Everest: Model Introduction Training For Approved Motor Body Repairers

Everest
Model Introduction Training For

Approved Motor Body Repairers
Powerful Stance with Eye-Catching Details
The new Everest has an unmistakably confident stance that communicates

this vehicle is ready to go, whether it’s around town, on a great journey or to
even greater heights.
The bodywork of Everest’s sides is accentuated by bold wheel arches, which

further communicate its stance, on-the-road handling character and off-road
capabilities. Visually, Everest is a vehicle of substance.
Everest’s profile also features a number of eye-catching details. These

features make selective use of contrasting metal shades and chrome to
achieve an effect like that of accessories in a fashion ensemble.
Copyright © 2009 Ford Motor Company of Southern Africa.

Contents
Overview 4
New Technical Specifications 10
Body 20
Supplemental Restraint System 42
Wildtrak 58
This self-study programme highlights the design and function of new vehicle models,
new automotive components or new technologies.
The self-study programme is not a repair manual!

All values given are intended as a guideline only.
For maintenance and repair work, always refer to the current technical literature.
REFERENCE! NOTE!
Overview
New and with Kinetic Design Cues
The elegant and refined styling of the front grille, power dome and headlamps
provide a distinctive and dependable premium character to the New Ford
Everest.
Integrated Rear Design

The graphically advanced design of the rear tail lamps, the integrated Centre
High Mount Stop Lamp, the new rear tail gate design and the chamfered rear
bumper epitomizes the New Ford Everest’s character and capabilities.
Distinctive and Dominant Alloy Wheels

Comes standard on all derivatives and adds stunning visual appeal to the
Tough and Contemporary New Ford Everest
Unique 5-Speed Automatic Transmission with Overdrive Feature

The class leading 5-speed automatic transmission offers the right balance of
performance and fuel economy.
Interior Flexibility with Synchronic Seats

The New Ford Everest’s interior versatility provides the optimal mix between
seven-seat comfort and outstanding space.
Safety
Sitting in the New Ford Everest you are cocooned in a shell with a whole host
of safety features like Dual-Stage front and side Airbags for the driver and
front passenger and Anti-lock braking Systems (ABS) with Electronic Brake
Force Distribution (EBD) for confident, comfortable braking.
Best in Class Peak Torque Performance

The New Ford Everest has been designed with ultra-modern technology to
create an ultra-responsive SUV that converts every last drop of fuel into
refined power.
Superior Driving Comfort

The leaf-spring suspension with rear stabilizer ensures that the New Ford
Everest provides excellent balance between driving comfort and spring stress
both on off-road drives and normal city roads.
4 Copyright © 2009 Ford Motor Company of Southern Africa.

Overview
Models
3.0TDCi 4x2 M/T XLT
Key Features:
• 3.0 TDCi DuraTorq Engine

• 4x2
• 5 Speed Manual Transmission
• ABS
• Dual Front Airbags
• Side Airbags
3.0TDCi 4x4 M/T XLT
Key Features:

• 4x4
• 5 Speed Manual Transmission
• ABS
• Side Airbags
3.0TDCi 4x4 A/T LTD
Key Features:

• 4x4
• 5 Speed Automatic Transmission
• ABS
• Side Airbags
Copyright © 2009 Ford Motor Company of Southern Africa. 5

Overview
Features
3.0TDCi 4x2 M/T XLT 3.0TDCi 4x$ M/T XLT 3.0TDCi 4x4 A/T LTD
Transmission
Drive wheels Rear 4WD 4WD
Type 5-Speed Manual 5-Speed Manual 5-Speed Automatic
Electronic Shift-On-The-Fly - - Std
Wheels
16”7JJ Ford design alloy 6”7JJ Ford design alloy 6”7JJ Ford design alloy
Front
245/70R16 (T-rated comm) 245/70R16 (T-rated comm) 245/70R16 (T-rated comm)
6”7JJ Ford design alloy 6”7JJ Ford design alloy 6”7JJ Ford design alloy
Rear
245/70R16 (T-rated comm) 245/70R16 (T-rated comm) 245/70R16 (T-rated comm)
Spare wheel Full size Full size Full size
Steering
Power assisted steering Std Std Std
Tilt adjustable steering Std Std Std
Suspension
Limited slip differential Std Std Std
High-trail suspension Std Std Std
Front: Double wishbone Std Std Std
Rear: Leaf springs Std Std Std
Rear stabilizer bar Std Std Std
Safety & Security

ABS braking + EBD Std Std Std
Airbags (number) 4 4 4
Remote central locking Std Std Std
Alarm Std Std Std
Immobiliser Std Std Std
Exterior
Roof rails Std Std Std
Side step Std Std Std
Body side cladding - - Std
Power mirror/indicator Std Std Std
Puddle lamp - - Std
Fog lamps Std Std Std
High mount stop lamp Std Std Std

Overview
Power and Performance

Peak Torque Performance
The 3-litre DuraTorq TDCi engine, delivers 115kW of power and 380Nm
torque and provides the true 4x4 experience. The New Ford Everest adds
quickness and agility to ultimate driving comfort.
3.0TDCI DuraTorq
Displacement cc 2953cc
Number of cylinders 4
Valve per cylinder 4
Bore and stroke 96x102 (mm)
Power (kW @ rpm) 115 @ 3200
Torque (Nm @ rpm) 380 @ 1800
Fuel system Stage II emissions
Turbocharger Std
Intercooler Std
Compression ratio 18.0:1
Variable Geometry Turbocharger

The variable geometry turbocharger (VGT) virtually eliminates turbo lag and
broadens the torque curve and provides great driving ease at low speeds,
positive response and spirited acceleration, as well as greater engine power
and torque in the New Ford Everest.
Engine Low Speed

Vane Opening: Small
Flow Speed: High
Engine High Speed

Vane Opening: Large
Flow Speed: Low

Overview
Colour Codes
Sparkling Gold- 34E
Black Mica-16W
Cool White-A2W
Highlight Silver-18G
Titanium Grey-30B
Winning Blue-37L
Desert Bronze-37P

Overview
Ford Everest Dimensions

5062mm
26 32
2860mm
1826mm
1788mm
3.0TDCi 4x2 M/T XLT 3.0TDCi 4x4 M/T XLT 3.0TDCi 4x4 A/T LTD
Front Track 1475mm 1475mm 1475mm
Rear Track 1470mm 1470mm 1470mm
GVM 2605kg 2705kg 2736kg
GCM 3805kg 3905kg 3936kg
Towing mass 1200kg 1200kg 1200kg
Fuel Tank 71 Litres 71 Litres 71 Litres
Ground Clearance 207mm 207mm 207mm

Technical Specifications
Conventional Brake System

Brakes
• A tandem-type master cylinder has been adopted, improving braking
force.
• A large diameter, tandem diaphragm power brake unit has been
adopted, improving braking force.
• A large diameter, ventilated disc-type front brake has been adopted,
improving braking force.
• A two-piston type front disc brake calliper has been adopted, improving
braking force.
• A wide width lining for the rear brake drum has been adopted,
improving braking force.
• An Automatic adjustment mechanism rear brake (drum) has been
adopted, improving serviceability.
• A vacuum pump has been adopted, improving braking force.
Load Sensing
Proportioning Valve (LSPV)
Master Cylinder
Power Brake Unit
Rear Brake Drum
Front Brake Disc
Vacuum Pump
Front Brake Disc

• Two-piston type front disc brake calliper
has been adopted, improving braking force.
• Large diameter, ventilated disc type front
brakes with a 289mm diameter and 28mm
thickness have been adopted, improving
braking force and fade resistance.

Rear Brake Drum

• A leading/trailing type rear drum brake, with a 295mm drum inner
diameter and 23.81mm wheel cylinder inner diameter, has been
adopted, improving braking force and fade resistance.
• Braking stability is ensured by use of 55mm width linings.
• It has an incremental automatic adjustment mechanism for shoe
clearance to improve serviceability
Backing Plate
Shoe Hold Pin
Wheel Cylinder
Operating Lever
Brake Shoe
Brake Drum
Rear Parking
Brake Cable Adjust Strut
Pawl Lever
Parking Brake Overview
Parking Brake
Parking Brake Lever
Switch
Rear Parking
Brake Cable
Front Parking Brake Cable

Anti-lock Brake System

Superior Braking with ABS and EBD
The New Ford Everest is designed for provide responsive and reassuring
braking performance with its four-wheel Anti-lock Braking System (ABS) with
G-sensor equipped Electronic Brakeforce Distribution (EBD) for stable braking
even when heavily loaded.
Anti-lock Braking System

Prevents wheel lockup during hard braking, even on slippery surfaces,
assisting the driver in maintaining directional control in the New Ford Everest.
Electronic Brakeforce Distribution

Optimizes the distribution of braking force to the front and rear wheels in
accordance with the vehicle’s speed and load. The system is calibrated for
excellent adaptability to a wide range of laden and un-laden conditions,
reflecting the premium versatility of the New Ford Everest.
Instrument Cluster
Rear ABS Wheel-Speed

Sensor
ABS Warning
Light
ABS HU/CM
G Sensor
Front ABS Wheel-Speed

Sensor
ABS [4W-ABS]
• The ABS HU/CM, integrating both the hydraulic unit (HU) and control
module (CM), has been adopted, resulting in size and weight reduction.
• Select-low controlled-4-wheel anti-lock brake system with 4-sensor and
3-channel has been adopted, and has the following features.
• The integrated ABS Hydraulic Unit/Control Module (HU/CM) system is
compact, lightweight and highly reliable.
ABS Wheel-Speed Sensor and Rotor Construction & Operation
ABS Wheel-Speed Sensor
Construction
• The front ABS wheel-speed sensor
is installed on the steering knuckle
Permanent Magnet and the front ABS sensor rotor is
integrated with the front wheel hub
(4x2) or drive shaft (4x4).
Coil
• The rear ABS wheel-speed sensor
is installed on the hub spindle and
ABS Sensor Rotor the rear ABS sensor rotor is
integrated with the rear axle shaft.
Pole Piece
Operation
• As the ABS sensor rotor rotates,
Output Voltage Waveform magnetic flux formed from the
+
High Speed
permanent magnet varies and an
alternating current is formed with
an electromagnetic conductor.
Using this alternating current,
V rotation speed is expressed as a
varying proportional cycle and from
detection of this cycle the CM part
Low Speed of the ABS HU/CM can then detect
the wheel rotation speed. While the
_
structures of the front and rear ABS
wheel-speed sensor differ, the
operation is the same.
G Sensor Function
• Because the 4x2 vehicle is based on the 4x4 vehicle, the 4x4 ABS
system has been adopted, Therefore, the G-sensor, which is generally
installed to 4x4 vehicles only, is installed to the 4x2 vehicle.
• Because the 4x4 vehicle ABS system has been adopted on the 4x2
NOTE! vehicle, the ABS is controlled in the same way as the 4x4 vehicle.
In the 4x2 vehicle and the 4x4 vehicle, the G-sensor detects and calculates
the vehicle G force (acceleration and deceleration G force), and outputs the
change in voltage to the ABS HU/CM.

Power Steering
Steering Wheel
Reserve Tank
Steering Column & Shaft
Power Steering
Oil Pump
Steering Gear & Linkage
With the adoption of an engine speed sensing power steering mechanism,

handling stability has been improved, as well as the adoption of a steering
column with a tilt mechanism, operability has been improved.
With the adoption of a steering shaft with an energy absorbing mechanism,
safety has been improved.
789.9-792.9mm

Suspension
Front suspension
• The double wishbone suspension, which has A-shape lower arms, is
used for the front suspension. A-shape lower arms have high rigidly
and durability.
• The torsion bar springs are used for both 4x2 and 4x4 models.
• The torsion bar spring is pre-coiled in one direction. It therefore gives

ample spring performance when installed correctly, but only half if
installed in reverse.
An R (right) or L (left) is marked on the rear end of the bar to
distinguish one from the other.
The left and right, and 4x2 and 4x4 torsion bar springs are not
interchangeable.
4x2
Shock Absorber
Upper Arm
Torsion Bar Spring
Front Stabilizer
Lower Arm
4x4
Shock Absorber
Torsion Bar Spring
Upper Arm
Front Stabilizer
Lower Arm

Wheel hub, Steering knuckle and Wheel bearing

24.5-36.2n.m
4x2
10 19-25n.m
108-127n.m
9
37.3-51.0n.m
7 5
1
4
6
2
3 19-25n.m
69.2-93.2n.m 235-314n.m
8 11
44.1-58.8n.m 157-209n.m
54.9-67.6n.m
88.2-117.6n.m
1 ABS Wheel Speed Sensor 7 Tie-Rod End Ball Joint
2 Hub Cap 8 Stabilizer Bolt
3 Locknut 9 Shock Bolt
4 Wheel & Tire 10 Upper Arm Ball Joint
5 Brake Caliper
11 Lower Arm Ball Joint
6 Brake Disc
1 Wheel Hub
4
2 ABS Sensor Rotor 3
2 5
3 Retaining Ring
4 Wheel Bearing
5 Dust Cover 1
6 Steering Knuckle Wheel

Bearing
7 Wheel Stud Side

4x4 24.5-36.2n.m
6 53.9-60.8n.m
108-127n.m
4
37.3-51.0n.m
8
69.2-93.2n.m
1 235-314n.m
44.1-58.8n.m
5
19-25n.m 157-209n.m
1 Locknut 5 Stabilizer Bolt
2 Brake Caliper 6 Shock Bolt
3 Brake Disc 7 Upper Arm Ball Joint
4 Tie-Rod End Ball Joint 8 Lower Arm Ball Joint
6
1
1 Oil Seal
4
3 2 Wheel Hub
5
3 Retaining Ring
4 Wheel Bearing
2 5 Dust Cover
6 Steering Knuckle
7 Wheel Stud

Vehicle Ride Height

• The vehicle height can be adjusted by turning the torsion bar spring
anchor bolt. When adjustment is required, adjust the vehicle height as
follows:
1. Place the vehicle on level ground.

2. Inspect the front and rear tire pressure and adjust it if necessary.
3. Measure the distance from the centre of each front wheel to the
fender brim.
Standard vehicle height: 502-542mm
*Difference between left and right: 10mm max
4. If the difference between left and right is not within the
specification, adjust the vehicle height by turning the torsion bar
spring anchor bolt.
Vehicle Height
4x2 4x4
Anchor Bolt
Anchor Bolt
Rear Suspension
4x2
4x4
• The rigid axle suspension with leaf spring is used for the rear
suspension.
• To prevent wind-up of the leaf springs during rapid acceleration or
deceleration, the shock absorber on the right side is mounted at the
rear of the axle and the left one is mounted at the front of the axle,
(bias mount).In order to increase the rigidity in the lateral direction,
wide shackle plates are used in the frame mounting.
• The rear springs are mounted on top of the axle housing to raise the
centre of gravity. Thus, the shock absorbers attach directly to brackets
welded to the axle housing.
8 275-313n.m
7
12.8-21.6n.m 3
11
14
12
13 15
9
2
18
10
19-25n.m 16
19
4 17
108-128n.m
20
1 Brake Drum 11 Bearing Inner Race
2 Park Brake Cable Connecting Pin 12 Bearing Spacer
3 Brake Pipe 13 Oil Seal
4 Nut 14 Bearing Outer Race
5 Axle Shaft 15 Backing Plate
6 Shim 16 Axle Shaft
7 ABS Sensor Rotor 17 Hub Bolt
8 Bearing Locknut 18 Baffle
9 Lock Washer 19 Oil Seal
10 Bearing Housing 20 O-Ring

Body
Towing and Jacking Vehicle

Towing
Proper lifting and towing are necessary to prevent damage to the vehicle.
Do not tow with sling-type equipment. This could damage your vehicle.
Use wheel-lift or flatbed equipment.

Body
With Manual Transmission

If the transmission, rear axle, and steering system are not damaged, the
vehicle may be towed on all four wheels. If any of these components are
damaged, use wheel dollies.
With Automatic Transmission

If excessive damage or other conditions prevent towing the vehicle with the
driving wheels off the ground, use wheel dollies.
If all four wheels are on the ground, the vehicle may be towed only forward.
Do not exceed 45 km/h and a distance of 15 km, you could damage the
transmission.
If speed must exceed 45 km/h or a towing distance of 15 km, use one of these
methods:
• Place the rear wheels on dollies.

• Tow with the rear wheels off the ground.
• Disconnect the propeller shaft.
If the transmission or rear axle is inoperative, tow with the rear wheels off the
ground.
Follow these instructions when towing the vehicle with all wheels on the
ground or with the front wheels on the ground and the rear wheels
raised.
4 x 4 Models
1. Put the transfer case in 2H.
2. Set the transfer case at 2H and the hubs at FREE.
All Models
1. Set the transmission in neutral.
2. Turn the engine switch to ACC(I).
3. Release the parking brake.
Remember that power assist for the brakes and steering will not be available
when the engine is not running.
If the vehicle has 4 x 4, change to 2-wheel drive before having the vehicle
towed. If this is not possible, tow with all four wheels raised.

Body
Towing Hooks
The towing hooks should be used only in an emergency. When using

the towing hooks, always pull the cable or chain in a straight direction
with respect to the hook. Apply no sideways force.
Tie down Hooks
Do not use the hook loops under the front for towing. They are designed
ONLY for tying down the vehicle when it is being transported. Using
them for towing will damage the bumper.
4x2 4x4
Jacking Positions, Vehicle Lift Positions, Safety Stand Positions
Improperly jacking a vehicle is dangerous. The vehicle can slip off the
jack and cause serious injury. Use only the correct front and rear
jacking positions and block the wheels.
Use safety stands to support the vehicle after it has been lifted.
Front Jack Position Rear Jack Position

Body
Front Lift Post Rear Lift Post
Front Safety Stands Rear Safety Stands

Body
Frame Dimensions
Flat-plane Dimensions
Hole Diameter/ Hole Diameter/

Point Point
Designation Bolt/Nut size Designation Bolt/Nut size
Symbol Symbol
mm mm
A Cabin Mounting Bracket 23 G Torsion Bar Bracket 13.7
B Bumper Stay Bracket 15 H Cabin Mounting Bracket 65
C Reboud Stop Bracket 12.5 I Cabin Mounting Bracket 26
D Upper Arm Bracket 16 J Side Member 15
E Rebound Stop Bracket 12.5

K Cabin Mounting Bracket 36
F Cabin Mounting Bracket 60

Body
Cabin Side Frame Straight Line Dimensions

Point Point
Symbol Symbol
mm mm
Wheel Apron Panel Front Rear Door Hinge Installation

A 12 G 12
Datum Hole Hole
Rear Door Hinge Installation

B Shroud Panel Datum Hole 7 H 12
Hole
Windshield Garnish Installa- Quater Window Installation

C 6.8x6.8 I 10
tion Square Hole Hole
Front Door Hinge Installation Rear Door Switch Installa-

D 12 J 12
Hole tion Hole
Front Door Hinge Installation

E 12 Quater Window Installation
Hole K 8.2x15
Hole
F Center pillar Notch -

Body
Front Body Straight Line Dimensions

Point Point
Symbol Symbol
mm mm
A Shroud Panel Datum Hole 7 D Shroud Panel Datum Hole 7
B Shroud Panel Datum Hole 7 E Shroud Panel Datum Hole 6.2
C Shroud Panel Datum Hole 7 F Shroud Panel Datum Hole 6.2x8

Body

Point Point
Symbol Symbol
mm mm
Windshield Garnish Installa-

A 6.8x6.8 E Shroud Gusset Datum Hole 14
tion Square Hole
Windshield Garnish Installa-

B 6.8x6.8 F Cowl Panel Datum Slot 6.2X8
tion Square Hole
Bonnet Hinge Installation

C 12 F’ Cowl Panel Datum Hole 6.2
Hole
Front Fender Installation

D 10 G Shroud Panel Datum Hole 10
Hole

Body
Room Straight Line Dimensions

Point Point
Symbol Symbol
mm mm
A Harness Installation Hole 7 E Rear Pillar Inner Datum Hole 12
Center Pillar Inner Datum

B Front Pillar Inner Datum Hole 10 F 10
Hole
Seatbelt Guide Installation

C Cowl Side Panel Datum Hole 6 G 7
Hole
Change Boots Installation Center Pillar Inner Datum

D 10 H 7
Hole Hole

Body

Point Point
Symbol Symbol
mm mm

A 10 F Rear Pillar Inner Datum Hole 12
Hole
Seatbelt Guide Installation

B 7 G Striker Installation Hole 7.2x12
Hole

C 7 H Shroud Panel Datum Hole 10.2
Hole
Rear Pillar Trim Installation

D Floor Mat Installation Hole 7.2x12 I 7.2x12
Hole

E 12 J Striker Installation Hole 10.2
Hole

Body

Point Point
Symbol Symbol
mm mm
Rear Pillar Trim Installation Rear Pillar Trim Installation

A 7.2x12 F 7.2x12
Hole Hole
B Rear Pillar Inner Datum Hole 12

Rear Pillar Trim Installation G 7.2x12
C 7.2x12 Hole
Hole
Mat Set Plate Installation

D Seat Installation Hole 16 H 12x7.2
Hole
Rear Pillar Trim Installation Rear Door Striker Installation

E 10.2 I 13
Hole Hole

Body
Rear Body Straight Line Dimensions

Point Point
Symbol Symbol
mm mm
RH: 12
A Roof Panel Notch - D Corner Plate Datum Hole
LH: 13
Rear Pillar Trim Installation Rear Bumper Installation

B 7.2x12 E 12.2
Hole Hole
RH: 12 Mat Set Plate Installation

C Corner Plate Datum Hole F 7.2x12
LH: 13 Hole

Body

Point Point
Symbol Symbol
mm mm
RH: 12
A Roof Panel Notch - D Corner Plate Datum Hole
LH: 13
Rear Pillar Trim Installation Rear Bumper Installation

B 7.2x12 E 12.2
Hole Hole
RH: 12 Mat Set Plate Installation

C Corner Plate Datum Hole F 7.2x12
LH: 13 Hole

Body
Body Structure
Pure SUV styling
The styling of the Everest is pure SUV. Various frontal presentations were
considered, but it was the bold front end of the Ranger that consumers liked.
The platform – chassis, suspension, brakes, etc – is shared with the Ranger
and so are some body panels like the front doors and the bonnet. However,
all other sheet metal and glass is unique to the Everest.
As it uses the Ranger platform, this means the Everest design has ‘body-on-
chassis’ (BOC) construction, the traditional way of building pick-ups and
SUVs. Typically, the body shell is bolted onto a chassis of two longitudinal
beams and the merits of this are in load-carrying capability.
Everest’s protective body structure features door intrusion beams and
reinforced A, B and C-pillars to manage crash forces away from the driver and
passengers and maintain the shape and integrity of the passenger safety cell.
Structure
Roof
1
2
1 Roof Panel 4 Roof Bow
2 Roof Plug
5 Roof Bracket
3 Header Assembly

Body
Side Outer Panels
10
5
7
1 Rail Assembly 6 Lower Sill (Rear)
2 Hinge Reinforcement 7 Rear Fender
3 Weather Strip 8 B-Pillar (Outer)
4 A-Pillar (Outer) 9 D-Pillar (Lower)
5 Lower Sill (Front) 10 D-Pillar (Upper & Lower)

Body
Side Inner Panels
4
7
3
5
2
6
1 9
10
12
11
1 Cowl Panel 7 Rail Assembly (Rear)
2 Support Bracket 8 D-Pillar (Inner)
3 A-Pillar (Inner) 9 Rear Fender
4 Reinforcement 10 C-Pillar (Inner)
5 Rail Assembly (Front) 11 Wheel Housing (Inner)
6 B-Pillar (Inner) 12 Rear Fender (Complete)

Body
Tailgate
1
2
7
8
9 10
1 Tail Gate 6 Boot Stay
2 Hinge 7 Wedge
3 Weather Strip 8 Striker
4 Weather Strip 9 Striker
5 Adjuster 10 Finisher

Body
Glass
1 Rear Window Glass 3 Rear Door Quarter Glass
2 Rear Door Glass 4 Side Glass
Side Window Glass Removal

1. Remove the C-pillar trim.
2. Apply protective tape along the edge of the body to protect it from damage
3. Avoiding pins and spacers, make a
hole through the sealant from the
inside of the vehicle using an awl.
4. Pass the piano wire through the hole.
• Using a piano wire with bare

hands can cause injury.
Always wear gloves when
using a piano wire.

Body
5. Wind each end of the piano wire

around a bar.
• Use a long sawing action to

spread the work over the whole
length of the piano wire to
prevent it from breaking.
6. Working with another person, saw

through the sealant around the edge
of the glass.
7. Remove the side window glass.
Side Window glass Installation
• Proper installation of the side window glass may be difficult if the

sealant is cracked or the glass is pushed out by air pressure
when a door is opened/closed with all the windows closed. Leave
all the windows open until the side window glass is installed
completely.
1. Cut away the old sealant using a razor so that 1-2mm thickness of
sealant remains around the circumference if the frame.
• Using a razor with bare hands can cause injury. Always wear
gloves when using a razor.
2. If the sealant has come off completely in any one place, apply some
primer after degreasing, and allow it approximately 30 minutes to dry.
Then put new sealant to create a 2mm layer.
3. Clean and degrease an approximately 50mm wide strip around the
circumference of the glass and the bonding area on the body.
4. Insert the spacers into the body.

Body
5. Use only glass primer on the glass,

and body primer on the body and
molding. Allow it to dry for
approximately 30 minutes.
• Keep the area free of dirt and

grease, and do not touch the
surface. Otherwise, the primer
may not properly bond to the
surface of the glass and body,
which may cause leaks to occur.
6. Apply sealant to the areas of the glass

surface as shown in the figure.
7. Set the side window in place and

insert the pins into the body. Install the
side window glass.
8. Allow the sealant to harden
completely.
Sealant hardening time: 24 Hours

Body
Aluminium Anodizing
Anodizing Aluminium and How It Works
Exposed to the earth's atmosphere, aluminium combines with oxygen to form
a protective surface film which inhibits further oxidation of the aluminium.
Unlike steel or iron alloys, aluminium will not continue to oxidize (rust) once
this protective layer is formed. This natural oxide is extremely thin and loosely
adhered to the aluminium surface, however, and is easily removed by
handling. Anodizing is a process which thickens the natural oxide film
resulting in a heavy aluminium oxide film of controlled thickness having the
hardness similar to that of a ruby or sapphire.
When aluminium is anodized conventionally, direct electrical current (DC) is
passed through a bath of sulphuric acid -- the electrolyte -- while the
aluminium being treated serves as the anode. This produces a clear film of
aluminium oxide on the aluminium’s surface. Electron microscopy indicates
that this layer is mostly porous with a very thin barrier layer at the base. This
structure lends itself very well to electrolytic colouring or absorptive dying.
During the anodizing process, several controls are critical to assure the
specified film thickness, its abrasion resistance and density. These controls
include a precise combination of chemical concentration, temperature and
current density.
Anodizing: Working With Aluminium

The quality of finished aluminium extrusions and anodized products is a
function of the knowledge, experience and capability of the people and
equipment used. To achieve this first-rate extrusions and anodized finishes,
meticulous attention must be paid to every detail -- from using the finest
aluminium and press practices to maintaining the tightest chemical and
electrical controls.
Anodizing Specifications
Coating Coating
Specification ADT Remarks
Thickness Weight
ESB-M4P6-B - - - Superceded by WSB-M4P9-B2
ESB-M4P9-A1 - - - Superceded by WSB-M4P9-B1
ESB-M4P9-A2 - - - Superceded by WSB-M4P9-B2
ESB-M4P10-A - - - Superceded by WSB-M4P10-B3
ESB-M4P11-A - - - Superceded by WSB-M4P11-B3
>0.1mil (2.5 um)

2
WSB-M4P9-B1 > 6.2 g/m < 6.0 Clear-Interior
2
WSB-M4P9-B2 >0.3mil (8 um) > 18.6 g/m < 6.0 Clear-Exterior
2
WSB-M4P10-B1 >0.1mil (2.5 um) > 6.2 g/m < 6.0 Dyed-Interior
2
WSB-M4P11-B1 >0.3mil (8 um) > 18.6 g/m < 6.0 Electrolytic Colour-Interior/Exterior

Body
The Aluminium Anodizing Process

Pre-Treatment: Cleaning is done in a non-etching, alkaline detergent heated
to approximately 145 degrees Fahrenheit. This process removes accumulated
contaminants and light oils.
Rinsing: Multiple rinses, some using strictly de-ionized water, follow each
process step.
Etching (Chemical Milling): Etching in caustic soda (sodium hydroxide)
prepares the aluminium for anodizing by chemically removing a thin layer of
aluminium. This alkaline bath gives the aluminium surface a matte
appearance.
Desmutting: Rinsing in an acidic solution removes unwanted surface alloy
constituent particles not removed by the etching process.
Anodizing: Aluminium is immersed in a tank containing an electrolyte having
a 15% sulphuric acid concentration. Electric current is passed through the
electrolyte and the aluminium is made the anode in this electrolytic cell; the
tank is the cathode. Voltage applied across the anode and cathode causes
negatively charged anions to migrate to the anode where the oxygen in the
anions combines with the aluminium to form aluminium oxide (Al2O3).
Colouring: Anodic films are well suited to a variety of colouring methods
including absorptive dyeing, both organic and inorganic dyestuffs, and
electrolytic colouring.
Sealing: In all the anodizing process, the proper sealing of the porous oxide
coating is absolutely essential to the satisfactory performance of the coating.
The pores must be rendered non-absorbent to provide maximum resistance to
corrosion and stains. This is accomplished through a hydrothermal treatment
in proprietary chemical baths or by capping the pores via the precipitation of
metal salts in the pore openings.
The Anodizing
Process

Restraint System
Airbag System
Airbag module inspection
• Inspecting an airbag module using a tester can operate (deploy) the
airbag module, which may cause serious injury. Do not use a tester to
inspect an airbag module. Always use the onboard diagnostic function
to diagnose the airbag module for malfunctions.
NOT GOOD
Airbag module handling

• Before removing the airbag module or disconnecting the airbag module
connector, always turn the ignition switch to the lock position,
disconnect the negative battery cable, and then wait for 1 minute or
more to allow the backup power supply of the SAS control module to
deplete its stored power.
• Handling a live (undeployed) airbag module that is pointed toward your

body could result in serious injury if the airbag module were to
accidentally operate (deploy). When carrying a live (undeployed)
airbag module, point the deployment surface away from your body to
lessen the chance of injury in case it operates (deploys).
GOOD NOT GOOD

Restraint System
• A live (undeployed) airbag module placed with its deployment surface

to ground is dangerous. If the airbag module were to accidentally
operate (deploy), it could cause serious injury. Always place a live
(undeployed) airbag module with its deployment surface up.
GOOD NOT GOOD
SAS control module handling

• Remove the SAS control module or disconnecting the SAS control
module connector with the ignition switch at the ON position can
activate the sensor in the SAS control module and operate (deploy) the
airbags and pre-tensioner seat belts, which may cause serious injury.
Before removing the SAS control module or disconnecting the SAS
control module connector, always turn the ignition switch to the LOCK
position, disconnect the negative battery cable, and wait for 1 minute or
more to allow the backup power supply of the SAS control module to
deplete its stored power.
• Connecting the SAS control module connector with the SAS control
module not securely fixed to the vehicle is dangerous. The sensor in
the SAS control module could send an electrical signal to the airbag
modules and pre-tensioner seat belts. This will operate (deploy) the
airbags and pre-tensioner seat belts, which may result in serious injury.
Therefore, before connecting the connector, securely fix the SAS
control module to the vehicle.
• Because a sensor is built into the SAS control module, once the airbag
and pre-tensioner seat belts have operated (deployed) due to a
collision or other causes, the SAS control module must be replaced
with a new one even if the used one does not have any visible external
damage or deformation. The used SAS control module may have been
damaged internally, which may cause improper operation. If the SAS
control module is reused, the airbags and pre-tensioner seat belts may
not operate (deploy) normally, which could result in a serious accident.
Always replace the SAS control module with a new one. The SAS
control module cannot be bench-checked or self-checked.

Restraint System
Side airbag module handling

• When a side airbag module operates (deploys) due to a collision, the
interior of the seat back (pad, frame, trim) may become damaged. If a
side airbag does not operate (deploy) normally from a seat back that
has been reused, a serious accident may result. After a side airbag
has operated (deployed), always replace both the side airbag module
and the seat back (pad, frame, trim) with new parts. After servicing,
verify that the seat operates normally and that the wiring harness is not
caught.
Crash zone sensor handling

• Removing the crash zone sensor or disconnecting the crash zone
sensor connector with the ignition switch at the ON position can
activate the crash zone sensor and operate (deploy) the airbags and
pre-tensioner seat belts, which may cause serious injury. Before
removing the crash zone sensor or disconnecting the crash zone
sensor connector, always turn the ignition switch to the LOCK position,
disconnect the negative battery cable, and then wait 1 minute or more
to allow the backup power supply of the SAS control module to deplete
its stored power.
• If the crash zone sensor is subjected to shock or the sensor is

disassembled, the airbags and pre-tensioner seat belts may
accidentally operate (deploy) and cause injury, or the system may fail
to operate normally and cause a serious accident. Do not subject the
crash zone sensor to shock or disassemble the sensor.
• Because a sensor is built into the crash zone sensor, once the airbags
collision or other causes, the crash zone sensor must be replaced with
a new one even if the used one does not have any visible external
damage or deformation. If the crash zone sensor is reused, the airbags
and pre-tensioner seat belts may not operate (deploy) normally, which
could result in a serious accident. Always replace the crash zone
sensor with a new one. The crash zone sensor cannot be bench-
checked or self-checked.
Side airbag sensor handling

• Removing the side airbag sensor or disconnecting the side airbag
sensor connector with the ignition switch at the ON position can
activate the side airbag sensor and operate (deploy) the airbags and
pre-tensioner seat belts, which may cause serious injury. Before
removing the side airbag sensor or disconnecting the side airbag
sensor connector, always turn the ignition switch to the LOCK position,
disconnect the negative battery cable, and then wait 1 minute or more
to allow the backup power supply of the SAS control module to deplete
its stored power.

Restraint System
• If the side airbag sensor is subjected to shock or the sensor is

disassembled, the airbags and pre-tensioner seat belts may
accidentally operate (deploy) and cause injury, or the system may fail
to operate normally and cause a serious accident. Do not subject the
side airbag sensor to shock or disassemble the sensor.
• Because a sensor is built into the side airbag sensor, once the airbags
collision or other causes, the side airbag sensor must be replaced with
a new one even if the used one does not have any visible external
damage or deformation. If the side airbag sensor is reused, the airbags
and pre-tensioner seat belts may not operate (deploy) normally, which
could result in a serious accident. Always replace the side airbag
sensor with a new one. The side airbag sensor cannot be bench-
checked or self-checked.
Pre-tensioner seat belt inspection

• Inspecting a pre-tensioner seat belt using a tester can operate (deploy)
the pre-tensioner seat belt, which may cause serious injury. Do not use
a tester to inspect a pre-tensioner seat belt. Always use the on-board
diagnostic function to diagnose the pre-tensioner seat belt for
malfunctions.
NOT GOOD

Restraint System
Airbag System Service Cautions

Airbag system component disassembly
• Disassembling the airbag system components could cause it to not
operate (deploy) normally. Never disassemble any airbag system
components.
NOT GOOD
Airbag module, pre-tensioner seat belt handling

• Oil, grease, or water on the airbag modules may cause the airbags,
pre-tensioner seat belts and lap pre-tensioner seat belt to fail to
operate (deploy) in an accident. Never allow oil, grease, or water to get
on the airbag module, pre-tensioner seat belts or lap pre-tensioner
seat belt.
• Inserting a screwdriver or similar object into the connector of an airbag

module, pre-tensioner seat belt ot lap pre-tensioner seat belt may
damage the connector and cause the airbag module, pre-tensioner
seat belts or lap pre-tensioner seat belt to operate (deploy) improperly,
which may cause serious injury. Never insert any foreign objects into
the airbag module, pre-tensioner seat belts or lap pre-tensioner seat
belt connectors.
NOT GOOD NOT GOOD

Restraint System
Airbag module, pre-tensioner seat belt reuse

• Even if an airbag or pre-tensioner seat belt does not operate (deploy)
in a collision and does not have any external signs of damage, it may
have been damaged internally, which may cause improper operation.
Before reusing a live (undeployed) airbag module and pre-tensioner
seat belts, always use the on-board diagnostic to diagnose the airbag
module and pre-tensioner seat belts to verify that they have no
malfunction.
Airbag wiring harness repair

• Incorrectly repairing an airbag wiring harness can accidentally operate
(deploy) the airbag module and pre-tensioner seat belts. If a problem is
found in the airbag wiring harness, always replace the wiring harness
with a new one.
NOT GOOD

Restraint System
Airbag System Component Location

7
1
4
1 Driver-Side Airbag Module 4 Pre-tensioner Seatbelt
5 SAS Control Module

2 Passenger-Side Airbag Module
6 Side Airbag Sensor
3 Side Airbag Module 7 Clock Spring
Driver-Side Airbag Module
• Handling the airbag module improperly can accidentally deploy

the airbag module, which may seriously injure you.
1. Turn the engine switch to the LOCK position.

2. Disconnect the negative battery cable and wait for 1 minute or more.
3. Remove in the order indicated in the table.
1 Bolt
2 Connector
3 Driver-Side Airbag Module

1
3 7.9-11.7n.m
2

Restraint System
4. Install in the reverse order of removal.

5. Turn the engine switch to the ON position.
6. Verify that the airbag system warning light illuminates for
approximately 6 seconds and goes out.
Passenger-Side Airbag Module


3. Remove the glove compartment.
1 Connector
2 Bolt
3 Passenger-Side Airbag Module

6.9-9.8n.m
2

Side Airbag Module

• If the side airbag module is installed with debris in the seat back,
the foreign material may be scattered when the side airbag
module operates (deploys), causing injury. Verify that there is no
foreign material in the seat back before installing the side airbag
module.


Restraint System
1 Cup
3
2 Bolt
3 Side Airbag Module
4 Connector 7.9-11.7n.m
2
1

SAS Control Module
• Handling the SAS control module improperly can accidentally

deploy the airbag modules and pre-tensioner seatbelt, which may
seriously injure you.

3. Remove the console.
3 2 6.9-9.8n.m
1 Connector 1
2 Bolt
3 SAS Control Module
Side Airbag Sensor
• Handling the side airbag sensor improperly can accidentally

deploy the airbag module, which may seriously injure you.


Restraint System
1 Bolt A
2 Cover
6.9-9.8n.m 1
2 3 Connector
4 Bolt B
6.9-9.8n.m 4
5 Side Airbag Sensor
3
5

Clock Spring
2. Remove the drive-side airbag module
3. Remove the steering wheel.
4. Remove the column cover.
1 1 Screw
2 Connector
3
3 Clock Spring

• If the clock spring is not adjusted, the spring wire in the clock
spring could over-wind and break when the steering wheel is
turned. Always adjust the clock spring after installing it.
• Do not forcibly turn the clock spring.

Restraint System
Clock Spring Adjustment
• The adjustment procedure is also specified on the caution label of

the clock spring.
1. Set the front tires straight-ahead.
2. Turn the clock spring clockwise until it stops.
3. From the stopped position, turn the clock spring counterclockwise 2 and ¾
turns.
Alignment Marks
4. Align the mark on the clock spring with the mark on the outer housing.

Restraint System
Clock Spring Inspection
Verify that the continuity is as indicated in the table.

• If not as indicated in the table, replace the clock spring.
: Continuity
Terminal
Test condition
1A 1B 2D 3A 3B 4D
Under
any condition
3B 3A 4D Vehicle Side Connector Airbag Module Side Connector
3B 3A
A/B 1B 1A 2D *
A/B Horn * * 4D * * *
+ -
1A 1B 2D
• When the vehicle-side connector for the clock spring is disconnected,

terminals 1A and 1B are shorted to prevent unexpected deployment of
the airbag module.
Seatbelt Pre-tensioner
• Handling the seatbelt improperly can accidentally deploy the pre-

tensioner seatbelt, which may seriously injure you.
• The ELR (emergency locking retractor) has a spring that will
unwind if the retractor cover is removed. The spring cannot be
rewound by hand. If this occurs, the ELR will not work properly.
Therefore, do not disassemble the retractor.

3. Remove the following parts.
1. Rear scuff plate
2. Front scuff plate
3. Remove the B-pillar lower trim
4. Front seatbelt upper anchor cover
5. Front seatbelt upper anchor installation bolt
6. Remove the B-pillar upper trim

Restraint System
Upper Anchor Bolt

39-78n.m
1 Lower Anchor Cover
2 Connector Upper Anchor

Cover
3 Bolt
4 Seatbelt 4
3
7.8-10.8n.m
1
3
39-78n.m

Adjuster Anchor
1. Remove the following parts.

1. Rear scuff plate
2. Front scuff plate
3. Remove the B-pillar lower trim
4. Front seatbelt upper anchor cover
5. Front seatbelt upper anchor installation bolt
6. Remove the B-pillar upper trim
1 39-78n.m
2
1 Bolt
2 Anchor Adjuster
1 39-78n.m

Restraint System
Seatbelt Inspection
Belt
1. Verify that the belt is installed properly with no twist or kinks.
2. Verify that there is no damage to the seatbelt and no deformation of
metal fittings.
• If there is any malfunction, replace the seatbelt.
ELR
1. Verify that the belt can be pulled
out smoothly, and that it retracts
smoothly.
• If there is any malfunction,
replace the seatbelt.
2. Verify that the retractor locks when
the belt is pulled quickly.
• If there is any malfunction,
3. Remove the retractor.
4. While pulling the seatbelt out,
make sure that the seatbelt does
not lock when the retractor is tilted
slowly up to 15° from the mounted
position and locks when the
retractor is tilted 40° or more.
Retractor • If there is any malfunction,
Load Limiter Retractor
• When the load limiter operates, the belt and anchor rub against
each other strongly leaving wear tracks. If the seatbelt is used in
this state, the seatbelt will not function at its full capability and
there is the possibility of serious injury to passengers. Be sure to
replace the seatbelt once the load limiter operates.
1. If the vehicle has been subjected to a

shock in an accident, pull the belt from
Belt Anchor the retractor and confirm that there are
no wear tracks (the load limiter has not
operated) by visually inspecting and
Trace feeling the belt.
Pull of Wear • If there is any malfunction,

Restraint System
Rear Seatbelt Location
1 2
4 3
1 Second-row Seatbelt 3 Third-row Buckle
2 Third-row Seatbelt 4 Second-row Buckle
Second-row Seatbelt
• The ELR has a spring that will unwind if the retractor is removed.
The spring cannot be rewound by hand. If this occurs, the ELR
will not work properly. Therefore, do not disassemble the retractor
1. Remove the rear side trim.

2. Remove in the order indicated in the 1
table. Bolt
38.2-78.4n.m 2
1 Anchor Cover
2 Second-row Seatbelt
7.65-11.5n.m

38.2-78.4n.m

Restraint System
Third-row Seatbelt
• The ELR has a spring that will unwind if the retractor is removed.
The spring cannot be rewound by hand. If this occurs, the ELR
will not work properly. Therefore, do not disassemble the retractor
1
1. Remove the third-row seat.
Bolt 2 2. Remove the rear side trim.
38.2-78.4n.m
3. Remove in the order indicated in the
table.
7.65-11.5n.m
1 Anchor Cover
2 Second-row Seatbelt
38.2-78.4n.m

Wildtrak
Wildtrak Supplement
The Wildtrak model features a number of stylistic and functional touches that
distinguish it from other models in the Ranger line-up. Visually, the Wildtrak
sports prominent decals on the doors and tailgate, along with silver roof rails,
body-colour cladding and a body-coloured Wildtrak-branded sports bar. Other
features include repeaters and puddle lamps integrated into the wing mirrors,
a lockable tailgate with locking Armadillo cover, rear parking distance sensors,
a Ford-branded load box liner and 18-inch diamond-cut alloy wheels.
Model-specific interior appointments include Alcantara/leather seat and door
trim with brushed aluminium accents and a healthy smattering of "Wildtrak"
logos on the seats, scuff plate and carpets. Perhaps the most noticeable
addition to the cabin is the Multi Meter atop the central facia section. This unit
features an inclinometer/yaw meter, compass and digital ambient and outside
temperature readouts.

Wildtrak
Wildtrak front bumper re-work procedure

The purpose of this supplement is to notify the Auto Body Repair Centres that
the templates shown below are available on the Loan-A-Tool program under
Ranger/Everest/Wildtrak., Tool Number: UD2D-5003.
These templates are used to rework the Ford Ranger front bumper to fit onto
the Ford Wildtrak, to accommodate the turning clearance of the 18 inch
wheels.
• A suitable cutting tool must be used to cut away the front bumper.
The following illustrations indicate the rework procedure:

Below is the templates marked "L" (left side) and "R" (right side) that needs to
be inserted onto the new bumper to mark the area that needs to be cut away.

Wildtrak
1. Insert the template as shown below by inserting the securing rivets into
the holes to keep the template in place to ensure that the cut away area is
marked accurately.
2. Mark the area that needs to be cut.
3. Ensure that the area is marked clearly before cutting.

Notes:

Notes:

www.fordabrc.co.za

Everest: Model Introduction Training For Approved Motor Body Repairers

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Everest

Model Introduction Training For

The new Everest has an unmistakably confident stance that communicates

The bodywork of Everest’s sides is accentuated by bold wheel arches, which

Everest’s profile also features a number of eye-catching details. These

Copyright © 2009 Ford Motor Company of Southern Africa.

New Technical Specifications 10

Supplemental Restraint System 42

The self-study programme is not a repair manual!

Integrated Rear Design

Distinctive and Dominant Alloy Wheels

Unique 5-Speed Automatic Transmission with Overdrive Feature

Interior Flexibility with Synchronic Seats

Best in Class Peak Torque Performance

Superior Driving Comfort

4 Copyright © 2009 Ford Motor Company of Southern Africa.

• 3.0 TDCi DuraTorq Engine

3.0TDCi 4x4 M/T XLT

• 3.0 TDCi DuraTorq Engine

3.0TDCi 4x4 A/T LTD

• 3.0 TDCi DuraTorq Engine

Copyright © 2009 Ford Motor Company of Southern Africa. 5

Type 5-Speed Manual 5-Speed Manual 5-Speed Automatic

Electronic Shift-On-The-Fly - - Std

Spare wheel Full size Full size Full size

Tilt adjustable steering Std Std Std

High-trail suspension Std Std Std

Front: Double wishbone Std Std Std

Rear: Leaf springs Std Std Std

Rear stabilizer bar Std Std Std

Safety & Security

Remote central locking Std Std Std

Alarm Std Std Std

Immobiliser Std Std Std

Side step Std Std Std

Body side cladding - - Std

Power mirror/indicator Std Std Std

Puddle lamp - - Std

Fog lamps Std Std Std

High mount stop lamp Std Std Std

6 Copyright © 2009 Ford Motor Company of Southern Africa.

Power and Performance

Valve per cylinder 4

Bore and stroke 96x102 (mm)

Power (kW @ rpm) 115 @ 3200

Torque (Nm @ rpm) 380 @ 1800

Fuel system Stage II emissions

Compression ratio 18.0:1

Variable Geometry Turbocharger

Engine Low Speed

Engine High Speed

Copyright © 2009 Ford Motor Company of Southern Africa. 7

Sparkling Gold- 34E

8 Copyright © 2009 Ford Motor Company of Southern Africa.

Ford Everest Dimensions

Rear Track 1470mm 1470mm 1470mm

GVM 2605kg 2705kg 2736kg

GCM 3805kg 3905kg 3936kg

Towing mass 1200kg 1200kg 1200kg

Fuel Tank 71 Litres 71 Litres 71 Litres

Ground Clearance 207mm 207mm 207mm

Copyright © 2009 Ford Motor Company of Southern Africa. 9

Conventional Brake System