The TheDieselStop.Com 1999-up FAQ

Thanks to Jeff Vincent who modified the already super Dodge Diesel Checklist for the Super Duty.

If you want to print it out, here is the "Printer Friendly" version.

Ford SuperDuty New Vehicle Inspection Checklist
Last update November 8, 1999

NOTE: To receive maximum benefit, the inspection should occur duringdaylight hours.
Take delivery of the new vehicle after it passes the following inspections:

Paperwork check: IMPORTANT - verify before you fall in love with the truck!!
OK?	INSPECT:
	Vehicle Identification - Check VIN on dashboard and door plate against title
	Option Verification - Check Sticker to verify all codes
	Owners manual, vehicle warranty, Ford contact pamphlet, tire warranty, diesel supplement, and trailer wiring kit (Optional) - should be in glovebox. These items can be very difficult to obtain after the dealership has your money.
	Check for Aux. Idle Control Kit
	Floor mats

Exterior Appearance Inspection: (walk around inspection of the exterior ) NOTE: While inspecting exterior, look for paint problems such as Bubbles in clear coat, Excessive orange peel, Industrial fallout on paint finish, Scratches, Dents, etc.
OK?	INSPECT:
Front End & Cab
Nose / Fender / Hood Area
	Bumpers (not even a hint of rust)
	Fender fit and finish
	Hood fit and finish
	Grille fit and finish
Cab Area
	Door fit and finish
	Door Jamb Area
	Hinges
	Locks
	Molding
	Rubber gaskets
	Outside decorative Trim
	Window operation
	Check for windshield cracks
	Mirrors
	Roof
	Check seams for separation
	Radio antenna
Bed & Rear End
Rear End
	Bumpers - watch for dents, rust, loose mounting bolts
	Tail gate - check latch function, cables
	Receiver - installed, bolts tight, trailer plug cover opens without interference
Bed
	Make sure the bed paint matches the cab paint, especially on the new colors
	Fender fit and finish
	Floor
	Front Wall
	Molding
Under body inspection
	Check for coffee cups and trash stuffed in chassis rails
	Check for proper amount of grease in grease fittings
	Check for loose steering box
	Shake intermediate steering shaft - feel for any loose parts/joints
	Check shocks for for looseness
	Check brake line routing (no kinks, no rubbing)
	Check routing of emergency brake cable

Jack, Lug Nut, and Tire Checks
OK?	INSPECT:
Wheels & Tires
	Check door plate against tire size for match
	Right Front Tire - proper size, tread pattern, inflation pressure
	Left Front Tire - proper size, tread pattern, inflation pressure
	Right Rear Tire - proper size, tread pattern, inflation pressure
	Left Rear Tire - proper size, tread pattern, inflation pressure
	Spare - installed, proper size and tread
Jack and wheel changing accessories
	Retrieve jack and tire tools - inspect for completeness
	Check jack function - it will be stiff, but should crank up and down
	Using the lug wrench, verify that all lugs are not crossthreaded and tight
	Check spare tire carrier - Check all functionality
	Return jack and accessories

Under hood Inspection
OK?	INSPECT:
	Check function of secondary hood latch
	Check for smooth hinge operation with no binding
	Check grill for loose fasteners
	Under hood light turns on with hood open, Light goes off before hood closes
	Identify all components
	Check brake fluid
	Check Power steering fluid
	Check PS tubing and hoses for rubbing
	Check Oil level
	Check washer fluid
	Check transmission fluid
	Check for coolant leak, heater hose
	Check Battery cables - tight?
	Check A/C hose routing for rubbing
	Test coolant additive level (FW-16)
Check Air Cleaner
	Installed?
	Check housing for obstructions (coffee cups, trash)
	Check filter seal - Smear vaseline on filter gasket, close cleaner, open again. check for 100% positive mating mark, vaseline should be displaced (plastic air cleaners housings can warp, allowing unfiltered air to pass)
	Check firewall noise deadening insulation. Compare against Excursion.
	Check on injector additive.

Take a break, go wash your hands

Interior Inspection - look inside for appearance problems
OK?	INSPECT:
Front Seats
	Appearance of upholstery and hardware
	6-way power seat test.
	Recline Function
	Front to rear adjustment
	Folding Function
	Center Console Raises and lowers smoothly
	Center Console Latch works.
Rear Seat
	Appearance of uphostery and hardware
	Function
	Fold
Carpet
	Check for window or door seal leaks.
	Check for stains and tears
General InteriorFit and Finish
	Dash & Steering wheel
	Shifter & Pedals
	Headliner & Door Panels
	Check for grill/vent on doors
	Sliding Rear Window Open/closing action
	Sliding Rear Window Latch Function

Operation Verification
OK?	INSPECT:
Set parking brake Put manual transmission in neutral, Automatic in Park Turn key to run position ( DO NOT START )
	Warning lights should illuminate and then go out (engine warning should stay lit )
	Oil pressure reads 0
	Water Temperature steady
	Voltmeter reads less than 12.5 Volts and steady - may be lower in a cold diesel while heater grids cycle
	Fuel Gauge steady
	Tachometer reads 0
	Warning Buzzer should sound if door is opened
	Warning Buzzer should sound if headlights are turned on
Start Engine
	Firm brake pedal (not mush, does not slowly sink to floor)
	Oil Pressure - normal and steady
	Water temperature - steady
	Voltmeter - should read 13.5 to 14.5 volts - may jump up and down on a cold diesel as heater grids cycle on and off
	Fuel Gauge - steady
	Tachometer - steady at a reasonable idle speed
	No Warning Lights or Buzzers
	Shift between forward and reverse gears listening for abnormal sounds and clunks
Test Lights
Turn on Lights and check bulbs
	Check Instrument Panel Light dimmer
	High beam
	Low Beam
	Tail Lights
	License plate lights
	Side marker lights
	Running lights
Turn lights off
	Brake lights
	flashers
	Turn signals
	Dome lights on when doors open
	Dome lights on when doors closed and switch on
	Check Map light switches
	Glove compartment light - on when door open
	Glove compartment light - Make certain that it shuts off when glove box door is closed
	Bed (cargo) light - Turn on and off with switch
	Temporarily Engage Transmission reverse gear and check backup lights
Radio & speaker test - Turn Radio on
	Tune an station AM
	balance speakers
	seek new station
	Tune an station FM
	balance speakers
	seek new station
	Play a tape
	Play a CD
Mirror Tests
	Vanity Mirror Left, Right
	Rearview Mirror - adjust, flip day/night
	Outside Mirror - Adjust Left, Right, Up Down, Check heating functionality
	Look for Mirror Vibration at idle
Steering Wheel
	Blow Horn (should require an easy push, not a great deal of force)
	Turn wheel to lock in both directions - should not bind
	Adjust tilt to fit
Overhead Console (if applicable)
	Check temperature - make sure all display segments light properly
	Check Compass - make sure all display segments light properly
	Check Map Lights - make sure all display segments light properly
Power options
	Lock and Unlock Doors
	Raise and lower windows
	Keyless entry functions.
Windshield Wipers
	Wash & Wipe
	Check All Speeds
Heat and Air Conditioner system
	Check for blower motor squeak
	cycle through all heat positions - vents should change as expected
	Check Fan on all speeds
	AC runs in Defrost positions
	Temperature knob turns smoothly - note: cold engine may not produce heat

Road Test - Ready for a drive?? Check Seat and Mirror Adjustments
OK?	INSPECT:
	Test reverse gear
	Parking Brake should hold in 1st gear
	Release parking brake and run through the gears - listen for noise
	Feel for scratchy synchronizers (manual)
	Torque Converter Lockup should stay locked, not hunting (auto)
	Firm shifts
	Listen for noises while running straight, turning, and when stopping
	Can you hear the turn signals?
	Listen for valve tappet noises
	Feel for a Steering wheel clunk over bumps or when stopping
	Push/pull top of steering wheel to check for play
	Check alignment - no pulling left or right
	Braking - no pulling left or right
	Cruise Control - check function of Set, Coast, Accelerate, Resume, Cancel
	Check mirrors for vibration at speed

If vehicle is still OK at this point, it can be accepted.
OK?	Complete:
	Finalize the paperwork and leave the dealer
	Fill up the fuel tank if the dealer did not do it.
	Drive the truck on expressway
	Test speedometer accuracy with stopwatch & mile markers
	Retest cruise control functions
	Listen for noises
	Feel for vibrations
	Watch for steering problems
	Note all the people staring at your sweet ride!

This inspection list was origianlly compiled by Tim Butterfield
starting with an inspection list written by Bob Brand.

Revision is constantly in progress.
For suggestions, additions, or corrections to this list, please e-mail submit@ford-diesel.com or shawn@ford-diesel.com