2006 FORD TRANSIT light

3.7Exhaust System..........................86
3.7.1Extensions and Optional Exhausts....
86
3.7.2Exhaust Pipes and Supports.............86
3.7.3Exhaust Heat Shields..........................86
3.8Fuel System.................................88
4 Electrical
4.1Communications Network..........90
4.1.1CAN-Bus System Description and
Interface................................................90
4.1.2Central Junction Box (CJB)................91
4.1.3Circuit Diagram....................................93
4.2Module Communications
Network—Specifications.............94
4.2.1Circit Diagram......................................94
4.3Charging System.........................95
4.3.1General Information and Specific
Warnings...............................................95
4.3.2Power Management Settings...........95
4.3.3Electrical Conversions........................95
4.3.4Fitting of Equipment Containing an
Electric Motor.......................................97
4.3.5Vehicle Electrical Capacity -
Alternator..............................................97
4.3.6Charge Balance Guidelines...............97
4.3.7Circuit Diagrams..................................97
4.4Battery and Cables.....................98
4.4.1Battery Information.............................98
4.4.2Generator and Alternator.................103
4.5Climate Control System.............106
4.6Instrument Cluster.....................107
4.7Horn...........................................108
4.8Tachograph................................109
4.8.1Legislation...........................................109
4.8.2Tachograph Mounting.......................110
4.9Information and Entertainment
System - General
Information—Specifications.......112
4.9.1Radio Connector................................112
4.9.2Possible Accessories.........................113
4.10Cellular Phone............................115
4.11Exterior Lighting.........................116
4.11.1Reversing Lamps...............................116
4.11.2Additional External Lamps................116
4.11.3Lamps – Hazard / Direction
Indication..............................................117
4.11.4Lamps – Front and Rear Fog Lights....
117
4.11.5Lamps for Wide Vehicles...................117
4.11.6Electrically operated Door Mirrors....
117
4.12Interior Lighting..........................118
4.12.1Additional Internal Lamps .................118
4.12.2Additional 'Theatre Lighting' for rear
of vehicle interior................................118
4.13Fuses and Relays.......................119
4.13.1Wiring Specification............................119
4.13.2Auxiliary Fuses, Fuse Box and Relays
(Fuses - Standard).............................119
4.13.3Customer Connection Points..........120
4.13.4Special Vehicle Option Auxiliary Fuse
Box........................................................121
4.13.5Additional Ignition, Instrument Panel
Illumination and Air Conditioning On
Signals.................................................124
4.13.6Relays and Switches.........................127
4.13.7Windscreen wipers...........................130
4.14Special Conversions..................131
4.14.1Vehicle Speed Output (Signal).........131
4.14.2Engine Run Signal (D+ Alternative)....
132
4.14.3Connectors.........................................133
4.14.4Installation and Routing Guides.......134
4.14.5Electrics for Tow bar.........................136
4.14.6Ground Points....................................140
4.14.7Special Vehicle Options (SVO) and
Aftermarket Kits.................................146
4.14.8Additional Vehicle Signals / Features..
147
4.14.9Engine RPM (Revs Per Minute) Speed
Controller.............................................157
4.14.10Adding Connectors, Terminals and
Wiring...................................................162
5 Body and Paint
5.1Body...........................................175
5.1.1Body Structures - General
Information..........................................175
5.1.2Back Panel Removal.........................177
5.1.3Integrated Bodies and Conversions...
177
5.1.4Chassis Cab........................................179
5.1.5Cab Van Floor.....................................185
5.1.6Hydraulic Lifting Equipment for Van,
Bus, Kombi and Chassis Cab..........186
5.1.7Partitions (Bulkhead) - Driver and
Front Passenger(s) Protection on Van,
Bus and Kombi..................................192
5.1.8Racking Systems...............................194
5.1.9Front End Integrity for Cooling, Crash,
Aerodynamics and Lighting.............198
5.1.10Tipper Bodies.....................................199
5.1.11Tank and Dry Bulk Carriers...............199
5.2Body System - General
Information—Specifications......200
5.2.1Van Floor - Load Compartment Tie
Downs for Van ,Bus and Kombi.....200
5.3Body Closures..........................203
5.3.1Load Compartment Interior Lining....
203
5.3.2Security, Anti Theft and Locking
System Security ...............................203
5.4Rear View Mirrors.....................208
5.4.1Mirrors for Wide Vehicles.................208
5.5Seats.........................................209
5.5.1Rear Seat Fixings Positions - Kombi...
209
5.5.2Heated Seats.....................................210
5.6Glass, Frames and Mechanisms...
211
5.6.1Rear Windows....................................211
Table of Contents
4

1.2 Commercial and Legal Aspects
1.2.1 Terminology
NOTE: Any modifications to the vehicle must
be noted in the owner's handbook or new
descriptive literature included with the owner's
documentation.
Vehicle Converter refers to any re-seller altering
the vehicle by converting the body and adding
or modifying any equipment not originally
specified and or supplied by Ford.
Unique component or similar wording refers to
non-Ford specified or after sale fitment not
covered by Ford warranty.
1.2.2 Warranty on Ford Vehicles
Please contact The National Sales Company in
the country where the vehicle will be registered
for details of the terms of any applicable Ford
warranty.
The Vehicle Converter should warrant its design,
materials and construction for a period at least
equal to any applicable Ford warranty
The Vehicle Converter must ensure that any
alteration made to a Ford vehicle or component
does not reduce the safety, function, or durability
of the vehicle or any component.
The Vehicle Converter shall be solely responsible
for any damage resulting from any alteration
made by the Vehicle Converter or any of its
agents to a Ford Vehicle Component.
The Vehicle Converter releases Ford from all
claims by any third party for any cost or loss
(including any consequential damages) arising
from work performed by a Vehicle Converter
unless Ford has given its prior written consent
to such liability.
1.2.3 Legal and Vehicle Type
Approval
•All components embodied on Ford vehicles
are approved to the applicable legal
requirements.
•Ford vehicles have Type Approval for the
intended marketing territories.
WARNING: Exception - Incomplete
vehicles require further approval
when completed by the Body
Builder.
•The Transit range has Type Approval for many
territories, although the full range of vehicles
shown in this manual are not necessarily
released in all territories. Check with your local
ford National Sales Company representative.
•Significant changes to the vehicle may affect
its legal compliance. Strict adherence to the
original design intent for brakes, weight
distribution, lighting, occupant safety and
hazardous materials compliance in particular
is mandatory.
1.2.4 Alternative Type Approval
If significant changes are made the Body Builder
must negotiate with the relevant authority. Any
changes to the vehicle operating conditions must
be advised to the customer.
1.2.5 Legal Obligations and
Liabilities
The Vehicle Converter should consult with its
legal advisor on any questions concerning its
legal obligations and liabilities.
1.2.6 General Product Safety
Requirement
The Vehicle Converter shall ensure that any
vehicle it places on the market complies with the
European General Product safety Directive
2001/95/EC (as amended periodically). The
Vehicle Converter shall also ensure that any
alteration it makes to a Ford vehicle or
component does not reduce its compliance with
the European General Product Safety Directive.
The Vehicle Converter shall release Ford from all
liability for damages resulting from:
•Failure to comply with these Body Equipment
Mounting directives, in particular warnings.
•Faulty design, production, installation,
assembly or alteration not originally specified
by Ford.
•Failure to comply with the basic fit for purpose
principles inherent in the original product.
WARNINGS:
Do not exceed the gross vehicle
mass, gross train mass, axle plates
and trailer plate
Do not change the tire size or load
rating
Do not modify the steering system.
Excessive heat can build up from
the exhaust system, in particular
from the catalytic converter. Ensure
adequate heat shields are
maintained. Maintain sufficient
clearance to hot parts
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
1 General Information
7

Dry Freight
Refer to: 1.14 (page 34).
Flat Bed /
Platform
Refer to: 4.4 Battery and Cables (page 98).
(Also Generator and Alternator).
Refer to: 4.8 Tachograph (page 109).
Refer to: 5.1 Body (page 175).
(Integrated Bodies and Conversions, Hydraulic Lifting Equipment for Van, Bus, Kombi
and Chassis Cab).
Refer to: 4.11 Exterior Lighting (page 116).
Refer to: 1.14 (page 34).
Float / Drop-
side
Refer to: 4.4 Battery and Cables (page 98).
(Also Generator and Alternator).
Refer to: 4.8 Tachograph (page 109).
Refer to: 5.1 Body (page 175).
(Integrated Bodies and Conversions, Hydraulic Lifting Equipment for Van, Bus, Kombi
and Chassis Cab).
Refer to: 4.11 Exterior Lighting (page 116).
Refer to: 4.4 Battery and Cables (page 98).
Tipper
(Also Generator and Alternator).
Refer to: 4.8 Tachograph (page 109).
Refer to: 5.1 Body (page 175).
(Chassis Cab & Tipper).
Refer to: 1.14 (page 34).
Box Van
Refer to: 4.4 Battery and Cables (page 98).
(Also Generator and Alternator).
Refer to: 4.8 Tachograph (page 109).
Refer to: 5.1 Body (page 175).
(Integrated Bodies and Conversions, Hydraulic Lifting Equipment for Van, Bus, Kombi
and Chassis Cab).
Refer to: 4.11 Exterior Lighting (page 116).
Refer to: 1.14 (page 34).
Curtain-side
Refer to: 4.4 Battery and Cables (page 98).
(Also Generator and Alternator).
Refer to: 4.8 Tachograph (page 109).
Refer to: 5.1 Body (page 175).
(Integrated Bodies and Conversions, Hydraulic Lifting Equipment for Van, Bus, Kombi
and Chassis Cab).
Refer to: 4.11 Exterior Lighting (page 116).
Refer to: 1.14 (page 34).
Pantechnicon
Refer to: 4.4 Battery and Cables (page 98).
(Also Generator and Alternator).
Refer to: 4.8 Tachograph (page 109).
Refer to: 5.1 Body (page 175).
(Integrated Bodies and Conversions, Hydraulic Lifting Equipment for Van, Bus, Kombi
and Chassis Cab).
Refer to: 4.11 Exterior Lighting (page 116).
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
1 General Information
15

Dry Freight
Refer to: 1.14 (page 34).
Money
Carriers
Refer to: 4.4 Battery and Cables (page 98).
(Also Generator and Alternator).
Refer to: 4.8 Tachograph (page 109).
Refer to: 5.1 Body (page 175).
(Roof Ventilation).
Refer to: 4.11 Exterior Lighting (page 116).
Refer to: 4.4 Battery and Cables (page 98).
(Also Generator and Alternator).
Refuse
Collection
Refer to: 4.8 Tachograph (page 109).
Refer to: 5.1 Body (page 175).
(Chassis Cab).
Refer to: 4.11 Exterior Lighting (page 116).
Refer to: 4.4 Battery and Cables (page 98).
(Also Generator and Alternator).
DemountableRefer to: 4.8 Tachograph (page 109).
Refer to: 5.1 Body (page 175).
(Chassis Cab).
Refer to: 4.11 Exterior Lighting (page 116).
Refer to: 4.4 Battery and Cables (page 98).
(Also Generator and Alternator).
Vehicle Trans-
porters
Refer to: 4.8 Tachograph (page 109).
Refer to: 5.1 Body (page 175).
(Chassis Cab).
Refer to: 4.11 Exterior Lighting (page 116).
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
1 General Information
16

Passenger Carrying
Refer to: 1.2 Commercial and Legal Aspects (page 7).
Taxi
(Restraints System).
Refer to: 4.11 Exterior Lighting (page 116).
Refer to: 4.12 Interior Lighting (page 118).
Refer to: 5.5 Seats (page 209).
Refer to: 5.6 Glass, Frames and Mechanisms (page 211).
Refer to: 5.7 Roof Opening Panel (page 214).
(Roof Ventilation).
Refer to: 5.8 Air Bag Supplemental Restraint System (SRS) (page 218).
Refer to: 5.1 Body (page 175).
Mobility
(Hydraulic Lifting Equipment for Van, Bus, Kombi and Chassis Cab).
Refer to: 4.11 Exterior Lighting (page 116).
Refer to: 4.12 Interior Lighting (page 118).
Refer to: 5.5 Seats (page 209).
Refer to: 5.6 Glass, Frames and Mechanisms (page 211).
Refer to: 5.7 Roof Opening Panel (page 214).
(Roof Ventilation).
Refer to: 5.8 Air Bag Supplemental Restraint System (SRS) (page 218).
Refer to: 5.1 Body (page 175).
Coach Built
(Hydraulic Lifting Equipment for Van, Bus, Kombi and Chassis Cab).
Refer to: 4.8 Tachograph (page 109).
Refer to: 4.11 Exterior Lighting (page 116).
Refer to: 4.12 Interior Lighting (page 118).
Refer to: 5.5 Seats (page 209).
Refer to: 5.6 Glass, Frames and Mechanisms (page 211).
Refer to: 5.7 Roof Opening Panel (page 214).
(Roof Ventilation).
Refer to: 5.8 Air Bag Supplemental Restraint System (SRS) (page 218).
Refer to: 5.1 Body (page 175).
Wheelchair
Accessible
(Hydraulic Lifting Equipment for Van, Bus, Kombi and Chassis Cab).
Refer to: 4.11 Exterior Lighting (page 116).
Refer to: 5.5 Seats (page 209).
Refer to: 5.6 Glass, Frames and Mechanisms (page 211).
Refer to: 5.7 Roof Opening Panel (page 214).
(Roof Ventilation).
Refer to: 5.8 Air Bag Supplemental Restraint System (SRS) (page 218).
Refer to: 4.11 Exterior Lighting (page 116).
Refer to: 4.12 Interior Lighting (page 118).
Refer to: 5.5 Seats (page 209).
Refer to: 5.8 Air Bag Supplemental Restraint System (SRS) (page 218).
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
1 General Information
17

Passenger Carrying
Refer to: 5.1 Body (page 175).
(Hydraulic Lifting Equipment for Van, Bus, Kombi and Chassis Cab).
Mini Bus
Refer to: 4.11 Exterior Lighting (page 116).
Refer to: 4.12 Interior Lighting (page 118).
Refer to: 5.5 Seats (page 209).
Refer to: 5.6 Glass, Frames and Mechanisms (page 211).
Refer to: 5.7 Roof Opening Panel (page 214).
(Roof Ventilation).
Refer to: 5.8 Air Bag Supplemental Restraint System (SRS) (page 218).
Vocational Conversion
Refer to: 4.4 Battery and Cables (page 98).
(Also Generator and Alternator).
Mobile Work-
shops
Refer to: 4.8 Tachograph (page 109).
Refer to: 5.1 Body (page 175).
(Integrated Bodies and Conversions, Hydraulic Lifting Equipment for Van, Bus, Kombi
and Chassis Cab, Racking System).
Refer to: 5.7 Roof Opening Panel (page 214).
(Roof Racks).
Refer to: 4.4 Battery and Cables (page 98).
(Also Generator and Alternator).
Mobile Shops
/ Offices
Refer to: 4.8 Tachograph (page 109).
Refer to: 5.1 Body (page 175).
(Integrated Bodies and Conversions, Hydraulic Lifting Equipment for Van, Bus, Kombi
and Chassis Cab, Racking System).
Refer to: 5.7 Roof Opening Panel (page 214).
(Roof Racks).
Refer to: 4.4 Battery and Cables (page 98).
(Also Generator and Alternator).
Glass
CarryingRefer to: 4.8 Tachograph (page 109).
Refer to: 5.1 Body (page 175).
(Racking System).
Refer to: 4.4 Battery and Cables (page 98).
(Also Generator and Alternator).
Racking
ConversionsRefer to: 4.8 Tachograph (page 109).
Refer to: 5.1 Body (page 175).
(Racking System).
Refer to: 4.4 Battery and Cables (page 98).
(Also Generator and Alternator).
Recovery
Vehicles
Refer to: 4.8 Tachograph (page 109).
Refer to: 5.1 Body (page 175).
(Chassis Cab).
Refer to: 5.11 Frame and Body Mounting (page 222).
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
1 General Information
18

Emergency Services
Refer to: 1.14 (page 34).
Ambulance -
Front Line
Refer to: 3.2 Engine Cooling (page 75).
(Airflow Restrictions).
Refer to: 4.4 Battery and Cables (page 98).
(Also Generator and Alternator).
Refer to: 4.11 Exterior Lighting (page 116).
Refer to: 4.12 Interior Lighting (page 118).
Refer to: 4.13 Fuses and Relays (page 119).
Refer to: 5.1 Body (page 175).
(Integrated Bodies and Conversions, Hydraulic Lifting Equipment for Van, Bus, Kombi
and Chassis Cab).
Refer to: 5.5 Seats (page 209).
Refer to: 5.8 Air Bag Supplemental Restraint System (SRS) (page 218).
Refer to: 1.14 (page 34).
Fire Brigade
Refer to: 3.2 Engine Cooling (page 75).
(Airflow Restrictions).
Refer to: 4.4 Battery and Cables (page 98).
(Also Generator and Alternator).
Refer to: 4.11 Exterior Lighting (page 116).
Refer to: 4.12 Interior Lighting (page 118).
Refer to: 4.13 Fuses and Relays (page 119).
Refer to: 5.1 Body (page 175).
(Integrated Bodies and Conversions, Hydraulic Lifting Equipment for Van, Bus, Kombi
and Chassis Cab).
Refer to: 5.5 Seats (page 209).
Refer to: 5.8 Air Bag Supplemental Restraint System (SRS) (page 218).
Refer to: 1.14 (page 34).
Armed
Forces
Refer to: 3.2 Engine Cooling (page 75).
(Airflow Restrictions).
Refer to: 4.4 Battery and Cables (page 98).
(Also Generator and Alternator).
Refer to: 4.11 Exterior Lighting (page 116).
Refer to: 4.12 Interior Lighting (page 118).
Refer to: 4.13 Fuses and Relays (page 119).
Refer to: 5.1 Body (page 175).
(Integrated Bodies and Conversions, Hydraulic Lifting Equipment for Van, Bus, Kombi
and Chassis Cab).
Refer to: 5.5 Seats (page 209).
Refer to: 5.8 Air Bag Supplemental Restraint System (SRS) (page 218).
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
1 General Information
21

Emergency Services
Refer to: 1.14 (page 34).
Police
Refer to: 3.2 Engine Cooling (page 75).
(Airflow Restrictions).
Refer to: 4.4 Battery and Cables (page 98).
(Also Generator and Alternator).
Refer to: 4.11 Exterior Lighting (page 116).
Refer to: 4.12 Interior Lighting (page 118).
Refer to: 4.13 Fuses and Relays (page 119).
Refer to: 5.1 Body (page 175).
(Integrated Bodies and Conversions, Hydraulic Lifting Equipment for Van, Bus, Kombi
and Chassis Cab).
Refer to: 5.5 Seats (page 209).
Refer to: 5.8 Air Bag Supplemental Restraint System (SRS) (page 218).
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
1 General Information
22