1986 Ford F250 Shop Manual

The 1986 Ford F250 Shop Manual provides comprehensive service and repair information for the F250 truck series. This manual covers engine systems (including 4.9L, 5.0L, 5.8L, 6.9L diesel, and 7.5L engines), transmission (manual and automatic), drivetrain, suspension, steering, brakes, electrical systems, body, and accessories. Below are key sections for maintenance procedures, specifications, troubleshooting, and repair instructions.

1. Vehicle Identification 2. Maintenance Schedules 3. Engine Systems 4. Transmission & Drivetrain 5. Suspension & Steering 6. Brake Systems 7. Electrical Systems 8. Body & Interior 9. Specifications 10. Troubleshooting 11. Wiring Diagrams

Vehicle Identification

Locate VIN (Vehicle Identification Number) on driver's side dashboard visible through windshield. VIN decoding: 1st digit=Country (1=USA), 2nd=Manufacturer (F=Ford), 3rd=Vehicle Type (T=Truck), 4th-8th=Engine/Model, 9th=Check Digit, 10th=Year (G=1986), 11th=Assembly Plant.

Component	Location
VIN Plate	Driver's side dashboard
Certification Label	Driver's door jamb
Engine Code	8th digit of VIN
Transmission Code	Certification label
Axle Code	Certification label

Maintenance Schedules

Regular maintenance intervals for optimal performance and longevity.

Every 3,000 miles: Change engine oil and filter
Every 6,000 miles: Inspect brakes, check fluid levels
Every 12,000 miles: Replace air filter, inspect suspension
Every 30,000 miles: Replace fuel filter, inspect timing components
Every 60,000 miles: Replace spark plugs, check transmission fluid

WARNING! Use only recommended fluids and follow torque specifications.

Engine Systems

Service procedures for gasoline and diesel engines.

4.9L I6: Valve clearance: 0.014" cold, Oil capacity: 6 quarts with filter
5.0L/5.8L V8: Firing order 1-5-4-2-6-3-7-8, Spark plug gap: 0.044"
6.9L Diesel: Glow plug resistance: 0.6-2.0 ohms, Injection timing: 8.5° BTDC
7.5L V8: Fuel pressure: 35-45 psi, Compression: 140-160 psi

CAUTION! Disconnect battery before servicing electrical components.

Transmission & Drivetrain

Manual Transmission: Borg-Warner T18 4-speed, Fluid: 80W-90 GL-5, Capacity: 3.5 pints
Automatic Transmission: C6 3-speed, Fluid: Type F, Capacity: 12 quarts (dry)
Transfer Case: Borg-Warner 1345, Fluid: ATF Type F
Front Axle: Dana 44 TTB, Gear oil: 80W-90
Rear Axle: Ford 10.25", Gear oil: 80W-140

Suspension & Steering

Twin Traction Beam (TTB) front suspension with coil springs.

Front Suspension: Ball joint inspection: check for play, Wheel bearing adjustment: 17 ft-lbs preload then back off 90°. Steering: Power steering pump pressure: 1200-1500 psi, Gear box lash adjustment: 1/8 turn maximum.

Brake Systems

Hydraulic brake system with front disc/rear drum configuration.

Master Cylinder: Bore diameter: 1.125", Fluid: DOT 3
Front Disc: Rotor thickness: 1.245" minimum, Pad replacement
Rear Drum: Drum diameter: 12.060" maximum, Shoe adjustment
Parking Brake: Cable adjustment at equalizer

WARNING! Bleed brakes after any line disconnection.

Electrical Systems

12-volt negative ground system.

Component	Specification
Battery	Group 65, 650 CCA
Alternator	65 amp output
Starter	1.4 kW, solenoid mounted
Fuse Panel	Under dashboard
Ignition System	Duraspark II electronic

Body & Interior

Regular cab and SuperCab configurations with various trim levels.

Door Adjustment: Hinge bolt torque: 45 ft-lbs
Window Regulator: Cable replacement procedure
Seat Removal: 4 bolts at 35 ft-lbs
Dash Components: Radio, heater controls, instrument cluster

Specifications

Wheelbase: 133" Regular Cab, 155" SuperCab
GVWR: 6,600-8,800 lbs depending on configuration
Fuel Capacity: 19 gallons (standard), 38 gallons (optional)
Tire Size: LT235/85R16 standard
Oil Pressure: 40-60 psi at 2000 RPM
Curb Weight: 4,200-5,100 lbs

Troubleshooting

Symptom	Possible Cause	Corrective Action
Engine won't start	Fuel, spark, or compression	Check fuel pressure, spark plugs, compression test
Rough idle	Vacuum leak, dirty injectors	Inspect vacuum lines, clean fuel injectors
Transmission slipping	Low fluid, worn clutches	Check fluid level and condition, pressure test
Brake pull	Stuck caliper, contaminated pads	Inspect calipers, replace pads
Electrical issues	Ground connections, alternator	Check grounds, test alternator output

Wiring Diagrams

Complete electrical schematics for all systems including starting, charging, lighting, and accessories. Color-coded wiring with connector locations and pin assignments.

Note: Diagrams show wire colors, gauge, and routing. Use multimeter for circuit testing.

Service Support: Ford Motor Company Technical Service Bulletins apply.