Ford has issued the following information to help you repair Ranger's safely. It has never been more critical that Ford manufactured vehicles are repaired using genuine Ford parts and repair methods.
Ford Motor Company vehicles are designed and built to provide optimum fit, function, safety and structural integrity. Failure to follow official Ford Motor Company repair methods which specify welding requirements and structural adhesives may adversely affect structural integrity and crash safety performance.
It has never before been possible to carry out a sectional repair to a damaged rear chassis on an Australian-specified Ford Ranger. With the use of new serviceable parts and repair methods on Ranger, it is now possible to replace the rear frame section. Additionally, the front frame sectionand front crossmember can now be replaced independently of the entire chassis. Carry-over from Ranger (PX Series) is the ability to still replace the front frame short sections.
NOTE: The images display awkwardly in this story you can download the full Ford Ranger modular chassis and serviceable parts release here which includes QR code links and further information.
What has changed?
It begs the question: Why now? Why not before? What has changed? The answer: A lot. Ford engineers have completely redesigned the Ranger chassis using a modular approach.
Diagram 1 shows the previous generation Ranger (PX Series). The inner section of the chassis rail is one continuous length from the front of the vehicle all the way to the rear (shown in red). Ford engineers state that it is unlikely this section would be able to be cut and welded to reproduce the manufactured characteristics, making most damage unable to be repaired.
Diagram 2 shows the 2022 Ranger (RA) which has a sophisticated modular design that allows the chassis rails to be separated at two points in the centre of the vehicle (shown in orange). The different colours in the diagram show which sections can be separated. In addition, some serviceable parts have tapers, allowing for ease and accuracy of fitment. The chassis of the Ranger double cab, super cab, single cab, Raptor and Ford Everest (2023 Wheels Car of the Year) all have their own methods, but importantly, note that Raptor and Everest can only be sectioned in one location. See official Ford procedures for more detail.
The Ranger chassis can be sectioned in two locations depending on where the damage has occurred.
Diagram 2
RA Series Ranger Chassis (excluding Raptor)
One of the key advantages of this modular approach is that, in most cases, the VIN stamp can be left intact.
Repair procedures and collision position statements are available by subscription at www.motorcraftservice.com. Information includes vehicle-specific Service Manuals, Body Repair Manuals, Technical Service Bulletins and Instruction Sheets.
Examples of Serviceable Chassis Rail Components
Front Frame Short Section
Front frame short section end
Front cross member
Also new to Ranger:
The Side Obstacle Detection (SOD) control module is located in both right and left tail lamps. If installing a new side obstacle detection module it is necessary to upload the module configuration information to the scan tool prior to removing the module. This information must be downloaded into the SOD after installation.
Technology
The 2022 Ford Ranger is fitted with comprehensive technology. Series dependent, a few examples include: a Connected Experience with FordPass* and embedded modem, 9 airbags (standard across the range), Emergency Assistance, a Wireless Mobile Phone Charging Pad, a large 10.1-12-inch SYNC®4A touchscreen (depending on series) and a Digital Instrument Cluster.
As Ford customers have come to expect, the Ranger also has a suite of Advanced Driver Assist Systems. During collision repairs, it is critical the proper function of these systems and features be restored back to pre-accident condition and performance. It is very important that pre- and post-repair diagnostic scans are conducted to properly identify all required repairs when planning the task and to verify the successful completion of those repairs. Calibration or initialisation of certain modules and other system components may be required. Ford dealerships can assist with all diagnostic and calibration requirements.
The table below lists the ADAS features that are available to raise awareness of what collision repairers may need to repair. The model application matrix for these features can be viewed/downloaded from the Ford website. https://www.ford.com.au/content/ford/au/en_au/site-wide-content/overlays/forms/download-brochure/