🏷️ Basic Information

Make:

Ford

Model:

F-250 Super Duty

Year:

2009

Chassis Code:

GMT900 platform (for context, F-Series has its own internal platform designations, but for general reference, the Super Duty line is distinct)

👋 Introduction

Market Position:

The 2009 Ford F-250 Super Duty is a flagship heavy-duty pickup truck renowned for its capability, durability, and towing/hauling prowess in the commercial and personal use sectors. It competes directly with models like the Ram Heavy Duty and Chevrolet Silverado HD. This manual caters to owners and independent repair shops seeking in-depth technical information to maintain and repair these robust vehicles.

Competitive Analysis:

The Super Duty line is Ford's answer to demanding work requirements. The 2009 model year represents a significant evolution in the Super Duty platform, featuring updated powertrains and chassis components. Access to an OEM-level workshop manual is crucial for servicing these complex machines accurately and efficiently, distinguishing it from less detailed aftermarket guides.

Key Features:

This manual provides OEM-level detail, which is the standard used by Ford dealerships. Its single-year specificity ensures accuracy for the 2009 F-250, avoiding confusion with other model years. The PDF format offers searchability and ease of access, and the inclusion of detailed illustrations and step-by-step instructions makes complex repairs manageable for DIY enthusiasts.

📋 Manual Details

Coverage Areas:

Engine mechanical, engine repair, transmission (manual and automatic), drivetrain, suspension, steering, brakes, HVAC, electrical systems, bodywork, diagnostics, interior components, exterior components, fuel system, exhaust system, cooling system, lubrication system, emissions control.

Estimated Page Count:

Approximately 1,500 - 2,500 pages (typical for a comprehensive workshop manual of this era and vehicle class).

Manual Type:

Workshop Repair Manual / Service Manual

Language:

English

Format:

Digital (Single PDF File)

📖 Manual Coverage

Systems Covered:

Engine (gasoline and diesel), transmission (manual/automatic), transfer case (4x4 models), axles, driveshafts, suspension (front/rear), steering system, brake system (hydraulic, ABS), climate control (HVAC), electrical distribution, lighting, charging system, starting system, ignition system, fuel system (including diesel injection), exhaust system, emissions control systems, cooling system, lubrication system, body control modules, interior electronics, exterior body panels, safety systems (airbags, seatbelts), diagnostic trouble codes (DTCs), powertrain control module (PCM) strategies.

Procedures Included:

Routine maintenance, scheduled maintenance, component removal and installation, disassembly and assembly, diagnostic procedures, troubleshooting guides, wiring diagram interpretation, electrical system testing, brake system bleeding and adjustment, suspension alignment specifications, engine timing, fuel injector testing and replacement, transmission fluid change, differential fluid change, torque specifications for critical fasteners, body panel repair and replacement, HVAC system diagnosis and repair, airbag system safety precautions and service.

Technical Depth:

Comprehensive. Covers everything from basic fluid changes and filter replacements to complex engine rebuilds, transmission overhauls, complex electrical diagnostics, and body repairs. Includes detailed step-by-step instructions, torque specifications, special tool requirements, and diagnostic flowcharts. Suitable for both DIY enthusiasts and professional technicians.

Wiring Diagrams Coverage:

Complete electrical schematics for all major systems, including engine control, lighting, HVAC, power windows, power locks, audio systems, trailer lighting, ABS, airbags, and more. These diagrams are crucial for diagnosing electrical faults.

Diagnostic Codes Coverage:

Detailed listing and explanation of Diagnostic Trouble Codes (DTCs) retrieved via the OBD-II port, including definition, possible causes, and diagnostic flowcharts for troubleshooting.

Body Work Coverage:

Repair procedures for body panels, doors, hood, tailgate, bumpers, fenders, and structural components. Includes guidance on welding, straightening, and part replacement.

Suspension Brakes Coverage:

Detailed information on front and rear suspension components (leaf springs, shocks, bushings, ball joints, steering knuckles), brake system components (discs, calipers, master cylinder, ABS modulator), and procedures for replacement, repair, and bleeding.

📊 Manual Specifications

File Format:

PDF

Print Quality:

High-resolution scans of original OEM documentation, ensuring clarity of text and illustrations.

Binding Type:

N/A (Digital File)

Paper Type:

N/A (Digital File)

⚙️ Engine Specifications

Primary Engine:

6.4L Power Stroke V8 Turbo Diesel (OHV, 32-valve, Intercooled Turbocharger)

Secondary Engine:

5.4L Triton V8 (SOHC, 24-valve)

Tertiary Engine:

6.8L Triton V10 (SOHC, 30-valve)

6.4L Power Stroke Horsepower:

350 HP @ 3,000 RPM

6.4L Power Stroke Torque:

650 lb-ft @ 1,600 RPM

5.4L Triton Horsepower:

325 HP @ 4,000 RPM

5.4L Triton Torque:

444 lb-ft @ 3,250 RPM

6.8L Triton Horsepower:

362 HP @ 4,750 RPM

6.8L Triton Torque:

457 lb-ft @ 3,250 RPM

6.4L Power Stroke Fuel System:

Common Rail High-Pressure Direct Injection with Diesel Particulate Filter (DPF) and Selective Catalytic Reduction (SCR) system (early implementation of emissions control).

5.4L/6.8L Triton Fuel System:

Sequential Electronic Fuel Injection (SEFI)

Cooling System Type:

Pressurized, liquid-cooled system with engine-driven fan or electric fan (depending on configuration).

Lubrication System Type:

Pressurized wet-sump system with oil pump, oil filter, and oil cooler (diesel models).

🔧 Transmission

Standard Transmission Gas:

6-Speed Manual Transmission (e.g., ZF6/FTE5406 series)

Optional Transmission Gas:

5-Speed Automatic Transmission (e.g., TorqShift 5R110W)

Standard Transmission Diesel:

5-Speed Automatic Transmission (TorqShift 5R110W)

Optional Transmission Diesel:

6-Speed Manual Transmission (e.g., ZF6/FTE5406 series)

Transfer Case Type:

Electronic Shift-On-The-Fly (ESOF) 2-speed transfer case

Automatic Transmission Fluid Gas:

Mercon V (e.g., Ford XT-5QCV) - approx. 13.5 quarts capacity.

Automatic Transmission Fluid Diesel:

Mercon LV (e.g., Ford XT-10-QLV) - approx. 13.5 quarts capacity.

Manual Transmission Fluid:

API GL-4, SAE 75W-90 Synthetic Gear Lubricant (specific Ford spec recommended).

📐 Dimensions

Exterior Length:

Varies by cab and bed configuration (e.g., ~233.7 inches for a regular cab, short bed to ~263.7 inches for a crew cab, long bed).

Exterior Width:

Approx. 79.9 inches (excluding mirrors).

Exterior Height:

Approx. 79.0 - 81.0 inches (depending on configuration).

Wheelbase:

Varies by configuration: 137.0 inches (regular cab, short bed) to 172.4 inches (crew cab, long bed).

Curb Weight:

Varies significantly by configuration, typically ranging from 6,000 lbs to over 7,500 lbs.

Maximum Conventional Towing Capacity:

Up to 12,500 lbs (with proper configuration and towing package).

Maximum Payload Capacity:

Up to 5,000 lbs (with proper configuration).

🛡️ Safety Features

NHTSA Front Impact Rating:

4 Stars (Driver), 4 Stars (Passenger) for SuperCrew models (typical for this era, exact rating may vary slightly by configuration).

IIHS Moderate Overlap Frontal Offset:

Good (typical for robust truck platforms of this period).

Active Safety Features:

Four-wheel Anti-lock Braking System (ABS), Trailer Brake Controller (optional/available), integrated trailer mirrors.

Passive Safety Features:

Frontal airbags (driver and passenger), side curtain airbags (optional on certain configurations), height-adjustable seatbelts, energy-absorbing steering column.

💡 Technology Features

Infotainment System:

Base models featured an AM/FM stereo with CD player. Higher trims offered an optional premium audio system, SiriusXM Satellite Radio, and navigation systems. Ford's SYNC voice-activated communications and entertainment system became available.

Driver Assistance Features:

Rear parking assist (optional), integrated trailer brake controller (optional). Advanced driver-assistance systems (ADAS) like adaptive cruise control, lane keeping assist, and forward collision warning were not common or available on this model year.

Connectivity Features:

Ford SYNC system offered Bluetooth connectivity for hands-free calling and music streaming on equipped models. USB ports were not standard on all models.

🔧 Maintenance

Oil Change Interval 6.4L Power Stroke:

Every 5,000 miles or 6 months, whichever comes first. Severe duty may require more frequent changes. Use CJ-4 rated diesel engine oil.

Oil Change Interval 5.4L/6.8L Triton:

Every 5,000 miles or 6 months, whichever comes first. Use SAE 5W-20 synthetic blend or full synthetic oil.

Engine Air Filter Replacement:

Inspect every 15,000 miles, replace as needed. Diesel models may require more frequent inspection/replacement due to operating environment.

Fuel Filter Replacement 6.4L Power Stroke:

Replace primary and secondary fuel filters every 15,000 miles or 12 months. Critical for maintaining injection system health.

Engine Coolant Type:

Ford Gold Coolant (G-05 specification) or equivalent with 50/50 mix of antifreeze and distilled water. Total capacity approx. 22.5 quarts (diesel) or 20 quarts (gas).

Brake Fluid Type:

DOT 3 (or higher, e.g., DOT 4) disc brake fluid.

Power Steering Fluid Type:

Ford Power Steering Fluid (e.g., XT-2-QX-DL or XT-2-QSM) or equivalent meeting specification WSS-M2C195-A.

Rear Axle Lubricant:

API GL-5, SAE 75W-140 synthetic gear lubricant for standard axles. If equipped with limited-slip differential, specific additive may be required (check manual for exact specification).

Common Issues 6.4L Power Stroke:

EGR cooler failures, DPF regeneration issues, injector problems, oil dilution in diesel engines, turbocharger failures, FICM (Fuel Injection Control Module) failures. These are often related to the complex emissions systems.

Common Issues 5.4L/6.8L Triton:

Spark plug ejection (on some earlier Triton variants, though less common on this generation), intake manifold issues, VCT solenoid problems, cam phaser noise.

Common Issues General:

DPF (Diesel Particulate Filter) clogging (especially if used for short trips), turbo soot buildup (diesel), exhaust gas recirculation (EGR) system issues (diesel), front-end component wear (ball joints, tie rods) due to heavy loads, brake pad and rotor wear, transmission cooler line leaks.

📚 Vehicle History

Brand Heritage:

Ford's F-Series truck line boasts a history dating back to 1948, consistently being one of America's best-selling vehicles. The 'Super Duty' designation, introduced in 1999, signifies heavy-duty capabilities above the standard F-150. The 2009 model is part of the second generation of the Super Duty (launched in 2008).

Model Evolution 2008-2010:

The 2008 redesign marked a significant update for the Super Duty line, featuring a bolder exterior design, a substantially improved interior, and the introduction of the highly capable 6.4L Power Stroke diesel engine. The 2009 model year largely carried over these advancements.

Production Location:

Kentucky Truck Plant, Louisville, Kentucky, USA.

🏆 Awards & Recognition

Heavy Duty Truck Awards:

The Ford Super Duty line has consistently received accolades and awards from automotive publications for its towing and hauling capabilities, durability, and powertrain options. While specific awards for the 2009 model year might be less publicized than current models, the platform itself is highly regarded in the heavy-duty segment.