2009 Ford F-550 Super Duty Service and Repair Manual

This factory service and repair manual for the 2009 Ford F-550 Super Duty covers three trims, XL, XLT and Lariat, on a chassis cab available as a four-door crew cab, a two-door conventional cab or a four-door extended cab. The two engines are the 6.4L V8 turbo diesel with overhead valves and 391 cubic inches, and the 6.8L V10 with single overhead cams, 415 cubic inches, natural aspiration and gasoline. Procedures, specifications, torque values, wiring diagrams and diagnostics are given for each engine and for the chassis, including the exhaust and power take-off area that upfitters used on this truck.

Engines covered

• 6.4L V8 (391 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

• Lariat
• XL
• XLT

Known issues on the 2009 F-550 Super Duty. Five recalls are on federal record for 2009, and all five come from upfitters rather than Ford: each involves a Muncie power take-off assembly whose pressure switch can leak oil onto the thermal blanket around the exhaust, where heat raises the risk of a fire. Owners have logged one complaint with NHTSA, on the fuel system. With the record concentrated on one add-on component, the manual's exhaust system procedures and specifications for the 6.4L diesel and 6.8L V10, and its fuel system diagnostics, are the relevant references for the chassis those PTO units were bolted to.