2006 FORD TRANSIT window

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

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

CAN-Bus System (Architecture)
Antilock Brake SystemKCentral Junction Box (Passenger Junction
Box)
A
Powertrain Control ModuleLVoice Recognition Module/Wireless
connection (blue tooth)
B
Steering Angle SensorMAudio Control Unit (Radio/CD)C*
Yaw Rate SensorNNavigation (Radio/CD)D*
Diagnostic ConnectorPRemote Keyless EntryE
Park Aid ModeQPassive Anti-Theft SystemF
Restraints Control ModuleRRain SensorG
Hybrid Electronic ClusterSBattery Backed Sounder (BBS)H
Interior Motion Sensing (IMS)J
* Either Audio Control Unit or Navigation
4.1.2 Central Junction Box (CJB)
WARNING: Unapproved and/or
incorrect connection to any of the
mating wiring can cause either the
associated systems to shut down
(overload protection), or permanent
damage to the Central Junction Box
itself.
Basic vehicle functions (for example: headlights,
front wipers) are available on all Central Junction
Boxes (CJBs). Increased vehicle features are
available on the mid- and high-level CJBs, as per
the following list:
Incremental FunctionalityCentral Junction Box (CJB)
6C1T-14A073-A_ (low)
(in addition to low level CJB)6C1T-14A073-B_ (mid)
Reverse CyclingRemote Keyless Entry
Slam LockingVIN Identification
Front Fog LightsPerimeter Alarm
Theatre Dimming (Interior Lights)Central and double Locking
Heated WindscreenZonal unlocking
Heated MirrorsAuto Locking on drive away
Rear WipersAuto Relocking on time out
Heated Rear Window(s)Crash Activated unlocking
Mis-locking feedback (audible
and visual)
(in addition to mid-level CJB)6C1T-14A073-C_ (high)
Ambient air temperature meas-
urement
Battery Backed Sounder (BBS)
Rain SensorInterior Motion Sensor (IMS)
Daytime Running LightsZonal opposite door relocking
AutolampsConfigurable unlocking
Fuel Pump Control (petrol only)CAT 1 Alarm (BBS, IMS & Rear
Glass Breakage)
Cruise control
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
4 Electrical
91

For Chassis Cab with tail lift design as described
above it is recommended to use unique body
sub-frame for fixing to Chassis Cab structure. For
connection between sub-frame Chassis Cab
body structure please refer to Figure E74696.
For Chassis Cab with under-slung tail lift load
capacity is up to 1000kg at 1000mm from rear
end of chassis frame to center of load if mounted
and functioning on centre line of vehicle. If
mounted and functioning off center line or at the
side of the vehicle load capacity is reduced to
500kg at 1000mm from side/rear end to center
of load.
Greater off-sets and/or loads require additional
stabilizing equipment such as outriggers or
ground jacks. It is recommended not to increase
vehicle body stress over limit as given by load
factors above. If uncertain please consult your
local national sales representative or the Vehicle
Converter Advisory Service [email protected].
It is the Vehicle converters responsibility to fit a
decal to the converted vehicle stating that the
equipment must not be used without
outriggers/ground jacks in operating position. It
is also the vehicle converters responsibility to
guarantee safe functioning of the equipment.
For hydraulic tail lifts as used for general loading
or more specialized for wheel-chair lifts please
refer to Figure E75874.
5.1.7 Partitions (Bulkhead) - Driver
and Front Passenger(s)
Protection on Van, Bus and Kombi
The following two figures show the standard
bulkhead fixing locations on B-pillar. These are
hexagonal holes for M6 thin sheet rivet type nuts.
The standard range of Ford Regular Production
Option bulkheads can be retro-fitted at these
points.
Conversely a Ford Regular Production Option
bulkheads can also be removed.
Ford Regular Production Option bulkheads do
have a clearance between bulkhead and body
structure to allow natural body flexing and an air
circulation from the cab to the rear load space
for ventilation control.
Air circulation and body flexing must be also given
consideration when engineering an alternative
bulkhead. It is not recommended to restrict
driver’s or passengers’s seat adjustment travel.
It is the vehicle converter’s responsibility to ensure
local current legislation, governing bulkheads and
protective window grilles, is met. It is also the
converter’s responsibility to ensure legal load
constraint requirements if using a non Ford
Regular Production Option bulkhead.
Low Roof Bulkhead Fixing Holes
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
5 Body and Paint
192E75919

5.6 Glass, Frames and Mechanisms
5.6.1 Rear Windows
For windows, it is recommended to specify the
base vehicle as a Kombi or Bus body - however,
when converting a van, the following should be
adhered to:
•Cut the outer panel of the body side and door
to within 1mm of the inner panel flange.
•Do not cut across panel joints or pillars.
•Use approved glass for installation according
to legal requirements.
WARNING: Do not install seats in the
cargo area of a Van. In case rear
seats are required, always specify
the base vehicle as Kombi or Bus.
DescriptionItem
Short Wheel BaseA
Medium Wheel BaseB
Long Wheel BaseC
Extra Long Wheel BaseD
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
5 Body and Paint
211E74559ABCD

Section through typical Van Body Side for Window Engineering
DescriptionItem
Horizontal Section Through 'C'-PillarA
Horizontal Section Through Rear Vent Window Hinge PillarB
Vertical Section Through Side Window (Non Side Load Door)C
Section through typical Van Body Side for Window Engineering
Window trim strip4Glass1
Use standard vent hinge assembly5Adhesive2
Cut within 0 and 1.5mm of inner body panel flange edge all around3
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
5 Body and Paint
2121413ABC21251424444211E74533

5.6.2 Heated Windshield and
Heated Rear Window
WARNING: The base system should
not be tampered with (controlled by
Central Junction Box and multiplex
architecture) and no feeds taken
from the associated wiring or
controller.
These options are not suitable for aftermarket
or Vehicle Converter fit.
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].
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
5 Body and Paint
213

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