Ford Ranger EV (2001 year). Manual — part 174

414-03B-92

414-03B-92

High Voltage/Traction Battery — Nickel Metal Hydride

GENERAL PROCEDURES (Continued)

2. Remove the damaged bracket or locator using a

heat gun positioned at least 150 mm (6 in) from
the part being removed. The gun will heat the
adhesive and allow the part to be removed.
Keep the gun moving over the part in order to
prevent exposing the composite material to
excessive heat. Once the adhesive softens, the
part can be removed and discarded.

3. Scrape and sand off all of the remaining

adhesive. The surface must be clean and
roughly sanded for correct adhesion.

4. Clean the area with alcohol.

5. Prepare a mixture of Pilogrip urethane adhesive

and apply it to the bonding area.

6. Position a new bracket. The adhesive should be

1-2 mm (.04-.08 in) thick for correct bonding.
Do not squeeze out excessive amounts of the
adhesive or the bond may fail.

7. Allow the adhesive to cure for 1 hour at 24

°

C

(75

°

F). After curing, excess adhesive may be

trimmed using a sharp knife.

Battery Tray Seal

1. NOTE: The seal surrounds the entire battery

tray to prevent moisture in the battery case.
Minor splits or gouges within the seal will not
affect the performance of the traction battery.
Significant rips or tears require replacement of
the seal.
Remove damaged seal by peeling it away from
the battery tray.

2. Scrape away any remaining seal pieces stuck to

the battery tray.

3. Clean the area with alcohol.

4. Place the new seal on the battery tray by

peeling back the white strip to expose the
adhesive. Start at one end of the seal to
maintain a good fit.

414-03B-93

414-03B-93

High Voltage/Traction Battery — Nickel Metal Hydride

GENERAL PROCEDURES (Continued)

5. Press down continuously along the entire length

of the seal to ensure a good bond to the surface
of the battery tray.

Module Charging

Special Tool(s)

12-Volt Battery Charger

SBC-BXE 203

1.

CAUTION: Do not use any charger

other than the required SBC-BXE 203
12-Volt Battery Charger.
Plug the Battery Charger in and ensure that it is
turned OFF.

2. Connect the Battery Charger to the module.

Connect the RED lead to the positive terminal
and the BLACK lead to the negative terminal
on the module. Turn the charger on. A flashing
green light on the charger will indicate that the
charger is operating and that the module is
being charged. During the charging cycle, the
charger will produce approximately 14 volts
DC.

3. The flashing green light on the charger

indicates that the charger is in the charge mode
and is working properly. The time that the
charger remains in this mode depends on the
size and state of charge of the module being
charged.

4. When the module reaches 100% state of charge,

the green light will steadily illuminate. The
steady green light indicates that the charger has
completed charging the module.

5. If the green and red lights flash sequentially,

the charger to module polarity is incorrect and
must be corrected before module charging can
begin.

414-03B-94

414-03B-94

High Voltage/Traction Battery — Nickel Metal Hydride

REMOVAL AND INSTALLATION

Battery Control Module (BCM)

Removal

1. Remove the traction battery. Refer to

Traction

Battery

.

2. Remove the traction battery cover.

1 Remove the 22 bolts.
2 Remove the cover.

3.

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.

4. Disconnect the high-voltage connector.

1 Loosen the bolts.
2 Disconnect the connectors.

414-03B-95

414-03B-95

High Voltage/Traction Battery — Nickel Metal Hydride

REMOVAL AND INSTALLATION (Continued)

5. Disconnect the low voltage connector.

1 Loosen the bolts.
2 Disconnect the connectors.

6. Remove the battery control module (BCM).

1 Remove the bolts.
2 Remove the BCM.

Installation

1.

CAUTION: Do not overtighten the

BCM multi-pin connectors. Damage to the
connectors may occur if overtightened.
To install, reverse the removal procedure.

•

Apply Locktite 242 to the 22 traction
battery cover bolts.

•

After installation, connect the New
Generation STAR (NGS). Turn the ignition
key ON. Enter the battery control module
(BCM) active command mode RESET
HISTORICAL DATA and set the active
command RESET to ALL.

•

Remove the NGS and charge the traction
battery. Refer to

Section 100-05

.