PJ Ranger Body Repair Manual (Part No. BR380) E>; | ® RANGER Body Measurement Chart Manual FOREWORD This manual has been prepared to provide information covering normal service repairs and maintenance for the ore As all information in this manual was the best available at the time of printing, vehicle specification and other information will be updated in Service Information. Ford Motor Company APPLICATION: This manual is applicable to vehicles beginning with the Vehicle Identification Numbers (VIN), and related materials shown, on the following page. CONTENTS Title Previous GENERAL INFORMATION DIMENSIONS © 2005 Ford Sales & Sarvice (Thailand) Co., Ltd. PRINTED IN THAILAND, DECEMBER 2005 F340-20-05LGENERAL INFORMATION GENERAL INFORMATION ... 00-00 00-00 GENERAL INFORMATION VEHICLE IDENTIFICATION NUMBER HOW TO USE THIS MANUAL .. -00-00-2 (VIN) CODE = 00-00-1 ABBREVIATION. -00-00-4 VEHICLE IDENTIFICATION NUMBERS (VIN). . = 00-00-1 VEHICLE IDENTIFICATION NUMBER (VIN) CODE MNBBS1D106W123456 Serial No. Plant W=A.A. Thailand 6=2006 722007 Production year Nomeaning 0 1=WL-CRSLD) 25 WLS (2.5 L Diesel-Emission Turbo) 9=WE-C (30L-D) D=2268~2721 kg (50016000 Ibs) E+ 27228175 kg {6001-7000 ibs) Fogularcab-wthout box ‘B= Regular cab--wth box E= Double cab-without box F= Double cab.-ith box 12 Stretch cab. (with Rear Acosss System) -without box 2 Stotch cab (with Rear Access System) -with box Grose vehicle weight Product sorce $= Japan (for Thalland) {B= Seatbelt only D= with Al bag (Driver sie) Le with Airbag (Driver and Passenger) Us with Airbag (Driver, Passenger and Side airbag) World manulacture identification MNB= FORD (Thailand) 00-00-1GENERAL INFORMATION HOW TO USE THIS MANUAL qcrmrorocs This manual contains frame and cabin dimensions. An explanation of how to read the dimensional drawing is given below. @ How To Read Frame Dimensions ‘= Frame dimensions are the dimensions measured by projecting certain reference points onto a plane surface. ‘+ When there are no specific indications, the sta ndard points and dimensions are symmetrical in regard to the center of the vehicle. ‘« The hypothetical ines may differ according to the vehicle model. + The outline drawing shows the figure that projected vehicle from the upper side. Example DIMENSIONS rase mensions ESET} — Shows box sizo [feta es enaT —}— Shows apeabe vehicle Fagan ceria ‘Shows cimension mn fay, men ql min Hae iyi ena ea ® wn eT tis Shows imagitary reference line | gti ‘Shows point name a : wean] [Go oie dame Ee ara ceetcree | amt Designation cater 7 [Sienemeoaetoted | | entopng angers ——|-908 (1.99 15 [crossnerer Nat guide pps | $125 OH t remberNoe gas | 870,276) | (Css member tandardncle | 8100.9] 1M [Gressnamter Nes ase hele |" $70 27 1D [arait pacie 101639) N [nes epenananer tons | 818 075 erent preg Raraerent —[-a 0 075) ‘0 [sora nee bakes $10{039) F [crestor Na sha —| 546.19), Pear aia. 3197 084] (S| Rast gue bait $10,639), ‘o|sorna lpr bat $10 (035) H[oressnombor nas seoree—|-¢ao(ts7)—| [A [neers ta CEE 1 [ourger mounting ae 13051) s aber 6 ste hale | 667 B64, ae TE [sce mente sandargnon | $9075 ost I Shows sich 00-00-2GENERAL INFORMATION How To Rear Cabin Dimensions * Cabin dimensions are the actual dimensions between two standard points. * When there are no specific indications, the standard points and dimensions are symmetrical in regard to the center of the vehicle. Example ‘Shows vehicle section | } shor dines \| ‘Shows point symbol 1 of (Right side of vehiciey Shows point symbol lo. (Lett side of vehicie) Bey te, Be Feo Jo stows dt SSS. drawing of points Shows front of vehicle ‘Shows point name : E=] ec oy onimaion | soca ‘tae tin | | S7B°t _size mm {in} soapesemmes “wees | [oleae “ste a a a 00-00-3GENERAL INFORMATION ‘Symbols of Body Dimensions ‘© The following 8 symbols are used to indicate the standard points. SYMBOL | MEANING | [syweou MEANING @ _| Center of circular hole arrow only) | Bott tip I @ _| Center elliptical hole | [| @ _ | Center of rectangular-shaped hole OG _| Noten | © __| Edge of rectangular-shaped hole ‘e__| Panel seam, bead, otc. ABBREVIATION [om [Control module (Gir [Center [DSO _ [Dynamic stability control Fr_ [Front HO | Hydrate unt tH__[Let iM [Weta MG__|Mical RH [Right Rr [Rear 00-00-4BODY & ACCESSORIES BODY STRUCTURE [DIMENSIONS] «+. 09-80D 09-80D BODY STRUCTURE [DIMENSIONS] FRAME DIMENSIONS (UNDERBODY REGULAR CAB 2WD) ... «+. 09-80D-2 FRAME DIMENSIONS (UNDERBODY DOUBLE CAB 2WD)... sees 09-80D-4 FRAME DIMENSIONS (UNDERBODY STRETCH CAB {WITH REAR ACCESS SYSTEM} 2WD). . ++ 09-80D-6 FRAME DIMENSIONS (UNDERBODY STRETCH CAB {WITH REAR ACCESS SYSTEM} HI-RIDER). - 09-80D-8 FRAME DIMENSIONS ( DOUBLE CAB 4WD)...........+... 09-80D-10 FRAME DIMENSIONS (UNDERBODY STRETCH CAB {WITH REAR ACCESS SYSTEM} AWD). ...-0. +. eeeeeee+ 09-B0D-12 FRONT BODY STRAIGHT-LINE DIMENSIONS (1). +++ 09-80D-14 FRONT BODY STRAIGHT-LINE DIMENSIONS (2) . . zi CABIN SIDE FRAME STRAIGHT-LINE DIMENSIONS (REGULAR CAB) . CABIN SIDE FRAME STRAIGHT-LINE DIMENSIONS (DOUBLE CAB) .. CABIN SIDE FRAME STRAIGHT-LINE DIMENSIONS (STRETHC CAB {WITH REAR ACCESS SYSTEM}, HLRIDER) ROOM STRi (REGULAR CAB)....... ROOM STRAIGHT-LINE DIMENSIONS (DOUBLE CAB) . ROOM STRAIGHT-LINE DIMENSIONS (STRETHC CAB {WITH REAR ACCESS SYSTEM), HIFRIDER).. = -08-80D-24 = 09-80-15 = -09-80D-17 = -09-80D-18 = -09-80D-22 09-80D-1 80DBODY STRUCTURE [DIMENSIONS] FRAME DIMENSIONS (UNDERBODY REGULAR CAB 2WD) Flat-plane dimensions mn 10 883 (94.76 1,280 (48.49) 1,224 (48.19) ca 1,150 (45.28) 1.140 (44.88). 1,140 (44.88). 1,024 (40.31) |-<~175 6.20) +385 (15.16) |<~400 (15.75) af ot ag 1375, (0:6) (0.89) (2.46) (4.45) (2.95) 167 (657) 09-80D-2BODY STRUCTURE [DIMENSIONS] Straight-line dimensions mm A f HW eerie ceK ° pom 01 (273, TI; 1191 S2i7 ere ; 147.91} {50.31} {46.89} an wosn Point Hole diameter Hole diameter pelt Designation ‘or bolt or nut Designation or bolt or nut rymbol | size mm {in} size mm {in} A_|Cabin mounting bracket No.1 027 {1.06} K__ [Box bracket No.2 816 (0.63) B__| Bumper stay bracket 015 {0.59} | Box bracket No.2 220 (0.79} [Tie down hook mounting hole | 0135 (053), Teo practet Ne 16x23 Front suspension bracket : eee {0.63 x 0.91} D 025 (098) | [tension rod. u Box bracket No.3 020 {0.79} E— [Rebound stopper bracket 3125 (asp 1 TB mounting hols” a0 078} F | Front suspension bracket 016 (083), TN [Front spring hanger 34 (055) | Rebound stopper brackot 7125 (0.49) [Dumper bracket mz aT} H__[Cabin mounting bracket No2 | _ 060 (2.36) [Dumper bracket i2 (0.47) T]Gabin mounting bracket No | 065 (256) [Rear sprig hanger rate) J__ [Box bracket No.1 220 (0.79) 09-80D-3BODY STRUCTURE [DIMENSIONS] FRAME DIMENSIONS (UNDERBODY DOUBLE CAB 2WD) Flat-plane dimensions 45.90) 059) 47 as sia tha Ys 206 (0.16) (0.83) (9.46) 12:96)(4.45)(2.95) 6.11) tt Te | I | 1 segieeee gD g g 3 sgelgs 2 23 & = a 3 eealkae & 5 g 3 mm {in} @ 1024 (4031) 98H 09-80D-4BODY STRUCTURE [DIMENSIONS] Straightline dimensions fa Hole diameter Pon Hote diameter nut Designation or bolt of nut symbol Pestgnation tanenn eymbot . size mm {in} ‘A__[ Cabin mounting bracket Net | _ 027 {1.06} K__[Box bracket Not 216 (0.63) B [Bumper stay bracket 015 (0.59) KBox bracket No.t 20 (0.79) ‘C_|Tie down hook mounting hole_| 613.5 (0.53) 016 x23 D [Front suspension bracket 25 (0.98) L_[Boxbracet Nos (0.63 x0.91} tension rod T [Bax bracket NaS 2200.79} E [Rebound stopper bracket 125 (0.48) M_|Box mounting hole 1920 (0.79} F [Front suspension Bracket 916 (0.83), N__[Front suspension bracket 2485 (1.91) ‘G_|RRebound stopper bracket 9125 (0.49) ‘© [Front spring hanger 214 (0.55) H__ [Cabin mounting bracket No2 | 960 (2.36) [Dumper bracket M2 (047) T__[Cabin mounting bracket Nos | 065 (2.56), [Dumper bracket Mia (0.47) J [latin mounting bracket No-4 [080 (1-18) R_[ Rear spring hanger 1932 (1.26} 09-80D-5BODY STRUCTURE [DIMENSIONS] FRAME DIMENSIONS (UNDERBODY STRETCH CAB {WITH REAR ACCESS SYSTEM} 2WD) Flat-plane dimensions | =e 1@ | & eee F a @ a VW) = & £288 € |. | go¢ = ¢ 8 gage & = ag 2 z A a\c\o\ AA d\n fm snow) pe 164.65) rr8.67 A gs 41875 (0.16) (0.89) (3.48) (4.45) (2.85) 09-80D-6BODY STRUCTURE [DIMENSIONS] — Straight-line dimensions Pome Tore aameter] [pam Tote diameter oink Designation orboltornut | | Point, Designation ‘or bolt or nut is size mm {in} a ‘size mm {in} A [Gabin mounting bracket No.1] 927 (1.06) [Box bracket Nor 576,065) 8 [Bumper stay bracket 215 (059), [Box bracket Nos 2200-79) ‘C— [Tie down hook mounting hole | "013.5 (0.59) o16x28 > [Front suspension bracket maaTae KC [Boxbracket Nos (0.69x0.91) OL? frersonres [Box bracket No 820,078 E | Rebound stopper bracket 312.5 (049) —]Box mounting hove 9200.78), F | Front euspension bracket 916 (063) Wi Font aprng hanger Tas [Rebound stopper bracket 3125 (0.40) N_|Bumper bracket m2 (0.47) H_|Gabin mounting bracket No2 | 060 (2:36) ‘© [Dumper bracket MTZ (047) T [Cabin mounting bracket No3 | ~ 685 (0.56) P| Rear spring Rano? 232 (1.26) 09-80D-7BODY STRUCTURE [DIMENSIONS] FRAME DIMENSIONS (UNDERBODY STRETCH CAB {WITH REAR ACCESS SYSTEM} HFRIDER), Flat-plane dimensions 008 © af on 10495 (016) (0.83) (4.09) (374) 09-80D-8BODY STRUCTURE [DIMENSIONS] ‘Straight-Jine dimensions jameter Tole diameter oes Designation ‘ebottornat | | Pola Designation ‘bolt or aut size mm {in} size mm {in} [Gain moaning bracket Woxt | 927 (1.06) e16x23 B [Bumper stay bracket 215 (0.59) | cee (0.63 x0.91} (C_|Tie down hook mounting Role | “a5 (0.59) F_[Boxtracet os 220,(0.79) 1 [Rebound stopper bracket 2125 (0.40) K— [Box mounting hte 2200.79) © __|Front suspension bracket 216 (0483) L_]Front suspension bracket 3165 (0.65) F | Rebound stopper bracket 3125 (0.49) M_| Front suspension bracket 240 (157) ‘| Cabin mounting bracket No | 060 (2.86) [Front pring hanger 314 (0.55) Fi | Cabin mounting racket No | 066 (256) ‘0 [Bumper brackst iz (0.47), | T[Box bracket Nos 316 0.63) P| Bumper bracket wre (047) | 7 [Box bracket No 2200.79) ‘| Rear spring hanger 082 (1.26) | 09-80D-9BODY STRUCTURE [DIMENSIONS] FRAME DIMENSIONS (UNDERBODY DOUBLE CAB 4WD) Flat-plane dimensions naa {0.16} (0.83) 104 95 (4.09) (374) 1,200 (50.79). (29.92) (96n 09-80D-10 61 BODY STRUCTURE [DIMENSIONS] Straight-line dimensions | m (60.50) 1475 (s2.07) 4.231 (48.46) 4 i 19.727 259 ean) Hole diameter Hole diameter Li forbottornut | | Polat, Designation rbot or nut eee size mm {in} eae size mm {in} ‘A_[Gabin mounting bracket Not_| 027 {1.06} 16x23 B__|Bumper stay bracket 015 (0.59) eee {0.63 x0.91} ‘© _|Tie down hook mounting hole | 913.5 (0.53) K_ [Box bracket Nos 20 {0.79} D___| Rebound stopper bracket 012.5 (0.48) L_[Box mounting hole 220 (0.79) E__ [Front suspension bracket 016 (0.63) ‘W__[Front suspension bracket 2165 (0.65), F _ [Rebound stopper bracket B12 (0.49), N__[Front suspension bracket 240 (1.57) G__[Cabin mounting bracket No2 | 60 (2.36) ‘0 [Front spring hanger 14 (0.55) H__[Cabin mounting bracket Nos | 085 (2.56) [Dumper bracket MATa (0.47) 1 [Cabin mounting bracket No.4 | 080 (1.18) ‘@ [Dumper bracket Mie (0.47) J__[Box bracket No.1 916 (0.63) __[Rear spring hanger 282 (1.26) F_ [Box bracket No.1 320 (0.79), 09-80D-11 Et)BODY STRUCTURE [DIMENSIONS] FRAME DIMENSIONS (UNDERBODY STRETCH CAB {WITH REAR ACCESS SYSTEM} 4WD) Flat-plane dimensions mmin |@ af ot 10495 0:16) (0.83) (4.09) (3:74) | | 09-80D-12BODY STRUCTURE [DIMENSIONS] Straight-line dimensions ae amar Tae amar Patt | esgnation Sroottermt | [,Pltt | oasignaton | arbattornt | Somn dn) sien fn) 7 [ean ring Baa NO Toy aera B__ [Bumper stay bracket 815 {0.59} v eerie {0.63 x 0.91} C—|Tisdowrfock nounngree—| was ox3)-] [7 —HBorbaaenes S008) 3 | Rebound spor bacat | “oT25 (5) "aoc mouning noe 0078) E—|Fontstoponton ratat ——|~-w16 106) [Frnt spension baetat | 188 5] #—|Rabound sper backet —[ ates 0407] | Ont |Frntauspenson batet | a0 r.57 &— [eatin ouring baat NOX —|-“oe0 23) | nt png anger oir(oss) | bin ang rit NaS —| 065 0 [Durpor back ino) Toba na 16083 P[ourporbastt wig oa7} Borba 201038) Rae tin are sea F 25) 09-80D-13BODY STRUCTURE [DIMENSIONS] FRONT BODY STRAIGHT-LINE DIMENSIONS (1) Wy’ CO" 5 \O Dy (31.30) O° —~ =. 3) B ) sr 198 (/ i433), taaa7hT 1416 Sass) L ars 255 ee 908 Bary (10.9814 ieee Tee ‘Seo ZO 40 7 (82.76 (21,22) oe Sed (30) : (5209, heLo eh of nn} STE meter jlamotor me) omen S| [eee symbol size mm {in} onanee size mm {in} ‘A [Shroud panel datum hole 7 (028) D__[ Shroud panel datum hore 07 (0.28) | Shroud panel datum hole 27 (028) E | Shroud panel datum hole 26.2 (024) ‘© __[ Shroud panel datum hole 07 (0.28) F | Grossmember datum hole (010 {0.39} 09-80D-14BODY STRUCTURE [DIMENSIONS] FRONT BODY STRAIGHT-LINE DIMENSIONS (2) CSET 09-80D-15BODY STRUCTURE [DIMENSIONS] 09-80D-16 Poni Hole diametor Point ae Hote diameter nas Designation or bolt or nut designation or bolt or nut | ra sania | [2 se ‘A [Windshield garnish installation | 68x68 E [Shroud gusset datum hole 314 (0.55) square hole (027x027) Salen o62x8 owl panel datum slot | Wns garichindaiain | 68x68 (o2sx09s) square hole (027x027) F__ [Cont panel datum hole 96.2 (0.24) T__[Bonnet hinge instalation Role | 012 (0.47) (G_[Shroud panel datum hole 910 (038) [Front fender instalation hole | 6700.39)BODY STRUCTURE [DIMENSIONS] CABIN SIDE FRAME STRAIGHT-LINE DIMENSIONS (REGULAR CAB) » pom Tote diameter Pom Hote diameter a Designation ore er nut | | rae, Designation oxtaitr it [Wheel apron panel front D__[Door hinge installation hole 012 (0.47) A 12 (04 datum hole staoel [Door hinge instalation nole | 012 (0.47) B | Shroud panel datum hole a7 O28) | Ske frame outer connection : c | Windshield garnish installation 68x68 G [Side frame outer datum hole 93.2 (0.13) square hole fo27x027) 09-80D-17BODY STRUCTURE [DIMENSIONS] CABIN SIDE FRAME STRAIGHT-LINE DIMENSIONS (DOUBLE CAB) ccromeroroe mm Go} SS ==} (15.31) )) 248 (98.39), 4,127 (44.37 B “125 or (46.207 1.186 46:69) 109] 194 (48.88) (701) Sa (484777, OF 376: J. (54.17) Alin.1d8 clseany — ab99) 1.133 (4.81) Hole diameter i eroit|——_esgnaton orbs roit,|——esignaton Sookornt "A | WhesT apron panel ont maa F [Side rame outer connection = datum hole G__ [Door hinge instalation hole | 612 (047) B__|Shroud panel datum hole 97 (0.28) [Door hinge installation hole 012 (0.47) le [Windshield garrishinstalaton | 68x68 1} Side frame outer connection : | square hole {0.27 x0.27) J ‘Side frame outer connection - 1D [Boor hinge instalation hole | ~ 012 (0.47) K_| Side rame outer datum hole | 632 (0.13) E [Door hinge installation hole | #12 (047) 09-80D-18BODY STRUCTURE [DIMENSIONS] CABIN SIDE FRAME STRAIGHT-LINE DIMENSIONS (STRETHC CAB {WITH REAR ACCESS SYSTEM}, HI- RIDER) e on mm fo} 09-80D-19BODY STRUCTURE [DIMENSIONS] 8 Si Hole diameter Hole diameter 09-80D-20 Point Point set Designation or bolt or nut Designation oF bolt or nut symbol | Size mm tn symbol ‘size mm {in} JWheel apron panel front | F__| Striker instalation hole 97 (0.28) A 12(0.47 [datum hole ieostaaa G__[Striker installation hole 013 {0.51} B__| Shroud panel datum hole 27 (0.28) T1[Side frame outer datum hole | 05 {0.20} [Windshield garnish installation | 6.8 x68 lear access panel hinge © | square hole (027x027) | [instatation hole 012 (0.47) D_ | Boor hinge installation hele | 12 (0.47) J [Rear access panel ings siz tua)BODY STRUCTURE [DIMENSIONS] ROOM STRAIGHT-LINE DIMENSIONS (REGULAR CAB) e 80D nee Hole diameter meal Hole diameter peor Designation oF bolt or nut eon Designation or bolt or nut zu size mm {in} a size mm {in} [Harness instalation hole | _ 07 {0.28} F_|Rearpilarinner datumhole | 072 (0.47) B Front pillar inner datum hole | 910 {0.39} 8 x 12. C__ [Gow side panel datum hole | 012 (0.47) Se | eae ee a {0.31 x0.47} "Tunnel reinforcement 982x768 [funnel relnorc 97 (028) H | strker installation stot aeraan E [Rear pillar inner datum hole | a2 (047), 09-80D-21BODY STRUCTURE [DIMENSIONS] ROOM STRAIGHT-LINE DIMENSIONS (DOUBLE CAB) ‘cressorenoiso2 mm {in} 09-80D-22BODY STRUCTURE [DIMENSIONS] 4 = | Poke Hole diameter Point Hole diameter O syrvs Designation oF bolt oF nut eymbsl Designation ‘or bolt or nut 2 size mm {in} size mm {in} ‘A_| Harness installation hole 97 (0.28) Rear pilarlaner datumole | 912 (0.47) [Front pla inner datum hole | 010 (0.89) [a naan 97 x9 (C_|Gowi side panel datum hole _| 012 (0.47) 7 (028%0.95) "Tunnel reinforcement T_|[Rearpilarianer datum hole | 06 (0.24) D [instalation hole alee K__ | Striker instalation hole t02 (0.40) E [Center pitar inner datum note | 67 {028} — 82x76 F [Genter pilarinner datum hole | 07 (0:28), | eeeesineenectenes (0320.30) G__[Ceniorpllarinner datum hole | 07 (0-28) 09-80D-23BODY STRUCTURE [DIMENSIONS] ROOM STRAIGHT-LINE DIMENSIONS (STRETCH CAB {WITH REAR ACCESS SYSTEM), HERIDER) H-(702(63,07) H:1,608(63:31) PH.509 fr ch | J 09-80D-24ary Hole diameter mare | Hole diameter Designation or bolt or nut Designation or bolt or nut symbol ‘size mm {in} symbol size mm {in} ‘A__|Hamess installation hole 27 (0.28) H__ [Rear pllarinner datumhole | 012 (0.47) B__ [Front pillar inner datum hole | 010 (0.39), 1 [Pillar trim datum hole 196 (024) [Cowl side panel datum hole | 012 (0.47) @10 x20 D__| Tim installation hole ‘a0 {0.39} Slee arma (0.39 x0.79) E [Striker installation hole a7 028) [fet einoreement datum | 7 1926) Se ee {0.39 x0.59) M_ [Side frame outer datum hole_| 610 (0.39) G_[Stiker installation hole 213 (0.54) 09-80D-25BODY STRUCTURE [DIMENSIONS] Hole diameter Hole diameter Point Point D or bolt ‘oF bolt oF nut peoral esignation erottor nat | | mol Designation oral or "| Farmess installation hole 97 (0.28) G__|Stiker stallion hore 213 (051) B__|Frontpilar inner datum hale | — 910 (0.39) H__|Rearpillarinner datum hole | 612 (0.47) ‘| Cowl side panel datum hole 012 (0.47), | [Pillar trim datum hole 06 (0.24) @ [rim installation hole 210 (0.39) lS 10x20 E | Sirker instalation hove 27 (0.28) ar trim dat (0:39x0.79) BT0x 15 Grossmember No3 datum rim L 910 (0.39) F | Timinstaltation slot ceetae fale (0:39) 09-80D-26