light FORD F650 2009 12.G Repair Manual

Removing the jumper cables
Remove the jumper cables in the reverse order that they were
connected.
1. Remove the jumper cable from thegroundmetal surface.
Note:In the illustrations,lightning boltsare used to designate the
assisting (boosting) battery.
2. Remove the jumper cable on the negative (-) connection of the
booster vehicle’s battery.
3. Remove the jumper cable from the positive (+) terminal of the booster
vehicle’s battery.
+–+–
+–+–
+–+–
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•The wheel hub ends must be covered to prevent loss of axle lubricant
and entrance of other contaminants. If the axle shafts are not
removed, removal of the driveshaft is required.
Note:To avoid transmission damage, vehicles should not be towed even
a short distance without suspending rear wheels or removing the axle
shaft or driveshaft.
Note:In the event the chassis is equipped with a tandem axle and the
vehicle is to be towed from the front, the forward rear axle may be
raised to clear the road surface and secured to the frame by chains or
U-bolts, allowing only the rear rear axle to contact the road surface. Axle
shafts must be removed from the rear rear axle assembly. The wheel hub
ends must be covered to prevent loss of axle lubricant and entrance of
contaminants. Use extreme care in securing the chains or U-bolts to
avoid possible damage to the brake lines, hoses or other components.
Towing vehicles equipped with a driver-controlled differential lock
Note:If the vehicle must be towed to a service facility with the drive
axle wheels on the ground, it is necessary to remove the axle shafts
before the vehicle is towed.
1. Shift collar in the locked position
2. Actuator assembly and shift fork
3. Axle shaft
4. Interference between the shift
collar and housing
5. Shift collar in the unlocked
position
6. Outer splines - axle shaft to collar
7. Shift collar and differential case
splines
8. Inner splines - axle shaft to side
gear
9. Side gear
10. Differential (plain) case half
Removing axle shafts before towing
1. Shift the main differential to the unlocked (disengaged) position. The
differential lock light will turn off.
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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.
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WASHING THE EXTERIOR
Wash your vehicle regularly with cool or lukewarm water and a neutral
pH shampoo, such as Motorcraft Detail Wash (ZC-3–A), which is
available from your dealer.
•Never use strong household detergents or soap, such as dish washing
or laundry liquid. These products can discolor and spot painted
surfaces.
•Never wash a vehicle that is “hot to the touch” or during exposure to
strong, direct sunlight.
•Always use a clean sponge or car wash mitt with plenty of water for
best results.
•Dry the vehicle with a chamois or soft terry cloth towel in order to
eliminate water spotting.
•It is especially important to wash the vehicle regularly during the
winter months, as dirt and road salt are difficult to remove and cause
damage to the vehicle.
•Immediately remove items such as gasoline, diesel fuel, bird droppings
and insect deposits because they can cause damage to the vehicle’s
paintwork and trim over time.
•Remove any exterior accessories, such as antennas, before entering a
car wash.
•Suntan lotions and insect repellents can damage any painted
surface; if these substances come in contact with your vehicle,
wash off as soon as possible.
WAXING
Applying a polymer paint sealant to your vehicle every six months will
assist in reducing minor scratches and paint damage.
•Wash the vehicle first.
•Do not use waxes that contain abrasives.
•Do not allow paint sealant to come in contact with any non-body
(low-gloss black) colored trim, such as grained door handles, roof
racks, bumpers, side moldings, mirror housings or the windshield cowl
area. The paint sealant will “gray” or stain the parts over time.
PAINT CHIPS
Your dealer has touch-up paint and sprays to match your vehicle’s color.
Take your color code (printed on a sticker in the driver’s door jam) to
your dealer to ensure you get the correct color.
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Cleaning
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WINDOWS AND WIPER BLADES
The windshield, rear and side windows and the wiper blades should be
cleaned regularly. If the wipers do not wipe properly, substances on the
vehicle’s glass or the wiper blades may be the cause. These may include
hot wax treatments used by commercial car washes, tree sap, or other
organic contamination. To clean these items, please follow these tips:
•The windshield, rear windows and side windows may be cleaned with
a non-abrasive cleaner such as Motorcraft Ultra Clear Spray Glass
Cleaner (ZC-23), available from your dealer.
•Do not use abrasives, as they may cause scratches.
•Do not use fuel, kerosene, or paint thinner to clean any parts.
•Wiper blades can be cleaned with isopropyl (rubbing) alcohol or
windshield washer solution. Be sure to replace wiper blades when they
appear worn or do not function properly.
INSTRUMENT PANEL AND CLUSTER LENS
Clean the instrument panel with a damp cloth, then dry with a dry cloth.
•Avoid cleaners or polish that increase the gloss of the upper portion of
the instrument panel. The dull finish in this area helps protect the
driver from undesirable windshield reflection.
•Be certain to wash or wipe your hands clean if you have been in
contact with certain products such as insect repellent and suntan
lotion in order to avoid possible damage to the painted surfaces.
INTERIOR TRIM
•Clean the interior trim areas with a damp cloth, then dry by wiping
with a dry, soft, clean cloth.
•Do not use household or glass cleaners as these may damage the
finish.
INTERIOR
For fabric, carpets, cloth seats and safety belts:
•Remove dust and loose dirt with a vacuum cleaner.
•Remove light stains and soil with Motorcraft Professional Strength
Carpet and Upholstery Cleaner (ZC-54).
•If grease or tar is present on the material, spot-clean the area first
with Motorcraft Spot and Stain Remover (ZC-14).
•Never saturate the seat covers with cleaning solution.
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WARNING:Batteries normally produce explosive gases which
can cause personal injury. Therefore, do not allow flames, sparks
or lighted substances to come near the battery. When working near the
battery, always shield your face and protect your eyes. Always provide
proper ventilation.
WARNING:When lifting a plastic-cased battery, excessive
pressure on the end walls could cause acid to flow through the
vent caps, resulting in personal injury and/or damage to the vehicle or
battery. Lift the battery with a battery carrier or with your hands on
opposite corners.
WARNING:Keep batteries out of reach of children. Batteries
contain sulfuric acid. Avoid contact with skin, eyes or clothing.
Shield your eyes when working near the battery to protect against
possible splashing of acid solution. In case of acid contact with skin or
eyes, flush immediately with water for a minimum of 15 minutes and
get prompt medical attention. If acid is swallowed, call a physician
immediately.
WARNING:Battery posts, terminals and related accessories
contain lead and lead compounds.Wash hands after handling.
Always dispose of automotive
batteries in a responsible manner.
Follow your local authorized
standards for disposal. Call your
local authorized recycling center to
find out more about recycling
automotive batteries.
ENGINE COOLANT
Refer to your engine operator’s manual for engine coolant checking and
adding instructions as well as engine coolant specifications and
capacities.
LEAD
RETURN
RECYCLE
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Number 1-D or winter blend number 2-D fuel is recommended at
temperatures below 20°F (-7°C) (seeCold weather operationin the
Drivingchapter. Diesel fuel containing no more than 5% biodiesel may
be used. Biodiesel fuel is a product that has been converted from
renewable fuel sources, including vegetable oil, animal fat and cooking
oil. Raw or refined vegetable oil, animal fat, cooking oil or recycled
greases should not be used.
Since it is normal for a small amount of unburned fuel to enter the
crankcase and mix with the engine oil, the use of biodiesel requires that
the engine oil and filter be changed more often. Refer to theExceptions
section of theScheduled Maintenance Guidechapter for more
information.
Do not use home heating oil or any diesel fuel not intended for
highway use. Red dye is used to identify fuels intended for
agricultural and non-highway use. Damage to the fuel injection
system, engine and exhaust catalyst can occur if an improper fuel
is used. Do not add gasoline, gasohol or alcohol to diesel fuel.
This practice creates a serious fire hazard and engine
performance problems.
NOTE:Use of any fuel other than those recommended may cause
powertrain damage, a loss of vehicle performance, and repairs may not
be covered under warranty.
WARNING:Using low sulfur (16-500 ppm) or high sulfur
(greater than 500 ppm) diesel fuel in a diesel engine designed to
use only Ultra Low Sulfur Diesel fuel increases the likelihood of engine
oil dilution with fuel which may lead to major engine damage.
WARNING:Using low sulfur (16-500 ppm) or high sulfur
(greater than 500 ppm) diesel fuel in a diesel engine designed to
use only Ultra Low Sulfur Diesel fuel will cause certain emission
components to malfunction which may also cause the Service Engine
Soon (
SERVICE
ENGINE
SOON) light to illuminate indicating an emissions-related
concern.
WARNING:Do not mix diesel fuel with gasoline, gasohol or
alcohol. This could cause an explosion resulting in personal
injury.
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Filling the tank
For consistent results:
•Use the same fill rate setting (low - medium - high) each time during
filling.
•Allow three automatic click-offs when filling.
•Always use fuel of a known quality, preferably a national brand.
•Have the vehicle loading and distribution the same every time.
•When refueling a vehicle equipped with dual fuel tanks, if the two
tanks are not filled equally, the fuel gauge reading may fluctuate
slightly until the fuel level between the two tanks balance out and
become equal.
Your results will be most accurate if your filling method is consistent.
Note:For vehicles equipped with dual fuel tanks, engine performance
may degrade if fuel is not added to both tanks when refueling.
Calculating fuel economy
1. Fill the fuel tank(s) completely and record the initial odometer
reading (in miles or kilometers).
2. Each time you fill the tank(s), record the amount of fuel added (in
gallons or liters).
3. After at least three to five tank fill-ups, fill the fuel tank(s) and record
the current odometer reading.
4. Subtract your initial odometer reading from the current odometer
reading.
5. Follow one of the simple calculations in order to determine fuel
economy:
•Divide total miles traveled by total gallons used.
•Multiply liters used by 100, then divide by total kilometers traveled.
Keep a record for at least one month and record the type of driving (city
or highway). This will provide an accurate estimate of the vehicle’s fuel
economy under current driving conditions. Additionally, keeping records
during summer and winter will show how temperature impacts fuel
economy. In general, lower temperatures give lower fuel economy.
Driving style - good driving and fuel economy habits
Give consideration to the lists that follow and you may be able to change
a number of variables and improve your fuel economy.
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Diesel particulate filter regeneration (Caterpillar engine only)
DPF regeneration requires no operator interaction and may occur at any
time. A small increase in engine sound-level during filter regeneration is
normal and should be no reason for concern.
A separate fuel injector/nozzle, which requires periodic cleaning, is used
in the regeneration process. Refer to Caterpillar’sOperation and
Maintenance Manualfor details regarding cleaning requirements.
Diesel particulate filter regeneration (Cummins engine only)
Under most operating conditions, DPF regeneration will be transparent
to the operator. A small increase in engine/turbo sound-level is normal
during filter regeneration. If, however, your engine is operated for
extended periods of time under one of the following conditions, operator
assistance may be required to facilitate the filter regeneration process:
•Vehicle is operated in stop-and-go traffic and/or maintains low speeds
as in a city/delivery driving
•Engine is started and shut-off frequently
•Vehicle payload is relatively light
•Vehicle is regularly operated in cold ambient temperatures (i.e. below
0°F [-18°C])
Diesel Particulate Filter Four–Level Loading Chart
Level/Lamp status Filter status Requested action
Level 1
DPF lamp solidRegeneration required. Drive on highway at
highway speedsOR
start “parked
regeneration” to
prevent loss of engine
performance. Level 2
DPF lamp flashing
(once per second)Nearly full. Engine
performance is limited.
Level 3
DPF lamp flashing +
Service Engine Soon
lamp solidFull. Engine is
increasingly limited.Perform “parked
regeneration” to
prevent loss of engine
performance.
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3. Remove feet from the accelerator pedal and clutch pedal (if
equipped).
4. Set the parking brake.
5.Within 5 seconds of setting the parking brake,remove foot from
the service brake pedal.
When these steps are performed successfully in the order outlined above,
the DPF lamp will begin flashing at a rate of once every 10 seconds. The
engine speed may also increase slightly. To allow parked regeneration to
continue uninterrupted:
1. The vehicle must remain parked
2. The transmission must remain in P (Park) or N (Neutral) (as
previously described in Step 2).
3. The accelerator pedal, service brake pedal, and clutch pedal (if
equipped) must not be depressed
4. The parking brake must remain set
On average (depending on filter level and other factors), the process will
take 20–30 minutes to complete. The DPF lamp will turn off when the
process is complete. Repeat Steps 1–5, if parked regeneration is
interrupted.
To discontinue parked regeneration (Cummins engine only)
Depress any of the floor pedals to discontinue parked regeneration.
Diesel particulate filter maintenance and service
The DPF is designed to retain a relatively large amount of residual ash
and provide many miles and hours of maintenance-free operation. At
some point, generally beyond 150,000 miles (240,000 km) or 5,000 hours
of operation (whichever comes first), the DPF will require professional
cleaning to remove the accumulated ash
The exact number of miles or hours of operation will vary greatly
depending upon vehicle/engine loading and operating conditions, ash
content of the engine oil, and quality of the diesel fuel used in your
truck. Adhering to your engine manufacturer’s recommended oil and fuel
specifications will maximize the miles and hours of operation before a
DPF professional cleaning is required. Refer to your engine
manufacturer’s owner’s manual for more details regarding recommended
maintenance and service of your DPF.
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