1999 Ford F-Series (F550) Service And Repair Manual
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🏷️ Basic Information Identification Make: Ford Model: F-Series (F550) Year: 1999 Codes Chassis Code: N/A (F550 is a specific chassis designation within the F-Series heavy-duty line) 👋 Introduction Market Position Target User: Ford F550 owners, independent repair shops, fleet maintenance personnel. Value Proposition: Enables DIY repairs, reduces reliance on dealerships, promotes vehicle longevity, cost savings. Competitive Analysis Differentiation: Specific to F550, factory data, A-Z repair coverage, not generic information. Key Features Key Feature 1: Factory-direct technical information. Key Feature 2: Comprehensive coverage of all repair procedures. Key Feature 3: Detailed diagrams and wiring schematics. Key Feature 4: All-in-one searchable PDF for ease of use. 📋 Manual Details Coverage Areas Primary Coverage: Comprehensive service and repair for the 1999 Ford F-Series F550 chassis cab and commercial truck models. Secondary Coverage: Includes all models and repairs from A-Z, specific to the F550 variant. Page Count Page Count: Not Specified (Implied to be extensive due to A-Z coverage and factory documentation) Manual Type Manual Type: Service and Repair Manual Source Authenticity: Factory-equivalent, used by dealership technicians. Language Language: English Format Digital Format: PDF Digital Features: Printable, zoomable images, single PDF for easy navigation. 📖 Manual Coverage Systems Covered Engine Mechanical: Complete overhaul, disassembly, assembly, component testing, torque specifications. Engine Control System: ECU diagnostics, sensor readings, wiring schematics, fuel injection, ignition timing. Fuel Service: Fuel pump, injectors, lines, tank service, specifications. Emission Control: Catalytic converter, EGR system, O2 sensors, evaporative emission control. Cooling System: Radiator, water pump, thermostat, hoses, coolant specifications. Lubrication System: Oil pump, oil filter, oil specifications, oil change intervals. Ignition Starting Charging: Spark plugs, coils, starter motor, alternator, battery specifications, testing. Automatic Transmission Clutch: Service, overhaul, diagnosis, fluid specifications, torque converter. Manual Transmission: Service, overhaul, clutch replacement, fluid specifications. Transfer Case Propeller Shaft: Service, U-joint replacement, driveline maintenance. Drive Axle Differential: Service, fluid specifications, gear inspection, limited-slip differential service. Suspension Steering: Front and rear suspension components, steering gear, power steering system, alignment specifications. Brake Control: Hydraulic system, ABS diagnostics, control modules, fluid specifications. Brake System: Front and rear brake components, rotor/pad replacement, caliper service, bleeding procedures. Parking Brake: Service, adjustment, components. Electrical System: Complete wiring diagrams, component testing, fuse/relay locations, multiplex communication (CAN). Climate Control HVAC: Air conditioning system service, refrigerant, blower motor, heater core. Restraint Systems: Supplemental Restraint System (SRS) / Airbag system diagnosis and service, seat belt mechanisms. Body Interior Exterior: Door mechanisms, hood latch, glass replacement, interior trim, exterior panels. Instrumentation Meters: Instrument cluster diagnostics, warning lights, gauges. Cruise Control: System diagnosis and repair. Wiper Washer: System components and service. Seat Belt: Service and replacement procedures. Immobilizer System: Diagnosis and service of engine immobilizer. Multiplex Can Communication: Covers the multiplexing systems and CAN communication protocols used in the vehicle's electrical architecture for diagnostics. Procedures Included Diagnostics: Troubleshooting guides, diagnostic trouble codes (DTCs), component testing procedures. Maintenance: Routine maintenance schedules, fluid changes, filter replacements. Repair: Step-by-step repair instructions for all covered systems. Rebuild: Complete engine and transmission rebuild procedures. Installation: Instructions for component replacement and installation. Wheel Alignment Specifications: Detailed front and rear wheel alignment specifications for optimal tire wear and handling. Tire And Wheel Service: Information on tire pressure recommendations, wheel torque specifications, and tire rotation. Technical Depth Depth Of Coverage: Factory high-detail, complete service and repair. Visual Aids: Diagrams, illustrations, and wiring schematics. 📊 Manual Specifications File Format File Format: PDF Compatibility: Windows and Mac OS Required Software: Adobe PDF Reader, Winzip (free) Print Quality Printability: All pages are printable. Image Resolution: Zoomable, allows for enlarged print-offs of diagrams. Binding Type Binding Type: N/A (Digital format) Paper Type Paper Type: N/A (Digital format, allows for selective printing on user's choice of paper) ⚙️ Engine Specifications Primary Engine Engine Options: Likely candidates for 1999 F550 include the 7.3L Power Stroke V8 Diesel and potentially a gasoline V8 option (e.g., 5.4L or 6.8L Triton V10 depending on specific configurations). Performance 7.3L Power Stroke Horsepower: Typically around 215-225 hp (specific rating may vary). 7.3L Power Stroke Torque: Typically around 450-500 lb-ft (specific rating may vary). Fuel System Fuel Type: Diesel (for Power Stroke) or Gasoline. Injection Type: Direct Injection (DI) for Power Stroke. 🔧 Transmission Standard Standard Transmission Type: Likely manual transmission options (e.g., 5-speed or 6-speed) and automatic transmission options (e.g., E4OD/4R100 for Power Stroke). Optional Optional Transmission Type: Automatic transmission (e.g., 4R100) common for heavy-duty applications. Features Transmission Fluid Spec: Specific to transmission type (e.g., Mercon V for 4R100, manual transmission fluid for manual gearboxes). 📐 Dimensions Exterior Chassis Type: Class 4/5/6 truck chassis, designed for custom body mounting (e.g., utility bodies, dump beds, service bodies). Weights Gvwr Range: Typically starts around 14,050 lbs and can go up to 23,000 lbs or more, depending on configuration. Curb Weight: Varies significantly based on wheelbase, engine, and installed equipment. 🛡️ Safety Features Ratings Crash Test Data: N/A for F550 chassis...
Step-by-step repair instructions for all covered systems.
Rebuild:
Complete engine and transmission rebuild procedures.
Installation:
Instructions for component replacement and installation.
Wheel Alignment Specifications:
Detailed front and rear wheel alignment specifications for optimal tire wear and handling.
Tire And Wheel Service:
Information on tire pressure recommendations, wheel torque specifications, and tire rotation.
Technical Depth
Depth Of Coverage:
Factory high-detail, complete service and repair.
Visual Aids:
Diagrams, illustrations, and wiring schematics.
📊 Manual Specifications
File Format
File Format:
PDF
Compatibility:
Windows and Mac OS
Required Software:
Adobe PDF Reader, Winzip (free)
Print Quality
Printability:
All pages are printable.
Image Resolution:
Zoomable, allows for enlarged print-offs of diagrams.
Binding Type
Binding Type:
N/A (Digital format)
Paper Type
Paper Type:
N/A (Digital format, allows for selective printing on user's choice of paper)
⚙️ Engine Specifications
Primary Engine
Engine Options:
Likely candidates for 1999 F550 include the 7.3L Power Stroke V8 Diesel and potentially a gasoline V8 option (e.g., 5.4L or 6.8L Triton V10 depending on specific configurations).
Performance
7.3L Power Stroke Horsepower:
Typically around 215-225 hp (specific rating may vary).
7.3L Power Stroke Torque:
Typically around 450-500 lb-ft (specific rating may vary).
Fuel System
Fuel Type:
Diesel (for Power Stroke) or Gasoline.
Injection Type:
Direct Injection (DI) for Power Stroke.
🔧 Transmission
Standard
Standard Transmission Type:
Likely manual transmission options (e.g., 5-speed or 6-speed) and automatic transmission options (e.g., E4OD/4R100 for Power Stroke).
Optional
Optional Transmission Type:
Automatic transmission (e.g., 4R100) common for heavy-duty applications.
Features
Transmission Fluid Spec:
Specific to transmission type (e.g., Mercon V for 4R100, manual transmission fluid for manual gearboxes).
📐 Dimensions
Exterior
Chassis Type:
Class 4/5/6 truck chassis, designed for custom body mounting (e.g., utility bodies, dump beds, service bodies).
Weights
Gvwr Range:
Typically starts around 14,050 lbs and can go up to 23,000 lbs or more, depending on configuration.
Curb Weight:
Varies significantly based on wheelbase, engine, and installed equipment.
🛡️ Safety Features
Ratings
Crash Test Data:
N/A for F550 chassis cab as it's designed for specialized upfitting; focus is on chassis integrity and component safety.
Active Features
ABS:
Antilock Braking System (ABS) is standard on the F550 for this era.
Passive Features
Airbags:
Driver and passenger airbags are typically included.
💡 Technology Features
Infotainment
Infotainment System:
Basic AM/FM radio, optional CD player. No complex touchscreens or advanced infotainment as standard for this era of heavy-duty truck.
Driver Assistance
Driver Assistance Features:
Limited by modern standards. Primarily focused on mechanical and basic electronic systems. ABS is the main active safety technology.
Connectivity
Connectivity:
No integrated Bluetooth or smartphone connectivity. Basic diagnostics via OBD-II port.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically 5,000-7,500 miles for diesel engines with conventional oil, potentially longer with synthetic. Gasoline engines may vary. Consult manual for exact interval.
Transmission Fluid Change:
Recommended every 30,000-60,000 miles depending on usage and transmission type. Refer to manual for specific intervals.
Coolant Change:
Typically every 30,000-100,000 miles depending on coolant type (e.g., conventional vs. extended life).
Fluid Specifications
Engine Oil Spec:
For 7.3L Power Stroke: API CJ-4 or CI-4 PLUS engine oil, SAE 15W-40 recommended (check manual for specific viscosity based on ambient temperature).
Transmission Fluid Spec:
For 4R100 automatic: MERCON V. For manual transmissions: GL-4 or GL-5 gear oil as specified.
Coolant Spec:
Ford Premium Gold Coolant or equivalent ethylene glycol-based coolant.
Known Issues
7.3L Power Stroke Heui Issues:
Hydraulic Electronic Unit Injector (HEUI) system can experience issues with the injection pressure regulator (IPR) and injection control pressure (ICP) sensor if maintenance is neglected.
Automatic Transmission 4R100:
Can be susceptible to overheating if towing heavily without proper transmission cooler. Torque converter issues can arise with high mileage.
Suspension Components:
Heavy-duty trucks can experience wear on ball joints, tie rod ends, and bushings due to load and operational stress.
📚 Vehicle History
Brand Heritage
Ford Truck Legacy:
The F-Series has been a dominant force in the pickup and commercial truck market for decades, with the Super Duty line (including F-250 through F-750) representing their heavy-duty offerings.
Model Evolution
Ninth Generation F Series:
The 1999 model year represents the introduction of the redesigned ninth generation F-Series Super Duty trucks, marking a significant update in chassis, styling, and capability.
Production
Manufacturing Plant:
Primary manufacturing for F-Series Super Duty was at Ford's Kentucky Truck Plant.
🏆 Awards & Recognition
Recognitions
7.3L Power Stroke Reputation:
The 7.3L Power Stroke engine is highly regarded for its durability and reliability, often considered one of the best diesel engines of its era.