Positioning:
A robust utility vehicle, popular in work and recreational applications. This manual targets owners and independent repair shops seeking professional-level repair information.
Competitors:
Toyota Hilux, Nissan Navara (D22), Mitsubishi Triton (L200).
Manual Features:
Detailed exploded views, step-by-step procedures, illustrations, diagrams, wiring schematics, technical data, special tools identification.
Visual Aid Quality:
Illustrated with clear, professional images and diagrams that aid in understanding complex procedures.
Primary Coverage:
North America, Australia, and potentially other markets where Courier and Ranger were sold and shared platforms/engines.
Estimated Page Count:
Likely exceeds 800 pages based on typical comprehensive factory service manuals for this era and vehicle type.
Type:
Factory Repair Service Manual (OEM equivalent)
Format:
Digital Download (PDF)
Searchability:
PDF format typically allows for text searching, enabling quick access to specific topics and keywords within the manual.
Powertrain:
Engine, Lubrication System, Cooling System, Fuel System, Emission Control, Engine Electrical System, Clutch, Manual Transmission, Transfer Case, Propeller Shaft, Front Axle, Rear Axle.
Chassis:
Steering System, Brake System, Suspension (Front and Rear).
Body And Electrical:
Body, Body Electrical System, Heater and Air Conditioning System.
Emission Control Systems:
Coverage of emission control components, diagnostics, and testing procedures for compliance with emissions regulations.
Maintenance:
Routine maintenance, fluid changes, filter replacements, tune-ups, inspection procedures.
Repair And Rebuild:
Detailed step-by-step procedures for component removal, repair, overhaul, and reinstallation for all major systems.
Diagnostics:
Troubleshooting guides, diagnostic charts, identifying symptoms, using diagnostic tools.
Component Torque Specs:
Detailed torque specifications for critical fasteners (engine components, suspension, drivetrain, etc.) essential for correct assembly and preventing damage.
Depth:
Comprehensive, from basic fluid checks to complete engine and transmission rebuilds, including electrical system schematics and diagnostic procedures.
Wiring Diagrams Detail:
Includes comprehensive wiring diagrams for engine control, lighting, accessories, and body electrical systems, crucial for troubleshooting electrical faults.
Diagnostic Tools Usage:
Guidance on using common diagnostic tools and techniques relevant to the vehicle's era.
2.6L G6 Series:
Inline 4-cylinder, gasoline, SOHC, multi-point fuel injection. Power output typically around 115-120 HP. Known for reliability.
2.5L Wl/Wl-T Series:
Inline 4-cylinder, naturally aspirated (WL) or turbocharged (WL-T) diesel. Indirect injection. Power output typically 75-95 HP. Known for fuel economy and durability.
2.2L F2 Series:
Inline 4-cylinder, gasoline. Less common than G6 in some markets, but also a robust option. Specific output varies.
Torque Output Typical:
Varies significantly by engine, but generally in the range of 140-200 lb-ft for the 2.6L gasoline and 110-150 lb-ft for the diesel variants.
Horsepower Range:
Gasoline: 115-125 HP (2.6L); Diesel: 75-95 HP (2.5L WL/WL-T).
Fuel Delivery Gasoline:
Electronic Multi-Point Fuel Injection (MPI).
Fuel Type Diesel:
Diesel fuel, indirect injection.
Manual Transmission:
Typically a 5-speed manual transmission (e.g., M50, R151F or similar robust designs) for all engine variants, designed for heavy-duty use.
Automatic Transmission:
Available on some models and engine configurations, often a 4-speed automatic.
Transfer Case:
Part-time 4WD system with a 2-speed transfer case (e.g., electronic or manual engagement) for off-road capability.
Body Styles:
Single Cab, Extended Cab (Space Cab).
Wheelbase Variations:
Multiple wheelbases available depending on cab configuration and intended use (e.g., standard, long wheelbase).
Curb Weight Range:
Approximately 3,000 - 4,000 lbs (1360 - 1815 kg), depending on configuration, engine, and drivetrain.
Towing Capacity Estimate:
Variable, but generally capable of towing 3,500 lbs to over 5,000 lbs (1588 kg to 2268 kg) with proper equipment and configuration.
Crash Test Results:
Variable by market and specific model year, generally met or exceeded regional safety standards for its class. Official ratings often available through NHTSA (US) or equivalent bodies.
Braking System:
Front disc, rear drum brakes are common. ABS available on higher trims or later models.
Airbags:
Driver and passenger airbags standard on most models within this timeframe.
Audio Systems:
Base to premium factory-installed AM/FM cassette/CD players. Limited digital integration compared to modern vehicles.
ABS:
Anti-lock Braking System (ABS) was an option or standard on higher trims, improving braking control.
Lighting Systems:
Halogen headlights, standard interior lighting. Manual covers bulb replacement and headlight aiming.
Oil Change Interval:
Typically 3,000-5,000 miles (5,000-8,000 km) or 6-12 months, depending on oil type and driving conditions. Consult manual for precise recommendations.
Spark Plug Replacement:
Gasoline engines: 30,000-60,000 miles (48,000-96,000 km) depending on plug type (copper vs. platinum/iridium).
Timing Belt Replacement Diesel:
WL/WL-T engines typically use a timing belt requiring replacement around 60,000-90,000 miles (96,000-145,000 km) as per manual. Critical maintenance to prevent catastrophic engine failure.
Engine Oil Spec Gasoline:
API Service SG, SH, SJ or later. Viscosity: SAE 5W-30 or 10W-30 recommended, with 10W-40 or 20W-50 for higher ambient temperatures. Refer to manual for exact viscosity range based on climate.
Engine Oil Spec Diesel:
API Service CF-4, CG-4 or CD. Viscosity: SAE 15W-40 or 10W-30 diesel engine oil. Refer to manual.
Coolant Spec:
Ethylene glycol-based antifreeze mixed with distilled water at a 50/50 ratio. Ford spec coolant or equivalent meeting Ford specifications (e.g., Ford Premium Gold or similar).
Transmission Fluid Manual:
API GL-4 or GL-5 gear oil, SAE 75W-90 or 80W-90. Specific Ford/Mazda specification is critical.
Transmission Fluid Automatic:
Mercon V or equivalent automatic transmission fluid (ATF). Refer to manual for exact specification.
Differential Fluid:
API GL-5 gear oil, SAE 80W-90 or 85W-140. For limited-slip differentials, a suitable additive may be required. Consult manual.
Brake Fluid Spec:
DOT 3 or DOT 4 brake fluid, depending on the specific system. Always refer to the manual and reservoir cap.
Diesel Engine Glow Plugs:
Glow plug failure can lead to hard starting in cold weather. The manual will detail testing and replacement.
Timing Belt Wear Diesel:
The WL-T diesel is an interference engine; timely timing belt replacement is crucial to prevent severe damage.
Suspension Wear:
Ball joints, tie rod ends, and bushings can wear over time, especially in vehicles used for heavy-duty work or off-roading. The manual provides inspection and replacement procedures.
Rear Main Seal Leaks:
Potential for rear main crankshaft seal leaks on higher mileage vehicles.
Ford Truck Legacy:
Ford has a long and successful history in the pickup truck market, dating back to the original Model A pickup. The Ranger nameplate has been a staple for decades.
Ranger Courier Relationship:
The Ford Courier was often a rebadged Mazda B-Series pickup in many markets, sharing platforms and powertrains. The Ranger in this era (especially outside North America) often shared significant components with Mazda's BT-50 and previous B-Series generations, making this manual highly relevant to Mazda B-Series owners of the same period.
Manufacturing Locations:
Assembly locations varied by region, including plants in North America, Thailand, South Africa, and Australia, depending on the specific model and market.
Segment Recognition:
Recognized as a reliable and capable compact pickup truck, often praised for its durability and work ethic, particularly the diesel variants in certain markets.
Consumer Reports Historical:
While specific ratings vary by year and market, the platform generally received moderate to good reliability ratings for its class, especially in mechanical components.
