DEMO - 1978 Ford Truck Shop Manual - ForelPublishing.com

Copyright © 2012, Forel Publishing Company, LLC, Woodbridge, VirginiaAll Rights Reserved. No part of this book may be used or reproduced in any manner whatsoeverwithout written permission of Forel Publishing Company, LLC. For information write to ForelPublishing Company, LLC, 3999 Peregrine Ridge Ct., Woodbridge, VA 221921978 Ford Truck Shop ManualEAN: 978-1-60371-086-2ISBN: 1-60371-086-8Forel Publishing Company, LLC3999 Peregrine Ridge Ct.Woodbridge, VA 22192Email address: sales@ForelPublishing.comWebsite: http://www.ForelPublishing.comThis publication contains material that is reproduced and distributed under a license from FordMotor Company. No further reproduction or distribution of the Ford Motor Company material isallowed without the express written permission of Ford Motor Company.Note from the PublisherThis product was created from the original Ford Motor Company’s publication. Every effort hasbeen made to use the original scanned images, however, due to the condition of the material;some pages have been modified to remove imperfections.DisclaimerAlthough every effort was made to ensure the accuracy of this book, no representations orwarranties of any kind are made concerning the accuracy, completeness or suitability of theinformation, either expressed or implied. As a result, the information contained within this bookshould be used as general information only. The author and Forel Publishing Company, LLCshall have neither liability nor responsibility to any person or entity with respect to any loss ordamage caused, or alleged to be caused, directly or indirectly by the information contained inthis book. Further, the publisher and author are not engaged in rendering legal or otherprofessional services. If legal, mechanical, electrical, or other expert assistance is required, theservices of a competent professional should be sought.

GROUP AND PART INDEXI VOLUME 1 I CHASSISIDENTIFICATION CODES 10-00-1GENERAL WHEEL AND TIRE SERViCE ., 11-01-1WHEEL HUBS AND BEARINGS - Front (Except Front Drive) 11-10-1- Front Wheel Drive 11-12-1- Rear (Semi-Floating Axle) 11-11-1- Rear (Full Floating Axle) 11-14-1WHEELS AND TIRES - Drop Center Rim ., .. ., ., 11-02-1- Three-Piece Rims 11-04-1- Two-Piece Rims 11-03-1AIR BRAKES - Cam Type 12-48-1AIR/HYDRAULIC INTENSIFIER 12-42-1ANTI-LOCK BRAKE SYSTEMS 12-41-1DISC BRAKES - Light and Heavy Duty Sliding Caliper '" 12-24-1- Heavy Duty 12-25-1DRUM BRAKES - Dual Cylinders, Dual Pistons 12-08-1- Dual Cylinders, Single Piston (Wagner) 12-09-1- Single Cylinder, Dual Pistons 12-02-1- Single Cylinder, Single Piston 12-05-1GENERAL AIR BRAKE SERViCE 12-40-1GENERAL HYDRAULIC BRAKE SERVICE 12-01-1PARKING BRAKE - Anchor Lok, Rear Wheels, Air 12-87-1- Cable Actuated, Rear Wheels 12-70-1- External Band, Transmission Mounted 12-77-1-Internal Shoe, Transmission Mounted 12-79-1-Internal Shoe, Transfer Case Mounted 12-81-1- Maxibrake, Rear Wheels, Air 12-83-1- MGM Stopgard - Rear Wheels, Air· 12-84-1VACUUM BRAKE BOOSTER - Single Diaphragm, Dash Mounted (Bendix) 12-50-1- Single Diaphragm, Dash Mounted (Midland) 12-58-1- Single Diaphragm, Frame Mounted (Bendix) 12-53-1- Single Diaphragm, Frame Mounted (Midland) 12-60-1- Tandem Diaphragm, Dash Mounted (Bendix) 12-52-1- Tandem Diaphragm, Frame Mounted (Bendix) 12-54-1GENERAL STEERING SERViCE ., ., ., .,13-01-1INTEGRAL POWER STEERING GEAR- Ford 13-41-1- Saginaw 13-42-1- Ross HF-54, HF-64 13-44-1- Ross HFB-52 13-45-1MANUAL STEERING GEAR- Recirculating Ball 13-33-1- Worm and Roller 13-34-1POWER STEERING PUMP- Eaton 13-51-1- Saginaw 13-52-1- C II 13-53-1STEERING COLUMN 13-06-1- Floor Mounted Shift Control 13-07-1- Shift Rod Above Tube 13-05-1STEERING LINKAGE - Manual 13-24-1- Power Cylinder/Control Valve ; 13-23-1- Power Gear/Power Cylinder 13-22-1FRONT SUSPENSION - Solid I-Beam 14-20-1- Twin I-Beam 14-21-1- 4-Wheel Drive " 14-22-1GENERAL SUSPENSION SERVICE 14-01-1REAR SUSPENSION - Hendrickson Tandems 14-40-1- Leaf Springs 14-31-1- Reyco 101 Tandem 14-41-1

I VOLUME 1 I CHASSIS IGROUP AND PART INDEX (CONT'D)DRIVE SHAFT - Double Cardan-Type U-Joint 15-66-1- Single Snap Ring Type U-Joint 15-60-1- Single Bearing Cap and BOlt-Type U-Joint and Bolted End Cap TypeU-Joint 15-62-1FRONT DRIVING AXLE - Rockwell 15-33-1- 44F-9F-Dana 15-30-1- 60-7F-Dana 15-32-1GENERAL DRIVING AXLE AND DRIVE SHAFT SERViCE 15-01-1INTEGRAL CARRIER AXLE - Dana 15-05-1LIMITED SLIP DIFFERENTIAL- Dana 15-42-1REMOVABLE CARRIER AXLE - Ford 15-10-1ROCKWELL TANDEM AXLES - Top Mounted 15-52-1SINGLE-SPEED, SINGLE REDUCTION AXLE - Eaton 15-15-1- Rockwell 15-16-1TANDEM AXLE - Eaton 15-50-1- Rockwell 15-51-1TRACTION-LOK LIMITED SLIP DIFFERENTIAL- Ford 15-40-12-SPEED DOUBLE REDUCTION AXLE - Eaton 15-20-1CLARK - 280 Five-Speed Transmission 16-40-1- 390 Five-Speed Transmission 16-39-1CLUTCH 16-02-1FORD 3.03 THREE SPEED TRANSMiSSiON 16-11-1- Four-Speed Over-Drive Transmission 16-30-1FULLER - RT-61 0 Ten-Speed Transmission 16-60-1- RT-613 Thirteen-Speed Transmission 16-63-1- RT-906 Six-Speed Transmission 16-22-1- RT-9509 and RT-12509 - Nine-Speed Transmission 16-66-1- RT-RTO-910, RT-1110 and RT-12510 Ten-Speed Transmissions 16-61-1- RT-RTO-12513 and RT-RTO-9513 Thirteen-Speed Transmission 16-65-1- T-905-B Five-Speed Transmission 16··46-1GENERAL CLUTCH SERViCE 16-01-1GENERAL MANUAL TRANSMISSION SERVICE 16-10-1HYDRAULIC CLUTCH CONTROLS 16-04-1MECHANICAL CLUTCH LINKAGE 16-03-1NEW PROCESS 203 FULL TIME TRANSFER CASE 16-85-1NEW PROCESS PART TIME 205 TRANSFER CASE 16-84-1NEW PROCESS 435 FOUR-SPEED TRANSMISSION 16-25-1NEW PROCESS 542 FIVE-SPEED TRANSMISSION 16-26-1ROCKWELL T-223 - C1 Transfer Case 16-83-1SPICER - Auxiliary Transmission 16·70-1- CM-50 and CM-60 Five-Speed Transmission 16-42-1- RP-8516-3A Sixteen-Speed Compound Transmission 16-64-1- SST-10073A Transmission 16-56-1WARNER T18 FOUR-SPEED TRANSMiSSiON 16-23-1WARNER T19 FOUR-SPEED TRANSMiSSiON 16-24-1AT-540 AUTOMATIC TRANSMiSSiON 17-27-1C6 AUTOMATIC TRANSMiSSiON 17-10-1C4 AUTOMATIC TRANSMiSSiON 17..05-1GENERAL AUTOMATIC TRANSMISSION SERViCE 17-01-1MT-SERIES AUTOMATIC TRANSMiSSiON 17··30-1SHIFT CONTROL LINKAGE 17-02-1NOISE, VIBRATION AND HARSHNESS DIAGNOSiS 18-01-1

foreword ...This 1978 Truck Shop Manual has been prepared to provide informationcovering normal service repairs and maintenance for 1978 Ford Trucksmanufactured in the United States and Canada. It is divided into fivevolumes, each covering a specific major area:Volume 1 - ChassisVolume 2 - EngineVolumes 3 & 4 - Body and ElectricalVolume 5 - Pre-Delivery, Maintenance and Lubrication.Information in each volume is divided into Groups covering a generalsystem. The table of contents on the cover of each volume indicates theGroup title, number, and volume in which each Group is located.For 1978, the basic part numberfor components covered in the Group is alsoincluded in parenthesis after the Group number.Example:Cooling System-------------­General System Coveredin GroupGroup 27~Group Number(8000)~Basic Part Numberfor Cooling SystemComponentsSome components covered within a Group do not have the same basic partnumber. In these cases, more than one basic part number will appear on theGroup index.Example: Gasoline Engines~General SystemCovered in GroupGroup 21 (6000~Basic PartNumber forGasolineEngineComponents& 9000)~Intake andExhaust ManifoldBasic PartNumber OnlyForeasy reference, information in each Group has been divided into smallerunits orParts. There is one Part for each component in the system, as well asa General Service Part in some Groups to cover procedures common toseveral components within the Group. In general, each Part contains theDescription, Operation, Diagnosis and Testing, Removal and Installationand Disassembly and Assembly procedures for the component covered inthe Part. Diagnosis Charts are also included in some Parts to help yousystematically locate and correct problems encountered. In most cases,specifications are included at the end of each Part.

To aid in locating specific items in·this manual, the index at the front ofeachvolume provides an alphabetical listing, with page number, for all Parts inthe volume. The tab locator on the right side ofthis index will help you findthe first page of each Group.On the first page ofeach Group there is an index listing the Parttitle and Partnumber for each component covered within the Group. The first page ofeach Part contains an index to locate service operations covered in thatPart. This Group-Part breakdown is also indicated in the page numberlocated at the top of each page.Example: 11-02-21 = (Group) 11 - (Part) 02 - (Page) 21Metric conversion tables have been included at the back ofeach volume toaid in converting specifications in this manual to the metric equivalent.The descriptions and specifications in this manual were in effect at the timethis manual was approved for printing. Ford Motor Company reserves theright to discontinue models at any time, or change specifications or designwithout notice and without incurring obligation.IMPORTANT SAFETY NOTICEAppropriate service methods and proper repair procedures are essential forthe safe, reliable operation of all motor vehicles as well as the personalsafety ofthe individual doing the work. This Shop Manual provides generaldirections for accomplishing service and repair work with tested, effectivetechniques. Following them will help assure reliability.There are numerous variations in procedures, techniques, tools, and partsfor servicing vehicles, as well as in the skill ofthe individual doing the work.This Manual cannot possibly anticipate all such variations and provideadvice or cautions as to each. Accordingly, anyone who departs from theinstructions provided in this Manual must first establish that he compromisesneither his personal safety nor the vehicle integrity by his choiceof methods, tools or parts....Ford Parts and Service DivisionTraining and Publications Department

10-00-1 Identification Codes 10-00-1Identification CodesPART10-00APPLIES TO ALL MODELSSUBJECT PAGE SUBJECT PAGERATING PLATE 00-1 VEHICLE DATA (Cont'd)VEHICLE CERTIFICATION DECAL 00-1 Exterior Paint Color Codes 00-7VEHICLE DATA 00-1 Max. GVW Codes 00-8Assembly Plant Codes 00-6 Sequential Serial and WarrantyAxle Codes (Front) 00-14 Number Codes 00-6Axle Codes (Rear) 00-13 Transmission Codes 00-12Body Codes 00-12 Truck Series Codes 00-4D.S.O. Codes 00-14 Type/GVW Codes 00-8Engine Codes 00-5 Wheelbase Codes 00-7VEHICLE IDENTIFICATION NUMBER 00-1GENERAL INFORMATIONVEHICLE CERTIFICATION DECALThe Vehicle Certification Decal (V. C.Decal) is attached to the rear face of thedriver's door or door pillar (Fig. I). Theupper half of the decal contains the name ofthe manufacturer, the month and year ofmanufacture and the certification statement.The V.C. Decal also contains theVehicle Identification Number.The remaining information codes on theV. C. Decal are the same as the Truck RatingPlate Codes (Fig. 2). Vehicle codes shownon the Truck Rating Plate are explained inthe following paragraphs.RATING PLATEFig. 2 illustrates a typical TruckRating Plate. On light and medium cowland windshield vehicles, the Rating Plateis mounted on the right side of the cowltop panel under the hood. On strippedParcel Delivery vehicles, the rating plateis placed in an envelope stapled to thedunnage box. On Bronco models, theplate is mounted on the inside panel ofthe glove compartment door. On all othervehicles, the Rating Plate is mounted onthe rear face of the left front door.VEHICLE IDENTIFICATIONNUMBER (VEHICLE SERIAL ANDWARRANTY)The identification number is the firstline of numbers and letters appearing onthe Rating Plate (Fig. 2). The first letterand two numbers indiate the truck seriescode. The letter following the truck seriescode designates the engine identificationcode. The letter following the engineidentification code indicates the assemblyplant at which the vehicle was built. Theremaining numbers indicate theconsecutive unit number (Serial andwarranty number). The charts thatfollow list the various vehicleidentification number codes.VEHICLE DATAThe Vehicle Data appears on theRating Plate on the two lines followingthe identification number. The first threedigits under W.B. designate thewheelbase in inches. The one or twoletters under COLOR identify theexterior paint color (two letters designatea two-tone). The letter and three digitsunder TYPE/G.V.W. designate thetruck model within a series and the grossvehicle weight rating. The letter andnumerals under BODY designate theinterior trim, seat and body type. Thetransmission installed in the vehicle isidentified under TRANS by either anumeric or alphabetical code (if twosymbols appear, the first identifies theauxiliary transmission, if so equipped,and the second symbol identifies the maintransmission). A letter and a number ortwo numbers under AXLE identify therear axle ratio (when required, a letter isalso stamped behind the rear axle code toidentify the front axle capacity). Themaximum gross vehicle weight in poundsis stamped under MAX. G.V.W.A two-digit number is stamped underD.S.O. to identify the district whichordered the vehicle. Ifthe vehicle is builtto special order (Domestic Special Order,Foreign Special Order, LimitedProduction Option, or other specialorder), the complete order number willalso appear under D.S.O. The charts thatfollow Figure 2 list the various vehicle datacodes.

10-00-2 Identification Codes 10-00-2COMPLETE VEHICLES(UNITED STATES)0f=MFD. BY FORD MOTOR CO. IN U.S.A.2 08n7 GYWR: 5750 L8/2608 KG4-0RONT GAWR: 2870L8 REAR GAWR n 181 L1301 KG WITH 1459 KG WITHH78 - 158 nRES H78 - 158 TIRES15 x 5.5K RIMS 15 x 5.5K RIMS~OAT 30 PSI COLDAT 32 PSI COLD""'IIi~t----THIS VEHICLE CONFORMS TO ALL APPLICABLE FEDERAL I 11MOTOR'VEIleLE SAFETY STANDARDS IN EFFECT ON THE DATEOF MANUFACTURE SHOWN ABOVE. 12VEH IDENT NO. E048HAETYPE TRUCKIFRONT GAWR:(CANADA)MFD, BY FORD MOTOR CO. OF CANADA LTD.GYWR:WITHnRESRIMSREAR GAWR:WITHnRESRIMSAT PSI COLD AT PSI COLDTHIS VEHICLE CONFORMS TO ALL APPLICABLE FEDERALMOTOR VEIICLE SAFm STANDARDS IN EFFECT ON THE DATEOF MANUFACTURE SHOWN ABOVEVEH. IDENT. NO. CANADA 8UILT UNITS r-­TYPE UTILITZE SAME TYPE DATA IAS U.S.AINCOMPLETE VEHICLESDECAL APPLIED TOALL CANADIAN BUILTUNITS.THE INCOMPLETE VEHICLE LABEL IS ATTACHED TO A BOOKLET (INCOMPLETE VEHICLE MA!'IL ALl A!'ID SECURED TO ASUITABLE INTERIOR LOCATION FOR INFORMATION USE AT DESTI!'IATlO!'l.16.5 x 6.060(UNITED STATES)THIS INCOMPLETE VEHICLE MFD. BYFORD MOTOR COMPANYTHE AMERICAN ROADDEARBORN, MICHIGAN 48121 ON: 08177VEH. IDENT. NO. E37HHAEoo02GVWR 1000 LB/43~5 KGFRONT GAWR REAR GAWR REAR REAR GAWRTIRESRIMSPSI COLD4000 LB 6700 LB1814 KG 3039 KGI 8,:aR~~!.5EILBKGREAR8.00 - 16.5E16.5 x 6.055MAY BECOMPLETED AS: TRUCK BUS (NOT SCHOOL BUS)FRONT(EXPORT)THIS INCOMPLETE VEHICLE MFD. BYFORD MOTOR COMPANYTHE AMERICAN ROADDEARBORN, MICHIGAN 48121 ON: 08177VEH. IDENT. NO.GVWRI FRONT GAWR I REAR GAWR IREAR REAR GAWRITIRESRIMSPSI COLDMAY BECOMPLETED AS:REARTHIS VEHICLE MFD FOR EXPORTONLY ON DATE SHOWN ABOVENOTE -The same information is on all safety certification decal although the location of the information on the decal may be different.IName of Manufacturerate of Manufacture3 Front Gross Axle Weight Ratings in Pounds (LB) and Kilograms (KG)4 Front Tire Size~Rim Size• ront Tire Cold PSI7 ross Vehicle Weight Rating in Pounds (LB) and Kilograms (KG)(!)Rear Gross Axle Weight Rating In Pounds (LB) and Kilograms (KG)Rear Tire SizeRim Size1 Rear Tire Cold PSI( 1 Vehicle Identification Number (See Fig. 2 for details)13 Vehicle Data (See Fig. 2 for details)GY1813-AFIG. 1 Typical Vehicle Certification Decal

10-00-3 Identification Codes 10-00-3TRUCK SERIES CODECD ®® ENGINE CODE ®CD ASSEMBLY PLANT CODE @ TRANSMISSION CODE0RECOMMENDED MAXIMUM GROSS VEHICLE® @ R,EAR AXLE CODESWEIGHT RATING IN POUNDS@WHEELBASE IN INCHES®MODEL CODE AND GVWINTERIOR TRIM, SEAT AND BODY/CAB TYPESEQUENTIAL SERIAL AND WARRANTY NUMBER @ DISTRICT/SPECIAL ORDER CODESG) EXTERIOR PAINT CODESFRONT AXLE CODES (IF SO EQUIPPED)W1017·LFIG. 2 Typical Truck Rating Plate

10-00-4 Identification Codes 10-00-4TIIUCI...CODESIROIICOCodeU15E·1. THRU E-3IG..........1 llperCollI Cod.--O.scrlptlonU-150 W on 4x4OllcrlptlonE·1...rII.E01 - E100 Club Wagon 5 PassengerE02 - E100 Club Wagon 8 PassengerE04- E100 cargo VanEOS - E100 Window VanE06 - E100 Display VanE·1...rII.E11 811 E150 Club Wagon 5 PassengerE12 812 E150 Club Wagon 8 PassengerE14 814 E150 cargo VanE15 815 E150 Window VanE16 816 E150 Display VanE·.......E20 820 E250 Club Wagon 11 PassengerE21 821 E250 Club Wagon 5 PassengerE22 822 E250 Club Wagon 8 PassengerE23 823 E250 Club Wagon 12 Passenger- 829 E250 Club Wagon 15 PassengerE24 824 E250 cargo VanE25 825 E250 Window VanE26 826 E250 Display VanE-3IGIIrII.E30 S30 E350 Club Wagon 11 Passenger832 E350 Club Wagon 8 Passenger833 E350 Club Wagon 12 Passenger- 839 E350 Club Wagon 15 PassengerE34 S34 E350 cargo VanE35 835 E350 Window VanE36 836 E350 Display VanEcllllIIH "C...!!!" Mod.1E27E250 CutawayE37 - E350 Cutaway.....1Dellv.ryE28 - E250 CutawayE38 - E350 CutawayF-IERIEI COIMImOIAL GASCIIIal.PleIl·UpClitCallI ~la.lc SlrlilF17 F10 F100F16 F14 F150 4x4F19 F15 F150F27 F25 F250F28 F26 F250 4x4Fg7 F35 F350F·SERIES SUPER CAB -F·700 - 7. - COWENnOHAL1·711 - 7a. lUI CHAlIII COWLCodeBalle S.nllL·IERIES -L·SlrllI -CodeF60F61F65F66CodeB60B61CodeF70F82K70K71B70B71J70CONVENnONALCodlOle..1L·I.rllI - Gal .GASChl..lsPlck·UpClbCodeCodeBille SlrlilX17 X10 F100X16 X14 F150 4x4X19 X15 F150X27 X25 F250X28 X26 F2504x4X37 X35 F350F-IOO - CONVENnONAL - GASB-tOO - COWL BUS - GASp·a-GASBa.1e S.rII.F600F600F600 4x4F600 4x4Ba.le SlnllB600B600Balle SlrlllF700 (Gas)F800 (Gas)F7000 (Diesel)F7000 (Diesel)B700 (Gas)8700 (Gas)B7000 (Diesel)Balle SerlllP600Balle SerlllA90 LT-900 (LTL 9000 080)L·IERIEI -CONVEmOIAL {Contid)F80. F81 L800Q80CTsOooF90 F91 L900 CY1700-DCod.Balle IIrlllL·Slrlll - 011111LT·lIrllI -K80K81K90Ga.L8000L8000L9000T80. T81 LT800TOO. T91LT900LT·S.rlll - 01.111U80. U81 LT8000U90. U91 LT9000LTS·S.rllI - GalLTS-SlrllS -N·SERIES -V80. V81 LT8800V90. V91. V92 LTS900Dle..1Y80. Y81 LT88000Y90. Y91. Y92 LTS9000SHORT COIIVEmOMALCod.N·Serlll- Gal.Ballc SlrIIIN60N600N61. N62 N600N70. N71 N700N75. N76 N750N80. N81 N800N90, N91 N900N·S.rlll - 01...1NT·llrlll -R70. R71 N7000R80. R81 N8000ROON9000Gilsao,881NT800590. S91 NT900NT·Slrlll - 0111.1C·IERIEI -W80. W81 NT8000W90. W91 NT9000.£H!.C·llrllI- GalceoC61C70C75C80COO. C91C·I.rlll - 01.111CT·Slrlil -LOW nLT CAli!alle I.rlilC600C600C700C750C800C900070 C7000080 C8000GilL80CT800L90. L91 CT900CT·llrlll - 01...1

10-00-5 Identification Codes 10-00-5ElGlIE CODESEIG.E CODESGAS ElellE CODES--IROICOCode Engl.e CID Litre Cyl.H 351-2V 5.8L 8S 400-2V 6.6L 6GAS EIlIIE CODE$-LT. TRUCK (F-100 THRU F-350)7 7 0 0 4 8Code Engl. CID Litre Cyl.B 300-1V 4.9L 6G 302-2V 5.0L 8Z(DSO)DIESEL ENGliE CODES - CATERPILLARH 351-2V 5.6L 6 CODE CID MODEL H.P. RPMS 400-2V 6.6L-6B 636 3208 175HP 2800J 460-4V 7.5L 8D 636 3208 210HP 2800GAS EIGIIE CODE~EDIUM TRUCK (F AND B-600) a 636 3208 200HP 2800Colle E.glne CID Litre Cyl.H 893 3406 280HP 2100J 893 3406 HT 280HP 1900B 3QO-1V H.D. 4.9L 6 M 893 3406 325HP 2100D 33()..2V X.D. 5.4L 8 C Special Order CaterpiJIar DSOE 361-4V X.D. 5.9L 80 330·2V LPG (DSO) 5.4L 8W 361·4V LPG (D50) 5.9L 8 DIESEL ENGINE CODES - CUMMINSM 361-2V LPG (DSO) 5.9L 8 CODE CID MODEL H.P RPMX 391-4V LPG (OSO) 6.4L 8J 3QO·2V LPG (OSO) 4.9L 61 855 NH230 230HP 2100Z (DSO) 9 855 NTC230 230HP 2100X 855 NTC230 230HP 1900-GAS ENGIIE CODES-EXPORT LOW COMP. F 855 NTC250 250HP 21005 855 NTC250 250HP 1900Code Engine CID Litre Cyl.K 855 NTC270PT 270HP 21002 300-1V 4.9L 6 V 855 NTC290 290HP 21004 330·2V X.D. 5.4L 8 U 855 NTC290 290HP 19005 361-2V X.O. 5.9L 8 8 855 NTC350 320HP 21008 351-2V 5.8L 8 3 855 NTC350 320HP 1900'GAS EIGI. CODES--E·100 THRU E-350 (ECONOLINE AND CLUB WAGON)L 855 NTC350 350HP 2100P 855 NTC350 350HP 1900Code Engine CID Litre Cyl. G 903 V903 295HP 2600B 3OO-1V 4.9L 6SSpecial Order Cummins OSOH 351-2V 5.8L 8A 460-4V 7.5L 8C 300-1V (3x6 4.9L 6DIESEL ENGINE CODES - DETROITFuel Economy) Code CID Model H.P. RPMGAS ENGl. CODES-7OG-1OG SERIES AND NIOG-CIOG PARCEL1 318 6V-53TT 210HP 25000 318 6V-53TT 225HP 2500CodeLow 2 426 671N 228HP 2100Compo Engine CIO Litre Cyl. 7 568 8V71N 263HP 2100Code 6 568 8V71N 280HP 2100G 300-1V H.D. 4.9L 6T 568 8V71N 304HP 21000 4 330-2V H.D. 5.4L 8N 568 8V71T 308HP 2100E 361-4V H.D. 5.9L 8E 568 8V71T 335HP 2100F 361-4V H.o. 5.9L 8Y 568 8V71T 350HP 2100J 475-4V 7.8L 84 568 8V71TT 305HP 1950K 477-4V S.D. 7.8L 8ASpecial Order Detroit DSOL 534-4V S.D. 8.8L 8 Z Special Order DSOZ OSO R Delete Engine (Glider) DSOCY1701-D

10-00-6Identification Codes10-00-6ASSEMBLY PLANT AND SEQUENTIAL SERIAL AND WARRANTY NUMBER CODESCodeAatmbly P1.nt•...................O.kvllieC•••••••••••••••Ontarto TruckE •••••••••••••••••••M hHLoralnK ...•.....••.....Klna. CityL ..•• , ..••....Mlchlg.n TruckN .•••...••...........NorfolkR •••••••••••••••.••S.n JOIISAllen PlrkU.••..•••...•••.••.LoulsvllleV •••••••••••••Kentucky Truck4 8SEQUENTIAL SERIAL AND NUMBER WARRANTY NUMBER CODES(1m MODEL YEAR)8nmco. LT Truck (F-100 Thru F-350)-CodeMonth.nd VearAEO, 000 - AF9, 999 August, 1977-AGO, 000 - AH9, 999 September, 1977AJO, 000 - AK9, 999 October, 1977BAO, 000 - BB9, 999 November, 1977BCO, 000 - BOO, 999 December, 1977BEO, 000 - BF9, 999 January, 1978BGO, 000 - BH9, 999 February, 1978BJO, 000 - BK9, 999 March,1978CAO, 000 - CB9, 999 April, 1978ceo, 000 - C09, 999 May, 1978CEO, 000 - CF9, 999 June, 1978CGO, 000 - CH9, 999 july, 1978CJO, 000 - CK9, 999 August, 1978F- and .-100 (Kentucky Truck Plant)-CodeMonth and VearAEO, 000 - AE4, 999 August, 1977-AGO, 000 - AG4, 999 September, 1977AJO, 000 - AJ4, 999 October, 1977BAO, 000 - BA4, 999 November, 1977BCO, 000 - BC4, 999 December, 1977BEO, 000 - BE4, 999 January, 1978GBO, 000 - BG4, 999 February, 1978BJO, 000 - BJ4, 999 March, 1978CAO, 000 - CA4, 999 April, 1978CCO, 000 - CC4, 999 May, 1978CEO, 000 - CE4, 999 June, 1978CGO, 000 - CG4, 999 July, 1978CJO, 000 - CJ4, 999 August, 1978E-100 Thru E-350 (Econollne and Club Wagon)-CodeMonth and VearAEO, 000 - AF9, 999 August, 1977-AGO, 000 - AH9, 999 SeptembE~r, 1977AJO, 000 - AK9, 999 October, 1977BAO, 000 - BB9, 999 November, 1977BCO, 000 - BD9, 999 December, 1977BEO, 000 - BF9, 999 January, 1978BGO, 000 - BH9, 999 February, 1978BJO, 000 - BK9, 999 March, HI78CAO, 000 - CB9, 999 April, 1978CCO, 000 - CD9, 999 May, 1978CEO, 000 - CF9, 999 June, 1978CGO, 000 - CH9, 999 JUly, 197flCJO, 000 - CK9, 999 August, 1!~78700Thru _0 Sertes and N600 --CodeC600 PlrcelMonth and VearAE5, 000 - AF9, 999 August, l!J77-AG5, 000 - AH9, 999 September, 1977AJ5, 000 - AK9, 999 October, 1977BA5, 000 - BB9, 999 November 1977BCS, 000 - BOO, 999 December, 1977BES, 000 - BF9, 999 January, 1978BGS, 000 - BH9, 999 February, "1978BJ5, 000 - BK9, 999 March, 19"78CAS, 000 - CB9, 999 April, 197flCCS, 000 - COO, 999 May, 1978CE5, 000 - CF9, 999 June, 197flCGS, 000 - CH9, 999 July, 1978CJ5, 000 - CK9, 999 August, 1978-Job #1-1978 Model YearCY1731-C

10-00-7 Identification Codes10-00-7WHEEL BASE AND EXTERIOR PAINT CODESWHEEL BASE (1ft INCHES)Branco104F-100 Dru F-350117 150133 155137 161139 167140EXTERIOR PAINT COLOR CODE (2 CODES IF TWO TOftED)Refer To Volume 3 &4, Group 30-00 For AComplete Usting of1978 Truck Exterior Paint Codes.F- Ind 1-100134 182 212146 188 222156 194 242158 198 260176E-100 Dru E-350 (Econallne Ind Club Wlgon)124138158700 Dru 1000 SlrllI Ind ~ ClOD Plrcel099 146 167 203111 148 174 204124 150 175 206134 153 176 212135 154 184 220136 155 185 222137 158 186 236138 161 188 242143 162 194 250144 166 202 260280CY1814-A

10-00-8 Identification Codes 10-00-8TYPE/GVW AND MAX. G.V.W. CODES7 7 0 0 4 8• •BRONCO F·2S0 (414)E!!!! G.V.W. Plcap Ch.1I11Codl C.b Codl ~U150 6100U151 6400F263 F283 6700U152 6550 F264 F284 7300U153 6010 F265 F285 8100F266 F286 8400F·100 (412)F·250 (414) SUPER CABPlclalp Ch.1111G.V.W. Pickup Ch.1I11£!!!!. C.b Codl£!!!.. C.b CodeG.V.W.Fl00 F170 4900Fl0l F171 4800X260 X280 7100Fl06 F176 5400X261 X281 7600Fl07 Fl77 5600X262 X282 8500Fl0N F17N 5200 F·350 (412)Pickup Ch.1I11F·100 (412) Su,er C.b Code ~ ~Plclalp Ch.1I11F370 6600~~ ~F351 F371 6750Xl08 X178 5700F372 8000F353 F373 8200Xl09 X179 5800F374Xl0N X17N 52008300F375 8500F376 8900F·150 (412) F377 9500F378 10,000Pickup Ch.1I11~ F354 8300Codl Clb Code F356 8900F150 Fl90 6050 F359 9900F151 F191 6150 F37N 10,250F37P 9100F150 (412) Super ClbF·350 (412) SUPER CABPlcllup Ch.1I11Code Clb CodeG.V.W. Pickup ChllillCode Clb CodeG.V.W.X150 X190 6050X152 X192 6200 X359 X379 9200X153 X193 6400 F-800 (412)'·150 (414)CodlG.V.W.F600 16,000Pickup ChllillG.V.W. F602 19,200~ C.b Code F603 14,000F140 F160 6050 F604 16,000F141 F161 6300 F605 17,400F142 F162 6500 F606 17,400F611 20,200F-:~~ 1~14) SUPER CABF612 21,000PI.p Chlllil F613 22,000£!!!!.. ~ G.V.W. F614 22,000F615 23,000X143 X163 6400 F616 24,000F:250 412}F61817 900 U-Haulf-lOO 414Pfeil, Chllill~ C.b Code ~ ~ G.V.W.F250 F270 6200 F650 17,200F251 F271 6800 F660 21,700F252 F272 7700 F661 24,000F253 F273 7900B. BUS (412)F·250 412 SUPER CABPlcllup Chlllil~ ~~ 8600 17,400£!f!. Clb Code 8601 19,200X251 X271 6800 8602 19,200X254 X274 6300 8610 19,700X255 X275 6550 8611 20,200X256 X276 7800 8613 21,000X257 X277 7050 8615 22,000X258 X278 7600 8617 24,500X259 X279 8100 8618 22,160X27N 7500E·100 CLUB, CUSTOM, AND CHATEAU WAGONSConv.CodeG.V.W.E010 5500E012 5900E013 5700E020 5900E021 6000E·150 CLUB, CUSTOM, AND CHATEAU 'WAGONSConv. Super Conv. Sul;rCode ~ G.V.W. G..W.- 5110 - 6025- 5111 - 6200El12 5112 6200 6400E113 5113 6400 6600E114 5114 6500 6800E120 5120 6300 6200- 5121 - 6400- 5122 - 6600E123 5123 6500 6800E124 - 6700 -E·250 CLUB, CUSTOM, AND CHATEAU 1NAGONSConv. Super Conv. s'U',lrCode ~ G.V.W. ~5200 76005201 7800- 5202 - 8000E203 5203 7600 8300E204 5204 7900 8500E205 8100 E206 - 8500 -E207 - 8900 -5210 70005211 72005212 7400- 5213 - 7700E214 5214 6800 8000E215 7100 E216 - 7800 -5220 6900- 5221 - 7200E222 5222 8200 7400- 5223 - 7700E224 5224 6900 8000E225 5225 7100 8300E226 7300 E227 7500 E228 - 7700 -5230 76005231 7800- 5232 - 8000E233 5233 7600 8300E234 5234 7900 8500E235 8100 E236 8500 -E237 - 8900 -5290 70005291 79005292 81005293 8200- 5294 - 8300- 5295 - 8400E·350 CLUB, CUSTOM, AND CHATEAU V~AGONSCode (Suplr)G.V.W.5300 80005301 83005302 88005303 90005304 93005320 79005321 81005322 84005323 87005324 91005330 80005331 83005332 88005333 90005334 93005390 86005391 88005392 91005393 9400CY1703-D

10-00-9 Identification Codes10-00-9TYPElGVW AND MAX. GVW CODES -CONTINUEDE·100 ECONOLINE CARGO. WINDOW. AND DISPLAY VANSE·150 ECONOLINE CARGO. WINDOW. AND DISPLAY VANSConv. Super Conv. SuperCargo Cargo Window WindowCode Code Code CodeE141E1428140 S150E151E152E·250 ECONOLINE CARGO, WINDOW, AND DISPLAY VANSConv. COnY. Conv.Cargo Window DisplayCode Code CodeE040 E050 E060E041 E051 E061Conv.DisplayCodeSuperDisplayCodeG.V.W.(Conv.)8160E161 6100E162 6300G.V.W.51505750G.V.W.(Super)6050Conv. Super Conv. SuperCargo Cargo Window WindowCode Code Code Code--5240 S250E241 5241 E251 82518242 8282E243E253E244E254CodeG.V.W.E270E·250 CUTAWAY VANE·350 ECONOLINE CARGO, WINDOW. AND DISPLAY VANSG.V.W.8400Conv. Super Conv. SuperCargo cargo Window WindowCode Code Code CodeS340 53505341 53515342 5352E343E344E345CodeE370E371E372E374E375E376E353E354E355Conv.DisplayCodeSuperDisplayCodeG.V.W.(Conv.)S260E261 8261 7550S262E263 6750E264 8250Conv.DllplayCodeE363E364E365CodeE280E-250 CUTAWAY PARCEL DELIVERY VANSuperDisplayCodeS360S3615362G.V.W.(Conv.)855095009800E·350 CUTAWAY VAN E·350 CUTAWAY PARCEL DELIVERY VANG.V.W.8700 8ingle Rear9650 Single Rear8750 Dual Rear11,000 Dual Rear10,000 Dual Rear10,100 Dual RearCodeE380E382E383E384Code7700G.V.W.8750 Dual Rear10,000 Dual Rear10,500 Dual Rear9800 Dual RearG.V.W.(Super)650071007900G.V.W.(Super)810091009400CY1704-D

10-00-10 Identification Codes10-00-10TYPE/GVW AND MAX. G.V.W. CODES -CONnNUEDB·700 BUS CHASSIS COWL - GAS L·. - GAS (Cont'd) LT·IOO - GAS (Cont'd) LTS·. - GAS (Cont'd)- -Cod. G.V.W. Cod. G.V.W. Cod. G.V.W. Cod. G.V.W.B702 23,160 F806 31,000 T911 60,000 V905 50,000BJ05 25,080 F807 32,000 Tg14 44,800 V906 50,000B706 24,500 F808 34,000 T915 48,000 V907 52,000B707 25,250 F809 35,000 T916 52,000 V908 54,000B708 27,080 F811 31,800 T917 58,000 V909 56:000B709 26,500 F812 27,000 V911 58,000B710 27,250 LT·8000 - DIESEL V912 60,000L·IOO- GASU800 39,000V913 62,0008-7. BUS CHASSIS COWL - DIESEL F900 25,500 U805 46,000 V914 64,000J707 26,500 F902 27,500 U806 50,000 V915 61,(00J708 27,250 F905 31,000 U807 50,000 V918 41,COOJ709 27,080 F906 32,000 U808 54,000 V920 48,000F·700- GASF908 34,000 U809 60,000F909 35,000 U810 55,000LT·...-GASF701 21,000A900 44,8,00F703 23,000F913 31,800 U812 62,000 A901 46,000F912 23,000 U811 56,000F704 24,000U815 41,000 A902 48,000L·a.-GASF706 25,500 U816 44,800 A903 50,000F7lJ7 25,000 K802 25,500 U817 61,000 A904 50,000F708 27,000 K803 27,000 A905 52,000F709 27,500 K805 31,000LT·9000 - DIESELA906 54,000K806 32,000 U900 43,000 A907 58,000F-800- GAS K807 34,000 U903 46,000 A908 60,000F820 23,000K808 35,000 U904 50,000K812 23,100 LTS·9000 - GASF821 25,000U905 50,000F822 25,500K813 31,800 U906 54,000 Y900 44,800F823 27,000U907 58,000 Y901 58,000L·9000- GASF824 27,500U908 60,000 Y902 60,000F825 29,000 K902 32,000 U909 60,000 Y903 50,000F826 31,000 K904 35,000 U910 62,000 Y904 50,000F827 32,000 K907 28,000 U911 52,000 Y905 52,000K908 31,000 U912 62,000 Y906 54,000F·7000 - DIESEL U913 72,000 Y907 56,000LT·.-GAS U914 44,800K703 23,000Y908 61,000K705 24,000 T804 43,000U915 61,000 Y909 58,0100K706 25,500 T806 46,000U916 48,000 Y910 60,000K707 27,500 T811 41,000U917 58,000 Y911 62,000K708 25,000 T812 44,800U918 74,000 Y912 62,0100U919 76,000K709 27,000Y913 72,000LT-.-GASK710Y91421,00074,0100LTS·.-GAST900Y9l539,00076,000L-800-GAS T902 41,000V804 46,000 Y916 78,000F800 23,000 T904 43,000V809 41,000 Y917 77,100F80l 25,000 T906 46,000V810 44,000 Y918 70,000F803 25,500 T907Y91950,00048,000LTS-900 - GASY920 79,100F804 27,500 T908 50,000F805 29,000 T909 54,000V900 39,000 Y921 81,100V904 46,000CY170~-D

10-00-11Identification Codes 10-00-11TYPE/OVW AND MAX. G.V.W. CODES -(CDNnNUED)e-.-GASLTS·IOOO - DIESEL N·too-GAS NT·IOOI - DIESELCode G.V.W. Code G.V.W. Code G.V.W.Y800 39,000 N900 25,500W800 39,000Y804 46,000 N902 27,500W803 56,000Y805 so,000 N905 31,000WB04 62,000Y806 so,000 N906 32,000W805 46,000Y807 52,000 N908 34,000W806 50,000Y808 54,000 N909 35,000W~07 50,000Y812 60,000 N911 23,100W808 54.000Y814 64,000N912 31,800W812 41,000Y815 55,000 N·7. - GAS W814 44,800Y816 56,000 W815 55,000Y817 61,000 R702 23,000 WB16 60,000Y818 41,000 R704 25,500 W817 61,000Y819 62,000 R705 25,000R707 27,500 NT-9000 - DIESELN-IOO - GAS R708 27,000W903 46,000N601 16,500 R710 21,000WOO4 50,000N602 19,500 R712 24,000WOO6 54,000N603 21,500N-S.-GAS W907 43,000N612 23,000 W910 58,000N615 24,000 R802 25,500 W911 44,800N620 22,000 R803 27,500 W912 48,000R805 31,000 W913 52,000N-700 - GAS R806 32,000 W914 60,000R807 34,000 W915 62,000N702 23,000 R808 35,000 W916 72,000N703 25,500 R810 23,100 W917 74,000N705 27,000 R811 31,800 W918 76,000N706 27,500N707 25,000 N-9000 - GAS P-800 - GASN710 21,000ROO2 32,000N712 24,000 P600 15,000R904 35,000P603 12,000N-Ioo- GAS R906 28,000P602 17,000ROO7 31,800N800 23,000P605 17,000N801 25,000 NT·IOO - GASC·880 - GASN803 25,5005804 43,000Na04 27,500 C602 17,0005806 46,000N805 29,000Cbl2 23,0005811 41,000N806 31,000C613 24,0005812 44,800N807 27,000C617 21,200N808 34,000 NT-IOO - GASN813 31,800C-7OO - GAS39,000C700 24,000N815 35,000 5902 41,000C701 25,0005904 43,000C702 25,5005906 46,000C703 27,0005907 50,000C704 27,5005909 54,000C705 21,0005914 44,800N814 32,000 59005915 48,0005916 52,0004 8CodeG.V.W.C802 27,500C803 31,000C804 34,000C807 25,100C·_-GASC904 25,100C906 31,000COO7 32,000C910 34,000C912 37,000C914 25,100C915 39,000C·7.-GA$0701 21,0000702 25,5000703 24,0000704 25,0000705 27,5000706 27,0000708 23,000C-IOOO -GAS0802 27,5000806 25,1000807 32,0000808 35,000CT·_- GASL801 42,860L803 44.000L805 45,000L807 46,000L808 48,000L809 50,000CT·IOO- GASL901 42,860Loo2 44,000L903 45,000L9,4 46,000L915 48,000L916 50,000L917 52,000L918 54.000L919 50,000CT·9000 -DIESEL0801 42.8600803 45,0000804 44,0000805 41,0000807 46,000Q808 48,0000809 50,000CY1706·0

10-00-12 Identification Codes 10-00-12BODY AND TRANSMISSION CODes4 8.ODY CODESRefer to Volume 3 & 4. Group 30-00 for a complete listing of 1978Truck Body Codes.700 THAU _ SERIES .ND ....ceoo PARCELTRANSMISSION CODESCodeAUXILIARY TRANSMISSIONfORD HEAVY AND EXTRA·HEAVY TRUCK -CodeDescriptionEconollne - Club WlgonC . . . . . .. . . .. . .. . . . .. 3-Speed ManualG. . . . . . . . . . . . . . . . . .. Cruisomatic8 . .. . . .. .. .. .. . . . ... Clark Manual 4-Speed OverdriveBronco - F·100·350G . . . . . . . . . . . . . . . . . .. AutomaticC . . . . . . . . . . . . . . . . . .. Ford Manual 3-SpeedFWarner 4·Speed ManualA . . . . . . . . . . . . . . . . . .. New Process 4-Speed Manual8 . . . . . . . . . . . . . . . . . .. Clark Manual 4-Speed OverdriveFa••L . .. . .. . .. .. .. . .. ... Allison AT540P ','. . . . . . . . . . . . . . . . .. Warner T-19 4-SpeedG. . . . . . . . .. . . . . . . . .. C-6 Automatic4 .. . . . . . . . . . . . . . . . .. Clark 280-VO Overdrive 5·Speed2 '" . . . . . . . . . . . . . . .. Clark 282-V Direct 5-SpeedM. . . . . . . . . . . . . . . . . .. Clark 285-V Direct 5-SpeedA . . . . . . . . . . . . . . . . . .. New Process 435 4-Speed9 . . . . . . . . . . . . . . . . . .. New Process 542-FD Direct 5·Speedo................... New Process 542-FL Direct 5·SpeedDe.crlptlonPARCEL4 "," Spicer 7231-07 Spicer R-8341-28 .. . . Spicer 70410•• 01...1LAllison AT-540 Automatic8 Allison MT-640 AutomaticH H Allison MT-650Automatic4 Clark 280 5-Speed2 2 Clark 282 5-SpeedM M Clark 285 5-Speed6 Clark 390 5-SpeedZ Clark 397 5-SpeedIFord C-6 AutomaticC C Fuller RT-61 0 10-SpeedP P Fuller RT-613 13-SpeedX Fuller T-905A 5-Speed0 Fuller T-9058 5-Speed3 Fuller RT-906 6-SpeedV Fuller RT-910 10-Speed5 Fuller RTO-910 1O~Speed 0/09 Fuller RTO-958LL 8-Speeda Fuller RT-111 0 10-Speed8 Fuller RT-9509A 9-Speed4 Fuller RT-9513 13-SpeedJ Fuller RTO-9513 13-Speed 0/0.:.- E Fuller RT-12510 10-SpeedF Fuller RTO·12513 10-Speed 0/0T Fuller RTOF-12513 10-SpeedANew Process NP-435 4-Speed9 New Process NP-542-FD 5-Speed0 New Process NP-542-FL 5-SpeedTNew Process NP-542-FO 5-SpeedG Spicer SST·1007-2A 7-SpeedA Spicer SST·1010 10-Speed7 7 Spicer CM-5052A 5-Speed0 0 Spicer CM-5252A 5-SpeedB 8 Spicer CM-6052A 5-SpeedK K Spicer CM-6052B 5-SpeedS S Spicer CM-6052C 5-SpeedY Spicer RP-85163-A 16-SpeedR Delete Transmission (Glider)CY1707-D2

10-00-13Identification Codes10-00-13AXLE CODES (REAR)BRONCO AND F·100 THRU F·350Code Description #Capaclty Ratio12 Ford 2900 ·3.0006 Ford 2900 2.7514 Ford 3750 3.0015 Ford 3750 3.2516 Ford 3750 3.5013 Ford 3750 2.75H2 Ltd. Slip 3750 3.50H9 Ltd. Slip 3750 4.11H4 Ltd. Slip 3750 3.2523 Dana 61 5300 3.3122 Dana 61 5300 3.0724 Dana 60 5300 4.1037 Dana 60 5300 3.5438 Dana 60 5300 3.73B4 Dana 60 Limited Slip 5300 4.10C7 Dana 60 Limited Slip 5300 3.54C8 Dana 60 Limited Slip 5300 3.7327 Dana 70 7400 4.1028 Dana 70 7400 4.5636 Dana 70 7400 3.73D7 Dana 70 Limited Slip 7400 4.10E-100 THRU E-350 (Non-Locking)Code Description #Capaclty Ratio01 Ford 2750 3.0005 Ford 2750 2.7513 Ford 3750 2.7514 Ford 3750 3.0016 Ford 3750 3.5015 Ford 3750 3.2522 Dana 5300 3.0723 Dana 5300 3.3138 Dana 5300 3.7324 Dana 5300 4.1036 Dana 7400 3.7327 Dana 7400 4.10E·100THRU E·350 (Loclllng)Code Description #Capaclty RatioH2 Ford 3750 3.50H4 Ford 3750 3.25H7 Ford 3750 3.00C8 Dana 5300 3.73D7 Dana 7400 4.10F- AND B·IOOCode Description #Capaclty Ratio41 Rockwell D-140 13000 5.8342 Rockwell D-140 13000 6.2062 Rockwell F-l06 15000 6.2064 Rockwell F-l06 15000 6.8066 Rockwell F-l06 15000 7.20F2 Eaton 15201 15000 2-Speed 5.83/8.12F3 Eaton 15201 15000 2-Speed 6.33/8.8152 Rockwell H-l72 17500 5.8353 Rockwell H-l72 17500 6.1754 Rockwell H-l72 17500 6.8355 Rockwell H-l72 17500 7.17El Eaton 16244 17500 2-Speed 5.57/7.75E2 Eaton 16244 17500 2-Speed 6.17/8.58E3 Eaton 16244 1750

10-00-14Identification Codes 10-00-14FRONT AXLE ANOO;S.O. CODES7 7 0 0DISTRICT SALES OFFICE (DSO) CODEDSO - FSO - PrO (DOMEmC. FOREIGN AND SPECIAL ORDER)The D.S.O. space will show atwo digit code number of the districtwhich ordered the unit (see chart below). This code will appear onall units-domestic or export. If unit is built on aD.S.O., E.S.O.,P.T.O., (special orders) the complete order number is under theD.S.O. space ....r the district code.DISTRICT CODESFRONT AXLE CODES (Not AppllCible On E·100 Thru E·350)Bronco .nd F·100 Thru F-350AdjultlbleWItIISturlng Col. Power CodeAnd Power Steering Steering --F· Ind 1-800PfSteerfngDeilleFront Axlef~erlng- J - Power SteeringI R 9 3800 #Dana-6OFE N 5 3550 #Dana 44-9FA - - Adjustable Steering Col.and Power SteeringW/PoWerSturlngCodef!!!t!!~A J - Power Steeling- K 2 5,500 STD, F-600- L 3 6,000 STD, B-6000 M 4 7,000E N 5 7,500700 THRU 1000 SERIES AND N-800 - C·. PARCELAxleSubllllullonPowerSteeringAxle Subll. Dele" PowerFront.nd Power or Ma••1AxleSteering S"erlng --V K A 2 5,500#V J Z 1 5,000#C L W 3 6,000#0 M X 4 7,000#E N 0 5 9,000#G P a 7 '12,000#H - - 8 12,000# SteerEase- S B - 16,000#T F - 18,000#U I - :20,000#- - - 6 4,700#11 Boston 41 Chigago 71 Los Angeles Ford of C.n.d.12 Buffalo 42 Cleveland 72 san Jose Mercury Re,lons ~!!!!!!13 New Vort< 43 Milwaukee 73 Salt Lake CityA1 CentralB1 Central14 Pittsburgh 45 Lansing 74 SeattleA2 EasternB2 Eastern15 Newark 46 Indianapolis 75 PhoenixA3 AtlanticB3 Atlanltic16 Philadelphia 47 Cincinnati 76 Denver A4 Midwestern B4 Midwestern17 Washington 48 DetroitA6 WesternB6 Western21 Atlanta 52 Dallas 83 Government A7 Pacific B7 Pacific22 Char10tte 53 Kansas City 84 Home Office Reserve 12 Export 12 Exp0l123 Memphis 54 Omaha 85 American Red Cross24 Jacksonville 55 St. Louis 89 Transportation Services25 Richmond 56 Davenport 87 Body CompanyNote: EXPORT ALPHABETICAL 126 New Or1eans 57 Houston28 Louisville 58 Twin Cities 90's ExportCV1702-D

11-01-1 Wheels and Tires 11-01-1General Wheel and Tire Service 11-01Wheels and Ti res -Drop-Center Rim 11-02Wheels and Tires -Three-Piece Rim 11-04Wheels and Tires -Two-Piece Rim 11-03Wheel Hubs and Bearings -Front (Except Front Drive) 11-10Wheel Hubs and Bearings -Front Wheel Drive 11-12Wheel Hubs and Bearings Rear(Semi Floating Axle) 11-11Wheel Hubs and Bearings -Rear (Full Floating Axle) 11-14General Wheel and Tire ServicePART11-01APPLIES TO ALL MODELSSUBJECT PAGE SUBJECT PAGESAFETY 01-2 Front Wheel Bearing Maintenance 01-10DIAGNOSIS AND TESTING Wheel and Tire Checking Procedure 01-8Diagnosis Guides 01-3 ADJUSTMENTS (Cont'd.)ADJUSTMENTSWheel and Tire VibrationBalancing Wheels Diagnosis Procedures 01-8Dual Wheels and Wheels of Trucks CLEANING AND INSPECTION 01-9Equipped with Full Floating Axles 01-9 Aluminum Wheels & Rims 01-9Rear Wheels of Trucks with Front Wheel Bearings 01-9Semi-Lock Differential 01-8 Rim &Wheel Maintenance 01-11Single RearWheels F-1 00-F-350, Safety Precautions 01-11E-100-E-350, Bronco 01-8 Tires 01-9Wheels 01-9

11-01-2General Wheel and Tire Service111-01-2SAFETYWhen replacing tires, use the samesize, load range and construction type(bias, bias belted or radial) as originallyinstalled on your vehicle. When replacingwheels, use original equipmentmanufacturers wheels or equivalentavailable from your Ford dealer withequivalent capacity, width, offset andmounting configuration as thoseoriginally installed on your vehicle. Useofimproper replacement wheels and tiresmay adversely affect ride, handling, loadcarrying capacity, bearing life, tireclearance to body and chassiscomponents, vehicle ground clearance,vehicle width and brake cooling.SAFETY PRECAUTIONS WHENSERVICING TRUCK TIRESCAUTION AND SAFETY FIRSTare bywords when handling tires,particularly truck tires. Careful attentionto the suggestions that follow mayprevent crippling injuries, or even death.Make it a rule to respect the terrific forcecontained in an inflated tire. You may beglad some day that you did.Prepare for any tire repair operationin a safe and efficient way. In changingtires on drop center wheels, remove thewheel and tire from the truck, aschanging tires with the wheel on thetruck is hazardous, more difficult, andtakes more time. In servicing of all tiresuse caution not to drop them (or thewheels or assemblies) on the feet, handsor body, or heavily on the floor (Fig. 1).Practice good methods oflifting; use yourlegs as well as your arms and your body.This will help to prevent painful, internalinjury. When carrying tires or wheelsdon't step in oil or grease. Keep the floorclean and dry.the pressure as much as you possibly canby pushing the valve core plunger. Onlythen should you remove the valve core.Keep your eyes away from the valve: Fig.2 shows the safe way to do it.FIG. 2 Safe Air RemovalF1853·BDemounting tires from wheels or rimsrequires special care. Tires on drop centerrims are best handled on a wheel holder,or tire-changing machine (Fig. 3).As with the drop-center rims, becertain on split-rim assemblies that all airis out before unlocking a rim or ring. Usespecial care when using tire irons. Gripthem firmly and keep them free ofoil andgrease. They can slip and fly withtremendous force (Fig. 4).FIG. 4 Use of Tire IronsF1858·BA careful inspection should be madeof the tire and all necessary repairsshould be performed. A tire spreader isvery helpful (Fig. 5) but use care whenworking around it. Keep the spreaderarms closed when the machine is idle.FIG. 1 Handling Wheels and TiresDeflating a tire properly is veryimportant to your safety. First, reduceFIG. 3 Changing Tire on Drop CenterRimThis can help prevent cuts on handsand wrists and will make it unnecessaryto' use a mallet for seating the tire.Use only standard tire mounting toolsand equipment. The use of makeshifttools, screwdrivers or pliers to force tireson or off rims or wheels is dangerous.Always lubricate tire beads to assuresealing of tire beads on rim with rubberlubricant ESA-MIB6-A, or equivalent.The Rotunda tire changer includes abead seater/inflator using anautomatically adjustable inflation ring,which aids in properly seating the beadfor inflation. To properly operate theRotunda tire changer, follow theinstructions provided.FIG. 5 Tire SpreaderInspect the rim parts carefully forrust, damage or distortion (Fig. 6). Neveruse rims, locking rings or flangl~s whichare out of shape, rusted or cracked orbroken in any way. Never use Ii ring orother rim parts of different manufacturethan the original rims or any differentsize or type.Tires and rims often require a buffingoperation before being mounted once theregular repairs have been made.Always wear Safety Goggles, or aface shield when performing any buffingoperation.Avoid hammering rings or rims withsteel hammers. Small bits ofsteel may bebroken off the hammer or rim, flying intothe eyes (wear safety goggles) face or

11-01-3General Wheel and Tire Service11-01-3FIG. 6 Visual InspectionF1854-Bbody. Use rubber-covered, steel-headedhammers wherever possible (Fig. 7).Rubber mallets only should be used onpassenger car tires; although withmodern tire changing equipment nopounding is necessary.Make certain the rim ring is seated tofull depth of the groove, fits tightly allaround, and is securely locked.Stand away from the valve stem as faras possible while inflating tires. Avoid aF1859-BFIG. 7 Seating of Ringsposition where the face or body isimmediately over the work being done onany tire in which there is pressure.Attach a portable safety device, madeespecially for the purpose, to theassembly. This portable device should beused with all types of wheels and rims.If the assembly is not of the typewhich requires inflation to seat the rings,a Safety Cage should be used, althoughthe portable device is the best (Fig. S).FIG. 8 Inflation DetailsF1855-BUse only accurate, tested gauges toinsure proper air pressure. Check allgauges regularly with a master gauge.Play it SAFE. Set a good example forothers who work with you. Follow theabove suggestions completely. If you areever tempted to take a short cut becauseyou are in a hurry, that is the time thatyou could get hurt.Finally, always remember, a jack isprovided for wheel and tire maintenanceonly. Never run the engine when thevehicle is supported by a jack.DIAGNOSIS AND T~STINGDIAGNOSIS GUIDESThe following guides can be used asan aid in wheel and tire service diagnosis.PROBLEM POSSIBLE CAUSE CORRECTION• Tires show excess wear on edges of tread • Underinflated tires • Adjust air pressure in tires• Vehicle overloaded• Correct as required• High speed cornering• Correct as required• Incorrect toe setting• Set toe to specifications• Tires show excess wear in center of tread • Tires overinflated • Adjust air pressure in tires• Excessive tire wear problems • Improper tire pressure • Adjust air pressure in tires• Incorrect tire/wheel usage• Install correct tire/wheel combination• Loose or leaking shock absorbers• Tighten or replace as necessary• Front wheels out of alignment• Align front wheels• Front wheel bearings out of adjustment• Adjust front wheel bearings• Loose. worn or damaged steering linkage• Inspect, repair or replace as requiredor joints• Loose, worn or damaged suspension components, • Inspect, repair or replace as requiredbushings and ball joints• Wheels and tires out of balance• Balance wheels and tires• Excessive lateral and/or radial runout• Check, repair or replace as requiredof wheels and tiresCF2458-A

11-01-4 General Wheel and Tire Service 11-01-4COMPLAINT POSSIBLE CAUSE CORRECTIONDemountable Rims • Improper procedures in mounting the rim to • Replace chorded rims. Check shop practices and toolsDriver reports excessive vehicle vibration the cast wheel. Failure to follow 'proper torquing to be sure manufacturers recommendations on torque footrough steering and excessive fatique. sequences and recommended foot pounds pounds and procedures are followedRelated maintenance complaints includeof torque results in "rim chording" where the rimexcessive vibration damage andclamps exert pressure as they are tightened whichrepair costs plus severe tire wearforces the rim out of round forming flatsides on the rim.• Improper positioning of side ring's split in relation • Reassemble with the ring split opposite (180°) the rim'sto the rim's valve opening and welded drivers.valve opening and welded drivers to improve balcnce.• Out ot balance rim and/or cast wheel. tire or hub • Determine out of balance component andand drum assembly.balance or replace.• Out of round rim (excessive radial runout).• Replace the rim and check the following:- For proper handling of rim prior to use:- For overloading and unbalanced loads.-For road hazards and rugged operatingconditions.- For proper rim specifications.- For proper mounting.Disc Wheels • Dirt and rocks wedged between disc and rim. • Clean and recommend the advantages ofgutter mount design.• Out of balance wheel and/or tire or hub and• Determine the out of balance component and balancedrum assembly.or replace.• Improper positioning of the side ring's split.• Reassemble with the ring split opposite (180°) thevalve opening to improve balance.• Out of round wheel (excessive radial runout). • Replace the wheel and check for: overhauling anljunbalanced loads. Road hazards and rugged ope'atingconditions. Proper wheel specifications.Vehicle • Loose or worn drive line or suspension parts. • Identify location of vibration carefully as it may betransmitted through frame making a rear endvibration appear to come from the front. Thenrepair or replace loose and worn parts.Drivers report excessive vehicle vibrationsrough steering, excessive fatique, severe • Excessive lateral runout. • Check mounting If proper. replace the rim.tire wear and road malfunctions.• Loose or improper attaching parts• Tighten or replace.• Worn or distorted spacers.• Replace.• Overloading or unbalanced loads.• Check rim specs against work load requirementswith tire engineer, recommend correct tire and rim.Check on loading procedures.• Road hazards (curb and rock impacts. etc.). • Check operating conditions with tire engineer forpossible change to heavier duty tire and rim.• Improperly installed rim.• Recommend that clamp nuts be retorqued aftera 50 -100 mile seating in period of the rim assenblyto the wheel.Disc Wheels • Excessive lateral runout. • Replace wheel.• Bent or distorted disc from overloading• Replace wheel. Attempts to straighten wheel canroad impact hazards or improper handling.result in fractures in the steel and weakening ofthe disc or the weld between disc and rim.Check loading and operating conditions. andand shop practices.• Loose mountings - Damaged studs, cap-nuts. • Tighten and/or replace worn or damaged parts. Cleanenlarged stud holes, worn or broken hubmounting surfaces.face, or foreign material on mounting surfaces.Vehicle • Improper alignment. • Have vehicle aligned.• Loose, worn or broken suspension parts.• Repair or replace.CF2602-2A1

11-01-5 General Wheel and Tire Service 11-01-5COMPLAINT POSSIBLE CAUSE CORRECTIONCracks develop in rim base, back flange • Overloading or road hazards. • Replace rim or wheel. Check loading and operatingor the gutter areaconditions. Avoid over inflation of tires.Check specs for rim load capacity, working loads,tire size, ply rating and tire construction.• Improper use of tools.• Check mounting, demounting and maintenanceprocedures.Demountable or Wheel RimsSide rings fail to hold properly, and are • Improper side and/or lock ring for wheel involved. • Recommend proper side and/or lock rings for rim.cracked or sprung on inspection• Improper mounting and demounting techniques. • Replace damaged rings. Check and recommendproper procedures.• Overloading, overinflation, road hazards.• Check operating conditions and recommendright specifications.Cracked or Broken Wheel DiscsCracks develop in the wheel disc from hand • Metal fatigue resulting from overloading • Replace wheel. Check position of wheel on vehiclehole to hand hole, from hand hole to rim, and/or road hazards. for working load specifications.or from hand hole to stud.Stud holes become worn, elongated or deformed, • Truck operated with loose wheel mounting. • Replace wheel and check for:metal builds up around stud hole edges, cracks - Installation of correct studs and nuts, anddevelop from stud hole to stud hole. Relatedrecommend exact specifications.driver complaints; unusual operating noise or - Cracked or broken studs, and replace.vibration, and on the road failures - Worn hub face machine if not excessive, or replaceif severe.- Broken or cracked hub barrel replace.- Worn stud grooves replace or install recommendedserrated bolts.- Clean mounting surfaces and re-torque capnuts periodically.- Rust streaks fanning out from stud holes are a sureindication that the cap nuts are, or have been loose.Demountable or Wheel RimsDecreased strength because of excessive rust • Adverse storage or operating conditions. • Recommend Goodyear Motor Wheel protective finish.or corrosion, bead seating problems, oror equivalent.loss of pressure with tubeless tires. • Poor maintenance practices. • Recommend correct cleaning and protectiveprocedures.Wheel Disc • Poor maintenance. • Keep clean and protected with paint.Demountable or Wheel RimsRelated maintenance complaints on tire damage • Wrong rim selection. • Match rims and tires to working loads andincluded erratic or spotty wear. tire slippage, plyoperating conditions.separation, excessive flexing, bead chafing, tube • Rims of different size in dual mountings. • Match rim size before mounting duals. Detachable sidepinching, valve stem tearoutsand lock rings should also be matched correctly.• Improper inflation.• Follow specifications.• Severe hop and wobble.• Follow recommendations under "Hop" and "Wobble."Wheel Disc • Rim flexing. • Recommend gutter mounted design.• Bent or distorted disc.• See Disc Wheels under "Wobble."• Other conditions.• See "Tire Mounting Difficulties." "Rim MountingDifficulties." and "Wheel Mounting Difficulties."Demountable or Wheel RimsMaintenance reports tire mounting problems, and • Mismatched tire and rim sizes. • Follow specifications.drivers may report on road tire mounting failures • Defective or mismatched rings for rim used. • Follow specifications.• Overinflation of tires.• Follow recommended tire pressures.• Corrosion and dirt.• See "Corrosion."Demountable RimsMaintenance reports rim mounting problems • Improper application or mismatched parts, including • Follow manufacturer's specifications. Check specs whenspacer and clamps.chains, V-Belt drives, or special load tires are involved.• Corroded or worn parts.• Clean or replace.Disc WheelsWheel mounting problems is the complaint • Improper application or mismatched parts, including • Follow manufacturer's specifications. Check specsstuds and nuts.for disc and spacing when chains, V belt drives, orspecial load tires are involved.• Corroded or worn parts.• Clean or replace.CF2602-2A2

11-01-6 General Wheel and Tire Service 11··01-6COMPLAINT POSSIBLE CAUSE CORRECTIONDual Tires Rubbing (kissing) • Insufficient Wheel Spacing. • Check tire and wheel sizes - Make certain propl~rsize tire and wheels are used.Damage Stud Threads • Sliding wheel across studs during assembly. • Replace studs. Follow proper wheel installationproced ures.Loose Drum • Stud too long. • Replace stud with proper length stud.Loose inner wheel • Excessive stud standout from mounting • Replace stud with proper length stud.face of hub permitting wheel nut to bottom out.Broken Studs • Loose Cap nuts. • Replace studs. Follow proper torque procedure.• Overloading. • Replace studs. Compare actual load against whel~1 loadratings.Stripped threads • Excessive torque. • Replace Studs. Follow proper torque procedure.Rust streaks from stud holes • Loose Cap Nuts. • Check complete assembly. Replace damagedparts. Follow proper torque procedure.Damaged inner or outer cap nuts • Loose wheel assembly. • Replace cap nuts. Check for proper stud nuts standout.Follow proper torque procedure.Frozen inner or outer cap nuts • Corrosion or galling. • If corrosion is slight. wire brush away corrosion.• If corrosion is excessive, replace studs and nuts.• If condition persists. lubricate first three threads of eachstud with a graphite-based lubricant.CAUTION: Do not permit lubricant to get on ball seats of studholes or on ball face of cap nuts.CF2602·2A3MUD AND SNOW TIRESNOTCOMPLAINTS. I VIBRATION, BEATING, OR I--- REPLACE WITH HIGHWAYnPROCEED ACCORDINITIRE/WHEELDRUMMING NOISE WITH MUD THREAD TIRES IF DRIVELINE HIGHWAY DIAGNOSIS.AND SNOW TIRES THAT CANVIBRATION IS SUSPECTED.HIGHWAY DIAGNOSISBE MISDIAGNOSED AS ADRIVELINE VIBRATION.10KCHECK DRIVELINE NOISVIBRATION COUPLING.ICHECK TIRES FOR EXCESSIVE INOT OK CHECK TIRE INFLATION, SUS- OK REPAIR, ADJUST OR DISCARD r ROAD TEST 1WEAR OR CUPPING. I PENSION, ALIGNMENT. RE- ITEM. IOKPLACE EXCESSIVELY WORNTIRES.10KFiICHECK WHEEL BEARING END INOT OK ADJUST TO CORREc3 I ROAD TESTPLAY AND ROUGHNESS. I PLAY OR REPLACE.IOKTNOT[CHECK TIRE, WHEEL INOT OK BALANCE TIRE/WHEEL OK REPLACE TIRE WHICH C~~BALANCE.ASSEMBLY.NOT BE BALANCED.IIOKNOTIREPOSITION TIRE 180" ON INOT OKCHECK TIRE RUNOUT. OK CHECK WHEEL RUNOUT. REPLACE WHEELWHEEL ASSEMBLY.IREBALANCE.II OKOKIROAD TESTICHECKALIGNMENT, SUS-PENSION, DRIVELINE.REPLACE TIREIIROAD TESTIIROAD TESTI ICF2626-A

11-01-7 General Wheel and Tire Service11-01-7ITIRE COMPLAINTSIICHECK TIRES FOR EXCESSIVEWEAR AND CUPPING.OK ~ t NOT OKCHECK WHEELS FORLATERAL AND RADIALRUN OUTREPLACE EXCESSIVEL Y WORNOR CUPPED TIRESOK ,~CHECK TI RES FOR LATE RA LRUNOUT.+NOT OKREPLACE WHEEL IF EITHERRUNOUT EXCEEDSSPECI FICATIONS.OKCHECK TIRES FOR RADIALRUNOUT.+NOT OKREPLACE TIRE IF LATERALRUNOUT EXCEEDSSPECI FICATIONS.OK+NOT OKBALANCE ALL WHEEL AND REINDEX TIRES AND REPLACETIRE ASSEMBLIES ON IF RADIAL RUNOUT EXCEEDSVEHICLE (HIGHWAY TREADI090" TOTAL WHEEL AND TIRE.t NOT OKREPLACE TI RES THAT CANNOTBE BALANCED (HIGH WAYTREADI.IBALA~CE ALL WHEEL ANolTIRE ASSEMBLIES ON VE-IHICLE IHIGHWAY TREAD).OKtROAD TEST'CF2603·2A

11-01-8General Wheel and Tire Service11-01-8ADJUSTMENTSWHEEL AND TIRE CHECKINGPROCEDUREInspect tires for wear from incorrectmounting misalignment, loose wheelbearings, bent wheels, or cupping orscalping from inbalance. Tires whichshow irregularities and definiteroughness must be replaced.See the instructions provided with theRotunda Wheel Balancer.Make certain that the brakes are notdragging and wheel bearings are properlyadjusted before attempting to spin thewheels. On vehicles equipped with discbrakes, push the brake shoes into thecaliper to free the rotor.7. If lateral runout is more than .090inch, measure the wheel lateralmnout (Fig. 9). If lateral mnout is lessthan .070 inch, replace the tire. Iftotal lateral runout is more than .070inch, replace the wheel. Afterreplacing, check runout again.NOTE:1. When remounting the tire on thewheel, use ample tire mountinglubricant, ESA-MIB6, or equivalent,on the tire and wheel bead seat area.Inflate tires to 45 psi for passengerwheel. Make sure the jack is secure andsafe. .Spin the wheel with the engine andtransmission in high gear at 30--40 mphon the speedometer. Do not spin poweredwheels with a wheel spinner. Start thewheel as gradually as possible. Take careto avoid jerking condition on trucksequipped with an automatic shift. Use anaccelerator pedal prop on vehicles notequipped with a hand throttle.To balance, place the pick-up as closeto the wheel as possible; then, with theWHEEL AND TIRE VIBRATIONDIAGNOSIS PROCEDURESNOTE: Mud and snow type tirevibration can often be mistaken fordriveline problems, especially when mudand snow type tires are used on all wheelson four wheel drive vehicles.1. Road test vehicle to verify complaint.As soon as possible after the road test,raise vehicle on a hoist to prevent tireflat spotting. Check tires for excessivewear, inflation pressure or cupping.Check for alignment, or suspensionproblems that are indicated by the tirewear patterns.2. Spin front tires by hand to checkbearing roughness. Replace wornbearings.3. Check for visible wheel or tire wobble.Replace as required.4. Check tire and wheel balance. Correctas necessary. Balance wheels by eitherstatic and dynamic wheel balance.Refer to section on "BalancingWheels".5. If problem still exists, check both theradial runout and lateral runout ofthetire as shown in Fig. 9.6. If radial runout is more than .090inch, perform one of the following:a. Reposition the tire 180 degrees onthe wheel.b. Find the highest point of tire radialrunout. Mark this point on the tire.Find lowest point of radial runouton the wheel. Mark this point onthe wheel. Demount the tire. Alignthe high point of the tire, with thelow point on the wheel. Remountthe tire. Recheck radial runout. Iftire radial runout is still more than.090 inch, check the wheel. Ifradialrunout is less than .070 inch,replace the tire. Ifthe wheel is morethan .070, replace the wheel.Rebalance the reworked assembly.f. '~CHECKTOTALRADIAL RUNOUT HEREFIG. 9 Correct Placement of Runout Indicator Pickupcar type tires, or 80 psi for truck typetires to insure proper bead seating.Bleed tires to specified inflationpressure.2. If wheel and tire assembly is still notin balance after using on-the-vehiclebalancer, or dynam ic balancemachine, the problem could beunbalanced brake drums. Withvehicle raised on a hoist,! remove thetire and wheel assembly. Place thewheel lug nuts on the wheel studs.Engage the transmission and drivethe rear wheels to 30-50 mph (48­80km). If vehicle vibrates, performstatic and dynamic balance on thedrums by welding metal weights onthe drum. Reinstall the wheel andtire assembly. Recheck balance andcorrect if necessary. Road test forfinal results.BALANCING WHEELSSingle Rear Wheels F-100-350,E100-350, BRONCODon't use the spinner on any singlerear wheels.Jack up one rear wheel at a time,locate the jack securely under the frame,approximately one-foot ahead of the rearCHECK TOTALLATERAL RUNOUT HEREF2457-Awheel spinning at the speed where themaximum vibration is showing, read thestrobe and follow the same proc,~dure asbalancing front wheels.Rear Wheels of Truck withSemi-lock DifferentialUse one of the following methods forrear wheels:1. Place a jack under the frame, one footahead of the rear wheel you want tobalance. Jack up the wheel. Placeanother jack under the axle near theopposite rear wheel, and raise thewheel. Place the pick-up under thewheel. Spin the wheel with the motorto approximately 60-70 mph, towhere the most vibration shows. Readthe strobe and follow the sameprocedure required for balancingfront wheels.2. Jack up the rear wheels as noted instep 1. Remove the rear wheelopposite the wheel you are to balance.Balance the rear wheel on the vehicleand reinstall the other wheel. Afterreversing the position of the jacks,balance the opposite rear wheel. Donot remove the first rear wheel.

11-01-9 General Wheel and Tire Service 11-01-9Dual Wheels and Wheels ofTrucks Equipped with Full­Floating AxlesJack up the rear wheels with the jacklocated securely under the differentialhousing. Raise the wheels 1-112 inchesfrom the floor.Disconnect the wheel from the axledrive by removing the hub flange nuts orscrews. Pull the hub flange out to clearthe studs at least 112 inch.Spin Dual Wheels with an 800-C2 or500-C Heavy-Duty Truck Spinner orequivalent.FRONT WHEEL BEARINGMAINTENANCEWheel bearings are adjustable.Satisfactory operation and long life ofbearings depend on proper adjustmentand correct lubrication. If bearings areadjusted too tightly, they will overheatand wear rapidly. An adjustment that isexcessively loose can cause pounding andcontribute to uneven tire wear, steeringdifficulties and inefficient brakes. Thebearing adjustment should be checked atregular inspection intervals.CLEANING AND INSPECTIONWHEELSWheel stud nuts should be inspectedand tightened twice within the first 500miles of operation. After the first 1000miles of operation, they should again beinspected and tightened. Loose wheelstud nuts may cause shimmy studdamage and/or failure, possible wheeldamage, and vibration. Elongated studholes in the wheels may also result fromthe loose stud nuts.Keep the wheels and hubs clean.Stones or lumps of mud wedged betweenthe wheel and drum will unbalance awheel and tire.Check for damage that would affectthe runout of the wheels. Wobble orshimmy caused by a damaged wheel willeventually damage the wheel bearingsand cause uneven tire wear. Inspect thewheel rims for dents that could permit airto leak from the tires.TIRESThe tires should be checkedfrequently to be sure that the airpressures agree with those specified forthe tires and vehicle model. Inspect thetire tread, and remove all stones, nails,glass or other objects that may be wedgedin the tread. Check for holes or cuts thatmay permit air leakage from the tire, andmake the necessary repairs.Inspect the tire side walls for cuts,bruises, and other damage. If internaldamage is suspected, demount the tirefrom the wheel for further inspection,repair or replacement.Check the tire valve for air leaks, andreplace the valve if necessary. Replaceany missing valve caps.On F-lOO-350, E-100-350, BRONCOit is important that all wheels bebalanced. Fig. to describes common tirewear conditions.FRONT WHEEL BEARINGSWheel bearings are adjustable, tocorrect for bearing and shoulder wear ofthe spindle. Satisfactory operation andlong life of bearings depend on properadjustment and correct lubrication. Ifbearings are adjusted too tightly, theywill overheat and wear rapidly. Anadjustment that is excessively loose cancause pounding and contribute to uneventire wear, steering difficulties andinefficient brakes. The bearingadjustment should be checked at regularinspection intervals.Frant hub assemblies and bearingsshould be cleaned, inspected andlubricated whenever the hub assembliesare removed or at the mileage/timeperiods indicated in the maintenanceschedule.New hub assembly grease seals shouldbe installed when the hub is removed. Adamaged or worn seal may permitbearing lubricant to reach the brakelinings, resulting in ineffective brakeoperation and necessitating prematurereplacement of linings.Bearing adjustment is described inPart II-to for front wheels. Part 11-12covers front drive bearing adjustment.Parts 11-11 and 11-14 cover rear wheelbearing adjustments.ALUMINUM WHEELS AND RIMSCLEANINGWhenever tire is removed, thoroughlyexamine the complete wheel. Remove allgrease and road dirt and use a wire brushor steel wool to remove the rubber fromthe bead seat.GUTTER AREAProjections on the side wall of thegutter may cause uneven seating of theside or lock ring and lead to chipping ofthe gutter. Such projections should beremoved.MOUNTING AREASmooth all projections in themounting area to assure even pressureswhen tightening nuts.FIXED FLANGED AREANicks and gouges in the vicinity ofthefixed flange may lead to rim fracture.STRAIGHTENING WHEELSDo not heat wheels in an attempt tosoften them for straightening to repairdamage from striking curbs, etc. Thespecial alloy used in these wheels is heattreated,and uncontrolled heating fromwelding affects the properties of thematerial. Do not weld the wheels for anyreason.VALVESAluminum and steel drop-centerwheels for tubeless tires come from thefactory with air valve installed. If itbecomes necessary to replace an air valveit _should be installed using 14 ft-Ibs oftorque onthehex nut.MAINTENANCE ANDPROTECTION IN CORROSIVEENVIRONMENTSDue to aluminum's natural resistanceto corrosion, aluminum forged discwheels and rims do not need to be paintedfor most operating conditions. Washingthem (do not use highly alkaline cleaningagents) when washing the rest of the rigwill be enough to keep wheels lookinggood for many years. Certainenvironments, as created by someoperations, can lead to corrosion. Someof these are: livestock hauling, salt,chloride compounds used for snowremoval and highly alkaline materials.When these conditions are encountered,the following practice is recommended:1. Clean frequently with steam or highpressurewater from a hose. Use of amild detergent will speed up thecleaning process.2. When tires are removed, the entirewheel should be cleaned andinspected. For maximum protection,there are various types of coatingswhich give good results. Thefollowing procedures are suggested:Surface Preparation1. Remove all the soil and oil from thewheel surface with either highpressuresteam or solvent. Suitablesolvents would be mineral spirits andregular paint thinner, obtained inpaint stores.2. Remove any adherent soil oroxidation products by using a wirebrush.3. Clean the surface again with solvent,using mineral spirits to remove looseproducts.4. Apply a clear protective or pigmentedproduct as follows:

11-01-10General Wheel and Tire Service11-01-10UNDERINFLATIONOVERINFLATIONCUPPING-UNDERINFLATION AND/ORMECHANICAL IRREGULABITIESINCORRECT TOE·IN OR EXTREME CAMBERFEATHERING DUE TO MISALIGNMENTOR SEVERE CORNERINGSTONE BRUISESTONE BRUISEBRUISEFIG. 10 Tire Wear ConditionsHEAT BRUISEDOUBLEBRUISE-SHARP OBJECTAND RESULTING FATIGUE F1467.D

11-01-11General Wheel and Tire Service11-01-11CleM Protectiye CoatingSpray apply about 1 112 to 2 mils wetfilm thickness, air curing clear epoxypolyamide meeting Military SpecificationMIL-C-22750 (WEP) or equivalent. Toproperly spray this particular coating,mix components A and B of the two-partorganic coating and thin where necessarywith 10 percent toluol. Spray apply witha spray gun at a pressure of30-40 pounds(suction feed).Pigmented ProtectiYe CostingPrimer-Spray apply the inhibitedprimer, meeting Military SpecificationMIL-C-23377 (SEP) or equivalent. Spraythis primer at a I to 2 mil wet filmthickness. Allow to air dry from 2 to 4hours before top-coating.Top Coat-Spray a 1 112 to 2 mils wetfilm of a leafing aluminum pigmentedepoxy. Allow enough time to air drybefore handling; overnight will usually besufficient.RIM AND WHEEL MAINTENANCEDURING TIRE INSPECTIONS1. Check all metal surfaces thoroughlywhile making tire inspections,including areas between duals and oninboard side of wheel. Watch for:• excessive rust or corrosion buildup• cracks in metal• bent flanges, resulting from roadobstructions• deep rim tool marks on rings orin gutter areas'• loose, missing or damaged nuts orclamps• bent or stripped studs• damaged or missing rim driveplates• matched rim parts2. Pull damaged rims or wheels.CAUTION: Excessively corroded orcracked rims or rings can bedangerous. Deflate tires prior to theremoval of rims or wheels from thevehicle.3. Mark damaged or hazardous areaswith chalk so that part will beremoved from service.4. Replace parts as required.CAUTION: Insure that replacementsare made with the proper sizes andtypes of rims and rings.5. Inflate tires only to recommended airpressures.DURING TIRE CHANGES1. Check ,all metal surfaces. Watch.particularly for the following items:• Cracks in the rim base, in theback flange and gutter areas. Theseare caused by deep rim tool marks,overloading and overinflating tiresor using larger than recommendedtire sizes.• Cracks in the wheel disc, betweenthe stud holes or hand holes. Theseare caused by loose wheel nuts,improper installation procedures orthe use of incorrect sizes or typesof attaching parts.• Cracks through the side ring,spreading laterally through theentire section. These are caused byimproper mounting anddemounting techniques, impactwith road obstructions, or excessiveclamping torques.• Sprung side ring, resulting fromimproper mounting procedures.• Errosion and chipping ofthe beadseat of the lock ring, resulting fromexcessive corrosion. This mayoccur with this part as well asothers if protective measures arenot taken.2. Replace the parts as necessary.CAUTION: Insure that replacementsare made with the proper sizes andtypes of rims and rings. Note:Openings between the ends ofthe splitside rings must not be less than 3/32"except where the ring design calls foran abutting condition, or more than5/16" after the ring is seated duringoperation. Split lock rings used withthe endless side rings must not butt.3. Thoroughly remove rust, dirt andother foreign materials from allsurfaces. Hand or electric wirebrushes, sand blasting or chemicalbaths may be used. Gutter of rim baseshould be cleared of rust and othermaterials obstructing safe, positiveseating of rings. Bead seat areas ofrimshould be free of rust and rubberdeposits. This is especially importantfor drop-center tubeless rims, becausethe 15 degree bead seat is the airsealingelement.4. Rings should be cleaned with wirebrush. Pay particular attention toseating surfaces and bead seat areas.Paint rim by brush or spray with afast-drying metal primer. Surfacesshould be clean and dry prior topainting. Insure that bare metal areason the outside or tire side of rim arecovered. This is especially importanton drop-center tubeless rims, becausewarm and sometimes moist air is inconstant contact with the metalsurface on the tire side of the rim.5. Lubricate the tire side of the rim ba~ejust prior to mounting tire. Avoid theuse of any lubricant which containswater or solvent that is injurious torubber. A combination lubricant andrust-preventive compound ispreferable. This protective measure isof particular importance with dr

11-02-1 Wheels and Tires-Drop-Center Rim 11-02-1Wheels and Tires -PARTDrop-Center Rim 11··02APPLIeS TO BRONCO, E·100-E-350, F-100-F-350 AND MEDIUM TRUCKSSUBJECT PAGE SUBJECT PAGEDESCRIPTIONREMOVAL AND INSTALLATIONFront Wheel Assembly ................. 02-1 Tire Replacement Precautions ...........02-2Front Wheel Assembly -Wheel ReplacementFour Wheel Drive ..................... 02-1 E-100 to E-350, F-100 to F-350 ........02-1Rear Wheel Assembly .................. 02-1 Medium Trucks .....................02-2SPECIFICATIONS ........................02-2DESCRIPTIONFRONT WHEEL ASSEMBLYEach front wheel and tire assembly isbolted to its respective front hub androtor assembly. Two opposed taperedroller bearings are installed in each fronthub and rotor assembly (Fig. 1). A greaseretainer is installed at the inner end ofthehub to prevent lubricant from leaking.The entire assembly is retained on itsspindle by the lock nut, adjusting nut andcotter pin.FRONT WHEEL ASSEMBLY­FOUR-WHEEL DRIVEThe front axles used on 4-wheel drivemodels are described in Parts 15-30, 15­32 and 15-33 ofthis manual. The lockinghub assemblies are described in Part 11­12.REAR WHEEL ASSEMBLYInformation on rear wheels may befound in Group 11, Parts 11 and 14.INNER 3EARING CONEAND ROLLERWH EEL ASSEMBL YFIG. 1 Front Hub, Bearings and Grease Retainer-Disc Brakes-F1OO-F350,4x2, E100-E350F 1851-AREMOVAL AND INSTALLATIONWHEEL REPLACEMENTE-'OO to E-350, F-'OO to F-350Removlll1. Pry ofT the hub cap or wheel cover (ifthe vehicle is so equipped), and loosenbut do not remove the wheel studnuts.2. Raise the vehicle until the wheel andtire clear the floor.3. Remove the wheel stud nuts and thewheel and tire from the hub and drumassembly, or the hub and rotorassembly.InstJdJlltion1. Clean all dirt from the hub and rotorassembly. The replacement wheel andtire must be clean.2. Position the wheel and tire on the huband rotor assembly, and install thewheel stud nuts. Tighten the stud nutsenough to hold the wheel firmly inplace. Always tighten alternate nutsto draw the wheel evenly against thehub and drum (or hub and rotor).E-350 and F-350 with dual wheelshave mounting bolt holes which arealternately flared inward andoutward. These surfaces must bemated when the wheels are mounted.Fig. 2 illustrates the dual wheel radialalignment locating pin used on E-350and F-350.3. Lower the vehicle to the floor, andtighten the wheel stud nuts to thespecified torque. On a new vehicle,and each time a wheel and tire isinstalled, the wheel nuts should betightened to specification andrechecked at 500 miles.

11-02-2 Wheels and Tires-Drop-Center Rim 11-02-2ALIGN DUAL WHEELSON LOCATING PINF 1829-AFIG. 2 Dual Rear Wheel RadialAlignment to Hub (E-350, F­350)Medium TrucksRemoYalI. Loosen but do not remove the wheelstud nuts.2. Raise the vehicle until the wheel andtire clear the floor.3. Remove the wheel stud nuts and thewheel and tire from the hub anddrum.Instal/stionI. Clean all dirt from the hub and drum.The replacement wheel and tire mustbe clean.2. Position the wheel and tire on the huband drum. and install the wheel studnuts. Tighten the stud nuts enough tohold the wheel firmly in place.Always tighten alternate nuts to drawthe wheel evenly against the hub anddrum.On dual wheels, be sure to back offthe outer nut before tightening theinner nut. Then tighten the outer nut.3. Lower vehicle to the floor, andtighten the wheel stud nuts to thespecifications. On a new vehicle, andeach time a wheel and tire is installed,the wheel nuts should be checked fortightness.TIRE REPLACEMENTPRECAUTIONSThe tire must be completely deflatedbefore removal, and the bead must not bedamaged by a tire iron.After installation, a tube tire shouldbe inflated to recommended pressure,deflated, and then inflated again to insurethat the tube is not folded inside the tire.Be sure the tube flap is properlypositioned before inflating the tire. OnFI00-350, EI00-350 and B-150 it isimportant that each front and rear tireand wheel be balanced.When installing tires on F-100/350,B-150, and E-IOO/350 vehicles,thoroughly lubricate the tire beads withlubricant ESA-MIB6A, or equivalent.Inflate the tire until both bead seatsagainst the rim of the wheel, then deflateto the specified "Tire InflationPressures" shown in the 1977 TruckOwners Manual for each vehicle series.To seat the tire beads, the initial inflationfor passenger-type tires is 30 psimaximum; for truck-type tubeless tires,50 psi maximum; for truck-type tubetires 75 psi maximum. Follow theinstructions supplied with the Rotunda(35-002, 35-0010 or equivalent) tirechanger. Refer to Part 11-01 fordiagnosis and testing procedures, safetyprocedures and illustrations.SPECIFICATIONSWHEEL TORQUE LIMITS -ModelF-l00 THRU F-350, E-l00-E-350, BRONCO-NutFt-lbModel Nut Size Ft-LbSizeE-100-E-250 1/2-20 90F-100, F-150 (4 x 4), Bronco,F-150, F-250 (4 x 4)F-350,' E-350 9/16-18 13f.)W/S R. Wheels CD 145E-350, F-350, 9/16-18 ® 220(W/Dual RearWheels) CD(~nd 7400 Ib Axle)(2)CD E-350, F-250 and F-350 Single Rear Wheel Lug Nuts areBlack in Color. (.066 inch length)(2) E-350, F-350, Dual Rear Wheel Lug Nutsare Zinc Plate or Black, in Color. (.94 inch length).The Lug Nuts Should not be mixed. The Dual Wheel LugNuts are Left Handed Threads for Left Rear Wheels Only.CF1804-Fi

11-03-1 Wheels and Tires-Twa-Piece Rims 11-03-1Wheels and Tires -PARTTwo-Piece Rims 11-03APPLIES TO F·250, F·350 VEHICLESSUBJECT PAGE SUBJECT PAGEDESCRiPTION ..........................03-1 REMOVAL AND INSTALLATION (Cont'd)REMOVAL AND INSTALLATION ............03-1 Mounting Tire to Wheel ..............03-1Tire Removal and MountingRemoval Side Ring from RimTwo-Piece Semi-Drop Center Rims .....03-1 with Ti re ........................03-1DESCRIPTIONTwo-piece drop center wheels with alock ring (Fig. 1) are used with 16 inchtube-type tires only.Refer to Part 11-01 for diagnosis andtesting procedures, safety procedures andillustrations.NOTCHRIMFIG. 1 Two-Piece RimSPLIT RINGF2627·AREMOVAL AND INSTALLATIONThe tire must be completely deflatedbefore removal, and the bead must not bedamaged by a tire iron.After installation, a tube tire shouldbe inflated to recommended pressure,deflated, and then inflated again to insurethat the tube is not folded inside the tire.Be sure the tube flap is properlypositioned before inflating the tire.It is recommended that tire-changingequipment be used in changing all trucktires. See Safety Precautions in Part 11­01.TIRE REMOVAL ANDMOUNTING-TWO-PIECE SEMI­DROP CENTER RIM-F250-F350Recent developments make possiblethe removal and mounting of tires fromthis type of wheel-rim combination withmechanical tire-changing equipment. Ifavailable, follow instructions ofequipment manufacturer. Otherwise, usethe following instructions.This two-piece wheel uses a split C­type ring, as shown in Fig. 2.Removal of Side Ring from Rimwith Tire1. Remove valve core and deflate the tirecompletely and place the wheel (ringside up) on the floor.2. Break the tire bead free from the rim,being careful not to damage the bead(Fig. 3).3. Insert the straight end of the rim toolinto and under the tool notch in thering (Fig. 4).4. Forc e the tool dow n ward todisengage the ring from the rimgutter. Work the tool around the rim,freeing the ring from the rim, andremove the ring.5. Tum the wheel over and loosen theopposite tire bead from the rim bydriving the hook end of the rim toolbetween the rim flange and the tirebead. Pry the tire bead away from thetaper, and remove the tire from therim (Fig. 5).Mounting Tire to Wheel1. Position the tube in the tire and placethe wheel (gutter side up) on the floor.Lubricate both beads of the tire withESA-M 1B6A or equivalent andposition the tire on the rim. It isimportant that the tire be lUbricatedwell as it must be forced over thesafety bead hump and the rim edge(Fig. 6). Be sure the tube flap iscorrectly positioned.2. Position the ring with the tool notchabout 3 inches from the valve stem.3. Insert the rim tool under the ring ata position approximately 180 degreesfrom the notch and pry tire onto rim.Work the remaining section of rimover the gutter with a second tool.

11-03-2 Wheels and Tires-Two-Piece Rims 11-03-24. Make certain that the ring is entirelyseated in the gutter. If the ring is notseated correctly as described, it maybe forced otT violently, either duringinflation or when the vehicle isoperated...C'. RING5. After installation, inflate the tire andtube to 80 psi maximum to snap thetire beads over the bead hump andfully seat the tire against the rim andlock ring. Deflate the tire, thenreinflate it to recommended pressureto insure that the tube is not foldedinside the tire. Always use a cage orsafety chain during initial inflation.6. Check the end gap of the lock ring(Fig. 1), the gap should be 3/8 inch.Rim ToolsSAFETY BEAD HUMPFIG. 5 Removing Tire From RimFIG. 2 Two-Piece Split Ring-Light TruckF1473-eWORK INDIRECTIONOF ARROWFIG. 3 Loosening Tire BeadFIG. 4 Removing Split RingF133S-eFIG. 6 Installing First Tire Bead onWheel

11·04·1 Wheels and Tires-Three Piece Rim 11·04·1Wheels and Tires ­Three-Piece RimsPAR'T11-Ct4APPLIES TO ALL 600·9000 SERIES VEHICLES_SU_B_JE_C_T ~P~AG;;.;:E S_U_B_JE_C_T ..;P....;.A;.;;.;",;;;GEDESCRIPTIONREMOVAL AND INSTALLATION (Cont'd)Tires ! ••••••••••••••••••04-1 Wheel and Tire RemovalWheels and Rims from Vehicle 04-2Drop Center 04-1 DISASSEMBLY AND ASSEMBLYDrum Mounting 04-1 Accu-Ride XL Rims 04-8Three-Piece Rim 04-1 Drop-Center TubelessTwo-Piece Convertible Rims and Wheels 04-5Rims 04-1 Semi-Drop Wheels 04-5REMOVAL AND INSTALLATIONThree-Piece RimsDemountable Rims and Wheels 04-7Installation 04-2 Two-Piece Rims andDisc Wheel Installation 04-3 Wheels ',' 04-6SPECIFICATIONS 04-11DESCRIPTIONTIRESBoth the tube type and.tubeless tiresare used. The tubeless tires are mountedon 15 degrees drop-center rims andwheels. The tube type tires are mountedon semi-drop wheels, two-piece flatbaserims or wheels, and three-piece flatbaserims or wheels (Figs. 1 and 2).WHEELS AND RIMSDROP-CENTERThe tubeless tires are all mounted ondrop-center rims and wheels. The dropcenterrim or wheel is of single-piececonstruction and is available in bothdemountable rim and disc wheelconfiguration. The drop-center rim orwheel has a 15 degr,ee bead seat forsealing tubeless tires. The drop-centerrim or wheel is available in eitheraluminum or steel.TWO-PIECE CONVERTIBLERIMSThe two-piece convertible rimconsists of a side ring and flatbase rimand is available in the demountable rimor disc wheel configuration. The rim hasa 5 degree bead seat for tube type tires.THREE-PIECE RIMThe three-piece rim consists of a lockring, side ring and flatbase type rim. Itis available in the demountable rim ordisc wheel configuration. The disc wheelis available in aluminum or steel,however, the lock ring and side ring aremade of steel in all cases. The rim has a5 degree bead seat for tube type mountings.mountings.CLAMP''----WIHEEL------------------DISC WHEELDEMOUNTABLE RIMFIG. 1 Typical Front Wheel/Rim InstallationDRUM MOUNTINGBoth the inboard and outboard drummountings are used. On inboardmounting the drum is inside themounting hub or spoke wheel, onoutboard mounting the drum i~ outsidethe mounting hub.HUBHUB STUDHUB BOLT\ \..--'BRAKE DRUMF2597-1A

11-04-2 Wheels and Tires-Three Piece Rim 11-04-2RIMCAST SPOKE WHEELDISC WHEELF2598-1AFIG. 2 Typical Rear Wheel/Rim InstallationREMOVAL AND INSTALLATIONWHEEL AND TIRE REMOVALFROM VEHICLE1. Prior to removal of the tire and rimfrom the vehicle, deflate the tirecompletely by first reducing thepressure as much as possible bydepressing the valve core plunger,then removing the valve core. (Seesafety precautions in this Part). Ifworking on dual wheels, deflate bothtires completely before loosening themounting bolts.2. Loosen, but do not remove the wheelstud nuts.3. Raise the vehicle until the wheel andtire clear the floor.4. Remove the wheel stud nuts and thewheel and tire from the hub anddrum. On dual disc wheels, the innercap nut will also have to be removedif the inner tire is to be removed. Ondual cast spoke wheels, the spacer willalso have to be removed.DEMOUNTABLE RIMSINSTALLATION1. Make sure that all parts, includingrims, rings, spacer bands, and castwheel studs are free from damage,dirt or rust as described in this Part.Replace any damaged parts.2. With dual wheels, place rims andspacer band on wheel and proceed tothe next step. On single wheels, placethe rim on the wheel and proceed toStep 7.Note: Spacer bands are designed torender adequate lateral strength withthe minimum amount of weight.Spacer bands should not be subjectedto loads or pressures other than thoseloads or pressures present duringnormal use.3. C h e c k the spa c e r ban d forconcentricity, and ensure that it hasnot been distorted or bent, orotherwise mishandled in shipment.4. Do not move the vehicles, wheels,axles or assemblies by rolling onspacers.5. Place the inside rim over the castspoke wheel as far as possible up tothe mounting bevel.6. Push the spacer band over the castspoke wheel with a consistentpressure on both sides. Guard againstcocking. The band should fit snuglyto the spokes and against the insiderim gutter edge. (At this point, theconcentricity can be checked byturning the spacer band on thewheel).7. Install outer rim (or rim in case ofsingle wheel) with the rim in betweenthe spokes as shown in Fig. 3. Installthe clamps and start the huts onto thestuds.8. Refer to Fig. 4 for the cast spokewheel triangulation torquing andproceed to the next step.9. Turn nut No.1 until snug.to. Rotate the wheel/rim assembly untilnut No.3 is in the top position. Turnuntil snug.1L Again rotate the wheel/rim assemblyuntil nut No.4 is in the top positionand turn the nut until snug. Since theentire weight ofthe tire/rim assemblyis on the top spoke position, thisprocedure allows even application offorce against three points of the rimfor proper alignment.12. Repeat the triangle procedure; thistime bringing each nut torecommended torque of 220-260 ftlbs.13. Bring remaining nuts to torque of220-260 ft-Ibs.14. Check to see that clamps do notbottom out, and be sure that on dualwheels, rim edges consistently meetthe spacer band edges.CAUTION: Insufficient mountingtorque can cause rim slippage,

11-04-3 Wheels and Tires-Three Piece Rim 11-04-3FIG. 3 Cast Spoke Wheel Rim Driver Arrangementresulting in broken valves, worn partsand damaged tires. Excessivemounting torque can cause damage bystripping studs, collapsing spacerbands or forcing rims into an out-ofroundcondition. Note: Even when thetriangulation method is used, nutswill still lose torque when the vehicleis operated. This· is caused by the"seating in" of the rim assembly tothe wheel. After 50-100 miles ofoperation the nuts should again bebrought to recommended torque andF2604-1Athereafter periodically inspected andretorqued. The wheel/rim assemblywill then remain tight, barringaccidents such as stud breakage orclamp failure.DISC WHEEL INSTALLATION1. Check all parts for damage, includingwheels and rings. Insure that studs,nuts, and mounting faces of hub andwheels are clean and free from greaseas described in this Part. Replace anyworn or damaged parts.2. Mount single wheel or inner dualwheel over studs, being careful not todamage stud threads (Fig. :5). Studsand cap nut threads should bl~ dry. Nooil or lubricant should be used.3. Draw the single cap nut or dual innercap nut alternately in the sequenceshown in Fig. 6. Left side wheels haveleft-hand threads. Do not tightenthem fully, however. This procedurewill permit uniform seating of thenuts and insure even, fact~-to-facecontact of the wheels and hub.4. Tighten the nuts fully to 400-500 ftlbsin the same sequence. Mount theouter wheel (for dual wh(:els) andrepeat the tightening procedure.CAUTION: Insufficient 11I10untingtorque can cause wheel iihimmy,resulting in damage to puts andextreme tire tread wear. E:xcessivemounting torque can cause studs tobreak and discs to crack in the studhole area.5. After 50 to 100 miles of servicerecheck the ·wheel nut torque. Whenthe inner cap nut (on dual wheels) arere-tightened, be sure to first loosenthe outer cap nuts several turns; thenre-tighten.25FIG. 4 Cast Spoke Wheel Triangulation Torquing

11-04-4 Wheels and Tires-Three Piece Rim 11-04-4SINGLEFIG. 5 Pisc Wheel MountingFIG. 6 Disc Wheel Tightening

11-04-5 Wheels and Tires-Three Piece Rim 11-04-5DISASSEMBLY AND ASSEMBLYDROP-CENTER TUBELESS RIMSAND WHEELSDEMOUNTING1. Make certain the tire is completelydeflated with the valve core removed.2. With the tire lying flat, loosen bothbeads by walking on the tire with theheels close to the rim.3. With the wide side of the rim down,lubricate the top bead.4. With the stops toward the rim, insertthe spoon ends ofthe two tubeless tiretools about 10" apart (Fig. 7, ViewA). Holding the bead in the well withfoot, pull one tool toward the centerof the rim.5. Hold the tool in position with one footand pun the second tool toward thecenter of the rim (Fig. 7, View B).Progressively work the bead otT therim, taking additional bites with thetools as necessary.6. Stand the assembly in a verticalposition. Lubricate the second bead.7. At the top of the assembly insert thestraight end of the tool between thebead and back the flange of the rimat about a 45 degree angle (Fig. 7,View C). Tum the tool so that it isperpendicular to the rim. Pry thesecond bead otT.8. Clean and inspect the wheel and tireas previously described in this Part.MOUNTING1. Be sure the right valve is used andproperly installed in the rim.2. Inspect the rim to insure the beadseats are clean and smooth.3. Place the rim on the floor with thewide side down and lubricate the firstbead of the tire and upper bead seatof the rim (Fig. 8, View A).4. Push the first bead into the well oftherim and onto the rim as far aspossible. Using the straight end ofthetool (with stop resting on the rimflange) take small bites to workremaining section of the first beadonto rim (Fig. 8, View B).5. Hold the second bead in the well bystanding on the tire and anchor withthe vise-grip pliers (snub side towardthe tire).6. Using the spoon end of the tire toolwith stop toward the rim, use smallbites until the bead slips over theflange. Ifnecessary, insert the secondtire tool and lubricate last 6" of beadbefore completing the mounting (Fig.8, View C).7. Inflate the tire as previously describedin this Part, making certain that allthe safety precautions are followed.Check for leaks.SEMI-DROP WHEELSCAUTION: Demounting andmounting truck tires can be extremelydangerous if proper safety precautionsare not followed. Before starting with thisprocedure, PLEASE read all safety precautionsdescribed in Part 11-01.DEMOUNTING1. Place the tire and wheel on the floorwith the side ring up. Make certainthat the tire is completely deflatedand that the valve core is removed.2. To loosen the first bead, drive thehooked end of the rim tool betweenthe tire and rim flange and pressdownward on the bead (Fig. 9, ViewA).3. Progress around the rim, using thetwo tools as shown in View A.4. To remove the ring, insert the tool inthe notch and force the ring oppositeof the notch into the gutter, then pryotT (Fig. 9, View B).5. Pry out and up on the side ring,carefully but firmly. Take care not tobend the side ring.6. Force the upper tire bead into the wellopposite the valve slot and with thetire tool, pry the opposite portion ofthe bead over the edge ofthe rim (Fig.9, View C).7. Tum the tire over, and by means ofrim tools, loosen the bead on theopposite bead seat. Insert thle straightend of the tool between the bead andback flange of the rim at about a 45degree angle. Tum tool so that it isperpendicular to the rim. Make sureone portion of the second bead is stillin the rim well, then pry the oppositeportion of the bead over th,e edge ofthe rim. This will free the tire (Fig. 9,View D).8. Clean and inspect the wheel and tireas previously described in this Part.MOUNTING1. Place the tire on the rim so that thevalve is in line with the rim slot andinsert the valve through the slot.Force the first bead down into thewell ofthe rim just to side ofthe valvewith foot. Mount the first bead overthe rim lip with the rim toolprogressing from each side of the footapproximately opposite foot (Fig. 10,View A).2. To apply the second bead, sltart at thepoint opposite the valve and press thetire bead over the rim lip and into therim well with foot pressure. Mountthe remainder of the bead over therim lip by means of thin tire tool,ABF2608·2AFIG. 7 Tubeless Tire Removal

1'1-04-6Wheels and Tires-Three Piece Rim11-04-6being careful not to pinch the tube. Ifnecessary, insert the second tire tooland lubricate the last 6" of the beadbefore completing the mounting (Fig.to, View B).3. Place the half of side ring oppositetool notch under the rim lip withcutaway portions in the position asshown. Force part of the ring directlyopposite of the notch down below therim lip approximately 1" to aid inmounting, Insert the thin end of therim tool in the tool notch and pullring outward over the rim lip, whilestriking the ring with a rubber malletto start engagement over the rim.Remove the rim tool, then strike theremaining portion of the side ring toforce it down over the rim lip (Fig. to,View C).4. Inflate the tire as previously describedin this Part, making certain that allsafety precautions are followed.Check for leaks.TWO·PIECE RIMS AND WHEELSCAUTION: Demounting andmounting truck tires can be extremelydangerous if proper safety precautionsare not followed. Before starting with thisprocedure, PLEASE read all safety precautionsdescribed in Part 11-01.DEMOUNTINGI. Place the tire on the floor and makecertain that the tire is completelydeflated and that the valve core isremoved.2. Insert the hooked end ofthe tire toolsbetween the side-ring and the sidewall of the tire and pry the bead loosefrom the side-ring by downwardpressure on the rim tools. Continueprying progressively around the tireuntil the bead is completely free fromthe side ring (Fig. 11, View A).3. Insert the tapered end of the tool intothe prying notch on the side ring andpry the side ring from the groove inthe rim by prying progressivelyaround the tire until the ring is free(Fig. 11, View B).4. Turn the assembly over and unseatthe second tire bead from the rim. Liftthe rim from the tire (Fig. 11, ViewC).5. Clean and inspect the wheel and tireas previously described in this Part.MOUNTINGI. Insert the tube and flap into the tireand inflate sufficiently to round outthe tube. Apply rubber lubricant tothe inside and outside surfaces ofboththe tire beads and to that portion ofthe tube and flap that appearsbetween the beads.AB~~===~F2609·2AFIG. 8 Tubeless Tire MountingDEMOUNTING: First remove valve core tocompletely deflate tire before loosening mountingbolts. Place tire and wheel on floor with sidering up. To loosen first bead, drive hooked endof rim tool between tire and rim flange and pressdownward on bead. Progress around rim, using2 tools, as shown.;0 remove ring, insert tool in notch and force ringopposite of notch into gutter, then pry off. Pryout and up on side ring, carefully but firmly. (Becareful not to bend side ring.)Force upper tire bead into well opposite the valveslot and with tire tool pry opposite portion of beadover edge of rim.F2610·2AFIG. 9 Demounting Semi-Drop Wheels

11-04-7Wheels and Tires-Three Piece Rim11-04-72. Lay the rim flat on the floor with thevalve slot up. Align the valve with thevalve slot, place the tire onto the rimand insert the valve through the valveslot (Fig. 12, View A).3. Place the side-ring on the rim base sothat the ring split is opposite the valvestem. Place the leading end ofthe ringinto the groove (Fig. 12, View B).4. Startingat the val v e sid e ,progressively "walk" the side ringinto place. Check to see that the ringin fully seated in the groove.Note: Openings between the ends ofthe split side ring must not be less that5/32-inch except where the ringdesign calls for an abutting condition,or more than 5/16-inch after ring isseated in during operation.5. Inflate the tire as previously describedin this Part, making certain that allsafety precautions are followed.Check for leaks.THREE-PIECE RIMS AND WHEELSCAUTION: Demounting andmounting truck tires can be extremelydangerous if proper safety precautionsare not followed. Before starting with thisprocedure, PLEASE read all safety precautionsdescribed in Part 11-01.DEMOUNTING1. Place the tire and wheel on the floorwith the side ring up and make certainthat the tire is completely deflatedwith the valve core removed.2. Insert hooked end of the tire toolsbetween the side ring and side-wall ofthe tire (Fig. 13, View A). Pry thebead loose from the side ring bydownward pressure on the rim tools.Continue prying progressively aroundthe tire until the bead is completelyfree from the side ring.3. With the side flange and tire beadpushed down, insert the tapered endofthe tool into the notch near the splitin the lock ring and push downwardto pry the lock ring from the guttergroove of the rim base (Fig. 13, ViewB).•. Use the hooked end of the tool tocomplete removal of the lock ring,progressively working around the tire(Fig. 13, View C). Lift off the sideflange.5. Turn the assembly over and unseatthe second tire bead from the rim. Liftthe rim from the tire. Rc::move thetube and flap (if used) from the tire.)MOUNTING: Place tire on rim so that valve is inline with valve hole and insert valve through valvehole. Force first bead down into well of rim just toside of valve with foot. Mount first bead over rimgutter with rim tool progressing from each side offoot to point approximately opposite foot.To apply second bead, start at point opposite valveand press bead toe over rim gutter and into rimwell with foot pressure. Mount remainder of beadover rim gutter by means of thin tire tool. beingcareful not to pinch tube.Place half of side ring in rim gutter with cutawayportions in position as shown. Insert thin end ofrim tool or heavy screwdriver and pull l"ing out·ward towerd centered position. Strike with malletforcing ring into gutter. Inflate tire in safety cage.F2611·2AFIG. 10 Mounting Semi-Drop WheelsDEMOUNTING: Before removing tire and rimassembly from truck, deflate tire completely byremoving valve core. If working on duals, deflateboth tires completely before loosening mountingbolts. Remove tire from truck and place on floorside, ring up. Insert hooked end of tire toolsbetween side-ring and side-wall of tire and prybead loose from side-ring by downward pressureon rim tools. Continue prying progressively aroundtire until bead is completely free from side-ring.Insert tapered end of tool into prying notch on sideringand pry side-ring from its groove in rim by pryingprogressively around tire until ring is free.Turn the assembly over and unseat seccnd tire beadfrom rim. Lift rim from tire. Remove tube and flap,if any, from tire.F2612·2AFIG. 11 Demounting Two-Piece Rims and Wheels

11-04-8Wheels and Tires-Three Piece Rfm11-04-8MOUNTING1. Insert the tube and flap (if used) intothe tire and inflate sufficiently toround out the tube. Apply rubberlubricant to the inside and outsidesurfaces of both the tire beads and tothat portion of the tube and flap thatappears between the beads.2. Lay the rim flat on the floor with thevalve slot up. Align the valve with therim valve slot. Place the tire into therim and insert the valve through thevalve slot (Fig. 14, View A).3. Place side flange on the rim base andstand on flange to position the flangebelow the gutter grooves in the rimbase (Fig. 14, View B).4. Snap the leading end of the lock ringinto the gutter groove of the rim baseand progressively "walk" the lockring into place (Fig. 14, View C).Check to ensure that the lock ring isfully seated in the gutter groove.5. Inflate the tire as previously describedin this Part, making certain that allsafety precautions are followed.Check for leaks.ACCU-RIDE XL RIMSCAUTION: Demounting andmounting truck tires can be extremelydangerous if proper safety precautionsare not followed. Before starting with thisprocedure, PLEASE read all safety precautionsdescribed in Part 11-01.For mounting and demountinginstructions for Accu-Ride XL rims referto Fig. 15.MOUNTING: Insert tube and flap into tire andpartially inflate to round out tube. Apply rubberlubricant to inside and outside surfaces of bothbeads and to that portion of tube and flap thatappears between beads. Lay rim flat on floor withvalve slot up. Align valve with rim valve slot, placetire onto rim and insert valve through valve slot.Place side-ring on the rim base so that ring split isopposite valve stem. Place leading end of ring intothe groove in the. rim as shown.Starting at the valve side, progressively "walk" sideringinto place. Check to insure ring is fully seatedin groove.F2613-2AFIG. 12 Mounting Two-Piece Rims and WheelsDEMOUNTING: Before removing tire and rim assemblyfrom truck, deflate tire completely by removingvalve core. If working on duals, deflate both tirescompletely before loosening mounting bolts. Removetire from truck and place on floor side, ring up.Insert hooked end of tire tools between side-ring andside-wall of tire and pry bead loose from side-ring bydownward pressure on rim tools. Continue pryingprogressively around tire until bead is completely freefrom side-ring.With side-flange and tire bead pushed down, inserttapered end of tool into notch near split in lock-ringand push downward to pry lock-ring from guttergroove of rim base.Use hooked end of tool to complete removal oflock-ring,progressively working around tire. Liftoff side-flange. Turn the assembly over and unseatsecond tire bead from rim. Lift rim from tire. Removetube, and flap if any, from tire.F2614·2AFIG. 13 Demounting Three-Piece Rims and Wheels

11-04-9"-Wheels and Tires-Three Piece Rim'11-04-9MOUNTING: Insert tube and flap into the tire andpartially inflate to round out tube. Apply rubberlubricant to inside and outside surfaces of bothbeads and to that portion of tube and flap that appearsbetween beads. Lay rim flat on floor withvalve slot up. Align valve with rim valve slot,placetire onto rim and insert valve through valve slot.Place side flange on rim base and stand on flange toposition it below gutter grooves in rim base.Snap leading end of lock-ring into,gutter groove of rimbase and progressively "walk" lock into place. Checkto insure lock-ring is fully seated in gutter groove.F2615·2AFIG. 14 Mounting Three-Piece Rims and Wheels

11-04-10 Wheels and Tires-Three Piece Rim11-04-10Tools required: 1 rim mallet - 2 tubeless tire tools RT-31 - 2 rim tools RT-29 or RT-3DMOUNTINGPlace tire on rim 30 that valve is in line withrim slot and insert valve through the slot.Force first bead down into well of rim withfoot just to side of valve. Mount first beadover rim lip with rim tool working alternatelyfrom each side of foot until first bead isseated.To apply second bead, start at point oppositevalve and press tire bead over rim lip andinto rim well with foot pressure. Mount remainderof bead over rim lip by means ofthin tire tool, being careful not to pinch tube.If necessary, insert second tire tool and lubricatelast 6" of bead before completingmounting.DEMOUNTINGPlace the half of side ring opposite toolnotch under rim lip with cutaway portions inposition as shown. Force part of ring directlyopposite notch down below rim lip approx.1" to aid in mounting. Insert thin end of rimtool in tool notch and pull ring outward overrim lip, while striking ring with rubber malletto start engagement over rim. Remove rimtool, then strike remaining portion of sidering to force it down over rim lip.First, standing clear of rim, remove valvecore to completely deflate tire. Place tire andwheelan floor with side ring up. To loosenfirst bead, drive hooked end of rim tool betweentire and rim flange and press downwardon bead. Progress around rim, using 2tools, as shown.Turn tire over, and by means of rim tools,loosen bead on opposite bead seatStand assembly in vertical position. Lubricatesecond bead At top of assembly insertstraight end of tool between bead and backflange of rim at about a 45° angle. Turn toolso that it is perpendicular to nm.To start removal of ring, insert rim tool Intotool notch and pry up on ring while forcingopposite side of ring down at least l' asshown. To fully remove ring, insert a secondrim tool to the right of tool notch and workring off with this second tool.Make sure one portion of second bead is stillin the rim well, then pry opposite portion ofbead over edge of rim. This will free the ':irefrom the rim as shown.Force upper tire bead into well opposite thevalve slot and with tire tool pry opposite portionof bead over edge of rim.SPECIAL NOTE:Interchanging of 20 x 6.0 XL and 20 x 6.5 XLside ring is not recommended. The 20 x 6.0XL side ring will not carry the load of the 20 x6.5 XL assembly, even though parts willsatisfactorily fit together.The 20 x 6.5 XL side ring satisfactorily fits the20 x 6.0 XL assembly but flange height isgreater than that of rim.Effective 9/13/74 SR238XL-3 revised ascommon ring for both 20 x 6.0 and 20 x 6.5sizes.F-2635-AFIG. 15 Accu-Ride Xl Rims-Mounting and Demounting

11-04-11Wheels and Tires-Three Piece Rim11-04-11SPECIFICATIONSTIRE SIZES AND TYPESWHEEL TORQUE LIMITSType Size Code LetlerTube Type 10.00 x 20 (12 PRJ F10.00 x 20 (14 PRJ G11.00 x 20 (12 PRJ F11.00 x 20 (14 PRJ G10.00 x 22 (12 PRJ F10.00 x 22 (14 PRJ G11.00 x 22 (12 PRJ F11.00 x 22 (14 PRJ GTubeless 11.00 x 22.5 (12 PRJ F11.00 x 22.5 (14 PRJ G12.00 x 22.5 (12 PRJ F12.00 x 22.5 (14 PRJ G11.00 x 24.5 (12 PRJ F11.00 x 24.5 (14 PRJ G12.00 x 24.5 (12 PRJ F12.00 x 24.5 (14 PRJ GTubeless Radials 10R x 22.5 (14 PRJ G11R x 22.5 (14 PRJG11R x 24.5 (14 PRJGDescriptionNut SizeCF2616-1ATorque Limits(ft-Ib)Disc Wheel Nuts 3/4-16 450-5001-1/8-16 450-500Cast Wheel Rim Clamp Nut 3/4-10 200-260CF2617-2A

11-10-1 Wheels, Hubs and Bearings-Front (Except Front Drive) 11-10-1Wheels, Hubs and Bearings ­Front (Except Front Drive)PART11-10APPLIES TO ALL MODELSSUBJECT PAGE SUBJECT PAGEDESCRIPTIONFront Wheel Assembly 10-1ADJUSTMENTSFront Wheel BearingAll Medium, Heavy and ExtraHeavy Trucks ,.10-4Double Nut with Lock Ring9000 and 12000 PoundFront Axle 10-4Single Nut with Cotter Pin16000, 18000 and 20000Pound Front Axle 10-4F-100 - F-350 (4x2) andE-1 00 - E-350 10-4P-600 10-4REMOVAL AND INSTALLATIONDisc BrakesMedium, Heavy and ExtraHeavy Vehicles , , . , , .. ,10-5F-100 - F-350, E-100 - E350 ...', . , ,10-5Drum BrakesP-600 10-4Front Wheel Grease Sealand Bearings 10-4Front HulJ SealNational 10-6Stemco 10-6Oil LubricationMedium, Heavy, Extra HeavyVehicles 10-6SPECIFICATIONS 10-9DESCRIPTIONFRONT WHEEL ASSEMBLYEach front wheel and tire assembly isbolted to its respective front hub andbrake drum or hub and rotor assembly.Two opposed tapered roller bearings areinstalled in each hub, Figs. 1 and 2. Agrease retainer is installed at the innerend of the hub to prevent lubricant fromleaking into the drum or onto the rotor.The entire assembly is retained to itsspindle by the lock nut or adjusting nutand cotter pin, or an adjusting nut andlock nut combination.

11-10-2 Wheels, Hubs and Bearings-Front (Except Front Drive) 11-10-2WHEELHUB CAP9000·'2.000L.\ IiWASHERGREASEBRAKEDRUMRETAINER=BEARING CUPAXLe ,....~((\il~ ------ ---~ INNER BEARING ~b~t 'I)! ~ADJUSTING NUT IGASKE\T ADJUSTING: ~ \@I..(f}O'~~------1'1~~::::'~~ ~~:CER.Ie. NUT I / ~I I'? LOCK LOCK IGREASE NUT RING I GREASE RETAINERCAP WASHER I,IIII HUB STUD--------:--1--ICAST I'-- -STYPE " ~OUTER BEARI~/HUBBRAKEDRUMWHEELBEARING CUPF1466-eFIG. 1 Typical Front Hubs and Bearings

11-10-3 Wheels, Hubs and Bearings-Front (Except Front Drive) 11-10-3INNERBEARING1201GREASERETAINER1190"OUTER BEARING1216P-SERIESCONE AND ROLLERASSEMBLY(lNNER) __""!'"""~..I1201-AE-100-350 SERIESF-100-350 SERIES(DISC)PIN72107-S36NUT,; 351163-S2HUB AND DRUMASSEMBLY1102-3CONE AND ROLLERASSEMBLY(lNNER)1216-BBEARINGASSEMBLY(OUTER)44135-AOUTERBEARING12165500,6000 AND 7000 LB. AXLESLOCKRINGw"2"J953293WASHERL~~;-----1190GREASERETAINER12000 LB. AXLERETAINER385603-S2NUT385602-S2PIN72169-S3-f9000-12000 LB. AXLESBAFFLE2060CONE AND ROLLERASSEMBLY(lNNER)1201GREASERETAINER1190NUl38560-S2PIN72145-S36NUT386218-S2CONE AND ROLLERASSEMBLY (OUTER)12167000,9000 LB. AXLES(HEAVY)GREASERETAINERADJUSTINGNUTCOTTERPIN16000, 18000,20000 LB. AXLES~F1474-JFIG. 2 Front Hubs, Bearings and Grease Retainers

50-32-3 Lights, Instruments, Controls, Heating, Air Conditioning and Accessories 50-32-3In winter, keep reservoir filled with asolution of two parts water to one partsolvent. This helps prevent freezing anddanlage to the reservoir.CHECK HEADLIGHT ALIGNMENTCheck the headlights for properalignment. If necessary, align theheadlights using the Headlight AimingKit-Model T.R.E 540 or equivalent. Besure to use the latest manufacturersinstructions.

50-41-1 BodySUBJECTBodyPRE-DELIVERYAfter Road Test 41-1Check Bumpers and Mouldings 41-1Check Doors, Locksand Latches 41-1Check Exterior For' Fit andAppearance 41-1Check Front Bumper BoltTorque , 41-1Check Seat ControlCheck Seatback Latches41-141-1Check Tailgate Operation 41-1Check Windows and Vents 41-1Clean and Inspect Vehicle 41-1Remove Shipping ProtectiveMaterial 41-1PRE·DELIVERYAPPLIES TO ALL MODELS50-41-1P RT 150- 1PAGE,-2CHECK SEAT CONTROLCheck lever operation and testfreeness of seat movement on track andsolid lock in detent when lever is released.If equipped with suspension seat, checkfor proper functioning of all controls.CHECK SEATBACK LATCHESBe sure latches operate properly andretain seatback.CHECK WINDOWS AND VENTSCheck ease of operation, matchingposition of both window handles, andtight fit against weatherstrip. Check foralignment to opening. Refer to 1978Truck Shop Manual, Group 42, fordetailed instructions.CHECK EXTERIOR FOR FIT ANDAPPEARANCEInspect the body exterior for door andhood gaps or evidence of rubbing orbinding with adjacent panels. Checkexterior moldings for adequate retentionor extreme misalignment. Inspectbumpers for appearance.CHECK DOORS, LOCKS ANDLATCHESBe sure all doors open, close and lockfrom both inside and outside the vehicle.Check for proper latching and alignmentof latch and striker.CHECK TAILGATE OPERATIONLubricate as necessary. Check latchalignment and adjust, if necessary. Referto 1978 Truck Shop Manual, Group 44,for detailed adjustment procedures.CHECK BUMPERS ANDMOLDINGSCheck condition, fit and alignment.Adjust as required. Refer to the 1978Truck Shop Manual, Group 47, fordetailed instructions.CHECK FRONT BUMPER BOLTTORQUETighten to specifications given inSpecifications Section of this Part.REMOVE SHIPPING PROTECTIVEMATERIALRemove all shipping: covers fromvehicle except the tape under the hoodflange on L-Series trucks. This tapeshould not be removed.CLEAN AND INSPECT VEHICLERemove the windshield andtapes. Wash the vehicle and check forleaks. Inspect rnetal and paint condition,and touch up chips and scratches. Check forexcess sealer. CAUTION: Do not use steelwooL abrasive type cleaners, or strong de-·tergents containing highly alkaline or causticagents on chrome plated materi,ds,aluminum wheels, or anodized aluminumparts because the protective coating may bedamaged and discoloration or paintdeterioration.AFTER ROAD TeSTRemove seat protector and tapes.Inspect interior paint condition, andtouch up chips and scratches. Check forsoft trim soilage and excess sealer.Check information on ownercardwith warranty plate and be sure Owner'sManual is in glove compartment.

50-41-2Body50-41-2LUBRICATIONLOCK AND PIVOT POINTSTo eliminate any binding conditionson pivot and friction points, spraypolyethylene grease on hood hinges,auxiliary catch and latch; door hinges,hinges check, rotor and striker plate; andon the tailgate hinges. Operate all pivotpoints several times to be sure lubricanthas been worked in.Also, apply lock lubricant to the lockcylinders, including the ignition lock, andinsert and turn key several times to workin the lubricant.See Part 50-03 for lubricantspecifications.CAB LATCH MECHANISM (C­SERIES)Lubricate the lock handle linkage andlocking cams with lOW oil at all pivotpoints. Operate the mechanism to workthe lubricant into all points.MAINTENANCECLEAN BODY AND DOOR DRAINHOLESDrain holes, located along the bottomsurface of the door and side panels,should be inspected periodically forobstructions. A practical time forinspection is whenever vehicle is washed.Use a small screwdriver or similar tool toclean drain holes.SPECIFICAliONSFRONT BUMPER BOLTS TORGUE3/8 Inch . .30-40 Ft-Lbs.7/16 Inch . 50-70 Ft-Lbs.9/16 Inch . 80-90 Ft-Lbs.1/2 Inch . 75-105 Ft-Lbs.5/8 Inch . . . . . . . . . . 140-180 Ft-Lbs.CY 1375-8

DECIMAL AND METRIC EQUIVALENTSFractions Decimal In. Metric MM. Fractions Decimal In. Metric MM.1/64 .015625 .39688 33/64 .515625 13.096871/32 .03125 .79375 17/32 .53125 13.493753/64 .046875 1.19062 35/64 .546875 13.890621/16 .0625 1.58750 9/16 .5625 14.287505/64 .078125 1.98437 36/64 .578125 14.684373/32 .09375 2.38125 19/32 .59375 15.081257/64 .109375 2.77812 39/64 .609375 15.478121/8 .125 3.1750 5/8 .625 15.875009/64 .140625 3.57187 41/64 .640625 16.271875/32 .15625 3.96875 21/32 .65625 16.6687511/64 .171875 4.36562 43/64 .671875 17.065623/16 .1875 4.76250 11/16 .6875 17.4625013/64 .203125 5.15937 45/64 .703125 17.859377/32 .21875 5.55625 23/32 .71875 18.2562515/64 .234375 5.95312 47/64 .734375 18.653121/4 .250 6.35000 3/4 .750 19.0500017/64 .265625 6.14687 49/64 .765625 19.446879/32 .28125 7.14375 25/32 .78125 19.8437519/64 .296875 7.54062 51/64 .796875 20.240625/16 .3125 7.93750 13/16 .8125 20.6375021/64 .328125 8.33437 53/64 .828125 21.0343711/32 .34375 8.73125 27/32 .84375 21.4312523/64 .359375 9.12812 55/64 .859375 21.828123/8 .375 9.52500 7/8 .875 22.2250025/64 .390625 9.92181 57/64 .890625 22.6218713/32 .40625 10.31875 29/32 .90625 23.0187527/64 .421875 10.71562 59/64 .921875 23.415627/16 .4375 11.11250 15/16 .9375 23.8125029/64 .453125 11.50937 61/64 .953125 24.2093715/32 .46875 11.90625 31/32 .96875 24.6062531/64 .484375 12.30312 63/64 .984375 25.003121/2 .500 12.70000 1 1.00 25.40000

METRIC-ENGLISH CONVERSION TABLEto get equivalentto get equivalentMultiply by number of: Multiply by number of:LENGTHACCELERATIONInch 25.4 millimetres (mm) Foot/see2 0.3048Ineh/see2 0.025 4 Foot 0.304 8 metres (m)metre/see2 (m/s2)metre/see2Yard 0.914 4 metresMile 1.609 kilometres (km) TORQUEPound-inch 0.112 98 newton-metres (N-m)AREAPound-foot 1.355 8 newton-metresIneh2 645.2 millimetres2 (mm2)6.45 centimetres2 (em2)POWERFoot2 0.092 9 metres2 (m2) I Horsepower 0.746 kilowatts (kV'J)Yard2 0.836 1 metres2PRESSURE OR STRESSVOLUMEInehes of water 0.249 1 kilopascals (kPa)Inch3 16 387. mm3 Pounds/sq. in. 6.895 kilopascals16.387 cm30.016 4 litres (1) ENERGY OR WORKQuart 0.946 4 litres BTU 1 055. joules (J)Gallon 3.785 4 litres Foot-pound 1.355 8 joulesYard3 0.764 6 metres3 (m3) Kilowatt-hour 3 600 000. joules (J = one W's)MASSor 3.6 x 106Pound 0.453 6 kilograms (kg) LIGHTTon 907.18 kilograms (kg) Foot candle 1.076 4 lumens/metre2 (Im/m2)Ton 0.907 tonne (t)FUEL PERFORMANCEFORCEMiles/gal 0.425 1 kilometres/litre (km/I)Kilogram 9.807 newtons (N) Gal/mile 2.352 7 litres/kilometre (I/km)Ounce 0.278 0 newtonsPound 4.448 newtons VELOCITYTEMPERATUREMiles/hour 1.609 3 kilometres/hr. (km/h)Degree Fahrenheit (t O F-32r:- 1.8 degree Celsius