🏷️ Basic Information

Make:

Ford

Model:

F-350 Super Duty

Year:

2005

Chassis Code:

GMT800 (for comparison, not Ford specific for this generation)

Engine Codes:

7.3L V8 Power Stroke Diesel (IDIT), 6.0L V8 Power Stroke Diesel, 5.4L V8 Triton, 6.8L V10 Triton

Super Duty Generation:

Second Generation (2005-2007)

👋 Introduction

Vehicle Segment:

Heavy-Duty Pickup Truck (Class 2b/3)

Target Audience:

Commercial users, fleet owners, towing enthusiasts, heavy-duty work applications

Key Competitors:

Chevrolet Silverado HD, GMC Sierra HD, Ram Heavy Duty

Value Proposition:

Renowned for its robust build, powerful diesel engine options, and towing/hauling capabilities

Durability:

Built on a ladder frame chassis designed for heavy-duty use

Powertrain Options:

Strong emphasis on V8 gasoline and turbodiesel engines

Towing Capacity:

Segment-leading towing and payload capacities

📋 Manual Details

Manual Type:

Workshop Repair Manual

Language:

English

Format:

PDF

File Size:

Approximately 100 MB

Manual Intended User:

DIY Enthusiasts, Dealerships, Auto Shops

📖 Manual Coverage

Engine Mechanical:

Engine assembly, disassembly, lubrication, cooling, fuel, ignition, emission controls, turbocharging (for diesel variants)

Engine Performance:

Troubleshooting, diagnostics, performance tuning (basic)

Transmission Manual:

Manual transmission (e.g., Getrag G56) service, repair, and overhaul

Transmission Automatic:

Automatic transmission (e.g., TorqShift 5R110W) service, repair, and overhaul

Drivetrain:

Driveshafts, U-joints, differentials, axle shafts, hub assemblies

Suspension:

Front and rear suspension components, springs, shock absorbers, steering linkage

Brakes:

Front and rear brake systems (disc/drum), ABS, parking brake

Electrical System:

Battery, charging system, starting system, lighting, accessories, instrument cluster

Electronic Controls:

PCM/ECM, body control module (BCM), diagnostic trouble codes (DTCs), OBD-II diagnostics

Air Conditioning:

HVAC system diagnosis and repair, refrigerant handling, component replacement

Safety Systems:

Airbag system diagnosis and repair, seatbelt systems

Bodywork:

Body panel removal and installation, interior trim, exterior trim, glass replacement

Chassis And Frame:

Frame inspection and repair, mounting points

Fuel System:

Fuel tank, fuel pump, fuel injectors, fuel lines

Exhaust System:

Exhaust manifolds, catalytic converter, mufflers, pipes

Cooling System:

Radiator, water pump, thermostat, coolant hoses, cooling fan

Maintenance Procedures:

Routine maintenance, scheduled servicing, fluid changes, filter replacements

Diagnostic Procedures:

Troubleshooting guides for common and uncommon faults, diagnostic code interpretation

Repair Procedures:

Step-by-step instructions for component removal, repair, and reinstallation (minor and major)

Rebuild Procedures:

Complete engine and transmission rebuild instructions

Electrical Troubleshooting:

Wiring schematics, circuit diagrams, pinpoint tests for electrical faults

Torque Specifications:

Precise torque values for all critical fasteners

Alignment Specifications:

Wheel alignment parameters

Wheel Balance And Tire:

Tire and wheel service procedures

Diagnostic Tools:

Information on utilizing diagnostic scan tools (e.g., Ford IDS) and interpreting data

Special Tools:

Identification of necessary special tools for specific procedures

Illustrations And Diagrams:

Detailed illustrations, exploded views, and wiring diagrams

Troubleshooting Charts:

Systematic approaches to diagnosing problems

Rebuild Information:

Comprehensive guides for rebuilding major components like transmissions and engines

📊 Manual Specifications

Digital Format:

PDF

Searchability:

Searchable text with bookmarks

Software Requirement:

None (viewable with standard PDF reader)

Print Capability:

Printable (depending on user's PDF reader capabilities)

Image Resolution:

High resolution for clarity of diagrams and illustrations

Text Clarity:

Sharp and readable text for easy comprehension

Binding:

N/A (Digital Format)

Paper:

N/A (Digital Format)

⚙️ Engine Specifications

Gasoline Engine 1:

5.4L Triton V8 (3-valve)

Gasoline Engine 1 Power:

Approx. 300 hp @ 4500 rpm

Gasoline Engine 1 Torque:

Approx. 365 lb-ft @ 3000 rpm

Gasoline Engine 2:

6.8L Triton V10 (3-valve)

Gasoline Engine 2 Power:

Approx. 310 hp @ 4250 rpm

Gasoline Engine 2 Torque:

Approx. 425 lb-ft @ 3250 rpm

Diesel Engine 1:

6.0L Power Stroke V8 Turbodiesel (Navistar VT365)

Diesel Engine 1 Power:

Approx. 325 hp @ 3300 rpm

Diesel Engine 1 Torque:

Approx. 560 lb-ft @ 2000 rpm

Diesel Engine 2:

7.3L Power Stroke V8 Turbodiesel (IDIT - International Diesel Indirect Injection, often found in earlier models but could be present in some early 2005 production runs as a carryover)

Diesel Engine 2 Power:

Approx. 250 hp @ 2600 rpm (earlier versions)

Diesel Engine 2 Torque:

Approx. 505 lb-ft @ 1600 rpm (earlier versions)

Gasoline Fuel Delivery:

Electronic Fuel Injection (EFI)

Diesel Fuel Delivery:

High-Pressure Common Rail (HPCR) for 6.0L Power Stroke, IDI for 7.3L

🔧 Transmission

Manual Transmission:

5-speed manual (e.g., Getrag G56)

Automatic Transmission:

5-speed TorqShift automatic (5R110W)

Transfer Case:

Manual or Electronic Shift-On-The-Fly (ESOF) 4WD systems

📐 Dimensions

Wheelbase Options:

137.0 in (Reg Cab), 156.2 in (SC/CC), 172.4 in (SC/CC Long Bed), 192.4 in (CC Long Bed Crew Cab)

Overall Length Range:

Approx. 237 in to 277 in

Overall Width:

Approx. 79.9 in

Overall Height Range:

Approx. 76.7 in to 78.8 in

Curb Weight Range:

Approx. 6,000 - 7,500 lbs (depending on configuration)

Gvwr Range:

10,000 lbs to 13,000 lbs (depending on configuration)

Payload Capacity Range:

Approx. 3,000 - 5,000 lbs+

Towing Capacity Range:

Up to 12,500 lbs (conventional hitch), up to 23,000 lbs (gooseneck/5th wheel hitch)

🛡️ Safety Features

NHTSA Front Impact Rating:

4 Stars (Driver), 5 Stars (Passenger) - Generally for comparable models of the era, specific 2005 F-350 may vary.

NHTSA Side Impact Rating:

4 Stars (Front Seat), 4 Stars (Rear Seat) - Generally for comparable models of the era, specific 2005 F-350 may vary.

Airbags:

Front driver and passenger airbags

Seatbelts:

Front and rear seat belts (as applicable), height-adjustable shoulder belts

Rollover Protection:

Enhanced body structure and frame design for stability

ABS:

Anti-lock Braking System (ABS) standard on all wheels

Trailer Brake Controller:

Optional integrated trailer brake controller for managing electric trailer brakes

💡 Technology Features

Audio System:

AM/FM stereo with CD player, available premium audio systems.

Navigation:

Optional factory navigation system available on higher trim levels.

Cruise Control:

Standard cruise control.

Tow Mirrors:

Available telescoping and power-adjustable tow mirrors.

Power Outlets:

12V power outlets.

Auxiliary Input:

Available auxiliary audio input jack.

🔧 Maintenance

Oil Change Gasoline:

Every 5,000-7,500 miles or 6 months, whichever comes first (depending on oil type and driving conditions)

Oil Change Diesel:

Every 5,000-10,000 miles or 6 months (depending on oil type, filter, and usage, consult manual for specific recommendations)

Coolant Flush:

Every 30,000-100,000 miles or 2-5 years (depending on coolant type, consult manual)

Transmission Fluid Change Auto:

Every 30,000-100,000 miles (severe duty or towing applications recommend more frequent changes, consult manual)

Transmission Fluid Change Manual:

Every 50,000-100,000 miles

Differential Fluid Change:

Every 30,000-100,000 miles (depending on usage, consult manual)

Engine Oil Gasoline:

API SN/SP, SAE 5W-20 (preferred) or 5W-30

Engine Oil Diesel 6.0L:

API CJ-4 or CK-4, SAE 15W-40 (preferred) or 10W-30 synthetic for cold weather

Engine Oil Diesel 7.3L:

API CF-4 or CG-4, SAE 15W-40 or 10W-30

Coolant:

Ford Gold Coolant (Premium Engine Coolant - VC-7)

Automatic Transmission Fluid:

Mercon V (for TorqShift 5R110W)

Manual Transmission Fluid:

API GL-4 or GL-5, SAE 75W-90 or 80W-90 (specific to transmission type)

Brake Fluid:

DOT 3

Diesel 6.0L Head Gaskets:

Potential for head gasket failure, often addressed with ARP head studs and updated gaskets.

Diesel 6.0L Egr:

Exhaust Gas Recirculation (EGR) cooler failures are common.

Diesel 6.0L Oil Cooler:

Oil cooler failures can lead to overheating of the EGR cooler and other issues.

Diesel 6.0L Fuel Injectors:

Injector seal failures or complete injector failure can occur.

Gasoline V10 Ignition:

Spark plug ejection (spark plug blow-out) can be an issue, requiring specific repair kits.

Suspension Front End:

Wear in ball joints, tie rod ends, and steering components is common with heavy use.

Diesel Exhaust Brake:

Operation of the integrated exhaust brake (on some models) can sometimes have issues.

📚 Vehicle History

Ford Truck Lineage:

Ford has a long-standing heritage in the truck market, with the F-Series being a dominant force for decades.

Super Duty Introduction:

The Super Duty line was introduced in 1998 to differentiate from the lighter-duty F-150, focusing on heavier workloads.

Second Generation Updates:

The 2005 model year represented a significant refresh for the second generation, including updated styling, interior refinements, and powertrain enhancements (especially the 6.0L Power Stroke and updated Triton V8s).

Manufacturing Location:

Various Ford assembly plants in the United States (e.g., Louisville, Kentucky)

🏆 Awards & Recognition

Heavy Duty Truck Awards:

The Ford Super Duty line consistently receives accolades from automotive publications and industry organizations for its performance, towing capabilities, and ruggedness.

Popular Mechanics Editor Choice:

Likely received 'Editor's Choice' awards in its segment from publications like Popular Mechanics for its utility and power.

Consumer Satisfaction:

High consumer satisfaction for overall capability and durability, particularly with diesel powertrains.