Factory Workshop Manual

Make

Ford

Model

Transit 2000.5 01.2000-05.2006

Engine and year

(01.2000-05.2006)

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This manual was submitted by

Anonymous

Date
1st January 2018
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 1 General Information > 100 Service Information > 100-00 General
Information > Description and Operation > About This Manual

Introduction This manual has been written in a format that is designed to meet the needs of
technicians worldwide. The objective is to use common formats and include similar content in each
manual. This manual provides general descriptions for accomplishing diagnosis and testing,
service and repair work with tested, effective techniques. Following them will help assure reliability.
Special Tools The special tool(s) table provided at the beginning of each procedure shows all
special tools required to carry out a repair. Where possible, illustrations are provided to assist in
identifying the special tool required. Important Safety Instructions Appropriate service methods and
correct repair procedures are essential for the safe, reliable operation of all motor vehicles as well
as the personal safety of the individual carrying out the work. This manual cannot possibly
anticipate all such variations and provide advice or cautions as to each. Anyone who departs from
the instructions provided in this manual must first establish that he compromises neither his
personal safety nor the vehicle integrity by his choice of methods, tools or components. Warnings,
Cautions and Notes in This Manual As you read through this manual, you will come across
WARNINGS, CAUTIONS and NOTES. A warning, caution or note is placed at the beginning of a
series of steps if it applies to multiple steps. If the warning, caution or note only applies to one step,
it is placed at the beginning of the specific step (after the step number). Overview Procedures
Overview procedures contain an exploded view illustration(s). The numbered sequence within the
illustration(s) indicate the order to be followed when removing/disassembling or when
installing/assembling a component. Additional information, symbol(s) or a torque figure, may also
be shown alongside the component. There are ten symbols used to give additional information
when removing/disassembling or when installing/assembling a component. Special Tools and
Torque Figures Any requirement for special tools will picture the tool, showing it in use and with its
tool number shown. Torque settings will be given at the relevant point in the procedure. Trustmark
Authoring Standards (TAS) Removal and Installation Procedures A TAS removal and installation
procedure uses a sequence of color illustrations to indicate the order to be followed when
removing/disassembling or installing/assembling a component. Many of the TAS procedures will
have the installation information within the removal steps. These procedures will have the following
note at the beginning of the procedure: Items such as O-ring seals, gaskets, seals, self-locking nuts
and bolts are to be discarded and new components installed unless otherwise stated within the
procedure. Coated nuts or bolts are to be reused, unless damaged or otherwise stated within the
procedure. Specification procedures will contain all technical data that are not part of a repair
procedure. TAS Graphics Colors used in the graphic are as follows: There may be multiple steps
assigned to one illustration. Numbered pointers are used to indicate the number of electrical
connectors and fasteners such as nuts, bolts, clamps or clips. Items in the illustration can be
transparent or use cutouts to show hidden detail(s). TAS Symbols Symbols are used inside the
graphics and in the text area to enhance the information display. The following paragraphs
describe the various types and categories of symbols. Prohibition symbols advise on prohibited
actions to either avoid damage or health and safety related risks. Health and Safety symbols
recommend the use of particular protection equipment to avoid or at least reduce the risk or
severity of possible injuries. Warning symbols are used to indicate potential risks resulting from a
certain component or area. Instruction symbols are used to apply sealer, lubricant, weight, tape or
cleaning detergent to a component. Location symbols are used to show the location of a
component or system within the vehicle. Gearshift lever or selector lever position symbols are used
to show which gearshift lever or selector lever position is to be set. Pointer symbols are used to
draw the attention to components and give special instructions such as a required sequence or
number of components. The number of components is reflected by the value inside the luty arrow.
A sequence number is located inside the circle. Numbers inside circles are also used to allocate
special information such as tightening torques or chemicals to a particular component. Movement
arrows are used to show three dimensional or rotational movements. These movements can
include specific values inside the symbol if required. The following graphic illustrates a set of
symbols that are used to provide detailed information on where to apply a material. Measurement
symbols provide detailed information on where to carry out a specific measurement. These
symbols can include specific values if required. Special Tools and Torque Figure(s) Special tools
will be shown with the tool number in the illustration. The special tool number(s), general
equipment, material(s) and torque figure(s) used for the procedure step will be shown in the text
column. How to Use This Manual This manual covers diagnosis and testing, service and repair
procedures. This manual is structured into groups and sections, with specific system sections
collected together under their relevant group. A group covers a specific portion of the vehicle. The
manual is divided into five groups, General Information, Chassis, Powertrain, Electrical and Body
and Paint. The number of the group is the first number of a section number. Pages at the start of
the manual list all sections available. Each section has a contents list detailing Specifications,
Description and Operation, Diagnosis and Testing, In Vehicle Repairs, Disassembly and Assembly,
Removal and Installation. If components need to be removed or disassembled in sequence, the
sequence will be identified numerically in a graphic and the corresponding text will be numbered
accordingly. All left and right-hand references to the vehicle are taken from a position sitting in the
driver seat looking forward. All left and right-hand references to the engine are taken from a
position at the flywheel looking towards the front camshaft pulley. Where appropriate, instructions
will be given for the use of the diagnostic tool. Inspection and Verification Visual Inspection Charts,
Symptom Charts and other information charts (such as diagnostic routines) or supplement test
procedures with technical specifications will navigate the user to a specific test procedure.
Symptom Chart The symptom chart indicates symptoms, sources and actions to address a
condition. Pinpoint Tests For electrical systems, pinpoint test steps are used to identify the source
of a concern in a logical, step-by-step manner. pinpoint tests have two columns: CONDITIONS and
DETAILS/RESULTS/ACTIONS. The CONDITIONS column is used exclusively for graphics and
icons (with or without captions) and the DETAILS/RESULTS/ACTIONS column provides direction
to another test step or specific corrective actions. The boxed numbers indicate the order in which
the described action is to be performed. Component Tests A component test is used when a
component is tested in multiple pinpoint tests, or if a procedure is too complicated to be formatted
within a single page of the pinpoint test. Graphics Test graphics show the measurement or test to
be performed in a test step. A representative tester graphic is used for voltmeters and ohmmeters.
If multiple measurements are made in a single graphic, the test leads are drawn with a solid line
until the test lead splits to indicate the multiple measurements, at which point dashed lines are
used. Breakout box-type testers are represented by a double circle test pin. Test pins are labeled
with the pin number.
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 1 General Information > 100 Service Information > 100-00 General
Information > Description and Operation > Health and Safety Precautions

Introduction Many of the procedures associated with vehicle maintenance and repair involve
physical hazards or other risks to health. This subsection lists, alphabetically, some of these
hazardous operations and the materials and equipment associated with them. Precautions
necessary to avoid these hazards are identified. The list is not exhaustive and all operations and
procedures, and the handling of materials, should be carried out with health and safety in mind.
Before using any product the Materials Safety Data Sheet supplied by the manufacturer or supplier
should be consulted. Acids and Alkalis See also Battery Acids. For example caustic soda, sulphuric
acid. Used in batteries and cleaning materials. Irritant and corrosive to the skin, eyes, nose and
throat. Cause burns. Can destroy ordinary protective clothing. Avoid splashes to the skin, eyes and
clothing. Wear suitable protective impervious apron, gloves and goggles. Do not breath mists.
Make sure access to eye wash bottles, shower and soap are readily available for splashing
accidents. Display Eye Hazard sign. Air Bags See also Fire, Chemical Materials. Highly flammable,
explosive – observe No Smoking policy. Used as a safety restraint system mounted in the steering
wheel and passenger side of the instrument panel. The inflator contains a high-energetic propellant
which, when ignited, produces a VERY HOT GAS (2500°C). The gas generant used in air bags is
Sodium Azide. This material is hermetically sealed in the module and is completely consumed
during deployment. No attempt should be made to open an air bag inflator as this will lead to the
risk of exposure to Sodium Azide. If a gas generator is ruptured, full protective clothing should be
worn when dealing with the spillage. After normal deployment, gloves and safety goggles must be
worn during the handling process. Deployed air bags should be disposed of in a plastic bag in
accordance with local regulations at an approved chemical waste site. Following any direct contact
with gas generant. Air Bags - Do's Air Bags - Do Nots Air Conditioning Refrigerant See also
Chlorofluorocarbon, Chemical Materials Highly flammable, combustible – observe No Smoking
policy. Skin contact may result in frostbite. Instructions given by the manufacturer must be followed.
Avoid naked lights, wear suitable protective gloves and goggles. If refrigerant comes into contact
with the skin or eyes, immediately rinse the affected areas with water. Eyes should also be rinsed
with an appropriate irrigation solution and should not be rubbed. SEEK MEDICAL ASSISTANCE IF
NECESSARY. Air Conditioning Refrigerant - Do Nots Adhesives and Sealers See also Fire,
Chemical Materials. Highly flammable, flammable, combustible – observe No Smoking policy.
Generally should be stored in No Smoking areas. Cleanliness and tidiness in use should be
observed, for example disposable paper covering benches; should be dispensed from applicators
where possible; containers, including secondary containers, should be labeled appropriately.
Solvent-based Adhesives/Sealers - See Solvents Follow manufacturers instructions. Water-based
Adhesives/Sealers Those based on polymer emulsions and rubber latexes may contain small
amounts of volatile toxic and harmful chemicals. Skin and eye contact should be avoided and
adequate ventilation provided during use. Hot Melt Adhesives In the solid state, they are safe. In
the molten state they may cause burns and health hazards may arise from the inhalation of toxic
fumes. Use appropriate protective clothing and a thermostatically controlled heater with a thermal
cut-out and adequate extraction. Resin-based Adhesives/Sealers, for example Epoxide and
Formaldehyde Resin-based Mixing should be carried out in well ventilated areas, as harmful or
toxic volatile chemicals may be released. Skin contact with uncured resins and hardeners can
result in irritation, dermatitis, and absorption of toxic or harmful chemicals through the skin.
Splashes can damage the eyes. Provide adequate ventilation and avoid skin and eye contact.
Anaerobic, Cyanoacrylate (super-glues) and other Acrylic Adhesives Many are irritant, sensitizing
or harmful to the skin and respiratory tract. Some are eye irritants. Skin and eye contact should be
avoided and the manufacturers instructions followed. Cyanoacrylate adhesives (super-glues)
MUST NOT contact the skin or eyes. If skin or eye tissue is bonded, cover with a clean moist pad
and SEEK IMMEDIATE MEDICAL ATTENTION. Do not attempt to pull tissue apart. Use in well
ventilated areas as vapors can cause irritation to the nose and eyes. For two-pack systems see
Resin-based and Isocyanate Adhesives/Sealers. Isocyanate (Polyurethane) Adhesives/Sealers
See also Resin-based Adhesives. Individuals suffering from asthma or respiratory allergies should
not work with or near these materials as sensitivity reactions can occur. Over exposure is irritating
to the eyes and respiratory system. Excessive concentrations may produce effects on the nervous
system including drowsiness. In extreme cases, loss of consciousness may result. Long term
exposure to vapor concentrations may result in adverse health effects. Prolonged contact with the
skin may have a defatting effect which may lead to skin irritation and in some cases, dermatitis.
Splashes entering the eye will cause discomfort and possible damage. Any spraying should
preferably be carried out in exhaust ventilated booths, removing vapors and spray droplets from the
breathing zone. Wear appropriate gloves, eye and respiratory protection. Antifreeze See also Fire,
Solvents. For example isopropanol, ethylene glycol, methanol. Highly flammable, flammable,
combustible. Used in vehicle coolant systems, brake air pressure systems, screenwash solutions.
Vapors may be given off from coolant antifreeze (glycol) when heated. Avoid breathing these
vapors. Antifreeze may be absorbed through the skin in toxic or harmful quantities. Antifreeze, if
swallowed, can be fatal and MEDICAL ATTENTION SHOULD BE SOUGHT IMMEDIATELY.
These products must not be used in any cooling or industrial water system that is connected or
linked to general, food preparation or drinking water supplies. Asbestos See also Warning Symbols
on Vehicles at the end of this subsection. Breathing asbestos dust may cause lung damage or, in
some cases, cancer. Used in brake and clutch linings, transmission brake bands and gaskets. The
use of drum cleaning units, vacuum cleaning or damp wiping is preferred. Asbestos dust waste
should be dampened, placed in a sealed container and marked for safe disposal. If any cutting or
drilling is attempted on materials containing asbestos the item should be dampened and only hand
tools or low speed power tools used. Battery Acids See also Acids and Alkalis. Gases released
during charging are explosive. Never use naked flames or allow sparks near charging or recently
charged batteries. Make sure there is adequate ventilation. Brake and Clutch Linings and Pads
See Asbestos. Brake Fluids (Polyalkylene Glycols) See also Fire. Splashes to the skin and eyes
are slightly irritating. Avoid skin and eye contact as far as possible. Inhalation vapor hazards do not
arise at ambient temperatures because of the very low vapor pressure. Brazing See Welding.
Chemical Materials See also Legal Aspects. Chemical materials such as solvents, sealers,
adhesives, paints, resin foams, battery acids, antifreeze, brake fluids, fuels, oils and grease should
always be used with caution and stored and handled with care. They may be toxic, harmful,
corrosive, irritant or highly flammable and give rise to hazardous fumes and dusts. The effects of
excessive exposure to chemicals may be immediate or delayed; briefly experienced or permanent;
cumulative; superficial; life threatening; or may reduce life expectancy. Chemical Materials - Do's
Chemical Materials - Do Nots Chlorofluorocarbons (CFC) There is concern in the scientific
community that CFCs and Halons are depleting the upper ozone layer which filters out harmful
ultraviolet radiation. Decreased filtration of ultraviolet radiation may result in increases in skin
cancer, cataracts and immune system suppression in humans, as well as decreased productivity of
crops and aquatic systems. CFCs are used primarily as refrigerants in vehicle air conditioning
systems and as aerosol propellants. Halons are used as fire extinguishants. Clutch Fluids See
Brake fluids. Clutch Linings and Pads See Asbestos. Corrosion Protection Materials See also
Solvents, Fire. Highly flammable, flammable – observe No Smoking policy. These materials are
varied and the manufacturers instructions must be followed. They may contain solvents, resins or
petroleum products. Skin and eye contact should be avoided. They should only be sprayed in
conditions of adequate ventilation and not in confined spaces. Cutting See Welding. Dewaxing See
Solvents and Fuels (Kerosene). Dusts Powder, dusts or clouds may be irritant, harmful or toxic.
Avoid breathing dusts from powdery chemical materials or those arising from dry abrasion
operations. Wear respiratory protection if ventilation is inadequate. Fine dusts of combustible
material can present an explosion hazard. Avoid explosive limits and sources of ignition. Electric
Shock Electric shock can result from the use of faulty electrical equipment or from the misuse of
equipment in good condition. Make sure that electrical equipment is maintained in good condition
and frequently tested. Faulty equipment should be labeled and preferably removed from the
workstation. Make sure that flexes, cables, plugs and sockets are not frayed, kinked, cut, cracked
or otherwise damaged. Make sure that electrical equipment and flexes do not come into contact
with water. Make sure that electrical equipment is protected by the correct rated fuse. Never
misuse electrical equipment and never use equipment that is in any way faulty. The results could
be fatal. Make sure that the cables of mobile electrical equipment cannot get trapped and
damaged, such as in a vehicle hoist. Make sure that the designated electrical workers are trained
in basic First Aid. In cases of electrocution: Engine Oils See Lubricants and Grease. Exhaust
Fumes These contain asphyxiating, harmful and toxic chemicals and particles such as carbon
oxides, nitrogen oxides, aldehydes, lead and aromatic hydrocarbons. Engines should be run only
under conditions of adequate exhaust extraction or general ventilation and not in confined spaces.
Gasoline (petrol) engine There may not be adequate warning of odor or of irritation before toxic or
harmful effects arise. These may be immediate or delayed. Diesel engine Soot, discomfort and
irritation usually give adequate warning of hazardous fume concentrations. Fibre Insulation See
also Dusts. Used in noise and sound insulation. The fibrous nature of surfaces and cut edges can
cause skin irritation. This is usually a physical and not a chemical effect. Precautions should be
taken to avoid excessive skin contact through careful organization of work practices and the use of
gloves. Fire See also Welding, Foams, Legal Aspects. Many of the materials found on or
associated with the repair of vehicles are highly flammable. Some give off toxic or harmful fumes if
burnt. Observe strict fire safety when storing and handling flammable materials or solvents,
particularly near electrical equipment or welding processes. Make sure, before using electrical or
welding equipment, that there is no fire hazard present. Have a suitable fire extinguisher available
when using welding or heating equipment. First Aid Apart from meeting any legal requirements it is
desirable for someone in the workshop to be trained in First Aid procedures. Splashes in the eye
should be flushed carefully with clean water for at least ten minutes. Soiled skin should be washed
with soap and water. In case of cold burns, from alternative fuels, place affected area in cool to
cold water. Individuals affected by inhalation of gases and fumes should be removed to fresh air
immediately. If effects persist, consult a doctor. If liquids are swallowed inadvertently, consult a
doctor giving him the information on the container or label. Do not induce vomiting unless this
action is indicated on the label. Fluoroelastomer See Viton. Foams - Polyurethane See also Fire.
Used in sound and noise insulation. Cured foams used in seat and trim cushioning. Follow
manufacturers instructions. Unreacted components are irritating and may be harmful to the skin
and eyes. Wear gloves and goggles. Individuals with chronic respiratory diseases, asthma,
bronchial medical problems, or histories of allergic diseases should not work in or near uncured
materials. The components, vapors or spray mists can cause direct irritation, sensitivity reactions
and may be toxic or harmful. Vapors and spray mists must not be inhaled. These materials must be
applied with adequate ventilation and respiratory protection. Do not remove the respirator
immediately after spraying; wait until the vapors/mists have cleared. Burning of the uncured
components and the cured foams can generate toxic and harmful fumes. Smoking, naked flames
or the use of electrical equipment during foaming operations and until vapors/mists have cleared
should not be allowed. Any heat cutting of cured foams or partially cured foams should be
conducted with extraction ventilation. See also the vehicle Body Repair Manual. Freon See Air
Conditioning Refrigerant. Fuels See also, Fire, Legal Aspects, Chemicals and Solvents. Avoid skin
contact with fuel where possible. Should contact occur, wash the affected skin with soap and water.
Gasoline (Petrol) Highly flammable - observe No Smoking policy. Swallowing can result in mouth
and throat irritation and absorption from the stomach can result in drowsiness and
unconsciousness. Small amounts can be fatal to children. Aspiration of liquid into the lungs,
through vomiting, is a very serious hazard. Gasoline dries the skin and can cause irritation and
dermatitis on prolonged or repeated contact. Liquid in the eye causes severe smarting. Motor
gasoline may contain appreciable quantities of benzene, which is toxic upon inhalation, and the
concentration of gasoline vapors must be kept very low. High concentrations will cause eye, nose
and throat irritation, nausea, headache, depression and symptoms of drunkenness. Very high
concentrations will result in rapid loss of consciousness. Make sure there is adequate ventilation
when handling and using gasoline. Great care must be taken to avoid the serious consequences of
inhalation in the event of vapor build up arising from spillages in confined spaces. Special
precautions apply to cleaning and maintenance operations on gasoline storage tanks. Gasoline
should not be used as a cleaning agent. It must not be siphoned by mouth. See First Aid. Gas-oil
(Diesel Fuel) Combustible. Gross or prolonged skin contact with high boiling point gas oils may
also cause serious skin disorders including skin cancer. Kerosene (Paraffin) Used also as heating
fuel, solvent and cleaning agent. Flammable - observe No Smoking policy. Irritation of the mouth
and throat may result from swallowing. The main hazard from swallowing arises if liquid aspiration
into the lungs occurs. Liquid contact dries the skin and can cause irritation or dermatitis. Splashes
in the eye may be slightly irritating. In normal circumstances the low volatility does not give rise to
harmful vapors. Exposure to mists and vapors from kerosene at elevated temperature should be
avoided (mists may arise in dewaxing). Avoid skin and eye contact and make sure there is
adequate ventilation. Alternative Fuel Highly flammable. Observe ``NO SMOKING" signs. Make
sure there is adequate ventilation when working on alternative fuelled vehicles. Great care must be
taken to avoid the serious consequences of inhalation in the event of vapor build up in confined
spaces. Inhalation in high concentrations may cause dizziness, headache, nausea and loss of
co-ordination. Very high concentrations may result in loss of consciousness. Contact with liquefied
petroleum gas (LPG) or compressed natural gas (CNG) to the skin may cause cold burns and frost
bite. Long sleeved cotton overalls, steel toe capped safety boots and rubber neoprene gloves
should be worn during removal and installation of LPG/CNG fuel system components. LPG/CNG
fuel leaks could cause a fire and be a hazard to health that can lead to personal injury, illness or
even death. If a leak is detected, under no circumstances attempt to seal the leak by tightening the
union/connection until the fuel in the system or component is depressurized. Once tightened the
system should be checked for integrity following the specified procedures. If the fuel tank is to be
removed for service or repair the fuel must be evacuated using dedicated equipment and following
the specified procedures. Gas Cylinders See also Fire. Gases such as oxygen, acetylene, argon
and propane are normally stored in cylinders at pressures of up to 138 bar (2000 psi) and great
care should be taken in handling these cylinders to avoid mechanical damage to them or to the
valve gear attached. The contents of each cylinder should be clearly identified by appropriate
markings. Cylinders should be stored in well-ventilated enclosures, and protected from ice and
snow, or direct sunlight. Fuel gases, for example acetylene and propane, should not be stored in
close proximity to oxygen cylinders. Care should be exercised to prevent leaks from gas cylinders
and lines, and to avoid sources of ignition. Only trained personnel should undertake work involving
gas cylinders. Gases See Gas Cylinders. Gaskets (Fluoroelastomer) See Viton. General Workshop
Tools and Equipment It is essential that all tools and equipment are maintained in good condition
and that the correct safety equipment is used where required. Never use tools or equipment for any
purpose other than that for which they were designed. Never overload equipment such as hoists,
jacks, axle and chassis stands or lifting slings. Damage caused by overloading is not always
immediately apparent and may result in a fatal failure the next time that the equipment is used. Do
not use damaged or defective tools or equipment, particularly high-speed equipment such as
grinding wheels. A damaged grinding wheel can disintegrate without warning and cause serious
injury. Wear suitable eye protection when using grinding, chiseling or sand blasting equipment.
Wear a suitable breathing mask when using abrasive blasting equipment, working with
asbestos-based materials or using spraying equipment. Make sure there is adequate ventilation to
control dusts, mists and fumes. High Pressure Air, Lubrication and Oil Test Equipment See also
Lubricants and Greases. Always keep high-pressure equipment in good condition, and regularly
maintained, particularly at joints and unions. Never direct a high-pressure nozzle, for example
diesel injector, at the skin as the fluid may penetrate to the underlying tissue, and cause serious
injury. Halon See CFCs. Legal Aspects There are many laws and regulations relating to health and
safety in the use and disposal of materials and equipment in a workshop. For a safe working
environment and to avoid environmental pollution, workshops should be familiar, in detail, with the
many health and safety laws and regulations within their country, published by both national and
local authorities. Lubricants and Greases Avoid all prolonged and repeated contact with mineral
oils. All lubricants and greases may be irritating to the eyes and skin. Transmission Fluids Safety
instructions Certain Transmission and Power Steering fluids supplied to Ford may contain additives
which have the potential to cause skin disease (dermatitis) to exposed persons. The dermatitis may
be irritant or allergic in nature. Risks are higher where prolonged or repeated skin contact with a
fluid may occur. These fluids are used for vehicle initial fill and service purposes. This sub-section
is to: Control measures Workplace risk assessments made under national chemical control
regulations should identify operations involving the fluids as potentially hazardous and specify
workplace control and worker awareness measures. In such circumstances, the relevant Material
Safety Datasheet (see the details specified below) which specifies hazards and control measures
in detail should be made available for guidance. Avoid unprotected skin contact with the fluids, and
in particular, avoid prolonged or repeated skin contact. Work practices should be organised so as
to minimise the potential for skin contact. This may include the use of drip trays, absorbents,
correct fluid handling equipment (funnels etc), and workplace housekeeping measures such as the
cleaning of contaminated surfaces. Personnel engaged in operations where skin contact could
occur (such as fluid draining or filling) should wear impervious gloves made from nitrile rubber,
certified to a chemical protection standard, e.g. Europe Standard EN374. This glove type is widely
available from reputable suppliers of gloves for chemical protection [including the manufacturers
Ansell-Admont (Solvex Range), North Safety products (North Nitrile Latex Gloves range), and
Marigold Industrial (Blue Nitrile range)]. If gloves become torn or contaminated on the inside they
should be replaced. Eye protection with safety glasses is appropriate. Use of an impervious apron
and arm protectors may be necessary if more extensive exposure is possible. Use of skin barrier
creams suitable for work with mineral oil products may offer some supplementary protection, but
such barrier creams should not be used in place of protective clothing. If accidental skin contact
occurs with the fluids, wash the area thoroughly with soap or skin cleanser and water. Accidental
eye contact should be dealt with as per normal first aid practices, by flushing the eyes with an eye
wash or clean cool water for 10 minutes, after which medical attention should be obtained. Remove
and launder clothing which becomes contaminated with the fluids. Do not place rags contaminated
with fluid in clothing pockets. Wash thoroughly after completing operations where skin exposure
may have occurred. It is important that personnel do not smoke, eat or drink whilst handling the
fluids or affected transmissions. These measures are designed to limit the risk from accidental
ingestion. Label any decanted fluid properly/use an equivalent label to that on original product
containers. Clean up any spills promptly using an inert absorbent and wash down contaminated
surfaces with detergent and water. Dispose of any waste fluids safely as hazardous waste. Safety
Data Sheets Safety Data Sheets, which detail specific material handling instructions and
precautions are available from the respective national sales company, and via internet
www.msds.ford.com. Used Engine Oil Prolonged and repeated contact with mineral oil will result in
the removal of natural fats from the skin, leading to dryness, irritation and dermatitis. In addition,
used engine oil contains potentially harmful contaminants, which may cause skin cancer. Adequate
means of skin protection and washing facilities must be provided. Do not employ used engine oils
as lubricants or for any application where appreciable skin contact is likely to occur. Environmental
Precautions Burning used engine oil in small space heaters or boilers can be recommended only
for units of approved design. If in doubt check with the appropriate local authority and manufacturer
of approved appliances. Dispose of used oil and used oil filters through authorized waste disposal
contractors or licensed waste disposal sites, or to the waste oil reclamation trade. If in doubt,
contact the relevant local authority for advice on disposal facilities. It is illegal to pour used oil on to
the ground, down sewers or drains, or into watercourses. Noise Some operations may produce
high noise levels, which could, in time, damage hearing. In these cases, suitable ear protection
must be worn. Noise Insulation Materials See Foams, Fibre Insulation. O-Rings (Fluoroelastomer)
See Viton. Paints See also Solvents, Chemical Materials. Highly flammable, flammable - observe
No Smoking policy One Pack Can contain harmful or toxic pigments, driers and other components
as well as solvents. Spraying should be carried out only with adequate ventilation. Two Pack Can
also contain harmful and toxic unreacted resins and resin hardening agents. The manufacturers
instructions should be followed. See also Resin-based Adhesives and Isocyanate Adhesives and
Sealers under Adhesives and Sealers. Spraying should preferably be carried out in exhausted
ventilated booths removing vapor and spray mists from the breathing zone. Individuals working in
booths should wear appropriate respiratory protection. Those doing small-scale repair work in the
open workshop should wear air-fed respirators. Pressurized Equipment See High Pressure Air,
Lubrication and Oil Test Equipment. Solder Solders are mixtures of metals such that the melting
point of the mixture is below that of the constituent metals (normally lead and tin). Solder
application does not normally give rise to toxic lead fumes, provided a gas/air flame is used.
Oxy-acetylene flames should not be used, as they are much hotter and will cause lead fumes to be
produced. Some fumes may be produced by the application of any flame to surfaces coated with
grease, and inhalation of these should be avoided. Removal of excess solder should be
undertaken with care, to make sure that fine lead dust is not produced, which can give toxic effects
if inhaled. Respiratory protection may be necessary. Solder spillage and filings should be collected
and removed promptly to prevent general air contamination by lead. High standards of personal
hygiene are necessary in order to avoid ingestion of lead or inhalation of solder dust from clothing.
Solvents See also Chemical Materials, Fuels (Kerosene), Fire. For example acetone, white spirit,
toluene, xylene, trichloroethane. Used in cleaning and dewaxing materials, paints, plastics, resins
and thinners. Some may be highly flammable or flammable. Skin contact will degrease the skin and
may result in irritation and dermatitis following repeated or prolonged contact. Some can be
absorbed through the skin in toxic or harmful quantities. Splashes in the eye may cause severe
irritation and could lead to loss of vision. Brief exposure of high concentrations of vapors or mists
will cause eye and throat irritation, drowsiness, dizziness, headaches and, in the worst
circumstances, unconsciousness. Repeated or prolonged exposure to excessive but lower
concentrations of vapors or mists, for which there might not be adequate warning indications, can
cause more serious toxic or harmful effects. Aspiration into the lungs, for example through
vomiting, is the most serious consequence of swallowing. Avoid splashes to the skin, eyes and
clothing. Wear protective gloves, goggles and clothing if necessary. Make sure there is good
ventilation when in use, avoid breathing fumes, vapors and spray mists and keep containers tightly
sealed. Do not use in confined spaces. When spraying materials containing solvents, for example
paints, adhesive, coatings, use extraction ventilation or personal respiratory protection in the
absence of adequate general ventilation. Do not apply heat or flame except under specific and
detailed manufacturers instructions. Sound Insulation See Fibre Insulation, Foams. Suspended
Loads There is always a danger when loads are lifted or suspended. Never work under an
unsupported, suspended or raised load, for example a suspended engine. Always make sure that
lifting equipment such as jacks, hoists, axle stands and slings are adequate and suitable for the
job, in good condition and regularly maintained. Transmission Brake Bands See Asbestos.
Underseal See Corrosion Protection. Viton In common with many other manufacturers vehicles,
some components have O-rings, seals or gaskets, which contain a material known as `Viton'. Viton
is a fluoroelastomer, that is a synthetic rubber type material, which contains Fluorine. It is
commonly used for O-rings, gaskets and seals of all types. Although Viton is the most well known
fluoroelastomer, there are others, including Fluorel and Tecmoflon. When used under design
conditions fluoroelastomers are perfectly safe. If, however, they are exposed to temperatures in
excess of 400°C, the material will not burn, but will decompose, and one of the products formed is
hydrofluoric acid. This acid is extremely corrosive and may be absorbed directly, through contact,
into the general body system. O-rings, seals or gaskets which have been exposed to very high
temperatures will appear charred or as a black sticky substance. DO NOT; under any
circumstances touch them or the attached components. Enquiries should be made to determine
whether Viton or any other fluoroelastomer has been used in the affected O-ring, seal or gasket. If
they are of natural rubber or nitrile there is no hazard. If in doubt, be cautious, as the material may
be Viton or any fluoroelastomer. If Viton or any other fluoroelastomers have been used, the
affected area should be decontaminated before the commencement of work. Disposable heavy
duty plastic gloves should be worn at all times, and the affected area washed down using wire wool
and a limewater (calcium hydroxide) solution to neutralize the acid before disposing of the
decomposed Viton residue and final cleaning of the area. After use, the plastic gloves should be
discarded carefully and safely. Welding See also Fire, Electric Shock, Gas Cylinders. Welding
processes include Resistance Welding (Spot Welding), Arc Welding and Gas Welding. Resistance
Welding This process may cause particles of molten metal to be emitted at a high velocity, and the
eyes and skin must be protected. Arc Welding This process emits a high level of ultra-violet
radiation, which may cause arc-eye, and skin burns to the operator and to other persons nearby.
Gas-shielded welding processes are particularly hazardous in this respect. Personal protection
must be worn, and screens used to shield other people. CONTACT LENS WEARERS ARE
ADVISED TO REVERT TO ORDINARY SPECTACLES WHEN ARC WELDING as the arc
spectrum is believed to emit microwaves which dry out the fluid between the lens and the eye. This
may result in blindness when the lens is removed from the eye. Metal spatter will also occur, and
appropriate eye and skin protection is necessary. The heat of the welding arc will produce fumes
and gases from the metals being welded, the rods and from any applied coatings or contamination
on the surfaces being worked on. These gases and fumes may be toxic and inhalation of these
should be avoided. The use of extraction ventilation to remove the fumes from the working area
may be necessary particularly in cases where the general ventilation is poor, or where considerable
welding work is anticipated. In extreme cases or confined spaces where adequate ventilation
cannot be provided, air-fed respirators may be necessary. Gas Welding (and Cutting)
Oxy-acetylene torches may be used for welding and cutting, and special care must be taken to
prevent leakage of these gases, with consequent risk of fire and explosion. The process will
produce metal spatter and eye and skin protection is necessary. The flame is bright, and eye
protection should be used, but the ultra-violet emission is much less than that from arc welding,
and lighter filters may be used. The process itself produces few toxic fumes, but such fumes and
gases may be produced from coatings on the work, particularly during cutting away of damaged
body parts, and inhalation of the fumes should be avoided. In brazing, toxic fumes may be
produced from the metals in the brazing rod, and a severe hazard may arise if brazing rods
containing cadmium are used. In this event particular care must be taken to avoid inhalation of
fumes and expert advice may be required. SPECIAL PRECAUTIONS MUST BE TAKEN BEFORE
ANY WELDING OR CUTTING TAKES PLACE ON VESSELS, WHICH HAVE CONTAINED
COMBUSTIBLE MATERIALS, FOR EXAMPLE BOILING OR STEAMING OUT OF FUEL TANKS.
Warning Symbols on Vehicles Decals showing warning symbols will be found on various vehicle
components. These decals must not be removed. The warnings are for the attention of
owners/operators and persons carrying out service or repair operations on the vehicle. The most
commonly found decals are reproduced below together with an explanation of the warnings. White
Spirit See Solvents.
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 1 General Information > 100 Service Information > 100-00 General
Information > Description and Operation > Standard Workshop Practices

Vehicle in Workshop When working on a vehicle in the workshop always make sure that:
Alternative Fuel If the odor of liquefied petroleum gas (LPG) or compressed natural gas (CNG) is
present in the air in the workshop, warn all persons in the area to: Alternative Fuel — Do's
Alternative Fuel — Do Nots Be aware of situations that may cause the LPG or CNG fuel system to
vent off fuel, such as: Only fully trained personnel, who are conversant with local standards, are to
work on alternative fuel vehicles. Towing the Vehicle When towing is necessary, the vehicle towing
eyes should be used. The rope must be securely fastened to the towing eyes and must also be
attached to the other vehicle such that the rope will not foul the bodywork. When a vehicle with
automatic transmission is towed, the gear selector must be in position N (Neutral). Never tow a
vehicle with automatic transmission at a speed greater than 30 mph (50 km/h) or for a distance
greater than 30 miles (50 km). If it is necessary to tow the vehicle a greater distance, the drive
wheels must be lifted clear off the ground. Alternatively the vehicle can be transported on a low
loader or a trailer. Connecting a Slave Battery Using Jumper Cables Always connect the jumper
cables in the following sequence: Always reduce the engine speed to idle before disconnecting the
jumper cables. Before removing the jumper cables from the vehicle that had the discharged
battery, switch on the heater blower (high) or the heated rear window, to reduce the voltage peak
when the cables are removed. Always disconnect the jumper cables in the reverse order to the
connecting sequence and do not short the ends of the cables. Do not rely on the generator to
restore a discharged battery. For a generator to recharge a battery, it would take in excess of eight
hours continuous driving with no additional loads placed on the battery. Component Cleaning To
prevent the ingress of dirt, accumulations of loose dirt and greasy deposits should be removed
before disconnecting or dismantling components or assemblies. Components should be thoroughly
cleaned before inspection prior to reassembly. Cleaning Methods: Various solvents are available
which are suitable for component cleaning. Some components, such as brake hydraulic parts and
electrical assemblies should be cleaned only with recommended solvents — refer to Solvents,
Sealers and Adhesives or to the section of the manual relevant to the component. Calibration of
Essential Measuring Equipment It is of fundamental importance that certain essential equipment,
for example torque wrenches, multimeters, exhaust gas analyzers or rolling roads, are regularly
calibrated in accordance with the manufacturers instructions.
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 1 General Information > 100 Service Information > 100-00 General
Information > Description and Operation > Road-Roller Testing

Road or roller testing may be carried out for various reasons and a procedure detailing pre-test
checks, engine starting and stopping, pre-driving checks, on-test checks and final checks to be
completed on completion of the test is given below. Unless complete vehicle performance is being
checked, the full road test procedure need not be carried out. Instead, those items particularly
relevant to the system(s) being checked can be extracted. Pre-Test Checks It is suggested that
pre-test checks and functional tests of those systems and circuits which affect the safe and legal
operations of the vehicle, such as brakes, lights and steering, should always be carried out before
the road or roller test. With the ignition switched off, check: Starting the Engine With the ignition
switched off, check: With the ignition switched on, check: Road or Roller Testing During the road or
roller test, check: Brake Testing Test the brakes at several speeds within the normal operating
range using both light and heavy pedal pressure. Note any tendency to snatch, pull or drag, and
any undue delay in application or release. Allow the vehicle to coast and note any tendency to pull
to one side, or evidence that the brakes are binding. After stopping the vehicle (not immediately
after a period of heavy braking), carefully check the brake temperature. A brake disc or brake drum
that feels hot or is appreciably hotter than the others, indicates that the brake is binding. After
completion of the test, check for:
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 1 General Information > 100 Service Information > 100-00 General
Information > Description and Operation > Solvents, Sealants and Adhesives

Introduction The Health and Safety Precautions subsection refers to some commonly used
chemicals and materials, hazards associated with their use, and safety measures to be taken.
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 1 General Information > 100 Service Information > 100-01 Identification
Codes > Description and Operation > Identification Codes

The VIN for registration purposes is stamped onto the body on the front right-hand side wheel arch.
The VIN is also stamped on the VIN plate. The VIN plate is located on the passenger side B-pillar.
The visible VIN (label) is located on the instrument panel close to the windshield glass on the
passenger side of the vehicle and is visible from the outside. Vehicle Identification Number VIN
Positions 2 and 20 — Constant * Not used. VIN Position 3, 4 and 5 — World Manufacturer
Identifier VIN Position 6 and 12 — Model Variant VIN Positions 7 and 8 — Constant XX Not used.
VIN Positions 9 — Product Source Company VIN Position 10 — Assembly Plant VIN Position 11 —
Model Range VIN Position 13 — Year of Manufacture VIN Position 14 — Month of Manufacture
VIN Position 15 to 19 — Vehicle Sequence Number Five digit number Vehicle Certification Label
(Typical) or VIN Plate Item 1: Type Approval Code A unique code required by legislation in certain
territories. Item 2: Vehicle Identification Number (VIN) Vehicle identification number Item 3: Gross
Vehicle Mass Indicates maximum legal laden mass, in territories where this is required. Item 4:
Gross Train Mass Indicates the maximum combined mass of vehicle and trailer or caravan. Item 5:
Maximum Permissible Front Axle Mass Maximum permissible loading on the front wheels of the
vehicle. Item 6: Maximum Permissible Rear Axle Mass Maximum permissible loading on the rear
wheels of the vehicle. Item 7: Vehicle Dimensions Dimensions of the vehicle in mm. Item 8: Model
Type Codes Model type code usage. Digit 1 - Vehicle Digit 2 - Body Digit 3 - Wheelbase/Drive Digit
4 - Model Year Digits 5 to 8 - Engine Variant Digit 9 - Body Variant Not used. Digit 10 - Variant and
Digit 11 - Gross Vehicle Mass in Kg - Vehicles built up to 08/2000 Digit 10 - Variant and Digit 11 -
Gross Vehicle Mass in Kg - Vehicles built up to 08/2000 (continued) Digit 12 - Seats - Vehicles built
up to 08/2000 Digit 13 - Transmission - Vehicles built up to 08/2000 Digit 14 - Final Drive - Vehicles
built up to 08/2000 Digit 10 - Variant and Digit 14 - Gross Vehicle Mass in Kg - Vehicles built from
08/2000 onwards Digit 10 - Variant and Digit 14 - Gross Vehicle Mass in Kg - Vehicles built from
08/2000 onwards (continued) Digit 11 - Final Drive Ratio - Vehicles built from 08/2000 to 02/2001
Digit 12 - Seats - Vehicles built from 08/2000 to 02/2001 Digit 13 - Transmission - Vehicles built
from 08/2000 to 02/2001 Digit 11 - Seats - Vehicles built 02/2001 onwards Digit 12 - Transmission -
Vehicles built 02/2001 onwards Digit 13 - Final Drive Ratio - Vehicles built 02/2001 onwards Item 9:
Wheelbase Item 10: Rear Axle/Axle Ratio Item 12: Transmission/Transaxle Identification Item 13:
Door Combination Item 13: Door Combination (continued) Item 14: Rear Suspension Item 15:
Hand of Drive Item 16: Body Color Codes Item 17: Brakes Item 18: Interior Trim Item 19: Smoke
Values Item 20: Engine Type Codes
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 1 General Information > 100 Service Information > 100-02 Jacking and
Lifting > Description and Operation > Jacking

All Vehicles Van, Bus and Kombi (Short Wheelbase [SWB], Medium Wheelbase [MWB], Long
Wheelbase [LWB] and Extended Length). Chassis Single Cab, Extended Frame Chassis Single
Cab, Chassis Double Cab and Extended Frame Chassis Double Cab
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 1 General Information > 100 Service Information > 100-02 Jacking and
Lifting > Description and Operation > Lifting

All Vehicles Van, Bus and Kombi (Short Wheelbase [SWB], Medium Wheelbase [MWB], Long
Wheelbase [LWB] and Extended Length). Chassis Single Cab, Extended Length Chassis Single
Cab, Chassis Double Cab and Extended Length Chassis Double Cab.
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 1 General Information > 100 Service Information > 100-04 Noise,
Vibration and Harshness > Diagnosis and Testing > Noise, Vibration and Harshness (NVH)

Inspection and Verification How to Use this Diagnostic Procedure Section Customer Interview The
road test and customer interview (if available) provide information that will help identify the concern
and will provide direction to the correct starting point for diagnosis. Identify the Condition NVH
usually occur in four areas: It is important, therefore, that an NVH concern be isolated into its
specific area(s) as soon as possible. The easiest and quickest way to do this is to carry out the
Road Test as outlined. To assist in the diagnosis and testing procedure(s), use a suitable approved
NVH diagnosis tester. Noise Diagnostic Procedure Non-Axle Noise The five most common sources
of non-axle noise are exhaust, tires, roof racks, trim panels and transmission. Therefore, make sure
that none of the following conditions are the cause of the noise before proceeding with a driveline
teardown and diagnosis. Noise Conditions Clicking, popping or grinding noises may be caused by
the following: Check and rule out tires, exhaust and trim items before disassembling the
transmission to diagnose and correct gear noise. The noises described under Road Test usually
have specific causes that can be diagnosed by observation as the unit is disassembled. The initial
clues are the type of noise heard on the road test and driving conditions. Vibration Conditions
Vibration at highway speeds may be caused by the following: Shudder or vibration during
acceleration may be caused by the following: Road Test A gear-driven unit will produce a certain
amount of noise. Some noise is acceptable and may be audible at certain speeds or under various
driving conditions, as on a newly paved asphalt road. The slight noise is in no way detrimental and
must be considered normal. The road test and customer interview (if available) provide information
needed to identify the condition and give direction to the correct starting point for diagnosis. Road
Test Quick Checks Road Conditions An experienced technician will always establish a route that
will be used for all NVH diagnosis road tests. The road selected should be reasonably smooth,
level and free of undulations (unless a particular condition needs to be identified). A smooth asphalt
road that allows driving over a range of speeds is best. Gravel or bumpy roads are unsuitable
because of the additional road noise produced. Once the route is established and consistently
used, the road noise variable is eliminated from the test results. If a customer complains of a noise
or vibration on a particular road and only on a particular road, the source of the concern may be the
road surface. If possible, try to test the vehicle on the same type of road. Vehicle Preparation Carry
out a thorough visual inspection of the vehicle before carrying out the road test. Note anything
which is unusual. Do not repair or adjust any condition until the road test is carried out, unless the
vehicle is inoperative or the condition could pose a hazard to the technician. After verifying that the
condition has been corrected, make sure all components removed have been installed. Power
Steering Conditions Check for the noise in the following conditions to verify the customer concern.
Power Steering Operation Noise Check Step 1: Check for NVH concerns from non-steering
components, which may sound like noises coming from the steering system. NVH concerns from
other components Step 2: Check for steering system NVH concerns according to operation
condition described at the customer interview. Steering system NVH concerns Step 3: According to
each identified operating condition (Column A, B, C, D, E, F), check each possible Steering System
NVH concern with the detail symptom charts below. Before conducting a vehicle test to identify a
NVH concern carry out the following checks. Symptom Chart Power Steering Moan Noise Test
Condition Listen for steering moan noise with the vehicle parked, transmission in neutral and all
windows closed in the following test conditions. Power Steering Whine Noise Test Condition Listen
for steering whine noise with the vehicle parked, transmission in neutral and all windows closed in
the following test conditions. Power Steering Hiss Noise Test Condition Listen for steering hiss
noise with the vehicle parked, transmission in neutral and all windows closed in the following test
conditions. Power Steering Lock Stop Impact Knock Noise Test Condition Listen for steering knock
noise with the engine speed at idle in the following test conditions (noise also apparent with engine
off). Power Steering Mechanical Knock Noise (PAS off) Test Condition Listen for steering knock
noise with the engine off in the following test conditions (no power assist). Power Steering
Mechanical Knock Noise (PAS on) Test Condition Listen for steering knock noise with the engine
speed at idle in the following test conditions (power assist). Power Steering Hammer Knock
(Hydraulic) Noise Test Condition Listen for steering knock noise with the engine speed at idle in the
following test conditions (for vehicles with hydraulic power assisted steering only, not
electro-hydraulic power steering). Power Steering Hydraulic Knock/Clonk Noise Test Condition
Listen for steering knock/clonk noise in the following test conditions with the windows closed.
Power Steering Column Knock Noise Test Condition Listen for steering knock noise in the following
test conditions with windows closed. Power Steering Toc-Toc Noise Test Condition Listen for
steering toc-toc noise with the engine speed at idle and the vehicle parked, automatic transmission
in "P" (PARK) or manual transmission in neutral and the windows closed. Power Steering Grinding
Noise Test Condition Listen for steering grinding noise with the engine speed at idle and the
vehicle parked, automatic transmission in "P" (PARK) or manual transmission in neutral and the
windows closed. Power Steering Zip Noise Driveline Noise and Vibration Suspension Noise and
Vibration Pinpoint Tests After verifying that the condition has been corrected, make sure all
components removed have been installed. PINPOINT TEST A : SHAKE AND VIBRATION WHILE
DRIVING PINPOINT TEST B : TIP-IN MOAN PINPOINT TEST C : IDLE
BOOM/SHAKE/VIBRATION/SHUDDER PINPOINT TEST D : WHEEL END VIBRATION
ANALYSIS PINPOINT TEST E : NON-AXLE NOISE
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 1 General Information > 100 Service Information > 100-04 Noise,
Vibration and Harshness > Diagnosis and Testing > General Procedures > Exhaust System Neutralizing
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 204 Suspension > 204-00 Suspension System - General
Information > Specifications
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 204 Suspension > 204-00 Suspension System - General
Information > Diagnosis and Testing > Suspension System

Alignment Pins, Subframe 205-316 (15-097A) Inspection and Verification Visual Inspection Chart
Symptom Chart Pinpoint Tests PINPOINT TEST A : DRIFT LEFT OR RIGHT PINPOINT TEST B :
EXCESSIVE NOISE Component Tests Raise and support the vehicle. REFER to: (100-02 Jacking
and Lifting) Ball Joint Inspection Strut or Shock Absorber Inspection Weepage: Leakage: Strut or
Shock Absorber Testing
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 204 Suspension > 204-00 Suspension System - General
Information > Diagnosis and Testing > General Procedures > Front Toe Adjustment
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 204 Suspension > 204-00 Suspension System - General
Information > Diagnosis and Testing > General Procedures > Wheel Bearing Inspection

Holding Fixture, Dial Indicator Gauge 205-044 (15-008) Check

Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 204 Suspension > 204-01 Front Suspension > Specifications
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 204 Suspension > 204-01 Front Suspension > Description
and Operation > Diagnosis and Testing > Front Suspension
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 204 Suspension > 204-01 Front Suspension > Description
and Operation > Diagnosis and Testing > Removal and Installation > Front Wheel Bearing

Remover/Installer,Wheel hub/Wheel bearing 204-595 Removal Installation

Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 204 Suspension > 204-01 Front Suspension > Description
and Operation > Diagnosis and Testing > Removal and Installation > Front Wheel Bearing and Wheel Hub - FWD

Remover/Installer,Wheel hub/Wheel bearing 204-595 Installer Halfshaft 204-602 Removal

Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 204 Suspension > 204-01 Front Suspension > Description
and Operation > Diagnosis and Testing > Removal and Installation > Front Wheel Bearing and Wheel Hub - RWD

Remover/Installer,Wheel hub/Wheel bearing 204-595 Installer Halfshaft 204-602 Removal

Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 204 Suspension > 204-01 Front Suspension > Description
and Operation > Diagnosis and Testing > Removal and Installation > Lower Arm

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 204 Suspension > 204-01 Front Suspension > Description
and Operation > Diagnosis and Testing > Removal and Installation > Front Stabilizer Bar - Vehicles With: Solid Stabilizer
Bar Link

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 204 Suspension > 204-01 Front Suspension > Description
and Operation > Diagnosis and Testing > Removal and Installation > Front Stabilizer Bar - Vehicles With: Ball Joint
Stabilizer Bar Link

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 204 Suspension > 204-01 Front Suspension > Description
and Operation > Diagnosis and Testing > Removal and Installation > Lower Arm Bushing

Installer, Wheel Hub 204–148 (14–037) Socket, Hub Nut 204–174 (14–049) Remover/Installer, Ball
Joint 204–288A (14–063A) Remover/Installer, Rear Suspension Bushing 205–050 (15–014)
Installer, Timing Cover Oil Seal 303–427 (21–178) Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 204 Suspension > 204-01 Front Suspension > Description
and Operation > Diagnosis and Testing > Removal and Installation > Wheel Knuckle

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 204 Suspension > 204-01 Front Suspension > Description
and Operation > Diagnosis and Testing > Removal and Installation > Lower Arm Ball Joint - RWD

Remover/Installer, Ball Joint 204-288A (14-063A) Installer Halfshaft 204-602 Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 204 Suspension > 204-01 Front Suspension > Description
and Operation > Diagnosis and Testing > Removal and Installation > Lower Arm Ball Joint - FWD

Remover/Installer, Ball Joint 204-288A (14-063A) Installer Halfshaft 204-602 Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 204 Suspension > 204-01 Front Suspension > Description
and Operation > Diagnosis and Testing > Removal and Installation > Driver Side Strut and Spring Assembly

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 204 Suspension > 204-01 Front Suspension > Description
and Operation > Diagnosis and Testing > Removal and Installation > Passenger Side Strut and Spring Assembly

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 204 Suspension > 204-01 Front Suspension > Description
and Operation > Diagnosis and Testing > Removal and Installation > Disassembly and Assembly > Front Strut and Spring
Assembly

Compressor, Coil Spring 204-167 (14-042) Adaptors for 204-167 204-167-01 (14-042-01)
Disassembly Assembly
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 204 Suspension > 204-01 Front Suspension > Description
and Operation > Front Suspension

Remover, wheel bearing Remover/installer, wheel hub/wheel bearing

Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 204 Suspension > 204-02 Rear Suspension > Specifications
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 204 Suspension > 204-02 Rear Suspension > Description
and Operation > Rear Suspension
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 204 Suspension > 204-02 Rear Suspension > Description
and Operation > Diagnosis and Testing > Rear Suspension
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 204 Suspension > 204-02 Rear Suspension > Description
and Operation > Diagnosis and Testing > Removal and Installation > Rear Stabilizer Bar

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 204 Suspension > 204-02 Rear Suspension > Description
and Operation > Diagnosis and Testing > Removal and Installation > Beam Axle

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 204 Suspension > 204-02 Rear Suspension > Description
and Operation > Diagnosis and Testing > Removal and Installation > Wheel Spindle

Removal Installation 1. Stage 1: Rotate the wheel hub 5 times. 2. Stage 2: Rotate the wheel hub in
the opposite direction while tightening the wheel hub retaining nut to 200 Nm. 3. Stage 3: Rotate
the wheel hub 5 times. 4. Stage 4: Rotate the wheel hub in the opposite direction while tightening
the wheel hub retaining nut to the specified torque. For additional information, refer to:
Specifications (204-02 Rear Suspension, Specifications). 5. Stage 5: Rotate the wheel hub 5 times.
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 204 Suspension > 204-02 Rear Suspension > Description
and Operation > Diagnosis and Testing > Removal and Installation > Spring

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 204 Suspension > 204-02 Rear Suspension > Description
and Operation > Diagnosis and Testing > Removal and Installation > Wheel Bearing and Wheel Hub

Remover Bearing 205-295 Collet for 205-295 205-295-05 Remover Drive Pinion Bearing 204-170
Collet for 204-170 204-170-02 Remover/Installer,Wheel hub/Wheel bearing 204-595 Adapter for
204-595 204-295-09 Removal Installation 1. Stage 1: Rotate the wheel hub 5 times. 2. Stage 2:
Rotate the wheel hub in the opposite direction while tightening the wheel hub retaining nut to 200
Nm. 3. Stage 3: Rotate the wheel hub 5 times. 4. Stage 4: Rotate the wheel hub in the opposite
direction while tightening the wheel hub retaining nut to the specified torque. For additional
information, refer to: Specifications (204-02 Rear Suspension, Specifications). 5. Stage 5: Rotate
the wheel hub 5 times.
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 204 Suspension > 204-04 Wheels and Tires > Description
and Operation > Diagnosis and Testing > Removal and Installation > Wheel and Tire

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 204 Suspension > 204-04 Wheels and Tires > Description
and Operation > Diagnosis and Testing > Wheels and Tires
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 204 Suspension > 204-04 Wheels and Tires > Specifications
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 204 Suspension > 204-05 Vehicle Dynamic Suspension >
Specifications
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 204 Suspension > 204-05 Vehicle Dynamic Suspension >
Description and Operation > Diagnosis and Testing > Vehicle Dynamic Suspension
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 204 Suspension > 204-05 Vehicle Dynamic Suspension >
Description and Operation > Diagnosis and Testing > Removal and Installation > Air Suspension Compressor

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 204 Suspension > 204-05 Vehicle Dynamic Suspension >
Description and Operation > Diagnosis and Testing > Removal and Installation > Air Suspension Compressor Drier

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 204 Suspension > 204-05 Vehicle Dynamic Suspension >
Description and Operation > Diagnosis and Testing > Removal and Installation > Air Suspension Reservoir

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 204 Suspension > 204-05 Vehicle Dynamic Suspension >
Description and Operation > Diagnosis and Testing > Removal and Installation > Air Spring

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 204 Suspension > 204-05 Vehicle Dynamic Suspension >
Description and Operation > Diagnosis and Testing > Removal and Installation > Air Suspension Solenoid Valve Block

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 204 Suspension > 204-05 Vehicle Dynamic Suspension >
Description and Operation > Diagnosis and Testing > Removal and Installation > Suspension Height Sensor

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 204 Suspension > 204-05 Vehicle Dynamic Suspension >
Description and Operation > Diagnosis and Testing > Removal and Installation > Air Spring Support Arm

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 204 Suspension > 204-05 Vehicle Dynamic Suspension >
Description and Operation > Vehicle Dynamic Suspension
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 205 Driveline > 205-00 Driveline System - General
Information > Diagnosis and Testing > Driveline System

Flange Holding Wrench, Universal 205-072 (15-030A) Inspection and Verification Certain axle
noise or vibration symptoms are also common to the engine, transmission, wheel bearings, tires
and other parts of the vehicle. For this reason, make sure that the cause of the trouble is in the axle
before disassembling, adjusting or repairing the axle. REFER to: Noise, Vibration and Harshness
(NVH) (100-04 Noise, Vibration and Harshness, Diagnosis and Testing). Certain driveshaft
vibration symptoms are common to the engine accessory drive, the engine, transmission or tires.
Make sure the cause of the concern is the driveshaft before repairing or installing a new driveshaft.
REFER to: Noise, Vibration and Harshness (NVH) (100-04 Noise, Vibration and Harshness,
Diagnosis and Testing). Noise Acceptability Universal Joint Inspection Raise and support the
vehicle. REFER to: (100-02 Jacking and Lifting) Inspection for Bent Rear Axle Positive (+) camber
is when the bottom measurement is less than the average of the front and rear measurements.
Negative (-) camber is when the bottom measurement is greater than the average of the front and
rear measurements. Toe - in: 0 - 1.6 mm. Toe - out: 0 - 4.8 mm. Camber: 0 ± 4 mm. If the axle
housing does not meet these specifications, a new axle housing must be installed. REFER to:
(205-02A Rear Drive Axle/Differential) Analysis of Leakage Clean up the leaking area to identify the
exact source. A blocked axle housing vent can cause excessive drive pinion oil seal lip wear due to
the internal pressure buildup. Make sure axle oil level is 6 - 14 mm below the bottom of the oil fill
hole. Axle Vent A blocked vent will cause excessive oil seal lip wear due to internal pressure
buildup. If a leak occurs, check the vent. Make sure the vent hose is not kinked. Remove the hose
from the vent nipple and clear the hose of any foreign material. While the hose is removed, pass a
length of mechanics wire or a small diameter Allen key in and out of the vent to clean it. Connect
the hose when done. Drive Pinion Oil Seal Leaks at the axle drive pinion oil seal orginate for the
following reasons: Any damage to the oil seal bore (dings, dents, gouges, or other imperfections)
will distort the oil seal casing and allow leakage past the outer edge of the axle drive pinion oil seal.
The axle drive pinion oil seal can be torn, cut, or gouged if it is not installed correctly. The spring
that holds the axle drive pinion oil seal lip against the drive pinion flange may be dislodged resulting
in allowing leakage past the lip of the oil seal. The rubber oil seal lips can occasionally become
hard (like plastic) with cracks at the lip contact point. The contact point on the drive pinion flange
may blacken, indicating excessive heat. Marks, nicks, gouges, or rough surface texture on the oil
seal journal of the drive pinion flange will also cause leaks. Axle drive pinion oil seal wear 1.27 mm
or greater is considered excessive. A new drive pinion flange must be installed if any of these
conditions exist. Metal chips or sand trapped at the oil seal lip may also cause oil leaks. This can
cause a wear groove on the drive pinion flange and heavy drive pinion oil seal wear. When an oil
seal leak occurs, install a new oil seal and check the vent. Make sure they are clean and free of
foreign material. Axle Shaft Oil Seals The axle shaft oil seals are susceptible to the same kinds of
damage as axle drive pinion oil seals if incorrectly installed. The oil seal bore must be clean and
the oil seal lip handled carefully to avoid cutting or tearing it. The axle shaft journal surface must be
free of nicks, gouges, and rough surface texture. Analysis of Vibration Few vibration conditions are
caused by the front or rear axle. Follow the diagnosis procedure unless there is a good reason to
suspect the axle. REFER to: Noise, Vibration and Harshness (NVH) (100-04 Noise, Vibration and
Harshness, Diagnosis and Testing). Tires Most vibration in the rear end is caused by tires or
driveline angle. Vibration is a concern with modern, high - mileage tires if they are not ``true" both
radially and laterally. They are more susceptible to vibration around the limits of radial and lateral
runout of the tire and wheel assembly. They also require more accurate balancing. Wheel and tire
runout checks, truing and balancing are normally done before axle inspection. REFER to: Wheels
and Tires (204-04 Wheels and Tires, Diagnosis and Testing). Driveline Angle Driveline angularity is
the angular relationship between the engine crankshaft, the driveshaft, and the rear axle drive
pinion. Factors determining driveline angularity include ride height, rear spring, and engine mounts.
Driveline Angle An incorrect driveline (drive pinion) angle can often be detected by the driving
condition in which the vibration occurs. When these conditions exist, check the driveline angles.
REFER to: Suspension System (204-00 Suspension System - General Information, Diagnosis and
Testing). If the tires and driveline angle are not the cause, carry out the NVH tests to determine
whether the concern is caused by a condition in the axle. REFER to: Noise, Vibration and
Harshness (NVH) (100-04 Noise, Vibration and Harshness, Diagnosis and Testing). Universal Joint
Wear Place the vehicle on a wheel free lift and rotate the driveshaft by hand. Check for rough
operation or seized universal joints. Pilot Runout Wheel hub or Axle Flange Face Runout Drive
Pinion and Drive Pinion Flange Check the drive pinion flange runout when all other checks have
failed to show the cause of vibration. One cause of excessive drive pinion flange runout is incorrect
installation of the axle drive pinion oil seal. Check to see if the spring on the oil seal lip has been
dislodged before installing a new ring gear and drive pinion. Axle Noise The noises described as
follows usually have specific causes that can be diagnosed by observation as the unit is
disassembled. The initial clues are the type of noise heard during the road test. Gear Howl and
Whine Howling or whining of the ring gear and drive pinion is due to an incorrect gear pattern, gear
damage or incorrect bearing preload. Bearing Whine Bearing whine is a high - pitched sound
similar to a whistle. It is usually caused by worn or damaged drive pinion bearings, which are
operating at driveshaft speed. Bearing noise occurs at all driving speeds. This distinguishes it from
gear whine which usually comes and goes as speed changes. As noted, drive pinion bearings
make a high - pitched, whistling noise, usually at all speeds. If however there is only one drive
pinion bearing that is worn or damaged, the noise may vary in different driving phases. New drive
pinion bearings must not be installed unless scoring or damage is found or there is a specific drive
pinion bearing noise. A worn or damaged bearing will normally be obvious at disassembly.
Examine the large diameter of the rollers for wear. If the drive pinion bearings original blend radius
has worn to a sharp edge, a new front and rear drive pinion bearing must be installed. A wheel
bearing noise can be mistaken for a drive pinion bearing noise. Check the wheel bearing for a
spalled cup, and spalled or damaged rollers. Install a new wheel bearing if any of these concerns
are detected. If the wheel bearing is damaged, the roller surface on the axle shaft may also be
damaged. Install a new axle shaft if any damage is detected. Chuckle Chuckle that occurs on
coasting is usually caused by excessive clearance between the differential gear wheel hub and the
differential case bore. Damage to a gear tooth on the coast side can cause a noise identical to a
chuckle. A very small tooth nick or ridge on the edge of a tooth can cause the noise. Clean the gear
tooth nick or ridge with a small grinding wheel. If the damaged area is larger than 3.2 mm, install a
new gearset. To check the ring gear and drive pinion, remove as much oil as possible from the
gears with clean solvent. Wipe the gears dry or blow them dry with compressed air. Look for scored
or damaged teeth. Also look for cracks or other damage. If either gear is scored or damaged badly,
a new ring gear and drive pinion must be installed. If metal has broken loose, the axle housing
must be cleaned to remove particles that will cause damage. At this time if any other damaged
parts are found in the axle housing, new parts must also be installed. Knock Knock, which can
occur on all driving phases, has several causes including damaged teeth or gearset. In most cases,
one of the following conditions will occur: Clunk Clunk is a metallic noise heard when the automatic
transmission is engaged in REVERSE or DRIVE. The noise may also occur when throttle is applied
or released. It is caused by backlash somewhere in the driveline or loose suspension components;
it is felt or heard in the axle. REFER to: Ring Gear Backlash Adjustment - VIN Plate Axle Code:
A/B/C/D/G/M/P/X/Y (205-00 Driveline System - General Information, General Procedures).
Additionally, clunk may be heard upon initial drive - away. This occurs as engine torque shifts
vehicle weight, forcing changes in driveline angles, preventing the driveshaft slip - yoke from sliding
on the output shaft. To correct this condition, lubricate the slip - yoke splines. Total Backlash Check
1. Elongation of the differential drive pinion shaft and holes in the differential case. 2. Galling of the
differential drive pinion shaft and bore. 3. Excessive ring gear and drive pinion backlash. Follow the
procedure for the type of rear axle to check backlash. Axle Shaft Bearing Noise Axle shaft bearing
noise is similar to gear noise and differential drive pinion bearing whine. Axle shaft bearing noise
will usually distinguish itself from gear noise by occuring in all driving modes (drive, coast, and
float), and will persist with the transmission in NEUTRAL while the vehicle is moving at the speed in
which the concern is occuring. If the vehicle makes this noise, remove the suspect axle shaft and
install a new bearing and axle oil seal. Re - evaluate the vehicle for noise before removing any
internal components. Bearing Rumble Bearing rumble sounds like marbles being tumbled. This
condition is usually caused by a worn or damaged wheel bearing. The lower pitch is because the
wheel bearing turns at only about one - third of the driveshaft speed. Wheel bearing noise also may
be high - pitched, similar to gear noise, but will be evident in all driving modes. Analysis of
Inoperative Conditions If the axle does not operate, it may be caused by broken welds or wheel
bearing wear or damage. Broken Welds If axle housing welds are completely broken, install a new
axle housing. Wheel Bearing Wear or Damage Because of the severe loads they must handle, new
wheel bearings may be required at high mileage. If a wheel bearing fails at low mileage, it is often
caused by overloading. Symptom Chart Symptom Chart Component Tests Driveline Vibration
Driveline vibration exhibits a higher frequency and lower amplitude than does high - speed shake.
Driveline vibration is directly related to the speed of the vehicle and is usually noticed at various
speed ranges. Driveline vibration can be perceived as a tremor in the floor pan or is heard as a
rumble, hum or boom. Driveline vibration can exist in all drive modes, but may exhibit different
symptoms depending upon whether the vehicle is accelerating, decelerating, floating, or coasting.
Check the driveline angles if the vibration is particulary noticeable during acceleration or
deceleration, especially at lower speeds. Driveline vibration can be duplicated by supporting the
axle upon a vehicle lift or upon axle stands, though the brakes may need to be applied lightly in
order to simulate road resistance. If the marks are on opposite sides of the driveshaft, the yoke or
drive pinion flange is responsible for the vibration. When installing a new drive pinion flange, the
driveshaft runout must not exceed 0.89 mm. When runout is within limits, recheck for vibration at
road speed. If vibration persists, balance the driveshaft. Check for vibration at road speed.
Recheck with the clamp at each of the other positions to find the position that shows minimum
vibration. If two adjacent positions show equal improvement, position the clamp head between
them. If no improvement is noted, rotate the clamps in opposite directions, equal distances from the
best position determined in the previous step. Separate the clamp heads about 13 mm and recheck
for vibration at the road speed. Repeat the process with increasing separation until the best
combination is found or the vibration is reduced to an acceptable level. Driveshaft Vibrates Drive
Pinion Flange Runout Check If the drive pinion flange runout exceeds 0.25 mm, remove the drive
pinion flange, reindex the drive pinion flange one - half turn on the drive pinion and install it.
REFER to: (205-02A Rear Drive Axle/Differential) Tooth Contact Pattern Check - Gearset Contact
Pattern Location In general, acceptable ring gear tooth patterns must have the following
characteristics: Acceptable ring gear tooth patterns for all axles. Correct backlash with a thinner
drive pinion position shim. Correct backlash with a thicker drive pinion position shim required.
Correct drive pinion position shim that requires a decrease in backlash. Correct drive pinion
position shim that requires an increase in backlash.
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 205 Driveline > 205-00 Driveline System - General
Information > Diagnosis and Testing > General Procedures > Ring Gear Backlash Adjustment - VIN Plate Axle Code:
A-B-C-D-G-M-P-X-Y

Wrench, Differential Adjustment 205-063 (15-027) Holding Fixture, Dial Indicator Gauge 205-070
(15-022A)
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 205 Driveline > 205-01 Driveshaft > Diagnosis and Testing >
Driveshaft
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 205 Driveline > 205-01 Driveshaft > Diagnosis and Testing >
Removal and Installation > Driveshaft

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 205 Driveline > 205-01 Driveshaft > Diagnosis and Testing >
Removal and Installation > Disassembly and Assembly > Driveshaft Center Bearing

Preload Gauge 205-067 (15-041) Remover, Bearing/Gear 205-310 (15-091) Remover,

Bearing/Gear 205-311 (15-092) Adaptor for 204-028 308-111 (16-042A) Disassembly Assembly
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 205 Driveline > 205-01 Driveshaft > Specifications
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 205 Driveline > 205-02A Rear Drive Axle-Differential >
Specifications

Lubricants, Fluids, Sealers and Adhesives Lubricants, Fluids, Sealers and Adhesives Capacities
Capacities Clearance, Tolerance and Adjustments Clearance, Tolerance and Adjustments a) Refer
to the procedure in this section. Torque Specifications a) Refer to the procedure in this section.
Torque Specifications a) Refer to the procedure in this section.
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 205 Driveline > 205-02A Rear Drive Axle-Differential >
Description and Operation > Rear Drive Axle and Differential - VIN Plate Axle Code: A-B-C-D-G-M-P-X-Y
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 205 Driveline > 205-02A Rear Drive Axle-Differential >
Description and Operation > Rear Drive Axle and Differential - VIN Plate Axle Code: E-F-H-J-K-L-R

The axle identification label is located on the axle casing. Axle Identification Label Color Code
Identification Full Floating Axle The axle assembly for the single rear wheel variants (shown) and
the twin rear wheel variants are identical with the exception of the brake drum and wheel hub
assembly profile and the axle shafts. The single rear wheel axle shafts are secured to the wheel
hub by three retaining screws and the wheel nuts. Twin rear axle shafts are secured to the wheel
hub by retaining bolts. Single Rear Wheel Axle Shaft Twin Rear Wheel Axle Shaft
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 205 Driveline > 205-02A Rear Drive Axle-Differential >
Description and Operation > Diagnosis and Testing > Rear Drive Axle and Differential
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 205 Driveline > 205-02A Rear Drive Axle-Differential >
Description and Operation > Diagnosis and Testing > General Procedures > Drive Pinion Depth Shim Selection - VIN Plate
Axle Code: A-B-C-D-G-M-P-X-Y

Holding Fixture, Dial Indicator Gauge 205-044 (15-008) Adapter for 205-044 (Step Gauge)
205-044-02 (15-008-03A) Adjustment Gauge, Drive Pinion 205-058 (15-019) Gauge, Master Pinion
205-059 (15-020) Preload Sleeve 205-060 (15-023) Preload Gauge 205-067 (15-041) Holding
Fixture, Dial Indicator Gauge 205-070 (15-022A)
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 205 Driveline > 205-02A Rear Drive Axle-Differential >
Description and Operation > Diagnosis and Testing > General Procedures > In-vehicle Repair > Rear Wheel Bearing and
Axle Shaft Seal

Installer, Rear Wheel Hub Bearing/Oil Seal 205-052 (15-016) Remover, Bearing/Gear 205-311
(15-092) Separator, Oil Pan 303-428 (21-179) Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 205 Driveline > 205-02A Rear Drive Axle-Differential >
Description and Operation > Diagnosis and Testing > General Procedures > In-vehicle Repair > Drive Pinion Flange and
Drive Pinion Seal - VIN Plate Axle Code: A-B-C-D-G-M-P-X-Y

Preload Gauge 205-067 (15-041) Flange Holding Wrench, Universal 205-072 (15-030A) Installer,
Drive Pinion Oil Seal 205-077 (15-047A) Remover, Crankshaft Rear Oil Seal 303-336 (21-151)
Remover, Mainshaft Double Lip Oil Seal 308-151 (16-055) Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 205 Driveline > 205-02A Rear Drive Axle-Differential >
Description and Operation > Diagnosis and Testing > General Procedures > In-vehicle Repair > Drive Pinion Flange and
Drive Pinion Seal - VIN Plate Axle Code: E-F-H-J-K-L-R

Flange Holding Wrench, Universal 205-072 (15-030A) Remover, Crankshaft Rear Seal 303-336
(21-151) Installer/Aligner, Front Cover Seal 303-373 (21-159) Remover, Mainshaft Double Lip Seal
308-151 (16-055) Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 205 Driveline > 205-02A Rear Drive Axle-Differential >
Description and Operation > Diagnosis and Testing > General Procedures > In-vehicle Repair > Drive Pinion Bearing Cups -
VIN Plate Axle Code: A-B-C-D-G-M-P-X-Y

Adapter for 205-066 205-066-02 (15-033-02A) Installer, Differential Bearing Cone 205-074
(15-035) Adapter for 205-074 205-074-01 (15-064) Remover, Differential Bearing Cone 205-176
(15-074)
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 205 Driveline > 205-02A Rear Drive Axle-Differential >
Description and Operation > Diagnosis and Testing > General Procedures > In-vehicle Repair > Drive Pinion - VIN Plate
Axle Code: A-B-C-D-G-M-P-X-Y

Installer, Drive Pinion Oil Seal 205-077 (15-047A) Removal Installation

Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 205 Driveline > 205-02A Rear Drive Axle-Differential >
Description and Operation > Diagnosis and Testing > General Procedures > In-vehicle Repair > Drive Pinion Bearing Cups -
VIN Plate Axle Code: E-F-H-J-K-L-R

Installer, Differential Bearing Cone 205-066 (15-033) Adapter for 205-066 205-066-02
(15-033-02A) Installer, Differential Bearing Cone 205-073 (15-034) Remover, Differential Bearing
Cone 205-176 (15-074)
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 205 Driveline > 205-02A Rear Drive Axle-Differential >
Description and Operation > Diagnosis and Testing > General Procedures > In-vehicle Repair > Drive Pinion - VIN Plate
Axle Code: E-F-H-J-K-L-R

Installer, Differential Bearing Cone 205-066 (15-033) Adapter for 205-066 205-066-02
(15-033-02A) Preload Gauge 205-067 (15-041) Universal Flange Holding Wrench 205-072
(15-030A) Installer, Differential Bearing Cone 205-073 (15-034) Installer, Drive Pinion Seal 205-077
(15-047A) Remover, Differential Bearing Cone 205-176 (15-074) Remover, Bearing/Gear 205-310
(15-091) Remover, Bearing/Gear 205-311 (15-092) Socket, Bearing Retainer 307-325 (17-072)
Removal Installation Pinion Shim Adjustment (inches)
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 205 Driveline > 205-02A Rear Drive Axle-Differential >
Description and Operation > Diagnosis and Testing > General Procedures > In-vehicle Repair > Differential Case - VIN
Plate Axle Code: A-B-C-D-G-M-P-X-Y

Wrench, Differential Adjustment 205-063 (15-027) Removal Installation

Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 205 Driveline > 205-02A Rear Drive Axle-Differential >
Description and Operation > Diagnosis and Testing > General Procedures > In-vehicle Repair > Differential Case - VIN
Plate Axle Code: E-F-H-J-K-L-R

Preload Gauge 205-067 (15-041) Dial Indicator Gauge 205-069 (15-046) Holding Fixture, Dial
Indicator Gauge 205-070 (15-022A) Adapter for 205-071 (Thrust Pad) 205-071-02 (15-026-51)
Remover/Installer, Pivot Bushing 205-297 Spreader, Differential Housing 205-542 Gauge,
Differential Dummy Bearing 205-544 Removal Installation Shiming Table
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 205 Driveline > 205-02A Rear Drive Axle-Differential >
Description and Operation > Diagnosis and Testing > General Procedures > In-vehicle Repair > Removal and Installation >
Axle Assembly - Vehicles With: Single Rear Wheels

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 205 Driveline > 205-02A Rear Drive Axle-Differential >
Description and Operation > Diagnosis and Testing > General Procedures > In-vehicle Repair > Removal and Installation >
Axle Assembly - Vehicles With: Dynamic Suspension-Twin Rear Wheels

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 205 Driveline > 205-02A Rear Drive Axle-Differential >
Description and Operation > Diagnosis and Testing > General Procedures > In-vehicle Repair > Removal and Installation >
Axle Assembly - Vehicles With: Twin Rear Wheels, Vehicles Without: Dynamic Suspension

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 205 Driveline > 205-02A Rear Drive Axle-Differential >
Description and Operation > Diagnosis and Testing > General Procedures > In-vehicle Repair > Removal and Installation >
Disassembly and Assembly > Differential Case and Ring Gear

Remover, Differential Bearing 205-071 (15-026A) Adaptor for 205-071 (Thrust Pad) 205-071-02
(15-026-51) Installer, Differential Bearing 205-082 (15-037) Disassembly Assembly
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 205 Driveline > 205-02A Rear Drive Axle-Differential >
Description and Operation > Diagnosis and Testing > General Procedures > In-vehicle Repair > Removal and Installation >
Disassembly and Assembly > Drive Pinion

Remover, Bearing/Gear 205-310 (15-091) Remover, Bearing/Gear 205-311 (15-092) Disassembly

Assembly
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 205 Driveline > 205-02B Wheel Hubs and Bearings - Full
Floating Axle > Diagnosis and Testing > Wheel Hubs and Bearings
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 205 Driveline > 205-02B Wheel Hubs and Bearings - Full
Floating Axle > Diagnosis and Testing > Removal and Installation > Axle Shaft - Vehicles With: Single Rear Wheels

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 205 Driveline > 205-02B Wheel Hubs and Bearings - Full
Floating Axle > Diagnosis and Testing > Removal and Installation > Axle Shaft - Vehicles With: Twin Rear Wheels

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 205 Driveline > 205-02B Wheel Hubs and Bearings - Full
Floating Axle > Diagnosis and Testing > Removal and Installation > Wheel Hub - VIN Plate Axle Code: E-F-H-J-K-L-R
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 205 Driveline > 205-02B Wheel Hubs and Bearings - Full
Floating Axle > Diagnosis and Testing > Removal and Installation > Wheel Hub - VIN Plate Axle Code: A-B-C-D-G-M-P-X-Y

Holding Fixture, Dial Indicator Gauge 205-044 (15-008) Socket, Axle Nut (65 mm) 205-121
(15-062) Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 205 Driveline > 205-02B Wheel Hubs and Bearings - Full
Floating Axle > Diagnosis and Testing > Removal and Installation > Wheel Bearing

Installer, Rear Wheel Hub Oil Seal 205-215 (15-078) Installer, Rear Wheel Hub Bearing Cone/Oil
Seal 205-216 (15-079) Installer, Rear Wheel Hub Bearing Cone/Oil Seal 205-217 (15-080)
Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 205 Driveline > 205-02B Wheel Hubs and Bearings - Full
Floating Axle > Diagnosis and Testing > Removal and Installation > Wheel Bearings, Wheel Hub Seal and Wheel Bearing
Cups - VIN Plate Axle Code: E-F-H-J-K-L-R

Adapter for 205-066 205-066-01 (15-033-01) Installer, Rear Wheel Hub Seal 205-215 (15-078)
Remover, Halfshaft Seal 308-208 (16-074) Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 205 Driveline > 205-02B Wheel Hubs and Bearings - Full
Floating Axle > Specifications

Lubricants, Fluids, Sealers and Adhesives Lubricants, Fluids, Sealers and Adhesives Clearance,
Tolerance and Adjustments Torque Specifications Torque Specifications
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 205 Driveline > 205-04 Front Drive Halfshafts > Description
and Operation > Front Drive Halfshafts

Exploded view of the halfshaft Working principle of the halfshafts Handling halfshafts If
removing/installing and disassembling/assembling the halfshafts, the following points should be
observed: Wheel balancing, front To use a portable balancing unit position a trolley jack under the
suspension arm opposite the wheel which is being balanced. This prevents the joint from being
bent too much when the vehicle is raised. Where possible, wheels should be removed for
balancing, and balanced using a stationary wheel balancing unit. Raising the vehicle Towing the
vehicle Underbody protection and corrosion prevention Foreign matter on the boots can cause
premature ageing of the material. Foreign matter on the halfshafts can cause imbalance.
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 205 Driveline > 205-04 Front Drive Halfshafts > Description
and Operation > Diagnosis and Testing > Front Drive Halfshafts
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 205 Driveline > 205-04 Front Drive Halfshafts > Description
and Operation > Diagnosis and Testing > Removal and Installation > Front Halfshaft LH

Remover, Halfshaft 204-226 (16-092) Adapter for 204-226 204-226-01 (16-092-01) Separator,
Lower arm-ball joint 204-602 Slide Hammer 205-047 (15-011) Installation Protection, Halfshaft Oil
Seal 205-775 Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 205 Driveline > 205-04 Front Drive Halfshafts > Description
and Operation > Diagnosis and Testing > Removal and Installation > Front Halfshaft RH

Installer, Halfshaft 204-602 Installation Protection, Halfshaft Oil Seal 205-775 Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 205 Driveline > 205-04 Front Drive Halfshafts > Description
and Operation > Diagnosis and Testing > Removal and Installation > Outer Constant Velocity (CV) Joint Boot

Clamping Tool, Boot Retaining Clamp 204-169 (14-044) Removal Installation

Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 205 Driveline > 205-04 Front Drive Halfshafts > Description
and Operation > Diagnosis and Testing > Removal and Installation > Inner Constant Velocity (CV) Joint Boot

Clamping Tool, Boot Retaining Clamp 204-169 (14-044) Remover, Bearing/Gear 205-310 (15-091)
Remover, Bearing/Gear 205-311 (15-092) Installer, Extension Housing Bushing/Oil Seal 308-046
(16-016) Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 205 Driveline > 205-04 Front Drive Halfshafts > Description
and Operation > Diagnosis and Testing > Removal and Installation > Intermediate Shaft

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 205 Driveline > 205-04 Front Drive Halfshafts > Specifications
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-00 Brake System - General
Information > Description and Operation > Brake System

The braking system is of a diagonally split, dual circuit design. The hydraulic system has separate
circuits for each pair of diagonally opposite wheels (left front, right rear and right front, left rear).
The brake pads and brake shoes are all asbestos-free. The parking brake control operates the rear
brakes through a cable system. The brake master cylinder is of a tandem design and is linked to a
brake booster which reduces the brake pedal effort. The tandem design will make sure that in the
event of one brake circuit failing the other will remain fully operational. The brake booster actuating
rod is connected directly to the brake pedal. The brake load sensing proportioning valve is
connected to the chassis and controls the brake fluid pressure to each rear wheel depending on
vehicle load. This will always make sure that braking effort at the front wheels is always greater
than that at the rear wheels.
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-00 Brake System - General
Information > Description and Operation > Diagnosis and Testing > Brake System

Inspection and Verification Visual Inspection Chart Symptom Chart Pinpoint Tests PINPOINT
TEST A : THE BRAKES PULL OR DRIFT. PINPOINT TEST B : THE RED BRAKE WARNING
INDICATOR IS ALWAYS ON PINPOINT TEST C : VIBRATION WHEN BRAKES ARE APPLIED
PINPOINT TEST D : THE PEDAL GOES DOWN FAST PINPOINT TEST E : THE PEDAL EASES
DOWN SLOWLY PINPOINT TEST F : THE PEDAL IS LOW OR FEELS SPONGY PINPOINT
TEST G : BRAKE LOCKUP DURING LIGHT BRAKE PEDAL FORCE PINPOINT TEST H : BRAKE
DRAG PINPOINT TEST I : EXCESSIVE BRAKE PEDAL EFFORT PINPOINT TEST J : SLOW OR
INCOMPLETE BRAKE PEDAL RETURN Component Tests Brake Booster Brake Master Cylinder
Usually, the first and strongest indicator of anything wrong in the brake system is a feeling through
the brake pedal. In diagnosing the condition of the brake master cylinder, check brake pedal feel as
evidence of a brake concern. Check for brake warning indicator illumination and the brake fluid
level in the brake fluid reservoir. Normal Conditions The following conditions are considered normal
and are not indications that the brake master cylinder is in need of repair. Abnormal Conditions
Changes in brake pedal feel or travel are indicators that something could be wrong in the brake
system. The diagnostic procedure and techniques are brake pedal feel, brake warning indicator
illumination and low brake fluid level as indicators in diagnosing brake system concerns. The
following conditions are considered abnormal and indicate that the brake master cylinder is in need
of repair. Bypass Condition Test Non-Pressure Leaks Any empty brake fluid reservoir condition
may be the result of two types of non-pressure external leaks.
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-00 Brake System - General
Information > Description and Operation > Diagnosis and Testing > General Procedures > Brake System Bleeding

Bleeding
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-00 Brake System - General
Information > Description and Operation > Diagnosis and Testing > General Procedures > Brake System Leak Check

Check
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-00 Brake System - General
Information > Description and Operation > Diagnosis and Testing > General Procedures > Brake Disc Runout Check

Dial Indicator Gauge (Metric) 205-069 (15-046) Holding Fixture, Dial Indicator Gauge 205-070
(15-022A) Holding Fixture, Dial Indicator Gauge (Disc Brake) 206-003 (12-003) Check
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-00 Brake System - General
Information > Description and Operation > Diagnosis and Testing > General Procedures > Brake Load Sensor Proportioning
Valve Adjustment

Adjustment 1. XX = Unladen ride height. 1. XX = Unladen ride height. 1. Remove all traces of used
adhesive. 1. Apply adhesive to the screw thread.
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-00 Brake System - General
Information > Specifications
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-02 Drum Brake > Description and
Operation > Drum Brake
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-02 Drum Brake > Description and
Operation > Diagnosis and Testing > Drum Brake
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-02 Drum Brake > Description and
Operation > Diagnosis and Testing > Removal and Installation > Brake Shoes

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-02 Drum Brake > Description and
Operation > Diagnosis and Testing > Removal and Installation > Wheel Cylinder

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-02 Drum Brake > Description and
Operation > Diagnosis and Testing > Removal and Installation > Brake Backing Plate

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-02 Drum Brake > Description and
Operation > Diagnosis and Testing > Removal and Installation > Brake Drum - VIN Plate Axle Code: E-F

Socket, Axle Nut (65 mm) 205-121 (15-062) Installer, Output Drive Flange Seal 204-650 Outside
Thread Chaser 204-655 Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-02 Drum Brake > Description and
Operation > Diagnosis and Testing > Removal and Installation > Disassembly and Assembly > Wheel Cylinder

Disassembly Assembly
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-02 Drum Brake > Specifications
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-03 Front Disc Brake >
Specifications
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-03 Front Disc Brake > Description
and Operation > Diagnosis and Testing > Front Disc Brake
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-03 Front Disc Brake > Description
and Operation > Diagnosis and Testing > Removal and Installation > Brake Pads

Retractor, Caliper Piston 206-005 (12-014) Removal Installation

Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-03 Front Disc Brake > Description
and Operation > Diagnosis and Testing > Removal and Installation > Brake Caliper Anchor Plate

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-03 Front Disc Brake > Description
and Operation > Diagnosis and Testing > Removal and Installation > Brake Caliper

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-03 Front Disc Brake > Description
and Operation > Diagnosis and Testing > Removal and Installation > Brake Disc - RWD
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-03 Front Disc Brake > Description
and Operation > Diagnosis and Testing > Removal and Installation > Brake Disc - FWD
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-03 Front Disc Brake > Description
and Operation > Diagnosis and Testing > Removal and Installation > Disassembly and Assembly > Brake Caliper

Retractor, Caliper Piston 206-005 (12-014) Disassembly Assembly

Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-03 Front Disc Brake > Description
and Operation > Front Disc Brake
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-05A Parking Brake and Actuation >
Description and Operation > Parking Brake
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-05A Parking Brake and Actuation >
Description and Operation > Diagnosis and Testing > Parking Brake
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-05A Parking Brake and Actuation >
Description and Operation > Diagnosis and Testing > General Procedures > Parking Brake Cable Adjustment

Adjustment
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-05A Parking Brake and Actuation >
Description and Operation > Diagnosis and Testing > General Procedures > Removal and Installation > Parking Brake
Control

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-05A Parking Brake and Actuation >
Description and Operation > Diagnosis and Testing > General Procedures > Removal and Installation > Parking Brake Front
Cable

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-05A Parking Brake and Actuation >
Description and Operation > Diagnosis and Testing > General Procedures > Removal and Installation > Parking Brake
Intermediate Cable

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-05A Parking Brake and Actuation >
Description and Operation > Diagnosis and Testing > General Procedures > Removal and Installation > Parking Brake Rear
Cables

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-05A Parking Brake and Actuation >
Specifications
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-05B Parking Brake and Actuation -
Vehicles With: Parking Brake Assist > Specifications
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-05B Parking Brake and Actuation -
Vehicles With: Parking Brake Assist > Description and Operation > Parking Brake
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-05B Parking Brake and Actuation -
Vehicles With: Parking Brake Assist > Description and Operation > Diagnosis and Testing > Parking Brake

Inspection and Verification Visual Inspection Chart Parking Brake Assist Diagnostic Trouble Code
(DTC) Index Symptom Chart Symptom Chart Pinpoint Tests PINPOINT TEST A : NO
COMMUNICATION WITH THE PARKING BRAKE MODULE PINPOINT TEST B : THE PARKING
BRAKE WILL NOT APPLY PINPOINT TEST C : THE PARKING BRAKE WILL NOT RELEASE
PINPOINT TEST D : THE PARKING BRAKE WARNING LAMP IS INOPERATIVE PINPOINT
TEST E : PARKING BRAKE WHEEL SPEED SENSOR WIRE(S) SHORT TO GROUND PINPOINT
TEST F : PARKING BRAKE WHEEL SPEED SENSOR WIRE(S) SHORTED TOGETHER
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-05B Parking Brake and Actuation -
Vehicles With: Parking Brake Assist > Description and Operation > Diagnosis and Testing > General Procedures > Parking
Brake Cable Adjustment

Electric parking brake release tool 206-082 Adjustment

Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-05B Parking Brake and Actuation -
Vehicles With: Parking Brake Assist > Description and Operation > Diagnosis and Testing > General Procedures > Removal
and Installation > Parking Brake Control

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-05B Parking Brake and Actuation -
Vehicles With: Parking Brake Assist > Description and Operation > Diagnosis and Testing > General Procedures > Removal
and Installation > Parking Brake Front Cable

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-05B Parking Brake and Actuation -
Vehicles With: Parking Brake Assist > Description and Operation > Diagnosis and Testing > General Procedures > Removal
and Installation > Parking Brake Intermediate Cable

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-05B Parking Brake and Actuation -
Vehicles With: Parking Brake Assist > Description and Operation > Diagnosis and Testing > General Procedures > Removal
and Installation > Parking Brake Rear Cables

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-05B Parking Brake and Actuation -
Vehicles With: Parking Brake Assist > Description and Operation > Diagnosis and Testing > General Procedures > Removal
and Installation > Parking Brake Module

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-05B Parking Brake and Actuation -
Vehicles With: Parking Brake Assist > Description and Operation > Diagnosis and Testing > General Procedures > Removal
and Installation > Parking Brake Wheel Speed Sensor

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-05B Parking Brake and Actuation -
Vehicles With: Parking Brake Assist > Description and Operation > Diagnosis and Testing > General Procedures > Removal
and Installation > Parking Brake Actuator

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-06 Hydraulic Brake Actuation >
Description and Operation > Hydraulic Brake Actuation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-06 Hydraulic Brake Actuation >
Description and Operation > Diagnosis and Testing > Hydraulic Brake Actuation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-06 Hydraulic Brake Actuation >
Description and Operation > Diagnosis and Testing > Removal and Installation > Brake Pedal and Bracket

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-06 Hydraulic Brake Actuation >
Description and Operation > Diagnosis and Testing > Removal and Installation > Brake Fluid Reservoir

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-06 Hydraulic Brake Actuation >
Description and Operation > Diagnosis and Testing > Removal and Installation > Brake Master Cylinder

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-06 Hydraulic Brake Actuation >
Specifications
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-07 Power Brake Actuation >
Specifications
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-07 Power Brake Actuation >
Description and Operation > Brake Booster
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-07 Power Brake Actuation >
Description and Operation > Diagnosis and Testing > Power Brake System
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-07 Power Brake Actuation >
Description and Operation > Diagnosis and Testing > Removal and Installation > Brake Booster

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-07 Power Brake Actuation >
Description and Operation > Diagnosis and Testing > Removal and Installation > Brake Vacuum Pump - 2.4L Duratorq-Di
(Puma) Diesel-2.4L Duratorq-TDCi (Puma) Diesel

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-07 Power Brake Actuation >
Description and Operation > Diagnosis and Testing > Removal and Installation > Brake Vacuum Pump - 2.0L Duratorq-Di
(Puma) Diesel-2.0L Duratorq-TDCi (Puma) Diesel-2.0L Duratorq-TDDi (Puma) Diesel

Remover/Install, Cooling Hose Clamp 303-097 (24-003) Removal Installation

Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-09 Anti-Lock Control >
Specifications
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-09 Anti-Lock Control > Description
and Operation > Anti-Lock Control
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-09 Anti-Lock Control > Description
and Operation > Diagnosis and Testing > Anti-Lock Control
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-09 Anti-Lock Control > Description
and Operation > Diagnosis and Testing > Removal and Installation > Hydraulic Control Unit (HCU)

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-09 Anti-Lock Control > Description
and Operation > Diagnosis and Testing > Removal and Installation > Rear Wheel Speed Sensor

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-09 Anti-Lock Control > Description
and Operation > Diagnosis and Testing > Removal and Installation > Front Wheel Speed Sensor

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 206 Brake System > 206-09 Anti-Lock Control > Description
and Operation > Diagnosis and Testing > Removal and Installation > Anti-Lock Brake System (ABS) Module

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 211 Steering System > 211-00 Steering System - General
Information > Specifications
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 211 Steering System > 211-00 Steering System - General
Information > Diagnosis and Testing > Steering System
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 211 Steering System > 211-00 Steering System - General
Information > Diagnosis and Testing > General Procedures > Power Steering System Flushing - 2.0L Duratorq-Di (Puma)
Diesel-2.0L Duratorq-TDCi (Puma) Diesel-2.0L Duratorq-TDDi (Puma) Diese
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 211 Steering System > 211-00 Steering System - General
Information > Diagnosis and Testing > General Procedures > Power Steering System Flushing - 2.3L DOHC-16V
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 211 Steering System > 211-00 Steering System - General
Information > Diagnosis and Testing > General Procedures > Power Steering System Bleeding

Adapter, Power Steering Bleeding 211-189 (13-016) Hand Vacuum Pump/Pressure Pump
416-D001 (23-036A) Bleeding
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 211 Steering System > 211-00 Steering System - General
Information > Diagnosis and Testing > General Procedures > Power Steering System Filling

Adapter, Power Steering Bleeding 211-189 (13-016) Hand Vacuum Pump/Pressure Pump
416-D001 (23-036A) Refill
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 211 Steering System > 211-02 Power Steering > Description
and Operation > Power Steering
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 211 Steering System > 211-02 Power Steering > Description
and Operation > Diagnosis and Testing > Power Steering
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 211 Steering System > 211-02 Power Steering > Description
and Operation > Diagnosis and Testing > Removal and Installation > Power Steering Pump - 2.4L Duratorq-Di (Puma)
Diesel-2.4L Duratorq-TDCi (Puma) Diesel

Expander, Teflon Seal 211-188 (13-015) Removal Installation

Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 211 Steering System > 211-02 Power Steering > Description
and Operation > Diagnosis and Testing > Removal and Installation > Power Steering Pump - 2.0L Duratorq-Di (Puma)
Diesel-2.0L Duratorq-TDCi (Puma) Diesel-2.0L Duratorq-TDDi (Puma) Diesel

Expander, Teflon Seal 211-188 (13-015) Removal Installation

Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 211 Steering System > 211-02 Power Steering > Description
and Operation > Diagnosis and Testing > Removal and Installation > Power Steering Pump - 2.3L DOHC-16V

Expander, Teflon Seal 211-188 (13-015) Removal Installation

Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 211 Steering System > 211-02 Power Steering > Description
and Operation > Diagnosis and Testing > Removal and Installation > Power Steering Pump Pulley - 2.4L Duratorq-Di
(Puma) Diesel-2.4L Duratorq-TDCi (Puma) Diesel

Remover, Power Steering Pump Pulley 211-198 (13-021) Installer, Camshaft Pulley 303-458
(21-192) Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 211 Steering System > 211-02 Power Steering > Description
and Operation > Diagnosis and Testing > Removal and Installation > Power Steering Pump to Steering Gear Pressure Line
- 2.4L Duratorq-Di (Puma) Diesel-2.4L Duratorq-TDCi (Puma) Diesel

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 211 Steering System > 211-02 Power Steering > Description
and Operation > Diagnosis and Testing > Removal and Installation > Power Steering Pump to Steering Gear Pressure Line
- 2.0L Duratorq-Di (Puma) Diesel-2.0L Duratorq-TDCi (Puma) Diesel-2.0L Durato

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 211 Steering System > 211-02 Power Steering > Description
and Operation > Diagnosis and Testing > Removal and Installation > Power Steering Pump to Steering Gear Pressure Line
- 2.3L DOHC-16V

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 211 Steering System > 211-02 Power Steering > Description
and Operation > Diagnosis and Testing > Removal and Installation > Steering Gear to Fluid Cooler Return Hose

Remover, Oil Cooling Pipe 307-242 (17-049) Remover/Installer, Cooling Hose Clamp 303-397
(24-003) Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 211 Steering System > 211-02 Power Steering > Description
and Operation > Diagnosis and Testing > Removal and Installation > Power Steering Fluid Cooler

Remover, Oil Cooling Pipe 307-242 (17-049) Remover/Installer, Cooling Hose Clamp 303-397
(24-003) Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 211 Steering System > 211-02 Power Steering > Description
and Operation > Diagnosis and Testing > Removal and Installation > Steering Gear

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 211 Steering System > 211-02 Power Steering >
Specifications
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 211 Steering System > 211-03 Steering Linkage >
Description and Operation > Steering Linkage
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 211 Steering System > 211-03 Steering Linkage >
Description and Operation > Diagnosis and Testing > Steering Linkage
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 211 Steering System > 211-03 Steering Linkage >
Description and Operation > Diagnosis and Testing > Removal and Installation > Tie Rod

Clamping Tool, Boot Retaining Clamp 204-169 (14-044) Removal Installation

Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 211 Steering System > 211-03 Steering Linkage >
Description and Operation > Diagnosis and Testing > Removal and Installation > Steering Gear Boot

Clamping Tool, Boot Retaining Clamp 204-169 (14-044) Removal Installation

Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 211 Steering System > 211-03 Steering Linkage >
Description and Operation > Diagnosis and Testing > Removal and Installation > Tie Rod End

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 211 Steering System > 211-03 Steering Linkage >
Specifications
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 211 Steering System > 211-04 Steering Column > Description
and Operation > Steering Column
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 211 Steering System > 211-04 Steering Column > Description
and Operation > Diagnosis and Testing > Steering Column
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 211 Steering System > 211-04 Steering Column > Description
and Operation > Diagnosis and Testing > Removal and Installation > Steering Wheel

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 211 Steering System > 211-04 Steering Column > Description
and Operation > Diagnosis and Testing > Removal and Installation > Steering Column

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 211 Steering System > 211-04 Steering Column > Description
and Operation > Diagnosis and Testing > Removal and Installation > Steering Column Flexible Coupling

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 211 Steering System > 211-04 Steering Column >
Specifications
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 211 Steering System > 211-05 Steering Column Switches >
Diagnosis and Testing > Steering Column Switches

Inspection and Verification Visual Inspection Chart Symptom Chart Pinpoint Test PINPOINT TEST
A : THE IGNITION SWITCH IS INOPERATIVE PINPOINT TEST B : NO POWER IN ACC
PINPOINT TEST C : NO POWER IN RUN PINPOINT TEST D : NO POWER IN START
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 211 Steering System > 211-05 Steering Column Switches >
Diagnosis and Testing > Removal and Installation > Steering Column Multifunction Switch

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 2 Chassis > 211 Steering System > 211-05 Steering Column Switches >
Diagnosis and Testing > Removal and Installation > Ignition Switch

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-00 Engine System - General Information
> Diagnosis and Testing > Engine

Inspection and Verification Visual Inspection Chart Symptom Chart Engine Oil Leaks If the oil leak
cannot be identified clearly by a visual inspection, carry out a UV test: Ultraviolet (UV) Testing
Measure the compression pressure (21 111 0) Measure the compression (Engine - 2.4L Diesel
with EGR) Measure the compression (Engine - 2.4L Diesel without EGR) Measure the
compression (Engine - 2.0L Diesel) Measure the compression (Engine - 2.3L) Oil Pressure -
Measure (21 113 0) The oil pressure depends on various factors (engine speed, oil temperature, oil
viscosity, amount of oil filter contamination etc.). Measure the oil pressure (Engine - 2.4L Diesel)
Measure the oil pressure (Engine - 2.0L Diesel) Measure the oil pressure (Engine - 2.3L) Valve
train analysis - static (engine off) Check all components of the valve train for damage and wear.
Make sure that only original components are installed and that all nuts and bolts are tightened to
the specified torque.
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-00 Engine System - General Information
> Diagnosis and Testing > General Procedures > Camshaft Bearing Journal Diameter
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-00 Engine System - General Information
> Diagnosis and Testing > General Procedures > Camshaft End Play

1. End play = maximum value minus minimum value

Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-00 Engine System - General Information
> Diagnosis and Testing > General Procedures > Camshaft Bearing Journal Clearance
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-00 Engine System - General Information
> Diagnosis and Testing > General Procedures > Camshaft Lobe Lift
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-00 Engine System - General Information
> Diagnosis and Testing > General Procedures > Camshaft Surface Inspection
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-00 Engine System - General Information
> Diagnosis and Testing > General Procedures > Crankshaft Main Bearing Journal Diameter
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-00 Engine System - General Information
> Diagnosis and Testing > General Procedures > Crankshaft Main Bearing Journal Clearance
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-00 Engine System - General Information
> Diagnosis and Testing > General Procedures > Crankshaft End Play
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-00 Engine System - General Information
> Diagnosis and Testing > General Procedures > Cylinder Bore Taper
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-00 Engine System - General Information
> Diagnosis and Testing > General Procedures > Piston Pin to Bore Diameter
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-00 Engine System - General Information
> Diagnosis and Testing > General Procedures > Piston Inspection
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-00 Engine System - General Information
> Diagnosis and Testing > General Procedures > Piston Ring End Gap
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-00 Engine System - General Information
> Diagnosis and Testing > General Procedures > Piston Diameter
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-00 Engine System - General Information
> Diagnosis and Testing > General Procedures > Piston Pin Diameter
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-00 Engine System - General Information
> Diagnosis and Testing > General Procedures > Piston Ring-to-Groove Clearance
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-00 Engine System - General Information
> Diagnosis and Testing > General Procedures > Connecting Rod Large End Bore
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-00 Engine System - General Information
> Diagnosis and Testing > General Procedures > Valve Stem Diameter
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-00 Engine System - General Information
> Diagnosis and Testing > General Procedures > Valve Seat Inspection
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-00 Engine System - General Information
> Diagnosis and Testing > General Procedures > Flywheel Inspection
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-00 Engine System - General Information
> Diagnosis and Testing > General Procedures > Flywheel Clutch Surface Inspection
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-00 Engine System - General Information
> Diagnosis and Testing > General Procedures > Flywheel Inspection - Vehicles With: Dual Mass Flywheel
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-00 Engine System - General Information
> Diagnosis and Testing > General Procedures > Cylinder Block Distortion
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-00 Engine System - General Information
> Diagnosis and Testing > General Procedures > Cylinder Head Distortion
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-00 Engine System - General Information
> Diagnosis and Testing > General Procedures > Exhaust Manifold Cleaning and Inspection
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-00 Engine System - General Information
> Diagnosis and Testing > General Procedures > Bearing Inspection
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01A Engine - 2.4L Duratorq-Di (Puma)
Diesel-2.4L Duratorq-TDCi (Puma) Diesel > Specifications
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01A Engine - 2.4L Duratorq-Di (Puma)
Diesel-2.4L Duratorq-TDCi (Puma) Diesel > Description and Operation > Engine

General view Engine identification code Engine code and engine serial number On the 2.4L engine
the engine code (4 digits) and the engine serial number (2 letters for the year and month and 5
figures for the serial number) are stamped in the cylinder block on the exhaust side (in line with
cylinder No. 4). If the engine or cylinder block is changed, the vehicle identification number must be
stamped in the indicated location. Engine identification plate The engine identification plate is
located on the cover of the timing cover. It contains the following data: General The 2.4L
turbocharged engine uses the direct injection principle. It is a 4-cylinder turbocharged diesel engine
with two overhead camshafts and 16 valves. The engine is available with various levels of power
output: * The engine is marketed as 135 PS, the actual power is 137 PS. The valves are operated
by rocker arms driven by two overhead camshafts. The camshafts, together with the fuel injection
pump, are driven by a twin timing chain from the crankshaft. An EEC V Powertrain Control Module
(PCM) is used for engine management. Diagnostics are carried out using FDS 2000 or WDS
through the data link connector (DLC). Both fuel injection pumps operate according to the "pilot
injection" principle, which results in a reduction of the engine noise level. Cylinder head The valve
cover incorporates the crankcase ventilation valve. Rocker shafts Camshafts and camshaft carrier
The intake and exhaust camshaft differ in the spacing between the cams. Camshaft carrier The
upper mounting of the camshafts is provided by a camshaft carrier which incorporates five bearing
caps. The camshaft carrier is bolted flush to the cylinder head and secures the camshafts. The
shape of the camshaft carrier prevents incorrect installation. Before the camshaft carrier is
installed, the mating faces on the underside of the camshaft carrier and the underside of the
cylinder head must be cleaned thoroughly. Cylinder head and valves The cylinder head is made of
aluminium and cannot be reworked. Four valves per cylinder provides improved cylinder charging,
a compact combustion chamber, and a vertical fuel injector which guarantees optimum distribution
of the fuel in the combustion chamber. Camshaft drive The camshafts and the fuel injection pump
are driven in the direction of the arrow by a timing chain (twin chain) from a the crankshaft
sprocket. When the timing chain is installed, the marked chain links must line up with the timing
marks on the sprockets on the camshafts and the fuel injection pump. Cylinder block and
crankcase - overview Connecting rods The connecting rods are available in three different lengths.
For identification, the large end and bearing cap are marked with the corresponding length code (H
to J): Only connecting rods of the same length must be installed. Pistons To ensure optimum
sealing of the cylinder, when installing the piston rings, make sure that the ring gaps are offset at
120 degrees to one another. The locations on the piston skirt which come into contact with the
cylinder bore incorporate molybdenum-coated surfaces. These counteract scoring of the cylinder
and piston and therefore increase the life of the engine. When installing a piston, make sure that
the piston is installed in the correct position. The arrow on the piston crown and the mark on the
piston skirt point towards the front of the engine. The size of piston installed (skirt diameter code)
matches the bore diameter code for the cylinder concerned. Crankshaft The crankshaft has
induction-hardened journals which run in five bearings with clamped two-layer bearing shells. The
bearing caps are numbered (cylinder Nos. 2, 3 and 4) or marked with the letters “F” (front) or “R”
(rear) and have an arrow which must point towards the front of the engine. Cylinder block The
cylinder bores are machined directly in the block. Three different bore diameters are used in
production to ensure very precise adjustment of the clearance between the pistons and cylinders.
Once the bore diameter has been established, the optimum piston is installed. The pistons are also
available in three different sizes in production. Oil splash nozzles Oil splash nozzles for piston
cooling are installed under the cylinder bores between the crankshaft bearings.
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01A Engine - 2.4L Duratorq-Di (Puma)
Diesel-2.4L Duratorq-TDCi (Puma) Diesel > Description and Operation > Diagnosis and Testing > Engine
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01A Engine - 2.4L Duratorq-Di (Puma)
Diesel-2.4L Duratorq-TDCi (Puma) Diesel > Description and Operation > Diagnosis and Testing > In-vehicle Repair > Intake
Manifold - Vehicles Built From: 04-2003, Vehicles Without: Common Rail Fuel Injection

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01A Engine - 2.4L Duratorq-Di (Puma)
Diesel-2.4L Duratorq-TDCi (Puma) Diesel > Description and Operation > Diagnosis and Testing > In-vehicle Repair > Intake
Manifold - Vehicles Built Up To: 04-2003, Vehicles Without: Common Rail Fuel Injection

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01A Engine - 2.4L Duratorq-Di (Puma)
Diesel-2.4L Duratorq-TDCi (Puma) Diesel > Description and Operation > Diagnosis and Testing > In-vehicle Repair > Intake
Manifold - Vehicles With: Common Rail Fuel Injection

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01A Engine - 2.4L Duratorq-Di (Puma)
Diesel-2.4L Duratorq-TDCi (Puma) Diesel > Description and Operation > Diagnosis and Testing > In-vehicle Repair > Valve
Cover - 75 PS-90 PS

Valve Cover, Fuel Injector Seal, Installer 303-695 Removal Installation

Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01A Engine - 2.4L Duratorq-Di (Puma)
Diesel-2.4L Duratorq-TDCi (Puma) Diesel > Description and Operation > Diagnosis and Testing > In-vehicle Repair > Valve
Cover - 120 PS

Valve Cover, Fuel Injector Seal, Installer 303-695 Removal Installation

Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01A Engine - 2.4L Duratorq-Di (Puma)
Diesel-2.4L Duratorq-TDCi (Puma) Diesel > Description and Operation > Diagnosis and Testing > In-vehicle Repair >
Crankshaft Front Seal

Holding Wrench, Crankshaft 303-1310 Remover/Installer, Crankshaft Front Oil Seal 303-679
Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01A Engine - 2.4L Duratorq-Di (Puma)
Diesel-2.4L Duratorq-TDCi (Puma) Diesel > Description and Operation > Diagnosis and Testing > In-vehicle Repair > Valve
Cover - 135 PS

Valve Cover, Fuel Injector Seal, Installer 303-1055 Removal Installation

Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01A Engine - 2.4L Duratorq-Di (Puma)
Diesel-2.4L Duratorq-TDCi (Puma) Diesel > Description and Operation > Diagnosis and Testing > In-vehicle Repair >
Engine Front Cover - 75 PS

Separator, Oil Pan 303-428 (21-179) Remover/Installer, Crankshaft Front Oil Seal 303-679
(21-238) Aligner Tool, Engine Front Cover 303-682 (21-241) Holding Wrench, Crankshaft 303-1177
Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01A Engine - 2.4L Duratorq-Di (Puma)
Diesel-2.4L Duratorq-TDCi (Puma) Diesel > Description and Operation > Diagnosis and Testing > In-vehicle Repair >
Engine Front Cover - 90 PS-120 PS

Separator, Oil Pan 303-428 (21-179) Remover/Installer Crankshaft Front Oil Seal 303-679 (21-238)
Aligner, Front Cover 303-682 (21-241) Holding Wrench, Crankshaft 303-1177 Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01A Engine - 2.4L Duratorq-Di (Puma)
Diesel-2.4L Duratorq-TDCi (Puma) Diesel > Description and Operation > Diagnosis and Testing > In-vehicle Repair > Valve
Springs

Compressor, Valve Spring 303-060 (21-024) Adapter for 303-060 303-060-05 (21-024-05) Adapter
for 303-060 303-060-07 (21-024-07) Installer, Valve Stem Collets 303-362 (21-156) Removal
Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01A Engine - 2.4L Duratorq-Di (Puma)
Diesel-2.4L Duratorq-TDCi (Puma) Diesel > Description and Operation > Diagnosis and Testing > In-vehicle Repair > Valve
Seals

Pliers, Valve Stem Oil Seal 303-508 (21-211) Removal Installation

Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01A Engine - 2.4L Duratorq-Di (Puma)
Diesel-2.4L Duratorq-TDCi (Puma) Diesel > Description and Operation > Diagnosis and Testing > In-vehicle Repair >
Valves

Compressor, Valve Spring 303-060 (21-024) Adaptor for 303-060 303-060-05 (21-024-05) Adaptor
for 303-060 303-060-07 (21-024-07) Installer, Valve Stem Collets 303-362 (21-156) Removal
Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01A Engine - 2.4L Duratorq-Di (Puma)
Diesel-2.4L Duratorq-TDCi (Puma) Diesel > Description and Operation > Diagnosis and Testing > In-vehicle Repair >
Camshafts

Timing Tool, Crankshaft TDC 303-675 Timing Tool, Crankshaft 303-698 Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01A Engine - 2.4L Duratorq-Di (Puma)
Diesel-2.4L Duratorq-TDCi (Puma) Diesel > Description and Operation > Diagnosis and Testing > In-vehicle Repair >
Exhaust Manifold

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01A Engine - 2.4L Duratorq-Di (Puma)
Diesel-2.4L Duratorq-TDCi (Puma) Diesel > Description and Operation > Diagnosis and Testing > In-vehicle Repair >
Cylinder Head

Dial Indicator Gauge (Metric) 205-069 (15-046) Holding Fixture, Dial Indicator Gauge 205-070
(15-022A) Remover/Installer, Cooling Hose Clamp 303-397 (24-003) Holding Fixture, Dial Indicator
Gauge 303-432 (21-183) Socket, Fuel Injector Remove/Install 303-677 (21-236) Aligner, Fuel
Injector 303-711 (21-258) Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01A Engine - 2.4L Duratorq-Di (Puma)
Diesel-2.4L Duratorq-TDCi (Puma) Diesel > Description and Operation > Diagnosis and Testing > In-vehicle Repair > Oil
Pan

Seperator, Oil Pan 303-428 (21-179) Removal Installation

Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01A Engine - 2.4L Duratorq-Di (Puma)
Diesel-2.4L Duratorq-TDCi (Puma) Diesel > Description and Operation > Diagnosis and Testing > In-vehicle Repair > Oil
Pump

Aligner, Oil Pump 303-705 (21-256) Removal Installation

Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01A Engine - 2.4L Duratorq-Di (Puma)
Diesel-2.4L Duratorq-TDCi (Puma) Diesel > Description and Operation > Diagnosis and Testing > In-vehicle Repair >
Crankshaft Rear Seal

Adapter for 205-044 205-044-01 Universal Flange Holding Wrench 205-072 Adapter for 205-072
205-072-02 Socket, Cylinder Head Bolt 303-033 Locking Tool, Flywheel 303-254 Removal
Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01A Engine - 2.4L Duratorq-Di (Puma)
Diesel-2.4L Duratorq-TDCi (Puma) Diesel > Description and Operation > Diagnosis and Testing > In-vehicle Repair >
Removal > Engine - Vehicles With: Exhaust Gas Recirculation (EGR)

Remover/Installer, Cooling Hose Clamp 303-397 (24-003) Spacer, Subframe 204-606 Removal
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01A Engine - 2.4L Duratorq-Di (Puma)
Diesel-2.4L Duratorq-TDCi (Puma) Diesel > Description and Operation > Diagnosis and Testing > In-vehicle Repair >
Removal > Disassembly > Engine

Universal Flange Holding Wrench 205-072 Separator, Oil Pan 303-428 (21-179) Mounting Stand
303-435 Mounting bracket for 303-435 303-435-06 Mounting plate for 303-435-06 303-435-011A
Remover/Installer, Crankshaft Front Oil Seal 303-679 Holding Wrench, Crankshaft 303-1177
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01A Engine - 2.4L Duratorq-Di (Puma)
Diesel-2.4L Duratorq-TDCi (Puma) Diesel > Description and Operation > Diagnosis and Testing > In-vehicle Repair >
Removal > Disassembly > Disassembly and Assembly of Subassemblies > Cylinder Head

Socket Wrench, Cylinder Head Temperature (CHT) Sensor 303-680 (21-239) Socket, Fuel Injector
303-677 (21-236) Aligner, Fuel Injector 303-711 (21-258) Disassembly Assembly
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01A Engine - 2.4L Duratorq-Di (Puma)
Diesel-2.4L Duratorq-TDCi (Puma) Diesel > Description and Operation > Diagnosis and Testing > In-vehicle Repair >
Removal > Disassembly > Disassembly and Assembly of Subassemblies > Assembly > Engine

Dial Indicator Gauge (Metric) 205-069 Holding Fixture, Dial Indicator Gauge 205-070 Universal
Flange Holding Wrench 205-072 Gauge, Bolt Angle 303-174 Setting Gauge, Crankshaft 303-391
Holding Fixture, Dial Indicator Gauge (Cylinder Liner Protrusion) 303-432 Mounting Stand 303-435
Mounting bracket for 303-435 303-435-06 Mounting plate for 303-435-06 303-435-011A Timing
Tool, Crankshaft 303-675 Socket, Fuel Injector (21 mm) 303-677 Remover/Installer Crankshaft
Front Oil Seal 303-679 Aligner, Engine Front Cover 303-682 Installer, Fuel Injector Seal 303-695
Timing Tool, Crankshaft 303-698 Aligner, Fuel Injector 303-711 Holding Wrench, Crankshaft
303-1177 Assembly
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01A Engine - 2.4L Duratorq-Di (Puma)
Diesel-2.4L Duratorq-TDCi (Puma) Diesel > Description and Operation > Diagnosis and Testing > In-vehicle Repair >
Removal > Disassembly > Disassembly and Assembly of Subassemblies > Assembly > Installation > Engine - Vehicles
With: Exhaust Gas Recirculation (EGR)

Remover/Installer, Cooling Hose Clamp 303-397 (24-003) Spacer, Subframe 204-606 Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01B Engine - 2.0L Duratorq-Di (Puma)
Diesel-2.0L Duratorq-TDCi (Puma) Diesel-2.0L Duratorq-TDDi (Puma) Diesel > Description and Operation > Engine

General View Engine identification code Engine code and engine serial number The engine code
(4 positions) and the engine serial number (consisting of two letters for year and month and five
digits which produce the serial number) are located on the timing chain housing in line with the fuel
injection pump. The engine codes are assigned to the engines as follows; Vehicles without
Common Rail Fuel Injection: Vehicles with Common Rail Fuel Injection: If an exchange engine or
cylinder block is installed, the vehicle identified number (VIN) number is to be stamped at the
position shown. General The turbodiesel engine operates using the direct injection process. The
turbodiesel engines are equipped with intercooling and a water cooled EGR system and are
installed transversely. A new feature on this engine is the shape of the cylinder head. The 16
valves are operated by rockers on two rocker shafts. Two overhead camshafts, which directly
operate the rockers, and the fuel injection pump are driven by a twin chain. The intake tracts in the
cylinder head are shaped in such a way that optimum charge air swirl and fuel and mixing are
achieved at all engine speeds. Together with the electronically controlled exhaust gas return
system and the oxidative catalytic converter directly attached to the exhaust manifold flange, these
properties also help to meet the requirements of the current emissions standards. Furthermore, the
engine forms a basis for further innovation and therefore has adequate potential for future
emissions standards. The fully electronic fuel injection is controlled by an EEC V Powertrain
Control Module (PCM). Diagnosis is performed using Worldwide Diagnostic System (WDS) via the
data link connector (DLC). The engine is equipped with a modern engine management system and
advanced fuel injection, this results in reduced engine noise. Vehicles without Common Rail Fuel
Injection Measured fuel delivery is fully electronically controlled by a Bosch distributor injection
pump, one of two variants is installed depending on the power classification (VP 30 for the 75 PS /
VP 44 for the 100 PS engine). Both fuel injection pumps operate according to the "pilot injection"
principle, which results in the noise level of the engine being further reduced. Vehicles with
Common Rail Fuel Injection The fuel system consists of a low-pressure and a high-pressure side
for fuel delivery. The low-pressure system provides fuel to the high-pressure chamber of the fuel
pump and also provides sufficent lubrication and cooling of the pump. For additional information,
refer to Section 303-04A Fuel Charging and Controls / 303-04B Fuel Charging and Controls /
303-04C Fuel Charging and Controls / 303-04D Fuel Charging and Controls - Turbocharger /
303-04E Fuel Charging and Controls / 303-04F Fuel Charging and Controls / 303-04G Fuel
Charging and Controls . Cylinder head Two cut-outs are machined into the cylinder head on the
side nearest the transaxle. The inlet camshaft drives the coolant and power steering pump, and the
exhaust camshaft drives the vacuum pump. For this reason the inlet camshaft is longer than the
exhaust camshaft. Rockers The rockers on both rocker shafts are identified by a spigot. Engine
front cover The engine front mount is secured to three studs which protrude through the engine
front cover. This requires a gasket between the timing chain housing and the engine front cover.
EGR system All variants are equipped with an EGR valve with an EGR position sensor. This
sensor informs the EEC V PCM of the position of the EGR valve at any moment in time. 100 PS
and 125 PS variants Both engine variants are equipped with an EGR cooler. 75 PS variant The 75
PS engine does not have an EGR cooler. Pistons The pistons do not incorporate oil galleries due
to the reduced combustion temperature, therefore there is only one classification code (engine
cooling code = "2"). When installing the pistons, make sure that the marking on the piston skirt is
towards the engine front cover. Oil spray nozzles The engine is equipped with oil spray nozzles for
piston cooling.
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01B Engine - 2.0L Duratorq-Di (Puma)
Diesel-2.0L Duratorq-TDCi (Puma) Diesel-2.0L Duratorq-TDDi (Puma) Diesel > Description and Operation > Diagnosis and
Testing > Engine
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01B Engine - 2.0L Duratorq-Di (Puma)
Diesel-2.0L Duratorq-TDCi (Puma) Diesel-2.0L Duratorq-TDDi (Puma) Diesel > Description and Operation > Diagnosis and
Testing > In-vehicle Repair > Intake Manifold

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01B Engine - 2.0L Duratorq-Di (Puma)
Diesel-2.0L Duratorq-TDCi (Puma) Diesel-2.0L Duratorq-TDDi (Puma) Diesel > Description and Operation > Diagnosis and
Testing > In-vehicle Repair > Valve Cover - Vehicles Without: Common Rail Fuel Injection

Socket, Fuel Injector Remover/Installer 303-677 (21-236) Valve Cover, Fuel Injector Seal, Installer
303-695 (21-248) Aligner Plate, Injector 303-678 (21-237) Timing Tool, Crankshaft TDC 303-675
(21-234) Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01B Engine - 2.0L Duratorq-Di (Puma)
Diesel-2.0L Duratorq-TDCi (Puma) Diesel-2.0L Duratorq-TDDi (Puma) Diesel > Description and Operation > Diagnosis and
Testing > In-vehicle Repair > Valve Cover - Vehicles With: Common Rail Fuel Injection

Installer, Fuel Injector Seal 303-695 (21-248) Aligner, Fuel Injector 303-711 (21-258) Worldwide
Diagnostic System (WDS) 418-F224 Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01B Engine - 2.0L Duratorq-Di (Puma)
Diesel-2.0L Duratorq-TDCi (Puma) Diesel-2.0L Duratorq-TDDi (Puma) Diesel > Description and Operation > Diagnosis and
Testing > In-vehicle Repair > Crankshaft Front Seal

Holding Wrench, Crankshaft 303-1310 Remover/Installer, Crankshaft Front Oil Seal 303-679
Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01B Engine - 2.0L Duratorq-Di (Puma)
Diesel-2.0L Duratorq-TDCi (Puma) Diesel-2.0L Duratorq-TDDi (Puma) Diesel > Description and Operation > Diagnosis and
Testing > In-vehicle Repair > Engine Front Cover

Flange Holding Wrench, Universal 205-072 (15-030A) Support Bar, Engine 303-290A (21-140)
Adapter for 303-290A 303-290-02 (21-140-02) Adapter for 303-290A 303-290-03 (21-140-03)
Separator, Oil Pan 303-428 (21-179) Remover/Installer, Crankshaft Front Oil Seal 303-679
(21-238) Aligner, Front Cover 303-682 (21-241) Holding Wrench, Crankshaft 303-1177 Removal
Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01B Engine - 2.0L Duratorq-Di (Puma)
Diesel-2.0L Duratorq-TDCi (Puma) Diesel-2.0L Duratorq-TDDi (Puma) Diesel > Description and Operation > Diagnosis and
Testing > In-vehicle Repair > Valve Seals

Pliers, Valve Stem Oil Seal 303-508 (21-211) Removal Installation

Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01B Engine - 2.0L Duratorq-Di (Puma)
Diesel-2.0L Duratorq-TDCi (Puma) Diesel-2.0L Duratorq-TDDi (Puma) Diesel > Description and Operation > Diagnosis and
Testing > In-vehicle Repair > Valve Springs

Compressor, Valve Spring 303-060 (21-024) Adapter for 303-060 303-060-05 (21-024-05) Adapter
for 303-060 303-060-07 (21-024-07) Installer, Valve Stem Collets 303-362 (21-156) Removal
Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01B Engine - 2.0L Duratorq-Di (Puma)
Diesel-2.0L Duratorq-TDCi (Puma) Diesel-2.0L Duratorq-TDDi (Puma) Diesel > Description and Operation > Diagnosis and
Testing > In-vehicle Repair > Valves

Compressor, Valve Spring 303-060 (21-024) Adaptor for 303-060 303-060-05 (21-024-05) Adaptor
for 303-060 303-060-07 (21-024-07) Installer, Valve Stem Collets 303-362 (21-156) Removal
Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01B Engine - 2.0L Duratorq-Di (Puma)
Diesel-2.0L Duratorq-TDCi (Puma) Diesel-2.0L Duratorq-TDDi (Puma) Diesel > Description and Operation > Diagnosis and
Testing > In-vehicle Repair > Camshafts

Universal Flange Holding Wrench 205-072 (15-030A) Timing Tool, Crankshaft 303-675 (21-234)
Installer, Camshaft Seal 303-683 (21-242) Timing Tool, Crankshaft 303-698 (21-251) Removal
Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01B Engine - 2.0L Duratorq-Di (Puma)
Diesel-2.0L Duratorq-TDCi (Puma) Diesel-2.0L Duratorq-TDDi (Puma) Diesel > Description and Operation > Diagnosis and
Testing > In-vehicle Repair > Camshaft Seal

Flange Holding Wrench 205-072 (15-030A) Remover, Crankshaft Oil Seal 303-293 (21-143)
Installer, Camshaft Oil Seal 303-683 (21-242) Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01B Engine - 2.0L Duratorq-Di (Puma)
Diesel-2.0L Duratorq-TDCi (Puma) Diesel-2.0L Duratorq-TDDi (Puma) Diesel > Description and Operation > Diagnosis and
Testing > In-vehicle Repair > Exhaust Manifold

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01B Engine - 2.0L Duratorq-Di (Puma)
Diesel-2.0L Duratorq-TDCi (Puma) Diesel-2.0L Duratorq-TDDi (Puma) Diesel > Description and Operation > Diagnosis and
Testing > In-vehicle Repair > Cylinder Head

Dial Indicator Gauge (Metric) 205-069 (15-046) Holding Fixture, Dial Indicator Gauge 205-070
(15-022A) Remover/Installer, Cooling Hose Clamp 303-397 (24-003) Holding Fixture, Dial Indicator
Gauge 303-432 (21-183) Socket, Fuel Injector Remove/Install 303-677 (21-236) Aligner, Fuel
Injector 303-711 (21-258) Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01B Engine - 2.0L Duratorq-Di (Puma)
Diesel-2.0L Duratorq-TDCi (Puma) Diesel-2.0L Duratorq-TDDi (Puma) Diesel > Description and Operation > Diagnosis and
Testing > In-vehicle Repair > Oil Pan

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01B Engine - 2.0L Duratorq-Di (Puma)
Diesel-2.0L Duratorq-TDCi (Puma) Diesel-2.0L Duratorq-TDDi (Puma) Diesel > Description and Operation > Diagnosis and
Testing > In-vehicle Repair > Oil Pump

Aligner, Oil Pump 303-705 (21-256) Removal Installation

Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01B Engine - 2.0L Duratorq-Di (Puma)
Diesel-2.0L Duratorq-TDCi (Puma) Diesel-2.0L Duratorq-TDDi (Puma) Diesel > Description and Operation > Diagnosis and
Testing > In-vehicle Repair > Crankshaft Rear Seal

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01B Engine - 2.0L Duratorq-Di (Puma)
Diesel-2.0L Duratorq-TDCi (Puma) Diesel-2.0L Duratorq-TDDi (Puma) Diesel > Description and Operation > Diagnosis and
Testing > In-vehicle Repair > Removal > Engine

Remover/Installer, Cooling Hose Clamp 303-397 (24-003) Remover, Halfshaft 308-192 (16-057)
Removal
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01B Engine - 2.0L Duratorq-Di (Puma)
Diesel-2.0L Duratorq-TDCi (Puma) Diesel-2.0L Duratorq-TDDi (Puma) Diesel > Description and Operation > Diagnosis and
Testing > In-vehicle Repair > Removal > Disassembly > Engine

Universal Flange Holding Wrench 205-072 (15-030A) Remover/Installer, Hose Clamp 303-397
(24-003) Separator, Oil Pan 303-428 (21-179) Mounting Stand 303-435 (21-187) Mounting Bracket
for 303-435 (21-187) 303-435-06 (21-031B) Mounting Plate for 303-435-06 (21-187) 303-435-14A
(21-212A) Adapter for 303-681 303-681-01 (21-240-01) Holding Wrench, Crankshaft 303-1177
Socket Fuel Injection Pump 310-083A (23-057)
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01B Engine - 2.0L Duratorq-Di (Puma)
Diesel-2.0L Duratorq-TDCi (Puma) Diesel-2.0L Duratorq-TDDi (Puma) Diesel > Description and Operation > Diagnosis and
Testing > In-vehicle Repair > Removal > Disassembly > Disassembly and Assembly of Subassemblies > Cylinder Head

Socket, Fuel Injector (21 mm) 303-677 (21-236) Socket Wrench, Cylinder Head Temperature
Sensor 303-680 (21-239) Aligner, Fuel Injector 303-711 (21-258) Disassembly Assembly
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01B Engine - 2.0L Duratorq-Di (Puma)
Diesel-2.0L Duratorq-TDCi (Puma) Diesel-2.0L Duratorq-TDDi (Puma) Diesel > Description and Operation > Diagnosis and
Testing > In-vehicle Repair > Removal > Disassembly > Disassembly and Assembly of Subassemblies > Assembly >
Engine

Dial Indicator Gauge (Metric) 205-069 (15-046) Holding Fixture, Dial Indicator Gauge 205-070
(15-022A) Universal Flange Holding Wrench 205-072 (15-030A) Setting Gauge, Crankshaft
303-391 (21-166) Remover/Installer, Hose Clamp 303-397 (24-003) Holding Fixture, Dial Indicator
Gauge (Cylinder Liner Protrusion) 303-432 (21-183) Mounting Stand 303-435 (21-187) Mounting
Bracket for 303-435 (21-187) 303-435-06 (21-031B) Mounting Plate for 303-435-06 (21-187)
303-435-14A (21-212A) Timing Tool, Crankshaft 303-675 (21-234) Socket, Fuel Injector (21 mm)
303-677 (21-236) Remover/Installer Crankshaft Front Oil Seal 303-679 (21-238) Aligner, Engine
Front Cover 303-682 (21-241) Timing Tool, Crankshaft 303-698 (21-251) Aligner, Fuel Injector
303-711 (21-258) Holding Wrench, Crankshaft 303-1177 Socket, Fuel Injection Pump 310-083
(23-057) Assembly
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01B Engine - 2.0L Duratorq-Di (Puma)
Diesel-2.0L Duratorq-TDCi (Puma) Diesel-2.0L Duratorq-TDDi (Puma) Diesel > Description and Operation > Diagnosis and
Testing > In-vehicle Repair > Removal > Disassembly > Disassembly and Assembly of Subassemblies > Assembly >
Installation > Engine

Remover/Installer, Hose Clamp 303-397 (24-003) Installation

Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01B Engine - 2.0L Duratorq-Di (Puma)
Diesel-2.0L Duratorq-TDCi (Puma) Diesel-2.0L Duratorq-TDDi (Puma) Diesel > Specifications
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01C Engine - 2.3L DOHC-16V >
Description and Operation > Engine

Engine Code Location

Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01C Engine - 2.3L DOHC-16V >
Description and Operation > Diagnosis and Testing > Engine
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01C Engine - 2.3L DOHC-16V >
Description and Operation > Diagnosis and Testing > In-vehicle Repair > Intake Manifold

Remover/Installer, Hose Clamp 303-397 (24-003) Removal Installation

Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01C Engine - 2.3L DOHC-16V >
Description and Operation > Diagnosis and Testing > In-vehicle Repair > Engine Front Cover

Flange Holding Wrench, Universal 202-072 (15-030A) Angle Gauge, Bolt Tightening 303-174
(21-540) Remover, Crankshaft Vibration Damper 303-317 (21-147) Locking Tool, Flywheel
303-393 (21-168) Installer, Crankshaft Vibration Damper 303-510 (21-214) Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01C Engine - 2.3L DOHC-16V >
Description and Operation > Diagnosis and Testing > In-vehicle Repair > Valve Seals

Installer, Intake Valve Stem Oil Seal 303-247 (21-130A) Compressor, Valve Spring 303-361
(21-155) Adapter for 303-361 (21-155) 303-361-02 Installer, Valve Stem Collets 303-362 (21-156)
Pliers, Valve Stem Oil Seal 303-508 (21-211) Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01C Engine - 2.3L DOHC-16V >
Description and Operation > Diagnosis and Testing > In-vehicle Repair > Valves

Installer, Intake Valve Stem Oil Seal 303-247 (21-130A) Compressor, Valve Spring 303-361
(21-155) Adapter for 303-361 (21-155) 303-361-02 Installer, Valve Stem Collets 303-362 (21-156)
Pliers, Valve Stem Oil Seal 303-508 (21-211) Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01C Engine - 2.3L DOHC-16V >
Description and Operation > Diagnosis and Testing > In-vehicle Repair > Camshafts

Flange Holding Wrench, Universal 205-072 (15-030A) Removal Installation

Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01C Engine - 2.3L DOHC-16V >
Description and Operation > Diagnosis and Testing > In-vehicle Repair > Timing Chain

Flange Holding Wrench, Universal 205-072 (15-030A) Removal Installation

Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01C Engine - 2.3L DOHC-16V >
Description and Operation > Diagnosis and Testing > In-vehicle Repair > Exhaust Manifold

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01C Engine - 2.3L DOHC-16V >
Description and Operation > Diagnosis and Testing > In-vehicle Repair > Cylinder Head

Socket, Cylinder Head Bolt 303-392 (21-167) Removal Installation

Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01C Engine - 2.3L DOHC-16V >
Description and Operation > Diagnosis and Testing > In-vehicle Repair > Oil Pan

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01C Engine - 2.3L DOHC-16V >
Description and Operation > Diagnosis and Testing > In-vehicle Repair > Oil Pump

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01C Engine - 2.3L DOHC-16V >
Description and Operation > Diagnosis and Testing > In-vehicle Repair > Crankshaft Rear Seal

Installer, Crankshaft Rear Oil Seal 303-291 (21-141) Remover, Crankshaft Rear Oil Seal 303-336
(21-151) Locking tool, flywheel 303-254 (21-135) Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01C Engine - 2.3L DOHC-16V >
Description and Operation > Diagnosis and Testing > In-vehicle Repair > Removal > Engine

Remover/Installer, Hose Clamp 303-397 (24-003) Removal

Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01C Engine - 2.3L DOHC-16V >
Description and Operation > Diagnosis and Testing > In-vehicle Repair > Removal > Disassembly > Engine

Flange Holding Wrench, Universal 205-072 (15-030A) Remover, Crankshaft Vibration Damper
303-317 (21-147) Socket, Cylinder Head Bolt 303-392 (21-167) Mounting Stand 303-435 (21-187)
Mounting Bracket for 303-435-04 303-435-04 (21-064) Mounting Plate for 303-435 303-435-12
(21-150A)
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01C Engine - 2.3L DOHC-16V >
Description and Operation > Diagnosis and Testing > In-vehicle Repair > Removal > Disassembly > Disassembly and
Assembly of Subassemblies > Cylinder Head

Disassembly Assembly
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01C Engine - 2.3L DOHC-16V >
Description and Operation > Diagnosis and Testing > In-vehicle Repair > Removal > Disassembly > Disassembly and
Assembly of Subassemblies > Assembly > Engine

Flange Holding Wrench, Universal 205-072 (15-030A) Installer, Crankshaft Rear Oil Seal 303-291
(21-141) Socket, Cylinder Head Bolt 303-392 (21-167) Mounting Stand 303-435 (21-187) Mounting
Bracket for 303-435 303-435-04 (21-064) Mounting Plate for 303-435 303-435-12 (21-150A)
Installer, Crankshaft Vibration Damper 303-510 (21-214)
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01C Engine - 2.3L DOHC-16V >
Description and Operation > Diagnosis and Testing > In-vehicle Repair > Removal > Disassembly > Disassembly and
Assembly of Subassemblies > Assembly > Installation > Engine

Remover/Installer, Hose Clamp 303-397 (24-003) Installation

Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-01C Engine - 2.3L DOHC-16V >
Specifications
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-03 Engine Cooling > Specifications
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-03 Engine Cooling > Description and
Operation > Engine Cooling

Vehicles with 2.4L Diesel Engine Vehicles with 2.0L Diesel Engine Vehicles with 2.3L Engine
Engine Coolant Coolant concentration should be checked through the neck of the coolant
expansion tank with a hydrometer. The acceptable range of specific gravity (sg) must be
maintaned. For additional information, refer to Specifications in this section. The coolant used is an
orange colored Motorcraft Super Plus 2000 engine coolant. This is a non silicated organic acid
technology (OAT) coolant that must not be mixed with other coolant types. For cooling system top
up, only use coolant which meets the correct specification. For additional information, refer to
Specifications in this section.
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-03 Engine Cooling > Description and
Operation > Diagnosis and Testing > General Procedures > Cooling System Draining, Filling and Bleeding
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-03 Engine Cooling > Description and
Operation > Diagnosis and Testing > General Procedures > Removal and Installation > Thermostat - 2.0L Duratorq-Di
(Puma) Diesel-2.0L Duratorq-TDCi (Puma) Diesel-2.0L Duratorq-TDDi (Puma) Diesel

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-03 Engine Cooling > Description and
Operation > Diagnosis and Testing > General Procedures > Removal and Installation > Thermostat - 2.4L Duratorq-Di
(Puma) Diesel-2.4L Duratorq-TDCi (Puma) Diesel

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-03 Engine Cooling > Description and
Operation > Diagnosis and Testing > General Procedures > Removal and Installation > Thermostat - 2.3L DOHC-16V

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-03 Engine Cooling > Description and
Operation > Diagnosis and Testing > General Procedures > Removal and Installation > Thermostat Housing - 2.4L
Duratorq-Di (Puma) Diesel-2.4L Duratorq-TDCi (Puma) Diesel

Remover/Installer, Cooling Hose Clamp 303-397 (24-003) Removal Installation

Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-03 Engine Cooling > Description and
Operation > Diagnosis and Testing > General Procedures > Removal and Installation > Thermostat Housing - 2.0L
Duratorq-Di (Puma) Diesel-2.0L Duratorq-TDCi (Puma) Diesel-2.0L Duratorq-TDDi (Puma) Diesel

Remover/Installer, Cooling Hose Clamp 303-397 (24-003) Removal Installation

Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-03 Engine Cooling > Description and
Operation > Diagnosis and Testing > General Procedures > Removal and Installation > Coolant Pump - 2.4L Duratorq-TDCi
(Puma) Diesel

Remover/Installer, Cooling Hose Clamp 303-397 (24-003) Removal Installation

Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-03 Engine Cooling > Description and
Operation > Diagnosis and Testing > General Procedures > Removal and Installation > Coolant Pump - 2.0L Duratorq-Di
(Puma) Diesel-2.0L Duratorq-TDCi (Puma) Diesel-2.0L Duratorq-TDDi (Puma) Diesel

Remover/Installer, Cooling Hose Clamp 303-397 (24-003) Removal Installation

Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-03 Engine Cooling > Description and
Operation > Diagnosis and Testing > General Procedures > Removal and Installation > Coolant Pump - 2.3L DOHC-16V

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-03 Engine Cooling > Description and
Operation > Diagnosis and Testing > General Procedures > Removal and Installation > Radiator - 2.4L Duratorq-Di (Puma)
Diesel-2.4L Duratorq-TDCi (Puma) Diesel

Remover/Installer, Cooling Hose Clamp 303-397 (24-003) Removal Installation

Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-03 Engine Cooling > Description and
Operation > Diagnosis and Testing > General Procedures > Removal and Installation > Radiator - 2.3L DOHC-16V

Remover/Installer, Cooling Hose Clamp 303-397 (24-003) Removal Installation

Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-03 Engine Cooling > Description and
Operation > Diagnosis and Testing > General Procedures > Removal and Installation > Radiator - 2.0L Duratorq-Di (Puma)
Diesel-2.0L Duratorq-TDCi (Puma) Diesel-2.0L Duratorq-TDDi (Puma) Diesel

Remover/Installer, Cooling Hose Clamp 303-397 (24-003) Removal Installation

Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-03 Engine Cooling > Description and
Operation > Diagnosis and Testing > General Procedures > Removal and Installation > Cooling Fan

Flange Holding Wrench, Universal 205-072 (15-030A) Removal Installation

Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-03 Engine Cooling > Description and
Operation > Diagnosis and Testing > General Procedures > Removal and Installation > Cooling Fan Motor and Shroud -
2.4L Duratorq-Di (Puma) Diesel-2.4L Duratorq-TDCi (Puma) Diesel, Vehicles With: Air Conditioning

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-03 Engine Cooling > Description and
Operation > Diagnosis and Testing > General Procedures > Removal and Installation > Cooling Fan Motor and Shroud -
2.0L Duratorq-Di (Puma) Diesel-2.0L Duratorq-TDCi (Puma) Diesel-2.0L Duratorq-TDDi (Puma) Diesel,

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-03 Engine Cooling > Description and
Operation > Diagnosis and Testing > General Procedures > Removal and Installation > Cooling Fan Shroud - 2.4L
Duratorq-Di (Puma) Diesel-2.4L Duratorq-TDCi (Puma) Diesel, Vehicles Without: Air Conditioning

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-03 Engine Cooling > Description and
Operation > Diagnosis and Testing > General Procedures > Removal and Installation > Cooling Fan Motor and Shroud -
2.3L DOHC-16V

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-03 Engine Cooling > Description and
Operation > Diagnosis and Testing > Engine Cooling

Pressure Tester, Cooling System 303-396 (24-001A) Adapter for 303-396 303-396-01 Adapter for
303-396 303-396-05 Inspection and Verification Visual Inspection Chart Symptom Chart Symptom
Chart Component Tests Pressure Test Radiator Leak Test, Removed From Vehicle Clean the
radiator thoroughly before leak testing it, to prevent contamination of the water in the test tank.
Leak test the radiator in clean water with 138 kpa (20 psi) air pressure. Check it thoroughly for air
leaks. INSTALL a new radiator if necessary. REFER to: Radiator - 2.4L Duratorq-Di (Puma)
Diesel/2.4L Duratorq-TDCi (Puma) Diesel (303-03 Engine Cooling, Removal and Installation) /
Radiator - 2.0L Duratorq-Di (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.0L Duratorq-TDDi
(Puma) Diesel (303-03 Engine Cooling, Removal and Installation) / Radiator - 2.3L DOHC-16V
(303-03 Engine Cooling, Removal and Installation). Coolant Expansion Tank Cap Pressure Test
Thermostat Test The IAT sensor output is useful if the engine being tested is cold or after an
over-night cold soak. The ECT sensor or CHT sensor and the IAT sensor should either indicate the
same value or be within 1 to 2 degrees Celsius of each other. The ECT sensor output is important
to display as it indicates the engine warm-up and opening temperature for the thermostat. It will
initially indicate a slightly higher reading just before the thermostat opens and then drops back
before settling to a near flat line output (see graphic below). If the WDS only allows the ECT sensor
to be displayed in volts, refer to the following table for corresponding Celsius values: The CHT
sensor output is useful to examine the cylinder head temperature rise during the warm-up cycle
and later during the normal light throttle cruise test. This sensor output may vary between vehicles
with manual transmission and vehicles with automatic transmission and should be used for
reference only. The LOAD display is used for reference as it is necessary to maintain a stable load
line during the test. It is necessary to carry out the test under normal light throttle cruise driving
conditions and average loads, typically 40% to 70% of the load value. The VSS output is used for
reference but can help to identify misfires and sensors which fail during the warm-up cycle. The
RPM display indicates the engine speed and can be compared with the DSRPM. The DSRPM is
the desired or calculated idle speed which the PCM commands the engine to reach. If the
thermostat opens too early (before the correct opening temperature has been reached), the engine
will not reach this value. When using the WDS in data logger mode, the signals recorded should
remain within the DEFAULT values set by the WDS. The graphic below shows the location and an
example of the opening temperature (88oC) and fully open temperature (102oC) of a thermostat.
The graphic below shows an alternative method used to show the opening temperature (88oC) and
fully open temperature (112oC) of a thermostat. The engine should start cleanly and the ECT value
will rise quite quickly with smooth progression. If the ECT signal appears unstable or erratic, the
ECT sensor, electrical connector and wiring harness to the PCM need to be visually inspected for
damage, chafing or water ingress. The temperature should rise to approximately 90oC for a
thermostat that has an 88oC value. The signal value will then fall as cooler coolant enters the
engine. If the ECT value fails to maintain a constant value and falls back to lower figures, typically
between 60oC (140oF) and 70oC (150oF), the thermostat and its sealing function within the
thermostat housing must be checked.
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-04A Fuel Charging and Controls - 2.4L
Duratorq-Di (Puma) Diesel > Description and Operation > Fuel Charging and Controls
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-04A Fuel Charging and Controls - 2.4L
Duratorq-Di (Puma) Diesel > Description and Operation > Diagnosis and Testing > Fuel Charging and Controls - Vehicles
With: Exhaust Gas Recirculation (EGR)

Inspection and Verification Verify the power output of the vehicle: Visual Inspection Chart Symptom
Chart Symptom Chart
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-04A Fuel Charging and Controls - 2.4L
Duratorq-Di (Puma) Diesel > Description and Operation > Diagnosis and Testing > General Procedures > Idle Speed
Adjustment
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-04A Fuel Charging and Controls - 2.4L
Duratorq-Di (Puma) Diesel > Description and Operation > Diagnosis and Testing > General Procedures > Removal and
Installation > Fuel Injectors

Socket, Fuel Injector Remover/Installer 303-677 (21-236) Aligner, Fuel Injector 303-711 (21-258)
Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-04A Fuel Charging and Controls - 2.4L
Duratorq-Di (Puma) Diesel > Description and Operation > Diagnosis and Testing > General Procedures > Removal and
Installation > Fuel Injection Pump - 75 PS-90 PS

Remover/Installer, Crankshaft Oil Seal 303-679 (21-238) Timing Tool, Crankshaft TDC 303-675
(21-234) Locking Tool, Fuel Injection Pump Sprocket 303-1151 Socket, Fuel Injection Pump
310-083 (23-057) Hand Pressure Pump with Adapter Kit 310-110 Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-04A Fuel Charging and Controls - 2.4L
Duratorq-Di (Puma) Diesel > Description and Operation > Diagnosis and Testing > General Procedures > Removal and
Installation > Fuel Injection Pump - 120 PS

Timing Tool, Crankshaft TDC 303-675 (21-234) Remover/Installer, Crankshaft Oil Seal 303-679
(21-238) Locking Tool, Fuel Injection Pump Sprocket 303-1151 Socket, Fuel Injection Pump
310-083 (23-057) Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-04A Fuel Charging and Controls - 2.4L
Duratorq-Di (Puma) Diesel > Description and Operation > Diagnosis and Testing > General Procedures > Removal and
Installation > Fuel Injection Timing Solenoid

Removal 1. Discard the oil cooler seal. Installation 1. Trim the new fuel injection timing solenoid
wiring harness and the fuel injection pump fuel injection timing solenoid wiring harness to produce
staggered joints. 2. Using the pink crimp electrical connectors, supplied in the service kit, join the
new fuel injection timing solenoid wiring harness to the fuel injection pump fuel injection timing
solenoid wiring harness. 3. Using a heat gun , heat shrink the two electrical connectors to the fuel
injection timing solenoid wiring harness.
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-04A Fuel Charging and Controls - 2.4L
Duratorq-Di (Puma) Diesel > Description and Operation > Diagnosis and Testing > General Procedures > Removal and
Installation > Fuel Injection One-Way Valve

Hand Pressure Pump with Adapter Kit 310-110 Removal Installation

Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-04A Fuel Charging and Controls - 2.4L
Duratorq-Di (Puma) Diesel > Description and Operation > Diagnosis and Testing > General Procedures > Removal and
Installation > Fuel Metering Valve

Wrench, Fuel Pump Solenoid 303-1286 Removal Installation

Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-04A Fuel Charging and Controls - 2.4L
Duratorq-Di (Puma) Diesel > Specifications
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-04B Fuel Charging and Controls - 2.0L
Duratorq-Di (Puma) Diesel-2.0L Duratorq-TDDi (Puma) Diesel > Description and Operation > Fuel Charging and Controls
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-04B Fuel Charging and Controls - 2.0L
Duratorq-Di (Puma) Diesel-2.0L Duratorq-TDDi (Puma) Diesel > Description and Operation > Diagnosis and Testing > Fuel
Charging and Controls

Inspection and Verification Verify the power output of the vehicle: Visual Inspection Chart Symptom
Chart Symptom Chart
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-04B Fuel Charging and Controls - 2.0L
Duratorq-Di (Puma) Diesel-2.0L Duratorq-TDDi (Puma) Diesel > Description and Operation > Diagnosis and Testing >
Removal and Installation > Fuel Injectors

Socket, Fuel Injector Remover/Installer 303-677 (21-236) Aligner, Fuel Injector 303-711 (21-258)
Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-04B Fuel Charging and Controls - 2.0L
Duratorq-Di (Puma) Diesel-2.0L Duratorq-TDDi (Puma) Diesel > Description and Operation > Diagnosis and Testing >
Removal and Installation > Fuel Injection Pump

Timing Tool, Crankshaft TDC 303-675 (21-234) Remover/Installer, Crankshaft Oil Seal 303-679
(21-238) Locking Tool, Fuel Injection Pump Sprocket 303-1151 Socket, Fuel Injection Pump
310-083 (23-057) Hand Pressure Pump with Adapter Kit 310-110 Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-04B Fuel Charging and Controls - 2.0L
Duratorq-Di (Puma) Diesel-2.0L Duratorq-TDDi (Puma) Diesel > Description and Operation > Diagnosis and Testing >
Removal and Installation > Fuel Injection One-Way Valve

Hand Pressure Pump with Adapter Kit 310-110 Removal Installation

Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-04B Fuel Charging and Controls - 2.0L
Duratorq-Di (Puma) Diesel-2.0L Duratorq-TDDi (Puma) Diesel > Description and Operation > Diagnosis and Testing >
Removal and Installation > Fuel Injection Timing Solenoid

Removal Installation 1. Trim the new fuel injection timing solenoid wiring harness and the fuel
injection pump fuel injection timing solenoid wiring harness to produce staggered joints. 2. Using
the pink crimp electrical connectors, supplied in the service kit, join the new fuel injection timing
solenoid wiring harness to the fuel injection pump fuel injection timing solenoid wiring harness. 3.
Using a heat gun , heat shrink the two electrical connectors to the fuel injection timing solenoid
wiring harness.
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-04B Fuel Charging and Controls - 2.0L
Duratorq-Di (Puma) Diesel-2.0L Duratorq-TDDi (Puma) Diesel > Description and Operation > Diagnosis and Testing >
Removal and Installation > Fuel Metering Valve

Wrench, Fuel Pump Solenoid 303-1286 Removal Installation

Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-04B Fuel Charging and Controls - 2.0L
Duratorq-Di (Puma) Diesel-2.0L Duratorq-TDDi (Puma) Diesel > Specifications
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-04C Fuel Charging and Controls - 2.3L
DOHC-16V > Specifications
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-04C Fuel Charging and Controls - 2.3L
DOHC-16V > Description and Operation > Diagnosis and Testing > Fuel Charging and Controls
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-04C Fuel Charging and Controls - 2.3L
DOHC-16V > Description and Operation > Diagnosis and Testing > Removal and Installation > Throttle Body

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-04C Fuel Charging and Controls - 2.3L
DOHC-16V > Description and Operation > Diagnosis and Testing > Removal and Installation > Fuel Injection Supply
Manifold

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-04C Fuel Charging and Controls - 2.3L
DOHC-16V > Description and Operation > Fuel Charging and Controls
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-04D Fuel Charging and Controls -
Turbocharger > Specifications
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-04D Fuel Charging and Controls -
Turbocharger > Description and Operation > Turbocharger
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-04D Fuel Charging and Controls -
Turbocharger > Description and Operation > Diagnosis and Testing > Turbocharger

Hand Vacuum/Pressure Pump 416-D001 (23-036A) Principles of Operation - Vehicles with fixed
vane turbocharger The turbocharger is governed by a wastegate control valve. The wastegate
control valve redirects some of the exhaust gas past the turbine and therefore acts as a governor.
The wastegate control valve is preset during manufacture and must not be tampered with.
Principles of Operation - Vehicles with variable vane turbocharger The turbocharger is designed to
improve engine induction and engine performance. The list below details the concerns relating to
turbocharger performance. The variable vane turbocharger does not have a wastegate control
valve. Instead, it has variable turbocharger vanes which are located in the turbocharger turbine
housing. The turbocharger vanes act as the control for the turbocharger boost pressure. The
variable turbocharger produces its full turbocharger boost pressure over the entire engine speed
range, not just at high engine speed. This is achieved through the adjustment of the vanes and the
resulting change in the velocity of the exhaust gas. The speed of flow of the stream of exhaust gas
is increased independent of engine speed by varying the intake cross section in front of the
turbocharger turbine. The variable vanes are controlled by the PCM. A duty cycle signal from the
powertrain control module (PCM), controls a vacuum supply to the turbocharger vacuum
diaphragm unit using a solenoid valve. Regulation at Low Engine Speed At low engine speeds the
PCM actuates the vane adjustment solenoid valve to enable a vacuum to be applied. The vacuum
diaphragm unit moves the adjusting ring so that the vanes are set at a shallow angle. The reduced
intake cross section this creates for the stream of exhaust gas increases the exhaust gas velocity
allowing the turbocharger boost pressure to build up rapidly and easily at low engine speeds.
Regulation at Moderate Engine Speed As the engine speed increases and the quantity of exhaust
gas increases as a result, the vane adjustment solenoid valve adjusts the vacuum level within the
vacuum diaphragm unit. The vacuum diaphragm unit moves the adjusting ring so that the vanes
are set at a steeper angle. The steeper angle opens the intake cross section effectively reducing
the gas flow and turbine speed while maintaining constant turbocharger boost pressure. Regulation
at Maximum Engine Speed As the engine speed increases the intake cross section in front of the
turbocharger turbine is continuously enlarged. The turbine speed and hence the quantity of the air
supplied to the engine, is adjusted to suit the engine speed. This means that the turbocharger
boost pressure remains optimized over all engine speeds. The maximum position of the
turbocharger vanes (maximum opening cross section) is also an emergency position e.g. in the
event of an electrical concern or leak in the vacuum system. Therefore, there is little chance of
engine damage due to excessive boost in the event of a turbocharger control concern. Inspection
and Verification Visual Inspection Chart Symptom Chart Symptom Chart Pinpoint Tests PINPOINT
TEST A : BLUE SMOKE WITH EXCESSIVE TURBOCHARGER NOISE PINPOINT TEST B :
BLUE SMOKE WITHOUT EXCESSIVE TURBOCHARGER NOISE PINPOINT TEST C : POOR
ENGINE PERFORMANCE PINPOINT TEST D : POOR ENGINE PERFORMANCE
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-04D Fuel Charging and Controls -
Turbocharger > Description and Operation > Diagnosis and Testing > Removal and Installation > Turbocharger - 2.4L
Duratorq-Di (Puma) Diesel-2.4L Duratorq-TDCi (Puma) Diesel

Removal
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-04D Fuel Charging and Controls -
Turbocharger > Description and Operation > Diagnosis and Testing > Removal and Installation > Turbocharger - 2.0L
Duratorq-Di (Puma) Diesel-2.0L Duratorq-TDCi (Puma) Diesel-2.0L Duratorq-TDDi (Puma) Diesel

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-04E Fuel Charging and Controls -
Liquified Petroleum Gas (LPG) > Specifications
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-04E Fuel Charging and Controls -
Liquified Petroleum Gas (LPG) > Description and Operation > Fuel Charging and Controls
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-04E Fuel Charging and Controls -
Liquified Petroleum Gas (LPG) > Description and Operation > Diagnosis and Testing > Fuel Charging and Controls

Inspection and Verification Visual Inspection Chart Diagnostic Trouble Codes (DTCs) Index DTC
Index Chart Symptom Chart Symtom Chart
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-04E Fuel Charging and Controls -
Liquified Petroleum Gas (LPG) > Description and Operation > Diagnosis and Testing > Removal and Installation > Throttle
Body

Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-04E Fuel Charging and Controls -
Liquified Petroleum Gas (LPG) > Description and Operation > Diagnosis and Testing > Removal and Installation > Fuel
Vaporizer

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-04E Fuel Charging and Controls -
Liquified Petroleum Gas (LPG) > Description and Operation > Diagnosis and Testing > Removal and Installation > Fuel
Injectors

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-04E Fuel Charging and Controls -
Liquified Petroleum Gas (LPG) > Description and Operation > Diagnosis and Testing > Removal and Installation > Fuel
Vaporizer Filter Element

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-04E Fuel Charging and Controls -
Liquified Petroleum Gas (LPG) > Description and Operation > Diagnosis and Testing > Removal and Installation >
Alternative Fuel Control Module

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-04E Fuel Charging and Controls -
Liquified Petroleum Gas (LPG) > Description and Operation > Diagnosis and Testing > Removal and Installation > Fuel
Injection Supply Manifold

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-04F Fuel Charging and Controls - 2.0L
Duratorq-TDCi (Puma) Diesel > Specifications
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-04F Fuel Charging and Controls - 2.0L
Duratorq-TDCi (Puma) Diesel > Description and Operation > Fuel Charging and Controls
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-04F Fuel Charging and Controls - 2.0L
Duratorq-TDCi (Puma) Diesel > Description and Operation > Diagnosis and Testing > Fuel Charging and Controls

Diagnostic Tool, Common Rail Fuel Injection 310-129 Hand Pressure Pump with Adapter Kit
310-110 Test Hose for 310-025 310-025-18 Test Hose for 310-025 310-025-19A Principles of
Operation System overview The common rail fuel system shown is known as the two box system
comprising of a separate injector driver module (IDM) and powertrain control module (PCM). Later
versions of this system combined the IDM and PCM into one unit known simply as the PCM. To
meet the increasing demands for lower exhaust emissions, greater economy, improved driving
characteristic's, lower noise output and increased power output from modern diesel engines, the
vehicle requires a fuel supply system which can deliver small fuel droplets at high speed with
refined control. The common rail fuel injection system has been introduced to the diesel engine to
meet these demands. The Delphi system fitted to the 2.0L and 2.4L diesel engines fulfills this role
by using controlled high-pressure fuel delivery to individually electronically controlled injectors. Fuel
pump fuel supply The fuel system on this vehicle is designed to prevent the fuel tank and fuel
injection system being run dry. When the fuel tank level reaches a preset limit, after the low fuel
indicator has been illuminated, the engine will be made to run rough to indicate that the fuel level in
the fuel tank is very low. To protect the fuel injection components if this warning is ignored, the
IDM/PCM will terminate the fuel injection process and the engine will stop. The fuel filter element in
the common rail fuel system is designed to extract far smaller particles from the fuel supply than
conventional fuel filters. To aid with the rapid warm up of the fuel supply to the fuel pump, the fuel
filter is fitted with a temperature conscious fuel return bypass valve. At temperatures below 50°C,
the bypass valve is fully open and the majority of the returned fuel is circulated through the fuel
filter and back to the fuel pump. When the fuel temperature in the fuel filter has reached a
temperature above 50°C, the fuel return bypass valve closes and the returned fuel is delivered
back to the fuel tank. The return fuel cannot be allowed to continue to circulate through the fuel
filter after 50°C as the temperatures produced by compressing the fuel to such high pressures
would cause the fuel to overheat. When the fuel is returned to the fuel tank, the fuel line which
transfers the fuel along the underbody, cools the fuel sufficiently to prevent overheat concerns.
High-pressure fuel pump Fuel is drawn from the fuel tank through the fuel filter by means of a
transfer pump. The transfer pump is built into the high-pressure pump and driven by the
high-pressure pump input shaft. Fuel from the transfer pump is passed through the high-pressure
pump low pressure fuel inlet channel into the high-pressure fuel pump chamber. In the
high-pressure pump low pressure fuel inlet channel is situated a fuel metering valve. The fuel
metering valve is controlled by the IDM/PCM. A fuel pressure sensor input signal is used by the
IDM/PCM to calculate the position required by the fuel metering valve to achieve the desired fuel
rail pressure. The fuel metering valve reduces the cross sectional area of the high-pressure pump
low pressure fuel inlet channel and so decreases the quantity of fuel allowed to reach the
high-pressure fuel pump chamber. Located in the rear of the fuel pump is a fuel temperature
sensor which monitors the fuel transfer pump fuel delivery temperature. The sensor information is
used by the IDM/PCM to adjust the fuel metering valve to compensate for cold fuel charge values.
If the fuel temperature sensor or its related circuits become shorted to ground, the engine will shut
down and not restart. If the fuel temperature sensor or its related circuits become open circuit, the
engine management system will default to a value of 39°C and cold start characteristics will be
impaired. Fuel pump high-pressure fuel development Fuel enters the high-pressure fuel pump
chamber through a fuel inlet valve. The inlet valve will only allow fuel to enter the fuel pump
chamber, if the fuel pressure in the chamber is lower than the pressure in the high-pressure pump
low pressure fuel inlet channel. Fuel entering the high-pressure fuel pump chamber, forces the fuel
pump piston's outwards and holds the fuel pump piston roller and shoe against the high-pressure
fuel pump cam ring. The high-pressure fuel pump fuel outlet valve will remain closed until the fuel
pressure inside the high-pressure fuel pump chamber exceeds the pressure in the fuel rail. As the
high-pressure fuel pump cam ring rotates, the fuel pump roller, shoe and piston is forced by the
cam lobe inwards compressing the fuel held in the high-pressure fuel pump chamber. The fuel
pressure in the high-pressure fuel pump chamber rises above the fuel pressure developed by the
transfer pump and the fuel inlet valve is closed. As the fuel in the high-pressure fuel pump chamber
exceeds the pressure of the fuel in the fuel rail, the fuel outlet valve opens and high-pressure fuel is
delivered to the fuel rail. Fuel from the high-pressure fuel pump chamber will enter the fuel rail until
the fuel pump pistons have reached the maximum delivery movement. At this point the fuel
pressure in the high-pressure fuel pump chamber drops to below the pressure of the fuel in the fuel
rail and the fuel outlet valve is closed. For each full rotation of the fuel pump cam ring, the fuel
pump pistons go through four compression cycles. As a safety precaution, built into the fuel pump
body is a high-pressure fuel relief valve. If the fuel pump fuel pressure exceeds the maximum
permissible value, the fuel relief valve will open and vent the excess fuel pressure into the fuel
pump inner chamber. Fuel pump fuel flow and control Under normal demand conditions, fuel is
delivered to the high-pressure fuel pump chamber unrestricted where it is compressed and
delivered to the fuel rail. A small proportion of fuel is diverted through the calibrated fuel pump fuel
return bore. This returned fuel is used to lubricate and cool the high-pressure pump. As the fuel
exits through the fuel return line venturi, the accelerated flow across the injector return line orifice
creates a partial vacuum in the fuel injector return line. This partial vacuum assists with the
scavenging of fuel injector fuel return fuel. When the engine is off demand (decelerating), the fuel
shut-off valve restricts the high-pressure pump fuel supply. As the pressure in the high-pressure
pump low pressure fuel inlet channel increases, the low pressure fuel control valve opens and
recirculates low pressure fuel through the fuel transfer pump. Fuel rail The fuel rail function, is to
supply a reservoir of fuel at a constant controlled pressure to all four fuel injectors. The action of
the fuel injectors opening and closing causes changes in pressure to the fuel behind the fuel
injector. The fuel rail acts as an accumulator, minimizing this affect. The volume of fuel held by the
fuel rail cannot be to large as this will cause a increase in pressurization time and a corresponding
increase in engine start time. The four fuel injector high-pressure fuel lines attached to the fuel rail
are of equal length. This is to eliminate any variation in delivery pressure at the fuel injectors. Fitted
into the fuel rail is the fuel pressure sensor. The fuel pressure sensor monitors the current fuel
pressure available at the fuel injectors. The fuel pressure sensor is a non serviceable component.
Due to the tapered thread construction of the fuel rail union, a fuel tight seal capable of
withstanding the high fuel pressures cannot be guaranteed. So the fuel rail and fuel pressure
sensor must be renewed as one component. If the fuel pressure sensor does not see a minimum
preset value during cranking, the IDM/PCM will not allow the fuel injectors to inject and the engine
will not start. If the fuel pressure sensor signal to the IDM/PCM is lost or the value indicated does
not match the expected value for the given engine condition, the fuel metering valve will default to
the closed position and will not allow the development of the high-pressure fuel supply. Fuel
injector The fuel injector consists of two main sections. The solenoid control valve has a switching
time of approximately 0.3 milliseconds. This short switching time is achieved by keeping the
moving components and the distances required to function to a minimum. The design of the fuel
injector chambers means that at no time does the solenoid control valve work against any major
forces other than that of the solenoid valve spring. The fuel injector needle works on a combination
of hydraulic and spring control. All injectors are calibrated to take into account manufacturing
tolerances. These calibrations are indicated on the exterior of the injector by a code. The code is
used by the IDM/PCM to adjust the duration of the injection cycle. If the codes for the individual
injector's are incorrectly matched to the codes stored in the IDM/PCM, the engine may exhibit
rough idle, increased combustion noise and black smoke emissions. Fuel injector working state
closed With the solenoid valve de-energised, the injection control valve is held in the closed
position by the injection control valve spring. Fuel pressure above and below the injection control
valve is slightly above atmospheric pressure during engine run conditions. Fuel pressure in the
injector needle upper chamber and injector needle lower chamber is equal to the high-pressure fuel
feed pressure. The injector needle is held in the closed position by the injector needle control
spring. Fuel injector working state opening The fuel injection process starts with a voltage being
applied to the solenoid valve with a pull-in current of 12 amperes. The solenoid valve moves the
injection control valve against the pressure of the injection control valve spring. The injection
control valve releases the high fuel pressure from the injector needle upper chamber and vents the
excess pressure out through the fuel injector fuel return bore. The fuel pressure does not drop
instantly but is slowed down by the injector needle upper control chamber fuel outlet choke.
High-pressure fuel entering the injector needle upper chamber and the injection control valve
chambers is restricted by the very small diameters of the injector needle upper chamber fuel inlet
choke and the control chamber inlet choke. Fuel injector working state injecting During the injection
state of the process, the current applied to the solenoid valve is reduced to 6 amperes. This value
is sufficient to maintain the injection control valve in the open position. As the fuel pressure in the
injector needle upper chamber decays, the fuel pressure in the injector needle lower chamber
forces the injector needle open against the injector needle control spring. Fuel is injected into the
engine combustion chamber. Fuel will continue to be injected as long as the fuel pressure in the
injector needle lower chamber is higher than the combined force of the fuel pressure in the injector
needle upper chamber and the injector needle control spring. Fuel injector working state closing
When the fuel injection process has reached the desired injection duration, the solenoid valve is
de-energised. The injection control valve spring closes the injection control valve and the fuel
pressure in the injector needle upper chamber rises to equal the pressure of the injector needle
lower chamber. As the pressures equalize, the injector needle spring closes the injector needle so
preventing fuel injection. To prevent a sudden increase in the pressure in the injector needle lower
chamber as the injector needle closes, the fuel entering the chamber is restricted by the injector
needle lower chamber fuel inlet choke. Fuel injector fuel return The fuel injector fuel return is
required to make the fuel injectors function. The amount of return fuel developed during the normal
functioning of a fuel injector indicates the condition of that injector. By measurement and
comparison of fuel injector fuel return quantities, diagnosis of the fuel injectors is possible.
Inspection and Verification Visual Inspection Chart Symptom Chart PINPOINT TEST A : FUEL
INJECTOR BACK LEAK TEST - VEHICLES WITHOUT IDM Example: PINPOINT TEST B : FUEL
INJECTOR BACK LEAK TEST - VEHICLES WITH IDM Example: PINPOINT TEST C : FUEL
PUMP FUEL SUPPLY TEST PINPOINT TEST D : FUEL INJECTOR BACK LEAK TEST -
VEHICLES WITHOUT IDM PINPOINT TEST E : FUEL INJECTOR BACK LEAK TEST -
VEHICLES WITH IDM Example:
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-04F Fuel Charging and Controls - 2.0L
Duratorq-TDCi (Puma) Diesel > Description and Operation > Diagnosis and Testing > General Procedures > Fuel Injection
Component Cleaning
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-04F Fuel Charging and Controls - 2.0L
Duratorq-TDCi (Puma) Diesel > Description and Operation > Diagnosis and Testing > General Procedures > Removal and
Installation > Fuel Injectors

Socket, Fuel Injector Remover/Installer 303-677 (21-236) Aligner, Fuel Injector 303-711 (21-258)
Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-04F Fuel Charging and Controls - 2.0L
Duratorq-TDCi (Puma) Diesel > Description and Operation > Diagnosis and Testing > General Procedures > Removal and
Installation > Fuel Pump

Remover/Installer, Crankshaft Oil Seal 303-679 (21-238) Locking Tool, Fuel Ijection Pump
Sprocket 303-1151 Socket, Fuel Injection Pump 310-083 (23-057) Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-04F Fuel Charging and Controls - 2.0L
Duratorq-TDCi (Puma) Diesel > Description and Operation > Diagnosis and Testing > General Procedures > Removal and
Installation > Fuel Injection Supply Manifold

Aligner, Fuel Injector 303-711 (21-258) Removal Installation

Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-04F Fuel Charging and Controls - 2.0L
Duratorq-TDCi (Puma) Diesel > Description and Operation > Diagnosis and Testing > General Procedures > Removal and
Installation > Fuel Return Line Venturi

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-04F Fuel Charging and Controls - 2.0L
Duratorq-TDCi (Puma) Diesel > Description and Operation > Diagnosis and Testing > General Procedures > Removal and
Installation > Fuel Metering Valve

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-04G Fuel Charging and Controls - 2.4L
Duratorq-TDCi (Puma) Diesel > Specifications
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-04G Fuel Charging and Controls - 2.4L
Duratorq-TDCi (Puma) Diesel > Description and Operation > Fuel Charging and Controls
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-04G Fuel Charging and Controls - 2.4L
Duratorq-TDCi (Puma) Diesel > Description and Operation > Diagnosis and Testing > Fuel Charging and Controls

Diagnostic Tool, Common Rail Fuel Injection 310-129 Hand Pressure Pump with Adapter Kit
310-110 Test Hose for 310-025 310-025-18 Test Hose for 310-025 310-025-19A Principles of
Operation System overview The common rail fuel system shown is known as the two box system
comprising of a separate injector driver module (IDM) and powertrain control module (PCM). Later
versions of this system combined the IDM and PCM into one unit known simply as the PCM. To
meet the increasing demands for lower exhaust emissions, greater economy, improved driving
characteristic's, lower noise output and increased power output from modern diesel engines, the
vehicle requires a fuel supply system which can deliver small fuel droplets at high speed with
refined control. The common rail fuel injection system has been introduced to the diesel engine to
meet these demands. The Delphi system fitted to the 2.0L and 2.4L diesel engines fulfills this role
by using controlled high-pressure fuel delivery to individually electronically controlled injectors. Fuel
pump fuel supply The fuel system on this vehicle is designed to prevent the fuel tank and fuel
injection system being run dry. When the fuel tank level reaches a preset limit, after the low fuel
indicator has been illuminated, the engine will be made to run rough to indicate that the fuel level in
the fuel tank is very low. To protect the fuel injection components if this warning is ignored, the
IDM/PCM will terminate the fuel injection process and the engine will stop. The fuel filter element in
the common rail fuel system is designed to extract far smaller particles from the fuel supply than
conventional fuel filters. To aid with the rapid warm up of the fuel supply to the fuel pump, the fuel
filter is fitted with a temperature conscious fuel return bypass valve. At temperatures below 50°C,
the bypass valve is fully open and the majority of the returned fuel is circulated through the fuel
filter and back to the fuel pump. When the fuel temperature in the fuel filter has reached a
temperature above 50°C, the fuel return bypass valve closes and the returned fuel is delivered
back to the fuel tank. The return fuel cannot be allowed to continue to circulate through the fuel
filter after 50°C as the temperatures produced by compressing the fuel to such high pressures
would cause the fuel to overheat. When the fuel is returned to the fuel tank, the fuel line which
transfers the fuel along the underbody, cools the fuel sufficiently to prevent overheat concerns.
High-pressure fuel pump Fuel is drawn from the fuel tank through the fuel filter by means of a
transfer pump. The transfer pump is built into the high-pressure pump and driven by the
high-pressure pump input shaft. Fuel from the transfer pump is passed through the high-pressure
pump low pressure fuel inlet channel into the high-pressure fuel pump chamber. In the
high-pressure pump low pressure fuel inlet channel is situated a fuel metering valve. The fuel
metering valve is controlled by the IDM/PCM. A fuel pressure sensor input signal is used by the
IDM/PCM to calculate the position required by the fuel metering valve to achieve the desired fuel
rail pressure. The fuel metering valve reduces the cross sectional area of the high-pressure pump
low pressure fuel inlet channel and so decreases the quantity of fuel allowed to reach the
high-pressure fuel pump chamber. Located in the rear of the fuel pump is a fuel temperature
sensor which monitors the fuel transfer pump fuel delivery temperature. The sensor information is
used by the IDM/PCM to adjust the fuel metering valve to compensate for cold fuel charge values.
If the fuel temperature sensor or its related circuits become shorted to ground, the engine will shut
down and not restart. If the fuel temperature sensor or its related circuits become open circuit, the
engine management system will default to a value of 39°C and cold start characteristics will be
impaired. Fuel pump high-pressure fuel development Fuel enters the high-pressure fuel pump
chamber through a fuel inlet valve. The inlet valve will only allow fuel to enter the fuel pump
chamber, if the fuel pressure in the chamber is lower than the pressure in the high-pressure pump
low pressure fuel inlet channel. Fuel entering the high-pressure fuel pump chamber, forces the fuel
pump piston's outwards and holds the fuel pump piston roller and shoe against the high-pressure
fuel pump cam ring. The high-pressure fuel pump fuel outlet valve will remain closed until the fuel
pressure inside the high-pressure fuel pump chamber exceeds the pressure in the fuel rail. As the
high-pressure fuel pump cam ring rotates, the fuel pump roller, shoe and piston is forced by the
cam lobe inwards compressing the fuel held in the high-pressure fuel pump chamber. The fuel
pressure in the high-pressure fuel pump chamber rises above the fuel pressure developed by the
transfer pump and the fuel inlet valve is closed. As the fuel in the high-pressure fuel pump chamber
exceeds the pressure of the fuel in the fuel rail, the fuel outlet valve opens and high-pressure fuel is
delivered to the fuel rail. Fuel from the high-pressure fuel pump chamber will enter the fuel rail until
the fuel pump pistons have reached the maximum delivery movement. At this point the fuel
pressure in the high-pressure fuel pump chamber drops to below the pressure of the fuel in the fuel
rail and the fuel outlet valve is closed. For each full rotation of the fuel pump cam ring, the fuel
pump pistons go through four compression cycles. As a safety precaution, built into the fuel pump
body is a high-pressure fuel relief valve. If the fuel pump fuel pressure exceeds the maximum
permissible value, the fuel relief valve will open and vent the excess fuel pressure into the fuel
pump inner chamber. Fuel pump fuel flow and control Under normal demand conditions, fuel is
delivered to the high-pressure fuel pump chamber unrestricted where it is compressed and
delivered to the fuel rail. A small proportion of fuel is diverted through the calibrated fuel pump fuel
return bore. This returned fuel is used to lubricate and cool the high-pressure pump. As the fuel
exits through the fuel return line venturi, the accelerated flow across the injector return line orifice
creates a partial vacuum in the fuel injector return line. This partial vacuum assists with the
scavenging of fuel injector fuel return fuel. When the engine is off demand (decelerating), the fuel
shut-off valve restricts the high-pressure pump fuel supply. As the pressure in the high-pressure
pump low pressure fuel inlet channel increases, the low pressure fuel control valve opens and
recirculates low pressure fuel through the fuel transfer pump. Fuel rail The fuel rail function, is to
supply a reservoir of fuel at a constant controlled pressure to all four fuel injectors. The action of
the fuel injectors opening and closing causes changes in pressure to the fuel behind the fuel
injector. The fuel rail acts as an accumulator, minimizing this affect. The volume of fuel held by the
fuel rail cannot be to large as this will cause a increase in pressurization time and a corresponding
increase in engine start time. The four fuel injector high-pressure fuel lines attached to the fuel rail
are of equal length. This is to eliminate any variation in delivery pressure at the fuel injectors. Fitted
into the fuel rail is the fuel pressure sensor. The fuel pressure sensor monitors the current fuel
pressure available at the fuel injectors. The fuel pressure sensor is a non serviceable component.
Due to the tapered thread construction of the fuel rail union, a fuel tight seal capable of
withstanding the high fuel pressures cannot be guaranteed. So the fuel rail and fuel pressure
sensor must be renewed as one component. If the fuel pressure sensor does not see a minimum
preset value during cranking, the IDM/PCM will not allow the fuel injectors to inject and the engine
will not start. If the fuel pressure sensor signal to the IDM/PCM is lost or the value indicated does
not match the expected value for the given engine condition, the fuel metering valve will default to
the closed position and will not allow the development of the high-pressure fuel supply. Fuel
injector The fuel injector consists of two main sections. The solenoid control valve has a switching
time of approximately 0.3 milliseconds. This short switching time is achieved by keeping the
moving components and the distances required to function to a minimum. The design of the fuel
injector chambers means that at no time does the solenoid control valve work against any major
forces other than that of the solenoid valve spring. The fuel injector needle works on a combination
of hydraulic and spring control. All injectors are calibrated to take into account manufacturing
tolerances. These calibrations are indicated on the exterior of the injector by a code. The code is
used by the IDM/PCM to adjust the duration of the injection cycle. If the codes for the individual
injector's are incorrectly matched to the codes stored in the IDM/PCM, the engine may exhibit
rough idle, increased combustion noise and black smoke emissions. Fuel injector working state
closed With the solenoid valve de-energised, the injection control valve is held in the closed
position by the injection control valve spring. Fuel pressure above and below the injection control
valve is slightly above atmospheric pressure during engine run conditions. Fuel pressure in the
injector needle upper chamber and injector needle lower chamber is equal to the high-pressure fuel
feed pressure. The injector needle is held in the closed position by the injector needle control
spring. Fuel injector working state opening The fuel injection process starts with a voltage being
applied to the solenoid valve with a pull-in current of 12 amperes. The solenoid valve moves the
injection control valve against the pressure of the injection control valve spring. The injection
control valve releases the high fuel pressure from the injector needle upper chamber and vents the
excess pressure out through the fuel injector fuel return bore. The fuel pressure does not drop
instantly but is slowed down by the injector needle upper control chamber fuel outlet choke.
High-pressure fuel entering the injector needle upper chamber and the injection control valve
chambers is restricted by the very small diameters of the injector needle upper chamber fuel inlet
choke and the control chamber inlet choke. Fuel injector working state injecting During the injection
state of the process, the current applied to the solenoid valve is reduced to 6 amperes. This value
is sufficient to maintain the injection control valve in the open position. As the fuel pressure in the
injector needle upper chamber decays, the fuel pressure in the injector needle lower chamber
forces the injector needle open against the injector needle control spring. Fuel is injected into the
engine combustion chamber. Fuel will continue to be injected as long as the fuel pressure in the
injector needle lower chamber is higher than the combined force of the fuel pressure in the injector
needle upper chamber and the injector needle control spring. Fuel injector working state closing
When the fuel injection process has reached the desired injection duration, the solenoid valve is
de-energised. The injection control valve spring closes the injection control valve and the fuel
pressure in the injector needle upper chamber rises to equal the pressure of the injector needle
lower chamber. As the pressures equalize, the injector needle spring closes the injector needle so
preventing fuel injection. To prevent a sudden increase in the pressure in the injector needle lower
chamber as the injector needle closes, the fuel entering the chamber is restricted by the injector
needle lower chamber fuel inlet choke. Fuel injector fuel return The fuel injector fuel return is
required to make the fuel injectors function. The amount of return fuel developed during the normal
functioning of a fuel injector indicates the condition of that injector. By measurement and
comparison of fuel injector fuel return quantities, diagnosis of the fuel injectors is possible.
Inspection and Verification Visual Inspection Chart Symptom Chart PINPOINT TEST A : FUEL
INJECTOR BACK LEAK TEST - VEHICLES WITHOUT IDM Example: PINPOINT TEST B : FUEL
INJECTOR BACK LEAK TEST - VEHICLES WITH IDM Example: PINPOINT TEST C : FUEL
PUMP FUEL SUPPLY TEST PINPOINT TEST D : FUEL INJECTOR BACK LEAK TEST -
VEHICLES WITHOUT IDM PINPOINT TEST E : FUEL INJECTOR BACK LEAK TEST -
VEHICLES WITH IDM Example:
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-04G Fuel Charging and Controls - 2.4L
Duratorq-TDCi (Puma) Diesel > Description and Operation > Diagnosis and Testing > Removal and Installation > Fuel
Injectors

Socket, Fuel Injector Remover/Installer 303-677 (21-236) Aligner, Fuel Injector 303-711 (21-258)
Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-04G Fuel Charging and Controls - 2.4L
Duratorq-TDCi (Puma) Diesel > Description and Operation > Diagnosis and Testing > Removal and Installation > Fuel
Pump

Remover/Installer, Crankshaft Oil Seal 303-679 (21-238) Locking Tool, Fuel Injection Pump
Sprocket 303-1151 Socket, Fuel Injection Pump 310-083 (23-057) Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-04G Fuel Charging and Controls - 2.4L
Duratorq-TDCi (Puma) Diesel > Description and Operation > Diagnosis and Testing > Removal and Installation > Fuel
Return Line Venturi

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-04G Fuel Charging and Controls - 2.4L
Duratorq-TDCi (Puma) Diesel > Description and Operation > Diagnosis and Testing > Removal and Installation > Fuel Rail

Aligner, Fuel Injector 303-711 (21-258) Removal Installation

Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-04G Fuel Charging and Controls - 2.4L
Duratorq-TDCi (Puma) Diesel > Description and Operation > Diagnosis and Testing > Removal and Installation > Fuel
Metering Valve

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-05 Accessory Drive > Specifications
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-05 Accessory Drive > Description and
Operation > Accessory Drive
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-05 Accessory Drive > Description and
Operation > Diagnosis and Testing > Accessory Drive

Inspection and Verification Visual Inspection Chart Accessory Drive Belt Concerns Cracking
Accessory drive belts are made from rubber which hardens with time and can develop cracks. As
the accessory drive belt runs on the back of some of the pulleys, the cracks are opened up. Small
cracks are not considered to be a failure of the accessory drive belt. Only if the crack is deep
enough to reach the bottom of the groove to expose the cord or any chunks are found to be
missing from the accessory drive belt, is the accessory drive belt condition considered to be
unacceptable. Chunking Chunking describes the condition where long lengths of rubber become
detached from the ribs of the accessory drive belt. This is considered to be a failure of the
accessory drive belt. Pilling Pilling is dust that forms in between the ribs of the accessory drive belt
from rubber that is worn off the accessory drive belt when it is new. There may also be loose
particles left on the accessory drive belt during the manufacturing process. These are worn off and
form into small balls of rubber that then get trapped in the grooves of the accessory drive belt. This
condition will usually clear itself within 4800 km - 8000 km (3000 miles - 5000 miles) of normal
driving. Fraying - Vehicles without accessory drive belt tensioner built up to 02/2003 Due to the
manufacturing process, the accessory drive belt edge may appear frayed, but this frayed
appearance does not necessarily affect the durability or performance of the accessory drive belt. If
a concern is raised during a service or repair over the level of fraying, the condition of the
accessory drive belt should be compared against the illustrations. Incorrect fitment Accessory drive
belt noise can be generated by the accessory drive belt being incorrectly fitted on the pulley as
shown in the following illustration. Make sure that all the V grooves on the accessory drive belt
contact correctly with the pulley. Symptom Chart Symptom Chart Component Tests Accessory
Drive Belt Tensioner - Static Check The accessory drive belt tensioner may be checked statically
as follows: Accessory Drive Belt Tensioner - Dynamic Check The accessory drive belt tensioner
may be checked dynamically as follows: Cooling Fan Pulley – Alignment Vehicles with air
conditioning The cooling fan pulley can be checked for correct alignment as follows: Vehicles
without air conditioning The cooling fan pulley can be checked for correct alignment as follows:
Generator Decoupler
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-05 Accessory Drive > Description and
Operation > Diagnosis and Testing > Removal and Installation > Accessory Drive Belt - 2.4L Duratorq-Di (Puma) Diesel

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-05 Accessory Drive > Description and
Operation > Diagnosis and Testing > Removal and Installation > Accessory Drive Belt - 2.4L Duratorq-TDCi (Puma) Diesel

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-05 Accessory Drive > Description and
Operation > Diagnosis and Testing > Removal and Installation > Accessory Drive Belt - 2.0L Duratorq-Di (Puma)
Diesel-2.0L Duratorq-TDCi (Puma) Diesel-2.0L Duratorq-TDDi (Puma) Diesel

Release Tool, Belt Tensioner 303-676 Removal Installation

Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-05 Accessory Drive > Description and
Operation > Diagnosis and Testing > Removal and Installation > Power Steering Pump Belt

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-05 Accessory Drive > Description and
Operation > Diagnosis and Testing > Removal and Installation > Accessory Drive Belt - 2.3L DOHC-16V

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-05 Accessory Drive > Description and
Operation > Diagnosis and Testing > Removal and Installation > Accessory Drive Belt - Vehicles Without: Accessory Drive
Belt Tensioner

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-06 Starting System > Description and
Operation > Starting System
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-06 Starting System > Description and
Operation > Diagnosis and Testing > Starting System - Vehicles With: Central Junction Box (CJB)

Inspection and Verification Visual Inspection Chart Symptom Chart Symptom Chart Pinpoint Tests
PINPOINT TEST A : THE ENGINE DOES NOT CRANK AND THE RELAY DOES CLICK
PINPOINT TEST B : THE ENGINE DOES NOT CRANK AND THE RELAY DOES NOT CLICK
PINPOINT TEST C : THE ENGINE CRANKS SLOWLY
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-06 Starting System > Description and
Operation > Diagnosis and Testing > Removal and Installation > Starter Motor - 2.4L Duratorq-Di (Puma) Diesel-2.4L
Duratorq-TDCi (Puma) Diesel

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-06 Starting System > Description and
Operation > Diagnosis and Testing > Removal and Installation > Starter Motor - 2.0L Duratorq-Di (Puma) Diesel-2.0L
Duratorq-TDCi (Puma) Diesel-2.0L Duratorq-TDDi (Puma) Diesel

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-06 Starting System > Description and
Operation > Diagnosis and Testing > Removal and Installation > Starter Motor - 2.3L DOHC-16V

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-06 Starting System > Specifications
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-07A Glow Plug System - 2.4L
Duratorq-Di (Puma) Diesel-2.4L Duratorq-TDCi (Puma) Diesel > Specifications
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-07A Glow Plug System - 2.4L
Duratorq-Di (Puma) Diesel-2.4L Duratorq-TDCi (Puma) Diesel > Description and Operation > Glow Plug System
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-07A Glow Plug System - 2.4L
Duratorq-Di (Puma) Diesel-2.4L Duratorq-TDCi (Puma) Diesel > Description and Operation > Diagnosis and Testing > Glow
Plug System
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-07A Glow Plug System - 2.4L
Duratorq-Di (Puma) Diesel-2.4L Duratorq-TDCi (Puma) Diesel > Description and Operation > Diagnosis and Testing >
Removal and Installation > Glow Plugs - 2.4L Duratorq-Di (Puma) Diesel

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-07A Glow Plug System - 2.4L
Duratorq-Di (Puma) Diesel-2.4L Duratorq-TDCi (Puma) Diesel > Description and Operation > Diagnosis and Testing >
Removal and Installation > Glow Plugs - 2.4L Duratorq-TDCi (Puma) Diesel
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-07A Glow Plug System - 2.4L
Duratorq-Di (Puma) Diesel-2.4L Duratorq-TDCi (Puma) Diesel > Description and Operation > Diagnosis and Testing >
Removal and Installation > Glow Plug Wires - 2.4L Duratorq-Di (Puma) Diesel

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-07A Glow Plug System - 2.4L
Duratorq-Di (Puma) Diesel-2.4L Duratorq-TDCi (Puma) Diesel > Description and Operation > Diagnosis and Testing >
Removal and Installation > Glow Plug Wires - 2.4L Duratorq-TDCi (Puma) Diesel

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-07B Glow Plug System - 2.0L
Duratorq-Di (Puma) Diesel-2.0L Duratorq-TDCi (Puma) Diesel-2.0L Duratorq-TDDi (Puma) Diesel > Description and
Operation > Glow Plug System
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-07B Glow Plug System - 2.0L
Duratorq-Di (Puma) Diesel-2.0L Duratorq-TDCi (Puma) Diesel-2.0L Duratorq-TDDi (Puma) Diesel > Description and
Operation > Diagnosis and Testing > Glow Plug System
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-07B Glow Plug System - 2.0L
Duratorq-Di (Puma) Diesel-2.0L Duratorq-TDCi (Puma) Diesel-2.0L Duratorq-TDDi (Puma) Diesel > Description and
Operation > Diagnosis and Testing > Removal and Installation > Glow Plugs - Vehicles Without: Common Rail Fuel Injection

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-07B Glow Plug System - 2.0L
Duratorq-Di (Puma) Diesel-2.0L Duratorq-TDCi (Puma) Diesel-2.0L Duratorq-TDDi (Puma) Diesel > Description and
Operation > Diagnosis and Testing > Removal and Installation > Glow Plugs - Vehicles With: Common Rail Fuel Injection

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-07B Glow Plug System - 2.0L
Duratorq-Di (Puma) Diesel-2.0L Duratorq-TDCi (Puma) Diesel-2.0L Duratorq-TDDi (Puma) Diesel > Description and
Operation > Diagnosis and Testing > Removal and Installation > Glow Plug Wires

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-07B Glow Plug System - 2.0L
Duratorq-Di (Puma) Diesel-2.0L Duratorq-TDCi (Puma) Diesel-2.0L Duratorq-TDDi (Puma) Diesel > Specifications
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-07C Engine Ignition - 2.3L DOHC-16V >
Description and Operation > Engine Ignition
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-07C Engine Ignition - 2.3L DOHC-16V >
Description and Operation > Diagnosis and Testing > Removal and Installation > Ignition Coil

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-07C Engine Ignition - 2.3L DOHC-16V >
Description and Operation > Diagnosis and Testing > Engine Ignition
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-07C Engine Ignition - 2.3L DOHC-16V >
Specifications
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-08 Engine Emission Control >
Specifications
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-08 Engine Emission Control >
Description and Operation > Diagnosis and Testing > Engine Emission Control
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-08 Engine Emission Control >
Description and Operation > Diagnosis and Testing > Removal and Installation > Exhaust Gas Recirculation (EGR) Valve -
2.4L Duratorq-Di (Puma) Diesel

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-08 Engine Emission Control >
Description and Operation > Diagnosis and Testing > Removal and Installation > Exhaust Gas Recirculation (EGR) Valve -
2.4L Duratorq-TDCi (Puma) Diesel

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-08 Engine Emission Control >
Description and Operation > Diagnosis and Testing > Removal and Installation > Exhaust Gas Recirculation (EGR) Valve -
2.0L Duratorq-Di (Puma) Diesel-2.0L Duratorq-TDDi (Puma) Diesel

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-08 Engine Emission Control >
Description and Operation > Diagnosis and Testing > Removal and Installation > Exhaust Gas Recirculation (EGR) Valve -
2.0L Duratorq-TDCi (Puma) Diesel

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-08 Engine Emission Control >
Description and Operation > Diagnosis and Testing > Removal and Installation > Exhaust Gas Recirculation (EGR) Valve -
2.3L DOHC-16V

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-08 Engine Emission Control >
Description and Operation > Diagnosis and Testing > Removal and Installation > Exhaust Manifold to Exhaust Gas
Recirculation (EGR) Valve Tube - 2.3L DOHC-16V

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-08 Engine Emission Control >
Description and Operation > Diagnosis and Testing > Removal and Installation > Exhaust Gas Recirculation (EGR) Cooler -
2.4L Duratorq-Di (Puma) Diesel-2.4L Duratorq-TDCi (Puma) Diesel

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-08 Engine Emission Control >
Description and Operation > Diagnosis and Testing > Removal and Installation > Exhaust Manifold to Exhaust Gas
Recirculation (EGR) Valve Tube - 2.0L Duratorq-Di (Puma) Diesel (85 PS-100 PS)

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-08 Engine Emission Control >
Description and Operation > Diagnosis and Testing > Removal and Installation > Exhaust Gas Recirculation (EGR) Cooler -
2.0L Duratorq-Di (Puma) Diesel-2.0L Duratorq-TDCi (Puma) Diesel-2.0L Duratorq-TDDi (Pum

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-08 Engine Emission Control >
Description and Operation > Engine Emission Control

Vehicles with 2.4L Diesel Engine Vehicles with 2.0L Diesel Engine Vehicles with 2.3L Engine
Vehicles with 2.3L Engine All Vehicles The EGR system recycles measured quantities of exhaust
gas back through the engine where they mix with the incoming air/fuel charge. The powertrain
control module (PCM) controls the vacuum regulator solenoid with grounding pulses. This
regulates the amount and duration of the vacuum signal supplied to the EGR valve, therefore the
valve lift and opening times are controlled. Vehicles with Diesel Engine On vehicles with a 90 PS,
100PS or 120 PS engine, the EGR system includes an EGR cooler. The EGR cooler is connected
to the engine cooling system. The EGR cooler cools the recirculated exhaust gas, therefore
lowering the combustion temperatures resulting in reduced tailpipe oxides of nitrogen (NOx) levels.
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-12 Intake Air Distribution and Filtering >
Specifications
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-12 Intake Air Distribution and Filtering >
Description and Operation > Diagnosis and Testing > Intake Air Distribution and Filtering

Inspection and Verification Visual Inspection Chart Component Test Air Cleaner Element Carry out
the following test to determine if a new air cleaner element should be installed .
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-12 Intake Air Distribution and Filtering >
Description and Operation > Diagnosis and Testing > Removal and Installation > Charge Air Cooler

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-12 Intake Air Distribution and Filtering >
Description and Operation > Diagnosis and Testing > Removal and Installation > Air Cleaner - 2.4L Duratorq-TDCi (Puma)
Diesel

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-12 Intake Air Distribution and Filtering >
Description and Operation > Diagnosis and Testing > Removal and Installation > Air Cleaner - 2.3L DOHC-16V-2.0L
Duratorq-Di (Puma) Diesel-2.0L Duratorq-TDCi (Puma) Diesel-2.0L Duratorq-TDDi (Puma) Diesel-2.4

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-12 Intake Air Distribution and Filtering >
Description and Operation > Intake Air Distribution and Filtering
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-13 Evaporative Emissions > Description
and Operation > Evaporative Emissions
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-13 Evaporative Emissions > Description
and Operation > Diagnosis and Testing > Removal and Installation > Evaporative Emission Canister Purge Valve

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-13 Evaporative Emissions > Description
and Operation > Diagnosis and Testing > Evaporative Emissions
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-14 Electronic Engine Controls >
Specifications
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-14 Electronic Engine Controls >
Description and Operation > Electronic Engine Controls
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-14 Electronic Engine Controls >
Description and Operation > Diagnosis and Testing > Electronic Engine Controls
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-14 Electronic Engine Controls >
Description and Operation > Diagnosis and Testing > Removal and Installation > Crankshaft Position (CKP) Sensor - 2.0L
Duratorq-Di (Puma) Diesel-2.0L Duratorq-TDDi (Puma) Diesel

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-14 Electronic Engine Controls >
Description and Operation > Diagnosis and Testing > Removal and Installation > Crankshaft Position (CKP) Sensor - 2.4L
Duratorq-Di (Puma) Diesel-2.4L Duratorq-TDCi (Puma) Diesel

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-14 Electronic Engine Controls >
Description and Operation > Diagnosis and Testing > Removal and Installation > Vehicle Speed Sensor (VSS) - 2.4L
Duratorq-Di (Puma) Diesel-2.4L Duratorq-TDCi (Puma) Diesel

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-14 Electronic Engine Controls >
Description and Operation > Diagnosis and Testing > Removal and Installation > Crankshaft Position (CKP) Sensor - 2.0L
Duratorq-TDCi (Puma) Diesel

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-14 Electronic Engine Controls >
Description and Operation > Diagnosis and Testing > Removal and Installation > Vehicle Speed Sensor (VSS) - 2.0L
Duratorq-Di (Puma) Diesel-2.0L Duratorq-TDCi (Puma) Diesel-2.0L Duratorq-TDDi (Puma) Diesel

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-14 Electronic Engine Controls >
Description and Operation > Diagnosis and Testing > Removal and Installation > Powertrain Control Module (PCM)

Removal and Installation Installation

Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-14 Electronic Engine Controls >
Description and Operation > Diagnosis and Testing > Removal and Installation > Knock Sensor (KS) - 2.4L Duratorq-TDCi
(Puma) Diesel

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-14 Electronic Engine Controls >
Description and Operation > Diagnosis and Testing > Removal and Installation > Cylinder Head Temperature (CHT) Sensor
- 2.0L Duratorq-Di (Puma) Diesel-2.0L Duratorq-TDCi (Puma) Diesel-2.0L Duratorq-TDDi (Pum

Socket, CHT Sensor 303-680 (21-239) Removal Installation

Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-14 Electronic Engine Controls >
Description and Operation > Diagnosis and Testing > Removal and Installation > Cylinder Head Temperature (CHT) Sensor
- 2.4L Duratorq-Di (Puma) Diesel-2.4L Duratorq-TDCi (Puma) Diesel

Socket, CHT Sensor 303-680 (21-239) Removal Installation

Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-14 Electronic Engine Controls >
Description and Operation > Diagnosis and Testing > Removal and Installation > Fuel Temperature Sensor - 2.0L
Duratorq-TDCi (Puma) Diesel

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-14 Electronic Engine Controls >
Description and Operation > Diagnosis and Testing > Removal and Installation > Fuel Temperature Sensor - 2.4L
Duratorq-TDCi (Puma) Diesel

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-14 Electronic Engine Controls >
Description and Operation > Diagnosis and Testing > Removal and Installation > Injector Driver Module (IDM) - 2.0L
Duratorq-TDCi (Puma) Diesel

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 303 Engine > 303-14 Electronic Engine Controls >
Description and Operation > Diagnosis and Testing > Removal and Installation > Ignition Signal Filter

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-00 Manual Transmission-Transaxle and Clutch - General Information > Specifications
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-00 Manual Transmission-Transaxle and Clutch - General Information > Diagnosis and Testing > Manual
Transmission and Clutch - Vehicles With: MT-75

Inspection and Verification Visual Inspection Chart The following checks should be carried out
before repairing or installing a new transmission. The inspection and verification of manual
transmission concerns can be considered in three main areas. Gear shifting concerns
Transmission noise concerns Oil leakage concerns Symptom Chart PINPOINT TEST A : CLUTCH
SLIPPAGE PINPOINT TEST B : CLUTCH CHATTER OR SHUDDER PINPOINT TEST C :
CLUTCH DRAG PINPOINT TEST D : EXCESSIVE NOISE
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-00 Manual Transmission-Transaxle and Clutch - General Information > Diagnosis and Testing > Manual
Transaxle and Clutch - Vehicles With: VXT-75

Inspection and Verification Visual Inspection Chart The following checks should be carried out
before repairing or installing a new transaxle. The inspection and verification of manual transaxle
concerns can be considered in three main areas. Gear shifting concerns Transaxle noise concerns
Oil leakage concerns Symptom Chart PINPOINT TEST A : CLUTCH SLIPPAGE PINPOINT TEST
B : CLUTCH CHATTER OR SHUDDER PINPOINT TEST C : CLUTCH DRAG PINPOINT TEST D :
EXCESSIVE NOISE
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-00 Manual Transmission-Transaxle and Clutch - General Information > Diagnosis and Testing > Manual
Transmission and Clutch - Vehicles With: MT82

Inspection and Verification Visual Inspection Chart The following checks should be carried out
before repairing or installing a new transmission. The inspection and verification of manual
transmission concerns can be considered in three main areas. Gear shifting concerns
Transmission noise concerns Oil leakage concerns Symptom Chart PINPOINT TEST A : CLUTCH
SLIPPAGE PINPOINT TEST B : CLUTCH CHATTER OR SHUDDER PINPOINT TEST C :
CLUTCH DRAG PINPOINT TEST D : EXCESSIVE NOISE
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-00 Manual Transmission-Transaxle and Clutch - General Information > Diagnosis and Testing > General
Procedures > Clutch System Bleeding - Vehicles With: MT-75

Vacuum Pump Kit 416-D001 (23-036 A)

Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-00 Manual Transmission-Transaxle and Clutch - General Information > Diagnosis and Testing > General
Procedures > Clutch System Bleeding - Vehicles With: VXT-75

Vacuum Pump Kit 416-D001 (23-036 A)

Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-00 Manual Transmission-Transaxle and Clutch - General Information > Diagnosis and Testing > General
Procedures > Clutch System Bleeding - Vehicles With: MT82

Vacuum Pump Kit 416-D001 (23-036 A)

Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-00 Manual Transmission-Transaxle and Clutch - General Information > Diagnosis and Testing > General
Procedures > Clutch System Bleeding - Vehicles With: Automated Gearshift

Vacuum and pressure manual pump 416-D001

Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-00 Manual Transmission-Transaxle and Clutch - General Information > Diagnosis and Testing > General
Procedures > Gearshift Cable Adjustment
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-00 Manual Transmission-Transaxle and Clutch - General Information > Diagnosis and Testing > General
Procedures > Gearshift Linkage Adjustment

Aligner, Gearshift Lever 308-561

Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-01A Clutch - Vehicles With: MT-75 > Specifications
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-01A Clutch - Vehicles With: MT-75 > Diagnosis and Testing > Clutch
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-01A Clutch - Vehicles With: MT-75 > Diagnosis and Testing > Removal and Installation > Clutch Disc and
Pressure Plate - 2.4L Duratorq-Di (Puma) Diesel

Aligner, Clutch Plate 308-204 (16-067) Removal Installation

Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-01A Clutch - Vehicles With: MT-75 > Diagnosis and Testing > Removal and Installation > Clutch Disc and
Pressure Plate - 2.3L DOHC-16V

Aligner, Clutch Plate 308-204 (16-067) Removal Installation

Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-01A Clutch - Vehicles With: MT-75 > Diagnosis and Testing > Removal and Installation > Pilot Bearing

Installer, Bearing 205-081 Installer, Crankshaft Pilot Bearing 303-090 Remover, Crankshaft Pilot
Bearing 303-1365 Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-01B Clutch - Vehicles With: VXT-75 > Diagnosis and Testing > Clutch
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-01B Clutch - Vehicles With: VXT-75 > Diagnosis and Testing > Removal and Installation > Clutch Disc and
Pressure Plate

Aligner, Clutch Friction Disc 308-204 (16-067) Removal Installation

Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-01B Clutch - Vehicles With: VXT-75 > Specifications
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-01C Clutch - Vehicles With: MT82 > Description and Operation > Clutch
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-01C Clutch - Vehicles With: MT82 > Description and Operation > Diagnosis and Testing > Clutch
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-01C Clutch - Vehicles With: MT82 > Description and Operation > Diagnosis and Testing > Removal and
Installation > Pilot Bearing

Installer, Bearing 205-081 Installer, Crankshaft Pilot Bearing 303-090 Remover, Crankshaft Pilot
Bearing 303-1365 Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-01C Clutch - Vehicles With: MT82 > Description and Operation > Diagnosis and Testing > Removal and
Installation > Clutch Disc and Pressure Plate

Aligner, Clutch Plate 308-204 (16-067) Removal Installation

Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-01C Clutch - Vehicles With: MT82 > Specifications
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-02A Clutch Controls - Vehicles With: MT-75 > Description and Operation > Clutch Controls
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-02A Clutch Controls - Vehicles With: MT-75 > Description and Operation > Diagnosis and Testing > Clutch
Controls
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-02A Clutch Controls - Vehicles With: MT-75 > Description and Operation > Diagnosis and Testing > Removal
and Installation > Clutch Master Cylinder

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-02A Clutch Controls - Vehicles With: MT-75 > Description and Operation > Diagnosis and Testing > Removal
and Installation > Clutch Slave Cylinder

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-02A Clutch Controls - Vehicles With: MT-75 > Specifications
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-02B Clutch Controls - Vehicles With: VXT-75 > Specifications
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-02B Clutch Controls - Vehicles With: VXT-75 > Description and Operation > Diagnosis and Testing > Clutch
Controls
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-02B Clutch Controls - Vehicles With: VXT-75 > Description and Operation > Diagnosis and Testing > Removal
and Installation > Clutch Master Cylinder

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-02B Clutch Controls - Vehicles With: VXT-75 > Description and Operation > Diagnosis and Testing > Removal
and Installation > Clutch Slave Cylinder

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-02B Clutch Controls - Vehicles With: VXT-75 > Description and Operation > Clutch Controls
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-02C Clutch Controls - Vehicles With: MT82 > Specifications
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-02C Clutch Controls - Vehicles With: MT82 > Description and Operation > Diagnosis and Testing > Clutch
Controls
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-02C Clutch Controls - Vehicles With: MT82 > Description and Operation > Diagnosis and Testing > Removal
and Installation > Clutch Master Cylinder

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-02C Clutch Controls - Vehicles With: MT82 > Description and Operation > Diagnosis and Testing > Removal
and Installation > Clutch Slave Cylinder

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-02C Clutch Controls - Vehicles With: MT82 > Description and Operation > Clutch Controls

The hydraulic clutch mechanism has been reworked for the MT82 6-speed manual transmission. In
contrast to the MT-75 5-speed manual transmission, the clutch slave cylinder is integral with the
clutch bell housing The hydraulic clutch operating mechanism is self-adjusting. There is no need to
change the clutch slave cylinder after the clutch has been renewed.
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-03A Manual Transmission-Transaxle - Vehicles With: MT-75 > Specifications
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-03A Manual Transmission-Transaxle - Vehicles With: MT-75 > Description and Operation > Diagnosis and
Testing > Manual Transmission
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-03A Manual Transmission-Transaxle - Vehicles With: MT-75 > Description and Operation > Diagnosis and
Testing > General Procedures > Transmission Draining and Filling
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-03A Manual Transmission-Transaxle - Vehicles With: MT-75 > Description and Operation > Diagnosis and
Testing > General Procedures > Removal > Transmission - 2.4L Duratorq-Di (Puma) Diesel, Vehicles With: Automated
Gearshift

Spacer, Subframe 204-606 Removal

Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-03A Manual Transmission-Transaxle - Vehicles With: MT-75 > Description and Operation > Diagnosis and
Testing > General Procedures > Removal > Transmission - 2.4L Duratorq-Di (Puma) Diesel, Vehicles Without: Automated
Gearshift

Spacer, Subframe 204-606 Removal

Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-03A Manual Transmission-Transaxle - Vehicles With: MT-75 > Description and Operation > Diagnosis and
Testing > General Procedures > Removal > Transmission - 2.3L DOHC-16V

Spacer, Subframe 204-606 Removal

Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-03A Manual Transmission-Transaxle - Vehicles With: MT-75 > Description and Operation > Diagnosis and
Testing > General Procedures > Removal > Disassembly > Transmission

Installer, Differential Bearing 205-062 (15-025A) Flange Holding Wrench, Universal 205-072
(15-030A) Remover, Drive Pinion Oil Seal 205-078 (15-048) Remover, Bearing/Gear 205-310
(15-091) Remover, Bearing/Gear 205-311 (15-092) Remover, Crankshaft Pilot Bearing 303-078
(21-036A) Remover, Crankshaft Pilot Bearing 303-079 (21-037B) Remover, Oil Seal 303-112
(21-051) Aligner, Clutch Plate 303-173 (21-103A) Mounting Stand 303-435 (21-187) Socket, Guide
Sleeve 308-109 (16-040A) Remover/Installer, Front Housing 308-110 (16-041) Mounting Bracket
for 303-435 308-114 (16-045) Mounting Brackets for 308-114 308-114-01 (16-045-01) Remover,
Mainshaft Needle Bearing Sleeve 308-191 (16-056) Disassembly
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-03A Manual Transmission-Transaxle - Vehicles With: MT-75 > Description and Operation > Diagnosis and
Testing > General Procedures > Removal > Disassembly > Disassembly and Assembly of Subassemblies > Input Shaft

Disassembly Assembly
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-03A Manual Transmission-Transaxle - Vehicles With: MT-75 > Description and Operation > Diagnosis and
Testing > General Procedures > Removal > Disassembly > Disassembly and Assembly of Subassemblies > Countershaft

Remover, Bearing (Main Tool) 205-295 (15-050A) Collet for 205-295 308-146 (16-050)
Disassembly Assembly
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-03A Manual Transmission-Transaxle - Vehicles With: MT-75 > Description and Operation > Diagnosis and
Testing > General Procedures > Removal > Disassembly > Disassembly and Assembly of Subassemblies > Output Shaft

Remover, Mainshaft Needle Bearing Sleeve 308 - 191 (16 - 056) Disassembly Assembly
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-03A Manual Transmission-Transaxle - Vehicles With: MT-75 > Description and Operation > Diagnosis and
Testing > General Procedures > Removal > Disassembly > Disassembly and Assembly of Subassemblies > Reverse Idler
Gear

Disassembly Assembly
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-03A Manual Transmission-Transaxle - Vehicles With: MT-75 > Description and Operation > Diagnosis and
Testing > General Procedures > Removal > Disassembly > Disassembly and Assembly of Subassemblies > Gearshift
Control Shaft

Disassembly Assembly
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-03A Manual Transmission-Transaxle - Vehicles With: MT-75 > Description and Operation > Diagnosis and
Testing > General Procedures > Removal > Disassembly > Disassembly and Assembly of Subassemblies > Synchronizers

Disassembly Assembly
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-03A Manual Transmission-Transaxle - Vehicles With: MT-75 > Description and Operation > Diagnosis and
Testing > General Procedures > Removal > Disassembly > Disassembly and Assembly of Subassemblies > Assembly >
Transmission

Installer, Wear Sleeve Stub Axle 204-276 (14-055) Adapter for 205-066 205-066-04 (15-068)
Flange Holding Wrench, Universal 205-072 (15-030A) Installer, Differential Bearing Cone 205-074
(15-035) Adapter for 205-074 205-074-01 (15-064) Installer, Rear Hub Oil Seal 205-075 (15-036)
Aligner, Clutch Plate 303-173 (21-103A) Angle Gauge, Bolt Tightening 303-174 (21-540) Mounting
Stand 303-435 (21-187) Socket, Guide Sleeve 308-109 (16-040A) Remover/Installer, Front
Housing 308-110 (16-041) Threaded Spindle 308-111 (16-042A-01) Adapter for 308-111
308-111-01 (16-042A) Installer, Output Drive Flange Oil Seal 308-112 (16-043A) Mounting Bracket
for 303-435 308-114 (16-045) Mounting Brackets for 308-114 308-114-01 (16-045-01) Assembly
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-03A Manual Transmission-Transaxle - Vehicles With: MT-75 > Description and Operation > Diagnosis and
Testing > General Procedures > Removal > Disassembly > Disassembly and Assembly of Subassemblies > Assembly >
Installation > Transmission - 2.4L Duratorq-Di (Puma) Diesel, Vehicles With: Automated Gearshift

Spacer, Subframe 204-606 Worldwide Diagnostic System (WDS) 418-F224 Installation

Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-03A Manual Transmission-Transaxle - Vehicles With: MT-75 > Description and Operation > Diagnosis and
Testing > General Procedures > Removal > Disassembly > Disassembly and Assembly of Subassemblies > Assembly >
Installation > Transmission - 2.4L Duratorq-Di (Puma) Diesel, Vehicles Without: Automated Gearshift

Spacer, Subframe 204-606 Installation

Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-03A Manual Transmission-Transaxle - Vehicles With: MT-75 > Description and Operation > Diagnosis and
Testing > General Procedures > Removal > Disassembly > Disassembly and Assembly of Subassemblies > Assembly >
Installation > Transmission - 2.3L DOHC-16V

Spacer, Subframe 204-606 Installation

Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-03A Manual Transmission-Transaxle - Vehicles With: MT-75 > Description and Operation > Manual
Transmission
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-03B Manual Transmission-Transaxle - Vehicles With: VXT-75 > Specifications
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-03B Manual Transmission-Transaxle - Vehicles With: VXT-75 > Description and Operation > Manual Transaxle

Overview Input Shaft - Vehicles built up to 08/2001 Input Shaft - Vehicles built 08/2001 onwards
Output Shaft Differential
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-03B Manual Transmission-Transaxle - Vehicles With: VXT-75 > Description and Operation > Diagnosis and
Testing > Manual Transaxle
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-03B Manual Transmission-Transaxle - Vehicles With: VXT-75 > Description and Operation > Diagnosis and
Testing > In-vehicle Repair > Halfshaft Seal LH

Installer, Drive Pinion Oil Seal 205-115 (15-058) Remover, Halfshaft Oil Seal 308-208 (16-074)
Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-03B Manual Transmission-Transaxle - Vehicles With: VXT-75 > Description and Operation > Diagnosis and
Testing > In-vehicle Repair > Halfshaft Seal RH

Installer, Drive Pinion Oil Seal 205-115 (15-058) Remover, Halfshaft Oil Seal 308-208 (16-074)
Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-03B Manual Transmission-Transaxle - Vehicles With: VXT-75 > Description and Operation > Diagnosis and
Testing > In-vehicle Repair > Removal > Transaxle

Support Bar, Engine 303-290A (21-140) Adapter for 303-290A 303-290-02 (21-140-02) Adapter for
303-290A 303-290-03 (21-140-03) Adapter for 303-290A 303-290-13 (21-140-09) Remover,
Halfshaft 308-192 (16-057)
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-03B Manual Transmission-Transaxle - Vehicles With: VXT-75 > Description and Operation > Diagnosis and
Testing > In-vehicle Repair > Removal > Disassembly > Transaxle

Remover, Drive Pinion Oil Seal 205-078 (15-048) Adapter for 205–078 (Thrust Pad) 205-078-01
(15-048-01) Remover, Differential Bearing Cone 205-176 (15-074) Mounting Bracket,
Engine/Differential 205-329 (15-105A) Mounting Stand 303-435 (21-187) Mounting Bracket for
303-435 303-435-06 (21-031B) Remover, Halfshaft Oil Seal 308-208 (16-074) Disassembly
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-03B Manual Transmission-Transaxle - Vehicles With: VXT-75 > Description and Operation > Diagnosis and
Testing > In-vehicle Repair > Removal > Disassembly > Disassembly and Assembly of Subassemblies > Input Shaft

Remover, Bearing (Main Tool) 205-295 (15-050A) Collet for 205-295 308-196 (16-061) Support
Plate, Gear Removal (Dia 81.2 mm) 308-229 (16-076) Support Plate, Gear Removal (Dia 85.1 mm)
308-230 (16-077) Disassembly Assembly
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-03B Manual Transmission-Transaxle - Vehicles With: VXT-75 > Description and Operation > Diagnosis and
Testing > In-vehicle Repair > Removal > Disassembly > Disassembly and Assembly of Subassemblies > Differential

Installer, Differential Bearing 205-062 (15-025A) Adapter for 205-071 205-071-01 (15-026A-01)
Remover, Bearing (Main Tool) 205-295 (15-050A) Collet for 205-095 308-197 (16-062)
Disassembly Assembly
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-03B Manual Transmission-Transaxle - Vehicles With: VXT-75 > Description and Operation > Diagnosis and
Testing > In-vehicle Repair > Removal > Disassembly > Disassembly and Assembly of Subassemblies > Output Shaft

Installer, Drive Pinion Bearing 205-068 (15-042) Remover, Bearing (Main Tool) 205-295 (15-050A)
Remover, Bearing/Gear 205-310 (15-091) Collet for 205-095 308-197 (16-062) Disassembly
Assembly
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-03B Manual Transmission-Transaxle - Vehicles With: VXT-75 > Description and Operation > Diagnosis and
Testing > In-vehicle Repair > Removal > Disassembly > Disassembly and Assembly of Subassemblies > Assembly >
Transaxle

Torque gauge 205-067 (15-041) Bearing outer race installer 205-075 (15-036) Installer, differential
oil seal 205-115 (15-058) Socket, Drive Pinion Nut 205-175 (15-073) Valve spring compressor
303-060 (21-024) Adapter for 303-060 303-060-02 (21-024-02) Adapter for 303-060 303-060-07
(21-024-07) Mounting Plate for 303-435-06 303-435-11 (21-146C) Holding Fixture, Dial Indicator
Gauge 308-216 (16-059A) Assembly 1. input shaft 2. output shaft 3. differential 1. input shaft 2.
output shaft 3. differential
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-03B Manual Transmission-Transaxle - Vehicles With: VXT-75 > Description and Operation > Diagnosis and
Testing > In-vehicle Repair > Removal > Disassembly > Disassembly and Assembly of Subassemblies > Assembly >
Installation > Transaxle

Support Bar, Engine 303-290A (21-140) Adapter for 303-290A 303-290-02 (21-140-02) Adapter for
303-290A 303-290-03 (21-140-03) Adapter for 303-290A 303-290-13 (21-140-09)
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-03C Manual Transmission-Transaxle - Vehicles With: MT82 > Specifications
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-03C Manual Transmission-Transaxle - Vehicles With: MT82 > Description and Operation > Diagnosis and
Testing > Manual Transmission
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-03C Manual Transmission-Transaxle - Vehicles With: MT82 > Description and Operation > Diagnosis and
Testing > General Procedures > Transmission Draining and Filling
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-03C Manual Transmission-Transaxle - Vehicles With: MT82 > Description and Operation > Diagnosis and
Testing > General Procedures > In-vehicle Repair > Input Shaft Seal

Remover, Crankshaft Rear Oil Seal 303-336 Installer, Input Shaft Oil Seal 308-605 Removal
Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-03C Manual Transmission-Transaxle - Vehicles With: MT82 > Description and Operation > Diagnosis and
Testing > General Procedures > In-vehicle Repair > Output Shaft Seal

Remover, Drive Pinion Oil Seal 205-078 Adapter for 205-078 (Thrust Pad) 205-078-01 Installer,
Output Drive Flange Oil Seal 308-604 Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-03C Manual Transmission-Transaxle - Vehicles With: MT82 > Description and Operation > Diagnosis and
Testing > General Procedures > In-vehicle Repair > Removal > Transmission

Spacer, Subframe 204-606 Removal

Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-03C Manual Transmission-Transaxle - Vehicles With: MT82 > Description and Operation > Diagnosis and
Testing > General Procedures > In-vehicle Repair > Removal > Disassembly > Transmission

Disassembly
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-03C Manual Transmission-Transaxle - Vehicles With: MT82 > Description and Operation > Diagnosis and
Testing > General Procedures > In-vehicle Repair > Removal > Disassembly > Disassembly and Assembly of
Subassemblies > Synchronizers

Disassembly Assembly
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-03C Manual Transmission-Transaxle - Vehicles With: MT82 > Description and Operation > Diagnosis and
Testing > General Procedures > In-vehicle Repair > Removal > Disassembly > Disassembly and Assembly of
Subassemblies > Assembly > Transmission

Assembly
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-03C Manual Transmission-Transaxle - Vehicles With: MT82 > Description and Operation > Diagnosis and
Testing > General Procedures > In-vehicle Repair > Removal > Disassembly > Disassembly and Assembly of
Subassemblies > Assembly > Installation > Transmission

Spacer, Subframe 204-606 Aligner, Gearshift Lever 308-561 Installation

Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-03C Manual Transmission-Transaxle - Vehicles With: MT82 > Description and Operation > Manual
Transmission

Overview The MT82 6-speed manual transmission was developed by Getrag-Ford Transmissions.
Designed for a rear wheel drive vehicle, it is first of all only installed in the Ford Transit (V184). The
MT82 6-speed manual transmission is only combined with the 135 PS 2.4L Duratorq-TDCi (Puma)
diesel engine (at the time of printing of this Student Information brochure). With a dry weight of 50.8
kg, the MT82 6-speed manual transmission is only slightly heavier than the MT-75 5-speed manual
transmission. Because of the 6th gear, the MT82 6-speed manual transmission is 23.8 mm longer
than the MT-75 5-speed manual transmission. The name of the MT82 6-speed manual
transmission is derived from the distance between the two shafts in the transmission: The
maximum transmissible torque is 370 Nm. Because of the design, a further increase in the
maximum transmissible torque is possible in the future. The inner shift mechanism is a new
development. The clutch has been strengthened because of the higher torque to be transmitted.
Compared with the MT-75 5-speed manual transmission, the outer diameter of the clutch has been
increased by 8 mm to 258 mm. The MT82 6-speed manual transmission will only be installed in
combination with the new Ford Transit rear axle designated "Dana". Because of the new
transmission ratio, the rear axle has been changed accordingly. There are two choices of axle ratio
available: The dual mass flywheel is equipped with a torque limiter. This mechanical manual
transmission also uses transmission oil with the oil specification WSD-M2C200-C . The fill quantity
is 2.4 l. Because of the different size of the transmission, the driveshaft for the MT82 6-speed
transmission is shorter. Gear ratios of the MT82 6-speed manual transmission The current gear
ratios are given in the following table. The input and output shafts are directly connected in 5th
gear. This produces a gear ratio of 1:1. Model plate sticker The model plate is located on the
right-hand side of the transmission, near the driveshaft drive flange. It is only used to identify the
transmission. All spare parts orders are still made using the Vehicle Identification Number (VIN).
Side view - left-hand side The reverse gear idler shaft is secured to the housing by the reverse
gear mounting retaining bolt (5). This not be mixed up with any other bolt on the transmission. The
specified torque for the reverse gear mounting retaining bolt can be found in the latest workshop
literature. Side view - right-hand side The transmission oil in the MT82 6-speed transmission does
not need to be changed in service. Only before repair work on the transmission should the
transmission oil be drained by removing the oil drain plug (6). The oil filler plug (7) also allows the
oil level to be checked. Overview The MT82 6-speed manual transmission is based on the MT-75
5-speed manual transmission. To improve gear shifting, the 1st and 2nd gears have triple
synchronisation, the 3rd and 4th gears have double synchronisation. Only the 5th and 6th gears
and the reverse gear have simple synchronisation. In order to reduce noise, all gear wheels and
gears are helical toothed and are constantly engaged Input shaft The input shaft is rotationally
mounted in the output shaft on the pilot bearing (3). In order to absorb the axial forces, the input
shaft ball bearing (7) is additionally secured. All the components of the input shaft can be detached
and renewed separately. Layshaft The layshaft transfers the torque from the input shaft onto the
output shaft. Gear wheels and gears and the 3rd/4th gear synchroniser assembly are located on
the shaft. The gears of the 1st, 2nd and reverse gears are an integral part of the shaft The layshaft
can be completely dismantled, i.e. faulty gearwheels or gears can be renewed singly. Because of
improved manufacturing tolerances, it is no longer necessary to change the gears and gear wheels
in pairs. The layshaft is a solid shaft. In order to prevent the shaft from moving axially, it is
additionally secured with a retaining bolt (1) and a bearing retaining plate (3). Reversal of the
direction of rotation of the output shaft is achieved using the reverse gear idler (21). Output shaft
The output shaft transfers the torque through the driveshaft output flange, the driveshaft and then
to the rear axle. 1st , 2nd and 6th gear wheels and also the reverse gear wheel are located on the
output shaft. The gears of 3rd and 4th gear are an integral part of the output shaft. In a similar way
to the input shaft, there is a splined synchroniser (4) pushed on the 6th gear gear wheel. This
makes it possible to transfer the torque in 6th gear. The output shaft can be completely dismantled.
Damaged gearwheels and gears can be renewed individually. Triple synchronisation Triple
synchronisation consists of three friction surfaces. The total friction surface of triple synchronisation
is considerably increased by the additional conical surface (6). This leads to a reduction in the force
needed to change into first or second gear. The conical surface is part of the gear wheel. There is
no need for an additional synchroniser ring. Synchroniser assembly The synchroniser assembly
has been reworked. The pressure springs and detent balls of the sliding blocks are combined in
one unit. The revised construction of the synchroniser assembly makes service work easier.
Reverse gear idler The reverse gear idler allows the direction of rotation of the output shaft to be
reversed. The reverse gear idler turns on a needle bearing, which runs on the reverse gear idler
shaft. The shaft is retained by the mounting (1) and a locating bore in the transmission housing. In
order to absorb the radial forces, the reverse gear idler runs on an additional mounting. If the
reverse gear idler becomes damaged, it can be changed as an individual unit. Torque flow in the
individual gears The following diagrams show the flow of torque in the MT82 6-speed transmission
in each gear. 1st gear The torque is transferred from the input shaft to the layshaft. 1st gear is
engaged by the force induced by the 1st/2nd gear synchroniser unit. 2nd gear 2nd gear is engaged
by the force induced by the 1st/2nd gear synchroniser unit. 3rd gear 3rd gear is engaged by the
force induced by the 3rd/4th gear synchroniser unit. 4th gear 4th gear is engaged by the force
induced by the 3rd/4th gear synchroniser unit. 5th gear The input and output shafts are engaged by
the 5th/6th gear synchroniser unit. The input speed of the transmission is the same as the output
speed. 6th gear 6th gear is engaged by the 5th/6th gear synchroniser unit. Reverse gear The
reverse gear synchroniser unit engages reverse gear. With the help of the reverse gear idler (only
indicated here), the direction of rotation at the output shaft is reversed. Torque flow in 5th gear
(diagram of operation) In fifth gear the input shaft is mechanically connected with the output shaft.
The input shaft speed is the same as the output shaft speed and the gear ratio is 1:1. The input
shaft (1), the 5th gear splined synchroniser (2), the 5th/6th gear synchroniser hub (5) and the
output shaft (9) are joined together by inner splines. In the 5th gear shift process, the 5th/6th gear
synchroniser sleeve (4) is slid over the synchroniser ring onto the 5th gear splined synchroniser (2).
The torque from the input shaft is taken up by the internal splines of the synchroniser unit and
transferred to the output shaft. Torque flow in 6th gear (diagram of operation) The torque is passed
from the input shaft (1) to the 6th gear gear of the layshaft (10). The gear wheel of the 6th gear (8)
runs on a needle bearing. Only once the 5th/6th gear sliding collar (5) has created a force induced
connection with the 6th gear splined synchroniser (7) will the torque be transferred to the output
shaft (9). Bearings The bearings of the MT82 6-speed manual transmission have been reworked:
In order to compensate for the heat expansion of the shafts, they run in one bearing which can
slide in its seat and one bearing which is pressed home in its seat. The input shaft ball bearing
(pressed in its seat) absorbs axial and radial forces. The opposite bearing (sliding seat) is located
in the crankshaft (pilot bearing) and can only absorb radial forces. Item 4 is the output shaft bearing
with pressed seat. Bearing 2 acts as the sliding seat. Because of the high torque which must be
passed from the output shaft and the layshaft, the shafts are additionally supported by the centre
bearings (3) and (6). The layshaft ball bearing (7) is a pressed in seat bearing, and with the sliding
seat bearing (5) forms the bearing system for the layshaft.
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-06A Manual Transmission-Transaxle External Controls - Vehicles With: MT-75 > Specifications
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-06A Manual Transmission-Transaxle External Controls - Vehicles With: MT-75 > Description and Operation >
External Controls
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-06A Manual Transmission-Transaxle External Controls - Vehicles With: MT-75 > Description and Operation >
Diagnosis and Testing > External Controls
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-06B Manual Transmission-Transaxle External Controls - Vehicles With: VXT-75 > Specifications
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-06B Manual Transmission-Transaxle External Controls - Vehicles With: VXT-75 > Description and Operation >
External Controls
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-06B Manual Transmission-Transaxle External Controls - Vehicles With: VXT-75 > Description and Operation >
Diagnosis and Testing > External Controls
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-06B Manual Transmission-Transaxle External Controls - Vehicles With: VXT-75 > Description and Operation >
Diagnosis and Testing > Removal and Installation > Gearshift Lever

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-06B Manual Transmission-Transaxle External Controls - Vehicles With: VXT-75 > Description and Operation >
Diagnosis and Testing > Removal and Installation > Gearshift Cables

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-06C Manual Transmission-Transaxle External Controls - Vehicles With: MT82 > Specifications
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-06C Manual Transmission-Transaxle External Controls - Vehicles With: MT82 > Description and Operation >
External Controls

Gearshift mechanism The external shift mechanism has been reworked for the MT82 6-speed
manual transmission. The external shift mechanism is secured to the transmission housing by four
bolts. This modular construction allows installation of a different shift mechanism, e.g. console
shifting. Overview The 1st/2nd, 3rd/4th and 5th/6th gear selector rods and the reverse gear
selector rod are operated by the main selector shaft. The selector detents hold the selector rods in
position. During the gear shift process, the main selector shaft (5) makes a turning movement first
of all, so that it can then be slid axially. The inner gearshift mechanism of the MT82 6-speed
manual transmission is a new development. In order to ensure secure bearing mounting of the
selector rods, these are passed through a central bearing mounting plate. The central bearing
mounting plate is in turn bolted to the housing. All selector forks and swinging selector forks are
made of 5mm thick steel. The sliding elements of the selector forks are made of a newly developed
plastic material, which also demonstrates high resistance to wear. Selector rods Because of the
turning of the main selector shaft, the selector finger of the main selector shaft (4) slides into the
required selector rod (see illustration). Both selector rods can now be slid and allow the shift
function of the synchroniser unit. Selector interlock Only one gear can ever be engaged, because
of the selector interlock. When the transmission is in the neutral position the selector interlock is
free to move on the radial notches of the selector shafts. Because of the slots in the selector
interlock, it can be slid horizontally (see illustration). If a selector rod is moved during a gear shift
process, because of the change in the selector shaft diameter, it moves the selector interlock. The
selector interlock slides into the radial notches of all the other selector rods and locks them.
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-06C Manual Transmission-Transaxle External Controls - Vehicles With: MT82 > Description and Operation >
Diagnosis and Testing > External Controls
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-11 Manual Transmission-Transaxle Automated Gearshift System > Specifications
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-11 Manual Transmission-Transaxle Automated Gearshift System > Description and Operation > Diagnosis and
Testing > Automated Gearshift System
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-11 Manual Transmission-Transaxle Automated Gearshift System > Description and Operation > Diagnosis and
Testing > Removal and Installation > Hydraulic Pressure Unit (HPU)

Disconnect Tool, Hydraulic Line 308-440 (16-099) Worldwide Diagnostic System 418-F224
Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-11 Manual Transmission-Transaxle Automated Gearshift System > Description and Operation > Diagnosis and
Testing > Removal and Installation > Hydraulic Pressure Accumulator

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-11 Manual Transmission-Transaxle Automated Gearshift System > Description and Operation > Diagnosis and
Testing > Removal and Installation > Hydraulic Pressure Sensor

Worldwide Diagnostic System (WDS) 418-F224 Removal Installation

Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-11 Manual Transmission-Transaxle Automated Gearshift System > Description and Operation > Diagnosis and
Testing > Removal and Installation > Hydraulic Fluid Temperature Sensor

Worldwide Diagnostic System (WDS) 418-F224 Removal Installation

Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-11 Manual Transmission-Transaxle Automated Gearshift System > Description and Operation > Diagnosis and
Testing > Removal and Installation > Hydraulic Pressure Unit (HPU) Wiring Harness

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-11 Manual Transmission-Transaxle Automated Gearshift System > Description and Operation > Diagnosis and
Testing > Removal and Installation > Gearshift Actuator

Disconnect Tool, Hydraulic Line 308-440 (16-099) Worldwide Diagnostic System (WDS) 418-F224
Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-11 Manual Transmission-Transaxle Automated Gearshift System > Description and Operation > Diagnosis and
Testing > Removal and Installation > Gearshift Actuator Position Sensor

Worldwide Diagnostic System (WDS) 418-F224 Removal Installation

Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-11 Manual Transmission-Transaxle Automated Gearshift System > Description and Operation > Diagnosis and
Testing > Removal and Installation > Gearshift Shaft Connector

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-11 Manual Transmission-Transaxle Automated Gearshift System > Description and Operation > Diagnosis and
Testing > Removal and Installation > Clutch Actuator

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-11 Manual Transmission-Transaxle Automated Gearshift System > Description and Operation > Diagnosis and
Testing > Removal and Installation > Gearshift Hydraulic Fluid Lines

Worldwide Diagnostic System (WDS) 418-F224 Removal Installation

Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-11 Manual Transmission-Transaxle Automated Gearshift System > Description and Operation > Diagnosis and
Testing > Removal and Installation > Clutch Actuator Position Sensor

Worldwide Diagnostic System (WDS) 418-F224 Removal Installation

Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-11 Manual Transmission-Transaxle Automated Gearshift System > Description and Operation > Diagnosis and
Testing > Removal and Installation > Gearshift Hydraulic Fluid Reservoir

Worldwide Diagnostic System (WDS) 418-F224 Removal Installation

Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-11 Manual Transmission-Transaxle Automated Gearshift System > Description and Operation > Diagnosis and
Testing > Removal and Installation > Driver Interface Module

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-11 Manual Transmission-Transaxle Automated Gearshift System > Description and Operation > Diagnosis and
Testing > Removal and Installation > Transmission Control Module (TCM)

Worldwide Diagnostic System (WDS) 418-F224 Removal Installation

Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-11 Manual Transmission-Transaxle Automated Gearshift System > Description and Operation > Diagnosis and
Testing > Removal and Installation > Steering Wheel Gearshift Controls

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-11 Manual Transmission-Transaxle Automated Gearshift System > Description and Operation > Diagnosis and
Testing > Removal and Installation > Input Shaft Speed (ISS) Sensor

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 308 Manual Transmission-Transaxle, Clutch and Transfer
Case > 308-11 Manual Transmission-Transaxle Automated Gearshift System > Description and Operation > Automated
Gearshift System

Transmission Overview The automated gearshift system uses a combination of auto-clutch and
shift by wire electronic control systems to provide a significant fuel economy improvement over the
base manual transmission. The select shift mode allows the driver to select gears using the
steering wheel gearshift controls. The auto-shift mode provides automatic sequential gear shifting
similar to an automatic transmission. Further advantages are the reduced exhaust and noise
emissions with a simultaneous increase in comfort and convenience for the driver with a consistent
of good performance. Main components of the automated manual transmission Modifications to the
MT-75 transmission for use with the automated gearshift system The following components on the
MT-75 transmission have been modified for use with the automated gearshift system. Overview of
the components The automated gearshift operations and the operation of the clutch are carried out
hydraulically. The complete system is controlled by a transmission control module. The hydraulics
system is divided into three main assemblies. The hydraulic pressure unit (HPU) Gearshift actuator
Gearshift actuator (function) Gearshift actuator components Clutch actuator Overview -
transmission control Selection and shift operation (electronic operation) Driver interface module
The Driver interface module is located in the instrument panel above the audio unit. The
transmission range switches are used to select the transmission range (R, N, D). The MODE
button can be used to select three driving programs (full load, winter, economy) which have the
following significance: Selective shifting with the steering wheel gearshift controls Location of the
transmission control module Diagnostic instructions
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 309 Exhaust System > 309-00 Exhaust System >
Description and Operation > Exhaust System
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 309 Exhaust System > 309-00 Exhaust System >
Description and Operation > Removal and Installation > Muffler Inlet Pipe

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 309 Exhaust System > 309-00 Exhaust System >
Description and Operation > Removal and Installation > Catalytic Converter - 2.0L Duratorq-Di (Puma) Diesel-2.0L
Duratorq-TDCi (Puma) Diesel-2.0L Duratorq-TDDi (Puma) Diesel-2.4L Dura

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 309 Exhaust System > 309-00 Exhaust System >
Description and Operation > Removal and Installation > Catalytic Converter - 2.3L DOHC-16V

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 309 Exhaust System > 309-00 Exhaust System >
Specifications
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 310 Fuel System > 310-00A Fuel System - General
Information > Description and Operation > Fuel System
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 310 Fuel System > 310-00A Fuel System - General
Information > Description and Operation > Diagnosis and Testing > Fuel System

Hand Vacuum/Pressure Pump 416-D001 (23-036A) Inspection and Verification Visual Inspection
Chart Symptom Chart Symptom Chart Pinpoint Tests PINPOINT TEST A : AIR INGRESS INTO
THE FUEL SYSTEM Component Tests Fuel Filter Element - Vehicles with 75 PS, 90 PS or 100 PS
Engine Carry out the following test to determine if a new fuel filter element should be installed. Fuel
Filter Element - Vehicles with 120 PS Engine Carry out the following test to determine if a new fuel
filter element should be installed. Fuel Filter Minder Gauge - Vehicles with Diesel Engine Fuel Lift
Pump - Vehicles with 120 PS Engine with EGR Water-In-Fuel Sensor - Vehicles with Diesel Engine
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 310 Fuel System > 310-00A Fuel System - General
Information > Description and Operation > Diagnosis and Testing > General Procedures > Fuel System Pressure Release -
2.3L DOHC-16V

Release
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 310 Fuel System > 310-00A Fuel System - General
Information > Description and Operation > Diagnosis and Testing > General Procedures > Quick Release Coupling

Disconnection Connection
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 310 Fuel System > 310-00A Fuel System - General
Information > Description and Operation > Diagnosis and Testing > General Procedures > Fuel Tank Draining
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 310 Fuel System > 310-00A Fuel System - General
Information > Description and Operation > Diagnosis and Testing > General Procedures > Fuel System Bleeding - Vehicles
Without: Common Rail Fuel Injection
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 310 Fuel System > 310-00A Fuel System - General
Information > Description and Operation > Diagnosis and Testing > General Procedures > Fuel System Bleeding - Vehicles
With: Common Rail Fuel Injection
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 310 Fuel System > 310-00B Fuel System - General
Information - Liquified Petroleum Gas (LPG) > Description and Operation > Fuel System
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 310 Fuel System > 310-00B Fuel System - General
Information - Liquified Petroleum Gas (LPG) > Description and Operation > Diagnosis and Testing > Fuel System
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 310 Fuel System > 310-00B Fuel System - General
Information - Liquified Petroleum Gas (LPG) > Description and Operation > Diagnosis and Testing > General Procedures >
Fuel System Service Precautions
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 310 Fuel System > 310-00B Fuel System - General
Information - Liquified Petroleum Gas (LPG) > Description and Operation > Diagnosis and Testing > General Procedures >
Fuel System Differential Pressure Check
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 310 Fuel System > 310-00B Fuel System - General
Information - Liquified Petroleum Gas (LPG) > Description and Operation > Diagnosis and Testing > General Procedures >
Fuel Tank Evacuation

Pressure Release Valve (PRV) Adaptor. 310-108 (23-068-05) Connector, fuel line 310-092
(23-065)
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 310 Fuel System > 310-00B Fuel System - General
Information - Liquified Petroleum Gas (LPG) > Description and Operation > Diagnosis and Testing > General Procedures >
Fuel Line Evacuation Using Recovery Equipment

Actuator Cable 310-090 (23-064) Actuator Cable for 310-090 310-090-01 (23-068-02) Fuel
Vaporizer Evacuation Hose 310-107 (23-068-02) Connector, fuel line 310-092 (23-065)
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 310 Fuel System > 310-00B Fuel System - General
Information - Liquified Petroleum Gas (LPG) > Description and Operation > Diagnosis and Testing > General Procedures >
Fuel Line Evacuation Without Using Recovery Equipment
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 310 Fuel System > 310-00B Fuel System - General
Information - Liquified Petroleum Gas (LPG) > Description and Operation > Diagnosis and Testing > General Procedures >
Fuel System Leak Test

Actuator Cable 310-098 (23-068)

Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 310 Fuel System > 310-01A Fuel Tank and Lines >
Description and Operation > Fuel Tank and Lines
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 310 Fuel System > 310-01A Fuel Tank and Lines >
Description and Operation > Diagnosis and Testing > Fuel Tank and Lines
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 310 Fuel System > 310-01A Fuel Tank and Lines >
Description and Operation > Diagnosis and Testing > Removal and Installation > Fuel Tank

Wrench, Fuel Tank Sender Unit 310-069 (23-055) Removal Installation

Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 310 Fuel System > 310-01A Fuel Tank and Lines >
Description and Operation > Diagnosis and Testing > Removal and Installation > Fuel Filter - Vehicles Without: Common
Rail Fuel Injection

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 310 Fuel System > 310-01A Fuel Tank and Lines >
Description and Operation > Diagnosis and Testing > Removal and Installation > Fuel Filter - Vehicles With: Common Rail
Fuel Injection

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 310 Fuel System > 310-01A Fuel Tank and Lines >
Description and Operation > Diagnosis and Testing > Removal and Installation > Fuel Filter Element - Vehicles With:
Exhaust Gas Recirculation (EGR)

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 310 Fuel System > 310-01A Fuel Tank and Lines >
Specifications
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 310 Fuel System > 310-01B Fuel Tank and Lines -
Liquified Petroleum Gas (LPG) > Description and Operation > Fuel Tank and Lines
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 310 Fuel System > 310-01B Fuel Tank and Lines -
Liquified Petroleum Gas (LPG) > Description and Operation > Diagnosis and Testing > Fuel Tank and Lines
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 310 Fuel System > 310-01B Fuel Tank and Lines -
Liquified Petroleum Gas (LPG) > Description and Operation > Diagnosis and Testing > Removal and Installation > Fuel
Tank

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 310 Fuel System > 310-01B Fuel Tank and Lines -
Liquified Petroleum Gas (LPG) > Description and Operation > Diagnosis and Testing > Removal and Installation > Fuel
Tank Filler Valve

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 310 Fuel System > 310-01B Fuel Tank and Lines -
Liquified Petroleum Gas (LPG) > Description and Operation > Diagnosis and Testing > Removal and Installation > Fuel
Filter

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 310 Fuel System > 310-01B Fuel Tank and Lines -
Liquified Petroleum Gas (LPG) > Specifications
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 310 Fuel System > 310-02A Acceleration Control - 2.0L
Duratorq-Di (Puma) Diesel-2.0L Duratorq-TDCi (Puma) Diesel-2.0L Duratorq-TDDi (Puma) Diesel- > Diagnosis and Testing
> Acceleration Control - Vehicles With: Exhaust Gas Recirculation (EGR)
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 310 Fuel System > 310-02A Acceleration Control - 2.0L
Duratorq-Di (Puma) Diesel-2.0L Duratorq-TDCi (Puma) Diesel-2.0L Duratorq-TDDi (Puma) Diesel- > Diagnosis and Testing
> Removal and Installation > Accelerator Cable

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 3 Powertrain > 310 Fuel System > 310-02B Acceleration Control - 2.3L
DOHC-16V > Diagnosis and Testing > Acceleration Control
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 412 Climate Control System > 412-00 Climate Control
System - General Information > Specifications
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 412 Climate Control System > 412-00 Climate Control
System - General Information > Diagnosis and Testing > Climate Control System - Vehicles With: Central Junction Box
(CJB)

Terminal probe kit 29-011A Inspection and Verification Visual Inspection Chart Refrigerant Circuit -
Quick Check Refrigerant Circuit Check During operation of the air conditioning system, the
following conditions shows be apparent: Evaporator Outlet Temperature Test In order to check the
A/C output, the temperature of the evaporator outlet line must be measured. The following
preparations must be taken for this purpose: Connect temperature sensor (Fluke 80 PK-8) to the
evaporator outlet line. The temperature sensor must be positioned as closely as possible to the
evaporator. Connect the temperature sensor to the digital multimeter. Start the engine and allow it
to run at idle speed for several minutes. Switch on the air-conditioning system. After three minutes,
measure the surface temperature of the evaporator outlet line. If the temperature measured is 5° C
(vehicles with dual A/C system: 2° C) or lower, the A/C system is OK. If the temperature is higher,
the A/C system may be under-filled. For further information REFER to: Air Conditioning (A/C)
System Recovery, Evacuation and Charging (412-00 Climate Control System - General
Information, General Procedures). Frequent faults and their causes Should a customer express
concern about poor cooling performance of the A/C system it must be ensured that actuation of the
temperature door(s) is functioning correctly. Symptom Chart Symptom Chart Pinpoint Tests
PINPOINT TEST A : THE BLOWER MOTOR IS INOPERATIVE/DOES NOT OPERATE
CORRECTLY PINPOINT TEST B : THE AUXILIARY BLOWER MOTOR IS INOPERATIVE/DOES
NOT OPERATE CORRECTLY PINPOINT TEST C : THE AIR CONDITIONING (A/C) IS
INOPERATIVE PINPOINT TEST D : THE AIR CONDITIONING (A/C) COMPRESSOR DOES NOT
OPERATE IN DEFROST PINPOINT TEST E : TEMPERATURE CONTROL IS
INOPERATIVE/DOES NOT OPERATE CORRECTLY - VEHICLES WITH AIR CONDITIONING
PINPOINT TEST F : THE TEMPERATURE CONTROL IS INOPERATIVE USING THE REAR
AUXILIARY CLIMATE CONTROLS PINPOINT TEST G : INCORRECT DIRECTION OF THE AIR
FLOW USING THE REAR AUXILIARY CLIMATE CONTROLS Component Tests Refrigerant
Circuit Workshop Equipment Servicing unit/pressure gauges Stopwatch Electronic leak tester Leak
test Test all components and refrigerant lines with an electronic leak tester. REFER to: Electronic
Leak Detection (412-00 Climate Control System - General Information, General Procedures). If
necessary switch on the motor and the air conditioning to locate any small leaks in the
high-pressure lines. Leaks In the event of any leaks, rectify the leak(s), renew any faulty
components and drain and refill the air conditioning system. System Test Three values are used for
the fault diagnosis: Connecting the testing equipment The following requirements must be met in
order to carry out an accurate test: Specified values for high and low-pressure The measured
values for high and low-pressure depend on the outside temperature. This is shown in the diagram
and the table. The area between the two curves corresponds to the tolerance range. The measured
value must lie in this range. Specified values for high-pressure Specified values for
low-temperature Required values: switching cycles The following three diagrams show the required
values for the A/C compressor switching cycles. Measure the cycles using a stopwatch and make a
note of the result. If the measured value lies outside the tolerance range then there is an error in
the system. Refer to the Symptom Chart in this section. Specified values for on-time Specified
values for off-time Specified values for total cycle time Check the on/off-cycles The following
conditions must be met before checking the switching cycle: As an example, after comparison with
the diagrams the following five faults could be present. Next compare these statements with those
in the following symptom chart and read off the cause of the fault. Example: Fault present: not
enough refrigerant in the system. Symptom Chart - Refrigerant Circuit
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 412 Climate Control System > 412-00 Climate Control
System - General Information > Diagnosis and Testing > General Procedures > Spring Lock Coupling
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 412 Climate Control System > 412-00 Climate Control
System - General Information > Diagnosis and Testing > General Procedures > Fluorescent Dye Leak Detection
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 412 Climate Control System > 412-00 Climate Control
System - General Information > Diagnosis and Testing > General Procedures > Air Conditioning (A-C) Clutch Air Gap
Adjustment
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 412 Climate Control System > 412-00 Climate Control
System - General Information > Diagnosis and Testing > General Procedures > Vacuum Leak Detection
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 412 Climate Control System > 412-00 Climate Control
System - General Information > Diagnosis and Testing > General Procedures > Electronic Leak Detection
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 412 Climate Control System > 412-00 Climate Control
System - General Information > Diagnosis and Testing > General Procedures > Air Conditioning (A-C) System Recovery,
Evacuation and Charging
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 412 Climate Control System > 412-00 Climate Control
System - General Information > Diagnosis and Testing > General Procedures > Refrigerant Oil Adding
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 412 Climate Control System > 412-00 Climate Control
System - General Information > Diagnosis and Testing > General Procedures > Contaminated Refrigerant Handling
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 412 Climate Control System > 412-01 Air Distribution and
Filtering > Description and Operation > Diagnosis and Testing > Air Distribution and Filtering
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 412 Climate Control System > 412-01 Air Distribution and
Filtering > Description and Operation > Diagnosis and Testing > Removal and Installation > Driver Side Register

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 412 Climate Control System > 412-01 Air Distribution and
Filtering > Description and Operation > Diagnosis and Testing > Removal and Installation > Center Registers

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 412 Climate Control System > 412-01 Air Distribution and
Filtering > Description and Operation > Air Distribution and Filtering

The purpose of the air distribution system is to route air to the designated registers. This is
accomplished when air enters the plenum through the fresh air inlet and is routed to the selected
outlets by use of distribution doors. The pollen filter is located underneath the cowl panel and
cleans the air of pollen and dirt particles. Air ducts route air to specific areas of the air distribution
system. Air Ducts These areas are the floor ducts, panel registers, side window demisters, and
defrost nozzles. Air Distribution The panel registers are adjustable and are used to aim the
discharged air to a required area. The footwell vents, side window vents, and defrost nozzles are
non - adjustable. The distribution door positions are determined by the control components. The
distribution doors open and close air flow passages inside the air distribution system to establish air
flow direction. There are two distribution doors inside the plenum assembly, defrost vent/duct blend
door and footwell vent/duct blend door. The defrost vent/duct blend door can be positioned to either
block off or allow air to the panel ducts or defrost ducts. The footwell vent/duct blend door can
block off or allow air to the panel/defrost ducts or the footwell duct.
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 412 Climate Control System > 412-02A Heating and
Ventilation > Specifications
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 412 Climate Control System > 412-02A Heating and
Ventilation > Diagnosis and Testing > Heating and Ventilation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 412 Climate Control System > 412-02A Heating and
Ventilation > Diagnosis and Testing > Removal and Installation > Blower Motor - Vehicles Without: Air Conditioning

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 412 Climate Control System > 412-02A Heating and
Ventilation > Diagnosis and Testing > Removal and Installation > Blower Motor - Vehicles With: Air Conditioning

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 412 Climate Control System > 412-02A Heating and
Ventilation > Diagnosis and Testing > Removal and Installation > Heater Core Housing - Vehicles With: Air Conditioning

Disconnect Tool, Spring Lock Coupling 1/2 inch (blue) 412-027 (34-001) Disconnect Tool, Spring
Lock Coupling 5/8 inch (black) 412-038 (34-003) Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 412 Climate Control System > 412-02A Heating and
Ventilation > Diagnosis and Testing > Removal and Installation > Heater Core Housing - Vehicles Without: Air Conditioning

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 412 Climate Control System > 412-02A Heating and
Ventilation > Diagnosis and Testing > Removal and Installation > Heater Core

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 412 Climate Control System > 412-02A Heating and
Ventilation > Diagnosis and Testing > Removal and Installation > Disassembly and Assembly > Heater Core Housing -
Vehicles With: Air Conditioning

Disassembly Assembly
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 412 Climate Control System > 412-02A Heating and
Ventilation > Diagnosis and Testing > Removal and Installation > Disassembly and Assembly > Heater Core Housing -
Vehicles Without: Air Conditioning

Disassembly Assembly
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 412 Climate Control System > 412-02B Auxiliary Heating >
Specifications
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 412 Climate Control System > 412-02B Auxiliary Heating >
Description and Operation > Auxiliary Heater

An additional heater with a second heat exchanger is optional, providing heating for the rear of the
passenger compartment (together with rear air conditioning). No recirculated air facility is provided.
The heater housing is located behind the left-hand side trim panel beside the last row of rear seats.
The operating switch for the rear heater is located in the front headlining between the driver and
front passenger. The blower motor switch has four settings, from off to high. The air distribution is
actuated electronically and routes air to the floor duct or center vent nozzle as required.
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 412 Climate Control System > 412-02B Auxiliary Heating >
Description and Operation > Booster Heater

Owing to the high efficiency of the diesel engines, at low temperatures there is insufficient waste
heat available for the heater. For this reason a fuel fired booster heater is installed (country
dependent) to increase the coolant temperature so that the discharge air in the heater core is
heated up sufficiently. A programmable control unit is optional on vehicles with programmable fuel
fired booster heater, which is located in the driver side instrument panel lower panel. The highest
output of the fuel fired booster heater is 5 kW and the lowest 2.4 kW. A fuel metering pump
attached to the fuel fired booster heater transfers diesel from the engine fuel return pipe and pumps
it into the evaporator section of the combustion chamber. Following preheating and ignition, the
combustion air blower and fuel metering pump are program - controlled to provide maximum
performance. The exhaust gases are discharged into the outside air by means of a separate
exhaust system. Several attempts to start the fuel fired booster heater can result in a single cloud
of black smoke. At low temperatures starting the fuel fired booster heater for the first time can
produce condensation and smoke in the exhaust gas. The system is automatically activated when
the engine is running (signal D+ from the generator is active) and the ambient temperature is lower
than 5 °C and the coolant temperature falls below 75 °C. The system is not activated automatically
if the ambient temperature lies above 5 °C or if the coolant temperature is higher than 75 °C or in
the event of a malfunction. The system is deactivated if the ambient temperature rises above 5 °C
or if the coolant temperature reaches 85 °C or in the event of a malfunction. The system shuts
down if: In the event of an electronic failure, the unit is deactivated at 125 °C. A hardware circuit
working independent of the micro controller switches off the fuel pump if the temperature at the
overheat sensor reaches 130°C (overheat protection in case of a micro controller failure). Sectional
view of Fuel Fired Booster Heater - Vehicles with non programmable fuel fired booster heater
Sectional view of Fuel Fired Booster Heater - Vehicles with programmable fuel fired booster heater
Exploded view - Fuel Fired Booster Heater - Vehicles with non programmable fuel fired booster
heater Exploded view - Fuel Fired Booster Heater - Vehicles with programmable fuel fired booster
heater
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 412 Climate Control System > 412-02B Auxiliary Heating >
Description and Operation > Diagnosis and Testing > Auxiliary Heater
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 412 Climate Control System > 412-02B Auxiliary Heating >
Description and Operation > Diagnosis and Testing > Booster Heater

Terminal Probe Kit 418-S035 Inspection and Verification Visual inspection Fault Code Table
Symptom chart Symptom chart Pinpoint Tests PINPOINT TEST A : FUEL FIRED BOOSTER
HEATER INOPERATIVE - VEHICLES WITH NON-PROGRAMMABLE FUEL FIRED BOOSTER
HEATER PINPOINT TEST B : FUEL FIRED BOOSTER HEATER INOPERATIVE - VEHICLES
WITH PROGRAMMABLE FUEL FIRED BOOSTER HEATER PINPOINT TEST C : HEATER
BLOWER MOTOR INOPERATIVE WHEN FUEL FIRED BOOSTER HEATER SWITCHED ON -
VEHICLES WITH PROGRAMMABLE FUEL FIRED BOOSTER HEATER BUILT UP TO 07/2003
PINPOINT TEST D : HEATER BLOWER MOTOR INOPERATIVE WHEN FUEL FIRED BOOSTER
HEATER SWITCHED ON - VEHICLES WITH PROGRAMMABLE FUEL FIRED BOOSTER
HEATER BUILT FROM 07/2003 PINPOINT TEST E : AUXILIARY HEATER METERING PUMP
INOPERATIVE PINPOINT TEST F : GLOW PLUG INOPERATIVE PINPOINT TEST G : COOLANT
FLOW AUXILIARY PUMP INOPERATIVE - VEHICLES WITH PROGRAMMABLE FUEL FIRED
BOOSTER HEATER Component Tests Heater blower relay of parking heater Combustion air
blower motor 1. If yes, CHECK the combustion air blower fanwheel and motor for blockage. See
above. 2. If no, RENEW the combustion air blower motor. Temperature sensor 1. If yes, go on to 3.
2. If no, RENEW the temperature sensor. 1. If yes, the temperature sensor is OK. 2. If no, RENEW
the temperature sensor. Overheating sensor 1. If yes, go on to 3. 2. If no, RENEW the overheating
sensor. 1. If yes, the overheating sensor is OK. 2. If no, RENEW the overheating sensor. Flame
sensor 1. If yes, go on to 3. 2. If no, RENEW the overheating sensor. 1. If yes, the flame sensor is
OK. 2. If no, RENEW the flame sensor. Booster heater metering pump fuel quantity Preparations
for measuring the fuel quantity Disconnect the fuel line between the auxiliary heater metering pump
and the heater. Lengthen the fuel line if necessary. Insert the free end of the fuel line into a suitable
graduated vessel. Switch on the programmable fuel fired booster heater via the parking heater
controls or for vehicles with non-programmable fuel fired booster heater, start the engine and run it
at idle speed. (Pay attention to the switch-on conditions of the fuel fired booster heater REFER to:
Booster Heater (412-02B Auxiliary Heating, Description and Operation). ) If necessary, bridge the
ambient temperature thermo switch. Fuel delivery begins 45 seconds after the fuel fired booster
heater is switched on. If the fuel escapes from the fuel line without air bubbles, switch off the fuel
fired booster heater again and empty the graduated vessel. Measure the fuel quantity Switch on
the programmable fuel fired booster heater via the parking heater controls or for vehicles with
non-programmable fuel fired booster heater, start the engine and run it at idle speed. (Observe the
activation conditions of the fuel fired booster heater REFER to: Booster Heater (412-02B Auxiliary
Heating, Description and Operation). ) Fuel delivery begins after 45 seconds. Fuel delivery ends
automatically after approx. 90 seconds. Switch off the fuel fired booster heater. The fuel quantity
delivered should be between 7.8 cm3 and 9.0 cm3. If the fuel quantity is outside this range, check
the screen in the suction connection of the auxiliary heater metering pump for dirt and clean if
necessary. Repeat the measurement. If the fuel quantity is outside the specified delivery quantity
after cleaning the screen, renew the auxiliary heater metering pump.
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 412 Climate Control System > 412-02B Auxiliary Heating >
Description and Operation > Diagnosis and Testing > Removal and Installation > Booster Heater

Remover/Installer, Cooling Hose Clamp 303-397 (24-003) Removal Installation

Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 412 Climate Control System > 412-02B Auxiliary Heating >
Description and Operation > Diagnosis and Testing > Removal and Installation > Auxiliary Blower Motor

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 412 Climate Control System > 412-02B Auxiliary Heating >
Description and Operation > Diagnosis and Testing > Removal and Installation > Auxiliary Heater Core

Remover/Installer, Cooling Hose Clamp 303-397 (24-003) Removal Installation

Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 412 Climate Control System > 412-02B Auxiliary Heating >
Description and Operation > Diagnosis and Testing > Removal and Installation > Auxiliary Heater Core Housing

Remover/Installer, Cooling Hose Clamp 303-397 (24-003) Removal Installation

Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 412 Climate Control System > 412-02B Auxiliary Heating >
Description and Operation > Diagnosis and Testing > Removal and Installation > Disassembly and Assembly > Booster
Heater

Disassembly Assembly
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 412 Climate Control System > 412-02B Auxiliary Heating >
Description and Operation > Diagnosis and Testing > Removal and Installation > Disassembly and Assembly > Auxiliary
Heater Core Housing

Remover/Installer, Cooling Hose Clamp 303-397 (24-003) Disassembly Assembly

Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 412 Climate Control System > 412-03A Air Conditioning >
Specifications
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 412 Climate Control System > 412-03A Air Conditioning >
Description and Operation > Diagnosis and Testing > Air Conditioning
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 412 Climate Control System > 412-03A Air Conditioning >
Description and Operation > Diagnosis and Testing > Removal and Installation > Air Conditioning (A-C) Compressor - 2.0L
Duratorq-Di (Puma) Diesel-2.0L Duratorq-TDCi (Puma) Diesel-2.0L Duratorq-TDDi (Puma) Di

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 412 Climate Control System > 412-03A Air Conditioning >
Description and Operation > Diagnosis and Testing > Removal and Installation > Air Conditioning (A-C) Compressor - 2.3L
DOHC-16V

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 412 Climate Control System > 412-03A Air Conditioning >
Description and Operation > Diagnosis and Testing > Removal and Installation > Clutch and Clutch Field Coil - 2.0L
Duratorq-Di (Puma) Diesel-2.0L Duratorq-TDCi (Puma) Diesel-2.0L Duratorq-TDDi (Puma) Diesel-

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 412 Climate Control System > 412-03A Air Conditioning >
Description and Operation > Diagnosis and Testing > Removal and Installation > Clutch and Clutch Field Coil - 2.3L
DOHC-16V

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 412 Climate Control System > 412-03A Air Conditioning >
Description and Operation > Diagnosis and Testing > Removal and Installation > Evaporator Core

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 412 Climate Control System > 412-03A Air Conditioning >
Description and Operation > Diagnosis and Testing > Removal and Installation > Evaporator Core Orifice - RHD

Disconnect Tool, Spring Lock Coupling 1/2 inch (blue) 412-027 (34-001) Remover/Installer, Fixed
Orifice 412-034 (34-004) Remover, Broken Orifice 412-035 (34-005) Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 412 Climate Control System > 412-03A Air Conditioning >
Description and Operation > Diagnosis and Testing > Removal and Installation > Evaporator Core Orifice - LHD

Disconnect Tool, Spring Lock Coupling 1/2 inch (blue) 412-027 (34-001) Remover/Installer, Fixed
Orifice 412-034 (34-004) Remover, Broken Orifice 412-035 (34-005) Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 412 Climate Control System > 412-03A Air Conditioning >
Description and Operation > Diagnosis and Testing > Removal and Installation > Suction Accumulator

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 412 Climate Control System > 412-03A Air Conditioning >
Description and Operation > Diagnosis and Testing > Removal and Installation > Low-Pressure Cutoff Switch

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 412 Climate Control System > 412-03A Air Conditioning >
Description and Operation > Diagnosis and Testing > Removal and Installation > High-Pressure Cutoff Switch - 2.3L
DOHC-16V-2.4L Duratorq-Di (Puma) Diesel-2.4L Duratorq-TDCi (Puma) Diesel

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 412 Climate Control System > 412-03A Air Conditioning >
Description and Operation > Diagnosis and Testing > Removal and Installation > High-Pressure Cutoff Switch - 2.0L
Duratorq-Di (Puma) Diesel-2.0L Duratorq-TDCi (Puma) Diesel-2.0L Duratorq-TDDi (Puma) Diesel

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 412 Climate Control System > 412-03A Air Conditioning >
Description and Operation > Diagnosis and Testing > Removal and Installation > Condenser Core - Vehicles With: Charge
Air Cooler

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 412 Climate Control System > 412-03A Air Conditioning >
Description and Operation > Diagnosis and Testing > Removal and Installation > Condenser Core - Vehicles Without:
Charge Air Cooler

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 412 Climate Control System > 412-03A Air Conditioning >
Description and Operation > Air Conditioning
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 412 Climate Control System > 412-03B Auxiliary Climate
Control > Specifications
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 412 Climate Control System > 412-03B Auxiliary Climate
Control > Description and Operation > Diagnosis and Testing > Auxiliary Climate Control
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 412 Climate Control System > 412-03B Auxiliary Climate
Control > Description and Operation > Diagnosis and Testing > Removal and Installation > Auxiliary Climate Control
Housing

Remover/Installer, Cooling Hose Clamp 303-397 (24-003) Removal Installation

Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 412 Climate Control System > 412-03B Auxiliary Climate
Control > Description and Operation > Diagnosis and Testing > Removal and Installation > Auxiliary Blower Motor

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 412 Climate Control System > 412-03B Auxiliary Climate
Control > Description and Operation > Diagnosis and Testing > Removal and Installation > Evaporator Core

Remover/Installer, Cooling Hose Clamp 303-397 (24-003) Removal Installation

Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 412 Climate Control System > 412-03B Auxiliary Climate
Control > Description and Operation > Diagnosis and Testing > Removal and Installation > Thermostatic Expansion Valve

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 412 Climate Control System > 412-03B Auxiliary Climate
Control > Description and Operation > Diagnosis and Testing > Removal and Installation > Disassembly and Assembly >
Auxiliary Climate Control Housing

Remover/Installer, Cooling Hose Clamp 303-397 (24-003) Disassembly Assembly

Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 412 Climate Control System > 412-03B Auxiliary Climate
Control > Description and Operation > Auxiliary Climate Control
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 412 Climate Control System > 412-04 Control Components
> Description and Operation > Control Components

Climate Control Assembly - Vehicles without Air Conditioning (A/C) Vehicles without A/C have a
climate control assembly with three rotary switches. Temperature control and air distribution control
are actuated mechanically by means of Bowden cables. The air inlet blend door actuator is vacuum
controlled. Climate Control Assembly - Vehicles with Air Conditioning (A/C) The climate control
assembly fitted to vehicles with A/C differs only in respect of the blower motor switch. Air
distribution is actuated mechanically by means of a Bowden Cable. Temperature control is
actuated electronically and the air inlet blend door actuator is vacuum controlled.
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 412 Climate Control System > 412-04 Control Components
> Description and Operation > Diagnosis and Testing > Control Components
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 412 Climate Control System > 412-04 Control Components
> Description and Operation > Diagnosis and Testing > Removal and Installation > Climate Control Assembly

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 412 Climate Control System > 412-04 Control Components
> Description and Operation > Diagnosis and Testing > Removal and Installation > Air Inlet Blend Door Actuator - Vehicles
With: Air Conditioning

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 412 Climate Control System > 412-04 Control Components
> Description and Operation > Diagnosis and Testing > Removal and Installation > Air Inlet Blend Door Actuator - Vehicles
Without: Air Conditioning

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 412 Climate Control System > 412-04 Control Components
> Description and Operation > Diagnosis and Testing > Removal and Installation > Blower Motor Resistor

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 412 Climate Control System > 412-05 Refrigeration >
Specifications
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 412 Climate Control System > 412-05 Refrigeration >
Description and Operation > Refrigeration

CFC-free refrigeration systems are used in the Ford Transit Freshliner. The powerful systems have
a modern hot gas defrost system and an adjustable temperature control system (0 to +12°C).
Additional stationary refrigeration is optionally available. The passenger compartment does not
have air conditioning. Refrigeration system In vehicles fitted with a refrigeration system, the
compressor, condenser core, high-pressure cutoff switch and electrical wiring of conventional air
conditioning systems have been adopted. However, an expansion valve is also used, in contrast to
vehicles with air conditioning. The function of the accumulator/drier is assumed by a combination
comprising a separate accumulator that is only used for the refrigeration system (in the engine
compartment instead of the accumulator/drier) and a drier/filter (behind the driver's seat). The
evaporator core is located above the loading space at the rear wall of the driver's cab and is
equipped with four evaporator core fans. The refrigeration compartment temperature is set via a
control panel located in the headliner instead of the front interior lamp. Stationary refrigeration The
stationary refrigeration system comprises the components of the refrigeration system as well as an
additional compressor which is driven by a 230-volt motor via a drive belt, an additional
accumulator, a power supply switch box and a power supply transformer. The compressors and the
accumulators in the refrigeration system and stationary refrigeration are identical. To prevent
manipulations by third parties, as well as to protect sensitive electrical components, these parts
have been positioned in the driver's cab, behind the seats. During operation of stationary
refrigeration, the vehicle voltage required for operating the evaporator core fans, the two radiator
fans etc. is generated by the power supply transformer to prevent the vehicle battery from being
drained. The system is connected to the 230-volt circuit via a special cable which is supplied with
the system Hot gas defrost The condensation that forms and freezes when the loading space
temperature drops, icing up the evaporator core, must be removed to retain the refrigerating
capacity. This is achieved via the hot gas defrost. A differential pressure sensor located in the
evaporator core case measures the air pressure upstream and downstream of the evaporator core.
If required, hot, gaseous refrigerant is conveyed directly upstream of the evaporator core and
mixes there with the cold, liquid refrigerant after the defrost valve Y2 has opened. The defrost
operation is also initiated automatically every two hours by the electronic controller or manually.
After the defrost procedure, the system continues to cool automatically. The condensation is
conducted away via two water drain hoses which are routed to the outside through the vehicle
floor. As a result, puddles of water may form under the vehicle. Bypass If the suction pressure at
the accumulator drops below 0.8 bar, the bypass is opened via the bypass valve Y3. This injects
refrigerant downstream of the evaporator core via an orifice pipe in order to ensure adequate
cooling and lubrication of the compressor in operation. Stationary refrigeration pressure regulator
The adjustable pressure regulator protects the stationary refrigeration motor from overloading when
starting up after relatively long downtimes or after the defrost period (high pressure in the
evaporator core). It should only be adjusted during hot gas defrost (set pressure p=0.8 bar). Fault
message An audible warning indicates a fault in the refrigeration system, which can also been seen
from a flashing display of the current fault code. The refrigeration system switches off and the
display continues to flash until the fault has been remedied. Refrigeration System Refrigerant
Circuit Refrigerant Circuit - Refrigeration System with Stationary refrigeration Controller Status
Display - Refrigeration System Controller Status Display - Refrigeration System with Stationary
refrigeration Refrigeration System Sequence After switching on the refrigeration system by
pressing the On/Off switch, the display will start flashing for the self-test. Then the actual loading
space temperature is displayed and the refrigeration valve Y1 opens. The compressor switches on
(with a time delay of 2 seconds for vehicles built after 11/2001) if the high pressure is below 28 bar
and the compressor temperature is below 120°C. The evaporator core fans switch on if the
evaporator core temperature is below 10°C. The bypass line to the compressor is opened via the
bypass valve Y3 if the suction pressure at the accumulator in the engine compartment is below 0.8
bar. Hot gas defrost takes place via the defrost valve Y2 if the evaporator core is iced up. Hot gas
defrost takes place in automatic mode after two hours of operation or via manual initialization. The
compressor switches off via the powertrain control module (PCM) if the suction pressure is below
0.2 bar; there is no feedback to the refrigeration system control module. After the compressor has
been switched on automatically, the controller checks the system pressure which must be above 2
bar. The compressor switches off if the compressor temperature is above 120°C and switches on
again when the compressor temperature is below 115°C. The refrigeration system switches off if
the high pressure is above 28 bar. Operation of the system can only be restarted by pressing the
Reset button. For vehicles built from 11/2001, the refrigeration system switches off if the high
pressure is above 28 bar and switches on again below 16 bar. After the 5th pressure peak above
28 bar, operation of the system can only be restarted by pressing the Reset button. The
compressor switches off via the PCM if the high pressure at the compressor is above 30 bar. The
compressor then switches on again automatically; there is no feedback to the refrigeration system
control module.
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 412 Climate Control System > 412-05 Refrigeration >
Description and Operation > Diagnosis and Testing > Refrigeration

Terminal Probe Kit 418-S035 Inspection and Checking Visual Inspection Symptom Chart Symptom
Chart System Checks PINPOINT TEST A : MOBILE REFRIGERATION INOPERATIVE PINPOINT
TEST B : STATIONARY REFRIGERATION INOPERATIVE (MOBILE REFRIGERATION OK)
PINPOINT TEST C : RADIATOR FAN INOPERATIVE WHEN STATIONARY REFRIGERATION IS
OPERATING - VEHICLES BUILT UP TO 11/2002 (OPERATION OK WITH MOBILE
REFRIGERATION) PINPOINT TEST D : RADIATOR FAN INOPERATIVE WHEN STATIONARY
REFRIGERATION IS OPERATING - VEHICLES BUILT FROM 11/2002 (OPERATION OK WITH
MOBILE REFRIGERATION) PINPOINT TEST E : EVAPORATOR CORE FANS INOPERATIVE
PINPOINT TEST F : HOT GAS DEFROST INOPERATIVE Component Tests Loading space
temperature sensor The applicable tolerance range which describes the "normal" range for a
measured value lies between the upper and lower curves. Evaporator core temperature sensor The
applicable tolerance range which describes the "normal" range for a measured value lies between
the upper and lower curves. Refrigeration system wide open throttle (WOT) relay Check
refrigeration system capacity Test preparations The following values must be determined: In order
to achieve a precise measurement, the loading space temperature must be at least + 18° C when
beginning the measurement. It is important to ensure an even temperature throughout the loading
space. This can be achieved through ventilation by leaving the loading space doors open for a
suitable period of time (at least 1 hour). The following steps must then be performed: Check
Evaluation The loading space temperature must be at least 6° C below the value of the initial
measurement. Otherwise, the refrigerating capacity is insufficient and more extensive diagnosis of
the refrigerant circuit must be performed. Testing the Refrigerant Circuit Workshop Equipment The
following equipment is required for the tests: Pinpoint Test: Refrigerant Circuit The following values
must be determined: Test preparations The following steps must be carefully followed to guarantee
accurate test results. Test the system pressures Target values The high and low pressure values
depend on the ambient temperature. The ambient temperature should be measured at a distance
of 1 m from the vehicle. The applicable tolerance range which describes the "normal" range for a
measured value lies between the upper and lower curves. High pressure Low pressure Symptom
Chart: Refrigeration System Refrigerant Circuit Symptom Chart: Refrigerant Circuit
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 412 Climate Control System > 412-05 Refrigeration >
Description and Operation > Diagnosis and Testing > General Procedures > Stationary Refrigeration Pressure Regulator
Adjustment

Refrigerant center or equivalent equipment Refrigerant analyzer or equivalent equipment Digital

multimeter 105-R0051 or equivalent equipment
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 412 Climate Control System > 412-05 Refrigeration >
Description and Operation > Diagnosis and Testing > General Procedures > Removal and Installation > Refrigeration
Control Assembly

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 412 Climate Control System > 412-05 Refrigeration >
Description and Operation > Diagnosis and Testing > General Procedures > Removal and Installation > Refrigeration
Accumulator

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 412 Climate Control System > 412-05 Refrigeration >
Description and Operation > Diagnosis and Testing > General Procedures > Removal and Installation > Refrigeration
Compressor

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 412 Climate Control System > 412-05 Refrigeration >
Description and Operation > Diagnosis and Testing > General Procedures > Removal and Installation > Stationary
Refrigeration Accumulator

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 412 Climate Control System > 412-05 Refrigeration >
Description and Operation > Diagnosis and Testing > General Procedures > Removal and Installation > Stationary
Refrigeration Compressor

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 412 Climate Control System > 412-05 Refrigeration >
Description and Operation > Diagnosis and Testing > General Procedures > Removal and Installation > Stationary
Refrigeration Compressor Belt

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 412 Climate Control System > 412-05 Refrigeration >
Description and Operation > Diagnosis and Testing > General Procedures > Removal and Installation > Refrigeration
Drier-Filter

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 412 Climate Control System > 412-05 Refrigeration >
Description and Operation > Diagnosis and Testing > General Procedures > Removal and Installation > Refrigeration
Evaporator Core

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 412 Climate Control System > 412-05 Refrigeration >
Description and Operation > Diagnosis and Testing > General Procedures > Removal and Installation > Refrigeration
Condenser Core - Vehicles With: Charge Air Cooler

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 412 Climate Control System > 412-05 Refrigeration >
Description and Operation > Diagnosis and Testing > General Procedures > Removal and Installation > Refrigeration
Condenser Core - Vehicles Without: Charge Air Cooler

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 412 Climate Control System > 412-05 Refrigeration >
Description and Operation > Diagnosis and Testing > General Procedures > Removal and Installation > Refrigeration
High-Pressure Cutoff Switch

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 412 Climate Control System > 412-05 Refrigeration >
Description and Operation > Diagnosis and Testing > General Procedures > Removal and Installation > Refrigeration
Low-Pressure Cutoff Switch

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 412 Climate Control System > 412-05 Refrigeration >
Description and Operation > Diagnosis and Testing > General Procedures > Removal and Installation > Refrigeration
Bypass Control Pressure Switch

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 412 Climate Control System > 412-05 Refrigeration >
Description and Operation > Diagnosis and Testing > General Procedures > Removal and Installation > Stationary
Refrigeration Pressure Regulator

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 412 Climate Control System > 412-05 Refrigeration >
Description and Operation > Diagnosis and Testing > General Procedures > Removal and Installation > Refrigeration
Control Module

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 412 Climate Control System > 412-05 Refrigeration >
Description and Operation > Diagnosis and Testing > General Procedures > Removal and Installation > Stationary
Refrigeration Non-Return Valve

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 412 Climate Control System > 412-05 Refrigeration >
Description and Operation > Diagnosis and Testing > General Procedures > Removal and Installation > Refrigeration Clutch
and Clutch Field Coil

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 412 Climate Control System > 412-05 Refrigeration >
Description and Operation > Diagnosis and Testing > General Procedures > Removal and Installation > Stationary
Refrigeration Clutch and Clutch Field Coil

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 412 Climate Control System > 412-05 Refrigeration >
Description and Operation > Diagnosis and Testing > General Procedures > Removal and Installation > Stationary
Refrigeration Power Supply Switch Box

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 412 Climate Control System > 412-05 Refrigeration >
Description and Operation > Diagnosis and Testing > General Procedures > Removal and Installation > Stationary
Refrigeration Motor

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 412 Climate Control System > 412-05 Refrigeration >
Description and Operation > Diagnosis and Testing > General Procedures > Removal and Installation > Stationary
Refrigeration Power Supply Socket

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 412 Climate Control System > 412-05 Refrigeration >
Description and Operation > Diagnosis and Testing > General Procedures > Removal and Installation > Stationary
Refrigeration Power Supply Transformer

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 413 Instrumentation and Warning Systems > 413-00
Instrument Cluster and Panel Illumination > Diagnosis and Testing > Instrument Cluster and Panel Illumination - Vehicles
With: Central Junction Box (CJB)

Inspection and Verification Visual Inspection Chart Symptom Chart Symptom Chart Pinpoint Tests
PINPOINT TEST A : THE CONTROL ILLUMINATION IS INOPERATIVE PINPOINT TEST B : THE
INSTRUMENT CLUSTER ILLUMINATION IS INOPERATIVE PINPOINT TEST C : THE CLIMATE
CONTROL/INTEGRATED CONTROL PANEL ILLUMINATION IS INOPERATIVE PINPOINT TEST
D : THE AUDIO SYSTEM ILLUMINATION IS INOPERATIVE PINPOINT TEST E : A SINGLE
ILLUMINATION SOURCE IS INOPERATIVE
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 413 Instrumentation and Warning Systems > 413-01
Instrument Cluster > Description and Operation > Instrument Cluster - Vehicles Built From: 07-2003
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 413 Instrumentation and Warning Systems > 413-01
Instrument Cluster > Description and Operation > Instrument Cluster - Vehicles Built Up To: 07-2003
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 413 Instrumentation and Warning Systems > 413-01
Instrument Cluster > Description and Operation > Diagnosis and Testing > Instrument Cluster - Vehicles Built Up To:
07-2003, Vehicles With: Central Junction Box (CJB)

Principles of Operation The instrument cluster carries out a display prove-out to verify that all
warning/indicator lamps and monitored systems are operating correctly. When the ignition switch is
turned to the ON position with the engine OFF, the following indicators will illuminate: Gauge
Indication Systems The gauge indication systems use magnetic gauges mounted in the instrument
cluster. No adjustment, calibration, or maintenance is required for any gauges. Fuel Sending Unit
The fuel sending unit is a variable resistor controlled by the action of a float arm. When the fuel
level is low, resistance in the unit is low. When the fuel level is high, the resistance is high. Water
Temperature Indicator Sender Unit When the engine temperature is low, the resistance of the
water temperature indicator sender unit is high, thus restricting the flow of current through the
gauge and moving the pointer only a short distance. As the temperature of the coolant increases,
the resistance decreases, allowing more current to flow through the gauge and resulting in a
corresponding movement of the pointer. For vehicles with diesel engines the temperature gauge
receives a pulse width modulation (PWM) signal from the powertrain control module (PCM). Oil
Pressure Indicator Sender Unit The oil pressure indicator sender unit consists of a diaphragm and
contact points. The contact points are open with oil pressure causing the oil pressure indicator to
extinguish. With no oil pressure, the contacts close and the low oil pressure indicator illuminates.
Charge System Warning Indicator A red charge indicator is located in the instrument cluster. This
indicator illuminates when there is low or no generator output. When the ignition switch contacts
are closed, battery current flows through the charge indicator and the parallel resistor (390 ohms)
to the voltage indicator, and the indicator comes on. When the generator builds up enough voltage
to energize a circuit in the voltage regulator, the indicator turns off. Speedometer On vehicles
equipped with tachograph, the speedometer receives the vehicle speed output (VSO) signal from a
speed sensor in the transmission. On vehicles without a tachograph, the speedometer receives the
vehicle speed signal directly from the PCM. Odometer A million-mile tamper-resistant odometer is
standard. The odometer can be reset when installing a new speedometer. Trip Odometer The trip
odometer indicates how many miles the vehicle has been driven since the last reset. Tachometer
All vehicles can be equipped with a tachometer as an option. Diesel vehicles are equipped with a
4500–rpm tachometer. The tachometer receives a signal from the PCM. Warning Indicators Brake
System All vehicles use a brake system warning indicator in the instrument cluster to warn of
system malfunctions. The red brake warning light (BRAKE) is used to indicate a low fluid level,
brake malfunction. The brake fluid level switch is located in the brake fluid reservoir. The yellow
brake warning indicator is used to indicate a malfunction or deactivation of the anti-lock brake
system (ABS). It illuminates when triggered by the ABS control module and stays illuminated as
long as the malfunction remains in the system. Service Indicator Lamp The service indicator lamp
will illuminate when a service is required. To extinguish the service indicator lamp following a
service, turn the ignition switch to position II, press the brake and accelerator pedals together for 15
seconds. The service indicator lamp will flash to confirm the lamp has been reset. Release the
pedals and turn the ignition switch to OFF. Low Fuel When the fuel level drops to a predetermined
level, approximately four to eight liters (one to two gallons), the low fuel warning indicator will
illuminate. High Beam This indicator is illuminated when the high beams are ON. Water-in-Fuel
(Diesel Only) The WATER-IN-FUEL indicator will illuminate when 100cc (0.2 pints) of water has
accumulated in the fuel filter/water separator. The WATER-IN-FUEL indicator will prove out when
the ignition switch is in the START position. Glow Plug Indicator/Engine Check Lamp (Diesel Only)
The glow plug indicator will illuminate when the ignition switch is in the ON position with the engine
OFF while the glow plugs are heating. The indicator also acts as an engine check lamp which will
flash continuously when a hard diagnostic trouble code (DTC) is detected by the powertrain control
module (PCM). CHECK ENGINE Warning Indicator (Petrol Only) The CHECK ENGINE warning
indicator is illuminated when a DTC is sensed in the closed loop by the PCM. Inspection and
Verification Visual Inspection Chart If a particular system(s) is not working correctly, refer to the
appropriate section of the workshop manual. Symptom Chart Symptom Chart Pinpoint Tests
PINPOINT TEST A : A GAUGE IS INOPERATIVE – ALL GAUGES PINPOINT TEST B :
INCORRECT FUEL GAUGE INDICATION PINPOINT TEST C : INCORRECT LPG FUEL GAUGE
INDICATION - VEHICLES WITH LPG FUEL SYSTEM PINPOINT TEST D : THE LPG SELECT
INDICATOR IS INOPERATIVE - VEHICLES WITH LPG FUEL SYSTEM PINPOINT TEST E : THE
LOW FUEL WARNING INDICATOR IS NEVER/ALWAYS ON PINPOINT TEST F : INCORRECT
TEMPERATURE GAUGE INDICATION PINPOINT TEST G : THE SPEEDOMETER/ODOMETER
IS INOPERATIVE PINPOINT TEST H : THE TACHOMETER IS INOPERATIVE PINPOINT TEST I
: INACCURATE SPEEDOMETER READING — ODOMETER FUNCTIONS CORRECTLY
PINPOINT TEST J : THE BRAKE WARNING INDICATOR IS NEVER/ALWAYS ON – YELLOW
ABS WARNING INDICATOR PINPOINT TEST K : THE BRAKE WARNING INDICATOR IS
NEVER/ALWAYS ON–RED BRAKE WARNING INDICATOR PINPOINT TEST L : CHECK
ENGINE INDICATOR IS INOPERATIVE/ALWAYS ON PINPOINT TEST M : THE CHARGE
SYSTEM WARNING INDICATOR IS NEVER/ALWAYS ON PINPOINT TEST N : THE AIR BAG
INDICATOR IS INOPERATIVE/ALWAYS ON PINPOINT TEST O : THE HIGH BEAM INDICATOR
IS INOPERATIVE PINPOINT TEST P : THE LH TURN INDICATOR IS INOPERATIVE PINPOINT
TEST Q : THE RH TURN INDICATOR IS INOPERATIVE PINPOINT TEST R : THE GLOW PLUG
INDICATOR IS INOPERATIVE/ALWAYS ON – DIESEL ONLY PINPOINT TEST S : THE
WATER-IN-FUEL INDICATOR IS INOPERATIVE/ALWAYS ON – DIESEL ONLY PINPOINT TEST
T : THE OIL PRESSURE WARNING INDICATOR IS INOPERATIVE/ALWAYS ON
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 413 Instrumentation and Warning Systems > 413-01
Instrument Cluster > Description and Operation > Diagnosis and Testing > Instrument Cluster - Vehicles Built From:
07-2003, Vehicles With: Central Junction Box (CJB)

Inspection and Verification Visual Inspection Chart Self-Diagnostic Mode Self-Diagnostic Mode
Make a test lamp - Vehicles built from 01/10/2003 to 30/01/2004 with Liquified Petroleum Gas
(LPG) If the LPG warning lamp is illuminating, the probable cause is a fault within in the LPG
system. Access to the alternative fuel control module DTCs is not possible without the use of a test
lamp. Installing the alternative fuel control module wiring harness Retrieving LPG DTCs Instrument
Cluster Configuration The instrument cluster is a programmable module, which must be configured
by selecting the Programmable Module Installation Routine on the WDS. The following feature will
need to be configured when a new instrument cluster is installed:
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 413 Instrumentation and Warning Systems > 413-01
Instrument Cluster > Description and Operation > Diagnosis and Testing > Removal and Installation > Instrument Cluster

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 413 Instrumentation and Warning Systems > 413-01
Instrument Cluster > Description and Operation > Diagnosis and Testing > Removal and Installation > Disassembly and
Assembly > Instrument Cluster

Disassembly Assembly
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 413 Instrumentation and Warning Systems > 413-06 Horn >
Diagnosis and Testing > Horn

Inspection and Verification Visual Inspection Chart Symptom Chart Symptom Chart Pinpoint Tests
PINPOINT TEST A : THE HORN SOUNDS CONTINUOUSLY PINPOINT TEST B : THE HORN
DOES NOT SOUND
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 413 Instrumentation and Warning Systems > 413-07 Clock >
Diagnosis and Testing > Clock

Inspection and Verification Visual Inspection Chart Symptom Chart Symptom Chart Pinpoint Tests
PINPOINT TEST A : THE CLOCK OPERATION IS ERRATIC/INOPERATIVE PINPOINT TEST B :
THE CLOCK ILLUMINATION IS INOPERATIVE
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 413 Instrumentation and Warning Systems > 413-07 Clock >
Diagnosis and Testing > Removal and Installation > Clock

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 413 Instrumentation and Warning Systems > 413-13 Parking
Aid > Specifications
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 413 Instrumentation and Warning Systems > 413-13 Parking
Aid > Description and Operation > Parking Aid
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 413 Instrumentation and Warning Systems > 413-13 Parking
Aid > Description and Operation > Diagnosis and Testing > Parking Aid

Principles of Operation The parking aid system detects objects behind the vehicle when the vehicle
reverse gear select input to the control module is enabled. The parking aid module does this by
calculating the distance to an object by the use of four ultrasonic sensors mounted in the rear
bumper. The sensors can detect objects approximately 1.8m to the rear of the vehicle, 50 cm to the
rear side of the vehicle, and 16 cm above the ground. An intermittent warning tone is generated
from a speaker located behind the instrument panel. The interval between the tones decreases as
the vehicle gets closer to an obstacle. When an object is detected within 25 cm of the sensors, the
warning tone becomes continuous. The parking aid disabled indicator will illuminate for three
seconds when the ignition is turned to the RUN position. Pressing the parking aid disable switch on
the instrument cluster will both disable this feature and illuminate the parking aid disabled indicator.
The system will always enable when the ignition switch is turned to the RUN position or reverse
gear is selected. The parking aid system will be disabled if a fault is detected in one of the four
sensors, the parking aid speaker or the parking aid module. Inspection and Verification Visual
Inspection Chart
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 413 Instrumentation and Warning Systems > 413-13 Parking
Aid > Description and Operation > Diagnosis and Testing > General Procedures > Azimuth System Check
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 413 Instrumentation and Warning Systems > 413-13 Parking
Aid > Description and Operation > Diagnosis and Testing > General Procedures > Elevation System Check
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 413 Instrumentation and Warning Systems > 413-13 Parking
Aid > Description and Operation > Diagnosis and Testing > General Procedures > Removal and Installation > Parking Aid
Module

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 413 Instrumentation and Warning Systems > 413-17
Tachograph > Diagnosis and Testing > Tachograph

Inspection and Verification Visual Inspection Chart Symptom Chart Pinpoint Tests PINPOINT
TEST A : THE TACHOGRAPH IS INOPERATIVE/DOES NOT OPERATE CORRECTLY
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 413 Instrumentation and Warning Systems > 413-17
Tachograph > Diagnosis and Testing > Digital Tachograph

Digital Tachograph New vehicles will arrive at the dealer with the digital tachograph disconnected.
This is intentional as the tachograph activation must be carried out by an authorized digital
tachograph service center. Digital tachograph legislation requires that before the digital tachograph
is disconnected it has the memory downloaded and backed up. This can only be carried out with
dedicated tachograph service equipment. Activation and Calibration Electrical connection of the
new parts should be carried out by an authorized digital tachograph service center. It is
recommended to use a Siemens VDO Automotive approved Service center for this activity. Details
of Siemens VDO Automotive approved Service centers can be found at
http://www.vdo.com/DTCO/. The web site will give details of Siemens VDO Automotive approved
Service centers qualified to activate and calibrate the digital tachograph, also contact details of
engineers responsible for each country. This web site will indicate which of the Siemens VDO
Automotive approved Service center can work with the digital tachograph as not all will be
authorized at the start of the digital tachograph launch. If there is any problem with Siemens VDO
Automotive approved Service centers contact the country representative. Contact details can be
found at the above web site under / Service / Contact. Procedures for any work on other vehicle
systems, which involve interference with the digital tachograph system, are unchanged from those
used with the mechanical tachograph. Any electrical disconnection will be recorded automatically
by the tachograph. This is acceptable, providing the system is refitted with the same parts and the
operator can prove the vehicle was in a workshop at the time. If the vehicle arrives with a digital
tachograph fitted but not connected, do not make the connections. Arrange for the vehicle to be
activated and calibrated at the Siemens VDO Automotive approved Service center (as with
previous Stoneridge Service center or Veeder Root Service center). However with the digital
version as well as calibration there are additional parameters which must be programmed. Please
make sure that a tachograph handbook is obtained from the Siemens VDO Automotive approved
service center. The handbook must be in the language of the country of operation. Legislation
requires that this procedure must be carried out within 2 weeks of vehicle registration. Service
Strategy If a new tachograph needs to be installed: Leave the old tachograph fitted, take the
vehicle plus a new tachograph to a Siemens VDO Automotive approved Service center for data
downloading, installation and calibration. If a new tachograph speed sensor needs to be installed:
Install the new tachograph speed sensor, take the vehicle to a Siemens VDO Automotive approved
Service center for calibration. If any seals are broken: Take the vehicle to a Siemens VDO
Automotive approved Service center for new seals to be installed and calibration. Inspection and
Verification Visual Inspection Chart Symptom Chart Pinpoint Tests PINPOINT TEST A : THE
TACHOGRAPH IS INOPERATIVE/READING INCORRECTLY Table 1 Table 2
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 413 Instrumentation and Warning Systems > 413-17
Tachograph > Diagnosis and Testing > Removal and Installation > Tachograph

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 413 Instrumentation and Warning Systems > 413-17
Tachograph > Diagnosis and Testing > Removal and Installation > Digital Tachograph

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 414 Battery and Charging System > 414-00 Charging
System - General Information > Description and Operation > Charging System
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 414 Battery and Charging System > 414-00 Charging
System - General Information > Description and Operation > Diagnosis and Testing > Charging System - 2.0L Duratorq-Di
(Puma) Diesel-2.0L Duratorq-TDCi (Puma) Diesel-2.0L Duratorq-TDDi (Puma) Diesel-2.4L Duratorq

Principles of Operation: All except vehicles with 2.4L diesel engine The generator, generates
alternating current (AC) which is internally converted to direct current (DC). This current is supplied
to the vehicle electrical system through the output (B+) terminal of the generator. With the engine
running, voltage is applied through the warning indicator, circuit 8-BA9 (WH/GN) to the voltage
regulator. This turns the regulator on, allowing current to flow from the battery circuit 30-BA12 (RD)
to the generator field coil. When the generator begins generating current, a voltage signal is taken
from the generator stator and fed back to the regulator internally. This voltage feedback signal
(typically half the battery voltage) is used to turn off the warning indicator. Principles of Operation:
Vehicles with 2.4L diesel engine Vehicles equipped with a 2.4L diesel engine are fitted with a
generator cut-off relay. The relay will make sure that the voltage feedback signal is only applied to
the instrument cluster and central junction box (CJB) when the ignition is in the ON position. As
soon as the ignition is switched to the OFF position, the generator cut-off relay grounds the
instrument cluster isolating the charging system warning indicator. Inspection and Verification
Visual Inspection Chart Normal Charging System Voltages Symptom Chart Pinpoint Tests
PINPOINT TEST A : THE CHARGING SYSTEM WARNING INDICATOR IS ON WITH THE
ENGINE RUNNING (THE BATTERY VOLTAGE DOES NOT INCREASE) PINPOINT TEST B :
THE SYSTEM OVERCHARGES (BATTERY VOLTAGE IS GREATER THAN 15.5 VOLTS)
PINPOINT TEST C : THE CHARGING SYSTEM WARNING INDICATOR IS ON WITH THE
ENGINE RUNNING (BATTERY VOLTAGE INCREASES) PINPOINT TEST D : THE CHARGING
SYSTEM WARNING INDICATOR IS OFF WITH THE IGNITION SWITCH IN THE RUN POSITION
AND THE ENGINE IS OFF (BATTERY VOLTAGE DOES NOT INCREASE) ALL EXCEPT
VEHICLES WITH 2.4L DIESEL ENGINE BUILT UP TO 07/2003 PINPOINT TEST E : THE
CHARGING SYSTEM WARNING INDICATOR IS OFF WITH THE IGNITION SWITCH IN THE
RUN POSITION AND THE ENGINE IS OFF (BATTERY VOLTAGE DOES NOT INCREASE) ALL
EXCEPT VEHICLES WITH 2.4L DIESEL ENGINE BUILT 07/2003 ONWARDS PINPOINT TEST F
: THE CHARGING SYSTEM WARNING INDICATOR IS OFF WITH THE IGNITION SWITCH IN
THE RUN POSITION AND THE ENGINE IS OFF (BATTERY VOLTAGE DOES NOT INCREASE)
VEHICLES WITH 2.4L DIESEL ENGINE BUILT UP TO 07/2003 PINPOINT TEST G : THE
CHARGING SYSTEM WARNING INDICATOR IS OFF WITH THE IGNITION SWITCH IN THE
RUN POSITION AND THE ENGINE IS OFF (BATTERY VOLTAGE DOES NOT INCREASE)
VEHICLES WITH 2.4L DIESEL ENGINE BUILT 07/2003 ONWARDS PINPOINT TEST H : THE
CHARGING SYSTEM WARNING INDICATOR FLICKERS OR IS INTERMITTENT PINPOINT
TEST I : THE GENERATOR IS NOISY VEHICLES BUILT UP TO 07/2003 PINPOINT TEST J :
THE GENERATOR IS NOISY VEHICLES BUILT 07/2003 ONWARDS PINPOINT TEST K : RADIO
INTERFERENCE VEHICLES BUILT UP TO 07/2003 PINPOINT TEST L : RADIO
INTERFERENCE VEHICLES BUILT 07/2003 ONWARDS Component Tests Generator On-Vehicle
Tests - No-Load Test Generator On-Vehicle Tests - Load Test Battery Identification Battery
Surface Charge Removal Surface charge dissipation unit (SCD2) Alternative Method To Dissipate
The Battery Surface Charge Battery Test Battery tester results and required actions *In addition, it
is advisable to check the vehicle electrical system. Check that the generator is functioning correctly
and that all key-off loads (luggage compartment lamps, glove compartment lamp and interior
lamps) are not staying on.
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 414 Battery and Charging System > 414-00 Charging
System - General Information > Description and Operation > Diagnosis and Testing > Charging System - 2.3L DOHC-16V

Principles of Operation Functionality When the engine is being started, the generator begins to
generate alternating current (AC) which is internally converted to direct current (DC). This current is
then supplied to the vehicles electrical system through the output (B+) terminal of the generator.
With the engine running, voltage is applied through the warning indicator I (ignition) Circuit 8-BA9
(WH/GN) to the voltage regulator. This turns the regulator on, allowing current to flow from battery
sense A circuit 30-BA6 (RD) to the generator field coil. When the generator begins generating
current, a voltage signal is taken from the generator stator and fed back to the regulator internally.
This voltage feedback signal (typically half the battery voltage) is used to turn off the warning
indicator. With the system functioning normally, the generator output current is determined by the A
circuit voltage. This is compared to a set voltage internal to the regulator, and the regulator controls
the generator field current to maintain the correct generator output. The set voltage will vary with
temperature and is typically higher in cold temperatures and lower in warm temperatures. This
provides better battery charging in the winter and reduces the chance of overcharging in the
summer. Inspection and Verification Visual Inspection Chart Symptom Chart Pinpoint Tests
PINPOINT TEST A : THE CHARGING SYSTEM WARNING INDICATOR IS ON WITH THE
ENGINE RUNNING (THE BATTERY VOLTAGE DOES NOT INCREASE) PINPOINT TEST B :
THE SYSTEM OVERCHARGES (BATTERY VOLTAGE IS GREATER THAN 15.5 VOLTS)
PINPOINT TEST C : THE CHARGING SYSTEM WARNING INDICATOR IS ON WITH THE
ENGINE RUNNING (BATTERY VOLTAGE INCREASES) PINPOINT TEST D : THE CHARGING
SYSTEM WARNING INDICATOR IS OFF WITH THE IGNITION SWITCH IN THE RUN POSITION
AND THE ENGINE IS OFF (BATTERY VOLTAGE DOES NOT INCREASE) PINPOINT TEST E :
THE CHARGING SYSTEM WARNING INDICATOR FLICKERS OR IS INTERMITTENT PINPOINT
TEST F : THE GENERATOR IS NOISY PINPOINT TEST G : RADIO INTERFERENCE Component
Tests Generator On-Vehicle Tests - No-Load Test Generator On-Vehicle Tests - Load Test Battery
Identification Battery Surface Charge Removal Surface charge dissipation unit (SCD2) Alternative
Method To Dissipate The Battery Surface Charge Battery Test Battery tester results and required
actions *In addition, it is advisable to check the vehicle electrical system. Check that the generator
is functioning correctly and that all key-off loads (luggage compartment lamps, glove compartment
lamp and interior lamps) are not staying on.
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 414 Battery and Charging System > 414-00 Charging
System - General Information > Description and Operation > Diagnosis and Testing > General Procedures > Battery
Charging
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 414 Battery and Charging System > 414-01 Battery,
Mounting and Cables > Specifications
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 414 Battery and Charging System > 414-01 Battery,
Mounting and Cables > Description and Operation > Diagnosis and Testing > Battery
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 414 Battery and Charging System > 414-01 Battery,
Mounting and Cables > Description and Operation > Diagnosis and Testing > General Procedures > Battery Disconnect and
Connect

Disconnect Connect
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 414 Battery and Charging System > 414-01 Battery,
Mounting and Cables > Description and Operation > Diagnosis and Testing > General Procedures > Removal and
Installation > Battery

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 414 Battery and Charging System > 414-01 Battery,
Mounting and Cables > Description and Operation > Diagnosis and Testing > General Procedures > Removal and
Installation > Jump Start Point to Starter Motor Solenoid Cable - 2.4L Duratorq-Di (Puma) Diesel-2.4L Duratorq-TDCi
(Puma) Diesel

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 414 Battery and Charging System > 414-01 Battery,
Mounting and Cables > Description and Operation > Diagnosis and Testing > General Procedures > Removal and
Installation > Battery to Jump Start Point Cable

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 414 Battery and Charging System > 414-01 Battery,
Mounting and Cables > Description and Operation > Diagnosis and Testing > General Procedures > Removal and
Installation > Jump Start Point to Starter Motor Solenoid Cable - 2.0L Duratorq-Di (Puma) Diesel-2.0L Duratorq-TDCi
(Puma) Diesel-2.0L Duratorq

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 414 Battery and Charging System > 414-01 Battery,
Mounting and Cables > Description and Operation > Diagnosis and Testing > General Procedures > Removal and
Installation > Jump Start Point to Starter Motor Solenoid Cable - 2.3L DOHC-16V

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 414 Battery and Charging System > 414-01 Battery,
Mounting and Cables > Description and Operation > Battery and Cables
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 414 Battery and Charging System > 414-02 Generator and
Regulator > Specifications
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 414 Battery and Charging System > 414-02 Generator and
Regulator > Description and Operation > Diagnosis and Testing > Generator
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 414 Battery and Charging System > 414-02 Generator and
Regulator > Description and Operation > Diagnosis and Testing > Removal and Installation > Generator - 2.4L Duratorq-Di
(Puma) Diesel-2.4L Duratorq-TDCi (Puma) Diesel

Holding Wrench, Generator Pulley 303-688 (21-247) Removal Installation

Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 414 Battery and Charging System > 414-02 Generator and
Regulator > Description and Operation > Diagnosis and Testing > Removal and Installation > Generator - 2.0L Duratorq-Di
(Puma) Diesel-2.0L Duratorq-TDCi (Puma) Diesel-2.0L Duratorq-TDDi (Puma) Diesel

Release Tool, Belt Tensioner 303-676 Removal Installation

Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 414 Battery and Charging System > 414-02 Generator and
Regulator > Description and Operation > Diagnosis and Testing > Removal and Installation > Generator - 2.3L DOHC-16V

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 414 Battery and Charging System > 414-02 Generator and
Regulator > Description and Operation > Generator
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 415 Information and Entertainment Systems > 415-00
Information and Entertainment System - General Information > Diagnosis and Testing > Audio System - Vehicles With:
Central Junction Box (CJB)

Inspection and Verification Visual Inspection Chart CD Error Codes - vehicles with 6000 Audio Unit
Error Codes Self-Diagnostic Mode Self-Diagnostic Mode Symptom Chart Pinpoint Tests PINPOINT
TEST A : THE AUDIO UNIT IS INOPERATIVE/DOES NOT OPERATE CORRECTLY PINPOINT
TEST B : POOR RECEPTION PINPOINT TEST C : POOR QUALITY /DISTORTED SOUND
FROM ONE OR MORE SPEAKERS (NOT ALL SPEAKERS) PINPOINT TEST D : NO SOUND
FROM ALL OF THE SPEAKERS
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 415 Information and Entertainment Systems > 415-01 Audio
Unit > Description and Operation > Audio System
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 415 Information and Entertainment Systems > 415-01 Audio
Unit > Description and Operation > Diagnosis and Testing > Audio System
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 415 Information and Entertainment Systems > 415-01 Audio
Unit > Description and Operation > Diagnosis and Testing > Removal and Installation > Audio Unit

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 415 Information and Entertainment Systems > 415-02
Antenna > Description and Operation > Antenna
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 415 Information and Entertainment Systems > 415-02
Antenna > Description and Operation > Diagnosis and Testing > Antenna
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 415 Information and Entertainment Systems > 415-02
Antenna > Description and Operation > Diagnosis and Testing > Removal and Installation > Antenna Cable

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 415 Information and Entertainment Systems > 415-03
Speakers > Diagnosis and Testing > Speakers
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 417 Lighting > 417-01 Exterior Lighting > Description and
Operation > Diagnosis and Testing > Headlamps - Vehicles Built Up To: 07-2003, Vehicles With: Central Junction Box
(CJB)

Terminal probe kit 29-011A Inspection and Verification Visual Inspection Chart Symptom Chart
Symptom Chart Pinpoint Tests PINPOINT TEST A : BOTH HEADLAMPS (LOW AND HIGH BEAM)
ARE INOPERATIVE PINPOINT TEST B : THE LOW BEAMS ARE INOPERATIVE PINPOINT
TEST C : THE HIGH BEAMS ARE INOPERATIVE PINPOINT TEST D : ONE LOW BEAM IS
INOPERATIVE PINPOINT TEST E : ONE HIGH BEAM IS INOPERATIVE PINPOINT TEST F :
THE HEADLAMPS (LOW OR HIGH BEAM) ARE ON CONTINUOUSLY PINPOINT TEST G : THE
FLASH-TO-PASS FEATURE IS INOPERATIVE
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 417 Lighting > 417-01 Exterior Lighting > Description and
Operation > Diagnosis and Testing > Headlamps - Vehicles Built From: 07-2003, Vehicles With: Central Junction Box (CJB)

Terminal probe kit 29-011A Inspection and Verification Visual Inspection Chart Symptom Chart
Symptom Chart Pinpoint Tests PINPOINT TEST A : BOTH HEADLAMPS (LOW AND HIGH BEAM)
ARE INOPERATIVE PINPOINT TEST B : THE LOW BEAMS ARE INOPERATIVE PINPOINT
TEST C : THE HIGH BEAM ARE INOPERATIVE PINPOINT TEST D : ONE LOW BEAM IS
INOPERATIVE PINPOINT TEST E : ONE HIGH BEAM IS INOPERATIVE PINPOINT TEST F :
THE HEADLAMPS (LOW OR HIGH BEAM) ARE ON CONTINUOUSLY PINPOINT TEST G : THE
FLASH-TO-PASS FEATURE IS INOPERATIVE
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 417 Lighting > 417-01 Exterior Lighting > Description and
Operation > Diagnosis and Testing > Stoplamps - Vehicles Built Up To: 07-2003, Vehicles With: Central Junction Box (CJB)

Terminal probe kit 29-011A Inspection and Verification Visual Inspection Chart Symptom Chart
Symptom Chart Pinpoint Tests PINPOINT TEST A : THE STOP LAMPS ARE INOPERATIVE
PINPOINT TEST B : ONE OR MORE STOP LAMPS ARE INOPERATIVE PINPOINT TEST C :
THE STOP LAMPS ARE ON CONTINUOUSLY
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 417 Lighting > 417-01 Exterior Lighting > Description and
Operation > Diagnosis and Testing > Stoplamps - Vehicles Built From: 07-2003, Vehicles With: Central Junction Box (CJB)

Terminal probe kit 29-011A Inspection and Verification Visual Inspection Chart Symptom Chart
Symptom Chart Pinpoint Tests PINPOINT TEST A : THE STOPLAMPS ARE INOPERATIVE
PINPOINT TEST B : ONE OR MORE STOPLAMPS ARE INOPERATIVE PINPOINT TEST C :
THE STOPLAMPS ARE ON CONTINUOUSLY
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 417 Lighting > 417-01 Exterior Lighting > Description and
Operation > Diagnosis and Testing > Turn Signal and Hazard Lamps - Vehicles Built Up To: 07-2003, Vehicles With:
Central Junction Box (CJB)

Terminal probe kit 29-011A Inspection and Verification Visual Inspection Chart Symptom Chart
Symptom Chart Pinpoint Tests PINPOINT TEST A : THE TURN SIGNAL LAMPS ARE
INOPERATIVE PINPOINT TEST B : THE HAZARD WARNING LIGHTS ARE INOPERATIVE
PINPOINT TEST C : ONE OR MORE TURN SIGNAL/HAZARD LAMP IS INOPERATIVE
PINPOINT TEST D : TURN SIGNAL LAMPS/HAZARD WARNING LIGHTS ARE FLASHING
CONTINUOUSLY PINPOINT TEST E : TURN SIGNAL LAMPS/HAZARD WARNING LIGHTS ARE
ON CONTINUOUSLY PINPOINT TEST F : THE FLASHER CYCLE IS TOO FAST
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 417 Lighting > 417-01 Exterior Lighting > Description and
Operation > Diagnosis and Testing > Turn Signal and Hazard Lamps - Vehicles Built From: 07-2003, Vehicles With: Central
Junction Box (CJB)

Terminal probe kit 29-011A Inspection and Verification Visual Inspection Chart Symptom Chart
Symptom Chart Pinpoint Tests PINPOINT TEST A : THE TURN SIGNAL LAMPS ARE
INOPERATIVE PINPOINT TEST B : THE HAZARD WARNING LAMPS ARE INOPERATIVE
WHEN THE HAZARD FLASHER SWITCH IS ACTUATED PINPOINT TEST C : ONE OR MORE
TURN SIGNAL/HAZARD WARNING LAMP(S) IS/ARE INOPERATIVE PINPOINT TEST D : ALL
TURN SIGNAL LAMPS/HAZARD WARNING LAMPS ARE FLASHING CONTINUOUSLY
PINPOINT TEST E : THE TURN SIGNAL LAMPS/HAZARD WARNING LAMPS, LEFT- OR
RIGHT-HAND SIDE ARE FLASHING CONTINUOUSLY PINPOINT TEST F : TURN SIGNAL
LAMPS/HAZARD WARNING LIGHTS ARE ON CONTINUOUSLY
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 417 Lighting > 417-01 Exterior Lighting > Description and
Operation > Diagnosis and Testing > Parking, Rear and License Plate Lamps - Vehicles Built Up To: 07-2003, Vehicles
With: Central Junction Box (CJB)

Terminal probe kit 29-011A Inspection and Verification Visual Inspection Chart Symptom Chart
Symptom Chart Pinpoint Tests PINPOINT TEST A : THE PARKING, REAR AND LICENSE PLATE
LAMPS ARE INOPERATIVE PINPOINT TEST B : ONE OR MORE PARKING, REAR OR
LICENSE PLATE LAMP IS INOPERATIVE PINPOINT TEST C : THE PARKING, REAR OR
LICENSE PLATE LAMPS ARE ON CONTINUOUSLY
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 417 Lighting > 417-01 Exterior Lighting > Description and
Operation > Diagnosis and Testing > Parking, Rear and License Plate Lamps - Vehicles Built From: 07-2003, Vehicles With:
Central Junction Box (CJB)

Terminal probe kit 29-011A Inspection and Verification Visual Inspection Chart Symptom Chart
Symptom Chart Pinpoint Tests PINPOINT TEST A : THE PARKING, REAR AND LICENSE PLATE
LAMPS ARE INOPERATIVE PINPOINT TEST B : ONE OR MORE PARKING, REAR OR
LICENSE PLATE LAMP(S) IS/ARE INOPERATIVE PINPOINT TEST C : THE PARKING, REAR
OR LICENSE PLATE LAMPS ARE ON CONTINUOUSLY
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 417 Lighting > 417-01 Exterior Lighting > Description and
Operation > Diagnosis and Testing > Fog Lamps - Vehicles Built Up To: 07-2003, Vehicles With: Central Junction Box
(CJB)

Terminal probe kit 29-011A Inspection and Verification Visual Inspection Chart Symptom Chart
Symptom Chart Pinpoint Tests PINPOINT TEST A : THE FOG LAMPS ARE INOPERATIVE
PINPOINT TEST B : THE INDIVIDUAL FOG LAMP IS INOPERATIVE PINPOINT TEST C : THE
FOG LAMPS ARE ON CONTINUOUSLY
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 417 Lighting > 417-01 Exterior Lighting > Description and
Operation > Diagnosis and Testing > Fog Lamps - Vehicles Built From: 07-2003, Vehicles With: Central Junction Box (CJB)

Terminal probe kit 29-011A Inspection and Verification Visual Inspection Chart Symptom Chart
Symptom Chart Pinpoint Tests PINPOINT TEST A : THE FOG LAMPS ARE INOPERATIVE
PINPOINT TEST B : THE INDIVIDUAL FOG LAMP IS INOPERATIVE PINPOINT TEST C : THE
FOG LAMPS ARE ON CONTINUOUSLY
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 417 Lighting > 417-01 Exterior Lighting > Description and
Operation > Diagnosis and Testing > Reversing Lamps - Vehicles Built Up To: 07-2003, Vehicles With: Central Junction Box
(CJB)

Terminal probe kit 29-011A Inspection and Verification Visual Inspection Chart Symptom Chart
Symptom Chart Pinpoint Tests PINPOINT TEST A : ONE/BOTH REVERSING LAMP(S) IS/ARE
INOPERATIVE PINPOINT TEST B : THE REVERSING LAMPS ARE ON CONTINUOUSLY
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 417 Lighting > 417-01 Exterior Lighting > Description and
Operation > Diagnosis and Testing > Reversing Lamps - Vehicles Built From: 07-2003, Vehicles With: Central Junction Box
(CJB)

Terminal probe kit 29-011A Inspection and Verification Visual Inspection Chart Symptom Chart
Symptom Chart Pinpoint Tests PINPOINT TEST A : ONE/BOTH REVERSING LAMP(S) IS/ARE
INOPERATIVE PINPOINT TEST B : THE REVERSING LAMPS ARE ON CONTINUOUSLY
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 417 Lighting > 417-01 Exterior Lighting > Description and
Operation > Diagnosis and Testing > Trailer Lamps - Vehicles Built Up To: 07-2003, Vehicles With: Central Junction Box
(CJB)

Terminal probe kit 29-011A Inspection and Verification Visual Inspection Chart Symptom Chart
Symptom Chart Pinpoint Tests PINPOINT TEST A : THE TRAILER LAMPS ARE INOPERATIVE
PINPOINT TEST B : THE INDIVIDUAL TRAILER LAMP IS INOPERATIVE PINPOINT TEST C :
THE FLASHER CYCLE IS TOO FAST
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 417 Lighting > 417-01 Exterior Lighting > Description and
Operation > Diagnosis and Testing > Trailer Lamps - Vehicles Built From: 07-2003, Vehicles With: Central Junction Box
(CJB)

Terminal probe kit 29-011A Inspection and Verification Visual Inspection Chart Symptom Chart
Symptom Chart Pinpoint Tests PINPOINT TEST A : THE TRAILER LAMPS ARE INOPERATIVE
PINPOINT TEST B : THE INDIVIDUAL TRAILER LAMP IS INOPERATIVE PINPOINT TEST C :
THE FLASHER CYCLE IS TOO FAST Component Test: Trailer tow relay 1. If yes, go to 2. 2. If not,
INSTALL a new trailer tow relay. 1. If yes, then the trailer tow relay is OK. 2. If not, INSTALL a new
trailer tow relay.
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 417 Lighting > 417-01 Exterior Lighting > Description and
Operation > Diagnosis and Testing > Headlamp Leveling - Vehicles Built Up To: 07-2003, Vehicles With: Central Junction
Box (CJB)

Terminal probe kit 29-011A Inspection and Verification Visual Inspection Chart Symptom Chart
Symptom Chart Pinpoint Tests PINPOINT TEST A : THE HEADLAMP LEVELING IS
INOPERATIVE PINPOINT TEST B : ONE HEADLAMP LEVELING UNIT IS INOPERATIVE
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 417 Lighting > 417-01 Exterior Lighting > Description and
Operation > Diagnosis and Testing > Headlamp Leveling - Vehicles Built From: 07-2003, Vehicles With: Central Junction
Box (CJB)

Terminal probe kit 29-011A Inspection and Verification Visual Inspection Chart Symptom Chart
Symptom Chart Pinpoint Tests PINPOINT TEST A : THE HEADLAMP LEVELING IS
INOPERATIVE PINPOINT TEST B : ONE HEADLAMP LEVELING UNIT IS INOPERATIVE
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 417 Lighting > 417-01 Exterior Lighting > Description and
Operation > Diagnosis and Testing > General Procedures > Headlamp Adjustment
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 417 Lighting > 417-01 Exterior Lighting > Description and
Operation > Diagnosis and Testing > General Procedures > Headlamp Masking
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 417 Lighting > 417-01 Exterior Lighting > Description and
Operation > Diagnosis and Testing > General Procedures > Front Fog Lamp Adjustment
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 417 Lighting > 417-01 Exterior Lighting > Description and
Operation > Diagnosis and Testing > General Procedures > Removal and Installation > Headlamp Assembly

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 417 Lighting > 417-01 Exterior Lighting > Description and
Operation > Diagnosis and Testing > General Procedures > Removal and Installation > Headlamp Leveling Motor

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 417 Lighting > 417-01 Exterior Lighting > Description and
Operation > Diagnosis and Testing > General Procedures > Removal and Installation > Headlamp Switch

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 417 Lighting > 417-01 Exterior Lighting > Specifications
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 417 Lighting > 417-02 Interior Lighting > Diagnosis and
Testing > Interior Lighting

Principles of Operation Interior Lighting Vehicles not equipped with anti-theft The door ajar switch
supplies a ground to the interior lamp(s) allowing lamp illumination. Vehicles equipped with
anti-theft The anti-theft alarm and double locking module supplies a ground to the interior lamp(s)
when any of the following inputs are received. All interior lamps are turned off when any of the
following occurs: The illuminated entry feature is another feature which activates the interior lamps.
This feature operates as follows: The anti-theft alarm and double locking module illuminates the
interior lamps when an unlock signal is received from a remote transmitter. If no door ajar signal is
received the anti-theft alarm and double locking module will time out and turn the interior lights off.
The illuminated entry feature will be cancelled when any of the following conditions are met:
Inspection and Verification Visual Inspection Chart Anti-Theft Alarm and Double Locking Module
Diagnostic Trouble Code (DTC) Index Anti-Theft Alarm and Double Locking Module Diagnostic
Trouble Code (DTC) Index Symptom Chart Symptom Chart Pinpoint Tests PINPOINT TEST A :
THE INTERIOR LAMPS ARE INOPERATIVE — CHASSIS CAB, DOUBLE CHASSIS CAB AND
VAN WITH ANTI-THEFT PINPOINT TEST B : THE INTERIOR LAMPS STAY ON
CONTINUOUSLY PINPOINT TEST C : THE INTERIOR LAMPS DO NOT TURN ON WITH ONE
DOOR OPEN — CHASSIS CAB AND VAN WITH BASE LIGHTING WITHOUT ANTI-THEFT
PINPOINT TEST D : THE INTERIOR LAMPS DO NOT TURN ON WITH ONE DOOR OPEN —
CHASSIS CAB, DOUBLE CHASSIS CAB AND VAN WITH ANTI-THEFT PINPOINT TEST E : THE
ILLUMINATED ENTRY IS INOPERATIVE WHEN USING THE REMOTE TRANSMITTER —
CHASSIS CAB, DOUBLE CHASSIS CAB AND VAN WITH ANTI-THEFT PINPOINT TEST F : THE
FRONT MAP READING LAMP IS INOPERATIVE PINPOINT TEST G : THE CENTER MAP
READING LAMP IS INOPERATIVE
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 417 Lighting > 417-04 Daytime Running Lamps (DRL) >
Description and Operation > Daytime Running Lamps (DRL)
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 417 Lighting > 417-04 Daytime Running Lamps (DRL) >
Description and Operation > Diagnosis and Testing > Daytime Running Lamps (DRL) - Vehicles Built Up To: 07-2003

Terminal probe kit 29-011A Principles of Operations The daytime running lamps (DRL) are ON
under the following conditions: The DRL system is designed to turn the low beam headlamps ON at
reduced intensity. The driver can disable the DRL system by any one of the following actions:
Inspection and Verification Visual Inspection Chart Symptom Chart Symptom Chart Pinpoint Tests
PINPOINT TEST A : THE DAYTIME RUNNING LAMPS ARE INOPERATIVE PINPOINT TEST B :
THE DAYTIME RUNNING LAMPS ARE ON WITH IGNITION SWITCH OFF PINPOINT TEST C :
THE PARKING, REAR AND LICENSE LAMPS ARE INOPERATIVE WITH THE DAYTIME
RUNNING LAMPS ON.
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 417 Lighting > 417-04 Daytime Running Lamps (DRL) >
Description and Operation > Diagnosis and Testing > Daytime Running Lamps (DRL) - Vehicles Built From: 07-2003

Terminal probe kit 29-011A Principles of Operations The daytime running lamps (DRL) are ON
under the following conditions: The DRL system is designed to turn the low beam headlamps ON
automatically as soon as engine is running. The driver can disable the DRL system by any one of
the following actions: Inspection and Verification Visual Inspection Chart Symptom Chart Symptom
Chart Pinpoint Tests PINPOINT TEST A : THE DAYTIME RUNNING LAMPS ARE INOPERATIVE
PINPOINT TEST B : THE DAYTIME RUNNING LAMPS ARE ON WITH IGNITION SWITCH OFF
PINPOINT TEST C : THE PARKING, REAR AND/OR LICENSE LAMPS ARE INOPERATIVE
WITH THE DAYTIME RUNNING LAMPS ON.
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 418 Electrical Distribution > 418-00 Module Communications
Network > Description and Operation > Communications Network
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 418 Electrical Distribution > 418-00 Module Communications
Network > Description and Operation > Diagnosis and Testing > Communications Network - Vehicles With: Central Junction
Box (CJB)

Terminal probe kit 29-011A Inspection and Verification Visual Inspection Chart Symptom Chart
Symptom Chart Pinpoint Tests PINPOINT TEST A : THE RESTRAINTS CONTROL MODULE
(RCM) DOES NOT RESPOND TO THE DIAGNOSTIC TOOL PINPOINT TEST B : THE
ANTI-LOCK BRAKE SYSTEM MODULE DOES NOT RESPOND TO THE DIAGNOSTIC TOOL
PINPOINT TEST C : THE FUEL FIRED BOOSTER HEATER DOES NOT RESPOND TO THE
DIAGNOSTIC TOOL PINPOINT TEST D : THE PARKING AID CONTROL MODULE DOES NOT
RESPOND TO THE DIAGNOSTIC TOOL PINPOINT TEST E : THE CENTRAL SECURITY
MODULE DOES NOT RESPOND TO THE DIAGNOSTIC TOOL PINPOINT TEST F : THE AIR
SUSPENSION MODULE DOES NOT RESPOND TO THE DIAGNOSTIC TOOL PINPOINT TEST
G : THE TRANSMISSION CONTROL MODULE (TCM) DOES NOT RESPOND TO THE
DIAGNOSTIC TOOL PINPOINT TEST H : THE POWERTRAIN CONTROL MODULE (PCM)
DOES NOT RESPOND TO THE DIAGNOSTIC TOOL PINPOINT TEST I : THE INSTRUMENT
CLUSTER DOES NOT RESPOND TO THE DIAGNOSTIC TOOL - VEHICLES BUILT 07/2003
ONWARDS PINPOINT TEST J : NO MODULE/NETWORK COMMUNICATION (SCP BUS)
PINPOINT TEST K : NO MODULE/NETWORK COMMUNICATION (ISO BUS)
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 418 Electrical Distribution > 418-01 Module Configuration >
General Procedures > Module Configuration
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 419 Electronic Feature Group > 419-01A Anti-Theft - Active
> Description and Operation > Anti-Theft - Active
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 419 Electronic Feature Group > 419-01A Anti-Theft - Active
> Description and Operation > Diagnosis and Testing > Anti-Theft - Active
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 419 Electronic Feature Group > 419-01A Anti-Theft - Active
> Description and Operation > Diagnosis and Testing > Removal and Installation > Anti-Theft Alarm Horn

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 419 Electronic Feature Group > 419-01A Anti-Theft - Active
> Specifications
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 419 Electronic Feature Group > 419-01B Anti-Theft -
Passive > Description and Operation > Anti-Theft - Passive
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 419 Electronic Feature Group > 419-01B Anti-Theft -
Passive > Description and Operation > Diagnosis and Testing > Anti-Theft - Passive - Vehicles With: Central Junction Box
(CJB)

Principles of Operation The passive anti-theft system (PATS) uses radio frequency identification
technology and a unique encryption code which matches the powertrain control module (PCM) to
the fuel injection pump control unit to deter a drive away theft. Passive means that it does not
require any activity from the user. The PATS uses a specially encoded ignition key. Each ignition
key contains a permanently installed electronic device called a transponder. Each transponder
contains a unique electronic rolling identification code to further enhance the security of the system.
This code may be any one out of millions of combinations. The ignition key on vehicles with a
PATS system is identified by a blue insert. Previous ignition keys with a red insert are not
compatible with this vehicle and must not be used. Each ignition key must be programmed into the
vehicle PCM using WDS before it may be used to start the engine. There are special diagnostic
repair procedures outlined in this manual that must be carried out if a new ignition key is required.
There are two methods to program a new ignition key to the PATS system. The first method
involves the use of two existing programmed keys. REFER to Key Programming Using Two
Programmed Keys in this section. The second method involves using WDS to program the key into
the PATS system. REFER to Erasing All Key Codes Using Diagnostic Equipment in this section.
The PATS transceiver module communicates with the transponder in the ignition key. The PATS
transceiver module is located behind the steering column shrouds and contains an antenna
connected to a small module. During each vehicle start sequence, the transceiver module reads
the ignition key identification code and sends the data to the PCM. The fuel injection pump control
unit must be programmed to the vehicle PCM before it allows fuel to be delivered to the injectors.
This is required only if a new fuel injection pump or PCM is installed. When the ignition key is
turned to the RUN or START position the PCM sends an encrypted code to the fuel injection pump
control unit. The fuel injection pump control unit then sends an encrypted code back to the PCM to
indicate that it has recognized the PCM. The PCM then sends a signal back to the fuel injection
pump control unit to allow fuelling to commence. The control functions are contained in the PCM.
The PCM carries out all of the PATS functions, such as receiving the identification code from the
ignition key and controlling engine enable. The PCM initiates the encoded key interrogation
sequence when the vehicle ignition switch is turned to RUN or START. When the key is turned to
the OFF position, the PCM will remain powered up for approximately 0.16 milliseconds. This allows
time for the PCM to store the rolling code in its memory. All elements of the PATS must be
functional before the engine is allowed to start. If any components are not working correctly, the
engine will not start. The PATS uses a visual PATS LED which is situated in the vehicles clock.
The PATS LED will self-test for three seconds when the ignition switch is turned to RUN or START
under normal operation. The PATS also flashes the PATS LED every two seconds at ignition OFF
to act as a visual deterrent. The PATS LED also acts as a diagnostic lamp which will flash different
codes depending on the PATS concern present. When the ignition key is turned to the RUN or
START position and a PATS concern is present, the PATS LED will flash for one minute before
flashing out the relevant fault code(s). It will flash the code(s) a total of ten times before resetting.
Code Flashing Example: Code 21. When the PATS LED begins to flash the code(s), it will indicate
the first digit of the code by flashing in one second intervals until the number of flashes is equal to
the first digit of the code. The PATS LED will then stop flashing for approximately two seconds
before the second digit of the code(s) is displayed in the same way as the first. The PATS LED will
then stop flashing for approximately three seconds before the process is repeated up to a total of
ten times. Inspection and Verification Visual Inspection Chart Symptom Chart Symptom Chart
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 419 Electronic Feature Group > 419-01B Anti-Theft -
Passive > Description and Operation > Diagnosis and Testing > General Procedures > Erasing All Key Codes Using
Diagnostic Equipment - Vehicles With: Central Junction Box (CJB)
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 419 Electronic Feature Group > 419-01B Anti-Theft -
Passive > Description and Operation > Diagnosis and Testing > General Procedures > Key Programming Using Two
Programmed Keys - Vehicles With: Central Junction Box (CJB)
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 419 Electronic Feature Group > 419-01B Anti-Theft -
Passive > Description and Operation > Diagnosis and Testing > General Procedures > Key Programming Switch State
Control - Vehicles With: Central Junction Box (CJB)
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 419 Electronic Feature Group > 419-01B Anti-Theft -
Passive > Description and Operation > Diagnosis and Testing > General Procedures > Anti-Theft Security Access -
Vehicles With: Central Junction Box (CJB)
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 419 Electronic Feature Group > 419-01B Anti-Theft -
Passive > Description and Operation > Diagnosis and Testing > General Procedures > Removal and Installation > Passive
Anti-Theft System (PATS) Transceiver

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 419 Electronic Feature Group > 419-10 Multifunction
Electronic Modules > Description and Operation > Diagnosis and Testing > Anti-Theft Alarm and Double Locking Module

Inspection and Verification Visual inspection Symptom Chart Symptom Chart Pinpoint Tests
PINPOINT TEST A : ANTI-THEFT ALARM AND DOUBLE LOCKING MODULE NOT
COMMUNICATING WITH THE DIAGNOSTIC TESTER
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 4 Electrical > 419 Electronic Feature Group > 419-10 Multifunction
Electronic Modules > Description and Operation > Diagnosis and Testing > Removal and Installation > Anti-Theft Alarm and
Double Locking Module

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-00 Body System - General
Information > Specifications
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-00 Body System - General
Information > Description and Operation > Insulation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-00 Body System - General
Information > Description and Operation > Body
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-00 Body System - General
Information > Description and Operation > Body Sealer Types and Applications
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-02 Front End Body Panels
> Specifications
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-02 Front End Body Panels
> Description and Operation > Front End Body Panels
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-02 Front End Body Panels
> Description and Operation > General Procedures > Hood Alignment
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-02 Front End Body Panels
> Description and Operation > General Procedures > Removal and Installation > Air Deflector

Removal 1. Raise the wiper arms and detach them from the taper with sideways movements.
Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-02 Front End Body Panels
> Description and Operation > General Procedures > Removal and Installation > Radiator Grille Opening Panel

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-02 Front End Body Panels
> Description and Operation > General Procedures > Removal and Installation > Fender

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-03 Body Closures >
Specifications
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-03 Body Closures >
General Procedures > Sliding Door Alignment
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-05 Interior Trim and
Ornamentation > Specifications
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-05 Interior Trim and
Ornamentation > Removal and Installation > B-Pillar Trim Panel

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-05 Interior Trim and
Ornamentation > Removal and Installation > A-Pillar Trim Panel

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-05 Interior Trim and
Ornamentation > Removal and Installation > Front Door Trim Panel

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-05 Interior Trim and
Ornamentation > Removal and Installation > Sliding Door Trim Panel

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-05 Interior Trim and
Ornamentation > Removal and Installation > Rear Door Trim Panel - Van-Kombi-Bus

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-05 Interior Trim and
Ornamentation > Removal and Installation > Liftgate Trim Panel

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-05 Interior Trim and
Ornamentation > Removal and Installation > Rear Door Trim Panel - Chassis Cab

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-05 Interior Trim and
Ornamentation > Removal and Installation > Loadspace Trim Panel LH

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-05 Interior Trim and
Ornamentation > Removal and Installation > Loadspace Trim Panel RH

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-05 Interior Trim and
Ornamentation > Removal and Installation > Rear Headliner - Van-Kombi-Bus

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-05 Interior Trim and
Ornamentation > Removal and Installation > Front Headliner

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-05 Interior Trim and
Ornamentation > Removal and Installation > Rear Headliner - Chassis Double Cab

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-08 Exterior Trim and
Ornamentation > Removal and Installation > Rear Quarter Panel Moulding

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-09 Rear View Mirrors >
Specifications
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-09 Rear View Mirrors >
Description and Operation > Rear View Mirrors
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-09 Rear View Mirrors >
Description and Operation > Diagnosis and Testing > Rear View Mirrors

Inspection and Verification Visual Inspection Chart Symptom Chart Pinpoint Tests PINPOINT
TEST A : THE MIRRORS ARE INOPERATIVE PINPOINT TEST B : A SINGLE MIRROR IS
INOPERATIVE PINPOINT TEST C : A SINGLE MIRROR DOES NOT FUNCTION WITH SWITCH
LOGIC
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-09 Rear View Mirrors >
Description and Operation > Diagnosis and Testing > Removal and Installation > Exterior Mirror

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-10 Seating > Specifications
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-10 Seating > Description
and Operation > Diagnosis and Testing > Seats

Inspection and Verification Visual Inspection Chart Symptom Chart Symptom Chart Pinpoint Tests
PINPOINT TEST A : THE HEATED SEATS ARE INOPERATIVE PINPOINT TEST B : THE
HEATED SEAT IS INOPERATIVE
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-10 Seating > Description
and Operation > Diagnosis and Testing > Removal and Installation > Front Seat Backrest

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-10 Seating > Description
and Operation > Diagnosis and Testing > Removal and Installation > Double Passenger Seat

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-10 Seating > Description
and Operation > Diagnosis and Testing > Removal and Installation > Front Seat

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-10 Seating > Description
and Operation > Diagnosis and Testing > Removal and Installation > Seat Track

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-10 Seating > Description
and Operation > Diagnosis and Testing > Removal and Installation > Disassembly and Assembly > Front Seat Cushion

Disassembly Assembly
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-10 Seating > Description
and Operation > Diagnosis and Testing > Removal and Installation > Disassembly and Assembly > Double Passenger Seat
Cushion

Disassembly Assembly
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-10 Seating > Description
and Operation > Diagnosis and Testing > Removal and Installation > Disassembly and Assembly > Rear Seat Cushion -
Chassis Double Cab

Disassembly Assembly
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-10 Seating > Description
and Operation > Diagnosis and Testing > Removal and Installation > Disassembly and Assembly > Treble Second Row
Seat Cushion

Disassembly Assembly
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-10 Seating > Description
and Operation > Diagnosis and Testing > Removal and Installation > Disassembly and Assembly > Treble Third Row Seat
Cushion

Disassembly Assembly
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-10 Seating > Description
and Operation > Diagnosis and Testing > Removal and Installation > Disassembly and Assembly > Front Seat Backrest

Disassembly Assembly
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-10 Seating > Description
and Operation > Diagnosis and Testing > Removal and Installation > Disassembly and Assembly > Double Passenger Seat
Backrest

Disassembly Assembly
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-10 Seating > Description
and Operation > Diagnosis and Testing > Removal and Installation > Disassembly and Assembly > Rear Seat Backrest -
Chassis Double Cab

Disassembly Assembly
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-10 Seating > Description
and Operation > Diagnosis and Testing > Removal and Installation > Disassembly and Assembly > Treble Second Row
Seat Backrest

Disassembly Assembly
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-10 Seating > Description
and Operation > Diagnosis and Testing > Removal and Installation > Disassembly and Assembly > Treble Third Row Seat
Backrest

Disassembly Assembly
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-10 Seating > Description
and Operation > Seats - Vehicles With: Central Junction Box (CJB)
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-11 Glass, Frames and
Mechanisms > Specifications
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-11 Glass, Frames and
Mechanisms > Description and Operation > Glass, Frames and Mechanisms

Opening Windows Manually operated front door windows are standard. There is a market option
for front power windows, which are activated by switches located in the door trim panels. The driver
switch also incorporates a one-touch down function. There is a market option for opening rear
quarter windows. Fixed/Direct Glazed Windows The front door quarter window glass is secured in a
rubber weatherstrip and retained by a flange in the door panel. The windshield, side and rear
windows are directly glazed to the window opening flange by means of a polyurethane (PU)
adhesive bead. In addition to fixing the glass to the opening flange, the PU adhesive bead also
forms a watertight seal around the inner edge of the glass. The glass is held in the correct position,
during the curing period of the PU adhesive, by locating pegs in the top corners. There is a market
option for sliding rear windows which are fitted into a cassette and secured in the same manner. All
new glass, including the sliding cassettes, is supplied in service with the locating pegs attached. It
is essential for good adhesion and sealing of the direct glazed windows and sliding rear window
cassettes that the correct materials are used and that the PU adhesive is allowed to cure. Any
moisture on the bond line of the glass or on the window opening flange must be removed using a
hot air gun before applying the PU adhesive bead. To carry out direct glazing operations an
oscillating cutter, an assortment of special cutting blades, a cartridge gun and two glaziers suction
cups will be required (in addition to the contents supplied with the Ford repair kit).
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-11 Glass, Frames and
Mechanisms > Description and Operation > Diagnosis and Testing > Glass, Frames and Mechanisms - Vehicles With:
Central Junction Box (CJB)

Inspection and Verification Visual Inspection Chart Symptom Chart Pinpoint Tests PINPOINT
TEST A : ALL POWER WINDOWS ARE INOPERATIVE Left-hand drive vehicles built up to
08/2003 Right-hand drive vehicles built up to 08/2003 All vehicles built from 08/2003 Left-hand
drive vehicles built up to 08/2003 Right-hand drive vehicles built up to 08/2003 All vehicles built
from 08/2003 PINPOINT TEST B : A SINGLE POWER WINDOW IS INOPERATIVE - DRIVER
SIDE Left-hand drive vehicles built up to 08/2003 Right-hand drive vehicles built up to 08/2003 All
vehicles built from 08/2003 Left-hand drive vehicles built up to 08/2003 Right-hand drive vehicles
built up to 08/2003 All vehicles built from 08/2003 Left-hand drive vehicles built up to 08/2003
Right-hand drive vehicles built up to 08/2003 All vehicles built from 08/2003 Left-hand drive
vehicles built up to 08/2003 Right-hand drive vehicles built up to 08/2003 All vehicles built from
08/2003 Left-hand drive vehicles built up to 08/2003 Right-hand drive vehicles built up to 08/2003
All vehicles built from 08/2003 Left-hand drive vehicles built up to 08/2003 Right-hand drive
vehicles built up to 08/2003 All vehicles built from 08/2003 Left-hand drive vehicles built up to
08/2003 Right-hand drive vehicles built up to 08/2003 All vehicles built from 08/2003 PINPOINT
TEST C : A SINGLE POWER WINDOW IS INOPERATIVE - PASSENGER SIDE Left-hand drive
vehicles built up to 08/2003 Right-hand drive vehicles built up to 08/2003 All vehicles built from
08/2003 Left-hand drive vehicles built up to 08/2003 Right-hand drive vehicles built up to 08/2003
All vehicles built from 08/2003 Left-hand drive vehicles built up to 08/2003 Right-hand drive
vehicles built up to 08/2003 All vehicles built from 08/2003 Left-hand drive vehicles built up to
08/2003 Right-hand drive vehicles built up to 08/2003 All vehicles built from 08/2003 Left-hand
drive vehicles built up to 08/2003 Right-hand drive vehicles built up to 08/2003 All vehicles built
from 08/2003 Left-hand drive vehicles built up to 08/2003 Right-hand drive vehicles built up to
08/2003 All vehicles built from 08/2003 Left-hand drive vehicles built up to 08/2003 Right-hand
drive vehicles built up to 08/2003 All vehicles built from 08/2003 Left-hand drive vehicles built up to
08/2003 Right-hand drive vehicles built up to 08/2003 All vehicles built from 08/2003 Left-hand
drive vehicles built up to 08/2003 Right-hand drive vehicles built up to 08/2003 All vehicles built
from 08/2003 PINPOINT TEST D : THE ONE-TOUCH DOWN FEATURE IS INOPERATIVE
Left-hand drive vehicles built up to 08/2003 Right-hand drive vehicles built up to 08/2003 All
vehicles built from 08/2003 Left-hand drive vehicles built up to 08/2003 Right-hand drive vehicles
built up to 08/2003 All vehicles built from 08/2003 Left-hand drive vehicles built up to 08/2003
Right-hand drive vehicles built up to 08/2003 All vehicles built from 08/2003 PINPOINT TEST E :
THE DEFROST SYSTEM IS INOPERATIVE Vehicles built up to 08/2003 Vehicles built from
08/2003 Vehicles with liftgate Vehicles built up to 08/2003 Vehicles built from 08/2003 Vehicles
with liftgate Vehicles built up to 08/2003 Vehicles built from 08/2003 Vehicles with liftgate Vehicles
built up to 08/2003 Vehicles built from 08/2003 Vehicles built up to 08/2003 Vehicles built from
08/2003 Vehicles built up to 08/2003 Vehicles built from 08/2003 Vehicles built up to 08/2003
Vehicles built from 08/2003 Vehicles built up to 08/2003 Vehicles built from 08/2003 Vehicles built
up to 08/2003 Vehicles built from 08/2003 Vehicles built up to 08/2003 Vehicles built from 08/2003
Vehicles built up to 08/2003 Vehicles built from 08/2003 Vehicles built up to 08/2003 Vehicles built
from 08/2003 Vehicles built up to 08/2003 Vehicles built from 08/2003 Vehicles built up to 08/2003
Vehicles built from 08/2003 Vehicles built up to 08/2003 Vehicles built from 08/2003 Vehicles built
up to 08/2003 Vehicles built from 08/2003 Vehicles built up to 08/2003 Vehicles built from 08/2003
Vehicles built up to 08/2003 Vehicles built from 08/2003 Vehicles built up to 08/2003 Vehicles built
from 08/2003 Vehicles built up to 08/2003 Vehicles built from 08/2003 Vehicles built up to 08/2003
Vehicles built from 08/2003 Vehicles built up to 08/2003 Vehicles built from 08/2003 Vehicles built
up to 08/2003 Vehicles built from 08/2003 Vehicles built up to 08/2003 Vehicles built from 08/2003
Vehicles built up to 08/2003 Vehicles built from 08/2003 Vehicles built up to 08/2003 Vehicles built
from 08/2004 Vehicles built up to 08/2004 Vehicles built from 08/2003 PINPOINT TEST F : THE
DEFROST SYSTEM WILL NOT SHUT OFF AUTOMATICALLY Vehicles built up to 08/2003
Vehicles built from08/2003 Vehicles built up to 08/2003 Vehicles built from 08/2003
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-11 Glass, Frames and
Mechanisms > Description and Operation > Diagnosis and Testing > Removal and Installation > Front Door Window Glass

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-11 Glass, Frames and
Mechanisms > Description and Operation > Diagnosis and Testing > Removal and Installation > Front Quarter Window
Glass

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-11 Glass, Frames and
Mechanisms > Description and Operation > Diagnosis and Testing > Removal and Installation > Second Row Side Window
Glass

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-11 Glass, Frames and
Mechanisms > Description and Operation > Diagnosis and Testing > Removal and Installation > Sliding Door Window Glass

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-11 Glass, Frames and
Mechanisms > Description and Operation > Diagnosis and Testing > Removal and Installation > Third Row Side Window
Glass

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-11 Glass, Frames and
Mechanisms > Description and Operation > Diagnosis and Testing > Removal and Installation > Rear Door Window Glass

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-11 Glass, Frames and
Mechanisms > Description and Operation > Diagnosis and Testing > Removal and Installation > Rear Door Window Glass -
Chassis Double Cab

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-11 Glass, Frames and
Mechanisms > Description and Operation > Diagnosis and Testing > Removal and Installation > Partition Panel Window
Glass

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-11 Glass, Frames and
Mechanisms > Description and Operation > Diagnosis and Testing > Removal and Installation > Rear Window Glass -
Chassis Double Cab

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-11 Glass, Frames and
Mechanisms > Description and Operation > Diagnosis and Testing > Removal and Installation > Liftgate Window Glass

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-11 Glass, Frames and
Mechanisms > Description and Operation > Diagnosis and Testing > Removal and Installation > Front Door Window
Regulator

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-11 Glass, Frames and
Mechanisms > Description and Operation > Diagnosis and Testing > Removal and Installation > Front Door Window
Regulator and Motor

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-11 Glass, Frames and
Mechanisms > Description and Operation > Diagnosis and Testing > Removal and Installation > Windshield Glass

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-11 Glass, Frames and
Mechanisms > Description and Operation > Diagnosis and Testing > Removal and Installation > Front Door Glass Top Run

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-12 Instrument Panel and
Console > Specifications
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-12 Instrument Panel and
Console > Removal and Installation > Instrument Panel

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-12 Instrument Panel and
Console > Removal and Installation > Disassembly and Assembly > Instrument Panel

Disassembly Assembly
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-14 Handles, Locks, Latches
and Entry Systems > Description and Operation > Handles, Locks, Latches and Entry Systems

The passenger compartment doors are of a conventional lock to striker plate design with the
strikers located on the B pillars. The hood, load space and sliding side door striker plates locate
into latches positioned on the vehicle body. The hood can only be opened by using the ignition key
in the hood lock cylinder. To open the hood: The door latch mechanisms are operated by a
conventional actuating rod and cable system connected to the inner and outer latch handles. On
higher specification models a power lock system is integrated into the original locking system, this
system consists of power door lock switches, power door lock actuators, circuit wiring and
protection. On models with a power lock system only one lock barrel is fitted, this is located on the
driver door. All remaining doors are fitted with blanking plugs and unlock simultaneously with the
driver door. In addition to power locking, higher specification models also have the option of a
keyless entry remote locking system. For additional information, refer to Section 419-10
Multifunction Electronic Modules . The sliding side door can be a combination of left or right hand
side with either twin opening rear doors or a tailgate. The door handle and latch are removed from
the inside of the door panel. The handle and latch cannot be removed separately, they must be
removed as a complete unit and then separated.
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-14 Handles, Locks, Latches
and Entry Systems > Description and Operation > Diagnosis and Testing > Locks, Latches and Entry Systems
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-14 Handles, Locks, Latches
and Entry Systems > Description and Operation > Diagnosis and Testing > General Procedures > Remote Transmitter
Programming
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-14 Handles, Locks, Latches
and Entry Systems > Description and Operation > Diagnosis and Testing > General Procedures > Removal and Installation
> Hood Latch

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-14 Handles, Locks, Latches
and Entry Systems > Description and Operation > Diagnosis and Testing > General Procedures > Removal and Installation
> Front Door Latch

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-14 Handles, Locks, Latches
and Entry Systems > Description and Operation > Diagnosis and Testing > General Procedures > Removal and Installation
> Sliding Door Latch

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-14 Handles, Locks, Latches
and Entry Systems > Description and Operation > Diagnosis and Testing > General Procedures > Removal and Installation
> Liftgate Latch

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-14 Handles, Locks, Latches
and Entry Systems > Description and Operation > Diagnosis and Testing > General Procedures > Removal and Installation
> Rear Door Latch - Van-Kombi-Bus

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-14 Handles, Locks, Latches
and Entry Systems > Description and Operation > Diagnosis and Testing > General Procedures > Removal and Installation
> Rear Door Latch - Chassis Double Cab

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-14 Handles, Locks, Latches
and Entry Systems > Description and Operation > Diagnosis and Testing > General Procedures > Removal and Installation
> Rear Door Lower Latch

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-14 Handles, Locks, Latches
and Entry Systems > Description and Operation > Diagnosis and Testing > General Procedures > Removal and Installation
> Rear Door Upper Latch

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-14 Handles, Locks, Latches
and Entry Systems > Description and Operation > Diagnosis and Testing > General Procedures > Removal and Installation
> Exterior Sliding Door Handle

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-14 Handles, Locks, Latches
and Entry Systems > Description and Operation > Diagnosis and Testing > General Procedures > Removal and Installation
> Exterior Front Door Handle

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-14 Handles, Locks, Latches
and Entry Systems > Description and Operation > Diagnosis and Testing > General Procedures > Removal and Installation
> Exterior Rear Door Handle LH - Van-Kombi-Bus

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-14 Handles, Locks, Latches
and Entry Systems > Description and Operation > Diagnosis and Testing > General Procedures > Removal and Installation
> Exterior Rear Door Handle - Chassis Double Cab

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-14 Handles, Locks, Latches
and Entry Systems > Description and Operation > Diagnosis and Testing > General Procedures > Removal and Installation
> Exterior Rear Door Handle RH - Van-Kombi-Bus

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-14 Handles, Locks, Latches
and Entry Systems > Description and Operation > Diagnosis and Testing > General Procedures > Removal and Installation
> Liftgate Release Handle

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-14 Handles, Locks, Latches
and Entry Systems > Description and Operation > Diagnosis and Testing > General Procedures > Removal and Installation
> Front Door Lock Cylinder

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-14 Handles, Locks, Latches
and Entry Systems > Description and Operation > Diagnosis and Testing > General Procedures > Removal and Installation
> Hood Lock Cylinder

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-14 Handles, Locks, Latches
and Entry Systems > Description and Operation > Diagnosis and Testing > General Procedures > Removal and Installation
> Rear Door Lock Cylinder - Van-Kombi-Bus

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-14 Handles, Locks, Latches
and Entry Systems > Description and Operation > Diagnosis and Testing > General Procedures > Removal and Installation
> Sliding Door Lock Cylinder

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-14 Handles, Locks, Latches
and Entry Systems > Description and Operation > Diagnosis and Testing > General Procedures > Removal and Installation
> Rear Door Lock Cylinder - Chassis Double Cab

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-14 Handles, Locks, Latches
and Entry Systems > Description and Operation > Diagnosis and Testing > General Procedures > Removal and Installation
> Liftgate Lock Cylinder

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-14 Handles, Locks, Latches
and Entry Systems > Description and Operation > Diagnosis and Testing > General Procedures > Removal and Installation
> Front Door Latch Remote Control

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-14 Handles, Locks, Latches
and Entry Systems > Description and Operation > Diagnosis and Testing > General Procedures > Removal and Installation
> Rear Door Latch Remote Control - Chassis Double Cab

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-14 Handles, Locks, Latches
and Entry Systems > Description and Operation > Diagnosis and Testing > General Procedures > Removal and Installation
> Sliding Door Latch Remote Control

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-14 Handles, Locks, Latches
and Entry Systems > Specifications
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-16 Wipers and Washers >
Specifications
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-16 Wipers and Washers >
Diagnosis and Testing > Wipers and Washers - Vehicles Built Up To: 07-2003, Vehicles With: Central Junction Box (CJB)

Terminal probe kit 29-011A Inspection and Verification Visual Inspection Chart Symptom Chart
Symptom Chart Pinpoint Tests PINPOINT TEST A : THE WIPERS ARE INOPERATIVE PINPOINT
TEST B : THE WIPERS STAY ON CONTINUOUSLY PINPOINT TEST C : THE HIGH WIPER
SPEED DOES NOT OPERATE CORRECTLY (INTERMITTENT WIPER MODE OK) PINPOINT
TEST D : THE LOW WIPER SPEED DOES NOT OPERATE CORRECTLY PINPOINT TEST E :
INTERMITTENT WIPER IS INOPERATIVE (OTHER FUNCTIONS OK) PINPOINT TEST F : THE
WIPERS WILL NOT PARK AT THE CORRECT POSITION PINPOINT TEST G : THE REAR
WIPER(S) DO NOT OPERATE CORRECTLY WITH THE WASHER FUNCTION PINPOINT TEST
H : THE WASHER PUMP IS INOPERATIVE Component Test Windshield wiper motor Measure the
amperage. Is the value at the digital multimeter next to 1,5 A? If yes, GO to 2. If no, INSTALL a
new wiper motor. Measure the amperage. Is the value at the digital multimeter next to 2,2 A? If yes,
GO to 3. If no, INSTALL a new wiper motor. Measure the resistance at the wiper motor, between
pin 2 and pin 3. Is the resistance less than 2 ohms? If yes, GO to 4. If no, GO to 4. and REPEAT
this test step (If no again, INSTALL a new wiper motor). Determine the condition Does the wiper
motor move to the WIPER PARK position? If yes, the wiper motor is OK. If no, INSTALL a new
wiper motor.
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-16 Wipers and Washers >
Diagnosis and Testing > Wipers and Washers - Vehicles Built From: 07-2003, Vehicles With: Central Junction Box (CJB)

Terminal probe kit 29-011A Inspection and Verification Visual Inspection Chart Symptom Chart
Symptom Chart Pinpoint Tests PINPOINT TEST A : THE WIPERS ARE INOPERATIVE PINPOINT
TEST B : THE WIPERS STAY ON CONTINUOUSLY PINPOINT TEST C : THE SLOW OR FAST
WIPER SPEED DOES NOT OPERATE CORRECTLY PINPOINT TEST D : INTERMITTENT
WIPER IS INOPERATIVE (OTHER FUNCTIONS OK) PINPOINT TEST E : THE WIPERS WILL
NOT PARK AT THE CORRECT POSITION PINPOINT TEST F : THE WASHER PUMP IS
INOPERATIVE
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-16 Wipers and Washers >
Diagnosis and Testing > General Procedures > Windshield Wiper Blade and Pivot Arm Adjustment

Aligner, Wiper Arm 501-027 (32-006) Vehicles without beam blade wipers Vehicles with beam
blade wipers
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-16 Wipers and Washers >
Diagnosis and Testing > General Procedures > Removal and Installation > Windshield Wiper Motor

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-16 Wipers and Washers >
Diagnosis and Testing > General Procedures > Removal and Installation > Rear Window Wiper Motor - Vehicles With: Rear
Doors

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-16 Wipers and Washers >
Diagnosis and Testing > General Procedures > Removal and Installation > Rear Window Wiper Motor - Vehicles With:
Liftgate

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-17 Roof Opening Panel >
Removal and Installation > Escape Hatch

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-19 Bumpers >
Specifications
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-19 Bumpers > Removal
and Installation > Rear Bumper Cover

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-19 Bumpers > Removal
and Installation > Front Bumper Cover

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-19 Bumpers > Removal
and Installation > Front Bumper

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-19 Bumpers > Removal
and Installation > Rear Bumper

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-20A Safety Belt System >
Specifications
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-20A Safety Belt System >
Description and Operation > Diagnosis and Testing > Safety Belt System - Vehicles With: Central Junction Box (CJB)

Principles of Operations The safety belt system utilizes a combination of two point lap safety belts
and three point lap and diagonal safety belts, depending on the individual vehicle specifications.
Emergency Locking Retractor (ELR) The ELR is part of the safety belt system that in normal
operation allows free movement of the belted occupant. In an emergency the ELR will lock,
preventing webbing payout and hence forward movement of the occupant. Locking may be
achieved by one of two mechanisms: Vehicle Motion Sensor (VMS) The ELR's VMS is operated by
sudden deceleration of the vehicle or excessive tilt. Once operated the VMS causes a locking pawl
to be engaged, thus locking the retractor, preventing webbing payout. The locking method used is
dependent on which type of ELR is fitted. When the vehicle is stationary, the VMS stabilizes,
causing the pawl to disengage and unlock the retractor, allowing webbing payout. Webbing Motion
Sensor (WMS) The ELR's WMS is operated by rapid acceleration of the webbing. Once operated,
it causes a locking pawl to be engaged thus locking the retractor. Webbing payout is prevented in
the same manner as VMS. The safety belt system utilizes two types of ELR: Web Grabber
Retractor (KCS.1) Fitted to all front seating positions and all 11 to 15 seater bus rear 3-point seat
positions. As soon as the VMS or WMS is activated, the clamping mechanism starts locking and
the steering disc puts the rotation lever in motion. The clamping wedge is moved up and clamps
the webbing against a force guide and clamp ring. Decreased webbing force leads to de-blocking
of the clamp mechanism, since the force of the retaining spring pulls back the clamping wedge.
Spindle Locking Retractor (R27W) Fitted to all Kombi, Double Chassis Cab and 8 or 9 seater bus
3-point seat positions. As soon as the VMS or WMS is activated, a lock dog located in the spindle
is steered into the teeth on the retractor frame, preventing the spindle turning and webbing payout.
When stationary, the VMS will stabilize, causing the pawl to disengage, unlocking the retractor and
allowing payout. Inspection and Verification Visual Inspection Chart Symptom Chart Symptom
Chart Component Test Poor Retraction If a safety belt does not retract correctly, check that the
anchor covers and trim are correctly installed and not rubbing against the safety belt webbing.
Where necessary, check that the safety belt webbing is not rubbing at one end of the retractor
cover slot and if so, correct by loosening the retaining bolt, aligning the retractor to centralize the
safety belt webbing and tightening the bolt. The safety belt retractors are dual sensitive, which
means that they have: Both systems should be fully operational and can be checked by the tests
below: Vehicle Motion Sensor Test Either of the following two procedures may be used to check
correct operation of the vehicle motion sensor. Both methods require two technicians, but note that
technicians of larger than normal build should not be asked to conduct these tests. This is to avoid
the possibility of a fully unrolled safety belt webbing being mistaken for a correctly locked safety
belt retractor. Test Method 1 (braking) Test Method 2 (turning circle) This method requires a flat
open area of private road, sufficient for the vehicle to be driven in a continuous circle on full
steering lock. Static Test With the vehicle stationary and on level ground, take firm hold of the
safety belt webbing (on the tongue side of the upper safety belt anchor) and pull quickly. The
retractor should lock within 0.25 meters (10 inches), preventing further webbing payout. Any safety
belt retractor from which it is possible to extract further webbing must not be used. A new safety
belt must be installed.
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-20A Safety Belt System >
Description and Operation > Diagnosis and Testing > Removal and Installation > Front Safety Belt Retractor

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-20A Safety Belt System >
Description and Operation > Diagnosis and Testing > Removal and Installation > Rear Safety Belt Retractor

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-20A Safety Belt System >
Description and Operation > Diagnosis and Testing > Removal and Installation > Front Safety Belt Retractor - Vehicles
With: Double Passenger Seat

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-20A Safety Belt System >
Description and Operation > Diagnosis and Testing > Removal and Installation > Rear Safety Belt Retractor - Chassis
Double Cab

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-20A Safety Belt System >
Description and Operation > Diagnosis and Testing > Removal and Installation > Safety Belt Shoulder Height Adjuster

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-20A Safety Belt System >
Description and Operation > Safety Belt System

The safety belt system utilizes a combination of two-point lap safety belts and three-point lap and
diagonal safety belts depending on the individual vehicle specification. The safety belt retractors in
all front seating positions, where a three-point safety belt is fitted and all 11 to 15 seater bus rear
seat positions incorporate web grabbers as standard. All other safety belt retractors are of the
conventional retractor type. Front outboard three-point safety belt retractors are mounted in the
B-pillar. The rear outboard seat positions in Chassis Double Cab vehicles incorporate conventional
three-point safety belt retractors mounted in the rear center beam. All other safety belt retractors
are seat mounted. Two-point lap safety belts are fitted on the rear center seating position in
Chassis Double Cab vehicles and on the double front passenger center seat where a passenger air
bag is not fitted. Safety belt shoulder height adjusters, mounted in the B-pillar, are fitted as
standard on the drivers side on all variants and the passenger side on all 8 to 15 seater bus
variants. Safety belt shoulder height adjusters, mounted in the B-pillar, on the passenger side are
available as an option on Van, Kombi and Chassis Cab variants. The safety belt buckles are either
seat or body mounted depending on the vehicle specifications.
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-20B Supplemental
Restraint System > Description and Operation > Air Bag Supplemental Restraint System (SRS)

The supplemental restraint system (SRS) is designed to protect the driver and front seat outer
passenger (when equipped with a passenger air bag) from sustaining severe facial and upper body
injuries in the event of a serious impact, when used in conjunction with the conventional two-point
and three-point safety belt system. The safety belts form an integral part of the SRS. The SRS is
designed to deploy only in the event of a collision, with the ignition in the RUN position. The driver,
wearing the safety belt provided, should position the seat as far back as is practical, so the steering
wheel can be reached with arms slightly angled, thereby leaving a gap between the steering wheel
and the driver. The passenger, wearing the safety belt provided, should not position himself or
herself so that the air bag cover is in direct contact with the occupants’ body. The front air bag(s)
will deploy in the event of a direct front impact or when the impact angle is up to 30 degrees from
the left or right of the vehicle center line. The air bag(s) will deploy only once. In a collision in which
they deployed at the first impact, the air bag(s) will not reduce the risk of injury in a subsequent
impact. Under certain circumstances, although the damage sustained by the vehicle may look
extensive, the impact may remain below the triggering threshold of the SRS and the air bag(s) will
not deploy. In such circumstances the safety belts would provide sufficient protection for the
occupants. The visible vehicle identification number (VIN) plate, which shows the air bag symbol
and either X1 or X2 dependent on the number of air bags fitted, is attached to the windshield edge
of the instrument panel. The SRS consists of the following components: The air bag control module
governs the operation of the whole system, including the diagnostic element. It contains two frontal
impact micro machine sensors; a crash sensor and a safing sensor. These two sensors are
connected in series and if they both sense a deceleration in excess of a predetermined limit, the air
bag control module will deploy the air bag module(s). The air bag control module also performs
continual system diagnostics. In the event of a fault being detected the warning indicator is
illuminated either constantly or intermittently. The behavior of the warning indicator depends on the
type of fault present. The warning indicator is located in the instrument cluster. The air bag control
module can be reset, using WDS, and used for up to five collisions in which the air bags deployed.
The wiring harness provides power to the air bag control module from the vehicle supply and hence
to the air bag module(s). The air bag sliding contact is designed to carry signals between the air
bag control module and the driver air bag module. The air bag sliding contact is fitted to the
steering column, and consists of fixed and moving parts connected by a coiled Mylar tape with
integral conducting tracks. The Mylar tape is able to "wind up" and "unwind" as the steering wheel
(to which the moving part is attached) is turned, maintaining electrical contact at all times between
the air bag control module and the driver air bag module. The air bag sliding contact is used in
order to achieve the high degree of circuit integrity required by such a critical safety system as the
SRS. A new air bag sliding contact must be installed following a driver air bag deployment. The
driver and passenger air bag modules consist of the following components which cannot be
disassembled: The inflator is screwed into a plastic container. The air bag is then folded on top of
the inflator and the whole subassembly is enclosed by the cover. The driver air bag module is fitted
to the steering wheel, the cover forming the outer surface of the steering wheel boss. The cover
has invisible "split lines" moulded in its surfaces allowing the air bag to easily exit through the cover
when the system deploys. A new driver air bag module and wiring harness with the air bag module
electrical connectors must be installed following deployment. The passenger air bag module is
integrated into the front of the instrument panel to provide an unobtrusive appearance. The cover
incorporates an invisible "split line" moulded in its surface along the lower edge and hinged along
the upper edge. As the air bag deploys, the lower edge of the cover splits allowing the air bag to
easily exit. The cover remains secured to the air bag module body by the hinge. A new passenger
air bag module and wiring harness with the air bag module electrical connectors must be installed
following deployment. Vehicles without a passenger air bag module have a bridge resistor fitted to
the passenger air bag wiring harness in place of the passenger air bag module. The purpose of the
inflator is to generate the gas needed to fill the air bag. It consists of a high strength steel casing
filled with a solid propellant charge and an electrically activated igniter. The igniter is activated by a
signal from the air bag control module which in turn ignites the propellant charge. The very rapid
burning of the propellant produces sufficient gas to fill the air bag(s). As the gases expand they
cool, preventing heat damage to the bag. The drivers air bag module has one inflator and bag, with
a filled volume of 57 liters. The passenger air bag module has one inflator and bag having a filled
volume of 57 liters. The air bag(s) are a one-piece woven item with a silicon coating to provide
flame and heat protection in the vicinity of the inflator. The shape of the passenger air bag is
tailored to the vehicle proportions. In order to prevent the folds of the air bag from sticking together
in its tightly stowed position, the fabric may be treated with talcum powder. When the air bag(s)
deploy, some of the fine powder is blown into the vehicle. This powder is visible as a dust cloud
and also has a characteristic odor. The particles soon settle and do not represent a health risk. The
dust cloud is not a sign of external combustion outside the air bag inflator cartridge. When the air
bag(s) deploy, they remain fully inflated for only a fraction of a second and start to deflate
immediately, cushioning the occupant. The high speed of inflation along with the surrounding
events and noise from the impact can give the impression that the air bag(s) did not deploy to their
full extent. In certain circumstance slight grazing or minor friction burns can result from air bag
deployment. There are two processes which are involved: The SRS will communicate concerns
during a driving cycle or after initial key ON by means of a warning indicator located in the
instrument cluster. If a concern is detected, the air bag control module will communicate by flashing
the warning indicator and a diagnostic trouble code (DTC) is logged by the air bag control module
in a non-volatile memory. The DTC can be downloaded using WDS. For additional information,
refer to Air Bag Supplemental Restraint System (SRS) in this section.
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-20B Supplemental
Restraint System > Description and Operation > Diagnosis and Testing > Air Bag Supplemental Restraint System (SRS) -
Vehicles Built Up To: 09-2003

Simulator, Air Bag 418-037 (40-001) Test and Deployment Lead, Air Bag/Pyrotechnic Safety Belt
418-S055 (40-007) Diagnosing Customer Concerns Without Hard DTCs/LFCs Speak with the
customer to determine if a particular set of conditions must be met in order for a fault to occur. If a
LFC is reported by the customer but is not present when the vehicle comes in for repair, pinpoint
test diagnostics cannot be used. Instruct the customer on how to count a LFC. Diagnosing
Customer Concerns with Hard DTCs/LFCs Most air bag system diagnostic procedures require the
use of system deactivation and system reactivation procedures. These procedures require the
removal of the driver and passenger air bag modules from the vehicle, thereby removing the risk of
air bag deployment while diagnostics are carried out. Air bag simulators are required to carry out
diagnosis and testing of the air bag system. The simulator contains a resistor, used to simulate an
air bag module connection to the system. It is not acceptable to short-circuit the air bag module
connections with a 0 ohm jumper wire. If a 0 ohm jumper wire is used to short-circuit the air bag
module connections, a LFC will be displayed and a DTC logged by the air bag control module.
Deactivation Reactivation Glossary Air Bag Simulator Air bag simulators are used to simulate air
bag module connections to the system. Deactivate the System Deactivate the system means to
carry out the deactivation procedure. Prove Out the System The air bag warning indicator will
illuminate for approximately six seconds. Reactivate the System Reactivate the system means to
carry out the reactivation procedure. Principles of Operation Supplemental Restraint System (SRS)
Operation The vehicle is equipped with DC fired single point sensing system. In the event of a
severe frontal or three-quarter frontal impact, in excess of a predetermined limit, the driver and
passenger (if equipped) air bag(s) will deploy. Air bag deployment will only occur, in the event of a
severe collision when the ignition key is in the RUN position. Air Bag Control Module The air bag
control module retains full control of the whole system. Providing continual system checks and full
diagnostic capabilities, the non-volatile memory stores the fault codes, which are down loaded
through the diagnostic link connector to WDS. A visual warning indicator which is housed within the
instrument cluster, is illuminated when the ignition is switched ON for approximately six seconds
then goes out. If a fault occurs the warning indicator, depending on the nature of the fault, remains
illuminated or begins to flash after a further five seconds. The air bag control module provides an
auxiliary power supply, sufficient to deploy the air bag(s) for a minimum of 150mS, in the event of a
failure in the vehicle power supply during or after an accident. The back up power supply is
discharged by the air bag control within 60 seconds of the battery ground cable being
disconnected. Thus making sure the supplemental restraint system remains operational. The air
bag control module contains a micro-controller to evaluate and process impact data and two
micromachine sensors. An electronic accelerometer, which converts the actual acceleration and
deceleration force, along the vehicles longitudinal axis into electrical signals. Provided both these
sensors sense an impact in excess of a predetermined limit the air bag control module initiates the
circuit to deploy the frontal air bags. The two micromachine sensors prevent unintentional
deployment of the frontal air bags. Air Bag Control Module Wiring Harness Connector Air Bag
Warning Indicator The air bag warning indicator is incorporated into the instrument cluster, together
with the automatic detach detect (ADD) circuit, the air bag warning indicator comes on for six
seconds at key ON. If the system self tests OK the indicator goes out, if a fault is detected the
indicator will flash after a further five seconds, illuminate continually from key ON or not illuminate
at all, depending on the nature of the fault. If the air bag warning indicator fails, the air bag control
module uses the secondary air bag warning indicator. The secondary air bag warning indicator will
only flash if there is a fault present and the primary air bag warning indicator is inoperative. The
ADD circuit is designed to illuminate the air bag warning indicator continuously, if the air bag
control module circuit is broken, either by loss of power or ground supply or electrical connector
disconnection. The air bag control module retaining bolts are part of the ground circuit. Diagnostic
evaluation of the supplemental restraints system can be made through the data link connector
(DLC) and WDS to establish the nature of the concern. Once the DTC is known the appropriate
course of action can be selected from the Symptom Chart. Lamp Fault Codes Inspection and
Verification Visual Inspection Chart Symptom Chart Symptom Chart Pinpoint Tests PINPOINT
TEST A : NO COMMUNICATION WITH THE MODULE PINPOINT TEST B : DTC C1414:
MODULE CONFIGURATION FAILURE – RWD VAN, BUS, KOMBI PINPOINT TEST C : DTC
C1414: MODULE CONFIGURATION FAILURE – FWD VAN, BUS, KOMBI PINPOINT TEST D :
DTC C1414: MODULE CONFIGURATION FAILURE – CHASSIS SINGLE CAB, CHASSIS
DOUBLE CAB PINPOINT TEST E : DTC B1921: AIR BAG WARNING INDICATOR MONITORING
GROUND CIRCUIT OPEN All vehicles Van, Bus and Kombi PINPOINT TEST F : DTC B1318:
BATTERY VOLTAGE LOW All vehicles Van, Bus and Kombi PINPOINT TEST G : DTC B1869:
AIR BAG WARNING INDICATOR OPEN CIRCUIT PINPOINT TEST H : DTC B1870: AIR BAG
WARNING INDICATOR SHORT TO BATTERY PINPOINT TEST I : DTC B1891: AIR BAG
SECONDARY WARNING INDICATOR SHORT TO BATTERY PINPOINT TEST J : DTC B1872:
AIR BAG SECONDARY WARNING INDICATOR OPEN CIRCUIT PINPOINT TEST K : DTC
B1887: DRIVER AIR BAG SHORT TO GROUND All vehicles Van, Bus and Kombi All vehicles
Van, Bus and Kombi PINPOINT TEST L : DTC B1916: DRIVER AIR BAG SHORT TO BATTERY
All vehicles Van, Bus and Kombi All vehicles Van, Bus and Kombi PINPOINT TEST M : DTC
B1932: DRIVER AIR BAG OPEN CIRCUIT OR HIGH RESISTANCE PINPOINT TEST N : DTC
B1934: DRIVER AIR BAG CIRCUIT LOW RESISTANCE PINPOINT TEST O : DTC B1888:
PASSENGER AIR BAG SHORT TO GROUND All vehicles Van, Bus and Kombi PINPOINT TEST
P : DTC B1925: PASSENGER AIR BAG SHORT TO BATTERY All vehicles Van, Bus and Kombi
PINPOINT TEST Q : DTC B1933: PASSENGER AIR BAG OPEN CIRCUIT OR HIGH
RESISTANCE PINPOINT TEST R : DTC B1935: PASSENGER AIR BAG CIRCUIT LOW
RESISTANCE
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-20B Supplemental
Restraint System > Description and Operation > Diagnosis and Testing > Air Bag Supplemental Restraint System (SRS) -
Vehicles Built From: 09-2003

Simulator, Air Bag 418-037 (40-001) Test and Deployment Lead, Air Bag/Pyrotechnic Safety Belt
418-S055 (40-007) Diagnosing Customer Concerns Without Hard DTCs/LFCs Speak with the
customer to determine if a particular set of conditions must be met in order for a fault to occur. If a
LFC is reported by the customer but is not present when the vehicle comes in for repair, pinpoint
test diagnostics cannot be used. Instruct the customer on how to count a LFC. Diagnosing
Customer Concerns with Hard DTCs/LFCs Most air bag system diagnostic procedures require the
use of system deactivation and system reactivation procedures. These procedures require the
removal of the driver and passenger air bag modules from the vehicle, thereby removing the risk of
air bag deployment while diagnostics are carried out. Air bag simulators are required to carry out
diagnosis and testing of the air bag system. The simulator contains a resistor, used to simulate an
air bag module connection to the system. It is not acceptable to short-circuit the air bag module
connections with a 0 ohm jumper wire. If a 0 ohm jumper wire is used to short-circuit the air bag
module connections, a LFC will be displayed and a DTC logged by the air bag control module.
Deactivation Reactivation Glossary Air Bag Simulator Air bag simulators are used to simulate air
bag module connections to the system. Deactivate the System Deactivate the system means to
carry out the deactivation procedure. Prove Out the System The air bag warning indicator will
illuminate for approximately six seconds. Reactivate the System Reactivate the system means to
carry out the reactivation procedure. Principles of Operation Supplemental Restraint System (SRS)
Operation The vehicle is equipped with DC fired single point sensing system. In the event of a
severe frontal or three-quarter frontal impact, in excess of a predetermined limit, the driver and
passenger (if equipped) air bag(s) will deploy. Air bag deployment will only occur, in the event of a
severe collision when the ignition key is in the RUN position. Air Bag Control Module The air bag
control module retains full control of the whole system. Providing continual system checks and full
diagnostic capabilities, the non-volatile memory stores the fault codes, which are down loaded
through the diagnostic link connector to WDS. A visual warning indicator which is housed within the
instrument cluster, is illuminated when the ignition is switched ON for approximately six seconds
then goes out. If a fault occurs the warning indicator, depending on the nature of the fault, remains
illuminated or begins to flash after a further five seconds. The air bag control module provides an
auxiliary power supply, sufficient to deploy the air bag(s) for a minimum of 150mS, in the event of a
failure in the vehicle power supply during or after an accident. The back up power supply is
discharged by the air bag control within 60 seconds of the battery ground cable being
disconnected. Thus making sure the supplemental restraint system remains operational. The air
bag control module contains a micro-controller to evaluate and process impact data and two
micromachine sensors. An electronic accelerometer, which converts the actual acceleration and
deceleration force, along the vehicles longitudinal axis into electrical signals. Provided both these
sensors sense an impact in excess of a predetermined limit the air bag control module initiates the
circuit to deploy the frontal air bags. The two micromachine sensors prevent unintentional
deployment of the frontal air bags. Air Bag Control Module Wiring Harness Connector Air Bag
Warning Indicator The air bag warning indicator is incorporated into the instrument cluster, together
with the automatic detach detect (ADD) circuit, the air bag warning indicator comes on for six
seconds at key ON. If the system self tests OK the indicator goes out, if a fault is detected the
indicator will flash after a further five seconds, illuminate continually from key ON or not illuminate
at all, depending on the nature of the fault. If the air bag warning indicator fails, the air bag control
module uses the secondary air bag warning indicator. The secondary air bag warning indicator will
only flash if there is a fault present and the primary air bag warning indicator is inoperative. The
ADD circuit is designed to illuminate the air bag warning indicator continuously, if the air bag
control module circuit is broken, either by loss of power or ground supply or electrical connector
disconnection. The air bag control module retaining bolts are part of the ground circuit. Diagnostic
evaluation of the supplemental restraints system can be made through the data link connector
(DLC) and WDS to establish the nature of the concern. Once the DTC is known the appropriate
course of action can be selected from the Symptom Chart. Lamp Fault Codes Inspection and
Verification Visual Inspection Chart Symptom Chart Symptom Chart Pinpoint Tests PINPOINT
TEST A : NO COMMUNICATION WITH THE MODULE PINPOINT TEST B : DTC C1414:
MODULE CONFIGURATION FAILURE – RWD VAN, BUS, KOMBI PINPOINT TEST C : DTC
C1414: MODULE CONFIGURATION FAILURE – FWD VAN, BUS, KOMBI PINPOINT TEST D :
DTC C1414: MODULE CONFIGURATION FAILURE – CHASSIS SINGLE CAB, CHASSIS
DOUBLE CAB PINPOINT TEST E : DTC B1921: AIR BAG WARNING INDICATOR MONITORING
GROUND CIRCUIT OPEN PINPOINT TEST F : DTC B1318: BATTERY VOLTAGE LOW
PINPOINT TEST G : DTC B1869: AIR BAG WARNING INDICATOR OPEN CIRCUIT PINPOINT
TEST H : DTC B1870: AIR BAG WARNING INDICATOR SHORT TO BATTERY PINPOINT TEST I
: DTC B1891: AIR BAG SECONDARY WARNING INDICATOR SHORT TO BATTERY PINPOINT
TEST J : DTC B1872: AIR BAG SECONDARY WARNING INDICATOR OPEN CIRCUIT
PINPOINT TEST K : DTC B1887: DRIVER AIR BAG SHORT TO GROUND PINPOINT TEST L :
DTC B1916: DRIVER AIR BAG SHORT TO BATTERY PINPOINT TEST M : DTC B1932: DRIVER
AIR BAG OPEN CIRCUIT OR HIGH RESISTANCE PINPOINT TEST N : DTC B1934: DRIVER AIR
BAG CIRCUIT LOW RESISTANCE PINPOINT TEST O : DTC B1888: PASSENGER AIR BAG
SHORT TO GROUND PINPOINT TEST P : DTC B1925: PASSENGER AIR BAG SHORT TO
BATTERY PINPOINT TEST Q : DTC B1933: PASSENGER AIR BAG OPEN CIRCUIT OR HIGH
RESISTANCE PINPOINT TEST R : DTC B1935: PASSENGER AIR BAG CIRCUIT LOW
RESISTANCE
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-20B Supplemental
Restraint System > Description and Operation > Diagnosis and Testing > General Procedures > Deployed Air Bag Disposal
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-20B Supplemental
Restraint System > Description and Operation > Diagnosis and Testing > General Procedures > Scrapped Vehicle
Undeployed Air Bag Disposal

Test and Deployment Lead, Air Bag/Pyrotechnic Safety Belt 418-S055 (40-007A)
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-20B Supplemental
Restraint System > Description and Operation > Diagnosis and Testing > General Procedures > Unserviceable Air Bag
Disposal
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-20B Supplemental
Restraint System > Description and Operation > Diagnosis and Testing > General Procedures > Removal and Installation >
Air Bag Control Module

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-20B Supplemental
Restraint System > Description and Operation > Diagnosis and Testing > General Procedures > Removal and Installation >
Driver Air Bag Module

Air Bag Simulator 418-037 (40-001) Removal Installation

Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-20B Supplemental
Restraint System > Description and Operation > Diagnosis and Testing > General Procedures > Removal and Installation >
Passenger Air Bag Module

Air Bag Simulator 418-037 (40-001) Removal Installation

Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-20B Supplemental
Restraint System > Description and Operation > Diagnosis and Testing > General Procedures > Removal and Installation >
Air Bag Sliding Contact

Air Bag Simulator 418-037 (40-001) Removal Installation

Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-20B Supplemental
Restraint System > Specifications
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-25 Body Repairs - General
Information > Specifications
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-25 Body Repairs - General
Information > Description and Operation > Description and Usage of Body Repair Literature
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-25 Body Repairs - General
Information > Description and Operation > Health and Safety Precautions

General 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 body repairs. Personal protection Welding gases
and grinding dusts can be harmful to the health. For this reason, make sure that rooms are well
ventilated and work using the welding fumes extraction system. Sealants, underbody protection
and paint residues must not be burnt down with an unshielded flame, as this will produce gases
which are damaging to health. A dedicated extraction system must always be used when welding
or brazing. When working with substances containing solvents, good ventilation must be provided,
respiratory protection must be worn and an extraction system must be used. Do not weld in damp
areas, if necessary use an insulation mat. Welding and grinding work near the battery presents the
danger of explosion. For this reason, it must be removed before the work is started. Cutting,
grinding and alignment work on metal panels can cause a noise level of 85 to 90 dB (A) or even
more. For this reason, you must always wear ear defenders. 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. Some special instructions must be followed when
working on airbag systems: Protection of the vehicle Protect affected areas from weld spatter and
dust during all welding and grinding work on the vehicle. If metallic dust stays on the vehicle for
some time, there is the likelihood of film rust formation. Grinding or sanding work produce tiny
spots of damage to the paint surface, which may cause corrosion. For this reason, make sure to:
Use suitable protective measures to protect the interior when performing repair operations which
relate to the inside of the vehicle. Carbon fibre blankets are used directly around the working area.
They offer maximum protection to the areas of the vehicle. In addition, take into account: Protective
equipment The following protective equipment must always be used: Electronic components
Increased use of comfort and safety electronics in modern motor vehicles also requires the
greatest attention to be paid during body work. Overvoltages produced during welding and in
alignment work during bodyshell rectification may cause electronic systems to be damaged. In
particular, the safety instructions for performing welding work on vehicles with airbag systems must
be adhered to. Pay attention to the following points:
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-25 Body Repairs - General
Information > Description and Operation > Symbols

Various symbols, signs, instructions and illustrations are used in this literature. Warnings and
cautions have different meanings and require different ways of proceeding. Diagrammatic
representations are provided with instructional signs for improved clarity. When reading this
handbook, you will come across the points WARNING, CAUTION AND NOTE. These points are
always immediately before a single job step or a series of job steps. These are briefly explained
below: Item numbers Item numbers are inserted into a diagram when details need to be
emphasized. Item numbers with one indicator line An item number and an indicator line point to a
special location or a component. In this diagram a component and a row of spot welds are
indicated. Item numbers with two indicator lines If two indicator lines lead away from one item
number, then an area is being referred to. In this case the area with the spot welds to be separated
is shown. Black arrows If the illustration of a detail is unambiguous, or there is only one detail
shown, then no item number is used. A black arrow is used for this. Broken arrows Broken arrows
represent movement. In this case the component must be removed in the direction given.
Enlargement/detail If a detail cannot be clearly seen in the illustration because of its size or
location, it is shown enlarged in a separate window. In this case a detail on the back of the B-pillar
cannot be seen, and is therefore shown separately. Different colors or shading Different colors or
shading are used to depict special areas. In an assembly operation, the colors show the sequence
of removal steps. In the repair specifications, the first component or the first partial replacement
component is always shown in magenta. The second component in an illustration is shown in
turquoise and a third component is shown in dark green. Spot welds, weld seams and cut lines are
shown in black. This principle also applies to line drawings. In these, illustrations under the same
topic will always show the same colors for the same components.
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-25 Body Repairs - General
Information > Description and Operation > Environmental Regulations

Orderly and responsible waste management is not only very important for the protection of health
and the environment, but it also has great importance where saving natural resources is
concerned. In body repair shops, since the introduction of the EU directives on the avoidance of
vehicle waste and the promotion of return, re-use and recycling of vehicles and their components
(2000/53/EU), more rigorous attention than before is also paid to avoidance and recycling of waste
materials. In this respect, body repair shops must take into account and comply with the following
requirements: The avoidance and recycling of waste must always take priority. However, despite all
measures which may be taken, waste cannot be completely avoided. All remaining waste must be
treated as commercial waste and disposed of according to the local requirements.
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-25 Body Repairs - General
Information > Description and Operation > Body Construction

General Two design principles have prevailed in body design. The body design can either be an
integral body-frame or a frame with all attached superstructures. Mixed versions are also possible,
with the design significantly increasing the stability of the frame. In all versions, the passenger cell
must be preserved in the event of an accident. To this end, the front and rear ends are designed so
that they absorb the energy of the impact via crumple zones. The use of modern design and
manufacturing methods, and the use of body panels whose reshaping and strength properties have
been finely balanced, mean that despite the reduced weight, all safety-related aspects and
requirements can be met. Integral body-frame In the car market, the integral safety body-frame is
the result of this technological development and manufacturing technology. The integral
body-frame is completed with ancillary components, such as doors, hood, bumpers and other
components. The advantages of this are: The safety of the driver and passengers is paramount for
every body design. There are two key safety aspects in the body: The safety body cell is
characterized by the following design features: Deformation behavior Different materials and
design features lead to staged deformation of the front and rear of the vehicle in an accident. The
passenger cell remains undamaged, and the driver and passengers are not shut in. The bolted
crash element is made of high-strength steel. Built-in pre-determined folding points prevent
damage to the cross member during gentle impacts. The use of bolts means that this can be
quickly and cheaply replaced. Side members can be manufactured from panels of different
thicknesses. These are joined together through laser welding. These panels are called tailored
blanks. The rear of the vehicle, like the front of the vehicle, has structures which protect the
passenger cell through staged deformation in the event of an accident. The design layouts,
however, are adapted to the requirements of the rear area. MPVs The body of an MPV has largely
the same design layout as a passenger car body. However, due to the different requirements of an
MPV, the floor pan in particular had to be designed in a more stable manner. It is therefore
produced as a frame construction with particularly high torsional rigidity and flexural strength. If
repair is required, the process is similar to the process for a passenger car body. Convertible The
body of a convertible differs from the principle of the integral body-frame of a saloon due to the lack
of a roof construction. To guarantee the high safety requirements, particular design changes are
required within the floor pan structure. These are: Frame structures Frame structures are used for
off-road vehicles and light commercial vehicles. With these structures, a distinction is made
between a separate frame structure, as on an off-road vehicle, and the composite structure of a
light commercial vehicle. The entire body structure of the commercial vehicle body differs
fundamentally from that of the saloon car. The requirements of such a body cannot be compared
with a passenger car body. The payload is paramount here. Accordingly, the stability requirements
must also be taken into account in the body design. These are: Off-road vehicles The body designs
of off-road vehicles are not subject to the principle of the integral body-frame. Their basic
construction corresponds to a chassis frame with an attached body. This stable chassis structure
has significant advantages for off-road vehicles: If repairs are to be carried out, a different repair
technique is required for this body and frame structure. A deformed frame structure requires high
suction power during straightening repairs. Frequently, the body also has to be detached from the
frame structure in order to carry out separate repair. Due to the very stable frame structure, please
note that the straightening behavior is completely different to that of a passenger vehicle. The
frame and the attached body must be repaired independently of each other.
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-25 Body Repairs - General
Information > Description and Operation > Body Sheet Metal

Types of steel 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 ultra-high-strength special steels are used in vehicle body construction. Types of steels are
classified by their properties of strength and elasticity. High-strength and ultra-high-strength steels
are mostly installed in safety relevant locations (structural components). Among others, these are
side members, pillars, roof frames. Example of the use of high-strength steel Normal strength
steels Normal strength steels are most often used in body construction. They are relatively soft and
are therefore particularly suitable for the deep drawing processes used in body manufacturing. As
well as very good reshaping properties, the panels also have a relatively high rigidity. High strength
steel panels The strength of the material and the nature of the surface can be changed as required
by different engineering processes. In order to achieve suitable configuration and a good match
between construction specifications and what is possible in production, a large range of high
strength panels is available. The range of the minimum yield strength is from 180 N/mm2 to 460
N/mm2. High strength thin steel panels usually have a surface finish. Electrolytic surface sealing is
preferred. Within the group of high strength steels, various types of steel are used in body
construction: Ultra-high-strength steels These steels are predominately used for body structural
components which are relevant to safety. Despite the reduced thicknesses of the panels used,
weight reduction is often achieved together with greater strength. As with high-strength steels,
special types of steel are used in the ultra-high-strength steels group: Because of the use of such
steels, some special points must be taken into account during body repair: The basic working
methods and the tools to be used are the same however. Coated steel panels In a similar way to
high-strength steel panels, coated steel panels are finding more applications because of the better
corrosion protection which they offer. There are basically two different process which are used to
apply a zinc layer: The following points must be noted when welding: Tailored blanks Tailored
blanks are panels which are made up of at least two separate panels with different material
thicknesses and/or material properties. The panels are joined together by a laser weld seam and
then shaped in a press. This technique allows panel shapes to be produced which meet special
requirements with regard to deformation behavior, strength and weight. Laser weld seams at the
sidemember Typical examples of application are: When repairing the vehicle body, pay special
attention that such a connection is never separated. The possible cut line locations are given in the
respective repair manuals. Aluminum Aluminum is becoming ever more important in body
construction because of the trend to reduce weight. Doors, hoods and body outer panels are
increasingly being made of aluminum alloy panels. Although at the time of publication of this
document, Ford of Europe has not yet introduced any aluminum body or aluminum body
components, this topic is briefly described in this section. All the tools needed for body repair must
be suitable for working aluminum, and they must be only used on aluminum. The main properties
of aluminum are: In the electrochemical potential series, aluminum has a negative potential of
1.23V in relation to steel. Because of this, when aluminum and steel touch and an electrolyte is
present, contact corrosion occurs. The following points should therefore be noted: In the main,
aluminum panels can be worked using the same processes as used for steel panels. There are
however some special features to pay attention to: In contrast to steel, aluminum does not display
any surface color change when heated. This therefore means that the level of heating of the
material cannot be seen. Only once the material is overheated does a change in the material
structure of the surface occur. By the time this has occurred, the structure of the material is already
seriously damaged, and its strength very much reduced. Overheated aluminum components must
always be replaced. Aluminum welding Aluminum welding requires a welder which is specially
designed to meet these requirements. Both repair welding processes are based on fusion welding.
Success of aluminum welding partly depends on how well the surface oxidation can be removed.
Because aluminum oxide remains solid at the melting point of pure aluminum, it is important to
remove it before welding. The aluminum surface must be cleaned before welding. Cleaning
improves the later fusion penetration and prevents contamination of the welding wire. The following
three steps are to be performed in preparation: Aluminum oxide forms very quickly, therefore steps
2 and 3 should be performed immediately before welding. Before working on the vehicle body,
create a test seam on scrap which is made of identical material. Test the test piece visually and
destructively, to make certain that all welding parameters are correctly set, and an acceptable weld
seam can be achieved. An optimum weld can be recognized by the following quality features:
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-25 Body Repairs - General
Information > Description and Operation > Diagnosis and Damage Evaluation

In order to correctly determine the extent of the damage caused by an accident, in-depth technical
knowledge, practical experience with the technical equipment and the testing and measuring
devices is required. Assessment of the extent of the damage includes visual inspection and
dimensional inspection of the vehicle. If damage to the chassis geometry is visible even during the
visual inspection, the vehicle is to be inspected on an axle alignment jig. Visual recording of the
damage From a profitability perspective, the possibility of a sectional replacement must be taken
into consideration when assessing the damage to a vehicle damaged in an accident. Positive
accidental damage assessment can only be achieved if the service technician is able to reconstruct
the effect of an impact on the body structure. For example: If the impact occurs on the front
left-hand side member, the right-hand side member will usually also have been damaged. Often
the length of this side member will not have changed, but because of the rigid body design, it may
have become deformed. This damage can be detected through the size of the gap between the
door and fender or by measuring the vehicle. In the case of more severe impacts, in which the front
part of the vehicle cannot absorb all of the impact energy, the passenger cell is also used to absorb
the energy. Here, the energy is transferred via the A pillar and distributed there. This results in
deformations in the roof and the door sill. It is possible to draw conclusions about the extent of the
damage through a visual inspection of the external damage. In general, the following areas are to
be checked during the visual inspection: Hidden damage In addition to external indicators, such as
flaked off paint or cracks in the underbody protection, it is vital to check for deformations that are
not visible from the outside (hidden body damage) during a damage assessment. Unless ancillary
components are removed, it is often impossible to achieve accurate diagnosis of the underlying
body parts. Particular attention must be paid to the following components: Light commercial
vehicles and off-road vehicles The basic body design of light commercial vehicles and off-road
vehicles corresponds to a chassis frame with an attached body. Therefore, both vehicle
components, the frame and the body, must be checked thoroughly during damage assessment. As
with all vehicles, it is important to inspect the impact area and the shock absorbing areas closely for
damage. With these vehicles too, simple inspections can also reveal indicators of possible
deformations. In addition, you must check for the following for vehicles with frame structures:
Convertible-specific crash characteristics Due to the convertible design, the deformation paths
arising during an impact are larger than the actual permanent deformations. In the case of severe
impacts to the front or rear end, deformations may even extensively deform the passenger cell with
no recognizable permanent damage. This is referred to as a large compression characteristic.
Adjacent mechanical components may nevertheless be damaged owing to these deformations.
The following should particularly be inspected:
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-25 Body Repairs - General
Information > Description and Operation > Tools and Equipment for Body Repairs

Alignment systems Straightening and alignment repairs are often required to restore a vehicle body
to its original shape after accident damage. Universal aligning and measuring systems and
universal alignment angle systems are suitable for this work. Basically, the aligning and measuring
system must satisfy the following requirements: Alignment angle devices survey the vehicle at
several points on the body. These are usually points which are also used in production. In addition,
a recording over the rocker panels is possible. A measuring system is not needed, because the
necessary body points are specified with gauges. For this purpose, vehicle specific or universal
gauges are available. Universal alignment systems consist of a vehicle mounting (universal clamps
at the rocker panels) and a pulling device. In addition, a measuring system is required. Pay
attention to the following points: Measuring systems In order to exactly diagnose a damaged
vehicle body, measuring systems are required. Depending on the measuring method, the systems
vary in having mechanical, optical and acoustic measuring devices. In some cases, hybrid versions
of particular systems are found. Basically, the measuring systems must meet the following
requirements: Beam compass The beam compass is a very practical and straightforward aid for
measuring bodywork and especially floor assemblies. The beam compass can be used to detect
dimensional variations across the length and the width by means of comparison measurements
and diagonal measurements. As a basic principal, body reference points should be chosen which
are shown in the body frame measurement data sheet. Comparison measurements can also be
made on the outside of the body. Depending on the damage, left/right measurements (symmetry
measurements) and diagonal measurements can be made using the beam compass, telescopic
rod or a measuring tape. Laser measuring systems These systems use laser beams which are
projected in one or more planes. By the use of two parallel laser heads which can be turned,
symmetrical points of a vehicle body can be tested and compared. Using the linear scales which
are attached to the measuring points, the measurement data is read off with the aid of the
projected laser beams. The integral inclination gauge also allows differences in height to be quickly
checked. Mechanical measuring system The use of mechanical measuring equipment is an easy
and effective way to check a vehicle frame and chassis assembly quickly, exactly and reliably. In
many cases an assessment of the damage can be made with the help of this system, without the
need for elaborate setting up. Because of its self-centering mount, measurement can be carried out
by one person. Further advantages: Measuring systems which are firmly mounted on an aligning
platform require more work in setting them up. They are used to constantly check measurements
during alignment work. This type of mechanical measuring system has measuring scales and
measuring slides in three measuring axes. So that the body can be measured, the vehicle is
secured on the aligning platform base frame using four universal chassis clamps. The exact fixing
points are given in each respective data sheet. Acoustic-electronic measuring systems These
measuring systems can be combined with all current aligning platforms. In addition these
measuring systems can be used independently of an aligning platform by using a vehicle lift or
suitable support stands. Acoustic measuring systems use ultrasonic emitters and sensors to survey
a body. To do this, ultrasonic emitters are mounted on the vehicle using special attachments.
During the measuring process the ultrasonic emitters constantly send out signals which are
received by sensors (microphones) and then passed to a computer. The measurements are
displayed on the computer screen and are compared with the required values supplied by the
vehicle manufacturer. Mechanical-electronic measuring system The ways in which
mechanical-electronic measuring systems can be used are similar to those of the acoustic
measuring systems. They can also be set up on a suitable understructure, without an alignment jig.
After this system has been arranged under the vehicle floor and adjusted to three undamaged
vehicle measuring points, the measuring arm is brought up to the required measuring points and
the readings compared with the reference values. The data is transmitted to a computer where it is
evaluated and the results displayed on a screen. Panel beating tools Depending on the type and
extent of the damage to the vehicle body, very different tools may be needed to repair it. The most
usual tools and the way they are used are described below. Aluminum hammer The aluminum
hammer is the most important and most commonly used tool during body panel repair. The most
usual areas of application are: Tapered hammer The tapered hammer is chiefly used to rectify
small high-spots. Universal hand dolly Because of its versatile shape, the universal hand dolly can
be used as a counterhold in almost all areas of the vehicle body. It is particularly suitable for use as
a counterhold when rectifying material excess. Because of its weight, the universal hand dolly can
also be used as a hammer to straighten a dent from inside without counterhold (hollow leveling).
Box file The box file is mainly used as counterhold in fine straightening work with the aluminum
hammer. It is available in various shapes and sizes. The corrugated surface (file-cut) prevents the
panel from stretching during fine straightening work (barb effect). Using the file-cut imprint on the
panel surface, the effect and extent of the blows from the panel beating hammer can be judged.
Pulling lever and spoon If access to the rear of the damage with the panel beating hammer is not
possible, a panel beating lever can be employed. Once the worst of the damage is rectified, work
continues with the spoon. This also allows short striking movements to be made in inaccessible
areas. A spoon is often used as a counterhold in work with the panel beating hammer. Caulkers A
caulker is mostly used in edge areas. In this case the caulker is inserted on the inside of the
damaged area. Selected blows on the shaft of the tool allow the damaged edge area to be
reworked. Caulkers can however also be used for straightening small areas which can only be
reached from the back through small openings. Body plane The body plane consists of the
two-faced plane blade and the solid plane body, which prevents pressure deformation of the plane
blade. The body plane is available in half-round and flat versions. The main application areas are:
Body file The body file is used solely during heat treatment working of dents. Because of the solid
body of the file, it can absorb much heat. It stabilizes repair areas which are being straightened by
warming. It does this by rapid removal of heat from the repair area, which has the effect of
stabilizing the body panel. Body files are graded by the size of their teeth (file-cut): Gas torch The
main area of use of the gas torch is heat working of small and mild dents. It is also suitable for soft
soldering work on body panels. The ready-to-use gas torch consists of the following parts:
Compare with oxy-acetylene equipment, the gas burner has the advantage of easier handling due
to its lower weight and shorter set-up times because of the quick-change burner heads. Soft
soldering equipment Despite good panel beating technique, it is not always possible to rectify all
unevenness. For that reason, application of filling solder is an important part of surface treatment.
Similarly the surface of weld seams created during partial repairs can be optimized. A complete
soft soldering kit consists of tinning paste, soft solder and brush. In addition, a set of wooden
paddles with a variety of shapes and a lint free cloth rag are needed. Shape gauge The shape
gauge is used to check the contours of the area to be reshaped, when there is no other way of
recognizing and checking the basic shape. There are various designs of shape gauge. The short
design made of steel is used for smaller repair areas. Because its segments are very thin, it allows
a very exact fit at a contour. The longer design made of plastic is applied to larger areas. Because
of its wider segments, it is better suited to large surface contours. External dent remover/puller
Because of their multi-purpose nature, external dent removers and pullers are very useful in
achieving an economical repair to a vehicle body outer skin. These repair methods are used on
vehicle body components which are inaccessible from the inside. Small dents such as those
caused during parking and larger areas of damage such as on the side panel, rocker panel etc. can
be rectified. Basically there are three different methods: Welding gear As in the past, the dominant
process in body construction is resistance welding, in particular spot welding. Depending on body
type, up to 5000 spot welds are applied, either by welding robots or in the multi-point welding
machine. During repairs the resistance spot welds used in production must be re-created
accordingly. Although in principle high-strength panels are adequately- or well-suited to resistance
spot welding, problems may arise, especially where large panel thicknesses or three layers of
panel need to be welded together in the workshop, but these problems can be overcome. In
particular, older welding equipment does not have the latest welding technology nor welding power
and therefore cannot reliably join panel thicknesses greater than 3 mm. Modern equipment with
inverter technology allows better spot weld quality because of a constant high welding current. In
addition the high welding current makes shorter welding times possible and the electrodes
therefore have a longer working life. In the case of resistance spot welded connections, faults in the
weld are difficult to see from the outside. It is therefore absolutely vital to know the particular
properties of the welding machine being used. A test weld with subsequent peeling test will provide
information on the quality of the weld. The spot weld itself must not separate, it must tear away
leaving a hole. In the production of vehicle bodies, MIG welding plays a minor role as a joining
technique. It is used for components subject to high demands, such as threaded plates for axle
mountings, or at locations which cannot be spot welded for access reasons. Separating tools A
variety of tools are available to the body specialist for the separation of body components. The use
of the different tools depends on the joining technique involved and the access available to the
repair location. Spot weld milling tool The spot weld milling tool is suitable for releasing spot welded
connections. In contrast to a normal drill, the milling depth can be set. This prevents the underlying
panel from being damaged. In addition a safety fixing system prevents the milling cutter from
slipping while working. Rod sander Spot welds which are not accessible to the spot weld milling
tool can be ground out using the rod sander. It is also suitable for releasing MIG spot welds and
MIG seam welds. Short stroke saw The short stroke saw is most often used to separate vehicle
body components. It is also very flexible in its ability to access hard-to-reach areas. Orbital saw
Among other things the orbital saw is suitable for the creation of narrow and straight cuts. In
addition the cut can be made to an exact depth limit. This prevents damage to underlying
components. After any work with swarf producing machines, all swarf must always be removed
from cavities, otherwise there is the danger of corrosion.
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-25 Body Repairs - General
Information > Description and Operation > Establish Repair Method

General Before starting an accident repair, a sequence plan must be compiled, containing an
outline of the individual job steps. Similarly, the availability and preparation of all the necessary
materials, spare parts, tools, workshop equipment such as alignment and measuring systems must
also be checked. Planning During planning the following job steps must be observed and adhered
to: After the scope of the work has been determined, before making the repair, check all own
technical prerequisites: Chronological sequence of repair The actual sequence of repair can be
divided into the following steps: Job steps:
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-25 Body Repairs - General
Information > Description and Operation > Straightening

General Straightening repairs are often required to restore the original body shape. For damaged
bodies, straightening is to be considered as the process of pulling out the deformed body parts up
to cutting out the parts that need replacing. As soon as straightening work is carried out on body
parts, this is referred to as repair work. Straightening with pulling equipment In order to restore the
damaged body to its original shape, the deformed part must remain on the body during the
straightening repairs. While the deformed parts remain on the body, the pulling equipment can be
attached anywhere. Only in this way can damaged parts of the body which have to be straightened
be pulled into the original position without problems. Straightening sequence Body straightening
requires practice and experience. Before starting, the exact direction of impact must be
determined. The straightening force must have the exact opposite direction of the impact force.
Only in this way can it be guaranteed that the original shape will be achieved again. The pulling
forces only work with their full impact if the pulling direction is direct. Using the wrong pulling
direction could lead to additional deformation, which is difficult to correct afterwards. Please note
the following points: During individual straightening steps (under a pulling load), relieve tension by
striking the deformed areas with an aluminum hammer while they are still under tension. Off-road
vehicles Straightening repairs on off-road vehicles are different to repairs on normal bodies due to
the two-part construction of the vehicle. This means there are two areas that must be taken into
consideration separately: Straightening the body If only the body is damaged in an accident, light
straightening repairs can be carried out. If a straightening jig is used for straightening work, the
holding clamps or alignment angles must be attached directly to the chassis frame. During the
straightening work, the pulling forces must not become too high. The bolted connections are to be
monitored continuously. Straightening the body and chassis frame If the body and chassis frame
have to be straightened, they must first be separated from each other. The following conditions
must be met:
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-25 Body Repairs - General
Information > Description and Operation > Alignment Check

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 model-specific 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. Measuring data example For exact
determination of the measuring points, enlarged sections are shown.
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-25 Body Repairs - General
Information > Description and Operation > Complete Panel Replacement-Partial Replacement

Repairs always mean intervention in the body shell structure and thus also intervention in the
vehicle's passive security system. The use of complete replacement or sectional replacement as
the best solution must always be weighed up before starting a repair. Complete replacement In a
complete replacement, the original connections are largely reused. A complete replacement is
advantageous if the damaged body part can be detached from its original connections and a
completely new part can be fitted without creating additional joints (e.g. liftgate). A complete
replacement is necessary if there is no sectional replacement solution. Sectional replacement
Sectional replacement (sectional repair) means the replacement of a section of the body shell
structure. Sectional repairs fulfill their purpose above all if the replacement of a complete part is too
time-consuming and thus not economical. Approved sectional repairs are clearly defined in the
model-specific body literature. These requirements must be complied with. Advantages of sectional
repair Sectional repair offers many advantages for correct repair of accidental damage. For the
sectional repairs approved by the factory and described in the model-specific body workshop
literature/technician's information, some spare parts (service parts) specially prepared for sectional
repairs are offered via the spare parts sales department. Decision-making criteria Depending on
the type and extent of the damage, the advantages of carrying out sectional replacement in the
area concerned must be weighed up against complete replacement. The following are always
crucial for the decision: In addition, Ford must have given its approval for a sectional replacement
solution in the damaged area. Depending on the damaged areas, further facts are to be taken into
account when deciding for or against sectional repair:
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-25 Body Repairs - General
Information > Description and Operation > Corrosion Prevention

The corrosion protection provided in production must be carefully maintained and reproduced
during body repair work, in order to ensure the long-term warranty for Ford vehicles. Only Ford
original bodywork components and Ford approved repair materials are to be used for body repairs.
The Ford logo is stamped onto every Ford original spare part. All Ford bodywork components have
a cathodic primer. Moreover, most parts are zinc-plated on one or both sides. If possible, these
protective layers must not be damaged. Corrosion protection measures during repair work All new
components must be inspected for transport or storage damage. Eliminate any existing damage,
such as dents and scratches. Depending on the damage, different operations are to be carried out.
Scratches in new component: Damaged new component: If the new component is not damaged,
any grease and wax must be thoroughly removed with a silicone remover. During repair work, body
panels are often heated at very high temperatures, which results in the destruction of the corrosion
protection. Reworking of the affected areas is therefore vital. Interior surfaces of the new body
components which are no longer accessible after installation must be primed. Before welding The
joint areas are not always accessible from inside later. Therefore, prepare these areas so that no
soot is produced by burning paint during welding. In the case of butt joints with a metal insert, soot
from the burning paint prevents coating of the panel with cavity wax. With this connection
technique, the welding area is to be prepared more thoroughly, as it is to be assumed that more
heat will be applied here. Procedure: After welding The corrosion protection previously applied is
partially damaged after the welding, so some reworking is required. Sealing work Depending on the
vehicle, the clinched flanges on the hood, doors, tailgate and trunk lid must be sealed with clinched
flange sealer. Clinched flange protection with flat nozzle Likewise, the sealing compound used in
production is to be renewed in the area of a repair weld. The sealing compound is to be applied so
that it matches the original condition visually. Clinched flange protection applied to the correct width
and thickness. Underbody protection The underbody protection is used as corrosion protection and
must also be applied such that it matches the original condition, from a visual perspective. Two
main application methods are used in production: Cavity protection After painting, treat all cavities
in the repair area with cavity protection. Please pay particular attention to the welded seams. In the
case of butt joints with a metal insert, the wax is to be applied so that the metal insert is also
reached. Wax entry Seal the inner flanges with the corrosion protection wax as far as possible. To
do this, ensure the doors are upright and spray the corrosion protection wax into the water
discharge holes in both directions for at least 10 seconds. Then tilt and turn the component to
spread the wax over the whole flange. Noise Insulation Noise insulation mats and cavity insulation
applied during production must be applied again.
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-25 Body Repairs - General
Information > Description and Operation > Corrosion Damage-Corrosion Repair

Modern vehicle bodies are protected from corrosion by elaborate measures. Multilayer coatings on
the panel surface prevent direct contact between the metal and oxygen, and so protect it from
corrosion. If the protective layers become damaged, electrochemical conversion processes are
initiated, which allow the metal to oxidize. This leads to the formation of corrosion. The following
factors lead to corrosion: In order to maintain long-term corrosion protection, the vehicle must be
checked at regular intervals. In doing so, the follow areas must be inspected and any damage
rectified: The corrosion formation can vary in extent. With rust film or edge rust formation, the
surface of the paint has small traces of corrosion present. The traces of corrosion can be removed
in such cases by polishing the paint surfaces. If this is not possible however, the traces of corrosion
must be rectified by using a touch-up technique. If rust is already under the paint finish to the steel
panel, then the whole paint finish in the affected area must be sanded away. Furthermore, the
existing traces of corrosion in the body panel must be carefully and completely removed. Finally a
new paint finish must be applied in this area. In the case of rusting through, the affected body panel
is already completely destroyed. Such damage requires complete or at least partial replacement.
The outcome of this is the following repair sequence: For a professional repair it is essential to
reproduce the corrosion protection during and after the repair.
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-25 Body Repairs - General
Information > Description and Operation > Sealer, Underbody Protection Material and Adhesives

Sealants, adhesives, cavity wax and underbody protection materials are used during the various
body repairs. In this area Ford offers a range of products which have been tested and matched to
each other. Clinched flange protection This is a 1-component PU adhesive sealant applied through
a flat nozzle. It is fast setting and is very resistant to ageing. After application it is easily sanded
and stretched and it can also be painted over. Seam sealant T Anthracite This is a 1-component
sealant material for sealing joints and seams. It is also suitable for gluing HVH elements into
position in their respective body areas. It is a solvent-free, odourless adhesive which does not
contain silicone or isocyanate. Body sealant T beige This sealant, which contains solvent and has a
long service life, is particularly suitable for visible seams. It can be painted after it has set.
Underbody protection Underbody protection is necessary for permanently elastic corrosion
protection of vehicle underbodies. It is very durable and has good resistance to abrasion, Cavity
wax This touch-proof, transparent corrosion protection wax is used for the preservation of cavities
and flange joints. Anti-corrosion wax Anti-corrosion wax is a coating material which can be applied
in fine spray, forming a very thin and grease-like protective film, therefore offering very good
corrosion protection. Metal adhesive For joining metal to metal and plastic to metal. The adhesive
reduces droning noises and improves corrosion protection. 1-component window glass adhesive kit
For direct glazing. The vehicle is ready to drive after 6 hours (passenger airbag). Prevents contact
corrosion. 2-component window glass adhesive kit For direct glazing. The vehicle is ready to drive
after 1 hour (passenger airbag). The adhesive is not an electrical conductor and permits
interference-free radio reception. Prevents contact corrosion. Using a 150ml additional cartridge,
the adhesive can also be used for large windows or to produce a double seam of adhesive.
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-25 Body Repairs - General
Information > Description and Operation > Cutting Technique

Depending on the separating tools used, there are some fundamental points to bear in mind: Spot
weld milling tool Resistance spot welds are best separated using a spot weld drilling machine or a
spot weld milling tool. The spot weld milling tool is particularly useful. It usually has an adjustable
depth stop and a safety fixing system. These prevent the machine from drilling too deep and the
cutter from slipping while working. When using an ordinary drill, the depth of the drilled hole must
be judged by the operator. Because of this, there is the danger of injury and also the danger of
drilling right though the workpiece. Rod sander Another option for separating resistance spot welds
is to use the rod sander. For welded connections which have a large diameter, or are difficult to
reach using the spot weld milling tool, the rod sander offers a useful alternative. MIG weld seams
can be worked using this machine. Short stroke saw The short stroke saw is suitable for separating
vehicle body components and for making a separating cut for partial repairs. The narrow design of
the saw blade permits cutting in tight curves. Straight cuts require a relatively great deal of practice.
Orbital saw Where use of the short stroke saw is difficult because of the body construction, the
orbital saw can be used. The cutting depth of the orbital saw can be set. This allows separating
cuts to be made, despite panels or other components lying in danger behind. Straight cut lines can
be more easily made using the orbital saw.
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-25 Body Repairs - General
Information > Description and Operation > Panel Beating Technique and Smart Repairs

General Smaller scale body repairs, where damaged panels do not need to be replaced, can often
be carried out by realignment work. Whether the repair is economical however, often depends on
the accessibility of the affected body area. During damage assessment, the following technical
points must be taken into account: Hollow leveling (removing dent without a dolly) Hollow leveling
can only be used on areas which are accessible from the rear. During hollow leveling, the dent is
removed from the inside a using suitable panel beating tool and applying knocking or pressing
movements. High spots around the edge of the dent area are flattened with blows from the
aluminum or wooden headed hammer. The usual tools are for instance hammers of various
designs, dollies, levering irons and various spoon irons. The correct choice of tool is made
depending on the shape of the dent and the access which is possible. Dent removal using hammer
and dolly Panel beating can only be performed using a hammer and dolly if access can be gained
from the rear side. The purpose of the dolly in this case is to transfer the force of the impacts from
the hammer to the steel panel which is in between. As this is done, the deformed body panel is
smoothed (dressed) and the tension fields in the body panel are removed. The favored tool for this
repair process is the aluminum hammer and as opposite support the universal hand dolly. To
rectify minor panel damage, the box file should be used as opposite support. Because of its
serrated surface, the box file prevents normal stretching of the body panel which would otherwise
occur. Dent removal from the outside using the slide hammer The slide hammer technique is
mostly used when a dent is not accessible from the rear, or a relatively large amount of
disassembly would be needed to make it accessible. By welding pulling rings or pulling electrodes
into position using a special welding gun, dents can be removed from outside using the slide
hammer. Dynamic puller with counter bearing The repair possibilities are much greater than with
the slide hammer method. Because of the versatile puller and the variable counter bearing, a wide
variety of damage can be worked and rectified using this repair method. Because of the
mechanical lever operation, the variable counter bearing and the optimum controlled application of
power, this external dent removal system allows dents in almost all vehicle body areas to be pulled
out. Depending on the application area and the damage, the fixing options to the panel being
worked can be corrugated wire, pulling bits or U-washers which are spot welded into position. Dent
removal using special panel beating levers This panel beating technique with pressure is mainly
used to rectify smaller dents as a result of hail impact, transportation or parking, without the paint
being damaged. Small dents are removed from the inside of the body panel by pushing them
outwards in a mechanical process using panel beating levers. Because of the great variety of
shapes of these levers, it is possible to use this panel beating technique on almost all areas of the
vehicle body. Heat working of panels This repair method allows small and mild dents to be rectified
without additional panel beating. During the repair process, a flame is used to selectively warm
areas of the panel to relieve the stresses in the metal. This can cause the dented area to return to
its correct shape. This method can only be used when the dent: Heat-induced material shrinking
Material shrinking, also called settling in, can be performed in a variety of ways depending on the
extent of the damage and the access to the repair area. These repair processes differ depending
on the type of heating and subsequent working of the heated surface. They sub-divide into two
basic processes: In the carbon electrode process the working is done exclusively by warming. In
this case the access to the repair position is only from the outside. If the damage is concentrated in
a spot and is in the form of a more rigid raised area, then the carbon electrode must be replaced by
a copper electrode. As heat is applied, slightly more pressure is applied to the raised area. In the
method using heating by the oxy-acetylene torch, material shrinking is achieved by a combination
of heat and mechanical working of the damaged area. The repair area must always be accessible
from both sides, so that the heated area can be properly worked mechanically. The combination of
heating and mechanical working is very effective. As soon as the warm point is established,
hammering is immediately started using the aluminum hammer together with a suitable dolly on the
inside of the repair surface, working in spiral movements towards the warm point. This causes
material to build up in the center of the warmed area. Lead loading Despite good external panel
beating techniques, it is not always possible to rectify every surface unevenness. For this reason,
application of lead loading is an important part of panel beating. For corrosion protection and
adhesion reasons, on body components subject to more demands, such as doors or hoods, it is
preferable to apply lead loading rather than stopper. In addition, lead loading application is suitable
for creation of surface contours when the options for panel beating are limited. Typical application
areas:
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-25 Body Repairs - General
Information > Description and Operation > Paintless Dent Removal

General In the past all damage to body surfaces had to be rectified by time-consuming and
cost-intensive repair work. New techniques allow small mild dents without paint damage to be
corrected. Using special levering tools (pressure tools) the dent is worked from the inside in such a
way that the damaged area can be returned to its original shape. Mild dent If strong and direct
force during the damage process causes the material to stretch in the middle of a dent, then the
result is a small and sharp edged dent. Such damage cannot be rectified without visible
deformation. Dent with material stretching Preconditions for a successful repair are a definite
diagnosis and the correct allocation of repair method. Furthermore, sufficient experience in the use
of special tools and knowledge of materials are also requirements for a successful repair. The
following characteristics must be present for a dent to be satisfactorily removed: The economic
viability of undamaged paint dent removal must be considered in addition to whether it is possible
practically. This depends on: While carrying out the repair, the following itemized repair route and
process flow must be complied with: In order to ensure corrosion protection, all inner areas of the
repair must be treated afterwards. Where it is possible, the paint is repaired. In every case the
inner area of the repair must be treated with cavity wax.
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-25 Body Repairs - General
Information > Description and Operation > Joining Techniques

Welding Before welding work is performed on a vehicle body, all safety measures for the protection
of people, modules and electrical components must be observed. In body construction, the main
type of welding used is resistance spot welding. In the course of repair work, this must be restored
accordingly. However, there are also fields of application for MIG welds. MIG welding Fields of
application Welding repairs can only be carried out properly if the equipment is set up correctly and
all welding-related preparations are complied with accurately. Full seam A welded joint with a full
seam is suitable for joining highly profiled body parts. Pillar and sill areas are typical application
areas. Before the welding process, you must carry out the following operations: Interrupted weld
seam - intermittent seam The intermittent seam is used for offset joint surfaces or for butt joints
with a metal insert. This form of seam is mainly used on the external panel area for sectional
repairs. Please note the following welding parameters: Puddle weld. Puddle welding is used as a
substitute if no spot welding equipment that is sufficiently powerful for the thickness of the panel is
available. This welding method is also used if the welding position cannot be accessed with a spot
welding gun. Please note the following welding parameters: Resistance spot welding. The basic
principle for repair welds is to restore the original welded joint as far as possible. The repair welds
must have the same number of weld spots as the welds used in production with the correct
diameters. This requires that: Well-prepared welding flanges are a prerequisite for a problem-free
welded joint. This means: Only in limited cases can welding errors in resistance spot weld joints be
detected from the outside . Therefore, a test weld should be carried out before each repair weld.
The peel test carried out after the welding gives information on the quality of the welding. The spot
weld must not flake off. Joining techniques Butt joints The butt joint is a joining technique frequently
used in body repairs. The butt joint is typically used for repairs in the pillar and rocker panel area.
Areas that are suitable for the use of the butt joint: The edges of the panels to be joined are placed
against each other and are joined with a full seam in whilst maintaining a required welding gap
(welding gap same as panel thickness). Preparation of the joint areas includes: Butt joint with panel
strip As with the butt joint without a panel strip, the panels to be joined are pushed together, but are
joined with an intermittent seam. A panel strip placed beneath the area to be joined stabilizes the
welding area. Preparation of the joint areas includes: Joggled joint The joggled joint variant is
restricted to body areas with a good surface condition without beads/swage lines or profiles. A
sectional replacement with a joggled joint is welded with an intermittent seam. This procedure is
used, for example, at the transition from the side panel to the rocker panel (3-door vehicles). The
amount of reworking required is kept to a minimum, by avoiding the use of a full seam. Other
advantages are: Preparation of the joint areas includes: MIG brazes Metal Inert Gas (MIG) brazing
is increasingly used in production for certain body areas. In areas in which resistance spot welding
is not possible due to limited space or higher strength requirements, MIG welding was previously
used. Increasingly, these MIG welded seams are being replaced by MIG brazes. MIG brazed
connections are partly used in production for the following areas: Inner fender reinforcement to
A-pillar, A-pillar reinforcement to A-pillar inner panel and outer wheelhouse to rocker panel
reinforcement. The temperature range used during MIG brazing is significantly lower. This keeps
the damage to the anti-corrosion zinc layer on zinc-coated panels to a minimum. This results in the
following advantages of the MIG brazed seam: Alternative repair methods are specified in the
model-specific body literature. MIG brazing requires a new generation of welding equipment and
training in the technique. For this reason, MIG brazed joints must be replaced by MIG welds at
another place if a repair is performed. When carrying out these repairs, the requirements in the
corresponding repair instructions must be taken into consideration. Rivets With riveting, two or
more panels are joined together using a joining element (rivet). In body construction, pop rivets and
punched rivets are used. Advantages of riveted connections: Disadvantage: Pop rivets are used if
only one side of the panel is accessible. In this process, overlapping panels are drilled and
connected with a pop rivet. Pop rivets can be inserted pneumatically, hydraulically or manually with
rivet guns. Brazed connections Brazing is a procedure for connecting metallic materials using a
further melted metal. The melting point of the brazing material is lower than that of the basic
material. The basic material is covered with the brazing material and not melted. As the material is
heated to a lesser extent than during welding, brazing is particularly suitable for parts that are
sensitive to warping, oxidization and heating. Brazing means it is possible to join together all
common metals. Brazed connections can be detached again through heating. Brazed parts have a
limited strength, low thermal resistance and a certain risk of corrosion due to the difference
between the basic materials used and the brazing material (difference in potential). Watertight,
permanent connections must be produced at the transitions between A or C pillars and the roof.
Continuous welded seams in visible areas require time-consuming finishing. For this reason, such
connections are not welded, but brazed. Brazed connections are: This means: Lead loading Lead
loading with tin is the best repair method for smoothing joins on sectional replacements or for
rectifying small uneven areas on the panel surface. Tin has the following advantages: For correct
repair, the panel is beaten out almost to the original shape and then the rest is smoothed out
through lead loading. First, the panel to be lead loaded must be properly prepared. To create a
basis for the actual lead loading process, a lead loading paste is first applied to the panel. The
paste is then heated and wiped away with a cloth. Now the tin can be applied and moulded with a
brazing block. After the repair site has cooled slowly, it is worked with the body plane until the
surface is smooth and has no visible joints. Bonding Bonded connections are used more and more
in modern body designs. Here, a distinction is made between bonds for stabilization purposes and
bonds for adhesive strength. Bonds for stabilization purposes are found on clinched flanges and on
cross beams in doors or on the roof. The repair adhesive is an elastic 1K adhesive on a
polyurethane basis. Bonds that rely on adhesive strength are used instead of conventional metal
connections. Here, the hardening 1K epoxy resin is used. Bonded connections have the advantage
over conventional connection procedures that no heating is required. This means it is not
necessary to remove heat-sensitive parts, such as the fuel tank, electronic modules or plastic parts.
In addition, bonded connections have further advantages: Different adhesives are used in body
repairs. Please refer to the repair instructions for the specific adhesive to be used. Please also take
into consideration the instructions of the adhesive manufacturer. Body bonding requires the
following steps: Bonding and welding On some vehicle models, (such as the Ford Ka), bonding is
combined with resistance spot welding. This connection technique has the following advantages:
Please note the following points during the repair work: Bonding and riveting As with welding,
bonding can also be combined with riveting. This connection technique has additional advantages.
These are:
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-25 Body Repairs - General
Information > Description and Operation > Plastic Repairs

General The proportion of plastics used in vehicle construction continues to rise. Up to now
damaged plastic components often had to be replaced. In the meantime plastic repair is becoming
more and more accepted because of rising costs. Because of the various compositions of plastics,
repair work to plastic parts involves a variety of repair methods. The following methods are used: In
repair work, the material properties of plastics are highly significant. There are two main groups:
Thermoplastics Heat causes thermoplastics (also called TP polymers) to transform from the solid
state into the thermoelastic state and then into the thermoplastic state. When thermoplastics are
cooled, they return to solid state. Thermosets Thermosets (also called TS polymers) are much
harder and more brittle than thermoplastics. Their strength remains largely unchanged when they
are heated. Thermosets are destroyed when heated above the critical temperature. Also, the
original state will no longer be restored on cooling. Plastics used by Ford Plastic identification
Normally the identifier is marked on the plastic components used in vehicle construction. If none is
present, it can be determined using two different procedures/methods: Visual Inspection Visual
inspections mainly serve to identify PUR and GRP materials. Thermoplastic components are often
painted and are therefore difficult to identify. Identification characteristics: A burning test allows the
plastic to be determined more exactly. This involves burning a small piece of the plastic material
and observing the behavior of the flame, the smoke characteristics and the dripping behavior.
Characteristics of plastics: Another method to determine the plastic group is the sanding test. In
this a place is chosen which will not be visible later, and the finger belt sander is used to sand the
plastic. The plastic group can be determined using the pattern of the dust: Mechanical Check The
plastic group can be determined by a sound test: Safety instructions In addition to the general
safety instructions, the relevant regulations and accident prevention legislation must be observed.
Information sheets, safety notices and guidelines for the processing of adhesives containing
isocyanate, polyester resin, adhesives, solvent and thinners provide more details on their use. The
following instructions must always be followed: Plastic welding Splits formed in plastic bumpers are
typical possible plastic repairs. If repair using adhesive methods is not possible because of
unfavorable conditions at the rear of the repair location, plastic welding is a possible repair process.
There are two methods of welding: hot air draw welding and hot air fanning welding. Plastic welding
set In addition to the components listed, plastic welding requires tools already found in the
workshop such as scrapers, sanders, face cutters etc. As with all other welding processes, only
certain material combinations can be joined together using plastic welding. Repair sequence during
plastic welding: Despite good preparation and the correct choice of welding materials, weld faults
may occur. The correct choice of temperature is important for the success of the repair. Possible
causes of weld faults: Adhesive bonding of plastics Adhesive bonding of plastics has some
advantages over welding methods: Tools and equipment also familiar from paint repairs can be
used in making adhesive repairs to thermoplastic components. Angle grinders and belt sanders
can be used to grind out scratches and splits. Orbital sanders with extractors are used for fine
sanding. The infrared heater is used to provide fast and secure drying throughout. Plastic adhesive
set Apart from the components shown, other materials may be needed to bond plastics, depending
on the repair position. For large scale repairs, it may be necessary to insert reinforcement panel
strips and reinforcement matting as fixing aids. Repair sequence during plastic adhesive bonding:
GRP repairs GRP material is hard and brittle in its strength properties. Because of these material
properties, splits and openings often result in cases of serious damage. The stability of GRP parts
is impaired if the glass fiber reinforcement is cracked. The component must be replaced in cases of
serious damage that affect the structure. Minor damage (such as abrasion, splits up to 80mm,
holes up to approx. 60mm diameter, etc.) can be repaired to a technically and visually perfect
standard, provided that the damage does not occur in heavily used or hard-to-reach areas. To
ensure perfect repair results, observe the following points: Tools and equipment from the paint
shop can be used to carry out repairs to GRP parts. Angle grinders and belt sanders can be used
to grind out scratches and splits. Orbital sanders with extractors are used for fine sanding. GRP
repair set Scissors, paintbrush and cleaning materials are other materials which will be needed to
perform a GRP repair. The repair process for a GRP repair is as follows:
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-25 Body Repairs - General
Information > Description and Operation > Special Repair Techniques

Cabriolet vehicles The body of a cabriolet vehicle is different to the self-supporting body of a saloon
car because of the special roof construction (folding top). The stability requirements must therefore
be ensured by construction changes within the body structure. These are for instance: If
deformation to load carrying components occurs, the stability of the whole body shell can be
adversely affected. On a cabriolet, accident damage repair to the components mentioned above is
considerably different in certain aspects compared with the usual repairs (closed body
construction): Liquefied gas vehicles Alternative fuel vehicles often require special handling in the
workshop area. Above all, assembly operations to some extent require particular knowledge when
dealing with the special technology and the safety regulations. These special requirements must be
understood and taken into account in the body shop as well. If the smell of liquefied petroleum gas
(LPG) or compressed natural gas (CNG) is noticed in the workshop, instruct everyone present as
follows: Alternative fuels require special handling: Avoid situations in which fuel from an LPG or
CNG fuel tank can escape. These include: Refrigerated conversion vehicles Apart from the special
materials used in building the structure of the refrigerated compartment, such vehicles have special
energy and refrigeration systems which require special handling during repair. Vehicles with a
refrigerated compartment are often used to transport foodstuffs. For this reason, additional hygiene
regulations must be complied with during repair work. Aluminum and plastic are used to construct
the two different types of compartment found on refrigerated vehicles. The aluminum conversion is
a very stable and technically perfect variant. However, against this the relatively high production
costs and a lower payload must be taken into account, because of the weight of the aluminum
conversion itself. The plastic conversion has developed into a light, clean and economical
alternative because of constant further development of materials and working techniques.
Refrigerated compartment constructions are often made using both materials. The floor pan is
made of structured, slip-proof aluminum panels and the wall and ceiling cladding is made of
smooth surfaced plastic elements. Polyurethane wall and ceiling elements are manufactured using
a sandwich principle. An insulating polyurethane core is coated with food grade ABS plastic on one
side. PUR hard foam does not decompose, is rot resistant and is odorless. These properties make
it suitable for use as insulation. Because of its closed cell structure, water uptake by PUR hard
foam is for the most part only a problem at edges. Cut edges or other mechanically worked
surfaces must however be sealed with the greatest care. The conversion to a refrigerated vehicle is
performed as made-to-order production. The large surfaces of the wall and ceiling cladding can be
changed and are particularly easy to repair. If access to the back of a body panel section is needed
because of body straightening work, in some circumstances it is cheaper to perform a cut-out
repair instead of removing an element. The repair process is fully described in the Student
Information booklet Refrigeration System Technology, Transit 2000.5 Freshline.
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-25 Body Repairs - General
Information > Description and Operation > Impact of Insufficient Repair Quality

Body repairs usually require a significant level of intervention in the existing body shell structure.
The corrosion protection, seals and NVH components are destroyed and must be replaced. To
prevent the vehicle quality from being reduced due to an insufficient repair quality, all repairs
carried out in all repair sections must be inspected during and after the accident repair. Simply
checking the vehicle at the time of delivery is not sufficient to guarantee the repair quality. Rather,
continuous checking of the work carried out is recommended. In the process, the entire repair
sequence must be split into reasonable sections, with the creation of check points to which
particular attention must be paid. The following are some possible sections: Completion of the body
repairs After completion of the body repairs, the following areas should be checked: Completion of
the paint repairs The following points should be noted when checking the paint repairs: Final
assembly, ancillary components, functional tests After final assembly, not only a visual inspection is
required, but also the functionality of many components must be checked: Vehicle delivery Vehicle
delivery again offers the opportunity of checking the repair quality. In the process, the following
points are to be checked again: After repair work on the body and vehicle, not only the visual
restoration of the damaged vehicle, but also the functional restoration must be guaranteed.
Customers are making increasingly high demands of vehicles, particularly in terms of driving
comfort. Customers find noise, vibrations and harshness (NVH) as well as squeaking and rattling
annoying, particularly after repair work. It is therefore important that the condition of the vehicle at
the time of production be restored after an accident repair. After body repairs, the entire repair area
must be checked for any water leaks. It is crucial that a leak test be carried out as part of the final
inspection so that water leaks can be detected and eliminated even before delivery of the vehicle to
the customer. The requirements of the vehicle manufacturer are to be taken into consideration
during all inspections. Only in this way can it be guaranteed that the vehicle quality is not reduced
through insufficient repair quality.
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-25 Body Repairs - General
Information > Description and Operation > Water Leaks

Water leaks can occur after body repair work, but can also occur on new vehicles. The test
methods described below allow the various causes to be identified. In all cases, a systematic and
logical procedure is required to locate water leaks. General When searching for faults, it must be
taken into account that water can enter the vehicle passenger compartment in various ways and
under different conditions. Therefore, it is sometimes not sufficient to perform a water test on a
stationary vehicle. Before beginning extensive checks, a thorough visual inspection must be carried
out. The following points are to be taken into account in the process: Testers Water leaks and wind
noise can have similar causes. This means that test methods and testers can be used for both
types of problem. The alternative tests are as follows: Test method Water leaks in the vehicle
passenger compartment cannot usually be located at the first go, as the water frequently distributes
itself across larger areas. For this reason, the passenger compartment must be dried before the
leak tests. Any ancillary components that block the view must be removed. Water test During the
water test, the vehicle is sprayed with water at the suspected location of the leak. At the same time,
a second person checks the passenger compartment for places where water enters the vehicle.
Washer test Certain leak problems only appear in a car wash or can only be simulated there. The
concerned area of the passenger compartment should be inspected with a torch during the wash
procedure. Road Test Some leaks only appear when the vehicle is moving. If no leaks are detected
during the above-mentioned tests, road tests should be carried out on wet roads. Test with UV
lamp As already indicated in the water test section, a leak test can be executed with a UV lamp and
a special contrast agent. The advantages of using contrast agent are: Procedure for using a UV
lamp. Chalk/powder test In this test, the contact area of the seal is checked. To do this, the door
seal is coated with powder or brushed with chalk. A thin layer of grease is applied to the contact
area of the seal. The door must then be slowly closed and reopened. The width and continuity of
the imprint can now be checked on the door seal. Smoke test This test can be used to detect leaks
visually. The process is as follows: Stethoscope test This procedure is very similar to the smoke
test. Instead of the smoke pipe, move a stethoscope past the areas of the body that are at risk.
Leaks can now be detected acoustically. Ultrasonic detection With this test, a leak can be found
electronically. The procedure is as follows: Sequence Possible complaints and corrective actions
An outline of the possible complaints due to water leaks is provided below. The causes of water
leaks and the possible remedies are presented using selected examples. They are intended to
provide troubleshooting tips and suggestions for the user but do not represent an exhaustive faults
list. Glued windows A broken pasted seam can cause water to enter around the window. A broken
pasted seam can be located using a water test or by carefully blowing compressed air onto the
inside of the window seal. Corrective action Broken pasted seams -Arrow- can be sealed from
inside using PU adhesive. If this seal does not resolve the problem or the broken pasted seam is
too extensive, it is necessary to remove the window and glue it back into place. Door seals If water
appears at the bottom of the door, it is possible that the door seal behind the door trim is damaged.
If the door is intact, water can enter through the window weatherstrip and flow out through gaps on
the underside of the door. If the door seal adhesion is faulty or the door seal is damaged, water can
get into the interior. Fastening bolts could be loose or clips incorrectly positioned on door modules.
Corrective action Depending on the door seals used, different sealing methods can be used. Once
the adhesive surfaces have been cleaned, plastic films must be stuck with double-sided adhesive
tape or replaced. Leaky foam seals are sealed with Butyl tape or replaced. Plastic door modules
are fitted with a weatherstrip, which cannot be replaced. Seal the leaky point with Butyl tape or
replace the part. Door weatherstrip Leaks can be caused by badly fitted seals. In particular, areas
with radii -Arrow- must be thoroughly checked. Door seals can develop leaks due to: The contact
pressure of a seal can be determined using a strip of paper. If a strip of paper trapped in the closed
door can be pulled out easily, the contact pressure is too low. Corrective action Replace damaged
or aged seals. Prevent kinks. The contact pressure can be changed by adjusting the catch bolt or
correcting the panel flange. Realign uneven welding flange thicknesses. Properly repair any paint
damage that occurs. Rubber grommets / plugs Rubber grommets or plugs are fitted at numerous
points on the body. They are frequently used as seals for cables, hoses or actuating links. Rubber
plugs are frequently used for gaps caused during production. Leaks can be caused by badly fitted
or damaged rubber grommets and plugs. Damaged cable insulation can also cause leaks. Where
components are bolted on, water can enter if there are inadequate seals at the connection point.
Corrective action Correctly fit rubber grommets / plugs. During fitting, ensure that the sealing lips
are not trapped and are applied properly. The contact area of the rubber grommets / plugs can also
be sealed with PU sealing compound. Replaced damaged rubber grommets and repair damaged
cable insulation. Heater housing/ventilation Loose Butyl sealing strips, damaged sealing surfaces
or a trapped carpet can cause leaks around the heater housing / ventilation -Arrow-. Badly
positioned or badly fitted hoses can also be responsible for water entry. Water drains must not be
blocked. Corrective action Before the actual repair, make sure that the water drains are not blocked
or stuck. Remove the heater housing / ventilation and fit a new Butyl sealing strip. Damaged
sealing surfaces must first be adjusted. A trapped carpet must be removed. Seal welds PU seal
welds are applied to welded or riveted connections -Arrows- to seal the interior of the vehicle.
Incorrectly applied or damaged seal welds can allow moisture to penetrate into the interior of the
vehicle. It is also possible that seal welds that visually appear to be intact in terms of their shape
and size actually have poor adhesion. Corrective action Incomplete seal welds must be
supplemented with PU sealing compound. Damaged seal welds must be removed and re-applied
properly. Make sure that any residual moisture is effectively removed before a new seal is applied.
Attached parts The add-on parts include: Add-on body parts must be fitted with seals, grommets or
sealing compound to prevent water entry. However, even when a sealing system is fitted, the
screw thread may still cause leaks. Corrective action Seals must be tested and, if necessary,
replaced. Check contact surface and adjust if necessary. Points sealed with sealing compound
must be thoroughly cleaned and the seal replaced. Check grommets and replace if necessary. At
all screwed connections, seal the thread with an appropriate sealing material.
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-25 Body Repairs - General
Information > Description and Operation > Noise, Vibration and Harshness

Noises means noises caused by the vehicle that are audible both inside and outside the vehicle.
Vibrations are oscillations that are palpable and noticeable in the vehicle passenger compartment.
Harshness means noises caused by the vehicle that are audible, palpable and noticeable inside
the vehicle. These terms are grouped together under the label Noise, Vibration, Harshness, or NVH
in short. The task of vehicle development and production is to ensure that noises caused by the
vehicle do not disturb the driver and passengers. Moreover, the the external noises emitted by the
vehicle must not exceed the thresholds set by law. The following section gives an overview of how
noise, vibration and harshness can occur in the vehicle and what remedial action is possible. Noise
types and causes Noises in and around the vehicle are assigned specific descriptions: Low to
middle tones are considered to be unpleasant. They are palpable and noticeable as oscillations
and vibrations throughout the body. Loud howling and whistling is painful to the ears. Where the
different notes come from in a vehicle: A noise usually consists of a superimposition of different
tones which spread as oscillations. Each of these oscillations has a specific oscillating time and
can be measured in frequencies. The frequency describes the number of oscillations per second.
The frequency unit is specified in Hertz (Hz). The human ear can perceive frequencies between 20
and 20000 Hz. Noises can already be contained where they occur or, if this is not possible, can be
confined with suitable measures. The basic procedures are the damping of oscillating parts, the
insulation of components or the absorption of the noises through appropriate materials. Damping If
a damper is installed next to an oscillating mass, the characteristic of the damper will reduce the
movement of this mass accordingly (e.g. bumper on chassis). Damping affects the resonance of an
object or system. Isolation In oscillation technology, the term isolation means decoupling
(separation) of components and systems. An engine is mounted in sprung elements, so that as
little oscillation as possible is passed to the vehicle. In automotive technology, the isolation
technique used is nearly always rubber mounting. The elasticity of the rubber acts like a spring.
Absorption Sound waves are reflected from hard surfaces Through the use of absorption material,
sound waves hit soft surfaces and are absorbed by them. The composition and thickness of the
material used plays an important role here. A soft surface, depending on its composition, absorbs
the sound waves and reduces their energy. NVH elements NVH elements are installed to prevent
airborne sound transfers to the passenger compartment in different body cavities. On the Focus
2004.75 (07/2004-) these elements are located in the cavities of the A, B and C pillars. On the
estate version, they are also located in the D pillars. The NVH elements consist of a carrier plate
with a compressed isolation material at the edges. In the drying system of the painting equipment
used in production, the body is heated to approx. 170° C. At this temperature, the isolation material
expands, completely sealing the gap between the carrier plate and the bodywork. For the exact
installation position of an NVH element, please refer to the vehicle-specific repair instructions. If an
NVH element is to be reused, the bonding on the body panel must be detached. To do this, the
body panel must be heated in the area around the NVH element. The bonding can be detached at
approx. 170° C. The damaged panel part can now be carefully dismantled. Before installing the
new panel part, PU adhesive must be applied to the contact areas between the panel and the NVH
element. Test techniques, measuring devices The shortest route to an accurate diagnosis results
from: The diagnosis and correction of noise, vibration and harshness concerns requires: It is often
very difficult to locate noises that are audible in the passenger compartment based on the problem
description provided by the customer and the road tests performed. The direction of the noise can
be detected subjectively, but the source of the noise cannot be found. Stethoscope Using the
stethoscope, you can listen to the entire vehicle passenger compartment to locate noise sources
more easily. This test procedure can be carried out either while the vehicle is moving, or with the
engine running and the vehicle stationary, depending on the concern. The noise source can be
assumed to be where the stethoscope identifies the highest noise radiation. Application examples:
Ultrasonic measuring device The ultrasonic detector is a good and reliable test method for acoustic
problems. It is used in a similar way to the stethoscope. In principle, it is suitable for all high
frequency interior noises and for leaks in the body seals. The device consists of an ultrasonic
transmitter and a receiver. During use, the transmitter sends an ultrasonic signal which is received
at the problem zones by the receiver. Electronic NVH tester The measuring device described below
is used for diagnosis of the solid-borne sound and solid-borne sound transmission paths. The
device is particularly suitable for medium and high frequency noise analyses. In order to obtain a
positive diagnosis of droning problems (low frequency noises) and their sources, you must have
sufficient experience of how to use this measuring device. The device works according to the
following operating principle: Accelerometers (transmitters) are fitted on various vehicle
components or body areas. The signals recorded here can be listened to one after the other on
headphones or speakers via the different channels. Simultaneous illustration of several or all
measuring channels (for comparison) is only possible visually on the display of the measuring
device. Layout and operation:
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-25 Body Repairs - General
Information > Description and Operation > Wind Noise

Wind noise and noises in general are dealt with under the label Noise, Vibration, Harshness, or
NVH in short. Due to the continuous reduction in drive noises, wind noise has come to the fore in
the vehicle and is perceived to a greater extent by the customer. There are various causes of wind
noise. They can be due to the design of the vehicle, or they can occur after a repair. They are
mostly caused by poorly mounted components, which must be located and installed in the correct
position. Diagnosis In order to carry out targeted diagnosis, it is important to know the basics of
noise formation and sound transmission. Potential areas of wind noise Normal air flow noises are
caused by air blowing against even, flat vehicle surfaces, such as the roof, doors and side
windows. When the vehicle is moving fast, air films (turbulence) form, which cause variations in air
pressure. These variations in air pressure spread in the form of sound waves and are transferred to
the vehicle interior via the side windows and seals. If air flows over an edge on a vehicle, the air
flow cannot follow the shape of the surface, but separates at the edge. Eddies are formed, which
collapse again after a certain time or distance. The associated variations in air pressure create a
corresponding sound wave. Streaming noise occurs if there are leaks in the sealing system to the
vehicle passenger compartment. The noise is caused when stationary air mixes with moving air. As
a result, the noise increases as the streaming speed increases. Cavity noises are noises that occur
when the air column is caused to oscillate. Workshop diagnosis Before carrying out repair work, a
visual inspection of the vehicle must be carried out. The gaps in the doors, the sunroof and at all
other body parts must be checked in particular. When the doors are adjusted to fit exactly,
development of wind noise can often be eliminated at high speeds (lifting of doors off the seals).
The following points are also to be checked: Road tests Wind noise can usually only be located
through road tests. The following points should be taken into account for such test drives: If it is
difficult to detect the noise sources, the search can be made easier by masking potential areas.
Sequence A basic prerequisite for a problem description with subsequent diagnosis is the
performance of a test drive with the customer.. Only once the customer's problem description is
clear should the service technician begin with the diagnosis of the problem. The service technician
should carry out specific road tests to achieve further containment of the problem. Sequence
(schematic): 1. Customer concern 2a. Diagnosis and corrective measures Sequence A: The
diagnosis is possible based on the information supplied by the customer. 2b. Diagnosis and
corrective measures Sequence B: The diagnosis is not possible based on the information supplied
by the customer. The vehicle acoustics do not always make it possible to draw up a clear
diagnosis. It is therefore all the more necessary to use all methods of detecting and suppressing
NVH problems. 3. Comparison of vehicles constructed in the same way. If no clear diagnosis is
possible based on a customer concern, a comparison test drive should be carried out on a vehicle
constructed in the same way. Test equipment Diagnosis of wind noise requires good hearing, basic
knowledge of acoustics and experience. Tools can provide assistance for the diagnosis and reduce
the fault finding times. Stethoscope Here, the tightness of the vehicle passenger compartment is
checked. The ventilator blower is set to the highest setting and the doors and windows are closed.
There is now a corresponding overpressure in the passenger compartment. The stethoscope is
now used to listen to the door and window seals. The sound of the streaming air can be heard at
the leaks. Smoke pipe The preparatory work is the same as for the stethoscope test. By scanning
past the seal areas with the smoke pipe, a leak can be visually detected based on the changed
smoke path. Ultrasonic detector The ultrasonic detector is a further method of finding leaks in the
vehicle passenger compartment. Here, an ultrasonic noise generator is placed in the passenger
compartment. The closed vehicle is then inspected from outside with the corresponding detector.
The detector will show any leaks present. Powder Door seals that do not make close contact can
be detected by coating the contact surface of the door seal with white powder. To do this, the door
is carefully closed and re-opened. In this way, the door seals which do not touch will be visible.
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-26 Body Repairs - Vehicle
Specific Information and Tolerance Checks > Specifications
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-26 Body Repairs - Vehicle
Specific Information and Tolerance Checks > Description and Operation > Body and Frame

Introduction With the Transit, Ford has developed a completely new bodywork concept in the
commercial vehicle sector. Taking into account all active and passive safety components, current
materials or material combinations have been integrated into the overall bodyshell design. The
combination of various jointing techniques within the overall bodyshell design makes rationalized
repair techniques possible in the service area. Technology and economy have been intentionally
balanced, resulting in development of a basic overall platform with the Transit that points the way
ahead for current Ford technology. Design features, Transit 2000.5 (01/2000-05/2006) and Transit
2006.5 (04/2006-) The Transit 2000.5 (01/2000-05/2006) will be replaced by the Transit 2006.5
(04/2006-). The bodywork of the two vehicles are identical apart from the front end. Important
structural components, particularly at the front end of the vehicle, such as the side member, cross
member and hood lock panel have been redeveloped or redesigned. Front cross member and side
member, Transit 2000.5 (01/2000-05/2006) From chassis no. 4412103 to 4515866 (manufactured
between 15.01.2000 and 15.05.2003), the front cross member is made of plastic. From chassis no.
4515867 (manufactured after 15.05.2003), the front cross member is made of sheet steel. The
cross member is attached to the front ends of the side members using screwed connections. The
integral deformation element in the cross member (crash element) absorbs a large proportion of
the forces arising from a collision. The subsequent deformation process is pre-determined by 3
designated yield points in the front side members. It is only possible to partially replace the side
members (see subsection 501-27). Front cross member and side member, Transit 2006.5
(04/2006-) The front cross member is made of sheet steel. It is attached to the front ends of the
side members using screwed connections, as on the Transit 2000.5 (01/2000-05/2006). There is
only one integral designated yield point on the outside and inside of the front side members. It is
only possible to partially replace the side members (see subsection 501-27). Hood lock panel,
Transit 2000.5 (01/2000-05/2006) The hood lock panel is made of a single piece of plastic and is
attached to the bodywork using screwed connections. The screwed connections allow the hood
lock panel to be aligned with the bodywork. Minor damage (cracks) can be eliminated with a
corresponding GFK repair material. Hood lock panel, Transit 2006.5 (04/2006-) The hood lock
panel is a three-part design and is made of sheet steel. In the event of damage, this modular
construction allows individual segments to be replaced. The segments are attached using screwed
connections. The screwed connections allow the individual segments of the hood lock panel to be
aligned with the bodywork. Important information for use during accident repair There follows some
important information which is helpful during accident repair work. front fender The fenders are
attached to the bodywork using screwed connections. The exterior mirror must be removed before
the fender can be removed. Fender attachment points Wiring harness and hose routing During
work on the bodywork, such as cutting, grinding or welding, the installation location of the wiring
harness and hoses must be taken into account due to the risk of damage. NVH measures Various
NVH components are installed in the A, B and C pillars in order to reduce noise. This reduces the
size of the resonance space which the actual cavities present. This has been made possible by the
development of new sound deadening technologies and the use of hybrid materials. During
servicing, the original insulating elements must be replaced with equivalent insulating elements.
The applicable replacement solutions are specified in the repair descriptions. Side panel seam seal
The seam seal for the side panels is applied after painting. This has the advantage that the sealant
retains its flexibility and later sealing work is possible without extra painting work. Corrosion
prevention measures All body parts that are liable to corrosion are zinc plated. It is therefore vitally
important that the corrosion protection measures are carried out with the greatest care during
bodywork repairs. Galvanised steel panels Galvanized and high strength steel panels Sheet metal
parts for partial panel replacement repairs The following illustrations represent he current sheet
metal parts available for partial panel replacement on all Transit model variants.
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-26 Body Repairs - Vehicle
Specific Information and Tolerance Checks > Description and Operation > General Procedures > Underbody Tolerance
Check
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-26 Body Repairs - Vehicle
Specific Information and Tolerance Checks > Description and Operation > General Procedures > Body Tolerance Check

Measuring points and dimensions Measuring points and dimensions Measuring points and
dimensions Measuring points and dimensions Measuring points and dimensions Measuring points
and dimensions Clearances and tolerances Clearances and tolerances
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-27 Front End Sheet Metal
Repairs > Removal and Installation > Fender Apron Panel Reinforcement

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-27 Front End Sheet Metal
Repairs > Removal and Installation > Fender Apron Panel

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-27 Front End Sheet Metal
Repairs > Removal and Installation > Fender Apron Panel Inner Reinforcement

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-27 Front End Sheet Metal
Repairs > Removal and Installation > Front Side Member Section

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-27 Front End Sheet Metal
Repairs > Removal and Installation > Front Side Member and Fender Apron Panel LH

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-29 Side Panel Sheet Metal
Repairs > Specifications
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-29 Side Panel Sheet Metal
Repairs > Removal and Installation > A-Pillar Outer Panel Section and Reinforcement

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-29 Side Panel Sheet Metal
Repairs > Removal and Installation > Sliding Door Step Outer Panel

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-29 Side Panel Sheet Metal
Repairs > Removal and Installation > Front Door Step

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-29 Side Panel Sheet Metal
Repairs > Removal and Installation > Side Panel Lower Section

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-29 Side Panel Sheet Metal
Repairs > Removal and Installation > Side Panel

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-30 Rear End Sheet Metal
Repairs > Specifications
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-30 Rear End Sheet Metal
Repairs > Removal and Installation > Quarter-Side Panel Rear Section LH

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-30 Rear End Sheet Metal
Repairs > Removal and Installation > Lower Quarter Panel Section

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-30 Rear End Sheet Metal
Repairs > Removal and Installation > Lower Side Panel Rear Section

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-30 Rear End Sheet Metal
Repairs > Removal and Installation > Rear Outer Wheelhouse Half

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-30 Rear End Sheet Metal
Repairs > Removal and Installation > Rear Inner Wheelhouse Half

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-30 Rear End Sheet Metal
Repairs > Removal and Installation > Box Corner Section

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-30 Rear End Sheet Metal
Repairs > Removal and Installation > Box Corner

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-30 Rear End Sheet Metal
Repairs > Removal and Installation > Back Panel and Crossmember

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 501 Body and Paint > 501-30 Rear End Sheet Metal
Repairs > Removal and Installation > Rear Side Member Section

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 502 Frame and Mounting > 502-00 Uni-Body,
Subframe and Mounting System > Specifications
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 502 Frame and Mounting > 502-00 Uni-Body,
Subframe and Mounting System > General Procedures > Body Misalignment Check
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 502 Frame and Mounting > 502-00 Uni-Body,
Subframe and Mounting System > General Procedures > Frame Inspection
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 502 Frame and Mounting > 502-00 Uni-Body,
Subframe and Mounting System > General Procedures > Underbody Misalignment Check
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 502 Frame and Mounting > 502-00 Uni-Body,
Subframe and Mounting System > General Procedures > Removal and Installation > Engine Crossmember - Vehicles With:
5-Speed Manual Transmission (MT-75)

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 502 Frame and Mounting > 502-00 Uni-Body,
Subframe and Mounting System > General Procedures > Removal and Installation > Engine Crossmember - Vehicles With:
6-Speed Manual Transmission (MT82)

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Mechanical Repairs > 5 Body and Paint > 502 Frame and Mounting > 502-00 Uni-Body,
Subframe and Mounting System > General Procedures > Removal and Installation > Front Axle Crossmember

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Body and Paint > 5 Body and Paint > 501 Body and Paint > 501-25 Body Repairs - General
Information > Specifications
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Body and Paint > 5 Body and Paint > 501 Body and Paint > 501-25 Body Repairs - General
Information > Description and Operation > Description and Usage of Body Repair Literature
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Body and Paint > 5 Body and Paint > 501 Body and Paint > 501-25 Body Repairs - General
Information > Description and Operation > Health and Safety Precautions

General 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 body repairs. Personal protection Welding gases
and grinding dusts can be harmful to the health. For this reason, make sure that rooms are well
ventilated and work using the welding fumes extraction system. Sealants, underbody protection
and paint residues must not be burnt down with an unshielded flame, as this will produce gases
which are damaging to health. A dedicated extraction system must always be used when welding
or brazing. When working with substances containing solvents, good ventilation must be provided,
respiratory protection must be worn and an extraction system must be used. Do not weld in damp
areas, if necessary use an insulation mat. Welding and grinding work near the battery presents the
danger of explosion. For this reason, it must be removed before the work is started. Cutting,
grinding and alignment work on metal panels can cause a noise level of 85 to 90 dB (A) or even
more. For this reason, you must always wear ear defenders. 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. Some special instructions must be followed when
working on airbag systems: Protection of the vehicle Protect affected areas from weld spatter and
dust during all welding and grinding work on the vehicle. If metallic dust stays on the vehicle for
some time, there is the likelihood of film rust formation. Grinding or sanding work produce tiny
spots of damage to the paint surface, which may cause corrosion. For this reason, make sure to:
Use suitable protective measures to protect the interior when performing repair operations which
relate to the inside of the vehicle. Carbon fibre blankets are used directly around the working area.
They offer maximum protection to the areas of the vehicle. In addition, take into account: Protective
equipment The following protective equipment must always be used: Electronic components
Increased use of comfort and safety electronics in modern motor vehicles also requires the
greatest attention to be paid during body work. Overvoltages produced during welding and in
alignment work during bodyshell rectification may cause electronic systems to be damaged. In
particular, the safety instructions for performing welding work on vehicles with airbag systems must
be adhered to. Pay attention to the following points:
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Body and Paint > 5 Body and Paint > 501 Body and Paint > 501-25 Body Repairs - General
Information > Description and Operation > Symbols

Various symbols, signs, instructions and illustrations are used in this literature. Warnings and
cautions have different meanings and require different ways of proceeding. Diagrammatic
representations are provided with instructional signs for improved clarity. When reading this
handbook, you will come across the points WARNING, CAUTION AND NOTE. These points are
always immediately before a single job step or a series of job steps. These are briefly explained
below: Item numbers Item numbers are inserted into a diagram when details need to be
emphasized. Item numbers with one indicator line An item number and an indicator line point to a
special location or a component. In this diagram a component and a row of spot welds are
indicated. Item numbers with two indicator lines If two indicator lines lead away from one item
number, then an area is being referred to. In this case the area with the spot welds to be separated
is shown. Black arrows If the illustration of a detail is unambiguous, or there is only one detail
shown, then no item number is used. A black arrow is used for this. Broken arrows Broken arrows
represent movement. In this case the component must be removed in the direction given.
Enlargement/detail If a detail cannot be clearly seen in the illustration because of its size or
location, it is shown enlarged in a separate window. In this case a detail on the back of the B-pillar
cannot be seen, and is therefore shown separately. Different colors or shading Different colors or
shading are used to depict special areas. In an assembly operation, the colors show the sequence
of removal steps. In the repair specifications, the first component or the first partial replacement
component is always shown in magenta. The second component in an illustration is shown in
turquoise and a third component is shown in dark green. Spot welds, weld seams and cut lines are
shown in black. This principle also applies to line drawings. In these, illustrations under the same
topic will always show the same colors for the same components.
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Body and Paint > 5 Body and Paint > 501 Body and Paint > 501-25 Body Repairs - General
Information > Description and Operation > Environmental Regulations

Orderly and responsible waste management is not only very important for the protection of health
and the environment, but it also has great importance where saving natural resources is
concerned. In body repair shops, since the introduction of the EU directives on the avoidance of
vehicle waste and the promotion of return, re-use and recycling of vehicles and their components
(2000/53/EU), more rigorous attention than before is also paid to avoidance and recycling of waste
materials. In this respect, body repair shops must take into account and comply with the following
requirements: The avoidance and recycling of waste must always take priority. However, despite all
measures which may be taken, waste cannot be completely avoided. All remaining waste must be
treated as commercial waste and disposed of according to the local requirements.
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Body and Paint > 5 Body and Paint > 501 Body and Paint > 501-25 Body Repairs - General
Information > Description and Operation > Body Construction

General Two design principles have prevailed in body design. The body design can either be an
integral body-frame or a frame with all attached superstructures. Mixed versions are also possible,
with the design significantly increasing the stability of the frame. In all versions, the passenger cell
must be preserved in the event of an accident. To this end, the front and rear ends are designed so
that they absorb the energy of the impact via crumple zones. The use of modern design and
manufacturing methods, and the use of body panels whose reshaping and strength properties have
been finely balanced, mean that despite the reduced weight, all safety-related aspects and
requirements can be met. Integral body-frame In the car market, the integral safety body-frame is
the result of this technological development and manufacturing technology. The integral
body-frame is completed with ancillary components, such as doors, hood, bumpers and other
components. The advantages of this are: The safety of the driver and passengers is paramount for
every body design. There are two key safety aspects in the body: The safety body cell is
characterized by the following design features: Deformation behavior Different materials and
design features lead to staged deformation of the front and rear of the vehicle in an accident. The
passenger cell remains undamaged, and the driver and passengers are not shut in. The bolted
crash element is made of high-strength steel. Built-in pre-determined folding points prevent
damage to the cross member during gentle impacts. The use of bolts means that this can be
quickly and cheaply replaced. Side members can be manufactured from panels of different
thicknesses. These are joined together through laser welding. These panels are called tailored
blanks. The rear of the vehicle, like the front of the vehicle, has structures which protect the
passenger cell through staged deformation in the event of an accident. The design layouts,
however, are adapted to the requirements of the rear area. MPVs The body of an MPV has largely
the same design layout as a passenger car body. However, due to the different requirements of an
MPV, the floor pan in particular had to be designed in a more stable manner. It is therefore
produced as a frame construction with particularly high torsional rigidity and flexural strength. If
repair is required, the process is similar to the process for a passenger car body. Convertible The
body of a convertible differs from the principle of the integral body-frame of a saloon due to the lack
of a roof construction. To guarantee the high safety requirements, particular design changes are
required within the floor pan structure. These are: Frame structures Frame structures are used for
off-road vehicles and light commercial vehicles. With these structures, a distinction is made
between a separate frame structure, as on an off-road vehicle, and the composite structure of a
light commercial vehicle. The entire body structure of the commercial vehicle body differs
fundamentally from that of the saloon car. The requirements of such a body cannot be compared
with a passenger car body. The payload is paramount here. Accordingly, the stability requirements
must also be taken into account in the body design. These are: Off-road vehicles The body designs
of off-road vehicles are not subject to the principle of the integral body-frame. Their basic
construction corresponds to a chassis frame with an attached body. This stable chassis structure
has significant advantages for off-road vehicles: If repairs are to be carried out, a different repair
technique is required for this body and frame structure. A deformed frame structure requires high
suction power during straightening repairs. Frequently, the body also has to be detached from the
frame structure in order to carry out separate repair. Due to the very stable frame structure, please
note that the straightening behavior is completely different to that of a passenger vehicle. The
frame and the attached body must be repaired independently of each other.
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Body and Paint > 5 Body and Paint > 501 Body and Paint > 501-25 Body Repairs - General
Information > Description and Operation > Body Sheet Metal

Types of steel 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 ultra-high-strength special steels are used in vehicle body construction. Types of steels are
classified by their properties of strength and elasticity. High-strength and ultra-high-strength steels
are mostly installed in safety relevant locations (structural components). Among others, these are
side members, pillars, roof frames. Example of the use of high-strength steel Normal strength
steels Normal strength steels are most often used in body construction. They are relatively soft and
are therefore particularly suitable for the deep drawing processes used in body manufacturing. As
well as very good reshaping properties, the panels also have a relatively high rigidity. High strength
steel panels The strength of the material and the nature of the surface can be changed as required
by different engineering processes. In order to achieve suitable configuration and a good match
between construction specifications and what is possible in production, a large range of high
strength panels is available. The range of the minimum yield strength is from 180 N/mm2 to 460
N/mm2. High strength thin steel panels usually have a surface finish. Electrolytic surface sealing is
preferred. Within the group of high strength steels, various types of steel are used in body
construction: Ultra-high-strength steels These steels are predominately used for body structural
components which are relevant to safety. Despite the reduced thicknesses of the panels used,
weight reduction is often achieved together with greater strength. As with high-strength steels,
special types of steel are used in the ultra-high-strength steels group: Because of the use of such
steels, some special points must be taken into account during body repair: The basic working
methods and the tools to be used are the same however. Coated steel panels In a similar way to
high-strength steel panels, coated steel panels are finding more applications because of the better
corrosion protection which they offer. There are basically two different process which are used to
apply a zinc layer: The following points must be noted when welding: Tailored blanks Tailored
blanks are panels which are made up of at least two separate panels with different material
thicknesses and/or material properties. The panels are joined together by a laser weld seam and
then shaped in a press. This technique allows panel shapes to be produced which meet special
requirements with regard to deformation behavior, strength and weight. Laser weld seams at the
sidemember Typical examples of application are: When repairing the vehicle body, pay special
attention that such a connection is never separated. The possible cut line locations are given in the
respective repair manuals. Aluminum Aluminum is becoming ever more important in body
construction because of the trend to reduce weight. Doors, hoods and body outer panels are
increasingly being made of aluminum alloy panels. Although at the time of publication of this
document, Ford of Europe has not yet introduced any aluminum body or aluminum body
components, this topic is briefly described in this section. All the tools needed for body repair must
be suitable for working aluminum, and they must be only used on aluminum. The main properties
of aluminum are: In the electrochemical potential series, aluminum has a negative potential of
1.23V in relation to steel. Because of this, when aluminum and steel touch and an electrolyte is
present, contact corrosion occurs. The following points should therefore be noted: In the main,
aluminum panels can be worked using the same processes as used for steel panels. There are
however some special features to pay attention to: In contrast to steel, aluminum does not display
any surface color change when heated. This therefore means that the level of heating of the
material cannot be seen. Only once the material is overheated does a change in the material
structure of the surface occur. By the time this has occurred, the structure of the material is already
seriously damaged, and its strength very much reduced. Overheated aluminum components must
always be replaced. Aluminum welding Aluminum welding requires a welder which is specially
designed to meet these requirements. Both repair welding processes are based on fusion welding.
Success of aluminum welding partly depends on how well the surface oxidation can be removed.
Because aluminum oxide remains solid at the melting point of pure aluminum, it is important to
remove it before welding. The aluminum surface must be cleaned before welding. Cleaning
improves the later fusion penetration and prevents contamination of the welding wire. The following
three steps are to be performed in preparation: Aluminum oxide forms very quickly, therefore steps
2 and 3 should be performed immediately before welding. Before working on the vehicle body,
create a test seam on scrap which is made of identical material. Test the test piece visually and
destructively, to make certain that all welding parameters are correctly set, and an acceptable weld
seam can be achieved. An optimum weld can be recognized by the following quality features:
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Body and Paint > 5 Body and Paint > 501 Body and Paint > 501-25 Body Repairs - General
Information > Description and Operation > Diagnosis and Damage Evaluation

In order to correctly determine the extent of the damage caused by an accident, in-depth technical
knowledge, practical experience with the technical equipment and the testing and measuring
devices is required. Assessment of the extent of the damage includes visual inspection and
dimensional inspection of the vehicle. If damage to the chassis geometry is visible even during the
visual inspection, the vehicle is to be inspected on an axle alignment jig. Visual recording of the
damage From a profitability perspective, the possibility of a sectional replacement must be taken
into consideration when assessing the damage to a vehicle damaged in an accident. Positive
accidental damage assessment can only be achieved if the service technician is able to reconstruct
the effect of an impact on the body structure. For example: If the impact occurs on the front
left-hand side member, the right-hand side member will usually also have been damaged. Often
the length of this side member will not have changed, but because of the rigid body design, it may
have become deformed. This damage can be detected through the size of the gap between the
door and fender or by measuring the vehicle. In the case of more severe impacts, in which the front
part of the vehicle cannot absorb all of the impact energy, the passenger cell is also used to absorb
the energy. Here, the energy is transferred via the A pillar and distributed there. This results in
deformations in the roof and the door sill. It is possible to draw conclusions about the extent of the
damage through a visual inspection of the external damage. In general, the following areas are to
be checked during the visual inspection: Hidden damage In addition to external indicators, such as
flaked off paint or cracks in the underbody protection, it is vital to check for deformations that are
not visible from the outside (hidden body damage) during a damage assessment. Unless ancillary
components are removed, it is often impossible to achieve accurate diagnosis of the underlying
body parts. Particular attention must be paid to the following components: Light commercial
vehicles and off-road vehicles The basic body design of light commercial vehicles and off-road
vehicles corresponds to a chassis frame with an attached body. Therefore, both vehicle
components, the frame and the body, must be checked thoroughly during damage assessment. As
with all vehicles, it is important to inspect the impact area and the shock absorbing areas closely for
damage. With these vehicles too, simple inspections can also reveal indicators of possible
deformations. In addition, you must check for the following for vehicles with frame structures:
Convertible-specific crash characteristics Due to the convertible design, the deformation paths
arising during an impact are larger than the actual permanent deformations. In the case of severe
impacts to the front or rear end, deformations may even extensively deform the passenger cell with
no recognizable permanent damage. This is referred to as a large compression characteristic.
Adjacent mechanical components may nevertheless be damaged owing to these deformations.
The following should particularly be inspected:
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Body and Paint > 5 Body and Paint > 501 Body and Paint > 501-25 Body Repairs - General
Information > Description and Operation > Tools and Equipment for Body Repairs

Alignment systems Straightening and alignment repairs are often required to restore a vehicle body
to its original shape after accident damage. Universal aligning and measuring systems and
universal alignment angle systems are suitable for this work. Basically, the aligning and measuring
system must satisfy the following requirements: Alignment angle devices survey the vehicle at
several points on the body. These are usually points which are also used in production. In addition,
a recording over the rocker panels is possible. A measuring system is not needed, because the
necessary body points are specified with gauges. For this purpose, vehicle specific or universal
gauges are available. Universal alignment systems consist of a vehicle mounting (universal clamps
at the rocker panels) and a pulling device. In addition, a measuring system is required. Pay
attention to the following points: Measuring systems In order to exactly diagnose a damaged
vehicle body, measuring systems are required. Depending on the measuring method, the systems
vary in having mechanical, optical and acoustic measuring devices. In some cases, hybrid versions
of particular systems are found. Basically, the measuring systems must meet the following
requirements: Beam compass The beam compass is a very practical and straightforward aid for
measuring bodywork and especially floor assemblies. The beam compass can be used to detect
dimensional variations across the length and the width by means of comparison measurements
and diagonal measurements. As a basic principal, body reference points should be chosen which
are shown in the body frame measurement data sheet. Comparison measurements can also be
made on the outside of the body. Depending on the damage, left/right measurements (symmetry
measurements) and diagonal measurements can be made using the beam compass, telescopic
rod or a measuring tape. Laser measuring systems These systems use laser beams which are
projected in one or more planes. By the use of two parallel laser heads which can be turned,
symmetrical points of a vehicle body can be tested and compared. Using the linear scales which
are attached to the measuring points, the measurement data is read off with the aid of the
projected laser beams. The integral inclination gauge also allows differences in height to be quickly
checked. Mechanical measuring system The use of mechanical measuring equipment is an easy
and effective way to check a vehicle frame and chassis assembly quickly, exactly and reliably. In
many cases an assessment of the damage can be made with the help of this system, without the
need for elaborate setting up. Because of its self-centering mount, measurement can be carried out
by one person. Further advantages: Measuring systems which are firmly mounted on an aligning
platform require more work in setting them up. They are used to constantly check measurements
during alignment work. This type of mechanical measuring system has measuring scales and
measuring slides in three measuring axes. So that the body can be measured, the vehicle is
secured on the aligning platform base frame using four universal chassis clamps. The exact fixing
points are given in each respective data sheet. Acoustic-electronic measuring systems These
measuring systems can be combined with all current aligning platforms. In addition these
measuring systems can be used independently of an aligning platform by using a vehicle lift or
suitable support stands. Acoustic measuring systems use ultrasonic emitters and sensors to survey
a body. To do this, ultrasonic emitters are mounted on the vehicle using special attachments.
During the measuring process the ultrasonic emitters constantly send out signals which are
received by sensors (microphones) and then passed to a computer. The measurements are
displayed on the computer screen and are compared with the required values supplied by the
vehicle manufacturer. Mechanical-electronic measuring system The ways in which
mechanical-electronic measuring systems can be used are similar to those of the acoustic
measuring systems. They can also be set up on a suitable understructure, without an alignment jig.
After this system has been arranged under the vehicle floor and adjusted to three undamaged
vehicle measuring points, the measuring arm is brought up to the required measuring points and
the readings compared with the reference values. The data is transmitted to a computer where it is
evaluated and the results displayed on a screen. Panel beating tools Depending on the type and
extent of the damage to the vehicle body, very different tools may be needed to repair it. The most
usual tools and the way they are used are described below. Aluminum hammer The aluminum
hammer is the most important and most commonly used tool during body panel repair. The most
usual areas of application are: Tapered hammer The tapered hammer is chiefly used to rectify
small high-spots. Universal hand dolly Because of its versatile shape, the universal hand dolly can
be used as a counterhold in almost all areas of the vehicle body. It is particularly suitable for use as
a counterhold when rectifying material excess. Because of its weight, the universal hand dolly can
also be used as a hammer to straighten a dent from inside without counterhold (hollow leveling).
Box file The box file is mainly used as counterhold in fine straightening work with the aluminum
hammer. It is available in various shapes and sizes. The corrugated surface (file-cut) prevents the
panel from stretching during fine straightening work (barb effect). Using the file-cut imprint on the
panel surface, the effect and extent of the blows from the panel beating hammer can be judged.
Pulling lever and spoon If access to the rear of the damage with the panel beating hammer is not
possible, a panel beating lever can be employed. Once the worst of the damage is rectified, work
continues with the spoon. This also allows short striking movements to be made in inaccessible
areas. A spoon is often used as a counterhold in work with the panel beating hammer. Caulkers A
caulker is mostly used in edge areas. In this case the caulker is inserted on the inside of the
damaged area. Selected blows on the shaft of the tool allow the damaged edge area to be
reworked. Caulkers can however also be used for straightening small areas which can only be
reached from the back through small openings. Body plane The body plane consists of the
two-faced plane blade and the solid plane body, which prevents pressure deformation of the plane
blade. The body plane is available in half-round and flat versions. The main application areas are:
Body file The body file is used solely during heat treatment working of dents. Because of the solid
body of the file, it can absorb much heat. It stabilizes repair areas which are being straightened by
warming. It does this by rapid removal of heat from the repair area, which has the effect of
stabilizing the body panel. Body files are graded by the size of their teeth (file-cut): Gas torch The
main area of use of the gas torch is heat working of small and mild dents. It is also suitable for soft
soldering work on body panels. The ready-to-use gas torch consists of the following parts:
Compare with oxy-acetylene equipment, the gas burner has the advantage of easier handling due
to its lower weight and shorter set-up times because of the quick-change burner heads. Soft
soldering equipment Despite good panel beating technique, it is not always possible to rectify all
unevenness. For that reason, application of filling solder is an important part of surface treatment.
Similarly the surface of weld seams created during partial repairs can be optimized. A complete
soft soldering kit consists of tinning paste, soft solder and brush. In addition, a set of wooden
paddles with a variety of shapes and a lint free cloth rag are needed. Shape gauge The shape
gauge is used to check the contours of the area to be reshaped, when there is no other way of
recognizing and checking the basic shape. There are various designs of shape gauge. The short
design made of steel is used for smaller repair areas. Because its segments are very thin, it allows
a very exact fit at a contour. The longer design made of plastic is applied to larger areas. Because
of its wider segments, it is better suited to large surface contours. External dent remover/puller
Because of their multi-purpose nature, external dent removers and pullers are very useful in
achieving an economical repair to a vehicle body outer skin. These repair methods are used on
vehicle body components which are inaccessible from the inside. Small dents such as those
caused during parking and larger areas of damage such as on the side panel, rocker panel etc. can
be rectified. Basically there are three different methods: Welding gear As in the past, the dominant
process in body construction is resistance welding, in particular spot welding. Depending on body
type, up to 5000 spot welds are applied, either by welding robots or in the multi-point welding
machine. During repairs the resistance spot welds used in production must be re-created
accordingly. Although in principle high-strength panels are adequately- or well-suited to resistance
spot welding, problems may arise, especially where large panel thicknesses or three layers of
panel need to be welded together in the workshop, but these problems can be overcome. In
particular, older welding equipment does not have the latest welding technology nor welding power
and therefore cannot reliably join panel thicknesses greater than 3 mm. Modern equipment with
inverter technology allows better spot weld quality because of a constant high welding current. In
addition the high welding current makes shorter welding times possible and the electrodes
therefore have a longer working life. In the case of resistance spot welded connections, faults in the
weld are difficult to see from the outside. It is therefore absolutely vital to know the particular
properties of the welding machine being used. A test weld with subsequent peeling test will provide
information on the quality of the weld. The spot weld itself must not separate, it must tear away
leaving a hole. In the production of vehicle bodies, MIG welding plays a minor role as a joining
technique. It is used for components subject to high demands, such as threaded plates for axle
mountings, or at locations which cannot be spot welded for access reasons. Separating tools A
variety of tools are available to the body specialist for the separation of body components. The use
of the different tools depends on the joining technique involved and the access available to the
repair location. Spot weld milling tool The spot weld milling tool is suitable for releasing spot welded
connections. In contrast to a normal drill, the milling depth can be set. This prevents the underlying
panel from being damaged. In addition a safety fixing system prevents the milling cutter from
slipping while working. Rod sander Spot welds which are not accessible to the spot weld milling
tool can be ground out using the rod sander. It is also suitable for releasing MIG spot welds and
MIG seam welds. Short stroke saw The short stroke saw is most often used to separate vehicle
body components. It is also very flexible in its ability to access hard-to-reach areas. Orbital saw
Among other things the orbital saw is suitable for the creation of narrow and straight cuts. In
addition the cut can be made to an exact depth limit. This prevents damage to underlying
components. After any work with swarf producing machines, all swarf must always be removed
from cavities, otherwise there is the danger of corrosion.
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Body and Paint > 5 Body and Paint > 501 Body and Paint > 501-25 Body Repairs - General
Information > Description and Operation > Establish Repair Method

General Before starting an accident repair, a sequence plan must be compiled, containing an
outline of the individual job steps. Similarly, the availability and preparation of all the necessary
materials, spare parts, tools, workshop equipment such as alignment and measuring systems must
also be checked. Planning During planning the following job steps must be observed and adhered
to: After the scope of the work has been determined, before making the repair, check all own
technical prerequisites: Chronological sequence of repair The actual sequence of repair can be
divided into the following steps: Job steps:
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Body and Paint > 5 Body and Paint > 501 Body and Paint > 501-25 Body Repairs - General
Information > Description and Operation > Alignment Check

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 model-specific 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. Measuring data example For exact
determination of the measuring points, enlarged sections are shown.
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Body and Paint > 5 Body and Paint > 501 Body and Paint > 501-25 Body Repairs - General
Information > Description and Operation > Straightening

General Straightening repairs are often required to restore the original body shape. For damaged
bodies, straightening is to be considered as the process of pulling out the deformed body parts up
to cutting out the parts that need replacing. As soon as straightening work is carried out on body
parts, this is referred to as repair work. Straightening with pulling equipment In order to restore the
damaged body to its original shape, the deformed part must remain on the body during the
straightening repairs. While the deformed parts remain on the body, the pulling equipment can be
attached anywhere. Only in this way can damaged parts of the body which have to be straightened
be pulled into the original position without problems. Straightening sequence Body straightening
requires practice and experience. Before starting, the exact direction of impact must be
determined. The straightening force must have the exact opposite direction of the impact force.
Only in this way can it be guaranteed that the original shape will be achieved again. The pulling
forces only work with their full impact if the pulling direction is direct. Using the wrong pulling
direction could lead to additional deformation, which is difficult to correct afterwards. Please note
the following points: During individual straightening steps (under a pulling load), relieve tension by
striking the deformed areas with an aluminum hammer while they are still under tension. Off-road
vehicles Straightening repairs on off-road vehicles are different to repairs on normal bodies due to
the two-part construction of the vehicle. This means there are two areas that must be taken into
consideration separately: Straightening the body If only the body is damaged in an accident, light
straightening repairs can be carried out. If a straightening jig is used for straightening work, the
holding clamps or alignment angles must be attached directly to the chassis frame. During the
straightening work, the pulling forces must not become too high. The bolted connections are to be
monitored continuously. Straightening the body and chassis frame If the body and chassis frame
have to be straightened, they must first be separated from each other. The following conditions
must be met:
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Body and Paint > 5 Body and Paint > 501 Body and Paint > 501-25 Body Repairs - General
Information > Description and Operation > Complete Panel Replacement-Partial Replacement

Repairs always mean intervention in the body shell structure and thus also intervention in the
vehicle's passive security system. The use of complete replacement or sectional replacement as
the best solution must always be weighed up before starting a repair. Complete replacement In a
complete replacement, the original connections are largely reused. A complete replacement is
advantageous if the damaged body part can be detached from its original connections and a
completely new part can be fitted without creating additional joints (e.g. liftgate). A complete
replacement is necessary if there is no sectional replacement solution. Sectional replacement
Sectional replacement (sectional repair) means the replacement of a section of the body shell
structure. Sectional repairs fulfill their purpose above all if the replacement of a complete part is too
time-consuming and thus not economical. Approved sectional repairs are clearly defined in the
model-specific body literature. These requirements must be complied with. Advantages of sectional
repair Sectional repair offers many advantages for correct repair of accidental damage. For the
sectional repairs approved by the factory and described in the model-specific body workshop
literature/technician's information, some spare parts (service parts) specially prepared for sectional
repairs are offered via the spare parts sales department. Decision-making criteria Depending on
the type and extent of the damage, the advantages of carrying out sectional replacement in the
area concerned must be weighed up against complete replacement. The following are always
crucial for the decision: In addition, Ford must have given its approval for a sectional replacement
solution in the damaged area. Depending on the damaged areas, further facts are to be taken into
account when deciding for or against sectional repair:
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Body and Paint > 5 Body and Paint > 501 Body and Paint > 501-25 Body Repairs - General
Information > Description and Operation > Corrosion Prevention

The corrosion protection provided in production must be carefully maintained and reproduced
during body repair work, in order to ensure the long-term warranty for Ford vehicles. Only Ford
original bodywork components and Ford approved repair materials are to be used for body repairs.
The Ford logo is stamped onto every Ford original spare part. All Ford bodywork components have
a cathodic primer. Moreover, most parts are zinc-plated on one or both sides. If possible, these
protective layers must not be damaged. Corrosion protection measures during repair work All new
components must be inspected for transport or storage damage. Eliminate any existing damage,
such as dents and scratches. Depending on the damage, different operations are to be carried out.
Scratches in new component: Damaged new component: If the new component is not damaged,
any grease and wax must be thoroughly removed with a silicone remover. During repair work, body
panels are often heated at very high temperatures, which results in the destruction of the corrosion
protection. Reworking of the affected areas is therefore vital. Interior surfaces of the new body
components which are no longer accessible after installation must be primed. Before welding The
joint areas are not always accessible from inside later. Therefore, prepare these areas so that no
soot is produced by burning paint during welding. In the case of butt joints with a metal insert, soot
from the burning paint prevents coating of the panel with cavity wax. With this connection
technique, the welding area is to be prepared more thoroughly, as it is to be assumed that more
heat will be applied here. Procedure: After welding The corrosion protection previously applied is
partially damaged after the welding, so some reworking is required. Sealing work Depending on the
vehicle, the clinched flanges on the hood, doors, tailgate and trunk lid must be sealed with clinched
flange sealer. Clinched flange protection with flat nozzle Likewise, the sealing compound used in
production is to be renewed in the area of a repair weld. The sealing compound is to be applied so
that it matches the original condition visually. Clinched flange protection applied to the correct width
and thickness. Underbody protection The underbody protection is used as corrosion protection and
must also be applied such that it matches the original condition, from a visual perspective. Two
main application methods are used in production: Cavity protection After painting, treat all cavities
in the repair area with cavity protection. Please pay particular attention to the welded seams. In the
case of butt joints with a metal insert, the wax is to be applied so that the metal insert is also
reached. Wax entry Seal the inner flanges with the corrosion protection wax as far as possible. To
do this, ensure the doors are upright and spray the corrosion protection wax into the water
discharge holes in both directions for at least 10 seconds. Then tilt and turn the component to
spread the wax over the whole flange. Noise Insulation Noise insulation mats and cavity insulation
applied during production must be applied again.
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Body and Paint > 5 Body and Paint > 501 Body and Paint > 501-25 Body Repairs - General
Information > Description and Operation > Corrosion Damage-Corrosion Repair

Modern vehicle bodies are protected from corrosion by elaborate measures. Multilayer coatings on
the panel surface prevent direct contact between the metal and oxygen, and so protect it from
corrosion. If the protective layers become damaged, electrochemical conversion processes are
initiated, which allow the metal to oxidize. This leads to the formation of corrosion. The following
factors lead to corrosion: In order to maintain long-term corrosion protection, the vehicle must be
checked at regular intervals. In doing so, the follow areas must be inspected and any damage
rectified: The corrosion formation can vary in extent. With rust film or edge rust formation, the
surface of the paint has small traces of corrosion present. The traces of corrosion can be removed
in such cases by polishing the paint surfaces. If this is not possible however, the traces of corrosion
must be rectified by using a touch-up technique. If rust is already under the paint finish to the steel
panel, then the whole paint finish in the affected area must be sanded away. Furthermore, the
existing traces of corrosion in the body panel must be carefully and completely removed. Finally a
new paint finish must be applied in this area. In the case of rusting through, the affected body panel
is already completely destroyed. Such damage requires complete or at least partial replacement.
The outcome of this is the following repair sequence: For a professional repair it is essential to
reproduce the corrosion protection during and after the repair.
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Body and Paint > 5 Body and Paint > 501 Body and Paint > 501-25 Body Repairs - General
Information > Description and Operation > Sealer, Underbody Protection Material and Adhesives

Sealants, adhesives, cavity wax and underbody protection materials are used during the various
body repairs. In this area Ford offers a range of products which have been tested and matched to
each other. Clinched flange protection This is a 1-component PU adhesive sealant applied through
a flat nozzle. It is fast setting and is very resistant to ageing. After application it is easily sanded
and stretched and it can also be painted over. Seam sealant T Anthracite This is a 1-component
sealant material for sealing joints and seams. It is also suitable for gluing HVH elements into
position in their respective body areas. It is a solvent-free, odourless adhesive which does not
contain silicone or isocyanate. Body sealant T beige This sealant, which contains solvent and has a
long service life, is particularly suitable for visible seams. It can be painted after it has set.
Underbody protection Underbody protection is necessary for permanently elastic corrosion
protection of vehicle underbodies. It is very durable and has good resistance to abrasion, Cavity
wax This touch-proof, transparent corrosion protection wax is used for the preservation of cavities
and flange joints. Anti-corrosion wax Anti-corrosion wax is a coating material which can be applied
in fine spray, forming a very thin and grease-like protective film, therefore offering very good
corrosion protection. Metal adhesive For joining metal to metal and plastic to metal. The adhesive
reduces droning noises and improves corrosion protection. 1-component window glass adhesive kit
For direct glazing. The vehicle is ready to drive after 6 hours (passenger airbag). Prevents contact
corrosion. 2-component window glass adhesive kit For direct glazing. The vehicle is ready to drive
after 1 hour (passenger airbag). The adhesive is not an electrical conductor and permits
interference-free radio reception. Prevents contact corrosion. Using a 150ml additional cartridge,
the adhesive can also be used for large windows or to produce a double seam of adhesive.
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Body and Paint > 5 Body and Paint > 501 Body and Paint > 501-25 Body Repairs - General
Information > Description and Operation > Cutting Technique

Depending on the separating tools used, there are some fundamental points to bear in mind: Spot
weld milling tool Resistance spot welds are best separated using a spot weld drilling machine or a
spot weld milling tool. The spot weld milling tool is particularly useful. It usually has an adjustable
depth stop and a safety fixing system. These prevent the machine from drilling too deep and the
cutter from slipping while working. When using an ordinary drill, the depth of the drilled hole must
be judged by the operator. Because of this, there is the danger of injury and also the danger of
drilling right though the workpiece. Rod sander Another option for separating resistance spot welds
is to use the rod sander. For welded connections which have a large diameter, or are difficult to
reach using the spot weld milling tool, the rod sander offers a useful alternative. MIG weld seams
can be worked using this machine. Short stroke saw The short stroke saw is suitable for separating
vehicle body components and for making a separating cut for partial repairs. The narrow design of
the saw blade permits cutting in tight curves. Straight cuts require a relatively great deal of practice.
Orbital saw Where use of the short stroke saw is difficult because of the body construction, the
orbital saw can be used. The cutting depth of the orbital saw can be set. This allows separating
cuts to be made, despite panels or other components lying in danger behind. Straight cut lines can
be more easily made using the orbital saw.
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Body and Paint > 5 Body and Paint > 501 Body and Paint > 501-25 Body Repairs - General
Information > Description and Operation > Panel Beating Technique and Smart Repairs

General Smaller scale body repairs, where damaged panels do not need to be replaced, can often
be carried out by realignment work. Whether the repair is economical however, often depends on
the accessibility of the affected body area. During damage assessment, the following technical
points must be taken into account: Hollow leveling (removing dent without a dolly) Hollow leveling
can only be used on areas which are accessible from the rear. During hollow leveling, the dent is
removed from the inside a using suitable panel beating tool and applying knocking or pressing
movements. High spots around the edge of the dent area are flattened with blows from the
aluminum or wooden headed hammer. The usual tools are for instance hammers of various
designs, dollies, levering irons and various spoon irons. The correct choice of tool is made
depending on the shape of the dent and the access which is possible. Dent removal using hammer
and dolly Panel beating can only be performed using a hammer and dolly if access can be gained
from the rear side. The purpose of the dolly in this case is to transfer the force of the impacts from
the hammer to the steel panel which is in between. As this is done, the deformed body panel is
smoothed (dressed) and the tension fields in the body panel are removed. The favored tool for this
repair process is the aluminum hammer and as opposite support the universal hand dolly. To
rectify minor panel damage, the box file should be used as opposite support. Because of its
serrated surface, the box file prevents normal stretching of the body panel which would otherwise
occur. Dent removal from the outside using the slide hammer The slide hammer technique is
mostly used when a dent is not accessible from the rear, or a relatively large amount of
disassembly would be needed to make it accessible. By welding pulling rings or pulling electrodes
into position using a special welding gun, dents can be removed from outside using the slide
hammer. Dynamic puller with counter bearing The repair possibilities are much greater than with
the slide hammer method. Because of the versatile puller and the variable counter bearing, a wide
variety of damage can be worked and rectified using this repair method. Because of the
mechanical lever operation, the variable counter bearing and the optimum controlled application of
power, this external dent removal system allows dents in almost all vehicle body areas to be pulled
out. Depending on the application area and the damage, the fixing options to the panel being
worked can be corrugated wire, pulling bits or U-washers which are spot welded into position. Dent
removal using special panel beating levers This panel beating technique with pressure is mainly
used to rectify smaller dents as a result of hail impact, transportation or parking, without the paint
being damaged. Small dents are removed from the inside of the body panel by pushing them
outwards in a mechanical process using panel beating levers. Because of the great variety of
shapes of these levers, it is possible to use this panel beating technique on almost all areas of the
vehicle body. Heat working of panels This repair method allows small and mild dents to be rectified
without additional panel beating. During the repair process, a flame is used to selectively warm
areas of the panel to relieve the stresses in the metal. This can cause the dented area to return to
its correct shape. This method can only be used when the dent: Heat-induced material shrinking
Material shrinking, also called settling in, can be performed in a variety of ways depending on the
extent of the damage and the access to the repair area. These repair processes differ depending
on the type of heating and subsequent working of the heated surface. They sub-divide into two
basic processes: In the carbon electrode process the working is done exclusively by warming. In
this case the access to the repair position is only from the outside. If the damage is concentrated in
a spot and is in the form of a more rigid raised area, then the carbon electrode must be replaced by
a copper electrode. As heat is applied, slightly more pressure is applied to the raised area. In the
method using heating by the oxy-acetylene torch, material shrinking is achieved by a combination
of heat and mechanical working of the damaged area. The repair area must always be accessible
from both sides, so that the heated area can be properly worked mechanically. The combination of
heating and mechanical working is very effective. As soon as the warm point is established,
hammering is immediately started using the aluminum hammer together with a suitable dolly on the
inside of the repair surface, working in spiral movements towards the warm point. This causes
material to build up in the center of the warmed area. Lead loading Despite good external panel
beating techniques, it is not always possible to rectify every surface unevenness. For this reason,
application of lead loading is an important part of panel beating. For corrosion protection and
adhesion reasons, on body components subject to more demands, such as doors or hoods, it is
preferable to apply lead loading rather than stopper. In addition, lead loading application is suitable
for creation of surface contours when the options for panel beating are limited. Typical application
areas:
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Body and Paint > 5 Body and Paint > 501 Body and Paint > 501-25 Body Repairs - General
Information > Description and Operation > Paintless Dent Removal

General In the past all damage to body surfaces had to be rectified by time-consuming and
cost-intensive repair work. New techniques allow small mild dents without paint damage to be
corrected. Using special levering tools (pressure tools) the dent is worked from the inside in such a
way that the damaged area can be returned to its original shape. Mild dent If strong and direct
force during the damage process causes the material to stretch in the middle of a dent, then the
result is a small and sharp edged dent. Such damage cannot be rectified without visible
deformation. Dent with material stretching Preconditions for a successful repair are a definite
diagnosis and the correct allocation of repair method. Furthermore, sufficient experience in the use
of special tools and knowledge of materials are also requirements for a successful repair. The
following characteristics must be present for a dent to be satisfactorily removed: The economic
viability of undamaged paint dent removal must be considered in addition to whether it is possible
practically. This depends on: While carrying out the repair, the following itemized repair route and
process flow must be complied with: In order to ensure corrosion protection, all inner areas of the
repair must be treated afterwards. Where it is possible, the paint is repaired. In every case the
inner area of the repair must be treated with cavity wax.
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Body and Paint > 5 Body and Paint > 501 Body and Paint > 501-25 Body Repairs - General
Information > Description and Operation > Joining Techniques

Welding Before welding work is performed on a vehicle body, all safety measures for the protection
of people, modules and electrical components must be observed. In body construction, the main
type of welding used is resistance spot welding. In the course of repair work, this must be restored
accordingly. However, there are also fields of application for MIG welds. MIG welding Fields of
application Welding repairs can only be carried out properly if the equipment is set up correctly and
all welding-related preparations are complied with accurately. Full seam A welded joint with a full
seam is suitable for joining highly profiled body parts. Pillar and sill areas are typical application
areas. Before the welding process, you must carry out the following operations: Interrupted weld
seam - intermittent seam The intermittent seam is used for offset joint surfaces or for butt joints
with a metal insert. This form of seam is mainly used on the external panel area for sectional
repairs. Please note the following welding parameters: Puddle weld. Puddle welding is used as a
substitute if no spot welding equipment that is sufficiently powerful for the thickness of the panel is
available. This welding method is also used if the welding position cannot be accessed with a spot
welding gun. Please note the following welding parameters: Resistance spot welding. The basic
principle for repair welds is to restore the original welded joint as far as possible. The repair welds
must have the same number of weld spots as the welds used in production with the correct
diameters. This requires that: Well-prepared welding flanges are a prerequisite for a problem-free
welded joint. This means: Only in limited cases can welding errors in resistance spot weld joints be
detected from the outside . Therefore, a test weld should be carried out before each repair weld.
The peel test carried out after the welding gives information on the quality of the welding. The spot
weld must not flake off. Joining techniques Butt joints The butt joint is a joining technique frequently
used in body repairs. The butt joint is typically used for repairs in the pillar and rocker panel area.
Areas that are suitable for the use of the butt joint: The edges of the panels to be joined are placed
against each other and are joined with a full seam in whilst maintaining a required welding gap
(welding gap same as panel thickness). Preparation of the joint areas includes: Butt joint with panel
strip As with the butt joint without a panel strip, the panels to be joined are pushed together, but are
joined with an intermittent seam. A panel strip placed beneath the area to be joined stabilizes the
welding area. Preparation of the joint areas includes: Joggled joint The joggled joint variant is
restricted to body areas with a good surface condition without beads/swage lines or profiles. A
sectional replacement with a joggled joint is welded with an intermittent seam. This procedure is
used, for example, at the transition from the side panel to the rocker panel (3-door vehicles). The
amount of reworking required is kept to a minimum, by avoiding the use of a full seam. Other
advantages are: Preparation of the joint areas includes: MIG brazes Metal Inert Gas (MIG) brazing
is increasingly used in production for certain body areas. In areas in which resistance spot welding
is not possible due to limited space or higher strength requirements, MIG welding was previously
used. Increasingly, these MIG welded seams are being replaced by MIG brazes. MIG brazed
connections are partly used in production for the following areas: Inner fender reinforcement to
A-pillar, A-pillar reinforcement to A-pillar inner panel and outer wheelhouse to rocker panel
reinforcement. The temperature range used during MIG brazing is significantly lower. This keeps
the damage to the anti-corrosion zinc layer on zinc-coated panels to a minimum. This results in the
following advantages of the MIG brazed seam: Alternative repair methods are specified in the
model-specific body literature. MIG brazing requires a new generation of welding equipment and
training in the technique. For this reason, MIG brazed joints must be replaced by MIG welds at
another place if a repair is performed. When carrying out these repairs, the requirements in the
corresponding repair instructions must be taken into consideration. Rivets With riveting, two or
more panels are joined together using a joining element (rivet). In body construction, pop rivets and
punched rivets are used. Advantages of riveted connections: Disadvantage: Pop rivets are used if
only one side of the panel is accessible. In this process, overlapping panels are drilled and
connected with a pop rivet. Pop rivets can be inserted pneumatically, hydraulically or manually with
rivet guns. Brazed connections Brazing is a procedure for connecting metallic materials using a
further melted metal. The melting point of the brazing material is lower than that of the basic
material. The basic material is covered with the brazing material and not melted. As the material is
heated to a lesser extent than during welding, brazing is particularly suitable for parts that are
sensitive to warping, oxidization and heating. Brazing means it is possible to join together all
common metals. Brazed connections can be detached again through heating. Brazed parts have a
limited strength, low thermal resistance and a certain risk of corrosion due to the difference
between the basic materials used and the brazing material (difference in potential). Watertight,
permanent connections must be produced at the transitions between A or C pillars and the roof.
Continuous welded seams in visible areas require time-consuming finishing. For this reason, such
connections are not welded, but brazed. Brazed connections are: This means: Lead loading Lead
loading with tin is the best repair method for smoothing joins on sectional replacements or for
rectifying small uneven areas on the panel surface. Tin has the following advantages: For correct
repair, the panel is beaten out almost to the original shape and then the rest is smoothed out
through lead loading. First, the panel to be lead loaded must be properly prepared. To create a
basis for the actual lead loading process, a lead loading paste is first applied to the panel. The
paste is then heated and wiped away with a cloth. Now the tin can be applied and moulded with a
brazing block. After the repair site has cooled slowly, it is worked with the body plane until the
surface is smooth and has no visible joints. Bonding Bonded connections are used more and more
in modern body designs. Here, a distinction is made between bonds for stabilization purposes and
bonds for adhesive strength. Bonds for stabilization purposes are found on clinched flanges and on
cross beams in doors or on the roof. The repair adhesive is an elastic 1K adhesive on a
polyurethane basis. Bonds that rely on adhesive strength are used instead of conventional metal
connections. Here, the hardening 1K epoxy resin is used. Bonded connections have the advantage
over conventional connection procedures that no heating is required. This means it is not
necessary to remove heat-sensitive parts, such as the fuel tank, electronic modules or plastic parts.
In addition, bonded connections have further advantages: Different adhesives are used in body
repairs. Please refer to the repair instructions for the specific adhesive to be used. Please also take
into consideration the instructions of the adhesive manufacturer. Body bonding requires the
following steps: Bonding and welding On some vehicle models, (such as the Ford Ka), bonding is
combined with resistance spot welding. This connection technique has the following advantages:
Please note the following points during the repair work: Bonding and riveting As with welding,
bonding can also be combined with riveting. This connection technique has additional advantages.
These are:
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Body and Paint > 5 Body and Paint > 501 Body and Paint > 501-25 Body Repairs - General
Information > Description and Operation > Plastic Repairs

General The proportion of plastics used in vehicle construction continues to rise. Up to now
damaged plastic components often had to be replaced. In the meantime plastic repair is becoming
more and more accepted because of rising costs. Because of the various compositions of plastics,
repair work to plastic parts involves a variety of repair methods. The following methods are used: In
repair work, the material properties of plastics are highly significant. There are two main groups:
Thermoplastics Heat causes thermoplastics (also called TP polymers) to transform from the solid
state into the thermoelastic state and then into the thermoplastic state. When thermoplastics are
cooled, they return to solid state. Thermosets Thermosets (also called TS polymers) are much
harder and more brittle than thermoplastics. Their strength remains largely unchanged when they
are heated. Thermosets are destroyed when heated above the critical temperature. Also, the
original state will no longer be restored on cooling. Plastics used by Ford Plastic identification
Normally the identifier is marked on the plastic components used in vehicle construction. If none is
present, it can be determined using two different procedures/methods: Visual Inspection Visual
inspections mainly serve to identify PUR and GRP materials. Thermoplastic components are often
painted and are therefore difficult to identify. Identification characteristics: A burning test allows the
plastic to be determined more exactly. This involves burning a small piece of the plastic material
and observing the behavior of the flame, the smoke characteristics and the dripping behavior.
Characteristics of plastics: Another method to determine the plastic group is the sanding test. In
this a place is chosen which will not be visible later, and the finger belt sander is used to sand the
plastic. The plastic group can be determined using the pattern of the dust: Mechanical Check The
plastic group can be determined by a sound test: Safety instructions In addition to the general
safety instructions, the relevant regulations and accident prevention legislation must be observed.
Information sheets, safety notices and guidelines for the processing of adhesives containing
isocyanate, polyester resin, adhesives, solvent and thinners provide more details on their use. The
following instructions must always be followed: Plastic welding Splits formed in plastic bumpers are
typical possible plastic repairs. If repair using adhesive methods is not possible because of
unfavorable conditions at the rear of the repair location, plastic welding is a possible repair process.
There are two methods of welding: hot air draw welding and hot air fanning welding. Plastic welding
set In addition to the components listed, plastic welding requires tools already found in the
workshop such as scrapers, sanders, face cutters etc. As with all other welding processes, only
certain material combinations can be joined together using plastic welding. Repair sequence during
plastic welding: Despite good preparation and the correct choice of welding materials, weld faults
may occur. The correct choice of temperature is important for the success of the repair. Possible
causes of weld faults: Adhesive bonding of plastics Adhesive bonding of plastics has some
advantages over welding methods: Tools and equipment also familiar from paint repairs can be
used in making adhesive repairs to thermoplastic components. Angle grinders and belt sanders
can be used to grind out scratches and splits. Orbital sanders with extractors are used for fine
sanding. The infrared heater is used to provide fast and secure drying throughout. Plastic adhesive
set Apart from the components shown, other materials may be needed to bond plastics, depending
on the repair position. For large scale repairs, it may be necessary to insert reinforcement panel
strips and reinforcement matting as fixing aids. Repair sequence during plastic adhesive bonding:
GRP repairs GRP material is hard and brittle in its strength properties. Because of these material
properties, splits and openings often result in cases of serious damage. The stability of GRP parts
is impaired if the glass fiber reinforcement is cracked. The component must be replaced in cases of
serious damage that affect the structure. Minor damage (such as abrasion, splits up to 80mm,
holes up to approx. 60mm diameter, etc.) can be repaired to a technically and visually perfect
standard, provided that the damage does not occur in heavily used or hard-to-reach areas. To
ensure perfect repair results, observe the following points: Tools and equipment from the paint
shop can be used to carry out repairs to GRP parts. Angle grinders and belt sanders can be used
to grind out scratches and splits. Orbital sanders with extractors are used for fine sanding. GRP
repair set Scissors, paintbrush and cleaning materials are other materials which will be needed to
perform a GRP repair. The repair process for a GRP repair is as follows:
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Body and Paint > 5 Body and Paint > 501 Body and Paint > 501-25 Body Repairs - General
Information > Description and Operation > Special Repair Techniques

Cabriolet vehicles The body of a cabriolet vehicle is different to the self-supporting body of a saloon
car because of the special roof construction (folding top). The stability requirements must therefore
be ensured by construction changes within the body structure. These are for instance: If
deformation to load carrying components occurs, the stability of the whole body shell can be
adversely affected. On a cabriolet, accident damage repair to the components mentioned above is
considerably different in certain aspects compared with the usual repairs (closed body
construction): Liquefied gas vehicles Alternative fuel vehicles often require special handling in the
workshop area. Above all, assembly operations to some extent require particular knowledge when
dealing with the special technology and the safety regulations. These special requirements must be
understood and taken into account in the body shop as well. If the smell of liquefied petroleum gas
(LPG) or compressed natural gas (CNG) is noticed in the workshop, instruct everyone present as
follows: Alternative fuels require special handling: Avoid situations in which fuel from an LPG or
CNG fuel tank can escape. These include: Refrigerated conversion vehicles Apart from the special
materials used in building the structure of the refrigerated compartment, such vehicles have special
energy and refrigeration systems which require special handling during repair. Vehicles with a
refrigerated compartment are often used to transport foodstuffs. For this reason, additional hygiene
regulations must be complied with during repair work. Aluminum and plastic are used to construct
the two different types of compartment found on refrigerated vehicles. The aluminum conversion is
a very stable and technically perfect variant. However, against this the relatively high production
costs and a lower payload must be taken into account, because of the weight of the aluminum
conversion itself. The plastic conversion has developed into a light, clean and economical
alternative because of constant further development of materials and working techniques.
Refrigerated compartment constructions are often made using both materials. The floor pan is
made of structured, slip-proof aluminum panels and the wall and ceiling cladding is made of
smooth surfaced plastic elements. Polyurethane wall and ceiling elements are manufactured using
a sandwich principle. An insulating polyurethane core is coated with food grade ABS plastic on one
side. PUR hard foam does not decompose, is rot resistant and is odorless. These properties make
it suitable for use as insulation. Because of its closed cell structure, water uptake by PUR hard
foam is for the most part only a problem at edges. Cut edges or other mechanically worked
surfaces must however be sealed with the greatest care. The conversion to a refrigerated vehicle is
performed as made-to-order production. The large surfaces of the wall and ceiling cladding can be
changed and are particularly easy to repair. If access to the back of a body panel section is needed
because of body straightening work, in some circumstances it is cheaper to perform a cut-out
repair instead of removing an element. The repair process is fully described in the Student
Information booklet Refrigeration System Technology, Transit 2000.5 Freshline.
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Body and Paint > 5 Body and Paint > 501 Body and Paint > 501-25 Body Repairs - General
Information > Description and Operation > Impact of Insufficient Repair Quality

Body repairs usually require a significant level of intervention in the existing body shell structure.
The corrosion protection, seals and NVH components are destroyed and must be replaced. To
prevent the vehicle quality from being reduced due to an insufficient repair quality, all repairs
carried out in all repair sections must be inspected during and after the accident repair. Simply
checking the vehicle at the time of delivery is not sufficient to guarantee the repair quality. Rather,
continuous checking of the work carried out is recommended. In the process, the entire repair
sequence must be split into reasonable sections, with the creation of check points to which
particular attention must be paid. The following are some possible sections: Completion of the body
repairs After completion of the body repairs, the following areas should be checked: Completion of
the paint repairs The following points should be noted when checking the paint repairs: Final
assembly, ancillary components, functional tests After final assembly, not only a visual inspection is
required, but also the functionality of many components must be checked: Vehicle delivery Vehicle
delivery again offers the opportunity of checking the repair quality. In the process, the following
points are to be checked again: After repair work on the body and vehicle, not only the visual
restoration of the damaged vehicle, but also the functional restoration must be guaranteed.
Customers are making increasingly high demands of vehicles, particularly in terms of driving
comfort. Customers find noise, vibrations and harshness (NVH) as well as squeaking and rattling
annoying, particularly after repair work. It is therefore important that the condition of the vehicle at
the time of production be restored after an accident repair. After body repairs, the entire repair area
must be checked for any water leaks. It is crucial that a leak test be carried out as part of the final
inspection so that water leaks can be detected and eliminated even before delivery of the vehicle to
the customer. The requirements of the vehicle manufacturer are to be taken into consideration
during all inspections. Only in this way can it be guaranteed that the vehicle quality is not reduced
through insufficient repair quality.
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Body and Paint > 5 Body and Paint > 501 Body and Paint > 501-25 Body Repairs - General
Information > Description and Operation > Water Leaks

Water leaks can occur after body repair work, but can also occur on new vehicles. The test
methods described below allow the various causes to be identified. In all cases, a systematic and
logical procedure is required to locate water leaks. General When searching for faults, it must be
taken into account that water can enter the vehicle passenger compartment in various ways and
under different conditions. Therefore, it is sometimes not sufficient to perform a water test on a
stationary vehicle. Before beginning extensive checks, a thorough visual inspection must be carried
out. The following points are to be taken into account in the process: Testers Water leaks and wind
noise can have similar causes. This means that test methods and testers can be used for both
types of problem. The alternative tests are as follows: Test method Water leaks in the vehicle
passenger compartment cannot usually be located at the first go, as the water frequently distributes
itself across larger areas. For this reason, the passenger compartment must be dried before the
leak tests. Any ancillary components that block the view must be removed. Water test During the
water test, the vehicle is sprayed with water at the suspected location of the leak. At the same time,
a second person checks the passenger compartment for places where water enters the vehicle.
Washer test Certain leak problems only appear in a car wash or can only be simulated there. The
concerned area of the passenger compartment should be inspected with a torch during the wash
procedure. Road Test Some leaks only appear when the vehicle is moving. If no leaks are detected
during the above-mentioned tests, road tests should be carried out on wet roads. Test with UV
lamp As already indicated in the water test section, a leak test can be executed with a UV lamp and
a special contrast agent. The advantages of using contrast agent are: Procedure for using a UV
lamp. Chalk/powder test In this test, the contact area of the seal is checked. To do this, the door
seal is coated with powder or brushed with chalk. A thin layer of grease is applied to the contact
area of the seal. The door must then be slowly closed and reopened. The width and continuity of
the imprint can now be checked on the door seal. Smoke test This test can be used to detect leaks
visually. The process is as follows: Stethoscope test This procedure is very similar to the smoke
test. Instead of the smoke pipe, move a stethoscope past the areas of the body that are at risk.
Leaks can now be detected acoustically. Ultrasonic detection With this test, a leak can be found
electronically. The procedure is as follows: Sequence Possible complaints and corrective actions
An outline of the possible complaints due to water leaks is provided below. The causes of water
leaks and the possible remedies are presented using selected examples. They are intended to
provide troubleshooting tips and suggestions for the user but do not represent an exhaustive faults
list. Glued windows A broken pasted seam can cause water to enter around the window. A broken
pasted seam can be located using a water test or by carefully blowing compressed air onto the
inside of the window seal. Corrective action Broken pasted seams -Arrow- can be sealed from
inside using PU adhesive. If this seal does not resolve the problem or the broken pasted seam is
too extensive, it is necessary to remove the window and glue it back into place. Door seals If water
appears at the bottom of the door, it is possible that the door seal behind the door trim is damaged.
If the door is intact, water can enter through the window weatherstrip and flow out through gaps on
the underside of the door. If the door seal adhesion is faulty or the door seal is damaged, water can
get into the interior. Fastening bolts could be loose or clips incorrectly positioned on door modules.
Corrective action Depending on the door seals used, different sealing methods can be used. Once
the adhesive surfaces have been cleaned, plastic films must be stuck with double-sided adhesive
tape or replaced. Leaky foam seals are sealed with Butyl tape or replaced. Plastic door modules
are fitted with a weatherstrip, which cannot be replaced. Seal the leaky point with Butyl tape or
replace the part. Door weatherstrip Leaks can be caused by badly fitted seals. In particular, areas
with radii -Arrow- must be thoroughly checked. Door seals can develop leaks due to: The contact
pressure of a seal can be determined using a strip of paper. If a strip of paper trapped in the closed
door can be pulled out easily, the contact pressure is too low. Corrective action Replace damaged
or aged seals. Prevent kinks. The contact pressure can be changed by adjusting the catch bolt or
correcting the panel flange. Realign uneven welding flange thicknesses. Properly repair any paint
damage that occurs. Rubber grommets / plugs Rubber grommets or plugs are fitted at numerous
points on the body. They are frequently used as seals for cables, hoses or actuating links. Rubber
plugs are frequently used for gaps caused during production. Leaks can be caused by badly fitted
or damaged rubber grommets and plugs. Damaged cable insulation can also cause leaks. Where
components are bolted on, water can enter if there are inadequate seals at the connection point.
Corrective action Correctly fit rubber grommets / plugs. During fitting, ensure that the sealing lips
are not trapped and are applied properly. The contact area of the rubber grommets / plugs can also
be sealed with PU sealing compound. Replaced damaged rubber grommets and repair damaged
cable insulation. Heater housing/ventilation Loose Butyl sealing strips, damaged sealing surfaces
or a trapped carpet can cause leaks around the heater housing / ventilation -Arrow-. Badly
positioned or badly fitted hoses can also be responsible for water entry. Water drains must not be
blocked. Corrective action Before the actual repair, make sure that the water drains are not blocked
or stuck. Remove the heater housing / ventilation and fit a new Butyl sealing strip. Damaged
sealing surfaces must first be adjusted. A trapped carpet must be removed. Seal welds PU seal
welds are applied to welded or riveted connections -Arrows- to seal the interior of the vehicle.
Incorrectly applied or damaged seal welds can allow moisture to penetrate into the interior of the
vehicle. It is also possible that seal welds that visually appear to be intact in terms of their shape
and size actually have poor adhesion. Corrective action Incomplete seal welds must be
supplemented with PU sealing compound. Damaged seal welds must be removed and re-applied
properly. Make sure that any residual moisture is effectively removed before a new seal is applied.
Attached parts The add-on parts include: Add-on body parts must be fitted with seals, grommets or
sealing compound to prevent water entry. However, even when a sealing system is fitted, the
screw thread may still cause leaks. Corrective action Seals must be tested and, if necessary,
replaced. Check contact surface and adjust if necessary. Points sealed with sealing compound
must be thoroughly cleaned and the seal replaced. Check grommets and replace if necessary. At
all screwed connections, seal the thread with an appropriate sealing material.
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Body and Paint > 5 Body and Paint > 501 Body and Paint > 501-25 Body Repairs - General
Information > Description and Operation > Wind Noise

Wind noise and noises in general are dealt with under the label Noise, Vibration, Harshness, or
NVH in short. Due to the continuous reduction in drive noises, wind noise has come to the fore in
the vehicle and is perceived to a greater extent by the customer. There are various causes of wind
noise. They can be due to the design of the vehicle, or they can occur after a repair. They are
mostly caused by poorly mounted components, which must be located and installed in the correct
position. Diagnosis In order to carry out targeted diagnosis, it is important to know the basics of
noise formation and sound transmission. Potential areas of wind noise Normal air flow noises are
caused by air blowing against even, flat vehicle surfaces, such as the roof, doors and side
windows. When the vehicle is moving fast, air films (turbulence) form, which cause variations in air
pressure. These variations in air pressure spread in the form of sound waves and are transferred to
the vehicle interior via the side windows and seals. If air flows over an edge on a vehicle, the air
flow cannot follow the shape of the surface, but separates at the edge. Eddies are formed, which
collapse again after a certain time or distance. The associated variations in air pressure create a
corresponding sound wave. Streaming noise occurs if there are leaks in the sealing system to the
vehicle passenger compartment. The noise is caused when stationary air mixes with moving air. As
a result, the noise increases as the streaming speed increases. Cavity noises are noises that occur
when the air column is caused to oscillate. Workshop diagnosis Before carrying out repair work, a
visual inspection of the vehicle must be carried out. The gaps in the doors, the sunroof and at all
other body parts must be checked in particular. When the doors are adjusted to fit exactly,
development of wind noise can often be eliminated at high speeds (lifting of doors off the seals).
The following points are also to be checked: Road tests Wind noise can usually only be located
through road tests. The following points should be taken into account for such test drives: If it is
difficult to detect the noise sources, the search can be made easier by masking potential areas.
Sequence A basic prerequisite for a problem description with subsequent diagnosis is the
performance of a test drive with the customer.. Only once the customer's problem description is
clear should the service technician begin with the diagnosis of the problem. The service technician
should carry out specific road tests to achieve further containment of the problem. Sequence
(schematic): 1. Customer concern 2a. Diagnosis and corrective measures Sequence A: The
diagnosis is possible based on the information supplied by the customer. 2b. Diagnosis and
corrective measures Sequence B: The diagnosis is not possible based on the information supplied
by the customer. The vehicle acoustics do not always make it possible to draw up a clear
diagnosis. It is therefore all the more necessary to use all methods of detecting and suppressing
NVH problems. 3. Comparison of vehicles constructed in the same way. If no clear diagnosis is
possible based on a customer concern, a comparison test drive should be carried out on a vehicle
constructed in the same way. Test equipment Diagnosis of wind noise requires good hearing, basic
knowledge of acoustics and experience. Tools can provide assistance for the diagnosis and reduce
the fault finding times. Stethoscope Here, the tightness of the vehicle passenger compartment is
checked. The ventilator blower is set to the highest setting and the doors and windows are closed.
There is now a corresponding overpressure in the passenger compartment. The stethoscope is
now used to listen to the door and window seals. The sound of the streaming air can be heard at
the leaks. Smoke pipe The preparatory work is the same as for the stethoscope test. By scanning
past the seal areas with the smoke pipe, a leak can be visually detected based on the changed
smoke path. Ultrasonic detector The ultrasonic detector is a further method of finding leaks in the
vehicle passenger compartment. Here, an ultrasonic noise generator is placed in the passenger
compartment. The closed vehicle is then inspected from outside with the corresponding detector.
The detector will show any leaks present. Powder Door seals that do not make close contact can
be detected by coating the contact surface of the door seal with white powder. To do this, the door
is carefully closed and re-opened. In this way, the door seals which do not touch will be visible.
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Body and Paint > 5 Body and Paint > 501 Body and Paint > 501-25 Body Repairs - General
Information > Description and Operation > Noise, Vibration and Harshness

Noises means noises caused by the vehicle that are audible both inside and outside the vehicle.
Vibrations are oscillations that are palpable and noticeable in the vehicle passenger compartment.
Harshness means noises caused by the vehicle that are audible, palpable and noticeable inside
the vehicle. These terms are grouped together under the label Noise, Vibration, Harshness, or NVH
in short. The task of vehicle development and production is to ensure that noises caused by the
vehicle do not disturb the driver and passengers. Moreover, the the external noises emitted by the
vehicle must not exceed the thresholds set by law. The following section gives an overview of how
noise, vibration and harshness can occur in the vehicle and what remedial action is possible. Noise
types and causes Noises in and around the vehicle are assigned specific descriptions: Low to
middle tones are considered to be unpleasant. They are palpable and noticeable as oscillations
and vibrations throughout the body. Loud howling and whistling is painful to the ears. Where the
different notes come from in a vehicle: A noise usually consists of a superimposition of different
tones which spread as oscillations. Each of these oscillations has a specific oscillating time and
can be measured in frequencies. The frequency describes the number of oscillations per second.
The frequency unit is specified in Hertz (Hz). The human ear can perceive frequencies between 20
and 20000 Hz. Noises can already be contained where they occur or, if this is not possible, can be
confined with suitable measures. The basic procedures are the damping of oscillating parts, the
insulation of components or the absorption of the noises through appropriate materials. Damping If
a damper is installed next to an oscillating mass, the characteristic of the damper will reduce the
movement of this mass accordingly (e.g. bumper on chassis). Damping affects the resonance of an
object or system. Isolation In oscillation technology, the term isolation means decoupling
(separation) of components and systems. An engine is mounted in sprung elements, so that as
little oscillation as possible is passed to the vehicle. In automotive technology, the isolation
technique used is nearly always rubber mounting. The elasticity of the rubber acts like a spring.
Absorption Sound waves are reflected from hard surfaces Through the use of absorption material,
sound waves hit soft surfaces and are absorbed by them. The composition and thickness of the
material used plays an important role here. A soft surface, depending on its composition, absorbs
the sound waves and reduces their energy. NVH elements NVH elements are installed to prevent
airborne sound transfers to the passenger compartment in different body cavities. On the Focus
2004.75 (07/2004-) these elements are located in the cavities of the A, B and C pillars. On the
estate version, they are also located in the D pillars. The NVH elements consist of a carrier plate
with a compressed isolation material at the edges. In the drying system of the painting equipment
used in production, the body is heated to approx. 170° C. At this temperature, the isolation material
expands, completely sealing the gap between the carrier plate and the bodywork. For the exact
installation position of an NVH element, please refer to the vehicle-specific repair instructions. If an
NVH element is to be reused, the bonding on the body panel must be detached. To do this, the
body panel must be heated in the area around the NVH element. The bonding can be detached at
approx. 170° C. The damaged panel part can now be carefully dismantled. Before installing the
new panel part, PU adhesive must be applied to the contact areas between the panel and the NVH
element. Test techniques, measuring devices The shortest route to an accurate diagnosis results
from: The diagnosis and correction of noise, vibration and harshness concerns requires: It is often
very difficult to locate noises that are audible in the passenger compartment based on the problem
description provided by the customer and the road tests performed. The direction of the noise can
be detected subjectively, but the source of the noise cannot be found. Stethoscope Using the
stethoscope, you can listen to the entire vehicle passenger compartment to locate noise sources
more easily. This test procedure can be carried out either while the vehicle is moving, or with the
engine running and the vehicle stationary, depending on the concern. The noise source can be
assumed to be where the stethoscope identifies the highest noise radiation. Application examples:
Ultrasonic measuring device The ultrasonic detector is a good and reliable test method for acoustic
problems. It is used in a similar way to the stethoscope. In principle, it is suitable for all high
frequency interior noises and for leaks in the body seals. The device consists of an ultrasonic
transmitter and a receiver. During use, the transmitter sends an ultrasonic signal which is received
at the problem zones by the receiver. Electronic NVH tester The measuring device described below
is used for diagnosis of the solid-borne sound and solid-borne sound transmission paths. The
device is particularly suitable for medium and high frequency noise analyses. In order to obtain a
positive diagnosis of droning problems (low frequency noises) and their sources, you must have
sufficient experience of how to use this measuring device. The device works according to the
following operating principle: Accelerometers (transmitters) are fitted on various vehicle
components or body areas. The signals recorded here can be listened to one after the other on
headphones or speakers via the different channels. Simultaneous illustration of several or all
measuring channels (for comparison) is only possible visually on the display of the measuring
device. Layout and operation:
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Body and Paint > 5 Body and Paint > 501 Body and Paint > 501-26 Body Repairs - Vehicle
Specific Information and Tolerance Checks > Specifications
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Body and Paint > 5 Body and Paint > 501 Body and Paint > 501-26 Body Repairs - Vehicle
Specific Information and Tolerance Checks > Description and Operation > Body and Frame

Introduction With the Transit, Ford has developed a completely new bodywork concept in the
commercial vehicle sector. Taking into account all active and passive safety components, current
materials or material combinations have been integrated into the overall bodyshell design. The
combination of various jointing techniques within the overall bodyshell design makes rationalized
repair techniques possible in the service area. Technology and economy have been intentionally
balanced, resulting in development of a basic overall platform with the Transit that points the way
ahead for current Ford technology. Design features, Transit 2000.5 (01/2000-05/2006) and Transit
2006.5 (04/2006-) The Transit 2000.5 (01/2000-05/2006) will be replaced by the Transit 2006.5
(04/2006-). The bodywork of the two vehicles are identical apart from the front end. Important
structural components, particularly at the front end of the vehicle, such as the side member, cross
member and hood lock panel have been redeveloped or redesigned. Front cross member and side
member, Transit 2000.5 (01/2000-05/2006) From chassis no. 4412103 to 4515866 (manufactured
between 15.01.2000 and 15.05.2003), the front cross member is made of plastic. From chassis no.
4515867 (manufactured after 15.05.2003), the front cross member is made of sheet steel. The
cross member is attached to the front ends of the side members using screwed connections. The
integral deformation element in the cross member (crash element) absorbs a large proportion of
the forces arising from a collision. The subsequent deformation process is pre-determined by 3
designated yield points in the front side members. It is only possible to partially replace the side
members (see subsection 501-27). Front cross member and side member, Transit 2006.5
(04/2006-) The front cross member is made of sheet steel. It is attached to the front ends of the
side members using screwed connections, as on the Transit 2000.5 (01/2000-05/2006). There is
only one integral designated yield point on the outside and inside of the front side members. It is
only possible to partially replace the side members (see subsection 501-27). Hood lock panel,
Transit 2000.5 (01/2000-05/2006) The hood lock panel is made of a single piece of plastic and is
attached to the bodywork using screwed connections. The screwed connections allow the hood
lock panel to be aligned with the bodywork. Minor damage (cracks) can be eliminated with a
corresponding GFK repair material. Hood lock panel, Transit 2006.5 (04/2006-) The hood lock
panel is a three-part design and is made of sheet steel. In the event of damage, this modular
construction allows individual segments to be replaced. The segments are attached using screwed
connections. The screwed connections allow the individual segments of the hood lock panel to be
aligned with the bodywork. Important information for use during accident repair There follows some
important information which is helpful during accident repair work. front fender The fenders are
attached to the bodywork using screwed connections. The exterior mirror must be removed before
the fender can be removed. Fender attachment points Wiring harness and hose routing During
work on the bodywork, such as cutting, grinding or welding, the installation location of the wiring
harness and hoses must be taken into account due to the risk of damage. NVH measures Various
NVH components are installed in the A, B and C pillars in order to reduce noise. This reduces the
size of the resonance space which the actual cavities present. This has been made possible by the
development of new sound deadening technologies and the use of hybrid materials. During
servicing, the original insulating elements must be replaced with equivalent insulating elements.
The applicable replacement solutions are specified in the repair descriptions. Side panel seam seal
The seam seal for the side panels is applied after painting. This has the advantage that the sealant
retains its flexibility and later sealing work is possible without extra painting work. Corrosion
prevention measures All body parts that are liable to corrosion are zinc plated. It is therefore vitally
important that the corrosion protection measures are carried out with the greatest care during
bodywork repairs. Galvanised steel panels Galvanized and high strength steel panels Sheet metal
parts for partial panel replacement repairs The following illustrations represent he current sheet
metal parts available for partial panel replacement on all Transit model variants.
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Body and Paint > 5 Body and Paint > 501 Body and Paint > 501-26 Body Repairs - Vehicle
Specific Information and Tolerance Checks > Description and Operation > General Procedures > Underbody Tolerance
Check
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Body and Paint > 5 Body and Paint > 501 Body and Paint > 501-26 Body Repairs - Vehicle
Specific Information and Tolerance Checks > Description and Operation > General Procedures > Body Tolerance Check

Measuring points and dimensions Measuring points and dimensions Measuring points and
dimensions Measuring points and dimensions Measuring points and dimensions Measuring points
and dimensions Clearances and tolerances Clearances and tolerances
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Body and Paint > 5 Body and Paint > 501 Body and Paint > 501-27 Front End Sheet Metal
Repairs > Removal and Installation > Fender Apron Panel

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Body and Paint > 5 Body and Paint > 501 Body and Paint > 501-27 Front End Sheet Metal
Repairs > Removal and Installation > Fender Apron Panel Reinforcement

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Body and Paint > 5 Body and Paint > 501 Body and Paint > 501-27 Front End Sheet Metal
Repairs > Removal and Installation > Fender Apron Panel Inner Reinforcement

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Body and Paint > 5 Body and Paint > 501 Body and Paint > 501-27 Front End Sheet Metal
Repairs > Removal and Installation > Front Side Member Section

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Body and Paint > 5 Body and Paint > 501 Body and Paint > 501-27 Front End Sheet Metal
Repairs > Removal and Installation > Front Side Member and Fender Apron Panel LH

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Body and Paint > 5 Body and Paint > 501 Body and Paint > 501-29 Side Panel Sheet Metal
Repairs > Specifications
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Body and Paint > 5 Body and Paint > 501 Body and Paint > 501-29 Side Panel Sheet Metal
Repairs > Removal and Installation > Sliding Door Step Outer Panel

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Body and Paint > 5 Body and Paint > 501 Body and Paint > 501-29 Side Panel Sheet Metal
Repairs > Removal and Installation > A-Pillar Outer Panel Section and Reinforcement

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Body and Paint > 5 Body and Paint > 501 Body and Paint > 501-29 Side Panel Sheet Metal
Repairs > Removal and Installation > Front Door Step

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Body and Paint > 5 Body and Paint > 501 Body and Paint > 501-29 Side Panel Sheet Metal
Repairs > Removal and Installation > Side Panel

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Body and Paint > 5 Body and Paint > 501 Body and Paint > 501-29 Side Panel Sheet Metal
Repairs > Removal and Installation > Side Panel Lower Section

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Body and Paint > 5 Body and Paint > 501 Body and Paint > 501-30 Rear End Sheet Metal
Repairs > Specifications
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Body and Paint > 5 Body and Paint > 501 Body and Paint > 501-30 Rear End Sheet Metal
Repairs > Removal and Installation > Quarter-Side Panel Rear Section LH

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Body and Paint > 5 Body and Paint > 501 Body and Paint > 501-30 Rear End Sheet Metal
Repairs > Removal and Installation > Lower Quarter Panel Section

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Body and Paint > 5 Body and Paint > 501 Body and Paint > 501-30 Rear End Sheet Metal
Repairs > Removal and Installation > Lower Side Panel Rear Section

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Body and Paint > 5 Body and Paint > 501 Body and Paint > 501-30 Rear End Sheet Metal
Repairs > Removal and Installation > Rear Outer Wheelhouse Half

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Body and Paint > 5 Body and Paint > 501 Body and Paint > 501-30 Rear End Sheet Metal
Repairs > Removal and Installation > Rear Inner Wheelhouse Half

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Body and Paint > 5 Body and Paint > 501 Body and Paint > 501-30 Rear End Sheet Metal
Repairs > Removal and Installation > Box Corner

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Body and Paint > 5 Body and Paint > 501 Body and Paint > 501-30 Rear End Sheet Metal
Repairs > Removal and Installation > Box Corner Section

Removal Installation
Ford Transit 2000.5 01.2000-05.2006 Workshop Manual ((01.2000-05.2006))
Ford Workshop Manuals > Body and Paint > 5 Body and Paint > 501 Body and Paint > 501-30 Rear End Sheet Metal
Repairs > Removal and Installation > Back Panel and Crossmember

Removal Installation