🏷️ Basic Information

Make:

Ford

Model:

E-450 Super Duty

Year:

2004

Chassis Code:

E-Series (VAN)

👋 Introduction

Vehicle Segment:

Full-Size Van / Chassis Cab

Target Audience:

Commercial fleet operators, tradespeople, RV manufacturers, and DIY enthusiasts requiring detailed repair information.

Competitors:

Chevrolet Express/GMC Savana, Mercedes-Benz Sprinter (commercial variants), Dodge Sprinter (later models).

Features:

Licensed OE material, digital convenience, comprehensive system coverage, DIY-friendly instructions, cost savings on repairs.

📋 Manual Details

Manual Type:

Service and Repair Manual

Language:

English

Format:

PDF Download

Access Duration:

1 Year Subscription

📖 Manual Coverage

Engine Mechanical:

Complete engine diagnostics, repair, and overhaul procedures for all available gasoline and diesel engines.

Fuel System:

Fuel delivery, injection systems (gasoline and diesel), fuel tank, fuel pump, and filters.

Cooling System:

Radiator, water pump, thermostat, hoses, coolant specifications, and pressure testing.

Ignition System:

Spark plugs, ignition coils, wiring, and ignition timing for gasoline engines.

Exhaust System:

Exhaust manifolds, catalytic converters, mufflers, pipes, and emissions control systems.

Drivetrain Manual Transmission:

Manual transmission removal, installation, internal component repair, clutch service, and fluid specifications.

Drivetrain Automatic Transmission:

Automatic transmission removal, installation, internal component repair, torque converter service, and fluid specifications.

Drivetrain Driveshafts Axles:

Driveshaft balancing, U-joints, CV joints, axle shafts, and differential service.

Suspension Front:

Independent front suspension components, ball joints, control arms, bushings, springs, shock absorbers/struts, and alignment specifications.

Suspension Rear:

Solid rear axle components, leaf springs, shock absorbers, bushings, and alignment specifications.

Steering System:

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

Brake System Front:

Front disc brake calipers, pads, rotors, brake lines, and hydraulic system diagnostics.

Brake System Rear:

Rear drum brake components (if applicable), wheel cylinders, brake shoes, drums, brake lines, and hydraulic system diagnostics.

Anti Lock Braking System:

ABS components, sensors, control module, hydraulic modulator, and diagnostic procedures.

Electrical System Charging:

Alternator, voltage regulator, battery, starter motor, and related wiring.

Electrical System Lighting:

Headlights, taillights, turn signals, interior lighting, and related switches and wiring.

Electrical System Instruments Gauges:

Instrument cluster, gauges, warning lights, and diagnostic procedures.

Electrical System Wiring Diagrams:

Comprehensive wiring schematics for all major vehicle systems.

Body Exterior:

Body panel removal and installation, door mechanisms, latches, hinges, glass replacement, and exterior trim.

Body Interior:

Interior trim panel removal and installation, seats, dashboard, console, and headliner.

HVAC System:

Air conditioning compressor, condenser, evaporator, heater core, blower motor, controls, and refrigerant handling.

Safety Systems:

Airbag system diagnostics and replacement, seat belt service.

Routine Maintenance:

Oil changes, filter replacements, fluid level checks and top-offs, tire rotation, spark plug replacement, and general inspections.

Troubleshooting:

Diagnostic charts and procedures for identifying and resolving common and uncommon problems across all vehicle systems.

Repair Procedures:

Step-by-step instructions for component removal, disassembly, repair, reassembly, and installation.

Diagnostics:

OBD-II diagnostic code interpretation, live data analysis, and specific diagnostic tests for electronic modules.

Calibration Procedures:

Procedures for recalibrating sensors and modules after replacement or repair, where applicable.

Depth Level:

Comprehensive factory-level repair and diagnostic information.

Detail Level:

Detailed exploded views, torque specifications, special tool requirements, and diagnostic flowcharts.

📊 Manual Specifications

File Type:

PDF

Searchability:

Searchable text content for quick information retrieval.

Image Resolution:

High-resolution images and diagrams for clarity.

Binding:

N/A (Digital Download)

Paper:

N/A (Digital Download)

⚙️ Engine Specifications

Engine Options:

5.4L Triton V8 (Gasoline), 6.8L Triton V10 (Gasoline), 7.3L Power Stroke V8 Turbo Diesel (Econoline chassis, though potentially less common in E-450 specific to this year).

Horsepower Range:

Approx. 215-310 hp (depending on engine)

Torque Range:

Approx. 300-525 lb-ft (depending on engine)

Fuel Type Gasoline:

Unleaded Gasoline

Fuel Type Diesel:

Diesel Fuel

Injection Type Gasoline:

Electronic Fuel Injection (EFI)

Injection Type Diesel:

Direct Injection (Turbocharged)

🔧 Transmission

Transmission Type Standard:

4-Speed Automatic (e.g., 4R75E, 4R100)

Transmission Type Optional:

5-Speed Manual (Less common for E-450)

Transmission Features:

Overdrive, electronic control, tow/haul mode.

📐 Dimensions

Wheelbase Options:

Multiple wheelbase options available depending on configuration (e.g., 138-inch, 158-inch).

Gvwr Range:

12,500 lbs to 14,050 lbs (Gross Vehicle Weight Rating), depending on configuration.

Payload Capacity:

Varies significantly based on configuration and chassis options.

🛡️ Safety Features

NHTSA Rollover Resistance:

Typically rated 4 out of 5 stars for rollover resistance in higher GVWR classes.

Active Safety Features:

Anti-lock Braking System (ABS).

Passive Safety Features:

Front airbags for driver and passenger, reinforced safety cage.

💡 Technology Features

Infotainment System:

Basic AM/FM radio with CD player was common. Higher trims may have offered premium audio systems. Advanced infotainment features were limited in this era.

Driver Assistance Features:

Limited to basic features like cruise control. Advanced driver-assistance systems (ADAS) were not common on commercial vans of this vintage.

Connectivity Options:

Auxiliary input jack for audio devices.

🔧 Maintenance

Oil Change Interval Gasoline:

Typically 5,000-7,500 miles or 6 months, depending on driving conditions (refer to manual for exact OE recommendation).

Oil Change Interval Diesel:

Typically 5,000-10,000 miles or 6 months, depending on driving conditions (refer to manual for exact OE recommendation).

Transmission Fluid Interval:

Check every 15,000 miles, change every 30,000-60,000 miles depending on usage (refer to manual).

Engine Oil Gasoline:

SAE 5W-30 (API Service SG or higher, check manual for specific SN/ILSAC requirements).

Engine Oil Diesel:

15W-40 (API Service CI-4 or CH-4, check manual for specific CJ-4 requirements).

Coolant Type:

Ford Premium Engine Coolant (Green) or equivalent with the correct ethylene glycol concentration (50/50 mix).

Transmission Fluid Type:

Mercon V (for most automatics, verify with VIN) or manual transmission fluid (e.g., SAE 75W-90).

Common Wear Items:

Ball joints, tie rod ends, front-end bushings, exhaust hangers, and potentially rear leaf spring bushings due to heavy loads.

Diesel Specific Issues:

For the 7.3L Power Stroke, common issues can include injector seal leaks, UVCH (Under Valve Cover Harness) issues, and turbocharger wear. For gasoline engines, spark plug blowouts (especially early Triton models) and intake manifold gasket leaks can occur.

📚 Vehicle History

Ford Commercial Vehicles:

Ford has a long-standing reputation for producing durable and reliable commercial vehicles, including the E-Series vans.

E Series Evolution:

The E-Series van platform has been in continuous production since the 1960s, with significant updates and powertrain evolutions over the decades. The E-450 represents a heavy-duty variant tailored for commercial and specialized applications.

Production Location:

Kansas City Assembly Plant, Claycomo, Missouri, USA (primary).

🏆 Awards & Recognition

Commercial Van Awards:

The Ford E-Series platform has historically been a leader in the commercial van segment, often recognized for its versatility and capability. Specific awards for the 2004 model year are not prominently documented, but its market dominance speaks to its industry standing.