2007 FORD F650 differential

Stop engine:This light is used in
conjunction with the electronic
engine control.
Refer to the Engine Operator’s Manual for specific information regarding
this feature.
If the engine shuts down, it can be restarted and operated for 30
seconds at a time or until the problem is corrected. Refer toEngine
shutdown systemin theDrivingchapter.
Drivers of electronically controlled engines should know the
extent of warning engine shutdown system before operating the
vehicle. This information can be obtained from your dealer.
Brake reserve system warning:
Illuminates to indicate normal
Hydromax booster reserve system
activation when the engine is OFF
and the service brake pedal is
applied.
This light may also illuminate momentarily if the engine is running and
the driver turns the steering wheel fully in one direction while braking.
If the light remains on while the engine is running, this indicates
inadequate hydraulic booster pressure or reserve pump system failure.
Stop the vehicle safely as soon as possible and seek service immediately.
Brake system warning light:To
confirm the brake system warning
light is functional, this light will
momentarily illuminate when the
ignition is turned to the ON position when the engine is not running. If
the brake system warning light does not illuminate at this time, seek
service immediately from your dealership. Illumination after starting the
vehicle indicates a pressure differential in the master cylinder and the
brake system should be inspected immediately by your dealership.
If equipped with an air brake system, the warning light stays on until the
air pressure builds up to 60 psi (414 kPa). If the air pressure drops
below 60 psi (414 kPa) during operation, the remaining brake system is
still operational but the stopping distance will be greater.
Driving a vehicle with the brake system warning light on is
dangerous. A significant decrease in braking performance may
occur. It will take you longer to stop the vehicle. Have the vehicle
checked by your dealer immediately.
STOP
ENGINE
BRAKE
2007 F-650/750(f67)
Supplement
USA(fus)
Instrument Cluster
23

Differential lock:Illuminates when
the main differential is locked
(engaged).
Parking brake warning:
Momentarily illuminates when the
ignition is turned to the ON position
and the engine is off. Also
illuminates when the parking brake
is engaged. If the brake warning
lamp does not illuminate at these
times, seek service immediately.
Vehicles equipped with the Power Park (air-operated parking
brake) option:If after setting the parking brake on your vehicle the
park brake warning lamp begins to blink, this may indicate a failure in
the parking brake system. Seek service from your dealer immediately.
Trailer ABS brake system:
Illuminates briefly when the engine
is powered-up and only when a PLC
trailer or a PLC diagnostic tool is
connected. If the light remains on
after the vehicle is started, continues to flash or fails to illuminate, have
the system serviced immediately.
Anti-lock brake system:If the
ABS light stays illuminated or
continues to flash, a malfunction has
been detected, have the system
serviced immediately. Normal
braking is still functional unless the brake warning light also is
illuminated.
P
BRAKE
ABS
2007 F-650/750(f67)
Supplement
USA(fus)
Instrument Cluster
25

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 with the vehicle stationary, first set the parking
brake (chock the wheels if the vehicle is on a hill or another uneven
surface).
REAR AXLE INFORMATION
Axle operating temperature normally will not exceed 100°F (38°C). If
the operating temperature exceeds 230°F (110°C), the rate of axle
lubrication oxidation will increase and shorten the life of the lubricant
and seals, requiring axle lubrication changes to become more frequent to
preserve the axle. Extreme Pressure (EP) lubricants should not be run
consistently above 230°F (110°C).
Gross axle weight
Your truck has gross axle weight, gross vehicle weight and gross
combination weight ratings. Do not exceed these ratings.
Exceeding these ratings by overloading can cause component
failure resulting in property damage, personal injury or death.
Rear axles with locking or limited-slip differentials
If your vehicle is equipped with a locking or limited-slip differential, note
the following:
• Power will be transmitted to the opposite wheel should one of the
wheels begin to slip.
• Both wheels must be raised off the ground should it be necessary to
operate one wheel with the vehicle stationary.
If both wheels are not raised off the ground, the one wheel that
is not raised may pull the vehicle off its support, possibly
resulting in personal injury
Driver-controlled differential lock
To prevent the vehicle from moving when servicing the wheels, tires or
brakes, turn the engine off and raise all drive wheels of the locker
differential axle. Axles equipped with NoSPIN Detroit Locker differentials
deliver power to both wheels even when only one wheel is on the ground.
2007 F-650/750 (f67)
Supplement
USA (fus)
Driving
130

Failure to raise all drive wheels with this type of differential
could cause the vehicle to move unexpectedly, resulting in
property damage, personal injury or death.
Care should be taken to avoid sudden accelerations when both drive
wheels are on a slippery surface.
Sudden accelerations on slippery surfaces could cause the
wheels to spin, the vehicle to turn sideways on a crowned road
surface or in a turn, possibly resulting in loss of vehicle control and
personal injury.
Some Dana/Spicer drive axles have a driver-controlled differential lock.
The differential lock can lock or unlock the differential when the vehicle
is moving or stopped. When extra traction is required, the differential
lock will provide full power to both axles.
When the differential is locked, the vehicle’s turning radius will increase
(vehicle will “under-steer”)
The differential can be locked or unlocked when the vehicle is moving at
a constant speed of less than 25 mph (40 km/h) and while the wheels
are not slipping. The differential must not be locked when the vehicle is
traveling down steep grades and traction is minimal.
Note: Never use the differential lock at vehicle speeds above 25 mph (40
km/h).
Note: The driver-controlled differential lock function will vary with some
transmissions.
• Vehicles equipped with an Allison 3000 Series transmission: The
differential lock and differential lock light will automatically disengage
at speeds above 25 mph (40 km/h). The differential lock will remain
off until either the vehicle is restarted or the differential lock switch is
turned off then back on.
• Vehicles equipped with a 5–speed, 6–speed or 7–speed manual:
The differential lock and differential lock light will automatically
disengage at speeds above 25 mph (40 km/h). The differential lock
will remain off until either the vehicle is restarted or the differential
lock switch is turned off then back on.
Axle conversions
It is not recommended, or approved, for axle conversions to be
performed. However, it is understood that, on occasion, aftermarket
2007 F-650/750 (f67)
Supplement
USA (fus)
Driving
131

Fuse/Relay
LocationFuse Amp
RatingFuse Description
12 10A Stoplamp switch (Hydraulic brake vehicles
only)
13 20A Radio, Cluster
14 10A Interior lamps
15 10A GEM, Interior lamp relay, Map lamps
16 15A High beams
17 — Not used
18 5A Headlamp switch
19 15A Engine ECM (Caterpillar and Cummins
engines)
Engine ECM, Accel, Crank (6.0L Power
Stroke engine only)
20 5A Starter relay
21 10A Daytime Running Lamps (DRL)
22 15A Air solenoid 4–pack (Air horn, Air suspension
dump, Differential lock axle and Two-speed
axle)
23 10A Electronic flasher
24 15A Vacuum pump, Air dryer, ABS, Fuel
heater/Fuel transfer pump relay, Heated
drain valve, 6.0L Power Stroke Water In Fuel
(WIF) module
25 10A Blower motor relay
26 10A RH low beam headlamp
27 — Not used
28 10A LH low beam headlamp
29 10A Cluster (Power, Warning lamps), Hydraulic
ABS relay, Air traction control, GEM,
Hourmeter, Transmission temp
30 15A Allison transmissions
31 15A Not used
Relay 1 — Interior lamps
2007 F-650/750(f67)
Supplement
USA(fus)
Roadside Emergencies
143

To reduce the risk of personal injury or property damage when
manually releasing the spring brakes, be sure to block the wheels
so the vehicle cannot move once the brakes are released.
Towing the vehicle with the front wheels suspended
When it is necessary to tow a vehicle with the front wheels suspended,
extra precautions must be taken to avoid transmission or differential
damage. Proceed as follows:
•Remove the axle shafts from the axle assembly to prevent the wheels
from driving the differential and the transmission.
•The wheel hub ends must be covered to prevent loss of axle lubricant
and entrance of other contaminants. If the axle shafts are not
removed, removal of the propeller shaft is required.
Note:To avoid transmission damage, vehicles should not be towed even
a short distance without suspending rear wheels or removing the axle
shaft or propeller shaft.
Note:In the event the chassis is equipped with a tandem axle and the
vehicle is to be towed from the front, the forward rear axle may be
raised to clear the road surface and secured to the frame by chains or
U-bolts, allowing only the rear rear axle to contact the road surface. Axle
shafts must be removed from the rear rear axle assembly. The wheel hub
ends must be covered to prevent loss of axle lubricant and entrance of
contaminants. Use extreme care in securing the chains or U-bolts to
avoid possible damage to the brake lines, hoses or other components.
Towing vehicles equipped with a driver-controlled differential lock
Note:If the vehicle must be towed to a service facility with the drive
axle wheels on the ground, it is necessary to remove the axle shafts
before the vehicle is towed.
2007 F-650/750(f67)
Supplement
USA(fus)
Roadside Emergencies
153

1. Shift collar in the locked position
2. Actuator assembly and shift fork
3. Axle shaft
4. Interference between the shift
collar and housing
5. Shift collar in the unlocked
position
6. Outer splines - axle shaft to collar
7. Shift collar and differential case
splines
8. Inner splines - axle shaft to side
gear
9. Side gear
10. Differential (plain) case half
Removing axle shafts before towing
1. Shift the main differential to the unlocked (disengaged) position. The
differential lock light will turn off.
2. Remove the capscrews and washers or stud nuts and washers from
flanges of both axle shafts.
3. Loosen the tapered dowels in the flanges of both axle shafts by
holding a 1
12inch diameter brass drift or hammer against the axle shaft
center and hitting it with a five or six pound hammer.Note:Do not use
a chisel or wedge to loosen the axle shafts and dowels. Use of a chisel or
wedge can damage the hub, axle shafts and oil seals.
4. Remove the tapered dowels and both axle shafts from the axle
assembly.
5. Assemble a cover over openings of both wheels ends to prevent loss of
lubricant and keep dirt away from the wheel bearing cavities.
Note:One of the axle shafts has two sets of splines. One set to engage
with the differential side gear and one set to engage with the shift collar
for the differential lock. It may be necessary to rotate the shaft slightly
to align the gear spline teeth with the shift collar teeth in order to
remove the axle shaft.
2007 F-650/750(f67)
Supplement
USA(fus)
Roadside Emergencies
154

Installing the axle shafts
1. Remove the covers from the wheel ends
2. Shift the differential lock to the unlocked position (disengaged)
position.
3. Install the axle shafts
•Place the gaskets on the wheel hub studs.
•Push the right-hand axle shaft and gasket into the wheel end and
housing until the shaft stops against the differential shift collar.
•Push down and in on the axle shaft flange and rotate the shaft until
the splines of the shaft and shift collar are engaged.
•Push the axle shaft further into the housing until the shaft stops
against the differential side gear.
•Push down on the axle shaft flange and rotate the shaft until the
splines of the shaft and side gear are engaged.
•Push the axle shaft completely into the housing until the axle shaft
flange and the gasket are flush against the wheel hub.
•Install the left-hand axle shaft and gasket into the wheel end.
4. If tapered dowels are required, install them at each stud and into the
flange of the axle shaft. Use a punch or drift and hammer, if needed.
5. Install the fasteners and tighten to correct torque value. Refer to the
Service Manual.
Towing the vehicle with the rear wheels suspended
Note:To avoid damage to the cab roof or air deflector when towing the
vehicle backward (rear wheels suspended) the air deflector must be
removed.
Whenever possible, it is preferable to tow a disabled vehicle from the
rear by raising the rear of the chassis. When towing a vehicle with the
rear of the chassis suspended the front wheels must be locked in the
straight-ahead position.
Vehicles equipped with a manual-shift transmission must have at least
1.0 pint (0.5L) of transmission fluid drained from the case. This will
prevent the transmission fluid from entering the clutch housing and fluid
saturating the clutch discs. Make sure that the transmission fluid is
replaced before the vehicle is returned to service.
2007 F-650/750(f67)
Supplement
USA(fus)
Roadside Emergencies
155