Ford Ranger EV (2001 year). Manual - part 145

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High Voltage/Traction Battery

DISASSEMBLY AND ASSEMBLY (Continued)

NOTE: The temperature sensor harness feeds up
through the space between the separators. 

NOTE: The HVJ wiring that runs between the
battery modules must fit into the separators. 

28. Install the front separator plates.

29. NOTE: The rear separator can be identified by

the velcro strips on the right-hand side. These
strips are for holding the contactor box in
position. 
Install the rear separator plates.

30. Use a heat gun to warm the temperature sensor

prior to installation.

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

of the thermistor.

32.

CAUTION: Do not use excessive force

to install the temperature sensor, or damage
to the module may occur. 
Install a temperature sensor on the - (negative)
terminal side of battery modules 16 and 17.
1 Position the temperature sensor prongs into

the holes in the battery module.

2 Clip the temperature sensor into the pin on

the battery module.

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High Voltage/Traction Battery

DISASSEMBLY AND ASSEMBLY (Continued)

33. The upper battery module heating elements are

adhesive backed and are positioned on the
battery modules as illustrated in the following
steps.

NOTE: The battery modules must be installed with
the terminals oriented correctly. Verify correct
installation. 

34. Install the upper front battery modules.

1 Apply the heating element to battery

module 21 on the side facing out, and
install the battery module.

2 Apply the heating element to battery

module 20 on the side facing battery
module 21, and install the battery module.

3 Apply the heating element to battery

module 19 on the side facing out, and
install the battery module.

4 Connect the heating element electrical

connectors.

X

Connect the battery module 19 male
connector to the battery module 20
female connector.

X

Connect the battery module 20 male
connector to the battery module 21
female connector.

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High Voltage/Traction Battery

DISASSEMBLY AND ASSEMBLY (Continued)

35. Install the upper front battery modules.

1 Apply the heating element to battery

module 17 on the side facing out, and
install the battery module.

2 Apply the heating element to battery

module 18 on the side facing out, and
install the battery module.

3 Connect the heating element electrical

connectors.

X

Connect the battery module 19 female
connector to the battery module 18 male
connector.

X

Connect the battery module 18 female
connector to the battery module 17 male
connector.

36. Install the upper rear battery modules.

1 Apply the heating element to battery

module 1 on the side facing out, and install
the battery module.

2 Apply the heating element to battery

module 6 on the side facing battery module
1, and install the battery module.

3 Apply the heating element to battery

module 7 on the side facing out, and install
the battery module.

4 Connect the heating element electrical

connectors.

X

Connect the battery module 1 female
connector to the battery module 6 male
connector.

X

Connect the battery module 6 female
connector to the battery module 7 male
connector.

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High Voltage/Traction Battery

DISASSEMBLY AND ASSEMBLY (Continued)

37. Install the remaining upper rear battery

modules.
1 Apply the heating element to battery

module 2 on the side facing out, and install
the battery module.

2 Apply the heating element to battery

module 3 on the side facing battery module
2, and install the battery module.

3 Apply the heating element to battery

module 4 on the side facing battery module
3, and install the battery module.

4 Apply the heating element to battery

module 5 on the side facing out, and install
the battery module.

5 Connect the heating element electrical

connectors.

X

Connect the battery module 2 male
connector to the battery module 3 female
connector.

X

Connect the battery module 3 male
connector to the battery module 4 female
connector.

X

Connect the battery module 4 male
connector to the battery module 5 female
connector.