2006 FORD TRANSIT roof

5.1 Body
5.1.1 Body Structures - General
Information
When carrying out vehicle
conversions/modifications the following points
should 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 the
load evenly.
CAUTION: Uneven load distribution
could result in unacceptable
handling and braking
characteristics.
•Re-paint metal edges after cutting or drilling.
All metal edges must comply with exterior and
interior protection legislation.
•All fixings through the floor, sides or roof must
be sealed.
Refer to: 5.10 Corrosion Prevention (page 221).
WARNING: Before drilling the floor,
check the no drill zones.
See figure E74574 - Floor (No Drill Zones) under
the Floor Fuel Tank.
•Make sure that fixings in the 'B'-pillar area do
not encroach on the seat belts or seat belt
reels.
For unique floor fixings, see (Frame Drilling and
Tube Reinforcing).
Refer to: 5.11 Frame and Body Mounting (page
222).
For Load Compartment Tie Downs(Load Lashing
Points).
Refer to: 5.2 (page 200).
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
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Chassis Cab with Dual Rear Wheel Drive Axle
Wheelhouse Dimensions for Chassis Cab with Dual Rear Wheel Drive Axle
141°G417mmA
197mmH445mmB
265mmJ406mmC
403mmK436mmD
577mmL165mmE
27mmM194mmF
75mmrCenter line of Vehicle1
Section through Centre of WheelhouseX
5.1.4 Chassis Cab
When carrying out vehicle
conversions/modifications the following points
should be considered:
•Make sure that all of the reinforced holes
provided in the chassis frame top surface are
used for full length bodies or sub-frames, see
Figures E74860, E74861, E74862, E74863
and E74696.
•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 the
load evenly.
CAUTION: Uneven load distribution
could result in unacceptable
handling and braking
characteristics.
•Re-paint metal edges after cutting or drilling.
All metal edges must comply with exterior and
interior protection legislation.
•All fixings through the floor, sides or roof must
be sealed.
Refer to: 5.10 Corrosion Prevention (page 221).
•Ensure that any additional equipment in the
vicinity of the fuel tank will not damage the
tank in a crash condition.
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
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179rE74530GABDCEFHJMKLJX1XX-X

WARNING: Excessive heat can build
up from the exhaust system, in
particular from the catalytic
converter. Ensure adequate heat
shields are maintained.
NOTE: The reinforcement plate in cab back
panel to chassis member area must be
maintained, please refer to Figure E74543.
Please refer also to the following Illustrations:
•Refer to: 5.11 Frame and Body Mounting (page
222).
(Figure E74576 - Self Supporting Body
Structure, Figure E74517 - Frame Drilling and
Tube Reinforcing and Figure E74577 - Low
floor Standard Chassis Frame).
•Refer to: 5.7 Roof Opening Panel (page 214).
(Figure E74678 - Driver's Standing Head
Room).
For any conversion structure attached to or
mounted onto the base vehicle cab structure the
following applies:
•Ensure that neither the conversion structure
nor the existing vehicle structure get
pre-loaded by the assembly process.
•Adhesive jointing is recommended but should
be supplemented with mechanical fasteners
to prevent initial peel and long term failure.
•Spread bolt loads to minimize local stress.
Body Attachment Holes in chassis Frame Top Flange Short Wheelbase
Dimensions (mm)for Body Attachment Holes in chassis Frame Top Flange Short
Wheelbase
110G19A
1406H11B
665J104C
592K101D
730L804E
506M799F
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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Medium and High Roof Bulkhead Fixing Holes
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
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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
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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
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5.7 Roof Opening Panel
5.7.1 Driver's Standing Head
Room
When planning cab walk-through capability on a
Van, Bus or Kombi, select the Special Vehicle
option, which replaces the front headlining and
parcel shelf in Vans and provides the maximum
height headlining for increased standing head
room height.
For Chassis Cab and Cab Van Floor vehicles, the
Special Vehicle Option “Roof Cutout Preparation”
can be ordered as shown in below Figure
E74678. Please consult your local National Sales
Company representative for availability.

Chassis Cab with Roof Cut Out Preparation
5.7.2 Back Panel Removal
When planning, select the Special Vehicle Option,
which has a detachable cab back panel (Chassis
Cab). Please consult your local National Sales
Company representative for availability.
5.7.3 Cab Roof Removal
For enhanced head room in the cabin of a Single
Chassis Cab, it is recommended to specify the
base vehicle with the Special Vehicle Option Roof
Cutout Preparation Pack, which provides a
perforated roof cut-out (only on Chassis Cabs)
and deletes “B”-pillar roof bow. Alternative
structure is added to comply with seat belt pull
requirements.
A unique Body Builder application where the
original Ford roof and back panel structure are
cut away must have a bolt-on reinforcing 'goal
post' structure or equivalent to resist seat belt
pull loads.
Body Preparation
When it is not possible to specify the Special
Vehicle Option it is advisable to observe the
engineering intent of the Special Vehicle
Engineering design.
Where new add-on bodies are attached to the
cab for an enclosed walk-through, the body
structure must be self-supporting and fixed such
that no local stress is created in the parent cab
structure.
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
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