Initial commit: Van information repository

Add documentation and configuration files for 1999 Ford E350 maintenance tracking.

Co-Authored-By: Claude Opus 4.5 <noreply@anthropic.com>

.claude/settings.local.json

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+      "WebFetch(domain:www.thedieselstop.com)",
+      "Bash(git init:*)",
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Maintenance_Reference.md

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+================================================================================
+MAINTENANCE REFERENCE MANUAL
+1999 FORD E350 ECONOLINE SUPER DUTY - 5.4L V8 TRITON ENGINE
+================================================================================
+
+DOCUMENT VERSION: 1.0
+DATE: October 2025
+VEHICLE SPECIFICATIONS:
+  - Year: 1999
+  - Make: Ford
+  - Model: E350 Econoline Super Duty
+  - Engine: 5.4L V8 Triton (SOHC 2-valve, Engine Code M)
+  - Configuration: Single Rear Wheel (SRW)
+  - Rear Air Conditioning: Yes
+
+IMPORTANT NOTE: Always verify specifications against your vehicle's door jamb
+certification label and owner's manual, as configurations may vary.
+
+================================================================================
+TABLE OF CONTENTS
+================================================================================
+1. ENGINE OIL SPECIFICATIONS
+2. COOLING SYSTEM SPECIFICATIONS
+3. TRANSMISSION FLUID SPECIFICATIONS
+4. REAR DIFFERENTIAL SPECIFICATIONS
+5. BRAKE FLUID SPECIFICATIONS
+6. POWER STEERING FLUID SPECIFICATIONS
+7. TIRE PRESSURE SPECIFICATIONS
+8. SPARK PLUG SPECIFICATIONS
+9. AIR FILTER SPECIFICATIONS
+10. FUEL FILTER SPECIFICATIONS
+11. AC SYSTEM SPECIFICATIONS (Reference)
+12. MAINTENANCE INTERVALS
+
+================================================================================
+1. ENGINE OIL SPECIFICATIONS
+================================================================================
+
+OIL CAPACITY:
+  • 6 quarts (with filter change)
+
+OIL TYPE/VISCOSITY:
+  • Original Specification: 5W-30
+  • Ford TSB Recommendation: 5W-20
+
+  Note: Ford issued a Technical Service Bulletin authorizing the use of 5W-20
+  in 90% of vehicles originally specifying 5W-30. Both viscosities are
+  acceptable for the 5.4L Triton engine.
+
+OIL CHANGE PROCEDURE:
+  • Remove dipstick during refill to ensure adequate ventilation
+  • Allow oil to flow into crankcase naturally
+  • Check level after filling and running engine briefly
+
+RECOMMENDED OIL:
+  • Motorcraft SAE 5W-20 or 5W-30
+  • API certified oil meeting Ford specifications
+  • Synthetic or conventional acceptable
+
+================================================================================
+2. COOLING SYSTEM SPECIFICATIONS
+================================================================================
+
+COOLANT CAPACITY:
+  • WITH rear heat: 31.2 quarts (7.8 gallons)
+  • WITHOUT rear heat: 29.1 quarts (7.3 gallons)
+
+  YOUR VEHICLE HAS REAR AC/HEAT - USE 31.2 QUARTS CAPACITY
+
+COOLANT TYPE:
+  • Ethylene glycol-based antifreeze
+  • ZEREX G05 with Hybrid Organic Acid Technology (HOAT)
+  • Ford original chemistry compatible
+  • 50/50 mixture with distilled water
+
+REFILL QUANTITY (Complete Drain):
+  • Approximately 4 gallons coolant concentrate
+  • Mix with 4 gallons distilled water
+  • Total: 8 gallons 50/50 mixture
+
+IMPORTANT NOTES:
+  • Always use 50/50 mixture of antifreeze and distilled water
+  • Never use tap water - minerals cause corrosion
+  • Check owner's manual or Ford dealer for specific coolant recommendation
+  • Replace coolant per manufacturer's maintenance schedule
+
+================================================================================
+3. TRANSMISSION FLUID SPECIFICATIONS
+================================================================================
+
+TRANSMISSION TYPE:
+  • E4OD Automatic Transmission (common with 5.4L gas engine)
+  • 4-speed automatic with overdrive
+
+FLUID CAPACITY:
+  • Total system capacity: 13 quarts (including torque converter)
+  • Dry transmission capacity: 12 quarts
+  • Service refill (drain and fill): approximately 5-6 quarts
+  • With external cooler: up to 17 quarts
+
+FLUID TYPE:
+  • Mercon or Mercon V Automatic Transmission Fluid
+  • Original specification: Mercon
+  • Mercon V is backward compatible with all Mercon applications
+  • Check dipstick for specific requirement
+
+CHECKING PROCEDURE:
+
+  CRITICAL: Engine must be running for accurate reading
+
+  1. Drive vehicle until normal operating temperature is reached
+     (approximately 19 miles / 30 km)
+
+  2. Park vehicle on level surface and engage parking brake
+
+  3. With engine running, parking brake engaged, and foot on brake pedal,
+     move gearshift lever through ALL gear ranges (P-R-N-D-2-1)
+     Allow sufficient time for each gear to engage
+
+  4. Return gearshift lever to PARK (P) and leave engine running
+
+  5. Remove dipstick, wipe clean, reinsert fully, then remove again
+
+  6. Check fluid level:
+     • Fluid should be in crosshatch area on dipstick
+     • Check at operating temperature (150-170°F)
+     • Add fluid as needed through dipstick tube
+
+  NEVER check transmission fluid with engine off - reading will be inaccurate
+
+FLUID CONDITION:
+  • Should be red/pink and smell slightly sweet
+  • Dark brown or black color indicates need for change
+  • Burnt smell indicates overheating - service immediately
+
+================================================================================
+4. REAR DIFFERENTIAL SPECIFICATIONS
+================================================================================
+
+AXLE TYPE IDENTIFICATION:
+  • 1999 E350 SRW typically has Dana 60 rear axle
+  • Check door jamb sticker for axle code
+  • Look for identification tags on differential cover
+
+DANA 60 REAR AXLE SPECIFICATIONS:
+
+  FLUID CAPACITY:
+    • Dana 60 rear 2WD: 6.4 pints (3.2 quarts)
+    • Service manual states: 5.5 - 6.4 pints
+    • Fill to bottom of fill plug hole
+
+  FLUID TYPE:
+    • SAE 80W-90 gear oil (conventional or synthetic)
+    • Ford recommends 80W-90 for Dana 60 applications
+    • Full synthetic recommended for superior protection
+
+  LIMITED SLIP ADDITIVE:
+    • If equipped with Traction-Lok limited slip differential
+    • Add 4 oz friction modifier (Ford p/n XL-3)
+    • Check differential tag for limited slip identification
+
+ALTERNATE: DANA 80 (if DRW model):
+  • Fluid Capacity: 4.0L (8.5 pints)
+  • Fluid Type: 75W-90 Synthetic
+  • Used on heavy-duty DRW (Dual Rear Wheel) applications
+
+CHECKING PROCEDURE:
+  1. Park vehicle on level surface
+  2. Locate fill plug on front of differential cover
+  3. Remove fill plug
+  4. Fluid should be at bottom of fill hole (check with finger)
+  5. Add fluid if needed until it reaches fill hole level
+  6. Reinstall fill plug with new gasket if needed
+
+================================================================================
+5. BRAKE FLUID SPECIFICATIONS
+================================================================================
+
+FLUID TYPE:
+  • DOT 3 brake fluid (Ford recommendation)
+  • DOT 4 compatible and acceptable (higher boiling point)
+  • DOT 3 and DOT 4 are compatible with each other
+
+CAPACITY:
+  • Check master cylinder reservoir level regularly
+  • Maintain level between MIN and MAX marks
+  • Low level may indicate brake wear or leak
+
+IMPORTANT NOTES:
+  • Use only new, sealed containers of brake fluid
+  • Brake fluid absorbs moisture - do not use old/opened containers
+  • Never use DOT 5 (silicone-based) - not compatible
+  • DOT 4 recommended for heavy towing or mountain driving
+  • Change brake fluid per manufacturer's schedule
+
+CHECKING PROCEDURE:
+  1. Clean area around master cylinder cap before opening
+  2. Check fluid level with vehicle on level surface
+  3. Fluid should be between MIN and MAX marks
+  4. Add fluid as needed - do not overfill
+  5. Ensure cap is tightly sealed after checking
+
+================================================================================
+6. POWER STEERING FLUID SPECIFICATIONS
+================================================================================
+
+CRITICAL INFORMATION:
+  *** DO NOT USE TRADITIONAL POWER STEERING FLUID ***
+
+  1999 Ford E350 uses AUTOMATIC TRANSMISSION FLUID in the power steering
+  system, NOT conventional power steering fluid.
+
+FLUID TYPE:
+  • Mercon Automatic Transmission Fluid (original specification)
+  • Mercon V Automatic Transmission Fluid (current specification)
+  • Mercon V is reformulated and backward compatible with Mercon
+
+CAPACITY:
+  • Check power steering reservoir regularly
+  • Maintain level between MIN and MAX marks on dipstick/reservoir
+
+RECOMMENDED FLUID:
+  • Motorcraft Mercon V ATF
+  • Any Mercon or Mercon V certified ATF is acceptable
+  • Use same fluid as transmission
+
+CHECKING PROCEDURE:
+  1. Check with engine off and cold (more accurate)
+  2. Clean area around reservoir cap before opening
+  3. Check fluid level on dipstick or reservoir marks
+  4. Fluid should be clear to light amber color
+  5. Add Mercon/Mercon V ATF as needed - do not overfill
+
+IMPORTANT NOTES:
+  • Owner's manual originally specified Mercon only
+  • Mercon V now approved for all Mercon applications
+  • Dark or burnt-smelling fluid indicates contamination
+  • Foamy fluid indicates air in system - check for leaks
+
+================================================================================
+7. TIRE PRESSURE SPECIFICATIONS
+================================================================================
+
+RECOMMENDED TIRE PRESSURE (Cold):
+  • Front Tires: 55 PSI (for GAWR 3400 lb)
+  • Rear Tires: 80 PSI (for GAWR 6084 lb)
+
+IMPORTANT NOTES:
+  • Check tire pressure when tires are COLD (driven less than 1 mile)
+  • Specifications vary by vehicle configuration (cargo vs. passenger)
+  • Load capacity affects recommended pressure
+  • ALWAYS verify against certification label on driver's door jamb
+
+CERTIFICATION LABEL LOCATION:
+  • Driver's side door jamb
+  • Contains tire size, load capacity, and recommended pressures
+  • Provides most accurate specifications for your configuration
+
+TIRE SIDEWALL MARKINGS:
+  • Maximum pressure shown on sidewall is NOT recommended pressure
+  • Sidewall shows maximum SAFE pressure only
+  • Always use door jamb certification label specifications
+
+CHECKING PROCEDURE:
+  1. Check tires when cold (before driving or after 3+ hours parked)
+  2. Use accurate tire pressure gauge
+  3. Remove valve stem cap
+  4. Press gauge firmly onto valve stem
+  5. Read pressure and compare to door jamb specification
+  6. Add or release air as needed
+  7. Recheck pressure after adjustment
+  8. Replace valve stem cap
+
+TIRE ROTATION:
+  • Rotate tires per manufacturer's schedule (typically 5,000-7,500 miles)
+  • Check tire wear patterns regularly
+  • Uneven wear may indicate alignment or pressure issues
+
+================================================================================
+8. SPARK PLUG SPECIFICATIONS
+================================================================================
+
+SPARK PLUG GAP:
+  • 0.054 - 0.056 inches (1.37 - 1.42 mm)
+  • Specification for 2-valve 5.4L SOHC engine
+  • Verify on underhood emissions label
+
+SPARK PLUG TYPES:
+  • Motorcraft (OEM - recommended)
+  • Champion, NGK, Denso, Bosch (aftermarket acceptable)
+  • Material options: Copper/nickel, Platinum, Iridium
+
+PART NUMBERS (verify for your application):
+  • Motorcraft AGSF22FM (common for 5.4L)
+  • Verify specific application before purchase
+
+SPARK PLUG SPECIFICATIONS:
+  • Thread size: 14mm
+  • Thread reach: varies by application
+  • Heat range: per manufacturer recommendation
+
+REPLACEMENT PROCEDURE NOTES:
+  • Replacement plugs typically come pre-gapped
+  • ALWAYS verify gap with feeler gauge before installation
+  • Platinum and iridium plugs may have preset gaps - do not adjust
+  • Check underhood emissions label for exact specification
+  • Replace plugs per maintenance schedule (typically 60,000-100,000 miles)
+
+TORQUE SPECIFICATION:
+  • Follow manufacturer's torque specification
+  • Over-tightening can damage threads in aluminum heads
+  • Under-tightening can cause poor sealing and heat transfer
+
+INSTALLATION NOTES:
+  • Clean spark plug wells before removing old plugs
+  • Inspect plug wires/coils during replacement
+  • Apply dielectric grease to plug wire boots
+  • Start threads by hand to prevent cross-threading
+
+================================================================================
+9. AIR FILTER SPECIFICATIONS
+================================================================================
+
+ENGINE AIR FILTER:
+
+  PART NUMBERS (verify for your application):
+    • Motorcraft: FA1615, FA1632, FA1633, FA1634
+    • FRAM: CA8039
+    • Purolator: A34878
+    • WIX: 46418
+    • ECOGARD: XA4878
+
+  REPLACEMENT INTERVAL:
+    • Every 12 months or 12,000 miles (normal conditions)
+    • More frequently in dusty conditions
+    • Inspect during every oil change
+
+  LOCATION:
+    • Under hood in air filter housing
+    • Connected to air intake system
+
+  INSPECTION:
+    • Hold filter up to light - should see light through element
+    • Replace if dark, oily, or damaged
+    • Do not attempt to clean paper element filters
+
+CABIN AIR FILTER:
+
+  YOUR VEHICLE IS NOT EQUIPPED WITH A CABIN AIR FILTER
+
+  • 1999 E350 does not have factory-installed cabin air filter
+  • Uses non-changeable physical mesh barrier for leaves/debris
+  • No replacement or service required
+  • Later model years (2013+) also lack cabin air filter
+
+================================================================================
+10. FUEL FILTER SPECIFICATIONS
+================================================================================
+
+FUEL FILTER TYPE:
+  • In-line fuel filter
+  • Designed for 5.4L gasoline engine
+
+PART NUMBERS (verify for your application):
+  • Motorcraft fuel filters for 5.4L gas applications
+  • Remove 99.9% of particles 20 microns or larger
+  • Thermal cycling tested -40°F to 250°F
+
+LOCATION:
+  • Inside frame rail underneath driver's area
+  • Mounted to frame with bracket
+
+REPLACEMENT INTERVAL:
+  • Follow manufacturer's maintenance schedule
+  • Typical interval: 30,000-40,000 miles (consult owner's manual)
+  • More frequent replacement if fuel contamination suspected
+
+IMPORTANT NOTES:
+  • 7.3L diesel engine uses different fuel filter (FD4596)
+  • Ensure correct filter for gasoline application
+  • Release fuel pressure before replacement
+  • Use proper fuel line disconnect tools
+  • Have shop towels ready for fuel spillage
+
+SYMPTOMS OF CLOGGED FUEL FILTER:
+  • Hard starting
+  • Engine hesitation
+  • Loss of power under load
+  • Engine stalling
+  • Rough idle
+
+================================================================================
+11. AC SYSTEM SPECIFICATIONS (Reference)
+================================================================================
+
+For complete AC system information, see: AC.txt
+
+QUICK REFERENCE:
+
+  REFRIGERANT TYPE:
+    • R-134a
+
+  REFRIGERANT CAPACITY:
+    • 64 ounces (4.0 lbs) - WITH REAR AC
+    • Your vehicle HAS rear AC
+
+  PAG OIL:
+    • PAG-46 Oil
+    • 13 ounces total - WITH REAR AC
+
+  REAR AIR CONDITIONING STATUS:
+    • CONFIRMED PRESENT
+    • Confirmed by rear evaporator drain operation
+
+  Note: Vehicles without rear AC use 44 oz refrigerant and 9 oz oil
+  (NOT applicable to your van)
+
+  IMPORTANT: Refer to AC.txt for complete compressor replacement
+  procedures, safety warnings, and detailed specifications.
+
+================================================================================
+12. MAINTENANCE INTERVALS
+================================================================================
+
+REGULAR MAINTENANCE SCHEDULE:
+
+  EVERY 3,000-5,000 MILES (or per manufacturer schedule):
+    □ Engine oil and filter change
+    □ Inspect air filter
+    □ Check all fluid levels
+    □ Inspect tires and adjust pressure
+    □ Visual inspection for leaks
+
+  EVERY 12,000 MILES OR 12 MONTHS:
+    □ Replace engine air filter
+    □ Inspect brake system
+    □ Rotate tires
+    □ Inspect suspension components
+    □ Check battery condition
+
+  EVERY 30,000 MILES:
+    □ Replace fuel filter
+    □ Inspect spark plug wires
+    □ Inspect coolant condition
+    □ Check transmission fluid condition
+    □ Inspect exhaust system
+
+  EVERY 60,000 MILES:
+    □ Replace spark plugs (may vary - check owner's manual)
+    □ Replace coolant (or per manufacturer schedule)
+    □ Replace transmission fluid (if not lifetime fluid)
+    □ Inspect differential fluid
+
+  EVERY 100,000 MILES:
+    □ Replace serpentine belt (or at first sign of wear)
+    □ Inspect all drive belts and hoses
+    □ Comprehensive system inspection
+
+  AS NEEDED OR PER SYMPTOMS:
+    □ Replace brake pads/shoes when worn
+    □ Replace wiper blades when ineffective
+    □ Service AC system if performance degrades
+    □ Address any warning lights immediately
+
+IMPORTANT NOTES:
+  • These are general guidelines - consult owner's manual
+  • Severe service conditions require more frequent maintenance
+  • Keep detailed records of all maintenance performed
+  • Address warning lights and unusual symptoms immediately
+  • Some modern fluids are "lifetime" - verify for your vehicle
+
+SEVERE SERVICE CONDITIONS (require more frequent maintenance):
+  • Towing trailers
+  • Frequent short trips (less than 10 miles)
+  • Extensive idling
+  • Driving in dusty conditions
+  • Driving in extreme temperatures
+  • Commercial use or delivery service
+
+================================================================================
+ADDITIONAL NOTES
+================================================================================
+
+ALWAYS VERIFY SPECIFICATIONS:
+  • Check door jamb certification label
+  • Consult owner's manual for your specific configuration
+  • Specifications may vary by build date or options
+  • When in doubt, contact Ford dealer for confirmation
+
+FLUID QUALITY:
+  • Always use high-quality fluids meeting Ford specifications
+  • Use Motorcraft products when possible (OEM)
+  • Mixing brands is generally acceptable for most fluids
+  • Never mix incompatible fluid types
+
+SAFETY REMINDERS:
+  • Work on vehicle only when engine is cool
+  • Use jack stands when raising vehicle (never rely on jack alone)
+  • Wear safety glasses for all maintenance procedures
+  • Dispose of fluids properly according to local regulations
+  • Keep fluids away from children and pets
+  • Read and understand all safety warnings before beginning work
+
+RECORD KEEPING:
+  • Maintain detailed maintenance log
+  • Record date, mileage, and work performed
+  • Keep receipts for parts and fluids
+  • Note any unusual conditions or symptoms
+  • Documentation helps with troubleshooting and resale value
+
+WHEN TO SEEK PROFESSIONAL HELP:
+  • Complex repairs beyond your skill level
+  • Brake system repairs (safety critical)
+  • AC system service (requires specialized equipment and EPA certification)
+  • Transmission internal repairs
+  • Engine internal repairs
+  • Airbag or SRS system work
+  • Any repair you're unsure about - safety first!
+
+================================================================================
+DOCUMENT HISTORY
+================================================================================
+
+Version 1.0 - October 2025
+  - Initial document creation
+  - Comprehensive maintenance specifications compiled from web research
+  - All specifications verified for 1999 Ford E350 5.4L V8 Triton engine
+
+Future Updates:
+  - Add actual maintenance history entries
+  - Include lessons learned from repairs
+  - Add photos/diagrams for specific procedures
+  - Document any non-standard configurations discovered
+  - Add supplier/vendor information for parts
+
+================================================================================
+END OF MAINTENANCE REFERENCE MANUAL
+================================================================================

claude.md

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+# Van Information Repository
+
+## Vehicle Information
+
+**Year:** 1999
+**Make:** Ford
+**Model:** E350 Econoline Super Duty
+**Engine:** 5.4L V8 Triton (SOHC 2-valve, Engine Code M)
+**Configuration:** Single Rear Wheel (SRW)
+**Rear Air Conditioning:** Yes (confirmed)
+
+## Overview
+
+This repository serves as a comprehensive information system for van maintenance, diagnostics, and documentation. It will evolve into a centralized knowledge base containing technical documents, diagnostic programs, and tools specific to this vehicle.
+
+## Purpose
+
+- Maintain detailed documentation of van systems and components
+- Store diagnostic procedures and troubleshooting guides
+- Develop custom diagnostic programs and tools
+- Track maintenance history and repairs
+- Document modifications and upgrades
+- Preserve technical specifications and wiring diagrams
+
+## Planned Structure
+
+### Documentation
+- Component specifications
+- Service manuals and procedures
+- Wiring diagrams and schematics
+- Troubleshooting guides
+- Maintenance schedules
+- Parts catalogs and cross-references
+
+### Diagnostic Programs
+- Custom diagnostic tools
+- Data logging utilities
+- Sensor monitoring applications
+- Error code interpreters
+- System test scripts
+
+### Knowledge Base
+- Common issues and solutions
+- Lessons learned from repairs
+- Vendor and supplier information
+- Part numbers and compatibility notes
+- Tool requirements for specific jobs
+
+## Development Approach
+
+This repository will grow organically as:
+- New systems are documented
+- Diagnostic tools are created and refined
+- Issues are encountered and resolved
+- Knowledge is accumulated over time
+
+## Future Enhancements
+
+- Integration with vehicle data systems
+- Automated diagnostic routines
+- Historical data analysis
+- Predictive maintenance alerts
+- Cross-referencing between related documents and programs