Ford Ranger EV (2001 year). Manual — part 123

414-03A-88

414-03A-88

High Voltage/Traction Battery

GENERAL PROCEDURES (Continued)

28. Charge the traction battery to a full state of

charge (SOC). Refer to

Section 100-05

.

29. After charging has been completed, press the

button to deactivate the power control station
(PCS).

30. NOTE: Electric Ranger shown, Postal Ranger

EV similar.
Disconnect the PCS from the charger inlet
connector.
1 Press and hold the release button.
2 Lift and disconnect the PCS from the

charger inlet connector.

31. NOTE: Electric Ranger shown, Postal Ranger

EV similar.
Close the charge inlet access door.

32. NOTE: For Postal Ranger EV.

Close the charge inlet access door.

33. Check the specific battery module number

procedure for specific removal information. The
battery modules are grouped as follows 1-7,
17-18, 19-21, 8-11, 34-39, 12-15 and 28-31, 16
and 25-27, and 22-24. Refer to the specific
Traction Battery Module procedure.

414-03A-89

414-03A-89

High Voltage/Traction Battery

GENERAL PROCEDURES (Continued)

34. Unclip the necessary connectors from the

separator plates above the In-Line Bypass
Battery Module(s) to be replaced.

35. Remove the separator plates above the In-Line

Bypass Battery Module(s) to be replaced.

36. Disconnect the HVJs from the In-Line Bypass

Battery Module(s).

37. Remove the In-Line Bypass Battery Module(s).

38. Install new module number decals on the

replacement battery module positive terminal
side.

39. NOTE: When viewing a heater element, with

the adhesive side on the back, the elements
with the male electrical connector on the left
side are considered LH heater elements.
Elements with the male connector on the right
side are considered RH elements.
If the module that was replaced was equipped
with a heating element, install a new heating
element on the new battery module.

•

Battery modules 1, 4, 20, and 21 require LH
heater elements.

•

Battery modules 2, 3, 5, 6, 7, 17, 18, and 19
require RH heater elements.

414-03A-90

414-03A-90

High Voltage/Traction Battery

GENERAL PROCEDURES (Continued)

40. Replace the In-Line Bypass Battery Module(s)

that were removed with new, charged, traction
battery module(s). If necessary, charge the new
battery modules prior to installation. Refer to
the

Module Charging

procedure in this section

to determine battery module charging
conditions.
1 Position the battery module(s).
2 Position the HVJs and tighten the nuts using

the Battery Post Torque Wrench.

41. Fill the area around the nuts with Nyogel and

close the caps.

42. Install the separator plates above the battery

module(s) that were installed.

43. Enter the indicated data on the Dealer Battery

Return Form that is packaged with the new
battery module.

44. Connect New Generation STAR (NGS) Tester

to the vehicle.

45. 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.

46. Remove the NGS Tester and charge the traction

battery to full SOC. Refer to

Section 100-05

.

47. Perform Battery Pack/Module Verification Test.

Refer to Diagnosis and Testing for Traction
Battery System in this section.

48. Clip the connectors into the separator plate.

414-03A-91

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High Voltage/Traction Battery

GENERAL PROCEDURES (Continued)

49. Install any components that were removed to

gain access to the In-Line Bypass Battery
Module(s) that were replaced. The battery
modules are grouped as follows 1-7, 17-18,
19-21, 8-11, 34-39, 12-15 and 28-31, 16 and
25-27, and 22-24. Refer to the specific
Traction Battery Module procedure.

50. Disconnect the Traction Battery High-Voltage

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

51. Disconnect the Traction Battery High-Voltage

Service Cord from the traction battery auxiliary
load high-voltage connector on the traction
battery.

52. Disconnect the Traction Battery Low-Voltage

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