1996 Bronco/F-Series

Section 00-03: Maintenance and Lubrication

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

MAINTENANCE

Severe-Duty Schedule

NOTE: Items for emission control service are shown in bold type.

For items marked with a number in parentheses, see footnotes at the end of this schedule.

NOTE: The Severe-Duty Schedule provides maintenance intervals for replacing air cleaner filter if vehicle is driven in severe dust conditions. However, some driving conditions may require even more frequent air cleaner replacement intervals than those shown.

NOTE: Kilometer intervals are rounded off.

3,000 Miles (5,000 km)

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

6,000 Miles (10,000 km)

Change engine oil and replace oil filter.
Rotate tires and adjust air pressure. (1) (2) (3)
Check clutch reservoir fluid level.
Inspect and lubricate automatic transmission shift linkage.
Inspect exhaust system for leaks, damage or loose parts. Remove any foreign material trapped by exhaust shielding. (4)
Lubricate steering linkage suspension, driveshaft U-joint, if equipped with grease fittings, and lubricate slip-yoke (if equipped). (5)

9,000 Miles (15,000 km)

Change engine oil and replace oil filter.

12,000 Miles (20,000 km)

Change engine oil and replace oil filter.
Check clutch reservoir fluid level.
Inspect and lubricate automatic transmission shift linkage.
Inspect exhaust system for leaks, damage or loose parts. Remove any foreign material trapped by exhaust shielding. (4)
Lubricate steering linkage suspension, driveshaft U-joint, if equipped with grease fittings, and lubricate slip-yoke (if equipped). (5)

15,000 Miles (25,000 km)

Change engine oil and replace oil filter.
Inspect engine cooling system, hoses, and clamps and check coolant strength every 15,000 miles (25,000 km) or 12 months.
For 7.3L DI turbo diesel engines, add 8-10 ounces of FW-15 to the engine coolant every 15,000 miles (24,000 km).
Rotate tires and adjust air pressure. (1) (2) (3)
Lubricate transfer case shift lever pivot bolt and control rod connecting pins (4x4).
Inspect disc brake system hoses and lines. (5)
Lubricate caliper slide rails (F-Super Duty). (5)
Inspect drum brake systems, hoses and lines.
Change fuel filter (recommended but not required for California certified vehicles).
Change fuel filter every 15,000 miles (25,000 km) (7.5L DI turbo diesel only).
Check spring U-bolt torque (F-Super Duty).
Inspect parking brake fluid (F-Super Duty).

18,000 Miles (30,000 km)

Change engine oil and replace oil filter.
Check clutch reservoir fluid level.
Inspect and lubricate automatic transmission shift linkage.
Inspect exhaust system for leaks, damage or loose parts. Remove any foreign material trapped by exhaust shielding. (4)
Lubricate steering linkage suspension, driveshaft U-joint, if equipped with grease fittings, and lubricate slip-yoke (if equipped). (5)
Check and lubricate clutch release lever (7.5L and 7.3L DI turbo diesel).

21,000 Miles (35,000 km)

Change engine oil and replace oil filter.
Change automatic transmission fluid.

24,000 miles (40,000 km)

Change engine oil and replace oil filter.
Rotate tires and adjust air pressure. (1) (2) (3)
Inspect and lubricate automatic transmission shift linkage.
Inspect exhaust system for leaks, damage or loose parts. Remove any foreign material trapped by exhaust shielding. (4)
Lubricate steering linkage suspension, driveshaft U-joint, if equipped with grease fittings, and lubricate slip-yoke (if equipped). (5)
Lubricate throttle kickdown or TV lever ball studs.

27,000 Miles (45,000 km)

Change engine oil and replace oil filter.

30,000 Miles (50,000 km)

Change engine oil and replace oil filter.
Replace air cleaner filter every 30,000 miles (50,000 km) or 30 months. (6)
Replace the air cleaner filter when the restriction gauge is in the red zone (7.3L DI turbo diesel only). (6)
Inspect engine cooling system, hoses, and clamps and check coolant strength every 15,000 miles (25,000 km) or 12 months.
For 7.3L DI turbo diesel engines, add 8-10 ounces of FW-15 to the engine coolant every 15,000 miles (25,000 km).
Replace crankcase emission air filter. (4.9L, 5.0L manual transmission and 7.5L only.) (6)
Check clutch reservoir fluid level.
Inspect and lubricate automatic transmission shift linkage.
Inspect exhaust system for leaks, damage or loose parts. Remove any foreign material trapped by exhaust shielding. (4)
Lubricate steering linkage suspension, driveshaft U-joint, if equipped with grease fittings, and lubricate slip-yoke (if equipped). (5)
Lubricate transfer case shift lever pivot bolt and control rod connecting pins (4x4).
Inspect disc brake system hoses and lines. (5)
Lubricate caliper slide rails (F-Super Duty). (5)
Inspect drum brake systems, hoses and lines.
Change fuel filter (recommended but not required for California certified vehicles).
Change fuel filter every 15,000 miles (25,000 km) (7.3L DI turbo diesel only).
Inspect and lubricate front wheel bearings. (5)
Inspect parking brake system for damage and operation.
Change manual transmission oil.
Lubricate front axle RH axle shaft slip-yoke (4x4).
Inspect and lubricate spindle needle bearings (4x4).
Change rear axle lube (F-Super Duty only). (7)
Inspect and lubricate hub locks (4x4).
Inspect parking brake fluid (F-Super Duty).
Check spring U-bolt torque (F-Super Duty).

33,000 Miles (55,000 km)

Change engine oil and replace oil filter.
Rotate tires and adjust air pressure. (1) (2) (3)
Check and lubricate clutch release lever (7.5L and 7.3L DI turbo diesel).

36,000 Miles (60,000 km)

Change engine oil and replace oil filter.
Check clutch reservoir fluid level.
Inspect and lubricate automatic transmission shift linkage.
Inspect exhaust system for leaks damage or loose parts. Remove any foreign material trapped by exhaust shielding. (4)
Lubricate steering linkage suspension, driveshaft U-joint, if equipped with grease fittings, and lubricate slip-yoke (if equipped). (5)

39,000 Miles (65,000 km)

Change engine oil and replace oil filter.

42,000 Miles (70,000 km)

Change engine oil and replace oil filter.
Change automatic transmission fluid.
Rotate tires and adjust air pressure. (1) (2) (3)
Check clutch reservoir fluid level.
Inspect and lubricate automatic transmission shift linkage.
Inspect exhaust system for leaks, damage or loose parts. Remove any foreign material trapped by exhaust shielding. (4)
Lubricate steering linkage suspension, driveshaft U-joint, if equipped with grease fittings, and lubricate slip-yoke (if equipped). (5)

45,000 Miles (75,000 km)

Change engine oil and replace oil filter.
Inspect engine cooling system, hoses, and clamps and check coolant strength every 15,000 miles (25,000 km) or 12 months.
For 7.3L DI turbo diesel engines, add 8-10 ounces of FW-15 to the engine coolant every 15,000 miles (25,000 km).
Lubricate transfer case shift lever pivot bolt and control rod connecting pins (4x4).
Inspect disc brake system hoses and lines. (5)
Lubricate caliper slide rails (F-Super Duty). (5)
Inspect drum brake systems, hoses and lines.
Change fuel filter (recommended but not required for California certified vehicles).
Change fuel filter every 15,000 miles (25,000 km) (7.3L DI turbo diesel only).
Inspect parking brake fluid (F-Super Duty).
Check spring U-bolt torque (F-Super Duty).

48,000 Miles (80,000 km)

Change engine oil and replace oil filter.
Change engine coolant initially at 48,000 miles (80,000 km) or 48 months. Thereafter, change engine coolant every 30,000 miles (50,000 km) or 36 months (gasoline engines only).
For 7.3L DI turbo diesel engines, add four (4) pints of FW-15 each time engine coolant is changed.
Check clutch reservoir fluid level.
Inspect and lubricate automatic transmission shift linkage.
Inspect exhaust system for leaks, damage or loose parts. Remove any foreign material trapped by exhaust shielding. (4)
Lubricate steering linkage suspension, driveshaft U-joint, if equipped with grease fittings, and lubricate slip-yoke (if equipped). (5)
Lubricate throttle kickdown or TV lever ball studs.
Check and lubricate clutch release lever (7.5L and 7.3L DI turbo diesel).

51,000 Miles (85,000 km)

Change engine oil and replace oil filter.
Rotate tires and adjust air pressure. (1) (2) (3)

54,000 Miles (90,000 km)

Change engine oil and replace oil filter.
Check clutch reservoir fluid level.
Inspect and lubricate automatic transmission shift linkage.
Inspect exhaust system for leaks, damage or loose parts. Remove any foreign material trapped by exhaust shielding.
Lubricate steering linkage suspension, driveshaft U-joint, if equipped with grease fittings, and lubricate slip-yoke (if equipped). (5)

57,000 Miles (95,000 km)

Change engine oil and replace oil filter.

60,000 Miles (100,000 km)

Change engine oil and replace oil filter.
Inspect engine cooling system, hoses, and clamps and check coolant strength every 15,000 miles (25,000 km) or 12 months.
Replace air cleaner filter every 30,000 miles (50,000 km) or 30 months. (6)
Replace the air cleaner filter when the restriction gauge is in the red zone (7.3L DI turbo diesel only). (6)
Replace crankcase emission air filter.
Replace PCV valve. (8)
Check Thermactor hoses and clamps (recommended but not required).
Inspect accessory drive belts.
Replace spark plugs (gasoline engines only).
Rotate tires and adjust air pressure. (1) (2) (3)
Check clutch reservoir fluid level.
Inspect and lubricate automatic transmission shift linkage.
Inspect exhaust system for leaks, damage or loose parts. Remove any foreign material trapped by exhaust shielding. (4)
Lubricate steering linkage suspension, driveshaft U-joint, if equipped with grease fittings, and lubricate slip-yoke (if equipped). (5)
Lubricate transfer case shift lever pivot bolt and control rod connecting pins (4x4).
Inspect disc brake system hoses and lines. (5)
Lubricate caliper slide rails (F-Super Duty). (5)
Inspect drum brake systems, hoses and lines.
Change fuel filter (recommended but not required for California certified vehicles).
Change fuel filter every 15,000 miles (25,000 km) (7.3L DI turbo diesel only).
Inspect and lubricate front wheel bearings (5).
Inspect parking brake system for damage and operation.
Lubricate front axle RH axle shaft slip-yoke (4x4).
Inspect and lubricate spindle needle bearings (4x4).
Inspect and lubricate hub locks (4x4).
Change transfer case oil (4x4).
Change manual transmission oil.
Change rear axle lube (F-Super Duty only). (7)
Inspect parking brake fluid (F-Super Duty).
Check spring U-bolt torque (F-Super Duty).

63,000 Miles (105,000 km)

Change engine oil and replace oil filter.
For 7.3L DI turbo diesel engines, add 8-10 ounces of FW-15 to the engine coolant every 15,000 miles (25,000 km).
Check and lubricate clutch release lever (7.5L and 7.3L DI turbo diesel).
Change automatic transmission fluid.

66,000 Miles (110,000 km)

Change engine oil and replace oil filter.
Check clutch reservoir fluid level.
Inspect and lubricate automatic transmission shift linkage.
Inspect exhaust system for leaks, damage or loose parts. Remove any foreign material trapped by exhaust shielding. (4)
Lubricate steering linkage suspension, driveshaft U-joint, if equipped with grease fittings, and lubricate slip-yoke (if equipped). (5)

69,000 Miles (115,000 km)

Change engine oil and replace oil filter.
Rotate tires and adjust air pressure. (1) (2) (3)

72,000 Miles (120,000 km)

Change engine oil and replace oil filter.
Check clutch reservoir fluid level.
Inspect and lubricate automatic transmission shift linkage.
Inspect exhaust system for leaks, damage or loose parts. Remove any foreign material trapped by exhaust shielding. (4)
Lubricate steering linkage suspension, driveshaft U-joint, if equipped with grease fittings, and lubricate slip-yoke (if equipped). (5)
Lubricate throttle kickdown or TV lever ball studs.

75,000 Miles (125,000 km)

Change engine oil and replace oil filter.
Inspect engine cooling system, hoses and clamps and check coolant strength every 15,000 miles (25,000 km) or 12 months.
Lubricate transfer case shift lever pivot bolt and control rod connecting pins (4x4).
Inspect disc brake system hoses and lines. (5)
Lubricate caliper slide rails (F-Super Duty). (5)
Inspect drum brake linings, hoses and lines.
Change fuel filter (recommended but not required for California certified vehicles).
Change fuel filter every 15,000 miles (25,000 km) (7.3L DI turbo diesel only).
Inspect parking brake fluid (F-Super Duty).
Check spring U-bolt torque (F-Super Duty).

78,000 Miles (130,000 km)

Change engine oil and replace oil filter.
Change engine coolant every 30,000 miles (50,000 km) or 36 months (gasoline engines only).
For 7.3L DI turbo diesel engines, add four (4) pints of FW-15 each time engine coolant is changed.
Rotate tires and adjust air pressure. (1) (2) (3)
Check clutch reservoir fluid level.
Inspect and lubricate automatic transmission shift linkage.
Inspect exhaust system for leaks, damage or loose parts. Remove any foreign material trapped by exhaust shielding. (4)
Lubricate steering linkage suspension, driveshaft U-joint, if equipped with grease fittings, and lubricate slip-yoke (if equipped). (5)
Check and lubricate clutch release lever (7.5L and 7.3L DI turbo diesel).

81,000 Miles (135,000 km)

Change engine oil and replace oil filter.

84,000 Miles (140,000 km)

Change engine oil and replace oil filter.
Check clutch reservoir fluid level.
Change automatic transmission fluid.
Inspect and lubricate automatic transmission shift linkage.
Inspect exhaust system for leaks, damage or loose parts. Remove any foreign material trapped by exhaust shielding. (4)
Lubricate steering linkage suspension, driveshaft U-joint, if equipped with grease fittings, and lubricate slip-yoke (if equipped). (5)

87,000 Miles (145,000 km)

Change engine oil and replace oil filter.
Rotate tires and adjust air pressure. (1) (2) (3)

90,000 Miles (150,000 km)

Change engine oil and replace oil filter.
Replace air cleaner filter every 30,000 miles (50,000 km) or 30 months. (6)
Replace the air cleaner filter when the restriction gauge is in the red zone (7.3L DI turbo diesel only). (6)
Inspect engine cooling system, hoses and clamps and check coolant strength every 15,000 miles (25,000 km) or 12 months.
Inspect accessory drive belts.
Replace crankcase emission air filter (4.9L, 5.0L manual transmission and 7.5L only). (6)
Check clutch reservoir fluid level.
Inspect and lubricate automatic transmission shift linkage.
Inspect exhaust system for leaks, damage or loose parts. Remove any foreign material trapped by exhaust shielding. (4)
Lubricate steering linkage suspension, driveshaft U-joint, if equipped with grease fittings, and lubricate slip-yoke (if equipped). (5)
Inspect disc brake system hoses and lines. (5)
Lubricate caliper slide rails (F-Super Duty). (5)
Inspect drum brake systems, hoses and lines.
Change fuel filter (recommended but not required for California certified vehicles).
Change fuel filter every 15,000 miles (25,000 km) (7.3L DI turbo diesel only).
Inspect and lubricate front wheel bearings. (5)
Inspect parking brake system for damage and operation.
Change manual transmission oil.
Lubricate transfer case shift lever pivot bolt and control rod connecting pins (4x4).
Lubricate front axle RH axle shaft slip-yoke (4x4).
Inspect and lubricate spindle needle bearings (4x4).
Change rear axle lube (F-Super Duty only). (4)
Inspect and lubricate hub locks (4x4).
Inspect parking brake fluid (F-Super Duty).
Check spring U-bolt torque (F-Super Duty).

93,000 Miles (155,000 km)

Change engine oil and replace oil filter.
For 7.3L DI turbo diesel engines, add 8-10 ounces of FW-15 to the engine coolant every 15,000 miles (25,000 km).
Check and lubricate clutch release lever (7.5L and 7.3L DI turbo diesel).

96,000 Miles (160,000 km)

Change engine oil and replace oil filter.
Rotate tires and adjust air pressure. (1) (2) (3)
Check clutch reservoir fluid level.
Inspect and lubricate automatic transmission shift linkage.
Inspect exhaust system for leaks, damage or loose parts. Remove any foreign material trapped by exhaust shielding. (4)
Lubricate steering linkage suspension, driveshaft U-joint, if equipped with grease fittings, and lubricate slip-yoke (if equipped). (5)
Lubricate throttle kick-down or TV lever ball studs.

99,000 Miles (165,000 km)

Change engine oil and replace oil filter.
Replace rear axle lube.

102,000 Miles (170,000 km)

Change engine oil and replace oil filter.
Check clutch reservoir fluid level.
Inspect and lubricate automatic transmission shift linkage.
Inspect exhaust system for leaks, damage or loose parts. Remove any foreign material trapped by exhaust shielding. (4)
Lubricate steering linkage suspension, driveshaft U-joint, if equipped with grease fittings, and lubricate slip-yoke (if equipped). (5)

105,000 Miles (175,000 km)

Change engine oil and replace oil filter.
Inspect engine cooling system, hoses, and clamps and check coolant strength every 15,000 miles (25,000 km) or 12 months.
Rotate tires and adjust air pressure. (1) (2) (3)
Change automatic transmission fluid.
Lubricate transfer case shift lever pivot bolt and control rod connecting pins (4x4).
Inspect disc brake system hoses and lines. (5)
Lubricate caliper slide rails (F-Super Duty). (5)
Inspect drum brake systems, hoses and lines.
Change fuel filter (recommended but not required for California certified vehicles).
Change fuel filter every 15,000 miles (25,000 km) (7.3L DI turbo diesel only).
Inspect parking brake fluid (F-Super Duty).
Check spring U-bolt torque (F-Super Duty).

108,000 Miles (180,000 km)

Change engine oil and replace oil filter.
Change engine coolant every 30,000 miles (50,000 km) or 36 months (gasoline engines only).
For 7.3L DI turbo diesel engines, add four (4) pints of FW-15 each time engine coolant is changed.
Check clutch reservoir fluid level.
Inspect and lubricate automatic transmission shift linkage.
Inspect exhaust system for leaks, damage or loose parts. Remove any foreign material trapped by exhaust shielding. (4)
Lubricate steering linkage suspension, driveshaft U-joint, if equipped with grease fittings, and lubricate slip-yoke (if equipped). (5)
Check and lubricate clutch release lever (7.5L and 7.3L DI turbo diesel).

111,000 Miles (185,000 km)

Change engine oil and replace oil filter.

114,000 Miles (190,000 km)

Change engine oil and replace oil filter.
Rotate tires and adjust air pressure. (1) (2) (3)
Check clutch reservoir fluid level.
Inspect and lubricate automatic transmission shift linkage.
Inspect exhaust system for leaks, damage or loose parts. Remove any foreign material trapped by exhaust shielding. (4)
Lubricate steering linkage suspension, driveshaft U-joint, if equipped with grease fittings, and lubricate slip-yoke (if equipped). (5)

117,000 Miles (195,000 km)

Change engine oil and replace oil filter.

120,000 Miles (200,000 km)

Change engine oil and replace oil filter.
Inspect engine cooling system, hoses, and clamps and check coolant strength every 15,000 miles (25,000 km) or 12 months.
Replace air cleaner filter every 30,000 miles (50,000 km) or 30 months. (6)
Replace the air cleaner filter when the restriction gauge is in the red zone (7.3L DI turbo diesel only). (6)
Replace spark plugs (gasoline engines only).
Replace crankcase emission air filter (4.9L, 5.0L manual transmission and 7.5L only). (6)
Replace PCV valve. (8)
Check Thermactor hoses and clamps (recommended but not required).
Inspect accessory drive belts.
Check clutch reservoir fluid level.
Inspect and lubricate automatic transmission shift linkage.
Inspect exhaust system for leaks, damage or loose parts. Remove any foreign material trapped by exhaust shielding. (4)
Lubricate steering linkage suspension, driveshaft U-joint, if equipped with grease fittings, and lubricate slip-yoke (if equipped). (5)
Lubricate throttle kickdown or TV lever ball studs.
Lubricate transfer case shift lever pivot bolt and control rod connecting pins (4x4).
Inspect disc brake system hoses and lines. (5)
Lubricate caliper slide rails (F-Super Duty). (5)
Inspect drum brake systems, hoses and lines.
Change fuel filter (recommended but not required for California certified vehicles).
Change fuel filter every 15,000 miles (25,000 km) (7.3L DI turbo diesel only).
Inspect and lubricate front wheel bearings. (5)
Inspect parking brake system for damage and operation.
Lubricate front axle RH axle shaft slip-yoke (4x4).
Inspect and lubricate spindle needle bearings (4x4).
Inspect and lubricate hub locks (4x4).
Change transfer case oil (4x4).
Change rear axle lube (F-Super Duty only). (7)
Change manual transmission oil.
Inspect parking brake fluid (F-Super Duty).
Check spring U-bolt torque (F-Super Duty).


(1)	City delivery vehicles and other unique applications that require constant turning may need more frequent tire rotation. Tire rotation interval may be based on the tire wear.
(2)	Wheel lug nuts must be retightened to proper torque specifications at 500 miles (800 km) of new vehicle operation 100 miles (160 km) and 500 miles (800 km) for vehicles equipped with dual rear wheels or equipped for snowplowing). Proper torque specifications are provided in this section. Also retighten to proper torque specification at 500 miles (800 km) after (1) any wheel change or (2) any other time the wheel lug nuts have been loosened.
(3)	On dual rear wheel vehicles, rotate the front tires side-to-side without disturbing the rear tires.
(4)	It is normal for a certain amount of moisture and staining to be present around the muffler seams. The presence of soot, light surface rust or moisture does not indicate a faulty muffler.
(5)	If the vehicle is operated "off road" in water that is deeper than the hubs (1/2 wheel height), then these items must be serviced daily.
(6)	Extremely dusty conditions will require more frequent replacement of your air filter. Check your air filter at 3,000 miles (5,000 km). If it is dirty, replace it and then keep replacing it at the same interval every 3,000 miles (5,000 km). If it is not dirty, check it again at 6,000 miles (10,000 km) and again at 9,000 miles (14,500 km) until the required maintenance interval is established. Do not go beyond 30,000 miles (48,000 km).
(7)	F-SUPER DUTY APPLICATIONS must change axle lube every 30,000 miles (48,000 km) unless synthetic oil is used. Super Duty vehicles are NOT equipped with synthetic oil from the factory. Synthetic oil MUST BE changed at 100,000 mile (160,000 km) intervals.
(8)	At 60,000 miles (96,000 km) dealer will replace the PCV valve at no cost except on Canada and California vehicles.

For F-Super Duty Rear Axles Only:

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

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

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