Page 1: Table Of Contents
782-4356. Available publications include workshop manuals, wiring diagrams, PC/ED Manuals and Owner Guides. In addition, you can obtain a publications order form by writing to: Ford Publications, care of Helm Inc., P.O. Box 07150, Detroit, MI 48207. All rights reserved. Reproduction by any means, electronic or mechanical, including photocopying, recording, or by any information storage and retrieval system or translation in whole or part is not permitted without written authorization from Ford Motor Company.
Page 2: General Information
100-00-1 Manual Table of Contents GROUP General Information SECTION TITLE PAGE General Information ........................100-00-1 Identification Codes ........................100-01-1 Jacking, Towing and Lifting ..................... 100-02-1 Noise, Vibration and Harshness....................100-04-1 Standard Service Procedures....................100-05-1 Pre-Delivery Instructions......................100-06-1 Electric Vehicle (EV) Diagnostic Direction................100-07-1 Powertrain Diagnostic Routines Identification ...............
Page 3: General Information
100-00-2 General Information 100-00-2 DESCRIPTION AND OPERATION WARNING: Batteries normally produce explosive gases which can cause personal injury General Information or death. Do not allow flames, sparks or lighted Format and Usage substances to come near the batteries. When charging or working near the batteries, always The Electric Ranger is a combination of shield your face and protect your eyes.
Page 4 100-00-3 General Information 100-00-3 DESCRIPTION AND OPERATION (Continued) 4. Remove any electrical modules within 300 mm Welding Precautions (12 in) of the welding area. The EV requires special care when welding is performed. The sensitive electric components can be 5. Disarm the passive restraint system. Follow the damaged by the heat associated with gas welding procedures outlined in the standard Ranger and the electrical current from electric resistance...
Page 5: Identification Codes
100-01-1 Identification Codes 100-01-1 Manual Table of Contents SECTION 100-01 Identification Codes VEHICLE APPLICATION: Ranger EV CONTENTS PAGE DESCRIPTION AND OPERATION Identification Codes ................... 100-01-2 Warnings ....................100-01-2 2001 Ranger EV, 01/2001...
Page 6: Ranger Ev
100-01-2 Identification Codes 100-01-2 DESCRIPTION AND OPERATION The Traction Battery Tray warning label is located Identification Codes on the left and right sides of the traction battery. NOTE: For Electric Ranger Only. The label warns of the potential for electric shock if an unauthorized person attempts to service the traction battery.
Page 7 100-01-3 Identification Codes 100-01-3 DESCRIPTION AND OPERATION (Continued) Nickel Metal Hydride (NiMH) Battery Pack This label indicates a Nickel Metal Hydride (NiMH) battery pack. 2001 Ranger EV, 01/2001...
Page 8: Jacking, Towing And Lifting
100-02-1 Jacking, Towing and Lifting 100-02-1 Manual Table of Contents SECTION 100-02 Jacking, Towing and Lifting VEHICLE APPLICATION: Ranger EV CONTENTS PAGE GENERAL PROCEDURES Jacking....................100-02-2 Towing ....................100-02-3 2001 Ranger EV, 01/2001...
Page 9 100-02-2 Jacking, Towing and Lifting 100-02-2 GENERAL PROCEDURES Jacking Jacking Points — Front 1. Set the parking brake and block the rear wheels. 2. Position the jack under the front A arms and lift the vehicle. Jacking Point — Rear 1.
Page 10 100-02-3 Jacking, Towing and Lifting 100-02-3 GENERAL PROCEDURES (Continued) Towing Pre-Towing Instructions WARNING: Tow truck operators should not attempt to service, recharge or operate the vehicle under any circumstances. This vehicle is made up of complex electrical systems, and these operations must be performed by authorized personnel only.
Page 11 100-02-4 Jacking, Towing and Lifting 100-02-4 GENERAL PROCEDURES (Continued) 3. Secure the tires to the wheel lift. 4. On normal roads, limit speed to 88km/hr (55mph). On rough roads, limit speed to 56km/hr (35 mph). Rear Wheel Lift Towing 1. Lock the front wheels in a straight ahead position with a steering wheel locking device.
Page 12 100-02-5 Jacking, Towing and Lifting 100-02-5 GENERAL PROCEDURES (Continued) 2. Position the hoist pad extensions. 1 Locate the rear hoist pad extensions on the front of the rear leaf spring hanger eyes. 2 Locate the front hoist pad extensions on the front cab mount extensions.
Page 13: Noise, Vibration And Harshness
100-04-1 Noise, Vibration and Harshness 100-04-1 Manual Table of Contents SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Ranger EV CONTENTS PAGE DESCRIPTION AND OPERATION Condenser Fan ..................100-04-2 Condenser Fan —Postal Ranger EV .............. 100-04-2 Power Steering Pump ................100-04-2 Traction Battery Cooling/Ventilation Fan ............
Page 14 100-04-2 Noise, Vibration and Harshness 100-04-2 DESCRIPTION AND OPERATION The power steering pump will create a whine when operated. This whine can be identified by turning Condenser Fan the vehicle on and turning the steering wheel with WARNING: Disconnect the cooling fan the vehicle stationary.
Page 15: Standard Service Procedures
100-05-1 Standard Service Procedures 100-05-1 Manual Table of Contents SECTION 100-05 Standard Service Procedures VEHICLE APPLICATION: Ranger EV CONTENTS PAGE GENERAL PROCEDURES Buffer Zone .................... 100-05-2 Rubber Insulating Gloves Testing ..............100-05-2 Traction Battery Auxiliary Load High-Voltage Connector ........100-05-6 Traction Battery Charging................
Page 16 100-05-2 Standard Service Procedures 100-05-2 GENERAL PROCEDURES Rubber Insulating Gloves Testing NOTE: The rubber insulating gloves that are to be worn while working on all high-voltage systems on the Ranger and the Postal Ranger EV are rated for use on equipment of up to 1000 volts. They must be inspected before use and must always be worn in conjunction with the leather outer glove.
Page 17 100-05-3 Standard Service Procedures 100-05-3 GENERAL PROCEDURES (Continued) 3. NOTE: For Postal Ranger EV. Position four orange cones around the corners of the vehicle to mark off a one meter (three feet) perimeter around the vehicle. 4. Do not allow any unauthorized personnel into the buffer zone during repairs involving high-voltage.
Page 18 100-05-4 Standard Service Procedures 100-05-4 GENERAL PROCEDURES (Continued) 4. NOTE: For Postal Ranger EV. Open the charger inlet access door. 5. NOTE: Electric Ranger shown, Postal Ranger EV similar. Insert the PCS connector into the charger inlet and push the connector down until it locks into place.
Page 19 100-05-5 Standard Service Procedures 100-05-5 GENERAL PROCEDURES (Continued) 8. NOTE: For Postal Ranger EV. The SCI PCS will autostart in either the immediate or economy modes. If using the SCI PCS, press the select button to choose either immediate or economy charging. Charging will begin automatically.
Page 20 100-05-6 Standard Service Procedures 100-05-6 GENERAL PROCEDURES (Continued) 13. NOTE: For Postal Ranger EV. Close the charger inlet access door. Traction Battery Auxiliary Load High-Voltage Connector Disconnect WARNING: The nominal traction battery voltage is 300 volts DC. The buffer zone must be set up and insulated rubber gloves and a face shield must be worn.
Page 21 100-05-7 Standard Service Procedures 100-05-7 GENERAL PROCEDURES (Continued) Connect 1. To connect, reverse the disconnect procedure. Traction Battery Two-Pin High-Voltage Connector Special Tool(s) Traction Battery High Voltage Lockout and Diagnostic Tool 418-F207 Disconnect WARNING: The nominal traction battery voltage is 300 volts DC. The buffer zone must be set up and insulated rubber gloves and a face shield must be worn.
Page 22 100-05-8 Standard Service Procedures 100-05-8 GENERAL PROCEDURES (Continued) 5. Disconnect the traction battery two-pin high-voltage connector. 1 Remove the retaining pin. 2 Lift up on the connector latch. 3 Pull the connector out. 6. Install Traction Battery High Voltage Lockout and Diagnostic Tool in the two-pin high-voltage connector.
Page 23 100-05-9 Standard Service Procedures 100-05-9 GENERAL PROCEDURES (Continued) Traction Inverter Module (TIM) Capacitor Discharge Special Tool(s) Capacitor Discharge Tool 418-F213 73 Digital Multimeter or Equivalent 105-R0051 1. Disconnect the auxiliary battery ground cable. 2. Raise and support the vehicle. Refer to Section 100-02.
Page 24 100-05-10 Standard Service Procedures 100-05-10 GENERAL PROCEDURES (Continued) 5. Disconnect the two-pin high-voltage connector. 1 Remove the retaining pin. 2 Lift up on the connector latch. 3 Pull the connector out. 6. Remove the traction inverter module (TIM) cover plate. Remove the 12 screws.
Page 25 100-05-11 Standard Service Procedures 100-05-11 GENERAL PROCEDURES (Continued) WARNING: Verify that the voltage is checked across the correct terminals. Wear the rubber insulating gloves. Failure to correctly discharge the capacitors could result in severe personal injury or death. NOTE: The positive and negative posts are color coded.
Page 26 100-06-1 Pre-Delivery Instructions 100-06-1 Manual Table of Contents SECTION 100-06 Pre-Delivery Instructions VEHICLE APPLICATION: Ranger EV CONTENTS PAGE DESCRIPTION AND OPERATION Pre-Delivery Form..................100-06-2 2001 Ranger EV, 01/2001...
Page 27: Pre-Delivery Form
100-06-2 Pre-Delivery Instructions 100-06-2 DESCRIPTION AND OPERATION Pre-Delivery Form The following pages are pre-delivery sheets that are to be used to check the Electric Ranger prior to customer delivery. Make additional copies of the sheets as needed, and be sure to keep the original in the supplement for future use.
Page 29: Electric Vehicle (Ev) Diagnostic Direction
100-07-1 Electric Vehicle (EV) Diagnostic Direction 100-07-1 Manual Table of Contents SECTION 100-07 Electric Vehicle (EV) Diagnostic Direction VEHICLE APPLICATION: Ranger EV CONTENTS PAGE DIAGNOSIS AND TESTING Electric Vehicle (EV) Diagnostic Direction ............100-07-2 Active Command Indices ................ 100-07-21 Diagnostic Preface ................. 100-07-2 Diagnostic Process .................
Page 30 100-07-2 Electric Vehicle (EV) Diagnostic Direction 100-07-2 DIAGNOSIS AND TESTING • Multiple diagnostic checks have been combined in test steps to avoid lengthy pinpoint tests. Electric Vehicle (EV) Diagnostic — There are no illustrations in the pinpoint tests Direction to assist in the diagnosis. Connector face Diagnostic Preface views can be accessed from the Ranger Electric Vehicle (EV) Electrical Vacuum...
Page 31 100-07-3 Electric Vehicle (EV) Diagnostic Direction 100-07-3 DIAGNOSIS AND TESTING (Continued) NOTE: If the vehicle will not start and the NOTE: Do not carry out diagnostic procedures for malfunction indicator lamp (MIL), power limit IAA module DTC C1862 Contactor Circuit Failure warning indicator, low state of charge (SOC) unless there is a multiple auxiliary load failure and indicator, auxiliary battery indicator, red brake...
Page 32 100-07-4 Electric Vehicle (EV) Diagnostic Direction 100-07-4 DIAGNOSIS AND TESTING (Continued) Diagnostic Process PINPOINT TEST DP: DIAGNOSTIC PROCESS TEST STEP ACTION TO TAKE DP1 VERIFY CUSTOMER CONCERN NOTE: Check technical service bulletins (TSBs), OASIS, and vehicle GO to DP2. Yes = repair records before proceeding.
Page 33 100-07-5 Electric Vehicle (EV) Diagnostic Direction 100-07-5 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST DP: DIAGNOSTIC PROCESS TEST STEP ACTION TO TAKE NOTE: It may take up to one minute for a DTC to be set in IAA module continuous memory. If the concern is related to climate control, turn on the system in question.
Page 34 100-07-6 Electric Vehicle (EV) Diagnostic Direction 100-07-6 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST DP: DIAGNOSTIC PROCESS TEST STEP ACTION TO TAKE If no DTCs occur for any of the modules and the heater, air conditioning (if equipped), power steering, and DC/DC converter all do not operate, REFER to Multiple Auxiliary Load Failure Diagnosis in...
Page 35 100-07-7 Electric Vehicle (EV) Diagnostic Direction 100-07-7 DIAGNOSIS AND TESTING (Continued) • Section 303-01 Basic/Motor Transaxle • Section 412-03 Air Conditioning (Motor/Transaxle Lubrication System) — Low refrigerant — Oil leak — Refrigerant leak — Low oil level — Climate control air filter —...
Page 36 100-07-8 Electric Vehicle (EV) Diagnostic Direction 100-07-8 DIAGNOSIS AND TESTING (Continued) Interface Adapter Assembly (IAA) Module Diagnostic Trouble Code (DTC) Index Test Mode Description Action B1249 Continuous, Blend Door - Failure REFER to Page 412-02-3. On-Demand B1250 Continuous, Air Temperature Internal Sensor Circuit Failure REFER to Page 412-02-3.
Page 37 100-07-9 Electric Vehicle (EV) Diagnostic Direction 100-07-9 DIAGNOSIS AND TESTING (Continued) Interface Adapter Assembly (IAA) Module Diagnostic Trouble Code (DTC) Index Test Mode Description Action B2517 Continuous Emergency Power Off System Faulted REFER to Page 414-03A-18 (lead acid vehicles) or Page 414-03B-18 (NiMH vehicles).
Page 38 100-07-10 Electric Vehicle (EV) Diagnostic Direction 100-07-10 DIAGNOSIS AND TESTING (Continued) Battery Control Module (BCM) Diagnostic Trouble Code (DTC) Index — Lead Acid Battery Control Module (BCM) Diagnostic Trouble Code (DTC) Index — Lead Acid Test Mode Description Action U1041 Continuous SCP (J1850) Invalid/Missing Data for Vehicle No action required.
Page 39 100-07-11 Electric Vehicle (EV) Diagnostic Direction 100-07-11 DIAGNOSIS AND TESTING (Continued) Battery Control Module (BCM) Diagnostic Trouble Code (DTC) Index — Lead Acid Test Mode Description Action B2236 Continuous Weak or Defective Electric Vehicle Battery REFER to Traction Battery Module Fault System in Page 414-03A-70.
Page 40 100-07-12 Electric Vehicle (EV) Diagnostic Direction 100-07-12 DIAGNOSIS AND TESTING (Continued) Battery Control Module (BCM) Diagnostic Trouble Code (DTC) Index — NiMH Test Mode Description Action C1862 Continuous, Contactor Circuit Failure REFER to Negative Main On-Demand Contactor Relay Control in Pages 414-03B-6, 414-03B-11, 414-03B-16.
Page 41 100-07-13 Electric Vehicle (EV) Diagnostic Direction 100-07-13 DIAGNOSIS AND TESTING (Continued) Interface Adapter Assembly (IAA) Module Parameter Identification (PID) Index Description Expected Values CORE BF Core B Fault YES, NO DCDC OC DC-DC Over Current Fault YES, NO EMG PO Emergency Power Off Status ENABLE, DISABLE External Temperature Sensor Filtered Data #2 °C, °F...
Page 42 100-07-14 Electric Vehicle (EV) Diagnostic Direction 100-07-14 DIAGNOSIS AND TESTING (Continued) Traction Inverter Module (TIM) Parameter Identification (PID) Index Description Expected Values CCNT Number of Continuous DTCs in Module Integer Value EMG PO Emergency Power Off Input Status ENABLE, DISABLE IGN S Ignition Switch - Start Position YES, NO...
Page 43 100-07-15 Electric Vehicle (EV) Diagnostic Direction 100-07-15 DIAGNOSIS AND TESTING (Continued) Battery Control Module (BCM) Parameter Identification (PID) Index — Lead Acid Description Expected Values BATTMP1 Battery Temperature Sensor 1 Out of Range YES, NO BATTMP2 Battery Temperature Sensor 2 Out of Range YES, NO BATTMP3 Battery Temperature Sensor 3 Out of Range...
Page 44 100-07-16 Electric Vehicle (EV) Diagnostic Direction 100-07-16 DIAGNOSIS AND TESTING (Continued) Battery Control Module (BCM) Parameter Identification (PID) Index — Lead Acid Description Expected Values HIGHTMP High Temperature Delta in Battery Pack YES, NO HTRPRST Heater Present YES, NO IGN R Ignition Switch - Run Position YES, NO LEAK CF...
Page 45 100-07-17 Electric Vehicle (EV) Diagnostic Direction 100-07-17 DIAGNOSIS AND TESTING (Continued) Battery Control Module (BCM) Parameter Identification (PID) Index — NiMH Description Expected Values °C, °F AVGTEMP Average Temperature BAT INT Battery Integrity Integer Value BAT MC Battery Module Capacity AMHR (Amp-Hours) BAT MV Battery Module Voltage...
Page 46 100-07-18 Electric Vehicle (EV) Diagnostic Direction 100-07-18 DIAGNOSIS AND TESTING (Continued) Battery Control Module (BCM) Parameter Identification (PID) Index — NiMH Description Expected Values D TIME Total Drive Time SEC (Seconds) EMG PO Emergency Power Off Input Status ENABLE, DISABLE FAN FL Flow Through Fan Power ENABLE, DISABLE...
Page 47 100-07-19 Electric Vehicle (EV) Diagnostic Direction 100-07-19 DIAGNOSIS AND TESTING (Continued) Battery Control Module (BCM) Parameter Identification (PID) Index — NiMH Description Expected Values TRAC MC Traction Main Current TRANSGR Transmission Gear D6 PRK, notPRK WRG BCM Wrong BCM Hardware Installed YES, NO Traction Inverter Module (TIM) Operating State Operating State Indices...
Page 48 100-07-20 Electric Vehicle (EV) Diagnostic Direction 100-07-20 DIAGNOSIS AND TESTING (Continued) Battery Control Module (BCM) Operating State Battery Control Module (BCM) Operating State Index — Lead Acid Index — Lead Acid Operating Operating State State Description State State Description LOS Drive-Current Sense Fault No Charge-Battery Installed in Reverse LOS Drive-Voltage Sense Fault...
Page 49 100-07-21 Electric Vehicle (EV) Diagnostic Direction 100-07-21 DIAGNOSIS AND TESTING (Continued) Battery Control Module (BCM) Operating State Battery Control Module (BCM) Operating State Index — NIMH Index — NIMH Operating Operating State State Description State State Description Shutdown-Battery Module Voltage No Charge-Charger Latchup Out of Balance No Charge-No Stored Code Logging...
Page 50 100-07-22 Electric Vehicle (EV) Diagnostic Direction 100-07-22 DIAGNOSIS AND TESTING (Continued) Interface Adapter Assembly (IAA) Module Active Interface Adapter Assembly (IAA) Module Active Command Index Command Index Active Active Command Active Active Command Command Mode Signal Command Mode Signal RECIRC Recirculation Door STOP, A/C DC...
Page 51 100-07-23 Electric Vehicle (EV) Diagnostic Direction 100-07-23 DIAGNOSIS AND TESTING (Continued) Battery Control Module (BCM) Active Command Traction Inverter Module (TIM) Active Index — Lead Acid Command Index Active Active Command Traction Inverter Module (TIM) Active Command Command Mode Signal Index FAN SPEED BCM Packeted...
Page 52 100-07-24 Electric Vehicle (EV) Diagnostic Direction 100-07-24 DIAGNOSIS AND TESTING (Continued) Battery Control Module (BCM) Active Command • DTC B1555 Ignition Run/Start - Circuit Failure Index — NiMH — The interface adapter assembly (IAA) module Active Active Command uses the key RUN/START input at pin 97 to Command Mode Signal...
Page 53: Fuse
100-07-25 Electric Vehicle (EV) Diagnostic Direction 100-07-25 DIAGNOSIS AND TESTING (Continued) Symptom Chart Symptom Chart Condition Possible Sources Action DTC B1342 ECU Is Interface adapter assembly GO to Pinpoint Test A. • • • Defective (IAA Module) (IAA) module. DTC B1555 Ignition Fuse.
Page 54 100-07-26 Electric Vehicle (EV) Diagnostic Direction 100-07-26 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST C : DTC B2477 MODULE CONFIGURATION FAILURE TEST STEP ACTION TO TAKE C1 CARRY OUT SOFTWARE DOWNLOAD NOTE: If the battery control module (BCM) sets DTC B2477, check the Yes = RETRY the software traction battery support tray in-line C1939 for secure connection.
Page 55: Powertrain Diagnostic Routines Identification
100-09-1 Powertrain Diagnostic Routines Identification 100-09-1 Manual Table of Contents SECTION 100-09 Powertrain Diagnostic Routines Identification VEHICLE APPLICATION: Ranger EV CONTENTS PAGE DIAGNOSIS AND TESTING Powertrain Diagnostic Routines Identification ............ 100-09-2 Diagnostic Preface ................. 100-09-2 Diagnostic Routines ................100-09-3 Directions .................... 100-09-2 Powertrain Diagnostic Routines Index ............
Page 56 100-09-2 Powertrain Diagnostic Routines Identification 100-09-2 DIAGNOSIS AND TESTING 1. Unless a fault is evident, it is recommended that all diagnosis begin with a thorough visual Powertrain Diagnostic Routines inspection of a suspected system or component. Identification 2. If an obvious cause for an observed or reported Diagnostic Preface malfunction can be found, correct the cause of the malfunction before proceeding to the next...
Page 57 100-09-3 Powertrain Diagnostic Routines Identification 100-09-3 DIAGNOSIS AND TESTING (Continued) Special Tool(s) Diagnostic Routines Traction Battery Low Voltage Service Cord 418-F219 Special Tool(s) Traction Battery High-Voltage Lockout and Diagnostic 104-Pin Breakout Box (BOB) 418-049 (014-00950) or Tool 418-F207 equivalent High-Voltage Insulated Safety Gloves 100-F036 or BCM/TIM Breakout Box (BOB) Adapter Cable equivalent 418-F212...
Page 58 100-09-4 Powertrain Diagnostic Routines Identification 100-09-4 DIAGNOSIS AND TESTING (Continued) ROUTINE 1: VEHICLE DOES NOT START/VEHICLE QUITS WHILE DRIVING (LEAD ACID VEHICLES) TEST STEP ACTION TO TAKE • With key ON, monitor BCM PIDs BAT INT, BAT MC, CHG CYC, Yes = REPLACE the battery and LOWVOLT, and enter the values on the Dealer Battery Return Form module(s) in question.
Page 59 100-09-5 Powertrain Diagnostic Routines Identification 100-09-5 DIAGNOSIS AND TESTING (Continued) ROUTINE 1: VEHICLE DOES NOT START/VEHICLE QUITS WHILE DRIVING (LEAD ACID VEHICLES) TEST STEP ACTION TO TAKE • Remove the traction battery and connect Traction Battery High-Voltage Yes = REPLACE the BCM. Lockout and Diagnostic Tool to the traction battery high-voltage two-pin REFER to Section...
Page 60 100-09-6 Powertrain Diagnostic Routines Identification 100-09-6 DIAGNOSIS AND TESTING (Continued) ROUTINE 1: VEHICLE DOES NOT START/VEHICLE QUITS WHILE DRIVING (LEAD ACID VEHICLES) TEST STEP ACTION TO TAKE • With key OFF, disconnect in-line C1939 on the traction battery support No = REPAIR the DG wire.
Page 61 100-09-7 Powertrain Diagnostic Routines Identification 100-09-7 DIAGNOSIS AND TESTING (Continued) ROUTINE 1: VEHICLE DOES NOT START/VEHICLE QUITS WHILE DRIVING (LEAD ACID VEHICLES) TEST STEP ACTION TO TAKE 1-20 CHECK KEY RUN/START SIGNAL TO CONTACTOR BOX AT TRACTION BATTERY SUPPORT TRAY •...
Page 62 100-09-8 Powertrain Diagnostic Routines Identification 100-09-8 DIAGNOSIS AND TESTING (Continued) ROUTINE 2: VEHICLE DOES NOT START/VEHICLE QUITS WHILE DRIVING (NIMH VEHICLES) TEST STEP ACTION TO TAKE • Disconnect and reconnect the 12-volt auxiliary battery negative cable. Yes = GO to 2-4. •...
Page 63 100-09-9 Powertrain Diagnostic Routines Identification 100-09-9 DIAGNOSIS AND TESTING (Continued) ROUTINE 2: VEHICLE DOES NOT START/VEHICLE QUITS WHILE DRIVING (NIMH VEHICLES) TEST STEP ACTION TO TAKE • Connect jumper wires between the connector for the temperature sensor in question and the known good temperature sensor that was disconnected.
Page 64 100-09-10 Powertrain Diagnostic Routines Identification 100-09-10 DIAGNOSIS AND TESTING (Continued) ROUTINE 2: VEHICLE DOES NOT START/VEHICLE QUITS WHILE DRIVING (NIMH VEHICLES) TEST STEP ACTION TO TAKE 2-11 CHECK STATUS OF KEY START SIGNAL TO TRACTION INVERTER MODULE (TIM) • With key ON, monitor TIM PID IGN S. Yes = GO to 2-14.
Page 65 100-09-11 Powertrain Diagnostic Routines Identification 100-09-11 DIAGNOSIS AND TESTING (Continued) ROUTINE 2: VEHICLE DOES NOT START/VEHICLE QUITS WHILE DRIVING (NIMH VEHICLES) TEST STEP ACTION TO TAKE No = REPAIR the DG wire. WARNING: The traction battery contains high-voltage components and wiring. High-voltage insulated safety gloves and face shield must be worn when carrying out the following steps.
Page 66 100-09-12 Powertrain Diagnostic Routines Identification 100-09-12 DIAGNOSIS AND TESTING (Continued) ROUTINE 2: VEHICLE DOES NOT START/VEHICLE QUITS WHILE DRIVING (NIMH VEHICLES) TEST STEP ACTION TO TAKE • Disconnect the BOB from in-line C1939M, remove the traction battery, Yes = REPLACE the contactor and connect Traction Battery High-Voltage Lockout and Diagnostic Tool box.
Page 67 100-09-13 Powertrain Diagnostic Routines Identification 100-09-13 DIAGNOSIS AND TESTING (Continued) ROUTINE 4: VEHICLE OPERATES AT REDUCED POWER (LEAD ACID VEHICLES) TEST STEP ACTION TO TAKE If BCM OP PID indicates 69, CHARGE the traction battery. REFER to Section 100-05. • Does the BCM OP PID indicate 67 (limited operating strategy drive-battery overtemperature), 68 (LOS drive-battery No = GO to 4-9.
Page 68 100-09-14 Powertrain Diagnostic Routines Identification 100-09-14 DIAGNOSIS AND TESTING (Continued) ROUTINE 4: VEHICLE OPERATES AT REDUCED POWER (LEAD ACID VEHICLES) TEST STEP ACTION TO TAKE WARNING: The traction battery contains high-voltage components and wiring. High-voltage insulated safety gloves and face shield must be worn when carrying out the following steps.
Page 69 100-09-15 Powertrain Diagnostic Routines Identification 100-09-15 DIAGNOSIS AND TESTING (Continued) ROUTINE 4: VEHICLE OPERATES AT REDUCED POWER (LEAD ACID VEHICLES) TEST STEP ACTION TO TAKE • Is there a temperature difference of greater than 7°C (13°F) between No = CONNECT the vehicle to the temperature sensor that is below -20°C (-4°F) and the other the PCS to warm the temperature sensors?
Page 70 100-09-16 Powertrain Diagnostic Routines Identification 100-09-16 DIAGNOSIS AND TESTING (Continued) ROUTINE 4: VEHICLE OPERATES AT REDUCED POWER (LEAD ACID VEHICLES) TEST STEP ACTION TO TAKE Resistance — 493 ohms = 0 °C (32°F) — 533 ohms = 10 °C (50°F) —...
Page 71 100-09-17 Powertrain Diagnostic Routines Identification 100-09-17 DIAGNOSIS AND TESTING (Continued) ROUTINE 5: VEHICLE OPERATES AT REDUCED POWER (NIMH VEHICLES) TEST STEP ACTION TO TAKE 5-1 CHECK STATUS OF BATTERY CONTROL MODULE (BCM) OPERATING STATE • With key ON, monitor BCM PID BCM OP. Yes = If BCM OP PID indicates 67, GO to 5-2.
Page 72 100-09-18 Powertrain Diagnostic Routines Identification 100-09-18 DIAGNOSIS AND TESTING (Continued) ROUTINE 5: VEHICLE OPERATES AT REDUCED POWER (NIMH VEHICLES) TEST STEP ACTION TO TAKE No = REPLACE the battery WARNING: The traction battery contains high-voltage temperature sensor in components and wiring. High-voltage insulated safety gloves and face question.
Page 73 100-09-19 Powertrain Diagnostic Routines Identification 100-09-19 DIAGNOSIS AND TESTING (Continued) ROUTINE 5: VEHICLE OPERATES AT REDUCED POWER (NIMH VEHICLES) TEST STEP ACTION TO TAKE No = REPLACE the battery WARNING: The traction battery contains high-voltage temperature sensor in components and wiring. High-voltage insulated safety gloves and face question.
Page 74 100-09-20 Powertrain Diagnostic Routines Identification 100-09-20 DIAGNOSIS AND TESTING (Continued) ROUTINE 5: VEHICLE OPERATES AT REDUCED POWER (NIMH VEHICLES) TEST STEP ACTION TO TAKE — 1,129 ohms = 120 °C (248°F) — 1,197 ohms = 130 °C (266°F) — 1,268 ohms = 140 °C (284°F) —...
Page 75 100-09-21 Powertrain Diagnostic Routines Identification 100-09-21 DIAGNOSIS AND TESTING (Continued) ROUTINE 6: NOTICEABLE DECREASE IN VEHICLE DRIVING RANGE (LEAD ACID VEHICLES) TEST STEP ACTION TO TAKE • Is the vehicle equipped with traction battery heaters? No = INFORM the customer that the decrease in vehicle driving range may be due to harsh driving or storage...
Page 76 100-09-22 Powertrain Diagnostic Routines Identification 100-09-22 DIAGNOSIS AND TESTING (Continued) ROUTINE 7: NOTICEABLE DECREASE IN VEHICLE DRIVING RANGE (NIMH VEHICLES) TEST STEP ACTION TO TAKE 7-1 CHECK STATUS OF TRACTION BATTERY MODULES BY CARRYING OUT THE BATTERY MODULE DIAGNOSTIC TEST •...
Page 77 100-09-23 Powertrain Diagnostic Routines Identification 100-09-23 DIAGNOSIS AND TESTING (Continued) ROUTINE 8: VEHICLE DOES NOT CHARGE (LEAD ACID VEHICLES) TEST STEP ACTION TO TAKE • Does the Battery Module Diagnostic Test indicate to replace any No = CHARGE the traction battery modules? battery to full SOC.
Page 78 100-09-24 Powertrain Diagnostic Routines Identification 100-09-24 DIAGNOSIS AND TESTING (Continued) ROUTINE 8: VEHICLE DOES NOT CHARGE (LEAD ACID VEHICLES) TEST STEP ACTION TO TAKE WARNING: The traction battery contains high-voltage components and wiring. High-voltage insulated safety gloves and face shield must be worn when carrying out the following steps. Failure to follow this warning may result in severe personal injury or death.
Page 79 100-09-25 Powertrain Diagnostic Routines Identification 100-09-25 DIAGNOSIS AND TESTING (Continued) ROUTINE 8: VEHICLE DOES NOT CHARGE (LEAD ACID VEHICLES) TEST STEP ACTION TO TAKE • Is there a temperature difference of greater than 7°C (13°F) between No = CONNECT the vehicle to the temperature sensor that is below 5°C (41°F) and the other the power control station temperature sensors?
Page 80 100-09-26 Powertrain Diagnostic Routines Identification 100-09-26 DIAGNOSIS AND TESTING (Continued) ROUTINE 8: VEHICLE DOES NOT CHARGE (LEAD ACID VEHICLES) TEST STEP ACTION TO TAKE No = REPLACE the BCM. WARNING: The traction battery contains high-voltage REFER to Section components and wiring. High-voltage insulated safety gloves and face 414-03A.
Page 81 100-09-27 Powertrain Diagnostic Routines Identification 100-09-27 DIAGNOSIS AND TESTING (Continued) ROUTINE 8: VEHICLE DOES NOT CHARGE (LEAD ACID VEHICLES) TEST STEP ACTION TO TAKE • With key OFF, disconnect traction battery support tray in-line C1939 and Yes = GO to 8-20. connect 104-Pin Breakout Box (BOB) to in-line C1939M using Traction Battery Low Voltage Service Cord;...
Page 82 100-09-28 Powertrain Diagnostic Routines Identification 100-09-28 DIAGNOSIS AND TESTING (Continued) ROUTINE 8: VEHICLE DOES NOT CHARGE (LEAD ACID VEHICLES) TEST STEP ACTION TO TAKE • With key OFF, disconnect traction battery support tray in-line C1939 and Yes = GO to 8-25. connect 104-Pin Breakout Box (BOB) to in-line C1939M using Traction Battery Low Voltage Service Cord;...
Page 83 100-09-29 Powertrain Diagnostic Routines Identification 100-09-29 DIAGNOSIS AND TESTING (Continued) ROUTINE 8: VEHICLE DOES NOT CHARGE (LEAD ACID VEHICLES) TEST STEP ACTION TO TAKE • With key OFF, disconnect traction battery support tray in-line C1939 and Yes = GO to 8-31. connect 104-Pin Breakout Box (BOB) to in-line C1939M using Traction Battery Low Voltage Service Cord;...
Page 84 100-09-30 Powertrain Diagnostic Routines Identification 100-09-30 DIAGNOSIS AND TESTING (Continued) ROUTINE 9: VEHICLE DOES NOT CHARGE (NIMH VEHICLES) TEST STEP ACTION TO TAKE • Charge the traction battery to full SOC. No = System OK. • With key ON, monitor BCM PID BCM OP. •...
Page 85 100-09-31 Powertrain Diagnostic Routines Identification 100-09-31 DIAGNOSIS AND TESTING (Continued) ROUTINE 9: VEHICLE DOES NOT CHARGE (NIMH VEHICLES) TEST STEP ACTION TO TAKE No = REPLACE the battery WARNING: The traction battery contains high-voltage temperature sensor in components and wiring. High-voltage insulated safety gloves and face question.
Page 86 100-09-32 Powertrain Diagnostic Routines Identification 100-09-32 DIAGNOSIS AND TESTING (Continued) ROUTINE 9: VEHICLE DOES NOT CHARGE (NIMH VEHICLES) TEST STEP ACTION TO TAKE No = REPLACE the battery WARNING: The traction battery contains high-voltage temperature sensor in components and wiring. High-voltage insulated safety gloves and face question.
Page 87 100-09-33 Powertrain Diagnostic Routines Identification 100-09-33 DIAGNOSIS AND TESTING (Continued) ROUTINE 9: VEHICLE DOES NOT CHARGE (NIMH VEHICLES) TEST STEP ACTION TO TAKE 9-12 CHECK EMERGENCY POWER OFF (EPO) SIGNAL TO BATTERY CONTROL MODULE (BCM) • Remove the traction battery and connect Traction Battery High-Voltage Yes = GO to 9-13.
Page 88 100-09-34 Powertrain Diagnostic Routines Identification 100-09-34 DIAGNOSIS AND TESTING (Continued) ROUTINE 9: VEHICLE DOES NOT CHARGE (NIMH VEHICLES) TEST STEP ACTION TO TAKE • With key OFF, measure the resistance between BOB pins 14, 20 and Yes = CARRY OUT Pinpoint Test ground (BOB pin 65).
Page 89 100-09-35 Powertrain Diagnostic Routines Identification 100-09-35 DIAGNOSIS AND TESTING (Continued) ROUTINE 9: VEHICLE DOES NOT CHARGE (NIMH VEHICLES) TEST STEP ACTION TO TAKE 9-23 CHECK CIRCUITS 3002 (O/LB) AND 3990 (LB/R) (OUTSIDE OF TRACTION BATTERY SUPPORT TRAY) FOR OPEN(S) • With key OFF, disconnect traction battery support tray in-line C1939 and Yes = GO to 9-24.
Page 90 100-09-36 Powertrain Diagnostic Routines Identification 100-09-36 DIAGNOSIS AND TESTING (Continued) ROUTINE 9: VEHICLE DOES NOT CHARGE (NIMH VEHICLES) TEST STEP ACTION TO TAKE 9-28 CHECK CIRCUIT 3009 (O/R) (OUTSIDE OF TRACTION BATTERY SUPPORT TRAY) FOR OPEN • With key OFF, disconnect traction battery support tray in-line C1939 and Yes = GO to 9-29.
Page 91 100-09-37 Powertrain Diagnostic Routines Identification 100-09-37 DIAGNOSIS AND TESTING (Continued) ROUTINE 9: VEHICLE DOES NOT CHARGE (NIMH VEHICLES) TEST STEP ACTION TO TAKE 9-34 CHECK CIRCUIT 3404 (Y) (OUTSIDE OF TRACTION BATTERY SUPPORT TRAY) FOR OPEN • With key OFF, disconnect traction battery support tray in-line C1939 and Yes = GO to 9-35.
Page 92 100-09-38 Powertrain Diagnostic Routines Identification 100-09-38 DIAGNOSIS AND TESTING (Continued) ROUTINE 10: VEHICLE CHARGING TAKES LONGER THAN NORMAL TO REACH FULL STATE OF CHARGE (SOC) (LEAD ACID VEHICLES) TEST STEP ACTION TO TAKE • Do any of the TMPSEN PIDs indicate between 50°C (122°F) and No = DISCONNECT and 60°C (140°F)?
Page 93 100-09-39 Powertrain Diagnostic Routines Identification 100-09-39 DIAGNOSIS AND TESTING (Continued) ROUTINE 11: VEHICLE CHARGING TAKES LONGER THAN NORMAL TO REACH FULL STATE OF CHARGE (SOC) (NIMH VEHICLES) TEST STEP ACTION TO TAKE • With key OFF and vehicle on-charge, monitor BCM PID BCM OP. •...
Page 94 100-09-40 Powertrain Diagnostic Routines Identification 100-09-40 DIAGNOSIS AND TESTING (Continued) ROUTINE 12: COOLANT PUMP AND DC/DC CONVERTER OPERATE WHEN POWER CONTROL STATION (PCS) IS DISCONNECTED FROM THE CHARGER INLET CONNECTOR TEST STEP ACTION TO TAKE 12-1 CARRY OUT RESET NOTE: The coolant pump and DC/DC converter sometimes operate after Yes = System OK.
Page 95: Chassis
204-02-1 Manual Table of Contents GROUP Chassis SECTION TITLE PAGE Rear Suspension........................204-02-1 Wheels and Tires ........................204-04-1 Rear Drive Halfshafts......................... 205-05-1 Rear Disc Brake ......................... 206-04-1 Parking Brake and Actuation....................206-05-1 Power Brake Actuation......................206-07-1 Anti-Lock Control ........................206-09-1 Power Steering ...........................
Page 96 204-02-2 Rear Suspension 204-02-2 SPECIFICATIONS Torque Specifications Torque Specifications Description Lb-Ft Lb-In Description Lb-Ft Lb-In Lug Nuts — Backing Plate Bolts — Rear Spring Mounting — Brake Line Bracket to — Bolts Axle Bolt Spring Clamp Plate — Caliper Adapter Bolts 40.5 —...
Page 97 204-02-3 Rear Suspension 204-02-3 DESCRIPTION AND OPERATION (Continued) The rear suspension of the Electric Ranger consists of special components designed for use with the vehicle’s unique electric motor/transaxle. The axle consists of thick walled aluminum tubing and cast aluminum knuckles. Tabs and brackets are welded to the axle in various points to attach the watts linkage, shock absorbers, and brake lines.
Page 98 204-02-4 Rear Suspension 204-02-4 REMOVAL AND INSTALLATION (Continued) 2. Remove the LH and RH hubs. Refer to Hub. 3. Release tension on the parking brake cable. 1 Depress the cable bracket tabs. 2 Pull the cable toward the front of the vehicle and slide the cable out of the bracket.
Page 99 204-02-5 Rear Suspension 204-02-5 REMOVAL AND INSTALLATION (Continued) 7. NOTE: LH shown, RH similar. Remove the two LH and RH harness clamp bolts. 8. NOTE: LH shown, RH similar. Disconnect the brake lines from the axle. 1 Unclip the ABS wire from the axle. 2 Remove the brake line bracket bolt.
Page 100 204-02-6 Rear Suspension 204-02-6 REMOVAL AND INSTALLATION (Continued) 11. Install the special tool to flatten the LH rear spring. 12. Position the front spring clamp. 13. Position the rear spring clamp. 14. Tighten the spring clamps alternately until the spring is parallel to the bar of the special tool. 2001 Ranger EV, 01/2001...
Page 101 204-02-7 Rear Suspension 204-02-7 REMOVAL AND INSTALLATION (Continued) 15. Remove the LH spring clamping plate. 16. Remove the rear axle. Installation CAUTION: Do not fully tighten the bolt until the vehicle has been lowered and the rear suspension is in the curb position. Position the spring and install the rear through bolt.
Page 102 204-02-8 Rear Suspension 204-02-8 REMOVAL AND INSTALLATION (Continued) 4. Install the special tools to flatten both the rear springs. 5. Position the front spring clamps. 6. Position the rear spring clamps. 7. Tighten the spring clamps alternately until the spring is parallel to the bar of the special tool. 2001 Ranger EV, 01/2001...
Page 103 204-02-9 Rear Suspension 204-02-9 REMOVAL AND INSTALLATION (Continued) 8. Apply a soap and water solution to the inside of the spring clamp plate. 9. Position the rear leaf spring shim in the spring clamp plate. 10. Position the insulator on top of the rear leaf spring shim.
Page 104 204-02-10 Rear Suspension 204-02-10 REMOVAL AND INSTALLATION (Continued) 12. Place a 15 mm deep socket through the hole in the spring clamp plate assembly to align all of the components. 13. Install the spring clamp plate assembly as shown and loosely install the bolts. 1 15 mm socket 2 Spring clamp plate 3 Rear leaf spring shim...
Page 105 204-02-11 Rear Suspension 204-02-11 REMOVAL AND INSTALLATION (Continued) 16. Using the special tool, align the spring clamp plate, spring, and hub assembly. • Tighten the bolt until the edges of the spring clamp plate and the hub assembly are parallel. 17.
Page 106 204-02-12 Rear Suspension 204-02-12 REMOVAL AND INSTALLATION (Continued) 20. Install the rear leaf spring shim bolt. 21. NOTE: LH shown, RH similar. Install the LH and RH lower shock mount bolts. 22. NOTE: LH shown, RH similar. Install the brake line bracket bolt and clip the ABS wire onto the axle.
Page 107 204-02-13 Rear Suspension 204-02-13 REMOVAL AND INSTALLATION (Continued) 24. NOTE: LH shown, RH similar. Position the LH and RH ABS wheel speed sensors and install the bolts. 25. NOTE: LH shown, RH similar. Position the LH and RH backing plates and install the bolts.
Page 108 204-02-14 Rear Suspension 204-02-14 REMOVAL AND INSTALLATION (Continued) 29. Install the LH and RH hubs. Refer to Hub. 30. Install the RH spring. Refer to Spring. Rear Shock Absorber Removal 1. Raise and support the vehicle. Refer to Section 100-02. CAUTION: Do not position the jack stand under the tube portion of the rear axle or vehicle damage may result.
Page 109 204-02-15 Rear Suspension 204-02-15 REMOVAL AND INSTALLATION (Continued) 5. Remove the shock absorber. • Remove the nut. Installation 1. To install, reverse the removal procedure. 2001 Ranger EV, 01/2001...
Page 110 204-02-16 Rear Suspension 204-02-16 REMOVAL AND INSTALLATION (Continued) Spring Special Tool(s) Spring Flattening Tools 204-F002 Cap Aligner 204-F003 Removal NOTE: Both Spring Flattening Tools (204-F002) must be used to flatten the rear springs. NOTE: The LH spring procedure is shown, the RH procedure is similar.
Page 111 204-02-17 Rear Suspension 204-02-17 REMOVAL AND INSTALLATION (Continued) 3. Install the special tools to flatten both the rear springs. 4. Position the front spring clamp. 5. Position the rear spring clamp. 6. Tighten the spring clamps alternately until the spring is parallel to the bar of the special tool. 2001 Ranger EV, 01/2001...
Page 112 204-02-18 Rear Suspension 204-02-18 REMOVAL AND INSTALLATION (Continued) 7. Remove the LH spring clamping plate. 8. Remove the front spring mount through bolt. 9. Remove the rear spring mount through bolt. Installation 1. Position the spring and install the rear mount through bolt.
Page 113 204-02-19 Rear Suspension 204-02-19 REMOVAL AND INSTALLATION (Continued) 2. Install the front spring mount through bolt. 3. Position the upper spring insulator between the spring and the axle. 4. Install the special tools to flatten both the rear springs. 5. Position the front spring clamp. 2001 Ranger EV, 01/2001...
Page 114 204-02-20 Rear Suspension 204-02-20 REMOVAL AND INSTALLATION (Continued) 6. Position the rear spring clamp. 7. Tighten the spring clamps alternately until the spring is parallel to the bar of the special tool. 8. Apply a soap and water solution to the inside of the spring clamp plate.
Page 115 204-02-21 Rear Suspension 204-02-21 REMOVAL AND INSTALLATION (Continued) 10. Position the insulator on top of the rear leaf spring shim. 11. Position the spacer on top of the insulator. 12. Place a 15 mm deep socket through the hole in the spring clamp plate assembly to align all of the components.
Page 116 204-02-22 Rear Suspension 204-02-22 REMOVAL AND INSTALLATION (Continued) 14. With the 15 mm socket still in place, pull the shim back as far as possible. 15. Verify that the spring clamp plate is contacting the hub assembly. If the two surfaces do not contact each other, replace the steel spacer with a thinner shim (four available).
Page 117 204-02-23 Rear Suspension 204-02-23 REMOVAL AND INSTALLATION (Continued) 18. Remove the special tool. 19. Using the special tool, install the rear leaf spring shim. • If the shim does not have enough travel to achieve the correct installation depth, remove the steel shim and install a thicker shim (four available).
Page 118 204-02-24 Rear Suspension 204-02-24 REMOVAL AND INSTALLATION (Continued) Wheel Bearing Special Tool(s) Special Tool(s) Safety Chain Wheel Bearing Removal and — Installation Kit or equivalent OTC-7686 Slide Hammer Hub Puller 100-D006 (D79P-100-A) D93P-1175-B (Continued) Removal 1. Remove the halfshaft. Refer to Section 205-05.
Page 119 204-02-25 Rear Suspension 204-02-25 REMOVAL AND INSTALLATION (Continued) 4. Remove the hub. 1 Install Hub Puller, Safety Chain, and Slide Hammer. 2 Remove the hub. 5. Remove snap ring. 6. Remove the wheel bearing using the Wheel Bearing Removal and Installation Kit or equivalent.
Page 120 204-02-26 Rear Suspension 204-02-26 REMOVAL AND INSTALLATION (Continued) 2. Install the wheel bearing using the Wheel Bearing Removal and Installation Kit or equivalent. 3. Install the snap ring. 4. Install the halfshaft. Refer to Section 205-05. 5. Install the hub. 1 Position the hub.
Page 121 204-02-27 Rear Suspension 204-02-27 REMOVAL AND INSTALLATION (Continued) 7. Install the caliper 1 Position the caliper. 2 Install the bolts. 8. Install the wheel. 9. Lower the vehicle. 2001 Ranger EV, 01/2001...
Page 122: Wheels And Tires
204-04-1 Wheels and Tires 204-04-1 Manual Table of Contents SECTION 204-04 Wheels and Tires VEHICLE APPLICATION: Ranger EV CONTENTS PAGE SPECIFICATIONS ..................204-04-2 DESCRIPTION AND OPERATION Safety Precautions ..................204-04-2 Wheels and Tires ..................204-04-2 Tire, Temporary Spare ................204-04-3 DIAGNOSIS AND TESTING Wheels and Tires ..................
Page 123 WARNING: Use only wheels and wheel nuts that have been designed for current model year Ford trucks. Aftermarket wheels or wheel nuts may not fit or function correctly, and can cause personal injury or damage the vehicle.
Page 124 204-04-3 Wheels and Tires 204-04-3 DESCRIPTION AND OPERATION (Continued) Tire, Temporary Spare Tire and Wheel Runout Excessive radial and lateral runout of a wheel and CAUTION: Do not attempt to mount a tire assembly can cause roughness, vibration, wheel high-pressure spare tire on a regular wheel. The tramp, tire wear and steering wheel tremor.
Page 125 204-04-4 Wheels and Tires 204-04-4 DIAGNOSIS AND TESTING (Continued) Wheels need to be installed new when: 1. Inspect for signs of uneven wear that may indicate a need for balancing, rotation, front • bent. suspension alignment, damaged tie rod, or •...
Page 126 204-04-5 Wheels and Tires 204-04-5 DIAGNOSIS AND TESTING (Continued) Symptom Chart (Continued) Condition Possible Sources Action Other excessive tire wear Incorrect tire pressure. ADJUST pressure. • • • problems Loose or leaking shock TIGHTEN or INSTALL new • • absorbers. as necessary.
Page 127 204-04-6 Wheels and Tires 204-04-6 REMOVAL AND INSTALLATION Wheel and Tire Removal 1. Remove the wheel cover (1130), if so equipped. CAUTION: Do not use heat to loosen a seized lug nut. Heat can damage the wheel and wheel bearings. NOTE: Do not remove the lug nuts (1012) at this time.
Page 128 204-04-7 Wheels and Tires 204-04-7 REMOVAL AND INSTALLATION (Continued) 4. Lower the vehicle. CAUTION: Failure to tighten the lug nuts in a star pattern can result in high brake disc runout, which will speed up the development of brake roughness, shudder and vibration.
Page 129: Rear Drive Halfshafts
205-05-1 Rear Drive Halfshafts 205-05-1 Manual Table of Contents SECTION 205-05 Rear Drive Halfshafts VEHICLE APPLICATION: Ranger EV CONTENTS PAGE SPECIFICATIONS ..................205-05-2 REMOVAL AND INSTALLATION Halfshafts ....................205-05-2 2001 Ranger EV, 01/2001...
Page 130 205-05-2 Rear Drive Halfshafts 205-05-2 SPECIFICATIONS Torque Specifications Description Lb-Ft Hub Nut REMOVAL AND INSTALLATION Halfshafts Special Tool(s) Wheel Bearing Removal and Installation Kit or equivalent OTC-7686 Removal 1. Remove the motor/transaxle. Refer to Section 303-01. 2. Remove the halfshaft hub nut and washer. 3.
Page 131 205-05-3 Rear Drive Halfshafts 205-05-3 REMOVAL AND INSTALLATION (Continued) Installation 1. Install the halfshaft. Use the installation tool from Wheel Bearing • Removal Removal and Installation Kit or equivalent. 2. Install the halfshaft end washer and nut. Tighten the nut to draw the halfshaft •...
Page 132: Rear Disc Brake
206-04-1 Rear Disc Brake 206-04-1 Manual Table of Contents SECTION 206-04 Rear Disc Brake VEHICLE APPLICATION: Ranger EV CONTENTS PAGE SPECIFICATIONS ..................206-04-2 DESCRIPTION AND OPERATION Rear Disc Brakes ..................206-04-2 REMOVAL AND INSTALLATION Rear Disc Brakes —Caliper ................. 206-04-3 Rear Disc Brakes —Rotor ................
Page 133 206-04-2 Rear Disc Brake 206-04-2 SPECIFICATIONS General Specifications Torque Specifications Item Specification Description Lb-Ft Rear Disc Brake Lining 3.12 mm (0.125 in) Brake Line Bolt Minimum Thickness Caliper Bolts 18.5 Rear Disc Brake Rotor 12 mm (0.472 in) Lug Nuts Nominal Thickness Rear Disc Brake Rotor 10.5 mm (0.40 in)
Page 134 206-04-3 Rear Disc Brake 206-04-3 REMOVAL AND INSTALLATION Rear Disc Brakes —Caliper Removal WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes.
Page 135 5. Inspect the caliper for leaks and replace if necessary. 6. Remove and clean the caliper slide pins. After cleaning, lubricate with Silicone Brake Caliper Grease D7AZ-19A331-A meeting Ford specification ESE-M1C171-A. Installation 1. To install, reverse the removal procedure. After installation, bleed the brake system to •...
Page 136 206-04-5 Rear Disc Brake 206-04-5 REMOVAL AND INSTALLATION (Continued) Rear Disc Brakes —Rotor Removal WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes.
Page 137 206-04-6 Rear Disc Brake 206-04-6 REMOVAL AND INSTALLATION (Continued) 3. Position the caliper. 1 Remove the bolts. 2 Position the caliper and support it so there is no weight on the brake hose. 4. Remove the rotor. 1 Remove the retaining clips. 2 Remove the rotor.
Page 138 206-04-7 Rear Disc Brake 206-04-7 REMOVAL AND INSTALLATION (Continued) 2001 Ranger EV, 01/2001...
Page 139: Parking Brake And Actuation
206-05-1 Parking Brake and Actuation 206-05-1 Manual Table of Contents SECTION 206-05 Parking Brake and Actuation VEHICLE APPLICATION: Ranger EV CONTENTS PAGE SPECIFICATIONS ..................206-05-2 REMOVAL AND INSTALLATION Parking Brake Assembly ................206-05-2 Parking Brake Cables —Front ..............206-05-7 Parking Brake Cables —Intermediate ............. 206-05-9 Parking Brake Cables —Postal Ranger EV ............
Page 140 206-05-2 Parking Brake and Actuation 206-05-2 SPECIFICATIONS General Specifications Torque Specifications—Postal Ranger EV Item Specification Description Lb-Ft Lb-In Parking Brake Shoe 0.508 mm (0.02 in) Brake cable — Lining Setup Diameter bracket bolts Torque Specifications Backing — plate bolts Description Lb-Ft Lb-In Control...
Page 141 206-05-3 Parking Brake and Actuation 206-05-3 REMOVAL AND INSTALLATION (Continued) 3. Remove the brake shoes. 1 Remove the lower spring and adjuster. 2 Remove the shoe retaining clips. 3 Remove the brake shoes. 4. Release tension on the parking brake cable. 1 Compress the retainer.
Page 142 206-05-4 Parking Brake and Actuation 206-05-4 REMOVAL AND INSTALLATION (Continued) 6. Remove the parking brake linkage. 7. Remove the backing plate. 1 Drill out the two rivet heads. 2 Remove the three bolts. 3 Remove the backing plate. Installation 1. Install new brake shoe retaining pins in the backing plate.
Page 143 206-05-5 Parking Brake and Actuation 206-05-5 REMOVAL AND INSTALLATION (Continued) 2. Install the backing plate. 1 Position the backing plate. 2 Install two new rivets. 3 Install the three bolts. 3. Assemble the parking brake linkage. 4. NOTE: Position the linkage that connects to the cable facing down.
Page 144 206-05-6 Parking Brake and Actuation 206-05-6 REMOVAL AND INSTALLATION (Continued) 5. Connect the parking brake cable. 6. Install the inside upper brake shoe spring on the brake shoes. 7. NOTE: The inside upper brake shoe spring must be installed prior to positioning the brake shoes.
Page 145 206-05-7 Parking Brake and Actuation 206-05-7 REMOVAL AND INSTALLATION (Continued) 9. Use Brake Adjusting Gauge to set the rear brake shoe and lining to 0.508 mm (0.02 in) less than the inside diameter of the drum portion of the rear disc brake rotor. Rotate the adjusting screw as necessary.
Page 146 206-05-8 Parking Brake and Actuation 206-05-8 REMOVAL AND INSTALLATION (Continued) 2. Remove the front cable from the bracket. 3. Remove the front cable from the rear cable. 4. Remove the front cable hold-down bolt. 5. Lower the vehicle. 2001 Ranger EV, 01/2001...
Page 147 206-05-9 Parking Brake and Actuation 206-05-9 REMOVAL AND INSTALLATION (Continued) 6. Disconnect the parking brake control switch electrical connector. 7. Remove the three bolts, loosen the grommet from the bulkhead and remove the parking brake control assembly. 8. Remove the front cable from the control assembly.
Page 148 206-05-10 Parking Brake and Actuation 206-05-10 REMOVAL AND INSTALLATION (Continued) Parking Brake Cables —Rear Removal 1. Remove the traction battery. Refer to Section 414-03A Section 414-03B. 2. Release tension on the parking brake cable. 1 Compress the retainer. 2 Remove the front parking brake cable from the bracket.
Page 149 206-05-11 Parking Brake and Actuation 206-05-11 REMOVAL AND INSTALLATION (Continued) 5. Disconnect the rear brake cable from the intermediate brake cable. 6. Remove the rear parking brake cable. Disconnect the parking brake cable. • Installation 1. To install, reverse the removal procedure. 2001 Ranger EV, 01/2001...
Page 150: Power Brake Actuation
206-07-1 Power Brake Actuation 206-07-1 Manual Table of Contents SECTION 206-07 Power Brake Actuation VEHICLE APPLICATION: Ranger EV CONTENTS PAGE SPECIFICATIONS........................206-07-2 DESCRIPTION AND OPERATION Power Disc Brake Actuation ....................206-07-2 DIAGNOSIS AND TESTING Vacuum System ........................206-07-3 Electrical Schematic ......................206-07-3 Inspection and Verification ....................206-07-3 Pinpoint Tests........................206-07-4...
Page 151 206-07-2 Power Brake Actuation 206-07-2 SPECIFICATIONS Torque Specifications Torque Specifications Description Lb-Ft Lb-In Description Lb-Ft Lb-In Vacuum Pressure Sensor — Battery Ground Cable — to Vacuum Tee Screws Vacuum Pump Bracket — Vacuum Pressure Sensor — Bolts Bolt (Continued) DESCRIPTION AND OPERATION The vacuum pressure sensor measures absolute pressure.
Page 152 206-07-3 Power Brake Actuation 206-07-3 DIAGNOSIS AND TESTING Electrical Schematic Vacuum System Refer to Electrical and Vacuum Troubleshooting Manual, Cell 139, Vacuum System for schematic Diagnostic Trouble Code (DTC) Definition and connector information. The following DTC relates to the vacuum system: Inspection and Verification •...
Page 153 206-07-4 Power Brake Actuation 206-07-4 DIAGNOSIS AND TESTING (Continued) Symptom Chart (Continued) Condition Possible Sources Action • Vacuum Pump Exhibits • Vacuum pump. • GO to Pinpoint Test D. • Incorrect vacuum pump Unusual or Excessive Noise bracket bolt torque specifications.
Page 154 206-07-5 Power Brake Actuation 206-07-5 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST A: DTC C1777 VACUUM PRESSURE CIRCUIT FAILURE TEST STEP ACTION TO TAKE • With key OFF, remove the vacuum pump relay from the EVPDB and No = REPAIR as necessary. measure the voltage between pins 1, 3 on the vacuum pump relay connector and ground.
Page 155 206-07-6 Power Brake Actuation 206-07-6 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST A: DTC C1777 VACUUM PRESSURE CIRCUIT FAILURE TEST STEP ACTION TO TAKE • Measure the resistance between terminals 3 and 5 on the vacuum pump REPLACE the vacuum relay. pump relay.
Page 156 206-07-7 Power Brake Actuation 206-07-7 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST C: VACUUM PUMP CYCLES ON AND OFF WITHOUT BRAKE PEDAL OR CLIMATE CONTROL ACTIVATION (VACUUM SYSTEM LEAK TEST) TEST STEP ACTION TO TAKE C1 CHECK SYSTEM FOR VACUUM LEAKS •...
Page 157 206-07-8 Power Brake Actuation 206-07-8 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST D: VACUUM PUMP EXHIBITS UNUSUAL OR EXCESSIVE NOISE TEST STEP ACTION TO TAKE D1 CHECK VACUUM PUMP ISOLATION MOUNT • With key OFF, check for excessive movement of the vacuum pump Yes = GO to D3.
Page 158 206-07-9 Power Brake Actuation 206-07-9 REMOVAL AND INSTALLATION (Continued) 3. NOTE: The vacuum pressure sensor is located in the underhood compartment underneath the card table. Disconnect the vacuum pressure sensor electrical connector. 4. Disconnect the vacuum pressure sensor vacuum lines. 5.
Page 159 206-07-10 Power Brake Actuation 206-07-10 REMOVAL AND INSTALLATION (Continued) Vacuum Pump Removal 1. Disconnect the auxiliary battery ground cable. 2. Raise and support the vehicle. For additional informstion, refer to Section 100-02. 3. Remove the vacuum pump. 1 Disconnect the vacuum line. 2 Disconnect the electrical connector.
Page 160 206-07-11 Power Brake Actuation 206-07-11 REMOVAL AND INSTALLATION (Continued) 2. Connect the traction battery. For additional information, refer to Section 414-03A Section 414-03B. 2001 Ranger EV, 01/2001...
Page 161: Anti-Lock Control
206-09-1 Anti-Lock Control 206-09-1 Manual Table of Contents SECTION 206-09 Anti-Lock Control VEHICLE APPLICATION: Ranger EV CONTENTS PAGE SPECIFICATIONS ..................206-09-2 DESCRIPTION AND OPERATION Anti-Lock Brake and Regenerative Braking System ..........206-09-2 Hydraulic Control Unit ................206-09-2 DIAGNOSIS AND TESTING Anti-Lock Control ..................
Page 162 206-09-2 Anti-Lock Control 206-09-2 SPECIFICATIONS Torque Specifications Torque Specifications Description Lb-Ft Lb-In Description Lb-Ft Lb-In Battery Ground Cable — 53.5 Anti-Lock Brake — Control Module Screws Brake Line Fittings — Anti-Lock Brake Sensor — Hydraulic Control Unit — Bolt (HCU) Anti-Lock Brake Control Module Anti-Lock Brake Sensor —...
Page 163 206-09-3 Anti-Lock Control 206-09-3 DIAGNOSIS AND TESTING • DTC B1342 ECU Is Defective Anti-Lock Control — DTC C1267 is generated when the anti-lock brake control module detects an internal Diagnostic Trouble Code (DTC) Definition failure. The following DTCs relate to the anti-lock brake •...
Page 164 206-09-4 Anti-Lock Control 206-09-4 DIAGNOSIS AND TESTING (Continued) • DTC U2015 Signal Link Fault (Non SCP) Electrical Schematic Refer to Electrical and Vacuum Troubleshooting — The anti-lock brake control module has an Manual, Cell 42, Anti-lock Brake System (ABS) for active line that it uses to notify the traction schematic and connector information.
Page 165: Fuse
206-09-5 Anti-Lock Control 206-09-5 DIAGNOSIS AND TESTING (Continued) Active Command Index Anti-Lock Brake Active Command Index Active Command Display Action ABS Output PMP Motor ON, OFF Control LF Inlet ON, OFF RF Inlet ON, OFF R Inlet ON, OFF LF Outlet ON, OFF RF Outlet ON, OFF...
Page 166: Fuse
206-09-6 Anti-Lock Control 206-09-6 DIAGNOSIS AND TESTING (Continued) Symptom Chart (Continued) Condition Possible Sources Action DTC C1234 RF Wheel Speed Loose RF anti-lock brake GO to Pinpoint Test D. • • • — Input Signal Missing sensor mounting. (Continuous Test Mode) RF anti-lock brake sensor.
Page 167 206-09-7 Anti-Lock Control 206-09-7 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST A: DTC C1095 HYDRAULIC PUMP MOTOR CIRCUIT FAILURE TEST STEP ACTION TO TAKE A1 CHECK FUSE AND POWER TO ANTI-LOCK BRAKE CONTROL MODULE GO to A2. • Check 60A fuse 4 in the electric vehicle power distribution box Yes = (EVPDB).
Page 168 206-09-8 Anti-Lock Control 206-09-8 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST B: DTCs C1145, C1155, C1165, AND C1175, SPEED SENSOR INPUT CIRCUIT FAILURE TEST STEP ACTION TO TAKE • With key OFF, reconnect anti-lock brake sensor, disconnect anti-lock Yes = GO to B5. brake control module C154, and measure the resistance between the indicated wires on the anti-lock brake control module C154: RF Anti-Lock Brake Sensor...
Page 169 206-09-9 Anti-Lock Control 206-09-9 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST B: DTCs C1145, C1155, C1165, AND C1175, SPEED SENSOR INPUT CIRCUIT FAILURE TEST STEP ACTION TO TAKE • With key OFF, disconnect LF anti-lock brake sensor C151 and measure No = REPAIR the Y/BK wire the resistance between pin 17 (T/BK wire) on anti-lock brake control (RF), T/BK wire (LF),...
Page 170 206-09-10 Anti-Lock Control 206-09-10 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST D: DTCs C1233, C1234, C1235, AND C1236, WHEEL SPEED — INPUT SIGNAL MISSING TEST STEP ACTION TO TAKE Yes = REPLACE the tone ring. CAUTION: Examine the tone ring carefully with good light. •...
Page 171 206-09-11 Anti-Lock Control 206-09-11 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST F: DTC U2015 SIGNAL LINK FAULT (NON SCP) TEST STEP ACTION TO TAKE F1 CHECK ANTI-LOCK BRAKE SYSTEM (ABS) FOR DIAGNOSTIC TROUBLE CODES (DTCs) NOTE: The red brake warning indicator and malfunction indicator lamp Yes = REFER to Symptom Chart.
Page 172 206-09-12 Anti-Lock Control 206-09-12 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST F: DTC U2015 SIGNAL LINK FAULT (NON SCP) TEST STEP ACTION TO TAKE • With key ON, measure the voltage between BOB pin B6 and ground No = REPLACE the anti-lock (BOB pin A29).
Page 173 206-09-13 Anti-Lock Control 206-09-13 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST G: NO COMMUNICATION WITH THE ANTI-LOCK BRAKE CONTROL MODULE TEST STEP ACTION TO TAKE G1 CHECK FUSE, IGNITION POWER, AND GROUND TO ANTI-LOCK BRAKE CONTROL MODULE • Check 10A fuse 14 in the I/P fuse panel. Yes = REFER to Section 418-00.
Page 174 206-09-14 Anti-Lock Control 206-09-14 REMOVAL AND INSTALLATION (Continued) 4. Position theHCU/anti-lock brake system (ABS) assembly. 1 Remove the HCU bracket bolts. 2 Position the ABS assembly aside to gain access to the anti-lock brake control module. 5. NOTE: The ABS assembly is shown removed from the vehicle for clarity.
Page 175 206-09-15 Anti-Lock Control 206-09-15 REMOVAL AND INSTALLATION (Continued) Anti-Lock Brake Sensor —Front Removal 1. Refer to Section 206-09 of the 2001 Ranger Workshop Manual. Anti-Lock Brake Sensor —Rear Removal and Installation 1. Raise and support the vehicle. Refer to Section 100-02.
Page 176 206-09-16 Anti-Lock Control 206-09-16 REMOVAL AND INSTALLATION (Continued) 3. Remove the harness bracket bolts. 4. Disconnect the sensor electrical connector and remove the anti-lock brake sensor. 5. To install, reverse the removal procedure. Hydraulic Control Unit Removal WARNING: Brake fluid contains polyglycol ethers and polyglycols.
Page 177 206-09-17 Anti-Lock Control 206-09-17 REMOVAL AND INSTALLATION (Continued) 2. Disconnect the upper hydraulic control unit (HCU) electrical connector. 1 Pull up on the connector latch. 2 Disconnect the electrical connector. 3. Disconnect the lower HCU electrical connector. 4. Disconnect the brake line fittings. 5.
Page 178 206-09-18 Anti-Lock Control 206-09-18 REMOVAL AND INSTALLATION (Continued) 6. Remove the anti-lock brake control module. 1 Remove the screws. 2 Remove the module. Installation 1. To install, reverse the removal procedure. After installation, bleed the brake system. • Refer to Section 206-09 of the 2001 Ranger Workshop Manual.
Page 179: Power Steering
211-02-1 Power Steering 211-02-1 Manual Table of Contents SECTION 211-02 Power Steering VEHICLE APPLICATION: Ranger EV CONTENTS PAGE SPECIFICATIONS ..................211-02-2 DESCRIPTION AND OPERATION Power Steering ..................211-02-2 Power Steering — Postal Ranger EV .............. 211-02-2 DIAGNOSIS AND TESTING Power Steering ..................211-02-3 Electrical Schematic ................
Page 180 211-02-2 Power Steering 211-02-2 SPECIFICATIONS Torque Specifications Torque Specifications Description Lb-Ft Lb-In Description Lb-Ft Lb-In Power Steering — A/C Compressor Bolts 22.5 16.5 — Assembly Nuts A/C Compressor 22.5 16.5 — Power Steering — 53.5 Bracket Bolts Reservoir Screws Line Clamp Bolt —...
Page 181 211-02-3 Power Steering 211-02-3 DESCRIPTION AND OPERATION (Continued) The power steering system on the Postal Ranger EV The power steering pump can be heard when the is composed of a steering gear and steering linkage vehicle is turned on and the steering wheel is turned from the Explorer.
Page 182 211-02-4 Power Steering 211-02-4 DIAGNOSIS AND TESTING (Continued) Symptom Chart Symptom Chart Condition Possible Sources Action DTC C1778 Power Steering Circuit(s). GO to Pinpoint Test A. • • • Failure Interface adapter assembly • (IAA) module. Power steering assembly. • High-voltage fuse.
Page 183 211-02-5 Power Steering 211-02-5 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST A: DTC C1778 POWER STEERING FAILURE TEST STEP ACTION TO TAKE NOTE: Before proceeding, verify the power control station is not plugged Yes = GO to A6. into the vehicle and the power steering fluid level is OK. •...
Page 184 211-02-6 Power Steering 211-02-6 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST A: DTC C1778 POWER STEERING FAILURE TEST STEP ACTION TO TAKE A10 CHECK CIRCUIT 3023 (BK/O) FOR OPEN GO to A11. • With key OFF, disconnect power steering assembly C1992 and measure Yes = the resistance of the BK/O wire between pin 17 on the power steering assembly C1992 and BOB pin 99.
Page 185 211-02-7 Power Steering 211-02-7 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST A: DTC C1778 POWER STEERING FAILURE TEST STEP ACTION TO TAKE • Measure the resistance between circuit 3140 (BK wire) terminal and Yes = REPLACE the power circuit 3141 (W wire) terminal on power steering assembly C1895M. steering assembly.
Page 186 211-02-8 Power Steering 211-02-8 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST B: MORE THAN USUAL STEERING EFFORT REQUIRED TO TURN STEERING WHEEL (POWER STEERING PUMP SPEED DOES NOT INCREASE WHILE TURNING THE STEERING WHEEL) TEST STEP ACTION TO TAKE • With key OFF, measure the resistance of the R wire between pin 2 on No = REPAIR the wire(s) in steering wheel sensor C2990 and pin 7 on power steering assembly...
Page 187 211-02-9 Power Steering 211-02-9 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST D: STEERING WHEEL SHUDDER TEST STEP ACTION TO TAKE • With vehicle parked and key ON, rotate the steering wheel from Yes = REMOVE power steering lock-to-lock. reservoir cap and use Vacuum Tester to purge air from the power steering system while rotating the...
Page 188 211-02-10 Power Steering 211-02-10 REMOVAL AND INSTALLATION (Continued) 4. Remove the power steering controller assembly. 1 Remove the nuts. 2 Remove the assembly. Installation 1. To install, reverse the removal procedure. Purge the power steering system of air. • Refer to Section 211-00 of the 2001 Ranger Workshop Manual.
Page 189 211-02-11 Power Steering 211-02-11 REMOVAL AND INSTALLATION (Continued) 2. NOTE: The A/C system is not evacuated for this procedure. Remove the two front A/C compressor bolts. 3. NOTE: The traction battery has been removed for clarity. Remove the two rear A/C compressor bolts. CAUTION: Do not force the compressor into position, or damage to the A/C lines may result.
Page 190 211-02-12 Power Steering 211-02-12 REMOVAL AND INSTALLATION (Continued) 6. NOTE: The traction battery has been removed for clarity. Remove the two rear bracket bolts. 7. Remove the rear half of the A/C compressor bracket. 8. The power steering gear is the same as the gasoline powered Ranger.
Page 191 211-02-13 Power Steering 211-02-13 REMOVAL AND INSTALLATION (Continued) Power Steering Gear — Postal Ranger EV Removal and Installation 1. The power steering gear is the same as the gasoline powered Ranger. For additional information, refer to Section 211-02 of the 2001 Ranger Workshop Manual.
Page 192 211-02-14 Power Steering 211-02-14 REMOVAL AND INSTALLATION (Continued) Power Steering Pump Hoses — Pressure Hose Removal 1. Disconnect the pressure hose from the power steering pump. 2. Raise and support the vehicle. Refer to Section 100-02. 3. Disconnect the pressure hose from the steering gear.
Page 193 211-02-15 Power Steering 211-02-15 REMOVAL AND INSTALLATION (Continued) Installation 1. To install, reverse the removal procedure. Purge the power steering system of air. • Refer to Section 211-00 of the 2001 Ranger Workshop Manual. 2001 Ranger EV, 01/2001...
Page 194 211-02-16 Power Steering 211-02-16 REMOVAL AND INSTALLATION (Continued) Power Steering Pump Hoses — Pressure Hose - Postal Ranger EV Removal 1. Disconnect the pressure hose from the power steering pump. 2. Raise and support the vehicle. For additional information, refer to Section 100-02.
Page 195 211-02-17 Power Steering 211-02-17 REMOVAL AND INSTALLATION (Continued) Installation 1. To install, reverse the removal procedure. Purge the power steering system of air. • Refer to Section 211-00 of the 2001 Ranger Workshop Manual. 2001 Ranger EV, 01/2001...
Page 196 211-02-18 Power Steering 211-02-18 REMOVAL AND INSTALLATION (Continued) Power Steering Pump Hoses — Return Hose Removal 1. Disconnect the return hose from the reservoir. 2. Disconnect the return hose from the steering gear. 3. Remove the return hose. 1 Remove the clamp bolt. 2 Remove the return hose.
Page 197 211-02-19 Power Steering 211-02-19 REMOVAL AND INSTALLATION (Continued) Installation 1. To install, reverse the removal procedure. Purge the power steering system of air. • Refer to Section 211-00 of the 2001 Ranger Workshop Manual. Power Steering Pump Hoses — Return Hose - Postal Ranger EV Removal 1.
Page 198 211-02-20 Power Steering 211-02-20 REMOVAL AND INSTALLATION (Continued) 2. Disconnect the return hose from the steering gear. 3. Remove the return hose. 1 Remove the clamp bolt. 2 Remove the return hose. Installation 1. To install, reverse the removal procedure. Purge the power steering system of air.
Page 199 211-02-21 Power Steering 211-02-21 REMOVAL AND INSTALLATION (Continued) Power Steering Pump Hoses — Supply Hose Removal 1. Disconnect the supply hose from the power steering pump. 2. Disconnect the supply hose from the reservoir. 3. Remove the supply hose. 2001 Ranger EV, 01/2001...
Page 200 211-02-22 Power Steering 211-02-22 REMOVAL AND INSTALLATION (Continued) Installation 1. To install, reverse the removal procedure. Purge the power steering system of air. • Refer to Section 211-00 of the 2001 Ranger Workshop Manual. Power Steering Pump Hoses — Supply Hose - Postal Ranger EV Removal 1.
Page 201 211-02-23 Power Steering 211-02-23 REMOVAL AND INSTALLATION (Continued) Power Steering Reservoir Removal 1. Remove the power steering reservoir. 1 Disconnect the lines. 2 Remove the screws. 3 Remove the reservoir. Installation 1. Install the power steering reservoir. 1 Position the reservoir. 2 Install the screws.
Page 202 211-02-24 Power Steering 211-02-24 REMOVAL AND INSTALLATION (Continued) Power Steering Reservoir — Postal Ranger EV Removal and Installation 1. Remove the power steering reservoir. 1 Disconnect the lines. 2 Remove the bolts. 3 Remove the reservoir. 2. To install, reverse the removal procedure. Purge the power steering system of air.
Page 203: Steering Column Switches
211-05-1 Steering Column Switches 211-05-1 Manual Table of Contents SECTION 211-05 Steering Column Switches VEHICLE APPLICATION: Ranger EV CONTENTS PAGE DESCRIPTION AND OPERATION Steering Column Switches................211-05-2 2001 Ranger EV, 01/2001...
Page 204 211-05-2 Steering Column Switches 211-05-2 DESCRIPTION AND OPERATION Traction Bus Operation After a key transition from OFF to RUN, if the Steering Column Switches vehicle is not being charged the traction inverter The key positions on the Electric Ranger are the module (TIM) will begin to precharge the traction same as on the gasoline-powered Ranger.
Page 205 211-05-3 Steering Column Switches 211-05-3 DESCRIPTION AND OPERATION (Continued) Auxiliary Bus Operation After a key transition from OFF to RUN, the IAA module will wake up and request authority to use the high-voltage auxiliary bus from the battery control module (BCM). If the BCM grants the authority, the IAA module will request the auxiliary bus to close.
Page 206: Powertrain
303-01-1 Manual Table of Contents GROUP Powertrain SECTION TITLE PAGE Basic Motor/Transaxle....................... 303-01-1 Engine Cooling........................... 303-03-1 Electric Motor Management ...................... 303-14-1 Automatic Transaxle External Controls .................. 307-05-1 Acceleration Control ........................310-02-1 SECTION 303-01 Basic Motor/Transaxle VEHICLE APPLICATION: Ranger EV CONTENTS PAGE SPECIFICATIONS ..................
Page 207 303-01-2 Basic Motor/Transaxle 303-01-2 SPECIFICATIONS General Specifications Torque Specifications Item Specification Description Lb-Ft Lb-In TIM +,-Cable Sleeve — 44.5 Tribolube L-6 Pro Gear 21 F8AZ-19M544-A Nuts Torque Specifications Traction Inverter Motor — 44.5 Controller (TIM) Cover Description Lb-Ft Lb-In Plate Bolts Cross Bar Bolts 34.5 —...
Page 208: Fuse
303-01-3 Basic Motor/Transaxle 303-01-3 DIAGNOSIS AND TESTING Electrical Schematic Refer to Electrical and Vacuum Troubleshooting Motor/Transaxle Lubrication System Manual, Cell 26, Motor/Transaxle Control for Diagnostic Trouble Code (DTC) Definition schematic and connector information. The following DTC relates to the Motor/Transaxle Inspection and Verification Lubrication System: Refer to...
Page 209 303-01-4 Basic Motor/Transaxle 303-01-4 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST A: DTC C1284 OIL PRESSURE SWITCH FAILURE TEST STEP ACTION TO TAKE A1 CHECK FUSE GO to A2. • Check 20A fuse 19 in the electric vehicle power distribution box Yes = (EVPDB).
Page 210 303-01-5 Basic Motor/Transaxle 303-01-5 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST A: DTC C1284 OIL PRESSURE SWITCH FAILURE TEST STEP ACTION TO TAKE • With key ON, measure the voltage between BOB pin B12 and ground Yes = REPAIR the DB/W wire. (BOB pin A29).
Page 211 303-01-6 Basic Motor/Transaxle 303-01-6 GENERAL PROCEDURES Oil Level Check Procedure 1. Raise and support the vehicle. Refer to Section 100-02. 2. Remove the LH rear wheel. 1 Remove the center cap. 2 Remove the lug nuts. 3 Remove the wheel. 3.
Page 212 303-01-7 Basic Motor/Transaxle 303-01-7 GENERAL PROCEDURES (Continued) 5. Install the fill plug. 6. Install the wheel. 1 Position the wheel. 2 Install the lug nuts. 3 Install the center cap. Oil Change Procedure Special Tool(s) Electric Motor/Transaxle Test 418-F211 NOTE: The oil capacity of the motor/transaxle is approximately 1600 ml (54 oz).
Page 213 303-01-8 Basic Motor/Transaxle 303-01-8 GENERAL PROCEDURES (Continued) 3. Remove the LH rear wheel. 1 Remove the center cap. 2 Remove the lug nuts. 3 Remove the wheel. 4. Disconnect the oil pump electrical connector. 5. Connect the Electric Motor/Transaxle Test Box electrical connector to the oil pump connector.
Page 214 303-01-9 Basic Motor/Transaxle 303-01-9 GENERAL PROCEDURES (Continued) 8. Turn the Electric Motor/Transaxle Test Box power on. This will activate the oil pump and force the oil out of the motor/transaxle. Leave the power on for two minutes. 9. Install the drain plug. 10.
Page 215 303-01-10 Basic Motor/Transaxle 303-01-10 GENERAL PROCEDURES (Continued) 13. Add one quart of Tribolube oil. Fill the transaxle using a clean funnel and hose. 14. Install the fill plug. 15. Install the wheel. 1 Position the wheel. 2 Install the lug nuts. 3 Install the center cap.
Page 216 303-01-11 Basic Motor/Transaxle 303-01-11 REMOVAL AND INSTALLATION (Continued) 3. Remove the LH and RH rear wheels. 1 Remove the center cap. 2 Remove the lug nuts. 3 Remove the wheel. 4. Disconnect the shift cable. 5. Position the shift cable bracket aside. 1 Remove the bolts.
Page 217 303-01-12 Basic Motor/Transaxle 303-01-12 REMOVAL AND INSTALLATION (Continued) 7. Disconnect the oil pump electrical connector from the front LH side of the transaxle. 8. NOTE: The electrical connector is not visible from the underneath the vehicle. The connector is shown with the box off the pickup for clarity. Disconnect the motor/transaxle electrical connector from the top RH side of the motor/transaxle by pressing on top tab and...
Page 218 303-01-13 Basic Motor/Transaxle 303-01-13 REMOVAL AND INSTALLATION (Continued) 11. Disconnect the TIM to motor/transaxle electrical cables. 1 Remove the nuts. 2 Remove the sleeve nuts and slide the cables out of the TIM. 12. Support the motor/transaxle using a high lift jack.
Page 219 303-01-14 Basic Motor/Transaxle 303-01-14 REMOVAL AND INSTALLATION (Continued) CAUTION: Do not lower the motor/transaxle more than 4 inches (102 mm) or damage to the motor/transaxle electrical connections may occur. Lower the motor/transaxle 4 inches (102 mm) to expose the top of the motor/transaxle frame. 16.
Page 220 303-01-15 Basic Motor/Transaxle 303-01-15 REMOVAL AND INSTALLATION (Continued) 2001 Ranger EV, 01/2001...
Page 221 303-01-16 Basic Motor/Transaxle 303-01-16 REMOVAL AND INSTALLATION (Continued) 2001 Ranger EV, 01/2001...
Page 222: Engine Cooling
303-03-1 Engine Cooling 303-03-1 Manual Table of Contents SECTION 303-03 Engine Cooling VEHICLE APPLICATION: Ranger EV CONTENTS PAGE SPECIFICATIONS ..................303-03-2 DESCRIPTION AND OPERATION Cooling System..................303-03-2 Cooling System —Postal Ranger EV .............. 303-03-3 DIAGNOSIS AND TESTING Cooling System..................303-03-4 Diagnostic Trouble Code (DTC) Definition .............
Page 223 303-03-2 Engine Cooling 303-03-2 SPECIFICATIONS Torque Specifications General Specifications Description Lb-Ft Lb-In Item Specification Coolant pump bolt — Cooling System Capacity 11.36 l (3 gal) Coolant tube clamp — Premium Cooling System ESE-M97B44-A screws Fluid E2FZ-19549-AA Radiator fan bolts — Pressure Relief Cap 110.5 kPa (16 psi) DESCRIPTION AND OPERATION...
Page 224 303-03-3 Engine Cooling 303-03-3 DESCRIPTION AND OPERATION (Continued) The cooling system removes heat from various The interface adapter assembly (IAA) controls the electronic components. The coolant pump has a operation of the electric coolant pump and the centrifugal impeller design with a 12-volt permanent electric radiator fan, based upon vehicle coolant magnet motor.
Page 225 303-03-4 Engine Cooling 303-03-4 DESCRIPTION AND OPERATION (Continued) The cooling system removes heat from various The interface adapter assembly (IAA) controls the electronic components. The coolant pump has a operation of the electric coolant pump and the centrifugal impeller design with a 12-volt permanent electric radiator fan, based upon vehicle coolant magnet motor.
Page 226: Fuse
303-03-5 Engine Cooling 303-03-5 DIAGNOSIS AND TESTING (Continued) Symptom Chart Symptom Chart Condition Possible Sources Action DTC C1774 Coolant Circuit(s). GO to Pinpoint Test A. • • • Temperature Sensor Out of Coolant temperature sensor. • Range Interface adapter assembly •...
Page 227 303-03-6 Engine Cooling 303-03-6 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST A: DTC C1774 COOLANT TEMPERATURE SENSOR OUT OF RANGE TEST STEP ACTION TO TAKE A3 CHECK CIRCUITS 3064 (BK/O) AND 3065 (LG/P) FOR OPEN(S) GO to A4. • Connect 104-Pin Breakout Box (BOB) to IAA module C1945; leave IAA Yes = module disconnected.
Page 228 303-03-7 Engine Cooling 303-03-7 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST B: COOLANT PUMP DOES NOT OPERATE TEST STEP ACTION TO TAKE • With key OFF, disconnect coolant pump C1998. Yes = REPLACE the coolant pump. • Enter the IAA module active command mode CLIMATE SYSTEM No = GO to B4.
Page 229 303-03-8 Engine Cooling 303-03-8 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST D: COOLING FAN DOES NOT OPERATE TEST STEP ACTION TO TAKE • With key OFF, remove the fan low speed relay from the cooling fan No = REPAIR as necessary. relay box and measure the voltage between pins 85, 87 on the fan low speed relay C1954 and ground.
Page 230 303-03-9 Engine Cooling 303-03-9 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST D: COOLING FAN DOES NOT OPERATE TEST STEP ACTION TO TAKE • With key OFF, measure the resistance between the BK wire on the Yes = GO to D11. cooling fan C1967 and ground. •...
Page 231 303-03-10 Engine Cooling 303-03-10 GENERAL PROCEDURES Cooling System Drain, Fill and Bleed Drain — Cooling System 1. Disconnect the auxiliary battery ground cable. WARNING: Do not remove the radiator pressure relief cap if the coolant is hot or if the coolant pump is running. Remove the radiator pressure relief cap.
Page 232 2. Lower the vehicle. 3. Add a 50/50 mix of Premium Cooling System Fluid E2FZ-19549-AA or equivalent meeting Ford specification ESE-M97B44-A and distilled water to the radiator until the coolant level reaches the bottom of the radiator filler neck. 4. Fill the coolant reservoir with the 50/50 coolant mix until the coolant level reaches the cold fill line.
Page 233 This forms a fluid link between the radiator and the overflow tank. Bleed — Cooling System 1. Fill the coolant reservoir with a 50/50 mix of coolant meeting Ford specification ESE-M97B44-A and distilled water to the cold mark. 2. Remove the radiator pressure relief cap.
Page 234 303-03-13 Engine Cooling 303-03-13 GENERAL PROCEDURES (Continued) 4. Add the 50/50 coolant mix to the radiator until the coolant level reaches the bottom of the radiator filler neck. 5. Install the radiator pressure relief cap. 6. Turn the key to the OFF position to deactivate the coolant pump.
Page 235 303-03-14 Engine Cooling 303-03-14 REMOVAL AND INSTALLATION Coolant Pump Removal 1. If connected, disconnect the vehicle from the charging station. 2. Disconnect the auxiliary battery ground cable. CAUTION: Do not remove the radiator pressure relief cap if the coolant is hot or if the coolant pump is running.
Page 236 303-03-15 Engine Cooling 303-03-15 REMOVAL AND INSTALLATION (Continued) 7. Disconnect the coolant pump electrical connector. 8. Remove the coolant pump. 1 Remove the bolt. 2 Remove the pump. Installation 1. To install, reverse the removal procedure. After installation, bleed the cooling system. •...
Page 237 303-03-16 Engine Cooling 303-03-16 REMOVAL AND INSTALLATION (Continued) CAUTION: Do not remove the radiator pressure relief cap if the coolant is hot or if the coolant pump is running. Turn the radiator pressure relief cap to the first stop to remove any remaining pressure. 4.
Page 238 303-03-17 Engine Cooling 303-03-17 REMOVAL AND INSTALLATION (Continued) 7. Disconnect the coolant pump electrical connector. 8. Remove the coolant pump. 1 Remove the bolt. 2 Remove the coolant pump. Installation 1. To install, reverse the removal procedure. After installation, bleed the cooling system. •...
Page 239 303-03-18 Engine Cooling 303-03-18 REMOVAL AND INSTALLATION (Continued) 2. Remove the radiator cooling fan. 1 Unclip the hose. 2 Remove the two bolts. 3 Disconnect the cooling fan electrical connector. 4 Remove the radiator fan. Installation 1. Install the radiator cooling fan. 1 Position the cooling fan.
Page 240 303-03-19 Engine Cooling 303-03-19 REMOVAL AND INSTALLATION (Continued) 3. Disconnect the front coolant tube rubber hose connections. Clamp off the hoses to prevent coolant loss. • Position a catch pan to collect the coolant. • 4. Disconnect the rear coolant tube rubber hose connections.
Page 241 303-03-20 Engine Cooling 303-03-20 REMOVAL AND INSTALLATION (Continued) Installation 1. To install, reverse the removal procedure. After installation, bleed the cooling system. • Refer to Bleed — Cooling System. Cooling System Tubes and Hoses —Postal Ranger EV Removal WARNING: Do not remove the radiator pressure relief cap if the coolant is hot or if the coolant pump is running.
Page 242 303-03-21 Engine Cooling 303-03-21 REMOVAL AND INSTALLATION (Continued) 3. Disconnect the front coolant tube rubber hose connections. Clamp off the hoses to prevent coolant loss. • Position a catch pan to collect the coolant. • 4. Disconnect the rear coolant tube rubber hose connections.
Page 243 303-03-22 Engine Cooling 303-03-22 REMOVAL AND INSTALLATION (Continued) Installation 1. To install, reverse the removal procedure. After installation, bleed the cooling system. • Refer to Cooling System Drain, Fill and Bleed. 2001 Ranger EV, 01/2001...
Page 244: Electric Motor Management
303-14-1 Electric Motor Management 303-14-1 Manual Table of Contents SECTION 303-14 Electric Motor Management VEHICLE APPLICATION: Ranger EV CONTENTS PAGE SPECIFICATIONS ..................303-14-2 DESCRIPTION AND OPERATION Electric Motor Management ................. 303-14-2 DIAGNOSIS AND TESTING Traction Inverter Module (TIM) Control System ..........303-14-2 Electrical Schematic ................
Page 245 303-14-2 Electric Motor Management 303-14-2 SPECIFICATIONS Torque Specifications Torque Specifications Description Lb-Ft Lb-In Description Lb-Ft Lb-In TIM B,+ Cable — Ground Strap Bolt — Connector Nuts TIM Bracket Bolts 14.5 — TIM C Cable Connector 14.5 — TIM Bracket to Frame —...
Page 246 303-14-3 Electric Motor Management 303-14-3 DIAGNOSIS AND TESTING (Continued) Inspection and Verification Refer to Section 100-07. Symptom Chart Symptom Chart Condition Possible Sources Action DTC C1854 Motor Motor/transaxle. GO to Pinpoint Test A. • • • Temperature Out of Range Circuit(s).
Page 247 303-14-4 Electric Motor Management 303-14-4 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST A: DTC C1854 MOTOR TEMPERATURE OUT OF RANGE TEST STEP ACTION TO TAKE —1340 ohms=150 °C (302°F) • Is the TRNTEMP PID approximately equal to the resistance readings from the motor temperature test box? GO to A2.
Page 248 303-14-5 Electric Motor Management 303-14-5 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST A: DTC C1854 MOTOR TEMPERATURE OUT OF RANGE TEST STEP ACTION TO TAKE • With key OFF, measure the resistance of the Y/LG wire between pin 8 Yes = Transaxle temp sensor is on in-line C2999 and BOB pin 35.
Page 249 303-14-6 Electric Motor Management 303-14-6 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST B: DTC 1856 TRACTION MOTOR ENCODER CIRCUIT FAILURE TEST STEP ACTION TO TAKE B5 CHECK CIRCUITS 3700 (LB/R) AND 3701 (DB/W) FOR SHORT(S) TO POWER • With key On, measure the voltage between BOB pins A26, A36 and Yes = REPAIR the wire(s) in ground (BOB pin A29).
Page 250 303-14-7 Electric Motor Management 303-14-7 REMOVAL AND INSTALLATION (Continued) 3. Disconnect the electrical connectors. 1 Loosen the bolts. 2 Disconnect the connectors. 4. Remove the ground strap bolt. 5. Clamp off and disconnect the coolant hoses. 6. Remove the TIM mounting bolts. 2001 Ranger EV, 01/2001...
Page 251 303-14-8 Electric Motor Management 303-14-8 REMOVAL AND INSTALLATION (Continued) 7. Remove the TIM. 1 Loosen the TIM bracket bolts. 2 Remove the bracket to frame bolts. 3 Remove the TIM. Installation 1. To install, reverse the removal procedure. 1 If excessive amounts of coolant were lost during the removal procedure, bleed the cooling system.
Page 252 303-14-9 Electric Motor Management 303-14-9 REMOVAL AND INSTALLATION (Continued) 2001 Ranger EV, 01/2001...
Page 253 303-14-10 Electric Motor Management 303-14-10 REMOVAL AND INSTALLATION (Continued) 2001 Ranger EV, 01/2001...
Page 254: Automatic Transaxle External Controls
307-05-1 Automatic Transaxle External Controls 307-05-1 Manual Table of Contents SECTION 307-05 Automatic Transaxle External Controls VEHICLE APPLICATION: Ranger EV CONTENTS PAGE SPECIFICATIONS ..................307-05-2 DESCRIPTION AND OPERATION Automatic Transaxle External Controls ............307-05-2 DIAGNOSIS AND TESTING Digital Transmission Range (DTR) Sensor ............307-05-2 Electrical Schematic ................
Page 255 307-05-2 Automatic Transaxle External Controls 307-05-2 SPECIFICATIONS Torque Specifications Torque Specifications Description Lb-Ft Lb-In Description Lb-Ft Lb-In Motor Mount Nuts 40.5 — Bracket to — Motor/Transaxle Bolts Motor Mount Through 84.5 — Bolt Nut Digital Transmission — Range Sensor Bolts Shift Lever Nut —...
Page 256 307-05-3 Automatic Transaxle External Controls 307-05-3 DIAGNOSIS AND TESTING (Continued) Symptom Chart Symptom Chart Condition Possible Sources Action DTC C1860 PRNDL Input #3 Digital transmission range GO to Pinpoint Test A. • • • Circuit Failure (DTR) sensor alignment. DTR sensor. •...
Page 257 307-05-4 Automatic Transaxle External Controls 307-05-4 DIAGNOSIS AND TESTING (Continued) Symptom Chart (Continued) Condition Possible Sources Action Vehicle Does Not Remain Halfshafts. CHECK halfshafts and motor • • • Stationary With Transmission Motor mounts. mounts. REPAIR as • Range Selector Lever in the Shift cable alignment.
Page 258 307-05-5 Automatic Transaxle External Controls 307-05-5 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST A: DIGITAL TRANSMISSION RANGE (DTR) SENSOR CIRCUIT FAILURE TEST STEP ACTION TO TAKE No = GO to A3. CAUTION: DO NOT PRY on connector. This will damage the •...
Page 259 307-05-6 Automatic Transaxle External Controls 307-05-6 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST A: DIGITAL TRANSMISSION RANGE (DTR) SENSOR CIRCUIT FAILURE TEST STEP ACTION TO TAKE • With key ON, measure the voltage between BOB pin B7 and ground Yes = REPAIR the R wire.
Page 260 307-05-7 Automatic Transaxle External Controls 307-05-7 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST A: DIGITAL TRANSMISSION RANGE (DTR) SENSOR CIRCUIT FAILURE TEST STEP ACTION TO TAKE WARNING: The traction battery contains high-voltage components and wiring. High-voltage insulated safety gloves and face shield must be worn when carrying out the following steps.
Page 261 307-05-8 Automatic Transaxle External Controls 307-05-8 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST A: DIGITAL TRANSMISSION RANGE (DTR) SENSOR CIRCUIT FAILURE TEST STEP ACTION TO TAKE A17 CHECK CIRCUITS 3502 (DG) AND 3504 (BK/O) FOR OPEN(S) GO to A18. • Connect 104-Pin Breakout Box (BOB) to TIM C4998, C4999 using the Yes = BCM/TIM BOB Adapter Cable and Overlay;...
Page 262 307-05-9 Automatic Transaxle External Controls 307-05-9 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST A: DIGITAL TRANSMISSION RANGE (DTR) SENSOR CIRCUIT FAILURE TEST STEP ACTION TO TAKE • Remove the traction battery and connect Traction Battery High-Voltage Yes = REPAIR the Y wire. Lockout and Diagnostic Tool to the traction battery high-voltage 2-pin REPLACE the DTR sensor.
Page 263 307-05-10 Automatic Transaxle External Controls 307-05-10 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST B: DIGITAL TRANSMISSION RANGE (DTR) SENSOR ALIGNMENT VERIFICATION TEST STEP ACTION TO TAKE B1 VERIFY DIGITAL TRANSMISSION RANGE (DTR) SENSOR ALIGNMENT • With key OFF, set the gear selector to the PARK position. Yes = REPLACE the motor/transaxle.
Page 264 307-05-11 Automatic Transaxle External Controls 307-05-11 GENERAL PROCEDURES (Continued) 3. NOTE: The D (Drive) position is one position from the shift lever’s most rearward position. Position the motor/transaxle shift lever in D (Drive). 4. Engage the cable clip (push down). 5.
Page 265 307-05-12 Automatic Transaxle External Controls 307-05-12 GENERAL PROCEDURES (Continued) 3. Disconnect the shift cable from the shift lever. NOTE: The motor/transaxle is shown removed from the vehicle. 4. Remove the shift lever. 1 Remove the nut. 2 Remove the shift lever. 5.
Page 266 307-05-13 Automatic Transaxle External Controls 307-05-13 GENERAL PROCEDURES (Continued) 6. NOTE: Do not remove the alignment tool until the sensor bolts have been tightened. Install the digital TR sensor alignment tool to positively locate the sensor in relation to the motor/transaxle neutral position.
Page 267 307-05-14 Automatic Transaxle External Controls 307-05-14 GENERAL PROCEDURES (Continued) 9. Install the shift lever. 1 Install the shift lever. 2 Install the nut. 10. Connect the shift cable to the shift lever. 11. Adjust the shift cable. Refer to PRNDE Shifter Adjustment.
Page 268 307-05-15 Automatic Transaxle External Controls 307-05-15 REMOVAL AND INSTALLATION (Continued) 2. Disconnect the shift cable from the digital transmission range (DTR) sensor shift lever. 3. Disconnect the shift cable from the bracket. 1 Depress the tabs. 2 Slide the cable through the bracket. 4.
Page 269 307-05-16 Automatic Transaxle External Controls 307-05-16 REMOVAL AND INSTALLATION (Continued) 6. Disconnect the shift cable from the bracket. Depress the tabs. • Slide the cable through the bracket. • 7. Remove the cable. Installation 1. To install, reverse the removal procedure. After installation, adjust the shift cable.
Page 270 307-05-17 Automatic Transaxle External Controls 307-05-17 REMOVAL AND INSTALLATION (Continued) 5. Remove the motor mount through bolt. 6. Remove the two motor mount nuts. 7. Remove the five motor mount bracket to motor/transaxle bolts. 2001 Ranger EV, 01/2001...
Page 271 307-05-18 Automatic Transaxle External Controls 307-05-18 REMOVAL AND INSTALLATION (Continued) 8. Disconnect the shift cable from the shift lever. 9. Lower the motor/transaxle approximately 2.5 cm (1 in). 10. Remove the motor/transaxle mount. 11. NOTE: The motor/transaxle is shown removed from the vehicle for clarity.
Page 272 307-05-19 Automatic Transaxle External Controls 307-05-19 REMOVAL AND INSTALLATION (Continued) 12. Remove the digital transmission range (DTR) sensor lever. 1 Remove the nut. 2 Remove the lever. 13. Disconnect the DTR sensor electrical connector. 14. Remove the DTR sensor. 1 Remove the two bolts. 2 Pry the bracket away from the motor/transaxle.
Page 273 307-05-20 Automatic Transaxle External Controls 307-05-20 REMOVAL AND INSTALLATION (Continued) 2. Install the digital TR sensor alignment tool on the sensor. 3. NOTE: The sensor is installed with alignment tool in place. Install the DTR sensor. 1 Position the sensor on the motor/transaxle. 2 Install the bolts.
Page 274 307-05-21 Automatic Transaxle External Controls 307-05-21 REMOVAL AND INSTALLATION (Continued) 5. Install the DTR sensor lever. 1 Position the lever. 2 Install the nut. 6. Position the motor/transaxle mount. 7. Install the five bracket to motor/transaxle bolts. The motor/transaxle may have to be lowered •...
Page 275 307-05-22 Automatic Transaxle External Controls 307-05-22 REMOVAL AND INSTALLATION (Continued) 8. Loosely install the two motor mount nuts. 9. Install the motor mount through bolt. 10. Tighten the two motor mount nuts. 2001 Ranger EV, 01/2001...
Page 276 307-05-23 Automatic Transaxle External Controls 307-05-23 REMOVAL AND INSTALLATION (Continued) 11. Connect the shift cable. 12. Install the LH rear wheel. 13. Adjust the shift cable. Refer to PRNDE Shifter Adjustment. 2001 Ranger EV, 01/2001...
Page 277: Acceleration Control
310-02-1 Acceleration Control 310-02-1 Manual Table of Contents SECTION 310-02 Acceleration Control VEHICLE APPLICATION: Ranger EV CONTENTS PAGE SPECIFICATIONS ..................310-02-2 DESCRIPTION AND OPERATION Acceleration Control .................. 310-02-2 DIAGNOSIS AND TESTING Acceleration Control .................. 310-02-3 Electrical Schematic ................310-02-3 Inspection and Verification ................ 310-02-3 Pinpoint Tests ..................
Page 278 310-02-2 Acceleration Control 310-02-2 SPECIFICATIONS Torque Specifications—Electric Ranger EV Torque Specifications—Postal Ranger EV Description Lb-In Description Lb-Ft Lb-In Acceleration 10.5 93.5 Accelerator — Position Sensor pedal bolt Bolt DESCRIPTION AND OPERATION NOTE: Electric Ranger shown, Postal Ranger EV similar. Acceleration Control The Electric Vehicle uses an acceleration position sensor (APS) to monitor driver demands for acceleration.
Page 279 310-02-3 Acceleration Control 310-02-3 DIAGNOSIS AND TESTING • DTC C1855 Acceleration Position Sensor Conflict Acceleration Control — DTC C1855 is set if there is a conflict between the three accelerator position sensor Diagnostic Trouble Code (DTC) Definition (APS) signals. It may also occur if there is an The following DTCs relate to the acceleration out of range condition for the sensors (DTC position sensor (APS):...
Page 280 310-02-4 Acceleration Control 310-02-4 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST A: DTC C1750 ACCELERATION POSITION SENSOR (APS) OUT OF RANGE TEST STEP ACTION TO TAKE • Depress the accelerator pedal. No = GO to A2. • Does the AP1V PID vary within the range of 0.25 and 4.85 volts? A2 CHECK CIRCUITS 3835 (Y/W), 3836 (Y/LB), AND 3837 (GY/Y) (TO APS1) FOR OPEN(S) GO to A3.
Page 281 310-02-5 Acceleration Control 310-02-5 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST A: DTC C1750 ACCELERATION POSITION SENSOR (APS) OUT OF RANGE TEST STEP ACTION TO TAKE • With key OFF, disconnect acceleration position sensor (APS) C2995 and No = REPAIR the wire(s) in measure the resistance of the T wire between pin D on APS C2995 and question.
Page 282 310-02-6 Acceleration Control 310-02-6 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST A: DTC C1750 ACCELERATION POSITION SENSOR (APS) OUT OF RANGE TEST STEP ACTION TO TAKE • With key OFF, measure the resistance between BOB pins B16, B17 and Yes = GO to A16.
Page 283 310-02-7 Acceleration Control 310-02-7 REMOVAL AND INSTALLATION (Continued) 2. Remove the position sensor. 1 Remove the bolt. 2 Swing the sensor up and off the clip and remove the sensor. Installation 1. Install the position sensor. 1 Position the sensor on the clip and swing it into position.
Page 284 310-02-8 Acceleration Control 310-02-8 REMOVAL AND INSTALLATION (Continued) 2. To install, reverse the removal procedure. 2001 Ranger EV, 01/2001...
Page 285: Electrical
412-01-1 Manual Table of Contents GROUP Electrical SECTION TITLE PAGE Air Distribution and Filtering ....................412-01-1 Heating and Ventilation ......................412-02-1 Air Conditioning ......................... 412-03-1 Control Components ......................... 412-04-1 Instrument Cluster ........................413-01-1 Auxiliary Battery Charging......................414-02-1 High Voltage/Traction Battery ....................414-03A-1 High Voltage/Traction Battery —...
Page 286: Air Distribution And Filtering
412-01-2 Air Distribution and Filtering 412-01-2 SPECIFICATIONS Torque Specifications Description Lb-Ft Lb-In Blower Motor Screws 1.75 15.5 — Reservoir Bolts and 62.5 — Nuts ABS Control Bracket — Bolts DESCRIPTION AND OPERATION The air filter is made from a pleated woven material that offers minimal restriction to airflow.
Page 287 412-01-3 Air Distribution and Filtering 412-01-3 REMOVAL AND INSTALLATION (Continued) 2. Disconnect the A/C electrical connector. 3. Disconnect the windshield solvent pump electrical connector. 4. Position the reservoirs. 1 Remove the nuts. 2 Remove the bolts. 3 Position the reservoir toward the front of the vehicle.
Page 288 412-01-4 Air Distribution and Filtering 412-01-4 REMOVAL AND INSTALLATION (Continued) 6. Pry the air filter arms from behind the housing tabs, which are located at the three and ten o’clock positions. 7. Remove the air filter. Grasp the air filter at the 3 and 9 o’clock •...
Page 289 412-01-5 Air Distribution and Filtering 412-01-5 REMOVAL AND INSTALLATION (Continued) 5. Snap the filter arms in behind the housing tabs. 6. Lightly pull the filter towards the blower motor opening to properly locate the filter. CAUTION: Overtightening of the blower screws will result in damage to the plastic housing.
Page 290 412-01-6 Air Distribution and Filtering 412-01-6 REMOVAL AND INSTALLATION (Continued) 9. Connect the windshield solvent pump electrical connector. 10. Connect the A/C electrical connector. 11. Connect the blower motor electrical connector. 2001 Ranger EV, 01/2001...
Page 291 412-01-7 Air Distribution and Filtering 412-01-7 REMOVAL AND INSTALLATION (Continued) Air Filter —Postal Ranger EV 1. Disconnect the blower motor electrical connector. 2. Remove the Anti-lock Brake System (ABS) control unit bracket. 3. NOTE: Electric Ranger shown, Postal Ranger EV similar. Remove the blower motor.
Page 292 412-01-8 Air Distribution and Filtering 412-01-8 REMOVAL AND INSTALLATION (Continued) 5. NOTE: Electric Ranger shown, Postal Ranger EV similar. Remove the air filter. Grasp the air filter at the 3 and 9 o’clock • positions by the pleats and fold the filter in half.
Page 293 412-01-9 Air Distribution and Filtering 412-01-9 REMOVAL AND INSTALLATION (Continued) 5. NOTE: Electric Ranger shown, Postal Ranger EV similar. Snap the filter arms in behind the housing tabs. 6. Lightly pull the filter towards the blower motor opening to properly locate the filter. CAUTION: Overtightening of the blower screws will result in damage to the plastic housing.
Page 294 412-01-10 Air Distribution and Filtering 412-01-10 REMOVAL AND INSTALLATION (Continued) 9. Connect the blower motor electrical connector. 2001 Ranger EV, 01/2001...
Page 295: Heating And Ventilation
412-02-1 Heating and Ventilation 412-02-1 Manual Table of Contents SECTION 412-02 Heating and Ventilation VEHICLE APPLICATION: Ranger EV CONTENTS PAGE SPECIFICATIONS ..................412-02-2 DESCRIPTION AND OPERATION Heating/Defrosting ..................412-02-2 Heating/Defrosting —Postal Ranger EV ............412-02-2 DIAGNOSIS AND TESTING Heating/Defrosting/Ventilation System ............. 412-02-3 Electrical Schematic ................
Page 296 412-02-2 Heating and Ventilation 412-02-2 SPECIFICATIONS Torque Specifications Torque Specifications Description Lb/In Description Lb/In Positive Temperature 26.5 Evaporator Housing Nuts 35.5 Coefficient Heater Core Cover Heater Plenum Retaining Nuts 35.5 Screws High-Voltage Power Reservoir Nuts and Bolts Distribution Box Cover Screws (Continued) DESCRIPTION AND OPERATION The PTC heater is located in the standard Ranger...
Page 297 412-02-3 Heating and Ventilation 412-02-3 DIAGNOSIS AND TESTING • DTC B1254 Air Temperature External Sensor Circuit Failure Heating/Defrosting/Ventilation System — The interface adapter assembly (IAA) module Diagnostic Trouble Code (DTC) Definition uses the ambient temperature sensor to The following DTCs relate to the monitor the temperature of the outside air.
Page 298 412-02-4 Heating and Ventilation 412-02-4 DIAGNOSIS AND TESTING (Continued) • DTC C1780 Temperature Select Failure • DTC B2513 Blower (Fan) Circuit Failure — The interface adapter assembly (IAA) module — The interface adapter assembly (IAA) module monitors the temperature control signal from provides the pulse width modulation (PWM) the climate control temperature control control signal to the variable blower controller...
Page 299 412-02-5 Heating and Ventilation 412-02-5 DIAGNOSIS AND TESTING (Continued) • DTC B2516 Blower Control Circuit Failure Electrical Schematic Refer to Electrical and Vacuum Troubleshooting — The interface adapter assembly (IAA) module Manual, Cell 53, Heater or Cell 54, Air provides the pulse width modulation (PWM) Conditioner/Heater for schematic and connector control signal to the variable blower controller information.
Page 300 412-02-6 Heating and Ventilation 412-02-6 DIAGNOSIS AND TESTING (Continued) Symptom Chart (Continued) Condition Possible Sources Action DTC C1780 Temperature Circuit(s). GO to Pinpoint Test G. • • • Select Failure Interface adapter assembly • (IAA) module. Temperature control • potentiometer. DTC B1857 Climate Control Interface adapter assembly GO to...
Page 301 412-02-7 Heating and Ventilation 412-02-7 DIAGNOSIS AND TESTING (Continued) Symptom Chart (Continued) Condition Possible Sources Action Vacuum Pump Cycles On and • Vacuum line(s)/connection(s). GO to Pinpoint Test Q. • • Off Without Brake Pedal Climate control vacuum • Activation (Climate Control reservoir.
Page 302 412-02-8 Heating and Ventilation 412-02-8 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST A: DTC B1238 OVER TEMPERATURE FAULT TEST STEP ACTION TO TAKE • With key OFF, disconnect in-line C2999 and measure the resistance Yes = GO to A3. between the Y/W wire and GY/W wire on C2999M. •...
Page 303 412-02-9 Heating and Ventilation 412-02-9 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST B: DTC B1249 BLEND DOOR FAILURE TEST STEP ACTION TO TAKE B3 CHECK CIRCUITS 245 (BR/LG), 246 (P), 436 (R/LG), 437 (Y/LG), AND 438 (R/W) FOR OPEN(S) • Connect 104-Pin Breakout Box (BOB) to IAA module C1945; leave the Yes = GO to B4.
Page 304 412-02-10 Heating and Ventilation 412-02-10 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST C: DTC B1250 AIR TEMPERATURE INTERNAL SENSOR CIRCUIT FAILURE TEST STEP ACTION TO TAKE — 5 °C (41°F) = 71,100-78,700 ohms — 10 °C (50°F) = 56,000-62,000 ohms — 15 °C (59°F) = 44,400-49,100 ohms —...
Page 305 412-02-11 Heating and Ventilation 412-02-11 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST D: DTC B1254 AIR TEMPERATURE EXTERNAL SENSOR CIRCUIT FAILURE TEST STEP ACTION TO TAKE D2 CHECK CIRCUITS 3061 (LB/O) AND 3062 (BK/W) FOR OPEN(S) GO to D3. • Connect 104-Pin Breakout Box (BOB) to IAA module C1945; leave IAA Yes = module disconnected.
Page 306 412-02-12 Heating and Ventilation 412-02-12 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST E: DTC C1776 HEATER SYSTEM FAILURE TEST STEP ACTION TO TAKE • Remove the high-voltage power distribution box (HVPDB) cover. No = REPLACE the PTC heater • Disconnect PTC switching module high-voltage C1912 and measure the core.
Page 307 412-02-13 Heating and Ventilation 412-02-13 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST E: DTC C1776 HEATER SYSTEM FAILURE TEST STEP ACTION TO TAKE E9 CHECK PTC HEATER CORE B CONTROL CIRCUIT FOR SHORT TO GROUND • With key OFF, disconnect BOB from IAA module; leave BOB Yes = GO to E10.
Page 308 412-02-14 Heating and Ventilation 412-02-14 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST E: DTC C1776 HEATER SYSTEM FAILURE TEST STEP ACTION TO TAKE • Is the resistance greater than 10,000 ohms? No = REPLACE the HVPDB. REFER to Section 414-03A Section 414-03B.
Page 309 412-02-15 Heating and Ventilation 412-02-15 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST F: DTC C1779 BLOWER SWITCH FAILURE TEST STEP ACTION TO TAKE • With key OFF, measure the resistance between BOB pins 60, 61, 62 and Yes = GO to F6. ground (BOB pin 80).
Page 310 412-02-16 Heating and Ventilation 412-02-16 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST G: DTC C1780 TEMPERATURE SELECT FAILURE TEST STEP ACTION TO TAKE • With key OFF, measure the resistance of the LG/O wire between No = REPAIR the wire(s) in temperature control C231 and BOB pin 84.
Page 311 412-02-17 Heating and Ventilation 412-02-17 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST H: DTC B1857 CLIMATE CONTROL ON/OFF SWITCH FAILURE TEST STEP ACTION TO TAKE H4 CARRY OUT ON-DEMAND SELF-TEST IN PANEL/FLOOR MODE • With key ON, set the mode select knob to the PANEL/FLOOR position Yes = GO to H11.
Page 312 412-02-18 Heating and Ventilation 412-02-18 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST H: DTC B1857 CLIMATE CONTROL ON/OFF SWITCH FAILURE TEST STEP ACTION TO TAKE • With key OFF, disconnect BOB from the IAA module; leave BOB Yes = REPLACE the IAA module. connected to IAA module C1945.
Page 313 412-02-19 Heating and Ventilation 412-02-19 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST J: DTC U2015 SIGNAL LINK FAULT (NON SCP) TEST STEP ACTION TO TAKE J1 CHECK HEATER CORE OVERTEMPERATURE STATUS NOTE: Diagnostic trouble code (DTC) U2015 Signal Link Fault (Non Yes = GO to Pinpoint Test A.
Page 314 412-02-20 Heating and Ventilation 412-02-20 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST J: DTC U2015 SIGNAL LINK FAULT (NON SCP) TEST STEP ACTION TO TAKE J8 CHECK PTC HEATER CORES GO to J9. • Disconnect the 12-volt auxiliary battery negative cable. Yes = •...
Page 315 412-02-21 Heating and Ventilation 412-02-21 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST K: DTC B2513 BLOWER (FAN) CIRCUIT FAILURE TEST STEP ACTION TO TAKE K1 RETRIEVE CONTINUOUS DIAGNOSTIC TROUBLE CODES (DTCs) FROM INTERFACE ADAPTER ASSEMBLY (IAA) MODULE WHILE IN PANEL/FLOOR MODE •...
Page 316 412-02-22 Heating and Ventilation 412-02-22 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST K: DTC B2513 BLOWER (FAN) CIRCUIT FAILURE TEST STEP ACTION TO TAKE • Is the resistance greater than 10,000 ohms? No = REPAIR the Y/R wire. K8 CHECK POWER TO BLOWER MOTOR GO to K9.
Page 317 412-02-23 Heating and Ventilation 412-02-23 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST L: DTC B2514 BLOWER (FAN) CIRCUIT SHORT TO VBAT TEST STEP ACTION TO TAKE • With key ON, measure the voltage between pin 30 on the blower motor No = GO to L5.
Page 318 412-02-24 Heating and Ventilation 412-02-24 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST N: DTC B2516 BLOWER CONTROL CIRCUIT FAILURE TEST STEP ACTION TO TAKE If both DTC B2514 and DTC B2515, GO to N3. • Do DTC B2514 Blower (Fan) Circuit Short to Vbat and/or DTC No = GO to N5.
Page 319 412-02-25 Heating and Ventilation 412-02-25 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST P: NO HEAT/INSUFFICIENT HEAT TEST STEP ACTION TO TAKE P1 CHECK POSITIVE TEMPERATURE COEFFICIENT (PTC) HEATER CORE CONTROL SIGNALS GO to P3. • Connect 104-Pin Breakout Box (BOB) to interface adapter assembly Yes = (IAA) module and IAA module C1945.
Page 320 412-02-26 Heating and Ventilation 412-02-26 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST Q: VACUUM PUMP CYCLES ON AND OFF WITHOUT BRAKE PEDAL ACTIVATION (CLIMATE CONTROL VACUUM SYSTEM LEAK TEST)/INCORRECT AIRFLOW THROUGH CLIMATE CONTROL OUTLETS TEST STEP ACTION TO TAKE Q2 CHECK CLIMATE CONTROL VACUUM RESERVOIR SUPPLY LINE CONNECTION GO to Q3.
Page 321 412-02-27 Heating and Ventilation 412-02-27 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST Q: VACUUM PUMP CYCLES ON AND OFF WITHOUT BRAKE PEDAL ACTIVATION (CLIMATE CONTROL VACUUM SYSTEM LEAK TEST)/INCORRECT AIRFLOW THROUGH CLIMATE CONTROL OUTLETS TEST STEP ACTION TO TAKE • With key OFF, disconnect the vacuum jumper harness leading to the Yes = RECONNECT the vacuum heater plenum and plug all ports on the blue vacuum jumper harness...
Page 322 412-02-28 Heating and Ventilation 412-02-28 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST Q: VACUUM PUMP CYCLES ON AND OFF WITHOUT BRAKE PEDAL ACTIVATION (CLIMATE CONTROL VACUUM SYSTEM LEAK TEST)/INCORRECT AIRFLOW THROUGH CLIMATE CONTROL OUTLETS TEST STEP ACTION TO TAKE • With key ON, remove the blue vacuum line from the floor/defrost door Yes = RECONNECT the blue vacuum motor and plug the vacuum line.
Page 323 412-02-29 Heating and Ventilation 412-02-29 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST R: RECIRCULATION FUNCTION DOES NOT OPERATE TEST STEP ACTION TO TAKE • Is the outside/recirculation door in the recirculation position? No = GO to R4. R4 CHECK OPERATION OF RECIRCULATION VACUUM SOLENOID •...
Page 324 412-02-30 Heating and Ventilation 412-02-30 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST R: RECIRCULATION FUNCTION DOES NOT OPERATE TEST STEP ACTION TO TAKE • With key ON, disconnect the black vacuum line from the recirculation Yes = CHECK the white vacuum vacuum solenoid and check for vacuum.
Page 325 412-02-31 Heating and Ventilation 412-02-31 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST S: PRE-HEAT FUNCTION DOES NOT OPERATE (POSTAL RANGER EV ONLY) TEST STEP ACTION TO TAKE S1 CHECK PRE-HEAT FOR CORRECT CONDITIONS GO to S2. • Key OFF. Yes = •...
Page 326 412-02-32 Heating and Ventilation 412-02-32 REMOVAL AND INSTALLATION PTC Heater Core —Electric Ranger Removal 1. Disconnect the traction battery auxiliary load high-voltage connector. Refer to Section 100-05. 2. Remove the instrument panel. Refer to the 2001 Ranger Workshop Manual. 3. NOTE: The evaporator housing nut is located inside the vehicle, on the lower bulkhead, on the passenger side.
Page 327 412-02-33 Heating and Ventilation 412-02-33 REMOVAL AND INSTALLATION (Continued) 6. Disconnect the positive temperature coefficient (PTC) heater core electrical connector. 1 Disconnect the PTC heater core harness clip. 2 Disconnect the electrical connector. 7. Disconnect the harness clip. 8. Position the evaporator housing forward. 1 Remove the nuts.
Page 328 412-02-34 Heating and Ventilation 412-02-34 REMOVAL AND INSTALLATION (Continued) 10. Remove the two upper heater plenum retaining nuts. 11. NOTE: The lower nut is located behind the lower driver side of the evaporator housing. Remove the lower heater plenum retaining nut. 12.
Page 329 412-02-35 Heating and Ventilation 412-02-35 REMOVAL AND INSTALLATION (Continued) Installation 1. NOTE: Remove the insulation from the electrical harness of the new PTC heater core prior to installation. To install, reverse the removal procedure. 2001 Ranger EV, 01/2001...
Page 330 412-02-36 Heating and Ventilation 412-02-36 REMOVAL AND INSTALLATION (Continued) PTC Heater Core —Postal Ranger EV Removal and Installation 1. Disconnect the traction battery auxiliary load high-voltage connector. Refer to Section 100-05. 2001 Ranger EV, 01/2001...
Page 331 412-02-37 Heating and Ventilation 412-02-37 REMOVAL AND INSTALLATION (Continued) 2. NOTE: Electric Ranger shown, Postal Ranger EV similar. Disconnect the positive temperature coefficient (PTC) heater core electrical connector. 1 Disconnect the wiring harness clip. 2 Disconnect the electrical connector. 3. Remove the LH ventilation duct. 4.
Page 332 412-02-38 Heating and Ventilation 412-02-38 REMOVAL AND INSTALLATION (Continued) 6. NOTE: Remove the insulation from this electrical harness of the new PTC heater core prior to installation. To install, reverse the removal procedure. 2001 Ranger EV, 01/2001...
Page 333: Air Conditioning
412-03-1 Air Conditioning 412-03-1 Manual Table of Contents SECTION 412-03 Air Conditioning VEHICLE APPLICATION: Ranger EV CONTENTS PAGE SPECIFICATIONS ..................412-03-2 DESCRIPTION AND OPERATION A/C Inverter Motor Controller................ 412-03-2 Air Conditioning ..................412-03-2 Compressor .................... 412-03-2 DIAGNOSIS AND TESTING Air Conditioning ..................412-03-3 Electrical Schematic ................
Page 334 412-03-2 Air Conditioning 412-03-2 SPECIFICATIONS General Specifications Torque Specifications Item Specification Description Lb-Ft Lb-In A/C Refrigerant R134a WSH-M17B19-A A/C compressor bolts 22.5 16.5 — Polyolester Compressor WSS-M2C31-B A/C inverter motor — controller bolts Electric cooling fan — 62.5 bolts High side A/C line bolts —...
Page 335 412-03-3 Air Conditioning 412-03-3 DIAGNOSIS AND TESTING • DTC B2518 Compressor Overtemperature Fault Air Conditioning — The interface adapter assembly (IAA) module uses the A/C overtemperature sensor to Diagnostic Trouble Code (DTC) Definition monitor the temperature of the A/C The following DTCs relate to the air conditioning compressor.
Page 336 412-03-4 Air Conditioning 412-03-4 DIAGNOSIS AND TESTING (Continued) Symptom Chart (Continued) Condition Possible Sources Action DTC B2119 Compressor A/C inverter motor controller GO to Pinpoint Test C. • • • Failure (IMC). Circuit(s). • Interface adapter assembly • (IAA) module. A/C compressor.
Page 337 412-03-5 Air Conditioning 412-03-5 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST A: DTC P1461 A/C PRESSURE SENSOR CIRCUIT HIGH INPUT TEST STEP ACTION TO TAKE • Is the pressure above 345 kPa (50 psi)? No = CHECK the refrigerant system for leaks. REPAIR as necessary.
Page 338 412-03-6 Air Conditioning 412-03-6 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST B: DTC B1946 A/C POST EVAPORATOR SENSOR CIRCUIT FAILURE TEST STEP ACTION TO TAKE • Connect 104-Pin Breakout Box (BOB) to IAA module C1945; leave IAA Yes = GO to B4. module disconnected.
Page 339 412-03-7 Air Conditioning 412-03-7 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST C: DTC B2119 COMPRESSOR FAILURE TEST STEP ACTION TO TAKE C3 CHECK CIRCUIT 3232 (P) FOR OPEN • Connect 104-Pin Breakout Box (BOB) to interface adapter assembly Yes = REPLACE IAA module. (IAA) module C1945;...
Page 340 412-03-8 Air Conditioning 412-03-8 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST D: DTC B2518 COMPRESSOR OVERTEMPERATURE FAULT TEST STEP ACTION TO TAKE D1 CHECK FOR A/C TEMPERATURE SENSOR OUT OF RANGE FAULT • Check the interface adapter assembly (IAA) module for continuous Yes = GO to Pinpoint Test E.
Page 341 412-03-9 Air Conditioning 412-03-9 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST E: DTC B2606 A/C TEMPERATURE SENSOR OUT OF RANGE TEST STEP ACTION TO TAKE E1 CHECK FOR COMPRESSOR OVERTEMPERATURE FAULT GO to E2. • Check the interface adapter assembly (IAA) module for continuous Yes = diagnostic trouble codes (DTCs).
Page 342 412-03-10 Air Conditioning 412-03-10 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST F: A/C COMPRESSOR DOES NOT OPERATE (NO COOLING) TEST STEP ACTION TO TAKE F1 CHECK A/C LOW PRESSURE SWITCH GO to F2. • With key OFF, disconnect A/C low pressure switch C1973 and connect a Yes = jumper wire between the P wire and PK/LB wire on A/C low pressure switch C1973.
Page 343 412-03-11 Air Conditioning 412-03-11 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST F: A/C COMPRESSOR DOES NOT OPERATE (NO COOLING) TEST STEP ACTION TO TAKE • With key OFF, disconnect IAA module from BOB; leave BOB Yes = REPLACE the IAA module. connected to IAA module C1945.
Page 344 412-03-12 Air Conditioning 412-03-12 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST F: A/C COMPRESSOR DOES NOT OPERATE (NO COOLING) TEST STEP ACTION TO TAKE • With key OFF, reconnect A/C IMC C1947 and HVPDB A/C IMC Yes = REPLACE the A/C IMC. high-voltage C1917.
Page 345 412-03-13 Air Conditioning 412-03-13 REMOVAL AND INSTALLATION (Continued) 5. NOTE: The low-voltage electrical connector is shown, the high-voltage electrical connector is behind the A/C compressor. Disconnect the low and the high-voltage electrical connectors at the A/C compressor. 6. Disconnect the traction battery charger electrical connectors.
Page 346 • down with the compressor. Installation CAUTION: The compressor uses Polyolester oil meeting Ford specification WSS-M2C31-B. This oil is not compatible with any other A/C oil. If the service compressor has no warning tag/label, then it has a full production (system) charge of oil (170 cc) and the following steps must be followed.
Page 347 412-03-15 Air Conditioning 412-03-15 REMOVAL AND INSTALLATION (Continued) A/C Inverter Motor Controller Removal 1. Disconnect the traction battery auxiliary load high-voltage connector. Refer to Section 100-05. 2001 Ranger EV, 01/2001...
Page 348 412-03-16 Air Conditioning 412-03-16 REMOVAL AND INSTALLATION (Continued) 2. Clamp off and disconnect the coolant hoses. 3. Disconnect the two A/C inverter motor controller (IMC) electrical connectors. One on HVPDB — upper rear. • One on A/C IMC. • 4. Raise and support the vehicle. Refer to Section 100-02.
Page 349 412-03-17 Air Conditioning 412-03-17 REMOVAL AND INSTALLATION (Continued) Installation 1. To install, reverse the removal procedure. After installation, bleed the cooling system. • For additional information, refer to Section 303-03. 2001 Ranger EV, 01/2001...
Page 350: Control Components
412-04-1 Control Components 412-04-1 Manual Table of Contents SECTION 412-04 Control Components VEHICLE APPLICATION: Ranger EV CONTENTS PAGE SPECIFICATIONS ..................412-04-2 DESCRIPTION AND OPERATION Control Components .................. 412-04-2 REMOVAL AND INSTALLATION Interface Adapter Assembly (IAA) Module ............412-04-2 Positive Temperature Coefficient (PTC) Switching Module........412-04-4 Variable Blower Controller (VBC)..............
Page 351 412-04-2 Control Components 412-04-2 SPECIFICATIONS Torque Specifications Torque Specifications Description Lb/In Description Lb/In IAA electrical connector bolt 53.5 Auxiliary battery ground cable IAA mounting nuts Harness clamp nut 62.5 PTC module bolts High voltage power VBC screws distribution box cover screws (Continued) DESCRIPTION AND OPERATION The interface adapter assembly (IAA) module is a...
Page 352 412-04-3 Control Components 412-04-3 REMOVAL AND INSTALLATION (Continued) 2. Disconnect the auxiliary battery ground cable. 3. Disconnect the interface adapter assembly (IAA) module electrical connector. 1 Loosen the connector bolt. 2 Remove the harness bracket nut. 3 Disconnect the connector. 4.
Page 353 412-04-4 Control Components 412-04-4 REMOVAL AND INSTALLATION (Continued) 2. Connect the IAA module electrical connector. 1 Connect the electrical connector. 2 Tighten the connector bolt. 3 Install the harness clamp nut. 3. Connect the auxiliary battery ground cable. Positive Temperature Coefficient (PTC) Switching Module Removal NOTE: Electric Ranger shown, Postal Ranger EV similar.
Page 354 412-04-5 Control Components 412-04-5 REMOVAL AND INSTALLATION (Continued) 4. Remove the positive temperature coefficient (PTC) switching module. 1 Disconnect the electrical connectors. 2 Remove the bolts. 3 Remove the module. Installation 1. To install, reverse the removal procedure. Variable Blower Controller (VBC) Removal and Installation 1.
Page 355 412-04-6 Control Components 412-04-6 REMOVAL AND INSTALLATION (Continued) 2. Disconnect the auxiliary battery ground cable. 3. Disconnect the Variable Blower Controller (VBC) electrical connector. 4. Remove the VBC. 1 Remove the mounting screws. 5. To install, reverse the removal procedure. 2001 Ranger EV, 01/2001...
Page 356: Instrument Cluster
413-01-1 Instrument Cluster 413-01-1 Manual Table of Contents SECTION 413-01 Instrument Cluster VEHICLE APPLICATION: Ranger EV CONTENTS PAGE DESCRIPTION AND OPERATION Gauges and Warning Lamps ................ 413-01-2 Indicator Bulbs ..................413-01-6 DIAGNOSIS AND TESTING Instrument Cluster ..................413-01-7 Electrical Schematic ................413-01-7 Inspection and Verification ................
Page 357 413-01-2 Instrument Cluster 413-01-2 DESCRIPTION AND OPERATION The economy gauge indicates current vehicle energy Gauges and Warning Lamps usage. Rapid acceleration and heavy use of vehicle The instrument cluster for the Electric Ranger accessories will cause the gauge to read towards the contains specific and unique gauges for the vehicle.
Page 358 413-01-3 Instrument Cluster 413-01-3 DESCRIPTION AND OPERATION (Continued) The speedometer indicates the vehicle’s speed in The temperature gauge is controlled by the IAA both miles per hour (mph) and kilometers per hour module. The gauge indicates to the operator the (km/h).
Page 359 413-01-4 Instrument Cluster 413-01-4 DESCRIPTION AND OPERATION (Continued) The charge indicator illuminates when the key is turned to the RUN or START position while the vehicle is connected to the power control station (PCS). If the lamp flashes when the key is in the RUN position, the BCM has detected a vehicle malfunction and the traction battery cannot be charged.
Page 360 413-01-5 Instrument Cluster 413-01-5 DESCRIPTION AND OPERATION (Continued) The electrical hazard warning indicator (LED) will illuminate if the BCM detects current leakage, or if one of the high-voltage interlocks in the traction bus or the auxiliary high-voltage bus is open. The electrical hazard warning indicator will also flash and the malfunction indicator lamp (MIL) will illuminate if the BCM detects an improperly closed...
Page 361 413-01-6 Instrument Cluster 413-01-6 DESCRIPTION AND OPERATION (Continued) The economy mode indicator indicates that the gear The power reset indicator indicates that the inertia selector has been switched into the E (Economy) switch has been tripped and all high voltage has position.
Page 362 413-01-7 Instrument Cluster 413-01-7 DESCRIPTION AND OPERATION (Continued) Item Description Item Description ABS Warning Indicator Low Oil Pressure Indicator Malfunction Indicator Lamp (MIL) Auxiliary Battery Indicator Low State of Charge (SOC) Indicator Power Limit Warning Indicator Seat Belt Indicator Cluster Illumination Cluster Illumination Charge Indicator Hi Beam Indicator...
Page 363 413-01-8 Instrument Cluster 413-01-8 DIAGNOSIS AND TESTING (Continued) Symptom Chart Symptom Chart Condition Possible Sources Action Speedometer, Malfunction Fuse 1 (10A) (I/P fuse panel). CHECK 10A fuse 1. • • • Indicator Lamp (MIL), Power Circuit 742 (LB wire). REPLACE if necessary. If •...
Page 364 413-01-9 Instrument Cluster 413-01-9 DIAGNOSIS AND TESTING (Continued) Symptom Chart (Continued) Condition Possible Sources Action Traction Battery State of Instrument cluster. GO to Pinpoint Test C. • • • Charge (SOC) Gauge Does Interface adapter assembly • Not Operate, Indicates (IAA) module.
Page 365 413-01-10 Instrument Cluster 413-01-10 DIAGNOSIS AND TESTING (Continued) Symptom Chart (Continued) Condition Possible Sources Action Low Oil Pressure Warning Interface adapter assembly GO to Pinpoint Test P. • • • Indicator Does Not Operate (IAA) module. or Stays On Continuously Bulb.
Page 366 413-01-11 Instrument Cluster 413-01-11 DIAGNOSIS AND TESTING (Continued) Symptom Chart (Continued) Condition Possible Sources Action Seat Belt Indicator Does Not Generic electronic module GO to Pinpoint Test Z. • • • Operate Properly (GEM). Bulb. • Instrument cluster. • Circuit(s). •...
Page 367 413-01-12 Instrument Cluster 413-01-12 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST B: SPEEDOMETER DOES NOT OPERATE OR INDICATES INCORRECT VEHICLE SPEED TEST STEP ACTION TO TAKE • Enter the TIM active command mode SPEEDOMETER CONTROL and No = GO to B4. set the active command SPDOMETER to 30%.
Page 368 413-01-13 Instrument Cluster 413-01-13 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST C: TRACTION BATTERY STATE OF CHARGE (SOC) GAUGE DOES NOT OPERATE, INDICATES THE INCORRECT SOC, OR ALWAYS INDICATES F (FULL) TEST STEP ACTION TO TAKE • Enter the interface adapter assembly (IAA) module active command Yes = GO to C3.
Page 369 413-01-14 Instrument Cluster 413-01-14 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST D: TEMPERATURE GAUGE DOES NOT OPERATE PROPERLY OR ALWAYS INDICATES H (HOT) TEST STEP ACTION TO TAKE D1 IDENTIFY SYMPTOM NOTE: Do not carry out the following tests steps if interface adapter GO to D6.
Page 370 413-01-15 Instrument Cluster 413-01-15 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST D: TEMPERATURE GAUGE DOES NOT OPERATE PROPERLY OR ALWAYS INDICATES H (HOT) TEST STEP ACTION TO TAKE D9 CHECK INSTRUMENT CLUSTER • With key OFF, reconnect instrument cluster C214, C215. Yes = REPLACE the IAA module.
Page 371 413-01-16 Instrument Cluster 413-01-16 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST E: ECONOMY GAUGE DOES NOT OPERATE PROPERLY OR ALWAYS INDICATES + (POSITIVE) TEST STEP ACTION TO TAKE E7 CHECK GROUND TO INSTRUMENT CLUSTER • With key OFF, measure the resistance between pin 6 (BK/W wire) on Yes = REPAIR circuit 584 (Y instrument cluster C215 and ground.
Page 372 413-01-17 Instrument Cluster 413-01-17 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST F: DISTANCE TO EMPTY (DTE) GAUGE DOES NOT OPERATE OR INDICATES INCORRECT DISTANCE TO EMPTY TEST STEP ACTION TO TAKE • Enter the active command mode DISTANCE TO EMPTY GAUGE and No = REPAIR the Y/W wire set the active command DTE G to 30%.
Page 373 413-01-18 Instrument Cluster 413-01-18 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST G: MOTOR ENABLED GAUGE DOES NOT OPERATE OR INDICATES WAY ABOVE THE ON MARK TEST STEP ACTION TO TAKE • With key OFF, disconnect the IAA module from the BOB; leave BOB Yes = REPLACE the IAA module.
Page 374 413-01-19 Instrument Cluster 413-01-19 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST H: MALFUNCTION INDICATOR LAMP (MIL) DOES NOT OPERATE OR STAYS ON CONTINUOUSLY TEST STEP ACTION TO TAKE H4 CHECK MIL BULB GO to H5. • With key OFF, remove and check the MIL bulb. Yes = •...
Page 375 413-01-20 Instrument Cluster 413-01-20 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST J: POWER RESET INDICATOR DOES NOT OPERATE OR STAYS ON CONTINUOUSLY TEST STEP ACTION TO TAKE • With key OFF, connect a jumper wire between BOB pin 9 and ground No = GO to J4.
Page 376 413-01-21 Instrument Cluster 413-01-21 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST K: CHARGE INDICATOR DOES NOT OPERATE OR STAYS ON CONTINUOUSLY TEST STEP ACTION TO TAKE • With key OFF, connect a jumper wire between BOB pin 10 and ground No = GO to K4.
Page 377 413-01-22 Instrument Cluster 413-01-22 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST L: ECONOMY MODE INDICATOR DOES NOT OPERATE OR STAYS ON CONTINUOUSLY TEST STEP ACTION TO TAKE • With key OFF, remove and check the economy mode indicator bulb. Yes = GO to L5.
Page 378 413-01-23 Instrument Cluster 413-01-23 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST M: AUXILIARY BATTERY INDICATOR DOES NOT OPERATE OR STAYS ON CONTINUOUSLY TEST STEP ACTION TO TAKE • Does the auxiliary battery indicator illuminate? No = GO to M3. M3 CHECK AUXILIARY BATTERY INDICATOR CONTROL CIRCUIT •...
Page 379 413-01-24 Instrument Cluster 413-01-24 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST N: POWER LIMIT WARNING INDICATOR DOES NOT OPERATE OR STAYS ON CONTINUOUSLY TEST STEP ACTION TO TAKE N1 IDENTIFY SYMPTOM NOTE: Verify no diagnostic trouble codes (DTCs) exist and the traction GO to N8.
Page 380 413-01-25 Instrument Cluster 413-01-25 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST P: LOW OIL PRESSURE INDICATOR DOES NOT OPERATE OR STAYS ON CONTINUOUSLY TEST STEP ACTION TO TAKE P1 IDENTIFY SYMPTOM NOTE: Verify no diagnostic trouble codes (DTCs) exist and there is no GO to P8.
Page 381 413-01-26 Instrument Cluster 413-01-26 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST Q: ELECTRICAL HAZARD WARNING INDICATOR DOES NOT OPERATE OR STAYS ON CONTINUOUSLY TEST STEP ACTION TO TAKE Q1 IDENTIFY SYMPTOM NOTE: Verify no diagnostic trouble codes (DTCs) exist and the vehicle is GO to Q8.
Page 382 413-01-27 Instrument Cluster 413-01-27 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST R: LOW STATE OF CHARGE (SOC) INDICATOR DOES NOT OPERATE OR STAYS ON CONTINUOUSLY TEST STEP ACTION TO TAKE R1 IDENTIFY SYMPTOM NOTE: Verify no diagnostic trouble codes (DTCs) exist and the traction GO to R8.
Page 383 413-01-28 Instrument Cluster 413-01-28 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST S: RED BRAKE WARNING INDICATOR DOES NOT OPERATE OR STAYS ON CONTINUOUSLY TEST STEP ACTION TO TAKE S1 IDENTIFY SYMPTOM NOTE: Verify no diagnostic trouble codes (DTCs) exist and there are no GO to S13.
Page 384 413-01-29 Instrument Cluster 413-01-29 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST S: RED BRAKE WARNING INDICATOR DOES NOT OPERATE OR STAYS ON CONTINUOUSLY TEST STEP ACTION TO TAKE • With key ON, depress the park brake pedal. Yes = GO to S12. •...
Page 385 413-01-30 Instrument Cluster 413-01-30 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST T: HI BEAM INDICATOR DOES NOT OPERATE TEST STEP ACTION TO TAKE • Turn the headlamp switch to the ON position, set the multi-function No = REPAIR the LG/BK wire. switch to the high beam position and measure the voltage between pin 1 (LG/BK wire) on instrument cluster C216 and ground.
Page 386 413-01-31 Instrument Cluster 413-01-31 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST W: INSTRUMENT CLUSTER ILLUMINATION LAMPS DO NOT OPERATE TEST STEP ACTION TO TAKE W1 CHECK CIRCUIT 19 (LB/R) FOR OPEN(S) GO to W2. • With key OFF, disconnect instrument illumination dimming module Yes = C204 and instrument cluster C214 and C215.
Page 387 413-01-32 Instrument Cluster 413-01-32 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST Y: DOOR AJAR INDICATOR DOES NOT OPERATE PROPERLY TEST STEP ACTION TO TAKE Y1 CHECK IGNITION SWITCH STATES GO to Y2. • Use New Generation STAR (NGS) Tester to monitor the PID Yes = IGN GEM while turning the ignition switch through the START, RUN, OFF and ACC positions.
Page 388 413-01-33 Instrument Cluster 413-01-33 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST Y: DOOR AJAR INDICATOR DOES NOT OPERATE PROPERLY TEST STEP ACTION TO TAKE • With key ON, measure the voltage between pin 1 (LB wire), pin 12 (LB Yes = GO to Y6.
Page 389 413-01-34 Instrument Cluster 413-01-34 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST Z: SEAT BELT INDICATOR DOES NOT OPERATE PROPERLY TEST STEP ACTION TO TAKE • With key ON, verify the seat belt warning chime operation. Yes = GO to Z4. • Does the seat belt warning chime operate? REFER to Section 413-09 of No = the 2001 Ranger Workshop...
Page 390 413-01-35 Instrument Cluster 413-01-35 REMOVAL AND INSTALLATION Instrument Cluster —Postal Ranger EV Removal and Installation 1. Disconnect the auxiliary battery ground cable. 2. Remove the eight instrument panel screws. 3. Remove the bolt, disconnect the gear indicator cable and position aside. 4.
Page 391 413-01-36 Instrument Cluster 413-01-36 REMOVAL AND INSTALLATION (Continued) 5. Disconnect the electrical connector. 6. Disconnect the heater control electrical and vacuum connectors. 7. Remove the bolt. 8. NOTE: The foam seal around the RH register vent may come off with the instrument panel. If this happens, install a new foam seal.
Page 392 413-01-37 Instrument Cluster 413-01-37 REMOVAL AND INSTALLATION (Continued) 9. To install, reverse the removal procedure. Make sure the register vents move properly • side to side after installation. 2001 Ranger EV, 01/2001...
Page 393: Auxiliary Battery Charging
414-02-1 Auxiliary Battery Charging 414-02-1 Manual Table of Contents SECTION 414-02 Auxiliary Battery Charging VEHICLE APPLICATION: Ranger EV CONTENTS PAGE SPECIFICATIONS ..................414-02-2 DESCRIPTION AND OPERATION Auxiliary Battery Charging ................414-02-2 DIAGNOSIS AND TESTING Auxiliary Battery Charging ................414-02-2 Electrical Schematic ................414-02-3 Inspection and Verification ................
Page 394 414-02-2 Auxiliary Battery Charging 414-02-2 SPECIFICATIONS Torque Specifications Torque Specifications Description Lb-In Description Lb-In Ground Strap Nut Cable Nuts High Voltage Power Direct Current to Direct 80.5 Distribution Box (HVPDB) Current (DC/DC) Hold-Down Screws Bolts (Continued) DESCRIPTION AND OPERATION The DC/DC converter is capable of supplying up to 100 amps of current for operation of the vehicle’s Auxiliary Battery Charging 12-volt systems.
Page 395 414-02-3 Auxiliary Battery Charging 414-02-3 DIAGNOSIS AND TESTING (Continued) • DTC B1318 Battery Voltage - Low • DTC C1775 DC/DC Converter Failure — The interface adapter assembly (IAA) module — The interface adapter assembly (IAA) module monitors the auxiliary battery voltage at pins monitors the auxiliary battery voltage at pins 75, 76 (hot at all times).
Page 396 414-02-4 Auxiliary Battery Charging 414-02-4 DIAGNOSIS AND TESTING (Continued) Symptom Chart (Continued) Condition Possible Sources Action DTC C1775 DC/DC Circuit(s). GO to Pinpoint Test C. • • • Converter Failure MEGA fuse. • Auxiliary battery cables. • Direct current to direct •...
Page 397 414-02-5 Auxiliary Battery Charging 414-02-5 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST C: DTC C1775 DC/DC CONVERTER FAILURE TEST STEP ACTION TO TAKE C1 CHECK DC/DC CONVERTER OPERATION NOTE: Before proceeding, verify the power control station (PCS) is not Yes = System OK.
Page 398 414-02-6 Auxiliary Battery Charging 414-02-6 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST C: DTC C1775 DC/DC CONVERTER FAILURE TEST STEP ACTION TO TAKE • With key OFF, disconnect DC/DC converter C1943. No = REPLACE the IAA module. • With key ON, measure the voltage between BOB pin 100 and ground REFER to Section 412-04.
Page 399 414-02-7 Auxiliary Battery Charging 414-02-7 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST C: DTC C1775 DC/DC CONVERTER FAILURE TEST STEP ACTION TO TAKE • Measure the resistance between circuit 3117 (DB wire) and circuit 3118 Yes = GO to C14. (W wire) on HVPDB DC/DC converter C1914F. •...
Page 400 414-02-8 Auxiliary Battery Charging 414-02-8 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST D: AUXILIARY BATTERY WARNING INDICATOR ILLUMINATED (AUXILIARY BATTERY TEMPERATURE SENSOR FAILURE) TEST STEP ACTION TO TAKE • With key ON, measure the voltage between Y/R wire, DG/P wire on Yes = REPAIR the wire(s) in auxiliary temperature sensor C1953 and ground.
Page 401 414-02-9 Auxiliary Battery Charging 414-02-9 REMOVAL AND INSTALLATION DC/DC Converter Removal 1. Disconnect the traction battery high-voltage 2-pin connector. Refer to Section 100-05. WARNING: Do not remove the radiator pressure relief cap if the coolant is hot or if the pump is running. Turn the radiator pressure relief cap to the first stop to relieve any remaining pressure.
Page 402 414-02-10 Auxiliary Battery Charging 414-02-10 REMOVAL AND INSTALLATION (Continued) 5. Clamp off and disconnect the coolant lines at the DC/DC converter. 6. Remove the hold-down bolts and remove the converter. Installation 1. NOTE: There are two locating tabs on the lower back side of the DC/DC converter.
Page 403 414-02-11 Auxiliary Battery Charging 414-02-11 REMOVAL AND INSTALLATION (Continued) 2. Connect the DC/DC converter electrical connectors. 1 Position the electrical cross bar and install the ground strap nut. 2 Position the cable and install the nuts. 3 Connect the electrical connector. 3.
Page 404 414-03A-1 High Voltage/Traction Battery 414-03A-1 Manual Table of Contents SECTION 414-03A High Voltage/Traction Battery VEHICLE APPLICATION: Ranger EV CONTENTS PAGE SPECIFICATIONS ..................414-03A-3 DESCRIPTION AND OPERATION High Voltage/Traction Battery ..............414-03A-3 DIAGNOSIS AND TESTING Auxiliary Contactor Relay Control ..............414-03A-5 Electrical Schematic ................
Page 405 414-03A-2 High Voltage/Traction Battery 414-03A-2 CONTENTS PAGE Pinpoint Tests ..................414-03A-46 Symptom Chart ..................414-03A-45 Traction Battery Cooling/Ventilation System ...........414-03A-65 Electrical Schematic ................414-03A-65 Inspection and Verification ..............414-03A-65 Pinpoint Tests ..................414-03A-65 Symptom Chart ..................414-03A-65 Traction Battery System ................414-03A-68 Battery Module Diagnostic Test ...............414-03A-68 Electrical Schematic ................414-03A-70 Inspection and Verification ..............414-03A-70 Pinpoint Tests ..................414-03A-71...
Page 406: High Voltage/Traction Battery
414-03A-3 High Voltage/Traction Battery 414-03A-3 SPECIFICATIONS Torque Specifications Torque Specifications Description Lb-Ft Lb-In Description Lb-Ft Lb-In High-Voltage Power — A/C Inverter Motor — Distribution Box Bolts Control Bolts High-Voltage Power — Battery Control Module — Distribution Box Cover Multi-Pin Connector Screws Bolts High-Voltage Power...
Page 407 414-03A-4 High Voltage/Traction Battery 414-03A-4 DESCRIPTION AND OPERATION (Continued) Battery Controller Module (BCM) The traction battery contains 39 lead acid battery The BCM is a combination low and high-voltage modules, a battery controller module (BCM), a module that controls all traction battery system contactor box, a cooling system, a heating system, operations.
Page 408: Fuse
414-03A-5 High Voltage/Traction Battery 414-03A-5 DIAGNOSIS AND TESTING Electrical Schematic Refer to Electrical and Vacuum Troubleshooting Auxiliary Contactor Relay Control Manual, Cell 21, Contactor Box Relay Control for Diagnostic Trouble Code (DTC) Definition schematic and connector information. The following DTC relates to the control of the Inspection and Verification auxiliary contactor relay: Refer to...
Page 409 414-03A-6 High Voltage/Traction Battery 414-03A-6 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST A: DTC C1862 CONTACTOR CIRCUIT FAILURE TEST STEP ACTION TO TAKE A1 CHECK FOR INTERFACE ADAPTER ASSEMBLY (IAA) MODULE, TRACTION INVERTER MODULE (TIM), AND BATTERY CONTROL MODULE (BCM) DIAGNOSTIC TROUBLE CODES (DTCs) NOTE: Do not go to test step A2 unless there is a multiple auxiliary load Yes =...
Page 410 414-03A-7 High Voltage/Traction Battery 414-03A-7 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST A: DTC C1862 CONTACTOR CIRCUIT FAILURE TEST STEP ACTION TO TAKE • Enter IAA module active command mode AUXILIARY SYSTEM Yes = System OK. CHECK wiring CONTROL, monitor IAA module PID AUX HVC, and set the active for intermittent connections.
Page 411 414-03A-8 High Voltage/Traction Battery 414-03A-8 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST A: DTC C1862 CONTACTOR CIRCUIT FAILURE TEST STEP ACTION TO TAKE • Remove the traction battery and connect Traction Battery High-Voltage No = REPLACE the contactor Lockout and Diagnostic Tool to traction battery high-voltage two-pin box.
Page 412 414-03A-9 High Voltage/Traction Battery 414-03A-9 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST A: DTC C1862 CONTACTOR CIRCUIT FAILURE TEST STEP ACTION TO TAKE A18 CHECK CIRCUITS 3998 (GY) AND 3999 (DB/LG) BETWEEN IAA MODULE AND TRACTION BATTERY SUPPORT TRAY FOR OPEN(S) GO to A19.
Page 413: Fuse
414-03A-10 High Voltage/Traction Battery 414-03A-10 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST A: DTC C1862 CONTACTOR CIRCUIT FAILURE TEST STEP ACTION TO TAKE A23 CHECK CONTACTOR BOX HIGH-VOLTAGE FUSE • Remove the 40A AUX fuse from the contactor box. Refer to Contactor Yes = REPLACE the 40A AUX Box Fuses Removal and Installation procedure in this section.
Page 414: Fuse
414-03A-11 High Voltage/Traction Battery 414-03A-11 DIAGNOSIS AND TESTING (Continued) Symptom Chart Symptom Chart Condition Possible Sources Action DTC B1676 Battery Pack Contactor box. GO to Pinpoint Test A. • • • Voltage Out of Range Circuit(s). • Traction inverter module •...
Page 415 414-03A-12 High Voltage/Traction Battery 414-03A-12 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST A: DTC B1676 BATTERY PACK VOLTAGE OUT OF RANGE TEST STEP ACTION TO TAKE • With key OFF, disconnect traction battery support tray in-line C1939 and Yes = GO to A3. connect 104-Pin Breakout Box (BOB) to traction battery support tray in-line C1939M using Traction Battery Low-Voltage Service Cord;...
Page 416 414-03A-13 High Voltage/Traction Battery 414-03A-13 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST A: DTC B1676 BATTERY PACK VOLTAGE OUT OF RANGE TEST STEP ACTION TO TAKE A8 CHECK CIRCUIT 3986 (DG) BETWEEN TIM AND TRACTION BATTERY SUPPORT TRAY FOR SHORT TO GROUND •...
Page 417 414-03A-14 High Voltage/Traction Battery 414-03A-14 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST B: DTC C1862 CONTACTOR CIRCUIT FAILURE TEST STEP ACTION TO TAKE If other BCM DTCs occur, REFER to the BCM DTC Index in Section 100-07. B2 CHECK FOR TRACTION INVERTER MODULE (TIM) PRECHARGE FAULT GO to B3.
Page 418 414-03A-15 High Voltage/Traction Battery 414-03A-15 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST B: DTC C1862 CONTACTOR CIRCUIT FAILURE TEST STEP ACTION TO TAKE • With key OFF, measure the resistance between BOB pin 22 and ground Yes = REPLACE the contactor (BOB pin 65).
Page 419 414-03A-16 High Voltage/Traction Battery 414-03A-16 DIAGNOSIS AND TESTING (Continued) Electrical Schematic Negative Contactor Relay Control Refer to Electrical and Vacuum Troubleshooting Diagnostic Trouble Code (DTC) Definition Manual, Cell 21, Contactor Box Relay Control for The following DTC relates to the negative contactor schematic and connector information.
Page 420 414-03A-17 High Voltage/Traction Battery 414-03A-17 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST A: DTC C1862 CONTACTOR CIRCUIT FAILURE TEST STEP ACTION TO TAKE A1 CHECK STATUS OF BATTERY CONTROL MODULE (BCM) OPERATING STATE If 106, GO to A2. • Connect the vehicle to the power control station (PCS) and press the Yes = START button (if necessary) to begin charging.
Page 421 414-03A-18 High Voltage/Traction Battery 414-03A-18 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST A: DTC C1862 CONTACTOR CIRCUIT FAILURE TEST STEP ACTION TO TAKE • Connect Traction Battery High-Voltage Service Cord to traction battery No = GO to A5. support tray in-line C1935F and in-line C1935M. •...
Page 422: Fuse
414-03A-19 High Voltage/Traction Battery 414-03A-19 DIAGNOSIS AND TESTING (Continued) Symptom Chart Symptom Chart Condition Possible Sources Action DTC B2517 Emergency Fuse. GO to Pinpoint Test A. • • • Power Off System Faulted Interface adapter assembly • (IAA) module. Circuit(s). •...
Page 423 414-03A-20 High Voltage/Traction Battery 414-03A-20 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST A: DTC B2517 EMERGENCY POWER OFF SYSTEM FAULTED TEST STEP ACTION TO TAKE • With key OFF, disconnect traction battery support tray in-line C1939 and No = REMOVE the traction connect BOB to traction battery support tray in-line C1939F and in-line battery and REPAIR circuit C1939M using Traction Battery Low-Voltage Service Cord.
Page 424 414-03A-21 High Voltage/Traction Battery 414-03A-21 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST A: DTC B2517 EMERGENCY POWER OFF SYSTEM FAULTED TEST STEP ACTION TO TAKE WARNING: The traction battery contains high-voltage components and wiring. High-voltage insulated safety gloves and face shield must be worn when performing the following steps. Failure to follow this warning may result in severe personal injury or death.
Page 425 414-03A-22 High Voltage/Traction Battery 414-03A-22 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST B: VEHICLE WILL NOT START (POWER RESET INDICATOR ILLUMINATED) TEST STEP ACTION TO TAKE B1 CHECK FOR ACTIVATED INERTIA SWITCH • Check the inertia switch. Yes = RESET the inertia switch. •...
Page 426 414-03A-23 High Voltage/Traction Battery 414-03A-23 DIAGNOSIS AND TESTING (Continued) Symptom Chart Symptom Chart Condition Possible Sources Action DTC C1835 Current Sense Circuit(s). GO to Pinpoint Test A. • • • Circuit Failure Contactor box. • Battery control module • (BCM). Special Tool(s) Pinpoint Tests Traction Battery High-Voltage Service Cord 418-F218...
Page 427 414-03A-24 High Voltage/Traction Battery 414-03A-24 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST A: DTC C1835 CURRENT SENSE CIRCUIT FAILURE TEST STEP ACTION TO TAKE No = GO to A5. WARNING: The traction battery contains high-voltage components and wiring. High-voltage insulated safety gloves and face shield must be worn when performing the following steps.
Page 428 414-03A-25 High Voltage/Traction Battery 414-03A-25 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST A: DTC C1835 CURRENT SENSE CIRCUIT FAILURE TEST STEP ACTION TO TAKE • With key OFF, measure the resistance of the DB wire between pin 15 on No = REPAIR the wire(s) in contactor box C1982 and BOB pin A15.
Page 429 414-03A-26 High Voltage/Traction Battery 414-03A-26 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST A: DTC C1835 CURRENT SENSE CIRCUIT FAILURE TEST STEP ACTION TO TAKE • Is the resistance less than 5 ohms? No = REPAIR the LB/BK wire. A17 CHECK CIRCUIT 3138 (LB/BK) FOR SHORT TO GROUND •...
Page 430 414-03A-27 High Voltage/Traction Battery 414-03A-27 DIAGNOSIS AND TESTING (Continued) Symptom Chart Symptom Chart Condition Possible Sources Action DTC C1839 Leakage Fault High-voltage harness GO to Pinpoint Test A. • • • (10B694). High-voltage harness(es) • (14A280). Battery control module • (BCM).
Page 431 414-03A-28 High Voltage/Traction Battery 414-03A-28 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST A: DTC C1839 LEAKAGE FAULT TEST STEP ACTION TO TAKE • Does the LEAK CF PID indicate YES? No = CLEAR the BCM DTCs. DRIVE the vehicle. If the electrical hazard warning indicator illuminates and DTC C1839 still occurs,...
Page 432 414-03A-29 High Voltage/Traction Battery 414-03A-29 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST A: DTC C1839 LEAKAGE FAULT TEST STEP ACTION TO TAKE • With key OFF, measure the resistance between the DB wire on in-line Yes = CLEAR the BCM DTCs. C1885F and battery module 39 positive (+) post.
Page 433 414-03A-30 High Voltage/Traction Battery 414-03A-30 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST A: DTC C1839 LEAKAGE FAULT TEST STEP ACTION TO TAKE • Turn the ignition key to the START position, set the gear selector lever No = If vehicle is equipped with A/C, GO to A12 .
Page 434 414-03A-31 High Voltage/Traction Battery 414-03A-31 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST A: DTC C1839 LEAKAGE FAULT TEST STEP ACTION TO TAKE • With key OFF, disconnect high-voltage auxiliary load in-line C1935 on Yes = GO to A24 (leakage is in the traction battery support tray.
Page 435 414-03A-32 High Voltage/Traction Battery 414-03A-32 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST A: DTC C1839 LEAKAGE FAULT TEST STEP ACTION TO TAKE • Reinstall the HVPDB cover. No = REPLACE the DC/DC • With key ON, monitor BCM PID LEAKRES. converter. REFER to Section •...
Page 436 414-03A-33 High Voltage/Traction Battery 414-03A-33 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST A: DTC C1839 LEAKAGE FAULT TEST STEP ACTION TO TAKE NOTE: If there is no continuity between the indicated battery module and No = REPLACE the contactor chassis ground, check for continuity between chassis ground and the box.
Page 437 414-03A-34 High Voltage/Traction Battery 414-03A-34 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST A: DTC C1839 LEAKAGE FAULT TEST STEP ACTION TO TAKE • With key ON, monitor BCM PID LEAK ID and note the indicated Yes = REPLACE high-voltage battery module. harness (10B694) and/or the high-voltage harness (14A280) in question.
Page 438 414-03A-35 High Voltage/Traction Battery 414-03A-35 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST A: DTC C1839 LEAKAGE FAULT TEST STEP ACTION TO TAKE • With key ON, monitor BCM PIDs LKRESB+ and LKRESB-. No = REPLACE the • Wait approximately 50 seconds. motor/transaxle.
Page 439 414-03A-36 High Voltage/Traction Battery 414-03A-36 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST A: DTC C1839 LEAKAGE FAULT TEST STEP ACTION TO TAKE • With key OFF, disconnect power steering assembly high-voltage C1895. No = REPLACE the power • Connect Power Steering Interlock Tool to power steering assembly steering assembly.
Page 440 414-03A-37 High Voltage/Traction Battery 414-03A-37 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST A: DTC C1839 LEAKAGE FAULT TEST STEP ACTION TO TAKE NOTE: The ignition key must be in the OFF position when performing Yes = GO to A58 (leakage is in this test step and you must wait approximately three minutes for the contactor box or battery results.
Page 441 414-03A-38 High Voltage/Traction Battery 414-03A-38 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST A: DTC C1839 LEAKAGE FAULT TEST STEP ACTION TO TAKE • With key OFF, disconnect high-voltage auxiliary load in-line C1935 on Yes = GO to A55 (leakage is in the traction battery support tray.
Page 442 414-03A-39 High Voltage/Traction Battery 414-03A-39 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST A: DTC C1839 LEAKAGE FAULT TEST STEP ACTION TO TAKE • With key ON, monitor BCM PID LEAK ID and note the indicated Yes = REPLACE high-voltage battery module. harness (10B694) and/or the high-voltage harness (14A280) in question.
Page 443 414-03A-40 High Voltage/Traction Battery 414-03A-40 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST A: DTC C1839 LEAKAGE FAULT TEST STEP ACTION TO TAKE A63 CHECK FOR CURRENT LEAKAGE IN A/C IMC GO to A64. • With key OFF, remove the high-voltage power distribution box Yes = (HVPDB) cover and disconnect HVPDB C1917 (to A/C IMC).
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414-03A-41 High Voltage/Traction Battery 414-03A-41 DIAGNOSIS AND TESTING (Continued) Symptom Chart Symptom Chart Condition Possible Sources Action DTC C1446 Brake Switch Fuse. GO to Pinpoint Test A. • • • Circuit Failure Circuit(s). • Traction inverter module • (TIM). Brake pedal position (BPP) •...
Page 445 414-03A-42 High Voltage/Traction Battery 414-03A-42 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST A: DTC C1446 BRAKE SWITCH CIRCUIT FAILURE TEST STEP ACTION TO TAKE A5 CHECK MASTER CYLINDER PRESSURE STATUS • With key ON, monitor the TIM PID MC PRES while depressing the Yes = System OK.
Page 446 414-03A-43 High Voltage/Traction Battery 414-03A-43 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST B: DTC C1849 MASTER CYLINDER PRESSURE OUT OF RANGE TEST STEP ACTION TO TAKE • With key ON, measure the resistance between BOB pin B22 and ground Yes = REPLACE the master (BOB pin A29).
Page 447 414-03A-44 High Voltage/Traction Battery 414-03A-44 DIAGNOSIS AND TESTING (Continued) • DTC C1838 Charging System Fault signal indicates zero. — The battery control module (BCM) sets DTC — A charger mode fault occurs if the BCM C1838 when a failure occurs in the traction detects the charger mode signal is not being battery charging system.
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414-03A-45 High Voltage/Traction Battery 414-03A-45 DIAGNOSIS AND TESTING (Continued) Electrical Schematic Inspection and Verification Refer to Electrical and Vacuum Troubleshooting Refer to Section 100-07. Manual, Cell 18, Traction Battery Charging/Heating System for schematic and connector information. Symptom Chart Symptom Chart Condition Possible Sources Action...
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414-03A-46 High Voltage/Traction Battery 414-03A-46 DIAGNOSIS AND TESTING (Continued) Symptom Chart (Continued) Condition Possible Sources Action Charger Under Current Fault High voltage power GO to Pinpoint Test H. • • • distribution box (HVPDB). High-voltage harness • (14B326). Contactor box high-voltage •...
Page 450 414-03A-47 High Voltage/Traction Battery 414-03A-47 DIAGNOSIS AND TESTING (Continued) Special Tool(s) Traction Battery High-Voltage Lockout and Diagnostic Tool 418-F207 High-Voltage Insulated Safety Gloves 100-F036 or equivalent Face Shield 100-F035 or equivalent PINPOINT TEST A: DTC C1836 BATTERY TEMPERATURE OUT OF RANGE TEST STEP ACTION TO TAKE A1 CHECK FOR BATTERY TEMPERATURE SENSOR OUT OF...
Page 451 414-03A-48 High Voltage/Traction Battery 414-03A-48 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST A: DTC C1836 BATTERY TEMPERATURE OUT OF RANGE TEST STEP ACTION TO TAKE • With key OFF, disconnect lower rear pack temperature sensor #4 C1985 and measure the resistance of the BK/LB wire between BOB pin A26 and temperature sensor #4 C1985.
Page 452 414-03A-49 High Voltage/Traction Battery 414-03A-49 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST A: DTC C1836 BATTERY TEMPERATURE OUT OF RANGE TEST STEP ACTION TO TAKE • Connect Traction Battery Low-Voltage Service Cord to traction battery No = System OK. If DTC C1836 support tray in-line C1939F and in-line C1939M.
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414-03A-50 High Voltage/Traction Battery 414-03A-50 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST B: DTC C1837 BATTERY HEATER CIRCUIT FAILURE TEST STEP ACTION TO TAKE B4 CHECK CONTACTOR BOX HIGH-VOLTAGE FUSE • Remove the 10A HTR fuse from the contactor box. Refer to the Yes = REPLACE the 10A HTR Contactor Box Fuses Removal and Installation procedure in this section.
Page 454 414-03A-51 High Voltage/Traction Battery 414-03A-51 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST B: DTC C1837 BATTERY HEATER CIRCUIT FAILURE TEST STEP ACTION TO TAKE B10 CHECK LOWER BATTERY HEATER FOR OPEN GO to B12. • Remove the traction battery and connect Traction Battery High-Voltage Yes = Lockout and Diagnostic Tool to the traction battery high-voltage two-pin C3994M.
Page 455 414-03A-52 High Voltage/Traction Battery 414-03A-52 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST C: DTC C1838 CHARGER SYSTEM FAULT TEST STEP ACTION TO TAKE • Wait approximately five minutes and retrieve continuous DTCs from the No = System OK. BCM. • Does DTC C1838 Charging System Fault occur? C2 IDENTIFY CHARGING SYSTEM FAULT •...
Page 456 414-03A-53 High Voltage/Traction Battery 414-03A-53 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST D: CHARGER CHARGING AFTER BEING DISABLED FAULT TEST STEP ACTION TO TAKE • With key OFF, measure the resistance between BOB pin 57 and ground Yes = GO to D5. (BOB pin 65).
Page 457 414-03A-54 High Voltage/Traction Battery 414-03A-54 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST F: CHARGER LATCHUP FAULT TEST STEP ACTION TO TAKE NOTE: Wait approximately five minutes to allow the CHG OTF PID to No = DISCONNECT the PCS be set. from the vehicle. GO to F2. •...
Page 458 414-03A-55 High Voltage/Traction Battery 414-03A-55 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST G: CHARGER CYCLING FAULT TEST STEP ACTION TO TAKE • Wait approximately five minutes and retrieve continuous DTCs from the No = If DTC C1838 does not BCM. occur, system OK. If DTC •...
Page 459 414-03A-56 High Voltage/Traction Battery 414-03A-56 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST H: CHARGER UNDER CURRENT FAULT TEST STEP ACTION TO TAKE NOTE: Contactor box C3985 is mounted on the passenger side of the No = REPLACE high-voltage BCM. harness (14B326) between •...
Page 460 414-03A-57 High Voltage/Traction Battery 414-03A-57 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST H: CHARGER UNDER CURRENT FAULT TEST STEP ACTION TO TAKE NOTE: Measure the voltage immediately after pressing the START button No = GO to H12. on the PCS. If no voltage output, monitor the voltage for approximately two minutes.
Page 461 414-03A-58 High Voltage/Traction Battery 414-03A-58 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST J: CHARGER OVER CURRENT FAULT TEST STEP ACTION TO TAKE • Turn the A/C on and turn the steering wheel back and forth. No = GO to J2. • Does the amperage for the AUX CNT PID increase and decrease? J2 CHECK AUXILIARY CURRENT SENSOR VOLTAGE STATUS •...
Page 462 414-03A-59 High Voltage/Traction Battery 414-03A-59 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST M: CHARGER LINE CAPACITY FAULT TEST STEP ACTION TO TAKE • Connect the power control station (PCS) to the vehicle and the depress Yes = REPLACE the traction the START button to begin charging. battery charger.
Page 463 414-03A-60 High Voltage/Traction Battery 414-03A-60 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST N: CHARGER MODE FEEDBACK FAULT TEST STEP ACTION TO TAKE N6 CHECK CIRCUIT 3826 (W) (INSIDE OF TRACTION BATTERY SUPPORT TRAY) FOR SHORT TO GROUND • With key OFF, measure the resistance between BOB pin 38 and ground Yes = REPLACE the BCM.
Page 464 414-03A-61 High Voltage/Traction Battery 414-03A-61 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST P: DTC C1859 PRNDL INPUT #2 CIRCUIT FAILURE TEST STEP ACTION TO TAKE • With key OFF, disconnect traction battery support tray in-line C1939 and Yes = GO to P3. connect 104-Pin Breakout Box (BOB) to in-line C1939M using Traction Battery Low-Voltage Service Cord;...
Page 465 414-03A-62 High Voltage/Traction Battery 414-03A-62 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST Q: DTC C1861 PRNDL INPUT #4 CIRCUIT FAILURE TEST STEP ACTION TO TAKE No = REPAIR the Y wire. WARNING: The traction battery contains high-voltage components and wiring. High-voltage insulated safety gloves and face shield must be worn when performing the following steps.
Page 466 414-03A-63 High Voltage/Traction Battery 414-03A-63 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST R: DTC C1863 EXTERNAL CHARGING FAULT TEST STEP ACTION TO TAKE • Remove the traction battery and connect Traction Battery High-Voltage Yes = REPLACE the BCM. Lockout and Diagnostic Tool to the traction battery high-voltage two-pin C3994M.
Page 467 414-03A-64 High Voltage/Traction Battery 414-03A-64 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST T: POWER CONTROL STATION (PCS) OPERATION VERIFICATION TEST TEST STEP ACTION TO TAKE • Push the STOP button on the PCS. Yes = CHECK the PCS cable for signs of damage (cuts, tears, or breaks in the cable insulation).
Page 468 414-03A-65 High Voltage/Traction Battery 414-03A-65 DIAGNOSIS AND TESTING (Continued) Electrical Schematic Traction Battery Cooling/Ventilation Refer to Electrical and Vacuum Troubleshooting System Manual, Cell 19, Traction Battery Diagnostic Trouble Code (DTC) Definition Cooling/Ventilation for schematic and connector information. The following DTC relates to the traction battery cooling/ventilation system: Inspection and Verification •...
Page 469 414-03A-66 High Voltage/Traction Battery 414-03A-66 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST A: DTC B2513 BLOWER (FAN) CIRCUIT FAILURE TEST STEP ACTION TO TAKE NOTE: If an emergency power off (EPO) condition occurs, the fan power Yes = GO to A3. will be disabled.
Page 470 414-03A-67 High Voltage/Traction Battery 414-03A-67 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST A: DTC B2513 BLOWER (FAN) CIRCUIT FAILURE TEST STEP ACTION TO TAKE • Measure the resistance between pins 30 and 87 on the traction battery No = REPLACE the traction cooling fan relay.
Page 471 414-03A-68 High Voltage/Traction Battery 414-03A-68 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST A: DTC B2513 BLOWER (FAN) CIRCUIT FAILURE TEST STEP ACTION TO TAKE • With key OFF, disconnect BOB from BCM; leave BOB connected to Yes = REPLACE the traction BCM C1986, C1987.
Page 472 414-03A-69 High Voltage/Traction Battery 414-03A-69 DIAGNOSIS AND TESTING (Continued) — The traction inverter module (TIM) sets DTC Battery Module Diagnostic Test C1755 when the vehicle is shut down for one NOTE: This is a two-step process. Battery module of four reasons: the temperature protection voltage information must be recorded within five within the TIM has limited current to zero minutes of completing discharge of the traction...
Page 473 414-03A-70 High Voltage/Traction Battery 414-03A-70 DIAGNOSIS AND TESTING (Continued) • DTC C1864 Battery Module Fault • DTC B2236 Weak or Defective Electric Vehicle Battery Module Fault — The battery control module (BCM) monitors the 39 individual 8-volt traction battery — The battery control module (BCM) monitors modules through voltage sense lines.
Page 474 414-03A-71 High Voltage/Traction Battery 414-03A-71 DIAGNOSIS AND TESTING (Continued) Symptom Chart (Continued) Condition Possible Sources Action DTC C1864 Battery Module Battery module(s) installed GO to Pinpoint Test C. • • • Fault incorrectly (reverse cable polarity). Incorrect battery module • (12-volt) installed.
Page 475 414-03A-72 High Voltage/Traction Battery 414-03A-72 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST A: DTC C1755 POWER LIMIT SHUTDOWN FAULT TEST STEP ACTION TO TAKE Yes = Go to A5 WARNING: Make sure the cooling system temperature is not • hot. Failure to follow these instructions, may result in personal injury or death.
Page 476 414-03A-73 High Voltage/Traction Battery 414-03A-73 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST B: BATTERY PACK/MODULE(S) VOLTAGE OUT OF RANGE TEST STEP ACTION TO TAKE — 1: circuit 3089 (LB/W) between in-line C1882M (label R) and pin 13 on BCM C1865 — 1, 2: circuit 3072 (PIK/Y) between in-line C1884M (label A) and pin 19 on BCM C1865 —...
Page 477 414-03A-74 High Voltage/Traction Battery 414-03A-74 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST B: BATTERY PACK/MODULE(S) VOLTAGE OUT OF RANGE TEST STEP ACTION TO TAKE — 26, 27: circuit 3098 (R/Y) between in-line C1870M (label N) and pin 5 on BCM C1866 —...
Page 478 414-03A-75 High Voltage/Traction Battery 414-03A-75 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST B: BATTERY PACK/MODULE(S) VOLTAGE OUT OF RANGE TEST STEP ACTION TO TAKE — 7, 8: between circuit 3078 (LB/O) on in-line C1879F (label G) and battery module 7 (+) post —...
Page 479 414-03A-76 High Voltage/Traction Battery 414-03A-76 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST B: BATTERY PACK/MODULE(S) VOLTAGE OUT OF RANGE TEST STEP ACTION TO TAKE — 33, 34: between circuit 3205 (O/Y) on in-line C1878F (label T) and battery module 33 (+) post —...
Page 480 414-03A-77 High Voltage/Traction Battery 414-03A-77 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST B: BATTERY PACK/MODULE(S) VOLTAGE OUT OF RANGE TEST STEP ACTION TO TAKE WARNING: The traction battery contains high-voltage components and wiring. High-voltage insulated safety gloves and face shield must be worn when performing the following steps. Failure to follow this warning may result in severe personal injury or death.
Page 481 414-03A-78 High Voltage/Traction Battery 414-03A-78 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST C: DTC C1864 BATTERY MODULE FAULT TEST STEP ACTION TO TAKE • With key ON, monitor BCM PIDs BTM 1FT through BTM39FT. Yes = REMOVE the traction battery (if necessary) and REINSTALL (correctly) the battery module for the BTM FT that indicates...
Page 482 414-03A-79 High Voltage/Traction Battery 414-03A-79 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST E: BATTERY PACK/MODULE VERIFICATION TEST TEST STEP ACTION TO TAKE E1 PERFORM THE DIAGNOSTIC PROCESS NOTE: Verify the power control station (PCS) charger cord is not plugged Yes = REFER to the appropriate into the charger inlet before performing this test step.
Page 483 414-03A-80 High Voltage/Traction Battery 414-03A-80 DIAGNOSIS AND TESTING (Continued) Symptom Chart Symptom Chart Condition Possible Sources Action All High-Voltage Auxiliary High-voltage harness GO to Pinpoint Test A. • • • Load Systems Do Not (14B326). Operate High-voltage power • distribution box (HVPDB). Contactor box.
Page 484 414-03A-81 High Voltage/Traction Battery 414-03A-81 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST A: ALL HIGH-VOLTAGE AUXILIARY LOAD SYSTEMS DO NOT OPERATE TEST STEP ACTION TO TAKE WARNING: The traction battery contains high-voltage components and wiring. High-voltage insulated safety gloves and face shield must be worn when performing the following steps.
Page 485 414-03A-82 High Voltage/Traction Battery 414-03A-82 GENERAL PROCEDURES (Continued) 4. When the module reaches an 80% state of charge, the green light will start to flash while the red light is steadily lit. 5. When the module reaches 100% state of charge, the red light goes out and the green light will stop flashing and steadily illuminate.
Page 486 414-03A-83 High Voltage/Traction Battery 414-03A-83 GENERAL PROCEDURES (Continued) Module Replacement Times 1. The battery module replacement time for an upper-level battery module is 0.5 hours, not including traction battery removal and charge time. 2. The battery module replacement time for an lower-level battery module is 1.5 hours, not including traction battery removal and charge time.
Page 487 414-03A-84 High Voltage/Traction Battery 414-03A-84 GENERAL PROCEDURES (Continued) 7. NOTE: The Traction Battery High-Voltage Lockout and Diagnostic Tool connects to the two-pin high-voltage connector located at the rear of the traction battery. Install the Traction Battery High-Voltage Lockout and Diagnostic Tool. 8.
Page 488 414-03A-85 High Voltage/Traction Battery 414-03A-85 GENERAL PROCEDURES (Continued) 13. For upper-level battery modules, disconnect the heating element connector and the temperature sensor, if equipped. 14. NOTE: The tool fits into slots in the side of the battery module. Use the Battery Module Lifting Tool to remove the battery module(s).
Page 489 414-03A-86 High Voltage/Traction Battery 414-03A-86 GENERAL PROCEDURES (Continued) 18. Replace any components that were removed to gain access to the battery module(s) that were replaced. The traction battery must be assembled prior to charging. The battery modules are grouped as follows 1-7, 17-18, 19-21, 8-11, 34-39, 12-15 and 28-31, 16 and 25-27, and 22-24.
Page 490 414-03A-87 High Voltage/Traction Battery 414-03A-87 GENERAL PROCEDURES (Continued) 24. Connect the Traction Battery High-Voltage Service Cord to the high-voltage auxiliary load connector on the vehicle. 25. Connect the Traction Battery High-Voltage Service Cord to the traction battery high-voltage auxiliary load connector on the traction battery. 26.
Page 491 414-03A-88 High Voltage/Traction Battery 414-03A-88 GENERAL PROCEDURES (Continued) 28. Charge the traction battery to a full state of charge (SOC). Refer to Section 100-05. 29. After charging has been completed, press the button to deactivate the power control station (PCS). 30.
Page 492 414-03A-89 High Voltage/Traction Battery 414-03A-89 GENERAL PROCEDURES (Continued) 34. Unclip the necessary connectors from the separator plates above the In-Line Bypass Battery Module(s) to be replaced. 35. Remove the separator plates above the In-Line Bypass Battery Module(s) to be replaced. 36.
Page 493 414-03A-90 High Voltage/Traction Battery 414-03A-90 GENERAL PROCEDURES (Continued) 40. Replace the In-Line Bypass Battery Module(s) that were removed with new, charged, traction battery module(s). If necessary, charge the new battery modules prior to installation. Refer to Module Charging procedure in this section to determine battery module charging conditions.
Page 494 414-03A-91 High Voltage/Traction Battery 414-03A-91 GENERAL PROCEDURES (Continued) 49. Install any components that were removed to gain access to the In-Line Bypass Battery Module(s) that were replaced. The battery modules are grouped as follows 1-7, 17-18, 19-21, 8-11, 34-39, 12-15 and 28-31, 16 and 25-27, and 22-24.
Page 495 414-03A-92 High Voltage/Traction Battery 414-03A-92 GENERAL PROCEDURES (Continued) 53. Disconnect the Traction Battery Low-Voltage Service Cord from the 76-pin low-voltage connector on the vehicle. 54. Apply Locktite 242 (threadlock and sealer) to the 22 traction battery cover bolts. 55. Install the traction battery cover. Install the 22 bolts.
Page 496 414-03A-93 High Voltage/Traction Battery 414-03A-93 GENERAL PROCEDURES (Continued) Traction Battery Tray Repair Battery Tray 2001 Ranger EV, 01/2001...
Page 497 414-03A-94 High Voltage/Traction Battery 414-03A-94 GENERAL PROCEDURES (Continued) 1. NOTE: A composite material forms the actual housing of the traction battery. The composite material is a resin transfer molded (RTM) glass-reinforced thermoset plastic with an integral foam core. A split or scratch on the side or corner of the composite material can be repaired, as long as the damage does not pass all the way through the surface of the composite material.
Page 498 414-03A-95 High Voltage/Traction Battery 414-03A-95 GENERAL PROCEDURES (Continued) 4. To repair cracks less than 25 mm (1 in) in length, clean the area surrounding the damage prior to repair. After cleaning, grind a 20 degree bevel extending 40 to 50 mm (1.57 to 2 in) around the damage.
Page 499 414-03A-96 High Voltage/Traction Battery 414-03A-96 GENERAL PROCEDURES (Continued) 5. Immediately after grinding, apply the repair patch. Cut a piece of glass mat that will extend 25 mm (1 in) beyond the damaged area. Prepare a mixture of vinyl ester resin and soak the glass mat in it.
Page 500 414-03A-97 High Voltage/Traction Battery 414-03A-97 GENERAL PROCEDURES (Continued) 8. Allow the patched area to cure for at least 1.5 to 2 hours at 24°C (75°F). Curing will take longer at colder temperatures. A heat lamp placed no less than 45 cm (18 in) from the repair for approximately 15 minutes will help decrease cure time.
Page 501 414-03A-98 High Voltage/Traction Battery 414-03A-98 GENERAL PROCEDURES (Continued) 2. Remove damaged seal by pealing it away from the battery tray. 3. Scrape away any remaining seal pieces stuck to the battery tray. 4. Clean the area with alcohol. 5. Place the new seal on the battery tray by pealing back the white strip to expose the adhesive.
Page 502 414-03A-99 High Voltage/Traction Battery 414-03A-99 REMOVAL AND INSTALLATION (Continued) WARNING: The nominal voltage of the traction battery is 312 volts. The buffer zone must be set up and insulated rubber gloves and a face shield must be worn. Failure to follow these precautions may result in severe personal injury or death.
Page 503 414-03A-100 High Voltage/Traction Battery 414-03A-100 REMOVAL AND INSTALLATION (Continued) Installation CAUTION: Do not overtighten the BCM multi-pin connectors. Damage to the connectors may occur if overtightened. To install, reverse the removal procedure. Fill the area around the high-voltage jumper • nuts with Nyogel.
Page 504 414-03A-101 High Voltage/Traction Battery 414-03A-101 REMOVAL AND INSTALLATION (Continued) Charge Inlet Removal 1. NOTE: For Electric Ranger Only. Disconnect the traction battery auxiliary load high-voltage connector. Refer to Section 100-05. 2. Remove the grille. 1 Remove the four screws. 2 Remove the grille. 3.
Page 505 414-03A-102 High Voltage/Traction Battery 414-03A-102 REMOVAL AND INSTALLATION (Continued) 5. Remove the two charge bracket bolts. 6. Remove the charge inlet. 1 Loosen the two charge inlet bracket bolts. 2 Slide the charge inlet from behind the bolts and remove. Installation 1.
Page 506 414-03A-103 High Voltage/Traction Battery 414-03A-103 REMOVAL AND INSTALLATION (Continued) Contactor Box Special Tool(s) Battery Terminal Cap Opener 418-F215 Removal 1. Remove the traction battery. Refer to Traction Battery. 2001 Ranger EV, 01/2001...
Page 507 414-03A-104 High Voltage/Traction Battery 414-03A-104 REMOVAL AND INSTALLATION (Continued) 2. Remove the traction battery cover. 1 Remove the 22 bolts. 2 Remove the cover. WARNING: The nominal voltage of the traction battery is 312 volts. The buffer zone must be set up and insulated rubber gloves and a face shield must be worn.
Page 508 414-03A-105 High Voltage/Traction Battery 414-03A-105 REMOVAL AND INSTALLATION (Continued) 6. Disconnect the contactor box. 1 Disconnect the heating element harness. 2 Disconnect the low-voltage harness from the contactor box. 3 Pull the connectors off the contactor box. 7. Disconnect one HVJ from module 17. CAUTION: Disconnect only one HVJ at a time.
Page 509 414-03A-106 High Voltage/Traction Battery 414-03A-106 REMOVAL AND INSTALLATION (Continued) 11. Remove the contactor box. 1 Unclip the contactor box harness from the separator plate. 2 Remove the contactor box. Installation 1. To install, reverse the removal procedure. 1 Fill the high-voltage jumper connectors with Nyogel after final tightening of the nuts and bolts.
Page 510 414-03A-107 High Voltage/Traction Battery 414-03A-107 REMOVAL AND INSTALLATION (Continued) Contactor Box Fuses Removal 1. Remove the traction battery. Refer to Traction Battery. 2. Remove the traction battery cover. 1 Remove the 22 bolts. 2 Remove the cover. 2001 Ranger EV, 01/2001...
Page 511 414-03A-108 High Voltage/Traction Battery 414-03A-108 REMOVAL AND INSTALLATION (Continued) WARNING: The nominal voltage of the traction battery is 312 volts. The buffer zone must be set up and insulated rubber gloves and a face shield must be worn. Failure to follow these precautions may result in severe personal injury or death.
Page 512 414-03A-109 High Voltage/Traction Battery 414-03A-109 REMOVAL AND INSTALLATION (Continued) Installation 1. To install, reverse the removal procedure. Apply Locktite 242 to the 22 traction • battery cover bolts. HVPDB Fuses Removal 1. Disconnect the traction battery auxiliary load high-voltage connector. Refer to Section 100-05.
Page 513 414-03A-110 High Voltage/Traction Battery 414-03A-110 REMOVAL AND INSTALLATION (Continued) 3. Remove the HVPDB fuse safety cover. 1 Remove the two screws. 2 Remove the cover. 4. Use a fuse puller to remove the necessary fuse. 1 10A Power Steering Fuse 2 25A Positive Temperature Coefficient (PTC) Heater Fuse 3 25A A/C Fuse...
Page 514 414-03A-111 High Voltage/Traction Battery 414-03A-111 REMOVAL AND INSTALLATION (Continued) High Voltage Power Distribution Box (HVPDB) Removal 1. Remove the positive temperature coefficient (PTC) module. Refer to Section 412-04. 2. Disconnect the power steering pump electrical connector. 3. Disconnect the electrical connectors. 2001 Ranger EV, 01/2001...
Page 515 414-03A-112 High Voltage/Traction Battery 414-03A-112 REMOVAL AND INSTALLATION (Continued) 4. NOTE: The HVPDB power supply cable is held in position with three clips. Remove the HVPDB. 1 Remove the bolts. 2 Remove the HVPDB. Installation 1. To install, reverse the removal procedure. High Voltage Wiring —...
Page 516 414-03A-113 High Voltage/Traction Battery 414-03A-113 REMOVAL AND INSTALLATION (Continued) WARNING: The nominal voltage of the traction battery is 312 volts. The buffer zone must be set up and insulated rubber gloves and a face shield must be worn. Failure to follow these precautions may result in severe personal injury or death.
Page 517 414-03A-114 High Voltage/Traction Battery 414-03A-114 REMOVAL AND INSTALLATION (Continued) WARNING: Do not cut into the orange high-voltage wiring harness. CAUTION: Do not allow the zip tie to fall into the traction battery. Verify that all zip ties are removed from the traction battery.
Page 518 414-03A-115 High Voltage/Traction Battery 414-03A-115 REMOVAL AND INSTALLATION (Continued) 11. Unclip and disconnect the sense lead wiring. 12. Unclip and disconnect the sense lead wiring. 13. Unclip and disconnect the sense lead wiring. 14. Cut the two zip ties from the high-voltage harness.
Page 519 414-03A-116 High Voltage/Traction Battery 414-03A-116 REMOVAL AND INSTALLATION (Continued) 15. Disconnect the multi-pin connectors from the battery control module (BCM). Loosen the two bolts. • 16. Remove the high-voltage sense lead harness. Installation 1. To install, reverse the removal procedure. Apply Locktite 242 to the 22 traction •...
Page 520 414-03A-117 High Voltage/Traction Battery 414-03A-117 REMOVAL AND INSTALLATION (Continued) High Voltage Wiring Special Tool(s) Battery Terminal Cap Opener 418-F215 2001 Ranger EV, 01/2001...
Page 521 414-03A-118 High Voltage/Traction Battery 414-03A-118 REMOVAL AND INSTALLATION (Continued) High-Voltage Jumper Routing Removal 1. Remove the traction battery. Refer to Traction Battery. 2001 Ranger EV, 01/2001...
Page 522 414-03A-119 High Voltage/Traction Battery 414-03A-119 REMOVAL AND INSTALLATION (Continued) 2. Remove the traction battery cover. 1 Remove the 22 bolts. 2 Remove the cover. WARNING: The nominal voltage of the traction battery is 312 volts. The buffer zone must be set up and insulated rubber gloves and a face shield must be worn.
Page 523 414-03A-120 High Voltage/Traction Battery 414-03A-120 REMOVAL AND INSTALLATION (Continued) 7. Remove the HVJ. Use the Battery Terminal Cap Opener to • open the battery module caps. Remove and discard the two nuts. • Installation 1. To install, reverse the removal procedure. When installing the HVJ on the battery •...
Page 524 414-03A-121 High Voltage/Traction Battery 414-03A-121 REMOVAL AND INSTALLATION (Continued) WARNING: The nominal voltage of the traction battery is 312 volts. The buffer zone must be set up and insulated rubber gloves and a face shield must be worn. Failure to follow these precautions may result in severe personal injury or death.
Page 525 414-03A-122 High Voltage/Traction Battery 414-03A-122 REMOVAL AND INSTALLATION (Continued) 7. Position the lift table under the battery pack assembly. The narrow end of the pallet faces the front • of the vehicle. 8. Completely lower the lift table and then lower the vehicle until the battery pack is within 25.5 cm (10 in) of the lift table.
Page 526 414-03A-123 High Voltage/Traction Battery 414-03A-123 REMOVAL AND INSTALLATION (Continued) CAUTION: Do not adjust either regulator for more than 60 psi. NOTE: The lift table is designed to only lift the battery pack assembly. It will not lift the entire vehicle. Continue to lift the battery pack until the lift table system pressure equalizes and both gauges reach 60 psi.
Page 527 414-03A-124 High Voltage/Traction Battery 414-03A-124 REMOVAL AND INSTALLATION (Continued) 2. Position the lift table and battery pack under the vehicle. Connect the lift table to the shop air supply. • 3. With the assistance of a second person, carefully lower the vehicle down to within ten inches of the battery pack.
Page 528 414-03A-125 High Voltage/Traction Battery 414-03A-125 REMOVAL AND INSTALLATION (Continued) 8. NOTE: The bolt will break if the specified torque is exceeded. If this happens, pull the connector off the bolt stem and remove the broken bolt. Connect the 76-pin connector. 1 Position the connector.
Page 529 414-03A-126 High Voltage/Traction Battery 414-03A-126 REMOVAL AND INSTALLATION (Continued) 3. Remove the harness bracket. Remove the bolt. • 4. Remove the A/C inverter motor controller (IMC) bracket. 1 Remove the bolts. 2 Remove the bracket. 5. Remove the ground strap bolt. 6.
Page 530 414-03A-127 High Voltage/Traction Battery 414-03A-127 REMOVAL AND INSTALLATION (Continued) Installation 1. To install, reverse the removal procedure. 2001 Ranger EV, 01/2001...
Page 531 414-03A-128 High Voltage/Traction Battery 414-03A-128 REMOVAL AND INSTALLATION (Continued) Traction Battery Cooling/Ventilation Fan Removal 1. Remove the traction battery. Refer to Traction Battery. 2. Remove the traction battery cover. 1 Remove the 22 bolts. 2 Remove the cover. 3. Remove the traction battery cooling fan. 1 Disconnect the cooling fan electrical connector.
Page 532 414-03A-129 High Voltage/Traction Battery 414-03A-129 REMOVAL AND INSTALLATION (Continued) Installation 1. To install, reverse the removal procedure. 2001 Ranger EV, 01/2001...
Page 533 414-03A-130 High Voltage/Traction Battery 414-03A-130 REMOVAL AND INSTALLATION (Continued) Traction Battery Heating Elements (U/L) — Upper Removal 1. NOTE: If any of the upper battery modules are replaced, do NOT attempt to reinstall the original heating element. Always install a new Heating Element when installing a new replacement battery module.
Page 534 414-03A-131 High Voltage/Traction Battery 414-03A-131 REMOVAL AND INSTALLATION (Continued) Installation 1. The lower traction battery heating element is located in the bottom of the traction battery tray. The entire traction battery must be disassembled in order to remove and install the heating element.
Page 535 414-03A-132 High Voltage/Traction Battery 414-03A-132 REMOVAL AND INSTALLATION (Continued) 3. Remove the traction battery cover. 1 Remove the 22 bolts. 2 Remove the cover. 4. Position the high-voltage fuse aside. 1 Remove the nut. 2 Move the fuse up and out of the traction battery pack.
Page 536 414-03A-133 High Voltage/Traction Battery 414-03A-133 REMOVAL AND INSTALLATION (Continued) Installation 1. To install, reverse the removal procedure. Fill the area around the high-voltage fuse • bolts with Nyogel. Apply Locktite 242 to the 22 traction • battery cover bolts. Traction Battery Module — Modules 1-7 Removal 1.
Page 537 414-03A-134 High Voltage/Traction Battery 414-03A-134 REMOVAL AND INSTALLATION (Continued) Installation 1. The battery module replacement procedure also contains the battery module installation. Traction Battery Module — Modules 17-18 Removal 1. These two battery modules are located in the upper level near the front of the traction battery.
Page 538 414-03A-135 High Voltage/Traction Battery 414-03A-135 REMOVAL AND INSTALLATION (Continued) Traction Battery Module — Modules 8-11 Special Tool(s) Battery Module Lifting Tool SR-10009 Battery Post Torque Wrench 307-026 Removal WARNING: The nominal voltage of the traction battery is 312 volts. The buffer zone must be set up and insulated rubber gloves and a face shield must be worn.
Page 539 414-03A-136 High Voltage/Traction Battery 414-03A-136 REMOVAL AND INSTALLATION (Continued) Installation 1. The battery module replacement procedure also contains the battery module installation. 2. Install battery modules 4-6. Use the Battery Module Lifting Tool to • install the battery modules. Install and tighten new battery module nuts •...
Page 540 414-03A-137 High Voltage/Traction Battery 414-03A-137 REMOVAL AND INSTALLATION (Continued) Removal 1. Remove the contactor box. Refer to Contactor Box. WARNING: The nominal voltage of the traction battery is 312 volts. The buffer zone must be set up and insulated rubber gloves and a face shield must be worn.
Page 541 414-03A-138 High Voltage/Traction Battery 414-03A-138 REMOVAL AND INSTALLATION (Continued) 3. Fill the area around the high-voltage jumper nuts with Nyogel. 4. Install the contactor box. Refer to Contactor Box. Traction Battery Module — Modules 12-15, 28-31 Removal 1. The battery modules are located in the lower center section of the traction battery and have no other battery modules above them.
Page 542 414-03A-139 High Voltage/Traction Battery 414-03A-139 REMOVAL AND INSTALLATION (Continued) Traction Battery Module — Modules 16, 25-27 Special Tool(s) Battery Module Lifting Tool SR-10009 Battery Post Torque Wrench 307-026 Removal WARNING: The nominal voltage of the traction battery is 312 volts. The buffer zone must be set up and insulated rubber gloves and a face shield must be worn.
Page 543 414-03A-140 High Voltage/Traction Battery 414-03A-140 REMOVAL AND INSTALLATION (Continued) Installation 1. The battery module replacement procedure also contains the battery module installation. 2. Install battery modules 17-18. Use the Battery Module Lifting Tool to • install the battery modules. Install and tighten new battery module nuts •...
Page 544 414-03A-141 High Voltage/Traction Battery 414-03A-141 REMOVAL AND INSTALLATION (Continued) Removal 1. Remove the battery control module (BCM). Refer to Battery Control Module (BCM). WARNING: The nominal voltage of the traction battery is 312 volts. The buffer zone must be set up and insulated rubber gloves and a face shield must be worn.
Page 545 414-03A-142 High Voltage/Traction Battery 414-03A-142 REMOVAL AND INSTALLATION (Continued) 3. Fill the area around the high-voltage jumper nuts with Nyogel. 4. Install the BCM. Refer to Battery Control Module (BCM). Traction Battery Temperature Sensor — Modules 22-24 Removal 1. The #1 temperature sensor is located on the negative side of the #17 traction battery module.
Page 546 414-03A-143 High Voltage/Traction Battery 414-03A-143 REMOVAL AND INSTALLATION (Continued) CAUTION: Do not use excessive force to remove the temperature sensor or damage to the battery module may occur. NOTE: If the sensor is difficult to remove, warm it using a heat gun. Be careful not to overheat the sensor or the battery module, or damage to both may occur.
Page 547 414-03A-144 High Voltage/Traction Battery 414-03A-144 DISASSEMBLY AND ASSEMBLY Traction Battery Temperature Sensor Special Tool(s) Battery Terminal Cap Opener 418-F215 Battery Module Lifting Tool 418-F206 Battery Post Torque Wrench 307-026 2001 Ranger EV, 01/2001...
Page 548 414-03A-145 High Voltage/Traction Battery 414-03A-145 DISASSEMBLY AND ASSEMBLY (Continued) Traction Battery LH View 2001 Ranger EV, 01/2001...
Page 549 414-03A-146 High Voltage/Traction Battery 414-03A-146 DISASSEMBLY AND ASSEMBLY (Continued) Item Description Item Description Upper Level Heating Elements Battery Control Module (BCM) Separator Plate Contactor Box Harness Low-Voltage Harness High-Voltage (Sensor Lead) Harness (10B694) Traction Battery Cooling Fan Relay Upper Level Battery Module Traction Battery Cooling Fan Contactor Box 76-Pin Connector...
Page 550 414-03A-147 High Voltage/Traction Battery 414-03A-147 DISASSEMBLY AND ASSEMBLY (Continued) Traction Battery RH View 2001 Ranger EV, 01/2001...
Page 551 414-03A-148 High Voltage/Traction Battery 414-03A-148 DISASSEMBLY AND ASSEMBLY (Continued) Item Description Item Description High Voltage Four-Pin Auxiliary Load Contactor Box Connector Two-Pin High-Voltage Connector High Voltage Four-Pin Auxiliary Load Separator Plates Connector Bracket Traction Battery Case Contactor Box Harness Traction Battery Cooling Fan Relay High-Voltage (Sensor Lead) Harness Traction Battery Cooling Fan (10B694)
Page 552 414-03A-149 High Voltage/Traction Battery 414-03A-149 DISASSEMBLY AND ASSEMBLY (Continued) 4. Unclip the low and high-voltage wiring harnesses from each other and from the separator plate. 5. Unclip the low and high-voltage wiring harnesses from each other and from the separator plate. Cut the zip tie.
Page 553 414-03A-150 High Voltage/Traction Battery 414-03A-150 DISASSEMBLY AND ASSEMBLY (Continued) 8. Unclip and disconnect the sense lead wiring. 9. Unclip and disconnect the sense lead wiring. 10. Unclip and disconnect the sense lead wiring. 11. Unclip and disconnect the sense lead wiring. 2001 Ranger EV, 01/2001...
Page 554 414-03A-151 High Voltage/Traction Battery 414-03A-151 DISASSEMBLY AND ASSEMBLY (Continued) 12. Unclip and disconnect the sense lead wiring. 13. Cut the two zip ties from the high-voltage harness. 14. NOTE: The battery control module (BCM) is held in position with strips of Velcro Remove the BCM.
Page 555 414-03A-152 High Voltage/Traction Battery 414-03A-152 DISASSEMBLY AND ASSEMBLY (Continued) CAUTION: Do not allow the high voltage jumper (HVJ) ends to contact one another. The ends of the HVJs must be wrapped with orange electrical tape to prevent them from contacting one another. Disconnect the HVJs from the contactor box, one at a time.
Page 556 414-03A-153 High Voltage/Traction Battery 414-03A-153 DISASSEMBLY AND ASSEMBLY (Continued) 20. Disconnect the low-voltage harness from the contactor box. 21. Remove the contactor box. 1 Unclip the heating element connector. 2 Unclip the temperature sensor connector. 3 Unclip and disconnect the traction battery high-voltage two-pin connector.
Page 557 414-03A-154 High Voltage/Traction Battery 414-03A-154 DISASSEMBLY AND ASSEMBLY (Continued) 24. Disconnect the two temperature sensors. 25. Disconnect the temperature sensor. 26. Disconnect the temperature sensor. 27. NOTE: The low-voltage harness remains connected to the traction battery at the 76-pin connector. Remove the low-voltage harness from the traction battery and position the harness aside.
Page 558 414-03A-155 High Voltage/Traction Battery 414-03A-155 DISASSEMBLY AND ASSEMBLY (Continued) 29. Remove the separator plate. 30. Remove the separator plates. 31. Remove all of the upper level battery module HVJs and discard the nuts. Use the Battery Terminal Cap Opener to •...
Page 559 414-03A-156 High Voltage/Traction Battery 414-03A-156 DISASSEMBLY AND ASSEMBLY (Continued) CAUTION: Do not use excessive force to remove the temperature sensor, or damage to the module may occur. NOTE: If the sensor is difficult to remove, warm it using a heat gun. Be careful not to overheat the sensor or the battery module, or damage to both may occur.
Page 560 414-03A-157 High Voltage/Traction Battery 414-03A-157 DISASSEMBLY AND ASSEMBLY (Continued) 37. Use Battery Module Lifting Tool to remove all of the lower level battery modules. 38. Remove the cross bar/blower bracket. 1 Remove the two nuts. 2 Remove the cross bar/blower bracket. 39.
Page 561 414-03A-158 High Voltage/Traction Battery 414-03A-158 DISASSEMBLY AND ASSEMBLY (Continued) Assembly 1. Position the lower heating element in the bottom of the battery tray and apply the battery module numbers to the blanket as illustrated. 2. NOTE: This step only applies to initial traction battery build-up.
Page 562 414-03A-159 High Voltage/Traction Battery 414-03A-159 DISASSEMBLY AND ASSEMBLY (Continued) 3. Install the cross bar/cooling fan bracket. 1 Position the cross bar/blower bracket. 2 Install the two nuts. 4. Install the cooling fan. 1 Position the cooling fan. 2 Install the three screws. 5.
Page 563 414-03A-160 High Voltage/Traction Battery 414-03A-160 DISASSEMBLY AND ASSEMBLY (Continued) 8. NOTE: The battery module numbers correspond to the numbers on the heating blanket. NOTE: The battery modules must be installed with the terminals oriented as illustrated. Install the 27 lower-level battery modules. Label the battery modules as illustrated.
Page 564 414-03A-161 High Voltage/Traction Battery 414-03A-161 DISASSEMBLY AND ASSEMBLY (Continued) 10. Install the W HVJ. Install the 39+ nut. • 2001 Ranger EV, 01/2001...
Page 565 414-03A-162 High Voltage/Traction Battery 414-03A-162 DISASSEMBLY AND ASSEMBLY (Continued) 11. Install the V HVJ. 1 Install the 39 - nut. 2 Install the 38+ nut. 2001 Ranger EV, 01/2001...
Page 566 414-03A-163 High Voltage/Traction Battery 414-03A-163 DISASSEMBLY AND ASSEMBLY (Continued) 12. Install the U HVJ. 1 Install the 35+ nut. 2 Install the 36- nut. 3 Install the 37+ nut. 4 Install the 38- nut. 5 Install the 36+ nut. 6 Install the 37- nut. 2001 Ranger EV, 01/2001...
Page 567 414-03A-164 High Voltage/Traction Battery 414-03A-164 DISASSEMBLY AND ASSEMBLY (Continued) 13. Install the T HVJ. 1 Install the 32+ nut. 2 Install the 33- nut. 3 Install the 33+ nut. 4 Install the 34- nut. 5 Install the 34+ nut. 6 Install the 35- nut. 2001 Ranger EV, 01/2001...
Page 568 414-03A-165 High Voltage/Traction Battery 414-03A-165 DISASSEMBLY AND ASSEMBLY (Continued) 14. Install the G HVJ. 1 Install the 8+ nut. 2 Install the 9- nut. 3 Install the 11+ nut. 4 Install the 12- nut. 5 Install the 9+ nut. 6 Install the 10- nut. 7 Install the 8- nut.
Page 569 414-03A-166 High Voltage/Traction Battery 414-03A-166 DISASSEMBLY AND ASSEMBLY (Continued) 15. Install the S HVJ. 1 Install the 31+ nut. 2 Install the 32- nut. 3 Install the 29+ nut. 4 Install the 30- nut. 5 Install the 28+ nut. 6 Install the 29- nut. 2001 Ranger EV, 01/2001...
Page 570 414-03A-167 High Voltage/Traction Battery 414-03A-167 DISASSEMBLY AND ASSEMBLY (Continued) 16. Install the R HVJ. 1 Install the 10+ nut. 2 Install the 11- nut. 3 Install the 13+ nut. 4 Install the 14- nut. 2001 Ranger EV, 01/2001...
Page 571 414-03A-168 High Voltage/Traction Battery 414-03A-168 DISASSEMBLY AND ASSEMBLY (Continued) 17. Install the K HVJ. 1 Install the 14+ nut. 2 Install the 15- nut. 2001 Ranger EV, 01/2001...
Page 572 414-03A-169 High Voltage/Traction Battery 414-03A-169 DISASSEMBLY AND ASSEMBLY (Continued) 18. Install the J HVJ. 1 Install the 30+ nut. 2 Install the 31- nut. 3 Install the 15+ nut. 4 Install the 16- nut. 5 Install the 12+ nut. 6 Install the 13- nut. 2001 Ranger EV, 01/2001...
Page 573 414-03A-170 High Voltage/Traction Battery 414-03A-170 DISASSEMBLY AND ASSEMBLY (Continued) 19. Install the L HVJ. 1 Install the 27+ nut. 2 Install the 28- nut. 3 Install the 16+ nut. The remaining end is not connected at this • time. Close the cap. 2001 Ranger EV, 01/2001...
Page 574 414-03A-171 High Voltage/Traction Battery 414-03A-171 DISASSEMBLY AND ASSEMBLY (Continued) 20. Install the N HVJ. 1 Install the 26+ nut. 2 Install the 27- nut. 3 Install the 24+ nut. 4 Install the 25+ nut. 5 Install the 26- nut. 6 Install the 25- nut. 2001 Ranger EV, 01/2001...
Page 575 414-03A-172 High Voltage/Traction Battery 414-03A-172 DISASSEMBLY AND ASSEMBLY (Continued) 21. Install the E HVJ. 1 Install the 22+ nut. 2 Install the 23- nut. 2001 Ranger EV, 01/2001...
Page 576 414-03A-173 High Voltage/Traction Battery 414-03A-173 DISASSEMBLY AND ASSEMBLY (Continued) 22. Install the P HVJ. 1 Install the 23+ nut. 2 Install the 24- nut. 2001 Ranger EV, 01/2001...
Page 577 414-03A-174 High Voltage/Traction Battery 414-03A-174 DISASSEMBLY AND ASSEMBLY (Continued) 23. Install the M HJV. Install the 22- nut. • The remaining end is not connected at this • time. Close the cap. 24. Using the Battery Post Torque Wrench, tighten the HVJ to battery module nuts.
Page 578 414-03A-175 High Voltage/Traction Battery 414-03A-175 DISASSEMBLY AND ASSEMBLY (Continued) 25. Fill the area around the high-voltage jumper nuts with Nyogel and snap the caps closed. 26. NOTE: The 76-pin connector is part of the low-voltage wiring harness and is installed from the inside of the battery tray.
Page 579 414-03A-176 High Voltage/Traction Battery 414-03A-176 DISASSEMBLY AND ASSEMBLY (Continued) NOTE: The temperature sensor harness feeds up through the space between the separators. NOTE: The HVJ wiring that runs between the battery modules must fit into the separators. 28. Install the front separator plates. 29.
Page 580 414-03A-177 High Voltage/Traction Battery 414-03A-177 DISASSEMBLY AND ASSEMBLY (Continued) 33. The upper battery module heating elements are adhesive backed and are positioned on the battery modules as illustrated in the following steps. NOTE: The battery modules must be installed with the terminals oriented correctly.
Page 581 414-03A-178 High Voltage/Traction Battery 414-03A-178 DISASSEMBLY AND ASSEMBLY (Continued) 35. Install the upper front battery modules. 1 Apply the heating element to battery module 17 on the side facing out, and install the battery module. 2 Apply the heating element to battery module 18 on the side facing out, and install the battery module.
Page 582 414-03A-179 High Voltage/Traction Battery 414-03A-179 DISASSEMBLY AND ASSEMBLY (Continued) 37. Install the remaining upper rear battery modules. 1 Apply the heating element to battery module 2 on the side facing out, and install the battery module. 2 Apply the heating element to battery module 3 on the side facing battery module 2, and install the battery module.
Page 583 414-03A-180 High Voltage/Traction Battery 414-03A-180 DISASSEMBLY AND ASSEMBLY (Continued) 38. Install the D HVJ. 1 Install the 6+ nut. 2 Install the 7- nut. 39. Install the B HVJ. 1 Install the 2+ nut. 2 Install the 3- nut. 3 Install the 4+ nut. 4 Install the 5- nut.
Page 584 414-03A-181 High Voltage/Traction Battery 414-03A-181 DISASSEMBLY AND ASSEMBLY (Continued) 40. Install the A HVJ. 1 Install the 3+ nut. 2 Install the 4- nut. 3 Install the 1+ nut. 4 Install the 2- nut. 41. Install the L HVJ. 1 Install the 5+ nut. 2 Install the 6- nut.
Page 585 414-03A-182 High Voltage/Traction Battery 414-03A-182 DISASSEMBLY AND ASSEMBLY (Continued) 42. Connect the remaining G HVJ end from the lower level battery module to the 7+ battery module terminal. Install the nut. • 43. NOTE: The remaining end of the H HVJ is not connected at this time.
Page 586 414-03A-183 High Voltage/Traction Battery 414-03A-183 DISASSEMBLY AND ASSEMBLY (Continued) 44. NOTE: The F HVJ contains a large fuse that is routed around the rear of the battery modules. Install the F HVJ. 1 Install the 20+ nut. 2 Install the 21- nut. 3 Install the 17+ nut.
Page 587 414-03A-184 High Voltage/Traction Battery 414-03A-184 DISASSEMBLY AND ASSEMBLY (Continued) WARNING: This step will energize the traction battery. Do not touch the contactor box HVJs or allow them to touch each other. Connect the remaining L HVJ end from the lower level battery module. Install the nut.
Page 588 414-03A-185 High Voltage/Traction Battery 414-03A-185 DISASSEMBLY AND ASSEMBLY (Continued) 49. Probe the contactor box HVJs to verify correct traction battery voltage. The voltage should be approximately 323 volts DC. 50. Wrap the contactor box HVJs with orange electrical tape to prevent contact or shorting. 51.
Page 589 414-03A-186 High Voltage/Traction Battery 414-03A-186 DISASSEMBLY AND ASSEMBLY (Continued) 54. Install the two-pin connector in the tray. 1 Position the connector. 2 Install the four nuts. 55. Mount the fuse. 1 Position the fuse bracket on the left rear stud. 2 Install the nut.
Page 590 414-03A-187 High Voltage/Traction Battery 414-03A-187 DISASSEMBLY AND ASSEMBLY (Continued) 56. Install the black low-voltage harness (part of the 76-pin harness). 1 Position the harness with the two BCM connectors at the front of the pack. 2 Push the four harness clips into the separator plate.
Page 591 414-03A-188 High Voltage/Traction Battery 414-03A-188 DISASSEMBLY AND ASSEMBLY (Continued) 58. Connect the temperature sensor electrical connector to the low-voltage harness. 59. Connect the low-voltage harness to the contactor box. 1 Clip the two harness clips to the contactor box. 2 Connect the two-pin auxiliary connector. 3 Connect the temperature sensor connector.
Page 592 414-03A-189 High Voltage/Traction Battery 414-03A-189 DISASSEMBLY AND ASSEMBLY (Continued) 61. Connect the two temperature sensor electrical connectors. Connect the 17- to the brown / brown and • white connector. Connect the 26+ lead to the green / red • connector. 62.
Page 593 414-03A-190 High Voltage/Traction Battery 414-03A-190 DISASSEMBLY AND ASSEMBLY (Continued) 64. Clip the three high-voltage harness clips onto the separator plate. 65. Clip the three high-voltage harness clips onto the separator plate. 66. Connect the J and S high-voltage connectors and clip them onto the separator plate. 2001 Ranger EV, 01/2001...
Page 594 414-03A-191 High Voltage/Traction Battery 414-03A-191 DISASSEMBLY AND ASSEMBLY (Continued) 67. Clip the heater harness connectors onto the high-voltage harness. 68. Connect the K and L sense lead connectors. 69. Connect the T, B, and H sense lead connectors. 1 Connect the T, B, and H connectors. 2 Clip the H connector into the separator plate.
Page 595 414-03A-192 High Voltage/Traction Battery 414-03A-192 DISASSEMBLY AND ASSEMBLY (Continued) 70. Connect the G sense lead connector. 71. Clip the G sense lead harness into the separator plate. 72. Connect the D sense lead connector. 2001 Ranger EV, 01/2001...
Page 596 414-03A-193 High Voltage/Traction Battery 414-03A-193 DISASSEMBLY AND ASSEMBLY (Continued) 73. Connect the C sense lead connector. 74. Clip the heater connector into the high-voltage harness. 75. Clip the two heating element connectors into the high-voltage harness, located behind the contactor box. 2001 Ranger EV, 01/2001...
Page 597 414-03A-194 High Voltage/Traction Battery 414-03A-194 DISASSEMBLY AND ASSEMBLY (Continued) 76. Connect the A sense lead and clip it into the separator plate. 77. Connect the V sense lead connector. Clip the sensor lead onto the separator plate. • 78. Connect the R, U, and W sense leads. 2001 Ranger EV, 01/2001...
Page 598 414-03A-195 High Voltage/Traction Battery 414-03A-195 DISASSEMBLY AND ASSEMBLY (Continued) 79. Connect the temperature sensor to the 2- battery module. 80. Connect the heater harness connector to the contactor box. 81. Connect the heating element connector to the heater harness, located on the side of battery module 2.
Page 599 414-03A-196 High Voltage/Traction Battery 414-03A-196 DISASSEMBLY AND ASSEMBLY (Continued) 82. Connect the two heating element connectors to the harness and clip them into the separator plate. 83. Connect the heating element connector to the harness. 84. Position the heater harness down the center of the battery around the LH front battery modules.
Page 600 414-03A-197 High Voltage/Traction Battery 414-03A-197 DISASSEMBLY AND ASSEMBLY (Continued) 86. Position the heater harness and low-voltage harness across the separator plate and zip tie them into place. 87. NOTE: The battery module is held into place with strips of Velcro Install the BCM.
Page 601 414-03A-198 High Voltage/Traction Battery 414-03A-198 DISASSEMBLY AND ASSEMBLY (Continued) 89. Clip the contactor box jumper harness into the separator plate. 90. Connect the P and M sense lead connectors. Clip the P sense lead connector into the • high-voltage harness. 91.
Page 602 414-03A-199 High Voltage/Traction Battery 414-03A-199 DISASSEMBLY AND ASSEMBLY (Continued) 92. Connect the heating element electrical connector and clip it into the BCM harness. 93. Position the contactor box harness. Clip the contactor box harness into the four • high-voltage harness clips. 94.
Page 603 414-03A-200 High Voltage/Traction Battery 414-03A-200 DISASSEMBLY AND ASSEMBLY (Continued) 95. Clip the heating element connector into the contactor box harness. 96. Connect the contactor box harness to the HVJ. 1 Position the bracket. 2 Install the screw. 3 Connect the harness to the jumper. 97.
Page 604: High Voltage/Traction Battery-Nickel Metal Hydride
414-03B-1 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-1 Manual Table of Contents SECTION 414-03B High Voltage/Traction Battery — Nickel Metal Hydride VEHICLE APPLICATION: Ranger EV CONTENTS PAGE SPECIFICATIONS ..................414-03B-3 DESCRIPTION AND OPERATION High Voltage/Traction Battery ..............414-03B-4 DIAGNOSIS AND TESTING Auxiliary Contactor Relay Control ..............
Page 605 414-03B-2 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-2 CONTENTS PAGE Inspection and Verification ..............414-03B-42 Pinpoint Tests ..................414-03B-43 Symptom Chart ..................414-03B-42 Traction Battery Cooling/Ventilation System ...........414-03B-63 Electrical Schematic ................414-03B-63 Inspection and Verification ..............414-03B-63 Pinpoint Tests ..................414-03B-63 Symptom Chart ..................414-03B-63 Traction Battery System ................414-03B-69 Battery Module Diagnostic Test ...............414-03B-69 Electrical Schematic ................414-03B-71 Inspection and Verification ..............414-03B-71...
Page 606 414-03B-3 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-3 SPECIFICATIONS Torque Specifications Torque Specifications Description Lb-Ft Lb-In Description Lb-Ft Lb-In High-Voltage Power — A/C Inverter Motor — Distribution Box Bolts Control Bolts High-Voltage Power — Battery Control Module — Distribution Box Cover Bolts Screws Battery Control...
Page 607 414-03B-4 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-4 DESCRIPTION AND OPERATION Battery Controller Module (BCM) The BCM is a combination low and high-voltage High Voltage/Traction Battery module that controls all traction battery system The traction battery is the primary source of power operations.
Page 608 414-03B-5 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-5 DESCRIPTION AND OPERATION (Continued) • If the BCM receives a normal fault detection • To unlatch the IOM, the auxiliary battery negative signal (no faults present) from the IOM, it cable must be removed for 30 seconds. Once this activates the onboard charger and the traction is done, the vehicle will again charge normally.
Page 609 414-03B-6 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-6 DIAGNOSIS AND TESTING Electrical Schematic Refer to Electrical and Vacuum Troubleshooting Auxiliary Contactor Relay Control Manual, Cell 21, Contactor Box Relay Control for Diagnostic Trouble Code (DTC) Definition schematic and connector information. The following DTC relates to the control of the Inspection and Verification auxiliary contactor relay:...
Page 610 414-03B-7 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-7 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST A: DTC C1862 CONTACTOR CIRCUIT FAILURE TEST STEP ACTION TO TAKE A1 CHECK FOR INTERFACE ADAPTER ASSEMBLY (IAA) MODULE AND TRACTION INVERTER MODULE (TIM) DIAGNOSTIC TROUBLE CODES (DTCs) NOTE: Do not go to test step A2 unless there is a multiple auxiliary load Yes = REFER to Pinpoint Test A...
Page 611 414-03B-8 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-8 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST A: DTC C1862 CONTACTOR CIRCUIT FAILURE TEST STEP ACTION TO TAKE If AUX HVC PID indicates OFAULT, GO to A14. A7 CHECK AUXILIARY CONTACTOR RELAY CONTROL SIGNAL (CLOSE FAULT) GO to A10.
Page 612 414-03B-9 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-9 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST A: DTC C1862 CONTACTOR CIRCUIT FAILURE TEST STEP ACTION TO TAKE WARNING: The traction battery contains high-voltage components and wiring. High-voltage insulated safety gloves and face shield must be worn when carrying out the following steps.
Page 613 414-03B-10 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-10 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST A: DTC C1862 CONTACTOR CIRCUIT FAILURE TEST STEP ACTION TO TAKE • With key OFF, disconnect traction battery support tray in-line C1939 and Yes = GO to A19.
Page 614 414-03B-11 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-11 DIAGNOSIS AND TESTING (Continued) • DTC C1862 Contactor Circuit Failure Main/Precharge Contactor Relay — The TIM controls two contactor box relays, Control the precharge and main contactor relays. There Diagnostic Trouble Code (DTC) Definition are capacitors at the high-voltage input to the The following DTCs relate to the contactor box TIM that are charged at a slow rate to a...
Page 615 414-03B-12 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-12 DIAGNOSIS AND TESTING (Continued) Special Tool(s) Pinpoint Tests Traction Battery Low-Voltage Service Cord 418-F219 Special Tool(s) Traction Battery High-Voltage Lockout and Diagnostic 104-Pin Breakout Box (BOB) 418-049 (014-00950) or Tool 418-F207 equivalent High-Voltage Insulated Safety Gloves 100-F036 or BCM/TIM Breakout Box (BOB) Adapter Cable...
Page 616 414-03B-13 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-13 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST A: DTC B1676 BATTERY PACK VOLTAGE OUT OF RANGE TEST STEP ACTION TO TAKE A5 CHECK MAIN CONTACTOR RELAY NOTE: The active command PRECHG IN must be sent before sending the GO to A6.
Page 617 414-03B-14 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-14 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST A: DTC B1676 BATTERY PACK VOLTAGE OUT OF RANGE TEST STEP ACTION TO TAKE • Measure the resistance between the terminals of the 250A traction battery Yes = REPLACE the contactor high-voltage fuse.
Page 618 414-03B-15 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-15 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST B: DTC C1862 CONTACTOR CIRCUIT FAILURE TEST STEP ACTION TO TAKE • Is the resistance greater than 10,000 ohms? No = REPAIR the T wire. B8 CHECK CIRCUIT 3991 (T) BETWEEN CONTACTOR BOX AND TRACTION BATTERY SUPPORT TRAY FOR OPEN •...
Page 619 414-03B-16 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-16 DIAGNOSIS AND TESTING (Continued) Electrical Schematic Negative Contactor Relay Control Refer to Electrical and Vacuum Troubleshooting Diagnostic Trouble Code (DTC) Definition Manual, Cell 21, Contactor Box Relay Control for The following DTC relates to the negative contactor schematic and connector information.
Page 620 414-03B-17 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-17 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST A: DTC C1862 CONTACTOR CIRCUIT FAILURE TEST STEP ACTION TO TAKE A2 CHECK FOR WELDED MAIN CONTACTOR RELAY GO to A3. • Press the STOP button on the PCS and disconnect the PCS from the Yes = charger inlet.
Page 621 414-03B-18 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-18 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST A: DTC C1862 CONTACTOR CIRCUIT FAILURE TEST STEP ACTION TO TAKE A6 CHECK CIRCUIT 3136 (W) FOR OPEN • With key OFF, disconnect contactor box C1982 and measure the Yes = REPLACE the contactor resistance of the W wire between pin 3 on contactor box C1982 and...
Page 622 414-03B-19 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-19 DIAGNOSIS AND TESTING (Continued) Special Tool(s) Pinpoint Tests BCM/TIM Breakout Box (BOB) Overlay 418-F220 Special Tool(s) Traction Battery High-Voltage Service Cord 418-F218 104-Pin Breakout Box (BOB) 418-049 (014-00950) or Traction Battery Low-Voltage Service Cord 418-F219 equivalent Traction Battery High-Voltage Lockout and Diagnostic BCM/TIM Breakout Box (BOB) Adapter Cable...
Page 623 414-03B-20 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-20 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST A: DTC B2517 EMERGENCY POWER OFF SYSTEM FAULTED TEST STEP ACTION TO TAKE • Measure the resistance between the LB/W wire terminal and O wire Yes = REPAIR the O wire terminal on the inertia switch with the inertia switch in the deactivated...
Page 624 414-03B-21 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-21 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST A: DTC B2517 EMERGENCY POWER OFF SYSTEM FAULTED TEST STEP ACTION TO TAKE • With key OFF, measure the voltage between BOB pin 47 and ground No = REPAIR circuit 974 (O (BOB pin 65).
Page 625 414-03B-22 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-22 DIAGNOSIS AND TESTING (Continued) Electrical Schematic Contactor Box Current Sensors Refer to Electrical and Vacuum Troubleshooting Diagnostic Trouble Code (DTC) Definition Manual, Cell 16, Traction Battery System for The following DTC relates to the main and schematic and connector information.
Page 626 414-03B-23 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-23 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST A: DTC C1835 CURRENT SENSE CIRCUIT FAILURE TEST STEP ACTION TO TAKE • Does the MAINSEN PID indicate between 0.5 and 4.5 volts? No = GO to A8.
Page 627 414-03B-24 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-24 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST A: DTC C1835 CURRENT SENSE CIRCUIT FAILURE TEST STEP ACTION TO TAKE No = GO to A9. WARNING: The traction battery contains high-voltage components and wiring. High-voltage insulated safety gloves and face shield must be worn when carrying out the following steps.
Page 628 414-03B-25 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-25 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST A: DTC C1835 CURRENT SENSE CIRCUIT FAILURE TEST STEP ACTION TO TAKE A14 CHECK CIRCUIT 3138 (LB/BK) FOR SHORT TO POWER • With key OFF, disconnect the BOB from the BCM; leave BOB Yes = REPAIR the LB/BK wire.
Page 629 414-03B-26 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-26 DIAGNOSIS AND TESTING (Continued) Symptom Chart Symptom Chart Condition Possible Sources Action DTC C1839 Leakage Fault High-voltage harness GO to Pinpoint Test A. • • • (10B694). High-voltage harness(es) • (14A280). Battery control module •...
Page 630 414-03B-27 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-27 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST A: DTC C1839 LEAKAGE FAULT TEST STEP ACTION TO TAKE • Does the LEAK CF PID indicate YES? No = CLEAR the BCM DTCs. DRIVE the vehicle. If the electrical hazard warning indicator illuminates and DTC C1839 still occurs,...
Page 631 414-03B-28 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-28 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST A: DTC C1839 LEAKAGE FAULT TEST STEP ACTION TO TAKE • With key OFF, measure the resistance between the DB wire on in-line Yes = CLEAR the BCM DTCs.
Page 632 414-03B-29 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-29 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST A: DTC C1839 LEAKAGE FAULT TEST STEP ACTION TO TAKE • Turn the ignition key to the START position, set the gear selector lever No = If vehicle is equipped with A/C, GO to A12 .
Page 633 414-03B-30 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-30 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST A: DTC C1839 LEAKAGE FAULT TEST STEP ACTION TO TAKE • With key OFF, disconnect high-voltage auxiliary load in-line C1935 on Yes = GO to A24 (leakage is in the traction battery support tray.
Page 634 414-03B-31 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-31 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST A: DTC C1839 LEAKAGE FAULT TEST STEP ACTION TO TAKE • Reinstall the HVPDB cover. No = REPLACE the DC/DC • With key ON, monitor BCM PID LEAKRES. converter.
Page 635 414-03B-32 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-32 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST A: DTC C1839 LEAKAGE FAULT TEST STEP ACTION TO TAKE NOTE: If there is no continuity between the indicated battery module and No = REPLACE the contactor chassis ground, check for continuity between chassis ground and the box.
Page 636 414-03B-33 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-33 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST A: DTC C1839 LEAKAGE FAULT TEST STEP ACTION TO TAKE • With key ON, enter the TIM active command mode CONTACTOR No = GO to A36 (leakage is in OUTPUT CONTROL, monitor the BCM PID LKRESB-, and set the the auxiliary negative bus).
Page 637 414-03B-34 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-34 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST A: DTC C1839 LEAKAGE FAULT TEST STEP ACTION TO TAKE A39 CHECK FOR CURRENT LEAKAGE IN POSITIVE TEMPERATURE COEFFICIENT (PTC) HEATER • With key OFF, disconnect PTC switching module high-voltage C1912. Yes = GO to A40.
Page 638 414-03B-35 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-35 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST A: DTC C1839 LEAKAGE FAULT TEST STEP ACTION TO TAKE NOTE: The active command PRECHG IN must be sent before sending the No = GO to A47 (leakage is in active command POS MAIN.
Page 639 414-03B-36 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-36 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST A: DTC C1839 LEAKAGE FAULT TEST STEP ACTION TO TAKE • With key ON, monitor BCM PID LEAK ID and note the indicated Yes = REPLACE high-voltage battery module.
Page 640 414-03B-37 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-37 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST A: DTC C1839 LEAKAGE FAULT TEST STEP ACTION TO TAKE A54 CHECK FOR CURRENT LEAKAGE IN A/C IMC GO to A55. • With key OFF, remove the high-voltage power distribution box Yes = (HVPDB) cover and disconnect HVPDB C1917 (to A/C IMC).
Page 641 414-03B-38 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-38 DIAGNOSIS AND TESTING (Continued) Symptom Chart Symptom Chart Condition Possible Sources Action DTC C1446 Brake Switch Fuse. GO to Pinpoint Test A. • • • Circuit Failure Circuit(s). • Traction inverter module •...
Page 642 414-03B-39 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-39 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST A: DTC C1446 BRAKE SWITCH CIRCUIT FAILURE TEST STEP ACTION TO TAKE A5 CHECK MASTER CYLINDER PRESSURE STATUS • With key ON, monitor the TIM PID MC PRES while depressing the Yes = System OK.
Page 643 414-03B-40 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-40 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST B: DTC C1849 MASTER CYLINDER PRESSURE OUT OF RANGE TEST STEP ACTION TO TAKE • With key ON, measure the resistance between BOB pin B22 and ground Yes = REPLACE the master (BOB pin A29).
Page 644 414-03B-41 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-41 DIAGNOSIS AND TESTING (Continued) • DTC C1838 Charging System Fault signal indicates zero. — The battery control module (BCM) sets DTC — A charger mode fault occurs if the BCM C1838 when a failure occurs in the traction detects the charger mode signal is not being battery charging system.
Page 645 414-03B-42 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-42 DIAGNOSIS AND TESTING (Continued) Inspection and Verification Refer to Section 100-07. Symptom Chart Symptom Chart Condition Possible Sources Action DTC C1836 Battery Circuit(s). GO to Pinpoint Test A. • • • Temperature Out of Range Battery temperature sensor.
Page 646 414-03B-43 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-43 DIAGNOSIS AND TESTING (Continued) Symptom Chart (Continued) Condition Possible Sources Action Charger Over Voltage Fault High-voltage harness GO to Pinpoint Test K. • • • (14A280-NC). High-voltage harness • (14A280-AB). Battery control module •...
Page 647 414-03B-44 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-44 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST A: DTC C1836 BATTERY TEMPERATURE OUT OF RANGE TEST STEP ACTION TO TAKE A1 CHECK FOR BATTERY TEMPERATURE SENSOR OUT OF RANGE FAULT GO to A2. •...
Page 648 414-03B-45 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-45 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST A: DTC C1836 BATTERY TEMPERATURE OUT OF RANGE TEST STEP ACTION TO TAKE No = REPAIR the BR/W wire (#1), DG wire (#2), R/W wire (#3), or O/R wire (#4). Battery Temperature Sensor #1 —...
Page 649 414-03B-46 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-46 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST C: DTC C1838 CHARGER SYSTEM FAULT TEST STEP ACTION TO TAKE C1 CHECK FOR CHARGING SYSTEM FAULT NOTE: Clear the diagnostic trouble codes (DTCs) from the battery control Yes = GO to C2.
Page 650 414-03B-47 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-47 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST D: CHARGER CHARGING AFTER BEING DISABLED FAULT TEST STEP ACTION TO TAKE • With key OFF, disconnect traction battery support tray in-line C1939 and Yes = GO to D4.
Page 651 414-03B-48 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-48 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST F: CHARGER LATCHUP FAULT TEST STEP ACTION TO TAKE • With key OFF, disconnect traction battery charger C1991 and measure No = REPAIR the LG/BK wire. the resistance of the LG/BK wire between pin 2 on traction battery charger C1991 and BOB pin 55.
Page 652 414-03B-49 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-49 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST H: CHARGER UNDER CURRENT FAULT TEST STEP ACTION TO TAKE H1 CHECK CONTACTOR BOX AUXILIARY CURRENT SENSOR FOR IN-RANGE FAILURE GO to H2. • With key ON, monitor battery control module (BCM) PID AUX CNT. Yes = •...
Page 653 414-03B-50 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-50 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST H: CHARGER UNDER CURRENT FAULT TEST STEP ACTION TO TAKE • Connect Traction Battery High-Voltage Service Cord to traction battery No = GO to H7. support tray in-line C1935F and in-line C1935M.
Page 654 414-03B-51 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-51 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST H: CHARGER UNDER CURRENT FAULT TEST STEP ACTION TO TAKE • Connect the vehicle to the PCS and press the START button to begin No = System OK.
Page 655 414-03B-52 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-52 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST J: CHARGER OVER CURRENT FAULT TEST STEP ACTION TO TAKE J1 CHECK CONTACTOR BOX AUXILIARY CURRENT SENSOR FOR IN-RANGE FAILURE • With key ON, monitor BCM PID AUX CNT. Yes = REPLACE the traction battery charger.
Page 656 414-03B-53 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-53 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST L: CHARGER OVER AMP-HOURS FAULT TEST STEP ACTION TO TAKE • Does the Battery Module Diagnostic Test indicate to replace any No = GO to L2. battery modules? L2 CHECK FOR CHARGING SYSTEM FAULT •...
Page 657 414-03B-54 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-54 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST N: CHARGER MODE FEEDBACK FAULT TEST STEP ACTION TO TAKE • With key OFF, disconnect traction battery support tray in-line C1939 and Yes = GO to N4. connect 104-Pin Breakout Box (BOB) to in-line C1939M using Traction Battery Low-Voltage Service Cord;...
Page 658 414-03B-55 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-55 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST N: CHARGER MODE FEEDBACK FAULT TEST STEP ACTION TO TAKE No = REPAIR the BR/Y wire. WARNING: The traction battery contains high-voltage components and wiring. High-voltage insulated safety gloves and face shield must be worn when carrying out the following steps.
Page 659 414-03B-56 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-56 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST P: IOM TO BCM DIAGNOSTIC INPUT STUCK HIGH FAULT TEST STEP ACTION TO TAKE No = GO to P4. WARNING: The traction battery contains high-voltage components and wiring.
Page 660 414-03B-57 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-57 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST P: IOM TO BCM DIAGNOSTIC INPUT STUCK HIGH FAULT TEST STEP ACTION TO TAKE — pins 37 and 16 • Are the resistances greater than 10,000 ohms? P7 CHECK SIGNAL WIRES TO IOM BATTERY TEMPERATURE SENSORS FOR SHORT(S) TO POWER •...
Page 661 414-03B-58 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-58 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST P: IOM TO BCM DIAGNOSTIC INPUT STUCK HIGH FAULT TEST STEP ACTION TO TAKE NOTE: The IOM to BCM Diagnostic Signal Stuck High Fault is due to a Yes = If TMPSEN1 is higher, rapid increase of temperature over time.
Page 662 414-03B-59 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-59 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST Q: IOM TO BCM DIAGNOSTIC INPUT STUCK LOW FAULT TEST STEP ACTION TO TAKE • Is the resistance greater than 10,000 ohms? No = REPAIR the R/BK wire. Q3 CHECK BCM TO IOM DIAGNOSTIC OUTPUT CIRCUIT 4007 (Y/LG) FOR SHORT TO POWER •...
Page 663 414-03B-60 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-60 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST S: DTC C1861 PRNDL INPUT #4 CIRCUIT FAILURE TEST STEP ACTION TO TAKE S1 CHECK STATUS OF DIGITAL TRANSMISSION RANGE (DTR) SENSOR SIGNAL TR4 TO BATTERY CONTROL MODULE (BCM) NOTE: Verify the transmission range selector lever is in the Park (P) Yes = System OK.
Page 664 414-03B-61 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-61 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST T: DTC C1863 EXTERNAL CHARGING FAULT TEST STEP ACTION TO TAKE T3 CHECK CHARGER CORD INPUT STATUS CIRCUIT FOR SHORT TO GROUND • With key OFF, measure the resistance between the Y wire on in-line Yes = REPLACE the BCM.
Page 665 414-03B-62 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-62 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST U: POWER CONTROL STATION (PCS) OPERATION VERIFICATION TEST TEST STEP ACTION TO TAKE • Push the STOP button on the PCS. Yes = CHECK the PCS cable for signs of damage (cuts, tears, or breaks in the cable insulation).
Page 666 414-03B-63 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-63 DIAGNOSIS AND TESTING (Continued) Electrical Schematic Traction Battery Cooling/Ventilation Refer to Electrical and Vacuum Troubleshooting System Manual, Cell 19, Traction Battery Diagnostic Trouble Code (DTC) Definition Cooling/Ventilation for schematic and connector information.
Page 667 414-03B-64 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-64 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST A: DTC B2513 BLOWER (FAN) CIRCUIT FAILURE TEST STEP ACTION TO TAKE A1 CHECK TRACTION BATTERY FANS FAULT STATUS • With key ON, monitor battery control module (BCM) PIDs FLOW F Yes = If both PIDs indicate YES, GO to A2.
Page 668 414-03B-65 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-65 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST A: DTC B2513 BLOWER (FAN) CIRCUIT FAILURE TEST STEP ACTION TO TAKE A6 CHECK CIRCUIT 3851 (Y/R) FOR SHORT TO POWER • Remove the traction battery and connect Traction Battery High-Voltage Yes = REPAIR the Y/R wire.
Page 669 414-03B-66 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-66 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST A: DTC B2513 BLOWER (FAN) CIRCUIT FAILURE TEST STEP ACTION TO TAKE • Connect BOB to BCM C1986, C1987 using the BCM/TIM BOB Adapter Yes = REPLACE the BCM.
Page 670 414-03B-67 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-67 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST A: DTC B2513 BLOWER (FAN) CIRCUIT FAILURE TEST STEP ACTION TO TAKE • Does the FANFDBK PID indicate ENABLE? No = If fan operates, GO to A23. If fan does not operate, GO to A18.
Page 671 414-03B-68 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-68 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST A: DTC B2513 BLOWER (FAN) CIRCUIT FAILURE TEST STEP ACTION TO TAKE • Measure the resistance between pins 30 and 87 on the recirculation fan No = REPLACE the recirculation relay.
Page 672 414-03B-69 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-69 DIAGNOSIS AND TESTING (Continued) Traction Battery System Battery Module Diagnostic Test The Battery Module Diagnostic Test is the method used to analyze electric vehicle traction battery modules. All 25 battery modules are analyzed simultaneously.
Page 673 414-03B-70 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-70 DIAGNOSIS AND TESTING (Continued) NOTE: This is a two-phase process. Battery module — The traction inverter module (TIM) sets DTC voltage information must be recorded within five C1755 when the vehicle is shut down for one minutes of completing discharge of the traction of three reasons: the temperature protection battery.
Page 674 414-03B-71 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-71 DIAGNOSIS AND TESTING (Continued) • DTC C1864 Battery Module Fault • DTC B2236 Weak or Defective Electric Vehicle Battery Module Fault — The battery control module (BCM) monitors the 25 individual 12-volt traction battery —...
Page 675 414-03B-72 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-72 DIAGNOSIS AND TESTING (Continued) Symptom Chart (Continued) Condition Possible Sources Action DTC C1864 Battery Module Battery module(s) installed GO to Pinpoint Test C. • • • Fault incorrectly (reverse cable polarity). Incorrect battery module •...
Page 676 414-03B-73 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-73 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST B: BATTERY PACK/MODULE(S) VOLTAGE OUT OF RANGE TEST STEP ACTION TO TAKE • Does DTC C1864 Battery Module Fault occur? No = GO to B2. If DTC B1676 Battery Pack Voltage Out of Range occurs, GO to B8.
Page 677 414-03B-74 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-74 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST B: BATTERY PACK/MODULE(S) VOLTAGE OUT OF RANGE TEST STEP ACTION TO TAKE — 3, 4: circuit 3074 (BK/O) between in-line C1752M (label C) and pin 22 on BCM C1865 —...
Page 678 414-03B-75 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-75 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST B: BATTERY PACK/MODULE(S) VOLTAGE OUT OF RANGE TEST STEP ACTION TO TAKE No = REPLACE the harness(es) (14A280) in question. GO to Battery Module Faults —...
Page 679 414-03B-76 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-76 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST B: BATTERY PACK/MODULE(S) VOLTAGE OUT OF RANGE TEST STEP ACTION TO TAKE — 24, 25: between circuit 3096 (W) on in-line C1748F (label M) and battery module 24 (+) post —...
Page 680 414-03B-77 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-77 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST B: BATTERY PACK/MODULE(S) VOLTAGE OUT OF RANGE TEST STEP ACTION TO TAKE • Is the resistance between 28,000 and 34,000 ohms? No = REPLACE high-voltage harness (14A280-NC).
Page 681 414-03B-78 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-78 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST D: DTC B2236 WEAK OR DEFECTIVE ELECTRIC VEHICLE BATTERY MODULE FAULT TEST STEP ACTION TO TAKE D1 CHECK STATUS OF TRACTION BATTERY MODULES BY CARRYING OUT THE BATTERY MODULE DIAGNOSTIC TEST NOTE: If DTC B1671 Battery Module Voltage Out of Range occurs along Yes = REPAIR as indicated.
Page 682 414-03B-79 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-79 DIAGNOSIS AND TESTING (Continued) Inspection and Verification Multiple Auxiliary Load Failure Refer to Section 100-07. Diagnosis Electrical Schematic Refer to Electrical and Vacuum Troubleshooting Manual, Cell 13, Power Distribution (High-Voltage) for schematic and connector information. Symptom Chart Symptom Chart Condition...
Page 683 414-03B-80 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-80 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST A: ALL HIGH-VOLTAGE AUXILIARY LOAD SYSTEMS DO NOT OPERATE TEST STEP ACTION TO TAKE No = REPLACE high-voltage harness 14B326 between traction battery support tray in-line C1935F and contactor box C3985.
Page 684 414-03B-81 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-81 GENERAL PROCEDURES (Continued) Special Tool(s) Traction Battery High-Voltage Service Cord 418-F218 Traction Battery Low-Voltage Service Cord 418-F219 Module Replacement 1. If necessary, charge all new replacement battery modules prior to installation. Refer to Module Charging to determine battery module charging conditions.
Page 685 414-03B-82 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-82 GENERAL PROCEDURES (Continued) WARNING: The nominal voltage of the traction battery is 300 volts. The buffer zone must be set up and insulated rubber gloves and a face shield must be worn. Failure to follow these precautions may result in severe personal injury or death.
Page 686 414-03B-83 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-83 GENERAL PROCEDURES (Continued) 8. NOTE: Do not replace more than 4 battery modules. If more than 4 battery modules need to be replaced, replace all 25 battery modules. Enter the indicated data on the Battery Module Replacement Data Form.
Page 687 414-03B-84 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-84 GENERAL PROCEDURES (Continued) 13. Connect the Traction Battery High-Voltage Service Cord to the traction battery auxiliary load high-voltage connector on the traction battery. 14. Connect the Traction Battery Low-Voltage Service Cord to the 76-pin low-voltage connector on the traction battery.
Page 688 414-03B-85 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-85 GENERAL PROCEDURES (Continued) 17. After charging has been completed, press the button to deactivate the power control station (PCS). 18. Disconnect the PCS from the charger inlet connector. 1 Press and hold the release button. 2 Lift and disconnect the PCS from the charger inlet connector.
Page 689 414-03B-86 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-86 GENERAL PROCEDURES (Continued) 22. Connect New Generation STAR (NGS) Tester to the vehicle. 23. Remove the NGS Tester and charge the traction battery to full SOC. Refer to Section 100-05. 24. Perform Battery Pack/Module Verification Test. Refer to Diagnosis and Testing for Traction Battery System in this section.
Page 690 414-03B-87 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-87 GENERAL PROCEDURES (Continued) 28. Disconnect the Traction Battery Low-Voltage Service Cord from the 76-pin low-voltage connector on the vehicle. 29. Apply Locktite 242 (threadlock and sealer) to the 22 traction battery cover bolts. 30.
Page 691 414-03B-88 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-88 GENERAL PROCEDURES (Continued) Traction Battery Tray Repair Battery Tray 2001 Ranger EV, 01/2001...
Page 692 414-03B-89 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-89 GENERAL PROCEDURES (Continued) 1. NOTE: The battery case consists of three main elements: composite enclosure, metal brackets, battery locators, and a battery tray seal. The repair method differs based on what element is affected.
Page 693 414-03B-90 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-90 GENERAL PROCEDURES (Continued) 4. To repair cracks less than 25 mm (1 in) in length, clean the area surrounding the damage prior to repair. After cleaning, grind a 20 degree bevel extending 40 to 50 mm (1.57 to 2 in) around the damage.
Page 694 414-03B-91 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-91 GENERAL PROCEDURES (Continued) 5. Immediately after grinding, apply the repair patch. Cut a piece of glass mat that will extend 25 mm (1 in) beyond the damaged area. Prepare a mixture of vinyl ester resin and soak the glass mat in it.
Page 695 414-03B-92 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-92 GENERAL PROCEDURES (Continued) 2. Remove the damaged bracket or locator using a heat gun positioned at least 150 mm (6 in) from the part being removed. The gun will heat the adhesive and allow the part to be removed.
Page 696 414-03B-93 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-93 GENERAL PROCEDURES (Continued) 5. Press down continuously along the entire length of the seal to ensure a good bond to the surface of the battery tray. Module Charging Special Tool(s) 12-Volt Battery Charger SBC-BXE 203 CAUTION: Do not use any charger other than the required SBC-BXE 203...
Page 697 414-03B-94 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-94 REMOVAL AND INSTALLATION Battery Control Module (BCM) Removal 1. Remove the traction battery. Refer to Traction Battery. 2. Remove the traction battery cover. 1 Remove the 22 bolts. 2 Remove the cover. WARNING: The nominal voltage of the traction battery is 300 volts.
Page 698 414-03B-95 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-95 REMOVAL AND INSTALLATION (Continued) 5. Disconnect the low voltage connector. 1 Loosen the bolts. 2 Disconnect the connectors. 6. Remove the battery control module (BCM). 1 Remove the bolts. 2 Remove the BCM. Installation CAUTION: Do not overtighten the BCM multi-pin connectors.
Page 699 414-03B-96 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-96 REMOVAL AND INSTALLATION (Continued) Charge Inlet Removal 1. Disconnect the traction battery auxiliary load high-voltage connector. Refer to Section 100-05. 2001 Ranger EV, 01/2001...
Page 700 414-03B-97 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-97 REMOVAL AND INSTALLATION (Continued) 2. Remove the grille. 1 Remove the four screws. 2 Remove the grille. 3. NOTE: The low-voltage connector is located at the rear of the charger inlet. Disconnect the low-voltage electrical connector.
Page 701 414-03B-98 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-98 REMOVAL AND INSTALLATION (Continued) 5. Remove the two charge bracket bolts. 6. Remove the charge inlet. 1 Loosen the two charge inlet bracket bolts. 2 Slide the charge inlet from behind the bolts and remove.
Page 702 414-03B-99 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-99 REMOVAL AND INSTALLATION (Continued) Contactor Box Special Tool(s) Battery Terminal Cap Opener 418-F215 Removal 1. Remove the traction battery. Refer to Traction Battery. 2001 Ranger EV, 01/2001...
Page 703 414-03B-100 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-100 REMOVAL AND INSTALLATION (Continued) 2. Remove the traction battery cover. 1 Remove the 22 bolts. 2 Remove the cover. WARNING: The nominal voltage of the traction battery is 300 volts. The buffer zone must be set up and insulated rubber gloves and a face shield must be worn.
Page 704 414-03B-101 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-101 REMOVAL AND INSTALLATION (Continued) 6. Remove the two-pin high-voltage connector nuts. 7. Disconnect the high-voltage interlock electrical connector. 8. Disconnect the low-voltage electrical connector. 9. Unclip the thermistors from the high-voltage harness and cut the zip tie.
Page 705 414-03B-102 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-102 REMOVAL AND INSTALLATION (Continued) 10. Open the clips that secure the contactor box harness to the high-voltage harness. 11. Cut the two zip ties securing the contactor box harness. 12. Disconnect the contactor box harness. 13.
Page 706 414-03B-103 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-103 REMOVAL AND INSTALLATION (Continued) Installation 1. To install, reverse the removal procedure. Fill the high-voltage jumper connectors with • Nyogel after final tightening of the nuts/bolts. Apply Locktite 242 to the 22 traction •...
Page 707 414-03B-104 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-104 REMOVAL AND INSTALLATION (Continued) 2. Remove the traction battery cover. 1 Remove the 22 bolts. 2 Remove the cover. WARNING: The nominal voltage of the traction battery is 300 volts. The buffer zone must be set up and insulated rubber gloves and a face shield must be worn.
Page 708 414-03B-105 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-105 REMOVAL AND INSTALLATION (Continued) 6. Use a fuse puller to remove the necessary fuse. 1 25A Charger Fuse 2 40A Auxiliary Fuse Installation 1. To install, reverse the removal procedure. Apply Locktite 242 to the 22 traction •...
Page 709 414-03B-106 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-106 REMOVAL AND INSTALLATION (Continued) 2. Remove the high-voltage power distribution box (HVPDB) cover. 1 Remove the four screws. 2 Remove the cover. 3. Remove the HVPDB fuse safety cover. 1 Remove the two screws. 2 Remove the cover.
Page 710 414-03B-107 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-107 REMOVAL AND INSTALLATION (Continued) High Voltage Power Distribution Box (HVPDB) Removal 1. Remove the positive temperature coefficient (PTC) module. Refer to Section 412-04. 2. Disconnect the power steering pump electrical connector. 3.
Page 711 414-03B-108 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-108 REMOVAL AND INSTALLATION (Continued) 4. NOTE: The HVPDB power supply cable is held in position with three clips. Remove the HVPDB. 1 Remove the bolts. 2 Remove the HVPDB. Installation 1. To install, reverse the removal procedure. High Voltage Wiring —...
Page 712 414-03B-109 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-109 REMOVAL AND INSTALLATION (Continued) WARNING: The nominal voltage of the traction battery is 300 volts. The buffer zone must be set up and insulated rubber gloves and a face shield must be worn. Failure to follow these precautions may result in severe personal injury or death.
Page 713 414-03B-110 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-110 REMOVAL AND INSTALLATION (Continued) 7. Unclip and disconnect the sense lead located above battery module 1. 8. Unclip and disconnect the sense lead located above battery module 24. 9. Unclip and disconnect the sense leads located in front of the contactor box.
Page 714 414-03B-111 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-111 REMOVAL AND INSTALLATION (Continued) 11. Unclip and disconnect the sense leads located above the recirculating blower cover. 12. Unclip and disconnect the sense lead located above battery module 19. 13. Unclip and disconnect the sense lead located between the battery control module and independent observer module.
Page 715 414-03B-112 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-112 REMOVAL AND INSTALLATION (Continued) 15. Unclip and disconnect the sense leads located above battery modules 11 and 10. 16. Remove the six high voltage harness pushpins and remove the harness. 17. Disconnect the high-voltage sense lead harness from the battery control module (BCM).
Page 716 414-03B-113 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-113 REMOVAL AND INSTALLATION (Continued) High Voltage Wiring Special Tool(s) Battery Terminal Cap Opener 418-F215 2001 Ranger EV, 01/2001...
Page 717 414-03B-114 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-114 REMOVAL AND INSTALLATION (Continued) High-Voltage Jumper Routing 2001 Ranger EV, 01/2001...
Page 718 414-03B-115 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-115 REMOVAL AND INSTALLATION (Continued) Removal 1. Remove the traction battery. Refer to Traction Battery. 2. Remove the traction battery cover. 1 Remove the 22 bolts. 2 Remove the cover. WARNING: The nominal voltage of the traction battery is 300 volts.
Page 719 414-03B-116 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-116 REMOVAL AND INSTALLATION (Continued) 7. Remove the HVJ. Use the Battery Terminal Cap Opener to • open the battery module caps. Remove and discard the two nuts. • Installation 1. To install, reverse the removal procedure. Refill the HVJ caps with Nyogel after •...
Page 720 414-03B-117 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-117 REMOVAL AND INSTALLATION (Continued) 2. Disconnect the traction battery high-voltage two-pin connector. Refer to Section 100-05. WARNING: The nominal voltage of the traction battery is 300 volts. The buffer zone must be set up and insulated rubber gloves and a face shield must be worn.
Page 721 414-03B-118 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-118 REMOVAL AND INSTALLATION (Continued) 6. Position the 76-pin electrical connector over the control arm. 7. Position the lift table under the battery pack assembly. The narrow end of the pallet faces the front •...
Page 722 414-03B-119 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-119 REMOVAL AND INSTALLATION (Continued) 11. NOTE: The lift table operates using a minimum of 80 psi and a maximum of 120 psi of compressed air. Slowly raise the lift table until it contacts the bottom of the battery pack.
Page 723 414-03B-120 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-120 REMOVAL AND INSTALLATION (Continued) 16. Release the lift table brake, disconnect the air hose, and roll the lift table from under the vehicle. Installation 1. Raise and support the vehicle. Refer to Section 100-02.
Page 724 414-03B-121 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-121 REMOVAL AND INSTALLATION (Continued) 5. NOTE: The RH front bolt must be installed first in order to correctly align the battery pack. Install the battery pack mounting bolts. Apply Locktite 242 to the bolts prior to •...
Page 725 414-03B-122 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-122 REMOVAL AND INSTALLATION (Continued) 2. Disconnect the traction battery charger electrical connectors. 3. Remove the harness bracket. Remove the bolt. • 4. Remove the A/C inverter motor controller (IMC) bracket. 1 Remove the bolts. 2 Remove the bracket.
Page 726 414-03B-123 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-123 REMOVAL AND INSTALLATION (Continued) 6. Remove the traction battery charger. 1 Remove the four bolts. 2 Remove the charger. Installation 1. To install, reverse removal procedure. 2001 Ranger EV, 01/2001...
Page 727 414-03B-124 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-124 REMOVAL AND INSTALLATION (Continued) Flow Through Blower Removal 1. Remove the traction battery. Refer to Traction Battery. 2. Remove the traction battery cover. 1 Remove the 22 bolts. 2 Remove the cover. 3.
Page 728 414-03B-125 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-125 REMOVAL AND INSTALLATION (Continued) 4. Disconnect the blower electrical connector. CAUTION: The flow through blower is very fragile and can easily be damaged if mishandled. Remove the flow through blower. 1 Remove the nuts. 2 Remove the blower.
Page 729 414-03B-126 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-126 REMOVAL AND INSTALLATION (Continued) Recirculating Blower Removal 1. Remove the traction battery. Refer to Traction Battery. 2001 Ranger EV, 01/2001...
Page 730 414-03B-127 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-127 REMOVAL AND INSTALLATION (Continued) 2. Remove the traction battery cover. 1 Remove the 22 bolts. 2 Remove the cover. 3. Disconnect the recirculating blower electrical connector and cut the zip tie. 4.
Page 731 414-03B-128 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-128 REMOVAL AND INSTALLATION (Continued) 6. Remove the low-voltage harness push pin. 7. Remove the battery hold down bracket. 1 Remove bolts. 2 Remove the bracket. 8. Remove the battery hold down bracket. 1 Remove the bolts.
Page 732 414-03B-129 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-129 REMOVAL AND INSTALLATION (Continued) 10. NOTE: Two of the bolts secure hold down brackets to the cover. Remove the blower cover. 1 Remove the bolts. 2 Remove the cover. 11. NOTE: Note the location of the ‘‘P’’ clip that retains the recirculating blower harness.
Page 733 414-03B-130 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-130 REMOVAL AND INSTALLATION (Continued) 2001 Ranger EV, 01/2001...
Page 734 414-03B-131 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-131 REMOVAL AND INSTALLATION (Continued) Traction Battery High Voltage Fuse (250A) Special Tool(s) Battery Terminal Cap Opener 418-F215 Removal 1. Remove the traction battery. Refer to Traction Battery. WARNING: The nominal voltage of the traction battery is 300 volts.
Page 735 414-03B-132 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-132 REMOVAL AND INSTALLATION (Continued) 3. Remove the traction battery cover. 1 Remove the 22 bolts. 2 Remove the cover. 4. Remove the high-voltage fuse clamp bolt. WARNING: Do not allow the HVJs to touch each other once they are removed from the high-voltage fuse.
Page 736 414-03B-133 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-133 REMOVAL AND INSTALLATION (Continued) Traction Battery Temperature Sensor Removal 1. Remove the traction battery. Refer to Traction Battery. WARNING: The nominal voltage of the traction battery is 300 volts. The buffer zone must be set up and insulated rubber gloves and a face shield must be worn.
Page 737 414-03B-134 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-134 REMOVAL AND INSTALLATION (Continued) 3. Remove the traction battery cover. 1 Remove the 22 bolts. 2 Remove the cover. 4. NOTE: There are two thermistors (temperature sensors) located on modules 3, 12, and 18. There is also one mounted in the cover of the recirculating blower.
Page 738 414-03B-135 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-135 REMOVAL AND INSTALLATION (Continued) Installation 1. Apply a thin layer of thermal grease to the thermistor. 2. Install the thermistor. 1 Install the thermistor. 2 Install the clips. 3. NOTE: If replacing module 12 thermistors, route both of the wires to the inboard side of the module.
Page 739 414-03B-136 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-136 REMOVAL AND INSTALLATION (Continued) 5. Install the module. Refer to the appropriate procedure. 6. Install the traction battery cover. Install the 22 bolts. • Traction Battery Module — Modules 2-6 Special Tool(s) Battery Post Torque Wrench 307-026 Battery Terminal Cap Opener...
Page 740 414-03B-137 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-137 REMOVAL AND INSTALLATION (Continued) Removal CAUTION: Module replacement requires a special charging procedure that is incorporated into the removal and installation of the module. To replace a faulty module, follow the Traction Battery Module Replacement located in the General Procedures section of this manual.
Page 741 414-03B-138 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-138 REMOVAL AND INSTALLATION (Continued) 5. Disconnect the high-voltage interlock electrical connector. 6. Disconnect the low-voltage electrical connector. 7. Position the contactor box towards the front of the traction battery. 8. Remove the composite bars. 1 Unclip the connectors.
Page 742 414-03B-139 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-139 REMOVAL AND INSTALLATION (Continued) 9. Remove the rear module hold down bracket. 1 Remove the bolts. 2 Remove the hold down. 10. Unclip the battery hold down tie bar. 1 Remove the pushpins. 2 Unclip the cover.
Page 743 414-03B-140 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-140 REMOVAL AND INSTALLATION (Continued) 13. Remove the battery hold down tie bar. 14. Disconnect the necessary module. If replacing module 3, disconnect the 2 two • thermistor electrical connectors. Disconnect the HVJ cables and discard the •...
Page 744 414-03B-141 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-141 REMOVAL AND INSTALLATION (Continued) 2001 Ranger EV, 01/2001...
Page 745 414-03B-142 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-142 REMOVAL AND INSTALLATION (Continued) Traction Battery Module — Modules 1, 7, 8, 9, 25 Special Tool(s) Battery Post Torque Wrench 307-026 Battery Terminal Cap Opener 418-F215 Battery Handles 414-F001 2001 Ranger EV, 01/2001...
Page 746 414-03B-143 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-143 REMOVAL AND INSTALLATION (Continued) Removal 1. This procedure contains steps specific to the modules listed. Do not start with this procedure. Refer to Traction Battery Module Replacement to begin module replacement. CAUTION: Disconnect only one HVJ at a time.
Page 747 414-03B-144 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-144 REMOVAL AND INSTALLATION (Continued) 5. Disconnect the high-voltage interlock electrical connector. 6. Disconnect the low-voltage electrical connector. 7. Position the contactor box towards the front of the traction battery. 8. Remove the composite bars. 1 Unclip the connectors.
Page 748 414-03B-145 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-145 REMOVAL AND INSTALLATION (Continued) 9. Unclip the battery hold down tie bar cover. 1 Remove the pushpins. 2 Unclip the cover. 10. Remove the battery hold down strap bolt and pull the straps back. 11.
Page 749 414-03B-146 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-146 REMOVAL AND INSTALLATION (Continued) 13. Remove the low and high-voltage harness push pins. 14. Unclip the battery hold down tie bar cover. 1 Unclip the sense lead connectors from the cover. 2 Unclip the cover.
Page 750 414-03B-147 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-147 REMOVAL AND INSTALLATION (Continued) 17. Disconnect the necessary module. Disconnect the HVJ cables and discard the • nuts. 18. Using the special tool, remove the module. Installation 1. NOTE: The arrow on the battery hold down tie bars must be pointed towards the front of the traction battery.
Page 751 414-03B-148 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-148 REMOVAL AND INSTALLATION (Continued) 2001 Ranger EV, 01/2001...
Page 752 414-03B-149 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-149 REMOVAL AND INSTALLATION (Continued) Traction Battery Module — Modules 10, 11, 12, 23, 24 Special Tool(s) Battery Post Torque Wrench 307-026 Battery Terminal Cap Opener 418-F215 Battery Handles 414-F001 Removal 1. This procedure contains steps specific to the modules listed.
Page 753 414-03B-150 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-150 REMOVAL AND INSTALLATION (Continued) 3. Unclip the battery hold down tie bar cover. 1 Unclip and disconnect the sensor lead electrical connectors. 2 Unclip the cover. 4. Unclip the battery hold down tie bar cover. 1 Unclip and disconnect the sensor lead electrical connector.
Page 754 414-03B-151 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-151 REMOVAL AND INSTALLATION (Continued) 7. Remove the battery hold down strap bolt and pull the straps back off the battery hold down tie bar. 8. Remove the battery hold down tie bar. 9.
Page 755 414-03B-152 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-152 REMOVAL AND INSTALLATION (Continued) Installation 1. NOTE: The arrow on the battery hold down tie bars must be pointed towards the front of the traction battery. To install, reverse the removal procedure. Fill the high-voltage jumper connectors with •...
Page 756 414-03B-153 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-153 REMOVAL AND INSTALLATION (Continued) Traction Battery Module — Modules 13-15 Special Tool(s) Battery Post Torque Wrench 307-026 Battery Terminal Cap Opener 418-F215 Battery Handles 414-F001 Removal Modules 13-15 1. This procedure contains steps specific to the modules listed.
Page 757 414-03B-154 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-154 REMOVAL AND INSTALLATION (Continued) 3. Unclip the battery hold down tie bar cover. 1 Unclip and disconnect the sensor lead electrical connector. 2 Unclip the relay. 3 Unclip the cover. 4. Remove the battery hold down strap bolt and pull the straps back off the battery hold down tie bar.
Page 758 414-03B-155 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-155 REMOVAL AND INSTALLATION (Continued) 7. Remove the battery hold down bracket. 1 Remove the bolts. 2 Remove the bracket. 8. Remove the battery hold down bracket. 1 Remove the bolts. 2 Remove the bracket. Module 15 9.
Page 759 414-03B-156 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-156 REMOVAL AND INSTALLATION (Continued) Modules 13-15 10. Disconnect the necessary module. Disconnect the HVJ cables and discard the • nuts. 11. Using the special tool, remove the module. Installation 1. NOTE: The arrow on the battery hold down tie bars must be pointed towards the front of the traction battery.
Page 760 414-03B-157 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-157 REMOVAL AND INSTALLATION (Continued) 2001 Ranger EV, 01/2001...
Page 761 414-03B-158 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-158 REMOVAL AND INSTALLATION (Continued) Traction Battery Module — Modules 17, 18, 21 Special Tool(s) Battery Post Torque Wrench 307-026 Battery Terminal Cap Opener 418-F215 Battery Handles 414-F001 Removal 1. This procedure contains steps specific to the modules listed.
Page 762 414-03B-159 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-159 REMOVAL AND INSTALLATION (Continued) 2. Remove the blower cover. 1 Remove the four bolts (two each side). 2 Remove the blower cover. 3. Disconnect the blower electrical connector. 4. Remove the flow through blower. 1 Remove the nuts.
Page 763 414-03B-160 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-160 REMOVAL AND INSTALLATION (Continued) 6. Disconnect the low-voltage connector. 1 Loosen the bolts. 2 Disconnect the connectors. 7. Remove the battery control module (BCM). 1 Remove the bolts. 2 Remove the BCM. 8.
Page 764 414-03B-161 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-161 REMOVAL AND INSTALLATION (Continued) 10. Remove the BCM/IOM bracket. 1 Remove the 4-pin auxiliary connector bracket bolt. 2 Remove the bracket mounting bolts. 3 Remove the bracket. 11. Disconnect the harness connectors. 1 Disconnect the sense lead connectors.
Page 765 414-03B-162 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-162 REMOVAL AND INSTALLATION (Continued) 14. Remove the battery hold down strap bolt and pull the straps back off the battery hold down tie bar. 15. Remove the battery hold down tie bar. 16.
Page 766 414-03B-163 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-163 REMOVAL AND INSTALLATION (Continued) Installation 1. NOTE: The arrow on the battery hold down tie bars must be pointed towards the front of the traction battery. To install, reverse the removal procedure. Fill the high-voltage jumper connectors with •...
Page 767 414-03B-164 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-164 REMOVAL AND INSTALLATION (Continued) 2001 Ranger EV, 01/2001...
Page 768 414-03B-165 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-165 REMOVAL AND INSTALLATION (Continued) Traction Battery Module — Modules 16, 19, 20, 22 Special Tool(s) Battery Post Torque Wrench 307-026 Battery Terminal Cap Opener 418-F215 Battery Handles 414-F001 2001 Ranger EV, 01/2001...
Page 769 414-03B-166 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-166 REMOVAL AND INSTALLATION (Continued) Removal 1. Disconnect the high-voltage connector. 1 Loosen the bolts. 2 Disconnect the connectors. 2. Disconnect the low-voltage connector. 1 Loosen the bolts. 2 Disconnect the connectors. 3.
Page 770 414-03B-167 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-167 REMOVAL AND INSTALLATION (Continued) 5. Unclip the sense lead and relay from the BCM/IOM bracket. 6. Remove the BCM/IOM bracket. 1 Remove the 4-pin auxiliary connector bracket bolt. 2 Remove the bracket mounting bolts. 3 Remove the bracket.
Page 771 414-03B-168 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-168 REMOVAL AND INSTALLATION (Continued) 9. Unclip the battery hold down tie bar cover. 10. Remove the battery hold down strap bolt and pull the straps back off the battery hold down tie bar.
Page 772 414-03B-169 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-169 REMOVAL AND INSTALLATION (Continued) 13. Disconnect the necessary module. Disconnect the HVJ cables and discard the • nuts. 14. Using the special tool, remove the module. Installation 1. NOTE: The arrow on the battery hold down tie bars must be pointed towards the front of the traction battery.
Page 773 414-03B-170 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-170 REMOVAL AND INSTALLATION (Continued) 2001 Ranger EV, 01/2001...
Page 774 414-03B-171 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-171 REMOVAL AND INSTALLATION (Continued) Independent Observer Module — (IOM) Removal 1. Remove the traction battery. Refer to Traction Battery. 2. Remove the traction battery cover. 1 Remove the 22 bolts. 2 Remove the cover. 2001 Ranger EV, 01/2001...
Page 775 414-03B-172 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-172 REMOVAL AND INSTALLATION (Continued) WARNING: The nominal voltage of the traction battery is 300 volts. The buffer zone must be set up and insulated rubber gloves and a face shield must be worn. Failure to follow these precautions may result in severe personal injury or death.
Page 776 414-03B-173 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-173 REMOVAL AND INSTALLATION (Continued) Installation 1. To install, reverse the removal procedure. 2001 Ranger EV, 01/2001...
Page 777 414-03B-174 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-174 DISASSEMBLY AND ASSEMBLY Traction Battery Special Tool(s) Battery Terminal Cap Opener 418-F215 Battery Post Torque Wrench 307-026 2001 Ranger EV, 01/2001...
Page 778 414-03B-175 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-175 DISASSEMBLY AND ASSEMBLY (Continued) Traction Battery 2001 Ranger EV, 01/2001...
Page 779 414-03B-176 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-176 DISASSEMBLY AND ASSEMBLY (Continued) Item Description Item Description 76 Pin Connector Flow Through Blower Housing Battery Tray Independent Observer Module (IOM) Battery Modules Battery Control Module (BCM) Two-Pin High Voltage Connector Recirculating Blower Assembly Contactor Box Assembly (CBA) (Continued)
Page 780 414-03B-177 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-177 DISASSEMBLY AND ASSEMBLY (Continued) 5. Wrap the HVJ ends with orange electrical tape. 6. Remove the two-pin high-voltage connector nuts. 7. Disconnect the high-voltage interlock electrical connector. 8. Unclip the thermistors from the high voltage harness and cut the zip tie.
Page 781 414-03B-178 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-178 DISASSEMBLY AND ASSEMBLY (Continued) 9. Open the clips that secure the contactor box harness to the high voltage harness. 10. Cut the two zip ties securing the contactor box harness. 11. Disconnect the contactor box harness. 12.
Page 782 414-03B-179 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-179 DISASSEMBLY AND ASSEMBLY (Continued) 13. Disconnect the high-voltage connector. 1 Loosen the bolts. 2 Disconnect the connectors. 14. Disconnect the low voltage connector. 1 Loosen the bolts. 2 Disconnect the connectors. 15.
Page 783 414-03B-180 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-180 DISASSEMBLY AND ASSEMBLY (Continued) 17. Disconnect the sense leads. 18. Disconnect the sense leads and unclip the relay. 19. Remove the high-voltage harness push pins. 20. Remove the high voltage harness. 1 Disconnect the sense leads.
Page 784 414-03B-181 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-181 DISASSEMBLY AND ASSEMBLY (Continued) 21. Disconnect the thermistor electrical connectors and unclip the relay. 22. Disconnect the low-voltage harness. 1 Disconnect the blower electrical connectors. 2 Disconnect the thermistor electrical connectors. 3 Unclip the relay.
Page 785 414-03B-182 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-182 DISASSEMBLY AND ASSEMBLY (Continued) 25. Remove the composite bars. 1 Remove the bolts. 2 Remove the bars. 26. Remove the BCM/IOM mounting bracket. 1 Remove the 4-pin auxiliary mounting bolt. 2 Remove the bolts. 3 Remove the bracket.
Page 786 414-03B-183 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-183 DISASSEMBLY AND ASSEMBLY (Continued) 29. Remove the battery hold down. 1 Remove the bolts. 2 Remove the hold down. 30. Remove the battery hold down. 1 Remove the bolts. 2 Remove the hold down. 31.
Page 787 414-03B-184 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-184 DISASSEMBLY AND ASSEMBLY (Continued) 33. Remove the rear battery hold down. 1 Remove the bolts. 2 Remove the hold down. 34. Unclip the battery hold down tie bar covers. 35. Remove the hold down strap bolts. 36.
Page 788 414-03B-185 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-185 DISASSEMBLY AND ASSEMBLY (Continued) 37. Remove the battery hold down. 1 Remove the bolt. 2 Remove the hold down. 38. Remove the battery hold down. 1 Remove the bolt. 2 Remove the hold down. 39.
Page 789 414-03B-186 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-186 DISASSEMBLY AND ASSEMBLY (Continued) 41. Remove the hold down strap bolt. 42. Remove the hold down tie bar. 43. Remove the front battery hold down. 1 Remove the bolts. 2 Remove the hold down. 44.
Page 790 414-03B-187 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-187 DISASSEMBLY AND ASSEMBLY (Continued) 46. For modules equipped with a thermistor, remove the module cover. 47. Remove the thermistor. 1 Remove the clips. 2 Remove the thermistor. Assembly 1. NOTE: The battery supports are all the same. NOTE: The battery supports must be pressed against the bottom of the traction battery tray.
Page 791 414-03B-188 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-188 DISASSEMBLY AND ASSEMBLY (Continued) 3. NOTE: The battery supports are all the same. NOTE: The battery supports must be pressed against the bottom of the traction battery tray. Install the front battery supports. 4.
Page 792 414-03B-189 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-189 DISASSEMBLY AND ASSEMBLY (Continued) 7. Apply a thin layer of thermal grease to six thermistors. 8. Install the thermistors on modules 3, 12, and 1 Install the thermistor. 2 Install the clips. 9.
Page 793 414-03B-190 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-190 DISASSEMBLY AND ASSEMBLY (Continued) 11. NOTE: The module orientation must be correct or the HVJs will not fit. Install the modules into the traction battery case. Match the numbers of the modules to the numbers in the bottom of the traction battery case.
Page 794 414-03B-191 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-191 DISASSEMBLY AND ASSEMBLY (Continued) 15. Install the battery hold down. 1 Install the hold down. 2 Install the bolts. 16. Install the recirculating blower cover and battery hold down bolts. 17. Install the front battery hold down. 1 Install the hold down.
Page 795 414-03B-192 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-192 DISASSEMBLY AND ASSEMBLY (Continued) 19. Install the front hold down strap bolt. 20. Clip the front battery hold down tie bar cover into place. 21. Install the rear battery hold down tie bars with the arrows pointing towards the front of the battery pack.
Page 796 414-03B-193 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-193 DISASSEMBLY AND ASSEMBLY (Continued) 23. Clip the rear battery hold down tie bar covers into place. 24. Install the B HVJ (2+ to 3-, 4+ to 5-) and loosely install new nuts. 25.
Page 797 414-03B-194 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-194 DISASSEMBLY AND ASSEMBLY (Continued) 27. Install the E HVJ (11+ to 12-, 9+ to 10-, 7+ to 8-) and loosely install new nuts. 28. Install the N HVJ (25+ to contactor box +) and loosely install a new nut.
Page 798 414-03B-195 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-195 DISASSEMBLY AND ASSEMBLY (Continued) 31. Install the G HVJ (13+ to 14-, 14+ to 15-) and loosely install new nuts. 32. Install the H HVJ (15+ to 16-) and loosely install new nuts. 33.
Page 799 414-03B-196 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-196 DISASSEMBLY AND ASSEMBLY (Continued) 35. Install the K HVJ (17+ to 18-, 21+ to 22-) and loosely install new nuts. 36. Install the A HVJ (1- to contactor box-) and loosely install a new nut. 37.
Page 800 414-03B-197 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-197 DISASSEMBLY AND ASSEMBLY (Continued) 38. Install the flow through blower. 39. Install the flow through blower cover. 40. Install the BCM/IOM bracket. 1 Position the bracket. 2 Install the bolts. 3 Install the 4-pin auxiliary connector bolt. 2001 Ranger EV, 01/2001...
Page 801 414-03B-198 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-198 DISASSEMBLY AND ASSEMBLY (Continued) 41. NOTE: The high voltage fuse is held in place by the composite bar bolt. Install the composite bars. 1 Position the bars. 2 Install the bolts. 42.
Page 802 414-03B-199 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-199 DISASSEMBLY AND ASSEMBLY (Continued) 44. Connect the low-voltage harness. 1 Connect the blower electrical connector. 2 Connect the thermistor electrical connector. 3 Clip the relay into place. 45. Connect the thermistors and clip the relay into the battery hold down tie bar covers.
Page 803 414-03B-200 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-200 DISASSEMBLY AND ASSEMBLY (Continued) 47. Install the high-voltage harness push pins. 48. Connect the sense leads and clip the relay into the battery hold down tie bar cover. 49. Connect the sense leads. 2001 Ranger EV, 01/2001...
Page 804 414-03B-201 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-201 DISASSEMBLY AND ASSEMBLY (Continued) 50. Install the IOM and install the bolts. 51. Connect the IOM electrical connector and tighten the bolt. 52. Position the BCM and install the bolts. 2001 Ranger EV, 01/2001...
Page 805 414-03B-202 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-202 DISASSEMBLY AND ASSEMBLY (Continued) 53. Connect the low-voltage BCM connector and tighten the bolts. 54. Connect the high-voltage BCM connector and tighten the bolts. 55. NOTE: The contactor box is held in place with strips of Velcro Install the contactor box.
Page 806 414-03B-203 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-203 DISASSEMBLY AND ASSEMBLY (Continued) 56. Connect the contactor box harness. 57. Instal two new zip ties to secure the high-voltage harness. 58. Clip the contactor box harness to the high-voltage harness. 2001 Ranger EV, 01/2001...
Page 807 414-03B-204 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-204 DISASSEMBLY AND ASSEMBLY (Continued) 59. Clip the thermistors into the contactor box harness and install a zip tie to secure the thermistor wires. 60. Connect the high-voltage interlock electrical connector. 61. Position the two-pin high-voltage connector and install the nuts.
Page 808 414-03B-205 High Voltage/Traction Battery — Nickel Metal Hydride 414-03B-205 DISASSEMBLY AND ASSEMBLY (Continued) 62. Remove the orange electrical tape from the HVJ ends. 63. NOTE: The HVJ from module 25 connects to the ‘‘+’’ terminal on the contactor box, the HVJ from module 1 connects to the ‘‘-’’...
Page 809: Module Communications Network
418-00-1 Module Communications Network 418-00-1 Manual Table of Contents SECTION 418-00 Module Communications Network VEHICLE APPLICATION: Ranger EV CONTENTS PAGE DESCRIPTION AND OPERATION Module Communication ................418-00-2 DIAGNOSIS AND TESTING Communications Network ................418-00-3 Electrical Schematic ................418-00-3 Inspection and Verification ................ 418-00-3 Pinpoint Tests ..................
Page 810 418-00-2 Module Communications Network 418-00-2 DESCRIPTION AND OPERATION The BCM is located in the upper front section of the traction battery and controls all of the traction Module Communication battery systems. The module controls traction The Electric Ranger has two module battery charging and cooling, and operates the communications networks.
Page 811 418-00-3 Module Communications Network 418-00-3 DESCRIPTION AND OPERATION (Continued) The CTM is mounted to the instrument panel The ECS module is located behind the instrument behind the radio. The CTM controls essential and panel next to the plenum assembly. The module convenience features, such as windshield wipers, controls the air bag deployment in a crash situation.
Page 812 418-00-4 Module Communications Network 418-00-4 DIAGNOSIS AND TESTING (Continued) Symptom Chart Symptom Chart Condition Possible Sources Action The Module Does Not Wire or connection in ISO GO to Pinpoint Test A. • • • Respond to the NGS Tester 9141 link circuit. —...
Page 813 418-00-5 Module Communications Network 418-00-5 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST A: THE MODULE DOES NOT RESPOND TO THE NGS TESTER — ANTI-LOCK BRAKE CONTROL MODULE TEST STEP ACTION TO TAKE A2 CHECK ANTI-LOCK BRAKE CONTROL MODULE C1942 CONNECTION • Reconnect anti-lock brake control module C1942 and rerun DATA LINK Yes = System OK.
Page 814 418-00-6 Module Communications Network 418-00-6 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST B: THE MODULE DOES NOT RESPOND TO THE NGS TESTER — BATTERY CONTROL MODULE (BCM) TEST STEP ACTION TO TAKE • With key OFF, disconnect in-line C136 and inspect C136M and C136F Yes = REPAIR the wire in for damage.
Page 815 418-00-7 Module Communications Network 418-00-7 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST C: THE MODULE DOES NOT RESPOND TO THE NGS TESTER — INTERFACE ADAPTER ASSEMBLY (IAA) MODULE TEST STEP ACTION TO TAKE • With key OFF, disconnect IAA module C1945 and NGS Tester. Inspect No = REPAIR as necessary.
Page 816 418-00-8 Module Communications Network 418-00-8 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST D: THE MODULE DOES NOT RESPOND TO THE NGS TESTER — TRACTION INVERTER MODULE (TIM) TEST STEP ACTION TO TAKE • With key OFF, disconnect TIM C4998, C4999 and NGS Tester. Inspect No = REPAIR as necessary.
Page 817 418-00-9 Module Communications Network 418-00-9 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST E: NO MODULE/NETWORK COMMUNICATION — ISO 9141 LINK TEST STEP ACTION TO TAKE E1 CHECK NGS TESTER CONNECTOR AND DATA LINK CONNECTOR (DLC) C209 GO to E2. • With key OFF, disconnect NGS Tester. Inspect terminals 5 and 7 on Yes = NGS Tester and pins 5 and 7 on DLC C209 for damage.
Page 818 418-00-10 Module Communications Network 418-00-10 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST E: NO MODULE/NETWORK COMMUNICATION — ISO 9141 LINK TEST STEP ACTION TO TAKE • Is the voltage greater than 0 volts? No = GO to E8. E8 CHECK CIRCUIT 70 (LB/W) FOR SHORT TO GROUND •...
Page 819 418-00-11 Module Communications Network 418-00-11 DIAGNOSIS AND TESTING (Continued) PINPOINT TEST F: NO MODULE/NETWORK COMMUNICATION — SCP LINK TEST STEP ACTION TO TAKE • With key OFF, reconnect in-line C1939 and disconnect BCM C1987. Yes = REPAIR the wire(s) in question.
Page 824 FCS-12887-01 FORD CUSTOMER SERVICE DIVISION Quality is Job 1 Ford Customer Service Division has developed a new format for the 2001 Electric Ranger Wiring Diagrams. Our goal is to ORDERING INFORMATION provide accurate and timely electrical information. Information about how to order...
Page 825 TABLE OF CONTENTS/INDEX 2001 RANGER ELECTRIC VEHICLE Table of Contents Component Testing ....149 1 Cooling Fan Relay Box ..13 2, 13 17 Grounds .
Page 826 TABLE OF CONTENTS/INDEX 2001 RANGER ELECTRIC VEHICLE Traction Battery State of Charge 61 2, 61 7 Interval Wiper/Washer ... 81 1, 81 3 Lamps: Headlamps ..... 85 1, 61 2 I/P Fuse Panel: Backup...
Page 827 TABLE OF CONTENTS/INDEX 2001 RANGER ELECTRIC VEHICLE IMPORTANT SAFETY NOTICE Appropriate service methods and proper repair procedures are essential for the safe, reliable operation of all motor vehicles, as well as the personal safety of the individual doing the work. This Manual provides gen eral directions for accomplishing service and repair work with tested, effective tech niques.
Page 828 TABLE OF CONTENTS/INDEX 2001 RANGER ELECTRIC VEHICLE...
Page 829 HOW TO USE THIS MANUAL 2001 ELECTRIC RANGER VEHICLE The purpose of this manual is to show electrical cir- Schematic pages contain circuit voltages to help The “LOCATION INDEX” (Cell 152) provides the cuits in a clear and simple fashion to make trouble- simplify troubleshooting hints.
Page 830 Each circuit compo- plaint. nent is named (underlined titles). Wire and con- D Use safety stands whenever a procedure nector colors are listed as follows (standard Ford Step 2. Narrow the concern. requires being under a vehicle. color abbreviations are used):...
Page 831 HOW TO USE THIS MANUAL 2001 ELECTRIC RANGER VEHICLE Some engine circuits may need special test equip- An Ohmmeter shows the resistance between two CAUTION ment and special procedures. See the Workshop connected points (Figure 1). Manual and other service books for details. You will When using a self-powered test lamp or ohmme- find the circuits in this manual to be helpful with those TEST LAMP...
Page 832 HOW TO USE THIS MANUAL 2001 ELECTRIC RANGER VEHICLE VOLTAGE CHECK 4. Connect one Test Lamp lead to hot end of blown Turn on power to the circuit. Perform a Voltage fuse. Connect other lead to ground. Bulb should Check between the suspected inoperative ground Connect one lead of test lamp to a known good glow, showing power to fuse.
Page 833 HOW TO USE THIS MANUAL 2001 ELECTRIC RANGER VEHICLE Male Half Female Half Locked Terminal TROUBLESHOOTING WIRING HARNESS Seal AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical con- cerns.
Page 834 HOW TO USE THIS MANUAL 2001 ELECTRIC RANGER VEHICLE Solder coated wire pierced through the insulation of another circuit. Solder Coated Wire to Ground Any probe entering the terminal may enlarge the contact spring opening creating an intermittent signal. Insert the correct mating Harness terminal (Location A) Protective Tape...
Page 835 HOW TO USE THIS MANUAL 2001 ELECTRIC RANGER VEHICLE ELECTRICAL SYMBOLS FUSE DASHED COMPONENT SPLICE OR CURRENT RATING S100 CRIMP ONLY PART OF THE COMPONENT IS SHOWN TERMINAL ON THE PAGE; THE COMPONENT IS SHOWN COMPLETE IN ANOTHER LOCATION FUSIBLE LINK 14 GA DG COMPONENT FROM...
Page 836 HOW TO USE THIS MANUAL 2001 ELECTRIC RANGER VEHICLE ELECTRICAL SYMBOLS DIODES MOTOR CURRENT FLOWS IN DIRECTION OF C105F ARROW ONLY C105M SOCKET C100F IN-LINE C100M CONNECTOR HEATING CAPACITOR ELEMENT PIN OR BLADE SINGLE DASHED LINE INDICATES THAT WIRE ON LEFT ALSO PASSES THROUGH TRANSISTOR THE SAME CONNECTOR THERMISTOR...
Page 837 10-1 GROUNDS 2001 RANGER ELECTRIC VEHICLE GENERIC PASSENGER ELECTRONIC INSTRUMENT AIRBAG AIR BAG MODULE CLUSTER SLIDING DEACTIVATION (GEM) AIR BAG DIAGNOSTIC PAGES 61 2, CONTACT DATA LINK PAGES 59 1, MONITOR (PAD) SWITCH 61 7 PAGE 44 1 PAGE 14 5 59 3 DATA LINK PAGE 46 1...
Page 838 GROUNDS 10-2 2001 RANGER ELECTRIC VEHICLE * POSTAL ** EXCEPT POSTAL TRACTION INVERTER MODULE (TIM) BATTERY INDEPENDENT PAGE 26 3 CONTROL CONTACTOR OBSERVER MODULE MODULE (IOM) PAGE 16 5 PAGE 16 11 FROM S205 PAGE 16 5 PAGE 10 1 C4998 3233 BK/LB...
Page 839 10-3 GROUNDS 2001 RANGER ELECTRIC VEHICLE All wires are 57 (BK) EXCEPT POSTAL unless otherwise noted. I/P RELAY A/C HEATER HEATER BLOWER A/C HEATER CENTER CONTROL CONTROL SWITCH LOCK UNLOCK CONTROL CIGAR POWER ASSEMBLY ASSEMBLY PAGES RELAY RELAY ASSEMBLY RADIO LIGHTER POINT PAGE 54 4...
Page 840 GROUNDS 10-4 2001 RANGER ELECTRIC VEHICLE All wires are 57 (BK) EXCEPT POSTAL unless otherwise noted. BRAKE INDEPENDENT BATTERY TRACTION INVERTER WINDSHIELD FLUID FLOW OBSERVER BATTERY RECIRCU CONTROL BATTERY MOTOR WIPER LEVEL THRU MODULE CONTROL LATING CONTACTOR MODULE COOLING CONTACTOR CONTROLLER MOTOR SWITCH...
Page 841 10-5 GROUNDS 2001 RANGER ELECTRIC VEHICLE All wires are 57 (BK) EXCEPT POSTAL unless otherwise noted. RECIRCULATION POWER TRACTION HEATER A/C HEATER FRESH/ VACUUM STEERING INVERTER CONTROL CONTROL RECIRCULATION INSTRUMENT SOLENOID ASSEMBLY MODULE (TIM) ASSEMBLY ASSEMBLY SELECT SWITCH CLUSTER PAGE 53 4 PAGE 54 4 PAGES 53 3, 54 3 PAGE 43 1...
Page 842 GROUNDS 10-6 2001 RANGER ELECTRIC VEHICLE POSITIVE All wires are 57 (BK) TEMPERATURE unless otherwise noted. COEFFICIENT LEFT FRONT TRACTION POWER (PTC) LEFT FRONT LEFT FRONT SIDE MARKER BATTERY STEERING SWITCHING COOLANT VACUUM PARK/TURN PARK/TURN LAMP CHARGER ASSEMBLY MODULE PUMP PUMP LAMP LAMP...
Page 843 10-7 GROUNDS 2001 RANGER ELECTRIC VEHICLE All wires are 57 (BK) EXCEPT POSTAL unless otherwise noted. VARIABLE DAYTIME BLOWER WINDSHIELD RIGHT FRONT RUNNING RIGHT FRONT RIGHT FRONT CONTROLLER WASHER PUMP COOLING SIDE MARKER CHARGER LAMPS (DRL) PARK/TURN PARK/TURN LEFT RIGHT MOTOR (VBC) LAMP...
Page 844 GROUNDS 10-8 2001 RANGER ELECTRIC VEHICLE EXCEPT POSTAL All wires are 57 (BK) unless otherwise noted. BRAKE PEDAL OUTSIDE SAFETY POSITION CARGO/HIGH AUXILIARY INTERFACE ADAPTER (BPP) DC/DC BELT MOUNTED SHIFT LOCK MAIN LIGHT BATTERY ASSEMBLY (IAA) SWITCH CONVERTER SWITCH STOP LAMP ACTUATOR FLASHER SWITCH...
Page 845: Backup
10-9 GROUNDS 2001 RANGER ELECTRIC VEHICLE All wires are 57 (BK) EXCEPT POSTAL unless otherwise noted. LEFT RIGHT LEFT RIGHT LEFT REAR RIGHT REAR BACKUP LEFT REAR RIGHT REAR BACKUP LICENSE LICENSE PRESSURE PARK/STOP PARK/STOP LAMP TURN LAMP TURN LAMP LAMP LAMP LAMP...
Page 846 GROUNDS 10-10 2001 RANGER ELECTRIC VEHICLE All wires are 57 (BK) EXCEPT POSTAL unless otherwise noted. RIGHT RIGHT EXTERIOR MASTER DOOR DOOR REAR VIEW WINDOW LOCK AJAR LEFT DOOR MIRROR CONTROL LEFT DOOR SWITCH SWITCH LOCK SWITCH SWITCH SWITCH AJAR SWITCH PAGE 110 2 PAGE 59 2 PAGE 110 2...
Page 847 10-11 GROUNDS 2001 RANGER ELECTRIC VEHICLE All wires are 57 (BK) POSTAL unless otherwise noted. TRACTION INDEPENDENT BATTERY BATTERY FLOW BATTERY OBSERVER CONTROL CONTROL THRU RECIRCU COOLING MODULE CONTACTOR MODULE CONTACTOR MODULE LATING FAN (IOM) PAGES 16 4, (BCM) PAGE 19 2 PAGE 19 2 PAGE 19 1 PAGE 19 3...
Page 848 GROUNDS 10-12 2001 RANGER ELECTRIC VEHICLE All wires are 57 (BK) POSTAL unless otherwise noted. FROM C136 PAGE BRAKE 10-16 RIGHT FRONT FLUID LEVEL CHARGER RIGHT FRONT FROM SIDE MARKER INLET SWITCH RIGHT PARK/TURN C124 LAMP PAGE 18 3 PAGE 61 8 HEADLAMP LAMP PAGE...
Page 849 10-13 GROUNDS 2001 RANGER ELECTRIC VEHICLE All wires are 57 (BK) POSTAL unless otherwise noted. RELAY MODULE WINDSHIELD WIPER PREHEAT RECIRCULATION TURN SIGNAL HAZARD WIPER PARK IGNITION VACUUM FLASHER FLASHER SHIFT LOCK MOTOR RELAY RELAY SOLENOID DATA LINK RELAY RELAY ACTUATOR DATA LINK PAGE 81 3...
Page 850 GROUNDS 10-14 2001 RANGER ELECTRIC VEHICLE All wires are 57 (BK) unless otherwise noted. AUXILIARY RELAY BOX R/H TURN L/H TURN REPEATER ECONO HAZARD HAZARD REAR HAZARD ISOLATION MODE RELAY RELAY RELAY ONLY RELAY LEFT HI BEAM RIGHT HI BEAM RELAY PAGE 71 4 PAGE 90 6...
Page 851 10-15 GROUNDS 2001 RANGER ELECTRIC VEHICLE All wires are 57 (BK) POSTAL unless otherwise noted. TRACTION FRESH/ POWER INVERTER RECIRCULATION PREHEAT BLOWER STEERING MODULE A/C HEATER CONTROL ASSEMBLY SELECT SWITCH SWITCH SWITCH ASSEMBLY (TIM) PAGE 54 4 PAGE 54 4 PAGE 53 6 PAGE 54 3 PAGE 43 1...
Page 852 GROUNDS 10-16 2001 RANGER ELECTRIC VEHICLE POSTAL All wires are 57 (BK) unless otherwise noted. BRAKE PEDAL POSITION GRUMMAN HEADLINER MAIN LIGHT HAZARD CIGAR CARGO SWITCH INSTRUMENT CLUSTER (BPP) SWITCH HARNESS SWITCH SWITCH LIGHTER GUIDE LAMP PAGES 61 9, 61 10 PAGE 90 4 PAGE 90 10 PAGE 13 29...
Page 853 10-17 GROUNDS 2001 RANGER ELECTRIC VEHICLE All wires are 57 (BK) POSTAL unless otherwise noted. VARIABLE BLOWER WINDSHIELD LEFT FRONT CONTROLLER WASHER PUMP COOLING BACKUP LEFT FRONT SIDE MARKER (VBC) MOTOR ALARM PARK/TURN LEFT LAMP PAGE 54 1 PAGE 81 2 PAGE 33 1 PAGE 93 2 LAMP...
Page 854 GROUNDS 10-18 2001 RANGER ELECTRIC VEHICLE POSTAL All wires are 57 (BK) unless otherwise noted. FROM DC/DC PRESSURE S209 AUXILIARY INTERFACE ADAPTER ASSEMBLY CONVERTER SWITCH OIL PUMP PAGE BATTERY (IAA) MODULE PAGE 12 1 PAGE 26 2 PAGE 26 2 10-13 C1945 C4997...
Page 855 FUSE PANEL/CIRCUIT PROTECTION 11-1 2001 RANGER ELECTRIC VEHICLE CIRCUIT PROTECTION DEVICES MAXI FUSE CARTRIDGE FUSE COLOR CODING Electrical circuits on this vehicle may be pro SIDE VIEW TOP VIEW AMPERE RATING HOUSING COLOR tected by fuses, fusible links, fusible link car Pink tridges, circuit breakers, or a combination of these devices.
Page 856 FUSE PANEL/CIRCUIT PROTECTION 11-2 2001 RANGER ELECTRIC VEHICLE * POSTAL ELECTRIC VEHICLE FUSE CIRCUITS PROTECTED AMPS POSITION Stop Lamp Relay, Stop Lamp Switch EVAC/Fill Connector #1, Anti Lock Brake Control Module Main Light Switch, Instrument Cluster Windshield Wiper Motor, Windshield Wiper Speed Relay, Windshield Wiper Relay, Windshield Washer Pump Motor Relay Cigar Lighter...
Page 857 FUSE PANEL/CIRCUIT PROTECTION 11-3 2001 RANGER ELECTRIC VEHICLE EXCEPT POSTAL ELECTRIC VEHICLE POWER DISTRIBUTION BOX (EVPDB)
Page 858 FUSE PANEL/CIRCUIT PROTECTION 11-4 2001 RANGER ELECTRIC VEHICLE POSITION FUSE/ AMPS CIRCUITS PROTECTED POSITION FUSE/ AMPS CIRCUITS PROTECTED RELAY RELAY Maxi Ignition Switch NOT USED Maxi I/P Fuse Panel NOT USED Maxi Anti Lock Brake Control Module NOT USED NOT USED Mini Power Windows NOT USED...
Page 859 FUSE PANEL/CIRCUIT PROTECTION 11-5 2001 RANGER ELECTRIC VEHICLE POSTAL ELECTRIC VEHICLE POWER DISTRIBUTION BOX (EVPDB)
Page 860 FUSE PANEL/CIRCUIT PROTECTION 11-6 2001 RANGER ELECTRIC VEHICLE POSITION FUSE/ AMPS CIRCUITS PROTECTED POSITION FUSE/ AMPS CIRCUITS PROTECTED RELAY RELAY Maxi Ignition Switch Mini ABS Motor Maxi I/P Fuse Panel Fuses 1, 5, 9, 13, 17, NOT USED 21, 25 and 29 NOT USED Maxi EVAC/Fill Connector, Anti Lock Brake...
Page 861 FUSE PANEL/CIRCUIT PROTECTION 11-7 2001 RANGER ELECTRIC VEHICLE FUSE CIRCUITS PROTECTED POSITION AMPS DC/DC Converter AC Inverter Motor Controller (IMC) DC/DC Positive Temperature Coefficient (PTC) 10 AMP Switching Module 25 AMP Power Steering Assembly 25 AMP 10 AMP PWR STR HIGH VOLTAGE POWER DISTRIBUTION BOX (HVPDB) CHARGER...
Page 862 FUSE PANEL/CIRCUIT PROTECTION 11-8 2001 RANGER ELECTRIC VEHICLE EXCEPT POSTAL I/P RELAY CENTER BOX DOOR PUMP AJAR LOCK RELAY RELAY RELAY BATTERY INTERIOR ONE TOUCH SAVER UNLOCK LAMP DOWN RELAY RELAY RELAY RELAY MODULE...
Page 863 FUSE PANEL/CIRCUIT PROTECTION 11-9 2001 RANGER ELECTRIC VEHICLE POSTAL RELAY MODULE AUXILIARY RELAY BOX #2 RIGHT ECONO LH TURN/ HIGH ISOLATION MODE HAZARD POWER WIPER BEAM RELAY RELAY RELAY PUMP STEERING PARK RELAY RELAY RELAY RELAY PREHEAT PREHEAT REAR RH TURN/ LEFT IGNITION INVERTER...
Page 864 FUSE PANEL/CIRCUIT PROTECTION 11-10 2001 RANGER ELECTRIC VEHICLE...
Page 865 12-1 AUXILIARY BATTERY CHARGING SYSTEM 2001 RANGER ELECTRIC VEHICLE WARNING: This system contains high voltage * POSTAL ELECTRIC VEHICLE For diagnostic information, refer to Section components and wiring. Do not attempt any 414 02 of the Workshop Manual. service procedures without direction from the workshop manual.
Page 866 AUXILIARY BATTERY CHARGING SYSTEM 12-2 2001 RANGER ELECTRIC VEHICLE...
Page 867 13-1 POWER DISTRIBUTION (LOW VOLTAGE) 2001 RANGER ELECTRIC VEHICLE For diagnostic information, refer to Section EXCEPT POSTAL 418 01 of the Workshop Manual. ELECTRIC MEGA FUSE VEHICLE POWER AUXILIARY DISTRIBUTION BATTERY BOX (EVPDB) CHARGING BK/OG SYSTEM 175A PAGE 12 1 2037 C136 AUXILIARY...
Page 868 POWER DISTRIBUTION (LOW VOLTAGE) 13-2 2001 RANGER ELECTRIC VEHICLE EXCEPT POSTAL ELECTRIC VEHICLE POWER DISTRIBUTION TO ELECTRIC BOX (EVPDB) VEHICLE POWER DISTRIBUTION BOX PAGE 13 3 1052 TN/BK YE/LG S1977 TO I/P C136 FUSE PANEL C154 PAGE 13 9 1052 TN/BK COOLING ANTI LOCK BRAKE...
Page 869 13-3 POWER DISTRIBUTION (LOW VOLTAGE) 2001 RANGER ELECTRIC VEHICLE EXCEPT POSTAL ELECTRIC VEHICLE FROM ELECTRIC POWER VEHICLE POWER DISTRIBUTION DISTRIBUTION BOX (EVPDB) PAGE 13 2 YE/LB 1049 BN/PK 1048 LB/WH WH/OG YE/LB C135 C136 C1939 ELECTRIC VEHICLE HORN POWER RELAY DISTRIBUTION BOX (EVPDB) YE/LG...
Page 870 POWER DISTRIBUTION (LOW VOLTAGE) 13-4 2001 RANGER ELECTRIC VEHICLE EXCEPT POSTAL ELECTRIC VEHICLE TO ELECTRIC POWER VEHICLE POWER DISTRIBUTION DISTRIBUTION BOX (EVPDB) PAGE 13 5 PK/BK BK/WH PK/BK C1939 C134 ELECTRIC WITH NiMH PK/BK VEHICLE BATTERY VACUUM POWER PUMP PK/BK BK/WH DISTRIBUTION RELAY...
Page 871 13-5 POWER DISTRIBUTION (LOW VOLTAGE) 2001 RANGER ELECTRIC VEHICLE EXCEPT POSTAL ELECTRIC VEHICLE FROM ELECTRIC POWER VEHICLE POWER DISTRIBUTION DISTRIBUTION BOX (EVPDB) 30A (LEAD ACID) PAGE 13 4 15A (NiMH) RD/LB YE/BK C135 C1939 DB/OG RD/LB YE/BK C239 LEAD ACID NIMH ACCESSORY C134...
Page 872 POWER DISTRIBUTION (LOW VOLTAGE) 13-6 2001 RANGER ELECTRIC VEHICLE EXCEPT POSTAL ELECTRIC VEHICLE POWER DISTRIBUTION BOX (EVPDB) 1059 LB/OG BN/PK C135 S1970 1059 LB/OG YE/LG 1059 LB/OG BN/PK YE/LG RELAY BN/PK CENTER PUMP RELAY ELECTRIC VEHICLE BLOWER COOLANT POWER MOTOR PUMP DISTRIBUTION RELAY...
Page 873 13-7 POWER DISTRIBUTION (LOW VOLTAGE) 2001 RANGER ELECTRIC VEHICLE HOT IN ACC OR RUN EXCEPT POSTAL I/P FUSE PANEL INTERVAL WIPER/WASHER PAGE 81 1 C136 S1968 WH/BK WH/BK WINDSHIELD WIPER RELAY BK/PK YE/WH ELECTRIC VEHICLE WINDSHIELD WINDSHIELD C136 POWER WIPER SPEED WASHER PUMP DISTRIBUTION RELAY...
Page 874 POWER DISTRIBUTION (LOW VOLTAGE) 13-8 2001 RANGER ELECTRIC VEHICLE EXCEPT POSTAL HOT IN START HOT IN RUN I/P FUSE PANEL 7.5A 7.5A 7.5A WH/PK LB/PK C201 1001 WH/YE 1002 BK/PK C136 WH/PK YE/BK 1002 BK/PK BK/LG BK/LG LB/PK 1003 GY/YE C3998 S163 WH/PK...
Page 875 13-9 POWER DISTRIBUTION (LOW VOLTAGE) 2001 RANGER ELECTRIC VEHICLE EXCEPT POSTAL FROM I/P FUSE PANEL PAGE 13 2 1052 TN/BK HOT IN RUN I/P FUSE PANEL RD/WH OG/YE VT/OG VT/OG C201 C208 RD/WH OG/YE C135 C211 VT/OG FLASHER LB/WH 1001 WH/YE LG/VT C3999...
Page 876 POWER DISTRIBUTION (LOW VOLTAGE) 13-10 2001 RANGER ELECTRIC VEHICLE HOT IN START OR RUN EXCEPT POSTAL I/P FUSE PANEL 7.5A 7.5A RD/YE LB/PK RD/YE LB/PK C136 C201 LB/PK C221 S1959 S2774 RD/YE LB/PK GENERIC C124 ELECTRONIC C3998 MODULE (GEM) LB/PK PAGE 59 1 RD/YE LB/PK...
Page 877 13-11 POWER DISTRIBUTION (LOW VOLTAGE) 2001 RANGER ELECTRIC VEHICLE EXCEPT POSTAL HOT AT ALL TIMES I/P FUSE PANEL 7.5A LG/RD LG/RD C134 LG/RD S2995 S1967 C209 LG/RD LG/RD ELECTRIC DATA LINK VEHICLE CONNECTOR STOP POWER (DLC) LAMP DISTRIBUTION PAGE 14 1 RELAY BOX (EVPDB) LG/RD...
Page 878 POWER DISTRIBUTION (LOW VOLTAGE) 13-12 2001 RANGER ELECTRIC VEHICLE EXCEPT POSTAL HOT AT ALL TIMES I/P FUSE PANEL TN/YE TN/WH TN/YE C201 C205 RELAY BATTERY CENTER SAVER RELAY MAIN LIGHT C3998 SWITCH PAGE 13 13 S2900 LG/OG INTERIOR LAMPS PAGE 89 1 1005 VT/OG S221...
Page 879 13-13 POWER DISTRIBUTION (LOW VOLTAGE) 2001 RANGER ELECTRIC VEHICLE EXCEPT POSTAL HOT IN START OR RUN HOT AT ALL TIMES HOT AT ALL TIMES I/P FUSE ELECTRIC I/P FUSE PANEL VEHICLE POWER PANEL PAGE 13 10 DISTRIBUTION PAGE 13 12 7.5A BOX (EVPDB) PAGE 13 5...
Page 880 POWER DISTRIBUTION (LOW VOLTAGE) 13-14 2001 RANGER ELECTRIC VEHICLE EXCEPT POSTAL FROM C205 PAGE 13 13 S2900 FUSE C201 C134 PANEL 7.5A C3999 1011 TN/OG S1004 C224 C204 EXTERIOR C403 LAMPS PAGE 92 1 INSTRUMENT GENERIC ILLUMINATION ELECTRONIC DIMMING MODULE C411 C412 MODULE...
Page 881 13-15 POWER DISTRIBUTION (LOW VOLTAGE) 2001 RANGER ELECTRIC VEHICLE HOT AT ALL TIMES HOT AT ALL TIMES EXCEPT POSTAL MAIN LIGHT ELECTRIC SWITCH VEHICLE POWER PAGE 13 13 DISTRIBUTION HEAD SEE PAGE 149 2 BOX (EVPDB) FOR SWITCH PAGE 13 5 PARK TESTING C205...
Page 882 POWER DISTRIBUTION (LOW VOLTAGE) 13-16 2001 RANGER ELECTRIC VEHICLE For diagnostic information, refer to Section POSTAL 418 01 of the Workshop Manual. ELECTRIC MEGA FUSE VEHICLE POWER AUXILIARY DISTRIBUTION BOX BATTERY (EVPDB) CHARGING BK/OG 175A SYSTEM PAGE 12 1 2037 C136 AUXILIARY S232...
Page 883 13-17 POWER DISTRIBUTION (LOW VOLTAGE) 2001 RANGER ELECTRIC VEHICLE POSTAL ELECTRIC VEHICLE TO ELECTRIC POWER DISTRIBUTION VEHICLE POWER BOX (EVPDB) DISTRIBUTION BOX PAGE 13 18 1052 TN/BK YE/LG S1977 TO I/P C136 FUSE PANEL EVAC/FILL PAGE 13 24 CONNECTOR #1 C1946 EVAC/FILL C1941...
Page 884 POWER DISTRIBUTION (LOW VOLTAGE) 13-18 2001 RANGER ELECTRIC VEHICLE POSTAL ELECTRIC FROM ELECTRIC VEHICLE VEHICLE POWER POWER DISTRIBUTION DISTRIBUTION BOX (EVPDB) PAGE 13 17 YE/LB 1048 LB/WH WH/OG S147 YE/LB C136 C1939 ELECTRIC VEHICLE HORN C135 POWER RELAY DISTRIBUTION BOX (EVPDB) YE/LG 1048 LB/WH...
Page 885 13-19 POWER DISTRIBUTION (LOW VOLTAGE) 2001 RANGER ELECTRIC VEHICLE POSTAL ELECTRIC VEHICLE TO ELECTRIC POWER VEHICLE POWER DISTRIBUTION DISTRIBUTION BOX (EVPDB) PAGE 13 20 PK/BK BK/WH PK/BK C1939 C134 ELECTRIC WITH NiMH PK/BK VEHICLE BATTERY VACUUM POWER PUMP PK/BK BK/WH DISTRIBUTION RELAY BOX (EVPDB)
Page 886 POWER DISTRIBUTION (LOW VOLTAGE) 13-20 2001 RANGER ELECTRIC VEHICLE ELECTRIC FROM ELECTRIC VEHICLE VEHICLE POWER POWER DISTRIBUTION DISTRIBUTION BOX (EVPDB) 30A (LEAD ACID) PAGE 13 19 15A (NiMH) YE/BK S182 YE/BK DB/OG YE/BK YE/BK C1939 YE/BK C134 LEAD ACID NIMH BATTERY PACK BLOWER...
Page 887 13-21 POWER DISTRIBUTION (LOW VOLTAGE) 2001 RANGER ELECTRIC VEHICLE ELECTRIC VEHICLE POSTAL POWER DISTRIBUTION BOX (EVPDB) 1059 LB/OG BN/PK C135 1059 LB/OG S1970 YE/LG 1059 LB/OG BN/PK YE/LG RELAY MODULE BN/PK PUMP RELAY ELECTRIC VE HICLE POWER BLOWER COOLANT DISTRIBUTION MOTOR PUMP BOX (EVPDB)
Page 888 POWER DISTRIBUTION (LOW VOLTAGE) 13-22 2001 RANGER ELECTRIC VEHICLE I/P FUSE POSTAL HOT IN ACC OR RUN PANEL INTERVAL WIPER/WASHER S150 PAGE 81 3 S149 C136 RELAY MODULE S1968 WIPER PARK RELAY PAGE 81 5 WINDSHIELD WIPER RELAY WH/BK WH/BK BK/PK YE/WH ELECTRIC VE...
Page 889 13-23 POWER DISTRIBUTION (LOW VOLTAGE) 2001 RANGER ELECTRIC VEHICLE POSTAL HOT IN START HOT IN RUN I/P FUSE PANEL 7.5A 7.5A LB/PK WH/PK C136 LB/PK C3998 1002 BK/PK 1003 GY/YE EVAC/FILL CONNECTOR C1946 C1941 EVAC/FILL WH/PK CONNECTOR LB/PK C221 C4999 C154 C212 GENERIC...
Page 890 POWER DISTRIBUTION (LOW VOLTAGE) 13-24 2001 RANGER ELECTRIC VEHICLE POSTAL FROM I/P FUSE PANEL PAGE 13 17 1052 TN/BK HOT IN RUN I/P FUSE PANEL 7.5A RD/WH OG/YE VT/OG S171 S170 C3999 OG/YE LB/WH 1001 WH/YE LG/VT RD/WH RD/WH OG/YE C208 VT/OG 1344...
Page 891 13-25 POWER DISTRIBUTION (LOW VOLTAGE) 2001 RANGER ELECTRIC VEHICLE POSTAL HOT IN START OR RUN I/P FUSE PANEL 7.5A 7.5A RD/YE RD/YE LB/PK LB/PK RELAY AUXILIARY C216 C221 MODULE RELAY BOX #2 C3998 TO C136 PAGE 13-26 INSTRUMENT PREHEAT GENERIC ECONO CLUSTER IGNITION...
Page 892 POWER DISTRIBUTION (LOW VOLTAGE) 13-26 2001 RANGER ELECTRIC VEHICLE POSTAL FROM I/P RELAY RELAY FUSE 19 MODULE MODULE PAGE 13-25 POWER PREHEAT STEERING INVERTER RELAY RELAY PAGE 43-2 PAGE 53-6 LB/PK C136 LB/PK LG/OG S1959 C135 C135 LB/PK LB/PK LB/PK LB/PK LB/PK S174...
Page 893 13-27 POWER DISTRIBUTION (LOW VOLTAGE) 2001 RANGER ELECTRIC VEHICLE POSTAL HOT AT ALL TIMES I/P FUSE PANEL 7.5A LG/RD C134 LG/RD S1967 LG/RD LG/RD LG/RD S172 ELECTRIC VEHICLE STOP POWER LAMP DISTRIBUTION RELAY BOX (EVPDB) S2995 C209 C2099 C134 C136 DATA LINK CONNECTOR YE/LG...
Page 894 POWER DISTRIBUTION (LOW VOLTAGE) 13-28 2001 RANGER ELECTRIC VEHICLE POSTAL HOT AT ALL TIMES I/P FUSE PANEL C3998 TN/WH TN/YE S291 S2900 TN/YE S4993 S292 TN/YE TN/WH TN/WH TN/YE C4998 C216 C215 C260 C903 C904 RELAY MODULE POWER STEERING TRACTION MAIN LIGHT GRUMMAN CARGO...
Page 895 13-29 POWER DISTRIBUTION (LOW VOLTAGE) 2001 RANGER ELECTRIC VEHICLE POSTAL HOT AT ALL TIMES HOT AT ALL TIMES ELECTRIC I/P FUSE FROM I/P VEHICLE POWER PANEL FUSE 7 DISTRIBUTION PAGE 13 28 PAGE 13 30 BOX (EVPDB) PAGE 13 20 DB/OG TN/WH SEE POWER...
Page 896 POWER DISTRIBUTION (LOW VOLTAGE) 13-30 2001 RANGER ELECTRIC VEHICLE POSTAL FROM C260 PAGE 13 29 S2993 FUSE PANEL 7.5A C134 1011 TN/OG AUXILIARY C224 C903 RELAY BOX #2 EXTERIOR TO C260 LAMPS PAGE 13 29 PAGE 92 1 GENERIC GRUMMAN ECONO ELECTRONIC HEADLINER...
Page 897 13-31 POWER DISTRIBUTION (LOW VOLTAGE) 2001 RANGER ELECTRIC VEHICLE POSTAL HOT AT ALL TIMES MAIN LIGHT SWITCH HEAD PAGE 13 29 SEE PAGE 149 3 FOR SWITCH PARK TESTING C261 RD/BK S173 RD/BK RD/BK I/P FUSE PANEL RD/YE C208 RD/YE 1055 WH/LG 1056...
Page 898 POWER DISTRIBUTION (HIGH VOLTAGE) 13-32 2001 RANGER ELECTRIC VEHICLE WARNING: This system contains high voltage components and wiring. Do not attempt any service procedures without direction from the workshop manual. Failure to follow this warning may result in severe personal injury or death. TRACTION FROM C1935 BATTERY...
Page 899 13-33 POWER DISTRIBUTION (HIGH VOLTAGE) 2001 RANGER ELECTRIC VEHICLE TRACTION TRACTION BATTERY PACK BATTERY UPPER LOWER PAGES 16 6, 16 7 SUPPORT BATTERY BATTERY TRAY HEATER HEATER C1859 C1861 C1863 C1862 WITH 3403 S1954 1161 LEAD TRACTION 3403 ACID 3709 BATTERY DB/OG BATTERY...
Page 900 POWER DISTRIBUTION (HIGH VOLTAGE) 13-34 2001 RANGER ELECTRIC VEHICLE...
Page 901 14-1 MULTIPLEX COMMUNICATION NETWORK 2001 RANGER ELECTRIC VEHICLE EXCEPT POSTAL HOT AT ALL TIMES I/P FUSE BATTERY TRACTION INTERFACE PANEL CONTROL INVERTER ADAPTER PAGE 13 11 MODULE (BCM) MODULE (TIM) ASSEMBLY (IAA) 7.5A PAGE 16 3 PAGE 16 3 MODULE C1987 C1945 C4998...
Page 902 MULTIPLEX COMMUNICATION NETWORK 14-2 2001 RANGER ELECTRIC VEHICLE EXCEPT POSTAL ANTI LOCK BRAKE AIR BAG GENERIC CONTROL MODULE DIAGNOSTIC ELECTRONIC PAGE 42 1 MODULE MODULE (GEM) PAGE 46 1 PAGE 59 1 C154 C250 C221 LB/WH LB/WH LB/WH C134 LB/WH S205 LB/WH C209...
Page 903 14-3 MULTIPLEX COMMUNICATION NETWORK 2001 RANGER ELECTRIC VEHICLE POSTAL BATTERY TRACTION INTERFACE CONTROL INVERTER ADAPTER MODULE (BCM) MODULE (TIM) ASSEMBLY (IAA) PAGE 16 3 PAGE 16 3 MODULE C1987 C1945 C4998 PK/LB TN/OG PK/LB TN/OG PK/LB TN/OG C3999 PK/LB TN/OG C1939 PK/LB C136...
Page 904 MULTIPLEX COMMUNICATION NETWORK 14-4 2001 RANGER ELECTRIC VEHICLE POSTAL INTERFACE POSITIVE TRACTION BATTERY TRACTION BATTERY ADAPTER TEMPERATURE BATTERY CONTROL BATTERY CONTROL ASSEMBLY COEFFICIENCY CHARGER MODULE CHARGER MODULE (IAA) MODULE (PTC) SWITCHING PAGE 16 4 (BCM) PAGE 16 4 (BCM) PAGE 54 5 MODULE PAGE 16 4 PAGE 16 4...
Page 905 14-5 MULTIPLEX COMMUNICATION NETWORK 2001 RANGER ELECTRIC VEHICLE POSTAL HOT AT ALL TIMES GENERIC ANTI LOCK I/P FUSE ELECTRONIC BRAKE CONTROL PANEL MODULE MODULE PAGE 13 27 (GEM) PAGE 42 1 7.5A PAGE 59 3 C221 C154 LB/WH EVAC/FILL CONNECTOR C1941 LB/WH C1946...
Page 906 MULTIPLEX COMMUNICATION NETWORK 14-6 2001 RANGER ELECTRIC VEHICLE...
Page 907 16-1 TRACTION BATTERY SYSTEM 2001 RANGER ELECTRIC VEHICLE For diagnostic information, refer to Section EXCEPT POSTAL 414 03 of the Workshop Manual. HOT IN START OR RUN HOT AT ALL TIMES I/P FUSE ELECTRIC WARNING: This system contains high voltage PANEL VEHICLE POWER components and wiring.
Page 908 TRACTION BATTERY SYSTEM 16-2 2001 RANGER ELECTRIC VEHICLE POSTAL HOT IN START OR RUN I/P FUSE PANEL PAGE 13-25 RELAY RELAY MODULE POWER MODULE PREHEAT STEERING INVERTER RELAY RELAY PAGE 43-2 LB/PK PAGE 53-6 C136 POWER LB/PK LG/OG DISTRIBUTION PAGE 13-25 C135 C135 S1959...
Page 909 16-3 TRACTION BATTERY SYSTEM 2001 RANGER ELECTRIC VEHICLE * EXCEPT POSTAL TRACTION SOLID STATE INVERTER MODULE (TIM) DIGITAL TRANSMISSION DATA LINK DATA LINK C4998 C4999 C4998 RANGE(DTR) SENSOR CONNECTOR (DLC) PAGE 14 3 PAGE 26 3 PAGES 14 1, 14 3 3404 3501 PK/LB...
Page 910 TRACTION BATTERY SYSTEM 16-4 2001 RANGER ELECTRIC VEHICLE * POSTAL TRACTION BATTERY CHARGER PAGE 18 1 C1993 C1991 3008 3826 3993 3401 DB/LG 3002 OG/LB 3827 GY/WH YE/RD 3992 BN/YE 3009 OG/RD 3990 LB/RD 3985 3800 LG/BK C124 3826 3827 GY/WH DATA DATA...
Page 911 16-5 TRACTION BATTERY SYSTEM 2001 RANGER ELECTRIC VEHICLE * POSTAL ELECTRIC VEHICLE FROM S1957 FROM S1958 PAGE 16 2 PAGE 16 2 HOT AT ALL TIMES INDEPENDENT BATTERY ELECTRIC OBSERVER CONTROL VEHICLE POWER SOLID STATE MODULE (IOM) MODULE (BCM) DISTRIBUTION BOX(EVPDB) PAGE 13 3, 13 18 C1986...
Page 912 TRACTION BATTERY SYSTEM 16-6 2001 RANGER ELECTRIC VEHICLE BATTERY MODULE BATTERY MODULE BATTERY MODULE LEAD ACID 3403 3403 3403 3403 TO BATTERY 36 PAGE 16 7 S1955 FROM BATTERY 1 PAGE 16 7 S1956 3403 3403 3403 3403 3403 30.9K 30.9K 30.9K RESISTOR...
Page 913 16-7 TRACTION BATTERY SYSTEM 2001 RANGER ELECTRIC VEHICLE BATTERY BATTERY BATTERY BATTERY BATTERY LEAD ACID MODULE MODULE MODULE MODULE MODULE 3403 3403 3403 3403 3403 3403 FROM S1955 BATTERY 6 PAGE PAGE 16 8 16 6 3403 3403 3403 3403 3403 3403 30.9K...
Page 914 TRACTION BATTERY SYSTEM 16-8 2001 RANGER ELECTRIC VEHICLE BATTERY BATTERY BATTERY BATTERY BATTERY LEAD ACID MODULE MODULE MODULE MODULE MODULE BATTERY 3403 3403 3403 3403 3403 3403 FROM BATTERY PAGE 16 7 PAGE 16 9 3403 3403 3403 3403 3403 30.9K 30.9K 30.9K...
Page 915 16-9 TRACTION BATTERY SYSTEM 2001 RANGER ELECTRIC VEHICLE BATTERY BATTERY BATTERY BATTERY BATTERY LEAD ACID MODULE MODULE MODULE MODULE MODULE FROM BATTERY 3403 3403 3403 3403 3403 3403 BATTERY PAGE 16 8 PAGE 16 10 3403 3403 3403 3403 3403 30.9K 30.9K 30.9K...
Page 916 TRACTION BATTERY SYSTEM 16-10 2001 RANGER ELECTRIC VEHICLE BATTERY BATTERY BATTERY BATTERY BATTERY LEAD ACID MODULE MODULE MODULE MODULE MODULE BATTERY 3403 3403 3403 3403 3403 PAGE 16 9 3403 3403 3403 3403 3403 30.9K 30.9K 30.9K 30.9K 30.9K RESISTOR RESISTOR RESISTOR RESISTOR...
Page 917 16-11 TRACTION BATTERY SYSTEM 2001 RANGER ELECTRIC VEHICLE To High Voltage Power Distribution Box (HVPDB) CONTACTOR To Traction To Traction Inverter Battery Module (TIM)
Page 918 TRACTION BATTERY SYSTEM 16-12 2001 RANGER ELECTRIC VEHICLE BATTERY MODULE NiMH 3403 3403 TO BATTERY 24 PAGE 16 16 S1955 FROM 3403 3403 BATTERY 1 PAGE 16 13 S1956 3403 3403 3403 30.9K 30.9K 30.9K RESISTOR RESISTOR RESISTOR 3403 3403 3403 30.9K 30.9K...
Page 919 16-13 TRACTION BATTERY SYSTEM 2001 RANGER ELECTRIC VEHICLE BATTERY BATTERY BATTERY BATTERY BATTERY NiMH MODULE MODULE MODULE MODULE MODULE 3403 3403 3403 3403 3403 3403 FROM S1955 BATTERY 6 PAGE PAGE 16 14 16 12 3403 3403 3403 3403 3403 3403 30.9K 30.9K...
Page 920 TRACTION BATTERY SYSTEM 16-14 2001 RANGER ELECTRIC VEHICLE BATTERY BATTERY BATTERY BATTERY BATTERY NiMH MODULE MODULE MODULE MODULE MODULE 3403 3403 3403 3403 3403 3403 BATTERY FROM BATTERY PAGE 16 13 PAGE 16 15 3403 3403 3403 3403 3403 30.9K 30.9K 30.9K 30.9K...
Page 921 16-15 TRACTION BATTERY SYSTEM 2001 RANGER ELECTRIC VEHICLE BATTERY BATTERY BATTERY BATTERY BATTERY NiMH MODULE MODULE MODULE MODULE MODULE BATTERY 3403 3403 3403 3403 3403 3403 FROM BATTERY PAGE 16 14 PAGE 16 16 3403 3403 3403 3403 3403 30.9K 30.9K 30.9K 30.9K...
Page 922 TRACTION BATTERY SYSTEM 16-16 2001 RANGER ELECTRIC VEHICLE BATTERY BATTERY BATTERY BATTERY BATTERY NiMH MODULE MODULE MODULE MODULE MODULE BATTERY 3403 3403 3403 3403 3403 PAGE 16 15 3403 3403 3403 3403 3403 30.9K 30.9K 30.9K 30.9K 30.9K RESISTOR RESISTOR RESISTOR RESISTOR RESISTOR...
Page 923 18-1 TRACTION BATTERY CHARGING/HEATING SYSTEM 2001 RANGER ELECTRIC VEHICLE TRACTION DIGITAL TRANSMISSION For diagnostic information, refer to Section INVERTER RANGE (DTR) SENSOR SOLID STATE 414 03 of the Workshop Manual. MODULE (TIM) PAGE 26 3 PAGE 16 3 C4998 C4999 HOT AT ALL TIMES C4996 3501...
Page 924 TRACTION BATTERY CHARGING/HEATING SYSTEM 18-2 2001 RANGER ELECTRIC VEHICLE HOT AT ALL TIMES ELECTRIC VEHICLE POWER UPPER LOWER 8 (Postal) DISTRIBUTION WITH LEAD BATTERY BATTERY BOX (EVPDB) WITH LEAD ACID HEATER HEATER PAGE 13 3, 13 18 ACID BATTERY BATTERY HEATERS C1859 C1861...
Page 925 18-3 TRACTION BATTERY CHARGING/HEATING SYSTEM 2001 RANGER ELECTRIC VEHICLE LEAD ACID * POSTAL CHARGER INLET C5000 3404 3984 3174 3172 C1969 3404 3984 3173 C1939 3984 S117 C1939 TO S1960 PAGE 18 1 SEE GROUNDS 3984 PAGES 10 7, 10 12 C124 G105 3984...
Page 926 TRACTION BATTERY CHARGING/HEATING SYSTEM 18-4 2001 RANGER ELECTRIC VEHICLE CHARGER NiMH * POSTAL INLET C5000 3404 3984 3174 3172 C1969 3984 C1939 3404 3984 C1810 3173 INDEPENDENT S117 OBSERVER MODULE (IOM) TO S1960 PAGE 18 1 SEE GROUNDS C1810 PAGES 10 7, 10 12 4009 LB/RD...
Page 927 18-5 TRACTION BATTERY CHARGING/HEATING SYSTEM 2001 RANGER ELECTRIC VEHICLE LEAD ACID BATTERY CONTROL MODULE (BCM) SOLID STATE PAGE 19 1 C1986 1163 1199 GY/BK 1197 LG/BK 1203 BK/LB 3703 BN/WH 3760 3704 RD/WH 3759 DG/WH C1988 C1989 C1981 C1985 UPPER UPPER LOWER LOWER...
Page 928 TRACTION BATTERY CHARGING/HEATING SYSTEM 18-6 2001 RANGER ELECTRIC VEHICLE HOT AT ALL TIMES * POSTAL NiMH ELECTRIC VEHICLE POWER DISTRIBUTION BOX (EVPDB) PAGES 13 4, 13 19 SEE POWER PK/BK DISTRIBUTION PAGE 13 4 C1810 INDEPENDENT OBSERVER MODULE (IOM) C1810 4001 4003 4002...
Page 929 19-1 TRACTION BATTERY COOLING/VENTILATION 2001 RANGER ELECTRIC VEHICLE FROM C1983 For diagnostic information, refer to Section LEAD ACID THIS PAGE 414 03 of the Workshop Manual. * POSTAL HOT AT ALL TIMES 3397 WH/RD ELECTRIC VEHICLE POWER DISTRIBUTION BOX (EVPDB) C1984 PAGES 13 5, 13 20 TRACTION...
Page 930 TRACTION BATTERY COOLING/VENTILATION 19-2 2001 RANGER ELECTRIC VEHICLE HOT AT ALL TIMES NiMH * POSTAL ELECTRIC VEHICLE POWER DISTRIBUTION BOX (EVPDB) PAGE 13 5, 13 20 YE/BK SEE POWER C1939 DISTRIBUTION YE/BK PAGE 13-5, 13-20 S1995 YE/BK YE/BK YE/BK YE/BK C1983 C2038 FLOW THRU...
Page 931 19-3 TRACTION BATTERY COOLING/VENTILATION 2001 RANGER ELECTRIC VEHICLE HOT AT ALL TIMES * POSTAL NiMH ELECTRIC VEHICLE POWER DISTRIBUTION BOX (EVPDB) PAGES 13 4, 13 19 SEE POWER DISTRIBUTION PK/BK PAGES 13 4, 13 19 C1810 INDEPENDENT OBSERVER MODULE (IOM) C1810 4001 4000...
Page 932 TRACTION BATTERY COOLING/VENTILATION 19-4 2001 RANGER ELECTRIC VEHICLE...
Page 933 20-1 EMERGENCY POWER OFF (EPO)/INTERLOCK SYSTEM 2001 RANGER ELECTRIC VEHICLE For diagnostic information, refer to Section * POSTAL 414 03 of the Workshop Manual. ** EXCEPT POSTAL HOT AT ALL TIMES ELECTRIC INTERFACE INTERFACE CONTACTOR VEHICLE ADAPTER ADAPTER POWER ASSEMBLY ASSEMBLY (IAA) PAGE 16 11 DISTRIBUTION...
Page 934 EMERGENCY POWER OFF (EPO)/INTERLOCK SYSTEM 20-2 2001 RANGER ELECTRIC VEHICLE * POSTAL FROM S1963 PAGE 20 1 CONTACTOR PAGE 16 11 *977 VT/WH 3131 C3985 C1948 3131 C1935 3130 3131 HIGH VOLTAGE POWER DISTRIBUTION C1931 INTERLOCK BOX (HVPDB) SWITCH PAGE 13 32 C1932 CLOSED WITH COVER ON...
Page 935 21-1 CONTACTOR BOX RELAY CONTROL 2001 RANGER ELECTRIC VEHICLE For diagnostic information, refer to Section 418 06 of the Workshop Manual. HOT IN START OR RUN HOT AT ALL TIMES ELECTRIC I/P FUSE VEHICLE POWER PANEL 8 (Postal) DISTRIBUTION PAGES 13 10, BOX (EVPDB) 13 25 PAGES 13 3, 13 18...
Page 936 CONTACTOR BOX RELAY CONTROL 21-2 2001 RANGER ELECTRIC VEHICLE EXCEPT POSTAL HOT IN START OR RUN TRACTION INVERTER I/P FUSE SOLID STATE MODULE (TIM) PANEL PAGE 13 10 C4998 SEE POWER DISTRIBUTION 3986 3991 PAGE 13 10 C3998 S1959 3986 3991 C201 3986...
Page 937 21-3 CONTACTOR BOX RELAY CONTROL 2001 RANGER ELECTRIC VEHICLE POSTAL RELAY PREHEAT MODULE INVERTER HOT IN START OR RUN TRACTION RELAY INVERTER I/P FUSE PAGE 53 6 SOLID STATE MODULE (TIM) PANEL PAGE 13 25 C4998 SEE POWER DISTRIBUTION 3986 3991 PAGE 13 25 C3998...
Page 938 CONTACTOR BOX RELAY CONTROL 21-4 2001 RANGER ELECTRIC VEHICLE...
Page 939 26-1 MOTOR/TRANSAXLE CONTROL 2001 RANGER ELECTRIC VEHICLE For diagnostic WARNING: This system contains high voltage HOT AT ALL TIMES HOT IN START AND RUN HOT IN START information, refer to components and wiring. Do not attempt any I/P FUSE PANEL Sections 303 01, service procedures without direction from the PAGES 13 8,...
Page 940 MOTOR/TRANSAXLE CONTROL 26-2 2001 RANGER ELECTRIC VEHICLE HOT AT ALL TIMES WARNING: This system contains high voltage * POSTAL ELECTRIC VEHICLE components and wiring. Do not attempt any ** EXCEPT POSTAL POWER DISTRIBUTION service procedures without direction from the BOX (EVPDB) workshop manual.
Page 941 26-3 MOTOR/TRANSAXLE CONTROL 2001 RANGER ELECTRIC VEHICLE HOT IN RUN * EXCEPT POSTAL BATTERY FUSE CONTROL SOLID STATE PANEL MODULE (BCM) PAGES 13 9, PAGE 18 1 13 24 C1987 VT/OG 3501 3503 *C201 C1939 3501 3503 C135 C136 VT/OG 3501 3503 TRACTION...
Page 942 MOTOR/TRANSAXLE CONTROL 26-4 2001 RANGER ELECTRIC VEHICLE CONTACTOR * EXCEPT POSTAL PAGES 21 2, 21 3 C1982 SIEMANS INTERACTIVE AUTOMOTIVE DIAGNOSTIC 3986 3997 INTERFACE SYSTEM (SIADIS) (NOT USED) 3991 C409 C1939 3986 3997 3991 C134 3986 3997 3991 3018 3019 GY/BK ANTI LOCK HIGH VOLTAGE...
Page 943 33-1 COOLING SYSTEM 2001 RANGER ELECTRIC VEHICLE For diagnostic information, HOT AT ALL TIMES refer to Section 303 03 of the ELECTRIC VEHICLE POWER DISTRIBUTION Workshop Manual. BOX (EVPDB) PAGES 13 2, 13 6, 13 17, 13 21 * POSTAL S1977 YE/LG YE/LG...
Page 944 COOLING SYSTEM 33-2 2001 RANGER ELECTRIC VEHICLE...
Page 945 37-1 SHIFT LOCK 2001 RANGER ELECTRIC VEHICLE For diagnostic information, HOT AT ALL TIMES HOT IN RUN refer to Section 307-05 of I/P FUSE the Workshop Manual. PANEL PAGES 13-8, 13-11, 7.5A 13-23, 13-27 * POSTAL ** EXCEPT POSTAL LG/RD SEE POWER S2995 DISTRIBUTION...
Page 946 SHIFT LOCK 37-2 2001 RANGER ELECTRIC VEHICLE...
Page 947 42-1 ANTI LOCK BRAKE SYSTEM (ABS) 2001 RANGER ELECTRIC VEHICLE For diagnostic information, HOT IN RUN HOT AT ALL TIMES HOT AT ALL TIMES refer to Section 206 09 of the ELECTRIC ELECTRIC I/P FUSE Workshop Manual. VEHICLE POWER VEHICLE POWER PANEL DISTRIBUTION DISTRIBUTION...
Page 948 ANTI LOCK BRAKE SYSTEM (ABS) 42-2 2001 RANGER ELECTRIC VEHICLE * POSTAL INSTRUMENT TRACTION ** EXCEPT POSTAL CLUSTER INVERTER PAGES 61 4, 61 9 MODULE (TIM) INDICATOR C4999 C216 OG/LB TN/WH C3997 C3998 OG/LB ** C201 S2996 OG/LB C134 OG/LB ELECTRIC VEHICLE POWER DISTRIBUTION...
Page 949 42-3 ANTI LOCK BRAKE SYSTEM (ABS) 2001 RANGER ELECTRIC VEHICLE HOT AT ALL TIMES * POSTAL FUSE PANEL PAGES 13 11, 13 27 LG/RD C134 LG/RD LG/RD SEE POWER S2995 DISTRIBUTION S1967 PAGES 13 11, 13 27 LG/RD LG/RD LG/RD ELECTRIC VEHICLE C210 POWER DISTRIBUTION...
Page 950 ANTI LOCK BRAKE SYSTEM (ABS) 42-4 2001 RANGER ELECTRIC VEHICLE...
Page 951 43-1 ELECTRONIC POWER STEERING 2001 RANGER ELECTRIC VEHICLE HOT IN START OR RUN For diagnostic information, WARNING: This system contains high voltage HOT IN START OR RUN I/P FUSE refer to Section 211 02 of the components and wiring. Do not attempt any PANEL HIGH VOLTAGE PAGES...
Page 952 ELECTRONIC POWER STEERING 43-2 2001 RANGER ELECTRIC VEHICLE POSTAL HOT IN START OR RUN HOT AT ALL TIMES I/P FUSE I/P FUSE PANEL PANEL PAGE 13-25 PAGE 13-28 SEE POWER SEE POWER LB/PK TN/YE DISTRIBUTION DISTRIBUTION PAGES 13-25, PAGE 13-28 13-26 S1959 S292...
Page 953 44-1 HORN/CIGAR LIGHTER 2001 RANGER ELECTRIC VEHICLE HOT AT ALL TIMES HOT AT ALL TIMES For diagnostic information, refer ELECTRIC VEHICLE POWER DISTRIBUTION to Section 413 06 FUSE BOX (EVPDB) PANEL of the Workshop PAGES 13 3, 13 18 PAGES 13 9, Manual.
Page 954 HORN/CIGAR LIGHTER 44-2 2001 RANGER ELECTRIC VEHICLE...
Page 955 46-1 AIR BAG RESTRAINT SYSTEM 2001 RANGER ELECTRIC VEHICLE HOT IN RUN For diagnostic information, refer to Section 501 20 of the Workshop Manual. FUSE PANEL 7.5A PAGES 13 1, 13 8 DRIVER PASSENGER AIR BAG AIR BAG BK/LG MODULE MODULE BK/LG C218...
Page 956 AIR BAG RESTRAINT SYSTEM 46-2 2001 RANGER ELECTRIC VEHICLE C250 AIR BAG DIAGNOSTIC MONITOR C256 CIRCUIT CIRCUIT FUNCTION PASSENGER AIR BAG DEACTIVATION (PAD) SWITCH NOT USED 364 (BK/LG) Power (Hot in Run) CIRCUIT CIRCUIT FUNCTION 614 (GY/OG) Driver Air Bag 615 (GY/WH) Driver Air Bag NOT USED...
Page 957 53-1 HEATER 2001 RANGER ELECTRIC VEHICLE For diagnostic information, refer to Section 412 02 of the Workshop Manual. HOT AT ALL TIMES ELECTRIC VEHICLE POWER DISTRIBUTION BOX (EVPDB) PAGE 13 6 C1971 BN/PK VARIABLE BLOWER CONTROLLER (VBC) S1970 C1971 BN/PK BN/PK OG/RD YE/RD...
Page 958 HEATER 53-2 2001 RANGER ELECTRIC VEHICLE BLEND DOOR IN CAR ACTUATOR TEMPERATURE SENSOR C240 C2997 BN/LG YE/LG RD/LG 3050 WH/OG 3060 GY/RD RD/WH C136 C134 NR/LG YE/LG RD/LG RD/WH 3050 WH/OG 3060 GY/RD C1945 INTERFACE ADAPTER ASSEMBLY SOLID STATE (IAA) MODULE C1945 3062 BK/WH...
Page 959 53-3 HEATER 2001 RANGER ELECTRIC VEHICLE RECIRCULATION CLIMATE VACUUM PRESSURE CONTROL SENSOR ASSEMBLY TEMPERATURE CONTROL C2993 3068 BN/PK 3066 OG/YE C231 3067 LB/RD C2999 3059 YE/LG 3058 LG/RD 3057 LG/OG 3068 BN/PK 3066 OG/YE 3067 LB/RD C135 C134 C134 3068 BN/PK 3066 OG/YE...
Page 960 HEATER 53-4 2001 RANGER ELECTRIC VEHICLE INSTRUMENT INSTRUMENT INTERFACE ADAPTER ILLUMINATION ILLUMINATION ASSEMBLY (IAA) PAGE 71 2 PAGE 71 2 MODULE C1945 3056 TN/LG LB/RD LB/RD C134 3056 TN/LG C233 C234 HEATER MODE SELECT CONTROL SWITCH C2998 ASSEMBLY FRESH/ PANEL/FLOOR FLOOR RECIRCULATION FLOOR/DEFROST...
Page 961 53-5 HEATER 2001 RANGER ELECTRIC VEHICLE WARNING: This system contains high voltage INTERFACE components and wiring. Do not attempt any ADAPTER service procedures without direction from the ASSEMBLY (IAA) workshop manual. Failure to follow this MODULE C1945 warning may result in severe personal injury or death.
Page 962 HEATER 53-6 2001 RANGER ELECTRIC VEHICLE INSTRUMENT POSTAL HOT AT ALL TIMES HOT IN START OR RUN ILLUMINATION I/P FUSE ELECTRIC PAGE 71-4 PANEL VEHICLE POWER PAGE 13 25 DISTRIBUTION BOX (EVPDB) LB/RD PAGE 13-18 C262 PREHEAT LB/PK LB/PK LG/BK SWITCH S147 C262...
Page 963 53-7 HEATER 2001 RANGER ELECTRIC VEHICLE POSTAL HOT AT ALL TIMES I/P FUSE PANEL PAGE 13-24 LG/VT C270 DASH FAN SWITCH C270 C271 DASH Refer to Location Index, Cell 152, for Component, Connector, Splice, Ground and Base Part Number descriptions and locations.
Page 964 HEATER 53-8 2001 RANGER ELECTRIC VEHICLE...
Page 965 54-1 AIR CONDITIONER/HEATER 2001 RANGER ELECTRIC VEHICLE For diagnostic information, refer to Section 412 03 of the Workshop Manual. HOT AT ALL TIMES * POSTAL ELECTRIC VEHICLE POWER DISTRIBUTION BOX (EVPDB) PAGES 13 6, 13 21 BN/PK C1971 VARIABLE BLOWER S1970 CONTROLLER SENSE...
Page 966 AIR CONDITIONER/HEATER 54-2 2001 RANGER ELECTRIC VEHICLE IN CAR BLEND DOOR TEMPERATURE ACTUATOR SENSOR C240 C2997 BN/LG YE/LG RD/LG 3050 WH/OG 3060 GY/RD RD/WH C136 C134 BN/LG YE/LG RD/LG RD/WH 3050 WH/OG 3060 GY/RD C1945 INTERFACE ADAPTER ASSEMBLY SOLID STATE (IAA) MODULE C1945 3062...
Page 967 54-3 AIR CONDITIONER/HEATER 2001 RANGER ELECTRIC VEHICLE RECIRCULATION CLIMATE VACUUM PRESSURE CONTROL SENSOR ASSEMBLY TEMPERATURE CONTROL C2993 3068 BN/PK 3066 OG/YE C231 3067 LB/RD C2999 * POSTAL 3059 YE/LG 3058 LG/RD 3057 LG/OG 3068 BN/PK 3066 OG/YE 3067 LB/RD C134 C134 C134 3068...
Page 968 AIR CONDITIONER/HEATER 54-4 2001 RANGER ELECTRIC VEHICLE INTERFACE INSTRUMENT * POSTAL ADAPTER ILLUMINATION ** EXCEPT POSTAL ASSEMBLY (IAA) PAGES 71 2, 71 5 **59 MODULE C1945 ** 3055 BN/LG 3056 TN/LG LB/RD C134 INSTRUMENT ILLUMINATION ** 3055 BN/LG 3056 TN/LG C233 PAGES 71 2, 71 5 C234...
Page 969 54-5 AIR CONDITIONER/HEATER 2001 RANGER ELECTRIC VEHICLE INTERFACE ADAPTER WARNING: This system contains high voltage ASSEMBLY (IAA) components and wiring. Do not attempt any service MODULE procedures without direction from the workshop manual. Failure to follow this warning may result in C1945 severe personal injury or death.
Page 970 AIR CONDITIONER/HEATER 54-6 2001 RANGER ELECTRIC VEHICLE EXCEPT POSTAL A/C INVERTER MOTOR A/C LOW CONTROLLER PRESSURE (IMC) SWITCH C1947 C1973 3232 3232 3026 RD/PK 3024 DB/LG S1964 3222 PK/LB S1965 3027 RD/WH 3025 YE/LG GROUNDS 3232 PK/LG PAGE 10 4 G103 C1945 INTERFACE...
Page 971 54-7 AIR CONDITIONER/HEATER 2001 RANGER ELECTRIC VEHICLE EXCEPT POSTAL WARNING: This system contains high voltage components and wiring. Do not attempt any POWER DISTRIBUTION service procedures without direction from the (HIGH VOLTAGE) workshop manual. Failure to follow this PAGE 13 32 warning may result in severe personal injury or death.
Page 972 AIR CONDITIONER/HEATER 54-8 2001 RANGER ELECTRIC VEHICLE...
Page 973 59-1 GENERIC ELECTRONIC MODULE (GEM) 2001 RANGER ELECTRIC VEHICLE For diagnostic information, refer to EXCEPT POSTAL Section 419 10 of the Workshop Manual. HOT AT ALL TIMES HOT IN RUN OR ACC HOT IN ACC OR RUN HOT AT ALL TIMES I/P FUSE RELAY PANEL...
Page 974 GENERIC ELECTRONIC MODULE (GEM) 59-2 2001 RANGER ELECTRIC VEHICLE EXCEPT POSTAL INTERVAL INSTRUMENT INSTRUMENT WIPER/WASHER MAINLIGHT I/P RELAY CLUSTER CLUSTER PAGES 81-1, 81-2 SWITCH INTERIOR CENTER BOX PAGE 61-4 PAGE 61-3 PAGE 13-13 COIL LAMP RELAY PAGE 89-1 C205 SEE POWER BK/OG GY/LB YE/WH...
Page 975 59-3 GENERIC ELECTRONIC MODULE (GEM) 2001 RANGER ELECTRIC VEHICLE POSTAL HOT AT ALL TIMES RELAY HOT IN ACC OR RUN HOT IN ACC OR RUN HOT AT ALL TIMES POWER MODULE I/P FUSE STEERING PANEL RELAY PAGES 13 23, PAGE 43 2 7.5A 7.5A 13 24, 13 25...
Page 976 GENERIC ELECTRONIC MODULE (GEM) 59-4 2001 RANGER ELECTRIC VEHICLE POSTAL INTERVAL WIPER/WASHER PAGES 81-3, 81-4 PK/YE LB/OG GY/LB YE/WH TN/RD C221 C224 GENERIC ELECTRONIC PARK WIPER WIPER WASHER MODE INTERVAL MODULE (GEM) SENSE HI–LO RUN/PARK PUMP SELECT DELAY/ RELAY RELAY RELAY SWITCH WASH...
Page 977 59-5 GENERIC ELECTRONIC MODULE (GEM) 2001 RANGER ELECTRIC VEHICLE * POSTAL C221 GENERIC ELECTRONIC MODULE (GEM) CIRCUIT CIRCUIT FUNCTION CIRCUIT CIRCUIT FUNCTION 1001 (WH/YE) Power (Hot at All Times) 996 (OG/WH) One Touch Down Sense (Low) 570 (BK/WH) Power Ground –...
Page 978 GENERIC ELECTRONIC MODULE (GEM) 59-6 2001 RANGER ELECTRIC VEHICLE * POSTAL C224 GENERIC ELECTRONIC MODULE (GEM) CIRCUIT CIRCUIT FUNCTION CIRCUIT CIRCUIT FUNCTION – NOT USED 991 (TN/LB) Down Window Command Input – NOT USED 671 (LB) Wiper Sense Input – NOT USED 627 (BK/OG) Door Ajar Indicator Output...
Page 979 INSTRUMENT CLUSTER 61-1 2001 RANGER ELECTRIC VEHICLE HOT AT ALL TIMES For diagnostic information, refer to EXCEPT POSTAL Section 413 01 of the Workshop Manual. I/P FUSE PANEL PAGE 13 12 HOT IN START OR RUN MAIN LIGHT SWITCH HEAD PAGE 13 13 S2900 TO C216...
Page 980 INSTRUMENT CLUSTER 61-2 2001 RANGER ELECTRIC VEHICLE FROM C1945 FROM S2900 EXCEPT POSTAL THIS PAGE PAGE 61 1 3049 BK/LG C134 3049 BK/LG S2997 3049 BK/LG 3049 BK/LG 3049 BK/LG C214 C215 C214 C216 INSTRUMENT DISTANCE TO TRACTION BATTERY MOTOR CLUSTER TEMPERATURE EMPTY (DTE)
Page 981 INSTRUMENT CLUSTER 61-3 2001 RANGER ELECTRIC VEHICLE HOT IN START OR RUN EXCEPT POSTAL I/P FUSE PANEL PAGE 13 10 7.5A S2774 C216 (START OR RUN) 12V FROM FROM INSTRUMENT INSTRUMENT INSTRUMENT ELECTRICAL CLUSTER CLUSTER CLUSTER DOOR LOW STATE OF BRAKE HAZARD PAGE 61 1...
Page 982 INSTRUMENT CLUSTER 61-4 2001 RANGER ELECTRIC VEHICLE HOT IN PASS, OR HI W/ MAIN EXCEPT POSTAL LIGHT SWITCH IN HEAD TURN/STOP/HAZARD LAMPS PAGE 90 2 FUSE PANEL PAGE 13 15 SEE POWER LB/BK LG/WH WH/LB DISTRIBUTION PAGE 13 15 C216 C214 (HI OR PASS) INSTRUMENT...
Page 983 INSTRUMENT CLUSTER 61-5 2001 RANGER ELECTRIC VEHICLE INSTRUMENT FROM C214 EXCEPT POSTAL ILLUMINATION PAGE 61 2 PAGE 71 2 LB/RD GY/BK S208 S2991 LB/RD LB/RD GY/BK GY/BK C214 C215 (PARK OR HEAD) (PARK OR HEAD) GY/BK INSTRUMENT CLUSTER C201 C135 INSTRUMENT ILLUMINATION GY/BK...
Page 984 INSTRUMENT CLUSTER 61-6 2001 RANGER ELECTRIC VEHICLE HOT AT ALL TIMES POSTAL I/P FUSE PANEL PAGE 13 28 S2900 INSTRUMENT TO C216 ILLUMINATION PAGE 61 7 PAGE 71 4 OG/BK C215 INSTRUMENT ECONOMY MALFUNCTION POWER CHARGE AUXILIARY POWER LOW OIL CLUSTER MODE INDICATOR...
Page 985 INSTRUMENT CLUSTER 61-7 2001 RANGER ELECTRIC VEHICLE FROM S2900 FROM C1945 POSTAL PAGE 61 6 THIS PAGE 3049 BK/LG C134 3049 BK/LG S2997 3049 BK/LG 3049 BK/LG 3049 BK/LG C214 C215 C214 C216 INSTRUMENT DISTANCE TO TRACTION BATTERY MOTOR CLUSTER TEMPERATURE EMPTY (DTE) STATE OF CHARGE...
Page 986 INSTRUMENT CLUSTER 61-8 2001 RANGER ELECTRIC VEHICLE HOT IN START OR RUN POSTAL I/P FUSE PANEL PAGE 13 25 7.5A SEE POWER DISTRIBUTION PAGE 13 25 C216 FROM FROM INSTRUMENT INSTRUMENT INSTRUMENT CLUSTER CLUSTER CLUSTER ELECTRICAL DOOR LOW STATE OF BRAKE PAGE 61 6 PAGE 61 7...
Page 987 INSTRUMENT CLUSTER 61-9 2001 RANGER ELECTRIC VEHICLE POSTAL TURN/STOP/ HAZARD LAMPS HEADLAMPS PAGE 90 6 PAGE 85 2 GY/OG LG/WH WH/LB C216 C214 INSTRUMENT FROM CLUSTER INSTRUMENT CLUSTER PAGE 61 8 HI BEAM LEFT RIGHT AIR BAG SAFETY BELT INDICATOR INDICATOR TURN TURN...
Page 988 INSTRUMENT CLUSTER 61-10 2001 RANGER ELECTRIC VEHICLE INSTRUMENT FROM C214 POSTAL ILLUMINATION PAGE 61 7 PAGE 71 5 LB/RD GY/BK S208 S2991 LB/RD LB/RD GY/BK GY/BK C214 C215 INSTRUMENT GY/BK CLUSTER C135 INSTRUMENT ILLUMINATION GY/BK C214 C221 GENERIC ELECTRONIC C124 C3999 MODULE (GEM) PAGE 59 4...
Page 989 INSTRUMENT ILLUMINATION 71-1 2001 RANGER ELECTRIC VEHICLE For diagnostic information, refer to Section 413 00 of the Workshop Manual. HOT AT ALL TIMES EXCEPT POSTAL MAIN LIGHT SWITCH PAGE 13 13 HEAD SEE PAGE 149 1 FOR SWITCH TESTING PARK C205 TO S208 PAGE 71 2...
Page 990 INSTRUMENT ILLUMINATION 71-2 2001 RANGER ELECTRIC VEHICLE FROM C204 EXCEPT POSTAL PAGE 71 1 LB/RD S208 TO C205 TO C228 PAGE 71 1 PAGE 71 1 LB/RD LB/RD LB/RD C219 AIR BAG SLIDING CONTACT LB/RD LB/RD LB/RD LB/RD C233 C2998 C214 C215 HEATER OR A/C...
Page 991 INSTRUMENT ILLUMINATION 71-3 2001 RANGER ELECTRIC VEHICLE POSTAL HOT AT ALL TIMES I/P FUSE PANEL FROM I/P PAGE 13 28 FUSE 7 THIS PAGE SEE POWER TN/WH DISTRIBUTION PAGES 13 28 S291 1011 TN/OG TN/WH C260 MAIN LIGHT SWITCH PAGE 13 29 HEAD ILLUMINATION HEAD...
Page 992 INSTRUMENT ILLUMINATION 71-4 2001 RANGER ELECTRIC VEHICLE POSTAL HOT IN START OR RUN HOT IN HEAD OR PARK FROM S208 I/P FUSE PAGE 71 5 PANEL PAGES 13 25, 7.5A 7.5A 13 30 SEE POWER DISTRIBUTION LB/RD LB/RD PAGES 13-29, 13-30 LB/RD S924 LB/RD...
Page 993 INSTRUMENT ILLUMINATION 71-5 2001 RANGER ELECTRIC VEHICLE TO S924 POSTAL PAGE 71 4 LB/RD TO ECONOMY S208 FROM C261 MODE RELAY PAGE 71 3 LB/RD LB/RD PAGE 71 4 LB/RD LB/RD C219 AIR BAG SLIDING TO S262 CONTACT PAGE 71 4 LB/RD LB/RD LB/RD...
Page 994 INSTRUMENT ILLUMINATION 71-6 2001 RANGER ELECTRIC VEHICLE...
Page 995 INTERVAL WIPER/WASHER 81-1 2001 RANGER ELECTRIC VEHICLE HOT IN ACC OR RUN For diagnostic information, refer to EXCEPT POSTAL Section 510 16 of the Workshop Manual. I/P FUSE SEE POWER PANEL DISTRIBUTION PAGE 13 7 PAGE 13 7 TO WINDSHIELD WH/BK WASHER PUMP RELAY...
Page 996 INTERVAL WIPER/WASHER 81-2 2001 RANGER ELECTRIC VEHICLE EXCEPT POSTAL MULTIFUNCTION SWITCH SEE PAGE 149 5 FOR SWITCH 1910 TESTING FROM S1968 WASHER SWITCH PAGE 81 1 HIGH WH/BK WH/BK C254 LB/OG GY/RD PK/YE 12V (RUN) 12V (RUN) ELECTRIC WINDSHIELD VEHICLE WASHER POWER PUMP...
Page 997 INTERVAL WIPER/WASHER 81-3 2001 RANGER ELECTRIC VEHICLE HOT IN ACC OR RUN POSTAL I/P FUSE SEE POWER PANEL DISTRIBUTION PAGE 13 22 PAGE 13 22 TO WINDSHIELD WH/BK WASHER PUMP RELAY PAGE 81 4 WH/BK S1968 BK/PK ELECTRIC ELECTRIC VEHICLE 12V (RUN) 12V (RUN) 12V (RUN)
Page 998 INTERVAL WIPER/WASHER 81-4 2001 RANGER ELECTRIC VEHICLE MULTIFUNCTION POSTAL SWITCH 1910 WASHER SWITCH FROM S1968 HIGH PAGE 81 3 C254 WH/BK WH/BK LB/OG GY/RD PK/YE 12V (RUN) 12V (RUN) ELECTRIC WINDSHIELD VEHICLE WASHER POWER C208 PUMP DISTRIBUTION RELAY BOX (EVPDB) PAGE 13 22 TN/RD BK/WH...
Page 999 INTERVAL WIPER/WASHER 81-5 2001 RANGER ELECTRIC VEHICLE HOT IN ACC OR RUN POSTAL I/P FUSE PANEL PAGE 13 22 SEE POWER DISTRIBUTION PAGE 13 22 S150 S209 I/P RELAY SEE GROUNDS CENTER WIPER PAGES 10 12, 10 13 PARK RELAY G105 YE/RD TO C131...
Page 1000 INTERVAL WIPER/WASHER 81-6 2001 RANGER ELECTRIC VEHICLE...
Page 1001 HEADLAMPS 85-1 2001 RANGER ELECTRIC VEHICLE For diagnostic information, HOT AT ALL TIMES HOT AT ALL TIMES EXCEPT POSTAL refer to Section 417 01 of the ELECTRIC MAIN LIGHT SWITCH Workshop Manual. VEHICLE POWER PAGE 13 13 * WITH MULTIFUNCTION DISTRIBUTION SEE PAGE 149 2 HEAD...
Page 1002 HEADLAMPS 85-2 2001 RANGER ELECTRIC VEHICLE HOT AT ALL TIMES Refer to Location Index, Cell 152, for POSTAL MAIN LIGHT SWITCH Component, Connector, Splice, and PAGE 13 29 Ground descriptions and locations. SEE PAGE 149 3 HEAD FOR SWITCH TESTING PARK C261 RD/BK...
Page 1003 89-1 COURTESY LAMPS 2001 RANGER ELECTRIC VEHICLE GENERIC For diagnostic information, HOT AT ALL TIMES RELAY ELECTRONIC refer to Section 417-02 of CENTER BATTERY MODULE the Workshop Manual. SAVER (GEM) PAGE 59 1 RELAY C224 EXCEPT PAGE 13-12 SEE POWER POSTAL DISTRIBUTION 1005...
Page 1004 COURTESY LAMPS 89-2 2001 RANGER ELECTRIC VEHICLE POSTAL HOT AT ALL TIMES I/P FUSE PANEL PAGE 13-28 TN/YE POWER DISTRIBUTION PAGE 13-28 C904 CARGO LAMP SWITCH C904 C903 GRUMMAN HEADLINER HARNESS Refer to Location Index, Cell 152, for Component, Connector, Splice, Ground and Base Part Number descriptions and locations.
Page 1005 TURN/STOP/HAZARD LAMPS 90-1 2001 RANGER ELECTRIC VEHICLE For diagnostic information, refer to EXCEPT POSTAL Section 417 01 of the Workshop Manual. HOT AT ALL TIMES HOT IN RUN I/P FUSE PANEL PAGE 13 9 RD/WH OG/YE C208 RD/WH OG/YE C211 12V (RUN) FLASHER C211...

Ford Electric Ranger 2001 Manual

Lectriclectricangeranger

Introduction

General Information

Suspension

Chassis

Driveline

Brake System

Steering System

Engine

Powertrain

Automatic Transmission

Fuel System

Electrical

Climate Control System

Instrumentation and Warning Systems

Battery and Charging System

Electrical Distribution

/Index

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Chapters

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Summary of Contents for Ford Electric Ranger 2001

Table of Contents