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

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.
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1.3 Contact Information
As a manufacturer, we want to provide you with
the information you need for your vehicle
conversion/modification. If the information you
require is not in this manual or you have further
questions, please contact your local National
Sales Company Representative (NSC) or Local
Ford Dealer in your Market.
If your Local National Sales Company
Representative or Local Ford Dealer are unable
to help you, please contact the Vehicle Converter
Advisory Service at [email protected].
Ford of Britain
Simon Easton - CV Sales &
Marketing
Contact:
+44-1277-252504Tele-
phone:
+44-1277-253054Fax:
[email protected]:
GB-1/673Postal
Address:
EAGLE WAY, GB-1
BRENTWOOD
CM13 3BW
GBR
Ford of Germany
Kurt Reinhold - Transit Brand
Manager
Contact:
+49-221-9017686Tele-
phone:
+49-221-9018409Fax:
[email protected]:
D-NH/4APostal
Address:
Henry Ford Strasse 1
Cologne
50725
DEU
Ford of France
Jean-Francois Taillefer - Transit
Brand Manager
Contact:
+33-1-61016547Tele-
phone:
+33-1-61016505Fax:
[email protected]:
St GermainPostal
Address:
34 rue de la Croix de Fer
Saint Germain en Laye
78100
FRA
Ford of Italy
Valentino Munno - Transit Brand
Manager
Contact:
+39-06-51855509Tele-
phone:
+39 035 4821331Fax:
[email protected]:
Via Andrea Argoli 54Postal
Address:
ROME
00143
ITA
Ford of Ireland
John Manning - Transit Brand
Manager
Contact:
+353-21-4329205Tele-
phone:
+353-21-4329213Fax:
[email protected]:
CorkPostal
Address:
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Ford of Australia
Alex Mihalovich- Transit Brand
Manager
Contact:
+61 3 93597678Tele-
phone:
+61 3 93598277Fax:
[email protected]:
Head OfficePostal
Address:
1735 Sydney Road
Private mail bag 6
Campbell Field
VI
3061
AUS
2D Engineering Drawings can be downloaded
in DWG format, you will find these by going to
the 'BEMM' tab then selecting the 'Drawings'
tab, this will give you the option to navigate
though a drop-down menu to specific drawings.
3D CAD data in iges format is available on
CD-ROM, you can request specific information
by contacting the Vehicle Converter Advisory
Service by e-mail. The data will be issued by
encrypted CD-ROM using the Ford Data Export
process
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Emergency Services
Refer to: 1.14 (page 34).
Ambulance -
Front Line
Refer to: 3.2 Engine Cooling (page 75).
(Airflow Restrictions).
Refer to: 4.4 Battery and Cables (page 98).
(Also Generator and Alternator).
Refer to: 4.11 Exterior Lighting (page 116).
Refer to: 4.12 Interior Lighting (page 118).
Refer to: 4.13 Fuses and Relays (page 119).
Refer to: 5.1 Body (page 175).
(Integrated Bodies and Conversions, Hydraulic Lifting Equipment for Van, Bus, Kombi
and Chassis Cab).
Refer to: 5.5 Seats (page 209).
Refer to: 5.8 Air Bag Supplemental Restraint System (SRS) (page 218).
Refer to: 1.14 (page 34).
Fire Brigade
Refer to: 3.2 Engine Cooling (page 75).
(Airflow Restrictions).
Refer to: 4.4 Battery and Cables (page 98).
(Also Generator and Alternator).
Refer to: 4.11 Exterior Lighting (page 116).
Refer to: 4.12 Interior Lighting (page 118).
Refer to: 4.13 Fuses and Relays (page 119).
Refer to: 5.1 Body (page 175).
(Integrated Bodies and Conversions, Hydraulic Lifting Equipment for Van, Bus, Kombi
and Chassis Cab).
Refer to: 5.5 Seats (page 209).
Refer to: 5.8 Air Bag Supplemental Restraint System (SRS) (page 218).
Refer to: 1.14 (page 34).
Armed
Forces
Refer to: 3.2 Engine Cooling (page 75).
(Airflow Restrictions).
Refer to: 4.4 Battery and Cables (page 98).
(Also Generator and Alternator).
Refer to: 4.11 Exterior Lighting (page 116).
Refer to: 4.12 Interior Lighting (page 118).
Refer to: 4.13 Fuses and Relays (page 119).
Refer to: 5.1 Body (page 175).
(Integrated Bodies and Conversions, Hydraulic Lifting Equipment for Van, Bus, Kombi
and Chassis Cab).
Refer to: 5.5 Seats (page 209).
Refer to: 5.8 Air Bag Supplemental Restraint System (SRS) (page 218).
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Emergency Services
Refer to: 1.14 (page 34).
Police
Refer to: 3.2 Engine Cooling (page 75).
(Airflow Restrictions).
Refer to: 4.4 Battery and Cables (page 98).
(Also Generator and Alternator).
Refer to: 4.11 Exterior Lighting (page 116).
Refer to: 4.12 Interior Lighting (page 118).
Refer to: 4.13 Fuses and Relays (page 119).
Refer to: 5.1 Body (page 175).
(Integrated Bodies and Conversions, Hydraulic Lifting Equipment for Van, Bus, Kombi
and Chassis Cab).
Refer to: 5.5 Seats (page 209).
Refer to: 5.8 Air Bag Supplemental Restraint System (SRS) (page 218).
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1.5 Conversion Homologation
The Vehicle Converter must observe any
statutory rules and regulations. When the
conversion needs a new approval the following
information must be quoted.
•All dimensional, weight and centre of gravity
data.
•The fixing of the body to the donor vehicle.
•Operating conditions.
The responsible Technical Service may require
additional information and/or testing.
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].
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1.7 Vehicle Duty Cycle Guidelines
It is necessary to take into account the customer
usage profile and the anticipated vehicle duty
cycles of the modified vehicle in order to choose
the appropriate specification of the base vehicle.
It is necessary to select the appropriate drive,
engine, gear ratio, gross vehicle mass, gross train
mass, axle plates and payloads of the base
vehicle to match the customer requirements.
Where possible make sure that the base vehicle
is ordered with any necessary plant fit options.
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].
A high numeric gear ratio is recommended for
vehicles with customer requirements for:
•high payload
•trailer tow
•frequent stop-and-go cycles
•high altitude and gradients
•terrain conditions such as found on building
and construction sites
Rear wheel drive is recommended for high
traction in combination with a high trailer weight
Front wheel drive is recommended for low
conversion weight
1.7.1 Conversion Affect on Fuel
Economy and Performance
Any conversion may effect the fuel consumption
and performance depending on the
aerodynamics and the weight added by the
conversion. The published information for fuel
consumption and performance of the base
vehicle therefore may not be valid. It is advisable
to control the weight, but without deteriorating
other vehicle attributes and functions (especially
those related to safety and durability).
1.7.2 Vehicle Ride and Handling
Attributes
CAUTION: Do not exceed the axle
plate, gross vehicle mass, trailer
plate and gross trailer mass limits.
Due to the displacement of the center of gravity
occurred by the conversion the ride and handling
attributes may be different to the base vehicle.
NOTE: This vehicle should be evaluated for safe
operation prior to sale
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1.8 End of Life Vehicle (ELV) Directive
The EU End-of-Life Vehicle (ELV) directive
requires that environmental and recycling aspects
are integrated in the development process of
new components and vehicles. This includes
requirements with aspect to:
•The overall recyclability (85%) / recoverability
(95%) of vehicles.
•Limited use of hazardous substances including
the elimination of prohibited substances such
as lead, hexavalent chromium cadmium and
mercury).
•Publication of dismantling information.
•Parts Marking according to the corresponding
ISO Standards: ISO 1043-1, 1043-2 and 11469
for plastics and ISO 1629 for rubber materials.
•Increasing use of recycled materials.
•Producers meet all, or a significant part of, the
costs to take back End-of-Life Vehicles
In addition to the requirements resulting from the
End-of-Life directive other environmental targets
should be taken into consideration such as:
•minimizing costs and environmental burden
along the product life-cycle.
•Maximizing use of renewable materials e.g.
natural fibres.
•minimizing the presence of substances
impacting vehicle interior air quality / clean
compartment or allergenic reactions (please
refer to 'Technischer Überwachungsverein
TÜV TOXPROOF). This refers to aspects like
smell, fogging, toxicity and allergy coming from
material in the interior.
•eliminate use of prohibited substances which
are listed in the Global Automotive Declarable
Substance List (GADSL) at
http://www.gadsl.org.
For continued legal compliance and
environmental performance of all Ford products
it is essential that any conversion of the vehicles
is in compliance with the requirements listed
above.
This is not a complete list of all legal requirements
to be met by every converted vehicle.
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].
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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].
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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.
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