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2004-2008 Ford F-150 Repair Manual

Ford F-150 repair manualsThe 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

2004-2008 Ford F-150

4.2L Ford Essex OHV V6 engine

4.2L Ford Essex OHV V6 engine

4.6L Triton OHC V8 engine

4.6L Triton OHC V8 engine

5.4L Triton OHC V8 engine

5.4L Triton OHC V8 engine

6-speed 6R automatic transmission

6-speed 6R automatic transmission

5-speed Mazda M5OD-R2 manual 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.