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Ford F250 F350 Truck 1999-2006 Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: Ford Model: F-250 / F-350 Super Duty Model Years Covered: 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006 Codes Platform Code: P 👋 Introduction Market...
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Type: Truck
Vendor:
Sku: 167647
Ford F250 F350 Truck 1999-2006 Service Repair Workshop Manual
🏷️ Basic Information
Identification
Make:
Ford
Model:
F-250 / F-350 Super Duty
Model Years Covered:
1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006
Codes
Platform Code:
P
👋 Introduction
Market Position
Target Audience:
DIY mechanics, professional technicians, fleet maintenance
Value Proposition:
Comprehensive, lifetime access, high detail, cost-effective repair solution
Competitive Analysis
Uniqueness:
Full factory service information, no limitations, lifetime access unlike subscription services
Key Features
Instant Download:
Immediate access to repair information
Lifetime Usage:
No expiry dates or renewal fees
Multi Device Support:
Usable on unlimited computers, tablets, and smartphones
📋 Manual Details
Coverage Areas
Primary Coverage:
All mechanical and electrical systems
Body And Frame:
Chassis, body panels, interior trim, glass, safety restraints
Powertrain:
Engine, transmission, drivetrain, exhaust
Suspension And Steering:
Front and rear suspension, steering gear, power steering
Brakes:
Hydraulic system, parking brake, ABS
Electrical System:
Wiring diagrams, charging system, starting system, lighting, instrumentation, body controls
HVAC:
Heating, ventilation, and air conditioning system
Diagnostics:
Troubleshooting procedures and diagnostic trouble codes (DTCs)
Page Count
Estimated Pages:
Hundreds of pages (specific count not provided, but implied to be extensive)
Manual Type
Type:
Factory Service Repair Workshop Manual
Language
Language:
English
Format
Format:
Digital Download (PDF)
File Format
Compatibility:
Windows and MAC compatible
Print Quality
Printability:
Printable pages (single page or entire manual)
Binding Type
Binding:
N/A (Digital PDF)
Paper Type
Paper Type:
N/A (Digital PDF)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine assembly, cylinder heads, block, pistons, crankshaft, camshafts, timing, lubrication, cooling
Engine Performance:
Fuel injection, ignition system, emissions control, turbocharging (if applicable)
Transmission Manual:
Clutch, gearbox, shift mechanism, maintenance, overhaul
Transmission Automatic:
Transmission assembly, valve body, torque converter, electronic controls, maintenance, overhaul
Drivetrain:
Drive shafts, universal joints, axles, differentials, hubs
Suspension Front:
Springs, shock absorbers, control arms, ball joints, bushings
Suspension Rear:
Leaf springs, shock absorbers, axles, mounting hardware
Steering System:
Steering column, steering gear, tie rods, steering linkage, power steering pump and components
Brake System Hydraulic:
Master cylinder, brake lines, calipers, wheel cylinders, brake fluid
Brake System Parking:
Mechanism, cable operation
Anti Lock Braking System:
ABS module, wheel speed sensors, hydraulic control unit
Charging System:
Alternator, voltage regulator, battery, wiring
Starting System:
Starter motor, solenoid, ignition switch
Lighting System:
Headlights, taillights, turn signals, interior lights, auxiliary lighting
Instrumentation And Gauges:
Speedometer, tachometer, fuel gauge, temperature gauge, warning indicators
Body Electrical:
Power windows, power locks, mirrors, horn, wipers, rear defroster
Engine Control Module:
ECM/PCM operation, sensors, actuators, wiring
HVAC Components:
Compressor, condenser, evaporator, blower motor, controls, refrigerant system
Procedures Included
Preventative Maintenance:
Fluid checks and changes, filter replacements, belt inspections, tire rotations
General Repairs:
Component removal and installation, adjustments
Engine Overhaul:
Complete engine rebuild procedures
Transmission Repair:
Manual and automatic transmission servicing and rebuilding
Suspension Repair:
Replacement of wear items, alignment procedures
Brake Service:
Pad and rotor replacement, caliper and master cylinder service, bleeding procedures
Electrical Troubleshooting:
Diagnostic strategies, component testing, wiring harness repair
HVAC Service:
Refrigerant handling, component replacement, system diagnostics
Diagnostic Troubleshooting:
Step-by-step guides for diagnosing common and complex issues
Body Repair:
Panel replacement, dent repair, rust mitigation
Safety Restraint Service:
Airbag system precautions and replacement
Technical Depth
Depth:
Comprehensive, from basic maintenance to complete rebuilds
Illustrations:
Hundreds of detailed photos and exploded diagrams
Instructions:
Step-by-step instructions for all procedures
Diagnostic Codes:
Coverage of Diagnostic Trouble Codes (DTCs) for advanced troubleshooting
Torque Specifications:
Detailed torque specifications for all fasteners
⚙️ Engine Specifications
Primary Engine
Engine Options Gas:
5.4L Triton V8 (SOHC), 6.8L Triton V10 (SOHC), 7.3L Power Stroke V8 Turbo Diesel (OHV)
Engine Options Diesel:
7.3L Power Stroke V8 Turbo Diesel
Performance
Typical Horsepower 5.4L:
Approx. 260 hp
Typical Torque 5.4L:
Approx. 350 lb-ft
Typical Horsepower 6.8L:
Approx. 310 hp
Typical Torque 6.8L:
Approx. 425 lb-ft
Typical Horsepower 7.3L Psd:
Approx. 250 hp (later models up to 275 hp)
Typical Torque 7.3L Psd:
Approx. 500 lb-ft (later models up to 525 lb-ft)
Fuel System
Gasoline Injection:
Electronic Fuel Injection (EFI)
Diesel Injection:
HEUI (Hydraulically Actuated Electronically Controlled Unit Injector)
🔧 Transmission
Standard
Manual Options:
5-speed manual (e.g., ZF S5-47, S5-47M)
Optional
Automatic Options:
4-speed automatic (e.g., 4R100)
Features
Transfer Case:
Manual or electronic shift transfer case (4x4 models)
📐 Dimensions
Exterior
Chassis Types:
Regular Cab, SuperCab (extended cab), Crew Cab
Bed Lengths:
Short Bed (approx. 6.75 ft), Long Bed (approx. 8 ft)
Weights
Gvwr:
Varies by configuration, typically 9,900 lbs to 13,000+ lbs for F-350
🛡️ Safety Features
Ratings
NHTSA Ratings:
Varies by year and configuration; generally good for its class, but subject to specific crash tests
Active Features
ABS:
Standard Anti-lock Braking System
Passive Features
Airbags:
Driver and passenger front airbags
💡 Technology Features
Infotainment
Audio Options:
AM/FM radio, CD player, cassette player (optional), premium sound systems
Driver Assistance
Cruise Control:
Standard on most trims
Tow Haul Mode:
Available for automatic transmissions to optimize towing performance
Connectivity
Wiring Diagrams:
Detailed wiring schematics for all electrical components
🔧 Maintenance
Service Intervals
Oil Change Gasoline:
Typically every 5,000-7,500 miles or 6 months (refer to specific engine recommendations)
Oil Change Diesel:
Typically every 5,000-10,000 miles or 6 months with diesel-specific oil
Transmission Fluid Change:
Every 30,000-60,000 miles, depending on usage and fluid type
Fluid Specifications
Engine Oil Gasoline:
e.g., SAE 5W-20, 5W-30 (refer to owner's manual for exact spec)
Engine Oil Diesel:
e.g., 15W-40 Diesel Engine Oil, API CI-4 or CK-4 rated
Coolant:
Ford Gold Coolant or equivalent (50/50 mix with distilled water)
Brake Fluid:
DOT 3
Automatic Transmission Fluid:
MERCON V (for 4R100)
Known Issues
Common Diesel Issues:
Injector seal leaks (O-rings), FICM (Fuel Injection Control Module) failure, updraft intake manifold issues
Common Gasoline Issues:
Spark plug blowouts (early 5.4L), intake manifold gasket leaks
Suspension Wear:
Ball joints, tie rod ends, leaf spring bushings
Brake Wear:
Rotor warping, pad wear due to heavy loads
📚 Vehicle History
Brand Heritage
Ford Trucks:
Longstanding legacy of heavy-duty truck manufacturing
Model Evolution
Super Duty Introduction:
Introduced as a distinct line from F-150 for enhanced capability
Platform Generation:
This manual covers the first generation of the Super Duty platform (P-code)
Production
Manufacturing Location:
Kentucky Truck Plant, Louisville, Kentucky, USA
🏆 Awards & Recognition
Recognitions
Truck Of The Year:
Ford Super Duty trucks have consistently received accolades and 'Truck of the Year' awards from various automotive publications throughout their production run.
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