🏷️ Basic Information

Make:

Ford

Model:

F-250 / F-350

Generation:

Seventh Generation (OBS Platform)

Production Years Covered:

1997-2004

Chassis Code:

N/A (Observed Platform Generation designation is sufficient)

👋 Introduction

Target Audience:

DIY enthusiasts, independent repair shops, fleet maintenance.

Value Proposition:

Provides dealership-level service information for cost-effective repairs and maintenance.

Analogy:

This is the 'bible' for technicians working on these trucks, directly equivalent to what a Ford dealership service department uses.

Completeness:

Covers 'every service and repair imaginable'.

Accessibility:

Free download and wide OS compatibility.

📋 Manual Details

Manual Type:

Factory Service Workshop Repair Manual

Language:

English

Format:

PDF (with index)

File Compatibility:

Windows (95, 98, ME, XP, Vista, 7), Linux, MAC

Page Count:

Estimated 2000+ pages (typical for comprehensive factory manuals of this era)

📖 Manual Coverage

Engine Mechanical:

Full overhaul, diagnostics, component replacement (e.g., cylinder heads, pistons, crankshafts, timing systems).

Engine Electrical:

Ignition system, starting and charging system, sensors, wiring diagrams, diagnostic trouble codes (DTCs).

Emission Control:

EGR system, catalytic converter, oxygen sensors, evaporative emission control (EVAP).

Fuel System:

Fuel pumps, injectors, fuel pressure regulator, fuel lines, evaporative emission system.

Clutch System:

Clutch assembly, hydraulic system, linkage, flywheel inspection and replacement.

Manual Transaxle:

Internal components, gearsets, synchronizers, bearing replacement, fluid specifications.

Automatic Transaxle:

Torque converter, valve body, planetary gears, clutch packs, seals, transmission fluid, diagnostic procedures.

Driveshaft Axle:

U-joints, CV joints (if applicable to specific models), differential, axle shafts, bearings.

Suspension System:

Front and rear suspension components, springs, shocks/struts, control arms, alignment procedures.

Steering System:

Power steering pump, steering gear/rack and pinion, steering column, tie rods, hydraulic fluid.

Restraint System:

Seat belts, airbag system components, SRS module diagnostics and replacement.

Brake System:

Disc and drum brakes, ABS, hydraulic lines, master cylinder, calipers, rotors, pads, brake fluid specifications.

Body Interior:

Interior trim, seats, dashboard, door panels, headliner, carpet replacement.

Body Exterior:

Body panels, doors, hood, tailgate, bumpers, glass, seals, paint repair.

Body Electrical:

Lighting system, power windows, locks, mirrors, horn, wipers, interior and exterior lighting circuits.

Heating Ventilation Air Conditioning:

HVAC system components, blower motor, heater core, evaporator, AC compressor, refrigerant types and service.

Maintenance:

Oil and filter changes, fluid checks and changes (coolant, transmission, brake, power steering), filter replacements, lubrication.

Troubleshooting:

Diagnostic charts, symptom-based troubleshooting, electrical system diagnosis, engine performance issues.

Repair:

Component removal, installation, overhaul, adjustment, and calibration for all systems.

Installation:

Optional accessories, upgrades, and component replacements.

Depth:

Comprehensive, covering everything from routine maintenance to complete engine and transmission rebuilds, including electrical system diagnostics and component-level repair.

📊 Manual Specifications

File Type:

PDF

Searchability:

Searchable text due to PDF format and included index.

Printability:

Printable pages for easy reference.

Quality:

Represents factory original quality, including diagrams and illustrations.

Binding:

N/A (Digital Format)

Paper:

N/A (Digital Format)

⚙️ Engine Specifications

Common Engines Offered:

4.2L V6 (OHV), 5.4L Triton V8 (SOHC), 6.8L Triton V10 (SOHC), 7.3L Power Stroke V8 Turbodiesel (OHV).

Horsepower Range:

Approx. 200-215 HP for V6, 235-275 HP for V8s, 250-275 HP for V10/Turbodiesel (varies by year and specific engine tune).

Torque Range:

Approx. 250-260 lb-ft for V6, 330-365 lb-ft for V8s, 370-425 lb-ft for V10/Turbodiesel (varies by year and specific engine tune).

Injection Type:

Electronic Fuel Injection (EFI) for gasoline, Direct Injection for Power Stroke diesel.

Fuel Type:

Unleaded gasoline (87 octane recommended for gasoline engines), Diesel fuel (B20 acceptable for Power Stroke).

🔧 Transmission

Manual Transmission:

Available on some gasoline models (e.g., 5-speed manual).

Automatic Transmission:

4-speed Automatic (e.g., 4R100 for diesel, 4R70W for gasoline V8, E4OD for earlier models/gasoline).

Powertrain Options:

RWD and 4WD configurations.

📐 Dimensions

Body Styles:

Regular Cab, SuperCab (extended cab), Crew Cab.

Bed Lengths:

Short Bed (approx. 6.75 ft), Long Bed (approx. 8 ft).

Gvwr Range:

Starts around 8,500 lbs (F-250) and goes up to 11,000+ lbs (F-350 DRW - Dual Rear Wheel).

🛡️ Safety Features

NHTSA Front Impact:

Varies by configuration, typically 4-star or 5-star for driver/passenger.

ABS:

Standard Anti-lock Braking System (ABS) on all four wheels.

Airbags:

Driver and front passenger airbags.

💡 Technology Features

Audio Options:

Factory AM/FM/Cassette, optional CD player, premium sound systems.

Cruise Control:

Standard cruise control available on most models.

Remote Keyless Entry:

Available on higher trim levels.

🔧 Maintenance

Oil Change:

Typically every 3,000-5,000 miles or 6 months for gasoline engines; 5,000-7,500 miles for Power Stroke diesel (check manual for exact specifications).

Transmission Fluid Change:

Every 30,000-60,000 miles, depending on usage and transmission type. Diesel transmissions often have longer intervals.

Coolant Change:

Every 2-5 years or 30,000-100,000 miles depending on coolant type (e.g., conventional vs. Gold Coolant).

Engine Oil Gasoline:

API Service SG or higher; Viscosity 5W-30 or 5W-20 depending on engine and climate (e.g., 5W-30 for 5.4L Triton, 5W-20 for later 5.4L variants).

Engine Oil Diesel:

API Service CH-4 or CI-4; Viscosity 15W-40 (specific Power Stroke 7.3L recommendations apply).

Transmission Fluid Auto:

Mercon or Mercon V for gasoline automatics; Mercon SP for 4R100 diesel transmissions.

Brake Fluid:

DOT 3.

Coolant:

Ford Premium Engine Coolant (Green) or Gold Coolant; 50/50 mix with distilled water.

Common Problems Gasoline:

Spark plug blow-out on 5.4L 2V Triton engines (early models), intake manifold gasket leaks, cooling system leaks (heater core, radiator).

Common Problems Diesel:

Injector O-ring leaks, turbocharger issues (early stages), exhaust back pressure sensor issues, UVCH (Under Valve Cover Harness) failure.

Suspension Components:

Ball joints, tie rod ends, and steering components are common wear items due to the heavy nature of these trucks.

📚 Vehicle History

Ford Trucks:

Ford has been a dominant force in the pickup truck market for decades, with the F-Series being the best-selling vehicle line in the United States for many years.

Seventh Generation:

This generation (1997-2003/2004 for Heavy Duty) marked a significant styling update from the previous OBS (Old Body Style) generation, featuring a more aerodynamic and refined design, while maintaining robust body-on-frame construction.

Manufacturing Locations:

Primarily assembled in North America, with major plants in Kentucky and Missouri.

🏆 Awards & Recognition

Truck Of The Year:

The F-Series consistently receives accolades and is a perennial winner in 'Truck of the Year' awards from various automotive publications due to its capability and popularity.