Ford RANGER PJ PK 2006-2011 Workshop Service Repair Manual
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🏷️ Basic Information Identification Make: Ford Model: Ranger Chassis Code: PJ / PK Series Production Years Covered: 2006-2011 Codes Engine Codes Covered: WL-C (2.5L DOHC TD), WE-C (3.0L DOHC TD), WL-3 (2.5L SOHC TD) Transmission Codes Covered: 5R55S (5-Speed Automatic), R15M-D / S15M-D / S15MX-D (5-Speed Manual) 👋 Introduction Market Position Target Audience: DIY owners, independent repair shops, and professional mechanics working on Ford Ranger PJ and PK series vehicles. Competitive Analysis Value Proposition: Provides factory-level repair and service information at a fraction of the cost of dealership service, enabling cost-effective maintenance and repairs. Key Features Instruction Style: Step-by-step written instructions paired with detailed illustrations and diagrams for clarity. Documentation Source: Factory-derived manual content, offering authoritative guidance. 📋 Manual Details Coverage Areas Primary Coverage: Ford Ranger PJ Series Secondary Coverage Note: Engine sections are applicable to PK Series due to shared powertrains. Page Count Estimated Page Count: Varies based on specific content and diagrams, typically several hundred pages for a comprehensive workshop manual. Manual Type Type: Workshop Service and Repair Manual Language Language: English Format Digital Format: PDF Download 📖 Manual Coverage Systems Covered Powertrain: Engine Mechanical, Lubrication, Fuel System, Cooling System, Intake Air System, Exhaust System, Emission Control, Starting System, Engine Control System, Driveline/Axle, Transmission/Transaxle Chassis: Suspension, Brakes, Steering Electrical And HVAC: Charging System, Heater, Ventilation, Air Conditioning (HVAC), Restraints, Wiring Diagrams Bodywork: Body and Accessories, Body Repair Manual Procedures Included Routine Maintenance: Oil changes, filter replacements, fluid checks, belt inspections, spark plug replacement (where applicable). Repair And Overhaul: Engine disassembly and reassembly, transmission overhaul, suspension component replacement, brake system servicing, steering system repair. Diagnostics: Troubleshooting guides, diagnostic procedures for various systems, fault code interpretation (where applicable). Component Specific: Detailed procedures for servicing and replacing individual components within each system. Technical Depth Depth: Comprehensive, covering from basic maintenance and diagnostics to in-depth repair and overhaul procedures, suitable for both DIY enthusiasts and professional mechanics. 📊 Manual Specifications File Format Format: PDF File Size: 65 MB Print Quality Printability: Printable pages for specific tasks. Illustration Quality: Detailed illustrations, diagrams, and pictures. Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) Software Requirements PDF Reader: Adobe Acrobat Reader (free download available) Extraction Software: WinZip or WinRAR (free download available for extraction from ZIP format) Compatibility Operating Systems: All Windows versions, All Mac versions ⚙️ Engine Specifications Primary Engine Engine 1: WL-C 2.5L DOHC Turbo Diesel Engine 2: WE-C 3.0L DOHC Turbo Diesel Engine 3: WL-3 2.5L SOHC Turbo Diesel Performance Typical Horsepower 2 5L: Around 110-120 HP (Varies by specific WL variant and tuning) Typical Torque 2 5L: Around 250-280 Nm (Varies by specific WL variant and tuning) Typical Horsepower 3 0L: Around 150-160 HP (Varies by specific WE variant and tuning) Typical Torque 3 0L: Around 330-380 Nm (Varies by specific WE variant and tuning) Fuel System Fuel Type: Diesel Injection System: Turbocharged Direct Injection (TD) - Specifics on common rail or older systems would be in manual. 🔧 Transmission Standard Transmission 1: 5-Speed Automatic (5R55S) Transmission 2: 5-Speed Manual (R15M-D, S15M-D, S15MX-D) Optional Optional Transmissions: N/A (Specific to configurations offered). Features Automatic Transmission Features: Electronic control, adaptive shifting strategies likely included in manual diagnostics. Manual Transmission Features: Robust designs for heavy-duty use, specific clutch and gearbox overhaul procedures detailed. 📐 Dimensions Exterior Body Styles Covered: Likely includes Single Cab, Dual Cab, and potentially Chassis Cab variants based on the Ranger PJ/PK generation. Weights Gross Vehicle Weight Rating: Specific GVWR would vary by configuration and engine, detailed in manual. 🛡️ Safety Features Ratings Crash Test Data: Specific crash test ratings (e.g., ANCAP, Euro NCAP) for the PJ/PK Ranger generation would need to be researched separately but manual covers related safety systems. Active Features Braking Systems: ABS (Anti-lock Braking System), EBD (Electronic Brakeforce Distribution) likely standard on many models. Manual covers diagnostics and repair. Passive Features Airbags: Driver and passenger airbags, side airbags may be present on higher trims. Manual covers restraint system servicing. 💡 Technology Features Infotainment Audio System: Basic AM/FM radio with CD player typically found, with higher trims potentially offering upgraded audio and auxiliary inputs. Manual covers electrical system for troubleshooting. Driver Assistance Braking Aids: ABS and EBD were common safety features. Traction control and stability control were less common in base models of this era. Connectivity Auxiliary Inputs: Auxiliary input jacks for audio devices were becoming more common in this period, details within electrical system section. 🔧 Maintenance Service Intervals Oil Change Interval: Typically 5,000-10,000 km or 6-12 months, depending on diesel type, driving conditions, and oil specification. Refer to manual for exact intervals. Transmission Fluid Interval: Automatic transmission fluid changes are typically recommended every 40,000-80,000 km, manual transmission fluid less frequently. Manual will specify. Fluid Specifications Engine Oil Specification: API CG-4 or higher, SAE 15W-40 or 10W-30 diesel engine oil recommended. Specific...
DIY owners, independent repair shops, and professional mechanics working on Ford Ranger PJ and PK series vehicles.
Competitive Analysis
Value Proposition:
Provides factory-level repair and service information at a fraction of the cost of dealership service, enabling cost-effective maintenance and repairs.
Key Features
Instruction Style:
Step-by-step written instructions paired with detailed illustrations and diagrams for clarity.
Engine disassembly and reassembly, transmission overhaul, suspension component replacement, brake system servicing, steering system repair.
Diagnostics:
Troubleshooting guides, diagnostic procedures for various systems, fault code interpretation (where applicable).
Component Specific:
Detailed procedures for servicing and replacing individual components within each system.
Technical Depth
Depth:
Comprehensive, covering from basic maintenance and diagnostics to in-depth repair and overhaul procedures, suitable for both DIY enthusiasts and professional mechanics.
📊 Manual Specifications
File Format
Format:
PDF
File Size:
65 MB
Print Quality
Printability:
Printable pages for specific tasks.
Illustration Quality:
Detailed illustrations, diagrams, and pictures.
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
Software Requirements
PDF Reader:
Adobe Acrobat Reader (free download available)
Extraction Software:
WinZip or WinRAR (free download available for extraction from ZIP format)
Compatibility
Operating Systems:
All Windows versions, All Mac versions
⚙️ Engine Specifications
Primary Engine
Engine 1:
WL-C 2.5L DOHC Turbo Diesel
Engine 2:
WE-C 3.0L DOHC Turbo Diesel
Engine 3:
WL-3 2.5L SOHC Turbo Diesel
Performance
Typical Horsepower 2 5L:
Around 110-120 HP (Varies by specific WL variant and tuning)
Typical Torque 2 5L:
Around 250-280 Nm (Varies by specific WL variant and tuning)
Typical Horsepower 3 0L:
Around 150-160 HP (Varies by specific WE variant and tuning)
Typical Torque 3 0L:
Around 330-380 Nm (Varies by specific WE variant and tuning)
Fuel System
Fuel Type:
Diesel
Injection System:
Turbocharged Direct Injection (TD) - Specifics on common rail or older systems would be in manual.
🔧 Transmission
Standard
Transmission 1:
5-Speed Automatic (5R55S)
Transmission 2:
5-Speed Manual (R15M-D, S15M-D, S15MX-D)
Optional
Optional Transmissions:
N/A (Specific to configurations offered).
Features
Automatic Transmission Features:
Electronic control, adaptive shifting strategies likely included in manual diagnostics.
Manual Transmission Features:
Robust designs for heavy-duty use, specific clutch and gearbox overhaul procedures detailed.
📐 Dimensions
Exterior
Body Styles Covered:
Likely includes Single Cab, Dual Cab, and potentially Chassis Cab variants based on the Ranger PJ/PK generation.
Weights
Gross Vehicle Weight Rating:
Specific GVWR would vary by configuration and engine, detailed in manual.
🛡️ Safety Features
Ratings
Crash Test Data:
Specific crash test ratings (e.g., ANCAP, Euro NCAP) for the PJ/PK Ranger generation would need to be researched separately but manual covers related safety systems.
Active Features
Braking Systems:
ABS (Anti-lock Braking System), EBD (Electronic Brakeforce Distribution) likely standard on many models. Manual covers diagnostics and repair.
Passive Features
Airbags:
Driver and passenger airbags, side airbags may be present on higher trims. Manual covers restraint system servicing.
💡 Technology Features
Infotainment
Audio System:
Basic AM/FM radio with CD player typically found, with higher trims potentially offering upgraded audio and auxiliary inputs. Manual covers electrical system for troubleshooting.
Driver Assistance
Braking Aids:
ABS and EBD were common safety features. Traction control and stability control were less common in base models of this era.
Connectivity
Auxiliary Inputs:
Auxiliary input jacks for audio devices were becoming more common in this period, details within electrical system section.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically 5,000-10,000 km or 6-12 months, depending on diesel type, driving conditions, and oil specification. Refer to manual for exact intervals.
Transmission Fluid Interval:
Automatic transmission fluid changes are typically recommended every 40,000-80,000 km, manual transmission fluid less frequently. Manual will specify.
Fluid Specifications
Engine Oil Specification:
API CG-4 or higher, SAE 15W-40 or 10W-30 diesel engine oil recommended. Specific viscosity depends on climate. Manual will provide exact Ford specifications.
Transmission Fluid Automatic:
Ford specifications for the 5R55S transmission, likely MERCON V or equivalent. Manual will list exact Ford specification.
Transmission Fluid Manual:
GL-4 or GL-5 gear oil, viscosity grade depending on temperature. Manual will specify.
Coolant Specification:
Ford Super Plus Premium coolant or equivalent (typically a long-life ethylene glycol based coolant).
Known Issues
Common Diesel Issues:
Potential for turbocharger issues, injector wear, EGR valve problems, and glow plug failures, especially with high mileage. Manual aids in diagnosing these.
Transmission Wear:
Some automatic transmissions may experience torque converter shudder or wear over time. Manual offers diagnostic and repair procedures.
📚 Vehicle History
Brand Heritage
Ford Truck Legacy:
Ford has a long and storied history in producing durable and capable pickup trucks, with the Ranger being a globally recognized nameplate.
Model Evolution
Ranger Pj Pk Generation:
The PJ (2006-2008) and PK (2009-2011) Ranger generations represented significant updates and facelifts to the previous Ranger models, with updated styling, powertrains, and features, often sharing platforms with Mazda BT-50.
Production
Manufacturing Locations:
Primarily manufactured in Thailand for many global markets, including Australia and other regions.
🏆 Awards & Recognition
Recognitions
Model Specific Awards:
Specific awards for the PJ/PK Ranger generation would require market-specific research, but the Ranger line is generally well-regarded for its utility and durability.