2004 Ford E-350 Super Duty Service & Repair Manual
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🏷️ Basic Information Identification Make: Ford Model: E-350 Super Duty Year: 2004 Product Type: Service & Repair Manual Software Generation Generation: Sixth Generation (2003-2007) Codes Platform: VN 👋 Introduction Market Position Market Segment: Heavy-duty Commercial Van / Chassis Cab Target Audience: Fleet owners, professional mechanics, serious DIY enthusiasts Competitive Analysis Competitors: Chevrolet Express/GMC Savana, Ram ProMaster (though later generation) Key Features Licensing: Officially Licensed OE Material Content Source: Derived from original equipment (OE) manufacturer materials User Interface: Intuitive, push-button access to information Convenience: Online accessibility, no need for physical storage or transport of bulky manuals Value Proposition: Cost savings compared to traditional printed manuals and professional repair services 📋 Manual Details Coverage Areas Primary Coverage: Comprehensive Service and Repair Information Secondary Coverage: Maintenance, Diagnostics, Troubleshooting, Reassembly Page Count Estimated Page Count: Thousands of pages (typical for OE-derived digital manuals) Manual Type Manual Type: Digital Service and Repair Manual (Software) Language Language: English Format Format: Online Access (Web Browser Based) Access Duration: 1 Year Subscription Device Compatibility: PC, Laptop, Smartphone, Tablet 📖 Manual Coverage Systems Covered Engine Systems: Engine mechanicals, fuel and emissions, lubrication, cooling, ignition, starting and charging systems Drivetrain Systems: Manual and automatic transmissions, transfer case (if applicable), drive shafts, axles, differentials, hubs Chassis Systems: Suspension (front and rear), steering system, braking system (hydraulic and ABS), wheels and tires Electrical Systems: Wiring diagrams, lighting, instrumentation, power distribution, body and chassis electrical components, electronic modules HVAC Systems: Heating, Ventilation, and Air Conditioning (HVAC) system operation and repair Body And Interior: Body panels, doors, glass, seats, interior trim, safety restraints (airbags, seatbelts) Procedures Included Maintenance Procedures: Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspections and replacement, scheduled maintenance intervals Repair Procedures: Detailed step-by-step instructions for component removal, installation, and adjustment across all vehicle systems Diagnostic Procedures: Troubleshooting guides, fault code interpretations, diagnostic routines, wiring schematic analysis Special Tool Requirements: Identification and usage instructions for specialized tools required for specific repairs Wiring Diagrams: Comprehensive and detailed electrical schematics for all vehicle circuits Technical Depth Diagnostic Capability: Advanced diagnostic procedures, including symptom-based troubleshooting and electronic module diagnosis Rebuild Procedures: Detailed instructions for engine, transmission, and differential rebuilds Specifications Data: Torque specifications, clearances, fluid capacities, and other critical technical data 📊 Manual Specifications File Format File Format Details: Proprietary RepairSurge digital format, accessible via web browser Print Quality Print Quality Description: N/A (Digital Format) Binding Type Binding Type Description: N/A (Digital Format) Paper Type Paper Type Description: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Options 2004: 4.6L Triton V8, 5.4L Triton V8, 6.8L Triton V10, 7.3L Power Stroke V8 Turbo Diesel (specific availability may vary by configuration) Engine Displacement 4 6L: 4.6 Liters / 281 cu. in. Engine Displacement 5 4L: 5.4 Liters / 330 cu. in. Engine Displacement 6 8L: 6.8 Liters / 415 cu. in. Engine Displacement 7 3L Diesel: 7.3 Liters / 444 cu. in. Performance Horsepower 4 6L V8: Approx. 215-234 hp (depending on specific calibration) Torque 4 6L V8: Approx. 280-295 lb-ft (depending on specific calibration) Horsepower 5 4L V8: Approx. 255-260 hp Torque 5 4L V8: Approx. 350-355 lb-ft Horsepower 6 8L V10: Approx. 305 hp Torque 6 8L V10: Approx. 425 lb-ft Horsepower 7 3L Diesel: Approx. 215 hp Torque 7 3L Diesel: Approx. 440 lb-ft Fuel System Fuel Delivery Gasoline: Electronic Fuel Injection (EFI) with Sequential Port Injection Fuel Type Diesel: Diesel Fuel Fuel System Diesel: Direct Injection, Turbocharged with Intercooler 🔧 Transmission Standard Standard Transmission: 5-Speed Manual Transmission (M5OD-R2) Optional Optional Transmission Gasoline: 4-Speed Automatic Overdrive (4R70W for lighter duty, 4R100 for heavier duty) Optional Transmission Diesel: 5-Speed Automatic Overdrive (5R110W 'TorqShift') Features Automatic Transmission Features: Electronic controls, torque converter lock-up, tow/haul mode (on 4R100 and 5R110W) Transfer Case: Part-time 4WD system available (with manual or electronic shift) for certain configurations 📐 Dimensions Exterior Body Styles: Van, Wagon, Chassis Cab, Cutaway Wheelbase Options: Various wheelbases available (e.g., 138-inch, 158-inch, etc.) depending on configuration Overall Length: Varies significantly by wheelbase and body style Overall Width: Approx. 79.9 inches (body only) Overall Height: Varies by roof height option Weights Gvwr Range: Class III (10,001-14,000 lbs GVWR) and Class IV (14,001-16,000 lbs GVWR) and higher Curb Weight: Varies significantly by configuration, typically 5,500 - 7,000+ lbs Towing Capacity: Up to 10,000+ lbs depending on configuration, engine, axle ratio, and trailer brake control 🛡️ Safety Features Ratings NHTSA Rollover Resistance: N/A (Typically rated based on vehicle class and configuration; vans have higher center of gravity) Active Features ABS: Anti-lock Braking System (ABS) standard on rear wheels, optional on all four wheels Traction Control: Optional Traction Control System (TCS) Passive Features Airbags: Driver and front passenger airbags Seatbelts: Three-point seatbelts for all passenger positions 💡 Technology Features Infotainment Infotainment Systems: Basic AM/FM radio with CD player, optional cassette player, optional premium sound systems....
Identification and usage instructions for specialized tools required for specific repairs
Wiring Diagrams:
Comprehensive and detailed electrical schematics for all vehicle circuits
Technical Depth
Diagnostic Capability:
Advanced diagnostic procedures, including symptom-based troubleshooting and electronic module diagnosis
Rebuild Procedures:
Detailed instructions for engine, transmission, and differential rebuilds
Specifications Data:
Torque specifications, clearances, fluid capacities, and other critical technical data
📊 Manual Specifications
File Format
File Format Details:
Proprietary RepairSurge digital format, accessible via web browser
Print Quality
Print Quality Description:
N/A (Digital Format)
Binding Type
Binding Type Description:
N/A (Digital Format)
Paper Type
Paper Type Description:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Options 2004:
4.6L Triton V8, 5.4L Triton V8, 6.8L Triton V10, 7.3L Power Stroke V8 Turbo Diesel (specific availability may vary by configuration)
Engine Displacement 4 6L:
4.6 Liters / 281 cu. in.
Engine Displacement 5 4L:
5.4 Liters / 330 cu. in.
Engine Displacement 6 8L:
6.8 Liters / 415 cu. in.
Engine Displacement 7 3L Diesel:
7.3 Liters / 444 cu. in.
Performance
Horsepower 4 6L V8:
Approx. 215-234 hp (depending on specific calibration)
Torque 4 6L V8:
Approx. 280-295 lb-ft (depending on specific calibration)
Horsepower 5 4L V8:
Approx. 255-260 hp
Torque 5 4L V8:
Approx. 350-355 lb-ft
Horsepower 6 8L V10:
Approx. 305 hp
Torque 6 8L V10:
Approx. 425 lb-ft
Horsepower 7 3L Diesel:
Approx. 215 hp
Torque 7 3L Diesel:
Approx. 440 lb-ft
Fuel System
Fuel Delivery Gasoline:
Electronic Fuel Injection (EFI) with Sequential Port Injection
Fuel Type Diesel:
Diesel Fuel
Fuel System Diesel:
Direct Injection, Turbocharged with Intercooler
🔧 Transmission
Standard
Standard Transmission:
5-Speed Manual Transmission (M5OD-R2)
Optional
Optional Transmission Gasoline:
4-Speed Automatic Overdrive (4R70W for lighter duty, 4R100 for heavier duty)
Optional Transmission Diesel:
5-Speed Automatic Overdrive (5R110W 'TorqShift')
Features
Automatic Transmission Features:
Electronic controls, torque converter lock-up, tow/haul mode (on 4R100 and 5R110W)
Transfer Case:
Part-time 4WD system available (with manual or electronic shift) for certain configurations
📐 Dimensions
Exterior
Body Styles:
Van, Wagon, Chassis Cab, Cutaway
Wheelbase Options:
Various wheelbases available (e.g., 138-inch, 158-inch, etc.) depending on configuration
Overall Length:
Varies significantly by wheelbase and body style
Overall Width:
Approx. 79.9 inches (body only)
Overall Height:
Varies by roof height option
Weights
Gvwr Range:
Class III (10,001-14,000 lbs GVWR) and Class IV (14,001-16,000 lbs GVWR) and higher
Curb Weight:
Varies significantly by configuration, typically 5,500 - 7,000+ lbs
Towing Capacity:
Up to 10,000+ lbs depending on configuration, engine, axle ratio, and trailer brake control
🛡️ Safety Features
Ratings
NHTSA Rollover Resistance:
N/A (Typically rated based on vehicle class and configuration; vans have higher center of gravity)
Active Features
ABS:
Anti-lock Braking System (ABS) standard on rear wheels, optional on all four wheels
Traction Control:
Optional Traction Control System (TCS)
Passive Features
Airbags:
Driver and front passenger airbags
Seatbelts:
Three-point seatbelts for all passenger positions
💡 Technology Features
Infotainment
Infotainment Systems:
Basic AM/FM radio with CD player, optional cassette player, optional premium sound systems.
Driver Assistance
Driver Assistance Features:
Limited driver assistance features for this era; primarily focused on mechanical systems and basic electronics.
Connectivity
Connectivity Options:
No modern connectivity features like Bluetooth or USB ports in base models.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically 5,000 miles or 6 months for gasoline engines, 5,000-7,500 miles for diesel engines, or as indicated by the Intelligent Oil Life Monitor system.
Engine Coolant Flush:
Initial flush at 100,000 miles, then every 50,000 miles thereafter (for conventional coolant).
Transmission Fluid Change:
Refer to manual, typically 30,000-60,000 miles for severe service, or as indicated by the transmission fluid monitor.
Fluid Specifications
Engine Oil 4 6L 5 4L V8:
SAE 5W-20, API SN certified (check manual for exact viscosity and specification)
Engine Oil 6 8L V10:
SAE 5W-20 or 5W-30, API SN certified (check manual for exact viscosity and specification)
Engine Oil 7 3L Diesel:
API CJ-4 or CK-4 rated diesel engine oil, SAE 15W-40 (check manual for exact specification and viscosity)
Transmission Fluid Auto:
MERCON V for 4R70W/4R100, MERCON LV or SP for 5R110W (confirm with manual)
Transmission Fluid Manual:
Manual Transmission Fluid (MTF) meeting specified Ford standards (e.g., Mercon V or specific MTF)
Coolant:
Ford Premium Engine Coolant (Green) or equivalent, 50/50 mix with distilled water.
Brake Fluid:
DOT 3 Motor Vehicle Brake Fluid
Power Steering Fluid:
Power Steering Fluid (PSF), consult manual for specific type.
Known Issues
Common Wear Items:
Ball joints, tie rod ends, wheel bearings, brake pads/rotors due to heavy use and load.
Diesel Specific:
7.3L Power Stroke: Potential for injector seal leaks, exhaust backpressure sensor (EBP) issues, UVCH (Under Valve Cover Harness) issues.
Gasoline Specific:
Spark plug blowout on early Triton engines (less common by 2004), intake manifold runner control (IMRC) issues.
📚 Vehicle History
Brand Heritage
Ford Commercial Vehicles:
Ford has a long-standing reputation for producing durable and capable commercial vehicles, dating back to the early 20th century.
Model Evolution
E Series Lineage:
The E-Series vans (including E-350) are a continuation of Ford's highly successful Econoline van line, introduced in 1961. The 2004 model represents the sixth generation, which introduced significant styling and engineering updates.
Production
Production Location:
United States (typically Ohio Assembly Plant)
Production Period:
Sixth Generation: 2003-2007
🏆 Awards & Recognition
Recognitions
Commercial Vehicle Accolades:
Ford E-Series vans have consistently been top sellers in the commercial van market for decades, indicative of their reliability and utility.
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