Page 1: Table Of Contents
Table of contents Introduction Congratulations Safety and environment protection Symbol glossary Vehicle inspection guide Instrumentation Warning and control lights Gauges Entertainment systems AM/FM stereo AM/FM stereo cassette AM/FM stereo cassette with CD AM/FM stereo with CD Climate controls Heater only Manual heating and air conditioning Lights Headlamps...
Page 2 Table of contents Locks and security Keys Locks Seating and safety restraints Seating Safety restraints Child restraints Driving Starting Brakes Air suspension Transmission operation Vehicle loading Roadside emergencies Hazard flasher switch Fuses and relays Jump starting Wrecker towing Customer assistance Getting assistance outside the U.S.
Page 4: Introduction
Introduction CALIFORNIA Proposition 65 Warning WARNING: Engine exhaust, some of its constituents, and certain vehicle components contain or emit chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. In addition, certain fluids contained in vehicles and certain products of component wear contain or emit chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.
Page 5 Introduction Protecting the environment We must all play our part in protecting the environment. Correct vehicle usage and the authorized disposal of waste cleaning and lubrication materials are significant steps towards this aim. Information in this respect is highlighted in this guide with the tree symbol.
Page 6 Introduction These are some of the symbols you may see on your vehicle. Safety Alert See Owner’s Guide Fasten Safety Belt Air Bag-Front Air Bag-Side Child Seat Child Seat Installation Child Seat Lower Warning Anchor Child Seat Tether Brake System Anchor Brake Fluid - Anti-Lock Brake System...
Page 7 Introduction Interior Luggage Child Safety Door Compartment Release Lock/Unlock Symbol Panic Alarm Engine Oil Engine Coolant Engine Coolant Temperature Do Not Open When Hot Battery Avoid Smoking, Flames, Battery Acid or Sparks Explosive Gas Fan Warning Maintain Correct Fluid Power Steering Fluid Level Emission System Engine Air Filter...
Page 8: Symbol Glossary
Introduction FEDERAL HIGHWAY ADMINISTRATION REGULATION Regulations such as those issued by the Federal Highway Administration or issued pursuant to the Occupational Safety and Health Act (OSHA), and/or state and local laws and regulations may require additional equipment for the way you intend to use the vehicle. It is the responsibility of the registered owner to determine the applicability of such laws and regulations to your intended use for the vehicle, and to arrange for the installation of required equipment.
Page 9: Vehicle Inspection Guide
Vehicle inspection guide To be sure your vehicle is ready to operate, conduct a pre-trip inspection at the beginning of each work period. Follow the steps listed in this section to assure a proper vehicle inspection procedure. The pages in this section may be produced locally and used on a regular basis.
Page 10 Vehicle inspection guide Engine compartment (with engine stopped) Any leaks: Check for signs of fluid puddles, dripping fluid on the ground under the engine or the underside of the engine. HVAC air inlet: Check for debris, leaves, etc. that may have collected on the HVAC air inlet grille or inside the exterior module as this may cause reduced system performance.
Page 11 Vehicle inspection guide Engine starting (with parking brake applied) Air chime sounds (if The low air pressure warning chime should equipped with air sound immediately after the engine starts but compressor): before the compressor has built up some pressure. The low air pressure warning chime should stop when the air pressure reaches 483 kPa (70 psi) (or more).
Page 12 Vehicle inspection guide Engine starting (with parking brake applied) Air brake check: Check the air brakes in the following manner (Chock the wheels, if necessary. Push in the parking brake and on tractors, also push in the tractor protection valve knob): 1.
Page 13 Vehicle inspection guide Front of vehicle Lights: Make sure all lights illuminate and are clean. Make sure headlights function on both high and low beams. Make sure reflectors are clean and unbroken and of proper color (red on rear, amber elsewhere). Make sure the running lights are also clean and unbroken.
Page 14 Vehicle inspection guide Front brakes Hoses: Checked for cracked, worn or frayed hoses. Make sure all couplings are secured. Make sure brake chambers are not cracked or Chambers: dented and that they are securely mounted. Slack adjuster: Check for broken, loose or missing parts; the angle between the push rod and adjuster arm should be approximately 90 degrees when the brakes are applied.
Page 15 Vehicle inspection guide Driver/Fuel area Fuel tank: Make sure the fuel tank and caps are secure. Make sure there is no damage to the tank. Leaks: Check for any leaks from the fuel tanks. Underbody of vehicle (rear of tractor) Driveshaft: Make sure that the driveshaft is not bent or cracked.
Page 16 Vehicle inspection guide Truck/Tractor Air/Electric lines: Make sure that air hoses are not cut, cracked, chafed or worn (steel braid should not show through). Listen for audible air leaks, Make sure air and electrical lines are not tangled, crimped or pinched or being dragged against any truck/tractor parts.
Page 17 Vehicle inspection guide Rear springs Springs: Check for broken or shifted leaves or leaves that are in contact, or nearly contacting a tire, rim, brake drum, frame or body components. Check for missing or broken leaves in the leaf spring. Spring mounts: Check for cracked or broken spring hangers, broken, missing or loose bolts, missing or...
Page 18 Vehicle inspection guide Rear wheels Spacers: Make sure dual wheels are evenly separated and that tires are not touching one another. Rims: Check for damaged or bent rims. Rims should not have welding repairs and no rust trails that indicate it is loose on the wheel. Lug nuts: Make sure all lug nuts are present and not loose (look for rust trails around the lug nuts).
Page 19 Vehicle inspection guide TRANSMISSION If your vehicle is equipped with an automatic transmission, have a qualified technician regularly check the transmission’s neutral start switch. If the unit starts in gear and/or the neutral start switch is defective, the vehicle may inadvertently move which could result in property damage, personal injury or death.
Page 20: Instrumentation
Instrumentation WARNING LIGHTS AND CHIMES Warning lights and gauges can alert you to a vehicle condition that may become serious enough to cause expensive repairs. A warning light may illuminate when a problem exists with one of your vehicle’s functions. Many lights will illuminate when you start your vehicle to make sure the bulb works.
Page 21 Instrumentation Brake reserve system warning BRAKE (if equipped): Illuminates to indicate normal Hydromax booster reserve system activation when the engine is OFF and the service brake pedal is applied. This light may also illuminate momentarily if the engine is running and the driver turns the steering wheel fully in one direction while braking.
Page 22 Instrumentation Trailer ABS brake system (if equipped): Illuminates briefly when the engine is powered-up and only when a PLC trailer or a PLC diagnostic tool is connected. If the light remains on after the vehicle is started, continues to flash or fails to illuminate, have the system serviced immediately.
Page 23 Instrumentation Charging system: Illuminates when the battery is not charging properly. Wait to start: Indicates the air WAIT intake heater is in operation and special starting procedures are START required. Refer to the Driving chapter. If equipped with an air intake heater, DO NOT use ether or any other starting fluids.
Page 24: Gauges
Instrumentation Traction control (if equipped): Illuminates when the traction control system is turned off. Differential lock (if equipped): Illuminates when the main differential is locked (engaged). Turn signal: Illuminates when the left or right turn signal or the hazard lights are turned on. If the indicators stay on or flash faster, check for a burned out bulb.
Page 25 Instrumentation Speedometer: Indicates the current vehicle speed. Engine coolant temperature gauge: Indicates engine coolant temperature. At normal operating temperature, the needle will be in the normal range (between “H” and “C”). If it enters the red section, the engine is overheating. Stop the vehicle as soon as safely possible, switch off the engine and let the engine cool.
Page 26 Instrumentation Tachometer: Indicates the engine speed in revolutions per minute. Driving with your tachometer DIESEL FUEL ONLY pointer continuously at the top of the scale may damage the engine. 1000 Battery voltage gauge: Indicates the battery voltage when the ignition is in the ON position. If the pointer moves and stays outside the normal operating range (as indicated by arrows), have the...
Page 27 Instrumentation Fuel gauge: Indicates approximately how much fuel is left in the fuel tank (when the ignition is in the on position). If your vehicle is equipped with dual fuel tanks, the engine will draw fuel from the passenger-side fuel tank only. With dual fuel tanks, the vehicle will be equipped with a fuel transfer pump system that will draw fuel from the driver-side fuel tank and send fuel to the passenger-side fuel tank.
Page 28: Entertainment Systems
Entertainment systems AM/FM STEREO (IF EQUIPPED) PUSH SEEK TONE TONE VOL TUNE AM/FM 1. Seek: Press to find the next strong station down/up the frequency band. 2. Tune: Press to manually change radio frequency down/up. 3. AM/FM: Press to choose a AM/FM frequency band in radio mode.
Page 29 Entertainment systems 5. Power/volume: Press to turn ON/OFF; turn to increase or decrease volume levels. 6. Tone: Press TONE until the PUSH desired level — Bass, Treble, Fade TONE appears on the display. Turn the volume control to raise/lower the levels, or to move the audio sound from the right to left or the front to back (if equipped).
Page 30: Am/Fm Stereo Cassette
Entertainment systems AM/FM STEREO CASSETTE (IF EQUIPPED) 14 15 16 17 VOL - PUSH ON BASS TREB FADE TAPE SEEK SIDE 1 - 2 SCAN TUNE 1. Balance: Press to shift sound to the left/right speakers. 2. Fade: Press to shift sound to the rear/front speakers.
Page 31 Entertainment systems 4. Tape AMS: In tape mode, press TAPE and hold to activate Automatic Music Search (allows you to quickly locate the beginning of the tape selection being played or to skip to the next selection). Then, press REW (for the beginning of the current selection) or FF (to advance to the next selection).
Page 32 Entertainment systems 12. Power/volume: Press to turn ON/OFF; turn to increase or decrease volume levels. 13. AM/FM: Press to choose a frequency band in radio mode. 14. Bass: Press decrease/increase the bass output. 15. Treble: Press decrease/increase the treble output. 16.
Page 33: Am/Fm Stereo Cassette With Cd
Entertainment systems PREMIUM AM/FM STEREO/CASSETTE/SINGLE CD (IF EQUIPPED) 1. Power/volume: Press to turn ON/OFF; turn to increase/decrease volume. 2. Scan: Press to hear a brief SCAN sampling of all listenable stations, tape selections or CD tracks. Press again to stop. 3.
Page 34 Entertainment systems 4. Cassette door: Insert the cassette with the opening to the right. 5. Eject: Press to eject the cassette/CD. The radio will resume playing. 6. Tape: Press to start tape play. Press to stop tape during rewind/fast forward. CD: Press to start CD play.
Page 35 Entertainment systems 10. Balance: Press BAL; then press to shift sound to the left/right speakers. Fade: Press FADE; then press to shift sound to the rear/front speakers. 11. Memory preset buttons: To set a station: Select frequency band AM/FM, tune to a station, press and hold a preset button until sound returns.
Page 36 Entertainment systems 18. Select (SEL): Use with Bass, Treble, Balance and Fade controls. 19. Bass: Press BASS; then press to decrease/increase the bass output. Treble: Press TREB; then press to decrease/increase the treble output. 20. Tune: Works in radio mode only. SEEK Press TUNE to change...
Page 37: Am/Fm Stereo With Cd
Entertainment systems PREMIUM IN-DASH SIX CD SOUND SYSTEM (IF EQUIPPED) DISC SHUF SCAN SEEK COMP TUNE MUTE LOAD BASS TREB FADE PUSH ON MENU 12 11 1. Seek: Press and release SEEK for previous/next strong station, selection or track. 2. Rewind: In CD mode, press until desired selection is reached.
Page 38 Entertainment systems 6. Bass: Press BASS; then press to decrease/increase the bass output. Treble: Press TREB; then press to decrease/increase the treble output. 7. Select: Use with Bass, Treble, Balance and Fade controls to adjust levels. 8. Balance: Press BAL; then press to shift sound to the left/right speakers.
Page 39 Entertainment systems 10. Memory presets: To set a station: Select frequency band AM/FM; tune to a station, press and hold a preset button until sound returns. 11. CD: Press to select CD mode. 12. AM/FM: Press to select AM/FM frequency band. Autostore: Allows you to set the strongest local radio stations without losing your original manually set preset stations for AM/FM1/FM2 .
Page 40 Entertainment systems 17. Disc tune: Radio: Press to manually tune down or up the radio frequency band. CD: Press to select the previous track or to select the next track on the CD. RADIO FREQUENCIES AM and FM frequencies are established by the Federal Communications Commission (FCC) and the Canadian Radio and Telecommunications Commission (CRTC).
Page 41 Due to technical incompatibility, certain recordable and re-recordable compact discs may not function correctly when used in Ford CD players. Irregular shaped CDs, CDs with a scratch protection film attached, and CDs with homemade paper (adhesive) labels should not be inserted into the CD player.
Page 42: Climate Controls
Climate controls HEATER ONLY SYSTEM 1. Fan speed adjustment: Controls the volume of air circulated in the vehicle. 2. Air flow selections: Controls the direction of the airflow in the vehicle. See the following for a brief description on each control. : Distributes outside air through the instrument panel vents.
Page 43: Manual Heating And Air Conditioning
Climate controls To increase airflow to the outer instrument panel vents, close the vents located in the middle of the instrument panel. Do not place objects on top of the instrument panel as these objects may become projectiles in a collision or sudden stop. MANUAL HEATING AND AIR CONDITIONING SYSTEM 1.
Page 44 Climate controls • Do not put objects under the front seats that will interfere with the airflow to the back seats. • Remove any snow, ice or leaves from the air intake area at the base of the windshield. To aid in side window defogging/demisting in cold weather: 1.
Page 45: Lights
Lights HEADLAMP CONTROL Turns the lamps off. Turns on the parking lamps, instrument panel lamps, license plate lamps and tail lamps. Turns the headlamps on. High beams Push the lever toward the instrument panel to activate. Pull the lever towards you to deactivate. Flash-to-pass Pull toward you slightly to activate and release to deactivate.
Page 46: Turn Signal Control
Lights • the headlamp control is in the OFF, parking lamp or autolamp position. Always remember to turn on your headlamps at dusk or during inclement weather. The Daytime Running Lamp (DRL) system does not activate your tail lamps and generally may not provide adequate lighting during these conditions.
Page 47: Interior Lamps
Lights INTERIOR LAMPS Map lamps (if equipped) To turn on the map lamps, press the control next to each lamp. EXTERIOR BULBS Checking operation of lamps, safety equipment and warning signals It is a good safety practice to check operation of headlamps, parking lamps, turn signals, clearance and marker lamps, instrument panel and control lamps each day.
Page 48 Lights 2. Remove four screws and move the parking lamp assembly away from the headlamp bulb. 3. Remove four screws and the retaining bracket from the headlamp bulb. 4. Pull headlamp bulb out of the housing, disconnect the electrical connector and remove the headlamp bulb.
Page 49 Lights 2. Remove four screws from the lamp assembly. 3. Carefully lower lamp assembly and pull the bulb socket straight out of the lamp assembly. 4. Carefully pull the bulb straight out of the socket and push in the new bulb. 5.
Page 50: Driver Controls
Driver controls WINDSHIELD WIPER/WASHER CONTROLS Rotate the windshield wiper control to the desired interval, low or high speed position. The bars of varying length are for intermittent wipers. When in this position rotate the control upward for fast intervals and downward for slow intervals.
Page 51: Steering Wheel Adjustment
Driver controls Changing the wiper blades To replace the wiper blades: 1. Pull the wiper arm away from the windshield and lock into the service position. 2. Turn the blade at an angle from the wiper arm. Push the lock pin manually to release the blade and pull the wiper blade down toward the windshield to remove it from the...
Page 52 Driver controls Never adjust the steering wheel when the vehicle is moving. AUXILIARY POWER POINT Power points are designed for accessory plugs only. Do not POWER POINT hang any type of accessory or accessory bracket from the plug. Improper use of the power point can cause damage not covered by your warranty.
Page 53: Power Windows
Driver controls POWER WINDOWS (IF EQUIPPED) Press and hold the rocker switches to open and close windows. • Press the top portion of the rocker switch to close. AUTO • Press the bottom portion of the rocker switch to open. AUTO One touch down •...
Page 54: Mirrors
Driver controls Window lock (if equipped) The window lock feature allows only the driver to operate the power windows. To lock out all the window controls except for the driver’s press the left side of the control. Press the right side to restore the window controls. MIRRORS With the doors closed and the seat adjusted for proper comfort, move...
Page 55 Driver controls 1. Select L to adjust the left mirror or R to adjust the right mirror. MIRRORS 2. Move the control in the direction you wish to tilt the mirror. MIRRORS 3. Return to the center position to lock mirrors in place. 4.
Page 56: Speed Control
Driver controls Fold-away mirrors The mirrors can be manually folded forward or backwards for narrow spaces like driving through an automatic car wash or backing out of a garage with the trailer tow mirror. The telescoping feature (if equipped) allows the mirror to extend approximately 76 mm (3 inches).
Page 57 Driver controls Do not shift the gearshift lever into N (Neutral) with the speed control on. To turn speed control off Instrument panel-mounted controls: Press OFF or turn off the ignition. CRUISE Once speed control is switched off, the previously programmed engine RPM will be erased.
Page 58 Driver controls If you drive up or down a steep hill, your vehicle speed may vary momentarily slower or faster than the set speed; this is normal. Speed control cannot reduce the vehicle speed if it increases above the set speed on a downhill. If your vehicle speed is faster than the set speed while driving on a downhill, you may want to shift to the next lower gear or apply the brakes to reduce your vehicle speed.
Page 59 Driver controls To set a lower set speed Instrument panel-mounted controls: Press and hold RESUME RESUME -. If the vehicle is moving, this will decrease vehicle speed; if the vehicle is stationary, this will decrease engine RPM. Release the control when the desired vehicle speed/engine RPM is reached.
Page 60 Driver controls To disengage speed control • Depress the brake pedal or • Depress the clutch pedal (if equipped). Disengaging the speed control will not erase the previously programmed set speed or engine RPM. Instrument panel-mounted controls: Pressing OFF will erase the previously programmed engine CRUISE RPM.
Page 61 Driver controls To return to a previously set speed Instrument panel-mounted controls: Press RESUME -. For RESUME RESUME - to operate, the vehicle speed must be above 48 km/h (30 mph) or engine speed must be above 1,000 RPM. Steering wheel-mounted controls: Press RES.
Page 62: Locks And Security
Locks and security KEYS The key operates all locks on your vehicle. In case of loss, replacement keys are available from your dealer. You should always carry a second key with you in a safe place in case you require it in an emergency. POWER DOOR LOCKS (IF EQUIPPED) Press U to unlock all doors and L to lock all doors.
Page 63: Seating And Safety Restraints
Seating and safety restraints SEATING Notes: Reclining the seatback can cause an occupant to slide under the seat’s safety belt, resulting in severe personal injuries in the event of a collision. Do not pile cargo higher than the seatbacks to reduce the risk of injury in a collision or sudden stop.
Page 64 Seating and safety restraints Easy-Aire seat (if equipped) Move handle to the left to move seat forward or backward. Rotate control to adjust seatback. Pump handle to raise seat height. Push handle full down to lower. Always adjust the seat height before fastening seat belt.
Page 65 Seating and safety restraints Air-Ride seat (if equipped) Push up on the switch to raise the seat height. Press down on the switch to lower the seat height. Always adjust the seat height before fastening seat belt. Press up on the switch to increase the firmness (lumbar support) of the seatback.
Page 66 Seating and safety restraints 40/20/40 split bench seat (if equipped) • Lift the track release bar to move the seat forward or backward. Ensure the seat is re-latched into place. • Pull the handle on the side of the seat up to recline the seat. •...
Page 67 Seating and safety restraints Press to raise or lower the rear portion of the seat cushion. Press the control to move the seat forward, backward, up or down. Heated seats (if equipped) To operate the heated seats: • Push control to activate. •...
Page 68: Safety Restraints
Seating and safety restraints REAR FLIP-UP SEAT (IF EQUIPPED) Flipping-up the seat The rear seatback has a split 60/40 seat. Each seat cushion can be flipped-up into the seatback position. 1. Pull the control to release the seat cushion. 2. Rotate the seat cushion up until it locks into the vertical storage position.
Page 69 Seating and safety restraints All occupants of the vehicle, including the driver, should always properly wear their safety belts. Never let a passenger hold a child on his or her lap while the vehicle is moving. The passenger cannot protect the child from injury in a collision.
Page 70 Seating and safety restraints 2. To unfasten, push the release button and remove the tongue from the buckle. The front and rear outboard safety restraints in the vehicle are combination lap and shoulder belts. The front and rear seat passenger outboard safety belts have vehicle sensitive emergency locking retractors.
Page 71 Seating and safety restraints • SuperCab • Regular Cab and CrewCab 2004 F650/750 (f67) Supplement USA English (fus)
Page 72 Seating and safety restraints To lower the shoulder belt height, push the button and slide the height adjuster down. To raise the height of the shoulder belt, slide the height adjuster up. Pull down on the height adjuster to make sure it is locked in place.
Page 73 Seating and safety restraints Conditions of operation If... Then... The driver’s safety belt is not The safety belt warning light buckled before the ignition illuminates 1-2 minutes and the switch is turned to the ON warning chime sounds 4-8 seconds. position...
Page 74 Seating and safety restraints If... Then... The driver’s safety belt is The BeltMinder feature will not buckled before the ignition activate. switch is turned to the ON position... The following are reasons most often given for not wearing safety belts: (All statistics based on U.S.
Page 75 Seating and safety restraints Reasons given... Consider... “The people I’m with don’t Set the example, teen deaths occur 4 wear belts” times more often in vehicles with TWO or MORE people. Children and younger brothers/sisters imitate behavior they see. “I have an air bag” Air bags offer greater protection when used with safety belts.
Page 76 Seating and safety restraints • The parklamps/headlamps are in OFF position (If vehicle is equipped with Autolamps, this will not affect the procedure). To reduce the risk of injury, do not deactivate/activate the Belt Minder feature while driving the vehicle. BeltMinder activation and deactivation procedure 1.
Page 77 Ford Motor Company recommends that all safety belt assemblies used in vehicles involved in a collision be inspected for proper function and replaced, if necessary. Safety belt assemblies not in use during a collision should also be inspected and replaced if either damage or improper operation is noted.
Page 78: Child Restraints
Seating and safety restraints SAFETY RESTRAINTS FOR CHILDREN Important child restraint precautions You are required by law to use safety restraints for children in the U.S. and Canada. If small children (generally children who are four years old or younger and who weigh 18 kg [40 lbs] or less) ride in your vehicle, you must put them in safety seats made especially for children.
Page 79 To improve the fit of both the lap and shoulder belt on children who have outgrown child safety seats, Ford Motor Company recommends use of a belt-positioning booster. Booster seats position a child so that safety belts fit better. They lift the child up so that the lap belt rests low across the hips and the knees bend comfortably.
Page 80 Seating and safety restraints Types of booster seats There are two types of belt-positioning booster seats: • Those that are backless. If your backless booster seat has a removable shield, remove the shield and use the lap/shoulder belt. If a seating position has a low seat back and no head restraint, a backless booster seat may place your child’s head (top...
Page 81 Seating and safety restraints The importance of shoulder belts Using a booster without a shoulder belt increases the risk of a child’s head hitting a hard surface in a collision. For this reason, you should never use a booster seat with a lap belt only. It is best to use a booster seat with lap/shoulder belts in the back seat- the safest place for children to ride.
Page 82 • Place seat back in upright position. Ford recommends the use of a child safety seat having a top tether strap. Install the child safety seat in a seating position with a tether anchor. For more information on top tether straps and anchors, refer to Attaching safety seats with tether straps.
Page 83 Seating and safety restraints Installing child safety seats with combination lap and shoulder belts 1. Position the child safety seat in a seat with a combination lap and shoulder belt. Children under 12 are safer when properly restrained in the rear seat, to the extent this is possible.
Page 84 Rebuckle the belt. Obtain the locking clip kit (part number FO3Z-5461248–A) at no charge from an authorized Ford or Lincoln-Mercury dealer. 5. Before placing the child in the seat, forcibly tilt the seat forward and back to make sure the seat is securely held in place. To check this, grab the seat at the belt path and attempt to move it side to side and forward and back.
Page 85 Ford or Lincoln/Mercury dealer. If you have a Super Cab or Crew Cab, Ford recommends you attach tether safety seats in the rear seating position (if possible) with the tether strap attached to the tether anchorage bracket as shown in the instructions provided with the tether anchor kit.
Page 86: Driving
Driving STARTING PROCEDURES Operating precautions • Always shift to a lower gear at high altitudes to prevent engine smoking. • Avoid extended and unnecessary idling. Diesel engine vapors are combustible. Do not operate the engine in an enclosed area. These vapors can be sucked through the air intake system and cause an explosion which may result in severe bodily injury and extensive property damage.
Page 87 Driving After the engine starts: • On some engines, the Wait to WAIT start light should illuminate after the engine starts. Allow the START engine to idle about three minutes or until the engine coolant temperature gauge begins to rise. Maintain idle speed until the Wait to start light cycles off to indicate the air intake heater has shut off (approximately six minutes).
Page 88 Driving • If your vehicle is equipped with a water-fuel separator, drain it daily. Fill the fuel tank at the end of daily operation to prevent condensation in the fuel system. • Make sure you use proper cold weather engine oil and that it is at its proper level.
Page 89 Driving Hot weather operation • Keep the engine cooling system filled with a clean, permanent coolant solution to protect against damage from overheating. • Fill the fuel tank at the end of daily operation to prevent condensation in the fuel system. •...
Page 90 Driving • Operate in a gear that will permit an engine speed not in excess of the maximum governed speed or high-idle RPM (no load). All vehicles have blind spots. To reduce the risk of severe injury or property damage, never move your vehicle to the side or rear or change lanes without being sure your way is clear on both sides and to your rear.
Page 91: Brakes
Driving Driving through water If driving through deep or standing water is unavoidable, proceed very slowly especially if the depth is not known. Never drive through water that is higher than the bottom of the hubs (for trucks) or the bottom of the wheel rims (for cars).
Page 92 Driving Hydraulic brake booster system (Hydromax) The Hydromax systems receive fluid pressure from the power steering pump to provide power assist during braking. The Hydromax booster receives backup pressure from the reserve system electric pump whenever the fluid in the power steering system is not flowing.
Page 93 Driving Parking brake Apply the parking brake whenever the vehicle is parked. To set the parking brake, pull handle up until it snaps into the locked position. When the parking brake is out of adjustment, seek service immediately. The parking BRAKE warning lamp BRAKE in the instrument cluster illuminates and remains illuminated (when the...
Page 94 Driving The parking brake is not recommended to stop a moving vehicle. However, if the normal brakes fail, the parking brake can be used to stop your vehicle in an emergency. Since the parking brake only applies retardation to the rear wheels, the vehicle’s stopping distance will increase greatly and the handling of your vehicle will be adversely affected.
Page 95 Driving POWER PARK (AIR-OPERATED PARKING BRAKE) OPTION (IF EQUIPPED) This feature uses a brake chamber mounted on the chassis to power a spring-applied, air-released driveline parking brake. It is controlled by a yellow, dash-mounted parking brake knob. Applying the parking brake To apply the parking brake, pull the yellow, dash-mounted parking brake knob.
Page 96 Driving Hold the brake pedal down while moving the gearshift lever from position to position. If the brake pedal is not held down, the vehicle may move unexpectedly resulting in property damage, personal injury or death. Parking brake light illumination due to low air pressure If at any time during vehicle operation air pressure is too low, the parking brake may apply and the parking brake light will turn on.
Page 97 Driving Loosen the jam nut (1) and un-thread the adjustment rod (2) from the chamber to reduce tension on the cable (3). Continue to un-thread the adjustment rod all the way and remove it from the chamber. The nut and shaft are metric.
Page 98 Driving Continuous application of the brakes will cause the brakes to overheat, resulting in a temporary loss of braking. Occasional or intermittent brake squeal or groan may result from environmental conditions such as cold, hot, wet, snow, salt, mud, etc. This condition will not affect braking effectiveness.
Page 99 Driving Do not drive or continue to drive if the low air pressure buzzer is sounding or the brake warning light is lit. These warnings indicate that air pressure is not to normal operating level. Continued use of the vehicle could result in loss of braking ability. Avoid repeated light application of the brake pedal.
Page 100 Driving Air brake inspection and adjustment should be performed by a qualified service technician in accordance with the instructions in the service manual. Cam brakes - automatic slack adjusters Standard air brakes (cam) are equipped with automatic brake adjusters. Automatic adjustment occurs during brake applications.
Page 101 Driving Unexpected and possible sudden vehicle movement may occur if these precautions are not taken. If the service brakes should fail to operate while the vehicle is in motion, you can make an emergency stop with the parking brake. The stopping distance, however, will be much greater than normal.
Page 102 Driving Releasing spring brake with air pressure The air system in all vehicles with spring-actuated rear wheel parking brakes is equipped with a tank valve located on the supply or service air tank for connection to an outside air supply. The valve permits the system to be recharged with air from an outside source, releasing the spring-actuated parking brakes.
Page 103 Driving 4. Turn the release stud one-quarter turn to engage the stud tangs with the slot in the pressure plate. Keep the stud engaged and install the nut on the release stud. 5. Tighten the nut until the spring is fully caged and the brakes are released.
Page 104 Driving The exhaust brake is a butterfly type valve mounted in the exhaust pipe. When the operator’s foot is not on the accelerator pedal and the exhaust brake switch is in the ON position, an air cylinder shuts the butterfly valve, restricting the flow of exhaust gases and retarding the engine.
Page 105 Driving Make sure the engine speed does not exceed the maximum allowable engine RPM. Exceeding the maximum allowable engine RPM will result in damage to the engine. Apply the service brakes to reduce the engine RPM or make a slower descent by using a lower gear. The exhaust brake is not recommended for use on slippery or low traction road surfaces.
Page 106 Driving Trailer brake hand control (if equipped) The hand control, located on the right-hand side of the instrument panel, is used to apply the trailer service brakes which are independent of the truck or tractor service brakes. The hand control should never be used to apply the brakes when the tractor and trailer are parked unattended.
Page 107 Driving The parking brake controls the spring brakes on the tractor. When the knob is pulled out it causes the trailer supply valve to pop out, applying both the tractor and trailer parking brakes. The trailer brakes may be independently released by pushing only the trailer air supply valve in. Initial charge With the air system completely discharged, both knobs (1 and 2) will be out.
Page 108 Driving Normal driving position With both knobs pushed in, air is then supplied to both trailer and tractor spring brakes, and all brakes are released. System park With both knobs pushed in (normal driving position), the parking brakes for both the tractor and trailer can be applied by pulling the parking brake knob (2) out, exhausting air from the tractor spring brakes, simultaneously causing the trailer air supply valve to pop out, applying the trailer brakes.
Page 109 Driving Trailer charge If both knobs are out, and you want to recharge the trailer while leaving the tractor spring brakes applied, the trailer air supply (1) can be pushed in to recharge the trailer air supply line. This mode may also be used to park a combination vehicle with tractor spring brakes.
Page 110 Driving Actuation of trailer park (emergency) or tractor bobtail position To actuate the trailer brakes only, pull out the trailer air supply knob (1). The trailer brakes are now applied whether emergency or spring brakes are used on the trailer. This mode is also used when the tractor or truck with trailer is used during bobtail operation.
Page 111 Driving ABS warning lamp warning lamp in the instrument cluster momentarily illuminates when the ignition is turned on and the engine is off. If the light does not illuminate momentarily at start up, remains on after the vehicle reaches 10 to 15 km/h (5 to 10 mph), or continues to flash, the ABS needs to be serviced.
Page 112: Air Suspension
Driving When the Traction Control switch, located on the instrument panel, is in the off position, the traction control light will be illuminated. If you should become stuck in snow or ice or on a very slippery road surface, try switching the Traction Control system off.
Page 113 Driving lowering the frame for loading. Pressing the lower portion of the switch causes air to fill the air springs so the vehicle will remain normal ride height. Tractor-trailer connections To reduce the risk of personal injury, use extreme caution when making brake and light connections.
Page 114 Driving When operating a loaded vehicle, the driver must keep all adjustable axles on the ground at all times, supporting their share of the vehicle’s load. Failure to do so can overload other axles, tires, wheels, springs, steering components, brakes and frames, resulting in early component failure, loss of vehicle control, possible property damage and personal injury.
Page 115: Transmission Operation
Driving 9. Charge the trailer brake system. Set the trailer brakes, either with the hand valve or tractor protection valve. Pull against the trailer for an additional check of proper hook-up. Do not pull hard enough to damage or strain the equipment. 10.
Page 116 Driving To avoid sudden, unexpected vehicle movement and possible personal injury or death: 1. Bring the vehicle to a complete stop. 2. Shift the transmission into: N (Neutral). 3. Apply the parking brake and make sure it is holding properly. 4.
Page 117 Driving If the engine speed is above idle when a gear is selected using the shifter, the vehicle will not move. To move the vehicle, the shifter must be moved to re-select a gear after the engine speed returns to idle. Note: For more information regarding the Allison MD-WT, refer to the separate Allison MD-WT Operator’s Manual.
Page 118 Driving If engagement is prevented by the gear teeth not meshing properly, release the brakes and allow the vehicle to creep slightly - or shift the selector to N (Neutral) and then back in gear. The PTO should never be engaged by clashing the gear teeth.
Page 119 Driving Power take-off (PTO) operation with an Allison automatic transmission (MD applications) The PTO drive gear is engine driven and provides direct engine power. The PTO can be operated when the vehicle is either stationary or moving. The PTO gear is in constant mesh with the drive gear in the torque converter housing.
Page 120 Driving If your vehicle’s transmission is equipped with a ceramic clutch, you must start the vehicle moving in first gear and engage the clutch before pressing the accelerator at idle. Also, don’t try to slip the clutch by raising engine RPM and riding or feathering the clutch pedal since the vehicle will experience erratic engagement.
Page 121 Driving MANUAL TRANSMISSION OPERATION (IF EQUIPPED) Continued use of a damaged or worn clutch, prolonged clutch slippage or downshifting at excessive speeds can result in a failure of the engine, transmission or clutch components. To avoid premature clutch wear and failure, do not drive with your foot resting on the clutch pedal or use it to hold the vehicle at a standstill on an upgrade as when waiting for a traffic light.
Page 122 Driving Shifting with a synchronized transmission With the clutch pedal depressed, use 2 (Second) gear synchronizer to stop the clutch disc rotation; this allows smooth engagement of 1 (First) or R (Reverse) To complete the gear engagement, it may be necessary to apply light pressure to the gearshift lever during initial engagement of the clutch.
Page 123 Driving Operating the Eaton FS–5406A, FS–5406N, FS–6406A and FS–6406N 6-speed transmissions These 6-speed transmissions are equipped with six forward gears and one reverse. All the forward gears are synchronized. The shift pattern is embossed on the gear shift knob. Do not shift the transmission into 1 (First) or R (Reverse) while the vehicle is moving as this could damage the transmission.
Page 124 Driving To go backward Reverse is obtained by putting the gearshift lever in R (Reverse) and engaging the clutch while pressing lightly on the accelerator. Operating the Eaton 8908LL 10-speed transmission These transmissions have five forward speeds in the LO range, and four forward speeds in the HI range.
Page 125 Driving To start forward, place the gearshift lever in LO gear and disengage the clutch while slightly depressing the accelerator. Operate the clutch and upshift through the shift pattern (up to 4th) as required by driving conditions. To shift into the HI range from 4th gear (LO range), place the range control button in the HI range, then shift to 5th gear.
Page 126 Driving Operating the Eaton 9210B 10–speed transmissions These transmission have five forward speeds in both the LO and HI ranges, and two reverse speeds. Study the instruction plate on the sun visor and learn the shift pattern Neutral of your transmission. To go forward With the engine idling, depress the clutch pedal and push the range...
Page 127 Driving Power-take off operation (PTO) with a manual transmission Transmission-mounted power take-off units are available for local installation on your vehicle. See your Body Builder’s Layout Book for restrictions on use and installation of power take-off units. To engage the PTO unit, stop the vehicle and place the transmission control in neutral.
Page 128 Driving Driver-controlled differential lock To prevent the vehicle from moving when servicing the wheels, tires or brakes, turn the engine off and raise all drive wheels of the locker differential axle. Axles equipped with NoSPIN Detroit Locker differentials deliver power to both wheels even when only one wheel is on the ground. Failure to raise all drive wheels with this type of differential could cause the vehicle to move unexpectedly, resulting in property damage, personal injury or death.
Page 129 Driving TWO-SPEED REAR AXLE (IF EQUIPPED) A two-speed rear axle allows the driver to select a LO range for greater pulling power and a HI range for greater road speed and fuel economy. These ranges can also be used to provide additional steps between transmission shifts when driving on steep grades and/or fuel economy may be factors.
Page 130 Driving Shifting the axle from LO to HI range - vehicle moving Accelerate to approximately 56 km/h (35 mph), press the lower part of the switch while the transmission is in N (Neutral), then release and apply the accelerator. Shifting the axle from HI to LO range - vehicle stopped Place the transmission in N (Neutral), then press the upper part of the switch.
Page 131: Vehicle Loading
Axle High MAXIMUM VEHICLE LOADING Every vehicle manufactured by Ford Motor Company is supplied with information on the Vehicle Rating Decal listing the maximum loading for the vehicle (GVWR), and its axle systems (GAWR) at the tire to ground interface.
Page 132 Driving • Canada Under no circumstances should your vehicle be loaded in excess of the GVWR or GAWR. It is the operator’s responsibility to assure that neither the axle capacities, spring capacities, tire capacities nor the vehicle rated GVWR is exceeded. For tire capacities, refer to Maintenance and specifications chapter.
Page 133 Driving Note: Do not exceed the GVWR or the GAWR specified on the certification label. Towing trailers beyond the maximum recommended gross trailer weight exceeds the limit of the vehicle and could result in engine damage, transmission damage, structural damage, loss of vehicle control, vehicle rollover and personal injury.
Page 134 Driving Trailer brakes Electric brakes and manual, automatic or surge-type trailer brakes are safe if installed properly and adjusted to the manufacturer’s specifications. The trailer brakes must meet local and Federal regulations. Do not connect a trailer’s hydraulic brake system directly to your vehicle’s brake system.
Page 135 Driving • After you have traveled 80 km (50 miles), thoroughly check your hitch, electrical connections and trailer wheel lug nuts. • To aid in engine/transmission cooling and A/C efficiency during hot weather while stopped in traffic, place the gearshift lever in P (Park) (if available on your automatic transmission) or N (Neutral) (manual transmissions and automatic transmissions without a P [Park] position).
Page 136: Roadside Emergencies
Roadside emergencies GETTING ROADSIDE ASSISTANCE To fully assist you should you have a vehicle concern, Ford offers a complimentary roadside assistance program. This program is separate from the New Vehicle Limited Warranty and is not applicable to vehicles sold in Canada. The service is available: •...
Page 137: Hazard Flasher Switch
Roadside emergencies HAZARD FLASHER The hazard flasher control is located on the steering column, just behind the steering wheel. The hazard flashers will operate when the ignition is off. Push in the flasher control and all front and rear direction signals will flash.
Page 138: Fuse Block: Battery Junction Box
Roadside emergencies Fuse block - battery junction box Fuse/Relay Fuse Amp Fuse Description Location Rating 15A* Main light switch 30A* Power seat (driver) 30A* Power seat (passenger) 15A* Washer pump relay, Washer pump motor 15A* Exhaust brake (Caterpillar and Cummins engine) 15A* Air intake heater (Caterpillar engine)
Page 139 Roadside emergencies Fuse/Relay Fuse Amp Fuse Description Location Rating — Not used — Not used 10A* Parking brake — Not used 7.5A* Body builder - trailer adapter stoplamps WABCO hydraulic ABS — Not used 10A* Fuel transfer pump — Not used 10A* Engine ECM power relay (6.0L Power Stroke engine)
Page 140 Roadside emergencies Fuse/Relay Fuse Amp Fuse Description Location Rating F115 40A** Ignition switch, CJB fuse 21 F116 30A** Turn relays and back-up lamp relay F117 20A** Stoplamp relay (Caterpillar and Cummins engine) F118 60A** Trailer tow left, right and ABS fuse block (Hydraulic brake vehicles) F119/F120 60A**...
Page 141 Roadside emergencies Fuse block - central junction box Fuse/Relay Fuse Amp Fuse Description Location Rating Horn relay Hazard flasher Cigar lighter Diagnostics Blend door actuator, Back-up lamps, DRL signal, Heated seats Horn switch — Not used Radio, GEM ACC Headlamp switch LED, Window switch LED and relay Heated and lighted mirrors 2004 F650/750 (f67)
Page 142 Roadside emergencies Fuse/Relay Fuse Amp Fuse Description Location Rating Wiper motor, Washer pump relay Stop lamp switch (Hydraulic brake vehicles) Cluster, Radio Interior lamp relay Interior lamp relay Headlamp high beam, High beam indicator — Not used Headlamp switch interior lighting Engine control (all engines), Accelerator pedal (6.0L Power Stroke engine) Starting system...
Page 143: Jump Starting
Roadside emergencies JUMP STARTING YOUR VEHICLE The gases around the battery can explode if exposed to flames, sparks, or lit cigarettes. An explosion could result in injury or vehicle damage. Batteries contain sulfuric acid which can burn skin, eyes and clothing, if contacted.
Page 144 Roadside emergencies 2. Connect the other end of the positive (+) cable to the positive (+) terminal of the assisting battery. 3. Connect the negative (-) cable to the negative (-) terminal of the assisting battery. 4. Make the final connection of the negative (-) cable to an exposed metal part of the stalled vehicle’s engine, away from the battery and the carburetor/fuel injection system.
Page 145 Roadside emergencies Jump starting 1. Start the engine of the booster vehicle and run the engine at moderately increased speed. 2. Start the engine of the disabled vehicle. 3. Once the disabled vehicle has been started, run both engines for an additional three minutes before disconnecting the jumper cables.
Page 146: Wrecker Towing
Roadside emergencies 3. Remove the jumper cable from the positive (+) terminal of the booster vehicle’s battery. 4. Remove the jumper cable from the positive (+) terminal of the disabled vehicle’s battery. After the disabled vehicle has been started and the jumper cables removed, allow it to idle for several minutes so the engine computer can relearn its idle conditions.
Page 147 Roadside emergencies To reduce the risk of personal injury or property damage when manually releasing the spring brakes, be sure to block the wheels so the vehicle cannot move once the brakes are released. Towing the vehicle with the front wheels suspended When it is necessary to tow a vehicle with the front wheels suspended, extra precautions must be taken to avoid transmission or differential damage.
Page 148 Roadside emergencies 1. Shift collar in the locked position 2. Actuator assembly and shift fork 3. Axle shaft 4. Interference between the shift collar and housing 5. Shift collar in the unlocked position 6. Outer splines - axle shaft to collar 7.
Page 149 Roadside emergencies Installing the axle shafts 1. Remove the covers from the wheel ends 2. Shift the differential lock to the unlocked position (disengaged) position. 3. Install the axle shafts • Place the gaskets on the wheel hub studs. • Push the right-hand axle shaft and gasket in to the wheel end and housing until the shaft stops against the differential shift collar.
Page 150: Customer Assistance
It is preferred that you return to the authorized dealer where your vehicle was purchased when warranty repairs are needed. However, you may also take your vehicle to another Ford Motor Company or Ford of Canada dealership authorized for warranty repairs.
Page 151: Getting Assistance Outside The U.s And Canada
Customer assistance In order to help you service your Ford vehicle, please have the following information available when contacting the Commercial Vehicle Hotline: • Your telephone number (home and business) • The name of the dealer and the city where the dealership is located •...
Page 152: Ordering Additional Owner's Literature
Customer assistance If you are in another foreign country, contact the nearest Ford dealership. If the dealership employees cannot help you, they can direct you to the nearest Ford affiliate office. If you buy your vehicle in North America and then relocate outside of the U.S.
Page 153: Reporting Safety Defects (U.s. Only)
However, NHTSA cannot become involved in individual problems between you, your dealer, or Ford Motor Company. To contact NHTSA, you may either call the Auto Safety Hotline toll-free at 1–800–424–9393 (or 366–0123 in the Washington D.C.
Page 154: Cleaning
Cleaning WASHING THE EXTERIOR Wash your vehicle regularly with cool or lukewarm water and a neutral Ph shampoo, such as Motorcraft Detail Wash (ZC-3–A), which is available from your dealer. • Never use strong household detergents or soap, such as dish washing or laundry liquid.
Page 155: Repairing Paint Chips
• Do not use hydrofluoric acid-based or high caustic-based wheel cleaners, steel wool, fuels or strong household detergent. • To remove tar and grease, use Ford Extra Strength Tar and Road Oil Removal (B7A-19520–AA), available from your dealer. ENGINE Engines are more efficient when they are clean because grease and dirt buildup keep the engine warmer than normal.
Page 156 Use only approved products to clean plastic parts. These products are available from your dealer. • For routine cleaning, use Motorcraft Detail Wash (ZC-3–A). • If tar or grease spots are present, use Ford Extra Strength Tar and Road Oil Removal (B7A-19520–AA). INSTRUMENT PANEL AND CLUSTER LENS Clean the instrument panel with a damp cloth, then dry with a dry cloth.
Page 157: Underbody Preservation
Cleaning LEATHER SEATS (IF EQUIPPED) Your leather seating surfaces have a clear, protective coating over the leather. • To clean, use a soft cloth with Motorcraft Deluxe Leather and Vinyl Cleaner (ZC-11–A). Dry the area with a soft cloth. • To help maintain its resiliency and color, use the Motorcraft Deluxe Leather Care Kit (ZC-11–D), available from your authorized dealer.
Page 158: Maintenance And Specifications
Maintenance and specifications GENERAL SERVICING GUIDELINES AND PRECAUTIONS As with any machine, care should be taken to avoid being injured when performing maintenance, repairs or system checks. Improper or incomplete service could result in the vehicle not working properly which, in turn, may result in personal injury or damage to the vehicle or equipment.
Page 159 Maintenance and specifications vehicle at least once a year. Remember that regular maintenance and replacement of worn components will usually prevent serious problems from developing later. Making modifications to various parts, components and systems of the vehicle, such as brake and steering systems can adversely affect the quality, reliability and operation of your vehicle and could result in property damage, personal injury or death.
Page 160 Maintenance and specifications Check to make sure that the axle mounting U-bolt nuts, attaching or mounting bolts and nuts are securely tightened. Regularly check front axle for damage, binding, worn parts and adequate lubrication. At regular intervals, or during other scheduled maintenance, (tire rotation/service, wheel bearing service, alignment, etc.) the kingpins should be checked for excessive wear.
Page 161 Maintenance and specifications non-asbestos, fiberglass, mineral wool, aramid or carbon) may be a potentially serious health hazard. Avoid breathing brake lining fiber dust as it may be extremely hazardous to your health. Always use of respirator during brake maintenance. Note: Persons handling brake linings should follow all precautions listed below: 1.
Page 162 Maintenance and specifications interval to determine if adjustment is necessary. Brake chamber push rods on original equipment chambers now incorporate a stroke indicator to aid in adjustment checks; an orange paint marker near the base of the push rod. If the push rod is clean and the brakes require adjustment, the orange marker can be seen protruding from the chamber when the brakes are applied.
Page 163 Maintenance and specifications Air brakes - desiccant air dryer Inspect for moisture in the air system by opening reservoirs, drain cocks or valves and checking for presence of water. The presence of small amounts of water due to condensation is normal and should not be considered as an indication that the dryer is not functioning properly.
Page 164 Maintenance and specifications Hydraulic brakes - fluid precautions The Hydro-Max brake system consists of two completely separate hydraulic systems operating with two different and incompatible fluids; power steering fluid and hydraulic brake fluid. Failure to observe precautions preventing the contamination of either system with fluid from the other will result in swelling and deterioration of rubber parts leading to reduced brake performance and eventual brake failure.
Page 165: Hood
Maintenance and specifications OPENING THE HOOD The hood and fenders are held in position by a latch located on each fender. The parking brake must be fully set before opening the hood or possible personal injury may occur. If you must leave the engine running while checking under the hood, do not allow any loose clothing, jewelry, hair or other items to get near moving engine components or possible personal injury may occur.
Page 166: Engine Oil
Maintenance and specifications 4. Tilt the hood forward until stopped by the retaining cables. To lower the hood: 1. Push the hood rearward at the top center of the hood above the grille until closed. 2. Engage the latch on each fender. 3.
Page 167 Maintenance and specifications 3. Set the parking brake and shift into N (Neutral) (automatic transmission) or 1 (First) (manual transmission). 4. Turn off the engine and wait a few minutes for the oil to drain completely into the oil pan. 5.
Page 168 Diesel engine oils with improved fuel economy properties (energy conserving) are currently available. If you use an energy conserving oil, be sure it meets Ford specification WSS-M2C171–D or API service category designation CI-4/SL and is of the proper viscosity grade for the temperature range in which you expect to operate your vehicle.
Page 169 The lower section of the API symbol will state energy conserving if the engine oil has been proven to have fuel savings capabilities. Use a Ford engine oil filter, part number FL-1995 or equivalent. This filter protects your engine by filtering harmful, abrasive or sludge particles.
Page 170 Maintenance and specifications ENGINE COOLING SYSTEM Inspect cooling system daily Note: The de-aeration tank requires air space for expansion volume. The proper fill level is identified on the reservoir; do not overfill the reservoir. To reduce the risk of personal injury or death, use only the following procedure to remove the pressure-type cap from the radiator or expansion tank.
Page 171 Maintenance and specifications Do not add engine coolant when the engine is hot. Steam and scalding liquids released from a hot cooling system can burn you badly. Also, you can be burned if you spill coolant on hot engine parts. Do not put engine coolant in the windshield washer fluid container.
Page 172 • Do not add extra inhibitors or additives to the coolant. These can be harmful and compromise the corrosion protection of the engine coolant. • Do not mix with recycled coolant unless from a Ford-approved recycling process (see Use of Recycled Engine Coolant section). Coolant condition inspection Engine cooling systems should be checked twice a year to assure proper glycol/water concentrations.
Page 173 Maintenance and specifications Engine coolant capacities and part numbers For cooling system capacities, refer to Refill capacities in this chapter. For coolant part numbers, refer to Lubricant specifications in this chapter. Severe climates If you drive in extremely cold climates (less than –36° C [–34° F]): •...
Page 174 Inspect the solution level in the washer reservoir when insufficient solution is sprayed. Use 3.8L (4.0 quarts) of windshield washer fluid that meets the Ford specification listed. Refer to Lubricant specifications in this chapter. State or local regulations on volatile organic compounds may restrict the use of methanol, a common windshield washer antifreeze additive.
Page 175 Maintenance and specifications BRAKE FLUID Check and refill the Hydromax brake fluid reservoir using the following procedure. Refer to the general maintenance information section for the service interval. 1. Clean the reservoir caps before removal to prevent dirt or water from entering the reservoir.
Page 176: Battery
Maintenance and specifications BATTERY Your vehicle is equipped with two maintenance-free batteries which are mounted in a covered tray and located on the left frame rail. The covered battery tray, depending upon application, may also have one or two steps attached. •...
Page 177 Maintenance and specifications For longer, trouble-free operation, keep the top of the batteries clean and dry. Also, make certain the battery cables are always tightly fastened to the battery terminals. If you see any corrosion on the battery or terminals, remove the cables from the terminals and clean with a wire brush.
Page 178 Maintenance and specifications Alternator Before connecting a fast-charger, booster battery or installing a new battery, make sure the ground polarities of the fast-charger, booster battery or alternator (when installing a battery) are matched to the ground polarity of the vehicle battery. Improper usage of the fast-charger, hook-up of booster battery or installation of a new battery can cause damage to the electrical system or to the alternator.
Page 179 Maintenance and specifications the vehicle to service. Failure to properly bleed the hydraulic system can result in degradation of power system performance. Consult your dealer who is aware of the proper procedures for filling and bleeding the system. POWER STEERING FLUID Check the power steering fluid level using the following procedure.
Page 180 Maintenance and specifications To avoid damage to the power steering system, do not operate the vehicle with a low power steering fluid level. Whenever the dipstick is installed, make sure it is properly seated and tightened securely. CLUTCH FLUID/LINKAGE ADJUSTMENTS Clutch fluid (if equipped) Check the clutch fluid level.
Page 181 Maintenance and specifications • Transmission and clutch removed for clarity. 3. With a grease gun, lubricate the clutch release bearing (at one location) and the clutch release shaft (at two locations) using the grease fittings provided. 4. Lubricate clutch release wear pads at the two locations where they contact the clutch release bearing using a brush or similar tool.
Page 182 Maintenance and specifications Your manual transmission may be filled with an optional synthetic fluid which allows the use of extended service intervals. A tag on the filler plug will identify the use of the synthetic fluid. Use only fluid that meets manufacturer specifications (refer to Lubricant specifications in this chapter.
Page 183 Maintenance and specifications For effective emissions control and low operating cost, it is important that maintenance operations listed in this section be performed at the specified periods or mileage intervals indicated (kilometers, miles, hours, or months, whichever comes first). Service intervals are based upon average operating conditions. Where dusty, frequent start and stop or heavily laden operations are encountered, more frequent servicing will be required.
Page 184: Fuel Information
Maintenance and specifications Air induction system Once each year, perform a complete inspection of the air induction system. In areas where road salt is used, the inspection consists of disassembling the joints of each aluminum component and inspecting for salt build-up, presence of chlorine that can cause aluminum particles to flake off and enter the engine combustion chambers.
Page 185 If you must replace the fuel filler cap, replace it with a genuine Ford or Motorcraft part. The customer warranty may be void for any damage to the fuel tank or fuel system if a genuine Ford or Motorcraft fuel filler cap is not used.
Page 186 Maintenance and specifications Use low sulfur (less than 0.05% by weight) fuel as required by the EPA for emission compliance. Do not mix diesel fuel with gasoline, gasohol or alcohol. This could cause an explosion resulting in personal injury. Do not use starting fluid such as ether or gasoline. Such fluids can cause immediate explosive damage to the engine and possible personal injury.
Page 187 Maintenance and specifications Fuel filter/water separator Do not drain water separator while engine is running. Fuel may ignite if separator is drained while engine is running or vehicle is moving. The fuel filter/water separator removes any contaminated particles and/or water from the fuel before the fuel enters the engine. The fuel filter/water separator should be drained as recommended in the general maintenance information section.
Page 188 Maintenance and specifications Replace the fuel filter with Motorcraft Part No. F81Z-9N184–AA (FD-4596). 1. Stop the vehicle and shut off the engine. The vehicle must be stopped with the engine off when draining the HFCM. Fuel may ignite if separator is drained while the engine is running or vehicle is moving.
Page 189 Maintenance and specifications Fuel filter replacement - Caterpillar engine The fuel filter/water separator is located on the left side of the engine. Replace the fuel filter/water separator as recommended in the general maintenance information section, or sooner if it becomes plugged.
Page 190 Maintenance and specifications Removal - Engine-mounted fuel filter 1. Remove the fuel filter cap by turning counterclockwise. 2. Remove and discard the old fuel filter element. 3. Carefully clean the mating surfaces. Removal - in-line fuel filter 1. Remove the fuel filter cap by turning counterclockwise.
Page 191 Maintenance and specifications After replacing the fuel filter, the engine will purge the trapped air as it runs. The engine may run roughly and smoke until the air is completely eliminated. Using a fuel which has more than average impurities may require the fuel filter to be replaced more frequently than the service interval specifies.
Page 192 Maintenance and specifications The amount of Empty Reserve varies and should not be relied upon to increase driving range. When refueling your vehicle after the fuel gauge indicates empty, you might not be able to refuel the full amount of the advertised capacity of the fuel tank due to the empty reserve still present in the tank.
Page 193 Maintenance and specifications Driving style — good driving and fuel economy habits Give consideration to the lists that follow and you may be able to change a number of variables and improve your fuel economy. Habits • Smooth, moderate operation can yield up to 10% savings in fuel. •...
Page 194 Maintenance and specifications Cooling System • Check the fan for damage to blades; replace, if damaged, with the recommended parts. Inspect for fan to shroud interference, and any damage to shroud such as cracks and holes. • The fan ratio should not be changed and the fan spacer dimensions and positions should not be altered.
Page 195 Maintenance and specifications Inspect air intake piping • Check for accumulation of salt deposits (where applicable). If present, disassemble and clean the complete air intake piping system. If the intake piping is pitted, use RTV silicone to seal joints against leakage. •...
Page 196 Maintenance and specifications • Check that torque rod mounting fasteners are tight. • Check to be sure the suspension alignment is maintained at all time. • Check U-bolts after the chassis has been operating under load for 1,600 km (1,000 miles) or six months, whichever comes first, the U-Bolt nuts must be re-torqued.
Page 197 Maintenance and specifications U-BOLT NUT TORQUE U-bolt diameter (nominal) (all U-bolt diameter (nominal) spring suspensions) Ft. lbs. IROS Air w/15,500 lb. axles and 353–407 260–300 less IROS Air w/ greater than 15,500 502–542 370–400 lb. axles Hendrickson 23,000 lb. axle 502–542 370–400 Air suspension U-bolt checks and re-torquing procedures...
Page 198 Maintenance and specifications PROPELLER SHAFT At the regular lubrication interval, check the universal joints for any evidence of wear or looseness. Should propeller shaft vibrations occur, stop the vehicle immediately to avoid possible hazardous consequences or damage to other components. REAR AXLE LUBRICANT Refer to your general maintenance information section for rear axle lubricant level checks and lubricant change intervals.
Page 199 Maintenance and specifications 6. Clean and install the drain plug securely. 7. Add enough lubricant through the filler plug opening so that the lubricant level is up to the bottom of the opening. 8. Clean and install the filler plug securely. WHEELS General Wheel bearings should be inspected, lubricated and adjusted at regular...
Page 200 Maintenance and specifications Installation, tightening and alignment 8–lug wheel 10–lug wheel When installing wheels, be certain that the threads on studs and nuts are clean to permit correct torquing of nuts. The mounting surfaces of rims, wheels, spacer rings and clamps must be free of dirt, rust, lubricants or damage.
Page 201 Maintenance and specifications Disc wheel with flange nuts (hub-piloted) Front wheel mounting of flange nut system 1. Flange nut 2. Wheel(s) 3. Brake drum 4. Wheel stud (22 mm) 5. Wheel hub Rear wheel mounting of flange nut system 1. Flange nut 2.
Page 202 Maintenance and specifications 4. Draw up the nuts alternately following the crisscross sequence illustrated under Installation, tightening and alignment. Do not fully tighten the nuts. This will allow uniform seating of the nuts and assure even face-to-face contact of the wheel and hub. 5.
Page 203 Maintenance and specifications Prior to re-installing rear aluminum hub-piloted wheels, clean each wheel locator pad on the hub from all dirt, rust and foreign material. Apply a light coat of chassis grease, never-seize or disc brake corrosion control grease, only to the wheel locator pad. When installing the tire and rim assembly on disc-brake equipped axles, make sure the tire valve stem clears the brake caliper.
Page 204 Maintenance and specifications Changing wheel types Consult your dealer or wheel/rim distributor before attempting any wheel or fastener changes. Use only the same type and style wheels and mounting hardware to replace original parts. Failure to do so may result in an assembly that looks fine, but does not fit together properly.
Page 205 Maintenance and specifications TIRE/WHEEL RIM SELECTION AND INFLATION PRESSURES Axle capacity Load Approved Tire size Front - kg Rear - kg range rim widths (lbs.)/kPa (psi) (lbs.)/kPa (psi) 3302 (7280) / 6196 (13660) / 225/70R19.5 6.00, 6.75 655 (95) 655 (95) 3701 (8160) / 7031 (15500) / 245/70R19.5...
Page 206 Maintenance and specifications LUBRICATION AND MAINTENANCE INTERVALS New vehicles are lubricated at the factory. After the vehicle is placed in operation, regular lubrication intervals, based on the type of service and road conditions, should be established. Thorough lubrication at the specified intervals will insure outstanding life cycle value and will reduce overall expense.
Page 207: Lubricant Specifications
Maintenance and specifications LUBRICANT SPECIFICATIONS Component / Lubrication type Vendor Equivalent Ford Component vendor recommendations: part name / number Viscosity / Ambient temperature / Notes Non-driving front axle Eaton-Spicer axle Multipurpose EP SAE 75W: –40°C to Motorcraft SAE (generic) - front gear lube of API –26°C (–40°F to...
Page 208 Maintenance and specifications Component / Lubrication type Vendor Equivalent Ford Component vendor recommendations: part name / number Viscosity / Ambient temperature / Notes Spicer axle - front Multipurpose EP SAE 75W: –40°C to Motorcraft SAE axle wheel bearing gear lube of API 0°C (–40°F to 32°F)
Page 209 Maintenance and specifications Component / Lubrication type Vendor Equivalent Ford Component vendor recommendations: part name / number Viscosity / Ambient temperature / Notes Eaton-Spicer axle, EP2 Lithium Note: Eaton-Spicer Motorcraft Premium Spicer axle - Front complex-based moly and Meritor Easy...
Page 210 Maintenance and specifications Component / Lubrication type Vendor Equivalent Ford Component vendor recommendations: part name / number Viscosity / Ambient temperature / Notes Clutch Release bearing / GC/LB NLGI #2 — Motorcraft Premium shafts / fork lithium Long Life Grease /...
Page 211 Maintenance and specifications Component / Lubrication type Vendor Equivalent Ford Component vendor recommendations: part name / number Viscosity / Ambient temperature / Notes Spicer Petroleum oil: SAE 50: –18°C — (non-synchronized) Engine oil API-SL or (above 0°F) (lubricants are listed API-CF SAE 40: –18°C...
Page 212 Maintenance and specifications Component / Lubrication type Vendor Equivalent Ford Component vendor recommendations: part name / number Viscosity / Ambient temperature / Notes Meritor Petroleum oil: Heavy SAE 50: –12°C — Duty Engine Oil (above 10°F) MIL-L-2104E or SAE 40: –12°C —...
Page 213 Maintenance and specifications Component / Lubrication type Vendor Equivalent Ford Component vendor recommendations: part name / number Viscosity / Ambient temperature / Notes Eaton - single-speed Generic lubricant SAE 75W: –40°C to Motorcraft SAE axles –26°C (–40°F to 75W-90 Fuel –15°F)
Page 214 Maintenance and specifications Component / Lubrication type Vendor Equivalent Ford Component vendor recommendations: part name / number Viscosity / Ambient temperature / Notes Spicer - single-speed Multipurpose EP SAE 75W: –40°C to Motorcraft SAE gear lube of API 0°C (–40°F to 32°F)
Page 215 Maintenance and specifications Component / Lubrication type Vendor Equivalent Ford Component vendor recommendations: part name / number Viscosity / Ambient temperature / Notes Meritor - Fill at the factory — single-speed axle with Synthetic SAE (cont’d) 75W-90, will have a...
Page 216 Maintenance and specifications Component / Lubrication type Vendor Equivalent Ford Component vendor recommendations: part name / number Viscosity / Ambient temperature / Notes Cab latch pivots; GC/LB NLGI #2 — Motorcraft Premium Door check, hinges, lithium Long Life Grease / latches and strikers;...
Page 217: Refill Capacities
Maintenance and specifications REFILL CAPACITIES Rear axle Weight capacity Fluid capacity - Axle code Description - kg (lbs.) liters (pints) S135–S 6123 (13500) Single rear axle, 11.6 (24.5) single reduction 4S150–S 7031 (15500) Single rear axle, 11.6 (24.5) single reduction 17060S 7938 (17500) Single rear axle,...
Page 218 Maintenance and specifications Engine coolant and oil Engine type Engine coolant Engine oil (approximate (approximate capacity) capacity) 6.0L Power Stroke 25.7L (54.4 pints) 18.0L (19 quarts) Caterpillar 28.4 (60.0) Cummins B 23.1 (24.4) Refer to the engine operator manual for engine oil refill capacities. Power steering system Power steering fluid volume (cubic inches/liters/pints)
Page 219 Maintenance and specifications Air conditioner refrigerant - r134a Kg. (lbs.) .85 (1.87) Note: This system uses PAG-type refrigerant oil. Refrigerant fitting torque Captured washer nut: 19–21 N.m. (170–190 inch lbs.) Note: This system uses mineral based refrigerant oil to lubricate o-rings and fittings.
Page 220 Maintenance and specifications Vehicle Tank type Liters Gallons F-650 Dock Single, steel Height, F-750 D-style Pick-up and Delivery, F-750 Severe Service F-650 Low Profile, Dual, steel 114 (LH)/170 30 (LH)/45 (RH) F-650 Dock rectangular (RH) Height, F-750 Pick-up and Delivery, F-750 Severe Service F-650 Low Profile, Dual, steel...
Page 221 The VIN is printed on the Vehicle Rating Decal attached to the vehicle. The VIN also serves as the warranty number. If you ever find it necessary to communicate with Ford Motor Company about your vehicle, always include the VIN in your communication.
Page 222: General Maintenance Information
Your authorized dealer specializes in knowing all about Ford Motor Company vehicles rather than knowing a little about all makes. There are Ford or Ford of Canada dealer service shops ready to serve you wherever you drive in the U.S. or Canada. They stock Ford and Motorcraft parts, and Ford Chemicals and lubricants.
Page 223 General maintenance information OWNER MAINTENANCE You can do much of the maintenance your vehicle requires yourself, if you have the time and a reasonable amount of mechanical ability. If you prefer to have this work done professionally, your authorized dealer stands ready to help you.
Page 224 General maintenance information Emissions control system(s) laws Federal law prohibits vehicle manufacturers, dealers and other persons engaged in the business of repairing, servicing, selling, leasing or trading motor vehicles, as well as fleet operators from knowingly removing or rendering an emissions control device or system inoperative. Further, modifications of the emissions control system(s) could create liability on the part of individual owners under the laws of some states.
Page 225 Required Maintenance Services and in the General Maintenance Checklist. To further help minimize noise emissions degradation throughout the life of the vehicle, Ford Motor Company recommends that this vehicle should be operated in the manner described within the Owner Guide.
Page 226 Information Decal. The following services are to be performed at scheduled intervals because they are considered essential to the life and performance of your vehicle. Ford recommends that you perform maintenance on all designated items to achieve best vehicle operation.
Page 227 Failure to maintain proper air brake adjustment can result in reduction or loss of braking ability. Air brake inspection and adjustment should be performed by a qualified service technician in accordance with the instructions in the Ford Truck Service Manual. Cam brakes - automatic slack adjusters...
Page 228 General maintenance information SCHEDULED MAINTENANCE GUIDE 2004 F650/750 (f67) Supplement USA English (fus)
Page 229 General maintenance information Daily Owner Checks Engine system Check the air filter restriction indicator Check the engine oil Inspect the coolant level - for Power Stroke engine (for Caterpillar and Cummins engines, refer to the Owner’s Manual) Brake system Drain the air brake system reservoir - manual valve Check the air brake system reservoir automatic drain valve operation Transmission system...
Page 230 If coolant is dirty or rusty in appearance, the system should be drained, flushed and refilled with the prescribed solution of cooling system fluid and water. Use only permanent type coolant that meets Ford specifications WSS-M97B51-A1. See the engine manufacturer’s operating guide for supplemental corrosion inhibitor specifications.
Page 231 General maintenance information In addition to the items to be performed daily or at each oil change, the following need to be completed as specified: 2004 F650/750 (f67) Supplement USA English (fus)
Page 232 General maintenance information Maintenance Operation Frequency - Observation Inspect the automatic slack Insufficient power shown in loaded adjuster function practice stop Check the operation of the Vehicle handling qualities not up to brakes, the clutch, and the steering (*a,b) Inspect the vehicle for missing, Excessive noise emanates from under damaged, or mislocated noise the cab or engine compartment...
Page 233 General maintenance information Maintenance Operation Frequency - Observation Check the transmission and Hard shifting or excessive vibration engine mountings (*b) Check and adjust transmission High effort to shift or noisy controls (*b) transmission Check fuel pump pressure Insufficient full-throttle power or backfiring Clean radiator cap seal.
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Page 254 General maintenance information Change according to transfer pump minimum specifications. 2004 F650/750 (f67) Supplement USA English (fus)
Page 255 General maintenance information 2004 F650/750 (f67) Supplement USA English (fus)
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Page 257 General maintenance information 2004 F650/750 (f67) Supplement USA English (fus)
Page 258: Index
Index Air conditioning ......43 Cassette tape player ....37 manual heating and air Catalytic converter conditioning system ....43 (see Emission control) .....183 Air suspension ......112 CD-single premium ..28, 30, 33 Anti-lock brake system Cell phone use ......52 (see Brakes) ......110 Child safety restraints ....78 Audio system child safety belts ......78 (see Radio) ....28, 30, 33, 37...
Page 259 Index refill capacities ......218 Engine fan .........174 specifications ......207 Engine oil ........166 temperature gauge ....24 checking and adding ....166 Cruise control oil pressure gauge ....24 (see Speed control) ....56 recommendations ....167 Customer Assistance ..136, 150 refill capacities ......218 Getting assistance outside specifications ......207 the U.S.
Page 260 Index headlamps .........45 headlamps, flash to pass ..45 high beams ........45 Hazard flashers ......137 instrument panel, dimming ..46 Headlamps ........45 interior lamps ......47 aiming ........46 replacing bulbs ....47–49 daytime running lights .....45 Lane change indicator flash to pass ......45 (see Turn signal) ......46 high beam .........45 warning chime ......20 Lights, warning and indicator ..20...
Page 261 Index Power point .........52 Specification chart, lubricants ........207 Power steering ......178 fluid, checking and adding ..179 Speed control ......56 fluid, refill capacity ....218 fluid, specifications ....207 Speedometer .......24 Power Windows ......53 Starting your vehicle ....86 jump starting ......143 preparing to start your vehicle ........86 Radio ......28, 30, 33, 37 Steering ........178...
Page 262 Index Waxing your vehicle ....154 Wheels ........199 Vehicle loading ....131–132 Windows Voltmeter (see Battery voltage power .........53 gauge) ..........24 Windshield defrosting ......42–43 Warning chimes ......20 Windshield washer fluid and wipers ..........50 Warning lights (see Lights) ..20 checking and cleaning ....50 Warranty coverage ......5 operation ........50 Washer fluid ......174...

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F650 2004 f750 2004 f650

Ford F750 Owner's Manual

Introduction

Vehicle Inspection Guide

Instrumentation

Entertainment Systems

Climate Controls

Locks and Security

Seating and Safety Restraints

Driving

Roadside Emergencies

Maintenance and Specifications

General Maintenance Information

Index

Quick Links

Table of contents

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