🏷️ Basic Information

Make:

Ford

Model:

F-Series (F350)

Year:

2004

Model Code:

Often identified by specific chassis codes depending on configuration (e.g., for Super Duty trucks, specific internal Ford codes apply).

Vin Decoder Reference:

Manual will provide VIN structure and decoding information relevant to 2004 F-Series models.

👋 Introduction

Target Audience:

Owners of the 2004 Ford F-Series (F350) seeking to perform maintenance, diagnosis, and repairs themselves, as well as independent repair shops and technicians.

Advantage:

Provides the same specific, in-depth information used by dealership technicians, unlike generic aftermarket guides.

Digital Convenience:

Single, easy-to-use PDF document, eliminating the need to handle physical manuals, with the ability to print only necessary pages.

Accuracy:

Factory-sourced information ensures accuracy and correctness for all procedures and specifications.

Comprehensiveness:

Covers every aspect of the vehicle's maintenance and repair, offering a complete resource for ownership.

📋 Manual Details

Primary Coverage:

Complete service, diagnosis, and repair for all 2004 Ford F-Series (F350) models.

Scope:

A-Z, encompassing all repairs from routine maintenance to major component overhauls.

Estimated Page Count:

High; typical factory service manuals for heavy-duty trucks of this era are extensive, often exceeding 2000 pages in printed form. Digital versions may be organized differently but contain equivalent information.

Type:

Factory Service Manual / Workshop Manual

Language:

English

Delivery Format:

PDF (Printable)

Information Source:

Factory Original Equipment Manufacturer (OEM) documentation.

📖 Manual Coverage

Powertrain:

Engine (all variants), Fuel System, Ignition System, Lubrication System, Cooling System, Emission Control Systems, Intake & Exhaust Systems, Automatic Transmission, Manual Transmission, Transfer Case, Driveline (Propeller Shaft, U-Joints, Differentials, Axles).

Chassis:

Suspension (front and rear), Steering System (including Power Steering), Brake Control Systems (ABS, Hydraulic), Brake Components (discs, calipers, drums, lines), Parking Brake, Wheels and Tires.

Electrical:

Starting and Charging System, Lighting, Instrument Panel and Gauges, Audio/Visual Systems, Horn, Wiper and Washer System, Power Windows, Door Locks, Cruise Control, Supplemental Restraint System (Airbags), Engine Immobilizer, Multiplex/CAN Communication Networks, Body Electrical and Wiring Schematics.

Body And Interior:

Body Exterior (Hood, Doors, Fenders, Bumpers), Body Interior (Seats, Trim Panels, Instrument Panel), Glass and Mirrors, Climate Control (Air Conditioning).

Maintenance:

Scheduled maintenance procedures, fluid checks and changes, filter replacements, lubrication, tire rotation.

Diagnostics:

Step-by-step diagnostic procedures for all major systems, including troubleshooting guides for common and intermittent faults, OBD-II codes and interpretations.

Repair And Rebuild:

Detailed instructions for component removal, disassembly, inspection, repair, reassembly, and installation for virtually all vehicle systems.

Technical Illustrations:

Extensive use of diagrams, illustrations, and photographs to clarify complex procedures and component identification.

Wiring Schematics:

Comprehensive, detailed wiring diagrams for all electrical systems, color-coded and specific to model configurations.

Depth:

Factory-level detail, suitable for professional technicians and advanced DIY mechanics. Covers everything from basic fluid changes to complex internal engine and transmission rebuilds, including electrical system diagnostics and repair.

📊 Manual Specifications

Format:

PDF (Portable Document Format)

Printability:

High; all pages are printable at original factory resolution. Images can be blown up for detailed inspection.

Binding:

N/A (Digital PDF format). Users can print and bind sections as needed.

Paper Type Recommendation:

N/A (Digital PDF format). Recommended for printing on standard copier paper for workshop use.

⚙️ Engine Specifications

2004 F350 Gas Options:

5.4L Triton V8 (SOHC) and 6.8L Triton V10 (SOHC).

2004 F350 Diesel Options:

6.0L Power Stroke V8 Turbo Diesel (OHV).

Displacement 6.0L Power Stroke:

370 cubic inches (6.0 liters)

Horsepower 6.0L Power Stroke:

Approximately 325-330 hp (varies slightly by tune).

Torque 6.0L Power Stroke:

Approximately 560-570 lb-ft (varies slightly by tune).

Diesel Fuel Injection:

High-Pressure Common Rail (HPCR) direct injection system.

Gas Fuel Injection:

Electronic Fuel Injection (EFI).

Oil Type Gas Engines:

Typically SAE 5W-20 or 5W-30, refer to manual for exact specifications and API service classification.

Oil Type Diesel Engine:

Typically SAE 15W-40, API CI-4 rated diesel engine oil, refer to manual for exact specifications.

Engine Control Module:

PCM (Powertrain Control Module) or ECM (Engine Control Module) controls all engine functions; manual details diagnostic procedures and sensor operations.

🔧 Transmission

Manual Transmission Options:

Typically a 6-speed manual transmission (e.g., ZF S6-650 on some models).

Automatic Transmission Options:

Typically a 5-speed automatic transmission (e.g., 5R110W 'Torque-Shift').

Automatic Transmission Control:

Electronic control with selectable tow/haul mode.

Automatic Transmission Fluid:

Ford specified MERCON® (e.g., MERCON® V or equivalent for 5R110W), refer to manual for exact specification.

Manual Transmission Fluid:

Specific manual transmission fluid (MTF) or gear oil, refer to manual for exact specification and viscosity grade.

4X4 Transfer Case:

Manual or electronic shift-on-the-fly (ESOF) transfer case options, detailed repair and maintenance procedures.

📐 Dimensions

Cab Configurations:

Regular Cab, SuperCab (extended cab), Crew Cab.

Bed Lengths:

Short bed (approx. 6.75 ft) and Long bed (approx. 8 ft).

Gvwr Range:

Gross Vehicle Weight Rating varied significantly based on configuration, typically ranging from 10,000 lbs to over 13,000 lbs for F350 models.

Gcwr Range:

Gross Combined Weight Rating also varied significantly, often exceeding 20,000 lbs depending on axle ratio and transmission.

Wheelbase Options:

Multiple wheelbase options available, from standard to long wheelbase configurations, impacting turning radius and cargo space.

🛡️ Safety Features

NHTSA Ratings 2004:

Specific NHTSA ratings for 2004 F-Series models would need to be verified, but generally, trucks of this era focused on structural integrity for heavy loads. Frontal impact and side impact ratings are typically available.

Brake Assist:

Available Anti-lock Braking System (ABS) for improved braking control.

Traction Control:

Available traction control system for enhanced stability.

Airbags:

Driver and front passenger airbags.

Seatbelts:

Front and rear seat belts, with pretensioners for front occupants.

💡 Technology Features

Audio System:

Basic AM/FM radio with CD player was common, with optional premium sound systems and satellite radio availability.

Cruise Control:

Standard or optional electronic cruise control system.

Diagnostic Ports:

OBD-II (On-Board Diagnostics II) port for engine and emissions system scanning.

Multiplex Communication:

CAN (Controller Area Network) bus communication for various electronic modules, detailed in the electrical schematics.

🔧 Maintenance

Oil Change Interval:

Typically every 5,000 to 7,500 miles for gasoline engines, and 5,000 to 10,000 miles for the 6.0L Power Stroke diesel, depending on driving conditions and oil type. Manual will specify exact intervals.

Transmission Service:

Automatic transmission fluid and filter change typically recommended every 30,000 to 50,000 miles, or under severe usage conditions. Manual will provide specific intervals.

Coolant Change:

Initial change at 100,000 miles or 5 years, then every 50,000 miles or 2-3 years thereafter for the 6.0L diesel. Gasoline engine intervals may differ. Manual is essential for correct type and interval.

Coolant Type:

For 6.0L Power Stroke: Ford Gold Premium Engine Coolant (50/50 mix) or equivalent. For gasoline engines: Ford Premium Engine Coolant (typically yellow or orange) or equivalent. Always verify with manual.

Brake Fluid:

DOT 3 or DOT 4 Motor Vehicle Brake Fluid, check manual for precise specification and brand recommendation.

6.0L Power Stroke Diesel Concerns:

Common concerns include EGR cooler failures, oil cooler failures, injector issues (stiction), and head gasket failures, often related to heat management and the evolution of the diesel emissions system. The manual will detail diagnostic and repair procedures for these.

Gasoline Engine Concerns:

Less common than diesel issues, but potential concerns can include ignition coil failures, spark plug issues (especially on V10), and minor oil leaks. Manual provides troubleshooting.

Oil Filter Diesel 6.0L:

Refer to manual for specific Ford part number (e.g., F81Z-6744-BA or equivalent). Always use specified filter for the 6.0L.

Fuel Filter Diesel 6.0L:

Crucial for the 6.0L Power Stroke. Refer to manual for specific Ford part number (e.g., F81Z-9N184-AA or equivalent) and replacement interval.

📚 Vehicle History

Ford Truck Legacy:

The Ford F-Series has been a dominant force in the pickup truck market for decades, renowned for its durability, capability, and workhorse performance.

Super Duty Introduction:

The 'Super Duty' line, which includes the F-250 and F-350, was introduced for the 1999 model year, representing a significant redesign and enhancement of Ford's heavy-duty truck offerings.

Manufacturing Plants:

Ford's Super Duty trucks were primarily manufactured in the United States, with key assembly plants including Kentucky Truck Plant (Louisville, KY) and Avon Lake Assembly Plant (Avon Lake, OH).

🏆 Awards & Recognition

Truck Of The Year:

Ford F-Series models, including the F-350, have historically received numerous 'Truck of the Year' awards from various automotive publications over the years, reflecting their capability and market success.