2006 FORD TRANSIT torque

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Page 122 of 234

FORD TRANSIT 2006 7.G Body And Equipment Mounting Section Manual
Special Vehicle Option Auxiliary Fuse Box - Later Installation (Right Hand Drive
Shown)
DescriptionItem
Special Vehicle Option Auxiliary Fuse Box1
Mounting Bracket2
Standard Relay Box3
Ground Point

Page 140 of 234

FORD TRANSIT 2006 7.G Body And Equipment Mounting Section Manual 4.14.6 Ground Points

Van, Bus, Kombi Ground Points
CAUTIONS:
Only use the ground points indicated.
Using alternative points may affect
the vehicle integrity.
Make sure that all ground points are
tig

Page 141 of 234

FORD TRANSIT 2006 7.G Body And Equipment Mounting Section Manual Ground Points Table - Van, Bus, Kombi
HarnessTypeTorqueFord Part
Number
Fixing
Type
LocationGround
Point
(GP)
14401Misc. Power
Electric
12NM +/-
1.8
W705661 S437MScrew
M6
Engine Bay LHSGP29
14401Misc.

Page 143 of 234

FORD TRANSIT 2006 7.G Body And Equipment Mounting Section Manual Ground Points Table - Chassis Cab
HarnessTypeTorqueFord Part
Number
Fixing
Type
LocationGround
Point
(GP)
14401Misc. Power
Electric
12NM +/-
1.8
W705661 S437MScrew
M6
Engine Bay LHSGP29
14401Misc. Pow

Page 199 of 234

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

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

Page 226 of 234

FORD TRANSIT 2006 7.G Body And Equipment Mounting Section Manual 5.11.3 Extended Chassis Frame
General:
•Rear overhang extensions are available as
Regular Production Option.
•Bodies or equipment exceeding the standard
extension length must be supported, please

5.11.3 Extended Chassis Frame
General:
•Rear overhang extensions are available as
Regular Production Option.
•Bodies or equipment exceeding the standard
extension length must be supported, please
refer to Figure E74575 low body longitudinal
members or Figure E74576 self-supporting
body structures.
•It is the Body Builder's responsibility to mark-up
the owners’ handbook advising the available
payload. Axle plated weights and maximum
allowable axle mass as shown in this manual
must not be exceeded.
•The vehicle should be planned for uniformly
distributed loads.
5.11.4 Non Standard Rear Chassis
Frame Extension
Extensions longer than the standard Regular
Production Option must comply with the following
guidelines:
•The original rear cross member and or
under-run bar or equivalent must be
repositioned at the end of any altered
extension to meet legislation, please refer to
Figure E74578 Non Regular Production Option
rear chassis frame extensions. Also see.
Refer to: 1.17 Towing (page 54).
(Figure E74854)
•The standard fit under-run bar is bolted on as
shown in Figure E74578 and Figure E74854
as mentioned in previous paragraph.
•The altered extension assembly must include
a cross member adjacent to the end of the
original chassis frame to replace the relocated
under-run bar, see Figure E74577.
•Flat-beds and low bodies built onto Non
Regular Production Option extensions must
have continuous longitudinal members
engineered by the Body Builder or equipment
supplier (please refer to Figure. E74577) to
resolve the worst case moments at rear bump
stop.
•Extensions should be secured to the chassis
frame sandwiched under the rear spring
shackle bracket utilizing the four (4) bolts and
four (4) holes in the rear of the chassis frame,
totaling eight (8) per vehicle side (please refer
to Figure E74578).
•The four (4) rear most existing holes in the
chassis frame must be sleeved with tubes to
prevent chassis frame collapse, refer to Figure
E74578.
•The spacer tubes should, ideally, be part of a
welded bracket and tube assembly to hold the
tubes accurately in place, avoiding the need
to weld the tubes in place, see Figure E74578.
•Care must be taken when tightening the spring
shackle bracket bolts and nuts to the correct
torque. See
Refer to: 1.15 (page 43).
(tightening torques).
•Extensions sleeved over the outside of the
chassis frame will necessitate the removal of
the under-run bar attachment flanges turned
out at the chassis frame ends. The cut edges
must be protected against corrosion.
Refer to: 5.10 Corrosion Prevention (page 221).
•Drilling of the top flanges turned out is only
permissible rearward of the spring hanger
brackets, for continuity of the altered extension
closing plate, if required. The diameter of the
holes should be 6.0mm maximum.
•If the chassis frame includes the inverted top
hat closure of the 4.25 tonne chassis double
cab variant, a similar closure must be included
in the extension and sleeved over the chassis
frame. It will be necessary to add two (2) holes
and reinforcing tubes in the inverted top hat
chassis frame vertically in line with the group
of four (4) holes see Figure E74578.
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
5 Body and Paint
226

Page 228 of 234

FORD TRANSIT 2006 7.G Body And Equipment Mounting Section Manual •It is recommended that the altered extension
has a similar closed section, material thickness
and properties to the existing chassis frame.
•An equivalent open section for the extension
assembly

•It is recommended that the altered extension
has a similar closed section, material thickness
and properties to the existing chassis frame.
•An equivalent open section for the extension
assembly is at the vehicle converters
discretion.
•Lightening holes in new extension and cross
members are discretional.
•Do not weld original chassis frame except as
specified when adding reinforcing tubes,
please refer to Figure E745171.
•Do not drill the top or bottom surface of the
chassis frame, including the flanges turned
out, except as recommended above for
continuity of closure.
•Any alternative finish such as hot dip
galvanizing is at the discretion of the Body
Builder providing it does not have a detrimental
effect on the original Ford product.
Refer to: 5.10 Corrosion Prevention (page 221).
5.11.5 Frame Drilling and Tube
Reinforcing
The chassis frame may be drilled and reinforcing
spacer tubes may be welded in place, providing
the following is applied:
•Adhere to all details shown in Figure E74517.
•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 frame
vertical centre line (note: allow for side member
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 aware
of side member draft angle.
•Apply corrosion protection inside and outside
of the chassis frame.
Refer to: 5.10 Corrosion Prevention (page 221).
•Holes should be in groups of two (2), either
vertically spaced at 30 to 35mm from chassis
frame top and/or bottom surface, or
horizontally at 50mm minimum pitch, 30 to
35mm from top and/or bottom chassis frame
surface, please refer to Figure E74517.
•Always use M10 bolts with grade 8.8 minimum.
•Do not position tubes at the medium chassis
frame height, this may create “oil canning” of
the deep section side walls.
•Where possible, the outrigger moments should
be resolved by matching inner cross members
between the chassis side members inline with
the outriggers, please refer to Figure E74577-
Low Floor.
•A diameter of 16.5mm is the maximum
allowable hole size in the chassis frame side
wall, irrespective of the usage.
Avoid drilling into closed frame body members
to avoid the risk of corrosion from swarf.
Refer to: 5.10 Corrosion Prevention (page 221).
Drilling and welding of frames and body structure
have to be conducted following the program
guidelines. Please consult the Vehicle Converter
Advisory Service [email protected] for details.
5.11.6 Ancillary Equipment - Sub
Frame Mounting
Typical sub-frames and longitudinal members for
flatbed and low or drop-side bodies or equipment
exceeding the standard or Regular Production
Order frame length should adhere to the following
guidelines:
•Flat-beds and low bodies mounted on integral
longitudinal members (channel or box section
metal – not wood) must use both sides of all
frame mounting brackets, see Figure E74575.
•Longitudinal members must be relieved at the
front end if they are to contact the chassis
frame top surface, to minimize stress
concentrations, see Figure E74575. However,
it is preferable to mount the longitudinal onto
the mounting brackets, with a clearance to the
chassis frame top surface.
•Each set of brackets must use two (2) x M10
bolts grade 8.8 minimum.
•The rear two (2) sets of chassis frame
mounting holes / locations should have a full
bolt torque with 100% grip. The attachment to
the remaining forward chassis frame holes /
locations must be precisely located and
retained, but allow some relative flexing
between the sub-frame and chassis frame.
For example, clamp control devices such as
conical washer stacks or machine springs with
self locking fasteners.
•Minimum floor heights will require wheel arch
boxes to clear the rear tires, see Vehicle Data
sheets for relevant tire jounce.
•Chassis frame, for example: clamp control
devices such as conical washer stacks or
machine springs with self locking fastenings.
•Minimum floor heights will require wheel arch
boxes to clear the rear tires.
Pedestal mounted low or drop side bodies – (not
illustrated)
For bodies or equipment not exceeding the
standard or Regular Production Order chassis
frame length.
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
5 Body and Paint
228

Page 229 of 234

FORD TRANSIT 2006 7.G Body And Equipment Mounting Section Manual For flat-beds and low bodies raised above the
maximum “jounced” tyre position to obtain an
uninterrupted flat floor surface see vehicle data
sheets.
•Fore and after longitudinal bracing must be

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