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2011.50 Ranger Workshop Manual Table of Contents GROUP General Information Service Information General Information Identification Codes Jacking and Lifting Noise, Vibration and Harshness GROUP Chassis Suspension Suspension System - General Information Front Suspension Rear Suspension Wheels and Tires Driveline Driveshaft Rear Drive Axle/Differential Front Drive Axle/Differential Front Drive Halfshafts Rear Drive Halfshafts Brake System Brake System - General Information Drum Brake Front Disc Brake Parking Brake and Actuation Hydraulic Brake Actuation Power Brake Actuation Anti-Lock Control Anti-Lock Control - Traction Control Steering System Steering System - General Information Power Steering Steering Linkage Steering Column Steering Column Switches GROUP Powertrain Engine 100-00 Engine System - General 100-01 Information 303-00 100-02 Engine - 2.5L Duratec-HE (122kW/165PS) - MI4 303-01A 100-04 Engine - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma 303-01B Engine - 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-01C 204-00 Engine Cooling - 2.2L Duratorq-TDCi 204-01 (88kW/120PS) - Puma/2.2L 204-02 Duratorq-TDCi (96kW/130PS) 204-04 Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma 303-03A 205-01 Engine Cooling - 3.2L Duratorq-TDCi 205-02 (148kW/200PS) - Puma 303-03B 205-03 Engine Cooling 303-03C 205-04 Fuel Charging and Controls - 2.5L 205-05 Duratec-HE (122kW/165PS) MI4 303-04A Fuel Charging and Controls - 2.2L Duratorq-TDCi (88kW/120PS) 206-00 Puma/2.2L Duratorq-TDCi 206-02 (96kW/130PS) - Puma/2.2L 206-03 Duratorq-TDCi (110kW/150PS) 206-05 Puma 303-04B 206-06 Fuel Charging and Controls 3.2L 206-07 Duratorq-TDCi (148kW/200PS) 206-09A Puma 303-04C Fuel Charging and Controls 206-09B Turbocharger 303-04D Accessory Drive - 2.5L Duratec-HE (122kW/165PS) - MI4 303-05A 211-00 Accessory Drive - 2.2L Duratorq-TDCi 211-02 (88kW/120PS) - Puma/2.2L 211-03 Duratorq-TDCi (96kW/130PS) 211-04 Puma/2.2L Duratorq-TDCi 211-05 2011.50 Ranger (110kW/150PS) - Puma/3.2L Duratorq-TDCi (148kW/200PS) Puma 303-05B Starting System - 2.5L Duratec-HE (122kW/165PS) - MI4 303-06A Starting System - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L Duratorq-TDCi (148kW/200PS) Puma 303-06B Engine Ignition - 2.5L Duratec-HE (122kW/165PS) - MI4 303-07A Glow Plug System - 2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma 303-07B Glow Plug System - 3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-07C Engine Emission Control - 2.2L Duratorq-TDCi (88kW/120PS) Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-08A Engine Emission Control 303-08B Intake Air Distribution and Filtering 2.5L Duratec-HE (122kW/165PS) MI4 303-12A Intake Air Distribution and Filtering 2.2L Duratorq-TDCi (88kW/120PS) Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-12B Evaporative Emissions 303-13 Electronic Engine Controls - 2.5L Duratec-HE (122kW/165PS) MI4 303-14A Electronic Engine Controls - 2.2L 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 303-14B Automatic Transmission Automatic Transmission - Vehicles With: 6-Speed Automatic Transmission 6R80 307-01 Transmission Cooling 307-02 Automatic Transmission External Controls 307-05 Manual Transmission, Clutch and Transfer Case Manual Transmission and Clutch General Information 308-00 Clutch - Vehicles With: 5-Speed Manual Transmission - MT75 308-01A Clutch - Vehicles With: 6-Speed Manual Transmission - MT82 308-01B Clutch Controls - Vehicles With: 5-Speed Manual Transmission MT75 308-02A Clutch Controls - Vehicles With: 6-Speed Manual Transmission MT82 308-02B Manual Transmission - Vehicles With: 5-Speed Manual Transmission MT75 308-03A Manual Transmission - Vehicles With: 6-Speed Manual Transmission MT82 308-03B Manual Transmission External Controls - Vehicles With: MT-75 308-06A Manual Transmission External Controls - Vehicles With: MT82 308-06B Transfer Case - Vehicles With: 5-Speed Manual Transmission MT75/6-Speed Manual Transmission - MT82 308-07A Transfer Case - Vehicles With: 6-Speed Automatic Transmission 6R80 308-07B Exhaust System Exhaust System - 2.5L Duratec-HE (122kW/165PS) - MI4 309-00A Exhaust System - 2.2L 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 309-00B Fuel System - General Information Fuel System - General Information 2.5L Duratec-HE (122kW/165PS) MI4 310-00A Fuel System - General Information 2.2L Duratorq-TDCi (88kW/120PS) Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma 310-00B 2011.50 Ranger Fuel Tank and Lines - 2.5L Duratec-HE Wiring Harnesses (122kW/165PS) - MI4 310-01A Electronic Feature Group Fuel Tank and Lines - 2.2L Anti-Theft - Active Duratorq-TDCi (88kW/120PS) Anti-Theft - Passive Puma/2.2L Duratorq-TDCi Multifunction Electronic (96kW/130PS) - Puma/2.2L Modules Duratorq-TDCi (110kW/150PS) Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma 310-01B GROUP Body and Paint Acceleration Control 310-02 Body and Paint Body System - General GROUP Electrical Information Front End Body Panels Climate Control System Body Closures Climate Control System - General Pickup Bed and Platform Body Information 412-00 Interior Trim and Climate Control 412-01 Ornamentation Instrumentation and Warning Systems Exterior Trim and Instrument Panel Cluster (IPC) 413-01 Ornamentation Horn 413-06 Rear View Mirrors Warning Chimes 413-09 Seating Parking Aid 413-13 Glass, Frames and Mechanisms Battery and Charging System Instrument Panel and Console Charging System - General Handles, Locks, Latches and Entry Information 414-00 Systems Battery, Mounting and Cables 414-01 Wipers and Washers Generator and Regulator 414-02 Bumpers Information and Entertainment Systems Safety Belt System Information and Entertainment System Supplemental Restraint - General Information 415-00 System Information and Entertainment Body Repairs - General System 415-01 Information Body Repairs - Vehicle Specific Lighting Information and Tolerance Exterior Lighting 417-01 Checks Interior Lighting 417-02 Front End Sheet Metal Repairs Daytime Running Lamps Roof Sheet Metal Repairs (DRL) 417-04 Side Panel Sheet Metal Electrical Distribution Repairs Module Communications Rear End Sheet Metal Repairs Network 418-00 Paint - General Information Module Configuration 418-01 418-02 419-01A 419-01B 419-10 501-00 501-02 501-03 501-04 501-05 501-08 501-09 501-10 501-11 501-12 501-14 501-16 501-19 501-20A 501-20B 501-25 501-26 501-27 501-28 501-29 501-30 501-36 2011.50 Ranger 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) 2011.50 Ranger GROUP General Information 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 GROUP Chassis SECTION TITLE PAGE Suspension 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 GROUP Powertrain SECTION TITLE PAGE 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 (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-06B Engine Ignition2.5L Duratec-HE (122kW/165PS) - MI4 .303-07A Glow Plug System2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma 303-07B Glow Plug System3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-07C Engine Emission Control2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-08A Engine Emission Control 303-08B Intake Air Distribution and Filtering2.5L Duratec-HE (122kW/165PS) - MI4 .303-12A Intake Air Distribution and Filtering2.2L Duratorq-TDCi (88kW/120PS) - Puma/2.2L Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma 303-12B Evaporative Emissions 303-13 Electronic Engine Controls2.5L Duratec-HE (122kW/165PS) - MI4 303-14A 2011.50 Ranger Electronic Engine Controls2.2L 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 303-14B Automatic Transmission Automatic TransmissionVehicles With: 6-Speed Automatic Transmission 6R80 307-01 Transmission Cooling 307-02 Automatic Transmission External Controls 307-05 Manual Transmission, Clutch and Transfer Case Manual Transmission 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 TransmissionVehicles With: 5-Speed Manual Transmission MT75 308-03A Manual TransmissionVehicles With: 6-Speed Manual Transmission MT82 308-03B Manual Transmission External ControlsVehicles With: MT-75 308-06A Manual Transmission 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 Transmission - 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 (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) - Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma 309-00B 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 Duratorq-TDCi (96kW/130PS) - Puma/2.2L Duratorq-TDCi (110kW/150PS) Puma/3.2L Duratorq-TDCi (148kW/200PS) - Puma 310-00B Fuel Tank and Lines2.5L Duratec-HE (122kW/165PS) - MI4 310-01A Fuel Tank and Lines2.2L 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 310-01B Acceleration Control .310-02 2011.50 Ranger GROUP Electrical SECTION TITLE PAGE Climate Control System Climate Control System - General Information 412-00 Climate Control 412-01 Instrumentation and Warning Systems Instrument Panel Cluster (IPC) 413-01 Horn .413-06 Warning Chimes 413-09 Parking Aid 413-13 Battery and Charging System Charging System - General Information 414-00 Battery, Mounting and Cables 414-01 Generator and Regulator .414-02 Information and Entertainment Systems Information and Entertainment System - General Information 415-00 Information and Entertainment System 415-01 Lighting Exterior Lighting 417-01 Interior Lighting 417-02 Daytime Running Lamps (DRL) 417-04 Electrical Distribution Module Communications Network .418-00 Module Configuration 418-01 Wiring Harnesses 418-02 Electronic Feature Group Anti-Theft - Active 419-01A Anti-Theft - Passive 419-01B Multifunction Electronic Modules 419-10 2011.50 Ranger GROUP Body and Paint SECTION TITLE PAGE Body and Paint Body System - General Information .501-00 Front End Body Panels 501-02 Body Closures 501-03 Pickup Bed and Platform Body 501-04 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 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 Roof Sheet Metal Repairs 501-28 Side Panel Sheet Metal Repairs 501-29 Rear End Sheet Metal Repairs 501-30 Paint - General Information 501-36 2011.50 Ranger ... Network 418 -00 Paint - General Information Module Configuration 418 - 01 418 -02 419 -01A 419 -01B 419 -10 5 01- 00 5 01- 02 5 01- 03 5 01- 04 5 01- 05 5 01- 08 5 01- 09 5 01- 10 5 01- 11 5 01- 12 5 01- 14 5 01- 16 5 01- 19 5 01- 20A... Information 211 -00 Power Steering . 211 -02 Steering Linkage 211 -03 Steering Column 211 -04 Steering Column Switches 211 -05 2 011 .50 Ranger GROUP... 5 01- 10 Glass, Frames and Mechanisms 5 01- 11 Instrument Panel and Console .5 01- 12 Handles, Locks, Latches and Entry Systems 5 01- 14 Wipers and Washers 5 01- 16

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