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Ford Flex 2009 2010 2011 2012 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Ford Model: Flex Years Covered: 2009, 2010, 2011, 2012 Codes Platform: D4 (shared with Lincoln MKS, Lincoln MKT) 👋 Introduction Market Position Segment: Full-size Crossover SUV Competitive Analysis Key Competitors: Chevrolet Traverse, Buick Enclave, GMC Acadia, Dodge Durango, Toyota Highlander Key Features Styling: Distinctive, unconventional styling with a focus on interior space and comfort. Seating: Standard 3-row seating accommodating up to 7 passengers. 📋 Manual Details Coverage Areas Primary Coverage: North America Page Count Total Pages: 6000+ Manual Type Type: Workshop Service Repair Manual Language Language: English Format File Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Comprehensive coverage including disassembly, assembly, inspection, and repair of all engine components. Engine Electrical: Wiring diagrams, component testing, diagnostics for ignition, fuel injection, sensors, and engine control modules. Transmission Automatic: Detailed procedures for removal, installation, overhaul, troubleshooting, and fluid service for the 6-speed automatic transmission. Powertrain Control: Diagnosis and repair of Powertrain Control Module (PCM) related issues, including sensor inputs and actuator outputs. Chassis Systems: Suspension (front and rear), steering system, and wheel alignment procedures. Brake System: Front and rear brake inspection, service, replacement of pads, rotors, calipers, and ABS system diagnostics. Electrical System: Complete electrical schematics, power distribution, lighting systems, accessories, and body control module (BCM) functions. HVAC System: Diagnosis and repair of heating, ventilation, and air conditioning (HVAC) systems, including refrigerant handling and component replacement. Body And Frame: Body panel removal and installation, interior trim, door mechanisms, and structural component repair. Infotainment And Navigation: Troubleshooting and repair of SYNC system, navigation units, audio components, and displays. Safety Systems: Airbag system diagnostics, seat belt mechanisms, and advanced safety features. Procedures Included Maintenance: Detailed scheduled maintenance procedures, fluid level checks, filter replacements, and lubrication points. Troubleshooting: Extensive diagnostic flowcharts, symptom-based troubleshooting guides, and error code interpretations. Repair And Rebuild: Step-by-step instructions for component removal, installation, disassembly, assembly, and calibration. Diagnostics: Guidance on using diagnostic scan tools, interpreting live data, and performing actuator tests. Wiring Diagrams: Complete and detailed electrical wiring schematics for all vehicle systems. Technical Depth Depth: Comprehensive, from basic maintenance to complete engine and transmission rebuilds, including electronic diagnostics. 📊 Manual Specifications File Format Quality: High-resolution PDF, fully searchable and zoomable. Print Quality Printability: All pages are printable for physical reference. Binding Type Binding: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) Compatibility Operating Systems: Compatible with Windows, macOS, and Linux operating systems. Requirements Software Requirement: Adobe Reader or compatible PDF viewer required. ⚙️ Engine Specifications Primary Engine Engine Code: 3.5L Duratec 35 V6 (262 hp @ 6250 rpm, 248 lb-ft @ 4500 rpm) Engine Description: Naturally aspirated 3.5-liter V6 engine. Optional Engine Engine Code: 3.5L EcoBoost V6 (365 hp @ 5500 rpm, 350 lb-ft @ 1500-5250 rpm) Engine Description: Twin-turbocharged 3.5-liter EcoBoost V6 engine (available from 2010 model year). Performance Fuel Type: Regular Unleaded gasoline (3.5L V6), Premium Unleaded gasoline recommended for EcoBoost V6. Fuel System Injection: Electronic Fuel Injection (EFI) Cooling System Coolant Capacity: Approximately 11.8 liters (12.5 US quarts) for 3.5L V6. Lubrication System Oil Capacity: Approximately 5.9 liters (6.2 US quarts) with filter change for 3.5L V6. Engine Management Ignition System: Electronic ignition, coil-on-plug. 🔧 Transmission Standard Type: 6-speed SelectShift Automatic Transmission Optional Type: N/A Features Drivetrain: Available in Front-Wheel Drive (FWD) and All-Wheel Drive (AWD). Fluid Type Transmission Fluid: Mercon LV Automatic Transmission Fluid (ATF) Fluid Capacity Capacity: Approximately 7.9 liters (8.4 US quarts) for transmission overhaul. 📐 Dimensions Exterior Length: 5019 mm (197.6 in) Width: 1976 mm (77.8 in) Height: 1761 mm (69.3 in) Wheelbase: 3020 mm (118.9 in) Weights Curb Weight FWD: Approx. 2000 kg (4400 lbs) Curb Weight AWD: Approx. 2075 kg (4575 lbs) Towing Capacity: Up to 2000 lbs (8000 lbs GVWR available with optional tow package) Cargo Cargo Volume Behind 3Rd Row: Approx. 42.0 cu ft Cargo Volume Behind 2Nd Row: Approx. 83.2 cu ft Cargo Volume Behind 1St Row: Approx. 110.0 cu ft 🛡️ Safety Features Ratings NHTSA Front Impact: 5-Star (Driver and Passenger) NHTSA Side Impact: 5-Star (Front and Rear Passengers) IIHS Top Safety Pick: Yes (for applicable years) Active Features ABS: Standard Anti-lock Braking System (ABS) Traction Control: Standard Traction Control System (TCS) Electronic Stability Control: Standard AdvanceTrac Electronic Stability Control (ESC) Passive Features Airbags: Front airbags, front side-impact airbags, Safety Canopy System (side-curtain airbags for all three rows). 💡 Technology Features Infotainment System Name: Ford SYNC (optional, varies by trim and year) Features: Voice-activated communication, entertainment, climate control, optional navigation, touchscreen displays. Driver Assistance Features: Available rearview camera, blind-spot monitoring (on later models/trims), rear parking sensors. Connectivity Ports: USB ports, auxiliary audio input, Bluetooth connectivity. 🔧 Maintenance Service Intervals Oil Change Interval: Every 7,500 miles (12,000 km) or 6 months, whichever comes first, under normal driving conditions. Up to 10,000 miles (16,000 km) with synthetic oil under ideal conditions....
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Ford Flex 2009 2010 2011 2012 Workshop Service Repair Manual
🏷️ Basic Information
Identification
Make:
Ford
Model:
Flex
Years Covered:
2009, 2010, 2011, 2012
Codes
Platform:
D4 (shared with Lincoln MKS, Lincoln MKT)
👋 Introduction
Market Position
Segment:
Full-size Crossover SUV
Competitive Analysis
Key Competitors:
Chevrolet Traverse, Buick Enclave, GMC Acadia, Dodge Durango, Toyota Highlander
Key Features
Styling:
Distinctive, unconventional styling with a focus on interior space and comfort.
Seating:
Standard 3-row seating accommodating up to 7 passengers.
📋 Manual Details
Coverage Areas
Primary Coverage:
North America
Page Count
Total Pages:
6000+
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
English
Format
File Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Comprehensive coverage including disassembly, assembly, inspection, and repair of all engine components.
Engine Electrical:
Wiring diagrams, component testing, diagnostics for ignition, fuel injection, sensors, and engine control modules.
Transmission Automatic:
Detailed procedures for removal, installation, overhaul, troubleshooting, and fluid service for the 6-speed automatic transmission.
Powertrain Control:
Diagnosis and repair of Powertrain Control Module (PCM) related issues, including sensor inputs and actuator outputs.
Chassis Systems:
Suspension (front and rear), steering system, and wheel alignment procedures.
Brake System:
Front and rear brake inspection, service, replacement of pads, rotors, calipers, and ABS system diagnostics.
Electrical System:
Complete electrical schematics, power distribution, lighting systems, accessories, and body control module (BCM) functions.
HVAC System:
Diagnosis and repair of heating, ventilation, and air conditioning (HVAC) systems, including refrigerant handling and component replacement.
Body And Frame:
Body panel removal and installation, interior trim, door mechanisms, and structural component repair.
Infotainment And Navigation:
Troubleshooting and repair of SYNC system, navigation units, audio components, and displays.
Safety Systems:
Airbag system diagnostics, seat belt mechanisms, and advanced safety features.
Procedures Included
Maintenance:
Detailed scheduled maintenance procedures, fluid level checks, filter replacements, and lubrication points.
Troubleshooting:
Extensive diagnostic flowcharts, symptom-based troubleshooting guides, and error code interpretations.
Repair And Rebuild:
Step-by-step instructions for component removal, installation, disassembly, assembly, and calibration.
Diagnostics:
Guidance on using diagnostic scan tools, interpreting live data, and performing actuator tests.
Wiring Diagrams:
Complete and detailed electrical wiring schematics for all vehicle systems.
Technical Depth
Depth:
Comprehensive, from basic maintenance to complete engine and transmission rebuilds, including electronic diagnostics.
📊 Manual Specifications
File Format
Quality:
High-resolution PDF, fully searchable and zoomable.
Print Quality
Printability:
All pages are printable for physical reference.
Binding Type
Binding:
N/A (Digital PDF)
Paper Type
Paper Type:
N/A (Digital PDF)
Compatibility
Operating Systems:
Compatible with Windows, macOS, and Linux operating systems.
Requirements
Software Requirement:
Adobe Reader or compatible PDF viewer required.
⚙️ Engine Specifications
Primary Engine
Engine Code:
3.5L Duratec 35 V6 (262 hp @ 6250 rpm, 248 lb-ft @ 4500 rpm)
Engine Description:
Naturally aspirated 3.5-liter V6 engine.
Optional Engine
Engine Code:
3.5L EcoBoost V6 (365 hp @ 5500 rpm, 350 lb-ft @ 1500-5250 rpm)
Engine Description:
Twin-turbocharged 3.5-liter EcoBoost V6 engine (available from 2010 model year).
Performance
Fuel Type:
Regular Unleaded gasoline (3.5L V6), Premium Unleaded gasoline recommended for EcoBoost V6.
Fuel System
Injection:
Electronic Fuel Injection (EFI)
Cooling System
Coolant Capacity:
Approximately 11.8 liters (12.5 US quarts) for 3.5L V6.
Lubrication System
Oil Capacity:
Approximately 5.9 liters (6.2 US quarts) with filter change for 3.5L V6.
Engine Management
Ignition System:
Electronic ignition, coil-on-plug.
🔧 Transmission
Standard
Type:
6-speed SelectShift Automatic Transmission
Optional
Type:
N/A
Features
Drivetrain:
Available in Front-Wheel Drive (FWD) and All-Wheel Drive (AWD).
Fluid Type
Transmission Fluid:
Mercon LV Automatic Transmission Fluid (ATF)
Fluid Capacity
Capacity:
Approximately 7.9 liters (8.4 US quarts) for transmission overhaul.
📐 Dimensions
Exterior
Length:
5019 mm (197.6 in)
Width:
1976 mm (77.8 in)
Height:
1761 mm (69.3 in)
Wheelbase:
3020 mm (118.9 in)
Weights
Curb Weight FWD:
Approx. 2000 kg (4400 lbs)
Curb Weight AWD:
Approx. 2075 kg (4575 lbs)
Towing Capacity:
Up to 2000 lbs (8000 lbs GVWR available with optional tow package)
Cargo
Cargo Volume Behind 3Rd Row:
Approx. 42.0 cu ft
Cargo Volume Behind 2Nd Row:
Approx. 83.2 cu ft
Cargo Volume Behind 1St Row:
Approx. 110.0 cu ft
🛡️ Safety Features
Ratings
NHTSA Front Impact:
5-Star (Driver and Passenger)
NHTSA Side Impact:
5-Star (Front and Rear Passengers)
IIHS Top Safety Pick:
Yes (for applicable years)
Active Features
ABS:
Standard Anti-lock Braking System (ABS)
Traction Control:
Standard Traction Control System (TCS)
Electronic Stability Control:
Standard AdvanceTrac Electronic Stability Control (ESC)
Passive Features
Airbags:
Front airbags, front side-impact airbags, Safety Canopy System (side-curtain airbags for all three rows).
💡 Technology Features
Infotainment
System Name:
Ford SYNC (optional, varies by trim and year)
Features:
Voice-activated communication, entertainment, climate control, optional navigation, touchscreen displays.
Driver Assistance
Features:
Available rearview camera, blind-spot monitoring (on later models/trims), rear parking sensors.
Connectivity
Ports:
USB ports, auxiliary audio input, Bluetooth connectivity.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 7,500 miles (12,000 km) or 6 months, whichever comes first, under normal driving conditions. Up to 10,000 miles (16,000 km) with synthetic oil under ideal conditions.
Tire Rotation:
Every 7,500 miles (12,000 km)
Transmission Fluid Change:
Typically at 100,000 miles (160,000 km) under normal conditions, or more frequently under severe use (refer to owner's manual).
Coolant Flush:
First flush at 100,000 miles (160,000 km), then every 50,000 miles (80,000 km).
Fluid Specifications
Engine Oil Viscosity:
SAE 5W-20 (for both 3.5L V6 and 3.5L EcoBoost V6)
Coolant Type:
Ford Premium Engine Coolant (Orange)
Brake Fluid Type:
DOT 3
Known Issues
Transmission Hard Shifts:
Some owners have reported rough shifting from the 6-speed automatic transmission, potentially requiring software updates or internal repairs.
Water Pump Leaks:
The water pump on the 3.5L V6 engine can develop leaks over time, requiring replacement.
Powertrain Control Module Failures:
Infrequent reports of PCM issues leading to various drivability problems.
HVAC System Performance:
Occasional issues with AC performance or blower motor functionality.
📚 Vehicle History
Brand Heritage
Brand Focus:
Ford Motor Company, established in 1903, known for a wide range of vehicles from trucks to performance cars.
Model Evolution
Introduction Year:
2008 (as a 2009 model year vehicle)
Design Philosophy:
Designed to offer a unique alternative to traditional SUV styling with a focus on spaciousness and a car-like driving experience.
Production
Assembly Location:
Oakville Assembly Plant, Oakville, Ontario, Canada
🏆 Awards & Recognition
Recognitions
IIHS Award:
Awarded 'Top Safety Pick' by the Insurance Institute for Highway Safety (IIHS) for multiple model years within this range.
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