you should take these
steps:

— Watch traffic carefully so that you can

anticipate when to stop.
— Begin braking well in advance.
— Apply the brakes gradually.

The break-in period for new brake linings
lasts for 100 miles (160 km) of city driving or
1,000 miles (1,600 km) of highway driving.

7

Wheel lug nuts must be retightened to proper

❑

torque specifications at 500 miles/800 km of
new vehicle operation. Proper torque
specifications are provided in this guide. Also
retighten to proper torque specification at 500
miles/800 km after any wheel change or any
other time the wheel lug nuts have been
loosened.

Use only the type of engine oil that Ford

❑

recommends. Don’t add anti-friction
compounds or special break-in oils during the
first few thousand miles of operation. These
additives may prevent piston ring seating.

8

Starting Your Motorhome

Understanding the Positions of the Ignition

The positions of the key in the ignition lock cylinder.

ON allows you to test your vehicle’s warning
lights (except the brake system warning light) to
make sure they work before you start the
engine. The key returns to the ON position once
the engine is started and remains in this position
while the engine runs.

START cranks the engine. Release the key once
the engine starts so that you do not damage the
starter. The key should return to ON when you
release it. The START position also allows you
to test the brake warning light.

OFF allows you to shut off the engine and all
accessories without locking the steering wheel or
the automatic transmission gearshift lever.

LOCK locks the steering wheel. It also locks the
gearshift.

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RWARNING

Always set the parking brake fully and
make sure that the gearshift is securely
latched in P (Park).

LOCK is the only position that allows you to
remove the key. The LOCK feature helps to
protect your vehicle from theft.

If the key is stuck in the LOCK position, move
the steering wheel left or right until the key
turns freely.

ACCESSORY allows some of your vehicle’s
electrical accessories such as the radio and the
windshield wipers to operate while the engine is
not running.

Removing the Key From the Ignition

Procedures for removing your key from the
ignition are as follows:

Your vehicle’s gearshift lever is mounted on
the column:

1. Put the gearshift in P (Park).

2. Set the parking brake fully before removing
your foot from the service brake. (This will
avoid “binding” or “loading” the park gear
if you park on a grade.)

3. Turn the ignition key to LOCK.

4. Remove the key.

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RWARNING

Always set the parking brake fully and
make sure that the gearshift is securely
latched in P (Park).

RWARNING

Do not leave children, unreliable adults,
or pets alone in your vehicle. They could
accidentally injure themselves or others
through inadvertent operation of the
vehicle. Further, on hot, sunny days,
temperatures in a closed vehicle could
quickly become high enough to cause
severe and possibly fatal injuries to
people as well as animals.

Climate conditions and other factors play a large
part in deciding how you should go about
starting your vehicle. Read all the starting
instructions carefully, so you’ll be aware of these
factors when you start your vehicle.

When starting a fuel-injected engine, the most

important thing to remember is to avoid
pressing down on the accelerator before or
during starting. See Starting Your Engine in this

chapter for details about when to use the
accelerator while you start your vehicle.

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Preparing to Start Your Vehicle

RWARNING

Do not start your vehicle in a closed
garage or other enclosed area. Never sit in
a stopped vehicle for more than a short
period of time with the engine running.
Exhaust fumes are toxic. See Guarding
Against Exhaust Fumes in this chapter for
more instructions.

Before you start your vehicle, do the following:

1. Make sure you and all your passengers
buckle your safety belts.

2. Make sure the headlamps and other
accessories are turned off when starting.

3. Make sure that the gearshift is in P (Park)
and the parking brake is set before you turn
the key.

Starting Your Engine

To start your engine:

1. Follow the steps under Preparing to Start
Your Vehicle at the beginning of this section.

2. Turn the ignition key to the ON position.

3. DO NOT depress the accelerator pedal when
starting your engine. DO NOT use the
accelerator while the vehicle is parked.

4. Turn the key to the START position
(cranking) until the engine starts. Allow the
key to return to the ON position after the
engine has started.

rotate the steering wheel slightly because it
may be binding.

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For a cold engine:

At temperatures 10˚F (-12˚C) and below: If

❑

the engine does not start in fifteen (15)
seconds on the first try, turn the key to OFF,

wait approximately ten (10) seconds so you
do not flood the engine, then try again.

At temperatures above 10˚F (-12˚C): If the

❑

engine does not start in five (5) seconds on
the first try, turn the key to OFF, wait
approximately ten (10) seconds so you do not
flood the engine, then try again.

Do not hold the key in the START position

❑

for more than fifteen (15) seconds at a time.

For a warm engine:

Do not hold the key in the START position

❑

for more than five (5) seconds at a time. If
the engine does not start within five (5)
seconds on the first try, turn the key to the
OFF position. Wait a few seconds after the
starter stops, then try again.

Whenever you start your vehicle, release the key
as soon as the engine starts. Excessive cranking
could damage the starter or flood the engine.

After you start the engine, let it idle for a few
seconds. Keep your foot on the brake pedal and
put the gearshift lever in gear. Release the
parking brake. Slowly release the brake pedal
and drive away in the normal manner.

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NOTE: Your vehicle is equipped with a

brake-shift interlock feature. This
feature prevents you from shifting
from P (Park) unless you have the
brake pedal depressed. (The ignition
must be in the ON position.) If you
cannot shift from P (Park) with the
brake pedal depressed:

1. Apply the parking brake.

2. Remove the key.

3. Insert the key and rotate one position
clockwise (ignition in the OFF position).

4. Apply the brake pedal and shift to N
(Neutral). (If the vehicle is shifted to P
(Park), you must repeat the previous steps.)

5. Start the vehicle.

If you need to shift out of P (Park) by using the
alternate procedure described above, it is
possible that a fuse has blown and that your
brakelamps may also not be functional. Please
refer to the chapter titled Servicing Your
Motorhome in this Owner Guide for instructions
on checking and replacing fuses.

RWARNING

DO NOT DRIVE YOUR VEHICLE UNTIL
YOU VERIFY THAT THE BRAKELAMPS
ARE WORKING.

For cold or warm engines:

If the engine still does not start after two
attempts:

1. Turn the ignition key to the OFF position.

2. Press the accelerator all the way to the floor
and hold it.

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3. Turn the ignition key to the START position.

4. Release the ignition key when the engine
starts.

5. Release the accelerator gradually as the
engine speeds up. Then drive away in the
normal manner.

If the engine still does not start, the fuel pump
shut-off switch may have been triggered. For
directions on how to reset the switch see Fuel
Pump Shut-Off Switch later in this chapter.

NOTE: When turning the ignition key from

the “OFF” to the “RUN” position, a
subtle humming may be heard for up
to three seconds. This is the normal
sound of an electronically controlled
fuel pump, and indicates the operation
or pre-pressurizing the EFI system for
starting.

If the engine idle speed does not slow down
automatically, do not allow your vehicle to idle
for more than 10 minutes. Have the vehicle
checked.

RWARNING

Extended idling at high engine speeds can
produce very high temperatures in the
engine and exhaust system, creating the
risk of fire or other damage.

RWARNING

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.

15

Not Start or Does Not Start After
a Collision

Fuel Pump Shut-off Switch

If the engine cranks but does not start or does
not start after a collision, the fuel pump shut-off
switch may have been triggered. The shut-off
switch is a device intended to stop the fuel
pump when your vehicle has been involved in a
substantial jolt.

Once the shut-off switch is triggered, you must
reset the switch by hand before you can start
your vehicle.

Fuel pump shut-off switch location

RWARNING

If you see or smell fuel, do not reset the
switch or try to start your vehicle. Have
all the passengers get out of the vehicle
and call the local fire department or a
towing service.

16

If your engine cranks but does not start after a
collision or substantial jolt:

1. Turn the ignition key to the OFF position.

2. Check under the vehicle for leaking fuel.

3. If you do not see or smell fuel, push the red
reset button down. If the button is already
set, you may have a different mechanical
problem.

4. Turn the ignition key to RUN for a few
seconds, then turn it OFF. (Do not start the
engine.)

5. Check under the vehicle again for leaking
fuel. If you see or smell fuel, do not start
your vehicle again. If you do not see or
smell fuel, you can try to start your vehicle
again.

6. Check all vehicle warning lights before
driving your vehicle.

Reset button for fuel pump shut-off switch

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Guarding Against Exhaust Fumes

Carbon monoxide, although colorless and
odorless, is present in exhaust fumes. Take
precautions to avoid its dangerous effects.

RWARNING

Do not start your vehicle in a closed
garage or other enclosed area. Never sit in
a stopped vehicle for more than a short
period of time with the engine running.
Exhaust fumes are toxic. See Guarding
Against Exhaust Fumes in this chapter for
more instructions.

RWARNING

If you smell exhaust fumes inside your
vehicle, have your dealer inspect your
vehicle immediately. Do not drive if you
smell exhaust fumes.

Have the exhaust and body ventilation systems
checked whenever:

your vehicle is raised for service

❑

the sound of the exhaust system changes

❑

your vehicle has been damaged in a collision

❑

Improve your ventilation by keeping all air inlet
vents clear of snow, leaves, and other debris.

If the engine is idling while you are stopped in
an open area for long periods of time, open the
windows at least one inch (2.5 cm). Also, adjust
the heating or air conditioning to bring in
outside air.

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HEATING — Set fan speed at MEDIUM or

❑

HIGH, the function selector knob on VENT,
FLOOR, FLR DEF or DEFROST symbol and
the temperature control knob on any desired
position.

AIR CONDITIONING — Set the fan speed at

❑

MEDIUM or HIGH, the function selector
lever on NORM or VENT and the
temperature control knob on any desired
position.

TAPPET NOISE

It is normal for the oil to drain down from the
hydraulic tappets in your engine during
extended shutdown periods (overnight). As a
result, these tappets may clatter for a few
seconds after the engine starts until oil pressure
builds up. This momentary start-up noise is
normal and is not harmful to engine operation.

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Notes

20

Warning Lights and Gauges

The instrument panel (dashboard) on your
vehicle is divided into several different sections.
The illustrations on the following pages show
the major parts of the instrument panel that are
described in this chapter. Some items shown
may not be on all vehicles.

In your vehicle, the warning lights and gauges
are grouped together on the instrument panel.
We call this grouping a cluster. Your vehicle has
a mechanical cluster.

21

22

Mechanical/stripped chassis cluster

The following warning lights and gauges are on
the mechanical cluster. All of the warning lights
and gauges alert you to possible problems with
your vehicle. Some of the lights listed are
optional. The following sections detail what each
of these indicators means.

Brake System Warning Light

The warning light for the brakes can show two
things — that the parking brake is not fully
released, or that the brake fluid level is low in
the master cylinder reservoir. If the fluid level is
low, the brake system should be checked by
your dealer or a qualified service technician.

This light comes on when you turn the ignition
key to START to verify that the indicator bulb is
working. If the light stays on or comes on after
you have released the parking brake fully, have
the hydraulic brake system serviced.

RWARNING

The BRAKE light indicates that the brakes
may not be working properly. Have the
brakes checked immediately.

Brake warning light symbols

23

Safety Belt Warning Light

The warning light reminds you to fasten your
safety belt. Each time the ignition is turned to
ON, the warning light comes on for four to
eight seconds to remind you to fasten your
safety belt.

Safety belt warning light symbol

Check Engine Warning Light

The Powertrain On-Board Diagnostic II (OBD II)
system consists of the hardware and software
necessary to monitor the operation of the
powertrain. The OBD II system is designed to
check the function of the vehicle’s powertrain
control system during normal operation. If an
emission problem is detected, the Check Engine
Warning Light (in the cluster) is turned on.

Check engine warning light symbol

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Modification or additions to the vehicle may
cause incorrect operation of the OBD II system.
Additions such as burglar alarms, cellular
phones, and CB radios must be carefully
installed. Do not install these devices by tapping
into or running wires close to powertrain control
system wires or components.

The light comes on briefly when you turn the
ignition key to ON, but it should turn off when
the engine starts. If the light does not come on
when you turn the ignition to ON or if it comes
on and stays on when you are driving, have
your vehicle serviced as soon as possible. This
indicates a possible problem with one of the
vehicle’s emission control systems. You do not
need to have your vehicle towed in.

If the light turns on and off at one (1) second
intervals while you are driving the vehicle, it
means that the engine is misfiring. If this
condition persists, damage could occur to the
engine or catalytic convertor. Have your vehicle
serviced at the first opportunity. You do not
need to have your vehicle towed in.

If the light turns on and off on rare occasions
while you are driving, it means that a
malfunction occurred and the condition corrected
itself.

An example of a condition which corrects itself
occurs when an engine running out of fuel
begins to misfire. In this case, the Check Engine
Warning Light may turn on and will then set a
Diagnostic Trouble Code indicating that the
engine was misfiring while the last of the fuel
was being consumed. After refueling, the Check
Engine Warning Light will turn off after the
vehicle has completed three consecutive warm
up cycles without a misfire condition occurring.
A warm up cycle consists of engine start from a

25

cold condition (engine at ambient temperature)
and running until the engine reaches normal
operating temperature.

On the fourth engine start up, the Check Engine
Warning Light will turn off as soon as the
engine begins to crank. It is not necessary to
have the engine serviced.

Under certain conditions, the Check Engine
Warning Light may come on if the fuel cap is
not properly installed. If the Check Engine
Warning Light comes on and you suspect that
the fuel cap is not properly installed, pull off the
road as soon as it is safely possible and turn off
the engine. Remove and replace the fuel cap,
making sure it is properly seated.

After completing the three consecutive warm up
cycles and on the fourth engine start up, the
Check Engine Warning Light should turn off. If
the light does not go off after the fourth engine
restart, have your vehicle serviced by your
dealer or a qualified technician.

Charging System Light

This light, shown as a battery symbol on your
cluster, indicates that your battery is not being
charged and that you need to have the electrical
system checked.

Charging system light

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