2006 FORD TRANSIT Body And Equipment Mounting Section Manual

2.1 Suspension System
WARNING: Do not modify, drill, cut
or weld any suspension
components, specifically the
steering gear system, subframe or
anti-roll bars, springs or shock
absorbers including mounting
brackets.
CAUTION: Modifications to the
suspension system can cause a
deterioration of the vehicle handling
characteristics and durability.
NOTE: For detailed information please contact
the Vehicle Converter Advisory Service at
[email protected].
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
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2.2 Front Suspension
2.2.1 Springs and Spring Mounting
WARNING: Do not modify, drill, cut
or weld any suspension
components, specifically the
steering gear system, subframe or
anti-roll bars, springs or shock
absorbers including mounting
brackets.
CAUTIONS:
When carrying out welding work the
springs must be covered to protect
them against weld splatter.
Do not touch springs with welding
electrodes or welding tongs.
Make sure that components
loosened or removed and reinstalled
are properly reassembled and the
torque set in accordance with
manufactures requirements.
NOTE: Do not modify the wheelbase or add any
type of frame extension to vehicles fitted with
Interactive Vehicle Dynamics (IVD)
NOTE: Do not damage the surface or corrosion
protection of the spring during disassembly and
installation.
NOTE: For detailed information please contact
the Vehicle Converter Advisory Service at
[email protected].
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
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2.3 Rear Suspension
2.3.1 Springs and Spring
Mounting
WARNING: Do not modify, drill, cut
or weld any suspension
components, specifically the
steering gear system, sub-frame or
anti-roll bars, springs or shock
absorbers including mounting
brackets.
CAUTIONS:
When carrying out welding work the
springs must be covered to protect
them against weld splatter.
Do not touch springs with welding
electrodes or welding tongs.
Make sure that components
loosened or removed and reinstalled
are properly reassembled and the
torque set in accordance with
manufactures requirements.
NOTE: Do not modify the wheelbase or add any
type of frame extension to vehicles fitted with
Interactive Vehicle Dynamics (IVD)
NOTE: Do not damage the surface or corrosion
protection of the spring during disassembly and
installation.
NOTE: For detailed information please contact
the Vehicle Converter Advisory Service at
[email protected].
2.3.2 Rear Anti-Roll Bar
Remove the rear anti-roll bar on Chassis Cabs,
except on:
•330 and 350 Front Wheel Drive Chassis Cabs
with Box Body or with another conversion that
gives a similar or higher Centre of Gravity
(CoG) height.
•Dual Rear Wheel Chassis Cabs with Box Body
or with another conversion that gives a similar
or higher Centre of Gravity (CoG) height
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Date of Publication: 12/2006
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2.4 Wheels and Tires
2.4.1 Wheel Clearance
The distance from the tire to the mudguard or
wheel arch must be sufficient, even if snow or
anti-skid chains are fitted and the suspension is
fully compressed allowing for axle twist as well.
Please consult the Vehicle Converter Advisory
Service [email protected] for clearance
requirements and data.
NOTE: Make sure that only approved wheels
and /or permissible tire sizes are fitted
For standard wheelhouse dimensions.
Refer to: 5.1 Body (page 175).
(Integral Bodies and Conversions)
2.4.2 Tire Manufacturers
Replacement tires should be of the same make,
size, tread pattern and load rating as the Original
Equipment Manufacturer. Under these conditions
the original tire label should be satisfactory,
however if the specified tires and/or inflation
pressures are changed then a new label should
be affixed over the original label.
2.4.3 Spare wheel
When converting or relocating the spare wheel,
access must be ensured.
2.4.4 Painting Road Wheels
CAUTION: Do not paint wheel clamp
surfaces in contact with other
wheels, brake drum or disc, hub and
holes, or surfaces under wheel nuts.
Any further treatment in these areas
may affect the wheel clamp
performance and the vehicle safety.
•Mask the wheel when changing the color or
repairing paint.
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
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2.5 Driveshaft
2.5.1 Power Take Off
Gear Box add-on - Auxiliary
Propeller Drive Shaft
CAUTIONS:
Make sure that an inhibitor is fitted
to any modified vehicle that uses
the prop-shaft to power auxillary
equipment.
The only modification to the engine
control system (throttle, powertrain
control module and fuel pump)
recommended by the manufacturer
is the addition of an engine (RPM)
controller.
Do not weld or join onto any part of
the axle assembley.
The transmission oil temperature
must not exceed 130° during
operation of the Power Take Off
Where power is to be taken from the prop-shaft
for accessory drive, the engine controller can be
used in the same way as for the Front End
Accessory Drive (FEAD).
Refer to: 3.3 Accessory Drive (page 77).
Exceeding the recommended power take off
ratings may result in the engine over heating.
If the driveshaft is modified, it must be balanced
to a limit of 80gmm at 5000rpm and the
installation must not have universal joint angles
exceeding 4°. The gearbox output included angle
must be no more than 1°.
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
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2.6 Brake System
2.6.1 General
The Brake System must be fully functional when
the vehicle conversion is completed. The vehicle
brake operating modes must be checked,
including warning system and parking brakes.
Brakes are certified to 71/320EEC and ECE R13
requirements as amended.
WARNING: Do not restrict the airflow
and cooling to the brake system
CAUTION: Spoilers and wheel covers
must not affect the brake cooling
performance.
NOTE: Do not obstruct the view of the brake
fluid reservoir level
NOTE: The donor vehicle brake fluid reservoir is
translucent so that it is possible to check the level
of fluid without opening the reservoir which will
reduce the risk of contamination.
The brake fluid reservoir must remain accessible
for servicing and for adding brake fluid.
2.6.2 Kerb Mass Data
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].
2.6.3 Brake Hoses General
CAUTION: Make sure that the front
and rear brake hoses are not
twisted and are correctly located
away from body and chassis
components.
Front and rear brake hoses must not rub, chafe
or rest on body or chassis components. There
must be clearance under all operating conditions,
between full compression and extension and full
lock to lock.
Brake lines must not be used to support or
secure any other component.
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
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2.7 Parking Brake
WARNINGS:
Do not modify the brakes
Do not splice into the parking brake
cable
CAUTION: Make sure that a new
parking brake cable is fitted if
modification to the wheelbase
impacts the existing parking brake
cable.
2.7.1 Relocated Parking Brake
Lever
For improved walk through capability it is
recommended to have the standard handbrake
moved to the outer side between the driver door
and the driver seat. If the handbrake is moved
the wiring will need to be modified/extended to
accommodate this.
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]..

Recommended Relocated Parking Brake Lever location
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
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2.8 Hydraulic Brake Actuation
2.8.1 Load Apportioning Valves
•It is not necessary or recommended to modify
the load apportioning valves, however, if a
special conversion should require modifications
–Maintain original settings
–Maintain brake certification load distribution
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].
2.8.2 Front and Rear Brakes
WARNINGS:
Do not modify the brakes
Do not modify the disc in flow and
out flow of cooling air
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
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