🏷️ Basic Information

Make:

Ford

Model:

F-Series Super Duty (F-250)

Year:

2004

Chassis Code:

GMT800

Engine Codes Typical:

7.3L V8 Power Stroke Turbo Diesel (International Harvester), 5.4L V8 Triton, 6.8L V10 Triton

👋 Introduction

Target Audience:

Ford F-250 Super Duty owners, independent repair shops, DIY mechanics

Value Proposition:

Provides dealership-level repair information for specific model, enabling cost savings and confident DIY repairs.

Advantage:

Directly sourced factory information, not generic, offering unparalleled specificity and detail.

Features:

Step-by-step instructions, diagrams, illustrations, wiring schematics, specifications, A-Z repair coverage.

Format Benefit:

Digital PDF allows for selective printing, portability, and protection from physical damage.

📋 Manual Details

Primary Coverage:

Complete Service and Repair for 2004 Ford F-250 Super Duty

Model Variants Covered:

All F-250 Super Duty Models

Estimated Page Count:

Extensive (Typically 2000+ pages for full dealership manuals)

Type:

Factory Service Manual (FSM)

Subtype:

Repair Manual, Diagnostic Manual, Electrical Troubleshooting Manual

Language:

English

Format:

Digital PDF

Deliverable Format:

Downloadable PDF

📖 Manual Coverage

Engine:

5.4L Triton V8, 6.8L Triton V10, 7.3L Power Stroke Turbo Diesel

Fuel System:

Fuel delivery, injection, pressure, evaporative emissions

Cooling System:

Radiator, water pump, thermostat, coolant, fan clutch

Lubrication System:

Oil pump, oil filter, oil pressure, oil type specifications

Ignition System:

Spark plugs, coils, ignition timing (gasoline engines)

Charging System:

Alternator, battery, voltage regulator

Starting System:

Starter motor, starter solenoid, ignition switch

Emission Control:

Catalytic converter, EGR system, O2 sensors, PCM control

Transmission Automatic:

Torque converter, valve body, transmission fluid, electronic controls (e.g., 4R100, 5R110W)

Transmission Manual:

Clutch, gearbox, shifter mechanism (e.g., ZF S6-650)

Transfer Case:

Operation, maintenance, and repair (e.g., BW 4406, BW 4446)

Drive Shaft And Axles:

U-joints, CV joints, driveshaft balancing, axle bearings

Differential:

Front and rear differential service, lubrication, and repair

Suspension System:

Front and rear suspension components, alignment, shock absorbers, springs

Steering System:

Power steering pump, steering gear, tie rods, steering column

Brake System:

Front and rear brakes (discs/drums), ABS system, hydraulic lines, master cylinder

Parking Brake:

Operation, adjustment, and repair

Wheel And Tire:

Tire pressure, rotation, balancing, wheel specifications

Body And Frame:

Body panel repair, doors, hood, tailgate, chassis components

HVAC System:

Air conditioning, heating, climate control operation and service

Restraint Systems:

Airbag system, seat belts, SRS diagnostics

Electrical System:

Lighting, power windows, locks, mirrors, interior and exterior lighting

Instrumentation:

Gauges, warning lights, instrument cluster diagnostics

Multiplex Communication:

CAN bus system, network diagnostics, module communication

Maintenance:

Scheduled maintenance, oil changes, fluid checks, filter replacements

Diagnostics:

Troubleshooting procedures, diagnostic trouble codes (DTCs), symptom-based diagnostics

Repair:

Component removal and installation, rebuilding procedures, adjustments

Specifications:

Torque values, clearances, fluid types and capacities, technical data

Wiring Schematics:

Complete electrical system wiring diagrams for all circuits

Illustrations Diagrams:

Step-by-step diagrams, exploded views, and illustrations for clarity

Depth:

Comprehensive from basic maintenance to complete engine and transmission rebuilds, including advanced diagnostics and electrical troubleshooting.

📊 Manual Specifications

File Type:

PDF

Searchability:

Likely text-searchable within PDF

Printability:

Yes, all pages are printable.

Image Resolution:

High, allows for blowing up images and printing enlarged copies.

Binding:

N/A (Digital PDF)

Paper Type:

N/A (Digital PDF, user prints on desired paper)

Reader:

Adobe PDF Reader (Free)

Unzipping:

Winzip or equivalent (Free)

Operating System Compatibility:

Windows and Mac

⚙️ Engine Specifications

Engine 1 Type:

5.4L Triton V8

Engine 1 Displacement:

5.4 Liters (330 cubic inches)

Engine 1 Configuration:

SOHC V8

Engine 1 Horsepower Est:

Approx. 260 HP

Engine 1 Torque Est:

Approx. 350 lb-ft

Engine 2 Type:

6.8L Triton V10

Engine 2 Displacement:

6.8 Liters (415 cubic inches)

Engine 2 Configuration:

SOHC V10

Engine 2 Horsepower Est:

Approx. 310 HP

Engine 2 Torque Est:

Approx. 425 lb-ft

Engine 3 Type:

7.3L Power Stroke Turbo Diesel

Engine 3 Displacement:

7.3 Liters (444 cubic inches)

Engine 3 Configuration:

Overhead Valve (OHV) V8 Turbocharged Diesel

Engine 3 Horsepower Est:

Approx. 250 HP

Engine 3 Torque Est:

Approx. 500 lb-ft

Fuel Type:

Gasoline (5.4L, 6.8L) / Diesel (7.3L)

🔧 Transmission

Transmission Type Standard:

Varies by engine and configuration, often 6-speed manual (e.g., ZF S6-650 for diesel) or 4-speed automatic (e.g., 4R100 for gas/older diesel) or 5-speed automatic (e.g., 5R110W for gas/newer diesel)

Transmission Type Optional:

See standard for variations based on engine and trim

Transmission Features:

Torque converter lock-up, electronic control, overdrive gear, manual gearbox with heavy-duty clutch assembly

📐 Dimensions

Wheelbase Typical:

137.1 inches (Reg Cab), 158.1 inches (SuperCab), 172.4 inches (Crew Cab)

Length Typical:

Approx. 210-235 inches depending on cab and bed configuration

Curb Weight Est:

6,000 - 7,500 lbs (depending on configuration)

Gvw Range Typical:

8,800 lbs to 11,500 lbs (F-250)

Bed Lengths Typical:

6.75 ft (Short Bed), 8.0 ft (Long Bed)

🛡️ Safety Features

NHTSA Front Impact Rating Est:

4/5 Stars (Varies by specific configuration and testing year)

NHTSA Side Impact Rating Est:

4/5 Stars (Varies by specific configuration and testing year)

ABS:

Standard Anti-lock Braking System

Traction Control:

Available Traction Control System (TCS)

Airbags:

Frontal airbags for driver and passenger

Seat Belts:

3-point front seat belts with pretensioners, shoulder belts for rear occupants

💡 Technology Features

Infotainment System Type:

Basic AM/FM stereo with CD player, optional cassette player, optional premium audio systems.

Display:

Simple digital or analog displays for audio and climate controls.

Driver Assistance Features:

Limited; primarily ABS and optional Traction Control System (TCS). Backup sensors and camera systems were not common in this era.

Connectivity Options:

Limited; no integrated Bluetooth or USB ports typically found on factory systems. Optional satellite radio.

Engine Control Module:

Powertrain Control Module (PCM) for managing engine and transmission functions, based on various sensor inputs.

Multiplex Communication:

Use of Controller Area Network (CAN) for inter-module communication and diagnostics.

🔧 Maintenance

Oil Change Interval:

Typically every 5,000 miles for gasoline engines, or as per specific recommendations for the 7.3L Power Stroke diesel (e.g., 3,000-5,000 miles, or based on oil analysis).

Tire Rotation Interval:

Every 5,000-7,500 miles

Transmission Fluid Change:

Typically every 30,000-50,000 miles for automatics, consult manual for specifics.

Coolant Change:

Initial change at around 100,000 miles, then every 50,000 miles for conventional coolant, or longer intervals for specialized coolant. Refer to manual for specific coolant type and interval.

Engine Oil Gasoline:

SAE 5W-20 or 5W-30 (API Service SG or higher, meeting Ford specification WSS-M2C153-H or equivalent).

Engine Oil Diesel 7.3L:

API CJ-4 or CI-4 PLUS, SAE 15W-40 or 10W-30 for colder climates (meeting Ford specification WSS-M2C171-C or equivalent).

Transmission Fluid Automatic 4R100/5R110W:

Mercon V (meeting Ford specification WSS-M2C195-A or equivalent).

Manual Transmission Fluid:

GL-4 or GL-5 gear oil, specific viscosity (e.g., 75W-90 or 80W-90) as per manual.

Coolant:

Ford Premium Engine Coolant (Green) or equivalent meeting specification WSS-M97B44-D.

Common Issues 7.3L Psd:

High-pressure oil system leaks (HPOP), injector issues (IDM, FICM), turbocharger problems, EGR cooler failures (on later models/6.0L), valley oil pan leaks, coolant leaks.

Common Issues Gasoline Tritons:

Spark plug blow-out (especially early Triton engines, though less common by 2004), intake manifold gasket leaks, coil-on-plug failures, exhaust manifold cracks.

Common Issues Transmission:

TorqShift automatic transmission issues related to solenoids, valve bodies, and torque converters. Manual transmission clutch wear.

Common Issues Suspension:

Ball joint wear, tie rod end wear, leaf spring issues on heavy-duty applications, front end shimmy.

📚 Vehicle History

Brand:

Ford F-Series

Heritage Significance:

Longest-running nameplate in automotive history, known for toughness and capability.

Generation:

11th Generation Ford F-Series (2004-2008)

Key Changes 2004:

Introduction of the redesigned 11th generation, featuring a more sculpted exterior, improved interior, and updated powertrains including the 5R110W TorqShift automatic transmission and the 6.0L Power Stroke diesel (though the 7.3L was still available early in the year or as a carry-over for some configurations).

Production Plant Typical:

Various Ford plants in the United States, notably Kentucky Truck Plant.