Service FORD F750 2011 12.G Repair Manual

WARNING:An inflated tire and rim can be very dangerous if
improperly used, serviced or maintained. To avoid serious injury,
never attempt to re-inflate a tire which has been run flat or seriously
under-inflated without first removing the tire from the wheel assembly
for inspection. Do not attempt to add air to tires or replace tires or
wheels without first taking precautions to protect persons and
property.
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Stay out of the trajectory (1) as indicated in the illustration.
WARNING:Do not mount tube type tires on tubeless wheels or
tubeless tires on tube type wheels. To do so could result in tire
or wheel failure and cause property damage, personal injury or death.
Preserving proper inflation pressure is a very important maintenance
practice to insure safe vehicle operation and long life for the tires.
Failure to maintain correct inflation pressure may result in sudden tire
destruction, improper vehicle handling, and may cause rapid and
irregular tire wear. Therefore, inflation pressures should be checked daily
and always before long distance trips.
Follow the tire manufacturer’s recommended cold inflation pressure for
the tire size, type, load range (ply rating) and axle loading typical for
your operation. (Each steer axle tire load will equal
12steer axle loading;
each drive tire load will be14the axle loading if fitted with four tires).
Checking inflation
Always check inflation pressure when tires are cold. Never bleed air from
hot tires to relieve normal pressure build-up. Normal increases in
pressure due to service conditions will be 10–15 psi (69–103 kPa), which
is allowable in truck tires.
Tires should be properly inflated to manufacturers recommended
pressure for the size and service load in which the vehicle is being used.
Refer to the specific tire manufacturer with which your vehicle is
equipped with for the latest information concerning service load and
inflation pressure.
It is particularly important to keep moisture from the inside of tires, and
proper selection of air compressor equipment, proper air line routing,
and the use of shop air dryers is strongly recommended to avoid
moisture in the high pressure air used for tire inflation.
Under-inflation
Tires should not be permitted to become under-inflated. Increased
flexing due to under-inflation causes heat build-up within the tire
components. This leads to reduced strength, breakdown of the rubber
compounds, and possible separation of the tire components (i.e., ply and
tread separation and reduced retreadability).
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Transmission
Description Pints (Liters)
Allison 2000 Series 30.0 (14.2)*
Allison 3000 Series 37.6 (17.8)*
5–speed manual 12.5 (5.9)
6–speed manual 19.5 (9.2)
7–speed manual 22.0 (10.4)
*Total fluid capacity (dry transmission and torque converter).
Air conditioner refrigerant - r134a
This system uses PAG-type refrigerant oil.
Refrigerant fitting torque
Captured washer nut: 170–190 inch lb. (19–21 N•m)
Note:This system uses mineral-based refrigerant oil to lubricate o-rings
and fittings.
Fuel tanks
Standard tanks are listed as such; all other tanks available for your
vehicle are optional equipment.
Vehicle Tank type Gallons
(Liters)
F-650 Low Profile (standard), F-650
Dock HeightSingle, steel
rectangular35 (132)
F-650 Low Profile, F-650 Dock
Height (standard), F-750 Pick-up
and Delivery (standard), F-750
Severe Service (standard)Single, steel
rectangular45 (170)
F-650 Dock Height, F-750 Pick-up
and Delivery, F-750 Severe ServiceSingle, steel
rectangular50 (189)
F-650 Low Profile, F-650 Dock
Height, F-750 Pick-up and Delivery,
F-750 Severe ServiceSingle, steel
rectangular65 (246)
F-650 Dock Height, F-750 Pick-up
and Delivery, F-750 Severe ServiceSingle, steel
D-style65 (246)
F-650 Dock Height, F-750 Pick-up
and Delivery, F-750 Severe ServiceSingle, steel
D-style80 (302)
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Vehicle Tank type Gallons
(Liters)
F-650 Low Profile, F-650 Dock
Height, F-750 Pick-up and Delivery,
F-750 Severe ServiceDual, steel
rectangular25(LH)/45(RH)
(95[LH]/170[RH])
F-650 Low Profile, F-650 Dock
HeightDual, steel
rectangular35(RH)/45(LH)
(132[RH]/170[LH])
F-650 Low Profile, F-650 Dock
Height, F-750 Pick-up and Delivery,
F-750 Severe ServiceDual, steel
rectangular45/45 (170/170)
F-650 Dock Height, F-750 Pick-up
and Delivery, F-750 Severe ServiceDual, steel
D-style50/50 (189/189)
F-650 Low Profile, F-650 Dock
Height, F-750 Pick-up and Delivery,
F-750 Severe ServiceDual, steel
rectangular45(RH)/65(LH)
(170[RH]/246[LH])
F-650 Low Profile, F-650 Dock
Height, F-750 Pick-up and Delivery,
F-750 Severe ServiceDual, steel
rectangular65/65 (246/246)
F-650 Dock Height, F-750 Pick-up
and Delivery, F-750 Severe ServiceDual, steel
D-style65/65 (246/246)
F-650 Dock Height, F-750 Pick-up
and Delivery, F-750 Severe ServiceDual, steel
D-style65 (LH)/80 (RH)
(246[LH]/302[RH])
F-650 Dock Height, F-750 Pick-up
and Delivery, F-750 Severe ServiceDual, steel
D-style80/80 (302/302)
VEHICLE IDENTIFICATION NUMBER (VIN)
The VIN is printed on the Vehicle Rating Decal attached to the vehicle
on the edge of the driver’s door or B-Pillar. The VIN also serves as the
warranty number. If you ever find it necessary to communicate with Ford
Motor Company about your vehicle, always include the VIN in your
communication.
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GENERAL MAINTENANCE INFORMATION
The general maintenance services listed in this section are required
because they are considered essential to the life and performance of
your vehicle. Refer to the Daily Owner Checks chart for important
maintenance items.
Ford Motor Company recommends you perform the owner maintenance
services listed in this section. These services are matters of day-to-day
care that are important to the proper operation of your vehicle. In
addition to the conditions described in owner maintenance, be alert for
any unusual noise, vibration or other indication that your vehicle may
need service and attend to it promptly.
Your vehicle is very sophisticated and built with multiple complex
performance systems. Every manufacturer develops these systems using
different specifications and performance features. That’s why it’s
important to rely upon your Ford dealership to properly diagnose and
repair your vehicle.
Use only recommended fuels, lubricants, fluids and service parts
conforming to Ford specifications. Motorcraftparts are designed and
built for best performance in your vehicle. Using these parts for
replacement is your assurance that Ford-built quality stays in your
vehicle.
Non-Ford approved chemicals or additives are not required for factory
recommended maintenance. In fact, Ford Motor Company recommends
against the use of such additive products unless specifically
recommended by Ford for a particular application.
Authorized dealer maintenance
Your authorized dealer specializes in knowing all about Ford Motor
Company vehicles rather than knowing a little about all makes.
There are Ford and Ford of Canada dealer service shops ready to serve
you wherever you drive in the U.S. or Canada. They stock Ford and
Motorcraftparts, and Ford chemicals and lubricants. You can be
confident that these meet the same exacting design and quality
standards as those used to build the vehicle originally. Dealer service
technicians have available training in the latest product developments
and service techniques.
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Daily owner checks
U.S. Department
of Transportation,
Federal Highway
Administration
requirements
(ensure that the
entire system is
functioning
properly)Service brakes
Parking brake
Steering mechanism
Lighting devices and reflectors
Tires
Horn
Windshield wipers
Rear vision mirrors
Wheels and rims
Emergency equipment
Every oil change
EngineInspect engine cooling system hoses, clamps and
protection.*
Inspect drive belts.
Exhaust systemInspect 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.)
SuspensionTighten the front and rear spring U-bolts to the
specified torque.
Driveline and rear
axleLubricate the U-joints and the slip yoke.
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Every oil change
BrakesLubricate the air brake foot control valve, hinge
and roller.
Inspect the drum brake linings through the
inspection holes.
Lubricate the rear caliper slide rails.
Lubricate the brake camshafts (air brakes only).
Lubricate the brake slack adjuster (air brakes
only).
Inspect the disc brake pads and the piston boots
(hydraulic brakes only).
ClutchLubricate the clutch release cross shaft and all
linkages.
Check the clutch fluid level.
Fuel systemDrain the accumulated water or sediment from
the fuel tank(s).
Steering systemLubricate the steering shaft(s), U-joints and
splines if equipped with grease fittings.
Lubricate the front axle spindle pins.
Lubricate the steering linkage when equipped
with grease fittings.
Lubricate 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 distilled water. Use only
permanent type coolant that meets specifications as listed in your
engine operator’s manual. See the engine manufacturer’s operating
guide for supplemental corrosion inhibitor specifications.
Periodic component/system checks
The following are vehicle checks that should be made periodically either
by the owner or a qualified technician. It is recommended that
deficiencies be brought to the attention of your dealer or another
qualified service outlet as soon as possible in order that advice regarding
the need for service or replacement can be obtained.
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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 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.
Avoid driving your vehicle if it does not operate properly. If the engine
diesels (more than five seconds of engine run-on after shut-off), misfires,
surges, stalls or backfires, see your dealer. Be alert for fluid leakage,
odor, smoke, loss of oil pressure, or charge indicator or over temperature
warning.
Do NOT use diesel fuel blended with waste oil in engines equipped with
a catalytic converter-muffler. Waste lube oil blending in fuel will plug the
catalytic converter-muffler, resulting in a significant loss of engine power.
Noise emissions warranty, prohibited tampering acts and
maintenance
On January 1, 1978, Federal regulations became effective governing the
noise emissions on trucks over 10,000 lb. (4,536 kg) GVWR. The
following statements concerning prohibited tampering acts and
maintenance and the noise warranty are found in the Warranty Guide,
and are applicable to completed trucks.
Tampering with noise control system prohibited
Federal law prohibits the following acts or the causing thereof: (1) The
removal or rendering inoperative, by any person other than for purposes
of maintenance, repair or replacement, of any device or element of
design incorporated into any new vehicle for the purpose of noise control
prior to its sale or delivery to the ultimate purchaser or while it is in use,
or (2) the use of the vehicle after such device or element of design has
been removed or rendered inoperative by any person.
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Maintenance
Instructions for maintenance and service of the noise control system
have been included in the required maintenance services and in the
general maintenance section. To further help minimize noise emissions
degradation throughout the life of the vehicle, Ford Motor Company
recommends that this vehicle should be operated in the manner
described within this owner guide. Caution should be exercised by the
owner when installing replacement parts to be sure that a tampering act
(as outlined above) is not committed. Note any inspection and service
performed in the maintenance log.
Emissions information label
Emissions information appears on the Important Engine Information
decal located on or near the engine.
SCHEDULED MAINTENANCE SERVICES
Maintenance service adjustments must conform to specifications
contained in this manual, and those shown on the Important Engine
Information decal. The following services are to be performed at
scheduled intervals because they are considered essential to the life and
performance of your vehicle. Ford recommends that you perform
maintenance on all designated items to achieve best vehicle operation.
Maintenance intervals are provided for three types of general vehicle
environments: On-Highway, City and Severe Service. In all applications,
the actual interval is determined by monitoring miles (kilometers) and
time and when the engine is due for an oil change. When the engine oil
change is required prior to the truck lubrication interval, it is
recommended that the lubrication be performed at the same time in
order to reduce your vehicle’s time out of service.
•On-Highway:60,000 miles (96,000 km) or more annually.
•City:60,000 miles (96,000 km) or fewer annually.
•Severe Service:20,000 miles (32,000 km) or fewer annually on/off
road in dirty conditions.
Scheduled maintenance beyond 100,000 miles (160,000 km) should be
continued as before 100,000 miles (160,000 km).
Maintenance intervals
Ford Motor Company has recommended maintenance intervals for
various parts and component systems based upon engineering testing.
Ford Motor Company relies upon this testing to determine the most
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appropriate mileage for replacement of oils and fluids to protect your
vehicle at the lowest overall cost to you and recommends against
maintenance schedules that deviate from the scheduled maintenance
information.
The maintenance or replacement of the emission control devices (or
systems) in your new Ford Motor Company vehicle (or engine) may be
performed at your expense. These services may be performed by any
automotive repair establishment or individual using automotive parts
equivalent to those with which your vehicle or engine was originally
equipped. If any parts other than Ford, Motorcraft, or Ford-authorized,
remanufactured parts are used for maintenance replacements (or for the
service) of components effecting the emission control, the owner should
be ensured that such parts are warranted by their manufacturer to be
equivalent to genuine Ford Motor Company parts in performance and
durability. Please consult yourWarranty Guidefor complete warranty
information.
Air brake adjustment
WARNING:Failure to maintain proper air brake adjustment can
result in reduction or loss of braking ability.
Air brake inspection and adjustment or repairs should be performed by a
qualified service technician in accordance with the instructions in the
service manual.
Cam brakes - automatic slack adjusters
Inspect standard air brakes equipped with automatic slack adjusters for
proper brake adjustment as listed in the maintenance schedule charts.
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.
WARNING:Do not manually adjust the automatic slack
adjusters to correct excessive push rod stroke as it may result in
reduced brake effectiveness and a vehicle crash. Excessive push rod
stroke indicates that a problem exists with the automatic adjuster, with
the installation of the adjuster, or with foundation brake components
that manual adjustment will not remedy. Seek service from a qualified
facility for excessive push rod stroke.
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