Ford Ranger EV (2001 year). Manual — part 171

414-03B-80

414-03B-80

High Voltage/Traction Battery — Nickel Metal Hydride

DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST A: ALL HIGH-VOLTAGE AUXILIARY LOAD SYSTEMS DO NOT OPERATE

TEST STEP

ACTION TO TAKE

No =

REPLACE high-voltage

harness 14B326 between

traction battery support tray

in-line C1935F and

contactor box C3985.

WARNING: The traction battery contains high-voltage components

and wiring. High-voltage insulated safety gloves and face shield must be

worn when carrying out the following steps. Failure to follow this

warning may result in severe personal injury or death.

•

Connect Traction Battery High-Voltage Service Cord to high-voltage

auxiliary load in-line C1935F on the traction battery support tray and in-line

C1935M.

NOTE: Contactor box C3985 is mounted on the passenger side of the BCM.

•

With key OFF, disconnect contactor box C3985 and measure the voltage

between the R wire on contactor box C3985 and chassis ground.

•

Is the voltage greater than 10 volts?

GENERAL PROCEDURES

Traction Battery Module Replacement

Special Tool(s)

Special Tool(s)

New Generation STAR (NGS)

Battery Post Torque Wrench

Tester or equivalent

307-026

418-F048 (007-00500)

Traction Battery High-Voltage

Battery Terminal Cap Opener

Lockout and Diagnostic Tool

418-F215

418-F207

(Continued)

In-Line Bypass Battery Module

418-F210

(Continued)

414-03B-81

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High Voltage/Traction Battery — Nickel Metal Hydride

GENERAL PROCEDURES (Continued)

Special Tool(s)

Traction Battery High-Voltage

Service Cord

418-F218

Traction Battery Low-Voltage

Service Cord

418-F219

Module Replacement

1. If necessary, charge all new replacement battery

modules prior to installation. Refer to Module
Charging to determine battery module charging
conditions.

2. With the key ON, enter battery control module

(BCM) active command mode RESET
HISTORICAL DATA and set the active
command RESET to the battery module(s) that
were replaced.

3. NOTE: If more than two battery modules need

to be replaced, do not replace the traction
battery cover or install the traction battery at
the end of the procedure. Repeat the battery
module removal and installation process until
all battery modules have been replaced. Only
two battery modules can be replaced at a time,
as there are only two In-Line Bypass Battery
Modules in the special service tool kit.
NOTE: Position the vehicle near a charging
station before beginning the procedure.
Remove the traction battery. Refer to Traction
Battery.

414-03B-82

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High Voltage/Traction Battery — Nickel Metal Hydride

GENERAL PROCEDURES (Continued)

4.

WARNING: The nominal voltage of

the traction battery is 300 volts. The buffer
zone must be set up and insulated rubber
gloves and a face shield must be worn.
Failure to follow these precautions may
result in severe personal injury or death.
Observe the EV-specific precautions. Refer to

Section 100-00

.

1 Set up the buffer zone.
2 Test and wear the insulated rubber gloves.
3 Wear the face shield.

5. NOTE: The Traction Battery High-Voltage

Lockout and Diagnostic Tool connects to the
two-pin high-voltage connector located at the
rear of the traction battery.
Install the Traction Battery High-Voltage
Lockout and Diagnostic Tool.

6. Remove the traction battery cover.

1 Remove the 22 bolts.
2 Remove the cover.

7. Check the specific battery module number

procedure for specific removal information. The
battery modules are grouped as follows: 2-6; 1,
7, 8, 9, 25; 10, 11, 12, 23, 24; 13-15; 16, 19,
20, 22; and 17, 18, 21. Refer to the specific
Traction Battery Module procedure.

414-03B-83

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High Voltage/Traction Battery — Nickel Metal Hydride

GENERAL PROCEDURES (Continued)

8. NOTE: Do not replace more than 4 battery

modules. If more than 4 battery modules need
to be replaced, replace all 25 battery modules.
Enter the indicated data on the Battery Module
Replacement Data Form. The form is located
on the Electric Ranger Service Card that is
inside the traction battery support tray. If more
than 4 modules need to be replaced, all of the
modules in the pack must be replaced. Refer to
Traction Battery Disassembly and Assembly.

9. Replace the battery module(s) that were

removed with the in-line bypass battery
module(s) and install the nuts.

10. Replace any components that were removed to

gain access to the battery module(s) that were
replaced. The traction battery must be
assembled prior to charging. The battery
modules are grouped as follows: 2-6; 1, 7, 8, 9,
25; 10, 11, 12, 23, 24; 13-15; 16, 19, 20, 22;
and 17, 18, 21. Refer to the specific Traction
Battery Module procedure.

11. Position the removed traction battery next to the

vehicle with the 76-pin connector and the
auxiliary load high-voltage connector toward the
front of the vehicle.

12. Connect the Traction Battery High-Voltage

Service Cord to the auxiliary load high-voltage
connector on the vehicle.