light FORD F650/750 2019 Repair Manual

Engine starting (with parking brake applied)
Check the gauge (diesel engine) or indicator light (gasoline
engine) to verify the alternator is charging.
Voltmeter
Inspect for excessive free play in the steering linkages. The
steering wheel should have less than 2 in (5 cm) of free play
at its rim.
Steering linkage free play
Verify the parking brake holds the vehicle by gently trying to
pull forward with the parking brake applied.
Parking brake
Verify operation using the following procedure. Chock the
wheels, if necessary. Push in the parking brake and, on
tractors, push in the tractor parking brake knob:
Air brakes
1. Verify the air compressor or governor cutout pressure is
approximately 120 psi (827 kPa).
2. Turn off the engine, and then turn the key back to the on
position (without starting the engine).
3. Without the brake pedal applied, note the air pressure drop
for one minute. It should be less than 2 psi (14 kPa) for single
vehicles and
3 psi (21 kPa) for combination vehicles.
4. Press and hold the brake pedal with
90 psi (621 kPa) or
more. Make sure there is no more than a 3 psi (21 kPa) per
minute leak for single vehicles and a 4 psi (28 kPa) minute
leak for combination vehicles.
5. Pump the brake pedal to deplete the system of air pressure.
The warning light and tone should turn on at 57 psi (393 kPa).
6. Pump the brake pedal and make sure the parking brake
and trailer parking brake knobs pop out at
20 psi (138 kPa)
or higher.
Verify that the fluid level is in the proper operating range. See
Automatic Transmission Fluid Check
(page 204).
Automatic transmission
fluid Front of vehicle
Verify all exterior lights illuminate and are clean.
Lights
Check headlights function on high and low beam.
Verify reflectors are clean, unbroken and of proper color (red
on rear, amber elsewhere).
180
F650750 (TBC) , enUSA, Edition date: 201804, Second-Printing Vehicle Inspection Guide

Front of vehicle
Verify running lights are clean and unbroken.
Inspect for any missing or loose fasteners, power steering
fluid leaks and damage to power steering hoses.
Steering gear
Verify connecting links, arms and rods are not worn or cracked.
Steering linkage
Verify joints, sockets and boot seals are not worn or loose.
Verify cotter keys, nuts and bolts are not loose or missing.
Inspect front and rear tow hooks for damage or loose
mounting. This is particularly important on vehicles that use
them frequently.
Tow hooks Front suspension
Inspect for missing, broken or shifted leaves, or leaves that
may be in contact with (or nearly contacting) a tire, rim, brake
drum, frame or body component.
Springs
Note: Never apply grease to spring pads.
Make sure there the following items are properly tightened
and that there are no cracks, breaks, wear, damage to spring
hangers, bolts, bushings, axle mounting bolts, and nuts.
Spring mounts
Inspect for any cracks, leaks, or missing or broken bolts or
bushings.
Shock absorbers
181
F650750 (TBC) , enUSA, Edition date: 201804, Second-Printing Vehicle Inspection Guide

Diesel Exhaust Fluid (DEF) area
Verify the tanks and caps are secure and that there are no
leaks from the tanks.
DEF tanks
Inspect for leaks from the tanks.
Leaks Underbody
Verify that the driveshaft is not bent or cracked and that all
driveshaft couplings are secure.
Driveshaft
Verify that the visible outside parts are securely mounted and
that there are no cracks, holes or severe dents.
Exhaust system
Inspect for cracks or bends in longitudinal frame members.
Verify there are no loose, cracked, bent, broken or missing
crossmembers or crossmember fasteners.
Frame Rear of vehicle
Verify there are no cuts, cracks, chafing or wear on the air
hoses and electrical line insulation. Listen for audible air leaks.
Air hoses and electrical
lines
Verify air and electrical lines are not tangled, crimped or
pinched or being dragged against any truck parts. None of
the air or electrical line should be spliced or taped.
Inspect for corrosion on pins and in electrical sockets to verify
continuity and reduced heat build-up potential.
Verify the deck plate is clean, bolted securely to the frame
and is clear of loose objects.
Deck plate
Verify that both brake lights illuminate when the pedal is
applied, each signal flashes and that the four-way flashers
work properly.
Turns signals, brake
lights and flashers
Verify all exterior lights illuminate and are clean.
Lights and reflectors
Verify reflectors are clean, unbroken and of proper color (red
on rear, amber elsewhere).
Verify running lights are clean and unbroken.
Note: Inspect rear running lights separately from signal,
flasher and brake lights.
183
F650750 (TBC) , enUSA, Edition date: 201804, Second-Printing Vehicle Inspection Guide

Rear brakes
Inspect for cracked, worn or frayed hoses, and that all coup-
lings are secure.
Hoses
Verify that there are no cracks or dents, and that the cham-
bers are securely mounted.
Brake chambers
Inspect for broken, loose or missing parts.
Slack adjusters
Note: The angle between the push rod and adjuster arm
should be approximately 90 degrees when the brakes are
applied. When pulled by hand, the push rod should not move
more than approximately
1 in (2.5 cm).
Verify that there are no cracks, dents, holes, and no loose or
missing bolts and that the brake linings are not worn,
dangerously thin or contaminated by lubricant.
Drums Rear wheels
Check for even separation of dual wheels, and that the tires
are not touching each other.
Spacers
Inspect for damaged or bent rims. They should not have
welding repairs, and there should be no rust trails, which
indicate it is loose on the wheel.
Rims
Verify all lug nuts are present and not loose (look for rust
trails around the lug nuts). There should be no cracks radiating
from the lug bolt holes or distortion of the bolt holes.
Lug nuts
Trailer
If you are pulling a trailer, perform an
inspection of the trailer similar to that of
the tractor. The inspection should follow
trailer manufacturer recommendations
and should include at a minimum: general
condition, landing gear, doors, sides, lights,
reflectors, suspension, brakes, tires,
wheels, cargo placement, stability and
tie-downs. Transmission WARNING: If the unit starts in gear
and/or the neutral start switch is not
functioning correctly, the vehicle may
inadvertently move which could result
in property damage, personal injury or
death.
Regularly inspect the transmission's
neutral start switch. The engine should
only start in neutral (N) or park (P) (if
equipped with a park position).
185
F650750 (TBC) , enUSA, Edition date: 201804, Second-Printing Vehicle Inspection Guide

4.
Make sure that the sealing surfaces on
the filter housing and cover are clean
and free of debris.
5. Install the new filter element.
6. Install the filter cover.
7. Install the bolts finger-tight. 8.
Fully tighten all of the bolts to between
3–4 lb.ft (4.5–6 Nm) in the sequence
shown.
9. Record the engine mileage and update
the service log accordingly.
OIL CHANGE INDICATOR
RESET
Use the information display controls on
the steering wheel to reset the oil change
indicator. See
General Information
(page 64). ENGINE COOLANT CHECK -
6.7L DIESEL WARNING:
Do not remove the
coolant reservoir cap when the engine is
on or the cooling system is hot. Wait 10
minutes for the cooling system to cool
down. Cover the coolant reservoir cap
with a thick cloth to prevent the
possibility of scalding and slowly remove
the cap. Failure to follow this instruction
could result in personal injury. WARNING:
Do not put coolant in
the windshield washer reservoir. If
sprayed on the windshield, coolant could
make it difficult to see through the
windshield. WARNING:
To reduce the risk of
personal injury, make sure the engine is
cool before unscrewing the coolant
pressure relief cap. The cooling system
is under pressure. Steam and hot liquid
can come out forcefully when you loosen
the cap slightly. WARNING:
Do not add coolant
further than the MAX mark.
When the engine is cold, check the
concentration and level of the coolant at
the intervals listed in the scheduled
maintenance information. See Scheduled
Maintenance
(page 322).
Note: Make sure that the coolant level is
between the
MIN and MAX marks on the
coolant reservoir.
Note: Coolant expands when it is hot. The
level may extend beyond the
MAX mark.
196
F650750 (TBC) , enUSA, Edition date: 201804, Second-Printing MaintenanceE211404
165
4
32
7

Engine-driven Cooling Fan
Your vehicle may have an engine driven
cooling fan drive also called a fan clutch.
This fan drive changes the fan speed to
match the vehicle
’s changing cooling air
flow requirements. Fan speed, fan noise
level and fuel consumption all will increase
based on the driving conditions that
include trailer towing, hill climbing, heavy
loads, high speed and high ambient
temperature, individually or in combination.
The fan drive is designed to provide the
minimum fan speed and resulting
minimum fan noise and fuel consumption
required to meet the ever-changing vehicle
cooling air flow requirements. You can hear
the amount of fan noise increasing and
decreasing as the engine power
requirements and vehicle driving conditions
change as you drive. This is normal to the
operation of your vehicle. You may also
hear high levels of the fan when the engine
is first started and should normally
decrease after driving for a short time.
ENGINE COOLANT CHECK -
6.8L WARNING: Do not remove the
coolant reservoir cap when the engine is
on or the cooling system is hot. Wait 10
minutes for the cooling system to cool
down. Cover the coolant reservoir cap
with a thick cloth to prevent the
possibility of scalding and slowly remove
the cap. Failure to follow this instruction
could result in personal injury. WARNING:
Do not put coolant in
the windshield washer reservoir. If
sprayed on the windshield, coolant could
make it difficult to see through the
windshield. WARNING:
To reduce the risk of
personal injury, make sure the engine is
cool before unscrewing the coolant
pressure relief cap. The cooling system
is under pressure. Steam and hot liquid
can come out forcefully when you loosen
the cap slightly. WARNING:
Do not add coolant
further than the MAX mark.
When the engine is cold, check the
concentration and level of the coolant at
the intervals listed in the scheduled
maintenance information. See Scheduled
Maintenance
(page 322).
Note: Make sure that the coolant level is
between the
MIN and the MAX marks on
the coolant reservoir.
Note: Coolant expands when it is hot. The
level may extend beyond the
MAX mark.
Maintain coolant concentration within
48% to 50%, which equates to a freeze
point between -30°F (-34°C) and -34°F
(-37°C). Coolant concentration should be
checked using a refractometer. We
recommend Robinair® Coolant and
Battery Refractometer 75240 (Rotunda
tool part number: ROB75240). We do not
recommend the use of hydrometers or
coolant test strips for measuring coolant
concentration.
Note: Automotive fluids are not
interchangeable. Do not use coolant or
windshield washer fluid outside of its
specified function and vehicle location.
Note: Do not use stop leak pellets, cooling
system sealants, or additives as they can
cause damage to the engine cooling or
heating systems. Resulting component
damage may not be covered by the vehicle
Warranty.
200
F650750 (TBC) , enUSA, Edition date: 201804, Second-Printing Maintenance

DRAINING THE FUEL FILTER
WATER TRAP - 6.7L DIESEL
Your vehicle is equipped with a diesel fuel
conditioner module located on the
frame-rail under the driver-side floorboard
near the transmission.
You should drain water from the
module assembly whenever the
warning light comes on and the
message center directs you to drain the
water separator. This will occur when
approximately 8.45 fl oz (250 ml) of water
accumulates in the module. If you allow
the water level to exceed this level, the
water may pass through to the engine and
may cause fuel injection equipment
damage.
Draining the Diesel Fuel
Conditioner Module (DFCM) WARNING: Do not drain the
water-in-fuel separator while the engine
is running. Failure to follow this warning
may result in fire, serious injury, death or
property damage.
Note: If you drain the diesel fuel conditioner
module while the system is running air will
enter into the fuel system. The engine will
not operate properly if air enters the system.
Note: With fuel tank levels above 3⁄4 tank
it may be necessary to loosen the bowl three
turns before opening the drain. This will
actuate an anti-siphon valve at the fuel and
water separator inlet and prevent the fuel
from siphoning out of the tank.
Note: A loose drain valve can allow air to
enter the fuel system and cause drivetrain
issues. The engine will not operate properly.
Be sure that you fully tighten the drain valve.
1. Stop your vehicle and shut off the engine. 2. Locate the diesel fuel conditioner
module and place an appropriate
container under the drain port. 3.
Rotate the drain counterclockwise until
the O-ring is visible. Allow the diesel
fuel conditioner module to drain for
approximately 25 seconds or until
clean fuel is observed. Rotate the drain
clockwise to tighten it. If no liquid
drains, there may be a clog in the drain.
Have the conditioner module serviced
by an authorized dealer.
4. Make sure that you fully tighten the drain valve and then remove the
container from under your vehicle.
5. Restart the engine. If the Water in Fuel
Drain Filter
message and light
continues to illuminate, have the fuel
system checked and repaired.
FUEL FILTER - 6.8L
Your vehicle is equipped with a lifetime
fuel filter that is integrated with the fuel
tank. Regular maintenance or replacement
is not needed.
207
F650750 (TBC) , enUSA, Edition date: 201804, Second-Printing Maintenance E163360

CHANGING THE 12V BATTERY
WARNING: This vehicle may be
equipped with more than one battery,
removal of cable from only one battery
does not disconnect the vehicle
electrical system. Be sure to disconnect
cables from all batteries when
disconnecting power. Failure to do so
may cause serious personal injury or
property damage. 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 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.
Note: If your battery has a cover/shield,
make sure it is reinstalled after the battery
has been cleaned or replaced. Note:
Battery posts, terminals and related
accessories contain lead and lead
compounds. Wash hands after handling.
Note: Electrical or electronic accessories
or components added to the vehicle by the
dealer or the owner may adversely affect
battery performance and durability.
Your vehicle is equipped with a Motorcraft
maintenance-free battery which normally
does not require additional water during
its life of service.
For longer, trouble-free operation, keep the
top of the battery clean and dry. Also,
make certain the battery cables are always
tightly fastened to the battery terminals.
If you see any corrosion on the battery or
terminals, remove the cables from the
terminals and clean with a wire brush. You
can neutralize the acid with a solution of
baking soda and water.
It is recommended that the negative
battery cable terminal be disconnected
from the battery if you plan to store your
vehicle for an extended period of time.
Because your vehicle ’s engine is
electronically controlled by a computer,
some control conditions are maintained
by power from the battery. When the
battery is disconnected or a new battery
is installed, the engine must relearn its idle
and fuel trim strategy for optimum
driveability and performance. To begin this
process
1. With the vehicle at a complete stop, set the parking brake.
2. Put the gearshift in park (P) or neutral (N) and turn off all accessories.
3. Start the engine. Run the engine until it reaches normal operating
temperature.
4. Allow the engine to idle for at least one
minute.
208
F650750 (TBC) , enUSA, Edition date: 201804, Second-Printing Maintenance

Headlamp Aiming Target
8 feet (2.4 meters)
A
Center height of lamp to ground
B
25 feet (7.6 meters)
C
Horizontal reference line
D
Vertical Aim Adjustment Procedure
1. Park the vehicle directly in front of a wall or screen on a level surface,
approximately 25 ft (7.6 m) away.
2. Measure the height of the headlamp bulb center from the ground and mark
an
8 ft (2.4 m) horizontal reference line
on the vertical wall or screen at this
height.
Note: To see a clearer light pattern for
adjusting, you may want to block the light
from one headlamp while adjusting the
other.
3. Turn on the low beam headlamps to illuminate the wall or screen and open
the hood. 4. On the wall or screen you will observe
a flat zone of high intensity light
located at the top of the right hand
portion of the beam pattern. If the top
edge of the high intensity light zone is
not at the horizontal reference line, the
headlamp will need to be adjusted. 5. Locate the vertical adjuster on each
headlamp. Using a Phillips #2
screwdriver, turn the adjuster either
clockwise or counterclockwise in order
to adjust the vertical aim of the
headlamp.
6. Repeat Steps 3 thru 5 to adjust the other headlamp.
7. Close the hood and turn off the lamps.
Horizontal Aim Adjustment
Horizontal aim is not required for this
vehicle and is not adjustable.
211
F650750 (TBC) , enUSA, Edition date: 201804, Second-Printing MaintenanceE142592 E142465 E163806

REMOVING A HEADLAMP
1. Remove the four bolts from the
headlamp assembly.
2. Pull the assembly straight out disengaging one snap clip from the
fender.
3. Disconnect the electrical connector by
squeezing the release tab and pushing
the connector forward, then pulling it
rearward.
CHANGING A BULB WARNING: Bulbs can become hot.
Let the bulb cool down before removing
it. Failure to do so could result in
personal injury.
Headlamp bulbs must be marked with an
authorized D.O.T. marking for North
America to make sure they have the proper
lamp performance, light brightness, light
pattern and safe visibility.
Install in the reverse order unless otherwise
stated.
Headlamp Bulbs
1. Switch all of the lamps and the ignition
off. 2. Remove the headlamp. See
Removing a Headlamp (page 212).
3. Release the clip and remove the bulb.
Note: Do not touch the bulb glass.
Note: If the bulb is accidentally touched, it
should be cleaned with rubbing alcohol
before being used.
Front Clearance and Identification
Lamp
(If Equipped) 1.
Switch all of the lamps and the ignition
off.
2. Remove the screw and lens from the lamp assembly.
3. Press the bulb in and turn the bulb counterclockwise to remove it.
212
F650750 (TBC) , enUSA, Edition date: 201804, Second-Printing MaintenanceE163822 E163825