PX Ranger BODY REPAIR SUMMARY INTRODUCTION

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1 PX Ranger BODY REPAIR SUMMARY INTRODUCTION The purpose of this document is to provide vehicle body specialists with an overview of the Supplemental Restraint System (SRS) and important information about the body construction of the vehicle. Key vehicle body dimension information is also included. Please note that this body repair summary is intended as an overview of the SRS and the body construction of the vehicle and as such is not comprehensive. For comprehensive information, the Workshop Manual, which is available from an Authorised Ford Dealer, should be consulted. PX Ranger The PX generation Ranger is available as a single cab, super cab and double cab. It features a fuel efficient 2.5L Duratec 16V petrol engine as well as two fuel efficient Duratorq-TDCi diesel engines of 2.2L and 3.2L displacements. Manual transmissions are offered in the petrol versions, while the diesel models are available with manual and automatic transmissions. The PX Ranger is available as 4x2 low rider, 4x2 high rider and 4x4. Ranger has a comprehensive array of safety equipment. ABS braking and Dynamic Stability Control (DSC) is fitted as standard across the range. Side curtain and knee airbags are optional on certain models. The body construction incorporates crumple zones which are designed to buckle at strategically placed weak points to transfer crash loads and maintain the cabin space of the passenger cell. Further engineered safety features include collapsible steering columns, breakaway pedals and specially designed door trims for side impact absorption. Page 1 PX Ranger

2 HEALTH AND SAFETY Appropriate repair methods and carrying out repairs correctly are particularly important for the operating safety of vehicles and for the safety of people. All the regulations governing Health and Safety at Work must be complied with during any repairs. The various body areas are subject to very high forces during realignment work. Should any component suddenly become detached during this process, there is a very great danger of injury. For this reason, pulling chains and pulling shackles must be secured with arrester cables. Note: Please refer to the PX Ranger Workshop Manual (available from your Authorised Ford Dealer) for detailed instructions and precautions regarding the repair of the vehicle s Supplementry Restraint System. Some special instructions must be followed when working on airbag systems: Note: After disconnecting the power supply and before performing further work, a wait time of 15 minutes must be maintained. Work on airbag systems may only be performed by persons who have a relevant certificate of competency. Always stand to the side of the airbag when removing or installing an airbag. Always store an airbag or an airbag/steering wheel with the airbag side pointing upwards and in a safe place. Only install the airbag again when the vehicle is fully repaired and the complete electrical system has been tested. Take into account the location of side airbags. Pay attention to the following points: Disconnect the battery negative clamp and cover the battery terminal. Disconnect the electrical connector at the airbag control module. If welding is to be performed directly near a control module, it must be removed beforehand. Never connect the negative cable of the welder near an airbag or a control module. Connect the negative cable of the welder close to the location of the weld. Disclaimer The information contained in this publication was correct at the time of going to print. In the interests of development Ford Motor Company of Australia Limited ( Ford ) reserves its rights to change specifications, designs or equipment at any time without notice and without incurring any obligations. This publication, or part thereof, may not be reproduced nor translated without the approval of Ford. To the maximum extent permitted by law Ford is not liable for any errors or omissions in this document. Copyright Ford Motor Company of Australia Limited. Reproduction in whole or part prohibited without written approval. Copyright 2012 Page 2 PX Ranger

3 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Single Cab Item Description 1 Instrument cluster with air bag indicator light and safety belt warning 2 Driver air bag module 3 Side air curtain module 4 Side impact sensor 5 Front safety belt retractor 6 Side air bag module 7 Front safety belt buckle 8 Restraints control module (RCM) 9 Front center safety belt retractor 10 Front center safety belt buckle 11 Passenger air bag module 12 Driver lower air bag module 13 Front impact severity sensor Page 3 PX Ranger

4 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Super Cab Item Description 1 Instrument cluster with air bag indicator light and safety belt warning 2 Driver air bag module 3 Side impact sensor 4 Side air curtain module 5 Front safety belt buckle 6 Side air bag module 7 Front safety belt retractor 8 Rear safety belt retractor 9 Side impact sensor (rear) 10 Rear safety belt buckle 11 Restraints control module (RCM 12 Passenger air bag module 13 Driver lower airbag module 14 Front impact severity sensor Page 4 PX Ranger

5 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Double Cab Item Description 1 Front impact severity sensor 2 Instrument cluster with air bag indicator light and safety belt warning 3 Driver air bag module 4 Side impact sensor 5 Front safety belt buckle 6 Side air bag module 7 Front safety belt retractor 8 Side air curtain module 9 Rear safety belt retractor 10 Side impact sensor (rear) 11 Rear safety belt buckle 12 Rear center safety belt retractor 13 Rear center safety belt buckle 14 Restraints control module (RCM 15 Passenger air bag module 16 Driver lower air bag module Page 5 PX Ranger

6 General airbag system Electronic sensors are incorporated into the RCM; these measure the vehicle acceleration / deceleration in the event of a collision. The calculated value is evaluated by the RCM to determine the severity of the impact. The RCM compares the values it receives from the crash sensor, side impact sensors and the internal electronic sensors. If the deceleration, due to a frontal or side impact, exceeds the stored value the RCM is designed to trigger the air bag modules and the safety belt pretensioners as required. The RCM can be used again after a collision, provided the RCM is not physically damaged and it passes a self-test. Driver air bag and driver lower air bag Restraint Control Module (RCM) This vehicle line is available with a steering wheel mounted driver air bag and a driver lower air bag (knee air bag, optional on certain models). Side impact sensors (front doors) Air bag warning indicator The airbag warning indicator is active when an airbag system fault has occurred or the airbag module is disconnected. The indicator will have a predetermined bulb prove- out following ignition being turned to 'Run' configurable with restraints system. There are two side impact sensors located in the front driver and passenger doors. The sensors transmit digitally encoded pressure information to the RCM, where it is evaluated to assess the severity of a side impact. Power is supplied to the sensor by the RCM. If the sensor fails, the RCM stores a diagnostic trouble code (DTC). Page 6 PX Ranger

7 Side impact sensor (Rear side) Safety belt retractor and pretensioners There are two side impact sensors located at the bottom of the C-pillars in super cab and double cab variants. The sensors transmit digitally encoded acceleration information to the RCM, where it is evaluated to assess the severity of a side impact. Power is supplied to the side impact sensor by the RCM. If the senor fails, the RCM stores a diagnostic trouble code (DTC). The front outboard seat belts are equipped with a retractor, pretensioner and load limiter. In the event of a collision, the safety belt pretensioner deploys in one of two ways: On their own. Simultaneously with the front air bag module(s). Safety belt use is necessary to obtain the best occupant protection and to receive the full advantage of the SRS. Side air curtain Front impact severity sensor In the event of a side impact, the side air curtains (curtain air bags) are designed to deploy from the headliner, protecting the first and second row outboard occupants during a side impact. There are two front impact severity sensors located at the front of the vehicle, behind the radiator grille. The sensors transmit digitally encoded acceleration information to the RCM, where it is evaluated to assess the severity of a front impact. Power is supplied to the sensor by the RCM. If the sensor fails, the RCM stores a diagnostic trouble code (DTC). Page 7 PX Ranger

8 Side air bag The side air bags are incorporated in the front seat backrests and side air bag modules deploy from the outboard of front seat backrest upon a side impact. When a side air bag is deployed, the seam of the seat cover tears open enabling the side air bag to inflate unhindered from the front seat backrest. Passenger air bag The passenger air bag is designed to provide increased collision protection for front seat passengers. Page 8 PX Ranger

9 SRS COMPONENT REPLACEMENT IN THE EVENT OF DEPLOYMENT CAUTION Safety with SRS components is paramount. Note: Please refer to the PX Ranger Workshop Manual (available from your Authorised Ford Dealer) for detailed instructions and precautions regarding the repair of the vehicle s Supplementry Restraint System. When any deployable device (driver airbag, passenger airbag, side airbag, safety belt pretensioner, etc.) or combination of devices are deployed and/or the RCM has stored DTC s in memory, the repair of the vehicle s supplemental restraint system (SRS) must include the removal of all deployed devices and the installation of new deployable devices. For further assistance on Diagnostic Trouble Codes (DTC s) contact your Authorised Ford Dealer. When any damage to the impact sensor mounting points or mounting hardware has occurred, repair or install new mounting points and mounting hardware as needed. During the repair process, inspect the entire vehicle for damage, including the following components: Steering column and clock spring. Instrument panel knee bolsters and mounting points. Instrument panel braces and brackets. Instrument panel and mounting points. Seats and seat mounting points. Safety belts, safety belt buckles and safety belt retractors, supplemental restraint system (SRS) wiring, wiring harnesses, and connectors. After a collision where the front airbag(s) and seat belt tensioners have deployed, replace the following components: RCM unit. Deployed airbag module(s). Seat belt pretensioners. Seat belt outer lap tensioners. Front impact severity sensor RCM unit. Deployed side airbag module(s). B-pillar side impact sensor(s) Seat trim(s). Airbag Reconnect Checklist The checklist below should be completed following diagnosis or repair of any airbag system concern: All restraint system diagnostic tools removed? All in-seat harness connectors connected? All airbag modules connected? Safety belt pretensioner connectors connected? Restraints control module (RCM) connected? All sensors (front and side impact sensors) connected? Battery connected? After a collision where the side airbag(s) have deployed, replace the following components: Page 9 PX Ranger

10 BODY CONSTRUCTION Introduction Increased occupant safety is provided through the use of highstrength and super-high-strength steels. The high-strength and super-high-strength steels used make extra demands on the tools to be employed for some body repairs. Usibor steel Single cab High-strength and super-high-strength steels Steel body panels are still the most important materials used in the fabrication of stressed skin vehicle bodies. In addition to the familiar types of steel, reinforced high-strength and also super-high-strength special steels are used in vehicle body construction. Super cab Item Description 1 UHSS (> 800 MPa) 2 EHSS ( MPa) 3 VHSS ( MPa) 4 HSS ( MPa) 5 MS (< 180 MPa) Double cab The reinforcements at the A- and B-pillars are made of Usibor steel. This material has a yield strength of 1300 MPa. Page 10 PX Ranger

11 BODY DIMENSIONS General If there is concern that the body has been deformed, the body must be measured. Several measuring procedures and tools can be used for this purpose. With simple measuring systems, it is possible in most cases to draw a conclusion about the extent of the damage through a quick measurement without time-consuming assembly work (straightening jig). Data sheets with the body frame dimensions for body measurement are specified in the modelspecific repair instructions in each case. All dimensions were measured with the aggregates removed, starting from the center of the hole, using an electronic measuring system and are specified in mm. A tolerance of ± 3 mm applies to all specified dimensions. All detailed illustrations correspond to the left-hand side of the vehicle. Measuring points that are specified in a curve are to be measured so that the greatest distance from the opposite measuring point is reflected. Page 11 PX Ranger

12 Frame Tolerance Check Body dimensions, vehicle front All dimensions with tolerance ± 3 mm. All dimensions were determined starting from the centre of each hole or panel edge using a symmetrically adjusted measuring gauge. Measuring points and dimensions 1-5 = 1258 mm 4-6 = 1282 mm 1-9 = 1527 mm 5-8 = 1064 mm 2-5 = 1062 mm 5-9 = 1264 mm 2-7= 1553 mm 5-10 = 845 mm 3-8 = 1553 mm Page 12 PX Ranger

13 Body dimensions, side view double cab All dimensions with tolerance ± 3 mm. All dimensions were determined starting from the edge of the steel panel using a symmetrically adjusted measuring gauge. Measuring points 1, 2, 3, 4, 6, 7, 10 and 11 are measured in the curve and represent the greatest distance to the measuring point opposite. The detailed views of measuring points 8, 9 and 12 are shown looking from the vehicle interior outwards. The detailed view of measuring point 5 is measured in the hole and represents the greatest distance to the measuring point opposite. Measuring points and dimensions 1-10 = 1243 mm 4-7 = 1054 mm 2-11 = 1280 mm 5-8 = 1116 mm 3-6 = 1380 mm 9-12 = 812 mm Page 13 PX Ranger

14 Body dimensions, side view single cab All dimensions with tolerance ± 3 mm. All dimensions were determined starting from the edge of the steel panel using a symmetrically adjusted measuring gauge. Measuring points 1, 2, 4 and 5 are measured in the curve and represent the greatest distance to the measuring point opposite. The detailed view of measuring point 3 is measured in the hole and represents the greatest distance to the measuring point opposite. The detailed view of measuring point 6 is shown looking from the vehicle interior outwards. Measuring points and dimensions 1-4 = 1323 mm 3-6 = 1323 mm 2-5 = 949 mm Page 14 PX Ranger

15 Body dimensions, side view super cab All dimensions with tolerance ± 3 mm. All dimensions were determined starting from the edge of the steel panel using a symmetrically adjusted measuring gauge. Measuring points 1, 2, 4 and 5 are measured in the curve and represents the greatest distance to the measuring point opposite. The detailed view of measuring point 3 is measured in the hole and represents the greatest distance to the measuring point opposite. The detailed view of measuring point 6 is shown looking from the vehicle interior outwards. Measuring points and dimensions 1-4 = 1799 mm 3-6 = 1543 mm 2-5 = 1516 mm Page 15 PX Ranger

16 Body dimensions, interior double cab All dimensions with tolerance ± 3 mm. All dimensions were determined starting from the center of the welded flange using a symmetrically adjusted measuring gauge. Measuring points 3 and 4 are measured in the hole and represents the greatest distance to the measuring point opposite. The detailed views of measuring points 1, 2, 5 and 6 are shown looking from the vehicle interior outwards. Measuring points and dimensions 1-6 = 1513 mm 3-4 = 1459 mm 2-5 = 1478 mm Page 16 PX Ranger

17 Body dimensions, interior single cab All dimensions with tolerance ± 3 mm. All dimensions were determined starting from the center of the welded flange using a symmetrically adjusted measuring gauge. Measuring points 1 and 2 are measured in the hole and represents the greatest distance to the measuring point opposite. The detailed views of measuring points 3 and 4 are shown looking from the vehicle interior outwards. Measuring points and dimensions 1-2 = 1489 mm 3-4 = 1460 mm Page 17 PX Ranger

18 Body dimensions, interior super cab All dimensions with tolerance ± 3 mm. All dimensions were determined starting from the center of the welded flange using a symmetrically adjusted measuring gauge. Measuring points 1 and 2 are measured in the hole and represents the greatest distance to the measuring point opposite. The detailed views of measuring points 3 and 4 are shown looking from the vehicle interior outwards. Measuring points and dimensions 1-2 = 1460 mm 3-4 = 1472 mm Page 18 PX Ranger

19 Body dimensions, rear all vechicles All dimensions with tolerance ± 3 mm. All dimensions were determined starting from the center of the welded flange using a symmetrically adjusted measuring gauge. Measuring points 1, 2, 3, 4, 6, 9, and 10 are measured in the curve and represents the greatest distance to the measuring point opposite. The detailed views of measuring points 5 and 8 are shown looking from the vehicle interior outwards. Measuring points and dimensions 1-3 = 1292 mm 4-7 = 1455 mm 2-10 = 1292 mm 5-8 = 1412 mm 6-9 = 1453 mm Page 19 PX Ranger

20 Tailgate opening dimensions, all vechicles All dimensions with tolerance ± 3 mm. All dimensions were determined starting from the center of the welded flange using a symmetrically adjusted measuring gauge. Measuring points and dimensions 1-4 = 1456 mm 5-2 = 1456 mm 6-3 = 1409 mm Page 20 PX Ranger