🏷️ Basic Information

Make:

Ford

Model:

F-250/F-350

Generation Name:

Tenth Generation (PST), Second Generation Super Duty

Platform Code:

PST (F-250/F-350 Super Duty)

👋 Introduction

Vehicle Segment:

Heavy-Duty Pickup Truck

Key Competitors:

Ram 2500/3500, Chevrolet Silverado 2500HD/3500HD, GMC Sierra 2500HD/3500HD

Vehicle Strengths Period:

Renowned for robust construction, powerful engine options (especially the Power Stroke diesel), towing and hauling capability, and a wide range of configurations.

Cost Savings:

Empowers owners to perform maintenance and repairs themselves, significantly reducing labor costs compared to dealership or independent mechanic charges. Enables informed decisions when discussing repairs with professionals.

📋 Manual Details

Model Years Covered:

1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006

Estimated Page Count:

Likely 2,000+ pages (typical for comprehensive manufacturer service manuals of this era)

Manual Type:

Factory Service Manual / Repair Manual

Language:

English

File Format:

PDF

📖 Manual Coverage

Powertrain:

Engine overhaul, fuel system, cooling system, exhaust system, powertrain control module (PCM), ignition system, emissions control systems, transmission (automatic and manual), drivetrain, transfer case (4x4 models)

Chassis:

Suspension (front and rear), steering system, brake system (hydraulic, ABS, parking brake), wheels and tires, frame and body mounting

Electrical:

Wiring diagrams, charging system, starting system, lighting, instrument cluster, audio system, power accessories (windows, locks, mirrors), climate control systems, diagnostic trouble codes (DTCs), body control module (BCM)

Maintenance:

Routine maintenance, oil changes, filter replacements, fluid checks and top-offs, lubrication, tune-up procedures

Diagnostics Troubleshooting:

System-specific troubleshooting flowcharts, symptom-based diagnostics, diagnostic trouble code (DTC) interpretation and resolution, component testing procedures

Repair Rebuild:

Component removal, installation, and overhaul for all major systems; engine rebuild procedures, transmission rebuilds, brake caliper replacement, suspension component replacement, electrical component repair

Body Interior:

Body panel repair and replacement, door mechanisms, interior trim removal and installation, seat mechanisms, HVAC system service

Depth Of Coverage:

Comprehensive, covering everything from basic scheduled maintenance to complete engine, transmission, and electrical system overhauls and diagnostics.

📊 Manual Specifications

PDF Quality:

High resolution, suitable for printing and on-screen viewing. Text should be searchable.

Printability:

Designed to be printed by the user. Clear diagrams and text.

Binding Type Digital:

N/A (Digital format)

Paper Type Digital:

N/A (Digital format)

⚙️ Engine Specifications

Engine Name:

Triton V10 (6.8L)

Engine Displacement:

6.8 L (415 cu in)

Engine Configuration:

V10 SOHC

Horsepower Gas:

Approx. 310-320 hp (varies slightly by year)

Torque Gas:

Approx. 410-425 lb-ft (varies slightly by year)

Engine Name:

Power Stroke (7.3L V8 OHV Turbo-Diesel)

Engine Displacement:

7.3 L (444 cu in)

Engine Configuration:

V8 OHV Turbocharged

Horsepower Diesel:

Approx. 235-275 hp (varies by year and tuning)

Torque Diesel:

Approx. 500-575 lb-ft (varies by year and tuning)

Fuel Type:

Gasoline (MPI) and Diesel (Direct Injection, Turbocharged)

Fuel Injection Gas:

Multi-Point Fuel Injection (MPI)

Fuel Injection Diesel:

Direct Injection, HEUI (Hydraulically Actuated Electronically Controlled Unit Injector) for early models, later models utilize HEUI with improved electronics and injection timing.

🔧 Transmission

Transmission Type:

For F-250: Ford TorqShift 5-speed automatic (e.g., 5R110W for later models), ZF 6-speed manual (less common on F-250).

Transmission Type:

For F-350: ZF 6-speed manual (e.g., ZF S6-650), Ford 4-speed automatic (e.g., E4OD/4R100 for earlier models), 5-speed automatic (TorqShift). Manual transmissions were more prevalent on F-350.

Transmission Features:

Heavy-duty construction, towing modes, manual shifting capabilities on some automatic units, integrated trailer brake controller compatibility (later models).

📐 Dimensions

Cab Configurations:

Regular Cab, SuperCab (extended cab), Crew Cab

Bed Lengths:

6.75 ft (short bed), 8.0 ft (long bed), 8.0 ft (DRW long bed)

Gvwr F250:

Ranges from 8,800 lbs to 9,900 lbs (varies by configuration)

Gvwr F350:

Ranges from 9,900 lbs to 11,500 lbs (or higher for some DRW models, varies by configuration)

🛡️ Safety Features

NHTSA Ratings:

Likely received 4 or 5 stars for various crashworthiness aspects in its class, though specific year ratings should be verified.

ABS:

Standard Anti-lock Braking System (ABS)

Traction Control:

Optional Traction Control System (TCS) on some models, particularly later years.

Airbags:

Driver and passenger front airbags. Side airbags were less common or optional on earlier models within this range.

Seatbelts:

Three-point seat belts with pretensioners

💡 Technology Features

Audio System:

Factory-installed AM/FM stereo with cassette and CD player (optional). Upgraded speaker options available. Later models offered basic digital displays.

Cruise Control:

Standard cruise control on most trims.

Trailer Towing Features:

Factory trailer wiring harnesses, optional integrated trailer brake controller (on later models), and heavy-duty towing packages.

🔧 Maintenance

Oil Change Interval:

Gasoline: 5,000-7,500 miles or 6 months. Diesel (7.3L Power Stroke): 5,000-10,000 miles or 6 months, depending on operating conditions and oil type used (synthetic blends recommended for heavy use).

Air Filter Replacement:

Every 15,000-30,000 miles or as needed based on conditions.

Fuel Filter Replacement Diesel:

Every 15,000-30,000 miles (critical for Power Stroke longevity).

Engine Oil Gasoline:

SAE 5W-20 or 5W-30 (check owner's manual for specific recommendations based on temperature and load).

Engine Oil Diesel:

API CI-4 or CH-4 rated diesel engine oil, SAE 15W-40 (or 5W-40 synthetic for cold weather operation).

Automatic Transmission Fluid:

MERCON V (for earlier models like E4OD/4R100) or MERCON LV / WSS-M2C195-A (for later TorqShift models). Verify specific type.

Manual Transmission Fluid:

GL-4 or GL-5 rated gear oil (specific viscosity, e.g., 75W-90 or 80W-90, varies by transmission model).

Coolant Type:

Ford Premium Gold Coolant (Orange), or equivalent meeting specification WSS-M97B44-D. Do not mix coolant types.

Diesel 7.3L Isms:

Potential issues with the Injector Control Module (ICM) and the UVCH (Under Valve Cover Harness) can lead to rough running or no-start conditions. Ford updated the UVCH design to address this.

Torqshift Transmission Reliability:

Generally robust, but early versions can experience solenoid issues or torque converter problems under extreme towing loads. Proper fluid maintenance is crucial.

Front Suspension Wear:

Common wear items include ball joints, tie rod ends, and radius arm bushings due to the heavy duty nature of the truck and potential for heavy use. Steering wander can be an indicator.

Fuel Injection Pump Diesel:

While the 7.3L Power Stroke is known for reliability, the HEUI system can eventually require maintenance or replacement, particularly the O-rings on the injectors.

📚 Vehicle History

Ford Truck Legacy:

Ford has a long-standing reputation for building durable and capable trucks, dating back to the early 20th century. The F-Series has consistently been a best-selling vehicle line.

Generation Context:

This period represents the introduction of the 'Super Duty' platform for heavy-duty trucks (F-250, F-350, F-450), marking a significant redesign from the light-duty F-150. This generation introduced bolder styling, improved chassis components, and updated powertrains.

Manufacturing Location:

Primarily manufactured at Ford's Kentucky Truck Plant (Louisville, Kentucky) and Ontario Truck Plant (Oakville, Ontario).

🏆 Awards & Recognition

Powertrain Recognition:

The 7.3L Power Stroke diesel engine was highly regarded for its durability, torque, and longevity, often cited as one of the best diesel engines of its era.