2003 FORD F650 Owners Manual

•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.
•If your vehicle is equipped with the Cummins B engine,a
secondary air filter is located the bottom of the air filter housing to
keep dirt and debris from falling into the engine when the air filter
element is being removed. This secondary filter needs to be replaced
only after the primary air filter element has been replaced several
times. If necessary replace the secondary air filter.
5. Reach inside the air filter housing and clean the outlet tube where it
extends into the housing. Be sure not to damage the tube because the
air filter element seals around this surface.
6. Check to be sure that the drain hole in the air filter housing is open
and clear of any dirt and debris.
7. Check to be sure the new air filter element is not damaged, then
install it. Make sure there is a tight seal (apply pressure at the outer rim
of the element, not the flexible center).
8. Align the air filter cover latches with the holes in the air filter housing
and install the cover.
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.
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209

11. Inspect the air induction system for loose fitting, damaged or missing
components and repair as necessary.
SERVICING YOUR WHEELS AND TIRES
Wheel assembly
Your vehicle is fitted with hub
piloted wheels and two-element
swiveling lug nuts (20 & 22 mm).
Do not use taper type wheels or ball
seat wheel nuts.
•Do not paint the mating face of the hub/drum.
•Do not paint the two-element swiveling lug nuts or wheel stud.
•Do not allow an excessive thickness of paint to build between the disc
wheel mounting surfaces.
•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
nut body and flange, it is
necessary to use clean engine oil
meeting Ford specification
WSS-M2C153-G between nut body and flange. Lubricate the nut body
and flange any time a wheel is removed.
The M20 & M22 wheel nuts are right-hand threads. Refer to the
following chart for approved wheel lug nut torque.
Wheel type Bolt size Wheel nut torque
10-hole disc 285.75
mm bolt circleM22 (22 by 1.5 mm) 610-677 Nm (450-500
lb-ft)
8-hole disc 19.5x6.75
mm bolt circleM20 (20 by 1.5 mm) 610-677 Nm (450-500
lb-ft)
The disc wheel nuts on your vehicle were tightened before delivery.
Recheck torque of nuts at 160 km (100 miles) and 800 km (500 miles) of
new vehicle operation or any time a wheel is removed. Reset to
recommended torque levels.
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210

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. Loose wheel studs may also cause
shimmy and vibration.
Use of aftermarket wheel assemblies is not recommended; they
may be incompatible with your vehicle and may result in
equipment failure and possible injury. Replacement with used wheels is
not advised; they may have been treated harshly or have high mileage
and could fail without warning.
A wheel or tire of the wrong size or type may adversely affect
such things as load carrying capacity, wheel and bearing life,
brake cooling, speedometer/odometer calibration, stopping ability,
headlight aim, bumper height, vehicle ground clearance and tire or tire
chain clearance to the body and chassis.
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211

•10–hole disc
•8–hole disc
Always tighten wheel lug nuts
alternately in the sequence shown.
Make sure the wheel is drawn
evenly against the hub or drum.
Check for damage that would affect
the runout of the wheels. Wobble or
shimmy caused by a damaged wheel
will eventually damage the wheel
bearings. Stones or lumps of mud
wedged between a wheel and drum
or between dual wheels can unbalance a wheel and tire.
Servicing your tires
Inspect the tire treads and remove stones, nails, glass or other objects
that may be wedged in the tread grooves. Check for holes or cuts that
may permit air leakage from the tire and make the necessary repairs.
Inspect the tire sidewalls for cuts, bruises and other damage. If internal
damage to the tire is suspected, have the tire removed from wheel and
inspected.
Check the pressure regularly. Maintain the recommended air pressure for
your vehicle, load, tires and rims or wheels. Check the tire valve for air
leaks and replace the valve if necessary. If the valve cap is missing,
install a new cap. Refer toTire/Wheel Rim Selection and Inflation
Pressuresor theVehicle Certification Labelin this chapter.
5310
1
8
6
4
9 2 7
1
3 4
27 6
5 8
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212

An inflated tire and rim can be very dangerous if improperly
used, serviced or maintained. To avoid serious injury, never
attempt to re-inflate a tire which has been run flat or seriously
under-inflated without first removing the tire from the wheel assembly
for inspection. 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.
Tire inflation pressure must not exceed the recommendations of
the axle, tire and/or wheel rim manufacturer for the specific
load, speed and application. The inflation pressures on the tire sidewall
do not take the wheel rim capabilities into consideration.
Never use a rim of different manufacture or any different size or
type than original rims.
Try to replace tires in pairs on the same axle shaft. Tires larger or
smaller than originally installed may affect the accuracy of the
speedometer. Consult your dealer about the need to change the switch
setting on the back of the speedometer.
Front wheel alignment
If abnormal tire wear or ride and handling characteristics such as vehicle
lead or wander are experienced with properly inflated tires, the front
end alignment should be checked.
Wheel bearing care
Front and rear wheel bearings are adjustable to correct for bearing and
spindle wear. Long bearing life depends upon proper adjustment and
correct lubrication. If bearings are adjusted too tightly (preloaded) they
will overheat and wear rapidly. Loose adjustment will cause pounding
and will contribute to uneven tire wear, steering difficulties and
inefficient brake operation.
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
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213

ADD and FULL marks indicated on the hub. Do not overfill. Overfilling
can result in oil on brake linings.
Refer to your general maintenance information section for fluid level
checks and change intervals for the front hubs.
Your front hubs may be filled with an optional synthetic fluid which
allows use of the extended service intervals. A green colored filler plug
identifies use of the synthetic fluid.
Tire/wheel rim selection and inflation pressures
Tire Size, Load
Range (PR)Wheel Width
(in.) and TypeSingle Rear Axle: Max. Tire
and Wheel Capacity kg. (lb.)
kPa @ (psi) (cold) by Axle
Tubeless Type Radial Ply Front Rear
10R22.5 F (12) 7.50 10H
(I.S.O.)10 300 (4 671)
698 10019 280 (8 745)
698 100
10R22.5 G (14) 7.50 10H
(I.S.O.)10 300 (4 671)
698 10021 000 (9 525)
711 115
11R22.5 G (14) 8.25 10H
(I.S.O.)12 080 (5 478)
703 10522 520 (10 213)
703 105
245/70R19.5 6.75 8H (I.S.O.) 10 300 (4 671)
698 10019 280 (8 745)
698 100
11X20 (16) 7.50 10H
(I.S.O.)12 080 (5 478)
703 10522 520 (10 213)
703 105
MINOR TROUBLESHOOTING GUIDE
Diesel engine
For troubleshooting information, refer to the diesel engine operator’s
manual.
If engine won’t crank
For troubleshooting information, refer to the engine operator’s manual.
If engine cranks but won’t start
For troubleshooting information, refer to the engine operator’s manual.
If engine runs hot
For troubleshooting information, refer to the engine operator’s manual.
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214

If fuses burn out
Burned-out or“blown-out”fuses or circuit breaker tripping (if equipped)
usually indicate an electrical short circuit, although a fuse may
occasionally fail from vibration. Insert a second fuse or reset the breaker
(if equipped). If this fuse immediately burns out or the breaker (if
equipped) trips and you cannot locate the fuse, return your vehicle to
your dealer for a circuit check.
If lamp bulbs burn out
Repeated lamp burn-out usually indicates a loose connection, either at
the lamp socket, the system ground or a malfunctioning voltage
regulator. If examination does not indicate the cause of the trouble,
return your vehicle to your dealer for inspection.
If headlamps flash on and off
If headlamps flash on and off at regular intervals, the system circuit
breaker (if equipped) is operating, indicating a short circuit or overload.
Take your vehicle to your dealer for a circuit check.
ENGINE COOLANT AND OIL REFILL CAPACITIES
Engine Engine coolant
(approximate
capacity)Engine oil
(approximate
capacity)
Caterpillar 3126 B 23.7L (25.0 quarts)
1
Cummins B 5.9L 23.1L (24.4 quarts)1
Power Stroke 7.3L 18.0L (19.0 quarts) 18.0L (19.0 quarts)2
1
Refer to the engine operator’s manual for engine oil refill capacities.
2Engine oil and filter change.
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)
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215

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.
REAR AXLE REFILL CAPACITIES
Axle ModelWeight
Capacity-kg
(lbs.)DescriptionFluid
Capacity-liters
(pints)
RS17–144
1, 26345 (17000) Single Speed;
Air Brake
Application15.9 (33.6)
RS17–145
1, 26345 (17000) Single Speed;
Hyd. Brake
Application15.9 (33.6)
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216