Ford Escape Hybrid 2004 to 2007 Service Repair Manual

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🏷️ Basic Information Identification Make: Ford Model: Escape Hybrid Generation Generation Code: First Generation (2001-2007) Generation Years: 2001-2007 Codes Vehicle Platform: Ford CD2 platform Powertrain Code: Hybrid Synergy Drive (HSD)...

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Type: Car

Vendor:

Sku: 267051

Tags: 2004 2005 2006 2007 Car Cars Escape Hybrid Ford

Product variants

Description

🏷️ Basic Information

Identification

Make:

Model:

Escape Hybrid

Generation

Generation Code:

First Generation (2001-2007)

Generation Years:

2001-2007

Codes

Vehicle Platform:

Ford CD2 platform

Powertrain Code:

Hybrid Synergy Drive (HSD) derivative, based on Toyota's system under license

👋 Introduction

Market Position

Segment:

Compact SUV / Hybrid Vehicle

Significance:

One of the first mass-produced hybrid SUVs in North America, pioneering the segment.

Competitive Analysis

Key Competitors:

Toyota Highlander Hybrid (later model), potentially some conventional compact SUVs with better fuel economy than non-hybrid Escapes.

Key Features

Powertrain Type:

Hybrid Electric Vehicle (HEV)

Fuel Efficiency:

Significantly improved MPG compared to its gasoline-only counterpart, especially in city driving.

Drivetrain:

Available in Front-Wheel Drive (FWD) and All-Wheel Drive (AWD).

Technology Integration:

Early integration of hybrid technology and sophisticated power management systems.

📋 Manual Details

Coverage Areas

Covered Years:

2004, 2005, 2006, 2007

Page Count

Estimated Page Count:

1500-2000 (estimated for a comprehensive factory service manual)

Manual Type

Manual Type:

Service and Repair Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Powertrain:

Internal Combustion Engine (ICE), Hybrid System (HS), Electric Motors, Power Split Device, High Voltage Battery System, Regenerative Braking System, Power Control Unit (PCU), Inverter/Converter

Transmission:

Electronic Continuously Variable Transmission (eCVT)

Chassis:

Suspension (front/rear), Steering, Brakes (including ABS and Hybrid regenerative braking), Wheels and Tires

Electrical:

Engine Control Module (ECM), Hybrid Control Module (HCM), Body Control Module (BCM), Lighting, Instrumentation, Audio System, HVAC Controls, Power Accessories, Diagnostic Trouble Codes (DTCs)

Body:

Exterior Body Panels, Interior Trim, Doors, Windows, Seats, HVAC Ducts, Exterior/Interior Lighting

Hybrid Specific:

High voltage system safety, Battery diagnostics, Hybrid system component testing, Regenerative braking calibration

Procedures Included

Routine Maintenance:

Oil changes, Filter replacements (air, oil, fuel), Spark plug replacement, Coolant flush, Brake fluid flush, Tire rotation, Battery checks

Major Repairs:

Engine overhaul, Transmission repair/replacement, Hybrid system component replacement (e.g., battery, inverter), Suspension component replacement, Brake system overhaul, Electrical system diagnosis and repair

Diagnostics:

Troubleshooting guides, DTC interpretation, Component testing procedures, Wiring diagrams, Diagnostic tool usage

Specifications:

Torque specifications, Fluid capacities, Gap specifications, Electrical resistance values, Performance benchmarks

Hybrid Procedures:

High-voltage disconnect procedures, Battery pack diagnostics and service, Hybrid control module programming/initialization, Regenerative braking system troubleshooting

Technical Depth

Depth:

Comprehensive: Covers everything from basic maintenance to complex diagnostics and major component overhaul, including specific hybrid system repair procedures.

📊 Manual Specifications

File Format

File Format:

Print Quality

Searchability:

Searchable text (OCR)

Zoom Capability:

High zoom capability for detailed diagrams and text

Printability:

Printable pages

Binding Type

Binding Type:

N/A (Digital PDF format)

Paper Type

Paper Type:

N/A (Digital PDF format)

Compatibility

Operating Systems:

Compatible with Windows and MAC operating systems

⚙️ Engine Specifications

Primary Engine

Engine Type:

Atkinson Cycle 4-cylinder gasoline engine

Displacement:

2.3 Liters (2300cc)

Engine Code:

Ford Duratec 23L

Performance

Combined Horsepower:

Approximately 155-160 hp (combined output from gasoline engine and electric motor)

Gasoline Engine Horsepower:

133 hp @ 5200 rpm

Electric Motor Horsepower:

Approximately 94 hp (peak)

Combined Torque:

Approximately 150-170 lb-ft (combined output)

Gasoline Engine Torque:

144 lb-ft @ 4250 rpm

Fuel System

Fuel Type:

Unleaded gasoline

Fuel Injection:

Electronic Fuel Injection (EFI), Sequential Multi-Port Fuel Injection (MPI)

Fuel Capacity:

15.1 gallons (57.2 L)

🔧 Transmission

Standard

Transmission Type:

Electronic Continuously Variable Transmission (eCVT)

Transmission Operation:

Utilizes a power-split device (planetary gear set) to blend power from the gasoline engine and electric motor, creating a seamless variable ratio.

Optional

Optional Transmission:

N/A (Only eCVT available for Hybrid models)

Features

Hybrid Integration:

Manages electric-only propulsion, gasoline-only propulsion, and combined propulsion. Facilitates regenerative braking energy capture.

Transmission Fluid:

Specialized CVT fluid (refer to manual for specific type and part number, e.g., Mercon LV or equivalent for hybrid systems)

📐 Dimensions

Exterior

Length:

175.7 inches (4463 mm)

Width:

71.1 inches (1806 mm)

Height:

66.5 inches (1689 mm)

Wheelbase:

103.1 inches (2619 mm)

Cargo

Cargo Volume Rear Seats Up:

Approx. 36.5 cu ft (1033 L)

Cargo Volume Rear Seats Down:

Approx. 69.3 cu ft (1962 L)

Weights

Curb Weight:

Approx. 3500-3700 lbs (1588-1678 kg), varies by FWD/AWD

Gross Vehicle Weight Rating:

Approx. 4700 lbs (2132 kg)

🛡️ Safety Features

Ratings

NHTSA Front Driver:

5-Star (2004 Model Year)

NHTSA Front Passenger:

5-Star (2004 Model Year)

IIHS Front Impact:

Good (2004 Model Year)

IIHS Side Impact:

Good (2004 Model Year)

Active Features

Standard Anti-lock Braking System (ABS), integrated with hybrid regenerative braking.

Traction Control:

Standard Traction Control System (TCS)

Electronic Stability Control:

Standard Electronic Stability Control (ESP) or AdvanceTrac

Passive Features

Airbags:

Front airbags, Front-side airbags, Available Curtain airbags

Seatbelts:

Three-point front and rear seatbelts, Pretensioners and load limiters for front seats.

Child Anchors:

LATCH (Lower Anchors and Tethers for Children) system

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM/CD audio system. Higher trims may include premium audio or an in-dash 6-disc changer. Auxiliary input jack may be present.

Navigation:

Optional factory navigation system available on higher trim levels.

Driver Assistance

Display Features:

Unique hybrid display in the instrument cluster showing energy flow, battery charge, and fuel economy data.

Connectivity

Auxiliary Input:

Optional auxiliary audio input jack for connecting external music players.

Hybrid Tech

Hybrid System Name:

Hybrid Synergy Drive (HSD) derivative.

Battery Type:

Nickel-Metal Hydride (NiMH) battery pack.

Modes Of Operation:

Electric-only driving (EV mode), Hybrid mode (blending ICE and electric), Regenerative braking, Engine braking.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 5,000-7,500 miles or 6 months, whichever comes first (refer to manual for exact recommendation based on driving conditions).

Air Filter Replacement:

Every 30,000 miles or as needed based on inspection.

Spark Plug Replacement:

Approx. 100,000 miles (iridium tipped spark plugs).

Coolant Flush:

Initial 100,000 miles, then every 50,000 miles thereafter for the hybrid system coolant.

Transmission Fluid Change:

Inspect periodically; replacement typically at higher mileage or if degraded. Refer to manual for specific intervals and procedures for eCVT.

Fluid Specifications

Engine Oil Type:

SAE 5W-20, API SN or ILSAC GF-5 certified synthetic blend or full synthetic (refer to manual for exact specification).

Engine Oil Capacity:

4.5 quarts (4.3 L) with filter.

Coolant Type:

Ford Super Premium Engine Coolant (VC-7B) or equivalent, typically a 50/50 mix with distilled water.

Brake Fluid Type:

DOT 3 or DOT 4 brake fluid.

Known Issues

Hybrid Battery Degradation:

As with any hybrid, the high-voltage battery pack can degrade over time, impacting range and efficiency. Replacement can be costly.

Inverter Failure:

While less common in early models, inverter failures can occur, leading to a complete loss of hybrid functionality. Diagnosing and replacing these units requires specialized knowledge.

Cvt Concerns:

Some early eCVT systems may exhibit occasional clunking or rough engagement, though generally considered robust.

Engine Oil Leaks:

Potential for oil leaks from valve cover gaskets or oil pan seals on the 2.3L Duratec engine, common with age and mileage.

Evap System Codes:

Can be prone to Evaporative Emission Control System (EVAP) codes, often due to faulty vent or purge valves, or a loose gas cap.

📚 Vehicle History

Brand Heritage

Ford Hybrid History:

Ford was an early adopter and developer of hybrid technology, with the Escape Hybrid being a landmark product following their licensing agreement with Toyota.

Model Evolution

First Generation Launch:

The first generation Escape was introduced for the 2001 model year. The Hybrid variant debuted for the 2005 model year.

Hybrid Powertrain Development:

Leveraged Toyota's Hybrid Synergy Drive (HSD) technology, adapting it to the Ford Escape platform. This partnership was crucial for Ford's early hybrid entry.

Production

Manufacturing Location:

Kansas City Assembly Plant, Claycomo, Missouri, USA

Production Years Covered:

2004-2007 (for this manual's scope, though Escape production started earlier)

🏆 Awards & Recognition

Recognitions

Early Hybrid Awards:

Received positive reviews for its fuel economy and pioneering status as a hybrid SUV. Often cited for its innovation in bringing hybrid technology to a popular segment.

Epa Fuel Economy:

EPA estimated MPG was significantly higher than conventional Escape models, often in the range of 30-33 MPG combined.