Ford Flex 2009-2012 Factory Workshop Service Repair Manual
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๐ท๏ธ Basic Information Identification Make: Ford Model: Flex Model Years Covered: 2009, 2010, 2011, 2012 Market Segment: Full-size Crossover SUV / Sport Wagon Codes Platform: D4 platform (shared with Lincoln MKS, Ford Taurus) ๐ Introduction Market Position Positioning: The Ford Flex (2009-2012) occupied a unique niche, often described as a 'sport wagon' or 'crossover utility vehicle', offering spaciousness and a distinctive styling that appealed to families seeking an alternative to traditional minivans and SUVs. Competitive Analysis Competitors: Competed with vehicles like the Chevrolet Traverse, GMC Acadia, Buick Enclave, Toyota Highlander, Honda Pilot, and Mazda CX-9 during its production run. Its boxy, retro-modern design set it apart. Key Features Design Philosophy: Emphasized interior space, comfort, and a high-quality cabin, often featuring unique options like a panoramic sunroof and a refrigerator between the second-row seats on certain trims. Manual Value Proposition: This manual provides factory-authorized procedures, crucial for maintaining the complex systems of the Ford Flex, ensuring accuracy and efficiency in repairs and diagnostics, comparable to what official Ford dealerships utilize. ๐ Manual Details Coverage Areas Engine Coverage: 3.5L V6 Duratec Drivetrain Coverage: Front-Wheel Drive (FWD) and All-Wheel Drive (AWD) / 4WD Systems Transmission Coverage: 6F50/6F55 SelectShift Automatic Transmission Chassis Coverage: Frame, Front and Rear Suspension, Steering, Brakes (ABS, Parking Brake), Wheels, Tires Body Coverage: Body Repairs, Bumpers, Doors, Glass, Sunroof, Exterior Trim, Interior Trim, Seats, Instrument Panel Electrical Coverage: Electrical Component Locations, Fuses, Airbags, Antitheft, Climate Control, Cruise Control, Door Locks, Horns, Lighting (Exterior/Interior), Parking Aid, Wiper/Washer Systems, Multifunction Electronic Module Powertrain Control Coverage: Electronic Engine Controls, Fuel Charging and Controls, Engine Cooling, Engine Exhaust, Engine Ignition, Evap, Accessory Drive Page Count Total Pages: 4400+ Manual Type Type: Factory Workshop Service Repair Manual Synonym: Repair Manual, Service Manual Language Language: English Format Format: PDF File Delivery: CD-ROM Compatibility Operating Systems: Windows (10, 8, 7, Vista 32/64, XP, ME, 98, NT, 2000), macOS, Tablets, Phones Architecture: 32-bit and 64-bit compatible ๐ Manual Coverage Systems Covered Powertrain Components: Engine mechanical, engine cooling, fuel delivery and control, intake air, exhaust systems, emissions controls, ignition system, automatic transmission and transfer case, differentials, driveshafts, axles. Chassis Components: Frame structure, front and rear suspension geometries, steering system (including power steering and column), brake systems (hydraulic, ABS, parking brake), wheels and tire specifications. Body And Interior: Body panel repairs, structural components, doors, hinges, latches, glass replacement, sunroof operation, bumpers, interior trim panels, seating systems, instrument cluster, HVAC controls. Electrical And Electronics: Detailed wiring diagrams, component locations, fuse and relay identification, power distribution, lighting circuits, horn system, starter and charging system, cruise control, antitheft systems, airbag systems, parking aid sensors, climate control modules. Procedures Included Maintenance: Scheduled maintenance procedures, fluid level checks, filter replacements, tune-ups, lubrication. Diagnostics: Troubleshooting guides, pinpoint tests for specific system failures, diagnostic trouble code (DTC) interpretations, symptom-based diagnostics. Repair: Step-by-step repair instructions for major components, component removal and installation, component overhaul, replacement of seals, gaskets, bearings, and other wear items. Specifications: Torque specifications for fasteners, electrical specifications, diagnostic parameter values, fluid capacities and types, dimensional data. Technical Depth Depth: Comprehensive, covering everything from basic fluid changes and component replacement to complex electrical diagnostics and powertrain rebuilds. Detail Level: Factory-level detail with high-resolution illustrations, photos, and diagrams for clarity. Usability: Designed for professional technicians but accessible to advanced DIY enthusiasts. Features searchable text and print-on-demand capabilities. ๐ Manual Specifications File Format File Type: PDF Searchability: Searchable text within PDF Print Quality Illustrations: High Resolution Diagrams: Detailed, clear Binding Type Binding: N/A (Digital format) Paper Type Paper: N/A (Digital format) Delivery Medium Medium: CD-ROM โ๏ธ Engine Specifications Primary Engine Engine Code: 3.5L V6 (Duratec) Displacement: 3.5 Liters (3496 cc) Configuration: DOHC, 24-valve, V6 Performance Horsepower Std: 262 hp @ 6250 rpm (approx.) Torque Std: 248 lb-ft @ 4500 rpm (approx.) Fuel System Induction: Electronic Fuel Injection (EFI) Fuel Type: Unleaded Gasoline (87 octane recommended) Cooling System Coolant Type: Ford Premium Engine Coolant (Gold) or equivalent meeting WSS-M97B51-A1 specifications Ignition System Ignition Type: Distributorless Ignition System (DIS) with coil-on-plug (COP) ignition ๐ง Transmission Standard Transmission Type: 6-Speed Automatic (6F50/6F55 SelectShift) Drivetrain Options: Front-Wheel Drive (FWD) or All-Wheel Drive (AWD) Features Selectshift: Manual shifting capability via steering wheel paddles or gear selector. Fluid Specifications Transmission Fluid Type: MERCON LV Automatic Transmission Fluid (ATF) meeting Ford specification WSS-M2C938-A Cooling Cooling Method: Integrated transmission cooler within the radiator or a separate auxiliary cooler (depending on configuration). ๐ Dimensions Exterior Length: Approx. 201.8 inches Width: Approx. 78.2 inches Height: Approx. 69.1 inches Wheelbase: Approx. 117.9 inches Weights Curb Weight FWD: Approx. 4,550 lbs Curb Weight AWD: Approx. 4,740 lbs Cargo Cargo Volume Behind 3Rd Row: Approx. 20.0 cu ft Cargo Volume Behind 2Nd Row: Approx. 40.0 cu ft Cargo Volume Behind 1St Row: Approx. 83.2 cu ft ๐ก๏ธ Safety Features Ratings NHTSA Rollover Rating: 4 out of 5 stars (typical for this...
D4 platform (shared with Lincoln MKS, Ford Taurus)
๐ Introduction
Market Position
Positioning:
The Ford Flex (2009-2012) occupied a unique niche, often described as a 'sport wagon' or 'crossover utility vehicle', offering spaciousness and a distinctive styling that appealed to families seeking an alternative to traditional minivans and SUVs.
Competitive Analysis
Competitors:
Competed with vehicles like the Chevrolet Traverse, GMC Acadia, Buick Enclave, Toyota Highlander, Honda Pilot, and Mazda CX-9 during its production run. Its boxy, retro-modern design set it apart.
Key Features
Design Philosophy:
Emphasized interior space, comfort, and a high-quality cabin, often featuring unique options like a panoramic sunroof and a refrigerator between the second-row seats on certain trims.
Manual Value Proposition:
This manual provides factory-authorized procedures, crucial for maintaining the complex systems of the Ford Flex, ensuring accuracy and efficiency in repairs and diagnostics, comparable to what official Ford dealerships utilize.
๐ Manual Details
Coverage Areas
Engine Coverage:
3.5L V6 Duratec
Drivetrain Coverage:
Front-Wheel Drive (FWD) and All-Wheel Drive (AWD) / 4WD Systems
Transmission Coverage:
6F50/6F55 SelectShift Automatic Transmission
Chassis Coverage:
Frame, Front and Rear Suspension, Steering, Brakes (ABS, Parking Brake), Wheels, Tires
Windows (10, 8, 7, Vista 32/64, XP, ME, 98, NT, 2000), macOS, Tablets, Phones
Architecture:
32-bit and 64-bit compatible
๐ Manual Coverage
Systems Covered
Powertrain Components:
Engine mechanical, engine cooling, fuel delivery and control, intake air, exhaust systems, emissions controls, ignition system, automatic transmission and transfer case, differentials, driveshafts, axles.
Chassis Components:
Frame structure, front and rear suspension geometries, steering system (including power steering and column), brake systems (hydraulic, ABS, parking brake), wheels and tire specifications.
Troubleshooting guides, pinpoint tests for specific system failures, diagnostic trouble code (DTC) interpretations, symptom-based diagnostics.
Repair:
Step-by-step repair instructions for major components, component removal and installation, component overhaul, replacement of seals, gaskets, bearings, and other wear items.
Specifications:
Torque specifications for fasteners, electrical specifications, diagnostic parameter values, fluid capacities and types, dimensional data.
Technical Depth
Depth:
Comprehensive, covering everything from basic fluid changes and component replacement to complex electrical diagnostics and powertrain rebuilds.
Detail Level:
Factory-level detail with high-resolution illustrations, photos, and diagrams for clarity.
Usability:
Designed for professional technicians but accessible to advanced DIY enthusiasts. Features searchable text and print-on-demand capabilities.
๐ Manual Specifications
File Format
File Type:
PDF
Searchability:
Searchable text within PDF
Print Quality
Illustrations:
High Resolution
Diagrams:
Detailed, clear
Binding Type
Binding:
N/A (Digital format)
Paper Type
Paper:
N/A (Digital format)
Delivery Medium
Medium:
CD-ROM
โ๏ธ Engine Specifications
Primary Engine
Engine Code:
3.5L V6 (Duratec)
Displacement:
3.5 Liters (3496 cc)
Configuration:
DOHC, 24-valve, V6
Performance
Horsepower Std:
262 hp @ 6250 rpm (approx.)
Torque Std:
248 lb-ft @ 4500 rpm (approx.)
Fuel System
Induction:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded Gasoline (87 octane recommended)
Cooling System
Coolant Type:
Ford Premium Engine Coolant (Gold) or equivalent meeting WSS-M97B51-A1 specifications
Ignition System
Ignition Type:
Distributorless Ignition System (DIS) with coil-on-plug (COP) ignition
๐ง Transmission
Standard
Transmission Type:
6-Speed Automatic (6F50/6F55 SelectShift)
Drivetrain Options:
Front-Wheel Drive (FWD) or All-Wheel Drive (AWD)
Features
Selectshift:
Manual shifting capability via steering wheel paddles or gear selector.
Fluid Specifications
Transmission Fluid Type:
MERCON LV Automatic Transmission Fluid (ATF) meeting Ford specification WSS-M2C938-A
Cooling
Cooling Method:
Integrated transmission cooler within the radiator or a separate auxiliary cooler (depending on configuration).
๐ Dimensions
Exterior
Length:
Approx. 201.8 inches
Width:
Approx. 78.2 inches
Height:
Approx. 69.1 inches
Wheelbase:
Approx. 117.9 inches
Weights
Curb Weight FWD:
Approx. 4,550 lbs
Curb Weight AWD:
Approx. 4,740 lbs
Cargo
Cargo Volume Behind 3Rd Row:
Approx. 20.0 cu ft
Cargo Volume Behind 2Nd Row:
Approx. 40.0 cu ft
Cargo Volume Behind 1St Row:
Approx. 83.2 cu ft
๐ก๏ธ Safety Features
Ratings
NHTSA Rollover Rating:
4 out of 5 stars (typical for this class)
IIHS Ratings:
Generally received 'Good' ratings in frontal and side impact tests (specific year variations apply).
Active Features
ABS:
Standard Anti-lock Braking System (ABS)
Traction Control:
Standard Traction Control System (TCS)
Electronic Stability Control:
Standard Electronic Stability Control (ESC)
Passive Features
Airbags:
Front airbags, front side-impact airbags, and available Safety Canopyยฎ side-curtain airbags for all three rows.
Seat Belts:
Three-point seat belts with pretensioners for all occupants, LATCH (Lower Anchors and Tethers for Children) system.
Child Safety:
Rear door child safety locks.
๐ก Technology Features
Infotainment
Infotainment System:
Optional SYNCยฎ voice-activated communications and entertainment system, touch-screen navigation systems, premium audio systems (e.g., Sony).
Driver Assistance
Parking Aid:
Available rear parking sensors and rearview camera.
Comfort Features:
Heated and cooled front seats, heated second-row seats, ambient interior lighting, power liftgate.
Connectivity
Connectivity Features:
Bluetooth connectivity for phone and audio streaming via SYNCยฎ system.
Other Tech
Keyless Entry Start:
Available Intelligent Access with Push-Button Start.
๐ง Maintenance
Service Intervals
Oil Change Interval:
Typically every 7,500 miles or 6 months, whichever comes first, under normal driving conditions. Refer to manual for severe conditions.
Tire Rotation Interval:
Recommended every 7,500 miles.
Transmission Fluid Change:
Typically inspected at 100,000 miles, replacement intervals vary based on usage and conditions, consult the manual.
Fluid Specifications
Engine Oil Type:
SAE 5W-30 synthetic blend or full synthetic motor oil meeting Ford specification WSS-M2C153-H.
Engine Oil Capacity:
Approx. 6.0 quarts (with filter) for the 3.5L V6.
Brake Fluid Type:
DOT 3 brake fluid.
Known Issues
Common Complaints:
Some owners have reported issues with the automatic transmission (harsh shifting, delayed engagement), power steering systems, and occasional electrical gremlins. Water pump leaks have also been noted.
Manual Utility For Issues:
The detailed diagnostic procedures and pinpoint tests within this manual are invaluable for troubleshooting these common and less common issues accurately.
๐ Vehicle History
Brand Heritage
Ford Crossover History:
Ford has a long history of producing versatile vehicles, evolving from traditional station wagons and SUVs to more modern crossover designs that blend car-like handling with SUV utility.
Model Evolution
Flex Introduction:
The Ford Flex was introduced for the 2009 model year, replacing the Ford Freestar minivan and offering a unique 'cooler' alternative. It was based on the Ford Fairlane concept car.
Platform Sharing:
Utilized the D4 platform, which also underpinned the Lincoln MKS and later the Ford Taurus, providing a robust and relatively sophisticated foundation.
Production
Manufacturing Location:
Oakville Assembly Plant in Oakville, Ontario, Canada.
Production Period:
2008-2019 (model years 2009-2012 covered by this manual).
๐ Awards & Recognition
Recognitions
Initial Reception:
The Ford Flex received critical acclaim for its distinctive styling and spacious interior upon its launch. MotorTrend named it a finalist for SUV of the Year in 2009.
Family Vehicle Awards:
Often cited for its family-friendly attributes, though specific awards may vary by publication and year.
Ratings
Safety Ratings Summary:
Consistent good safety ratings from IIHS and NHTSA contributed to its appeal as a family vehicle.
Certifications
Manual Certification:
Factory certified documentation, identical to what authorized Ford service centers would use.
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