2006 FORD TRANSIT engine

Use metal fasteners through double thickness
flanges for example with nuts, bolts and spreader
plates where possible.
“Pop” type rivet structural value is only as good
as the material or thickness of the body panels,
therefore ensure the application is suitably
engineered.
Protect all metal edges to comply with interior
projection legislation.
Corrosion protect all cut or drilled metal edges
and repair any paint damage.
5.7.4 Roof Ventilation
General
Apertures must not cut through roof bows.
Ventilators must prevent direct entry of water
and dust.
A shut-off system should be available to prevent
fume ingress.
Interior and exterior projection legal requirements
must be maintained.
Sun Roof
The low roof has provision in the roof swage
pattern to accommodate a retrofit glass roof
above the driver as shown in the following figure
E74679.

Sun Roof Retrofit Option
DescriptionItem
Local form in Roof Panel (Low Roof Only)1
Ventilation Units
The roof panel can support up to 1kg on an
unsupported area of roof.
Loads up to a maximum of 25kg must be
distributed over 2 - roof bows.
Air Conditioning Units
Units weighing more than 25kg must be internally
supported on cross brace members distributing
the load out to the roof rails.
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
5 Body and Paint
215E746791

Typical Design Principle of a Self-Supporting Body Structure
DescriptionItem
Use all standard locations with 2x M10 fixings1
Floor Panel2
Body side frames3
Floor cross members4
Continuous floor U-profile frame5
Longitudinal L-profile6
Chassis frame rail of base vehicle7
Vehicle center line of base vehicle8
Also see.
Refer to: 5.1 Body (page 175).
5.11.2 Self-Supporting Body
Structure
Bodies and structures can be judged as
self-supporting providing they maintain the
following rules:
•Cross members are used at each chassis
mounting point, please refer to Figures.
E74576, E74860, E74861, E74862 and E74803
•Each cross member has a suitably engineered
connection to the body side wall (3) or to the
continuous floor frame (5), see Fig. E74576.
•The body side wall or the continuous floor
frame supports any overhang beyond the
chassis frame, whether on standard frame or
extended frame.
Alternatively, the self-supporting body structure
can also be designed as shown in Fig. E74577.
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
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•This concept is based on a self-supporting
structure where the floor is mounted directly
onto the top surface of the chassis frame.
•See Fig.E74577 for a generic vehicle cross
section where the cross members and
opposing out riggers are flush with the surface
of the chassis frame side members.
•It is important to the overall function of the
vehicle structure that the out riggers are each
connected to a continuous longitudinal floor
side frame or a structural body side structure
assembly.

Low Floor Standard Chassis Frame
DescriptionItem
Vertical centre line of vehicle1
Floor panel2
Continuous floor edge longitudinal3
Outrigger4
Low floor5
Low floor-re-work for guidance only:
•Engineer unique cross members and
out-riggers spaced at approximately 600mm
maximum pitch
•Out-rigger moment to be re-acted with
cross-member between chassis frame with
common through bolts where possible (see
Figure E74577 Low floor standard chassis
frame)
•Drill frame and add spacer tubes.
Refer to: 5.11 Frame and Body Mounting (page
222).
(frame drilling & tube reinforcing Figure
E74517)
•Out-rigger outboard ends should be attached
to load bearing body side / floor edge frame
or body side structure (including over wheel
support).
•Structural wheel box should maintain
longitudinal continuity with a rigid attachment
to the floor edge frame or to the body side
structure.
•Floor boards should be substantially attached
to cross members and outriggers, but not to
the chassis frame top surface.
Low floor exhaust heat shields:
Refer to: 3.7 Exhaust System (page 86).
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Date of Publication: 12/2006
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225E7457723451

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

A
About This Manual................................................6
Accessory Drive..................................................77
Adding Connectors, Terminals and Wiring....
162
Additional 'Theatre Lighting' for rear of vehicle
interior...............................................................118
Additional External Lamps...............................116
Additional Ignition, Instrument Panel Illumination
and Air Conditioning On Signals...................124
Additional Internal Lamps ................................118
Additional Vehicle Signals / Features.............147
Aids for Vehicle Entry and Exit..........................33
Air Bags..............................................................218
Air Bag Supplemental Restraint System (SRS)..
218
Air Flow Restrictions...........................................76
Alternative Type Approval....................................7
Ancillary Equipment - Sub Frame Mounting....
228
Antenna Location...............................................24
Anti-Lock Control - Stability Assist..................65
Auxiliary Fuses, Fuse Box and Relays (Fuses -
Standard)..........................................................119
Auxiliary Heater Installation...............................76
Auxiliary Heater Systems..................................75
B
Back Panel Removal................................177, 214
Battery and Cables............................................98
Battery Information............................................98
Body....................................................................175
Body Closures..................................................203
Body Structures - General Information.........175
Body System - General
Information—Specifications.........................200
Brake Hoses General........................................62
Brake System.....................................................62
C
Cab Roof Removal...........................................214
Cab Van Floor....................................................185
CAN-Bus System Description and Interface....
90
Cellular Phone....................................................115
Center of Gravity ...............................................46
Central Junction Box (CJB)...............................91
Charge Balance Guidelines..............................97
Charging System...............................................95
Chassis Cab.......................................................179
Circit Diagram.....................................................94
Circuit Diagram...................................................93
Circuit Diagrams.................................................97
Climate Control System..................................106
Clutch...................................................................82
Commercial and Legal Aspects.........................7
Communications Network...............................90
Connectors........................................................133
Contact Corrosion............................................221
Contact Information.............................................9
Conversion Affect on Fuel Economy and
Performance.....................................................25
Conversion Affects on Parking Aids................33
Conversion Homologation...............................23
Conversion Type.................................................14
Corrosion Prevention.......................................221
Customer Connection Points.........................120
D
Drilling and Welding..............................................8
Driver's Standing Head Room........................214
Driver Field of View.............................................33
Driver Reach Zones...........................................33
Driveshaft.............................................................61
E
Electrical Conversions.......................................95
Electrically operated Door Mirrors..................117
Electrics for Tow bar........................................136
Electromagnetic Compatibility (EMC)............24
Electronic Engine Controls................................81
End of Life Vehicle (ELV) Directive...................26
Engine Cooling....................................................75
Engine..................................................................66
Engine Power Curves.......................................66
Engine RPM (Revs Per Minute) Speed
Controller..........................................................157
Engine Run Signal (D+ Alternative)................132
Exhaust Heat Shields.........................................86
Exhaust Pipes and Supports............................86
Exhaust System.................................................86
Extended Chassis Frame...............................226
Extensions and Optional Exhausts..................86
Exterior Lighting.................................................116
F
Fitting of Equipment Containing an Electric
Motor..................................................................97
Frame and Body Mounting............................222
Frame Drilling and Tube Reinforcing.............228
Front, Rear and Side Under-run Protection....
38
Front and Rear Brakes......................................64
Front End Accessory Drive 2.2l Diesel............79
Front End Accessory Drive 2.4l Diesel and 2.3l
Petrol...................................................................77
Front End Integrity for Cooling, Crash,
Aerodynamics and Lighting..........................198
Front Suspension...............................................58
Fuel System........................................................88
Fuses and Relays..............................................119
G
General........................................................62, 221
General Component Package Guidelines.....33
General Information and Specific Warnings....
95
General........................................................62, 221
General Product Safety Requirement...............7
Index
230