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
FORD RANGER 2011.50MY WORKSHOP REPAIR MANUAL
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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
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
(110kW/150PS) - Puma
303-07B
Glow Plug System - 3.2L Duratorq-TDCi
303-07C
Engine Emission Control - 2.2L
(96kW/130PS) - Puma/2.2L
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
303-12B
Evaporative Emissions
303-13
Electronic Engine Controls - 2.5L
Duratec-HE (122kW/165PS) MI4
303-14A
Electronic Engine Controls - 2.2L
(96kW/130PS) - Puma/2.2L
303-14B
Automatic Transmission/Transaxle
Automatic Transmission/Transaxle Vehicles With: 6-Speed Automatic
Transaxle - 6R80
307-01
Transmission/Transaxle
Cooling
307-02
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
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(88kW/120PS) - Puma/2.2L
(110kW/150PS) - Puma/3.2L
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
TO MODEL INDEX
(96kW/130PS) - Puma/2.2L
Fuel Tank and Lines
Fuel Tank and Lines - 2.2L
(96kW/130PS) - Puma/2.2L
Acceleration Control
Electrical Distribution
Module Communications
Network
310-00B Module Configuration
310-01A Wiring Harnesses
Electronic Feature Group
Anti-Theft - Active
Anti-Theft - Passive
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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
2011.50 Ranger
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GROUP
Chassis
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
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
2011.50 Ranger
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PAGE 2 OF 2
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
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
Fuel Tank and Lines.......................................................................................................310-01A
Fuel Tank and Lines2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi
Acceleration Control.......................................................................................................310-02
2011.50 Ranger
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GROUP
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
2011.50 Ranger
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FORD RANGER 2011.

50MY WORKSHOP REPAIR MANUAL

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FORD RANGER 2011.50MY WORKSHOP REPAIR MANUAL

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FORD RANGER 2011.50MY WORKSHOP REPAIR MANUAL

FORD RANGER 2011.50MY WORKSHOP REPAIR MANUAL

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GROUP 5 Body & Paint

Climate Control System

FORD RANGER 2011.50MY WORKSHOP REPAIR MANUAL

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FORD RANGER 2011.50MY WORKSHOP REPAIR MANUAL

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6(&7,21  *HQHUDO ,QIRUPDWLRQ

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