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Body and Equipment Mounting ManualFORD RANGER 2012

Date of Publication: 12/2014

The information contained in this publication was correct at the time of going to print. In the interest of development the right is reserved to changespecifications, design or equipment at any time without notice and without incurring any obligations. This publication, or part thereof, may not bereproduced nor translated without our approval. Errors and omissions excepted.

© Ford Motor Company 2014

All rights reserved.

1 General Information1.1 About This Manual..............................5

1.1.1 New for this BEMM publication12/2014.............................................................5

1.1.2 Introduction....................................................51.1.3 Important Safety Instructions.................51.1.4 Warnings, Cautions and Notes in This

Manual.............................................................51.1.5 How to Use This Manual...........................5

1.2 Commercial and Legal Aspects..........61.2.1 Terminology....................................................61.2.2 Warranty on Ford Vehicles.......................61.2.3 Legal and Vehicle Type Approval...........61.2.4 Alternative Type Approval........................61.2.5 Legal Obligations and Liabilities............61.2.6 General Product Safety

Requirement..................................................61.2.7 Product Liability............................................71.2.8 Restraints System........................................71.2.9 Drilling and Welding.....................................71.2.10 Minimum Requirements for Brake

system and Load Apportioning Valves.............................................................................7

1.2.11 Road Safety....................................................71.3 Conversion Homologation..................81.4 Electromagnetic Compatibility

(EMC)..................................................91.4.1 Suggested Antenna Location................10

1.5 Vehicle Duty Cycle Guidelines............111.5.1 Conversion Affect on Fuel Economy

and Performance.........................................111.5.2 Vehicle Ride and Handling

Attributes........................................................111.6 Jacking................................................121.7 Lifting.................................................131.8 Noise, Vibration and Harshness

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

Vehicle Storage..................................151.10 Package and Ergonomics..................16

1.10.1 General Component PackageGuidelines......................................................16

1.10.2 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 andErgonomics—Specifications.............17

1.11.1 Recommended Body Dimensions........171.11.2 Chassis Cab Body - Basic Dimensions

and Weights................................................201.11.3 Kerb Weights and Payload......................211.11.4 Front, Rear and Side Under-run

Protection......................................................211.12 Hardware—Specifications................221.13 Load

Distribution—Specifications............231.13.1 Load Distribution Calculations - Driver

and Passenger WeightDistribution...................................................23

1.13.2 Center of Gravity........................................251.14 Towing...............................................28

1.14.1 Towing Requirements..............................281.14.2 Towing............................................................281.14.3 Towing capacities......................................28

1.14.4 Trailer Nose Weight...................................291.14.5 Towing Specifications..............................29

2 Chassis2.1 Suspension System..........................302.2 Brake System......................................31

2.2.1 General...........................................................312.2.2 Brake Hoses..................................................312.2.3 Trailer brakes................................................31

3 Powertrain3.1 Fuel System.......................................32

3.1.1 Fuel Filler Pipe Shipping Bracket.........323.1.2 Fuel Filler Mounting..................................343.1.3 Fuel Filler Vent Hose.................................37

4 Electrical4.1 Battery and Cables............................39

4.1.1 Battery Information..................................394.1.2 Auxiliary Battery (Vehicles with

Special Equipment Pack).......................414.1.3 Auxiliary Battery Relocation and use

of Electrical Harness Extension (FlyLead) (Vehicles with SpecialEquipment Pack).......................................45

4.1.4 Generator and Alternator.......................464.2 Electronic Engine Controls...............47

4.2.1 Vehicle Speed Output (Signal)............474.3 Exterior Lighting................................52

4.3.1 Rear Combination lamps........................524.3.2 Rear Fog Lamp...........................................534.3.3 Rear License Plate Lamp........................554.3.4 Reversing Lamps.......................................564.3.5 Additional External Lamps....................564.3.6 Additional External Lamps (Vehicles

with Special Equipment Pack).............574.3.7 Lamps – Hazard / Direction

Indication......................................................644.3.8 Electrically operated Door Mirrors......64

5 Body and Paint5.1 Body...................................................65

5.1.1 Body Structures - GeneralInformation..................................................65

5.1.2 Integrated Bodies andConversions.................................................65

5.1.3 Chassis Cab.................................................665.1.4 Front End Integrity for Cooling, Crash,

Aerodynamics and Lighting..................695.1.5 Tipper Bodies..............................................695.1.6 Tank and Dry Bulk Carriers.....................70

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5.1.7 Bull Bar (Vehicles with SpecialEquipment Pack)........................................70

5.1.8 Roof Racks......................................................715.1.9 Canopies.........................................................72

5.2 Airbag Supplemental RestraintSystem (SRS).....................................75

5.2.1 Air Bags...........................................................755.2.2 Supplementary Restraint Sensors

(Front).............................................................785.3 Safety Belt System.............................795.4 Corrosion Prevention.........................80

5.4.1 General...........................................................805.4.2 Repairing Damaged Paint.......................805.4.3 Under Body Protection and

Material..........................................................805.4.4 Painting Road Wheels..............................805.4.5 Contact Corrosion......................................80

5.5 Frame and Body Mounting.................815.5.1 Mounting Points and Tubing...................815.5.2 Self-Supporting Body Structure...........825.5.3 Frame Drilling and Tube

Reinforcing....................................................835.5.4 Ancillary Equipment - Sub Frame

Mounting........................................................835.5.5 Area for Fitting Additional Body

Attachments to the Rear of theBumper. .........................................................83

5.5.6 Water Tank on Camper Vehicles...........83

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1.1 About This Manual

1.1.1 New for this BEMM publication12/2014

The following sections of the manual have beenupdated since the last publication of the BEMM07/2014.Battery InformationRefer to: 4.1 Battery and Cables (page 39).

1.1.2 Introduction

This manual has been written in a format that isdesigned to meet the needs of Vehicle Converters.The objective is to use common formats with theworkshop manual which is used by techniciansworldwide.This guide is published by Ford and providesgeneral descriptions and advice for convertingvehicles. These requirements must be compliedwith before a Ford Dealer should take delivery ofmotor vehicle accessories from an externalsupplier either for themselves or on behalf of amotor vehicle client.It must be emphasized that any change to thebasic vehicle which does not meet the enclosedguideline standards may severely inhibit the abilityof the vehicle to perform its function. Mechanicalfailures, structure failure, component unreliabilityor vehicle instability will lead to customerdissatisfaction. Appropriate design andapplication of body, equipment and or accessoriesis key to ensuring that customer satisfaction isnot adversely affected.The information contained within this publicationtakes the form of recommendations to befollowed when vehicle modifications areundertaken. It must be remembered that certainmodifications may invalidate legal approvals andapplication for re-certification may be necessary.Ford cannot guarantee the operation of thevehicle if non-Ford approved electrical systemsare installed. Ford electrical systems are designedand tested to function under operationalextremes, and have been subjected to theequivalent of ten years of driving under suchconditions.

1.1.3 Important Safety Instructions

Appropriate conversion procedures 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. Anyone who 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.

1.1.4 Warnings, Cautions and Notes inThis Manual

WARNING: Warnings are used to indicatethat failure to follow a procedurecorrectly may result in personal injury.CAUTION: Cautions are used to indicatethat failure to follow a procedurecorrectly may result in damage to thevehicle or equipment being 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 note onlyapplies to one step, it is placed at the beginningof the specific step (after the step number).

1.1.5 How to Use This Manual

This manual covers vehicle conversion procedures.The pages at the start of this manual list thecontent, by group. A group covers a specificportion of the vehicle. The manual 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 for theprinted version, this will help guide you to the startof the section which contains the relevantinformation.There is also an alphabetical index at the back ofthe manual. As with the contents pages you willbe able to link to sections. To do this just click onthe 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: 12/2014FORD RANGER 2012

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1.2 Commercial and Legal Aspects

1.2.1 Terminology

NOTE: Any modifications to the vehicle must benoted in the owner's handbook or new descriptiveliterature included with the owner'sdocumentation.Vehicle Converter refers to any re-seller alteringthe vehicle by converting the body and adding ormodifying any equipment not originally specifiedand or supplied by Ford.Unique component or similar wording refers tonon-Ford specified or after sale fitment notcovered by Ford warranty.

1.2.2 Warranty on Ford Vehicles

Please contact The National Sales Company inthe country where the vehicle will be registered orrefer to the vehicle Owner Guide for details of theterms of any applicable Ford warranty.The Vehicle Converter should warrant its design,materials and construction for a period at leastequal to any applicable Ford warranty.The Vehicle Converter must ensure that anyalteration made 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 alteration madeby the Vehicle Converter or any of its agents to aFord 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 Converter unlessFord has given its prior written consent to suchliability.

1.2.3 Legal and Vehicle Type Approval

• All components embodied on Ford vehicles areapproved to the applicable legal requirements.

• Ford vehicles have Type Approval for theintended marketing territories.

WARNING: Exception - Incompletevehicles require further approval whencompleted by the Body Builder.

• The Ranger range has Type Approval for manyterritories, although the full range of vehiclesshown in this manual are not necessarilyreleased in all territories. Check with your localFord National Sales Company representative.

• 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 Type Approval

If significant changes are made the Body Buildermust negotiate with the relevant authority. Anychanges to the vehicle operating conditions mustbe advised to the customer.

1.2.5 Legal Obligations and Liabilities

The Vehicle Converter should consult with its legaladvisor on any questions concerning its legalobligations and liabilities.Ford recomends that the Vehicle Converter andFord Dealer must understand their individual andjoint responsibilities in supplying a safe andcompliant motor vehicle fitted with safe andcompliant accessories.

1.2.6 General Product SafetyRequirement

The Vehicle Converter shall ensure that any vehicleit places on the market complies with all local lawsrelating to the safe carriage of loads on publicroads. The Vehicle Converter shall also ensure thatany alteration it makes to a Ford vehicle orcomponent does not reduce its compliance withlocal design rules.The Vehicle Converter must provide sufficient LoadRestraint tie down points or compartmentisedstorage areas that enable the driver to safely carryloads that match the use criteria for which thebody was designed.The Vehicle Converter shall release Ford from allliability 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 trailerplate.Do not change the tire size or load rating.

Do not modify the steering system.

Excessive heat can build up from theexhaust system, in particular from thecatalytic converter and from the Dieselparticulate filter (cDPF). Ensure adequateheat shields are maintained. Maintainsufficient clearance to hot parts.Do not modify or remove heat protectionshields.

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Do not route any electrical cables withthe Antilock Brakes System and TractionControl System cables because ofextraneous signal risk. It is generally notrecommended to hang electrical cablesoff existing looms or pipes.Do not change original location or removewarning labels provided with the basevehicle in view to the driver. Ensure thatlabels in view to the driver remain in fullview to the driver.

NOTE: For further information please contactyour local National Sales Company representative,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. Fordshall not be liable for any such liability (except asprovided by law).The Vehicle Converter or equipment manufactureris 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 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 unique electricalor electronic systems.

• Functional safety and freedom of movementof all moving parts (for example axles, springs,propeller shafts, steering mechanisms, 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 restraints systemare not allowed.Airbags are explosive. For safe removaland storage during conversion follow theprocedures in the Ford workshop manualor consult your local National SalesCompany representative.

Do not alter, modify or relocate theairbag, sensor and modules of therestraints system or any of itscomponents.Attachments or modifications to thefront end of the vehicle may affect theairbag fire timing and result inuncontrolled deployment.Modifications to the B-Pillar bodystructure may affect the side airbag firetiming and result in uncontrolled sideairbag deployment.

Refer to: 5.2 Airbag Supplemental RestraintSystem (SRS) (page 75).

1.2.9 Drilling and Welding

Drilling and welding of frames and body structureshave to be conducted following the guidelineswithin this document.

1.2.10 Minimum Requirements forBrake system and Load ApportioningValves

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

distribution.• Changes to the Antilock Brake System (ABS),

Traction Control System (TCS) and ElectronicStability Program (ESP) system are notpermitted.

1.2.11 Road Safety

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


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1.3 Conversion HomologationThe Vehicle Converter must observe any statutoryrules and regulations. When the conversion needsa new approval the following information must bequoted.• All dimensional, weight and centre of gravity

data.• The fixing of the body to the donor vehicle.• Operating conditions.The responsible Technical Service may requireadditional information and/or testing.NOTE: For further information please contact yourlocal National Sales Company representative, orLocal Ford Dealer.


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1.4 Electromagnetic Compatibility (EMC)WARNINGS:

Your vehicle has been tested andcertified to European legislation relatingto electromagnetic compatibility(2004/104/EC). It is your responsibilityto ensure that any equipment fittedcomplies with applicable locallegislation. Ensure you have anyequipment fitted by properly trainedtechnicians.

Radio frequency (RF) transmitterequipment (for example: cellulartelephones, amateur radio transmittersand so on.) may only be fitted to yourvehicle if they comply with theparameters shown in the following'Frequency Overview' table. There are nospecial provisions or conditions forinstallations or use.Do not mount any transceiver,microphones, speakers, or any other itemin the deployment path of the airbagsystem.Do not fasten antenna cables to originalvehicle wiring, fuel pipes and brake pipes.Keep antenna and power cables at least100mm from any electronic modules andairbags and associated wiring.

Frequency Overview

Antenna PositionMaximum Output Power (W)(Peak RMS)

Frequency Band (MHz)

1501-3015030-5415068-87.5150142-176150380-512110806-94012*806-9401101200-14001101710-188511*1710-18851101885-202511*1885-2025

Anywhere0.12400-2500

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


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1.4.1 Suggested Antenna Location

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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 standby andtransmit modes.Check all electrical equipment:• With ignition ON.• With the engine running.• During a road test at various speeds.Check that electromagnetic fields generated insidethe vehicle cabin by the transmitter installed donot exceed human exposure limits specified in EUdirective 2004/40/EC.


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1.5 Vehicle Duty Cycle GuidelinesIt is necessary to take into account the customerusage profile and the anticipated vehicle dutycycles of the modified 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, gross trainmass, axle plates and payloads of the base vehicleto match the customer requirements.Where possible make sure that the base vehicleis ordered with any necessary plant fit options.NOTE: For further information please contactyour local National Sales Company representative,or Local Ford Dealer.

1.5.1 Conversion Affect on FuelEconomy and Performance

Any conversion may effect the fuel consumptionand performance depending on the aerodynamicsand the weight added by the conversion. Thepublished information for fuel consumption andperformance of the base vehicle therefore maynot be valid. It is advisable to control the weight,but without deteriorating other vehicle attributesand functions (especially those related to safetyand durability).

1.5.2 Vehicle Ride and HandlingAttributes

CAUTION: Do not exceed the axle plate,gross vehicle mass, trailer plate andgross trailer mass limits.

Due to the displacement of the center of gravityoccurred by the conversion the ride and handlingattributes may be different to the base vehicle.NOTE: This vehicle should be evaluated for safeoperation prior to sale.


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1.6 JackingWARNINGS:

Always position the vehicle on a hardlevel surface. If the vehicle must be jackedup on a soft surface use load spreadingblocks under the jack. Always chock thewheel diagonally opposite the jackingpoint. Failure to follow these instructionsmay result in personal injury.Do not get under a vehicle that issupported by a jack.This jack is only intended for changingwheels.

CAUTIONS:It is important that only the correctjacking and support locations are used atall times.Make sure that access to the spare wheelis maintained when converting the vehicleor relocating the spare wheel.

NOTE: When using the vehicle jack, refer to theowner guide for correct operating instructions.NOTE: Make sure that reinforcements are installedto maintain the integrity of the original bodystructure for/at jacking points.NOTE: Any modifications to the vehicle must benoted in the owner's handbook or new descriptiveliterature included with the owner'sdocumentation.

The spare wheel winch is located above the sparewheel and can be accessed from the rear of thechassis frame.The jack must be assembled and fixedappropriately to the body to ensure safety,durability and accessibility.

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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 a jack.

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1.7 LiftingWARNING: When lifting the vehicle witha two post lift for the removal of theengine/transmission or rear axle, makesure the vehicle is secured to the liftusing vehicle retention straps to preventtilting. Failure to follow theseinstructions may result in personal injury.

CAUTIONS:When lifting the vehicle with a two postlift, vehicle lift arm adapters must beused under the lifting points.When lifting the vehicle with a two postlift, the maximum kerb weight must notbe exceeded.It is important that only the correct liftingand support locations are used at alltimes.

All Vehicles

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1.8 Noise, Vibration and Harshness (NVH)WARNING: Make sure that the modifiedvehicle complies with all relevant legalrequirements.CAUTION: The travel and function ofpedals must not be restricted.

Changes to the powertrain, engine, transmission,exhaust, air intake system or tires may influencethe exterior noise emission. Therefore the exteriornoise level of the converted vehicle has to beverified.The interior noise levels should not be deterioratedby the conversion. Reinforce panels and structuresas appropriate to avoid vibrations. Consider theusage of sound deadening material on panels.


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1.9 Vehicle Transportation Aids and Vehicle StorageCAUTIONS:

Disconnect the battery if the vehicle is tobe stored for more than 30 days.Make sure that the protective covers arenot removed from an incomplete vehicleuntil the conversion is started.Make sure that components removedduring conversion are kept clean and dry.Make sure that components removedduring conversion are refitted to thesame vehicle.

In addition:• The windscreen wipers should be lifted off the

glass and set right up.• All air intakes should be closed.• Increase normal tire pressure by 0.5 bar.• The hand brake system should not be used.• Apply suitable wheel chock to prevent roll

away.A significant risk during storage is deterioration ofvehicle bodywork, therefore, appropriate storageprocedures must be observed, including periodicinspection and maintenance.Claims arising from deterioration caused byincorrect storage, maintenance or handling arenot the responsibility of Ford.Vehicle Converters must determine their ownprocedures and precautions, particularly wherevehicles are stored in the open as they areexposed to any number of airborne contaminants.The following may be considered a sensibleapproach to storage:Short Term Storage• Wherever possible vehicles should be stored

in an enclosed, dry, well-ventilated area basedon firm, well drained ground which is free oflong grass or weeds and where possibleprotected from direct sunlight.

• Vehicles must not be parked near, under foliageor close to water as additional protection maybe necessary for certain areas.

Long term storage:• Battery to be disconnected but not removed

from the vehicle.• The wiper blades should be removed and

placed inside the vehicle. Make sure the wiperarms are suitably prevented from resting onthe windscreen.

• Engage first gear and release the parking brakecompletely. Chock the wheels first if the vehicleis not on level ground.

• Set climate controls to the "open" position toprovide ventilation, where possible.

• Where protective film has been applied inmanufacture it must be left on the vehicle untilprepared for delivery but must be removedafter a maximum storage period of six months(film is date stamped to indicate requiredremoval date).

• Make sure that all windows, doors, hood,tailgate and luggage compartment lid arecompletely closed and the vehicle is locked.

The Pre Delivery Inspection (PDI) is the finalopportunity to make sure a battery is fit forpurpose prior to the customer taking delivery oftheir new vehicle. The battery must be checkedand appropriate action taken prior to the vehiclebeing handed over to the customer. Test resultsmust be recorded on the PDI repair order.Batteries. To make sure the battery is maintainedcorrectly and to assist in preventing prematurefailure, it is necessary to check and recharge thebattery regularly while a vehicle is not in use.Where a battery is left below its optimum chargelevel for any length of time, it may result inpremature failure of the battery.

Every 3Months

MonthlyAction / Time instorage

-XCheck vehicle isclean

-XRemove externalcontamination

DisconnectedConnectedCheck batterycondition -Recharge if neces-sary

-XVisually check tiresX-Check interior for

condensationX-Run engine for 5

minutes minimumwith air conditioningswitched on, whereapplicable

To reduce the likelihood of premature batteryfailure it is recommended that where:• A battery is left connected – monthly checks

should be carried out.• A battery has been disconnected – no greater

than a 3 monthly check should be carried out.


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1.10 Package and Ergonomics

1.10.1 General Component PackageGuidelines

WARNING: Do not modify, drill, cut orweld any suspension components,specifically the steering gear system,subframe or anti-roll bars, springs orshock absorbers including mountingbrackets.

The Vehicle Converter has to ensure that sufficientclearance is maintained under all drive conditionsto moving components such as axles, fans,steering, brake system etc.The Vehicle Converter is responsible for allinstalled components during the conversion. Thedurability has to be confirmed by appropriate testprocedures.

1.10.2 Driver Reach Zones

Controls and/or equipment required to be usedwhile driving should be located within easy reachof the driver so as not to impair driver control.

1.10.3 Driver Field of View

WARNING: Make sure that the modifiedvehicle complies with all relevant legalrequirements.

1.10.4 Conversion Affects on ParkingAids

WARNING: Ensure that monitors mountedin the cabin meet the interior package andsafety requirements.

On conversions requiring a rear camera, the reversesignal may be taken as described in the electricalsection, described in reversing lamps.Refer to: 4.3 Exterior Lighting (page 52).

1.10.5 Aids for Vehicle Entry and Exit

Steps

WARNINGS:Make sure that the modified vehiclecomplies with all relevant legalrequirements.If this modification alters thehomologated dimensions, a new approvalmay be necessary.CAUTION: Make sure that reinforcementsare installed to maintain the integrity ofthe original body structure.

Steps can be ordered as an accessory on the basevehicle. Please check for availability.Where additional steps are installed the requiredground clearance line is to be maintained.The Vehicle Converter must make sure that amovable step is set in the stored position whenthe vehicle is running. The step surface must benon-slip.

Rear View Mirrors

Rear view mirror is homologated up to 1880 mmmaximum body width, see the Figure below,dimension 'X'.

XX

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1.11 Package and Ergonomics—Specifications

1.11.1 Recommended Body Dimensions

WARNINGS:Do not modify the wheelbase or add anytype of frame extension to vehicles fittedwith Electronic Stability Program (ESP).Ensure that any mass added to thevehicle does not compromise vehiclestability.

NOTE: Extreme rear overhang may encourageunacceptable loading conditions, which couldunload the front axle, producing unacceptablehandling and braking characteristics. Ensure thatthe centre of gravity of the body and payload doesnot fall outside of the recommended zone.NOTE: An excessively high centre of gravity couldreduce vehicle stability. Ensure that the centre ofgravity of the body and payload does not falloutside of the recommended zone.Refer to: 1.13 (page 23).

NOTE: When extending the length of the framerearward of the rear axle, it is recommended thatthe overall rear overhang is limited to a maximumof 50% of the wheelbase of the vehicle.NOTE: If a towball is fitted to the vehicle, the bodydimensions must incorporate a towball clearancezone in accordance with local requirements. Foradditional information, refer to AustralianStandard 4177.1 and ECE 55.If a conversion requires more than 50% overhang,please contact one of the below.For further information please contact your localNational Sales Company representative, or LocalFord Dealer.Load carrying structures should not be mountedonto an existing load tray or load box. Bodyattachment points are provided on the frame.Refer to: 5.1 Body (page 65).


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Chassis Cab Body - Single Cab Illustrated

A

H

B

G

D

F

E

A

J

B

C

G

D E

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Dimensions - not to exceed for Chassis Cab body Length

Dimension (mm)DescriptionDouble CabStretch

CabSingle Cab

148317812251Frame length behind back of cab (not including rearlight cross-member)

A

Under run bar and towing attachment legislation to be maintainedB2400 over the top of frame, provided loaddistribution requirements are met

Maximum recommended external body heightC

4737711241Front outside of body to rear axleD1610 (50% of vehicle wheelbase),provided load distribution requirementsare met

Maximum recommended rear overhangE

25 MinimumClearance between the back of the cab and the bodyFEnsure local lighting legislation is maintained Refer to: 4.3 Exterior Lighting (page 52).G

30Clearance between the top of the cab and the bodyH1880Maximum external body widthJ

All dimensions (shown in mm) are subject to manufacturing tolerances and refer to min specificationmodels which do not include additional equipment. The illustrations are for guidance only.


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1.11.2 Chassis Cab Body - Basic Dimensions and Weights

Chassis Cab Body - Single Cab Illustrated

C

B

E

A

D F

C

B

E

A

D F

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Chassis Cab Body - Basic Dimensions and Weights

DoubleCab

Stretch CabSingleCab

Description

5110Overall length (mm)A1850Overall width - excluding exterior mirrors (mm)B

171617061703Overall height 4x2 (mm)C1815 - 18211804 - 18101800-1806Overall height 4x4 (mm)C

3220Wheelbase (mm)D1590Track - front 4x2 (mm)E1560Track - front 4x4 (mm)E1590Track - rear 4x2 (mm)E1560Track - rear 4x4 (mm)E985Rear Overhang (mm)F2925Gross Vehicle Mass GVM (kg)-

3200Gross Vehicle Mass 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 Kerb Weights and Payload

Details of vehicle kerb weights and payloadcapacities are given in the vehicle weights table,which is provided as a supplement to thisdocument. Refer to the vehicle weights table forfurther information.

1.11.4 Front, Rear and Side Under-runProtection

WARNING: Check local legislation forlegal requirements.

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


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1.12 Hardware—SpecificationsMaterial Specification, Strength and Torque

Standard Hardware and Tightening Torques (Nm) Bolts/Studs: ISO 898-1, Nuts: ISO 898-2Grade 10.9Grade 8.8Grade 4.8

MaximumMinimumMaximumMinimumMaximumMinimumThread Size3.42.41.41.1M46.74.92.72.2M5

15.011.011.58.54.73.7M635.025.028.020.0M870.050.055.041.0M10125.095.092.068.0M12200150153113M14

310.0230.0230.0170.0M16399.4317.5317.0252.0M18541.8434.7430.0345.0M20743.4592.2590.0470.0M22945.0756.0750.0600.0M24

This torque chart is a recommendation and the converter is responsible for the optimal torque for aspecific joint.


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1.13 Load Distribution—Specifications

1.13.1 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 bemaintained.

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

NOTE: Over loading of the vehicle could result inunacceptable ground clearance.NOTE: The centre of mass of the body equipmentand the payload it contains should be locatedwithin the dimensions given.NOTE: Avoid one-sided load distribution.NOTE: For further information please contactyour local National Sales Company representative,or Local Ford Dealer.

Single Cab

1

AB

E133921


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Single Cab Driver and Passenger Weight Distribution

Weight distribution per person (Kg)'B' Front rowseats and driver

(mm)

'A' Wheelbase(mm)

TotalOn Rear AxleOn Front Axle75354014903220

Double Cab

1

AC

B

E133926

Double Cab Driver and Passenger Weight Distribution

Weight distribution per person (Kg)'C' Second rowseats (mm)

'B' Front rowseats and

driver (mm)

'A' Wheelbase(mm)

TotalOn Rear AxleOn Front Axle753540-149032207554212310--

Stretch Cab

1

AC

B

E133925


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RAP Cab Driver and Passenger Weight Distribution

Weight distribution per person (Kg)'C' Secondrow seats

(mm)

'B' Front rowseats and

driver (mm)

'A' Wheelbase(mm)

TotalOn Rear AxleOn Front Axle753540-149032207551242180--

1.13.2 Center of Gravity

NOTE: Calculations shown are not inclusive oftow bar and other dealer fitted accessories.The following charts define the recommendedcentre of gravity position for the mass added tothe vehicle by the vehicle converter.

"Added mass" includes all added body equipmentand cargo, but excludes passengers seated instandard cab seating.For double cab vehicles, there is a limit to theadded mass that must be observed, in additionto not exceeding the gross axle and train weights.

Single Cab

1

B

A

C

E134583

Single Cab Center of Gravity Critical Zone

Recommended C of G location for added massModel'C' Max (mm)'B' Max (mm)'A' Min (mm)

740322019654x2590343519654x2*

590343519654x4* Vehicles with increased ride height.


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Double Cab

1

B

A

C

E134585

Double Cab Centre of Gravity Critical Zone

Max gross addedmass (kg)


700740361525854x2625590361524354x2*



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Stretch Cab

1

B

A

C

E134584

Stretch Cab Center of Gravity Critical Zone


740322023954x2590343523654x2*



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1.14 Towing

1.14.1 Towing Requirements

When a towing device is required, the VehicleConverter should use a Ford approved tow bar.Refer to: 1.13 (page 23).Load Distribution.Refer to: 1.6 Jacking (page 12).

1.14.2 Towing

WARNINGS:Do not exceed the Gross Train Weight(GTW) or towing capacities stated in thissection.Ensure that the trailer nose weight fallswithin the specified range.

For towing devices fitted by the Vehicle Converterthe following applies:

• Towing capacities must not exceed those ofthe unmodified vehicle.

• Any modifications to the vehicle must be notedin the owner's handbook or new descriptiveliterature included with the owner'sdocumentation.

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

• Whenever frame drilling is necessary use tubereinforcement.Refer to: 5.5 Frame and Body Mounting (page

81).

1.14.3 Towing capacities

NOTE: The towing capacities below relate tovehicles with Ford tow bars only.

Towing capacities - For Base series

Max. Gross TrainWeight kg (lbs)

With trailerbrake kg (lbs)

Withouttrailer brake

kg (lbs)

TransmissionDriveVariant

4425 (9755)1500 (3307)750 (1654)Manual4X22.5L Petrol4525 (9976)1500 (3307)750 (1654)Manual4x2*

4125 (9094)1100 (2425)750 (1654)Manual4x44425 (9755)1500 (3307)750 (1654)Manual4X22.2L Diesel

(88kW) 4525 (9976)1500 (3307)750 (1654)Manual4x44700 (10362)1500 (3307)750 (1654)Manual4x2* and 4x42.2L Diesel

(92kW)4425 (9755)1500 (3307)750 (1654)Manual4x22.2L Diesel

(110kW) 4700 (10362)1500 (3307)750 (1654)Manual4x2* and 4x4

4700 (10362)1500 (3307)750 (1654)Manual4x2* and 4x43.2L Diesel


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Towing capacities- For all other series

Max. Gross TrainWeight kg (lbs)

With trailerbrake kg (lbs)

Withouttrailer brake

kg (lbs)

TransmissionDriveVariant

5125 (11299)2200 (4850)750 (1654)Manual4X22.5L Petrol4900 (10803)1700 (3748)750 (1654)Manual4x2*

4300 (9480)1100 (2425)750 (1654)Manual4x45125 (11299)2200 (4850)750 (1654)Manual4X22.2L Diesel

(88kW &92kW) 4800 (10582)1600 (3527)750 (1654)Manual4x2* and 4x4

5425 (11960)2500 (5512)750 (1654)Manual4x22.2L Diesel(110kW) 5000 (11023)1800 (3968)750 (1654)Manual4x2 * (Final

drive ratio 3.31)5950 (13118)1

6000 (13288)23350 (7386)1

3500 (7716)2750 (1654)Manual4x2 * and 4x4

(Final driveratio 3.55)

5950 (13118)1

6000 (13288)23350 (7386)1

3500 (7716)2750 (1654)Auto4x2 * and 4x4

5000 (11023)1800 (3968)750 (1654)Manual4x2 * and 4x4(Final driveratio 3.31)

3.2L Diesel

5950 (13118)1

6000 (13288)23350 (7386)1

3500 (7716)2750 (1654)Manual4x2* and 4x4

(Final driveratio 3.55)

5950 (13118)1

6000 (13288)23350 (7386)1

3500 (7716)2750 (1654)Auto4x2* and 4x4

*Vehicles with increased ride height1 European vehicles built before 11th March 2013, Australia and New Zealand vehicles built before 1stNovember 2012 and all non European/Australian/New Zealand vehicles.2 European vehicles built on or after 11th March 2013 and Australia and New Zealand vehicles built onor after 1st November 2012.

1.14.4 Trailer Nose Weight

NOTE: The maximum trailer nose weight valuesbelow relate to vehicles with Ford tow bars only.

Trailer Nose Weight

Maximum trailer nose weightMinimum trailer noseweight

Region / Vehicle

335 kg10% of the towed weightAustralia and New Zealand - Vehiclesbuilt before 1st November 2012

350 kg10% of the towed weightAustralia and New Zealand - Vehiclesbuilt on or after 1st November 2012

225 kg for 4x2* and 4x46% of the towed weightRest of World

165 kg for 4x2* Vehicles with increased ride height.

1.14.5 Towing Specifications

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


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2.1 Suspension SystemWARNINGS:

Do not modify, drill, cut or weld anysuspension components, specifically thesteering gear system, subframe oranti-roll bars, springs or shock absorbersincluding mounting brackets.The rear leaf springs are pre-stressed inmanufacture and should not be alteredfor rate or height in any way during vehicleconversion. Adding or removing leavesmay result in failure or reduced functionof the spring as well as other vehiclerelated issues for which Ford MotorCompany can not be held responsible.

CAUTIONS:Modifications to the suspension systemcan cause a deterioration of the vehiclehandling characteristics and durability.When carrying out welding work thesprings must be covered to protect themagainst weld splatter.Do not touch springs with weldingelectrodes or welding tongs.

NOTE: Do not modify the wheelbase or add anytype of frame extension to vehicles fitted withElectronic Stability Program ESP.NOTE: Do not damage the surface or corrosionprotection of the spring during disassembly andinstallation.NOTE: Do not add any additional axles.


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2.2 Brake System

2.2.1 General

The Brake System must be fully functional whenthe vehicle conversion is completed. The vehiclebrake operating modes must be checked,including warning system and parking brakes.

WARNING: Do not restrict the airflow andcooling to the brake system.

NOTE: Do not obstruct the view of the brake fluidreservoir level.The brake fluid reservoir must remain accessiblefor servicing and for adding brake fluid.

2.2.2 Brake Hoses

CAUTION: Make sure that the front andrear brake hoses are not twisted and arecorrectly located away from body andchassis components.

Front and rear brake hoses must not rub, chafe orrest on body or chassis or body components.There must be clearance under all operatingconditions, between full compression andextension and full lock to lock.Brake lines must not be used to support or secureany other component.

2.2.3 Trailer brakes

If electric trailer brakes are to be installed, theycan be triggered by the brake light switch. Thebrake light switch is the lower of 2 switchespositioned above the brake pedal inside the cabin.The maximum additional load is 1A.

1

2

E201170

Brake Light Circuit FeedDescriptionItem

Brake Pedal1+12V when brake pedal is pressed2


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3.1 Fuel SystemWARNINGS:

Make sure that the modified vehiclecomplies with all relevant legalrequirements.Do not remove or relocate the fuel coolerwhen modifying vehicle.

CAUTIONS:Ensure modifications to vehicle do notobstruct airflow to fuel cooler.Make sure that sufficient clearance ismaintained for all driving conditions toall hot and moving components.Make sure that there are no sharp edges,including fasteners, pointing towards anyfuel system component.

The fuel filler pipe must be supported inaccordance with the guidelines in thissection.

3.1.1 Fuel Filler Pipe Shipping Bracket

CAUTION: The fuel filler pipe mountingbracket on cab chassis vehicles isdesigned for shipping of the vehicle only.

The fuel filler pipe mounting bracket fitted to cabchassis vehicles is designed to be removed oncethe body or tray is fitted to the vehicle. The bodyor tray must include a fuel filler mounting thatcomplies with the guidelines in this section. Theshipping bracket can be left installed on the vehicleif desired, but only if an additional fuel filler pipemounting bracket is used in accordance with theguidelines in this section.

Fuel Filler Pipe Shipping Bracket - Single Cab

E145838


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Fuel Filler Pipe Shipping Bracket - Stretch Cab

E145839

Fuel Filler Pipe Shipping Bracket - Double Cab

E145837


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3.1.2 Fuel Filler Mounting

CAUTION: Make sure that the filler neckmounting bracket is made of a conductivematerial, and that it provides a groundingpath for the fuel filler neck.

If the vehicle body and mounting bracket does notprovide a grounding path for the fuel filler neck, anearth strap must be added, connecting the fillerneck to the chassis frame.

Fuel Filler Mounting Bracket

E145833

A

1

Fuel Filler Mounting NotesDescriptionItem

180 mm minimum at the area must be adhered to above the filler neckAAll 3x hardware fixation points on the filler neck must be utilised1


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Angle of Filler Neck

AB

E145836

A

Filler Neck Installation DimensionsDescriptionItem

2mm minimum bracket thicknessA30°B


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Clearance From Vehicle Body

A

E145835

DescriptionItemAt least 9mm clearance between the fuel filler cap and vehicle body, in the worst case openingangle if applicable

A


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Axle Breather Hose and Vent Hose

1

E145834

DescriptionItemThe rear differential breather hose should be mounted to the filler neck/vehicle body1

3.1.3 Fuel Filler Vent Hose

• The fuel tank vent hose should be clipped tothe vehicle body, with the open end at least600mm (4x2) or 800mm (4x4 or vehicles withincreased ride height) above ground height.

• The fuel tank vent hose should be protectedand positioned away from direct water spray,wheel splash and mud splash.

• The fuel tank vent hose must be pointing in adownward direction.

Fuel Filler Vent Hose

E170965


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Fuel Tank Vent Hose Mounting Locations

2

1

3

2

1

3

E171721

DescriptionItemFront lower head board of the aluminium load tray (load tray rotated for clarity)1Rear of the passenger cabin (cabin back panel)2Underside of the pick up box load tray3


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4.1 Battery and Cables

4.1.1 Battery Information

If a battery is disconnected, there is norequirement to reprogram the vehicle; the vehicleretains its ‘normal’ power management settingand remembers exactly what its previousconfiguration was (although the central lockinglatches may cycle if a door or lock latch wasopened manually in the intervening period). Allradio settings will be retained, but the key codeneeds to be entered to restore functionality. Theclock will need resetting.

Battery Voltage Requirements andTesting

All voltages are to be measured with an accuracyof: + /– 5% of published values.To maximize battery life, at the time of arrival atthe vehicle converter, all batteries must have aminimum Open Circuit 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 than 12.50volts.

Surface Charge Dissipation

Prior to carrying out manual voltage checks, it isnecessary to establish that the battery voltage isstable and free from surface charges, that couldbe present due to certain engine run conditionsmaking the voltage readings unreliable andinaccurate.To ensure surface charges are not present thefollowing actions are recommended:1. Turn the ignition key to "ON" (do not start the

engine) and switch on the headlamps (mainbeam) and if fitted, the heated front window,rear window demister and the heater blowermotor (on position II). Leave the vehicle in thiscondition for at least 1 minute to dissipate whatever surface charge is present in the battery.

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

Delayed Vehicles

Vehicles held at the vehicle convertor premisesand not in use for longer than 4 days, should havethe battery's negative cable disconnected. Beforeshipping to the customer, the battery negativecable must be re-connected and the voltagere-checked. The voltage should be not less than12.5 volts.

Battery Charging Procedure

1. Cold batteries will not readily accept a charge.Therefore, batteries should be allowed to warmup to approximately 5°C (41°F) beforecharging. This may 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 can bestarted by use of the dead battery switch onchargers that have this facility equipped.

3. To determine whether a battery is accepting acharge, follow the manufacturers instructionsfor the charger and the dead battery switch. Ifthe switch is the spring-loaded type, it shouldbe held in the ON position for up to threeminutes.

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 capable ofbeing recharged. However, it may require up totwo hours of charging, with batteries colderthan 5°C (41°F) before the charge rate is highenough to show a charge on a ammeter. It hasbeen found that all non-damaged batteriescan be charged by this procedure. If a batterycannot be charged by this procedure, a newone should be installed.

5. A rapid recharge procedure has beendeveloped for recharging batteries that havepassed the load test and only need a recharge.This can be due to in-service no-start batteryfailures (vehicle will not crank due to lowbattery state of charge) or battery dischargedin vehicle due to key-off loads.

6. With the cables then disconnected, the batterycan be rapidly recharged by using either of thefollowing methods:

• Carry out a two hour charge using 20A constantcurrent (manual setting on charger).

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


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7. Please connect the battery charger to thevehicle ground - not the battery negative post.This is to ensure the Battery Monitoring System(if fitted) is able to identify the battery charger.

Battery Cable Fixing Torque

The battery cables should be fixed to the terminalposts with a torque of 4.8 Nm -/+ 0.8Nm.

Battery Part Numbers and Usage

SizeSpecificationsBatterySupplier

Ford Plant

Standard Duty BatteryT660Ah, 590CCA, 105RC (Calcium Technology)Siam GSThailandT648Ah, 590CCA, 105RC (Silver Calcium Technology)First National

BatterySouth Africa

T660Ah, 590CCA, 105RC (Silver Calcium Technology)MouraSouth AmericaHeavy Duty Battery

T768Ah, 750CCA, 150RC (Calcium Technology)Siam GSThailandT768Ah, 750CCA, 150RC (Silver Calcium Technology)First National

BatterySouth Africa

Auxiliary Battery (Vehicles with Special Equipment Pack)H780Ah, 800CCA, 140RC (VRLA AGM Deep Cycle

Technology)First National

BatterySouth Africa

Battery Monitor System (BMS)

E181583

Ford Ranger vehicles are equipped with a newfeature called Battery Monitor System (BMS). Thissystem measures the battery load in order toefficiently charge the battery while improving fueleconomy and emissions.It is important to ensure any additional electricalload or accessory is properly grounded to thevehicle’s body, in order for the system to identifythe additional load. If a connection is made to thebattery negative terminal, the BMS will not identifythe load or charge. This may cause the battery tobe undercharged and consequently not able tore-start the vehicle.

Auxiliary Battery and with Battery MonitorSystem (BMS)

WARNING: Under no circumstancesshould a secondary battery connectionbe made directly to any of the vehicle'sbattery terminals.

NOTE: The addition of an auxiliary battery in avehicle with BMS would cause both batteries tonot reach a state of full charge. The system willonly allow charging of the batteries duringdeceleration. Refer to Dual Batteries with BatteryMonitor System (BMS) in this section.NOTE: Disabling the BMS will negate the fueleconomy benefit provided by the BMS.For vehicles equipped with BMS, an additionalbattery can be connected using one of thefollowing methods:1. Use an in-vehicle battery charger (DC/DC

converter) such as BCDC1220 model fromRedarc (or similar) and ground it to the vehiclebody.

2. Request a Ford dealer to disable the BMS.Disabling the BMS enables voltage sensitiverelay based dual battery systems to work.

Connection of Auxiliary Loads

WARNING: Under no circumstancesshould any unfused connections be madedirectly to any of the vehicle's batteryterminals.

NOTE: Auxiliary loads must always be connectedto the vehicle ground and not to the batterynegative terminal.


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• For auxiliary customer electrical loads, asuitable fused connection must be used.

• If multiple auxiliary loads are required, it isrecommended that an auxiliary fuse box isfitted to the vehicle.

• For the connection of auxiliary exterior lighting,refer to the guidelines given in the exteriorlighting section.Refer to: 4.3 Exterior Lighting (page 52).

Auxiliary loads for external devices which requirean ignition feed (such as UHF/CB radios) may beconnected via a relay energised by the IG+ feedto the Body Control Module.

WARNING: Under no circumstancesshould the IG+ feed be used to driveauxiliary loads directly. A suitable relaymust be used.

The Body Control Module is positioned on thedriver's side of the vehicle underneath the dashpanel.

IG+ Connection at Body Control Module

1

2

1

E144657

2

DescriptionItemBody Control Module1IG+ Feed2

Battery Rules:

WARNINGS:For vehicles fitted with non-sealedbatteries (non-maintenance free), it isessential that regular checks are madeto determine that the electrolyte (acid)levels are correctly maintained.

When charging, ensure the batterycharger is securely connected to thevehicle ground and not to the batterynegative terminal. This is to ensure thatthe BMS identifies the battery charge.

• For external charging of batteries ensure thatthe maximum voltage of 14.6V is not exceeded.

4.1.2 Auxiliary Battery (Vehicles withSpecial Equipment Pack)


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Battery Specifications

SpecificationDescriptionH7 DIN VRLA/AGMBattery Type

12VVoltage80AhCapacity800ACCC

CAUTION: The vehicle must not be drivenon the road while the auxiliary battery ismounted to the temporary battery carrier.

When exiting the production plant, the auxiliarybattery is fitted in the load tray near the rear wheelarch for the style side (tub) variant. For the cabchassis variants, the auxiliary battery is securedon a temporary battery carrier which itself ismounted on the chassis and used for transportfrom the plant to the dealer.

Temporary Battery Carrier (Cab ChassisVariant Only) (Vehicles with SpecialEquipment Pack)

NOTE: The temporary battery carrier has to beremoved before the vehicle is operated on the roador in service.

E179834


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1

2

3

3

4

5

6

E179835

DescriptionItemAuxiliary battery ground point1Battery cable (towards main battery)2Auxiliary battery carrier mounting bolts3Auxiliary battery fuse box4Auxiliary battery5Temporary battery carrier6


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Instructions for Auxiliary Battery Fitment(Vehicles with Special Equipment Pack)

CAUTIONS:It is important to ensure that the auxiliarybattery is mounted securely, away fromany moving parts and does not interferewith the operation of anyclosures/tailgate.The selected location should be such thatelectrical components are above the800mm water wading level and protectedduring off road excursions.The attachment of the auxiliary batteryshould be suitably durable for off roadexcursions.It is important to ensure that the auxiliarybattery fitment does not crush or causedamage to any wiring either part of theauxiliary battery wiring or the vehiclewiring.It is important that the auxiliary batteryis mounted in a suitable location to enableeasy access for servicing.Ensure that the auxiliary battery cable isnot kinked and is routed away frommoving parts, exhaust and fuel systemcomponents. All mounting positions mustbe securely mounted to the vehicle body.The location of the auxiliary battery mustbe carefully considered. The auxiliarybattery's weight and its affect on thevehicle's centre of gravity must be takeninto account when fitting it to anaftermarket body.

NOTE: Avoid damage to the vehicle and the loadtray during the auxiliary battery fitment.

NOTE: Avoid any interference with operation ofthe vehicle lighting system.NOTE: Ensure that a good ground location is used;preferably use the ground point provided on thechassis rail.NOTE: Ensure that the auxiliary battery cablesand electrical harness extension are suitablylocated using grommets, insulation and fixingpoints on the vehicle body.NOTE: Ensure that sufficient ventilation isprovided for the auxiliary battery when locatedwithin enclosed spaces.NOTE: The addition of an auxiliary battery in avehicle with Battery Monitor System (BMS) wouldcause both batteries to not reach a state of fullcharge. The system will only allow charging of thebatteries during deceleration. Refer to DualBatteries with BMS in this section.The auxiliary battery and temporary carrier mustbe completely removed from the frame inpreparation for fitment to the vehicle tray or anaftermarket body.The location of the auxiliary battery should beselected considering that the battery and thecables within the tray should be protected fromcontact with any items that could be placed in theload tray or within the aftermarket body. Forvariants fitted with an aluminium load tray, theselected location should be such that suitablespace in the load tray is available for use.The auxiliary battery cable provides a 12V / 125Acharge to the auxiliary battery. The auxiliary batterycable is routed from the primary starting batteryin the engine compartment, down the right handchassis rail and terminates at the connection tothe auxiliary battery wiring harness. In situationswhere the auxiliary battery is relocated,consideration must be made as to the routing andsecurity of the auxiliary battery cable location.


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Auxiliary Battery Cable

E201190

1

DescriptionItemAuxiliary Battery Cable1

4.1.3 Auxiliary Battery Relocation anduse of Electrical Harness Extension(Fly Lead) (Vehicles with SpecialEquipment Pack)

An Electrical Harness Extension (fly lead) may berequired when the auxiliary battery is beingrelocated from the temporary battery carrier. Thefly lead is required to connect the auxiliary batterywiring harness to the 16-pin connector on thevehicle wiring harness. This allows the operationof auxiliary battery powered accessories from thedash mounted switch panel within the vehiclecabin.

The electrical harness extension is available intwo lengths:• Single Cab Chassis: 1850 mm• Double Cab Chassis: 1390 mmWhen used on a vehicle fitted with an aluminiumload tray, the electrical harness extension is fittedin the shown orientation:


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Electrical Harness Extension (Fly Lead)

1

3

2

1

3

2

E201186

DescriptionItemElectrical Harness Extension (fly lead)1Connection to the vehicle harness2Connection to the auxiliary wiring harness3

4.1.4 Generator and Alternator

Alternator Current Output

All vehicles are fitted with 110A alternators.


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4.2 Electronic Engine Controls

4.2.1 Vehicle Speed Output (Signal)

General Information

WARNING: Do not interface with the CAN(controller area network) for vehiclespeed.

NOTE: A hard-wired vehicle speed signal isavailable if integration is required.NOTE: The vehicle speed signal is a direct currentcoupled square wave that varies in frequency inproportion to vehicle speed. This provides a squarewave-form (50% duty cycle) signal.

Circuit hardware

E180281

Square Wave Characteristics - Output signal

Sunroof Taxi Speed OutputSignal RequirementsBattery VoltageMaximum High Signal3.67 VoltsMinimum High Signal1.1 VoltsMaximum Low Signal-1.1 VoltsMinimum Low Signal+/- 1.0 VoltsMaximum Ground Offset10μ sec <= tr <= 250μ secRise Time10μ sec <= tf <= 250μ secFall Time50% +/- 10%Duty Cycle1.38 * v (Vehicle speed (CAN) km/h) ± 2%between 1km/h - 250km/h

Frequency

1.38 Hz (1 kmph)Minimum speed<0.3%Linearity error398 HzMax frequency1 k ohmsRload


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Instructions for connection

1. The vehicle speed output is available on:[connector 3 pin number 52] or [connector 4pin 3]. Choose one of the connections andpopulate the connector with a terminal andwire.

2. The output must be connected to a device with1k ohms resistance (600 ohms to 2k ohms isthe guideline) in order for it to work. Thisprotects the BCM (body control module) fromovercurrent risk.

3. The output must be connected to a powersource.

4. Once the device is connected, reset the BCMby disconnecting the vehicle battery.

5. Reconnect the vehicle battery.

6. Turn the ignition ON.7. The signal should now be available.NOTE: Rload should be present and connectedto battery voltage for this function to work.

For Information Only

Terminal part number: 96AG-14474-RSA.Wire size and color: 0.5 CSA, blue - green.

Terminal Insertion

1. Connector C3 or C4 need to be unplugged inorder to insert the speed signal terminal.

E180282

2. Once the connector C3 or C4 is removed, thegrey cap needs to be removed by first removingthe cable tie, and then levering up the twodetents on the sides; the cap can then be slidoff.


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E180283

E180284

E180285


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E180286

3. There is a red terminal latching plate that needsto be removed.

E180287

4. Insert the wire with terminal into cavity C3: 52or C4: 3 – there is a tab on the terminal thatshould allow this to be inserted one way only.

E180293


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5. Slide back the terminal latching plate, refit thegrey cap (and refit cable tie as required), and

plug both connectors back into the BCM. Refitany shields/covers.

E180294

E180295

E180296


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4.3 Exterior LightingWARNING: Make sure that the modifiedvehicle complies with all relevant legalrequirements.

NOTE: Chassis Cab vehicles are supplied with rearcombination lamps, license plate lamps and foglamps. Where fitted, these lamps must bemounted in accordance with the followingguidelines.

4.3.1 Rear Combination lamps

Positioning of Rear Combination Lamps

AB

AB

D

C

G

E

F

E141460


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Positioning of Rear Combination Lamps

DimensionDescription250mmMinimum distance from ground to lower edge of lampA1200mmMaximum distance from ground to upper edge of lampB

15°Minimum angle of obstruction free zone downwards of the lampC15°Minimum angle of obstruction free zone upwards of the lampD80°Minimum angle of obstruction free zone towards the outside of

the vehicleE

45°Minimum angle of obstruction free zone towards the centre of thevehicle

F

400mmMaximum distance from outer edge of vehicle to inner edge oflamp

G

4.3.2 Rear Fog Lamp

NOTE: Where only one rear fog lamp is fitted, itmust be positioned on the vehicle centre line, orto the drivers side of the vehicle.


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Positioning of Rear Fog Lamp

AB

AB

D

C

E

F

E141472

Positioning of Rear Fog Lamp

DimensionDescription250mmMinimum distance from ground to lower edge of lampA

1000mmMaximum distance from ground to upper edge of lampB5°Minimum angle of obstruction free zone downwards of the lampC5°Minimum angle of obstruction free zone upwards of the lampD

25°Minimum angle of obstruction free zone towards the outside of thevehicle

E

25°Minimum angle of obstruction free zone towards the centre of thevehicle

F


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4.3.3 Rear License Plate Lamp

Positioning of Rear License Plate Lamp

E

D

E

D

E141462

C

B

A

Positioning of Rear License Plate Lamp

DimensionDescription35mmDistance from rear face of license plate to centre of lamp along

lamp mounting faceA

10°Angle between license plate and lamp mounting faceB35mmDistance between top of rear face of license plate and lamp

mounting faceC

175mmDistance between license plate centre line and centre of lampD175mmDistance between license plate centre line and centre of lampE


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4.3.4 Reversing Lamps

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

4.3.5 Additional External Lamps

When installing auxiliary tail lamps, Fordrecommends that power is provided via the trailerplug control module and associated circuitry. Referto Trailer Tow for additional information.

For all other additional exterior lamps, power mustbe taken through an auxiliary fuse box with asuitable switch and / or relay as required.

WARNING: Directly splicing into thevehicle wiring in order to install auxiliarylamps or other electrical devices mayoverload the system and impact theoperation of other vehicle systems.

When installing auxiliary driving lights, power canbe provided via a relay energised by the headlampfeed.

1

2

E144659

12

DescriptionItemLow beam1High beam2

Lighting Loads

Trailer TowVehicleControlling DeviceLamp

28W2x5WBody control moduleNumber plate lamp

5WBody control modulePosition / Parking lamp-21WBody control moduleFront direction indicator

28W21WBody control moduleBrake lamps24W21WBody control moduleRear direction indicator24W21WBody control moduleReverse lamp48W21WBody control moduleRear fog lamp

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


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Lighting FusesHeadlamp20AF74Front fog lamp15AF75Reversing lamp10AF76

Trailer Tow

Vehicles with a factory fitted tow bar also comewith a trailer plug control module for lighting. Inaddition to providing the trailer plug functionality,the trailer plug control module protects theprimary electrical circuits of the vehicle from anyelectrical concern or failure that the customer'strailer may experience.For vehicles fitted without a tow bar as standard,a genuine Ford accessory trailer tow electrical kithas been developed to enable a tow bar to beinstalled. The kit comprises of the trailer plugcontrol module, trailer plug, wiring and associatedhardware components.Once the kit is installed, the vehicle must then beconfigured using a Ford IDS diagnostic tool. Thisconfiguration can be performed by your Fordauthorised dealer.NOTE: The trailer tow electrical kit is availablefrom your Ford authorised dealer.Ford recommends that all trailer tow electricalconnections use the genuine Ford accessory trailertow kit.

WARNING: Installation of aftermarkettrailer tow electrical kits or directlysplicing into the vehicle wiring in orderto install trailer lamps or other electricaldevices may overload the system andimpact the operation of other vehiclesystems.

When fitting low power LED (light emitting diode)lamps that require less than 2W, the lamps mayflicker when in use. A trailer patch harness shouldbe used with low power LED lamps.

CAUTION: Do not connect the trailerpatch harness to the vehicle when thetrailer is not connected.

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

4.3.6 Additional External Lamps(Vehicles with Special EquipmentPack)

The plastic switch fascia is located at the front ofthe console. It can house up to four aftermarketswitches. Driving Lights, LED beacon lamp andwork lights can be powered via the switches onthe fascia. A fourth switch is provided as a sparewith 20A capacity.


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E175900

DescriptionItemU nuts1

NOTE: Cut out the switch blanks with a suitabletool without damaging the plastic fascia.


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1 2 3 4

E175901

DescriptionItemDriving lights switch blank1Work lights switch blank2LED beacon lamp switch blank3Spare switch blank4

NOTE: The driving lights will only operate whenthe vehicles high beam is selected.NOTE: The vehicle is equipped with a batteryisolator which ensures that the main vehiclebattery remains in a charged state and only theauxiliary battery becomes discharged. Once thevehicle is running the isolator will close allowingthe auxiliary battery to be charged by the vehiclescharging system.

NOTE: The connector for the driving light islocated behind the grille.NOTE: Discard the sealing end-cap afterconnecting the driving light connector.


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Driving Light Connector Location

E183105

DescriptionItemSealing end-cap1Driving light connector2

NOTE: The light switch connector is locatedbehind the switch fascia in the vehicle.


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Switch Panel Connector

1

E175902


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DescriptionItemSwitch connector1

Switch Panel Connector Details

123456

789101112

E175903

Connects toColor cableConnector PinCentral electronic module controlVT/WH1Cross car beam groundBK/BU2Cross car beam groundBK/BU3Cross car beam groundBK/BU4Cross car beam groundBK/BU5LED beacon lamp Relay (R2)VT/WH8Spare populated relay (R3)BN/GN9Work lights relay (R1)GN/BN10Driving lights relayWH/GN11Blank (not used)-12

Connections for the load box lamps, LED Beaconlamp and driving lights are provided by a 16 wayconnector located at the rear of the auxiliarybattery box below the isolator. The connectordetails are as follows.


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FunctionColor cableConnector PinBrake / stop +12v (lamp Bar)YE-GN2LED beacon lamp +12vWH3Position / tail lamps +12V (lamp Bar)VT-WH4Reverse lamps +12v (lamp Bar)GN-BU5Turn right +12v (lamp Bar)GY-OG6Turn left +12v (lamp Bar)GY-OG7Spare +12vYE-GY9Load box lamps +12vYE-BU10GroundBK-YE16

Fuse specification chart

Auxiliary Fuse Box

E174549

Protected ComponentsFuse Amp RatingFuseDriving lights251Position lamp152LED beacon lamp103Work lights154Spare205Power point206Reversing lamp157Direction indicators, stop lamp158Crew chief59Disable fuse (isolator ground)510Not used-11Not used-12


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Protected ComponentsRelay NumberWork lightsR1LED beacon lampR2SpareR3Position lampR4Direction indicator (left)R5Direction indicator (right)R6Stop lampR7Not usedR8Not usedR9

4.3.7 Lamps – Hazard / DirectionIndication

The maximum permissible load with the standardsystem is:• 3 x 5W – front and rear indicators + side

repeaters (Left Hand Side)• 3 x 5W – front and rear indicators + side

repeaters (Right Hand Side)

4.3.8 Electrically operated DoorMirrors

WARNING: Do not tamper with the basesystem (controlled by Central JunctionBox and multiplex architecture) and anyfeeds taken from the associated wiringor controller.

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


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5.1 Body

5.1.1 Body Structures - GeneralInformation

CAUTION: Load carrying structuresshould not be mounted onto an existingload tray or load box.

When carrying out vehicleconversions/modifications the following pointsshould be considered:• Make sure that the vehicle structural integrity

is maintained.• Do not drill into closed frame body members.• Make sure that the design for the body

alterations or additional structure disperse theload evenly.

CAUTION: Uneven load distribution couldresult in unacceptable handling andbraking characteristics.

• Re-paint metal edges after cutting or drilling.All metal edges must comply with exterior andinterior protection legislation.

• All fixings through the floor, sides or roof mustbe sealed.

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

5.1.2 Integrated Bodies andConversions

For integral structures such as ambulances ormotor-homes with increased rear overhang builtonto 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 spare wheel stowage may be requiredif obscured by rear step, check for accessibility.

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

Wheelhouse Envelope

r

B H

K

L

A

C D

E E

X 1

X

X-X

FG

rr

r r

E134132


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Wheelhouse Dimensions265/65R17255/

70R16255/

70R16215/

70R16Dimension265/

65R18265/

65R17255/

70R16215/

70R16Dimensio

n190mmG*455mmA

922mm922mm915mm914mmH425mmB588mmK305mmC30mmL275mmD20mmr110°ECenter 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 build upfrom the exhaust system, in particularfrom the catalytic converter. Ensureadequate heat shields are maintained.CAUTION: Uneven load distribution couldresult in unacceptable handling andbraking 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 body members.• 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 exterior andinterior protection legislation.

• All fixings through the floor, sides or roof mustbe sealed.

Refer to: 5.4 Corrosion Prevention (page 80).• Ensure that any additional equipment in the

vicinity of the fuel tank will not damage the tankin a crash condition.

For any conversion structure attached to ormounted onto the base vehicle cab structure thefollowing applies:• Ensure that neither the conversion structure nor

the existing vehicle structure get pre-loaded bythe assembly process.

• Adhesive jointing is recommended but 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.


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Body Attachment Holes in Chassis Frame - Single cab

C

E F

NM

HG

K

L

C

D

E F

ML

HG

J

K

A

B

N

P

E134152

C

E F

NM

HG

K

L

C

D

E F

ML

HG

J

K

A

B

N

P

E134152

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

P375DimensionP375Dimension1086H16A

95J28B768K23C893L20D509M1244E26N1244F20P1244G


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Body Attachment Holes in Chassis Frame - Double cab

A

B

E F G

H KJ

C

D

E134154

L

M

A

B

E F G

H KJ

C

D

E134154

L

M

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

P375DimensionP375Dimension1086G16A

95H28B893J23C509K20D26L1244E20M1244F


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Body Attachment Holes in Chassis Frame - Stretch cab

A

B

E F

H

G

J K

C

D

E134153

L

M

A

B

E F

H

G

J K

C

D

E134153

L

M

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

P375DimensionP375Dimension1086G16A

95H28B1191J23C509K20D26L1244E20M1244F

5.1.4 Front End Integrity for Cooling,Crash, Aerodynamics and Lighting

Cooling Continuous air flow through the frontend and engine compartment is not to be hinderedby adding any additional equipment. If uncertainplease consult the Ford dealer.Lighting Do not alter the lighting system.Crash Do not cut, drill or weld any parts that areload path relevant in case of crash. Do not addmaterial in the crash zone. This could affect thecrash 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 Finishing Ensureproper sealing against ingress of water, salt, dustetc. after cutting or drilling the body. Use Fordapproved sealing and finishing material, andunderbody corrosion protection.Refer to: 5.4 Corrosion Prevention (page 80).

5.1.5 Tipper Bodies

For tipper conversions single and double ChassisCab versions except extended rear chassis framecan be used. All variants allow single and threeway tipping.It is recommended to have the tipping systemoperative only when the engine is running. It is alsorecommended to have the master control switchin the security of the cab. According routing ofwires and hydraulic lines please refer to sectionhydraulic lift.


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Ensure that axle plated weights including the frontaxle minimum are not exceeded.For tipper sub-frames please refer to the followingguidelines:• Design for full length continuous frame with

mountings for motor, pump unit, reservoir, pivotpoints and ram.

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

• Very stiff sub-frames may damage the chassisframe by preventing its natural flexing, thereforecompliant mounts should be used, with up toplus and minus 12mm compliance with thevehicle laden or un-laden (whichever is worstcase). Compliant mounts should be rated witha minimum of 2mm deflection per 200kg massat each chassis frame forward mount.Compliant mounts shall have captive fail safebolts.

• Use two M10 grade 8.8 minimum bolts, washersand self locking nuts at each solid andcompliant chassis frame location.

• Sub-frame must extend to the back of the caband attach to all mounting locations, with theforward end designed to minimize local framestress. It is however, preferable to mount thesub-frame onto the mounting brackets with aclearance to the chassis frame top surface.

• Side tipping loads/forces must be resolved bythe sub-frame. It is not recommended to strainthe chassis frame.

5.1.6 Tank and Dry Bulk Carriers

Due to the high rigidity of tanks it is necessary toisolate the tank and its sub-frame from the chassisframe allowing the chassis frame to naturally flex.Please refer to the following guidelines:

• 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 the caband not contact chassis frame at forward endunder worst case deflection.

• Compliant mounts should be used, with up toplus and minus 12mm compliance with thevehicle laden or un-laden (whichever is worstcase). Compliant mounts should be rated witha minimum of 2mm deflection per 200kg massat each chassis frame forward mount.Compliant mounts shall have captive fail safebolts.

• Use two M10 grade 8.8 minimum bolts, washersand self lock nuts per chassis frame mountbracket at each solid and compliant location.

5.1.7 Bull Bar (Vehicles with SpecialEquipment Pack)

The bull bar includes brackets which are mountingpoints for driving lights, aerials, antennas and flags.

WARNING: Follow all accessorymanufacturer's instructions whenconnecting accessories and equipmentto the vehicle.

NOTE: Please refer to the electromagneticcompatibility (EMC) section in this book beforeinstalling any aerials or antennae.


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Bull Bar Accessory Mounting Positions

221

E177160

DescriptionItemAerials, antennas and flag mounting location1Driving lights mounting location2

Aerial/Antenna Cables Routing

WARNINGS:Ensure that the aerial/antennae cableshave sufficient clearance from hot andmoving parts.Do not fasten the aerial/antenna cablesto original vehicle wiring, fuel pipes andbrake pipes.Keep the aerial/antenna and powercables at least 100mm from anyelectronic modules and airbags andassociated wiring.

NOTE: Make sure the sealing integrity ismaintained to avoid water ingress into the cabinwhile routing the cables through the grommet.Aerial/Antenna cables should be routed from theengine bay into the cabin area through the existinggrommet. There is a service nib provided on thegrommet.Refer to Exterior lighting - Additional externallamps for driving lights cable routing.

5.1.8 Roof Racks

Roof racks may be fitted to all variants asillustrated in figure, providing the following issatisfied:• The carried load does not exceed 80kg (Body

Builder to ensure owner’s hand book identifiesthis limitation).

• The carried load does not exceed 300mm loadheight (converter to ensure owner’sinformation book identifies this limitation).

• The load is evenly distributed (converter toensure owner’s information book identifies thislimitation).

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


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Double Cab / Stretch Cab

The forgoing limitations are based on ensuringbody structure integrity, vehicle handling, brakingand plated axle weights. Such considerations mustalso be applied to any double cab and stretch cabapplications, in particular steering, braking andfront axle plated weight and the extra continuousloads on the “A” pillar, which should not exceed60 kg total incremental load.

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

Roof Rack Vehicle Converter Special Fit

1

4

5

3

2

6

E134129

DescriptionItemRear edge of front attachment point180kg Maximum2Maximum roof rack length: Within length of drain channel3Maximum Load Height 300mm4Drain channel5Roof rack supports6

5.1.9 Canopies

All Vehicles

WARNINGS:Only use the recommended attachmentpoints for the canopy fitment, otherwisedamage may occur to the load box.The return flange on the load box sidesshould never be cut away, be drilled into,or be used otherwise for bolting of thecanopy.

The top surface of the load box sidesshould not bear canopy (or other)structural loading. To be used as a canopy'sealing-surface' only.Canopy weight and canopy load shouldpass through the recommended load boxstructural attachment points.

NOTE: Usage of clamps for the canopy fitmentare only allowed on the centre and rear portion ofthe load box.


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NOTE: Use both points from group A and aminimum of one point from group B as frontstructural attachment points.

Load Box Structural Attachment Points

E170921

A

B

B

DescriptionItemFront structural attachment points1Centre structural attachment points2Rear structural attachment points3Top surface of load box sides*4

Return flange of load box sides*5

*Do not cut, drill, or use these surfaces to bolt thecanopy.


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Example of a Sports Bar Fitment

E172331

DescriptionItemFront mounting bracket1Clamped attachment2


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5.2 Airbag Supplemental Restraint System (SRS)

5.2.1 Air Bags

Front Seats

Side airbags are not compatible with swivelingfront seats.Do not specify the base vehicle with 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 the functionand/or deployment of the side airbags.

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

WARNING: Modifications orreinforcements in the area of the sensorsmay affect the side airbag fire timing andresult in uncontrolled side air bagdeployment.

Please note that vehicles not equipped with sideairbags but equipped with front airbags only arenot affected.Drilling or grinding operations in this area are onlypermitted when battery cables are disconnected.

Driver and Passenger Front Airbag Deployment Zones

E

D

B

A

C

F

E134101


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Dimensions (mm)660D400A630E700B700F700C

Side Airbag

AC

B

E134609

Dimensions (mm)250C550A

350B

Curtain Airbag - Single cab

DC

B

A

E136172


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Dimensions (mm)250C140A100D40B

Curtain Airbag - Double cab

D

C

B

A

E134610


Curtain Airbag - Stretch cab

DC

B

A

E136173



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5.2.2 Supplementary RestraintSensors (Front)

WARNING: Modifications orreinforcements in the area of the frontsupplementary restraint sensors mayaffect their operation.

E201479

1

DescriptionItemFront SRS Impact Sensors1


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5.3 Safety Belt SystemWARNING: Follow removal andinstallation procedures for the seat beltsystem to ensure correct function of therestraints 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 required duringthe conversion, follow the removal and installationguidelines of the seat belt system as described inthe workshop manual. Please consult your localNational Sales Company representative for furtherinformation.When removing the seat belt system, a seat beltwebbing forked retainer should be applied to thewebbing 200mm below the webbing button stop.This prevents a situation where all the webbingruns back into the retractor and the retractorbecomes locked.When reinstalling, fit the retractor to the body firstand gently pull the webbing out of the retractorto allow fitment of the D loop. Then remove theforked retainer. If the retractor is locked, allow asmall amount of webbing to reel back into theretractor to allow the webbing lock to release. Donot attempt to release the retractor by pulling onthe webbing with significant force or by manuallyinterfering with the locking mechanism.


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5.4 Corrosion Prevention

5.4.1 General

Avoid drilling into closed frame body members toavoid the risk of corrosion from swarf.If drilling is required, however:• Re-paint metal edges and protect against

corrosion after cutting or drilling operations.• Endeavor to remove all swarf from inside the

side member and treat to prevent corrosion.• Apply corrosion protection inside and outside

of the chassis frame.

5.4.2 Repairing Damaged Paint

After cutting or reworking any sheet metal on thevehicle the damaged paint must 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 of componentssuch as brakes or catalytic 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 corrosion protectionmaterials, please consult your local National SalesCompany representative.

5.4.4 Painting Road Wheels

WARNING: Do not paint wheel clampsurfaces in contact with other wheels,brake drum or disc, hub and holes orsurface under wheel nuts. Any furthertreatment in these areas may affect thewheel clamp performance and the vehiclesafety. Mask the wheel when changingthe color or repairing paint.

5.4.5 Contact 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, choose materials with low levelof electrochemical potential difference.


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5.5 Frame and Body Mounting

5.5.1 Mounting Points and Tubing

Holes on frame are a result of the productionprocess. They are not designed for fixingadditional equipment. Always use chassis mountsas shown in sub frame for low floor or otherequipment. If additional fixings are required pleasefollow the recommendation given in the figureshown. This does not apply to areas of loadapplications such as spring fixings or damperfixings.

NOTE: After drilling, deburr and countersink allholes and remove chips from the frame. Followcorrosion prevention.Refer to: 5.4 Corrosion Prevention (page 80).

Frame Drilling and Welding

A

B

D

C

E

F

E134173

Dimensions (mm) for Body Attachment Holes in Chassis Frame Top Flange Medium WheelbaseDescriptionItem

19 mmA11 mmB10 mmC10 mmDDo NOT enlarge chassis rail holes, or drill within the surrounding area.EDo not drill any more than 2 vertical holes in the chassis rail.F

1. No Welding is Allowed to the Vehicle Structure.2. To make holes in frames do not use a gas

flame. Drill holes using sharp drills.3. Use cold riveting only when attaching brackets

with rivets.4. Use high tensile bolts and appropriate nuts

when 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 1.0mm x 45 degree on the bolt headside of the hole to facilitate bolt seating.

6. Holes must NOT be drilled near side memberprofile changes.

7. Existing holes in top and bottom flanges mustNOT 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 the vehiclestructure where appropriate, to avoid excessiveload concentrations.


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Typical Design Principle of a Self-Supporting Body Structure

E74576

1

2

3

4

5

67

8

DescriptionItemUse all standard locations with 2x M10 fixings1Floor panel2Body side frames3Floor cross members4Continuous floor U-profile frame5Longitudinal L-profile6Chassis frame rail of base vehicle7Vehicle center line of base vehicle8

Also see:Refer to: 5.1 Body (page 65).

5.5.2 Self-Supporting Body Structure

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 thecontinuous floor frame (5), see figure shown.

• The body side wall or the continuous floorframe supports any overhang beyond thechassis frame, whether on standard frame orextended 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 and opposingout riggers are flush with the surface of thechassis 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 600mm maximumpitch.

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


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• Drill frame and add spacer tubes.Refer to: 5.5 Frame and Body Mounting (page

81).• Out-rigger outboard ends should be attached

to load bearing body side / floor edge frame orbody 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 Frame Drilling and TubeReinforcing

The chassis frame may be drilled and reinforcingspacer tubes may be welded 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.Refer to: 5.4 Corrosion Prevention (page 80).

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

• Always use M10 bolts with grade 8.8 minimum.• Do not position tubes at the medium chassis

frame height, this may create “oil canning” ofthe deep section side walls.

• Where possible, the outrigger moments shouldbe resolved by matching inner cross membersbetween the chassis side members inline withthe 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 members toavoid the risk of corrosion from swarf.Refer to: 5.4 Corrosion Prevention (page 80).

Drilling and welding of frames and body structurehave to be conducted following the programguidelines. Please consult the Ford dealer fordetails.

5.5.4 Ancillary Equipment - Sub FrameMounting

Typical sub-frames and longitudinal members forflatbed and low or drop-side bodies or equipmentexceeding the standard or Regular ProductionOrder frame length should adhere to the followingguidelines:• Flat-beds and low bodies mounted on integral

longitudinal members (channel or box sectionmetal – not wood) must use both sides of allframe mounting brackets.

• Longitudinal members must be relieved at thefront 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 chassis frametop 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 Additional BodyAttachments to the Rear of theBumper.

NOTE: With the vehicle on level ground and withall measurements taken rear ward of the bumperbar edge: The area designated for the fitting ofattachment is defined as 220mm horizontally by95mm vertical downward to the road surface,with a max width of 1390mm about vehicle centerline.It is not the manufactures recommendation to fitadditional body attachments (Tow bars, Steps,Bicycle racks & Carriers) outside of the designatedarea.

5.5.6 Water Tank on Camper Vehicles

NOTE: It is recommended that a decal or labelis fitted adjacent to the filler apertureidentifying the correct fluid to be used, forexample: 'Water only' for water tanks.


5 Body and P

aint

83

AAbout This Manual..........................................................5Additional External Lamps........................................56Additional External Lamps (Vehicles with Special

Equipment Pack).........................................................57Aids for Vehicle Entry and Exit..................................16Air Bags..............................................................................75Airbag Supplemental Restraint System

(SRS)...............................................................................75Alternative Type Approval............................................6Ancillary Equipment - Sub Frame Mounting......83Area for Fitting Additional Body Attachments to

the Rear of the Bumper............................................83Auxiliary Battery Relocation and use of Electrical

Harness Extension (Fly Lead) (Vehicles withSpecial Equipment Pack)........................................45

Auxiliary Battery (Vehicles with SpecialEquipment Pack).........................................................41

BBattery and Cables.......................................................39Battery Information......................................................39Body...................................................................................65Body Structures - General Information................65Brake Hoses......................................................................31Brake System...................................................................31Bull Bar (Vehicles with Special Equipment

Pack)................................................................................70

CCanopies............................................................................72Center of Gravity............................................................25Chassis Cab Body - Basic Dimensions and

Weights...........................................................................20Chassis Cab.....................................................................66Commercial and Legal Aspects.................................6Contact Corrosion........................................................80Conversion Affect on Fuel Economy and

Performance...................................................................11Conversion Affects on Parking Aids........................16Conversion Homologation............................................8Corrosion Prevention...................................................80

DDrilling and Welding........................................................7Driver Field of View........................................................16Driver Reach Zones........................................................16

EElectrically operated Door Mirrors..........................64Electromagnetic Compatibility (EMC)....................9Electronic Engine Controls.........................................47Exterior Lighting.............................................................52

FFrame and Body Mounting.........................................81Frame Drilling and Tube Reinforcing......................83Front, Rear and Side Under-run Protection..........21Front End Integrity for Cooling, Crash,

Aerodynamics and Lighting....................................69Fuel Filler Mounting......................................................34Fuel Filler Pipe Shipping Bracket.............................32Fuel Filler Vent Hose.....................................................37Fuel System.....................................................................32

GGeneral.......................................................................31, 80General Component Package Guidelines.............16General.......................................................................31, 80General Product Safety Requirement......................6Generator and Alternator...........................................46

HHardware—Specifications..........................................22How to Use This Manual...............................................5

IImportant Safety Instructions.....................................5Integrated Bodies and Conversions.......................65Introduction........................................................................5

JJacking................................................................................12

KKerb Weights and Payload..........................................21

LLamps – Hazard / Direction Indication.................64Legal and Vehicle Type Approval..............................6Legal Obligations and Liabilities................................6Lifting..................................................................................13Load Distribution—Specifications...........................23Load Distribution Calculations - Driver and

Passenger Weight Distribution...............................23

MMinimum Requirements for Brake system and

Load Apportioning Valves...........................................7Mounting Points and Tubing......................................81

NNew for this BEMM publication 12/2014.................5Noise, Vibration and Harshness (NVH).................14

PPackage and Ergonomics—Specifications............17Package and Ergonomics............................................16Painting Road Wheels.................................................80Product Liability................................................................7

RRear Combination lamps............................................52Rear Fog Lamp...............................................................53Rear License Plate Lamp............................................55Recommended Body Dimensions............................17Repairing Damaged Paint..........................................80Restraints System............................................................7Reversing Lamps...........................................................56Road Safety........................................................................7Roof Racks.........................................................................71

SSafety Belt System.......................................................79

Inde

x

84

Self-Supporting Body Structure............................82Suggested Antenna Location...................................10Supplementary Restraint Sensors (Front).........78Suspension System....................................................30

TTank and Dry Bulk Carriers........................................70Terminology......................................................................6Tipper Bodies................................................................69Towing capacities........................................................28Towing Requirements.................................................28Towing Specifications................................................29Towing..............................................................................28Trailer brakes...................................................................31Trailer Nose Weight.....................................................29

UUnder Body Protection and Material...................80

VVehicle Duty Cycle Guidelines...................................11Vehicle Ride and Handling Attributes.....................11Vehicle Speed Output (Signal)...............................47Vehicle Transportation Aids and Vehicle

Storage............................................................................15

WWarnings, Cautions and Notes in This

Manual..............................................................................5Warranty on Ford Vehicles..........................................6Water Tank on Camper Vehicles............................83

Index

85

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