2004 Ford F-550 Super Duty Service and Repair Manual
This factory service and repair manual for the 2004 Ford F-550 Super Duty is written for two engines, the 6.0L V8 turbo diesel with overhead valves and 363 cubic inches, and the 6.8L SOHC V10 gasoline engine, naturally aspirated at 415 cubic inches. The chassis cab came as a four-door crew cab, a two-door conventional cab or a four-door extended cab, in Base, XL, XLT and Lariat trims. The procedures, specifications, torque values, wiring diagrams and diagnostics separate the diesel and the V10 where their fuel, electrical and cooling systems differ and treat the chassis under all four trims together.
Engines covered
- 6.0L V8 (363 cu in) — OHV, turbocharged, diesel
- 6.8L V10 (415 cu in) — SOHC, naturally aspirated, gasoline
Body styles covered
- 4-door cab & chassis, crew cab
- 2-door cab & chassis, conventional
- 4-door cab & chassis, extended cab
Trims covered
- Base
- Lariat
- XL
- XLT
Known issues on the 2004 F-550 Super Duty. Three recalls are on federal record for 2004: service replacement tail lamps that may not function, an aftermarket seven-way trailer wiring adaptor wired incorrectly so trailer lights fail, and wiring on 6.0L diesel trucks that can cause stalling without warning and prevent a restart. Owners have logged 49 complaints with NHTSA, split mainly between the fuel system with 18 and the engine and engine cooling with 16, with five on the electrical system. Fuel delivery, engine cooling and wiring on the 6.0L diesel are exactly what the manual's procedures, wiring diagrams and diagnostics for that engine address.
FORD IS RECALLING CERTAIN MODEL YEAR 2011 RANGER TRUCKS BUILT FROM JANUARY 25, 2011, THROUGH APRIL 25, 2011 AT THE TWIN CITIES ASSEMBLY PLANT, AND SERVICE PARTS DISTRIBUTED TO DEALERS FOR CERTAIN 2004
CERTAIN CEQUENT 90 DEGREE 7-WAY RIGHT ANGLE ADAPTORS SOLD BY DISTRIBUTORS IN TOW PACKAGES FOR AFTERMARKET SALES TO TOW 5TH WHEEL RV TRAVEL TRAILERS. DUE TO INCORRECT WIRING OF THE HARNESS, THE TRAILE
CERTAIN PICKUP TRUCKS, SPORT UTILITY VEHICLES AND VANS EQUIPPED WITH 6.0L DIESEL ENGINES MAY EXPERIENCE STALLING WITHOUT WARNING WHILE DRIVING AND MAY OR MAY NOT RESTART.
When performing any transmission fluid changes or topoffs involving MERCON SP, MERCON LV has replaced all versions of MERCON SP and can be used going forward. Mixing MERCON LV and MERCON SP in the same transmission is acceptable. After 30-J
This SKU is a Transmission Line. The customer communication requested return of unsold inventory to inspect the connector. The transmission line connector may have an incorrect thread size, which will prevent it from being installed.
FORD: WHEN SHIFTING BETWEEN PARK, REVERSE AND/OR DURING 2-3 SHIFT, AN INTERMITTENT CLUNK OCCURS WITH A TORQSHIFT TRANSMISSION. MODEL 2003-2014 F-SUPER DUTY, E SERIES, EXCURSION, F-53 MOTORHOME CHASSIS, LOW CAB FORWARD. *PE
FORD: THE RESTRAINT CONTROL MODULE (RCM) WHEN USING VCM II, WOULD HAVE AN ERROR CODE 35 AND DIAGNOSTIC TROUBLE CODE (DTC) B1035, AND DIFFICULTY ATTEMPTING PROGRAMMABLE MODULE INSTALLATION (PMI). MODEL 2001-2004 F-SUPER DUTY. *PE
FORD: ON SOME TRUCKS, THERE IS A NO CRANK SITUATION AND IF VOLTAGE ON TRANSMISSION RANGE SENSOR AT PIN 21, IS LESS THAN 5 VOLTS, DISCONNECT THE ENGINE COOLING FAN CLUTCH, ELECTRONICALLY, AND RECHECK VOLTAGE. MODEL 2003-2007 F SUPER DUTY, 20
DTC'S P006A OR P132B - LACKS POWER, SURGE, OR FLUTTER AFTER FIELD SERVICE ACTION 06E17. *KB
REPEAT TURBOCHARGER OR VGT REPLACEMENT. *TT
MISFIRE, LACK OF POWER, BUCK/JERK, EXCESSIVE SMOKE OR CRANK/NO START. *TT
Showing the 8 most recent of 126 technical service bulletins on file with NHTSA.
TL* THE CONTACT OWNS A 2004 FORD F-550 SUPER DUTY. WHILE THE LINK WAS IN THE AIR WITH A WORKER LOCATED IN THE BUCKET, THE LINK FRACTURED WITHOUT WARNING. THE WORKER'S BUCKET CAME DOWN WITH FORCE CAUSING INJURY TO HIS HEAD, BACK, AND PELVIC
TL* THE CONTACT OWNS A 2004 FORD F-550. THE CONTACT STATED THAT THE VEHICLE WOULD NOT START. THE DEALER DIAGNOSED THAT THE FUEL INJECTOR WIRE WAS MELTING ON THE ENGINE. THE VEHICLE WAS REPAIRED AND RECURRED. THE MANUFACTURER WAS NOTIFIE
Showing the 2 most serious of 49 complaints filed with NHTSA.
