1998-2006 Ford Ranger (PD/PE/PG) OEM Service & Repair Manual

VIEW MAIN INDEX TO MODEL INDEX RANG.DRFT.OVERHAUL MANUAL Ranger/Drifter Overhaul Manual BACK TO MODEL INDEX FOREWORD This Manual has been prepared to provide information covering normal service repairs and maintenance for the RANGER / DRIFTER SERIES. As all information in this manual was the best available at the time of printing, vehicle specification and other information will be updated in Service Information. Ford/Mazda Motor Company WARNING Servicing a vehicle can be dangerous. If you have not received service-related training, the risks of injury, property damage, and failure of servicing increase. The recommended servicing procedures for the vehicle in this workshop manual were developed with Ford/Mazda-trained technicians in mind. This manual may be useful to non-Ford/Mazda trained technicians, but a technician with our service-related training and experience will be at less risk when performing service operations. However, all users of this manual are excepted at least to know general safety procedures. This manual contains "Warnings" and "Cautions" applicable to risks not normally encountered in a general technician's experience. They should be followed to reduce the risk of injury and the risk that improper service or repair may damage the vehicle or render it unsafe. It is also important to understand that the "Warnings" and "Cautions" are not exhaustive. It is impossible to warn of all the hazardous consequences that might result from failure to follow the procedures. The procedures recommended and described in this manual are effective methods of performing service and repair. Some require tools specifically designed for a specific purpose. Persons using procedures and tools, which are not recommended by Ford/Mazda Motor Corporation, must satisfy themselves thoroughly that neither personal safety nor safety of the vehicle will be jeopardized. The contents of this manual, including drawings and specifications, are the latest available at the time of printing, and Ford/Mazda Motor Corporation reserves the right to change the vehicle designs and alter the contents of this manual without notice and without incurring obligation. Parts should be replaced with genuine Ford/Mazda replacement parts or with parts, which match the quality of genuine Ford/Mazda replacement parts. Persons using replacement parts of lesser quality than that of genuine Ford/Mazda replacement parts must satisfy themselves thoroughly that neither personal safety nor safety of the vehicle will be jeopardized. Ford/Mazda Motor Corporation is not responsible for any problems, which may arise from the use of this manual. The cause of such problems includes but is not limited to insufficient service related training, use of improper tools, use of replacement parts of lesser quality than that of genuine Mazda replacement parts, or not being aware of any revision of this manual.

1999 Ford/Mazda Motor Company 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/Mazda Motor Company. PRINTED IN JAPAN, JAN.1999 F161–20–99A CONTENTS Title Section General Information GI G6 B1 Ranger / Drifter Overhaul Manual D ENGINE D MANUAL TRANSMISSION APPLICATION: This manual is applicable to vehicles beginning with the Vehicle Identification Numbers (VIN) shown on the following page. B2 Engine Engine WL, WL Turbo R15M–D R15MX–D J2 J3 Manual transmission Transfer TD Technical Data ST Special Tools F2 B3 J1 Engine Manual transmission M15M–D M15MX–D TO. MODEL .INDEX BACK TO FOREWORD & ENGINE INDEX RANG.DRFT.OVERHAUL MANUAL PAGES FROM SUPPLEMENT

VEHICLE IDENTIFICATION NUMBERS (VIN) U.K. specs. WF0 DMB]30WW 100001 — WF0 LMB]30WW 100001 — WF0 DMDD30WW 100001 — WF0 LMDD30WW 100001 — WF0 DMFE40WW 100001 — WF0 LMFE40WW 100001 — European specs. WF0 BMF]30WW 100001 — WF0 BME]30WW 100001 — WF0 DMF]30WW 100001 — WF0 DME]30WW 100001 — WF0 LMF]30WW 100001 — WF0 LME]30WW 100001 — WF0 BMD]30WW 100001 — WF0 BMC]30WW 100001 — WF0 DMD]30WW 100001 — WF0 DMC]30WW 100001 — WF0 LMD]30WW 100001 — WF0 LMC]30WW 100001 — WF0 BMB]30WW 100001 — WF0 BMA]30WW 100001 — WF0 DMB]30WW 100001 — WF0 DMA]30WW 100001 — WF0 LMB]30WW 100001 — WF0 LMA]30WW 100001 — WF0 BMFE40WW 100001 — WF0 BMEE40WW 100001 — WF0 DMFE40WW 100001 — WF0 DMEE40WW 100001 — WF0 LMFE40WW 100001 — WF0 LMEE40WW 100001 — WF0 BMD]40WW 100001 — WF0 BMC]40WW 100001 — WF0 DMD]40WW 100001 — WF0 DMC]40WW 100001 — WF0 LMD]40WW 100001 — WF0 LMC]40WW 100001 — WF0 BMB]40WW 100001 — WF0 BMA]40WW 100001 — WF0 DMB]40WW 100001 — WF0 DMA]40WW 100001 — WF0 LMB]40WW 100001 — WF0 LMA]40WW 100001 — General specs. (L.H.D.) MNC BSF]30WW 100001 — MNC BSE]30WW 100001 — MNC BSF]3WWW 100001 — MNC BSE]3WWW 100001 — MNC BSB]30WW 100001 — MNC BSA]30WW 100001 — MNC BSB]3WWW 100001 — MNC BSA]3WWW 100001 — General specs. (R.H.D.) MNB BSF]30WW 100001 — MNB BSE]30WW 100001 — MNB BSBD50WW 100001 — MNB BSAD50WW 100001 — MNB BSB]30WW 100001 — MNB BSA]30WW 100001 — CONTINUED TO. MODEL .INDEX BACK.TO.MAIN.INDEX PAGES FROM SUPPLEMENT RANG.DRFT.OVERHAUL MANUAL

GI–1 GENERAL INFORMATION HOW TO USE THIS MANUAL GI–1 . . . . . . . . . . . . . . . RANGE OF TOPICS GI–1 . . . . . . . . . . . . . . . . . . . . . SERVICING PROCEDURE GI–1/2 . . . . . . . . . . . . . . . SYMBOLS GI–1 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADVISORY MESSAGES GI–1 3 . . . . . . . . . . . . . . . . . . TEXT SEQUENCE GI–1 3 . . . . . . . . . . . . . . . . . . . . . . . UNITS GI–1 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUNDAMENTAL PROCEDURES GI–1 5 . . . . . . . . . . . . PREPARATION OF TOOLS AND MEASURING EQUIPMENT GI–1 5 . . . . . . . . . . . . . . SPECIAL SERVICE TOOLS GI–1 5 . . . . . . . . . . . . . . . DISASSEMBLY GI–1 5 . . . . . . . . . . . . . . . . . . . . . . . . . . INSPECTION DURING REMOVAL, DISASSEMBLY GI–1 5 . . . . . . . . . . . . . . . . . . . . . . . . . ARRANGEMENT OF PARTS GI–1 5 . . . . . . . . . . . . . . CLEANING OF PARTS GI–1 5 . . . . . . . . . . . . . . . . . . . REASSEMBLY GI–1 5/6 . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTMENT GI–1 6 . . . . . . . . . . . . . . . . . . . . . . . . . . RUBBER PARTS AND TUBING GI–1 6 . . . . . . . . . . . HOSE CLAMPS GI–1 6 . . . . . . . . . . . . . . . . . . . . . . . . . TORQUE FORMULAS GI–1 6 . . . . . . . . . . . . . . . . . . . . VISE GI–1 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ELECTRICAL SYSTEM GI–1 7 . . . . . . . . . . . . . . . . . . . . . CONNECTORS GI–1 7 . . . . . . . . . . . . . . . . . . . . . . . . . . NEW STANDARDS GI–1 8/10 . . . . . . . . . . . . . . . . . . . . . . . . ABBREVIATIONS GI–10 . . . . . . . . . . . . . . . . . . . . . . . . . . HOW TO USE THIS MANUAL RANGE OF TOPICS D This manual contains the procedures for performing all of the required service operations. The procedures are divided into the following five basic operations. (1) Removal/Installation (2) Disassembly/Assembly (3) Replacement (4) Inspection (5) Adjustment D Simple operations which can be performed easily just by looking at the vehicle, such as removal/installation of parts, jacking, vehicle lift, cleaning of parts, and visual inspection, have been omitted. SERVICING PROCEDURE Inspection, Adjustment D The procedures for inspections and adjustments are divided into steps. Important points in regard to the location and contents of the procedures are explained in detail and are shown in the illustrations. SHOWS PROCEDURE ORDER FOR SERVICE SHOWS TIGHTENING TORQUE SPECIFICATIONS BACK.TO.MAIN.INDEX CONTINUED TO. MODEL .INDEX PAGES FROM SUPPLEMENT RANG.DRFT.OVERHAUL MANUAL

HOW TO USE THIS MANUAL GI–2 Repair procedure 1. Most repair operations begin with an overview illustration. It identifies the components, shows how the parts fit together, and describes visual part inspection. However, only the removal/installation procedures which need to be performed methodically have written instructions. 2. Expendable parts, tightening torques, and symbols for oil, grease, and sealant are shown in the overview illustration. In addition, symbols indicating parts which require the use of special service tools for removal/installation are also shown. 3. The procedures are numbered and the part that is the main point of that procedure is shown in the illustration with the corresponding number. Occasionally, there are important points or information concerning a procedure. Refer to this information when servicing the related part. SHOWS SERVICE ITEM (S) SHOWS TIGHTENING TORQUE SPECIFICATIONS SHOWS PROCEDURE ORDER FOR SERVICE SHOWS SPECIAL SERVICE TOOL (SST) FOR SERVICE OPERATION SHOWS APPLICATION POINTS OF GREASE, ETC. SHOWS EXPENDABLE PARTS SHOWS DETAILS SHOWS TIGHTENING TORQUE UNITS SHOWS THERE ARE REFERRAL NOTES FOR SERVICE SHOWS REFERRAL NOTES FOR SERVICE Procedure “Removal/Installation” Portion Indicates any relevant references which need to be followed during installation. “Inspection After Installation” Portion Install the parts by performing steps 1—3 in reverse order SHOWS SPECIAL SERVICE TOOL (SST) NO. BACK.TO.CHAPTER.INDEX CONTINUED TO. MODEL .INDEX PAGES FROM SUPPLEMENT RANG.DRFT.OVERHAUL MANUAL

1998-2006 Ford Ranger (PD/PE/PG) OEM Service & Repair Manual

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