2006 FORD TRANSIT Body And Equipment Mounting Section Manual

Reinforcement Plate on Single Chassis Cab Vehicles
5.1.5 Cab Van Floor
NOTE: Cab Van Floor Models are currently only
available for use in Motor Caravan applications.
Please refer to general advice and warnings for
Chassis Cab. For the Cab Van Floor vehicle, the
following guidelines apply in addition:
•Design a sufficient connection in the B-pillar
area (sidewall to cab connection) as shown
in Figure E74864.
•The body side skirt reinforcements are the
main area where the floor and/or the sidewalls
of the conversion should be connected to.
For this purpose, use the holes and M8 weld
nuts provided on the top land and on the sides
of the side skirt reinforcements.
•It is recommended to use additional U-type
fixings around the main rails and cross
members for floor fixings wherever possible.
•For additional seat fixings behind the cab.
Refer to: 5.5 Seats (page 209).
(Figure E74532 Typical Design Principle for
Cab Van Floor Seat Frame fixing).
•It is not recommended to cut the side skirt
reinforcement for e.g. a doorstep.
Attachments to the base vehicle.
Refer to: 5.11 Frame and Body Mounting (page
222).
(Self–Supporting Body Structure).
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
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185E74543

Design Principle of fixing the Box to the 'B'-Pillar
DescriptionItem
Forward Direction1
Not Recommended Fixing of Box to 'B'-pillar2
Recommended Design Principle of Fixing the Box to 'B'-Pillar3
5.1.6 Hydraulic Lifting Equipment
for Van, Bus, Kombi and Chassis
Cab
General
WARNINGS:
Do not to cut away any structural
member.
Equipped vehicles must be designed
to be stable under “worst case”
operating conditions with support
legs extended (if fitted).
The vehicle converter / modifier is responsible
for:
•Fitting decals, advising on the safe use of the
equipment
•Route electrical and hydraulics separately and
away from original Ford equipment
•Route electrical and hydraulics separately and
away from original Ford equipment
•Use suitable clip to fix on vehicle body and sub
frame
•Offer master switch in the cab to isolate the
hole system
Chassis Cab.
Refer to: 5.11 Frame and Body Mounting (page
222).
(Frame Drilling and Tube reinforcing)
Cranes and Platforms
It is recommended to mount Cranes and aerial
platforms on a full length sub-frame by using all
load compartment tie downs for Van, Bus and
Kombi as shown in Figure E75874 and all
reinforced holes on longitudinal rail for Chassis
Cabs as shown in Figure E75880.
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
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Rigid or Torsion Stiff Sub-frame for Van, Bus and Kombi
DescriptionItem
Compliant MountA
Fixed MountB
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
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Rigid or Torsion Stiff Sub-frame for Chassis Cab
DescriptionItem
Compliant mountA
Fixed MountB
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
5 Body and Paint
188E75880AB

Sub-frame Mounted on Floor - Fixed Mount
DescriptionItem
Sub-frame Longitudinal1
Sub-frame Outriggers2
Floor of Van3
Load Compartment Tie Down (Load Lashing Point)4
It is recommended to design sub frames in way
that there is no adverse strain on the vehicle
structure. For fixing elements please refer to
Figures E75875 and E75876 for Van, Bus and
Kombi and Figure E74696 for Chassis Cabs.
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
5 Body and Paint
1891234E75875

Sub-frame Mounted on Floor - Compliant Mount
DescriptionItem
Sub-frame Longitudinal1
Sub-frame Outriggers2
Floor of Van3
Load Compartment Tie Down (Load Lashing Point)4
Captive Compliant Bush5
For Van, Bus and Kombi:
•It is recommended to fix every mount with M8
bolt grade 8.8 minimum. For load
compartment tie down locations.
Refer to: 5.2 (page 200).
(Figures E74505 - E74508)
•It is recommended to fix sub-frame to the floor
at the load compartment tie downs only. Any
other floor contact should be padded to
prevent local stress and to allow function of
compliant mounts.
•It is not recommended to engineer through
the floor fixings to clamp around side
members.
•If the load compartment tie downs are not
suitable see, Frame Drilling and Tube
Reinforcing.
Refer to: 5.11 Frame and Body Mounting (page
222).
•Very stiff sub-frames should not be rigidly
mounted to the floor, please refer to Figure
E75876 for an example of a compliant mount.
Compliant bushes should allow up to +/-12mm
movement at a rate of 100kg per 1.0mm
deflection with only the rear pair of load
compartment tie down mounting brackets
being fixed.
•Support legs, if required, must be fitted directly
to the sub-frame
•Support legs must be designed to prevent any
adverse strain on the vehicle structure when
operating the equipment
CAUTIONS:
Safety devices must ensure the legs
are deployed when operating the
lifting equipment.
Safety devices must ensure the legs
are stowed and locked away prior
to engaging vehicle drive.
For Chassis Cab:
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
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•Sub-frame ends must be relieved at forward
end to minimize local contact stress
concentrations, see Figure E74575.
Refer to: 5.11 Frame and Body Mounting (page
222).
(However it is recommended to mount the
longitudinal onto the mounting brackets with
a clearance to the chassis frame top surface).
•Stiff sub-frames, for example closed section
Longitudinal rigidly connected with similar
section cross members, may damage the
chassis frame by preventing its natural flexing.
Therefore compliant mounts should be used
with up to plus and minus (+/-) 12mm
compliance, vehicle laden or un-laden
which-ever is worst case, rated at 2.0mm
deflection minimum per 200kg mass at each
chassis frame forward mount, please refer to
Figure E74696 for example of compliant
mount and Figure E75880 for location.
•Each set of brackets must use two (2) x M10
bolts grade 8.8 minimum
•For safety device on outriggers/legs please
refer to Van, Kombi and Bus
Hydraulic tail lift

DescriptionItem
1000mmA
It is recommended to fix lift framework on bottom
and on top side by using reinforcing plates and
through bolts. It is also recommended to design
and/or locate the reinforcing plates in a way that
load can be routed into adjacent reinforced body
structure. If mounted at rear door symmetrical
to the vehicle center line load capacity is up to
1000kg at 1000mm from floor edge to center of
load.
If mounted asymmetrical to the vehicle center
line or if mounted at side load door load capacity
is up to 500kg at 1000mm from floor edge to
center of load. For pillar lifts with adjustable reach
swing jib fixed only to one rear door pillar load
capacity is reduced to 100kg at maximum
1000mm reach.
For load conditions as described above additional
stabilizing equipment is not necessary. Hydraulic
under-slung tail lifts are not recommended for
Transit Van, bus and Kombi.
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
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For Chassis Cab with tail lift design as described
above it is recommended to use unique body
sub-frame for fixing to Chassis Cab structure. For
connection between sub-frame Chassis Cab
body structure please refer to Figure E74696.
For Chassis Cab with under-slung tail lift load
capacity is up to 1000kg at 1000mm from rear
end of chassis frame to center of load if mounted
and functioning on centre line of vehicle. If
mounted and functioning off center line or at the
side of the vehicle load capacity is reduced to
500kg at 1000mm from side/rear end to center
of load.
Greater off-sets and/or loads require additional
stabilizing equipment such as outriggers or
ground jacks. It is recommended not to increase
vehicle body stress over limit as given by load
factors above. If uncertain please consult your
local national sales representative or the Vehicle
Converter Advisory Service [email protected].
It is the Vehicle converters responsibility to fit a
decal to the converted vehicle stating that the
equipment must not be used without
outriggers/ground jacks in operating position. It
is also the vehicle converters responsibility to
guarantee safe functioning of the equipment.
For hydraulic tail lifts as used for general loading
or more specialized for wheel-chair lifts please
refer to Figure E75874.
5.1.7 Partitions (Bulkhead) - Driver
and Front Passenger(s)
Protection on Van, Bus and Kombi
The following two figures show the standard
bulkhead fixing locations on B-pillar. These are
hexagonal holes for M6 thin sheet rivet type nuts.
The standard range of Ford Regular Production
Option bulkheads can be retro-fitted at these
points.
Conversely a Ford Regular Production Option
bulkheads can also be removed.
Ford Regular Production Option bulkheads do
have a clearance between bulkhead and body
structure to allow natural body flexing and an air
circulation from the cab to the rear load space
for ventilation control.
Air circulation and body flexing must be also given
consideration when engineering an alternative
bulkhead. It is not recommended to restrict
driver’s or passengers’s seat adjustment travel.
It is the vehicle converter’s responsibility to ensure
local current legislation, governing bulkheads and
protective window grilles, is met. It is also the
converter’s responsibility to ensure legal load
constraint requirements if using a non Ford
Regular Production Option bulkhead.
Low Roof Bulkhead Fixing Holes
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
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