Ford FCSD, Technical Training Manual

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IMPORTANT SAFETY NOTICE
Appropriate service methods and proper repair procedures are essential for the safe, reliable operation of all motor vehicles, as
well as the personal safety of the individual doing the work. This manual provides general directions for accomplishing service
and repair work with tested, effective techniques. Following them will help assure reliability.
There are numerous variations in procedures, techniques, tools and parts for servicing vehicles, as well as in the skill of the
individual doing the work. This manual cannot possibly anticipate all such variations and provide advice or cautions as to each.
Accordingly, anyone who departs from instructions provided in this manual must first establish that he compromises neither his
personal safety nor the vehicle integrity by his choice of methods, tools or parts.
As you read through the procedures, you will come across NOTES, CAUTIONS, and WARNINGS. Each one is there for a
specific purpose. NOTES give you added information that will help you to complete a particular procedure. CAUTIONS are given
to prevent you from making an error that could damage the vehicle. WARNINGS remind you to be especially careful in those
areas where carelessness can cause personal injury. The following list contains some general WARNINGS that you should
follow when you work on a vehicle.
•
Always wear safety glasses for eye protection.
•
To prevent serious burns, avoid contact with hot metal
parts such as the radiator, exhaust manifold, tail pipe,
•
Use safety stands whenever a procedure requires you to
catalytic converter and muffler.
be under the vehicle.
•
Be sure that the ignition switch is always in the OFF
•
Do not smoke while working on the vehicle.
position, unless otherwise required by the procedure.
•
To avoid injury, always remove rings, watches, loose
•
Set the parking brake when working on the vehicle. If you
hanging jewelry, and loose clothing before beginning to
have an automatic transmission, set it in PARK unless
work on a vehicle. Tie long hair securely behind your
instructed otherwise for a specific service operation. If you
head.
have a manual transmission it should be in RE-VERSE
(engine OFF) or NEUTRAL (engine ON) unless instructed
otherwise for a specific service operation.
•
Keep hands and other objects clear of the radiator fan
blades. Electric cooling fans can start to operate at any
•
Operate the engine only in a well-ventilated area to avoid
time by an increase in underhood temperatures, even
the danger of carbon monoxide.
though the ignition is in the OFF position. Therefore, care
•
Keep yourself and your clothing away from moving parts should be taken to ensure that the electric cooling fan is
when the engine is running, especially the fan and belts. completely disconnected when working under the hood.
The recommendations and suggestions contained in this manual are made to assist the dealer in improving his dealership parts and/or
service department operations. These recommendations and suggestions do not supersede or override the provisions of the Warranty
and Policy Manual, and in any cases where there may be a conflict, the provisions of the Warranty and Policy Manual shall govern.
The descriptions, testing procedures, and specifications in this handbook were in effect at the time the handbook was approved
for printing. Ford Motor Company reserves the right to discontinue models at any time, or change specifications, design, or
testing procedures without notice and without incurring obligation. Any reference to brand names in this manual is intended
merely as an example of the types of tools, lubricants, materials, etc. recommended for use. Equivalents, if available, may be
used. The right is reserved to make changes at any time without notice.
WARNING: MANY BRAKE LININGS CONTAIN ASBESTOS FIBERS. WHEN WORKING ON BRAKE COMPONENTS, AVOID
BREATHING THE DUST. BREATHING THE ASBESTOS DUST CAN CAUSE ASBESTOSIS AND CANCER.
Breathing asbestos dust is harmful to your health.
Dust and dirt present on car wheel brake and clutch assemblies may contain asbestos fibers that are hazardous to your health when
made airborne by cleaning with compressed air or by dry brushing.
Wheel brake assemblies and clutch facings should be cleaned using a vacuum cleaner recommended for use with asbestos fibers.
Dust and dirt should be disposed of in a manner that prevents dust exposure, such as sealed bags. The bag must be labeled per OSHA
instructions and the trash hauler notified as to the contents of the bag.
If a vacuum bag suitable for asbestos is not available, cleaning should be done wet. If dust generation is still possible, technicians
should wear government approved toxic dust purifying respirators.
OSHA requires areas where asbestos dust generation is possible to be isolated and posted with warning signs. Only technicians
concerned with performing brake or clutch service should be present in the area.
Copyright

2000 Ford Motor Company Produced and Coordinated by
Technical Support Operations
Ford Customer Service Division
August, 2000