Ford RANGER PJ PK 2006-2011 Workshop Service Repair Manual
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🏷️ Basic Information Identification Make: Ford Model: Ranger Generation: PJ / PK Series Year Range: 2006-2011 Chassis Codes: PJ, PK 👋 Introduction Market Market Position: The Ford Ranger PJ/PK series was a robust and popular compact pickup truck, known for its utility, off-road capability, and diesel engine options. It competed in a segment with vehicles like the Toyota Hilux, Nissan Navara (D40), and Mitsubishi Triton (ML). Competitors Competitive Analysis: Positioned as a reliable workhorse and adventure vehicle, the Ranger offered strong payload and towing capacities. The diesel engines provided good fuel economy and torque, making them suitable for commercial use and off-roading. This manual caters to owners and technicians needing detailed support for maintaining and repairing these specific strengths. Features Key Features Vehicle: Durable chassis, capable diesel engines, rear-wheel-drive or selectable four-wheel-drive, available in single cab, space cab, and double cab configurations. Known for its solid construction and straightforward mechanicals. Key Features Manual: Comprehensive coverage across multiple vehicle systems, including detailed engine and transmission specifics, electrical diagrams, and specific repair procedures. The inclusion of 'Standard Repair Times' and 'Body Repair Manual' sections adds significant value for professional shops and accurate repair quoting. 📋 Manual Details Coverage Coverage Areas: Engine Mechanical, Lubrication, Suspension, Intake Air System, Charging System, Cooling System, Fuel System, Exhaust System, Emission Control, Starting System, Engine Control System, Driveline/Axle, Brakes, Transmission/Transaxle, Steering, Heater, Ventilation, Air Conditioning, Restraints, Body and Accessories, General Information, Service Procedures (General, Engine, Suspension, Driveline/Axle), Overhaul Manual, Standard Repair Times, Body Repair Manual, Wiring Diagrams Format Manual Type: Workshop Service Repair Manual Language: English Format: Likely PDF (digital) or Printed Book 📖 Manual Coverage Systems Systems Covered: Engine Mechanical, Lubrication, Suspension, Intake Air System, Charging System, Cooling System, Fuel System, Exhaust System, Emission Control, Starting System, Engine Control Systems (ECU, sensors, actuators), Driveline/Axle Systems (driveshafts, differentials, CV joints), Brake Systems (hydraulic, ABS, parking brake), Transmission/Transaxle (automatic and manual), Steering Systems (power steering), HVAC Systems (heater, ventilation, air conditioning), Restraint Systems (airbags, seatbelts), Body and Accessories (trim, interior, exterior, electrical components) Procedures Procedures Included: General Maintenance, Engine Repair and Overhaul, Drivetrain Component Repair, Suspension and Steering Component Repair, Brake System Service, Transmission Service and Repair, Electrical System Diagnostics and Repair, HVAC System Service, Body Panel Repair, Diagnostic Procedures, Troubleshooting Guides, Standard Repair Times (SRT), Wiring Diagram Interpretation Depth Technical Depth: Comprehensive, covering routine maintenance, diagnostics, repair, and overhaul procedures for all major vehicle systems. Includes detailed specifications, exploded views, and step-by-step instructions suitable for professional technicians and advanced DIYers. 📊 Manual Specifications Physical Binding Type: Likely Spiral-bound or Perfect-bound if printed Paper Type: Durable, matte finish paper suitable for workshop environments if printed Digital File Format: PDF (common for digital versions), potentially with searchable text and hyperlinks Print Quality: High-resolution scans/digital files ensuring clarity of diagrams and text if digital ⚙️ Engine Specifications Primary Primary Engine Options: WL-C 2.5L DOHC TD, WE-C 3.0L DOHC TD, WL-3 2.5L SOHC TD Engine Description: All specified engines are turbocharged direct injection diesel engines, designed for torque and fuel efficiency. The DOHC variants offer better breathing for higher power output, while the SOHC version provides a simpler, robust design. Performance Engine 2 5L Wl Power Hp: Approximately 105-110 HP (Varies slightly by specific WL variant and market) Engine 2 5L Wl Torque Nm: Approximately 280-300 Nm (Varies slightly by specific WL variant and market) Engine 3 0L We Power Hp: Approximately 154 HP (WE-C variant) Engine 3 0L We Torque Nm: Approximately 380 Nm (WE-C variant) Fuel System Fuel System: Direct Injection, Turbocharged Diesel (likely common rail injection system for these models) Maintenance Timing Belt Chain 2 5L: Timing Belt (WL-3 SOHC) or Timing Chain (WL-C DOHC) - Service interval crucial Timing Belt Chain 3 0L: Timing Chain (WE-C) 🔧 Transmission Standard Standard Transmission: 5-Speed Manual (R15M-D, S15M-D, S15MX-D) Optional Optional Transmission: 5-Speed Automatic (5R55S) Features Transmission 5R55S Features: Electronic control, adaptive shift logic, likely with a torque converter lock-up feature for improved highway efficiency. Maintenance Transmission Fluid Type Manual: GL-4 or GL-5 gear oil, specific viscosity (e.g., 75W-90) required as per manual Transmission Fluid Type Auto: Mercon V or equivalent (specific to 5R55S) 📐 Dimensions Exterior Wheelbase Mm: Typically around 3000-3100 mm, depending on cab and configuration Weights Gross Vehicle Weight Rating Kg: Varies by configuration, generally between 2700-3100 kg Towing Capacity Kg: Up to 2500 kg (braked trailer), depending on engine and drivetrain configuration 🛡️ Safety Features Ratings Ancap Rating Pj Pk: Varies by year and specific test, but generally around 3-4 stars for early models. Later PK models might see improvements. Full details would be in the manual's body repair or general sections. Active Features Active Safety Features Available: ABS (Anti-lock Braking System), EBD (Electronic Brakeforce Distribution) Passive Features Passive Safety Features Available: Driver and Passenger Airbags, Seatbelt Pre-tensioners, Reinforced Cab Structure 💡 Technology Features Infotainment Infotainment...
The Ford Ranger PJ/PK series was a robust and popular compact pickup truck, known for its utility, off-road capability, and diesel engine options. It competed in a segment with vehicles like the Toyota Hilux, Nissan Navara (D40), and Mitsubishi Triton (ML).
Competitors
Competitive Analysis:
Positioned as a reliable workhorse and adventure vehicle, the Ranger offered strong payload and towing capacities. The diesel engines provided good fuel economy and torque, making them suitable for commercial use and off-roading. This manual caters to owners and technicians needing detailed support for maintaining and repairing these specific strengths.
Features
Key Features Vehicle:
Durable chassis, capable diesel engines, rear-wheel-drive or selectable four-wheel-drive, available in single cab, space cab, and double cab configurations. Known for its solid construction and straightforward mechanicals.
Key Features Manual:
Comprehensive coverage across multiple vehicle systems, including detailed engine and transmission specifics, electrical diagrams, and specific repair procedures. The inclusion of 'Standard Repair Times' and 'Body Repair Manual' sections adds significant value for professional shops and accurate repair quoting.
📋 Manual Details
Coverage
Coverage Areas:
Engine Mechanical, Lubrication, Suspension, Intake Air System, Charging System, Cooling System, Fuel System, Exhaust System, Emission Control, Starting System, Engine Control System, Driveline/Axle, Brakes, Transmission/Transaxle, Steering, Heater, Ventilation, Air Conditioning, Restraints, Body and Accessories, General Information, Service Procedures (General, Engine, Suspension, Driveline/Axle), Overhaul Manual, Standard Repair Times, Body Repair Manual, Wiring Diagrams
Format
Manual Type:
Workshop Service Repair Manual
Language:
English
Format:
Likely PDF (digital) or Printed Book
📖 Manual Coverage
Systems
Systems Covered:
Engine Mechanical, Lubrication, Suspension, Intake Air System, Charging System, Cooling System, Fuel System, Exhaust System, Emission Control, Starting System, Engine Control Systems (ECU, sensors, actuators), Driveline/Axle Systems (driveshafts, differentials, CV joints), Brake Systems (hydraulic, ABS, parking brake), Transmission/Transaxle (automatic and manual), Steering Systems (power steering), HVAC Systems (heater, ventilation, air conditioning), Restraint Systems (airbags, seatbelts), Body and Accessories (trim, interior, exterior, electrical components)
Procedures
Procedures Included:
General Maintenance, Engine Repair and Overhaul, Drivetrain Component Repair, Suspension and Steering Component Repair, Brake System Service, Transmission Service and Repair, Electrical System Diagnostics and Repair, HVAC System Service, Body Panel Repair, Diagnostic Procedures, Troubleshooting Guides, Standard Repair Times (SRT), Wiring Diagram Interpretation
Depth
Technical Depth:
Comprehensive, covering routine maintenance, diagnostics, repair, and overhaul procedures for all major vehicle systems. Includes detailed specifications, exploded views, and step-by-step instructions suitable for professional technicians and advanced DIYers.
📊 Manual Specifications
Physical
Binding Type:
Likely Spiral-bound or Perfect-bound if printed
Paper Type:
Durable, matte finish paper suitable for workshop environments if printed
Digital
File Format:
PDF (common for digital versions), potentially with searchable text and hyperlinks
Print Quality:
High-resolution scans/digital files ensuring clarity of diagrams and text if digital
All specified engines are turbocharged direct injection diesel engines, designed for torque and fuel efficiency. The DOHC variants offer better breathing for higher power output, while the SOHC version provides a simpler, robust design.
Performance
Engine 2 5L Wl Power Hp:
Approximately 105-110 HP (Varies slightly by specific WL variant and market)
Engine 2 5L Wl Torque Nm:
Approximately 280-300 Nm (Varies slightly by specific WL variant and market)
Engine 3 0L We Power Hp:
Approximately 154 HP (WE-C variant)
Engine 3 0L We Torque Nm:
Approximately 380 Nm (WE-C variant)
Fuel System
Fuel System:
Direct Injection, Turbocharged Diesel (likely common rail injection system for these models)
Maintenance
Timing Belt Chain 2 5L:
Timing Belt (WL-3 SOHC) or Timing Chain (WL-C DOHC) - Service interval crucial
Timing Belt Chain 3 0L:
Timing Chain (WE-C)
🔧 Transmission
Standard
Standard Transmission:
5-Speed Manual (R15M-D, S15M-D, S15MX-D)
Optional
Optional Transmission:
5-Speed Automatic (5R55S)
Features
Transmission 5R55S Features:
Electronic control, adaptive shift logic, likely with a torque converter lock-up feature for improved highway efficiency.
Maintenance
Transmission Fluid Type Manual:
GL-4 or GL-5 gear oil, specific viscosity (e.g., 75W-90) required as per manual
Transmission Fluid Type Auto:
Mercon V or equivalent (specific to 5R55S)
📐 Dimensions
Exterior
Wheelbase Mm:
Typically around 3000-3100 mm, depending on cab and configuration
Weights
Gross Vehicle Weight Rating Kg:
Varies by configuration, generally between 2700-3100 kg
Towing Capacity Kg:
Up to 2500 kg (braked trailer), depending on engine and drivetrain configuration
🛡️ Safety Features
Ratings
Ancap Rating Pj Pk:
Varies by year and specific test, but generally around 3-4 stars for early models. Later PK models might see improvements. Full details would be in the manual's body repair or general sections.
Driver and Passenger Airbags, Seatbelt Pre-tensioners, Reinforced Cab Structure
💡 Technology Features
Infotainment
Infotainment System Availability:
Base models likely featured a basic AM/FM radio with CD player. Higher trims might have offered optional premium sound systems, auxiliary inputs, or even basic Bluetooth connectivity in later PJ/PK models.
Driver Assistance
Driver Assistance Features:
Limited by modern standards. Primarily ABS and EBD. No advanced driver-assistance systems (ADAS) like adaptive cruise control or lane keeping assist were available.
Connectivity
Connectivity Options:
Auxiliary input for audio, potential for basic Bluetooth hands-free calling on later/higher trims.
🔧 Maintenance
Intervals
Oil Change Interval Km:
Typically 5,000-10,000 km or 6-12 months for diesel engines, depending on driving conditions (refer to manual for exact intervals)
Fuel Filter Replacement Km:
Crucial for diesel engines; typically 20,000-40,000 km or annually
Air Filter Replacement Km:
Every 20,000-40,000 km or as needed based on dusty conditions
Timing Belt Replacement Km:
Critical for WL-3 (if fitted with belt); often around 100,000 km or 5-7 years (check manual for specific engine)
Fluids
Engine Oil Spec Diesel:
API CI-4 or higher, SAE 5W-30 or 10W-30 (check manual for specific engine and climate recommendations)
Coolant Type:
Ethylene Glycol based, meeting Ford specifications (e.g., WSS-M97B44-D or similar)
Brake Fluid Type:
DOT 3 or DOT 4
Known Issues
Common Issues:
Turbocharger issues (wear, oil leaks), injector problems (diesel specific), clutch wear (manual transmissions), front suspension wear (bushings, ball joints), EGR valve issues (diesel), potential for rust on body panels in corrosive environments.
Specifications
Torque Spec Wheel Nuts Nm:
Approximately 130-150 Nm (common range for light trucks)
📚 Vehicle History
Brand
Brand Heritage:
Ford has a long history of producing robust trucks, with the Ranger nameplate being synonymous with utility and reliability across various global markets for decades.
Model Evolution
Model Evolution Pj Pk:
The PJ Ranger (2006-2009) was a significant update to the Ranger line, often based on Mazda BT-50 underpinnings. The PK Ranger (2009-2011) received styling updates and potential minor mechanical refinements, sharing core components with the PJ.
Production
Production Locations:
Primarily manufactured in South Africa (for export markets including Australia) and Thailand.
🏆 Awards & Recognition
Recognitions
Model Recognition:
The Ford Ranger has consistently been a strong performer in its segment, often praised for its ruggedness and value. Specific awards for the PJ/PK generation would typically focus on utility, value for money, and off-road capability within their respective launch years.
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