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Ford Five Hundred 2005-2007 Service Repair Workshop Manual

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$16.99
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🏷️ Basic Information Identification Make: Ford Model: Five Hundred Model Years Covered: 2005, 2006, 2007 Codes Platform: Ford D3 Platform 👋 Introduction Market Position Positioning: A premium, full-size sedan offering...
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Ford Five Hundred 2005-2007 Service Repair Workshop Manual
🏷️ Basic Information
Identification
Make:
Ford
Model:
Five Hundred
Model Years Covered:
2005, 2006, 2007
Codes
Platform:
Ford D3 Platform
👋 Introduction
Market Position
Positioning:
A premium, full-size sedan offering comfort and space, positioned as a family-oriented vehicle in its segment.
Competitive Analysis
Key Competitors:
Buick LaCrosse, Toyota Avalon, Chrysler 300, Dodge Charger, Mercury Montego.
Key Features
Platform Sharing:
Shared the D3 platform with Volvo S80 and XC90, contributing to its robust chassis and safety.
Design Philosophy:
Emphasized a comfortable, quiet ride and spacious interior, with a focus on practicality for families.
📋 Manual Details
Coverage Areas
Technical Scope:
Comprehensive service, repair, diagnosis, and troubleshooting
Target Audience:
Professional mechanics and knowledgeable DIY enthusiasts
Page Count
Estimated Page Count:
Varies by specific edition, typically over 2000 pages
Manual Type
Type:
Factory Service Manual / Workshop Manual
Language
Language:
English
Format
Format:
Digital (PDF)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Detailed procedures for disassembly, assembly, inspection, and repair of engine components.
Engine Electrical:
Wiring diagrams, diagnostic procedures for ignition, charging, starting systems, and sensors.
Emission Control:
Diagnosis and repair of emissions-related systems, including EGR, O2 sensors, and catalytic converters.
Fuel System:
Fuel injection system diagnosis, fuel pump, injectors, fuel pressure testing, and fuel tank service.
Clutch System:
Service and repair procedures for clutch assembly and related components (for manual transmission variants).
Manual Transaxle:
Complete repair and maintenance of the manual transaxle, including gear inspection and synchronization.
Automatic Transaxle:
Detailed overhaul, diagnosis, fluid changes, and electronic control module (TCM) procedures for the automatic transmission.
Driveshaft Axle:
Inspection, repair, and replacement of driveshafts, CV joints, and wheel bearings.
Suspension System:
Front and rear suspension component diagnosis, replacement (struts, shocks, control arms, bushings), and alignment specifications.
Steering System:
Power steering system diagnosis, pump, rack and pinion repair, and steering column service.
Restraint System:
Airbag system diagnosis, SRS module, seatbelt service, and occupant restraint component repair.
Brake System:
Disc brake service (pads, rotors), caliper repair, ABS system diagnosis, hydraulic lines, and parking brake.
Body Interior Exterior:
Body panel alignment, door, hood, trunk service, interior trim removal and installation, glass replacement.
Body Electrical System:
Lighting systems, power windows, door locks, mirrors, wipers, horn, and body control module (BCM) diagnostics.
HVAC System:
Air conditioning system diagnosis, refrigerant handling, blower motor, evaporator, condenser, and heater core service.
Procedures Included
Maintenance:
Oil changes, filter replacements, fluid checks and changes, spark plug replacement, belt replacement.
Troubleshooting:
Diagnostic flowcharts, common symptom-based troubleshooting guides, and error code explanations.
Repair:
Step-by-step instructions for component replacement and repair, including torque specifications.
Diagnostics:
Procedures for using diagnostic scan tools, interpreting data streams, and pinpointing electrical or mechanical faults.
Technical Depth
Depth:
Factory-level detail, suitable for complete engine rebuilds, transmission overhauls, and complex electrical diagnostics.
📊 Manual Specifications
File Format
File Type:
PDF
Print Quality
Printability:
Fully printable; individual pages can be printed for workshop use.
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper Quality:
N/A (Digital Format)
Compatibility
Operating Systems:
Compatible with all versions of Windows and macOS.
Requirements
Software:
Adobe PDF Reader required for viewing.
⚙️ Engine Specifications
Primary Engine
Engine Model:
Ford Duratec 30 (3.0L V6)
Engine Code:
AJ30
Performance
Horsepower:
203 hp @ 6250 rpm (approx.)
Torque:
207 lb-ft @ 4250 rpm (approx.)
Fuel System
Injection Type:
Sequential Electronic Fuel Injection (SEFI)
Engine Mechanical
Bore X Stroke:
89 mm x 79.5 mm (approx.)
Compression Ratio:
9.7:1 (approx.)
Valve Train:
Dual Overhead Camshafts (DOHC), 4 valves per cylinder
🔧 Transmission
Standard
Transmission Type:
6-speed Automatic Transaxle (CD4E derived)
Optional
Transmission Type:
Not applicable for standard models; manual was not offered.
Features
Drive Type:
Front-Wheel Drive (FWD) or All-Wheel Drive (AWD)
Fluid Specifications
Automatic Transmission Fluid:
Mercon V (Refer to manual for exact specification and capacity)
📐 Dimensions
Exterior
Length:
200.4 inches (approx.)
Width:
76.5 inches (approx.)
Height:
57.9 inches (approx.)
Wheelbase:
114.4 inches (approx.)
Interior
Passenger Volume:
107.4 cubic feet (approx.)
Cargo
Trunk Volume:
16.1 cubic feet (approx.)
Weights
Curb Weight:
3,595 - 3,828 lbs (approx.)
🛡️ Safety Features
Ratings
NHTSA Front Impact Driver:
5 Stars
NHTSA Front Impact Passenger:
5 Stars
IIHS Frontal Offset:
Good
Active Features
ABS:
Standard Anti-lock Braking System (ABS)
Traction Control:
Standard Traction Control System (TCS)
Electronic Stability Control:
Optional Electronic Stability Control (AdvanceTrac)
Passive Features
Airbags:
Standard front airbags, optional side-curtain airbags.
💡 Technology Features
Infotainment
Audio System:
Available AM/FM/CD player, optional premium audio systems, SiriusXM satellite radio.
Navigation:
Optional factory navigation system was available.
Driver Assistance
Parking Assist:
Optional rear parking assist sensors.
Connectivity
Remote Start:
Optional factory remote start system.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000 miles or 6 months, whichever comes first (synthetic blend recommended).
Engine Air Filter:
Inspect every 15,000 miles, replace as needed or every 30,000 miles.
Spark Plugs:
Replace every 100,000 miles (Long-life platinum or iridium plugs recommended).
Transmission Fluid Change:
Every 100,000 miles or as per severe duty schedule.
Fluid Specifications
Engine Oil Type:
SAE 5W-20 (Full Synthetic or Synthetic Blend)
Engine Oil Capacity:
5.7 quarts (5.4 liters) with filter change (approx.)
Coolant Type:
Ford Premium Gold Coolant (or equivalent meeting WSS-M97B51-A1)
Coolant Capacity:
10.0 quarts (9.5 liters) (approx.)
Known Issues
Transmission Harsh Shifting:
Some owners reported harsh shifting or delayed engagement, often related to TCM software or transmission fluid degradation.
Powertrain Control Module Issues:
Reports of PCM faults leading to various engine or transmission performance issues.
Front Suspension Components:
Premature wear of front control arm bushings and ball joints on some models.
📚 Vehicle History
Brand Heritage
Ford Sedan Legacy:
Followed Ford's long tradition of producing large, comfortable sedans.
Model Evolution
Introduction Year:
2005
Name Origin:
The 'Five Hundred' name was revived from a previous Ford model, signifying a higher-class vehicle.
Redesign Successor:
Replaced by the Ford Taurus in 2008, which retained much of the Five Hundred's platform and powertrains.
Production
Manufacturing Plant:
Chicago Assembly Plant, Illinois, USA
🏆 Awards & Recognition
Recognitions
IIHS Top Safety Pick Designation:
While not explicitly a 'Top Safety Pick' award in the modern sense, it consistently received high marks in frontal crash tests.
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