204-00-I Suspension System - General Information 204-00-I

204-00-i Suspension System — General Information 204-00-i
SECTION 204-00 Suspension System — General Information

CONTENTS PAGE
GENERAL PROCEDURES
Camber and Caster Adjustment — F-250 and F-350 Four Wheel Drive (4WD), F-450, F-550 ........................................... 204-00-2
2008 F-250, 350, 450, 550 Super Duty, 7/2007

204-00-2 Suspension System — General Information 204-00-2
GENERAL PROCEDURES
Camber and Caster Adjustment — F-250 and F-350 Four Wheel Drive (4WD), F-450, F-550
Special Tool(s)
Remover, Steering Arm

211-003 (T64P-3590-F)
1. NOTICE:
Do not bend the axles or the radius arms to change alignment angles or damage to the vehicle's axle and radius arms can occur.
Using alignment equipment and the manufacturer's instructions, measure the caster and camber.
• Refer to Alignment Specifications in the Specifications portion of this section for optimal alignment settings.
• If the caster and camber values are not within specification, go to the next step.
2. Remove the cotter pin and the nut from the upper ball joint.
• Discard the cotter pin.
3. Loosely install the nut, inverted, onto the upper ball joint stud.
4. Loosen the lower ball joint nut to the end of the lower ball joint stud.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

GENERAL PROCEDURES (Continued)
5. NOTICE:
Use care not to damage the brake and vacuum lines when striking the spindle.
Separate the wheel knuckle from the axle.

6. Remove the nut from the upper ball joint.
7. Using the Steering Arm Remover, remove the existing LH and RH adjuster sleeves. All vehicles are built by the assembly plant with a non-adjustable
camber/caster sleeve.
1 Service adjusters have a 8-sided flange with the camber/caster adjustment range stamped into the bottom (0 degree, 1/4 degree, 1/2 degree, 3/4
degree or 1 degree).
2 Production adjusters have a round flange with a flattened edge. The amounts of pre-set camber and caster are stamped into the top of the adjuster.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

8. Install interim 0 degree service adjusters to both sides of the vehicle.

9. Install the nut onto the upper ball joint.
• Tighten to 94 Nm (69 lb-ft).
10. Install the front wheel(s) and check the caster and camber readings with the 0 degree service adjusters installed.
11. Calculate the maximum amount of camber and/or caster adjustment required to achieve the optimal settings, as provided in the Alignment
Specifications table, by subtracting the measured values from the optimal target values.
Example: For a Four-Wheel Drive (4WD) F-350 pickup with Single Rear Wheel (SRW),
• optimal camber spec target = 0.15 ± 0.75.
• optimal LH caster spec target = 2.7 ± 1.2.
• measured camber = 1.2 (out-of-spec).
• measured LH caster = 2.0 (within spec).
• required camber adjustment = 0.15 - 1.2 = -1.05.
• preferred caster adjustment = 2.7 - 2.0 = +0.7, however not required.
12. Using the Camber/Caster Service Adjuster table, determine the appropriate replacement service adjuster needed to correct alignment. There is usually
more than one combination of service adjuster and orientation that can be chosen to achieve alignment measurements within specifications. If a
compromise is required, choose the adjuster and orientation which optimizes the camber value and maximizes the caster value.
Example: continuing the above example,
• Choose an adjuster with a 1 degree adjustment circle.
• Set the adjuster to the 180 degree position to achieve a -1 degree camber and 0 degree caster shift setting.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

NOTE:
When selecting a replacement service adjuster to achieve the desired amount of camber and caster offsets, caution is required to make sure that all other
alignment characteristics (camber split, caster split and individual caster) are maintained to within their specified ranges. When in doubt of which service
adjuster to choose, make the selection which achieves measured results closest to the optimal targets in the following order of priority:
— Caster split
— Individual camber
— Camber split
— Individual caster
13. Remove the nut from the upper ball joint.

• Discard the nut.
14. Using the Steering Arm Remover, remove the 0 degree service adjusters and install the appropriate replacement service adjusters to the correct
rotational orientation specified in the Camber/Caster Service Adjuster table.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

15. Tighten the lower ball joint nut to 59 Nm (44 lb-ft).
16. Install the upper ball joint nut and a new cotter pin.
18. Verify the camber and caster settings, adjust as necessary.

• Once the optimal caster/camber has been achieved, check the total toe and adjust as necessary. For additional information, refer to Toe
Adjustment — F-250 and F-350 Four Wheel Drive (4WD), F-450, F-550 in this section.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

2008 F-250, 350, 450, 550 Super Duty, 7/2007


CONTENTS PAGE
GENERAL PROCEDURES
Camber and Caster Adjustment — F-250 and F-350 Rear Wheel Drive (RWD) ................................................................. 204-00-2
2008 F-250, 350, 450, 550 Super Duty, 7/2007

GENERAL PROCEDURES
Camber and Caster Adjustment — F-250 and F-350 Rear Wheel Drive (RWD)
1. Using alignment equipment and the manufacturer's instructions, measure the caster and camber.
• If the caster and camber values are not within specification, go to the next step.
2. Remove the upper ball joint pinch bolt and nut.
3. Remove the existing adjuster sleeves. All vehicles are built by the assembly plant with a non-adjustable camber/caster sleeve.
1 Service adjusters have a 6-sided flange with the camber/caster adjustment range stamped into the top (0 degree, 1/4 degree, 1/2 degree, 3/4 degree
or 1 degree, 1-1/4 degree and 1-1/2 degree).
2 Production adjusters have a round flange with a side tab. The amounts of pre-set camber and caster are stamped into the top of the adjuster.
4. Install interim 0 degree service adjusters to both sides of the vehicle.

5. Install the upper ball joint pinch bolt and a new nut.
6. Install the front wheel(s) and check caster and camber readings with the 0 degree service adjusters installed.
7. Calculate the maximum amount of camber and/or caster adjustment required to achieve the optimal settings, as provided in the Alignment
Specifications table, by subtracting the measured values from the optimal target values.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

Example: for an F-350 Rear Wheel Drive (RWD), Dual Rear Wheels (DRW), Pickup:
• optimal camber spec target = 0.62 ± 1.0.
• optimal caster LH spec target = 4.0 ± 1.2.
• measured camber = 1.85 (out-of-spec).
• measured caster = 3.0 (within spec).
• required camber adjustment = 0.62 - 1.85 = -1.23.
• preferred caster adjustment = 4.0 - 3.0 = 1.0, however not required.
8. Using the Camber/Caster Service Adjuster table, determine the appropriate replacement service adjuster needed to correct alignment. There is usually
more than one combination of service adjuster and orientation that can be chosen to achieve alignment measurements within specifications. If a
compromise is required, choose the adjuster and orientation which optimizes the camber value and maximizes the caster value.
Example: continuing the above example:
• Choose an adjuster with a one and a quarter degree adjustment circle.
• Set the adjuster to the 180 degree position to achieve a -1.25 degree camber and 0 degree caster shift setting.
NOTE:
When selecting a replacement service adjuster to achieve the desired amount of camber and caster offsets, caution is required to make sure that all other
alignment characteristics (camber split, caster split and individual caster) are maintained to within their specified ranges. When in doubt of which service
adjuster to choose, make the selection which achieves measured results closest to the optimal targets in the following order of priority:
— Caster split
— Individual camber
— Camber split
— Individual caster
9. Remove the 0 degree service adjusters and install the appropriate replacement service adjusters to the correct rotational orientation specified in the
Camber/Caster Service Adjuster table.
10. Install the pinch bolt with a new nut and tighten to 80 Nm (59 lb-ft).
2008 F-250, 350, 450, 550 Super Duty, 7/2007

11. Verify the camber and caster settings, adjust as necessary.

• Once the optimal caster/camber has been achieved, check the total toe and adjust as necessary. For additional information, refer to Toe
Adjustment — F-250 and F-350 Rear Wheel Drive (RWD) in this section.
2008 F-250, 350, 450, 550 Super Duty, 7/2007


CONTENTS PAGE
GENERAL PROCEDURES
Lean Correction .................................................................................................................................................................. 204-00-2
2008 F-250, 350, 450, 550 Super Duty, 7/2007

GENERAL PROCEDURES
Lean Correction
Front and rear lean correction
1. NOTE:
When verifying the vehicle lean, all tires must be inflated to the correct specifications and all equipment must be removed from the vehicle, such as
tool boxes, caps and bed fuel tanks. The vehicle must also be parked on a level surface.
Inspect all 4 tires for correct inflation, adjust as necessary.

• Refer to the Safety Certification sticker located on driver door jamb.
2. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section 100-02.
3. NOTE:
The front and rear springs must be in correct working order before a vehicle lean condition can be correctly diagnosed.
Inspect the front and rear springs for any signs of damage (fractured or broken).
• If a spring is damaged, install a new spring and re-evaluate the vehicle. Refer to the appropriate section in Group 204 for the procedure.
• If the lean condition is not corrected, proceed to Step 4.
4. With the vehicle on a level surface and the suspension at curb height, measure from the wheel lip to the top of the wheel well opening at all 4 corners.
Record the measured values.
5. Using the front wheel well opening measurements, take the smaller measured value and subtract it from the larger measured value, this is the wheel
well difference number. Record this number.
• Repeat the calculation using the rear measurements.
6. Measure chassis ride height and record the measured values. For additional information, refer to Ride Height Measurement in this section.
7. Using the front chassis ride height measurements, take the smaller measured value and subtract it from the larger measured value. This is the chassis
ride height difference number. Record this number.
• Repeat the calculation using the rear measurements.
Front lean correction
NOTE:
Correcting the front or rear lean condition will have an effect on the other lean condition.
NOTE:
If the recorded front wheel well difference number is greater than the rear, correct the front lean condition before correcting any rear lean conditions.
8. Remove the high side front coil spring. Refer to the appropriate section in Group 204 for the procedure.
9. Compare the height of the original front coil spring with a new one with the same part number. Note the difference.
10. Compare all 3 front coil springs and select the 2 most evenly matched for installation.
11. From the 2 most evenly matched coil springs, select the tallest and install it on the lower side of the vehicle. Install the shorter of the 2 on the higher
side of the vehicle. Refer to the appropriate section in Group 204 for the procedure.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

Front Lean Correction Chart
Wheel Lip to Wheel Well Difference Left Chassis Ride Height Difference Left to Action
to Right Right
0 to 16 mm (0 to 5/8 in) N/A No action to be taken
Greater than 16 mm (5/8 in) Less than 16 mm (5/8 in) No chassis correction authorized, investigate
frame and body systems
Greater than 16 mm (5/8 in) 16 mm and greater (5/8 in and greater) Install new spring
12. If the original front coil spring exceeds the height of the new spring by 13 mm (1/2 in), install the new front coil spring in the vehicle. For additional
information, refer to Section 204-01A (Rear Wheel Drive (RWD) vehicles) and Section 204-01B (Four-Wheel Drive (4WD) vehicles).
13. If the original front coil spring is shorter than the new spring by at least 13 mm (1/2 in), remove the low side front coil spring from the vehicle. For
additional information, refer to Section 204-01A (RWD vehicles) and Section 204-01B (4WD vehicles).
Rear lean correction
NOTE:
If the recorded rear wheel well difference number is greater than the front, correct the rear lean condition before correcting any front lean conditions.
14. Using the recorded wheel well difference numbers, the recorded chassis ride height difference numbers and the following repair action chart,
determine what repair action is needed to correct the vehicle lean condition.
Rear Lean Correction Chart
Wheel Lip to Wheel Well Difference Left Chassis Ride Height Difference Left to Action
to Right Right
0 to 19 mm (0 to 3/4 in) N/A No action to be taken
Greater than 19 mm (3/4 in) Less than 19 mm (3/4 in) No chassis correction authorized, investigate
frame and body systems
Greater than 19 mm (3/4 in) 19 to 25 mm (3/4 in to 1 in) Install shim 3C4Z-5A300-AA on low side of
vehicle
Greater than 19 mm (3/4 in) Greater than 25 to 38 mm (1 in to 1-1/2 in) Install shim 5C3Z-5742-AA on low side of
vehicle
Greater than 19 mm (3/4 in) 38 mm and greater (1-1/2 in and greater) Install new spring
• If shim installation is required, continue with this procedure.

15. Support the axle.
16. Remove and discard the 4 nuts and 2 U-bolts to allow the rear axle to separate from the rear spring.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

17. Turn the shim so the recess is facing upward.
18. Insert the shim between the rear spring and the spring seat.
• Position the shim so the center bolt through the spring leafs is in the shim recess, the stud on the bottom of the shim is in the spring seat recess
and the shim is aligned with the rear spring.
19. Install 2 new U-bolts and 4 new nuts. Tighten the nuts evenly in a cross-type pattern in 4 stages.
NOTE:
If thicker shims are installed, the new u-bolts (5705) may need to be longer than the original u-bolts.
• For F-250 and F-350:

▪ Stage 1: Tighten to 65 Nm (48 lb-ft).
• For F-450 and F-550:
2008 F-250, 350, 450, 550 Super Duty, 7/2007


20. Remove the support from the axle.

21. Install new spring(s) as necessary. Refer to the appropriate section in Group 204 for the procedure.
2008 F-250, 350, 450, 550 Super Duty, 7/2007


CONTENTS PAGE
GENERAL PROCEDURES
Ride Height Measurement .................................................................................................................................................. 204-00-2
Front Ride Height Measurement .................................................................................................................................. 204-00-2
Rear Ride Height Measurement ................................................................................................................................... 204-00-3
2008 F-250, 350, 450, 550 Super Duty, 7/2007

GENERAL PROCEDURES
Ride Height Measurement
Front Ride Height Measurement
F-250 and F-350, Rear Wheel Drive (RWD)
Item Description
1 Bottom of the jounce bumper bracket at the frame (measurement point 1)
2 Top of I-beam axle (measurement point 2)
3 Ride height = distance between measurement point 1 and measurement point 2
F-250 and F-350, Four-Wheel Drive (4WD), F-450 and F-550
Item Description
1 Bottom of the jounce bumper bracket at the frame (measurement point 1)
2 Top of shock tower (measurement point 2)
1. NOTE:
Make sure that the vehicle is positioned on a flat, level surface and the tires are inflated to the correct pressure.
To obtain vehicle ride height, measure the distance between points 1 and 2. For additional information, refer to Specifications in this section.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

Rear Ride Height Measurement

F-250 and F-350, Rear Wheel Drive (RWD) and F-450 and F-550 without Low Deflection Package
Item Description
1 Bottom of the jounce bumper at the frame (measurement point 1)
2 Top of axle tube (measurement point 2)
F-250 and F-350, Four-Wheel Drive (4WD) and F-450 and F-550 with Low Deflection Package
Item Description
1 Bottom of the jounce bumper at the frame (measurement point 1)
2 Top of spring spacer (measurement point 2)
1. NOTE:
Make sure that the vehicle is positioned on a flat, level surface and the tires are inflated to the correct pressure.
To obtain vehicle ride height, measure the distance between points 1 and 2. For additional information, refer to Specifications in this section.
2008 F-250, 350, 450, 550 Super Duty, 7/2007


CONTENTS PAGE
SPECIFICATIONS ..................................................................................................................................................................... 204-00-2
2008 F-250, 350, 450, 550 Super Duty, 7/2007

SPECIFICATIONS
Alignment Specifications
Item LH RH Total/ Split

F-250 and F-350 Rear Wheel Drive (RWD) Pickup
Camber 0.62° ± 1.0° 0.62° ± 1.0° 0° ± 0.75° a
Caster (Heavy Duty Suspension) b 3.6° ± 1.3° 3.6° ± 1.3° 0° ± 0.75° c

Caster (Standard Suspension) 4.0° ± 1.2° 4.0° ± 1.2° 0° ± 0.75°
c
Toe @ Curb Ride Height (Positive Value is Toe In, Negative Value is Toe — — 0.1° ± 0.25°
Out)
F-350 RWD Chassis Cab Single Rear Wheel (SRW)
Camber 0.62° ± 1.0° 0.62° ± 1.0° 0° ± 0.75°
a
Caster (Heavy Duty Suspension)

b 3.2° ± 1.3° 3.2° ± 1.3° 0° ± 0.75°
c

c
Out)
F-350 RWD Chassis Cab Dual Rear Wheel (DRW)
Camber 0.62° ± 1.0° 0.62° ± 1.0° 0° ± 0.75°
a

b 2.5° ± 1.3° 2.5° ± 1.3° 0° ± 0.75°
c

c
Out)
F-250 Four Wheel Drive (4WD) Pickup
Camber 0.15° ± 0.75° 0.15° ± 0.75° 0° ± 0.75°
a

b 2.8° ± 1.3° 2.8° ± 1.3° 0° ± 0.55°
c

c
Out)
F-350 4WD, Pickup SRW
Camber 0.15° ± 0.75° 0.15° ± 0.75° 0° ± 0.75°
a

b 2.1° ± 1.3° 2.1° ± 1.3° 0° ± 0.55°
c

c
Out)
F-350 4WD Pickup DRW
Camber 0.15° ± 0.75° 0.15° ± 0.75° 0° ± 0.75°
a

b 2.6° ± 1.3° 2.9° ± 1.3° -0.30° ± 0.55°
c
Caster (Standard Suspension) 3.3° ± 1.2° 3.6° ± 1.2° -0.30° ± 0.55°

c
Out)
F-350 4WD Chassis Cab SRW
Camber 0.15° ± 0.75° 0.15° ± 0.75° 0° ± 0.75°
a

b 2.4° ± 1.3° 2.4° ± 1.3° 0° ± 0.55°
c

c
2008 F-250, 350, 450, 550 Super Duty, 7/2007

SPECIFICATIONS (Continued)
Alignment Specifications (Continued)

Item LH RH Total/ Split
Out)
F-350 4WD Chassis Cab DRW
Camber 0.15° ± 0.75° 0.15° ± 0.75° 0° ± 0.75°
a

b 2.2° ± 1.3° 2.5° ± 1.3° -0.30° ± 0.55°
c

c
Out)
F-450 Pickup (All vehicles)
Camber 0.15° ± 0.75° 0.15° ± 0.75° 0° ± 0.75°
a

b 2.5° ± 1.3° 2.9° ± 1.3° -0.40° ± 0.55°
c

c
Out)
F-450/550 (Chassis Cab)
Camber 0.15° ± 0.75° 0.25° ± 0.75° -0.40° ± 0.75°
a

b 2.1° ± 1.3° 3.0° ± 1.3° -0.40° ± 0.55°
c

c
Out)
a Camber Total/Split = LH Camber — RH Camber
b Heavy duty suspensions include vehicles equipped with the following equipment group packages: Heavy Duty, Extra Heavy Duty, Camper, Snowplow, Ambulance.
c Caster Total/Split = LH Caster — RH Caster
Camber/Caster Service Adjusters — F-250/F-350 Rear Wheel Drive (RWD)
Adju Nominal Alignment Adjustment @ Position

st-
ment 0 45 90 135 180 225 270 315
Circl
e Cam/Cas Cam/Cas Cam/Cas Cam/Cas Cam/Cas Cam/Cas Cam/Cas Cam/Cas
0 0/0 0/0 0/0 0/0 0/0 0/0 0/0 0/0

0.25 +0.25/0 +0.18/-0.18 0/-0.25 -0.18/-0.18 -0.25/0 -0.18/+0.18 0/+0.25 +0.18/+0.18
0.5 +0.50/0 +0.35/-0.35 0/-0.50 -0.35/-0.35 -0.50/0 -0.35/+0.35 0/+0.50 +0.35/+0.35
0.75 +0.75/0 +0.53/-0.53 0/-0.75 -0.53/-0.53 -0.75/0 -0.53/+0.53 0/+0.75 +0.53/+0.53
1 +1.00/0 +0.70/-0.70 0/-1.00 -0.70/-0.70 -1.00/0 -0.70/+0.70 0/+1.00 +0.70/+0.70
1.25 +1.25/0 +0.88/-0.88 0/-1.25 -0.88/-0.88 -1.25/0 -0.88/+0.88 0/+1.25 +0.88/+0.88
1.5 +1.50/0 +1.05/-1.05 0/-1.50 -1.05/-1.05 -1.50/0 -1.05/+1.05 0/+1.50 +1.05/+1.05
Camber/Caster Service Adjusters — F-250/F-350 Four Wheel Drive (4WD) and All F-450/F-550

st-
ment 0 45 90 135 180 225 270 315
Circl
0 0/0 0/0 0/0 0/0 0/0 0/0 0/0 0/0

0.25 +0.25/0 +0.18/-0.18 0/-0.25 -0.18/-0.18 -0.25/0 -0.18/+0.18 0/+0.25 +0.18/+0.18
0.5 +0.50/0 +0.35/-0.35 0/-0.50 -0.35/-0.35 -0.50/0 -0.35/+0.35 0/+0.50 +0.35/+0.35
2008 F-250, 350, 450, 550 Super Duty, 7/2007

Camber/Caster Service Adjusters — F-250/F-350 Four Wheel Drive (4WD) and All F-450/F-550 (Continued)
st-
ment 0 45 90 135 180 225 270 315
Circl
0.75 +0.75/0 +0.53/-0.53 0/-0.75 -0.53/-0.53 -0.75/0 -0.53/+0.53 0/+0.75 +0.53/+0.53

1 +1.00/0 +0.70/-0.70 0/-1.00 -0.70/-0.70 -1.00/0 -0.70/+0.70 0/+1.00 +0.70/+0.70
General Specifications
Item Specification
Ride Height — F-250, Rear Wheel Drive (RWD)
Front, LH — camper 107 mm (4.212 in) ± 15 mm (0.590 in)
Front, LH — heavy duty suspension 104 mm (4.094 in) ± 15 mm (0.590 in)
Front, LH — standard suspension 101 mm (3.976 in) ± 15 mm (0.590 in)
Front, RH — camper 98 mm (3.858 in) ± 15 mm (0.590 in)
Front, RH — heavy duty suspension 95 mm (3.740 in) ± 15 mm (0.590 in)
Front, RH — standard suspension 92 mm (3.622 in) ± 15 mm (0.590 in)
Rear — heavy duty (auxiliary spring) 209 mm (8.228 in) ± 25 mm (0.984 in)
Rear — standard suspension 207 mm (8.149 in) ± 25 mm (0.984 in)
Ride Height — F-250, Four Wheel Drive (4WD)
Front — camper 133 mm (5.236 in) ± 15 mm (0.590 in)
Front — heavy duty suspension 133 mm (5.236 in) ± 15 mm (0.590 in)
Front — standard suspension 123 mm (4.842 in) ± 15 mm (0.590 in)
Front — snowplow package (without plow installed) 139 mm (5.472 in) ± 15 mm (0.590 in)
Rear — heavy duty suspension 191 mm (7.519 in) ± 25 mm (0.984 in)
Ride Height — F-350 RWD, Single Rear Wheel (SRW), Pickup
Ride Height — F-350 4WD, SRW, Pickup
Front — snowplow (without plow installed) 139 mm (5.472 in) ± 15 mm (0.590 in)
Ride Height — F-350 Pickup, RWD, Dual Rear Wheel (DRW) Pickup
2008 F-250, 350, 450, 550 Super Duty, 7/2007

General Specifications (Continued)

Item Specification
Ride Height — F-350, 4WD, DRW, Pickup
Front — camper 134 mm (5.275in) ± 15 mm (0.590 in)
Ride Height — F-350, RWD, SRW, Chassis Cab
Front, LH — extra heavy duty suspension 112 mm (4.409 in) ± 15 mm (0.590 in)
Front, RH — extra heavy duty suspension 103 mm (4.055 in) ± 15 mm (0.590 in)
Ride Height — F-350, 4WD, SRW, Chassis Cab
Front — extra heavy duty suspension 145 mm (5.708 in) ± 15 mm (0.590 in)
Ride Height — F-350, RWD, DRW, Chassis Cab
Front, — extra heavy duty suspension 114 mm (4.488 in) ± 15 mm (0.590 in)
Front, RH — extra heavy duty suspension 105 mm (4.133 in) ± 15 mm (0.590 in)
Ride Height — F-350, 4WD, DRW, Chassis Cab
Front — extra heavy duty suspension 143 mm (5.629in) ± 15 mm (0.590 in)
Ride Height — F-450, Pickup
Ride Height — F-450/550, RWD, Chassis Cab
2008 F-250, 350, 450, 550 Super Duty, 7/2007


Item Specification
Ride Height — F-450/550, 4WD, Chassis Cab
Front — standard suspension 139mm (5.472 in) ± 25 mm (0.984 in)
Ride Height — F-550+, RWD
Ride Height — F-550+, 4WD
Ride Height — F-450/F-550, RWD, Low Deflection Package
Ride Height — F-450/F-550, 4WD, Low Deflection Package
Vehicle Lean (Side-to-Side Height Differences) — F-250, F-350, F-450, F-550
Rear wheel opening (maximum) 19 mm (0.748 in)
Front wheel opening (maximum) 16 mm (0.629 in)
Dogtracking
F-250, F-350, F-450, F-550
Dogtracking — maximum (centerline of front tires compared to centerline 30 mm (1.18 in)
of rear tires)
Ball Joint Deflection
Lower 0-1.0 mm (0-0.04 in)
2008 F-250, 350, 450, 550 Super Duty, 7/2007


Item Specification
Upper 0-0.6 mm (0-0.024 in)
Track bar 0-1.0 mm (0-0.04 in)
Wheel bearing end play (4WD) — maximum radial 0.13 mm (0.005 in)
Measurements listed at curb load. Curb load is defined as "full service fluids, full fuel tank(s), no passengers and no cargo".
Torque Specifications
Description Nm lb-ft
Drag link adjuster sleeve nuts — All 55 41
Lower ball joint nut — F-250, F-350, 4WD and F-450, F-550
a — —
Rear spring U-bolt nut — F-250, F-350 a — —
Rear spring U-bolt nut — F-450, F-550

a — —
Tie-rod adjuster sleeve nuts — All 55 41

Upper ball joint nut — F-250, F-350, 4WD and F-450, F-550 94 69
Upper ball joint pinch bolt — F-250, F-350, RWD 80 59
a Refer to the procedure.
2008 F-250, 350, 450, 550 Super Duty, 7/2007


CONTENTS PAGE
DIAGNOSIS AND TESTING

Suspension System ............................................................................................................................................................ 204-00-2
Inspection and Verification ........................................................................................................................................... 204-00-2
Symptom Chart — Suspension System ....................................................................................................................... 204-00-2
Symptom Chart — NVH ............................................................................................................................................... 204-00-4
Pinpoint Tests ............................................................................................................................................................... 204-00-5
Component Tests ......................................................................................................................................................... 204-00-6
Ball Joint Inspection ............................................................................................................................................... 204-00-6
2008 F-250, 350, 450, 550 Super Duty, 7/2007


Suspension System
Inspection and Verification
1. Road test.
• If any suspension alignment or ride height concerns are present, GO to Symptom Chart — Suspension System.
• Verify the customer concern by carrying out a road test on a smooth road. If any vibrations are present, GO to Symptom Chart - NVH.
2. Inspect tires.
• Check the tire pressure with all normal loads in the vehicle and with the tires cold. Refer to the Vehicle Certification (VC) label.
• Verify that all tires are sized to specification. Refer to Section 204-04.
• Inspect the tires for incorrect wear and damage. Refer to Section 204-04.
3. Inspect chassis and underbody.
• Remove any excessive accumulation of mud, dirt or road deposits from the chassis and underbody.
4. Inspect for aftermarket equipment.
• Check for aftermarket changes to the steering, suspension, wheel and tire components (such as competition or heavy duty) The specifications
shown in this manual do not apply to vehicles equipped with aftermarket equipment.
Visual Inspection Chart
Mechanical
• Front wheel bearing(s)
• Loose or damaged front or rear suspension components
• Loose, damaged or missing suspension fastener(s)
• Loose or damaged leaf spring shackle(s)
• Incorrect spring usage
• Damaged or sagging spring(s)
• Damaged or leaking shock absorber(s)
• Worn or damaged suspension bushing(s)
• Loose, worn or damaged steering system components
• Damaged axle components
5. If an obvious cause for an observed or reported condition is found, correct the cause (if possible) before proceeding to the next step.
6. If the fault is not visually evident, GO to Symptom Chart — Suspension System or GO to Symptom Chart - NVH.
Symptom Chart — Suspension System
Symptom Chart — Suspension System

Condition Possible Sources Action
• Incorrect thrust angle (dogtracking) • Rear suspension components • INSPECT the rear suspension system.
CHECK the rear alignment for the correct
thrust angle. REPAIR or INSTALL new
suspension components as necessary.
REFER to Section 204-02.
• Drift/pull • Tire pressure • GO to Pinpoint Test A.
• Tire forces
• Caster total split is not within specification
• Camber total split is not within specification
• Brake drag
• Steering components
• Unevenly loaded vehicle
• Front bottoming or riding low • Spring(s) • CHECK the front ride height. REFER to
Section 204-04. INSTALL new spring(s) as
necessary. Refer to the appropriate section
in Group 204 for the procedure.
• Front shock absorber(s) • INSTALL new front shock absorber(s) as
2008 F-250, 350, 450, 550 Super Duty, 7/2007

DIAGNOSIS AND TESTING (Continued)
Symptom Chart — Suspension System (Continued)

• Rear bottoming or riding low • Rear spring(s) • CHECK the rear ride height. REFER to
Section 204-00. INSTALL new spring(s) as
• Rear shock absorbers • INSTALL new rear shock absorbers.
• Incorrect/abnormal tire wear • Underinflated tires • REFER to Section 204-04 for tire wear
• Incorrect wheel alignment diagnosis.
• Incorrect wheel and tire assembly rotation
intervals
• Excessive high speed cornering
• Sticky steering, poor returnability • Front caster angle • CHECK the front caster and ADJUST as
necessary. REFER to Camber and Caster
Adjustment — F-250 and F-350 Four Wheel
Drive (4WD), F-450, F-550 or Camber and
Caster Adjustment — F-250 and F-350 Rear
Wheel Drive (RWD) in this section.
• Steering components • REFER to Section 211-00 for steering
system diagnosis.
• Ball joints • INSPECT the front ball joints. REFER to
the Ball Joint Inspection Component Test in
this section. INSTALL new ball joints as
necessary.
• Steering wheel off center • Unequal (side-to-side) front toe • CHECK the front toe and ADJUST as
necessary. REFER to Toe Adjustment —
F-250 and F-350 Rear Wheel Drive (RWD)
or Toe Adjustment — F-250 and F-350
Four Wheel Drive (4WD), F-450, F-550 in
this section.
system diagnosis.
• Sway or roll • Overloaded, unevenly or incorrectly loaded • NOTIFY the customer of incorrect vehicle
vehicle loading.
• Loose wheel nut(s) • TIGHTEN to specification. REFER to
Section 204-04.
• Shock absorber(s) • INSPECT the shock absorbers. INSTALL
new shock absorber(s) as necessary. Refer
to the appropriate section in Group 204 for
the procedure.
• Loose or worn stabilizer bar, links or • INSPECT the stabilizer bar assemblies.
bushings TIGHTEN to specification or INSTALL
new stabilizer bar components as necessary.
Refer to the appropriate section in Group
204 for the procedure.
• Worn spring(s) • CHECK the front and rear ride height.
REFER to Ride Height Measurement in this
section. INSTALL new spring(s) as
• Vehicle leans to one side • Unevenly loaded or overloaded vehicle • NOTIFY the customer of incorrect vehicle
loading.
• Front or rear suspension components • CHECK and ADJUST lean condition as
necessary. REFER to Lean Correction in
this section.
• Wander • Excessive total toe in/out • CHECK the front toe settings and ADJUST
as necessary. REFER to Toe Adjustment —
F-250 and F-350 Rear Wheel Drive (RWD)
or Toe Adjustment — F-250 and F-350
2008 F-250, 350, 450, 550 Super Duty, 7/2007

Symptom Chart — Suspension System (Continued)

Four Wheel Drive (4WD), F-450, F-550 in
this section.
• Unevenly loaded or overloaded vehicle • NOTIFY the customer of incorrect vehicle
loading.
system diagnosis.
• Ball joint(s) • INSPECT the front ball joints. REFER to
the Ball Joint Inspection Component Test in
this section. INSTALL new ball joints as
necessary.
• Loose, worn or damaged front wheel • INSPECT the front wheel bearings. REFER
bearing(s) to Wheel Bearing Inspection in this section.
INSTALL new wheel bearing(s) as
necessary.
• Worn or damaged front suspension • INSPECT and INSTALL new front
component(s) suspension component(s) as necessary.
• Loose suspension fasteners • TIGHTEN to specification. Refer to the
appropriate section in Group 204 for the
procedure.
Symptom Chart — NVH
NOTE:
NVH symptoms should be identified using the diagnostic tools that are available. For a list of these tools, an explanation of their uses and a glossary of
common terms, refer to Section 100-04. Since it is possible any one of multiple systems may be the cause of a symptom, it may be necessary to use a process
of elimination type of diagnostic approach to pinpoint the responsible system. If this is not the causal system for the symptom, refer back to Section 100-04
for the next likely system and continue diagnosis.

• Squeak or grunt — noise from the front • Front stabilizer bar insulators • Under these conditions, the noise is
suspension, occurs more in cold ambient acceptable. CHECK TSBs.
temperatures. More noticeable over rough
roads or when turning
• Clunk — noise from the front suspension, • Loose front shocks • INSPECT for shock absorber fasteners.
occurs in and out of turns TIGHTEN to specifications. Refer to the
appropriate section in Group 204 for the
procedure.
• Clunk — noise from the rear suspension, • Loose or damaged rear suspension • INSPECT for loose or damaged rear
occurs when shifting from REVERSE to components suspension components. REPAIR or
drive INSTALL new components as necessary.
• Click or pop — noise from the front • Worn or damaged ball joint(s) • INSPECT the front ball joints. REFER to
suspension. More noticeable over rough the Ball Joint Inspection Component Test in
roads or over bumps this section. INSTALL new ball joints as
necessary.
• Front suspension noise — a squeak, creak or • Loose or bent front shock absorber(s) • INSPECT the front suspension. INSTALL
rattle noise. Occurs mostly over bumps or • Damaged spring or spring mount(s) new components as necessary. Refer to the
rough roads • Damaged or worn control/radius arm appropriate section in Group 204 for the
bushing(s) procedure.
• Worn or damaged stabilizer bar bushings or
link(s)
2008 F-250, 350, 450, 550 Super Duty, 7/2007

Symptom Chart — NVH (Continued)

• Rear suspension noise — a squeak, creak or • Loose or bent rear shock absorber(s) • INSPECT the rear suspension. INSTALL
rattle noise. Occurs mostly over bumps or • Damaged spring or spring mount(s) new components as necessary. REFER to
rough roads • Damaged or worn bushing(s) Section 204-02.
• Worn or damaged stabilizer bar bushing(s)
or link(s)
• Shudder — occurs during acceleration from • Incorrect ride height causing incorrect • REFER to Section 205-00 for driveline
a slow speed or stop driveline angle angle diagnosis.
• Shimmy • Loose wheel nut(s) • TIGHTEN the nut(s) to specification.
• Loose front suspension fastener(s) • TIGHTEN the fastener(s) to specification.
• Loose front wheel bearing(s) • INSPECT the front wheel bearing(s).
REFER to Wheel Bearing Inspection in this
section. INSTALL new bearing(s) as
necessary.
• Shock absorber(s) • INSTALL new shock absorbers as
• Shimmy — most noticeable on coast/ • Excessive positive caster • CHECK the front caster and ADJUST as
deceleration. Also hard steering condition necessary. REFER to Camber and Caster
Adjustment — F-250 and F-350 Four Wheel
Drive (4WD), F-450, F-550 or Camber and
Caster Adjustment — F-250 and F-350 Rear
Wheel Drive (RWD) in this section.
• Rough/harsh ride • Shock absorber(s) • INSTALL new shock absorber(s) as
• Spring(s) • INSTALL new spring(s) as necessary. Refer
to the appropriate section in Group 204 for
the procedure.
Pinpoint Tests
Pinpoint Test A: Vehicle Drifts/Pulls
This pinpoint test is intended to diagnose the following:
• Unevenly loaded vehicle

• Tire pressure
• Tire forces
• Brake drag
• Incorrect vehicle alignment
• Steering system
PINPOINT TEST A: VEHICLE DRIFTS/PULLS

Test Step Result / Action to Take
A1 CHECK FOR UNEVENLY LOADED VEHICLE
• Visually check the vehicle for an uneven loading condition. Yes
• Is the vehicle unevenly loaded? ADVISE the customer of uneven loading condition.
No
GO to A2.
A2 CHECK THE TIRE PRESSURE
• Check the tire pressures. Refer to the Vehicle Certification (VC) label
located on the driver door jamb. Yes
• Is the tire pressure OK? GO to A3.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

PINPOINT TEST A: VEHICLE DRIFTS/PULLS (Continued)

A2 CHECK THE TIRE PRESSURE (Continued)
No
ADJUST the tire pressures to the specified pressure.
A3 ISOLATE TIRE PULL CONDITION
• Cross the front wheel and tire assemblies from left-to-right. Refer to Yes
section Section 204-04. If the vehicle drifts/pulls in the opposite direction, tire
• Does the vehicle pull/drift? forces are causing the drift/pull. REFER to Section
204-04 to diagnose tire drift/pull. If the vehicle drifts/
pulls in the same direction, GO to A4.
No
Tire forces were causing the drift/pull and the concern
has been corrected.
A4 CHECK FOR BRAKE DRAG
• Spin all 4 wheel and tire assemblies by hand and check for brake Yes
drag. GO to A5.
• Do the wheels spin freely?
No
REFER to Section 206-00 to diagnose brake drag
condition.
A5 CHECK FOR STEERING SYSTEM DRIFT/PULL
• Check the steering system components. Refer to Section 211-00 to Yes
diagnose steering system drift/pull/wander condition. REPAIR the steering system as necessary.
• Is the steering system the cause of the drift/pull?
No
GO to A6.
A6 CHECK THE WHEEL ALIGNMENT
• NOTE: Yes
A 1/4 degree to 1/2 degree side-to-side caster difference is usually ADJUST the caster total/split to counteract the drift/pull
sufficient to correct a drift/pull concern. concern. REFER to General Procedures in this section.
If the concern is vehicle drifts/pulls left, INCREASE the
Using alignment equipment and the manufacturer's instructions, caster total/split toward the upper end of the
check the wheel alignment. specification range.
• Is the caster total/split and the camber total/split within If the concern is vehicle drifts/pulls right, DECREASE
specification? the caster total/split toward the lower end of the
specification range.
No
ADJUST the camber and caster total/split as close to
the nominal specification as possible. REFER to
General Procedures in this section.
Component Tests
Ball Joint Inspection
1. Prior to inspecting the ball joints for wear, inspect the wheel bearings. Refer to Section 100-04.
2. Raise and support the vehicle by the frame or by the axle beams.
3. Inspect the ball joint and ball joint boot for damage.
• If the ball joint or ball joint boot is damaged, install a new ball joint. Refer to the appropriate section in Group 204 for the procedure.
NOTE:
Carry out Steps 4-6 to inspect the lower ball joint. Carry out Steps 7-9 to inspect the upper ball joint. Carry out Steps 10-12 to inspect the track bar ball joint.
4. NOTICE:
Do not use any tools or equipment to move the wheel and tire assembly or suspension components while checking for relative movement.
Suspension damage can occur. The use of tools or equipment will also create relative movement that may not exist when using hand force.
Relative movement must be measured using hand force only.
NOTE:
To avoid lateral movement of the steering linkage and steering components, make sure to apply hand force only at the 12 o'clock and 6 o'clock
positions of the wheel and tire assembly.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

Inspect the ball joint for relative movement by alternately pulling outward and pushing inward on the wheel and tire assembly at the 12 o'clock and 6
o'clock positions, by hand. Note any relative movement between the wheel knuckle and the axle at the lower ball joint.
• If relative movement is not felt or seen, the ball joint is OK. Do not install a new ball joint.
• If relative movement is found, continue with Step 5.
5. NOTE:
In order to obtain an accurate measurement, the dial indicator should be aligned as close as possible with the center line of the ball joint.
To measure ball joint deflection, attach a suitable dial indicator with a flexible arm between the axle and the wheel knuckle at the lower ball joint.
6. Measure the ball joint deflection while an assistant alternately pulls outward and pushes inward on the wheel and tire assembly at the 12 o'clock and 6
o'clock positions, by hand.
• If the deflection exceeds the specification, a new lower ball joint must be installed. Refer to the appropriate section in Group 204 for the
procedure.
• If the deflection meets the specification, continue with the procedure.
7. NOTICE:
Do not use any tools or equipment to move the wheel and tire assembly or suspension components while checking for relative movement.
Suspension damage can occur. The use of tools or equipment will also create relative movement that may not exist when using hand force.
Relative movement must be measured using hand force only.
NOTE:
To avoid lateral movement of the steering linkage and steering components, make sure to apply hand force only at the 12 o'clock and 6 o'clock
positions of the wheel and tire assembly.
Inspect the ball joint for relative movement by alternately pulling outward and pushing inward on the wheel and tire assembly at the 12 o'clock and 6
o'clock positions, by hand. Note any relative movement between the wheel knuckle and the axle at the upper ball joint.
8. NOTE:
To measure ball joint deflection, attach a suitable dial indicator with a flexible arm between the axle and the wheel knuckle at the upper ball joint.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

9. Measure the ball joint deflection while an assistant alternately pulls outward and pushes inward on the wheel and tire assembly at the 12 o'clock and 6
o'clock positions, by hand.
• If the deflection exceeds the specification, a new upper ball joint must be installed. Refer to the appropriate section in Group 204 for the
procedure.
• If the deflection meets the specification, no further action is required.
10. NOTE:
When inspecting the track bar ball joint, use a suitable drive-on hoist (such as a drive-on alignment rack). If a drive-on hoist is not available, unload
the track bar by supporting the front axle with suitable jackstands.
Inspect the ball joint for relative movement by alternately pushing up and pulling down on the track bar, by hand. Note any relative movement
between the track bar and the axle at the track bar ball joint.
11. NOTE:
To measure ball joint deflection, attach a suitable dial indicator with a flexible arm between the axle and the track bar at the ball joint.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

12. Measure the ball joint deflection while an assistant alternately pulls downward and pushes upward on the track bar, by hand.
• If the deflection exceeds the specification, a new track bar ball joint must be installed. For additional information, refer to Section 204-01A.
2008 F-250, 350, 450, 550 Super Duty, 7/2007


CONTENTS PAGE
GENERAL PROCEDURES
Toe Adjustment — F-250 and F-350 Four Wheel Drive (4WD), F-450, F-550 .................................................................... 204-00-2
2008 F-250, 350, 450, 550 Super Duty, 7/2007

GENERAL PROCEDURES
Toe Adjustment — F-250 and F-350 Four Wheel Drive (4WD), F-450, F-550
1. Using alignment equipment and the manufacturer's instructions, measure the toe settings.
• If the toe settings are not within specification, go to the next step.
2. Start the engine and center the steering wheel.
3. Turn the engine off and, using a suitable steering wheel holding device, lock the steering wheel in the straight ahead position.
4. Loosen the tie-rod adjuster sleeve nuts.
5. Rotate the center link to the correct toe setting.

6. Make sure that the RH tie-rod end is not misaligned, as shown in image 2. Adjust the position as necessary as shown in image 1.
7. Tighten the tie-rod adjuster sleeve nuts to 55 Nm (41 lb-ft).

8. Verify the toe settings and adjust as necessary.
2008 F-250, 350, 450, 550 Super Duty, 7/2007


CONTENTS PAGE
GENERAL PROCEDURES
Toe Adjustment — F-250 and F-350 Rear Wheel Drive (RWD) .......................................................................................... 204-00-2
2008 F-250, 350, 450, 550 Super Duty, 7/2007

GENERAL PROCEDURES
Toe Adjustment — F-250 and F-350 Rear Wheel Drive (RWD)
1. Using alignment equipment and the manufacturer's instructions, measure the toe settings.
• If the toe settings are not within specification, go to the next step.
2. Start the engine and center the steering wheel.
3. Turn the engine off and, using a suitable steering wheel holding device, lock the steering wheel in the straight ahead position.
4. Loosen the tie-rod adjuster sleeve nuts.
5. Rotate the tie-rod adjusting sleeves to obtain the correct toe setting.
6. Position both adjusting sleeve clamp openings downward within 45 degrees of vertical. Tighten the nuts to 55 Nm (41 lb-ft).
7. Verify the toe settings and adjust as necessary.
2008 F-250, 350, 450, 550 Super Duty, 7/2007


CONTENTS PAGE
DESCRIPTION AND OPERATION

Wheel Alignment Angles ..................................................................................................................................................... 204-00-2
Camber ......................................................................................................................................................................... 204-00-2
Caster ........................................................................................................................................................................... 204-00-2
Toe ............................................................................................................................................................................... 204-00-3
Wander ......................................................................................................................................................................... 204-00-4
Shimmy ......................................................................................................................................................................... 204-00-4
Nibble ........................................................................................................................................................................... 204-00-4
Poor Return/Sticky Steering ......................................................................................................................................... 204-00-4
Drift/Pull ........................................................................................................................................................................ 204-00-4
2008 F-250, 350, 450, 550 Super Duty, 7/2007


Wheel Alignment Angles
F-Super Duty vehicle caster and camber correction requirements are factory determined. Adjusters are available to correct a caster/camber measurement that
does not meet specification. Before changing the production caster/camber adjuster, thoroughly inspect the suspension system to locate worn or damaged
components that may have caused the setting to change.
Camber
Negative and Positive Camber
Camber is the vertical tilt of the wheel when viewed from the front. Camber can be positive or negative and has a direct effect on tire wear.
Camber split = LH camber — RH camber.
Caster
Caster and Steering Axis
Item Description
1 True vertical
2 Positive caster angle
3 Ball joint centerline
Caster is the deviation from vertical of an imaginary line drawn through the ball joints when viewed from the side. The caster specifications in this section
will give the vehicle the best directional stability characteristics when loaded and driven. The caster setting is not related to tire wear.
Caster split = LH caster — RH caster.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

DESCRIPTION AND OPERATION (Continued)
Toe
Positive Toe (Toe In)
Negative Toe (Toe Out)
Incorrect Thrust Angle (Dogtracking)
Item Description
1 Vertical centerline
2 Axle centerline
3 Thrust angle
Incorrect thrust angle (dogtracking) is the condition in which the rear axle is not square to the chassis. Heavily crowned roads can give the illusion of
dogtracking.
The vehicle toe setting:
• affects tire wear and directional stability.

• must be checked after adding aftermarket equipment, such as a snowplow or body.
When the wheels are turned in toward the front of the vehicle, the toe is positive (+) (toe in). When the wheels are turned out toward the front of the vehicle,
the toe is negative (-) (toe out). This is measured in degrees, from side-to-side, and totaled.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

Wander
Wander is the tendency of the vehicle to require frequent, random left and right steering wheel corrections to maintain a straight path down a level road.
Shimmy
Shimmy, as observed by the driver, is large, consistent, rotational oscillations of the steering wheel resulting from large, side-to-side (lateral) tire/wheel
movements.
Shimmy is usually experienced near 64 km/h (40 mph) and can begin or be amplified when the tire contacts pot holes or irregularities in the road surface.
Nibble
Sometimes confused with shimmy, nibble is a condition resulting from tire interaction with various road surfaces and observed by the driver as small
rotational oscillations of the steering wheel.
Poor Return/Sticky Steering

Poor return and sticky steering is used to describe the poor return of the steering wheel to center after a turn or a steering correction.
Drift/Pull
Pull is a tugging sensation, felt by the hands on the steering wheel, that must be overcome to keep the vehicle going straight.
Drift describes what a vehicle with this condition does with hands off the steering wheel.
• A vehicle-related drift/pull, on a flat road, will cause a consistent deviation from the straight-ahead path and require constant steering input in the
opposite direction to counteract the effect.
• Drift/pull may be induced by conditions external to the vehicle (for example, wind or road camber).
Poor Groove Feel

Poor groove feel is characterized by little or no buildup of turning effort felt in the steering wheel as the wheel is rocked slowly left and right within very
small turns around center or straight-ahead (under 20 degrees of steering wheel turn). Efforts may be said to be "flat on center".
• In the diagnosis of a driveability problem, it is important to understand the difference between wander and poor groove feel.
2008 F-250, 350, 450, 550 Super Duty, 7/2007


CONTENTS PAGE
GENERAL PROCEDURES
Wheel Bearing Inspection ................................................................................................................................................... 204-00-2
2008 F-250, 350, 450, 550 Super Duty, 7/2007

GENERAL PROCEDURES
Wheel Bearing Inspection
Special Tool(s)
Dial Indicator Gauge With Holding Fixture

100-D002 (D78P-4201-B) or equivalent
NOTE:
Inspect the tires for cupping. A tire with cupping wear can duplicate a bearing noise. For additional information, refer to Section 204-04.
All vehicles
Rear Wheel Drive (RWD) vehicles
2. NOTE:
Make sure the wheel rotates freely and the brake pads are retracted sufficiently to allow movement of the tire and wheel assembly.
Grasp each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing.
3. If the tire and wheel (hub) is loose on the wheel spindle, adjust the front wheel bearings. For additional information, refer to Section 204-01A.
Four-Wheel Drive (4WD) vehicles
NOTE:
An assistant will be needed for this procedure.
4. Carry out the following steps:

• Rotate the hublocks to the locked position.
• Shift the transfer case to an engaged position.
• With the vehicle in DRIVE, run the vehicle to 40 km/h (25 mph).
5. NOTE:
If the vehicle is equipped with a limited-slip front axle, both the wheels will be turning. Evaluate both wheels at this time, then continue to Step 7.
Evaluate the front wheel that is turning.

• Place the stethoscope on the knuckle near the wheel bearing.
• Make a mental note of the sound.
• Using the brakes, stop the wheels from turning.
6. NOTE:
If the vehicle is equipped with a limited-slip front axle, do not hold the wheel. Evaluate both wheels simultaneously. Go to Step 7.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

Evaluate the other front wheel.

• While holding the previously evaluated wheel, run the vehicle to 40 km/h (25 mph). Release the wheel being held.
• Place the stethoscope on the knuckle near the wheel bearing.
• Make a mental note of the sound.
• Using the brakes, stop the wheels from turning.
7. Compare the results.

• If one side sounds louder than the other, install a new bearing on the louder side.
• If both sides sound equally loud, go to Step 8.
• If both sides sound similar (not loud or noisy), carry out a wheel bearing end play check.
8. NOTE:
Make sure the wheel rotates freely.
NOTE:
Rotate the hublocks to the unlocked position.
Carry out the following steps for the wheel bearing end play setup:
• Install the Dial Indicator Gauge With Holding Fixture to the knuckle.
• Place the probe on the brake disc where the splash shield has a V opening.
• Make sure the probe can move in a lateral direction.
• Tighten the neck of the probe.
9. Carry out the following steps for the wheel bearing end play:
• Push the wheel inward at the 6 o'clock position.
• Set the Dial Indicator Gauge With Holding Fixture to 0.
• Pull the wheel outward at the 6 o'clock position.
• Record the measurement.
• Repeat this step 3 to 5 times.
▪ If the wheel bearing end play is greater than 0.13 mm (0.005 in), install a new wheel bearing.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

▪ If the wheel bearing end play is less than 0.13 mm (0.005 in), the wheel bearing is within specification. Go to the next step.
10. Remove the wheel hub. For additional information, refer to Section 204-01B.
11. Carry out the following steps for the needle bearing visual inspection:
• With the wheel hub on a bench, visually inspect the needle bearing.
• Check for any rust, wear or damage.
• Check the condition of the rollers.
• Make sure there is a small amount of grease on the needle bearing.
▪ If the needle bearing has rust, is worn or damaged, install a new needle bearing.
▪ If the needle bearing looks OK, go to the next step.
12. Carry out the following steps for the wheel bearing roughness inspection:
• With the wheel hub on a bench, rotate the outer flange of the wheel bearing while applying downward pressure.
▪ If the wheel bearing rotates freely, without roughness, check the bearing for noise.
▪ If the wheel bearing does not rotate freely, install a new bearing.
• Rotate the outer flange of the wheel bearing while applying downward pressure. Using a stethoscope, check the wheel bearing for noise.
▪ If the wheel bearing rotates freely, without noise, the wheel bearing is OK. Conduct a diagnosis on other suspect components or systems.
▪ If the wheel bearing does not rotate without noise, install a new bearing.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

13. Install the wheel hub. For additional information, refer to Section 204-01B.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

204-01B-i Front Suspension — Four Wheel Drive (4WD) 204-01B-i
SECTION 204-01B Front Suspension — Four Wheel Drive (4WD)

CONTENTS PAGE
SPECIFICATIONS ................................................................................................................................................................... 204-01B-2
2008 F-250, 350, 450, 550 Super Duty, 7/2007

204-01B-2 Front Suspension — Four Wheel Drive (4WD) 204-01B-2
SPECIFICATIONS
Material
Item Specification Fill Capacity
High Temperature 4x4 Front Axle and Wheel WSS-M1C267-A1 —
Bearing Grease
XG-11
Threadlock and Sealer WSK-M2G351-A5 —
TA-25
Description Nm lb-ft lb-in

Brake caliper anchor plate bolts (F-250/F-350) 225 166 —
Brake caliper anchor plate bolts (F-450/F-550) 400 295 —
Hublock screws 6 — 53
Jounce bumper nuts 35 26 —
Lower ball joint nut a — — —
Radius arm front and rear nuts 300 222 —

Shock absorber lower bolts 150 111 —
Shock absorber upper nuts 63 46 —
Spring lower nuts 200 148 —
Stabilizer bar bracket nuts 48 35 —
Stabilizer bar link lower bolts 150 111 —
Stabilizer bar link upper nuts 150 111 —
Tie-rod end nuts 115 85 —
Track bar ball joint nut 250 184 —
Track bar bracket nut 550 406 —
Upper ball joint nut 94 69 —
Wheel extension nuts 176 130 —
Wheel bearing and wheel hub nuts 180 133 —
Wheel speed sensor bolt 18 — 159
Wheel speed sensor harness bolts 15 — 133
a Refer to the procedure in this section.
2008 F-250, 350, 450, 550 Super Duty, 7/2007


CONTENTS PAGE

Front Suspension ............................................................................................................................................................. 204-01B-2
2008 F-250, 350, 450, 550 Super Duty, 7/2007


Front Suspension
Front Suspension with Dana Model 60 Front Drive Axles
The front suspension consists of the following components:
• Coil springs
• Dana model 60 axle
• Radius arms
• Shock absorbers
• Stabilizer bar
• Stabilizer bar links
• Track bar
• Wheel knuckles
• Wheel studs
The front suspension system for the F-Super Duty F-250, F-350, F-450 and F-550 Four-Wheel Drive (4WD) uses a Dana model 60 driving type axle with
radius arms to control lateral movement. The wheel knuckles are attached to the front axle with upper and lower ball joints and the system uses coil springs
and shock absorbers. The F-Super Duty 4WD also incorporates a track bar to aid in vehicle stability.
2008 F-250, 350, 450, 550 Super Duty, 7/2007


CONTENTS PAGE

Front Suspension ............................................................................................................................................................. 204-01B-2
2008 F-250, 350, 450, 550 Super Duty, 7/2007


Front Suspension
Refer to Section 204-00 or Section 100-04.
2008 F-250, 350, 450, 550 Super Duty, 7/2007


CONTENTS PAGE
Ball Joint — Track Bar ....................................................................................................................................................... 204-01B-2
2008 F-250, 350, 450, 550 Super Duty, 7/2007

Ball Joint — Track Bar

Removal and Installation
For additional information, refer to Section 204-01A.
2008 F-250, 350, 450, 550 Super Duty, 7/2007


CONTENTS PAGE
Ball Joint ........................................................................................................................................................................... 204-01B-2
2008 F-250, 350, 450, 550 Super Duty, 7/2007

Ball Joint
Special Tool(s)
Installer/Remover, C-Frame and Screw

205-086 (T74P-4635-C)
Remover/Installer, Ball Joint

204-355
Remover/Installer, Ball Joint

204-358
Item Part Number Description

1 — Grease fitting (part of 3050)
2 — Snap ring (part of 3050)
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)

3 3050 Lower ball joint
4 3131 LH/ 3130 RH Wheel knuckle
5 — Grease fitting (part of 3049)
6 3049 Upper ball joint
Removal
1. Remove the wheel knuckle. For additional information, refer to Wheel Knuckle in this section.
2. If equipped, remove the ball joint grease fitting.
3. Position the wheel knuckle in a vise and remove the snap ring from the lower ball joint.
4. NOTICE:
To avoid damage to the components, do not use heat to aid ball joint removal.
Using the C-Frame and Screw Installer/Remover and the Ball Joint Remover/Installer, remove the lower ball joint.
5. Using the C-Frame and Screw Installer/Remover and the Ball Joint Remover/Installer, remove the upper ball joint.
Installation
1. NOTICE:
The grease fitting must be removed from the ball joint prior to installation or damage to the grease fitting can occur.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
NOTICE:
To avoid damage to components, do not use heat to aid installation.
NOTE:
Clean the wheel knuckle ball joint bore.
Position the ball joint into the wheel knuckle.

2. NOTE:
The upper ball joint must be installed first.
Using the C-Frame and Screw Installer/Remover and the Ball Joint Remover/Installer, install the upper ball joint.
3. Using the C-Frame and Screw Installer/Remover and the Ball Joint Remover/Installer, install the lower ball joint.
4. Install the snap ring in the groove at the bottom of the lower ball joint.
5. NOTICE:
Do not overtighten the ball joint grease fitting or damage to the ball joint may occur.
If removed, install the ball joint grease fitting.

6. Install the wheel knuckle. For additional information, refer to Wheel Knuckle in this section.
2008 F-250, 350, 450, 550 Super Duty, 7/2007


CONTENTS PAGE
Radius Arm Bushing ......................................................................................................................................................... 204-01B-2
2008 F-250, 350, 450, 550 Super Duty, 7/2007

Radius Arm Bushing

2008 F-250, 350, 450, 550 Super Duty, 7/2007


CONTENTS PAGE
Radius Arm ....................................................................................................................................................................... 204-01B-2
2008 F-250, 350, 450, 550 Super Duty, 7/2007

Radius Arm
NOTE:
LH shown, RH similar.

1 W505273 Wheel speed sensor harness bolt
2 N807659 Radius arm front nut (2 required)
3 W709860 Radius arm front bolt (2 required)
4 N807659 Radius arm rear nut
5 N806967 Radius arm rear bolt
6 3B346 LH/ 3405 RH Radius arm
NOTICE:
Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure can result in major
service expense. They must be replaced with the same part number or an equivalent part if replacement is necessary. Do not use a replacement part
of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts.
1. Remove the shock absorber. For additional information, refer to Shock Absorber in this section.
2. NOTICE:
Tighten the radius arm front nuts with the suspension at curb height or damage to the bushings may occur.
Remove and discard the 2 radius arm front nuts and bolts.
• To install, tighten the new nuts to 300 Nm (222 lb-ft).
3. Remove the wheel speed sensor harness bolt.
• To install, tighten to 8 Nm (71 lb-in).
4. NOTICE:
Tighten the radius arm rear nut with the suspension at curb height or damage to the bushing may occur.
Remove and discard the radius arm rear nut and bolt.
• To install, tighten the new nut to 300 Nm (222 lb-ft).
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
5. Remove the radius arm.
6. To install, reverse the removal procedure.
2008 F-250, 350, 450, 550 Super Duty, 7/2007


CONTENTS PAGE
Shock Absorber ................................................................................................................................................................ 204-01B-2
2008 F-250, 350, 450, 550 Super Duty, 7/2007

Shock Absorber
NOTE:

1 18A192 Upper nut, washer and bushing assembly (upper half)
2 W500765 Shock absorber lower bolt
3 W711430 Shock absorber lower flagnut
4 18045 Shock absorber
WARNING:
Do not apply heat or flame to the shock absorber or strut tube. The shock absorber and strut tube are gas pressurized and could explode if heated.
Failure to follow this instruction may result in serious personal injury.
NOTICE:
2. Remove and discard the shock absorber upper nut, washer and bushing assembly (upper half).
3. Remove and discard the shock absorber lower bolt and flagnut.
• To install, tighten the new bolt to 150 Nm (111 lb-ft).
4. Remove the shock absorber.
2008 F-250, 350, 450, 550 Super Duty, 7/2007


CONTENTS PAGE
Spring ............................................................................................................................................................................... 204-01B-2
2008 F-250, 350, 450, 550 Super Duty, 7/2007

Spring
NOTE:

2 W701642 Shock absorber lower flag nut
3 5C491 Stabilizer bar link lower bolt
4 5310 Spring
5 5415 Spring upper insulator
WARNING:
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
NOTICE:
1. Remove the wheel and tire. For additional information, refer to Section 204-04.
2. Index-mark the spring and the spring upper insulator.
3. Using a suitable jack, support the front axle assembly.

4. Remove and discard the front shock absorber lower bolt and flag nut.
5. Remove and discard the stabilizer bar link lower bolt.
6. Lower the axle and remove the spring.
7. NOTE:
Inspect the spring upper and lower seats, install new as necessary.
To install, reverse the removal procedure.
2008 F-250, 350, 450, 550 Super Duty, 7/2007


CONTENTS PAGE
Stabilizer Bar Bushing ...................................................................................................................................................... 204-01B-2
2008 F-250, 350, 450, 550 Super Duty, 7/2007

Stabilizer Bar Bushing

1 5484 Stabilizer bar bushing (2 required)
2 5494 Stabilizer bar
3 W520113 Stabilizer bar bracket nut (4 required)
4 5486 Stabilizer bar bracket (2 required)

2. Remove the 4 stabilizer bar bracket nuts and the 2 stabilizer bar brackets.
• Discard the nuts.
3. Position the stabilizer bar to access the bushing.
4. Remove the bushing.
2008 F-250, 350, 450, 550 Super Duty, 7/2007


CONTENTS PAGE
Stabilizer Bar Link ............................................................................................................................................................ 204-01B-2
2008 F-250, 350, 450, 550 Super Duty, 7/2007

Stabilizer Bar Link
NOTE:

1 W707243 Stabilizer bar link upper nut (2 required)
2 W709373 Stabilizer bar link upper bolt (2 required)
3 3B438 Stabilizer bar link (2 required)
4 W709373 Stabilizer bar link lower bolt (2 required)
5 W711358 Washer
NOTICE:
2. Remove the stabilizer bar link lower bolt and washer.
• Discard the bolt.
3. NOTE:
If the clinch nut in the axle is stripped or damaged, remove the clinch nut and install a new flagnut (W711430) in place of the clinch nut.
Remove and discard the stabilizer bar link upper nut, bolt and washer.
4. Remove the stabilizer bar link.
2008 F-250, 350, 450, 550 Super Duty, 7/2007


CONTENTS PAGE
Stabilizer Bar .................................................................................................................................................................... 204-01B-2
2008 F-250, 350, 450, 550 Super Duty, 7/2007

Stabilizer Bar

1 W707243 Stabilizer bar link upper nut (2 required)
2 W709373 Stabilizer bar link upper bolt (2 required)
3 W709373 Stabilizer bar link lower bolt (2 required)
4 W711358 Washer (2 required)
5 W520113 Stabilizer bar bracket nut (4 required)
6 3B353 Stabilizer bar bracket (2 required)
7 5494 Stabilizer bar
8 W712045 Stabilizer bar bracket bolt and retainer (4 required)
9 3B438 Stabilizer bar link (2 required)
10 5484 Stabilizer bar bushing (2 required)
NOTICE:
2. NOTE:
If the clinch nut in the axle is stripped or damaged, remove the clinch nut and install a new flagnut (W711430) in place of the clinch nut.
Remove and discard the stabilizer bar link upper nuts, bolts and washers.
3. Remove the stabilizer bar bracket nuts, brackets and the stabilizer bar.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
2008 F-250, 350, 450, 550 Super Duty, 7/2007


CONTENTS PAGE
Track Bar .......................................................................................................................................................................... 204-01B-2
2008 F-250, 350, 450, 550 Super Duty, 7/2007

Track Bar
2008 F-250, 350, 450, 550 Super Duty, 7/2007


CONTENTS PAGE
Wheel Bearing and Wheel Hub ........................................................................................................................................ 204-01B-2
2008 F-250, 350, 450, 550 Super Duty, 7/2007

Wheel Bearing and Wheel Hub
Material
Item Specification
High Temperature 4x4 Front Axle and Wheel Bearing Grease WSS-M1C267-A1
XG-11

1 W709789 Brake caliper anchor plate bolt (2 required)
2 2B121 LH/ 2B210 RH Brake caliper
3 W709526 Hublock screw
4 3B396 Hublock
5 1K106 Hublock gasket
6 W520506 Wheel extension nut (part of 1A104) (8 required)
7 1A104 Wheel extension
8 1125 Brake disc
9 1B093 Axle shaft snap ring
10 1107 Wheel bearing and wheel hub nut (part of 2B663) (4 required)
11 2B663 Wheel bearing and wheel hub
12 2K005 Brake disc shield
13 — Wheel speed sensor bolt
14 2C204 Wheel speed sensor
15 4A322 Wheel bearing and wheel hub O-ring
16 1120 Wheel bearing and wheel hub stud (part of 2B663)
Removal
All vehicles
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
Vehicles with ABS
2. Unclip the wheel speed sensor harness from the frame.
3. Remove the 2 wheel speed sensor harness bolts.
4. Remove the wheel speed sensor harness-to-wheel knuckle bolt.

Vehicles with Dual Rear Wheels (DRW)
5. Remove and discard the 8 wheel extension nuts and the wheel extension.
All vehicles
6. NOTICE:
Do not allow the caliper to hang from the brake hose or damage to the hose can occur.
Remove the 2 brake caliper anchor plate bolts and position the brake caliper aside.
• Support the brake caliper using mechanic's wire.
7. Index-mark and remove the brake disc.
8. NOTICE:
The service replacement kit includes 2 O-ring seals; one for testing the hublock assembly and one for reassembly into the wheel hub. DO
NOT REUSE O-RING SEALS or hublock failure may occur.
NOTE:
Due to the fit of the splines, the hublock will be difficult to remove. Lifting or lightly prying (with a small bar) on the axle U-joint will ease removal.
When prying on the cap/hub flange, work around the flange to uniformly withdraw the hublock.
NOTE:
Always check the vacuum leak rate of the wheel end assembly when repairing or diagnosing the axle, wheel end or hublock performance.
Remove the hublock.

• Loosen each screw 1 to 2 turns.
• Gently pry on the hublock cap edge to release gasket adhesion.
• Remove and discard the screws.
• While lifting/jiggling the axle U-joint, pull or uniformly pry the hublock from the wheel bearing and wheel hub.
9. Remove the axle shaft snap ring.
10. NOTE:
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
The wheel bearing and wheel hub assembly is a slip-fit design and should not require a puller to remove it.
Remove the 4 wheel hub nuts and the wheel hub.

11. If necessary, remove the brake disc shield.
Vehicles with ABS
12. Remove the wheel speed sensor bolt and position the sensor aside.
All vehicles
13. Remove and discard the wheel bearing and wheel hub O-ring seal.
14. Position the wheel bearing and wheel hub in a vise with protective caps and remove the 4 studs using 2 mounting nuts.
Installation
All vehicles
1. Position the wheel bearing and wheel hub in a vise with protective caps and install the 4 studs using 2 mounting nuts.
2. NOTE:
Any time the wheel bearing and wheel hub are removed for any reason, a new O-ring seal must be installed. Failure to do so can cause a vacuum leak
and loss of Four-Wheel Drive (4WD) operations.
Install a new wheel bearing and wheel hub O-ring seal.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
Vehicles with ABS

3. Position the wheel speed sensor and install the bolt.
• Tighten to 18 Nm (159 lb-in).
All vehicles
4. If removed, position the brake disc shield.
5. NOTE:
Apply a coat of grease to the O-ring area of the wheel bearing and wheel hub before installation.
Position the wheel bearing and wheel hub and install the 4 new nuts.
All vehicles
6. Install the axle shaft snap ring.
7. NOTE:
Any time the hublock is removed, a new O-ring seal must be installed. Failure to do so can cause a vacuum leak and loss of 4WD functions.
Install a new hublock O-ring seal.

8. NOTICE:
The service replacement kit includes 2 O-ring seals; one for testing the hublock assembly and one for reassembly into the wheel hub. DO
NOT REUSE O-RING SEALS or hublock failure may occur.
NOTE:
Always check the vacuum leak rate of the wheel end assembly when repairing or diagnosing the axle, wheel end or hublock performance.
Install a new hublock gasket, then install the hublock in the following sequence.
1 Rotate the hublock dial clockwise to the lock position. Apply the specified grease to the inner and outer splines.
2 Insert the hublock into the wheel hub while slowly turning the wheel hub to align the splines. Lift/jiggle the axle U-joint while pushing the
hublock into the wheel hub.
9. Install new hublock screws. Rotate the dial to the counterclockwise position (free/auto) and confirm that the wheel hub turns free of the axle shaft.
10. NOTICE:
Make sure that the wheel hub and brake disc mounting surfaces are clean and free of foreign material or excessive runout and/or vibration
may occur.
Position the brake disc onto the wheel hub noting the position of the index mark.
11. Position the brake caliper and anchor plate assembly and install the bolts.
• F-250 and F-350, tighten to 225 Nm (166 lb-ft).
Vehicles with DRW
12. Position the wheel extension and install the new nuts.
Vehicles with ABS
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
13. Install the wheel speed sensor harness-to-wheel knuckle bolt.
14. Install the 2 wheel speed sensor harness-to-axle bolts.
15. Connect the wheel speed sensor harness to the frame.
2008 F-250, 350, 450, 550 Super Duty, 7/2007


CONTENTS PAGE
Wheel Knuckle ................................................................................................................................................................. 204-01B-2
2008 F-250, 350, 450, 550 Super Duty, 7/2007

Wheel Knuckle
Special Tool(s)
C-Frame and Screw Assembly

211-023 (T74P-3044-A1)
Installer/Remover, Drive Pinion Oil Seal

205-440
Installer, Wheel Knuckle Seal (F250/350)

205-830
Installer, Wheel Knuckle Seal (F450/550)

205-831
Separator, Ball Joint

204-592
Steering Arm Remover

211-003 (T64P-3590-F)
Material
Item Specification
Threadlock and Sealer WSK-M2G351-A5
TA-25
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)

1 3219 LH/ 3220 RH Axle shaft
2 3254 Axle shaft main seal
3 W525287 Cotter pin
4 W711373 Tie-rod end nut
5 W525287 Cotter pin
6 3A049 Upper ball joint nut
7 3B404 Camber adjustment sleeve
8 3A050 Lower ball joint nut
9 3131 LH/ 3130 RH Wheel knuckle
Removal
1. Remove the wheel bearing and wheel hub. For additional information, refer to Wheel Bearing and Wheel Hub in this section.
2. Using a drift, drive the axle shaft main seal out of the wheel knuckle.
3. If equipped, disconnect the pulse vacuum hub hose.

4. Remove the axle shaft and main seal.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
5. Remove the cotter pin and the tie-rod end nut.

6. If removing the RH wheel knuckle, using the C-Frame and Screw Assembly, disconnect the RH tie-rod end from the wheel knuckle.
7. If removing the LH wheel knuckle, using the Ball Joint Separator, disconnect the LH tie-rod end from the wheel knuckle.
8. Remove the upper ball joint cotter pin and nut.

9. Loosen, but do not remove, the lower ball joint nut.
10. NOTICE:
To prevent damage to the ball joint seal and the ball joint socket, do not use a pickle fork-type remover to loosen the ball joints.
Strike the lower and upper end of the axle to loosen the ball joints and the camber adjustment sleeve.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
11. Using the Steering Arm Remover, remove the camber adjuster.
12. Remove the lower ball joint nut and the wheel knuckle.
13. Clean and inspect the wheel knuckle bore. If the wheel knuckle is cracked, a new one must be installed.
Installation
1. NOTICE:
The caster/camber adjustment sleeve must be removed and the axle bores and adjustment sleeve contact areas cleaned to ensure proper
torque sequence. If not clean, damage to the ball joint, adjustment sleeve and/or axle bores can occur.
NOTICE:
Failure to remove the caster/camber adjustment sleeve can result in a hard to steer condition.
Remove the caster adjustment sleeve and thoroughly clean the axle bore and adjustment sleeve contact areas.
2. Install the camber adjustment sleeve.
3. Position the wheel knuckle onto the axle and install the nut onto the upper ball joint. Do not tighten the nut at this time.
4. Apply threadlock and sealer to the threads of the lower ball joint and install the new nut onto the lower ball joint. Do not tighten the nut at this time.
6. NOTE:
Do not loosen the nut to install the cotter pin.
Tighten the upper ball joint nut to 94 Nm (69 lb-ft) and install the cotter pin.
• If necessary, tighten the nut until the cotter pin can be installed.
8. Connect the tie-rod end to the wheel knuckle and install the nut and a new cotter pin.
• Tighten to 115 Nm (85 lb-ft). If necessary, tighten the nut until the cotter pin can be installed.
9. Install the new main seal onto the axle shaft.
1 Position the main seal onto the axle shaft.
2 Using the Drive Pinion Oil Seal Installer/Remover and Wheel Knuckle Seal Installer, seat the main seal onto the axle shaft.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
10. NOTICE:
The knuckle bore must be clean enough to allow the Drive Pinion Oil Seal Installer/Remover to seat completely by hand. Do not press or
draw the wheel knuckle seal and axle shaft into place or damage to the seal may occur.
NOTE:
Do not apply any lubricant to the surface of the wheel knuckle bore.
Position the axle shaft and main seal in to the wheel knuckle and axle housing.
11. NOTE:
F-450/F-550 shown, F-250/F-350 similar.
Position the Wheel Knuckle Seal Installer onto the axle shaft and install the snap ring.
12. NOTE:
F-450/F-550 shown, F-250/F-350 similar.
Using the Drive Pinion Oil Seal Installer/Remover and Wheel Knuckle Seal Installer, install the wheel knuckle seal and axle shaft.
13. Install the wheel bearing and wheel hub. For additional information, refer to Wheel Bearing and Wheel Hub in this section.
14. If equipped, connect the pulse vacuum hub hose.
2008 F-250, 350, 450, 550 Super Duty, 7/2007


CONTENTS PAGE
Wheel Studs ..................................................................................................................................................................... 204-01B-2
2008 F-250, 350, 450, 550 Super Duty, 7/2007

Wheel Studs
Special Tool(s)
C-Frame and Clamp Assembly

211-023 (T74P-3044-A1)

1 1104 Brake disc
2 2B121 RH/ 2B210 LH Brake caliper assembly
3 2B663 Wheel bearing and hub assembly
4 N811625 Brake caliper anchor plate bolt (2 required)
5 1107 Wheel stud
Removal
2. NOTICE:
Do not allow the caliper assembly to hang from the brake hose or damage to the hose may occur.
Remove the 2 caliper anchor plate bolts and position the caliper assembly aside.
• Support the caliper assembly using mechanic's wire.
3. Index-mark and remove the brake disc.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
4. Using the C-Frame and Clamp Assembly, remove and discard the wheel stud.
Installation
1. Position a new wheel stud, aligning the serrations in the wheel hub made by the original stud.
2. NOTE:
Make sure to use washers that have an ID that is larger than the OD of the wheel stud serrations. Use enough washers (approximately 4) to allow the
wheel stud to fully seat against the hub flange.
Place 4 washers over the outside end of the wheel stud and thread a standard wheel nut with the flat side against the washers. Tighten the wheel nut
until the wheel stud seats against the back side of the wheel extension.
3. Remove the wheel nut and washers.

4. NOTE:
Be sure to align index marks made during the removal step.
Install the brake disc.

5. Position the brake caliper and anchor plate assembly and install the 2 anchor plate bolts.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

204-02-i Rear Suspension 204-02-i
SECTION 204-02 Rear Suspension

CONTENTS PAGE
Shock Absorber .................................................................................................................................................................. 204-02-2
2008 F-250, 350, 450, 550 Super Duty, 7/2007

204-02-2 Rear Suspension 204-02-2
Shock Absorber

1 N806085 Shock absorber upper nut and washer
2 W520114 Shock absorber lower nut
4 18125 Shock absorber
5 18178 Shock absorber bracket
6 W520113 Shock absorber bracket nuts (2 required)
WARNING:
NOTICE:
Suspension fasteners are critical components because they affect performance of vital components and systems and their failure can result in major
service expense. Install new components with the same component number or an equivalent component if installation is necessary. Do not use an
installation component of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct
retention of these components.
2. Using a suitable jack, support the rear axle.
3. Remove and discard the shock absorber lower nut and bolt.
• To install, tighten the new nut and bolt to 90 Nm (66 lb-ft).
4. Remove and discard the shock absorber upper nut and remove the shock absorber.
2008 F-250, 350, 450, 550 Super Duty, 7/2007


CONTENTS PAGE

Rear Suspension ................................................................................................................................................................ 204-02-2
Rear Suspension System ............................................................................................................................................. 204-02-2
2008 F-250, 350, 450, 550 Super Duty, 7/2007


Rear Suspension
Rear Suspension System
The rear suspension consists of the following components:
• Axle jounce bumpers

• Leaf springs
• Shock absorbers
• Stabilizer bar
• Stabilizer bar links
• Wheel studs
The rear suspension system utilizes a solid driving axle supported by shock absorbers and semi-elliptic, leaf-type rear springs. The rear suspension may also
incorporate a stabilizer bar to enhance vehicle stability. Rear vehicle height can be adjusted through the use of shims placed between the axle and the leaf
springs.
2008 F-250, 350, 450, 550 Super Duty, 7/2007


CONTENTS PAGE

Rear Suspension ................................................................................................................................................................ 204-02-2
2008 F-250, 350, 450, 550 Super Duty, 7/2007


Rear Suspension
Refer to Section 204-00.
2008 F-250, 350, 450, 550 Super Duty, 7/2007


CONTENTS PAGE
Spring — F-250, F-350 ........................................................................................................................................................ 204-02-2
2008 F-250, 350, 450, 550 Super Duty, 7/2007

Spring — F-250, F-350
NOTE:
Pickup shown, other vehicles similar.

1 N620485 U-bolt nut (4 required)
2 5796 Bottom cap
3 W714005 Spring-to-front bracket bolt
4 W520117 Spring-to-front bracket nut
5 W715138 Shackle-to-rear bracket bolt
6 W711218 Shackle-to-rear bracket flagnut
7 5776 Spring shackle
8 W714456 Spring-to-shackle bolt
9 N620485 Spring-to-shackle nut
10 5560/ 5A975 Spring assembly
11 5588 Auxiliary spring
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)

12 5705 U-bolt (2 required)
13 — Auxiliary spring nut (part of 5588)
14 5598 Spacer
Removal
NOTICE:
2. Using a suitable jack, support the rear axle.
3. Remove and discard the U-bolt nuts and U-bolts and remove the rear spring bottom cap.
4. Remove and discard the spring-to-front bracket bolt and nut.
5. Remove and discard the shackle-to-rear bracket bolt and flagnut.
6. NOTE:
If the rear spring has an auxiliary spring and spacer, it is serviced as part of the rear spring assembly.
Remove the rear spring assembly.
Installation
1. NOTICE:
Final tightening of the shackle-to-rear bracket bolt must be done with the suspension at curb height or damage to the bushing may occur.
Position the rear spring and install the shackle-to-rear bracket bolt and flagnut until snug. Do not tighten the nut at this time.
2. NOTICE:
Final tightening of the spring-to-front bracket bolt must be done with the suspension at curb height or damage to the bushing may occur.
Install the spring-to-front bracket bolt and nut until snug. Do not tighten the nut at this time.
3. NOTICE:
Final tightening of the U-bolt nuts must be done with the suspension at curb height or incorrect clamp load may occur.
Position the bottom cap and install the U-bolts and nuts, align the U-bolts so they are as vertical as possible, and tighten until snug. Do not fully
tighten the nuts at this time.
4. With the suspension at curb height, tighten the new shackle-to-rear bracket bolt to 225 Nm (166 lb-ft).
5. With the suspension at curb height, tighten the new spring-to-front bracket bolt to 515 Nm (340 lb-ft).
6. With the suspension at curb height, tighten the new nuts evenly in a cross-type pattern in 4 stages.
• Stage 1: Tighten to 65 Nm (48 lb-ft).
7. Install the wheel and tire. For additional information, refer to Section 204-04.
2008 F-250, 350, 450, 550 Super Duty, 7/2007


CONTENTS PAGE
Stabilizer Bar and Link — F-250, F-350 .............................................................................................................................. 204-02-2
2008 F-250, 350, 450, 550 Super Duty, 7/2007

Stabilizer Bar and Link — F-250, F-350

F-250 and F-350 Wide Frame Vehicles

1 W707492 Stabilizer bar link lower nuts (2 required)
2 W707492 Stabilizer bar link upper nuts (2 required)
3 5K484 Stabilizer bar links (2 required)
4 N605920 Stabilizer bar bracket bolts (4 required)
5 5486 Stabilizer bar brackets (2 required)
6 5A772 Stabilizer bar
7 5493 Stabilizer bar bushings
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
F-350 Single Rear Wheel (SRW), Narrow Frame Vehicles

1 W707492 Stabilizer bar link lower nuts (2 required)
2 5K484 Stabilizer bar links (2 required)
3 W707492 Stabilizer bar link upper nuts (2 required)
4 W520113 Stabilizer bar bracket nuts (4 required)
5 4A340 Stabilizer bar bracket U-bolts (2 required)
6 5486 Stabilizer bar brackets (2 required)
7 5A772 Stabilizer bar
8 5493 Stabilizer bar bushings
9 5B498 Stabilizer bar mounting bracket (2 required)
NOTICE:
All vehicles
2. Remove and discard the stabilizer bar link lower nuts.
3. Remove and discard the stabilizer bar link upper nuts and remove the stabilizer bar links.
F-350 Single Rear Wheel (SRW), narrow frame vehicles
4. Remove the stabilizer bar bracket nuts, U-bolts, brackets and the stabilizer bar.
• Discard the nuts and U-bolts.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
F-250/F-350 wide frame vehicles
5. Remove the stabilizer bar bracket bolts, brackets and the stabilizer bar.
• Discard the bolts.
• To install, tighten the new bolts to 48 Nm (35 lb-ft).
All vehicles
2008 F-250, 350, 450, 550 Super Duty, 7/2007


CONTENTS PAGE
Wheel Hub .......................................................................................................................................................................... 204-02-2
2008 F-250, 350, 450, 550 Super Duty, 7/2007

Wheel Hub
For additional information, refer to Section 205-02C.
2008 F-250, 350, 450, 550 Super Duty, 7/2007


CONTENTS PAGE
Wheel Studs — Single Rear Wheel (SRW) ......................................................................................................................... 204-02-2
2008 F-250, 350, 450, 550 Super Duty, 7/2007

Wheel Studs — Single Rear Wheel (SRW)

Special Tool(s)
C-Frame and Screw Assembly

211-023 (T74P-3044-A1)

1 — Wheel hub (part of 4001)
2 390268 Wheel stud (also part of 4001)
Removal
1. Remove the rear wheel hub assembly. For additional information, refer to Section 205-02C.
2. Using the C-Frame and Screw Assembly, remove and discard the wheel stud.
Installation
1. Position the wheel stud in the flange making sure that the serrations are aligned with those made by the original wheel stud.
2. Using the C-Frame and Screw Assembly, install the wheel stud.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
3. Install the rear wheel hub assembly. For additional information, refer to Section 205-02A.
2008 F-250, 350, 450, 550 Super Duty, 7/2007


CONTENTS PAGE
SPECIFICATIONS ..................................................................................................................................................................... 204-02-2
2008 F-250, 350, 450, 550 Super Duty, 7/2007

SPECIFICATIONS
Description Nm lb-ft
Auxiliary spring nut a — —
Shackle-to-bracket bolt 225 166

Shock absorber bracket nuts 40 30
Shock absorber lower nut 90 66
Shock absorber upper nut and washer 70 52
Spring-to-front bracket bolt 515 340
Spring-to-shackle nut 225 166
Stabilizer bar bracket bolts — F-250, F-350 48 35
Stabilizer bar bracket bolts — F-450, F-550 80 59
Stabilizer bar bracket nuts 40 30
Stabilizer bar link lower nuts 103 76
Stabilizer bar link upper nuts 80 59
U-bolt nuts
a — —
2008 F-250, 350, 450, 550 Super Duty, 7/2007

204-04-i Wheels and Tires 204-04-i
SECTION 204-04 Wheels and Tires

CONTENTS PAGE

Wheels And Tires ............................................................................................................................................................... 204-04-2
Tire Inflation Information ............................................................................................................................................... 204-04-2
Tire Rotation ................................................................................................................................................................. 204-04-2
Safety Precautions ....................................................................................................................................................... 204-04-2
Tire Pressure Monitoring System (TPMS) .................................................................................................................... 204-04-5
Tire Pressure Monitoring System (TPMS) Module ................................................................................................. 204-04-5
Tire Pressure Monitoring System (TPMS) Pressure Sensor .................................................................................. 204-04-5
Tire Pressure Monitoring System (TPMS) Pressure Sensor Cradle ...................................................................... 204-04-5
Tire Pressure Monitoring System (TPMS) Pressure Sensor Strap ........................................................................ 204-04-5
2008 F-250, 350, 450, 550 Super Duty, 7/2007

204-04-2 Wheels and Tires 204-04-2

Wheels And Tires
WARNING:
Only use replacement tires that are the same size, load index, speed rating and type (such as P-metric versus LT-metric or all-season versus all-
terrain) as those originally provided by Ford. The recommended tire and wheel size may be found on either the Safety Compliance Certification
Label or the Tire Label, which is located on the B-pillar or edge of the driver's door. If the information is not found on these labels, consult a Ford
dealer. Use of any tire or wheel not recommended by Ford can affect the safety and performance of the vehicle, which could result in an increased
risk of loss of vehicle control, vehicle rollover, personal injury and death. Additionally, the use of non-recommended tires and wheels could cause
steering, suspension, axle or transfer case/power transfer unit failure.
Factory-installed tires and wheels are designed to operate satisfactorily with loads up to and including full-rated load capacity when inflated to recommended
inflation pressures.
Tire Inflation Information
WARNING:
Never inflate a tire that has been run flat without first removing the tire from the wheel to inspect for damage. A damaged tire can fail during
inflation. Failure to follow this instruction may result in serious personal injury.
The vehicle is equipped with a tire that is an all-steel radial. All-steel radial tires utilize steel cords in the sidewalls and also require increased inflation
pressures of up to 85 psi. As such, they cannot be treated like normal light truck tires. Tire service, including adjusting tire pressure, must be carried out by
personnel trained, supervised and equipped according to OSHA regulations. For example, during any procedure involving tire inflation, the technician or
individual must utilize a remote inflation device and make sure that all persons are at a safe distance.
Tire Rotation
For vehicles with different front and rear tire pressure (such as E-Series and certain F-Series), the tire pressures must be adjusted and the tire pressure sensors
must be trained following a tire rotation. Refer to Wheel and Tire Rotation in this section. Failure to train the sensors will result in a false low tire pressure
event, which will cause the Tire Pressure Monitoring System (TPMS) indicator to illuminate.
For vehicles with the same tire pressure for front and rear tires, tire rotation will not affect the TPMS.
Safety Precautions
CAUTION and SAFETY FIRST are bywords when handling truck tires. Careful attention to the safety precautions that follow can prevent crippling injuries
or even death. Make it a rule to respect the terrific force contained in an inflated tire.
Wheels must be correctly maintained. Incorrectly maintained wheels can adversely affect the life of the tire and the wheel. When inflated, a tire is potentially
very destructive. Accidents are caused by careless handling and inexperience.
Follow the safety precautions in this section and obtain safety literature from your wheel and rim distributor, wheel and rim manufacturer, National Highway
Traffic Safety Administration (NHTSA) or OSHA. For additional questions, consult the distributor or manufacturer directly.
The load carrying requirements of each vehicle should be determined before selecting the correct tire/wheel combination. Always remember that the weakest
weight carrying component of the vehicle (tire, wheel, axle, bearings, etc.) determines the overall maximum and safe load carrying capacity for the vehicle.
WARNING:
Do not overload beyond the capacity of the lowest rated wheel/tire assembly on the vehicle. Tire failure could result. Failure to follow this
instruction may result in serious injury to vehicle occupant(s).
2008 F-250, 350, 450, 550 Super Duty, 7/2007

Rims and wheels are designed to sustain their rated load using the maximum tire size recommended for that rim width by the Tire and Rim Association.
WARNING:
Never inflate a tire that has been run flat without first removing the tire from the wheel to inspect for damage. A damaged tire can fail during
inflation. Failure to follow this instruction may result in serious personal injury.
WARNING:
Always match the tire size to the wheel size during assembly. Incorrect matching can result in tire bead damage or tire separation from the wheel.
Failure to follow this instruction may result in serious personal injury to technician or vehicle occupant(s).
When installing new tires, use the same size, load range and construction type as originally installed on the vehicle. When installing new wheels, use OEM
wheels or equivalent available from the Ford dealer with equivalent capacity, width, offset and mounting configuration as those originally installed on the
vehicle. Use of incorrect tires and wheels can adversely affect ride, handling, load carrying capacity, bearing life, tire clearance to body and chassis
components, vehicle ground clearance, vehicle width and brake cooling.
Prepare for any tire repair operation in a safe and efficient way. In servicing all tires, use caution not to drop them (or the wheels) on the feet, hands, body or
heavily on the floor. Truck tires are heavy and a wheel jack such as Rotunda Heavy Duty Wheel Dolly 014-00030 or equivalent should be used to maneuver
tires.
WARNING:
Cracked wheels can be dangerous. Deflate tires on cracked wheels prior to removal of wheels from the vehicle. Failure to follow this instruction
may result in serious personal injury.
WARNING:
Keep eyes away from valve stem when deflating tires. Reduce air pressure in tire as much as possible by pushing in valve core plunger prior to
removing the core. Escaping air can carry particles that can injure the eyes. Failure to follow these instructions may result in serious personal
injury.
Deflating a tire correctly is very important for safety. First, reduce the pressure as much as possible by depressing the valve core plunger. Only then should
the valve core be removed to completely deflate the tire before removal from the vehicle or disassembly. On dual wheels, deflate both tires completely.
Demounting tires from the wheels requires special care. Use only standard tire mounting tools and equipment. The use of makeshift tools to force tires on or
off the wheels is dangerous and must be avoided.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

Always lubricate tire beads to make sure of correct sealing of the tire beads on the rim. Use Silicone Spray Lubricant.
Make sure all the air is out before removing the tires from the wheels. Use special care when using tire irons. Grip the tire irons firmly and keep them free of
oil and grease. They can slip and fly with tremendous force.
WARNING:
Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury.
WARNING:
Do not hit the wheel or tire with a metallic hammer. This action may damage the wheel or tire, resulting in tire or wheel failure. Failure to follow
this instruction may result in serious personal injury to the technician or vehicle occupant(s).
WARNING:
Always inflate steel carcass tires and/or split rim wheels using an Occupational Safety and Health Administration (OSHA) approved tire safety
cage. Use a clip-on air chuck with remote valve and pressure gauge for inflation. Stand as far away as possible while using the remote valve. Split
rims can come apart under great force if not correctly assembled. Failure to follow these instructions may result in serious personal injury.
Place the wheel and tire assembly in the safety cage and inflate to a maximum of 10 pounds. Check to see that the beads are correctly seated. Continue to
inflate to recommended pressure.
Use only accurate, tested gauges to make sure of correct air pressure. Check all gauges regularly with a master gauge.
Never attempt to short-cut the above procedures.
WARNING:
Block all wheels, set the parking brake and firmly apply the service brake to reduce the risk of vehicle movement during this procedure. Failure to
follow these instructions may result in serious personal injury.
WARNING:
Inflating tires to pressures that exceed maximum tire inflation rating on tire sidewall may result in tire failure and serious personal injury to the
technician or vehicle occupant(s).
WARNING:
Do not operate a vehicle equipped with dual rear wheels (DRW) and tires on a single rear wheel and tire. The increased load on the remaining rear
wheel and tire assembly could result in tire failure. Always operate vehicle with all rear wheels installed. Failure to follow this instruction may
result in serious injury to vehicle occupant(s).
WARNING:
Vehicle may have multiple drive wheels. Do not use engine to power the driveline unless all drive wheels are elevated off the ground. Drive wheels
in contact with ground could cause unexpected vehicle movement. Failure to follow this instruction may result in serious personal injury.
WARNING:
Before servicing any tire, ask the customer if anyone injected a tire sealant into the tire. Tire sealants may be flammable and can burn or explode if
exposed to an ignition source. Failure to follow this instruction may result in serious personal injury.
WARNING:
Never use wheels different than the original equipment. Additionally, never use wheel nuts different than the original equipment. Failure to follow
these instructions may result in damage to the wheel or mounting system. This damage could cause the wheel to come off while the vehicle is being
driven, which could result in serious personal injury or death to vehicle occupant(s).
NOTE:
Thumping or simply looking at the tire does not give an accurate pressure reading. Periodically check the air pressure gauge for accuracy and use it to check
tire pressure.
When carrying out any inspection or repair procedures on wheels and tires, follow the preceding safety precautions.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

Tire Pressure Monitoring System (TPMS)

The Tire Pressure Monitoring System (TPMS) includes:
• the VSM, TPMS functionality is integrated within the VSM.

• four tire pressure sensors.
• four tire pressure sensor cradles.
• four tire pressure sensor straps.
• an instrument cluster indicator.
• a message center (if equipped).
Tire Pressure Monitoring System (TPMS) Module

The VSM contains the TPMS functionality. Refer to Tire Pressure Monitoring System (TPMS) in Diagnosis and Testing for TPMS fault diagnosis and
repair.
The VSM compares the information of each tire pressure sensor transmission against a pressure limit. If the VSM determines that the tire pressure has fallen
below the low limit, the VSM communicates this to the Instrument Cluster (IC) on the vehicle communication bus.
Tire Pressure Monitoring System (TPMS) Pressure Sensor

The VSM monitors the air pressure in the 4 road tires with tire pressure sensors. The sensors transmit radio frequency signals to the VSM approximately
every 60 seconds when the vehicle speed exceeds 32 km/h (20 mph).
The tire pressure sensors are battery operated and are mounted to metal brackets (called cradles) on the wheels inside the tires. The sensors are mounted 180
degrees from the valve stem.
The tire pressure sensor can be serviced separately from the cradle and the strap.
Tire Pressure Monitoring System (TPMS) Pressure Sensor Cradle

The tire pressure sensor cradles are mounted to the wheels with metal straps and have an adhesive strip to aid in their retention to the wheel.
To service the sensor cradle, the strap must also be removed.
Tire Pressure Monitoring System (TPMS) Pressure Sensor Strap

The sensor strap keeps the sensor and the cradle retained to the wheel. A factory-installed strap is joined together with a one-time use buckle and a dealer-
installed strap is joined together with a worm gear (similar to a radiator hose clamp). Both straps should be discarded after removal and should not be re-
used.
The sensor can be serviced separately from the strap and cradle. The sensor is available separately from the cradle and the strap. The cradle and strap are
available as a strap kit. There are several different strap kits available based on wheel diameter, all strap kits share the same base part number.
Instrument Cluster and Message Center

The IC illuminates the TPMS indicator when it receives a message from the VSM to do so and displays the appropriate message(s) in the message center (if
equipped).
The instrument cluster and message center are diagnosed and serviced in their own respective workshop manual sections.
2008 F-250, 350, 450, 550 Super Duty, 7/2007


CONTENTS PAGE

Tire Pressure Monitoring System (TPMS) .......................................................................................................................... 204-04-2
Principles of Operation ................................................................................................................................................. 204-04-2
Ambient Temperature Change and Tire Pressure ................................................................................................. 204-04-2
Tire Pressure Monitoring System (TPMS) Indicator and Message Center Messages ........................................... 204-04-3
Tire Pressure Monitoring System (TPMS) Indicator Illuminates Continuously ....................................................... 204-04-3
Tire Pressure Monitoring System (TPMS) Indicator Flashes ................................................................................. 204-04-4
Tire Pressure Monitoring System (TPMS) PID Definitions and Intermittent Troubleshooting ...................................... 204-04-4
DTC Charts ................................................................................................................................................................... 204-04-6
Symptom Chart ............................................................................................................................................................. 204-04-7
Pinpoint Tests ............................................................................................................................................................... 204-04-9
2008 F-250, 350, 450, 550 Super Duty, 7/2007


Special Tool(s)
Activation Tool, Tire Pressure Monitor

204-363
Digital Tire Pressure Gauge

204-354
Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS)

software with appropriate hardware, or equivalent scan tool
Principles of Operation
NOTE:
The Smart Junction Box (SJB) is also referred to as the Generic Electronic Module (GEM).
The Tire Pressure Monitoring System (TPMS) monitors the air pressure of all 4 road tires. The wheel-mounted tire pressure sensors transmit via radio
frequency signals, to the SJB. TPMS functionality is integral to the SJB. These transmissions are sent approximately every 60 seconds when the vehicle
speed exceeds 32 km/h (20 mph). The TPMS function compares each tire pressure sensor transmission against a low-pressure limit. If it has been determined
that the tire pressure has fallen below this limit, the SJB communicates this on the vehicle communication bus to the instrument cluster. The instrument
cluster then illuminates the TPMS indicator and displays the appropriate message(s) in the message center (if equipped).
For vehicles with different front and rear tire pressures (such as the E-Series and certain F-Series), the tire pressures must be adjusted and the tire pressure
sensors must be trained following a tire rotation. Failure to train the sensors will cause the TPMS indicator to illuminate.
For vehicles with the same tire pressures for front and rear tires, tire rotation will not affect the system.
Ambient Temperature Change and Tire Pressure
WARNING:
The tire pressure monitoring system (TPMS) sensor battery may release hazardous chemicals if exposed to extreme mechanical damage. If these
chemicals contact the skin or eyes, flush immediately with water for a minimum of 15 minutes and get prompt medical attention. If any part of the
battery is swallowed, contact a physician immediately. When disposing of TPMS sensors, follow the correct procedures for hazardous material
disposal. Failure to follow these instructions may result in serious personal injury.
NOTICE:
Do not inflate tire higher than maximum pressure stamped on tire sidewall. Premature tire wear or damage to the tire may result.
Tire pressures fluctuate with temperature changes. For this reason, tire pressure must be set to specification when tires are at outdoor ambient temperatures.
If the vehicle is allowed to warm up to shop temperatures, and the outside temperature is less than shop temperature, the tire inflation pressure must be
adjusted accordingly.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

If the tires are inflated to specification at shop temperatures, and the vehicle is moved outdoors when the outdoor ambient temperature is significantly lower,
the tire pressure may drop enough to be detected by the TPMS and activate the TPMS indicator.
As the ambient temperature decreases by 6°C (10°F), tire pressure decreases 7 kPa (1 psi). Adjust the tire pressure by 7 kPa (1 psi) for each 6°C (10°F)
ambient temperature drop as necessary to keep the tire at the specified Vehicle Certification (VC) label pressure. Refer to the following tables to adjust the
tire pressure indoors for colder outside temperatures.
Tire Pressure Monitoring System (TPMS) Indicator and Message Center Messages
The TPMS indicator and vehicle message center (if equipped) sometimes displays faults that cannot be resolved by the customer. Treat these messages as
TPMS faults that must be serviced.
Tire Pressure Monitoring System (TPMS) Indicator Illuminates Continuously
NOTE:
If the spare tire is in use, the damaged road tire must be repaired and installed on the vehicle to restore complete TPMS functionality before carrying out any
diagnosis.
NOTE:
For vehicles with different front and rear tire pressures (such as E-Series and certain F-Series), the tire pressure sensors must be trained following a tire
rotation. Failure to train the sensors will result in a false low tire pressure event, which will cause the TPMS indicator to illuminate.
1. The TPMS indicator remains on continuously for the following condition:
2008 F-250, 350, 450, 550 Super Duty, 7/2007

• Low Tire Pressure — The TPMS indicator is illuminated solid and the message center displays LOW TIRE PRESSURE (if equipped). This is
displayed when any of the tire pressures are low. When this condition exists, the tire pressure must be adjusted to the recommended cold pressure
as indicated on the VC label.
2. NOTE:
The TPMS sensors do not transmit when the vehicle is stationary. If the vehicle has been stationary for more than 30 minutes, it will be necessary to
wake up the sensors so they will transmit the latest tire pressure information to the SJB.
If the vehicle has been stationary for more than 30 minutes, carry out the Tire Pressure Monitoring System (TPMS) Sensor Activation procedure in
this section.
Tire Pressure Monitoring System (TPMS) Indicator Flashes
The TPMS indicator flashes for 70 seconds, then remains ON solid when the ignition switch is turned to the ON position, for the following conditions:
1. Tire Pressure Sensor Fault — If equipped, the message center will display TIRE PRESSURE SENSOR FAULT when a tire pressure sensor is
malfunctioning. GO to Symptom Chart.
2. No communication with the SJB (TPMS is integral to the SJB) — The TPMS indicator is illuminated when the Instrument Cluster (IC) has not
received any signals from the SJB for more than 5 seconds. If equipped, the message center displays TIRE PRESSURE MONITOR FAULT. GO to
Symptom Chart.
3. Tire Pressure Monitor Fault — If equipped, the message center will display TIRE PRESSURE MONITOR FAULT when the TPMS is malfunctioning
or communication with the IC has been lost. GO to Symptom Chart.
Tire Pressure Monitoring System (TPMS) PID Definitions and Intermittent Troubleshooting
TPMS Status (TP_STAT) PID
The SJB monitors the TPMS status. The current status can be viewed by accessing the TPMS status PID: TP_STAT using the scan tool. This helps identify
the current system status and may aid in diagnosing the system. The PID has 4 valid states:
1. TP_STAT = SENSOR FAULT.

• If the module has not received the tire pressure status from 1 to 3 TPMS sensors for 20 minutes when the vehicle speed is above 32 km/h (20
mph), the PID displays SENSOR FAULT.
2. TP_STAT = SYSTEM FAULT.
• If the module has not received the tire pressure status from all 4 TPMS sensors for 20 minutes and the vehicle speed is above 32 km/h (20 mph),
the PID displays SYSTEM FAULT.
3. TP_STAT = LOW.
• If the module has detected that at least 1 TPMS sensor is reporting low tire pressure, the PID displays LOW.
4. TP_STAT = SYSTEM ACTIVE.
• If the TPMS is functioning normally, the PID displays SYSTEM ACTIVE.
TPMS Last Warning Event PID Definitions
The TPMS uses the TPMS last warning event PIDs to store detailed information about the last 5 times the TPMS warning indicator was activated. These
PIDs can be used to acquire more information about a particular TPMS event.
EVT1_IGN through EVT5_IGN

The number of key cycles since the TPMS warning indicator was activated. This PID cycles from zero to 255 and then starts over from zero again. This can
be used to determine how long ago a TPMS event occurred and the time (in key cycles) between events.
EVT1_TLOC through EVT5_TLOC

This is the last programmed location for the sensor identifier causing each TPMS event. Due to tire rotation, the sensor may no longer be at the original
location. It is suggested that all the PIDs be recorded, the system retrained, and then the sensor identifier PIDs be used to pinpoint the actual location of each
sensor.
EVT1_PSI through EVT5_PSI

This is the tire pressure associated with each TPMS warning indicator event. This can be used along with the function code to clearly identify the TPMS
events that were strictly due to low pressure. It can also be used to determine when a sensor is transmitting inaccurate tire pressure.
EVT1_STAT through EVT5_STAT

Describes the warning status of each TPMS event by using the information received from the TPMS status (TP_STAT) PID. If there is a communication
issue, the status could be Normal.
• Unknown
• Normal (normal operation)
• Low (low pressure event)
• Fault (sensor fault or system fault)
2008 F-250, 350, 450, 550 Super Duty, 7/2007

EVT1_TxID through EVT5_TxID

This is the identifier of the sensor involved in each TPMS event. EVT1 is the most recent event that triggered the TPMS warning indicator.
Wheel Rotation and Sensor Training Techniques
Moving a Problem Sensor/Wheel to a Different Position

If a sensor in a certain location has caused several events, yet the sensor trains and seems to operate normally, moving that particular wheel to a different
location on the vehicle is a good way to isolate the issue to a certain sensor/wheel location. Rotate the wheels and road test the vehicle. This can be done in
an attempt to replicate the issue. This determines if the issue followed the sensor or remained in the original sensor location.
Training Sensors in a Different Order

This is a technique to get past a left front sensor that may not be responding to determine if the remaining sensors train to the module. This can help save
time determining if other sensors are having issues or if the module is experiencing training difficulties with a certain location.
Training Known Good Sensors From Another Vehicle

Training known good sensors from another vehicle cannot differentiate between a faulted module and Radio Frequency Interference (RFI), as some noise
source could be preventing the module from receiving the tire pressure status from the original sensors as well as the known good sensors. This technique
that can be used to differentiate between a sensor and module issue. If the module in the vehicle cannot train any of its own sensors, and likewise cannot
train known good sensors from another vehicle, then the issue is with the module or the RFI, and not with the original sensors. The original sensors should
not be replaced.
Items That Cause RFI
Non-OEM Equipment
The following equipment has been found to sometimes cause RFI:
• Video equipment has been found to cause RFI especially when the video and power supply lines are near the TPMS.
• Car alarms (even those installed by dealerships) have been found to create enough RFI to cause the TPMS to malfunction or lose considerable range.
These car alarms can sometimes be difficult to locate, as they are usually hidden somewhere out of the way for reduced accessibility.
• Many different in-vehicle cell phone chargers have been found to cause considerable RFI. The vehicles with the power point closest to the TPM are the
most affected. It must be noted that most cell phone chargers do not produce high levels of RFI all the time. This depends on the state of charge of the
cell phone battery. The phone must be almost completely discharged in some cases.
• Power supplies and DC/AC inverters typically create a lot of RFI. Most consumer grade equipment has very little filtering or shielding.
OEM Modules
In some cases, the RFI may actually be caused by a module or ground on the vehicle. Depending on the severity of the issue, a dirty ground, improperly built
ground shield or module can disable the system. Modules that have microcontrollers using clock circuits to create the timing pulses for the microprocessor
may radiate RFI.
Using Customer's Electronics to Pinpoint the Radio Frequency Interference (RFI) Source
This can be a way to determine the cause of an issue well before the sensors and module are replaced with little or no affect on the system performance.
Since this takes more up-front work, it relies on working with the customer to determine what equipment was being used at the time of the event.
Options for Eliminating Intermittent TPMS Conditions Caused by RFI
• If an OEM component or customer device is causing an RFI issue, replace the device.
• If a phone charger is causing an RFI issue, the customer should consult their cell phone provider to acquire a different phone charger.
• If a device such as a dealer-installed alarm is causing an RFI issue, move the device to another location on the vehicle. In the case of a portable device,
move the power cord to another power point location.
In summary, if the RFI source is present and cannot be moved or replaced, the intermittent issue remains. The vehicle owner must accept RFI and the
unwanted system operation it can cause.

1. NOTE:
The tire pressure sensors are not designed to be used with aftermarket wheels.
NOTE:
The use of run-flat tires (tires with steel body cord plies in the tire sidewall) where not originally equipped, may cause the Tire Pressure Monitoring
System (TPMS) to malfunction and is therefore not recommended.
Verify the customer concern by inspecting the vehicle and observing the message center (if equipped) and the TPMS indicator.
2. NOTE:
The valve-mounted TPMS sensors and the strap-mounted TPMS sensors are not compatible. Swapping wheels from one vehicle to another with the
different systems will set a TPMS fault.
NOTE:
2008 F-250, 350, 450, 550 Super Duty, 7/2007

Swapping wheels between vehicles with the same TPMS will cause a TPMS fault to be set if the sensors are not trained. Refer to Tire Pressure
Monitoring System (TPMS) Sensor Training in this section.
NOTE:
Non-OEM modifications made to the vehicle may result in false TPMS warnings.
Inspect to determine if one of the following mechanical or electrical concerns apply:

Visual Inspection Chart
Mechanical Electrical
• Low tire pressure • Wiring, terminals or connectors
• Tire Pressure Monitoring System (TPMS) sensor damaged or missing • Smart Junction Box (SJB) damaged
• Spare tire installed as a road wheel • Aftermarket electronic accessories
• Incorrect TPMS sensor installed
• TPMS sensor installed incorrectly
• Sensors not trained after a tire rotation on vehicles with different front
and rear tire pressures
• Non-OEM wheels installed (aftermarket rims)
• Non-OEM equipped run-flat tires installed
• Other non-OEM modifications (roll cages, service barriers, part racks,
ladder racks)
3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step.
4. NOTE:
Make sure to use the latest scan tool software release.
If the cause is not visually evident, connect the scan tool to the Data Link Connector (DLC).
5. NOTE:
The Vehicle Communication Module (VCM) LED prove out confirms power and ground from the DLC are provided to the VCM.
If the scan tool does not communicate with the VCM:

• check the VCM connection to the vehicle.
• check the scan tool connection to the VCM.
• refer to Section 418-00, No Power To The Scan Tool, to diagnose no power to the scan tool.
6. If the scan tool does not communicate with the vehicle:
• verify the ignition key is in the ON position.
• verify the scan tool operation with a known good vehicle.
• refer to Section 418-00 to diagnose no response from the PCM.
7. Carry out the network test.
• If the scan tool responds with no communication for one or more modules, refer to Section 418-00.
• If the network test passes, retrieve and record Continuous Memory Diagnostic Trouble Codes (CMDTCs).
8. Clear the CMDTCs and carry out the self test diagnostics for the SJB (the TPMS is part of the SJB).
9. If the DTCs retrieved are related to the concern, GO to the Tire Pressure Monitoring System (TPMS) DTC Chart. For all other DTCs, refer to the
Master DTC Chart in Section 419-10.
10. If no DTCs related to the concern are retrieved, GO to Symptom Chart.
DTC Charts
Tire Pressure Monitoring System (TPMS) DTC Chart
DTC Description Source Action

B106A Pressure Sensor Range Bit Incorrect State Smart Junction GO to Pinpoint Test G.
Box (SJB)
B106B Tire Pressure Sensor Low Battery SJB DTC B106B can be set during SJB configuration. GO to
Pinpoint Test H.
B106D Tire Pressure Monitoring System (TPMS) Initiators Not SJB DTC B106D is only present when a new SJB is
Configured installed, the SJB is incorrectly flashed or the SJB is
incorrectly configured. Successfully configuring the SJB
2008 F-250, 350, 450, 550 Super Duty, 7/2007

Tire Pressure Monitoring System (TPMS) DTC Chart (Continued)

DTC Description Source Action
is the only way to clear this DTC. VERIFY the SJB is
correctly configured. If DTC B106D is still present,
B2477 Module Configuration Failure/Mismatch SJB DTC B2477 is only present when a new SJB is installed,
the SJB is incorrectly flashed or the SJB is incorrectly
configured. Successfully configuring the SJB is the only
way to clear this DTC. MAKE SURE the SJB is
configured correctly. If DTC B2477 is still present,
B2868 LF Tire Pressure Sensor Fault SJB DTC B2868 is only present when a new SJB is installed,
the SJB is flashed or the SJB is reconfigured. TRAIN
the tire pressure sensors. REFER to Tire Pressure
Monitoring System (TPMS) Sensor Training in this
section.
B2869 RF Tire Pressure Sensor Fault SJB DTC B2869 is only present when a new SJB is installed,
section.
B2870 RR Tire Pressure Sensor Fault SJB DTC B2870 is only present when a new SJB is installed,
section.
B2871 LR Tire Pressure Sensor Fault SJB DTC B2871 is only present when a new SJB is installed,
section.
B2872 Tire Pressure Sensor Fault SJB NOTE:
If the vehicle has been stationary for more than 30
minutes, the sensors will go into a "sleep mode" to
conserve battery power. It will be necessary to wake
them up so they will transmit the latest tire pressure
information to the SJB.
ACTIVATE the TPMS sensors. REFER to Tire Pressure

Monitoring System (TPMS) Sensor Activation in this
section. GO to Pinpoint Test F.
B287A Tire Pressure System Fault SJB GO to Pinpoint Test F.
C2780 ECU in Manufacturing Mode SJB DTC C2780 is only present when a new SJB is installed,
section.
U0155 Lost Communication with Instrument Cluster SJB REFER to Section 418-00 to diagnose the no
communication problem.
All other SJB — SJB REFER to the Master DTC Chart in Section 419-10.
DTCs
Symptom Chart
NOTE:
must be trained following a tire rotation. Failure to train the sensors will result in a false low tire pressure event, which will cause the Tire Pressure
Monitoring System (TPMS) indicator to illuminate.
For vehicles with the same tire pressure for front and rear tires, tire rotation will not affect the system.
Failure of a TPMS component may not cause the message center to display a fault message or a DTC to be stored. The Symptom Chart is a starting point to
begin diagnosis of these concerns.
Symptom Chart
2008 F-250, 350, 450, 550 Super Duty, 7/2007

Symptom Chart (Continued)

• Tire Pressure Monitoring System (TPMS) • Spare tire currently in use • INSTALL the repaired road wheel/tire in
indicator ON solid and message center (if place of the spare tire.
equipped) displays LOW TIRE PRESSURE
• Air pressure not set to specifications listed • GO to Pinpoint Test D.
on the Vehicle Certification (VC) label
• Sensors not trained following tire rotation • ADVISE customer that on vehicles with
different front and rear tire pressure, the
sensors must be trained as directed in their
Owner's Literature.
• Smart Junction Box (SJB) will not enter • Brake ON/OFF switch • GO to Pinpoint Test E.
sensor training mode when using the TPMS • Ignition switch
sensor training procedure • Vehicle communication bus
• SJB
• TPMS indicator FLASHES for 70 seconds • Intermittent TPMS operation due to Radio • NOTE:
and then remains ON solid when the Frequency Interference (RFI) If the vehicle has been stationary for more
ignition key is turned to the ON position, the • TPMS sensors not trained than 30 minutes, the sensors will go into a
message center (if equipped) displays TIRE • Not all TPMS sensors are installed "sleep mode" to conserve battery power. It
PRESSURE SENSOR FAULT and DTC • TPMS sensor(s) will be necessary to wake them up so they
B2872 is present • SJB will transmit the latest tire pressure
ACTIVATE the TPMS sensors. REFER to

Sensor Activation in this section. GO to
Pinpoint Test F.
• TPMS indicator FLASHES for 70 seconds • TPMS sensors not trained • NOTE:
and then remains ON solid when the • Not all TPMS sensors are installed If the vehicle has been stationary for more
ignition key is turned to the ON position, the than 30 minutes, the sensors will go into a
message center (if equipped) displays TIRE "sleep mode" to conserve battery power. It
PRESSURE MONITOR FAULT and DTC will be necessary to wake them up so they
B287A is present will transmit the latest tire pressure
ACTIVATE the TPMS sensors. REFER to

Sensor Activation in this section. GO to
Pinpoint Test F.
• TPMS indicator FLASHES for 70 seconds • Vehicle communication issue between the • REFER to Section 418-00 to diagnose the
and then remains ON solid when the SJB and the Instrument Cluster (IC) no communication concern.
ignition key is turned to the ON position, the
message center (if equipped) displays TIRE
PRESSURE MONITOR FAULT and there
are no DTCs present
• SJB • REFER to Section 419-10 to diagnose the
SJB.
• One or more sensors will not train • TPMS sensor(s) • RETRIEVE and RECORD DTCs. REFER
• Vehicle communication issue to Tire Pressure Monitoring System (TPMS)
• SJB DTC Chart.
• One or more sensors will not train and no • TPMS sensor(s) • TRAIN all 4 tire pressure sensors. REFER
DTCs are present to Tire Pressure Monitoring System (TPMS)
Sensor Training in this section.
• For any sensor(s) that did not train,
ATTEMPT to activate the same sensor with
the activation tool. If the sensor still does
not respond, MOVE the vehicle to rotate the
wheels at least one-fourth turn and
ATTEMPT to activate the same sensor
again.
• If the sensor(s) fail to train a second time,
INSTALL a new sensor(s). REFER to Tire
2008 F-250, 350, 450, 550 Super Duty, 7/2007

Symptom Chart (Continued)

Pressure Monitoring System (TPMS) Sensor
in this section.
Pinpoint Tests
Pinpoint Test D: Tire Pressure Monitoring System (TPMS) Indicator ON Solid and Message Center (if equipped) Displays LOW TIRE
PRESSURE
Normal Operation
The Tire Pressure Monitoring System (TPMS) monitors the air pressure of all 4 road tires. The wheel-mounted tire pressure sensors transmit via radio
frequency signals, to the Smart Junction Box (SJB). TPMS functionality is integral to the SJB. These transmissions are sent approximately every 60 seconds
when the vehicle speed exceeds 32 km/h (20 mph). The TPMS function (integral to the SJB) compares each tire pressure sensor transmission against a low-
pressure limit. If it has been determined that the tire pressure has fallen below this limit, the SJB communicates this on the vehicle communication bus to the
Instrument Cluster (IC). The IC then illuminates the TPMS indicator and displays the appropriate message(s) in the message center (if equipped).
This symptom can also be caused by a spare tire currently being used in place of a road tire. Make sure that the spare tire is not currently in use. On vehicles
with different front and rear tire pressures, if the sensors are not trained following a tire rotation, this symptom will also be present. Advise the customer that
on vehicles with different front and rear tire pressures, the sensors must be trained as directed in the Owner's Literature.
• Low air pressure in tire(s)

• Tire pressure sensor(s)
PINPOINT TEST D: TPMS INDICATOR ON SOLID AND MESSAGE CENTER (IF EQUIPPED)
DISPLAYS LOW TIRE PRESSURE
NOTE:
Use only the Digital Tire Pressure Gauge any time tire pressures are measured to be sure that accurate values are obtained.
NOTE:
If a warranty case is opened for an actual TPMS fault, document and include the actual tire pressure data in all warranty communications.
D1 CHECK THE TIRE PRESSURE
• Measure and record the air pressure in all 4 road tires.
• Adjust the air pressure for those found to be below the specification
listed on the Vehicle Certification (VC) label.
• NOTE:
If the vehicle has been stationary for more than 30 minutes, activate
Yes
each TPMS sensor. Refer to Tire Pressure Monitoring System
The system is functioning normally, diagnosis is
(TPMS) Sensor Activation in this section. The TPMS sensor does not
complete. INFORM the customer of correct tire
transmit when the vehicle is stationary.
pressure maintenance as instructed in the scheduled
maintenance guide and the Owner's Literature.
Verify system operation.
• Have the TPMS indicator and the message center (if equipped) No
warnings gone out? GO to D2.
D2 CHECK THE SYSTEM COMPONENTS
• Train all 4 tire pressure sensors. Refer to Tire Pressure Monitoring Yes
System (TPMS) Sensor Training in this section. The system is functioning normally, diagnosis
• Connect the scan tool. complete.
• Ignition ON.
No
• Enter the following diagnostic mode on the scan tool: DataLogger
Before installing a new sensor(s): If a sensor(s) does
SJB.
not respond to the Tire Pressure Monitor Activation
• Read and record the following PIDs:
Tool, ATTEMPT to activate the same sensor(s) with the
— Left Front Tire Pressure (LF_PRES)
Tire Pressure Monitor Activation Tool. If the sensor(s)
— Right Front Tire Pressure (RF_PRES)
still does not respond, MOVE the vehicle to rotate the
— Left Rear Outer Tire Pressure (LRO_PRES)
wheels at least one-fourth turn and ATTEMPT to
— Right Rear Outer Tire Pressure (RRO_PRES)
activate the same sensor(s) again.
• Compare the air pressure readings recorded from the function test to
INSTALL new tire pressure sensors for those with
those recorded in D1.
discrepancies or those that fail to activate. REFER to
Tire Pressure Monitoring System (TPMS) Sensor in
this section.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

204-04-10 Wheels and Tires 204-04-10
PINPOINT TEST D: TPMS INDICATOR ON SOLID AND MESSAGE CENTER (IF EQUIPPED)
DISPLAYS LOW TIRE PRESSURE (Continued)
D2 CHECK THE SYSTEM COMPONENTS (Continued)
• Do the compared tire pressure values match within ±5 psi, and
have the TPMS indicator and the message center (if equipped)
warnings gone out?
Pinpoint Test E: SJB Will Not Enter Sensor Training Mode When Using the TPMS Sensor Training Procedure
Normal Operation
For the Smart Junction Box (SJB) to enter Tire Pressure Monitoring System (TPMS) sensor training mode, the SJB must receive valid inputs from the Brake
Pedal Position (BPP) switch (OFF-ON-OFF) and ignition switch (both OFF and RUN), and it must receive valid vehicle speed sensor input (0 km/h [0
mph]). Refer to Tire Pressure Monitoring System (TPMS) Sensor Training in this section for the complete sensor training procedure.
• Wiring, terminals or connectors

• Brake ON/OFF switch
• Ignition switch
• SJB
PINPOINT TEST E: SJB WILL NOT ENTER SENSOR TRAINING MODE WHEN USING THE TPMS
SENSOR TRAINING PROCEDURE
E1 CHECK THE SJB BRAKE ON/OFF (GEM_BOO) PID
• Connect the scan tool.
• Ignition ON.
Yes
• Enter the following diagnostic mode on the scan tool: DataLogger
GO to E2.
SJB.
• Monitor the GEM_BOO PID (SJB reads the brake switch directly). No
• Press and release the brake pedal while monitoring the PID. REFER to Section 417-01 to continue diagnosis of the
• Do the brake pedal PID values match the brake pedal positions? stoplamp switch.
E2 CHECK THE SJB IGNITION SWITCH PIDs
• Monitor the following ignition switch PIDs:
— Ignition Switch Off (IGN_O_ECU)
Yes
— Ignition Switch RUN (IGN_R_ECU)
GO to E3.
• Cycle the ignition switch to the RUN and OFF position while
monitoring the PIDs (SJB reads the ignition switch directly). No
• Do the ignition switch status PID values match the ignition REFER to Section 211-05 to continue diagnosis of the
switch positions? ignition switch.
E3 CHECK THE SJB VEHICLE SPEED (VSS_GEM) PID
• Monitor the VSS_GEM PID (SJB receives vehicle speed from the Yes
Instrument Cluster (IC)). GO to E4.
• Does the vehicle speed PID value match the speed of the
No
vehicle?
REFER to Section 413-01 to diagnosis of the IC/vehicle
speed concern.
E4 CHECK FOR CORRECT SJB OPERATION
• Disconnect all the SJB connectors.
• Check the connectors for:
Yes
— corrosion.
INSTALL a new SJB. REFER to Section 419-10.
— pushed-out pins.
CLEAR the DTCs. REPEAT the self-test.
— spread terminals.
• Connect all the SJB connectors and make sure that they are seated No
correctly. The system is operating correctly at this time. The
• Operate the system and verify the concern is still present. concern may have been caused by a loose or corroded
• Is the concern still present? connector. CLEAR the DTCs. REPEAT the self-test.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

204-04-11 Wheels and Tires 204-04-11
Pinpoint Test F: TPMS Indicator FLASHES for 70 Seconds and Then Remains ON Solid When the Ignition Key is Turned to the ON
Position, the Message Center (if equipped) Displays TIRE PRESSURE SENSOR or MONITOR FAULT and DTC B2872 or B287A is
Present
Normal Operation
If there is a fault with 1, 2 or 3 of the Tire Pressure Monitoring System (TPMS) sensors, DTC B2872 sets. The TPMS warning indicator flashes for 70
seconds and then remains ON continuously when the ignition switch is turned to the ON position and the message center (if equipped) displays TIRE
PRESSURE SENSOR FAULT.
If the Smart Junction Box (SJB) does not get a response from all 4 of the TPMS sensors, DTC B287A sets and the message center (if equipped) displays
TIRE PRESSURE MONITOR FAULT.
It should be noted that TPMS communication can be interrupted by Radio Frequency Interference (RFI), which can cause intermittent issues. RFI is
generated by electrical motors and appliance operation, cellular telephones, remote transmitters, power inverters and portable entertainment equipment.
Anytime the TPMS sensor training procedure is performed successfully, the warning indicator is extinguished and the vehicle must be driven for 18-20
minutes before the SJB initiates a self test to verify system operation.
• TP_STAT PID = SYSTEM FAULT is displayed if the SJB does not receive a signal transmission from all 4 TPMS sensors for 20 minutes and the
vehicle speed is above 32 km/h (20 mph).
• TP_STAT PID = SENSOR FAULT is displayed if the SJB does not receive a signal transmission from 1, 2, or 3 TPMS sensors for 20 minutes and the
vehicle speed is above 32 km/h (20 mph).
• Intermittent TPMS operation due to RFI

• TPMS sensor(s) not trained
• Not all TPMS sensors are installed
• TPMS sensor(s)
• SJB
PINPOINT TEST F: TPMS INDICATOR FLASHES FOR 70 SECONDS AND THEN REMAINS ON
SOLID WHEN THE IGNITION KEY IS TURNED TO THE ON POSITION, THE MESSAGE CENTER
(IF EQUIPPED) DISPLAYS TIRE PRESSURE SENSOR OR MONITOR FAULT AND DTC B2872 OR
B287A IS PRESENT
F1 CHECK THE HORN OPERATION
• Press the steering wheel horn pad for 2 seconds. Yes
• Does the horn sound? GO to F2.
No
For horn diagnosis, REFER to Section 413-06.
F2 CHECK THE TPMS STATUS (TP_STAT) PID
NOTE:
Make sure that all aftermarket electronic equipment has been disconnected (if
possible) and that the customer has been questioned about the kinds of electronic
equipment they may have been using in the vehicle when this issue was
identified.
• Connect the scan tool.
NOTE:
A spare tire cannot be programmed to the vehicle, even if equipped
with a TPMS sensor. If a damaged road wheel is located in the trunk
and the SJB cannot communicate with it, or if the damaged wheel has
been dropped off at a dealership or repair shop, the SJB sets a TPMS
sensor fault.
Yes
• Ignition ON.
GO to F3.
• Enter the following diagnostic mode on the scan tool: DataLogger —
SJB. No
• Monitor the TP_STAT PID. If the TP_STAT PID displays SYSTEM FAULT, GO to
• Does the PID display SENSOR FAULT? F5.
F3 CARRY OUT THE SENSOR TRAINING PROCEDURE
2008 F-250, 350, 450, 550 Super Duty, 7/2007

204-04-12 Wheels and Tires 204-04-12
PINPOINT TEST F: TPMS INDICATOR FLASHES FOR 70 SECONDS AND THEN REMAINS ON
SOLID WHEN THE IGNITION KEY IS TURNED TO THE ON POSITION, THE MESSAGE CENTER
(IF EQUIPPED) DISPLAYS TIRE PRESSURE SENSOR OR MONITOR FAULT AND DTC B2872 OR
B287A IS PRESENT (Continued)
F3 CARRY OUT THE SENSOR TRAINING PROCEDURE (Continued)
System (TPMS) Sensor Training in this section. The system is operating correctly at this time. The
• Did all of the tire pressure sensors transmit correctly and did the concern may have been caused by RFI. CLEAR the
horn sound when each TPMS sensor transmitted to the SJB? DTCs. REPEAT the self-test. TEST for normal
operation. REFER to PID Definitions and Intermittent
Troubleshooting in this section for information on
locating sources of RFI.
No
GO to F4.
F4 CHECK FOR CORRECT TPMS OPERATION
• Move the vehicle to rotate the wheels at least one-fourth of a turn. Yes
Leave the vehicle doors open. The system is operating correctly at this time. The
• Train all 4 tire pressure sensors. Refer to Tire Pressure Monitoring concern may have been caused by RFI. CLEAR the
System (TPMS) Sensor Training in this section. DTCs. REPEAT the self-test. TEST for normal
• Did all of the tire pressure sensors transmit correctly and did the operation. REFER to PID Definitions and Intermittent
horn sound when each TPMS sensor transmitted to the SJB? Troubleshooting in this section for information on
locating sources of RFI.
No
GO to F5.
F5 CHECK FOR CORRECT SJB OPERATION
• Disconnect all the SJB electrical connectors. Yes
• Check the connectors for: NOTE: The sensors may not be present. DISMOUNT
the tire. REFER to Wheel and Tire in this section.
— corrosion VERIFY the sensors are present and mounted to the
— pushed-out pins wheels. If missing, INSTALL new sensors.
— bent pins If the sensors are present, INSTALL a new SJB.
— spread terminals REFER to Section 419-10. CLEAR the DTCs. REPEAT
• Connect all the SJB connectors and make sure that they are seated the self-test.
correctly.
No
• Operate the system and verify the concern is still present.
The system is operating correctly at this time. The
• Is the concern still present?
concern may have been caused by a loose or corroded
connector. CLEAR the DTCs. REPEAT the self-test.
Pinpoint Test G: DTC B106A
Normal Operation
This DTC may be encountered if a sensor designed for a different application is installed. Low pressure applications utilize a black- or blue-colored sensor,
while heavy duty applications utilize a green-colored sensor. The Smart Junction Box (SJB) will only allow one type of sensor to be trained using the Tire
Pressure Monitoring System (TPMS) sensor training procedure. Make sure the correct sensors are used to avoid compatibility issues.
• DTC B106A (Pressure Sensor Range Bit Incorrect State) — When an attempt has been made to train a non-compatible sensor, the SJB will set DTC
B106A.
• Incorrect tire pressure sensor(s) installed
PINPOINT TEST G: DTC B106A

G1 DETERMINE IF THE VEHICLE IS EQUIPPED WITH AN INCORRECT SENSOR
• Train all 4 tire pressure sensors. Refer to Tire Pressure Monitoring
System (TPMS) Sensor Training in this section.
• Did all of the tire pressure sensors transmit correctly and did the Yes
horn sound when each tire pressure sensor transmitted to the CLEAR the DTCs. REPEAT the self test. VERIFY
SJB? system operation.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

204-04-13 Wheels and Tires 204-04-13
PINPOINT TEST G: DTC B106A (Continued)

G1 DETERMINE IF THE VEHICLE IS EQUIPPED WITH AN INCORRECT SENSOR (Continued)
No
wheels at least one-fourth of a turn and ATTEMPT to
If the sensor(s) fails to train a second time, INSTALL a
new tire pressure sensor(s). REFER to Tire Pressure
Monitoring System (TPMS) Sensor in this section.
Pinpoint Test H: DTC B106B
Normal Operation
If there is a fault in the Tire Pressure Monitoring System (TPMS), such as a damaged or missing sensor(s), damaged module or a communication issue
within the vehicle, DTCs are set in the Smart Junction Box (SJB), the TPMS warning indicator will flash for 70 seconds and then remain ON solid when the
ignition switch is turned to the ON position and the message center (if equipped) will display TIRE PRESSURE SENSOR FAULT.
The tire pressure sensor is battery powered.
This DTC may be set when attempting to train a tire pressure sensor(s) with a low battery.
• Tire pressure sensor battery

• Tire pressure sensor(s)
PINPOINT TEST H: DTC B106B

H1 DETERMINE WHICH SENSOR HAS A LOW BATTERY
System (TPMS) Sensor Training in this section. CLEAR the DTCs. REPEAT the self test. VERIFY
• Did all of the tire pressure sensors transmit correctly and did the system operation.
horn sound when each tire pressure sensor transmitted to the
No
SJB?
wheels at least one-fourth of a turn and ATTEMPT to
If the sensor(s) fails to train a second time, INSTALL a
new tire pressure sensor(s). REFER to Tire Pressure
Monitoring System (TPMS) Sensor in this section.
2008 F-250, 350, 450, 550 Super Duty, 7/2007


CONTENTS PAGE

Wheels And Tires ............................................................................................................................................................... 204-04-2
Tire Wear ............................................................................................................................................................... 204-04-3
Symptom Chart — Tire Wear ....................................................................................................................................... 204-04-5
Symptom Chart — NVH ............................................................................................................................................... 204-04-5
Pinpoint Tests ............................................................................................................................................................... 204-04-6
Component Tests ......................................................................................................................................................... 204-04-7
Radial Runout ........................................................................................................................................................ 204-04-7
Loaded Runout Measurement (Hunter Road Force® 9700 Series Wheel Balancer) ............................................ 204-04-7
Runout Measurement (Dial Indicator) .................................................................................................................... 204-04-9
Match Mounting .................................................................................................................................................... 204-04-11
Wheel-to-Hub Optimization ........................................................................................................................................ 204-04-13
Front Wheels and Single Rear Wheel (SRW) ...................................................................................................... 204-04-14
Dual Rear Wheels (DRW) .................................................................................................................................... 204-04-14
2008 F-250, 350, 450, 550 Super Duty, 7/2007


Wheels And Tires
Special Tool(s)
Digital Tire Gauge

204-354
Hunter Road Force® Wheel Balancer

GSP9700 Series
WARNING:
Vehicle may have multiple drive wheels. Do not use engine to power the driveline unless all drive wheels are elevated off the ground. Drive wheels
in contact with ground could cause unexpected vehicle movement. Failure to follow this instruction may result in serious personal injury.
Verify the customer concern by carrying out a road test on a smooth road. If any vibrations are apparent, GO to Symptom Chart — NVH.
To maximize tire performance, inspect for signs of incorrect inflation and uneven wear, which may indicate a need for balancing, rotation or front
suspension alignment.
Correct tire pressure and driving techniques have an important influence on tire life. Heavy cornering, excessively rapid acceleration and unnecessary sharp
braking increase tire wear.
Replacement tires must follow the recommended:
• tire sizes.
• speed rating.
• load range.
• tire construction type.
The use of any other tire/wheel size, type or load range can seriously affect:
• ride.
• handling.
• speedometer/odometer calibration.
• vehicle ground clearance.
• tire clearance between the body and chassis.
• wheel bearing life.
• brake performance.
New wheels need to be installed when the vehicle's wheels:
• are bent.
• are cracked.
• are dented.
• are heavily corroded.
• are leaking.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

• have elongated wheel hub bolt holes.

• have excessive lateral or radial runout.
It is mandatory to use only the tire sizes recommended on the tire label located on the driver door or door pillar. Larger or smaller tires can damage the
vehicle, affect durability and require changing the speedometer calibration. Make sure wheel size and offsets match those recommended for the tire in use.
1. Inspect the tires for signs of uneven wear. Refer to the following descriptions to identify the type of wear and GO to Symptom Chart - Tire Wear for
the appropriate repair action to be carried out.
2. Check the tires for:
• cuts.
• stone bruises.
• abrasions.
• blisters.
• embedded objects.
3. Check the valve stem for:
• cracks.
• cuts.
Install a new valve stem when damage is found or any time a new tire is installed.
4. Tread wear indicators are molded into the bottom of the tread grooves. Install a new tire when the indicator bands are less than 2/32 inch.
Tire Wear
Tire wear is commonly defined as a loss of tread depth. Tire tread wear occurs due to friction with the contact surface (road/pavement). The tread should
wear down uniformly all the way around the circumference of the tire and all the way across the tread face. When this does not occur, the tire may have
abnormal/incorrect wear.
Normal Tire Wear

Normal tire wear is identified as even wear around and across the tread. Because there are many factors (driving style, road surfaces, type of vehicle, type of
tire) that can affect tire wear, there is no absolute mileage expectation for a normal wear condition. A tire is considered worn-out when the tread has worn to
the level of the tread-wear indicators.
Abnormal/Incorrect Tire Wear

Abnormal/incorrect tire wear is identified as tire wear that is not even around or across the tread and that creates performance-related issues.
Abnormal/incorrect wear can be caused by numerous factors, some of which include driving style (aggressive, passive), climate (hot, cold), road conditions,
vehicle loading and maintenance (correct tire pressure, rotation intervals and balance). It is important to determine the root cause of wear on a vehicle before
carrying out repair. Tires exhibiting abnormal/incorrect tire wear may still be serviceable provided that the minimum tread depth is greater than 2/32 inch
and the tire is not causing a vehicle performance (noise/vibration) concern.
Some abnormal/incorrect wear patterns look the same all the way around the tread of the tire, other wear patterns are not consistent and can occur in various
spots on the tread area. The underlying causes of the 6 wear categories are different. Refer to the following descriptions to identify the type of wear and GO
to Symptom Chart - Tire Wear for the appropriate repair action to be carried out.
Inner Edge/Shoulder Wear

Inner edge (or shoulder) wear occurs on the inside edge of the tire and is usually caused by excessive toe out and/or excessive negative camber. If the tread
depth of the outer shoulder is at least 50% greater than the tread depth of the inner shoulder, the tire is experiencing inner edge/shoulder wear. To determine
whether tires have this type of wear, visually inspect the tires. In some instances, the tread depth of each rib may need to be measured and compared to that
of the shoulder.
NOTE:
RF tire shown, others similar.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

Outer Edge/Shoulder Wear

Outer edge (or shoulder) wear occurs on the outside edge of the tire and is usually caused by excessive toe in and/or excessive positive camber. If the tread
depth of the inner shoulder is at least 50% greater than the tread depth of the outer shoulder, the tire is experiencing outer edge/shoulder wear. To determine
whether tires have this type of wear, visually inspect the tires. In some instances, the tread depth of each rib may need to be measured and compared to that
of the shoulder.
NOTE:
RF tire shown, others similar.
Heel/Toe Wear
Heel/toe wear (also known as feathering) occurs along the outside or inside edge/shoulder of the tire. To determine whether tires have this type of wear,
visually inspect the tires in both the inside and outside shoulder ribs. In some instances, the difference in tread depth of leading versus trailing edge of each
lug in the inside and outside shoulder rib may need to be measured.
Diagonal Wear
Diagonal wear occurs diagonally across the tread area and around the circumference of the tire. To determine whether tires have this type of wear, visually
inspect the tires to determine if the wear pattern runs diagonally across the tread and around the circumference of the tire. In some instances, the difference in
tread depth along the diagonal wear pattern may need to be measured.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

Symptom Chart — Tire Wear
NOTE:
For suspension system and additional alignment diagnosis, refer to Section 204-00.
Symptom Chart — Tire Wear

• Inner edge/shoulder wear • Excessive toe out and/or negative camber • GO to Pinpoint Test A.
• Incorrect wheel and tire assembly rotation • GO to Pinpoint Test A.
intervals
• High-speed cornering • GO to Pinpoint Test A.
• Outer edge/shoulder wear • Excessive toe in and/or positive camber • GO to Pinpoint Test B.
• Incorrect wheel and tire assembly rotation • GO to Pinpoint Test B.
intervals
• High-speed cornering • GO to Pinpoint Test B.
• Heel/toe wear • Excessive toe in/out • ROTATE the wheel and tire assemblies.
• Incorrect wheel and tire assembly rotation REFER to Wheel and Tire Rotation in this
intervals section. CHECK the alignment, ADJUST as
necessary.
• Diagonal wear • Excessive toe in/out • GO to Pinpoint Test C.
• Incorrect tire rotation intervals • GO to Pinpoint Test C.
• Loose, worn or damaged suspension • REFER to Section 204-00.
components
NOTE:
NVH symptoms should be identified using the diagnostic tools that are available. For a list of these tools, an explanation of their uses and a glossary of
common terms, refer to Section 100-04. Since it is possible any one of multiple systems may be the cause of a symptom, it may be necessary to use a process
of elimination type of diagnostic approach to pinpoint the responsible system. If this is not the causal system for the symptom, refer back to Section 100-04
for the next likely system and continue diagnosis.

• Wobble or shimmy • Bent wheel • INSTALL a new wheel as necessary.
• Damaged tire • INSTALL a new tire as necessary.
• Loose wheel nuts • TIGHTEN to specification.
• High-speed shake • Tires/wheels • REFER to Wheel and Tire Runout
Component Tests in this section.
• Vehicle vibration • Tires/wheels • REFER to Wheel and Tire Runout
Component Tests in this section.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

Pinpoint Tests
For a description of the various tire wear patterns, refer to Inspection and Verification.
must be trained following a tire rotation. Refer to Tire Pressure Monitoring System (TPMS) Sensor Training in this section. Failure to train the sensors will
result in a false low tire pressure event, which will cause the Tire Pressure Monitoring System (TPMS) indicator to illuminate.
For vehicles with the same tire pressure for front and rear tires, tire rotation will not affect the TPMS.
Pinpoint Test A: Inner Edge/Shoulder Wear
• Excessive toe out

• Incorrect wheel and tire rotation
PINPOINT TEST A: INNER EDGE/SHOULDER WEAR

A1 MEASURE THE TREAD DEPTH
• Using a tread depth gauge or similar tool, measure the inside edge/ Yes
shoulder tread depth. ROTATE the wheel and tire assemblies. REFER to
• Is the tread depth greater than 2/32 inch? Wheel and Tire Rotation in this section.
CHECK and ADJUST the toe to nominal +0.15 degrees
(toe in). CHECK and ADJUST caster and camber to
nominal. REFER to Section 204-00.
No
INSTALL a new tire(s). CHECK and ADJUST the toe to
nominal. CHECK and ADJUST caster and camber to
Pinpoint Test B: Outer Edge/Shoulder Wear
• Excessive toe in
PINPOINT TEST B: OUTER EDGE/SHOULDER WEAR

B1 MEASURE THE TREAD DEPTH
• Using a tread depth gauge or similar tool, measure the outside edge/ Yes
shoulder tread depth. ROTATE the wheel and tire assemblies. REFER to
• Is the tread depth greater than 2/32 inch? Wheel and Tire Rotation in this section.
CHECK and ADJUST the toe to nominal -0.15 degrees
(toe out). CHECK and ADJUST caster and camber to
No
INSTALL a new tire(s). CHECK and ADJUST the toe to
nominal. CHECK and ADJUST caster and camber to
Pinpoint Test C: Diagonal Wear

• Excessive toe in/out
• Incorrect tire inflation
• Loose, worn or damaged suspension components
PINPOINT TEST C: DIAGONAL WEAR
2008 F-250, 350, 450, 550 Super Duty, 7/2007

PINPOINT TEST C: DIAGONAL WEAR (Continued)

C1 MEASURE THE TREAD DEPTH
• Using a tread depth gauge or similar tool, measure the tread depth of Yes
the wear pattern. If no performance concerns (noise/vibration) are
• Is the tread depth greater than 2/32 inch? present, the tire can remain in service. CHECK the tire
pressure, ADJUST as necessary. ROTATE the wheel
and tire assemblies. REFER to Wheel and Tire
Rotation in this section.
INSPECT for loose, worn or damaged suspension
components. INSTALL new components as necessary.
CHECK the alignment and ADJUST as necessary.
No
INSTALL a new tire(s). CHECK the tire pressure in the
tires, ADJUST as necessary. ROTATE the wheel and
tire assemblies. REFER to Wheel and Tire Rotation in
this section.
INSPECT for loose, worn or damaged suspension
components. INSTALL new components as necessary.
CHECK the alignment and ADJUST as necessary.
Component Tests
Radial Runout
Radial runout is the egg-shaped deviation from a perfect circle and is measured perpendicular to the circumference. On a wheel and tire assembly, this means
measuring the center tire tread rib. The center rib is indicative of the condition of the tire as a whole. Total runout is the difference between the maximum-to-
minimum gauge reading. The high spot is the location of maximum runout.
Item Description
1 High spot
2 Low spot
Loaded Runout Measurement (Hunter Road Force® 9700 Series Wheel Balancer)
NOTE:
Diagnosis of tire/wheel vibration should not be performed on tires with less than 320 km (200 mi). Some initial tire/wheel vibration issues (such as flat
spotting) will correct themselves after the tires have been in service for 320 km (200 mi).
This procedure is intended to assist with the diagnosis of wheel and tire assembly runout and/or force variation issues.
The Hunter Road Force® 9700 Series Wheel Balancer measures the wheel and tire assembly's loaded runout and the tire's radial spring rate. The balancer
then converts the runout into pounds of force (termed as Road Force®). Measuring loaded runout (Road Force®) is more effective than measuring unloaded
runout using a dial indicator.
1. Using a tire crayon, record the vehicle position on the inward sidewall of all tires.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

2. Remove the wheel and tire assemblies. For additional information, refer to Wheel and Tire — Single Rear Wheel (SRW) or Wheel and Tire — Dual
Rear Wheel (DRW) in this section.
3. NOTE:
Use only the Digital Tire Gauge any time tire pressures are measured to be sure that accurate values are obtained.
Make sure that the tire pressures are set to the correct pressure as indicated on the Vehicle Certification (VC) label.
4. NOTICE:
Make sure that the correct wheel balancer adapters are used when mounting the assembly to the wheel balancer or damage to the wheel may
occur.
NOTE:
Make sure that the wheel and tire assembly is clean and free of foreign material prior to installation on the balancer.
NOTE:
The wheel balancer inflation station must be turned OFF for tires with inflation pressures of 414 kPa (60 psi) or above.
Mount the wheel and tire assembly on a suitable wheel balancer using the correct wheel balancer adapters as shown. Refer to the list of recommended
wheel balancer adapters on the PTS website.
E-Series with Single Rear Wheel (SRW) and F-Super Duty or E-Series with Dual Rear Wheels (DRW)
Item Description
1 Wheel balancer
2 Spacer
3 Plastic spacer
4 Cone
5 Wheel and tire assembly
6 Finger plate
7 Balancer wing nut
8 Finger
F-Super Duty Dual Rear Wheels (DRW)
2008 F-250, 350, 450, 550 Super Duty, 7/2007

Item Description
1 Wheel balancer
2 Magnetic plate (part of Dual Rear Wheels (DRW) kit)
4 Step plate
5 Balancer wing nut
5. Measure the Road Force®.

• Temporarily mark the high spot and Road Force® on the sidewall of the tire. If the wheel and tire assembly Road Force® value is not within
specification, carry out the Match Mounting procedure to optimize the wheel and tire assembly.
• If the wheel and tire assembly Road Force® value is within specification, permanently mark the high spot and the Road Force® value on the
inward sidewall of the tire for reference during future wheel and tire service. Balance the assembly and install the wheel and tire on the vehicle
using the Wheel-to-Hub Optimization procedure.
Vehicle Maximum allowable Road

Force® value
F-250, F-350 F-450 pickup and E-Series with tire pressures of 414-448 kPa (60-65 psi) 16 kg (35 lb)
F-250, F-350, F-450 pickup and E-Series with tire pressures of 483-552 kPa (70-80 psi) 20 kg (45 lb)
E-Series with 381 mm (15 in) wheels 11 kg (25 lb)
F-450/F-550 chassis cab and E-550 50 kg (110 lb)
F53 Motorhome Chassis 41 kg (90 lb)
Runout Measurement (Dial Indicator)
NOTE:
Diagnosis of tire/wheel vibration should not be performed on tires with less than 320 km (200 mi). Some initial tire/wheel vibration issues (such as flat
spotting) will correct themselves after the tires have been in service for 320 km (200 mi).
NOTE:
Loaded run-out measurements are the preferred method for verifying tire serviceability. While a dial indicator can be used to optimize the position of the tire
on the wheel the unloaded run-out measurement cannot accurately determine if the tire should be removed from service.
The following procedures should be used if normal diagnostics leads to a potential runout issue.
Some vehicles may exhibit a wheel and tire vibration caused by excessive runout. Radial runout measurements can be taken using a dial indicator and should
be measured with the wheel and tire assembly mounted on a suitable wheel balancer. The dial indicator should be mounted securely to eliminate gauge
movement when measuring runout.
1. NOTE:
Use only the Digital Tire Gauge any time tire pressures are measured to be sure that accurate values are obtained.
Make sure that the tire pressures are set to the correct pressure as indicated on the VC label.
2. Using a tire crayon, record the vehicle position on the inward sidewall of all tires.
3. Remove the wheel and tire assemblies. Refer to Wheel and Tire — Single Rear Wheel (SRW) or Wheel and Tire — Dual Rear Wheel (DRW) in this
section.
4. NOTICE:
Make sure that the correct wheel balancer adapters are used when mounting the assembly to the wheel balancer or damage to the wheel may
occur.
NOTE:
Make sure that the wheel and tire assembly is clean and free of foreign material prior to installation on the balancer.
Mount the wheel and tire assembly on a suitable wheel balancer using the correct wheel balancer adapters as shown. Refer to the list of recommended
wheel balancer adapters on the PTS website.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

204-04-10 Wheels and Tires 204-04-10
F-Super Duty with Single Rear Wheel (SRW)
Item Description
1 Wheel balancer
2 Spacer
3 Plastic spacer
4 Cone
6 Finger plate
7 Balancer wing nut
8 Finger
E-Series with Single Rear Wheel (SRW) and F-Super Duty or E-Series with Dual Rear Wheels (DRW)
Item Description
1 Wheel balancer
2 Magnetic plate (part of Dual Rear Wheels (DRW) kit)
4 Step plate
5 Balancer wing nut
5. NOTE:
Masking tape can be applied on the center tread rib to allow for a smoother measuring surface. Some fluctuation of the gauge reading is expected.
Observe the overall sweep of the gauge from the highest to the lowest spot on the tire.
Position a suitable dial indicator and stand with the dial indicator on the center tread rib.
• Rotate the wheel and tire assembly (or wheel) to locate the low spot.
• Adjust the runout gauge to read 0.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

204-04-11 Wheels and Tires 204-04-11
• Rotate the wheel and tire assembly one complete revolution to make sure that the low spot has been found and that the dial indicator returns to a 0
reading.
6. While slowly and constantly rotating the wheel and tire assembly (or wheel), measure the radial runout.
• Note the variance (runout) from 0 on the dial of the gauge.
• If the runout reading of a wheel and tire assembly is greater than 1.14 mm (0.045 in), locate and temporarily mark the high spot and runout
reading on the sidewall of the tire and carry out the Match Mounting procedure to optimize the wheel and tire assembly.
• If the runout reading of a wheel and tire assembly is 1.14 mm (0.045 in) or less, permanently mark the high spot and the runout reading on the
inward sidewall of the tire for reference during future wheel and tire service. Balance the assembly and install the wheel and tire on the vehicle
Match Mounting
NOTE:
Road Force® values in illustrations are shown in pounds.
Match mounting is a technique used to reduce radial runout or road force on wheel and tire assemblies. Excessive runout is a source of ride quality
complaints and match mounting can be used to minimize the runout. Match mounting can be accomplished by changing the position of the tire on the wheel.
1. Position the wheel and tire assembly on a tire machine and put a reference mark on the tire sidewall at the valve stem position.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

204-04-12 Wheels and Tires 204-04-12
Item Description
1 Valve stem
2 Reference mark
2. NOTICE:
For tires equipped with a Tire Pressure Monitoring System (TPMS), the sensor may be damaged by incorrect tire mounting or dismounting.
Dismount the tire from the wheel as instructed in the Disassembly and Assembly procedure. Failure to follow these instructions may result in
TPMS component damage.
Using a suitable tire machine, separate the tire beads from the wheel.
• Lubricate the tire beads using a suitable fast drying, corrosion inhibiting tire bead lubricant.
• Position the tire 180 degrees (half-way around) on the rim so the valve stem reference mark is now opposite the valve stem.
3. Re-inflate the wheel and tire assembly to the specified air pressure and measure the assembly again using the Dial Indicator or Hunter Road Force®
9700 Series Wheel Balancer. Mark the second high spot on the tire.
• If the runout or Road Force® is reduced to within specifications, the concern has been resolved. Balance the assembly and install on the vehicle
4. If the second runout or Road Force® measurement is still not within specification and both high spots are close to each other (within 101.6 mm [4
in]), the root cause is probably the tire (the high spot followed the tire).
• To be SURE that the tire is causing the high runout, it is necessary to have 2 runout or Road Force® measurements that are not within
specification and the high spots must be in approximately the same location on the tire's sidewall. If the tire is the cause, install a new tire,
balance the assembly and install on the vehicle using the Wheel-to-Hub Optimization procedure.
• If the second high spot is not within 101.6 mm (4 in) of the first high spot, proceed to the next step.
Item Description
1 First high spot on the tire
2 Second high spot on the tire
5. If the second high spot is still above specification and is within 101.6 mm (4 in) of being opposite the first high spot on the wheel, the root cause is
probably the wheel (the high spot followed the wheel). Dismount the tire from the wheel, mount the wheel on a balancer and check the wheel runout.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

204-04-13 Wheels and Tires 204-04-13
If the wheel runout exceeds 1.14 mm (0.045 in), install a new wheel, balance the assembly and install on the vehicle using the Wheel-to-Wheel Hub
Optimization procedure.
Item Description
6. NOTE:
If the second high spot did not follow the wheel or the tire and the runout is still not within specification, improvements may be made by rotating the
tire 90 degrees (one-fourth of a turn).
Draw an arrow on the tire sidewall from the second high spot towards the first high spot (in the shortest direction).
• Separate the tire beads from the wheel and rotate the tire 90 degrees (one-fourth of a turn) in the direction of the arrow.
Item Description
Wheel-to-Hub Optimization
Wheel-to-hub optimization is important. Clearance between the wheel and hub can be used to offset or neutralize the Road Force® or run-out of the wheel
and tire assembly. For every 0.001 inch of wheel-to-hub clearance, the Road Force® can be affected between 1 and 3 pounds depending on the tire stiffness.
NOTE:
The example below illustrates how the clearance between the wheel and the hub can be used to offset the high spot of radial run-out or Road Force®.
Following the procedure will make sure of the best optimization.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

204-04-14 Wheels and Tires 204-04-14
Front Wheels and Single Rear Wheel (SRW)

1. Position the wheel and tire assembly on the vehicle so that the high spot location is at the 12 o'clock position.
2. Tighten the wheel nuts as described in Wheel and Tire — Single Rear Wheel (SRW) in this section.
Dual Rear Wheels (DRW)
NOTE:
The valve stem on the inner and outer assemblies will most likely not align through the same window. Although the valve stem of the inner assembly may
not be as easy to locate, it is still possible to put air in the inner assembly without removing the outer assembly. The customer should be informed of the
valve stem position and the reason for the alignment.
NOTE:
Road Force® values in illustrations are shown in pounds.
1. Add the Road Force® values recorded on the inner and outer wheel and tire assemblies (one side). If the total is less than 32 kg (70 lb) for F350/450
DRW pick-ups or 41 kg (90 lb) for F450/550 and F53 DRW chassis cabs, install the assemblies in the following order.
1 Position the inner wheel and tire assembly on the vehicle so that the high spot location is at the 12 o'clock position.
2 Position the outer wheel and tire assembly on the vehicle so that the high spot location is at the 12 o'clock position.
3 Tighten the wheel nuts as described in Wheel and Tire — Dual Rear Wheel (DRW) in this section.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

204-04-15 Wheels and Tires 204-04-15
2. If the total Road Force® values are greater than 32 kg (70 lb) for F350/450 DRW pick-ups or 41 kg (90 lb) for F450/550 and F53 DRW chassis cabs
and the inner assembly has a higher value, install the assemblies in the following order.
1 Position the inner assembly on the vehicle so that the high spot location is at the 12 o'clock position.
2 Position the outer assembly on the vehicle so that the high spot location is at the 6 o'clock position.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

204-04-16 Wheels and Tires 204-04-16
3. If the total Road Force® values are greater than 32 kg (70 lb) for F350/450 DRW pick-ups or 41 kg (90 lb) for F450/550 and F53 DRW chassis cabs
and the outer assembly has a higher value, install the assemblies in the following order.
1 Position the inner assembly on the vehicle so that the high spot location is at the 6 o'clock position.
2 Position the outer assembly on the vehicle so that the high spot location is at the 12 o'clock position.
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CONTENTS PAGE
Tire Pressure Monitoring System (TPMS) Sensor .............................................................................................................. 204-04-2
2008 F-250, 350, 450, 550 Super Duty, 7/2007

Tire Pressure Monitoring System (TPMS) Sensor

1 1A150/1A189 Tire pressure sensor/sensor kit
2 1A175 Sensor cradle
3 14C202 Locking clip (also part of 1A189)
Disassembly
WARNING:
NOTE:
Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of accordingly.
NOTE:
Tire pressure sensors are manufactured in multiple colors based on their application. When installing a new sensor, make sure the color of the sensor being
installed matches the color of the sensor that was removed. The different colored sensors are not interchangeable.
NOTE:
The sensor can be removed and installed without removing the strap or the cradle.
1. NOTICE:
The sensor, cradle and strap may be damaged by incorrect tire mounting or dismounting. Dismount the tire only as instructed.
Remove the tire from the wheel. For additional information, refer to Wheel and Tire in this section.
2. NOTICE:
Do not use a large screwdriver. Apply minimum force during removal or damage to the sensor locking clip may occur.
Using a pocket screwdriver or similar tool, remove the sensor locking clip. An animated version of this procedure is available on-line.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
3. NOTICE:
Do not use a large screwdriver. Apply minimum force during removal or damage to the sensor may occur.
Using a pocket screwdriver or similar tool, detach the sensor from the cradle. An animated version of this procedure is available on-line.
4. Remove the sensor.
Assembly
1. NOTICE:
Damage to the sensor may occur if excessive force is applied during sensor installation.
NOTE:
Make sure the sensor is fully seated into the cradle. The sensor will make a "click" noise when correctly seated.
Position the sensor into the cradle by inserting the hinge end of the sensor into the hook end of the cradle and pushing the opposite end of the sensor
down onto the cradle.
2. NOTE:
The locking clip can only be fully seated when installed in the correct orientation. If the sensor locking clip cannot be fully inserted, then the sensor
may not be fully seated on the cradle or the locking clip may be inserted backward.
Insert a new locking clip into the sensor.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
3. NOTICE:
The sensor, cradle and strap may be damaged by incorrect tire mounting or dismounting. Mount the tire only as instructed.
Install the tire onto the wheel. For additional information, refer to Wheel and Tire in this section.
4. NOTE:
A new tire pressure sensor is shipped in an off mode (or battery saver mode) and must be turned on before it can be trained. To turn the sensor on,
install it on a wheel, mount the tire and inflate the tire to the recommended inflation pressure. Wait at least 2 minutes, then continue with the sensor
training procedure.
Train the tire pressure sensor(s). For additional information, refer to Tire Pressure Monitoring System (TPMS) Sensor Training in this section.
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CONTENTS PAGE
Tire Pressure Monitoring System (TPMS) Strap and Cradle .............................................................................................. 204-04-2
2008 F-250, 350, 450, 550 Super Duty, 7/2007

Tire Pressure Monitoring System (TPMS) Strap and Cradle
Material
Item Specification
Motorcraft® Wheel and Tire Cleaner —
ZC-37-A

1 1A177/1A193 Strap/strap kit
2 1A150/1A189 Tire pressure sensor/sensor kit
3 1A175 Sensor cradle (also part of 1A193)
4 14C202 Locking clip (also part of 1A189)
Disassembly
WARNING:
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
NOTE:
Tire pressure sensors are equipped with Lithium-ion batteries and must be disposed of accordingly.
NOTE:
Tire pressure sensors are manufactured in multiple colors based on their application. When installing a new sensor, make sure the color of the sensor being
installed matches the color of the sensor that was removed. The different colored sensors are not interchangeable.
NOTE:
The sensor is available separately, the cradle and strap are available as a strap kit. There are several different strap kits available based on wheel diameter,
but all strap kits share the same base part number.
1. Remove the Tire Pressure Monitoring System (TPMS) sensor. For additional information, refer to Tire Pressure Monitoring System (TPMS) Sensor in
this section.
2.
WARNING:
Always wear eye protection when servicing a vehicle. Failure to follow this instruction may result in serious personal injury.
WARNING:
Wear protective gloves when handling components or parts that have pointed or sharp edges. Failure to follow this instruction may result in
serious personal injury.
Remove a factory-installed strap in the following sequence:

1 Locate the strap buckle and secure the strap to the wheel using duct tape or a similar item on both sides of the buckle, approximately 25 mm (0.98
in) from the buckle.
2 Using a large screwdriver and a twisting motion, unbuckle the strap.
3 Discard the strap.
3. To remove a dealer-installed strap, turn the worm gear screw until the strap is fully released from the worm gear.
• Discard the strap.
4. NOTE:
To aid assembly, mark the location of the cradle prior to disassembly.
Using a screwdriver, or similar tool, remove the cradle by inserting the screwdriver under the cradle and prying up. An animated version of this
procedure is available on-line.
Assembly
1. NOTE:
Make sure the sensor is fully seated into the new cradle. The sensor will make a "click" noise when fully seated.
Position the sensor into the new cradle by inserting the hinge end of the sensor into the hook end of the cradle and pushing the opposite end of the
sensor down onto the cradle.
2. NOTICE:
Metal scrapers may damage the wheel. Use only plastic or non-metallic scrapers to remove the cradle adhesive strip residue.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
NOTE:
The sensor and cradle must be installed in the drop well of the wheel, 180 degrees from the valve stem.
Using wheel and tire cleaner, clean the area where the sensor and cradle are to be installed.
3. NOTE:
The sensor and cradle must be positioned with the hinge side of the sensor on the RH side when viewed from the curb side (beauty side) of the wheel.
NOTE:
The sensor has raised markings indicating how to position the sensor.
Remove the adhesive tape liner from the cradle and position the sensor and cradle into the wheel drop well 180 degrees from the valve stem. A video
version of this procedure is available on-line.
4. Install the tapered end of the strap through the opening of the cradle on the hinge side of the sensor. This will position the worm gear on the locking
clip side of the sensor. An animated version of this procedure is available on-line.
5. NOTICE:
Steel wheels have a "high spot" along their circumference. Make sure the strap and sensor are mounted at the lowest spot possible to avoid
damaging the sensor during wheel and tire disassembly and assembly.
NOTE:
Keep the strap parallel with the wheel flange while tightening the worm gear.
Position the worm gear 13-26 mm (0.5-1.0 in) away from the sensor and tighten the worm gear.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
6. NOTICE:
The sensor, cradle and strap may be damaged by incorrect tire mounting or dismounting. Mount the tire only as instructed.
Install the tire onto the wheel. For additional information, refer to Wheel and Tire in this section.
7. NOTE:
A new tire pressure sensor is shipped in an off mode (or battery saver mode) and must be turned on before it can be trained. To turn the sensor on,
install it on a wheel, mount the tire and inflate the tire to the recommended inflation pressure. Wait at least 2 minutes, then continue with the sensor
training procedure.
Train the tire pressure sensor(s). For additional information, refer to Tire Pressure Monitoring System (TPMS) Sensor Training in this section.
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CONTENTS PAGE
Wheel and Tire ................................................................................................................................................................... 204-04-2
2008 F-250, 350, 450, 550 Super Duty, 7/2007

Wheel and Tire

Special Tool(s)
Digital Tire Gauge

204-354

1 1508 Tire
2 1007 Wheel
Disassembly
NOTICE:
Failure to follow the instructions below may result in damage to the Tire Pressure Monitoring System (TPMS) sensor.
NOTE:
Use only Digital Tire Gauge any time tire pressures are measured to be sure that accurate values are obtained.
NOTE:
A wheel and tire assembly equipped with a Tire Pressure Monitoring System (TPMS) sensor will have the following verbiage stamped or cast on the wheel:
SENSOR MAY BE INSIDE. An animated version of this procedure is available on-line.
NOTE:
The TPMS sensor is mounted to the wheel 180 degrees opposite of the valve stem and is held in place by a stainless steel strap. The sensor is not mounted to
the valve stem.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
1. Remove the wheel and tire. For additional information, refer to Wheel and Tire — Single Rear Wheel (SRW) or Wheel and Tire — Dual Rear Wheel
(DRW) in this section.
NOTICE:
Do not allow the tire beads to move beyond the wheel mid-plane (middle of the wheel) when separating the beads from the wheels, damage to the
Tire Pressure Monitoring System (TPMS) sensor may occur.
2. NOTICE:
Tire and valve stem position is critical to prevent damage to the Tire Pressure Monitoring System (TPMS) sensor when using a paddle-type
bead separator. An animated version of this procedure is available on-line.
NOTE:
Some machines may have a nylon roller bead separator at the 12 o'clock position instead of the paddle-type bead separator at the 3 o'clock position.
An animated version of this procedure is available on-line.
Position the wheel and tire assembly on a suitable tire machine and separate both beads of the tire from the wheel.
• For a paddle-type tire machine, position the valve stem at the 12 o'clock or 6 o'clock position and the paddle at the 3 o'clock position.
• For a roller-type tire machine, align the valve stem with the roller at any position.
3. NOTE:
A video version of this procedure is available on-line.
NOTE:
Index-mark the valve stem and wheel weight positions on the tire.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
Place the wheel and tire assembly on the turntable of the tire machine with the valve stem between the 5 o'clock and 6 o'clock positions and the
machine arm at the 12 o'clock position and dismount the outer bead from the wheel.
4. Reset the wheel and tire assembly on the turntable of the tire machine with the valve stem between the 5 o'clock and 6 o'clock positions and the
machine arm at the 12 o'clock position and dismount the inner bead from the wheel.
5. Inspect the TPMS sensor, cradle and strap for damage, install new parts as necessary.
• For information on removal and installation of the TPMS sensor, refer to Tire Pressure Monitoring System (TPMS) Sensor in this section.
• When installing a new wheel, reuse the TPMS sensor from the previous wheel if possible. The TPMS will not have to be trained if the sensor is
reused. The new wheel will not come with a sensor strap. A sensor strap kit will need to be ordered with the new wheel.
Assembly
NOTICE:
Damage to the Tire Pressure Monitoring System (TPMS) sensor may result if the tire mounting is not carried out as instructed.
1. NOTE:
Lubricate the tire beads using a suitable, fast-drying, corosion-inhibiting tire bead lubricant.
NOTE:
Do not mount the tire at this time.
NOTE:
A video version of this procedure is available on-line.
Position the wheel on the turntable of the tire machine, then lubricate and position the bottom bead of the tire on the wheel.
2. Position the wheel to align the valve stem with the machine arm, at the 12 o'clock position, and mount the bottom bead of the tire. A video version of
this procedure is available on-line.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
3. Reposition the wheel to align the valve stem with the machine arm, at the 12 o'clock position, and mount the top bead of the tire.
4. NOTE:
Use only the Digital Tire Gauge any time tire pressures are measured to make sure that accurate values are obtained.
Inflate the tire to the pressure specified on the Vehicle Certification (VC) label located on the driver door or door pillar.
5.
WARNING:
If there is a need to exceed the maximum pressure indicated on the sidewall of the tire, in order to seat the beads, follow ALL the steps listed
below. Failure to follow these steps may result in serious personal injury.
The following steps should only be performed if the tire beads cannot be set by inflating the tire up to the maximum inflation pressure listed
on the tire sidewall.
1 Re-lubricate the tire bead and wheel bead seat area.
2 Install a remote valve and pressure gauge.
3 Wear eye and ear protection and stand at a minimum of 3.65 m (12 ft) away from the wheel and tire assembly.
4 Inflate tire using the remote valve and pressure gauge until the beads have seated or until the pressure gauge is 138 kPa (20 psi) more than
maximum inflation pressure on tire sidewall. If beads have not seated, proceed to the next step.
5 Place the wheel and tire assembly in an OSHA-approved tire safety cage.
6 Inflate the tire using the remote valve and pressure gauge until the beads have seated or until the pressure gauge is 276 kPa (40 psi) more than
maximum inflation pressure on the tire sidewall. Do not exceed 276 kPa (40 psi) above the max pressure on tire sidewall. Install a new tire if
the beads do not seat at this pressure.
6. Install the wheel and tire. For additional information, refer to Wheel and Tire — Single Rear Wheel (SRW) or Wheel and Tire — Dual Rear Wheel
(DRW) in this section.
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CONTENTS PAGE
GENERAL PROCEDURES
Tire Pressure Monitoring System (TPMS) Sensor Activation ............................................................................................. 204-04-2
2008 F-250, 350, 450, 550 Super Duty, 7/2007

GENERAL PROCEDURES
Tire Pressure Monitoring System (TPMS) Sensor Activation
Special Tool(s)

204-363
NOTE:
The tire pressure sensors will go into a "sleep mode" after 30 minutes of inactivity to conserve battery power. The sensors do not transmit information while
in sleep mode. It will be necessary to wake them up so they will transmit the latest tire pressure information.
1. Turn the ignition switch to the ON position.

2. Position the Tire Pressure Monitor Activation Tool against the LF tire sidewall, 180 degrees from the tire valve stem.
3. NOTE:
The Tire Pressure Monitor Activation Tool will provide feedback in the form of a flashing green light and a beep sound for each successful response
from a tire pressure sensor.
Press the test button on the Tire Pressure Monitor Activation Tool to activate the sensor, activate the sensor at least 2 times.
4. Repeat Steps 2 and 3 for the remaining tires.
5. If the Tire Pressure Monitoring System (TPMS) indicator remains illuminated after adjusting and activating each sensor, refer to the Symptom Chart
in Diagnosis and Testing in this section.
2008 F-250, 350, 450, 550 Super Duty, 7/2007


CONTENTS PAGE
GENERAL PROCEDURES
Tire Pressure Monitoring System (TPMS) Sensor Training ................................................................................................ 204-04-2
2008 F-250, 350, 450, 550 Super Duty, 7/2007

GENERAL PROCEDURES
Tire Pressure Monitoring System (TPMS) Sensor Training
Special Tool(s)

204-363
Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS)

software with appropriate hardware, or equivalent scan tool
NOTE:
If the vehicle has been stationary for more than 30 minutes, the sensors will go into a "sleep mode" to conserve battery power. It will be necessary to wake
them up so they will transmit the latest tire pressure information to the Smart Junction Box (SJB). For additional information, refer to Tire Pressure
Monitoring System (TPMS) Sensor Activation in this section.
NOTE:
The tire pressure sensor training procedure must be done on a single vehicle, in an area without radio frequency noise and at least 1 m (3 ft) away from other
vehicles equipped with a Tire Pressure Monitoring System (TPMS).
Radio frequency noise is generated by electrical motors and appliance operation, cellular telephones, remote transmitters, power inverters and portable
entertainment equipment.
NOTE:
If a sensor does not respond to the Tire Pressure Monitor Activation Tool, attempt to activate the same sensor with the Tire Pressure Monitor Activation
Tool. If the sensor still does not respond, move the vehicle to rotate the wheels at least one-fourth of a turn and attempt to activate the same sensor again.
NOTE:
The SJB has a 2-minute time limit between sensor responses. If the SJB does not recognize any 1 of the 4 tire pressure sensors during this time limit, the
horn will sound twice and the message center (if equipped) will display TIRE NOT TRAINED REPEAT and the entire procedure must be repeated.
NOTE:
For vehicles with different front and rear tire pressures (such as the E-Series and certain F-Series), the tire pressure sensors must be trained following a tire
rotation. Failure to train the sensors will cause the TPMS indicator to illuminate. For vehicles with the same tire pressure for front and rear tires, tire rotation
will not affect the system.
1. NOTE:
An animated version of this procedure is available on-line.
Turn the ignition switch to the OFF position, then press and release the brake pedal.
2. Cycle the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position.
3. Press and release the brake pedal.
4. Turn the ignition switch to the OFF position.
5. Turn the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN position.
• The horn will sound once and the TPMS indicator will flash if the training mode has been entered successfully. If equipped, the message center
will display TRAIN LF TIRE.
6. NOTE:
It may take up to 6 seconds to activate a tire pressure sensor. During this time, the Tire Pressure Monitor Activation Tool must remain in place 180
degrees from the valve stem.
2008 F-250, 350, 450, 550 Super Duty, 7/2007

Place the Tire Pressure Monitor Activation Tool on the LF tire sidewall opposite (180 degrees) from the valve stem. Press and release the test button
on the Tire Pressure Monitor Activation Tool. The horn will sound briefly to indicate that the tire pressure sensor has been recognized by the SJB. An
animated version of this procedure is available on-line.
7. Within 2 minutes of the horn sounding, place the Tire Pressure Monitor Activation Tool on the RF tire sidewall opposite (180 degrees) from the valve
stem and press and release the test button to train the RF tire pressure sensor.
8. NOTE:
Do not wait more than 2 minutes between training each sensor or the SJB will time out and the entire procedure must be repeated.
Repeat Step 7 for the RR and LR tires.

The procedure is completed after the last tire has been trained. When the training procedure is complete, the message center (if equipped) will display
TIRE TRAINING COMPLETE.
For vehicles not equipped with a message center, successful completion of the training procedure will be verified by turning the ignition switch to the
OFF position without the horn sounding. If the horn sounds twice when the switch is turned to the OFF position, the training procedure was not
successful.
9. Using the scan tool, locate the updated TPMS sensor identifiers trained to the SJB and document them on the applicable warranty claim.
10. NOTE:
This step is required to clear DTC C2780, cause the SJB to exit the manufacturing mode and to make sure there are no other concerns with a newly
programmed SJB.
If the sensors are being trained due to the installation of a new SJB, clear any DTCs and carry out the SJB On-Demand Self Test.
2008 F-250, 350, 450, 550 Super Duty, 7/2007


CONTENTS PAGE
GENERAL PROCEDURES
Wheel and Tire Rotation ..................................................................................................................................................... 204-04-2
2008 F-250, 350, 450, 550 Super Duty, 7/2007

GENERAL PROCEDURES
Wheel and Tire Rotation
NOTE:
This procedure is intended for vehicles equipped with Tire Pressure Monitoring System (TPMS) and different front and rear tire pressures. For vehicles with
Dual Rear Wheels (DRW), refer to the Owner's Literature for wheel and tire rotation information.
1. Remove the wheel and tire. For additional information, refer to Wheel and Tire — Single Rear Wheel (SRW) in this section.
2. NOTE:
The front tires are shown at the top of the illustration.
Rotate the wheel and tire assemblies as shown.

• Cross the front tires and move them to the rear of the vehicle.
• Move the rear tires (without crossing) to the front of the vehicle.
3. Install the wheel and tire. For additional information, refer to Wheel and Tire — Single Rear Wheel (SRW) in this section.
4. Adjust the tire pressures. Refer to the Vehicle Certification (VC) label located on the driver door jamb.
5. NOTE:
The tire pressures must be adjusted and the tire pressure sensors must be trained following a tire rotation. Failure to train the sensors will result in a
false low tire pressure event, which will cause the TPMS indicator to illuminate.
Train the TPMS sensors. For additional information, refer to Tire Pressure Monitoring System (TPMS) Sensor Training in this section.
2008 F-250, 350, 450, 550 Super Duty, 7/2007


CONTENTS PAGE
Wheel and Tire — Single Rear Wheel (SRW) ..................................................................................................................... 204-04-2
2008 F-250, 350, 450, 550 Super Duty, 7/2007

Wheel and Tire — Single Rear Wheel (SRW)
Material
Item Specification
High Temperature Nickel Anti-Seize Lubricant —
XL-2
Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (US); WSS-M2C945-A
Motorcraft® SAE 5W-20 Super Premium Motor Oil (Canada)
XO-5W20-QSP (US); CXO-5W20-LSP12 (Canada)

1 1012 Wheel nut
2 — Wheel and tire assembly
Removal
1. If equipped, remove the wheel cover.
2. Check the torque for all of the wheel nuts. If any wheel nuts have a torque above 312 Nm (230 lb-ft), install all new wheel studs on that wheel hub.
For additional information, Refer to the appropriate section in Group 204 for the procedure.
4. NOTICE:
Do not use heat to loosen a seized wheel nut or damage to the wheel and wheel bearing an occur.
Remove the wheel nuts and the wheel and tire assembly.
Installation
1. Inspect the wheel and tire assembly for cracks, dents, leaks, severe wear or rust flaking. Install a new wheel if cracks or rust flaking of the surface
exists.
2.
WARNING:
When a wheel is installed, always remove any corrosion, dirt or foreign material present on the mounting surface of the wheel and the
mounting surface of the wheel hub, brake drum or brake disc. Make sure that any fasteners that attach the rotor to the hub are secured so
they do not interfere with the mounting surfaces of the wheel. Failure to follow these instructions when installing wheels may result in the
wheel nuts loosening and the wheel coming off while the vehicle is in motion, which could result in loss of control, leading to serious injury or
death to vehicle occupant(s).
NOTICE:
Make sure to apply a thin coat of anti-seize lubrication only to the interface between the wheel pilot bore and the hub pilot. Do not allow the
anti-seize to make contact with the wheel-to-brake disc/drum mounting surface, wheel studs, wheel nuts, brake pads or brake disc friction
surfaces or damage to the components may occur.
Clean the wheel to remove any loose paint, dirt, rust pitting or foreign material without damaging the metal.
• Using a clean, dry shop towel, wipe off any excess metallic particles.
• Re-inspect the wheel after cleaning. Fatigue cracks or rust flaking may be seen only after cleaning has been completed.
• Clean the wheel mounting surfaces and apply a thin coat of anti-seize to the wheel hub pilot surface (wheel only).
2008 F-250, 350, 450, 550 Super Duty, 7/2007

(Continued)
3.
WARNING:
Use only the specified lubricant on the wheel studs as directed in the following procedure. Incorrect lubricant application may result in
insufficient wheel nut torque, resulting in possible wheel/tire separation from the vehicle. Failure to follow this instruction may result in
serious injury to the vehicle occupant(s).
NOTE:
Do not allow oil to build up in the wheel stud threads. Only use 2 to 3 drops of oil per wheel hub.
Apply 2 to 3 drops of the specified motor oil to a clean shop towel. Using the shop towel, apply the oil to the wheel stud threads.
• Wipe off any excess oil from the wheel stud threads.
4. Install the wheel and tire assembly.
5. On all 2-piece flat wheel nuts, apply one drop of the specified motor oil between the flat washer and the nut. If corrosion exists, or the integral 2-piece
swiveling wheel nuts do not rotate freely, install new swiveling wheel nuts as necessary.
• Install the wheel nuts by hand.
• Tighten the wheel nuts until snug in a star/cross pattern to minimize runout.
6.
WARNING:
Retighten wheel nuts within 160 km (100 mi) after a wheel is reinstalled. For dual rear wheel (DRW) only, a second retightening is required
within 800 km (500 mi). Wheels can loosen after initial tightening. Failure to follow this instruction may result in serious injury to vehicle
occupant(s).
NOTICE:
Failure to tighten the wheel nuts in a star/cross pattern may result in high wheel and tire runout, which will speed up the development of
brake roughness, shudder and vibration.
With the weight of the vehicle on the tires, tighten the wheel nuts to 224 Nm (165 lb-ft) in a star/cross pattern.
7. If equipped, install the wheel cover.
2008 F-250, 350, 450, 550 Super Duty, 7/2007


CONTENTS PAGE
SPECIFICATIONS ..................................................................................................................................................................... 204-04-2
2008 F-250, 350, 450, 550 Super Duty, 7/2007

SPECIFICATIONS
Material
Item Specification Fill Capacity
Motorcraft® SAE 5W-20 Premium Synthetic Blend WSS-M2C945-A —
Motor Oil (US); Motorcraft® SAE 5W-20 Super
Premium Motor Oil (Canada)
XO-5W20-QSP (US); CXO-5W20-LSP12 (Canada)
Motorcraft® Wheel and Tire Cleaner — —
ZC-37-A
General Specifications
Item Specification
Tire Inflation
Tires See Safety Certification Sticker Located on Driver Door Jamb.
Description Nm lb-ft lb-in

Sensor band (worm gear) 3 — 27
Wheel nuts a — — —
2008 F-250, 350, 450, 550 Super Duty, 7/2007

204-00-I Suspension System - General Information 204-00-I

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204-00-i Suspension System — General Information 204-00-i

SECTION 204-00 Suspension System — General Information

2008 F-250, 350, 450, 550 Super Duty, 7/2007

Remover, Steering Arm

2008 F-250, 350, 450, 550 Super Duty, 7/2007

Separate the wheel knuckle from the axle.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

8. Install interim 0 degree service adjusters to both sides of the vehicle.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

13. Remove the nut from the upper ball joint.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

15. Tighten the lower ball joint nut to 59 Nm (44 lb-ft).

18. Verify the camber and caster settings, adjust as necessary.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

2008 F-250, 350, 450, 550 Super Duty, 7/2007

SECTION 204-00 Suspension System — General Information

2008 F-250, 350, 450, 550 Super Duty, 7/2007

4. Install interim 0 degree service adjusters to both sides of the vehicle.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

2008 F-250, 350, 450, 550 Super Duty, 7/2007

11. Verify the camber and caster settings, adjust as necessary.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

SECTION 204-00 Suspension System — General Information

2008 F-250, 350, 450, 550 Super Duty, 7/2007

Inspect all 4 tires for correct inflation, adjust as necessary.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

Front Lean Correction Chart

• If shim installation is required, continue with this procedure.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

17. Turn the shim so the recess is facing upward.

• For F-250 and F-350:

2008 F-250, 350, 450, 550 Super Duty, 7/2007

▪ Stage 3: Tighten to 300 Nm (221 lb-ft).

20. Remove the support from the axle.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

SECTION 204-00 Suspension System — General Information

2008 F-250, 350, 450, 550 Super Duty, 7/2007

F-250 and F-350, Four-Wheel Drive (4WD), F-450 and F-550

2008 F-250, 350, 450, 550 Super Duty, 7/2007

Rear Ride Height Measurement

2008 F-250, 350, 450, 550 Super Duty, 7/2007

SECTION 204-00 Suspension System — General Information

SPECIFICATIONS ..................................................................................................................................................................... 204-00-2

2008 F-250, 350, 450, 550 Super Duty, 7/2007

Item LH RH Total/ Split

Caster (Heavy Duty Suspension) b 3.6° ± 1.3° 3.6° ± 1.3° 0° ± 0.75° c

Caster (Heavy Duty Suspension)

Caster (Standard Suspension) 3.5° ± 1.2° 3.5° ± 1.2° 0° ± 0.75°

Caster (Heavy Duty Suspension)

Caster (Standard Suspension) 2.9° ± 1.2° 2.9° ± 1.2° 0° ± 0.75°

Caster (Heavy Duty Suspension)

Caster (Standard Suspension) 3.5° ± 1.2° 3.5° ± 1.2° 0° ± 0.55°

Caster (Heavy Duty Suspension)

Caster (Standard Suspension) 2.7° ± 1.2° 2.7° ± 1.2° 0° ± 0.55°

Caster (Heavy Duty Suspension)

Caster (Standard Suspension) 3.3° ± 1.2° 3.6° ± 1.2° -0.30° ± 0.55°

Caster (Heavy Duty Suspension)

Caster (Standard Suspension) 2.9° ± 1.2° 2.9° ± 1.2° 0° ± 0.55°

2008 F-250, 350, 450, 550 Super Duty, 7/2007

Alignment Specifications (Continued)

Caster (Heavy Duty Suspension)

Caster (Standard Suspension) 2.5° ± 1.2° 2.8° ± 1.2° -0.30° ± 0.55°

Caster (Heavy Duty Suspension)