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Ford F-650 2001, Owner'S Manual

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Ford F-650 2001 Owner'S Manual Download Page 168

Adding and replacing engine coolant-Caterpillar 3126 B engine

Refer to the engine operator’s manual for additional engine cooling
system information.

FAN CLUTCHES

Your vehicle’s cooling system is equipped with a viscous variable speed
fan clutch.

•

The fan clutch helps control cooling, increase performance, improve
fuel economy and reduce noise.

•

The fan clutch is controlled by bimetallic spring sensors. Do not
tamper with these sensors as this may change their calibration or keep
the fan clutch from operating at all.

Stay clear of the fan/fan area while the engine is running or
possible personal injury may occur.

CHECKING AND ADDING POWER STEERING FLUID

Checking power steering fluid level

Check the power steering fluid level using the following procedure. Refer
to the scheduled maintenance guide for the recommended service
intervals. If adding fluid is necessary, use only MERCON

t

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. Clean the top of the power
steering fluid reservoir.

4. Remove the dipstick from the
reservoir and wipe the dipstick clean.

Maintenance and care

168

Summary of Contents for F-650 2001

Page 1: ...0 Customer assistance 226 Reporting safety defects 236 Index 237 All rights reserved Reproduction by any means electronic or mechanical including photocopying recording or by any information storage a...

Page 2: ...the following section on Warnings Indicates vehicle information related to recycling and other environmental concerns will follow Correct vehicle usage and the authorized disposal of waste cleaning a...

Page 3: ...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...

Page 4: ...ild Seat Installation Warning Child Seat Tether Anchorage Brake System Anti Lock Brake System Brake Fluid Non Petroleum Based Traction Control Master Lighting Switch Hazard Warning Flasher Fog Lamps F...

Page 5: ...ngine Oil Engine Coolant Engine Coolant Temperature Do Not Open When Hot Battery Avoid Smoking Flames or Sparks Battery Acid Explosive Gas Fan Warning Power Steering Fluid Maintain Correct Fluid Level...

Page 6: ...mly placed during all phases of entering exiting and or climbing Always keep your shoe soles and hands clean Keep the steps and assist handles free of snow ice oil grease substances or debris Be sure...

Page 7: ...Instrumentation 7...

Page 8: ...0 70 80 90 100 P ABS TRAILER BRAKE ABS TRANS TEMP L E F H RPM 1000 DIESEL FUEL ONLY X 0 1 2 3 4 P R N 2 1 8 C 18 H D BRAKE BRAKE Headlamp control pg 21 Panel dimmer control pg 21 Parking brake hydraul...

Page 9: ...P U S H T O TRAILER AIR SUPPLY NOT FOR PARKING P U L L TO TO E V A C U A T E P U S H S U P P L Y Air pressure gauge pg 20 Cruise control pg 66 Electronic sound system pg 28 Auxiliary power point pg 22...

Page 10: ...minate momentarily if the engine is running and the driver turns the steering wheel fully in one direction while braking If the light remains on while the engine is running this indicates inadequate h...

Page 11: ...r engine start up this indicates a brake system malfunction Stop the vehicle safely as soon as possible and seek service immediately If equipped with an air brake system the warning light stays on unt...

Page 12: ...this feature If the engine shuts down it can be restarted and operated for 30 seconds at a time or until the problem is corrected Refer to Engine shutdown system in the Starting chapter Drivers of el...

Page 13: ...S light on the anti lock brake system is disabled and normal braking is still effective unless the brake warning light also remains illuminated Wait to start Indicates the air intake heater is in oper...

Page 14: ...e the valve at the bottom of the filter assembly allowing water to drain from the system Close the valve upon completion Do not drain water separator while engine is running Fuel may ignite if separat...

Page 15: ...oon light to illuminate Examples are 1 The vehicle has run out of fuel The engine may misfire or run poorly 2 Poor fuel quality or water in the fuel These and other temporary malfunctions can be corre...

Page 16: ...on and the driver s door is opened Safety belt warning chime Sounds to remind you to fasten your safety belts For information on the safety belt warning chime refer to the Seating and safety restraint...

Page 17: ...coolant temperature gauge Indicates the temperature of the engine coolant At normal operating temperature the needle remains within the normal area the area between the H and C If it enters the red se...

Page 18: ...not at its proper level the gauge indication will not be accurate Speedometer Indicates the current vehicle speed Odometer Registers the total kilometers miles of the vehicle 0 0 0 0 0 0 0 0 0 0 MPH 2...

Page 19: ...damage the engine Battery voltage gauge This shows 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...

Page 20: ...ician 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...

Page 21: ...on interior lamps Daytime running lamps DRL if equipped Turns the headlamps on with a reduced output To activate the ignition must be in the ON position and the headlamp control is in the OFF or Parki...

Page 22: ...towards you to turn foglamps on The foglamp indicator light will illuminate AUXILIARY POWER POINT The auxiliary power point is located on the instrument panel Do not plug optional electrical accessori...

Page 23: ...ucts Floor and defrost Distributes outside air through the floor ducts and the windshield defroster ducts Defrost Distributes outside air through the windshield defroster ducts It can be used to clear...

Page 24: ...of the windshield Do not place objects over the defroster outlets These objects may block airflow and reduce visibility through the windshield Avoid placing small objects on top of the instrument pan...

Page 25: ...used to prevent undesirable odors from entering the vehicle A C Uses outside air to cool the vehicle It is quieter than MAX A C but not as economical Airflow will be from the instrument panel register...

Page 26: ...the climate control system in DEF before driving This will reduce fogging on your windshield Once the windshield has been cleared operate the climate control system as desired To reduce humidity buil...

Page 27: ...to see through your windshield Avoid placing small objects on top of the instrument panel These objects may fall down into the defroster outlets and block airflow in addition to damaging the climate...

Page 28: ...AUDIO SYSTEM AM FM Stereo AM FM Stereo 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 Controls and fe...

Page 29: ...rned off the volume will come back on at a nominal listening level when the ignition switch is turned back on AM FM select The AM FM select control works in radio mode AM FM select in radio mode This...

Page 30: ...station down the frequency band Press to find the next listenable station up the frequency band Radio station memory preset The radio is equipped with four station memory preset controls These contro...

Page 31: ...the volume knob to adjust the desired level Speaker balance adjust Speaker sound distribution can be adjusted between the right and left speakers Press the TONE control three times then use the volum...

Page 32: ...the TUNE control to decrease minutes and to increase minutes The CLK control will allow you to switch between media display mode radio station stereo information etc and clock display mode time When...

Page 33: ...AM FM stereo cassette Volume power control Press the control to turn the audio system on or off Turn the control to raise or lower volume SCAN BASS TREB BAL FADE SIDE EJ REW FF 1 2 TAPE AMS VOL PUSH O...

Page 34: ...trol to select from FM1 or FM2 memory preset stations AM FM select in tape mode Press this control to stop tape play and begin radio play Tune adjust The tune control works in radio mode Tune adjust i...

Page 35: ...adio station memory preset The radio is equipped with six station memory preset controls These controls can be used to select up to six preset AM stations and twelve FM stations six in FM1 and six in...

Page 36: ...reble adjust control allows you 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 f...

Page 37: ...ton Then press either REW for the beginning of the current selection or FF to advance to the next selection The tape deck stops and returns to play mode when the AMS circuit senses a blank section on...

Page 38: ...d eject a tape DolbyT noise reduction Dolbyt noise reduction operates only in tape mode Dolbyt noise reduction reduces the amount of hiss and static during tape playback Press the control to activate...

Page 39: ...hour press and hold the CLK control and press the SEEK control to decrease hours and to increase hours To set the minute press and hold the CLK control and press the TUNE control to decrease minutes a...

Page 40: ...conds before reverting back to the clock In media mode the media information will always be displayed Premium AM FM Stereo Cassette Single CD Volume power control Press the control to turn the audio s...

Page 41: ...the control to switch between AM FM1 or FM2 memory preset stations AM FM select in tape mode Press this control to stop tape play and begin radio play Tune adjust The tune control works in radio mode...

Page 42: ...e tape Seek function in CD mode Press to seek to the previous track of the current disc Press to seek forward to the next track of the current disc After the last track has been completed the first tr...

Page 43: ...io is equipped with six station memory preset controls These controls can be used to select up to six preset AM stations and twelve FM stations six in FM1 and six in FM2 Setting memory preset stations...

Page 44: ...emporarily stored in the memory preset controls until deactivated and are accessed in the same manner of your original presets To deactivate autoset and return to your audio system s manually set memo...

Page 45: ...ween the right and left speakers Press the BAL control then press to shift sound to the left and to shift sound to the right Speaker fade adjust Speaker sound can be adjusted between the front and rea...

Page 46: ...ol or the beginning of the tape is reached In CD mode pressing the REW control rewinds the CD within the current track Fast forward The fast forward control works in tape and CD modes In the tape mode...

Page 47: ...on Dolbyt and the double D symbol are trademarks of Dolbyt Laboratories Licensing Corporation Compression adjust Compression adjust brings soft and loud CD passages together for a more consistent list...

Page 48: ...set the minute press and hold the CLK control and press TUNE to decrease minutes and to increase minutes If your vehicle has a separate clock module other than the digital radio display the CLK butto...

Page 49: ...is changed new radio station etc the media information will again display for 10 seconds before reverting back to the clock In media mode the media information will always be displayed Mute mode Pres...

Page 50: ...e 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 LOAD EJ...

Page 51: ...a listenable station is located there Hold the control to move through the frequencies quickly Press to move to the next frequency up the band whether or not a listenable station is located there Hol...

Page 52: ...will automatically replay Scan function The scan function works in radio or CD mode Scan function in radio mode Press the SCAN control to hear a brief sampling of all listenable stations on the freque...

Page 53: ...utostore Autostore allows you to set the strongest local radio stations without losing your original manually set preset stations This feature is helpful on trips when you travel between cities with d...

Page 54: ...allow you to toggle between accessing the multi disc system and the CD changer The display will read CD or CDDJ Do not insert any promotional odd shaped or sized discs or discs with removable labels...

Page 55: ...as been loaded The process is repeated until all 6 slots are full The audio system plays the last CD loaded and the display is updated If some slots are already full and autoload is activated the syst...

Page 56: ...rst disc Release the control to disengage fast forward mode When in fast forward mode your audio system will automatically lower the volume level of the playing media Shuffle feature Press the SHUF co...

Page 57: ...ease the amount of bass Treble adjust The treble adjust control allows you to increase or decrease the audio system s treble output Press the TREB control Use the SEL control to increase or decrease t...

Page 58: ...adio data system 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 MINUTES...

Page 59: ...F 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 tuntil TRAFFIC ON is displa...

Page 60: ...rol 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 Inte...

Page 61: ...display Digital signal processing if equipped The digital signal processing DSP feature allows you to change the signal mode to suit your listening tastes Press the DSP control to access the DSP menu...

Page 62: ...hone if equipped through the radio controls Press the phone mute control to enter phone mode The playing media will mute Use SEEK TUNE or radio presets 1 through 6 to select a phone number previously...

Page 63: ...ean discs only with an approved CD cleaner and wipe the center out to the edge Do not use circular motion CD and CD player care Handle discs by their edges only Never touch the playing surface Do not...

Page 64: ...strength The further an FM signal travels the weaker it is The listenable range of the average FM station is approximately 40 km 24 miles This range can be affected by signal modulation Signal modula...

Page 65: ...e left turn signal Push up to activate the right turn signal WINDSHIELD WIPER WASHER CONTROLS Rotate the windshield wiper control to the desired interval low or high speed position The bars of varying...

Page 66: ...eactivate SPEED CONTROL IF EQUIPPED To turn speed control on except Caterpillar Cummins engines Press ON Vehicle speed cannot be controlled until the vehicle is traveling at or above 48 km h 30 mph Do...

Page 67: ...ic or on roads that are winding slippery or unpaved To turn speed control off Except Caterpillar Cummins engines Press OFF or Turn off the vehicle ignition Once speed control is switched off the previ...

Page 68: ...vehicle speed falls below 48 km h 30 mph or engine RPM falls below 1 000 RPM your speed control will disengage This is normal Pressing RESUME will re engage it Do not use the speed control in heavy tr...

Page 69: ...and hold CST Release the control when the desired speed is reached or Press and release CST to operate the Tap Down function Each press will decrease the set speed by 1 6 km h 1 mph or Caterpillar Cum...

Page 70: ...edal or Depress the clutch pedal if equipped Disengaging the speed control will not erase the previously programmed set speed or engine RPM Pressing OFF will erase the previously programmed set speed...

Page 71: ...ctronic compass temperature display SuperCrewzer only Outside air temperature The outside temperature display is contained in the overhead console The temperature can be displayed in Centigrade or Fah...

Page 72: ...curate a manual calibration may be necessary Refer to Compass calibration adjustment Most geographic areas zones have a magnetic north compass point that varies slightly from the northerly direction o...

Page 73: ...el 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 locat...

Page 74: ...to remove ice mist and fog from the mirrors This feature will automatically turn off after 10 minutes Do not remove ice from the mirrors with a scraper or attempt to readjust the mirror glass if it i...

Page 75: ...dows 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 op...

Page 76: ...he left side of the control Press the right side to restore the window controls POWER DOOR LOCKS IF EQUIPPED Press U to unlock all doors and L to lock all doors The ignition can be in any position to...

Page 77: ...red Pull the mirrors inward carefully when driving through a narrow space MIRRORS With the doors closed and the seat adjusted for proper comfort move the mirrors to maximize rear viewing area by adjus...

Page 78: ...id in troubleshooting Unlocking the doors Press this control to unlock the driver s door The interior lamps will illuminate Press the control a second time within five seconds to unlock all doors Lock...

Page 79: ...ot expressly approved by the party responsible for compliance could void the user s authority to operate the equipment Illuminated entry The illuminated entry system will turn on the interior lights w...

Page 80: ...rapid succession within 10 seconds with the eighth turn ending in the 4 ON position The doors will lock unlock to confirm that programming mode has been entered Within 20 seconds program a remote tra...

Page 81: ...les parked next to the vehicle To replace the battery 1 Twist a thin coin between the two halves of the transmitter near the key ring DO NOT TAKE THE FRONT PART OF THE TRANSMITTER APART 2 Place the po...

Page 82: ...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 83: ...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 83...

Page 84: ...o higher than the seatbacks to avoid injuring people in a collision or sudden stop Always drive and ride with your seatback upright and the lap belt snug and low across the hips Reclining the seatback...

Page 85: ...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 Push again to deactivate The indicator light will i...

Page 86: ...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 87: ...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 88: ...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 89: ...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 90: ...tion the shoulder belt height adjusters so that the belt rests across the middle of your shoulder Failure to adjust the safety belt properly could reduce the effectiveness of the seat belt and increas...

Page 91: ...the safety belt assembly by adding a safety belt extension assembly part number 611C22 Safety belt extension assemblies can be obtained from your dealer at no cost Use only extensions manufactured by...

Page 92: ...d 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 k...

Page 93: ...k which should be as upright as possible this can improve comfort 9I was in a hurry9 Prime time for an accident Belt Minder reminds us to take a few seconds to buckle up 9Seat belts don t work9 Safety...

Page 94: ...uckled during an ignition ON cycle Belt Minder will be disabled for that ignition cycle only Deactivating activating the belt minder feature Read steps 1 9 thoroughly before proceeding with the deacti...

Page 95: ...Minder is provided by flashing the safety belt warning light four times per second for three seconds 8 Confirmation of enabling Belt Minder is provided by flashing the safety belt warning light four...

Page 96: ...ide in your vehicle generally children who are four years old or younger and who weigh 18 kg 40 lbs or less you must put them in safety seats made especially for children Check your local and state or...

Page 97: ...raise the child and provide a shorter firmer seating 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 th...

Page 98: ...ent 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 capa...

Page 99: ...ith 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 100: ...and back to make sure the seat is securely held in place If the child seat is not tight enough unbuckle the seat belt move the tongue and locking clip to shorten the lap portion and push down hard on...

Page 101: ...re kits part number 613D74 including instructions may be obtained at no charge from any Ford or Lincoln Mercury dealer If you have a Super Cab or Crew Cab Ford recommends you attach tether safety seat...

Page 102: ...ING THE ENGINE 1 Ensure headlamps and all accessories are turned off and the parking brake is applied 2 Automatic transmissions ensure gearshift is in N Neutral 3 Manual transmissions ensure gearshift...

Page 103: ...ut off approximately six minutes Operating the engine at higher speeds will reduce the effectiveness of the air inlet heater Do not increase engine speed until the oil pressure gauge indicates normal...

Page 104: ...o normal operating range Continuous operation with low coolant temperature below 60 C 140 F or high coolant temperature 100 C 212 F can damage the engine Most failures give some kind of early warning...

Page 105: ...starting the vehicle Using the heater for longer than three hours will not harm the engine so the heater can be plugged in the night before starting the vehicle To prevent electrical shock do not use...

Page 106: ...eaves and 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...

Page 107: ...aggravated by environmental conditions such as cold heat moisture road dust salt or mud If a metal to metal continuous grinding or continuous squeal sound is present while braking the brake linings ma...

Page 108: ...ABS light on the anti lock brake system is disabled and normal braking is still effective unless the brake warning light also remains illuminated If your parking brake warning lamp illuminates have yo...

Page 109: ...normal operating conditions noise of the fluid flowing through the booster may be heard whenever the brake is applied This condition is normal Vehicle service is not required If braking performance or...

Page 110: ...AKE warning lamp in the instrument cluster illuminates and remains illuminated when the ignition is turned ON until the parking brake is released Do not use the gearshift selector in place of the park...

Page 111: ...the handling of your vehicle will be adversely affected Push the palm release lever on the parking brake handle and push down as far as possible to release the brake Driving with the parking brake on...

Page 112: ...y circumstances The high spring load may cause serious injury if the chamber clamps are removed If air pressure is released from the spring brake chamber the power spring applies the brake and unless...

Page 113: ...ment brakes are designed to be self adjusting Automatic adjustment when required occurs whenever the brakes are applied and released during forward or reverse operation Know the required stopping dist...

Page 114: ...brakes After starting the engine give the air compressor time to build up the air pressure to 414 kPa 60 psi before moving the vehicle Do not drive or continue to drive if the low air pressure buzzer...

Page 115: ...id overspeeding the engine Air chamber stroke indication All Ford air chamber push rods have orange stroke indicator stripes that alert the operator when the braking system requires adjustment or repa...

Page 116: ...pedal The ABS keeps the wheels rolling during braking to maintain control and reduce stopping distances For information on the anti lock braking system ABS refer to Hydraulic brakes in this chapter Pa...

Page 117: ...e valve permits the system to be recharged with air from an outside source releasing the spring actuated parking brakes The vehicle may then be towed in an emergency An outside air source can be used...

Page 118: ...ne 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 bra...

Page 119: ...reaches 448 kPa 65 psi the red control trailer supply may be pushed in and should stay in charging the trailer system and releasing the trailer brakes The yellow control parking brake may now be push...

Page 120: ...it is desired to recharge the trailer leaving the tractor spring brakes applied the trailer air supply control may be pushed in repressurizing the trailer supply line This mode could also be used to...

Page 121: ...rument panel in combination with the accelerator and clutch pedal switches allows the operator to make maximum use of the exhaust brake in the following conditions off highway driving mountain driving...

Page 122: ...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 123: ...ually 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 the vehicle wi...

Page 124: ...eering Power steering uses energy from the engine to help steer the vehicle Never hold the steering wheel to the extreme right or the extreme left for more than a few seconds when the engine is runnin...

Page 125: ...nderinflated tire s on any wheel s Vehicle overload Misalignment of the front tires Lack of lubricant in the front spindle bearings or linkage components Low oil level in the power steering system Bro...

Page 126: ...omponents 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 l...

Page 127: ...ng the different manual transmissions used in your vehicle Always use the lowest gear to start the vehicle Do not slam or jerk lever into gear When shifting into 1 First or R Reverse with vehicle stan...

Page 128: ...R Reverse and engaging the clutch while pressing lightly on the accelerator Operating the Eaton FS 5306A and FS 6306A 6 speed transmissions These 6 speed transmissions are equipped with six forward g...

Page 129: ...nd engaging the clutch while pressing lightly on the accelerator Operating the Spicer ES52 7B and ES066 7B 7 speed transmissions These 7 speed transmissions are equipped with seven forward gears and o...

Page 130: ...and upshift as required by driving conditions To go backward Reverse is obtained by putting the gearshift lever in R Reverse and engaging the clutch while pressing lightly on the accelerator Removing...

Page 131: ...owing the vehicle to coast in N Neutral could result in loss of vehicle control and severe transmission damage The Allison automatic transmissions are a torque converter type full power shifting and f...

Page 132: ...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 133: ...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 134: ...verse Reverse has only one gear and provides the greatest traction The Select and Monitor indicators will display R when reverse is attained N Neutral Use N Neutral for starting the engine If the engi...

Page 135: ...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 display the gear selected 1st gear Use for pulling thr...

Page 136: ...d set the parking brake any time the engine is to be running while the operator is not at the controls The engine should be at idle speed when any shift from N Neutral to a drive range is made Do not...

Page 137: ...earshift lever is latched in P Park Turn off the ignition whenever you leave your vehicle When parking on hilly or off road terrains be sure to set the parking brake fully and chock the wheels to prev...

Page 138: ...rive 1 First The transmission has to be manually shifted into 1 First and will not shift into a higher gear Use this position when pulling through mud or snow driving up steep grades hauling extra hea...

Page 139: ...on shift to the desired range and drive the vehicle The speed of the PTO during this period of operation will always maintain direct relation to vehicle speed PTO speed will decrease in relation to ve...

Page 140: ...especially if the depth is unknown Traction or brake capability may be limited and if the ignition system gets wet your engine may stall Water may also enter your engine s air intake and severely dam...

Page 141: ...ions you can stretch your fuel use Avoid changes in speed as much as possible Anticipate changing traffic conditions Sudden stops and fast acceleration waste fuel Avoid extensive idling Do not drive w...

Page 142: ...ership if within 56 km 35 miles Even non warranty related tows like accidents or getting stuck in the mud or snow are covered some exclusions apply such as impound towing or repossession Using roadsid...

Page 143: ...s simultaneously Depress control again to turn the flashers off FUSES AND RELAYS Fuses If electrical components in the vehicle are not working a fuse may have blown Blown fuses are identified by a bro...

Page 144: ...Fuse Link Cartridge 2A Grey Grey 3A Violet Violet 4A Pink Pink 5A Tan Tan 7 5A Brown Brown 10A Red Red 15A Blue Blue 20A Yellow Yellow Yellow Blue Blue 25A Natural Natural 30A Green Green Green Pink P...

Page 145: ...Fuse Amp Rating Passenger Compartment Fuse Panel Description 1 20A Horn 2 15A Turn Hazard Lamps 3 20A Cigar Lighter 4 10A Diagnostic Connectors 5 15A Back Up Lamps DRL Relays Blend Door Actuator Heate...

Page 146: ...rain Control Module PCM Keep Alive Memory 14 10A Interior Lamps Runningboard lamps SuperCrewzer only 15 10A GEM Interior Lamp Relay Map Lamps Glove Box Lamps SuperCrewzer only Power Mirrors SuperCrewz...

Page 147: ...10A Cluster GEM 7 3L Power Stroke PCM clutch switch input APCM 7 3L Power Stroke only Overhead Console SuperCrewzer only Keyless Entry Module SuperCrewzer only Traxx Fuel Module SuperCrewzer only 30 3...

Page 148: ...as been disconnected and reconnected refer to the Battery section of the Maintenance and care chapter The high current fuses and relays are coded as follows Fuse Relay Location Fuse Amp Rating Power D...

Page 149: ...lison 2000 2400 Trans 12 10A Keyless Entry Module SuperCrewzer only 13 10A Park Brake Adjustment Module SuperCrewzer only 14 Not Used 15 7 5A Body Builder Prep Hydraulic Vehicles Only 16 10A Allison 2...

Page 150: ...eats SuperCrewzer only 114 30A E Brake SuperCrewzer only 115 40A Ignition Switch JB fuses 5 8 9 11 21 116 30A Body Builder Prep 117 20A 7 3L Power Stroke PCM 118 30A IDM 7 3L Power Stroke only 119 120...

Page 151: ...e Relay SuperCrewzer only 208 Backup Lamps Relay 209 Stop Lamps Relay Foglamps Relay SuperCrewzer only 301 Fuel Heater Relay CAT and Cummins only 7 3L Power Stroke PCM Relay 302 Park Lamps Relay 303 B...

Page 152: ...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 Marker Lamp Relay R4 Trailer Tow Park Marker Lamp Relay R5 Not Used R6 Not Use...

Page 153: ...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 154: ...n system and other electrical components Do not attach the 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 batt...

Page 155: ...ing boosting battery 6 Connect one end of the cable to the negative terminal of the booster battery and the other end to a ground at least 12 inches from the battery of the discharged vehicle The vehi...

Page 156: ...w the starter to cool If the engine does not start after several attempts call for road service Removing the jumper cables 1 Remove the ground connection from the disabled vehicle first followed by th...

Page 157: ...t the loss of axle lubricant during towing To tow a vehicle with an inoperative rear axle the rear wheels must be raised onto a dolly or tow the vehicle on the front wheels If your vehicle is equipped...

Page 158: ...ngine 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 To open the hood 1 Se...

Page 159: ...the latch on each fender 3 Push down on the bottom of each latch until locked To avoid the possibility of personal injury never stand beneath the hood when it is being raised or lowered ENGINE OIL Ch...

Page 160: ...he engine and wait a few minutes for the oil to drain completely into the oil pan 5 Open the hood Protect yourself from engine heat 6 Locate and carefully remove the engine oil level indicator dipstic...

Page 161: ...emperatures or short driving distances Diesel engines require specially formulated oil to resist contamination Proper quality oils also provide maximum efficiency of the crankcase ventilation system w...

Page 162: ...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 conserving if the e...

Page 163: ...efer to Lubricant specifications in the Capacities and specifications chapter Brake fluid is toxic If brake fluid contacts the eyes flush eyes with running water for 15 minutes Seek medical attention...

Page 164: ...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 o...

Page 165: ...quarts of Ultra Clear Windshield Washer Concentrate or a washer fluid that meets the Ford specification listed Refer to Lubricant specifications in the Capacities and specifications chapter State or l...

Page 166: ...n engine coolant refer to Adding and replacing engine coolant in this chapter Never remove the coolant reservoir cap while the engine is running or hot or personal injury may occur If you must remove...

Page 167: ...er mixture should never exceed a 60 40 antifreeze to water ratio Operating the engine with insufficient coolant can cause severe cooling system and engine damage When refilling the engine cooling syst...

Page 168: ...clutch from operating at all Stay clear of the fan fan area while the engine is running or possible personal injury may occur CHECKING AND ADDING POWER STEERING FLUID Checking power steering fluid lev...

Page 169: ...power steering system and repair the leak If necessary see your dealer or a qualified service technician To avoid damage to the power steering system do not operate the vehicle with a low power steeri...

Page 170: ...Use of a non approved transmission fluid may cause internal transmission component damage For location of the transmission filler plug refer to your transmission operator s manual or Transmission Ref...

Page 171: ...bricant that meets Ford specifications refer to Lubricant specifications in the Capacities and specification chapter Use of a non approved rear axle lubricant may cause internal axle component damage...

Page 172: ...l authorized standards 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 ins...

Page 173: ...you do not use hard water water with a high mineral or alkali content If possible however try to only fill the battery cells with distilled water If the battery needs water often have the charging sy...

Page 174: ...ntact with skin eyes or clothing Shield your eyes when working near the battery to protect against possible splashing of acid solution In case of acid contact with skin or eyes flush immediately with...

Page 175: ...equipped 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 C...

Page 176: ...pen the 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 th...

Page 177: ...y filter needs to be replaced only after the primary air filter element has been replaced several times If necessary replace the secondary air filter 5 Reach inside the air filter housing and clean th...

Page 178: ...es Checking the wiper blades If the wiper blades do not wipe properly clean both the windshield and wiper blades using undiluted windshield wiper solution or a mild detergent Rinse thoroughly with cle...

Page 179: ...t parts To maintain the desired torque tension relation between nut body and flange it is necessary to use clean engine oil meeting Ford specification WSS M2C153 G between nut body and flange Lubricat...

Page 180: ...n Use of aftermarket wheel assemblies is not recommended they may be incompatible with your vehicle and may result in equipment failure and possible injury Replacement with used wheels is not advised...

Page 181: ...mage to the tire is suspected have the tire removed from wheel and inspected Check the pressure regularly Maintain the recommended air pressure for your vehicle load tires and rims or wheels Check the...

Page 182: ...earings are adjustable to correct for bearing and spindle wear Long bearing life depends upon proper adjustment and correct lubrication If bearings are adjusted too tightly preloaded they will overhea...

Page 183: ...703 105 22 520 10 213 703 105 245 70R19 5 6 75 8H I S O 10 300 4 671 698 100 19 280 8 745 698 100 11X20 16 7 50 10H I S O 12 080 5 478 703 105 22 520 10 213 703 105 FUEL INFORMATION Important safety...

Page 184: ...lenses if worn flush with water for 15 minutes and seek medical attention Failure to seek proper medical attention could lead to permanent injury Fuels can also be harmful if absorbed through the skin...

Page 185: ...l as this will allow air to enter the fuel system which will make restarting the vehicle difficult If you have run out of fuel If your vehicle is equipped with dual fuel tanks add at least 15 19 liter...

Page 186: ...cated at the bottom of the fuel filter water separator by turning it counterclockwise 2 Drain the filter until clear fuel is visible 3 Turn the drain valve clockwise to close the valve Do not overtigh...

Page 187: ...d on fuel with more than average impurities may require replacement 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...

Page 188: ...ith more 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 fil...

Page 189: ...best source of information about actual fuel economy is you the driver You must gather information as accurately and consistently as possible Fuel expense frequency of fillups or fuel gauge readings...

Page 190: ...if the two tanks are not filled 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...

Page 191: ...usually give the best fuel economy Anticipate stopping slowing down may eliminate the need to stop Sudden or hard accelerations may reduce fuel economy Slow down gradually Driving at reasonable speeds...

Page 192: ...bulbs To remove the headlamp bulbs 1 Make sure headlamp switch is in OFF position 2 Open the hood 3 Remove four screws and move the parking lamp assembly away from the headlamp bulb 4 Remove four scre...

Page 193: ...socket straight out of the lamp assembly 5 Carefully pull the bulb straight out of the socket and push in the new bulb 6 To complete installation follow the removal procedure in reverse order Replacin...

Page 194: ...ully pull the bulb straight out of the socket and push in the new bulb 3 Install the lens on the lamp assembly with the four screws Replacing foglamp bulbs if equipped 1 Remove the bulb socket from th...

Page 195: ...your dealer a Replace entire lamp assembly bulb is not serviceable AIMING THE HEADLAMPS The headlamps on your vehicle are properly aimed at the assembly plant If your vehicle has been in an accident t...

Page 196: ...s not indicate the cause of the trouble return your vehicle to your dealer for inspection If headlamps flash on and off If headlamps flash on and off at regular intervals the system circuit breaker if...

Page 197: ...age Wax when water stops beading on the surface This could be every three or four months depending on operating conditions Use only carnauba or synthetic based waxes Use a cleaning fluid with a clean...

Page 198: ...of time can corrode them and result in electrical system damage and malfunctions Cleaning non painted plastic exterior parts Use vinyl cleaner for routine cleaning Clean with a tar remover if necessar...

Page 199: ...flection Cleaning the instrument cluster lens Clean with a damp cloth then dry with a dry cloth Do not use household or glass cleaners as these may damage the lens Cleaning the interior fabric Remove...

Page 200: ...speed Eaton FS 4205A 1 2 5 4L 5 75 quarts 5 speed Eaton FS 5205A 1 2 5 9L 6 25 quarts 6 speed Eaton FS 5306A and FS 6306A 1 2 9 2L 9 75 quarts 7 speed Spicer ES52 7B and ES066 7B 1 2 10 4L 11 0 quarts...

Page 201: ...l 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 LUBRICANT SPECI...

Page 202: ...ings grease packed type and seals fuel shut off solenoid linkage air brake control valve linkage treadle hinge and roller transmission and transmission cables clutch release bearing hub transmission s...

Page 203: ...ar Axle Lubricant XY 80W90 QL WSP M2C197 A SAE 75W 140 High Performance Rear Axle Lubricant semi synthetic F1TZ 19580 B WSL M2C192 A Manual transmission 1 Motor oil SAE 50 above 18 C 0 F 2 WSE M2C908...

Page 204: ...cheduled maintenance guide to determine the correct service interval for the lubricant which you are using 2 Ford Motor Company currently does not offer a SAE 50 Motor oil 3 Ford Motor Company current...

Page 205: ...111 113 115 116 124 205 206 207 208 209 210 AND 302 THIS VEHICLE WILL CONFORM TO STANDARD NOS 108 120 AND 105 OR 121 AS APPLICABLE IF IT IS COMPLETED IN ACCORDANCE WITH THE INSTRUC TIONS CONTAINED IN...

Page 206: ...e manufacturers with the manufacture of the completed vehicle occurring at a later date than the manufacture of the chassis or incomplete vehicle Consequently the model year of the completed vehicle m...

Page 207: ...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 208: ...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 209: ...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 210: ...ncreased diameter different number of blades or different pitch width MAINTENANCE Instructions for maintenance and service of the noise control system have been included in the Required Maintenance Se...

Page 211: ...km ten miles when outside temperatures remain below freezing Operating during hot weather in stop and go rush hour traffic Operating in severe dust conditions Extensive idling or low speed operation...

Page 212: ...andard air brakes equipped with automatic slack adjusters for proper brake adjustment every four months or 32 000 km 20 000 miles whichever occurs first However more frequent inspection is required if...

Page 213: ...keep records of any emission control systems maintenance services performed on your vehicle Maintenance Record Warranty Start Date ______________________________________ Engine Displacement __________...

Page 214: ...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 215: ...other components Adjust service or replace with 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 r...

Page 216: ...of freezing weather where applicable 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 onl...

Page 217: ...filter Change the manual 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 Repl...

Page 218: ...hetic lubricant 400 000 KM 250 000 MILES Change the rear axle lubricant when equipped with optional synthetic lubricant 500 000 KM 300 000 MILES Disassemble the air dryer replace the desiccant and che...

Page 219: ...ping the blades with a clean cloth and mild detergent and washing the windshield with a cleaner does not restore a clean wipe Difficult to operate or noisy Lamp beams in wrong position when vehicle op...

Page 220: ...ning 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 leakage breakage looseness and corrosive dam...

Page 221: ...he 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 and 1 000 mile intervals after each tire r...

Page 222: ...Maintenance Intervals Service Performed Service Shop Name and Address Date Service Performed Mileage Maintenance Record General maintenance information 222...

Page 223: ...Maintenance Intervals Service Performed Service Shop Name and Address Date Service Performed Mileage Maintenance Record General maintenance information 223...

Page 224: ...Maintenance Intervals Service Performed Service Shop Name and Address Date Service Performed Mileage Maintenance Record General maintenance information 224...

Page 225: ...Maintenance Intervals Service Performed Service Shop Name and Address Date Service Performed Mileage Maintenance Record General maintenance information 225...

Page 226: ...ed States and Canada provided by a network of more than 5 000 participating Ford or Lincoln Mercury and Ford of Canada dealers If you did not take advantage of the Ford Extended Service Plan at the ti...

Page 227: ...nd accessories providing you with equipment reliability Away from home If you own a Ford or Mercury vehicle and are away from home when your vehicle needs service or if you need more help than the dea...

Page 228: ...r to help you service your Ford or Lincoln Mercury vehicle please have the following information available when contacting a Customer Relationship Center Your telephone number home and business The na...

Page 229: ...without notice and without incurring obligations per applicable state law What kinds of cases does the Board review Unresolved warranty repair concerns or vehicle performance as designed concerns on...

Page 230: ...ust complete the application in the DSB brochure and mail it to the address provided on the application form Some states will require you to use certified mail with return receipt requested Your appli...

Page 231: ...complaint including oral presentations and arrive at a fair and impartial decision Board review may be terminated at any time by either party Every effort is made to decide the case within 40 days of...

Page 232: ...the need for lengthy and expensive legal proceedings In the CAMVAP program impartial third party arbitrators conduct hearings at mutually convenient times and places in an informal environment These...

Page 233: ...ontact 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 outsi...

Page 234: ...ehicle through your local authorized Ford Lincoln Mercury or Ford of Canada dealer These quality accessories have been specifically engineered to fulfill your automotive needs they are custom designed...

Page 235: ...r a free publication catalog order toll free 1 800 782 4356 Monday Friday 8 00 a m 6 00 p m EST for credit card holders only Obtaining a French owner s guide French Owner s Guides can be obtained from...

Page 236: ...it finds that a safety defect exists in a group of vehicles it may order a recall and remedy campaign However NHTSA cannot become involved in individual problems between you your dealer or Ford Motor...

Page 237: ...g your vehicle 196 engine compartment 198 exterior 197 exterior lamps 198 instrument cluster lens 199 instrument panel 199 interior 199 plastic parts 198 safety belts 199 washing 196 waxing 197 wheels...

Page 238: ...onomy 141 189 choosing the right fuel 185 filling your vehicle with fuel 183 filter specifications 186 187 gauge 17 improving fuel economy 141 189 safety information relating to automotive fuels 183 F...

Page 239: ...2 194 Lane change indicator see Turn signal 65 Lights warning and indicator 10 anti lock brakes ABS 13 108 brake 10 11 charging system 11 check coolant 14 16 high beam 13 safety belt 15 service engine...

Page 240: ...eed control 66 Speedometer 18 Starting your vehicle 102 jump starting 157 preparing to start your vehicle 102 T Tachometer 19 Tires checking the pressure 183 Towing wrecker 157 Transmission fluid chec...

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