Powertrain:
Engine mechanical, fuel system, ignition system, exhaust system, cooling system, lubrication system, engine control systems (ECU/PCM), manual transmissions, automatic transmissions, transfer case (4WD models).
Chassis:
Front suspension, rear suspension, steering system, brake system (front and rear), wheels and tires, driveline (driveshafts, axles).
Electrical:
Battery, charging system, starting system, lighting system, instrument cluster, gauges, warning indicators, power distribution (fuse box, relays), wiring diagrams, body control module (BCM), power windows, power locks, mirrors, wipers, horn, audio system, anti-theft system.
Body:
Body structure, interior trim, exterior trim, doors, hood, tailgate, bumpers, glass, seats, HVAC (heating, ventilation, air conditioning), body panel repair, paint codes.
Engine Control:
Powertrain Control Module (PCM) diagnostics, sensor testing (e.g., MAF, MAP, O2, crank, cam position), actuator testing (e.g., fuel injectors, ignition coils), emissions control systems (EGR, PCV).
Climate Control:
HVAC system diagnosis and repair, including refrigerant charging, compressor, condenser, evaporator, blower motor, and control head operations.
Interior Components:
Detailed procedures for removing and installing interior trim panels, seats, dashboard components, and associated electrical connectors.
Maintenance:
Scheduled maintenance, fluid changes (oil, coolant, transmission fluid, brake fluid), filter replacements (oil, air, fuel, cabin), lubrication, tire rotation, battery maintenance.
Repair Overhaul:
Complete engine disassembly, rebuild, and reassembly; transmission removal, overhaul, and installation; brake system repairs (pads, rotors, calipers, lines); suspension component replacement; steering system repairs; electrical component diagnosis and replacement; body panel repair and replacement.
Troubleshooting:
Diagnostic procedures for engine performance, transmission issues, electrical faults, brake system problems, HVAC system malfunctions, using diagnostic trouble codes (DTCs) and flowcharts.
Diagnostics:
Includes diagnostic trouble code (DTC) interpretation and troubleshooting flowcharts for a wide range of vehicle issues, from engine misfires to ABS faults.
Engine Tuning:
Information on spark plug replacement, idle speed control, timing adjustments (if applicable), and basic engine performance tuning procedures.
Body Repair:
Guidelines for minor body panel alignment, rust repair, dent removal, and replacement of exterior trim and glass.
Depth:
Comprehensive: Covers basic to advanced diagnostics, repair, maintenance, and overhaul procedures. Includes detailed exploded views, torque specifications, and step-by-step instructions.
Torque Specifications:
Provides precise torque values for critical fasteners across all major mechanical systems, essential for proper assembly and avoiding component failure.
Engines Covered:
2.3L I4 (DOHC, Duratec), 2.5L I4 (OHV, Lima), 3.0L V6 (OHV, Vulcan), 4.0L V6 (OHV/SOHC, Cologne).
Engine Codes:
Common engine codes include: 2.3L Duratec (9L5Z), 2.5L Lima (OHC), 3.0L Vulcan (OHV), 4.0L OHV (ologne), 4.0L SOHC ( Cologne).
Horsepower Torque:
Specific horsepower and torque figures vary by engine and model year, detailed within the manual for each variant.
Fuel Delivery:
Electronic Fuel Injection (EFI) with sequential port injection for most models. Information on fuel pumps, injectors, pressure regulators, and diagnostic procedures included.
Oil Change Intervals:
Typical recommendations: 3,000-5,000 miles or 3-6 months for conventional oil; 5,000-7,500 miles or 6 months for synthetic oil, depending on driving conditions. Consult manual for specific engine/oil type.
Engine Oil:
API Service SJ or higher. Viscosity grades vary by temperature: 5W-30 (most common), 10W-30, 10W-40, 5W-20 for some later models. Always confirm with the manual for the specific engine.
Coolant:
Ford Premium Engine Coolant (Green) or equivalent. Typically a 50/50 mix with distilled water. Capacity varies by engine, approximately 10-15 quarts.
Transmission Fluid Auto:
Mercon V for 4R44E, 4R55E, 5R55E transmissions. Capacity approximately 3-5 quarts for a drain and fill.
Transmission Fluid Manual:
Gear oil, typically GL-4 or GL-5 rated, with viscosity grades such as 75W-90 or 75W-85. Capacity around 2-3 quarts.
Brake Fluid:
DOT 3 or DOT 4 brake fluid.
Power Steering Fluid:
Typically Mercon or Mercon V automatic transmission fluid (ATF) is used in the power steering system for these Rangers.
Rear Axle Fluid:
Hypoid gear oil, typically API GL-5 rated, with viscosity dependent on ambient temperature. Specification like 80W-90 or 75W-140 for heavy-duty use. Limited-slip differentials require specific friction modifiers.
Common Problems:
Ignition coil failure, exhaust manifold cracks (especially on V6 engines), ABS sensor issues, power window motor failures, rear main seal leaks, some transmission solenoid issues.
Suspension Components:
Wear on ball joints, tie rod ends, and bushings is common in higher mileage examples. Shocks and struts may require replacement.
Ford Trucks:
The Ford Ranger has a long-standing reputation as a capable and reliable compact pickup truck, evolving significantly from its earlier generations.
Generation Overview:
This manual covers the second generation of the North American Ford Ranger, characterized by significant styling updates and powertrain refinements from the first generation. It bridges the gap before the major redesign in 2006 (for the 2007 model year).
Design Changes:
The 1998 redesign brought a more rounded, aerodynamic styling compared to the preceding generation, along with updated interiors and chassis refinements. The 2001 model year saw further updates to styling and features.
Powertrain Updates:
Introduction of the 4.0L SOHC V6 engine in later years offered improved power and refinement over the older OHV 4.0L and 3.0L V6 options.
Manufacturing Locations:
Primarily manufactured in North America, with assembly plants historically located in the United States (e.g., St. Paul, Minnesota; Edison, New Jersey).
