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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 and produced through 2012, offering a distinctive, unconventional styling focused on interior space and comfort. This...
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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 and produced through 2012, offering a distinctive, unconventional styling focused on interior space and comfort. This versatile vehicle features standard 3-row seating for up to seven passengers and is built on the D4 platform, shared with Lincoln models. Available with a naturally aspirated 3.5-liter V6 engine or an optional twin-turbocharged 3.5-liter EcoBoost V6 (from 2010), the Flex provides a comfortable ride and ample cargo capacity, making it a unique option in its segment, which included competitors like the Chevrolet Traverse and Toyota Highlander. Its engineering quality is underscored by its strong safety ratings, including 5-star NHTSA front and side impact ratings and IIHS Top Safety Pick awards. This comprehensive Workshop Service Repair Manual, presented in English, covers the Ford Flex models from 2009 to 2012. With over 6,000 pages, it offers extensive detail on all aspects of the vehicle, from scheduled maintenance procedures, fluid specifications, and routine service intervals to in-depth troubleshooting guides and step-by-step repair instructions for all major systems. This includes detailed coverage of the engine mechanical and electrical components, the 6-speed automatic transmission, chassis systems like suspension and brakes, the electrical system, HVAC, and body and frame repairs. The manual is an indispensable resource for owners, technicians, and mechanics seeking to maintain, diagnose, and repair the Ford Flex accurately and efficiently.
🏷️ Basic Information
Identification
Make:
Ford
Model:
Flex
Years Covered:
2009, 2010, 2011, 2012
Codes
Platform:
D4 (shared with Lincoln MKS, Lincoln MKT)
👋 Introduction
Market Position
Segment:
Full-size Crossover SUV
Competitive Analysis
Key Competitors:
Chevrolet Traverse, Buick Enclave, GMC Acadia, Dodge Durango, Toyota Highlander
Key Features
Styling:
Distinctive, unconventional styling with a focus on interior space and comfort.
Seating:
Standard 3-row seating accommodating up to 7 passengers.
📋 Manual Details
Coverage Areas
Primary Coverage:
North America
Page Count
Total Pages:
6000+
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
English
Format
File Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Comprehensive coverage including disassembly, assembly, inspection, and repair of all engine components.
Engine Electrical:
Wiring diagrams, component testing, diagnostics for ignition, fuel injection, sensors, and engine control modules.
Transmission Automatic:
Detailed procedures for removal, installation, overhaul, troubleshooting, and fluid service for the 6-speed automatic transmission.
Powertrain Control:
Diagnosis and repair of Powertrain Control Module (PCM) related issues, including sensor inputs and actuator outputs.
Chassis Systems:
Suspension (front and rear), steering system, and wheel alignment procedures.
Brake System:
Front and rear brake inspection, service, replacement of pads, rotors, calipers, and ABS system diagnostics.
Electrical System:
Complete electrical schematics, power distribution, lighting systems, accessories, and body control module (BCM) functions.
HVAC System:
Diagnosis and repair of heating, ventilation, and air conditioning (HVAC) systems, including refrigerant handling and component replacement.
Body And Frame:
Body panel removal and installation, interior trim, door mechanisms, and structural component repair.
Infotainment And Navigation:
Troubleshooting and repair of SYNC system, navigation units, audio components, and displays.
Safety Systems:
Airbag system diagnostics, seat belt mechanisms, and advanced safety features.
Procedures Included
Maintenance:
Detailed scheduled maintenance procedures, fluid level checks, filter replacements, and lubrication points.
Troubleshooting:
Extensive diagnostic flowcharts, symptom-based troubleshooting guides, and error code interpretations.
Repair And Rebuild:
Step-by-step instructions for component removal, installation, disassembly, assembly, and calibration.
Diagnostics:
Guidance on using diagnostic scan tools, interpreting live data, and performing actuator tests.
Wiring Diagrams:
Complete and detailed electrical wiring schematics for all vehicle systems.
Technical Depth
Depth:
Comprehensive, from basic maintenance to complete engine and transmission rebuilds, including electronic diagnostics.
📊 Manual Specifications
File Format
Quality:
High-resolution PDF, fully searchable and zoomable.
Print Quality
Printability:
All pages are printable for physical reference.
Binding Type
Binding:
N/A (Digital PDF)
Paper Type
Paper Type:
N/A (Digital PDF)
Compatibility
Operating Systems:
Compatible with Windows, macOS, and Linux operating systems.
Requirements
Software Requirement:
Adobe Reader or compatible PDF viewer required.
⚙️ Engine Specifications
Primary Engine
Engine Code:
3.5L Duratec 35 V6 (262 hp @ 6250 rpm, 248 lb-ft @ 4500 rpm)
Engine Description:
Naturally aspirated 3.5-liter V6 engine.
Optional Engine
Engine Code:
3.5L EcoBoost V6 (365 hp @ 5500 rpm, 350 lb-ft @ 1500-5250 rpm)
Engine Description:
Twin-turbocharged 3.5-liter EcoBoost V6 engine (available from 2010 model year).
Performance
Fuel Type:
Regular Unleaded gasoline (3.5L V6), Premium Unleaded gasoline recommended for EcoBoost V6.
Fuel System
Injection:
Electronic Fuel Injection (EFI)
Cooling System
Coolant Capacity:
Approximately 11.8 liters (12.5 US quarts) for 3.5L V6.
Lubrication System
Oil Capacity:
Approximately 5.9 liters (6.2 US quarts) with filter change for 3.5L V6.
Engine Management
Ignition System:
Electronic ignition, coil-on-plug.
🔧 Transmission
Standard
Type:
6-speed SelectShift Automatic Transmission
Optional
Type:
N/A
Features
Drivetrain:
Available in Front-Wheel Drive (FWD) and All-Wheel Drive (AWD).
Fluid Type
Transmission Fluid:
Mercon LV Automatic Transmission Fluid (ATF)
Fluid Capacity
Capacity:
Approximately 7.9 liters (8.4 US quarts) for transmission overhaul.
📐 Dimensions
Exterior
Length:
5019 mm (197.6 in)
Width:
1976 mm (77.8 in)
Height:
1761 mm (69.3 in)
Wheelbase:
3020 mm (118.9 in)
Weights
Curb Weight FWD:
Approx. 2000 kg (4400 lbs)
Curb Weight AWD:
Approx. 2075 kg (4575 lbs)
Towing Capacity:
Up to 2000 lbs (8000 lbs GVWR available with optional tow package)
Cargo
Cargo Volume Behind 3Rd Row:
Approx. 42.0 cu ft
Cargo Volume Behind 2Nd Row:
Approx. 83.2 cu ft
Cargo Volume Behind 1St Row:
Approx. 110.0 cu ft
🛡️ Safety Features
Ratings
NHTSA Front Impact:
5-Star (Driver and Passenger)
NHTSA Side Impact:
5-Star (Front and Rear Passengers)
IIHS Top Safety Pick:
Yes (for applicable years)
Active Features
ABS:
Standard Anti-lock Braking System (ABS)
Traction Control:
Standard Traction Control System (TCS)
Electronic Stability Control:
Standard AdvanceTrac Electronic Stability Control (ESC)
Passive Features
Airbags:
Front airbags, front side-impact airbags, Safety Canopy System (side-curtain airbags for all three rows).
💡 Technology Features
Infotainment
System Name:
Ford SYNC (optional, varies by trim and year)
Features:
Voice-activated communication, entertainment, climate control, optional navigation, touchscreen displays.
Driver Assistance
Features:
Available rearview camera, blind-spot monitoring (on later models/trims), rear parking sensors.
Connectivity
Ports:
USB ports, auxiliary audio input, Bluetooth connectivity.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 7,500 miles (12,000 km) or 6 months, whichever comes first, under normal driving conditions. Up to 10,000 miles (16,000 km) with synthetic oil under ideal conditions.
Tire Rotation:
Every 7,500 miles (12,000 km)
Transmission Fluid Change:
Typically at 100,000 miles (160,000 km) under normal conditions, or more frequently under severe use (refer to owner's manual).
Coolant Flush:
First flush at 100,000 miles (160,000 km), then every 50,000 miles (80,000 km).
Fluid Specifications
Engine Oil Viscosity:
SAE 5W-20 (for both 3.5L V6 and 3.5L EcoBoost V6)
Coolant Type:
Ford Premium Engine Coolant (Orange)
Brake Fluid Type:
DOT 3
Known Issues
Transmission Hard Shifts:
Some owners have reported rough shifting from the 6-speed automatic transmission, potentially requiring software updates or internal repairs.
Water Pump Leaks:
The water pump on the 3.5L V6 engine can develop leaks over time, requiring replacement.
Powertrain Control Module Failures:
Infrequent reports of PCM issues leading to various drivability problems.
HVAC System Performance:
Occasional issues with AC performance or blower motor functionality.
📚 Vehicle History
Brand Heritage
Brand Focus:
Ford Motor Company, established in 1903, known for a wide range of vehicles from trucks to performance cars.
Model Evolution
Introduction Year:
2008 (as a 2009 model year vehicle)
Design Philosophy:
Designed to offer a unique alternative to traditional SUV styling with a focus on spaciousness and a car-like driving experience.
Production
Assembly Location:
Oakville Assembly Plant, Oakville, Ontario, Canada
🏆 Awards & Recognition
Recognitions
IIHS Award:
Awarded 'Top Safety Pick' by the Insurance Institute for Highway Safety (IIHS) for multiple model years within this range.
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