Ford FLEX 2009-2012 Factory Repair Service Workshop Manual
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🏷️ Basic Information Identification Make: Ford Model: Flex Years Covered: 2009, 2010, 2011, 2012 Market Focus: US/Canada Models Codes Chassis Code: D2C (Ford D3 platform) Engine Codes: Duratec 3.5L V6 (2009-2012), EcoBoost 3.5L V6 Twin-Turbo (2010-2012) 👋 Introduction Market Position Vehicle Segment: Full-size crossover SUV, positioned as a more stylish and car-like alternative to traditional SUVs. Target Audience: Families seeking versatile transportation with modern styling and available all-wheel drive. Competitive Analysis Key Competitors: Buick Enclave, Chevrolet Traverse, GMC Acadia, Mazda CX-9. Unique Selling Proposition: Distinctive styling, spacious three-row seating, and a comfortable ride compared to many competitors. Key Features Design: Unconventional, 'long wagon' styling; distinctive grille and rear fascia. Interior Versatility: Three rows of seating, available second-row captain's chairs, fold-flat third-row seat. Performance Options: Available powerful EcoBoost twin-turbocharged V6 engine. Manual Value Proposition: Provides comprehensive OEM-level repair and maintenance data essential for preserving vehicle integrity and performance. 📋 Manual Details Coverage Areas Geographical Coverage: United States and Canada Regional Variations: Includes specifications and procedures relevant to North American market vehicles. Page Count Estimated Page Count: Extensive (Exact count not provided, but typical factory service manuals are several thousand pages when considering all variants and combined electrical manuals). Manual Type Type: Factory Service and Repair Workshop Manual Purpose: Official guide for diagnosing, servicing, and repairing the vehicle. Language Language: English Format File Format: PDF 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical, fuel systems, emission control, lubrication, cooling systems, ignition systems, starter, charging system, clutch, manual transmission, automatic transmission, transfer case, propeller shaft. Chassis: Suspension and axle, brake systems, steering systems. Electrical: Electrical wiring manual, body electrical systems, starting and charging systems, ignition, infotainment, lighting, instrument cluster, power accessories. Body: Body construction, interior trim, exterior panels, doors, windows, seating systems. HVAC: Air conditioning system diagnosis and repair. Safety: Restraint system (airbags, seatbelts), structural integrity. Procedures Included Maintenance: Scheduled maintenance, fluid changes, filter replacements, component inspections. Diagnostics: Troubleshooting procedures, diagnostic trouble codes (DTCs), symptom-based diagnostics. Repair: Component removal and installation, overhaul procedures, assembly and disassembly. Adjustment: Wheel alignment, brake adjustments, belt tensioning. Calibration: Electronic module calibration, sensor recalibration. Technical Depth Depth: Comprehensive from basic maintenance to complex diagnostics and component overhaul. User Level: Suitable for professional technicians and knowledgeable DIY enthusiasts. Detail Level: Detailed torque specifications, clearances, procedures, and electrical schematics. 📊 Manual Specifications File Format Compatibility: Win95/98/ME/XP/vista/7/8/8.1/10/Linux/MAC/IOS/Android Searchability: Likely text-searchable within the PDF for quick information retrieval. Readability: Clear and concise text with detailed illustrations for ease of understanding. Print Quality Printability: Designed to be printable for hands-on use. Binding Type Binding: Not applicable (PDF format) Paper Type Paper: Not applicable (PDF format) ⚙️ Engine Specifications Primary Engine Base Engine: 3.5L Duratec V6 Base Engine Power: Approx. 262 hp @ 6250 rpm Base Engine Torque: Approx. 248 lb-ft @ 4500 rpm Optional Engine Optional Engine: 3.5L EcoBoost V6 Twin-Turbo Optional Engine Power: Approx. 355 hp @ 5700 rpm Optional Engine Torque: Approx. 350 lb-ft @ 3500 rpm Performance Fuel Type: Unleaded Gasoline Emission Standards: Meets EPA emissions standards for the specified model years. Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) with sequential port or direct injection for EcoBoost. Fuel Pump: In-tank electric fuel pump module. 🔧 Transmission Standard Transmission Type: 6-speed SelectShift Automatic Transmission Transmission Code: 6F50 (for 3.5L V6), 6F55 (for EcoBoost 3.5L V6 and AWD variants) Optional Drivetrain: Available Front-Wheel Drive (FWD) and All-Wheel Drive (AWD). Features Shifting Modes: SelectShift functionality allowing manual gear selection. Transmission Fluid Type: Mercon LV (for 6F50/6F55) Transmission Fluid Capacity: Approx. 9.7 - 10.7 quarts (9.2 - 10.1 liters) depending on configuration (refer to manual for exact capacity). 📐 Dimensions Exterior Length: Approx. 201.9 inches (5128 mm) Width: Approx. 78.2 inches (1986 mm) Height: Approx. 68.4 inches (1737 mm) Wheelbase: Approx. 117.9 inches (3000 mm) Interior Seating Capacity: 7 passengers (standard 2-3-2 configuration). Passenger Volume: Approx. 157.0 cubic feet (4446 liters). Cargo Cargo Volume Behind 3Rd Row: Approx. 20.0 cubic feet (566 liters). Cargo Volume Behind 2Nd Row: Approx. 40.2 cubic feet (1138 liters). Cargo Volume Behind 1St Row: Approx. 83.2 cubic feet (2356 liters). Weights Curb Weight FWD: Approx. 4535 lbs (2057 kg) Curb Weight AWD: Approx. 4767 lbs (2162 kg) Gross Vehicle Weight Rating Gvwr: Approx. 5900-6150 lbs (2676-2790 kg), varies by configuration. Towing Capacity: Up to 5,000 lbs (2268 kg) with optional tow package. 🛡️ Safety Features Ratings NHTSA Overall Rating: Achieved 5-star ratings in some NHTSA tests for frontal and side impact during its generation. IIHS Rating: Received 'Good' ratings in many IIHS crashworthiness tests for its era. Active Features ABS: Standard Anti-lock Braking System (ABS). Esc: Standard Electronic Stability Control (ESC) with Roll Stability Control (RSC). Traction Control: Traction Control System (TCS) standard, enhanced with AWD. Passive Features Airbags: Frontal airbags, front side-impact airbags, Safety Canopy side-curtain airbags for all three rows. Seatbelts: Three-point seatbelts for all seating...
Full-size crossover SUV, positioned as a more stylish and car-like alternative to traditional SUVs.
Target Audience:
Families seeking versatile transportation with modern styling and available all-wheel drive.
Competitive Analysis
Key Competitors:
Buick Enclave, Chevrolet Traverse, GMC Acadia, Mazda CX-9.
Unique Selling Proposition:
Distinctive styling, spacious three-row seating, and a comfortable ride compared to many competitors.
Key Features
Design:
Unconventional, 'long wagon' styling; distinctive grille and rear fascia.
Interior Versatility:
Three rows of seating, available second-row captain's chairs, fold-flat third-row seat.
Performance Options:
Available powerful EcoBoost twin-turbocharged V6 engine.
Manual Value Proposition:
Provides comprehensive OEM-level repair and maintenance data essential for preserving vehicle integrity and performance.
📋 Manual Details
Coverage Areas
Geographical Coverage:
United States and Canada
Regional Variations:
Includes specifications and procedures relevant to North American market vehicles.
Page Count
Estimated Page Count:
Extensive (Exact count not provided, but typical factory service manuals are several thousand pages when considering all variants and combined electrical manuals).
Manual Type
Type:
Factory Service and Repair Workshop Manual
Purpose:
Official guide for diagnosing, servicing, and repairing the vehicle.
Approx. 9.7 - 10.7 quarts (9.2 - 10.1 liters) depending on configuration (refer to manual for exact capacity).
📐 Dimensions
Exterior
Length:
Approx. 201.9 inches (5128 mm)
Width:
Approx. 78.2 inches (1986 mm)
Height:
Approx. 68.4 inches (1737 mm)
Wheelbase:
Approx. 117.9 inches (3000 mm)
Interior
Seating Capacity:
7 passengers (standard 2-3-2 configuration).
Passenger Volume:
Approx. 157.0 cubic feet (4446 liters).
Cargo
Cargo Volume Behind 3Rd Row:
Approx. 20.0 cubic feet (566 liters).
Cargo Volume Behind 2Nd Row:
Approx. 40.2 cubic feet (1138 liters).
Cargo Volume Behind 1St Row:
Approx. 83.2 cubic feet (2356 liters).
Weights
Curb Weight FWD:
Approx. 4535 lbs (2057 kg)
Curb Weight AWD:
Approx. 4767 lbs (2162 kg)
Gross Vehicle Weight Rating Gvwr:
Approx. 5900-6150 lbs (2676-2790 kg), varies by configuration.
Towing Capacity:
Up to 5,000 lbs (2268 kg) with optional tow package.
🛡️ Safety Features
Ratings
NHTSA Overall Rating:
Achieved 5-star ratings in some NHTSA tests for frontal and side impact during its generation.
IIHS Rating:
Received 'Good' ratings in many IIHS crashworthiness tests for its era.
Active Features
ABS:
Standard Anti-lock Braking System (ABS).
Esc:
Standard Electronic Stability Control (ESC) with Roll Stability Control (RSC).
Traction Control:
Traction Control System (TCS) standard, enhanced with AWD.
Passive Features
Airbags:
Frontal airbags, front side-impact airbags, Safety Canopy side-curtain airbags for all three rows.
Seatbelts:
Three-point seatbelts for all seating positions, height-adjustable front belts, Belt Minder system.
Child Anchors:
LATCH (Lower Anchors and Tethers for Children) system for second-row seating.
💡 Technology Features
Infotainment
Infotainment System:
Available SYNC infotainment system with voice recognition, Bluetooth connectivity, and USB ports.
Navigation:
Optional GPS navigation system.
Audio Options:
Premium audio systems, including Sony branded units, available on higher trims.
Driver Assistance
Rear Camera:
Available rearview camera system.
Parking Sensors:
Available rear parking sensors.
Blind Spot Monitoring:
Not commonly available on these early models, but advanced driver-assist features were emerging.
Connectivity
Usb Ports:
Standard or available USB ports for media playback and device charging.
Bluetooth:
Standard or available Bluetooth for hands-free calling and audio streaming.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 7,500 miles (12,000 km) or 6 months, whichever comes first, under normal driving conditions. Severe conditions may require more frequent changes (refer to manual).
Tire Rotation:
Every 7,500 miles (12,000 km) or oil change interval.
Cabin Air Filter:
Recommended every 15,000-30,000 miles (24,000-48,000 km) or annually, depending on environment.
Spark Plugs:
Duratec 3.5L V6: Typically iridium plugs with a 100,000-mile (160,000 km) interval. EcoBoost 3.5L V6: May have different recommendations; consult manual.
Fluid Specifications
Engine Oil Type:
SAE 5W-20, meeting Ford WSS-M2C945-A specification.
Engine Oil Capacity:
Approx. 6.0 quarts (5.7 liters) for 3.5L V6; consult manual for EcoBoost capacity.
Coolant Type:
Ford Premium Engine Coolant (Green) or equivalent meeting Ford WSS-M97B44-D specification (typically a 50/50 mix with distilled water).
Brake Fluid Type:
DOT 3 or DOT 4 motor vehicle brake fluid.
Known Issues
Transmission Issues:
Some owners have reported occasional transmission harshness or delayed engagement, particularly in earlier models.
Engine Mounts:
Can wear prematurely, leading to vibrations felt in the cabin, especially at idle or during acceleration.
Water Pump:
Occasionally reported leaks or failure, especially as mileage increases.
Climate Control:
Blend door actuator failures can lead to improper temperature control or airflow direction.
📚 Vehicle History
Brand Heritage
Manufacturer:
Ford Motor Company, a long-standing American automotive manufacturer with a rich history of innovation and diverse vehicle offerings.
Model Evolution
Introduction Year:
2008 for the 2009 model year.
Platform:
Built on Ford's D3 platform, shared with other large Ford and Volvo vehicles.
Facelifts Updates:
Received minor updates during its production run, including powertrain enhancements (EcoBoost introduction in 2010) and interior/exterior styling tweaks.
Production
Manufacturing Location:
Oakville Assembly Plant, Ontario, Canada.
Production End Year:
2019 (this manual covers up to 2012).
🏆 Awards & Recognition
Recognitions
Initial Reception:
Praised for its unique styling and comfortable interior by automotive journalists upon release.
Safety Awards:
Achieved good safety ratings from NHTSA and IIHS, indicating a structurally sound vehicle.
Ratings
Consumer Reports:
Varied consumer reports on reliability during its production run; this manual is key to maintaining optimal performance.