This is Ford's own workshop manual for the F-Super Duty, 6,567 pages in a single searchable PDF. It is a chassis manual rather than a single-model book, so F-250, F-350, F-450 and F-550 are all documented in it, along with the F53 motorhome chassis and the Excursion that shares the same frame. The phrase “F-Super Duty” appears more than 8,100 times through the text. Section 502-02 opens by describing exactly what you are working on: “The frame is made up of channel steel two-piece rails and riveted crossmembers, except for the transmission support crossmember which is bolted.”

Which vehicles this manual fits

• Fits: Ford F-250, F-350, F-450 and F-550 Super Duty, plus the F53 motorhome chassis. All three cab styles are covered, and the manual says so itself in the frame section: “The Crew Cab frame assembly is shown, the regular and Super Cab frame assemblies are similar”
• Covers years: 2004, 2003, 2002, 2001, 2000
• Engine options: 5.4L Triton V8, 6.8L Triton V10 and the 7.3L direct-injection turbo diesel V8, listed in the specifications as “7.3L, OHV, DI Turbo, V8, Diesel, F-Series/Excursion”. Bi-fuel trucks have their own fuel system and fuel tank sections
• Diesel note: the diesel here is the 7.3L. Ford replaced it with the 6.0L during 2003, and the 6.0L is not covered in this book. If your truck is a 2003 or 2004 with the 6.0L, every section outside the engine and its fuel system still applies
• Gearbox: 4R100 automatic with separate cooling and external control sections, the earlier E4OD, and two manuals, the ZF S5-47 five-speed and the ZF six-speed
• Rear axles: Dana 80, Dana S135 and the Ford 10.50-inch ring gear, with full floating wheel hubs documented in both Dana and Ford forms. Dual rear wheel trucks are covered throughout
• Power take-off: PTO-equipped trucks are handled in the transmission sections, with the control logic spelled out, for example that the coast clutch solenoid stays energised during PTO operation
• Language: English
• Pages: 6,567 in a single PDF
• File type: PDF

Inside this manual

Every entry below is a section present in the document, and the numbers are Ford's own:

Sample pages from this manual

These are real pages taken from the document:

What you can repair with it

The work that separates a Super Duty from a light truck is here in full. Section 501-04 covers the pickup bed and platform body, taking you through bed removal step by step with the note that the eight foot bed is shown and the six foot bed is similar. Section 502-02 covers the full frame and body mounting, with the frame assembly illustrated and every crossmember, gusset and stub assembly numbered and listed by Ford part number. If you are dealing with a chassis cab, a flatbed conversion or corrosion in the rails, that is the section you will live in.

Power take-off gets proper treatment instead of a passing mention. The transmission sections explain how a PTO-equipped truck behaves differently, including which solenoids stay energised while the PTO is running and how the powertrain control module treats the request. Anyone maintaining a truck with a tipper, a crane or a utility body will recognise why that matters.

Underneath, coverage follows the hardware, not the badge on the tailgate. The Dana 80, the Dana S135 and the Ford 10.50-inch ring gear each have their own axle section, and full floating wheel hubs are documented in both Dana and Ford forms, which is what you need for dual rear wheel trucks. Braking is split so that rear-wheel anti-lock and four-wheel anti-lock are documented apart from one another, and the front suspension is split again between two-wheel drive and four-wheel drive. Four-wheel drive systems and the transfer case each get a section of their own.

Engine work is organised the same way. The 5.4L Triton V8, the 6.8L Triton V10 and the 7.3L turbo diesel each have a full engine section, and the diesel adds its own fuel charging and controls section, a turbocharger section and a glow plug system section. Electronic engine controls are separated into gasoline and diesel, as is the starting system, so you are never reading around an engine you do not have.

Manual language and format

The manual is in English, supplied as a single PDF running to 6,567 pages. Because the text layer is intact you can search a Ford section number, a part number or a torque figure and land on the right page, and individual pages print cleanly for taking out to the truck. Any standard PDF reader opens it, on Windows, Mac, tablet or phone.

Questions about this manual

What year did Ford stop putting the 7.3 in their trucks?
The 7.3L Power Stroke diesel finished during the 2003 model year, when the 6.0L took over. That is the engine documented in this manual, so the diesel coverage here suits trucks up to that changeover. Worth clearing up a common mix-up: the 7.3L that Ford reintroduced later is a petrol V8 nicknamed the Godzilla and has nothing to do with this diesel beyond sharing a capacity.

How much can an F-350 dually tow?
A workshop manual does not carry towing ratings, and you should not take one from a website either. Your figure depends on cab, bed, axle ratio and engine, and it is printed on the door jamb sticker and in the towing guide for your build. What this manual does give you is the hardware behind the number, including the rear axles up to the Dana S135, the springs, the hitch mounting points on the frame and the frame itself.

What is the real difference between an F-250 and an F-350?
For repair purposes it comes down to what is under the back of the truck. This manual documents F-250, F-350, F-450 and F-550 side by side, and the differences that change a job are the rear axle fitted, single or dual rear wheels, and the springs. That is why the axles have separate sections by type instead of by model, and why full floating hubs are covered in both Dana and Ford versions.

Does this cover the Crew Cab and the SuperCab, or only the regular cab?
All three. The manual makes the point itself in the frame section, noting that the Crew Cab frame assembly is the one illustrated and that the regular and Super Cab frames are similar, and the body sections carry the same convention for door trim and rear door mechanisms on SuperCab and Crew Cab bodies.

Will this work on my 2004 F-250?
Yes for everything except one case. Ford dated this book to 2000 and the mechanical package carried through to 2004, so suspension, axles, brakes, frame, body, climate control and electrical all apply. The exception is the diesel engine: if your 2004 came with the 6.0L instead of the 7.3L, the engine and its fuel system sections will not match your truck, though the rest of the manual still will.

How you receive it

Checkout is secure and your download link follows straight away, with nothing posted and nothing to wait in for. Keep the file, and re-download it as needed while the link stays active.