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Thread: Truck Specs and Stuff

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    ResFirma Mitescere Nescit
    Name: stew

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    Jun 2004
    Charleston, SC
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    Truck Specs and Stuff

    Torque Specifications
    Description lb-ft lb-in

    Valve cover bolts — 89in

    Camshaft bearing cap bolts — 89in
    Camshaft sprocket bolts
    Cylinder head temperature sensor (CHT) 19ft —
    Camshaft position sensor bolt — 89in
    Crankshaft position sensor bolt — 89in
    Connecting rod bolts
    Crankshaft damper pulley bolt
    Crankshaft main bearing bolts (cross-mounted)
    Crankshaft main bearing bolts (vertical)
    Cylinder heads bolts
    EGR valve to intake manifold bolts 15ft
    EGR to Exhaust Manifold Tube Nuts 44ft
    Exhaust manifold nuts 18ft —

    Exhaust manifold studs 9ft —
    Exhaust manifold-to-mid-pipe nuts 30ft —
    Exhaust clamps 35ft
    Exhaust Heat Shields 11ft
    Drive belt idler pulley bolt 18ft —
    Flywheel bolts 59ft —

    Transmission-to-engine bolts 35ft —
    Torque converter-to-flexplate nuts 26ft —
    Fuel Rail supply manifold bracket bolts — 89in
    Alternator upper mounting bracket bolts — 89in
    Alternator lower mounting bolts 18ft —
    Heater return tube studs 30ft —
    Ignition coil bolt— 53in
    Oil filter 12ft —
    Oil filter adapter bolts 18ft —
    Oil level indicator tube bolt — 89in
    Oil line connector adapter assembly bolt 18ft —
    Oil pan bolts 15ft

    Oil pan drain plug 10ft —
    Oil pressure switch 10ft —
    Oil pump bolts — 89in
    Oil pump screen and pickup tube bolts — 89in
    Oil pump screen and pickup tube spacer 18ft —
    Oil pump screen and pickup tube spacer bolt 18ft —
    Power steering pump bolts 18ft —
    Rear main oil seal retainer bolts — 89in
    Spark plugs 13ft —
    Thermostat housing bolts — 19ft
    Idle air control valve screws 89in
    Throttle body-to-Upper intake Plenum bolts 89in
    Front Timing Chain COver
    Stage 1: Tighten fasteners 1 through 5 to 25 Nm (18 lb-ft).
    Stage 2: Tighten fasteners 6 and 7 to 48 Nm (35 lb-ft).
    Stage 3: Tighten fasteners 8 through 15 to 48 Nm (35 lb-ft).

    Timing chain guide bolts — 89in
    Timing chain tensioner arm 18ft
    Timing chain hydraulic tensioner bolts 18 —
    Water pump bolts 18ft —
    Water pump pulley bolts 18ft —
    Power steering reservoir upper bracket-to-thermostat housing bolt 8ft —
    Power steering reservoir upper bracket-to-middle bracket bolts 13ft —
    Power steering reservoir middle bracket-to-lower bracket bolts 17 ft—
    Power steering reservoir lower bracket-to-engine cylinder head bolts 59ft —
    38-pin bulkhead connector bolt — 44in
    42-pin bulkhead connector bolt — 44in
    Bulkhead connector bracket cover bolts 9ft —
    Bulkhead connector bracket-to-cowl bolts 9ft —
    Starter relay nuts — 71in
    Accelerator control splash shield bolts — 62in
    Accelerator cable bracket bolts — 89in
    Motor mount to cylinder block bolts 44ft —
    Motor mount through bolts 66ft —
    Oil pressure switch 10ft —
    Fan shroud bolts — 80in
    Differential pressure feedback EGR sensor nuts (5.4L) — 89in
    Differential pressure feedback EGR sensor bracket nut (5.4L) — 89in
    Differential pressure feedback EGR sensor bracket bolt (5.4L) — 89in
    RFI Capacitors 89in
    Accessory Drive Idler Pullies18ft
    Accessory Drive Tensioner Arm 89in
    Starter 15ft
    Starter Electrical Connections 65in
    Accessory Belt Drive Routing

    Torque Specifications
    Description Nm lb-ft lb-in
    Supercharged Engines Only

    Power steering bracket lower bolts 30ft —
    Power steering bracket upper bolt — 89in
    Ground strap nut — 89in
    Fuel injection supply manifold bolts — 89in
    Ignition coil bolts — 44in
    Alternator bracket bolts — 89in
    Intake manifold bolts 19ft -

    Super CHarger SNout Bolts 13ft
    Inner Cooler to Midplate Bolts 53ft
    Super CHarger to Lower intake manifold bolts 33ft

    Inner COoler Fluid Supply tube bracket 89in
    Accelerator Cable Bracket 89in
    Crankshaft damper pulley bolt
    Auxiliary crankshaft pulley 74ft —
    Auxiliary crankshaft pulley brace nuts 35ft —
    Transmission cooler line bracket nut 11ft —
    Transmission Pan bolt 11ft
    FLex Plate Inspection Cover bolts 25ft
    Transmission Fluid Level Indicator Tube 88-115in
    Transmission SUpport Brace 66ft
    Super Charger Tensioner Arm 89in
    Power steering shield nut 11ft —
    Super charger pulley adapter bolts 35ft —
    Upper Plenum to Super CHarger bolts 89in
    Super CHarger Belt Routing

    Lower A Arm 121-148ft
    Upper A Arm 84-112
    Lower Ball Joint 83-112ft
    Upper Ball Joint 57-76ft
    Front Sway Bar ENd Link 15-21ft
    Front Sway Bar Frame Mount 19-26ft
    Upper Shock 35-46ft
    Lower shock 22-29ft
    Brake Line Keeper 13-17ft
    Bump Stops 15-21ft

    Rear Sway Bar End Link 76ft
    Rear Sway Bar Axle Mount 35ft
    Front Hanger Spring Eye 157-212ft
    Rear Spring t SHackle 73-97
    LEaf Pack to Axle Ubolts 73-97
    Rear SHackle to Rear Hanger 73-97ft
    Axle Bump Stops 15-21ft
    Upper SHock 35-46ft
    Lower SHock 35ft

    Center Carrier Bearing mount 46ft
    DS to Rear Axle Flange 83ft

    General Specifications
    Item Specification

    Silicone Gasket and Sealant F7AZ-19554-EA
    Metal Surface Cleaner
    Motorcraft Premium Engine Coolant VC-4-A (in Oregon VC-5,
    in Canada CXC-10). a
    ESE-M97B44-A (Green in color)
    Motorcraft Premium Gold Engine Coolant VC-7-A (in Oregon VC-7-B). a WSS-M97B51-A1 (Yellow in color)
    Super Premium SAE 5W-20 Motor Oil XO-5W20-QSP WSS-M2C153-H
    Petrolatum Jelly WSD-M1C226-A
    High Temperature Nickel Anti-Seize Lubricant
    Engine Oil Refill Capacity (Includes Filter Change) 5.7L (6.0 qts)

    General Specifications
    Item Specification
    Supercharged Engines Only

    Displacement 5.4L
    No. cylinder 8
    Bore/stroke 90.215/105.8 mm
    Fire order 1-3-7-2-6-5-4-8

    Cylinder Head/Valve Train

    Combustion chamber volume 43.95 ± 1.5 cc
    Valve seat width — intake 1.3-1.5 mm (0.0512-0.0590 inch)
    Valve seat width — exhaust 2.1-1.9 mm (0.0827-0.0748 inch)
    Valve seat angle 45.00-44.50 degrees
    Valve seat runout (T.I.R.) 0.025 mm (0.00098 inch)

    Valve Arrangement (Front to Rear)

    Valve stem guide clearance
    Intake 0.069-0.020 mm (0.00272-0.00079inch)
    Exhaust 0.095-0.045 mm (0.0037-0.0018inch)

    Valve head diameter
    Intake 44.63-44.37 mm (1.757-1.747 inch)
    Exhaust 34.12-33.88 mm (1.343-1.373 inch)
    Valve face runout (limit) 0.05 mm (0.00197 inch)
    Valve face angle 45.75-45.25 degrees

    Valve stem diameter
    Intake 6.995-6.975 mm (0.2754-0.2746inch)
    Exhaust 6.970-6.949 mm (0.2744-0.2736inch)

    Valve stem diameter (list oversizes)
    Intake N/A
    Exhaust N/A

    Valve spring compression pressure
    Intake (N @ spec.length)720-800 N @ 28.02 mm (1.1031inch)
    Exhaust (N @ spec.length)720-800 N @ 28.02 mm (1.1031inch)

    Valve spring free length
    Intake 53.37 mm (2.101 inch)
    Exhaust 53.37 mm (2.101 inch)

    Valve spring installed pressure N @ spec. length
    Intake 287.19-321.19 N @ 42.56 mm(1.676 inch)
    Exhaust 287.19-321.19 N @ 42.56 mm(1.676 inch)

    Valve springs installed pressure N @ spec. length — service limit
    Intake 5% pressure loss @ 28.80 mm(1.134 inch)
    Exhaust 5% pressure loss @ 28.80 mm(1.134 inch)

    Valve springs — out of square limit
    Intake 2.0 degrees
    Exhaust 2.0 degrees
    Valve guide inside diameter 7.044-7.015 mm (0.2773-0.2762inch)

    Hydraulic Lash Adjuster

    Diameter 16.000-15.988 mm (0.66-0.629 in)
    Clearance-to-bore 0.018-0.069 mm (0.00071-0.00272in)
    Service limit 0.016 mm (0.00063 in)
    Hydraulic leakdown rate a 5-25 seconds
    Collapsed lash adjuster gap — desired 0.085-0.45 mm (0.0033-0.0177 in)


    Lobe lift
    Exhaust 7.49744 mm (0.29517 inch)
    Intake 7.11038 mm (0.27994 inch)

    Lobe lift — allowable lift loss 0
    Valve lift @ zero lash
    Intake 13.01 mm (0.5122 inch)

    Exhaust 13.75 mm (0.5413 inch)
    Camshaft end play 0.027-0.190 mm (0.00106-0.00748inch)
    End play service limit 0.025-0.190 mm (0.00098-0.00748inch)
    Journal to bearing clearance 0.076-0.025 mm (0.002992-0.00098inch)

    Clearance service limit
    Journal diameters 26.962-26.936 mm (1.0615-1.0605inch)
    Journal inside diameter (cap assembled) 27.012-26.987 mm (1.0635-1.0625inch)
    Camshaft runout: full indicator measurement on all journals when supported on front and rear journals. (4 places)0.03 mm (0.0018 inch)

    Cylinder bore diameter
    Grade 1 90.200-90.210 mm (3.5512-3.5516inch)
    Grade 2 90.210-90.220 mm (3.5516-3.5518inch)
    Grade 3 90.220-90.230 mm (3.5518-3.5524inch)


    Piston diameter (Grade 2) at right angle to pin bore 90.180 ± 0.005
    Piston to bore clearance (-0.005) to +0.025 mm ([-0.0002] to+0.0010 inch)
    Pin bore diameter (piston) 22.008-22.014 mm (0.8664-0.8667inch)
    Pin diameter 22.0005-22.0030 mm (0.8662-0.8663 inch)
    Clearance 0.01395-0.005 mm (0.00055-0.00020 inch)
    Pin bore diameter (rod) 22.012-22.024 mm (0.8666-0.8670inch)
    Clearance 0.009-0.0235 mm (0.00035-0.00092inch)

    Ring groove width
    Top 1.53-1.55 mm (0.0602-0.0610 inch)
    Intermediate 1.52-1.54 mm (0.0598-0.0606 inch)
    Oil control 3.030-3.050 mm (0.1192-0.1201inch)
    Piston ring gap
    Top 0.13-0.28 mm (0.0051-0.110 inch)
    Intermediate 0.25-0.40 mm (0.0098-0.0157 inch)
    Oil control 0.15-0.65 mm (0.0059-0.0256 inch)


    Main bearing journal diameter 67.483-67.503 mm (2.657-2.658inch)
    Maximum out-of-round 0.0075 mm (0.00030 inch) between cross sections
    Maximum taper 0.004 mm (0.00016 inch)
    Runout: FIM of center journals when located on front and rear journal 0.05 mm (0.0020 inch) (3 places)
    Clearance — crankshaft journal to main bearing clearance 0.048-0.024 mm (0.0019-0.0009inch)
    Connecting rod journal diameter 53.003-52.983 mm (2.087-2.085inch)
    Maximum out-of-round 0.0075 mm (0.00030 inch) between cross sections
    Maximum taper 0.004 mm (0.00016 inch)
    Crankshaft end play 0.075-0.377 mm (0.0029-0.0148inch)

    Connecting Rod

    Big end journal inside diameter with assembled liners 53.049-53.027 mm (2.0885-2.0877inch)
    Rod bearing to journal clearance 0.064-0.026 mm (0.00252-0.00102inch)
    Pin bore diameter (rod) 22.024-22.012 mm (0.8671-0.8666inch)
    Rod length (centerline bore-to-bore) 169.1 mm (6.66 inch)

    Bore-to-bore Max. twist ± 0.05 mm (0.0020 inch)
    Bore-to-bore Max. bend ± 0.038 mm (0.0015 inch)

    Side play (as assembled to crank)
    Standard play 0.300 ± 0.175 mm (0.0118 ± 0.0069

    Maintenance and Service

    Refill Capacities

    Super Charger 6oz GM #12345982 supercharger oil

    Brake fluid Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid
    Fill to line on reservoir

    Engine coolant Motorcraft Premium Engine Coolant (green-colored) or Motorcraft Premium Gold Engine Coolant (yellow-colored)
    5.4L V8 engine with 1 row radiator 22.6L (23.9 quarts)
    5.4L V8 engine with 2 row radiator 24.1L (25.5 quarts)

    Intercooler coolant Motorcraft Premium Engine Coolant (green-colored) or Motorcraft Premium Gold Engine Coolant (yellow-colored)
    5.4L Supercharged V8 engine 4.0L (4.2 quarts)

    Engine oil (includes filter change)
    Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil
    All 5.4L (6.0 quarts)

    Fuel tank 4x2 Regular Cab, SuperCab and SuperCrew with short wheelbase
    94.6L (25.0 gallons)

    Power steering fluid
    Motorcraft MERCON III ATF
    Fill to line on reservoir

    Transmission fluid Motorcraft MERCON III ATF
    Automatic- 4R100 (4x2) 16.1L (17.0 quarts)
    Motorcraft MERCON V ATF
    Automatic- 4R70W 13.2L (13.9 quarts)

    Rear axle Motorcraft SAE 75W-140
    Synthetic Rear Axle Lubricant
    9.75 inch axle 2.6L (5.5 pints)
    Add 118 ml (4 oz.) of Additive Friction Modifier

    Windshield washer fluid Ultra-Clear Windshield Washer Concentrate
    All 4.0L (4.25 quarts)

    Engine Data

    Cubic inches 330
    Required fuel 91 octane
    Firing order 1-3-7-2-6-5-4-8
    Spark plug gap (0.042-0.046inch)
    Ignition system DIS Coil on plug
    Compression ratio 9.0:1

    Vehicle Dimensions

    (1) Overall length 5 738 (225.9in)
    (2) Overall width 2 009 (79.1in) including mirrors (90.3in
    (3) Overall height 1 878 (72.9in)
    (4) Wheel base 3 518 (138.5in)
    (5)Track front/rear 1 661 (65.4in)


    Transmission Identification
    On the Vehicle Cert Label (drivers side Door frame)

    Look for the Code below "TR"

    U= 4 speed automatic (AODE, W/4R70W)
    E= 4 speed automatice (4R100)
    7= 4 speed automatice (4R100), Lightning

    Rear axle 9.75 in limited-slip differential with 3.73:1 final drive ratio
    Driveshaft 2pc Steel with hardened yoke
    Transmission Modified 4R100 4-speed automatic with OD lockout
    Gear ratios
    1st 2.71
    2nd 1.53
    3rd 1.00
    4th (OD) 0.71
    Reverse 2.176

    CX = Factory color code for Dark Shadow Grey (see DSG)
    EK01 = Factory computer code for most '02 H-D's
    EK02 = Factory computer code for '03 H-D's and some late model '02 H-D's
    Last edited by bgstew6; 09-11-2007 at 04:40 PM.

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