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Ford Flex 2009 2010 2011 2012 Workshop Service Repair Manual

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The Ford Flex is a full-size crossover SUV introduced for the 2009 model year, offering a unique alternative in its segment with distinctive styling and spacious three-row seating for up...
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Ford Flex 2009 2010 2011 2012 Workshop Service Repair Manual
The Ford Flex is a full-size crossover SUV introduced for the 2009 model year, offering a unique alternative in its segment with distinctive styling and spacious three-row seating for up to seven passengers. Built on the D3 platform, shared with models like the Lincoln MKS and Taurus SHO, the Flex was designed with a focus on interior comfort and a bold aesthetic, often described as a wagon-like profile. It was available with a 3.5L V6 Duratec engine or a more powerful 3.5L EcoBoost V6 twin-turbocharged engine, paired with a 6-speed automatic transmission and available in Front-Wheel Drive (FWD) or All-Wheel Drive (AWD) configurations. Its generous dimensions, including a wheelbase of approximately 117.9 inches, contribute to its comfortable ride and substantial cargo capacity, making it a versatile family vehicle. This comprehensive Workshop Service Repair Manual covers the Ford Flex models from 2009 through 2012, providing detailed information essential for maintenance and repair. It includes extensive procedures for engine and transmission overhaul, fuel and ignition systems, lubrication, exhaust, electrical systems, body, chassis, HVAC, and cooling systems. The manual offers guidance on routine maintenance, advanced diagnostics, component removal and installation, and rebuilding procedures, all presented with factory specifications and emphasis on quality service. With approximately 6000 pages of information in English, this manual is an invaluable resource for DIY mechanics and professional technicians alike, enabling them to effectively maintain and repair the Ford Flex.
🏷️ Basic Information
Identification
Make:
Ford
Model:
Flex
Model Years Covered:
2009, 2010, 2011, 2012
Product Name:
Ford Flex 2009 2010 2011 2012 Workshop Service Repair Manual
Codes
Vehicle Platform:
D3 Platform (shared with Lincoln MKS, Taurus SHO)
👋 Introduction
Market Position
Vehicle Segment:
Full-size Crossover SUV, often positioned as a family-friendly, stylish alternative to traditional SUVs.
Competitive Analysis
Key Competitors:
Chevrolet Traverse, Buick Enclave, Toyota Highlander, Honda Pilot, Mazda CX-9.
Key Features
Unique Selling Proposition:
Distinctive styling, spacious three-row seating, comfortable ride, available all-wheel drive.
Manual Usefulness
Value Proposition:
Enables owners to perform maintenance and repairs, potentially saving on labor costs and time compared to dealer visits.
Manual Target User
Intended User:
DIY mechanics and professional technicians seeking detailed service information.
📋 Manual Details
Coverage Areas
Breadth Of Coverage:
Comprehensive repair and overhaul of Ford Flex 2009-2012 models.
Page Count
Total Pages:
6000
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine:
Detailed repair, overhaul, diagnostics for V6 and EcoBoost engines.
Transmission:
Repair, overhaul, and diagnostic procedures for automatic transmissions.
Fuel System:
Components, diagnostics, and repair of fuel delivery, injection, and evaporative emission systems.
Ignition System:
Spark plugs, coils, wiring, ignition timing, and diagnostics.
Lubrication System:
Oil pump, passages, filters, and oil change procedures.
Exhaust System:
Muffler, catalytic converter, piping, and emissions control components.
Electrical System:
Wiring diagrams, power distribution, lighting, charging system, starting system, body electronics.
Body:
Body panels, doors, glass, interior trim, bumpers, and related hardware.
Chassis:
Suspension components, steering system, brakes, wheel bearings.
HVAC:
Heating, ventilation, and air conditioning system components, diagnosis, and repair.
Cooling System:
Radiator, water pump, thermostat, hoses, coolant specifications.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, fluid checks, tire rotations.
Diagnostics:
System-specific diagnostic procedures, troubleshooting guides, symptom-based fault finding.
Removal Installation:
Step-by-step instructions for removing and installing major components and sub-assemblies.
Overhaul Rebuild:
Detailed procedures for rebuilding engines, transmissions, and other major assemblies.
Component Repair:
Instructions for repairing specific components, including proprietary parts from manufacturers.
Technical Depth
Depth Of Information:
Advanced diagnostics, detailed repair procedures, component-level troubleshooting, factory specifications.
Target Audience:
Mechanical technicians familiar with general automotive practices and BRP products (note: likely a typo in product description, should be Ford).
Emphasis:
Special aspects of the Ford Flex product, ensuring quality service.
📊 Manual Specifications
File Format
Format:
PDF
Digital Delivery:
Fast and free electronic delivery via Email
Print Quality
Printability:
Yes, printable pages
Binding Type
Binding:
Not Applicable (PDF)
Paper Type
Paper Type:
Not Applicable (PDF)
Content Accuracy
Accuracy Statement:
Endeavored to ensure accuracy; considered a complete service manual.
⚙️ Engine Specifications
Primary Engine
Engine Options:
3.5L V6 (Duratec) and 3.5L EcoBoost V6 (twin-turbocharged).
Performance
3.5L V6 (Duratec) Power:
Approximately 263 hp @ 6250 rpm (variations by year).
3.5L V6 (Duratec) Torque:
Approximately 249 lb-ft @ 4500 rpm (variations by year).
3.5L Ecoboost V6 Power:
Approximately 355 hp @ 5700 rpm.
3.5L Ecoboost V6 Torque:
Approximately 350 lb-ft @ 3500 rpm.
Fuel System
Injection Type:
Sequential Electronic Fuel Injection (SEFI).
Fuel Type
Recommended Fuel:
Regular Unleaded (3.5L V6), Premium Unleaded recommended for 3.5L EcoBoost for optimal performance.
🔧 Transmission
Standard
Transmission Type:
6-speed automatic transmission (6F50/6F55).
Optional
Drivetrain Options:
Front-Wheel Drive (FWD), All-Wheel Drive (AWD).
Features
Transmission Features:
SelectShift™ capability (manual mode), electronic control.
📐 Dimensions
Exterior
Length:
Approximately 201.8 inches.
Width:
Approximately 78.2 inches (excluding mirrors).
Height:
Approximately 68.0 inches.
Wheelbase:
Approximately 117.9 inches.
Interior
Seating Capacity:
7 passengers (2+3+2 configuration).
Cargo
Cargo Volume Behind 3Rd Row:
Approximately 20.0 cubic feet.
Cargo Volume Behind 2Nd Row:
Approximately 40.0 cubic feet.
Cargo Volume Behind 1St Row:
Approximately 83.2 cubic feet.
Weights
Curb Weight FWD:
Approximately 4,510 lbs.
Curb Weight AWD:
Approximately 4,695 lbs.
Gross Vehicle Weight Rating Gvwr:
Approximately 5,900 - 6,100 lbs (depending on configuration).
🛡️ Safety Features
Ratings
NHTSA Overall Rating:
Typically 5-star (for frontal and side impact) for models tested.
Active Features
Brake System:
Four-wheel disc brakes with ABS, Electronic Brake Force Distribution (EBD), Brake Assist (BA).
Traction Control:
Traction Control System (TCS).
Stability Control:
AdvanceTrac® with Electronic Stability Control (ESC).
Passive Features
Airbags:
Frontal airbags, front side-impact airbags, Safety Canopy® System (rollover protection).
Seat Belts:
3-point safety belts with pretensioners and load-limiting retractors.
💡 Technology Features
Infotainment
Available Systems:
Ford SYNC® infotainment system (voice-activated, Bluetooth connectivity, USB port), optional navigation system, premium audio systems (Sony).
Driver Assistance
Available Features:
Rearview camera, rear parking sensors, blind-spot monitoring system (optional).
Connectivity
Connectivity Options:
Bluetooth for hands-free calling and audio streaming, USB ports for device charging and media playback.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 7,500 miles or 6 months (using synthetic blend or full synthetic oil), or as indicated by the Intelligent Oil-Life Monitor™.
Tire Rotation Interval:
Every 7,500 miles.
Transmission Fluid Change:
Refer to manual, often at higher mileage intervals (e.g., 100,000 miles) or as needed based on driving conditions.
Fluid Specifications
Engine Oil Type:
SAE 5W-30 (for both 3.5L V6 and 3.5L EcoBoost).
Engine Oil Capacity:
Approximately 5.5 - 6.0 quarts (check specific engine variant).
Coolant Type:
Ford Premium Engine Coolant (Orange) or equivalent meeting WSS-M97B44-D specification.
Transmission Fluid Type:
Mercon® LV Automatic Transmission Fluid.
Known Issues
Common Wear Items:
Brake pads/rotors, suspension components (bushings, struts), water pump leaks, PCV valve issues on some EcoBoost engines.
Powertrain Issues:
Occasional transmission shudder or rough shifting, turbocharger issues on some EcoBoost models (e.g., wastegate actuators).
Electrical Issues:
Potential issues with body control modules or infotainment system glitches.
📚 Vehicle History
Brand Heritage
Ford History:
Ford Motor Company, a global automotive manufacturer with a long history of innovation and production since 1903.
Model Evolution
Flex Introduction:
The Ford Flex was introduced for the 2009 model year, replacing the Ford Freestar minivan and offering a unique alternative in the SUV segment.
Design Philosophy:
Designed with a distinctive 'wagon-like' or 'minivan-like' profile, emphasizing interior space and comfort over traditional SUV ruggedness.
Production
Manufacturing Location:
Oakville Assembly Plant in Oakville, Ontario, Canada.
🏆 Awards & Recognition
Recognitions
Safety Awards:
Some models received 'Top Safety Pick' from the IIHS (Insurance Institute for Highway Safety) in their respective years.
Design Awards:
Praised for its distinctive and polarizing design, often cited as a bold styling choice.
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