🏷️ Basic Information

Make:

Ford

Model:

500

Model Nickname:

Five Hundred

Years Covered:

2005, 2006, 2007

Platform:

Ford D3 Platform

Assembly Plant:

Oakville Assembly, Ontario, Canada

👋 Introduction

Segment:

Full-size sedan, later rebranded as Taurus

Target Audience:

Families seeking comfort, space, and a smooth ride

Key Competitors:

Buick LaCrosse, Toyota Avalon, Chevrolet Impala, Chrysler Concorde/300M

Design Philosophy:

Emphasis on refined ride quality, spacious interior, and distinctive styling

Powertrain Options:

Standard V6 engine with available AWD

📋 Manual Details

Primary Coverage:

Complete vehicle repair and maintenance

Included Systems:

Engine, Transmission, Drivetrain, Suspension, Steering, Brakes, HVAC, Electrical, Body, Interior, Diagnostics

Estimated Pages:

1500+

Type:

Service and Repair Manual

Language:

English

Format:

PDF

📖 Manual Coverage

Engine Mechanical:

Detailed overhaul procedures, component identification, timing, lubrication, cooling system

Engine Electrical:

Ignition system, starting and charging system, fuel injection system, sensors, actuators, diagnostic codes (DTCs)

Transmission Mechanical:

Automatic transmission (AX4N/4F50N) disassembly, assembly, torque converter, valve body, clutch packs

Transmission Electrical:

Transmission Control Module (TCM), solenoids, sensors, wiring diagrams

Drivetrain:

Front-wheel drive (FWD) and All-wheel drive (AWD) systems, CV axles, differential, driveshafts

Suspension Front:

MacPherson strut, control arms, ball joints, bushings, springs, shock absorbers

Suspension Rear:

Independent multi-link, bushings, springs, shock absorbers

Steering:

Power steering system, steering rack, tie rods, steering column

Brakes:

Front and rear disc brakes, ABS system, hydraulic lines, master cylinder, brake calipers, rotors, pads

HVAC:

Air conditioning, heating, ventilation, climate control system, blower motor, evaporator, condenser, refrigerant

Electrical Body:

Lighting, wipers, power windows, locks, mirrors, seats, door latches, keyless entry

Electrical Chassis:

Horn, exterior lights, interior lights, instrument cluster, infotainment system wiring

Interior:

Dashboard removal, trim panels, seating systems, airbags

Body Exterior:

Bumpers, fenders, doors, hood, trunk, glass, seals, paint repair basics

Diagnostics:

On-Board Diagnostics (OBD-II) procedures, diagnostic trouble codes (DTCs), diagnostic flowcharts

Routine Maintenance:

Oil changes, filter replacements, fluid checks and changes, tire rotations

Scheduled Maintenance:

Tune-ups, spark plug replacement, belt replacement, fluid flush intervals

Troubleshooting:

Diagnostic flowcharts for common problems, symptom analysis

Repair And Replacement:

Detailed step-by-step instructions for component repair and replacement

Overhaul And Rebuild:

Engine and transmission overhaul procedures with specifications

Wiring Diagrams:

Comprehensive electrical schematics for all systems

Torque Specifications:

Detailed torque values for all fasteners

Depth:

Comprehensive: Covers everything from basic fluid changes to full engine and transmission rebuilds

Diagnostic Capability:

Advanced: Includes diagnostic flowcharts, DTC explanations, and component testing procedures

📊 Manual Specifications

File Type:

PDF

Searchability:

Searchable text for quick information retrieval

Resolution:

High-resolution for clear diagrams and text

Printability:

Fully printable for workshop use

Binding:

N/A (Digital PDF)

Paper:

N/A (Digital PDF)

Operating Systems:

Windows and macOS compatible

⚙️ Engine Specifications

Engine Code:

AJ35 (Duratec 35)

Engine Type:

3.0L V6, DOHC, 24-valve

Horsepower:

203 hp @ 6200 rpm

Torque:

207 lb-ft @ 4800 rpm

Fuel Delivery:

Electronic Fuel Injection (EFI)

Recommended Fuel:

87 Octane (Regular Unleaded)

Engine Control Module:

PCM (Powertrain Control Module)

🔧 Transmission

Type:

6-Speed Automatic (AX4N / 4F50N)

Drivetrain:

All-Wheel Drive (AWD)

Shift Control:

Electronic, with Overdrive

Transmission Fluid:

MERCON V Automatic Transmission Fluid

Transmission Fluid Capacity:

Approx. 13.3 US quarts (12.6 liters) total

📐 Dimensions

Length:

200.4 inches (5090 mm)

Width:

74.4 inches (1890 mm)

Height:

56.5 inches (1435 mm)

Wheelbase:

114.5 inches (2908 mm)

Passenger Volume:

105.2 cubic feet (2.98 m³)

Trunk Volume:

16.1 cubic feet (0.456 m³)

Curb Weight FWD:

3700 lbs (1678 kg)

Curb Weight AWD:

3870 lbs (1755 kg)

🛡️ Safety Features

NHTSA Front Driver Impact:

★★★★★ (5 Stars)

NHTSA Front Passenger Impact:

★★★★★ (5 Stars)

NHTSA Side Driver Impact:

★★★★☆ (4 Stars)

NHTSA Side Passenger Impact:

★★★★☆ (4 Stars)

IIHS Front Overlap:

Good

IIHS Side Impact:

Good

ABS:

Standard Anti-lock Braking System (ABS)

Traction Control:

Optional Traction Control System (TCS)

Electronic Stability:

Optional Electronic Stability Control (ESC) - known as AdvanceTrac

Airbags Front:

Standard Dual-stage front airbags

Airbags Side:

Optional front side-impact airbags

Airbags Curtain:

Optional side-curtain airbags (for front and rear passengers)

Seatbelts:

Three-point seat belts for all seating positions, pretensioners, load limiters

💡 Technology Features

Audio System:

Optional Audiophile Sound System with 6-disc CD changer and amplifier.

Navigation:

Optional factory-installed navigation system.

Cruise Control:

Standard speed-sensitive cruise control.

Auxiliary Input:

Not standard, may have been added aftermarket or on very late models as an option.

🔧 Maintenance

Oil Change Interval:

Every 5,000 miles (8,000 km) or 6 months (whichever comes first), or 7,500 miles (12,000 km) under ideal conditions with synthetic oil.

Air Filter Replacement:

Every 15,000 miles (24,000 km) or annually

Cabin Air Filter:

Every 10,000 miles (16,000 km) or annually

Spark Plug Replacement:

Every 100,000 miles (160,000 km) (typically iridium-tipped plugs)

Transmission Fluid Change:

Every 30,000-60,000 miles (48,000-97,000 km), consult owner's manual for specific recommendation based on driving conditions.

Coolant Flush:

Every 30,000 miles (48,000 km) or 2 years

Engine Oil Type:

SAE 5W-20 (Synthetic blend or full synthetic recommended for best performance and protection)

Engine Oil Capacity:

6.0 US quarts (5.7 liters) with filter change

Coolant Type:

Ford Premium Engine Coolant (VC-7 or equivalent)

Brake Fluid Type:

DOT 3

Power Steering Fluid:

MERCON V or equivalent power steering fluid

Transmission Problems:

Some reports of rough shifting, delayed engagement, or transmission fluid leaks. Proper fluid maintenance is critical.

Engine Mounts:

Premature wear or failure of engine mounts, leading to vibration and clunking noises.

Suspension Components:

Wear in control arm bushings and sway bar links can cause clunks and steering looseness.

Cv Axle Boots:

Tears in CV axle boots can lead to premature axle wear if not addressed.

📚 Vehicle History

Manufacturer:

Ford Motor Company

Market Introduction:

Introduced as a new model for the 2005 model year

Platform Sharing:

Utilized the Volvo-derived D3 platform, also used for the Ford Freestyle and Mercury Montego

Name Change:

Replaced by the Ford Taurus for the 2008 model year, with the 500's styling cues incorporated.

Production Span:

2004 - 2007

Total Units Produced:

Approximately 158,000 units (all model years combined)

🏆 Awards & Recognition

Car And Driver Award:

Named to Car and Driver's '10Best' list for 2005.

Consumers Reports Rating:

Varied ratings over its production life, with some praise for ride comfort and interior space, but common criticism for transmission performance and overall reliability by some consumer organizations.