Ford Ranger 2003-2006 Factory Repair Service Workshop Manual
FILE DETAILS:
Ford Ranger 2003-2006 Factory Repair Service Workshop Manual
Language : English
Pages : 3169
Downloadable : Yes
File Type : PDF
Size: 139 MB
TABLE OF CONTENTS:
Ford Ranger 2003-2006 Factory Repair Service Workshop Manual
INTRODUCTION.................................................................................... 0 Ford Ranger 2006 Repair Manual&Wiring Diagrams.................................................. 1 GROUP 00 Service Information .............................................................. 1 GROUP 01 Body.............................................................................. 103 SECTION 501-00 Body System — General Information .................................... 103 SECTION 501-02 Front End Body Panels................................................... 109 SECTION 501-03 Body Closures .......................................................... 121 SECTION 501-04 Pickup Bed and Platform Body ........................................... 125 SECTION 501-05 Interior Trim and Ornamentation ........................................ 134 SECTION 501-08 Exterior Trim and Ornamentation ........................................ 151 SECTION 501-09 Rear View Mirrors ...................................................... 154 SECTION 501-10 Seating ................................................................ 169 SECTION 501-11 Glass, Frames and Mechanisms ........................................... 222 SECTION 501-12 Instrument Panel and Console ......................................... 251 SECTION 501-14 Handles, Locks, Latches and Entry Systems .............................. 263 SECTION 501-16 Wipers and Washers ................................................... 307 SECTION 501-19 Bumpers ................................................................ 347 SECTION 501-20A Safety Belt System .................................................... 357 SECTION 501-20B Supplemental Restraint System ......................................... 385 SECTION 501-35 Body Repairs ........................................................... 500 GROUP 02 Frame and Mounting ............................................................... 537 GROUP 03 Engine............................................................................ 556 SECTION 303-00 Engine System — General Information .................................. 556 SECTION 303-01A Engine — 2.3L ......................................................... 632 SECTION 303-01B Engine — 3.0L (2V) .................................................... 772 SECTION 303-01C Engine — 4.0L SOHC .................................................... 893 SECTION 303-03 Engine Cooling .........................................................1071 SECTION 303-04A Fuel Charging and Controls — 2.3L .....................................1135 SECTION 303-04B Fuel Charging and Controls — 3.0L (2V) ................................1143 SECTION 303-04C Fuel Charging and Controls — 4.0L SOHC ................................1152 SECTION 303-05n Accessory Drive .......................................................1163 SECTION 303-06 Starting System ........................................................1183 SECTION 303-07A Engine Ignition — 2.3L ................................................1205 SECTION 303-07B Engine Ignition — 3.0L (2V) ...........................................1212 SECTION 303-07C Engine Ignition — 4.0L SOHC ...........................................1218 SECTION 303-08 Engine Emission Control ................................................1227 SECTION 303-12 Intake Air Distribution and Filtering ..................................1245 SECTION 303-13 Evaporative Emissions ..................................................1254 SECTION 303-14 Electronic Engine Controls .............................................1269 GROUP 04 Suspension........................................................................1316 SECTION 204-00 Suspension System — General Information ................................1316 SECTION 204-01A Front Suspension — 4x2 ................................................1332 SECTION 204-01B Front Suspension — 4x4 ..............................................1358 SECTION 204-02 Rear Suspension ......................................................1371 SECTION 204-04 Wheels and Tires .......................................................1379 GROUP 05 Driveline.........................................................................1387 SECTION 205-00 Driveline System — General Information .................................1387 SECTION 205-01 Driveshaft ...........................................................1406 SECTION 205-02A Rear Drive Axle Differential — Ford 7.5-Inch Ring Gear ................1426 SECTION 205-02B Rear Drive Axle Differential — Ford 8.8-Inch Ring Gear ..............1494 SECTION 205-02C Rear Drive Axle,Differential — Ford 8.8-Inch Ring Gear High Torque ....1562 SECTION 205-03 Front Drive Axle Differential — Dana 35 ..............................1617 SECTION 205-04 Front Drive Halfshafts ...............................................1680 GROUP 06 Brake System......................................................................1689 SECTION 206-00 Brake System — General Information ...................................1689 SECTION 206-02 Drum Brake..............................................................1711 SECTION 206-03 Front Disc Brake .......................................................1725 SECTION 206-05 Parking Brake and Actuation ............................................1737 SECTION 206-06 Hydraulic Brake Actuation ..............................................1747 SECTION 206-07 Power Brake Actuation ..................................................1757 SECTION 206-09 Anti-Lock Control ......................................................1761 GROUP 07 Automatic Transmission............................................................1797 SECTION 307-01 Automatic Transmission — 5R44E and 5R55E ...............................1797 SECTION 307-02 Transaxle,Transmission Cooling .........................................2093 SECTION 307-05 Automatic Transaxle,Transmission External Controls .....................2107 GROUP 08 Manual Transmission, Clutch and Transfer Case.....................................2130 SECTION 308-00 Manual Transaxle,Transmission and Clutch — General Information ........2130 SECTION 308-01 Clutch .................................................................2160 SECTION 308-02 Clutch Controls ........................................................2169 SECTION 308-03 Manual Transaxle ,Transmission .......................................2181 SECTION 308-07A Four-Wheel Drive Systems ..............................................2229 SECTION 308-07B Transfer Case — Automatic Shift .....................................2268 GROUP 09 Exhaust System ...................................................................2300 GROUP 10 Fuel System.......................................................................2321 SECTION 310-00 Fuel System — General Information ......................................2321 SECTION 310-01 Fuel Tank and Lines ....................................................2333 SECTION 310-02 Acceleration Control ...................................................2349 SECTION 310-03 Speed Control ..........................................................2357 GROUP 11 Steering System...................................................................2396 SECTION 211-00 Steering System — General Information ................................2396 SECTION 211-02 Power Steering .........................................................2415 SECTION 211-04 Steering Column ......................................................2444 SECTION 211-05 Steering Column Switches .............................................2486 GROUP 12 Climate Control System............................................................2500 SECTION 412-00 Climate Control System — General Information and Diagnostics ...........2500 SECTION 412-01 Climate Control ......................................................2581 GROUP 13 Instrumentation and Warning Systems...............................................2645 SECTION 413-00 Instrument Cluster and Panel Illumination ..............................2645 SECTION 413-01 Instrument Cluster .....................................................2661 SECTION 413-06 Horn ...................................................................2728 SECTION 413-09 Warning Devices ........................................................2738 GROUP 14 Battery and Charging System.......................................................2749 SECTION 414-00 Charging System — General Information ..................................2749 SECTION 414-01 Battery, Mounting and Cables ...........................................2767 SECTION 414-02 Generator and Regulator.................................................2785 GROUP 15 Audio Systems.....................................................................2795 SECTION 415-00 Entertainment System — General Information .............................2795 SECTION 415-01 Audio Unit ...........................................................2822 SECTION 415-02 Antenna ................................................................2827 SECTION 415-03 Speakers ...............................................................2830 GROUP 17 Lighting..........................................................................2835 SECTION 417-01 Exterior Lighting ......................................................2835 SECTION 417-02 Interior Lighting ......................................................2903 SECTION 417-04 Daytime Running Lamps ..................................................2919 GROUP 18 Electrical Distribution...........................................................2922 SECTION 418-00 Module Communications Network ..........................................2922 SECTION 418-01 Module Configuration ...................................................2943 GROUP 19 Electronic Feature Group..........................................................2947 SECTION 419-01 Anti-Theft — PATS ......................................................2947 SECTION 419-10 Multifunction Electronic Modules .....................................2977 GROUP 20 WIRING DIAGRAMS....................................................................2990 01.Introduction.........................................................................2990 02.Symbols..............................................................................2995 03.Connector Repair Procedures..........................................................3000 04.Wiring Harness Overview.............................................................. 0 05.Grounds..............................................................................3005 06.Fuse and Relay Information...........................................................3014 07.Charging System......................................................................3016 08.Power Distribution,SJB...............................................................3017 09.Module Communications Network........................................................3030 10.Starting System......................................................................3032 11.Electronic Engine Controls - 2.3L....................................................3033 12.Electronic Engine Controls - 3.0L....................................................3040 13.Electronic Engine Controls - 4.0L....................................................3047 14.Transmission Controls................................................................3054 15.Speed Control........................................................................3057 16.Cooling Fan..........................................................................3059 17.All Wheel Drive (AWD)................................................................3060 18.Shift Interlock......................................................................3062 19.Vehicle Dynamic Systems..............................................................3063 20.Horn,Cigar Lighter...................................................................3065 21.Supplemental Restraint System........................................................3066 22.Heating..............................................................................3069 23.Manual Climate Control System........................................................3071 24.Instrument Cluster...................................................................3074 25.Cluster and Panel Illumination.......................................................3077 26.Wipers and Washers...................................................................3079 27.Headlamps,Autolamps..................................................................3081 28.Fog Lamps............................................................................3083 29.Interior Lamps.......................................................................3084 30.Turn Signal,Stop,Hazard Lamps........................................................3086 31.Parking, Rear and License Lamps......................................................3091 32.Reversing Lamps......................................................................3093 33.Trailer,Camper Adapter...............................................................3094 34.Daytime Running Lamps................................................................3095 35.Power Windows........................................................................3097 36.Power Door Locks.....................................................................3099 37.Passive Anti-Theft System............................................................3101 38.Remote Keyless Entry and Alarm.......................................................3102 39.Tire Pressure Monitor System.........................................................3106 40.Power Mirrors........................................................................3107 41.Audio System Navigation..............................................................3108 42.Component Testing.................................................................... 0 43.Connector Views......................................................................3117 44.Component Location Views.............................................................3120 45.Component Location Charts............................................................3147 GNU Free Documentation License..................................................................3151 GNU General Public License......................................................................3159
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