2005 FORD F650 service interval

REAR AXLE LUBRICANT
Refer to your general maintenance information section for rear axle
lubricant level checks and lubricant change intervals.
Your rear axle may be filled with an optional synthetic lubricant which
allows the use of extended service intervals. A tag on the filler plug will
identify the use of the synthetic lubricant.
Use only a lubricant that meets manufacturer specifications (refer to
Lubricant specificationsin this chapter).
Use of a non-approved rear axle lubricant may cause internal axle
component damage.
Check your rear axle lubricant level using the following procedure:
1. Park the vehicle on level ground.
2. Set the parking brake and shift into N (Neutral) (automatic
transmission) or 1 (First) (manual transmission) and turn the engine off.
3. Clean any dirt from around the rear axle filler plug.
4. Remove the filler plug and inspect the lubricant level.
5. The lubricant level should be up to the bottom of the filler plug
opening.
6. If necessary, add enough lubricant through the filler plug opening so
that the lubricant level is at the bottom of the opening.
7. Clean and install the filler plug securely.
Drain and refill your rear axle lubricant using the following procedure:
1. Drain the rear axle while the lubricant is warm.
2. Park the vehicle on level ground.
3. Set the parking brake and shift into N (Neutral) (automatic
transmission) or 1 (First) (manual transmission) and turn the engine off.
4. Clean any dirt from around the rear axle filler and drain plugs.
5. Remove the filler and drain plugs and drain the lubricant into a
suitable container. Dispose all used automotive fluids in a responsible
manner following your local authorized standards.
6. Clean and install the drain plug securely.
7. Add enough lubricant through the filler plug opening so that the
lubricant level is up to the bottom of the opening.
8. Clean and install the filler plug securely.
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WHEELS
General
Wheel bearings should be inspected, lubricated and adjusted at regular
intervals. This is especially important if operating in deep sand, mud, or
water. Refer toLubricant specificationsin this chapter.
When installing wheel balance weights, they must be mounted on the
dome-side of the wheel only. Failure to do so may result in loss of wheel
weight and/or damage to brakes or wheels.
Oil lubricated front wheel bearings
During normal vehicle duty cycle, the lube and air inside the hub/wheel
cavity expands and if not vented, causes pressure build-up that could
cause accelerated seal wear.
There are two venting methods:
•a slit or small hole in the rubber check vent or
•the window
You can use either of these methods to prevent pressure build-up.
Normal maintenance
Over a period of time, if not routinely cleaned, a slight film of oil can
collect dirt around the rubber fill plug and face, which could appear to
be a leak. Routine cleaning ensures that the lube level can be easily
observed through the clear window as intended. In situations where the
window is clean on the outside but discolored on the inside, the lube
level may be checked by inserting a finger through the rubber check
vent hole.
The specified lube level for a clear window type hubcaps is from the
minimum line to + 5/16 inch above the minimum line.
If the lube level should suddenly drop dramatically below the minimum
level, see the Service Manual for diagnostic procedure.
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Tire sizeLoad
rangeApproved
rim widthsAxle capacity
Front - lbs.
(kg)/psi (kPa)Rear - lbs.
(kg)/psi (kPa)
12R22.5 H 8.25, 9.0014780 (6704) /
120 (827)27000 (12247) /
120 (827)
245/75R22.5 G 6.75, 7.509350 (4241) /
110 (758)17640 (8002) /
110 (758)
255/70R22.5 H6.75, 7.50,
8.2511020 (4999) /
115 (793)20280 (9199) /
115 (793)
265/75R22.5 G 7.50, 8.2510410 (4722) /
110 (758)19220 (8718) /
100 (690)
275/70R22.5 H 7.50, 8.2513220 (5997) /
125 (862)24700 (11204) /
125 (862)
275/80R22.5 G 7.50, 8.2512350 (5602) /
110 (758)22700 (10297) /
110 (758)
295/75R22.5 G 8.25, 9.0012350 (5602) /
110 (758)22700 (10297) /
100 (690)
295/80R22.5 H 8.25, 9.0014780 (6704) /
115 (793)26440 (11993) /
115 (793)
LUBRICATION AND MAINTENANCE INTERVALS
New vehicles are lubricated at the factory. After the vehicle is placed in
operation, regular lubrication intervals, based on the type of service and
road conditions, should be established. Thorough lubrication at the
specified intervals will insure outstanding life cycle value and will reduce
overall expense.
The lubrication intervals specified should be performed at whatever
interval occurs first, whether it is months, miles (kilometers) or hours.
Only lubricants of superior quality, such as Motorcraft lubricants, should
be used. The use of inferior products will reduce the service life of the
vehicle or result in failure of its components.
Unless otherwise specified, never add lubricant unless it is the same
grade as that which is already being used. If the grade is not known or
not available, drain, flush and refill with new lubricant.
The interval between lubrication periods, oil changes, etc. depends
entirely upon operating conditions. The loads carried, speeds, road and
weather conditions all contribute to the frequency of lubrication periods.
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In some types of operation, and where operating conditions are
extremely severe (such as in deep water, mud or unusually dusty
conditions), the vehicle may require lubrication after every 24 hours of
operation.
Maintenance intervals
Maintenance intervals are provided for three types of general vehicle
environments: On-Highway, City and Severe Service. In all applications,
the actual interval is determined by monitoring kilometers (miles) and
time and when the engine is due for an oil change. When the engine oil
change is required prior to the truck lubrication interval, it is
recommended that the lubrication be performed at the same time in
order to reduce your vehicle’s time out of service.
•On-Highway:60,000 miles (96,000 km) or more annually.
•City:59,000 miles (95,000 km) or less annually.
•Severe Service:20,000 miles (32,000 km) or less annually on/off
road in dirty conditions.
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OWNER MAINTENANCE
You can do much of the maintenance your vehicle requires yourself, if
you have the time and a reasonable amount of mechanical ability. If you
prefer to have this work done professionally, your authorized dealer
stands ready to help you.
All mechanical components and attachments are important in that they
could affect the performance of vital components and systems. If
replacement becomes necessary, they must be replaced with parts having
the same part number or with equivalent parts. Torque values of the
attaching parts must be used as specified during any reassembly
procedure to assure proper retention.
EMISSIONS CONTROL SYSTEM
To assure the emissions control systems operate effectively, you should
have the services listed in the maintenance schedule performed at the
specified time and km/mileage intervals. You should avoid running out of
fuel or turning off the ignition while the vehicle is in motion, especially
at high speeds.
Because of high engine compartment and exhaust system
temperatures resulting from emissions equipment, do not park,
idle or operate your vehicle in dry grass or other dry ground cover
where the possibility of ground fire exists.
Do not make unauthorized modifications to the engine or vehicle.
Modifications causing increased amounts of unburned fuel to reach the
exhaust system can significantly increase the temperature of the engine
compartment and/or the exhaust system.
Avoid driving your vehicle if it does not operate properly. If the engine
diesels (more than five seconds of engine run-on after shut-off), misfires,
surges, stalls or backfires, see your dealer. Be alert for fluid leakage,
odor, smoke, loss of oil pressure, or charge indicator or over temperature
warning.
Do NOT use diesel fuel blended with waste oil in engines equipped with
a catalytic converter-muffler. Waste lube oil blending in fuel will plug the
catalytic converter-muffler, resulting in a significant loss of engine power.
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SCHEDULED MAINTENANCE SERVICES
Maintenance service adjustments must conform to specifications
contained in this manual, and those shown on the Important Engine
Information Decal. The following services are to be performed at
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 100,000 miles (161,000 km) should be
continued as before 100,000 miles (161,000 km).
SPECIAL OPERATING CONDITIONS
If your driving habitsfrequentlyinclude one or more the following
conditions:
•Short trips oflessthan 10 miles (16 km) when outside temperatures
remain below freezing.
•Operating duringhot weatherin stop-and-go“rush hour”traffic.
•Operating in severe dust conditions.
•Extensive idling, or low speed operation such as door-to-door delivery
service.
•High speed operation with a fully loaded vehicle (maximum GVW).
•Snowplowing.
Perform the following:
•Change engine oil and oil filter every three months, 5,000 miles (8,000
km) or 125 hours of engine service.
•If 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.
•Lube the manual transmission and the rear axle every 30,000 miles
(48,279 km) or six months, whichever comes first.
•See 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.
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Check every oil
changeOil
change intervals
are as follows:
Power Stroke -
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
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
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
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 WSS-M97B51-A1. See the engine manufacturer’s operating guide for
supplemental corrosion inhibitor specifications.
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6.0 Power Stroke Engine
ComponentMiles (000) 130 140 150 160 170 180 190 200 210 220 230 250
Hours 4550 4900 5250 5600 5950 6300 6650 7000 7350 7700 8050 8400
Kilometers (000) 208 224 240 256 272 288 304 320 336 352 368 384
Months 78 84 90 96 102 108 114 120 126 132 138 144
Change engine oil and filter
2
••••••••••••
Inspect belt••••••••••••
Clean fuel filter pre-strainer
1
••••••••••••
Change fuel filter
1,5
••••••
Measure air intake restriction
3,4
••••••
Service the cooling system•••
Inspect electrical system (A) (Every 12
months, 160,000 km [100,000 miles] or 3,800
hours)•••••(A)•
Pressurize air induction system (every 12
months)••••••
1If refueling source is prone to water contamination, also clean the fuel filter pre-strainer.2If fuel is more than 0.05% but less than 1.0% sulfur, change oil at 75% of regular interval. If 1.0%
or higher, change oil at 50% of scheduled interval.3Service air cleaner element as required.4Refer to PCED manual for specification.5Change according to transfer pump minimum specifications.
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