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2003 Ford F-550 Super Duty Pickup CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT Ford REPAIR SHOPS DON'T WANT YOU TO KNOW
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- A/C & Heater Service
- Brake Service
- Fuel Filter Replacement
- Driveline, U-Joint & CV Axles Replacement
- Starter & Alternator Replacement
- Radiator & Hose Replacement
A/C & HEATER SERVICE PROCEDURES FOR 2003 Ford F-550 Super Duty Pickup AUTOMOBILES
Air Bag System Precautions -> Ford Motor Co. -> Disarming -> 1990-91 -> 1990-92 -> 1991-92 -> 1992-93 -> 1992-94 -> 1992-96 -> 1993 -> 1993-94 -> 1993-95 -> 1994 -> 1994-95 -> 1994-97 -> 1995-2000 -> 1995-2004 -> 1995-96 -> 1995-97 -> 1995-98 -> 1996-97 -> 1996-99 -> 1997-2000 -> 1997-2001 -> 1997-2004 -> 1997-99 -> 1998 -> 1998-2000 -> 1998-2002 -> 1999-2000 -> 1999-2001 -> 1999-2002 -> 1999-2004 -> 2000 -> 2000-01 -> 2000-04 -> 2001-02 -> 2001-03 -> 2001-04 -> 2002-03 -> 2002-04 -> 2004 -> Aerostar & Bronco -> Aspire -> Aviator -> Blackwood, Expedition & Navigator -> Built After February 2002 -> Built Before March 2002 -> Capri -> Continental -> Contour & Mystique -> Cougar -> Crown Victoria, Grand Marquis & Marauder -> Econoline -> Escape -> Escort, Tracer & ZX2 -> Excursion -> Explorer & Mountaineer -> Explorer Sport & Sport Trac -> F Series -> Focus -> Freestar & Monterey -> Light Trucks & Vans -> LS -> Mark VII -> Mark VIII -> Mustang -> Passenger Cars -> Probe -> Ranger -> Sable & Taurus -> Tempo & Topaz -> Thunderbird -> Town Car -> Villager -> Windstar
Vehicle: 2003 Ford F-550 Super Duty Pickup 7.3 V8 DIESEL
Passenger Cars
Prior to disconnecting battery, record preset radio frequencies.
After the battery has been disconnected and connected again, abnormal drive conditions may be present while the powertrain control module relearns its adaptive strategy. The vehicle may need to be driven 10 miles or more to relearn the strategy.
Aspire
- Disconnect battery ground cable and isolate.
- Wait one minute for back-up power supply to deplete stored energy.
- Remove four driver's side air bag module mounting bolts.
- Disconnect driver's side air bag module...
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BRAKE SERVICE PROCEDURES FOR 2003 Ford F-550 Super Duty Pickup AUTOMOBILES
Hydraulic Brake Systems -> Description -> Bendix Hydro-Boost Brake Booster -> Bendix Hydro-Max Brake Booster -> Combination Valve -> Height Sensing Proportioning Valve -> Hydraulic Control Unit (HCU) -> Hydraulic Control Valves -> Integral Bypass Proportioning Valve -> Master Cylinder
Vehicle: 2003 Ford F-550 Super Duty Pickup 7.3 V8 DIESEL
Master Cylinder
The master cylinder consists primarily of a hydraulic cylinder, primary and secondary hydraulic pistons and a single or dual chamber fluid reservoir. The front brakes are connected to the primary outlet port(s) and are actuated by the primary piston assembly. The rear brakes are connected to the secondary outlet port and are actuated by the secondary piston assembly.
Hydraulic Control Valves
Combination Valve
This multi-function hydraulic control unit consists primarily of a pressure differential valve, brake lamp warning switch and a proportioning valve. A pressure diff...
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FUEL FILTER REPLACEMENT PROCEDURES FOR 2003 Ford F-550 Super Duty Pickup AUTOMOBILES
Ford Motor Co. Light Trucks, SUVs & Vans -> Fuel Filter Scheduled Maintenance -> 1999-06 F250-550 Super Duty w/Diesel Engine -> Normal Service -> Severe Service
Vehicle: 2003 Ford F-550 Super Duty Pickup 7.3 V8 DIESEL
Normal Service
Repl...
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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR 2003 Ford F-550 Super Duty Pickup AUTOMOBILES
DRIVESHAFT, Replace -> Front -> One Piece Driveshaft -> Rear -> Three Piece Driveshaft -> Two Piece Driveshaft
Vehicle: 2003 Ford F-550 Super Duty Pickup 6.0 V8 DIESEL
Front
- Raise and support the vehicle.
- Index-mark front driveshaft to front axle flange and at transfer case flange.
- Remove and discard bolts and U-joint retainers.
- Remove and discard four flange bolts.
- Compress and separate front driveshaft from front axle, then separate driveshaft from transfer case. Wrap electrical tape around the bearing cups to prevent them from falling off the U-joint spider.
- Reverse procedure to install, noting the following:
- Torque front propeller shaft flange bolts to 82 ft. lbs., if equipped.
- Torque front propeller shaft U-joint retainer bolts to 26 ft. lbs.
...
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STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR 2003 Ford F-550 Super Duty Pickup AUTOMOBILES
Starter, Replace
Vehicle: 2003 Ford F-550 Super Duty Pickup 6.8 V10 GAS
- Disconnect battery ground cable.
- Raise and support vehicle, if required
- Disconnect electrical connector or solenoid relay wire from starter motor.
- Remove starter motor attaching bolts and starter motor ...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 2003 Ford F-550 Super Duty Pickup AUTOMOBILES
Heater Hose, Replace -> Inlet -> Outlet
Vehicle: 2003 Ford F-550 Super Duty Pickup 6.0 V8 DIESEL
Inlet
- Drain cooling system into a suitable container.
- Reposition heater core inlet hose clamp at heater inlet tube.
- Remove hose from heater inlet tube.
- Reposition heater hose inlet clamp at heater core.
- Remove heater inlet hose from heater core.
- Remove hose from vehicle.
- Reverse procedure to ins...
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COMPONENT LOCATION DIAGRAMS FOR 2003 Ford F-550 Super Duty Pickup AUTOMOBILES
Component location diagrams for most 2003 Ford F-550 Super Duty Pickup cars and light trucks sold in the U.S. from 1990+.
Underbody Components Diagram for 2003 Ford F-550 Super Duty Pickup 6.0 V8 DIESEL Components on diagram: |
Driveshaft Diagram for 2003 Ford F-550 Super Duty Pickup 6.0 V8 DIESEL Components on diagram: |
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WIRING DIAGRAMS FOR 2003 Ford F-550 Super Duty Pickup AUTOMOBILES
OEM drawn wiring diagrams for most 2003 Ford F-550 Super Duty Pickup cars and light trucks sold in the U.S.
2003 Ford F-550 Super Duty Pickup 7.3 V8 DIESEL Wiring Diagram Components on diagram: |
2003 Ford F-550 Super Duty Pickup 6.0 V8 DIESEL Wiring Diagram Components on diagram: |
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TECHNICAL SERVICE BULLETINS FOR 2003 Ford F-550 Super Duty Pickup AUTOMOBILES
OEM TSB listings for most 2003 Ford F-550 Super Duty Pickup cars and light trucks sold in the U.S. from 1985+.
Document: Diesel Coolant Maintenance - Service Tips Vehicle: 2003 Ford F-550 Super Duty Pickup 7.3 V8 DIESEL Auto Systems: |
Document: COOLANT LOSS - 6.0L Vehicle: 2003 Ford F-550 Super Duty Pickup 6.0 V8 DIESEL Symptoms: |
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COMPONENT/PARTS SPECIFICATIONS FOR 2003 Ford F-550 Super Duty Pickup AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 2003 Ford F-550 Super Duty Pickup cars and light trucks sold in the U.S. and Canada from 1970+.
- Brake caliper mounting bolt torque
- Brake drum runout, machining, & discard specs
- Minimum brake lining thickness.
- Brake rotor runout, parallelism, machining, discard, & finish specs
A/C SYSTEM SPECIFICATIONS: Air conditioning refrigerant capacity and type as well as lubricant capacity for most 2003 Ford F-550 Super Duty Pickup cars and light trucks sold in the U.S. and Canada from 1980+.
- Refrigerant capacity & type, compressor oil viscosity, total system oil capacity & compressor clutch gap
COOLING SYSTEM BLEED: Cooling system bleeder valve identification, bleeder type and bleed procedures for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1986+.
PREVENTIVE MAINTENANCE: Preventive maintenance recommendations and required services for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1980+. Includes severe and routine service schedules
QUICK-LUBE and ILLUSTRATIONS: Fluid recommendations, capacities, drain plug torques, tire data, and severe service recommended preventive maintenance schedules. Information covers most 2003 Ford F-550 Super Duty Pickup cars and light trucks sold in the U.S. and Canada from 1980+. Engine and chassis service images.
- Automatic transmission/transaxles capacities, lubricant recommendations
- Differential/final drive capacities, lube recommendations, grades, & viscosities
- Final drive fill & drain plug torques
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Manual transmission/transaxle capacities, lube recommendations, grades, & viscosities
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Engine oil capacities, API grade recommendations, SAE viscosity recommendations, drain plug torque
- Severe service maintenance & interval recommendations
- Tire sizes, wheel nut/bolt torque, pressures & rim sizes
- Transfer case capacities, lube recommendations, grades, & viscosities
TUNE-UP & DRIVEABILITY SPECIFICATIONS: Most tune-up specifications for most 2003 Ford F-550 Super Duty Pickup cars and light trucks sold in the U.S. and Canada from 1980+
- Airflow sensor electrical specifications
- Tensioning specifications for systems with automatic tensioners
- Barometric pressure sensor specs
- Battery group number and cranking performance
- Crankshaft & camshaft position sensor resistance
- Engine compression pressures
- Coolant temperature sensor specs
- Computer advance.
- Diesel fuel temperature sensor resistance.
- Distributor advance specifications
- Ignition pickup coil resistance
- Exhaust gas recirculation temperature sensor resistance
- Engine fastener torque values
- Firing order diagrams
- Fuel system pressures
- Generator (alternator) specs
- Intake air temperature sensor specs
- Ignition coil specifications
- Fuel injector resistance
- Engine idle speeds
- Knock sensor resistance
- Manifold absolute pressure sensor specs
- Mixture control solenoid resistance
- Voltage regulator specs
- Spark plug applications & gaps
- Starter motor electrical specs.
- Tensioning specifications for systems without automatic tensioners
- Throttle body temperature sensor resistance
- Ignition timing in degrees at rpm
- Transmission oil temperature sensor resistance
- Throttle position sensor specs
- Vacuum sensor valve specs
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