2002 FORD F650 Owners Manual

To go backward
Reverse is obtained by putting the
gearshift lever in R (Reverse) and
engaging the clutch while pressing
lightly on the accelerator.
Removing key from ignition
²Turn the ignition key to position
2.
²Push the release lever forward
and rotate the key towards you
and remove.
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. Depress the clutch and allow the gears to stop
rotating, then engage the PTO unit. The PTO can also be selected with
the transmission in gear as long as the clutch is depressed.
When operating the PTO unit with the vehicle stationary, first set the
parking brake (chock the wheels if the vehicle is on a hill or other
unlevel surface).
2 4 6
3 5 7
1 R
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145

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. If other persons are in the vicinity, have
someone standing well behind the vehicle and outside your intended
path - visible through an exterior mirror - guide you as you back up.
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.
TWO SPEED REAR AXLE
General Information
A 2±speed axle allows the vehicle operator to selectLow Rangefor good
starting and pulling power. The operator may also selectHigh Range
which allows for greater road speed and economy.
High or Low Range can also be used to provide additional steps between
transmission gear ratios when either gradeability or economy are a
driving factor.
Axle upshift
Brake Torque
In any type of shift, you must brake torque your vehicle. This is done by
releasing the accelerator, because torque creates a binding action on the
sliding clutch gear. This binding must be relieved in order for the shift to
take place.
Axle upshifts transmission gears may be abrupt, causing the truck to
jerk. Using the clutch with the accelerator will smooth the shift.
In order to shift from LOW to HIGH,
²Pull the axle shift accelerator up.
²Release the accelerator.
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Axle downshift
In order to shift from HIGH to LOW,
²Push the axle shift control down.
²Release the accelerator (while pushing the axle shift control down).
²Depress the accelerator to resume driving.
Split upshift
A split upshift is when there is an axle downshift with a transmission
upshift.
A split upshift can be done as follows:
²Depress the clutch.
²Shift the transmission, while keeping the axle shift control up in
HIGH.
²After the transmission lever movement has ended, push the axle shift
control down.
²Release the clutch.
²Depress the accelerator.
When split shifting, the axle shift control must stay UP in the
HIGH range until after any transmission lever movement.
Split downshift
A split downshift is when there is an axle upshift with a transmission
downshift.
A split downshift can be done as follows:
²Pull the axle shift control up.
²Depress the clutch.
²Shift the transmission, while keeping the axle shift control up in
HIGH.
²Release the clutch.
Split shift sequence
123 4 567891011
1st 1st 2nd 2nd 3rd 3rd 4th 4th 5th 6th 6th
LO HI LO HI LO HI LO HI LO LO HI
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147

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. When you are on a down grade, the wheels
will not slow down, but will tend to speed up. As a result, the ring gear
must be accelerated to synchronize speeds. You are however limited in
doing so by your engine governed speed, and may not be able to reach
synchronization to allow the shift to take place. If the shift is not
completed , the axle will be in neither HIGH nor LOW range and all
driveline retardation will be lost.
Ratio extender use
Low End
A 2±speed axle can be used as a ratio-extender when split shifting is not
necessary. For low end use, just shift the axle into the LOW to start out,
and shift to HIGH when the extra torque is no longer needed.
Transmission (5-speed) 1st 1st 2nd 3rd 4th 5th 6th
2-speed Axle Axle
LowAxle High
High End
To use the 2±speed axle as a high end ratio-extender, stay in the LOW
range for normal upshifts and only shift the axle to HIGH on the freeway
for greater road speed.
Transmission (5-speed) 1st 2nd 3rd 4th 5th 6th
Speed
Axle
High 2-Speed Axle Low for Gradeability
DRIVING THROUGH WATER
Do not drive quickly through standing water, especially if the depth is
unknown. Traction or brake capability may be limited and if the ignition
system gets wet, your engine may stall. Water may also enter your
engine's air intake and severely damage your engine.
If driving through deep or standing water is unavoidable, proceed very
slowly. Never drive through water that is higher than the bottom of the
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148

hubs (for trucks) or the bottom of the wheel rims (for cars).
Once through the water, always try the brakes. Wet brakes do not stop
the vehicle as effectively as dry brakes. Drying can be improved by
moving your vehicle slowly while applying light pressure on the brake
pedal.
Driving through deep water where the transmission vent tube is
submerged may allow water into the transmission and cause
internal transmission damage.
MAXIMUM VEHICLE LOADING
Every vehicle manufactured by Ford
Motor Company is supplied with
information on the Vehicle Rating
Decal listing the maximum loading
for the vehicle (GVWR), and its axle
systems (GAWR) at the tire to
ground interface.
Under no circumstances should your vehicle be loaded in excess of the
GVWR or GAWR. It is the operator's responsibility to assure that neither
the axle capacities, spring capacities, tire capacities nor the vehicle rated
GVWR is exceeded. For tire capacities, refer toMaintenance and
specificationschapter.
Unloaded or lightly loaded vehicles
The braking system has been designed to safely stop your vehicle when
fully loaded to its GVWR.
When operating empty or lightly loaded, sudden or hard braking
may induce wheel lockup with loss of vehicle control and the
possibility of accident and serious injury, especially on wet or slippery
road surfaces.
MFD. BY FORD MOTOR CO. IN U.S.A.
WB TYPE/GVW BODY TRANS AXLE EXT PNT DSO
XXX XXXXXX XXX XXX XXX XXXX XXXXXX
ÑFOHT-15294A10-GA
DATE: XXXXX GVWR:XXXXX LB/ XXXXX KGFGAWR: XXXXXX/XXXXXXX RGAWR: XXXXXXX/XXXXXXX
XXXXXXXXXXXX W/TIRES XXXXXXXXXXXX W/TIRES
XXXXXXXXX RIMS XXXXXXXXX RIMS
AT XXX PSI COLD AT XXX PSI COLD
THIS VEHICLE CONFORMS TO ALL APPLICABLE FEDERAL
MOTOR VEHICLE SAFETY STANDARDS IN EFFECT ON THE
DATE OF MANUFACTURE SHOWN ABOVE.
VIN: XXXXXXXXXXXXXXXXX REAR REAR GAWR
TYPE: XXXXXXXXXXXXXXXXXX XXXXXXX/XXXXXXX
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149

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:
²24±hours, seven days a week
²for the New Vehicle Limited Warranty period (U.S.) of two years
(unlimited miles)
Roadside assistance will cover:
²jump-starts
²lock-out assistance
²towing to the nearest Ford Motor Company dealership, or towing to
your selling dealership if within 56 km (35 miles). Even non-warranty
related tows, like accidents or getting stuck in the mud or snow, are
covered (some exclusions apply, such as impound towing or
repossession).
USING ROADSIDE ASSISTANCE
Complete the roadside assistance identification card and place it in your
wallet for quick reference. This card is found in the Owner Guide
portfolio in the glove compartment.
To receive roadside assistance in the United States, call 1-800-241-3673.
If you need to arrange roadside assistance for yourself, Ford will
reimburse a reasonable amount. To obtain information about
reimbursement, call 1-800-241-3673.
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.
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150

²The hazard lights control is
located on top of the steering
column.
²Depress hazard lights control to
activate all hazard flashers
simultaneously.
²Depress 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. Blown fuses are
identified by a broken wire within
the fuse. Check the appropriate
fuses before replacing any electrical
components.
Note:Always replace a fuse with one that has the specified amperage
rating. Using a fuse with a higher amperage rating can cause severe wire
damage and could start a fire.
15
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151

Standard fuse amperage rating and color
COLOR
Fuse
ratingMini
fusesStandard
fusesMaxi
fusesCartridge
maxi
fusesFuse link
cartridge
2A Grey Grey Ð Ð Ð
3A Violet Violet Ð Ð Ð
4A Pink Pink Ð Ð Ð
5A Tan Tan Ð Ð Ð
7.5A Brown Brown Ð Ð Ð
10A Red Red Ð Ð Ð
15A Blue Blue Ð Ð Ð
20A Yellow Yellow Yellow Blue Blue
25A Natural Natural Ð Ð Ð
30A Green Green Green Pink Pink
40A Ð Ð Orange Green Green
50A Ð Ð Red Red Red
60A Ð Ð Blue Ð Yellow
70A Ð Ð Tan Ð Brown
80A Ð Ð Natural Ð Black
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.
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152