🏷️ Basic Information

Make:

Ford

Model:

Super Duty F-250

Year:

2006

Code:

Fourth Generation (2005-2007)

👋 Introduction

Segment:

Heavy-duty pickup truck segment, targeted at commercial and fleet use, as well as heavy-duty consumer applications.

Target Audience:

Professional mechanics, fleet maintenance personnel, and serious DIY enthusiasts seeking in-depth knowledge and repair capabilities for their Ford Super Duty truck.

Competitors:

Chevrolet Silverado HD, GMC Sierra HD, Dodge Ram HD (now Ram Heavy Duty).

Manual Benefits:

Enables owners and professionals to perform a wide range of repairs and maintenance, reducing labor costs and empowering self-sufficiency. Provides dealer-level repair information.

Visual Guidance:

The manual's claim of 'step-by-step illustrated repair procedures' is a significant asset, providing visual aids that clarify complex mechanical and electrical tasks, making them understandable for users of all skill levels.

📋 Manual Details

Primary Coverage:

Vehicle service and repair

Estimated Pages:

Varies by specific Ford manual, typically 1000-3000+ pages for a complete factory service manual.

Type:

Service and Repair Manual

Language:

English

Format:

PDF

Accessibility Features:

The PDF format is generally accessible and can be viewed on a wide range of devices without special software beyond a PDF reader. Compatibility with e-readers and tablets is a key feature.

📖 Manual Coverage

Major Systems:

Engine, Clutch, Gearbox, Propeller Shafts, Rear Axles, Front Axle, Front and Rear Suspensions, Wheels and Tyres, Steering System, Brakes, Bodywork and Chassis Frame, Electrical/Electronic System, Heating and Air Conditioning

Specific Systems Detailed:

Includes diagnostics and repair procedures for fuel system, cooling system, exhaust system, engine mechanical components (short block, cylinder heads, valve train), climate control system (HVAC), power steering system, wheel bearings, differential assemblies, transfer case, driveshafts, U-joints, ABS modulator, master cylinder, calipers, parking brake, body panels, door mechanisms, interior trim, and all wiring harnesses.

Body And Interior:

Comprehensive coverage of body panel removal and installation, door and window mechanisms, interior trim components, seat adjustments, airbag system precautions, and body electrical accessories.

Repair Procedures:

Diagnosis, troubleshooting, repair, maintenance, component replacement, system adjustments, electrical schematics interpretation.

Specific Procedures:

Detailed procedures for engine tune-ups, component removal and installation (e.g., alternator, starter, water pump), transmission fluid and filter changes, brake fluid flushes, suspension component replacement (shocks, springs, ball joints), steering gear service, axle seal replacement, clutch adjustment/replacement, electrical component testing (sensors, actuators), and body panel alignment.

Electrical Repairs:

Detailed wiring diagrams for all major systems (engine controls, lighting, HVAC, power accessories, etc.). Procedures for diagnosing and repairing electrical faults, including component testing, wiring harness repair, and module programming (where applicable).

Troubleshooting Guides:

Structured troubleshooting flowcharts and tables to systematically identify and resolve common vehicle problems based on symptoms, electrical readings, and component testing.

Depth:

Comprehensive: from basic maintenance to advanced diagnostics and complete component overhauls, including torque specifications, clearances, and testing procedures.

Diagnostic Procedures:

Advanced diagnostic procedures are covered, including using scan tools to read diagnostic trouble codes (DTCs), data stream analysis, and performing actuator tests. Specific Ford diagnostic protocols and connector pinouts will be provided.

Torque Specifications:

Extensive torque specifications for all critical fasteners throughout the vehicle, ensuring proper assembly and preventing component damage or failure.

📊 Manual Specifications

Compatibility:

Adobe PDF Reader, compatible with Windows OS, smartphones, and tablets.

Searchability:

PDF format allows for text searching of keywords, making it easier to locate specific information quickly.

Printability:

High resolution for clear printing of all pages, images, and schematics.

Binding:

Not Applicable (Digital PDF format)

Paper Type:

Not Applicable (Digital PDF format)

⚙️ Engine Specifications

Engine Options:

The 2006 Ford F-250 Super Duty offered multiple engine options including the 5.4L Triton V8 (330 ci), the 6.0L Power Stroke V8 Turbo Diesel, and the 6.8L Triton V10 (415 ci). The manual will cover all of these.

Engine Code Examples:

Examples: 5.4L Triton (e.g., 5.4L 3V V8), 6.0L Power Stroke Diesel (e.g., 6.0L V8 Power Stroke), 6.8L Triton (e.g., 6.8L 3V V10). The manual will refer to specific engine codes as per Ford's internal numbering system.

Power Torque Ranges:

Specific horsepower and torque figures vary by engine and year-end tuning. For example, the 6.0L Power Stroke typically produced around 325 hp and 560-570 lb-ft of torque. The manual will detail these for each engine.

Torque Converter Lockup Info:

Information on the operation and service of the torque converter, including lockup clutch engagement, which is crucial for fuel economy and performance in automatic transmissions.

Fuel Delivery:

Includes gasoline fuel injection systems (likely Electronic Fuel Injection - EFI) for V8 and V10, and advanced diesel fuel injection systems (likely common rail for the 6.0L Power Stroke) for the diesel variants.

Gasoline Injection Type:

Sequential Electronic Fuel Injection (SEFI) for gasoline engines, ensuring precise fuel delivery and engine performance.

🔧 Transmission

Standard Transmission Type:

Manual transmissions (e.g., 5-speed) were available, particularly on lower trim levels or specific configurations. This manual will detail their operation and repair.

Optional Transmission Type:

Automatic transmissions, most notably the TorqShift 5-speed automatic (5R110W), were common and will be thoroughly covered for repair and maintenance.

Transmission Features:

Information on Powertrain Control Module (PCM) integration, torque converter operation, transmission fluid specifications (e.g., MERCON), and diagnostic trouble codes (DTCs) related to the transmission.

Gear Ratios:

Manuals will include detailed gear ratios for all available transmissions (manual and automatic) and differential options, crucial for calculating towing performance and understanding vehicle operation.

📐 Dimensions

Wheelbase Options:

Multiple wheelbase options were available (e.g., 137", 156", 172") depending on cab style (Regular Cab, SuperCab, Crew Cab) and bed length (6.75' Styleside, 8.0' Styleside, 9.75' Long Bed). The manual will provide detailed chassis dimensions.

Track Width Front Rear:

The manual will contain precise measurements for front and rear track width, essential for alignment procedures and tire fitment.

Ground Clearance:

The manual will provide ground clearance figures for various configurations, important for off-road capability and understanding potential underbody damage.

Gross Vehicle Weight Rating:

GVWRs varied significantly based on configuration, typically ranging from 8,800 lbs to 11,500 lbs or higher for F-350 models if applicable to the manual's scope. The F-250 would fall within this range. The manual will specify these for different configurations.

Curb Weight Range:

Curb weight would vary significantly based on configuration, but typically ranged from approximately 5,800 lbs to 7,500 lbs for F-250 models. The manual will provide specific weights for different configurations.

Payload Capacity:

Payload capacities vary greatly by configuration but are a defining characteristic of Super Duty trucks. The manual will outline how to determine payload capacity for specific models and the factors affecting it.

🛡️ Safety Features

NHTSA Ratings:

Specific NHTSA crash test ratings for the 2006 model year would need to be consulted from official sources. However, Ford's Super Duty line generally emphasized structural integrity for heavy-duty applications. The manual might reference relevant safety system diagnostics.

Active Safety Systems:

Likely included Anti-lock Braking System (ABS) on all wheels, and potentially integrated trailer brake controller preparation. The manual will cover ABS diagnostics and component replacement.

Towing Stability Features:

While electronic stability control (ESC) wasn't standard on all 2006 models, the manual will cover related systems that contribute to towing stability, such as trailer sway control preparation or diagnostics if equipped.

Passive Safety Features:

Front airbags, three-point seat belts with pretensioners, and reinforced safety cage construction are standard. The manual covers the electrical systems associated with these components.

💡 Technology Features

Audio Systems:

Base models would have AM/FM radios with CD players. Higher trims could feature premium audio systems, satellite radio capability, and potentially navigation systems. The manual will cover the electrical components and wiring for these systems.

Driver Aid Features:

Limited driver assistance technologies compared to modern vehicles. Focus would be on robust mechanical systems. Electronic features would primarily relate to powertrain control and diagnostics.

Diagnostic Tools Interface:

Information on the OBD-II (On-Board Diagnostics) connector location and how to interface with diagnostic scan tools to retrieve powertrain and chassis fault codes.

Electrical Systems Integration:

The manual details the extensive electrical system, including fuse box locations, wiring diagrams for various circuits, Body Control Module (BCM) functions, and communication networks (e.g., CAN bus) used for module integration and diagnostics.

🔧 Maintenance

Recommended Intervals:

The manual will detail specific service intervals for oil changes (e.g., 5,000-7,500 miles for gasoline, 5,000 miles for diesel), filter replacements, fluid checks, tire rotations, brake inspections, and other scheduled maintenance tasks based on mileage and time.

Filter Replacement Schedule:

Specific recommendations for replacing engine oil filters, fuel filters (especially critical for diesel), air filters, cabin air filters, and transmission filters, often with associated part numbers.

Engine Oil:

Engine oil specifications will vary by engine. For gasoline engines, SAE 5W-20 or 5W-30 API Certified oil would be typical. For the 6.0L Power Stroke diesel, SAE 15W-40 API CJ-4 or CI-4 PLUS specification diesel engine oil is required. The manual will list exact types and capacities.

Transmission Fluid:

Automatic transmissions typically require MERCON V or MERCON LV (check specific application). Manual transmissions would use appropriate gear oil. Capacities for each will be listed, e.g., TorqShift 5R110W typically holds around 12.8 quarts (12.1 liters) for a dry fill.

Coolant Type:

Typically a 50/50 mix of Motorcraft Premium Engine Coolant (yellow) or equivalent with distilled water. The manual will specify capacity and service interval for coolant replacement.

Brake Fluid:

DOT 3 brake fluid is the standard. The manual will provide capacity and recommendations for flushing.

Power Steering Fluid:

Typically uses Automatic Transmission Fluid (ATF), often MERCON V. The manual will specify exact type and capacity.

Differential Fluid:

Specifications for front and rear differential fluid, including GL-5 gear oil for conventional differentials and specific fluids for limited-slip or electronic locking differentials if equipped. Capacities will be listed.

Common Problems 2006 F250:

While the manual provides comprehensive repair information, common issues for the 2006 F-250, particularly with the 6.0L Power Stroke diesel, could include EGR cooler failures, oil cooler issues, and fuel injection control module (FICM) problems. Gasoline engines might face typical wear and tear. The manual will guide in diagnosing and repairing these.

Common Gasoline Engine Issues:

For gasoline engines (5.4L and 6.8L V10), potential issues could include ignition coil failures, spark plug ejection (especially on earlier 3-valve 5.4Ls), and exhaust manifold leaks. The manual will guide diagnostics for these.

Diesel Specific Maintenance Points:

Focus on critical diesel maintenance items like fuel filter replacement intervals, checking and changing crankcase ventilation filters, and monitoring the integrity of the cooling system and exhaust gas recirculation (EGR) system, all detailed in the manual.

📚 Vehicle History

Ford Truck Legacy:

Ford has a long and storied history in the pickup truck market, with the F-Series being a dominant force for decades. The Super Duty line, introduced in 1999, represents Ford's commitment to the heavy-duty segment.

Fourth Generation Updates:

The 2005 model year marked a significant redesign for the Super Duty, with a bolder exterior, improved interior, and updated powertrain options. The 2006 model year continued this iteration, often with minor refinements and feature packaging changes. This manual covers this specific design period.

Chassis And Suspension Updates:

Details on the frame construction, suspension geometry, and component upgrades introduced in the fourth generation, which provided improved ride quality and handling while maintaining heavy-duty capability.

Manufacturing Locations:

Ford Super Duty trucks for this era were primarily manufactured in the United States, with key assembly plants including the Kentucky Truck Plant in Louisville, Kentucky, and the Avon Lake Assembly Plant in Avon Lake, Ohio.

🏆 Awards & Recognition

Industry Awards:

Ford Super Duty trucks consistently receive recognition from automotive publications and organizations for their towing and hauling capabilities, durability, and powertrain performance. Specific awards for the 2006 model may be found in historical automotive press archives.