2007-2010 Ford Transit Van Service & Repair Manual

SECTION 100-00 General Information VEHICLE APPLICATION:2007.50 Transit PAGE CONTENTS DESCRIPTION AND OPERATION 100-00-3 About This Manual.............................................................................................................. 100-00-3 Introduction......................................................................................................................... 100-00-3 Special Tools...................................................................................................................... 100-00-3 Important Safety Instructions.............................................................................................. 100-00-3 Warnings, Cautions and Notes in This Manual.................................................................. 100-00-3 Overview Procedures......................................................................................................... 100-00-4 Trustmark Authoring Standards (TAS) Removal and Installation Procedures.................... 100-00-13 How to Use This Manual.................................................................................................... 100-00-15 Health and Safety Precautions........................................................................................... 100-00-15 Introduction......................................................................................................................... 100-00-15 Acids and Alkalis................................................................................................................ 100-00-15 Air Bags.............................................................................................................................. 100-00-15 Air Conditioning Refrigerant............................................................................................... 100-00-16 Adhesives and Sealers....................................................................................................... 100-00-17 Antifreeze........................................................................................................................... 100-00-17 Asbestos............................................................................................................................. 100-00-17 Battery Acids...................................................................................................................... 100-00-17 Brake and Clutch Linings and Pads................................................................................... 100-00-17 Brake Fluids (Polyalkylene Glycols)................................................................................... 100-00-17 Brazing............................................................................................................................... 100-00-17 Chemical Materials............................................................................................................. 100-00-18 Chlorofluorocarbons (CFC)................................................................................................ 100-00-18 Clutch Fluids....................................................................................................................... 100-00-18 Clutch Linings and Pads..................................................................................................... 100-00-18 Corrosion Protection Materials........................................................................................... 100-00-18 Cutting................................................................................................................................ 100-00-19 Dewaxing............................................................................................................................ 100-00-19 Dusts .................................................................................................................................. 100-00-19 Electric Shock..................................................................................................................... 100-00-19 Engine Oils......................................................................................................................... 100-00-19 Exhaust Fumes................................................................................................................... 100-00-19 Fibre Insulation................................................................................................................... 100-00-19 Fire ..................................................................................................................................... 100-00-20 First Aid.............................................................................................................................. 100-00-20 Fluoroelastomer.................................................................................................................. 100-00-20 Foams - Polyurethane........................................................................................................ 100-00-20 Freon.................................................................................................................................. 100-00-20 Fuels................................................................................................................................... 100-00-21 Gas Cylinders..................................................................................................................... 100-00-21 Gases................................................................................................................................. 100-00-21 Gaskets (Fluoroelastomer)................................................................................................. 100-00-21 General Workshop Tools and Equipment........................................................................... 100-00-22 High Pressure Air, Lubrication and Oil Test Equipment...................................................... 100-00-22 Halon.................................................................................................................................. 100-00-1 General Information 100-00-1 .

100-00-22 Legal Aspects..................................................................................................................... 100-00-22 Lubricants and Greases..................................................................................................... 100-00-22 Transmission Fluids............................................................................................................ 100-00-23 Noise .................................................................................................................................. 100-00-23 Noise Insulation Materials.................................................................................................. 100-00-23 O-Rings (Fluoroelastomer)................................................................................................. 100-00-23 Paints.................................................................................................................................. 100-00-24 Pressurized Equipment...................................................................................................... 100-00-24 Solder ................................................................................................................................. 100-00-24 Solvents.............................................................................................................................. 100-00-24 Sound Insulation................................................................................................................. 100-00-24 Suspended Loads............................................................................................................... 100-00-25 Transmission Brake Bands................................................................................................. 100-00-25 Underseal ........................................................................................................................... 100-00-25 Viton.................................................................................................................................... 100-00-25 Welding............................................................................................................................... 100-00-26 Warning Symbols on Vehicles............................................................................................ 100-00-27 White Spirit......................................................................................................................... 100-00-28 Standard Workshop Practices............................................................................................ 100-00-28 Vehicle in Workshop........................................................................................................... 100-00-28 Alternative Fuel................................................................................................................... 100-00-28 Alternative Fuel — Do's...................................................................................................... 100-00-28 Alternative Fuel — Do Nots................................................................................................ 100-00-29 Towing the Vehicle.............................................................................................................. 100-00-29 Connecting a Slave Battery Using Jumper Cables............................................................ 100-00-30 Component Cleaning.......................................................................................................... 100-00-30 Calibration of Essential Measuring Equipment................................................................... 100-00-31 Solvents, Sealants and Adhesives..................................................................................... 100-00-31 Introduction......................................................................................................................... 100-00-32 Road/Roller Testing............................................................................................................ 100-00-32 Pre-Test Checks................................................................................................................. 100-00-32 Starting the Engine............................................................................................................. 100-00-32 Road or Roller Testing........................................................................................................ 100-00-33 Brake Testing...................................................................................................................... 100-00-34 Battery and Battery Charging Health and Safety Precautions............................................ 100-00-35 Engine Cooling System Health and Safety Precautions..................................................... 100-00-36 Petrol Fuel System Health and Safety Precautions............................................................ 100-00-37 Diesel Fuel System Health and Safety Precautions........................................................... 100-00-38 Air Conditioning (A/C) System Health and Safety Precautions.......................................... 100-00-39 Supplemental Restraint System (SRS) Health and Safety Precautions............................. 100-00-40 Brake System Health and Safety Precautions.................................................................... 100-00-2 General Information 100-00-2 .

About This Manual Introduction This manual has been written in a format that is designed to meet the needs of technicians worldwide. The objective is to use common formats and include similar content in each manual. This manual provides general descriptions for accomplishing diagnosis and testing, service and repair work with tested, effective techniques. Following them will help assure reliability. Special Tools The special tool(s) table provided at the beginning of each procedure shows all special tools required to carry out a repair. Where possible, illustrations are provided to assist in identifying the special tool required. Important Safety Instructions Appropriate service methods and correct repair procedures are essential for the safe, reliable operation of all motor vehicles as well as the personal safety of the individual carrying out the work. This manual cannot possibly anticipate all such variations and provide advice or cautions as to each. Anyone who departs from the instructions provided in this manual must first establish that he compromises neither his personal safety nor the vehicle integrity by his choice of methods, tools or components. Warnings, Cautions and Notes in This Manual WARNING:Warnings are used to indicate that failure to follow a procedure correctly may result in personal injury. CAUTION:Cautions are used to indicate that failure to follow a procedure correctly may result in damage to the vehicle or equipment being used. NOTE:Notes are used to provide additional essential information required to carry out a complete and satisfactory repair. As you read through this manual, you will come across WARNINGS, CAUTIONS and NOTES. A warning, caution or note is placed at the beginning of a series of steps if it applies to multiple steps. If the warning, caution or note only applies to one step, it is placed at the beginning of the specific step (after the step number). Overview Procedures Overview procedures contain an exploded view illustration(s). The numbered sequence within the illustration(s) indicate the order to be followed when removing/disassembling or when installing/assembling a component. Additional information, symbol(s) or a torque figure, may also be shown alongside the component. There are ten symbols used to give additional information when removing/disassembling or when installing/assembling a component. TIE42918 1 2 3 4 5 6 7 8 9 10 Description Designation Item A special tool is required for this component. There will also be a removal or installation symbol alongside the special tool symbol. Special tool 1 Discard the old component and install a new component. Install new component 2 Check the component for damage. Inspect 3 G935689en 2007.50 Transit 11/2006 100-00-3 General Information 100-00-3 DESCRIPTION AND OPERATION

Description Designation Item Apply sealant to the component as specified in the materials table. Apply sealant 4 Apply petroleum jelly to the component as specified in the materials table. Apply petroleum jelly 5 Apply oil to the component as specified in the materials table. Apply oil 6 Apply fluid to the component as specified in the materials table. Apply fluid 7 Apply grease to the component as specified in the mate-rials table. Apply grease 8 Go to the removal or disassembly detail for additional information to remove or disassemble a component Removal or Disassembly detail 9 Go to the installation or assembly detail for additional information to install or assemble a component Installation or Assembly detail 10 Special Tools and Torque Figures Any requirement for special tools will picture the tool, showing it in use and with its tool number shown. Torque settings will be given at the relevant point in the procedure. TIA2301151 59 Nm 23-045 Trustmark Authoring Standards (TAS) Removal and Installation Procedures NOTE:TAS style procedures can be identified by steps that have no accompanying step text and the magenta color of the electrical connectors and fasteners such as nuts, bolts, clamps or clips. A TAS removal and installation procedure uses a sequence of color illustrations to indicate the order to be followed when removing/disassembling or installing/assembling a component. Many of the TAS procedures will have the installation information within the removal steps. These procedures will have the following note at the beginning of the procedure: NOTE:Removal steps in this procedure may contain installation details. Items such as O-ring seals, gaskets, seals, self-locking nuts and bolts are to be discarded and new components installed unless otherwise stated within the procedure. Coated nuts or bolts are to be reused, unless damaged or otherwise stated within the procedure. Specification procedures will contain all technical data that are not part of a repair procedure. TAS Graphics Colors used in the graphic are as follows: • Blue - Indicates the target item, item to be removed/installed or disassembled/assembled • Green and Brown - Indicates a secondary item that needs to be detached, removed/installed or disassembled/assembled prior to the target item • Magenta - Indicates electrical connectors and fasteners such as nuts, bolts, clamps or clips • Pale Blue - is for the special tool(s) and general equipment There may be multiple steps assigned to one illustration. Numbered pointers are used to indicate the number of electrical connectors and fasteners such as nuts, bolts, clamps or clips. Items in the illustration can be transparent or use cutouts to show hidden detail(s). G935689en 2007.50 Transit 11/2006 100-00-4 General Information 100-00-4 DESCRIPTION AND OPERATION

E63828 2 4 x3 1 3 303-378 205-072 E60043 TAS Symbols Symbols are used inside the graphics and in the text area to enhance the information display. The following paragraphs describe the various types and categories of symbols. Prohibition symbols advise on prohibited actions to either avoid damage or health and safety related risks. 1 2 1 2 E85026 Health and Safety symbols recommend the use of particular protection equipment to avoid or at least reduce the risk or severity of possible injuries. G935689en 2007.50 Transit 11/2006 100-00-5 General Information 100-00-5 DESCRIPTION AND OPERATION

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2007-2010 Ford Transit Van Service & Repair Manual

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