FORD RANGER Workshop Manual

FORD RANGER 2011.50MY WORKSHOP REPAIR MANUAL

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FOREWORD To the best of our knowledge, the illustrations, technical information, data and descriptions in this issue were correct at the time of going to print. The right to change prices, specifications, and equipment and maintenance instructions at any time without notice is reserved as part of FORD policy of continuous development and improvement for the benefit of our customers. No part of this publication may be reproduced, stored in a data processing system or transmitted in any form, electronic, mechanical, photocopy, recording, translation or by any other means without prior permission of Ford Motor Company. No liability can be accepted for any inaccuracies in this publication, although every possible care has been taken to make it as complete and accurate as possible. © Ford Motor Company 2011

2011.50 Ranger


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(110kW/150PS) - Puma/3.2L Duratorq-TDCi (148kW/200PS) Puma 303-05B Starting System - 2.5L Duratec-HE (122kW/165PS) - MI4 303-06A Starting System - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L Duratorq-TDCi (148kW/200PS) Puma 303-06B Engine Ignition - 2.5L Duratec-HE (122kW/165PS) - MI4 303-07A Glow Plug System - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma 303-07B Glow Plug System - 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-07C Engine Emission Control - 2.2L Duratorq-TDCi (88kW/120PS) Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-08A Engine Emission Control 303-08B Intake Air Distribution and Filtering 2.5L Duratec-HE (122kW/165PS) MI4 303-12A Intake Air Distribution and Filtering 2.2L Duratorq-TDCi (88kW/120PS) Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-12B Evaporative Emissions 303-13 Electronic Engine Controls - 2.5L Duratec-HE (122kW/165PS) MI4 303-14A Electronic Engine Controls - 2.2L Duratorq-TDCi (88kW/120PS) Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-14B Automatic Transmission/Transaxle Automatic Transmission/Transaxle Vehicles With: 6-Speed Automatic Transaxle - 6R80 307-01

Transmission/Transaxle Cooling 307-02 Automatic Transmission/Transaxle External Controls 307-05 Manual Transmission/Transaxle, Clutch and Transfer Case Manual Transmission/Transaxle and Clutch - General Information 308-00 Clutch - Vehicles With: 5-Speed Manual Transmission - MT75 308-01A Clutch - Vehicles With: 6-Speed Manual Transmission - MT82 308-01B Clutch Controls - Vehicles With: 5-Speed Manual Transmission MT75 308-02A Clutch Controls - Vehicles With: 6-Speed Manual Transmission MT82 308-02B Manual Transmission/Transaxle Vehicles With: 5-Speed Manual Transmission - MT75 308-03A Manual Transmission/Transaxle Vehicles With: 6-Speed Manual Transmission - MT82 308-03B Manual Transmission/Transaxle External Controls - Vehicles With: MT-75 308-06A Manual Transmission/Transaxle External Controls - Vehicles With: MT82 308-06B Transfer Case - Vehicles With: 5-Speed Manual Transmission MT75/6-Speed Manual Transmission - MT82 308-07A Transfer Case - Vehicles With: 6-Speed Automatic Transaxle 6R80 308-07B Exhaust System Exhaust System - 2.5L Duratec-HE (122kW/165PS) - MI4 309-00A Exhaust System - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L Duratorq-TDCi (148kW/200PS) Puma 309-00B Fuel System - General Information Fuel System - General Information 2.5L Duratec-HE (122kW/165PS) MI4 310-00A Fuel System - General Information 2.2L Duratorq-TDCi (88kW/120PS) Puma/2.2L Duratorq-TDCi 2011.50 Ranger



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(96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma Fuel Tank and Lines Fuel Tank and Lines - 2.2L Duratorq-TDCi (88kW/120PS) Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma Acceleration Control

Electrical Distribution Module Communications Network 310-00B Module Configuration 310-01A Wiring Harnesses Electronic Feature Group Anti-Theft - Active Anti-Theft - Passive Multifunction Electronic Modules

418-00 418-01 418-02 419-01A 419-01B 419-10

310-01B 310-02

GROUP 4 Electrical

GROUP 5 Body & Paint

Climate Control System Climate Control System - General Information 412-00 Climate Control 412-01 Auxiliary Climate Control 412-02 Instrumentation and Warning Systems Instrument Cluster 413-01 Horn 413-06 Warning Devices 413-09 Parking Aid 413-13 Battery and Charging System Charging System - General Information 414-00 Battery, Mounting and Cables 414-01 Generator and Regulator 414-02 Information and Entertainment Systems Information and Entertainment System - General Information 415-00 Information and Entertainment System 415-01 Lighting Exterior Lighting 417-01 Interior Lighting 417-02 Daytime Running Lamps (DRL) 417-04

2011.50 Ranger


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GROUP

General Information SECTION TITLE

1 PAGE

Service Information General Information.......................................................................................................100-00 Identification Codes.......................................................................................................100-01 Jacking and Lifting.........................................................................................................100-02 Noise, Vibration and Harshness....................................................................................100-04

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SECTION TITLE PAGE Suspension Wheel Alignment Specifications Suspension System - General Information....................................................................204-00 Front Suspension...........................................................................................................204-01 Rear Suspension...........................................................................................................204-02 Wheels and Tires...........................................................................................................204-04 Driveline Driveshaft.......................................................................................................................205-01 Rear Drive Axle/Differential............................................................................................205-02 Front Drive Axle/Differential...........................................................................................205-03 Front Drive Halfshafts....................................................................................................205-04 Rear Drive Halfshafts.....................................................................................................205-05 Brake System Brake System - General Information..............................................................................206-00 Drum Brake....................................................................................................................206-02 Front Disc Brake............................................................................................................206-03 Parking Brake and Actuation.........................................................................................206-05 Hydraulic Brake Actuation..............................................................................................206-06 Power Brake Actuation..................................................................................................206-07 Anti-Lock Control...........................................................................................................206-09A Anti-Lock Control - Traction Control...............................................................................206-09B Steering System Steering System - General Information..........................................................................211-00 Power Steering...............................................................................................................211-02 Steering Linkage............................................................................................................211-03 Steering Column............................................................................................................211-04 Steering Column Switches.............................................................................................211-05

2011.50 Ranger



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GROUP

Powertrain SECTION TITLE

3 PAGE

PAGE 1 OF 2

Engine Engine System - General Information............................................................................303-00 Engine2.5L Duratec-HE (122kW/165PS) - MI4.............................................................303-01A Engine2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma........................303-01B Engine3.2L Duratorq-TDCi (148kW/200PS) - Puma.....................................................303-01C Engine Cooling2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma........................303-03A Engine Cooling3.2L Duratorq-TDCi (148kW/200PS) - Puma........................................303-03B Engine Cooling..............................................................................................................303-03C Fuel Charging and Controls2.5L Duratec-HE (122kW/165PS) - MI4............................303-04A Fuel Charging and Controls2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) Puma..........................................................................................................................303-04B Fuel Charging and Controls3.2L Duratorq-TDCi (148kW/200PS) - Puma....................303-04C Fuel Charging and Controls - Turbocharger..................................................................303-04D Accessory Drive2.5L Duratec-HE (122kW/165PS) - MI4..............................................303-05A Accessory Drive2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma.....................................................................303-05B Starting System2.5L Duratec-HE (122kW/165PS) - MI4...............................................303-06A Starting System2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma.....................................................................303-06B Engine Ignition2.5L Duratec-HE (122kW/165PS) - MI4.................................................303-07A Glow Plug System2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma........................303-07B Glow Plug System3.2L Duratorq-TDCi (148kW/200PS) - Puma...................................303-07C Engine Emission Control2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma..................................................303-08A Engine Emission Control................................................................................................303-08B Intake Air Distribution and Filtering2.5L Duratec-HE (122kW/165PS) - MI4.................303-12A Intake Air Distribution and Filtering2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma..................................................303-12B Evaporative Emissions...................................................................................................303-13 Electronic Engine Controls2.5L Duratec-HE (122kW/165PS) - MI4..............................303-14A Electronic Engine Controls2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma..................................................303-14B 2011.50 Ranger



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PAGE 2 OF 2

Automatic Transmission/Transaxle Automatic Transmission/TransaxleVehicles With: 6-Speed Automatic Transaxle 6R80...........................................................................................................................307-01 Transmission/Transaxle Cooling....................................................................................307-02 Automatic Transmission/Transaxle External Controls...................................................307-05 Manual Transmission/Transaxle, Clutch and Transfer Case Manual Transmission/Transaxle and Clutch - General Information...............................308-00 ClutchVehicles With: 5-Speed Manual Transmission - MT75........................................308-01A ClutchVehicles With: 6-Speed Manual Transmission - MT82........................................308-01B Clutch ControlsVehicles With: 5-Speed Manual Transmission - MT75.........................308-02A Clutch ControlsVehicles With: 6-Speed Manual Transmission - MT82.........................308-02B Manual Transmission/TransaxleVehicles With: 5-Speed Manual Transmission MT75..........................................................................................................................308-03A Manual Transmission/TransaxleVehicles With: 6-Speed Manual Transmission MT82..........................................................................................................................308-03B Manual Transmission/Transaxle External ControlsVehicles With: MT-75.....................308-06A Manual Transmission/Transaxle External ControlsVehicles With: MT82.......................308-06B Transfer CaseVehicles With: 5-Speed Manual Transmission - MT75/6-Speed Manual Transmission - MT82..................................................................................................308-07A Transfer CaseVehicles With: 6-Speed Automatic Transaxle - 6R80.............................308-07B Exhaust System Exhaust System2.5L Duratec-HE (122kW/165PS) - MI4..............................................309-00A Exhaust System2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma.....................................................................309-00B Fuel System - General Information Fuel System - General Information2.5L Duratec-HE (122kW/165PS) - MI4.................310-00A Fuel System - General Information2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma..................................................310-00B Fuel Tank and Lines.......................................................................................................310-01A Fuel Tank and Lines2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma.....................................................................310-01B Acceleration Control.......................................................................................................310-02

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Electrical SECTION TITLE

4 PAGE

Climate Control System Climate Control System - General Information..............................................................412-00 Climate Control..............................................................................................................412-01 Auxiliary Climate Control................................................................................................412-02 Instrumentation and Warning Systems Instrument Cluster..........................................................................................................413-01 Horn...............................................................................................................................413-06 Warning Devices............................................................................................................413-09 Parking Aid.....................................................................................................................413-13 Battery and Charging System Charging System - General Information........................................................................414-00 Battery, Mounting and Cables........................................................................................414-01 Generator and Regulator...............................................................................................414-02 Information and Entertainment Systems Information and Entertainment System - General Information......................................415-00 Information and Entertainment System..........................................................................415-01 Lighting Exterior Lighting.............................................................................................................417-01 Interior Lighting..............................................................................................................417-02 Daytime Running Lamps (DRL).....................................................................................417-04 Electrical Distribution Module Communications Network.................................................................................418-00 Module Configuration.....................................................................................................418-01 Wiring Harnesses...........................................................................................................418-02 Electronic Feature Group Anti-Theft - Active..........................................................................................................419-01A Anti-Theft - Passive........................................................................................................419-01B Multifunction Electronic Modules...................................................................................419-10

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FORD RANGER Workshop Manual

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