power steering FORD F650 2004 11.G User Guide

Hydraulic brakes - fluid precautions
The Hydro-Max brake system consists of two completely separate
hydraulic systems operating with two different and incompatible fluids;
power steering fluid and hydraulic brake fluid. Failure to observe
precautions preventing the contamination of either system with fluid
from the other will result in swelling and deterioration of rubber parts
leading to reduced brake performance and eventual brake failure.
To avoid fluid contamination, the following should always be observed:
1. Use only fluids specified (or equivalent) and properly identified.
2. Add fluids only to the following locations:
•Power steering fluid to the power steering fluid pump reservoir
•Brake fluid to the brake master cylinder
Hydraulic brakes - brake lines, hoses and fittings
Inspect these components every 6,000 km (4,000 miles).
•Check lines for kinks, dents, corrosion or rupture.
•Check hoses for abrasions, kinks, soft spots or rupture, collapse,
cracks, twists or loose frame supports. When replacing a hose, be sure
there is adequate clearance to the hose to avoid an abrasion to the
new hose.
•Examine all connections for leaks.
•Repair or replace brake line tubes, hoses or fittings as required.
Driveline parking brake
Parking brake adjustment should only be performed by a qualified
technician, and in accordance with the instructions in the service
manual.
Use wheel chocks and exercise caution when inspecting under
the vehicle. A vehicle roll-away could result in property damage,
personal injury or death.
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Alternator
Before connecting a fast-charger, booster battery or installing a new
battery, make sure the ground polarities of the fast-charger, booster
battery or alternator (when installing a battery) are matched to the
ground polarity of the vehicle battery. Improper usage of the
fast-charger, hook-up of booster battery or installation of a new battery
can cause damage to the electrical system or to the alternator. Do not
attempt to polarize the alternator.
STEERING - GENERAL INSPECTION
•Ask your service technician to examine the steering mechanism. Only
minor adjustments may be necessary.
•Check tie rod, drag link end clamp bolts and ball joints. They must be
tight.
•Check for installation and spread of cotter pins and tightness of nuts
at both ends of the tie rod and drag link.
•Check that pitman arm (steering arm at steering gear) mounting is
tight and locked. Check system for leaks or hose chafing. Repair at
once.
•Maintain proper steering gear and power steering pump lubricant
levels.
•Regularly inspect steering column joint bolts and steering linkage,
particularly for body-to-chassis clearance.
Note:Have any steering problems corrected at once by a qualified
service technician.
Failure to maintain the steering system in proper condition can
cause reduced steering ability resulting in property damage,
personal injury or death.
Tightening steering column joint bolts
As a good maintenance practice, it is recommended that steering column
joint bolts be checked for tightness every 96,000 km (60,000 miles) or
annually, whichever occurs first. DO NOT OVERTIGHTEN.
Power steering
Whenever the hydraulic (power steering) system has been drained and
refilled for any reason, air must be bled from the system before returning
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the vehicle to service. Failure to properly bleed the hydraulic system can
result in degradation of power system performance.
Consult your dealer who is aware of the proper procedures for filling and
bleeding the system.
POWER STEERING FLUID
Check the power steering fluid level using the following procedure. Refer
to the general maintenance information section for the recommended
service intervals. If adding fluid is necessary, use only MERCON
AT F.
1. Set the parking brake, shift into N (Neutral) (automatic transmission)
or 1 (First) (manual transmission) and turn the engine off.
2. Open the hood.
3. Clean the top of the power steering fluid reservoir.
4. Remove the dipstick from the reservoir and wipe the dipstick clean.
5. Reinstall the dipstick. Remove it again and check the fluid level.
•If the fluid temperature is at
approximately 20°C-49°C (68°F
- 120°F) (fluid cool or warm to
the touch), check the COLD side
of the dipstick. The fluid level
should be within the FULL range
•If the fluid level is below the ADD
line, add fluid in small amounts,
continuously checking the level until it reaches the proper level.
•If the fluid temperature is at
approximately 80°C - 110°C
(176°F - 230°F) (fluid too hot
to touch), check the HOT side of
the dipstick. The fluid level
should be within the FULL range.
•If the fluid level is below the ADD
line, add fluid in small amounts,
continuously checking the level until it reaches the proper level.
Note:The fluid level may also be checked by looking at the see-through
plastic reservoir. Make sure that the fluid is within the minimum and
maximum fluid range as marked on the reservoir.
A low fluid level may indicate a leak in the power steering system.
Inspect the power steering system and repair the leak. If necessary, see
your dealer or a qualified service technician.
ADD MAX. COLDFULL
ADD MAX. HOTFULL
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To avoid damage to the power steering system,do notoperate the
vehicle with a low power steering fluid level.
Whenever the dipstick is installed, make sure it is properly seated and
tightened securely.
CLUTCH FLUID/LINKAGE ADJUSTMENTS
Clutch fluid (if equipped)
Check the clutch fluid level. Refer to the general maintenance
information section for the service interval schedules.
During normal operation, the fluid level in the clutch reservoir should
remain constant. If the fluid level drops, maintain the fluid level at the
step in the reservoir.
Use only a DOT 3 brake fluid designed to meet manufacturer
specifications. Refer toLubricant specificationsin this chapter.
1. Set the parking brake, shift into 1
(First) and turn the engine off.
2. Open the hood.
3. Clean the reservoir cap before
removal to prevent dirt and water
from entering the reservoir.
4. Remove cap and rubber
diaphragm from reservoir.
5. Add fluid until the level reaches
the step in the reservoir.
6. Reinstall rubber diaphragm and cap onto reservoir.
Clutch linkage (if equipped)
Lubricate the clutch linkage using the following procedure. Refer to the
general maintenance information section for the service interval
schedules.
Use a grease which meets manufacturer specifications. Refer to
Lubricant specificationsin this chapter.
1. Set the parking brake, shift into 1 (First) and turn the engine off.
2. Remove the inspection cover from the clutch housing.
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Component /
Component vendorLubrication type Vendor
recommendations:
Viscosity / Ambient
temperature / NotesEquivalent Ford
part name / number
Eaton-Spicer axle,
Spicer axle - Front
axle wheel bearing
grease, tie rod ends,
drag link, kingpin
and bushingEP2 Lithium
complex-based moly
grease (or
equivalent) GC/LB
NLGI #2
multi-purpose
lithium complex
greaseNote:Eaton-Spicer
and Meritor Easy
Steer axles: With
chassis load on axle,
force grease through
thrust bearings; then
with axle lifted clear
of the floor, force
grease between
kingpin and bushing
surfaces.Motorcraft Premium
Long Life Grease /
XG-1-C
Steering
Power steering fluid
changeMERCON
—Motorcraft Mercon
Multi-Purpose (ATF)
Transmission Fluid /
XT-2-QDX
Steering gear Ross
TAS-Output SealGC/LB NLGI #2
lithium
complex-based moly
grease or
multi-purpose
lithium complex
grease—Motorcraft Premium
Long Life Grease /
XG-1-C
Steering column
U-joints / slip jointGC/LB NLGI #2
lithium
complex-based moly
grease or
multi-purpose
lithium complex
grease—Motorcraft Premium
Long Life Grease /
XG-1-C
Propeller shaft
U-joint GC/LB NLGI #2
lithium
complex-based moly
grease or
multi-purpose
lithium complex
grease—Motorcraft Premium
Long Life Grease /
XG-1-C
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Engine coolant and oil
Engine type Engine coolant
(approximate
capacity)Engine oil
(approximate
capacity)
6.0L Power Stroke 25.7L (54.4 pints) 18.0L (19 quarts)
Caterpillar 28.4 (60.0)
1
Cummins B 23.1 (24.4)1
1Refer to the engine operator manual for engine oil refill capacities.
Power steering system
Steering gearPower steering fluid volume (cubic
inches/liters/pints)
V8 engine
TAS40 steering gear 506/8.3/17.6
TAS65 steering gear 533/8.7/18.4
Transmission
Description Liters Pints
MD-3060P 5–speed automatic 27.4 58.01
MD-3560P 5–speed automatic 27.4 58.01
MD-3060P 6–speed automatic 27.4 58.01
FS-4205A 5–speed manual 5.4 11.5
MD-3066P 6–speed automatic 27.4 58.01
FS-5406A 6–speed manual 9.2 19.5
FS-5406N 6–speed manual 9.2 19.5
MD-3560P 6–speed automatic 27.4 58.0
1
2000P Series 5–speed automatic 18.0 38.01
2400 Series 5–speed automatic 18.0 38.01
FS-5205A 5–speed manual 5.9 12.5
FS-6406N 6–speed manual 9.2 19.5
FS-6406A 6–speed manual 9.2 19.5
ES066–7B 7–speed manual 9.9 20.9
ES56–7B 7–speed manual 9.9 20.9
FR-9210B 10–speed manual 11.1 23.5
RT–8908LL 10–speed manual 13.2 28.0
1Total fluid capacity (dry transmission and torque converter).
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Daily Owner Checks Engine system
Check the air filter restriction indicator
Check the engine oil
Inspect the coolant level - for Power Stroke 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
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Check every oil
changeOil change
intervals are as follows:
Power Stroke - 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
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
* 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 WSS-M97B51-A1. See the engine
manufacturer’s operating guide for supplemental corrosion inhibitor specifications.
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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 (*a,b)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
2004 F650/750(f67)
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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 800 and 1,600 km
(500 and 1,000 miles). Perform again
at 800 and 1,600 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.
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