Model Variant:
Full-size SUV (Heavy Duty utility, F-250 Super Duty based)
Production Years Covered:
2000, 2001, 2002, 2003, 2004, 2005
Target Audience:
Technicians and owners servicing the largest production SUV sold in North America; heavy-duty towing and hauling users
Positioning:
Heavy-duty SUV built on the F-250 Super Duty truck platform
Primary Users:
Professional mechanics, fleet operators, DIY owners performing dealer-level repair
Platform:
Shared with F-250 Super Duty heavy-duty pickup
Powertrain Range:
Gas V8, V10, and diesel engine options with heavy-duty automatic transmissions
Capability:
Very high towing and payload capacity for its class
Serviceability:
Body-on-frame construction, straightforward mechanical access
Engine:
Complete removal, installation, disassembly, overhaul and reassembly procedures
Transmission:
Disassembly, repair and reassembly of automatic transmission
Fuel System:
Diagnosis, repair and overhaul procedures
Ignition System:
Testing and repair procedures
Lubrication System:
Service and repair procedures
Exhaust System:
Removal, installation and repair
Electrical System:
Complete diagnostics and repair procedures
Body:
Panel removal, installation, adjustments and repair
Suspension and Steering:
Front and rear suspension, steering linkage service and alignment
Brakes:
Hydraulic system, disc and drum brake service
Tune-Ups:
Complete tune-up specifications and procedures
Routine Maintenance:
Scheduled service intervals and servicing instructions
Removal and Installation:
Step-by-step component R&I procedures
Assemblies and Disassemblies:
Full teardown and rebuild sequences
Diagnostics:
Troubleshooting charts and diagnostic procedures for faults
Torque Specifications:
Fastener torque values throughout; torque wrench use emphasized
Special Tools:
Special tools identified by Ford tool number and illustrated where required
Proprietary Components:
Instructions from respective component manufacturers included
Safety Notices:
WARNING, CAUTION and NOTE callouts throughout the text
Depth:
Dealer service department level; includes engine and transmission disassembly
Assumed Knowledge:
Assumes technician fully conversant with general automobile practices
Focus:
Emphasizes special aspects of the product beyond general procedures
Accuracy:
Depicts parts and procedures applicable to the product at time of writing
Parts Coverage:
Parts identification within procedures applicable to the product
Vendor Components:
Repairs of proprietary components per respective component manufacturer instructions
File Format:
PDF (searchable, bookmarked, zoomable)
Compatibility:
Windows, macOS, Linux, iOS, and Android — any device with a PDF reader
Requirements:
A PDF reader application (e.g. Adobe Acrobat Reader, free)
Searchability:
Fully text searchable for fast lookup of any topic
Print Quality:
High-resolution digital pages, printable at full clarity
Binding Type:
N/A — digital download, no physical binding
Paper Type:
N/A — digital download, no physical paper
Base Gasoline Engine:
5.4L Triton SOHC V8
Optional Gasoline Engine:
6.8L Triton SOHC V10
Diesel Engine 2000-2003:
7.3L Power Stroke turbocharged V8 diesel
Diesel Engine 2003-2005:
6.0L Power Stroke turbocharged V8 diesel
5.4L V8 Output:
Approximately 255 hp / 350 lb-ft of torque
6.8L V10 Output:
Approximately 310 hp / 425 lb-ft of torque
7.3L Diesel Output:
Approximately 250 hp / 505 lb-ft of torque
6.0L Diesel Output:
Approximately 325 hp / 560 lb-ft of torque
Gasoline Engines:
Sequential multi-port electronic fuel injection
Diesel Engines:
Direct injection with turbocharging and oil-fed HEUI (7.3L) / common-rail style high-pressure (6.0L) systems
Fuel Tank:
Large capacity rear-mounted tank suited to heavy-duty towing use
Coverage in Manual:
Full fuel system diagnosis and repair procedures included
Standard Transmission:
4-speed automatic (4R100), heavy-duty with tow haul usage
Optional Transmission 2003-2005:
5-speed TorqShift automatic (5R110W) with diesel and later applications
Drivetrain:
Rear-wheel drive or 4-wheel drive (4x4 models)
Manual Coverage:
Transmission removal, installation, disassembly and reassembly procedures included
Towing Gear Ratios:
Deep low gearing matched to heavy towing duty
TorqShift Benefits:
Additional overdrive ratio, integrated trailer towing calibration (2003+)
Wheelbase:
137.1 in (3,482 mm)
Length:
Approximately 226.4 in (5,750 mm)
Body Style:
4-door full-size SUV, body-on-frame
Seating Capacity:
Up to 9 passengers depending on configuration
Curb Weight:
Approximately 6,650-7,190 lb depending on engine and drivetrain
GVWR Class:
Heavy duty, F-250 Super Duty derived chassis
Front Airbags:
Dual front airbags, second-generation depowered
Body Structure:
Heavy full-frame truck construction with large crumple zones
Seatbelts:
Three-point belts with pretensioners on front outboard positions
ABS:
4-wheel anti-lock brakes standard
Braking:
Power 4-wheel disc front / drum rear system
4WD Traction:
Optional 4-wheel drive for adverse conditions
Crash Test Information:
N/A - not specified for this model in this manual
Audio System:
AM/FM stereo with CD/cassette options; premium audio available by trim
Climate Control:
Manual or available rear auxiliary air conditioning/heat for rear passengers
Driver Assistance Systems:
N/A - none offered; era-appropriate vehicle
Convenience:
Available power adjustable pedals, power seats, and trailer tow packages
4WD Controls:
Electronic shift-on-the-fly 4x4 on equipped models
Oil and Filter:
Per Ford severe/normal schedule as detailed in manual; diesel intervals differ from gasoline
Scheduled Maintenance:
Full routine maintenance and servicing procedures with intervals provided
Tune-Ups:
Complete tune-up procedures and specifications included
Engine Oil:
Viscosity per Ford specification chart for gasoline and diesel engines
Transmission Fluid:
Mercon/Mercon V type fluids per application specified in manual
Coolant:
Ford-specified extended-life coolant procedures included
Diesel Systems:
Fuel filter and oil separator service procedures for Power Stroke engines
7.3L Diesel:
Fuel filter changes and injector O-ring service; known for overall durability
6.0L Diesel:
Oil cooler and EGR cooler service procedures included due to known issues
Front End:
Ball joints and front suspension wear items from heavy-duty use
Brakes:
Pads, rotors and rear drum service given vehicle weight
Manufacturer:
Ford Motor Company
Platform Origin:
Derived from the F-250 Super Duty heavy-duty pickup line
Market Role:
Largest SUV in its class during production, designed to compete with the Chevrolet Suburban
Introduction:
Launched as a 2000 model year vehicle
2003 Update:
Introduction of the 6.0L Power Stroke diesel and 5-speed TorqShift transmission
End of Production:
Discontinued after the 2005 model year
Legacy:
Remains popular with towing and diesel enthusiasts
Assembly Plant:
Louisville, Kentucky, USA
Class Standing:
Largest and one of the most capable SUVs sold in North America during its production run
Towing Reputation:
Widely recognized for exceptional towing and payload capability, especially with Power Stroke diesel
Collector Interest:
Strong following among diesel and heavy-duty SUV enthusiasts after discontinuation
Formal Awards:
N/A - no specific awards documented for this model
