2003 Ford F-350 F350 Super Duty Workshop Repair Manual

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🏷️ Basic Information Identification Make: Ford Model: F-350 Super Duty Year: 2003 Codes Chassis Code: GMT800 Platform: P356 👋 Introduction Market Position Target Audience: DIY enthusiasts, independent repair shops, fleet...

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标签: 2003 Cars F Series F-350 F350 Ford Super Duty Truck

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Description

🏷️ Basic Information

Identification

Make:

Model:

F-350 Super Duty

Year:

Codes

Chassis Code:

GMT800

Platform:

👋 Introduction

Market Position

Target Audience:

DIY enthusiasts, independent repair shops, fleet maintenance

Value Proposition:

Provides dealership-level repair information for self-service, saving on labor costs.

Competitive Analysis

Comparison To Owner Manual:

Significantly more detailed than owner's manuals; focuses on repair procedures, not just operation and basic care.

Vs Generic Manuals:

Single-year specific and OEM-based for precision, unlike generic manuals covering multiple years or generations.

Key Features

Specificity:

Dedicated to the 2003 Ford F-350 Super Duty model year only.

Content Scope:

Extensive coverage of mechanical, electrical, body, and diagnostic aspects.

Illustrations:

Includes detailed illustrations and diagrams to aid in understanding procedures.

📋 Manual Details

Coverage Areas

All Systems Covered:

Specific Systems:

Engine, Transmission, Drivetrain, Suspension, Steering, Brakes, Electrical System, HVAC, Body, Interior, Fuel System, Exhaust System, Cooling System, Emission Control

Page Count

Estimated Page Count:

Approximately 2000-3000 pages (typical for comprehensive workshop manuals of this era, though not explicitly stated in product info)

Manual Type

Type:

Workshop Repair Manual / Service Manual

Classification:

OEM-based DIY Repair Manual

Language

Language:

English

Format

File Format:

Software Requirement:

None (Standalone PDF)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Detailed overhauls, component inspection, timing, seals, gaskets

Engine Electrical:

Ignition system, sensors, actuators, starting and charging

Transmission Manual:

Service, repair, clutch, gearshift mechanisms

Transmission Automatic:

Service, repair, torque converter, valve body, internal components, fluid service

Drivetrain:

Front axle, rear axle, differentials, driveshafts, U-joints, CV joints (if applicable)

Suspension:

Front suspension components (ball joints, control arms, springs, shocks), rear suspension components (leaf springs, shocks)

Steering:

Power steering system, steering gear, tie rods, steering column

Brakes:

Hydraulic system, ABS, brake calipers, rotors, pads, lines, master cylinder, parking brake

Electrical System:

Wiring diagrams, fuse box layouts, lighting, power accessories, starting and charging, battery, alternator, starter motor

HVAC:

Air conditioning system (refrigerant, compressor, evaporator, condenser), heating system, climate control

Body And Interior:

Panel removal, door mechanisms, glass, trim, seats, dashboard, fasteners

Fuel System:

Fuel pump, fuel filter, injectors, fuel lines, fuel tank

Exhaust System:

Muffler, catalytic converter, exhaust pipes, hangers

Cooling System:

Radiator, water pump, thermostat, hoses, coolant

Emission Control:

EGR system, PCV system, O2 sensors, emissions related components

Safety Systems:

Airbag system, seat belts, SRS components

Procedures Included

Maintenance:

Oil changes, filter replacements, fluid checks and changes, tire rotation, tune-ups

Troubleshooting:

Diagnostic trouble codes (DTCs), symptom-based diagnostics, electrical circuit testing

Repair:

Component removal, disassembly, inspection, repair, reassembly, and installation for all major systems

Rebuilds:

Transmission rebuilds, engine component rebuilds (pistons, bearings, etc.)

Calibration:

Wheel alignment specifications, torque specifications for all fasteners

Diagnostics:

PCM diagnostic codes, sensor data interpretation, electrical system diagnosis

Technical Depth

Depth:

Comprehensive: From basic scheduled maintenance and fluid changes to complex engine and transmission overhauls, electrical diagnostics, and bodywork repairs.

Detail Level:

Detailed step-by-step instructions with accompanying illustrations and diagrams.

📊 Manual Specifications

File Format

Type:

Features:

Searchable text, hyperlinked bookmarks for easy navigation

Print Quality

Resolution:

High-resolution images and text suitable for printing

Binding Type

Type:

Digital (N/A for printed, but implies a single cohesive document)

Paper Type

Type:

Digital (N/A for printed)

⚙️ Engine Specifications

Primary Engine

Engine Options:

5.4L Triton V8 (Gasoline), 6.8L Triton V10 (Gasoline), 7.3L Power Stroke V8 Turbo Diesel

Performance

5.4L V8 Horsepower:

Approximately 260 hp @ 4500 rpm

5.4L V8 Torque:

Approximately 350 lb-ft @ 3000 rpm

6.8L V10 Horsepower:

Approximately 310 hp @ 4100 rpm

6.8L V10 Torque:

Approximately 425 lb-ft @ 3250 rpm

7.3L Power Stroke V8 Horsepower:

Approximately 250 hp @ 2600 rpm (Standard output)

7.3L Power Stroke V8 Torque:

Approximately 505 lb-ft @ 1600 rpm (Standard output)

Fuel System

Gasoline Engines:

Electronic Fuel Injection (EFI)

Diesel Engine:

Direct Injection, Turbocharged, Intercooled (HEUI injection system for Power Stroke)

🔧 Transmission

Standard

Manual Transmission:

5-speed manual (e.g., ZF S5-47 for gas, ZF S6-650 for diesel)

Optional

Automatic Transmission:

4-speed automatic (e.g., E4OD/4R100 for gas and diesel)

Features

Transfer Case:

Part-time 4WD system with electronic shift-on-the-fly (ESOF) or manual transfer case options.

📐 Dimensions

Exterior

Wheelbase Options:

Several options depending on cab and bed configuration (e.g., 137.1" to 172.4")

Overall Length Approx:

Varies widely based on configuration, typically 210" - 260"

Weights

Gvwr Range:

9900 lbs to 12500 lbs (depending on configuration)

Curb Weight Approx:

5,500 lbs - 7,000 lbs+

🛡️ Safety Features

Ratings

NHTSA Front Impact Driver:

Not rated for 2003 model year in the same standardized way as modern vehicles.

Active Features

Standard Anti-lock Braking System (ABS) on all wheels.

Traction Control:

May be available on some configurations, particularly diesel models.

Passive Features

Airbags:

Driver and passenger front airbags.

Seat Belts:

Front and rear seat belts, shoulder belts with pretensioners.

💡 Technology Features

Infotainment

Audio System:

AM/FM stereo with CD player, optional premium sound system with cassette.

Navigation:

Not typically available from the factory for this model year; aftermarket options would be required.

Driver Assistance

Cruise Control:

Standard cruise control system.

Trailer Brake Controller:

Provision for factory or aftermarket trailer brake controller.

Connectivity

Phone Integration:

No factory integrated Bluetooth or smartphone connectivity.

🔧 Maintenance

Service Intervals

Oil Change Gasoline:

Every 3,000-5,000 miles or 6 months, whichever comes first (refer to manual for exact specifications and oil type).

Oil Change Diesel:

Every 5,000-7,500 miles or 6 months, whichever comes first (diesel-specific oil required, refer to manual).

Transmission Fluid Change:

Every 30,000-50,000 miles, depending on usage and transmission type (consult manual).

Fluid Specifications

Engine Oil Gasoline:

API Service SG, SH, or SJ classification; SAE 5W-30 or 10W-30 recommended (consult manual for precise viscosity based on temperature).

Engine Oil Diesel:

API Service CD, CE, CF, CF-2, CF-M, or CG-4 classification; SAE 15W-40 or 10W-30 heavy-duty diesel engine oil recommended (consult manual).

Coolant:

Ford Premium Engine Coolant (Green) or equivalent meeting Ford specification ESE-M97B44-A.

Transmission Fluid Automatic:

Mercon V (for 4R100)

Transmission Fluid Manual:

Refer to manual for specific gear oil type and viscosity (e.g., GL-4 or GL-5).

Known Issues

Diesel Glow Plugs:

Glow plug failure or control module issues can lead to hard starting in cold weather (7.3L Power Stroke).

Rear Main Seal Leaks:

Seepage or leaks from the rear main seal can occur over time, particularly on the 7.3L Power Stroke.

Upgraded Parts:

Many owners opt for aftermarket upgrades for fuel injectors, turbochargers, and exhaust systems on the 7.3L Power Stroke to enhance performance and reliability.

Cab Mount Bushings:

Wear and tear on cab mount bushings can lead to noise and vibration.

📚 Vehicle History

Brand Heritage

Ford Trucks:

Ford has a long and storied history in the pickup truck market, with the F-Series being a dominant force for decades.

Model Evolution

Super Duty Launch:

The Super Duty line was introduced for the 1999 model year, replacing the older F-250/F-350 trucks. The 2003 model represents a refinement of this generation.

Production

Manufacturing Location:

Kentucky Truck Plant (Louisville, Kentucky), Mexico