Generation:
Third Generation (Second Facelift)
Production Years Covered:
1996-2006
Body Styles Covered:
Regular Cab, SuperCab (Extended Cab), SuperCrew (Crew Cab)
Drive Types Covered:
Rear-Wheel Drive (RWD), Four-Wheel Drive (4WD/4x4)
Platform:
Ford Ranger (PN-204)
Segment:
Compact Pickup Truck
Target Audience:
DIY Mechanics, Fleet Owners, Enthusiasts, Professional Technicians
Key Competitors:
Toyota Tacoma, Chevrolet S-10/Colorado, GMC Sonoma/Canyon, Dodge Dakota, Nissan Hardbody/Frontier
Manual Benefit 1:
Complete Official Factory Information
Manual Benefit 2:
Cost Savings on Repairs and Maintenance
Manual Benefit 3:
Empowerment for DIY Projects
Manual Benefit 4:
Enhanced Vehicle Longevity and Performance
Manual Benefit 5:
Specific to Vehicle, Not Generic
Geographic Coverage:
North America (USA, Canada, Mexico)
Market Coverage:
Domestic (North American specifications)
Estimated Page Count:
Extensive (typical for comprehensive factory service manuals, often exceeding 1000 pages)
Manual Type:
Factory Service and Repair Manual
Content Focus:
Repair, Maintenance, Diagnostics, Troubleshooting, Specifications
Delivery Method:
Instant Download
Powertrain:
Engine, Fuel System, Exhaust System, Cooling System, Lubrication System, Drivetrain (Transmission, Transfer Case, Axles)
Chassis:
Suspension (Front and Rear), Steering System, Brake System (Front and Rear), Wheels and Tires
Electrical:
Battery, Charging System, Starting System, Ignition System, Lighting System, Instrumentation, Wiper/Washer System, Power Accessories, Body Control Modules, HVAC Controls, Safety Systems (SRS)
Body:
Exterior Body Panels, Doors, Hood, Tailgate, Bumpers, Interior Trim, Seats, Glass, Mirrors, Body Sealing
Maintenance:
Scheduled Maintenance (Oil Changes, Filter Replacements, Lubrication), Fluid Checks and Replacements, Belt and Hose Inspections
Repair:
Engine Overhaul, Transmission Repair/Replacement, Brake System Overhaul, Suspension Component Replacement, Steering System Repair, Electrical Component Diagnosis and Repair, Body Panel Replacement
Diagnostics:
Troubleshooting Flowcharts, Symptom-Based Diagnosis, Diagnostic Trouble Codes (DTCs) Interpretation (for applicable models with OBD-II)
Specifications:
Torque Specifications for Fasteners, Fluid Capacities and Types, Engine Timing Specifications, Wheel Alignment Specifications, Electrical Resistance Values
Depth Of Information:
Comprehensive, Factory-Level Detail, Step-by-Step Instructions
Diagrams Illustrations:
Detailed Diagrams, Exploded Views, Wiring Schematics, Component Illustrations
Special Tools:
Identification and Usage of Specialized Ford Tools
Searchability:
Searchable Text Content (typically)
Printability:
Full Printable Pages
Zoom Capability:
Zoom In/Out Functionality for Detailed Views
Binding Type:
Digital (PDF Format)
Paper Type:
N/A (Digital)
Software Requirements:
Adobe PDF Reader, WinZip (or similar decompression utility)
Operating System Compatibility:
Compatible with All Versions of Windows & Mac
Engine Option 1 Displacement:
2.5 L (153 cu in) Lima I4
Engine Option 1 Power:
Approx. 118-127 hp @ 4800-5000 rpm
Engine Option 1 Torque:
Approx. 140-145 lb-ft @ 2800-3000 rpm
Engine Option 2 Displacement:
3.0 L (182 cu in) Vulcan V6
Engine Option 2 Power:
Approx. 145-150 hp @ 4900-5000 rpm
Engine Option 2 Torque:
Approx. 165-170 lb-ft @ 3000-3500 rpm
Engine Option 3 Displacement:
4.0 L (245 cu in) Cologne V6 (OHV)
Engine Option 3 Power:
Approx. 160-207 hp @ 4200-5000 rpm (depending on year/tune)
Engine Option 3 Torque:
Approx. 220-230 lb-ft @ 2700-3000 rpm (depending on year/tune)
Fuel Delivery:
Electronic Fuel Injection (EFI) for all engines
Fuel Type:
Unleaded Gasoline
Emission Controls:
Catalytic Converter, EGR System, PCV System
Standard Transmission Type:
5-Speed Manual Transmission (e.g., M5OD-R1 for 2WD, M5OD-R1HD for 4WD and heavier duty applications)
Optional Transmission Type 1:
4-Speed Automatic Transmission (e.g., 4R44E, 4R55E, 5R55E for V6 models)
Transfer Case 4Wd:
Manual Shift 4x4 (BW1350, BW1354) or Electronic Shift-on-the-Fly (ESOF) systems depending on trim/year
Rear Axle Ratio:
Various ratios available (e.g., 3.73, 4.10, 4.56) depending on engine, transmission, and package
Wheelbase Short Bed:
Approx. 113.9 inches (2893 mm)
Wheelbase Long Bed:
Approx. 125.8 inches (3195 mm)
Overall Length:
Varies by bed length and cab configuration
Width Excluding Mirrors:
Approx. 71.5 inches (1816 mm)
Height:
Approx. 65.7 - 67.3 inches (1669 - 1709 mm) depending on configuration
Bed Length Short:
Approx. 71.6 inches (1819 mm)
Bed Length Long:
Approx. 97.5 inches (2477 mm)
Curb Weight:
Approx. 3,300 - 4,000 lbs (1497 - 1814 kg) depending on configuration
Gross Vehicle Weight Rating Gvwr:
Varies by configuration and payload package, typically 4,500 - 5,800 lbs
NHTSA Rollover Resistance:
Generally rated 4 out of 5 stars for rollover resistance (for 2WD models)
ABS:
Anti-lock Braking System (ABS) standard on front wheels, optional on rear wheels or 4-wheel ABS on some models/years
Traction Control:
Optional on some models/years
Airbags:
Driver and Passenger Airbags (SRS) standard from 1999 onwards, optional or standard on earlier models
Seatbelts:
Three-point front seat belts with pretensioners, lap belts in rear for extended cabs
Audio System:
Standard AM/FM stereo with cassette and/or CD player. Optional premium sound systems available.
Speaker Configuration:
Typically 2 or 4 speakers, with optional premium systems offering more.
Cruise Control:
Optional on most models, standard on higher trims.
Power Windows Locks:
Optional, typically found on XLT and higher trim levels.
OBD Ii Port:
Standard from 1996 onwards for engine diagnostics.
Oil Change Interval:
Typically every 3,000-5,000 miles (4,800-8,000 km) or 3-6 months, depending on driving conditions and oil type (refer to manual for specific recommendations).
Tire Rotation Interval:
Every 5,000-7,500 miles (8,000-12,000 km)
Coolant Flush Interval:
Typically every 30,000-50,000 miles (48,000-80,000 km) or 2-3 years
Engine Oil Type:
Refer to manual for specific API service classification and viscosity grades (e.g., 5W-30, 10W-30 depending on engine and climate). Ford Motorcraft synthetic blend or full synthetic recommended.
Transmission Fluid Type Auto:
Mercon V (or Mercon compatible fluid) is common for 4RxxE transmissions. Refer to manual for exact specification.
Transmission Fluid Type Manual:
Refer to manual for specific gear oil type (e.g., Motorcraft Manual Transmission Lubricant).
Coolant Type:
Ford Premium Engine Coolant (Green) or equivalent meeting specification WSS-M97B51-A1.
Brake Fluid Type:
DOT 3 brake fluid
Common Issue 1:
Spark plug blow-out on 2004-2007 4.0L SOHC V6 engines (thread repair often required).
Common Issue 2:
Transmission solenoid issues (especially with 4R44E/4R55E models) leading to harsh shifting or failure to engage gears.
Common Issue 3:
Corrosion on frame rails and rear axle components, particularly in rust-belt regions.
Common Issue 4:
ABS sensor failures leading to ABS warning light illumination.
Common Issue 5:
Door hinge wear and sagging doors.
Ford Truck Legacy:
Ford has a long and established history in the pickup truck market, dating back to the Ford Model AA.
Ranger Introduction North America:
The Ford Ranger was first introduced in North America for the 1983 model year, replacing the Courier compact pickup.
Third Generation Facelift:
The 1998 model year saw a significant redesign (the second facelift of the second generation), which continued through 2006 with minor updates.
Manufacturing Locations:
Primarily assembled in North America (e.g., St. Paul, Minnesota; Edison, New Jersey; Louisville, Kentucky)
Global Presence:
While this manual focuses on North American models, the Ranger platform was also used globally with variations.
Automotive Journal Awards:
The Ford Ranger has historically received various accolades from automotive publications for its utility, capability, and value in the compact truck segment.
Consumer Satisfaction:
Generally well-regarded for its durability and workhorse capabilities, though specific ratings varied by model year and powertrain.
Factory Training Equivalence:
This manual mirrors the information used by Ford dealership technicians, representing the highest level of factory certification for repair knowledge.
