Ford Ranger EV (2001 year). Manual — part 131

414-03A-120

414-03A-120

High Voltage/Traction Battery

REMOVAL AND INSTALLATION (Continued)

7. Remove the HVJ.

•

Use the Battery Terminal Cap Opener to
open the battery module caps.

•

Remove and discard the two nuts.

Installation

1. To install, reverse the removal procedure.

•

When installing the HVJ on the battery
module, route the sense lead wiring under
the HVJ cable.

•

Refill the HVJ caps with Nyogel after
tightening the nuts.

•

Apply Locktite 242 to the 22 traction
battery cover bolts.

Traction Battery

Removal

NOTE: The total traction battery removal and
installation time is 40 minutes.

1. Disconnect the traction battery auxiliary load

high-voltage connector. Refer to

Section

100-05

.

2. Disconnect the traction battery high-voltage

two-pin connector. Refer to

Section 100-05

.

414-03A-121

414-03A-121

High Voltage/Traction Battery

REMOVAL AND INSTALLATION (Continued)

3.

WARNING: The nominal voltage of

the traction battery is 312 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.

4. Secure the two-pin high-voltage cable to the

rear axle to hold it out of the way.

5. Disconnect the 76-pin electrical connector.

1 Loosen the bolt.
2 Disconnect the electrical connector.

6. Position the 76-pin electrical connector over the

control arm.

414-03A-122

414-03A-122

High Voltage/Traction Battery

REMOVAL AND INSTALLATION (Continued)

7. Position the lift table under the battery pack

assembly.

•

The narrow end of the pallet faces the front
of the vehicle.

8. Completely lower the lift table and then lower

the vehicle until the battery pack is within 25.5
cm (10 in) of the lift table. Verify that the
safety locks on the lift are engaged.

9. Adjust the lift table so it is parallel with the

battery pack.

•

Turn the adjustment screw at the front of
the lift table to vary the angle of the lift
table.

10. NOTE: A second person is necessary to

position and guide the lift table.
Align the lift table with the battery pack.

11. NOTE: The lift table operates using a minimum

of 80 psi and a maximum of 120 psi of
compressed air.
Slowly raise the lift table until it contacts the
bottom of the battery pack.

•

Push the lever up.

414-03A-123

414-03A-123

High Voltage/Traction Battery

REMOVAL AND INSTALLATION (Continued)

12.

CAUTION: Do not adjust either

regulator for more than 60 psi.
NOTE: The lift table is designed to only lift
the battery pack assembly. It will not lift the
entire vehicle.
Continue to lift the battery pack until the lift
table system pressure equalizes and both gauges
reach 60 psi.

13. NOTE: There are three mounting bolts on both

the left and right sides of the traction battery.
Remove the six mounting bolts from the battery
pack.

14. Lower the lift table slowly until it rests on the

pallet stops and system pressure is completely
released (0 psi).

15. Raise the vehicle.

16. Release the lift table brake, disconnect the air

hose, and roll the lift table from under the
vehicle.

Installation

1. Raise and support the vehicle. Refer to

Section

100-02

.