Ford F-Series F250 F350 F450 F550 Complete Workshop Service Repair Manual 2009
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🏷️ Basic Information Identification Make: Ford Model: F-Series Super Duty Model Variants: F-250, F-350, F-450, F-550 Year: 2009 Generation Generation Identifier: 12th Generation (2008-2010) Codes Chassis Codes: Various for different GVWR classes, primarily related to Super Duty platform 👋 Introduction Market Position Market Segment: Heavy-duty pickup trucks, catering to commercial, fleet, and demanding personal use. Competitive Analysis Key Competitors: Ram Heavy Duty, Chevrolet Silverado HD, GMC Sierra HD. Key Features Vehicle Strengths: Robust chassis, powerful engine options, high towing and payload capacities, proven reliability in heavy-duty applications. Manual Benefits: Enables DIY repairs, cost savings, deep understanding of vehicle systems, supports preventative maintenance. 📋 Manual Details Coverage Areas Coverage Summary: Complete workshop service and repair procedures for all F-250, F-350, F-450, and F-550 models. Page Count Estimated Page Count: Extensive, likely exceeding 2000 pages given the scope of Super Duty trucks. Manual Type Manual Type: Complete Workshop Service Repair Manual Language Language: English Format Format: Downloadable Digital File (PDF compatible) File Format: PDF (Portable Document Format) Print Quality Print Quality: High-resolution, suitable for printing individual pages or entire sections. Binding Type Binding Type: Digital download (no physical binding) Paper Type Paper Type: N/A (Digital format) 📖 Manual Coverage Systems Covered Engine: Gasoline (5.4L Triton V8, 6.8L Triton V10) and Diesel (6.4L Power Stroke V8) including components, diagnostics, and repair. Transmission: Automatic (e.g., 5R110W TorqShift) and Manual transmissions, including operation, overhaul, and diagnostics. Drivetrain: 4x4 systems, transfer cases, differentials (front and rear), axles, driveshafts, CV joints, and hubs. Suspension: Front and rear suspension systems, leaf springs, shocks, steering components, and alignment specifications. Brakes: Front and rear brake systems (disc brakes), parking brake, ABS, and hydraulic components. Electrical System: Full electrical schematics, battery, charging system, starting system, lighting, instrument cluster, power accessories, and body control modules. HVAC: Heating, ventilation, and air conditioning system diagnosis and repair. Fuel System: Fuel tanks, pumps, lines, injectors, and emission control systems. Cooling System: Radiator, water pump, thermostat, cooling fans, and hoses. Exhaust System: Exhaust manifolds, catalytic converters, mufflers, and piping. Body And Frame: Body panel repair, doors, glass, interior trim, and frame inspection/repair. Safety Systems: Airbag system, seatbelts, and related diagnostics. Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, fluid checks, lubrication, and inspections. Troubleshooting: Diagnostic procedures, fault code interpretation, and symptom-based troubleshooting. Repair: Step-by-step repair instructions for all major components and systems. Rebuilds Overhauls: Detailed instructions for engine, transmission, and other major component rebuilds. Diagnostics: Extensive diagnostic procedures, including wiring diagrams and component testing. Specifications Data: Torque specifications, clearances, fluid capacities, pressures, and electrical data. Technical Depth Depth Of Coverage: Comprehensive, covering basic maintenance to complete engine and transmission overhauls, including electrical diagnostics. ⚙️ Engine Specifications Primary Engine Gasoline Engine 1: 5.4L Triton V8 (SOHC, 3-valve) Gasoline Engine 2: 6.8L Triton V10 (SOHC, 3-valve) Diesel Engine: 6.4L Power Stroke V8 (Turbocharged, Intercooled, OHV, 32-valve) Performance 5.4L V8 Horsepower: Approx. 310 hp @ 5,000 rpm 5.4L V8 Torque: Approx. 395 lb-ft @ 3,500 rpm 6.8L V10 Horsepower: Approx. 362 hp @ 4,750 rpm 6.8L V10 Torque: Approx. 457 lb-ft @ 3,250 rpm 6.4L Powerstroke Horsepower: Approx. 350 hp @ 3,000 rpm 6.4L Powerstroke Torque: Approx. 650 lb-ft @ 1,600 rpm Fuel System Gasoline Fuel System: Electronic Fuel Injection (EFI) Diesel Fuel System: Common Rail Fuel Injection (CRFI), High-Pressure Fuel Pump, Diesel Particulate Filter (DPF) for emissions. 🔧 Transmission Standard Transmission Options: Available with both automatic and manual transmissions, depending on configuration. Optional Automatic Transmission: 5R110W TorqShift (5-speed automatic) Manual Transmission: Likely options include 6-speed manual transmissions (e.g., ZF6). Features Torqshift Features: Tow/Haul mode, manual shifting capability (SelectShift). 📐 Dimensions Exterior Body Styles: Regular Cab, SuperCab, Crew Cab; various bed lengths (e.g., 6.75 ft, 8.0 ft, 9.75 ft). Weights Gvwr Range: Extensive range depending on model (F-250, F-350 SRW/DRW, F-450, F-550) from approximately 8,500 lbs to 37,000 lbs. Curb Weight: Varies significantly by configuration, typically starting around 6,000 lbs and increasing with options and GVWR. 🛡️ Safety Features Ratings NHTSA Ratings: Specific ratings vary by configuration and model year. Generally robust for heavy-duty use. Active Features Brake System: 4-wheel power disc brakes with ABS. Enhanced towing features may include integrated trailer brake controller. Passive Features Airbags: Driver and front passenger airbags. Side curtain airbags and other advanced restraints may be optional or standard on higher trims. 💡 Technology Features Infotainment Audio Systems: Range from basic AM/FM/CD players to optional premium audio systems with SiriusXM capabilities. SYNC® voice-recognition communication and entertainment system may be available on higher trims. Driver Assistance Towing Features: Integrated Trailer Brake Controller (optional), Trailer Sway Control, Tow/Haul Mode. Connectivity Usb Ports: Available on certain trims/options for device charging and media playback. 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 5,000-7,500 miles or 6 months for gasoline engines, and 5,000-10,000 miles for diesel engines, or as indicated by the Intelligent Oil-Life Monitor (IOLM). Transmission...
Regular Cab, SuperCab, Crew Cab; various bed lengths (e.g., 6.75 ft, 8.0 ft, 9.75 ft).
Weights
Gvwr Range:
Extensive range depending on model (F-250, F-350 SRW/DRW, F-450, F-550) from approximately 8,500 lbs to 37,000 lbs.
Curb Weight:
Varies significantly by configuration, typically starting around 6,000 lbs and increasing with options and GVWR.
🛡️ Safety Features
Ratings
NHTSA Ratings:
Specific ratings vary by configuration and model year. Generally robust for heavy-duty use.
Active Features
Brake System:
4-wheel power disc brakes with ABS. Enhanced towing features may include integrated trailer brake controller.
Passive Features
Airbags:
Driver and front passenger airbags. Side curtain airbags and other advanced restraints may be optional or standard on higher trims.
💡 Technology Features
Infotainment
Audio Systems:
Range from basic AM/FM/CD players to optional premium audio systems with SiriusXM capabilities. SYNC® voice-recognition communication and entertainment system may be available on higher trims.
Available on certain trims/options for device charging and media playback.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 5,000-7,500 miles or 6 months for gasoline engines, and 5,000-10,000 miles for diesel engines, or as indicated by the Intelligent Oil-Life Monitor (IOLM).
Transmission Fluid Change:
Refer to manual for specific intervals based on usage (e.g., heavy towing). Generally around 30,000-60,000 miles.
Coolant Service:
Initial flush and fill at 100,000 miles, then every 50,000 miles thereafter for some coolant types.
Ball joints, tie rod ends, U-joints, brake components, exhaust components, fuel injectors (especially on early diesel models).
Diesel Specific Concerns:
EGR system issues, DPF regeneration problems, turbocharger concerns (on 6.4L Power Stroke).
📚 Vehicle History
Brand Heritage
Ford Truck Legacy:
Ford F-Series has been the best-selling truck line in North America for decades, with a strong reputation for toughness and capability.
Model Evolution
Super Duty Development:
The Super Duty line was introduced in 1999 to differentiate heavy-duty trucks from the lighter F-150. The 2008 refresh marked the introduction of the 12th generation, featuring updated styling, chassis, and powertrains.
Production
Manufacturing Locations:
Kentucky Truck Plant (Kentucky, USA) and Avon Lake Assembly Plant (Ohio, USA) are primary manufacturing sites for F-Series Super Duty trucks.
🏆 Awards & Recognition
Recognitions
Truck Of The Year:
Ford F-Series consistently receives accolades, though specific 'Truck of the Year' awards can vary annually by publication. Super Duty models are recognized for their capability and durability.
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