Product Name:
Ford F250 F350 1997-2004 Service Repair Workshop Manual Pdf
Production Years Covered:
1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004
Platform Code:
GMT800 (for competitive context, actual F-Series platform designation is different but for this context, it's about the generation)
Target Audience:
Owners, DIY enthusiasts, professional mechanics, technicians seeking detailed repair information for 1997-2004 Ford F-250/F-350 Super Duty trucks.
Comparison To Other Manuals:
This is a comprehensive factory-level manual, providing the same depth of information found in official dealer-issued service literature, unlike condensed or unauthorized versions.
Features:
Instant download, lifetime usage, no expiry dates, no extra fees, detailed photos & diagrams, step-by-step instructions.
Diagram Quality:
Contains highly detailed exploded diagrams and pictures to illustrate repair and assembly processes.
General Coverage:
All repairs, servicing, and troubleshooting procedures for Ford F-250 and F-350 models from 1997 to 2004.
Estimated Page Count:
Hundreds of pages (specific count not provided, but described as comprehensive).
Type:
Factory Service Repair Workshop Manual
Additional Types:
Workshop Manual, Service Manual, Repair Manual, Technical Manual.
Powertrain:
Engine mechanical, fuel system, cooling system, lubrication system, exhaust system, engine electrical, ignition system, transmission (automatic and manual), driveline, transfer case.
Chassis:
Suspension (front and rear), steering system, braking system (front and rear disc, parking brake), wheels and tires.
Electrical And Body:
Body and paint, interior trim, exterior trim, HVAC system, lighting system, instrumentation, power accessories (windows, locks, seats), safety systems (airbags, seatbelts), chassis electrical (wiring diagrams, fuses, relays, power distribution).
Body And Paint:
Includes procedures for body panel removal/installation, dent repair, paint preparation, and refinishing.
Maintenance:
Scheduled maintenance, oil changes, filter replacements, fluid checks and changes, tire rotation, brake inspections, battery maintenance.
Repair And Rebuild:
Engine overhaul, transmission repair/rebuild, brake component replacement, suspension and steering component replacement, electrical component diagnosis and replacement, body panel repair and replacement.
Troubleshooting:
Diagnostic procedures for common and uncommon issues, fault code interpretation, symptom-based troubleshooting guides.
Diagnostic Tools:
Information on diagnostic trouble codes (DTCs) and procedures, often referencing the need for scan tools (e.g., OBD-II scanners).
Diagnostic Procedures:
Detailed step-by-step diagnostic procedures for diagnosing drivability, electrical, and mechanical issues, often including flowcharts.
Depth:
Comprehensive from basic maintenance to complete engine and transmission rebuilds, including detailed diagnostic trees and wiring schematics.
Wiring Diagrams:
Includes detailed electrical schematics and wiring diagrams for all vehicle systems, essential for diagnosing electrical faults.
Gas V8 5.4L Triton:
Engine Code: 5.4L Triton V8 (2-valve SOHC). Displacement: 5.4 L (330 cu in). Bore x Stroke: 3.55 in x 4.16 in. Compression Ratio: 9.0:1. Horsepower: 235-260 hp @ 4500-4800 rpm. Torque: 330-370 lb-ft @ 3000-3250 rpm.
Gas V10 6.8L Triton:
Engine Code: 6.8L Triton V10 (2-valve SOHC). Displacement: 6.8 L (415 cu in). Bore x Stroke: 3.55 in x 4.16 in. Compression Ratio: 8.7:1. Horsepower: 275 hp @ 4000 rpm. Torque: 410 lb-ft @ 3000 rpm.
Diesel 7.3L Powerstroke:
Engine Control Module (ECM) calibration and diagnostic procedures are thoroughly covered.
Fuel Type:
Gasoline (5.4L, 6.8L), Diesel (7.3L Power Stroke).
Cooling System Capacity:
Approximately 18-23 quarts (depending on engine and radiator size). Specifics in manual.
Injection Type Gas:
Electronic Fuel Injection (EFI) with sequential multi-port injection (MPI).
Injection Type Diesel:
Direct Injection, HEUI (Hydraulically Actuated Electronically Controlled Unit Injector) for Power Stroke.
Manual Transmission:
Various manual transmissions available, including 5-speed and 6-speed options depending on model year and engine. (e.g., ZF S5-47, ZF S6-650).
Automatic Transmission:
Available automatic transmissions include 4-speed TorqShift (e.g., 4R100) for diesel and some gas models, and E4OD for earlier gas models.
Transmission Features:
Tow/haul mode, electronic controls, overdrive gears.
4Wd System:
Coverage of manual and electronic 4-wheel drive systems, including transfer case operation and maintenance.
Automatic Transmission Fluid:
Approx. 13-16 pints (dry fill). Consult manual for specific capacities and fluid types (e.g., Mercon, Mercon V).
Body Styles:
Regular Cab, SuperCab (extended cab), Crew Cab. Wheelbases vary (e.g., 137.5 in, 158 in, 172 in). Various bed lengths (e.g., 8 ft Styleside, 6.75 ft Styleside).
Wheelbase Options:
Common wheelbases include 137.5" (Reg Cab SRW), 158" (Reg Cab DRW, SuperCab SRW), 172" (SuperCab DRW, Crew Cab SRW), 178" (Crew Cab DRW).
Track Width:
Varies by SRW (Single Rear Wheel) and DRW (Dual Rear Wheel) configurations. Manual provides specific measurements.
Gvwr:
Gross Vehicle Weight Rating varies significantly by configuration, typically ranging from 8,800 lbs to 11,500 lbs or higher for F-350 models.
Curb Weight:
Curb weight varies significantly based on cab, bed, drivetrain, and engine, generally starting around 6,000 lbs and exceeding 7,500 lbs for heavier configurations.
Payload Capacity:
Payload capacities range significantly, from approximately 2,500 lbs up to 6,000+ lbs depending on configuration (F-250 vs F-350, SRW vs DRW).
Towing Capacity:
Towing capacities vary widely, typically from 10,000 lbs up to 12,500 lbs or more for F-350 DRW models. Consult specific vehicle's VIN or manual for exact rating.
Audio System:
Various factory radio options including AM/FM, CD players, and cassette players. Higher trims may offer premium sound systems.
ABS:
Standard Anti-lock Braking System (ABS) on most models.
Trailer Support:
Provision for trailer brake controller and trailer wiring harnesses.
Oil Change Interval:
Typically every 3,000-5,000 miles for conventional oil, or 5,000-7,500 miles for synthetic oil, depending on engine and usage. Consult manual for specifics.
Transmission Fluid Change:
Intervals vary by transmission type and usage, generally recommended between 30,000 to 100,000 miles. Diesel transmissions often have longer intervals. Fluid type is critical (e.g., Mercon V for later models, Mercon for earlier).
Engine Oil Gas:
API Service SG, SH, SJ, or SL. Viscosity: 5W-20, 5W-30, or 10W-30 depending on temperature. Consult manual for exact specification for each engine.
Engine Oil Diesel:
API Service CD, CE, CF, CF-2, CF-M, or CG-4. Viscosity: 15W-40 or 10W-30 Heavy Duty Diesel Engine Oil.
Coolant:
Ford Premium Engine Coolant (Gold) or equivalent, a 50/50 mixture of antifreeze and distilled water. Do NOT use conventional green coolant for these models.
Differential Fluid Front Rear:
API GL-5 gear oil. Viscosity typically 75W-90 or 75W-140. Specify if limited-slip additive is required.
Transfer Case Fluid:
Ford Part # F8UZ-19A509-AA or equivalent (Mercon ATF for electronic 4WD). Manual for specific transfer case type.
Diesel 7.3L Powerstroke:
Injector O-ring failures (leaking fuel into oil/coolant), UVCH (Under Valve Cover Harness) chafing, FICM (Fuel Injection Control Module) failures, turbocharger issues (sticking vanes).
Gas Engines 5.4L 6.8L:
Spark plug ejection (especially on early 5.4L 2-valve), intake manifold gasket leaks, exhaust manifold cracks, cam synchronizer failures.
Suspension And Steering:
Worn ball joints, tie rod ends, and steering gear issues are common due to heavy-duty use and towing. Leaf spring issues on rear suspension.
Brake System:
Premature wear of brake pads and rotors on some models due to towing loads. ABS sensor issues.
Ford Trucks:
Ford has a long and storied history in the pickup truck market, with the F-Series being the best-selling vehicle in America for decades.
1997-2004 F Series:
This generation, often referred to as the '9th Generation' (though it bridges into the 10th for some aspects), saw the introduction of the 'Super Duty' designation for F-250 and F-350 models starting in 1999, signifying a more robust and heavy-duty platform. Key updates included the introduction of the Triton V8 and V10 engines and the powerful Power Stroke diesel, along with significant styling and chassis enhancements.
Manufacturing Locations:
Assembled in various Ford plants in the United States, primarily in Kentucky and Missouri.
