2004 Ford F-150 Service & Repair Manual

About This Manual Printable View (8 KB) Introduction To make it easier to locate information, we have consolidated several small sections into a single section. Those sections are: 204-00 — Suspension System (now includes front suspension, rear suspension and wheels and tires). 205-00 — Driveline System (now includes driveshaft, axle and halfshafts). 206-00 — Brake System (now includes front brakes, rear brakes, caliper, brake booster and parking brake). 211-00 — Steering System (now includes steering gear, pump, linkage, column and column switches). 303-01 Engine (now includes accessory drive and emission controls). 303-04 Intake Air, Fuel Charging and Engine Electronics (now includes intake air, fuel charging, starting system and electronic engine controls). 307-01 — Automatic Transmission/Transaxle (now includes cooling and external controls). 310-00 — Fuel System (now includes tanks, lines, pump, filter, pedal and linkage and evaporative emissions). 412-00 — Climate Control System (now includes air distribution, heating, air conditioning, auxiliary climate control and control components). 413-00 — Information, Gauge and Warning Devices (now includes illumination, cluster, horn, clock, message center, warning devices, and parking aid). 414-00 — Battery and Charging System (now includes battery and generator). 415-00 — Entertainment System (now includes all video and audio components). 418-00 — Module Communications Network (now includes all module diagnostics and configuration). 419-02 — Electronic Features (now includes remote convenience, telematics, cell phone, navigation and compass). 501-00 — Body System — Exterior (now includes body panels, exterior trim, mirrors, glass, bumpers and wiper system). 501-01 — Body System — Interior (now includes interior trim, instrument panel and console and roof opening panel). SECTION 100-00: General Information 2004 F-150 Workshop Manual DESCRIPTION AND OPERATION Procedure revision date: 11/11/2003 Page 1 of 2 2004 F-150 Workshop Manual

How To Use This Manual Printable View (20 KB) Icons There are ten symbols indicating oil, grease, sealant, visual inspection, use of special service tools and removal and installation details. These symbols show the points of inspecting, applying or using such materials during service. SECTION 100-00: General Information 2004 F-150 Workshop Manual DESCRIPTION AND OPERATION Procedure revision date: 05/28/2003 Symbol Meaning Apply petroleum jelly Apply oil Apply fluid Apply grease Apply sealant Inspect Page 1 of 3 2004 F-150 Workshop Manual

General Standards All left- and right-hand references to the vehicle are taken from a position sitting in the driver seat looking forward. All left- and right-hand references to the engine are taken from a position at the flywheel looking toward the front camshaft pulley. Where appropriate, instructions will be given for the use of Worldwide Diagnostic System (WDS), Ford Diagnostic System (FDS) 2000 or New Generation STAR (NGS) Tester diagnostic equipment. Install new Use special tool Installation/assembly Removal/disassembly Page 2 of 3 2004 F-150 Workshop Manual

Identification Codes Printable View (469 KB) Vehicle Identification Number Vehicle Identification Number (VIN) Tag Locator The vehicle identification number (VIN) is a seventeen-digit combination of letters and numbers. The VIN is stamped on a metal tab riveted on the instrument panel, top upper left of the dash. The VIN is also found on the vehicle certification (VC) label. SECTION 100-00: General Information 2004 F-150 Workshop Manual DESCRIPTION AND OPERATION Procedure revision date: 05/28/2003 Item Description 1 World manufacturer identifier 2 Brake type and gross vehicle weight rating (GVWR) 3 Vehicle line, series, body type Page 1 of 16 2004 F-150 Workshop Manual

World Manufacturer Identifier The first three vehicle identification number (VIN) positions are the world manufacturer identifier. 1FT — Ford Motor Company, USA, truck (completed vehicle) Brake Type and Gross Vehicle Weight Rating (GVWR) The fourth VIN position is the vehicle brake type and gross vehicle weight rating (GVWR) code, all vehicles use hydraulic brakes. This code may also identify the vehicle safety restraint system. R — 6,001-7,000 pounds GVWR with driver and front passenger air bags P — 7,001-8,000 pounds GVWR with driver and front passenger air bags V — 8,001-9,000 pounds GVWR with driver and front passenger air bags Line, Series and Body Type 4 Engine type 5 Check digit 6 Model year 7 Assembly plant 8 Production sequence number Page 2 of 16 2004 F-150 Workshop Manual

VIN positions five through seven indicate the vehicle line, series and body type. F02 — F-150, 4x2, regular cab, flareside F04 — F-150, 4x4, regular cab, flareside F12 — F-150, 4x2, regular cab, styleside F14 — F-150, 4x4, regular cab, styleside W12 — F-150, 4x2, Crew Cab, 5.5 ft. styleside W14 — F-150, 4x4, Crew Cab, 5.5 ft. styleside X02 — F-150, 4x2, SuperCab, 6.5 ft. flareside X04 — F-150, 4x4, SuperCab, 6.5 ft. flareside X12 — F-150, 4x2, SuperCab, 8 ft. styleside, 5.5 ft. styleside, 6.5 ft. styleside X14 — F-150, 4x4, SuperCab, 8 ft. styleside, 5.5 ft. styleside, 6.5 ft. styleside Engine Type The eighth VIN position is the engine type (displacement and number of cylinders). 5 — 5.4L, 3-valve, SOHC, V8, EFI W — 4.6L, SOHC, V8, EFI Check Digit Page 3 of 16 2004 F-150 Workshop Manual

The ninth VIN position is a government assigned, computer-generated check digit. Model year The tenth VIN position is the model year code. 4 — 2004 Assembly Plant The eleventh VIN position is the assembly plant code. K — Kansas City — Claycomo, Missouri, USA N — Norfolk — Norfolk, Virginia, USA Build Sequence Page 4 of 16 2004 F-150 Workshop Manual

VIN positions 12 through 17 are an alphanumeric code for the vehicle build sequence. This is also the vehicle serial and warranty number. A00001-F99999 Vehicle Certification (VC) Codes Vehicle Certification (VC) Label Locator Page 5 of 16 2004 F-150 Workshop Manual

The vehicle (VC) label contains information on the manufacturer name, the month and year of manufacture, the certification statement and the VIN. This label also includes gross vehicle weight (GVWR) information. Exterior Paint Item Description 1 Exterior paint code 2 Region code 3 Domestic special order 4 Wheelbase code 5 Brake code 6 Interior trim code 7 Tape/paint stripe code 8 Radio code 9 Axle code 10 Transmission code 11 Spring code 12 Powertrain calibration information Page 6 of 16 2004 F-150 Workshop Manual

Exterior paint codes may be listed as a two-part code. The first set of characters identify the primary body color. The second set of characters (if applicable) identify the vehicle accent or two-tone body color. Primary Exterior Color Codes AQ — Arizona Beige CX — Dark Shadow Gray (clear coat) D6 — Screaming Yellow E4 — Vermilion (clear coat) JL — Dark Toreador Red L2 — True Blue Pearl (clear coat) LD — Medium Wedgewood Blue (clear coat) P5 — Aspen Green Metallic (clear coat) UA — Ebony (clear coat) YN — Silver Metallic (clear coat) YZ — Oxford White (clear coat) Exterior Accent Color Codes AQ — Arizona Beige (body side moulding) CX — Dark Shadow Gray (body side moulding) YN — Silver Metallic (wheel opening moulding) Wheelbase Page 7 of 16 2004 F-150 Workshop Manual

2004 Ford F-150 Service & Repair Manual

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