2024 FORD F650/750 maintenance

Removal
1.Disconnect the fuel lines by squeezingthe connector tabs and pulling the linesstraight off.
2.Rotate the filter fully counterclockwiseuntil the peg is at the far end of the slot.
3.Pull the filter straight up from thebracket and discard the filter.
Installation
1.Install the new filter into the filterbracket. Turn the filter clockwise tolock it in place.
2.Reconnect the fuel lines.
3.Switch the ignition on for 30 secondsand then switch the ignition off.Repeat this operation six times in a rowto purge any trapped air from the fuelsystem.
ELECTRICAL SYSTEM
INSPECTION
Periodically inspect electrical connectorson the outside of the cab and on the engineand frame for corrosion and tightness.Exposed terminals, such as the fuel sender,cranking motor, alternator andfeed-through studs, should be cleaned andre-coated with a lubricant sealing greasesuch as Motorcraft Silicone Brake CaliperGrease and Dielectric Compound XG-3, orequivalent. This should include the groundcable connector for batteries, engine andcab as well as the jump-starting stud.
Accessory Feed Connections
Vehicle electrical systems are complex andoften include powertrain components,such as engine and transmission controls,instrument panels and ABS. While mostsystems operate on battery voltage (12volts), some systems can be as high as 90volts or as low as five volts. See theElectrical Circuit Diagram Manuals,available from your vehicle’s manufacturer,to make sure that any extra body lights andaccessory connections to circuits are bothappropriate and not overloaded. Do notmake modifications to any vehicle controlsystem without first contacting anauthorized dealer.
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AIR INDUCTION SYSTEM
INSPECTION
WARNING: When performingmaintenance to any turbocharged enginewith engine air inlet piping disconnected,keep loose clothing, jewelry and long hairaway from the engine air inlet piping. Aturbocharger compressor air inletprotective shield should be installed overthe turbocharger air inlet to reduce therisk of personal injury or death.
Perform a complete inspection of the airinduction system annually.
In areas where road salt is used,disassemble the joints of each aluminumcomponent and inspect for salt build-upand presence of chlorine that can causealuminum particles to flake off and enterthe engine combustion chambers. Ifevidence of corrosion is found (usually atthe pipe connections), use a wire brush toclean the inside of the pipes and inside therubber hoses.
If pitting is evident at the joint ends of theintake pipes, use Motorcraft SiliconeGasket and Sealant TA-30 to seal thejoints. Make sure no excess material, whichcan pull into the engine, is on the inside ofthe pipes. If the service condition of thepipes, hoses or clamps is questionable,replace the defective part(s).
Make sure to clean all dust and debris outof the pipes and couplings with a clean,damp rag before reassembly.
Chassis-mounted Charge AirCooler
Visually inspect the core assembly fordebris and clogging of external fins withthe engine off.
Before engine operation, remove any debrisblocking the core.
•Turbocharger-to-charge air cooler.
•Charge air cooler-to-intake manifoldpipe.
•Mounting bracket.
•Chassis-mounted charge air coolercore.
Inspect air intake piping:
•Check for accumulation of saltdeposits (where applicable). If present,disassemble and clean the completeair intake piping system. If pitting isevident on the intake piping, useMotorcraft Silicone Gasket and SealantTA-30 to seal joints against leakage.
•Check for loose hoses and clamps.
•Check for ruptured or collapsed hoses.
•Check air cleaner housing for cracks.
EXHAUST SYSTEM
INSPECTION
Note:If your vehicle is equipped with acatalytic converter or muffler, do not blendwaste oil with diesel fuel. Operate only onultra-low sulfur (less than 15 parts permillion sulfur) diesel fuel with a cetanevalue of 45 or higher.
If your diesel engine is equipped with acatalytic converter, it is important to reviewthe maintenance schedule to make sureproper functioning of the catalyticconverter. Also, take precautions not todamage the catalytic converter whenservicing your engine or storing yourvehicle.
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BRAKE SYSTEM INSPECTION
WARNING: Always wear arespirator approved by the NationalInstitute of Occupational Studies ofHealth (NIOSH) or Mine Safety andAppliance (MSA) during all brake serviceprocedures. Wear the respirator fromremoval of the wheels through assembly.Never use compressed air or dry brushingto clean brake parts or assemblies.Clean brake parts and assemblies inopen air. During assembly, carefullyplace all parts on the floor to avoidgetting dust in the air. Use an industrialvacuum cleaner with a HEPA filtersystem to clean dust from the brakedrums, backing plates and other brakeparts. After using the vacuum, removeany remaining dust with a rag soaked inwater and wrung until nearly dry.Never use compressed air or drysweeping to clean the work area. Use anindustrial vacuum cleaner with a HEPAfilter system and rags soaked in waterand wrung until nearly dry. Dispose ofused rags with care to avoid getting dustin the air. Use an approved respiratorwhen emptying vacuum cleaners andhandling used rags.Worker clean-up: Wash your handsbefore eating, drinking or smoking.Vacuum your work clothes after use andthen launder them separately, withoutshaking them, to prevent fiber dustgetting into the air.
Your vehicle is equipped withnon-asbestos brake linings. However,exposure to excessive amounts of brakematerial (whether asbestos ornon-asbestos, fiberglass, mineral wool,aramid or carbon) may be a serious healthhazard.
Air Brakes
WARNING: Do not manually adjustthe automatic slack adjusters to correctexcessive push rod stroke as it may resultin reduced brake effectiveness and avehicle crash. Excessive push rod strokeindicates that a problem exists with theautomatic adjuster, with the installationof the adjuster, or with foundation brakecomponents that manual adjustmentdoes not remedy. Seek service from aqualified facility for excessive push rodstroke.
Inspection and Adjustment
Establish a regular schedule for periodiccleaning, lubrication and adjustmentinspection based on vehicle use. Exactmaintenance intervals are difficult topredetermine due to vehicle applicationsand operating conditions. If you areuncertain of the proper schedule for yourvehicle, contact an authorized dealer.
Regular inspections should include:
•Periodic checking (every serviceinterval) of push rod travel or brakeadjustment. This is essential foreffective braking. Brake chamber pushrods on original equipment chambersnow incorporate an orange paintmarker near the base of the push rod
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as a stroke indicator to aid inadjustment checks. If the push rod isclean and the brakes are out ofadjustment, you can see the orangemarker protruding from the chamberwhen the brakes are applied.
•Checking the brake lining (every serviceinterval). When brake linings or blockswear within 0.063 in (1.6 mm) theymust be replaced.
•Periodic checking (every serviceinterval) of the air compressor filter.Check the filter minder and when theindicator is near or on the red linemarked Service, replace the filter andreset the service filter minder.
Do not back off or disconnect the frontbrakes so that they are less effective,letting the rear brakes do all the stoppingof your vehicle. Do not overlook the brakeson the trailer either. Brake condition on thetrailer is just as important as the tractor.Proper brake balance on trucks andtractor-trailers is essential for effectivebraking.
Once a year, inspect the entire brakesystem:
•Rubber components for deterioration.A qualified technician should inspectthese components and replace themas necessary. Replacement intervalsvary according to the severity andlength of vehicle service.
•Condition of brake drums, brakechambers and slack adjusters.
•System for air leaks.
•Hose or pipes for rust, damage anddeterioration.
•Operation of service and parkingbrakes.
Periodically inspect parts such as air brakechamber diaphragm, air compressor andair cleaner. Replace any parts if you canconsider them unserviceable.
Air Dryer
Climactic conditions affect performanceof desiccant or after-cooler type air dryers.You must establish a maintenanceschedule for each specific operation.
The use of an air dryer on a vehicle doesnot eliminate the need to drain the airreservoirs periodically.
Inspect for moisture in the air system byopening reservoirs, draincocks or valvesand checking for presence of water. Thepresence of small amounts of water dueto condensation is normal and is not anindication that the dryer is not functioningproperly.
Replace or rebuild the desiccant cartridgewhen you determine that the desiccant iscontaminated and does not have adequatewater absorption capacity. The desiccantchange interval may vary. A generalrecommendation is to replace thedesiccant every 12 months (yearly). Ifexperience has shown that extended orshortened life has resulted for a particularinstallation, then the yearly interval can beincreased or decreased accordingly.
Draining the Air Brake Reservoir
WARNING: Failure to drain airbrake reservoirs can result in a reductionor loss of braking ability due to fluidaccumulation in the reservoir and/orpossible freeze-up during cold weather.
Completely drain all the air brake reservoirsdaily by opening the draincock at the endsof the tanks. (Where accessible.Pull-chains are used when the drains areundercab or otherwise inaccessible.) Closethe draincock after draining. Manually drain
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any air tanks equipped with automaticmoisture ejector valves, as required, tomaintain a dry air system. Contact anauthorized dealer if you are unsure of theair reservoir locations or the drainingprocedure.
Hydraulic Brakes
Establish a regular schedule for periodiccleaning, lubrication and adjustmentinspection based on vehicle use. Exactmaintenance intervals are difficult topredetermine due to vehicle applicationsand operating conditions. If you areuncertain of the proper schedule for yourvehicle, contact an authorized dealer.
Regular inspections should include:
•Checking the brake lining (every serviceinterval). Establish inspection intervalsthat provide for lining replacementbefore damage to the disc occurs.Excessive lining wear may expose thebacking plate to the disc causingscoring of the disc faces. A qualifiedtechnician should perform this
inspection and keep to instructionsprovided by the service manual.Hydraulic brake systems arepower-assisted. There is a greatreduction in braking capabilitieswithout engine assist.
•Proper fluid level. The level should beat the bottom edge of the ring on eachreservoir fill port. Do not fill the mastercylinder to the top of the reservoir. Iffluid level requires attention tomaintain a proper master cylinder level,this is an indication of either severeoperation (pad wear) or fluid leakage.A more frequent and thorough brakeinspection is required.
•Brake lines, hoses and fittings. Repairor replace brake line tubes, hoses orfittings as required. Inspect thesecomponents every 4,000 mi(6,000 km) for the following.
•Lines for kinks, dents, corrosion orrupture.
•Hoses for abrasions, kinks, softspots or rupture, collapse, cracks,twists or loose frame supports.When replacing a hose, be surethere is adequate clearance to thehose to avoid an abrasion to thenew hose.
•All connections for leaks.
Driveline Parking Brake
WARNING: Use wheel chocks andexercise caution when inspecting underthe vehicle. A vehicle roll-away couldresult in property damage, personal injuryor death.
A qualified technician should adjust theparking brake and keep to the instructionsin the service manual.
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AXLE INSPECTION
Front Axle
Maintaining the front axle alignment tospecifications is very important. A qualifiedtechnician should check and maintain thealignment.
Regular inspections should include:
•Toe-in inspection and adjustment (ifnecessary), particularly with radialtires.
•Checking for proper tightness of axlemounting U-bolt nuts, attaching ormounting bolts and nuts.
•Checking the axle for damage, binding,worn parts and adequate lubrication.
•Checking the kingpins for excessivewear. Also, perform this check duringother scheduled maintenance, forexample as tire rotation or service,wheel bearing service and alignment.See the workshop manual for properprocedures.
Toe-in
It is essential to maintain correct toe-inand tire pressure for optimum tire wear.
Inspecting steer axle tires in the first3,000–10,000 mi (5,000–16,000 km)generally shows if tires are wearingnormally.
Rapid outside shoulder wear on both tiresindicates too much toe-in.
Rapid inside shoulder wear on both tiresindicates too much toe-out.
In P&D-type service, there can be aleft-to-right steer tire tread life differentialup to 40% depending on routes and othervariables.
Follow the tire manufacturer'srecommended cold inflation pressure forthe tire size, load range (ply rating) andsteer axle loading typical for their operation(each steer axle tire equals ½ steer axleloading).
Special applications may warrant a settingbased on experience with the type of tireoperating loads and conditions. Radial tiresare more sensitive to toe-in setting thanbias ply tires. Fine tuning school busalignment to line-haul truck standardsdoes not drastically improve tire tread life.
STEERING SYSTEM
INSPECTION
WARNING: Failure to maintain thesteering system in proper condition cancause reduced steering ability resultingin property damage, personal injury ordeath.
Note:Have any steering problemsimmediately corrected by a qualified servicetechnician.
Ask your service technician to examine thesteering mechanism. Only minoradjustments may be necessary.
Regular inspections should include:
•Checking the tie rod, drag link endclamp bolts and ball joints for propertightness.
•Checking for installation and spread ofcotter pins and tightness of nuts atboth ends of the tie rod and drag link.
•Checking that the pitman arm (steeringarm at steering gear) mounting is tightand locked. Check system for leaks orhose chafing. Repair immediately, ifnecessary.
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•Maintaining proper steering gear andpower steering pump lubricant levels.
•Checking steering column joint boltsand steering linkage, particularly forbody-to-chassis clearance.
Steering Column Joint Bolts
As a good maintenance practice, checksteering column joint bolt tightness every60,000 mi (96,000 km) or annually,whichever occurs first. Do not overtightenthe bolts.
Hydraulic System
Whenever draining and refilling the powersteering's hydraulic system for any reason,bleed air from the system before returningthe vehicle to service. Failure to bleed thehydraulic system properly can result indegradation of power system performance.
Consult an authorized dealer who is awareof the proper procedures for filling andbleeding the system.
SUSPENSION SYSTEM
INSPECTION (IF EQUIPPED)
Note:Do not adjust air suspension heightto any setting other than the specifiedsetting. Altering the height setting changesthe driveline angle and may result inunwarrantable component damage, suchas transmission component damage.
Verify drive axle air suspension height andheight control valve performance at engineoil change intervals.
Periodically check:
•Condition of spring leaves for evidenceof fatigue, bending or breakage.
•Condition of suspension mountingbrackets and bushings.
•Torque rod mounting fasteners fortightness.
•For proper suspension alignment.Maintain proper alignment at all times.
•U-bolts. After the chassis has beenoperating under load for 1,000 mi(1,600 km) or six months (whichevercomes first), the U-bolt nuts must bere-torqued. Re-torque the U-bolt nutsevery 37,000 mi (60,000 km)thereafter. Clean and lubricate theU-bolt and nut threads and seats tomake sure a like new condition whenre-torqueing. See Spring U-BoltCheck (page 261).
FRAME AND TOW HOOK
INSPECTION
Your vehicle's chassis is manufacturedwith frame rails of either HSLA steel orheat-treated steel. Handle each in aspecific manner to make sure maximumservice life. Consult the service manual oran authorized dealer before attemptingframe repair or modification.
It is important, particularly on vehicles thatuse tow hooks frequently, to inspect thefront and rear tow hooks for damage or aloose mounting.
REAR AXLE FLUID CHECK
Your rear axle may have an optionalsynthetic lubricant that allows the use ofextended service intervals. A tag on thefiller plug identifies the use of the syntheticlubricant.
Only use a lubricant that meetsmanufacturer specifications. Use of anon-approved rear axle lubricant maycause internal axle component damage.See Rear Axle Fluid Capacity andSpecification (page 311).
Checking the Fluid Level
1.Park your vehicle on level ground.
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2.Set the parking brake and shift intoposition neutral (N) or park (P). Turnthe engine off.
3.Clean any dirt from around the axlefiller plug.
4.Remove the filler plug and inspect thelubricant level. It should be at thebottom of the filler plug opening.
5.Add lubricant, if necessary, through thefiller plug opening.
6.Clean and install the filler plug securely.
Changing the Fluid
Note:Drain the rear axle while the lubricantis warm.
1.Park your vehicle on level ground.
2.Set the parking brake and shift intoposition neutral (N) or park (P). Turnthe engine off.
3.Clean any dirt from around the axlefiller and drain plugs.
4.Remove the filler and drain plugs. Drainthe lubricant into a suitable container.Dispose of all used automotive fluidsin a responsible manner following yourlocal authorized standards.
5.Clean and install the drain plugsecurely.
6.Add lubricant through the filler plugopening.
7.Clean and install the filler plug securely.
SPRING U-BOLT CHECK
Check and tighten the U-bolt nuts afteryour vehicle has been operated under loadfor 1,000 mi (1,600 km) or six months,whichever occurs first.
Check and tighten the U-bolt nuts every37,000 mi (60,000 km).
Check and tighten the U-bolt nuts withyour vehicle at curb height and unloaded.
Inspect the U-bolt threads for rust anddebris. Clean the threads if contaminated.
U-bolt Nut Torque
Front Axle
Note:Check and tighten the U-bolt nutsevenly using a criss-cross pattern in thefollowing stages.
lb.ft (Nm)Stage
40 (60)1.
90 (125)2.
170 (225)3.
240 (325)4.
Rear Axle
Note:Check and tighten the U-bolt nutsevenly using a criss-cross pattern in thefollowing stages.
lb.ft (Nm)Stage
60 (75)1.
90 (125)2.
170 (225)3.
240 (325)4.
320 (440)5.
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