INTRODUCTION
Use this article to find specifications related to servicing and on-vehicle adjustments. This article may be used as a quick reference when you are familiar with proper adjustment procedures but need a specification.
BATTERY SPECIFICATIONS
| Application & Group | Amp Hour Rating |
|---|
| Aerostar, Bronco, Explorer & "F" Series |
| Standard BXT-65 | 650 |
| Optional BXT-65 | 850 |
| Ranger |
| Regular Cab 2.3, 2.9L & 3.0L BX-58C | N/A |
| Optional BXT-65 | 650 |
| Regular Cab 4.0L BXT-65 | 650 |
| Optional BXT-65 | 850 |
| Super Cab All Engines BXT-65 | 650 |
| Optional BXT-65 | 850 |
| "E" Series |
| Standard BXT-64A | N/A |
| Auxiliary BH-27A | N/A |
COOLING SYSTEM CAPACITIES
| Application | Qts. (L) |
|---|
| Aerostar, Explorer & Ranger |
| 2.3L: Automatic or Manual Transmission | 7.2 (6.8) |
| 2.9L |
| Automatic or Manual Transmission (1) | 7.2 (6.8) |
| Automatic or Manual Transmission (2) | 7.8 (7.4) |
| 3.0L |
| Automatic or Manual Transmission | 11.8 (11.2) |
| 4.0L |
| Automatic Transmission (2) (3) | 8.3 (7.9) |
| Automatic or Manual Transmission (1) | 7.8 (7.4) |
| Bronco & "F" Series |
| 4.9L |
| Automatic or Manual Transmission (1) | 13 (12) |
| Automatic Transmission (2) (5) | 15 (14) |
| Automatic Transmission (5) | 14 (13) |
| Manual Transmission (4) | 14 (13) |
| Manual Transmission (2) (3) | 15 (14) |
| 5.0L |
| Automatic Transmission (1) | 14 (13) |
| Automatic or Manual Transmission (2) | 14 (13) |
| Automatic or Manual Transmission (3) | 15 (14) |
| Manual Transmission (1) | 13 (12) |
| 5.8L |
| Automatic Transmission (1) | 16 (15) |
| Automatic or Manual Transmission (2) | 16 (15) |
| Automatic or Manual Transmission (3) | 17 (16) |
| Manual Transmission (1) | 15 (14) |
| 7.3L | (6) 29 (27) |
| 7.5L | 18 (17) |
| "E" Series |
| 4.9L |
| Automatic or Manual Transmission (1) | 15 (14) |
| Automatic or Manual Transmission (4) | 18 (17) |
| 5.0L |
| Automatic or Manual Transmission (1) (2) | 17.5 (16.6) |
| Automatic or Manual Transmission (3) | 18.5 (17.5) |
| 5.8L |
| Automatic or Manual Transmission (1) | 20 (19) |
| Automatic or Manual Transmission (4) | 21 (20) |
| 7.3L | (6) 31 (29) |
| 7.5L | 28 (26) |
| (1) With Standard Cooling. (2) With A/C. (3) With Super Cooling. (4) With A/C or Super Cooling. (5) With Standard or Super Cooling. (6) Include 5 quarts (4.7L) in reservoir bottle. |
| (1) | With Standard Cooling. |
| (4) | With A/C or Super Cooling. |
| (5) | With Standard or Super Cooling. |
| (6) | Include 5 quarts (4.7L) in reservoir bottle. |
COOLING SYSTEM CAPACITIES
ENGINE OIL CAPACITIES
| Application | (1) Qts. (L) |
|---|
| All Engines Except 3.0L & 7.3L | (2) 5.0 (4.7) |
| 3.0L | 4.5 (4.25) |
| 7.3L | 10.0 (9.5) |
| (1) Add 1/2 qt. if equipped with oil cooler. (2) "F" Series, 6 quarts (5.6L). |
| (1) | Add 1/2 qt. if equipped with oil cooler. |
| (2) | "F" Series, 6 quarts (5.6L). |
TRANSMISSION & TRANSFER CASE CAPACITIES
| Application | Specification | Quantity |
|---|
| Aerostar |
| A4LD Auto. | Mercon | 9.7 Qts. (9.2L) |
| E4WD Auto. | Mercon | 10.0 Qts. (9.5L) |
| 5-Speed Overdrive |
| (Mazda R-1) | Mercon | 5.6 Pts. (2.65L) |
| Transfer Case |
| (TC-28 Dana) | Mercon | 4.5 Qts. (4.3L) |
| Bronco |
| AOD Auto. | Mercon | 12.3 Qts. (11.6L) |
| C-6 Auto. (4X4) | Mercon | 13.5 Qts. (12.7L) |
| E4OD Auto. (4X2) | Mercon | 16.2 Qts. (15.3L) |
| 4-Speed |
| (Warner T-18) | SAE 80W-90 | 3.5 Qts. (3.3L) |
| 5-Speed Overdrive |
| (Mazda R-2) | Mercon | 3.8 Qts. (3.6L) |
| Transfer Case |
| (1356 Warner) | Mercon | 2.0 Qts. (1.9L) |
| Explorer |
| A4LD Auto. (4X2) | Mercon | 9.7 Qts. (9.2L) |
| A4LD Auto. (4X4) | Mercon | 10.0 Qts. (9.5L) |
| 5-Speed Overdrive |
| (Mazda R-1) | Mercon | 5.6 Pts. (2.65L) |
| Transfer Case |
| 13-54 Warner | Mercon | 2.5 Pts. (1.2L) |
| Ranger |
| A4LD Auto. (4X2) | Mercon | 9.7 Qts. (9.2L) |
| A4LD Auto. (4X4) | Mercon | 10.0 Qts. (9.5L) |
| 5-Speed Overdrive |
| (Mazda R-1) | Mercon | 5.6 Pts. (2.65L) |
| 5-Speed Overdrive |
| (Mitsubishi) | SAE 80W-85 | 4.8 Pts. (2.3L) |
| Transfer Case |
| 13-54 Warner | Mercon | 2.5 Pts. (1.2L) |
| "E" Series |
| AOD Auto. | Mercon | 12.3 Qts. (11.6L) |
| C-6 Auto. | Mercon | 12.0 Qts. (11.4L) |
| E4OD Auto. | Mercon | 15.7 Qts. (14.8L) |
| 5-Speed Overdrive |
| (ZF HD) | Mercon | 3.4 Qts. (3.2L) |
| "F" Series |
| AOD Auto. (4X2) | Mercon | 12.3 Qts. (11.6L) |
| C-6 Auto. (4X2) | Mercon | 12.0 Qts. (11.4L) |
| C-6 Auto. (4X4) | Mercon | 13.5 Qts. (12.7L) |
| E4OD Auto. (4X2) | Mercon | 15.7 Qts. (14.8L) |
| E4OD Auto. (4X4) | Mercon | 16.2 Qts. (15.3L) |
| 4-Speed |
| (Warner T-18) | SAE 80W-90 | 3.5 Qts. (3.3L) |
| 5-Speed Overdrive |
| (Mazda R-2) | Mercon | 3.8 Qts. (3.6L) |
| 5-Speed Overdrive |
| (ZF S5-42) | Mercon | 3.4 Qts. (3.2L) |
| Transfer Case |
| (1356 Warner) | Mercon | 2.0 Qts. (1.9L) |
TRANSMISSION & TRANSFER CASE CAPACITIES
DIFFERENTIAL FLUID CAPACITIES
| Application | Pts. (L) |
|---|
| Aerostar |
| Front | 2.2 (1.0) |
| Rear |
| 7.5" Ford (1) | (2) 3.5 (1.65) |
| 8.8" Ford (1) | (2) 5.0 (2.4) |
| Bronco |
| Front | 3.8 (1.8) |
| Rear (8.8" Ford (1) ) | (2) 5.5 (2.6) |
| Explorer |
| Front (Dana 35) | 3.5 (1.65) |
| Rear (8.8" Ford (1) ) | (2) 5.5 (2.6) |
| Ranger |
| Front (Dana 35) | 3.5 (1.65) |
| Rear (7.5" & 8.8" Ford) (1) | (2) 5.0 (2.4) |
| "E" Series: Rear |
| 8.8" Ford (1) | (2) 5.5 (2.6) |
| 9.75" Dana M60-1U | 6.3 (3.0) |
| 10.5" Dana M70-2U | 6.6 (3.1) |
| "F" Series |
| Front |
| Dana 44-IFS L.D. | 3.6 (1.7) |
| Dana 50-IFS H.D. | 3.8 (1.8) |
| Dana 60 Monobeam | 5.8 (2.8) |
| Rear |
| 8.8" Ford | 5.5 (2.6) |
| 10.25" Ford (3) | 7.5 (3.5) |
| 11.25" Dana 80 | 8.3 (3.9) |
| (1) Conventional and Traction-Lok. (2) Add 4 oz. Friction Modifier for Traction-Lok Axles. (3) Conventional and Traction-Lok, Semi and Full Float. |
| (1) | Conventional and Traction-Lok. |
| (2) | Add 4 oz. Friction Modifier for Traction-Lok Axles. |
| (3) | Conventional and Traction-Lok, Semi and Full Float. |
SERVICE INTERVALS & SPECIFICATIONS
| Component | Interval (Miles) |
|---|
| Air Filter | 30,000 |
| Cam Timing Belt | 60,000 |
| Coolant | 30,000 |
| Crankcase Ventilation Filter | 30,000 |
| Oil & Filter | 7500 |
| PCV Valve | 60,000 |
| Spark Plugs (Standard) | 30,000 |
| Spark Plugs (Platinum) | 60,000 |
| Spark Plug Wires | 60,000 |
| Transfer Case Oil | 60,000 |
| Transmission Oil |
| Automatic Transmission | 30,000 |
| Manual Transmission | 60,000 |
| Component | Interval (Miles) |
|---|
| Air Filter | 30,000 |
| Coolant | 30,000 |
| Oil & Filter | 5000 |
| Transfer Case Oil | 60,000 |
| Transmission Oil |
| Automatic Transmission | 30,000 |
| Manual Transmission | 60,000 |
REPLACEMENT INTERVALS - DIESEL ENGINES
| Application | New Belt: Lbs. (kg) | (1) Used Belt: Lbs. (kg) |
|---|
| 2.3L |
| Fixed | 150-190 (68-86) | 140-160 (64-73) |
| With Tensioner (2) | 150-190 (68-86) | 140-160 (64-73) |
| 2.9L | 120-160 (54-73) | 110-130 (50-59) |
| 3.0L |
| Fixed | 100-140 (45-64) | 80-100 (36-45) |
| With Tensioner (2) | 150-190 (68-86) | 140-160 (64-73) |
| 4.0L With Tensioner (2) | 108-132 (49-60) | 108-132 (49-60) |
| 4.9L With Tensioner (2) | (3) | (3) |
| 5.0L With Tensioner (2) | (4) | (4) |
| 5.8L With Tensioner (2) | (4) | (4) |
| 7.3L Except Ambulance |
| Vac. Pump W/ 3/8" Belt | 90-130 (41-59) | 65-85 (30-39) |
| Vac. Pump W/ 1/2" Belt | 110-150 (50-68) | 75-95 (34-43) |
| All Others W/ 1/2" Belt | 140-180 (64-82) | 95-115 (43-52) |
| 7.3L Ambulance |
| Alternator | 140-160 (64-73) | 140-160 (64-73) |
| Vac. Pump | 90-130 (41-59) | 65-85 (30-39) |
| A/C & P/S | 140-180 (64-82) | 95-115 (43-52) |
| 7.5L |
| With Tensioner (2) | (5) | (5) |
| Alt. & Air Pump | 160-200 (73-91) | 110-130 (50-59) |
| (1) Any belt operated for 10 minutes. (2) Tension is correct if tensioner is within indicator marks. (3) 90 lbs. (41 kg) minimum for vehicles with 60 and 75 amp alternators. 117 lbs. (53 kg) minimum for vehicles with 100 amp alternators. (4) 77 lbs. (35 kg) minimum for vehicles with 60 & 75 amp alternators. 111 lbs. (50 kg) minimum for vehicles with 100 amp alternators. (5) 94 lbs. (43 kg) minimum tension. |
| (1) | Any belt operated for 10 minutes. |
| (2) | Tension is correct if tensioner is within indicator marks. |
| (3) | 90 lbs. (41 kg) minimum for vehicles with 60 and 75 amp alternators. 117 lbs. (53 kg) minimum for vehicles with 100 amp alternators. |
| (4) | 77 lbs. (35 kg) minimum for vehicles with 60 & 75 amp alternators. 111 lbs. (50 kg) minimum for vehicles with 100 amp alternators. |
| (5) | 94 lbs. (43 kg) minimum tension. |
Scheme 1
Scheme 1: Drive Belt Routing (2.3L)
Scheme 2
Scheme 2: Drive Belt Routing (2.9L)
Scheme 3
Scheme 3: Drive Belt Routing (3.0L)
Scheme 4
Scheme 4: Drive Belt Routing (4.0L)
Scheme 5
Scheme 5: Drive Belt Routing (4.9L)
Scheme 6
Scheme 6: Drive Belt Routing (5.0L & 5.8L)
Scheme 7
Scheme 7: Drive Belt Routing (7.3L Diesel)
Scheme 8
Scheme 8: Drive Belt Routing (7.5L)
ENGINE COMPRESSION
Check engine compression at specified cranking speed with engine at normal operating temperature, all spark plugs removed (on dual plugs, remove exhaust side only) and throttle wide open. Ensure crankcase is full and oil is of correct viscosity. With compression gauge installed, use remote starter to crank engine.
Crank engine at least 5 revolutions, and record highest reading. Repeat procedure for all cylinders using approximately same number of revolutions. Lowest compression reading should not be less than 75 percent of highest compression reading. No cylinder compression reading should be less than 100 psi (7 kg/cm 2 ).
COMPRESSION RATIO SPECIFICATIONS - 4-CYLINDER
| Application | Compression Ratio |
|---|
| 2.3L | 9.5:1 |
COMPRESSION RATIO SPECIFICATIONS - 4-CYLINDER
COMPRESSION RATIO SPECIFICATIONS - 6-CYLINDER
| Application | Compression Ratio |
|---|
| 4.9L | 8.8:1 |
COMPRESSION RATIO SPECIFICATIONS - 6-CYLINDER
COMPRESSION RATIO SPECIFICATIONS - V6
| Application | Compression Ratio |
|---|
| 2.9L & 4.0L | 9.0:1 |
| 3.0L | 9.3:1 |
COMPRESSION RATIO SPECIFICATIONS - V6
COMPRESSION RATIO SPECIFICATIONS - V8
| Application | Compression Ratio |
|---|
| 5.0L | 9.0:1 |
| 5.8L | 8.8:1 |
| 7.3L (Diesel) | 21.5:1 |
| 7.5L | 8.0:1 |
COMPRESSION RATIO SPECIFICATIONS - V8
VALVE CLEARANCE
Note. On 2.9L models, valve clearance is set by turning adjusting screw an additional 1 1/2 turns past zero lash. On all other models, no valve adjustment is required as hydraulic valve lifters are used. If incorrect valve clearance is suspected, collapse lifter before checking clearance.
COLLAPSED VALVE LIFTER CLEARANCE - 4-CYLINDER
| Application | In. (mm) |
|---|
| 2.3L OHC | .035-.055 (.89-1.39) |
COLLAPSED VALVE LIFTER CLEARANCE - 4-CYLINDER
COLLAPSED VALVE LIFTER CLEARANCE - 6-CYLINDER
| Application | In. (mm) |
|---|
| 4.9L |
| Allowable | .100-.200 (2.54-5.10) |
| Desired | .125-.175 (3.18-4.45) |
COLLAPSED VALVE LIFTER CLEARANCE - 6-CYLINDER
COLLAPSED VALVE LIFTER CLEARANCE - V6
| Application | In. (mm) |
|---|
| 2.9L | (1) |
| 3.0L | .088-.189 (2.23-4.77) |
| 4.0L | (2) |
| (1) Valve clearance is set by turning adjusting screw an additional 1 1/2 turns past zero lash. (2) Information not available. |
| (1) | Valve clearance is set by turning adjusting screw an additional 1 1/2 turns past zero lash. |
| (2) | Information not available. |
COLLAPSED VALVE LIFTER CLEARANCE - V6
COLLAPSED VALVE LIFTER CLEARANCE - V8
| Application | In. (mm) |
|---|
| 5.0L |
| Allowable | .071-.193 (1.80-4.90) |
| Desired | .096-.165 (2.44-4.19) |
| 5.8L |
| Allowable | .098-.198 (2.48-5.03) |
| Desired | .123-.173 (3.12-4.39) |
| 7.3L (Diesel) | (1) .185 (4.70) |
| 7.5L |
| Allowable | .075-.175 (1.91-4.45) |
| Desired | .100-.150 (2.54-4.81) |
| (1) Maximum clearance value. |
| (1) | Maximum clearance value. |
COLLAPSED VALVE LIFTER CLEARANCE - V8
5.0L SPARK PLUG WIRE ROUTING
Note. Spark plug wire routing for 5.0L V8 engines must be correct. For additional information and illustrations, see 5.0L BUCK/JERK/MISS/SPARK KNOCK: INDUCTION CROSSFIRE .
IGNITION COIL RESISTANCE - 4-CYLINDER
| Application | Primary Ohms | Secondary Ohms |
|---|
| 2.3L DIS | .5 | (1) |
| (1) Information not available. |
| (1) | Information not available. |
IGNITION COIL RESISTANCE - 4-CYLINDER
IGNITION COIL RESISTANCE - 6-CYLINDER
| Application | Primary Ohms | Secondary Ohms |
|---|
| 4.9L TFI-IV | .8-1.6 | 8000-11,500 |
IGNITION COIL RESISTANCE - 6-CYLINDER
IGNITION COIL RESISTANCE - V6
| Application | Primary Ohms | Secondary Ohms |
|---|
| 2.9L & 3.0L TFI-IV | .8-1.6 | 8000-11,500 |
| 4.0L EDIS | .5 | (1) |
| (1) Information not available. |
| (1) | Information not available. |
IGNITION COIL RESISTANCE - V6
IGNITION COIL RESISTANCE - V8
| Application | Primary Ohms | Secondary Ohms |
|---|
| 5.0L & 5.8L TFI-IV | .8-1.6 | 8700-11,500 |
| 7.5L TFI-IV/(CBD) | .8-1.6 | 8700-11,500 |
IGNITION COIL RESISTANCE - V8
HIGH TENSION WIRE RESISTANCE
| Application | Ohms |
|---|
| DIS, EDIS & TFI-IV | 7000 Per Foot |
HIGH TENSION WIRE RESISTANCE
SPARK PLUGS
| Application | (1) Specification: In. (mm) |
|---|
| 2.3L | .044 (1.1) |
| 2.9L | .044 (1.1) |
| 3.0L | .044 (1.1) |
| 4.0L | .054 (1.3) |
| 4.9L | .044 (1.1) |
| 5.0L | .044 (1.1) |
| 5.8L | .044 (1.1) |
| 7.5L | .044 (1.1) |
| (1) If Vehicle Emissions Information decal contradicts spark plug gap specification in table, use information on decal. |
| (1) | If Vehicle Emissions Information decal contradicts spark plug gap specification in table, use information on decal. |
SPARK PLUG GAP SPECIFICATION
| Application | Motorcraft No. |
|---|
| 2.3L | AWSF-32C |
| 2.9L | AWSF-42C |
| 3.0L | AWSF-32P |
| 4.0L | AWSF-42PP |
| 4.9L | BSF-44C |
| 5.0L | ASF-42C |
| 5.8L | ASF-32C |
| 7.5L | ASF-44P |
Scheme 9
Scheme 9: 2.3L Firing Order & Timing Marks
2.3L Spark Plug Wire Routing. Scheme 10
Scheme 10: 2.3L Spark Plug Wire Routing
2.9L & 3.0L Firing Order & Timing Marks. Scheme 11
Scheme 11: 2.9L & 3.0L Firing Order & Timing Marks
4.0L Firing Order & Timing Marks. Scheme 12
Scheme 12: 4.0L Firing Order & Timing Marks
Scheme 13
Scheme 13: 4.0L Spark Plug Wire Routing
4.9L Firing Order & Timing Marks. Scheme 14
Scheme 14: 4.9L Firing Order & Timing Marks
5.0L & 7.5L Firing Order & Timing Marks. Scheme 15
Scheme 15: 5.0L & 7.5L Firing Order & Timing Marks
5.8L Firing Order & Timing Marks. Scheme 16
Scheme 16: 5.8L Firing Order & Timing Marks
7.3L Diesel Firing Order. Scheme 17
Scheme 17: 7.3L Diesel Firing Order
BASE IGNITION TIMING - 4-CYLINDER
| Application | Degrees BTDC @ RPM |
|---|
| 2.3L | Timing Not Adjustable |
BASE IGNITION TIMING - 4-CYLINDER
BASE IGNITION TIMING - 6-CYLINDER
| Application | Degrees BTDC @ RPM |
|---|
| 4.9L | 10 @ (1) |
| (1) Information not available. |
| (1) | Information not available. |
BASE IGNITION TIMING - 6-CYLINDER
BASE IGNITION TIMING - V6
| Application (1) | Degrees BTDC @ RPM |
|---|
| 2.9L |
| Automatic Transmission | 10 @ 800 |
| Manual Transmission | 10 @ 850 |
| 3.0L | 10 @ (2) |
| 4.0L | Timing Not Adjustable. |
| (1) With SPOUT in-line connector disconnected. (2) Information not available. |
| (1) | With SPOUT in-line connector disconnected. |
| (2) | Information not available. |
BASE IGNITION TIMING - V6
BASE IGNITION TIMING - V8
| Application | (1) Degrees BTDC @ RPM |
|---|
| 5.0L |
| Automatic Transmission | 10 @ 525-825 |
| Manual Transmission | 10 @ 550-850 |
| 5.8L |
| C6 Automatic Transmission | 10 @ 630-930 |
| E4OD Automatic Transmission | 10 @ 580-880 |
| Manual Transmission | 10 @ 580-880 |
| 7.5L | 10 @ 500-800 |
| (1) With SPOUT in-line connector disconnected. |
| (1) | With SPOUT in-line connector disconnected. |
BASE IGNITION TIMING - V8
Note. For 7.3L injection pump timing procedures, see ADJUSTMENTS article in the ENGINE PERFORMANCE Section.
DISTRIBUTOR SPECIFICATIONS
Note. All models use computed timing advance. No adjustment is possible.
FUEL PUMP
Note. Fuel pump performance is a measurement of fuel pressure and volume availability, not regulated fuel pressure.
| Application | Specification |
|---|
| Gasoline Engines |
| Pressure | (1) |
| Volume | 1.5 Pts. (.72L) In 30 Seconds |
| Diesel Engines |
| Pressure | (1) |
| Volume | 1 Pt. (.5L) In 30 Seconds |
| (1) For fuel pressure specifications, see FUEL PRESSURE SPECIFICATIONS article. |
IDLE SPEED & MIXTURE
Note. No idle mixture adjustments are possible. If engine performance is unsatisfactory, see TESTS W/CODES article in the ENGINE PERFORMANCE Section.
FAST IDLE SPEED
Note. Refer to underhood engine decal for engine fast idle RPM specification.
THROTTLE POSITION SENSOR/SWITCH
| Application | Idle | Wide Open Throttle |
|---|
| 2.3L, 2.9L (2) , 3.0L & 4.0L | 0.20 | 4.84 |
| 2.9L (3) & 4.9L | 0.34 | 4.84 |
| 5.0L, 5.8L & 7.5L | 0.34 | 4.84 |
| (1) Minimum and maximum specifications are given. (2) Vehicles equipped with mass airflow sensor only. (3) Except vehicles equipped with mass airflow sensor. |
| (1) | Minimum and maximum specifications are given. |
| (2) | Vehicles equipped with mass airflow sensor only. |
| (3) | Except vehicles equipped with mass airflow sensor. |
TPS VOLTAGE SPECIFICATIONS (1)
