Special Service Tools

What’s inside

Identification and chassis

1. 1Foreword and Truck Identificationpp. 1–4
2. 2-1Brakes: General Brake Servicepp. 5–11
3. 2-2Brakes: F- and P-100 Seriespp. 12–19
4. 2-3Brakes: F-250, F-350 and P-Seriespp. 20–38
5. 2-4Brake SpecificationsBrake specifications by model, including lining and drum data, hydraulic brake pedal free travel, vacuum booster hydraulic pressures and parking brake band data.pp. 39–40
6. 3-1Suspension, Steering, Wheels and Tires: General Servicepp. 41–44
7. 3-2Suspensionpp. 45–49
8. 3-3Steeringpp. 50–57
9. 3-4Wheels and Tirespp. 58–61
10. 3-5Suspension, Steering and Wheel SpecificationsFront wheel alignment angles, steering gear torque limits, suspension torques and tire data by truck model.pp. 62–64
11. 4-1Rear Axles: General Axle Servicepp. 65–74
12. 4-2F-100 and P-100 Rear Axle (Ford)pp. 75–83
13. 4-3F-250, F-350, P-350 to P-4000 Rear Axle (Spicer)pp. 84–91
14. 4-4F-100 and F-250 4-Wheel Drive Front Axle (Spicer)pp. 92–97
15. 4-5F-100 to F-250 Limited-Slip Differential (Spicer)pp. 98–101
16. 4-6P-500 to P-5000 Timken Single-Speed Rear Axlepp. 102–108
17. 4-7P-500 Eaton Two-Speed Rear Axlepp. 109–117
18. 4-8Rear Axle SpecificationsAxle adjustments, torque limits, rear axle ratios with gear tooth counts and axle model identification with lubricant capacities.pp. 118–120

Power train and engine

1. 5-1Driveline and Universal Jointspp. 121–127
2. 5-3Clutchpp. 128–131
3. 5-4Clutch SpecificationsClutch identification by engine and truck model, pedal travel, free travel and clutch finger height data.pp. 132–132
4. 6-1Manual Transmissions: General ServiceGroup 6 contents and general transmission service, with a diagnosis guide for noise in each gear, extension housing seal and bushing replacement and cleaning and inspection.pp. 133–134
5. 6-2Three-Speed Light Duty TransmissionRemoval, disassembly, cleaning and assembly of the three-speed light duty transmission, including shift rails, forks, detent springs, the cluster gear and the speedometer drive gear.pp. 135–137
6. 6-3Three-Speed Medium Duty TransmissionService of the three-speed medium duty transmission used on heavier trucks, with disassembly and reassembly steps.pp. 138–139
7. 6-4Three-Speed Heavy Duty TransmissionService of the three-speed heavy duty transmission, including disassembly, inspection and assembly.pp. 140–142
8. 6-5Four-Speed TransmissionService of the four-speed manual transmission used in F-100 to F-350 trucks, with removal, disassembly and assembly.pp. 143–144
9. 6-6Three-Speed Overdrive Transmissionpp. 145–150
10. 6-7Four-Wheel Drive Transfer CaseService of the 4-wheel drive transfer case: disassembly, shift rails, detent balls and shift forks, output shaft bearings, and assembly with oil seal installation.pp. 151–153
11. 6-8Manual Transmission SpecificationsTorque limits for manual transmissions and for the 4-wheel drive transfer case, by nomenclature.pp. 154–155
12. 7-1Heavy Duty Cruise-O-Matic: General Servicepp. 156–160
13. 7-2Heavy Duty Cruise-O-Matic Dual Range Transmissionpp. 161–173
14. 7-3Cruise-O-Matic SpecificationsAutomatic transmission specifications with shift speed charts and clutch plate application by transmission and engine.pp. 174–174
15. 8-1Engine: General Servicepp. 175–193
16. 8-2144 Six Enginepp. 194–215
17. 8-3223 Six Enginepp. 216–240
18. 8-4262 Six Enginepp. 241–264
19. 8-5292 V-8 Enginepp. 265–289
20. 8-6Engine SpecificationsEngine specifications for the 144, 223, 262 and 292 engines: cylinder bore, oil pump data, relief valve spring tension and torque limits for main bearing, cylinder head and other bolts.pp. 290–292
21. 9Ignition Systempp. 293–305
22. 10Fuel Systempp. 306–330
23. 11Cooling Systempp. 331–336
24. 12Exhaust Systempp. 337–340

Electrical and body

1. 13-1Charging System: General Servicepp. 341–346
2. 13-2Generator and Generator RegulatorGenerator removal and installation, disassembly and assembly with field coils, brushes and armature, and regulator adjustment.pp. 347–348
3. 13-442- and 52-Ampere Ford Alternators and RegulatorDescription, in-vehicle adjustment, removal and repair of the Ford 42- and 52-ampere alternators and their regulator.pp. 349–351
4. 13-660-Ampere Leece-Neville Alternator and RegulatorThe 60-ampere Leece-Neville alternator and its regulator: belt adjustment, removal and installation, major repair and charging system specifications.pp. 352–353
5. 14-1Starting System: General ServiceGroup 14 contents and general starting system service, with a starter trouble diagnosis guide, starter relay check, voltage drop test and starter load test.pp. 354–356
6. 14-2Ford, Delco-Remy and Autolite Starters and Specificationspp. 357–360
7. 15Lighting System, Horns and Instrumentspp. 361–382
8. 16-1Ventilating, Heating and Accessories: General Servicepp. 383–386
9. 16-2Ventilating and HeatingHeater and ventilating components: heater blower motor, controls, heater core and hoses, with removal and installation.pp. 387–388
10. 16-3RadioRadio removal and installation, antenna replacement, dial light and tube replacement, with a radio circuit diagram and tube arrangement.pp. 389–390
11. 16-4Heating and Radio SpecificationsBlower motor current draw and torque specifications for the antenna mounting nut and radio mounting plate nuts.pp. 391–392
12. 17-1Body, Doors and Windows: General Body Servicepp. 393–397
13. 17-2Front Sheet Metal and Framepp. 398–401
14. 17-3Doors and Windowspp. 402–408
15. 18Soft Trim: Interior Trim and Seatspp. 409–412

Maintenance and reference

1. 19Maintenance ScheduleMaintenance schedule chart listing engine, transmission, axle, brake, steering, body and lubrication jobs, with notes for 4x4 models and P-Series trucks.pp. 413–414
2. 20-1Maintenance Operations: Enginepp. 415–424
3. 20-2Maintenance Operations: Transmission and Rear Axlepp. 425–428
4. 20-3Maintenance Operations: Chassispp. 429–434
5. 20-4Maintenance Operations: BodyBody maintenance: lubricating latches, hinges and locks, door drain holes, wiper blades and headlight alignment with a wall screen.pp. 435–436
6. 21Lubricant Charts and Specificationspp. 437–440
7. 22Special Service Toolspp. 441–444
8. 23Indexpp. 445–452