engine FORD F650 2003 10.G Service Manual

DRIVING WITH A MANUAL TRANSMISSION (IF EQUIPPED)
Continued use of a damaged or worn clutch, prolonged clutch
slippage or downshifting at excessive speeds can result in a
failure of the engine, transmission or clutch components.
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 light.
Manual transmission shift patterns
are displayed on the shift lever
knob.
Study this information carefully before you drive the vehicle even though
you may be familiar with similar units. Do not attempt to drive the
vehicle without knowing the exact shift pattern of the transmission.
Consult your authorized dealer if any questions exist as to the shifting
instructions posted in your vehicle.
Do not coast the vehicle with the clutch pedal depressed or with
the transmission in neutral. This practice could result in loss of
vehicle control.
Always use a gear ratio low enough to allow the engine to operate above
the minimum engine operation speed range. Do not lug the engine. When
more power is required, shift to a lower gear and accelerate the engine
near the governed speed.
Driving hints
The following driving hints are provided as a brief, general guide in
operating 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 standing still,
quickly release and depress the clutch pedal (if necessary to complete
gear engagement).
R 1 3 5
4
6 2
Driving
141

Operating the Eaton FS-4205A and FS-5205A 5–speed
transmissions
The 5-speed transmission is
equipped with five forward gears
and one reverse. The 2nd, 3rd, 4th
and 5th gears are synchronized. The
shift pattern is embossed on the
gear shift knob.
Do not shift the transmission into R (Reverse) while the vehicle is
moving as this could damage the transmission.
To go forward
With the engine idling, depress the
clutch pedal and shift into 1 (First).
Engage the clutch while pressing
the accelerator to start forward.
Operate the clutch 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.
R 2 4
3 5 1
R 2 4
3 5
1
R 2 4
3 5 1
Driving
142

Operating the Eaton FS-5306A and FS–6306A 6-speed
transmissions
These 6-speed transmissions are
equipped with six forward gears and
one reverse. All the forward gears
are synchronized. The shift pattern
is embossed on the gear shift knob.
Do not shift the transmission into 1 (First) or R (Reverse) while the
vehicle is moving as this could damage the transmission.
To go forward
With the engine idling, depress the
clutch pedal and shift into 1 (First).
Engage the clutch while pressing
the accelerator to start forward.
Operate the clutch 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.
R 1 3 5
4
6 2
R 1 3 5
4
6 2
R 1 3 5
4
6 2
Driving
143

Operating the Spicer ES52-7B and ES066-7B 7-speed
transmissions
These 7-speed transmissions are
equipped with seven forward gears
and one reverse. The 2nd, 3rd, 4th,
5th, 6th and 7th gears are
synchronized. The shift pattern is
embossed on the gear shift knob.
Do not shift the transmission into 1 (First) or R (Reverse) while the
vehicle is moving as this could damage the transmission.
To go forward
With the engine idling, depress the
clutch pedal and shift into 1 (First).
Engage the clutch while pressing
the accelerator to start forward.
Operate the clutch 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.
2 4 6
3 5 71 R
2 4 6
3 5 7
1 R
2 4 6
3 5 7
1 R
Driving
144

Ratio extender use
Low End
A two-speed axle can be used as a ratio-extender when split shifting is
not necessary. For low end use, just shift the axle into the LO to start
out, and shift to HI when the extra torque is no longer needed.
Transmission (5-speed) 1st 1st 2nd 3rd 4th 5th 6th
Two-speed Axle Axle
LowAxle High
High End
To use the two-speed axle as a high end ratio-extender, stay in the LO
range for normal upshifts and only shift the axle to HI on the freeway for
greater road speed.
Transmission (5-speed) 1st 2nd 3rd 4th 5th 6th
Speed
Axle
High Two-Speed Axle Low for Gradeability
DRIVING THROUGH WATER
Do not drive quickly through standing water, 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 damage your engine.
If driving through deep or standing water is unavoidable, proceed very
slowly. Never drive through water that is higher than the bottom of the
hubs (for trucks) or the bottom of the wheel rims (for cars).
Once through the water, always try the brakes. Wet brakes do not stop
the vehicle as effectively as dry brakes. Drying can be improved by
moving your vehicle slowly while applying light pressure on the brake
pedal.
Driving through deep water where the transmission vent tube is
submerged may allow water into the transmission and cause
internal transmission damage. Have the fluid checked and, if
water is found, replace the fluid.
Driving
148

Fuse/Relay
LocationFuse Amp
RatingPassenger Compartment Fuse
Panel Description
15 10A GEM, Interior lamp relay, Map
lamps, Glove box lamps
(SuperCrewzer only), Power
mirrors (SuperCrewzer only),
Warning chime module
(SuperCrewzer only)
16 15A Highbeams
17—Not used
18 5A Headlamp switch, GEM
19 15A Engine, Cluster, Cummins PCM,
CAT PCM, 7.3L Power Stroke
PCM (idle valid switch input),
Alternator (Ambulance only)
20 15A Starter relay, GEM
21 10A DRL
22 15A Exhaust brake (SuperCrewzer
only), Heated mirrors
(SuperCrewzer only), Rear air
suspension (SuperCrewzer and
Ambulance)
23 10A Electronic flasher
24 15A Vacuum pump, Air dryer, ABS,
Fuel heater relay
25 10A Blower motor relay
26 10A Right-hand low beam headlamp
27—Not used
28 10A Left-hand low beam headlamp
Roadside Emergencies
154

Fuse/Relay
LocationFuse Amp
RatingPassenger Compartment Fuse
Panel Description
29 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 30A 7.3L Power Stroke PCM diode,
7.3L Power Stroke fuel heater
31 15A Allison MD Transmission, Neutral
start relay and PCM (7.3L Power
Stroke only)
Relay 1—Interior lamps
Relay 2—Not used
Relay 3—Horn
Relay 4—One touch down power window
Relay 5—Not used
Power distribution box
The power distribution box is located in the engine compartment. The
power distribution box contains high-current fuses that protect your
vehicle’s main electrical systems from overloads.
Always disconnect the battery before servicing high current
fuses.
Always replace the cover to the power distribution box before
reconnecting the battery or refilling fluid reservoirs
If the battery has been disconnected and reconnected, refer to the
Batterysection of theMaintenance and specificationschapter.
Roadside Emergencies
155

JUMP STARTING YOUR VEHICLE
The gases around the battery can explode if exposed to flames,
sparks, or lit cigarettes. An explosion could result in injury or
vehicle damage.
Batteries contain sulfuric acid which burns skin, eyes, and
clothing.
Preparing your vehicle
Also see the label on the battery.
1. Use only a 12–volt supply to start your vehicle. If you connect your
battery to a 24–volt power supply you can damage your starter, ignition
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 battery of the disabled vehicle as this could
damage the vehicle’s electrical system.
3. Park the booster vehicle close to the disabled vehicle making sure
theydo nottouch. Set the parking brake on both vehicles and stay clear
of the engine cooling fan and other moving parts.
4. Check all battery terminals and remove any excessive corrosion before
you attach the battery cables. Ensure the vent caps are tight and level.
5. Turn the heater fan on in both vehicles to protect any electrical
surges. Turn all other accessories off.
Roadside Emergencies
162

Connecting the jumper cables
1. Position the vehicles so that they
do not touch one another.
2. Apply the parking brakes.
3. Switch off the engine and any
unnecessary electrical equipment.
4. Find the positive (+) terminal of
the discharged battery.
5. Using the jumper cables, connect
the positive (+) terminal of the
discharged battery to the positive
(+) terminal of the booster battery.
NOTE:In the illustration,
lightning bolts are used to
designate the assisting (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 vehicle frame is usually a good
ground.
7. Ensure that the jump leads are clear of moving parts of the engine,
and that the clamps from one cable do not touch the clamps on the
other cable.
8. Do not lean over the batteries when making the connections.
Do not connect the end of the second cable to the negative (-)
terminal of the battery to be jumped. A spark may cause an
explosion of the gases that surround the battery.
Jump starting
1. Start the booster vehicle and run the engine at moderately increased
speed.
2. After a few minutes, start the engine of the vehicle with the
discharged battery.
3. After starting, run the engine at about 1,000 RPM for 3–5 minutes.
13
2
4
Roadside Emergencies
163

Do not operate the starter longer than 30 seconds. Wait at least
two minutes between starting attempts to allow 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 the cable on the
negative (-) battery terminal of the
booster vehicle.
2. Remove the cable from the
positive (+) terminal of the
discharged battery and then from
the positive (+) terminal of the
booster battery.
3. After the disabled vehicle has
been started, allow it to idle for a
while so the engine can“relearn”its
idle conditions.
WRECKER TOWING
Always unload your vehicle before towing it. The recommended method
of towing is with the drive wheels off the ground.
Before towing, make sure:
•the parking brake is released.
•if air pressure has been lost, to release the brakes manually.
Improper towing of the vehicle will not allow sufficient lubrication of the
transmission which may cause serious damage to internal transmission
components. Always follow the outlined towing procedures.
•To tow a vehicle on the front wheels,the steering wheel must be
in the straight ahead position. Secure the steering wheel with a
holding device (such as provided by a towing company).
42
3
1
Roadside Emergencies
164