Vehicle Segment:
Heavy Duty Pickup Truck (Class 4)
Key Competitors:
Chevrolet Silverado HD 4500/5500, GMC Sierra HD 4500/5500, Ram 4500/5500 Chassis Cab
Utility:
Designed for heavy towing, hauling, and commercial applications, often configured as a chassis cab for custom upfitting.
Manual Utility:
Empowers owners and technicians to perform a wide range of repairs and maintenance, reducing reliance on costly dealership services.
Engine:
Comprehensive diagnostics, repair, and overhaul of gasoline and diesel engines (e.g., 6.0L Power Stroke Diesel, 6.8L Triton V10)
Drivetrain:
Covers clutch, manual and automatic transmissions, transfer cases (if applicable), propeller shafts, rear axles, and front axle (4x4 models)
Suspension Steering:
Front and rear suspension systems, steering system components, alignment procedures
Brakes:
Hydraulic brake system, ABS, parking brake, component replacement and bleeding procedures
Electrical Electronic System:
Wiring diagrams, electrical component testing, charging system, starting system, lighting, accessories, diagnostic trouble codes (DTCs)
Bodywork Chassis:
Body panels, interior trim, chassis frame, doors, windows, glass, bumpers, and related hardware
HVAC:
Heating, Ventilation, and Air Conditioning (HVAC) system diagnostics and repair
Maintenance:
Routine maintenance, oil changes, filter replacements, fluid checks and changes, lubrication schedules
Troubleshooting:
Systematic diagnostic procedures for identifying and resolving common and complex issues
Repair:
Step-by-step repair instructions for all major vehicle systems and components
Rebuild:
Detailed procedures for engine, transmission, and axle overhauls
Depth:
Comprehensive, covering basic maintenance to complete engine and transmission rebuilds, including diagnostics and electrical schematics
PDF Quality:
High-resolution, ensuring clarity of text, diagrams, and images; searchable text for efficient navigation
Printability:
Fully printable, allowing users to print specific pages or sections as needed
Binding Type:
Not Applicable (Digital PDF Format)
Paper Type:
Not Applicable (Digital PDF Format)
Engine Options:
6.0L Triton V8 Gasoline, 6.0L Power Stroke V8 Turbo Diesel
V8 Gasoline Horsepower:
Approximately 325-350 hp (depending on specific tuning)
V8 Diesel Torque:
Approximately 560-570 lb-ft @ 2000 rpm (6.0L Power Stroke)
Diesel Injection:
Common Rail Direct Injection (CRDI) for Power Stroke engine
Gasoline Fuel Delivery:
Electronic Fuel Injection (EFI)
Cooling Capacity:
Approx. 28-30 Quarts (Diesel), 20-22 Quarts (Gasoline) - Manual will specify exact capacities
Transmission Type:
5-speed Manual (less common on F-450) or 5-speed TorqShift Automatic (common)
Transmission Options:
5-speed Automatic (TorqShift) for diesel and gasoline; 6-speed Manual (less prevalent on F-450) might be an option on certain configurations.
Torqshift Features:
Torque converter lock-up, tow/haul mode, manual shifting capability
Wheelbase:
Typically 137.1 inches (standard configuration), but chassis cab configurations offer various wheelbase options.
Gvwr:
14,500 lbs to 16,000 lbs (depending on configuration and options)
Curb Weight:
Varies significantly based on configuration (e.g., 7,000 - 8,000 lbs)
Conventional Towing Capacity:
Up to 19,500 lbs (with proper equipment and configuration)
5Th Wheel Gooseneck Towing Capacity:
Up to 21,500 lbs (with proper equipment and configuration)
NHTSA Rollover Rating:
Likely 3-star or 4-star (typical for heavy-duty trucks of this era, manual may have specific data)
ABS:
Standard Anti-lock Braking System (ABS) on all wheels
Towing Features:
Integrated trailer brake controller provisions, trailer sway control (if equipped)
Airbags:
Driver and passenger front airbags
Audio System:
Base AM/FM, optional CD player, available premium audio systems
Towing Assistance:
Factory trailer brake controller integration, wiring for trailer lights and braking
Diagnostic Port:
OBD-II (On-Board Diagnostics II) port for engine and system diagnostics
Oil Change Interval:
Approximately 5,000 miles or 6 months for gasoline, 5,000-7,500 miles or 6 months for diesel (consult manual for exact recommendations based on usage)
Engine Coolant Flush:
Every 30,000 miles or 2 years for gasoline; Longer intervals for Power Stroke diesel coolant (e.g., 50,000 miles or 2 years, or per specific Power Stroke recommendations).
Engine Oil Gasoline:
SAE 5W-20 (API SN or equivalent) - capacity approx. 7 quarts
Engine Oil Diesel:
15W-40 API CI-4 or CJ-4 rated diesel engine oil - capacity approx. 15 quarts
Transmission Fluid Automatic:
Mercon V (or equivalent) for TorqShift automatic transmission
Transfer Case Fluid:
Mercon LT (or equivalent) for 4x4 models
Rear Axle Fluid:
GL-5 gear oil (e.g., 75W-90 or 75W-140 depending on differential type and ambient temperature)
Power Stroke Diesel 6.0L:
Common issues can include EGR cooler failures, oil cooler failures, head gasket leaks, and injector issues. The manual will provide diagnostic and repair steps for these.
General Wear Items:
Brake components, suspension bushings, exhaust systems, and turbocharger (on diesel) are common wear items requiring inspection and potential replacement.
Ford Truck Legacy:
Ford has a long-standing reputation for building durable and capable trucks, particularly the F-Series line dating back to 1948.
Super Duty Development:
The Super Duty line was introduced in 1998 to differentiate heavy-duty trucks from the lighter F-150. The F-450 is positioned as a Class 4 chassis cab or pickup.
Manufacturing Plant:
Kentucky Truck Plant, Louisville, Kentucky
Generation:
This manual covers the second generation of the Super Duty F-Series (2005-2007), which received a significant refresh for 2005.
