2002 FORD F650 brakes

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.
5. Using the jumper cables, connect
the positive (+) terminal of the
discharged battery to the positive
(+) terminal of the booster battery.
NOTE:In the illustration,
lightning bolts are used to
designate the assisting (boosting)
battery.
6. Connect one end of the cable to
the negative (-) terminal of the
booster battery and the other end to
a ground at least 12 inches from the
battery of the discharged vehicle. The vehicle frame is usually a good
ground.
7. Ensure that the jump leads are clear of moving parts of the engine,
and that the clamps from one cable do not touch the clamps on the
other cable.
8. Do not lean over the batteries when making the connections.
Do not connect the end of the second cable to the negative (-)
terminal of the battery to be jumped. A spark may cause an
explosion of the gases that surround the battery.
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.
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162

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.
Removing the jumper cables
1. Remove the ground connection
from the disabled vehicle first,
followed by the cable on the
negative (-) battery terminal of the
booster vehicle.
2. Remove the cable from the
positive (+) terminal of the
discharged battery and then from
the positive (+) terminal of the
booster battery.
3. After the disabled vehicle has
been started, allow it to idle for a
while so the engine can ªrelearnº its
idle conditions.
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:
²the parking brake is released.
²if 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. Always follow the outlined towing procedures.
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Roadside Emergencies
163

BRAKE FLUID
Checking and adding brake fluid
Check and refill the Hydromax
brake fluid reservoir using the
following procedure. Refer to the
scheduled maintenance guide for
the service interval.
1. Clean the reservoir caps before
removal to prevent dirt or water
from entering the reservoir.
2. Visually inspect the fluid level.
3. If necessary, add brake fluid from
a clean un-opened container until
the level reaches MAX. Do not fill
above this line.
4. Use only a DOT 3 brake fluid
certified to meet Ford specifications. Refer toLubricant specifications
in this chapter.
Brake fluid is toxic. If brake fluid contacts the eyes, flush eyes
with running water for 15 minutes. Seek medical attention if
irritation persists. If taken internally, drink water and induce vomiting.
Seek medical attention immediately.
If you use a brake fluid that is not DOT 3, you will cause
permanent damage to your brakes.
Do not let the reservoir for the master cylinder run dry. This
may cause the brakes to fail.
AVOID MIXING LUBRICANTS
In some cases, different brands of lubricants are not compatible with
each other and deteriorate when mixed. It is best to stick with one brand
during a maintenance interval.
Maintenance and Specifications
208

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:
²Frequent brake applications while fully loaded.
²Operation on hilly or mountainous terrain.
²Frequent operation on dirt, gravel or mud.
Some aftermarket brake linings also require more frequent inspections.
General Maintenance Information
235

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
Transmission system
Visually check the automatic transmission for
fluid leakage
Steering system
Check the power steering pump fluid level and
check the system for leaks
Check the entire vehicle for evidence of fluid
leaks
U.S. Department of Transportation,
Federal Highway Administration
requirements (ensure that the entire
system is functioning properly)
Check the service brakes
Check the parking brake
Check the steering mechanism
Check the lighting devices and reflectors
Check the tires
Check the horn
Check the windshield wipers
Check the rear vision mirrors
Check the wheels and rims
Check the emergency equipment
General Maintenance Information
237

Check every oil
changeOil change
intervals are as
follows: Powerstroke -
10 000 ; Caterpillar -
15 000 ; Cummins - 15
000 (refer to the
Caterpillar and
Cummins service
manuals for further
instructions and
information)Engine system
Check the engine cooling system - hoses,
clamps and protection
Inspect the drive belts
Exhaust system
Inspect the entire exhaust system (including
the inlet pipe(s), muffler(s), outlet pipe(s),
clamps and fasteners) for holes, leakage,
breakage, corrosive damage and separation
from other components. Adjust, service or
replace with the same or the equivalent part.
(Also a noise emission control service)
Suspension system
Lubricate the front and rear spring pins
Tighten the front and rear spring U-bolts to
the specified torque
Driveline and rear axle system
Lubricate the U-joints and the slip yoke
Brake system
Lube the air brake foot control valve, hinge
and roller
Inspect the drum brake linings through the
inspection holes
Lubricate the brake camshafts (air brakes)
Lubricate the brake slack adjuster (air brakes)
Lubricate rear caliper slide rails (F650
SuperCrewzer only)
Inspect the disc brake pads and the piston
boots (hydraulic brakes)
Clutch system
Lubricate the clutch release cross shaft and all
linkages
Check the clutch fluid
General Maintenance Information
238

Maintenance Operation Frequency - Observation
Inspect the automatic slack
adjuster functionInsufficient power shown in loaded
practice stop
Check the operation of the
brakes, the clutch, and the
steering (*b,a)Vehicle handling qualities not up to
par
Inspect the vehicle for missing,
damaged, or mislocated noise
shieldsExcessive noise emanates from under
the cab or engine compartment
Check the engine performance
and the engine governorExcessive engine noise
Inspect the fan, the fan shroud,
and the fan clutchEngine overheats, fans runs at high
speed constantly, excessive fan noise,
or fan wobble due to worn bearings
Check for operation of ABS
warning lampAt each engine start up
Inspect the entire exhaust
system (including inlet pipe,
muffler, outlet pipe and all
exhaust clamps and fasteners)
for holes, leakage, breakage,
looseness and corrosive
damageExcessive noise or the smell of fumes
is experienced
Inspect the engine air
induction system (including the
air ducts, the air cleaner, and
the air cleaner element) for
loose fitting, damaged or
missing componentsExcessive noise emanates from the
engine compartment
Inspect the tires and check the
air pressure (*c)Poor steering, wandering or excessive
tire wear
Balance the wheels and the
tiresVibration or abnormal tire wear
indicates imbalance
Check the front end alignment
(*c)Poor steering, wandering or excessive
tire wear
General Maintenance Information
243

A
Air cleaner filter .......................211
Air conditioning
manual heating and air
conditioning system .................57
Audio system
(see Radio) ..........20, 25, 31, 39±40
Automatic transmission ............132
Auxiliary power point .................73
B
Battery .......................................187
jumping a disabled battery ....164
voltage gauge ............................18
BeltMinder ...................................98
Brakes ................................113, 119
anti-lock ...................114±115, 121
anti-lock brake system
(ABS) warning light ...11±12, 114
brake warning light ............11±12
fluid, checking and adding ....208
parking ....................115, 118, 122
trailer .......................................124
C
CD-6 disc .....................................40
CD-single premium .....................31
Child safety restraints ..............102
child safety belts ....................102
Child safety seats ......................103
attaching with tether straps ..107
in front seat ............................105
in rear seat ..............................105
tether anchorage hardware ...107Cleaning your vehicle
engine compartment ..............176
exterior ....................................179
instrument cluster lens ..........178
instrument panel ....................177
interior .....................................178
plastic parts ............176±177, 179
safety belts ..............................179
washing ....................................174
waxing .....................................174
wheels ......................................175
windows ..................................179
wiper blades ............................177
Climate control (see Air
conditioning or Heating) ......56±57
Clock ..........................23, 28, 36, 44
Clutch ........................................207
fluid ..........................................206
Compass, electronic ....................70
calibration .................................72
set zone adjustment .................71
Console
overhead ....................................70
Controls
power seat .................................90
Coolant ......................................189
refill capacities ........................194
Cruise control (see Speed
control) ........................................77
Customer Assistance ................150
Ford accessories for your
vehicle .....................................180
Getting assistance outside
the U.S. and Canada ..............170
Getting roadside assistance ...150
Getting the service
you need .................................165
Index
249