2005 FORD F650 service

POWER STEERING FLUID
Check the power steering fluid level using the following procedure. Refer
to the general maintenance information section for the recommended
service intervals. If adding fluid is necessary, use only MERCON
AT F.
1. Set the parking brake, shift into N (Neutral) (automatic transmission)
or 1 (First) (manual transmission) and turn the engine off.
2. Open the hood.
3. Clean the top of the power steering fluid reservoir.
4. Remove the dipstick from the reservoir and wipe the dipstick clean.
5. Reinstall the dipstick. Remove it again and check the fluid level.
•If the fluid temperature is at
approximately 68°F - 120°F (20°C
-49°C) (fluid cool or warm to
the touch), check the COLD side
of the dipstick. The fluid level
should be within the FULL range
•If the fluid level is below the ADD
line, add fluid in small amounts,
continuously checking the level until it reaches the proper level.
•If the fluid temperature is at
approximately 176°F–230°F
(80°C - 110°C) (fluid too hot to
touch), check the HOT side of
the dipstick. The fluid level
should be within the FULL range.
•If the fluid level is below the ADD
line, add fluid in small amounts,
continuously checking the level until it reaches the proper level.
Note:The fluid level may also be checked by looking at the see-through
plastic reservoir. Make sure that the fluid is within the minimum and
maximum fluid range as marked on the reservoir.
A low fluid level may indicate a leak in the power steering system.
Inspect the power steering system and repair the leak. If necessary, see
your dealer or a qualified service technician.
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.
ADD MAX. COLDFULL
ADD MAX. HOTFULL
2005 F650/750(f67)
Supplement
USA English(fus)
Maintenance and specifications
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CLUTCH FLUID/LINKAGE ADJUSTMENTS
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 manufacturer
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 linkage (if equipped)
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 manufacturer specifications. Refer to
Lubricant 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.
2005 F650/750(f67)
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3. With the parking brake engaged and your foot on the brake pedal,
start the engine and move the gearshift lever through all of the gear
ranges. Allow sufficient time for each gear to engage.
4. Place the gearshift lever in N (Neutral) or P (Park) and leave the
engine running.
5. Remove the dipstick, wiping it clean with a clean, dry lint free rag.
6. Install the dipstick making sure it is fully seated in the filler tube.
7. Remove the dipstick and inspect the fluid level.
If you must add transmission fluid, make sure the correct type of fluid is
being used. The type of fluid used is indicated in your Allison Automatic
Transmission Operator’s Manual.
Fluid levels above the safe range may result in transmission failure; an
overfill condition of transmission fluid may cause shift and/or
engagement concerns and/or possible damage.
Use of a non-approved automatic transmission fluid may cause
internal transmission component damage.
Manual transmission fluid
Refer to your general maintenance information section for transmission
fluid level checks and fluid change intervals.
Your manual transmission may be filled with an optional synthetic fluid
which allows the use of extended service intervals. A tag on the filler
plug will identify the use of the synthetic fluid.
Use only fluid that meets manufacturer specifications (refer to
Lubricant specificationsin this chapter.
Use of a non-approved transmission fluid may cause internal
transmission component damage.
Check your transmission fluid level using the following procedure:
1. Park the vehicle on level ground.
2. Set the parking brake and shift into 1 (First) and turn the engine off.
3. Clean any dirt from around the filler plug.
4. Remove the filler plug and inspect the fluid level.
5. The fluid level should be up to the bottom of the filler plug opening.
6. If necessary, add enough fluid through the filler plug opening so that
the fluid level is at the bottom of the opening.
7. Clean and install the filler plug securely.
2005 F650/750(f67)
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USA English(fus)
Maintenance and specifications
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Drain and refill your transmission fluid using the following procedure:
1. Drain the transmission while the fluid is warm.
2. Park the vehicle on level ground.
3. Set the parking brake and shift into 1 (First) and turn the engine off.
4. Clean any dirt from around the filler and drain plugs.
5. Remove the filler and drain plugs and drain the fluid 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 fluid through the filler plug opening so that the fluid level
is up to the bottom of the opening.
8. Clean and install the filler plug securely.
ENGINE AND SUBSYSTEM MAINTENANCE
Note:Information in this section pertains to the 6.0L Power Stroke
engine only. For information pertaining to other engines, see the
respective engine operator manual.
Note:To prevent damage to the engine control module, never
spray-wash it directly. Never spray any connector.
For effective emissions control and low operating cost, it is important
that maintenance operations listed in this section be performed at the
specified periods or mileage intervals indicated (kilometers, miles, hours,
or months, whichever comes first).
Service intervals are based upon average operating conditions. Where
dusty, frequent start and stop or heavily laden operations are
encountered, more frequent servicing will be required.
As the vehicle (engine) owner, you are responsible for the performance
of all scheduled maintenance. The required maintenance operations may
be performed by the owner at a service establishment of the owner’s
choosing. Any replacement parts used for required maintenance services
or repairs should be genuine manufacturer service parts or equivalent in
quality and performance to genuine manufacturer service parts. Use of
inferior parts hinders operations of the engine and emissions controls
and can reduce engine life and/or jeopardize the warranty.
Receipts covering the performance of regular maintenance should be
retained in the event questions arise concerning maintenance. The
receipts should be transferred to each subsequent owner of the vehicle
(engine).
2005 F650/750(f67)
Supplement
USA English(fus)
Maintenance and specifications
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Catalytic converter
If your Diesel engine is equipped with a catalytic converter, it is
important to review the maintenance schedule to insure proper
functioning of the catalytic converter. Also, take precautions not to
damage the catalytic converter when servicing your engine or storing
your vehicle.
Note:If your vehicle is equipped with a catalytic converter/muffler,do
notblend waste oil with Diesel fuel. Operate only on low sulfur (less
than 500 parts per million sulfur) Diesel fuel with a cetane value of 45 or
higher.
Note:If your vehicle is equipped with a vertical exhaust pipe, it is very
important to have and maintain a rain cap on the exhaust pipe to
prevent water from entering the exhaust system and catalytic converter.
Any water entering the catalytic converter may damage the catalyst and
affect the function of the converter.
Air induction system
Once each year, perform a complete inspection of the air induction
system. In areas where road salt is used, the inspection consists of
disassembling the joints of each aluminum component and inspecting for
salt build-up, presence of chlorine that can cause aluminum particles to
flake off and enter the engine combustion chambers.
If evidence of corrosion is found (usually at the pipe connections), use a
wire brush to clean the inside of the pipes and inside the rubber hoses.
If the intake pipes are pitted at the joint ends, use RTV silicone to seal
the joints. Be certain that no excess material is on the inside of the pipes
that can be pulled into the engine. If the service condition of the pipes,
hoses or clamps is questionable, replace the defective part(s).
Be sure that prior to reassembly all dust and debris has been cleaned out
of the pipes and couplings with a clean, damp rag.
To reduce the risk of personal injury or death when performing
maintenance to any turbocharged engine with engine air inlet
piping disconnected, a turbocharger compressor air inlet protective
shield should be installed over the turbocharger air inlet.
Cummins B and Caterpillar engines
Refer to the respective engine operator manual for air filter replacement
procedure.
2005 F650/750(f67)
Supplement
USA English(fus)
Maintenance and specifications
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2. Locate the module and place an
appropriate container under the
drain plug (see illustration).
3. Remove the drain plug by turning it counterclockwise. Allow to drain
for approximately 25 seconds or until clean fuel is observed. Install the
drain plug by turning it clockwise until it is firmly seated.
4. Verify that the drain plug is closed and sealed, then remove the
container from under the vehicle.
5. Restart the engine and check WATER IN FUEL indicator light; it
should be illuminated. If it continues to illuminate, have the fuel system
checked and repaired.
Draining the fuel filter/water separator - Cummins B engine
Refer to your engine operator’s manual for service procedures.
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2. Remove and discard the old fuel
filter element.
3. Carefully clean the mating
surfaces.
Installation-both
The engine will not run properly if the fuel filter is not installed
in housing.
1. Install new fuel filter into the fuel filter housing.
2. Tighten cap onto fuel filter housing slowly, allowing fuel to soak into
the fuel filter element. Tighten cap until it contacts the housing.
After replacing the fuel filter, the engine will purge the trapped
air as it runs. The engine may run roughly and smoke until the air
is completely eliminated.
Using a fuel which has more than average impurities may require
the fuel filter to be replaced more frequently than the service
interval specifies.
Fuel filter replacement - Cummins B engine
Refer to your engine operator’s manual for service intervals and
procedures.
FUEL CONSUMPTION IMPROVEMENT MEASURES
There are two important factors you can control to improve fuel
economy: the mechanical condition of your vehicle and how you drive it.
A properly maintained vehicle will deliver better performance than a
neglected vehicle. Always follow your maintenance schedule to keep your
vehicle in top operating condition.
2005 F650/750(f67)
Supplement
USA English(fus)
Maintenance and specifications
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Supporting your vehicle for service
When performing service repairs on your vehicle, first prepare the
vehicle by doing the following:
1. Park the vehicle on a level concrete floor.
2. Set the parking brake and block the wheels to prevent the vehicle
from moving.
3. Select a jack with a rated capacity sufficient to lift and hold up the
vehicle.
4. Raise the vehicle with the jack applied to the axle(s). DO NOT use the
bumper as a lifting point.
5. Support the vehicle with floor stands under the axle(s). If the axle or
the suspension are being serviced, support the vehicle with floor stands
under the frame side-members, preferably between the axles.
Do not use a jack when working under a vehicle. It may give
way, causing the vehicle to fall and result in property damage,
personal injury or death. Always use floor stands to support the
vehicle.
FRAME AND TOW HOOKS
Your vehicles chassis is manufactured with frame rails of either mild
carbon steel, or HSLA steel. Each must be handled in a specific manner
to assure maximum service life. Before attempting frame repair or
modification, consult the service manual or your dealer.
It is important, particularly on vehicles where the tow hooks are used
frequently to inspect the front and rear tow hooks for damage or a loose
mounting.
U-BOLT NUT TORQUE
U-bolt diameter (nominal) (all spring
suspensions)U-bolt diameter
(nominal)
Ft. lbs. N•m
IROS Air w/15,500 lb. axles and less 260–300 353–407
IROS Air w/ greater than 15,500 lb. axles 370–400 502–542
Hendrickson 23,000 lb. axle 370–400 502–542
2005 F650/750(f67)
Supplement
USA English(fus)
Maintenance and specifications
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