2009 FORD F750 engine

Exhaust outlet assembly
WARNING:The normal operating temperature of the exhaust
system is very high. Never work around or attempt to repair any
part of the exhaust system until it has cooled. Failure to follow these
instructions may result in serious personal injury.
The exhaust outlet assembly on your vehicle is a uniquely functioning
device that accompanies the DPF assembly. It is designed to help control
the temperature of the exhaust during the DPF regeneration process.Do
not modify or remove this device. Modification of the system
and/or additions of aftermarket devices can reduce the
effectiveness of the system, as well as cause damage to the
exhaust system and/or engine. Any modifications may also
invalidate the vehicle and/or engine warranties. See the vehicle
and engine warranty guides for more information.
The inlet holes in the side of the assembly are functional. These holes
allow outside air to be drawn into the outlet assembly. The holes need to
be kept clear of mud and other foreign material to maintain proper
functionality of the system. One way to keep the holes clear is to spray
the outlet assembly with a hose when washing the vehicle. Failure to
keep the functional holes clear of foreign material may result in the holes
becoming blocked or plugged.Blocked/plugged holes or
modification/removal of the outlet assembly could result in
elevated exhaust temperatures which may result in
vehicle/property damage and/or personal injury.
NOISE EMISSIONS – EXTERIOR
In order to comply with the federal exterior noise regulations, your
vehicle may be equipped with noise emission items. Depending on the
vehicle configuration, it may have all or some of the following items:
Air Intake System
•Air Cleaner:should be inspected and its location should not be
altered. Do not alter inlet and outlet piping.
Body
•Wheel Well:splash shields, cab shields and under-hood insulation
should be inspected for deterioration, dislocation, and orientation.
Cooling System
•Check the fan for damage to blades; replace, if damaged, with the
recommended parts. Inspect for fan to shroud interference, and any
damage to shroud such as cracks and holes.
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•The fan ratio should not be changed and the fan spacer dimensions
and positions should not be altered.
•Inspect the fan clutch for proper operation, make sure that the fan is
disengaged when cooling of the engine is not required.
•Check for proper operation of radiator shutters, if equipped. The
shutters should be open during normal operating temperatures.
Engine and Driveline System
•Transmission Enclosure:inspect for cracks, holes, and tears. Clean
any deposits such as oil, dirt, and stones.
•Engine valve covers and block covers are made to damp out engine
mechanical noise and, if needed, should be replaced with
recommended parts. Check for mechanical isolations.
Exhaust System
•Inspect the exhaust system for leaks at various joint connections and
tighten the clamps.
•Do a visual inspection for cracks or holes in the muffler and tail pipe.
•Always use the recommended parts when items need to be replaced.
•The tail pipe elbow or offset tail pipe orientation must not be changed
from the standard position as originally received.
•To avoid abnormal changes in vehicle sound levels, it is necessary for
the owner to perform inspections and necessary maintenance at the
intervals shown in theScheduled Maintenance Guidechapter.
POWER STEERING FLUID
Check the power steering fluid level using the following procedure. If
adding fluid is necessary, refer toLubricant Specificationsin this
chapter for the proper fluid type. Refer to theScheduled Maintenance
Guidechapter for the recommended service intervals.
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.
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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
Scheduled Maintenance Guidechapter 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.
•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.
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TRANSMISSION FLUID
Always dispose of used automotive fluids in a responsible manner.
Follow your community’s standards for disposing of these types of fluids.
Call your recycling center to find out about recycling automotive fluids.
Automatic transmission fluid
Refer to your Allison Automatic Transmission Operator’s Manual for
scheduled intervals for transmission fluid checks and changes. Your
transmission does not consume fluid. However, the fluid level should be
checked if the transmission is not working properly, i.e., if the
transmission slips or shifts slowly or if you notice some sign of fluid
leakage.
Automatic transmission fluid expands when warmed. To obtain an
accurate fluid check, drive the vehicle until it is warmed up
(approximately 20 miles [30 km]). If your vehicle has been operated for
an extended period at high speeds, in city traffic or during hot weather,
the vehicle should be turned off for about 30 minutes to allow fluid to
cool before checking.
1. Drive the vehicle 20 miles (30 km) or until it reaches normal operating
temperature.
2. Park the vehicle on a level surface and engage the parking brake.
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.
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Eaton UltraShift (if equipped)
The Eaton UltraShift transmission is filled with synthetic fluid from the
factory with no scheduled lube change intervals. This fluid is intended to
last the life of the transmission. However, the system should be checked
regularly to ensure that proper transmission fluid levels remain constant.
Refer to theEaton Driver Instructions Manualfor details.
Manual transmission fluid
Refer to theScheduled Maintenance Guidechapter 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.
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.
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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.
CHASSIS-MOUNTED CHARGE AIR COOLER
Inspect charge air cooler daily
With the engine off, visually inspect the charge air cooler core assembly
for debris and clogging of external fins. Prior to engine operation,
remove any debris blocking the core.
•Turbocharger-to-charge air cooler
•Charge air cooler-to-intake manifold pipe
•Mounting bracket
•Chassis-mounted charge air cooler core
Inspect air intake piping
•Check for accumulation of salt deposits (where applicable). If present,
disassemble and clean the complete air intake piping system. If the
intake piping is pitted, use Motorcraft Silicone Gasket and Sealant
TA-30 to seal joints against leakage.
•Check for loose hoses and clamps.
•Check for ruptured or collapsed hoses.
•Check air cleaner housing for cracks.
ELECTRICAL SYSTEM INSPECTIONS
Periodically inspect electrical connectors on the outside of the cab, on
the engine and frame for corrosion and tightness. Exposed terminals
such as the fuel sender, cranking motor, alternator and feed-through
studs should be cleaned and re-coated with a lubricant sealing grease
such as Motorcraft Silicone Brake Caliper Grease and Dielectic
Compound XG-3, or equivalent. This should include the ground cable
connector for batteries, engine and cab as well as the jump starting stud.
Accessory feed connections
Vehicle electrical systems are complex and often include powertrain
components such as engine and transmission controls, instrument panels,
ABS, etc. While most systems operate on battery voltage (12 volts),
some systems can be as high as 90 volts or as low as five volts. Refer to
the Electrical Circuit Diagram Manuals, available from your vehicle’s
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manufacturer, to ensure that any additional body lights and accessories
are connected to circuits that are both appropriate and not overloaded.
No modification should be made to any vehicle control system without
first contacting your dealer.
SUSPENSION INSPECTION
Note:Do not adjust air suspension height to any setting other than the
specified setting. Altering the height setting will change the driveline
angle and may result in unwarrantable component damage, such as
transmission component damage.
Verify drive axle air suspension height and height control valve
performance at engine lube oil change intervals.
Periodically:
•Check condition of spring leaves for evidence of fatigue, bending or
breakage.
•Check condition of suspension mounting brackets and bushings.
•Check that torque rod mounting fasteners are tight.
•Check to be sure the suspension alignment is maintained at all times.
•Check U-bolts after the chassis has been operating under load for
1,000 miles (1,600 km) or six months, whichever comes first, the
U-Bolt nuts must be re-torqued. The U-Bolt nuts thereafter must be
re-torqued every 36,000 miles (58,000 km). The U-Bolt and nut
threads and seats should be cleaned and lubricated to ensure a “like
new” condition when re-torquing.
Note:See theU-Bolt Nut Torquechart later in this section.
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.
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3. Re-torque the nuts to 100 ft. lb. (136 N•m), using a diagonal pattern.
4. Re-torque the nuts to 200 ft. lb. (271 N•m), using a diagonal pattern.
5. Re-torque the nuts to 400 ft. lb. (542 N•m), using a diagonal pattern.
(For vehicles equipped with 14ACC, 14 ADN and 14ADP axles, do not
use Step 6.)
6. Re-torque the nuts to 425 ft. lb (576 N•m), using a diagonal pattern.
(For vehicles equipped with 14ACC, 14 ADN and 14ADP axles.)
7. Use the same diagonal pattern with each U-bolt nut re-torque.
Spring U-bolt checks
Check U-bolt nuts and re-torque every 36,000 miles (58,000 km) after
initial 1,000 miles (1,600 km) re-torque. The U-bolt and nut threads and
seats should be cleaned and lubricated to ensure peak condition when
re-torqued.
DRIVESHAFT
At the regular lubrication interval, check the universal joints for any
evidence of wear or looseness. Should driveshaft vibrations occur, stop
the vehicle immediately to avoid possible hazardous consequences or
damage to other components.
REAR AXLE LUBRICANT
Refer to theScheduled Maintenance Guidechapter 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.
Checking the rear axle lubricant level
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.
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