Ford Ranger EV (2001 year). Manual - part 173

414-03B-88

414-03B-88

High Voltage/Traction Battery — Nickel Metal Hydride

GENERAL PROCEDURES (Continued)

Traction Battery Tray Repair

Battery Tray

414-03B-89

414-03B-89

High Voltage/Traction Battery — Nickel Metal Hydride

GENERAL PROCEDURES (Continued)

1. NOTE: The battery case consists of three main

elements: composite enclosure, metal brackets,
battery locators, and a battery tray seal. The
repair method differs based on what element is
affected. 
NOTE: The composite enclosure is a resin
transfer molded (RTM) glass-reinforced
thermoset plastic with an integral foam core. 
A minor resin split of scratch on the surface of
the composite enclosure does not need to be
repaired and will not affect the performance of
the traction battery case. A resin split can be
found on the radii or in smooth high gloss
areas.

2. NOTE: A crack in the composite enclosure is

more significant than a resin split and requires
repair or replacement of the battery tray. A
crack can be identified as a surface that is
separated or crushed exposing glass fiber ends
or foam core. 
A crack in the composite enclosure less than 25
mm (1 in) in length can also be repaired. If the
crack is longer than 25 mm (1 in), or the
damage passes all the way through the case, the
battery case must be replaced.

3. A scratch or split on the surface of the

composite enclosure does not need to be
repaired and will not affect the performance of
the traction battery. If the damage is visible, it
can be blended into the surrounding surface by
lightly sanding  the area.

414-03B-90

414-03B-90

High Voltage/Traction Battery — Nickel Metal Hydride

GENERAL PROCEDURES (Continued)

4. To repair cracks less than 25 mm (1 in) in

length, clean the area surrounding the damage
prior to repair. After cleaning, grind a 20
degree bevel extending 40 to 50 mm (1.57 to 2
in) around the damage.

414-03B-91

414-03B-91

High Voltage/Traction Battery — Nickel Metal Hydride

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. Seal repaired area with catalyzed resin and a

thin ply of glass. Allow the surface resin to
cure 1.5 to 2 hours at 24

°

C (75

°

F). Blend the

repaired area to the surrounding material.

Metal Bracket Replacement

1. Make locating marks to indicate the position of

the damaged bracket or locator.