4 Ford Ranger Workshop

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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 Transmission/Transaxle
Duratorq-TDCi (148kW/200PS) - Cooling 307-02
Puma 303-05B Automatic Transmission/Transaxle
Starting System - 2.5L Duratec-HE External Controls 307-05
(122kW/165PS) - MI4 303-06A Manual Transmission/Transaxle, Clutch and
Starting System - 2.2L Duratorq-TDCi Transfer Case
(88kW/120PS) - Puma/2.2L Manual Transmission/Transaxle and
Duratorq-TDCi (96kW/130PS) - Clutch - General Information 308-00
Puma/2.2L Duratorq-TDCi Clutch - Vehicles With: 5-Speed Manual
(110kW/150PS) - Puma/3.2L Transmission - MT75 308-01A
Duratorq-TDCi (148kW/200PS) - Clutch - Vehicles With: 6-Speed Manual
Puma 303-06B Transmission - MT82 308-01B
Engine Ignition - 2.5L Duratec-HE Clutch Controls - Vehicles With:
(122kW/165PS) - MI4 303-07A 5-Speed Manual Transmission -
Glow Plug System - 2.2L Duratorq-TDCi MT75 308-02A
(88kW/120PS) - Puma/2.2L Clutch Controls - Vehicles With:
Duratorq-TDCi (96kW/130PS) - 6-Speed Manual Transmission -
Puma/2.2L Duratorq-TDCi MT82 308-02B
(110kW/150PS) - Puma 303-07B Manual Transmission/Transaxle -
Glow Plug System - 3.2L Duratorq-TDCi Vehicles With: 5-Speed Manual
(148kW/200PS) - Puma 303-07C Transmission - MT75 308-03A
Engine Emission Control - 2.2L Manual Transmission/Transaxle -
Duratorq-TDCi (88kW/120PS) - Vehicles With: 6-Speed Manual
Puma/2.2L Duratorq-TDCi Transmission - MT82 308-03B
(96kW/130PS) - Puma/2.2L Manual Transmission/Transaxle
Duratorq-TDCi (110kW/150PS) - External Controls - Vehicles With:
Puma/3.2L Duratorq-TDCi MT-75 308-06A
(148kW/200PS) - Puma 303-08A Manual Transmission/Transaxle
Engine Emission Control 303-08B External Controls - Vehicles With:
Intake Air Distribution and Filtering - MT82 308-06B
2.5L Duratec-HE (122kW/165PS) - Transfer Case - Vehicles With: 5-Speed
MI4 303-12A Manual Transmission -
Intake Air Distribution and Filtering - MT75/6-Speed Manual Transmission
2.2L Duratorq-TDCi (88kW/120PS) - - MT82 308-07A
Puma/2.2L Duratorq-TDCi Transfer Case - Vehicles With: 6-Speed
(96kW/130PS) - Puma/2.2L Automatic Transaxle -
Duratorq-TDCi (110kW/150PS) - 6R80 308-07B
Puma/3.2L Duratorq-TDCi
(148kW/200PS) - Puma 303-12B Exhaust System
Evaporative Emissions 303-13 Exhaust System - 2.5L Duratec-HE
Electronic Engine Controls - 2.5L (122kW/165PS) - MI4 309-00A
Duratec-HE (122kW/165PS) - Exhaust System - 2.2L Duratorq-TDCi
MI4 303-14A (88kW/120PS) - Puma/2.2L
Electronic Engine Controls - 2.2L Duratorq-TDCi (96kW/130PS) -
Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi
Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L
(96kW/130PS) - Puma/2.2L Duratorq-TDCi (148kW/200PS) -
Duratorq-TDCi (110kW/150PS) - Puma 309-00B
Puma/3.2L Duratorq-TDCi Fuel System - General Information
(148kW/200PS) - Puma 303-14B Fuel System - General Information -
Automatic Transmission/Transaxle 2.5L Duratec-HE (122kW/165PS) -
Automatic Transmission/Transaxle - MI4 310-00A
Vehicles With: 6-Speed Automatic Fuel System - General Information -
Transaxle - 6R80 307-01 2.2L Duratorq-TDCi (88kW/120PS) -
2011.50 Ranger
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(96kW/130PS) - Puma/2.2L Electrical Distribution

Duratorq-TDCi (110kW/150PS) - Module Communications
Puma/3.2L Duratorq-TDCi Network 418-00
(148kW/200PS) - Puma 310-00B Module Configuration 418-01
Fuel Tank and Lines 310-01A Wiring Harnesses 418-02
Fuel Tank and Lines - 2.2L Electronic Feature Group
Duratorq-TDCi (88kW/120PS) -
Anti-Theft - Active 419-01A
Anti-Theft - Passive 419-01B
(96kW/130PS) - Puma/2.2L
Multifunction Electronic
Duratorq-TDCi (110kW/150PS) -
Modules 419-10
(148kW/200PS) - Puma 310-01B
Acceleration Control 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 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
2011.50 Ranger
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ENGINEERING SPECIFICATION ESAB39-1255-AA

NAME : VEHICLE SUSPENSION & ALIGNMENT - Ranger (P375) & BT50 (J26E)
SERVICE SPECIFICATIONS
Curb Condition : Service equipment (caster sweep), No Occupants, fuel full and other fluids full
PRODUCTION SPECIFICATION FRONT REAR
P375 (T6) NEW RANGER FMCSA LH TOE / TOTAL RIDE HEIGHT TOE / RIDE HEIGHT
RH CASTER* CAMBER CAMBER
NCA MACHINE CASTER* WHL** TOE*** FORD (P375) MAZDA (J26E) WHL FORD (P375) MAZDA (J26E)
Nominal +2.88° +2.88° +0.00° +0.00° +0.00° 0.00° 0.00°

REG
Tol. ±0.75° ±0.75° ±0.15° ±0.30°
4x2 LR
RAP/ Nominal +3.00° +3.00° +0.00° +0.00° +0.00° 0.00° 0.00°
DBL
MODEL
Tol. ±0.75° ±0.75° ±0.15° ±0.30°
Nominal +3.07° +2.57° +0.00° +0.00° +0.00° 0.00° 0.00°

RHD
4x2HR/ Tol. ±0.75° ±0.75° +0.00° +0.00°
4x4
Nominal +2.57° +3.07° +0.00° +0.00° +0.00° 0.00° 0.00°
LHD
Tol. ±0.75° ±0.75° ±0.15° ±0.30°
4x2LR : 0°
Side to Side Nominal 0.00° 0.00°
4x2 / 4x4 RHD: +0.50°
Difference**** LHD: -0.50°
Tol. ±0.75° ±0.75° ±0.30°
Steering Axis Incl. Reference 4x2 LR : 12.36° , 4x2HR/4x4 : 11.10°
Turns Lock to Lock Reference 4x2 LR : 3.49 , 4x2HR/4x4 : 3.29
Maximum Steering Inner 4x2 LR : 41.4° ±3° , 4x2HR/4x4 : 38.0° ±3°
Angle Outer 4x2 LR : 35.5° ±3° , 4x2HR/4x4 : 33.0° ±3°
Clear Vision Max 3°
* Production measures true caster via inclinometer tool. Audit and Service measures approx caster via caster sweep method.
** Difference in toe adjuster length max 3mm, refer to figure 6
*** Toe compensated by thrust angle, for clear vision purposes (requirement : 4 wheel alignment)
**** Camber difference = Cross camber =Left front camber – Right front camber
Caster difference = Cross caster= Left front caster – Right front caster
Rear toe difference = Thrust angle = (Left rear toe toe – Right rear toe)/2
t/b With plant fitment of any towbar
Date : 20-Oct-2011 Rev : -- Description : Engineering Release : SC01.E.12478211 Est : Appr :

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GROUP
Chassis 2
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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SECTION TITLE 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
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
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/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
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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4 Ford Ranger Workshop

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BACK TO FRONT PAGE FORD RANGER 2011.

50MY WORKSHOP REPAIR MANUAL

No part of this publication may be reproduced, stored in a data processing

© Ford Motor Company 2011

(96kW/130PS) - Puma/2.2L Electrical Distribution

GROUP 4 Electrical GROUP 5 Body & Paint

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