2006 FORD TRANSIT Body And Equipment Mounting Section Manual

Medium and High Roof Bulkhead Fixing Holes
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
5 Body and Paint
193E75920

5.1.8 Racking Systems
Ford Regular Production Option Racking System (Left Hand Side Shown)

FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
5 Body and Paint
194312E75924 312E75925

It is recommended to choose Ford Regular
Production Option racking system as shown in
figures E75924, E75925 and E75926. This fully
crash tested solution can also be ordered as an
aftermarket fix. For further information please
contact your local National Sales Representative.
For alternatively designs the following is
recommended see Figures E75921 and E75922.
•Frames should be rigid, self-supporting and
bolted through the floor using the standard
floor load lashing points at bottom side and
also bolted through the body side structure
at roof rail level at upper side.
•For alternatively fixing through the floor to the
side members please refer also to Figure
E74517 Frame Drilling and Tube Reinforcing.
•To minimize stress in drip-rail area additional
cross brace roof bows are to be used
•If linings are planned for the inside of the load
area. All racking through bolts must be
designed to be accessible through the lining
to the body structure with spreader plate.
•No load bearing fixing to the lining only.
•For increased crash performance the racking
system should be designed with diagonal
reinforcements.
•Vehicle should be equipped with Ford Regular
Production Option bulkhead to give best
protection to driver and front passengers
•Preferably, there should be a rack each side
to balance the vehicle load.
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
5 Body and Paint
195213E75926

Design Proposal for non Ford Production Option Racking System (Left Hand
Side Shown)

Racking- Top Attachment, Cross Brace Roof Bow and Through Fixing
DescriptionItem
Roof Panel1
Full Width Cross Brace Bow2
Through Bolt3
Rigid, Self Supporting Rack Structure Fixed to Cross Brace Bow at Roof Height4
Drip Channel5
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
5 Body and Paint
196E75921213435

Racking - Floor Fixings to Load Compartment Tie Downs
DescriptionItem
Rigid Self-Supporting Racking Frame Work1
Cross Brace2
Load Compartment Tie Down3
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
5 Body and Paint
1971132E75922

Glass Racking on Outside of Van

Glass Racking on Outside of Van - Through Fixed to Internal Racking (Recommended Minimum )
DescriptionItem
Top Load Bearing Attachments (2x)1
Lower Load Bearing Attachments Through Body side to Internal Racking (2x)2
New Through Bolts (2 bolts per top attachment and 1 bolt per lower attachment)2
For designing glass carrying rack on body side
outer following unique requirements are
recommended:
•Do not fix the rack to the drip rail
•Construct internal rack and bolt through the
body side to the internal rack, see figure
E75923 below
•Location in the drip rail gutter, if used, must be
protected to prevent future corrosion
5.1.9 Front End Integrity for
Cooling, Crash, Aerodynamics
and Lighting
Cooling
Continuous air flow through the front end and
engine compartment is not to be hindered by
adding any additional equipment. If uncertain
please consult the Vehicle Converter Advisory
Service [email protected].
Crash
Do not cut, drill or weld any parts that are load
path relevant in case of crash. Do not add material
in the crash zone. This could affect the crash
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 inner and/or
outer area.
Lighting:
Do not alter the lighting system.
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
5 Body and Paint
198E759233123

Static & Dynamic Sealing and
Finishing
Use Ford approved sealing and finishing material,
and underbody corrosion protection.
Refer to: 5.10 Corrosion Prevention (page 221).
Ensure proper sealing against ingress of water,
salt, dust etc. after cutting or drilling the body.
5.1.10 Tipper Bodies
For tipper conversions single an double Chassis
Cab versions except extended rear chassis
frame can be used. All variants allow single and
three way tipping.
It is recommended to have the tipping system
operative only when the engine is running. It is
also recommended to have the master control
switch in the security of the cab. According
routing of wires and hydraulic lines please refer
to section hydraulic lift.
Ensure that axle plated weights including the
front axle minimum are not exceeded.
For tipper sub-frames please refer to the
following guidelines:
•Design for full length continuous frame with
mountings for motor, pump unit, reservoir,
pivot points and ram
•Use all mounting points on chassis frame to
mount sub-frame
•The rear two sets of chassis frame mounting
brackets should have a full torque with 100%
grip. The attachment to the remaining forward
chassis frame brackets must be precisely
located and retained, but allow some relative
flexing between the sub-frame and chassis
frame. That is clamp control devices such as
conical washer stacks or machine springs with
self locking fastenings.
•Very stiff sub-frames may damage the chassis
frame by preventing its natural flexing,
therefore compliant mounts should be captive
fail safe with up to plus and minus 12mm
compliance, vehicle laden or un-laden
whichever is worst case, rated 2mm
deflection minimum per 200kg mass at each
chassis frame forward mount, please see also
Figures E74696 Sub-frame attachment to
Chassis frame and Figure E75880 Rigid or
Torsion Stiff sub-frame for Chassis Cab.
•Use two M10 grade 8.8 minimum bolts,
washers and self locking nuts at each solid
and compliant chassis frame location.
•Sub-frame must extend to the back of the
cab and attach to all mounting locations, with
the forward end designed to minimize local
frame stress, please refer to Figure E74575
Sub-frame for low floor or other equipment.
However it is preferable to mount the
sub-frame onto the mounting brackets with
a clearance to the chassis frame top surface.
•Side tipping loads/forces must be resolved
by the sub-frame. It is not recommended to
strain the chassis frame.
5.1.11 Tank and Dry Bulk Carriers
Due to the high rigidity of tanks it is necessary to
isolate the tank and its sub-frame from the
chassis frame 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 rear two sets of chassis frame mounting
brackets should have solid full bolts torque
with 100% grip.
•The remaining forward location mounts must
be compliant to allow relative chassis frame
to sub-frame deflections.
•Sub-frame must extend to the back of the
cab and not contact chassis frame at forward
end under worst case deflection.
•Compliant mounts should have captive fail
safe through bolts, please refer to Figures
E74696 Sub-frame attachment to Chassis
frame and Figure E75880 Rigid or Torsion Stiff
sub-frame for Chassis Cab, with up to
plus/minus 12mm compliance, vehicle laden
or un-laden whatever is worst case, rated at
2.0mm minimum deflection per 200kg mass
each.
•Use two M10 grade 8.8 minimum bolts,
washers and self lock nuts per chassis frame
mount bracket at each solid and compliant
location.
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
5 Body and Paint
199

5.2 Body System - General Information—Specifications
5.2.1 Van Floor - Load Compartment Tie Downs for Van ,Bus and
Kombi
Plain M8 weld nuts are supplied as standard on
right hand drive vehicles and available to order
as an option on left hand drive vehicles.
Alternatively the floor can be drilled, with care, to
access the weld nuts. Use M8 thread rolling bolts.
The forward load compartment tie down is not
available in combination with the side load door(s).
For details see the following figures E74505,
E74506, E74507, 74508 and table 'Dimensions
to locate Compartment Tie Downs'.
Location of Underfloor M8 Weld Nuts for Short Wheel Base
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
5 Body and Paint
200FBCAGDE1E74505