1-Body & Equipment Manual

FORD RANGER T6REPAIR MANUALWIRING DIAGRAM

BODY & EQUIPMENT MOUNTING MANUAL

Date of Publication: 05/2011

TO MODEL INDEX VIEW MAIN INDEX

FORD RANGER 2011.5MY BODY AND EQUIPMENT MOUNTING MANUAL

1 General Information1.1 About ThisManual..........................41.1.1 Introduction............................................41.1.2 Important Safety Instructions..............41.1.3 Warnings, Cautions andNotes in This

Manual.....................................................41.1.4 How to Use This Manual......................4

1.2 Commercial and Legal Aspects.....51.2.1 Terminology............................................51.2.2 Warranty on Ford Vehicles...................51.2.3 Legal and Vehicle Type Approval........51.2.4 Alternative Type Approval....................51.2.5 Legal Obligations and Liabilities...........51.2.6 General Product Safety

Requirement..........................................51.2.7 Product Liability......................................61.2.8 Restraints System.................................61.2.9 Drilling and Welding...............................61.2.10 Minimum Requirements for Brake

systemandLoadApportioningValves..................................................................6

1.2.11 Road Safety............................................61.3 Conversion Homologation.............71.4 Electromagnetic Compatibility

(EMC).............................................81.4.1 Suggested Antenna Location.............9

1.5 Vehicle Duty Cycle Guidelines......101.5.1 Conversion Affect on Fuel Economy

and Performance.................................101.5.2 Vehicle Ride and Handling

Attributes...............................................101.6 Jacking..........................................111.7 Lifting............................................131.8 Noise, Vibration andHarshness

(NVH)............................................141.9 Vehicle Transportation Aids and

Vehicle Storage............................151.10 Package and Ergonomics............161.10.1 General Component Package

Guidelines..............................................161.10.2 Driver Reach Zones.............................161.10.3 Driver Field of View..............................161.10.4 Conversion Affects on Parking

Aids.........................................................161.10.5 Aids for Vehicle Entry and Exit...........16

1.11 Package andErgonomicsSpecifications........17

1.11.1 Recommended BodyDimensions............................................17

1.11.2 Chassis Cab Body - BasicDimensions and Weights....................19

1.11.3 Kerb Weights........................................211.11.4 Front, Rear and Side Under-run

Protection.............................................221.12 HardwareSpecifications...........231.13 Load

DistributionSpecifications........241.13.1 LoadDistributionCalculations - Driver

and Passenger WeightDistribution............................................24

1.13.2 Center of Gravity.................................261.14 Towing.........................................29

1.14.1 Towing Requirements........................291.14.2 Towing...................................................291.14.3 Towing capacities...............................291.14.4 Towing Specifications.........................30

2 Chassis2.1 Suspension System......................31

4 Electrical4.1 Battery and Cables......................324.1.1 Battery Information.............................324.1.2 Generator and Alternator..................33

4.2 Exterior Lighting..........................344.2.1 Reversing Lamps................................344.2.2 Additional External Lamps.................344.2.3 Lamps Hazard / Direction

Indication..............................................344.2.4 Electrically operated Door

Mirrors...................................................34

5 Body and Paint5.1 Body.............................................355.1.1 Body Structures - General

Information...........................................355.1.2 Integrated Bodies and

Conversions.........................................355.1.3 Chassis Cab.........................................365.1.4 Front End Integrity for Cooling, Crash,

Aerodynamics and Lighting...............425.1.5 Tipper Bodies.......................................425.1.6 Tank and Dry Bulk Carriers................425.1.7 Roof Racks...........................................43

5.2 Air BagSupplemental RestraintSystem (SRS)...............................45

5.2.1 Air Bags.................................................455.3 Safety Belt System.......................485.4 Corrosion Prevention..................495.4.1 General.................................................495.4.2 Repairing Damaged Paint..................495.4.3 Under Body Protection and

Material.................................................495.4.4 Painting Road Wheels........................495.4.5 Contact Corrosion..............................49

5.5 Frame and BodyMounting...........505.5.1 Mounting Points and Tubing.............505.5.2 Self-Supporting Body Structure........515.5.3 Frame Drilling and Tube

Reinforcing...........................................525.5.4 Ancillary Equipment - Sub Frame

Mounting..............................................525.5.5 Area for Fitting Additional Body

Attachments to the Rear of theBumper. ...............................................52

5.5.6 Water Tank on Camper Vehicles......53

TableofContents

3

BACK TO TO FOREWORD & TO MODEL INDEXTO MODEL INDEX

Body and Equipment Mounting Manual Ford Ranger 2011.5

1.1 About This Manual

1.1.1 Introduction

This manual has been written in a format that isdesigned to meet the needs of VehicleConverters. The objective is to use commonformatswith theworkshopmanualwhich is usedby technicians worldwide.

This guide is published by Ford and providesgeneral descriptions and advice for convertingvehicles. These requirementsmust be compliedwith before a Ford Dealer should take deliveryof motor vehicle accessories from an externalsupplier either for themselves or on behalf of amotor vehicle client.

It must be emphasized that any change to thebasic vehiclewhich does notmeet the enclosedguideline standards may severely inhibit theability of the vehicle to perform its function.Mechanical failures, structure failure, componentunreliability or vehicle instability will lead tocustomer dissatisfaction. Appropriate designand application of body, equipment and oraccessories is key to ensuring that customersatisfaction is not adversely affected.

The information containedwithin this publicationtakes the form of recommendations to befollowed when vehicle modifications areundertaken. Itmust be remembered that certainmodificationsmay invalidate legal approvals andapplication for re-certificationmay be necessary.

Ford cannot guarantee the operation of thevehicle if non-Ford approved electrical systemsare installed. Ford electrical systems aredesigned and tested to function underoperational extremes, and have been subjectedto the equivalent of ten years of driving undersuch conditions.

1.1.2ImportantSafetyInstructions

Appropriate conversionprocedures are essentialfor the safe, reliable operation of all vehicles aswell as the personal safety of the individualcarrying out the work.

This manual cannot possibly anticipate all suchvariations and provide advice or cautions as toeach. Anyonewho departs from the instructionsprovided in this manual must first establish thathe compromises neither his personal safety northe vehicle integrity by his choice of methods,tools or components.

1.1.3Warnings, Cautions andNotes in ThisManual

WARNING:Warnings are used toindicate that failure to followaprocedure correctlymay result inpersonal injury.

CAUTION: Cautions are used toindicate that failure to followaprocedure correctlymay result indamage to the vehicle or equipmentbeing used.

NOTE:Notes are used to provide additionalessential information required to carry out acomplete and satisfactory repair.

As you read through this manual, you will comeacross WARNINGS, CAUTIONS and NOTES.

A warning, caution or note is placed at thebeginning of a series of steps if it applies tomultiple steps. If the warning, caution or noteonly applies to one step, it is placed at thebeginning of the specific step (after the stepnumber).

1.1.4How toUse ThisManual

This manual covers vehicle conversionprocedures.

The pages at the start of this manual list thecontent, by group. A group covers a specificportion of the vehicle. Themanual is divided intofour groups, General Information, Chassis,Electrical, Body and Paint. The number of thegroup is the first number of a section number.Each title listed in the contents links to therelevant section of the manual.

In some section of the book it may refer you tosee additional sections for information, links havebeen provided, these links are in blue text.

This manual is designed to be used online or asprinted material, document links for the onlineversion are also shown with page numbers forthe printed version, this will help guide you to thestart of the section which contains the relevantinformation.

There is also an alphabetical index at the backof the manual. As with the contents pages youwill be able to link to sections. To do this just clickon the page number.

All left and right-handed references to the vehicleare taken from a position sitting in the driver seatlooking forward unless otherwise stated.

Date of Publication: 05/2011FordRanger 2011.5

BACK TO CHAPTER INDEXTO MODEL INDEX

1 General Information


1.2 Commercial and Legal Aspects

1.2.1 Terminology

NOTE: Any modifications to the vehicle mustbe noted in the owner's handbook or newdescriptive literature included with the owner'sdocumentation.

Vehicle Converter refers to any re-seller alteringthe vehicle by converting the body and addingor modifying any equipment not originallyspecified and or supplied by Ford.

Unique component or similar wording refers tonon-Ford specified or after sale fitment notcovered by Ford warranty.

1.2.2Warranty on Ford Vehicles

Please contact The National Sales Company inthe country where the vehicle will be registeredor refer to the vehicle Owner Guide for details ofthe terms of any applicable Ford warranty.

The Vehicle Converter shouldwarrant its design,materials and construction for a period at leastequal to any applicable Ford warranty.

The Vehicle Converter must ensure that anyalterationmade to a Ford vehicle or componentdoes not reduce the safety, function, or durabilityof the vehicle or any component.

The Vehicle Converter shall be solely responsiblefor any damage resulting from any alterationmade by the Vehicle Converter or any of itsagents to a Ford Vehicle Component.

The Vehicle Converter releases Ford from allclaims by any third party for any cost or loss(including any consequential damages) arisingfrom work performed by a Vehicle Converterunless Ford has given its prior written consentto such liability.

1.2.3 Legal and Vehicle TypeApproval

All components embodied on Ford vehiclesare approved to the applicable legalrequirements.

Ford vehicles have Type Approval for theintended marketing territories.

WARNING: Exception - Incompletevehicles require further approvalwhencompletedbytheBodyBuilder.

The Ranger range has Type Approval formany territories, although the full range ofvehicles shown in this manual are notnecessarily released in all territories. Checkwith your local Ford National Sales Companyrepresentative.

Significant changes to the vehicle may affectits legal compliance. Strict adherence to theoriginal design intent for brakes, weightdistribution, lighting, occupant safety andhazardous materials compliance in particularis mandatory.

1.2.4 Alternative TypeApproval

If significant changes aremade theBodyBuildermust negotiate with the relevant authority. Anychanges to the vehicle operating conditionsmust be advised to the customer.

1.2.5 Legal Obligations andLiabilities

The Vehicle Converter should consult with itslegal advisor on any questions concerning itslegal obligations and liabilities.

Ford recomends that the Vehicle Converter andFordDealermust understand their individual andjoint responsibilities in supplying a safe andcompliant motor vehicle fitted with safe andcompliant accessories.

1.2.6General Product SafetyRequirement

The Vehicle Converter shall ensure that anyvehicle it places on the market complies with alllocal laws relating to the safe carriage of loadson public roads. The Vehicle Converter shall alsoensure that any alteration it makes to a Fordvehicle or component does not reduce itscompliance with local design rules.

The Vehicle Converter must provide sufficientLoad Restraint tie down points orcompartmentised storage areas that enable thedriver to safely carry loads that match the usecriteria for which the body was designed.

The Vehicle Converter shall release Ford fromall liability for damages resulting from:

Failure to complywith these Body EquipmentMounting directives, in particular warnings.

Faulty design, production, installation,assembly or alteration not originally specifiedby Ford.

Failure to complywith the basic fit for purposeprinciples inherent in the original product.

WARNINGS:

Do not exceed the gross vehiclemass, gross trainmass, axle platesand trailer plate.

Do not change the tire size or loadrating.




Donotmodify the steering system.

Excessiveheatcanbuildupfromtheexhaust system, in particular fromthe catalytic converter and from theDiesel particulate filter (cDPF).Ensure adequate heat shields aremaintained.Maintain sufficientclearance to hot parts.

Do notmodify or remove heatprotection shields.

Do not route any electrical cableswiththeAntilockBrakesSystemandTractionControl Systemcablesbecauseofextraneoussignal risk. Itis generally not recommended tohang electrical cables off existingloomsor pipes.

Do not change original location orremovewarninglabelsprovidedwiththebasevehicle inviewtothedriver.Ensure that labels in view to thedriverremain infullviewtothedriver.

NOTE: For further information please contactyour local National Sales Companyrepresentative, or Local Ford Dealer.

1.2.7 Product Liability

The Vehicle Converter shall be liable for anyproduct liability (whether for death, personalinjury, or property damage) arising from anyalteration to a Ford vehicle or component madeby the Vehicle Converter or any of its agents.Ford shall not be liable for any such liability(except as provided by law).

The Vehicle Converter or equipmentmanufacturer is liable for the:

Operational reliability and road-worthiness ofthe vehicle to its original intent.

Operational reliability and road-worthiness ofany component or conversion, not listed inoriginal Ford documentation.

Operational reliability and road-worthiness ofthe vehicle as a whole (for example the bodychanges and/or additional equipment mustnot have a negative effect on the driving,braking or steering characteristics of thevehicle).

Subsequent damage resulting from theconversion or attachment and installation ofunique components, including uniqueelectrical or electronic systems.

Functional safety and freedom of movementof all moving parts (for example axles, springs,propeller shafts, steeringmechanisms, brakeand transmission linkage).

Functional safety and freedom of the testedand approved flexibility of the body andintegral chassis structure.

1.2.8 Restraints System

WARNINGS:

Modifications to the restraintssystemare not allowed.

Airbags are explosive. For saferemoval and storage duringconversion follow theprocedures intheFordworkshopmanualorconsultyour local National SalesCompanyrepresentative.

Do not alter,modify or relocate theairbag, sensor andmodules of therestraints systemor any of itscomponents.

Attachmentsormodifications to thefront end of the vehiclemay affectthe airbag fire timing and result inuncontrolled deployment.

Modifications to theB-Pillar bodystructuremay affect the side airbagfire timing and result in uncontrolledside airbag deployment.

Refer to: 5.2 Air Bag Supplemental RestraintSystem (SRS) (page 45).

1.2.9Drilling andWelding

Drilling and welding of frames and bodystructures have to be conducted following theguidelines within this document.

1.2.10MinimumRequirementsforBrake systemand LoadApportioning Valves

It is not necessary or recommended tomodifythe load apportioning valves, however, if aspecial conversion should requiremodifications, Maintain original settings. Maintain brake certification load

distribution.

Changes to the Antilock Brake System (ABS),TractionControl System (TCS) and ElectronicStability Program (ESP) system are notpermitted.

1.2.11 RoadSafety

The respective instructions should be strictlyobserved tomaintain operational and road safetyof the vehicle.




1.3 Conversion HomologationThe Vehicle Converter must observe anystatutory rules and regulations. When theconversion needs a new approval the followinginformation must be quoted.

All dimensional, weight and centre of gravitydata.

The fixing of the body to the donor vehicle.

Operating conditions.

The responsible Technical Service may requireadditional information and/or testing.





1.4 Electromagnetic Compatibility (EMC)WARNINGS:

Your vehicle has been tested andcertified to European legislationrelating to electromagneticcompatibility (2004/104/EC). It isyourresponsibility toensurethatanyequipment fitted complieswithapplicable local legislation. Ensureyou have any equipment fitted byproperly trained technicians.

Radio frequency (RF) transmitterequipment (for example: cellulartelephones, amateur radiotransmittersandsoon.)mayonlybefitted to your vehicle if they complywith the parameters shown in thefollowing 'FrequencyOverview'table.Therearenospecialprovisionsorconditionsfor installationsoruse.

Do notmount any transceiver,microphones,speakers,oranyotheritem in the deployment path of theairbag system.

Do not fasten antenna cables tooriginalvehiclewiring, fuelpipesandbrake pipes.

Keep antenna and power cables atleast 100mm fromany electronicmodulesandairbagsandassociatedwiring.

FrequencyOverview

AntennaPositionMaximumOutput PowerWatts (PeakRMS)

FrequencyBandMHz

150W1-30

150W30-54

150W68-87.5

150W142-176

150W380-512

110W806-940

12W*806-940

110W1200-1400

110W1710-1885

11W*1710-1885

110W1885-2025

11W*1885-2025

Anywhere0.1W2400-2500

* Only for GSM/3G cellular phones, with a patch antenna installed inside of the front windscreen




1.4.1 SuggestedAntenna Location

The antenna can be mounted on the roof of thevehicle, with the exception of cellular phone carkit antennas which transmit power below 2W.Such low powered systems should have theirantenna located at the bottom of the A-pillarbehind the trim or on the front windscreen.

NOTE: After the installation of RF transmitters,check for disturbances from and to all electricalequipment in the vehicle, both in the standbyand transmit modes.

Check all electrical equipment:

With ignition ON

With the engine running

During a road test at various speeds.

Check that electromagnetic fields generatedinside the vehicle cabin by the transmitterinstalled do not exceed human exposure limitsspecified in EU directive 2004/40/EC




1

E134105

1.5 Vehicle Duty Cycle GuidelinesIt is necessary to take into account the customerusage profile and the anticipated vehicle dutycycles of themodified vehicle in order to choosethe appropriate specification of the base vehicle.

It is necessary to select the appropriate drive,engine, gear ratio, gross vehicle mass, grosstrainmass, axle plates and payloads of the basevehicle to match the customer requirements.

Where possiblemake sure that the base vehicleis ordered with any necessary plant fit options.


1.5.1 Conversion Affect on FuelEconomy andPerformance

Any conversionmay effect the fuel consumptionand performance depending on theaerodynamics and the weight added by theconversion. The published information for fuelconsumption and performance of the basevehicle thereforemay not be valid. It is advisableto control the weight, but without deterioratingother vehicle attributes and functions (especiallythose related to safety and durability).

1.5.2 Vehicle Ride andHandlingAttributes

CAUTION: Do not exceed the axleplate, gross vehiclemass, trailerplate and gross trailermass limits.

Due to the displacement of the center of gravityoccurredby the conversion the ride andhandlingattributes may be different to the base vehicle.

NOTE: This vehicle should be evaluated for safeoperation prior to sale.




1.6 JackingWARNINGS:

Alwayspositionthevehicleonahardlevel surface. If the vehiclemust bejacked upon a soft surface use loadspreading blocks under the jack.Always chock thewheel diagonallyopposite the jackingpoint. Failure tofollow these instructionsmay resultin personal injury.

Do not get under a vehicle that issupported by a jack.

This jack is only intended forchangingwheels.

CAUTIONS:

It is important that only the correctjacking and support locations areused at all times.

Make sure that access to the sparewheel ismaintainedwhenconvertingthe vehicle or relocating the sparewheel.

NOTE:When using the vehicle jack, refer to theowner guide for correct operating instructions.

NOTE:Make sure that reinforcements areinstalled to maintain the integrity of the originalbody structure for/at jacking points.

NOTE: Any modifications to the vehicle mustbe noted in the owner's handbook or newdescriptive literature included with the owner'sdocumentation.

The spare wheel winch is located above thesparewheel and can be accessed from the rearof the chassis frame.

The jack must be assembled and fixedappropriately to the body to ensure safety,durability and accessibility.

E140512

1. Ensure screwthread is adequately lubricatedbefore use.

2. The jack should be used on level firm groundwherever possible.

3. Apply park brake fully before lifting the vehicle.4. It is recommended that the wheels of the

vehicle should be chocked, and no personshould remain in a vehicle being jacked.

5. No person should place any portion of theirbody under a vehicle that is supported by ajack.




All Vehicles

E133942




Dimensions - not to exceed for Chassis Cab body Length

DoubleCab

StretchCab

SingleCab

Description

148317812251Frame length behind back of cab (not includingrear light cross-member)

A

Under run bar and towing attachment legislationto be maintained

B

2.4m over the top of frameMaximum recommended external body heightC

4737711241Front outside of body to rear axleD

Maximum 50% overhang, provided thethe Center of Gravity of body andpayload is not rearwards of the rear axlecenterline

Maximum recomended rear overhangE

25mmMinimumClearance between the back of the cab and thebody

F

Ensure local lighting legislation is maintainedG

30mmClearance between the top of the cab and thebody

H

1880Maximum external body widthJ

All dimensions (shown inmm) are subject tomanufacturing tolerances and refer tomin specificationmodels which do not include additional equipment. The illustrations are for guidance only.

1.11.2 Chassis CabBody - BasicDimensions andWeights

NOTE: Single Cab illustrated.




CB

E

A

D F

C

B

E

A

D F

E134164




Chassis CabBody - Basic Dimensions andWeights

DoubleCab

StretchCab

SingleCab

Description

5110Wheelbase (mm)A

1850Overall width - excluding exterior mirrors 4x2 (mm)B

1850Overall width - excluding exterior mirrors 4x2 (mm)B

171617061703Overall height 4x2 (mm)C

1815 - 18211804 - 18101800-1806Overall height 4x4 (mm)

3220Wheelbase (mm)D

1590Track - front 4x2 (mm)E

1560Track - front 4x4 (mm)E

1590Track - rear 4x2 (mm)E

1560Track - rear 4x4 (mm)E

985Rear Overhang (mm)F

2925Gross Vehicle Mas GVM (kg)-

3200Gross Vehicle Mas GVM (kg)*-

1325Front Axle Load (kg)-

1480Front Axle Load (kg)*-

1755Rear Axle Load (kg)-

1850Rear Axle Load (kg)*-* Vehicles with increased ride height.

1.11.3 KerbWeights

Kerb weight is the weight of the completevehicle including full fluids (water, oil and Fuel),but without payload, driver or any passengers.

Single Cab

Weight Range (KG)Model

TBC2.5L Petrol 4x2

TBC2.2L Diesel 4x2

TBC2.2L Diesel 4x4

TBC3.2L Diesel 4x4

DoubleCab


TBC2.2L Diesel 4x2*

TBC2.2L Diesel 4x4

TBC3.2L Diesel 4x4* Vehicles with increased ride height.




StretchCab


TBC2.2L Diesel 4x2*

TBC3.2L Diesel 4x2*

TBC2.2L Diesel 4x4

TBC3.2L Diesel 4x4* Vehicles with increased ride height.

1.11.4 Front, Rear andSideUnder-run Protection

WARNING:Checklocal legislationforlegal requirements.

Front Under run Protection, Rear Under runProtection and Side Under run Protection mustmeet the requirements of local design rules.




1.12 HardwareSpecificationsMaterial Specification, Strength and Torque

StandardHardwareandTighteningTorques(Nm)Bolts/Studs: ISO898-1,Nuts: ISO898-2

Grade 10.9Grade8.8Grade4.8

MaximumMinimumMaximumMinimumMaximumMinimumThreadSize

3.42.41.41.1M4

6.74.92.72.2M5

15.011.011.58.54.73.7M6

35.025.028.020.0M8

70.050.055.041.0M10

125.095.092.068.0M12

200150153113M14

310.0230.0230.0170.0M16

399.4317.5317.0252.0M18

541.8434.7430.0345.0M20

743.4592.2590.0470.0M22

945.0756.0750.0600.0M24




1.13 Load DistributionSpecifications

1.13.1 LoadDistributionCalculations - Driver andPassengerWeightDistribution

CAUTIONS:

Do not exceed the axle platedweights.

Do not exceed the gross vehicleweight.

Tiremanufacturerspecificationmustbemaintained.

NOTE:Uneven load distribution could result inunacceptable handling and brakingcharacteristics.

NOTE:Over loading of the vehicle could resultin unacceptable ground clearance.

NOTE: The centre of mass of the bodyequipment and the payload it contains shouldbe located within the dimensions given.

NOTE: Avoid one-sided load distribution.


Single Cab

1

AB

E133921

Single CabDriver andPassengerWeight Distribution

Weight distribution Per Person (Kg)'B' Front RowSeats andDriver (mm)

'A'Wheelbase(mm)

TotalOnRear AxleOn Front Axle

75354014903220




StretchCab

1

B

A

C

E134584

StretchCabCenter of Gravity Critical Zone

RecommendedCofG location for addedmassModel

'C'Max (mm)'B'Max (mm)'A'Min (mm)

740322023954x2

590343523654x2*

590343523654x4* Vehicles with increased ride height.




1.14 Towing

1.14.1 TowingRequirements

When a towing device is required, the VehicleConverter should use a Ford approved tow bar.

Refer to: 1.13 (page 24).Load Distribution

Refer to: 1.6 Jacking (page 11).

1.14.2 Towing

For towing devices fitted by the VehicleConverter the following applies:

Towing allowances must not exceed thoseof the standard vehicle.

Any modifications to the vehicle must benoted in the owner's handbook or newdescriptive literature includedwith theowner'sdocumentation.

Tow bar installations must meet therequirements of the local design rules.

Whenever framedrilling is necessary use tubereinforcement.

Refer to: 5.5 FrameandBodyMounting (page50).

1.14.3 Towing capacities

WARNING: Do not exceed the grossvehicleweight, gross trainweightandgrossaxleweightsstatedonthevehicle identification plate.

Australia andNewZealand

Trailer noseweight kg

(lbs)

With trailerbrake kg(lbs)

Withouttrailerbrakekg (lbs)

TransmissionDriveVariant

250 (551)2200 (4850)750 (1653.5)Manual4X22.5L Petrol

250 (551)2500 (5511)750 (1653.5)Manual4x22.2L Diesel(110kW)

335 (738)3350 (7385)750 (1653.5)Manual andAuto

4x2*

335 (738)3350 (7385)750 (1653.5)Manual andAuto

4x4

335 (738)3350 (7385)750 (1653.5)Manual andAuto

4x2*3.2L Diesel

335 (738)3350 (7385)750 (1653.5)Manual andAuto

4x4

* Vehicles with increased ride height.




Rest OfWorld

Trailer noseweight kg

(lbs)

With trailerbrake kg(lbs)

Withouttrailerbrakekg (lbs)

TransmissionDriveVariant

165 (364)2200 (4850)750 (1653.5)Manual4X22.5L Petrol

225 (496)1700 (3748)750 (1653.5)Manual4x2*

225 (496)1100 (2425)750 (1653.5)Manual4x4

165 (364)2200 (4850)750 (1653.5)Manual4X22.2L Diesel(88kW &92kW) 225 (496)1600 (3527)750 (1653.5)Manual4x2

*

225 (496)1600 (3527)750 (1653.5)Manual4x4

165 (364)2500 (5511)750 (1653.5)Manual4x22.2L Diesel(110kW)

225 (496)1800 (3968)750 (1653.5)Manual4x2* (Drive ratio3.31)

225 (496)3350 (7385)750 (1653.5)Manual4x2* (Drive ratio3.55)

225 (496)3350 (7385)750 (1653.5)Auto4x2*

225 (496)3350 (7385)750 (1653.5)Manual andAuto

4x4

225 (496)1800 (3968)750 (1653.5)Manual4x2 *and 4x4(Drive ratio

3.31)

3.2L Diesel

225 (496)3350 (7385)750 (1653.5)Manual4x2* and 4x4(Drive ratio

3.55)

225 (496)3350 (7385)750 (1653.5)Auto4x2*

225 (496)3350 (7385)750 (1653.5)Auto4x4* Vehicles with increased ride height.

1.14.4 Towing Specifications

For any further details and advice please consultyour local National Sales Companyrepresentative, or Local Ford Dealer.




2.1 Suspension SystemWARNINGS:

Do notmodify, drill, cut orweld anysuspensioncomponents,specificallythe steeringgear system, subframeor anti-roll bars, springs or shockabsorbers includingmountingbrackets.

The rear leaf springs arepre-stressed inmanufacture andshould not be altered for rate orheight in anyway during vehicleconversion. Adding or removingleavesmay result in failure orreducedfunctionofthespringaswellas other vehicle related issues forwhich FordMotor Company can notbe held responsible.

CAUTIONS:

Modifications to the suspensionsystemcancauseadeteriorationofthe vehicle handling characteristicsand durability.

Whencarrying outweldingwork thespringsmust be covered to protectthemagainstweld splatter.

Do not touch springswithweldingelectrodes orwelding tongs.

NOTE:Donotmodify thewheelbase or add anytype of frame extension to vehicles fitted withElectronic Stability Program ESP.

NOTE:Donot damage the surface or corrosionprotection of the spring during disassembly andinstallation.

NOTE:Do not add any additional axles.



2 Chassis


4.1 Battery and Cables

4.1.1 Battery Information

If a battery is disconnected, there is norequirement to reprogram the vehicle; thevehicle retains its normal power managementsetting and remembers exactlywhat its previousconfiguration was (although the central lockinglatches may cycle if one of these was openedmanually in the intervening period). With theradio, all of the settings are retained, but the keycode needs to be entered to restorefunctionality. The clock will need resetting.

Battery VoltageRequirements andTesting

All voltages are to bemeasuredwith an accuracyof: + / 5% of values published.

To maximize battery life, at the time of arrival atthe vehicle converter, all batteries must have aminimumOpenCircuit Voltage (OCV) of not lessthan 12.75 volts.

When the battery is installed and connected tothe vehicle's electrical system with no load, theClosed Circuit Voltage (CCV) must not be lessthan 12.65 volts. When the vehicle is released tothe customer, the CCV must not be less than12.50 volts.

SurfaceChargeDissipation

Prior to carrying out manual voltage checks, it isnecessary to establish that the battery voltageis stable and free from surface charges, thatcould be present due to certain engine runconditions making the voltage readingsunreliable and inaccurate.

To ensure surface charges are not present thefollowing actions are recommended:

1. Turn the ignition key to position II and switchon the headlamps (main beam) and if fitted,the heated front window, rear windowdemister and the heater blower motor (onposition II). Leave the vehicle in this conditionfor at least 1 minute to dissipate what eversurface charge is present in the battery.

2. Turn the ignition key to position 0 and switchoff the loads; headlamps, heatedwindshield/rear window demister and heaterblower motor. Leave the vehicle in thiscondition for at least 5minutes, before takinga battery voltage reading.

Delayed Vehicles

Vehicles held at the vehicle convertor premisesand not in use for longer than 4 days, shouldhave the battery's negative cable disconnected.Before shipping to the customer, the batterynegative cable must be re-connected and thevoltage re-checked. The voltage should be notless than 12.5 volts.

Battery Charging Procedure

1. Cold batterieswill not readily accept a charge.Therefore, batteries should be allowed towarm up to approximately 5C (41F) beforecharging. Thismay require four to eight hoursat room temperature depending on the initialtemperature and battery size.

2. A battery which has been completelydischarged may be slow to accept a chargeinitially, and in some cases may not accept acharge at the normal charger setting. Whenbatteries are in this condition, charging canbe started by use of the dead battery switchon chargers that have this facility equipped.

3. To determine whether a battery is acceptinga charge, follow the manufacturersinstructions for the charger and the deadbattery switch. If the switch is thespring-loaded type, it should be held in theON position for up to three minutes.

4. After releasing the dead battery switch andwith the charger still on, measure the batteryvoltage. If it shows 12 volts or higher, thebattery is accepting a charge and is capableof being recharged. However, it may requireup to two hours of charging, with batteriescolder than 5C (41F) before the charge rateis high enough to show a charge on aammeter. It has been found that allnon-damaged batteries can be charged bythis procedure. If a battery cannot be chargedby this procedure, a new one should beinstalled.

5. A rapid recharge procedure has beendeveloped for recharging batteries that havepassed the load test and only need arecharge. This can be due to in-serviceno-start battery failures (vehicle will not crankdue to low battery state of charge) or batterydischarged in vehicle due to key-off loads.

6. With the cables then disconnected, thebattery can be rapidly recharged by usingeither of the following methods:

Carry out a two hour charge using 20Aconstant current (manual setting on charger).

Carry out a two hour charge using a constantpotential (automatic setting on charger).



4 Electrical


Battery Cable Fixing Torque The battery cables should be fixed to theterminal posts with a torque of 4.8 Nm -/+0.8Nm.

Battery Part Numbers andUsage

SizeSpecificationsBatterySupplier

Ford Plant

StandardDuty Battery

T660Ah, 590CCA, 105RC (Calcium Technology)Siam GSThailand

T660Ah, 590CCA, 105RC (Silver Calcium Techno-logy)

First NationalBattery

South Africa

T660Ah, 590CCA, 105RC (Silver Calcium Techno-logy)

MouraSouth America

HeavyDuty Battery

T768Ah, 750CCA, 150RC (Calcium Technology)Siam GSThailand

T768Ah, 750CCA, 150RC (SilverCalciumTechnology)First NationalBattery

South Africa

T775Ah, 750CCA, 105RC (SilverCalciumTechnology)MouraSouth America

Connection of Auxiliary Loads

WARNING: Under no circumstancesshould any additional connectionsbemadedirectly to any of thevehicle's battery terminals.

For auxiliary customer electrical loads, thesemust only be made via the customerconnection points provided.

Battery Rules:

WARNING: For vehicles fittedwithnon-sealed batteries(non-maintenance free), it isessential that regular checks aremade to determine that theelectrolyte(acid) levelsarecorrectlymaintained.

For external charging of batteries ensure thatthe maximum voltage of 14.6V is notexceeded.

4.1.2Generator andAlternator

Alternator Current Output

All vehicles are fitted with 110A alternators.




4.2 Exterior Lighting

WARNING:Make sure that themodified vehicle complieswith allrelevant legal requirements.

4.2.1 Reversing Lamps

The reverse lamps are activated by the reverseswitch on the transmission and passing throughthe Central Junction Box where the signal issensed. Amarginal increase in current (via a relayor buffered electrical input) is permissible totrigger a rear-view camera system, or audibledevice.

4.2.2 Additional External Lamps

All power for additional exterior lamps must betaken through the Auxiliary Fuse Box with asuitable switch and / or relay as required.

Lighting Loads

Trailer TowVehicleControllingDeviceLamp

28W2x5WBody control moduleNumber plate lamp

5WBody control modulePosition / Parking lamp

-21WBody control moduleFront direction indicator

28W21WBody control moduleBrake lamps

24W21WBody control moduleRear direction indicator

24W21WBody control moduleReverse lamp

48W21WBody control moduleRear fog lamp

Trailer tow maximum power ratings shown, also see trailer tow below.

Lighting Fuses

Headlamp20AF74

Front fog lamp15AF75

Reversing lamp10AF76

Trailer Tow

Vehicles fitted with a trailer tow as standard alsocome with a trailer control module for lighting.

When fitting low power LED lights that requireless than 2W, the lights may flicker when in use.A trailer patch harness should be used with lowpower LED lights.

CAUTION: Do not connect the trailerpatch harness to the vehiclewhenthe trailer is not connected.

NOTE:The trailer patch harness is available fromyour Ford authorised dealer.

4.2.3 Lamps Hazard / DirectionIndication

Themaximumpermissible loadwith the standardsystem is:

3 x 5W front and rear indicators + siderepeaters (Left Hand Side)

3 x 5W front and rear indicators + siderepeaters (Right Hand Side)

4.2.4 Electrically operatedDoorMirrors

WARNING: Do not tamperwith thebase system (controlled byCentralJunctionBox andmultiplexarchitecture) and any feeds takenfrom the associatedwiring orcontroller.

NOTE: These options are not suitable foraftermarket or Body Builder fit.




5.1 Body

5.1.1 Body Structures - GeneralInformation

CAUTION: Load carrying structuresshould not bemounted onto anexisting load tray or load box.

When carrying out vehicleconversions/modifications the following pointsshould be considered:

Make sure that the vehicle structural integrityis maintained.

Do not drill into closed frame bodymembers. Make sure that the design for the body

alterations or additional structure disperse theload evenly.

CAUTION: Uneven load distributioncouldresult inunacceptablehandlingand braking characteristics.

Re-paint metal edges after cutting or drilling.All metal edges must comply with exteriorand interior protection legislation.

All fixings through the floor, sides or roofmustbe sealed.

Make sure that fixings in the 'B'-pillar area donot encroach on the seat belts or seat beltreels.

5.1.2 IntegratedBodies andConversions

For integral structures such as ambulances ormotor-homeswith increased rear overhangbuiltonto the chassis the following applies: Reduced departure angles, e.g. rear entry

step, should be discussed with the end user/ customer.Consider removable componentsto avoid damage on ferries or low-loaders.

Unique sparewheel stowagemaybe requiredif obscured by rear step, check foraccessibility.

The recommended dimensions forwheelhouses on conversions are outlined inthe following figure.

Wheelhouse Envelope

B H

K

L

A

C D

E E

X 1

X

X-X

FG

r r

E134132



5 Body and Paint


WheelhouseDimensions

265/65R17255/70R16

255/70R16

215/70R16

Dimension265/65R18

265/65R17

255/70R16

215/70R16

Dimension

190mmG*455mmA

922mm922mm915mm914mmH425mmB

588mmK305mmC

25mmL275mmD

20mmr110E

Center line of Vehicle1420mmF

Section through Center of WheelhouseX

* Dimension G is to the bottom of the swage

5.1.3 Chassis Cab

WARNING: Excessive heat can buildup from the exhaust system, inparticular from the catalyticconverter. Ensure adequate heatshields aremaintained.

CAUTION: Uneven load distributioncouldresult inunacceptablehandlingand braking characteristics.

When carrying out vehicle conversions /modifications the following points should beconsidered: Make sure that all of the reinforced holes

provided in the chassis frame top surface areused for full length bodies or sub-frames, seefigures shown.

Make sure that the vehicle structural integrityis maintained.

Do not drill into closed frame bodymembers. Make sure that the design for the body

alterations or additional structure disperse theload evenly.

Re-paint metal edges after cutting or drilling.All metal edges must comply with exteriorand interior protection legislation.

All fixings through the floor, sides or roofmustbe sealed.

Refer to: 5.4 Corrosion Prevention (page 49).

Ensure that any additional equipment in thevicinity of the fuel tank will not damage thetank in a crash condition.

For any conversion structure attached to ormounted onto the base vehicle cab structurethe following applies: Ensure that neither the conversion structure

nor the existing vehicle structure getpre-loaded by the assembly process.

Adhesive jointing is recommendedbut shouldbe supplemented with mechanical fastenersto prevent initial peel and long term failure.

Spread bolt loads to minimize local stress.

NOTE:The following chassis frame images anddimensions are showing the previous Ranger(J97) chassis frame above the new Ranger(P375) chassis frame for comparison purposes.




BodyAttachment Holes in Chassis Frame - Single cab




D C

E134152

A

B

D

J97

HGFE

D

K LJM

D

B

AD

P375

E F G H

C

P

N

K L M

J

Dimensions (mm) for Body Attachment Holes in Chassis Frame - Single Cab

P375J97DimensionP375J97Dimension

10861024H1620A

95-J2813B

768568K2313C

8901007L2020D

505496M12441150E

26-N12441140F

20-P12441140G




BodyAttachment Holes in Chassis Frame -Double cab

A

B

GF

J KH

C

D

D

D

A

B

E

E

F G

H KJ

C

D

E134154

L

M




Dimensions (mm) for Body Attachment Holes in Chassis Frame -Double cab


10241024G1620A

95-H2813B

890776J2313C

505498K2020D

26-L12441130E

20-M12441140F




BodyAttachment Holes in Chassis Frame - Stretch cab

A

B

GFE

J K

C

D

D

D

A

B

E F

H

G

J K

C

D

E134153

L

M




Dimensions (mm) for Body Attachment Holes in Chassis Frame - StretchCab


10241024G1620A

95-H2813B

1188776J2313C

505498K2020D

26-L12441130E

20-M12441140F

5.1.4 Front End Integrity forCooling, Crash, Aerodynamicsand Lighting

Cooling Continuous air flow through the frontend and engine compartment is not to behindered by adding any additional equipment. Ifuncertain please consult the Ford dealer.

Lighting Do not alter the lighting system.

Crash Do not cut, drill or weld any parts thatare load path relevant in case of crash. Do notaddmaterial in the crash zone. This could affectthe crash sensor calibration.

The side airbag system is not permitted if: A swiveling device is fitted on the front seats. A side wall or any other additional material or

structure is attached to the B-pillar innerand/or outer area.

Static &Dynamic Sealing and FinishingEnsure proper sealing against ingress of water,salt, dust etc. after cutting or drilling the body.Use Ford approved sealing and finishingmaterial,and underbody corrosion protection.


5.1.5 Tipper Bodies

For tipper conversions single anddoubleChassisCab versions except extended rear chassisframe can be used. All variants allow single andthree way tipping.

It is recommended to have the tipping systemoperative only when the engine is running. It isalso recommended to have the master controlswitch in the security of the cab. Accordingrouting of wires and hydraulic lines please referto section hydraulic lift.

Ensure that axle plated weights including thefront axle minimum are not exceeded.

For tipper sub-frames please refer to thefollowing guidelines:

Design for full length continuous frame withmountings for motor, pump unit, reservoir,pivot points and ram.

Use all mounting points on chassis frame tomount sub-frame.

Very stiff sub-frames may damage thechassis frameby preventing its natural flexing,therefore compliant mounts should be used,with up to plus and minus 12mm compliancewith the vehicle laden or un-laden (whicheveris worst case). Compliant mounts should berated with a minimum of 2mm deflection per200kg mass at each chassis frame forwardmount. Compliant mounts shall have captivefail safe bolts.

Use two M10 grade 8.8 minimum bolts,washers and self locking nuts at each solidand compliant chassis frame location.

Sub-frame must extend to the back of thecab and attach to all mounting locations, withthe forward end designed to minimize localframe stress. It is however, preferable tomount the sub-frame onto the mountingbrackets with a clearance to the chassisframe top surface.

Side tipping loads/forces must be resolvedby the sub-frame. It is not recommended tostrain the chassis frame.

5.1.6 Tank andDry Bulk Carriers

Due to the high rigidity of tanks it is necessaryto isolate the tank and its sub-frame from thechassis frame allowing the chassis frame tonaturally flex. Please refer to the followingguidelines:

Mount tank to full length of sub-frame. Mount sub-frame to all chassis frame

mounting points. The forward location mounts must be

compliant to allow relative chassis frame tosub-frame deflections.

Sub-frame must extend to the back of thecab and not contact chassis frame at forwardend under worst case deflection.




Compliant mounts should be used, with upto plus andminus 12mmcompliancewith thevehicle laden or un-laden (whichever is worstcase). Compliantmounts should be ratedwitha minimum of 2mm deflection per 200kgmass at each chassis frame forward mount.Compliant mounts shall have captive fail safebolts.

Use two M10 grade 8.8 minimum bolts,washers and self lock nuts per chassis framemount bracket at each solid and compliantlocation.

5.1.7 Roof Racks

Roof racks may be fitted to all variants asillustrated in figure, providing the following issatisfied:

The carried loaddoes not exceed80kg (BodyBuilder to ensure owners handbook identifiesthis limitation).

The carried load does not exceed 300mmload height (converter to ensure ownersinformation book identifies this limitation).

The load is evenly distributed (converter toensure owners information book identifiesthis limitation).

The rack and subsequent carried load issupported in the roof drip rails irrespective ofrack retaining method.

DoubleCab / StretchCab

The forgoing limitations are based on ensuringbody structure integrity, vehicle handling, brakingand plated axle weights. Such considerationsmust also be applied to any double cab andstretch cab applications, in particular steering,braking and front axle plated weight and theextra continuous loads on the A pillar, whichshould not exceed 60 kg total incremental load.

Ensure that the planned loaded vehicle operateswithin its designed Center of Gravity condition.For details please consult the Ford dealer.




Roof Rack Vehicle Converter Special Fit

1

4

5

3

2

6

E134129

DescriptionItem

Rear edge of front attachment point1

80kg Maximum2

Maximum roof rack length: Within length of drain channel3

Maximum Load Height 300mm4

Drain Channel5

Roof Rack Supports6




5.2 Air Bag Supplemental Restraint System (SRS)

5.2.1 Air Bags

Front Seats

Side airbags are not compatible with swivelingfront seats.

Do not specify the base vehiclewith side airbagswhen planning to retrofit a swiveling device onthe front seats and/or an armrest on the outerside of the front seats, this may affect thefunction and/or deployment of the side airbags.

The acceleration based airbag sensors for sideairbags are located nearby the bottom of theC-pillar inner for RAP andDBLCab vehicles. Thepressure based airbag sensors for side airbagsare located near the centre of the front doors'inner door sheet metal for all Cab styles.

WARNING:Modifications orreinforcements in the area of thesensorsmay affect the side airbagfire timing and result in uncontrolledside air bag deployment.

Please note that vehicles not equippedwith sideairbags but equipped with front airbags only arenot affected.

Drilling or grinding operations in this area are onlypermitted when battery cables aredisconnected.

Driver andPassenger Front AirbagDeployment Zones

E

D

B

A

C

F

E134101

Dimensions (mm)

660D400A

630E700B

700F700C




Side Airbag


AC

B

E134609

Dimensions (mm)

250C550A

350B

Curtain Airbag - Single cab


DC

B

A

E136172

Dimensions (mm)

250C140A

100D40B




Curtain Airbag - Double cab


D

C

B

A

E134610

Dimensions (mm)

250C140A

100D40B

Curtain Airbag - Stretch cab


DC

B

A

E136173

Dimensions (mm)

250C140A

100D40B




5.3 Safety Belt System

WARNING: Follow removal andinstallation procedures for the seatbelt system to ensure correctfunction of the restraints system.

The removal and reinstallation of the seat belt,restrainer or any component of the seat beltsystem should be avoided. However if removaland re-installation of the system is requiredduring the conversion, follow the removal andinstallation guidelines of the seat belt system asdescribed in the workshop manual. Pleaseconsult your local National Sales Companyrepresentative for further information.

When removing the seat belt system, a seat beltwebbing forked retainer should be applied tothewebbing200mmbelow thewebbingbuttonstop. This prevents a situation where all thewebbing runs back into the retractor and theretractor becomes locked.

When reinstalling, fit the retractor to the bodyfirst and gently pull the webbing out of theretractor to allow fitment of the D loop. Thenremove the forked retainer. If the retractor islocked, allow a small amount of webbing to reelback into the retractor to allow thewebbing lockto release. Do not attempt to release theretractor by pulling on the webbing withsignificant force or by manually interfering withthe locking mechanism.




5.4 Corrosion Prevention

5.4.1 General

Avoid drilling into closed frame body membersto avoid the risk of corrosion from swarf.

If drilling is required, however:

Re-paint metal edges and protect againstcorrosion after cutting or drilling operations.

Endeavor to remove all swarf from inside theside member and treat to prevent corrosion.

Apply corrosion protection inside and outsideof the chassis frame.

5.4.2 RepairingDamagedPaint

After cutting or reworking any sheet metal onthe vehicle the damagedpaintmust be repaired.

Ensure all materials are compatible with therelevant Ford specifications and maintain theoriginal performance where possible.

5.4.3 Under Body Protection andMaterial

WARNING: Do not over-coat orcontaminate surfaces ofcomponents such as brakes orcatalytic converters.

Ensure all materials are compatible with therelevant Ford specifications and maintain theoriginal performance where possible.

Some proprietary products affect the originalcoatings. For specifications of corrosionprotection materials, please consult your localNational Sales Company representative.

5.4.4 Painting RoadWheels

WARNING:Donotpaintwheelclampsurfaces in contactwith otherwheels,brakedrumordisc,hubandholes or surface underwheel nuts.Any further treatment in theseareasmay affect thewheel clampperformanceand thevehicle safety.Mask thewheelwhen changing thecolor or repairing paint.

5.4.5Contact Corrosion

When using different materials with a differentelectrochemical potential, ensure that materialsare isolated from each other to prevent contactcorrosion caused by a potential difference.

Use appropriate isolation materials.

Where possible, choosematerials with low levelof electrochemical potential difference.




5.5 Frame and Body Mounting

5.5.1Mounting Points and Tubing

Holes on frame are a result of the productionprocess. They are not designed for fixingadditional equipment. Always use chassismounts as shown in sub frame for low floor orother equipment. If additional fixings are requiredplease follow the recommendation given in thefigure shown. This does not apply to areas ofload applications such as spring fixings ordamper fixings.

NOTE: After drilling, deburr and countersink allholes and remove chips from the frame. Followcorrosion prevention.


FrameDrilling andWelding

A

B

D

C

E

F

E134173

Dimensions (mm)forBodyAttachmentHoles in chassis FrameTopFlangeMediumWheelbase

110D19A

Do not drill within 20mmhole, or in the areasshaded in green.

E11B

No more than 2 holesto be drilled in a vertical

line.

F100C

1. No Welding is Allowed to the VehicleStructure.

2. To make holes in frames do not use a gasflame. Drill holes using sharp drills.

3. Use cold riveting only when attachingbrackets with rivets.

4. Use high tensile bolts and appropriate nutswhen bolted attachments are used. Bolt Specifications : Metric Property class 8.8 or 10.9 Japanese 7T or 9T SAE Grade 8 5.

5. Deburr holes after drilling to fit bolts or rivets.Chamfer 1.0mmx45degree on the bolt headside of the hole to facilitate bolt seating.

6. Holesmust NOT be drilled near sidememberprofile changes.

7. Existing holes in top and bottom flangesmustNOT be bored out.

8. No more than two holes are to be drilled in avertical line down from the frame web.

9. Corrosion protection is to be applied postdrilling operations to the vehicle. Corrosionprotection & protective coatings for allmodifications should conform to all localdesign rules.

10. Reinforcements should be added to thevehicle structurewhere appropriate, to avoidexcessive load concentrations.




Typical Design Principle of a Self-SupportingBody Structure

E74576

1

2

3

4

5

67

8

DescriptionItem

Use all standard locations with 2x M10 fixings1

Floor Panel2

Body side frames3

Floor cross members4

Continuous floor U-profile frame5

Longitudinal L-profile6

Chassis frame rail of base vehicle7

Vehicle center line of base vehicle8

Also see:

Refer to: 5.1 Body (page 35). 5.5.2 Self-SupportingBodyStructure

Bodies and structures can be judged asself-supporting providing they maintain thefollowing 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), seefigure shown.

The body side wall or the continuous floorframe supports any overhang beyond thechassis frame,whether on standard frameorextended frame.




Alternatively, the self-supporting body structurecan also be designed as shown in figure shown.

This concept is based on a self-supportingstructure where the floor is mounted directlyonto the top surface of the chassis frame.

See figure shown for a generic vehicle crosssection where the cross members andopposingout riggers are flushwith the surfaceof the chassis frame side members.

It is important to the overall function of thevehicle structure that the out riggers are eachconnected to a continuous longitudinal floorside frame or a structural body side structureassembly.

Low floor-re-work for guidance only: Engineer unique cross members and

out-riggers spaced at approximately 600mmmaximum pitch.

Out-rigger moment to be re-acted withcross-member between chassis frame withcommon through bolts where possible.

Drill frame and add spacer tubes.

Refer to: 5.5 FrameandBodyMounting (page50).

Out-rigger outboard ends should be attachedto load bearing body side / floor edge frameor body side structure (including over wheelsupport).

Structural wheel box should maintainlongitudinal continuity with a rigid attachmentto the floor edge frame or to the body sidestructure.

Floor boards should be substantially attachedto cross members and outriggers, but not tothe chassis frame top surface.

Low floor exhaust heat shields.

5.5.3 FrameDrilling and TubeReinforcing

The chassis framemay be drilled and reinforcingspacer tubesmay bewelded in place, providingthe following is applied:

Adhere to all details shown in figure. Drill and weld only side walls of the chassis

frame. Locate and drill holes accurately, using a drill

guide to ensure holes are square to framevertical center line (note: allow for sidemember draft angle).

Drill undersize and ream out to size. Endeavor to remove all swarf from inside side

member, and treat to prevent corrosion. Fully weld each end of the tube and grind flat

and square, in groups if applicable. Be awareof side member draft angle.

Apply corrosion protection inside and outsideof the chassis frame.


Holes should be in groups of two (2), eithervertically spaced at 30 to 35mm fromchassisframe top and/or bottom surface, orhorizontally at 50mmminimum pitch, 30 to35mm from top and/or bottomchassis framesurface.

Always use M10 bolts with grade 8.8minimum.

Do not position tubes at the medium chassisframe height, this may create oil canning ofthe deep section side walls.

Where possible, the outrigger momentsshould be resolved by matching inner crossmembersbetween thechassis sidemembersinline with the outriggers.

A diameter of 16.5mm is the maximumallowable hole size in the chassis frame sidewall, irrespective of the usage.

Avoid drilling into closed frame body membersto avoid the risk of corrosion from swarf.


Drilling andwelding of frames andbody structurehave to be conducted following the programguidelines. Please consult the Ford dealer fordetails.

5.5.4 Ancillary Equipment - SubFrameMounting

Typical sub-frames and longitudinal membersfor flatbed and low or drop-side bodies orequipment exceeding the standard or RegularProduction Order frame length should adhereto the following guidelines:

Flat-beds and lowbodiesmountedon integrallongitudinalmembers (channel or box sectionmetal not wood) must use both sides of allframe mounting brackets.

Longitudinal members must be relieved atthe front end if they are to contact the chassisframe top surface, to minimize stressconcentrations. It is preferable however, tomount the longitudinal onto the mountingbrackets, with a clearance to the chassisframe top surface.

Each set of brackets must use two (2) x M10bolts grade 8.8 minimum.

Minimum floor heights will require wheel archboxes to clear the rear tires, see Vehicle Datasheets for relevant tire jounce.

5.5.5 Area for Fitting AdditionalBody Attachments to theRear oftheBumper.

NOTE:With the vehicle on level ground andwithallmeasurements taken rearwardof thebumperbar edge: The area designated for the fitting ofattachment is defined as 220mmhorizontally by95mm vertical downward to the road surface,with a max width of 1390mm about vehiclecenter line.




It is not the manufactures recommendation tofit additional body attachments (Towbars, Steps,Bicycle racks & Carriers) outside of thedesignated area.

5.5.6Water Tank onCamperVehicles

NOTE: It is recommended thatadecalorlabel is fitted adjacent to the filleraperture identifying the correct fluid tobe used, for example: 'Water only' forwater tanks.




AAbout This Manual..................................................4Additional External Lamps..................................34Aids for Vehicle Entry and Exit............................16Air Bags..................................................................45Air Bag Supplemental Restraint System(SRS)....................................................................45Alternative Type Approval.....................................5Ancillary Equipment - Sub Frame Mounting....52Area for Fitting Additional Body Attachments tothe Rear of the Bumper....................................52

BBattery and Cables..............................................32Battery Information..............................................32Body.......................................................................35Body Structures - General Information............35

CCenter of Gravity..................................................26Chassis Cab Body - Basic Dimensions andWeights.................................................................19Chassis Cab..........................................................36Commercial and Legal Aspects...........................5Contact Corrosion...............................................49Conversion Affect on Fuel Economy andPerformance........................................................10Conversion Affects on Parking Aids..................16Conversion Homologation....................................7Corrosion Prevention..........................................49

DDrilling and Welding................................................6Driver Field of View...............................................16Driver Reach Zones..............................................16

EElectrically operated Door Mirrors.....................34Electromagnetic Compatibility (EMC).................8Exterior Lighting....................................................34

FFrame and Body Mounting................................50Frame Drilling and Tube Reinforcing.................52Front, Rear and Side Under-run Protection.....22Front End Integrity for Cooling, Crash,Aerodynamics and Lighting..............................42

GGeneral Component Package Guidelines........16General..................................................................49General Product Safety Requirement.................5Generator and Alternator...................................33

HHardwareSpecifications..................................23How to Use This Manual.......................................4

IImportant Safety Instructions...............................4Integrated Bodies and Conversions.................35Introduction.............................................................4

JJacking....................................................................11

KKerb Weights.........................................................21

LLamps Hazard / Direction Indication..............34Legal and Vehicle Type Approval.........................5Legal Obligations and Liabilities............................5Lifting.......................................................................13Load DistributionSpecifications......................24Load Distribution Calculations - Driver andPassenger Weight Distribution........................24

MMinimum Requirements for Brake system andLoad Apportioning Valves...................................6Mounting Points and Tubing..............................50

NNoise, Vibration and Harshness (NVH)..............14

PPackage and ErgonomicsSpecifications.......17Package and Ergonomics...................................16Painting Road Wheels.........................................49Product Liability.......................................................6

RRecommended Body Dimensions.....................17Repairing Damaged Paint...................................49Restraints System..................................................6Reversing Lamps.................................................34Road Safety.............................................................6Roof Racks............................................................43

SSafety Belt System...............................................48Self-Supporting Body Structure.........................51Suggested Antenna Location..............................9Suspension System..............................................31

Index

54



TTank and Dry Bulk Carriers................................42Terminology............................................................5Tipper Bodies.......................................................42Towing capacities...............................................29Towing Requirements........................................29Towing Specifications.........................................30Towing...................................................................29

UUnder Body Protection and Material...............49

VVehicle Duty Cycle Guidelines...........................10Vehicle Ride and Handling Attributes................10Vehicle Transportation Aids and VehicleStorage................................................................15

WWarnings, Cautions and Notes in ThisManual...................................................................4Warranty on Ford Vehicles...................................5Water Tank on Camper Vehicles......................53

Index

55



front_page.pdfBody & Equipment Manual6.pdfford_ranger_body_&_equipment_manual1.pdfford_ranger_body_&_equipment_manual3.pdfford_ranger_body_&_equipment_manual4.pdfford_ranger_body_&_equipment_manual5.pdfford_ranger_body_&_equipment_manual6.pdfford_ranger_body_&_equipment_manual7.pdfford_ranger_body_&_equipment_manual8.pdfford_ranger_body_&_equipment_manual9.pdfford_ranger_body_&_equipment_manual10.pdfford_ranger_body_&_equipment_manual11.pdfford_ranger_body_&_equipment_manual12.pdfford_ranger_body_&_equipment_manual19.pdfford_ranger_body_&_equipment_manual20.pdfford_ranger_body_&_equipment_manual21.pdfford_ranger_body_&_equipment_manual22.pdfford_ranger_body_&_equipment_manual23.pdfford_ranger_body_&_equipment_manual24.pdfford_ranger_body_&_equipment_manual28.pdfford_ranger_body_&_equipment_manual29.pdfford_ranger_body_&_equipment_manual30.pdfford_ranger_body_&_equipment_manual31.pdfford_ranger_body_&_equipment_manual32.pdfford_ranger_body_&_equipment_manual33.pdfford_ranger_body_&_equipment_manual34.pdfford_ranger_body_&_equipment_manual35.pdfford_ranger_body_&_equipment_manual36.pdfford_ranger_body_&_equipment_manual37.pdfford_ranger_body_&_equipment_manual38.pdfford_ranger_body_&_equipment_manual39.pdfford_ranger_body_&_equipment_manual40.pdfford_ranger_body_&_equipment_manual41.pdfford_ranger_body_&_equipment_manual42.pdfford_ranger_body_&_equipment_manual43.pdfford_ranger_body_&_equipment_manual44.pdfford_ranger_body_&_equipment_manual45.pdfford_ranger_body_&_equipment_manual46.pdfford_ranger_body_&_equipment_manual47.pdfford_ranger_body_&_equipment_manual48.pdfford_ranger_body_&_equipment_manual49.pdfford_ranger_body_&_equipment_manual50.pdfford_ranger_body_&_equipment_manual51.pdfford_ranger_body_&_equipment_manual52.pdfford_ranger_body_&_equipment_manual53.pdfford_ranger_body_&_equipment_manual54.pdfford_ranger_body_&_equipment_manual55.pdf

Date post:	14-Sep-2015
Category:	Documents
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1-Body & Equipment Manual

Documents