2006 FORD TRANSIT transmission

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

Do not modify or remove heat
protection shields.
Do not route any electrical cables
with the Antilock Brakes System and
Traction Control System cables
because of extraneous signal risk.
It is generally not recommended to
hang electrical cables off existing
looms or pipes.
NOTE: For further information please contact
your local National Sales Company representative,
or Local Ford Dealer.
Refer to: 1.3 Contact Information (page 9).
If they are unable to help you then please contact
the Vehicle Converter Advisory Service at
[email protected].
1.2.7 Product Liability
The Vehicle Converter shall be liable for any
product liability (whether for death, personal injury,
or property damage) arising from any alteration
to a Ford vehicle or component made by the
Vehicle Converter or any of its agents. Ford shall
not be liable for any such liability (except as
provided by law).
The Vehicle Converter or equipment
manufacturer is liable for the:
•Operational reliability and road-worthiness of
the vehicle to its original intent.
•Operational reliability and road-worthiness of
any component or conversion, not listed in
original Ford documentation.
•Operational reliability and road-worthiness of
the vehicle as a whole (for example the body
changes and/or additional equipment must
not have a negative effect on the driving,
braking or steering characteristics of the
vehicle).
•Subsequent damage resulting from the
conversion or attachment and installation of
unique components, including unique electrical
or electronic systems.
•Functional safety and freedom of movement
of all moving parts (for example axles, springs,
propeller shafts, steering mechanisms, brake
and transmission linkage, retarders).
•Functional safety and freedom of the tested
and approved flexibility of the body and integral
chassis structure.
1.2.8 Restraints System
WARNINGS:
Modifications to the restraints
system are not allowed.
Airbag are explosive. for safe
removal and storage during
conversion follow the procedures in
the Ford workshop manual or
consult your local National Sales
Company representative.
Do not alter, modify or relocate the
airbag, sensor and modules of the
restraints system or any of its
components.
Attachments or modifications to the
front end of the vehicle may affect
the airbag fire timing and result in
uncontrolled deployment.
Modifications to the B-Pillar body
structure may affect the side airbag
fire timing and result in uncontrolled
side airbag deployment.
Refer to: 5.8 Air Bag Supplemental
Restraint System (SRS) (page 218).
1.2.9 Drilling and Welding
Drilling and welding of frames and body structure
have to be conducted following the program
guidelines.
1.2.10 Minimum Requirements for
Brake system and 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
•Changes to the Antilock Brake System (ABS),
Traction Control System (TCS) and the
Interactive Vehicle Dynamics (IVD) / Electronic
Stability Program (ESP) system are not
permitted.
1.2.11 Road Safety
The respective instructions should be strictly
observed to maintain operational and road safety
of the vehicle.
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
1 General Information
8

1.6 Electromagnetic Compatibility (EMC)
The base vehicle has been tested and certified
to all relevant legislation relating to
Electromagnetic Compatibility. All retrofitted
equipment must also comply with the relevant
legislation.
In addition, 2-way radio communication and other
equipment with built in radio transmitters (for
example anti-theft alarms, tracking devices)
should only be fitted to the vehicle if they operate
within the listed frequency bands and do not
exceed the maximum transmission output power
specified below
Frequency Overview
Maximum Output
Power (W)
Frequency (MHz)
501-54
5068-87.5
50142-176
50220-225
50380-512
10806-940
101200-1400
101710-1885
101885-2025
1.6.1 Antenna Location
The antenna can be placed on the roof of the
vehicle with the exception of cellular phone car
kits which transmit power below 2W. Such low
power devices may also be installed at the
bottom of the A-pillar behind the trim or on the
front windscreen.
Installation must be performed by suitably
qualified personnel in accordance with the
equipment manufacturer's installation instructions
and comply with the ISO technical specification
ISO/TS 21609: Road Vehicles - Electromagnetic
Compatibility guidelines for the installation of after
market radio frequency transmitting equipment.
In addition, the following guidelines must be
followed during installation:
•Do not mount any transceiver, microphones,
speakers or any other item in the deployment
path of the airbag system.
•Do not attach antenna cables to any part of
the original vehicle wiring or fuel and brake
pipes.
•Antenna and power cables must be a
minimum of 100mm from any electronic
modules and airbags.
•Make sure that any additional power feed is
taken directly from the SVO fuse box (when
available) or a recommended connection
point.
•Power and ground cables should be of higher
current capacity that the protection fuse.
Ground feed must be taken directly to the
battery.
Post installation checks must be made for
disturbances from and to all electrical equipment
in the vehicle both in the standby and transmit
modes. Checks should be carried out with the
ignition ON, engine running and be followed by a
road test at various speeds.
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
1 General Information
24

1.10 Lifting
WARNING: When lifting the vehicle
with a two post lift for the removal
of the engine/transmission or rear
axle, make sure the vehicle is
secured to the lift using vehicle
retention straps to prevent tilting.
Failure to follow these instructions
may result in personal injury.
CAUTIONS:
when lifting the vehicle with two
post lift, vehicle lift arm adapters
must be used under the lifting
points.
when lifting the vehicle with a two
post lift, the maximum kerb weight
must not be exceeded.
It is important that only the correct
lifting and support locations are
used at all times.
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
29E0025128

1.11 Noise, Vibration and Harshness (NVH)
WARNING: Make sure that the
modified vehicle complies with all
relevant legal requirements.
CAUTION: The travel and function of
pedals must not be restricted.
Changes to the powertrain, engine, transmission,
exhaust, air intake system or tyres may influence
the exterior noise emission. Therefore the
exterior noise level of the converted vehicle has
to be verified.
The interior noise levels should not be
deteriorated by the conversion. Reinforce panels
and structures as appropriate to avoid vibrations.
Consider the usage of sound deadening material
on panels
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
1 General Information
31

Explanation of terms used in body lengths
Nominal (Rearward Biased) Body Lengths- Recommended for best overall weight distri-
bution and payload latitude. Nominal (rearward biased) body lengths are recommended when tail-
lifts, rear mounted cranes, tow bars or rear mounted equipment are fitted. Nominal (rearward biased)
body lengths assume a typical back of cab to interface of body bulkhead dimension is 100mm
Nominal Uniformly Distributed Load (UDL) Body Lengths- is the maximum length of a
typical Float / Dropside body maintaining UDL loading without exceeding individual axle plating,
assuming no more than 100mm back of cab to internal face of body bulkhead dimension. However
specific non-standard applications, e.g. frame or body mounted equipment behind cab, or non UDL
loads may allow longer body lengths. These may be permissible providing the following are not
exceeded
- Individual axle plating.
- Maximum rear overhang greater that 50% of wheelbase.
- Body and payload combined CofG within a maximum 5% of wheelbase when rearwards of rear
axle centre line.
- Minimum variant front axle kerb mass.
Single Chassis Cab
Body Length (Internal)Drivetrain
Nominal
(UDL)
Nominal
(Rearward
Biased)
Rear AxleTransmissionWheelbaseModel
28002800Single Rear
Wheel
Front wheel Drive
/Rear Wheel Drive
Short Wheelbase300
36003200Dual rear WheelRear Wheel DriveMedium Wheel-
base
350
35003200Single Rear
Wheel
Rear Wheel Drive
35003200Single Rear
Wheel
Front Wheel Drive
3950*3650Dual rear WheelRear Wheel DriveLong Wheelbase
3950*3650Single Rear
Wheel
Rear Wheel Drive
3950*3650Single Rear
Wheel
Front Wheel Drive
44004000Dual rear WheelRear Wheel DriveExtended Frame
44004000Single Rear
Wheel
Rear Wheel Drive
42004000Single Rear
Wheel
Front Wheel Drive
30002850Dual rear WheelRear Wheel DriveLong Wheelbase430-(4.25t
GVM)30003000Dual rear WheelRear Wheel DriveExtended Frame
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
1 General Information
37

Double Chassis Cab
Body Length (Internal)Drivetrain
Nominal
(UDL)
Nominal
(Rearward
Biased)
Rear AxleTransmissionWheelbaseModel
27002450Dual rear WheelRear Wheel DriveMedium Wheel-
base
350
24002400Single Rear
Wheel
Rear Wheel Drive
24002400Single Rear
Wheel
Front Wheel Drive
3100*2850Dual rear WheelRear Wheel DriveLong Wheelbase
30002850Single Rear
Wheel
Rear Wheel Drive
31002850Single Rear
Wheel
Front Wheel Drive
33503200Dual rear WheelRear Wheel DriveExtended Frame
31003100Single Rear
Wheel
Rear Wheel Drive
31003100Single Rear
Wheel
Front Wheel Drive
30002850Dual rear WheelRear Wheel DriveLong Wheelbase430-(4.25t
GVM)30003000Dual rear WheelRear Wheel DriveExtended Frame
1.14.3 Front, Rear and Side
Under-run Protection
WARNING: Check local legislation for
legal requirements
Front Under run Protection must be designed to
directive ECE 93.00 EU equivalent 2000/40 EC
Rear Under run Protection must be designed to
directive ECE 58.00 EU equivalent 70/221 EC
Side Under run Protection must be designed to
directive ECE 73.00 EU equivalent 89/297 EC
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
1 General Information
38

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
2 Chassis
61