Ford F-650 2001 Owner's Manual
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Ford F-650 2001 Owner's Manual

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Before driving
Starting and driving
Servicing
All rights reserved. Reproduction by any means, electronic or mechanical including
photocopying, recording or by any information storage and retrieval system or translation
in whole or part is not permitted without written authorization from Ford Motor Company.
Ford may change the contents without notice and without incurring obligation.
Copyright © 2000 Ford Motor Company
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  • Page 1: Table Of Contents

    All rights reserved. Reproduction by any means, electronic or mechanical including photocopying, recording or by any information storage and retrieval system or translation in whole or part is not permitted without written authorization from Ford Motor Company. Ford may change the contents without notice and without incurring obligation.

  • Page 2: Introduction

    Introduction The following warning may be required by California law: CALIFORNIA Proposition 65 Warning WARNING: Engine exhaust, some of its constituents, and certain vehicle components contain or emit chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.
  • Page 3 Your Ford dealer has information about the availability of equipment which may be ordered for...

  • Page 4: Vehicle 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 Air Bag-Front Air Bag-Side Child Seat Child Seat Installation Child Seat Tether Warning Anchorage Brake System Anti-Lock Brake System Brake Fluid - Traction Control...
  • Page 5 Introduction Vehicle Symbol Glossary Interior Luggage Child Safety Door Compartment Release Lock/Unlock Symbol 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...
  • Page 6 Introduction ENTERING, EXITING AND/OR CLIMBING ON THIS VEHICLE You must be careful and deliberate to minimize the possibility of personal injury from a slip and fall when entering, exiting and/or climbing on this vehicle. Always use the steps and assist handles before climbing. Do not skip any steps or assist handles.

  • Page 7: Instrumentation

    Instrumentation...
  • Page 8 Instrumentation Parking brake* Instrument cluster (hydraulic brake system) (pg. 10) (pg. 107) Panel dimmer control (pg. 21) PRESSURE Headlamp control (pg. 21) Turn signal and wiper/washer control (pg. 65)
  • Page 9 Instrumentation Cruise control* Electronic sound system Air pressure gauge* (pg. 66) (pg. 28) (pg. 20) VOL - PUSH ON BASS TREB FADE TAPE SEEK SIDE 1 - 2 SCAN TUNE POWER POINT TRAILER PARKING AIR SUPPLY BRAKE NOT FOR PARKING Auxiliary power point Climate control system...

  • Page 10: Warning Lights And Chimes

    Instrumentation WARNING LIGHTS AND CHIMES STOP ENGINE ENGINE PROTECT 0 0 0 0 0 BRAKE DIESEL FUEL ONLY CRUISE BRAKE 0 0 0 0 WAIT km/h 1000 START BRAKE CLEAN P R N WATER RANGE SERVICE TRAILER INHIBIT ENGINE CHECK FUEL SOON TRANS...
  • Page 11 Instrumentation Charging system Illuminates when the ignition is turned to the ON position and the engine is off. The light also illuminates when there is no alternator output, or an over voltage condition requiring electrical system service. Brake system warning Momentarily illuminates when the ignition is turned to the ON position BRAKE...
  • Page 12 Instrumentation Engine protect warning (Cummins engine only) Illuminates when there is a fault in ENGINE the electronic subsystem but the PROTECT vehicle can be driven, and indicates one of the following conditions: • low oil pressure • low coolant level •...
  • Page 13 Instrumentation High beams Illuminates when the high beam headlamps are turned on. Anti-lock brake system (ABS) Momentarily illuminates when the ignition is turned to the ON position and the engine is off. If the light remains on after the vehicle is started, continues to flash or fails to illuminate, have the system serviced immediately.
  • Page 14 Instrumentation 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 water in fuel 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 Instrumentation Safety belt Momentarily illuminates when the ignition is turned to the ON position to remind you to fasten your safety belts. For more information, refer to the Seating and safety restraints chapter. Service engine soon The Service Engine Soon indicator SERVICE light illuminates when the ignition is ENGINE...
  • Page 16 Instrumentation 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. Key-in-ignition warning chime Sounds when the ignition key is left in the ignition in the OFF/LOCK or ACC position and the driver’s door is opened.
  • Page 17 Instrumentation GAUGES STOP ENGINE ENGINE PROTECT 0 0 0 0 0 BRAKE DIESEL FUEL ONLY CRUISE BRAKE 0 0 0 0 WAIT km/h 1000 START BRAKE CLEAN P R N WATER RANGE SERVICE TRAILER INHIBIT ENGINE CHECK FUEL SOON TRANS Fuel gauge Displays approximately how much fuel is in the fuel tank (when the...
  • Page 18 Instrumentation Never remove the coolant reservoir cap while the engine is running or hot. This gauge indicates the temperature of the engine coolant, not the coolant level. If the coolant is not at its proper level the gauge indication will not be accurate. Speedometer Indicates the current vehicle speed.
  • Page 19 Instrumentation Trip odometer Registers the kilometers (miles) of individual journeys. To reset, depress the control. 0 0 0 0 0 0 0 0 0 km/h Tachometer Indicates the engine speed in revolutions per minute. Driving with your tachometer DIESEL FUEL ONLY pointer in the red zone may damage the engine.
  • Page 20 Instrumentation Engine oil pressure gauge This shows the engine oil pressure in the system. Sufficient pressure exists as long as the needle remains in the normal range (the area between the “L” and “H”). If the gauge indicates low pressure, stop the vehicle as soon as safely possible and switch off the engine immediately.

  • Page 21: Controls And Features

    Controls and features HEADLAMP CONTROL Rotate the headlamp control to the first position to turn on the parking lamps. Rotate to the second position to also turn on the headlamps. PANEL DIMMER CONTROL Use to adjust the brightness of the PANEL instrument panel during headlamp and parklamp operation.
  • Page 22 Controls and features Foglamp control (if equipped) The headlamp control also operates the foglamps. The foglamps can be turned on only when the headlamp control is in the position and the high beams are not turned on. Pull headlamp control towards you to turn foglamps on.

  • Page 23: Controls And Features

    Controls and features Temperature control Controls the temperature of the airflow inside the vehicle. On heater-only systems, the air cannot be cooled below the outside temperature. Mode selector control Controls the direction of the airflow to the inside of the vehicle. •...
  • Page 24 Controls and features • Under snowy or dirty weather conditions, your vehicle’s climate control system should be left in the OFF position when the vehicle is parked. This allows the climate control system to be free from contamination of outside pollutants. •...
  • Page 25 Controls and features 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 26 Controls and features • (Floor) -Allows for maximum heating by distributing outside air through the floor ducts. However, the air will not be cooled below the outside temperature because the air conditioning does not operate in this mode. • (Floor and defrost) -Distributes outside air through the windshield defroster ducts and the floor ducts.
  • Page 27 Controls and features windows open. This will force most of the hot, stale air out of the vehicle. Once the vehicle has been “aired out”, operate the climate control system as desired. • Do not put objects under the front seat that will interfere with the airflow to the rear seats (if equipped).

  • Page 28: Using Your Audio System

    Controls and features USING YOUR AUDIO SYSTEM AM/FM Stereo PUSH SEEK TONE TONE VOL TUNE AM/FM AM/FM Stereo PUSH SEEK TONE TONE VOL TUNE AM / FM STEREO AM/FM...
  • Page 29 Controls and features 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 30 Controls and features Tune adjust The tune control works in radio mode. Tune adjust in radio mode • Press to move to the next SEEK frequency down the band (whether or not a listenable TUNE station is located there). Hold the control to move through the frequencies quickly.
  • Page 31 Controls and features Bass adjust The bass adjust control allows you PUSH to increase or decrease the audio system’s bass output. TONE Press the TONE control once, then use the volume knob to adjust the desired level. Treble adjust The treble adjust control allows you PUSH to increase or decrease the audio system’s treble output.
  • Page 32 Controls and features Setting the clock Press CLK to toggle between listening frequencies and clock TONE mode. To set the hour, press and hold the CLK control until CLOCK SET appears in the display and press the SEEK control: • to decrease hours and •...
  • Page 33 Controls and features reverting back to the clock. In media mode, the media information will always be displayed. 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.
  • Page 34 Controls and features If the volume is set above a certain level and the ignition is turned off, the volume will come back on at a “nominal” listening level when the ignition switch is turned back on. AM/FM select The AM/FM select control works in radio and tape modes.
  • Page 35 Controls and features Seek function in radio mode • Press to find the next SEEK listenable station down the frequency band. TUNE • Press to find the next listenable station up the frequency band. Scan function The scan function works in radio mode.
  • Page 36 Controls and features 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 37 Controls and features Tape select • To enter tape mode while in radio mode, press the TAPE AMS control. TAPE Automatic Music Search The Automatic Music Search feature allows you to quickly locate the beginning of the tape selection being played or to skip to the next selection.
  • Page 38 Controls and features Fast forward The fast forward control works in SIDE 1 - 2 tape mode. • In the tape mode, tape direction will automatically reverse when the end of the tape is reached. Tape direction select Press SIDE and 1–2 at the same SIDE 1 - 2 time to play the alternate side of a...
  • Page 39 Controls and features Setting the clock Press CLK to toggle between listening frequencies and clock mode while in radio mode. To set the hour, press and hold the CLK control and press the SEEK TAPE control: • to decrease hours and •...
  • Page 40 Controls and features 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. Anytime 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 41 Controls and features Turn control to raise or lower VOL - PUSH ON volume. If the volume is set above a certain level and the ignition is turned off, the volume will come back on at a “nominal” listening level when the ignition switch is turned back on.
  • Page 42 Controls and features Seek function The seek function control works in radio, tape or CD mode. 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.
  • Page 43 Controls and features 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 44 Controls and features Starting autoset memory preset 1. Select a frequency using the AM/FM select controls. 2. Press the AUTO control. 3. When the first six strong stations AUTO are filled, the station stored in memory preset control 1 will start playing.
  • Page 45 Controls and features Press the TREB control then press: • to decrease the treble output • to increase the treble output. Speaker balance adjust Speaker sound distribution can be FADE adjusted between the right and left speakers. Press the BAL control then press: •...
  • Page 46 Controls and features Tape select • To begin tape play (with a tape loaded into the audio system) TAPE while in the radio or CD mode, press the TAPE control. Press the button during rewind or fast forward to stop the rewind or fast forward function.
  • Page 47 Controls and features Press the EJ control to stop and eject a CD. Dolby noise reduction Dolby noise reduction operates in tape mode. Dolby noise reduction reduces the amount of hiss and static during tape playback. Press the control to activate (and deactivate) the Dolby noise reduction.
  • Page 48 Controls and features Setting the clock To set the hour, press and hold the CLK control and press SEEK: AUTO • to decrease hours and • to increase hours. SEEK SEEK TUNE TUNE To set the minute, press and hold the CLK control and press TUNE: AUTO •...
  • Page 49 Controls and features The CLK button will allow you to switch between media display mode AUTO (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.
  • Page 50 Controls and features 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 51 Controls and features AM/FM select The AM/FM select control works in radio and CD modes (if equipped). 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 52 Controls and features Seek function in radio mode • Press to find the next listenable station down the frequency band. SEEK DOWN SEEK will display. • Press to find the next listenable station up the frequency band. SEEK UP will display. Seek function in CD mode •...
  • Page 53 Controls and features Setting memory preset stations 1. Select the frequency band with the AM/FM select control. Press the AM/FM control to toggle between AM, FM1, or FM2. 2. Press the SEEK control to access the next listenable station up or down the frequency band.
  • Page 54 Controls and features CD select CD mode may be entered by pressing the CD control and the LOAD control. Load the CD into the audio system. The first track of the disc will begin playing. After that, CD play will begin where it stopped last. If an alternative CD is desired, press the corresponding preset control (1–6) of a loaded CD, or press the TUNE control to access the other loaded CDs.
  • Page 55 Controls and features 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 56 Controls and features Rewind The rewind control works in CD modes. Press and hold the REW control until the desired selection is reached. If the beginning of the disc is reached, the CD will begin play at the first track. Release the control to disengage rewind mode. When in rewind mode, your audio system will automatically lower the volume level of the playing media.
  • Page 57 Controls and features On Audiophile audios, press the MENU control until compression status is displayed. Press the SEL control to enable the compression feature when COMP OFF is displayed. Press the SEL control again to disable the feature when COMP ON is displayed. On Premium audios, press the COMP COMP control until COMP ON is...
  • Page 58 Controls and features 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 59 Controls and features 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 60 Controls and features 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 61 Controls and features • 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. With RDS activated, press the MENU control until SHOW is displayed.
  • Page 62 Controls and features • JAZZ CLUB—jazz club with clearly reflected sounds • HALL—rectangular concert hall capacity of about 2 000 • CHURCH—church with a high vault • STADIUM—outdoor stadium with a capacity of about 30 000 Press the DSP control again to access the occupancy modes. Use the SEL control to optimize the sound based upon the occupants in the vehicle.
  • Page 63 Controls and features Troubleshooting the CD player The laser beam used in the compact disc player is harmful to the eyes. Do not attempt to disassemble the case. If sound skips: • You may be traveling on a rough road, playing badly scratched discs or the disc may be dirty.
  • Page 64 Controls and features • 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. • Tighten very loose tapes by inserting a finger or pencil into the hole and turning the hub.
  • Page 65 Controls and features 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. HAZARD FLASHER For information on the hazard flasher control, refer to Hazard flasher in the Roadside emergencies chapter.
  • Page 66 Controls and features HIGH BEAMS Push forward to activate. Pull toward you to deactivate. FLASH TO PASS Pull toward you to activate and release to deactivate. SPEED CONTROL (IF EQUIPPED) To turn speed control on-except Caterpillar/Cummins engines • Press ON. Vehicle speed cannot be controlled until the vehicle is traveling at or above 48 km/h (30 mph).
  • Page 67 Controls and features Do not shift the gearshift lever into N (Neutral) with the speed control on. Caterpillar/Cummins engines Press CRUISE RPM. If the vehicle is moving, speed control will be enabled; if the vehicle is stationary, engine RPM can be controlled. Do not use the speed control in heavy traffic or on roads that are winding, slippery, or unpaved.
  • Page 68 Controls and features Do not use the speed control in heavy traffic or on roads that are winding, slippery, or unpaved. Caterpillar/Cummins engines Press SET +. If the vehicles is moving, this will set the vehicle speed. If the vehicle is stationary, this will set the vehicle idle RPM. If you drive up or down a steep hill, your vehicle speed may vary momentarily slower or faster than the set speed.
  • Page 69 Controls and features Caterpillar/Cummins engines Press and hold SET +. If the vehicle is moving, this will increase vehicle speed; if the vehicle is stationary, this will increase engine RPM. Release the control when the desired vehicle speed/engine RPM is reached. Press and release SET + to operate the Tap-Up function.
  • Page 70 Controls and features 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. Pressing OFF will erase the previously programmed set speed or engine RPM.
  • Page 71 Controls and features To return to a previously set speed-except Caterpillar/Cummins engines • Press RES. For RES to operate, the vehicle speed must be faster than 48 km/h (30 mph). Caterpillar/Cummins engines Press RESUME -. For RESUME - to operate, the vehicle speed must be above 48 km/h (30 mph) or engine speed must be above 1 000 RPM.
  • Page 72 Controls and features The compass reading may be affected when you drive near large buildings, bridges, power lines and powerful broadcast antenna. Magnetic or metallic objects placed in or on the vehicle may also affect compass accuracy. Adjustments may need to be made to the zone and calibration of the compass.
  • Page 73 Controls and features 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 74 Controls and features 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 10 minutes.
  • Page 75 Controls and features 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 76 Controls and features 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. POWER DOOR LOCKS (IF EQUIPPED) Press U to unlock all doors and L to lock all doors.
  • Page 77 Controls and features 2. Move the control in the direction you wish to tilt the mirror. MIRRORS 3. Return to the center position to lock mirrors in place. HEATED TELESCOPING TRAILER TOW MIRRORS Manually pull the mirror outward or inward as desired. Pull the mirrors inward carefully when driving through a narrow space.
  • Page 78 Controls and features REMOTE ENTRY SYSTEM (IF EQUIPPED) The remote entry system allows you to lock or unlock all vehicle doors without a key. The remote entry features only operate with the ignition in the LOCK position. If there is any potential remote keyless entry problem with your vehicle, ensure ALL key fobs (remote entry transmitters) are brought to the dealership, to aid in troubleshooting.
  • Page 79 Controls and features Sounding a panic alarm Press both controls to activate the alarm. The horn will sound and the lights will flash. To deactivate the alarm, press both controls again or turn the ignition to ACC or ON. This device complies with part 15 of the FCC rules and with RS-210 of Industry Canada.
  • Page 80 Controls and features Replacing lost transmitters If a remote transmitter has been lost and you would like to remove it from the vehicle’s memory, or you would like to purchase additional remote transmitters and have them programmed to your vehicle: •...
  • Page 81 Controls and features 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 82: 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 83 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 84: Seating And Safety Restraints

    Seating and safety restraints Pump handle to raise seat height. Push handle full down to lower. Always adjust the seat height before fastening seatbelt. Adjusting the front power seat (if equipped) Never adjust the driver’s seat or seatback when the vehicle is moving.
  • Page 85 Seating and safety restraints Press rear to raise or lower the rear portion of the seat cushion. Press the control to move the seat forward, backward, up or down. Heated seats (if equipped) To operate the heated seats: • Push control to activate. •...
  • Page 86 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 87 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 88 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 89 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 90 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 91 Seating and safety restraints Insert the tongue into the correct buckle (the buckle closest to the direction the tongue is coming from). To lengthen the belt, turn the tongue at a right angle to the belt and pull across your lap until it reaches the buckle.
  • Page 92 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 illuminates1-2 minutes and the switch is turned to the ON warning chime sounds 4-8 seconds. position... The driver’s safety belt is The safety belt warning light and buckled while the indicator...
  • Page 93 I’m not going far 3 of 4 fatal crashes occur within 25 miles of home. Belts are uncomfortable Ford designs its safety belts to enhance comfort. If you are uncomfortable - try different positions for the safety belt upper anchorage and seatback which should be as upright as possible;...
  • Page 94 Seating and safety restraints Reasons given... Consider... I have an air bag Air bags offer greater protection when used with safety belts. Frontal airbags are not designed to inflate in rear and side crashes or rollovers. I’d rather be thrown clear Not a good idea.
  • Page 95 (slide bar-if equipped), shoulder belt height adjusters (if equipped), shoulder belt guide on seatback (if equipped), child safety seat tether bracket assemblies (if equipped), and attaching hardware, should be inspected after a collision. Ford...
  • Page 96 Seating and safety restraints recommends that all safety belt assemblies used in vehicles involved in a collision be replaced. However, if the collision was minor and a qualified technician finds that the belts do not show damage and continue to operate properly, they do not need to be replaced.
  • Page 97 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 98 • 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 99 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 100 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. If the child seat is...
  • Page 101 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 102: Starting

    Starting STARTING PROCEDURES Operating precautions • Always shift to a lower gear at high altitudes to prevent engine smoking. • Avoid extended and unnecessary idling. Do not operate a diesel engine where the vapors can be combustible. 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 103 Starting 4. Do not depress the accelerator during starting the engine. 5. Start the engine. If the engine does not start after 30 seconds of cranking, allow two minutes for the starter to cool before trying again. Excessive cranking may damage the starter. After the engine starts: •...
  • Page 104 Starting OPERATING THE ENGINE Do not operate the engine at full throttle below peak torque engine speed (RPM) for more than one minute at a time (peak torque RPM varies from 1200-1500 RPM depending on engine rated speed). Monitor the oil pressure and coolant temperature gauges frequently.
  • Page 105 Starting COLD WEATHER STARTING Perform the following to assure efficient starting in cold weather: • Use the proper grade oil for your climate. Refer to your engine operator’s manual for proper grade oil. • Test the battery more frequently to assure ample power for starting. •...

  • Page 106: Driving

    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 107 Driving Although OSHA or other governmental regulations may require use of an electrical or mechanical back-up alarm to warn bystanders, such an alarm does not assure that the intended path is clear. An electrical back-up alarm, if installed, is connected to the back-up lamp circuit.
  • Page 108 Driving The ABS operates by detecting the onset of wheel lockup during brake applications and compensating for this tendency. The wheels are prevented from locking even when the brakes are firmly applied. The accompanying illustration depicts the advantage of an ABS equipped vehicle (on bottom) to a non-ABS equipped vehicle (on top) during hard braking with loss of front braking traction.
  • Page 109 Driving Hydraulic brake booster system (Hydromax) The Hydromax systems receive fluid pressure from the power steering pump to provide power assist during braking. The Hydromax booster receives backup pressure from the reserve system electric pump whenever the fluid in the power steering system is not flowing.
  • Page 110 Driving Parking brake Apply the parking brake whenever the vehicle is parked. To set the parking brake, pull handle up until it snaps into the locked position. A properly adjusted parking brake requires approximately 116 Nm (90 lb-ft) to activate. For maximum parking brake effectiveness turn handle clockwise to adjust for wear.
  • Page 111 Driving The parking brake is not recommended to stop a moving vehicle. However, if the normal brakes fail, the parking brake can be used to stop your vehicle in an emergency. Since the parking brake only applies retardation to the rear wheels, the vehicle’s stopping distance will increase greatly and the handling of your vehicle will be adversely affected.
  • Page 112 Driving Parking brake warning chime — F650 SuperCrewzer Only If a chime sounds when pulling the yellow knob out, your parking brake is not functioning properly, seek service immediately. This chime will sound until the yellow knob is pushed in or eight minutes have passed. If the yellow knob is pulled out again the chime sounds as a reminder that immediate service is required to the parking brake system.
  • Page 113 Driving Burnish procedure — All except F650 SuperCrewzer For optimal performance of a new parking brake system/new linings perform the following procedure: 1. While driving the vehicle at 40 km/h (20 mph) apply the parking brake (with applicable force to set to approximately 18kg [40 lbs.]). Allow the vehicle to come to a complete stop.
  • Page 114 Driving Occasional or intermittent brake squeal may result from environmental conditions such as cold, hot, wet, snow, salt, mud, etc. This condition will not affect braking effectiveness. The brakes should be checked only if squeal occurs continuously with every application. If brakes do not grip well •...
  • Page 115 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 repair. The orange stripe is painted on the air chamber push rod at the slack adjuster readjustment stroke dimension.
  • Page 116 Driving Emergency air brake All vehicles are equipped with a dual brake system. In the unlikely event of a failure of one system, the second system will function for emergency stopping. These systems are all controlled by the brake pedal in the same manner as for normal stops.
  • Page 117 Driving Parking brake control Pull the yellow parking brake knob out to apply the parking brake. Push the knob in to release the parking brake. PARKING This control is used for BRAKE parking only. Do not leave the vehicle unattended after setting the parking brake without placing the transmission in R (Reverse) for manual transmission...
  • Page 118 Driving Block the wheels to prevent the vehicle from moving. Unexpected and possibly sudden vehicle movement may occur if these precautions are not taken. Impact wrenches should not be used as they may damage the piston and prevent proper caging of the spring. Do not apply more than 68 Nm (50 lb-ft) torque to the release bolt nut.
  • Page 119 Driving Do not use the trailer brake manual control lever for parking. Trailer air supply control (MV-3) (Tractor package) The MV-3 control module is a two-button, push-pull control valve housed in a single body which includes a dual circuit supply valve and a check valve.
  • Page 120 Driving Actuation of trailer parking or emergency brakes To actuate the trailer brakes only, pull out the red control (trailer air supply), exhausting the trailer supply line. The trailer brakes are now applied either by air emergency TRAILER or spring brakes, depending on the AIR SUPPLY type of trailer system.
  • Page 121 Driving Reservoir selection The number one service reservoir will at all times be selected as the primary supply source for the MV-3. This is accomplished automatically by the function of the dual circuit supply valve contained in the body of the MV-3.
  • Page 122 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 123 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 124 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 125 Driving If the steering wanders or pulls This condition can be caused by any of the following conditions: • Underinflated tire(s) on any wheel(s) • Front end out of alignment • Total vehicle out of alignment (i.e. rear axle[s] out of alignment with front axle) •...
  • Page 126 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 A MANUAL TRANSMISSION, IF EQUIPPED Continued use of a damaged or worn clutch, prolonged clutch slippage or downshifting at excessive speeds can result in a failure of the engine, transmission or clutch components.
  • Page 127 Driving Do not coast the vehicle with the clutch pedal depressed or with the transmission in neutral. This practice could result in loss of vehicle control. Always use a gear ratio low enough to allow the engine to operate above the minimum engine operation speed range.
  • Page 128 Driving To go forward With the engine idling, depress the clutch pedal and shift into 1 (First). Engage the clutch while pressing the accelerator to start forward. Operate the clutch and upshift as required by driving conditions. To go backward Reverse is obtained by putting the gearshift lever in R (Reverse) and engaging the clutch while pressing...
  • Page 129 Driving To go forward With the engine idling, depress the clutch pedal and shift into 1 (First). Engage the clutch while pressing the accelerator to start forward. Operate the clutch and upshift as required by driving conditions. To go backward Reverse is obtained by putting the gearshift lever in R (Reverse) and engaging the clutch while pressing...
  • Page 130 Driving To go forward With the engine idling, depress the clutch pedal and shift into 1 (First). Engage the clutch while pressing the accelerator to start forward. Operate the clutch and upshift as required by driving conditions. To go backward Reverse is obtained by putting the gearshift lever in R (Reverse) and engaging the clutch while pressing...
  • Page 131 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 132 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 133 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 134 Driving These transmissions have no P (Park) position. Before leaving the driver’s seat, always shift into N (Neutral) and set the parking brake. Shut the engine off and remove your ignition key. Always use wheel chocks for hilly or off-road parking. Unexpected and possibly sudden vehicle movement may occur if these precautions are not taken.
  • Page 135 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 136 Driving 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. Shut off the engine and remove your ignition key. Always use wheel chocks for hilly or off-road parking. Unexpected and possibly sudden vehicle movement may occur if these precautions are not taken.
  • Page 137 Driving 1 (First) The transmission has to be manually shifted into 1 (First) and will not shift into a higher gear. Use this position when pulling through mud or snow, driving up steep grades, hauling extra heavy loads or where maximum reduction is required.
  • Page 138 Driving Do not allow your vehicle to coast in N (Neutral). Engine braking is not available in N (Neutral). Allowing your vehicle to coast in N (Neutral) may result in loss of vehicle control and severe internal transmission damage. D (Drive—Normal driving position) In this position, the transmission starts in first gear and automatically shifts through second, third, fourth and fifth depending on load and speed demands.
  • Page 139 Driving PTO operation with vehicle stationary To operate the power take-off, stop the vehicle, idle the engine and set the parking brake. Make sure the gear selector is in any forward drive range, then engage the PTO. After the PTO is engaged for stationary vehicle operation, move the range selector to N (Neutral).
  • Page 140 Driving 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 FGAWR: XXXXXX/XXXXXXX RGAWR: XXXXXXX/XXXXXXX XXXXXXXXXXXX W/TIRES XXXXXXXXXXXX W/TIRES...
  • Page 141 Driving Driving through deep water where the transmission vent tube is submerged may allow water into the transmission and cause internal transmission damage. FUEL CONSUMPTION IMPROVEMENT MEASURES There are two important factors you can control to improve fuel economy: the mechanical condition of your vehicle and how you drive it. A properly maintained vehicle will deliver better performance than a neglected vehicle.

  • Page 142: 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 143 Roadside emergencies HAZARD FLASHER Use only in an emergency to warn traffic of vehicle breakdown, approaching danger, etc. The hazard flashers can be operated when the ignition is off. • The hazard lights control is located on top of the steering column.

  • Page 144: Roadside Emergencies

    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 145 Roadside emergencies Passenger compartment fuse panel The fuse panel is located below and to the left of the steering wheel by the brake pedal. Remove the panel cover to access the fuses. To remove a fuse use the fuse puller tool provided on the fuse panel cover. The fuses are coded as follows.
  • Page 146 Roadside emergencies Fuse/Relay Fuse Amp Passenger Compartment Fuse Location Rating Panel Description — Not Used — Not Used Radio, GEM 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)
  • Page 147 Roadside emergencies Fuse/Relay Fuse Amp Passenger Compartment Fuse Location Rating Panel Description Electronic Flasher Vacuum Pump, Air Dryer, ABS, Fuel Heater Relay Blower Motor Relay Right Low Beam Headlamp — Not Used Left Low Beam Headlamp Cluster, GEM, 7.3L Power Stroke PCM (clutch switch input), APCM (7.3L Power Stroke only), Overhead Console (SuperCrewzer...
  • Page 148 Roadside emergencies Power distribution box The power distribution box is located in the engine compartment. The power distribution box contains high-current fuses that protect your vehicle’s main electrical systems from overloads. Always disconnect the battery before servicing high current fuses. Always replace the cover to the Power Distribution Box before reconnecting the battery or refilling fluid reservoirs.
  • Page 149 Roadside emergencies Fuse/Relay Fuse Amp Power Distribution Box Location Rating Description 15A* Air Intake Heater Relay (CAT), Cummins PCM 20A* CAT PCM, Cummins PCM 15A* Stop Lamps 25A* C AT Fuel Heater 30A* Trailer Hook Up lamps (SuperCrewzer only) 15A* Shift Modulator (Allison AT trans only) 20A*...
  • Page 150 Roadside emergencies Fuse/Relay Fuse Amp Power Distribution Box Location Rating Description 20A** Power Point 20A** Power Door Locks 30A** Headlamps 50A** Junction Box Battery Feed (fuses 1, 2, 3, 4, 12, 13, 14, 15) 40A** Cummins Fuel Heater 40A** Power Windows 30A** Power Seats (SuperCrewzer only) 30A**...
  • Page 151 Roadside emergencies Fuse/Relay Fuse Amp Power Distribution Box Location Rating Description — Shift Modulator Relay (CAT and Power Stroke only), Cummins UP-44 Relay, A/C High Pressure Relay (SuperCrewzer only — Backup Lamps Relay — Stop Lamps Relay, Foglamps Relay (SuperCrewzer only) —...
  • Page 152 Roadside emergencies Relays The relay box is located on the rear crossmember near the rear bumper. Air Brake Trailer Tow Relays (if equipped) TRLR TRLR MARKER LP USED USED RELAY RELAY TRLR TRLR STOP LP TAIL LAMP TURN TURN RELAY RELAY NOT USED The relays are coded as follows:...
  • Page 153 Roadside emergencies SuperCrewzer (if equipped) N.U. HOOK EXHAUST 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 154 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. Do not push start your vehicle. You could damage the catalytic converter.
  • Page 155 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 156 Roadside emergencies Jump starting 1. Start the booster vehicle and run the engine at moderately increased speed. 2. After a few minutes, start the engine of the vehicle with the discharged battery. 3. After starting, run the engine at about 1,000 RPM for 3–5 minutes. Do not operate the starter longer than 30 seconds.
  • Page 157 Roadside emergencies WRECKER TOWING Always unload your vehicle before towing it. The recommended method of towing is with the drive wheels off the ground. Before towing, make sure: • the parking brake is released. • if air pressure has been lost, to release the brakes manually. Improper towing of the vehicle will not allow sufficient lubrication of the transmission which may cause serious damage to internal transmission components.

  • Page 158: Maintenance And Care

    Maintenance and care CHECKING UNDER THE HOOD 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...
  • Page 159 Maintenance and care 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 160 Maintenance and care Checking engine oil level—7.3L Power Stroke engine Refer to the Scheduled Maintenance Guide for the appropriate intervals for checking the engine oil. Check the engine oil level consistently and accurately. The following procedure is recommended: 1. Start the engine and let it run until it reaches normal operating temperature (the engine coolant temperature gauge indicator will be near the center of the normal area between H and C).
  • Page 161 Proper quality oils also provide maximum efficiency of the crankcase ventilation system which reduces air pollution. Use Motorcraft motor oil or an equivalent oil meeting Ford specification WSS-M2C171–C or API service category designation CH-4/SJ. Do not use oils labeled with only one of the category designations SG, SH, SJ, CE, CF-4, CH-4 or CG-4, as they could cause engine damage.
  • Page 162 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 163 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 the Capacities and specifications chapter. Brake fluid is toxic. If brake fluid contacts the eyes, flush eyes with running water for 15 minutes.
  • Page 164 During normal operation, the fluid level in the clutch reservoir should remain constant. 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 Capacities and specifications.
  • Page 165 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 the Capacities and specifications chapter. State or local regulations on volatile organic compounds may restrict the use of methanol, a common windshield washer antifreeze additive.
  • Page 166 Maintenance and care ENGINE COOLANT Checking coolant level Refer to the Scheduled Maintenance Guide for the appropriate intervals for checking the engine coolant level. Check the engine coolant level in the coolant reservoir when the engine is cold. If the coolant level has not been checked at the recommended interval, the coolant reservoir may become empty.
  • Page 167 Use Ford Premium Engine Coolant E2FZ-19549–AA (in Canada, MotorcraftCXC-10 ) or a premium engine coolant that meets Ford specification ESE-M97B44–A. Do not use alcohol or methanol antifreeze. The use of an improper coolant may cause cooling system and/or engine damage and may void the warranty of your vehicle’s engine cooling...
  • Page 168 Maintenance and care Adding and replacing engine coolant-Caterpillar 3126 B engine Refer to the engine operator’s manual for additional engine cooling system information. FAN CLUTCHES Your vehicle’s cooling system is equipped with a viscous variable speed fan clutch. • The fan clutch helps control cooling, increase performance, improve fuel economy and reduce noise.
  • Page 169 Maintenance and care 5. Reinstall the dipstick. Remove it again and check the fluid level. • If the fluid temperature is at approximately 20°C - 49°C (68°F - 120°F) (fluid cool or warm to the touch ), check the COLD side FULL MAX.
  • Page 170 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 the Capacities and specification chapter). Use of a non-approved transmission fluid may cause internal transmission component damage.
  • Page 171 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 the Capacities and specification chapter). Use of a non-approved rear axle lubricant may cause internal axle component damage.
  • Page 172 Maintenance and care 3. Set the parking brake and shift into N (Neutral) (automatic transmission) or 1 (First) (manual transmission) and turn the engine off. 4. Clean any dirt from around the rear axle filler and drain plugs. 5. Remove the filler and drain plugs and drain the lubricant into a suitable container.
  • Page 173 Maintenance and care • Battery tray with cover removed. 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”.
  • Page 174 Maintenance and care Batteries normally produce explosive gases which can cause personal injury. Therefore, do not allow flames, sparks or lighted substances to come near the battery. When working near the battery, always shield your face and protect your eyes. Always provide proper ventilation.
  • Page 175 Maintenance and care 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 176 Maintenance and care • 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 177 Maintenance and care • 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 178 Maintenance and care 9. Push in on the cover latches, then turn the latches clockwise 90 degrees. Make sure that all air filter cover latches are fully engaged. 10. Reset the air filter restriction indicator. 11. Inspect the air induction system for loose fitting, damaged or missing components and repair as necessary.
  • Page 179 • 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 180 Maintenance and care Tires are one of the weaker weight carrying components of the vehicle. Do not overload the vehicle beyond safe load carrying capacity. Avoid hammering rim with steel hammers. Never run the engine with one wheel off the ground. Failure to retighten wheel lug nuts as required could allow the wheel to come off while the vehicle is in motion, possibly causing loss of vehicle control and collision.
  • Page 181 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 182 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 183 Maintenance and care Tire/wheel rim selection and inflation pressures Single Rear Axle: Max. Tire Tire Size, Load Wheel Width and Wheel Capacity kg. (lb.) Range (PR) (in.) and Type kPa @ (psi) (cold) by Axle Tubeless Type Radial Ply Front Rear 10R22.5 F (12) 7.50 10H...
  • Page 184 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 185 Maintenance and care Choosing the right fuel At operating temperatures below 0°C (32°F), use a blend of No. 1D and No. 2D Diesel fuels, also known as winterized No. 2D. Do not use diesel fuel blended with waste oil in engines equipped with a catalytic converter-muffler.
  • Page 186 Maintenance and care Fuel filter/water separator The fuel filter/water separator removes any contaminated particles and/or water from the fuel before the fuel enters the engine. The fuel filter/water separator should be drained as recommended in the Scheduled Maintenance Guide. Draining the fuel filter/water separator—Caterpillar 3126 B engine 1.
  • Page 187 Maintenance and care Draining the fuel filter/water separator—Cummins B engine Refer to your engine operator’s manual for service procedures. 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.
  • Page 188 Maintenance and care 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 189 Maintenance and care Installation 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 190 Maintenance and care The amount of Empty Reserve varies and should not be relied upon to increase driving range. When refueling your vehicle after the fuel gauge indicates empty, you might not be able to refuel the full amount of the advertised capacity of the fuel tank due to the empty reserve still present in the tank.
  • Page 191 Maintenance and care 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 192 Maintenance and care EXTERIOR BULBS Check operation of lamps, safety equipment and warning signals It is a good safety practice to check operation of headlamps, parking lamps, turn signals, clearance and marker lamps, instrument panel and control lamps each day. Replacing headlamp bulbs To remove the headlamp bulbs: 1.
  • Page 193 Maintenance and care Replacing front parking lamp/turn signal bulbs To remove the parking/turn signal bulbs: 1. Make sure the headlamp control is in the OFF position. 2. Open the hood. 3. Remove four screws from the lamp assembly. 4. Carefully lower lamp assembly and pull the bulb socket straight out of the lamp assembly.
  • Page 194 Maintenance and care Replacing brake/tail/backup lamp bulbs The brake/tail/backup lamp bulbs are located in the same portion of the tail lamp assembly. Follow the same steps to replace either bulb: 1. Remove the four screws and the lamp lens from lamp assembly. 2.
  • Page 195 Maintenance and care 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 196 (if equipped) is operating, indicating a short circuit or overload. Take your vehicle to your dealer for a circuit check. CLEANING AND CARING FOR YOUR VEHICLE Refer to the Customer Assistance chapter for a list of Ford-approved cleaners, polishes and waxes. Washing your vehicle Wash your vehicle regularly with cold or lukewarm water.
  • Page 197 Ultra Touch Prep and Finishing Kit (#F7AZ-19K507–BA), Lacquer Touch-up Paint (#ALBZ-19500–XXXXA), or Exterior Acrylic Spray Lacquer (#ALAZ-19500–XXXXA) from the Ford Car Care Chemicals line. Please note that the part numbers (shown as XXXX above) will vary with your vehicle’s specific coloring. Observe the application instructions on the products.
  • Page 198 Cleaning the exterior lamps Wash with the same detergent as the exterior of your vehicle. If necessary, use a tar remover such as Ford Extra Strength Tar and Road Oil Remover (B7A-19520–AA). To avoid scratching the lamps, do not use a dry paper towel, chemical solvents or abrasive cleaners.
  • Page 199 Ford Ultra-Clear Spray Glass Cleaner, (E4AZ-19C507–AA), available from your Ford Dealer. Do not use abrasive cleansers on glass as they may cause scratches. The windshield or rear window is clean if beads do not form when you rinse it with water.

  • Page 200: Capacities And Specifications

    Capacities and specifications ENGINE COOLANT AND OIL REFILL CAPACITIES Engine Engine coolant Engine oil (approximate capacity) (approximate capacity) Caterpillar 3126 B 23.7L (25.0 quarts) Cummins B 5.9L 23.1L (24.4 quarts) Power Stroke 7.3L 18.0L (19.0 quarts) 18.0L (19.0 quarts) Refer to the engine operator’s manual for engine oil refill capacities. Engine oil and filter change.
  • Page 201 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 clutch High Performance C6AZ-19542-AB ESA-M6C25-A fluid DOT 3 Motor and DOT 3 (if equipped)
  • Page 202 Capacities and specifications Ford Part Ford Item Ford Part Name Number Specification Front axle spindle Premium Long Life XG-1-C or ESA-M1C75-B pins, steering Grease XG-1-K linkage, front and rear spring shackle pins, steering column U-joints, steering shaft slip yoke and universal...
  • Page 203 Capacities and specifications Ford Part Ford Item Ford Part Name Number Specification Spring leaves, Motorcraft SAE XO-10W30-QSD WSS-M2C171-B transmission 10W30 Super Duty linkage pivots, 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 204 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 lubricant for this viscosity grade.

  • Page 205: 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 206 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 207: 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 208 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 209 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 210 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 211 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.
  • Page 212 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. Cam brakes - automatic slack adjusters...
  • Page 213 General maintenance information SCHEDULED MAINTENANCE GUIDE...
  • Page 214 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 215 General maintenance information Check every oil Engine system change Oil change Check the engine cooling system - hoses, intervals are as clamps and protection follows: Inspect the drive belts Powerstroke - 10 000; Caterpillar - 15 000; Exhaust system Cummins - 15 000 Inspect the entire exhaust system (including (refer to the the inlet pipe(s), muffler(s), outlet pipe(s),...
  • Page 216 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 217 General maintenance information 65 000 KM / 40 000 MILES • Replace the fuel filter.* 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.
  • Page 218 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 219 General maintenance information 800 000 KM / 500 000 MILES • Change the lubricant in the manual shift transmission (all applications) when equipped with optional synthetic lubricant.
  • Page 220 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 221 General maintenance information Maintenance Operation Frequency - Observation 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. Clean When the cap does not hold pressure and inspect the cap surface on the radiator Check the battery terminals for...
  • Page 222 General maintenance information...
  • Page 223 General maintenance information...
  • Page 224 General maintenance information...
  • Page 225 General maintenance information...

  • Page 226: Customer Assistance

    United States and Canada, provided by a network of more than 5,000 participating Ford or Lincoln Mercury and Ford of Canada dealers. If you did not take advantage of the Ford Extended Service Plan at the time of purchasing your vehicle, you may still be eligible. Please contact your dealer for further information.
  • Page 227 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 228: Customer Assistance

    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 229 THE DISPUTE SETTLEMENT BOARD (U.S. only) The Dispute Settlement Board is: • an independent, third-party arbitration program for warranty disputes • available free to owners and lessees of qualifying Ford Motor Company vehicles The Dispute Settlement Board may not be available in all states. Ford...
  • Page 230 • 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 231 Customer assistance • 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) • a description of the action you expect to resolve your concern You will receive a letter of explanation if your application does not qualify for Board review.
  • Page 232 UTILIZING THE MEDIATION/ARBITRATION PROGRAM (CANADA ONLY) In those cases where you continue to feel that the efforts by Ford and the dealer to resolve a factory-related vehicle service concern have been unsatisfactory, Ford of Canada participates in an impartial third party mediation/arbitration program administered by the Canadian Motor Vehicle Arbitration Plan (CAMVAP).
  • Page 233 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 234 Customer assistance Ford Deluxe Leather and Vinyl Cleaner (not available in Canada) Motorcraft Vinyl Cleaner (Canada only) Ford Extra Strength Tar and Road Oil Remover* (not available in Canada) Ford Extra Strength Upholstery Cleaner (Canada only) Ford Extra Strength Upholstery Cleaner (not available in Canada)
  • Page 235 Obtaining a French owner’s guide French Owner’s Guides can be obtained from your dealer or by writing to Ford Motor Company of Canada, Limited, Service Publications, P.O. Box 1580, Station B, Mississauga, Ontario L4Y 4G3.

  • Page 236: Reporting Safety Defects

    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 237: Index

    ........118 checking and adding ....166 Cruise control (see Speed control) ........66 Cassette tape player .....49–50 Customer Assistance ....142 Ford accessories for your Child safety restraints ....96 vehicle ........233 child safety belts ......96 Ford Extended Service Child safety seats ......97 Plan ..........226...
  • Page 238 Index Utilizing the gauge .........17 Mediation/Arbitration improving fuel Program ........232 economy ......141, 189 safety information relating to automotive fuels .....183 Fuses ........143, 145 Daytime running lamps (see Lamps) ........21 Driving under special conditions Gas mileage (see Fuel through water ......140 economy) ......141, 189 Gauges .........17 battery voltage gauge ....19...
  • Page 239 Index charging system ......11 check coolant ......14, 16 Ignition high beam .........13 removing the key ....130 safety belt .........15 service engine soon ....15 Infant seats (see Safety seats) ..97 turn signal indicator ....12 Instrument panel Lubricant specifications ...201 cleaning ........199 cluster ........199 lighting up panel and interior ........21...
  • Page 240 Index panic alarm .......79 Towing replacement/additional wrecker ........157 transmitters .......80 Transmission replacing the batteries .....81 fluid, checking and adding (automatic) ......169 fluid, checking and adding (manual) .........169 Safety belts (see Safety manual operation ....126 restraints) ......87–89 Trip odometer ......19 Safety defects, reporting ..236 Turn signal ......12, 65 Safety restraints ....87–89 belt minder .......92...

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