2005 Ford E-250 Service and Repair Manual

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Factory-Grade Data

The 2005 Ford E-250 service and repair manual is a detailed, OEM-style reference for diagnostics, maintenance, and repair work. Use it to verify procedures, specifications, and system information before you start a job.

You'll find coverage across key vehicle systems with clear section structure, including wiring diagrams and powertrain, braking, steering, suspension, HVAC, and electrical topics. Digital format makes it easy to search while you work.

Trims covered

  • Base Extended Cargo Van 3-Door
  • Base Standard Cargo Van 3-Door
  • Base Stripped Chassis

Engines covered

  • 4.6L 281Cu. In. V8 GAS SOHC Naturally Aspirated
  • 5.4L 330Cu. In. V8 GAS SOHC Naturally Aspirated

Index / Table of contents

  • Body
  • Brakes
  • Chassis Electrical
  • Driveline
  • Engine Cooling
  • Engine Electrical
  • Engine Mechanical
  • Engine Performance & Emission Controls
  • Fuel System
  • General Information & Identification
  • Heating, Ventilation, & Air Conditioning
  • Hybrid & Electric Vehicle Systems
  • Steering
  • Suspension
  • Transmission, Clutch, & Transfer Case
  • Wiring Diagrams

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Vehicle Safety Data

2005 Ford E-250 Recalls & Complaints

NHTSA #09V24300029/06/2009Component: EQUIPMENT ADAPTIVE/MOBILITY

HANDICAPPED DRIVER SERVICES IS RECALLING 3 MODEL YEAR 2004 AND 2005 FORD E-250 TRANSIT BUSES BUILT ON FORD CHASSIS AND EQUIPPED WITH RICON PLATFORM STYLE WHEELCHAIR LIFTS. THESE V

Consequence

THE USER OF THE LIFT COULD BE INJURED SHOULD THE LIFT MOVE UNINTENTIONALLY.

Remedy

HANDICAPPED DRIVER SERVICES IS WORKING WITH RICON TO CORRECT THE WHEELCHAIR LIFTS FREE OF

NHTSA #09V10000027/03/2009Component: EQUIPMENT ADAPTIVE/MOBILITY

VAN CONVERSIONS IS RECALLING 52 MY 2004-2007 FORD E-150, E-250 E-350 AND MY 2006 GM SAVANNA 3500 VANS BUILT ON FORD AND GM CHASSIS AND EQUIPPED WITH RICON PLATFORM STYLE WHEELCHAIR

Consequence

A LIFT OCCUPANT CAN BE INJURED SHOULD THE LIFT BEGIN TO STOW UNINTENTIONALLY.

Remedy

VAN CONVERSIONS IS WORKING WITH RICON TO CORRECT THE WHEELCHAIR LIFTS FREE OF CHARGE (PLEA

NHTSA #09V10200027/03/2009Component: EQUIPMENT ADAPTIVE/MOBILITY

VAN CONVERSIONS IS RECALLING 74 MY 2004-2007 FORD E-150, E-250 E-350 AND MY 2006 GM SAVANNA 3500 VANS BUILT ON FORD AND GM CHASSIS AND EQUIPPED WITH RICON PLATFORM STYLE WHEELCHAIR

Consequence

THE USER OF THE LIFT COULD BE INJURED SHOULD THE LIFT MOVE UNINTENTIONALLY.

Remedy

VAN CONVERSIONS IS WORKING WITH RICON TO CORRECT THE WHEELCHAIR LIFTS FREE OF CHARGE (PLEA

NHTSA #09V24200026/06/2009Component: EQUIPMENT ADAPTIVE/MOBILITY

HANDICAPPED DRIVER SERVICES IS RECALLING 3 MODEL YEAR 2004 AND 2005 FORD E-250 RENTAL VANS BUILT ON FORD CHASSIS AND EQUIPPED WITH RICON PLATFORM STYLE WHEELCHAIR LIFTS. THESE VEH

Consequence

THE USER OF THE LIFT COULD BE INJURED SHOULD THE LIFT MOVE UNINTENTIONALLY.T

Remedy

HANDICAPPED DRIVER SERVICES IS WORKING WITH RICON TO CORRECT THE WHEELCHAIR LIFTS FREE OF

NHTSA #08V48900022/09/2008Component: EQUIPMENT ADAPTIVE/MOBILITY

QUALITY VAN SALES IS RECALLING 18 MY 2005-2007 FORD E-250, MY 2006 FORD E-350 AND CHEVROLET EXPRESS VANS EQUIPPED WITH RICON PLATFORM STYLE WHEELCHAIR LIFTS. THESE LIFTS FAIL TO

Consequence

A LIFT OCCUPANT CAN BE INJURED SHOULD THE LIFT BEGIN TO STOW UNINTENTIONALLY.

Remedy

QUALITY VAN SALES IS WORKING WITH RICON TO CORRECT THE WHEELCHAIR LIFTS FREE OF CHARGE (PL

NHTSA #08V48800022/09/2008Component: EQUIPMENT ADAPTIVE/MOBILITY

QUALITY VAN SALES IS RECALLING 18 MY 2005-2007 FORD E-250, MY 2006 FORD E-350, AND CHEVROLET EXPRESS VANS EQUIPPED WITH RICON PLATFORM STYLE WHEELCHAIR LIFTS. THESE VEHICLES FAIL

Consequence

THE USER OF THE LIFT COULD BE INJURED SHOULD THE LIFT MOVE UNINTENTIONALLY.

Remedy

QUALITY VAN SALES IS WORKING WITH RICON TO CORRECT THE WHEELCHAIR LIFTS FREE OF CHARGE (PL

NHTSA #11E04700008/11/2011Component: FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY

FORD IS RECALLING CERTAIN REPLACEMENT FUEL TANKS THAT COULD BE INSTALLED INTO MODEL YEAR 2004 THROUGH 2008 E-150, E-250, AND E-350 VANS AND WAGONS. THE AFFECTED FUEL TANKS HAVE A

Consequence

A FUEL LEAK IN THE PRESENCE OF AN IGNITION SOURCE MAY RESULT IN A FIRE.

Remedy

FORD WILL NOTIFY OWNERS, AND DEALERS WILL REPLACE THE FUEL TANKS FREE OF CHARGE. THE SAFE

NHTSA #09V24900001/07/2009Component: EQUIPMENT ADAPTIVE/MOBILITY

J'S MOBILITY UNLIMITED, INC., IS RECALLING ONE MODEL YEAR 2005 FORD E-250 VAN EQUIPPED WITH A RICON PLATFORM STYLE WHEELCHAIR LIFT. THIS VEHICLE FAILS TO COMPLY WITH THE REQUIREME

Consequence

THE USER OF THE LIFT COULD BE INJURED SHOULD THE LIFT MOVE UNINTENTIONALLY.

Remedy

J'S MOBILITY UNLIMITED IS WORKING WITH RICON TO CORRECT THE WHEELCHAIR LIFTS FREE OF CHARG

NHTSA #09V25000001/07/2009Component: EQUIPMENT ADAPTIVE/MOBILITY

J'S MOBILITY UNLIMITED, INC., IS RECALLING ONE MODEL YEAR 2005 FORD E-250 VAN EQUIPPED WITH A RICON PLATFORM STYLE WHEELCHAIR LIFT. THIS VEHICLE FAILS TO COMPLY WITH THE REQUIREME

Consequence

THE USER OF THE LIFT COULD BE INJURED SHOULD THE LIFT MOVE UNINTENTIONALLY.

Remedy

J'S MOBILITY UNLIMITED IS WORKING WITH RICON TO CORRECT THE WHEELCHAIR LIFTS FREE OF CHARG

TSB #10243490

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

TSB #10178768

These SKUs are Trailer Brake Control Modules. The customer communication requested return of unsold inventory due to an internal software issue. The internal software issue leads to a false check trailer brake message and Trailer Brake Cont

TSB #10096432

ON SOME VEHICLES, WHEN THE GATEWAY 401 MODULE TRANSITIONS FROM ITS POWER DOWN MODE (IGNITION OFF) TO ITS POWER UP MODE (IGNITION ON) THE MODULE MAY NOT WAKE UP. IF THIS ACTION OCCURS, THE MODULE'S LED DISPLAY PANELS WILL NOT PROVE-OUT AND T

TSB #10096425

GTWY501-AI MODULE REPEATEDLY RESETS DUE TO EXCESSIVE AMBIENT TEMPERATURE OF 150 F OR HIGHER, MODULE WILL NOT FUNCTION AND ALL LED'S FLASH REPEATEDLY.

TSB #10056196

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

TSB #10055629

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

TSB #10022675

BRAKE BOOSTER SYSTEM MAY EXHIBIT A BRAKE PEDAL KICKBACK AND/OR GRABBING CONDITION WHEN APPLYING THE BRAKES. *NJ

TSB #10022243

LACK OF POWER DUE TO LOW FUEL PRESSURE - FUEL TANK LINER SEPERATION. *KB

Showing the 8 most recent of 56 technical service bulletins on file with NHTSA.

20050722Component: AIR BAGS:SIDE/WINDOWCrash reportedFire reported1 injured

DT: CONTACT'S VEHICLE WAS INVOLVED IN AN ACCIDENT ON JULY 18, 2005. THE VEHICLE DID NOT BELONG TO THE CONTACT, BUT WAS A COMPANY VEHICLE. THE VEHICLE STRUCK A POLE FROM THE RIGHT

20100218Component: TIRESCrash reported1 injured

2005 FORD ECONLINE E250 LEFT REAR TIRE BLEW OUT CAUSING THE DRIVER TO LOSE CONTROL AND DROVE DOWN AN EMBANKMENT INTO A DITCH. *KB THE DRIVER CLAIMED MINOR INJURY TO HIS RIGHT HAN

20171203Component: STEERINGCrash reported

WARNING. SAFETY HAZARD ABOUT DURALAST CENTER LINK PART# DS1287, ALTERNATIVE PART NUMBER:DS6070X. I INSTALLED THIS PART IN 2005 FORD E250 BUT YOU CAN INSTALL THIS PART IN OTHER VEHI

20190708Component: ELECTRONIC STABILITY CONTROL (ESC)

STALLS OUT WHEN DRIVING AND HAS NO TURBO BOOST LIKE IT SHOULD. ALSO USES WAY TO MUCH DIESEL BURNS THRU TO FAST.

Showing the 4 most serious of 12 complaints filed with NHTSA.

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