2004-2008 Ford F-150 Repair Manual
The eleventh generation Ford F-150 was introduced in 2004 in two body styles: 2-door pickup and 4-door pickup (2WD and 4WD submodels). Three trim levels were available: XLT, Lariat and FX4.
General information: Class: full-size pickup truck; Body style: 2-door pickup, 4-door pickup; Layout: front engine, rear-wheel drive or four-wheel drive; Wheelbase: 126.0 in (3,200 mm) [regular cab 6.5′ box], 133.0 in (3,378 mm) [supercab 5.5′ box], 139.0 in (3,531 mm) [supercrew 5.5′ box], 145.0 in (3,683 mm) [supercab 6.5′ box and regular cab 8′ box], 151.0 in (3,835 mm) [supercrew 6.5′ box], 163.0 in (4,140 mm) [supercab 8′ box]; Length: 211.8 in (5,380 mm) [regular cab 6.5′ box], 217.8 in (5,532 mm) [supercab 5.5′ box], 223.8 in (5,685 mm) [supercrew 5.5′ box], 229.8 in (5,837 mm) [supercab 6.5′ box and regular cab 8′ box], 235.8 in (5,989 mm) [supercrew 6.5′ box], 247.8 in (6,294 mm) [supercab 8′ box); Width: 78.9 in (2,004 mm); Height: 73.5 in (1,867 mm) [2WD], 76.1 in (1,933 mm) [4WD].
 2004-2008 Ford F-150  4.2L Ford Essex OHV V6 engine  4.6L Triton OHC V8 engine  5.4L Triton OHC V8 engine  6-speed 6R automatic transmission  5-speed Mazda M5OD-R2 manual transmission |
Engines:
4.2L Essex OHV V6 produced 210 hp (157 kW) at 4,350 rpm and 260 lb·ft (353 N·m) at 3,750 rpm
General information: Configuration: V6; Displacement: 256 cu in (4,195 cc); Cylinder bore: 3.8 in (96.8 mm); Piston stroke: 3.7 in (95.0 mm); Cylinder block alloy: Iron; Cylinder head alloy: Aluminum; Valvetrain: OHV [pushrod] (2 Valves Per Cylinder, 12 Valves total); Fuel system: 2-barrel carburetor; Fuel type: gasoline; Cooling system: Liquid-cooled.
4.6L Ford Triton SOHC V8 produced 231 hp (172 kW) at 4,750 rpm and 293 lb·ft (397 N·m) at 3,500 rpm [2004-2006], 248 hp (185 kW) at 4,750 rpm and 294 lb·ft (399 N·m) at 4,000 rpm [2007-2008]
General information: Configuration: 90° V8; Displacement: 280.8 cu in (4,601 cc); Cylinder bore: 3.6 in (90.2 mm); Piston stroke: 3.5 in (90.0 mm); Valvetrain: OHC with Roller finger followers.
5.4L Ford Triton SOHC V8 produced 300 hp (224 kW) at 5,000 rpm and 365 lb·ft (495 N·m) at 3,750 rpm
General information: Configuration: 90° V8; Displacement: 330.0 cu in (5,408 cc); Cylinder bore: 3.7 in (94.0 mm); Piston stroke: 3.8 in (95.3 mm); Valvetrain: OHC with Roller finger followers.
Repair operations: repair operations possible with the engine in the vehicle; intake manifold: removal and installation; exhaust manifold: removal and installation; valve covers: removal and installation; cylinder head: removal, inspection and installation; engine: removal and installation; engine block: cleaning and inspection; spark plug thread repair; timing chain wear: check; timing cover and timing chain: removal and installation; oil pump: removal, inspection and installation; oil pan: removal, inspection and installation; camshaft and lifters: removal, inspection and installation; crankshaft: inspection, removal and installation etc.
Transmissions:
4-speed Ford 4R70W automatic transmission
Gear ratios (overall): I – 2.84:1; II – 1.55:1; III – 1.0:1; IV – 0.7:1; R – 2.32:1
4-speed Ford 4R100 automatic transmission
Gear ratios (overall): I – 2.71:1; II – 1.54:1; III – 1.0:1; IV – 0.71:1; R – 2.18:1
6-speed Ford 6R automatic transmission
Gear ratios (overall): I – 4.17:1; II – 2.34:1; III – 1.52:1; IV – 1.14:1; V – 0.86:1; VI – 0.69:1; R – 3.40:1
Repair operations: manual shift linkage: inspection, removal, installation and adjustment; throttle valve mechanisms: removal, installation and adjustment; kickdown mechanisms: removal, installation and adjustment; vacuum modulator: check and replacement; band adjustment; automatic transmission: removal and installation; electronic shift transmission: general information; manual lever position sensor: adjustment; neutral start switch: adjustment.
5-speed Mazda M5OD-R2 manual transmission
Gear ratios (overall): I – 3.72:1; II – 2.2:1; III – 1.5:1; IV – 1.0:1; V – 0.79:1; R – 3.42:1
Repair operations: shift linkage adjustment; shift lever: removal and installation; transmission mounts: check and replacement; manual transmission: removal and installation; speedometer pinion gear and seal: replacement; extension housing oil seal: replacement.
Transfer case:
Borg Warner BW 4416 transfer case
General information: Low-range ratio: 2.64:1; Low-range: helical planetary design; Fluid type: ATF; Shift pattern: 2H-4WD-4H-4L; Shift control: electrical
Repair operations: transfer case: removal and installation; transfer case: overhaul; front output shaft oil seal: removal and replacement; rear output shaft oil seal: removal and replacement; rear extension housing bushing: removal and replacement; manual shift lever assembly: removal and installation; electronic shift: removal and installation.
Other manuals: cooling, heating and air conditioning systems; fuel and exhaust systems; engine electrical systems; emissions and engine control systems; driveline; brakes; suspension and steering systems; body; chassis electrical system; wiring diagrams. All 2004-2008 Ford F-150 repair manuals are written specifically for the do-it-yourselfer.
