SM 77 Batery

2010 Ranger Workshop Manual
SECTION 414-01: Battery, Mounting and Cables 2010 Ranger Workshop Manual
SPECIFICATIONS Procedure revision date: 09/01/2009
General Specifications
Item Specification
Battery
Cold Cranking Amps (CCA) 540 CCA
measured at -18°C (0°F)

Voltage 12 volts
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Torque Specifications
Description Nm lb-ft lb-in

Battery cable body ground terminal bolt 12 - 106
Battery cable engine bracket bolt (2.3L) 12 - 106
Battery cable engine bracket bolt (4.0L) 25 18 -
Battery cable engine ground terminal nut 27 20 -
Battery cable fender well bracket bolt (2.3L) 17 - 150
Battery cable generator B+ terminal nut (2.3L early build) 8 - 71
Battery cable generator B+ terminal nut (2.3L late build) 17 - 150
Battery cable generator B+ terminal nut (4.0L) 17 - 150
Battery cable shield assembly bolt (4.0L) 5 - 44
Battery cable starter solenoid terminal nut 12 - 106
Battery cable starter solenoid wire terminal nut 5 - 44
Battery cable terminal bolts 6 - 53
Battery hold-down bolt 12 - 106
Battery Junction Box (BJB) terminal nuts 12 - 106
Generator Pulley 3143

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Generator Pulley 3144

DESCRIPTION AND OPERATION Procedure revision date: 09/01/2009
Battery and Cables
Vehicles are equipped with a 12-volt, maintenance-free battery.
The battery and cable system consists of the following components:
• Battery
• Battery cable assembly
• Battery tray
The battery is a 12V DC source connected in a negative ground system. The battery case is sealed with 2 vent
holes to release gases. The battery has 3 major functions:
• Engine cranking power source

• Voltage stabilizer for the electrical system
• Temporary power source when electrical loads exceed the generator output current
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Ford Motor Company strongly recommends that lead-acid batteries be returned to an authorized recycling
facility for disposal.
Battery and Cables 3145

DIAGNOSIS AND TESTING Procedure revision date: 09/01/2009
Principles of Operation
Battery Eye Operation
The battery eye indicates the state-of-charge of the battery by responding to the specific gravity of a single
battery cell electrolyte. The battery eye has a viewing plate, 2 colored balls of different specific gravity and a
small passage. As the state-of-charge and specific gravity changes, the balls change their position in the
passageway and subsequently display a different color in the viewing eye. The primary purpose of the battery
is to be a quick indicator of state-of-charge for assembly plants and dealership pre-delivery processes.
The color of the battery eye indicates the approximate state-of-charge.
• Red - indicates low state-of-charge.

• Yellow/Black - indicates between high and low state-of-charge.
• Green - indicates high state-of-charge.
• No color can occur after the battery has been in service for several years and some of the plate
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material has coated the balls.
• A clear battery eye can occur if the battery case becomes damaged and the electrolyte has fallen
below the plates.
NOTE: The battery eye may remain red for a period of time (up to several days), even after the battery is
fully charged, because the acid is not yet fully mixed.
Do not install a new battery based solely on the indication of the battery eye. The battery eye color simply
indicates the battery state-of-charge, not its condition. For example, a red or yellow/black battery eye usually
indicates the battery is discharged, not defective. If the battery eye indicates the battery may be discharged, it
is necessary to recharge the battery before testing its condition.
Charging a Battery
Batteries discharge while the vehicle is on the dealer lot or parked by the customer for an extended period of
time due to normal parasitic key-off loads. Also, vehicles still in dealer inventory or in long-term storage may
be driven short distances with heavy electrical loads. Over a period of time (30 days or more), this could result
in vehicles having shallow or deeply discharged batteries.
• Deeply discharged - A battery that is drained over a prolonged period of time, such as an unsold
vehicle or a vehicle in storage, to the point the battery is dead.
• Shallow discharge - A battery that is drained by leaving an accessory on for several hours or a few
days and has a very low charge.
The vehicle charging system is designed to supply the electrical power needed to maintain the battery near full
charge during normal vehicle use. The charging system is not capable of bringing a deeply discharged battery
back to near full charge in a short amount of time such as allowing the vehicle to idle for 15 minutes to
"recharge the battery". Discharged batteries should be charged using an external charger.
NOTE: Battery chargers have improved greatly with the addition of the new generation pulse chargers. These
chargers pulse current into the battery, breaking down the sulfation layer on the battery plates and generally
reduce charging times to less than an hour.
NOTE: Cold batteries will not readily accept a charge. Therefore, batteries should be allowed to warm to
approximately 5°C (41°F) before charging. This may require 4 to 8 hours at room temperature.
Principles of Operation 3146

The following chart summarizes 2 recommended methods of charging.
Type of Battery
Discharge Pulse Charger Standard Charger
Deeply discharged Follow directions supplied with the 2 to 8 hours and may take up to an hour to
pulse charger accept initial charge
Shallow discharge 45 minutes to an hour charge 2 hours below (40A) on manual setting or
medium automatic setting
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Principles of Operation 3147

Inspection And Verification
1. Verify the customer concern.
2. Visually inspect for obvious signs of mechanical or electrical damage.
Visual Inspection Chart
Mechanical Electrical
• Battery • Battery
• Battery cables
mounting • Battery
posts
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3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before
proceeding to the next step.
4. If the fault is not visually evident, GO to Pinpoint Test A in the Pinpoint Test procedure.
Inspection And Verification 3148

Pinpoint Test
Special Tool(s)
GR 1 190 V3.0 Intelligent Diagnostic

Charger
162-00036 or equivalent
Pinpoint Test A: Battery Condition Test
Normal Operation
Battery condition is determined by measuring battery terminal voltage after a specific discharge current is
applied for a specified time period.
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This pinpoint test is intended to diagnose the following:
• Battery charge
• Battery
PINPOINT TEST A: BATTERY CONDITION TEST
Test Step Result / Action to Take

A1 TEST THE BATTERY
CONDITION
Yes
NOTE: A red test-eye indicates RETURN the battery to service.
the battery is discharged, not
necessarily defective. No
If the analyzer reads REPLACE BATTERY or
NOTE: Failure to fully charge REPLACE-BAD CELL, INSTALL a new battery. REFER to
the battery before retesting may Battery in this section.
cause false readings.
• Verify the battery condition using

the Intelligent Diagnostic
Charger.
• Is the battery OK?
Pinpoint Test 3149

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PINPOINT TEST A: BATTERY CONDITION TEST 3150

Component Test
Battery - Drain Tests
WARNING: Batteries contain sulfuric acid and produce explosive gases. Work in a well-ventilated
area. Do not allow the battery to come in contact with flames, sparks or burning substances. Avoid
contact with skin, eyes or clothing. Shield eyes when working near the battery to protect against
possible splashing of acid solution. In case of acid contact with skin or eyes, flush immediately with
water for a minimum of 15 minutes, then get prompt medical attention. If acid is swallowed, call a
physician immediately. Failure to follow these instructions may result in serious personal injury.
NOTICE: To prevent damage to the meter, do not crank the engine or operate accessories that draw
more than 10A.
NOTE: No factory-equipped vehicle should have more than a 50 mA (0.050 amp) draw.
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Check for current drains on the battery in excess of 50 mA (0.050 amp) with all the electrical accessories off
and the vehicle at rest for at least 40 minutes. Current drains can be tested with the following procedure.
NOTE: Many electronic modules draw 10 mA (0.010 amp) or more continuously.
NOTE: Typically, a drain of approximately 1 amp is attributed to an engine compartment lamp, glove
compartment lamp or interior lamp staying on continually. Other component failures or wiring shorts are
located by selectively pulling fuses to pinpoint the location of the current drain. When the current drain is
found, the meter reading falls to an acceptable level. If the drain is still not located after checking all the fuses,
it may be due to the generator. Disconnect the generator and retest.
NOTE: To accurately test the drain on a battery, an in-line ammeter must be used between the negative
battery post and its respective cable. Use of a test lamp or voltmeter is not an accurate method.
1. Drive the vehicle at least 5 minutes and over 48 km/h (30 mph) to turn on and activate the vehicle
systems.
2. After driving the vehicle and before testing, make sure the junction box(es)/fuse panel(s) is accessible
without turning on the interior lights or the underhood lights.
3. Allow the vehicle to sit with the key out of the ignition for at least 40 minutes to allow the modules to
time out/power down.
4. Connect a fused jumper wire (30A) between the negative battery cable and the negative battery post
to prevent modules from resetting.
5. Disconnect the negative battery cable from the negative battery post without breaking the connection
of the jumper wire.
6. NOTE: It is very important that continuity is not broken between the battery and the negative battery
cable when connecting the meter. If this happens, the entire 40-minute procedure must be repeated.
Connect the battery tester between the negative battery cable and the post. The meter must be capable
of reading milliamps and should have a 10-amp capability.
Component Test 3151

7. NOTE: If the meter settings need to be switched or the test leads need to be moved to another jack,
the jumper wire must be reinstalled to avoid breaking continuity.
Remove the jumper wire.
8. Note the amperage draw. Draw varies from vehicle to vehicle depending on the equipment package.
Compare to a similar vehicle for reference.
NOTE: If the vehicle sits for an extended period of time and the battery drains, there is the possibility of a
control module staying alive and not going into sleep mode. If a module does stay alive, it can also result in
battery drain. If a module is suspect, isolate individual modules by disconnecting each module one at a time
and note if the excessive draw goes away.
NOTE: For vehicles equipped with aftermarket bodies or boxes which contain electrical connections,
disconnect the aftermarket to factory connections to isolate the body from the chassis.
9. If the current draw is excessive, remove the fuses from the Battery Junction Box (BJB) one at a time
and note the current drop. When the current level drops to an acceptable level after removing a fuse,
the circuit containing the excessive draw has been located. The excessive draw can be isolated by
continuing to pull sub system fuses. Do not reinstall the fuses until testing is finished. To correctly
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isolate each of the circuits, all of the fuses may need to be removed, then install one fuse and note the
amperage draw, remove the fuse and install the next fuse. Continue this process with each fuse.
• Once the main circuit is identified, continue to remove the fuses from the Smart Junction Box
(SJB) one at a time and note the current reading. Do not reinstall the fuses until testing is
finished. To correctly isolate each of the circuits, all of the fuses may need to be removed,
then install one fuse and note the amperage draw, remove the fuse and install the next fuse.
Continue this process with each fuse.
10. Check the wiring diagrams for any circuits that run from the battery without passing through the BJB
or the SJB . If the current draw is still excessive, disconnect these circuits until the draw is found.
Also, disconnect the generator electrical connections and retest if the draw cannot be located. The
generator may be internally shorted, causing the current drain.
Component Test 3152

GENERAL PROCEDURES Procedure revision date: 09/01/2009
Battery Disconnect
WARNING: Always deplete the backup power supply before repairing or installing any new front
or side air bag supplemental restraint system (SRS) component and before servicing, removing,
installing, adjusting or striking components near the front or side impact sensors or the restraints
control module (RCM). Nearby components include doors, instrument panel, console, door latches,
strikers, seats and hood latches. Refer to the Description and Operation portion of Section 501-20B for
location of the RCM and impact sensor(s). To deplete the backup power supply energy, disconnect the
battery ground cable and wait at least 1 minute. Be sure to disconnect auxiliary batteries and power
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supplies (if equipped). Failure to follow these instructions may result in serious personal injury or death
in the event of an accidental deployment.
WARNING: Always lift a plastic-cased battery with a battery carrier or with hands on opposite
corners. Excessive pressure on the battery end walls may cause acid to flow through the vent caps,
resulting in personal injury and/or damage to the vehicle or battery.
NOTE: When the battery is disconnected and connected, some abnormal drive symptoms may occur while
the vehicle relearns its adaptive strategy. The vehicle may need to be driven to relearn its strategy.
NOTE: When disconnecting the battery ground cable to interrupt power to the vehicle electrical system,
disconnect the battery ground cable only. It is not necessary to disconnect the positive battery cable.
1. Disconnect the battery ground cable.

• To connect, tighten to 6 Nm (53 lb-in).
2. Disconnect the battery positive cable.

3. Disconnect the positive battery cable.

4. To connect, reverse the disconnect procedure.
Battery Disconnect 3153

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Battery Disconnect 3154

REMOVAL AND INSTALLATION Procedure revision date: 09/01/2009
Battery and Battery Tray - Exploded View
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Item Part Number Description
1 10718 Battery hold-down bolt and clamp
2 10A687 Battery heat shield
3 10655 Battery
1. For additional information, refer to the procedures in this section.
Battery and Battery Tray - Exploded View 3155

Battery
Removal and Installation
WARNING: Always deplete the backup power supply before repairing or installing any new front
or side air bag supplemental restraint system (SRS) component and before servicing, removing,
installing, adjusting or striking components near the front or side impact sensors or the restraints
control module (RCM). Nearby components include doors, instrument panel, console, door latches,
strikers, seats and hood latches. Refer to the Description and Operation portion of Section 501-20B for
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location of the RCM and impact sensor(s). To deplete the backup power supply energy, disconnect the
battery ground cable and wait at least 1 minute. Be sure to disconnect auxiliary batteries and power
supplies (if equipped). Failure to follow these instructions may result in serious personal injury or death
in the event of an accidental deployment.
WARNING: Always lift a plastic-cased battery with a battery carrier or with hands on opposite
corners. Excessive pressure on the battery end walls may cause acid to flow through the vent caps,
resulting in personal injury and/or damage to the vehicle or battery.
NOTE: When the battery is disconnected and connected, some abnormal drive symptoms may occur while
the vehicle relearns its adaptive strategy. The vehicle may need to be driven to relearn its strategy.
1. Disconnect the battery. For additional information, refer to Battery Disconnect in this section.
2. Remove the battery hold-down bolt and clamp.

• To install, tighten to 12 Nm (106 lb-in).
3. Remove the battery heat shield (if equipped).
4. Remove the battery.
5. To install, reverse the removal procedure.
Battery 3156
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Battery 3157
Battery Cables - 2.3L
LH Battery Cable Connections
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1 W705661 Battery cable body ground terminal bolt
2 - Battery cable body ground terminal
3 - A/C cut-off switch connector (if equipped)
4 - Battery cable locators
5 14A003 Battery Junction Box (BJB) cover
6 W706199 BJB terminal nuts (2 required)
7 - BJB terminal
8 - Connector (to 14290)
9 - Connector (part of 14290)
10 - Battery cable fender well bracket
11 N802777 Battery cable fender well bracket bolt
LH Battery Cable Engine Connections
Battery Cables - 2.3L 3158


12 W500223 Battery cable engine bracket bolt
13 - Battery cable engine bracket
14 11N087 Starter solenoid terminal cover
15 W706414 Battery cable starter solenoid terminal nut
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16 - Battery cable starter solenoid terminal
17 N805320 Battery cable starter solenoid wire terminal nut
18 - Battery cable starter solenoid wire terminal
19 N802001 Battery cable engine ground terminal nut
20 - Battery cable engine ground terminal
21 - Battery cable locator
22 - Oil pressure switch connector
RH Battery Cable Engine Connections

24 - Battery cable locators (2 required)
25 W705790 Battery cable generator B+ terminal nut (early build)
25 W711953 Battery cable generator B+ terminal nut (late build)
LH Battery Cable Engine Connections 3159

26 - Battery cable generator B+ terminal

27 - Generator electrical connector
28 - A/C compressor electrical connector (if equipped)
29 14A280 Battery cable
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section
100-02 .
3. Remove the bolt and position the battery cable body ground terminal aside.
4. If equipped, disconnect the A/C cut-off switch connector.
5. Remove the 3 battery cable locators from the battery tray and fender.
6. Remove the Battery Junction Box (BJB) cover, remove the 2 nuts and position the BJB terminal
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aside.
7. Disconnect the battery cable connector located on the fender well.
8. Remove the bolt and position the battery cable fender well bracket aside.
9. Remove the bolt and position the battery cable engine bracket aside.
10. Remove the starter solenoid terminal cover.
11. Remove the nut and position the battery cable starter solenoid terminal aside.
12. Remove the nut and position the battery cable starter solenoid wire terminal aside.
13. Remove the nut and position the battery cable engine ground terminal aside.
• To install, tighten to 27 Nm (20 lb-ft).
14. Remove the battery cable locator from the starter stud bolt.
15. Disconnect the oil pressure switch connector.
16. Remove the battery cable locator from the bell housing bracket.
17. Remove the 2 battery cable locators from the engine oil level indicator tube bracket.
18. Position the generator B+ protective cover aside, remove the nut and position the battery cable
generator B+ terminal aside.
• To install, tighten to 8 Nm (71 lb-in) (early build).
• To install tighten to 17 Nm (150 lb-in) (late build).
RH Battery Cable Engine Connections 3160

19. Disconnect the generator electrical connector.
20. If equipped, disconnect the A/C compressor electrical connector.
21. Remove the battery cable.
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RH Battery Cable Engine Connections 3161

Battery Cables - 4.0L
LH Battery Cable Connections
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1 W705661 Battery cable body ground terminal bolt
2 - Battery cable body ground terminal
3 - A/C cut-off switch connector (if equipped)
4 - A/C compressor electrical connector (if equipped)
5 - Battery cable locators
6 - Connector (to 14290)
7 - Connector (part of 14290)
8 - Battery Junction Box (BJB) terminal
9 W706199 BJB terminal nuts (2 required)
10 14A003 BJB cover
LH Battery Cable Engine Connections
Battery Cables - 4.0L 3162

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11 - A/C compressor electrical connector
12 W506411 Battery cable shield assembly bolt
13 W506431 Battery cable engine bracket bolt
14 - Battery cable engine bracket
15 - Oil pressure switch connector
17 11N087 Starter solenoid terminal cover
18 W706414 Battery cable starter solenoid terminal nut
19 - Battery cable starter solenoid terminal
20 N805320 Battery cable starter solenoid wire terminal nut
21 - Battery cable starter solenoid wire terminal
22 N802001 Battery cable engine ground terminal nut
23 - Battery cable engine ground terminal
Battery Cable Generator Connections
LH Battery Cable Engine Connections 3163


24 - Battery cable locator (part of 14A280)
25 - Generator electrical connector (part of 14A280)
26 W711953 Battery cable generator B+ terminal nut
27 - Battery cable generator B+ terminal (part of 14A280)
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28 14300 Battery cables
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section
100-02 .
3. Remove the bolt and position the battery cable body ground terminal aside.
4. Release the 3 battery cable locators from the battery tray and fender.
5. Remove the Battery Junction Box (BJB) cover, remove the 2 nuts and position the BJB terminal
aside.
6. Disconnect the battery cable connector located on the fenderwell.
7. If equipped, disconnect the A/C compressor electrical connector.
8. If equipped, disconnect the A/C compressor cut-off switch connector.
9. Remove the bolt and position the battery cable engine bracket aside.
10. Disconnect the oil pressure switch electrical connector.
11. Release the battery cable locator.
12. Remove the starter solenoid terminal cover.
13. Remove the bolt and position the battery cable starter solenoid terminal aside.
Battery Cable Generator Connections 3164

14. Remove the nut and position the battery cable starter solenoid wire terminal aside.
15. Remove the nut and position the battery cable engine ground terminal aside.
16. Remove the bolt from the front of the LH cylinder head which holds the harness bracket in place.
17. Release the battery cable locator from the generator bracket.
18. Disconnect the generator electrical connector.
19. Position the generator B+ protective cover aside, remove the nut and position the battery cable
generator B+ terminal aside.
20. Remove the battery cable.
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Battery Cable Generator Connections 3165

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2010 Ranger Workshop Manual

measured at -18°C (0°F)

Description Nm lb-ft lb-in

Generator Pulley 3143

Generator Pulley 3144

Battery and Cables

Vehicles are equipped with a 12-volt, maintenance-free battery.

The battery and cable system consists of the following components:

• Engine cranking power source

Battery and Cables 3145

Battery Eye Operation

The color of the battery eye indicates the approximate state-of-charge.

• Red - indicates low state-of-charge.

Principles of Operation 3146

Principles of Operation 3147

Inspection And Verification

1. Verify the customer concern.

2. Visually inspect for obvious signs of mechanical or electrical damage.

Visual Inspection Chart

Inspection And Verification 3148

GR 1 190 V3.0 Intelligent Diagnostic

PINPOINT TEST A: BATTERY CONDITION TEST

Test Step Result / Action to Take

• Verify the battery condition using

Pinpoint Test 3149

PINPOINT TEST A: BATTERY CONDITION TEST 3150

Battery - Drain Tests

NOTE: Many electronic modules draw 10 mA (0.010 amp) or more continuously.

Component Test 3151

Remove the jumper wire.

Component Test 3152

1. Disconnect the battery ground cable.

2. Disconnect the battery positive cable.

3. Disconnect the positive battery cable.

4. To connect, reverse the disconnect procedure.

Battery Disconnect 3153

Battery Disconnect 3154

Battery and Battery Tray - Exploded View

1. For additional information, refer to the procedures in this section.

Battery and Battery Tray - Exploded View 3155

Removal and Installation

2. Remove the battery hold-down bolt and clamp.

3. Remove the battery heat shield (if equipped).

4. Remove the battery.

5. To install, reverse the removal procedure.

Battery Cables - 2.3L

LH Battery Cable Connections

LH Battery Cable Engine Connections

Battery Cables - 2.3L 3158

Item Part Number Description

RH Battery Cable Engine Connections

Item Part Number Description

LH Battery Cable Engine Connections 3159

26 - Battery cable generator B+ terminal

4. If equipped, disconnect the A/C cut-off switch connector.

7. Disconnect the battery cable connector located on the fender well.

10. Remove the starter solenoid terminal cover.

15. Disconnect the oil pressure switch connector.

RH Battery Cable Engine Connections 3160

19. Disconnect the generator electrical connector.

20. If equipped, disconnect the A/C compressor electrical connector.

21. Remove the battery cable.