brake FORD RANGER 2005 2.G Service Manual

Maintenance and Modifications
The suspension and steering systems on your vehicle have been designed
and tested to provide predictable performance whether loaded or empty
and durable load carrying capability. For this reason, Ford Motor
Company strongly recommends that you do not make modifications such
as adding or removing parts (such as lift kits or stabilizer bars) or by
using replacement parts not equivalent to the original factory equipment.
Any modifications to a vehicle that raise the center of gravity can make
it more likely the vehicle will roll over as a result of a loss of control.
Ford Motor Company recommends that caution be used with any vehicle
equipped with a high load or device (such as ladder racks or pickup box
cover).
Failure to maintain your vehicle properly may void the warranty, increase
your repair cost, reduce vehicle performance and operational capabilities
and adversely affect driver and passenger safety. Frequent inspection of
vehicle chassis components is recommended if the vehicle is subjected to
heavy off-road usage.
DRIVING THROUGH WATER
If driving through deep or standing water is unavoidable, proceed very
slowly especially if the depth is not known. Never drive through water
that is higher than the bottom of the hubs (for trucks) or the bottom of
the wheel rims (for cars). Traction or brake capability may be limited
and your vehicle may stall. Water may also enter your engine’s air intake
and severely damage your engine.
Once through the water, always dry the brakes by moving your vehicle
slowly while applying light pressure on the brake pedal. Wet brakes do
not stop the vehicle as quickly as dry brakes.Driving through deep
water where the transmission vent tube or transfer case vent
tube (4x4 vehicles only) are submerged may allow water into the
transmission or transfer case and cause internal
transmission/transfer case damage.
CAMPER BODIES
Your Ranger Pickup is not recommended for slide–in camper bodies.
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Driving
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Fuse/Relay
LocationFuse Amp
RatingPassenger Compartment Fuse Panel
Description
11 10A Smart Junction Box (SJB) (Logic power)
12 15A Center console subwoofer amplifier
13 15A Horn, Interior lamps
14 15A High beam headlamp, High beam indicator
(cluster)
15—One-touch down relay
16 30A
cartridge
fusePower windows
17 15A Turn signals/Hazards
18—Not used
19 20A Center High-Mounted Stop Lamp
(CHMSL)/Stop lamps
20 10A Anti-lock Brake System (ABS) module,
Brake-shift interlock, Speed control
module, Back-up lamps, Overdrive cancel
switch, Electronic flasher (turn/hazard)
21 5A Starter relay
22 5A Radio (START), 4x4 Neutral sense
(manual only)
23 30A Headlamps (low and high beam)
24 20A Radio
25—Accessory relay
26 2A Brake pressure switch
27 10A Climate control blower relay/blend doors,
4x4 module
28 15A 4x4 module B+
29 20A Cigar lighter or power point, Diagnostic
connector (OBD II)
30 5A Power mirrors
31 20A Front park lamps, Rear park lamps,
License plate lamps
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Roadside Emergencies
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Fuse/Relay
LocationFuse Amp
RatingPassenger Compartment Fuse Panel
Description
32 5A Brake switch (logic)
33 5A Instrument cluster, TPMS module
34 20A Power point
35 15A Power locks
Power distribution box
The power distribution box is
located in the engine compartment.
The power distribution box contains
high-current fuses that protect your
vehicle’s main electrical systems
from overloads.
Always disconnect the battery before servicing high current
fuses.
To reduce risk of electrical shock, always replace the cover to
the Power Distribution Box before reconnecting the battery or
refilling fluid reservoirs.
If the battery has been disconnected and reconnected, refer to the
Batterysection of theMaintenance and Specificationschapter.
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Fuse/Relay
LocationFuse Amp
RatingPower Distribution Box Description
14—Not used
15—Not used
16—Not used
17 40A** ABS (motor)
18—Not used
19 20A** Engine fan
20—Not used
21 10A* PCM
22—Not used
23 20A* Fuel pump
24—Not used
25 10A* A/C clutch solenoid
26—Not used
27—Not used
28—Not used
29—Not used
30—Not used
31—Not used
32—Not used
33 30A* Anti-lock Brake System (ABS) (solenoids)
34—Not used
35—Not used
36—Not used
37—Not used
38 7.5A* Trailer tow (right turn)
39—Not used
40—Not used
41 15A* Heated Exhaust Gas Oxygen (HEGO)
sensors, EVAP canister vent valve,
Exhaust Gas Recirculation (EGR) stepper
motor, Transmission
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Fuse/Relay
LocationFuse Amp
RatingPower Distribution Box Description
15—Not used
16—Not used
17 40A** ABS (motor)
18—Not used
19—Not used
20—Not used
21 10A* PCM
22—Not used
23 20A* Fuel pump
24—Not used
25 10A* A/C clutch solenoid
26—Not used
27 20A* 4x4 module
28—Not used
29—Not used
30—Not used
31 15A* Foglamps
32—Not used
33 30A* Anti-lock Brake System (ABS) (solenoids)
34—Not used
35—Not used
36—Not used
37—Not used
38 7.5A* Trailer tow (right turn)
39—Not used
40—Not used
41 15A* Heated Exhaust Gas Oxygen (HEGO)
sensors, EVAP canister vent valve,
Exhaust Gas Recirculation (EGR) stepper
motor, Transmission
42 7.5A* Trailer tow (left turn)
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Roadside Emergencies
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1.Use only a 12–volt supply to start your vehicle.
2. Do not disconnect the battery of the disabled vehicle as this could
damage the vehicle’s electrical system.
3. Park the booster vehicle close to the hood of the disabled vehicle
making sure the two vehiclesdo nottouch. Set the parking brake on
both vehicles and stay clear of the engine cooling fan and other moving
parts.
4. Check all battery terminals and remove any excessive corrosion before
you attach the battery cables. Ensure that vent caps are tight and level.
5. Turn the heater fan on in both vehicles to protect any electrical
surges. Turn all other accessories off.
Connecting the jumper cables
1. Connect the positive (+) jumper cable to the positive (+) terminal of
the discharged battery.
Note:In the illustrations,lightning boltsare used to designate the
assisting (boosting) battery.
+–+–
+–+–
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PAINT CHIPS
Your dealer has touch-up paint and sprays to match your vehicle’s color.
Take your color code (printed on a sticker in the driver’s door jam) to
your dealer to ensure you get the correct color.
•Remove particles such as bird droppings, tree sap, insect deposits, tar
spots, road salt and industrial fallout before repairing paint chips.
•Always read the instructions before using the products.
ALUMINUM WHEELS AND WHEEL COVERS
Aluminum wheels and wheel covers are coated with a clearcoat paint
finish. In order to maintain their shine:
•Clean weekly with Motorcraft Wheel and Tire Cleaner (ZC-37–A),
which is available from your dealer. Heavy dirt and brake dust
accumulation may require agitation with a sponge. Rinse thoroughly
with a strong stream of water.
•Never apply any cleaning chemical to hot or warm wheel rims or
covers.
•Some automatic car washes may cause damage to the finish on your
wheel rims or covers. Chemical-strength cleaners, or cleaning
chemicals, in combination with brush agitation to remove brake dust
and dirt, could wear away the clearcoat finish over time.
•Do not use hydrofluoric acid-based or high caustic-based wheel
cleaners, steel wool, fuels or strong household detergent.
•To remove tar and grease, use Motorcraft Bug and Tar Remover
(ZC-42), available from your dealer.
ENGINE
Engines are more efficient when they are clean because grease and dirt
buildup keep the engine warmer than normal. When washing:
•Take care when using a power washer to clean the engine. The
high-pressure fluid could penetrate the sealed parts and cause
damage.
•Do not spray a hot engine with cold water to avoid cracking the
engine block or other engine components.
•Spray Motorcraft Engine Shampoo and Degreaser (ZC-20) on all parts
that require cleaning and pressure rinse clean.
•Cover the highlighted areas to prevent water damage when cleaning
the engine.
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Cleaning
190

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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Maintenance and Specifications
Maintenance and Specifications
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•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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Maintenance and Specifications
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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
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Maintenance and Specifications
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