Ford Flex Complete Workshop Service Repair Manual 2016

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🏷️ Basic Information Identification Make: Ford Model: Flex Year: 2016 Product Type: Workshop Service Repair Manual Codes Platform: Ford D4 Platform 👋 Introduction Market Position Vehicle Segment: Full-Size Crossover SUV...

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Sku: 513582

Tags: 2016 Car Cars Flex Ford

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Description

🏷️ Basic Information

Identification

Make:

Model:

Year:

Product Type:

Workshop Service Repair Manual

Codes

Platform:

Ford D4 Platform

👋 Introduction

Market Position

Vehicle Segment:

Full-Size Crossover SUV

Positioning:

Family-oriented, spacious, stylish alternative to traditional minivans and large SUVs.

Competitive Analysis

Competitors:

Chevrolet Traverse, Buick Enclave, Dodge Durango, Mazda CX-9.

Key Features

Interior Space:

Standard 3-row seating, ample cargo volume, comfortable for long journeys.

Design:

Distinctive, polarizing 'wagon-like' styling with a focus on interior practicality.

Powertrain Options:

Available naturally aspirated V6 and powerful twin-turbocharged EcoBoost V6 engines.

📋 Manual Details

Coverage Areas

All Procedures:

Yes (A-Z)

Page Count

Estimated Page Count:

Varies by Engine/Trim (Typically 2000+ pages for complete service manuals)

Manual Type

Manual Type:

Complete Workshop Service Repair Manual

Language

Language:

English

Format

Delivery Format:

Digital Download (PDF)

📖 Manual Coverage

Systems Covered

Engine:

3.5L EcoBoost V6, 3.5L Ti-VCT V6

Transmission:

6-Speed SelectShift Automatic (6F55)

Drivetrain:

All-Wheel Drive (AWD), Front-Wheel Drive (FWD)

Suspension:

Front Independent MacPherson Struts, Rear Independent Multi-Link

Brakes:

Four-Wheel Anti-lock Disc Brakes (ABS), Electronic Stability Control (ESC), Traction Control (TCS)

Steering:

Electric Power-Assisted Steering (EPAS)

Electrical:

Battery, Charging System, Starting System, Lighting, Instruments, Body Control Modules (BCM), Powertrain Control Modules (PCM)

Climate Control:

HVAC System, Automatic Climate Control

Body And Frame:

Body Panels, Doors, Hood, Tailgate, Chassis

Restraints:

Airbags, Seatbelts

Procedures Included

Routine Maintenance:

Oil Changes, Filter Replacements, Fluid Checks and Replenishment, Tire Rotation

Engine Repair:

Engine Overhaul, Component Replacement (Spark Plugs, Ignition Coils, Belts, Hoses), Timing Chain System

Transmission Service:

Fluid and Filter Changes, Torque Converter Service, Internal Component Repair

Brake Service:

Brake Pad and Rotor Replacement, Caliper Service, Bleeding Procedures

Suspension And Steering:

Shock/Strut Replacement, Ball Joint Service, Tie Rod End Replacement, Power Steering Pump/Motor Service

Electrical Diagnostics:

Troubleshooting Schematics, Component Testing, Wiring Harness Repair

Bodywork And Trim:

Panel Replacement, Door Hinge and Lock Repair, Interior Trim Removal and Installation

Climate Control Service:

Evaporator/Heater Core Replacement, AC System Recharge, Blower Motor Service

Troubleshooting:

Diagnostic Trouble Codes (DTCs), Symptom-Based Troubleshooting Guides

Technical Depth

Depth:

Comprehensive from Basic Maintenance to Full Rebuilds and Advanced Diagnostics

📊 Manual Specifications

File Format

File Format:

Print Quality

Print Quality:

High-Resolution, Sharable and Printable Pages

Binding Type

Binding Type:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

Software Requirements

Required Software:

Adobe Reader (or compatible PDF viewer)

Searchability

Text Searchability:

Yes (Searchable PDF)

⚙️ Engine Specifications

Primary Engine

Engine 1 Type:

3.5L Ti-VCT V6 (GDI/Port Injection)

Engine 1 Displacement:

3.5 Liters (3496 cc)

Engine 1 Bore X Stroke:

92.5 mm x 87.1 mm

Engine 1 Compression Ratio:

10.3:1

Engine 1 Horsepower:

287 hp @ 6250 rpm

Engine 1 Torque:

254 lb-ft @ 4000 rpm

Engine 1 Fuel System:

Sequential Multi-Port Fuel Injection (MPFI) & Gasoline Direct Injection (GDI)

Performance

Engine 2 Type:

3.5L EcoBoost V6 (Twin-Turbocharged)

Engine 2 Displacement:

3.5 Liters (3496 cc)

Engine 2 Horsepower:

365 hp @ 5500 rpm

Engine 2 Torque:

350 lb-ft @ 1500-5250 rpm

Engine 2 Fuel System:

Direct Injection (DI) with Twin Turbochargers

Fuel System

Fuel Type Recommended:

Regular Unleaded 87 Octane (3.5L Ti-VCT), Premium Unleaded 91 Octane Recommended (3.5L EcoBoost)

Fuel Tank Capacity:

18.6 Gallons (70.4 Liters)

🔧 Transmission

Standard

Transmission Type:

6-Speed Automatic SelectShift

Transmission Code:

Optional

Drivetrain Options:

Front-Wheel Drive (FWD), Intelligent All-Wheel Drive (AWD)

Features

Selectshift Capability:

Manual shifting mode via paddle shifters on steering wheel.

Transmission Fluid Type:

Mercon LV (Refer to specific model year for exact fill)

📐 Dimensions

Exterior

Length:

201.8 inches (5126 mm)

Width Without Mirrors:

78.2 inches (1986 mm)

Height:

68.3 inches (1735 mm)

Wheelbase:

117.9 inches (2995 mm)

Front Track:

67.0 inches (1702 mm)

Rear Track:

67.5 inches (1715 mm)

Ground Clearance:

Approximately 6.4 inches (163 mm)

Cargo

Cargo Volume Behind 3Rd Row:

20.0 cubic feet (566 L)

Cargo Volume Behind 2Nd Row:

43.8 cubic feet (1240 L)

Cargo Volume Behind 1St Row:

83.2 cubic feet (2356 L)

Weights

Curb Weight Fw:

Approx. 4,557 lbs (2067 kg)

Curb Weight AWD:

Approx. 4,769 lbs (2163 kg)

Max Towing Capacity:

Up to 2,000 lbs (907 kg) (Requires Trailer Tow Package)

🛡️ Safety Features

Ratings

NHTSA Overall Rating:

5-Star (Model Year Dependent, typical for 2016)

IIHS Top Safety Pick:

Yes (Good ratings in most categories for relevant years)

Active Features

Electronic Stability Control:

Standard

Traction Control:

Standard

Antilock Braking System:

Standard

Tire Pressure Monitoring System:

Standard

Rearview Camera:

Standard

Passive Features

Airbag System:

Driver and Front Passenger Airbags, Front Side-Impact Airbags, First and Second Row Side-Curtain Airbags

Seatbelts:

3-Point Safety Belts with Pretensioners and Load Limiters

💡 Technology Features

Infotainment

Infotainment System:

Ford SYNC with MyFord Touch (or later SYNC 3 on higher trims/options).

Display Size:

8-inch touchscreen central display.

Audio Options:

Sony Premium Audio System (Optional), AM/FM/CD/MP3, SiriusXM Satellite Radio.

Driver Assistance

Adaptive Cruise Control:

Optional

Blind Spot Monitoring:

Optional (Blind Spot Information System - BLIS)

Lane Departure Warning:

Optional (Lane Departure Warning System)

Parking Assist:

Optional (Active Park Assist)

Connectivity

Usb Ports:

Multiple USB ports for charging and media playback.

Bluetooth Connectivity:

Standard for hands-free calling and audio streaming.

Navigation System:

Optional, integrated with SYNC system.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 7,500 miles or 12 months, whichever comes first (with synthetic blend or full synthetic oil)

Engine Air Filter:

Inspect every 15,000 miles, replace as needed. Recommend replacement every 30,000 miles.

Cabin Air Filter:

Replace every 15,000-20,000 miles or annually.

Spark Plugs 3.5L Ti-Vct:

Replace at 100,000 miles.

Spark Plugs 3.5L Ecoboost:

Replace at 60,000 miles (specific type required).

Transmission Fluid Change:

Refer to manual for severe usage (e.g., towing), typically around 60,000-100,000 miles for normal use.

Fluid Specifications

Engine Oil Type 3.5L Ti-Vct:

SAE 5W-20 Synthetic Blend or Full Synthetic (API SN)

Engine Oil Capacity 3.5L Ti-Vct:

6.5 Quarts (6.2 Liters)

Engine Oil Type 3.5L Ecoboost:

SAE 5W-30 Full Synthetic (API SN)

Engine Oil Capacity 3.5L Ecoboost:

6.5 Quarts (6.2 Liters)

Coolant Type:

Ford Gold Coolant (Nitrite-free, HOAT) or equivalent

Brake Fluid Type:

DOT 3

Known Issues

Common Problem 1:

Transmission shudder/harsh shifting (often related to fluid degradation or valve body issues).

Common Problem 2:

Water pump leaks (especially on early models, but can occur on later ones).

Common Problem 3:

Turbocharger issues on EcoBoost models (oil leaks, boost leaks, turbo failure).

Common Problem 4:

Power steering assist failure (EPAS system issues).

📚 Vehicle History

Brand Heritage

Ford Brand Focus:

Known for trucks, SUVs, and accessible innovation across a broad range of vehicles.

Model Evolution

Flex Introduction Year:

Flex Generation 2016:

Second Generation (Facelifted in 2013)

Production

Production Location:

Oakville Assembly Plant, Ontario, Canada

Production End Year:

🏆 Awards & Recognition

Recognitions

Family Vehicle Awards:

Often praised by automotive journalists for its practicality and unique styling, although sales were never blockbuster.

Safety Awards:

Consistently received good safety ratings from NHTSA and IIHS.

Ratings

Fuel Economy Ratings:

EPA estimated MPG: FWD 3.5L Ti-VCT: 17 City / 23 Hwy. AWD 3.5L Ti-VCT: 16 City / 22 Hwy. AWD 3.5L EcoBoost: 15 City / 21 Hwy.