torque FORD F650 2008 11.G Owners Manual

Releasing spring brake manually
Do not attempt to disassemble the parking brake chamber under
any circumstances. The high spring load may cause serious
injury if the chamber clamps are removed.
If air pressure is released from the spring brake chamber the power
spring applies the brake and, unless air pressure can be re-established,
the spring brake must be released as follows in order to move the
vehicle.
Block the wheels to help prevent the vehicle from moving.
Unexpected and possibly sudden vehicle movement may occur if
these precautions are not taken.
Impact wrenches should not be used as they may damage the piston and
prevent proper caging of the spring. Do not apply more than 50 lb. ft.
(68 N•m) torque to the release bolt nut.
1. Remove the stud tool and nut
from the carrying pocket on the
brake chamber assembly.
2. Remove the access plug from the
end of the spring chamber.
3. Insert the release stud through
the opening in the chamber and into
the spring pressure plate.
2008 F-650/750(f67)
Supplement
USA(fus)
Driving
102

Allison 2500
This transmission is available with a column-mounted gearshift lever. The
gear positions are displayed on the RNDL in the instrument cluster.
To avoid sudden, unexpected vehicle movement and
possible personal injury or death:
1. Bring the vehicle to a complete stop.
2. Shift the transmission into N (Neutral).
3. Apply the parking brake and make sure it is holding properly.
4. Turn the engine off when you leave the vehicle.Never leave the
vehicle unattended when the engine is running.
Allison 3000 series
Two modes are available for the Allison 3000 Series: Performance and
Economy. Performance mode will give you the best all-around
transmission operation; Economy provides operation at lower engine
RPM while maintaining adequate performance. The transmission will
automatically default to Performance mode when you start the engine.
Pressing MODE on the shifter will activate the Economy mode; this will
also illuminate the Mode ON lamp.
If the engine speed is above idle when a gear is selected using the
shifter, the vehicle will not move. To move the vehicle, the shifter must
be moved to re-select a gear after the engine speed returns to idle.
Note:For more information regarding the Allison 3000 Series, refer to
the separate Allison 3000 Series Operator’s Manual.
Torque lock
If your vehicle is parked on an incline and P (Park) is not properly
engaged (The parking brake is not applied before the transmission is
shifted into P [Park]), the weight of the vehicle may generate an
excessive amount of torque on the park pawl. In this situation, it may be
difficult to shift the transmission out of P (Park). Hold the brake pedal
down while shifting out of P (Park), then release the parking brake.
2008 F-650/750(f67)
Supplement
USA(fus)
Driving
116

PTO operation while vehicle is moving
After the PTO is engaged for driven vehicle operation, shift to the
desired range and drive the vehicle. The speed of the PTO, during this
period of operation, will always maintain direct relation to vehicle speed.
PTO speed will decrease in relation to vehicle (transmission output)
speed as shifts to a higher gear occur. When operating the PTO while the
vehicle is moving, the PTO may be disengaged whenever it is no longer
required. When there is no load on the PTO gear, it can be pulled out of
engagement.
Vehicles equipped with an Allison 3000 Series automatic
transmission
The PTO drive gear is engine driven and provides direct engine power.
The PTO can be operated when the vehicle is either stationary or
moving.
The PTO gear is in constant mesh with the drive gear in the torque
converter housing. A friction clutch or constant drive is used to transmit
power to the PTO.
Vehicles equipped with a Caterpillar engine
The PTO will only operate if the transmission is in N (Neutral). This
feature can be overridden by a special service tool; see your dealer or
service representative for more information.
Vehicles equipped with a manual transmission
Transmission-mounted PTO units are available for local installation on
your vehicle. See yourBody Builder’s Layout Bookfor restrictions on
use and installation of PTO units.
To engage the PTO unit, stop the vehicle and place the transmission in N
(Neutral). Depress the clutch and allow the gears to stop rotating, then
engage the PTO unit. The PTO can also be selected with the
transmission in gear as long as the clutch is depressed.
When operating the PTO with the vehicle stationary, first set the parking
brake (chock the wheels if the vehicle is on a hill or another uneven
surface).
REAR AXLE INFORMATION
Axle operating temperature normally will not exceed 100°F (38°C). If
the operating temperature exceeds 230°F (110°C), the rate of axle
lubrication oxidation will increase and shorten the life of the lubricant
2008 F-650/750(f67)
Supplement
USA(fus)
Driving
123

Shifting the axle from HI to LO range - vehicle stopped
Place the transmission in N (Neutral), then press the upper part of the
switch.
Note:Do not shift the axle to LO range with the vehicle in motion.
Split-shifting (combined axle and transmission shift - manual
transmissions only)
Split-shift sequence
Ratio
combination1234567891011
Transmission
gear1st 1st 2nd 2nd 3rd 3rd 4th 4th 5th 6th 6th
Axle range LO HI LO HI LO HI LO HI LO LO HI
To downshiftthe axle to a slower ratio and shift the transmission, shift
the transmission and move the control switch to the lower ratio before
the clutch is re-engaged.
To upshiftthe axle and shift the transmission, move the control switch
to a faster ratio and make the transmission shift in the usual manner.
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 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 low Axle 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
Two-speed axle Low for gradeability Axle high
2008 F-650/750(f67)
Supplement
USA(fus)
Driving
127

2. Remove the capscrews and washers or stud nuts and washers from
flanges of both axle shafts.
3. Loosen the tapered dowels in the flanges of both axle shafts by
holding a 1
12inch diameter brass drift or hammer against the axle shaft
center and hitting it with a five or six pound hammer.Note:Do not use
a chisel or wedge to loosen the axle shafts and dowels. Use of a chisel or
wedge can damage the hub, axle shafts and oil seals.
4. Remove the tapered dowels and both axle shafts from the axle
assembly.
5. Assemble a cover over openings of both wheels ends to prevent loss of
lubricant and keep dirt away from the wheel bearing cavities.
Note:One of the axle shafts has two sets of splines. One set to engage
with the differential side gear and one set to engage with the shift collar
for the differential lock. It may be necessary to rotate the shaft slightly
to align the gear spline teeth with the shift collar teeth in order to
remove the axle shaft.
Installing the axle shafts
1. Remove the covers from the wheel ends
2. Shift the differential lock to the unlocked position (disengaged)
position.
3. Install the axle shafts
•Place the gaskets on the wheel hub studs.
•Push the right-hand axle shaft and gasket into the wheel end and
housing until the shaft stops against the differential shift collar.
•Push down and in on the axle shaft flange and rotate the shaft until
the splines of the shaft and shift collar are engaged.
•Push the axle shaft further into the housing until the shaft stops
against the differential side gear.
•Push down on the axle shaft flange and rotate the shaft until the
splines of the shaft and side gear are engaged.
•Push the axle shaft completely into the housing until the axle shaft
flange and the gasket are flush against the wheel hub.
•Install the left-hand axle shaft and gasket into the wheel end.
4. If tapered dowels are required, install them at each stud and into the
flange of the axle shaft. Use a punch or drift and hammer, if needed.
5. Install the fasteners and tighten to correct torque value. Refer to the
Service Manual.
2008 F-650/750(f67)
Supplement
USA(fus)
Roadside Emergencies
148

Check to make sure that the axle mounting U-bolt nuts, attaching or
mounting bolts and nuts are securely tightened. Regularly check front
axle for damage, binding, worn parts and adequate lubrication.
At regular intervals, or during other scheduled maintenance, (tire
rotation/service, wheel bearing service, alignment, etc.) the kingpins
should be checked for excessive wear. Refer to the service manual for
proper procedures.
Toe-in setting - general inspection
Inspecting steer axle tires in the first 3,000–10,000 service miles
(4,800–16,000 service km) will generally show if tires are wearing
normally.
Rapid outside shoulder wear on both tires indicates too much toe-in.
Rapid inside shoulder wear on both tires indicates too much toe-out. In
P&D-type service, left-to-right steer tire tread life differentials up to 40%
can be observed depending on routes and other variables.
Follow the tire manufacturer’s recommended cold inflation pressure for
the tire size, load range (ply rating) and steer axle loading typical for
their operation (each steer axle tire will equal
12steer axle loading).
Special applications may warrant a setting based on past experience with
the type of tire operating loads and conditions. Radial tires are more
sensitive to toe-in setting than bias ply tires. While not insensitive to
vehicle alignment, fine tuning school bus alignment to line-haul truck
standards will not drastically improve tire tread life.
It is essential that correct toe-in and tire pressure be maintained for
optimum tire wear.
Rear axle - general inspection
Check to make sure that the axle mounting U-bolts, attaching or
mounting bolts and nuts are securely tightened. Refer toU-bolt nut
torquein this chapter. Regularly check the rear axle for damaged,
binding or worn parts.
NoSpin Detroit Locker positive locking differential
Vehicles equipped with this type differential have the operator’s manual
supplied with the vehicle. Refer to this manual for maintenance checks.
Brake system - general inspection
Your vehicle is equipped with non-asbestos brake linings. However,
exposure to excessive amounts of brake material (whether asbestos or
2008 F-650/750(f67)
Supplement
USA(fus)
Maintenance and Specifications
162

such as the fuel sender, cranking motor, alternator and feed-through
studs should be cleaned and re-coated with a lubricant sealing grease
such as Motorcraft Silicone Brake Caliper Grease and Dielectic
Compound XG-3, or equivalent. This should include the ground cable
connector for batteries, engine and cab as well as the jump starting stud.
Accessory feed connections
Vehicle electrical systems are complex and often include electronic
components such as engine and transmission controls, instrument panels,
ABS, etc. While most systems operate on battery voltage (12 volts),
some systems can be as high as 90 volts or as low as five volts. Refer to
the Electrical Circuit Diagram Manuals, available from your vehicle’s
manufacturer, to ensure that any additional body lights and accessories
are connected to circuits that are both appropriate and not overloaded.
No modification should be made to any vehicle control system without
first contacting your dealer.
SUSPENSION INSPECTION
Note:Do not adjust air suspension height to any setting other than the
specified setting. Altering the height setting will change the driveline
angle and may result in unwarrantable component damage, such as
transmission component damage.
Verify drive axle air suspension height and height control valve
performance at engine lube oil change intervals.
Periodically:
•Check condition of spring leaves for evidence of fatigue, bending or
breakage.
•Check condition of suspension mounting brackets and bushings.
•Check that torque rod mounting fasteners are tight.
•Check to be sure the suspension alignment is maintained at all times.
•Check U-bolts after the chassis has been operating under load for
1,000 miles (1,600 km) or six months, whichever comes first, the
U-Bolt nuts must be re-torqued. The U-Bolt nuts thereafter must be
re-torqued every 36,000 miles (58,000 km). The U-Bolt and nut
threads and seats should be cleaned and lubricated to ensure a “like
new” condition when re-torquing.
Note:See theU-Bolt Nut Torquechart later in this section.
2008 F-650/750(f67)
Supplement
USA(fus)
Maintenance and Specifications
193

Supporting your vehicle for service
When performing service repairs on your vehicle, first prepare the
vehicle by doing the following:
1. Park the vehicle on a level concrete floor.
2. Set the parking brake and block the wheels to prevent the vehicle
from moving.
3. Select a jack with a rated capacity sufficient to lift and hold up the
vehicle.
4. Raise the vehicle with the jack applied to the axle(s). DO NOT use the
bumper as a lifting point.
5. Support the vehicle with floor stands under the axle(s). If the axle or
the suspension are being serviced, support the vehicle with floor stands
under the frame side-members, preferably between the axles.
Do not use a jack when working under a vehicle. It may give way,
causing the vehicle to fall and result in property damage, personal
injury or death. Always use floor stands to support the vehicle.
FRAME AND TOW HOOKS
Your vehicles chassis is manufactured with frame rails of either HSLA
steel or heat-treated steel. Each must be handled in a specific manner to
ensure maximum service life. Before attempting frame repair or
modification, consult the service manual or your dealer.
It is important, particularly on vehicles where the tow hooks are used
frequently to inspect the front and rear tow hooks for damage or a loose
mounting.
U-BOLT NUT TORQUE
U-bolt diameter (nominal)
(all spring suspensions)U-bolt diameter (nominal)
Ft. lb. N•m
IROS Air w/15,500 lb. axles and
less260–300 353–407
IROS Air w/greater than 15,500 lb.
axles370–400 502–542
Hendrickson 23,000 lb. axle 370–400 502–542
2008 F-650/750(f67)
Supplement
USA(fus)
Maintenance and Specifications
194

Air suspension U-bolt checks and re-torquing procedures
1. Inspect the threads of the U-bolt and nut for rust and debris. Clean
the threads if contaminated.
2. Using a torque wrench, determine if any nuts can be turned with a
force below the specified torque.
3. Using the lowest discovered torqued nut as a starting point, retighten
the nuts using the sequence listed underAir suspension U-bolt and
U-bolt nut installation.
Air suspension U-bolt and U-bolt nut installation
1. Inspect the threads of the U-bolt and nut for rust and debris. Clean
the threads if contaminated.
2. Install the U-bolts and nuts and torque the nuts to 15 ft. lb. (20 N•m),
using a diagonal pattern.
3. Re-torque the nuts to 100 ft. lb. (136 N•m), using a diagonal pattern.
4. Re-torque the nuts to 200 ft. lb. (271 N•m), using a diagonal pattern.
5. Re-torque the nuts to 400 ft. lb. (542 N•m), using a diagonal pattern.
(For vehicles equipped with 14ACC, 14 ADN and 14ADP axles, do not
use Step 6.)
6. Re-torque the nuts to 425 ft. lb (576 N•m), using a diagonal pattern.
(For vehicles equipped with 14ACC, 14 ADN and 14ADP axles.)
7. Use the same diagonal pattern with each U-bolt nut re-torque.
Spring U-bolt checks
Check U-bolt nuts and re-torque every 36,000 miles (58,000 km) after
initial 1,000 miles (1,600 km) re-torque. The U-bolt and nut threads and
seats should be cleaned and lubricated to ensure peak condition when
re-torqued.
DRIVESHAFT
At the regular lubrication interval, check the universal joints for any
evidence of wear or looseness. Should driveshaft vibrations occur, stop
the vehicle immediately to avoid possible hazardous consequences or
damage to other components.
REAR AXLE LUBRICANT
Refer to theScheduled Maintenance Guidechapter for rear axle
lubricant level checks and lubricant change intervals.
2008 F-650/750(f67)
Supplement
USA(fus)
Maintenance and Specifications
195

When installing wheel balance weights, they must be mounted on the
dome-side of the wheel only. Failure to do so may result in loss of wheel
weight and/or damage to brakes or wheels.
Important:Remember to replace the wheel air valves when the road
tires are replaced at the end of their useful life.
Oil lubricated front wheel bearings
During normal vehicle duty cycle, the lube and air inside the hub/wheel
cavity expands and if not vented, causes pressure build-up that could
cause accelerated seal wear.
There are two venting methods:
•a slit or small hole in the rubber check vent or
•the window
You can use either of these methods to prevent pressure build-up.
Normal maintenance
Over a period of time, if not routinely cleaned, a slight film of oil can
collect dirt around the rubber fill plug and face, which could appear to
be a leak. Routine cleaning ensures that the lube level can be easily
observed through the clear window as intended. In situations where the
window is clean on the outside but discolored on the inside, the lube
level may be checked by inserting a finger through the rubber check
vent hole.
The specified lube level for a clear window type hubcaps is from the
minimum line to + 5/16 inch above the minimum line.
If the lube level should suddenly drop dramatically below the minimum
level, see theWorkshop Manualfor diagnostic procedure.
Installation, tightening and alignment
When installing wheels, be certain that the threads on studs and nuts are
clean to permit correct torque. The mounting surfaces of rims, wheels,
spacer rings and clamps must be free of dirt, rust, lubricants or damage.
Use a wire brush to clean the mounting contact surfaces. Do not use
lubricant on threads.
After the rim or wheel has been properly tightened, it should be checked
for alignment. Rotate the wheel with a piece of chalk attached to a
steady, firm surface, and placed to just barely clear the outside surface of
the tire bead seat. This procedure will point out the high spot. A high
spot does not necessarily mean that the lug nuts have been unevenly
tightened. This condition or misalignment could be caused by a bent
wheel.
2008 F-650/750(f67)
Supplement
USA(fus)
Maintenance and Specifications
197