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Ford 2002 F650 Owner's Manual

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Summary of Contents for Ford 2002 F650

  • Page 1: Table Of Contents

    Table of Contents Introduction Congratulations Safety and environment protection Symbol glossary Instrument Cluster Gauges Entertainment Systems AM/FM stereo AM/FM stereo cassette AM/FM stereo cassette with CD AM/FM stereo with CD Climate Controls Heater only Manual heating and air conditioning Lights Headlamps Driver Controls Windshield wiper/washer control...
  • Page 2 Ford Motor Company. Ford may change the contents without notice and without incurring obligation. Copyright © 2001 Ford Motor Company...

  • Page 3: Introduction

    State of California to cause cancer and birth defects or other reproductive harm. CONGRATULATIONS Congratulations on acquiring your new Ford. Please take the time to get well acquainted with your vehicle by reading this handbook. The more you know and understand about your vehicle the greater the safety and pleasure you will derive from driving it.

  • Page 4: Safety And Environment Protection

    Introduction SAFETY AND ENVIRONMENT PROTECTION Warning symbols in this guide How can you reduce the risk of personal injury and prevent possible damage to others, your vehicle and its equipment? In this guide, answers to such questions are contained in comments highlighted by the warning triangle symbol.
  • Page 5 Introduction SPECIAL NOTICES Emission warranty The New Vehicle Limited Warranty includes Bumper-to-Bumper Coverage, Safety Restraint Coverage, Corrosion Coverage, and 7.3L Power Stroke Diesel Engine Coverage. In addition, your vehicle is eligible for Emissions Defect and Emissions Performance Warranties. For a detailed description of what is covered and what is not covered, refer to the Warranty Guide that is provided to you along with your Owner’s Guide.

  • Page 6: Symbol Glossary

    Introduction These are some of the symbols you may see on your vehicle. Vehicle Symbol Glossary Safety Alert See Owner’s Guide Fasten Safety Belt Child Seat Child Seat Installation Child Seat Tether Warning Anchorage Brake System Anti-Lock Brake System Brake Fluid - Traction Control Non-Petroleum Based Master Lighting Switch...
  • Page 7 Introduction Vehicle Symbol Glossary Panic Alarm Engine Oil Engine Coolant Engine Coolant Temperature Do Not Open When Hot Battery Avoid Smoking, Flames, Battery Acid or Sparks Explosive Gas Fan Warning Maintain Correct Fluid Power Steering Fluid Level Emission System Engine Air Filter Passenger Compartment Jack Air Filter...
  • Page 8 Your Ford dealer has information about the availability of equipment which may be ordered for your vehicle.

  • Page 9: Instrument Cluster

    Instrument Cluster WARNING LIGHTS AND CHIMES Warning lights and gauges can alert you to a vehicle condition that may become serious enough to cause expensive repairs. A warning light may illuminate when a problem exists with one of your vehicle’s functions. Many lights will illuminate when you start your vehicle to make sure the bulb works.
  • Page 10 Instrument Cluster If the Service Engine Soon light remains on, have your vehicle serviced at the first available opportunity. Under engine misfire conditions, excessive exhaust temperatures could damage the fuel system, interior floor coverings or other vehicle components, possibly causing a fire. Engine protect warning (Cummins engine only) Illuminates when there is a fault in ENGINE...
  • Page 11 Instrument Cluster Brake reserve system warning (if equipped) Illuminates to indicate normal BRAKE Hydromax booster reserve system activation when the engine is OFF and the service brake pedal is applied, or when the ignition is in the ON or START position. This light may also illuminate momentarily if the engine is running and the driver turns the steering wheel fully in one direction while braking.
  • Page 12 Instrument Cluster Trailer ABS brake system (if equipped) Illuminates briefly when the engine is powered-up and only when a PLC trailer or a PLC diagnostic tool is connected. If the light remains on after the vehicle is started, continues to flash or fails to illuminate, have the system serviced immediately.
  • Page 13 Instrument Cluster Range inhibit Illuminates when the transmission is RANGE not engaged in the selected gear. INHIBIT The warning light will go off when the gearshift lever is adjusted in to the appropriate gear. Refer to the Transmission Operator’s Manual for more information. Charging system Illuminates when the ignition is turned to the ON position and the...
  • Page 14 Instrument Cluster Water in fuel (if equipped) During refueling it is possible for WATER water-contaminated diesel fuel to be pumped into your fuel tank. Your FUEL vehicle fuel system is equipped with a fuel filter/water separator to remove water from the fuel. The indicator light illuminates when the fuel filter/water separator has a significant quantity of water, or when the ignition key is switched to the START position.
  • Page 15 Instrument Cluster High beams Illuminates when the high beam headlamps are turned on. Safety belt warning chime Sounds to remind you to fasten your safety belts. BeltMinder chime Sounds intermittently to remind you to fasten your safety belts. Headlamps on warning chime Sounds when the headlamps or parking lamps are on, the key is removed from the ignition and the driver’s door is opened.

  • Page 16: Gauges

    Instrument Cluster GAUGES Engine coolant temperature gauge Indicates the temperature of the engine coolant. At normal operating temperature, the needle remains within the normal area (the area between the “H” and “C”). If it enters the red section, the engine is overheating.
  • Page 17 Instrument Cluster Engine oil pressure gauge Indicates engine oil pressure. At normal operating temperature, the needle will be in the normal range (the area between the “L” and “H”); if the needle goes below the normal range, stop the vehicle as soon as safely possible and switch off the engine immediately.
  • Page 18 Instrument Cluster Battery voltage gauge Indicates battery voltage. If the pointer moves and stays outside the normal operating range (as indicated by the arrows), have the vehicle’s electrical system checked as soon as possible. Fuel gauge Displays approximately how much fuel is in the fuel tank.
  • Page 19 Instrument Cluster Odometer Registers the total kilometers (miles) of the vehicle. 0 0 0 0 0 0 0 0 0 0 km/h Trip odometer Registers the kilometers (miles) of individual journeys. To reset, depress the control. Tachometer Indicates the engine speed in revolutions per minute.

  • Page 20: Entertainment Systems

    Entertainment Systems AM/FM STEREO (WITH 2 SPEAKERS) PUSH SEEK TONE TONE VOL TUNE AM/FM AM/FM STEREO (WITH 4 SPEAKERS AND FADE CAPABILITY) PUSH SEEK TONE TONE VOL TUNE AM / FM STEREO AM/FM...
  • Page 21 Entertainment Systems Volume/power control Press the control to turn the audio PUSH system on or off. Turn the control to raise or lower volume. PUSH If the volume is set above a certain level and the ignition is turned off, the volume will come back on at a “nominal”...
  • Page 22 Entertainment Systems Speaker balance adjust Speaker sound distribution can be PUSH adjusted between the right and left speakers. TONE Press the TONE control three times, then use the volume knob to adjust the desired level. Speaker fade adjust (if equipped) Speaker sound can be adjusted PUSH between the front and rear...
  • Page 23 Entertainment Systems Radio station memory preset The radio is equipped with four station memory preset controls. These controls can be used to select up to four preset AM stations and eight FM stations (four in FM1 and four in FM2). Setting memory preset stations 1.
  • Page 24 Entertainment Systems To set the minute, press and hold the CLK control until CLOCK SET TONE appears in the display and press the TUNE control: • to decrease minutes and • to increase minutes. The CLK control will allow you to switch between media display mode (radio station, stereo information, etc.) and clock display mode (time).
  • Page 25 Entertainment Systems AM/FM STEREO CASSETTE VOL - PUSH ON BASS TREB FADE TAPE SEEK SIDE 1 - 2 SCAN TUNE Volume/power control Press the control to turn the audio VOL - PUSH ON system on or off. Turn the control to raise or lower volume.
  • Page 26 Entertainment Systems Bass adjust The bass adjust control allows you to increase or decrease the audio system’s bass output. BASS Treble adjust The treble adjust control allows you to increase or decrease the audio system’s treble output. TREB Speaker balance adjust Speaker sound distribution can be adjusted between the right and left speakers.
  • Page 27 Entertainment Systems Seek function in radio mode • Press to find the next listenable station down the frequency band. • Press to find the next listenable station up the frequency band. Scan function The scan function works in radio mode. SCAN Scan function in radio mode Press the SCAN control to hear a brief sampling of all listenable stations on...
  • Page 28 Entertainment Systems 2. Select a station. Refer to Tune adjust or Seek function for more information on selecting a station. 3. Press and hold a memory preset control until the sound returns, indicating the station is held in memory on the control you selected. Setting the clock Press CLK to toggle between listening frequencies and clock...
  • Page 29 Entertainment Systems The CLK control will allow you to switch between media display mode (radio station, stereo information, etc.) and clock display mode (time). When in clock mode, the media information will display for 10 seconds, when the radio is turned on, and then revert to clock information. Any time that the media is changed, (new radio station, etc.), the media information will again display for 10 seconds before reverting back to the clock.
  • Page 30 Entertainment Systems Then, press either REW (for the beginning of the current selection) or FF (to advance to the next selection). The tape deck stops and returns to play mode when the AMS circuit senses a blank section on the tape. In order to ensure proper operation of the AMS feature, the tape MUST have a blank section of at least four seconds duration between programs.

  • Page 31: Am/Fm Stereo Cassette With Cd

    Entertainment Systems Dolby noise reduction is manufactured under license from Dolby Laboratories Licensing Corporation. “Dolby ” and the double-D symbol are registered trademarks of Dolby Laboratories Licensing Corporation. PREMIUM AM/FM STEREO/CASSETTE/SINGLE CD DISC VOL PUSH ON FM 1 MUTE TAPE AUTO DOLBY B NR SEEK...
  • Page 32 Entertainment Systems Bass adjust The bass adjust control allows you BASS TREB to increase or decrease the audio system’s bass output. Press the BASS control then press: • to decrease the bass output • to increase the bass output. Treble adjust The treble adjust control allows you BASS TREB...
  • Page 33 Entertainment Systems Press the FADE control then press: • to shift the sound to the front and • to shift the sound to the rear. Seek function The seek function control works in radio, tape or CD mode. Seek function in radio mode •...
  • Page 34 Entertainment Systems Scan function in tape mode Press the SCAN control to hear a short sampling of all selections on the tape. (The tape scans in a forward direction. At the end of the tape’s first side, direction automatically reverses to the opposite side of the tape.) To stop on a particular selection, press the control again.
  • Page 35 Entertainment Systems 3. Press and hold a memory preset control until the sound returns, indicating the station is held in memory on the control you selected. SIDE 1-2 COMP SHUFFLE Autoset memory preset Autoset allows you to set strong radio stations without losing your original manually set preset stations.
  • Page 36 Entertainment Systems Setting the clock To set the hour, press and hold the CLK control and press SEEK: AUTO • to decrease hours and • to increase hours. To set the minute, press and hold the CLK control and press TUNE: AUTO •...
  • Page 37 Entertainment Systems again display for 10 seconds before reverting back to the clock. In media mode, the media information will always be displayed. Tune adjust The tune control works in radio mode. Tune adjust in radio mode • Press to move to the next frequency down the band (whether or not a listenable station is located there).
  • Page 38 Entertainment Systems • In CD mode, pressing the control fast forwards the CD within the current track. Tape direction select Press SIDE 1–2 to play the alternate SIDE 1-2 side of a tape. Eject function Press the EJ control to stop and eject a tape.

  • Page 39: Am/Fm Stereo With Cd

    Entertainment Systems Shuffle feature The shuffle feature operates in CD SHUFFLE mode and plays all tracks in random order. Press the SHUFFLE control to start this feature. Random order play will continue until the SHUFFLE control is pressed again. Mute mode Press the MUTE control to mute the playing media.
  • Page 40 Entertainment Systems PREMIUM AM/FM STEREO IN DASH SIX CD RADIO DISC SHUF SCAN COMP SEEK TUNE MUTE LOAD BASS TREB FADE PUSH ON MENU Volume/power control Press the control to turn the audio system on or off. PUSH ON Turn the control to raise or lower volume.
  • Page 41 Entertainment Systems Bass adjust The bass adjust control allows you BASS to increase or decrease the audio system’s bass output. TREB Press the BASS control. Use the SEL control to increase or decrease the amount of bass. Treble adjust The treble adjust control allows you BASS to increase or decrease the audio system’s treble output.
  • Page 42 Entertainment Systems Seek function in radio mode • Press to find the next listenable station down the frequency band. SEEK DOWN will display. • Press to find the next listenable station up the frequency band. SEEK UP will display. Seek function in CD mode •...
  • Page 43 Entertainment Systems AM/FM select The AM/FM select control works in radio and CD modes. AM/FM select in radio mode This control allows you to select AM or FM frequency bands. Press the control to switch between AM, FM1 or FM2 memory preset stations. AM/FM select in CD mode Press this control to stop CD play and begin radio play.
  • Page 44 Entertainment Systems Autostore Autostore allows you to set the strongest local radio stations without losing your original manually set preset stations. This feature is helpful on trips when you travel between cities with different radio stations. Starting autostore 1. Press and momentarily hold the AM/FM control. 2.
  • Page 45 Entertainment Systems Tune adjust in radio mode • Press to move to the next frequency down the band (whether or not a listenable station is located there). Hold the control to move through the frequencies quickly. • Press to move to the next frequency up the band (whether or not a listenable station is located there).
  • Page 46 Entertainment Systems Display description Six circles are always lit in the digital display. These signify the six CD slots in the audio system. When a disc is loaded into a particular slot (1–6), the number inside that specific circle lights. If the circle is empty, there is no CD in that particular slot.
  • Page 47 Entertainment Systems Press the LOAD control. (You can choose which slot will be loaded by pressing the desired preset number. If you do not choose a slot, the system will choose the next available one.) Wait until the CD door opens. Load the CD into the player.
  • Page 48 Entertainment Systems Auto eject Press and momentarily hold the EJ control to engage auto eject. All CDs which are present in the player will be ejected one at a time. If a CD is ejected and not removed from the door of the CD player, the player will automatically reload the CD.
  • Page 49 Entertainment Systems Menu mode The MENU control allows you to MENU access many different features within your audio system. There are three sets of menus available depending upon which mode or feature is activated. While in FM mode, two menus are available. If RDS is turned OFF, you can access the following: •...
  • Page 50 Entertainment Systems Traffic announcements This feature allows you to hear traffic announcements. When in this MENU mode, traffic announcements will interrupt radio and CD play. When in FM mode and RDS is activated, press the MENU until TRAFFIC OFF displays. Press the SEL control to engage the feature.
  • Page 51 Entertainment Systems To activate RDS: • When in FM mode, press the MENU control until RDS OFF displays. • Press the SEL control to engage this feature (RDS ON). RDS features: Once the RDS feature is on, press the MENU control to scroll through the following selections: Traffic announcements This feature allows you to hear traffic announcements while in CD mode.
  • Page 52 Entertainment Systems • Jazz • Oldies • R & B • Religious • Rock • Soft • Top 40 Show This feature allows you to select the type of RDS broadcast information MENU the radio will regularly show in the display.
  • Page 53 Entertainment Systems Use the SEL control to select the desired signal mode (the selected mode will appear in the display). The following signal modes can be selected: • DSP OFF—disengages the feature • NEWS—”voice-only” type of sound with a limited audio band •...
  • Page 54 Due to technical incompatibility, certain recordable and re-recordable compact discs may not function correctly when used in Ford CD players. Irregular shaped CDs, CDs with a scratch protection film attached, and CDs with homemade paper (adhesive) labels should not be inserted into the CD player.
  • Page 55 Entertainment Systems CASSETTE AND CASSETTE PLAYER CARE • Use only cassettes that are 90 minutes long or less. • Do not expose tapes to direct sunlight, high humidity, extreme heat or extreme cold. Allow tapes that may have been exposed to extreme temperatures to reach a moderate temperature before playing.

  • Page 56: Climate Controls

    Climate Controls The audio system automatically switches to single channel reception if it will improve the reception of a station normally received in stereo. AUDIO SYSTEM WARRANTIES AND SERVICE Refer to the Warranty Guide for audio system warranty information. If service is necessary, see your dealer or a qualified technician. HEATER ONLY SYSTEM (IF EQUIPPED) Fan speed control Controls the volume of air circulated...

  • Page 57: Manual Heating And Air Conditioning

    Climate Controls • (Floor) – Distributes outside air through the floor ducts. • (Floor and defrost) – Distributes outside air through the floor ducts and the windshield defroster ducts. • (Defrost) – Distributes outside air through the windshield defroster ducts. It can be used to clear ice or fog from the windshield. Operating tips •...
  • Page 58 Climate Controls Fan speed control Controls the volume of air circulated in the vehicle. Temperature control knob Controls the temperature of the airflow inside the vehicle. Mode Selector Control Controls the direction of the airflow to the inside of the vehicle. The air conditioning compressor can operate in all modes except .
  • Page 59 Climate Controls • OFF – Outside air is shut out and the fan will not operate. For short periods of time only, use this mode to prevent undesirable odors from entering the vehicle. • (Panel and floor) – Distributes outside air through the instrument panel registers and the floor ducts.
  • Page 60 Climate Controls • Under normal weather conditions, your vehicle’s climate control system should be left in any position other than the MAX A/C or OFF when the vehicle is parked. This allows the vehicle to “breathe” through the outside air inlet duct. •...

  • Page 61: Lights

    Lights HEADLAMP CONTROL Rotate the headlamp control to the first position to turn on the parking lamps. Rotate to the second position to turn on the headlamps. High beams • Push forward to activate. • Pull toward you to deactivate. Flash to pass Pull toward you to activate and release to deactivate.
  • Page 62 Lights Always remember to turn on your headlamps at dusk or during inclement weather. The Daytime Running Lamp (DRL) system does not activate with your tail lamps and generally may not provide adequate lighting during these conditions. Failure to activate your headlamps under these conditions may result in a collision.
  • Page 63 Lights TURN SIGNAL CONTROL • Push down to activate the left turn signal. • Push up to activate the right turn signal. INTERIOR LAMPS Map lamps (if equipped) To turn on the map lamps, press the control next to each lamp. EXTERIOR BULBS Check operation of lamps, safety equipment and warning signals It is a good safety practice to check operation of headlamps, parking...

  • Page 64: Headlamps

    Lights Using the right bulbs Function Number of Trade number bulbs Headlamps 4652 Park/turn signal 1157 Sidemarker/rear marker lamp 5 red 12 (amber) Tail/stop lamp 2057 Backup 1156 Foglamp Running board/courtesy lamp License plate lamp Cabmarker Exterior visor lamp (if equipped) Rear fender clearance Rear identification Dome lamp...
  • Page 65 Lights 3. Remove four screws and the retaining bracket from the headlamp bulb. 4. Pull headlamp bulb out of the housing, disconnect the electrical connector and remove the headlamp bulb. 5. To complete installation, follow the removal procedure in reverse order.
  • Page 66 Lights Replacing visor/cab marker bulbs To change the cab marker bulbs: 1. Remove the screw and lens from the lamp assembly. 2. Carefully pull the bulb straight out of the socket and push in the new bulb. 3. Install lens on lamp assembly with screw.
  • Page 67 Lights Replacing tail lamp/turn/backup lamp bulbs — F650 SuperCrewzer only The tail lamp/backup lamp bulbs are located in the same portion of the tail lamp assembly, one just below the other. Follow the same steps to replace either bulb: 1. Remove the two screws holding the light cover to the light housing.

  • Page 68: Driver Controls

    Driver Controls WINDSHIELD WIPER/WASHER CONTROLS Rotate the windshield wiper control to the desired interval, low or high speed position. The bars of varying length are for intermittent wipers. When in this position rotate the control upward for fast intervals and downward for slow intervals.

  • Page 69: Steering Wheel Adjustment

    Driver Controls Changing the wiper blades To replace the wiper blades: 1. Pull the wiper arm away from the windshield and lock into the service position. 2. Turn the blade at an angle from the wiper arm. Push the lock pin manually to release the blade and pull the wiper blade down toward the windshield to remove it from the...
  • Page 70 Driver Controls Never adjust the steering wheel when the vehicle is moving. OVERHEAD CONSOLE (IF EQUIPPED) The overhead console will show the outside temperature and compass display. Electronic compass/temperature display — SuperCrewzer only Mode control Press the MODE control to turn the display on/off.
  • Page 71 Driver Controls accuracy. Adjustments may need to be made to the zone and calibration of the compass. Usually, when something affects the compass readings, the compass will correct itself after a few days of operating your vehicle in normal conditions. If the compass still appears to be inaccurate, a manual calibration may be necessary.
  • Page 72 Driver Controls 4. Press and hold both controls. After approximately four seconds, the compass will enter zone setting mode. Zone setting mode is MODE indicated when the display lights the “ZONE” indicator. RESET 5. Release both controls. Subsequent pressing of either control will increment the zone.
  • Page 73 Driver Controls Trailer hook up lamps — F650 SuperCrewzer only Press the control to activate the trailer lamps. Press the control to deactivate the trailer lamps. Heated Mirrors — F650 SuperCrewzer only Press this control to remove ice, mist and fog from the mirrors. This feature will automatically turn off after 8 minutes.

  • Page 74: Power Windows

    Driver Controls POWER WINDOWS (IF EQUIPPED) Press and hold the rocker switches to open and close windows. • Press the top portion of the rocker switch to close. AUTO • Press the bottom portion of the rocker switch to open. One touch down •...

  • Page 75: Mirrors

    Driver Controls Window lock (if equipped) The window lock feature allows only the driver to operate the power windows. To lock out all the window controls except for the driver’s press the left side of the control. Press the right side to restore the window controls. MIRRORS With the doors closed and the seat adjusted for proper comfort, move...
  • Page 76 Driver Controls Power side view mirrors (if equipped) The ignition can be in any position to adjust the power side view mirrors. To adjust your mirrors: 1. Select L to adjust the left mirror or R to adjust the right mirror. MIRRORS 2.
  • Page 77 Driver Controls SPEED CONTROL (IF EQUIPPED) To turn speed control on 7.3L Power Stroke engine • Press ON. Vehicle speed cannot be controlled until the vehicle is traveling at or above 48 km/h (30 mph). Do not shift the gearshift lever into N (Neutral) with the speed control on.
  • Page 78 Driver Controls To turn speed control off 7.3L Power Stroke engine • Press OFF or • Turn off the vehicle ignition. Once speed control is switched off, the previously programmed set speed will be erased. Caterpillar/Cummins engines • Press OFF or •...
  • Page 79 Driver Controls To set a speed 7.3L Power Stroke engine • Press SET ACCEL. For speed control to operate, the speed control must be ON and the vehicle speed must be greater than 48 km/h (30 mph). Do not use the speed control in heavy traffic or on roads that are winding, slippery, or unpaved.
  • Page 80 Driver Controls Do not use the speed control in heavy traffic or on roads that are winding, slippery, or unpaved. To set a higher set speed 7.3L Power Stroke engine • Press and hold SET ACCEL. Release the control when the desired vehicle speed is reached •...
  • Page 81 Driver Controls To set a lower set speed 7.3L Power Stroke engine • Press and hold COAST. Release the control when the desired speed is reached or • Press and release COAST to operate the Tap-Down function. Each press will decrease the set speed by 1.6 km/h (1 mph) or Caterpillar/Cummins engine Press and hold RESUME -.
  • Page 82 Driver Controls To disengage speed control • Depress the brake pedal or • Depress the clutch pedal (if equipped). Disengaging the speed control will not erase the previously programmed set speed or engine RPM. 7.3L Power Stroke engine Pressing OFF will erase the previously programmed set speed.
  • Page 83 Driver Controls Caterpillar/Cummins engines Pressing OFF will erase the previously programmed engine RPM. To return to a previously set speed 7.3L Power Stroke engine • Press RES. For RES to operate, the vehicle speed must be faster than 48 km/h (30 mph). Caterpillar/Cummins engines Press RESUME -.

  • Page 84: Locks And Security

    Locks and Security KEYS The key operates all locks on your vehicle. In case of loss, replacement keys are available from your dealer. You should always carry a second key with you in a safe place in case you require it in an emergency. POWER DOOR LOCKS (IF EQUIPPED) Press U to unlock all doors and L to lock all doors.
  • Page 85 Locks and Security Unlocking the doors Press this control to unlock the driver’s door. The interior lamps will illuminate. Press the control a second time within five seconds to unlock all doors. Locking the doors Press this control to lock all doors. To confirm all doors are closed and locked, press the control a second time within five seconds.
  • Page 86 Locks and Security Replacing the battery The remote transmitter is powered by one coin type three-volt lithium battery CR2032 or equivalent. Typical operating range will allow you to be up to 10 meters (33 feet) away from your vehicle. A decrease in operating range can be caused by: •...
  • Page 87 Locks and Security Programming remote transmitters It is necessary to have all (maximum of four — original and/or new) of your remote transmitters available prior to beginning this procedure. To program the transmitters yourself: • Place the key in the ignition and turn from 2 (LOCK) to 3 (OFF) and cycle between 3 (OFF) and 4(ON) eight times in rapid...

  • Page 88: Seating And Safety Restraints

    Seating and Safety Restraints SEATING Driver’s seat adjustment Never adjust the driver’s seat or seatback when the vehicle is moving. Always drive and ride with your seatback upright and the lap belt snug and low across the hips. Reclining the seatback can reduce the effectiveness of the seat’s safety belt in the event of a collision.
  • Page 89 Seating and Safety Restraints Rotate control to adjust seatback. Easy-Aire seat (if equipped) Move handle to the left to move seat forward or backward. Rotate control to adjust seatback.
  • Page 90 Seating and Safety Restraints Pump handle to raise seat height. Push handle full down to lower. Always adjust the seat height before fastening seatbelt. Heated seats (if equipped) To operate the heated seats: • Push control to activate. • Push again to deactivate. The indicator light on the control will illuminate when activated.
  • Page 91 Seating and Safety Restraints Reclining the seatback can reduce the effectiveness of the seat’s safety belt in the event of a collision. The control is located on the outboard side of the seat cushion. Press to raise or lower the front portion of the seat cushion.
  • Page 92 Seating and Safety Restraints REAR FOLDING BENCH SEAT (IF EQUIPPED) FOLDING DOWN THE REAR SEATS All safety belts should be properly stowed in the seat pockets before folding down the rear seat. Make sure that no objects such as books, purses or briefcases are on the floor in front of the second row seats before folding them down.

  • Page 93: Safety Restraints

    Seating and Safety Restraints RETURNING THE SEAT TO UPRIGHT Always latch the vehicle seat to the floor, whether the seat is occupied or empty. If not latched, the seat may cause injury during a sudden stop. 1. Lift/rotate the seatback toward the rear of the vehicle and make sure it latches securely.
  • Page 94 Seating and Safety Restraints Each seating position in your vehicle has a specific safety belt assembly which is made up of one buckle and one tongue that are designed to be used as a pair. 1) Use the shoulder belt on the outside shoulder only.
  • Page 95 Seating and Safety Restraints Vehicle sensitive retractor The vehicle sensitive retractor allows free shoulder belt length adjustment to your movements and locks in response to vehicle movement. For example, if the driver brakes suddenly or turns a corner sharply, or the vehicle receives an impact of approximately 8 km/h (5 mph) or more, the combination safety belts will lock to help reduce forward movement of the driver and passengers.
  • Page 96 Seating and Safety Restraints • 4–door CrewCab To lower the shoulder belt height, push the button and slide the height adjuster down. To raise the height of the shoulder belt, slide the height adjuster up. Pull down on the height adjuster to make sure it is locked in place.
  • Page 97 Seating and Safety Restraints Lap belts Adjusting the center lap belt The lap belt does not adjust automatically. The lap belt should fit snugly and as low as possible around the hips, not across the waist. Insert the tongue into the correct buckle (the buckle closest to the direction the tongue is coming from).
  • Page 98 Seating and Safety Restraints Conditions of operation If... Then... The driver’s safety belt is not The safety belt warning light buckled before the ignition switch illuminates 1-2 minutes and the is turned to the ON position... warning chime sounds 4-8 seconds.
  • Page 99 Seating and Safety Restraints The following are reasons most often given for not wearing safety belts: (All statistics based on U.S. data) Reasons given... Consider... “Crashes are rare 36 700 crashes occur every day. The more we events” drive, the more we are exposed to “rare” events, even for good drivers.
  • Page 100 Seating and Safety Restraints One time disable Any time the safety belt is buckled and then unbuckled during an ignition ON cycle, BeltMinder will be disabled for that ignition cycle only. Deactivating/activating the BeltMinder feature Read steps 1 - 9 thoroughly before proceeding with the deactivation/activation programming procedure.
  • Page 101 (if equipped), LATCH child seat tether anchors and lower anchors (if equipped), and attaching hardware, should be inspected after a collision. Ford Motor Company recommends that all safety belt assemblies used in vehicles involved in a collision be replaced.

  • Page 102: Child Restraints

    Seating and Safety Restraints continue to operate properly, they do not need to be replaced. Safety belt assemblies not in use during a collision should also be inspected and replaced if either damage or improper operation is noted. Failure to inspect and if necessary replace the safety belt assembly under the above conditions could result in severe personal injuries in the event of a collision.
  • Page 103 To improve the fit of lap and shoulder belts on children who have outgrown child safety seats, Ford recommends use of a belt-positioning booster seat that is labelled as conforming to all applicable Federal motor vehicle safety standards. Belt-positioning booster seats raise the child and provide a shorter, firmer seating cushion that encourages safer seating posture and better fit of lap and shoulder belts on the child.
  • Page 104 • Place seat back in upright position. Ford recommends the use of a child safety seat having a top tether strap. Install the child safety seat in a seating position which is capable of providing a tether anchorage. For more information on top tether straps, refer to Attaching safety seats with tether straps.
  • Page 105 Seating and Safety Restraints Installing child safety seats in combination lap and shoulder belt seating positions 1. Position the child safety seat in a seat with a combination lap and shoulder belt. Children are safer restrained in the rear seat when possible. 2.
  • Page 106 Rebuckle the belt. Obtain the locking clip kit (Part Number FO3Z-5461248–A) at no charge from an authorized Ford or Lincoln-Mercury dealer. 5. Before placing the child in the seat, forcibly tilt the seat forward and back to make sure the seat is securely held in place. To check this, grab the seat at the belt path and attempt to move it side to side and forward and back.
  • Page 107 Ford or Lincoln/Mercury dealer. If you have a Super Cab or Crew Cab, Ford recommends you attach tether safety seats in the rear seating position (if possible) with the tether strap attached to the tether anchorage bracket as shown in the instructions provided with the tether anchor kit.

  • Page 108: Driving

    Driving STARTING PROCEDURES Operating precautions • Always shift to a lower gear at high altitudes to prevent engine smoking. • Avoid extended and unnecessary idling. Diesel engine vapors are combustible. Do not operate the engine in an enclosed area. These vapors can be sucked through the air intake system and cause engine acceleration and overspeeding, which may result in bodily injury and extensive property damage.
  • Page 109 Driving After the engine starts: • On some engines, the Wait to WAIT start light should illuminate after the engine starts. Allow the START engine to idle about three minutes or until the engine coolant temperature gauge begins to rise. Maintain idle speed until the Wait to start light cycles off to indicate the air intake heater has shut off (approximately six minutes).
  • Page 110 Driving Using the engine block heater (if equipped) An engine block heater warms the engine coolant, which improves starting, warms up the engine faster and allows the heater-defroster system to respond quickly. Use of an engine block heater is strongly recommended if you live in a region where temperatures reach -23°...
  • Page 111 Driving Continuous operation with low coolant temperature, below 60°C (140°F) or high coolant temperature 100°C (212°F) can damage the engine. Most failures give some kind of early warning. Look and listen for changes in performance, sound or engine appearance that can indicate service or engine repair is needed.
  • Page 112 Driving Exhaust fumes Never idle the engine in closed areas. Never sit in a parked or stopped vehicle for any amount of time with engine running. If you ever smell exhaust fumes of any kind inside your vehicle, have your dealer inspect and fix your vehicle immediately. Do not drive if you smell exhaust fumes.

  • Page 113: Brakes

    Driving HYDRAULIC BRAKES (IF EQUIPPED) Your service brakes are self-adjusting. Refer to the Scheduled maintenance guide for scheduled maintenance. Occasional brake noise is normal and often does not indicate a performance concern with the vehicle’s brake system. In normal operation, automotive brake systems may emit occasional or intermittent squeal or groan noises when the brakes are applied.
  • Page 114 Driving If the red BRAKE warning lamp in the instrument cluster remains BRAKE illuminated after engine start up, this indicates a system failure in the master cylinder of the brake system. Stop the vehicle safely as soon as possible and seek service immediately. If the yellow BRAKE RESERVE BRAKE (E-motor) warning light remains on...
  • Page 115 Driving With the ABS light on, the anti-lock brake system is disabled and normal braking is still effective unless the brake warning light also remains illuminated. (If your parking brake warning lamp illuminates, have your vehicle serviced immediately). Using ABS •...
  • Page 116 Driving The parking BRAKE warning lamp BRAKE in the instrument cluster illuminates and remains illuminated (when the ignition is turned ON) until the parking brake is released. Do not use the gearshift selector in place of the parking brake. Always set the parking brake fully AND make sure the gearshift selector is in R (Reverse) for vehicles equipped with manual transmission, P (Park) (if equipped) or N (Neutral) for vehicles with automatic transmission.
  • Page 117 Driving Push the palm release lever on the parking brake handle and push down as far as possible to release the brake. Driving with the parking brake on will cause the brakes to wear out quickly and reduce fuel economy. Parking brake —...
  • Page 118 Driving Releasing spring brake manually — F650 SuperCrewzer 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.
  • Page 119 Driving AIR BRAKES (IF EQUIPPED) Foot service brakes Air brakes are operated by a standard dash-mounted foot pedal. All standard equipment brakes are designed to be self-adjusting. Automatic adjustment, when required, occurs whenever the brakes are applied and released during forward or reverse operation. Know the required stopping distances for all driving conditions that may be encountered.
  • Page 120 Supplement with brakes as required to safely slow the vehicle and avoid overspeeding the engine. Air chamber stroke indication All Ford air chamber push rods have orange stroke indicator stripes that alert the operator when the braking system requires adjustment or...
  • Page 121 The orange stripe is painted on the air chamber push rod at the slack adjuster readjustment stroke dimension. Air brake inspection and adjustment should be performed by a qualified service technician in accordance with the instructions in the Ford Truck Service Manual. Cam brakes—automatic slack adjusters...
  • Page 122 Driving during braking to maintain control and reduce stopping distances. For information on the anti-lock braking system (ABS), refer to Hydraulic brakes in this chapter. Parking brake Do not use the gearshift selector in place of the parking brake. Always set the parking brake fully AND make sure the gearshift selector is in R (Reverse) for vehicles equipped with manual transmission or N (Neutral) for vehicles with automatic transmission.
  • Page 123 Driving tank for connection to an outside air supply. The valve permits the system to be recharged with air from an outside source, releasing the spring-actuated parking brakes. The vehicle may then be towed in an emergency. An outside air source can be used only if the protected system is in operating condition.
  • Page 124 Driving 4. Turn the release stud one-quarter turn to engage the stud tangs with the slot in the pressure plate. Keep the stud engaged and install the nut on the release stud. 5. Tighten the nut until the spring is fully caged and the brakes are released.
  • Page 125 Driving When a trailer is hooked-up correctly and system pressure reaches 448 kPa (65 psi), the red control (trailer supply) may be pushed in and should stay in, TRAILER charging the trailer system and AIR SUPPLY releasing the trailer brakes. NOT FOR PARKING The yellow control (parking brake) may now be pushed in, which will...
  • Page 126 Driving System park With both controls in for normal run modes, the parking brakes on both tractor and trailer may be actuated by pulling the yellow control (parking brake) out, which exhausts the air from the tractor spring brakes and simultaneously causes the red control (trailer supply) to pop out, applying the trailer brakes.

  • Page 127: Mountain Driving

    Driving Exhaust brake (if equipped) An exhaust brake is an optional auxiliary braking system that assists but does not replace the primary service brake system. An on-off switch on the instrument panel, in combination with the accelerator and clutch pedal switches, allows the operator to make maximum use of the exhaust brake in the following conditions:...
  • Page 128 Driving Operation Push the rocker switch up to turn the exhaust brake on. The switch will illuminate in the ON position. Push the switch down to turn the brake off. Starting engine Before starting the engine, make sure that the exhaust brake switch is in the OFF position.
  • Page 129 Driving Exhaust brake operating characteristics When you remove your feet from both the accelerator and clutch pedals and the exhaust brake switch is in the ON position, the exhaust brake is activated. The following conditions should exist if the brake is operating properly: •...
  • Page 130 Driving Drain all the air brake reservoirs daily, completely to 0 kPa/psi, by opening the draincock at the bottom of the tanks. Close draincock after complete draining. Air tanks equipped with automatic moisture ejector valves may also be drained manually as required to maintain a dry air system.
  • Page 131 Driving • Front end out of alignment • Total vehicle out of alignment (i.e. rear axle[s] out of alignment with front axle) • Improper adjustment in the steering gear • Vehicle overloaded or unevenly loaded • High crosswinds • High crown in center of road •...

  • Page 132: Transmission Operation

    Driving Air suspension dump valve The dump valve switch activates the dump valve. The dump valve releases air from the air springs and lowers the rear suspension, allowing you to back under a low trailer when necessary. DRIVING WITH AN AUTOMATIC TRANSMISSION (IF EQUIPPED) Allison automatic transmission Do not allow your vehicle to coast in N (Neutral).
  • Page 133 Driving R (Reverse) Use this position to back the vehicle. Completely stop the vehicle before shifting from R (Reverse) to any forward gear (1, 2, 3 or D). The reverse warning signal will sound when the selector is in R (Reverse). Reverse has only one gear and provides the greatest gear reduction.
  • Page 134 Driving The push button shifter has a R (Reverse), N (Neutral) and D (Drive) selections as well as a MODE button, up arrow (for upshifts) and a down arrow (downshift) and a digital display. When a range button is pressed, a MODE tone will sound, the SELECT indicator displays a chosen...
  • Page 135 Driving Gearshift positions R (Reverse) - Use this position to back the vehicle. Completely stop the vehicle before shifting from R (Reverse) to any forward gear. The reverse warning signal will sound when the selector is in R (Reverse). MODE Reverse has only one gear and provides the greatest reduction.
  • Page 136 Driving D (Drive) - The vehicle will attain first gear, and as the speed increases, the transmission will automatically upshift through each gear. As the vehicle slows down, the transmission will automatically MODE downshift. The Select indicator will display the highest gear available. 5th or 4th- 2nd gears (depending on application) - Road conditions, load or traffic can make it desirable to restrict the automatic shifting to a lower gear.
  • Page 137 Driving monitor on the shift pad will display N (Neutral) when the ignition key is turned to the ON position. Allison 2000 series These transmissions have no P (Park) position. Before leaving the driver’s seat, always shift into N (Neutral) and set the parking brake.
  • Page 138 Driving 4 and 2 (Fourth and Second) Use these ranges when road, load or traffic conditions require a lower gear. These ranges provide greater engine braking than D (Drive). When conditions are improved that no longer require these lower gears, shift back to D (Drive).
  • Page 139 Driving engine should be at idle speed when any shift from N (Neutral) to a drive range is made. The N (Neutral) position may also be used during stationary operation of the Power Take-Off (PTO), if equipped. Do not allow your vehicle to coast in N (Neutral). Engine braking is not available in N (Neutral).
  • Page 140 Driving engaged by clashing the gear teeth. This may damage the PTO unit and the transmission PTO drive gear teeth. This could result in further damage to the transmission and PTO. PTO operation with vehicle stationary To operate the power take-off, stop the vehicle, idle the engine and set the parking brake.
  • Page 141 Driving Power take-off (PTO) operation on vehicles equipped with a Caterpillar 3126E engine If your vehicle is equipped with a Caterpillar 3126E engine, the PTO will only operate if the vehicle is in Neutral. This feature can be overriden by a special service tool;...
  • Page 142 Driving Driving hints The following driving hints are provided as a brief, general guide in operating the different manual transmissions used in your vehicle. • Always use the lowest gear to start the vehicle. • Do not slam or jerk lever into gear. •...
  • Page 143 Driving To go backward Reverse is obtained by putting the gearshift lever in R (Reverse) and engaging the clutch while pressing lightly on the accelerator. Operating the Eaton FS-5306A and FS–6306A 6-speed transmissions These 6-speed transmissions are equipped with six forward gears and one reverse.
  • Page 144 Driving To go backward Reverse is obtained by putting the gearshift lever in R (Reverse) and engaging the clutch while pressing lightly on the accelerator. Operating the Spicer ES52-7B and ES066-7B 7-speed transmissions These 7-speed transmissions are equipped with seven forward gears and one reverse.
  • Page 145 Power-take off operation (PTO) with a manual transmission Transmission-mounted power take-off units are available for local installation on Ford vehicles. See your Body Builder’s Layout Book for restrictions on use and installation of power take-off units. To engage the PTO unit, stop the vehicle and place the transmission control in neutral.
  • Page 146 Driving BACKING UP To avoid the possibility of personal injury while backing the vehicle, always be sure your vehicle’s path is clear. Before backing your vehicle, be sure you can do so safely. If anything behind the cab limits your view, do not rely on mirrors alone to assure that your intended path is clear.
  • Page 147 Driving Axle downshift In order to shift from HIGH to LOW, • Push the axle shift control down. • Release the accelerator (while pushing the axle shift control down). • Depress the accelerator to resume driving. Split upshift A split upshift is when there is an axle downshift with a transmission upshift.
  • Page 148 Driving When split shifting, the axle shift control must stay UP in the HIGH range until after any transmission lever movement. A 2–speed axle should NEVER be shifted on a downgrade. To downshift the axle from HIGH to LOW range, either the ring gear has to speed up by one-third, or the wheels have to slow down by one-third to allow for synchronization.

  • Page 149: Vehicle Loading

    MAXIMUM VEHICLE LOADING Every vehicle manufactured by Ford MFD. BY FORD MOTOR CO. IN U.S.A. Motor Company is supplied with DATE: XXXXX GVWR:XXXXX LB/ XXXXX KG information on the Vehicle Rating...

  • Page 150: Roadside Emergencies

    Roadside Emergencies GETTING ROADSIDE ASSISTANCE To fully assist you should you have a vehicle concern, Ford offers a complimentary roadside assistance program. This program is separate from the New Vehicle Limited Warranty. The service is available: • 24–hours, seven days a week •...

  • Page 151: Fuses And Relays

    Roadside Emergencies • The hazard lights control is located on top of the steering column. • Depress hazard lights control to activate all hazard flashers simultaneously. • Depress control again to turn the flashers off. FUSES AND RELAYS Fuses If electrical components in the vehicle are not working, a fuse may have blown.

  • Page 152: Passenger Compartment Fuse Panel

    Roadside Emergencies Standard fuse amperage rating and color COLOR Cartridge Fuse Mini Standard Maxi Fuse link maxi rating fuses fuses fuses cartridge fuses Grey Grey — — — Violet Violet — — — Pink Pink — — — — — —...
  • Page 153 Roadside Emergencies The fuses are coded as follows: Fuse/Relay Fuse Amp Passenger Compartment Location Rating Fuse Panel Description Horn Turn/Hazard Lamps Cigar Lighter Diagnostic Connectors Back-Up Lamps, DRL Relays, Blend Door Actuator, Heated Seat Module (SuperCrewzer only), On/Off Fan Clutch (SuperCrewzer only), Warning Chime Module (SuperCrewzer only) —...
  • Page 154 Roadside Emergencies Fuse/Relay Fuse Amp Passenger Compartment Location Rating Fuse Panel Description Switch Illumination (Headlamp, Power Windows, Power Door Locks), Power Window Relay, Trailer Hook Up Lamps (SuperCrewzer only) — Not Used Wiper Motor, Washer Pump Relay Stoplamp Switch (Hydraulic Vehicles Only) Radio, Cluster, 7.3L Power Stroke Powertrain Control Module (PCM), Keep Alive Memory...
  • Page 155 Roadside Emergencies Fuse/Relay Fuse Amp Passenger Compartment Location Rating Fuse Panel Description Left Low Beam Headlamp Cluster, GEM, 7.3L Power Stroke PCM (clutch switch input), APCM (7.3L Power Stroke only), Overhead Console (SuperCrewzer only), Keyless Entry Module (SuperCrewzer only), Traxx (Fuel) Module (SuperCrewzer only) 7.3L Power Stroke PCM Diode, 7.3L Power Stroke Fuel Heater...
  • Page 156 Roadside Emergencies The high-current fuses and relays are coded as follows. Fuse/Relay Fuse Amp Power Distribution Box Description Location Rating 15A* Park Lamps, Roof Lamps 25A* Cummins Powertrain Control Module (PCM) 15A* Foglamps (SuperCrewzer only) 10A* Generator 15A* Washer Pump 15A* Air Intake Heater Relay (CAT), Cummins 20A*...
  • Page 157 Roadside Emergencies Fuse/Relay Fuse Amp Power Distribution Box Description Location Rating 10A* Keyless Entry Module (SuperCrewzer only) 10A* Park Brake Adjustment Module (SuperCrewzer only) — Not Used 7.5A* Body Builder Prep (Hydraulic Vehicles Only) 10A* Allison 2000/2400 Trans (Except F650 SuperCrewzer) Radio (SuperCrewzer only) —...
  • Page 158 Roadside Emergencies Fuse/Relay Fuse Amp Power Distribution Box Description Location Rating 40A** Ignition Switch (JB fuses 5, 8, 9, 11, 21) 30A** Body Builder Prep 20A** 7.3L Power Stroke PCM 30A** IDM (7.3L Power Stroke only) 119/120 60A** Hydraulic ABS, Air Brake Trailer Tow Fuse Block 121/122 60A**...
  • Page 159 Roadside Emergencies Relays The relay box is located on the rear crossmember. Air Brake Trailer Tow Relays (if equipped) The relays are coded as follows: Fuse/Relay Fuse Amp Description Location Rating 30A** Trailer Tow Run Feed 30A** Trailer Tow Park/Marker Lamps 30A** Trailer Tow Stop Lamps 30A**...
  • Page 160 Roadside Emergencies SuperCrewzer (if equipped) N.U. EXHAUST HOOK BRAKE LAMP USED USED RELAY RELAY#1 N.U. N.U. EXHAUST N.U. N.U. BRAKE USED USED RELAY#2 N.U. The relays are coded as follows: Fuse/Relay Fuse Amp Description Location Rating — Not Used — Not Used —...

  • Page 161: Jump Starting

    Roadside Emergencies JUMP STARTING YOUR VEHICLE The gases around the battery can explode if exposed to flames, sparks, or lit cigarettes. An explosion could result in injury or vehicle damage. Batteries contain sulfuric acid which burns skin, eyes, and clothing. Preparing your vehicle Also see the label on the battery.
  • Page 162 Roadside Emergencies Connecting the jumper cables 1. Position the vehicles so that they do not touch one another. 2. Apply the parking brakes. 3. Switch off the engine and any unnecessary electrical equipment. 4. Find the positive (+) terminal of the discharged battery.
  • Page 163 Roadside Emergencies 3. After starting, run the engine at about 1,000 RPM for 3–5 minutes. Do not operate the starter longer than 30 seconds. Wait at least two minutes between starting attempts to allow the starter to cool. If the engine does not start after several attempts, call for road service.
  • Page 164 Roadside Emergencies • To tow a vehicle on the front wheels, the steering wheel must be in the straight ahead position. Secure the steering wheel with a holding device (such as provided by a towing company). • To tow a vehicle on the rear wheels, it will be necessary to remove the drive axles or disconnect the driveshaft.

  • Page 165: Customer Assistance

    Ford Customer Relationship Center. Away from home If you own a Ford or Mercury vehicle and are away from home when your vehicle needs service, or if you need more help than the dealership could provide, after following the steps described above, contact the Ford Customer Relationship Center to find an authorized dealership to help you.
  • Page 166 P.O. Box 2000 Oakville, Ontario L6J 5E4 1-800-565-3673 (FORD) In order to help you service your Ford or Lincoln Mercury vehicle, please have the following information available when contacting a Customer Relationship Center: • Your telephone number (home and business).

  • Page 167: The Dispute Settlement Board

    Customer Assistance In some states (in the U.S.) you must directly notify Ford in writing before pursuing remedies under your state’s warranty laws. Ford is also allowed a final repair attempt in some states. In the United States, a warranty dispute must be submitted to the...
  • Page 168 • The file number assigned to your application. • The toll-free phone number of the DSB’s independent administrator. Your dealership and a Ford Motor Company representative will then be asked to submit statements. To properly review your case, the Board needs the following information: •...
  • Page 169 • The name of the dealer(s) who sold or serviced the vehicle. • A brief description of your unresolved concern. • A brief summary of the action taken by the dealer(s) and Ford Motor Company. • The names (if known) of all the people you contacted at the dealership(s).

  • Page 170: Getting Assistance Outside The U.s. And Canada

    The use of leaded fuel in your vehicle without proper conversion may damage the effectiveness of your emission control system and may cause engine knocking or serious engine damage. Ford Motor Company/Ford of Canada is not responsible for any damage caused by use of improper fuel.

  • Page 171: Ordering Additional Owner's Literature

    If your vehicle must be serviced while you are traveling or living in Central or South America, the Caribbean, or the Middle East, contact the nearest Ford dealership. If the dealership cannot help you, write or call: FORD MOTOR COMPANY...

  • Page 172: Reporting Safety Defects (U.s. Only)

    REPORTING SAFETY DEFECTS (U.S. ONLY) If you believe that your vehicle has a defect which could cause a crash, or could cause injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying Ford Motor Company.
  • Page 173 However, NHTSA cannot become involved in individual problems between you, your dealer or Ford Motor Company. To contact NHTSA, you may either call the Auto Safety Hotline toll-free at 1–800–424–9393 (202–366–0123 in the Washington D.C.

  • Page 174: Cleaning

    Ph shampoo, such as Detail Wash (ZC-3–A), which is available from your authorized Ford, Lincoln or Mercury dealer. Always use a clean sponge or carwash 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.
  • Page 175 Minor scratches or paint damage from road debris may be repaired using the Ultra Touch Prep and Finishing Kit (F7AZ-19K507–BA), which is available at your authorized Ford, Lincoln or Mercury dealer. This kit contains: • Lacquer Touch-Up Paint (ALBZ-19500–XXXXA) •...
  • Page 176 Use Detail Wash (ZC-3–A) for routine cleaning. If tar or grease spots are present, clean with Extra Strength Tar and Road Oil Removal (B7A-19520–AA). Use only approved products to clean plastic parts. These products are available from your authorized Ford, Lincoln or Mercury dealer.
  • Page 177 Clean the outside of the windshield or rear window with a non-abrasive cleaner such as Ultra Clear Spray Glass Cleaner (E4AZ-19C507–AA), available from your authorized Ford, Lincoln or Mercury dealer. If after cleaning the glass surface, the water sheets from the glass (e.g., does not bead), then the window is clean.
  • Page 178 Extra Strength Upholstery Cleaner (E8AZ-19523–AA). CLEANING LEATHER SEATS (IF EQUIPPED) All Ford, Lincoln and Mercury vehicles with leather seating surfaces have a clear, protective coating over the leather. To clean the leather seats, simply use a soft cloth with Deluxe Leather and Vinyl Cleaner (F2AZ-19521–WA).

  • Page 179: Underbody Preservation

    CLEANING AND MAINTAINING THE SAFETY BELTS Clean the safety belts with Extra Strength Upholstery Cleaner (E8AZ-19523–AA), available from your authorized Ford, Lincoln or Mercury dealer. Do not use bleach, dye or any other solvent to clean the belts, as these actions may weaken the belt webbing.
  • Page 180 Cleaning FORD, LINCOLN AND MERCURY CAR CARE PRODUCTS Your Ford, Lincoln or Mercury dealer has many quality products available to clean your vehicle and protect its finishes. These quality products have been specifically engineered to fulfill your automotive needs; they are custom designed to complement the style and appearance of your vehicle.

  • Page 181: Maintenance And Specifications

    Maintenance and Specifications OPENING THE HOOD The hood and fenders are held in position by a latch located on each fender. The parking brake must be fully set before opening the hood or possible personal injury may occur. If you must leave the engine running while checking under the hood, do not allow any loose clothing, jewelry, hair or other items to get near moving engine components or possible personal injury may occur.
  • Page 182 Maintenance and Specifications 4. Tilt the hood forward until stopped by the retaining cables. To lower the hood: 1. Push the hood rearward at the top center of the hood above the grille until closed. 2. Engage the latch on each fender. 3.
  • Page 183 Use 3.8L (4.0 quarts) of Ultra—Clear Windshield Washer Concentrate or a washer fluid that meets the Ford specification listed. Refer to Lubricant specifications in this chapter. State or local regulations on volatile organic compounds may restrict the use of methanol, a common windshield washer antifreeze additive.
  • Page 184 Maintenance and Specifications 2. Park the vehicle on level ground. 3. Set the parking brake and shift into N (Neutral) (automatic transmission) or 1 (First) (manual transmission). 4. Turn off the engine and wait a few minutes for the oil to drain completely into the oil pan.
  • Page 185 Diesel engine oils with improved fuel economy properties (energy conserving) are currently available. If you use an energy conserving oil, be sure it meets Ford specification WSS-M2C171–C or API service category designation CH-4/SJ and is of the proper viscosity grade for the temperature range in which you expect to operate your vehicle.
  • Page 186 The lower section of the API symbol will state energy conserving if the engine oil has been proven to have fuel savings capabilities. Use a Ford engine oil filter, part number FL-1995 or equivalent. This filter protects your engine by filtering harmful, abrasive or sludge particles.
  • Page 187 Maintenance and Specifications BATTERY Your vehicle is equipped with two Motorcraft maintenance-free batteries which are mounted in a covered tray and located on the left frame rail. The covered battery tray, depending upon application, may also have one or two steps attached. •...
  • Page 188 Maintenance and Specifications Motorcraft maintenance-free batteries do not normally require adding additional water. However, for severe usage or in high temperature climates, check the battery electrolyte levels. Refer to the Scheduled Maintenance Guide for the service interval schedules. Keep the electrolyte level in each cell up to the “level indicator”. Do not overfill the battery cells.
  • Page 189 Maintenance and Specifications 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.
  • Page 190 Vehicles with diesel engines typically are used to carry heavy loads and accumulate mileage rapidly. These two factors cause the additives in the coolant to “wear out” in a shorter time. Ford recommends an interim service interval performed at 12 months or 24 000 km (15 000 miles), whichever occurs first.
  • Page 191 The cooling system in your vehicle is filled with either green-colored Motorcraft Premium Engine Coolant meeting Ford specification ESE-M97B44–A or yellow-colored Motorcraft Premium Gold Engine Coolant meeting Ford Specification WSS-M97B51–A1. To determine your vehicle’s coolant type (color), check your coolant reservoir. • Add Motorcraft Premium Engine Coolant (green-colored), VC-4–A (U.S.) or CXC-10 (Canada) or Motorcraft Premium...
  • Page 192 • Do not mix with recycled coolant unless from a Ford-approved recycling process (see Use of Recycled Engine Coolant section). For vehicles with overflow coolant systems with a non-pressurized cap on the coolant recovery system, add coolant to the coolant recovery reservoir when the engine is cool.
  • Page 193 Adding Coolant section to determine the coolant type in your vehicle. Add 1.89L (4 pints) of Motorcraft Heavy Duty Cooling System Additive FW-16 or equivalent meeting Ford specification ESN-M99B169–A, directly to the cooling system. An additional 237–295 ml (8–10 oz.) of supplemental coolant additive FW-16 should be added at 24 000 km (15 000 mile) intervals to maintain proper concentration.
  • Page 194 Refer to the engine operator’s manual for additional engine cooling system information. Recycled engine coolant Ford Motor Company recommends the use of a recycled engine coolant produced by Ford-approved processes in vehicles originally equipped with Motorcraft Premium Engine Coolant (green-colored). However, not all coolant recycling processes produce coolant that meets Ford specification ESE-M97B44–A.
  • Page 195 Coolant conditioner (liquid) For engines filled with green-colored Motorcraft Premium Engine Coolant, a supplemental coolant additive FW-16 meeting Ford specification ESN-M99B169–A has been added to the coolant in this engine. This additive aids in the prevention of rust and scale buildup on the internal parts of the cooling system.
  • Page 196 Maintenance and Specifications Stay clear of the fan/fan area while the engine is running or possible personal injury may occur. FUEL INFORMATION Important safety precautions Do not overfill the fuel tank. The pressure in an overfilled tank may cause leakage and lead to fuel spray and fire. The fuel system may be under pressure.
  • Page 197 If you must replace the fuel filler cap, replace it with a genuine Ford or Motorcraft part. The customer warranty may be void for any damage to the fuel tank or fuel system if a genuine Ford or Motorcraft fuel filler cap is not used.
  • Page 198 Maintenance and Specifications Running out of fuel Avoid running out of fuel as this will allow air to enter the fuel system, which will make restarting the vehicle difficult. If you have run out of fuel: • If your vehicle is equipped with dual fuel tanks, add at least 15–19 liters (4–5 gallons) of fuel to each tank before attempting to restart the engine.
  • Page 199 Maintenance and Specifications Draining the fuel filter/water separator—Caterpillar 3126 B engine 1. With the engine off, open the drain valve located at the bottom of the fuel filter/water separator by turning it counterclockwise. 2. Drain the filter until clear fuel is visible. 3.
  • Page 200 Maintenance and Specifications Fuel filter replacement—Caterpillar 3126 B engine The fuel filter/water separator is located on the left side of the engine. Replace the fuel filter/water separator as recommended in the Scheduled Maintenance Guide, or sooner if it becomes plugged. Vehicles operated on fuel with more than average impurities may require replacement of the fuel filter more...
  • Page 201 Maintenance and Specifications Fuel filter replacement—7.3L Power Stroke engine The fuel filter/water separator is located on the right side of the engine. Replace the fuel filter/water separator as recommended in the Scheduled Maintenance Guide, or sooner if it becomes plugged. Vehicles operated on fuel with more than average impurities may require replacement of the fuel filter more...
  • Page 202 Maintenance and Specifications Installation Note: The engine will not run properly if the fuel filter is not installed in housing. 1. Apply a coating of clean diesel fuel to the new bevel gasket and install it onto the fuel filter housing. 2.
  • Page 203 Maintenance and Specifications the full amount of the advertised capacity of the fuel tank due to the empty reserve still present in the tank. Your vehicle may be equipped with dual fuel tanks. If so, you will have a selector control. For information on the Dual Fuel Tank Selector Control refer to the Driving Tips section in the 7.3 Liter Power Stroke Direct Injection Turbo Diesel Owner’s Guide Supplement.
  • Page 204 Maintenance and Specifications 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.
  • Page 205 Maintenance and Specifications Also, your driving habits have a significant influence on use of fuel. By following these suggestions, you can stretch your fuel use: • Avoid changes in speed as much as possible. • Anticipate changing traffic conditions. Sudden stops and fast acceleration waste fuel.
  • Page 206 If the fluid level drops, maintain the fluid level at the step in the reservoir. Use only a DOT 3 brake fluid designed to meet Ford specifications. Refer to Lubricant Specifications in this chapter. 1. Set the parking brake, shift into 1 (First) and turn the engine off.
  • Page 207 Lubricate the clutch linkage using the following procedure. Refer to the Scheduled Maintenance Guide for the service interval schedules. Use a grease which meets Ford specifications. Refer to Lubricant Specifications in this chapter. 1. Set the parking brake, shift into 1 (First) and turn the engine off.
  • Page 208 MAX. Do not fill above this line. 4. Use only a DOT 3 brake fluid certified to meet Ford specifications. Refer to Lubricant specifications in this chapter. Brake fluid is toxic. If brake fluid contacts the eyes, flush eyes with running water for 15 minutes.
  • Page 209 A tag on the filler plug will identify the use of the synthetic fluid. Use only fluid that meets Ford specifications (refer to Lubricant specifications in this chapter. Use of a non-approved transmission fluid may cause internal transmission component damage.
  • Page 210 A tag on the filler plug will identify the use of the synthetic lubricant. Use only a lubricant that meets Ford specifications (refer to Lubricant specifications in thischapter). Use of a non-approved rear axle lubricant may cause internal axle component damage.
  • Page 211 Maintenance and Specifications 5. The lubricant level should be up to the bottom of the filler plug opening. 6. If necessary, add enough lubricant through the filler plug opening so that the lubricant level is at the bottom of the opening. 7.
  • Page 212 Maintenance and Specifications Servicing the air filter Your vehicle is equipped with a dry-type air cleaner element. When the yellow indicator on the air filter restriction indicator reaches the red line the air filter element should be replaced. • 7.3L Power Stroke engine •...
  • Page 213 Maintenance and Specifications • Caterpillar 3126 B engine Replace the air filter element using the following procedure: 1. Set the parking brake and shift into N (Neutral) (automatic transmission) or 1 (First) (manual transmission) and turn the engine off. 2. Open the hood. Protect yourself from engine heat. 3.
  • Page 214 Maintenance and Specifications • If your vehicle is equipped with the 7.3L Power Stroke engine, it will be necessary to remove the air filter element from the filter housing by moving the exposed end of the filter element down and to the rear of the vehicle, then lifting the other end of the filter element up and out of the engine compartment.
  • Page 215 • Do not install disc wheels where the paint has not fully cured. • At wheel changes, ensure mounting faces are clean and free of rust, dirt and excess paint. If fasteners are needed, use only Ford recommended replacement parts. • To maintain the desired torque/tension relation between...
  • Page 216 Maintenance and Specifications The M20 & M22 wheel nuts are right-hand threads. Refer to the following chart for approved wheel lug nut torque. Wheel type Bolt size Wheel nut torque 10-hole disc 285.75 M22 (22 by 1.5 mm) 610-677 Nm (450-500 mm bolt circle lb-ft) 8-hole disc 19.5x6.75...
  • Page 217 Maintenance and Specifications A wheel or tire of the wrong size or type may adversely affect such things as load carrying capacity, wheel and bearing life, brake cooling, speedometer/odometer calibration, stopping ability, headlight aim, bumper height, vehicle ground clearance and tire or tire chain clearance to the body and chassis.
  • Page 218 Do not attempt to add air to tires or replace tires or wheels without first taking precautions to protect persons and property. Refer to the Ford Service Manual or the regulations of the Occupational Safety and Health Administration (OSHA) for appropriate procedures and cautions.
  • Page 219 Maintenance and Specifications Refer to the Ford Service Manual applicable to your vehicle for proper tightening procedures and torque specifications. Periodically check the oil level on oil filled front bearing hubs. If necessary, add oil through the filler plug so the oil level is between the ADD and FULL marks indicated on the hub.
  • Page 220 Maintenance and Specifications If engine cranks but won’t start For troubleshooting information, refer to the engine operator’s manual. If engine runs hot For troubleshooting information, refer to the engine operator’s manual. If fuses burn out Burned-out or “blown-out” fuses or circuit breaker tripping (if equipped) usually indicate an electrical short circuit, although a fuse may occasionally fail from vibration.
  • Page 221 Maintenance and Specifications POWER STEERING FLUID CAPACITIES GVWR Axle application System capacity 11 794/13 608 kg (26 3 856/4 082 kg (8 4.3L (4.5 quarts) 000/30 000 lb.) 000/9 000 lb.) 14 969 kg (33 000 lb.) 5 443 kg (12 000 lb.) 4.5L (4.7 quarts) TRANSMISSION REFILL CAPACITIES Type and make...
  • Page 222 FUEL TANK CAPACITIES Type Approximate capacity Single tank 246.09L (65 gallons) Dual tank 492.18L (130 gallons) LUBRICANT SPECIFICATIONS Ford Part Ford Item Ford Part Name Number Specification Brake and Motorcraft High PM-1 ESA-M6C25-A clutch fluid Performance DOT and DOT 3 (if equipped)
  • Page 223 Maintenance and Specifications Ford Part Ford Item Ford Part Name Number Specification Front axle Premium Long XG-1-C or ESA-M1C75-B spindle pins, Life Grease XG-1-K steering linkage, front and rear spring shackle pins, steering column U-joints, steering shaft slip yoke and...
  • Page 224 Maintenance and Specifications Ford Part Ford Item Ford Part Name Number Specification Bushings, Premium Long XG-1-C or ESA-M1C75-B front wheel Life Grease XG-1-K bearings (grease packed type)and seals, fuel shut-off solenoid linkage, air brake control valve, linkage, treadle hinge and roller,...
  • Page 225 Maintenance and Specifications Ford Part Ford Item Ford Part Name Number Specification Spring leaves, Motorcraft SAE XO-10W30-QSD WSS-M2C171-C transmission 10W30 Super linkage pivots, Duty Motor Oil brake and clutch pedal pivots and clevises, transmatic detent stop, starter motor. Automatic Refer to the Allison Automatic Transmission Operator’s transmission manual.
  • Page 226 Refer to your scheduled maintenance guide to determine the correct service interval for the lubricant which you are using. Ford Motor Company currently does not offer a SAE 50 Motor oil. Ford Motor Company currently does not offer a synthetic based...

  • Page 227: Certification Label

    The rating decal is attached to the front door latch pillar (B-pillar) on the driver’s side. If you ever find it necessary to communicate with Ford Motor Company about your vehicle, always include the VIN in your communication. CERTIFICATION LABEL THIS CHASIS CAB CONFORMS TO FEDERAL MOTOR VEHICLE SAFETY STANDARD NOS.
  • Page 228 Certification Label is located on the front door latch pillar on the driver’s side. In many instances, the vehicle is sold by Ford Motor Company to an intermediate or final stage manufacturer who is required to affix the Compliance Label. In these...

  • Page 229: Accessories

    Accessories FORD ACCESSORIES FOR YOUR VEHICLE A wide selection of genuine Ford accessories are available for your vehicle through your local authorized Ford, Lincoln Mercury or Ford of Canada dealer. These quality accessories have been specifically engineered to fulfill your automotive needs; they are custom designed to complement the style and aerodynamic appearance of your vehicle.

  • Page 230: General Maintenance Information

    Your authorized dealer specializes in knowing all about Ford Motor Company vehicles rather than knowing a little about all makes. There are Ford or Ford of Canada dealer service shops ready to serve you wherever you drive in the U.S. or Canada. They stock Ford and Motorcraft parts, and Ford Chemicals and lubricants.
  • Page 231 General Maintenance Information OWNER MAINTENANCE You can do much of the maintenance your vehicle requires yourself, if you have the time and a reasonable amount of mechanical ability. If you prefer to have this work done professionally, your authorized dealer stands ready to help you.
  • Page 232 General Maintenance Information Emissions control system(s) laws Federal law prohibits vehicle manufacturers, dealers and other persons engaged in the business of repairing, servicing, selling, leasing or trading motor vehicles, as well as fleet operators from knowingly removing or rendering an emissions control device or system inoperative. Further, modifications of the emissions control system(s) could create liability on the part of individual owners under the laws of some states.
  • Page 233 Required Maintenance Services and in the General Maintenance Checklist. 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 the Owner Guide.
  • Page 234 Failure to maintain proper air brake adjustment can result in reduction or loss of braking ability. Air brake inspection and adjustment should be performed by a qualified service technician in accordance with the instructions in the Ford Truck Service Manual.
  • Page 235 General Maintenance Information Cam brakes - automatic slack adjusters Inspect standard air brakes equipped with automatic slack adjusters for proper brake adjustment every four months or 32 000 km (20 000 miles) whichever occurs first. However, more frequent inspection is required if your vehicle’s brakes are subjected to heavy use or adverse operating conditions such as: •...
  • Page 236 General Maintenance Information SCHEDULED MAINTENANCE GUIDE...
  • Page 237 General Maintenance Information Daily Owner Checks Engine system Check the air filter restriction indicator Check the engine oil Inspect the coolant level - for Powerstroke engine (for Caterpillar and Cummins engines, refer to the Owner’s Manual) Brake system Drain the air brake system reservoir - manual valve Check the air brake system reservoir automatic drain valve operation...
  • Page 238 General Maintenance Information Check every oil Engine system change Oil change Check the engine cooling system - hoses, intervals are as clamps and protection follows: Powerstroke - Inspect the drive belts 10 000 ; Caterpillar - Exhaust system 15 000 ; Cummins - 15 Inspect the entire exhaust system (including 000 (refer to the the inlet pipe(s), muffler(s), outlet pipe(s),...
  • Page 239 Use only permanent type coolant that meets Ford specifications ESE-M97B18-C. See the engine manufacturer’s operating guide for supplimental corrosion inhibitor specifications.
  • Page 240 General Maintenance Information 80 000 KM / 50 000 MILES • Disassemble the single check valve (SC-2) and the automatic drain valve (DB–2) — clean and inspect the valve for wear and deterioration. 100 000 KM / 60 000 MILES •...
  • Page 241 General Maintenance Information 160 000 KM / 100 000 MILES • Disassemble the single check valve (SC-3) and the automatic drain valve (DB–2) — clean and inspect the valves for wear and deterioration. • Lube the clutch release and the cross shaft lever. •...
  • Page 242 General Maintenance Information...
  • Page 243 General Maintenance Information Maintenance Operation Frequency - Observation Inspect the automatic slack Insufficient power shown in loaded adjuster function practice stop Check the operation of the Vehicle handling qualities not up to brakes, the clutch, and the steering (*b,a) Inspect the vehicle for missing, Excessive noise emanates from under damaged, or mislocated noise the cab or engine compartment...
  • Page 244 General Maintenance Information Maintenance Operation Frequency - Observation Check the transmission and Hard shifting or excessive vibration engine mountings (*b) Check and adjust transmission High effort to shift or noisy controls (*b) transmission Check fuel pump pressure Insufficient full-throttle power or backfiring Clean radiator cap seal.
  • Page 245 General Maintenance Information...
  • Page 246 General Maintenance Information...
  • Page 247 General Maintenance Information...
  • Page 248 General Maintenance Information...

  • Page 249: Index

    Cruise control (see Speed CD-6 disc ........40 control) ........77 CD-single premium .....31 Customer Assistance ....150 Child safety restraints ....102 Ford accessories for your child safety belts ....102 vehicle ........180 Child safety seats ......103 Getting assistance outside attaching with tether straps ..107 the U.S.
  • Page 250 Index Ordering additional owner’s filter, specifications ..198–200 literature .........171 gauge .........18 The Dispute Settlement improving fuel Board ........167 economy ......202, 204 safety information relating to automotive fuels .....196 Fuses ........151–152 Daytime running lamps (see Lamps) ........61 Driving under special conditions Gas mileage through water ......148 (see Fuel economy) ..202, 204...
  • Page 251 Index anti-lock brakes (ABS) ......11–12, 114 Ignition brake ........11–12 removing the key ....145 charging system ......13 check coolant ......12–13 Infant seats high beam .........15 (see Safety seats) .....103 safety belt .........12 Instrument panel service engine soon ....9 cleaning ........177 turn signal indicator ....14 cluster ........178 Lubricant specifications ...222 lighting up panel and...
  • Page 252 Index Speedometer .......18 Starting your vehicle ....108 Radio ....20, 25, 31, 39–40 jump starting ......164 Radio reception ......55 preparing to start your vehicle ........108 Refill capacities for fluids ..220 Steering wheel Relays ........151, 159 controls ........69, 77 Remote entry system ...84–85 tilting .........69 illuminated entry ......87 locking/unlocking doors ..84–85...
  • Page 253 Index Washer fluid ......183 Windshield washer fluid and reservoir ........183 wipers checking and cleaning ....68 Water, Driving through .....148 operation ........68 Wheels ........215 replacing wiper blades .....69 Windows Wrecker towing ......163 power .........74...

This manual is also suitable for:

2002 f750

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