Ford Flex 2009 Repair Manual Set

Use the workshop chapters for fault isolation, component testing, and repair. The Ford guides cover vehicle operation, maintenance intervals, and service records.

Workshop scope: The 2010 Owner’s Guide covers operation and maintenance for the base 3.5L and the 3.5L EcoBoost. Workshop procedures cover the 2009 3.5L and 6F50. The 6F50 chapter covers diagnosis, in-vehicle service, and transaxle removal and installation, with internal overhaul outside its scope. Full vehicle wiring schematics are referenced separately. The set includes selected internal circuit diagrams, connector pin tables, and component locations.

PDF search, bookmarks, and file layout

Finding procedures and pinouts: The repair chapters and Ford guides have searchable body text. Some labels and form text are embedded in images. All four Ford guides have PDF bookmarks. The repair chapters can be navigated by file name and text search. Pin numbers in the 6F50 connector diagrams are legible when zoomed in.

The English-language ZIP contains 73 printable PDFs with 5,768 pages total, including three supplemental pages in the 2010 Owner’s Guide.

Engine, driveline, and electrical troubleshooting

This selected preview highlights workshop procedures and reference material. The set also includes power liftgate service and windshield wiper and washer diagnosis.

• 3.5L engine: In-vehicle repair, engine removal and installation, teardown and reassembly, cylinder head and crankshaft work, valve-clearance checks, and VCT and timing-chain service.
• Fuel, ignition, and emissions: Fuel delivery and ignition checks, electronic throttle diagnosis, and pinpoint tests for EVAP, catalyst efficiency, and misfire faults.
• 6F50 and AWD: Shift and torque-converter road tests, line-pressure and stall-speed checks, solenoid strategy programming, cooler backflushing, and PTU, halfshaft, and rear differential service.
• Brakes, steering, and suspension: ABS and AdvanceTrac pinpoint tests, hydraulic control unit service, brake bleeding, power steering repairs, subframe work, alignment checks, and TPMS training.
• Electrical and restraint systems: Module fault-code charts and pinpoint tests for PATS, lighting, locks, parking aid, and SYNC/APIM, plus airbag depowering and occupant-classification checks.
• Climate control and body repair: Manual, automatic, and rear HVAC diagnosis, refrigerant recovery and leak testing, plus body dimensions, approved sectioning points, weld bonding, and corrosion protection.

The repair chapters suit technicians and experienced owners who can use scan tools, electrical test equipment, and the specified service tools. The owner and maintenance guides also support routine service and roadside procedures.

Pinpoint tests and module setup

The engine-performance pinpoint tests cover no-start faults, power and ground circuits, reference voltage, sensor inputs, fuel delivery, and VCT. The separate Reference Values chapter links symptoms to scan-data PIDs and typical readings. For an intermittent fault, those tables help you choose what to monitor before moving to connector-pin measurements or commanded output tests.

The electrical chapters cover programmable module installation, PATS parameter reset, window and roof initialization, and the occupant classification system zero-seat-weight test. The 6F50 connector diagrams map solenoid-body pins to the transmission-range, turbine-speed, and output-speed sensor circuits.

Build-specific fluids and component service

The engine chapter distinguishes vehicles built before January 19, 2009, from those built on or after that date. Check the build date before selecting coolant, since mixing the two specified types reduces corrosion protection. The chapter also distinguishes oil-filter adapters and pickup tubes, oil-cooler configurations, and early versus late or replacement right-hand timing-chain guides. It warns that incomplete VCT housing dowel engagement can cause severe engine damage.

The 6F50 chapter distinguishes early-build MERCON V from late-build MERCON LV and gives the solenoid-body strategy download and drive cycle. Match both the fluid and the programmed strategy to the unit to avoid shift problems. PTU service covers specified seals and the output flange. Internal gear, bearing, case, or shaft damage calls for unit replacement.

Owner and maintenance references

The Ford guides cover oil-life and message-center resets, fuse and relay charts, towing, AWD operation, keys and security, fluid capacities, and service part-number tables. The maintenance guides provide service intervals and record pages.

6F50 line-pressure reference

The 6F50 diagnostic chart gives an approximate line pressure of 80–90 psi (552–621 kPa) in Drive at idle. The chart lists separate ranges for other selector positions and for the wide-open-throttle stall test.