2006 FORD TRANSIT warning

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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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
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Date of Publication: 12/2006
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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–)
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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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5.3 Body Closures
Authoring Template
5.3.1 Load Compartment Interior
Lining
Do not damage the lock or latch system
(electrical cables, release system) when applying
interior lining.
WARNING: Plan fixing points for
other fitments such as racking to
ensure through bolting can be
achieved. Fixing to the lining
material may be inadequate for
normal safe operation of the vehicle.
The additional weight of the linings on doors may
require additional reinforcements to the door and
pillar at the hinge and check mechanism.
5.3.2 Security, Anti Theft and
Locking System Security
NOTE: It is not recommended to alter the
locking system.
However, in case a modification is required for
the conversions, please consult the Vehicle
Converter Advisory Service [email protected].
To avoid locking system security complications,
it is recommended to discuss with the local Ford
dealer prior to modifications taking place.
The Central Junction Box is designed to work
specifically with the Ford Transit lock and latch
mechanisms and therefore drives latches to lock
and unlock for specific time periods. Additional
power locking functionality should be based
around the use of additional Ford Transit latch
mechanisms. Additional latches can be driven
via relays connected in parallel with existing
latches.
On Chassis Cabs fitted with a high-level
Passenger Junction Box, the cargo door latch
driver is not used by the base vehicle and can
be used by Body Builders wishing to add power
locking capability to the vehicle load space. This
latch can be controlled via the driver's door key
barrel or the cargo unlock button on the remote
key fob (dependent on vehicle configuration).
The following figures outline the areas in which
it is not advisable to drill:
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Date of Publication: 12/2006
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Typical Design Principle for Cab Van Floor Seat Frame Fixing
5.5.2 Heated Seats
WARNING: The electrical feed for the
original heated Ford seat must not
be used for other purposes, e.g.
other electrical consumers
It is not advisable to retrofit heated seats due to
potential airbag operation or malfunction
(incorrect configuration).
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5.6 Glass, Frames and Mechanisms
5.6.1 Rear Windows
For windows, it is recommended to specify the
base vehicle as a Kombi or Bus body - however,
when converting a van, the following should be
adhered to:
•Cut the outer panel of the body side and door
to within 1mm of the inner panel flange.
•Do not cut across panel joints or pillars.
•Use approved glass for installation according
to legal requirements.
WARNING: Do not install seats in the
cargo area of a Van. In case rear
seats are required, always specify
the base vehicle as Kombi or Bus.
DescriptionItem
Short Wheel BaseA
Medium Wheel BaseB
Long Wheel BaseC
Extra Long Wheel BaseD
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5.6.2 Heated Windshield and
Heated Rear Window
WARNING: The base system should
not be tampered with (controlled by
Central Junction Box and multiplex
architecture) and no feeds taken
from the associated wiring or
controller.
These options are not suitable for aftermarket
or Vehicle Converter fit.
NOTE: For further information please contact
your local National Sales Company
representative, or Local Ford Dealer. If they are
unable to help you then please contact the
Vehicle Converter Advisory Service at
[email protected].
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