2009 Ford F-450 F450 Super Duty Workshop Repair Manual
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🏷️ Basic Information Identification Make: Ford Model: F-450 Super Duty Year: 2009 Codes Chassis Code: P473 👋 Introduction Market Position Target Audience: Designed for F-450 Super Duty owners and independent repair shops performing DIY repairs, maintenance, and diagnostics. Value Proposition: Provides dealership-level repair information in an accessible digital format, empowering users to perform their own service. Competitive Analysis Comparison To Owner Manual: Significantly more detailed than the owner's manual, focusing on repair and service procedures rather than basic operation. Comparison To Software Manuals: Offers a streamlined, non-software dependent solution for accessing comprehensive repair data. Key Features Single Year Specificity: Guarantees accuracy and relevance by focusing solely on the 2009 model year, avoiding information for other generations. Diagnostic Codes: Includes coverage of computer diagnostic codes for effective troubleshooting. Support: Offers customer support for product-related issues and questions. 📋 Manual Details Coverage Areas Manual Type: Workshop Repair Manual Language: English Format: PDF (Single File) Delivery Method: Digital Download File Size: Approx. 100 MB Page Count Estimated Pages: Hundreds of pages (specific count not provided, but described as comprehensive). 📖 Manual Coverage Systems Covered Engine: Includes detailed procedures for the 6.4L Power Stroke V8 Turbo Diesel and 5.4L Triton V8 gasoline engines, including diagnostics, repair, and overhaul. Transmission: Covers both the 5R110W TorqShift Automatic and the ZF6-650 6-Speed Manual transmissions, including removal, installation, internal repairs, and fluid services. Drivetrain: Detailed information on front and rear axle assemblies, transfer case, driveshafts, U-joints, and differential servicing. Suspension: Covers front and rear suspension components, including springs, shock absorbers, control arms, ball joints, steering linkage, and alignment procedures. Brakes: Comprehensive coverage of hydraulic brake systems, including master cylinder, brake lines, calipers, pads, rotors, ABS system, and parking brake. Electrical System: Extensive wiring schematics, electrical diagrams for all systems, component testing, troubleshooting guides, and connector information. Body And Frame: Information on body panel repair, door mechanisms, tailgate, interior trim, glass replacement, and frame alignment. Heating Ventilation Air Conditioning: Service and repair procedures for the HVAC system, including refrigerant handling, component replacement, and troubleshooting. Safety Systems: Detailed coverage of airbag system diagnostics, SRS components, and related safety features. Diagnostics: Information on diagnostic trouble codes (DTCs), scan tool usage, and component-level diagnostic procedures. Procedures Included Maintenance: Routine maintenance procedures such as oil changes, filter replacements, fluid checks and top-offs, tire rotation, and lubrication. Troubleshooting: Systematic troubleshooting guides for common and uncommon issues, enabling effective diagnosis and repair. Repair: Step-by-step instructions for minor and major mechanical and electrical repairs, including component replacement and adjustments. Rebuilding: Procedures for rebuilding major components like transmissions, engines, and differentials, including detailed exploded views. Installation: Guidelines for installing new components and accessories. Calibration: Procedures for calibrating sensors and modules after component replacement (e.g., steering angle sensor). Technical Depth Level Of Detail: OEM-level detail, suitable for professional technicians and advanced DIYers. Illustrations: Includes detailed, high-quality illustrations, diagrams, and exploded views to clarify procedures. Searchability: Fully searchable PDF content with integrated bookmarks for easy navigation and keyword-based access. 📊 Manual Specifications File Format Type: Portable Document Format (PDF) Requirements: No software installation required; compatible with standard PDF readers. Print Quality Resolution: High-resolution, suitable for clear viewing and printing of diagrams and text. Binding Type Digital: N/A (Digital File) Paper Type Digital: N/A (Digital File) ⚙️ Engine Specifications Primary Engine Diesel Engine Code: 6.4L OHV V8 Power Stroke Turbo Diesel Displacement: 390 cubic inches (6.4 Liters) Fuel System: High-pressure Common Rail (HPCR) direct injection, Denso fuel system. Turbocharging: Sequential Twin Turbochargers (STT) Horsepower Peak: 350 HP @ 3,000 RPM (approx.) Torque Peak: 650 lb-ft @ 1,600 RPM (approx.) Primary Engine Gasoline Engine Code: 5.4L OHV V8 Triton Displacement: 330 cubic inches (5.4 Liters) Fuel System: Sequential Electronic Fuel Injection (SEFI) Horsepower Peak: 362 HP @ 5,000 RPM (approx.) Torque Peak: 455 lb-ft @ 3,500 RPM (approx.) 🔧 Transmission Automatic Type: 5R110W TorqShift Automatic Features: Electronically controlled, heavy-duty, 5-speed with overdrive and Tow/Haul mode. Fluid Type: Mercon SP (Specify Mercon V for older 5R110W if applicable, but SP is standard for 2009) Manual Type: ZF6-650 6-Speed Manual Fluid Type: Mercon LV ATF (Mercon V can be substituted if LV is unavailable, check service bulletin) 📐 Dimensions Exterior Crew Cab Long Bed Wheelbase: 172.4 inches Overall Length: 263.7 inches Overall Width: 97.2 inches (without mirrors) Overall Height: 80.0 inches Weights Gvwr: 14,500 lbs (approx.) Gcwr: Up to 26,000 lbs (with appropriate trailer/hitch) Curb Weight: 6,500 - 7,500 lbs (depending on configuration) 🛡️ Safety Features Ratings NHTSA Rollover Resistance: 3-star (typical for heavy-duty trucks of this era, consult NHTSA for specific test data) Active Features ABS: Standard Anti-lock Braking System (ABS) Trailer Sway Control: Available Trailer Sway Control (TSC) Passive Features Airbags: Front airbags for driver and passenger. Seatbelts: Three-point safety belts with pretensioners. 💡 Technology Features Infotainment Audio System: Available AM/FM stereo with CD player, auxiliary input, and SiriusXM Satellite Radio....
Designed for F-450 Super Duty owners and independent repair shops performing DIY repairs, maintenance, and diagnostics.
Value Proposition:
Provides dealership-level repair information in an accessible digital format, empowering users to perform their own service.
Competitive Analysis
Comparison To Owner Manual:
Significantly more detailed than the owner's manual, focusing on repair and service procedures rather than basic operation.
Comparison To Software Manuals:
Offers a streamlined, non-software dependent solution for accessing comprehensive repair data.
Key Features
Single Year Specificity:
Guarantees accuracy and relevance by focusing solely on the 2009 model year, avoiding information for other generations.
Diagnostic Codes:
Includes coverage of computer diagnostic codes for effective troubleshooting.
Support:
Offers customer support for product-related issues and questions.
📋 Manual Details
Coverage Areas
Manual Type:
Workshop Repair Manual
Language:
English
Format:
PDF (Single File)
Delivery Method:
Digital Download
File Size:
Approx. 100 MB
Page Count
Estimated Pages:
Hundreds of pages (specific count not provided, but described as comprehensive).
📖 Manual Coverage
Systems Covered
Engine:
Includes detailed procedures for the 6.4L Power Stroke V8 Turbo Diesel and 5.4L Triton V8 gasoline engines, including diagnostics, repair, and overhaul.
Transmission:
Covers both the 5R110W TorqShift Automatic and the ZF6-650 6-Speed Manual transmissions, including removal, installation, internal repairs, and fluid services.
Drivetrain:
Detailed information on front and rear axle assemblies, transfer case, driveshafts, U-joints, and differential servicing.
Suspension:
Covers front and rear suspension components, including springs, shock absorbers, control arms, ball joints, steering linkage, and alignment procedures.
Brakes:
Comprehensive coverage of hydraulic brake systems, including master cylinder, brake lines, calipers, pads, rotors, ABS system, and parking brake.
Electrical System:
Extensive wiring schematics, electrical diagrams for all systems, component testing, troubleshooting guides, and connector information.
Body And Frame:
Information on body panel repair, door mechanisms, tailgate, interior trim, glass replacement, and frame alignment.
Heating Ventilation Air Conditioning:
Service and repair procedures for the HVAC system, including refrigerant handling, component replacement, and troubleshooting.
Safety Systems:
Detailed coverage of airbag system diagnostics, SRS components, and related safety features.
Diagnostics:
Information on diagnostic trouble codes (DTCs), scan tool usage, and component-level diagnostic procedures.
Procedures Included
Maintenance:
Routine maintenance procedures such as oil changes, filter replacements, fluid checks and top-offs, tire rotation, and lubrication.
Troubleshooting:
Systematic troubleshooting guides for common and uncommon issues, enabling effective diagnosis and repair.
Repair:
Step-by-step instructions for minor and major mechanical and electrical repairs, including component replacement and adjustments.
Rebuilding:
Procedures for rebuilding major components like transmissions, engines, and differentials, including detailed exploded views.
Installation:
Guidelines for installing new components and accessories.
Calibration:
Procedures for calibrating sensors and modules after component replacement (e.g., steering angle sensor).
Technical Depth
Level Of Detail:
OEM-level detail, suitable for professional technicians and advanced DIYers.
Illustrations:
Includes detailed, high-quality illustrations, diagrams, and exploded views to clarify procedures.
Searchability:
Fully searchable PDF content with integrated bookmarks for easy navigation and keyword-based access.
📊 Manual Specifications
File Format
Type:
Portable Document Format (PDF)
Requirements:
No software installation required; compatible with standard PDF readers.
Print Quality
Resolution:
High-resolution, suitable for clear viewing and printing of diagrams and text.
Binding Type
Digital:
N/A (Digital File)
Paper Type
Digital:
N/A (Digital File)
⚙️ Engine Specifications
Primary Engine Diesel
Engine Code:
6.4L OHV V8 Power Stroke Turbo Diesel
Displacement:
390 cubic inches (6.4 Liters)
Fuel System:
High-pressure Common Rail (HPCR) direct injection, Denso fuel system.
Turbocharging:
Sequential Twin Turbochargers (STT)
Horsepower Peak:
350 HP @ 3,000 RPM (approx.)
Torque Peak:
650 lb-ft @ 1,600 RPM (approx.)
Primary Engine Gasoline
Engine Code:
5.4L OHV V8 Triton
Displacement:
330 cubic inches (5.4 Liters)
Fuel System:
Sequential Electronic Fuel Injection (SEFI)
Horsepower Peak:
362 HP @ 5,000 RPM (approx.)
Torque Peak:
455 lb-ft @ 3,500 RPM (approx.)
🔧 Transmission
Automatic
Type:
5R110W TorqShift Automatic
Features:
Electronically controlled, heavy-duty, 5-speed with overdrive and Tow/Haul mode.
Fluid Type:
Mercon SP (Specify Mercon V for older 5R110W if applicable, but SP is standard for 2009)
Manual
Type:
ZF6-650 6-Speed Manual
Fluid Type:
Mercon LV ATF (Mercon V can be substituted if LV is unavailable, check service bulletin)
📐 Dimensions
Exterior Crew Cab Long Bed
Wheelbase:
172.4 inches
Overall Length:
263.7 inches
Overall Width:
97.2 inches (without mirrors)
Overall Height:
80.0 inches
Weights
Gvwr:
14,500 lbs (approx.)
Gcwr:
Up to 26,000 lbs (with appropriate trailer/hitch)
Curb Weight:
6,500 - 7,500 lbs (depending on configuration)
🛡️ Safety Features
Ratings
NHTSA Rollover Resistance:
3-star (typical for heavy-duty trucks of this era, consult NHTSA for specific test data)
Active Features
ABS:
Standard Anti-lock Braking System (ABS)
Trailer Sway Control:
Available Trailer Sway Control (TSC)
Passive Features
Airbags:
Front airbags for driver and passenger.
Seatbelts:
Three-point safety belts with pretensioners.
💡 Technology Features
Infotainment
Audio System:
Available AM/FM stereo with CD player, auxiliary input, and SiriusXM Satellite Radio. Higher trims may offer upgraded sound systems.
Driver Assistance
Towing Features:
Integrated trailer brake controller (optional), Tow/Haul mode for transmission, trailer hitch and wiring provisions.
Parking Assist:
Rear parking sensors (optional on some trims).
Connectivity
Power Outlets:
12V auxiliary power outlets.
🔧 Maintenance
Service Intervals Diesel
Engine Oil And Filter:
Every 5,000 to 7,500 miles or 6 months, or as indicated by the oil life monitoring system, depending on operating conditions (severe duty may require more frequent changes).
Fuel Filter:
Every 15,000 to 30,000 miles, or as recommended by Ford, particularly important for diesel fuel quality.
Engine Coolant:
Initial change at 50,000 miles, then every 25,000 miles or 2 years thereafter (using Ford Gold Coolant or equivalent).
Service Intervals Gasoline
Engine Oil And Filter:
Every 5,000 miles or 6 months, or as indicated by the oil life monitoring system.
Engine Coolant:
Initial change at 100,000 miles, then every 50,000 miles or 5 years thereafter (using Ford Premium Gold Coolant or equivalent).
Fluid Specifications
Engine Oil Diesel:
API CJ-4 (or preferred specification for 2009 6.4L Power Stroke), SAE 15W-40 (or 5W-40 synthetic for colder climates).
Engine Oil Gasoline:
API SN or SP, SAE 5W-20
Brake Fluid:
DOT 3 (refer to specific reservoir cap for exact type)
Known Issues
Diesel Egr And Dpf:
The 6.4L Power Stroke engine can be prone to EGR cooler failures and Diesel Particulate Filter (DPF) clogging if not maintained or driven properly (e.g., frequent short trips).
Transmission Shifting:
Some automatic transmissions may exhibit harsh shifting or torque converter issues; manual transmissions are generally robust.
📚 Vehicle History
Brand Heritage
Ford Trucks:
Ford has a long-standing reputation for building durable and capable trucks, dating back to the early 20th century.
Model Evolution
F Series Super Duty:
The Super Duty line, introduced in 1999, represents Ford's heavy-duty truck offerings, positioned above the F-150. The F-450 is a Class 4 truck designed for commercial and heavy towing/hauling applications.
2009 Updates:
The 2009 model year falls within the second generation of the Super Duty (2008-2010), which saw significant updates including the introduction of the 6.4L Power Stroke diesel and revised styling.
🏆 Awards & Recognition
Recognitions
Segment Awards:
Ford Super Duty trucks consistently receive accolades in the heavy-duty pickup segment for towing, hauling, and overall capability.
Ratings
Consumer Reports:
While specific ratings vary, Ford Super Duty trucks are generally recognized for their robust build and performance in their class.
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