Ford Ranger EV (2001 year). Manual — part 122

414-03A-84

414-03A-84

High Voltage/Traction Battery

GENERAL PROCEDURES (Continued)

7. 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.

8. Remove the traction battery cover.

1 Remove the 22 bolts.
2 Remove the cover.

9. 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.

10. Unclip the necessary connectors from the

separator plates above the battery module(s) to
be replaced.

11. Remove the separator plates above the battery

module(s) to be replaced.

12. Disconnect the HVJs of the battery module(s)

to be replaced.

•

Remove and discard the two nuts.

414-03A-85

414-03A-85

High Voltage/Traction Battery

GENERAL PROCEDURES (Continued)

13. For upper-level battery modules, disconnect the

heating element connector and the temperature
sensor, if equipped.

14. NOTE: The tool fits into slots in the side of the

battery module.
Use the Battery Module Lifting Tool to remove
the battery module(s).

15. NOTE: Do not replace more than 5 battery

modules. If more than 5 battery modules need
to be replaced, replace all 39 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 5 modules are to be replaced, refer to

Traction Battery Temperature Sensor

Disassembly and Assembly.

16. NOTE: Install a new heating element when

installing new battery modules. For additional
information, refer to the 2001 Ranger EV
Workshop Manual Section 414-03.
Replace the battery module(s) that were
removed with the in-line bypass battery
module(s).
1 Position the In-Line Bypass Battery Module.
2 Position the HVJs and tighten the nuts using

the Battery Post Torque Wrench.

17. Install the separator plates above the In-Line

Bypass Battery Module(s) that were installed.

414-03A-86

414-03A-86

High Voltage/Traction Battery

GENERAL PROCEDURES (Continued)

18. 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 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.

19.

CAUTION: Do not use excessive force

to remove the temperature sensor, or damage
to the module may occur.
NOTE: If the sensor is difficult to remove,
warm it using a heat gun. Be careful not to
overheat the sensor or the battery module, or
damage to both may occur.
If the battery module that was removed is
equipped with a temperature sensor, remove the
sensor.

•

Pull the bottom of the temperature sensor
from the battery module and remove the
sensor.

20. Use a heat gun to warm the temperature sensor

prior to installation.

21. Apply a thin coat of thermal grease to the back

of the thermistor.

22.

CAUTION: Do not use excessive force

to install the temperature sensor, or damage
to the module may occur.
Install the temperature sensor on the new
battery module.
1 Position the two prongs on the sensor into

the battery module.

2 Clip the sensor onto the battery module.

23. 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.

414-03A-87

414-03A-87

High Voltage/Traction Battery

GENERAL PROCEDURES (Continued)

24. Connect the Traction Battery High-Voltage

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

25. Connect the Traction Battery High-Voltage

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

26. Connect the Traction Battery Low-Voltage

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

•

Loosely install the bolt.

27. Connect the Traction Battery Low-Voltage

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

•

Loosely install the bolt.