Ford F250 F350 F450 F550 2005 Factory Workshop Service Repair Manual

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Loaded with Hi Resolution illustrations, instructions, photos, and diagrams, complete to service and repair your FORD. Read and print pages, or copy the entire manual to your hard drive.

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Ford F250 F350 F450 F550 2005 Factory Workshop Service Repair Manual

These are the same manuals used by professionals to diagnose and repair these models.

Loaded with illustrations, instructions, photos, and diagrams, complete to service and repair your Ford. Read and print pages or copy the entire manual to your hard drive.

12180 Pages

CD COVER:

Ford F-250 F-350 F-450 F-550 2005 Service Manual

SERVICE MANUAL COVER:

General Information

Maintenance Schedules

Chassis

Suspension Removal and Installation

Suspension Disassembly and Assembly

Wheels and Tires

Tire Pressure Monitoring System (TPMS)

Driveline

Driveshaft

Rear Drive Axle|Differential

Drive Halfshafts

Brake System

Front Disc Brake

Rear Disc Brake

Parking Brake and Actuation

Hydraulic Brake Actuation

Power Brake Actuation

Anti-Lock Brake System (ABS) and Stability Control

Steering System

Power Steering

Steering Wheel Removal and Installation

Steering Column Switches

Powertrain

Engine

Engine General Procedures

Engine Assembly and Disassembly

Engine Cooling

Engine – 5.4L (3V)

Engine – 6.8L (3V)

Engine – 6.0L Diesel

Fuel Charging and Controls

Turbocharger

Starting System

Engine Ignition

Spark Plugs

Spark Plug Wires

Engine Emission Control

Positive Crankcase Ventilation (PCV) Valve

Intake Air Distribution and Filtering

Evaporative Emissions

Air Cleaner Removal and Installation

Electronic Engine Controls

Automatic Transmission

Transmission Removal and Installation

Transmission Disassembly and Assembly of Subassemblies

Transaxle|Transmission Cooling

Automatic Transaxle|Transmission External Controls

Manual Transmission, Clutch and Transfer Case

Manual Transmission Disassembly and Assembly

Four Wheel Drive (4WD) Systems

Transfer Case — Power Transfer Unit (PTU)

Exhaust System

Fuel System

Fuel Tank and Lines

Electrical

Climate Control System

Air Conditioning Removal and Installation

Instrumentation and Warning Systems

Instrumentation, Message Center, and Warning Chimes

Horn

Parking Aid — Audible

Active Park Assist

Battery and Charging System

Generator and Regulator

Information and Entertainment Systems

Audio Systems

Lighting

Exterior Lighting Removal and Installation

Fog Lamps

Headlamps

Parking, Rear and License Plate Lamps

Turn Signal and Hazard Lamps

Bulb Removal and Installation

Interior Lighting

Electrical Distribution

Anti-Theft — Passive Anti-Theft System (PATS), With Intelligent Access (IA)

Cruise Control

Remote Function

Body and Paint

Body System

Front End Body Panels

Body Closures

Doors Alignment

Hood Alignment

Luggage Compartment Lid Alignment

Front Door Removal and Installation

Rear Door Removal and Installation

Interior Trim and Ornamentation

Exterior Trim and Ornamentation

Interior Rear View Mirror Removal and Installation

Exterior Mirror Removal and Installation

Seating

Glass, Frames and Mechanisms

Instrument Panel and Console

Handles, Locks, Latches and Entry Systems — Without Intelligent Access (IA)

Wipers and Washers

Roof

Bumpers

Seatbelt System

Supplemental Restraint System

Airbag

Body Repairs

Frame and Mounting

Front End Sheet Metal Repairs

Rear End Sheet Metal Repairs

Roof Sheet Metal Repairs

Side Panel Sheet Metal Repairs

Uni-Body, Subframe and Mounting System Removal and Installation

Front Subframe

This manual is the same as the manual used by workshops. Service Manual contains detailed instructions and step by step diagrams for all workshop procedures.

Language: English
Format: PDF – Indexed and Searchable

COMPATIBLE WITH ALL WINDOWS & MAC COMPUTERS
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The 2005 Ford F-Series Super Duty trucks, including the F-250, F-350, F-450, and F-550, received significant mechanical and cosmetic updates for this model year. Notable upgrades included a more rigid frame, an improved front suspension on 4×4 models, and more powerful gasoline engines. However, the diesel engine carried over with updates but continued to have reliability concerns.

Performance and specifications

2005 Super Duty engine options

For the 2005 model year, Ford offered three engine choices:

5.4L Triton 3-Valve V8 (Gasoline): 300 horsepower and 365 lb-ft of torque. It was standard on F-250 and F-350 models.
6.8L Triton V10 (Gasoline): 362 horsepower and 457 lb-ft of torque. It was available on all Super Duty models.
6.0L Power Stroke V8 (Turbo Diesel): 325 horsepower and 570 lb-ft of torque. It was the premium engine option for maximum towing and hauling.

Transmission and drivetrain

Transmissions: A 6-speed manual transmission was standard, while Ford’s 5-speed TorqShift automatic transmission with Tow/Haul mode was a popular option.
Drivetrain: All Super Duty trucks were available in rear-wheel drive or 4-wheel drive.
Integrated Trailer Brake Controller: A factory-installed, integrated trailer brake controller was a new feature for 2005, a first for its class.

Model comparisons

F-250 vs. F-350

F-250 (3/4-ton): Considered a heavy-duty truck, but offers lower payload and towing capacity than the F-350. Can be configured with single rear wheels (SRW).
F-350 (1-ton): Also built to handle tough jobs, but offers higher payload and towing capacities than the F-250. It can be equipped with either single or dual rear wheels (DRW).

F-450 and F-550 (Chassis Cab)

Purpose: The F-450 and F-550 were exclusively sold as chassis cabs for the 2005 model year, meaning they were delivered to a third-party upfitter to install a specific body, such as a dump bed, service box, or wrecker.
Heavy-duty components: The F-450 and F-550 featured a stronger frame, wider front axles, and larger brakes compared to the F-250 and F-350 to handle significantly higher gross vehicle weight ratings (GVWR).
Higher Axle Ratings: The front axle on the F-450 and F-550 had a higher 7,000 lbs rating.
Tighter Turning: Despite a wider front track, new steering gears allowed for a tighter turning diameter.

Known problems and issues

The 2005 model year continued to be plagued by reliability issues related to the 6.0L Power Stroke diesel engine, which was carried over from previous years with minor updates. Common failures often required expensive repairs:

EGR Cooler Failure: The Exhaust Gas Recirculation (EGR) cooler could clog and fail, leading to overheating and head gasket problems.
Oil Cooler Clogging: Coolant contamination from manufacturing debris could clog the oil cooler, causing the engine to run hot.
High-Pressure Oil Pump (HPOP) Failure: This could cause the engine to crank but not start.
Delamination of Diesel Fuel Tank: The in-tank fuel pump module could cause delamination of the fuel tank liner.

Model year changes and updates

For 2005, Ford made several updates to its Super Duty lineup:

Updated Exterior: A redesigned front grille, new headlights, a revised tailgate, and larger side mirrors provided a bolder, more modern look.
Improved Suspension: 4×4 models received a new coil-spring front suspension, and all trucks got new rear springs with staggered shock geometry. This significantly improved ride quality and handling.
Powertrain Updates: The gasoline V8 and V10 engines both received new 3-valve heads, boosting horsepower and torque.
New Trim Level: The luxurious King Ranch trim was introduced for the Super Duty lineup.
Special Edition: The Harley-Davidson Edition received unique styling updates, including new black-trimmed headlights and 20-inch wheels.