2005–2007 Ford Five Hundred 500 Service & Repair Manual (P/N WSM-FORD-500-2005)

• The package contains 73 PDF files / 4,663 total pages, rather than one single 5,000-page owner’s manual.
• Year-specific content is split between the 2005 Ford Five Hundred Owner’s Guide, the 2005 Scheduled Maintenance Guide, and a large set of 2007 system-level repair articles labeled for the Five Hundred, Freestyle, and Montego. There is no separate 2006-labeled workshop publication in the set.
• Powertrain coverage includes the 3.0L DOHC V6, both automatic transaxle types, FWD/AWD driveline systems, ABS, steering, suspension, HVAC, SRS, body electronics, and fault-finding material.

Vehicle Systems and Interior Operation

The 2005 Owner’s Guide covers the instrument cluster and message center, Premium/Audiophile in-dash six-CD/MP3 audio with RDS, HomeLink wireless control, SecuriLock passive anti-theft, perimeter alarm, power seat/mirror/pedal memory, lighting, driver controls, and climate operation. Workshop-level articles add repair and diagnostic coverage for the instrument cluster, information and entertainment systems, seats, locks and latches, windows, mirrors, exterior and interior lighting, wipers, steering-column switches, roof opening panel, and related electrical controls. Climate-control material uses the service terminology EMTC and dual-zone EATC and includes pressure/temperature diagnosis, leak detection, refrigerant handling, and compressor/clutch service.

Ford Motor Company is identified as the publisher of the 2005 Five Hundred Owner’s Guide and Scheduled Maintenance Guide. The 2007 repair-information PDFs carry Mitchell Repair Information Company notices, while many component views and service illustrations are credited to Ford Motor Co. The package therefore combines Ford owner/maintenance literature with workshop repair information rather than representing one continuous OEM manual for every model year.

Powertrain, Diagnostics, and Repair Scope

The Owner’s Guide identifies the Five Hundred transmission codes: code A = CVT and code B = six-speed automatic (Aisin F21). The 2007 repair articles provide separate coverage for both units. The six-speed section specifies Motorcraft Premium Automatic Transmission Fluid meeting WSS-M2C924-A and a 7.0 L (7.4 qt) capacity, with gear/solenoid charts, DTC diagnosis, PID data, drive-cycle testing, torque-converter diagnosis, TCM initial learning, and transaxle removal/installation.

The CVT section goes much further into internal repair. It specifies Motorcraft Continuously Variable Chain Type Fluid WSS-M2C933-A, 9.6 L (10 qt) approximate dry fill, clutch clearances, input-shaft end play, selective differential shims, mechatronic service, primary and secondary variator covers, forward and reverse clutch work, and complete transaxle/subassembly disassembly and assembly. A useful build break is documented for transaxles built before versus after December 6, 2005, including the change from O-ring-sealed feed tubes to bonded-seal feed tubes. Specialist tools are identified by number, including Variator Assembly Holding Fixture 307-547 and Secondary Variator Compressor 307-564.

Engine repair coverage includes timing-drive components, camshafts and valve train, cylinder heads, crankshaft seals, oil pan and oil pump work, and engine removal/installation. IDS/VCM-based diagnostic material, gasoline-engine pinpoint tests, Mode $06 monitor data, ABS/vehicle-dynamics diagnosis, SRS diagnostics, and instrument-cluster testing are also included. The SRS section identifies dedicated diagnostic tools such as 418-133, 418-F395, and 418-F403.

AWD material covers the PTU, driveshaft, rear axle/differential, rear halfshafts, active on-demand coupling, oil pump, and differential electronic module (DEM). The PTU holds 0.9 L (2 pt) and treats internal gears, bearings, and shafts as non-serviceable; internal damage calls for PTU replacement, while specified seals and the output flange are serviceable. The rear axle uses separate front and rear lubricant chambers of 0.7 L (1.5 pt) each, and the DEM-controlled coupling can command up to 1,000 Nm of torque to the rear axle.

A dedicated 143-page system-wiring PDF is labeled 2007 Ford Freestyle and contains 71 numbered circuit figures. Representative names include “3.0L Engine Performance Circuit,” “AWD Circuit,” “Anti-lock Brakes Circuit,” “Passive Anti-theft Circuit,” and “Supplemental Restraints Circuit.” The Five Hundred/Freestyle/Montego repair articles also contain extensive exploded views and service figures, including PTU serviceable-component views and timing-chain alignment illustrations. Buyers specifically needing Five Hundred-labeled wiring should note the Freestyle labeling of the dedicated wiring file.

Specification Highlights and Technical Data

The 3.0L 4-valve V6 specification table lists 182 CID displacement, a 10:1 compression ratio, 5.7 L (6.0 qt) engine-oil capacity, and minimum hot oil pressure of 76 kPa (11 psi) at 1,500 rpm after the stated warm-up condition. HVAC data specifies R-134a capacity of 0.82 kg (29 oz) without auxiliary climate control and 1.08 kg (38 oz) with auxiliary climate control, with PAG oil capacities of 207 ml (7 oz) and 266 ml (9 oz), respectively. The 2005 Owner’s Guide gives 100 lb-ft (135 N·m) wheel lug-nut torque and a 19.0-gallon (71.9 L) fuel-tank capacity.

The repair procedures also spell out failure-sensitive details that matter during bench work. CVT fluid types are explicitly non-interchangeable, and solvent contamination can damage the transaxle. The variator chain must not be dragged, dropped, or solvent-cleaned; documented chain or variator damage requires replacement of all three variator components. Engine timing-drive alignment is equally critical, with incorrect alignment specifically identified as a cause of severe engine damage.

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.