Internal Repair Instruction P375 Ford Ranger SA Coating of Complete Underbody With Corrosion Protection Wax Ver 14092020

Internal Repair Instruction
Ranger 2012 (P375)

Coating of complete underbody with corrosion protection wax
Instruction for Ford of South-Africa
Internal repair instruction for Ranger (P375) 2012 -

Coating of complete underbody
with corrosion protection wax
This is not a TSB. Repairs cannot be claimed unless

approved up front by the warranty department. Surface
rust is normal and not warrantable. Severe corrosion due
to operation in a corrosive environment is not warrantable
and requires regular and thorough cleaning as described in
the owners manual.
Last change: 15.09.2020
Date of creation: 22.01.2015

1
Ranger 2012 (P375)
Table of content
1. INTRODUCTION ................................................................................. 3
1.1 General description ........................................................................................... 3
2. LABOR TIMES .................................................................................. 12
2.1 Labor times for coating of complete underbody with corrosion protection wax 12
3. SPARE PARTS AND MATERIALS .................................................. 13
3.1 Materials for complete coating of underbody with corrosion protection wax ... 13
4. REPAIR PROCEDURE ..................................................................... 14
4.1 Repair procedure for coating of complete underbody with corrosion protection
wax........................................................................................................................ 14

2
Ranger 2012 (P375)
1. Introduction
1.1 General description
The underbody of some Rangers (P375) shows visible corrosion. In particular, the
long members and the cross members are affected as well as the front and the rear
axles. This report describes the complete coating of the underbody with corrosion
protection wax to prevent further corrosion. A step-by-step instruction is provided,
which explains the coating process for all affected parts and areas at the underbody.
The term “PPE” is used below as an abbreviation for “Personal Protective
Equipment”.
Figure 1: The frame and the welded parts at the frame, particularly the welded joints are
corroded. Red rust is visible.

3
Ranger 2012 (P375)
Figure 2: The welded reinforcement parts at the frame are corroded and show red rust.

4
Ranger 2012 (P375)
Figure 3: The welded torsion bar at the frame and the mounting brackets of the shock
absorbers are corroded and show red rust.

5
Ranger 2012 (P375)
Figure 4: The mounting brackets and support brackets at the frame are corroded. For
example the support bracket for the fuel tank support strap is corroded. Red rust is visible
(see picture).

6
Ranger 2012 (P375)
example the support brackets for the handbrake-cables are corroded. Red rust is visible (see
picture).

7
Ranger 2012 (P375)
example the support brackets for the handbrake-cables are corroded. Red rust is visible (see
picture).

8
Ranger 2012 (P375)
Figure 7: The mounting brackets and support brackets for the front axle are corroded. Red
rust is visible.

9
Ranger 2012 (P375)
Figure 8: The mounting brackets and support brackets for the front axle are corroded. For
example red rust is visible at areas in the vicinity of the adjusting-screw for the lower
suspension arm.

10
Ranger 2012 (P375)
Figure 9: The housings of the front and the rear axle are partially corroded. Red rust is
visible.

11
Ranger 2012 (P375)
2. Labor Times
2.1 Labor times for coating of complete underbody with corrosion
protection wax
Time for main Time for combination

Operation
operation operation
Wheel R&I (four) 0.5 h 0.3 h

Body Shop
Wax application underbody 2.8 h 2.8 h
Paint Shop not necessary

12
Ranger 2012 (P375)
3. Spare parts and materials

3.1 Materials for complete coating of underbody with corrosion protection
wax
Material FINIS Code Amount
WB Corrosion Protection Wax 1 672 153 2.5 L

Water-based remover - Commercially available
Silicone remover - Commercially available

13
Ranger 2012 (P375)
4. Repair procedure
4.1 Repair procedure for coating of complete underbody with corrosion
protection wax
The following steps describe the coating of the complete underbody with corrosion
protection wax:
1. Mask the ground under the car with a foil and fix it with tape
2. Mark the position of the tires
3. Dismantle the wheels
4. Clean the underbody completely with compressed air
5. Clean the surface of the underbody completely with water-based dirt cleaner
6. Clean the surface of the underbody completely with weld splatter silicone remover
7. Mask the parts and areas that should not be penetrated with wax: brake parts
front and rear axle
8. Mask the parts and areas that should not be penetrated with wax: exhaust parts
9. Mask the parts and areas that should not be penetrated with wax: outer side sill
10. Mask the parts and areas that should not be penetrated with wax: cooling gill for
diesel fuel-cooling
11. Dismantle the spare wheel
12. Apply the underbody-protection-wax with the flow cup: area in front of the front-
axle
13. Apply the underbody-protection-wax with the flow cup: front axle area
14. Apply the underbody-protection-wax with the flow cup: long member (LHS)
15. Apply the underbody-protection-wax with the flow cup: long member (RHS)
16. Apply the underbody-protection-wax with the flow cup: cross member 1
19. Apply the underbody-protection-wax with the flow cup: cross member 4 (over the
spare wheel)
20. Apply the underbody-protection-wax with the flow cup: rear axle
21. Apply the underbody-protection-wax with the brush: axle driveshaft LH and RH
22. Apply the underbody-protection-wax with the brush: leaf spring LH and RH
23. Apply the underbody-protection-wax with the brush: all the driveshaft
24. Apply the underbody-protection-wax with the brush: cover plate at the transfer-
box
25. Remove all the covering-foil an covering-papers
26. Apply the underbody-protection-wax with the brush: non-covered metal parts at
the front axle (LH and RH)
27. Mount the spare wheel
28. Mount the wheels and fix them with a torque wrench
29. Apply the underbody-protection-wax with the flow cup: remove the lifting arms

14
Ranger 2012 (P375)
Step 1:
Mask the ground under

the car with a foil and fix it
with tape
Dimensions of the foil:

4m × 8m
Tools and material:

Plastic foil; tape; knife
Step 2:
Mark the position of the

tires
At the end of the repair

procedure all tires should
be at the same position
as before.
Tools and material:

Tape, water-resist pen

15
Ranger 2012 (P375)
Step 3:
Dismantle the wheels
In case of special wheel-

nuts (like on the picture),
release the tires with a
long ratchet and wrench
socket.
Otherwise release it with

an impact wrench.
Tools and material:

Impact wrench; long
ratchet; wrench socket
Step 4:
Clean the underbody

completely with
compressed air
Loose dirt must be

removed with
compressed air.
Clean all frames, cross

members, axles, wires,
mounting supports and
leaf springs. Do not forget
the upper and invisible
areas. Use PPE: safety
googles; ear defenders;
protective mask
Tools and material:

Compressed-air-gun;
safety googles; ear
defenders; protective
mask

16
Ranger 2012 (P375)
Step 5:
Clean the surface of the

underbody completely
with water-based remover
Clean all the frames,

cross members, axle-
parts, mounting supports
and leaf springs.
Do not forget the upper
and invisible areas. Use
PPE: protective gloves;
protective mask
Tools and material:

Standard water-based
remover; clean cloth;
protective gloves;
protective mask
Step 6:
Clean the surface of the

underbody completely
with silicone remover
Clean all frames, cross

members, axle-parts,
mounting supports and
leaf spring.
and invisible areas.
Use PPE: protective
gloves; protective mask
Tools and material:

Standard silicone
remover; clean cloth;
protective gloves;
protective mask

17
Ranger 2012 (P375)
Step 7:
Mask the parts and areas

that should not be
penetrated with wax:
brake parts at front and
rear axle.
The brake parts should

never get contact with the
underbody-protection-
wax! Protect the parts
with foil.

that should not be
brake parts at front and
rear axle.

never get contact with the
wax! Protect the parts
with foil.
Tools and material:

Masking foil; tape

18
Ranger 2012 (P375)
Step 8:

that should not be
exhaust parts
Especially the cables and

the measuring probes of
the exhaust system must
be protected (see red
circles at the picture).

that should not be
exhaust parts

be protected (see red
circles).

19
Ranger 2012 (P375)

that should not be
exhaust parts

be protected.
Mask the components

with paper.
ATTENTION: The
exhaust components can
be hot!

that should not be
exhaust parts
Mask the complete

exhaust system.
Tools and material:
Masking paper; tape

20
Ranger 2012 (P375)
Step 9:

that should not be
outer side sill (LHS and
RHS)
Attach at first one wide

enough tape the outer
side of the side sill flange.
Then attach the masking
paper to the extending
adhesive surface of the
tape.

that should not be
outer side sill (LH and
RH)
The surface of the side

pipe will be protected by
the masking paper.
Tools and material:

Masking paper; tape

21
Ranger 2012 (P375)
Step 10:

that should not be
cooling gill for diesel fuel-
cooling

that should not be
cooling gill for diesel fuel-
cooling
Tools and material:

Making paper; tape

22
Ranger 2012 (P375)
Step 11:
Dismantle the spare

wheel
Tools and material:

Vehicle tools
NOTE:
Use PPE when applying

the underbody-protection-
wax:
protective suit; protective
gloves; protective mask;
ear protectors

23
Ranger 2012 (P375)
For the following

procedure the material
"Ford WB corrosion
protection wax" will be
use.
FINIS-Code:
1 672 153
Needed material volume:
2.5 liters
Rubber parts including

brake hoses and plastic
parts can be covered with
the Ford WB material.
Rotating parts must be

covered by brush.
Brake parts should never

come into contact with
the underbody-protection-
wax!
Step 12:
Apply the underbody-

protection-wax with a flow
cup: area in front of the
front-axle
The affected area in front

of the front-axle is colored
red

24
Ranger 2012 (P375)

protection-wax with the
flow cup: area in front of
the front-axle
Apply the wax all over the

cover plate and the front
metal sheet.
Do not apply the wax

directly on engine parts.
Tools and material:

flow cup; underbody-
protection-wax; personal
protective equipment
Step 13

flow cup: front axle area
The affected area at the

front axle is colored red.

front axle parts.
Do not apply wax directly
on the engine parts.

covered by brush.

get contact with the
wax!

25
Ranger 2012 (P375)

flow cup: front axle area
The affected area at the

front axle is colored red

front axle parts.

directly on the engine
parts.

covered by brush.

wax!
flow cup:
front axle area

front axle pats.

directly on the engine
parts.

covered by brush.

wax!
Tools and material:


26
Ranger 2012 (P375)
Step 14:

flow cup: long member
(LHS)
The affected area is

colored red.
Apply the wax on the

complete long member,

side, the mounting
brackets and support
brackets.

(LHS)

colored red

complete long member.

side, the mounting
brackets.

27
Ranger 2012 (P375)

(LHS)

colored red


side, the mounting
brackets.

(LHS)

colored red.


side, the mounting
brackets.

28
Ranger 2012 (P375)

(LHS)


side, the mounting
brackets.
Tools and material:

Flow cup; underbody-
Step 15:

(RHS)

colored red.


side, the mounting
brackets.

29
Ranger 2012 (P375)

(RHS)

colored red


side, the mounting
brackets.

(RHS)
colored red.


side, the mounting
brackets.

30
Ranger 2012 (P375)

(RHS)


side, the mounting
brackets.
Tools and material:

Step 16:

flow cup: cross member 1
colored red.

complete cross member.

side, the mounting
brackets.

31
Ranger 2012 (P375)



side, the mounting
brackets.
Tools and material:

Step 17:


colored red.


side, the mounting
brackets.

32
Ranger 2012 (P375)



side, the mounting
brackets.
Tools and material:

Step 18:


colored red


side, the mounting
brackets.

33
Ranger 2012 (P375)



side, the mounting
brackets.
Tools and material:

Step 19:


colored red.


side, the mounting
brackets.

34
Ranger 2012 (P375)

Flow cup:
cross member 4


side, the mounting
brackets.
Tools and material:

Step 20:

flow cup: rear axle
colored red.

complete axle-housing.

side, the mounting
brackets.

upper surface and the
bottom surface of the leaf
springs.
Never apply wax on the

sides and the striking
surfaces between the leaf
springs!

35
Ranger 2012 (P375)

flow cup: rear axle

complete axle-housing.

side, the mounting
brackets.

upper surface and the
bottom surface of the leaf
springs. Never apply on
the sides and the striking
surfaces between the leaf
springs!
Do not apply the wax on

rotating parts.
Tools and material:


36
Ranger 2012 (P375)
Step 21:

protection-wax with a
brush: axle driveshaft
LHS and RHS
Apply the wax on the axle

driveshaft joint LHS

LHS and RHS
Apply wax on the axle

driveshaft joint RHS

37
Ranger 2012 (P375)

LHS and RHS
Apply wax on the axle

driveshaft LHS and RHS

never come into contact
with the underbody-
protection-wax!
Tools and material:

brush; underbody-
Step 22:

brush: leaf spring LHS
and RHS
Apply the wax only on the

outer sides.
Do not apply the wax on

the striking surfaces
between the leaf springs!
Tools and material:

brush; underbody-

38
Ranger 2012 (P375)
Step 23:

brush: driveshaft
Apply the wax on all

driveshaft mountings and
the driveshaft.
Step 23:

brush: driveshaft

driveshaft mountings and
the driveshaft.
Tools and material:

brush; underbody-

39
Ranger 2012 (P375)
Step 24:

brush: cover plate at the
transfer-box
Apply wax on the black,

corroded cover plate.
Tools and material:

brush; underbody-
Step 25:
Remove all covering foils

and covering papers

40
Ranger 2012 (P375)
Step 26:

brush: non-covered metal
parts at the front axle
(LHS and RHS)
After removing the cover

foil and the paper, wax
must be applied with a
brush on the corroded
metal parts underneath.
The affected areas are

colored red. The red
areas apply for both LHS
and RHS

(LHS and RHS)


and RHS.

41
Ranger 2012 (P375)

(LHS and RHS)

and RHS.

(LHS and RHS)


and RHS.
Tools and material:
brush; underbody-

42
Ranger 2012 (P375)
Step 27:
Mounting of the spare

wheel
Tools and material:

Vehicle tools
Step 28:
Mount the wheels and fix

them with a torque
wrench.
Torque:
120 Nm
Tools and material:

Impact wrench; wrench
socket; torque wrench

43
Ranger 2012 (P375)
Step 29:

flow cup: remove the
lifting arms
After removal of the lifting

arms wax must be
applied on the four
contact surfaces.
Tools and material:


44

Internal Repair Instruction P375 Ford Ranger SA Coating of Complete Underbody With Corrosion Protection Wax Ver 14092020

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Internal Repair Instruction

Ranger 2012 (P375)

Instruction for Ford of South-Africa

Internal repair instruction for Ranger (P375) 2012 -

This is not a TSB. Repairs cannot be claimed unless

Last change: 15.09.2020

Date of creation: 22.01.2015

Last change: 15.09.2020

Date of creation: 22.01.2015

1.1 General description

Last change: 15.09.2020

Date of creation: 22.01.2015

Last change: 15.09.2020

Date of creation: 22.01.2015

Last change: 15.09.2020

Date of creation: 22.01.2015

Last change: 15.09.2020

Date of creation: 22.01.2015

Last change: 15.09.2020

Date of creation: 22.01.2015

Last change: 15.09.2020

Date of creation: 22.01.2015

Last change: 15.09.2020

Date of creation: 22.01.2015

Last change: 15.09.2020

Date of creation: 22.01.2015

Last change: 15.09.2020

Date of creation: 22.01.2015

Time for main Time for combination

Wheel R&I (four) 0.5 h 0.3 h

Paint Shop not necessary

Last change: 15.09.2020

Date of creation: 22.01.2015

3. Spare parts and materials

Material FINIS Code Amount

WB Corrosion Protection Wax 1 672 153 2.5 L

Last change: 15.09.2020

Date of creation: 22.01.2015

Last change: 15.09.2020

Date of creation: 22.01.2015

Mask the ground under

Dimensions of the foil:

Tools and material:

Mark the position of the

At the end of the repair

Tools and material:

Last change: 15.09.2020

Date of creation: 22.01.2015

Dismantle the wheels

In case of special wheel-

Otherwise release it with

Tools and material:

Clean the underbody

Loose dirt must be

Clean all frames, cross

Tools and material:

Last change: 15.09.2020

Date of creation: 22.01.2015

Clean the surface of the

Clean all the frames,

Tools and material:

Clean the surface of the