Introduction 4 Instrument Cluster 12 Warning lights and chimes 12 Gauges 16 Entertainment Systems 19 AM/FM stereo with CD/MP3 19 Auxiliary input jack (Line in) 28 USB port 30 Satellite radio information 34 Family entertainment system 37 Navigation system 67 SYNC 67 Climate Controls 68 Manual heating and air conditioning 68 Dual electronic automatic temperature control 71 Navigation system based climate control 74 Rear window defroster 80 Lights 81 Headlamps 81 Turn signal control 85 Bulb replacement 87 Driver Controls 92 Windshield wiper/washer control 92 Steering wheel adjustment 93 Power windows 102 Mirrors 104 Speed control 107 Moon roof 112 Message center 116 Table of Contents 1 2009 Flex (471) Owners Guide, 2nd Printing USA (fus)
Locks and Security 132 Keys 132 Locks 134 Anti-theft system 149 Seating and Safety Restraints 155 Seating 155 Safety restraints 175 Airbags 188 Child restraints 202 Tires, Wheels and Loading 222 Tire information 224 Tire inflation 226 Tire Pressure Monitoring System (TPMS) 239 Vehicle loading 245 Trailer towing 251 Recreational towing 255 Driving 257 Starting 257 Brakes 262 AdvanceTrac 264 Transmission operation 269 Reverse camera 275 All wheel drive 277 Roadside Emergencies 284 Getting roadside assistance 284 Hazard flasher control 285 Fuses and relays 286 Changing tires 295 Temporary mobility kit 302 Wheel lug nut torque 311 Jump starting 313 Wrecker towing 318 Table of Contents 2 2009 Flex (471) Owners Guide, 2nd Printing USA (fus)
CONGRATULATIONS Congratulations on acquiring your new Ford Motor Company product. Please take the time to get well acquainted with your vehicle by reading this handbook. The more you know and understand about your vehicle, the greater the safety and pleasure you will derive from driving it. For more information on Ford Motor Company and its products visit the following website: • In the United States: www.ford.com • In Canada: www.ford.ca • In Mexico: www.ford.com.mx • In Australia: www.ford.com.au Additional owner information is given in separate publications. This vehicle’s Owner’s Guide describes every option and model variant available and therefore some of the items covered may not apply to your particular vehicle. Furthermore, due to printing cycles it may describe options before they are generally available. Remember to pass on this vehicle’s Owner’s Guide when reselling the vehicle. It is an integral part of the vehicle. SAFETY AND ENVIRONMENT PROTECTION Warning symbols in this guide How can you reduce the risk of personal injury to yourself or others? In this guide, answers to such questions are contained in comments highlighted by the warning triangle symbol. These comments should be read and observed. Warning symbols on your vehicle When you see this symbol, it is imperative that you consult the relevant section of this guide before touching or attempting adjustment of any kind. 2009 Flex (471) Owners Guide, 2nd Printing USA (fus) Introduction 4
Protecting the environment We must all play our part in protecting the environment. Correct vehicle usage and the authorized disposal of waste, cleaning and lubrication materials are significant steps towards this aim. Information in this respect is highlighted in this guide with the tree symbol. CALIFORNIA Proposition 65 Warning WARNING: Engine exhaust, some of its constituents, and certain vehicle components contain or emit chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. In addition, certain fluids contained in vehicles and certain products of component wear contain or emit chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. PERCHLORATE MATERIAL Certain components of this vehicle such as airbag modules, seat belt pretensioners, and button cell batteries may contain Perchlorate Material – Special handling may apply for service or vehicle end of life disposal. See www.dtsc.ca.gov/hazardouswaste/perchlorate. BREAKING-IN YOUR VEHICLE Your vehicle does not need an extensive break-in. Try not to drive continuously at the same speed for the first 1,000 miles (1,600 km) of new vehicle operation. Vary your speed frequently in order to give the moving parts a chance to break in. Drive your new vehicle at least 1,000 miles (1,600 km) before towing a trailer. For more detailed information about towing a trailer, refer to Trailer towing in the Tires, Wheels and Loading chapter. Do not add friction modifier compounds or special break-in oils since these additives may prevent piston ring seating. See Engine oil in the Maintenance and Specifications chapter for more information on oil usage. 2009 Flex (471) Owners Guide, 2nd Printing USA (fus) Introduction 5
SPECIAL NOTICES New Vehicle Limited Warranty For a detailed description of what is covered and what is not covered by your vehicle’s New Vehicle Limited Warranty, refer to the Warranty Guide/Customer Information Guide that is provided to you along with your Owner’s Guide. Special instructions For your added safety, your vehicle is fitted with sophisticated electronic controls. WARNING: Please read the section Airbag Supplemental Restraint System (SRS) in the Seating and Safety Restraints chapter. Failure to follow the specific warnings and instructions could result in personal injury. WARNING: Front seat mounted rear-facing child or infant seats should NEVER be placed in front of an active passenger airbag. Service Data Recording Service data recorders in your vehicle are capable of collecting and storing diagnostic information about your vehicle. This potentially includes information about the performance or status of various systems and modules in the vehicle, such as engine, throttle, steering or brake systems. In order to properly diagnose and service your vehicle, Ford Motor Company, Ford of Canada, and service and repair facilities may access vehicle diagnostic information through a direct connection to your vehicle when diagnosing or servicing your vehicle. For U.S. only (if equipped), if you choose to use the SYNC Vehicle Health Report, you consent that certain diagnostic information may also be accessed electronically by Ford Motor Company and Ford authorized service facilities, and that the diagnostic information may be used for any purpose. See your SYNC supplement for more information. 2009 Flex (471) Owners Guide, 2nd Printing USA (fus) Introduction 6
Event Data Recording Other modules in your vehicle — event data recorders — are capable of collecting and storing data during a crash or near crash event. The recorded information may assist in the investigation of such an event. The modules may record information about both the vehicle and the occupants, potentially including information such as: • how various systems in your vehicle were operating; • whether or not the driver and passenger seatbelts were buckled; • how far (if at all) the driver was depressing the accelerator and/or the brake pedal; • how fast the vehicle was traveling; and • where the driver was positioning the steering wheel. To access this information, special equipment must be directly connected to the recording modules. Ford Motor Company and Ford of Canada do not access event data recorder information without obtaining consent, unless pursuant to court order or where required by law enforcement, other government authorities or other third parties acting with lawful authority. Other parties may seek to access the information independently of Ford Motor Company and Ford of Canada. Please note that once 911 Assist (if equipped) is activated by you, 911 Assist may, through any paired and connected cell phone, disclose to emergency services that the vehicle has been in a crash involving the deployment of an airbag or the activation of the fuel pump shut-off. Certain versions or updates to 911 Assist may also be capable of electronically or verbally disclosing to 911 operators the vehicle location, and/or other details about the vehicle or crash to assist 911 operators to provide the most appropriate emergency services. If you do not want to disclose this information, do not activate the feature. See your SYNC supplement for more information. 2009 Flex (471) Owners Guide, 2nd Printing USA (fus) Introduction 7
Cell phone use The use of Mobile Communications Equipment has become increasingly important in the conduct of business and personal affairs. However, drivers must not compromise their own or others’ safety when using such equipment. Mobile Communications can enhance personal safety and security when appropriately used, particularly in emergency situations. Safety must be paramount when using mobile communications equipment to avoid negating these benefits. Mobile Communication Equipment includes, but is not limited to cellular phones, pagers, portable email devices, in-vehicle communications systems, telematics devices and portable two-way radios. WARNING: Driving while distracted can result in loss of vehicle control, accident and injury. Ford strongly recommends that drivers use extreme caution when using any device that may take their focus off the road. The driver’s primary responsibility is the safe operation of their vehicle. Only use cell phones and other devices not essential to the driving task when it is safe to do so. 2009 Flex (471) Owners Guide, 2nd Printing USA (fus) Introduction 8
Export unique (Non–United States/Canada) vehicle specific information For your particular global region, your vehicle may be equipped with features and options that are different from the ones that are described in this Owner’s Guide. A market unique supplement may be supplied that complements this book. By referring to the market unique supplement, if provided, you can properly identify those features, recommendations and specifications that are unique to your vehicle. This Owner’s Guide is written primarily for the U.S. and Canadian Markets. Features or equipment listed as standard may be different on units built for Export. Refer to this Owner’s Guide for all other required information and warnings. 2009 Flex (471) Owners Guide, 2nd Printing USA (fus) Introduction 9
These are some of the symbols you may see on your vehicle. Vehicle Symbol Glossary Safety Alert See Owner’s Guide Fasten Safety Belt Airbag - Front Airbag - Side Child Seat Lower Anchor Child Seat Tether Anchor Brake System Anti-Lock Brake System Parking Brake System Brake Fluid - Non-Petroleum Based Parking Aid System Stability Control System Speed Control Master Lighting Switch Hazard Warning Flasher Fog Lamps-Front Fuse Compartment Fuel Pump Reset Windshield Wash/Wipe Windshield Defrost/Demist Rear Window Defrost/Demist 2009 Flex (471) Owners Guide, 2nd Printing USA (fus) Introduction 10
This workshop service manual for the Ford Flex 2009-2012 is designed for use by professional mechanics and DIY enthusiasts. It covers repair and overhaul procedures, including components manufactured specifically for Ford Flex models in the 2009 through 2012 range. The manual provides reliable information with clearly marked details—WARNING, CAUTION, and NOTE—to ensure safety and accuracy in all repair processes.
It includes detailed instructions for routine maintenance, servicing, and diagnostic and repair procedures. Topics covered include tune-ups, removal and installation, assemblies and disassemblies, as well as comprehensive systems such as the fuel system, ignition, lubrication, exhaust, electrical, and body repairs. The manual also explains extensive repair procedures, including engine and transmission disassembly.
For anyone performing maintenance and repairs, the guide stresses the importance of using proper safety equipment and following safety precautions. It also highlights the use of special tools identified by specific tool numbers, and includes illustrations to assist in adjustments and repairs.
Owning and referring to this manual will empower Ford Flex 2009-2012 owners to perform repairs with the confidence and skill of a professional automotive technician. Every necessary instruction for keeping your Ford Flex in prime condition is provided.
Language: English. This is an electronic delivery via email. The content of the service manual depicts parts and/or procedures applicable to the particular product at the time of writing.
General Information
Maintenance
Lubrication
Heating
Ventilation
Air Conditioning
Suspension
Front Suspension
Rear Suspension
Wheel
Tire System
Differential
Driveline
Drive Shaft
Transfer Case
Brakes
Engine
Engine Mechanical
Engine Cooling
Engine Fuel
Engine Electrical
Ignition System
Starting
Charging System
Emissions
Engine Exhaust
Engine Lubrication
Engine Speed Control System
Clutch
Cooling
Electronic Control Modules
Engine Systems
Heated Systems
Horn
Ignition Control
Instrument Cluster
Lamps
Power Systems
Restraints
Speed Control
Transmission
Exhaust System
Body Structure
Seats
Security and Locks
Air Bag System
Exterior Trim
Interior Trim
Frame
Bumpers
Fuel System
Steering
Transmission and Transfer Case
Tires
Wheels
Body
Heating
Air Conditioning
Emissions Control
Engine Removal
Engine Installation
Final Drive
Electrical System
Air cleaner element renewal
Air cleaner temperature control check
Auxiliary drivebelt check
Battery electrolyte level check
Battery terminal check
Brake hydraulic fluid renewal
Brake hydraulic system seal and hose renewal
Brake pipe and hose check
Choke adjustment check
Contact breaker point renewal and distributor lubrication