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My 1996 Ford Ranger 4x4 (TRS-2) Re-Build


Jim Oaks

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Transmission
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2WD / 4WD
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Total Lift
6-inches
Tire Size
33x12.50x15
The Pains Of Getting This Ranger Registered In Texas:

So in order to get this Ranger registered in Texas, I have to get it inspected. The inspection involves hooking up a scanner and checking for an On-Board Diagnostics (OBDII) emissions test.

What systems are checked during the OBDII test?

The On-Board Diagnostics (OBDII) emissions test for 1996 & newer vehicles consists of the following:

Check 1 - Malfunction Indicator Lamp (MIL) or Service Engine Soon Light, Check Engine Light, Check Engine Symbol check This is considered the bulb check portion of the test. The light must come on when the ignition is turned to the ON position and the light must go OFF when the engine is started. The inspector answers these two bulb check questions as either a PASS or FAIL. If the light is not working, the vehicle will FAIL the test, because the purpose of the light is to alert the driver of the vehicle that there is a problem with the OBDII system (exceeding emissions) and the vehicle needs to be diagnosed and repaired.

Check 2 - MIL Command Status and Diagnostic Trouble Codes (DTC's) check If the MIL command status is ON, then the vehicle's Powertrain Control Module (PCM) is commanding the MIL to turn ON, because a problem has been detected within the OBDII system and a DTC has been set. For example, an engine misfire DTC - PO301. If the MIL command status is ON with a DTC set, the vehicle will fail. If the OBDII system is operating properly, the MIL command status will be OFF.

Check 3 - OBDII (Non -Continuous) Readiness Monitors check. These monitors are like self checks of each emissions component (EGR, O2 sensor, etc) within the OBDII system. These non-continuous monitors are considered Ready until either DTC's have been cleared with a scan tool or if battery power has been disconnected, then the monitors will reset back to Not Ready.

In order to get the monitors set back to Ready, the vehicle must be driven through a drive cycle, which is a combination of city/highway driving for a set period of time. This drive cycle relearns the OBDII system and rechecks all of the emissions component's individual systems. As each system completes its own self test, the monitor will set back to Ready.

Effective October 15, 2008:

For vehicles year model 2001 and newer, we allow one (1) non-continuous monitor to be Not Ready and still pass the test, but two (2) or more Not Ready's will cause the vehicle to fail.

For vehicles year model 1996 – 2000, we allow two (2) non-continuous monitors to be Not Ready and still pass the test, but three (3) or more Not Ready's will cause the vehicle to fail.

There are three (3) continuous monitors that are always Ready: Misfire, Fuel System, and Comprehensive Components. If you look at your Vehicle Inspection Report (VIR), you will see the emissions monitors listed and their Ready/Not Ready status. If any of the non-continuous monitors say N/A (Not Available) or N/S (Not Supported), then there is no monitor for that system.

The Problem:

Since I towed the Ranger back to Texas with the battery disconnected, the Ranger is not test ready.

31800

Everything shows ready but the CAT.

Since I can't get the Ranger inspected, I got a Texas title and a 30-day tag. It appears that I need to drive the Ranger for a while to get it ready for testing. I've driven it a few times, and then today I drove it on the highway 14-miles each way to a Dairy Queen keeping it above 55-MPH, and the damn thing still isn't showing ready. WTF!?

The other thing is that this is showing me (12) codes:

trs-2_code-1.JPG

Code 1: P1443 EVAP Emission CTRL System CTRL Valve

trs-2_code-2.JPG

Code 2: P0155 O2 Sensor Heater Circuit Bank 2 Sensor 1

trs-2_code-3.JPG

Code 3: P0401 Exhaust Gas Recirculation Flow - Insufficient Detected

trs-2_code-4.JPG

Code 4: P1443 EVAP Emission CTRL System CTRL Valve

trs-2_code-5.JPG

Code 5: P0155 O2 Sensor Heater Circuit Bank 2 Sensor 1

trs-2_code-6.JPG

Code 6: P0401 Exhaust Gas Recirculation Flow Insufficient Detected

trs-2_code-7.JPG

Code 7: P1443 Evap Emission CTRL system CTRL Valve

trs-2_code-8.JPG

Code 8: P0155 O2 Sensor Heater Circuit Bank 2 Sensor 1

trs-2_code-9.JPG

Code 9: P0401 Exhaust Gas Recirculation Flow Insufficient Detected

trs-2_code-10.JPG

Code 10: P1151 Lock of HO2S21 Switch - Sensor Indicates Lean

trs-2_code-11.JPG

Code 11: P1151 Lock of HO2S21 Switch - Sensor Indicates Lean

trs-2_code-12.JPG

Code 12: P1151 Lock Of HO2S21 Switch - Sensor Indicates Lean

:dntknw:

I need to figure out how to get CAT ready, get rid of these codes, and get this damn thing inspected.

OH YA,

I need to replace the bulb for my Check Engine light.
 


Rock Auto 5% Discount Code: 80CBDBD15DC160 Expires: January 4th, 2021

bobbywalter

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Total Lift
sawzall?
Tire Size
33-44
My credo
it is easier to fix and understand than "her"
there were no hard permanant codes but it was lean a few times in ohio.


before i cleaned up the throttle body there were no codes in pa....drove about 1/4 tank thru it.


never checked it after cleaning the throttle body. cel did work as well a few times. had intermittent codes until fresh gas was in it in ohio. plugs were okish..acceptable. dont know where my notebook is with cop results. i should have put plugs in it....pretty sure there is a box of them. look at all of the fuses.

heater circuit fuse should be under the hood box somewhere... that will cause some headaches.
 

bobbywalter

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FORD mostly
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4WD
Total Lift
sawzall?
Tire Size
33-44
My credo
it is easier to fix and understand than "her"
i think number 5 was 18 percent from avg....ifi did the math right.

and figured that for the miss i was detecting.


move...or get an address to an area that does not have emission testing. because the next engine probably wont like emission testing.
 

Jim Oaks

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4.0 V6
Transmission
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2WD / 4WD
4WD
Total Lift
6-inches
Tire Size
33x12.50x15
What's wrong with the suspension bouncing? It handles way worse driving down a rutted road. And if you hit a bad enough bump you will break the strap, possibly sending pieces into oncoming or following traffic.

Same applies to anyone strapping a vehicle to a car trailer. NEVER strap to sprung weight like the frame or bumpers. Always strap to unsprung suspension like axles or tires. If I was on my regular computer I would post a pic of how I strap down as an example of one way to strap safely.
I generally just strap down the axles, but I realized the front shock was hitting the radius arm when I was leaving Ohio, so I strapped down the frame to keep it from bouncing and beating the shock up. It was easier than digging the tools out of the bottom of the big box in the truck bed, and removing the shock.

It was a weird trade off. With the frame strapped down, I didn't feel it swaying as much behind me, but it transferred some force in to the back of the Loan Ranger. With the suspension free, it didn't nudge me as much, but I could feel it swaying.
 

bobbywalter

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1988
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FORD mostly
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BIGGER
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Automatic
2WD / 4WD
4WD
Total Lift
sawzall?
Tire Size
33-44
My credo
it is easier to fix and understand than "her"
What's wrong with the suspension bouncing? It handles way worse driving down a rutted road. And if you hit a bad enough bump you will break the strap, possibly sending pieces into oncoming or following traffic.

Same applies to anyone strapping a vehicle to a car trailer. NEVER strap to sprung weight like the frame or bumpers. Always strap to unsprung suspension like axles or tires. If I was on my regular computer I would post a pic of how I strap down as an example of one way to strap safely.


this is 101 general for towing vehicles..... variations of course from there.
 

Jim Oaks

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Transmission
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2WD / 4WD
4WD
Total Lift
6-inches
Tire Size
33x12.50x15
31818


At least I got to drive it some this evening​
 

mtnrgr

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6" Skyjacker, with 1.5" coil spacers, custom radius arms, custom traction bars
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31x10.50
My credo
Lord God is my guardian
Great looking picture of the Ranger, and the good ole Texas sunset. Have seen many of those in my times of going there. Now the Ranger in Texas, don't need to be concerned with rust, like it did in Ohio when you lived there.
 

deathbypsi

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Great job guys! Truck looks awesome!
 

Jim Oaks

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6-inches
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33x12.50x15
Skyjacker Shock Correction - Not Leaking:

I was wrong about the Skyjacker shock leaking oil. I typically use the silver anti-seize. When I was at Bobby's, he had the copper anti-seize, and I had put some on the upper shock mount before I slid the shock on. It had dripped down on to the shock piston, and on to the top of the shock. The color and consistency made it look like the shock had leaked oil.

Still Not Ready To Test:

I drove the Ranger some more yesterday. The CAT still isn't showing that it's ready to test, and the check engine light doesn't come on at all when you turn the key on. On a side note, I replaced the fuse #17 for the cigarette lighter.

Looks like I'm just going to have to tackle these codes.

Code 1: P1443 EVAP Emission CTRL System CTRL Valve
Code 2: P0155 O2 Sensor Heater Circuit Bank 2 Sensor 1
Code 3: P0401 Exhaust Gas Recirculation Flow - Insufficient Detected
Code 4: P1443 EVAP Emission CTRL System CTRL Valve
Code 5: P0155 O2 Sensor Heater Circuit Bank 2 Sensor 1
Code 6: P0401 Exhaust Gas Recirculation Flow Insufficient Detected
Code 7: P1443 Evap Emission CTRL system CTRL Valve
Code 8: P0155 O2 Sensor Heater Circuit Bank 2 Sensor 1
Code 9: P0401 Exhaust Gas Recirculation Flow Insufficient Detected
Code 10: P1151 Lock of HO2S21 Switch - Sensor Indicates Lean
Code 11: P1151 Lock of HO2S21 Switch - Sensor Indicates Lean
Code 12: P1151 Lock Of HO2S21 Switch - Sensor Indicates Lean

As you can see, some are repeated. So what I'm getting is this:

P1443
EVAP Emission CTRL System CTRL Valve
I read that "The P1443 in 99% of all cases is set due to a bad purge flow sensor (P0401 below) and replacing it will most likely clear this code"​
P0155 O2 Sensor Heater Circuit Bank 2 Sensor 1
What are the common causes of code P0155 ?​
- Problem on the ground side of the O2 sensor heater circuit​
- Problem on the power side of the O2 sensor heater circuit​
- O2 sensor heater element has high resistance​
- O2 sensor heater element has an open circuit​
P0401 Exhaust Gas Recirculation Flow - Insufficient Detected
What could cause the code P0401​
- clogged or restricted EGR passages​
- faulty EGR valve​
- EGR valve stuck closed​
- problems with the DPFE sensor (Ford)​
- problems with hoses to the DPFE sensor (Ford)​
- problem with the EGR vacuum switching valve (Toyota)​
- clogged catalytic converter​
- carboned up EGR temperature sensor​
- vacuum supply issues at the vacuum-operated EGR valve​
- electrical problems with the EGR valve control circuit​
- engine computer problems​
P1151 Lock of HO2S21 Switch - Sensor Indicates Lean
P1151 FORD Possible Causes​
- Faulty Upstream Oxygen Sensor Bank 2 (P0155 above?)​
- Fuel pressure high or low​
- MAF sensor dirty/defective​
- Vacuum leak on engine​
- Leaking fuel injector or fuel pressure regulator​
- Faulty Powertrain Control Module (PCM)​
 
Last edited:

bobbywalter

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1988
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FORD mostly
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BIGGER
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2WD / 4WD
4WD
Total Lift
sawzall?
Tire Size
33-44
My credo
it is easier to fix and understand than "her"

bobbywalter

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FORD mostly
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BIGGER
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4WD
Total Lift
sawzall?
Tire Size
33-44
My credo
it is easier to fix and understand than "her"
How is the switching rate.
 

Jim Oaks

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4WD
Total Lift
6-inches
Tire Size
33x12.50x15
Switching rate?
 

Jim Oaks

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Total Lift
6-inches
Tire Size
33x12.50x15
Correction:

P0155
O2 Sensor Heater Circuit Bank 2 Sensor 1

I believe Bank 1 would be the side of the engine that cylinder 1 is on, which is the passenger side. So I think Bank 2 is actually on the drivers side. I initially said I thought it was the passenger side sensor.

32021
 

85_Ranger4x4

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I would have guessed it the other way.
 

deathbypsi

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Seems to me almost all of those codes could be traced back to some kind of vacuum leak at the intake
 


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