Index to Ford Transit Workshop Manual 2001-2006

BDC for Manuals - specs - Bolt torques https://barringtondieselclub.co.za/

2004.75 Transit

Workshop ManualTable of ContentsGROUP 1 General Information

Service InformationGeneral Information 100-00Identification Codes 100-01Jacking and Lifting 100-02Noise, Vibration andHarshness 100-04

GROUP 2 Chassis

SuspensionSuspension System - GeneralInformation 204-00

Front Suspension 204-01Rear Suspension 204-02Wheels and Tires 204-04Vehicle Dynamic Suspension 204-05DrivelineDriveline System - GeneralInformation 205-00

Driveshaft 205-01Rear Drive Axle/Differential 205-02AWheel Hubs and Bearings - Full FloatingAxle 205-02B

Front Drive Halfshafts 205-04Brake SystemBrake System - GeneralInformation 206-00

Drum Brake 206-02Front Disc Brake 206-03Parking Brake and Actuation 206-05AParking Brake and Actuation - VehiclesWith: Parking Brake Assist 206-05B

Hydraulic Brake Actuation 206-06Power Brake Actuation 206-07Anti-Lock Control 206-09

Steering SystemSteering System - GeneralInformation 211-00

Power Steering 211-02Steering Linkage 211-03Steering Column 211-04Steering Column Switches 211-05

GROUP 3 Powertrain

EngineEngine System - GeneralInformation 303-00

Engine - 2.4L Duratorq-TDCi (Puma)Diesel/2.4L Duratorq-Di (Puma)Diesel 303-01A

Engine - 2.0L Duratorq-TDCi (Puma)Diesel/2.0L Duratorq-Di (Puma)Diesel/2.0L Duratorq-TDDi (Puma)Diesel 303-01B

Engine - 2.3L DOHC-16V 303-01CEngine Cooling 303-03Fuel Charging and Controls - 2.4LDuratorq-Di (Puma) Diesel 303-04A

Fuel Charging and Controls - 2.0LDuratorq-Di (Puma) Diesel/2.0LDuratorq-TDDi (Puma)Diesel 303-04B

Fuel Charging and Controls - 2.3LDOHC-16V 303-04C

Fuel Charging and Controls -Turbocharger 303-04D

Fuel Charging and Controls - 2.0LDuratorq-TDCi (Puma)Diesel 303-04F

Fuel Charging and Controls - 2.4LDuratorq-TDCi (Puma)Diesel 303-04G

Accessory Drive 303-05Starting System 303-06

2004.75 Transit BDC for Manuals - specs - Bolt torques

https://barringtondieselclub.co.za/

Glow Plug System - 2.4L Duratorq-TDCi(Puma) Diesel/2.4L Duratorq-Di(Puma) Diesel 303-07A

Glow Plug System - 2.0L Duratorq-TDCi(Puma) Diesel/2.0L Duratorq-Di(Puma) Diesel/2.0L Duratorq-TDDi(Puma) Diesel 303-07B

Engine Ignition - 2.3LDOHC-16V 303-07C

Engine Emission Control 303-08Intake Air Distribution andFiltering 303-12

Evaporative Emissions 303-13Electronic Engine Controls 303-14Manual Transmission/Transaxle, Clutch andTransfer CaseManual Transmission/Transaxle andClutch - General Information 308-00

Clutch - Vehicles With: MT-75 308-01AClutch - Vehicles With:VXT-75 308-01B

Clutch - Vehicles With: MT82 308-01CClutch Controls - Vehicles With:MT-75 308-02A

Clutch Controls - Vehicles With:VXT-75 308-02B

Clutch Controls - Vehicles With:MT82 308-02C

Manual Transmission/Transaxle -Vehicles With: MT-75 308-03A

Manual Transmission/Transaxle -Vehicles With: VXT-75 308-03B

Manual Transmission/Transaxle -Vehicles With: MT82 308-03C

Manual Transmission/TransaxleExternal Controls - Vehicles With:MT-75 308-06A

Manual Transmission/TransaxleExternal Controls - Vehicles With:VXT-75 308-06B

Manual Transmission/TransaxleExternal Controls - Vehicles With:MT82 308-06C

Manual Transmission/TransaxleAutomated Gearshift System 308-11

Exhaust SystemExhaust System 309-00Fuel SystemFuel System - GeneralInformation 310-00

Fuel Tank and Lines 310-01Acceleration Control - 2.0LDuratorq-TDCi (Puma) Diesel/2.4LDuratorq-TDCi (Puma) Diesel/2.0LDuratorq-Di (Puma) Diesel/2.0LDuratorq-TDDi (Puma) Diesel/2.4LDuratorq-Di (Puma) Diesel 310-02A

Acceleration Control - 2.3LDOHC-16V 310-02B

GROUP 4 Electrical

Climate Control SystemClimate Control System - GeneralInformation 412-00

Air Distribution and Filtering 412-01Heating and Ventilation 412-02AAuxiliary Heating 412-02BAir Conditioning 412-03AAuxiliary Climate Control 412-03BControl Components 412-04Instrumentation and Warning SystemsInstrument Cluster and PanelIllumination 413-00

Instrument Cluster 413-01Horn 413-06Clock 413-07Parking Aid 413-13Battery and Charging SystemCharging System - GeneralInformation 414-00

Battery, Mounting and Cables 414-01Generator and Regulator 414-02Information and Entertainment SystemsInformation and Entertainment System- General Information 415-00

Audio Unit 415-01Antenna 415-02Speakers 415-03LightingExterior Lighting 417-01Interior Lighting 417-02Electrical DistributionModule CommunicationsNetwork 418-00

Module Configuration 418-01Electronic Feature GroupAnti-Theft - Active 419-01AAnti-Theft - Passive 419-01B

2004.75 Transit BDC for Manuals - specs - Bolt torques

https://barringtondieselclub.co.za/

Multifunction ElectronicModules 419-10

GROUP 5 Body and Paint

Body and PaintBody System - GeneralInformation 501-00

Front End Body Panels 501-02Body Closures 501-03Interior Trim andOrnamentation 501-05

Exterior Trim andOrnamentation 501-08

Rear View Mirrors 501-09Seating 501-10Glass, Frames andMechanisms 501-11

Instrument Panel and Console 501-12

Handles, Locks, Latches and EntrySystems 501-14

Wipers and Washers 501-16Roof Opening Panel 501-17Bumpers 501-19Safety Belt System 501-20ASupplemental RestraintSystem 501-20B

Body Repairs - GeneralInformation 501-25

Body Repairs - Vehicle SpecificInformation and ToleranceChecks 501-26

Front End Sheet Metal Repairs 501-27Side Panel Sheet MetalRepairs 501-29

Rear End Sheet Metal Repairs 501-30Frame and MountingUni-Body, Subframe and MountingSystem 502-00

2004.75 Transit BDC for Manuals - specs - Bolt torques

https://barringtondieselclub.co.za/

To the best of our knowledge, the illustrations,technical information, data and descriptions inthis issue were correct at the time of going toprint. The right to change prices, specifications,equipment and maintenance instructions atany time without notice is reserved as part ofFORD policy of continuous development andimprovement for the benefit of our customers.

No part of this publication may be reproduced,stored in a data processing system ortransmitted in any form, electronic, mechanical,photocopy, recording, translation or by anyother means without prior permission ofFord-Werke Aktiengesellschaft. No liability canbe accepted for any inaccuracies in thispublication, although every possible care hasbeen taken to make it as complete andaccurate as possible.

Copyright ©

FORD-WERKE AKTIENGESELLSCHAFT

Service training programs D-F/GT-1

Printed in Germany - rewi druckhaus, Wissen-

Printed on environmentally friendlychlorine-free paper. (GB)

2004.75 Transit BDC for Manuals - specs - Bolt torques

https://barringtondieselclub.co.za/

GROUP

General Information 1SECTION TITLE PAGE

Service InformationGeneral Information.......................................................................................................100-00Identification Codes.......................................................................................................100-01Jacking and Lifting.........................................................................................................100-02Noise, Vibration and Harshness....................................................................................100-04

2004.75 Transit BDC for Manuals - specs - Bolt torques

https://barringtondieselclub.co.za/

GROUP

Chassis 2SECTION TITLE PAGE

SuspensionSuspension System - General Information....................................................................204-00Front Suspension...........................................................................................................204-01Rear Suspension...........................................................................................................204-02Wheels and Tires...........................................................................................................204-04Vehicle Dynamic Suspension.........................................................................................204-05

DrivelineDriveline System - General Information.........................................................................205-00Driveshaft.......................................................................................................................205-01Rear Drive Axle/Differential............................................................................................205-02AWheel Hubs and Bearings - Full Floating Axle..............................................................205-02BFront Drive Halfshafts....................................................................................................205-04

Brake SystemBrake System - General Information..............................................................................206-00Drum Brake....................................................................................................................206-02Front Disc Brake............................................................................................................206-03Parking Brake and Actuation.........................................................................................206-05AParking Brake and ActuationVehicles With: Parking Brake Assist................................206-05BHydraulic Brake Actuation..............................................................................................206-06Power Brake Actuation..................................................................................................206-07Anti-Lock Control...........................................................................................................206-09

Steering SystemSteering System - General Information..........................................................................211-00Power Steering...............................................................................................................211-02Steering Linkage............................................................................................................211-03Steering Column............................................................................................................211-04Steering Column Switches.............................................................................................211-05

2004.75 Transit BDC for Manuals - specs - Bolt torques

https://barringtondieselclub.co.za/

GROUP

Powertrain 3SECTION TITLE PAGE

EngineEngine System - General Information............................................................................303-00Engine2.4L Duratorq-TDCi (Puma) Diesel/2.4L Duratorq-Di (Puma) Diesel.................303-01AEngine2.0L Duratorq-TDCi (Puma) Diesel/2.0L Duratorq-Di (Puma) Diesel/2.0LDuratorq-TDDi (Puma) Diesel....................................................................................303-01B

Engine2.3L DOHC-16V.................................................................................................303-01CEngine Cooling...............................................................................................................303-03Fuel Charging and Controls2.4L Duratorq-Di (Puma) Diesel........................................303-04AFuel Charging and Controls2.0L Duratorq-Di (Puma) Diesel/2.0L Duratorq-TDDi(Puma) Diesel.............................................................................................................303-04B

Fuel Charging and Controls2.3L DOHC-16V................................................................303-04CFuel Charging and Controls - Turbocharger..................................................................303-04DFuel Charging and Controls2.0L Duratorq-TDCi (Puma) Diesel....................................303-04FFuel Charging and Controls2.4L Duratorq-TDCi (Puma) Diesel....................................303-04GAccessory Drive.............................................................................................................303-05Starting System..............................................................................................................303-06Glow Plug System2.4L Duratorq-TDCi (Puma) Diesel/2.4L Duratorq-Di (Puma)Diesel.........................................................................................................................303-07A

Glow Plug System2.0L Duratorq-TDCi (Puma) Diesel/2.0L Duratorq-Di (Puma)Diesel/2.0L Duratorq-TDDi (Puma) Diesel.................................................................303-07B

Engine Ignition2.3L DOHC-16V.....................................................................................303-07CEngine Emission Control................................................................................................303-08Intake Air Distribution and Filtering................................................................................303-12Evaporative Emissions...................................................................................................303-13Electronic Engine Controls.............................................................................................303-14

Manual Transmission/Transaxle, Clutch and Transfer CaseManual Transmission/Transaxle and Clutch - General Information...............................308-00ClutchVehicles With: MT-75...........................................................................................308-01AClutchVehicles With: VXT-75.........................................................................................308-01BClutchVehicles With: MT82............................................................................................308-01CClutch ControlsVehicles With: MT-75............................................................................308-02AClutch ControlsVehicles With: VXT-75..........................................................................308-02BClutch ControlsVehicles With: MT82.............................................................................308-02CManual Transmission/TransaxleVehicles With: MT-75..................................................308-03AManual Transmission/TransaxleVehicles With: VXT-75................................................308-03BManual Transmission/TransaxleVehicles With: MT82...................................................308-03C

2004.75 Transit BDC for Manuals - specs - Bolt torques

https://barringtondieselclub.co.za/

Manual Transmission/Transaxle External ControlsVehicles With: MT-75.....................308-06AManual Transmission/Transaxle External ControlsVehicles With: VXT-75....................308-06BManual Transmission/Transaxle External ControlsVehicles With: MT82......................308-06CManual Transmission/Transaxle Automated Gearshift System.....................................308-11

Exhaust SystemExhaust System.............................................................................................................309-00

Fuel SystemFuel System - General Information................................................................................310-00Fuel Tank and Lines.......................................................................................................310-01Acceleration Control2.0L Duratorq-TDCi (Puma) Diesel/2.4L Duratorq-TDCi (Puma)Diesel/2.0L Duratorq-Di (Puma) Diesel/2.0L Duratorq-TDDi (Puma) Diesel/2.4LDuratorq-Di (Puma) Diesel.........................................................................................310-02A

Acceleration Control2.3L DOHC-16V............................................................................310-02B

2004.75 Transit BDC for Manuals - specs - Bolt torques

https://barringtondieselclub.co.za/

GROUP

Electrical 4SECTION TITLE PAGE

Climate Control SystemClimate Control System - General Information..............................................................412-00Air Distribution and Filtering...........................................................................................412-01Heating and Ventilation..................................................................................................412-02AAuxiliary Heating............................................................................................................412-02BAir Conditioning..............................................................................................................412-03AAuxiliary Climate Control................................................................................................412-03BControl Components......................................................................................................412-04

Instrumentation and Warning SystemsInstrument Cluster and Panel Illumination.....................................................................413-00Instrument Cluster..........................................................................................................413-01Horn...............................................................................................................................413-06Clock..............................................................................................................................413-07Parking Aid.....................................................................................................................413-13

Battery and Charging SystemCharging System - General Information........................................................................414-00Battery, Mounting and Cables........................................................................................414-01Generator and Regulator...............................................................................................414-02

Information and Entertainment SystemsInformation and Entertainment System - General Information......................................415-00Audio Unit......................................................................................................................415-01Antenna..........................................................................................................................415-02Speakers........................................................................................................................415-03

LightingExterior Lighting.............................................................................................................417-01Interior Lighting..............................................................................................................417-02

Electrical DistributionModule Communications Network.................................................................................418-00Module Configuration.....................................................................................................418-01

Electronic Feature GroupAnti-Theft - Active..........................................................................................................419-01AAnti-Theft - Passive........................................................................................................419-01B

2004.75 Transit BDC for Manuals - specs - Bolt torques

https://barringtondieselclub.co.za/

Multifunction Electronic Modules...................................................................................419-10

2004.75 Transit BDC for Manuals - specs - Bolt torques

https://barringtondieselclub.co.za/

GROUP

Body and Paint 5SECTION TITLE PAGE

Body and PaintBody System - General Information...............................................................................501-00Front End Body Panels..................................................................................................501-02Body Closures................................................................................................................501-03Interior Trim and Ornamentation....................................................................................501-05Exterior Trim and Ornamentation...................................................................................501-08Rear View Mirrors..........................................................................................................501-09Seating...........................................................................................................................501-10Glass, Frames and Mechanisms....................................................................................501-11Instrument Panel and Console.......................................................................................501-12Handles, Locks, Latches and Entry Systems................................................................501-14Wipers and Washers......................................................................................................501-16Roof Opening Panel.......................................................................................................501-17Bumpers.........................................................................................................................501-19Safety Belt System.........................................................................................................501-20ASupplemental Restraint System.....................................................................................501-20BBody Repairs - General Information..............................................................................501-25Body Repairs - Vehicle Specific Information and Tolerance Checks.............................501-26Front End Sheet Metal Repairs......................................................................................501-27Side Panel Sheet Metal Repairs....................................................................................501-29Rear End Sheet Metal Repairs......................................................................................501-30

Frame and MountingUni-Body, Subframe and Mounting System...................................................................502-00

2004.75 Transit BDC for Manuals - specs - Bolt torques

https://barringtondieselclub.co.za/

Blank Page