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Ford Ranger EV (2001 year). Manual - part 91

413-01-8

Instrument Cluster

DIAGNOSIS AND TESTING (Continued)

Symptom Chart

Condition

Possible Sources

Action

•

Speedometer, Malfunction

•

Fuse 1 (10A) (I/P fuse panel).

•

CHECK 10A fuse 1.

Indicator Lamp (MIL), Power

•

Circuit 742 (LB wire).

REPLACE if necessary. If

Reset Indicator, Charge

OK, REPAIR circuit 742 (LB

Indicator, Auxiliary Battery

wire).

Warning Indicator, Power

Limit Warning Indicator, Low

Oil Pressure Warning

Indicator, Electrical Hazard

Warning Indicator, and Door

Ajar Indicator Do Not

Operate

•

Speedometer, Economy

•

Fuse 15 (7.5A) (I/P fuse

•

CHECK fuse 15. REPLACE

Gauge, Low State of Charge

panel).

if necessary. If OK, CHECK

(SOC) Indicator, Brake

•

Circuit 584 (Y wire).

power (with key ON) to pin 4

Warning Indicator, Air Bag

•

Instrument cluster.

(Y wire) on instrument cluster

Warning Indicator, Seat Belt

C216. If no power, REPAIR

Indicator, and Anti-lock

circuit 584 (Y wire). If OK,

Brake System (ABS) Warning

REPLACE the instrument

Indicator Do Not Operate

cluster.

•

Speedometer, Economy

•

Circuit 570 (BK/W wire).

•

CHECK circuit 570 (BK/W)

Gauge, Motor Enabled

•

Instrument cluster.

for open. REPAIR if

Gauge, Traction Battery State

necessary. If OK, REPLACE

of Charge (SOC) Gauge,

the instrument cluster.

Distance To Empty (DTE)

Gauge, and Temperature

Gauge Do Not Operate

•

Temperature Gauge Indicates

•

Interface adapter assembly

•

GO to

Pinpoint Test A.

Way Above the H (Hot)

(IAA) module.

Mark, Distance To Empty

•

Circuit.

(DTE) Gauge Indicates Below

the Miles Mark, Traction

Battery State of Charge

(SOC) Gauge Indicates Way

Above the F (Full) Mark, and

the Motor Enabled Gauge

Indicates Way Above the

ON Mark

•

Speedometer Operates, But

•

Speedometer.

•

REPLACE the instrument

Odometer Does Not Operate

cluster.

•

Speedometer Does Not

•

Instrument cluster.

•

GO to

Pinpoint Test B.

Operate or Indicates Incorrect

•

Traction inverter module

Vehicle Speed

(TIM).

•

Circuit(s).

•

DTC B1834 Gauge Drive

•

Circuit(s).

•

CHECK circuits 3406

Current Fault

•

Instrument cluster.

(DG/LG wire), 3048 (O

wire), and 3408 (DB/O wire)

for short(s) to ground.

REPAIR as necessary. If OK,

REPLACE the instrument

cluster.

413-01-9

Instrument Cluster

DIAGNOSIS AND TESTING (Continued)

Symptom Chart (Continued)

Condition

Possible Sources

Action

•

Traction Battery State of

•

Instrument cluster.

•

GO to

Pinpoint Test C.

Charge (SOC) Gauge Does

•

Interface adapter assembly

Not Operate, Indicates

(IAA) module.

Incorrect SOC, or Always

•

Circuit(s).

Indicates F (Full)

•

Temperature Gauge Does Not

•

Instrument cluster.

•

GO to

Pinpoint Test D.

Operate Properly or Always

•

Interface adapter assembly

Indicates H (Hot)

(IAA) module.

•

Circuit(s).

•

Economy Gauge Does Not

•

Instrument cluster.

•

GO to

Pinpoint Test E.

Operate Properly or Always

•

Interface adapter assembly

Indicates + (Positive)

(IAA) module.

•

Circuit(s).

•

Distance To Empty (DTE)

•

Instrument cluster.

•

GO to

Pinpoint Test F.

Gauge Does Not Operate or

•

Interface adapter assembly

Indicates Incorrect Distance

(IAA) module.

to Empty

•

Circuit(s).

•

Motor Enabled Gauge Does

•

Interface adapter assembly

•

GO to

Pinpoint Test G.

Not Operate or Indicates Way

(IAA) module.

Above the ON Mark

•

Circuit(s).

•

Instrument cluster.

•

Malfunction Indicator Lamp

•

Interface adapter assembly

•

GO to

Pinpoint Test H.

(MIL) Does Not Operate or

(IAA) module.

Stays On Continuously

•

Bulb.

•

Circuit(s).

•

Instrument cluster.

•

Power Reset Indicator Does

•

Interface adapter assembly

•

GO to

Pinpoint Test J.

Not Operate or Stays On

(IAA) module.

Continuously

•

Bulb.

•

Circuit(s).

•

Instrument cluster.

•

Charging Indicator Does Not

•

Interface adapter assembly

•

GO to

Pinpoint Test K.

Operate or Stays On

(IAA) module.

Continuously

•

Bulb.

•

Circuit(s).

•

Instrument cluster.

•

Economy Mode Indicator

•

Interface adapter assembly

•

GO to

Pinpoint Test L.

Does Not Operate or Stays

(IAA) module.

On Continuously

•

Bulb.

•

Circuit(s).

•

Instrument cluster.

•

Auxiliary Battery Indicator

•

Interface adapter assembly

•

GO to

Pinpoint Test M.

Does Not Operate or Stays

(IAA) module.

On Continuously

•

Bulb.

•

Circuit(s).

•

Instrument cluster.

•

Power Limit Warning

•

Interface adapter assembly

•

GO to

Pinpoint Test N.

Indicator Does Not Operate

(IAA) module.

or Stays On Continuously

•

Bulb.

•

Circuit(s).

•

Instrument cluster.

413-01-10

Instrument Cluster

DIAGNOSIS AND TESTING (Continued)

Symptom Chart (Continued)

Condition

Possible Sources

Action

•

Low Oil Pressure Warning

•

Interface adapter assembly

•

GO to

Pinpoint Test P.

Indicator Does Not Operate

(IAA) module.

or Stays On Continuously

•

Bulb.

•

Circuit(s).

•

Instrument cluster.

•

Electrical Hazard Warning

•

Interface adapter assembly

•

GO to

Pinpoint Test Q.

Indicator Does Not Operate

(IAA) module.

or Stays On Continuously

•

Bulb.

•

Circuit(s).

•

Instrument cluster.

•

Low State of Charge (SOC)

•

Interface adapter assembly

•

GO to

Pinpoint Test R.

Indicator Does Not Operate

(IAA) module.

or Stays On Continuously

•

Bulb.

•

Circuit(s).

•

Instrument cluster.

•

Red Brake Warning Indicator

•

Interface adapter assembly

•

GO to

Pinpoint Test S.

Does Not Operate or Stays

(IAA) module.

On Continuously

•

Bulb.

•

Circuit(s).

•

Instrument cluster.

•

Brake fluid level switch.

•

Park brake switch.

•

Hi Beam Indicator Does Not

•

Circuit(s).

•

GO to

Pinpoint Test T.

Operate

•

Bulb.

•

Instrument cluster.

•

Left Turn Indicator Does Not

•

Circuit(s).

•

GO to

Pinpoint Test U.

Operate

•

Bulb.

•

Instrument cluster.

•

Right Turn Indicator Does

•

Circuit(s).

•

GO to

Pinpoint Test V.

Not Operate

•

Bulb.

•

Instrument cluster.

•

Instrument Cluster

•

Circuit(s).

•

GO to

Pinpoint Test W.

Illumination Lamps Do Not

•

Bulb.

Operate

•

Instrument cluster.

•

Anti-Lock Brake System

•

Anti-lock brake control

•

GO to

Pinpoint Test X.

(ABS) Warning Indicator

module.

Does Not Operate

•

Bulb.

•

Circuit(s).

•

Instrument cluster.

•

Anti-Lock Brake System

•

Anti-lock brake system

•

REFER to

Section 206-09.

(ABS) Warning Indicator

(ABS).

Stays On Continuously

•

Air Bag Indicator Does Not

•

Air bag diagnostic monitor.

•

REFER to Section 501-20B

Operate

•

Bulb. of the 2001 Ranger Workshop

•

Circuit(s). Manual.

•

Instrument cluster.

•

Air Bag Indicator Stays On

•

Circuit(s).

•

REFER to Section 501-20B

Continuously

•

Air bag diagnostic monitor. of the 2001 Ranger Workshop

Manual.

•

Door Ajar Indicator Does Not

•

Generic electronic module

•

GO to

Pinpoint Test Y.

Operate Properly

(GEM).

•

Bulb.

•

Instrument cluster.

•

Circuit(s).

413-01-11

Instrument Cluster

DIAGNOSIS AND TESTING (Continued)

Symptom Chart (Continued)

Condition

Possible Sources

Action

•

Seat Belt Indicator Does Not

•

Generic electronic module

•

GO to

Pinpoint Test Z.

Operate Properly

(GEM).

•

Bulb.

•

Instrument cluster.

•

Circuit(s).

Pinpoint Tests

Special Tool(s)

104-Pin Breakout Box (BOB) 418-049 (014-00950) or

equivalent

BCM/TIM Breakout Box (BOB) Adapter Cable

418-F212

BCM/TIM Breakout Box (BOB) Overlay 418-F220

PINPOINT TEST A: TEMPERATURE GAUGE INDICATES WAY ABOVE THE H (HOT) MARK, DISTANCE
TO EMPTY (DTE) GAUGE INDICATES BELOW THE MILES MARK, TRACTION BATTERY STATE OF
CHARGE (SOC) GAUGE INDICATES WAY ABOVE THE F (FULL) MARK, AND THE MOTOR ENABLED
GAUGE INDICATES WAY ABOVE THE ON (MARK)

TEST STEP

ACTION TO TAKE

A1 CHECK INTERFACE ADAPTER ASSEMBLY (IAA) MODULE

•

Connect 104-Pin Breakout Box (BOB) to the IAA module and IAA

Yes =

REPAIR circuit 3049

module C1945.

(BK/LG wire).

•

With key ON, measure the voltage between BOB pin 41 and ground

No =

REPLACE the IAA module.

(BOB pin 80). REFER to

Section 412-04.

•

Is the voltage greater than 10 volts?

PINPOINT TEST B: SPEEDOMETER DOES NOT OPERATE OR INDICATES INCORRECT VEHICLE SPEED

TEST STEP

ACTION TO TAKE

B1 IDENTIFY SYMPTOM

•

Enter the traction inverter module (TIM) active command mode

Yes =

GO to B2.

SPEEDOMETER CONTROL and set the active command SPDOMETER

to 30%.

•

Does the speedometer indicate greater than 0 mph?

No =

GO to B3.

B2 CHECK SPEEDOMETER FOR CORRECT SPEED

•

Set the active command SPDOMETER to the following percentages and

Yes =

System OK. CHECK wiring

verify the speedometer operation:

for intermittent connections.

Percentage/Speed

No =

REPLACE the instrument

cluster.

— 10% = 16-21 km/h (10-13 mph)
— 20% = 29-34 km/h (18-21 mph)
— 30% = 43-48 km/h (27-30 mph)
— 40% = 60-64 km/h (37-40 mph)
— 50% = 72-77 km/h (45-48 mph)
— 60% = 87-92 km/h (54-57 mph)
— 70% = 100-105 km/h (62-65 mph)

•

Is the speedometer OK?

B3 CHECK TRACTION INVERTER MODULE (TIM)

•

Connect 104-Pin Breakout Box (BOB) to the TIM and TIM C4998,

Yes =

GO to B6.

C4999 using the BCM/TIM BOB Adapter Cable and Overlay.

(Continued)

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