engine FORD F-650/750 2018 Repair Manual

GENERAL INFORMATION
WARNINGS
Do not drive with your foot resting on
the brake pedal. This results in
abnormally high brake temperatures,
excessive lining wear and increased
stopping distance. Continuous application of the brakes
causes the brakes to overheat,
resulting in temporary loss of braking.
Note:
Occasional brake noise is normal. If
a metal-to-metal, continuous grinding or
continuous squeal sound is present, the
brake linings may be worn-out. Have the
system checked by an authorized dealer. If
your vehicle has continuous vibration or
shudder in the steering wheel while braking,
have it checked by an authorized dealer.
All standard equipment brakes are
self-adjusting. Automatic adjustment,
when required, occurs whenever you apply
and release the brakes during forward or
reverse operation.
Know the required stopping distances for
all driving conditions you may encounter.
For longer brake lining life, take full
advantage of engine braking power when
coming to a stop. See Warning Lamps and
Indicators (page 60).
Wet brakes result in reduced braking
efficiency. Gently press the brake pedal a
few times when driving from a car wash or
standing water to dry the brakes.
If brakes do not grip well:
• Check brake adjustment.
• Check brake linings for excessive wear.
• Check system air pressure on vehicle
equipped with air brakes. •
Let the brakes cool if you have been
using them excessively, as in mountain
driving or after several fast, high-speed
stops.
• If you have been driving through deep
water, gently apply the brakes several
times while your vehicle is moving
slowly.
Brake Over Accelerator
In the event the accelerator pedal
becomes stuck or entrapped, apply steady
and firm pressure to the brake pedal to
slow the vehicle and reduce engine power.
If you experience this condition, apply the
brakes and bring your vehicle to a safe
stop. Move the transmission to park (P),
switch the engine off and apply the parking
brake. Inspect the accelerator pedal for
any interference. If none are found and the
condition persists, have your vehicle towed
to the nearest authorized dealer
Anti-lock Brake System
This system helps you maintain steering
control during emergency stops by keeping
the brakes from locking. This lamp momentarily
illuminates when you turn the
ignition on. If the light does not
illuminate during start up, remains on or
flashes, the system may be disabled. Have
the system checked by an authorized
dealer. If the system is disabled, normal
braking is still effective. If the
brake warning lamp illuminates
when you release the parking brake, have
the system checked by an authorized
dealer.
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Releasing Spring Manually
WARNINGS
Do not attempt to disassemble the
parking brake air chamber under any
circumstances as this may cause
serious injury. Block the wheels to help prevent the
vehicle from moving.
Unexpected and possibly sudden
vehicle movement may occur if you
do not take these precautions.
If you release hydraulic pressure from the
spring brake chamber, the power spring
applies the brake. If the hydraulic pressure
can be re-established, you must release
the spring brake in order to move your
vehicle.
Air Brakes (If Equipped)
WARNING
This control is for parking only. Do
not leave the vehicle unattended
after setting the parking brake
without placing the transmission in park
(P). We recommend using wheel chocks
for hilly or off-road circumstances. If the service brakes fail to operate while
your vehicle is moving, you can make an
emergency stop with the parking brake.
Since the parking brake only applies
stopping power to the rear wheels, your
vehicle
’s stopping distance greatly
increases and the handling of your vehicle
is adversely affected. Make repairs
immediately to an inoperative air brake
system circuit. Pull the yellow, dash-mounted parking
brake knob to apply the parking brake.
The parking brake light
illuminates and remains
illuminated (when you switch
the ignition to the on position) until you
release the parking brake.
Releasing the Parking Brake WARNING
When your vehicle is stationary, keep
the brake pedal fully pressed when
shifting gears. Failure to follow this
instruction could result in personal injury,
death or property damage. Note:
Read and understand the following
steps and perform them whenever you
prepare to drive the vehicle.
Note: The parking brake does not disengage
unless sufficient system air pressure is
available.
1. Press and hold the service brake pedal
while the engine is running.
2. Select the appropriate drive gear.
3. Push and hold the yellow dash-mounted parking brake knob until
the parking brake light turns off, then
release.
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AIR BRAKES (If Equipped)
WARNINGS
Do not drive or continue to drive if the
low air pressure buzzer is sounding
or the brake warning light is lit. These
warnings indicate that air pressure is not
to normal operating level. Continued use
of the vehicle could result in loss of braking
ability. Avoid repeated light application of
the brake pedal. This depletes air
pressure faster and could result in
loss of braking capability. Do not move the vehicle when the
air pressure is insufficient because
the brake system may be inoperative.
After starting the engine, give the air
compressor time to build up the air
pressure to
60 psi (414 kPa) before moving
your vehicle. Periodically check the air pressure gauge
while driving. Pressure should range
between approximately 100 psi (690 kPa)
to
130 psi (896 kPa). The air compressor
governor cut-in and cutout pressure
settings are set at the factory and are not
adjustable. When air pressure is insufficient
(below
60 psi (414 kPa)), a
warning light illuminates and a
buzzer sounds when the ignition is in the
on position. This may happen because
excessive brake applications are depleting
the system air pressure. If this condition
occurs, stop driving your vehicle until the
compressor has fully recharged the air
system.
Select a gear ratio to help slow your vehicle
before descending grades. Supplementing
with brakes, as required, help to safely slow
the vehicle and avoids overspeeding the
engine.
Air Chamber Stroke Indication
Air chamber push rods have orange stroke
indicator markers that warn when the
braking system requires adjustment or
repair. The painted orange indicator is on
the air chamber push rod at the slack
adjuster stroke dimension that requires
service when visible during brake
application.
A qualified service technician should
perform air brake inspection and
adjustment or repairs keeping to the
instructions in the service manual.
Cam Brakes - Automatic Slack
Adjusters WARNING
Do not manually adjust the
automatic slack adjusters to correct
excessive push rod stroke as it may
result in reduced brake effectiveness and
a vehicle crash. Excessive push rod stroke
indicates that a problem exists with the
automatic adjuster, with the installation
of the adjuster, or with foundation brake
components that manual adjustment does
not remedy. Seek service from a qualified
facility for excessive push rod stroke. 125
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Standard air brakes (cam) are equipped
with automatic brake adjusters. Automatic
adjustment occurs during brake
applications. Inspect brakes for proper
adjustment at the specified intervals. See
Scheduled Maintenance (page 320).
Emergency Air Brake WARNING
Do not continue to operate the
vehicle with a failure of one of the
brake systems. Take the vehicle to
your dealer for service immediately. All vehicles are equipped with a dual brake
system. In the unlikely event of a failure of
one system, the second system functions
for emergency stopping. The brake pedal
controls all these systems in the same
manner as for normal stops.
EXHAUST BRAKE
(If Equipped)
WARNINGS
Do not use tow/haul when the road
surface is slippery. Failure to follow
this instruction could result in the
loss of control of your vehicle. WARNINGS
Do not use diesel engine exhaust
braking when the road surface is
slippery. Failure to follow this
instruction could result in the loss of
control of your vehicle. Note:
Installing an exhaust or auxiliary
brake does not necessarily protect the
engine from exceeding the maximum
governed speed. Use the primary brakes to
make sure the engine never exceeds the
maximum governed speed under any
circumstance.
Note: Before starting the engine, make sure
that the exhaust brake is off. Do not switch
the exhaust brake on until the engine has
reached normal operating temperature.
Note: Maximum exhaust brake
performance relates to the type of
transmission your vehicle has.
Note: Engine speed has a major influence
on limiting performance. When engine
speed stays at the maximum allowable
level, the exhaust brake operates at peak
performance.
Note: Exhaust brakes operate effectively
with automatic transmissions. However,
performance varies with engine speed and
the gear selected by the transmission.
An exhaust brake is an auxiliary braking
system that assists, but does not replace,
the primary brake system. It helps control
vehicle speed. It is not a vehicle-stopping
device.
Use the button on the instrument panel, in
combination with the accelerator and
clutch pedals, to maximize the use of the
exhaust brake in the following conditions:
• Off-highway driving.
• Mountain driving.
• Heavy traffic.
• High-speed highway driving.
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To switch the exhaust brake on, press the
button. A light on the instrument cluster
indicates the system is on. Press the button
again to switch it off.
While approaching a steep grade, make
sure that the exhaust brake switch is on.
The exhaust brake begins working as soon
as you remove your foot from the
accelerator pedal.
Before descending a hill or steep grade,
always select the proper gear. If you take
the transmission out of gear while
descending, you may not be able to select
another gear because of maximum
governed RPM.
Make sure the engine speed does not
exceed the maximum allowable engine
RPM. Exceeding the maximum allowable
engine RPM can result in damage to the
engine. Apply the service brakes to reduce
the engine RPM or make a slower descent
by using a lower gear. While driving down a grade, use a low
enough gear to descend safely with a
minimum application of the service brakes.
As a general guideline, use the same gear
as you use to ascend the hill.
Exhaust Brake Operating
Characteristics
The exhaust brake switches on when you
remove your feet from both the accelerator
and clutch pedals and the exhaust brake
is on.
If the brake is working properly, there will
be:
•
A slight change in engine sound when
the exhaust brake turns on.
• A smooth braking effect. Do not expect
a retarding effect similar to sudden,
hard application of the service brakes.
• A retarding force possibly felt acting
against your body during brake
application (depending on the grade
and vehicle load). This force prevents
the vehicle from going much faster.
• Engine temperatures remaining in the
normal operating range.
• A drop in engine RPM (depending on
grade and vehicle load) during a
descent.
• A decrease in road speed when
applying the exhaust brake during a
descent, except when your vehicle is
carrying a heavy load or the grade is
extremely steep. In these instances,
you may need to apply the service
brakes occasionally.
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PRINCIPLE OF OPERATION
The traction control system helps avoid
drive wheel spin and loss of traction.
If your vehicle begins to slide, the system
applies the brakes to individual wheels
and, when needed, reduces engine power
at the same time. If the wheels spin when
accelerating on slippery or loose surfaces,
the system reduces engine power in order
to increase traction.
Note:
The system does not apply the brakes
when vehicle speed is above 25 mph
(40 km/h).
USING TRACTION CONTROL -
VEHICLES WITH: AIR BRAKES WARNING
The stability and traction control
light illuminates steadily if the
system detects a failure. Make sure
you did not manually disable the traction
control system using the information
display controls or the switch. If the
stability control and traction control light
is still illuminating steadily, have the
system serviced by an authorized dealer
immediately. Operating your vehicle with
the traction control disabled could lead to
an increased risk of loss of vehicle control,
vehicle rollover, personal injury and death. Use the traction control switch on the
instrument panel to select Mud/Snow
traction mode.
This is beneficial when your vehicle is stuck
in snow or on a slippery road surface. This
mode allows wheel spin to dig your vehicle
out and allows you to rock your vehicle.
Press the switch again to select standard
traction control. The system automatically
selects standard traction control at the
next ignition cycle. System Indicator Light
Note:
If the traction control light does not
flash during a traction control event or stays
illuminated, the system is not functioning
properly. Take your vehicle to an authorized
dealer for service.
During traction control operation, the
traction control light flashes rapidly and
the engine does not rev-up when you press
further on the accelerator. This is normal
and is no reason for concern.
In Mud/Snow mode, the traction control
light illuminates and flashes slowly. If a
traction event occurs in either mode, the
light flashes rapidly.
USING TRACTION CONTROL -
VEHICLES WITH: HYDRAULIC
BRAKES WARNING
Aggressive driving in any road
conditions can cause you to lose
control of your vehicle increasing the
risk of severe personal injury or property
damage. The occurrence of a traction
control event is an indication that at least
some of the tires have exceeded their
ability to grip the road; this may lead to an
increased risk of loss of vehicle control,
vehicle rollover, personal injury and death.
If you experience a severe road event,
SLOW DOWN. The system automatically turns on each
time you switch the ignition on.
Use the traction control switch on the
instrument panel to switch the system off
or on.
If your vehicle is stuck in mud or snow,
switching traction control off may be
beneficial as this allows the wheels to spin.
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(If Equipped)

Press the switch again to enable the
traction control system.
System Indicator Light
Note:
If the traction control light does not
flash during a traction control event or stays
illuminated, the system is not functioning
properly. Take your vehicle to an authorized
dealer for service.
During traction control operation, the
traction control light flashes rapidly and
the engine does not rev-up when you press
further on the accelerator. This is normal
and is no reason for concern.
When traction control is disabled, the
traction control light illuminates and
flashes slowly.
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PRINCIPLE OF OPERATION
WARNINGS
Vehicle modifications involving
braking system, aftermarket roof
racks, suspension, steering system,
tire construction and wheel and tire size
may change the handling characteristics
of your vehicle and may adversely affect
the performance of the electronic stability
control system. In addition, installing any
stereo loudspeakers may interfere with
and adversely affect the electronic stability
control system. Install any aftermarket
stereo loudspeaker as far as possible from
the front center console, the tunnel, and
the front seats in order to minimize the risk
of interfering with the electronic stability
control sensors. Reducing the
effectiveness of the electronic stability
control system could lead to an increased
risk of loss of vehicle control, vehicle
rollover, personal injury and death. Remember that even advanced
technology cannot defy the laws of
physics. It's always possible to lose
control of a vehicle due to inappropriate
driver input for the conditions. Aggressive
driving on any road condition can cause
you to lose control of your vehicle
increasing the risk of personal injury or
property damage. Activation of the
electronic stability control system is an
indication that at least some of the tires
have exceeded their ability to grip the road;
this could reduce the operator's ability to
control the vehicle potentially resulting in
a loss of vehicle control, vehicle rollover,
personal injury and death. If your electronic
stability control system activates, SLOW
DOWN. The system automatically turns on each
time you switch the ignition on. If a fault occurs in either the stability
control or the traction control system, you
may experience the following conditions:
•
The stability and traction control light
illuminates steadily.
• The stability control and traction
control systems do not enhance your
vehicle's ability to maintain traction of
the wheels.
Vehicles With: Hydraulic Brakes
If a driving condition activates either the
stability control or the traction control
system you may experience the following
conditions:
• The stability and traction control light
flashes rapidly.
• Your vehicle slows down.
• Reduced engine power.
• A vibration in the brake pedal.
• The brake pedal is stiffer than usual.
• If the driving condition is severe and
your foot is not on the brake, the brake
pedal may move as the system applies
higher brake force.
Vehicles With: Air Brakes
If a driving condition activates either the
stability control or the traction control
system you may experience the following
conditions:
• The stability and traction control light
flashes rapidly.
• Your vehicle slows down.
• Reduced engine power.
The stability control system has several
features built into it to help you maintain
control of your vehicle:
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Electronic Stability Control
The system enhances your vehicle
’s ability
to prevent skids or lateral slides by
applying brakes to one or more of the
wheels individually and, if necessary,
reducing engine power.
Roll Stability Control
The system enhances your vehicle ’s ability
to prevent rollovers by detecting your
vehicle ’s motion and the rate at which it
changes by applying the brakes to one or
more wheels individually.
Traction Control
The system enhances your vehicle ’s ability
to maintain traction of the wheels by
detecting and controlling wheel spin. See
Using Traction Control (page 132). Vehicle without stability control
skidding off its intended route.
A
Vehicle with stability control
maintaining control on a slippery
surface.
B USING STABILITY CONTROL
The system automatically turns on each
time you switch the ignition on.
You cannot switch the stability control and
roll stability control systems off, but when
you shift into reverse (R), the systems
deactivate.
You can switch the traction control system
off or on.
See Traction Control (page 132).
Limitations of the Stability System
Stability Control effectiveness may be
greatly reduced if:
• Your load shifts due to improper
retention, accident damage or the
inherently mobile nature of some loads,
for example, hanging meat, live
animals or partially laden tankers.
• Your vehicle or load has an unusually
high or off-set center of gravity (CG).
• Your brakes are not properly adjusted
or maintained.
• One side of your vehicle drops off the
pavement at an angle that is too great
to be counteracted by a reduction in
speed.
To Maximize the Effectiveness Of
Stability Control
• Make sure that the weight of your load
is evenly distributed, from front to back,
side to side and you secure it properly
at all times.
• Exercise extreme caution at all times
while driving and avoid sharp turns,
sudden steering inputs or abrupt lane
changes at high speeds, particularly if:
•Hauling loads that can shift.
• Your vehicle or load has a high or
off-set center of gravity when
loaded.
• You are towing doubles or triples.
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(If Equipped)E72903A
AA
B
BB
B

STEERING
To help prevent damage to the power
steering system:
•
Never hold the steering wheel at its
furthest turning points (until it stops)
for more than three to five seconds
when the engine is running.
• Do not operate the vehicle with a low
power steering pump fluid level (below
the MIN mark on the reservoir).
• Some noise is normal during operation.
If excessive, check for low power
steering pump fluid level before
seeking service by your dealer.
• Heavy or uneven efforts may be caused
by low power steering fluid. Check for
low power steering pump fluid level
before seeking service by your dealer.
• Do not fill the power steering pump
reservoir above the MAX mark on the
reservoir, as this may result in leaks
from the reservoir.
If the power steering system breaks down
(or if the engine is turned off), you can
steer the vehicle manually, but it takes
more effort.
Operating the steering system excessively
at an elevated engine RPM (>1200 rpm)
for more than 2 minutes can result in
steering system damage from overheating.
Move the steering wheel to the full left
position then full right position at idle
speed, or stop using the system for 2
minutes to allow the system to cool down.
If the power steering system exhibits heavy
or uneven efforts, check for the following
before seeking service from your dealer:
• An improperly inflated tire.
• Overloading of front suspension.
• Uneven vehicle loading.
• Binding suspension components. If the power steering system wanders or
pulls, check for:
•
An improperly inflated tire.
• Uneven vehicle loading.
• Uneven tire wear.
• Loose or worn suspension
components.
• Loose or worn steering components.
• Improper vehicle alignment.
• High crosswinds.
If any steering components are serviced or
replaced, install new fasteners (many are
coated with thread adhesive or have
prevailing torque features which may not
be re-used). Never re-use a bolt or nut.
Torque fasteners to specifications.
A high crown in the road or high crosswinds
may also make the steering seem to
wander or pull.
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