engine FORD F650 2003 10.G Owners Manual

SCHEDULED MAINTENANCE GUIDE
MAINTENANCE SERVICES AND RECORD RETENTION
The maintenance record form which follows is for your convenience. In addition to recording the services performed, you should
retain copies of your receipts for the services. You also should keep records of any emission control systems maintenance
services performed on your vehicle.
Maintenance Record
Warranty
Start Date ______________________________________ Engine Displacement ______________________________________
Vehicle
Identification
Number _________________________________________ Owner Name ___________________________________________
IMPORTANT — This document should remain with the vehicle at all times.
General Maintenance Information
231

Daily Owner Checks Engine system
Check the air filter restriction indicator
Check the engine oil
Inspect the coolant level - for Powerstroke
engine (for Caterpillar and Cummins engines,
refer to the Owner’s Manual)
Brake system
Drain the air brake system reservoir - manual
valve
Check the air brake system reservoir
automatic drain valve operation
Transmission system
Visually check the automatic transmission 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,
Federal Highway Administration
requirements (ensure that the entire
system is functioning properly)
Check the service brakes
Check the parking brake
Check the steering mechanism
Check the lighting devices and reflectors
Check the tires
Check the horn
Check the windshield wipers
Check the rear vision mirrors
Check the wheels and rims
Check the emergency equipment
General Maintenance Information
232

Check every oil change
Oil change intervals are as
follows: Powerstroke - 10 000
; Caterpillar - 15 000 ;
Cummins - 15 000 (refer to
the Caterpillar and Cummins
service manuals for further
instructions and information)Engine system
Check the engine cooling system - hoses, clamps and
protection
Inspect the drive belts
Exhaust system
Inspect the entire exhaust system (including the inlet
pipe(s), muffler(s), outlet pipe(s), clamps and fasteners)
for holes, leakage, breakage, corrosive damage and
separation from 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 rear spring U-bolts to the specified
torque
Driveline and rear axle system
Lubricate the U-joints and the slip yoke
Brake system
Lube the air brake foot control valve, hinge and roller
Inspect the drum brake linings through the inspection
holes
Lubricate the brake camshafts (air brakes)
Lubricate the brake slack adjuster (air brakes)
Lubricate rear caliper slide rails (F650 SuperCrewzer
only)
Inspect the disc brake pads and the piston boots
(hydraulic brakes)
Clutch system
Lubricate the clutch release cross shaft and all linkages
Check the clutch fluid
Fuel system
Drain the accumulated water or sediment from the fuel
tank(s)
Steering system
Lubricate the steering shaft(s), U-joints and splines when
equipped with grease fittings
Lubricate the front axle spindle pins
Lubricate the steering linkage when equipped with grease
fittings
Grease the power steering gear output shaft
General Maintenance Information
233

* Coolant protection checks should be made just prior to the onset 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 only permanent type coolant that meets Ford specifications ESE-M97B18-C.
See the engine manufacturer’s operating guide for supplimental corrosion inhibitor
specifications.
In addition to the items to be performed daily or at each oil change, the
following need to be completed as specified:
8 000KM / 5 000 MILES
•Initial change—change the lubricant in the manual shift transmission
–5 speed and 6 speed Eaton manual transmission. (Not required
when equipped with optional synthetic lubricant.)
32 000 KM / 20 000 MILES
•Replace the fuel filter.*
50 000 KM / 30 000 MILES
•Replace the engine spin-on coolant filter.*
•Repack and adjust the front wheel bearings—grease-filled hubs.
65 000 KM / 40 000 MILES
•Replace the fuel filter.*
80 000 KM / 50 000 MILES
•Disassemble the single check valve (SC-2) and the automatic drain
valve (DB–2)—clean and inspect the valve for wear and
deterioration.
100 000 KM / 60 000 MILES
•Replace the engine spin-on coolant filter.*
•Oil filled front hubs—drain oil, adjust bearings and refill the front
hubs with oil. (Not required when equipped with optional synthetic
lubricant.)
•Drain the oil, adjust the bearing and refill with axle lubricant—oil
filled hubs.
•Replace the fuel filter.*
•Change the manual transmission oil—Eaton 5 and 6 speeds only.
(Not required when equipped with optional synthetic lubricant.)
General Maintenance Information
234

110 000 KM / 70 000 MILES
•Replace the engine spin-on coolant filter.*
•Replace the engine coolant.* See the engine manufacturer’s operating
guide for supplemental corrosion inhibitor specifications.
130 000 KM / 80 000 MILES
•Replace the fuel filter.*
150 000 KM / 90 000 MILES
•Replace the engine spin-on coolant filter*.
•Repack and adjust the front wheel bearings—grease-filled hubs.
•Change the lubricant in the manual shift transmission–7 speed
Spicer. (Not required when equipped with optional synthetic
lubricant.)
•Change the power steering fluid and filter.
160 000 KM / 100 000 MILES
•Disassemble the single check valve (SC-3) and the automatic drain
valve (DB–2)—clean and inspect the valves for wear and
deterioration.
•Lube the clutch release and the cross shaft lever.
•Replace the fuel filter.*
•Change the rear axle lubricant. (Not required when equipped with
optional synthetic 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 check the
mounting of the dryer to the vehicle (if equipped).
Please continue with these scheduled maintenance intervals for your
vehicle.
* Shown intervals are for Powerstroke engine only. Refer to Caterpillar
and Cummins Owner Manuals for intervals for their respective engines.
General Maintenance Information
235

Maintenance Operation Frequency - Observation
Inspect the automatic slack
adjuster functionInsufficient power shown in loaded
practice stop
Check the operation of the
brakes, the clutch, and the
steering (*b,a)Vehicle handling qualities not up to
par
Inspect the vehicle for missing,
damaged, or mislocated noise
shieldsExcessive noise emanates from under
the cab or engine compartment
Check the engine performance
and the engine governorExcessive engine noise
Inspect the fan, the fan shroud,
and the fan clutchEngine overheats, fans runs at high
speed constantly, excessive fan noise,
or fan wobble due to worn bearings
Check for operation of ABS
warning lampAt 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
damageExcessive noise or the smell of fumes
is experienced
Inspect the engine air
induction system (including the
air ducts, the air cleaner, and
the air cleaner element) for
loose fitting, damaged or
missing componentsExcessive noise emanates from the
engine compartment
Inspect the tires and check the
air pressure (*c)Poor steering, wandering or excessive
tire wear
Balance the wheels and the
tiresVibration or abnormal tire wear
indicates imbalance
Check the front end alignment
(*c)Poor steering, wandering or excessive
tire wear
General Maintenance Information
237

Maintenance Operation Frequency - Observation
Check the transmission and
engine mountings (*b)Hard shifting or excessive vibration
Check and adjust transmission
controls (*b)High effort to shift or noisy
transmission
Check fuel pump pressure Insufficient full-throttle power or
backfiring
Clean radiator cap seal. Clean
and inspect the cap surface on
the radiatorWhen the cap does not hold pressure
Check the battery terminals for
corrosionWhenever electrical power supply has
diminished
Tighten the wheel mounting
nuts to the specified torque.
Refer toServicing your
wheels and tiresRequired 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
removal/replacement.
*a During maintenance and repair, protect the fuel tube and the hose
assemblies, the power steering lines, and the brake lines from the
external heat, the acids and the abrasion that could damage the lines.
*b Check for (free) linkage action and ensure that (return) spring
force is adequate to maintain pedal free play.
*c Adjust, repair or replace as required with the same or equivalent
parts.
General Maintenance Information
238

A
Air cleaner filter .......................206
Air conditioning
manual heating and air
conditioning system .................57
Audio system
(see Radio) ................20, 25, 32, 40
Automatic transmission ............132
Auxiliary power point .................73
B
Battery .......................................184
jumping a disabled battery ....165
voltage gauge ............................17
BeltMinder ...................................96
Brakes ................................113, 119
anti-lock ...................114–115, 121
anti-lock brake system
(ABS) warning light ...11–12, 115
brake warning light ............11–12
fluid, checking and adding ....203
parking ....................116, 118, 122
pedals (see Power
adjustable foot pedals) ............73
trailer .......................................124
C
CD-6 disc .....................................40
CD-single premium .....................32
Child safety restraints ..............101
child safety belts ....................101
Child safety seats ......................104
attaching with tether straps ..108
in front seat ............................106
in rear seat ..............................106
tether anchorage hardware ...108Cleaning your vehicle
engine compartment ..............175
exterior ....................................177
instrument panel ....................176
interior .....................................176
plastic parts ............................176
washing ....................................174
waxing .....................................174
wheels ......................................175
woodtone trim ........................176
Climate control (see Air
conditioning or Heating) ......56–57
Clock ..........................23, 29, 36, 44
Clutch ........................................202
fluid ..........................................202
Compass, electronic ....................70
calibration .................................72
set zone adjustment .................71
Console
overhead ....................................70
Controls
power seat .................................89
Coolant ......................................186
refill capacities ........................190
Cruise control
(see Speed control) ....................76
Customer Assistance ................150
Getting assistance outside
the U.S. and Canada ..............171
Getting roadside assistance ...150
Getting the service
you need .................................166
Ordering additional
owner’s literature ...................172
The Dispute Settlement
Board .......................................168
Index
243

D
Daytime running lamps
(see Lamps) ................................61
Driving under special
conditions
through water .........................148
E
Emergencies, roadside
jump-starting ..........................165
Emission control system ..........226
Engine
check engine/service engine
soon light ....................................9
cleaning ...................................175
coolant .....................................186
Engine block heater .................110
Engine fan .................................192
Engine oil ..................................180
checking and adding ..............180
oil pressure gauge ....................17
recommendations ...................181
Exhaust fumes ..........................112
F
Foglamps .....................................62
Fuel ............................................192
calculating fuel
economy ..........................198, 200
choosing the right fuel ...........193
filling your vehicle
with fuel ..................................192
filter, specifications ........194–196
gauge .........................................18
improving fuel
economy ..........................198, 200safety information relating
to automotive fuels ................192
Fuses ..................................151–152
G
Gas mileage
(see Fuel economy) .........198, 200
Gauges .........................................15
battery voltage gauge ...............17
engine coolant temperature
gauge .........................................16
engine oil pressure gauge ........16
fuel gauge ..................................18
odometer ...................................18
speedometer .............................18
tachometer ................................19
trip odometer ............................19
H
Hazard flashers .........................150
Headlamps ...................................61
aiming ........................................62
daytime running lights .............61
flash to pass ..............................61
high beam ...........................14, 61
turning on and off ....................61
warning chime ..........................15
Heating
heater only system ...................56
heating and air conditioning
system .......................................57
I
Ignition
removing the key ....................145
Infant seats
(see Safety seats) .....................104
Index
244

Instrument panel
cleaning ...................................176
lighting up panel
and interior ...............................62
J
Jump-starting your vehicle ......165
K
Keys
key in ignition chime ...............15
removing from the ignition ....145
L
Lamps ..........................................72
bulb replacement
specifications chart ..................64
cargo lamps ...............................62
daytime running light ...............61
fog lamps ...................................62
headlamps .................................61
headlamps, flash to pass ..........61
instrument panel, dimming .....62
interior lamps ...........................63
replacing bulbs ...................63–67
Lane change indicator
(see Turn signal) ........................63
Lights, warning and
indicator ..................................9, 14
anti-lock brakes
(ABS) ..........................11–12, 115
brake ....................................11–12
charging system ........................13
check coolant ......................12–13
high beam .................................14
safety belt .................................12
service engine soon ....................9
turn signal indicator .................14
Lubricant specifications ...........218M
Maintenance and Care ..............229
Manual transmission .................141
Mirrors .........................................75
heated ........................................73
side view mirrors (power) .......75
O
Odometer .....................................18
P
Panic alarm feature,
remote entry system ..................83
Parking brake ............116, 118, 122
Power distribution box
(see Fuses) ...............................155
Power door locks ........................82
Power mirrors .............................75
Power point .................................73
Power steering ..................130–131
fluid, checking and adding ....201
Power Windows ...........................74
R
Radio ..........................20, 25, 32, 40
Radio reception .....................54–55
Refill capacities for fluids ........215
Relays ................................151, 159
Remote entry system ...........82–83
illuminated entry ......................85
locking/unlocking doors .....82–83
panic alarm ...............................83
replacement/additional
transmitters ...............................84
Index
245