2004 Ford F-650 Service and Repair Manual
This factory service and repair manual for the 2004 Ford F-650 covers the medium duty straight truck in Base trim, in two-door long conventional, four-door extended cab and four-door crew cab forms, with three turbocharged diesels: the 5.9L inline-six of 359 cubic inches, the 7.2L inline-six of 441 cubic inches and the 6.0L V8 of 365 cubic inches. The engine and cooling system and the air brakes carry the weight of this year's record, and the procedures, specifications, torque values, wiring diagrams and diagnostics for those systems on each engine are the core of the reference.
Engines covered
- 5.9L inline-six (359 cu in) — turbocharged, diesel
- 7.2L inline-six (441 cu in) — turbocharged, diesel
- 6.0L V8 (365 cu in) — turbocharged, diesel
Body styles covered
- 2-door straight truck, long conventional
- 4-door straight truck, extended cab
- 4-door straight truck, crew cab
Trims covered
- Base
Known issues on the 2004 F-650. Two recalls are on federal record for the 2004 F-650: air brake lines that may be misrouted between the primary and secondary reservoir tanks, so a loss of air from the primary tank leaves the truck without service brakes, and tire placard and incomplete vehicle labels that may carry incorrect metric tire pressure information. Owners have logged 10 complaints with NHTSA, four on the engine and engine cooling, two on tires and two on the service brakes. The manual's air brake line routing procedures, tire pressure specifications and cooling system diagnostics for the three diesels cover those areas.
CERTAIN MEDIUM DUTY CHASSIS CABS FAIL TO COMPLY TO THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 121, "AIR BRAKE SYSTEMS." THE AIR BRAKE LINES MAY BE MISROUTED BETWEEN THE PRIMARY AN
CERTAIN MEDIUM DUTY CHASSIS CABS FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 120, "TIRE SELECTION AND RIMS FOR MOTOR VEHICLES OTHER THAN PASSENGER CARS." THE TIR
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
6.0L TURBOCHARGER CARBON DEPOSIT DIAGNOSTICS AND SERVICE TIPS. *NJ UPDATED 5/29/08. *NJ
2004-2006 F-650/F-750 AND 2006 LCF - FUEL TANKS. *NJ
6.0L--MIL ON--P0401, P0402, P0404, P1335--LACK OF POWER OR SURGE WITH SOME 2003-2007 F-SUPER DUTY, 2003-2005 EXCURSION AND 2004-2008 E-SERIES VEHICLES. *NJ
SOME 2004-2008 F-SUPER DUTY 650-750 VEHICLES EQUIPPED WITH AIR SUSPENSION MAY EXHIBIT A CONDITION WHERE THE AIR SUSPENSION SPRINGS ARE NOT RE-INFLATING. *NJ
BRAKE BOOSTER SYSTEM MAY EXHIBIT A BRAKE PEDAL KICKBACK AND/OR GRABBING CONDITION WHEN APPLYING THE BRAKES. *NJ
Showing the 8 most recent of 61 technical service bulletins on file with NHTSA.
The contact works for a trucking company that owns a 2004 Ford F-650 SD 3-Ton Commercial Vehicle. The contact stated that the gear shifter rubber boot was not securely mounted onto the floorboard, resulting in a gap that allowed the driver
LIGHTS ON THE UNIT WILL JUST SHUT OF RANDOMLY I BOUGHT THIS NEW AUG 24 2007 DEALER LOOKED AT IT SAID ITS A FORD ISSUE I CONTACTED FORD TO GET REPAIRED FORD SAYS IT IS OUT OF WARRANTY. THE DEALER HAD TO SEND IN A FORM ON LINE TO GET WARRANTY
Showing the 2 most serious of 10 complaints filed with NHTSA.
