Ford Trader Mazda T Truck Complete Workshop Service Repair Manual 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000
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๐ท๏ธ Basic Information Identification Make: Ford / Mazda Model: Trader / T-Series (Mazda BT-Series rebadge) Model Generation: Third Generation (BT-50 platform equivalent) Codes Chassis Code Platform: Unspecified (based on Mazda BT-50 platform) ๐ Introduction Market Position Market Segment: Light Commercial Vehicle (LCV) / Compact Pickup Truck Competitive Analysis Competitors: Nissan D21/D22 (Navara/Hardbody), Toyota Hilux (Pickup), Mitsubishi L200 (Triton), Isuzu KB (Rodeo/TF). Key Features Key Features Manual: Comprehensive A-Z coverage, step-by-step instructions, photographic aids, troubleshooting guides, diagnostic data. Value Proposition Value Proposition: Enables DIY repairs, saving significant costs on labor and dealership services. ๐ Manual Details Coverage Areas Applicable Years: 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000 Models Covered: All models, engine types, trim levels, and transmission types within the specified years. Page Count Page Count Estimate: Comprehensive (exact page count not provided, but described as covering all procedures A-Z). Manual Type Manual Type: Workshop Service and Repair Manual Language Language: English Format Format: Downloadable Digital Format (PDF compatible) ๐ Manual Coverage Systems Covered Engine Mechanical: Engine overhaul, disassembly, assembly, inspection, lubrication, cooling system, fuel system, ignition system, emission control systems. Engine Electrical: Starting system, charging system, engine control module (ECM) diagnostics, sensors, actuators, wiring diagrams. Transmission Drivetrain: Manual and automatic transmission service, clutch operation, driveshafts, differentials, axle assemblies. Brakes: Hydraulic system, brake calipers, rotors, pads, drums, shoes, parking brake, ABS (if equipped). Suspension Steering: Front and rear suspension components, shock absorbers, springs, bushings, steering gear, power steering system. Electrical Body: Lighting system, interior and exterior electrical components, HVAC system, power windows/locks, body panels, doors, glass. Chassis: Frame inspection and repair, body mounting, exhaust system. Procedures Included Maintenance: Routine maintenance, oil changes, filter replacements, fluid checks and changes, belt and hose inspection/replacement. Troubleshooting: Diagnostic procedures for common and uncommon issues, symptom-based troubleshooting guides. Repair: Step-by-step repair instructions for all major components and systems. Overhaul: Detailed instructions for complete engine, transmission, and other major component overhauls. Specifications Data: Torque specifications, clearances, fluid capacities, electrical specifications, diagnostic values. Technical Depth Technical Depth: Comprehensive from basic maintenance to full mechanical and electrical overhaul and diagnostics. ๐ Manual Specifications File Format File Format: Adobe Acrobat PDF (compatible with most digital devices). Print Quality Print Quality: High resolution, clear text and diagrams, printable on standard paper. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) Software Requirements Software Requirements: Adobe Reader (free download available). Access Access Method: Instant email delivery upon payment confirmation. โ๏ธ Engine Specifications Primary Engine Gas Engine Code Gas 1: FE-E (2.0L SOHC I4) - Common in earlier models. Displacement Gas 1: 1998 cc (2.0 Liters) Engine Code Gas 2: B-series (2.2L OHC I4) - Less common, possible earlier variants. Displacement Gas 2: 2184 cc (2.2 Liters) Primary Engine Diesel Engine Code Diesel 1: R2 (2.2L Diesel I4) - Naturally Aspirated. Displacement Diesel 1: 2209 cc (2.2 Liters) Engine Code Diesel 2: WL (2.5L Diesel I4) - Naturally Aspirated and Turbocharged variants. Displacement Diesel 2: 2490 cc (2.5 Liters) Performance Hp Gas 2.0L: Approx. 100-110 HP (Varies by specific engine variant and market) Torque Gas 2.0L: Approx. 120-130 lb-ft (Varies by specific engine variant and market) Hp Diesel 2.2L: Approx. 60-70 HP Hp Diesel 2.5L: Approx. 75 HP (NA) / 90-105 HP (Turbo) Fuel System Fuel Delivery Gas: Carbureted (earlier models) or Electronic Fuel Injection (EFI) (later models). Fuel Delivery Diesel: Indirect injection via rotary or inline injection pump. ๐ง Transmission Standard Transmission Standard Type: 5-speed Manual Transmission Optional Transmission Optional Type: 4-speed Automatic Transmission (Availability depends on market and specific model). Features Drivetrain Options: Rear-Wheel Drive (RWD) and Four-Wheel Drive (4WD) configurations available. ๐ Dimensions Exterior Body Styles: Single Cab, Extended Cab (Cab Plus), Dual Cab (less common). Wheelbase Options: Multiple wheelbase configurations were offered, typically ranging from approximately 105 to 125 inches. Weights Curb Weight Estimate: Approximately 2800 - 3800 lbs (depending on configuration). Payload Capacity Estimate: Approximately 1500 - 2500 lbs. ๐ก๏ธ Safety Features Ratings Safety Ratings Era: Safety standards of the late 1980s and 1990s; ABS not widely standard, airbags often optional or limited to driver side. Active Features Active Safety Features: Anti-lock Braking System (ABS) - optional on some models/years. Passive Features Passive Safety Features: Seat belts, reinforced cabin structure. ๐ก Technology Features Infotainment Infotainment Systems: Basic AM/FM radio with cassette player. Limited to analog systems of the era. Driver Assistance Driver Assistance Features: Primarily basic features; ABS was the most advanced driver assistance system available, often as an option. Connectivity Connectivity Features: No advanced connectivity features like Bluetooth or USB. Analog systems. ๐ง Maintenance Service Intervals Oil Change Interval: Typically 3,000 - 5,000 miles or 6 months, depending on oil type and driving conditions (refer to manual for specifics). Air Filter Replacement: Every 15,000 - 30,000 miles or as needed based on driving environment. Coolant Flush: Every...
Comprehensive from basic maintenance to full mechanical and electrical overhaul and diagnostics.
๐ Manual Specifications
File Format
File Format:
Adobe Acrobat PDF (compatible with most digital devices).
Print Quality
Print Quality:
High resolution, clear text and diagrams, printable on standard paper.
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
Software Requirements
Software Requirements:
Adobe Reader (free download available).
Access
Access Method:
Instant email delivery upon payment confirmation.
โ๏ธ Engine Specifications
Primary Engine Gas
Engine Code Gas 1:
FE-E (2.0L SOHC I4) - Common in earlier models.
Displacement Gas 1:
1998 cc (2.0 Liters)
Engine Code Gas 2:
B-series (2.2L OHC I4) - Less common, possible earlier variants.
Displacement Gas 2:
2184 cc (2.2 Liters)
Primary Engine Diesel
Engine Code Diesel 1:
R2 (2.2L Diesel I4) - Naturally Aspirated.
Displacement Diesel 1:
2209 cc (2.2 Liters)
Engine Code Diesel 2:
WL (2.5L Diesel I4) - Naturally Aspirated and Turbocharged variants.
Displacement Diesel 2:
2490 cc (2.5 Liters)
Performance
Hp Gas 2.0L:
Approx. 100-110 HP (Varies by specific engine variant and market)
Torque Gas 2.0L:
Approx. 120-130 lb-ft (Varies by specific engine variant and market)
Hp Diesel 2.2L:
Approx. 60-70 HP
Hp Diesel 2.5L:
Approx. 75 HP (NA) / 90-105 HP (Turbo)
Fuel System
Fuel Delivery Gas:
Carbureted (earlier models) or Electronic Fuel Injection (EFI) (later models).
Fuel Delivery Diesel:
Indirect injection via rotary or inline injection pump.
๐ง Transmission
Standard
Transmission Standard Type:
5-speed Manual Transmission
Optional
Transmission Optional Type:
4-speed Automatic Transmission (Availability depends on market and specific model).
Features
Drivetrain Options:
Rear-Wheel Drive (RWD) and Four-Wheel Drive (4WD) configurations available.
๐ Dimensions
Exterior
Body Styles:
Single Cab, Extended Cab (Cab Plus), Dual Cab (less common).
Wheelbase Options:
Multiple wheelbase configurations were offered, typically ranging from approximately 105 to 125 inches.
Weights
Curb Weight Estimate:
Approximately 2800 - 3800 lbs (depending on configuration).
Payload Capacity Estimate:
Approximately 1500 - 2500 lbs.
๐ก๏ธ Safety Features
Ratings
Safety Ratings Era:
Safety standards of the late 1980s and 1990s; ABS not widely standard, airbags often optional or limited to driver side.
Active Features
Active Safety Features:
Anti-lock Braking System (ABS) - optional on some models/years.
Passive Features
Passive Safety Features:
Seat belts, reinforced cabin structure.
๐ก Technology Features
Infotainment
Infotainment Systems:
Basic AM/FM radio with cassette player. Limited to analog systems of the era.
Driver Assistance
Driver Assistance Features:
Primarily basic features; ABS was the most advanced driver assistance system available, often as an option.
Connectivity
Connectivity Features:
No advanced connectivity features like Bluetooth or USB. Analog systems.
๐ง Maintenance
Service Intervals
Oil Change Interval:
Typically 3,000 - 5,000 miles or 6 months, depending on oil type and driving conditions (refer to manual for specifics).
Air Filter Replacement:
Every 15,000 - 30,000 miles or as needed based on driving environment.
Coolant Flush:
Every 30,000 - 60,000 miles or 2-4 years.
Timing Belt Replacement:
Crucial for specific engines (e.g., some FE-E variants). Typically 60,000 - 90,000 miles. Check manual for engine-specific requirements.
Fluid Specifications
Engine Oil Spec:
API SG or higher, viscosity typically 10W-30 or 10W-40 for gasoline engines. Diesel engines may require API CF or higher. Always consult manual for precise API rating and viscosity based on ambient temperature.
Coolant Type:
Ethylene glycol-based antifreeze, typically a green color. Check for compatibility with your specific model's original fill.
Transmission Fluid Auto:
Dexron III or equivalent (for automatic transmissions).
Gear Oil Spec:
GL-4 or GL-5 gear oil, typically SAE 75W-90 or 80W-90 for differentials and manual transmissions.
Known Issues
Common Issues:
Rust and corrosion on body panels (especially in exposed climates), wear in suspension bushings, potential for head gasket issues in high-mileage gasoline engines, injector pump/glow plug issues in diesel variants, interior trim wear.
๐ Vehicle History
Brand Heritage
Ford Heritage Lcav:
Ford's history in the light commercial vehicle segment, leveraging global platforms.
Model Evolution
Mazda Bt Series Relation:
The Ford Trader is a rebadge of the Mazda BT-Series pickup truck (specifically the third generation, often referred to as the B2500/B3000/B4000 platform in its later iterations, but this generation predates those badges).
Production
Production Period:
The specific generation covered by this manual, as a rebadge, corresponds to the Mazda BT-50 predecessor, broadly from the late 1980s to late 1990s.
Manufacturing Locations:
Primarily manufactured by Mazda in Japan and then exported or assembled in various global locations for Ford distribution.
๐ Awards & Recognition
Recognitions
Recognitions Model:
As a rebadge of the Mazda BT-Series, it benefited from Mazda's reputation for reliability in this segment during that period. Specific awards for the 'Ford Trader' variant are less documented than for the Mazda original.