06-11 Ford PJ PK RANGER Truck Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Ford Model: Ranger Generation Codes: PJ (2006-2009), PK (2009-2011) Model Years Covered By Manual: 2006, 2007, 2008, 2009, 2010, 2011 Codes Engine Codes: WL-C (2.5L...

Taper: Truck

Distributeur:

UGS: 472881

Mots clés:

Variantes de produits

Description

🏷️ Basic Information

Identification

Make:

Model:

Ranger

Generation Codes:

PJ (2006-2009), PK (2009-2011)

Model Years Covered By Manual:

2006, 2007, 2008, 2009, 2010, 2011

Codes

Engine Codes:

WL-C (2.5L DOHC TD), WE-C (3.0L DOHC TD), WL-3 (2.5L SOHC TD)

Transmission Codes Manual:

R15M-D, S15M-D, S15MX-D

Transmission Codes Automatic:

5R55S

👋 Introduction

Market Position

Segment:

Mid-size Pickup Truck

Target Audience:

Owners, independent repair shops, fleet maintenance personnel.

Competitive Analysis

Key Competitors:

Toyota Hilux, Mitsubishi Triton, Nissan Navara, Holden Colorado (during the period).

Key Features

Manual Value Proposition:

Provides in-depth technical knowledge for maintenance, repair, and diagnostics of Ford Ranger PJ/PK models, enabling cost savings and proper vehicle upkeep.

📋 Manual Details

Coverage Areas

Primary Coverage:

Ford Ranger PJ Series (2006-2009)

Secondary Coverage Notes:

Engine sections applicable to Ford Ranger PK Series (2009-2011) due to shared engine platforms.

Page Count

Estimated Page Count:

Extensive (Specific number not provided, but typical for full workshop manuals)

Manual Type

Type:

Workshop Service Repair Manual

Language

Language:

English

Format

Format:

Digital (typically PDF)

📖 Manual Coverage

Systems Covered

Powertrain:

Engine mechanical, lubrication, intake air system, cooling system, fuel system, exhaust system, emission control, starting system, engine control system, transmission/transaxle.

Chassis:

Suspension, driveline/axle, brakes, steering.

Body And Comfort:

Heater, ventilation, air conditioning (HVAC), restraints (airbags, seatbelts), body and accessories.

Electrical:

Charging system, engine control system, wiring diagrams.

Interior Systems:

Includes details on interior trim removal, seats, dashboard, and associated components.

Procedures Included

Routine Maintenance:

Scheduled maintenance, fluid changes, filter replacements, lubrication.

Diagnostics And Troubleshooting:

Component testing, fault code interpretation, diagnostic procedures for all major systems.

Repair And Rebuild:

Detailed disassembly, inspection, repair, and reassembly procedures for engine, transmission, suspension, brakes, etc.

Specialized Sections:

Overhaul manuals for key components, standard repair times (SRTs), body repair manual, wiring diagrams.

Wiring Diagrams Detail:

Extensive, color-coded wiring diagrams covering all electrical systems, essential for diagnosing electrical faults.

Technical Depth

Depth:

Comprehensive (from basic maintenance to full engine and transmission rebuilds, electrical system diagnostics).

Specifications Detail:

Includes precise torque specifications, clearances, and tolerances for all mechanical components.

📊 Manual Specifications

File Format

Digital Format:

PDF (typically searchable and bookmarkable)

Print Quality

Print Readability:

High (designed for clear reproduction if printed)

Binding Type

Binding:

N/A (Digital Format)

Paper Type

Paper Quality:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine 1 Variant:

WL-C 2.5L DOHC Turbo Diesel

Engine 2 Variant:

WE-C 3.0L DOHC Turbo Diesel

Engine 3 Variant:

WL-3 2.5L SOHC Turbo Diesel

Performance

Typical Power Output 2.5L:

Approx. 105-110 kW (143-149 hp) depending on specific tune and year.

Typical Torque Output 2.5L:

Approx. 300-330 Nm (221-243 lb-ft) depending on specific tune and year.

Typical Power Output 3.0L:

Approx. 115-125 kW (156-169 hp) depending on specific tune and year.

Typical Torque Output 3.0L:

Approx. 380-400 Nm (280-295 lb-ft) depending on specific tune and year.

Fuel System

Fuel Type:

Diesel

Injection Type:

Common Rail Direct Injection (CRDI) for WE-C and likely later WL-C variants, Indirect Injection for earlier WL-3.

Maintenance Notes

Timing Belt Vs Chain:

The WL-C and WL-3 engines typically utilize a timing belt system, requiring periodic replacement. The WE-C engine likely uses a timing chain. Manual will specify intervals.

🔧 Transmission

Standard

Manual Transmission Options:

R15M-D, S15M-D, S15MX-D (5-Speed Manual)

Optional

Automatic Transmission Options:

5R55S (5-Speed Automatic)

Features

Automatic Transmission Capabilities:

The 5R55S is a robust automatic transmission often found in Ford vehicles of this era, known for its smooth shifting and towing capabilities.

Fluid Specifications

Automatic Transmission Fluid:

Mercon V or equivalent (refer to manual for exact specification and capacity).

Manual Transmission Fluid:

GL-4 or GL-5 gear oil (refer to manual for exact viscosity grade, e.g., 75W-90).

📐 Dimensions

Exterior

Body Styles:

Single Cab, Extended Cab (Space Cab), Crew Cab (Double Cab).

Wheelbase Variants:

Multiple wheelbases available depending on cab configuration (refer to manual for specific dimensions).

Weights

Gross Vehicle Weight Rating Gvwr:

Varies by configuration, typically in the 2,500 - 3,000 kg range. Manual will provide exact figures for each variant.

Towing Capacity:

Varies by engine, transmission, and drivetrain configuration. Can be up to 2,700 kg or more for appropriately equipped models.

🛡️ Safety Features

Ratings

Ancap Rating:

Varies by model year and specific crash test. Early models might have lower ratings; later models improved. Manual may reference or omit specific ANCAP figures.

Active Features

Anti Lock Braking System ABS:

Standard on most variants.

Electronic Stability Control Esc:

Became more common and standard on later PK models and specific trims.

Traction Control System TCS:

Often paired with ESC.

Passive Features

Airbags:

Driver and passenger airbags standard on most models. Side airbags may be optional on higher trims.

Seatbelts:

Pre-tensioning seatbelts for front occupants.

💡 Technology Features

Infotainment

Audio System:

Base models feature AM/FM radio with CD player; higher trims offer more advanced audio systems, potentially with Bluetooth connectivity on later models.

Navigation:

Optional satellite navigation system available on higher trim levels.

Driver Assistance

Cruise Control:

Available on most variants, often standard on higher trims.

Connectivity

Usb Ports:

May be present on later models or optional trims.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 10,000 km or 12 months, whichever comes first (refer to manual for exact specification and engine type).

Fuel Filter Replacement:

Crucial for diesel engines. Intervals vary, often around 40,000 - 60,000 km or as indicated by the manual.

Timing Belt Replacement:

For WL-C/WL-3 engines, typically around 100,000 - 120,000 km or 5-7 years. Critical to follow the manual's recommendation to prevent catastrophic engine damage.

Fluid Specifications

Engine Oil Specification:

API CJ-4 or ACEA C3/C2 (for DPF equipped engines if applicable), viscosity typically 5W-30 or 10W-30. Manual is essential for exact spec.

Coolant Specification:

Ford Super Plus Premium Coolant (or equivalent ethylene glycol-based antifreeze with demineralized water).

Brake Fluid Specification:

DOT 3 or DOT 4 (refer to manual for specific type and replacement interval).

Known Issues

Common Diesel Issues:

Turbocharger wear, EGR valve clogging, injector issues (especially with fuel quality), glow plug failure, potential for diesel particulate filter (DPF) issues on later models.

Common Transmission Issues:

Automatic transmission fluid leaks, potential for torque converter issues on high-mileage vehicles. Manual transmission clutch wear.

Suspension Wear:

Ball joints, control arm bushings, and shock absorbers are common wear items on high-mileage trucks.

📚 Vehicle History

Brand Heritage

Ford Truck Legacy:

Ford has a long history of producing robust and capable pickup trucks, with the Ranger nameplate being globally recognized for decades.

Model Evolution

Pj Series:

Introduced in 2006, a significant redesign over previous generations, often considered the start of the 'global Ranger' platform.

Pk Series:

Facelifted version of the PJ, introduced in late 2009 for the 2010 model year, featuring updated styling and potentially improved features.

Production

Manufacturing Locations:

Primarily manufactured in Thailand for export to many international markets, including Australia, South Africa, and others.

🏆 Awards & Recognition

Recognitions

Sales Performance:

Consistently one of the best-selling vehicles in its class in many markets where it was sold.

Ratings

Consumer Satisfaction:

Generally well-regarded for its ruggedness and capability, though specific satisfaction ratings vary by market and model year.