🏷️ Basic Information

Make:

Ford

Model:

F-550 Super Duty

Year:

2004

Generation Code:

Third Generation (2004-2007)

Platform:

P262

👋 Introduction

Market Position:

Essential resource for owners and independent repair facilities of the 2004 Ford F-550 Super Duty, offering factory-level technical data.

Competitive Advantage:

Officially licensed OE data from RepairSurge provides superior accuracy and completeness compared to generic aftermarket manuals. Digital format offers convenience and instant access.

Key Features:

Licensed OE information, comprehensive coverage, easy online access, detailed diagrams, diagnostic procedures, repair guides, troubleshooting assistance.

📋 Manual Details

Coverage Areas:

Engine, Transmission, Drivetrain, Brakes, Suspension, Steering, Electrical System, HVAC, Bodywork, Chassis, Diagnostics

Page Count:

Extensive (digital, no fixed page count)

Manual Type:

Service and Repair Manual Software

Language:

English

Format:

Online Software/Web-based Access

📖 Manual Coverage

Engine Systems:

Power Stroke 6.0L V8 Turbo Diesel, 5.4L V8 Triton Gasoline, 6.8L V10 Triton Gasoline (including diagnosis, repair, component testing, specifications)

Transmission Systems:

TorqShift 5R110W Automatic, ZF S6-650 Manual (including overhaul, diagnostics, fluid specifications)

Drivetrain Systems:

Front and Rear Axles (Dana 50/60/70), Transfer Case (BW 4446/4447), Driveshafts, U-joints (including lubrication, inspection, repair)

Brake Systems:

Hydraulic Brake System, ABS, Parking Brake (including pad/rotor replacement, caliper service, fluid bleeding, diagnostics)

Suspension Steering:

Front Independent Front Suspension (IFS), Rear Solid Axle, Leaf Springs, Steering Gear (including alignment, component replacement, lubrication)

Electrical Systems:

Battery, Charging System, Starting System, Lighting, Instrument Cluster, Powertrain Control Module (PCM), Body Control Module (BCM), Wiring Diagrams, Fuses, Relays

HVAC Systems:

Air Conditioning, Heater, Ventilation (including refrigerant handling, component replacement, leak testing)

Bodywork Chassis:

Frame, Body Panels, Doors, Hood, Tailgate, Bumpers, Interior Trim (including removal, installation, adjustment)

General Maintenance:

Oil and filter changes, air filter replacement, fuel filter replacement, coolant checks and changes, tire rotation and inspection

Engine Repair:

Head gasket replacement, injector service, turbocharger diagnosis and replacement, EGR system service, engine component overhaul

Transmission Repair:

Clutch replacement (manual), valve body diagnosis (automatic), torque converter service, transmission fluid and filter replacement

Brake Service:

Brake pad and rotor replacement, caliper rebuilding, brake line replacement, hydraulic system bleeding

Suspension Steering Repair:

Ball joint replacement, tie rod end replacement, wheel bearing replacement, shock absorber replacement, steering box service

Electrical Troubleshooting:

Diagnostic trouble code (DTC) interpretation, circuit testing, component testing, wiring harness repair, sensor replacement

HVAC Repair:

Compressor replacement, condenser service, evaporator cleaning, heater core replacement, refrigerant recharge

Body Repair:

Panel alignment, door mechanism repair, glass replacement, trim component installation

Diagnostic Capabilities:

Advanced diagnostics, including flow charts, pinpoint tests, and electrical schematics for troubleshooting complex issues.

Repair Procedures:

Step-by-step repair instructions with detailed diagrams and torque specifications for component removal and installation.

Component Rebuilds:

Information on overhauling major components such as engines, transmissions, and differentials.

Specifications:

Comprehensive technical specifications, including torque values, clearances, fluid capacities, and electrical data.

📊 Manual Specifications

File Format:

Proprietary Web-based Application (requires internet connection and web browser)

Print Quality:

N/A (Digital Format)

Binding Type:

N/A (Digital Format)

Paper Type:

N/A (Digital Format)

Access Duration:

1 Year (with option for renewal)

Compatibility:

PC, Laptop, Smartphone, Tablet (via web browser)

⚙️ Engine Specifications

Primary Engine Diesel:

6.0L Power Stroke V8 Turbo Diesel

Primary Engine Gasoline 1:

5.4L Triton V8 Gasoline

Primary Engine Gasoline 2:

6.8L Triton V10 Gasoline

Horsepower Diesel:

Approximately 325 hp @ 3300 rpm (varies slightly by configuration)

Torque Diesel:

Approximately 560 lb-ft @ 2000 rpm (varies slightly by configuration)

Horsepower Gasoline 1:

Approximately 260 hp @ 4500 rpm

Torque Gasoline 1:

Approximately 350 lb-ft @ 2500 rpm

Horsepower Gasoline 2:

Approximately 310 hp @ 4250 rpm

Torque Gasoline 2:

Approximately 425 lb-ft @ 3250 rpm

Fuel System Diesel:

High-Pressure Common Rail (HPCR) direct injection

Fuel System Gasoline:

Electronic Fuel Injection (EFI)

🔧 Transmission

Standard Transmission Type:

TorqShift 5R110W 5-Speed Automatic (Heavy-Duty)

Optional Transmission Type:

ZF S6-650 6-Speed Manual

Automatic Transmission Features:

SelectShift Automatic, Tow/Haul Mode

Automatic Transmission Fluid:

Mercon SP (or equivalent)

Manual Transmission Fluid:

Mercon LV or XT-11QGC (75W-85W GL-4)

📐 Dimensions

Wheelbase Options:

Multiple options ranging from 137" to 201" depending on cab and configuration

Cab Configurations:

Regular Cab, SuperCab (Crew Cab)

Gvwr Range:

14,500 lbs to 20,500 lbs (Class 4/5/6 depending on specific configuration)

Curb Weight Range:

Approximately 6,000 lbs - 8,000 lbs (varies greatly by configuration)

🛡️ Safety Features

NHTSA Ratings:

Specific ratings vary by configuration and test year; generally focused on occupant protection in frontal and side impacts.

Active Safety Features:

Four-wheel Anti-lock Braking System (ABS)

Passive Safety Features:

Front airbags, high-strength steel frame, side-impact door beams.

💡 Technology Features

Infotainment System:

Base AM/FM stereo, optional CD player, auxiliary input (availability varies by trim).

Driver Assistance Features:

Primarily ABS. No advanced driver-assistance systems (ADAS) like adaptive cruise control or lane keeping assist in this generation.

Connectivity Features:

N/A (basic analog systems)

🔧 Maintenance

Oil Change Interval Diesel:

Typically 5,000 - 7,500 miles or 6 months, depending on usage and oil type (refer to specific manual for exact intervals).

Oil Change Interval Gasoline:

Typically 5,000 miles or 6 months (refer to specific manual for exact intervals).

Fuel Filter Replacement Diesel:

Typically every 15,000 - 30,000 miles or as per manual recommendations, especially important for the 6.0L Power Stroke.

Engine Coolant Change:

Initial change at 50,000 miles or 5 years, then every 25,000 miles or 2 years. Use Ford Gold Coolant (VCT-G-4)

Engine Oil Spec Diesel:

API CJ-4 or CI-4 Plus, SAE 15W-40 (check manual for specific viscosity based on temperature)

Engine Oil Spec Gasoline:

API SL, SAE 5W-20 or 5W-30 (check manual for specific viscosity based on temperature)

Brake Fluid:

DOT 3 Heavy Duty

6.0L Power Stroke Common Issues:

EGR cooler failure, oil cooler failure, FICM (Fuel Injection Control Module) issues, head gasket failures, injector stiction. The manual would detail diagnosis and repair for these.

General Common Issues:

Various suspension and steering component wear (tie rods, ball joints), potential for brake wear due to heavy use, electrical connector corrosion in certain environments.

📚 Vehicle History

Ford Truck Heritage:

Ford has a long-standing reputation for building durable and capable trucks, dating back to the early 20th century. The 'Super Duty' line, introduced in 1998, was designed to handle heavier workloads than the F-150.

F-Series Evolution:

The 2004 model year represents the third generation of the Super Duty F-Series, featuring updated styling, powertrains (notably the introduction of the 6.0L Power Stroke), and chassis enhancements.

Manufacturing Location:

Kentucky Truck Plant, Louisville, Kentucky, USA

🏆 Awards & Recognition

Truck Of The Year Awards:

Ford Super Duty line has historically received various 'Truck of the Year' accolades from automotive publications for its capability and features.