Ford F150 2004 to 2008 Factory Workshop Service Repair Manual
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🏷️ Basic Information Identification Make: Ford Model: F-150 Generation: 12th Generation Production Years Covered: 2004, 2005, 2006, 2007, 2008 Codes Platform: P242 👋 Introduction Market Position Segment: Full-size Pickup Truck Reputation: Known for its robust build, capability, and versatility in work and personal use. Competitive Analysis Competitors: Chevrolet Silverado, Ram 1500, Toyota Tundra, GMC Sierra. Key Features Engine Options: Range of powerful V8 engines and a capable V6 option. Towing Hauling: Class-leading towing and payload capacities. Durability: Renowned for its toughness and longevity. Customization: Wide variety of trim levels, cab configurations, and bed lengths. 📋 Manual Details Coverage Areas Systems Covered: Engine Mechanical, Engine Fuel & Emission Control, Transmission (Automatic & Manual), Driveline, Suspension, Steering, Brakes (ABS/Non-ABS), Wheels & Tires, Body & Frame, HVAC, Electrical System, Powertrain Control Module (PCM), Body Control Module (BCM), Restraints (Airbag), Lighting, Audio Systems, Navigation Systems, Diagnostic Procedures, Troubleshooting Guides, Wiring Diagrams, Torque Specifications, Lubrication and Maintenance, Cooling System, Starting System, Charging System, Ignition System, Exhaust System, Fuel Tank & Lines, Transfer Case (4WD models), Drive Shafts, Axles, Front Axle, Rear Axle, Wheel Bearings, Power Steering, Steering Column, Power Rack and Pinion, Disc Brakes, Drum Brakes, Parking Brake, Anti-lock Brake System (ABS), Traction Control System (TCS), Electronic Stability Control (ESC - if equipped), Body Panels, Doors, Hood, Tailgate, Bumpers, Interior Trim, Seats, Restraint Systems, Climate Control, Interior Lighting, Exterior Lighting, Battery, Alternator, Starter Motor, Fuses and Relays, Engine Control Unit (ECU), Powertrain Control Module (PCM), Body Control Module (BCM), Instrument Cluster, Audio Unit, Navigation Unit, Power Windows, Power Locks, Wiper System, Horn, Airbag System, Seatbelt Pretensioners, Diagnostic Trouble Codes (DTCs), Software Updates, Component Location Charts, Exploded Views, Tightening Torques, Fluid Types and Capacities Procedures Included: Routine Maintenance, Scheduled Maintenance, Engine Tune-up, Oil Change, Filter Replacement, Spark Plug Replacement, Coolant Flush, Brake Service (Pad/Rotor Replacement, Fluid Flush), Suspension Component Replacement (Shocks, Struts, Ball Joints, Tie Rods), Steering Component Repair, Driveline Component Service, Transmission Service (Fluid/Filter Change, Rebuild Procedures), Electrical System Diagnosis, Wiring Harness Repair, Body Panel Alignment and Repair, HVAC System Diagnosis and Repair, Lighting System Repair, Battery Testing and Replacement, Starter and Alternator Testing, Fuel System Cleaning and Diagnosis, Emission Control System Diagnosis, ABS/TCS/ESC System Diagnosis, Diagnostic Trouble Code (DTC) Retrieval and Interpretation, Component Testing and Replacement, Torque Specifications for all fasteners, Troubleshooting for common drivability issues, Overhaul and rebuild procedures for major components. Page Count Total Pages: Approximately 2,000+ Manual Type Type: Factory Workshop Service and Repair Manual Language Language: English Format Format: Digital (PDF) 📖 Manual Coverage Systems Covered Powertrain: Comprehensive coverage of all engine variants, automatic and manual transmissions, driveline components including transfer case and axles. Chassis: In-depth coverage of suspension, steering systems, brake systems (including ABS, TCS, ESC), wheels, and tires. Electrical: Detailed wiring diagrams, component testing, diagnostic procedures for all electrical systems including PCM, BCM, lighting, audio, and power accessories. Body: Coverage for interior and exterior body panels, doors, hood, tailgate, bumpers, glass, and trim components. HVAC: Complete diagnosis and repair procedures for the heating, ventilation, and air conditioning system. Safety Restraint: Detailed information on airbag systems, seatbelt pretensioners, and associated sensors and modules. Procedures Included Diagnostics: Extensive diagnostic flowcharts, symptom-based troubleshooting, and DTC code explanations. Repair: Step-by-step repair procedures for all major and minor components, including rebuilds. Maintenance: Detailed routine and scheduled maintenance tasks, fluid specifications, and service intervals. Component Replacement: Clear instructions for removing, installing, and adjusting all vehicle components. Technical Specifications: Inclusion of all necessary torque values, clearances, fluid capacities, and electrical specifications. Technical Depth Depth: Factory-level diagnostic and repair procedures, suitable for professional technicians and experienced DIYers. Scope: Covers everything from basic fluid changes and filter replacements to complete engine and transmission overhauls. Detail Level: Includes detailed explanations of system operation, component function, and diagnostic logic. 📊 Manual Specifications File Format Type: PDF Searchability: Searchable text for quick information retrieval. Resolution: High-resolution images and diagrams for clarity. Accessibility: Viewable on computers, tablets, and smartphones. Print Quality Quality: N/A (Digital Format) Binding Type Type: N/A (Digital Format) Paper Type Type: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine 1: 4.6L Triton V8 Engine 1 Power: 232 hp @ 4,500 rpm Engine 1 Torque: 291 lb-ft @ 3,500 rpm Engine 2: 5.4L Triton V8 (3-valve) Engine 2 Power: 300 hp @ 5,000 rpm Engine 2 Torque: 365 lb-ft @ 3,750 rpm Engine 3: 4.6L Triton V8 (3-valve - later models) Engine 3 Power: 248 hp @ 4,750 rpm Engine 3 Torque: 294 lb-ft @ 4,000 rpm Engine 4: 5.4L Triton V8 (3-valve - Supercharged - SVT Raptor, Shelby) Engine 4 Power: 500 hp @ 5,000 rpm (Shelby) / 310 hp @ 5,000 rpm (Raptor) Engine 4 Torque: 500 lb-ft @ 3,250 rpm (Shelby) / 365 lb-ft @ 3,000 rpm (Raptor) Engine 5: 4.2L Essex V6 (early models) Engine 5 Power: 202 hp @ 4,800 rpm Engine 5...
Known for its robust build, capability, and versatility in work and personal use.
Competitive Analysis
Competitors:
Chevrolet Silverado, Ram 1500, Toyota Tundra, GMC Sierra.
Key Features
Engine Options:
Range of powerful V8 engines and a capable V6 option.
Towing Hauling:
Class-leading towing and payload capacities.
Durability:
Renowned for its toughness and longevity.
Customization:
Wide variety of trim levels, cab configurations, and bed lengths.
📋 Manual Details
Coverage Areas
Systems Covered:
Engine Mechanical, Engine Fuel & Emission Control, Transmission (Automatic & Manual), Driveline, Suspension, Steering, Brakes (ABS/Non-ABS), Wheels & Tires, Body & Frame, HVAC, Electrical System, Powertrain Control Module (PCM), Body Control Module (BCM), Restraints (Airbag), Lighting, Audio Systems, Navigation Systems, Diagnostic Procedures, Troubleshooting Guides, Wiring Diagrams, Torque Specifications, Lubrication and Maintenance, Cooling System, Starting System, Charging System, Ignition System, Exhaust System, Fuel Tank & Lines, Transfer Case (4WD models), Drive Shafts, Axles, Front Axle, Rear Axle, Wheel Bearings, Power Steering, Steering Column, Power Rack and Pinion, Disc Brakes, Drum Brakes, Parking Brake, Anti-lock Brake System (ABS), Traction Control System (TCS), Electronic Stability Control (ESC - if equipped), Body Panels, Doors, Hood, Tailgate, Bumpers, Interior Trim, Seats, Restraint Systems, Climate Control, Interior Lighting, Exterior Lighting, Battery, Alternator, Starter Motor, Fuses and Relays, Engine Control Unit (ECU), Powertrain Control Module (PCM), Body Control Module (BCM), Instrument Cluster, Audio Unit, Navigation Unit, Power Windows, Power Locks, Wiper System, Horn, Airbag System, Seatbelt Pretensioners, Diagnostic Trouble Codes (DTCs), Software Updates, Component Location Charts, Exploded Views, Tightening Torques, Fluid Types and Capacities
Procedures Included:
Routine Maintenance, Scheduled Maintenance, Engine Tune-up, Oil Change, Filter Replacement, Spark Plug Replacement, Coolant Flush, Brake Service (Pad/Rotor Replacement, Fluid Flush), Suspension Component Replacement (Shocks, Struts, Ball Joints, Tie Rods), Steering Component Repair, Driveline Component Service, Transmission Service (Fluid/Filter Change, Rebuild Procedures), Electrical System Diagnosis, Wiring Harness Repair, Body Panel Alignment and Repair, HVAC System Diagnosis and Repair, Lighting System Repair, Battery Testing and Replacement, Starter and Alternator Testing, Fuel System Cleaning and Diagnosis, Emission Control System Diagnosis, ABS/TCS/ESC System Diagnosis, Diagnostic Trouble Code (DTC) Retrieval and Interpretation, Component Testing and Replacement, Torque Specifications for all fasteners, Troubleshooting for common drivability issues, Overhaul and rebuild procedures for major components.
Page Count
Total Pages:
Approximately 2,000+
Manual Type
Type:
Factory Workshop Service and Repair Manual
Language
Language:
English
Format
Format:
Digital (PDF)
📖 Manual Coverage
Systems Covered
Powertrain:
Comprehensive coverage of all engine variants, automatic and manual transmissions, driveline components including transfer case and axles.
Chassis:
In-depth coverage of suspension, steering systems, brake systems (including ABS, TCS, ESC), wheels, and tires.
Electrical:
Detailed wiring diagrams, component testing, diagnostic procedures for all electrical systems including PCM, BCM, lighting, audio, and power accessories.
Body:
Coverage for interior and exterior body panels, doors, hood, tailgate, bumpers, glass, and trim components.
HVAC:
Complete diagnosis and repair procedures for the heating, ventilation, and air conditioning system.
Safety Restraint:
Detailed information on airbag systems, seatbelt pretensioners, and associated sensors and modules.
Procedures Included
Diagnostics:
Extensive diagnostic flowcharts, symptom-based troubleshooting, and DTC code explanations.
Repair:
Step-by-step repair procedures for all major and minor components, including rebuilds.
Maintenance:
Detailed routine and scheduled maintenance tasks, fluid specifications, and service intervals.
Component Replacement:
Clear instructions for removing, installing, and adjusting all vehicle components.
Technical Specifications:
Inclusion of all necessary torque values, clearances, fluid capacities, and electrical specifications.
Technical Depth
Depth:
Factory-level diagnostic and repair procedures, suitable for professional technicians and experienced DIYers.
Scope:
Covers everything from basic fluid changes and filter replacements to complete engine and transmission overhauls.
Detail Level:
Includes detailed explanations of system operation, component function, and diagnostic logic.
Motorcraft Premium Engine Coolant (Ford Gold Color) or equivalent.
Power Steering Fluid:
Mercon V or equivalent.
Brake Fluid:
DOT 3.
Known Issues
Spark Plug Fouling:
Especially on early 5.4L 3V engines, the spark plugs can break upon removal, requiring specialized extraction tools.
Cam Phaser/Timing Chain:
Issues with cam phasers and timing chain wear can cause knocking or rattling noises, particularly on the 5.4L 3V.
Throttle Body Issues:
Electronic throttle body problems can lead to rough idling or stalling.
Rear Main Seal Leaks:
Occasional leaks from the rear main crankshaft seal.
ABS/Brake System:
Wheel speed sensor failures can illuminate ABS and Traction Control lights.
📚 Vehicle History
Brand Heritage
Ford Truck Lineage:
The F-Series has been a dominant force in the pickup truck market for decades, consistently leading sales in North America.
Model Evolution
Generation Introduction:
The 12th generation F-150 was introduced for the 2004 model year, representing a significant redesign from the previous generation.
Key Updates During Generation:
Refreshes included updated styling, improved interior amenities, and powertrain enhancements, particularly the introduction of the 3-valve 5.4L Triton V8.
Production
Manufacturing Locations:
Ford's North American assembly plants, including Dearborn Truck Plant (Michigan) and Kansas City Assembly Plant (Missouri).
Sales Figures Trend:
Consistently one of the best-selling vehicles in North America throughout its production run.
🏆 Awards & Recognition
Recognitions
Motor Trend Truck Of The Year:
Ford F-150 was named MotorTrend's Truck of the Year for 2004 and 2009 (for the following generation, but recognizing the lineage).
Car And Driver:
Frequently listed on Car and Driver's '10Best' lists for trucks in various years.
Ratings
Consumer Reports:
Generally received good ratings for predicted reliability, though specific issues were noted and addressed by Ford.