2006 FORD TRANSIT jacking

1 General Information
1.1About This Manual........................6
1.1.1Introduction...........................................6
1.1.2Important Safety Instructions.............6
1.1.3Warnings, Cautions and Notes in This
Manual....................................................6
1.1.4How to Use This Manual.....................6
1.2Commercial and Legal Aspects...
7
1.2.1Terminology...........................................7
1.2.2Warranty on Ford Vehicles..................7
1.2.3Legal and Vehicle Type Approval....
7
1.2.4Alternative Type Approval....................7
1.2.5Legal Obligations and Liabilities..........7
1.2.6General Product Safety
Requirement..........................................7
1.2.7Product Liability.....................................8
1.2.8Restraints System................................8
1.2.9Drilling and Welding..............................8
1.2.10Minimum Requirements for Brake
system and Load Apportioning Valves
.................................................................8
1.2.11Road Safety...........................................8
1.3Contact Information.....................9
1.4Conversion Type.........................14
1.5Conversion Homologation.........23
1.6Electromagnetic Compatibility
(EMC)..........................................24
1.6.1Antenna Location...............................24
1.7Vehicle Duty Cycle Guidelines....25
1.7.1Conversion Affect on Fuel Economy
and Performance...............................25
1.7.2Vehicle Ride and Handling
Attributes.............................................25
1.8End of Life Vehicle (ELV)
Directive.....................................26
1.9Jacking.......................................27
1.10Lifting..........................................29
1.11Noise, Vibration and Harshness
(NVH)...........................................31
1.12Vehicle Transportation Aids and
Vehicle Storage..........................32
1.13Package and Ergonomics..........33
1.13.1General Component Package
Guidelines............................................33
1.13.2Driver Reach Zones...........................33
1.13.3Driver Field of View.............................33
1.13.4Conversion Affects on Parking Aids..
33
1.13.5Aids for Vehicle Entry and Exit..........33
1.14Package and
Ergonomics—Specifications......34
1.14.1Recommended Main Dimensions....
34
1.14.2Recommended Nominal Body
Lengths for Chassis Cab models....
36
1.14.3Front, Rear and Side Under-run
Protection............................................38
1.14.4Recommended Main Load Area
Dimensions for Bulkhead with
Depression Driver Side......................39
1.14.5Recommended Main Load Area
Dimensions for Bulkhead with Full
Depression..........................................40
1.14.6Recommended Main Load Area
Dimensions for Double Cab In Van
Bulkhead..............................................41
1.15Hardware—Specifications..........43
1.16Load Distribution—Specifications.
44
1.16.1Load Distribution Calculations - Driver
and Passenger Weight Distribution...
44
1.16.2Center of Gravity ...............................46
1.17Towing........................................54
1.17.1Towing Requirements.......................54
1.17.2Towing..................................................54
2 Chassis
2.1Suspension System....................57
2.2Front Suspension.......................58
2.2.1Springs and Spring Mounting...........58
2.3Rear Suspension........................59
2.3.1Springs and Spring Mounting...........59
2.3.2Rear Anti-Roll Bar...............................59
2.4Wheels and Tires........................60
2.4.1Wheel Clearance................................60
2.4.2Tire Manufacturers.............................60
2.4.3Spare wheel........................................60
2.4.4Painting Road Wheels.......................60
2.5Driveshaft....................................61
2.5.1Power Take Off....................................61
2.6Brake System.............................62
2.6.1General................................................62
2.6.2Kerb Mass Data..................................62
2.6.3Brake Hoses General........................62
2.7Parking Brake.............................63
2.7.1Relocated Parking Brake Lever.......63
2.8Hydraulic Brake Actuation.........64
2.8.1Load Apportioning Valves.................64
2.8.2Front and Rear Brakes......................64
2.9Anti-Lock Control - Stability
Assist..........................................65
3 Powertrain
3.1Engine.........................................66
3.1.1Engine Power Curves.......................66
3.2Engine Cooling............................75
3.2.1Auxiliary Heater Systems..................75
3.2.2Auxiliary Heater Installation...............76
3.2.3Air Flow Restrictions...........................76
3.3Accessory Drive.........................77
3.3.1Front End Accessory Drive 2.4l Diesel
and 2.3l Petrol.....................................77
3.3.2Front End Accessory Drive 2.2l
Diesel....................................................79
3.4Electronic Engine Controls.........81
3.5Clutch.........................................82
3.6Manual Transmission.................83
Table of Contents
3

1.9 Jacking
WARNING: Always position the
vehicle on a hard level surface. If
the vehicle must be jacked up on a
soft surface use load spreading
blocks under the jack. Always chock
the wheel diagonally opposite the
jacking point. Failure to follow these
instructions may result in personal
injury.
CAUTIONS:
It is important that only the correct
jacking and support locations are
used at all times
Make sure that access to the spare
wheel is maintained when
converting the vehicle or relocating
the spare wheel.
NOTE: When using the vehicle jack, refer to the
owner guide for correct operating instructions.
NOTE: Make sure that reinforcements are
installed to maintain the integrity of the original
body structure for/at jacking points.
NOTE: Any modifications to the vehicle must
be noted in the owner's handbook or new
descriptive literature included with the owner's
documentation.
On Cab Van Floor vehicles, the spare wheel
winch is located behind the right hand side rear
wheel and can be accessed from the right hand
side. The access must be ensured under
maximum gross vehicle mass and rear axle load.
On right hand drive derivatives of camper base
Chassis Cab and Cab Van Floor vehicles, the jack
assembly is placed in a temporary location during
transportation of the base vehicle after the
conversion. The jack must be assembled and
fixed appropriately to the body to ensure safety,
durability and accessibility.
Van, Bus and Kombi (Short Wheelbase [SWB], Medium Wheelbase [MWB], Long
Wheelbase [LWB] and Extended Length)
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
1 General Information
27TIE0025125

1.17 Towing
1.17.1 Towing Requirements
When a towing device is required, the Vehicle
Converter should use a Ford approved tow bar.
Refer to: 1.16 (page 44).
Refer to: 1.9 Jacking (page 27).
1.17.2 Towing
For towing devices fitted by the Vehicle Converter
the following applies:
•Towing allowances must not exceed those of
the standard vehicle.
•For attachment of the tow bar, underrun bar
and step see the following diagrams
–E74854 Tow Bar Chassis Cab
–E74855 Tow Bar Van, Bus and Kombi.
Use the upper position to fix the tow ball on front
wheel drive vehicles and the lower position to fix
on rear wheel drive vehicles.
•Any modifications to the vehicle must be noted
in the owner's handbook or new descriptive
literature included with the owner's
documentation.
•The maximum allowable tow ball static load is
120kg on a Van, Bus and Kombi and 150kg on
Chassis Cabs.
•Tow bar installations must meet the
requirements of the EEC Directive 94/20 EC
Tow Bar Chassis Cab
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
1 General Information
54E74854

For flat-beds and low bodies raised above the
maximum “jounced” tyre position to obtain an
uninterrupted flat floor surface see vehicle data
sheets.
•Fore and after longitudinal bracing must be
added between the rear-most two (2) cross
members only
•All chassis frame mounting holes / locations
must always be used.
•All chassis frame mounting bracket fastenings
must have a full bolt torque with 100% friction
grip.
5.11.7 Spare Tire Access and
Mounting
Refer to: 1.9 Jacking (page 27).
The spare wheel winch on Cab Van Floor variants
is accessible from the side as illustrated in Figure
E74521. Ensure accessibility to the winch with
given or especially designed tools after
completion of conversion and advise in owner's
manual.

Spare Wheel Winch access on Cab Van Floor Variants
DescriptionItem
Spare Wheel Winch1
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
5 Body and Paint
2291E74521

Generator and Alternator...............................103
Glass, Frames and Mechanisms...................211
Ground Points..................................................140
H
Hardware—Specifications...............................43
Heated Seats...................................................210
Heated Windshield and Heated Rear Window.
213
Horn...................................................................108
How to Use This Manual....................................6
Hydraulic Brake Actuation...............................64
Hydraulic Lifting Equipment for Van, Bus, Kombi
and Chassis Cab...........................................186
I
Important Safety Instructions............................6
Information and Entertainment System -
General Information—Specifications...........112
Installation and Routing Guides.....................134
Instrument Cluster...........................................107
Integrated Bodies and Conversions.............177
Interior Lighting.................................................118
Introduction..........................................................6
J
Jacking................................................................27
K
Kerb Mass Data.................................................62
L
Lamps for Wide Vehicles.................................117
Lamps – Front and Rear Fog Lights..............117
Lamps – Hazard / Direction Indication..........117
Legal and Vehicle Type Approval......................7
Legal Obligations and Liabilities.........................7
Legislation.........................................................109
Lifting...................................................................29
Load Apportioning Valves................................64
Load Compartment Interior Lining...............203
Load Distribution—Specifications...................44
Load Distribution Calculations - Driver and
Passenger Weight Distribution.....................44
M
Manual Transmission........................................83
Minimum Requirements for Brake system and
Load Apportioning Valves ...............................8
Mirrors for Wide Vehicles...............................208
Module Communications
Network—Specifications................................94
Mounting Points and Tubing.........................222
N
Noise, Vibration and Harshness (NVH)...........31
Non Standard Rear Chassis Frame Extension.
226
P
Package and Ergonomics—Specifications....
34
Package and Ergonomics...............................33
Painting Road Wheels..............................60, 221
Parking Brake....................................................63
Partitions (Bulkhead) - Driver and Front
Passenger(s) Protection on Van, Bus and
Kombi..............................................................192
Possible Accessories.......................................113
Power Management Settings.........................95
Power Take Off...................................................61
Product Liability....................................................8
R
Racking Systems.............................................194
Radio Connector..............................................112
Rear Anti-Roll Bar..............................................59
Rear Seat Fixings Positions - Kombi............209
Rear Suspension...............................................59
Rear View Mirrors...........................................208
Rear Windows..................................................211
Recommended Main Dimensions.................34
Recommended Main Load Area Dimensions
for Bulkhead with Depression Driver Side....
39
Recommended Main Load Area Dimensions
for Bulkhead with Full Depression................40
Recommended Main Load Area Dimensions
for Double Cab In Van Bulkhead...................41
Recommended Nominal Body Lengths for
Chassis Cab models......................................36
Relays and Switches.......................................127
Relocated Parking Brake Lever......................63
Repairing Damaged Paint..............................221
Restraints System...............................................8
Reversing Lamps.............................................116
Road Safety..........................................................8
Roof Opening Panel........................................214
Roof Racks.......................................................216
Roof Ventilation................................................215
S
Safety Belt System.........................................220
Seats.................................................................209
Security, Anti Theft and Locking System
Security ..........................................................203
Self-Supporting Body Structure...................224
Spare Tire Access and Mounting.................229
Spare wheel.......................................................60
Special Conversions........................................131
Special Vehicle Option Auxiliary Fuse Box....
121
Index
231