Ford Ranger 1996-2006 Service Repair Manual

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🏷️ Basic Information Identification Make: Ford Model: Ranger Generation: Third Generation (Second Facelift) Production Years Covered: 1996-2006 Body Styles Covered: Regular Cab, SuperCab (Extended Cab), SuperCrew (Crew Cab) Drive Types Covered: Rear-Wheel Drive (RWD), Four-Wheel Drive (4WD/4x4) Codes Platform: Ford Ranger (PN-204) 👋 Introduction Market Position Segment: Compact Pickup Truck Target Audience: DIY Mechanics, Fleet Owners, Enthusiasts, Professional Technicians Competitive Analysis Key Competitors: Toyota Tacoma, Chevrolet S-10/Colorado, GMC Sonoma/Canyon, Dodge Dakota, Nissan Hardbody/Frontier Key Features Manual Benefit 1: Complete Official Factory Information Manual Benefit 2: Cost Savings on Repairs and Maintenance Manual Benefit 3: Empowerment for DIY Projects Manual Benefit 4: Enhanced Vehicle Longevity and Performance Manual Benefit 5: Specific to Vehicle, Not Generic 📋 Manual Details Coverage Areas Geographic Coverage: North America (USA, Canada, Mexico) Market Coverage: Domestic (North American specifications) Page Count Estimated Page Count: Extensive (typical for comprehensive factory service manuals, often exceeding 1000 pages) Manual Type Manual Type: Factory Service and Repair Manual Content Focus: Repair, Maintenance, Diagnostics, Troubleshooting, Specifications Language Language: English Format File Format: PDF Delivery Method: Instant Download 📖 Manual Coverage Systems Covered Powertrain: Engine, Fuel System, Exhaust System, Cooling System, Lubrication System, Drivetrain (Transmission, Transfer Case, Axles) Chassis: Suspension (Front and Rear), Steering System, Brake System (Front and Rear), Wheels and Tires Electrical: Battery, Charging System, Starting System, Ignition System, Lighting System, Instrumentation, Wiper/Washer System, Power Accessories, Body Control Modules, HVAC Controls, Safety Systems (SRS) Body: Exterior Body Panels, Doors, Hood, Tailgate, Bumpers, Interior Trim, Seats, Glass, Mirrors, Body Sealing Procedures Included Maintenance: Scheduled Maintenance (Oil Changes, Filter Replacements, Lubrication), Fluid Checks and Replacements, Belt and Hose Inspections Repair: Engine Overhaul, Transmission Repair/Replacement, Brake System Overhaul, Suspension Component Replacement, Steering System Repair, Electrical Component Diagnosis and Repair, Body Panel Replacement Diagnostics: Troubleshooting Flowcharts, Symptom-Based Diagnosis, Diagnostic Trouble Codes (DTCs) Interpretation (for applicable models with OBD-II) Specifications: Torque Specifications for Fasteners, Fluid Capacities and Types, Engine Timing Specifications, Wheel Alignment Specifications, Electrical Resistance Values Technical Depth Depth Of Information: Comprehensive, Factory-Level Detail, Step-by-Step Instructions Diagrams Illustrations: Detailed Diagrams, Exploded Views, Wiring Schematics, Component Illustrations Special Tools: Identification and Usage of Specialized Ford Tools 📊 Manual Specifications File Format File Type: Adobe PDF Searchability: Searchable Text Content (typically) Print Quality Printability: Full Printable Pages Zoom Capability: Zoom In/Out Functionality for Detailed Views Binding Type Binding Type: Digital (PDF Format) Paper Type Paper Type: N/A (Digital) Requirements Software Requirements: Adobe PDF Reader, WinZip (or similar decompression utility) Operating System Compatibility: Compatible with All Versions of Windows & Mac ⚙️ Engine Specifications Primary Engine Engine Option 1 Displacement: 2.5 L (153 cu in) Lima I4 Engine Option 1 Power: Approx. 118-127 hp @ 4800-5000 rpm Engine Option 1 Torque: Approx. 140-145 lb-ft @ 2800-3000 rpm Engine Option 2 Displacement: 3.0 L (182 cu in) Vulcan V6 Engine Option 2 Power: Approx. 145-150 hp @ 4900-5000 rpm Engine Option 2 Torque: Approx. 165-170 lb-ft @ 3000-3500 rpm Engine Option 3 Displacement: 4.0 L (245 cu in) Cologne V6 (OHV) Engine Option 3 Power: Approx. 160-207 hp @ 4200-5000 rpm (depending on year/tune) Engine Option 3 Torque: Approx. 220-230 lb-ft @ 2700-3000 rpm (depending on year/tune) Performance Fuel Delivery: Electronic Fuel Injection (EFI) for all engines Fuel System Fuel Type: Unleaded Gasoline Emission Controls: Catalytic Converter, EGR System, PCV System 🔧 Transmission Standard Standard Transmission Type: 5-Speed Manual Transmission (e.g., M5OD-R1 for 2WD, M5OD-R1HD for 4WD and heavier duty applications) Optional Optional Transmission Type 1: 4-Speed Automatic Transmission (e.g., 4R44E, 4R55E, 5R55E for V6 models) Features Transfer Case 4Wd: Manual Shift 4x4 (BW1350, BW1354) or Electronic Shift-on-the-Fly (ESOF) systems depending on trim/year Rear Axle Ratio: Various ratios available (e.g., 3.73, 4.10, 4.56) depending on engine, transmission, and package 📐 Dimensions Exterior Wheelbase Short Bed: Approx. 113.9 inches (2893 mm) Wheelbase Long Bed: Approx. 125.8 inches (3195 mm) Overall Length: Varies by bed length and cab configuration Width Excluding Mirrors: Approx. 71.5 inches (1816 mm) Height: Approx. 65.7 - 67.3 inches (1669 - 1709 mm) depending on configuration Cargo Bed Length Short: Approx. 71.6 inches (1819 mm) Bed Length Long: Approx. 97.5 inches (2477 mm) Weights Curb Weight: Approx. 3,300 - 4,000 lbs (1497 - 1814 kg) depending on configuration Gross Vehicle Weight Rating Gvwr: Varies by configuration and payload package, typically 4,500 - 5,800 lbs 🛡️ Safety Features Ratings NHTSA Rollover Resistance: Generally rated 4 out of 5 stars for rollover resistance (for 2WD models) Active Features ABS: Anti-lock Braking System (ABS) standard on front wheels, optional on rear wheels or 4-wheel ABS on some models/years Traction Control: Optional on some models/years Passive Features Airbags: Driver and Passenger Airbags (SRS) standard from 1999 onwards, optional or standard on earlier models Seatbelts: Three-point front seat belts with pretensioners, lap belts in rear for extended cabs 💡 Technology Features Infotainment Audio System: Standard AM/FM stereo with cassette and/or CD player....

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Type: Truck

Verkoper:

Sku: 217009

Collecties: ALL Ford

Beschikbaarheid: Op voorraad

Labels: 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 Cars Ford Ranger Truck

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Description

🏷️ Basic Information

Identification

Make:

Model:

Ranger

Generation:

Third Generation (Second Facelift)

Production Years Covered:

1996-2006

Body Styles Covered:

Regular Cab, SuperCab (Extended Cab), SuperCrew (Crew Cab)

Drive Types Covered:

Rear-Wheel Drive (RWD), Four-Wheel Drive (4WD/4x4)

Codes

Platform:

Ford Ranger (PN-204)

👋 Introduction

Market Position

Segment:

Compact Pickup Truck

Target Audience:

DIY Mechanics, Fleet Owners, Enthusiasts, Professional Technicians

Competitive Analysis

Key Competitors:

Toyota Tacoma, Chevrolet S-10/Colorado, GMC Sonoma/Canyon, Dodge Dakota, Nissan Hardbody/Frontier

Key Features

Manual Benefit 1:

Complete Official Factory Information

Manual Benefit 2:

Cost Savings on Repairs and Maintenance

Manual Benefit 3:

Empowerment for DIY Projects

Manual Benefit 4:

Enhanced Vehicle Longevity and Performance

Manual Benefit 5:

Specific to Vehicle, Not Generic

📋 Manual Details

Coverage Areas

Geographic Coverage:

North America (USA, Canada, Mexico)

Market Coverage:

Domestic (North American specifications)

Page Count

Estimated Page Count:

Extensive (typical for comprehensive factory service manuals, often exceeding 1000 pages)

Manual Type

Manual Type:

Factory Service and Repair Manual

Content Focus:

Repair, Maintenance, Diagnostics, Troubleshooting, Specifications

Language

Language:

English

Format

File Format:

Delivery Method:

Instant Download

📖 Manual Coverage

Systems Covered

Powertrain:

Engine, Fuel System, Exhaust System, Cooling System, Lubrication System, Drivetrain (Transmission, Transfer Case, Axles)

Chassis:

Suspension (Front and Rear), Steering System, Brake System (Front and Rear), Wheels and Tires

Electrical:

Battery, Charging System, Starting System, Ignition System, Lighting System, Instrumentation, Wiper/Washer System, Power Accessories, Body Control Modules, HVAC Controls, Safety Systems (SRS)

Body:

Exterior Body Panels, Doors, Hood, Tailgate, Bumpers, Interior Trim, Seats, Glass, Mirrors, Body Sealing

Procedures Included

Maintenance:

Scheduled Maintenance (Oil Changes, Filter Replacements, Lubrication), Fluid Checks and Replacements, Belt and Hose Inspections

Repair:

Engine Overhaul, Transmission Repair/Replacement, Brake System Overhaul, Suspension Component Replacement, Steering System Repair, Electrical Component Diagnosis and Repair, Body Panel Replacement

Diagnostics:

Troubleshooting Flowcharts, Symptom-Based Diagnosis, Diagnostic Trouble Codes (DTCs) Interpretation (for applicable models with OBD-II)

Specifications:

Torque Specifications for Fasteners, Fluid Capacities and Types, Engine Timing Specifications, Wheel Alignment Specifications, Electrical Resistance Values

Technical Depth

Depth Of Information:

Comprehensive, Factory-Level Detail, Step-by-Step Instructions

Diagrams Illustrations:

Detailed Diagrams, Exploded Views, Wiring Schematics, Component Illustrations

Special Tools:

Identification and Usage of Specialized Ford Tools

📊 Manual Specifications

File Format

File Type:

Adobe PDF

Searchability:

Searchable Text Content (typically)

Print Quality

Printability:

Full Printable Pages

Zoom Capability:

Zoom In/Out Functionality for Detailed Views

Binding Type

Binding Type:

Digital (PDF Format)

Paper Type

Paper Type:

N/A (Digital)

Requirements

Software Requirements:

Adobe PDF Reader, WinZip (or similar decompression utility)

Operating System Compatibility:

Compatible with All Versions of Windows & Mac

⚙️ Engine Specifications

Primary Engine

Engine Option 1 Displacement:

2.5 L (153 cu in) Lima I4

Engine Option 1 Power:

Approx. 118-127 hp @ 4800-5000 rpm

Engine Option 1 Torque:

Approx. 140-145 lb-ft @ 2800-3000 rpm

Engine Option 2 Displacement:

3.0 L (182 cu in) Vulcan V6

Engine Option 2 Power:

Approx. 145-150 hp @ 4900-5000 rpm

Engine Option 2 Torque:

Approx. 165-170 lb-ft @ 3000-3500 rpm

Engine Option 3 Displacement:

4.0 L (245 cu in) Cologne V6 (OHV)

Engine Option 3 Power:

Approx. 160-207 hp @ 4200-5000 rpm (depending on year/tune)

Engine Option 3 Torque:

Approx. 220-230 lb-ft @ 2700-3000 rpm (depending on year/tune)

Performance

Fuel Delivery:

Electronic Fuel Injection (EFI) for all engines

Fuel System

Fuel Type:

Unleaded Gasoline

Emission Controls:

Catalytic Converter, EGR System, PCV System

🔧 Transmission

Standard

Standard Transmission Type:

5-Speed Manual Transmission (e.g., M5OD-R1 for 2WD, M5OD-R1HD for 4WD and heavier duty applications)

Optional

Optional Transmission Type 1:

4-Speed Automatic Transmission (e.g., 4R44E, 4R55E, 5R55E for V6 models)

Features

Transfer Case 4Wd:

Manual Shift 4x4 (BW1350, BW1354) or Electronic Shift-on-the-Fly (ESOF) systems depending on trim/year

Rear Axle Ratio:

Various ratios available (e.g., 3.73, 4.10, 4.56) depending on engine, transmission, and package

📐 Dimensions

Exterior

Wheelbase Short Bed:

Approx. 113.9 inches (2893 mm)

Wheelbase Long Bed:

Approx. 125.8 inches (3195 mm)

Overall Length:

Varies by bed length and cab configuration

Width Excluding Mirrors:

Approx. 71.5 inches (1816 mm)

Height:

Approx. 65.7 - 67.3 inches (1669 - 1709 mm) depending on configuration

Cargo

Bed Length Short:

Approx. 71.6 inches (1819 mm)

Bed Length Long:

Approx. 97.5 inches (2477 mm)

Weights

Curb Weight:

Approx. 3,300 - 4,000 lbs (1497 - 1814 kg) depending on configuration

Gross Vehicle Weight Rating Gvwr:

Varies by configuration and payload package, typically 4,500 - 5,800 lbs

🛡️ Safety Features

Ratings

NHTSA Rollover Resistance:

Generally rated 4 out of 5 stars for rollover resistance (for 2WD models)

Active Features

Anti-lock Braking System (ABS) standard on front wheels, optional on rear wheels or 4-wheel ABS on some models/years

Traction Control:

Optional on some models/years

Passive Features

Airbags:

Driver and Passenger Airbags (SRS) standard from 1999 onwards, optional or standard on earlier models

Seatbelts:

Three-point front seat belts with pretensioners, lap belts in rear for extended cabs

💡 Technology Features

Infotainment

Audio System:

Standard AM/FM stereo with cassette and/or CD player. Optional premium sound systems available.

Speaker Configuration:

Typically 2 or 4 speakers, with optional premium systems offering more.

Driver Assistance

Cruise Control:

Optional on most models, standard on higher trims.

Power Windows Locks:

Optional, typically found on XLT and higher trim levels.

Connectivity

OBD Ii Port:

Standard from 1996 onwards for engine diagnostics.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 3,000-5,000 miles (4,800-8,000 km) or 3-6 months, depending on driving conditions and oil type (refer to manual for specific recommendations).

Tire Rotation Interval:

Every 5,000-7,500 miles (8,000-12,000 km)

Coolant Flush Interval:

Typically every 30,000-50,000 miles (48,000-80,000 km) or 2-3 years

Fluid Specifications

Engine Oil Type:

Refer to manual for specific API service classification and viscosity grades (e.g., 5W-30, 10W-30 depending on engine and climate). Ford Motorcraft synthetic blend or full synthetic recommended.

Transmission Fluid Type Auto:

Mercon V (or Mercon compatible fluid) is common for 4RxxE transmissions. Refer to manual for exact specification.

Transmission Fluid Type Manual:

Refer to manual for specific gear oil type (e.g., Motorcraft Manual Transmission Lubricant).

Coolant Type:

Ford Premium Engine Coolant (Green) or equivalent meeting specification WSS-M97B51-A1.

Brake Fluid Type:

DOT 3 brake fluid

Known Issues

Common Issue 1:

Spark plug blow-out on 2004-2007 4.0L SOHC V6 engines (thread repair often required).

Common Issue 2:

Transmission solenoid issues (especially with 4R44E/4R55E models) leading to harsh shifting or failure to engage gears.

Common Issue 3:

Corrosion on frame rails and rear axle components, particularly in rust-belt regions.

Common Issue 4:

ABS sensor failures leading to ABS warning light illumination.

Common Issue 5:

Door hinge wear and sagging doors.

📚 Vehicle History

Brand Heritage

Ford Truck Legacy:

Ford has a long and established history in the pickup truck market, dating back to the Ford Model AA.

Model Evolution

Ranger Introduction North America:

The Ford Ranger was first introduced in North America for the 1983 model year, replacing the Courier compact pickup.

Third Generation Facelift:

The 1998 model year saw a significant redesign (the second facelift of the second generation), which continued through 2006 with minor updates.

Production

Manufacturing Locations:

Primarily assembled in North America (e.g., St. Paul, Minnesota; Edison, New Jersey; Louisville, Kentucky)

Global Presence:

While this manual focuses on North American models, the Ranger platform was also used globally with variations.

🏆 Awards & Recognition

Recognitions

Automotive Journal Awards:

The Ford Ranger has historically received various accolades from automotive publications for its utility, capability, and value in the compact truck segment.

Ratings

Consumer Satisfaction:

Generally well-regarded for its durability and workhorse capabilities, though specific ratings varied by model year and powertrain.

Certifications

Factory Training Equivalence:

This manual mirrors the information used by Ford dealership technicians, representing the highest level of factory certification for repair knowledge.