Ford Five Hundred 500 Service & Repair Manual Set, 2005–2007

The owner and maintenance guides cover vehicle operation and scheduled service, while the repair articles provide system diagnosis and workshop procedures. Ford Motor Company published the 2005 guides; the repair-information PDFs carry Mitchell Repair Information Company notices, with many illustrations credited to Ford.

Edition and wiring fit: This collection combines different publications rather than one continuous OEM workshop manual for every listed model year. There is no separate 2006-labeled workshop publication, and the dedicated wiring PDF is labeled 2007 Ford Freestyle; buyers needing Five Hundred-specific wiring should check that distinction before purchase.

Searchable Text, Bookmarks and Wiring Detail

Text search and circuit labels: The PDFs contain searchable document text, but labels embedded in wiring-diagram images are not searchable. The Owner’s Guide has embedded PDF bookmarks; the other files do not. Small wire-color, connector and pin labels in the dedicated wiring file require zooming.

The ZIP contains 73 printable PDF files totaling 4,663 pages, including the 27-page general repair supplement and three otherwise blank numbered pages at the end of the Owner’s Guide. All publication page counts are listed above.

Powertrain Repair, Chassis Service and Electrical Diagnosis

These selected content highlights show the main workshop areas rather than a complete contents list. Other topics include EVAP component service and oil-life reminder resets.

• Engine repair: Step-by-step engine removal and installation, timing-drive service, cylinder-head disassembly and assembly, camshaft work, crankshaft seals, and oil-pump replacement.

• Automatic transaxles: CVT teardown and subassembly repair, plus separate six-speed diagnostic routines, transaxle removal and installation, and control-module learning procedures.

• Brakes and chassis: ABS pinpoint tests, hydraulic brake bleeding, disc-brake component replacement, wheel-bearing service, suspension repair, and alignment adjustments.

• AWD driveline: PTU seal service, driveshaft and halfshaft replacement, rear axle work, and differential electronic module diagnosis.

• Climate control: EMTC and dual-zone EATC diagnosis, blower and actuator testing, refrigerant leak detection, and compressor/clutch service.

• Electrical troubleshooting: Gasoline-engine pinpoint tests, Mode $06 monitor data, starter-circuit diagnosis, component-location information, and system wiring diagrams.

• Body and restraints: SRS fault isolation and component service, plus repair information for seats, locks, windows, mirrors, lighting, wipers, and the roof opening panel.

The workshop material suits experienced technicians equipped for scan-tool diagnosis, electrical testing and supported powertrain work; the Owner’s Guide also covers everyday operation and basic checks.

Six-Speed Diagnosis and CVT Bench Repair

Six-speed automatic: Gear and solenoid charts, DTC diagnosis, PID data, drive-cycle testing, torque-converter diagnosis and TCM initial learning support fault isolation before transaxle replacement. The fluid specification is Motorcraft Premium Automatic Transmission Fluid meeting WSS-M2C924-A, with a listed capacity of 7.0 L (7.4 qt).

CVT repair depth: The CVT article includes clutch clearances, input-shaft end play, selective differential shims, mechatronic service, primary and secondary variator covers, and forward/reverse clutch work. It specifies Motorcraft Continuously Variable Chain Type Fluid WSS-M2C933-A and an approximate dry-fill capacity of 9.6 L (10 qt).

Build-date differences: Feed-tube lengths and seals differ for transaxles built before and after December 6, 2005. These distinctions help match the mechatronic service procedure to the transaxle on the bench; using the wrong feed-tube arrangement can cause cross-leakage.

Specialist equipment includes Variator Assembly Holding Fixture 307-547 and Secondary Variator Compressor 307-564. CVT fluid is not interchangeable with the other listed transmission fluids, and solvent contamination can damage internal components.

The variator chain must not be dragged, dropped or solvent-cleaned; damage to the chain or either variator requires replacement of all three components.

Engine Testing, Timing and Repair Limits

The engine material covers compression testing, leakage diagnosis and component inspection, alongside the illustrated timing-drive, valve-train and lubrication-system procedures. Timing-chain alignment illustrations show the required relationship between the crankshaft and camshafts; incorrect alignment can cause severe engine damage.

Short-block scope: Cylinder-head disassembly and assembly are included. For specified piston, cylinder and crankshaft-bearing faults, the diagnostic charts direct short-block replacement rather than a piston-and-crankshaft overhaul procedure.

AWD Coupling and PTU Service

The rear driveline material covers the active on-demand coupling, oil pump, rear halfshafts and differential electronic module (DEM). The coupling and rear differential use different lubricants in separate front and rear chambers, each listed at 0.7 L (1.5 pt); the DEM can regulate up to 1,000 Nm at the coupling.

The PTU has its own 0.9 L (2 pt) oil sump. Its serviceable components are the specified seals, deflector and output flange; worn or damaged internal gears, bearings or shafts call for PTU replacement.

Interior Controls, HVAC and Diagnostic References

The Owner’s Guide explains the instrument cluster and message center, Premium/Audiophile six-CD/MP3 audio with RDS, HomeLink, SecuriLock passive anti-theft, the perimeter alarm, and seat/mirror/pedal memory functions.

Body-system articles add component replacement and fault testing for the instrument cluster, entertainment equipment, seats, locks, glass, mirrors, interior and exterior lighting, wipers, steering-column switches and roof opening panel.

Climate-control diagnosis: EMTC and dual-zone EATC coverage includes pressure/temperature diagnosis, fluorescent and electronic leak detection, refrigerant recovery and charging, and compressor/clutch work. EATC procedures distinguish current faults from intermittent faults and explain where scan-tool diagnosis is required.

Electrical references: IDS/VCM-based diagnostic material accompanies the gasoline-engine pinpoint tests, Mode $06 monitor data, ABS/vehicle-dynamics diagnosis, SRS diagnostics and instrument-cluster testing. SRS tool references include 418-133, 418-F395 and 418-F403.

The dedicated wiring file contains 71 numbered circuit figures, including “3.0L Engine Performance Circuit,” “AWD Circuit,” “Anti-lock Brakes Circuit,” “Passive Anti-theft Circuit” and “Supplemental Restraints Circuit.” Other service figures include PTU serviceable-component views and timing-chain alignment illustrations.

Some diagnostic procedures also call for current OASIS messages, technical service bulletins or calibration updates obtained separately.

Because the set includes SRS, brake, hoist-supported driveline work and R-134a A/C service, follow the stated depowering, support and refrigerant-recovery precautions before beginning repair work.

Examples of Engine Oil and Climate-Control Specifications

The Duratec V6 specification table lists a 10:1 compression ratio and 5.7 L (6.0 qt) engine-oil capacity with a filter change. Minimum oil pressure is 76 kPa (11 psi) at 1,500 rpm with the engine warmed up after 10 minutes of idling.

The shared-platform HVAC data lists R-134a capacity of 0.82 kg (29 oz) without auxiliary climate control and 1.08 kg (38 oz) with it. Corresponding PAG oil capacities are 207 ml (7 oz) and 266 ml (9 oz), respectively.