Ford F-53 Motorhome Chassis 1997 Owner's Manual

Table of Contents

Introduction ......................................................1

Instrumentation ................................................ 9

Controls and Features .................................. 21

Starting ............................................................. 37

Driving ............................................................. 45

Roadside Emergencies .................................. 77

Maintenance and Care ................................. 99

Capacities and Specifications ................... 147

Customer Assistance ................................... 155

Reporting Safety Defects ........................... 163

Maintenance Schedule and Record.......... 169

Index ............................................................... 203

Introduction

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

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

You are the focus of everything we do. Our

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

Continuous improvement is essential to our

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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.

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

Dealers and suppliers are our partners. We

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

Integrity is never compromised. Our conduct

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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.

R WARNING

Because subsequent owners require this important information as well, these publications should remain with the vehicle when it is sold.

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.

Your vehicle is covered by four types of warranties:

Basic Vehicle Warranty

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Extended Warranties on certain parts

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Emissions Warranties

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Noise Emissions Warranty Coverage;

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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.

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.

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.

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

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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.

Wheel lug nuts must be retightened to proper

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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

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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.

Instrumentation

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.

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.

R WARNING

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

Brake warning light symbols

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

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 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

This light comes on every time you turn the ignition to the ON or START position (engine off). The light should go off when the engine starts and the alternator begins to charge.

If the light stays on or comes on when the engine is running, have the electrical system checked as soon as possible.

Battery Voltage Gauge (Voltmeter)

This gauge shows you the battery voltage when the ignition key is in the ON position.

If you are running electrical accessories (when the engine is off, or idling at a low speed), the pointer may move toward the lower end of the normal band. If it stays outside the normal band area, have your vehicle’s electrical system checked as soon as it is safely possible.

If the battery is operating under cold weather conditions, the pointer may indicate in the upper range of the NORMAL band while the battery is charging. If you are running electrical accessories with the engine off or idling at a low speed, or the battery is not fully charged, the pointer may move toward the lower end of the NORMAL band.

If it stays outside the NORMAL band, have your vehicle’s electrical system checked as soon as it is safely possible.

Battery voltage gauge

Engine Oil Pressure Gauge

This gauge indicates the engine’s oil pressure, not the oil level. However, if your engine’s oil level is low, it could affect the oil pressure. With the engine running, the pointer should move into the NORMAL band. If the pointer drops below the NORMAL band while the engine is running, you have lost oil pressure and continued operation will cause severe engine damage.

If you lose engine oil pressure:

1. Pull off the road as soon as safely possible.

2. Shut off the engine immediately or severe engine damage could result.

3. Check the engine’s oil level, following the instructions on checking and adding engine oil. Refer to Engine oil in the Index. If you do not follow these instructions, you or others could be injured. To assure an accurate reading, your vehicle should be on level ground.

4. If the level is low, add only as much oil as necessary before you start the engine again. Do not overfill. Do not operate the engine if the pointer is below the NORMAL band, regardless of the oil level. Contact your nearest dealer for further service actions.

Engine oil pressure gauge

High Beam Light

This light comes on when the headlamps are turned on high beam or when you flash the lights.

High beam indicator light

Fuel Gauge

The fuel gauge displays approximately how much fuel is in the fuel tank only when the ignition switch is ON.

For a proper fuel gauge indication after adding fuel, the ignition switch should be in the OFF position while the vehicle is being refueled.

The fuel gauge indicator may vary slightly when the vehicle is in motion.

With ignition switch OFF, the fuel gauge indicator may drift from the ignition switch ON position.

Fuel gauge

Engine Coolant Temperature Gauge

This gauge tells you the temperature of the engine coolant, not the coolant level. If the coolant is not at its proper level or mixture, the gauge indicator will not be accurate.

The pointer moves from the C (cold) mark into the Normal band as the engine coolant warms up. It is acceptable for the pointer to fluctuate within the Normal band under normal driving conditions. Under certain driving conditions, such as heavy stop and go traffic or driving up hills in hot weather, the pointer may move to the top of the Normal band.

If, under any circumstances, the pointer moves above the NORMAL band, the engine coolant is overheating and continued operation may cause engine damage.

If your engine coolant overheats:

1. Pull off the road as soon as it is safely possible.

2. Turn off the engine. If you do not stop the engine as soon as safely possible, severe engine damage could result.

3. Let the engine cool. DO NOT REMOVE

COOLANT SYSTEM FILL CAP UNTIL THE ENGINE IS COOL.

4. Check the coolant level following the instructions on checking and adding coolant to your engine, see Engine Coolant in the Index. If you do not follow these instructions, you or others could be injured.

For instructions on checking and adding coolant to your engine, see Engine coolant in the Index. If you do not follow these instructions, you or others could be injured.

Engine coolant temperature gauge

Speedometer

The speedometer tells you how many miles (kilometers) per hour your vehicle is moving.

Your vehicle contains a speedometer which receives its input from a speed sensor. The speedometer is also used to provide a speed signal for correct operation of the vehicle’s Electronic Engine Control (EEC) module, electronic transmission, and speed control (if so equipped).

Speedometer

Odometer/Trip Odometer

The Liquid Crystal Display (LCD) odometer is a combination trip odometer and total odometer. The total odometer is normally displayed. To see the trip odometer, press and release the SELECT button on the upper right side of the speedometer. To zero out the trip odometer, press and release the RESET button on the upper left side of the speedometer while the trip odometer is displayed. If the trip odometer is displayed, press and release the SELECT button to return the display to the total odometer value.

Controls and Features

NOTE: The following section does not apply

to Stripped Chassis vehicles. See your Body Builder’s instructions for location and operation of controls for climate control systems, lamps and radio.

Turning On the Exterior Lights

To turn on your headlamps, parking lamps, marker lamps, license plate lamps and tail lamps, use the headlamp switch to the left of the steering column.

1. Pull the headlamp control knob toward you to the first position. Parking lamps, tail lamps and marker lamps are now on.

2. Pull the headlamp control knob toward you to the outer position. Headlamps are now on in addition to the above.

Headlamp switch

Daytime Running Light System

(Canadian vehicles only)

The Daytime Running Light (DRL) system turns the high beam headlamps on, with a reduced light output, when:

The headlamp system is in the OFF position,

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and The vehicle is running, and

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The vehicle has a fully released parking

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brake.

NOTE: You may notice that the lights flicker

when the vehicle is turned on or off. This is a normal condition.

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.

R WARNING

Always set the parking brake fully and make sure the gearshift is latched in P (Park). Turn off the ignition whenever you leave your vehicle.

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.

R WARNING

Always set the parking brake fully and make sure the gearshift is latched in P (Park). Turn off the ignition whenever you leave your vehicle.

R WARNING

Do not leave children, unreliable adults, or pets unattended in your vehicle.

You can use the turn signal lever on the left side of the steering column to:

operate the turn signals and cornering lamps

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Turn Signals

Move the lever up to signal a right turn. Move it down to signal a left turn. The corresponding indicator light in the instrument cluster will flash.

If the turn signal stays on after you turn, move the lever back to the center (off) position.

Turn signal lever and functions

If the turn indicator light in the instrument panel does not illuminate or remains on (doesn’t flash) when you signal a turn, the turn signaling system is malfunctioning. Have this condition corrected as soon as possible, but make sure that you use the accepted hand signals in the meantime.

High Beams

To turn on the high beams, turn the headlamp control knob to the headlamp ON position and push the turn signal lever away from you until it latches. When the high beams are ON, the high beam indicator light on the instrument panel comes on.

To turn off the high beams, pull the lever toward you until it latches. The high beam indicator light turns off.

Headlamp high beam switch and turn signal lever

Flashing the Lights

To flash the headlamps, pull the lever toward you for a moment and then release it. The headlamps will flash whether the headlamp knob is in the on or off position.

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