2005 Ford E-350 Super Duty Service and Repair Manual

This factory service and repair manual for the 2005 Ford E-350 Super Duty covers the two trims offered that year, Base and Base Stripped, across the two-door standard cargo van, the chassis, the two-door cutaway van and the two-door extended cargo van. Three engines are documented, the 6.0L OHV turbocharged diesel V8, the 6.8L SOHC V10 and the 5.4L SOHC V8, each with its own procedures, specifications and torque values. Wiring diagrams and diagnostics are included for the engine control and fuel systems of all three, with the diesel and gasoline harness differences called out where they matter.

Engines covered

• 6.0L V8 (363 cu in) — OHV, turbocharged, diesel
• 6.8L V10 (415 cu in) — SOHC, naturally aspirated, gasoline
• 5.4L V8 (330 cu in) — SOHC, naturally aspirated, gasoline

Body styles covered

• 2-door standard cargo van
• Chassis
• 2-door cutaway van
• 2-door extended cargo van

Trims covered

• Base
• Base Stripped

Known issues on the 2005 E-350 Super Duty. Eight recalls stand on the federal record for this model year. Six come from converters whose Ricon platform-style wheelchair lifts could stow or move unintentionally and injure the occupant. One concerns replacement fuel tanks with an unsealed extra sensor hole that can leak fuel and start a fire, and another covers paratransit conversions whose air conditioning evaporator fuse holder can arc, melt and catch fire. Owners have lodged 55 complaints with NHTSA, clustering on the engine and cooling system, the fuel system and the electrical system. The manual's fuel, cooling and wiring procedures, specifications and diagnostics address exactly those areas.