🏷️ Basic Information

Make:

Ford

Model:

F-Series (F550)

Year:

2004

Generation:

Sixth Generation (2000-2007)

Platform:

P268

👋 Introduction

Market Position:

Commercial and heavy-duty segment, targeting fleet owners, vocational users, and heavy-duty repair shops.

Competitive Analysis:

Directly competes with heavy-duty trucks from manufacturers like Chevrolet (Silverado HD), Dodge (Ram Heavy Duty), and International (TerraStar).

Key Features:

Comprehensive repair coverage, factory-specific data, digital format for ease of use and printing, detailed diagrams and schematics.

📋 Manual Details

Coverage Areas:

All F550 models, all repairs A-Z

Page Count:

Not Specified (but described as comprehensive, suggesting a substantial volume)

Manual Type:

Service and Repair Manual

Language:

English

Format:

PDF (digital download)

Digital Features:

Searchable text, bookmarks for easy navigation, zoomable diagrams.

Compatibility:

All Versions of Windows AND Mac

Download Speed:

Speed Download

Requirements:

Adobe PDF Reader and Winzip (free online).

📖 Manual Coverage

Systems Covered:

Engine, Control System, Mechanical, Fuel Service Specifications, Emission Control, Intake/Exhaust/Cooling, Lube, Ignition/Starting/Charging, Automatic Transmission, Clutch, Manual Transmission, Transfer Case, Propeller Shaft, Drive Shaft, Differential, Axle, Suspension, Tire & Wheel, Brake Control, Brakes, Parking Brake, Steering Column, Power Steering, Air Conditioning, Supplemental Restraint System (SRS), Seat Belts, Engine Immobilizer, Cruise Control, Wiper & Washer, Door Lock, Meter/Audio/Visual, Horn, Windshield/Glass/Mirror, Instrument Panel, Seats, Engine Hood/Doors, Exterior & Interior, Electrical, Multiplex/CAN Communication, and more.

Procedures Included:

Maintenance, Servicing, Diagnosis, Repair, Component Replacement, Troubleshooting, Electrical Schematics, Wiring Diagrams.

Procedures Included Detail:

Includes troubleshooting charts, diagnostic procedures, step-by-step repair instructions, component removal and installation, torque specifications for fasteners, and system diagrams.

Technical Depth:

Factory-level, highly detailed, step-by-step instructions with diagrams, illustrations, and specifications for complete vehicle repair.

📊 Manual Specifications

File Format:

PDF

Print Quality:

Printable pages, scalable images for enlarged copies.

Binding Type:

Digital (no physical binding)

Paper Type:

N/A (Digital format, printable on user's choice of paper)

⚙️ Engine Specifications

Primary Engine:

6.0L Triton V8 Gasoline (Gasoline Part Number: F81Z-6007-RA for long block assembly, check specific VIN for exact part number).

Optional Engine 1:

7.3L Power Stroke V8 Turbo Diesel (Diesel Part Number: 1842126C91 for complete engine assembly, consult for specific VIN and application).

6.0L V8 Gasoline Horsepower:

Approximately 300-325 HP (dependent on specific F550 configuration)

6.0L V8 Gasoline Torque:

Approximately 370-390 lb-ft (dependent on specific F550 configuration)

7.3L Power Stroke Diesel Horsepower:

Approximately 250-275 HP (dependent on specific F550 configuration)

7.3L Power Stroke Diesel Torque:

Approximately 500-525 lb-ft (dependent on specific F550 configuration)

Fuel System:

Port Fuel Injection (Gasoline), High-Pressure Common Rail Direct Injection (Diesel).

Engine Type Gasoline:

Overhead Valve (OHV) V8

Engine Type Diesel:

Overhead Valve (OHV) V8 Turbocharged

🔧 Transmission

Standard:

5-Speed Manual Transmission (e.g., ZF F50-650)

Optional:

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

Features:

Heavy-duty construction, suitable for towing and hauling. Automatic transmission includes manual override mode.

Transfer Case Type:

Manual or Electronic Shift-On-The-Fly (ESOF) for 4WD models.

📐 Dimensions

Wheelbase:

Varies by configuration (e.g., 137.1", 158.1", 179.1")

Gvwr:

Up to 20,500 lbs (9299 kg) for F550

Ground Clearance:

Varies by configuration, typically designed for higher ground clearance for off-road and vocational use.

Curb Weight:

Approximately 7,000 - 8,500 lbs (3175 - 3856 kg), depending on configuration and powertrain.

Payload Capacity:

Significant, typically exceeding 8,000 lbs (3629 kg) for F550.

🛡️ Safety Features

Safety Ratings:

NHTSA and IIHS ratings not typically assigned to heavy-duty commercial vehicles in the same way as light-duty vehicles. Focus is on compliance with federal motor vehicle safety standards (FMVSS).

Active Features:

Anti-lock Braking System (ABS), Daytime Running Lights (DRLs) on some models.

Passive Features:

Front airbags for driver and passenger, high-strength steel frame, integrated seatbelt systems.

💡 Technology Features

Infotainment System:

Basic AM/FM radio, optional CD player, and potentially cassette player. Limited to audio entertainment, no advanced touchscreen or navigation systems common in modern vehicles.

Driver Assistance Features:

Limited to ABS. No electronic stability control (ESC), traction control, or advanced driver-assistance systems (ADAS) common in contemporary passenger vehicles.

Connectivity Features:

Primarily analogue systems. Some models may have basic power accessory ports.

🔧 Maintenance

Oil Change Interval:

Gasoline: 5,000 miles / 6 months or 7,500 miles / 6 months (synthetic blend) under normal driving. Diesel: 7,500 miles / 6 months to 10,000 miles / 12 months depending on oil specification and driving conditions. Refer to manual for severe duty intervals.

Tire Rotation Interval:

Every 5,000 - 7,500 miles.

Engine Oil Gasoline:

API SG, SH, or SJ service category SAE 5W-30 or 5W-40 (check owner's manual for specific OEM recommendation). Capacity: Approx. 7 quarts (6.6 liters).

Engine Oil Diesel:

API CI-4 or CH-4 SAE 15W-40 (e.g., Motorcraft Super Duty Diesel Engine Oil). Capacity: Approx. 15 quarts (14.2 liters).

Coolant:

Ford Premium Gold Coolant (e.g., Motorcraft Premium Engine Coolant VC-7B) or equivalent meeting Ford specification WSS-M97B44-D. Capacity: Varies by engine and cooling system configuration (e.g., 20-30 quarts).

Automatic Transmission Fluid:

MERCON® V (e.g., Motorcraft MERCON® V Automatic Transmission Fluid). Capacity: Approx. 13-17 quarts (12.3-16.1 liters) for refill, higher for complete flush.

Manual Transmission Fluid:

Refer to manual for specific viscosity and specification (e.g., SAE 75W-90 GL-4 or GL-5 synthetic gear oil, depending on transmission type).

Differential Fluid:

SAE 75W-90 or 75W-140 synthetic gear oil (check manual for specific application and requirements, e.g., Ford XL-3, or equivalent). Limited-slip differentials may require additive.

Brake Fluid:

DOT 3 (e.g., Motorcraft High Performance DOT 3 Brake Fluid).

Power Steering Fluid:

MERCON® LV or MERCON® V (consult manual for specific application, generally a Type F or Type H ATF is acceptable).

Known Issues:

6.0L Power Stroke Diesel (if equipped): EGR cooler failures, oil cooler failures, injector seal issues (standpipes/isors), head gasket issues. Gasoline 6.0L V8: Less prone to major issues, but focus on standard tune-up components, cooling system, and exhaust.

Known Issues Gasoline:

Spark plug replacement, ignition coil failures, fuel injector service, cooling system maintenance (radiator, hoses, thermostat).

📚 Vehicle History

Brand Heritage:

Ford has a long-standing history in the truck market, with the F-Series being a flagship model since its introduction in 1948, evolving into America's best-selling truck.

Model Evolution:

The F-Series Super Duty line (including the F-450 and F-550) was introduced in 1999 to differentiate from the F-150. The 2004 model falls into the second year of the sixth generation (2000-2007), which saw significant updates and the introduction of the Power Stroke diesel and Triton gasoline engines.

Chassis Design:

Robust C-channel frame, designed for heavy-duty applications and upfitting with various vocational bodies.

Production Location:

Typically assembled at Ford's Kentucky Truck Plant in Louisville, Kentucky.

🏆 Awards & Recognition

Recognitions:

Ford F-Series Super Duty has consistently received awards for towing and hauling capabilities, work truck of the year designations from various automotive publications, and recognition for its robust chassis and powertrain options.