brakes FORD F-650/750 2022 Service Manual

Front brakes
Inspect for cracked, worn or frayed hoses, and that all coup-
lings are secure.
Hoses
Verify that there are no cracks or dents, and that the cham-
bers are securely mounted.
Brake chambers
Inspect for broken, loose or missing parts.
Slack adjusters
Note: The angle between the push rod and adjuster arm
should be approximately 90 degrees when the brakes are
applied. When pulled by hand, the push rod should not move
more than approximately
1 in (2.5 cm).
Verify that there are no cracks, dents, holes, and no loose or
missing bolts and that the brake linings are not worn,
dangerously thin or contaminated by lubricant.
Drums Front wheels
Inspect for damaged or bent rims. They should not have
welding repairs, and there should be no rust trails, which
indicate it is loose on the wheel.
Rims
Verify all lug nuts are present and not loose (look for rust
trails around the lug nuts). There should be no cracks radiating
from the lug bolt holes or distortion of the bolt holes.
Lug nuts
Inspect wheel hub oil seal for leaks and, if sight glass if
present, verify the oil level is adequate.
Hub oil seals
Inspect for proper lubrication level if the hubcap has a trans-
parent window. If the hubcap does not have a transparent
window, remove the rubber fill-plug and inspect for proper
level.
Oil-lubricated front
wheel bearings Fuel area
Verify the tank(s) and cap(s) are secure and that there are
no leaks from the tank(s).
Fuel tank(s)
Inspect for leaks from the tank(s).
Leaks
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Rear brakes
Inspect for cracked, worn or frayed hoses, and that all coup-
lings are secure.
Hoses
Verify that there are no cracks or dents, and that the cham-
bers are securely mounted.
Brake chambers
Inspect for broken, loose or missing parts.
Slack adjusters
Note: The angle between the push rod and adjuster arm
should be approximately 90 degrees when the brakes are
applied. When pulled by hand, the push rod should not move
more than approximately
1 in (2.5 cm).
Verify that there are no cracks, dents, holes, and no loose or
missing bolts and that the brake linings are not worn,
dangerously thin or contaminated by lubricant.
Drums Rear wheels
Check for even separation of dual wheels, and that the tires
are not touching each other.
Spacers
Inspect for damaged or bent rims. They should not have
welding repairs, and there should be no rust trails, which
indicate it is loose on the wheel.
Rims
Verify all lug nuts are present and not loose (look for rust
trails around the lug nuts). There should be no cracks radiating
from the lug bolt holes or distortion of the bolt holes.
Lug nuts
Trailer
If you are pulling a trailer, perform an
inspection of the trailer similar to that of
the tractor. The inspection should follow
trailer manufacturer recommendations
and should include at a minimum: general
condition, landing gear, doors, sides, lights,
reflectors, suspension, brakes, tires,
wheels, cargo placement, stability and
tie-downs. Transmission WARNING:
If the unit starts in gear
and/or the neutral start switch is not
functioning correctly, the vehicle may
inadvertently move which could result
in property damage, personal injury or
death.
Regularly inspect the transmission's
neutral start switch. The engine should
only start in neutral (N) or park (P) (if
equipped with a park position).
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GENERAL INFORMATION
WARNING: Making modifications
to various parts, components and
systems of the vehicle, such as brake and
steering systems, can adversely affect
the quality, reliability and operation of
your vehicle and could result in property
damage, personal injury or death. Such
modifications must be avoided. WARNING:
Failure to properly
perform maintenance and servicing
procedures could result in vehicle
damage, personal injury or death. WARNING:
Take care when
performing any maintenance, system
check or service on your vehicle. Some
of the materials may also be hazardous
if used, serviced or handled improperly
and could result in property damage,
personal injury or death.
If the owner or operator of the vehicle is a
skilled technician and intends on
performing the vehicle maintenance and
service, he is strongly urged to purchase a
service manual.
Always use care when performing vehicle
maintenance, repairs or system checks.
Improper or incomplete service could result
in your vehicle not working properly which
may result in personal injury or damage to
your vehicle or equipment. It is the
operator ’s responsibility to see that your
vehicle receives proper care and
maintenance. If you have any questions
about performing service, have the service
done by a qualified technician.
To help you service your vehicle, we
provide scheduled maintenance
information which makes tracking routine
service easy. See
Scheduled
Maintenance (page 321). If your vehicle requires professional service,
an authorized dealer can provide the
necessary parts and service. Check your
warranty information to find out which
parts and services are covered.
Use only recommended fuels, lubricants,
fluids and service parts conforming to
specifications. Motorcraft® parts are
designed and built to provide the best
performance in your vehicle.
Servicing Guidelines
WARNING: The use of inferior parts
can adversely affect the quality and
reliability of your vehicle and could result
in property damage, personal injury or
death.
When servicing your vehicle:
• Always wear safety glasses for eye
protection.
• Always set the parking brake or chock
the wheels.
• Always use support stands, not a jack,
when working under a raised vehicle.
• Always turn off the ignition unless a
procedure requires the engine to be
running.
• Always avoid contact with hot metal
parts. Allow the components to cool
before working with, or around, them.
• Always operate the engine in a
well-ventilated area.
• Do not wear loose-fitting clothing,
hanging jewelry, watches or rings.
• Do not smoke.
• Do not work on the brakes or the clutch
unless you take the proper precautions
to avoid inhaling friction material dust.
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Air Brakes
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.
Inspection and Adjustment
Establish a regular schedule for periodic
cleaning, lubrication and adjustment
inspection based on vehicle use. Exact
maintenance intervals are difficult to
predetermine due to vehicle applications
and operating conditions. If you are
uncertain of the proper schedule for your
vehicle, contact an authorized dealer.
Regular inspections should include:
• Periodic checking (every service
interval) of push rod travel or brake
adjustment. This is essential for
effective braking. Brake chamber push
rods on original equipment chambers
now incorporate an orange paint
marker near the base of the push rod as a stroke indicator to aid in
adjustment checks. If the push rod is
clean and the brakes are out of
adjustment, you can see the orange
marker protruding from the chamber
when the brakes are applied.
• Checking the brake lining (every service
interval). When brake linings or blocks
wear within 0.063 in (1.6 mm) they
must be replaced.
• Periodic checking (every service
interval) of the air compressor filter.
Check the filter minder and when the
indicator is near or on the red line
marked
Service, replace the filter and
reset the service filter minder.
Do not back off or disconnect the front
brakes so that they are less effective,
letting the rear brakes do all the stopping
of your vehicle. Do not overlook the brakes
on the trailer either. Brake condition on the
trailer is just as important as the tractor.
Proper brake balance on trucks and
tractor-trailers is essential for effective
braking.
Once a year, inspect the entire brake
system:
• Rubber components for deterioration.
A qualified technician should inspect
these components and replace them
as necessary. Replacement intervals
vary according to the severity and
length of vehicle service.
• Condition of brake drums, brake
chambers and slack adjusters.
• System for air leaks.
• Hose or pipes for rust, damage and
deterioration.
• Operation of service and parking
brakes.
Periodically inspect parts such as air brake
chamber diaphragm, air compressor and
air cleaner. Replace any parts if you can
consider them unserviceable.
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Air Dryer
Climactic conditions affect performance
of desiccant or after-cooler type air dryers.
You must establish a maintenance
schedule for each specific operation.
The use of an air dryer on a vehicle does
not eliminate the need to drain the air
reservoirs periodically.
Inspect for moisture in the air system by
opening reservoirs, draincocks or valves
and checking for presence of water. The
presence of small amounts of water due
to condensation is normal and is not an
indication that the dryer is not functioning
properly.
Replace or rebuild the desiccant cartridge
when you determine that the desiccant is
contaminated and does not have adequate
water absorption capacity. The desiccant
change interval may vary. A general
recommendation is to replace the
desiccant every 12 months (yearly). If
experience has shown that extended or
shortened life has resulted for a particular
installation, then the yearly interval can be
increased or decreased accordingly.
Draining the Air Brake Reservoir
WARNING: Failure to drain air
brake reservoirs can result in a reduction
or loss of braking ability due to fluid
accumulation in the reservoir and/or
possible freeze-up during cold weather.
Completely drain all the air brake reservoirs
daily by opening the draincock at the ends
of the tanks. (Where accessible.
Pull-chains are used when the drains are
undercab or otherwise inaccessible.) Close
the draincock after draining. Manually drain any air tanks equipped with automatic
moisture ejector valves, as required, to
maintain a dry air system. Contact an
authorized dealer if you are unsure of the
air reservoir locations or the draining
procedure.
Hydraulic Brakes
Establish a regular schedule for periodic
cleaning, lubrication and adjustment
inspection based on vehicle use. Exact
maintenance intervals are difficult to
predetermine due to vehicle applications
and operating conditions. If you are
uncertain of the proper schedule for your
vehicle, contact an authorized dealer.
Regular inspections should include:
•
Checking the brake lining (every service
interval). Establish inspection intervals
that provide for lining replacement
before damage to the disc occurs.
Excessive lining wear may expose the
backing plate to the disc causing
scoring of the disc faces. A qualified
technician should perform this
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•
With your foot on the brake, shift
through all the gears while the engine
is running.
• We recommend that you change the
engine oil before you use your vehicle
again.
Fuel system
• Fill the fuel tank with high-quality fuel
until the first automatic shutoff of the
fuel pump nozzle.
Cooling system
• Protect against freezing temperatures.
• When removing your vehicle from
storage, check coolant fluid level.
Confirm that there are no cooling
system leaks and that fluid is at the
recommended level.
Disconnecting Your 12 Volt Battery
• Check and recharge as necessary. Keep
connections clean.
• If storing your vehicle for more than 30
days without recharging the battery,
we recommend that you disconnect
the battery cables to maintain battery
charge for quick starting.
Note: It is necessary to reset memory
features if you disconnect the battery
cables.
Brakes
• Make sure the brakes and parking brake
release fully.
Tires
• Maintain recommended air pressure. Miscellaneous
•
Make sure all linkages, cables, levers
and pins under your vehicle are covered
with grease to prevent rust.
• Move vehicles at least 25 ft (7.5 m)
every 15 days to lubricate working parts
and prevent corrosion.
Removing Vehicle From Storage
When your vehicle is ready to come out of
storage, do the following:
• Wash your vehicle to remove any dirt
or grease film build-up on window
surfaces.
• Check windshield wipers for any
deterioration.
• Check under the hood for any foreign
material that may have collected
during storage such as mice or squirrel
nests.
• Check the exhaust for any foreign
material that may have collected
during storage.
• Check tire pressures and set tire
inflation per the Tire Label.
• Check brake pedal operation. Drive
your vehicle
15 ft (4.5 m) back and
forth to remove rust build-up.
• Check fluid levels (including coolant,
oil and gas) to make sure there are no
leaks, and fluids are at recommended
levels.
• If you remove the battery, clean the
battery cable ends and check for
damage.
Contact an authorized dealer if you have
any concerns or issues.
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Alternative Rear Axle Fluid for
Severe Duty Service
Materials
Specification
Name
WSL-M2C192-A
Motorcraft® SAE 75W-140 Synthetic Rear Axle
Lubricant(U.S.)
Motorcraft® SAE 75W-140 Synthetic Rear Axle
Lubricant / Lubrifiant synthétique pour pont arrière
SAE 75W-140 Motorcraft®(Canada)
XY-75W140-QL(U.S.)
CXY-75W140-1L(Canada)
HYDRAULIC POWER
STEERING FLUID CAPACITY
AND SPECIFICATION
Use oil and fluid that meets the defined
specification and viscosity grade. If you do not use oil and fluid that meets
the defined specification and viscosity
grade, it could result in:
•
Component damage that your vehicle
warranty does not cover.
• Longer engine cranking periods.
• Increased emission levels.
• Reduced engine performance.
• Reduced fuel economy.
• Reduced brake performance.
Capacities Quantity
Variant
5.2 qt (4.9 L)
With air brakes.
6.1 qt (5.8 L)
With hydraulic brakes.
Materials Specification
Name
WSS-M2C938-AMERCON® LV,
Motorcraft® MERCON® LV Automatic Transmission
Fluid(U.S.)
Motorcraft® MERCON® LV Automatic Transmission
Fluid / Huile pour boîte automatique MERCON® LV
Motorcraft®(Canada)
XT-10-QLVC(U.S.)
CXT-10-LV6(Canada)
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There are three types of maintenance
intervals for general vehicle environments:
On-Highway, City and Severe Service. In
all applications, monitoring miles
(kilometers) and time and when the engine
is due for an oil change determine the
actual interval. When the engine oil change
is required before the truck lubrication
interval, perform the lubrication at the
same time in order to reduce your vehicle
’s
time out of service.
Air Brake Adjustment WARNING: Failure to maintain
proper air brake adjustment can result
in reduction or loss of braking ability.
A qualified service technician, keeping to
the instructions in the service manual,
should perform air brake inspection and
adjustment or repairs.
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.
Inspect standard air brakes equipped with
automatic slack adjusters for proper brake
adjustment as listed in the maintenance
schedule charts.
However, inspect the brakes more
frequently when subjecting them to heavy
use or adverse operating conditions such
as:
• Frequent brake applications while fully
loaded.
• Operation on hilly or mountainous
terrain.
• Frequent operation on dirt, gravel or
mud.
Some aftermarket brake linings also
require more frequent inspections.
Owner Checks and Services
Make sure you perform the following basic
maintenance checks and inspections every
month or at six-month intervals. Check Every Month
Air filter restriction gauge. 1
Engine oil level.
Fuel and water separator. Drain if necessary, or if indicated by the information display. 1
Function of all interior and exterior lights.
Holes and slots in the tail pipe to make sure they are functional and clear of debris. 1
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2
2-Speed Rear Axle.......................................135
A
A/C See: Climate Control........................................... 85
About This Manual
...........................................7
ABS See: Brakes........................................................... 136
ABS driving hints See: Hints on Driving With Anti-Lock
Brakes................................................................. 137
Accessories......................................................317
Accessories See: Replacement Parts
Recommendation............................................. 17
ACC See: Using Adaptive Cruise Control.............154
Adjusting the Headlamps........................246
Adjusting the Steering Wheel.....................51
Air Brakes
..........................................................141
Air Conditioning See: Climate Control........................................... 85
Air Conditioning System Capacity and Specification - 6.7L Diesel
....................298
Air Conditioning System Capacity and Specification - 7.3L..................................299
Air Filter See: Changing the Engine Air Filter - 6.7L
Diesel.................................................................. 227
See: Changing the Engine Air Filter - 7.3L..................................................................... 229
Air Induction System Inspection............253
Air Suspension
...............................................175
Appendices....................................................345
At a Glance
.......................................................23
Audible Warnings and Indicators.............69
Audio Input Jack............................................314
Audio System...............................................308 General Information......................................... 308
Audio Unit
......................................................308
Autolamps........................................................55
Automatic High Beam Control.................56
Automatic Transmission
............................128
Automatic Transmission Fluid Capacity and Specification
.....................................300 Automatic Transmission Fluid
Check
..............................................................241
Auxiliary Power Points.................................95
Auxiliary Switches.........................................317
Axle Inspection..............................................257
B
Battery See: Changing the 12V Battery..................... 245
Bonnet Lock See: Opening and Closing the Hood...........219
Booster Seats
..................................................32
Brake Fluid Check........................................243
Brake Fluid Specification...........................301
Brakes...............................................................136 General Information.......................................... 136
Brake System Inspection
..........................254
Breaking-In......................................................185
Bulb Specification Chart
..........................290
C
Canceling the Set Speed
............................161
Capacities and Specifications...............286
Car Wash See: Cleaning the Exterior.............................. 262
Catalytic Converter
.......................................116
Changing a Bulb...........................................249
Changing a Fuse...........................................207
Changing a Road Wheel
...........................283
Changing the 12V Battery.........................245
Changing the Engine Air Filter - 6.7L Diesel.............................................................227
Changing the Engine Air Filter - 7.3L.................................................................229
Changing the Engine-Mounted and Diesel Fuel Conditioner Module Fuel
Filters - 6.7L Diesel...................................250
Changing the Engine Oil and Oil Filter...............................................................225
Changing the Wiper Blades
.....................248
Charging a Device..........................................98
Checking the Wiper Blades.....................248
Child Restraint and Seatbelt Maintenance.................................................44
Child Restraint Positioning
.........................34
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Engine Oil Capacity and Specification -
6.7L Diesel...................................................290
Engine Oil Capacity and Specification - 7.3L.................................................................293
Engine Oil Check - 6.7L Diesel.................223
Engine Oil Check - 7.3L..............................224
Engine Oil Dipstick - 6.7L Diesel.............223
Engine Oil Dipstick - 7.3L...........................223
Engine Specifications - 6.7L Diesel............................................................286
Engine Specifications - 7.3L.....................287
Entering, Exiting or Climbing on This Vehicle
.............................................................20
Environment......................................................21
Essential Towing Checks
...........................179
Event Data Recording See: Data Recording............................................. 13
Exhaust Brake................................................142
Exhaust System Inspection.....................254
Export Unique Options................................20
Exterior Mirrors...............................................60
F
Fastening the Seatbelts..............................38
Federal Highway Administration Regulation......................................................20
Fifth Wheel Operation...............................180
Flat Tire See: Changing a Road Wheel....................... 283
Ford Credit
..........................................................17
Ford Protect....................................................319
Frame and Tow Hook Inspection..........259
Front Seat Armrest........................................94
Fuel and Refueling.......................................105
Fuel Consumption.........................................112
Fuel Filter - 7.3L
............................................248
Fuel Quality - Diesel....................................106
Fuel Quality - Gasoline..............................109
Fuel Shutoff
...................................................188
Fuel Tank Capacity - Diesel.....................296
Fuel Tank Capacity - Gasoline................297
Fuel Tank Selector Switch..........................114
Fuses.................................................................199
Fuse Specification Chart...........................199 G
Gauges...............................................................63
Gearbox
See: Transmission.............................................. 128
General Driving Points
................................182
General Information on Radio Frequencies...................................................45
General Maintenance Information
.........321
Getting Assistance Outside the U.S. and Canada..........................................................196
Getting the Services You Need................193
H
Handbrake See: Parking Brake.............................................. 137
Hazard Flashers
............................................188
Headlamp Adjusting See: Adjusting the Headlamps..................... 246
Headlamp Exit Delay....................................55
Headlamp Removal See: Removing a Headlamp.......................... 249
Headrest See: Head Restraints.......................................... 88
Head Restraints
..............................................88
Heated Exterior Mirrors................................87
Heating See: Climate Control........................................... 85
Hill Start Assist.............................................140
Hints on Controlling the Interior Climate
...........................................................86
Hints on Driving With Anti-Lock Brakes.............................................................137
Hood Lock See: Opening and Closing the Hood...........219
Horn
.....................................................................52
Hydraulic Power Steering Fluid Capacity and Specification.....................................304
I
Ignition Switch
..............................................100
In California (U.S. Only).............................194
Information Display Control.......................52
Information Displays
.....................................70
General Information............................................ 70
Information Messages..................................74
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2022 F650750 (TBC) , enUSA, Edition date: 202010, Second-Printing Index