2004 Ford TAURUS SABLE Workshop Service Repair Manual
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🏷️ Basic Information Identification Make: Ford Model: Taurus Model Variant: Sable Year: 2004 Generation Generation Designation: Fourth Generation (D3) Codes Chassis Code: DG3 👋 Introduction Market Position Target Audience: DIY enthusiasts, independent repair shops, and Ford owners seeking in-depth technical knowledge. Competitive Analysis Comparison To Owner Manual: Significantly more detailed and technically oriented than the standard owner's manual. Comparison To Software Manuals: Provides direct OEM data without software installation or compatibility issues. Key Features Content Exclusivity: Single-year specific OEM data, not a generalized generation manual. Illustration Detail: Includes detailed illustrations to aid in repair procedures. Accessibility: Easy to use, no installation required, readily searchable. 📋 Manual Details Coverage Areas Primary Coverage: North America Secondary Coverage: Global markets with applicable variations Page Count Estimated Page Count: ~2000-3000 (estimated for comprehensive OEM workshop manual) Manual Type Type: Workshop Service Repair Manual Content Type: OEM (Original Equipment Manufacturer) Specific Language Language: English Format Format: PDF Download File Size Mb: ~100 MB Software Requirement: None (standalone PDF) 📖 Manual Coverage Systems Covered Engine: Complete diagnosis, repair, and overhaul of all engine variants including timing components, cooling, lubrication, fuel, and emission control systems. Transmission: Detailed procedures for automatic transmission (e.g., AX4N/AX4S depending on engine) service, repair, and component replacement; including torque converter, valve body, and clutch pack diagnostics. Brakes: Front and rear brake system service, repair, and bleeding procedures, including ABS (Anti-lock Braking System) diagnostics and component replacement (e.g., master cylinder, calipers, rotors, pads). Suspension: Front and rear suspension system diagnostics, alignment procedures, component replacement (struts, shocks, control arms, ball joints, tie rods), and wheel bearing service. Steering: Power steering system service, rack and pinion repair, and steering column component replacement. Electrical: Comprehensive electrical schematics, wiring diagrams, diagnostic trouble codes (DTCs), and troubleshooting for all vehicle electrical systems including lighting, power windows, locks, mirrors, and accessories. HVAC: Air conditioning system service, refrigerant handling, component replacement (compressor, condenser, evaporator), and climate control system diagnostics. Safety Systems: Airbag system diagnosis, SRS (Supplemental Restraint System) component replacement, and seat belt service. Bodywork: Body panel repair, door and latch mechanism service, exterior trim replacement, and interior trim panel removal/installation. Diagnostic Systems: OBD-II (On-Board Diagnostics II) procedures, generic and manufacturer-specific DTC interpretation, and diagnostic tool usage. Procedures Included Routine Maintenance: Oil and filter changes, fluid level checks and top-offs, tire rotation and pressure checks, brake pad/rotor inspection. Major Repairs: Engine component replacement (alternator, starter, water pump), transmission overhaul, brake caliper replacement, suspension strut replacement. Troubleshooting: Systematic diagnostic approaches for common and complex vehicle issues. Rebuilding: Engine and transmission rebuilding procedures, including torque specifications and clearances. Installation: Procedures for installing replacement parts and accessories. Technical Depth Depth: Comprehensive: from basic DIY tasks to advanced professional-level diagnostics and repairs. Detail Level: Detailed step-by-step instructions with illustrations and diagrams. 📊 Manual Specifications File Format Type: PDF (Portable Document Format) Searchability: Searchable text content via keywords Navigation: Bookmarked for easy chapter navigation Print Quality Printability: Printable pages Binding Type Binding Type: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Type 1: 3.0L Duratec V6 Engine Code 1: Requires specific VIN lookup for exact code Displacement 1: 183 cu in (2998 cc) Horsepower 1: 200 hp @ 6000 rpm (approx.) Torque 1: 200 lb-ft @ 4000 rpm (approx.) Fuel System Fuel Delivery 1: Electronic Fuel Injection (EFI) Fuel Type 1: Unleaded Gasoline (87 octane recommended) Engine Type 2 Engine Type 2: 3.0L Vulcan V6 (less common in 2004 Sable, typically in base Taurus models) Displacement 2 Displacement 2: 182 cu in (2986 cc) Horsepower 2 Horsepower 2: 150 hp @ 5000 rpm (approx.) Torque 2 Torque 2: 170 lb-ft @ 3800 rpm (approx.) 🔧 Transmission Standard Transmission Type: 4-Speed Automatic (AX4N or similar) Optional Transmission Type: N/A for this model year Features Drive Type: Front-Wheel Drive (FWD) Fluid Specifications Transmission Fluid Type: MERCON V Automatic Transmission Fluid 📐 Dimensions Exterior Length: 197.7 inches Width: 72.9 inches Height: 57.6 inches Wheelbase: 112.9 inches Weights Curb Weight: ~3500-3700 lbs (depending on engine and options) Cargo Trunk Volume: 16.0 cubic feet 🛡️ Safety Features Ratings NHTSA Front Driver: Good (5-star) NHTSA Front Passenger: Good (5-star) NHTSA Side Driver: Good (5-star) NHTSA Side Rear Passenger: Good (5-star) IIHS Front Offset Crash: Good Active Features ABS: Standard Traction Control: Optional/Standard on certain trims Passive Features Airbags Front: Driver and Passenger Airbags (Front) Airbags Side: Optional/Standard Side Curtain Airbags Seatbelts: Front and Rear Seat Belts with Pretensioners 💡 Technology Features Infotainment Audio System: AM/FM stereo with CD player; optional premium sound systems (e.g., Mach 460) available. Display: Central dashboard display for audio and climate controls; optional navigation system for higher trims. Driver Assistance Cruise Control: Standard Parking Sensors: Optional Connectivity Auxiliary Input: N/A (pre-auxiliary era) Bluetooth: N/A 🔧 Maintenance Service Intervals Oil Change Interval: Every 5,000-7,500 miles or 6 months (severe vs. normal...
DIY enthusiasts, independent repair shops, and Ford owners seeking in-depth technical knowledge.
Competitive Analysis
Comparison To Owner Manual:
Significantly more detailed and technically oriented than the standard owner's manual.
Comparison To Software Manuals:
Provides direct OEM data without software installation or compatibility issues.
Key Features
Content Exclusivity:
Single-year specific OEM data, not a generalized generation manual.
Illustration Detail:
Includes detailed illustrations to aid in repair procedures.
Accessibility:
Easy to use, no installation required, readily searchable.
📋 Manual Details
Coverage Areas
Primary Coverage:
North America
Secondary Coverage:
Global markets with applicable variations
Page Count
Estimated Page Count:
~2000-3000 (estimated for comprehensive OEM workshop manual)
Manual Type
Type:
Workshop Service Repair Manual
Content Type:
OEM (Original Equipment Manufacturer) Specific
Language
Language:
English
Format
Format:
PDF Download
File Size Mb:
~100 MB
Software Requirement:
None (standalone PDF)
📖 Manual Coverage
Systems Covered
Engine:
Complete diagnosis, repair, and overhaul of all engine variants including timing components, cooling, lubrication, fuel, and emission control systems.
Transmission:
Detailed procedures for automatic transmission (e.g., AX4N/AX4S depending on engine) service, repair, and component replacement; including torque converter, valve body, and clutch pack diagnostics.
Brakes:
Front and rear brake system service, repair, and bleeding procedures, including ABS (Anti-lock Braking System) diagnostics and component replacement (e.g., master cylinder, calipers, rotors, pads).
Suspension:
Front and rear suspension system diagnostics, alignment procedures, component replacement (struts, shocks, control arms, ball joints, tie rods), and wheel bearing service.
Steering:
Power steering system service, rack and pinion repair, and steering column component replacement.
Electrical:
Comprehensive electrical schematics, wiring diagrams, diagnostic trouble codes (DTCs), and troubleshooting for all vehicle electrical systems including lighting, power windows, locks, mirrors, and accessories.
HVAC:
Air conditioning system service, refrigerant handling, component replacement (compressor, condenser, evaporator), and climate control system diagnostics.
Safety Systems:
Airbag system diagnosis, SRS (Supplemental Restraint System) component replacement, and seat belt service.
Bodywork:
Body panel repair, door and latch mechanism service, exterior trim replacement, and interior trim panel removal/installation.
Diagnostic Systems:
OBD-II (On-Board Diagnostics II) procedures, generic and manufacturer-specific DTC interpretation, and diagnostic tool usage.
Procedures Included
Routine Maintenance:
Oil and filter changes, fluid level checks and top-offs, tire rotation and pressure checks, brake pad/rotor inspection.
Systematic diagnostic approaches for common and complex vehicle issues.
Rebuilding:
Engine and transmission rebuilding procedures, including torque specifications and clearances.
Installation:
Procedures for installing replacement parts and accessories.
Technical Depth
Depth:
Comprehensive: from basic DIY tasks to advanced professional-level diagnostics and repairs.
Detail Level:
Detailed step-by-step instructions with illustrations and diagrams.
📊 Manual Specifications
File Format
Type:
PDF (Portable Document Format)
Searchability:
Searchable text content via keywords
Navigation:
Bookmarked for easy chapter navigation
Print Quality
Printability:
Printable pages
Binding Type
Binding Type:
N/A (Digital PDF)
Paper Type
Paper Type:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Type 1:
3.0L Duratec V6
Engine Code 1:
Requires specific VIN lookup for exact code
Displacement 1:
183 cu in (2998 cc)
Horsepower 1:
200 hp @ 6000 rpm (approx.)
Torque 1:
200 lb-ft @ 4000 rpm (approx.)
Fuel System
Fuel Delivery 1:
Electronic Fuel Injection (EFI)
Fuel Type 1:
Unleaded Gasoline (87 octane recommended)
Engine Type 2
Engine Type 2:
3.0L Vulcan V6 (less common in 2004 Sable, typically in base Taurus models)
Displacement 2
Displacement 2:
182 cu in (2986 cc)
Horsepower 2
Horsepower 2:
150 hp @ 5000 rpm (approx.)
Torque 2
Torque 2:
170 lb-ft @ 3800 rpm (approx.)
🔧 Transmission
Standard
Transmission Type:
4-Speed Automatic (AX4N or similar)
Optional
Transmission Type:
N/A for this model year
Features
Drive Type:
Front-Wheel Drive (FWD)
Fluid Specifications
Transmission Fluid Type:
MERCON V Automatic Transmission Fluid
📐 Dimensions
Exterior
Length:
197.7 inches
Width:
72.9 inches
Height:
57.6 inches
Wheelbase:
112.9 inches
Weights
Curb Weight:
~3500-3700 lbs (depending on engine and options)
Cargo
Trunk Volume:
16.0 cubic feet
🛡️ Safety Features
Ratings
NHTSA Front Driver:
Good (5-star)
NHTSA Front Passenger:
Good (5-star)
NHTSA Side Driver:
Good (5-star)
NHTSA Side Rear Passenger:
Good (5-star)
IIHS Front Offset Crash:
Good
Active Features
ABS:
Standard
Traction Control:
Optional/Standard on certain trims
Passive Features
Airbags Front:
Driver and Passenger Airbags (Front)
Airbags Side:
Optional/Standard Side Curtain Airbags
Seatbelts:
Front and Rear Seat Belts with Pretensioners
💡 Technology Features
Infotainment
Audio System:
AM/FM stereo with CD player; optional premium sound systems (e.g., Mach 460) available.
Display:
Central dashboard display for audio and climate controls; optional navigation system for higher trims.
Driver Assistance
Cruise Control:
Standard
Parking Sensors:
Optional
Connectivity
Auxiliary Input:
N/A (pre-auxiliary era)
Bluetooth:
N/A
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000-7,500 miles or 6 months (severe vs. normal driving, check manual for specific recommendation)
Transmission Fluid Change:
Every 60,000-100,000 miles (refer to manual for specific interval based on usage)
Coolant Flush:
Every 100,000 miles or 5 years
Spark Plug Replacement:
100,000 miles (Duratec V6)
Fluid Specifications
Engine Oil Type:
SAE 5W-20 (Synthetic Blend or Full Synthetic recommended)
Engine Oil Capacity:
5.5 US quarts (with filter) for 3.0L Duratec V6
Coolant Type:
Ford Premium Engine Coolant (Orange) or equivalent (50/50 mix with distilled water)
Brake Fluid Type:
DOT 3
Power Steering Fluid Type:
Mercon ATF or Ford specified power steering fluid
Known Issues
Ignition Coils:
Premature failure of ignition coils on Duratec V6 engines is a common complaint.
Transmission Issues:
Some units experienced rough shifting or premature wear, particularly the AX4N transmission.
Powertrain Control Module:
Occasional issues with the PCM requiring recalibration or replacement.
Wheel Bearings:
Front wheel bearings can be a wear item.
HVAC Blend Door Actuators:
Failure of blend door actuators leading to improper climate control.
📚 Vehicle History
Brand Heritage
Ford History:
Ford Motor Company, founded by Henry Ford, is one of the oldest and largest automobile manufacturers in the world, known for its innovation and mass production techniques.
Model Evolution
Taurus History:
The Ford Taurus was a groundbreaking model upon its introduction in 1986, significantly influencing automotive design. The 2004 model is part of the fourth generation (D3 platform), sharing its underpinnings with the Mercury Sable and Lincoln LS, representing a shift towards European-influenced styling and engineering.
Production
Production Years For Generation:
2000-2007
Manufacturing Locations:
Chicago, Illinois, USA (Primary)
🏆 Awards & Recognition
Recognitions
Safety Awards:
Achieved 'Good' ratings in NHTSA and IIHS crash tests for its era.
Design Awards:
The D3 platform vehicles were generally praised for improved styling and driving dynamics compared to previous generations.