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20-05-2011, 01:13 PM
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Chairman & Administrator
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Ford Launches the Power Ranger (inc. Pricing & Specs)
February 2007
Ford Australia has launched the vehicle that will replace Courier and spearhead its light commercial vehicle line-up in 2007 – the all-new Ford Ranger.
"Setting new standards in the light commercial sector, the all-new Ford Ranger is a no-compromise, powerful vehicle offering the style, comfort and refinement of a passenger car," said Ford Australia President Tom Gorman.
"The new Ranger is more powerful compared with Courier, offers improved functionality, significantly increased three-tonne towing ability (when using a 3.0-litre manual transmission model fitted with a genuine Ford towpack and load leveling kit), and maintains a one-tonne plus payload across the range.
“Ford engineers have built on the company’s vast experience in trucks to deliver the ultimate one-tonne vehicle with the performance and power to get the job done.
"At the same time, we recognised that Ranger had to be versatile enough to adapt to the changing needs of the light commercial owner in the 21st century. It needs to be a combination of reliable work mate, family vehicle, lifestyle statement and an adventure vehicle.
"We engineered Ranger to deliver on all these expectations. It’s the can do truck – a truck that means business."
Mr Gorman said the new Ranger light commercial range replaces the Courier line-up, with the name change to Ranger coming after numerous hours of exhaustive customer research.
"It was a tough decision to change a name that has been part of the Ford Australia family since 1978, but the research was overwhelming.
"The light commercial vehicle sector has changed dramatically in recent years, with customers wanting more from their truck than just a reliable work vehicle.
"Today's light truck owner wants the best of both worlds – a dependable, genuine truck for the industrious worker and a great family vehicle with the quality, comfort, safety and modern conveniences they demand. Ranger researched well as a brand name that exemplified all these attributes.
"The Ranger brand is used by Ford around the world and, with an all-new vehicle for 2007, we saw this as the ideal time to introduce a new light truck with a bold new name for the Australian light commercial market," Mr Gorman said.
New Ranger features a more aggressive and bolder look, a modern car-like interior, two new common-rail turbo-diesel engines featuring direct injection, improved ride and handling and significantly higher towing capacity.
“We developed Ranger to be rugged and tough for the most challenging truck applications,” Mr Gorman said.
“We listened to the market and focused our improvements on Ranger’s classic rugged exterior, its refined and comfortable interior, exceptional diesel performance, great driving feel and fantastic ability both on and off-road."
New high-torque, fuel-efficient engines
The new Ranger line-up will be powered by two new twin-cam turbo-diesel engines featuring common-rail direct fuel injection for effortless high-torque pulling power.
The new 16-valve 2.5-litre and 3.0-litre four-cylinder Duratorq engines are quiet and offer greater performance, improved fuel economy and lower emissions.
A variable geometry turbocharger has significantly reduced turbo lag, broadens the torque curve and promotes smoother and faster acceleration.
Hauling or towing loads is a breeze with the new 2.5-litre engine, which delivers maximum power of 105kW at 3500rpm and an impressive 330Nm of torque at 1800rpm.
When compared with the previous Courier model's 2.5-litre diesel, torque is up 22% at 200 fewer revs and fuel economy has improved 14.4% in the new 2.5-litre engine.
Even more impressive is the 3.0-litre engine, which produces a thumping 380Nm of torque at 1800rpm and 115kW of power at 3200rpm.
Mr Gorman said the common-rail direct-injection system and other engine technology were tuned for significant gains in both performance and fuel efficiency.
“The engines are monitored by a 32-bit microprocessor that constantly adjusts all systems to ensure the optimal fuel-air mixture. Power and economy are enhanced by creating the most efficient swirl patterns within each cylinder through use of a swirl control valve.
"This ensures more complete combustion at all engine speeds, leading to greatly improved fuel economy and a substantial reduction in emissions,” he said.
Mr Gorman said the new 3.0-litre turbo-diesel powerplant could be matched to either a five-speed manual or an optional five-speed automatic transmission.
An added appeal of the new 3.0-litre turbo-diesel manual transmission model is the ability to tow up to 3.0 tonnes (when fitted with a genuine Ford towpack and load leveling kit), up from 1800kg on Courier.
Tough, modern exterior
The exterior of the new Ford Ranger is designed to be tougher and more modern with a purposeful stance and a bolder, more athletic appearance.
A self-assured, aggressive on-road presence is achieved through an imposing new front-end, prominent wheel arches, higher beltline and taller cargo box.
The bold front-end design – featuring a large, wide grille and dominant power dome – conveys strength and gives a hint of the powerful new engines underneath. Clear-lens reflector headlamps with jewel-like details and a bold split front bumper, helping protect integrated fog lamps (where fitted), complete the look.
At the rear, the side-wall of the cargo box is 60mm higher than the previous Courier model (405mm up to 465mm), boosting storage to 1266 litres on single cab pick-up models.
The new line up offers a combination of torque, payload and towing ability which positions Ranger as one of the most desirable vehicles in the light commercial vehicle sector.
Fresh, refined interior
The confidence, power and refinement of all-new Ranger continues on the inside where owners will find the features, comfort and craftsmanship normally reserved for passenger cars.
“Truck owners are spending more and more time in the vehicles, both at work and with their friends and family on weekends,” Mr Gorman said.
“We designed the new Ranger interior to ensure they enjoy the comfort they want and deserve.” For passenger comfort during spirited driving or over long distances, the front seats feature a new, more sculpted back, more supportive bolsters and larger headrests. New switches and controls are easier to operate and placed logically so the driver knows intuitively where to find them. A new centre stack is displayed prominently in the modern instrument panel. Flowing visually from the hood’s power dome, the centre stack dynamically links the exterior and interior.
The centre stack contains new ventilation controls and a standard audio system that features an AM/FM radio, in-dash CD player with MP3 capability.
Convenient storage areas abound, including a pull out tray from the passenger-side instrument panel. Other storage areas are located on top of the instrument panel, below the ventilation controls and inside the front doors. The two-bin centre console can store up to 10 CDs plus a pair of sunglasses and two mobile phones.
Ranger also retains its interior spaciousness and flexibility with a Single Cab, Crew Cab, Chassis Cab and the Super Cab, incorporating the innovative Rear Access System. With two front doors and two access panels that open towards the rear, the Supercab provides the largest possible opening to the cabin for the convenience of passengers and for loading large valuable objects. All cab styles are also available in cab chassis or pick-up box.
4x4 - A tough off-roader
Ford Ranger’s credentials as an authentic off-roader have been enhanced with a more rigid chassis and tougher, more durable suspension for overcoming challenging conditions. Wide tracks, superb ground clearance and excellent approach, departure and ramp-over angles are designed to negotiate the roughest terrain including steep hills and deep ruts.
High-torque performance, mated to a robust 4x4 transfer case and fed to the road through larger wheels and all-terrain tyres, provide the extra traction needed to take customers anywhere – and get them back safely.
New Ranger has undergone extensive durability and performance testing in the most severe conditions – from a numbing -25°C to a searing 50°C. It has survived torture tests at proving grounds in the United States, Europe, Japan, Australia and South Africa, including extensive trailer-towing.
Early production vehicles were put through their paces in the mountains of northern Thailand and Laos, the jungles of Borneo, the Australian outback, South Africa’s Kruger National Park and German autobahns.
Improved ride and handling
Every mechanical aspect of new Ford Ranger has been engineered and refined to deliver superior driving and handling. The Ranger’s tougher and more durable chassis and suspension have been tuned to deliver sharper handling and a more refined ride, even when fully laden and towing heavy loads.
At the same time, Ford engineers have ensured Ranger can handle some of the most challenging driving conditions and road surfaces in the world.
At the front, Ranger’s 4x2 and 4x4 models are fitted with a car-like independent double-wishbone suspension with a longer and larger torsion bar and larger-diameter dampers for greater driver control and ride comfort.
Ranger’s rear suspension, carefully tuned for improved ride and handling, has been strengthened to support the vehicle’s hauling and towing capabilities with longer leaf springs.
Steering has been optimized for easy handling in low-speed manoeuvres such as parking and better control at high speeds.
Quieter, more refined vehicle
A great deal of attention was paid to reducing noise, vibration and harshness in the new Ranger – particularly engine, wind and road noise.
The new engines are markedly quieter, especially at idle and under heavy acceleration loads. The common-rail direct-injection technology, with multiple injections of fuel per cycle, reduces combustion noise, making the cabin interior much more pleasant for listening to the sound system or conversing. A quieter cooling fan system has also been used.
Ranger’s stiffer frame, suspension and body as well as improved body, engine and transmission mounts all contribute to reduced noise, vibration and harshness.
Improved seals around the doors and glass and new door-latching mechanisms have dramatically cut wind noise, along with better air flow over the new external mirrors to reduce buffeting. New all-terrain tyres, revised floor damping and a new dash insulator combine to cut road noise.
Safety
New Ranger offers a host of structural improvements over and above Courier, including the availability of side-airbags on XL Supercab and Crewcab models as part of an optional safety pack. The safety pack also features anti-lock braking system (ABS) with electronic brakeforce distribution (EBD), XLT trim, power windows and central locking. Side-airbags are a no cost option on XLT models and will be available from the second quarter.
Ranger’s excellent body construction directs crash forces through the strengthened frame and away from vehicle occupants. Protective beams in the doors and the raised beltline provide added safety and protection from side crashes.
The more durable suspension, improved aerodynamics and more responsive steering contribute to safety by improving handling at high speeds and ensuring long-distance travel is more comfortable and less tiring.
Stopping power comes from ventilated discs at the front and larger leading and trailing drums at the rear. Braking effort has been reduced and four-wheel anti-lock brakes (ABS) with electronic brakeforce distribution (EBD) are standard on XLT models and available as an option across the rest of the range.
All front passenger positions are fitted with pre-tensioners in the seatbelt retractors with load-limiters for improved passenger restraint in the event of a collision. Rear seat passengers in Crew Cab models also receive three-point seatbelts in outboard positions.
The high hip point of the driver’s seat and Ranger’s large windows and sloping hood afford excellent visibility and a commanding view of the road and traffic conditions.
"The light commercial segment is one of the most dynamic and fastest growing in the Australian market," said Mr Gorman.
"The new Ranger, with its impressive list of features, gives Ford Australia a fantastic vehicle to enhance our well earned light truck reputation."
TOUGH TRUCK DESIGN
"The tough, clean, modern design of the new Ford Ranger is drawn directly from the spirit of the legendary Ford F Series." Paul Gibson, Chief Designer, Asia Pacific and Africa
The distinctively rugged new exterior of Ford Ranger immediately announces its “tough truck” pedigree and takes it to a new level.
New Ranger boasts a more muscular appearance that exudes greater confidence and toughness and an even bolder spirit. To create this confident presence, Ford designers drew on the company’s 89 years of truck experience to ensure the new look meets the expectations of customers.
Chief Designer Asia Pacific and Africa Paul Gibson said the inherent knowledge among Ford designers for styling trucks was supplemented by research amongst truck customers around the world.
“The exterior design of new Ford Ranger emphasises the power and capability inherent in all Ford trucks,” Gibson said.
Invoking the spirit of the legendary F-Series, new Ranger has a more commanding on-road presence: it looks bigger and stronger with a bold design that is tough, durable and thoroughly modernised to meet the tastes of customers. The Ford Tough Truck DNA is evident from every angle – from the prominent grille and power dome on the hood, through the solid wedge-shaped side profile, to the deeper pickup box at the rear.
Strong and tough at the front
The powerful front view has been totally redesigned to make an even stronger, bolder statement with its larger and more aggressive grille, new headlamps and fog lamps (where fitted), two-piece bumper and an imposing power dome on the hood.
In combination with its wide track and new wheels shod with all-terrain tyres, new Ranger produces a more confident and purposeful on-road stance. The styling is distinctly Ford with a larger, truck-sized Ford emblem proudly mounted as a badge of distinction on two horizontal chrome bars that comprise the front grille.
Designers have opened up the front end to direct more air into the engine bay through a wider grille as well as from under the bumpers. This redesign generates even better cooling for heavy-duty hauling and towing, particularly in the warmer climates of outback Australia.
Flowing upwards from the grille and over the hood is a muscular V-shaped power dome that progressively widens towards the base of the windshield.
The grille is aggressively set forward of the split front fascia that houses new rectangular headlamps that highlight the new bold face of Ranger. Good-looking and functional, the new headlamps are contoured for a modern look while the clear-lens reflectors feature jewel-like details and provide superior light distribution.
Housing stylish new fog lamps (where fitted), a new two-piece front bumper features a lower section designed to reduce repair costs in case of accidental damage.
Wedge-shaped side profile
New Ranger’s side view has also been beefed up with a higher beltline giving it more strength and substance. As well as adding to Ranger’s rugged appeal, the redesigned body side is sleeker, more aerodynamic and modernised with a cleaner, simplified look.
The revised beltline has been raised and angled so that the side creates a modern, wedge-shaped profile. It is 17mm higher at the front, 25mm higher in the B-pillar area and 35mm higher at the rear of the cabin than the superseded model. The sheet metal flows seamlessly into the side walls of the pickup box, which has been raised 60mm for greater storage volume and a more solid look.
Further adding to Ranger’s 'tough truck' presence are dominant fenders – a highly visible design cue that emphasizes off-road ability and enhances the muscular presence of the truck. The fenders are more than cosmetic, they also protect the body.
New open-grip door handles add to the solid appearance and are easier to use, even when wearing work gloves. The solid-looking door handles are complemented by larger chrome-over-black outside mirrors on XLT models that provide a commanding view of the road and fold in for tight clearance areas.
A lower feature line provides a harmonious exterior, flowing from the lower part of the front bumper, above the thicker rocker panel, all the way to the rear combination lamps. It also allows the introduction of a stylish two-tone exterior.
Ranger’s sleek, modern appearance is aided by concealed B-pillars and the added flair of rounded rear edges for the side windows. The doors have been pulled forward at the base of the A-pillar to give a sleeker, more aerodynamic look. Other modern touches include a fuel-lid door that is integrated into the fender and bold new model badges.
The rear – designed for tough, industrial use
The rear of new Ranger is stable and strong, dominated by the new pick-up box with taller sidewalls and tailgate for a tougher appearance and greater functionality.
Capacity of the box on single cab pick-up models has been increased by 166 litres to 1,266 litres, providing ample space for large items and a genuine one-tonne payload.
Designers have made innovative use of the taller side walls by installing interior ledges that will accommodate custom-made shelves for flexible cargo storage. The system makes loading easier and enables greater utilization of the available volume, meaning owners can carry more cargo on each trip.
For example, heavier items can be stowed on the box floor while lighter items such as construction materials can be placed on the shelves above.
“Ford customers use their trucks for heavy-duty work, so we designed the cargo-box to ensure it truly meets their needs and usage,” said Paul Gibson.
“The interior ledges are designed for more flexible and efficient storage using do-it-yourself shelves and are ideal for a trader or farmer carrying their products along with their heavy equipment.”
The tailgate itself is easy to open and features a handle specifically designed for workers wearing thick gloves. Flanking the tailgate are larger tail-lamps, which are more stylish and offer greater visibility at night and when customers are braking.
Flexible body designs
New Ford Ranger is available with a range of body styles designed to suit the particular requirements of a wide variety of customers.
Ford Ranger is available in body styles including Single Cab, Super Cab (incorporating the innovative Rear Access System) and Crew Cab. All models are available in cab chassis and pick-up box configurations.
Ford’s unique Super Cab is another innovation underlying the company’s extensive truck heritage. Ford was the first to introduce this flexibility and added convenience for customers.
The Super Cab features two forward-opening front doors and two access panels that open towards the rear, creating the largest possible opening to the cabin. This system provides excellent access for occupants and for stowing large, awkward cargo.
Ford designed the revolutionary opening because research among customers and other truck owners identified a need to carry large objects that are too delicate or valuable to be exposed to the weather. Highlighting the flexibility and attention to customer requirements, the Super Cab also offers a larger pickup box than the Crew Cab.
The Single Cab has two doors and the longest possible pickup box.
For customers needing even more flexibility, Ford offers a Chassis Cab that enables them to tailor their vehicle for specialist purposes. Delivered without the pickup box, owners often use qualified modifiers to add custom-built bodies. As a result, Ford is able to cater for a diverse range of customers who require the ruggedness and refinement of the Ranger and want to install customized conversions to suit their particular application.
Designed for safety
The superior strength of new Ford Ranger is more than skin deep.
A revised ladder-frame platform features overlapped and cross-braced construction that boosts rigidity, making Ranger stronger and easier to drive - especially when carrying or towing heavy loads.
The unique body construction directs crash forces through the strengthened frame and away from vehicle occupants. Protective beams in the doors and the raised beltline provide added safety and protection from side crashes.
These improvements add to more precise handling (due to a revised suspension), improved aerodynamics and more responsive steering which make the new Ranger more enjoyable to drive.
REFINED INTERIOR
"While customers demand a tough truck, they also want the interior comfort of a passenger car – especially for long trips and for driving with friends or family." Paul Gibson, Chief Designer, Asia Pacific and Africa
On opening the doors, the new Ranger will surprise and delight customers with its modern and refined interiors that provide sedan-like comfort and an up-market ambience.
Interior layout, fittings and materials feature quality craftsmanship, clever attention to detail, intuitive design, modern style and relaxing comfort – without compromising the day-to-day use of Ranger as a trusted work mate.
Chief Designer Paul Gibson said customers immediately recognise Ranger as an authentic Ford tough truck – rugged, dependable and designed for the toughest assignments.
“On the face of it, you might think our tough-truck customers would be expecting a rather bare-bones, utilitarian interior,” he said.
“Far from it! They’ve told us they want similar quality, refinement and creature comforts found in passenger cars.
“When they’re using their vehicle as a workhorse, they’ll have the convenience and comfort they need, especially for long cross-country drives. At the same time, their families will feel at home in Ranger’s car-like interior which has been thoroughly updated. Of course, everything inside their truck has to be robust and capable of standing up to knocks and scrapes because our customers certainly don’t treat their trucks with kid gloves – inside or out.”
Step inside
The interior of new Ranger is reached through wide door openings that reveal a spacious and thoroughly modern interior crafted for people who typically spend long periods in their vehicle.
Ford drew on its vast global manufacturing experience to incorporate car-like features including MP3/CD/radio sound system as standard across the range. Modern instrument panel and gauges, lockable glovebox, a passenger-side vanity mirror and an array of handy storage areas further complement interior appointments.
The spacious cabin provides generous head, leg and shoulder room, while the airy feeling is accentuated with large windows. Owners have a great view of the road through a commanding driving position and excellent all-around visibility.
Stylish new seats offer a more comfortable and supportive shape, ensuring drivers are in the ideal position, especially for long-distance travel.
Ford designers responded to demands for improved convenience, comfort and safety by addressing ergonomic issues throughout the cabin of the new Ranger. Functional and stylish dials and other controls are placed thoughtfully so customers intuitively know their location.
The instrument cluster features three intersecting pods. The speedometer is placed centrally, the tachometer to the left and the fuel and temperature gauges grouped to the right.
These improvements to ergonomics also make driving safer by ensuring controls can be operated easily without taking eyes off the road for extended periods.
As with instrument controls, the manual transmission lever is now more car-like and easier to operate, thanks to shorter and more precise throws that make changing gears quicker and easier.
In addition, drivers will find that fewer gear changes are required in a normal day’s driving because of the greater responsiveness and performance of Ranger’s new engines and revised transmission ratios.
Ford designers analysed customer requirements to improve the quality and texture of materials, particularly in the seat fabric, door trim and center console.
In response to customer demands, Ranger now offers a two-tone interior – a primary charcoal finish mated with grey. The grain used in the plastics has been changed to give a more contemporary and welcoming feel for drivers and passengers.
Center stack
Design cues from the famous F-Series extend to the interior of new Ranger. In particular, the prominent center stack visually flows from the hood’s power dome, giving the overall design an integrated feeling.
The center stack, which houses the audio and ventilation systems, is framed with an uplifting silver finish surround that continues Ranger’s overall design theme of power and adds a touch of class.
On XLT models, bright chrome details continue in the instrument cluster, ventilator grilles, window switches, door handles and the top of the gear selector.
Sound system
Ford has recognised the long periods that owners spend in their vehicles by introducing an integrated sound system into the vehicle.
In response to modern trends, the unit is fitted with an audio system incorporating an AM/FM radio, high-fidelity CD player with MP3 compatibility. A LCD multi-function display including a digital clock and all controls for the system are placed at the top of the center stack for maximum convenience and safety.
Two speakers are standard on regular cab, four speakers on Super Cab and a six-speaker system is standard on XLT models, as is a six-stack CD player. One special feature of the system is an auto level control, which thoughtfully returns the volume to a neutral position after each drive.
Heating, ventilation and air-conditioning
Ranger is designed to keep occupants comfortable in any weather with controls for heating, ventilation and air-conditioning conveniently located in the lower portion of the center stack. Totally redesigned for the new model, the system is more effective with increased flow and a quieter, more effective fan. It is also easy to operate with low-effort rotary controls.
Tall vertical vents are placed either side of the center stack. Vents on the instrument panel near the doors are round, enabling them to be rotated 360 degrees to ensure air is directed where it is needed most.
More supportive seats
New front-seat cushions and bolsters are designed to hold and support occupants during dynamic driving as well as those faced with long-distance travel. The newly developed seats feature a high density urethane material along with a better seat shape, revised spring construction and thicker bolsters, all of which help provide more comfort and support for occupants.
The seat backs are taller for better body fit and help improve the distribution of body pressure points. The result is more accurate support for the hips and back while allowing the driver and passenger to slide easily in and out of the vehicle.
A comfortable driver’s seat with firm lateral support is essential for safety as it ensures the driver remains in an optimum position at all times. Head restraints have been redesigned and are larger for greater protection and added comfort.
The seats use three different styles of material for a quality, up-market appearance – one for the headrest and upper part of the seat back, a second for the lower part of the back and cushion, and a third for the bolsters.
Passenger comfort across the range is improved due to Ranger’s improved ride and seat isolation from road harshness.
In the Crew Cab models, the angle of the rear-seat back has been improved. It is now fixed at 23 degrees (previously 20 degrees) to make it more relaxing for passengers. A centre-rear armrest in the Crew Cab also provides occupants with greater comfort, balance and control, especially when the vehicle is being driven in a spirited manner. Integrated rear headrests for outboard passengers are also included.
Flexible storage
New Ranger provides customers with a vast number of storage areas for the convenience of drivers and passengers. In an industry first, a tray table (380 x 130 x 15mm) pulls out from the instrument panel above the capacious 8.05-litre glovebox. The tray slides away neatly out of sight after use.
Designers have also responded to customer demands by providing a sculpted storage area on top of the instrument panel – a handy area suitable for pens and small personal items.
The center-console armrest now provides more flexible storage by opening in two stages to reveal a shallow storage area at the top and a much deeper storage bin underneath. The two bins can store up to 10 CDs plus a pair of sunglasses and two cell phones. In addition, a storage area below the ventilation controls takes up to nine CDs in their cases, and has a night-time lighting feature.
Ranger offers five cup holders between the driver and front passenger. Both front-door trim panels contain 500ml bottle holders. Door bins can also accommodate a large notebook.
Safety
Like the rugged exterior, the interior of new Ranger reiterates Ford’s commitment to designing, engineering and building vehicles with the highest levels of real-world safety.
New Ranger continues to set new safety standards in the pickup truck sector with the availability of side airbags for the driver and front passenger on XL Supercab and Crewcab models (as part of an optional safety pack which includes ABS with EBD, XLT trim, power windows and central locking).
Side-airbags are a no cost option on XLT models and will be available from the second quarter.
Front airbag volume is 45 litres for the driver and 70 litres for the passenger. The side airbags are larger than average at 18 litres. The front airbags offer advanced protection performance in the event of a collision, deploying to protect the head and chest while the side airbags are triggered in the event of a side impact.
A locally developed and integrated airbag compatible bull bar will also be available as a genuine Ford accessory from the second quarter.
Three-point seatbelts in outboard positions come with seatbelt pre-tensioners that provide improved passenger restraint during a collision. In some models, the driver and front passenger also benefit from height adjustment for their seatbelts.
Anti-theft
For the security of customers and their vehicle, new Ranger XLT models are fitted with an engine immobiliser and passive anti-theft system. This system prevents the engine being started by anyone who does not have the correctly coded ignition key.
The key’s built-in transponder communicates with an electronic control module via an antenna coil mounted in the steering lock. If the module fails to recognise and accept the key’s transponder identification code, it automatically shuts off fuel to the fuel-injection system after two seconds.
POWERTRAIN TECHNOLOGY
"New Ranger is engineered to work the way you work; the way you expect your truck to work. Acceleration is instant, smooth and predictable so you can confidently undertake highway merging and passing on a hill, even with a full cargo load and 3.0-tonne trailer." Mark Bill, Chief Platform Engineer
Exceptional performance, superb low-down torque, rapid engine response and great fuel economy are some of the key features customers will find in the cutting-edge diesel technology in the new Ford Ranger.
The heart of Ford’s rugged one-tonne pickup truck has been revitalized with the introduction of two new turbo-diesel common-rail direct-injection (TDCi) engines.
Significant characteristics of the TDCi engines include:
* Increased power and torque;
* Rapid engine response;
* Strong performance from idle;
* Instant turbocharger response;
* Smooth acceleration;
* Improved fuel efficiency;
* Fewer harmful emissions;
* Reduced noise and vibration levels.
Responding to customer demands, Ford has achieved the winning combination of delivering substantially better performance while using markedly less fuel and producing fewer harmful emissions.
The key to the performance increase is the high-torque characteristics of these 16-valve DOHC engines. The new 2.5-litre powerplant produces a substantial 330Nm while the 3.0-litre engine develops a mammoth 380Nm at just 1800 rpm.
Reflecting the high-torque nature of Ford’s cutting-edge technology, the new 16-valve 2.5-litre and 3.0-litre four-cylinder TDCi engines have adopted the Duratorq badge. Duratorq is a trademark of Ford Motor Company and is synonymous with modern high-performance diesel technology.
These two new engines deliver the performance, reliability and economy expected in the pickup market where customers typically haul heavy loads, tow fully laden trailers and traverse rugged terrain.
Greater power and performance are achieved by the fuel being injected directly into the combustion chamber multiple times per cycle under extremely high pressure (1600 bar) from a common-rail pump. The technology ensures the best possible mixture of fuel and air in the cylinders, resulting in efficient combustion for high torque and excellent fuel economy while also reducing engine noise and vibration.
Combined with a variable geometry turbocharger that reduces turbo lag, the system increases power and torque across the driving range, ideal for powerful acceleration, carting heavy loads and negotiating treacherous off-road conditions.
The key technologies involved in these engines are:
High-pressure common-rail fuel injection – up to 1600 bar for optimum injection pressures during all engine speeds and loads with improved power, torque, fuel efficiency, emissions, noise and vibration.
Direct Injection – injects fuel directly in the combustion chamber to provide more efficient combustion, more power and torque, better fuel efficiency and cleaner emissions.
Double overhead camshafts with four valves per cylinder – high-lift valves significantly increase air intake, improve intake/exhaust efficiency and boost power and torque output.
Variable geometry turbocharger (VGT) – the design virtually eliminates turbo lag and broadens the torque curve for rapid engine response.
Closed-loop exhaust gas recirculation (EGR) with cooler – reduces emissions.
High-output microprocessor – provides sophisticated control of engine variables under all driving and climatic conditions. The engine program control module (PCM) now has a self-diagnostic function.
Intake manifold with swirl control valve – delivers improved efficiency and reduced harmful emissions.
Roller finger follower – reduces camshaft friction for improved fuel economy.
Dual counter-rotating balance shafts – for reduced engine vibrations.
More power and torque
High torque and superior performance in all driving conditions were the keys to development of the new TDCi engines.
Chief Platform Engineer Mark Bill said the engine technology was developed specifically to enhance the high-torque characteristics.
“It's torque that provides the grunt to move a truck,” Bill said.
“These engines develop high torque and provide it right across the rev range, resulting in improved engine and towing performance compared with Courier.”
Ford’s new direct-injection diesel engines use the latest technology to deliver real-world results for owners, especially those with heavy-duty requirements.
Along with the 330Nm of torque, the new 2.5-litre engine develops maximum power of 105kW at 3500 rpm. Compared with the more conventional 2.5-litre indirect-injection engine, this is 28 percent more power and 22 percent more torque.
Figures for the new 3.0-litre engine are even more impressive with peak torque of 380Nm – a leap of 40 percent over the previous Courier's 2.5-litre engine – while maximum power is up 40 percent to 115kW at 3200rpm.
While both engines develop their peak torque at 1800rpm, 90 percent of this maximum is available from just 1400rpm. The abundance of torque on tap from the moment the ignition key is turned – all the way through the usable rev range – provides customers with the certainty of knowing they can get the job done in any conditions.
Fuel economy
At the same time as producing substantially more power, the new 2.5-litre engine is much more fuel efficient and cleaner burning than the 2.5-litre turbo-diesel engine in the previous Courier model. It delivers 14.4 percent better fuel economy and achieves an impressive fuel-consumption rate of just 8.3 litres/100km in a 4x2 Single Cab.
Despite its bigger capacity and associated increase in performance, the fuel-efficiency of the 3.0-litre engine (with manual transmission) is even more amazing with fuel economy 8.9 percent better than the previous Courier's 2.5-litre engine.
“The outright performance from these high-torque engines combined with their fuel-sipping economy puts the new Ranger among the leaders in the segment,” Bill said.
“Not only are we helping the environment, we’re also protecting the pockets of our customers.”
Advantages of common-rail direct fuel injection
Ford’s all-new common-rail direct-injection system allows substantial advances in performance, economy, emissions and comfort. It features very rapid glo-plug heating time and, compared with older systems, produces less engine noise and fewer emissions.
Being a cleaner-burning and more efficient engine, fuel consumption is reduced significantly compared with similar-sized engines with indirect injection.
Ford’s common-rail system enables:
* More precise control of injection pressure and spray volume for optimised combustion, independent of engine speed or load;
* Reduced waste, exhaust gas and engine heat resulting in lower emissions, better fuel economy and improved powertrain performance;
* Reduced engine noise and vibration and smoother acceleration.
The common-rail system mainly consists of a fuel-compression pump, an injector, and an electronic control unit. The system utilizes an extremely high-pressure pump that can store a reservoir of fuel at up to 1600 bar in a common rail.
The pressurised fuel is temporarily collected in this common rail and then injected into each cylinder using solenoid valves in the injector nozzles.
Piezo electric injectors enable fine electronic control over the timing and amount of fuel injected into each combustion chamber. Each injector has an array of orifices for controlled multi-stage injection, adjusting and metering the amount of diesel fuel multiple times per stroke.
The system provides a finely atomised spray that is injected under high pressure directly into the combustion chamber. This produces the optimum injection timing and fuel quantity, even where there are variations in fuel quality or cold starting. Another benefit of high-pressure direct injection is improved idle quality.
Air is inducted into the equation through an advanced four-valve cylinder head, with swirl control valves to provide the optimum in-cylinder air motion for complete mixing with the fuel. Each cylinder in the Duratorq TDCi uses a double helical port to generate aggressive swirl and tumbling of the air-fuel mixture. The result is very efficient combustion for excellent power and fuel economy, with low emissions.
Variable geometry turbocharger
New Ford Ranger uses a variable geometry turbocharger (VGT) that virtually eliminates turbo lag and broadens the torque curve for rapid engine response and superior performance. The unique variable nozzle design adjusts the speed and volume of exhaust gas flow, ensuring it consistently strikes the turbine blades at the optimal speed and direction.
The result is rapid engine response and high torque performance combined with consistently efficient boost pressure that delivers the power needed for spirited performance across the entire rev range.
This mechanism maintains boost pressure, even at low speeds when relatively small amounts of exhaust gas are produced, by reducing the size of the opening for each nozzle to secure adequate velocity of the gases striking the blades.
While conventional systems secure just one side of the nozzle, the Ford TDCi VGT design secures both sides, for improved durability and less friction.
Clearance control pins mounted in three locations are used to secure the shroud plates that sandwich the nozzles. This provides the right amount of side clearance required by the nozzles, maintaining a high level of flow efficiency while also improving durability and reliability.
Adopting this new low-friction nozzle link mechanism, the compact turbine housing design and turbine with low inertial moment improves VGT control response.
These technologies come together to realise driving ease at low speeds, positive response and spirited acceleration, as well as greater engine power and torque.
The new TDCi engines are quieter and a new cooling fan is much more capable than the prior model. Closed-loop control of exhaust gas recirculation, with a cooling system for the hot gases, also promotes lower emissions.
Manual transmission
Given the massive torque of the new TDCi engines, Ford's new five-speed manual transmission now comes with a dual-mass flywheel, triple-cone synchronizers and other enhancements to improve vehicle refinement.
Designed with the customer in mind, it has a more car-like feel with a shorter lever and reduced throw between gears.
The dual-mass flywheel has separated primary and secondary flywheels and a damper spring located inside the flywheel. This structure stabilises rotation of the transmission primary shaft, reducing noise created by fluctuating engine speeds.
A triple, rather than double-cone, synchronizer increases the friction surface area, reducing the force and meshing time for operating the manual transmission.
Transfer case
Manual transmission vehicles use a two-speed manual shift transfer case. In normal on-road driving, torque is directed solely to the rear wheels, saving fuel and reducing wear on driveline components.
In 4x2 mode, the remote free-wheel front axle can be disengaged via a switch on the instrument panel, allowing the front wheels to rotate freely. The effect is similar to unlocking wheel hubs. Owners benefit from reduced drag and improved fuel economy.
For off-road or low-traction conditions, the driver can select 4x4 high, which directs torque to both the front and rear wheels. The front axle is locked into drive from the cabin without the driver having to leave the vehicle. For really rugged conditions, the driver can also select low-range 4x4 for the best traction performance.
A mechanical, multi-plate, torque-sensing limited slip differential (LSD) apportions torque between the left and right sides of the vehicle. During cornering, the driving force is transmitted efficiently to the side with most traction, maintaining optimum torque balance. The result is a vehicle that offers better drivability and handling, particularly during high-speed cornering.
All-new five-speed automatic transmission
New Ranger also features an impressive all-new five-speed automatic transmission, available as an option across select 4x2 and 4x4 models fitted with the 3.0-litre powertrain.
The electronically controlled five-speed automatic transmission has closely spaced ratios that keep the engine in its power band to produce better acceleration under full throttle.
Its wide overall ratio provides a unique combination of off-the-line jump and remarkably good highway fuel economy. The powerful 32-bit PCM delivers benefits in the transmission, as well as the engine, by precisely controlling shift duration and shift timing. Throttle position, engine speed, load, environmental factors and other parameters guide the transmission shift schedule.
An electronic interface complements the added capability of the PCM, allowing it high-speed communication with the automatic transmission, and giving powertrain engineers the ability to match controls with other sophisticated features such as electronic throttle control. As a result, the entire powertrain works together to deliver smooth performance.
Other measures taken to greatly improve the quietness of the transmission include adopting the dual-mass flywheel, increasing rigidity of the transmission case and optimising rib placement.
Electronic shift-on-fly mechanism creates an easier 4x4 operation. This means the driver does not have to stop the vehicle to switch between two-wheel drive and four-wheel drive.
DRIVING QUALITY
"The skill of the engineers behind the Ranger program is that they have produced a vehicle that is well-balanced and a joy to drive. Such a result is not attributable to any single feature; rather, it’s due to exacting attention to detail and the precise way that every system in the vehicle has been tuned to work together in harmony." - Mark Bill, Chief Platform Engineer
Ford engineers have tuned all systems in the new Ranger to deliver a superb driving experience.
“Our focus is the driver,” said Chief Platform Engineer Mark Bill.
“We have succeeded in delivering a well-balanced vehicle, and it’s this balance that delivers exactly the type of driving experience we were seeking.
“It’s the way everything works together – the powerful engines, strong chassis and body, car-like front suspension, load-bearing rear suspension, precise steering and cornering, potent stopping power and advanced safety features. An important factor is knowledge and understanding of the truck business – a business Ford knows better than anyone else.
“It also means having a deep understanding of truck customers and their needs so that we achieve the right balance between often-competing demands such as performance versus fuel economy or a comfortable ride versus load-carrying capacity.
“At Ford, our knowledge of what it takes to develop a better truck and to meet and exceed owners’ requirements is an integral component of the decision-making process. Apart from mechanical features, the driving experience is also enhanced by the overall ambience of the interior. This includes the quality of the fabrics, the touch of the controls, the ease of operation, supportive seats, low noise and vibration levels. Further peace of mind is provided by two front airbags as standard, and the availability of side airbags on XL (as part of a safety pack) and XLT models (a no-cost option from the second quarter). All of these features and attributes have been improved in the new Ranger for the benefit of customers.”
Ladder-frame chassis
The new Ford Ranger features a new frame and revised suspension to handle increased payload and trailer-towing ability while providing improved ride comfort. Ranger’s payload capacity exceeds one tonne on all models, and 3.0-litre manual models can haul up to 3.0 tonnes when fitted with a genuine Ford towpack and load leveling kit.
The strong ladder-frame platform features unique overlapped and cross-braced construction for greater rigidity. Compared with trucks based on more conventional H-beam or open beam configurations, Ranger’s platform delivers excellent load-bearing characteristics and durability.
At the same time, it also ensures better handling, ride comfort and passenger safety.
Suspension: strength and comfort
Ranger’s tougher and more durable suspension is also designed to improve ride comfort with car-like double-wishbone front suspension and revised rear leaf springs.
A longer and larger torsion bar at the front helps provide a more comfortable ride while the stabilizer bar prevents excessive pitching and rolling. Large diameter (32mm) dampers have been used to improve rigidity, driver control and confidence.
At the rear, new leaf springs provide maximum load capability together with improved ride and handling.
“Ranger is, first and foremost, an authentic ‘Built Ford Tough’ vehicle – that’s what truck customers expect and what they need. We have chosen the best suspension system, front and rear, to support the daily demands placed on this workhorse vehicle – and we have been able to optimise the chassis to provide great ride and handling levels,” Bill said.
Ranger’s leaf springs are longer than the previous model’s (1320mm vs. 1200mm) and feature a linear spring rate for improved ride comfort and durability. A two-stage set-up allows the second set of leafs to engage only when demanded by heavier loads.
Leaf-spring positioning is optimized to suppress roll steer, and stiffer rear spring shackles and brackets deliver greater rigidity.
Optimised steering
New Ranger delivers balanced steering response with a robust ball-and-nut system.
The density of the natural rubber bushings has been increased 15 percent to make it stronger and to provide more responsive steering. At the same time, handling characteristics have been optimized to make low-speed manoeuvers such as parking easier while ensuring greater stability at high speeds.
Improved aerodynamics for new Ranger also result in more precise high-speed handling with less susceptibility to strong cross-winds.
Wheels and tyres
New Ranger 4x2 and 4x4 models sit on a large tyre footprint for improved traction, ride comfort and passenger safety.
Standard steel wheels are 15-inch, teamed with 215/70 series rubber on single cab chassis and pick-up XL 4x2 models, and 235/75 on 4x2 Hi-Rider and 4x4 XL models. Ranger XLT models have 16-inch alloy wheels fitted with 245/70 tyres.
Ford chose to adopt all-terrain tyres because they provide great grip and traction over a variety of surfaces, especially in bad weather.
Brakes
ABS brakes are standard on Ranger XLT models, and are available as part of the optional safety pack across the rest of the line up. Ranger has impressive stopping power for the safety of its occupants – even when fully laden and towing a heavy load.
Up front, the braking system features 289mm ventilated discs while the rear wheels have leading and trailing drums that are 21mm wider than the outgoing model.
When ABS is fitted, added stopping power is provided by electronic brake-force distribution (EBD), which adjusts the braking bias front-to-rear for optimum braking power.
SUPERIOR FUNCTIONALITY
"Ranger customers tend to use the vehicle’s capabilities extensively. They absolutely rely on their trucks to live up to these challenges. New Ranger has the performance and capability to take you, your family and your cargo anywhere you need to go." Mouin Harbali, Truck Vehicle Engineering Manager
New Ford Ranger 4x4 is a true off-roader – rugged and capable in the harshest conditions.
For 2007, the Ranger’s proven off-road capability gets even better with improved powertrain and revised suspension that will enable it to negotiate challenging terrain. The new common-rail direct-injection turbo-diesel engines offer power when it is needed with substantially more torque for plowing through the tough stuff. The flexible performance is delivered to the wheels through a proven 4x4 transfer case, which provides optimum off-road traction.
Off-road testing was conducted at Ford proving grounds in the United States and Japan as well as a military course in Thailand. Additional 4x4 testing was conducted in the rugged conditions of Borneo, the Australian outback and South Africa.
Ranger shines in challenging terrain. It has superior ground clearance with approach, departure and ramp-over angles designed to make it easier to traverse obstacles, rivers and deep ruts. Depending on series, Ranger is fitted with 16-inch alloy (XLT) or 15-inch steel wheels and all-terrain tyres for excellent traction on and off the road.
All Ranger models are equipped with a 70-litre steel fuel tank, located forward of the rear axle and protected by a solid steel plate. This is a uniquely engineered tough fuel tank for increased safety, particularly in severe off-road conditions.
Payload and towing
Ranger has been developed to carry a full load and haul a heavy trailer over the most challenging surfaces. It is designed for a payload of up to 1406kg (Single Cab chassis) and a mammoth 3.0-tonne towing capacity on 3.0L manual models when fitted with a genuine Ford towpack and load leveling kit.
These impressive capabilities are made possible by Ranger’s new powertrain, stiffer body and upgraded suspension.
To validate these capabilities and ensure the expectations of demanding Ford truck customers are achieved, Ranger was subjected to extensive payload and trailer-towing tests in the United States, Australia and South Africa. Ranger excelled in these no-holds-barred sessions, including a rugged test at 50°C hauling a full payload and trailer up a steady grade of six percent with half the radiator and half the intercooler blocked.
Beyond the impressive payload and towing performance, Ranger also delivers a flexible storage system that is vital in meeting the needs of customers with a variety of cargo-carrying needs. The side walls of the cargo box are now 60mm taller, enabling owners to store more equipment. This translates into a cargo capacity of 1266 litres on single cab pick-up models, an improvement of 166 litres over the previous Courier.
But the flexibility does not end there. Ford has built an innovative cargo-management system inside the cargo box. Ledges along the walls accommodate a simple do-it-yourself shelving system that allows heavier items to be stored on the load floor of the pickup box while smaller items can be carried on top of the shelves.
Lower operating costs
New Ranger’s operating costs are improved, largely due to clever design to reduce repair costs and improved fuel economy.
The new turbo-diesel common-rail direct-injection (TDCi) engines are stronger and more fuel-efficient than the engines in the previous Courier. They deliver better performance as well as excellent real-world fuel economy that is among the best in the industry. Based on ADR 81/01, the 4x2 models provide a driving range of approximately 800km – ideal for non-stop long-distance travel between large cities and towns.
The long-life design of the engines also cuts the cost of ownership with reduced engine wear and oil deterioration. The timing belt, for example, is made of a more durable material and is equipped with an auto-adjuster, extending its expected life by one-third to 120,000km.
Changes to reduce powertrain stress and wear include a wider grille opening to increase air flow and cooling plus a new highly efficient cooling fan with extended shroud for lower engine and transmission temperatures.
Another example of Ford’s effort to reduce operating costs can be found with the innovative two-piece design of the front bumper. If there is accidental damage, the entire bumper does not necessarily need replacing. Rather, the lower half of the bumper is designed to absorb the energy of an impact. The system then allows convenient and cost-effective repairs by replacing only the damaged lower portion of the bumper.
Additionally, all 4x2 Hi-Rider and 4x4 models feature a large under-body protector to shield the engine and other components when traveling over rough terrain.
Ford, through its substantial dealer network, offers quality genuine replacement parts with competitive prices that result in lower overall repair costs.
Craftsmanship
In a dramatic leap forward from its predecessor, the new Ranger matches many passenger cars for its high standards of craftsmanship. Superior quality materials are used, particularly in seat fabrics, door trims and the center console to make the interior more relaxing, particularly for long trips. Not only do these materials add a refined ambience to the interior, they also have a more up-market feel that adds to the overall impression of comfort and quality.
Controls have been designed so they are easier to use. They have been placed more intuitively to improve ergonomics in the cabin, making driving more pleasant and less tiring.
Improved craftsmanship is also revealed in the external design with the front bumper beam concealed under the body-color fascia. This provides a significantly reduced gap between the bumper and front end.
Other examples include:
* Integrated front bumper, grille and fog lamps (on XLT models only);
* Easy-grip door handles;
* Tighter panel fit;
* Screwless rear combination lamp;
* Modern instrument panel with bright silver centre stack;
* Silver surround for the ventilator louvre, meter ring, shifter knob top, inner door handle and power switch panel (on XLT models only);
* Fuel door integrated into the wheel fender
Reduced noise, vibration and harshness
The all-new Ranger delivers a substantially quieter environment with less noise, vibration and harshness from engines, road and wind.
Common-rail direct-injection technology in Ford’s new TDCi engines dramatically reduces combustion noise and engine knock under heavy acceleration. This is achieved by precise multiple injections of fuel, making the cabin interior much quieter.
The new variable geometry turbocharger, cooling fan and front-end accessory drive belts also reduce noise as well as being more efficient. Further gains were realised with the manual transmission: its dual-mass flywheel and triple-cone synchronizers cut vibration and noise from the transmission gear and driveline. Even the Ranger’s new air-cleaner design lowers induction noise and helps to make Ford’s newest pickup a quieter, more pleasant place to spend time.
The determination to reduce noise, vibration and harshness did not stop with the engine. Ranger’s stiffer frame, improved body and suspension and new engine and transmission mounts all contribute to reduced noise, vibration and harshness. The cabin construction has been optimised to prevent undesirable vibrations, giving the driver confidence and comfort for long cross-country driving even with a full load.
Improved seals around the doors and glass and new door-latching mechanisms have dramatically cut wind noise, along with better air flow over the new external mirrors to reduce buffeting.
Other actions to reduce road noise include new all-terrain tyres, thicker and more widespread use of floor damping and a new dash insulator.
Built Ford Tough
New Ranger has undergone extensive development in extremely severe testing conditions by engineering teams in Europe, the United States, Asia, Australia and South Africa. To prove Ranger’s reliability as a tough, rugged vehicle, testing was conducted under laboratory and real-world conditions ranging from -250C to 500C.
More than 60 early production vehicles were driven almost one million kilometers on proving grounds to ensure Ranger’s structural capability and to provide the 'Built Ford Tough' stamp of approval.
Testing for drivability, performance, towing, payload and ride comfort was also conducted on local highways, roads and off-road areas. Early production vehicles were driven through the mountain ranges of northern Thailand and Laos, the jungles of Borneo, the Australian outback and Kruger National Park in South Africa.
Validation of Ranger’s dependability and performance involved local vehicle development engineers from around the world, trained to perform extreme vehicle testing. Ford truck owners and operators from many markets were asked to demonstrate how customers use Ford trucks in their daily routines and to ensure the new Ranger would meet and exceed their needs and expectations.
High-tech laboratories, advanced Computer Aided Engineering (CAE) and the latest vehicle testing technology were used to ensure robust, durable, rugged and reliable engineering. For example, vehicle systems were subjected to the equivalent of 250,000km of shaking abuse to ensure the strength and capability of the frame, suspension and body construction.
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