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1996 Ford F-250 Pickup CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT Ford REPAIR SHOPS DON'T WANT YOU TO KNOW
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- Component Locations
- Wiring Diagrams
- Technical Service Bulletins
- Specifications
- A/C & Heater Service
- Brake Service
- Fuel Filter Replacement
- Driveline, U-Joint & CV Axles Replacement
- Starter & Alternator Replacement
- Maintenance Lamp Reset
- Radiator & Hose Replacement
- Serpentine Belt Service
A/C & HEATER SERVICE PROCEDURES FOR 1996 Ford F-250 Pickup AUTOMOBILES
Computer Relearn Procedures -> Ford Motor Co. -> 1999-2002 -> 2003-04 -> Automatic Data Transfer -> Except 1999-2002 -> Manual Data Entry -> Powertrain Control Module (PCM)
Vehicle: 1996 Ford F-250 Pickup 5.8 V8 GAS
Powertrain Control Module (PCM)
Except 1999-2002
Disconnect negative battery cable for a minimum of five minutes. After clearing memory, it is required to drive vehicle a minimum of 10 miles to allow PCM time to relearn operating strategy.
1999-2002
Automatic Data Transfer
- Prior to removing old PCM, connect a suitably programmed scan tool to Data Link Connector (DLC).
- Follow scan tool manufacturers' instructions to download data from old PCM.
- Install new PCM and connect scan tool to DLC.
- Follow scan tool manufactur...
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BRAKE SERVICE PROCEDURES FOR 1996 Ford F-250 Pickup AUTOMOBILES
Hydraulic Brake Systems -> Brake System Bleed -> ABS Bleeding -> Except Windstar -> Manual Bleeding -> Pressure Bleeding -> Windstar
Vehicle: 1996 Ford F-250 Pickup Super CAB 7.3 V8 DIESEL
Except Windstar
Bleed primary and secondary hydraulic brake systems separately, bleeding the longest line first on each system. Do not allow reservoir to run dry during bleeding operation. Never reuse fluid that has been drained from the hydraulic system. Ensure proper bleed sequence is followed.
On Aerostar, Bronco, E-Series, Explorer, F-Series and Ranger models, the bleed order is right rear, left rear, right front, left front.
On Villager models, the bleed order is left front, right front, left rear, right rear.
- Loosen master cylinder to hydraulic line nuts and wrap sho...
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FUEL FILTER REPLACEMENT PROCEDURES FOR 1996 Ford F-250 Pickup AUTOMOBILES
Ford Motor Co. Light Trucks, SUVs & Vans -> Fuel Filter Replacement -> 1995-04 7.3L Diesel Engine
Vehicle: 1996 Ford F-250 Pickup Super CAB 7.3 V8 DIESEL
The fuel system remains under high pressure even when the engine is not running. This residual pressure must be relieved before servicing the fuel system. To avoid injury or fire, release pressure from the fuel system before disconnecting any fuel line.
The fuel system pressure must be relieved prior to disconnecting fuel lines to prevent accidental spray of fuel.
After the battery has been disconnected and reconnected, some abnormal driveability symptoms may occur. The vehicle may need to be driven 10 miles or more while it relearns its adaptive strategy.
- Disconnect the...
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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR 1996 Ford F-250 Pickup AUTOMOBILES
DRIVESHAFT, Replace -> Front -> One Piece Driveshaft -> Rear -> Three Piece Driveshaft -> Two Piece Driveshaft
Vehicle: 1996 Ford F-250 Pickup 5.0 V8 GAS
Front
- Raise and support the vehicle.
- Index-mark front driveshaft to front axle flange and at transfer case flange.
- Remove and discard bolts and U-joint retainers.
- Remove and discard four flange bolts.
- Compress and separate front driveshaft from front axle, then separate driveshaft from transfer case. Wrap electrical tape around the bearing cups to prevent them from falling off the U-joint spider.
- Reverse procedure to install, noting the following:
- Torque flange bolts to 30 ft. lbs.
- Torque U-joint retainer bolts to 16 ft. lbs.
Rear
One Piece Driveshaft
- Raise and support vehicle.
- To maint...
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STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR 1996 Ford F-250 Pickup AUTOMOBILES
Starter, Replace
Vehicle: 1996 Ford F-250 Pickup Super CAB 7.3 V8 DIESEL
- Disconnect battery ground cable.
- Raise and support vehicle, if required.
- Disconnect electrical connector or solenoid relay wire from starter motor.
- Remove starter motor attach...
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MAINTENANCE LAMP RESET PROCEDURES FOR 1996 Ford F-250 Pickup AUTOMOBILES
Ford Motor Co. Trucks -> Electronic Throttle Control ->
Vehicle: 1996 Ford F-250 Pickup 4.9 L6 BI-FUEL
Electronic throttle displays when the system has malfunctioned and the engine has defaulted to a limp-home operation. On vehicles equipped with ...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 1996 Ford F-250 Pickup AUTOMOBILES
Radiator, Replace
Vehicle: 1996 Ford F-250 Pickup 4.9 L6 BI-FUEL
- Drain cooling system into a suitable container by removing radiator cap and opening draincock located at the lower rear corner of the radiator tank.
- Remove rubber radiator overflow hose from radiator coolant recovery reservoir and disconnect it from radiator, Figs. .
- Remove fan shroud upper attaching screws.
- Lift fan shroud out of lower retaining clips and drape it on fan.
- Loosen upper and lower hose clamps at radiator and remove upper radiator hose and lower radiator fr...
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SERPENTINE BELT SERVICE PROCEDURES FOR 1996 Ford F-250 Pickup AUTOMOBILES
Serpentine Drive Belt, Replace -> Automatic Tension -> Manual Tension
Vehicle: 1996 Ford F-250 Pickup 7.5 V8 GAS
Automatic Tension
- Install suitable 5/16 inch closed end wrench on tensioner pulley bolt, then lift tensioner arm away from belt. Do not use socket and ratchet.
- Remove belt, slowly release tensioner. Do not allow tensioner to snap back, as damage may result.
- Reverse procedure to install.
Manual Tension
- Loosen accessory adjustment bolt and pivot bolt.
- Remove belt.
- Reverse procedure to install, adjust belt tension as follows:
- Lo...
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COMPONENT LOCATION DIAGRAMS FOR 1996 Ford F-250 Pickup AUTOMOBILES
Component location diagrams for most 1996 Ford F-250 Pickup cars and light trucks sold in the U.S. from 1990+.
I/P Components Diagram for 1996 Ford F-250 Pickup 4.9 L6 BI-FUEL Components on diagram: |
Body Components Diagram for 1996 Ford F-250 Pickup Super CAB 7.5 V8 GAS Components on diagram: |
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WIRING DIAGRAMS FOR 1996 Ford F-250 Pickup AUTOMOBILES
OEM drawn wiring diagrams for most 1996 Ford F-250 Pickup cars and light trucks sold in the U.S.
1996 Ford F-250 Pickup 7.5 V8 GAS Wiring Diagram Components on diagram: |
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TECHNICAL SERVICE BULLETINS FOR 1996 Ford F-250 Pickup AUTOMOBILES
OEM TSB listings for most 1996 Ford F-250 Pickup cars and light trucks sold in the U.S. from 1985+.
Document: SAFETY RECALL - SPEED CONTROL SYSTEM MODIFICATION Vehicle: 1996 Ford F-250 Pickup 5.0 V8 GAS Auto Systems: |
Document: RECALL - CERTAIN 1992-2003 MODEL YEAR CARS AND TRUCKS - FUSED JUMPER HARNESS REPLACEMENT FOR VEHICLES SERVICED WITH AN INCOMPATIBLE FUSED JUMPER HARNESS Vehicle: 1996 Ford F-250 Pickup 5.0 V8 GAS Auto Systems: |
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COMPONENT/PARTS SPECIFICATIONS FOR 1996 Ford F-250 Pickup AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 1996 Ford F-250 Pickup cars and light trucks sold in the U.S. and Canada from 1970+.
- Brake caliper mounting bolt torque
- Brake drum runout, machining, & discard specs
- Minimum brake lining thickness.
- Brake rotor runout, parallelism, machining, discard, & finish specs
A/C SYSTEM SPECIFICATIONS: Air conditioning refrigerant capacity and type as well as lubricant capacity for most 1996 Ford F-250 Pickup cars and light trucks sold in the U.S. and Canada from 1980+.
- Refrigerant capacity & type, compressor oil viscosity, total system oil capacity & compressor clutch gap
COOLING SYSTEM BLEED: Cooling system bleeder valve identification, bleeder type and bleed procedures for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1986+.
PREVENTIVE MAINTENANCE: Preventive maintenance recommendations and required services for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1980+. Includes severe and routine service schedules
QUICK-LUBE and ILLUSTRATIONS: Fluid recommendations, capacities, drain plug torques, tire data, and severe service recommended preventive maintenance schedules. Information covers most 1996 Ford F-250 Pickup cars and light trucks sold in the U.S. and Canada from 1980+. Engine and chassis service images.
- Automatic transmission/transaxles capacities, lubricant recommendations
- Differential/final drive capacities, lube recommendations, grades, & viscosities
- Final drive fill & drain plug torques
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Manual transmission/transaxle capacities, lube recommendations, grades, & viscosities
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Engine oil capacities, API grade recommendations, SAE viscosity recommendations, drain plug torque
- Severe service maintenance & interval recommendations
- Tire sizes, wheel nut/bolt torque, pressures & rim sizes
- Transfer case capacities, lube recommendations, grades, & viscosities
TUNE-UP & DRIVEABILITY SPECIFICATIONS: Most tune-up specifications for most 1996 Ford F-250 Pickup cars and light trucks sold in the U.S. and Canada from 1980+
- Airflow sensor electrical specifications
- Tensioning specifications for systems with automatic tensioners
- Barometric pressure sensor specs
- Battery group number and cranking performance
- Crankshaft & camshaft position sensor resistance
- Engine compression pressures
- Coolant temperature sensor specs
- Computer advance.
- Diesel fuel temperature sensor resistance.
- Distributor advance specifications
- Ignition pickup coil resistance
- Exhaust gas recirculation temperature sensor resistance
- Engine fastener torque values
- Firing order diagrams
- Fuel system pressures
- Generator (alternator) specs
- Intake air temperature sensor specs
- Ignition coil specifications
- Fuel injector resistance
- Engine idle speeds
- Knock sensor resistance
- Manifold absolute pressure sensor specs
- Mixture control solenoid resistance
- Voltage regulator specs
- Spark plug applications & gaps
- Starter motor electrical specs.
- Tensioning specifications for systems without automatic tensioners
- Throttle body temperature sensor resistance
- Ignition timing in degrees at rpm
- Transmission oil temperature sensor resistance
- Throttle position sensor specs
- Vacuum sensor valve specs
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