Ford Ranger EV (2001 year). Manual — part 124

414-03A-92

414-03A-92

High Voltage/Traction Battery

GENERAL PROCEDURES (Continued)

53. Disconnect the Traction Battery Low-Voltage

Service Cord from the 76-pin low-voltage
connector on the vehicle.

54. Apply Locktite 242 (threadlock and sealer) to

the 22 traction battery cover bolts.

55. Install the traction battery cover.

•

Install the 22 bolts.

56. Remove the Traction Battery High-Voltage

Lockout and Diagnostic Tool.

57. Install the traction battery. Refer to

Traction

Battery

.

414-03A-93

414-03A-93

High Voltage/Traction Battery

GENERAL PROCEDURES (Continued)

Traction Battery Tray Repair

Battery Tray

414-03A-94

414-03A-94

High Voltage/Traction Battery

GENERAL PROCEDURES (Continued)

1. NOTE: A composite material forms the actual

housing of the traction battery. The composite
material is a resin transfer molded (RTM)
glass-reinforced thermoset plastic with an
integral foam core.
A split or scratch on the side or corner of the
composite material can be repaired, as long as
the damage does not pass all the way through
the surface of the composite material.

2. A crack in the composite material less than 25

mm (1 in) in length can also be repaired. A
crack is damage that passes all the way through
the outer layer of the composite material,
exposing the foam core. If the crack is longer
than 25 mm (1 in), or the damage passes all
the way through the case, the battery case must
be replaced.

3. A scratch or split on the surface of the

composite material does not need to be repaired
and will not affect the performance of the
traction battery. If the damage is visible, it can
be blended into the surrounding surface by
lightly sanding the area.

414-03A-95

414-03A-95

High Voltage/Traction Battery

GENERAL PROCEDURES (Continued)

4. To repair cracks less than 25 mm (1 in) in

length, clean the area surrounding the damage
prior to repair. After cleaning, grind a 20
degree bevel extending 40 to 50 mm (1.57 to 2
in) around the damage.