Transit Workshop Manual Table of Contents GROUP 1 General Information Service Information General Information 100-00 Identification Codes 100-01 Jacking and Lifting 100-02 Noise, Vibration and Harshness 100-04 GROUP 2 Chassis Suspension Suspension System - General Information 204-00 Front Suspension 204-01 Rear Suspension 204-02 Wheels and Tires 204-04 Driveline Driveline System - General Information 205-00 Driveshaft 205-01 Rear Drive Axle/Differential 205-02A Wheel Hubs and Bearings - Full Floating Axle 205-02B Brake System Brake System - General Information 206-00 Front Disc Brake 206-03 Rear Disc Brake 206-04 Parking Brake and Actuation 206-05A Parking Brake and Actuation - Vehicles With: Parking Brake Assist 206-05B Hydraulic Brake Actuation 206-06 Power Brake Actuation 206-07 Anti-Lock Control 206-09 Steering System Steering System - General Information 211-00 Power Steering 211-02 Steering Linkage 211-03 Steering Column 211-04 Steering Column Switches 211-05 GROUP 3 Powertrain Engine Engine System - General Information 303-00 Engine - 2.4L Duratorq-TDCi (Puma) Diesel 303-01A Engine - 2.3L Duratec-HE (MI4) 303-01B Engine Cooling 303-03 Fuel Charging and Controls - 2.3L Duratec-HE (MI4) 303-04A Fuel Charging and Controls - Turbocharger 303-04B Fuel Charging and Controls - 2.4L Duratorq-TDCi (Puma) Diesel 303-04C Accessory Drive 303-05 Starting System 303-06 Glow Plug System - 2.4L Duratorq-TDCi (Puma) Diesel 303-07A Engine Ignition - 2.3L Duratec-HE (MI4) 303-07B Engine Emission Control 303-08 Intake Air Distribution and Filtering 303-12 Evaporative Emissions 303-13 Electronic Engine Controls 303-14 01/2017 2007.50Transit

Manual Transmission/Transaxle, Clutch and Transfer Case Manual Transmission/Transaxle and Clutch - General Information 308-00 Clutch - Vehicles With: MT-75 308-01 Clutch Controls - Vehicles With: MT-75 308-02 Manual Transmission/Transaxle - Vehicles With: MT-75 308-03 Manual Transmission/Transaxle External Controls - Vehicles With: MT-75 308-06 Exhaust System Exhaust System 309-00 Fuel System Fuel System - General Information 310-00 Fuel Tank and Lines 310-01 Acceleration Control - 2.2L Duratorq-TDCi (Puma) Diesel/2.4L Duratorq-TDCi (Puma) Diesel 310-02A Acceleration Control - 2.3L Duratec-HE (MI4) 310-02B Speed Control 310-03 GROUP 4 Electrical Climate Control System Climate Control System - General Information 412-00 Air Distribution and Filtering 412-01 Heating and Ventilation 412-02 Air Conditioning 412-03A Auxiliary Climate Control 412-03B Control Components 412-04 Instrumentation and Warning Systems Instrument Cluster and Panel Illumination 413-00 Instrument Cluster 413-01 Horn 413-06 Warning Devices 413-09 Battery and Charging System Charging System - General Information 414-00 Battery, Mounting and Cables 414-01 Generator and Regulator 414-02 Information and Entertainment Systems Information and Entertainment System - General Information 415-00 Information and Entertainment System 415-01 Lighting Exterior Lighting 417-01 Interior Lighting 417-02 Electrical Distribution Module Communications Network 418-00 Module Configuration 418-01 Wiring Harnesses 418-02 Electronic Feature Group Anti-Theft - Passive 419-01 Multifunction Electronic Modules 419-10 GROUP 5 Body and Paint Body and Paint Body System - General Information 501-00 Front End Body Panels 501-02 Body Closures 501-03 Interior Trim and Ornamentation 501-05 Exterior Trim and Ornamentation 501-08 Rear View Mirrors 501-09 Seating 501-10 Glass, Frames and Mechanisms 501-11 Instrument Panel and Console 501-12 Handles, Locks, Latches and Entry Systems 501-14 Wipers and Washers 501-16 Roof Opening Panel 501-17 Bumpers 501-19 Safety Belt System 501-20A Supplemental Restraint System 501-20B Body Repairs - General Information 501-25 Body Repairs - Vehicle Specific Information and Tolerance Checks 501-26 Front End Sheet Metal Repairs 501-27 Side Panel Sheet Metal Repairs 501-29 01/2007 2007.50 Transit

Rear End Sheet Metal Repairs 501-30 Paint - General Information 501-36 Frame and Mounting Uni-Body, Subframe and Mounting System 502-00 To the best of our knowledge, the illustrations, technical information, data and descriptions in this issue were correct at the time of going to print. The right to change prices, specifications, equipment and maintenance instructions at any time without notice is reserved as part of FORD policy of continuous development and improvement for the benefit of our customers. No part of this publication may be reproduced, stored in a data processing system or transmitted in any form, electronic, mechanical, photocopy, recording, translation or by any other means without prior permission of Ford-Werke Aktiengesellschaft. No liability can be accepted for any inaccuracies in this publication, although every possible care has been taken to make it as complete and accurate as possible. Copyright © FORD-WERKE AKTIENGESELLSCHAFT Service training programs D-F/GT-1 Printed in Germany - rewi druckhaus, Wissen - Printed on environmentally friendly chlorine-free paper. (GB) 01/2007 2007.50 Transit

GROUP General Information 1 SECTION TITLE PAGE Service Information General Information....................................................................................................... 100-00 Identification Codes....................................................................................................... 100-01 Jacking and Lifting......................................................................................................... 100-02 Noise, Vibration and Harshness.................................................................................... 100-04 01/2007 2007.50 Transit

GROUP Chassis 2 SECTION TITLE PAGE Suspension Suspension System - General Information.................................................................... 204-00 Front Suspension........................................................................................................... 204-01 Rear Suspension........................................................................................................... 204-02 Wheels and Tires........................................................................................................... 204-04 Driveline Driveline System - General Information......................................................................... 205-00 Driveshaft....................................................................................................................... 205-01 Rear Drive Axle/Differential............................................................................................ 205-02A Wheel Hubs and Bearings - Full Floating Axle.............................................................. 205-02B Brake System Brake System - General Information.............................................................................. 206-00 Front Disc Brake............................................................................................................ 206-03 Rear Disc Brake............................................................................................................. 206-04 Parking Brake and Actuation......................................................................................... 206-05A Parking Brake and ActuationVehicles With: Parking Brake Assist................................ 206-05B Hydraulic Brake Actuation.............................................................................................. 206-06 Power Brake Actuation.................................................................................................. 206-07 Anti-Lock Control........................................................................................................... 206-09 Steering System Steering System - General Information.......................................................................... 211-00 Power Steering............................................................................................................... 211-02 Steering Linkage............................................................................................................ 211-03 Steering Column............................................................................................................ 211-04 Steering Column Switches............................................................................................. 211-05 01/2007 2007.50 Transit

GROUP Powertrain 3 SECTION TITLE PAGE Engine Engine System - General Information............................................................................ 303-00 Engine2.4L Duratorq-TDCi (Puma) Diesel.................................................................... 303-01A Engine2.3L Duratec-HE (MI4)........................................................................................ 303-01B Engine Cooling............................................................................................................... 303-03 Fuel Charging and Controls2.3L Duratec-HE (MI4)....................................................... 303-04A Fuel Charging and Controls - Turbocharger.................................................................. 303-04B Fuel Charging and Controls2.4L Duratorq-TDCi (Puma) Diesel................................... 303-04C Accessory Drive............................................................................................................. 303-05 Starting System.............................................................................................................. 303-06 Glow Plug System2.4L Duratorq-TDCi (Puma) Diesel.................................................. 303-07A Engine Ignition2.3L Duratec-HE (MI4)........................................................................... 303-07B Engine Emission Control................................................................................................ 303-08 Intake Air Distribution and Filtering................................................................................ 303-12 Evaporative Emissions................................................................................................... 303-13 Electronic Engine Controls............................................................................................. 303-14 Manual Transmission/Transaxle, Clutch and Transfer Case Manual Transmission/Transaxle and Clutch - General Information............................... 308-00 ClutchVehicles With: MT-75........................................................................................... 308-01 Clutch ControlsVehicles With: MT-75............................................................................ 308-02 Manual Transmission/TransaxleVehicles With: MT-75.................................................. 308-03 Manual Transmission/Transaxle External ControlsVehicles With: MT-75.....................308-06 Exhaust System Exhaust System............................................................................................................. 309-00 Fuel System Fuel System - General Information................................................................................ 310-00 Fuel Tank and Lines....................................................................................................... 310-01 Acceleration Control2.2L Duratorq-TDCi (Puma) Diesel/2.4L Duratorq-TDCi (Puma) Diesel......................................................................................................................... 310-02A Acceleration Control2.3L Duratec-HE (MI4).................................................................. 310-02B Speed Control................................................................................................................ 310-03 01/2007 2007.50 Transit

GROUP Electrical 4 SECTION TITLE PAGE Climate Control System Climate Control System - General Information.............................................................. 412-00 Air Distribution and Filtering........................................................................................... 412-01 Heating and Ventilation.................................................................................................. 412-02 Air Conditioning.............................................................................................................. 412-03A Auxiliary Climate Control................................................................................................ 412-03B Control Components...................................................................................................... 412-04 Instrumentation and Warning Systems Instrument Cluster and Panel Illumination..................................................................... 413-00 Instrument Cluster.......................................................................................................... 413-01 Horn............................................................................................................................... 413-06 Warning Devices............................................................................................................ 413-09 Battery and Charging System Charging System - General Information........................................................................ 414-00 Battery, Mounting and Cables........................................................................................ 414-01 Generator and Regulator............................................................................................... 414-02 Information and Entertainment Systems Information and Entertainment System - General Information...................................... 415-00 Information and Entertainment System.......................................................................... 415-01 Lighting Exterior Lighting............................................................................................................. 417-01 Interior Lighting.............................................................................................................. 417-02 Electrical Distribution Module Communications Network................................................................................. 418-00 Module Configuration..................................................................................................... 418-01 Wiring Harnesses........................................................................................................... 418-02 Electronic Feature Group Anti-Theft - Passive........................................................................................................ 419-01 Multifunction Electronic Modules................................................................................... 419-10 01/2007 2007.50 Transit

GROUP Body and Paint 5 SECTION TITLE PAGE Body and Paint Body System - General Information............................................................................... 501-00 Front End Body Panels.................................................................................................. 501-02 Body Closures................................................................................................................ 501-03 Interior Trim and Ornamentation.................................................................................... 501-05 Exterior Trim and Ornamentation................................................................................... 501-08 Rear View Mirrors.......................................................................................................... 501-09 Seating........................................................................................................................... 501-10 Glass, Frames and Mechanisms.................................................................................... 501-11 Instrument Panel and Console....................................................................................... 501-12 Handles, Locks, Latches and Entry Systems................................................................ 501-14 Wipers and Washers...................................................................................................... 501-16 Roof Opening Panel....................................................................................................... 501-17 Bumpers......................................................................................................................... 501-19 Safety Belt System......................................................................................................... 501-20A Supplemental Restraint System..................................................................................... 501-20B Body Repairs - General Information.............................................................................. 501-25 Body Repairs - Vehicle Specific Information and Tolerance Checks............................. 501-26 Front End Sheet Metal Repairs...................................................................................... 501-27 Side Panel Sheet Metal Repairs.................................................................................... 501-29 Rear End Sheet Metal Repairs...................................................................................... 501-30 Paint - General Information............................................................................................ 501-36 Frame and Mounting Uni-Body, Subframe and Mounting System................................................................... 502-00 01/2007 2007.50 Transit

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 .