brake FORD TRANSIT 2006 7.G Body And Equipment Mounting Section Manual

1 General Information
1.1About This Manual........................6
1.1.1Introduction...........................................6
1.1.2Important Safety Instructions.............6
1.1.3Warnings, Cautions and Notes in This
Manual....................................................6
1.1.4How to Use This Manual.....................6
1.2Commercial and Legal Aspects...
7
1.2.1Terminology...........................................7
1.2.2Warranty on Ford Vehicles..................7
1.2.3Legal and Vehicle Type Approval....
7
1.2.4Alternative Type Approval....................7
1.2.5Legal Obligations and Liabilities..........7
1.2.6General Product Safety
Requirement..........................................7
1.2.7Product Liability.....................................8
1.2.8Restraints System................................8
1.2.9Drilling and Welding..............................8
1.2.10Minimum Requirements for Brake
system and Load Apportioning Valves
.................................................................8
1.2.11Road Safety...........................................8
1.3Contact Information.....................9
1.4Conversion Type.........................14
1.5Conversion Homologation.........23
1.6Electromagnetic Compatibility
(EMC)..........................................24
1.6.1Antenna Location...............................24
1.7Vehicle Duty Cycle Guidelines....25
1.7.1Conversion Affect on Fuel Economy
and Performance...............................25
1.7.2Vehicle Ride and Handling
Attributes.............................................25
1.8End of Life Vehicle (ELV)
Directive.....................................26
1.9Jacking.......................................27
1.10Lifting..........................................29
1.11Noise, Vibration and Harshness
(NVH)...........................................31
1.12Vehicle Transportation Aids and
Vehicle Storage..........................32
1.13Package and Ergonomics..........33
1.13.1General Component Package
Guidelines............................................33
1.13.2Driver Reach Zones...........................33
1.13.3Driver Field of View.............................33
1.13.4Conversion Affects on Parking Aids..
33
1.13.5Aids for Vehicle Entry and Exit..........33
1.14Package and
Ergonomics—Specifications......34
1.14.1Recommended Main Dimensions....
34
1.14.2Recommended Nominal Body
Lengths for Chassis Cab models....
36
1.14.3Front, Rear and Side Under-run
Protection............................................38
1.14.4Recommended Main Load Area
Dimensions for Bulkhead with
Depression Driver Side......................39
1.14.5Recommended Main Load Area
Dimensions for Bulkhead with Full
Depression..........................................40
1.14.6Recommended Main Load Area
Dimensions for Double Cab In Van
Bulkhead..............................................41
1.15Hardware—Specifications..........43
1.16Load Distribution—Specifications.
44
1.16.1Load Distribution Calculations - Driver
and Passenger Weight Distribution...
44
1.16.2Center of Gravity ...............................46
1.17Towing........................................54
1.17.1Towing Requirements.......................54
1.17.2Towing..................................................54
2 Chassis
2.1Suspension System....................57
2.2Front Suspension.......................58
2.2.1Springs and Spring Mounting...........58
2.3Rear Suspension........................59
2.3.1Springs and Spring Mounting...........59
2.3.2Rear Anti-Roll Bar...............................59
2.4Wheels and Tires........................60
2.4.1Wheel Clearance................................60
2.4.2Tire Manufacturers.............................60
2.4.3Spare wheel........................................60
2.4.4Painting Road Wheels.......................60
2.5Driveshaft....................................61
2.5.1Power Take Off....................................61
2.6Brake System.............................62
2.6.1General................................................62
2.6.2Kerb Mass Data..................................62
2.6.3Brake Hoses General........................62
2.7Parking Brake.............................63
2.7.1Relocated Parking Brake Lever.......63
2.8Hydraulic Brake Actuation.........64
2.8.1Load Apportioning Valves.................64
2.8.2Front and Rear Brakes......................64
2.9Anti-Lock Control - Stability
Assist..........................................65
3 Powertrain
3.1Engine.........................................66
3.1.1Engine Power Curves.......................66
3.2Engine Cooling............................75
3.2.1Auxiliary Heater Systems..................75
3.2.2Auxiliary Heater Installation...............76
3.2.3Air Flow Restrictions...........................76
3.3Accessory Drive.........................77
3.3.1Front End Accessory Drive 2.4l Diesel
and 2.3l Petrol.....................................77
3.3.2Front End Accessory Drive 2.2l
Diesel....................................................79
3.4Electronic Engine Controls.........81
3.5Clutch.........................................82
3.6Manual Transmission.................83
Table of Contents
3

1.2 Commercial and Legal Aspects
1.2.1 Terminology
NOTE: Any modifications to the vehicle must
be noted in the owner's handbook or new
descriptive literature included with the owner's
documentation.
Vehicle Converter refers to any re-seller altering
the vehicle by converting the body and adding
or modifying any equipment not originally
specified and or supplied by Ford.
Unique component or similar wording refers to
non-Ford specified or after sale fitment not
covered by Ford warranty.
1.2.2 Warranty on Ford Vehicles
Please contact The National Sales Company in
the country where the vehicle will be registered
for details of the terms of any applicable Ford
warranty.
The Vehicle Converter should warrant its design,
materials and construction for a period at least
equal to any applicable Ford warranty
The Vehicle Converter must ensure that any
alteration made to a Ford vehicle or component
does not reduce the safety, function, or durability
of the vehicle or any component.
The Vehicle Converter shall be solely responsible
for any damage resulting from any alteration
made by the Vehicle Converter or any of its
agents to a Ford Vehicle Component.
The Vehicle Converter releases Ford from all
claims by any third party for any cost or loss
(including any consequential damages) arising
from work performed by a Vehicle Converter
unless Ford has given its prior written consent
to such liability.
1.2.3 Legal and Vehicle Type
Approval
•All components embodied on Ford vehicles
are approved to the applicable legal
requirements.
•Ford vehicles have Type Approval for the
intended marketing territories.
WARNING: Exception - Incomplete
vehicles require further approval
when completed by the Body
Builder.
•The Transit range has Type Approval for many
territories, although the full range of vehicles
shown in this manual are not necessarily
released in all territories. Check with your local
ford National Sales Company representative.
•Significant changes to the vehicle may affect
its legal compliance. Strict adherence to the
original design intent for brakes, weight
distribution, lighting, occupant safety and
hazardous materials compliance in particular
is mandatory.
1.2.4 Alternative Type Approval
If significant changes are made the Body Builder
must negotiate with the relevant authority. Any
changes to the vehicle operating conditions must
be advised to the customer.
1.2.5 Legal Obligations and
Liabilities
The Vehicle Converter should consult with its
legal advisor on any questions concerning its
legal obligations and liabilities.
1.2.6 General Product Safety
Requirement
The Vehicle Converter shall ensure that any
vehicle it places on the market complies with the
European General Product safety Directive
2001/95/EC (as amended periodically). The
Vehicle Converter shall also ensure that any
alteration it makes to a Ford vehicle or
component does not reduce its compliance with
the European General Product Safety Directive.
The Vehicle Converter shall release Ford from all
liability for damages resulting from:
•Failure to comply with these Body Equipment
Mounting directives, in particular warnings.
•Faulty design, production, installation,
assembly or alteration not originally specified
by Ford.
•Failure to comply with the basic fit for purpose
principles inherent in the original product.
WARNINGS:
Do not exceed the gross vehicle
mass, gross train mass, axle plates
and trailer plate
Do not change the tire size or load
rating
Do not modify the steering system.
Excessive heat can build up from
the exhaust system, in particular
from the catalytic converter. Ensure
adequate heat shields are
maintained. Maintain sufficient
clearance to hot parts
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
1 General Information
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Do not modify or remove heat
protection shields.
Do not route any electrical cables
with the Antilock Brakes System and
Traction Control System cables
because of extraneous signal risk.
It is generally not recommended to
hang electrical cables off existing
looms or pipes.
NOTE: For further information please contact
your local National Sales Company representative,
or Local Ford Dealer.
Refer to: 1.3 Contact Information (page 9).
If they are unable to help you then please contact
the Vehicle Converter Advisory Service at
[email protected].
1.2.7 Product Liability
The Vehicle Converter shall be liable for any
product liability (whether for death, personal injury,
or property damage) arising from any alteration
to a Ford vehicle or component made by 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 equipment
manufacturer is liable for the:
•Operational reliability and road-worthiness of
the vehicle to its original intent.
•Operational reliability and road-worthiness of
any component or conversion, not listed in
original Ford documentation.
•Operational reliability and road-worthiness of
the vehicle as a whole (for example the body
changes and/or additional equipment must
not have a negative effect on the driving,
braking or steering characteristics of the
vehicle).
•Subsequent damage resulting from the
conversion or attachment and installation of
unique components, including unique electrical
or electronic systems.
•Functional safety and freedom of movement
of all moving parts (for example axles, springs,
propeller shafts, steering mechanisms, brake
and transmission linkage, retarders).
•Functional safety and freedom of the tested
and approved flexibility of the body and integral
chassis structure.
1.2.8 Restraints System
WARNINGS:
Modifications to the restraints
system are not allowed.
Airbag are explosive. for safe
removal and storage during
conversion follow the procedures in
the Ford workshop manual or
consult your local National Sales
Company representative.
Do not alter, modify or relocate the
airbag, sensor and modules of the
restraints system or any of its
components.
Attachments or modifications to the
front end of the vehicle may affect
the airbag fire timing and result in
uncontrolled deployment.
Modifications to the B-Pillar body
structure may affect the side airbag
fire timing and result in uncontrolled
side airbag deployment.
Refer to: 5.8 Air Bag Supplemental
Restraint System (SRS) (page 218).
1.2.9 Drilling and Welding
Drilling and welding of frames and body structure
have to be conducted following the program
guidelines.
1.2.10 Minimum Requirements for
Brake system and Load
Apportioning Valves
•It is not necessary or recommended to modify
the load apportioning valves, however, if a
special conversion should require
modifications,
–Maintain original settings
–Maintain brake certification load distribution
•Changes to the Antilock Brake System (ABS),
Traction Control System (TCS) and the
Interactive Vehicle Dynamics (IVD) / Electronic
Stability Program (ESP) system are not
permitted.
1.2.11 Road Safety
The respective instructions should be strictly
observed to maintain operational and road safety
of the vehicle.
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
1 General Information
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Camper Conversion
Refer to: 1.14 (page 34).
Van conver-
sion
Refer to: 1.16 (page 44).
Refer to: 1.17 Towing (page 54).
Refer to: 2.6 Brake System (page 62).
(Relocated Handbrake).
Refer to: 3.8 Fuel System (page 88).
Refer to: 4.4 Battery and Cables (page 98).
Refer to: 4.14 Special Conversions (page 131).
Refer to: 5.1 Body (page 175).
(Integrated Bodies and Conversions).
Refer to: 5.5 Seats (page 209).
(Rear Seat Fixings Positions - Kombi).
Refer to: 5.7 Roof Opening Panel (page 214).
Refer to: 1.14 (page 34).
Multi Purpose
Vehicle
Conversion
Refer to: 1.16 (page 44).
Refer to: 1.17 Towing (page 54).
Refer to: 2.6 Brake System (page 62).
(Relocated Handbrake).
Refer to: 3.8 Fuel System (page 88).
Refer to: 4.4 Battery and Cables (page 98).
Refer to: 4.14 Special Conversions (page 131).
Refer to: 5.1 Body (page 175).
(Integrated Bodies and Conversions).
Refer to: 5.5 Seats (page 209).
(Rear Seat Fixings Positions - Kombi).
Refer to: 5.7 Roof Opening Panel (page 214).
Refer to: 1.14 (page 34).
Chassis
Conversion
Refer to: 1.16 (page 44).
Refer to: 1.17 Towing (page 54).
Refer to: 2.6 Brake System (page 62).
(Relocated Handbrake).
Refer to: 3.8 Fuel System (page 88).
Refer to: 4.4 Battery and Cables (page 98).
Refer to: 4.14 Special Conversions (page 131).
Refer to: 5.1 Body (page 175).
(Integrated Bodies and Conversions).
Refer to: 5.5 Seats (page 209).
(Rear Seat Fixings Positions - Kombi).
Refer to: 5.7 Roof Opening Panel (page 214).
Refer to: 5.1 Body (page 175).
(Cab Van Floor).Cab Van FloorRefer to: 5.11 Frame and Body Mounting (page 222).
(Spare Tire Access and Mounting).
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
1 General Information
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1.6 Electromagnetic Compatibility (EMC)
The base vehicle has been tested and certified
to all relevant legislation relating to
Electromagnetic Compatibility. All retrofitted
equipment must also comply with the relevant
legislation.
In addition, 2-way radio communication and other
equipment with built in radio transmitters (for
example anti-theft alarms, tracking devices)
should only be fitted to the vehicle if they operate
within the listed frequency bands and do not
exceed the maximum transmission output power
specified below
Frequency Overview
Maximum Output
Power (W)
Frequency (MHz)
501-54
5068-87.5
50142-176
50220-225
50380-512
10806-940
101200-1400
101710-1885
101885-2025
1.6.1 Antenna Location
The antenna can be placed on the roof of the
vehicle with the exception of cellular phone car
kits which transmit power below 2W. Such low
power devices may also be installed at the
bottom of the A-pillar behind the trim or on the
front windscreen.
Installation must be performed by suitably
qualified personnel in accordance with the
equipment manufacturer's installation instructions
and comply with the ISO technical specification
ISO/TS 21609: Road Vehicles - Electromagnetic
Compatibility guidelines for the installation of after
market radio frequency transmitting equipment.
In addition, the following guidelines must be
followed during installation:
•Do not mount any transceiver, microphones,
speakers or any other item in the deployment
path of the airbag system.
•Do not attach antenna cables to any part of
the original vehicle wiring or fuel and brake
pipes.
•Antenna and power cables must be a
minimum of 100mm from any electronic
modules and airbags.
•Make sure that any additional power feed is
taken directly from the SVO fuse box (when
available) or a recommended connection
point.
•Power and ground cables should be of higher
current capacity that the protection fuse.
Ground feed must be taken directly to the
battery.
Post installation checks must be made for
disturbances from and to all electrical equipment
in the vehicle both in the standby and transmit
modes. Checks should be carried out with the
ignition ON, engine running and be followed by a
road test at various speeds.
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
1 General Information
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1.12 Vehicle Transportation Aids and Vehicle Storage
CAUTIONS:
Disconnect the battery if the vehicle
is to be stored for more than 30
days.
Make sure that the protective covers
are not removed from an incomplete
vehicle until the conversion is
started.
Make sure that components
removed during conversion are kept
clean and dry.
Make sure that components
removed during conversion are
refitted to the same vehicle.
In addition:
•The windscreen wipers should be lifted off the
glass and set right up.
•All air intakes should be closed.
•Increase normal tyre pressure by 0.5 bar.
•The hand brake system should not be used.
•Apply suitable wheel chock to prevent roll
away.
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
1 General Information
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1.13 Package and Ergonomics
1.13.1 General Component
Package Guidelines
WARNING: 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 Vehicle Converter has to ensure that
sufficient clearance is maintained under all drive
conditions to moving components such as axles,
fans, steering, brake system etc.
The Vehicle Converter is responsible for all
installed components during the conversion. The
durability has to be confirmed by appropriate test
procedures.
1.13.2 Driver Reach Zones
Controls and/or equipment required to be used
while driving should be located within easy reach
of the driver so as not to impair driver control
1.13.3 Driver Field of View
WARNING: Make sure that the
modified vehicle complies with all
relevant legal requirements.
1.13.4 Conversion Affects on
Parking Aids
WARNING: Ensure that monitors
mounted in the cabin meet the
interior package and safety
requirements
On conversions requiring a rear camera, the
reverse signal may be taken as described in the
electrical section, described in reversing lamps.
Refer to: 4.11 Exterior Lighting (page 116).
1.13.5 Aids for Vehicle Entry and
Exit
Steps
WARNINGS:
Make sure that the modified vehicle
complies with all relevant legal
requirements.
If this modification alters the
homologated dimensions, a new
approval may be necessary.
CAUTION: Make sure that
reinforcements are installed to
maintain the integrity of the original
body structure.
Steps can be ordered as an option on the base
vehicle. Please check for availability.
Where additional steps are installed the required
ground clearance line is to be maintained.
The Vehicle Converter must make sure that a
movable step is set in the stored position when
the vehicle is running. The step surface must be
non-slip.
Grab Handles
WARNING: Make sure that the
location of the no-drill zones are
checked before drilling.
CAUTION: Make sure that
reinforcements are installed to
maintain the integrity of the original
body structure.
Grab handles can be ordered as an option on
the base vehicle. Please check for availability.
NOTE: For further information please contact
your local National Sales Company
representative, or Local Ford Dealer. If they are
unable to help you then please contact the
Vehicle Converter Advisory Service at
[email protected].
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
1 General Information
33

Van and Kombi
Van and Kombi Driver and Passenger Weight Distribution
Weight distribution Per Person in
Kg
'D' Third
Row Seats
'C' Second
Row Seats
'B' Front
Row Seats
and Driver
'A' Wheel-
base (mm)
TotalOn Rear
Axle
On Front
Axle
752649--9852933
755124-1859--
757412916---
752352--9853300
754530-1859--
7549262916---
752055--9853750
754035-1859--
7525502916---
Dimensions taken from Front Axle (1)
1.16.2 Center of Gravity
The following charts show the Center of Gravity
used for Brake Certification at Kerb and maximum
Gross Vehicle Mass also the beneficial effect of
fitting a High Center of Gravity pack.
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
1 General Information
46E74208ADCB1

Minimum Kerb + Driver
Running Order (Dimensions
mm)
Laden Gross Vehicle Mass (GVM)
with all passengers (Dimensions
mm)
Roof
Height
Model
8508001568136595723131750High300L
Diesel
8508001549136595724431818Medium330L
Diesel
8508001566136595724431818High330L
Diesel
8508001544136595724181762Medium350L
Diesel
8508001562136595724181762High350L
Diesel
All 430 Series have Anti-lock Brake System (ABS) so are not shown on these charts
Single Chassis Cab
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
1 General Information
49EABCD1E76472

Single Chassis Cab Center of Gravity Critical Zone to EEC Category N1. Non-ABS
Minimum Kerb + Driver Running Order
Without Float (Dimensions mm)
Laden Gross Vehicle Mass
(GVM) with all passengers
(Dimensions mm)
Model
'G' High
Center of
Gravity
Max
'F'
Standard
Vehicle
Max
'E'
Design
'D' High
Center of
Gravity
Max
'C'
Standard
Vehicle
Max
'B' Max'A' Min
Short Wheelbase (SWB) Single Rear Wheel
TBD7701119TBD91618401464300S
Diesel
TBD7701196TBD91620441521330S
Diesel
Medium Wheelbase (MWB) Single Rear Wheel
TBD7851134TBD95421611635300M
Diesel
TBD7851411TBD95422831699330M
Diesel
TBD7851390TBD95422531752350M
Diesel
Medium Wheelbase (MWB) Dual Rear Wheel
TBD7851390TBD95422531752350M
Diesel
Long Wheelbase (LWB) Single Rear Wheel
TBD8001619TBD95725761917330L
Diesel
TBD8001658TBD95727761858350L
Diesel
Long Wheelbase (LWB) Dual Rear Wheel
TBD8001658TBD95727761858350L
Diesel
Extended Frame (EF) Single Rear Wheel
TBD8001693TBD95727681858350L
Diesel
Extended Frame (EF) Dual Rear Wheel
TBD8001746TBD95733331858350L
Diesel
300,330 Rear Wheel Drive and 330,350 Forward Wheel Drive, M2 Buses and all 430 Series have
Anti-lock Brake System (ABS) so are not shown on these charts
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
1 General Information
50