Ford Five Hundred 2005-2007 Service & Repair Workshop Manual
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🏷️ Basic Information Identification Make: Ford Model: Five Hundred Years Covered: 2005, 2006, 2007 Codes Platform Code: Ford D3 platform 👋 Introduction Market Position Vehicle Segment: Full-size sedan, later categorized as a large car. Target Audience: Families seeking comfortable, spacious, and safe transportation. Competitive Analysis Competitors: Buick Lucerne, Toyota Avalon, Chrysler 300, Dodge Charger, Chevrolet Impala. Key Features Platform Sharing: Shared the D3 platform with the Mercury Montego and Lincoln MKZ, highlighting a focus on ride quality and chassis dynamics. Design Philosophy: Emphasized American styling cues, spacious interior, and comfortable ride, with an available All-Wheel Drive system for enhanced all-weather capability. 📋 Manual Details Coverage Areas Manual Type: Factory Service & Repair Workshop Manual Language: English Format: Downloadable PDF Availability: Instant Download Licensing: Lifetime Use, No Expiry Dates Compatibility: Windows and MAC computers, tablets, smartphones Printing Capability: Printable (single pages or entire manual) Device Usage: Usable on multiple devices 📖 Manual Coverage Systems Covered Engine: Complete engine overhaul, diagnostics, timing components, cooling system, lubrication system, fuel delivery, ignition system, emissions control. Transmission: Automatic transmission service, repair, diagnostics, fluid specifications, torque converter, valve body, planetary gear sets. Drivetrain: All-Wheel Drive (AWD) system service, front-wheel drive (FWD) components, drive shafts, CV joints, differential service. Brakes: Hydraulic brake system, ABS (Anti-lock Braking System) diagnostics and repair, brake pad and rotor replacement, brake caliper service, parking brake. Steering Suspension: Power steering system, steering rack and pinion, suspension components (struts, shocks, control arms, ball joints), wheel alignment specifications. Electrical System: Battery, charging system (alternator), starting system (starter motor), lighting system, interior and exterior lighting, fuses, relays, wiring diagrams, diagnostic trouble codes (DTCs). HVAC: Heating, Ventilation, and Air Conditioning (HVAC) system service, refrigerant charging, component replacement (compressor, condenser, evaporator). Body Interior: Body panel removal and installation, door mechanisms, interior trim, seating, headliner, glass replacement, sealants. Body Exterior: Bumpers, fenders, hood, trunk lid, exterior trim, lighting (headlights, taillights), mirrors. Restraints: Airbag system diagnostics and service, seatbelt mechanisms, pre-tensioners. Instrumentation Controls: Instrument cluster diagnostics, control modules, switches, driver information systems. Procedures Included Maintenance: Routine maintenance schedules, oil changes, filter replacements, fluid checks and top-offs, tire rotation. Troubleshooting: Diagnostic procedures for common and uncommon faults, symptom-based troubleshooting guides, DTC interpretation. Repair: Step-by-step repair instructions for all major components and systems, including detailed disassembly and reassembly procedures. Diagnostics: Advanced diagnostic techniques, scan tool usage, live data analysis, component testing. Installation: Procedures for replacing or installing new parts and components. Specifications: Torque specifications, clearances, fluid capacities, pressure specifications, electrical resistance values. Technical Depth Depth Level: Comprehensive; suitable for professional mechanics, technicians, and advanced DIY enthusiasts. Visuals: Hundreds of detailed photos and diagrams, including exploded views and step-by-step illustrations. Content Type: Factory-level repair procedures, technical service bulletins (TSBs) often referenced, service bulletins. 📊 Manual Specifications File Format File Type: PDF (Portable Document Format) Searchability: Likely text-searchable (depending on PDF creation) for quick information retrieval. Print Quality Resolution: High-resolution images and diagrams suitable for printing. Binding Type Binding: Digital Download (not a physical book) Paper Type Paper: N/A (Digital) ⚙️ Engine Specifications Primary Engine Engine Code: AJ35 (3.0L Duratec V6) Engine Type: 3.0L Naturally Aspirated V6 Displacement: 2967 cc (181 cubic inches) Bore X Stroke: 89.0 mm x 79.5 mm (3.50 in x 3.13 in) Compression Ratio: 10.0:1 Horsepower: 203 hp @ 6300 rpm Torque: 207 lb-ft @ 4000 rpm Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded Gasoline Octane Rating: 87 octane (minimum) Ignition System Ignition Type: Distributorless Electronic Ignition (DIS) with Coil-on-Plug (COP) Cooling System Cooling Type: Liquid-cooled 🔧 Transmission Standard Transmission Type: 6-speed Automatic (6F50) Optional AWD Availability: All-Wheel Drive (AWD) available on select trims. Features Transmission Fluid: Specify Mercon V or equivalent (refer to manual for exact Ford part number). 📐 Dimensions Exterior Length: 200.1 inches (5083 mm) Width: 74.4 inches (1890 mm) Height: 59.1 inches (1501 mm) Wheelbase: 114.1 inches (2898 mm) Interior Passenger Volume: 105.7 cu ft (2993 L) Cargo Trunk Volume: 15.1 cu ft (427 L) Weights Curb Weight FWD: Approximately 3,700 - 3,800 lbs (1678 - 1724 kg) Curb Weight AWD: Approximately 3,900 - 4,000 lbs (1769 - 1814 kg) 🛡️ Safety Features Ratings NHTSA Front Impact Driver: 5 Stars NHTSA Front Impact Passenger: 5 Stars NHTSA Side Impact Front Seat: 5 Stars NHTSA Side Impact Rear Seat: 5 Stars IIHS Front Offset Crash Rating: Good IIHS Side Impact Crash Rating: Good Active Features ABS: Standard Anti-lock Braking System (ABS) Traction Control: Traction Control System (TCS) available or standard on some trims. Passive Features Airbags: Front airbags, front side-impact airbags, and available side-curtain airbags. Seatbelts: Three-point seatbelts with pretensioners and load limiters. 💡 Technology Features Infotainment Audio System: Available AM/FM stereo with CD player, optional premium audio systems, and SiriusXM satellite radio capability. Navigation: Optional factory navigation system available on higher trims. Driver Assistance Cruise Control: Standard cruise control system. Parking Assist:...
Full-size sedan, later categorized as a large car.
Target Audience:
Families seeking comfortable, spacious, and safe transportation.
Competitive Analysis
Competitors:
Buick Lucerne, Toyota Avalon, Chrysler 300, Dodge Charger, Chevrolet Impala.
Key Features
Platform Sharing:
Shared the D3 platform with the Mercury Montego and Lincoln MKZ, highlighting a focus on ride quality and chassis dynamics.
Design Philosophy:
Emphasized American styling cues, spacious interior, and comfortable ride, with an available All-Wheel Drive system for enhanced all-weather capability.
Comprehensive; suitable for professional mechanics, technicians, and advanced DIY enthusiasts.
Visuals:
Hundreds of detailed photos and diagrams, including exploded views and step-by-step illustrations.
Content Type:
Factory-level repair procedures, technical service bulletins (TSBs) often referenced, service bulletins.
📊 Manual Specifications
File Format
File Type:
PDF (Portable Document Format)
Searchability:
Likely text-searchable (depending on PDF creation) for quick information retrieval.
Print Quality
Resolution:
High-resolution images and diagrams suitable for printing.
Binding Type
Binding:
Digital Download (not a physical book)
Paper Type
Paper:
N/A (Digital)
⚙️ Engine Specifications
Primary Engine
Engine Code:
AJ35 (3.0L Duratec V6)
Engine Type:
3.0L Naturally Aspirated V6
Displacement:
2967 cc (181 cubic inches)
Bore X Stroke:
89.0 mm x 79.5 mm (3.50 in x 3.13 in)
Compression Ratio:
10.0:1
Horsepower:
203 hp @ 6300 rpm
Torque:
207 lb-ft @ 4000 rpm
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded Gasoline
Octane Rating:
87 octane (minimum)
Ignition System
Ignition Type:
Distributorless Electronic Ignition (DIS) with Coil-on-Plug (COP)
Cooling System
Cooling Type:
Liquid-cooled
🔧 Transmission
Standard
Transmission Type:
6-speed Automatic (6F50)
Optional
AWD Availability:
All-Wheel Drive (AWD) available on select trims.
Features
Transmission Fluid:
Specify Mercon V or equivalent (refer to manual for exact Ford part number).
📐 Dimensions
Exterior
Length:
200.1 inches (5083 mm)
Width:
74.4 inches (1890 mm)
Height:
59.1 inches (1501 mm)
Wheelbase:
114.1 inches (2898 mm)
Interior
Passenger Volume:
105.7 cu ft (2993 L)
Cargo
Trunk Volume:
15.1 cu ft (427 L)
Weights
Curb Weight FWD:
Approximately 3,700 - 3,800 lbs (1678 - 1724 kg)
Curb Weight AWD:
Approximately 3,900 - 4,000 lbs (1769 - 1814 kg)
🛡️ Safety Features
Ratings
NHTSA Front Impact Driver:
5 Stars
NHTSA Front Impact Passenger:
5 Stars
NHTSA Side Impact Front Seat:
5 Stars
NHTSA Side Impact Rear Seat:
5 Stars
IIHS Front Offset Crash Rating:
Good
IIHS Side Impact Crash Rating:
Good
Active Features
ABS:
Standard Anti-lock Braking System (ABS)
Traction Control:
Traction Control System (TCS) available or standard on some trims.
Passive Features
Airbags:
Front airbags, front side-impact airbags, and available side-curtain airbags.
Seatbelts:
Three-point seatbelts with pretensioners and load limiters.
💡 Technology Features
Infotainment
Audio System:
Available AM/FM stereo with CD player, optional premium audio systems, and SiriusXM satellite radio capability.
Navigation:
Optional factory navigation system available on higher trims.
Driver Assistance
Cruise Control:
Standard cruise control system.
Parking Assist:
Rear parking sensors were an option on some models.
Connectivity
Phone Integration:
Optional hands-free phone system (Microsoft SYNC) was introduced in later model years of the Ford line, potentially available in late 2007 models or as an aftermarket addition.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000 to 7,500 miles (8,000 to 12,000 km) or 6 to 12 months, depending on driving conditions (refer to manual for specific recommendation).
Air Filter Replacement:
Every 20,000 to 30,000 miles (32,000 to 48,000 km).
Cabin Air Filter Replacement:
Every 15,000 to 20,000 miles (24,000 to 32,000 km) or annually.
Spark Plug Replacement:
Typically at 100,000 miles (160,000 km) for iridium spark plugs.
Fluid Specifications
Engine Oil Type:
SAE 5W-20, API SN or newer specification (refer to manual for exact Ford spec WSS-M2C930-A).
Engine Oil Capacity:
Approximately 6.0 US quarts (5.7 liters) with filter.
Coolant Type:
Ford Premium Engine Coolant (Green) or equivalent meeting WSS-M97B44-D specification.
Coolant Capacity:
Approximately 12.0 US quarts (11.4 liters).
Known Issues
Transmission Issues:
Some reports of rough shifting or transmission shudder, particularly with earlier models. Torque converter shudder can occur.
Interior Rattles:
Some owners have reported interior trim rattles and squeaks due to the extensive use of plastic.
Powertrain Control Module (PCM) Issues:
Occasional PCM or sensor failures can lead to check engine lights or drivability issues.
Cv Axle Wear:
Front CV axles can wear over time, especially on AWD models, leading to clicking noises when turning.
📚 Vehicle History
Brand Heritage
Ford Legacy:
Ford has a long history of producing large, comfortable American sedans, continuing this tradition with the Five Hundred.
Model Evolution
Introduction Year:
Introduced for the 2005 model year.
Facelift Redesign:
Received a minor facelift for the 2008 model year, coinciding with its rebranding as the Ford Taurus.
Production
Assembly Plant:
Oakville Assembly Plant, Ontario, Canada.
Production Years:
2005-2007
🏆 Awards & Recognition
Recognitions
IIHS Top Safety Pick:
Received Good ratings in IIHS crash tests, contributing to its strong safety reputation.
Car And Driver 10Best:
Was not a recipient of Car and Driver's 10Best list during its production run.
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