Demo 20078

Copyright © 2012, Forel Publishing Company, LLC, Woodbridge, Virginia
All Rights Reserved. No part of this book may be used or reproduced in any manner whatsoever
without written permission of Forel Publishing Company, LLC. For information write to Forel
Publishing Company, LLC, 3999 Peregrine Ridge Ct., Woodbridge, VA 22192
1978 Ford Truck Shop Manual

EAN: 978-1-60371-086-2
ISBN: 1-60371-086-8
Forel Publishing Company, LLC
3999 Peregrine Ridge Ct.
Woodbridge, VA 22192
Email address: sales@ForelPublishing.com
Website: http://www.ForelPublishing.com
This publication contains material that is reproduced and distributed under a license from Ford
Motor Company. No further reproduction or distribution of the Ford Motor Company material is
allowed without the express written permission of Ford Motor Company.
Note from the Publisher

This product was created from the original Ford Motor Company’s publication. Every effort has
been made to use the original scanned images, however, due to the condition of the material;
some pages have been modified to remove imperfections.
Disclaimer
Although every effort was made to ensure the accuracy of this book, no representations or
warranties of any kind are made concerning the accuracy, completeness or suitability of the
information, either expressed or implied. As a result, the information contained within this book
should be used as general information only. The author and Forel Publishing Company, LLC
shall have neither liability nor responsibility to any person or entity with respect to any loss or
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this book. Further, the publisher and author are not engaged in rendering legal or other
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services of a competent professional should be sought.
I VOLUME 1 I CHASSIS
GROUP AND PART INDEX
IDENTIFICATION CODES 10-00-1
GENERAL WHEEL AND TIRE SERViCE ., 11-01-1

WHEEL 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) 11-14-1
WHEELS AND TIRES - Drop Center Rim ., .. ., ., 11-02-1
- Three-Piece Rims 11-04-1
- Two-Piece Rims 11-03-1
AIR BRAKES - Cam Type 12-48-1

AIR/HYDRAULIC INTENSIFIER 12-42-1
ANTI-LOCK BRAKE SYSTEMS 12-41-1
DISC BRAKES - Light and Heavy Duty Sliding Caliper '" 12-24-1
- Heavy Duty 12-25-1
DRUM 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 12-05-1
GENERAL AIR BRAKE SERViCE 12-40-1
GENERAL HYDRAULIC BRAKE SERVICE 12-01-1
PARKING 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· 12-84-1
VACUUM 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) 12-54-1
GENERAL STEERING SERViCE ., ., ., .,13-01-1

INTEGRAL POWER STEERING GEAR- Ford 13-41-1
- Saginaw 13-42-1
- Ross HF-54, HF-64 13-44-1
- Ross HFB-52 13-45-1
MANUAL STEERING GEAR- Recirculating Ball 13-33-1
- Worm and Roller 13-34-1
POWER STEERING PUMP- Eaton 13-51-1
- Saginaw 13-52-1
- C II 13-53-1
STEERING COLUMN 13-06-1
- Floor Mounted Shift Control 13-07-1
- Shift Rod Above Tube 13-05-1
STEERING LINKAGE - Manual 13-24-1
- Power Cylinder/Control Valve ; 13-23-1
- Power Gear/Power Cylinder 13-22-1
FRONT SUSPENSION - Solid I-Beam 14-20-1

- Twin I-Beam 14-21-1
- 4-Wheel Drive " 14-22-1
GENERAL SUSPENSION SERVICE 14-01-1
REAR SUSPENSION - Hendrickson Tandems 14-40-1
- Leaf Springs 14-31-1
- Reyco 101 Tandem 14-41-1
I VOLUME 1 I CHASSIS I
GROUP 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 Type
U-Joi nt 15-62-1
FRONT DRIVING AXLE - Rockwell 15-33-1
- 44F-9F-Dana 15-30-1
- 60-7F-Dana 15-32-1
GENERAL DRIVING AXLE AND DRIVE SHAFT SERViCE 15-01-1
INTEGRAL CARRIER AXLE - Dana 15-05-1
LIMITED SLIP DIFFERENTIAL- Dana 15-42-1
REMOVABLE CARRIER AXLE - Ford 15-10-1
ROCKWELL TANDEM AXLES - Top Mounted 15-52-1
SINGLE-SPEED, SINGLE REDUCTION AXLE - Eaton 15-15-1
- Rockwell 15-16-1
TANDEM AXLE - Eaton 15-50-1
- Rockwell 15-51-1
TRACTION-LOK LIMITED SLIP DIFFERENTIAL- Ford 15-40-1
2-SPEED DOUBLE REDUCTION AXLE - Eaton 15-20-1
CLARK - 280 Five-Speed Transmission 16-40-1

- 390 Five-Speed Transmission 16-39-1
CLUTCH 16-02-1
FORD 3.03 THREE SPEED TRANSMiSSiON 16-11-1
- Four-Speed Over-Drive Transmission 16-30-1
FULLER - 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··46-1
GENERAL CLUTCH SERViCE 16-01-1
GENERAL MANUAL TRANSMISSION SERVICE 16-10-1
HYDRAULIC CLUTCH CONTROLS 16-04-1
MECHANICAL CLUTCH LINKAGE 16-03-1
NEW PROCESS 203 FULL TIME TRANSFER CASE 16-85-1
NEW PROCESS PART TIME 205 TRANSFER CASE 16-84-1
NEW PROCESS 435 FOUR-SPEED TRANSMISSION 16-25-1
NEW PROCESS 542 FIVE-SPEED TRANSMISSION 16-26-1
ROCKWELL T-223 - C1 Transfer Case 16-83-1
SPICER - 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 16-56-1
WARNER T18 FOUR-SPEED TRANSMiSSiON 16-23-1
WARNER T19 FOUR-SPEED TRANSMiSSiON 16-24-1
AT-540 AUTOMATIC TRANSMiSSiON 17-27-1

C6 AUTOMATIC TRANSMiSSiON 17-10-1
C4 AUTOMATIC TRANSMiSSiON 17..05-1
GENERAL AUTOMATIC TRANSMISSION SERViCE 17-01-1
MT-SERIES AUTOMATIC TRANSMiSSiON 17··30-1
SHIFT CONTROL LINKAGE 17-02-1
NOISE, VIBRATION AND HARSHNESS DIAGNOSiS 18-01-1

foreword ...
This 1978 Truck Shop Manual has been prepared to provide information
covering normal service repairs and maintenance for 1978 Ford Trucks
manufactured in the United States and Canada. It is divided into five
volumes, each covering a specific major area:
Volume 1 - Chassis
Volume 2 - Engine
Volumes 3 & 4 - Body and Electrical
Volume 5 - Pre-Delivery, Maintenance and Lubrication.
Information in each volume is divided into Groups covering a general

system. The table of contents on the cover of each volume indicates the
Group title, number, and volume in which each Group is located.
For 1978, the basic part number for components covered in the Group is also
included in parenthesis after the Group number.
Example: Cooling System Group 27 (8000)
--------------
General System Covered
in Group
~
Group Number
~
Basic Part Number
for Cooling System
Components
Some components covered within a Group do not have the same basic part
number. In these cases, more than one basic part number will appear on the
Group index.
Example: Gasoline Engines Group 21 (6000 & 9000)

~ ~ ~
General System Basic Part Intake and

Covered in Group Number for Exhaust Manifold
Gasoline Basic Part
Engine Number Only
Components
For easy reference, information in each Group has been divided into smaller
units or Parts. There is one Part for each component in the system, as well as
a General Service Part in some Groups to cover procedures common to
several components within the Group. In general, each Part contains the
Description, Operation, Diagnosis and Testing, Removal and Installation
and Disassembly and Assembly procedures for the component covered in
the Part. Diagnosis Charts are also included in some Parts to help you
systematically 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 ofeach
volume provides an alphabetical listing, with page number, for all Parts in
the volume. The tab locator on the right side of this index will help you find
the first page of each Group.
On the first page ofeach Group there is an index listing the Part title and Part
number for each component covered within the Group. The first page of
each Part contains an index to locate service operations covered in that
Part. This Group-Part breakdown is also indicated in the page number
located at the top of each page.
Example: 11-02-21 = (Group) 11 - (Part) 02 - (Page) 21

Metric conversion tables have been included at the back of each volume to
aid in converting specifications in this manual to the metric equivalent.
The descriptions and specifications in this manual were in effect at the time
this manual was approved for printing. Ford Motor Company reserves the
right to discontinue models at any time, or change specifications or design
without notice and without incurring obligation.
IMPORTANT SAFETY NOTICE
Appropriate service methods and proper repair procedures are essential for
the safe, reliable operation of all motor vehicles as well as the personal
safety of the individual doing the work. This Shop Manual provides general
directions for accomplishing service and repair work with tested, effective
techniques. Following them will help assure reliability.
There are numerous variations in procedures, techniques, tools, and parts

for servicing vehicles, as well as in the skill of the individual doing the work.
This Manual cannot possibly anticipate all such variations and provide
advice or cautions as to each. Accordingly, anyone who departs from the
instructions provided in this Manual must first establish that he com-
promises neither his personal safety nor the vehicle integrity by his choice
of methods, tools or parts .
...
Ford Parts and Service Division
Training and Publications Department
10-00-1 Identification Codes 10-00-1
PART
Identification Codes 10-00
APPLIES TO ALL MODELS
SUBJECT PAGE SUBJECT PAGE
RATING PLATE 00-1 VEHICLE DATA (Cont'd)
VEHICLE CERTIFICATION DECAL 00-1 Exterior Paint Color Codes 00-7
VEHICLE DATA 00-1 Max. GVW Codes 00-8
Assembly Plant Codes 00-6 Sequential Serial and Warranty
Axle Codes (Front) 00-14 Number Codes 00-6
Axle Codes (Rear) 00-13 Transmission Codes 00-12
Body Codes 00-12 Truck Series Codes 00-4
D.S.O. Codes 00-14 Type/GVW Codes 00-8
Engine Codes 00-5 Wheelbase Codes 00-7
VEHICLE IDENTIFICATION NUMBER 00-1
GENERAL INFORMATION
VEHICLE CERTIFICATION DECAL VEHICLE IDENTIFICATION under TYPE/G.V.W. designate the
The Vehicle Certification Decal (V. C. NUMBER (VEHICLE SERIAL AND truck model within a series and the gross
Decal) is attached to the rear face of the WARRANTY) vehicle weight rating. The letter and
driver's door or door pillar (Fig. I). The The identification number is the first numerals under BODY designate the
upper half of the decal contains the name of line of numbers and letters appearing on interior trim, seat and body type. The
the manufacturer, the month and year of the Rating Plate (Fig. 2). The first letter transmission installed in the vehicle is
manufacture and the certification state- and two numbers indiate the truck series identified under TRANS by either a
ment. The V.C. Decal also contains the code. The letter following the truck series numeric or alphabetical code (if two
Vehicle Identification Number. code designates the engine identification symbols appear, the first identifies the
The remaining information codes on the code. The letter following the engine auxiliary transmission, if so equipped,
V. C. Decal are the same as the Truck Rating identification code indicates the assembly and the second symbol identifies the main
Plate Codes (Fig. 2). Vehicle codes shown plant at which the vehicle was built. The transmission). A letter and a number or
on the Truck Rating Plate are explained in remaining numbers indicate the two numbers under AXLE identify the
the following paragraphs. consecutive unit number (Serial and rear axle ratio (when required, a letter is
warranty number). The charts that also stamped behind the rear axle code to
RATING PLATE follow list the various vehicle identify the front axle capacity). The
Fig. 2 illustrates a typical Truck identification number codes. maximum gross vehicle weight in pounds
Rating Plate. On light and medium cowl is stamped under MAX. G.V.W.
and windshield vehicles, the Rating Plate A two-digit number is stamped under
is mounted on the right side of the cowl VEHICLE DATA D.S.O. to identify the district which
top panel under the hood. On stripped The Vehicle Data appears on the ordered the vehicle. If the vehicle is built
Parcel Delivery vehicles, the rating plate Rating Plate on the two lines following to special order (Domestic Special Order,
is placed in an envelope stapled to the the identification number. The first three Foreign Special Order, Limited
dunnage box. On Bronco models, the digits under W.B. designate the Production Option, or other special
plate is mounted on the inside panel of wheelbase in inches. The one or two order), the complete order number will
the glove compartment door. On all other letters under COLOR identify the also appear under D.S.O. The charts that
vehicles, the Rating Plate is mounted on exterior paint color (two letters designate follow Figure 2 list the various vehicle data
the rear face of the left front door. a two-tone). The letter and three digits codes.
COMPLETE VEHICLES
(UNITED STATES) (CANADA)
0f=MFD. BY FORD MOTOR CO. IN U.S.A. I MFD, BY FORD MOTOR CO. OF CANADA LTD.
2 08n7 GYWR: 5750 L8/2608 KG4-0 GYWR:
RONT GAWR: 2870L8 REAR GAWR n 181 L FRONT GAWR: REAR GAWR:
1301 KG WITH 1459 KG WITH WITH WITH
H78 - 158 nRES H78 - 158 TIRES nRES nRES
RIMS~O RIMS RIMS
I
15 x 5.5K RIMS 15 x 5.5K
AT 30 PSI COLD AT 32 PSI COLD""'IIi~t---- AT PSI COLD AT PSI COLD
THIS VEHICLE CONFORMS TO ALL APPLICABLE FEDERAL 11 THIS VEHICLE CONFORMS TO ALL APPLICABLE FEDERAL
MOTOR'VEIleLE SAFETY STANDARDS IN EFFECT ON THE DATE MOTOR VEIICLE SAFm STANDARDS IN EFFECT ON THE DATE
OF MANUFACTURE SHOWN ABOVE. 12 OF MANUFACTURE SHOWN ABOVE
VEH IDENT NO.

TYPE TRUCK
E048HAE VEH. IDENT. NO.
TYPE
CANADA 8UILT UNITS
UTILITZE SAME TYPE DATA
r--
I
AS U.S.A
DECAL APPLIED TO
ALL CANADIAN BUILT
UNITS.
INCOMPLETE VEHICLES
THE INCOMPLETE VEHICLE LABEL IS ATTACHED TO A BOOKLET (INCOMPLETE VEHICLE MA!'IL ALl A!'ID SECURED TO A
SUITABLE INTERIOR LOCATION FOR INFORMATION USE AT DESTI!'IATlO!'l.
(UNITED STATES) (EXPORT)

THIS INCOMPLETE VEHICLE MFD. BY THIS INCOMPLETE VEHICLE MFD. BY
FORD MOTOR COMPANY FORD MOTOR COMPANY
THE AMERICAN ROAD THE AMERICAN ROAD
DEARBORN, MICHIGAN 48121 ON: 08177 DEARBORN, MICHIGAN 48121 ON: 08177
VEH. IDENT. NO. E37HHAEoo02 VEH. IDENT. NO.
GVWR
GVWR 1000 LB/43~5 KG
FRONT GAWR
4000 LB
REAR GAWR
6700 LB
REAR REAR GAWR
LB
I FRONT GAWR I REAR GAWR I REAR REAR GAWR I
1814 KG 3039 KG KG
I 8,:aR~~!.5E
16.5 x 6.0
I REAR
8.00 - 16.5E
16.5 x 6.0
FRONT REAR
60 55
TIRES TIRES
RIMS RIMS
PSI COLD PSI COLD
MAY BE MAY BE THIS VEHICLE MFD FOR EXPORT
COMPLETED AS: TRUCK BUS (NOT SCHOOL BUS) COMPLETED AS: ONLY ON DATE SHOWN ABOVE
NOTE - The same information is on all safety certification decal although the location of the information on the decal may be different.
I
Name of Manufacturer (!)Rear Gross Axle Weight Rating In Pounds (LB) and Kilograms (KG)
ate of Manufacture Rear Tire Size
3 Front Gross Axle Weight Ratings in Pounds (LB) and Kilograms (KG) Rim Size
4 Front Tire Size 1 Rear Tire Cold PSI
~
Rim Size (1 Vehicle Identification Number (See Fig. 2 for details)
• ront Tire Cold PSI 13 Vehicle Data (See Fig. 2 for details)
7 ross Vehicle Weight Rating in Pounds (LB) and Kilograms (KG)
GY1813-A
FIG. 1 Typical Vehicle Certification Decal

CD TRUCK SERIES CODE

® MODEL CODE AND GVW
® ENGINE CODE
® INTERIOR TRIM, SEAT AND BODY/CAB TYPE
CD ASSEMBL Y PLANT CODE @ TRANSMISSION CODE
0 SEQUENTIAL SERIAL AND WARRANTY NUMBER @ DISTRICT/SPECIAL ORDER CODES
® RECOMMENDED MAXIMUM GROSS VEHICLE @ R,EAR AXLE CODES

WEIGHT RATING IN POUNDS
@ FRONT AXLE CODES (IF SO EQUIPPED)
® WHEELBASE IN INCHES
G) EXTERIOR PAINT CODES
W1017·L
FIG. 2 Typical Truck Rating Plate

TIIUCI . . . CODES
L·IERIEI - CONVEmOIAL {Conti d)
Cod. Balle IIrlll
L·Slrlll - 011111
K80 L8000
K81 L8000
K90 L9000
LT·lIrllI - Ga.
IROIICO F·SERIES SUPER CAB - GAS T80. T81 LT800
Code O.scrlptlon TOO. T91 LT900
Chl..ls
U15 U-150 W on 4x4 Plck·Up LT·S.rlll - 01.111
Clb Bille Slrlil
Code
Code U80. U81 LT8000
E·1. THRU E-3IG
U90. U91 LT9000
..........1 llper X17 X10 F100
Ollcrlptlon LTS·S.rllI - Gal
CollI X16 X14 F150 4x4
E·1. . .rII.
Cod.
-- X19 X15 F150 V80. V81 LT8800
X27 X25 F250 V90. V91. V92 LTS900
E01 - E100 Club Wagon 5 Passenger
X28 X26 F2504x4
E02 - E100 Club Wagon 8 Passenger
X37 X35 F350
LTS-SlrllS - Dle..1
E04 - E100 cargo Van Y80. Y81 LT88000
EOS - E100 Window Van F-IOO - CONVENnONAL - GAS Y90. Y91. Y92 LTS9000
E06 - E100 Display Van
Ba.1e S.rII.
E·1. . .rII. Code N·SERIES - SHORT COIIVEmOMAL
E11 F60 F600 Cod. .Ballc SlrIII

811 E150 Club Wagon 5 Passenger
E12 812 E150 Club Wagon 8 Passenger F61 F600
N·Serlll- Gal
E14 814 F65 F600 4x4
E150 cargo Van
F66 F600 4x4 N60 N600
E15 815 E150 Window Van
N61. N62 N600
E16 816 E150 Display Van
N70. N71 N700
E·....... N75. N76 N750
B-tOO - COWL BUS - GAS
E20 820 E250 Club Wagon 11 Passenger N80. N81 N800
Code Ba.le Slnll N90, N91
E21 821 E250 Club Wagon 5 Passenger N900
E22 822 E250 Club Wagon 8 Passenger B60 B600 N·S.rlll - 01...1
E23 823 E250 Club Wagon 12 Passenger B61 B600
R70. R71 N7000
- 829 E250 Club Wagon 15 Passenger
R80. R81 N8000
E24 824 E250 cargo Van F·700 - 7 . - COWENnOHAL
E25 825 E250 Window Van ROO N9000
Code Balle Slrlll
E26 826 E250 Display Van NT·llrlll - Gil
F70 F700 (Gas)
E-3IGIIrII. sao,881 NT800
F82 F800 (Gas)
E30 S30 E350 Club Wagon 11 Passenger 590. S91 NT900
K70 F7000 (Diesel)
-- 832 E350 Club Wagon 8 Passenger
833 E350 Club Wagon 12 Passenger
K71 F7000 (Diesel) NT·Slrlll - 0111.1
W80. W81 NT8000
- 839 E350 Club Wagon 15 Passenger 1·711 - 7a. lUI CHAlIII COWL W90. W91 NT9000
E34 S34 E350 cargo Van
E35 835 E350 Window Van Code Balle S.nll C·IERIEI - LOW nLT CAli
E36 836 E350 Display Van B70 B700 (Gas) .£H!. !alle I.rlil
B71 8700 (Gas) C·llrllI- Gal
EcllllIIH "C...!!!" Mod.1
J70 B7000 (Diesel) ceo C600
E27 - E250 Cutaway
C61 C600
E37 - E350 Cutaway
p·a-GAS C70 C700
.....1Dellv.ry
C75 C750
E28 - E250 Cutaway Balle Serlll C80 C800
E38 - E350 Cutaway P600 COO. C91 C900
F-IERIEI COIMImOIAL GAS C·I.rlll - 01.111
CIIIal. L·IERIES - CONVENnONAL 070 C7000
PleIl·Up 080
Clit la.lc Slrlil Codl Balle Serlll C8000
CallI ~ CT·Slrlil - Gil
F17 F10 F100 L·SlrllI - Ole..1
L80 CT800
F16 F14 F150 4x4 A90 LT-900 (LTL 9000 080) L90. L91 CT900
F19 F15 F150
L·I.rllI - Gal . CT·llrlll - 01...1
F27 F25 F250
F28 F26 F250 4x4 F80. F81 L800 Q80 CTsOoo
Fg7 F35 F350 F90 F91 L900 CY1700-D
ElGlIE CODES
EIG.E CODES
GAS ElellE CODES--IROICO
Code Engl.e CID Litre Cyl.
H 351-2V 5.8L 8
S 400-2V 6.6L 6
GAS EIlIIE CODE$-LT. TRUCK (F-100 THRU F-350) 7 7 0 0 4 8
Code Engl. CID Litre Cyl.

B 300-1V 4.9L 6
G 302-2V 5.0L 8
DIESEL ENGliE CODES - CATERPILLAR
Z (DSO)
H 351-2V 5.6L 6 CODE CID MODEL H.P. RPM
S 400-2V 6.6L 6
-
B 636 3208 175HP 2800
J 460-4V 7.5L 8
D 636 3208 210HP 2800
GAS EIGIIE CODE~EDIUM TRUCK (F AND B-600) a 636 3208 200HP 2800
H 893 3406 280HP 2100
Colle E.glne CID Litre Cyl. J 893 3406 HT 280HP 1900
B 3QO-1V H.D. 4.9L 6 M 893 3406 325HP 2100
D 33()..2V X.D. 5.4L 8 C Special Order CaterpiJIar DSO
E 361-4V X.D. 5.9L 8
0 330·2V LPG (DSO) 5.4L 8
W 361·4V LPG (D50) 5.9L 8 DIESEL ENGINE CODES - CUMMINS
M 361-2V LPG (DSO) 5.9L 8 CODE CID MODEL H.P RPM
X 391-4V LPG (OSO) 6.4L 8
J 3QO·2V LPG (OSO) 4.9L 6 1 855 NH230 230HP 2100
Z (DSO) 9 855 NTC230 230HP 2100
X 855 NTC230 230HP 1900-
GAS ENGIIE CODES-EXPORT LOW COMP. F 855 NTC250 250HP 2100
5 855 NTC250 250HP 1900
Code Engine CID Litre Cyl.
K 855 NTC270PT 270HP 2100
2 300-1V 4.9L 6 V 855 NTC290 290HP 2100
4 330·2V X.D. 5.4L 8 U 855 NTC290 290HP 1900
5 361-2V X.O. 5.9L 8 8 855 NTC350 320HP 2100
8 351-2V 5.8L 8 3 855 NTC350 320HP 1900
L 855 NTC350 350HP 2100
'GAS EIGI. CODES--E·100 THRU E-350 (ECONOLINE AND CLUB WAGON) P 855 NTC350 350HP 1900
Code Engine CID Litre Cyl. G 903 V903 295HP 2600
S Special Order Cummins OSO
B 3OO-1V 4.9L 6
H 351-2V 5.8L 8
A 460-4V 7.5L 8
DIESEL ENGINE CODES - DETROIT
C 300-1V (3x6 4.9L 6
Fuel Economy) Code CID Model H.P. RPM
GAS ENGl. CODES-7OG-1OG SERIES AND NIOG-CIOG PARCEL 1 318 6V-53TT 210HP 2500
0 318 6V-53TT 225HP 2500
Low 2 426 671N 228HP 2100
Code Compo Engine CIO Litre Cyl. 7 568 8V71N 263HP 2100
Code 6 568 8V71N 280HP 2100
G 300-1V H.D. 4.9L 6 T 568 8V71N 304HP 2100
0 4 330-2V H.D. 5.4L 8 N 568 8V71T 308HP 2100
E 361-4V H.D. 5.9L 8 E 568 8V71T 335HP 2100
F 361-4V H.o. 5.9L 8 Y 568 8V71T 350HP 2100
475-4V 7.8L 8 4 568 8V71TT 305HP 1950
J
K 477-4V S.D. 7.8L 8 A Special Order Detroit DSO
L 534-4V S.D. 8.8L 8 Z Special Order DSO
Z OSO R Delete Engine (Glider) DSO
CY1701-D
ASSEMBLY PLANT AND SEQUENTIAL SERIAL AND WARRANTY NUMBER CODES
Code Aatmbly P1.nt

•...................O.kvllie
C••••••••••••••• Ontarto Truck
E •••••••••••••••••••M h
H Loraln
K ...•.....••.....Klna. City
4 8
L ..•• , ..••....Mlchlg.n Truck
N .•••...••...........Norfolk
R •••••••••••••••.•• S.n JOII
S Allen Plrk
U.••..•••...•••.••.Loulsvllle
V ••••••••••••• Kentucky Truck
SEQUENTIAL SERIAL AND NUMBER WARRANTY NUMBER CODES

(1m MODEL YEAR)
8nmco. LT Truck (F-100 Thru F-350) E-100 Thru E-350 (Econollne and Club Wagon)
Code
-
AEO, 000 - AF9, 999
Month.nd Vear
August, 1977-
-
Code
AEO, 000 - AF9, 999
Month and Vear
August, 1977-
AGO, 000 - AH9, 999 September, 1977 AGO, 000 - AH9, 999 SeptembE~r, 1977
AJO, 000 - AK9, 999 October, 1977 AJO, 000 - AK9, 999 October, 1977
BAO, 000 - BB9, 999 November, 1977 BAO, 000 - BB9, 999 November, 1977
BCO, 000 - BOO, 999 December, 1977 BCO, 000 - BD9, 999 December, 1977
BEO, 000 - BF9, 999 January, 1978 BEO, 000 - BF9, 999 January, 1978
BGO, 000 - BH9, 999 February, 1978 BGO, 000 - BH9, 999 February, 1978
BJO, 000 - BK9, 999 March,1978 BJO, 000 - BK9, 999 March, HI78
CAO, 000 - CB9, 999 April, 1978 CAO, 000 - CB9, 999 April, 1978
ceo, 000 - C09, 999 May, 1978 CCO, 000 - CD9, 999 May, 1978
CEO, 000 - CF9, 999 June, 1978 CEO, 000 - CF9, 999 June, 1978
CGO, 000 - CH9, 999 july, 1978 CGO, 000 - CH9, 999 JUly, 197fl
CJO, 000 - CK9, 999 August, 1978 CJO, 000 - CK9, 999 August, 1!~78
F- and .-100 (Kentucky Truck Plant) 700Thru _0 Sertes and N600 - C600 Plrcel
-Code
AEO, 000 - AE4, 999
Month and Vear
August, 1977-
-
Code
AE5, 000 - AF9, 999
Month and Vear
August, l!J77-
AGO, 000 - AG4, 999 September, 1977 AG5, 000 - AH9, 999 September, 1977
AJO, 000 - AJ4, 999 October, 1977 AJ5, 000 - AK9, 999 October, 1977
BAO, 000 - BA4, 999 November, 1977 BA5, 000 - BB9, 999 November 1977
BCO, 000 - BC4, 999 December, 1977 BCS, 000 - BOO, 999 December, 1977
BEO, 000 - BE4, 999 January, 1978 BES, 000 - BF9, 999 January, 1978
GBO, 000 - BG4, 999 February, 1978 BGS, 000 - BH9, 999 February, "1978
BJO, 000 - BJ4, 999 March, 1978 BJ5, 000 - BK9, 999 March, 19"78
CAO, 000 - CA4, 999 April, 1978 CAS, 000 - CB9, 999 April, 197fl
CCO, 000 - CC4, 999 May, 1978 CCS, 000 - COO, 999 May, 1978
CEO, 000 - CE4, 999 June, 1978 CE5, 000 - CF9, 999 June, 197fl
CGO, 000 - CG4, 999 July, 1978 CGS, 000 - CH9, 999 July, 1978
CJO, 000 - CJ4, 999 August, 1978 CJ5, 000 - CK9, 999 August, 1978
-Job #1-1978 Model Year
CY1731-C
WHEEL BASE AND EXTERIOR PAINT CODES
WHEEL BASE (1ft INCHES) EXTERIOR PAINT COLOR CODE (2 CODES IF TWO TOftED)
Branco
Refer To Volume 3 & 4, Group 30-00 For AComplete Usting of
104 1978 Truck Exterior Paint Codes.
F-100 Dru F-350
117 150
133 155
137 161
139 167
140
F- Ind 1-100
134 182 212
146 188 222
156 194 242
158 198 260
176
E-100 Dru E-350 (Econallne Ind Club Wlgon)
124
138
158
700 Dru 1000 SlrllI Ind ~ ClOD Plrcel
099 146 167 203
111 148 174 204
124 150 175 206
134 153 176 212
135 154 184 220
136 155 185 222
137 158 186 236
138 161 188 242
143 162 194 250
144 166 202 260
280 CY1814-A
TYPE/GVW AND MAX. G.V.W. CODES
E·100 CLUB, CUSTOM, AND CHATEAU WAGONS
Conv. G.V.W.
Code
E010 5500
E012 5900
E013 5700
E020 5900
E021 6000
7 7 0 0 4 8 E·150 CLUB, CUSTOM, AND CHATEAU 'WAGONS

•• Conv. Super Conv. Sul;r
Code ~ G.V.W. G..W.
BRONCO F·2S0 (414) - 5110 - 6025
E!!!! G.V.W. Plcap Ch.1I11 - 5111 - 6200
Codl C.b Codl ~ El12 5112 6200 6400
U150 6100 E113 5113 6400 6600
U151 6400 F263 F283 6700 E114 5114 6500 6800
U152 6550 F264 F284 7300 E120 5120 6300 6200
U153 6010 F265 F285 8100 - 5121 - 6400
F266 F286 8400 - 5122 - 6600
F·100 (412) E123 5123 6500 6800
F·250 (414) SUPER CAB
Plclalp Ch.1111 G.V.W. Pickup Ch.1I11
E124 - 6700 -
£!!!!. C.b Codl C.b Code G.V.W.
Fl00 F170 4900 £!!!.. E·250 CLUB, CUSTOM, AND CHATEAU 1NAGONS
Fl0l F171 4800 X260 X280 7100
X261 X281 7600 Conv. Super Conv. s'U',lr
Fl06 F176 5400
Fl07 Fl77 5600 X262 X282 8500 Code ~ G.V.W. ~
Fl0N F17N 5200 F·350 (412) - 5200 - 7600
- 5201 - 7800
Pickup Ch.1I11 - 5202 - 8000
F·100 (412) Su,er C.b Code ~ ~ E203 5203 7600 8300
Plclalp Ch.1I11 F370 6600 E204 5204 7900 8500
~ ~ ~ F351 F371 6750 E205 - 8100 -
F372 8000 E206 - 8500 -
Xl08 X178 5700 F353 F373 8200 E207 - 8900 -
Xl09 X179 5800 F374 8300 - 5210 - 7000
Xl0N X17N 5200 F375 8500 - 5211 - 7200
F376 8900 - 5212 - 7400
F·150 (412) F377 9500 -
E214
5213
5214
-
6800
7700
8000
F378 10,000
Pickup Ch.1I11
~ F354 8300 E215 - 7100 -
Codl Clb Code F356 8900 E216 - 7800 -
F150 Fl90 6050 F359 9900 - 5220 - 6900
F151 F191 6150 F37N 10,250 - 5221 - 7200
F37P 9100 E222 5222 8200 7400
F150 (412) Super Clb - 5223 - 7700
F·350 (412) SUPER CAB E224 5224 6900 8000
Plcllup Ch.1I11 G.V.W. E225 5225 7100 8300
Code Clb Code Pickup Chllill G.V.W. E226 - 7300 -
Code Clb Code - -
X150 X190 6050
X359 X379 9200
E227
E228 -
7500
7700 -
X152 X192 6200
X153 X193 6400 F-800 (412)
- 5230 - 7600
- 5231 - 7800
Codl G.V.W. - 5232 - 8000
'·150 (414) E233 5233 7600 8300
F600 16,000 E234 5234 7900 8500
Pickup Chllill
~ C.b Code G.V.W. F602
F603
19,200
14,000
E235
E236
-- 8100
8500
-
-
F140 F160 6050 F604 16,000 E237 - 8900 -
F141 F161 6300 F605 17,400 - 5290 - 7000
F142 F162 6500 F606 17,400 - 5291 - 7900
F611 20,200 - 5292 - 8100
F-:~~ 1~14)
SUPER CAB F612
F613
21,000
22,000
-
-
5293
5294
-- 8200
8300
PI.p Chlllil
£!!!!.. ~
G.V.W. F614 22,000 - 5295 - 8400
F615 23,000
X143 X163 6400 F616 24,000 E·350 CLUB, CUSTOM, AND CHATEAU V~AGONS
F:250 412} F618 17 900 U-Haul Code (Suplr) G.V.W.
f-lOO 414
Pfeil, Chllill 5300 8000
~ C.b Code ~ ~ G.V.W. 5301 8300
F250 F270 6200 F650
F660
17,200
21,700
5302
5303
8800
9000
F251 F271 6800
F252 F272 7700 F661 24,000 5304 9300
F253 F273 7900 5320 7900
B. BUS (412) 5321 8100
F·250 412 SUPER CAB 5322 8400
~ ~ 5323 8700
Plcllup Chlllil 5324 9100
£!f!. Clb Code ~ 8600
8601
17,400
19,200 5330 8000
X251 X271 6800 8602 19,200 5331 8300
X254 X274 6300 8610 19,700 5332 8800
X255 X275 6550 8611 20,200 5333 9000
X256 X276 7800 8613 21,000 5334 9300
X257 X277 7050 8615 22,000 5390 8600
X258 X278 7600 8617 24,500 5391 8800
X259 X279 8100 8618 22,160 5392 9100
X27N 7500 5393 9400
CY1703-D
TYPElGVW AND MAX. GVW CODES - CONTINUED
E·100 ECONOLINE CARGO. WINDOW. AND DISPLAY VANS

Conv. COnY. Conv.
Cargo Window Display G.V.W.
Code Code Code
E040 E050 E060 5150
E041 E051 E061 5750
E·150 ECONOLINE CARGO. WINDOW. AND DISPLAY VANS
Conv. Super Conv. Super Conv. Super
G.V.W. G.V.W.
Cargo Cargo Window Window Display Display
(Conv.) (Super)
Code Code Code Code Code Code
8140 S150 8160 6050
E141 E151 E161 6100
E142 E152 E162 6300
E·250 ECONOLINE CARGO, WINDOW, AND DISPLAY VANS
G.V.W. G.V.W.
Cargo Cargo Window Window Display Display
(Conv.) (Super)
--
5240 S250 S260 6500
E241 5241 E251 8251 E261 8261 7550 7100
8242 8282 S262 7900
E243 E253 E263 6750
E244 E254 E264 8250
E·250 CUTAWAY VAN E-250 CUTAWAY PARCEL DELIVERY VAN
Code G.V.W. Code Code
G.V.W.
E270 8400 E280 7700
E·350 ECONOLINE CARGO, WINDOW. AND DISPLAY VANS

G.V.W. G.V.W.
Cargo cargo Window Window Dllplay Display
(Conv.) (Super)
S340 5350 S360 8100
5341 5351 S361 9100
5342 5352 5362 9400
E343 E353 E363 8550
E344 E354 E364 9500
E345 E355 E365 9800
E·350 CUTAWAY VAN E·350 CUTAWAY PARCEL DELIVERY VAN

Code G.V.W. Code G.V.W.
E370 8700 8ingle Rear E380 8750 Dual Rear
E371 9650 Single Rear
E382 10,000 Dual Rear
E372 8750 Dual Rear E383 10,500 Dual Rear
E374 11,000 Dual Rear E384 9800 Dual Rear
CY1704-D
TYPE/GVW AND MAX. G.V.W. CODES - CONnNUED
B·700 BUS CHASSIS COWL - GAS L·. - GAS (Cont'd) LT·IOO - GAS (Cont'd) LTS·. - GAS (Cont'd)
Cod.
B702
G.V.W.
23,160
Cod.
F806
G.V.W.
31,000
Cod.
T911
-
G.V.W.
60,000
-
Cod.
V905
G.V.W.
50,000
BJ05 25,080 F807 32,000 Tg14 44,800 V906 50,000
B706 24,500 F808 34,000 T915 48,000 V907 52,000
B707 25,250 F809 35,000 T916 52,000 V908 54,000
B708 27,080 F811 31,800 T917 58,000 V909 56:000
B709 26,500 F812 27,000 V911 58,000
B710 27,250 LT·8000 - DIESEL V912 60,000
L·IOO- GAS
U800 39,000 V913 62,000
8-7. BUS CHASSIS COWL - DIESEL F900 25,500 V914 64,000
U805 46,000
J707 26,500 F902 27,500 U806 50,000 V915 61,(00
J708 27,250 F905 31,000 U807 50,000 V918 41,COO
J709 27,080 F906 32,000 U808 54,000 V920 48,000
F908 34,000 U809 60,000
F·700- GAS F909 35,000 LT·. . . -GAS
U810 55,000
F701 21,000 F912 23,000 U811 56,000 A900 44,8,00
F703 23,000 F913 31,800 U812 62,000 A901 46,000
F704 24,000 U815 41,000 A902 48,000
L·a.-GAS
F706 25,500 U816 44,800 A903 50,000
F7lJ7 25,000 K802 25,500 U817 61,000 A904 50,000
F708 27,000 K803 27,000 A905 52,000
K805 31,000 LT·9000 - DIESEL A906 54,000
F709 27,500
K806 32,000 U900 43,000 A907 58,000
F-800- GAS K807 34,000 U903 46,000 A908 60,000
F820 K808 35,000 U904 50,000
23,000 LTS·9000 - GAS
K812 23,100 U905 50,000
F821 25,000
K813 31,800 U906 54,000 Y900 44,800
F822 25,500
F823 27,000 U907 58,000 Y901 58,000
L·9000- GAS U908 60,000
F824 27,500 Y902 60,000
F825 29,000 K902 32,000 U909 60,000 Y903 50,000
F826 31,000 K904 35,000 U910 62,000 Y904 50,000
F827 32,000 K907 28,000 U911 52,000 Y905 52,000
K908 31,000 U912 62,000 Y906 54,000
F·7000 - DIESEL U913 72,000 Y907 56,000
LT·.-GAS U914 44,800 Y908 61,000
K703 23,000
T804 43,000 U915 61,000 Y909 58,0100
K705 24,000
T806 46,000 U916 48,000 Y910 60,000
K706 25,500
T811 41,000 U917 58,000 Y911 62,000
K707 27,500
T812 44,800 U918 74,000 Y912 62,0100
K708 25,000
U919 76,000 Y913 72,000
K709 27,000
LT-.-GAS Y914 74,0100
K710 21,000 LTS·.-GAS
T900 Y9l5 76,000
39,000
L-800-GAS T902 41,000 V804 46,000 Y916 78,000
T904 43,000 V809 41,000 Y917 77,100
F800 23,000
T906 46,000 V810 44,000 Y918 70,000
F80l 25,000
T907 Y919 48,000
F803 25,500 50,000 LTS-900 - GAS
T908 50,000 Y920 79,100
F804 27,500
T909 54,000 V900 39,000 Y921 81,100
F805 29,000
V904 46,000
CY170~-D
TYPE/OVW AND MAX. G.V.W. CODES - (CDNnNUED)
e-.-GAS
Code G.V.W.
C802 27,500
C803 31,000
C804 34,000
4 8 C807 25,100
C·_-GAS
LTS·IOOO - DIESEL N·too-GAS NT·IOOI - DIESEL C904 25,100

C906 31,000
Code G.V.W. Code G.V.W. Code G.V.W.
COO7 32,000
Y800 39,000 N900 25,500 34,000
W800 39,000 C910
Y804 46,000 N902 27,500 37,000
W803 56,000 C912
Y805 so ,000 N905 31,000 25,100
WB04 62,000 C914
Y806 so ,000 N906 32,000 39,000
W805 46,000 C915
Y807 52,000 N908 34,000
W806 50,000
N909 35,000 C·7.-GA$
Y808 54,000 W~07 50,000
Y812 60,000 N911 23,100
W808 54.000 0701 21,000
Y814 64,000 N912 31,800
W812 41,000 0702 25,500
Y815 55,000 N·7. - GAS W814 44,800 0703 24,000
Y816 56,000 W815 55,000 0704 25,000
Y817 61,000 R702 23,000 WB16 60,000 0705 27,500
Y818 41,000 R704 25,500 W817 61,000 0706 27,000
Y819 62,000 R705 25,000 0708 23,000
R707 27,500 NT-9000 - DIESEL
N-IOO - GAS R708 27,000 C-IOOO - GAS
W903 46,000
N601 16,500 R710 21,000 WOO4 50,000 0802 27,500
N602 19,500 R712 24,000 WOO6 54,000 0806 25,100
N603 21,500 N-S.-GAS W907 43,000 0807 32,000
N612 23,000 W910 58,000 0808 35,000
N615 24,000 R802 25,500 W911 44,800
N620 22,000 R803 27,500 W912 48,000 CT·_- GAS
R805 31,000 W913 52,000 L801 42,860
N-700 - GAS R806 32,000 W914 60,000
R807 L803 44.000
34,000 W915 62,000
N702 23,000 L805 45,000
R808 35,000 W916 72,000
N703 25,500 L807 46,000
R810 23,100 W917 74,000
N705 27,000 L808 48,000
R811 31,800 W918 76,000
N706 27,500 L809 50,000
N707 25,000 N-9000 - GAS P-800 - GAS CT·IOO- GAS
N710 21,000
ROO2 32,000 15,000
N712 24,000 P600 L901 42,860
R904 35,000
P603 12,000 Loo2 44,000
N-Ioo- GAS R906 28,000
P602 17,000 L903 45,000
ROO7 31,800
N800 23,000 P605 17,000 L9,4 46,000
N801 25,000 NT·IOO - GAS L915 48,000
C·880 - GAS
N803 25,500 L916 50,000
5804 43,000 17,000
Na04 27,500 C602 L917 52,000
5806 46,000 23,000
N805 29,000 Cbl2 L918 54.000
5811 41,000
N806 31,000 C613 24,000 L919 50,000
5812 44,800 21,200
N807 27,000 C617
CT·9000 - DIESEL
N808 34,000 NT-IOO - GAS
N813 31,800 C-7OO - GAS
0801 42.860
N814 32,000 5900 39,000 45,000
C700 24,000 0803
N815 35,000 5902 41,000 44,000
C701 25,000 0804
5904 43,000
C702 25,500 0805 41,000
5906 46,000 46,000
C703 27,000 0807
5907 50,000 48,000
C704 27,500 Q808
5909 54,000
C705 21,000 0809 50,000
5914 44,800
5915 48,000
5916 52,000 CY1706·0
BODY AND TRANSMISSION CODes
4 8
.ODY CODES
Refer to Volume 3 & 4. Group 30-00 for a complete listing of 1978

Truck Body Codes.
700 THAU _ SERIES .ND .... ceoo PARCEL

0•• 01...1
L Allison AT-540 Automatic
TRANSMISSION CODES 8 Allison MT-640 Automatic
H H Allison MT-650Automatic
Code Description 4 Clark 280 5-Speed
Econollne - Club Wlgon 2 2 Clark 282 5-Speed
C . . . . . .. . . .. . .. . . . .. 3-Speed Manual M M Clark 285 5-Speed
G . . . . . . . . . . . . . . . . . .. Cruisomatic 6 Clark 390 5-Speed
8 . .. . . .. .. .. .. . . . ... Clark Manual 4-Speed Overdrive Z Clark 397 5-Speed
I Ford C-6 Automatic
Bronco - F·100·350
C C Fuller RT-61 0 10-Speed
G . . . . . . . . . . . . . . . . . .. Automatic
P P Fuller RT-613 13-Speed
C . . . . . . . . . . . . . . . . . .. Ford Manual 3-Speed
X Fuller T-905A 5-Speed
F Warner 4·Speed Manual
0 Fuller T-9058 5-Speed
A . . . . . . . . . . . . . . . . . .. New Process 4-Speed Manual
3 Fuller RT-906 6-Speed
8 . . . . . . . . . . . . . . . . . .. Clark Manual 4-Speed Overdrive
V Fuller RT-910 10-Speed
Fa • • 5 Fuller RTO-910 1O~Speed 0/0
L . .. . .. . .. .. .. . .. ... Allison AT540
9 Fuller RTO-958LL 8-Speed
P ','. . . . . . . . . . . . . . . . .. Warner T-19 4-Speed
G. . . . . . . . .. . . . . . . . .. C-6 Automatic
a Fuller RT-111 0 10-Speed
8 Fuller RT-9509A 9-Speed
4 .. . . . . . . . . . . . . . . . .. Clark 280-VO Overdrive 5·Speed 4 Fuller RT-9513 13-Speed
2 '" . . . . . . . . . . . . . . .. Clark 282-V Direct 5-Speed J Fuller RTO-9513 13-Speed 0/0
M. . . . . . . . . . . . . . . . . .. Clark 285-V Direct 5-Speed .:.- E Fuller RT-12510 10-Speed
A . . . . . . . . . . . . . . . . . .. New Process 435 4-Speed F Fuller RTO·12513 10-Speed 0/0
9 . . . . . . . . . . . . . . . . . .. New Process 542-FD Direct 5·Speed T Fuller RTOF-12513 10-Speed
o................... New Process 542-FL Direct 5·Speed A New Process NP-435 4-Speed
9 New Process NP-542-FD 5-Speed
0 New Process NP-542-FL 5-Speed
T New Process NP-542-FO 5-Speed
G Spicer SST·1007-2A 7-Speed
A Spicer SST·1010 10-Speed
AUXILIARY TRANSMISSION 7 7 Spicer CM-5052A 5-Speed
fORD HEAVY AND EXTRA·HEAVY TRUCK - PARCEL 0 0 Spicer CM-5252A 5-Speed
B 8 Spicer CM-6052A 5-Speed
Code De.crlptlon K K Spicer CM-6052B 5-Speed
4 "," Spicer 7231-0 S S Spicer CM-6052C 5-Speed
7 Spicer R-8341-2 Y Spicer RP-85163-A 16-Speed
8 .. . . Spicer 7041 R Delete Transmission (Glider)
CY1707-D2
AXLE CODES (REAR)
700 THRU 9000 SERIES AND N·IOO - C·600 PARCEL

Code Description #Capaclty Ratio
- --~
KA Rockwell R-170
w!Traction 23000 4.33
LA Rockwell R-170
MA Rockwell R-170
JF Eaton 34-0SC 34000 4.11
BF Eaton 34-DSC 34000 4.33
CF Eaton 34-DSC 34000 4.56
DF Eaton 34-DSC 34000 4.88
LF Eaton 34-0SC 34000 3.70
FF Eaton 34-DSC 34000 5.57
GF Eaton 34-DSE 34000 6.14
BRONCO AND F·100 THRU F·350 700 THRU . . SERIES AND N·. - C·800 PARCEL HF Eaton 34-DSE 34000 6.50
Code Description #Capaclty Ratio Code Description #Capaclty Ratio MF Eaton 34-DSE 34000 7.17
KF Eaton 34-DSE 34000 7.60
12 Ford 2900 ·3.00 43 Rockwell 0-140 13000 5.29 FN Eaton 34-DPC 34000 7.60
06 Ford 2900 2.75 41 Rockwell D-140 13000 5.83 FW Eaton 34-DTE 34000 6.14/8.38
14 Ford 3750 3.00 42 Rockwell D-140 13000 6.20 GW Eaton 34-0TE 34000 6.50/8.87
15 Ford 3750 3.25 44 Rockwell D-140 13000 6.80 HW Eaton 34 DTE 34000 7.17/9.77
16 Ford 3750 3.50 62 Rockwell F-l06 15000 6.20 BC Rockwell SLHD 34000 3.70
13 Ford 3750 2.75 64 Rockwell F-l06 15000 6.80 81 Rockwell SLHD 34000 4.11
H2 Ltd. Slip 3750 3.50 66 Rockwell F-l06 15000 7.20 B2 Rockwell SLHD 34000 4.44
H9 Ltd. Slip 3750 4.11 F2 Eaton 15201 15000 2-Speed 5.83/8.12 B6 Rockwell SLHD 34000 5.83
H4 Ltd. Slip 3750 3.25 F3 Eaton 15201 15000 2-Speed 6.33/8.81 B7 Rockwell SLHD 34000 6.17
23 Dana 61 5300 3.31 52 Rockwell H-17 175000 5.83 . B8 Rockwell SLHD 34000 6.83
22 Dana 61 5300 3.07 53 Rockwell H-17 175000 6.17 B9 Rockwell SLHD 34000 7.80
24 Dana 60 5300 4.10 54 Rockwell H-17 175000 6.83 AJ Eaton 38-DSC 38000 4.56
37 Dana 60 5300 3.54 55 Rockwell H-17 175000 7.17 BJ Eaton 38-DSC 38000 4.88
38 Dana 60 5300 3.73 El Eaton 16244 175002-Speed 5.57/7.57 CJ Eaton 38-DSC 38000 5.57
B4 Dana 60 Limited Slip 5300 4.10 E2 Eaton 16244 17500 2-Speed 6.17/8.58 FJ Eaton 38-DSC 38000 4.11
C7 Dana 60 Limited Slip 5300 3.54 E3 Eaton 16244 17500 2-Speed 6.50/9.04 GJ Eaton 38-DSC 38000 4.33
C8 Dana 60 Limited Slip 5300 3.73 E4 Eaton 16244 17500 2-Speed 4.88/6.78 HJ Eaton 38-DSC 38000 5.29
27 Dana 70 7400 4.10 EQ Eaton 17121 18500 5.57 LJ Eaton 38-DSC 38000 3.70
28 Dana 70 7400 4.56 FQ Eaton 17121 18500 6:14 DJ Eaton 38-DSE 38000 6.14
36 Dana 70 7400 3.73 GQ Eaton 17121 18500 6.50 EJ Eaton 38-DSE 38000 6.50
D7 Dana 70 Limited Slip 7400 4.10 HQ Eaton 17121 18500 7.17 JJ Eaton 38-DSE 38000 7.17
JQ Eaton 17121 18500 7.60 KJ Eaton 38-DSE 38000 7.60
EH Eaton 17221 18500 2-Speed 5.57/7.60 AR Eaton 38-DPC 38000 5.05
E-100 THRU E-350 (Non-Locking) FH Eaton 17221 18500 2-Speed 6.14/8.38 ER Eaton 38-DPC 38000 6.65
GH Eaton 17221 18500 2-Speed 6.50/8.87 FR Eaton 38-DPC 38000 7.60
Code Description #Capaclty Ratio HH Eaton 17221 185002-Speed 7.17/9.77 TA Rockwell SQHP 38000 3.70
01 Ford 2750 3.00 DK Eaton 18121 22000 6.50 TB Rockwell SQHP 38000 4.11
05 Ford 2750 2.75 EK Eaton 18121 22000 7.17 TC Rockwell SQHP 38000 4.44
13 Ford 3750 2.75 DB Eaton 18221 22000 2-Speed 5.57/7.60 TO Rockwell SOHP 38000 4.63
14 Ford 3750 3.00 EB Eaton 18221 22000 2-Speed 6.14/8.38 TE Rockwell SQHP 38000 4.88
16 Ford 3750 3.50 FB Eaton 18221 22000 2-Speed 6.50/8.87 TF Rockwell SQHP 38000 5.29
15 Ford 3750 3.25 GB Eaton 18221 22000 2-Speed 7.17/9.77 TG Rockwell SOHP 38000 5.83
22 Dana 5300 3.07 AG Eaton 19121 23000 4.11 TH Rockwell SQHP 38000 6.17
23 Dana 5300 3.31 BG Eaton 19121 23000 4.33 TJ Rockwell SQHP 38000 6.83
38 Dana 5300 3.73 HG Eaton 19121 23000 4.56 TK Rockwell SQHP 38000 7.80
24 Dana 5300 4.10 CG Eaton 19121 23000 4.88 Dl Rockwell SQHD
36 Dana 7400 3.73 DG Eaton 19121 23000 5.43 Hendrickson 38000 4.11
27 Dana 7400 4.10 EG Eaton 19121 23000 6.17 D2 Rockwell SQHO
FG Eaton 19121 23000 6.67 Hendrickson 38000 4.44
GG Eaton 19121 23000 3.70 D3 Rockwell SQHD
GG Eaton 23121 23000 3.70 Hendrickson 38000 4.63
E·100THRU E·350 (Loclllng) AG Eaton 23121 23000 4.11 D4 Rockwell SQHD
Code Description #Capaclty Ratio BG Eaton 23121 23000 4.33 Hendrickson 38000 5.29
HG Eaton 23121 23000 4.56 D5 Rockwell SQHD
H2 Ford 3750 3.50 CG Eaton 23121 23000 4.88 Hendrickson 38000 5.83
H4 Ford 3750 3.25 DG Eaton 23121 23000 5.43 D6 Rockwell SQHD
H7 Ford 3750 3.00 EG Eaton 23121 23000 6.17 Hendrickson 38000 6.63
C8 Dana 5300 3.73 FG Eaton 23121 23000 6.67 07 Rockwell SQHD
D7 Dana 7400 4.10 GP Eaton 23221 23000 2-Speed 4.11/5.60 Hendrickson 38000 7.80
CP Eaton 23221 23000 2-Speed 5.4317.39 D8 Rockwell SQHD
DP Eaton 23221 23000 2-Speed 6.1718.40 Hendrickson 38000 4.88
F- AND B·IOO EP Eaton 23221 23000 2-Speed 6.67/9.08 DA Rockwell SQHD
AP Eaton 23221 23000 2-Speed 4.35/5.90 Hendrickson 38000 6.17
Code Description #Capaclty Ratio Nl Rockwell R-171 23000 4.11 DB Rockwell SQHD
41 Rockwell D-140 13000 5.83 N2 Rockwell R-171 23000 4.33 Hendrickson 38000 3.70
42 Rockwell D-140 13000 6.20 N3 Rockwell R-171 23000 4.63 AV Eaton 42-DPB 44000 7.60
62 Rockwell F-l06 15000 6.20 N4 Rockwell R-171 23000 4.88 DV Eaton 42-DP8 44000 5.91
64 Rockwell F-l06 15000 6.80 N5' Rockwell R-171 23000 5.29 XB Rockwell SRDD 44000 5.78
66 Rockwell F-l06 15000 7.20 N6 Rockwell R-171 23000 5.86 6Y Rockwell SSHD 44000 3.90
F2 Eaton 15201 15000 2-Speed 5.83/8.12 N7 Rockwell R-171 23000 6.14 1Y Rockwell SSHD 44000 4.11
F3 Eaton 15201 15000 2-Speed 6.33/8.81 lA Rockwell R-170 23000 4.11 2Y Rockwell SSHD 44000 4.33
52 Rockwell H-l72 17500 5.83 2A Rockwell R-170 23000 4.33 5Y Rockwell SSHD 44000 4.63
55 Rockwell H-l72 17500 7.17 7A Rockwell R-170 23000 5.86 AX Eaton 50-DP 50000 5.61
El Eaton 16244 17500 2-Speed 5.57/7.75 8A Rockwell R-170 23000 3.70 XK Rockwell SHDD 58000 5.96
E2 Eaton 16244 17500 2-Speed 6.17/8.58 JA Rockwell R-170 XS Rockwell SFDD 65000 5.76
E3 Eaton 16244 1750<! ~-Speed 6.50/9.04 w!Traction 23000 4.11 XT Rockwell SFDD 65000 8.08
CY1707-Dl
FRONT AXLE ANOO;S.O. CODES
7 7 0 0
FRONT AXLE CODES (Not AppllCible On E·100 Thru E·350)

Bronco .nd F·100 Thru F-350
Adjultlble WItII
Front Axlef
Sturlng Col.
And Power Steering
Power
Steering --
Code
~erlng
- J - Power Steering
I R 9 3800 #Dana-6OF
E N 5 3550 #Dana 44-9F
A - - Adjustable Steering Col.
and Power Steering
F· Ind 1-800
DISTRICT SALES OFFICE (DSO) CODE PfSteerfng W/PoWer
Deille Sturlng
Code f!!!t!!~
DSO - FSO - PrO (DOMEmC. FOREIGN AND SPECIAL ORDER)
A J - Power Steeling
The D.S.O. space will show atwo digit code number of the district - K 2 5,500 STD, F-600
which ordered the unit (see chart below). This code will appear on - L 3 6,000 STD, B-600
all units-domestic or export. If unit is built on aD.S.O., E.S.O., 0 M 4 7,000
P.T.O., (special orders) the complete order number is under the E N 5 7,500
D.S.O. space ....r the district code. 700 THRU 1000 SERIES AND N-800 - C·. PARCEL
Axle Subll. Dele" Power
Axle Power Front
Steering
.nd Power or Ma••1
Subllllullon
Steering S"erlng -- Axle
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# Steer
Ease
- S B - 16,000#
- T F - 18,000#
- U I - :20,000#
- - - 6 4,700#
DISTRICT CODES
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 City A1 Central B1 Central
14 Pittsburgh 45 Lansing 74 Seattle B2 Eastern
A2 Eastern
15 Newark 46 Indianapolis 75 Phoenix B3 Atlanltic
A3 Atlantic
16 Philadelphia 47 Cincinnati 76 Denver A4 Midwestern B4 Midwestern
17 Washington 48 Detroit A6 Western B6 Western
21 Atlanta 52 Dallas 83 Government A7 Pacific B7 Pacific
22 Char10tte 53 Kansas City 84 Home Office Reserve 12 Export 12 Exp0l1
23 Memphis 54 Omaha 85 American Red Cross
24 Jacksonville 55 St. Louis 89 Transportation Services
25 Richmond 56 Davenport 87 Body Company Note: EXPORT ALPHABETICAL 1
26 New Or1eans 57 Houston
28 Louisville 58 Twin Cities 90's Export
CV1702-D
11-01-1 Wheels and Tires 11-01-1
General Wheel and Tire Service 11-01 Wheel Hubs and Bearings -
Wheels and Ti res - Front (Except Front Drive) 11-10
Drop-Center Rim 11-02 Wheel Hubs and Bearings -
Wheels and Tires - Front Wheel Drive 11-12
Three-Piece Rim 11-04 Wheel Hubs and Bearings Rear
Wheels and Tires - (Semi Floating Axle) 11-11
Two-Piece Rim 11-03 Wheel Hubs and Bearings -
Rear (Full Floating Axle) 11-14
PART
General Wheel and Tire Service 11-01
SAFETY 01-2 Front Wheel Bearing Maintenance 01-10
DIAGNOSIS AND TESTING Wheel and Tire Checking Procedure 01-8
Diagnosis Guides 01-3 ADJUSTMENTS (Cont'd.)
ADJUSTMENTS Wheel and Tire Vibration
Balancing Wheels Diagnosis Procedures 01-8
Dual Wheels and Wheels of Trucks CLEANING AND INSPECTION 01-9
Equipped with Full Floating Axles 01-9 Aluminum Wheels & Rims 01-9
Rear Wheels of Trucks with Front Wheel Bearings 01-9
Semi-Lock Differential 01-8 Rim & Wheel Maintenance 01-11
Single RearWheels F-1 00-F-350, Safety Precautions 01-11
E-100-E-350, Bronco 01-8 Tires 01-9
Wheels 01-9
11-01-2 General Wheel and Tire Service 111-01-2
SAFETY the pressure as much as you possibly can As with the drop-center rims, be
by pushing the valve core plunger. Only certain on split-rim assemblies that all air
When replacing tires, use the same then should you remove the valve core. is out before unlocking a rim or ring. Use
size, load range and construction type Keep your eyes away from the valve: Fig. special care when using tire irons. Grip
(bias, bias belted or radial) as originally 2 shows the safe way to do it. them firmly and keep them free of oil and
installed on your vehicle. When replacing grease. They can slip and fly with
wheels, use original equipment tremendous force (Fig. 4).
manufacturers wheels or equivalent
available from your Ford dealer with
equivalent capacity, width, offset and
mounting configuration as those
originally installed on your vehicle. Use
of improper replacement wheels and tires
may adversely affect ride, handling, load
carrying capacity, bearing life, tire
clearance to body and chassis
components, vehicle ground clearance,
vehicle width and brake cooling.
SAFETY PRECAUTIONS WHEN
SERVICING TRUCK TIRES
CAUTION AND SAFETY FIRST F1858·B
are bywords when handling tires, F1853·B
FIG. 4 Use of Tire Irons
particularly truck tires. Careful attention
to the suggestions that follow may FIG. 2 Safe Air Removal
A careful inspection should be made
prevent crippling injuries, or even death. Demounting tires from wheels or rims of the tire and all necessary repairs
Make it a rule to respect the terrific force requires special care. Tires on drop center should be performed. A tire spreader is
contained in an inflated tire. You may be rims are best handled on a wheel holder, very helpful (Fig. 5) but use care when
glad some day that you did. or tire-changing machine (Fig. 3). working around it. Keep the spreader
Prepare for any tire repair operation arms closed when the machine is idle.
in a safe and efficient way. In changing
tires on drop center wheels, remove the
wheel and tire from the truck, as
changing tires with the wheel on the
truck is hazardous, more difficult, and
takes more time. In servicing of all tires
use caution not to drop them (or the
wheels or assemblies) on the feet, hands
or body, or heavily on the floor (Fig. 1).
Practice good methods of lifting; use your
legs as well as your arms and your body.
This will help to prevent painful, internal
injury. When carrying tires or wheels
don't step in oil or grease. Keep the floor
clean and dry.
FIG. 3 Changing Tire on Drop Center FIG. 5 Tire Spreader

Rim Inspect the rim parts carefully for
This can help prevent cuts on hands rust, damage or distortion (Fig. 6). Never
and wrists and will make it unnecessary use rims, locking rings or flangl~s which
to' use a mallet for seating the tire. are out of shape, rusted or cracked or
Use only standard tire mounting tools broken in any way. Never use Ii ring or
and equipment. The use of makeshift other rim parts of different manufacture
tools, screwdrivers or pliers to force tires than the original rims or any different
on or off rims or wheels is dangerous. size or type.
Always lubricate tire beads to assure Tires and rims often require a buffing
sealing of tire beads on rim with rubber operation before being mounted once the
lubricant ESA-MIB6-A, or equivalent. regular repairs have been made.
The Rotunda tire changer includes a Always wear Safety Goggles, or a
bead seater/inflator using an face shield when performing any buffing
automatically adjustable inflation ring, operation.
which aids in properly seating the bead Avoid hammering rings or rims with
FIG. 1 Handling Wheels and Tires
for inflation. To properly operate the steel hammers. Small bits of steel may be
Deflating a tire properly is very Rotunda tire changer, follow the broken off the hammer or rim, flying into
important to your safety. First, reduce instructions provided. the eyes (wear safety goggles) face or
F1854-B F1855-B
FIG. 6 Visual Inspection F1859-B FIG. 8 Inflation Details

Use only accurate, tested gauges to
FIG. 7 Seating of Rings insure proper air pressure. Check all
body. Use rubber-covered, steel-headed
position where the face or body is gauges regularly with a master gauge.
hammers wherever possible (Fig. 7).
immediately over the work being done on Play it SAFE. Set a good example for
Rubber mallets only should be used on
any tire in which there is pressure. others who work with you. Follow the
passenger car tires; although with
Attach a portable safety device, made above suggestions completely. If you are
modern tire changing equipment no
especially for the purpose, to the ever tempted to take a short cut because
pounding is necessary.
assembly. This portable device should be you are in a hurry, that is the time that
Make certain the rim ring is seated to used with all types of wheels and rims. you could get hurt.
full depth of the groove, fits tightly all If the assembly is not of the type Finally, always remember, a jack is
around, and is securely locked. which requires inflation to seat the rings, provided for wheel and tire maintenance
Stand away from the valve stem as far a Safety Cage should be used, although only. Never run the engine when the
as possible while inflating tires. Avoid a the portable device is the best (Fig. S). vehicle is supported by a jack.
DIAGNOSIS AND T~STING

DIAGNOSIS GUIDES
The following guides can be used as
an 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 required
or joints
• Loose, worn or damaged suspension components, • Inspect, repair or replace as required
bushings and ball joints
• Wheels and tires out of balance • Balance wheels and tires
• Excessive lateral and/or radial runout • Check, repair or replace as required
of wheels and tires
CF2458-A
COMPLAINT POSSIBLE CAUSE CORRECTION
Demountable Rims • Improper procedures in mounting the rim to • Replace chorded rims. Check shop practices and tools
Driver reports excessive vehicle vibration the cast wheel. Failure to follow 'proper torquing to be sure manufacturers recommendations on torque foot
rough steering and excessive fatique. sequences and recommended foot pounds pounds and procedures are followed
Related maintenance complaints include of torque results in "rim chording" where the rim
excessive vibration damage and clamps exert pressure as they are tightened which
repair costs plus severe tire wear forces the rim out of round forming flat
sides on the rim.
• Improper positioning of side ring's split in relation • Reassemble with the ring split opposite (180°) the rim's
to 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 and
and 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 operating
conditions.
- For proper rim specifications.
- For proper mounting.
Disc Wheels • Dirt and rocks wedged between disc and rim. • Clean and recommend the advantages of
gutter mount design.
• Out of balance wheel and/or tire or hub and • Determine the out of balance component and balance
drum assembly. or replace.
• Improper positioning of the side ring's split. • Reassemble with the ring split opposite (180°) the
valve opening to improve balance.
• Out of round wheel (excessive radial runout). • Replace the wheel and check for: overhauling anlj
unbalanced loads. Road hazards and rugged ope'ating
conditions. Proper wheel specifications.
Vehicle • Loose or worn drive line or suspension parts. • Identify location of vibration carefully as it may be
transmitted through frame making a rear end
vibration appear to come from the front. Then
repair or replace loose and worn parts.
Drivers report excessive vehicle vibrations
rough 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 requirements
with tire engineer, recommend correct tire and rim.
Check on loading procedures.
• Road hazards (curb and rock impacts. etc.). • Check operating conditions with tire engineer for
possible change to heavier duty tire and rim.
• Improperly installed rim. • Recommend that clamp nuts be retorqued after
a 50 -100 mile seating in period of the rim assenbly
to the wheel.
Disc Wheels • Excessive lateral runout. • Replace wheel.
• Bent or distorted disc from overloading • Replace wheel. Attempts to straighten wheel can
road impact hazards or improper handling. result in fractures in the steel and weakening of
the disc or the weld between disc and rim.
Check loading and operating conditions. and
and shop practices.
• Loose mountings - Damaged studs, cap-nuts. • Tighten and/or replace worn or damaged parts. Clean
enlarged stud holes, worn or broken hub mounting 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

Cracks develop in rim base, back flange • Overloading or road hazards. • Replace rim or wheel. Check loading and operating
or the gutter area conditions. 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 maintenance
procedures.
Demountable or Wheel Rims
Side 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 recommend
proper procedures.
• Overloading, overinflation, road hazards. • Check operating conditions and recommend
right specifications.
Cracked or Broken Wheel Discs
Cracks develop in the wheel disc from hand • Metal fatigue resulting from overloading • Replace wheel. Check position of wheel on vehicle
hole 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, and
develop from stud hole to stud hole. Related recommend 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 replace
if severe.
- Broken or cracked hub barrel replace.
- Worn stud grooves replace or install recommended
serrated bolts.
- Clean mounting surfaces and re-torque cap
nuts periodically.
- Rust streaks fanning out from stud holes are a sure
indication that the cap nuts are, or have been loose.
Decreased strength because of excessive rust • Adverse storage or operating conditions. • Recommend Goodyear Motor Wheel protective finish.
or corrosion, bead seating problems, or or equivalent.
loss of pressure with tubeless tires. • Poor maintenance practices. • Recommend correct cleaning and protective
procedures.
Wheel Disc • Poor maintenance. • Keep clean and protected with paint.
Related maintenance complaints on tire damage • Wrong rim selection. • Match rims and tires to working loads and
included erratic or spotty wear. tire slippage, ply operating conditions.
separation, excessive flexing, bead chafing, tube • Rims of different size in dual mountings. • Match rim size before mounting duals. Detachable side
pinching, valve stem tearouts and 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 Mounting
Difficulties." and "Wheel Mounting Difficulties."
Maintenance 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 Rims
Maintenance reports rim mounting problems • Improper application or mismatched parts, including • Follow manufacturer's specifications. Check specs when
spacer and clamps. chains, V-Belt drives, or special load tires are involved.
• Corroded or worn parts. • Clean or replace.
Disc Wheels
Wheel mounting problems is the complaint • Improper application or mismatched parts, including • Follow manufacturer's specifications. Check specs
studs and nuts. for disc and spacing when chains, V belt drives, or
special load tires are involved.
• Corroded or worn parts. • Clean or replace.
CF2602-2A2
11-01-6 General Wheel and Tire Service 11··01-6

Dual Tires Rubbing (kissing) • Insufficient Wheel Spacing. • Check tire and wheel sizes - Make certain propl~r
size tire and wheels are used.
Damage Stud Threads • Sliding wheel across studs during assembly. • Replace studs. Follow proper wheel installation
proced 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 load
ratings.
Stripped threads • Excessive torque. • Replace Studs. Follow proper torque procedure.
Rust streaks from stud holes • Loose Cap Nuts. • Check complete assembly. Replace damaged
parts. 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 each
stud with a graphite-based lubricant.
CAUTION: Do not permit lubricant to get on ball seats of stud
holes or on ball face of cap nuts.
CF2602·2A3
MUD AND SNOW TIRES
n
NOT
I TIRE/WHEEL COMPLAINTS. I
HIGHWAY DIAGNOSIS
VIBRATION, BEATING, OR
DRUMMING NOISE WITH MUD
AND SNOW TIRES THAT CAN
I--- REPLACE WITH HIGHWAY
THREAD TIRES IF DRIVELINE
VIBRATION IS SUSPECTED.
PROCEED ACCORDIN
HIGHWAY DIAGNOSIS.
BE MISDIAGNOSED AS A
DRIVELINE VIBRATION.
10K
CHECK DRIVELINE NOIS
VIBRATION COUPLING.
I CHECK TIRES FOR EXCESSIVE INOT OK

WEAR OR CUPPING. I CHECK TIRE INFLATION, SUS-
PENSION, ALIGNMENT. RE-
PLACE EXCESSIVELY WORN
TIRES.
Fi
OK REPAIR, ADJUST OR DISCARD
ITEM.
r
I
ROAD TEST 1
0K
OK
1
ICHECK WHEEL BEARING END INOT OK I ROAD TEST I

PLAY AND ROUGHNESS. I ADJUST TO CORREc3
PLA Y OR REPLACE.
OK
NOT
C~~
T
[CHECK TIRE, WHEEL INOT OK BALANCE TIRE/WHEEL OK REPLACE TIRE WHICH
BALANCE. ASSEMBLY. NOT BE BALANCED.
I
I
OK
NOT
REPOSITION TIRE 180" ON
WHEEL ASSEMBLY.
INOT OK CHECK TIRE RUNOUT. OK CHECK WHEEL RUNOUT. REPLACE WHEEL
I I
I OK
REBALANCE.
REPLACE TIRE
I
OK
I I ROAD TEST
I
I ROAD TEST
I CHECK ALIGNMENT, SUS-
PENSION, DRIVELINE. I
ROAD TEST
I C F2626-A
I TIRE COMPLAINTS
I
I
CHECK TIRES FOR EXCESSIVE

WEAR AND CUPPING.
OK ~ t NOT OK
CHECK WHEELS FOR

REPLACE EXCESSIVEL Y WORN
LATERAL AND RADIAL
OR CUPPED TIRES
RUN OUT
OK ,~ + NOT OK
CHECK TI RES FOR LATE RA L REPLACE WHEEL IF EITHER

RUNOUT. RUNOUT EXCEEDS
SPECI FICATIONS.
OK + NOT OK
CHECK TIRES FOR RADIAL REPLACE TIRE IF LATERAL

RUNOUT. RUNOUT EXCEEDS
SPECI FICATIONS.
OK + NOT OK
BALANCE ALL WHEEL AND REINDEX TIRES AND REPLACE

TIRE ASSEMBLIES ON IF RADIAL RUNOUT EXCEEDS
VEHICLE (HIGHWAY TREADI 090" TOTAL WHEEL AND TIRE.
IBALA~CE ALL WHEEL ANol
t NOT OK I
TIRE ASSEMBLIES ON VE-
HICLE IHIGHWAY TREAD).
OK
REPLACE TI RES THAT CANNOT
BE BALANCED (HIGH WAY
TREADI.
tROAD TEST'
CF2603·2A
ADJUSTMENTS
WHEEL AND TIRE CHECKING 7. If lateral runout is more than .090 wheel. Make sure the jack is secure and
PROCEDURE inch, measure the wheel lateral safe. .
Inspect tires for wear from incorrect mnout (Fig. 9). If lateral mnout is less Spin the wheel with the engine and
mounting misalignment, loose wheel than .070 inch, replace the tire. If transmission in high gear at 30--40 mph
bearings, bent wheels, or cupping or total lateral runout is more than .070 on the speedometer. Do not spin powered
scalping from inbalance. Tires which inch, replace the wheel. After wheels with a wheel spinner. Start the
show irregularities and definite replacing, check runout again. wheel as gradually as possible. Take care
roughness must be replaced. NOTE: to avoid jerking condition on trucks
See the instructions provided with the 1. When remounting the tire on the equipped with an automatic shift. Use an
Rotunda Wheel Balancer. wheel, use ample tire mounting accelerator pedal prop on vehicles not
Make certain that the brakes are not lubricant, ESA-MIB6, or equivalent, equipped with a hand throttle.
dragging and wheel bearings are properly on the tire and wheel bead seat area. To balance, place the pick-up as close
adjusted before attempting to spin the Inflate tires to 45 psi for passenger to the wheel as possible; then, with the
wheels. On vehicles equipped with disc
brakes, push the brake shoes into the
caliper to free the rotor.
WHEEL AND TIRE VIBRATION

DIAGNOSIS PROCEDURES
NOTE: Mud and snow type tire

vibration can often be mistaken for
driveline problems, especially when mud
and snow type tires are used on all wheels
on 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 tire
f. '
flat spotting. Check tires for excessive ~CHECKTOTAL CHECK TOTAL
RADIAL RUNOUT HERE LATERAL RUNOUT HERE
wear, inflation pressure or cupping.
Check for alignment, or suspension
problems that are indicated by the tire
F2457-A
wear patterns.
2. Spin front tires by hand to check FIG. 9 Correct Placement of Runout Indicator Pickup
bearing roughness. Replace worn car type tires, or 80 psi for truck type wheel spinning at the speed where the
bearings. tires to insure proper bead seating. maximum vibration is showing, read the
3. Check for visible wheel or tire wobble. Bleed tires to specified inflation strobe and follow the same proc,~dure as
Replace as required. pressure. balancing front wheels.
4. Check tire and wheel balance. Correct 2. If wheel and tire assembly is still not
as necessary. Balance wheels by either in balance after using on-the-vehicle
static and dynamic wheel balance. Rear Wheels of Truck with
balancer, or dynam ic balance Semi-lock Differential
Refer to section on "Balancing machine, the problem could be
Wheels". unbalanced brake drums. With Use one of the following methods for
5. If problem still exists, check both the vehicle raised on a hoist,! remove the rear wheels:
radial runout and lateral runout of the tire and wheel assembly. Place the 1. Place a jack under the frame, one foot
tire as shown in Fig. 9. wheel lug nuts on the wheel studs. ahead of the rear wheel you want to
6. If radial runout is more than .090 Engage the transmission and drive balance. Jack up the wheel. Place
inch, perform one of the following: the rear wheels to 30-50 mph (48- another jack under the axle near the
a. Reposition the tire 180 degrees on 80km). If vehicle vibrates, perform opposite rear wheel, and raise the
the wheel. static and dynamic balance on the wheel. Place the pick-up under the
b. Find the highest point of tire radial drums by welding metal weights on wheel. Spin the wheel with the motor
runout. Mark this point on the tire. the drum. Reinstall the wheel and to approximately 60-70 mph, to
Find lowest point of radial runout tire assembly. Recheck balance and where the most vibration shows. Read
on the wheel. Mark this point on correct if necessary. Road test for the strobe and follow the same
the wheel. Demount the tire. Align final results. procedure required for balancing
the high point of the tire, with the front wheels.
low point on the wheel. Remount BALANCING WHEELS 2. Jack up the rear wheels as noted in
the tire. Recheck radial runout. If Single Rear Wheels F-100-350, step 1. Remove the rear wheel
tire radial runout is still more than E100-350, BRONCO opposite the wheel you are to balance.
.090 inch, check the wheel. If radial Don't use the spinner on any single Balance the rear wheel on the vehicle
runout is less than .070 inch, rear wheels. and reinstall the other wheel. After
replace the tire. If the wheel is more Jack up one rear wheel at a time, reversing the position of the jacks,
than .070, replace the wheel. locate the jack securely under the frame, balance the opposite rear wheel. Do
Rebalance the reworked assembly. approximately one-foot ahead of the rear not remove the first rear wheel.
Dual Wheels and Wheels of screws. Pull the hub flange out to clear bearings depend on proper adjustment
Trucks Equipped with Full- the studs at least 112 inch. and correct lubrication. If bearings are
Floating Axles Spin Dual Wheels with an 800-C2 or adjusted too tightly, they will overheat
500-C Heavy-Duty Truck Spinner or and wear rapidly. An adjustment that is
Jack up the rear wheels with the jack
equivalent. excessively loose can cause pounding and
located securely under the differential
contribute to uneven tire wear, steering
housing. Raise the wheels 1-112 inches FRONT WHEEL BEARING difficulties and inefficient brakes. The
from the floor. MAINTENANCE bearing adjustment should be checked at
Disconnect the wheel from the axle Wheel bearings are adjustable. regular inspection intervals.
drive by removing the hub flange nuts or Satisfactory operation and long life of
CLEANING AND INSPECTION

WHEELS will overheat and wear rapidly. An welding affects the properties of the
Wheel stud nuts should be inspected adjustment that is excessively loose can material. Do not weld the wheels for any
and tightened twice within the first 500 cause pounding and contribute to uneven reason.
miles of operation. After the first 1000 tire wear, steering difficulties and VALVES
miles of operation, they should again be inefficient brakes. The bearing Aluminum and steel drop-center
inspected and tightened. Loose wheel adjustment should be checked at regular wheels for tubeless tires come from the
stud nuts may cause shimmy stud inspection intervals. factory with air valve installed. If it
damage and/or failure, possible wheel Frant hub assemblies and bearings becomes necessary to replace an air valve
damage, and vibration. Elongated stud should be cleaned, inspected and it _should be installed using 14 ft-Ibs of
holes in the wheels may also result from lubricated whenever the hub assemblies torque onthehex nut.
the loose stud nuts. are removed or at the mileage/time
periods indicated in the maintenance MAINTENANCE AND
Keep the wheels and hubs clean. PROTECTION IN CORROSIVE
Stones or lumps of mud wedged between schedule.
New hub assembly grease seals should ENVIRONMENTS
the wheel and drum will unbalance a
be installed when the hub is removed. A Due to aluminum's natural resistance
wheel and tire.
damaged or worn seal may permit to corrosion, aluminum forged disc
Check for damage that would affect
bearing lubricant to reach the brake wheels and rims do not need to be painted
the run out of the wheels. Wobble or
linings, resulting in ineffective brake for most operating conditions. Washing
shimmy caused by a damaged wheel will
operation and necessitating premature them (do not use highly alkaline cleaning
eventually damage the wheel bearings
replacement of linings. agents) when washing the rest of the rig
and cause uneven tire wear. Inspect the
Bearing adjustment is described in will be enough to keep wheels looking
wheel rims for dents that could permit air
Part II-to for front wheels. Part 11-12 good for many years. Certain
to leak from the tires.
covers front drive bearing adjustment. environments, as created by some
TIRES Parts 11-11 and 11-14 cover rear wheel operations, can lead to corrosion. Some
bearing adjustments. of these are: livestock hauling, salt,
The tires should be checked chloride compounds used for snow
frequently to be sure that the air ALUMINUM WHEELS AND RIMS removal and highly alkaline materials.
pressures agree with those specified for When these conditions are encountered,
the tires and vehicle model. Inspect the CLEANING
Whenever tire is removed, thoroughly the following practice is recommended:
tire tread, and remove all stones, nails, 1. Clean frequently with steam or high-
glass or other objects that may be wedged examine the complete wheel. Remove all
grease and road dirt and use a wire brush pressure water from a hose. Use of a
in the tread. Check for holes or cuts that mild detergent will speed up the
may permit air leakage from the tire, and or steel wool to remove the rubber from
the bead seat. cleaning process.
make the necessary repairs. 2. When tires are removed, the entire
Inspect the tire side walls for cuts, GUTTER AREA wheel should be cleaned and
bruises, and other damage. If internal Projections on the side wall of the inspected. For maximum protection,
damage is suspected, demount the tire gutter may cause uneven seating of the there are various types of coatings
from the wheel for further inspection, side or lock ring and lead to chipping of which give good results. The
repair or replacement. the gutter. Such projections should be following procedures are suggested:
Check the tire valve for air leaks, and removed.
replace the valve if necessary. Replace
Surface Preparation
MOUNTING AREA 1. Remove all the soil and oil from the
any missing valve caps.
Smooth all projections in the wheel surface with either high-
On F-lOO-350, E-100-350, BRONCO
mounting area to assure even pressures pressure steam or solvent. Suitable
it is important that all wheels be
when tightening nuts. solvents would be mineral spirits and
balanced. Fig. to describes common tire
wear conditions. FIXED FLANGED AREA regular paint thinner, obtained in
Nicks and gouges in the vicinity of the paint stores.
FRONT WHEEL BEARINGS fixed flange may lead to rim fracture. 2. Remove any adherent soil or
oxidation products by using a wire
Wheel bearings are adjustable, to STRAIGHTENING WHEELS brush.
correct for bearing and shoulder wear of Do not heat wheels in an attempt to 3. Clean the surface again with solvent,
the spindle. Satisfactory operation and soften them for straightening to repair using mineral spirits to remove loose
long life of bearings depend on proper damage from striking curbs, etc. The products.
adjustment and correct lubrication. If special alloy used in these wheels is heat- 4. Apply a clear protective or pigmented
bearings are adjusted too tightly, they treated, and uncontrolled heating from product as follows:
UNDERINFLATION OVERINFLATION CUPPING-UNDERINFLATION AND/OR

MECHANICAL IRREGULABITIES
INCORRECT TOE·IN OR EXTREME CAMBER FEATHERING DUE TO MISALIGNMENT STONE BRUISE

OR SEVERE CORNERING
STONE BRUISE
BRUISE HEAT BRUISE DOUBLEBRUISE-SHARP OBJECT

AND RESULTING FATIGUE F1467.D
FIG. 10 Tire Wear Conditions
CleM Protectiye Coating CAUTION: Insure that replacements materials obstructing safe, positive
Spray apply about 1 112 to 2 mils wet are made with the proper sizes and seating of rings. Bead seat areas of rim
film thickness, air curing clear epoxy types of rims and rings. should be free of rust and rubber
polyamide meeting Military Specification 5. Inflate tires only to recommended air deposits. This is especially important
MIL-C-22750 (WEP) or equivalent. To pressures. for drop-center tubeless rims, because
properly spray this particular coating, the 15 degree bead seat is the air-
mix components A and B of the two-part DURING TIRE CHANGES sealing element.
organic coating and thin where necessary 1. Check ,all metal surfaces. Watch 4. Rings should be cleaned with wire
with 10 percent toluol. Spray apply with .particularly for the following items: brush. Pay particular attention to
a spray gun at a pressure of 30-40 pounds • Cracks in the rim base, in the seating surfaces and bead seat areas.
(suction feed). back flange and gutter areas. These Paint rim by brush or spray with a
Pigmented ProtectiYe Costing are caused by deep rim tool marks, fast-drying metal primer. Surfaces
Primer-Spray apply the inhibited overloading and overinflating tires should be clean and dry prior to
primer, meeting Military Specification or using larger than recommended painting. Insure that bare metal areas
MIL-C-23377 (SEP) or equivalent. Spray tire sizes. on the outside or tire side of rim are
this primer at a I to 2 mil wet film • Cracks in the wheel disc, between covered. This is especially important
thickness. Allow to air dry from 2 to 4 the stud holes or hand holes. These on drop-center tubeless rims, because
hours before top-coating. are caused by loose wheel nuts, warm and sometimes moist air is in
Top Coat-Spray a 1 112 to 2 mils wet improper installation procedures or constant contact with the metal
film of a leafing aluminum pigmented the use of incorrect sizes or types surface on the tire side of the rim.
epoxy. Allow enough time to air dry of attaching parts. 5. Lubricate the tire side of the rim ba~e
before handling; overnight will usually be • Cracks through the side ring, just prior to mounting tire. Avoid the
sufficient. spreading laterally through the use of any lubricant which contains
entire section. These are caused by water or solvent that is injurious to
RIM AND WHEEL MAINTENANCE improper mounting and rubber. A combination lubricant and
DURING TIRE INSPECTIONS demounting techniques, impact rust-preventive compound is
1. Check all metal surfaces thoroughly with road obstructions, or excessive preferable. This protective measure is
while making tire inspections, clamping torques. of particular importance with dr<?p-
including areas between duals and on • Sprung side ring, resulting from center tubeless rims as the air in the
inboard side of wheel. Watch for: improper mounting procedures. tire is contained by the tire-side rim
• excessive rust or corrosion build- • Errosion and chipping of the bead surface.
up seat of the lock ring, resulting from 6. Inflate tire only to recommended air
• cracks in metal excessive corrosion. This may pressure
• bent flanges, resulting from road occur with this part as well as
obstructions others if protective measures are SAFETY PRECAUTIONS
• deep rim tool marks on rings or not taken.
in gutter areas' 2. Replace the parts as necessary. 1. Insure that rings are properly seated,
• loose, missing or damaged nuts or CAUTION: Insure that replacements prior to inflation.
clamps are made with the proper sizes and 2. Use safety cage or lock ring guard. In
• bent or stripped studs types of rims and rings. Note: emergency situations where a safety
• damaged or missing rim drive Openings between the ends of the split cage or portable safety device is not
plates side rings must not be less than 3/32" available, use clip-on type air chuck,
• matched rim parts except where the ring design calls for so that operator may stand aside
2. Pull damaged rims or wheels. an abutting condition, or more than during inflation. When clip-on air
CAUTION: Excessively corroded or 5/16" after the ring is seated during chuck is used, pressure must be
cracked rims or rings can be operation. Split lock rings used with restricted to maximum inflation
dangerous. Deflate tires prior to the the endless side rings must not butt. capacity of tire or rim, whichever is
removal of rims or wheels from the 3. Thoroughly remove rust, dirt and lower.
vehicle. other foreign materials from all 3. Air tank should incorporate moisture
3. Mark damaged or hazardous areas surfaces. Hand or electric wire trap when used with drop-center
with chalk so that part will be brushes, sand blasting or chemical tubeless rims in order to reduce the
removed from service. baths may be used. Gutter of rim base moisture in contact with the metal
4. Replace parts as required. should be cleared of rust and other rim surfaces.
11-02-1 Wheels and Tires-Drop-Center Rim 11-02-1
Wheels and Tires - PART

Drop-Center Rim 11··02
APPLIeS TO BRONCO, E·100-E-350, F-100-F-350 AND MEDIUM TRUCKS
DESCRIPTION REMOVAL AND INSTALLATION
Front Wheel Assembly ................. 02-1 Tire Replacement Precautions ........... 02-2
Front Wheel Assembly - Wheel Replacement
Four Wheel Drive ..................... 02-1 E-100 to E-350, F-100 to F-350 ........02-1
Rear Wheel Assembly .................. 02-1 Medium Trucks .....................02-2
SPECIFICATIONS ........................02-2
DESCRIPTION
FRONT WHEEL ASSEMBLY
Each front wheel and tire assembly is
bolted to its respective front hub and
rotor assembly. Two opposed tapered
roller bearings are installed in each front
hub and rotor assembly (Fig. 1). A grease
retainer is installed at the inner end of the
hub to prevent lubricant from leaking.
The entire assembly is retained on its INNER 3EARING CONE
spindle by the lock nut, adjusting nut and AND ROLLER
cotter pin.
FRONT WHEEL ASSEMBLY-
WH EEL ASSEMBL Y
FOUR-WHEEL DRIVE
The front axles used on 4-wheel drive
models are described in Parts 15-30, 15-
32 and 15-33 of this manual. The locking
hub assemblies are described in Part 11-
12. F 1851-A
REAR WHEEL ASSEMBLY
Information on rear wheels may be FIG. 1 Front Hub, Bearings and Grease Retainer-Disc Brakes-F 1OO-F350,
found in Group 11, Parts 11 and 14. 4x2, E100-E350
REMOVAL AND INSTALLATION

WHEEL REPLACEMENT InstJdJlltion alternately flared inward and
E-'OO to E-350, F-'OO to F-350 1. Clean all dirt from the hub and rotor outward. These surfaces must be
assembly. The replacement wheel and mated when the wheels are mounted.
Removlll Fig. 2 illustrates the dual wheel radial
1. Pry ofT the hub cap or wheel cover (if tire must be clean.
2. Position the wheel and tire on the hub alignment locating pin used on E-350
the vehicle is so equipped), and loosen
and rotor assembly, and install the and F-350.
but do not remove the wheel stud
nuts. wheel stud nuts. Tighten the stud nuts 3. Lower the vehicle to the floor, and
2. Raise the vehicle until the wheel and enough to hold the wheel firmly in tighten the wheel stud nuts to the
tire clear the floor. place. Always tighten alternate nuts specified torque. On a new vehicle,
3. Remove the wheel stud nuts and the to draw the wheel evenly against the and each time a wheel and tire is
wheel and tire from the hub and drum hub and drum (or hub and rotor). installed, the wheel nuts should be
assembly, or the hub and rotor E-350 and F-350 with dual wheels tightened to specification and
assembly. have mounting bolt holes which are rechecked at 500 miles.
11-02-2 Wheels and Tires-Drop-Center Rim 11-02-2
The replacement wheel and tire must deflated, and then inflated again to insure
be clean. that the tube is not folded inside the tire.
2. Position the wheel and tire on the hub Be sure the tube flap is properly
and drum. and install the wheel stud positioned before inflating the tire. On
nuts. Tighten the stud nuts enough to FI00-350, EI00-350 and B-150 it is
hold the wheel firmly in place. important that each front and rear tire
Always tighten alternate nuts to draw and wheel be balanced.
ALIGN DUAL WHEELS the wheel evenly against the hub and When installing tires on F -100/350,
ON LOCATING PIN
F 1829-A drum. B-150, and E-IOO/350 vehicles,
On dual wheels, be sure to back off thoroughly lubricate the tire beads with
FIG. 2 Dual Rear Wheel Radial the outer nut before tightening the lubricant ESA-MIB6A, or equivalent.
Alignment to Hub (E-350, F- inner nut. Then tighten the outer nut. Inflate the tire until both bead seats
350) 3. Lower vehicle to the floor, and against the rim of the wheel, then deflate
tighten the wheel stud nuts to the to the specified "Tire Inflation
specifications. On a new vehicle, and Pressures" shown in the 1977 Truck
Medium Trucks
each time a wheel and tire is installed, Owners Manual for each vehicle series.
RemoYal the wheel nuts should be checked for To seat the tire beads, the initial inflation
I. Loosen but do not remove the wheel tightness. for passenger-type tires is 30 psi
stud nuts. maximum; for truck-type tubeless tires,
2. Raise the vehicle until the wheel and TIRE REPLACEMENT 50 psi maximum; for truck-type tube
tire clear the floor. PRECAUTIONS tires 75 psi maximum. Follow the
3. Remove the wheel stud nuts and the The tire must be completely deflated instructions supplied with the Rotunda
wheel and tire from the hub and before removal, and the bead must not be (35-002, 35-0010 or equivalent) tire
drum. damaged by a tire iron. changer. Refer to Part 11-01 for
Instal/stion After installation, a tube tire should diagnosis and testing procedures, safety
I. Clean all dirt from the hub and drum. be inflated to recommended pressure, procedures and illustrations.
SPECIFICATIONS
WHEEL TORQUE LIMITS - F-l00 THRU F-350, E-l00-E-350, BRONCO

-
Nut
Model Ft-lb Model Nut Size Ft-Lb
Size
E-100-E-250 1/2-20 90 E-350, F-350, 9/16-18 ® 220
F-100, F-150 (4 x 4), Bronco, (W/Dual Rear
Wheels) CD
F-150, F-250 (4 x 4) (~nd 7400 Ib Axle)(2) i
CD E-350, F-250 and F-350 Single Rear Wheel Lug Nuts are
F-350,' E-350 13f.) Black in Color. (.066 inch length)
9/16-18
(2) E-350, F-350, Dual Rear Wheel Lug Nuts
W/S R. Wheels CD 145 are Zinc Plate or Black, in Color. (.94 inch length).
The Lug Nuts Should not be mixed. The Dual Wheel Lug
Nuts are Left Handed Threads for Left Rear Wheels Only.
CF1804-F
11-03-1 Wheels and Tires-Twa-Piece Rims 11-03-1
Wheels and Tires - PART

Two-Piece Rims 11-03
APPLIES TO F·250, F·350 VEHICLES
DESCRiPTION ..........................03-1 REMOVAL AND INSTALLATION (Cont'd)
REMOVAL AND INSTALLATION ............03-1 Mounting Tire to Wheel ..............03-1
Tire Removal and Mounting Removal Side Ring from Rim
Two-Piece Semi-Drop Center Rims ..... 03-1 with Ti re ........................03-1
DESCRIPTION
Two-piece drop center wheels with a Refer to Part 11-01 for diagnosis and
lock ring (Fig. 1) are used with 16 inch testing procedures, safety procedures and
tube-type tires only. illustrations.
NOTCH
RIM
SPLIT RING F2627·A
FIG. 1 Two-Piece Rim

The tire must be completely deflated equipment manufacturer. Otherwise, use driving the hook end of the rim tool
before removal, and the bead must not be the following instructions. between the rim flange and the tire
damaged by a tire iron. This two-piece wheel uses a split C- bead. Pry the tire bead away from the
After installation, a tube tire should type ring, as shown in Fig. 2. taper, and remove the tire from the
be inflated to recommended pressure, rim (Fig. 5).
Removal of Side Ring from Rim
deflated, and then inflated again to insure with Tire Mounting Tire to Wheel
that the tube is not folded inside the tire. 1. Position the tube in the tire and place
1. Remove valve core and deflate the tire
Be sure the tube flap is properly the wheel (gutter side up) on the floor.
completely and place the wheel (ring
positioned before inflating the tire. Lubricate both beads of the tire with
side up) on the floor.
It is recommended that tire-changing 2. Break the tire bead free from the rim, ESA-M 1B6A or equivalent and
equipment be used in changing all truck being careful not to damage the bead position the tire on the rim. It is
tires. See Safety Precautions in Part 11- (Fig. 3). important that the tire be lUbricated
01. well as it must be forced over the
3. Insert the straight end of the rim tool safety bead hump and the rim edge
into and under the tool notch in the (Fig. 6). Be sure the tube flap is
TIRE REMOVAL AND ring (Fig. 4). correctly positioned.
MOUNTING-TWO-PIECE SEMI-
4. For c e the tool dow n war d to 2. Position the ring with the tool notch
DROP CENTER RIM-F250-F350
disengage the ring from the rim about 3 inches from the valve stem.
Recent developments make possible gutter. Work the tool around the rim, 3. Insert the rim tool under the ring at
the removal and mounting of tires from freeing the ring from the rim, and a position approximately 180 degrees
this type of wheel-rim combination with remove the ring. from the notch and pry tire onto rim.
mechanical tire-changing equipment. If 5. Tum the wheel over and loosen the Work the remaining section of rim
available, follow instructions of opposite tire bead from the rim by over the gutter with a second tool.
11-03-2 Wheels and Tires-Two-Piece Rims 11-03-2
4. Make certain that the ring is entirely 5. After installation, inflate the tire and to insure that the tube is not folded
seated in the gutter. If the ring is not tube to 80 psi maximum to snap the inside the tire. Always use a cage or
seated correctly as described, it may tire beads over the bead hump and safety chain during initial inflation.
be forced otT violently, either during fully seat the tire against the rim and 6. Check the end gap of the lock ring
inflation or when the vehicle is lock ring. Deflate the tire, then (Fig. 1), the gap should be 3/8 inch.
operated. reinflate it to recommended pressure
Rim Tools
..C'. RING
SAFETY BEAD HUMP FIG. 5 Removing Tire From Rim

F1473-e
FIG. 2 Two-Piece Split Ring-Light Truck
WORK IN
DIRECTION
OF ARROW
F133S-e
FIG. 6 Installing First Tire Bead on

FIG. 3 Loosening Tire Bead FIG. 4 Removing Split Ring Wheel
11·04·1 Wheels and Tires-Three Piece Rim 11·04·1
Wheels and Tires - PAR'T

Three-Piece Rims 11-Ct4
APPLIES TO ALL 600·9000 SERIES VEHICLES
_SU_B_JE_C_T ~P~AG;;.;:E S_U_B_JE_C_T . ;P. . ;.A;.; .;",; ;GE
DESCRIPTION REMOVAL AND INSTALLATION (Cont'd)
Tires ! •••••••••••••••••• 04-1 Wheel and Tire Removal
Wheels and Rims from Vehicle 04-2
Drop Center 04-1 DISASSEMBLY AND ASSEMBLY
Drum Mounting 04-1 Accu-Ride XL Rims 04-8
Three-Piece Rim 04-1 Drop-Center Tubeless
Two-Piece Convertible Rims and Wheels 04-5
Rims 04-1 Semi-Drop Wheels 04-5
REMOVAL AND INSTALLATION Three-Piece Rims
Demountable Rims and Wheels 04-7
Installation 04-2 Two-Piece Rims and
Disc Wheel Installation 04-3 Wheels ',' 04-6
SPECIFICATIONS 04-11
DESCRIPTION
TIRES is available in the demountable rim or DRUM MOUNTING
Both the tube type and. tubeless tires disc wheel configuration. The disc wheel Both the inboard and outboard drum
are used. The tubeless tires are mounted is available in aluminum or steel, mountings are used. On inboard
on 15 degrees drop-center rims and however, the lock ring and side ring are mounting the drum is inside the
wheels. The tube type tires are mounted made of steel in all cases. The rim has a mounting hub or spoke wheel, on
on semi-drop wheels, two-piece flatbase 5 degree bead seat for tube type mountings. outboard mounting the drum i~ outside
rims or wheels, and three-piece flatbase mountings. the mounting hub.
rims or wheels (Figs. 1 and 2).
WHEELS AND RIMS
DROP-CENTER HUB BOLT
''----WIHEEL
The tubeless tires are all mounted on
drop-center rims and wheels. The drop-
center rim or wheel is of single-piece
------------------
construction and is available in both HUB
demountable rim and disc wheel

configuration. The drop-center rim or DISC WHEEL
wheel has a 15 degr,ee bead seat for

sealing tubeless tires. The drop-center BRAKE DRUM
rim or wheel is available in either CLAMP HUB STUD

aluminum or steel.
TWO-PIECE CONVERTIBLE
RIMS
The two-piece convertible rim
..
consists of a side ring and flatbase rim
and is available in the demountable rim
or disc wheel configuration. The rim has \
\
a 5 degree bead seat for tube type tires. --'

DEMOUNTABLE RIM F2597-1A
THREE-PIECE RIM
The three-piece rim consists of a lock
ring, side ring and flatbase type rim. It FIG. 1 Typical Front Wheel/Rim Installation
11-04-2 Wheels and Tires-Three Piece Rim 11-04-2
RIM
CAST SPOKE WHEEL
DISC WHEEL
F2598-1A
FIG. 2 Typical Rear Wheel/Rim Installation

WHEEL AND TIRE REMOVAL 2. With dual wheels, place rims and 7. Install outer rim (or rim in case of
FROM VEHICLE spacer band on wheel and proceed to single wheel) with the rim in between
the next step. On single wheels, place the spokes as shown in Fig. 3. Install
1. Prior to removal of the tire and rim
the rim on the wheel and proceed to the clamps and start the huts onto the
from the vehicle, deflate the tire
Step 7. studs.
completely by first reducing the 8. Refer to Fig. 4 for the cast spoke
pressure as much as possible by Note: Spacer bands are designed to
render adequate lateral strength with wheel triangulation torquing and
depressing the valve core plunger, proceed to the next step.
then removing the valve core. (See the minimum amount of weight.
Spacer bands should not be subjected 9. Turn nut No.1 until snug.
safety precautions in this Part). If to. Rotate the wheel/rim assembly until
working on dual wheels, deflate both to loads or pressures other than those
loads or pressures present during nut No.3 is in the top position. Turn
tires completely before loosening the until snug.
mounting bolts. normal use.
1 L Again rotate the wheel/rim assembly
2. Loosen, but do not remove the wheel 3. C h e c k the spa c e r ban d for until nut No.4 is in the top position
stud nuts. concentricity, and ensure that it has and turn the nut until snug. Since the
3. Raise the vehicle until the wheel and not been distorted or bent, or entire weight of the tire/rim assembly
tire clear the floor. otherwise mishandled in shipment. is on the top spoke position, this
4. Remove the wheel stud nuts and the 4. Do not move the vehicles, wheels, procedure allows even application of
wheel and tire from the hub and axles or assemblies by rolling on force against three points of the rim
drum. On dual disc wheels, the inner spacers. for proper alignment.
cap nut will also have to be removed 5. Place the inside rim over the cast 12. Repeat the triangle procedure; this
if the inner tire is to be removed. On spoke wheel as far as possible up to time bringing each nut to
dual cast spoke wheels, the spacer will the mounting bevel. recommended torque of 220-260 ft-
also have to be removed. 6. Push the spacer band over the cast lbs.
spoke wheel with a consistent 13. Bring remaining nuts to torque of
DEMOUNTABLE RIMS pressure on both sides. Guard against 220-260 ft-Ibs.
INSTALLATION cocking. The band should fit snugly 14. Check to see that clamps do not
1. Make sure that all parts, including to the spokes and against the inside bottom out, and be sure that on dual
rims, rings, spacer bands, and cast rim gutter edge. (At this point, the wheels, rim edges consistently meet
wheel studs are free from damage, concentricity can be checked by the spacer band edges.
dirt or rust as described in this Part. turning the spacer band on the CAUTION: Insufficient mounting
Replace any damaged parts. wheel). torque can cause rim slippage,
2. Mount single wheel or inner dual

wheel over studs, being careful not to
damage stud threads (Fig. :5). Studs
and cap nut threads should bl~ dry. No
oil or lubricant should be used.
3. Draw the single cap nut or dual inner
cap nut alternately in the sequence
shown in Fig. 6. Left side wheels have
left-hand threads. Do not tighten
them fully, however. This procedure
will permit uniform seating of the
nuts and insure even, fact~-to-face
contact of the wheels and hub.
4. Tighten the nuts fully to 400-500 ft-
F2604-1A lbs in the same sequence. Mount the
outer wheel (for dual wh(:els) and
FIG. 3 Cast Spoke Wheel Rim Driver Arrangement repeat the tightening procedure.
resulting in broken valves, worn parts thereafter periodically inspected and CAUTION: Insufficient 11I10unting
and damaged tires. Excessive retorqued. The wheel/rim assembly torque can cause wheel iihimmy,
mounting torque can cause damage by will then remain tight, barring resulting in damage to puts and
stripping studs, collapsing spacer accidents such as stud breakage or extreme tire tread wear. E:xcessive
bands or forcing rims into an out-of- clamp failure. mounting torque can cause studs to
round condition. Note: Even when the break and discs to crack in the stud
triangulation method is used, nuts DISC WHEEL INSTALLATION hole area.
will still lose torque when the vehicle 1. Check all parts for damage, including 5. After 50 to 100 miles of service
is operated. This· is caused by the wheels and rings. Insure that studs, recheck the ·wheel nut torque. When
"seating in" of the rim assembly to nuts, and mounting faces of hub and the inner cap nut (on dual wheels) are
the wheel. After 50-100 miles of wheels are clean and free from grease re-tightened, be sure to first loosen
operation the nuts should again be as described in this Part. Replace any the outer cap nuts several turns; then
brought to recommended torque and worn or damaged parts. re-tighten.
FIG. 4 Cast Spoke Wheel Triangulation Torquing

SINGLE
FIG. 5 Pisc Wheel Mounting
FIG. 6 Disc Wheel Tightening

DISASSEMBLY AND ASSEMBLY

DROP-CENTER TUBELESS RIMS 4. Push the first bead into the well of the 4. To remove the ring, insert the tool in
AND WHEELS rim and onto the rim as far as the notch and force the ring opposite
DEMOUNTING possible. Using the straight end of the of the notch into the gutter, then pry
tool (with stop resting on the rim otT (Fig. 9, View B).
1. Make certain the tire is completely 5. Pry out and up on the side ring,
flange) take small bites to work
deflated with the valve core removed. carefully but firmly. Take care not to
remaining section of the first bead
2. With the tire lying flat, loosen both bend the side ring.
onto rim (Fig. 8, View B).
beads by walking on the tire with the 6. Force the upper tire bead into the well
5. Hold the second bead in the well by
heels close to the rim. opposite the valve slot and with the
standing on the tire and anchor with
3. With the wide side of the rim down, tire tool, pry the opposite portion of
the vise-grip pliers (snub side toward
lubricate the top bead. the bead over the edge of the rim (Fig.
the tire).
4. With the stops toward the rim, insert 9, View C).
the spoon ends of the two tubeless tire 6. Using the spoon end of the tire tool
with stop toward the rim, use small 7. Tum the tire over, and by means of
tools about 10" apart (Fig. 7, View rim tools, loosen the bead on the
bites until the bead slips over the
A). Holding the bead in the well with opposite bead seat. Insert thle straight
flange. If necessary, insert the second
foot, pull one tool toward the center end of the tool between the bead and
of the rim. tire tool and lubricate last 6" of bead
before completing the mounting (Fig. back flange of the rim at about a 45
5. Hold the tool in position with one foot
8, View C). degree angle. Tum tool so that it is
and pun the second tool toward the
7. Inflate the tire as previously described perpendicular to the rim. Make sure
center of the rim (Fig. 7, View B).
in this Part, making certain that all one portion of the second bead is still
Progressively work the bead otT the
the safety precautions are followed. in the rim well, then pry the opposite
rim, taking additional bites with the
Check for leaks. portion of the bead over th,e edge of
tools as necessary.
the rim. This will free the tire (Fig. 9,
6. Stand the assembly in a vertical
SEMI-DROP WHEELS View D).
position. Lubricate the second bead.
CAUTION: Demounting and 8. Clean and inspect the wheel and tire
7. At the top of the assembly insert the
mounting truck tires can be extremely as previously described in this Part.
straight end of the tool between the
bead and back the flange of the rim dangerous if proper safety precautions MOUNTING
at about a 45 degree angle (Fig. 7, are not followed. Before starting with this 1. Place the tire on the rim so that the
View C). Tum the tool so that it is procedure, PLEASE read all safety precau- valve is in line with the rim slot and
perpendicular to the rim. Pry the tions described in Part 11-01. insert the valve through the slot.
second bead otT. Force the first bead down into the
DEMOUNTING well of the rim just to side of the valve
8. Clean and inspect the wheel and tire 1. Place the tire and wheel on the floor with foot. Mount the first bead over
as previously described in this Part.
with the side ring up. Make certain the rim lip with the rim tool
MOUNTING that the tire is completely deflated progressing from each side of the foot
1. Be sure the right valve is used and and that the valve core is removed. approximately opposite foot (Fig. 10,
properly installed in the rim. 2. To loosen the first bead, drive the View A).
2. Inspect the rim to insure the bead hooked end of the rim tool between 2. To apply the second bead, sltart at the
seats are clean and smooth. the tire and rim flange and press point opposite the valve and press the
3. Place the rim on the floor with the downward on the bead (Fig. 9, View tire bead over the rim lip and into the
wide side down and lubricate the first A). rim well with foot pressure. Mount
bead of the tire and upper bead seat 3. Progress around the rim, using the the remainder of the bead over the
of the rim (Fig. 8, View A). two tools as shown in View A. rim lip by means of thin tire tool,
A B
F2608·2A
FIG. 7 Tubeless Tire Removal

1'1-04-6 Wheels and Tires-Three Piece Rim 11-04-6
being careful not to pinch the tube. If safety precautions are followed. until the bead is completely free from
necessary, insert the second tire tool Check for leaks. the side ring (Fig. 11, View A).
and lubricate the last 6" of the bead 3. Insert the tapered end of the tool into
before completing the mounting (Fig. TWO·PIECE RIMS AND WHEELS the prying notch on the side ring and
to, View B). CAUTION: Demounting and pry the side ring from the groove in
3. Place the half of side ring opposite mounting truck tires can be extremely the rim by prying progressively
tool notch under the rim lip with dangerous if proper safety precautions around the tire until the ring is free
cutaway portions in the position as are not followed. Before starting with this (Fig. 11, View B).
shown. Force part of the ring directly procedure, PLEASE read all safety precau- 4. Turn the assembly over and unseat
opposite of the notch down below the tions described in Part 11-01. the second tire bead from the rim. Lift
rim lip approximately 1" to aid in the rim from the tire (Fig. 11, View
mounting, Insert the thin end of the
DEMOUNTING C).
rim tool in the tool notch and pull I. Place the tire on the floor and make 5. Clean and inspect the wheel and tire
ring outward over the rim lip, while certain that the tire is completely as previously described in this Part.
striking the ring with a rubber mallet deflated and that the valve core is MOUNTING
to start engagement over the rim. removed. I. Insert the tube and flap into the tire
Remove the rim tool, then strike the 2. Insert the hooked end of the tire tools and inflate sufficiently to round out
remaining portion of the side ring to between the side-ring and the side the tube. Apply rubber lubricant to
force it down over the rim lip (Fig. to, wall of the tire and pry the bead loose the inside and outside surfaces of both
View C). from the side-ring by downward the tire beads and to that portion of
4. Inflate the tire as previously described pressure on the rim tools. Continue the tube and flap that appears
in this Part, making certain that all prying progressively around the tire between the beads.
A B
~~===~
F2609·2A
FIG. 8 Tubeless Tire Mounting
DEMOUNTING: First remove valve core to ;0 remove ring, insert tool in notch and force ring Force upper tire bead into well opposite the valve
completely deflate tire before loosening mounting opposite of notch into gutter, then pry off. Pry slot and with tire tool pry opposite portion of bead
bolts. Place tire and wheel on floor with side out and up on side ring, carefully but firmly. (Be over edge of rim.
ring up. To loosen first bead, drive hooked end careful not to bend side ring.)
of rim tool between tire and rim flange and press
downward on bead. Progress around rim, using
2 tools, as shown.
F2610·2A
FIG. 9 Demounting Semi-Drop Wheels

2. Lay the rim flat on the floor with the safety precautions are followed. Continue prying progressively around
valve slot up. Align the valve with the Check for leaks. the tire until the bead is completely
valve slot, place the tire onto the rim free from the side ring.
and insert the valve through the valve THREE-PIECE RIMS AND WHEELS
slot (Fig. 12, View A). CAUTION: Demounting and 3. With the side flange and tire bead
3. Place the side-ring on the rim base so mounting truck tires can be extremely pushed down, insert the tapered end
that the ring split is opposite the valve dangerous if proper safety precautions of the tool into the notch near the split
stem. Place the leading end of the ring are not followed. Before starting with this in the lock ring and push downward
into the groove (Fig. 12, View B). procedure, PLEASE read all safety precau- to pry the lock ring from the gutter
4. S tar tin gat the val v e sid e , tions described in Part 11-01. groove of the rim base (Fig. 13, View
progressively "walk" the side ring B).
into place. Check to see that the ring DEMOUNTING
1. Place the tire and wheel on the floor •. Use the hooked end of the tool to
in fully seated in the groove.
with the side ring up and make certain complete removal of the lock ring,
Note: Openings between the ends of
that the tire is completely deflated progressively working around the tire
the split side ring must not be less that
with the valve core removed. (Fig. 13, View C). Lift off the side
5/32-inch except where the ring
flange.
design calls for an abutting condition, 2. Insert hooked end of the tire tools
or more than 5/16-inch after ring is between the side ring and side-wall of 5. Turn the assembly over and unseat
seated in during operation. the tire (Fig. 13, View A). Pry the the second tire bead from the rim. Lift
5. Inflate the tire as previously described bead loose from the side ring by the rim from the tire. Rc::move the
in this Part, making certain that all downward pressure on the rim tools. tube and flap (if used) from the tire.
MOUNTING: Place tire on rim so that valve is in To apply second bead, start at point opposite valve Place half of side ring in rim gutter with cutaway
line with valve hole and insert valve through valve and press bead toe over rim gutter and into rim portions in position as shown. Insert thin end of
hole. Force first bead down into well of rim just to well with foot pressure. Mount remainder of bead rim tool or heavy screwdriver and pull l"ing out·
side of valve with foot. Mount first bead over rim over rim gutter by means of thin tire tool. being ward towerd centered position. Strike with mallet
gutter with rim tool progressing from each side of careful not to pinch tube. forcing ring into gutter. Inflate tire in safety cage.
foot to point approximately opposite foot.
F2611·2A
FIG. 10 Mounting Semi-Drop Wheels
DEMOUNTING: Before removing tire and rim Insert tapered end of tool into prying notch on side- Turn the assembly over and unseat seccnd tire bead
assembly from truck, deflate tire completely by ring and pry side-ring from its groove in rim by prying from rim. Lift rim from tire. Remove tube and flap,
removing valve core. If working on duals, deflate progressively around tire until ring is free. if any, from tire.
both tires completely before loosening mounting
bolts. Remove tire from truck and place on floor
side, ring up. Insert hooked end of tire tools
between side-ring and side-wall of tire and pry
bead loose from side-ring by downward pressure
on rim tools. Continue prying progressively around
tire until bead is completely free from side-ring.
F2612·2A
FIG. 11 Demounting Two-Piece Rims and Wheels

11-04-8 Wheels and Tires-Three Piece Rfm 11-04-8
MOUNTING 3. Place side flange on the rim base and safety precautions are followed.
1. Insert the tube and flap (if used) into stand on flange to position the flange Check for leaks.
the tire and inflate sufficiently to below the gutter grooves in the rim
round out the tube. Apply rubber base (Fig. 14, View B). ACCU-RIDE XL RIMS
lubricant to the inside and outside 4. Snap the leading end of the lock ring CAUTION: Demounting and
surfaces of both the tire beads and to into the gutter groove of the rim base mounting truck tires can be extremely
that portion of the tube and flap that and progressively "walk" the lock dangerous if proper safety precautions
appears between the beads. ring into place (Fig. 14, View C). are not followed. Before starting with this
2. Lay the rim flat on the floor with the Check to ensure that the lock ring is procedure, PLEASE read all safety precau-
valve slot up. Align the valve with the fully seated in the gutter groove. tions described in Part 11-01.
rim valve slot. Place the tire into the For mounting and demounting
rim and insert the valve through the 5. Inflate the tire as previously described instructions for Accu-Ride XL rims refer
valve slot (Fig. 14, View A). in this Part, making certain that all to Fig. 15.
MOUNTING: Insert tube and flap into tire and Place side-ring on the rim base so that ring split is Starting at the valve side, progressively "walk" side-
partially inflate to round out tube. Apply rubber opposite valve stem. Place leading end of ring into ring into place. Check to insure ring is fully seated
lubricant to inside and outside surfaces of both the groove in the. rim as shown. in groove.
beads and to that portion of tube and flap that
appears between beads. Lay rim flat on floor with
valve slot up. Align valve with rim valve slot, place
tire onto rim and insert valve through valve slot.
F2613-2A
FIG. 12 Mounting Two-Piece Rims and Wheels
DEMOUNTING: Before removing tire and rim as- With side-flange and tire bead pushed down, insert Use hooked end of tool to complete removal of
sembly from truck, deflate tire completely by remov- tapered end of tool into notch near split in lock-ring lock-ring,progressively working around tire. Lift
ing valve core. If working on duals, deflate both tires and push downward to pry lock-ring from gutter off side-flange. Turn the assembly over and unseat
completely before loosening mounting bolts. Remove groove of rim base. second tire bead from rim. Lift rim from tire. Re-
tire from truck and place on floor side, ring up. move tube, and flap if any, from tire.
Insert hooked end of tire tools between side-ring and
side-wall of tire and pry bead loose from side-ring by
downward pressure on rim tools. Continue prying
progressively around tire until bead is completely free
from side-ring.
F2614·2A
FIG. 13 Demounting Three-Piece Rims and Wheels

"-
11-04-9 Wheels and Tires-Three Piece Rim '11-04-9
MOUNTI NG: Insert tube and flap into the tire and Place side flange on rim base and stand on flange to Snap leading end of lock-ring into,gutter groove of rim
partially inflate to round out tube. Apply rubber position it below gutter grooves in rim base. base and progressively "walk" lock into place. Check
lubricant to inside and outside surfaces of both to insure lock-ring is fully seated in gutter groove.
beads and to that portion of tube and flap that ap-
pears between beads. Lay rim flat on floor with
valve slot up. Align valve with rim valve slot,place
tire onto rim and insert valve through valve slot.
F2615·2A
FIG. 14 Mounting Three-Piece Rims and Wheels

Tools required: 1 rim mallet - 2 tubeless tire tools RT-31 - 2 rim tools RT-29 or RT-3D
MOUNTING
Place tire on rim 30 that valve is in line with To apply second bead, start at point oppo- Place the half of side ring opposite tool
rim slot and insert valve through the slot. site valve and press tire bead over rim lip and notch under rim lip with cutaway portions in
Force first bead down into well of rim with into rim well with foot pressure. Mount reposition as shown. Force part of ring directly
foot just to side of valve. Mount first bead mainder of bead over rim lip by means of opposite notch down below rim lip approx.
over rim lip with rim tool working alternately thin tire tool, being careful not to pinch tube. 1" to aid in mounting. Insert thin end of rim
from each side of foot until first bead is If necessary, insert second tire tool and lu- tool in tool notch and pull ring outward over
seated. bricate last 6" of bead before completing rim lip, while striking ring with rubber mallet
mounting. to start engagement over rim. Remove rim
tool, then strike remaining portion of side
ring to force it down over rim lip.
DEMOUNTING
First, standing clear of rim, remove valve To start removal of ring, insert rim tool Into Force upper tire bead into well opposite the
core to completely deflate tire. Place tire and tool notch and pry up on ring while forcing valve slot and with tire tool pry opposite por-
wheelan floor with side ring up. To loosen opposite side of ring down at least l' as tion of bead over edge of rim.
first bead, drive hooked end of rim tool be- shown. To fully remove ring, insert a second
tween tire and rim flange and press down- rim tool to the right of tool notch and work
ward on bead. Progress around rim, using 2 ring off with this second tool.
tools, as shown.
SPECIAL NOTE:
Interchanging of 20 x 6.0 XL and 20 x 6.5 XL
side ring is not recommended. The 20 x 6.0
XL side ring will not carry the load of the 20 x
6.5 XL assembly, even though parts will
satisfactorily fit together.
The 20 x 6.5 XL side ring satisfactorily fits the
20 x 6.0 XL assembly but flange height is
greater than that of rim.
Effective 9/13/74 SR238XL-3 revised as
common ring for both 20 x 6.0 and 20 x 6.5
sizes.
Turn tire over, and by means of rim tools, Make sure one portion of second bead is still
loosen bead on opposite bead seat in the rim well, then pry opposite portion of
bead over edge of rim. This will free the ':ire
Stand assembly in vertical position. Lubri-
from the rim as shown.
cate second bead At top of assembly insert
straight end of tool between bead and back
flange of rim at about a 45° angle. Turn tool
so that it is perpendicular to nm.
F-2635-A
FIG. 15 Accu-Ride Xl Rims-Mounting and Demounting

SPECIFICATIONS
TIRE SIZES AND TYPES
Type Size Code Letler
Tube Type 10.00 x 20 (12 PRJ F
10.00 x 20 (14 PRJ G
11.00 x 20 (12 PRJ F
11.00 x 20 (14 PRJ G
10.00 x 22 (12 PRJ F
10.00 x 22 (14 PRJ G
11.00 x 22 (12 PRJ F
11.00 x 22 (14 PRJ G
Tubeless 11.00 x 22.5 (12 PRJ F
11.00 x 22.5 (14 PRJ G
12.00 x 22.5 (12 PRJ F
12.00 x 22.5 (14 PRJ G
11.00 x 24.5 (12 PRJ F
11.00 x 24.5 (14 PRJ G
12.00 x 24.5 (12 PRJ F
12.00 x 24.5 (14 PRJ G
Tubeless Radials 10R x 22.5 (14 PRJ G
11R x 22.5 (14 PRJ G
11R x 24.5 (14 PRJ G
CF2616-1A
WHEEL TORQUE LIMITS
Torque Limits
Description Nut Size
(ft-Ib)
Disc Wheel Nuts 3/4-16 450-500
1-1/8-16 450-500
Cast Wheel Rim Clamp Nut 3/4-10 200-260
CF2617-2A
11-10-1 Wheels, Hubs and Bearings-Front (Except Front Drive) 11-10-1
Wheels, Hubs and Bearings - PART

Front (Except Front Drive) 11-10
DESCRIPTION REMOVAL AND INSTALLATION
Front Wheel Assembly 10-1 Disc Brakes
ADJUSTMENTS Medium, Heavy and Extra
Front Wheel Bearing Heavy Vehicles , , . , , .. ,10-5
All Medium, Heavy and Extra F-100 - F-350, E-100 - E350 ... ', . , ,10-5
Heavy Trucks ,.10-4 Drum Brakes
Double Nut with Lock Ring P-600 10-4
9000 and 12000 Pound Front Wheel Grease Seal
Front Axle 10-4 and Bearings 10-4
Single Nut with Cotter Pin Front HulJ Seal
16000, 18000 and 20000 National 10-6
Pound Front Axle 10-4 Stemco 10-6
F-100 - F-350 (4x2) and Oil Lubrication
E-1 00 - E-350 10-4 Medium, Heavy, Extra Heavy
P-600 10-4 Vehicles 10-6
SPECIFICATIONS 10-9
DESCRIPTION
FRONT WHEEL ASSEMBLY
Each front wheel and tire assembly is grease retainer is installed at the inner and cotter pin, or an adjusting nut and
bolted to its respective front hub and end of the hub to prevent lubricant from lock nut combination.
brake drum or hub and rotor assembly. leaking into the drum or onto the rotor.
Two opposed tapered roller bearings are The entire assembly is retained to its
installed in each hub, Figs. 1 and 2. A spindle by the lock nut or adjusting nut
WHEEL
BRAKE
BEARING CUP DRUM
AXLe
HUB CAP
9000·'2.000
,....
~t
Ii WASHER
L.\~((\il~ ------ ---~

'I)! ~ADJUSTING NUT I
~b
GREASE RETAINER
INNER BEARING
=
GASKE\T ADJUSTING:
..'?(f}O'~~------1'1~~:: ::'~~ ~~:CER.I

e. NUT I /
~ \@I
~I I
LOCK LOCK I
GREASE NUT RING I GREASE RETAINER
CAP WASHER
,
I
I
I HUB
BRAKE
I
DRUM
I HUB STUD
--------:--1-- I
CAST I
TYPE "
'-- -S~
OUTER BEARI~/
WHEEL BEARING CUP
F1466-e
FIG. 1 Typical Front Hubs and Bearings

GREASE
RETAINER
1190
INNER
BEARING
" OUTER BEARING
1216
1201
P-SERIES E-100-350 SERIES

F-100-350 SERIES
(DISC)
PIN
72107-S36
CONE AND ROLLER
ASSEMBLY(lNNER) _ _""!'"""~.. I
1201-A NUT
,; 351163-S2
HUB AND DRUM
ASSEMBL Y
1102-3
BEARING
CONE AND ROLLER ASSEMBLY
ASSEMBLY(lNNER) (OUTER)
1216-B 44135-A
5500,6000 AND 7000 LB. AXLES RETAINER

LOCK 385603-S2
RING
J95
3293 NUT
-----
GREASE
WASHER 385602-S2
RETAINER
L~~;
w"2"
1190
PIN
72169-S3
OUTER
BEARING
12000 LB. AXLE
-f
1216
9000-12000 LB. AXLES
CONE AND ROLLER

ASSEMBL Y(lNNER)
1201
NUl
GREASE 38560-S2
RETAINER
BAFFLE 1190
2060
PIN CONE AND ROLLER

72145-S36 ASSEMBLY (OUTER)
1216
7000,9000 LB. AXLES
(HEAVY)
ADJUSTING
NUT
NUT GREASE
~
386218-S2 RETAINER
COTTER
PIN
16000, 18000,
20000 LB. AXLES
F1474-J
FIG. 2 Front Hubs, Bearings and Grease Retainers

50-32-3 Lights, Instruments, Controls, Heating, Air Conditioning and Accessories 50-32-3
In winter, keep reservoir filled with a CHECK HEADLIGHT ALIGNMENT Kit-Model T.R.E 540 or equivalent. Be
solution of two parts water to one part Check the headlights for proper sure to use the latest manufacturers
solvent. This helps prevent freezing and alignment. If necessary, align the instructions.
danlage to the reservoir. headlights using the Headlight Aiming
50-41-1 Body 50-41-1
P RT
1
Body 50- 1
SUBJECT PAGE,
PRE-DELIVERY
After Road Test 41-1
Check Bumpers and Mouldings 41-1
Check Doors, Locks -2
and Latches 41-1
Check Exterior For' Fit and
Appearance 41-1
Check Front Bumper Bolt
Torque , 41-1
Check Seat Control 41-1
Check Seatback Latches 41-1
Check Tailgate Operation 41-1
Check Windows and Vents 41-1
Clean and Inspect Vehicle 41-1
Remove Shipping Protective
Material 41-1
PRE·DELIVERY
CHECK SEAT CONTROL CHECK DOORS, LOCKS AND vehicle except the tape under the hood
Check lever operation and test LATCHES flange on L-Series trucks. This tape
freeness of seat movement on track and Be sure all doors open, close and lock should not be removed.
solid lock in detent when lever is released. from both inside and outside the vehicle.
If equipped with suspension seat, check Check for proper latching and alignment
for proper functioning of all controls. of latch and striker. CLEAN AND INSPECT VEHICLE
Remove the windshield and
CHECK SEATBACK LATCHES CHECK TAILGATE OPERATION tapes. Wash the vehicle and check for
Lubricate as necessary. Check latch leaks. Inspect rnetal and paint condition,
Be sure latches operate properly and
alignment and adjust, if necessary. Refer and touch up chips and scratches. Check for
retain seatback.
to 1978 Truck Shop Manual, Group 44, excess sealer. CAUTION: Do not use steel
for detailed adjustment procedures. wooL abrasive type cleaners, or strong de-·
CHECK WINDOWS AND VENTS
tergents containing highly alkaline or caus-
Check ease of operation, matching CHECK BUMPERS AND tic agents on chrome plated materi,ds,
position of both window handles, and MOLDINGS aluminum wheels, or anodized aluminum
tight fit against weatherstrip. Check for Check condition, fit and alignment. parts because the protective coating may be
alignment to opening. Refer to 1978 Adjust as required. Refer to the 1978 damaged and discoloration or paint
Truck Shop Manual, Group 42, for Truck Shop Manual, Group 47, for deterioration.
detailed instructions. detailed instructions.
CHECK EXTERIOR FOR FIT AND CHECK FRONT BUMPER BOLT AFTER ROAD TeST
APPEARANCE TORQUE Remove seat protector and tapes.
Inspect the body exterior for door and Tighten to specifications given in Inspect interior paint condition, and
hood gaps or evidence of rubbing or Specifications Section of this Part. touch up chips and scratches. Check for
binding with adjacent panels. Check soft trim soilage and excess sealer.
exterior moldings for adequate retention REMOVE SHIPPING PROTECTIVE Check information on ownercard
or extreme misalignment. Inspect MATERIAL with warranty plate and be sure Owner's
bumpers for appearance. Remove all shipping: covers from Manual is in glove compartment.
50-41-2 Body 50-41-2
LUBRICATION
LOCK AND PIVOT POINTS insert and turn key several times to work
To eliminate any binding conditions in the lubricant.
on pivot and friction points, spray See Part 50-03 for lubricant
polyethylene grease on hood hinges, specifications.
auxiliary catch and latch; door hinges, CAB LATCH MECHANISM (C-
hinges check, rotor and striker plate; and
SERIES)
on the tailgate hinges. Operate all pivot
points several times to be sure lubricant Lubricate the lock handle linkage and
has been worked in. locking cams with lOW oil at all pivot
Also, apply lock lubricant to the lock points. Operate the mechanism to work
cylinders, including the ignition lock, and the lubricant into all points.
MAINTENANCE
CLEAN BODY AND DOOR DRAIN
HOLES should be inspected periodically for Use a small screwdriver or similar tool to
Drain holes, located along the bottom obstructions. A practical time for clean drain holes.
surface of the door and side panels, inspection is whenever vehicle is washed.
SPECIFICAliONS
FRONT BUMPER BOLTS TORGUE
3/8 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 EQUIVALENTS
Fractions Decimal In. Metric MM. Fractions Decimal In. Metric MM.
1/64 .015625 .39688 33/64 .515625 13.09687

1/32 .03125 .79375 17/32 .53125 13.49375
3/64 .046875 1.19062 35/64 .546875 13.89062
1/16 .0625 1.58750 9/16 .5625 14.28750
5/64 .078125 1.98437 36/64 .578125 14.68437
3/32 .09375 2.38125 19/32 .59375 15.08125
7/64 .109375 2.77812 39/64 .609375 15.47812
1/8 .125 3.1750 5/8 .625 15.87500
9/64 .140625 3.57187 41/64 .640625 16.27187
5/32 .15625 3.96875 21/32 .65625 16.66875
11/64 .171875 4.36562 43/64 .671875 17.06562
3/16 .1875 4.76250 11/16 .6875 17.46250
13/64 .203125 5.15937 45/64 .703125 17.85937
7/32 .21875 5.55625 23/32 .71875 18.25625
15/64 .234375 5.95312 47/64 .734375 18.65312
1/4 .250 6.35000 3/4 .750 19.05000
17/64 .265625 6.14687 49/64 .765625 19.44687
9/32 .28125 7.14375 25/32 .78125 19.84375
19/64 .296875 7.54062 51/64 .796875 20.24062
5/16 .3125 7.93750 13/16 .8125 20.63750
21/64 .328125 8.33437 53/64 .828125 21.03437
11/32 .34375 8.73125 27/32 .84375 21.43125
23/64 .359375 9.12812 55/64 .859375 21.82812
3/8 .375 9.52500 7/8 .875 22.22500
25/64 .390625 9.92181 57/64 .890625 22.62187
13/32 .40625 10.31875 29/32 .90625 23.01875
27/64 .421875 10.71562 59/64 .921875 23.41562
7/16 .4375 11.11250 15/16 .9375 23.81250
29/64 .453125 11.50937 61/64 .953125 24.20937
15/32 .46875 11.90625 31/32 .96875 24.60625
31/64 .484375 12.30312 63/64 .984375 25.00312
1/2 .500 12.70000 1 1.00 25.40000
METRIC-ENGLISH CONVERSION TABLE
to get equivalent to get equivalent

Multiply by number of: Multiply by number of:
LENGTH ACCELERATION
Inch 25.4 millimetres (mm) Foot/see 2 0.3048 metre/see 2 (m/s 2)
Foot 0.304 8 metres (m) Ineh/see 2 0.025 4 metre/see 2
Yard 0.914 4 metres
Mile 1.609 kilometres (km) TORQUE
Pound-inch 0.112 98 newton-metres (N-m)
AREA Pound-foot 1.355 8 newton-metres
Ineh2 645.2 millimetres2 (mm 2)
6.45 centimetres2 (em 2) POWER
Foot 2
Yard 2
0.092 9
0.836 1
metres 2 (m 2)
metres2
I Horsepower 0.746 kilowatts (kV'J)
PRESSURE OR STRESS
VOLUME Inehes of water 0.249 1 kilopascals (kPa)
Inch3 16 387. mm 3 Pounds/sq. in. 6.895 kilopascals
16.387 cm 3
0.016 4 litres (1) ENERGY OR WORK
Quart 0.946 4 litres BTU 1 055. joules (J)
Gallon 3.785 4 litres Foot-pound 1.355 8 joules
Yard3 0.764 6 metres3 (m 3) Kilowatt-hour 3 600 000. joules (J = one W's)
or 3.6 x 106
MASS
Pound 0.453 6 kilograms (kg) LIGHT
Ton 907.18 kilograms (kg) Foot candle 1.076 4 lumens/metre 2 (Im/m 2)
Ton 0.907 tonne (t)
FUEL PERFORMANCE
FORCE Miles/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 newtons
Pound 4.448 newtons VELOCITY
Miles/hour 1.609 3 kilometres/hr. (km/h)
TEMPERATURE
Degree Fahrenheit (t OF-32r:- 1.8 degree Celsius

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Copyright © 2012, Forel Publishing Company, LLC, Woodbridge, Virginia

1978 Ford Truck Shop Manual

Note from the Publisher

IDENTIFICATION CODES 10-00-1

GENERAL WHEEL AND TIRE SERViCE ., 11-01-1

AIR BRAKES - Cam Type 12-48-1

GENERAL STEERING SERViCE ., ., ., .,13-01-1

FRONT SUSPENSION - Solid I-Beam 14-20-1

CLARK - 280 Five-Speed Transmission 16-40-1

AT-540 AUTOMATIC TRANSMiSSiON 17-27-1

NOISE, VIBRATION AND HARSHNESS DIAGNOSiS 18-01-1

Information in each volume is divided into Groups covering a general

Example: Cooling System Group 27 (8000)

Example: Gasoline Engines Group 21 (6000 & 9000)

General System Basic Part Intake and

Example: 11-02-21 = (Group) 11 - (Part) 02 - (Page) 21

IMPORTANT SAFETY NOTICE

There are numerous variations in procedures, techniques, tools, and parts

VEH IDENT NO.

(UNITED STATES) (EXPORT)

FIG. 1 Typical Vehicle Certification Decal

CD TRUCK SERIES CODE

CD ASSEMBL Y PLANT CODE @ TRANSMISSION CODE

0 SEQUENTIAL SERIAL AND WARRANTY NUMBER @ DISTRICT/SPECIAL ORDER CODES

® RECOMMENDED MAXIMUM GROSS VEHICLE @ R,EAR AXLE CODES

G) EXTERIOR PAINT CODES

FIG. 2 Typical Truck Rating Plate

E11 F60 F600 Cod. .Ballc SlrIII

GAS EIlIIE CODE$-LT. TRUCK (F-100 THRU F-350) 7 7 0 0 4 8

Code Engl. CID Litre Cyl.

ASSEMBLY PLANT AND SEQUENTIAL SERIAL AND WARRANTY NUMBER CODES

Code Aatmbly P1.nt

SEQUENTIAL SERIAL AND NUMBER WARRANTY NUMBER CODES

-Job #1-1978 Model Year

WHEEL BASE AND EXTERIOR PAINT CODES

7 7 0 0 4 8 E·150 CLUB, CUSTOM, AND CHATEAU 'WAGONS

TYPElGVW AND MAX. GVW CODES - CONTINUED

E·100 ECONOLINE CARGO. WINDOW. AND DISPLAY VANS

E·350 ECONOLINE CARGO, WINDOW. AND DISPLAY VANS

E·350 CUTAWAY VAN E·350 CUTAWAY PARCEL DELIVERY VAN

TYPE/GVW AND MAX. G.V.W. CODES - CONnNUED

TYPE/OVW AND MAX. G.V.W. CODES - (CDNnNUED)

LTS·IOOO - DIESEL N·too-GAS NT·IOOI - DIESEL C904 25,100

BODY AND TRANSMISSION CODes

Refer to Volume 3 & 4. Group 30-00 for a complete listing of 1978

700 THAU _ SERIES .ND .... ceoo PARCEL

AXLE CODES (REAR)

700 THRU 9000 SERIES AND N·IOO - C·600 PARCEL

FRONT AXLE ANOO;S.O. CODES

FRONT AXLE CODES (Not AppllCible On E·100 Thru E·350)

FIG. 3 Changing Tire on Drop Center FIG. 5 Tire Spreader

FIG. 6 Visual Inspection F1859-B FIG. 8 Inflation Details

DIAGNOSIS AND T~STING

PROBLEM POSSIBLE CAUSE CORRECTION

COMPLAINT POSSIBLE CAUSE CORRECTION

..'?(f}O'------1'1:: ::' :CER.I