2002 FORD F650 transmission

²Caterpillar 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. Push in and turn the latches that retain the air filter housing cover
counterclockwise 90 degrees, then carefully remove the cover.
4. Carefully remove the air filter element.Use caution to keep dirt
and debris from falling into the engine.A twisting rocking motion
may be needed to break the seal between the filter element and the filter
housing.
Maintenance and Specifications
213

POWER STEERING FLUID CAPACITIES
GVWR Axle application System capacity
11 794/13 608 kg (26
000/30 000 lb.)3 856/4 082 kg (8
000/9 000 lb.)4.3L (4.5 quarts)
14 969 kg (33 000 lb.) 5 443 kg (12 000 lb.) 4.5L (4.7 quarts)
TRANSMISSION REFILL CAPACITIES
Type and make Approximate capacity
5-speed (Eaton FS-4205A)1, 25.4L (5.75 quarts)
5-speed (Eaton FS-5205A)1, 25.9L (6.25 quarts)
6-speed (Eaton FS-5306A and
FS-6306A)
1, 29.2L (9.75 quarts)
7-speed (Spicer ES52-7B and
ES066-7B)
1, 210.4L (11.0 quarts)
Allison AT-545
318.9L (20.0 quarts)
2000/2400 Series-Standard sump 10.0L (10.6 quarts)4
2000/2400 Series-Shallow sump 7.0L (7.4 quarts)5
MD series327.4L (29.0 quarts)
1Quantity shown is nominal; fluid level should be at lower edge of fill
hole.
2Fill plug is located on the right side of the transmission and the drain
plug on the rear of the transmission.
3Fluid level should be checked by your dealer or a qualified service
technician.
4Approximate quantites only, does not include external lines and cooler
hose.
5Approximate quantites only, does not include external lines and cooler
hose.
Maintenance and Specifications
221

Item Ford Part NameFord Part
NumberFord
Specification
Bushings,
front wheel
bearings
(grease
packed
type)and
seals, fuel
shut-off
solenoid
linkage, air
brake control
valve, linkage,
treadle hinge
and roller,
transmission
and
transmission
cables, clutch
release
bearing hub,
transmission
shift lever
pivot.Premium Long
Life GreaseXG-1-C or
XG-1-KESA-M1C75-B
Door
weatherstripsSilicone Lubricant F7AZ-19G208-BA
and
F5AZ-19553-AAESR-M13P4-A
Driveshaft
U-joints and
slip splines,
power
steering gear
output shaft.High Temperature
4 x 4 Front Axle
and Wheel
Bearing GreaseE8TZ-19590-A ESA-M1C198-A
Maintenance and Specifications
224

Item Ford Part NameFord Part
NumberFord
Specification
Spring leaves,
transmission
linkage pivots,
brake and
clutch pedal
pivots and
clevises,
transmatic
detent stop,
starter motor.Motorcraft SAE
10W30 Super
Duty Motor OilXO-10W30-QSD WSS-M2C171-C
Automatic
transmissionRefer to the Allison Automatic Transmission Operator's
manual.
Rear axle and
front wheel
bearings (oil
filled)
1
Motorcraft SAE
80W-90 Premium
Rear Axle
LubricantXY-80W90-QL WSP-M2C197-A
Motorcraft SAE
75W-140 High
Performance Rear
Axle LubricantXY-75W-140±QL WSL-M2C192-A
Manual
transmission
1Motor oil SAE 50
(above -18ÉC
[0ÉF])2WSE-M2C908-A
Motorcraft SAE 30
Super Duty Motor
oil (below -18ÉC
[0ÉF])XO-30-QSD
3WSS-M2C171-C
Engine oil
-7.3L Power
Stroke
engine
1, 4
Motorcraft Super
Duty Motor oilXO-15W40-QSD3
XO-10W30-QSD3WSS-M2C171-C
Motorcraft SAE
0W-30 Super All
Season Motor oil
(synthetic)XO-0W30-LAS
Maintenance and Specifications
225

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.
Scheduled maintenance beyond 160 930 km (100 000 miles) should be
continued as before 160 930 km (100 000 miles).
SPECIAL OPERATING CONDITIONS
If your driving habitsfrequentlyinclude one or more the following
conditions:
²Short trips oflessthan 16 km (ten miles) when outside temperatures
remain below freezing.
²Operating duringhot weatherin stop-and-go ªrush hourº traffic.
²Operating in severe dust conditions.
²Extensive idling, or low speed operation such as door-to-door delivery
service.
²High speed operation with a fully loaded vehicle (max. GVW).
²Snowplowing.
Perform the following:
²Change engine oil and oil filter every three months, 8 000 km (5 000
miles) or 125 hours of engine service.
²If operating in severe dust conditions, replace the air cleaner filter
more often than regular intervals as determined by the air filter
restriction indicator. Make sure that the air filter restriction indicator
is in good working order.
²Lube the manual transmission and the rear axle every 48 279 km
(30 000 miles) or 6 months, whichever comes first.
²See the Allison, Cummins and Caterpillar Operator's Manual.
AIR BRAKE ADJUSTMENT
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.
General Maintenance Information
234

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)Fuel system
Drain the accumulated water or sediment from
the fuel tank(s)
Steering system
Lubricate the steering shaft(s), U-joints and
splines when equipped with grease fittings
Lubricate the front axle spindle pins
Lubricate the steering linkage when equipped
with grease fittings
Grease the power steering gear output shaft
* Coolant protection checks should be made just prior to the onset of
freezing weather, where applicable. If coolant is dirty or rusty in
appearance, the system should be drained, flushed and refilled with the
prescribed solution of cooling system fluid and water. Use only
permanent type coolant that meets Ford specifications ESE-M97B18-C.
See the engine manufacturer's operating guide for supplimental
corrosion inhibitor specifications.
In addition to the items to be performed daily or at each oil change, the
following need to be completed as specified:
8 000KM / 5 000 MILES
²Initial change Ð change the lubricant in the manual shift transmission
± 5 speed and 6 speed Eaton manual transmission. (Not required
when equipped with optional synthetic lubricant.)
32 000 KM / 20 000 MILES
²Replace the fuel filter.*
50 000 KM / 30 000 MILES
²Replace the engine spin-on coolant filter.*
²Repack and adjust the front wheel bearings Ð grease-filled hubs.
65 000 KM / 40 000 MILES
²Replace the fuel filter.*
General Maintenance Information
239

80 000 KM / 50 000 MILES
²Disassemble the single check valve (SC-2) and the automatic drain
valve (DB±2) Ð clean and inspect the valve for wear and
deterioration.
100 000 KM / 60 000 MILES
²Replace the engine spin-on coolant filter.*
²Oil filled front hubsÐ drain oil, adjust bearings and refill the front
hubs with oil. (Not required when equipped with optional synthetic
lubricant.)
²Drain the oil, adjust the bearing and refill with axle lubricant Ð oil
filled hubs.
²Replace the fuel filter.*
²Change the manual transmission oil Ð Eaton 5 and 6 speeds only.
(Not required when equipped with optional synthetic lubricant.)
110 000 KM / 70 000 MILES
²Replace the engine spin-on coolant filter.*
²Replace the engine coolant.* See the engine manufacturer's operating
guide for supplemental corrosion inhibitor specifications.
130 000 KM / 80 000 MILES
²Replace the fuel filter.*
150 000 KM / 90 000 MILES
²Replace the engine spin-on coolant filter*.
²Repack and adjust the front wheel bearings Ð grease-filled hubs.
²Change the lubricant in the manual shift transmission ± 7 speed
Spicer. (Not required when equipped with optional synthetic
lubricant.)
²Change the power steering fluid and filter.
General Maintenance Information
240