Ford Ranger EV (2001 year). Manual - part 125

414-03A-96

High Voltage/Traction Battery

GENERAL PROCEDURES (Continued)

5. Immediately after grinding, apply the repair

patch. Cut a piece of glass mat that will extend
25 mm (1 in) beyond the damaged area.
Prepare a mixture of vinyl ester resin and soak
the glass mat in it. Lay the resin soaked glass
mat over the damaged area and smooth out the
patch using a spreader. The patch should lay on
the surface of the composite member as
illustrated.

6. Allow the patched area to cure for at least 1.5

to 2 hours at 24

C (75

F). Curing will take

longer at colder temperatures. A heat lamp
placed no less than 45 cm (18 in) from the
repair for approximately 15 minutes will help
decrease cure time. After the patch has cured,
grind the repair until it is flush with the
surrounding area.

7. Cut a piece of glass mat that is 25 mm (1 in)

larger than the entire repair area. Prepare a
mixture of catalyzed resin and soak the glass
mat in it. Lay the resin soaked mat over the
patched area and smooth it out with a spreader.

414-03A-97

High Voltage/Traction Battery

GENERAL PROCEDURES (Continued)

8. Allow the patched area to cure for at least 1.5

to 2 hours at 24

C (75

F). Curing will take

longer at colder temperatures. A heat lamp
placed no less than 45 cm (18 in) from the
repair for approximately 15 minutes will help
decrease cure time. After curing, lightly sand
the repaired area to smooth and blend it into
the surrounding material.

Metal Bracket and Battery Locator
Replacement

1. Remove the damaged bracket or locator using a

heat gun positioned at least 150 mm (6 in) from
the part being removed. The gun will heat the
adhesive and allow the part to be removed.
Keep the gun moving over the part in order to
prevent exposing the composite material to
excessive heat. Once the adhesive softens, the
part can be removed and discarded.

2. Scrape and sand off all of the remaining

adhesive. The surface must be clean and
roughly sanded for proper adhesion.

3. Clean the area with alcohol.

4. Prepare a mixture of Pilogrip urethane adhesive

and apply it to the bonding area.

5. Position a new bracket or locator. The adhesive

should be 1-2 mm (0.04-0.08 in) thick for
proper bonding. Do not squeeze out excessive
amounts of the adhesive or the bond may fail.

6. Allow the adhesive to cure for 1 hour at 24

(75

F). After curing, excess adhesive may be

trimmed using a sharp knife.

Battery Tray Seal

1. The seal surrounds the entire battery tray to

prevent moisture in the battery case. Minor
splits or gouges within the seal will not affect
the performance of the traction battery.
Significant rips or tears require replacement of
the seal.

414-03A-98

High Voltage/Traction Battery

GENERAL PROCEDURES (Continued)

2. Remove damaged seal by pealing it away from

the battery tray.

3. Scrape away any remaining seal pieces stuck to

the battery tray.

4. Clean the area with alcohol.

5. Place the new seal on the battery tray by

pealing back the white strip to expose the
adhesive. Start at one end of the seal to
maintain a good fit.

6. Press down continuously along the entire length

of the seal to ensure a good bond to the surface
of the battery tray.

REMOVAL AND INSTALLATION

Battery Control Module (BCM)

Removal

1. Remove the traction battery. Refer to

Traction

Battery

2. Remove the traction battery cover.

1 Remove the 22 bolts.
2 Remove the cover.

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High Voltage/Traction Battery

REMOVAL AND INSTALLATION (Continued)

WARNING: The nominal voltage of

the traction battery is 312 volts. The buffer
zone must be set up and insulated rubber
gloves and a face shield must be worn.
Failure to follow these precautions may
result in severe personal injury or death.
Observe the EV-specific precautions. Refer to

Section 100-00

1 Set up the buffer zone.
2 Test and wear the insulated rubber gloves.
3 Wear the face shield.

4. Remove the contactor box harness bracket.

5. NOTE: The battery control module (BCM) is

held in position with strips of Velcro

Remove the BCM.
1 Loosen the four bolts and disconnect the

four multi-pin connectors from the BCM.

2 Remove the BCM.

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