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1-Body & Equipment Manual PDF
1-Body & Equipment Manual PDF
REPAIR MANUAL
WIRING DIAGRAM
BODY & EQUIPMENT MOUNTING MANUAL
TO MODEL INDEX FORD RANGER 2011.5MY BODY AND EQUIPMENT MOUNTING MANUAL
VIEW MAIN INDEX
Table of Contents
1 General Information
1.1 About This Manual..........................4 1.14.1 Towing Requirements........................29
1.1.1 Introduction............................................4 1.14.2 Towing...................................................29
1.1.2 Important Safety Instructions..............4 1.14.3 Towing capacities...............................29
1.1.3 Warnings, Cautions and Notes in This 1.14.4 Towing Specifications.........................30
Manual.....................................................4
1.1.4 How to Use This Manual......................4
1.2 Commercial and Legal Aspects.....5
2 Chassis
1.2.1 Terminology............................................5
1.2.2 Warranty on Ford Vehicles...................5 2.1 Suspension System......................31
1.2.3 Legal and Vehicle Type Approval........5
1.2.4 Alternative Type Approval....................5
1.2.5 Legal Obligations and Liabilities...........5 4 Electrical
1.2.6 General Product Safety
Requirement..........................................5
4.1 Battery and Cables......................32
1.2.7 Product Liability......................................6
4.1.1 Battery Information.............................32
1.2.8 Restraints System.................................6
4.1.2 Generator and Alternator..................33
1.2.9 Drilling and Welding...............................6
4.2 Exterior Lighting..........................34
1.2.10 Minimum Requirements for Brake
4.2.1 Reversing Lamps................................34
system and Load Apportioning Valves
4.2.2 Additional External Lamps.................34
..................................................................6
4.2.3 Lamps Hazard / Direction
1.2.11 Road Safety............................................6
Indication..............................................34
1.3 Conversion Homologation.............7
4.2.4 Electrically operated Door
1.4 Electromagnetic Compatibility
Mirrors...................................................34
(EMC).............................................8
1.4.1 Suggested Antenna Location.............9
1.5 Vehicle Duty Cycle Guidelines......10
1.5.1 Conversion Affect on Fuel Economy
5 Body and Paint
and Performance.................................10
1.5.2 Vehicle Ride and Handling 5.1 Body.............................................35
Attributes...............................................10 5.1.1 Body Structures - General
1.6 Jacking..........................................11 Information...........................................35
1.7 Lifting............................................13 5.1.2 Integrated Bodies and
1.8 Noise, Vibration and Harshness Conversions.........................................35
(NVH)............................................14 5.1.3 Chassis Cab.........................................36
1.9 Vehicle Transportation Aids and 5.1.4 Front End Integrity for Cooling, Crash,
Vehicle Storage............................15 Aerodynamics and Lighting...............42
1.10 Package and Ergonomics............16 5.1.5 Tipper Bodies.......................................42
1.10.1 General Component Package 5.1.6 Tank and Dry Bulk Carriers................42
Guidelines..............................................16 5.1.7 Roof Racks...........................................43
1.10.2 Driver Reach Zones.............................16 5.2 Air Bag Supplemental Restraint
1.10.3 Driver Field of View..............................16 System (SRS)...............................45
1.10.4 Conversion Affects on Parking 5.2.1 Air Bags.................................................45
Aids.........................................................16 5.3 Safety Belt System.......................48
1.10.5 Aids for Vehicle Entry and Exit...........16 5.4 Corrosion Prevention..................49
1.11 Package and 5.4.1 General.................................................49
ErgonomicsSpecifications........17 5.4.2 Repairing Damaged Paint..................49
1.11.1 Recommended Body 5.4.3 Under Body Protection and
Dimensions............................................17 Material.................................................49
1.11.2 Chassis Cab Body - Basic 5.4.4 Painting Road Wheels........................49
Dimensions and Weights....................19 5.4.5 Contact Corrosion..............................49
1.11.3 Kerb Weights........................................21 5.5 Frame and Body Mounting...........50
1.11.4 Front, Rear and Side Under-run 5.5.1 Mounting Points and Tubing.............50
Protection.............................................22 5.5.2 Self-Supporting Body Structure........51
1.12 HardwareSpecifications...........23 5.5.3 Frame Drilling and Tube
1.13 Load Reinforcing...........................................52
DistributionSpecifications........24 5.5.4 Ancillary Equipment - Sub Frame
1.13.1 Load Distribution Calculations - Driver Mounting..............................................52
and Passenger Weight 5.5.5 Area for Fitting Additional Body
Distribution............................................24 Attachments to the Rear of the
1.13.2 Center of Gravity.................................26 Bumper. ...............................................52
1.14 Towing.........................................29 5.5.6 Water Tank on Camper Vehicles......53 3
BACK TO CHAPTER INDEX FORD RANGER 2011.5MY BODY AND EQUIPMENT MOUNTING MANUAL
TO MODEL INDEX
1 General Information
The Vehicle Converter should warrant its design, Ford recomends that the Vehicle Converter and
materials and construction for a period at least Ford Dealer must understand their individual and
equal to any applicable Ford warranty. joint responsibilities in supplying a safe and
compliant motor vehicle fitted with safe and
The Vehicle Converter must ensure that any compliant accessories.
alteration made to a Ford vehicle or component
does not reduce the safety, function, or durability
of the vehicle or any component. 1.2.6 General Product Safety
Requirement
The Vehicle Converter shall be solely responsible
for any damage resulting from any alteration The Vehicle Converter shall ensure that any
made by the Vehicle Converter or any of its vehicle it places on the market complies with all
agents to a Ford Vehicle Component. local laws relating to the safe carriage of loads
The Vehicle Converter releases Ford from all on public roads. The Vehicle Converter shall also
claims by any third party for any cost or loss ensure that any alteration it makes to a Ford
(including any consequential damages) arising vehicle or component does not reduce its
from work performed by a Vehicle Converter compliance with local design rules.
unless Ford has given its prior written consent The Vehicle Converter must provide sufficient
to such liability. Load Restraint tie down points or
compartmentised storage areas that enable the
1.2.3 Legal and Vehicle Type driver to safely carry loads that match the use
Approval criteria for which the body was designed.
The Vehicle Converter shall release Ford from
All components embodied on Ford vehicles all liability for damages resulting from:
are approved to the applicable legal
requirements. Failure to comply with these Body Equipment
Mounting directives, in particular warnings.
Ford vehicles have Type Approval for the
intended marketing territories. Faulty design, production, installation,
assembly or alteration not originally specified
WARNING: Exception - Incomplete by Ford.
vehicles require further approval
when completed by the Body Builder. Failure to comply with the basic fit for purpose
principles inherent in the original product.
The Ranger range has Type Approval for
many territories, although the full range of WARNINGS:
vehicles shown in this manual are not
necessarily released in all territories. Check Do not exceed the gross vehicle
with your local Ford National Sales Company mass, gross train mass, axle plates
representative. and trailer plate.
Do not change the tire size or load
rating.
The Vehicle Converter shall be liable for any Drilling and welding of frames and body
product liability (whether for death, personal structures have to be conducted following the
injury, or property damage) arising from any guidelines within this document.
alteration to a Ford vehicle or component made
by the Vehicle Converter or any of its agents. 1.2.10 Minimum Requirements for
Ford shall not be liable for any such liability Brake system and Load
(except as provided by law). Apportioning Valves
The Vehicle Converter or equipment
manufacturer is liable for the: It is not necessary or recommended to modify
the load apportioning valves, however, if a
Operational reliability and road-worthiness of special conversion should require
the vehicle to its original intent. modifications,
Operational reliability and road-worthiness of Maintain original settings.
any component or conversion, not listed in
Maintain brake certification load
original Ford documentation.
distribution.
Operational reliability and road-worthiness of
Changes to the Antilock Brake System (ABS),
the vehicle as a whole (for example the body
Traction Control System (TCS) and Electronic
changes and/or additional equipment must
Stability Program (ESP) system are not
not have a negative effect on the driving,
permitted.
braking or steering characteristics of the
vehicle).
Subsequent damage resulting from the 1.2.11 Road Safety
conversion or attachment and installation of
unique components, including unique The respective instructions should be strictly
electrical or electronic systems. observed to maintain operational and road safety
of the vehicle.
Functional safety and freedom of movement
of all moving parts (for example axles, springs,
propeller shafts, steering mechanisms, brake
and transmission linkage).
Functional safety and freedom of the tested
and approved flexibility of the body and
integral chassis structure.
Frequency Overview
Frequency Band MHz Maximum Output Power Antenna Position
Watts (Peak RMS)
1-30 50W 1
30-54 50W 1
68-87.5 50W 1
142-176 50W 1
380-512 50W 1
806-940 10W 1
806-940 2W* 1
1200-1400 10W 1
1710-1885 10W 1
1710-1885 1W* 1
1885-2025 10W 1
1885-2025 1W* 1
2400-2500 0.1W Anywhere
* Only for GSM/3G cellular phones, with a patch antenna installed inside of the front windscreen
E134105
1.6 Jacking
WARNINGS: The spare wheel winch is located above the
spare wheel and can be accessed from the rear
Always position the vehicle on a hard
of the chassis frame.
level surface. If the vehicle must be
jacked up on a soft surface use load The jack must be assembled and fixed
spreading blocks under the jack. appropriately to the body to ensure safety,
Always chock the wheel diagonally durability and accessibility.
opposite the jacking point. Failure to
follow these instructions may result
in personal injury.
Do not get under a vehicle that is
supported by a jack.
This jack is only intended for
changing wheels.
CAUTIONS:
It is important that only the correct
jacking and support locations are
used at all times. E140512
All Vehicles
E133942
D F
A
E134164
Single Cab
Model Weight Range (KG)
2.5L Petrol 4x2 TBC
2.2L Diesel 4x2 TBC
2.2L Diesel 4x4 TBC
3.2L Diesel 4x4 TBC
Double Cab
Model Weight Range (KG)
*
2.2L Diesel 4x2 TBC
2.2L Diesel 4x4 TBC
3.2L Diesel 4x4 TBC
*
Vehicles with increased ride height.
Stretch Cab
Model Weight Range (KG)
*
2.2L Diesel 4x2 TBC
*
3.2L Diesel 4x2 TBC
2.2L Diesel 4x4 TBC
3.2L Diesel 4x4 TBC
*
Vehicles with increased ride height.
1.12 HardwareSpecifications
Material Specification, Strength and Torque
Standard Hardware and Tightening Torques (Nm) Bolts/Studs: ISO 898-1, Nuts: ISO
898-2
Grade 4.8 Grade 8.8 Grade 10.9
Thread Size Minimum Maximum Minimum Maximum Minimum Maximum
M4 1.1 1.4 2.4 3.4
M5 2.2 2.7 4.9 6.7
M6 3.7 4.7 8.5 11.5 11.0 15.0
M8 20.0 28.0 25.0 35.0
M10 41.0 55.0 50.0 70.0
M12 68.0 92.0 95.0 125.0
M14 113 153 150 200
M16 170.0 230.0 230.0 310.0
M18 252.0 317.0 317.5 399.4
M20 345.0 430.0 434.7 541.8
M22 470.0 590.0 592.2 743.4
M24 600.0 750.0 756.0 945.0
Single Cab
B
A
E133921
Stretch Cab
E134584
1.14 Towing
1.14.1 Towing Requirements Any modifications to the vehicle must be
noted in the owner's handbook or new
When a towing device is required, the Vehicle descriptive literature included with the owner's
Converter should use a Ford approved tow bar. documentation.
Refer to: 1.13 (page 24). Tow bar installations must meet the
Load Distribution requirements of the local design rules.
Refer to: 1.6 Jacking (page 11). Whenever frame drilling is necessary use tube
reinforcement.
Refer to: 5.5 Frame and Body Mounting (page
1.14.2 Towing 50).
For towing devices fitted by the Vehicle
Converter the following applies: 1.14.3 Towing capacities
Towing allowances must not exceed those
of the standard vehicle. WARNING: Do not exceed the gross
vehicle weight, gross train weight
and gross axle weights stated on the
vehicle identification plate.
Rest Of World
Variant Drive Transmission Without With trailer Trailer nose
trailer brake brake kg weight kg
kg (lbs) (lbs) (lbs)
2.5L Petrol 4X2 Manual 750 (1653.5) 2200 (4850) 165 (364)
*
4x2 Manual 750 (1653.5) 1700 (3748) 225 (496)
4x4 Manual 750 (1653.5) 1100 (2425) 225 (496)
2.2L Diesel 4X2 Manual 750 (1653.5) 2200 (4850) 165 (364)
(88kW & *
4x2 Manual 750 (1653.5) 1600 (3527) 225 (496)
92kW)
4x4 Manual 750 (1653.5) 1600 (3527) 225 (496)
2.2L Diesel 4x2 Manual 750 (1653.5) 2500 (5511) 165 (364)
(110kW) *
4x2 (Drive ratio Manual 750 (1653.5) 1800 (3968) 225 (496)
3.31)
*
4x2 (Drive ratio Manual 750 (1653.5) 3350 (7385) 225 (496)
3.55)
*
4x2 Auto 750 (1653.5) 3350 (7385) 225 (496)
4x4 Manual and 750 (1653.5) 3350 (7385) 225 (496)
Auto
*
3.2L Diesel 4x2 and 4x4 Manual 750 (1653.5) 1800 (3968) 225 (496)
(Drive ratio
3.31)
*
4x2 and 4x4 Manual 750 (1653.5) 3350 (7385) 225 (496)
(Drive ratio
3.55)
*
4x2 Auto 750 (1653.5) 3350 (7385) 225 (496)
4x4 Auto 750 (1653.5) 3350 (7385) 225 (496)
*
Vehicles with increased ride height.
2 Chassis
2.1 Suspension System
WARNINGS:
Do not modify, drill, cut or weld any
suspension components, specifically
the steering gear system, subframe
or anti-roll bars, springs or shock
absorbers including mounting
brackets.
The rear leaf springs are
pre-stressed in manufacture and
should not be altered for rate or
height in any way during vehicle
conversion. Adding or removing
leaves may result in failure or
reduced function of the spring as well
as other vehicle related issues for
which Ford Motor Company can not
be held responsible.
CAUTIONS:
Modifications to the suspension
system can cause a deterioration of
the vehicle handling characteristics
and durability.
When carrying out welding work the
springs must be covered to protect
them against weld splatter.
Do not touch springs with welding
electrodes or welding tongs.
NOTE: Do not modify the wheelbase or add any
type of frame extension to vehicles fitted with
Electronic Stability Program ESP.
NOTE: Do not damage the surface or corrosion
protection of the spring during disassembly and
installation.
NOTE: Do not add any additional axles.
4 Electrical
Delayed Vehicles
4.1 Battery and Cables Vehicles held at the vehicle convertor premises
and not in use for longer than 4 days, should
4.1.1 Battery Information have the battery's negative cable disconnected.
Before shipping to the customer, the battery
If a battery is disconnected, there is no negative cable must be re-connected and the
requirement to reprogram the vehicle; the voltage re-checked. The voltage should be not
vehicle retains its normal power management less than 12.5 volts.
setting and remembers exactly what its previous
configuration was (although the central locking
latches may cycle if one of these was opened Battery Charging Procedure
manually in the intervening period). With the
radio, all of the settings are retained, but the key 1. Cold batteries will not readily accept a charge.
code needs to be entered to restore Therefore, batteries should be allowed to
functionality. The clock will need resetting. warm up to approximately 5C (41F) before
charging. This may require four to eight hours
at room temperature depending on the initial
Battery Voltage Requirements and temperature and battery size.
Testing 2. A battery which has been completely
discharged may be slow to accept a charge
All voltages are to be measured with an accuracy initially, and in some cases may not accept a
of: + / 5% of values published. charge at the normal charger setting. When
To maximize battery life, at the time of arrival at batteries are in this condition, charging can
the vehicle converter, all batteries must have a be started by use of the dead battery switch
minimum Open Circuit Voltage (OCV) of not less on chargers that have this facility equipped.
than 12.75 volts. 3. To determine whether a battery is accepting
When the battery is installed and connected to a charge, follow the manufacturers
the vehicle's electrical system with no load, the instructions for the charger and the dead
Closed Circuit Voltage (CCV) must not be less battery switch. If the switch is the
than 12.65 volts. When the vehicle is released to spring-loaded type, it should be held in the
the customer, the CCV must not be less than ON position for up to three minutes.
12.50 volts. 4. After releasing the dead battery switch and
with the charger still on, measure the battery
voltage. If it shows 12 volts or higher, the
Surface Charge Dissipation battery is accepting a charge and is capable
of being recharged. However, it may require
Prior to carrying out manual voltage checks, it is up to two hours of charging, with batteries
necessary to establish that the battery voltage colder than 5C (41F) before the charge rate
is stable and free from surface charges, that is high enough to show a charge on a
could be present due to certain engine run ammeter. It has been found that all
conditions making the voltage readings non-damaged batteries can be charged by
unreliable and inaccurate. this procedure. If a battery cannot be charged
To ensure surface charges are not present the by this procedure, a new one should be
following actions are recommended: installed.
5. A rapid recharge procedure has been
1. Turn the ignition key to position II and switch
developed for recharging batteries that have
on the headlamps (main beam) and if fitted,
passed the load test and only need a
the heated front window, rear window
recharge. This can be due to in-service
demister and the heater blower motor (on
no-start battery failures (vehicle will not crank
position II). Leave the vehicle in this condition
due to low battery state of charge) or battery
for at least 1 minute to dissipate what ever
discharged in vehicle due to key-off loads.
surface charge is present in the battery.
6. With the cables then disconnected, the
2. Turn the ignition key to position 0 and switch
battery can be rapidly recharged by using
off the loads; headlamps, heated
either of the following methods:
windshield/rear window demister and heater
blower motor. Leave the vehicle in this Carry out a two hour charge using 20A
condition for at least 5 minutes, before taking constant current (manual setting on charger).
a battery voltage reading. Carry out a two hour charge using a constant
potential (automatic setting on charger).
Battery Cable Fixing Torque The battery cables should be fixed to the
terminal posts with a torque of 4.8 Nm -/+
0.8Nm.
Battery Rules:
Lighting Loads
Lamp Controlling Device Vehicle Trailer Tow
Number plate lamp Body control module 2x5W
28W
Position / Parking lamp Body control module 5W
Front direction indicator Body control module 21W -
Brake lamps Body control module 21W 28W
Rear direction indicator Body control module 21W 24W
Reverse lamp Body control module 21W 24W
Rear fog lamp Body control module 21W 48W
Trailer tow maximum power ratings shown, also see trailer tow below.
Lighting Fuses
F74 20A Headlamp
F75 15A Front fog lamp
F76 10A Reversing lamp
Trailer Tow
4.2.4 Electrically operated Door
Vehicles fitted with a trailer tow as standard also Mirrors
come with a trailer control module for lighting.
When fitting low power LED lights that require WARNING: Do not tamper with the
less than 2W, the lights may flicker when in use. base system (controlled by Central
A trailer patch harness should be used with low Junction Box and multiplex
power LED lights. architecture) and any feeds taken
from the associated wiring or
CAUTION: Do not connect the trailer controller.
patch harness to the vehicle when
the trailer is not connected. NOTE: These options are not suitable for
aftermarket or Body Builder fit.
NOTE: The trailer patch harness is available from
your Ford authorised dealer.
Wheelhouse Envelope
X 1
H
A B
K
C D
r r
L
G
F
E E
X-X
E134132
Wheelhouse Dimensions
Dimension 215/ 255/ 265/ 265/ Dimension 215/ 255/ 255/ 265/65R17
70R16 70R16 65R17 65R18 70R16 70R16 70R16
A 455mm G* 190mm
B 425mm H 914mm 915mm 922mm 922mm
C 305mm K 588mm
D 275mm L 25mm
E 110 r 20mm
F 420mm 1 Center line of Vehicle
X Section through Center of Wheelhouse
* Dimension G is to the bottom of the swage
CAUTION: Uneven load distribution Ensure that any additional equipment in the
could result in unacceptable handling vicinity of the fuel tank will not damage the
and braking characteristics. tank in a crash condition.
When carrying out vehicle conversions / For any conversion structure attached to or
modifications the following points should be mounted onto the base vehicle cab structure
considered: the following applies:
Make sure that all of the reinforced holes Ensure that neither the conversion structure
provided in the chassis frame top surface are nor the existing vehicle structure get
used for full length bodies or sub-frames, see pre-loaded by the assembly process.
figures shown. Adhesive jointing is recommended but should
Make sure that the vehicle structural integrity be supplemented with mechanical fasteners
is maintained. to prevent initial peel and long term failure.
Do not drill into closed frame body members. Spread bolt loads to minimize local stress.
Make sure that the design for the body NOTE: The following chassis frame images and
alterations or additional structure disperse the dimensions are showing the previous Ranger
load evenly. (J97) chassis frame above the new Ranger
(P375) chassis frame for comparison purposes.
J97 B
D C
A
F G H
E
D
D
K L M
J
B
P375
D A
E F G H
N
J
K L M
E134152
Dimensions (mm) for Body Attachment Holes in Chassis Frame - Single Cab
Dimension J97 P375 Dimension J97 P375
A 20 16 H 1024 1086
B 13 28 J - 95
C 13 23 K 568 768
D 20 20 L 1007 890
E 1150 1244 M 496 505
F 1140 1244 N - 26
G 1140 1244 P - 20
B
C
E F G
J K
H
B
C
A
E F G
H
J K
E134154
Dimensions (mm) for Body Attachment Holes in Chassis Frame - Double cab
Dimension J97 P375 Dimension J97 P375
A 20 16 G 1024 1024
B 13 28 H - 95
C 13 23 J 776 890
D 20 20 K 498 505
E 1130 1244 L - 26
F 1140 1244 M - 20
B
C
E F G
J K
D A
C
E F G
L
H
J K
E134153
Dimensions (mm) for Body Attachment Holes in Chassis Frame - Stretch Cab
Dimension J97 P375 Dimension J97 P375
A 20 16 G 1024 1024
B 13 28 H - 95
C 13 23 J 776 1188
D 20 20 K 498 505
E 1130 1244 L - 26
F 1140 1244 M - 20
5.1.4 Front End Integrity for Very stiff sub-frames may damage the
Cooling, Crash, Aerodynamics chassis frame by preventing its natural flexing,
and Lighting therefore compliant mounts should be used,
with up to plus and minus 12mm compliance
Cooling Continuous air flow through the front with the vehicle laden or un-laden (whichever
end and engine compartment is not to be is worst case). Compliant mounts should be
hindered by adding any additional equipment. If rated with a minimum of 2mm deflection per
uncertain please consult the Ford dealer. 200kg mass at each chassis frame forward
Lighting Do not alter the lighting system. mount. Compliant mounts shall have captive
fail safe bolts.
Crash Do not cut, drill or weld any parts that
are load path relevant in case of crash. Do not Use two M10 grade 8.8 minimum bolts,
washers and self locking nuts at each solid
add material in the crash zone. This could affect
and compliant chassis frame location.
the crash sensor calibration.
Sub-frame must extend to the back of the
The side airbag system is not permitted if: cab and attach to all mounting locations, with
A swiveling device is fitted on the front seats. the forward end designed to minimize local
A side wall or any other additional material or frame stress. It is however, preferable to
structure is attached to the B-pillar inner mount the sub-frame onto the mounting
and/or outer area. brackets with a clearance to the chassis
frame top surface.
Static & Dynamic Sealing and Finishing
Ensure proper sealing against ingress of water, Side tipping loads/forces must be resolved
salt, dust etc. after cutting or drilling the body. by the sub-frame. It is not recommended to
Use Ford approved sealing and finishing material, strain the chassis frame.
and underbody corrosion protection.
Refer to: 5.4 Corrosion Prevention (page 49). 5.1.6 Tank and Dry Bulk Carriers
Due to the high rigidity of tanks it is necessary
5.1.5 Tipper Bodies to isolate the tank and its sub-frame from the
chassis frame allowing the chassis frame to
For tipper conversions single and double Chassis naturally flex. Please refer to the following
Cab versions except extended rear chassis guidelines:
frame can be used. All variants allow single and
three way tipping. Mount tank to full length of sub-frame.
Mount sub-frame to all chassis frame
It is recommended to have the tipping system
mounting points.
operative only when the engine is running. It is
also recommended to have the master control The forward location mounts must be
switch in the security of the cab. According compliant to allow relative chassis frame to
routing of wires and hydraulic lines please refer sub-frame deflections.
to section hydraulic lift. Sub-frame must extend to the back of the
cab and not contact chassis frame at forward
Ensure that axle plated weights including the
end under worst case deflection.
front axle minimum are not exceeded.
For tipper sub-frames please refer to the
following guidelines:
Design for full length continuous frame with
mountings for motor, pump unit, reservoir,
pivot points and ram.
Use all mounting points on chassis frame to
mount sub-frame.
Compliant mounts should be used, with up The load is evenly distributed (converter to
to plus and minus 12mm compliance with the ensure owners information book identifies
vehicle laden or un-laden (whichever is worst this limitation).
case). Compliant mounts should be rated with The rack and subsequent carried load is
a minimum of 2mm deflection per 200kg supported in the roof drip rails irrespective of
mass at each chassis frame forward mount. rack retaining method.
Compliant mounts shall have captive fail safe
bolts.
Use two M10 grade 8.8 minimum bolts, Double Cab / Stretch Cab
washers and self lock nuts per chassis frame
mount bracket at each solid and compliant The forgoing limitations are based on ensuring
location. body structure integrity, vehicle handling, braking
and plated axle weights. Such considerations
must also be applied to any double cab and
5.1.7 Roof Racks stretch cab applications, in particular steering,
braking and front axle plated weight and the
Roof racks may be fitted to all variants as extra continuous loads on the A pillar, which
illustrated in figure, providing the following is should not exceed 60 kg total incremental load.
satisfied:
Ensure that the planned loaded vehicle operates
The carried load does not exceed 80kg (Body within its designed Center of Gravity condition.
Builder to ensure owners hand book identifies For details please consult the Ford dealer.
this limitation).
The carried load does not exceed 300mm
load height (converter to ensure owners
information book identifies this limitation).
1
3 4
E134129
Item Description
1 Rear edge of front attachment point
2 80kg Maximum
3 Maximum roof rack length: Within length of drain channel
4 Maximum Load Height 300mm
5 Drain Channel
6 Roof Rack Supports
E134101
Dimensions (mm)
A 400 D 660
B 700 E 630
C 700 F 700
Side Airbag
C
A B
E134609
Dimensions (mm)
A 550 C 250
B 350
C
D
B
E136172
Dimensions (mm)
A 140 C 250
B 40 D 100
B
E134610
Dimensions (mm)
A 140 C 250
B 40 D 100
C
D
E136173
Dimensions (mm)
A 140 C 250
B 40 D 100
A D
F
E
B
E134173
Dimensions (mm)for Body Attachment Holes in chassis Frame Top Flange Medium
Wheelbase
A 19 D 110
B 11 E Do not drill within 20mm
hole, or in the areas
shaded in green.
C 100 F No more than 2 holes
to be drilled in a vertical
line.
1. No Welding is Allowed to the Vehicle 6. Holes must NOT be drilled near side member
Structure. profile changes.
2. To make holes in frames do not use a gas 7. Existing holes in top and bottom flanges must
flame. Drill holes using sharp drills. NOT be bored out.
3. Use cold riveting only when attaching 8. No more than two holes are to be drilled in a
brackets with rivets. vertical line down from the frame web.
4. Use high tensile bolts and appropriate nuts 9. Corrosion protection is to be applied post
when bolted attachments are used. drilling operations to the vehicle. Corrosion
Bolt Specifications : protection & protective coatings for all
Metric Property class 8.8 or 10.9 modifications should conform to all local
design rules.
Japanese 7T or 9T
SAE Grade 8 5. 10. Reinforcements should be added to the
vehicle structure where appropriate, to avoid
5. Deburr holes after drilling to fit bolts or rivets. excessive load concentrations.
Chamfer 1.0mm x 45 degree on the bolt head
side of the hole to facilitate bolt seating.
7
6
E74576
Item Description
1 Use all standard locations with 2x M10 fixings
2 Floor Panel
3 Body side frames
4 Floor cross members
5 Continuous floor U-profile frame
6 Longitudinal L-profile
7 Chassis frame rail of base vehicle
8 Vehicle center line of base vehicle
Also see:
Refer to: 5.1 Body (page 35). 5.5.2 Self-Supporting Body
Structure
Bodies and structures can be judged as
self-supporting providing they maintain the
following rules:
Cross members are used at each chassis
mounting point, please refer to figures shown.
Each cross member has a suitably
engineered connection to the body side wall
(3) or to the continuous floor frame (5), see
figure shown.
The body side wall or the continuous floor
frame supports any overhang beyond the
chassis frame, whether on standard frame or
extended frame.
Alternatively, the self-supporting body structure Holes should be in groups of two (2), either
can also be designed as shown in figure shown. vertically spaced at 30 to 35mm from chassis
frame top and/or bottom surface, or
This concept is based on a self-supporting
horizontally at 50mm minimum pitch, 30 to
structure where the floor is mounted directly
35mm from top and/or bottom chassis frame
onto the top surface of the chassis frame.
surface.
See figure shown for a generic vehicle cross
section where the cross members and Always use M10 bolts with grade 8.8
minimum.
opposing out riggers are flush with the surface
of the chassis frame side members. Do not position tubes at the medium chassis
frame height, this may create oil canning of
It is important to the overall function of the
the deep section side walls.
vehicle structure that the out riggers are each
connected to a continuous longitudinal floor Where possible, the outrigger moments
side frame or a structural body side structure should be resolved by matching inner cross
assembly. members between the chassis side members
inline with the outriggers.
Low floor-re-work for guidance only:
A diameter of 16.5mm is the maximum
Engineer unique cross members and allowable hole size in the chassis frame side
out-riggers spaced at approximately 600mm wall, irrespective of the usage.
maximum pitch.
Avoid drilling into closed frame body members
Out-rigger moment to be re-acted with
to avoid the risk of corrosion from swarf.
cross-member between chassis frame with
common through bolts where possible. Refer to: 5.4 Corrosion Prevention (page 49).
Drill frame and add spacer tubes. Drilling and welding of frames and body structure
Refer to: 5.5 Frame and Body Mounting (page have to be conducted following the program
50). guidelines. Please consult the Ford dealer for
details.
Out-rigger outboard ends should be attached
to load bearing body side / floor edge frame
or body side structure (including over wheel 5.5.4 Ancillary Equipment - Sub
support). Frame Mounting
Structural wheel box should maintain
longitudinal continuity with a rigid attachment Typical sub-frames and longitudinal members
to the floor edge frame or to the body side for flatbed and low or drop-side bodies or
structure. equipment exceeding the standard or Regular
Floor boards should be substantially attached Production Order frame length should adhere
to cross members and outriggers, but not to to the following guidelines:
the chassis frame top surface. Flat-beds and low bodies mounted on integral
Low floor exhaust heat shields. longitudinal members (channel or box section
metal not wood) must use both sides of all
frame mounting brackets.
5.5.3 Frame Drilling and Tube Longitudinal members must be relieved at
Reinforcing the front end if they are to contact the chassis
frame top surface, to minimize stress
The chassis frame may be drilled and reinforcing concentrations. It is preferable however, to
spacer tubes may be welded in place, providing mount the longitudinal onto the mounting
the following is applied: brackets, with a clearance to the chassis
Adhere to all details shown in figure. frame top surface.
Drill and weld only side walls of the chassis Each set of brackets must use two (2) x M10
frame. bolts grade 8.8 minimum.
Locate and drill holes accurately, using a drill Minimum floor heights will require wheel arch
guide to ensure holes are square to frame boxes to clear the rear tires, see Vehicle Data
vertical center line (note: allow for side sheets for relevant tire jounce.
member draft angle).
Drill undersize and ream out to size. 5.5.5 Area for Fitting Additional
Endeavor to remove all swarf from inside side Body Attachments to the Rear of
member, and treat to prevent corrosion. the Bumper.
Fully weld each end of the tube and grind flat
and square, in groups if applicable. Be aware NOTE: With the vehicle on level ground and with
of side member draft angle. all measurements taken rear ward of the bumper
Apply corrosion protection inside and outside bar edge: The area designated for the fitting of
of the chassis frame. attachment is defined as 220mm horizontally by
95mm vertical downward to the road surface,
Refer to: 5.4 Corrosion Prevention (page 49). with a max width of 1390mm about vehicle
center line.
A H
About This Manual..................................................4 HardwareSpecifications..................................23
Index
J
B Jacking....................................................................11
Battery and Cables..............................................32
Battery Information..............................................32
Body.......................................................................35 K
Body Structures - General Information............35
Kerb Weights.........................................................21
C L
Center of Gravity..................................................26
Lamps Hazard / Direction Indication..............34
Chassis Cab Body - Basic Dimensions and
Legal and Vehicle Type Approval.........................5
Weights.................................................................19
Legal Obligations and Liabilities............................5
Chassis Cab..........................................................36
Lifting.......................................................................13
Commercial and Legal Aspects...........................5
Load DistributionSpecifications......................24
Contact Corrosion...............................................49
Load Distribution Calculations - Driver and
Conversion Affect on Fuel Economy and
Passenger Weight Distribution........................24
Performance........................................................10
Conversion Affects on Parking Aids..................16
Conversion Homologation....................................7
Corrosion Prevention..........................................49
M
Minimum Requirements for Brake system and
D Load Apportioning Valves...................................6
Mounting Points and Tubing..............................50
Drilling and Welding................................................6
Driver Field of View...............................................16
Driver Reach Zones..............................................16
N
Noise, Vibration and Harshness (NVH)..............14
E
Electrically operated Door Mirrors.....................34
P
Electromagnetic Compatibility (EMC).................8 Package and ErgonomicsSpecifications.......17
Exterior Lighting....................................................34 Package and Ergonomics...................................16
Painting Road Wheels.........................................49
F Product Liability.......................................................6
T
Tank and Dry Bulk Carriers................................42
Index
Terminology............................................................5
Tipper Bodies.......................................................42
Towing capacities...............................................29
Towing Requirements........................................29
Towing Specifications.........................................30
Towing...................................................................29
U
Under Body Protection and Material...............49
V
Vehicle Duty Cycle Guidelines...........................10
Vehicle Ride and Handling Attributes................10
Vehicle Transportation Aids and Vehicle
Storage................................................................15
W
Warnings, Cautions and Notes in This
Manual...................................................................4
Warranty on Ford Vehicles...................................5
Water Tank on Camper Vehicles......................53
55