light FORD F650 2009 12.G Manual PDF

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.
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.
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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.
Use the following installation procedure:
1. Slide inner rear or front tire and wheel in position over studs and push
it back as far as possible. Use care so that the threads on studs are not
damaged.
Disc wheel with flange nuts (hub-piloted)
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1. Flange nut
2. Wheel(s)
3. Brake drum
4. Wheel stud (22 mm)
5. Wheel hub
6. Wheel locator pad
Note for aluminum wheels:Prior to re-installing rear aluminum
hub-piloted wheels, clean each wheel locator pad on the hub from all
dirt, rust and foreign material. Apply a light coat of chassis grease,
never-seize or disc brake corrosion control grease, only to the wheel
locator pad.
3. Run the nuts on the studs until they contact the wheel(s). Rotate the
wheel assembly a half-turn to permit the parts to seat.
4. Draw up the nuts alternately following the crisscross sequence
illustrated under the following wheel tightening sequence illustrations.
Do not fully tighten the nuts. This will allow uniform seating of the nuts
and ensure even face-to-face contact of the wheel and hub.
1
6
5
4
32
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WARNING:Use only the same type and style wheels and
mounting hardware to replace original parts. Failure to do so
may result in an assembly that looks fine, but does not fit together
properly. This could possibly cause wheel or fastener failures which
could result in property damage, personal injury or death.
Note:Do not attempt to mix stud-piloted wheels or fasteners with
hub-piloted wheels or fasteners.
Note:Do not change from aluminum wheels to steel wheels or
vice-versa without changing the mounting hardware required or, with
flange-nut mounting systems, changing the hub and stud assembly.
WHEEL NUT TORQUE
Size Nut mountingTorque
Ft. lb. N•m
22 mm Flange 450–500 610–678
Note:Do not use lubrication on dry threads. Where excessive corrosion
exists, a light coat of lubricant on the first three threads of the stud bolt
is permitted. Keep lubricant away from:
•Hex nut and rim clamp contact surfaces.
•Cap nut ball face and ball seat on the disc wheel.
•Flange nut washer surface and flat on the disc wheel.
TIRE INFORMATION
Inflation
WARNING:Always maintain your tires in good condition.
Frequently check and maintain correct inflation pressures as
specified by tire manufacturers. Inspect periodically for abnormal wear
patterns and repair/replace cut or broken tire casing. Always use
experienced, trained personnel with proper equipment and correct
procedures to mount or remove tires and wheels. Failure to adhere to
these warnings could result in wheel or tire malfunction, damage to
your vehicle, personal injury, or death.
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Maintenance and Specifications
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WARNING:To avoid personal injury or death, always follow
these instructions when mounting radial tires on wheels:
•Only personnel that have had proper training and experience should
mount or remove tires from rims or wheels.
•Use only heavy-duty rims or approved rims for radial tires. It may be
necessary to contact your wheel and rim distributor to determine if
your rims are approved for radial tires.
•If a tube is to be used, make sure special radial tire tubes are used
because of the increased flexing of the sidewalls on radial tires.
•Never use anti-freeze, silicones, or petroleum based lubricants when
mounting radial tires. Only an approved lubricant should be used as
an aid for mounting tires.
•Always inflate tires in a safety cage.
•Do not attempt to mix stud piloted wheels or fasteners with hub
piloted wheels or fasteners. To do so may cause premature wheel
failure resulting in property damage, personal injury, or death.
•Do no mix foreign (not made in North America) wheel mounting
parts with domestic (made in North America) parts. Many foreign
wheel components look similar to, but not exactly the same as
domestic made components. Mixing components could cause wheel
or fastener failures and result in property damage, personal injury, or
death.
•Do not change from aluminum wheels to steel wheels or vice-versa
without changing the mounting hardware where required or, in some
cases with flange nut mounting systems, changing the hub and stud
assembly. Mixing components could cause wheel or fastener failures
and result in property damage, personal injury, or death.
All tires with Steel Carcass Plies (if equipped):
This type of tire utilizes steel cords in the sidewalls. As such, they
cannot be treated like normal light truck tires. Tire service, including
adjusting the air pressure, must be performed by personnel trained,
supervised and equipped according to Federal Occupational Safety and
Health Administration (OSHA) regulations. For example, during any
procedure involving tire inflation, the technician or individual must
utilize a remote inflation device, and ensure that all persons are clear of
the trajectory area.
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ComponentLubrication
typeViscosity /
Ambient
temperature /
NotesEquivalent
Ford part
name /
number
Cab components
Hydraulic lift pump
fluidDexron III — Motorcraft
MERCON
Multi-Purpose
(ATF)
Transmission
Fluid /
XT-2-QDX
Cab latch and lock
leversMobile SHC 32
Low
Temperature
Lubricant (or
equivalent)——
Cab latch pivots;
Door check, hinges,
latches and strikers;
Seat adjuster slidesGC/LB NLGI #2
lithium
complex-based
moly grease (or
equivalent) or
multi-purpose
lithium
complex grease— Motorcraft
Premium Long
Life Grease /
XG-1-C
Cab latch pivot pins Light engine oil — Motorcraft SAE
5W-30 Super
Premium Motor
Oil /
XO-5W30-QSP
Door lock cylinders Lock oil — Motorcraft
Penetrating
and Lock
Lubricant /
XL-1
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FACTORY AUTHORIZED SYSTEMS CHECKS
In the event that your vehicle experiences a component related concern,
please contact your Ford dealership. The Ford Motor Company Trained
Technicians who work at Ford dealerships are specifically trained to
understand your vehicle.
A proper repair begins with a thorough system check. A Factory
Authorized Systems Check can ONLY be found at a Ford dealership. In
some circumstances, the technician may need to request your
authorization to perform additional operations to determine the final
diagnosis. The technician’s goal is to ensure that your vehicle is fixed
right the first time, at the best value to you.
The following list represents several of the Factory Authorized Systems
Checks available at a participating Ford dealers:
•Air Conditioning
•Check Engine Light
•All Wheel Drive and 4x4
•Automatic Transmission
•Engine Cooling and Cabin Heating
•Steering and Suspension
•Charge/Start/Battery
•Wheel Alignment
•Anti-Lock Brake System
EMISSIONS CONTROL SYSTEM
To ensure the emissions control systems operate effectively, you should
have the services listed in the maintenance schedule performed at the
specified time and mileage/km intervals. You should avoid running out of
fuel or turning off the ignition while the vehicle is in motion, especially
at high speeds.
WARNING:Because of high engine compartment and exhaust
system temperatures resulting from emissions equipment, do not
park, idle or operate your vehicle in dry grass or other dry ground
cover where the possibility of ground fire exists.
Do not make unauthorized modifications to the engine or vehicle.
Modifications causing increased amounts of unburned fuel to reach the
exhaust system can significantly increase the temperature of the engine
compartment and/or the exhaust system.
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Scheduled Maintenance Guide
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Daily owner checks
EngineCheck the air filter restriction gauge.
Check the engine oil.
Inspect the coolant level
Brake systemCheck the air brake system reservoir
automatic drain valve operation.
Drain the air brake system reservoir -
manual valve.
Transmission systemVisually check the automatic
transmission for fluid leakage.
Steering systemCheck 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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A
Air conditioning ..........................47
manual heating and air
conditioning system .................47
Air suspension ...........................121
Anti-lock brake system
(see Brakes) ..............................119
Audio system
(see Radio) ......................33, 35, 40
Automatic transmission ............123
fluid, adding ............................201
fluid, checking ........................201
fluid, refill capacities ..............234
fluid, specification ..................220
Auxiliary power point .................55
Axle ............................132, 173, 206
lubricant specifications ..........220
refill capacities ........................232
B
Battery .......................................182
charging system warning
light ............................................22
jumping a disabled battery ....153
voltage gauge ............................28
Belt-Minder...............................75
Booster seats ...............................88
Brakes ........................100, 105, 174
adjustment ..............................176
anti-lock ...................................119
anti-lock brake system (ABS)
warning light .....................22, 119
brake warning light ..................22
fluid, checking and
adding ..............................176, 198
fluid, specifications .................220
parking ....................101, 108, 177Bulbs ............................................51
C
Catalytic converter
(see Emission control) .............177
CD-single premium .....................33
Cell phone use ..............................7
Child safety seats ........................82
attaching with tether straps ....86
in front seat ..............................84
in rear seat ..........................84, 86
tether anchorage hardware .....86
Child safety seats - booster
seats .............................................88
Cleaning your vehicle
chrome and aluminum
parts .........................................167
engine compartment ..............167
exterior ....................................169
instrument panel ....................168
interior .....................................168
interior trim ............................168
plastic parts ............................167
washing ....................................166
waxing .....................................166
wheels ......................................167
Climate control (see Air
conditioning or Heating) ......46–47
Clutch ................................126, 199
adjusting ..................................200
fluid ..........................................199
operation while driving ..........126
specifications ..........................220
Controls
power seat .................................66
Coolant ......................................184
refill capacities ........................234
specifications ..........................220
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H
Hazard flashers .........................144
Headlamps ...................................49
aiming ........................................50
daytime running lights .............49
high beam .................................49
warning chime ..........................22
Heating ..................................46–47
heater only system ...................46
manual heating and air
conditioning system .................47
Hood ..........................................179
I
Ignition .........................................92
chime .........................................22
Infant seats (see Safety seats) ..82
Instrument panel
cleaning ...................................168
lighting up panel and
interior .......................................50
J
Jump-starting your vehicle ......153
K
Keys
key in ignition chime ...............22
positions of the ignition ...........92
L
Lamps
bulb replacement
specifications chart ..................51
cargo lamps ...............................50
daytime running light ...............49headlamps .................................49
high beams ................................49
instrument panel, dimming .....50
interior lamps ...........................51
replacing bulbs ...................51–53
Lane change indicator
(see Turn signal) ........................50
Lights, warning and indicator ....22
air suspension ...........................22
anti-lock brakes (ABS) ....22, 119
brake ..........................................22
charging system ........................22
safety belt .................................22
service engine soon ..................22
traction control off ...................22
turn signal indicator .................22
Lubricant specifications ...........220
M
Manual transmission .................127
lubricant specifications ..........220
Mirrors .........................................57
fold away ...................................59
heated ........................................58
side view mirrors (power) .......58
O
Odometer .....................................28
P
Paint chips, repairing ...............166
Parking brake ....................101, 108
warning light .............................22
Power door locks ........................64
Power mirrors .............................58
Power point .................................55
Power steering ..........................179
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