Ford 2002 F650 Owner'S Manual Download

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Maintenance Intervals/

Service Performed

Service Shop

Name and Address

Date

Service

Performed

Mileage

Maintenance Record

General Maintenance Information

245

Summary of Contents for 2002 F650

Page 1: ...ith CD 31 AM FM stereo with CD 39 Climate Controls 56 Heater only 56 Manual heating and air conditioning 57 Lights 61 Headlamps 61 Driver Controls 68 Windshield wiper washer control 68 Steering wheel...

Page 2: ...172 Cleaning 174 Cleaning your vehicle 174 Underbody preservation 179 Maintenance and Specifications 181 Accessories 229 General Maintenance Information 230 Index 249 All rights reserved Reproduction...

Page 3: ...inted with your vehicle by reading this handbook The more you know and understand about your vehicle the greater the safety and pleasure you will derive from driving it For more information on Ford Mo...

Page 4: ...be read and observed Warning symbols on your vehicle When you see this symbol it is imperative that you consult the relevant section of this guide before touching or attempting adjustment of any kind...

Page 5: ...cription of what is covered and what is not covered refer to the Warranty Guide that is provided to you along with your Owner s Guide Special instructions For your added safety your vehicle is fitted...

Page 6: ...horage Brake System Anti Lock Brake System Brake Fluid Non Petroleum Based Traction Control Master Lighting Switch Hazard Warning Flasher Fog Lamps Front Fuse Compartment Fuel Pump Reset Windshield Wa...

Page 7: ...rature Do Not Open When Hot Battery Avoid Smoking Flames or Sparks Battery Acid Explosive Gas Fan Warning Power Steering Fluid Maintain Correct Fluid Level MAX MIN Emission System Engine Air Filter Pa...

Page 8: ...possibility of personal injury from a slip and fall when entering exiting and or climbing on this vehicle Always use the steps and assist handles before climbing Do not skip any steps or assist handle...

Page 9: ...n control systems may be malfunctioning The light may illuminate without a driveability concern being noted The vehicle will usually be drivable and will not require towing Light turns on solid Tempor...

Page 10: ...level high coolant temperature high intake manifold temperature Refer to the Engine Operator s Manual Stop engine if equipped This light is used in conjunction with the electronic engine control Refe...

Page 11: ...eek service immediately If equipped with a hydraulic brake system and the warning lamp remains illuminated after engine start up this indicates a brake system malfunction Stop the vehicle safely as so...

Page 12: ...to fasten your safety belts For more information refer to the Seating and safety restraints chapter Check trans Allison automatic transmission The lamp will illuminate for several seconds after the ig...

Page 13: ...the ON position and the engine is off or an over voltage condition requiring electrical system service Wait to start Indicates the air intake heater is in operation and special starting procedures ar...

Page 14: ...age to or failure of the fuel injection system To drain the fuel filter water separator refer to Maintenance and Specifications chapter for procedure Rotate the valve at the bottom of the filter assem...

Page 15: ...from the ignition and the driver s door is opened Key in ignition warning chime Sounds when the key is left in the ignition and the driver s door is opened Parking brake warning chime F650 SuperCrewze...

Page 16: ...ely possible switch off the engine immediately and let the engine cool Refer to Engine coolant in the Maintenance and specifications chapter Never remove the coolant reservoir cap while the engine is...

Page 17: ...Air pressure gauge and warning buzzer if equipped Indicates the amount of air pressure in the brake system green primary red secondary in pounds per square inch When the pressure is too low for normal...

Page 18: ...ely how much fuel is in the fuel tank The fuel gauge may vary slightly when the vehicle is in motion or on a grade When refueling the vehicle from empty indication the amount of fuel that can be added...

Page 19: ...rneys To reset depress the control Tachometer Indicates the engine speed in revolutions per minute Driving with your tachometer pointer in the red zone may damage the engine 0 0 0 0 MPH 20 km h 40 60...

Page 20: ...KERS AM FM STEREO WITH 4 SPEAKERS AND FADE CAPABILITY 1 2 3 4 AM FM SEEK TONE CLK TUNE TONE VOL 12 FM ST DX VOL PUSH ON 1 2 3 4 AM FM SEEK TONE CLK TUNE TONE VOL 12 FM ST DX VOL PUSH ON AM FM STEREO E...

Page 21: ...urned back on Bass adjust The bass adjust control allows you to increase or decrease the audio system s bass output Press the TONE control once then use the volume knob to adjust the desired level Tre...

Page 22: ...to adjust the desired level Seek function The seek function control works in radio mode Seek function in radio mode Press to find the next listenable station down the frequency band Press to find the...

Page 23: ...tation Refer to Tune adjust or Seek function for more information on selecting a station 3 Press and hold a memory preset control until the sound returns indicating the station is held in memory on th...

Page 24: ...mation Any time that the media is changed new radio station etc the media information will again display for ten seconds before reverting back to the clock In media mode the media information will alw...

Page 25: ...olume If the volume is set above a certain level and the ignition is turned off the volume will come back on at a nominal listening level when the ignition switch is turned back on SCAN BASS TREB BAL...

Page 26: ...u to increase or decrease the audio system s treble output Speaker balance adjust Speaker sound distribution can be adjusted between the right and left speakers Speaker fade adjust Speaker sound can b...

Page 27: ...tape modes AM FM select in radio mode This control allows you to select AM or FM frequency bands Press the AM control to select from AM selections and press the FM control to select from FM1 or FM2 m...

Page 28: ...Setting the clock Press CLK to toggle between listening frequencies and clock mode while in radio mode To set the hour press and hold the CLK control and press the SEEK control to decrease hours and t...

Page 29: ...ntrol works in radio mode Tune adjust in radio mode Press to move to the next frequency down the band whether or not a listenable station is located there Hold the control to move through the frequenc...

Page 30: ...rd The fast forward control works in tape mode To fast forward in tape mode press the FF control In the tape mode tape direction will automatically reverse when the end of the tape is reached Tape dir...

Page 31: ...io power can also be turned on by pressing the AM FM select control or the TAPE CD select control Turn control to raise or lower volume If the volume is set above a certain level and the ignition is t...

Page 32: ...io system s treble output Press the TREB control then press to decrease the treble output and to increase the treble output Speaker balance adjust Speaker sound distribution can be adjusted between th...

Page 33: ...evious selection on the tape Press to listen to the next selection on the tape Seek function in CD mode Press to seek to the previous track of the disc Press to seek forward to the next track of the c...

Page 34: ...in AM FM select The AM FM select control works in radio tape and CD modes AM FM select in radio mode This control allows you to select AM or FM frequency bands Press the control to switch between AM F...

Page 35: ...ls 2 Press the AUTO control 3 When the first six strong stations are filled the station stored in memory preset control 1 will start playing If there are less than six strong stations available on the...

Page 36: ...digital radio display the CLK control will not function in the above manner The CLK control will allow you to switch between media display mode radio station stereo information etc and clock display...

Page 37: ...ement Tape select To begin tape play with a tape loaded into the audio system while in the radio or CD mode press the TAPE control Press the button during rewind or fast forward to stop the rewind or...

Page 38: ...amount of hiss and static during tape playback Press the control to activate and deactivate the Dolbyt noise reduction Dolbyt noise reduction is manufactured under license from Dolbyt Laboratories Li...

Page 39: ...continue until the SHUFFLE control is pressed again Mute mode Press the MUTE control to mute the playing media Press the MUTE control again to return to the playing media AUDIOPHILE AM FM STEREO IN DA...

Page 40: ...raise or lower volume If the volume is set above a certain level and the ignition is turned off the volume will come back on at a nominal listening level when the ignition switch is turned back on LOA...

Page 41: ...rease or decrease the amount of treble Speaker balance adjust Speaker sound distribution can be adjusted between the right and left speakers Press the BAL control Use the SEL control to adjust the sou...

Page 42: ...he next track of the current disc After the last track has been completed the first track of the current disc will automatically replay Scan function The scan function works in radio or CD mode Scan f...

Page 43: ...FM stations six in FM1 and six in FM2 Setting memory preset stations 1 Select the frequency band with the AM FM select control Press the AM FM control to toggle between AM FM1 or FM2 2 Press the SEEK...

Page 44: ...laying If there are less than six strong stations available on the frequency band the remaining memory preset controls will all store the last strong station available To deactivate autoset and return...

Page 45: ...s CD select CD mode may be entered by pressing the CD control and the LOAD control Load the CD into the audio system The first track of the disc will begin playing After that CD play will begin where...

Page 46: ...ally lower the volume level of the playing media Fast forward The fast forward control works in CD modes Press and hold the FF control until the desired selection is reached If the end of the disc is...

Page 47: ...e audio system will display CD Each time the CD door opens INSERT CD is displayed The door will close and the player will move to the next slot after each disc has been loaded The process is repeated...

Page 48: ...erent modes SHUFFLE DISC and SHUFFLE TRK SHUFFLE DISC randomly plays tracks from all the discs presently in the audio system SHUFFLE TRK plays all the tracks on the current disc in random order Compre...

Page 49: ...data system feature SELECT HOURS Refer to Setting the clock SELECT MINUTES Refer to Setting the clock When in CD mode you can access SELECT HOURS SELECT MINUTES or COMP ON OFF SELECT HOURS SELECT MINU...

Page 50: ...FF RDS traffic seek feature When in traffic mode you can use the SEEK feature to seek up or down the listenable traffic capable frequencies With the RDS activated press MENU until TRAFFIC ON is displa...

Page 51: ...trol the volume of traffic announcements With the display reading TRAFFIC ON adjust the volume using the volume control to the desired level The volume level will show at the bottom of the display Int...

Page 52: ...YPE displays the RDS program type rock jazz etc NAME displays the name of the radio station or NONE deactivates the RDS display Digital signal processing if equipped The digital signal processing DSP...

Page 53: ...o optimize the sound based upon the occupants in the vehicle The following occupancy modes can be selected ALL SEATS DRIVER SEAT REAR SEATS Phone mode This feature allows you to control the factory in...

Page 54: ...a time Do not expose discs to direct sunlight or heat sources for extended periods of time After playing store the disc in its case CD units are designed to play commercially pressed 12 cm 4 75 in au...

Page 55: ...ll frequencies are used in a given area RADIO RECEPTION FACTORS Three factors can affect radio reception Distance strength The further an FM signal travels the weaker it is The listenable range of the...

Page 56: ...cle Temperature control knob Controls the temperature of the airflow inside the vehicle On heater only systems the air cannot be cooled below the outside temperature Mode selector control Controls the...

Page 57: ...de air inlet duct Under snowy or dirty weather conditions your vehicle s climate control system should be left in the OFF position when the vehicle is parked This allows the climate control system to...

Page 58: ...der the air conditioner drain while the system is working and even after you have stopped the vehicle MAX A C Uses recirculated air to cool the vehicle MAX A C is noisier than A C but more economical...

Page 59: ...s are provided in this mode For added customer comfort the air distributed through the floor ducts will be slightly warmer than the air sent to the windshield defroster ducts If the temperature is abo...

Page 60: ...d Do not put objects under the front seat which may interfere with the airflow to the rear seats if equipped Remove any snow ice or leaves from the air intake area at the bottom of the windshield and...

Page 61: ...mps High beams Push forward to activate Pull toward you to deactivate Flash to pass Pull toward you to activate and release to deactivate Daytime running lamps DRL if equipped Turns the headlamps on w...

Page 62: ...position and the high beams are not turned on Pull headlamp control towards you to turn foglamps on The foglamp indicator light will illuminate PANEL DIMMER CONTROL Use to adjust the brightness of the...

Page 63: ...lamps if equipped To turn on the map lamps press the control next to each lamp EXTERIOR BULBS Check operation of lamps safety equipment and warning signals It is a good safety practice to check operat...

Page 64: ...ate lamp 2 194 Cabmarker 5 168 Exterior visor lamp if equipped 4 194 Rear fender clearance 4 a Rear identification 3 194 Dome lamp 1 105 To replace all instrument panel lights see your dealer a Replac...

Page 65: ...rder Replacing front parking lamp turn signal bulbs To remove the parking turn signal bulbs 1 Make sure the headlamp control is in the OFF position 2 Remove four screws from the lamp assembly 3 Carefu...

Page 66: ...nly For visor bulb replacement see a dealer or qualified technician Replacing brake tail backup lamp bulbs Except F650 SuperCrewzer The brake tail backup lamp bulbs are located in the same portion of...

Page 67: ...Twist the bulb 1 8 of a turn counter clockwise and remove it from the socket 4 Pull the bulb straight out and push the new bulb in 5 Turn the bulb clockwise to secure in place 6 Replace the tail lamp...

Page 68: ...atically shut off after ten seconds of continuous use Windshield wiper blades Check the wiper blades at least twice a year or when they seem less effective Substances such as tree sap and some hot wax...

Page 69: ...e blade and pull the wiper blade down toward the windshield to remove it from the arm 3 Attach the new wiper to the wiper arm and press it into place until a click is heard TILT STEERING WHEEL Pull th...

Page 70: ...displayed in Centigrade or Fahrenheit by pressing the E M control If the outside temperature falls below 3 C 38 F the display will alternate from ICE to the outside temperature at a two second rate f...

Page 71: ...c areas zones have a magnetic north compass point that varies slightly from the northerly direction on maps This variation is four degrees between adjacent zones and will become noticeable as the vehi...

Page 72: ...steel structures and high voltage lines For optimum calibration turn off all electrical accessories heater air conditioning wipers etc and make sure all vehicle doors are shut 1 Locate the controls lo...

Page 73: ...h a scraper or attempt to readjust the mirror glass if it is frozen in place These actions could cause damage to the glass and mirrors AUXILIARY POWER POINT Power outlets are designed for accessory pl...

Page 74: ...windows Press the top portion of the rocker switch to close Press the bottom portion of the rocker switch to open One touch down Press AUTO completely down and release quickly The driver s window will...

Page 75: ...sed and the seat adjusted for proper comfort move the mirrors to maximize rear viewing area by adjusting the western mirrors left or right as required Adjust the auxiliary convex mirrors Convex mirror...

Page 76: ...ors To adjust your mirrors 1 Select L to adjust the left mirror or R to adjust the right mirror 2 Move the control in the direction you wish to tilt the mirror 3 Return to the center position to lock...

Page 77: ...to N Neutral with the speed control on Do not use the speed control in heavy traffic or on roads that are winding slippery or unpaved Caterpillar Cummins engines Press CRUISE RPM If the vehicle is mov...

Page 78: ...the previously programmed set speed will be erased Caterpillar Cummins engines Press OFF or Turn off the vehicle ignition Once speed control is switched off the previously programmed engine RPM will b...

Page 79: ...le idle RPM 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 increase...

Page 80: ...eached press and release SET ACCEL You can accelerate with the accelerator pedal at any time during speed control usage Releasing the accelerator pedal will return your vehicle to the previously progr...

Page 81: ...terpillar Cummins engine Press and hold RESUME If the vehicle is moving this will decrease vehicle speed by 1 6 km h 1 mph increments if the vehicle is stationary this will decrease engine RPM Release...

Page 82: ...al or Depress the clutch pedal if equipped Disengaging the speed control will not erase the previously programmed set speed or engine RPM 7 3L Power Stroke engine Pressing OFF will erase the previousl...

Page 83: ...usly set speed 7 3L Power Stroke engine Press RES For RES to operate the vehicle speed must be faster than 48 km h 30 mph Caterpillar Cummins engines Press RESUME For RESUME to operate the vehicle spe...

Page 84: ...his device may not cause harmful interference and 2 This device must accept any interference received including interference that may cause undesired operation Changes or modifications not expressly a...

Page 85: ...d and locked press the control a second time within five seconds The doors will lock again the horn will chirp and the lamps will flash If any of the doors are ajar the horn will make two quick chirps...

Page 86: ...TRANSMITTER APART 2 Place the positive side of new battery in the same orientation Refer to the diagram inside the transmitter unit 3 Snap the two halves back together Replacement of the battery will...

Page 87: ...ill have to be repeated Repeat the previous step to program additional remote transmitters The doors will lock unlock to confirm that each remote transmitter has been programmed When you have complete...

Page 88: ...right and the lap belt snug and low across the hips Reclining the seatback can reduce the effectiveness of the seat s safety belt in the event of a collision Fixed back seat Move handle to the left to...

Page 89: ...Rotate control to adjust seatback Easy Aire seat if equipped Move handle to the left to move seat forward or backward Rotate control to adjust seatback Seating and Safety Restraints 89...

Page 90: ...activate The indicator light on the control will illuminate when activated Adjusting the front power seat if equipped Never adjust the driver s seat or seatback when the vehicle is moving Do not pile...

Page 91: ...a collision The control is located on the outboard side of the seat cushion Press to raise or lower the front portion of the seat cushion Press to raise or lower the rear portion of the seat cushion P...

Page 92: ...books purses or briefcases are on the floor in front of the second row seats before folding them down 1 Locate the strap on the rear of the lower seat cushion 2 Lift the strap and rotate the lower sea...

Page 93: ...trained All occupants of the vehicle including the driver should always properly wear their seat belts Never let a passenger hold a child on his or her lap while the vehicle is moving The passenger ca...

Page 94: ...ne person Combination lap and shoulder belts 1 Insert the belt tongue into the proper buckle the buckle closest to the direction the tongue is coming from until you hear a snap and feel it latch Make...

Page 95: ...ehicle receives an impact of approximately 8 km h 5 mph or more the combination safety belts will lock to help reduce forward movement of the driver and passengers Front safety belt height adjustment...

Page 96: ...ht adjuster up Pull down on the height adjuster to make sure it is locked in place Position the shoulder belt height adjusters so that the belt rests across the middle of your shoulder Failure to adju...

Page 97: ...engthen the belt turn the tongue at a right angle to the belt and pull across your lap until it reaches the buckle To tighten the belt pull the loose end of the belt through the tongue until it fits s...

Page 98: ...ed by intermittently sounding a chime and illuminating the safety belt warning lamp in the instrument cluster If Then The driver s safety belt is not buckled before the vehicle has reached at least 5...

Page 99: ...by 60 in light trucks Traffic is light Nearly 1 of 2 deaths occur in single vehicle crashes many when no other vehicles are around Belts wrinkle my clothes Possibly but a serious crash can do much mor...

Page 100: ...mps 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...

Page 101: ...tured by the same supplier as the safety belt Manufacturer identification is located at the end of the webbing on the label Also use the safety belt extension only if the safety belt is too short for...

Page 102: ...for children Check your local and state or provincial laws for specific requirements regarding the safety of children in your vehicle Never let a passenger hold a child on his or her lap while the veh...

Page 103: ...g cushion that encourages safer seating posture and better fit of lap and shoulder belts on the child A belt positioning booster should be used if the shoulder belt rests in front of the child s face...

Page 104: ...nt accidental unbuckling 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 which is capab...

Page 105: ...th a combination lap and shoulder belt Children are safer restrained in the rear seat when possible 2 While holding the shoulder and lap belt portions together route the tongue through the child seat...

Page 106: ...ury 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 mo...

Page 107: ...nside of the back panel of your vehicle The anchor bracket must be installed using the instructions provided with the tether anchorage hardware kit Tether anchorage hardware kits part number 613D74 in...

Page 108: ...and the transmission is in the neutral position or P Park for Allison 2400 transmissions If your vehicle is equipped with an air intake heater the heater will activate in cooler weather If the Wait t...

Page 109: ...three to five minutes before operating with a full load Try to limit engine idle to 10 minutes Excessive idling reduces fuel economy When starting a cold engine increase the engine speed RPM slowly to...

Page 110: ...vent electrical shock do not use your heater with ungrounded electrical systems or two pronged cheater adapters Operating the engine Do not operate the engine at full throttle below peak torque engine...

Page 111: ...e serious engine damage Operation of the engine below peak torque RPM can occur during gear shifting due to difference of gear ratios Engine shutdown system if equipped This system is designed to help...

Page 112: ...other debris If you run the engine while stopped idled in an unconfined area open the windows at least 2 5 cm one inch and adjust the heating or air conditioning to draw outside air into the vehicle...

Page 113: ...KE 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 reserv...

Page 114: ...oose gravel bumps wet or snowy roads is normal and indicates proper functioning of the vehicle s anti lock brake system If the vehicle has continuous vibration or shudder in the steering wheel while b...

Page 115: ...ing the vehicle to a controlled stop The Anti Lock system does not decrease the time necessary to apply the brakes or always reduce stopping distance Always leave enough room between your vehicle and...

Page 116: ...or N Neutral for vehicles with automatic transmission Use of wheel chocks is also recommended in hilly or off road usage Unexpected and possible sudden vehicle movement may occur if these precautions...

Page 117: ...ke Push the knob in to release the parking brake Parking brake warning chime F650 SuperCrewzer If a chime sounds when pulling the knob out your parking brake is not functioning properly seek service i...

Page 118: ...occur if these precautions are not taken Remove the clevis which is attached to the end of the spring chamber rod This can be done by using a wrench on the flats of the rod to thread it out of the cl...

Page 119: ...will result in abnormally high brake temperatures excessive lining wear and increased stopping distances Continuous application of the brakes will cause the brakes to overheat resulting in a temporary...

Page 120: ...cut out pressure settings are preset at the factory and are not adjustable When air pressure is insufficient below 414 kPa 60 psi a warning light illuminates and a buzzer sounds when the ignition is...

Page 121: ...hicle Service Maintenance Guide Emergency air brake All vehicles are equipped with a dual brake system In the unlikely event of a failure of one system the second system will function for emergency st...

Page 122: ...e parking brake The stopping distance however will be much greater than normal Repairs should be made immediately to an inoperative air brake system circuit Parking brake control Pull the yellow parki...

Page 123: ...are removed If air pressure is released from the spring brake chamber the power spring applies the brake and unless air pressure can be re established the spring brake must be released as follows in o...

Page 124: ...he access plug Trailer brake if equipped During normal operation the trailer brakes operate whenever the tractor brakes are applied A manual control lever is provided so the trailer brakes can be appl...

Page 125: ...ring brakes all brakes are released Actuation of trailer parking or emergency brakes To actuate the trailer brakes only pull out the red control trailer air supply exhausting the trailer supply line T...

Page 126: ...pplication With both controls in in the normal run configuration if the supply pressure to the push pull valves is reduced to approximately 240 to 310 kPa 35 45 psi the red control trailer supply valv...

Page 127: ...ighway driving It is not available with automatic transmissions 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...

Page 128: ...ear to descend safely with a minimum application of the service brakes As a general guideline use the same gear as you would to ascend the hill Before descending a hill or steep grade always select th...

Page 129: ...e tachometer usually shows a drop in RPM depending on the grade and the vehicle load Do not expect a retarding effect similar to sudden hard application of the service brakes The exhaust brake retards...

Page 130: ...e vehicle Never hold the steering wheel to the extreme right or the extreme left for more than a few seconds when the engine is running This action could damage the power steering pump Suspension and...

Page 131: ...f the front tires Lack of lubricant in the front spindle bearings or linkage components Low oil level in the power steering system Broken or loose power steering pump direct drive connection Malfuncti...

Page 132: ...the added flexibility of manually selecting and holding in the lower drive ranges which permit the drive selection of the most suitable gear range to match varying road and load conditions To prevent...

Page 133: ...normal conditions 3 and 2 Third and Second Use these ranges when road load or traffic conditions require a lower gear These ranges provide greater engine braking than D Drive When conditions are impro...

Page 134: ...cated on the instrument panel is illuminated the shifter control pad may be disabled tones will not be heard shifts may not occur and directional shift changes will not be able to be performed The MOD...

Page 135: ...l for starting the engine If the engine starts in any gear other than N Neutral the start circuit should be serviced immediately Shift to N Neutral and set the parking brake any time the engine is to...

Page 136: ...lower the gear the greater the braking effect The push button selector uses up and down arrow buttons to select the desired gear The select indicator will display your choice and the monitor will disp...

Page 137: ...r is in R Reverse Reverse has only one gear and provides the greatest gear reduction N Neutral Place the selector in N Neutral before starting the engine Shift to N Neutral and set the parking brake a...

Page 138: ...stop before shifting into P Park Make sure the gearshift is securely latched in P Park This position locks the transmission and prevents the rear wheels from turning Always set the parking brake full...

Page 139: ...le to restrict the automatic shifting to a lower range These ranges provide greater engine braking than D Drive When conditions no longer require these lower gears shift back to D Drive 1 First The tr...

Page 140: ...e control an increase in engine speed can overpower the parking brake and cause the vehicle to move possibly resulting in personal and or property damage PTO operation while vehicle is moving After th...

Page 141: ...e at a standstill on an upgrade as when waiting for a traffic light Manual transmission shift patterns are displayed on the shift lever knob Study this information carefully before you drive the vehic...

Page 142: ...g the Eaton FS 4205A and FS 5205A 5 speed transmissions The 5 speed transmission is equipped with five forward gears and one reverse The 2nd 3rd 4th and 5th gears are synchronized The shift pattern is...

Page 143: ...rse 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...

Page 144: ...d 3rd 4th 5th 6th and 7th 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...

Page 145: ...able for local installation on Ford vehicles 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...

Page 146: ...ected to the back up lamp circuit TWO SPEED REAR AXLE General Information A 2 speed axle allows the vehicle operator to select Low Range for good starting and pulling power The operator may also selec...

Page 147: ...on lever movement has ended push the axle shift control down Release the clutch Depress the accelerator When split shifting the axle shift control must stay UP in the HIGH range until after any transm...

Page 148: ...2 speed axle can be used as a ratio extender when split shifting is not necessary For low end use just shift the axle into the LOW to start out and shift to HIGH when the extra torque is no longer nee...

Page 149: ...acities spring capacities tire capacities nor the vehicle rated GVWR is exceeded For tire capacities refer to Maintenance and specifications chapter Unloaded or lightly loaded vehicles The braking sys...

Page 150: ...ike accidents or getting stuck in the mud or snow are covered some exclusions apply such as impound towing or repossession USING ROADSIDE ASSISTANCE Complete the roadside assistance identification car...

Page 151: ...ses If electrical components in the vehicle are not working a fuse may have blown Blown fuses are identified by a broken wire within the fuse Check the appropriate fuses before replacing any electrica...

Page 152: ...Yellow Yellow Yellow Blue Blue 25A Natural Natural 30A Green Green Green Pink Pink 40A Orange Green Green 50A Red Red Red 60A Blue Yellow 70A Tan Brown 80A Natural Black Passenger compartment fuse pa...

Page 153: ...ctors 5 15A Back Up Lamps DRL Relays Blend Door Actuator Heated Seat Module SuperCrewzer only On Off Fan Clutch SuperCrewzer only Warning Chime Module SuperCrewzer only 6 Not Used 7 Not Used 8 5A Radi...

Page 154: ...zer only 15 10A GEM Interior Lamp Relay Map Lamps Glove Box Lamps SuperCrewzer only Power Mirrors SuperCrewzer only Warning Chime Module SuperCrewzer only 16 15A Highbeams 17 Not Used 18 5A Headlamp s...

Page 155: ...roke only Relay 1 Interior Lamps Relay 2 Not Used Relay 3 Horn Relay 4 One Touch Down Relay 5 Not Used Power distribution box The power distribution box is located in the engine compartment The power...

Page 156: ...PCM 6 20A CAT PCM Cummins PCM 7 15A Stop Lamps 8 25A C AT Fuel Heater 9 30A Trailer Hook Up lamps SuperCrewzer only 10 15A Shift Modulator Allison AT trans only Except for f650 SuperCrewzer and Caterp...

Page 157: ...ed 21 10A GEM Hydraulic Vehicles Only 22 Not Used 23 Not Used 24 Not Used 101 40A ABS Air Only 102 20A Body Builder Prep Run Feed 103 50A Ignition Switch JB fuses 8 9 11 19 20 22 23 24 25 29 30 31 104...

Page 158: ...lay 204 7 3L Power Stroke Neutral Start Relay Stoplamp Relay CAT and Cummins only 205 Right Hand Stop Turn Relay 206 Left Hand Stop Turn Relay 207 Shift Modulator Relay CAT and Power Stroke only Cummi...

Page 159: ...Run Feed 2 30A Trailer Tow Park Marker Lamps 3 30A Trailer Tow Stop Lamps 4 30A Trailer Tow Turn Stop Lamps 5 Not Used R1 Trailer Tow Run Relay R2 Trailer Tow Stop Lamp relay R3 Trailer Tow Park Mark...

Page 160: ...4 Not Used 5 Not Used R1 Trailer Hookup Lamps Relay R2 Exhaust Brake Relay R3 Exhaust Brake Relay R4 Not Used R5 Not Used R6 Not Used R7 Not Used R8 Not Used HOOK LAMP RELAY NOT USED N U N U N U N U...

Page 161: ...e jumper cables to the glow plug relay as this could severely damage the glow plugs injector driver module and PCM 2 Do not disconnect the battery of the disabled vehicle as this could damage the vehi...

Page 162: ...ster battery and the other end to a ground at least 12 inches from the battery of the discharged vehicle The vehicle frame is usually a good ground 7 Ensure that the jump leads are clear of moving par...

Page 163: ...of the discharged battery and then from the positive terminal of the booster battery 3 After the disabled vehicle has been started allow it to idle for a while so the engine can relearn its idle condi...

Page 164: ...ks chains must be fastened directly to the tow hooks on the vehicle If your vehicle is not equipped with tow hooks chains must be routed under the bottom edge of the bumper with a protection bar to pr...

Page 165: ...erns or are unsatisfied with the service you are receiving follow these steps 1 Contact your Sales Representative or Service Advisor at your selling servicing dealership 2 If your inquiry or concern r...

Page 166: ...48121 1 800 521 4140 TDD for the hearing impaired 1 800 232 5952 In Canada Customer Relationship Centre Ford Motor Company of Canada Limited P O Box 2000 Oakville Ontario L6J 5E4 1 800 565 3673 FORD I...

Page 167: ...hicles The Dispute Settlement Board may not be available in all states Ford Motor Company reserves the right to change eligibility limitations modify procedures and or to discontinue this service with...

Page 168: ...e dealership Board member is chosen from Ford and Lincoln Mercury dealership management recognized for their business leadership qualities What the Board needs To have your case reviewed you must comp...

Page 169: ...oard will decide the case whether or not an oral presentation is made An oral presentation may be requested by the Board as well Making a decision Board members review all available information relate...

Page 170: ...your vehicle to a foreign country contact the appropriate foreign embassy or consulate These officials can inform you of local vehicle registration regulations and where to find unleaded fuel If you c...

Page 171: ...vehicle in North America and then relocate outside of the U S or Canada register your vehicle identification number VIN and new address with Ford Motor Company Worldwide Direct Market Operations ORDE...

Page 172: ...of ownership of a new vehicle or the first 29 000 km 18 000 miles whichever occurs first 1 Two or more repair attempts are made on the same nonconformity likely to cause death or serious bodily injury...

Page 173: ...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 202 366 0123 in the Washington D...

Page 174: ...ve and do cause damage to the vehicle Items such as gasoline diesel fuel bird droppings and insect deposits should be washed and sponged off as soon as possible Deposits not removed promptly can cause...

Page 175: ...Some automatic car washes may cause damage to the finish on your wheel rims or covers Chemical strength cleaners or cleaning chemicals in combination with brush agitation to remove brake dust and dir...

Page 176: ...ne compartment including belt dressing For general cleaning of the engine and engine compartment spray Engine Shampoo and Degreaser F4AZ 19A536 A on all parts that require cleaning and pressure rinse...

Page 177: ...kerosene or paint thinner to clean the windshield rear window or the wiper blades as damage may occur Clean the outside of the windshield or rear window with a non abrasive cleaner such as Ultra Clea...

Page 178: ...eaning the area with Extra Strength Upholstery Cleaner E8AZ 19523 AA CLEANING LEATHER SEATS IF EQUIPPED All Ford Lincoln and Mercury vehicles with leather seating surfaces have a clear protective coat...

Page 179: ...e a soft cloth and Detail Wash ZC 3 A mixed with water in order to clean the mirror housing Use Glass Cleaner E4AZ 19C507 AA in order to clean the reflective mirror surface Use care when removing ice...

Page 180: ...lish Ford Custom Silicone Gloss Polish Ford Custom Vinyl Protectant not available in Canada Motorcraft Vinyl Conditioner Canada only Ford Deluxe Leather and Vinyl Cleaner not available in Canada Motor...

Page 181: ...le 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 To open the hood 1 Set the parking bra...

Page 182: ...earward at the top center of the hood above the grille until closed 2 Engage the latch on each fender 3 Push down on the bottom of each latch until locked To avoid the possibility of personal injury n...

Page 183: ...wiper blades or washer system Do not put engine coolant or antifreeze in the washer fluid reservoir Engine coolant or antifreeze can severely reduce visibility if sprayed on the windshield ENGINE OIL...

Page 184: ...een FULL and OPERATING RANGE the oil level is acceptable DO NOT ADD OIL Maintain the oil level between ADD and OPERATING RANGE on the dipstick by adding oil as required The distance from ADD to OPERAT...

Page 185: ...pecially formulated oil to resist contamination Proper quality oils also provide maximum efficiency of the crankcase ventilation system which reduces air pollution For normal or severe service use Mot...

Page 186: ...symbol shows the API service category designation This should be CH 4 SJ The center section of the API symbol shows the SAE viscosity grade The lower section of the API symbol will state energy conser...

Page 187: ...ation may also have one or two steps attached Covered battery tray shown Battery tray with steps similar Battery tray with cover removed To access the battery follow these steps 1 Open the fairing sto...

Page 188: ...cleaned or replaced 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 a...

Page 189: ...water which equates to a freeze point of 36 C 34 F Coolant concentration testing is possible with a hydrometer or antifreeze tester such as the Rotunda Battery and Antifreeze Tester 014 R1060 The leve...

Page 190: ...tifreeze or windshield washer fluid outside of its specified function and vehicle location Vehicles with diesel engines typically are used to carry heavy loads and accumulate mileage rapidly These two...

Page 191: ...your coolant reservoir or contact your local dealer Note Use of Motorcraft Cooling System Stop Leak Pellets VC 6 darkens the color of Motorcraft Premium Gold Engine Coolant from yellow to golden tan D...

Page 192: ...cool 2 When the engine is cool wrap a thick cloth around the coolant pressure relief cap on the coolant reservoir an opaque plastic bottle Slowly turn cap counterclockwise left until pressure begins t...

Page 193: ...ne Coolant green colored or equivalent meeting Ford specification ESE M97B44 A a supplemental coolant additive is required Refer to Adding Coolant section to determine the coolant type in your vehicle...

Page 194: ...posed of in an appropriate manner Follow your community s regulations and standards for recycling and disposing of automotive fluids Coolant refill capacity To find out how much fluid your vehicle s c...

Page 195: ...ter for optimum cooling system and engine protection Coolant conditioner liquid For engines filled with green colored Motorcraft Premium Engine Coolant a supplemental coolant additive FW 16 meeting Fo...

Page 196: ...y open flames before fueling your vehicle Always turn off the vehicle before fueling Automotive fuels can be harmful or fatal if swallowed If fuel is swallowed call a physician immediately even if no...

Page 197: ...may result in possible personal injury Choosing the right fuel At operating temperatures below 0 C 32 F use a blend of No 1D and No 2D Diesel fuels also known as winterized No 2D Do not use diesel fu...

Page 198: ...crank the engine for a longer time than normal If the engine fails to start in 30 seconds turn the ignition to the OFF position and wait for two minutes before cranking the engine again Any remaining...

Page 199: ...vertighten the drain valve as this could cause damage to the fuel filter water separator Draining the fuel filter water separator 7 3L Power Stoke engine 1 With the engine off open the drain valve loc...

Page 200: ...nt of the fuel filter more frequently The spin on filter has a water drain valve built into the bottom of the filter canister Removal 1 Using an oil filter wrench remove the filter 2 Carefully clean t...

Page 201: ...ore than average impurities may require replacement of the fuel filter more frequently The filter has a water drain valve built into the bottom of the filter housing Removal 1 Remove the fuel filter c...

Page 202: ...ather information as accurately and consistently as possible Fuel expense frequency of fillups or fuel gauge readings are NOT accurate as a measure of fuel economy We do not recommend taking fuel econ...

Page 203: ...equally the fuel gauge reading may fluctuate slightly until the fuel level between the two tanks balance out and become equal Your results will be most accurate if your filling method is consistent No...

Page 204: ...at reasonable speeds traveling at 88 km h 55 mph uses 15 less fuel than traveling at 105 km h 65 mph Using the air conditioner or defroster may reduce fuel economy Resting your foot on the brake peda...

Page 205: ...rvals If adding fluid is necessary use only MERCONt ATF 1 Set the parking brake shift into N Neutral automatic transmission or 1 First manual transmission and turn the engine off 2 Open the hood 3 Cle...

Page 206: ...t is properly seated and tightened securely CLUTCH FLUID IF EQUIPPED Check the clutch fluid level Refer to the Scheduled Maintenance Guide for the service interval schedules During normal operation th...

Page 207: ...First and turn the engine off 2 Remove the inspection cover from the clutch housing Transmission and clutch removed for clarity 3 With a grease gun lubricate the clutch release bearing at one location...

Page 208: ...ications Refer to Lubricant specifications in this chapter Brake fluid is toxic If brake fluid contacts the eyes flush eyes with running water for 15 minutes Seek medical attention if irritation persi...

Page 209: ...matic Transmission Operator s Manual Use of a non approved automatic transmission fluid may cause internal transmission component damage Manual transmission fluid Refer to your scheduled maintenance g...

Page 210: ...through the filler plug opening so that the fluid level is up to the bottom of the opening 8 Clean and install the filler plug securely REAR AXLE LUBRICANT Refer to your Scheduled Maintenance Guide f...

Page 211: ...ricant into a suitable container Dispose all used automotive fluids in a responsible manner following your local authorized standards 6 Clean and install the drain plug securely 7 Add enough lubricant...

Page 212: ...ped with a dry type air cleaner element When the yellow indicator on the air filter restriction indicator reaches the red line the air filter element should be replaced 7 3L Power Stroke engine Cummin...

Page 213: ...he hood Protect yourself from engine heat 3 Push in and turn the latches that retain the air filter housing cover counterclockwise 90 degrees then carefully remove the cover 4 Carefully remove the air...

Page 214: ...as been replaced several times If necessary replace the secondary air filter 5 Reach inside the air filter housing and clean the outlet tube where it extends into the housing Be sure not to damage the...

Page 215: ...eling lug nuts or wheel stud Do not allow an excessive thickness of paint to build between the disc wheel mounting surfaces Do not install disc wheels where the paint has not fully cured At wheel chan...

Page 216: ...weaker weight carrying components of the vehicle Do not overload the vehicle beyond safe load carrying capacity Avoid hammering rim with steel hammers Never run the engine with one wheel off the grou...

Page 217: ...bearings Stones or lumps of mud wedged between a wheel and drum or between dual wheels can unbalance a wheel and tire Servicing your tires Inspect the tire treads and remove stones nails glass or othe...

Page 218: ...essures on the tire sidewall do not take the wheel rim capabilities into consideration Never use a rim of different manufacture or any different size or type than original rims Try to replace tires in...

Page 219: ...use of the synthetic fluid Tire wheel rim selection and inflation pressures Tire Size Load Range PR Wheel Width in and Type Single Rear Axle Max Tire and Wheel Capacity kg lb kPa psi cold by Axle Tube...

Page 220: ...ually indicates a loose connection either at the lamp socket the system ground or a malfunctioning voltage regulator If examination does not indicate the cause of the trouble return your vehicle to yo...

Page 221: ...7B 1 2 10 4L 11 0 quarts Allison AT 545 3 18 9L 20 0 quarts 2000 2400 Series Standard sump 10 0L 10 6 quarts 4 2000 2400 Series Shallow sump 7 0L 7 4 quarts 5 MD series 3 27 4L 29 0 quarts 1 Quantity...

Page 222: ...n additional 0 75 liter 1 6 pints of axle lubricant Add lubricant through the axle vent FUEL TANK CAPACITIES Type Approximate capacity Single tank 246 09L 65 gallons Dual tank 492 18L 130 gallons LUBR...

Page 223: ...pins steering linkage front and rear spring shackle pins steering column U joints steering shaft slip yoke and universal joint steering shaft pillow block bearing clutch linkage fittings Premium Long...

Page 224: ...ion and transmission cables clutch release bearing hub transmission shift lever pivot Premium Long Life Grease XG 1 C or XG 1 K ESA M1C75 B Door weatherstrips Silicone Lubricant F7AZ 19G208 BA and F5A...

Page 225: ...el bearings oil filled 1 Motorcraft SAE 80W 90 Premium Rear Axle Lubricant XY 80W90 QL WSP M2C197 A Motorcraft SAE 75W 140 High Performance Rear Axle Lubricant XY 75W 140 QL WSL M2C192 A Manual transm...

Page 226: ...W 16 ESN M99B169 A Engine coolant Caterpillar 3126 B engine and Cummins B engine Refer to the engine operator s manual Power steering Motorcraft MERCONt ATF XT 2 QDX MERCONt Windshield washer fluid Ul...

Page 227: ...ttached to the front door latch pillar B pillar on the driver s side If you ever find it necessary to communicate with Ford Motor Company about your vehicle always include the VIN in your communicatio...

Page 228: ...acture of the chassis or incomplete vehicle Consequently the model year of the completed vehicle may be later than the model year of the incomplete vehicle or chassis INCOMPLETE VEHICLE MANUFACTURED B...

Page 229: ...any properly dealer installed Ford accessory found to be defective in factory supplied materials or workmanship during the warranty period as well as any component damaged by the defective accessory T...

Page 230: ...These services may be performed by any automotive repair establishment or individual using automotive parts equivalent to those with which your vehicle or engine was originally equipped If any parts...

Page 231: ...ition while the vehicle is in motion especially at high speeds Because of high engine compartment and exhaust system temperatures resulting from emissions equipment do not park idle or operate your ve...

Page 232: ...noise warranty are found in the Warranty Guide and are applicable to completed trucks Tampering with noise control system prohibited Federal law prohibits the following acts or the causing thereof 1...

Page 233: ...nd service of the noise control system have been included in the Required Maintenance Services and in the General Maintenance Checklist To further help minimize noise emissions degradation throughout...

Page 234: ...eration with a fully loaded vehicle max GVW Snowplowing Perform the following Change engine oil and oil filter every three months 8 000 km 5 000 miles or 125 hours of engine service If operating in se...

Page 235: ...occurs first However more frequent inspection is required if your vehicle s brakes are subjected to heavy use or adverse operating conditions such as Frequent brake applications while fully loaded Op...

Page 236: ...keep records of any emission control systems maintenance services performed on your vehicle Maintenance Record Warranty Start Date ______________________________________ Engine Displacement __________...

Page 237: ...ssion for fluid leakage Steering system Check the power steering pump fluid level and check the system for leaks Check the entire vehicle for evidence of fluid leaks U S Department of Transportation F...

Page 238: ...the same or the equivalent part Also a noise emission control service Suspension system Lubricate the front and rear spring pins Tighten the front and rear spring U bolts to the specified torque Drive...

Page 239: ...pearance 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 ESE M97B18 C Se...

Page 240: ...al transmission oil Eaton 5 and 6 speeds only Not required when equipped with optional synthetic lubricant 110 000 KM 70 000 MILES Replace the engine spin on coolant filter Replace the engine coolant...

Page 241: ...when equipped with optional synthetic lubricant 500 000 KM 300 000 MILES Disassemble the air dryer replace the desiccant and check the mounting of the dryer to the vehicle if equipped Please continue...

Page 242: ...ndshield with a cleaner does not restore a clean wipe Difficult to operate or noisy Lamp beams in wrong position when vehicle operating loaded If washers do not spray fluid when operated GENERAL MAINT...

Page 243: ...rn bearings Check for operation of ABS warning lamp At each engine start up Inspect the entire exhaust system including inlet pipe muffler outlet pipe and all exhaust clamps and fasteners for holes le...

Page 244: ...shed Tighten the wheel mounting nuts to the specified torque Refer to Servicing your wheels and tires Required initially at 804 and 1 609 km 500 and 1 000 miles Perform again at 804 and 1 609 km 500 a...

Page 245: ...Maintenance Intervals Service Performed Service Shop Name and Address Date Service Performed Mileage Maintenance Record General Maintenance Information 245...

Page 246: ...Maintenance Intervals Service Performed Service Shop Name and Address Date Service Performed Mileage Maintenance Record General Maintenance Information 246...

Page 247: ...Maintenance Intervals Service Performed Service Shop Name and Address Date Service Performed Mileage Maintenance Record General Maintenance Information 247...

Page 248: ...Maintenance Intervals Service Performed Service Shop Name and Address Date Service Performed Mileage Maintenance Record General Maintenance Information 248...

Page 249: ...her straps 107 in front seat 105 in rear seat 105 tether anchorage hardware 107 Cleaning your vehicle engine compartment 176 exterior 179 instrument cluster lens 178 instrument panel 177 interior 178...

Page 250: ...calculating fuel economy 202 204 choosing the right fuel 197 filling your vehicle with fuel 196 filter specifications 198 200 gauge 18 improving fuel economy 202 204 safety information relating to au...

Page 251: ...63 replacing bulbs 63 67 Lane change indicator see Turn signal 63 Lights warning and indicator 9 14 anti lock brakes ABS 11 12 114 brake 11 12 charging system 13 check coolant 12 13 high beam 15 safe...

Page 252: ...light and chime 12 15 97 98 Safety seats for children 103 Seat belts see Safety restraints 93 Seats 88 child safety seats 103 Servicing your vehicle 233 Speed control 77 Speedometer 18 Starting your v...

Page 253: ...fluid 183 reservoir 183 Water Driving through 148 Wheels 215 Windows power 74 Windshield washer fluid and wipers checking and cleaning 68 operation 68 replacing wiper blades 69 Wrecker towing 163 Ind...

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Ford 2002 F650, Owner'S Manual

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