Segment:
Heavy-duty pickup trucks
Target Audience:
Owners, DIY mechanics, professional technicians, fleet maintenance.
Competitors 1996:
Chevrolet C/K Series (Silverado), Dodge Ram Heavy Duty.
Ease Of Use:
Step-by-step instructions and illustrations designed for ease of understanding and execution of repairs.
Cost Savings:
Enables owners to perform their own maintenance and repairs, leading to significant cost savings.
Accessibility:
Downloadable to various devices (PC, Mac, tablet, smartphone) for convenient access.
Permanence:
Download once, own forever, with the ability to print as needed.
Engines Covered:
All gasoline and diesel engines
Transmissions Covered:
All manual and automatic transmissions
Trim Levels Covered:
All trim levels
Estimated Page Count:
Over 1500 pages (estimated for a comprehensive workshop manual of this scope)
Type:
Complete Workshop Service Repair Manual
Format:
Downloadable Digital Format (PDF)
Powertrain:
Engine mechanical, fuel system, cooling system, lubrication system, ignition system, exhaust system, manual transmission, automatic transmission, transfer case (4WD models), drive axles, drivelines.
Chassis:
Steering system, suspension system (front and rear), brake system (front and rear), wheel and tire service.
Electrical:
Charging system, starting system, lighting system, instrument cluster, wiring diagrams, body electrical, power accessories (windows, locks, mirrors), HVAC controls, audio system.
Body:
Body panels, doors, hoods, tailgates, interior trim, exterior trim, glass, bumpers, chassis lubrication.
Maintenance:
Scheduled maintenance, oil changes, filter replacements, fluid checks and changes, lubrication, tune-ups, belt and hose inspection/replacement.
Repair:
Engine overhaul and component replacement (e.g., cylinder heads, pistons, crankshaft), transmission overhaul and component replacement, brake system repair (e.g., calipers, rotors, lines), suspension component replacement (e.g., ball joints, tie rods, shocks), steering system repair, electrical component diagnosis and repair, body panel repair and replacement.
Diagnostics:
Troubleshooting guides, symptom-based diagnosis, diagnostic trouble codes (DTCs) interpretation (where applicable for the era), circuit testing, component testing.
Specifications:
Torque specifications, clearances, fluid capacities, electrical specifications, emissions data.
Depth:
Comprehensive: Covers basic maintenance, routine service, advanced diagnostics, component removal/installation, overhaul procedures, and detailed repair instructions.
Engine Code:
4.9L (300 cu in) I6 (OHV)
Horsepower 300:
145 hp @ 3600 rpm (approx.)
Torque 300:
265 lb-ft @ 2000 rpm (approx.)
Engine Code 2:
5.8L (351 cu in) Windsor V8 (OHV)
Horsepower 351:
215 hp @ 4000 rpm (approx.)
Torque 351:
325 lb-ft @ 3200 rpm (approx.)
Engine Code 3:
7.5L (460 cu in) Big-Block V8 (OHV)
Horsepower 460:
245 hp @ 3600 rpm (approx.)
Torque 460:
400 lb-ft @ 3200 rpm (approx.)
Engine Code Diesel:
7.3L (444 cu in) Power Stroke V8 Turbo Diesel (OHV)
Horsepower Diesel:
210-225 hp @ 3500-3600 rpm (approx., depending on specific configuration)
Torque Diesel:
425-450 lb-ft @ 2000-2500 rpm (approx., depending on specific configuration)
Gasoline:
Electronic Fuel Injection (EFI) for all gasoline engines.
Diesel:
Direct Injection, HEUI (Hydraulically Actuated Electronically Controlled Unit Injector) system for Power Stroke diesel.
Type:
5-speed manual transmission (e.g., NP 435 or ZF S5-47)
Type:
4-speed automatic transmission (e.g., E4OD)
Type:
5-speed manual transmission (ZF S5-47) or 4-speed automatic transmission (E4OD).
Type:
Heavy-duty manual transmissions (e.g., ZF S6-650 6-speed) or heavy-duty automatic transmissions (e.g., Allison). Specific availability may vary.
Automatic Transmission Fluid:
Mercon V or equivalent (for E4OD and similar units).
Manual Transmission Fluid:
API GL-4 or GL-5 gear oil, SAE 75W-90 or 80W-90, depending on transmission model.
4Wd Transfer Case:
Manual or electronically controlled transfer cases for 4WD models (e.g., BorgWarner BW 1345/1356).
Chassis Type:
Body-on-frame construction.
Cab Configurations:
Regular Cab, SuperCab (extended cab), Crew Cab (4-door on some models).
Bed Lengths:
Various bed lengths available (e.g., 6.75 ft, 8.0 ft) depending on configuration and model.
Gvwr Class:
Class A (10,001-14,000 lbs GVWR) for F-250/F-350, Class C (14,001-16,000 lbs GVWR) for F-450, Class E (19,501-26,000 lbs GVWR) for F-550 (approximate ranges, specific configurations vary).
Crash Test Results:
Vehicle safety ratings for this era would be based on NHTSA and IIHS standards, specific results are not readily available without referencing original documentation, but generally expected to be robust for heavy-duty applications.
ABS:
Anti-lock Braking System (ABS) standard on front wheels, often optional or rear-only on some configurations.
Airbags:
Driver-side airbag standard.
Seat Belts:
Three-point seat belts for front occupants.
Audio System:
Standard AM/FM radio, optional cassette player, CD player (early adoption for some models), and speaker configurations.
Cruise Control:
Available electronic cruise control system.
Wiring Harnesses:
Comprehensive wiring diagrams provided in the manual for diagnosing and repairing electrical systems and accessories.
Service Intervals Oil Gas
Interval:
Every 3,000 to 5,000 miles or 6 months, whichever comes first (depending on driving conditions and engine).
Service Intervals Oil Diesel
Interval:
Every 5,000 to 7,500 miles or 6 months, whichever comes first (depending on driving conditions and oil quality).
Fluid Specifications Engine Oil Gas
Type Viscosity:
API SG or SH rated, SAE 5W-30, 10W-30, or 10W-40 depending on temperature and specific engine.
Fluid Specifications Engine Oil Diesel
Type Viscosity:
API CF-2, CG-4, or CH-4 rated, SAE 15W-40 heavy-duty diesel engine oil.
Fluid Specifications Coolant
Type:
Ford Premium Gold Coolant or equivalent (ethylene glycol based) with the correct concentration of additives for heavy-duty applications.
Fluid Specifications Brake Fluid
Type:
DOT 3 or DOT 4 brake fluid.
Diesel Glow Plugs:
Potential for worn or failing glow plugs impacting cold-weather starting.
E4Od Transmission:
Some E4OD transmissions may require specific maintenance or adjustments to ensure longevity, particularly with heavy loads.
Wear And Tear:
Common wear items like ball joints, tie rod ends, and bushings due to the truck's heavy-duty nature and usage.
Fuel Injectors Diesel:
The HEUI system's fuel injectors can be a source of issues if not maintained properly or if fuel quality is poor.
Ford Trucks:
Ford has a long and storied history in the truck market, with the F-Series being a dominant player for decades.
Ninth Generation:
The 1996 model year falls within the Ninth Generation (1992-1997) of the Ford F-Series. This generation saw significant styling updates and the introduction of the Power Stroke diesel engine.
Manufacturing Locations:
Assembled in North America, primarily in the United States and Canada.
