Ford Ranger EV (2001 year). Manual - part 136

414-03A-140

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High Voltage/Traction Battery

REMOVAL AND INSTALLATION (Continued)

Installation

1. The battery module replacement procedure also

contains the battery module installation.

2. Install battery modules 17-18.

•

Use the Battery Module Lifting Tool to
install the battery modules.

•

Install and tighten new battery module nuts
using the Battery Post Torque Wrench.

•

Install the separator plates.

•

Connect the heating element connectors.

•

Clip the connectors into the separator plate.

3. Fill the area around the high-voltage jumper

nuts with Nyogel.

Traction Battery Module — Modules 22-24

Special Tool(s)

Battery Module Lifting Tool

SR-10009

Battery Post Torque Wrench

307-026

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High Voltage/Traction Battery

REMOVAL AND INSTALLATION (Continued)

Removal

1. Remove the battery control module (BCM).

Refer to 

Battery Control Module (BCM)

.

2.

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.

3. Remove battery modules 17-21.

•

Unclip and disconnect the heating element
electrical connectors.

•

Remove the separator plates.

•

Remove and discard the high-voltage jumper
retaining nuts.

•

Use the Battery Module Lifting Tool to
remove the battery modules.

4. Replace the faulty battery module(s). Refer to

Traction Battery Module Replacement

.

Installation

1. The battery module replacement procedure

contains the battery module installation.

2. Install battery modules 17-21.

•

Use the Battery Module Lifting Tool to
install the battery modules.

•

Install and tighten new battery module nuts
using the Battery Post Torque Wrench.

•

Install the separator plates.

•

Connect the heating element connectors.

•

Clip the connectors into the separator plate.

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High Voltage/Traction Battery

REMOVAL AND INSTALLATION (Continued)

3. Fill the area around the high-voltage jumper

nuts with Nyogel.

4. Install the BCM. Refer to 

Battery Control

Module (BCM)

.

Traction Battery Temperature Sensor — Modules 22-24

Removal

1. The #1 temperature sensor is located on the

negative side of the #17 traction battery
module. To remove the temperature sensor,
remove traction battery module #17. Refer to
Traction Battery Module — Modules17-18.

2. The #2 temperature sensor is located on the

negative side of the #6 traction battery module.
To remove the temperature sensor, remove
traction battery module #6. Refer to Traction
Battery Module — Modules17-18.

3. The #3 temperature sensor is located on the

positive side of the #26 traction battery module.
To remove the temperature sensor, remove
traction battery module #26. Refer to Traction
Battery Module — Modules 16, 25-27.

4. The #4 temperature sensor is located on the

positive side of the #31 traction battery module.
To remove the temperature sensor, remove
traction battery module #31. Refer to Traction
Battery Module — Modules 12-15,  28-31.

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High Voltage/Traction Battery

REMOVAL AND INSTALLATION (Continued)

5.

CAUTION: Do not use excessive force

to remove the temperature sensor or damage
to the battery module may occur. 
NOTE: If the sensor is difficult to remove,
warm it using a heat gun. Be careful not to
overheat the sensor or the battery module, or
damage to both may occur. 
Remove the temperature sensor.

•

Pull the bottom of the temperature sensor
from the battery module and remove the
sensor.

Installation

1. Apply a thin coat of thermal grease to the back

of the thermistor.

2. The traction battery temperature sensors are

mounted on the side of the battery modules. To
install the temperature sensors, reverse the
removal procedure for the battery module on
which the sensor is located. Refer to the
appropriate Traction Battery Module procedure.