Ford F250 F350 F450 F550 Super Duty 2009 Factory Workshop Service Repair Manual

Ford F250 F350 F450 F550 Super Duty 2009 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. 

24 400 Pages

CD COVER:

Ford F-250 F-350 F-450 F-550 Super Duty 2009 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 – 6.4L 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 
(WINDOWS 11, WINDOWS 10, WINDOWS 8 ETC.) 

Windows/Mac/Tablet/Phone Friendly

• 5.4L Triton 3-Valve V8 (Gasoline): This was the standard engine on F-250 and F-350 models, providing 300 horsepower and 365 lb-ft of torque.
• 6.8L Triton V10 (Gasoline): This optional engine for F-250 and F-350 models produced 362 horsepower and 457 lb-ft of torque.
• 6.4L Power Stroke V8 (Turbo Diesel): This twin-turbo diesel was standard on F-450 and F-550 models and optional for F-250 and F-350s. It was rated at 350 horsepower and 650 lb-ft of torque.

• Transmissions: A 6-speed manual transmission was standard, while an optional 5-speed TorqShift automatic transmission with a Tow/Haul mode was widely available.
• Drivetrain: Rear-wheel drive (4×2) was standard, with four-wheel drive (4×4) available across the lineup.
• TowCommand System: This system with an integrated trailer brake controller was either standard or available as an option, making towing easier and safer. 

• Towing and payload: The primary difference between the two models lies in their load-carrying capabilities. The F-350 has higher payload and towing capacities due to stronger chassis and suspension components, which include a larger rear block.
• Dual Rear Wheels (DRW): The F-350 can be configured with dual rear wheels (DRW) for increased stability and capacity, an option not available on the F-250.
• Ride quality: Because of its reinforced components, the F-350 can feel stiffer, especially when unloaded. The F-250 offers a slightly smoother ride for everyday use. 

• Purpose: In 2009, the F-450 and F-550 were exclusively sold as chassis cabs, meant to be upfitted with custom bodies for vocational purposes.
• Heavy-duty components: The F-450 and F-550 came equipped with stronger frames, wider axles, and larger brakes compared to the F-250 and F-350 to handle significantly higher gross vehicle weight ratings (GVWRs).
• Highest capacity: As the highest-rated models, the F-450 and F-550 offered the maximum payload and towing capacities in the lineup. 

• Ford Work Solutions: A collection of technologies designed for businesses, including an in-dash computer with Internet access, the Tool Link RFID tracking system, and the Cable Lock system by Master Lock.
• SYNC: The optional, voice-activated Ford SYNC system was introduced for communication and entertainment.
• Convenience features: A new tailgate step, a stowable bed extender, and power-telescoping tow mirrors were all new features.
• Limited edition trims: A new Cabela’s FX4 off-road package was added, joining the luxurious King Ranch and Harley-Davidson editions. 

• Oil dilution: Fuel mixing with the engine oil during the diesel particulate filter (DPF) regeneration process, which could cause premature engine wear.
• Radiator and EGR cooler leaks: The factory radiator and exhaust gas recirculation (EGR) coolers were prone to cracking and leaking.
• Piston failure: A known weakness in the piston design could lead to cracks, especially in engines with aftermarket tuning.
• Exhaust up-pipe cracks: The bellows in the exhaust up-pipes could fail, leading to a loss of power.
• Fuel system problems: The high-pressure common rail fuel system was sensitive to contaminated fuel, which could lead to injector and pump failure.
• 5.4L Triton V8 (Gasoline): This engine also has a reputation for reliability issues, particularly with the cam phasers and spark plugs.