Ford F650 Owners Manual
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• Robinair® Coolant and Battery Refractometer 75240 – Recommended refractometer to test coolant concentration. (Rotunda tool part number: ROB75240). • Rotunda 328-R071–ELC (Antifreeze Coolant ELC Contamination Kit) – Evaluates the corrosion inhibitor additive strength. Note the first step is to verify the vehicle ’s coolant concentration is in the correct range of 40 – 60%. Coolant concentrations outside this range will not provide valid test results. If the report results in a pass, for example the cooling system does not show excessive contamination, the corrosion inhibitor additive strength is sufficient, and no action is required. If the report results as insufficient (does not pass), the corrosion inhibitor additive strength of the coolant is too low. If the engine cooling system corrosion inhibitor additive strength is low, add 47 fl oz (1.4 L) of Motorcraft Specialty Orange Engine Coolant Revitalizer. If the secondary cooling system corrosion inhibitor additive strength is low, add 16 fl oz (0.47 L) of Motorcraft Specialty Orange Engine Coolant Revitalizer. • Motorcraft Specialty Orange Engine Coolant Revitalizer – Additive to boost the corrosion inhibitor level based upon the test results of the Antifreeze Coolant ELC Contamination Kit. The Revitalizer may be added two times over the life of the coolant. If additional dosages are required, the cooling system must be flushed and refilled per the instructions in the Workshop Manual. Make sure to follow the proper coolant and additive specifications. See Capacities and Specifications (page 255). Coolant Change At specific mileage intervals, as listed in the scheduled maintenance information, the coolant should be changed. The information display may display a message to change coolant at this time. Add prediluted coolant approved to the correct specification. See Capacities and Specifications (page 255). Engine-driven Cooling Fan (Fan Clutch) Your vehicle may have an engine driven cooling fan drive (also called a fan clutch). This fan drive changes the fan speed to match the vehicle ’s changing cooling air flow requirements. Fan speed, fan noise level and fuel consumption all will increase based on the driving conditions that include trailer towing, hill climbing, heavy loads, high speed and high ambient temperature, individually or in combination. The fan drive is designed to provide the minimum fan speed (and resulting minimum fan noise and fuel consumption) required to meet the ever changing vehicle cooling air flow requirements. You will hear the amount of fan noise increasing and decreasing as the engine power requirements and vehicle driving conditions change as you drive. This is to be expected as being normal to the operation of your vehicle. High levels of fan noise might also be heard when your engine is first started, and should normally decrease after driving for a short time. ENGINE COOLANT CHECK - 6.8L WARNINGS Never remove the coolant reservoir cap when the engine is running or hot. 198 F650750 (TBC) , enUSA, Edition date: 201708, First Printing Maintenance
WARNINGS Do not put coolant in the windshield washer reservoir. If sprayed on the windshield, coolant could make it difficult to see through the windshield. To reduce the risk of personal injury, make sure the engine is cool before unscrewing the coolant pressure relief cap. The cooling system is under pressure. Steam and hot liquid can come out forcefully when you loosen the cap slightly. Do not add coolant further than the MAX mark. When the engine is cold, check the concentration and level of the coolant at the intervals listed in the scheduled maintenance information. See Scheduled Maintenance (page 320). Note: Make sure that the coolant level is between the MIN and MAX marks on the coolant reservoir. Note: Coolant expands when it is hot. The level may extend beyond the MAX mark. Maintain coolant concentration within 48% to 50%, which equates to a freeze point between -30°F (-34°C) and -34°F (-37°C). Coolant concentration should be checked using a refractometer. We do not recommend the use of hydrometers or coolant test strips for measuring coolant concentration. Adding Coolant WARNINGS Do not add engine coolant when the engine is hot. Failure to follow this instruction could result in personal injury. Never remove the coolant reservoir cap when the engine is running or hot. Note: Automotive fluids are not interchangeable. Do not use coolant or windshield washer fluid outside of its specified function and vehicle location. Note: Do not use stop leak pellets, cooling system sealants, or non-specified additives as they can cause damage to the engine cooling or heating systems. Resulting component damage may not be covered by the vehicle Warranty. It is very important to use prediluted coolant approved to the correct specification in order to avoid plugging the small passageways in the engine cooling system. See Capacities and Specifications (page 269). Do not mix different colors or types of coolant in your vehicle. Mixing of engine coolants or using an incorrect coolant may harm the engine or cooling system components and may not be covered by the vehicle Warranty. Note: Coolants marketed for all makes and models may not be approved to Ford specifications and may cause damage to the cooling system. Resulting component damage may not be covered by the vehicle Warranty. If the coolant level is at or below the minimum mark, add prediluted coolant immediately. For vehicles with overflow coolant systems with a non-pressurized cap on the coolant recovery system, add coolant to the coolant recovery reservoir when the engine is cool. Add prediluted coolant to the maximum level. For all vehicles which have a coolant degas system with a pressurized cap, or if it is necessary to remove the coolant pressure relief cap on the radiator, follow these steps to add engine coolant: 1. Turn the engine off and let it cool. 2. Unscrew the cap slowly. Any pressure escapes as you unscrew the cap. 199 F650750 (TBC) , enUSA, Edition date: 201708, First Printing Maintenance
3. Fill the coolant reservoir slowly with prediluted engine coolant to within the minimum and maximum range on the engine coolant reservoir. If you removed the radiator cap in an overflow system, fill the radiator until the coolant is visible and the radiator is almost full. If coolant is added to bring the level within the minimum and maximum range when the engine is not cold, the system may remain underfilled. 4. Replace the coolant reservoir cap, turn it clockwise until you feel a strong resistance. 5. Check the coolant level in the coolant reservoir the next few times you drive your vehicle. If necessary, add enough prediluted engine coolant to bring the coolant level to the proper level. Note: If prediluted coolant is not available, use the approved antifreeze concentrate diluting it to 50/50 with distilled water. See Capacities and Specifications (page 269). Using water that has not been deionized may contribute to deposit formation, corrosion or plugging of the small cooling system passageways. If you have to add more than 1.1 qt (1 L) of engine coolant per month, have your vehicle checked as soon as possible. Operating an engine with a low level of coolant can result in engine overheating and possible engine damage. Note: During normal vehicle operation, the coolant may change color from orange to pink or light red. As long as the coolant is clear and uncontaminated, this color change does not indicate the coolant has degraded nor does it require the coolant to be drained, the system to be flushed, or the coolant to be replaced. Note: In case of emergency, you can add a large amount of water without coolant in order to reach a vehicle service location. Water alone, without coolant, can cause engine damage from corrosion, overheating or freezing. When you reach a service location, you must have the cooling system drained, flushed and refilled using the correct specification prediluted coolant or antifreeze concentrate. See Capacities and Specifications (page 269). Do not use the following as a coolant substitute: • Alcohol. • Methanol. • Brine. • Any coolant mixed with alcohol or methanol antifreeze. Alcohol and other liquids can cause engine damage from overheating or freezing. Do not add extra inhibitors or additives to the coolant. These can be harmful and compromise the corrosion protection of the coolant. Recycled Coolant We do not recommend the use of recycled coolant as an approved recycling process is not yet available. Dispose of used engine coolant in an appropriate manner. Follow your community ’s regulations and standards for recycling and disposing of automotive fluids. 200 F650750 (TBC) , enUSA, Edition date: 201708, First Printing Maintenance
Severe Climates If you drive in extremely cold climates: • It may be necessary to increase the coolant concentration above 50%. • A coolant concentration of 60% provides improved freeze point protection. Coolant concentrations above 60% decrease the overheat protection characteristics of the coolant and may cause engine damage. If you drive in extremely hot climates: • You can decrease the coolant concentration to 40%. • Coolant concentrations below 40% decrease the freeze and corrosion protection characteristics of the coolant and may cause engine damage. Vehicles driven year-round in non-extreme climates should use prediluted engine coolant for optimum cooling system and engine protection. Coolant Change At specific mileage intervals, as listed in the scheduled maintenance information, the coolant should be changed. The information display may display a message to change coolant at this time. Add prediluted coolant approved to the correct specification. See Capacities and Specifications (page 255). Engine-driven Cooling Fan (Fan Clutch) Your vehicle is equipped with an engine driven cooling fan drive (also called a fan clutch). This fan drive changes the fan speed to match the vehicle ’s changing cooling air flow requirements. Fan speed, fan noise level and fuel consumption all will increase based on the driving conditions that include trailer towing, hill climbing, heavy loads, high speed and high ambient temperature, individually or in combination. The fan drive is designed to provide the minimum fan speed (and resulting minimum fan noise and fuel consumption) required to meet the ever changing vehicle cooling air flow requirements. You will hear the amount of fan noise increasing and decreasing as the engine power requirements and vehicle driving conditions change as you drive. This is to be expected as being normal to the operation of your vehicle. High levels of fan noise might also be heard when your engine is first started, and should normally decrease after driving for a short time. Fail-Safe Cooling Fail-safe cooling allows you to temporarily drive your vehicle before any incremental component damage occurs. The fail-safe distance depends on ambient temperature, vehicle load and terrain. How Fail-Safe Cooling Works If the engine begins to overheat, the coolant temperature gauge moves toward the red zone: A warning lamp illuminates and a message may appear in the information display. 201 F650750 (TBC) , enUSA, Edition date: 201708, First Printing Maintenance
If the engine reaches a preset over-temperature condition, the engine automatically switches to alternating cylinder operation. Each disabled cylinder acts as an air pump and cools the engine. When this occurs, your vehicle still operates, however: • Engine power is limited. • The air conditioning system turns off. Continued operation increases the engine temperature, causing the engine to completely shut down. Your steering and braking effort increases in this situation. When the engine temperature cools, you can re-start the engine. Have your vehicle checked as soon as possible to minimize engine damage. When Fail-Safe Mode Is Activated WARNINGS Fail-safe mode is for use during emergencies only. Operate your vehicle in fail-safe mode only as long as necessary to bring your vehicle to rest in a safe location and seek immediate repairs. When in fail-safe mode, your vehicle will have limited power, will not be able to maintain high-speed operation, and may completely shut down without warning, potentially losing engine power, power steering assist, and power brake assist, which may increase the possibility of a crash resulting in serious injury. Never remove the coolant reservoir cap when the engine is running or hot. Your vehicle has limited engine power when in the fail-safe mode, drive your vehicle with caution. Your vehicle does not maintain high-speed operation and the engine may operate poorly. Remember that the engine is capable of automatically shutting down to prevent engine damage. In this situation: 1. Pull off the road as soon as safely possible and switch the engine off. 2. If you are a member of a roadside assistance program, we recommend that you contact your roadside assistance service provider. 3. If this is not possible, wait a short period for the engine to cool. 4. Check the coolant level. If the coolant level is at or below the minimum mark, add prediluted coolant immediately. 5. When the engine temperature cools, you can re-start the engine. Have your vehicle checked as soon as possible to minimize engine damage. Note: Driving your vehicle without repair increases the chance of engine damage. Engine Coolant Temperature Management (If Equipped) WARNING To reduce the risk of crash and injury, be prepared that the vehicle speed may reduce and the vehicle may not be able to accelerate with full power until the coolant temperature reduces. If you tow a trailer with your vehicle, the engine may temporarily reach a higher temperature during severe operating conditions, for example ascending a long or steep grade in high ambient temperatures. At this time, you may notice the coolant temperature gauge moves toward the red zone and a message may appear in the information display. 202 F650750 (TBC) , enUSA, Edition date: 201708, First Printing Maintenance
You may notice a reduction in vehicle speed caused by reduced engine power in order to manage the engine coolant temperature. Your vehicle may enter this mode if certain high-temperature and high-load conditions take place. The amount of speed reduction depends on vehicle loading, grade and ambient temperature. If this occurs, there is no need to pull off the road. You can continue to drive your vehicle. The air conditioning may automatically turn on and off during severe operating conditions to protect the engine from overheating. When the coolant temperature decreases to the normal operating temperature, the air conditioning turns on. If the coolant temperature gauge moves fully into the red zone, or if the coolant temperature warning or service engine soon messages appear in your information display, do the following: 1. Pull off the road as soon as safely possible and shift the transmission into park (P). 2. Leave the engine running until the coolant temperature gauge needle returns to the normal position. After several minutes, if the temperature does not drop, follow the remaining steps. 3. Switch the engine off and wait for it to cool. Check the coolant level. 4. If the coolant level is at or below the minimum mark, add prediluted coolant immediately. 5. If the coolant level is normal, restart the engine and continue. AUTOMATIC TRANSMISSION FLUID CHECK The transmission does not consume fluid. However, the fluid level should be checked if the transmission is not working properly, for example if the transmission slips, shifts slowly or if there are signs of fluid loss. The transmission fluid and filter on your vehicle must be replaced at the specified service interval. See Scheduled Maintenance (page 320). Automatic transmission fluid expands when warmed. To check the fluid level consistently and accurately, do the following: 1. Drive the vehicle until it reaches normal operating temperature. This may take up to 20 mi (30 km). 2. Make sure that your vehicle is on level ground. 3. With the engine running, parking brake engaged and your foot on the brake pedal, move the gearshift lever through all of the gear ranges. Allow sufficient time for each gear to engage. 4. Make sure the parking brake is on. Make sure the transmission is in park (P) or neutral (N) and leave the engine running. 5. Open the hood. See Opening and Closing the Hood (page 186). 6. Remove the dipstick and wipe it with a clean, lint-free cloth. See Under Hood Overview (page 189). 7. Replace the dipstick and remove it again to check the fluid level. 8. If the fluid level is correct, replace the dipstick and make sure it is fully seated. Note: If the fluid level is between the maximum and minimum marks, the fluid level is acceptable. Do not add fluid. 203 F650750 (TBC) , enUSA, Edition date: 201708, First Printing Maintenance
Transmission Fluid Level Low Fluid Level If the fluid level is at or below the minimum mark, add fluid immediately. See Capacities and Specifications (page 269). Note: If there is no indication of fluid on the dipstick, have your vehicle checked immediately. Correct Fluid Level Make sure that the fluid level is between the maximum and minimum marks. High Fluid Level Do not add fluid further than the maximum mark. Fluid levels above the maximum mark may cause shift or engagement concerns and possible damage. Note: High fluid levels can be caused by an overheating condition. Adding Transmission Fluid Do not use supplemental transmission fluid additives, treatments or cleaning agents. The use of these materials may affect transmission operation and result in damage to internal transmission components and could lead to transmission damage that may not be covered by the vehicle Warranty. Use only recommended transmission fluid that meets our specifications. See Capacities and Specifications (page 269). Note: Use of a non-approved automatic transmission fluid may cause internal transmission component damage. If necessary, add fluid in 8 fl oz (250 ml) increments through the filler tube until the level is correct. If an overfill occurs, excess fluid should be removed, have your vehicle checked as soon as possible. 204 F650750 (TBC) , enUSA, Edition date: 201708, First Printing MaintenanceE163740 E163742 E163744
BRAKE FLUID CHECK WARNINGS Do not use any fluid other than the recommended brake fluid as this will reduce brake efficiency. Use of incorrect fluid could result in the loss of vehicle control, serious personal injury or death. Only use brake fluid from a sealed container. Contamination with dirt, water, petroleum products or other materials may result in brake system damage or failure. Failure to adhere to this warning could result in the loss of vehicle control, serious personal injury or death. Do not allow the fluid to touch your skin or eyes. If this happens, rinse the affected areas immediately with plenty of water and contact your physician. A fluid level between the MAX and MIN lines is within the normal operating range and there is no need to add fluid. A fluid level not in the normal operating range could compromise the performance of the system. Have your vehicle checked immediately. To avoid fluid contamination, the reservoir cap must remain in place and fully tight, unless you are adding fluid. Only use fluid that meets Ford specifications. See Capacities and Specifications (page 255). POWER STEERING FLUID CHECK Check the power steering fluid. See Scheduled Maintenance (page 320). If adding fluid is necessary, use only MERCON LV ATF Check the fluid level when it is at ambient temperature. 1. Check the fluid level in the reservoir. It should be between the MIN and MAX range. Do not add fluid if the level is within this range. 2. If the fluid level is low, add fluid to bring the fluid level up to between the MIN and MAX range. 3. Switch the engine on. 205 F650750 (TBC) , enUSA, Edition date: 201708, First Printing MaintenanceE170684
4. While the engine idles, turn the steering wheel left and right several times. 5. Switch the engine off. 6. Recheck the fluid level in the reservoir. Do not add fluid if the level is between the MIN and MAX range. 7. If the fluid is low, add the proper type of fluid in small amounts, continuously checking the level until it is between the MIN and MAX range. See Capacities and Specifications (page 269). Be sure to put the cap back on the reservoir. WASHER FLUID CHECK WARNING If you operate your vehicle in temperatures below 40°F (5°C), use washer fluid with antifreeze protection. Failure to use washer fluid with antifreeze protection in cold weather could result in impaired windshield vision and increase the risk of injury or accident. Add fluid to fill the reservoir if the level is low. Only use a washer fluid that meets Ford specifications. See Capacities and Specifications (page 255). State or local regulations on volatile organic compounds may restrict the use of methanol, a common windshield washer antifreeze additive. Washer fluids containing non-methanol antifreeze agents should be used only if they provide cold weather protection without damaging the vehicle ’s paint finish, wiper blades or washer system. DRAINING THE FUEL FILTER WATER TRAP - 6.7L DIESEL Your vehicle is equipped with a diesel fuel conditioner module located on the frame-rail under the driver-side floorboard near the transmission. You should drain water from the module assembly whenever the warning light comes on and the message center directs you to drain the water separator. This will occur when approximately 8.45 fl oz (250 ml) of water accumulates in the module. If you allow the water level to exceed this level, the water may pass through to the engine and may cause fuel injection equipment damage. Draining the Diesel Fuel Conditioner Module (DFCM) WARNING Do not drain the water-in-fuel separator while the engine is running. Failure to follow this warning may result in fire, serious injury, death or property damage. Note: If you drain the diesel fuel conditioner module while the system is running air will enter into the fuel system. The engine will not operate properly if air enters the system. Note: With fuel tank levels above 3⁄4 tank it may be necessary to loosen the bowl three turns before opening the drain. This will actuate an anti-siphon valve at the fuel and water separator inlet and prevent the fuel from siphoning out of the tank. Note: A loose drain valve can allow air to enter the fuel system and cause drivetrain issues. The engine will not operate properly. Be sure that you fully tighten the drain valve. 206 F650750 (TBC) , enUSA, Edition date: 201708, First Printing Maintenance
1. Stop your vehicle and shut off the engine. 2. Locate the diesel fuel conditioner module and place an appropriate container under the drain port. 3. Rotate the drain counterclockwise until the O-ring is visible. Allow the diesel fuel conditioner module to drain for approximately 25 seconds or until clean fuel is observed. Rotate the drain clockwise to tighten it. If no liquid drains, there may be a clog in the drain. Have the conditioner module serviced by an authorized dealer. 4. Make sure that you fully tighten the drain valve and then remove the container from under your vehicle. 5. Restart the engine. If the Water in Fuel Drain Filter message and light continues to illuminate, have the fuel system checked and repaired. FUEL FILTER - 6.8L Your vehicle is equipped with a lifetime fuel filter that is integrated with the fuel tank. Regular maintenance or replacement is not needed. CHANGING THE 12V BATTERY WARNINGS This vehicle may be equipped with more than one battery, removal of cable from only one battery does not disconnect the vehicle electrical system. Be sure to disconnect cables from all batteries when disconnecting power. Failure to do so may cause serious personal injury or property damage. Batteries normally produce explosive gases which can cause personal injury. Therefore, do not allow flames, sparks or lighted substances to come near the battery. When working near the battery, always shield your face and protect your eyes. Always provide proper ventilation. When lifting a plastic-cased battery, excessive pressure on the end walls could cause acid to flow through the vent caps, resulting in personal injury and damage to the vehicle or battery. Lift the battery with a battery carrier or with your hands on opposite corners. Keep batteries out of reach of children. Batteries contain sulfuric acid. Avoid contact with skin, eyes or clothing. Shield your eyes when working near the battery to protect against possible splashing of acid solution. In case of acid contact with skin or eyes, flush immediately with water for a minimum of 15 minutes and get prompt medical attention. If acid is swallowed, call a physician immediately. Note: If your battery has a cover/shield, make sure it is reinstalled after the battery has been cleaned or replaced. Note: Battery posts, terminals and related accessories contain lead and lead compounds. Wash hands after handling. 207 F650750 (TBC) , enUSA, Edition date: 201708, First Printing MaintenanceE163360