clutch FORD RANGER 2003 2.G User Guide

Fuse/Relay
LocationFuse Amp
RatingPower Distribution Box Description
45A—Wiper HI/LO
45B—Wiper park/run
46A—Fuel pump
46B—Trailer tow
47A—A/C clutch solenoid
47B—Front washer pump
48A—Fog lamps
48B—Fog lamp relay
51—Not used
52—Not used
53—PCM Diode
54—PCM
55—Blower
56—Starter
* Mini Fuses ** Maxi Fuses
CHANGING THE TIRES
If you get a flat tire while driving, do not apply the brake heavily.
Instead, gradually decrease your speed. Hold the steering wheel firmly
and slowly move to a safe place on the side of the road.
The use of tire sealants is not recommended and may
compromise the integrity of your tires.
Temporary spare tire information
Your vehicle is equipped with a conventional spare tire that may be
different in size (smaller diameter and narrower width) than other tires
on your vehicle. If this is the case, your spare tire is considered
“temporary”and the spare wheel will be labeled as such. Replace this
tire with a tire of the same size, speed rating and load carrying capacity
as the other road tires as soon as possible.
It is not recommended that the vehicle be operated in 4WD modes with
a“temporary”(i.e. dissimilar size) spare. If 4WD operation is necessary,
do not operate above speeds of 16 km/h (10 mph) or for distances above
80 km (50 miles).
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SERVICE RECOMMENDATIONS
To help you service your vehicle:
•We highlight do-it-yourself items in the engine compartment for easy
location.
•We provide a scheduled maintenance guide which makes tracking
routine service easy.
If your vehicle requires professional service, your dealership can provide
the necessary parts and service. Check yourWarranty Guide/Owner
Information Guideto find out which parts and services are covered.
Use only recommended fuels, lubricants, fluids and service parts
conforming to specifications. Motorcraft parts are designed and built to
provide the best performance in your vehicle.
PRECAUTIONS WHEN SERVICING YOUR VEHICLE
•Do not work on a hot engine.
•Make sure that nothing gets caught in moving parts.
•Do not work on a vehicle with the engine running in an enclosed
space, unless you are sure you have enough ventilation.
•Keep all open flames and other lit material away from the battery and
all fuel related parts.
Working with the engine off
•Automatic transmission:
1. Set the parking brake and shift to P (Park).
2. Turn off the engine and remove the key.
3. Block the wheels.
•Manual transmission:
1. Set the parking brake, depress the clutch and place the gearshift in 1
(First).
2. Turn off the engine and remove the key.
3. Block the wheels.
Working with the engine on
•Automatic transmission:
1. Set the parking brake and shift to P (Park).
2. Block the wheels.
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187

•Manual transmission:
1. Set the parking brake, depress the clutch and place the gearshift in N
(Neutral).
2. Block the wheels.
Note:Do not start your engine with the air cleaner removed and do not
remove it while the engine is running.
OPENING THE HOOD
1. Inside the vehicle, pull the hood
release handle located under the
bottom of the instrument panel near
the steering column.
2. Go to the front of the vehicle and
release the auxiliary latch that is
located under the front center of
the hood.
3. Lift the hood and support it with
the prop rod.
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188

IDENTIFYING COMPONENTS IN THE ENGINE COMPARTMENT
2.3L I4 engine
1. Windshield washer fluid reservoir
2. Engine coolant reservoir
3. Engine oil dipstick
4. Transmission fluid dipstick (automatic transmission)
5. Engine oil filler cap
6. Brake fluid reservoir
7. Power distribution box
8. Clutch fluid reservoir (manual transmission)
9. Battery
10. Power steering fluid reservoir
11. Air filter assembly
Maintenance and Specifications
189

3.0L V6 engine
1. Engine coolant reservoir
2. Windshield washer fluid reservoir
3. Engine oil filler cap
4. Automatic transmission fluid dipstick (if equipped)
5. Engine oil dipstick
6. Brake fluid reservoir
7. Power distribution box
8. Clutch fluid reservoir (if equipped)
9. Battery
10. Power steering fluid reservoir
11. Air filter assembly
Maintenance and Specifications
190

4.0L SOHC V6 engine
1. Windshield washer fluid reservoir
2. Automatic transmission fluid dipstick (if equipped)
3. Engine oil filler cap
4. Engine oil dipstick
5. Brake fluid reservoir
6. Power distribution box
7. Clutch fluid reservoir (if equipped)
8. Battery
9. Power steering fluid reservoir
10. Air filter assembly
11. Engine coolant reservoir
Maintenance and Specifications
191

Check the power steering fluid. Refer to the scheduled maintenance
guide for the service interval schedules. If adding fluid is necessary, use
only MERCONAT F.
1. Start the engine and let it run until it reaches normal operating
temperature (the engine coolant temperature gauge indicator will be
near the center of the normal area between H and C).
2. While the engine idles, turn the steering wheel left and right several
times.
3. Turn the engine off.
4.If your vehicle is equipped with a 3.0L V6 engine,check the fluid
level on the dipstick. It should be within the FULL HOT range. Do not
add fluid if the level is within this range.
5.If your vehicle is equipped with a 4.0L SOHC V6 or 2.3L I4
engine,check the fluid level in the reservoir. It should be between the
MIN and MAX lines. Do not add fluid if the level is within this range.
6. If the fluid is low, add fluid in small amounts, continuously checking
the level until it reaches the FULL HOT range. Be sure to put the
dipstick back in the reservoir.
BRAKE FLUID RESERVOIR
The fluid level will drop slowly as
the brakes wear, and will rise when
the brake components are replaced.
Fluid levels below the“MAX”line
that do not trigger the brake system
warning lamp are within the normal
operating range, there is no need to
add fluid. If the fluid levels are outside of the normal operating range,
the performance of your brake system could be compromised, seek
service from your dealer immediately.
CLUTCH FLUID (IF EQUIPPED)
Check the fluid level. Refer to the scheduled maintenance guide for the
service interval schedules.
During normal operation, the fluid level in the clutch reservoir should
remain constant. If the fluid level drops, refill the fluid level to the step
in the reservoir.
Use only a DOT 3 brake fluid designed to meet Ford specification
ESA-M6C25–A. Refer toLubricant Specificationsin this chapter.
MAX
Maintenance and Specifications
218

MOTORCRAFT PART NUMBERS
Component2.3L
I4engine3.0LV6
engine3.0L V6 FFV
engine4.0L V6
engine
Air filter
element FA-1658 FA-1658 FA-1658FA-1658
FA-1665
(FX4 only)
Fuel filter FG-1002 FG-1002 FG-1002 FG-1002
Battery BXT-59 BXT-59 BXT-59 BXT-59
Oil filter FL-400S FL-400S FL-400S FL-820S
PCV valve EV-227 EV-130 EV-130 EV-225
Spark plugs* AWSF-32FEM AWSF-32PP** AGSF-22PP** AGSF-34FP
* Refer to Vehicle Emissions Control Information (VECI) decal for spark
plug gap information.
** If any spark plug needs to be removed for inspection, it must be
re-installed in the same cylinder. Cylinders No.1, 2 and 3 have a“PG”
suffix. Cylinders No. 4, 5 and 6 have a“P”suffix. If any spark plug needs
to be replaced, use only spark plugs with the service part number suffix
letters“PP”as shown on the engine decal.
REFILL CAPACITIES
Fluid Ford Part
NameApplication Capacity
Engine oil
(includes filter
change)Motorcraft SAE
5W- 20 Premium
Synthetic Blend
Motor Oil2.3L engine 3.8L (4.0
quarts)
3.0L V6 engine 4.3L (4.5
quarts)
Motorcraft SAE
5W- 30 Super
Premium Motor
Oil4.0L V6 engine 4.7L (5.0
quarts)
Brake fluid and
Clutch fluidMotorcraft High
Performance
DOT 3 Motor
Vehicle Brake
FluidAll Fill to line or
step (for clutch)
on reservoir
Maintenance and Specifications
229

LUBRICANT SPECIFICATIONS
ItemFord part
name or
equivalentFord part
numberFord
specification
Front axle
(4X4)Motorcraft SAE
80W-90
Premium Rear
Axle LubricantXY-80W90-QL WSP-M2C197-A
Rear axleMotorcraft SAE
80W-90
Premium Rear
Axle Lubricant
1
XY-80W90-QL WSP-M2C197-A
Rear axle (FX4
only)Motorcraft SAE
75W-140
Synthetic Rear
Axle Lubricant
1
XY-75W140–QL WSL-M2C192–A
Brake fluid and
clutch fluid (if
equipped)Motorcraft High
Performance
DOT 3 Motor
Vehicle Brake
FluidPM-1 ESA-M6C25-A
and DOT 3
Door weather
stripsSilicone
LubricantF5AZ-19553–AA ESR-M13P4-A
Engine coolant Motorcraft
Premium Engine
Coolant
(green-colored)VC-4–A (US) or
CXC-10
(Canada)ESE-M97B44-A
Motorcraft
Premium Gold
Engine Coolant
(yellow-colored)VC-7–A WSS-M97B51-A1
Maintenance and Specifications
233

ItemFord part
name or
equivalentFord part
numberFord
specification
Engine oil2.3L and 3.0L
engines
Motorcraft SAE
5W-20 Premium
Synthetic Blend
Motor OilXO-5W20-QSP WSS-M2C153-H
and API
Certification
Mark
4.0L engines
Motorcraft SAE
5W-30 Super
Premium Motor
OilXO-5W30-QSP WSS-M2C205–A
and API
Certification
Mark
Hinges, door
checks, latches,
striker plates,
fuel filler door
hinge and seat
tracksMulti-Purpose
GreaseXG-4 or XL-5 ESB-M1C159-A
or ESB-M1C93-B
Transmission
/steering/parking
brake linkages
and pivots,
brake and clutch
pedal shaft,
clutch pilot
bearing and.
input shaft
spline (manual
transmission)Motorcraft
Premium
Long-Life GreaseXG-1-C or
XG-1-KESA-M1C75-B
Maintenance and Specifications
234