2009 Ford F-450 F550 Super Duty Workshop Repair Manual
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🏷️ Basic Information Identification Make: Ford Model: F-550 Super Duty Year: 2009 Codes Chassis Code: P527 (F-450/F-550) 👋 Introduction Market Position Positioning: Targets owners and independent repair shops of heavy-duty Ford trucks seeking comprehensive, dealership-level repair information. Competitive Analysis Alternatives: Offers a significant advantage over generic online repair guides or partial manuals by providing OEM-specific, year-specific data. Key Features Diy Focus: Designed for the 'Do-It-Yourself' enthusiast or professional mechanic, enabling self-sufficiency in repairs. Oem Standard: Represents original equipment manufacturer (OEM) standards and procedures, ensuring accuracy and quality. Illustration Quality: Includes detailed illustrations and diagrams to clarify complex procedures. 📋 Manual Details Coverage Areas General Coverage: Complete repair and service for 2009 Ford F-450 and F-550 Super Duty trucks. Page Count Estimated Pages: Approximately 2000-3000 (typical for this class of vehicle and manual scope, actual may vary within the PDF). Manual Type Type: Workshop Repair Manual / Service Manual Language Language: English Format Format: PDF (single file) 📖 Manual Coverage Systems Covered Engine: Detailed coverage including diagnostics, component removal/installation, and overhaul for gasoline and diesel engines. Fuel System: Components, diagnostics, pressure testing, fuel pump, injectors, lines, and filtration. Cooling System: Radiator, water pump, thermostat, hoses, fan, and coolant specifications. Ignition System: Spark plugs, coils, wiring, and ignition timing (for gasoline engines). Exhaust System: Manifolds, catalytic converter, mufflers, pipes, and emissions control. Transmission: Detailed service, repair, and overhaul procedures for automatic and manual transmissions. Drivetrain: Front and rear axles, differentials, driveshafts, U-joints, and hubs. Suspension: Front and rear suspension components, springs, shocks, control arms, bushings, and alignment. Steering: Power steering system, pump, hoses, steering gear/rack, tie rods, and alignment. Brakes: Hydraulic system, ABS, master cylinder, brake lines, calipers, pads, rotors, and parking brake. Electrical System: Battery, charging system, starting system, lighting, instrumentation, and power distribution. Climate Control: Air conditioning system (R-134a), heating, ventilation, and blower motor. Body And Chassis: Frame, body panels, doors, hood, tailgate, interior trim, and exterior components. Restraint Systems: Airbag system, sensors, control module, and seat belts. Diagnostic Trouble Codes: List and explanation of OBD-II codes and specific Ford diagnostic codes. Procedures Included Maintenance: Routine maintenance schedules, fluid changes, filter replacements, and inspections. Troubleshooting: Systematic diagnostic procedures for identifying and resolving common and complex issues. Repair: Step-by-step instructions for component removal, repair, and installation. Overhaul: Detailed procedures for complete engine, transmission, and axle rebuilds. Wiring Schematics: Comprehensive electrical diagrams for all vehicle systems. Diagnostics: Procedures for using diagnostic tools and interpreting data. Technical Depth Depth: Extensive, covering everything from basic fluid services to complete engine and transmission rebuilds, including advanced diagnostics and electrical troubleshooting. 📊 Manual Specifications File Format Format: PDF Searchability: Searchable text with bookmarks for easy navigation. File Size: Approximately 100 MB (as stated). Print Quality Quality: High-resolution digital reproduction of original factory documentation, enabling clear printing of text and illustrations. Binding Type Binding: Not Applicable (Digital PDF File). Paper Type Paper: Not Applicable (Digital PDF File). ⚙️ Engine Specifications Primary Engine Gasoline Engine 1: 6.8L Triton V10 (362 CID) Gasoline Engine 1 Hp: Approx. 362 hp @ 4,750 rpm Gasoline Engine 1 Torque: Approx. 457 lb-ft @ 3,250 rpm Diesel Engine 1: 6.4L Power Stroke V8 Turbo Diesel Diesel Engine 1 Hp: Approx. 350 hp @ 3,000 rpm Diesel Engine 1 Torque: Approx. 650 lb-ft @ 1,600 rpm Fuel System Gasoline Fuel System: Electronic Fuel Injection (EFI) with sequential port injection. Diesel Fuel System: High-pressure common rail (HPCR) direct injection with variable geometry turbocharger (VGT). 🔧 Transmission Standard Automatic Transmission: TorqueShift 5R110W (5-speed automatic) Optional Manual Transmission: ZF 6-speed manual transmission (various configurations depending on GVWR/configuration) Features Torque Shift: Adaptive shift control, tow/haul mode for improved performance under load. 📐 Dimensions Exterior Wheelbase F450: Starts at 141.8 inches (Crew Cab 4x4) Wheelbase F550: Starts at 141.8 inches (Crew Cab 4x4) Overall Length F450: Varies significantly by cab and bed configuration, typically 236-250 inches. Overall Length F550: Varies significantly by cab and chassis configuration, typically 236-250 inches for cutaway/chassis cab. Weights Gvwr F450: Up to 14,500 lbs Gvwr F550: Up to 19,500 lbs Gcwr F450: Up to 26,000 lbs Gcwr F550: Up to 33,000 lbs 🛡️ Safety Features Ratings NHTSA Rating: Generally 4-star overall safety rating (specific configuration dependent). Active Features ABS: Anti-lock Braking System (ABS) standard on all wheels. Traction Control: Electronic Stability Control (ESC) and Traction Control System (TCS) available/standard depending on configuration. Passive Features Airbags: Front airbags for driver and passenger. Side curtain airbags may be available on certain configurations. Seat Belts: Three-point seat belts with pretensioners. 💡 Technology Features Infotainment Audio System: AM/FM stereo with CD player, MP3 capability, and auxiliary input jack. Optional SiriusXM Satellite Radio. Driver Assistance Parking Aids: Optional rearview camera and rear parking sensors. Connectivity Phone Integration: Optional Ford SYNC voice-activated communications and entertainment system. 🔧 Maintenance Service Intervals Oil Change Gasoline: Every 5,000 miles or 6 months (refer...
Battery, charging system, starting system, lighting, instrumentation, and power distribution.
Climate Control:
Air conditioning system (R-134a), heating, ventilation, and blower motor.
Body And Chassis:
Frame, body panels, doors, hood, tailgate, interior trim, and exterior components.
Restraint Systems:
Airbag system, sensors, control module, and seat belts.
Diagnostic Trouble Codes:
List and explanation of OBD-II codes and specific Ford diagnostic codes.
Procedures Included
Maintenance:
Routine maintenance schedules, fluid changes, filter replacements, and inspections.
Troubleshooting:
Systematic diagnostic procedures for identifying and resolving common and complex issues.
Repair:
Step-by-step instructions for component removal, repair, and installation.
Overhaul:
Detailed procedures for complete engine, transmission, and axle rebuilds.
Wiring Schematics:
Comprehensive electrical diagrams for all vehicle systems.
Diagnostics:
Procedures for using diagnostic tools and interpreting data.
Technical Depth
Depth:
Extensive, covering everything from basic fluid services to complete engine and transmission rebuilds, including advanced diagnostics and electrical troubleshooting.
📊 Manual Specifications
File Format
Format:
PDF
Searchability:
Searchable text with bookmarks for easy navigation.
File Size:
Approximately 100 MB (as stated).
Print Quality
Quality:
High-resolution digital reproduction of original factory documentation, enabling clear printing of text and illustrations.
Binding Type
Binding:
Not Applicable (Digital PDF File).
Paper Type
Paper:
Not Applicable (Digital PDF File).
⚙️ Engine Specifications
Primary Engine
Gasoline Engine 1:
6.8L Triton V10 (362 CID)
Gasoline Engine 1 Hp:
Approx. 362 hp @ 4,750 rpm
Gasoline Engine 1 Torque:
Approx. 457 lb-ft @ 3,250 rpm
Diesel Engine 1:
6.4L Power Stroke V8 Turbo Diesel
Diesel Engine 1 Hp:
Approx. 350 hp @ 3,000 rpm
Diesel Engine 1 Torque:
Approx. 650 lb-ft @ 1,600 rpm
Fuel System
Gasoline Fuel System:
Electronic Fuel Injection (EFI) with sequential port injection.
Diesel Fuel System:
High-pressure common rail (HPCR) direct injection with variable geometry turbocharger (VGT).
🔧 Transmission
Standard
Automatic Transmission:
TorqueShift 5R110W (5-speed automatic)
Optional
Manual Transmission:
ZF 6-speed manual transmission (various configurations depending on GVWR/configuration)
Features
Torque Shift:
Adaptive shift control, tow/haul mode for improved performance under load.
📐 Dimensions
Exterior
Wheelbase F450:
Starts at 141.8 inches (Crew Cab 4x4)
Wheelbase F550:
Starts at 141.8 inches (Crew Cab 4x4)
Overall Length F450:
Varies significantly by cab and bed configuration, typically 236-250 inches.
Overall Length F550:
Varies significantly by cab and chassis configuration, typically 236-250 inches for cutaway/chassis cab.
Weights
Gvwr F450:
Up to 14,500 lbs
Gvwr F550:
Up to 19,500 lbs
Gcwr F450:
Up to 26,000 lbs
Gcwr F550:
Up to 33,000 lbs
🛡️ Safety Features
Ratings
NHTSA Rating:
Generally 4-star overall safety rating (specific configuration dependent).
Active Features
ABS:
Anti-lock Braking System (ABS) standard on all wheels.
Traction Control:
Electronic Stability Control (ESC) and Traction Control System (TCS) available/standard depending on configuration.
Passive Features
Airbags:
Front airbags for driver and passenger. Side curtain airbags may be available on certain configurations.
Seat Belts:
Three-point seat belts with pretensioners.
💡 Technology Features
Infotainment
Audio System:
AM/FM stereo with CD player, MP3 capability, and auxiliary input jack. Optional SiriusXM Satellite Radio.
Driver Assistance
Parking Aids:
Optional rearview camera and rear parking sensors.
Connectivity
Phone Integration:
Optional Ford SYNC voice-activated communications and entertainment system.
🔧 Maintenance
Service Intervals
Oil Change Gasoline:
Every 5,000 miles or 6 months (refer to manual for severe duty recommendations).
Oil Change Diesel:
Every 5,000-10,000 miles or 6 months (refer to manual for specific recommendations based on usage and fuel quality).
Air Filter Replacement:
Inspect every 15,000 miles, replace as needed or every 30,000 miles (more often in dusty conditions).
Coolant Flush:
Initial flush at 50,000 miles, then every 30,000-50,000 miles thereafter, depending on coolant type.
Fluid Specifications
Engine Oil Gasoline:
SAE 5W-20, API SN or newer, meeting Ford Specification WSS-M2C153-H.
Engine Oil Diesel:
API CJ-4 or CK-4, SAE 15W-40 or 10W-30 synthetic blend (refer to manual for precise specification based on climate).
Transmission Fluid Auto:
Mercon LV (Low Viscosity), Ford Specification WSS-M2C200-D2.
Transmission Fluid Manual:
Refer to manual; typically high-quality manual transmission fluid, GL-4 or GL-5 rated depending on the specific transmission model.
Brake Fluid:
DOT 3.
Known Issues
Diesel Dpf Regeneration:
Diesel Particulate Filter (DPF) regeneration issues, especially with frequent short trips or incomplete burns.
Diesel Egr Problems:
EGR (Exhaust Gas Recirculation) cooler leaks and clogging are common on the 6.4L Power Stroke.
Gasoline V10 Ignition:
Occasional spark plug ejection (coil-over-plug design) and coil failures.
Rear Axle Bearings:
Premature wear of rear axle bearings in some heavy-duty applications.
📚 Vehicle History
Brand Heritage
Ford Truck Lineage:
Part of Ford's long-standing and highly successful F-Series truck line, dating back to 1948, known for durability and capability.
Model Evolution
Super Duty Development:
The Super Duty line was introduced in 1999, significantly upgrading capability, design, and technology over previous heavy-duty Fords. The 2008-2010 models represent the second generation of the Super Duty.
Production
Manufacturing Location:
Kentucky Truck Plant, Louisville, Kentucky, USA.
🏆 Awards & Recognition
Recognitions
Motor Trend Truck Of The Year:
Ford Super Duty trucks have historically been recognized by various automotive publications for their towing and hauling capabilities.
Ratings
Towing Capacity:
Class-leading towing and payload capacities, making them highly regarded in their segment for commercial and heavy-duty personal use.