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2004.

75 Transit

Workshop Manual
Table of Contents
Steering System
GROUP 1 General Information Steering System - General
Information 211-00
Service Information Power Steering 211-02
General Information 100-00 Steering Linkage 211-03
Identification Codes 100-01 Steering Column 211-04
Jacking and Lifting 100-02 Steering Column Switches 211-05
Noise, Vibration and
Harshness 100-04 GROUP 3 Powertrain
GROUP 2 Chassis Engine
Engine System - General
Suspension Information 303-00
Suspension System - General Engine - 2.4L Duratorq-TDCi (Puma)
Information 204-00 Diesel/2.4L Duratorq-Di (Puma)
Front Suspension 204-01 Diesel 303-01A
Rear Suspension 204-02 Engine - 2.0L Duratorq-TDCi (Puma)
Wheels and Tires 204-04 Diesel/2.0L Duratorq-Di (Puma)
Vehicle Dynamic Suspension 204-05 Diesel/2.0L Duratorq-TDDi (Puma)
Driveline Diesel 303-01B
Engine - 2.3L DOHC-16V 303-01C
Driveline System - General Engine Cooling 303-03
Information 205-00 Fuel Charging and Controls - 2.4L
Driveshaft 205-01 Duratorq-Di (Puma) Diesel 303-04A
Rear Drive Axle/Differential 205-02A Fuel Charging and Controls - 2.0L
Wheel Hubs and Bearings - Full Floating Duratorq-Di (Puma) Diesel/2.0L
Axle 205-02B Duratorq-TDDi (Puma)
Front Drive Halfshafts 205-04 Diesel 303-04B
Brake System Fuel Charging and Controls - 2.3L
Brake System - General DOHC-16V 303-04C
Information 206-00 Fuel Charging and Controls -
Drum Brake 206-02 Turbocharger 303-04D
Front Disc Brake 206-03 Fuel Charging and Controls - 2.0L
Parking Brake and Actuation 206-05A Duratorq-TDCi (Puma)
Parking Brake and Actuation - Vehicles Diesel 303-04F
With: Parking Brake Assist 206-05B Fuel Charging and Controls - 2.4L
Hydraulic Brake Actuation 206-06 Duratorq-TDCi (Puma)
Power Brake Actuation 206-07 Diesel 303-04G
Anti-Lock Control 206-09 Accessory Drive 303-05
Starting System 303-06

2004.75 Transit
Glow Plug System - 2.4L Duratorq-TDCi Fuel Tank and Lines 310-01
(Puma) Diesel/2.4L Duratorq-Di Acceleration Control - 2.0L
(Puma) Diesel 303-07A Duratorq-TDCi (Puma) Diesel/2.4L
Glow Plug System - 2.0L Duratorq-TDCi Duratorq-TDCi (Puma) Diesel/2.0L
(Puma) Diesel/2.0L Duratorq-Di Duratorq-Di (Puma) Diesel/2.0L
(Puma) Diesel/2.0L Duratorq-TDDi Duratorq-TDDi (Puma) Diesel/2.4L
(Puma) Diesel 303-07B Duratorq-Di (Puma) Diesel 310-02A
Engine Ignition - 2.3L Acceleration Control - 2.3L
DOHC-16V 303-07C DOHC-16V 310-02B
Engine Emission Control 303-08
Intake Air Distribution and GROUP 4 Electrical
Filtering 303-12
Evaporative Emissions 303-13 Climate Control System
Electronic Engine Controls 303-14
Climate Control System - General
Manual Transmission/Transaxle, Clutch and Information 412-00
Transfer Case Air Distribution and Filtering 412-01
Manual Transmission/Transaxle and Heating and Ventilation 412-02A
Clutch - General Information 308-00 Auxiliary Heating 412-02B
Clutch - Vehicles With: MT-75 308-01A Air Conditioning 412-03A
Clutch - Vehicles With: Auxiliary Climate Control 412-03B
VXT-75 308-01B Control Components 412-04
Clutch - Vehicles With: MT82 308-01C Instrumentation and Warning Systems
Clutch Controls - Vehicles With:
MT-75 308-02A Instrument Cluster and Panel
Clutch Controls - Vehicles With: Illumination 413-00
VXT-75 308-02B Instrument Cluster 413-01
Clutch Controls - Vehicles With: Horn 413-06
MT82 308-02C Clock 413-07
Manual Transmission/Transaxle - Parking Aid 413-13
Vehicles With: MT-75 308-03A Battery and Charging System
Manual Transmission/Transaxle - Charging System - General
Vehicles With: VXT-75 308-03B Information 414-00
Manual Transmission/Transaxle - Battery, Mounting and Cables 414-01
Vehicles With: MT82 308-03C Generator and Regulator 414-02
Manual Transmission/Transaxle Information and Entertainment Systems
External Controls - Vehicles With: Information and Entertainment System
MT-75 308-06A - General Information 415-00
Manual Transmission/Transaxle Audio Unit 415-01
External Controls - Vehicles With: Antenna 415-02
VXT-75 308-06B Speakers 415-03
Manual Transmission/Transaxle
External Controls - Vehicles With: Lighting
MT82 308-06C Exterior Lighting 417-01
Manual Transmission/Transaxle Interior Lighting 417-02
Automated Gearshift System 308-11 Electrical Distribution
Exhaust System Module Communications
Exhaust System 309-00 Network 418-00
Module Configuration 418-01
Fuel System
Fuel System - General Electronic Feature Group
Information 310-00 Anti-Theft - Active 419-01A
Anti-Theft - Passive 419-01B

2004.75 Transit
Multifunction Electronic Handles, Locks, Latches and Entry
Modules 419-10 Systems 501-14
Wipers and Washers 501-16
GROUP 5 Body and Paint Roof Opening Panel 501-17
Bumpers 501-19
Body and Paint Safety Belt System 501-20A
Supplemental Restraint
Body System - General System 501-20B
Information 501-00 Body Repairs - General
Front End Body Panels 501-02 Information 501-25
Body Closures 501-03 Body Repairs - Vehicle Specific
Interior Trim and Information and Tolerance
Ornamentation 501-05 Checks 501-26
Exterior Trim and Front End Sheet Metal Repairs 501-27
Ornamentation 501-08 Side Panel Sheet Metal
Rear View Mirrors 501-09 Repairs 501-29
Seating 501-10 Rear End Sheet Metal Repairs 501-30
Glass, Frames and
Mechanisms 501-11 Frame and Mounting
Instrument Panel and Console 501-12 Uni-Body, Subframe and Mounting
System 502-00

2004.75 Transit
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,
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-Werke Aktiengesellschaft. 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.

Copyright ©

FORD-WERKE AKTIENGESELLSCHAFT

Service training programs D-F/GT-1

Printed in Germany - rewi druckhaus, Wissen


-

Printed on environmentally friendly


chlorine-free paper. (GB)

2004.75 Transit
GROUP

General Information 1
SECTION TITLE PAGE

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

2004.75 Transit
GROUP

Chassis 2
SECTION TITLE PAGE

Suspension
Suspension System - General Information....................................................................204-00
Front Suspension...........................................................................................................204-01
Rear Suspension...........................................................................................................204-02
Wheels and Tires...........................................................................................................204-04
Vehicle Dynamic Suspension.........................................................................................204-05
Driveline
Driveline System - General Information.........................................................................205-00
Driveshaft.......................................................................................................................205-01
Rear Drive Axle/Differential............................................................................................205-02A
Wheel Hubs and Bearings - Full Floating Axle..............................................................205-02B
Front Drive Halfshafts....................................................................................................205-04
Brake System
Brake System - General Information..............................................................................206-00
Drum Brake....................................................................................................................206-02
Front Disc Brake............................................................................................................206-03
Parking Brake and Actuation.........................................................................................206-05A
Parking Brake and ActuationVehicles With: Parking Brake Assist................................206-05B
Hydraulic Brake Actuation..............................................................................................206-06
Power Brake Actuation..................................................................................................206-07
Anti-Lock Control...........................................................................................................206-09
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

2004.75 Transit
GROUP

Powertrain 3
SECTION TITLE PAGE

Engine
Engine System - General Information............................................................................303-00
Engine2.4L Duratorq-TDCi (Puma) Diesel/2.4L Duratorq-Di (Puma) Diesel.................303-01A
Engine2.0L Duratorq-TDCi (Puma) Diesel/2.0L Duratorq-Di (Puma) Diesel/2.0L
Duratorq-TDDi (Puma) Diesel....................................................................................303-01B
Engine2.3L DOHC-16V.................................................................................................303-01C
Engine Cooling...............................................................................................................303-03
Fuel Charging and Controls2.4L Duratorq-Di (Puma) Diesel........................................303-04A
Fuel Charging and Controls2.0L Duratorq-Di (Puma) Diesel/2.0L Duratorq-TDDi
(Puma) Diesel.............................................................................................................303-04B
Fuel Charging and Controls2.3L DOHC-16V................................................................303-04C
Fuel Charging and Controls - Turbocharger..................................................................303-04D
Fuel Charging and Controls2.0L Duratorq-TDCi (Puma) Diesel....................................303-04F
Fuel Charging and Controls2.4L Duratorq-TDCi (Puma) Diesel....................................303-04G
Accessory Drive.............................................................................................................303-05
Starting System..............................................................................................................303-06
Glow Plug System2.4L Duratorq-TDCi (Puma) Diesel/2.4L Duratorq-Di (Puma)
Diesel.........................................................................................................................303-07A
Glow Plug System2.0L Duratorq-TDCi (Puma) Diesel/2.0L Duratorq-Di (Puma)
Diesel/2.0L Duratorq-TDDi (Puma) Diesel.................................................................303-07B
Engine Ignition2.3L DOHC-16V.....................................................................................303-07C
Engine Emission Control................................................................................................303-08
Intake Air Distribution and Filtering................................................................................303-12
Evaporative Emissions...................................................................................................303-13
Electronic Engine Controls.............................................................................................303-14
Manual Transmission/Transaxle, Clutch and Transfer Case
Manual Transmission/Transaxle and Clutch - General Information...............................308-00
ClutchVehicles With: MT-75...........................................................................................308-01A
ClutchVehicles With: VXT-75.........................................................................................308-01B
ClutchVehicles With: MT82............................................................................................308-01C
Clutch ControlsVehicles With: MT-75............................................................................308-02A
Clutch ControlsVehicles With: VXT-75..........................................................................308-02B
Clutch ControlsVehicles With: MT82.............................................................................308-02C
Manual Transmission/TransaxleVehicles With: MT-75..................................................308-03A
Manual Transmission/TransaxleVehicles With: VXT-75................................................308-03B
Manual Transmission/TransaxleVehicles With: MT82...................................................308-03C

2004.75 Transit
Manual Transmission/Transaxle External ControlsVehicles With: MT-75.....................308-06A
Manual Transmission/Transaxle External ControlsVehicles With: VXT-75....................308-06B
Manual Transmission/Transaxle External ControlsVehicles With: MT82......................308-06C
Manual Transmission/Transaxle Automated Gearshift System.....................................308-11
Exhaust System
Exhaust System.............................................................................................................309-00
Fuel System
Fuel System - General Information................................................................................310-00
Fuel Tank and Lines.......................................................................................................310-01
Acceleration Control2.0L Duratorq-TDCi (Puma) Diesel/2.4L Duratorq-TDCi (Puma)
Diesel/2.0L Duratorq-Di (Puma) Diesel/2.0L Duratorq-TDDi (Puma) Diesel/2.4L
Duratorq-Di (Puma) Diesel.........................................................................................310-02A
Acceleration Control2.3L DOHC-16V............................................................................310-02B

2004.75 Transit
GROUP

Electrical 4
SECTION TITLE PAGE

Climate Control System


Climate Control System - General Information..............................................................412-00
Air Distribution and Filtering...........................................................................................412-01
Heating and Ventilation..................................................................................................412-02A
Auxiliary Heating............................................................................................................412-02B
Air Conditioning..............................................................................................................412-03A
Auxiliary Climate Control................................................................................................412-03B
Control Components......................................................................................................412-04
Instrumentation and Warning Systems
Instrument Cluster and Panel Illumination.....................................................................413-00
Instrument Cluster..........................................................................................................413-01
Horn...............................................................................................................................413-06
Clock..............................................................................................................................413-07
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
Audio Unit......................................................................................................................415-01
Antenna..........................................................................................................................415-02
Speakers........................................................................................................................415-03
Lighting
Exterior Lighting.............................................................................................................417-01
Interior Lighting..............................................................................................................417-02
Electrical Distribution
Module Communications Network.................................................................................418-00
Module Configuration.....................................................................................................418-01
Electronic Feature Group
Anti-Theft - Active..........................................................................................................419-01A
Anti-Theft - Passive........................................................................................................419-01B

2004.75 Transit
Multifunction Electronic Modules...................................................................................419-10

2004.75 Transit
GROUP

Body and Paint 5


SECTION TITLE PAGE

Body and Paint


Body System - General Information...............................................................................501-00
Front End Body Panels..................................................................................................501-02
Body Closures................................................................................................................501-03
Interior Trim and Ornamentation....................................................................................501-05
Exterior Trim and Ornamentation...................................................................................501-08
Rear View Mirrors..........................................................................................................501-09
Seating...........................................................................................................................501-10
Glass, Frames and Mechanisms....................................................................................501-11
Instrument Panel and Console.......................................................................................501-12
Handles, Locks, Latches and Entry Systems................................................................501-14
Wipers and Washers......................................................................................................501-16
Roof Opening Panel.......................................................................................................501-17
Bumpers.........................................................................................................................501-19
Safety Belt System.........................................................................................................501-20A
Supplemental Restraint System.....................................................................................501-20B
Body Repairs - General Information..............................................................................501-25
Body Repairs - Vehicle Specific Information and Tolerance Checks.............................501-26
Front End Sheet Metal Repairs......................................................................................501-27
Side Panel Sheet Metal Repairs....................................................................................501-29
Rear End Sheet Metal Repairs......................................................................................501-30
Frame and Mounting
Uni-Body, Subframe and Mounting System...................................................................502-00

2004.75 Transit