1996 Bronco/F-Series

Section 00-03: Maintenance and Lubrication

1996 F-150, F-250, F-350, F-Super Duty and Bronco Workshop Manual

MAINTENANCE

Normal Schedule

NOTE: Items for emission control service are shown in bold type. For items marked with number in parentheses, see footnotes at end of this schedule.

NOTE: Kilometer intervals are rounded off.

5,000 Miles (8,000 km)

Change engine oil and replace oil filter.
Rotate tires and adjust air pressure. (1) (2)
Check and lubricate clutch release lever (7.5L and 7.3L DI turbo diesel).
Check clutch reservoir fluid level.
Inspect and lubricate automatic transmission shift linkage.
Lubricate steering linkage suspension, driveshaft U-joint, if equipped with grease fittings, and lubricate slip-yoke (if equipped).
Inspect exhaust system for leaks, damage or loose parts. Remove any foreign material trapped by exhaust system shielding. (3)

10,000 Miles (16,000 km)

Change engine oil and replace oil filter.

15,000 Miles (24,000 km)

Change engine oil and replace oil filter.
Inspect engine cooling system, hoses, and clamps and check coolant strength every 15,000 miles (24,000 km) or 12 months.
For 7.3L DIT diesel engines, add 8-10 ounces of FW-15 to the engine coolant every 15,000 miles (24,000 km).
Rotate tires and adjust air pressure. (1) (2)
Check clutch reservoir fluid level.
Lubricate transfer case shift lever pivot bolt and control rod connecting pins (4x4).
Inspect and lubricate automatic transmission shift linkage.
Lubricate steering linkage suspension, driveshaft U-joint, if equipped with grease fittings, and lubricate slip-yoke (if equipped).
Inspect disc brake system hoses and lines.
Lubricate caliper slide rails (F-Super Duty).
Inspect drum brake systems, hoses and lines.
Inspect exhaust system for leaks, damage or loose parts. Remove any foreign material trapped by exhaust system shielding. (3)
Inspect parking brake fluid level (F-Super Duty).
Replace fuel filter every 15,000 miles (24,000 km) or when the filter restriction lamp is illuminated (7.3L DI turbo diesel only).
Change fuel filter (recommended but not required for California certified vehicles).
Check spring U-bolt torque (F-Super Duty).
Change fuel filter (recommended but not required for California certified vehicles).

20,000 Miles (32,000 km)

Change engine oil and replace oil filter.
Check and lubricate clutch release lever (7.5L and 7.3L DI turbo diesel).

25,000 Miles (40,000 km)

Change engine oil and replace oil filter.
Rotate tires and adjust air pressure. (1) (2)
Check clutch reservoir fluid level.
Inspect and lubricate automatic transmission shift linkage.
Lubricate steering linkage suspension, driveshaft U-joint, if equipped with grease fittings, and lubricate slip-yoke (if equipped).
Inspect exhaust system for leaks, damage or loose parts. Remove any foreign material trapped by exhaust system shielding. (3)

30,000 Miles (48,000 km)

Change engine oil and replace oil filter.
Inspect engine cooling system, hoses, and clamps and check coolant strength every 15,000 miles (24,000 km) or 12 months.
For 7.3L DI turbo diesel engines, add 8-10 ounces of FW-15 to the engine coolant every 15,000 miles (24,000 km).
Replace air cleaner filter every 30,000 miles (48,000 km) or 30 months. If operating in dusty conditions, follow severe-duty maintenance schedule.
Replace the air cleaner filter when the restriction gauge is in the red zone (7.3L DIT diesel only).
Replace crankcase emission air filter. If operating in dusty conditions, follow severe-duty maintenance schedule (4.9L, 5.0L manual transmission, and 7.5L only).
Change automatic transmission fluid (5).
Lubricate transfer case shift lever pivot bolt and control rod connecting pins (4x4).
Inspect disc brake system hoses and lines.
Lubricate caliper slide rails (F-Super Duty).
Inspect drum brake systems, hoses and lines.
Inspect and lubricate front wheel bearings.
Inspect parking brake system for damage and operation.
Inspect parking brake fluid level (F-Super Duty).
Lubricate throttle kickdown or TV lever ball studs.
Lubricate front axle RH axle shaft slip-yoke (4x4).
Inspect and lubricate spindle needle bearings (4x4).
Inspect and lubricate hub locks (4x4).
Check spring U-bolt torque (F-Super Duty).
Replace fuel filter every 15,000 miles (24,000 km) or when the filter restriction lamp is illuminated (7.3L DI turbo diesel only).
Change fuel filter (recommended but not required for California certified vehicles).

35,000 Miles (56,000 km)

Change engine oil and replace oil filter.
Rotate tires and adjust air pressure. (1) (2)
Check and lubricate clutch release lever (7.5L and 7.3L DI turbo diesel).
Check clutch reservoir fluid level.
Inspect and lubricate automatic transmission shift linkage.
Lubricate steering linkage suspension, driveshaft U-joint, if equipped with grease fittings, and lubricate slip-yoke (if equipped).
Inspect exhaust system for leaks, damage or loose parts. Remove any foreign material trapped by exhaust system shielding. (3)

40,000 Miles (64,000 km)

Change engine oil and replace oil filter.

45,000 Miles (72,000 km)

Change engine oil and replace oil filter.
Inspect engine cooling system, hoses, and clamps and check coolant strength every 15,000 miles (24,000 km) or 12 months.
For 7.3L DI turbo diesel engines, add 8-10 ounces of FW-15 to the engine coolant every 15,000 miles (24,000 km).
Rotate tires and adjust air pressure. (1) (2)
Check clutch reservoir fluid level.
Lubricate transfer case shift lever pivot bolt and control rod connecting pins (4x4).
Inspect and lubricate automatic transmission shift linkage.
Lubricate steering linkage suspension, driveshaft U-joint, if equipped with grease fittings, and lubricate slip-yoke (if equipped).
Change fuel filter (recommended but not required for California certified vehicles).
Replace fuel filter every 15,000 miles (24,000 km) or when the filter restriction lamp is illuminated (7.3L DI turbo diesel only).
Inspect disc brake system hoses and lines.
Lubricate caliper slide rails (F-Super Duty).
Inspect drum brake systems, hoses and lines.
Inspect exhaust system for leaks, damage or loose parts. Remove any foreign material trapped by exhaust system shielding. (3)
Inspect parking brake fluid level (F-Super Duty).
Check spring U-bolt torque (F-Super Duty).

50,000 Miles (80,000 km)

Change engine oil and replace oil filter.
Change engine coolant initially at 50,000 miles (80,000 km) or 48 months. Thereafter, change engine coolant every 30,000 miles (48,000 km) 36 months (gasoline engines only).
For 7.3L DI turbo diesel engines, add four (4) pints of FW-15 each time engine coolant is changed.
Check and lubricate clutch release lever (7.5L and 7.3L DI turbo diesel).

55,000 Miles (88,000 km)

Change engine oil and replace oil filter.
Rotate tires and adjust air pressure. (1) (2)
Inspect and lubricate automatic transmission shift linkage.
Lubricate steering linkage suspension, driveshaft U-joint, if equipped with grease fittings, and lubricate slip-yoke (if equipped).
Inspect exhaust system for leaks, damage or loose parts. Remove any foreign material trapped by exhaust system shielding. (3)

60,000 Miles (96,000 km)

Change engine oil and replace oil filter.
Inspect engine cooling system, hoses, and clamps and check coolant strength every 15,000 miles (24,000 km) or 12 months.
Replace spark plugs (gasoline engines only).
Replace air cleaner filter every 30,000 miles (48,000 km) or 30 months. If operating in dusty conditions, follow severe-duty maintenance schedule.
Replace the air cleaner filter when the restriction gauge is in the red zone (7.3L DI turbo diesel only).
Replace crankcase emission air filter. If operating in dusty conditions, follow severe-duty maintenance schedule (4.9L, 5.0L manual transmission and 7.5L only).
Replace PCV valve. (4)
Check Thermactor hoses and clamps (recommended but not required).
Inspect accessory drive belt condition.
Lubricate transfer case shift lever pivot bolt and control rod connecting pins (4x4).
Change automatic transmission fluid (5).
Replace fuel filter every 15,000 miles (24,000 km) or when the filter restriction lamp is illuminated (7.3L DI turbo diesel only).
Change fuel filter (recommended but not required for California certified vehicles).
Inspect disc brake system hoses and lines.
Lubricate caliper slide rails (F-Super Duty).
Inspect drum brake systems, hoses and lines.
Inspect and lubricate front wheel bearings.
Inspect parking brake system for damage and operation.
Inspect parking brake fluid level (F-Super Duty).
Lubricate throttle kickdown or TV lever ball studs.
Inspect and lubricate spindle needle bearings (4x4).
Inspect and lubricate hub locks (4x4).
Change transfer case oil (4x4).
Lubricate front axle RH axle shaft slip-yoke (4x4).
Change manual transmission oil.
Check spring U-bolt torque (F-Super Duty).

65,000 Miles (104,000 km)

Change engine oil and replace oil filter.
For 7.3L DI turbo diesel engines, add 8-10 ounces of FW-15 to the engine coolant every 15,000 miles (24,000 km).
Rotate tires and adjust air pressure. (1) (2)
Lubricate steering linkage suspension, driveshaft U-joint, if equipped with grease fittings, and lubricate slip-yoke (if equipped).
NOTE: It is normal for a certain amount of moisture and staining to be present around the muffler seams. The presence of soot, light surface rust or moisture does not indicate a faulty muffler.
Inspect exhaust system for leaks, damage or loose parts. Remove any foreign material trapped by exhaust system shielding.
Inspect and lubricate automatic transmission shift linkage.
Check clutch reservoir fluid level.
Check and lubricate clutch release lever (7.5L and 7.3L DI turbo diesel).

70,000 Miles (112,000 km)

Change engine oil and replace oil filter.

75,000 Miles (120,000 km)

Change engine oil and replace oil filter.
Inspect engine cooling system, hoses, and clamps and check coolant strength every 15,000 miles (24,000 km) or 12 months.
Rotate tires and adjust air pressure. (1) (2)
Lubricate steering linkage suspension, driveshaft U-joint, if equipped with grease fittings, and lubricate slip-yoke (if equipped).
Inspect exhaust system for leaks, damage or loose parts. Remove any foreign material trapped by exhaust system shielding. (3)
Inspect disc brake system hoses and lines.
Lubricate caliper slide rails (F-Super Duty).
Inspect drum brake systems, hoses and lines.
Change fuel filter (recommended but not required for California certified vehicles).
Replace fuel filter every 15,000 miles (24,000 km) or when the filter restriction lamp is illuminated (7.3L DI turbo diesel only).
Inspect and lubricate automatic transmission shift linkage.
Check clutch reservoir fluid level.
Lubricate transfer case shift lever pivot bolt and control rod connecting pins (4x4).
Inspect parking brake fluid level (F-Super Duty).
Check spring U-bolt torque (F-Super Duty).

80,000 Miles (128,000 km)

Change engine oil and replace oil filter.
Change engine coolant every 30,000 miles (48,000 km) or every 36 months (gasoline engines only).
For 7.3L DI turbo diesel engines, four (4) pints of FW-15 each time engine coolant is changed.
Check and lubricate clutch release lever (7.5L and 7.3L DI turbo diesel).

85,000 Miles (136,000 km)

Change engine oil and replace oil filter.
Rotate tires and adjust air pressure. (1) (2)
Lubricate steering linkage suspension, driveshaft U-joint, if equipped with grease fittings, and lubricate slip-yoke (if equipped).
Inspect exhaust system for leaks, damage or loose parts. Remove any foreign material trapped by exhaust system shielding. (3)
Inspect and lubricate automatic transmission shift linkage.
Check clutch reservoir fluid level.

90,000 Miles (144,000 km)

Change engine oil and replace oil filter.
Inspect engine cooling system, hoses, and clamps and check coolant strength every 15,000 miles (24,000 km) or 12 months.
Replace air cleaner filter every 30,000 miles (48,000 km) or 30 months. If operating in dusty conditions, follow severe-duty maintenance schedule.
Replace the air cleaner filter when the restriction gauge is in the red zone (7.3L DI turbo diesel only).
Replace crankcase emission air filter. If operating in dusty conditions, follow severe-duty maintenance schedule (4.9L, 5.0L manual transmission and 7.5L only).
Inspect accessory drive belt condition.
Replace fuel filter every 15,000 miles (24,000 km) or when the filter restriction lamp is illuminated (7.3L DI turbo diesel only).
Change fuel filter (recommended but not required for California certified vehicles).
Inspect parking brake system for damage and operation.
Inspect disc brake system hoses and lines.
Lubricate caliper slide rails (F-Super Duty).
Inspect drum brake systems, hoses and lines.
Inspect and lubricate front wheel bearings.
Lubricate throttle kickdown or TV lever ball studs.
Inspect and lubricate hub locks (4x4).
Inspect and lubricate spindle needle bearings (4x4).
Lubricate transfer case shift lever pivot bolt and control rod connecting pins (4x4).
Change automatic transmission fluid (5).
Inspect parking brake fluid level (F-Super Duty).
Check spring U-bolt torque (F-Super Duty).
Lubricate front axle RH axle shaft slip-yoke (4x4).

95,000 Miles (152,000 km)

Change engine oil and replace oil filter.
For 7.3L DI turbo diesel engines, add 8-10 ounces of FW-15 to the engine coolant every 15,000 miles (24,000 km).
Rotate tires and adjust air pressure. (1) (2)
Lubricate steering linkage suspension, driveshaft U-joint, if equipped with grease fittings, and lubricate slip-yoke (if equipped).
Inspect exhaust system for leaks, damage or loose parts. Remove any foreign material trapped by exhaust system shielding. (3)
Inspect and lubricate automatic transmission shift linkage.
Check clutch reservoir fluid level.
Check and lubricate clutch release lever (7.5L and 7.3L DI turbo diesel).

100,000 Miles (160,000 km)

Change engine oil and replace oil filter.
All rear axle lube quantities must be replaced every 100,000 miles (160,000 km) or if the axle has been submerged in water. Otherwise, the lube should not be checked or changed unless a leak is suspected or repair required.

105,000 Miles (168,000 km)

Change engine oil and replace oil filter.
Inspect engine cooling system, hoses, and clamps and check coolant strength every 15,000 miles (24,000 km) or 12 months.
Rotate tires and adjust air pressure. (1) (2)
Lubricate steering linkage suspension, driveshaft U-joint, if equipped with grease fittings, and lubricate slip-yoke (if equipped).
Replace fuel filter every 15,000 miles (24,000 km) or when the filter restriction lamp is illuminated (7.3L DI turbo diesel only).
Change fuel filter (recommended but not required for California certified vehicles).
Inspect exhaust system for leaks, damage or loose parts. Remove any foreign material trapped by exhaust system shielding. (3)
Inspect disc brake system hoses and lines.
Lubricate caliper slide rails (F-Super Duty).
Inspect drum brake systems, hoses and lines.
Inspect and lubricate automatic transmission shift linkage.
Check clutch reservoir fluid level.
Lubricate transfer case shift lever pivot bolt and control rod connecting pins (4x4).
Inspect parking brake fluid level (F-Super Duty).
Check spring U-bolt torque (F-Super Duty).

110,000 Miles (176,000 km)

Change engine oil and replace oil filter.
Change engine coolant every 30,000 miles (48,000 km) or every 36 months (gasoline engines only).
For 7.3L DI turbo diesel engines, add four (4) pints of FW-15 each time engine coolant is changed.
Check and lubricate clutch release lever (7.5L and 7.3L DI turbo diesel).

115,000 Miles (184,000 km)

Change engine oil and replace oil filter.
Rotate tires and adjust air pressure. (1) (2)
Lubricate steering linkage suspension, driveshaft U-joint, if equipped with grease fittings, and lubricate slip-yoke (if equipped).
Inspect exhaust system for leaks, damage or loose parts. Remove any foreign material trapped by exhaust system shielding. (3)
Inspect and lubricate automatic transmission shift linkage.
Check clutch reservoir fluid level.

120,000 Miles (192,000 km)

Change engine oil and replace oil filter.
Replace spark plugs (gasoline engines only).
Inspect accessory drive belt condition.
Inspect engine cooling system, hoses, and clamps and check coolant strength every 15,000 miles (24,000 km) or 12 months.
Replace air cleaner filter every 30,000 miles (48,000 km) or 30 months. If operating in dusty conditions, follow severe-duty maintenance schedule.
Replace the air cleaner filter when the restriction gauge is in the red zone (7.3L DI turbo diesel only).
Replace crankcase emission air filter. If operating in dusty conditions, follow severe-duty maintenance schedule (4.9L, 5.0L manual transmission and 7.5L only).
Replace PCV valve. (4)
Check Thermactor hoses and clamps (recommended but not required).
Inspect parking brake system for damage and operation.
Inspect disc brake system hoses and lines.
Lubricate caliper slide rails (F-Super Duty).
Inspect drum brake systems, hoses and lines.
Inspect and lubricate front wheel bearings.
Lubricate throttle kickdown or TV lever ball studs.
Inspect and lubricate hub locks (4x4).
Inspect and lubricate spindle needle bearings (4x4).
Lubricate transfer case shift lever pivot bolt and control rod connecting pins (4x4).
Change automatic transmission fluid (5).
Inspect parking brake fluid level (F-Super Duty).
Check spring U-bolt torque (F-Super Duty).
Replace manual transmission oil.
Replace transfer case oil (4x4).
Lubricate front axle RH axle shaft slip-yoke (4x4).
Change fuel filter (recommended but not required for California certified vehicles).
Replace fuel filter every 15,000 miles (24,000 km) or when the filter restriction lamp is illuminated (7.3L DI turbo diesel only).


(1)	Wheel lug nuts must be retightened to proper torque specifications at 500 miles/800 km of new vehicle operation (100 miles/160 km and 500 miles/800 km for vehicles equipped with dual rear wheels or equipped for snowplowing). Proper torque specifications are provided in this section. Also retighten to proper torque specification at 500 miles/800 km after (1) any wheel change or (2) any other time the wheel lug nuts have been loosened.
(2)	On dual rear wheel vehicles, rotate the front tires side to side without disturbing the rear tires.
(3)	It is normal for a certain amount of moisture and staining to be present around the muffler seams. The presence of soot, light surface rust or moisture does not indicate a faulty muffler.
(4)	At 60,000 miles (96,000 km) dealer will replace the PCV valve at no cost except on Canada and California vehicles.
(5)	Except C6 and E4OD transmissions, which do not require regular fluid changes under normal operating conditions. Refer to the Severe Duty Maintenance Schedule for regular maintenance intervals for all transmissions, including C6 and E4OD.

For F-Super Duty Rear Axles Only:

The lube change interval should be shortened to 4,800 km (3,000 miles) or 3 months, whichever occurs first, under the following conditions:

Extended trailer tow operation above 21°C (70°F).
Ambient and wide open throttle for extended periods above 72 km/h (45 mph).

The 3,000 miles (4,800 km) change interval may be waived if the axle has been filled with Ford approved 75W-140 synthetic gear lubricant meeting WSL-M2C192-A, Ford specification F1TZ-19580-B.