Ford Transit 06 Index Manual

 

2004.75 Transit Workshop Manual Table of Contents

100-00 100-01 100-02

Steering System Steering System - General Information Power Steering Steering Linkage Steering Column Steering Column Switches

100-04

GROUP 3 Powertrain

GROUP 1 General Information Service Information General Information Identification Codes Jacking and Lifting Noise, Vibration and Harshness

GROUP 2 Chassis Suspension Suspension System - General Information 204-00 Front Suspension 204-01 Rear Suspension 204-02 Wheels and Tires 204-04 Vehicl hicle e Dyn ynam amic ic Su Sus spe pens nsio ion n 204 04-0 -05 5 Driveline Driveline System - General Information 205-00 Driveshaft 205-01 Rear Dri riv ve Axle/Differ ferenti tia al 205-02A Whee Wh eell Hu Hubs bs an and d Be Bear arin ings gs - Fu Fullll Fl Floa oati ting ng  Axle 205-02B Front Drive Halfshafts 205-04 Brake System Brake System - General Information 206-00 Drum Brake 206-02 Front Disc Brake 206-03 Parkin ing g Brak rake and Actu tua ation 206-05A Parking Brake and Actuation - Vehicles With: th: Park rkiing Brak rake Assist 206-05B Hydraulic Brake Actuation 206-06 Power Brake Actuation 206-07  Anti-Lock Control

206-09

211-00 211-02 211-03 211-04 211-05

Engine Engine System - General Information 303-00 Engine - 2.4L Duratorq-TDCi (Puma) Diesel/2.4L Duratorq-Di (Puma) Diesel 303-01A Engine - 2.0L Duratorq-TDCi (Puma) Diesel/2.0L Duratorq-Di (Puma) Diesel/2.0L Duratorq-TDDi (Puma) Diesel 303-01B Engine - 2.3L DOHC-16V 303-01C Engine Cooling 303-03 Fuel Charging and Controls - 2.4L DuCharging rato torrq-Di (Pu (P umControls a) Diese-l 2.0L Fuel and Duratorq-Di (Puma) Diesel/2.0L Duratorq-TDDi (Puma) Diesel Fuel Charging and Controls - 2.3L DOHC-16V Fuel Charging and Controls Turbocharger Fuel Charging and Controls - 2.0L Duratorq-TDCi (Puma) Diesel Fuel Charging Charging and Control Controls s - 2.4L Duratorq-TDCi (Puma) Diesel  Accessory Starting SyDrive stem

303-04A 303-04B 303-04C 303-04D 303-04F 303-04G 303-05 303-06

2004.75 Transit

 

Glow Glow Pl Plug ug Sy Syst stem em - 2. 2.4L 4L Du Dura rato torqrq-TD TDCi Ci (Puma) Diesel/2.4L Duratorq-Di (Puma) Diesel 303-07A Glow Glow Pl Plug ug Sy Syst stem em - 2. 2.0L 0L Du Dura rato torqrq-TD TDCi Ci (Puma) Diesel/2.0L Duratorq-Di

Fuel Tank and Lines 310-01  Acceleration Control - 2.0L Duratorq-TDCi (Puma) Diesel/2.4L Duratorq-TDCi (Puma) Diesel/2.0L Duratorq-Di (Puma) Diesel/2.0L

Duratorq-TDDi Diesel/2.4L Duratorq-TDDi 303-07B D ur urat ator orq q-Di -Di (P (Pu u(Puma) ma ma)) Die iese sell 310 10-0 -02A 2A ((Puma) Puma) Diesel/2.0L Diesel  Acceleration Control - 2.3L Engine Ignition - 2.3L DOHC-16V 310-02B DOHC-16V 303-07C Engine Emission Control 303-08 Intake Air Distribution and GROUP 4 Electrical Filtering 303-12 Evaporative Emissions 303-13 Climate Control System Electronic Engine Controls 303-14 Climate Control System - General Manual Manu al Tran ransmis smission sion/T /Tran ransaxl saxle, e, Clutc Clutch h and Information 412-00 Tr Transfer ansfer Case  Air Distribution and Filtering 412-01 Manual Transmission/Transaxle and Heating and Ventilation 412-02A Cl Clut utch ch - Ge Gene nera rall In Info form rmat atio ion n 30 3088-00 00  Auxiliary Heating 412-02B Clu lutc tch h - Vehic hicles les With ith: MTT-75 75 308 08-0 -01A 1A  Air Conditioning 412-03A Clutch - Vehicles With:  Auxiliary Climate Control 412-03B Control Components 412-04 VXT-75 308-01B Clu lutc tch h - Vehic hicles les With ith: MT8 T82 2 308 08-0 -01C 1C Instrumentation and Warning Systems Clutch Controls - Vehicles With: Instrument Cluster and Panel MT-75 308-02A Illumination 413-00 Clutch Controls - Vehicles With: Instrument Cluster 413-01 VXT-75 308-02B Horn 413-06 Clutch Controls - Vehicles With: Clock 413-07 MT82 308-02C Parking Aid 413-13 Manual Transmission/Transaxle Vehicles With: MT-75 308-03A Battery and Charging System Charging System - General Manual Transmission/Transaxle Information 414-00 Vehicles With: VXT-75 308-03B Batte attery ry,, Mo Mou unt ntin ing g and and Ca Cabl bles es 41 4144-01 01 Manual Transmission/Transaxle Generator and Regulator 414-02 Vehicles With: MT82 308-03C Manual Transmis Transmission/Trans sion/Transaxle axle Information and Entertainment Systems External Controls - Vehicles With: Information and Entertainment System MT-75 308-06A - General Information 415-00 Manual Transmis Transmission/Trans sion/Transaxle axle  Audio Unit 415-01 External Controls - Vehicles With:  Antenna 415-02 VXT-75 308-06B Speakers 415-03 Manual Transmis Transmission/Trans sion/Transaxle axle Lighting External Controls - Vehicles With: Exterior Lighting 417-01 MT82 308-06C Interior Lighting 417-02 Manual Transmis Transmission/Trans sion/Transaxle axle Electrical Distribution  Automated Gearshift System 308-1 308-11 1 Module Communications Exhaust System Network 418-00 Exhaust System 309-00 Module Configuration 418-01 Fuel System Electronic Feature Group Fuel System - General Information

310-00

 Anti-Theft  Anti-Theft -- Active Passive

419-01A 419-01B

2004.75 Transit

 

Multifunction Electronic Modules

419-10

GROUP 5 Body and Paint Body and Paint Body System - General Information Front End Body Panels Body Closures Interior Trim and Ornamentation Exterior Trim and Ornamentation Rear View Mirrors Seating Glass, Frames and Mechanisms In Inst stru rume ment nt Pa Pane nell an and d Co Cons nsol ole e

501-00 501-02 501-03 501-05 501-08 501-09 501-10 501-11 50 5011-12 12

Handles, Locks, Latches and Entry Systems Wipers and Washers Roof Opening Panel Bumpers Safety Belt SysRestraint tem Supplemental System Body Repairs - General Information Body Repairs - Vehicle Specific Information and Tolerance Checks Fron Frontt En End d Shee Sheett Meta Metall Re Repa pair irs s Side Panel Sheet Metal Repairs Rear Re ar End End Shee Sheett Meta Metall Re Repa pair irs s Frame and Mounting Uni-Body, Subframe and Mounting System

501-14 501-16 501-17 501-19 501-20A 501-20B 501-25 501-26 50 5011-27 27 501-29 50 5011-30 30

502-00

2004.75 Transit

 

To the best of our knowledge, the illustrations, techni tec hnical cal inf inform ormati ation, on, dat data a and des descri cripti ptions ons in this issue were correct at the time of going to print. pri nt. The rig right ht to cha change nge pri prices ces,, spe specif cifica icatio tions, ns, equipment and maintenance instructions at any time without notice is reserved as part of  FORD policy of continuous development and improvement for the benefit of our customers. No pa part rt of th this is pu publ blic icat atio ion n ma may y be repr reprod oduc uced ed,, stored in a data processing system or  transm tra nsmitt itted ed in any for form, m, ele electr ctroni onic, c, mec mechan hanica ical, l, photocopy, recording, translation or by any other means without prior permission of  Ford-We Ford -Werke rke Akt Aktien ienges gesells ellscha chaft. ft. No liab liabilit ility y can be accepted for any inaccuracies in this publication, although every possible care has been taken to make it as complete and accurate as possible. Copyright © FORD-WERKE AKTIENGESELLSCHAF AKTIENGESELLSCHAFT T Service training programs D-F/GT-1 Printed in Germany - rewi druckhaus, Wissen Printed on environmentally friendly chlorine-free paper. (GB)

2004.75 Transit

 

GROUP

General Information SECTION TITLE

 1 PAGE

Service Information General Information........................... Information.................................................. .............................................. .............................................. .............................. .......100-00 100-00 Identification Codes.............................. Codes...................................................... ............................................... .............................................. .......................... ...100-01 100-01 Jacking and Lifting.........................................................................................................100-02 Noise, Vibration and Harshness....................................................................................100-04

2004.75 Transit

 

GROUP

Chassis SECTION TITLE

 2 PAGE

Suspension Suspension System - General Information....................................................................204-00 Front Suspension...........................................................................................................204-01 Rear Suspension............................................................ Suspension..................................... .............................................. ...............................................204-02 ........................204-02 Wheels and Tires...........................................................................................................204-04 Vehicle Dynamic Suspension.........................................................................................204-05 Driveline Driveline System - General Information.........................................................................205-00 Driveshaft.......................................................................................................................205-01 Rear Drive Axle/Differential............................................................................................205-02A Wheel Hubs and Bearings - Full Floating Axle..............................................................205-02B Front Drive Halfshafts....................................................................................................205-04 Brake System Brake System - General Information..............................................................................206-00 Drum Brake....................................................................................................................206-02 Front Disc Brake............................................................................................................206-03 Parking Brake and Actuation.........................................................................................206-05A Parking Brake and ActuationVehicles With: Parking Brake Assist................................206-05B Hydraulic Brake Actuation..............................................................................................206-06 Power Brake Actuation..................................................................................................206-07  Anti-Lock Control.......................... Control................................................. .............................................. .............................................. ...................................2 ............206-09 06-09 Steering System Steering System - General Information..........................................................................211-00 Power Steering...............................................................................................................211-02 Steering Linkage............................... Linkage...................................................... .............................................. ............................................... ............................... .......21 211-03 1-03 Steering Column........................... Column.................................................. ............................................... ............................................... .................................. ...........21 211-04 1-04 Steering Column Switches.............................................................................................211-05

2004.75 Transit

 

GROUP

Powertrain SECTION TITLE

 3 PAGE

Engine Engine System - General Information............................................................................303-00 Engine2.4L Duratorq-TDCi (Puma) Diesel/2.4L Duratorq-Di (Puma) Diesel.................303-01A Engine2.0L Duratorq-TDCi (Puma) Diesel/2.0L Duratorq-Di (Puma) Diesel/2.0L Duratorq-TDDi (Puma) Diesel....................................................................................303-01B Engine2.3L DOHC-16V............................... DOHC-16V....................................................... ............................................... ..........................................303 ...................303-01C -01C Engine Cooling...............................................................................................................303-03 Fuel Charging and Controls2.4L Duratorq-Di (Puma) Diesel........................................303-04A Fuel Charging and Controls2.0L Duratorq-Di (Puma) Diesel/2.0L Duratorq-TDDi (Puma) Diesel.............................................................................................................303-04B Fuel Charging and Controls2.3L DOHC-16V................................................................303-04C Fuel Charging and Controls - Turbocharger..................................................................303-04D Fuel Charging and Controls2.0L Duratorq-TDCi (Puma) Diesel....................................303-04F Fuel Charging and Controls2.4L Duratorq-TDCi (Puma) Diesel....................................303-04G  Accessory Drive........................... Drive.................................................. .............................................. .............................................. .................................... .............303-05 303-05 Starting System..............................................................................................................303-06 Glow Plug System2.4L Duratorq-TDCi (Puma) Diesel/2.4L Duratorq-Di (Puma) Diesel.........................................................................................................................303-07A Glow Plug System2.0L Duratorq-TDCi (Puma) Diesel/2.0L Duratorq-Di (Puma) Diesel/2.0L Duratorq-TDDi (Puma) Diesel.................................................................303-07B Engine Ignition2.3L DOHC-16V.....................................................................................303-07C Engine Emission Control................................................................................................303-08 Intake Air Distribution and Filtering................................................................................303-12 Evaporative Emissions...................................................................................................303-13 Electronic Engine Controls.............................................................................................303-14 Manual Transmission/Transaxle, Clutch and Transfer Case Manual Transmission/Transaxle and Clutch - General Information...............................308-00 ClutchVehicles With: MT-75...........................................................................................308-01A ClutchVehicles With: VXT-75.........................................................................................308-01B ClutchVehicles With: MT82............................................................................................308-01C Clutch ControlsVehicles With: MT-75............................................................................308-02A Clutch ControlsVehicles With: VXT-75..........................................................................308-02B Clutch ControlsVehicles With: MT82.............................................................................308-02C Manual Transmission/TransaxleVehicles With: MT-75..................................................308-03A Manual Transmission/TransaxleVehicles With: VXT-75................................................308-03B Manual Transmission/TransaxleVehicles With: MT82...................................................308-03C 2004.75 Transit

 

Manual Transmission/Transaxle External ControlsVehicles With: MT-75.....................308-06A Manual Transmission/Transaxle External ControlsVehicles With: VXT-75....................308-06B Manual Transmission/Transaxle External ControlsVehicles With: MT82......................308-06C Manual Transmission/Transaxle Automated Gearshift System.....................................308-11 Exhaust System Exhaust System.............................................................................................................309-00 Fuel System Fuel System - General Information................................................................................310-00 Fuel Tank and Lines.......................................................................................................310-01  Acceleration  Accele ration Control Control2.0L 2.0L Duratorq Duratorq-TDCi -TDCi (Puma) Diesel/ Diesel/2.4L 2.4L Durato Duratorq-TDCi rq-TDCi (Puma) Diesel/2.0L Duratorq-Di (Puma) Diesel/2.0L Duratorq-TDDi (Puma) Diesel/2.4L Duratorq-Di (Puma) Diesel.........................................................................................310-02A  Acceleration Control2.3L DOHC-16V................................ DOHC-16V....................................................... ............................................310-02B .....................310-02B

2004.75 Transit

 

GROUP

Electrical SECTION TITLE

 4 PAGE

Climate Control System Climate Control System - General Information..............................................................412-00  Air Distribution and Filtering.......................... Filtering................................................. .............................................. ..........................................412-01 ...................412-01 Heating and Ventilation..................................................................................................412-02A  Auxiliary Heating............................ Heating................................................... .............................................. .............................................. .................................. ...........412-02B 412-02B  Air Conditioning................................. Conditioning........................................................ .............................................. ............................................... ............................... .......412-03A 412-03A  Auxiliary Climate Control........................... Control.................................................. .............................................. ..............................................412-03B .......................412-03B Control Components......................................................................................................412-04 Instrumentation and Warning Systems Instrument Cluster and Panel Illumination.....................................................................413-00 Instrument Cluster..........................................................................................................413-01 Horn...............................................................................................................................413-06 Clock..............................................................................................................................413-07 Parking Aid.....................................................................................................................413-13 Battery and Charging System Charging System - General Information........................................................................414-00 Battery, Mounting and Cables........................................................................................414-01 Generator and Regulator...............................................................................................414-02 Information and Entertainment Systems Information and Entertainment System - General Information......................................415-00  Audio Unit...................... Unit............................................. .............................................. .............................................. .............................................. ........................... ....415-01 415-01  Antenna.................................................  Antenna.......................... .............................................. ............................................... ............................................... .......................... ...415-02 415-02 Speakers........................................................................................................................415-03 Lighting Exterior Lighting.............................................................................................................417-01 Interior Lighting............................ Lighting................................................... .............................................. .............................................. ....................................4 .............417-02 17-02 Electrical Distribution Module Communications Network.................................................................................418-00 Module Configuration.....................................................................................................418-01 Electronic Feature Group  Anti-Theft - Active........................... Active.................................................. .............................................. .............................................. ................................. ..........419-01A 419-01A  Anti-Theft - Passive................................. Passive........................................................ .............................................. .............................................. ......................... ..419-01B 419-01B

2004.75 Transit

 

Multifunction Electronic Modules...................................................................................419-10

2004.75 Transit

 

GROUP

Body and Paint SECTION TITLE

 5 PAGE

Body and Paint Body System - General Information...............................................................................501-00 Front End Body Panels..................................................................................................501-02 Body InteriorClosures................................................................................................................501-03 Trim and Ornamentation....................................................................................501-05 Exterior Trim and Ornamentation...................................................................................501-08 Rear View Mirrors..........................................................................................................501-09 Seating...........................................................................................................................501-10 Glass, Frames and Mechanisms....................................................................................501-11 Instrument Panel and Console.......................................................................................501-12 Handles, Locks, Latches and Entry Systems................................................................501-14 Wipers and Washers......................................................................................................501-16 Roof Opening Panel.......................................................................................................501-17 Bumpers.........................................................................................................................501-19 Safety Belt System.........................................................................................................501-20A Supplemental Restraint System.....................................................................................501-20B Body Repairs - General Information..............................................................................501-25 Body Repairs - Vehicle Specific Information and Tolerance Checks.............................501-26 Front End Sheet Side Panel SheetMetal MetalRepairs......................................................................................501-27 Repairs....................................................................................501-29 Rear End Sheet Metal Repairs......................................................................................501-30 Frame and Mounting Uni-Body, Subframe and Mounting System...................................................................502-00

2004.75 Transit