Ford RANGER PJ 2006-2010 Workshop Service Repair Manual
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🏷️ Basic Information Identification Make: Ford Model: Ranger Generation: PJ Year Range: 2006-2010 Codes Chassis Code: PJ 👋 Introduction Market Position Segment: Compact/Mid-size Pickup Truck, popular in utility and lifestyle segments. Competitive Analysis Competitors: Toyota Hilux, Mitsubishi Triton/Pajero Sport, Nissan Navara, Isuzu D-Max/Mu-X. Key Features Design Philosophy: Rugged, reliable, utilitarian, capable off-road and for light commercial use. 📋 Manual Details Coverage Areas Engines: WL-C 2.5L DOHC TD, WE-C 3.0L DOHC TD, WL-3 2.5L SOHC TD Transmissions: 5 Speed Automatic (5R55S), 5 Speed Manual (R15M-D, S15M-D, S15MX-D) Model Variants: Covers various body styles (single cab, freestyle cab, double cab) and driveline configurations (2WD, 4WD). Page Count Estimated Page Count: Extensive (specific page count not provided in product info, but typical for workshop manuals covering multiple systems and including overhaul sections). Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: Likely PDF, often provided as a digital download for workshop manuals of this era, or potentially a printed compilation. 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical, lubrication, fuel system, intake air system, cooling system, exhaust system, emission control, starting system, engine control system, transmission (automatic and manual), driveline/axle. Chassis: Suspension, brakes, steering. Body And Electrical: Heater, ventilation, air conditioning (HVAC), restraints, body and accessories, charging system, wiring diagrams. Electrical System: Comprehensive coverage including battery, alternator, starter, ignition system, lighting, instruments, switches, and body electrical components, supported by detailed wiring diagrams. Procedures Included Maintenance: General maintenance procedures, routine service, fluid changes, filter replacements. Repair: Component-level repair, assembly/disassembly procedures for engine, transmission, suspension, brakes, steering, driveline. Overhaul: Detailed overhaul procedures for major components like engines and transmissions. Diagnostics: Troubleshooting guides, fault diagnosis for various systems, likely including diagnostic trouble codes (DTCs) and test procedures. Electrical: Wiring diagrams, electrical component testing, circuit tracing. Body Repair: Dedicated section for body repair procedures. Special Tools: Likely lists specific Ford-recommended special tools for certain repair procedures, particularly for engine timing, transmission, and suspension components. Technical Depth Depth: Comprehensive, covering general information, description & operation, detailed service procedures, overhaul instructions, and standard repair times. Suitable for professional technicians and advanced DIY mechanics. Diagnostics Tools: The manual implies the use of diagnostic scan tools for engine control system troubleshooting, often referencing specific diagnostic procedures. Torque Specifications: Detailed torque specifications for all critical fasteners across engine, transmission, chassis, and body components. 📊 Manual Specifications File Format File Type: Likely PDF (searchable, printable). Print Quality Quality: High resolution images and diagrams (assuming digital PDF format). Binding Type Binding: N/A (if digital PDF), typically spiral-bound or perfect-bound if printed. Paper Type Paper: N/A (if digital PDF), typically heavy-duty, glossy paper for printed manuals to withstand workshop environments. ⚙️ Engine Specifications Primary Engine Engine 1 Code: WL-C Engine 1 Displacement: 2.5 Liters Engine 1 Configuration: DOHC Turbo Diesel (TD) Secondary Engine Engine 2 Code: WE-C Engine 2 Displacement: 3.0 Liters Engine 2 Configuration: DOHC Turbo Diesel (TD) Tertiary Engine Engine 3 Code: WL-3 Engine 3 Displacement: 2.5 Liters Engine 3 Configuration: SOHC Turbo Diesel (TD) Performance Horsepower Range: Typically in the 100-140 HP range depending on engine variant and tuning. Torque Range: Typically in the 200-300 Nm range, providing good low-end grunt. Fuel System Type: Direct injection common rail (likely for WE-C and later WL-C variants), mechanically controlled injection for earlier WL-3. Turbocharger System: All listed engines are turbo-diesel, implying intercooling and turbocharger system diagnostics and repair procedures are covered. 🔧 Transmission Standard Transmission 1 Type: 5 Speed Manual Transmission 1 Codes: R15M-D, S15M-D, S15MX-D Optional Transmission 2 Type: 5 Speed Automatic Transmission 2 Code: 5R55S Features Drive Type: Rear-wheel drive (RWD) or selectable 4-wheel drive (4WD/4x4). 📐 Dimensions Exterior Body Styles: Single Cab, Freestyle Cab (extended cab), Double Cab (crew cab). Weights Curb Weight Range: Approx. 1700-2000 kg depending on configuration. Gross Vehicle Weight Rating Gvwr: Typically around 2500-2900 kg. 🛡️ Safety Features Ratings Ancap Rating: Varies by specific model year and testing region, generally rated 3-4 stars for the PJ generation. Active Features ABS: Available on higher trims, standard on some later models. Traction Control: Available on some 4x4 models. Passive Features Airbags: Driver and passenger airbags standard on most models, side airbags available on some trims. 💡 Technology Features Infotainment Audio System: Basic AM/FM radio with CD player, optional cassette player on early models. Higher trims may have upgraded speakers or auxiliary input. Driver Assistance Cruise Control: Available on higher trim levels. Connectivity Usb Aux: Auxiliary input jack becoming more common on later models within this range, USB not typically standard. 🔧 Maintenance Service Intervals Oil Change Interval: Typically 5,000-10,000 km or 6-12 months, depending on driving conditions and oil type specified in manual. Timing Belt Replacement: For SOHC WL-3: Likely a timing belt, check manual for interval (e.g., 100,000 km). For DOHC WL-C/WE-C: Often chain-driven, check manual for inspection intervals. Fluid Specifications Engine Oil Viscosity: Commonly...
Covers various body styles (single cab, freestyle cab, double cab) and driveline configurations (2WD, 4WD).
Page Count
Estimated Page Count:
Extensive (specific page count not provided in product info, but typical for workshop manuals covering multiple systems and including overhaul sections).
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Format:
Likely PDF, often provided as a digital download for workshop manuals of this era, or potentially a printed compilation.
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanical, lubrication, fuel system, intake air system, cooling system, exhaust system, emission control, starting system, engine control system, transmission (automatic and manual), driveline/axle.
Chassis:
Suspension, brakes, steering.
Body And Electrical:
Heater, ventilation, air conditioning (HVAC), restraints, body and accessories, charging system, wiring diagrams.
Electrical System:
Comprehensive coverage including battery, alternator, starter, ignition system, lighting, instruments, switches, and body electrical components, supported by detailed wiring diagrams.
Procedures Included
Maintenance:
General maintenance procedures, routine service, fluid changes, filter replacements.
Likely lists specific Ford-recommended special tools for certain repair procedures, particularly for engine timing, transmission, and suspension components.
Technical Depth
Depth:
Comprehensive, covering general information, description & operation, detailed service procedures, overhaul instructions, and standard repair times. Suitable for professional technicians and advanced DIY mechanics.
Diagnostics Tools:
The manual implies the use of diagnostic scan tools for engine control system troubleshooting, often referencing specific diagnostic procedures.
Torque Specifications:
Detailed torque specifications for all critical fasteners across engine, transmission, chassis, and body components.
📊 Manual Specifications
File Format
File Type:
Likely PDF (searchable, printable).
Print Quality
Quality:
High resolution images and diagrams (assuming digital PDF format).
Binding Type
Binding:
N/A (if digital PDF), typically spiral-bound or perfect-bound if printed.
Paper Type
Paper:
N/A (if digital PDF), typically heavy-duty, glossy paper for printed manuals to withstand workshop environments.
⚙️ Engine Specifications
Primary Engine
Engine 1 Code:
WL-C
Engine 1 Displacement:
2.5 Liters
Engine 1 Configuration:
DOHC Turbo Diesel (TD)
Secondary Engine
Engine 2 Code:
WE-C
Engine 2 Displacement:
3.0 Liters
Engine 2 Configuration:
DOHC Turbo Diesel (TD)
Tertiary Engine
Engine 3 Code:
WL-3
Engine 3 Displacement:
2.5 Liters
Engine 3 Configuration:
SOHC Turbo Diesel (TD)
Performance
Horsepower Range:
Typically in the 100-140 HP range depending on engine variant and tuning.
Torque Range:
Typically in the 200-300 Nm range, providing good low-end grunt.
Fuel System
Type:
Direct injection common rail (likely for WE-C and later WL-C variants), mechanically controlled injection for earlier WL-3.
Turbocharger System:
All listed engines are turbo-diesel, implying intercooling and turbocharger system diagnostics and repair procedures are covered.
🔧 Transmission
Standard
Transmission 1 Type:
5 Speed Manual
Transmission 1 Codes:
R15M-D, S15M-D, S15MX-D
Optional
Transmission 2 Type:
5 Speed Automatic
Transmission 2 Code:
5R55S
Features
Drive Type:
Rear-wheel drive (RWD) or selectable 4-wheel drive (4WD/4x4).
📐 Dimensions
Exterior
Body Styles:
Single Cab, Freestyle Cab (extended cab), Double Cab (crew cab).
Weights
Curb Weight Range:
Approx. 1700-2000 kg depending on configuration.
Gross Vehicle Weight Rating Gvwr:
Typically around 2500-2900 kg.
🛡️ Safety Features
Ratings
Ancap Rating:
Varies by specific model year and testing region, generally rated 3-4 stars for the PJ generation.
Active Features
ABS:
Available on higher trims, standard on some later models.
Traction Control:
Available on some 4x4 models.
Passive Features
Airbags:
Driver and passenger airbags standard on most models, side airbags available on some trims.
💡 Technology Features
Infotainment
Audio System:
Basic AM/FM radio with CD player, optional cassette player on early models. Higher trims may have upgraded speakers or auxiliary input.
Driver Assistance
Cruise Control:
Available on higher trim levels.
Connectivity
Usb Aux:
Auxiliary input jack becoming more common on later models within this range, USB not typically standard.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically 5,000-10,000 km or 6-12 months, depending on driving conditions and oil type specified in manual.
Timing Belt Replacement:
For SOHC WL-3: Likely a timing belt, check manual for interval (e.g., 100,000 km). For DOHC WL-C/WE-C: Often chain-driven, check manual for inspection intervals.
Fluid Specifications
Engine Oil Viscosity:
Commonly 5W-30 or 10W-30 for diesel engines, consult manual for specific API classification (e.g., API CI-4 or CJ-4).
Coolant Type:
Ethylene glycol-based coolant, typically orange or pink type (HOAT or OAT). Check manual for specific Ford specification (e.g., Ford Supercoolant).
Automatic Transmission Fluid:
Mercon V or equivalent specified for the 5R55S transmission. Manual specifies Dexron III or equivalent for manual transmissions.
Differential Fluid:
API GL-5, SAE 75W-90 or 80W-90 for rear differential. Check manual for specific front differential fluid if applicable.
Known Issues
Common Concerns:
Turbocharger issues (wastegate rattle, oil leaks), injector problems (diesel), EGR valve clogging, clutch wear on manual transmissions, rear main seal leaks, occasional suspension component wear.
Specific Engine Notes:
WL-C/WE-C engines: potential for carbon buildup on intake valves with direct injection; WL-3: potential for glow plug issues, injector pump wear.
📚 Vehicle History
Brand Heritage
Ford Truck Legacy:
Ford has a long and storied history in pickup trucks, dating back to the Ford Model TT.
Model Evolution
Ranger Lineage:
The Ranger has been a globally popular pickup truck for Ford since its introduction in the mid-1980s, evolving through multiple generations.
Production
Manufacturing Locations:
Produced in various Ford plants worldwide, including Thailand and South Africa for markets covered by this manual.
🏆 Awards & Recognition
Recognitions
Local Awards:
The Ford Ranger has historically received numerous 'Ute of the Year' or similar segment awards in various markets due to its utility and value.
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