brakes FORD F650 2004 11.G Service Manual

AIR BRAKE ADJUSTMENT
Failure to maintain proper air brake adjustment can result in
reduction or loss of braking ability.
Air brake inspection and adjustment should be performed by a qualified
service technician in accordance with the instructions in the Ford Truck
Service Manual.
Cam brakes - automatic slack adjusters
Inspect standard air brakes equipped with automatic slack adjusters for
proper brake adjustment every four months or 32,000 km (20,000 miles)
whichever occurs first.
However, more frequent inspection is required if your vehicle’s brakes
are subjected 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.
2004 F650/750(f67)
Supplement
USA English(fus)
General maintenance information
227

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
2004 F650/750(f67)
Supplement
USA English(fus)
General maintenance information
229

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.
2004 F650/750(f67)
Supplement
USA English(fus)
General maintenance information
230

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)
Supplement
USA English(fus)
General maintenance information
232

A
Air conditioning ..........................43
manual heating and air
conditioning system .................43
Air suspension ...........................112
Anti-lock brake system
(see Brakes) ..............................110
Audio system
(see Radio) ................28, 30, 33, 37
Automatic transmission ............115
fluid, adding ............................181
fluid, checking ........................181
fluid, refill capacities ..............218
fluid, specification ..................207
Auxiliary power point .................52
Axle ............................127, 160, 198
lubricant specifications ..........207
refill capacities ........................217
B
Battery .......................................176
charging system warning
light ............................................20
jumping a disabled battery ....143
voltage gauge ............................24
BeltMinder ...................................73
Brakes ......................91–92, 97, 160
adjustment ..............................163
anti-lock ...........................110–111
anti-lock brake system (ABS)
warning light .....................20, 111
brake warning light ..................20
fluid, checking and
adding ..............................163, 175
fluid, specifications .................207
parking ................93–94, 100, 164
Bulbs ............................................47C
Cassette tape player ...................37
Catalytic converter
(see Emission control) .............183
CD-single premium .........28, 30, 33
Cell phone use ............................52
Child safety restraints ................78
child safety belts ......................78
Child safety seats ........................81
attaching with tether straps ....85
in front seat ..............................83
in rear seat ................................83
tether anchorage hardware .....85
Child safety seats - booster
seats .............................................79
Cleaning your vehicle
chrome and aluminum parts..155
engine compartment ..............155
exterior ....................................157
instrument panel ....................156
interior .....................................156
interior trim ............................156
plastic parts ............................156
washing ....................................154
waxing .....................................154
wheels ......................................155
Climate control (see Air
conditioning or Heating) ......42–43
Clutch ................................119, 180
adjusting ..................................180
fluid ..........................................180
operation while driving ..........119
specifications ..........................207
Controls
power seat .................................66
Coolant ......................................170
checking and adding ..............170
2004 F650/750(f67)
Supplement
USA English(fus)
Index
258

H
Hazard flashers .........................137
Headlamps ...................................45
aiming ........................................46
daytime running lights .............45
flash to pass ..............................45
high beam .................................45
warning chime ..........................20
Heating ..................................42–43
heater only system ...................42
manual heating and air
conditioning system .................43
Hood ..........................................165
I
Ignition
chime .........................................20
Infant seats (see Safety seats) ..81
Instrument panel
cleaning ...................................156
lighting up panel and
interior .......................................46
J
Jump-starting your vehicle ......143
K
Keys
key in ignition chime ...............20
L
Lamps
bulb replacement
specifications chart ..................47
cargo lamps ...............................46
daytime running light ...............45headlamps .................................45
headlamps, flash to pass ..........45
high beams ................................45
instrument panel, dimming .....46
interior lamps ...........................47
replacing bulbs ...................47–49
Lane change indicator
(see Turn signal) ........................46
Lights, warning and indicator ....20
air suspension ...........................20
anti-lock brakes (ABS) ....20, 111
brake ..........................................20
charging system ........................20
safety belt .................................20
service engine soon ..................20
traction control off ...................20
turn signal indicator .................20
Lubricant specifications ...........207
M
Maintenance and Care ..............226
Manual transmission .................121
lubricant specifications ..........207
Mirrors .........................................54
fold away ...................................56
heated ........................................55
side view mirrors (power) .......54
O
Odometer .....................................24
P
Paint chips, repairing ...............155
Parking brake ................93–94, 100
warning light .............................20
Power door locks ........................62
Power mirrors .............................54
2004 F650/750(f67)
Supplement
USA English(fus)
Index
260