Ford F650 750 2002 Owner's Manual

Introduction 3

Congratulations 3 Safety and environment protection 4 Symbol glossary 6

Instrument Cluster 9

Gauges 16

Entertainment Systems 20

AM/FM stereo 20 AM/FM stereo cassette 20 AM/FM stereo cassette with CD 31 AM/FM stereo with CD 39

Climate Controls 56

Heater only 56 Manual heating and air conditioning 57

Lights 61

Headlamps 61

Driver Controls 68

Windshield wiper/washer control 68 Steering wheel adjustment 69 Power windows 74 Mirrors 75

Locks and Security 84

Keys 84 Locks 84 Anti-theft system 84

Seating and Safety Restraints 88

Seating 88 Safety restraints 93 Child restraints 102

Table of Contents

Driving 108

Starting 108 Brakes 113 Transmission operation 132 Vehicle loading 149

Roadside Emergencies 150

Hazard flasher switch 150 Fuses and relays 151 Jump starting 161

Customer Assistance 165

The dispute settlement board 167 Getting assistance outside the U.S. and Canada 170 Ordering additional owner’s literature 171 Reporting safety defects (U.S. only) 172

Cleaning 174

Cleaning your vehicle 174 Underbody preservation 179

Maintenance and Specifications 181 Accessories 229 General Maintenance Information 230 Index 249

All rights reserved. Reproduction by any means, electronic or mechanical including photocopying, recording or by any information storage and retrieval system or translation in whole or part is not permitted without written authorization from Ford Motor Company. Ford may change the contents without notice and without incurring obligation.

Introduction

The following warning may be required by California law:

CALIFORNIA Proposition 65 Warning

WARNING: Engine exhaust, some of its constituents, and

certain vehicle components contain or emit chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. In addition, certain fluids contained in vehicles and certain products of component wear contain or emit chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.

CONGRATULATIONS

Congratulations on acquiring your new Ford. Please take the time to get well acquainted with your vehicle by reading this handbook. The more you know and understand about your vehicle the greater the safety and pleasure you will derive from driving it.

For more information on Ford Motor Company and its products visit the following website:

In the United States: www.ford.com In Canada: www.ford.ca In Mexico: www.ford.com.mx In Australia: www.ford.com.au Additional owner information is given in separate publications.

This Owner’s Guide describes every option and model variant

available and therefore some of the items covered may not apply to your particular vehicle. Furthermore, due to printing cycles it may describe options before they are generally available.

Remember to pass on the Owner’s Guide when reselling the

vehicle. It is an integral part of the vehicle.

Introduction

SAFETY AND ENVIRONMENT PROTECTION

Warning symbols in this guide

How can you reduce the risk of personal injury and prevent possible damage to others, your vehicle and its equipment? In this guide, answers to such questions are contained in comments highlighted by the warning triangle symbol. These comments should be read and observed.

Warning symbols on your vehicle

When you see this symbol, it is imperative that you consult the relevant section of this guide before touching or attempting adjustment of any kind.

Protecting the environment

We must all play our part in protecting the environment. Correct vehicle usage and the authorized disposal of waste cleaning and lubrication materials are significant steps towards this aim. Information in this respect is highlighted in this guide with the tree symbol.

Introduction

SPECIAL NOTICES Emission warranty

The New Vehicle Limited Warranty includes Bumper-to-Bumper Coverage, Safety Restraint Coverage, Corrosion Coverage, and 7.3L Power Stroke Diesel Engine Coverage. In addition, your vehicle is eligible for Emissions Defect and Emissions Performance Warranties. For a detailed description of what is covered and what is not covered, refer to the Warranty Guide that is provided to you along with your Owner’s Guide.

Special instructions

For your added safety, your vehicle is fitted with sophisticated electronic controls.

By operating other electronic equipment (e.g. mobile telephone

without exterior aerial) electromagnetic fields can occur which can cause malfunctions of the vehicle electronics. Therefore you should observe the instructions of the equipment manufacturers

Introduction

These are some of the symbols you may see on your vehicle.

Vehicle Symbol Glossary

Safety Alert

Fasten Safety Belt Child Seat

Child Seat Installation Warning

Brake System Anti-Lock Brake System

Brake Fluid Non-Petroleum Based

Master Lighting Switch Hazard Warning Flasher

Fog Lamps-Front Fuse Compartment

Fuel Pump Reset Windshield Wash/Wipe

Windshield Defrost/Demist

See Owner’s Guide

Child Seat Tether Anchorage

Traction Control

Rear Window Defrost/Demist

Power Windows Front/Rear

Child Safety Door Lock/Unlock

Power Window Lockout

Interior Luggage Compartment Release Symbol

Vehicle Symbol Glossary

MAX

MIN

Introduction

Panic Alarm

Engine Coolant

Engine Oil

Engine Coolant Temperature

Do Not Open When Hot Battery

Avoid Smoking, Flames, or Sparks

Battery Acid

Explosive Gas Fan Warning

Power Steering Fluid

Maintain Correct Fluid Level

Emission System Engine Air Filter

Passenger Compartment Air Filter

Jack

Check fuel cap Low tire warning

Introduction

FEDERAL HIGHWAY ADMINISTRATION REGULATION

Regulations such as those issued by the Federal Highway Administration or issued pursuant to the Occupational Safety and Health Act (OSHA), and/or state and local laws and regulations may require additional equipment for the way you intend to use the vehicle. It is the responsibility of the registered owner to determine the applicability of such laws and regulations to your intended use for the vehicle, and to arrange for the installation of required equipment. Your Ford dealer has information about the availability of equipment which may be ordered for your vehicle.

ENTERING, EXITING AND/OR CLIMBING ON THIS VEHICLE

You must be careful and deliberate to minimize the possibility of personal injury from a slip and fall when entering, exiting and/or climbing on this vehicle. Always use the steps and assist handles before climbing. Do not skip any steps or assist handles. Use three point contact at all times with at least two feet and one hand or two hands and one foot firmly placed during all phases of entering, exiting and/or climbing. Always keep your shoe soles and hands clean. Keep the steps and assist handles free of snow, ice, oil, grease, substances or debris. Be sure to use extra care in bad weather. Avoid wearing thick gloves. Always perform trailer hook-up while standing on the ground.

Do not carry items while entering, exiting, and/or climbing. Make

sure you keep a firm grip. Always FACE the VEHICLE STEP and HANDLE SYSTEM while climbing up and down. Do not climb behind the cab unless you have three point contact with a step and handle system at all times.

Instrument Cluster

WARNING LIGHTS AND CHIMES

Warning lights and gauges can alert you to a vehicle condition that may become serious enough to cause expensive repairs. A warning light may illuminate when a problem exists with one of your vehicle’s functions. Many lights will illuminate when you start your vehicle to make sure the bulb works. If any light remains on after starting the vehicle, have

the respective system inspected immediately.

Service engine soon

Illuminates briefly to ensure the system is functional. If it comes on after the engine is started, one of the engine’s emission control systems may be malfunctioning. The light may illuminate without a driveability concern being noted. The vehicle will usually be drivable and will not require towing.

Light turns on solid:

Temporary malfunctions may cause your Service Engine Soon light to illuminate. Examples are:

1. The vehicle has run out of fuel.

2. Poor fuel quality or water in the fuel. These and other temporary malfunctions can be corrected by filling the

fuel tank with good quality fuel. After three driving cycles without these or any other temporary malfunctions present, the Service Engine Soon light should turn off. (A driving cycle consists of a cold engine startup followed by mixed city/highway driving.) No additional vehicle service is required.

SERVICE

ENGINE

SOON

Instrument Cluster

If the Service Engine Soon light remains on, have your vehicle serviced at the first available opportunity.

Under engine misfire conditions, excessive exhaust temperatures

could damage the fuel system, interior floor coverings or other vehicle components, possibly causing a fire.

Engine protect warning (Cummins engine only)

Illuminates when there is a fault in the electronic subsystem but the vehicle can be driven, and indicates one of the following conditions:

• low oil pressure

• low coolant level

• high coolant temperature

• high intake manifold temperature

Refer to the Engine Operator’s Manual.

Stop engine (if equipped)

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 to Engine shutdown system in the Driving chapter.

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.

ENGINE

PROTECT

STOP

ENGINE

Instrument Cluster

Brake reserve system warning (if equipped)

Illuminates to indicate normal Hydromax booster reserve system activation when the engine is OFF and the service brake pedal is applied, or when the ignition is in the ON or START position.

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

Momentarily illuminates when the ignition is turned to the ON position and the engine is off. If the brake warning lamp does not illuminate at this time seek service immediately.

If equipped with a hydraulic brake system and the warning lamp remains illuminated after engine start up, this indicates a brake system malfunction. Stop the vehicle safely as soon as possible and seek service immediately.

If equipped with an air brake system, the warning light stays on until the air pressure builds up to 414 kPa (60 psi). If the air pressure drops below 414 kPa (60 psi) during operation, the remaining brake system is still operational but the stopping distance will be greater.

BRAKE

Anti-lock brake system (ABS)

Momentarily illuminates when the ignition is turned to the ON position and the engine is off. If the light remains on after the vehicle is started, continues to flash or fails to illuminate, have the system serviced immediately. With the ABS light on, the anti-lock brake system is disabled and normal braking is still effective unless the brake warning light also remains illuminated.

ABS

Instrument Cluster

Trailer ABS brake system (if equipped)

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.

Parking brake warning (Hydraulic brakes only)

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.

Safety belt

Illuminates to remind you to fasten your safety belts. For more information, refer to the Seating and safety restraints chapter.

BRAKE

Check trans (Allison automatic transmission)

The lamp will illuminate for several seconds after the ignition is turned to the ON position. Illumination of this light indicates that a problem has been detected and shifting may be restricted. Depending upon the severity of the problem, the read-out digit on the shifter display may be blank. Operation may continue in order to reach service assistance. The ECU may not respond to shift selector requests, since operating limitations are being placed on the transmission, i.e. upshifts and downshifts may be restricted. Direction changes will not occur.

Refer to the Transmission Operator’s Manual for more information.

CHECK

TRANS

Instrument Cluster

Range inhibit

Illuminates when the transmission is not engaged in the selected gear. The warning light will go off when the gearshift lever is adjusted in to the appropriate gear.

Refer to the Transmission Operator’s Manual for more information.

Charging system

Illuminates when the ignition is turned to the ON position and the engine is off, or an over voltage condition requiring electrical system service.

Wait to start

Indicates the air intake heater is in operation and special starting procedures are required. Refer to the Driving chapter.

If equipped with an air intake heater, DO NOT use ether or any

other starting fluids. The use of starting fluids (ether) in an engine equipped with an air intake heater could result in damage and/or personal injury.

RANGE

INHIBIT

WAIT

START

Instrument Cluster

Water in fuel (if equipped)

During refueling it is possible for water-contaminated diesel fuel to be pumped into your fuel tank. Your vehicle fuel system is equipped with a fuel filter/water separator to remove water from the fuel. The indicator light illuminates when the fuel filter/water separator has a significant quantity of water, or when the ignition key is switched to the START position. If the light illuminates when the engine is running, stop the vehicle as soon as safely possible, shut off the engine and drain the filter bowl. Allowing water to stay in the system could result in extensive damage to, or failure of, the fuel injection system.

To drain the fuel filter/water separator (refer to Maintenance and Specifications chapter for procedure). Rotate the valve at the bottom of the filter assembly allowing water to drain from the system. Close the valve upon completion.

Do not drain water separator while engine is running. Fuel may

ignite if separator is drained while engine is running or vehicle is moving.

Air clean warning (if equipped)

Illuminates when the air system is restricted (dirty, clogged).

WATER

FUEL

AIR

CLEAN

Turn signal

Illuminates when the left or right turn signal or the hazard lights are turned on. If one or both of the indicators stay on continuously or flash faster, check for a burned-out turn signal bulb. Refer to Exterior bulbs in the Lights chapter.

Instrument Cluster

High beams

Illuminates when the high beam headlamps are turned on.

Safety belt warning chime

Sounds to remind you to fasten your safety belts.

BeltMinder chime

Sounds intermittently to remind you to fasten your safety belts.

Headlamps on warning chime

Sounds when the headlamps or parking lamps are on, the key is removed from the ignition and the driver’s door is opened.

Key-in-ignition warning chime

Sounds when the key is left in the ignition and the driver’s door is opened.

Parking brake warning chime — F650 SuperCrewzer

Sounds when the parking brake knob is pulled and the parking brake is not functioning properly.

For information on the parking brake warning chime, refer to the

Parking brake (SuperCrewzer and Allison automatic transmission with Park in Park) in the Hydraulic brakes section in the Driving

chapter.

Instrument Cluster

GAUGES

Engine coolant temperature gauge

Indicates the temperature of the engine coolant. At normal operating temperature, the needle remains within the normal area (the area between the “H” and “C”). If it enters the red section, the engine is overheating. Stop the vehicle as soon as safely possible, switch off the engine immediately and let the engine cool. Refer to Engine

coolant in the Maintenance and specifications chapter.

Never remove the coolant reservoir cap while the engine is

running or hot. Steam and scalding liquid from a hot cooling system can burn you badly.

This gauge indicates the temperature of the engine coolant, not the coolant level. If the coolant is not at its proper level the gauge indication will not be accurate.

Instrument Cluster

Engine oil pressure gauge

Indicates engine oil pressure. At normal operating temperature, the needle will be in the normal range (the area between the “L” and “H”); if the needle goes below the normal range, stop the vehicle as soon as safely possible and switch off the engine immediately. Check the oil level. Add oil if needed (refer to

Engine oil in the Maintenance and specifications chapter). If the

oil level is correct, have your vehicle checked at your dealership or by a qualified technician.

Air pressure gauge and warning buzzer (if equipped)

Indicates the amount of air pressure in the brake system (green=primary, red=secondary) in pounds per square inch. When the pressure is too low for normal brake operation (less than 414 kPa [60 psi]) and the

ignition is turned to ON:

• a warning buzzer sounds

• the warning light illuminates

PRESSURE

All vehicles have a dual-pointer air pressure gauge to indicate the pressure in both brake circuits.

PSI

AIR

9060

120

150

Do not drive the vehicle when the low air pressure buzzer is

sounding or the warning light is lit. These warnings indicate there is not enough air pressure for the brake system to operate properly.

Instrument Cluster

Battery voltage gauge

Indicates battery voltage. If the pointer moves and stays outside the normal operating range (as indicated by the arrows), have the vehicle’s electrical system checked as soon as possible.

Fuel gauge

Displays approximately how much fuel is in the fuel tank. The fuel gauge may vary slightly when the vehicle is in motion or on a grade.

When refueling the vehicle from empty indication, the amount of fuel that can be added will be less than the advertised capacity due to the reserve fuel.

Speedometer

Indicates the current vehicle speed.

0000

MPH

00000

100

km/h

120

140

160

100

Odometer

Registers the total kilometers (miles) of the vehicle.

Trip odometer

Registers the kilometers (miles) of individual journeys. To reset, depress the control.

Instrument Cluster

000000

0000

MPH

100

km/h

120

140

160

100

Tachometer

Indicates the engine speed in revolutions per minute.

Driving with your tachometer pointer in the red zone may damage the engine.

DIESEL FUEL ONLY

RPM

1000

Entertainment Systems

AM/FM STEREO (WITH 2 SPEAKERS)

VOL

PUSH

TONE

CLK

1 2 3 4 AM/FM

AM/FM STEREO (WITH 4 SPEAKERS AND FADE CAPABILITY)

VOL

PUSH

TONE

CLK

TONE VOL

ST DX

SEEK TUNE

AM / FM STEREO

1 2 3 4 AM/FM

Entertainment Systems

Volume/power control

Press the control to turn the audio system on or off.

Turn the control to raise or lower volume.

If the volume is set above a certain level and the ignition is turned off, the volume will come back on at a “nominal” listening level when the ignition switch is turned back on.

Bass adjust

The bass adjust control allows you to increase or decrease the audio system’s bass output.

TONE

Press the TONE control once, then use the volume knob to adjust the

CLK

desired level.

VOL

PUSH

VOL

PUSH

VOL

PUSH

Treble adjust

The treble adjust control allows you to increase or decrease the audio system’s treble output.

Press the TONE control twice, then use the volume knob to adjust the desired level.

TONE

CLK

VOL

PUSH

Entertainment Systems

Speaker balance adjust

Speaker sound distribution can be adjusted between the right and left speakers.

Press the TONE control three times, then use the volume knob to adjust the desired level.

Speaker fade adjust (if equipped)

Speaker sound can be adjusted between the front and rear speakers.

Press the TONE control four times, then use the volume knob to adjust the desired level.

Seek function

The seek function control works in radio mode.

Seek function in radio mode

• Press to find the next listenable station down the frequency band.

• Press

to find the next listenable station up the frequency band.

TONE

CLK

TONE

CLK

SEEK

TUNE

VOL

PUSH

VOL

PUSH

AM/FM select

The AM/FM select control works in radio mode.

AM/FM

AM/FM select in radio mode

This control allows you to select AM or FM frequency bands. Press the control to switch between AM, FM1 or FM2 memory preset stations.

Entertainment Systems

Radio station memory preset

1 2 3 4

The radio is equipped with four station memory preset controls. These controls can be used to select up to four preset AM stations and eight FM stations (four in FM1 and four in FM2).

Setting memory preset stations

1. Select the frequency band with the AM/FM select control.

2. Select a station. Refer to Tune adjust or Seek function for more information on selecting a station.

3. Press and hold a memory preset control until the sound returns, indicating the station is held in memory on the control you selected.

1 2 3 4

Setting the clock

Press CLK to toggle between listening frequencies and clock mode.

To set the hour, press and hold the CLK control until CLOCK SET appears in the display and press the SEEK control:

TONE

CLK

•

to decrease hours and to increase hours.

Entertainment Systems

To set the minute, press and hold the CLK control until CLOCK SET appears in the display and press the TUNE control:

TONE

CLK

•

The CLK control will allow you to switch between media display mode (radio station, stereo information, etc.) and clock display mode (time). When in clock mode, the media information will display for ten seconds, when the radio is turned on, and then revert to clock information. Any time that the media is changed, (new radio station, etc.), the media information will again display for ten seconds before reverting back to the clock. In media mode, the media information will always be displayed.

Tune adjust

The tune control works in radio mode.

Tune adjust in radio mode

• Press to move to the next

• Press

to decrease minutes and to increase minutes.

frequency down the band (whether or not a listenable station is located there). Hold the control to move through the frequencies quickly.

to move to the next frequency up the band (whether or not a listenable station is located there). Hold for quick movement.

SEEK TUNE

AM/FM STEREO CASSETTE

VOL - PUSH ON

BASS TREB BAL FADE

Entertainment Systems

FM1

CLK

TAPE

AMS

SEEK TUNE

SCAN

123456

Volume/power control

Press the control to turn the audio system on or off.

Turn the control to raise or lower volume.

SIDE REW FF

VOL - PUSH ON

1 - 2

If the volume is set above a certain level and the ignition is turned off, the volume will come back on at a “nominal” listening level when the ignition switch is turned back on.

Entertainment Systems

Bass adjust

The bass adjust control allows you to increase or decrease the audio system’s bass output.

Treble adjust

The treble adjust control allows you to increase or decrease the audio system’s treble output.

Speaker balance adjust

Speaker sound distribution can be adjusted between the right and left speakers.

BASS

TREB

BAL

Speaker fade adjust

Speaker sound can be adjusted between the front and rear speakers.

Seek function

The seek function control works in radio mode.

FADE

Entertainment Systems

Seek function in radio mode

• Press to find the next listenable station down the frequency band.

• Press listenable station up the frequency band.

Scan function

The scan function works in radio mode.

Scan function in radio mode

Press the SCAN control to hear a brief sampling of all listenable stations on the frequency band. Press the SCAN control again to stop the scan mode.

AM/FM select

The AM/FM select control works in radio and tape modes.

to find the next

SCAN

AM/FM select in radio mode

This control allows you to select AM or FM frequency bands. Press the AM control to select from AM selections, and press the FM control to select from FM1 or FM2 memory preset stations.

AM/FM select in tape mode

Press this control to stop tape play and begin radio play.

Radio station memory preset

The radio is equipped with six station memory preset controls. These controls can be used to select up to six preset AM stations and twelve FM stations (six in FM1 and six in FM2).

Setting memory preset stations

1. Select the frequency band with the AM or the FM select control.

Entertainment Systems

2. Select a station. Refer to Tune adjust or Seek function for more

information on selecting a station.

3. Press and hold a memory preset control until the sound returns,

indicating the station is held in memory on the control you selected.

123456

Setting the clock

Press CLK to toggle between listening frequencies and clock mode while in radio mode.

To set the hour, press and hold the CLK control and press the SEEK control:

CLK

TAPE

AMS

•

To set the minute, press and hold the CLK control and press the TUNE control:

•

to decrease hours and to increase hours.

to decrease minutes and to increase minutes.

SEEK

TUNE

SEEK

TUNE

DISCS

CLK

TAPE

AMS

SEEK

TUNE

Entertainment Systems

The CLK control will allow you to switch between media display mode (radio station, stereo information, etc.) and clock display mode (time). When in clock mode, the media information will display for 10 seconds, when the radio is turned on, and then revert to clock information. Any time that the media is changed, (new radio station, etc.), the media information will again display for 10 seconds before reverting back to the clock. In media mode, the media information will always be displayed.

Tune adjust

The tune control works in radio mode.

Tune adjust in radio mode

• Press to move to the next frequency down the band (whether or not a listenable station is located there). Hold the control to move through the frequencies quickly.

• Press frequency up the band (whether or not a listenable station is located there). Hold for quick movement.

Tape select

• To enter tape mode while in radio mode, press the TAPE AMS control.

to move to the next

CLK

Automatic Music Search

The Automatic Music Search feature allows you to quickly locate the beginning of the tape selection being played or to skip to the next selection.

To activate the feature, momentarily depress the TAPE AMS button.

TAPE

AMS

CLK

TAPE

AMS

Entertainment Systems

Then, press either REW (for the beginning of the current selection) or FF (to advance to the next selection). The tape deck stops and returns to play mode when the AMS circuit senses a blank section on the tape.

In order to ensure proper operation of the AMS feature, the tape MUST have a blank section of at least four seconds duration between programs.

Rewind

The rewind control works in tape mode.

To rewind in tape mode, press the REW control.

Fast forward

The fast forward control works in tape mode.

To fast forward in tape mode, press the FF control.

In the tape mode, tape direction will automatically reverse when the end of the tape is reached.

Tape direction select

Press SIDE and 1–2 at the same time to play the alternate side of a tape.

SIDE

1 - 2

REW FF

SIDE

1 - 2

REW FF

SIDE

1 - 2

REW FF

Eject function

Press the control to stop and eject a tape.

DolbyT noise reduction

Dolbyt noise reduction operates only in tape mode. Dolbyt noise reduction reduces the amount of hiss and static during tape playback.

Press the control to activate (and deactivate) Dolbyt noise reduction.

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