weight 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
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1 General Information
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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 General Information
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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
FordTransit 2006.5 (April 2006–)
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1.10 Lifting
WARNING: When lifting the vehicle
with a two post lift for the removal
of the engine/transmission or rear
axle, make sure the vehicle is
secured to the lift using vehicle
retention straps to prevent tilting.
Failure to follow these instructions
may result in personal injury.
CAUTIONS:
when lifting the vehicle with two
post lift, vehicle lift arm adapters
must be used under the lifting
points.
when lifting the vehicle with a two
post lift, the maximum kerb weight
must not be exceeded.
It is important that only the correct
lifting and support locations are
used at all times.
Van, Bus and Kombi (Short Wheelbase [SWB], Medium Wheelbase [MWB], Long
Wheelbase [LWB] and Extended Length)
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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
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Explanation of terms used in body lengths
Nominal (Rearward Biased) Body Lengths- Recommended for best overall weight distri-
bution and payload latitude. Nominal (rearward biased) body lengths are recommended when tail-
lifts, rear mounted cranes, tow bars or rear mounted equipment are fitted. Nominal (rearward biased)
body lengths assume a typical back of cab to interface of body bulkhead dimension is 100mm
Nominal Uniformly Distributed Load (UDL) Body Lengths- is the maximum length of a
typical Float / Dropside body maintaining UDL loading without exceeding individual axle plating,
assuming no more than 100mm back of cab to internal face of body bulkhead dimension. However
specific non-standard applications, e.g. frame or body mounted equipment behind cab, or non UDL
loads may allow longer body lengths. These may be permissible providing the following are not
exceeded
- Individual axle plating.
- Maximum rear overhang greater that 50% of wheelbase.
- Body and payload combined CofG within a maximum 5% of wheelbase when rearwards of rear
axle centre line.
- Minimum variant front axle kerb mass.
Single Chassis Cab
Body Length (Internal)Drivetrain
Nominal
(UDL)
Nominal
(Rearward
Biased)
Rear AxleTransmissionWheelbaseModel
28002800Single Rear
Wheel
Front wheel Drive
/Rear Wheel Drive
Short Wheelbase300
36003200Dual rear WheelRear Wheel DriveMedium Wheel-
base
350
35003200Single Rear
Wheel
Rear Wheel Drive
35003200Single Rear
Wheel
Front Wheel Drive
3950*3650Dual rear WheelRear Wheel DriveLong Wheelbase
3950*3650Single Rear
Wheel
Rear Wheel Drive
3950*3650Single Rear
Wheel
Front Wheel Drive
44004000Dual rear WheelRear Wheel DriveExtended Frame
44004000Single Rear
Wheel
Rear Wheel Drive
42004000Single Rear
Wheel
Front Wheel Drive
30002850Dual rear WheelRear Wheel DriveLong Wheelbase430-(4.25t
GVM)30003000Dual rear WheelRear Wheel DriveExtended Frame
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Date of Publication: 12/2006
1 General Information
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1.16 Load Distribution—Specifications
1.16.1 Load Distribution Calculations - Driver and Passenger Weight
Distribution
CAUTIONS:
Do not exceed the axle plated
weights.
Do not exceed the gross vehicle
weight
Tire manufacturer specification must
be maintained.
NOTE: Uneven load distribution could result in
unacceptable handling and braking
characteristics.
NOTE: The centre of mass of the payload should
be located within the wheelbase of the vehicle
NOTE: Avoid one-sided load distribution.
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
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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
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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
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