Ford Ranger EV (2001 year). Manual — part 151
414-03A-200
414-03A-200
High Voltage/Traction Battery
DISASSEMBLY AND ASSEMBLY (Continued)
95. Clip the heating element connector into the
contactor box harness.
96. Connect the contactor box harness to the HVJ.
1 Position the bracket.
2 Install the screw.
3 Connect the harness to the jumper.
97. Connect the HVJs to the contactor box. The
traction battery is now energized.
1 Position the HVJs.
2 Install the bolts.
98. Install the traction battery cover.
1 Position the cover.
2 Install the 22 bolts.
X
Apply Locktite 242 (Threadlock and
Sealer) to the bolts prior to installation.
414-03B-1
414-03B-1
High Voltage/Traction Battery — Nickel Metal Hydride
SECTION 414-03B High Voltage/Traction Battery — Nickel
Metal Hydride
VEHICLE APPLICATION:
Ranger EV
CONTENTS
PAGE
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . 414-03B-3
DESCRIPTION AND OPERATION
High Voltage/Traction Battery . . . . . . . . . . . . . . . . . . 414-03B-4
DIAGNOSIS AND TESTING
Auxiliary Contactor Relay Control . . . . . . . . . . . . . . . . 414-03B-6
Electrical Schematic . . . . . . . . . . . . . . . . . . . . 414-03B-6
Inspection and Verification . . . . . . . . . . . . . . . . . .. 414-03B-6
Pinpoint Tests . . . . . . . . . . . . . . . . . . . . . . 414-03B-6
Symptom Chart . . . . . . . . . . . . . . . . . . . . ... 414-03B-6
Contactor Box Current Sensors. . . . . . . . . . . . . . . . ..414-03B-22
Electrical Schematic . . . . . . . . . . . . . . . . . . ....414-03B-22
Inspection and Verification . . . . . . . . . . . . . . . . . .414-03B-22
Pinpoint Tests . . . . . . . . . . . . . . . . . . . . ....414-03B-22
Symptom Chart . . . . . . . . . . . . . . . . . . . . ..414-03B-22
Current Leakage Detection . . . . . . . . . . . . . . . . . ...414-03B-25
Electrical Schematic . . . . . . . . . . . . . . . . . . ....414-03B-25
Inspection and Verification . . . . . . . . . . . . . . . . . .414-03B-25
Pinpoint Tests . . . . . . . . . . . . . . . . . . . . ....414-03B-26
Symptom Chart . . . . . . . . . . . . . . . . . . . . ..414-03B-26
Emergency Power Off (EPO)/Interlock System . . . . . . . . . . . ...414-03B-18
Electrical Schematic . . . . . . . . . . . . . . . . . . . 414-03B-18
Inspection and Verification . . . . . . . . . . . . . . . . . .414-03B-18
Pinpoint Tests . . . . . . . . . . . . . . . . . . . . ....414-03B-19
Symptom Chart . . . . . . . . . . . . . . . . . . . . ..414-03B-18
Main/Precharge Contactor Relay Control . . . . . . . . . . . . . ..414-03B-11
Electrical Schematic . . . . . . . . . . . . . . . . . . . 414-03B-11
Inspection and Verification . . . . . . . . . . . . . . . . . .414-03B-11
Pinpoint Tests . . . . . . . . . . . . . . . . . . . . . 414-03B-12
Symptom Chart . . . . . . . . . . . . . . . . . . . . ..414-03B-11
Multiple Auxiliary Load Failure Diagnosis . . . . . . . . . . . . . ..414-03B-79
Negative Contactor Relay Control . . . . . . . . . . . . . . . ...414-03B-16
Regenerative Braking. . . . . . . . . . . . . . . . . . . ..414-03B-37
Electrical Schematic . . . . . . . . . . . . . . . . . . . 414-03B-37
Inspection and Verification . . . . . . . . . . . . . . . . . .414-03B-37
Pinpoint Tests . . . . . . . . . . . . . . . . . . . . . 414-03B-38
Symptom Chart . . . . . . . . . . . . . . . . . . . . ..414-03B-38
Traction Battery Charging/Heating System . . . . . . . . . . . . ....414-03B-40
Electrical Schematic . . . . . . . . . . . . . . . . . . . 414-03B-41
414-03B-2
414-03B-2
High Voltage/Traction Battery — Nickel Metal Hydride
CONTENTS
PAGE
Inspection and Verification . . . . . . . . . . . . . . . . . .414-03B-42
Pinpoint Tests . . . . . . . . . . . . . . . . . . . . . 414-03B-43
Symptom Chart . . . . . . . . . . . . . . . . . . . . ..414-03B-42
Traction Battery Cooling/Ventilation System . . . . . . . . . . . . ...414-03B-63
Traction Battery System . . . . . . . . . . . . . . . . . . ..414-03B-69
Battery Module Diagnostic Test . . . . . . . . . . . . . . . ...414-03B-69
Electrical Schematic . . . . . . . . . . . . . . . . . . . 414-03B-71
Inspection and Verification . . . . . . . . . . . . . . . . . .414-03B-71
Pinpoint Tests . . . . . . . . . . . . . . . . . . . . . 414-03B-72
Symptom Chart . . . . . . . . . . . . . . . . . . . . ..414-03B-71
GENERAL PROCEDURES
Battery Tray Seal . . . . . . . . . . . . . . . . . . . . ..414-03B-92
Module Charging . . . . . . . . . . . . . . . . . . . . ...414-03B-93
Traction Battery Module Replacement . . . . . . . . . . . . . . ..414-03B-80
Traction Battery Tray Repair . . . . . . . . . . . . . . . . . .414-03B-88
REMOVAL AND INSTALLATION
Battery Control Module (BCM) . . . . . . . . . . . . . . . . ...414-03B-94
Charge Inlet . . . . . . . . . . . . . . . . . . . . . . .414-03B-96
Contactor Box . . . . . . . . . . . . . . . . . . . . . ..414-03B-99
Contactor Box Fuses . . . . . . . . . . . . . . . . . . .... 414-03B-103
Flow Through Blower . . . . . . . . . . . . . . . . . . .... 414-03B-124
HVPDB Fuses . . . . . . . . . . . . . . . . . . . . .... 414-03B-105
High Voltage Power Distribution Box (HVPDB) . . . . . . . . . . . . 414-03B-107
High Voltage Wiring . . . . . . . . . . . . . . . . . . . . 414-03B-113
High Voltage Wiring — Sensor Lead Harness (10B694) . . . . . . . . .. 414-03B-108
Independent Observer Module — (IOM) . . . . . . . . . . . . . . 414-03B-171
Recirculating Blower . . . . . . . . . . . . . . . . . . . . 414-03B-126
Traction Battery . . . . . . . . . . . . . . . . . . . . .. 414-03B-116
Traction Battery Charger . . . . . . . . . . . . . . . . . .... 414-03B-121
Traction Battery High Voltage Fuse (250A) . . . . . . . . . . . . .. 414-03B-131
Traction Battery Module — Modules 1, 7, 8, 9, 25 . . . . . . . . . . . 414-03B-142
Traction Battery Module — Modules 10, 11, 12, 23, 24 . . . . . . . . ... 414-03B-149
Traction Battery Module — Modules 13-15 . . . . . . . . . . . . .. 414-03B-153
Traction Battery Module — Modules 16, 19, 20, 22 . . . . . . . . . .... 414-03B-165
Traction Battery Module — Modules 17, 18, 21 . . . . . . . . . . . 414-03B-158
Traction Battery Module — Modules 2-6 . . . . . . . . . . . . . . 414-03B-136
Traction Battery Temperature Sensor . . . . . . . . . . . . . .... 414-03B-133
DISASSEMBLY AND ASSEMBLY
Traction Battery . . . . . . . . . . . . . . . . . . . . .. 414-03B-174
414-03B-3
414-03B-3
High Voltage/Traction Battery — Nickel Metal Hydride
SPECIFICATIONS
Torque Specifications
Torque Specifications
Description
Nm
Lb-Ft
Lb-In
Description
Nm
Lb-Ft
Lb-In
High-Voltage Power
12
—
107
A/C Inverter Motor
12
—
107
Distribution Box Bolts
Control Bolts
High-Voltage Power
2
—
18
Battery Control Module
5
—
44
Distribution Box Cover
Bolts
Screws
Battery Control
5
—
44
High-Voltage Power
2
—
18
Module/Independent
Distribution Box Fuse
Observer Module
Safety Cover Screws
Bracket Bolts
Recirculating Blower
14
—
10
Battery Control Module
3
—
27
Cover Bolts
Multi-Pin Connector
Bolts
Recirculating Blower
3
—
27
Bracket Bolts
Battery Hold Down
14
10
—
Bolts
Recirculating Blower
6
—
53
Nuts
Battery Hold Down
5
—
44
Strap Bolts
Traction Battery Charger
22
16
—
Bolts
Charger Inlet Bracket
7
—
62.5
Bolts
Traction Battery Cover
17
12.5
—
Bolts
Composite Bar Bolts
5
—
44
Traction Battery
126
92.5
—
Contactor Box Screws
2
—
18
Mounting Bolts
Flow Through Blower
12
—
107
Two-Pin High-Voltage
5
—
44.5
Cover Bolts
Connector Nuts
Flow Through Blower
3
—
27
76-Pin Connector Bolt
4.8
—
43
Bracket Bolts
Flow Through Blower
6
—
53
General Specifications
Nuts
Item
Specification
Grille Screws
1.5
—
13.5
Locktite 242 (Threadlock
WSK-M2G351A5 (Type
Ground Strap Bolt
12
—
107
and Sealer)
II)
Harness Bracket Bolt
5.4
—
48
EOAZ-19554-AA
High-Voltage Fuse Bolts
12
—
107
Nyogel 760G
WSB-M1C239-A
High-Voltage Jumper to
12
—
107
Thermal Grease
ESF-M99G123-A
Battery Module Nuts
(Continued)
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