dimensions 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

1.13 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

1.14 Package and Ergonomics—Specifications
1.14.1 Recommended Main Dimensions
WARNING: Do not modify the
wheelbase or add any type of frame
extension to vehicles fitted with
Interactive Vehicle Dynamics
(IVD)/Electronic Stability Program
ESP
NOTE: Extreme rear overhang may encourage
unacceptable loading conditions, which could
unload the front axle producing unacceptable
handling and braking characteristics
NOTE: When extending the length of the
wheelbase during conversion, do not increase
the overall length more than 50% of the
wheelbase of the donor vehicle. The maximum
legal overhang of the donor vehicle is 60%.
If a conversion requires more than 50% overhang,
please contact one of the below.
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].
The Special Vehicle Option 2.3m body Width pack
includes long arm mirrors and side repeater
lamps. Please check for availability.
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
1 General Information
34

Dimensions - not to exceed for Chassis Cab body Length
Long Wheel-
base 3954
Medium Wheel-
base 3504
Short Wheel-
base 3137
Wheelbase
Maximum allowable by territorial legislationMaximum recommended rear
overhang (requires self supporting
body or continuous sub frame).
A
252320731706Front outside of body to rear axle
- Single Cab
B
17091259-Front outside of body to rear axle
Double Cab
210021002100Maximum external body width
short mirror arms
C
230023002300Maximum external body width long
mirror arms
Maximum allowable by territorial legislation (We recom-
mend up to 2,4m over top of frame).
Maximum recommended external
body height (1) Rear Wheel Drive
(RWD) and Front Wheel Drive
(FWD)
D
25 minimumE
30 minimumF
Ensure local lighting legislation is maintainedG
Under run bar and towing couple legislation must be maintainedH
1.14.2 Recommended Nominal
Body Lengths for Chassis Cab
models
The following is the recommend method for
selecting best fit body lengths to suit the Chassis
Cab range, dependant on the load biases of the
conversion
Body lengths shown in the following charts are
given for guidance only, based on a minimum
specification chassis including driver, spare wheel
and full fuel. In the case of Uniformly Distributed
Load (UDL) figures the combined body and
payload Center of Gravity (CofG) is positioned
midway along the internal length of the body.
Body lengths are given as Nominal or Maximum.
Under most conditions the nominal body length
is recommended, maximum body length should
only be used when a nominal length body cannot
accommodate a specific load length requirement.
CAUTION: When considering
maximum length bodies, payload
latitude and flexibility will be reduced
as the available rear axle capacity
is used to the full. Non Uniformly
Distributed Load (UDL) loads that
are rearwards biased, should not be
used with maximum length bodies.
In order to achieve the largest load latitude
nominal (rearward biased) body lengths are the
primary recommendation. However recognizing
each body and its associated payload will have
an infinite number of CofG positions, in addition
to the large number of chassis specifications, it
is recommended that the chassis kerb weight
and plated weights are determined before a
weight distribution calculation is performed.
Chassis specification is assumed minimum with
base engine and drivetrain, any additional
equipment or alternative drivetrain's may reduce
the body length. It is recommended that physical
Chassis kerb weights are established to calculate
weight distribution when ever a body length
greater than nominal is considered.
Bodywork longer than the nominal dimension
may require a rear overhang extension with the
repositioning of the rear light bar and extension
electrical supply circuits. Body floor height may
require an increase in height to accommodate
angle of vision requirements for rear light and
license plate.
430 derivatives are fitted with a rear under-run
bar, modification of the rear overhang may
invalidate approvals, consult your local National
Sales Representative before considering
modification.
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
1 General Information
36

1.14.4 Recommended Main Load Area Dimensions for Bulkhead with
Depression Driver Side

Height 'C'
(mm) High
Floor
Height 'C'
(mm) Low
Floor
Width 'B'
(mm)
Length 'A'
(mm)
RoofWheelbase
1230133013802230LowShort Wheelbase
1550165012502280MediumShort Wheelbase
1550165012402650MediumMedium Wheelbase
1750185012302610HighMedium Wheelbase
1550165012403100MediumLong Wheelbase
1750185012303060HighLong Wheelbase
1750185012303780HighExtended Frame
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
1 General Information
39E74204CBA

1.14.5 Recommended Main Load Area Dimensions for Bulkhead with
Full Depression
Height 'C'
(mm) High
Floor
Height 'C'
(mm) Low
Floor
Width 'B'
(mm)
Length 'A'
(mm)
RoofWheelbase
1230133013802280LowShort Wheelbase
1550165012502230MediumShort Wheelbase
1550165012402600MediumMedium Wheelbase
1750185012302560HighMedium Wheelbase
1550165012403050MediumLong Wheelbase
1750185012303010HighLong Wheelbase
1750185012303730HighExtended Frame
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
1 General Information
40E74206CBA

1.14.6 Recommended Main Load Area Dimensions for Double Cab In
Van Bulkhead
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
1 General Information
41E77081CBA

Single and Double Cab
Single and Double Cab Driver and Passenger Weight Distribution
Weight distribution Per Person in Kg'C' Second
Row Seats
'B' Front
Row Seats
and Driver
'A' Wheel-
base (mm)
TotalOn Rear AxleOn Front
Axle
752352-9853137
752055-9853504
7536391859--
7519569853954
7540351859--
Dimensions taken from Front Axle (1)
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
1 General Information
45ABCAB1E74207

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

Van Center of Gravity Critical Zone to EEC Category N1. Non-ABS
Minimum Kerb + Driver
Running Order (Dimensions
mm)
Laden Gross Vehicle Mass (GVM)
with all passengers (Dimensions
mm)
Roof
Height
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 Wheel Base (SWB)
8257701100128090021268799Low260S
Diesel
8257701119128090021268799Medium260S
Diesel
8257701100128090019361232Low280S
Diesel
8257701119128090019361232Medium280S
Diesel
8257701225128086218091369Low300S
Diesel
8257701224128086218091369Medium300S
Diesel
8257701242128091619111422Low330S
Diesel
8257701240128091619111422Medium330S
Diesel
Medium Wheelbase (MWB)
8257701245128090019671460Low280M
Diesel
8387851265136595419671460Medium280M
Diesel
8257701245128090021781320Low300M
Diesel
8387851265136595421781320Medium300M
Diesel
8387851281136595421781320High300M
Diesel
8257701245128090019361540Low330M
Diesel
8387851406136595419361540Medium330M
Diesel
8387851420136595419361540High330M
Diesel
8387851232136595421281551Low350M
Diesel
8387851400136595421281551Medium350M
Diesel
8387851412136595421281551High350M
Diesel
Long Wheel Base (LWB)
8508001550136595723131750Medium300L
Diesel
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
1 General Information
48