2003 FORD F650 clutch

Removing key from ignition
•Turn the ignition key to position
2.
•Push 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).
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.
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145

An electrical back-up alarm, if installed, is connected to the back-up
lamp circuit.
TWO-SPEED REAR AXLE
General Information
A two-speed rear axle allows the vehicle operator to selectLO rangefor
good starting and pulling power. The operator may also selectHI range
which allows for greater road speed and economy.
LO or HI range can also be used to provide additional steps between
transmission gear ratios when either gradeability or economy are a
driving factor.
Note:The two-speed rear axle should not be shifted while driving with
the speed control engaged.
Operation of the two-speed rear axle with a manual transmission
Split-shift sequence
Ratio
combination1234567891011
Transmission
gear1st 1st 2nd 2nd 3rd 3rd 4th 4th 5th 6th 6th
Axle range LO HI LO HI LO HI LO HI LO LO HI
Split-shifting upshift from LO to HI
•With the accelerator down, move the axle selector to HI by pulling the
selector up.
•Release the accelerator, then depress the clutch. Pause while the axle
upshifts, then release the clutch and depress the accelerator.
Transmission upshift and HI to LO axle
•Shift transmission to next higher gear.
•Move the axle selector to LO, by pressing the selector down, before
engaging the clutch.
Downshifting HI to LO axle
•With the accelerator down, move the axle selector to LO by pressing
the selector down.
•Rapidly release and depress the accelerator.
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146

The fuses are coded as follows:
Fuse/Relay
LocationFuse Amp
RatingPassenger Compartment Fuse
Panel Description
1 20A Horn
2 15A Turn/Hazard lamps
3 20A Cigar lighter
4 10A Diagnostic connectors
5 15A Back-up lamps, Daytime Running
Lamps (DRL) relays, Blend door
actuator, Heated seat module
(SuperCrewzer only), On/Off fan
clutch (SuperCrewzer only),
Warning chime module
(SuperCrewzer and Ambulance)
6—Not used
7—Not used
8 5A Radio, GEM
9 5A Switch Illumination (headlamp,
power windows, power door
locks), Power window relay,
Trailer hook-up lamps
(SuperCrewzer only)
10—Not used
11 30A Wiper motor, Washer pump relay
12 10A Stoplamp switch (hydraulic brake
vehicles only)
13 20A Radio, Cluster, 7.3L Power Stroke
Powertrain Control Module
(PCM), Keep Alive Memory
14 10A Interior lamps, Running board
lamps (SuperCrewzer only)
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153

Fuse/Relay
LocationFuse Amp
RatingPassenger Compartment Fuse
Panel Description
29 10A Cluster, GEM, 7.3L Power Stroke
PCM (clutch switch input), APCM
(7.3L Power Stroke only),
Overhead console (SuperCrewzer
only), Keyless entry module
(SuperCrewzer only), Traxx
(Fuel) module (SuperCrewzer
only)
30 30A 7.3L Power Stroke PCM diode,
7.3L Power Stroke fuel heater
31 15A Allison MD Transmission, Neutral
start relay and PCM (7.3L Power
Stroke only)
Relay 1—Interior lamps
Relay 2—Not used
Relay 3—Horn
Relay 4—One touch down power window
Relay 5—Not used
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
If the battery has been disconnected and reconnected, refer to the
Batterysection of theMaintenance and specificationschapter.
Roadside Emergencies
155

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.
•The fan clutch is controlled by bimetallic spring sensors. Do not
tamper with these sensors as this may change their calibration or keep
the fan clutch from operating at all.
Stay clear of the fan/fan area while the engine is running or
possible personal injury may occur.
FUEL INFORMATION
Important safety precautions
Do not overfill the fuel tank. The pressure in an overfilled tank
may cause leakage and lead to fuel spray and fire.
The fuel system may be under pressure. If the fuel cap is venting
vapor or if you hear a hissing sound, wait until it stops before
completely removing the cap.
Automotive fuels can cause serious injury or death if misused or
mishandled.
Observe the following guidelines when handling fuel:
•Extinguish all smoking materials
and any open flames before
fueling your vehicle.
•Always turn off the vehicle before
fueling.
•Automotive fuels can be harmful
or fatal if swallowed. If fuel is swallowed, call a physician immediately,
even if no symptoms are immediately apparent. The toxic effects of
fuel may not be visible for hours.
•Avoid inhaling fuel vapors. Inhaling too much fuel vapor of any kind
can lead to eye and respiratory tract irritation. In severe cases,
Maintenance and Specifications
192

To avoid damage to the power steering system,do notoperate the
vehicle with a low power steering fluid level.
Whenever the dipstick is installed, make sure it is properly seated and
tightened securely.
CLUTCH FLUID (IF EQUIPPED)
Check the clutch fluid level. Refer to the general maintenance
information section for the service interval schedules.
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
toLubricant Specificationsin this chapter.
1. Set the parking brake, shift into 1
(First) and turn the engine off.
2. Open the hood.
3. Clean the reservoir cap before
removal to prevent dirt and water
from entering the reservoir.
4. Remove cap and rubber
diaphragm from reservoir.
5. Add fluid until the level reaches
the step in the reservoir.
6. Reinstall rubber diaphragm and cap onto reservoir.
Clutch (if equipped)—linkage lubrication
Lubricate the clutch linkage using the following procedure. Refer to the
general maintenance information section for the service interval
schedules.
Use a grease which meets Ford specifications. Refer toLubricant
Specificationsin this chapter.
1. Set the parking brake, shift into 1 (First) and turn the engine off.
2. Remove the inspection cover from the clutch housing.
Maintenance and Specifications
202

•Transmission and clutch
removed for clarity.
3. With a grease gun, lubricate the clutch release bearing (at one
location) and the clutch release shaft (at two locations) using the grease
fittings provided.
4. Lubricate clutch release wear pads at the two locations where they
contact the clutch release bearing using a brush or similar tool.
5. Install the inspection cover onto the clutch housing.
BRAKE FLUID
Checking and adding brake fluid
Check and refill the Hydromax
brake fluid reservoir using the
following procedure. Refer to the
general maintenance information
section 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.
Maintenance and Specifications
203

LUBRICANT SPECIFICATIONS
Item Ford Part NameFord Part
NumberFord
Specification
Brake and clutch
fluid (if
equipped)Motorcraft High
Performance DOT
3 Motor Vehicle
Brake FluidPM-1 ESA-M6C25-A
and DOT 3
Body hinges,
hood hinges and
latches.Multi-Purpose
GreaseXG—4or
F5AZ-19G209-AAESR-M1C159-A
Lock cylinders Penetrating
LubricantXL-1 N/A
Front axle
spindle pins,
steering linkage,
front and rear
spring shackle
pins, steering
column U-joints,
steering shaft
slip yoke and
universal joint,
steering shaft
pillow block
bearing, clutch
linkage fittings.Premium Long
Life GreaseXG-1-C or
XG-1-KESA-M1C75-B
Maintenance and Specifications
218