Ford F150 2004-2008 Workshop Service Repair Manual
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🏷️ Basic Information Identification Make: Ford Model: F-150 Generation: 11th Generation Production Years Covered: 2004, 2005, 2006, 2007, 2008 Codes Platform: P255 (Ford P2 Platform) 👋 Introduction Market Position Segment: Full-size pickup truck, consistently a best-selling vehicle in North America. Competitive Analysis Competitors: Chevrolet Silverado, GMC Sierra, Ram Pickup, Toyota Tundra, Nissan Titan. Key Features Strengths: Robust build, wide range of engine options, towing and payload capability, comfortable ride for a truck, interior space and comfort. Target Audience Audience: Professionals, fleet operators, families, individuals seeking utility, towing, and hauling capabilities. 📋 Manual Details Coverage Areas Coverage: Complete Workshop Service Repair Manual Page Count Pages: Over 2500 pages (estimated, typical for comprehensive workshop manuals) Manual Type Type: Factory Authorized Service Manual / Repair Manual Language Language: English Format Format: Digital (PDF) 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical, fuel system, ignition system, exhaust system, cooling system, lubrication system, powertrain control module (PCM) diagnostics. Transmission: Automatic Transmission (4R75E, 4R75W, 6R80) and Manual Transmission (M5R2-HD) repair, diagnostics, and service procedures. Drivetrain: Driveshaft, axles, differential, four-wheel-drive (4WD) system, transfer case, hubs. Suspension: Front and rear suspension components, steering system, power steering, alignment specifications. Brakes: Front and rear brake systems (disc and drum), ABS, electronic brake force distribution (EBD), parking brake, brake fluid specifications. Electrical: Battery, charging system, starting system, lighting, instrumentation, power accessories, body control module (BCM), chassis control module (CCM), diagnostic connectors (OBD-II). HVAC: Heating, ventilation, and air conditioning (HVAC) system components, refrigerant handling, diagnostics. Body: Body panels, doors, windows, interior trim, bumpers, hood, tailgate, frame repair. Restraints: Airbag system (SRS), seat belt mechanisms, diagnostic and service procedures for restraint systems. Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, fluid checks, tire rotation, brake inspections. Repair: Component removal and installation, engine rebuilds, transmission overhaul, suspension and steering repairs, brake system servicing. Diagnostics: Troubleshooting guides, symptom-based diagnostics, diagnostic trouble codes (DTCs), electrical system testing, component testing. Technical Data: Torque specifications, clearances, fluid capacities, wiring diagrams, diagnostic flowcharts, exploded views. Technical Depth Depth: Comprehensive, covering everything from basic maintenance to complete engine and transmission rebuilds, including advanced electrical diagnostics and body repair. 📊 Manual Specifications File Format Format Details: Searchable PDF with high-resolution images and diagrams, allowing for easy navigation and keyword searches. Print Quality Quality: Professionally scanned and formatted for clarity and readability, suitable for printing key sections. Binding Type Binding: N/A (Digital Format) Paper Type Paper: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Options: 4.6L Triton V8 (2V and 3V), 5.4L Triton V8 (3V), 6.8L Triton V10, 4.0L/4.2L/4.6L/5.4L/6.0L Power Stroke Diesel (for Heavy Duty variants, but less common in standard F-150 models of this era). Performance 4.6L V8 (3V) Power: Approx. 248-302 hp, 294-353 lb-ft torque 5.4L V8 (3V) Power: Approx. 300 hp, 365 lb-ft torque Fuel System Injection Type: Electronic Fuel Injection (EFI) with Sequential Fuel Injection (SFI) Fuel Type: Unleaded Gasoline (typically 87 octane, check specific engine) Cooling System Coolant Type: Ford Premium Engine Coolant (Yellow) or equivalent HOAT coolant. 🔧 Transmission Standard Transmission Type: 4-Speed Automatic (4R75E/4R75W) was common, manual transmissions also available on some trims. Optional Optional Transmission: 6-Speed Automatic (6R80) introduced in later years of this generation. Manual transmission options included M5R2-HD. Features Transmission Fluid Type: Mercon V for 4R75E/4R75W; Mercon LV for 6R80. Check manual for exact specifications. Transfer Case Fluid: ATF (Automatic Transmission Fluid) or specific transfer case fluid depending on model/transfer case type. Consult manual. 📐 Dimensions Exterior Wheelbase: Varies by cab style and bed length (e.g., 126.0 in, 133.0 in, 145.5 in, 150.5 in). Overall Length: Varies significantly by configuration. Cargo Bed Lengths: Available in various lengths: 5.5 ft (Short Bed), 6.5 ft (Standard Bed), 8 ft (Long Bed). Weights Curb Weight: Varies greatly by configuration, typically ranging from 4,500 lbs to 5,500 lbs+ Payload Capacity: Up to approximately 3,100 lbs, depending on configuration and options. Towing Capacity: Up to approximately 11,000 lbs, depending on configuration, engine, axle ratio, and towing package. 🛡️ Safety Features Ratings NHTSA Front Crash: Generally rated 4 or 5 stars for driver and passenger front crash protection (check specific model year and configuration). IIHS Side Crash: Good ratings for side crash protection often achieved. Active Features ABS: Standard Anti-lock Braking System (ABS). Traction Control: Traction control system (TCS) available on many models. Stability Control: AdvanceTrac with Roll Stability Control (RSC) became increasingly available or standard during this generation. Passive Features Airbags: Front airbags, side-impact airbags, and available side-curtain airbags. 💡 Technology Features Infotainment Audio System: Base AM/FM/CD, optional SiriusXM satellite radio, premium sound systems available. Navigation: Optional factory navigation system available on higher trim levels. Driver Assistance Cruise Control: Standard cruise control, adaptive cruise control not typically available in this generation. Connectivity Bluetooth: Available SYNC infotainment system with Bluetooth hands-free calling and audio streaming introduced during this generation. Convenience Remote Start: Optional remote start system....
Automatic Transmission (4R75E, 4R75W, 6R80) and Manual Transmission (M5R2-HD) repair, diagnostics, and service procedures.
Drivetrain:
Driveshaft, axles, differential, four-wheel-drive (4WD) system, transfer case, hubs.
Suspension:
Front and rear suspension components, steering system, power steering, alignment specifications.
Brakes:
Front and rear brake systems (disc and drum), ABS, electronic brake force distribution (EBD), parking brake, brake fluid specifications.
Electrical:
Battery, charging system, starting system, lighting, instrumentation, power accessories, body control module (BCM), chassis control module (CCM), diagnostic connectors (OBD-II).
HVAC:
Heating, ventilation, and air conditioning (HVAC) system components, refrigerant handling, diagnostics.
Comprehensive, covering everything from basic maintenance to complete engine and transmission rebuilds, including advanced electrical diagnostics and body repair.
📊 Manual Specifications
File Format
Format Details:
Searchable PDF with high-resolution images and diagrams, allowing for easy navigation and keyword searches.
Print Quality
Quality:
Professionally scanned and formatted for clarity and readability, suitable for printing key sections.
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Options:
4.6L Triton V8 (2V and 3V), 5.4L Triton V8 (3V), 6.8L Triton V10, 4.0L/4.2L/4.6L/5.4L/6.0L Power Stroke Diesel (for Heavy Duty variants, but less common in standard F-150 models of this era).
Performance
4.6L V8 (3V) Power:
Approx. 248-302 hp, 294-353 lb-ft torque
5.4L V8 (3V) Power:
Approx. 300 hp, 365 lb-ft torque
Fuel System
Injection Type:
Electronic Fuel Injection (EFI) with Sequential Fuel Injection (SFI)
Fuel Type:
Unleaded Gasoline (typically 87 octane, check specific engine)
Cooling System
Coolant Type:
Ford Premium Engine Coolant (Yellow) or equivalent HOAT coolant.
🔧 Transmission
Standard
Transmission Type:
4-Speed Automatic (4R75E/4R75W) was common, manual transmissions also available on some trims.
Optional
Optional Transmission:
6-Speed Automatic (6R80) introduced in later years of this generation. Manual transmission options included M5R2-HD.
Features
Transmission Fluid Type:
Mercon V for 4R75E/4R75W; Mercon LV for 6R80. Check manual for exact specifications.
Transfer Case Fluid:
ATF (Automatic Transmission Fluid) or specific transfer case fluid depending on model/transfer case type. Consult manual.
📐 Dimensions
Exterior
Wheelbase:
Varies by cab style and bed length (e.g., 126.0 in, 133.0 in, 145.5 in, 150.5 in).
Overall Length:
Varies significantly by configuration.
Cargo
Bed Lengths:
Available in various lengths: 5.5 ft (Short Bed), 6.5 ft (Standard Bed), 8 ft (Long Bed).
Weights
Curb Weight:
Varies greatly by configuration, typically ranging from 4,500 lbs to 5,500 lbs+
Payload Capacity:
Up to approximately 3,100 lbs, depending on configuration and options.
Towing Capacity:
Up to approximately 11,000 lbs, depending on configuration, engine, axle ratio, and towing package.
🛡️ Safety Features
Ratings
NHTSA Front Crash:
Generally rated 4 or 5 stars for driver and passenger front crash protection (check specific model year and configuration).
IIHS Side Crash:
Good ratings for side crash protection often achieved.
Active Features
ABS:
Standard Anti-lock Braking System (ABS).
Traction Control:
Traction control system (TCS) available on many models.
Stability Control:
AdvanceTrac with Roll Stability Control (RSC) became increasingly available or standard during this generation.
Passive Features
Airbags:
Front airbags, side-impact airbags, and available side-curtain airbags.
💡 Technology Features
Infotainment
Audio System:
Base AM/FM/CD, optional SiriusXM satellite radio, premium sound systems available.
Navigation:
Optional factory navigation system available on higher trim levels.
Driver Assistance
Cruise Control:
Standard cruise control, adaptive cruise control not typically available in this generation.
Connectivity
Bluetooth:
Available SYNC infotainment system with Bluetooth hands-free calling and audio streaming introduced during this generation.
Convenience
Remote Start:
Optional remote start system.
Backup Camera:
Rearview camera system became available as an option on later models within this generation.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 5,000 miles or 6 months, or as indicated by the Intelligent Oil Life Monitor (IOLM) system if equipped.
Transmission Fluid Change:
Recommended every 30,000-60,000 miles depending on usage (towing, heavy loads). Consult manual for specific interval.
Coolant Flush:
Typically every 30,000-100,000 miles depending on coolant type and manufacturer recommendation.
Fluid Specifications
Engine Oil Type:
SAE 5W-20 (most common for V8 engines), SAE 5W-30 for some applications. Always verify with the owner's manual or oil filler cap.
5.4L 3V Triton engines are notorious for spark plug issues (breaking off during removal). Requires special tools and procedure, detailed in the manual.
Cam Phasers Timing Chain:
Common wear item on the 5.4L 3V engines, leading to ticking noises and potential performance issues.
Transmission Shifts:
Some transmissions may exhibit hard shifting or delayed engagement, often resolvable with fluid changes or control module updates.
Exhaust Manifold Studs:
Can break during exhaust manifold removal, especially on V8 engines. Manual provides best practices.
📚 Vehicle History
Brand Heritage
Ford Trucks:
Ford has a long and storied history in the pickup truck market, with the F-Series being a flagship product for decades.
Model Evolution
11Th Gen Introduction:
The 11th generation (2004-2008) represented a significant redesign from the previous generation, featuring a bolder exterior styling, revised interior, and updated powertrains.
Major Updates:
Introduction of the Super Duty-inspired styling, improved interior comfort, and the availability of the 3-valve Triton V8 engines and the 6-speed automatic transmission.
Production
Manufacturing Locations:
Primarily assembled in North America, with major plants in Dearborn, Michigan, and Kansas City, Missouri.
Sales Figures:
Consistently one of the best-selling vehicles in the United States and Canada throughout this period.
🏆 Awards & Recognition
Recognitions
Motor Trend Truck Of The Year:
The Ford F-150 has won MotorTrend's Truck of the Year award multiple times, including likely for models within this generation's lifecycle.
Consumers Guide Best Buy:
Often recognized as a best buy in the full-size truck segment by automotive publications.
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