2006 FORD TRANSIT belt

5.6.2Heated Windshield and Heated Rear
Window..............................................213
5.7Roof Opening Panel..................214
5.7.1Driver's Standing Head Room........214
5.7.2Back Panel Removal........................214
5.7.3Cab Roof Removal...........................214
5.7.4Roof Ventilation.................................215
5.7.5Roof Racks........................................216
5.8Air Bag Supplemental Restraint
System (SRS)............................218
5.8.1Air Bags..............................................218
5.9Safety Belt System...................220
5.10Corrosion Prevention...............221
5.10.1General...............................................221
5.10.2Repairing Damaged Paint...............221
5.10.3Under Body Protection and
Material...............................................221
5.10.4Painting Road Wheels......................221
5.10.5Contact Corrosion............................221
5.11Frame and Body Mounting......222
5.11.1Mounting Points and Tubing..........222
5.11.2Self-Supporting Body Structure....224
5.11.3Extended Chassis Frame...............226
5.11.4Non Standard Rear Chassis Frame
Extension..........................................226
5.11.5Frame Drilling and Tube Reinforcing..
228
5.11.6Ancillary Equipment - Sub Frame
Mounting...........................................228
5.11.7Spare Tire Access and Mounting....
229
Table of Contents
5

3.3 Accessory Drive
When the correct belt is used, tensioning is and
remains fully automatic for the life of the belt.
CAUTIONS:
Only use the manufacturers
recommended (or equivalent
specification) components
Make sure that the ancillary pulley
diameter is less than the crankshaft
pulley diameter.
Systems requiring a unique belt
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].
The eigenfrequency of any bracket including the
auxiliary added should be above the maximum
excitation frequency of the main excitation order
of the individual engine at engine top speed. On
4-cylinder inline engines, this is the second
engine order.
3.3.1 Front End Accessory Drive
2.4l Diesel and 2.3l Petrol
CAUTION: Do not fit an additional
front end accessory drive to a
vehicle already equipped with and
air-conditioning compressor.
When engineering and installing a new front end
accessory drive, i.e. belt drive of the crankshaft
pulley, the longitudinal alignment must be within
+/- 0.25mm and angular within +/- 0.33°.
For most front end accessory drive applications
the longer Regular Production Option air
-conditioning belt can replace the standard belt
and pulley layout.
The maximum power that is available for front
end accessory drive applications, in lieu of the
air conditioning compressor is 26Nm torque at
any engine speed up to a maximum of 6kW.
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
3 Powertrain
77

Front End Accessory Drive Assembly on 2.4l Diesel Engine
Pulley and Belt Layout on 2.4l Diesel Engine
DescriptionItem
Power Steering Pump1
Fan2
Idler3
Vacuum Pump4
Coolant Pump5
Compressor (may be replace by ancillary unit)6
Crankshaft Pulley7
Alternator8
Auto Tensioner9
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
3 Powertrain
78123456789E74218

Front End accessory Drive Assembly on 2.3l Petrol Engine
Pulley and Belt Layout on 2.3l Petrol Engine
DescriptionItem
Alternator1
Idler2
Coolant Pump3
Power Steering Pump4
Compressor (may be replaced by ancillary unit)5
Crankshaft Pulley6
Auto Tensioner7
3.3.2 Front End Accessory Drive
2.2l Diesel
CAUTION: Do not fit an additional
front end accessory drive to a
vehicle already equipped with and
air-conditioning compressor.
When engineering and installing a new front end
accessory drive, i.e. belt drive of the crankshaft
pulley, the longitudinal alignment must be within
+/- 0.25mm and angular within +/- 0.33°.
The maximum power that is available for front
end accessory drive applications, in lieu of the
air conditioning compressor is 26Nm torque at
any engine speed up to a maximum of 6kW.
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
3 Powertrain
79E742191234567

Front End Accessory drive Assembly on 2.2l Diesel Engine
Pulley and Belt Layout on 2.2l Diesel Engine
DescriptionItem
Idler1
Idler2
Alternator3
Power Steering Pump4
Crankshaft Pulley5
Auto Tensioner6
Compressor7
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
3 Powertrain
807123456E74220

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
5 Body and Paint
175

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
5 Body and Paint
214E74678

5.9 Safety Belt System
WARNING: Follow removal and
installation procedures for the seat
belt system to ensure correct
function of the restraints system.
The removal and reinstallation of the seat belt,
strainer or any component of the seat belt system
should be avoided. In case the removal and
re-installation system is required during the
conversion, however, follow the guidelines for
removal and installation of the seat belt system
as described in the workshop manual. Please
consult your local National Sales Company
representative for further information
When removing the seat belt system, a seat belt
webbing forked retainer should be applied to the
webbing 200mm below the webbing button stop.
This prevents a situation where all the webbing
runs back into the retractor and the retractor
becomes locked.
When reinstalling, fit the retractor to the body first
and gently pull the webbing out of the retractor
to allow fitment of the D loop. Then remove the
forked retainer. If the retractor is locked, allow a
small amount of webbing to reel back into the
retractor to allow the webbing lock to release. Do
not attempt to release the retractor by pulling on
the webbing with significant force or by manually
interfering with the locking mechanism.
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
5 Body and Paint
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