FORD Ranger 2019 Body and Equipment Mounting Manual

E289759

FORD Ranger 2019Body and Equipment Mounting Manual

Date of Publication: 01/2020

The information contained in this publication was correct at the time of going to print. In the interest of development the right is reserved to changespecifications, design or equipment at any time without notice and without incurring any obligations. This publication, or part thereof, may not bereproduced nor translated without our approval. Errors and omissions excepted.

© Ford Motor Company 2020

All rights reserved.

1 General Information1.1 About this Manual...............................5

1.1.1 .............................................................................51.1.2 Introduction....................................................51.1.3 Important Safety Instructions.................51.1.4 Warnings, Cautions and Notes in This

Manual.............................................................51.1.5 How to Use This Manual...........................51.1.6 Low Level and High Level

Vehicles............................................................61.2 Commercial and Legal Aspects..........7

1.2.1 Terminology....................................................71.2.2 Warranty on Ford Vehicles........................71.2.3 Legal and Vehicle Type Approval...........71.2.4 Alternative Type Approval.........................71.2.5 Legal Obligations and Liabilities.............71.2.6 General Product Safety

Requirement...................................................71.2.7 Product Liability............................................81.2.8 Restraints System........................................81.2.9 Drilling and Welding....................................81.2.10 Minimum Requirements for Brake

system and Load Apportioning Valves.............................................................................8

1.2.11 Road Safety....................................................81.3 Conversion Homologation..................91.4 Electromagnetic Compatibility

(EMC).................................................101.4.1 ...........................................................................10

1.5 Vehicle Duty Cycle Guidelines............111.5.1 Vehicle Ride and Handling

Attributes........................................................111.6 Jacking................................................121.7 Lifting.................................................131.8 Noise, Vibration and Harshness

(NVH).................................................141.9 Vehicle Transportation Aids and

Vehicle Storage..................................151.10 Package and Ergonomics...................17

1.10.1 General Component PackageGuidelines......................................................17

1.10.2 Driver Reach Zones.....................................171.10.3 Driver Field of View.....................................171.10.4 Conversion Effects on Parking

Aids...................................................................171.10.5 Aids for Vehicle Entry and Exit...............171.10.6 Registration Plates.....................................18

1.11 Package andErgonomics—Specifications.............19

1.11.1 Recommended Body Dimensions.......191.11.2 Chassis Cab Body - Basic Dimensions

and Weights................................................201.11.3 Kerb Mass and Payload............................211.11.4 Front, Rear and Side Under-run

Protection......................................................211.12 Hardware—Specifications................221.13 Load

Distribution—Specifications............231.13.1 Load Distribution Calculations - Driver

and Passenger WeightDistribution...................................................23

1.13.2 Center of Gravity........................................261.14 Towing...............................................30

1.14.1 Towing Requirements..............................301.14.2 Towing...........................................................30

1.14.3 Towing Capacities andSpecifications.............................................30

2 Chassis2.1 Suspension System............................312.2 Brake System.....................................32

2.2.1 General..........................................................322.2.2 Brake Hoses.................................................322.2.3 Trailer Brakes ..............................................32

3 Powertrain3.1 Fuel System.......................................34

3.1.1 Fuel Filler Pipe Shipping Bracket (ifequipped).....................................................34

3.1.2 Fuel Filler Mounting..................................363.1.3 Fuel Filler Vent Hose................................383.1.4 Long Range Fuel Tanks...........................393.1.5 Axle Breather Vent Hose.........................39

4 Electrical4.1 Wiring Installation and Routing

Guides................................................404.1.1 Wiring Splicing Procedures...................40

4.2 Battery and Cables.............................414.2.1 Battery Information...................................414.2.2 Generator and Alternator........................47

4.3 Parking Aid........................................484.3.1 Sensor Location.........................................49

4.4 Electronic Engine Controls................514.4.1 Vehicle Speed Output (Signal) (Low

Level Vehicles Only)..................................514.4.2 Vehicle Speed Output (Signal) (High

Level Vehicles )...........................................574.5 Exterior Lighting...............................58

4.5.1 Rear Combination lamps.......................594.5.2 Rear Fog Lamp...........................................594.5.3 Rear License Plate Lamp.......................604.5.4 Reversing Lamps, Rear View Camera,

Reversing Alarm (ManualTransmission).............................................62

4.5.5 Additional External Lamps - (LowLevel Vehicles Only).................................62

4.5.6 Trailer Towing..............................................634.5.7 Auxiliary Lighting Loads (Low Level

Vehicles Only).............................................654.5.8 Lamps – Hazard / Direction

Indication......................................................664.5.9 Electrically Operated Door

Mirrors............................................................664.5.10 Centre High Mount Stop Lamp

(CHMSL) - Canopy Fitment -LowLevel Vehicles.............................................66

4.5.11 Centre High Mount Stop Lamp(CHMSL) - Canopy Fitment - HighLevel Vehicles..............................................67

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4.6 Handles, Locks, Latches and EntrySystems..............................................69

4.6.1 Central Locking...........................................694.7 Fuses and Relays................................70

4.7.1 Low Level and High Level Vehicles......704.7.2 Auxiliary Battery and Fuse Box - Low

Level Vehicles...............................................704.7.3 Auxiliary Fuse Box (Vehicles with

Special Equipment Pack) (Low LevelVehicles Only)................................................71

5 Body and Paint5.1 Body....................................................74

5.1.1 Body Structures - GeneralInformation....................................................74

5.1.2 Integrated Bodies andConversions...................................................74

5.1.3 Chassis Cab...................................................755.1.4 Front End Integrity for Cooling, Crash,

Aerodynamics and Lighting....................785.1.5 Tipper Bodies...............................................785.1.6 Tank and Dry Bulk Carriers......................795.1.7 Genuine Ford Accessory Bull Bar..........795.1.8 Roof Racks....................................................805.1.9 Canopies.........................................................81

5.2 Airbag Supplemental RestraintSystem (SRS)....................................84

5.2.1 Air Bags - (Low Level Vehicles)............845.2.2 Air Bags - (High Level Vehicles)............875.2.3 Supplementary Restraint Sensors

(Front)............................................................905.3 Seatbelt Systems – Australia............925.4 Corrosion Prevention.........................93

5.4.1 General...........................................................935.4.2 Repairing Damaged Paint.......................935.4.3 Under Body Protection and

Material...........................................................935.4.4 Painting Road Wheels..............................935.4.5 Contact Corrosion......................................93

5.5 Frame and Body Mounting................945.5.1 Mounting Points and Tubing..................945.5.2 Self-Supporting Body Structure...........955.5.3 Frame Drilling and Tube

Reinforcing....................................................965.5.4 Ancillary Equipment - Sub Frame

Mounting........................................................965.5.5 Area for Fitting Additional Body

Attachments to the Rear of theBumper. .........................................................96

5.5.6 Water Tank on Camper Vehicles..........96

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1.1 About this Manual

1.1.1

It is recommended to review this manual in full.The BEMM is a live document which can be viewedon www.etis.ford.com/BEMM orhttp://www.fordtechservice.dealerconnection.com/.It is the vehicle converters responsibility to reviewthe online version for the most current informationprior to starting any conversion.

1.1.2 Introduction

NOTE: Printed copies are uncontrolled.This manual has been written in a format that isdesigned to meet the needs of Vehicle Converters.The objective is to use common formats with theworkshop manual which is used by techniciansworldwide.This guide is published by Ford and providesgeneral descriptions and advice for convertingvehicles. These requirements must be compliedwith before a Ford Dealer should take delivery ofmotor vehicle accessories from an externalsupplier either for themselves or on behalf of amotor vehicle client.It must be emphasized that any change to thebasic vehicle which does not meet the enclosedguideline standards may severely inhibit the abilityof the vehicle to perform its function. Mechanicalfailures, structure failure, component unreliabilityor vehicle instability will lead to customerdissatisfaction. Appropriate design andapplication of body, equipment and or accessoriesis key to ensuring that customer satisfaction isnot adversely affected.The information contained within this publicationtakes the form of recommendations to befollowed when vehicle modifications areundertaken. It must be remembered that certainmodifications may invalidate legal approvals andapplication for re-certification may be necessary.Ford cannot guarantee the operation of thevehicle if non-Ford approved electrical systemsare installed. Ford electrical systems are designedand tested to function under operationalextremes, and have been subjected to theequivalent of ten years of driving under suchconditions.

1.1.3 Important Safety Instructions

Appropriate conversion procedures are essentialfor the safe, reliable operation of all vehicles aswell as the personal safety of the individualcarrying out the work.

This manual cannot possibly anticipate all suchvariations and provide advice or cautions as toeach. Anyone who departs from the instructionsprovided in this manual must first establish thatthey compromise neither their personal safety northe vehicle integrity by their choice of methods,tools or components.

1.1.4 Warnings, Cautions and Notes inThis Manual

WARNING: Warnings are used to indicatethat failure to follow a procedurecorrectly may result in serious injury ordeath.CAUTION: Cautions are used to indicatethat failure to follow a procedurecorrectly may result in damage to thevehicle or equipment being used.

NOTE: Notes are used to provide additionalessential information required to carry out acomplete and satisfactory repair.As you read through this manual, you will comeacross WARNINGS, CAUTIONS and NOTES.A warning, caution or note is placed at thebeginning of a series of steps if it applies tomultiple steps. If the warning, caution or note onlyapplies to one step, it is placed at the beginningof the specific step (after the step number).

1.1.5 How to Use This Manual

This manual covers vehicle conversion procedures.The pages at the start of this manual list thecontent, by group. A group covers a specificportion of the vehicle. The manual is divided intofour groups, General Information, Chassis,Electrical, Body and Paint. The number of thegroup is the first number of a section number.Each title listed in the contents links to therelevant section of the manual.In some section of the book it may refer you tosee additional sections for information, links havebeen provided, these links are in blue text.This manual is designed to be used online or asprinted material, document links for the onlineversion are also shown with page numbers for theprinted version, this will help guide you to the startof the section which contains the relevantinformation.There is also an alphabetical index at the back ofthe manual. As with the contents pages you willbe able to link to sections. To do this just click onthe page number.All left and right-handed references to the vehicleare taken from a position sitting in the driver seatlooking forward unless otherwise stated.

Date of Publication: 01/2020FORD RANGER 2019 2012

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1.1.6 Low Level and High Level Vehicles

WARNING: Prior to work on any vehiclebeing undertaken it is critical to identifythe type of electrical architecture thevehicle at hand is equipped with. Failureto identify the type of electricalarchitecture present on the vehicle priorto work being undertaken may causeelectrical damage or have safetyimplications.

Ford Ranger vehicles are equipped with one of twoelectrical architectures.Refer to: 4.7 Fuses and Relays (page 70).

FORD RANGER 2019 2012Date of Publication: 01/2020

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1.2 Commercial and Legal Aspects

1.2.1 Terminology

NOTE: Any modifications to the vehicle must benoted in the owner's handbook or new descriptiveliterature included with the owner'sdocumentation.Vehicle Converter refers to any re-seller alteringthe vehicle by converting the body and adding ormodifying any equipment not originally specifiedand or supplied by Ford.Unique component or similar wording refers tonon-Ford specified or after sale fitment notcovered by Ford warranty.

1.2.2 Warranty on Ford Vehicles

Please contact The National Sales Company inthe country where the vehicle will be registeredor refer to the vehicle Owner Guide for details ofthe terms of any applicable Ford warranty.The Vehicle Converter should warrant its design,materials and construction for a period at leastequal to any applicable Ford warranty.The Vehicle Converter must ensure that anyalteration made to a Ford vehicle or componentdoes not reduce the safety, function, or durabilityof the vehicle or any component.The Vehicle Converter shall be solely responsiblefor any damage resulting from any alterationmade by the Vehicle Converter or any of its agentsto a Ford Vehicle Component.The Vehicle Converter releases Ford from allclaims by any third party for any cost or loss(including any consequential damages) arisingfrom work performed by a Vehicle Converterunless Ford has given its prior written consent tosuch liability.

1.2.3 Legal and Vehicle Type Approval

• All components embodied on Ford vehicles areapproved to the applicable legal requirements.

• Ford vehicles have Type Approval for theintended marketing territories.

WARNING: Exception - Incompletevehicles require further approval whencompleted by the Body Builder.

• The Ranger range has Type Approval for manyterritories, although the full range of vehiclesshown in this manual are not necessarilyreleased in all territories. Check with your localFord National Sales Company representative.

• Significant changes to the vehicle may affectits legal compliance. Strict adherence to theoriginal design intent for brakes, weightdistribution, lighting, electrical systems,occupant safety and hazardous materialscompliance in particular is mandatory.

1.2.4 Alternative Type Approval

If significant changes are made the Body Buildermust negotiate with the relevant authority. Anychanges to the vehicle operating conditions mustbe advised to the customer.

1.2.5 Legal Obligations and Liabilities

The Vehicle Converter should consult with its legaladvisor on any questions concerning its legalobligations and liabilities.Ford recommends that the Vehicle Converter andFord Dealer must understand their individual andjoint responsibilities in supplying a safe andcompliant motor vehicle fitted with safe andcompliant accessories.

1.2.6 General Product SafetyRequirement

The Vehicle Converter shall ensure that anyvehicle it places on the market complies with alllocal laws, including laws relating to the safecarriage of loads on public roads. The VehicleConverter shall also ensure that any alteration itmakes to a Ford vehicle or component does notreduce its compliance with local regulatorystandards.The Vehicle Converter must provide sufficientLoad Restraint tie down points orcompartmentalised storage areas that enablethe driver to safely carry loads that match the usecriteria for which the body was designed.The Vehicle Converter shall release Ford from allliability 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 specifiedby Ford.

• Failure to comply with the basic fit for purposeprinciples inherent in the original product.

WARNINGS:Do not exceed the gross vehicle mass,gross combination mass, axle ratings andtrailer rating.Do not change the tire size or load rating.

Do not modify the steering system.

Excessive heat can build up from theexhaust system, in particular from thecatalytic converter and from the DieselParticulate Filter (DPF). Ensure adequateheat shields are maintained. Maintainsufficient clearance to hot parts.


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Do not modify or remove heat protectionshields.Do not route any electrical cables with theAnti-lock Brakes System and TractionControl System cables because ofextraneous signal risk. Do not hangelectrical cables off existing looms orpipes.Do not change original location or removewarning labels provided with the basevehicle in view to the driver. Ensure thatlabels in view to the driver in the basevehicle remain in full view to the driverafter any conversion.

NOTE: For further information please contact yourlocal National Sales Company representative, orLocal Ford Dealer.

1.2.7 Product Liability

The Vehicle Converter shall be liable for anyproduct liability (whether for death, personal injury,or property damage) arising from any alterationto a Ford vehicle or component made by theVehicle Converter or any of its agents. Ford shallnot be liable for any such liability (except asprovided by law).The Vehicle Converter or equipment manufactureris 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 inoriginal Ford documentation.

• Operational reliability and road-worthiness ofthe vehicle as a whole (for example the bodychanges and/or additional equipment must nothave a negative effect on the driving, brakingor steering characteristics of the vehicle).

• Any damage resulting from the conversion orattachment and installation of uniquecomponents, including unique electrical orelectronic systems.

• Functional safety and freedom of movementof all moving parts (for example axles, springs,propeller shafts, steering mechanisms, brakeand transmission linkage).

• Functional safety and freedom of the testedand approved flexibility of the body and integralchassis structure.

1.2.8 Restraints System

WARNINGS:Modifications to the restraints systemare not allowed.Airbags are explosive. For safe removaland storage during conversion follow theprocedures in the Ford workshop manualor consult your local National SalesCompany representative.

Do not alter, modify or relocate the airbag,sensor and modules of the restraintssystem or any of its components.Attachments or modifications to the frontend of the vehicle may affect the airbagfire timing and result in uncontrolleddeployment.Modifications to the B-Pillar bodystructure may affect the side airbag firetiming and result in uncontrolled sideairbag deployment.

Refer to: Airbag Supplemental Restraint System(SRS) (page ?).

1.2.9 Drilling and Welding

Drilling and welding of frames and body structureshave to be conducted following the guidelineswithin this document.

1.2.10 Minimum Requirements forBrake system and Load ApportioningValves

• It is not necessary or recommended to modifythe load apportioning valves, however, if aspecial conversion should require modifications,– Maintain original settings.– Maintain brake certification load distribution.

• Changes to the Antilock Brake System (ABS),Traction Control System (TCS) and ElectronicStability Program (ESP) system are notpermitted.

1.2.11 Road Safety

The respective instructions should be strictlyobserved to maintain operational and road safetyof the vehicle.


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1.3 Conversion HomologationThe Vehicle Converter must observe any statutoryrules and regulations. When the conversion needsa new approval the following information mustbe quoted.• All dimensional, weight and centre of gravity

data.• The fixing of the body to the donor vehicle.• Operating conditions.The responsible Technical Service may requireadditional information and/or testing.NOTE: For further information please contactyour local National Sales Company representative,or Local Ford Dealer.


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1.4 Electromagnetic Compatibility (EMC)

1.4.1

WARNINGS:Do not place objects or mount equipmenton or near the airbag cover, on the side ofthe seatbacks (of the front seats), or infront seat areas that may come intocontact with a deploying airbag. Failureto follow these instructions may increasethe risk of personal injury in the event ofa crash.Do not fasten antenna cables to originalvehicle wiring, fuel pipes and brake pipes.

Keep antenna and power cables at least100mm from any electronic modules andairbags.

NOTE: We test and certify your vehicle to meetlocal electromagnetic compatibility legislation orequivalent, where applicable. It is yourresponsibility to make sure that any equipment anauthorized dealer installs on your vehicle complieswith local regulatory standards.NOTE: Any radio frequency transmitter equipmentin your vehicle (such as cellular telephones andamateur radio transmitters) must keep to theparameters in the following table. We do notprovide special provisions or conditions forinstallations or use.

E239121

Antenna PositionMaximum Output Power Watts(Peak RMS)

Frequency Band MHz

1501-302, 35050-542, 35068-882, 350142-1762, 350380-5122, 310806-870

NOTE: After the installation of radio frequencytransmitters, check for disturbances from and toall electrical equipment in your vehicle, both in thestandby and transmit modes.Check all electrical equipment:• with the ignition ON• with the engine running• during a road test at various speeds

NOTE: Check that electromagnetic fieldsgenerated inside your vehicle cabin by thetransmitter installed do not exceed applicablehuman exposure requirements.


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1.5 Vehicle Duty Cycle GuidelinesNOTE: For further information contact yourNational Sales Company representative, or localFord dealer.It is necessary to take into account the customerusage profile and the anticipated vehicle dutycycles of the modified vehicle in order to choosethe appropriate specification of the base vehicle.It is necessary to select the appropriate drive,engine, gear ratio, gross vehicle mass, gross trainmass, axle plates and payloads of the base vehicleto match the customer requirements.Where possible make sure that the base vehicleis ordered with any necessary plant fit options.A high numeric gear ratio is recommended forvehicles with customer requirements for:• High payload• Trailer tow• Frequent stop-and-go cycles• High altitude and gradients• Terrain conditions such as found on building

and construction sites

1.5.1 Vehicle Ride and HandlingAttributes

CAUTION: Do not exceed the axle plate,gross vehicle mass, trailer plate andgross trailer mass limits.

Conversions to the base vehicle that change thecenter of gravity may affect the ride and handlingattributes.NOTE: All vehicles should be evaluated for safeoperation prior to sale.


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1.6 JackingWARNINGS:

Ensure screwthread is adequatelylubricated before use.The jack should be used on level firmground wherever possible.Switch the ignition off and apply parkbrake fully before lifting vehicle.It is recommended that the wheels of thevehicle be chocked, and that no personshould remain in a vehicle that is beingjacked.No person should place any portion oftheir body under a vehicle that issupported by a jack.WARNING: Do not get under a vehicle thatis supported by a jack.

E166722

WARNING: The jack supplied with thisvehicle is only intended for changingwheels. Do not use the vehicle jack otherthan when you are changing a wheel in anemergency.CAUTION: Make sure that access to thespare wheel is maintained whenconverting the vehicle or relocating thespare wheel.

NOTE: When using the vehicle jack, refer to theowner guide for correct operating instructions.The spare wheel winch is located above the sparewheel and can be accessed from the rear of thechassis frame.The jack must be assembled and fixedappropriately to the body to ensure safety,durability and accessibility.

Vehicle Jacking Points and Axle Stand Positions

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1.7 LiftingWARNING: When lifting the vehicle witha two post lift for the removal of theengine/transmission or rear axle, makesure the vehicle is secured to the liftusing vehicle retention straps to preventtilting. Failure to follow theseinstructions may result in serious injuryor death.

CAUTIONS:When lifting the vehicle with a two postlift, vehicle lift arm adapters must beused under the lifting points.When lifting the vehicle with a two postlift, the maximum kerb weight must notbe exceeded.It is important that only the correct liftingand support locations are used at alltimes.

All Vehicles

E133943


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1.8 Noise, Vibration and Harshness (NVH)WARNING: Make sure that the modifiedvehicle complies with all relevant legalrequirements.

Changes to the powertrain, engine, transmission,exhaust, air intake system or tires may influencethe exterior noise emissions. Therefore the exteriornoise level of the converted vehicle has to beverified.The interior noise levels should not be deterioratedby the conversion. Reinforce panels and structuresas appropriate to avoid vibrations. Consider theusage of sound deadening material on panels.


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1.9 Vehicle Transportation Aids and Vehicle StorageCAUTIONS:

Disconnect the battery if the vehicle is tobe stored for more than 30 days.Make sure that the protective covers arenot removed from an incomplete vehicleuntil the conversion is started.Make sure that components removedduring conversion are kept clean and dry.Make sure that components removedduring conversion are refitted to thesame vehicle.Transport Mode includes a calibrationfeature to reduce the risk of fuel injectornozzle corrosion. Exiting TransportationMode prior to upfi tting/ conversionincreases the risk of early life injectorfailure.

In addition:• The windscreen wipers should be lifted off the

glass and set right up.• All air intakes should be closed.• Increase normal tire pressure by 0.5 bar.• The hand brake system should not be used.• Apply suitable wheel chocks to prevent roll

away.A significant risk during storage is deterioration ofvehicle bodywork, therefore, appropriate storageprocedures must be observed, including periodicinspection and maintenance.Claims arising from deterioration caused byincorrect storage, maintenance or handling arenot the responsibility of Ford.Vehicle Converters must determine their ownprocedures and precautions, particularly wherevehicles are stored in the open as they areexposed to any number of airborne contaminants.The following may be considered a sensibleapproach to storage:Short Term Storage• Wherever possible vehicles should be stored

in an enclosed, dry, well-ventilated area basedon firm, well drained ground which is free oflong grass or weeds and where possibleprotected from direct sunlight.

• Vehicles must not be parked near, under foliageor close to water as additional protection maybe necessary for certain areas.

Long term storage:• Battery to be disconnected but not removed

from the vehicle.• The wiper blades should be removed and

placed inside the vehicle. Make sure the wiperarms are suitably prevented from resting onthe windscreen.

• Engage first gear and release the parking brakecompletely. Chock the wheels first if the vehicleis not on level ground.

• Set climate controls to the "open" position toprovide ventilation, where possible.

• Where protective film has been applied inmanufacture it must be left on the vehicle untilprepared for delivery but must be removedafter a maximum storage period of six months(film is date stamped to indicate requiredremoval date).

• Make sure that all windows, doors, hood,tailgate and luggage compartment lid arecompletely closed and the vehicle is locked.

The Pre Delivery Inspection (PDI) is the finalopportunity to make sure a battery is fit forpurpose prior to the customer taking delivery oftheir new vehicle. The battery must be checkedand appropriate action taken prior to the vehiclebeing handed over to the customer. Test resultsmust be recorded on the PDI repair order.Batteries. To make sure the battery is maintainedcorrectly and to assist in preventing prematurefailure, it is necessary to check and recharge thebattery regularly while a vehicle is not in use.Where a battery is left below its optimum chargelevel for any length of time, it may result inpremature failure of the battery.

Every 3Months

MonthlyAction / Time instorage

-XCheck vehicle isclean

-XRemove externalcontamination

DisconnectedConnectedCheck batterycondition -Recharge if neces-sary

-XVisually check tiresX-Check interior for

condensationX-Run engine until

coolant gaugereaches temper-ature (60 ° C) withaircon switched on,where applicable

Protection from Injector Nozzle CorrosionDuring the Upfitting/Conversion ProcessFordEngineering has identified a concern with the fuelinjectors on the 2.0L EcoBlue / Duratorq enginewhereby the injector nozzle can become corroded.This is caused by condensation which forms onthe nozzle when the engine is new and runrepeatedly for very short periods of time when theengine is cold (less than 60 degrees centigrade).Fuel injectors may fail as a consequence, eitherduring vehicle storage or early time in service.


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If the vehicle cannot be left in transportation modethen the procedure to disconnect the ManifoldAbsolute Pressure Temperature (MAPT) sensorelectrical connector, until the vehicle is preparedfor delivery to the customer, should be followedto achieve the same result.Experience shows that vehicles undergoing aconversion where the engine is regularly startedfor short periods of time when cold, are most atrisk; for example, vehicles undergoing aMotorhome conversion.

Vehicles held in storage for long periods of timeare particularly susceptible to this concern, forexample vehicles awaiting or undergoing aconversion.To overcome this and protect fuel injectors fromearly time-in-service failures, the ManifoldAbsolute Pressure Temperature (MAPT) must bedisconnected by following the following simpleprocedure.Procedure for disconnecting the ManifoldAbsolute Pressure Temperature (MAPT)sensor

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• Disconnect the electrical connector.• Start and stop the engine 4 times to ensure that

the Malfunction Indicator Lamp (MIL) isilluminated and corresponding informationmessage is displayed in the instrument cluster.– The vehicle can be operated safely with the

MAP sensor disconnected during anyconversion that the vehicle may beundergoing, for example a Motorhomeconversion.

• Before the vehicle is handed over to thecustomer, the Manifold Absolute PressureTemperature (MAPT) must be reconnectedand the engine must be started 4 times to turnoff the Malfunction Indicator Lamp (MIL),remove the information message and restorethe engine’s normal power and torque outputs.

NOTE: When the Manifold Absolute PressureTemperature (MAPT) sensor is disconnected, thevehicle must only be used at the storage facilityand NOT on public roads.

To reduce the likelihood of premature batteryfailure it is recommended that where:• A battery is left connected – monthly checks

should be carried out.• A battery has been disconnected – no greater

than a 3 monthly check should be carried out.


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1.10 Package and Ergonomics

1.10.1 General Component PackageGuidelines

WARNING: Do not modify, drill, cut orweld any suspension components,specifically the steering gear system,subframe or anti-roll bars, springs orshock absorbers including mountingbrackets.

The Vehicle Converter must ensure that sufficientclearance is maintained under all drive conditionsto moving components such as axles, fans,steering, brake system etc.The Vehicle Converter is responsible for allinstalled components during the conversion. Thedurability must be confirmed by appropriate testprocedures.

1.10.2 Driver Reach Zones

Controls and/or equipment required to be usedwhile driving should be located within easy reachof the driver so as not to impair driver control.

1.10.3 Driver Field of View

WARNING: Make sure that the modifiedvehicle complies with all relevant legalrequirements.

1.10.4 Conversion Effects on ParkingAids

WARNING: Ensure that monitorsmounted in the cabin meet the interiorpackage and safety requirements.

On conversions requiring a rear camera, thereverse signal may be taken as described in thereversing lamps section.Refer to: Exterior Lighting (page ?).

1.10.5 Aids for Vehicle Entry and Exit

Steps

WARNINGS:Make sure that the modified vehiclecomplies with all relevant legalrequirements.If this modification alters thehomologated dimensions, a newapproval may be necessary.CAUTION: Make sure that reinforcementsare installed to maintain the integrity ofthe original body structure.

Steps can be ordered as an accessory on the basevehicle. Please check for availability.Where additional steps are installed the requiredground clearance line must be maintained.The Vehicle Converter must make sure that amovable step is set in the stored position whenthe vehicle is running. The step surface must benon-slip.

Rear View Mirrors

NOTE: Overall width with exterior rear viewmirrors extended is 2163 mm.


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E278311

DescriptionItemMaximum Body Width: 1860mmX

1.10.6 Registration Plates

Front Registration Plate

WARNINGS:The mounting of a registration plate tothe front of the vehicle must comply withlocal regulatory standards.No part of a vehicle registration plate maybe obscured by standard equipment,regular production options or equipment,in line with local regulatory standards.

The registration plate must be affixed to the frontof the motor vehicle forward of and parallel to thefront ‘Axle’ in line with local regulatory standards.

Rear Registration Plate

WARNINGS:The mounting of a registration plate tothe rear of the vehicle must comply withlocal regulatory standards.No part of a vehicle registration plate maybe obscured by standard equipment,regular production options or equipment,in line with local regulatory standards.

The registration plate must be affixed to the rearof the motor vehicle in line with local regulatorystandards.


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1.11 Package and Ergonomics—Specifications

1.11.1 Recommended Body Dimensions

WARNINGS:Do not modify the wheelbase or add anytype of frame extension to vehicles fittedwith Electronic Stability Program (ESP).Ensure that any mass added to thevehicle does not compromise vehiclestability.

NOTE: Extreme rear overhang may encourageunacceptable loading conditions, which couldunload the front axle, producing unacceptablehandling and braking characteristics. Ensure thatthe centre of gravity of the body and payload doesnot fall outside of the recommended zone.NOTE: An excessively high centre of gravity couldreduce vehicle stability. Ensure that the centre ofgravity of the body and payload does not falloutside of the recommended zone.Refer to: (page ?).

NOTE: When extending the length of the framerearward of the rear axle, it is recommended thatthe overall rear overhang is limited to a maximumof 50% of the wheelbase of the vehicle.NOTE: If a towball is fitted to the vehicle, the bodydimensions must incorporate a towball clearancezone in accordance with local regulatorystandards. For additional information, refer tolocal regulatory standards.If a conversion requires more than 50% overhang,please contact your local National Sales Companyrepresentative, or Local Ford Dealer.Load carrying structures should not be mountedonto an existing load tray or load box. Bodyattachment points are provided on the frame.Refer to: Body (page ?).

Chassis Cab Body - Single Cab Illustrated

E278312

J

A

E

C

D

B

H F

G


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Dimensions - not to exceed for Chassis Cab body Length

Dimension (mm)DescriptionDouble CabSuper CabSingle Cab

148317812251Frame length behind back of cab (not including rearlight cross-member)

A

Under run bar and towing attachment legislation to be maintainedB2400 over the top of frame, provided loaddistribution requirements are met

Maximum recommended external body heightC

4737711241Front outside of body to rear axleD1610 (50% of vehicle wheelbase),provided load distribution requirementsare met

Maximum recommended rear overhangE

25 MinimumClearance between the back of the cab and the bodyFEnsure local lighting legislation is maintained Refer to: Exterior Lighting (page ?).G

30Clearance between the top of the cab and the bodyH1860Maximum external body widthJ

All dimensions (shown in mm) are subject to manufacturing tolerances and refer to min specificationmodels which do not include additional equipment. The illustrations are for guidance only.

1.11.2 Chassis Cab Body - Basic Dimensions and Weights

Chassis Cab Body - Single Cab Illustrated

E

B

C

D

A

F

E278313


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Chassis Cab Body - Basic Dimensions and Weights

Double CabSingle CabDescription5110Overall length (mm)A1860Overall width - excluding exterior mirrors (mm)B

17161703Overall height 4x2 (mm)C1815 - 18211800-1806Overall height 4x4 (mm)C

3220Wheelbase (mm)D

1590Track - front (mm)*E

1560Track - front (mm)**E

1590Track - rear (mm)*E

1560Track - rear (mm)**E

1234985Rear Overhang with rear bumper where fitted (mm)F

1325Front Axle Load (kg)*-

1480Front Axle Load (kg)**-

1755Rear Axle Load (kg)*-

1850Rear Axle Load (kg)**-* 4x2 vehicles with low ride height.** 4x2 Vehicles with increased ride height / 4x4 vehicles.

1.11.3 Kerb Mass and Payload

WARNING: Check local legislation forlegal requirements.

Details of vehicle kerb mass and payloadcapacities can be provided by your local NationalSales Company representative.

1.11.4 Front, Rear and Side Under-runProtection

WARNING: Check local legislation forlegal requirements.

Front Under run Protection, Rear Under runProtection and Side Under run Protection mustmeet the requirements of local design rules.


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1.12 Hardware—SpecificationsMaterial Specification, Strength and Torque

Standard Hardware and Tightening Torques (Nm) Bolts/Studs: ISO 898-1, Nuts: ISO 898-2Grade 10.9Grade 8.8Grade 4.8

MaximumMinimumMaximumMinimumMaximumMinimumThread Size3.42.41.41.1M46.74.92.72.2M5

15.011.011.58.54.73.7M635.025.028.020.0M870.050.055.041.0M10125.095.092.068.0M12200150153113M14

310.0230.0230.0170.0M16399.4317.5317.0252.0M18541.8434.7430.0345.0M20743.4592.2590.0470.0M22945.0756.0750.0600.0M24

This torque chart is a recommendation and the converter is responsible for the optimal torque for aspecific joint.


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1.13 Load Distribution—Specifications

1.13.1 Load Distribution Calculations- Driver and Passenger WeightDistribution

CAUTIONS:Do not exceed the axle ratings.

Do not exceed the gross vehicle mass.

Tire manufacturer specification must bemaintained.

NOTE: Uneven load distribution could result inunacceptable handling and brakingcharacteristics.NOTE: Over loading of the vehicle could result inunacceptable ground clearance.NOTE: The center of mass of the body equipmentand the payload it contains should be locatedwithin the dimensions given.NOTE: Avoid one-sided load distribution.NOTE: For further information please contactyour local National Sales Company representative,or local Ford dealer.


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Single Cab

1

B

A

E278314

Single Cab Driver and Passenger Weight Distribution

Weight distribution per person (Kg)'B' Front rowseats and driver

(mm)

'A' Wheelbase(mm)

TotalOn Rear AxleOn Front Axle75354014903220


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Super Cab

E278316

1

BC

A

Super Cab Driver and Passenger Weight Distribution

Weight distribution per person (Kg)'C' Secondrow seats

(mm)

'B' Front rowseats and

driver (mm)

'A' Wheelbase(mm)

TotalOn Rear AxleOn Front Axle753540-149032207551242180--


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Double Cab

E278315

1

B

CA

Double Cab Driver and Passenger Weight Distribution

Weight distribution per person (Kg)'C' Second rowseats (mm)

'B' Front rowseats and

driver (mm)

'A' Wheelbase(mm)

TotalOn Rear AxleOn Front Axle753540-149032207554212310--

1.13.2 Center of Gravity

NOTE: Calculations shown are not inclusive oftow bar and other dealer fitted accessories.The following charts define the recommendedCentre of Gravity Position for the mass added tothe vehicle by the vehicle converter.

"Added mass" includes all added body equipmentand cargo, but excludes passengers seated instandard cab seating.For double cab vehicles, there is a limit to theadded mass that must be observed, in addition tonot exceeding the gross axle and train weights.


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Single Cab

E278317

1

B

A

C

Single Cab Center of Gravity Critical Zone

Recommended C of G location for added massModel'C' Max (mm)'B' Max (mm)'A' Min (mm)

740322019654x2590343519654x2*

590343519654x4* 4x2 vehicles with increased ride height


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Super Cab

E278319

1

B

A

C

Super Cab Center of Gravity Critical Zone


740322023954x2590343523654x2*



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Double Cab

E278318

1

B

A

C

Double Cab Centre of Gravity Critical Zone

Max gross addedmass (kg)


700740361525854x2625590361524354x2*



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1.14 Towing

1.14.1 Towing Requirements

When a towing device is required, the VehicleConverter should use a Ford approved tow bar.Refer to: (page ?).Load Distribution.Refer to: Jacking (page ?).

1.14.2 Towing

WARNINGS:Do not exceed the Gross CombinationMass (GCM) or towing capacities for yourspecific vehicle. Refer to the vehiclesowner guide for specifications related tothe towing capacities and local regulatorystandards.Ensure that the trailer towball downloadweight falls within the specified range.Towing trailers beyond the maximumrecommended gross trailer weightexceeds the limit of your vehicle andcould result in engine damage,transmission damage, structural damage,loss of vehicle control, vehicle rolloverand personal injury.Do not cut, drill, weld or modify the trailerhitch. Modifying the trailer hitch couldreduce the hitch rating.Do not exceed the maximum vertical loadon the tow ball. Failure to follow thisinstruction could result in the loss ofcontrol of your vehicle, personal injury ordeath.

For towing devices fitted by the Vehicle Converterthe following applies:• Towing capacities must not exceed those of

the unmodified vehicle.• Any modifications to the vehicle must be noted

in the vehicle owner guide descriptive literatureincluded with the owners documentation.

• Tow bar installations must meet therequirements of the local regulatory standards.

• Whenever frame drilling is necessary use tubereinforcement.Refer to: 5.5 Frame and Body Mounting (page

94).

1.14.3 Towing Capacities andSpecifications

NOTE: Refer to the vehicles owner guide forspecifications related to the towing capacities andlocal regulatory standards.


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2.1 Suspension SystemWARNINGS:

Do not modify, drill, cut or weld anysuspension components, specifically thesteering gear system, subframe oranti-roll bars, springs or shock absorbersincluding mounting brackets.The rear leaf springs are pre-stressed inmanufacture and should not be alteredfor rate or height in any way duringvehicle conversion. Adding or removingleaves may result in failure or reducedfunction of the spring as well as othervehicle related issues for which FordMotor Company cannot be heldresponsible.

CAUTIONS:Modifications to the suspension systemcan cause a deterioration of the vehiclehandling characteristics and durability.When carrying out welding work thesprings must be covered to protect themagainst weld splatter.Do not touch springs with weldingelectrodes or welding tongs.

NOTE: Do not modify the wheelbase or add anytype of frame extension to vehicles fitted withElectronic Stability Program (ESP).NOTE: Do not damage the surface or corrosionprotection of the spring during disassembly andinstallation.NOTE: Do not add any additional axles.


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2.2 Brake System

2.2.1 General

The Brake System must be fully functional whenthe vehicle conversion is completed. The vehiclebrake operating modes must be checked, includingwarning system and parking brakes.

WARNING: Do not restrict the airflow andcooling to the brake system.

NOTE: Do not obstruct the view of the brake fluidreservoir level.The brake fluid reservoir must remain accessiblefor servicing and for adding brake fluid.

2.2.2 Brake Hoses

CAUTION: Make sure that the front andrear brake hoses are not twisted and arecorrectly located away from body andchassis components.

Front and rear brake hoses must not rub, chafe orrest on body or chassis or body components. Theremust be clearance under all operating conditions,between full compression and extension and fulllock to lock.Brake lines must not be used to support or secureany other component.

2.2.3 Trailer Brakes

WARNING: A pre-installed trailer brakewire provides a pulsed brake signal ofvarying frequencies. This pulsed signal isnot a direct current (DC) signal. TheFord-approved FLA Trailer BrakeController (p/n VGB3Z2C405E) iscompatible with these pulsed signals. Ifanother aftermarket brake controller isinstalled, the vehicle owner or installermust ensure that it is compatible with allpulsed signals from the pre-installedtrailer brake wire. Failure to ensurecompatibility of your brake controller mayresult in loss of vehicle control, whichcould result in serious injury or death. Ifclarification is required on thespecifications of the pulsed signals,please contact your Authorised FordDealer.

NOTE: Ford new-vehicle warranty is provided forthe Ford Licensed Accessory (FLA) Trailer BrakeController (TBC) when it is fitted to the vehicle bya Authorised Ford Dealer (Part NumberVGB3Z2C405E). Ford is not responsible forwarranty and performance of other aftermarketbrake controllers which are not approved by Ford.

Trailer Brake Connection

E275788

NOTE: RHD (right-hand drive) shown, LHD(left-hand drive) similar.

A pre-installed wire is located behind the A-Pillarkick panel and is marked TRAILER BRAKECONTROLLER.


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Contact your Authorised Ford Dealer for furtherinformation on Ford Licensed Accessories and theFord Approved Trailer Brake Controller.


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3.1 Fuel SystemWARNINGS:

Make sure that the modified vehiclecomplies with all relevant legalrequirements.Do not remove or relocate the fuel cooler(if equipped) when modifying the vehicle.

CAUTIONS:Ensure modifications to vehicle do notobstruct airflow to fuel cooler.Make sure that sufficient clearance ismaintained for all driving conditions toall hot and moving components.Make sure that there are no sharp edges,including fasteners, pointing towards anyfuel system component.The fuel filler pipe must be supported inaccordance with the guidelines in thissection.Transport Mode includes a calibrationfeature to reduce the risk of fuel injectornozzle corrosion. Exiting TransportationMode prior to upfitting/ conversionincreases the risk of early life injectorfailure.

Procedure for protection from Injector NozzleCorrosion During the Upfitting/Conversion Process:Refer to: 1.9 Vehicle Transportation Aids and

Vehicle Storage (page 15).

3.1.1 Fuel Filler Pipe Shipping Bracket(if equipped)

CAUTION: The fuel filler pipe shippingmounting bracket on cab chassis vehiclesis designed for shipping of the vehicleonly.

The fuel filler pipe shipping bracket fitted to cabchassis vehicles is designed to be removed oncethe body or tray is fitted to the vehicle. The bodyor tray must include a fuel filler mounting thatcomplies with the guidelines in this section. Theshipping bracket can be left installed on the vehicleif desired, but only if an additional fuel filler pipemounting bracket is used in accordance with theguidelines in this section.

Fuel Filler Pipe Shipping Bracket - Single Cab

E145838


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Fuel Filler Pipe Shipping Bracket - Super Cab

E145839

Fuel Filler Pipe Shipping Bracket - Double Cab

E213151


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3.1.2 Fuel Filler Mounting

CAUTION: Make sure that the filler neckmounting bracket is made of a conductivematerial, and that it provides a groundingpath for the fuel filler neck.

If the vehicle body and mounting bracket does notprovide a grounding path for the fuel filler neck, anearth strap must be added, connecting the fillerneck to the chassis frame.

Fuel Filler Mounting Bracket

E145833

A

1

Fuel Filler Mounting NotesDescriptionItem

The width of the bracket, where it joins the body to be at least 180 mmAAll 3x hardware fixation points on the filler neck must be utilised1


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Angle of Filler Neck

AB

E145836

A

Filler Neck Installation DimensionsDescriptionItem

2mm minimum bracket thicknessA30° - angle to be maintained to ensure good flow of fuel when refueling and prevent flow back.B


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Clearance From Vehicle Body

A

E145835

DescriptionItemAt least 9mm clearance between the fuel filler cap and vehicle body, in the worst case openingangle if applicable

A

3.1.3 Fuel Filler Vent Hose

• The fuel tank vent hose and breather capshould be rerouted from the shipped positionto the position described in this document inorder to maintain water wading specificationsand prevent water ingress into the fuel system.

• The supplied fuel tank breather cap must beused.

• A length of fuel grade flexible hose should beclipped to the vehicle body, with the open endat least 600 mm (4x2) or 800 mm (4x4 or 4x2hi-rider) above ground height. It isrecommended to measure this height when thevehicle is fully loaded.

• The fuel tank vent hose should be protectedand positioned away from direct water spray,wheel splash and mud splash, and waterdrainage holes that may be present.

• The fuel tank vent hose breather cap must beupright with its arrow pointing UP.

Fuel Filler Vent Breather Cap

E212453

NOTE: See your authorised dealer to confirm thecorrect part number for your vehicle.


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Example of Fuel Tank Vent Hose Mounting Location

E212452

2

1

DescriptionItemFront Lower Head Board of a Load Tray (load tray rotated for clarity)1Fuel Tank Vent Hose2

3.1.4 Long Range Fuel Tanks

NOTE: Long Range Fuel Tanks are not engineeredby Ford Motor Company and Ford Motor Companymakes no determination as to the fit, finish, qualityor durability of these parts.NOTE: Whilst functionality will be improved bythis modification, distance to empty calculationsmay express some discrepancy compared tostandard parts and calculations.Following installation of a long range fuel tank,distance to empty (DTE) functionality will bereduced.To improve system functionality, using IDS/FDRSas appropriate:• Plug IDS/FDRS into vehicle• Allow IDS/FDRS to read parameters and show

applicable menus• In Configuration Parameter; Select Fuel Tank

Capacity Volume (Tank Size A);• Select appropriate option following the

dialogue selections: Fuel Tank Capacity >Configuration Description– Standard 80L– 140L ARB Long Range Tank

3.1.5 Axle Breather Vent Hose

The rear differential breather hose should bemounted to the filler neck/vehicle body. Whererequired due to the fitment of an auxiliary body,aftermarket additions, or the relocation of the fuelfiller, the axle vent hose routing must follow therelocated fuel tank venting. A length of fuel gradeflexible hose should be clipped to the vehiclebody, with the open end at least 600 mm (4x2)or 800 mm (4x4 or 4x2 hi-rider) above groundheight. It is recommended to measure this heightwhen the vehicle is fully loaded. A vent breathercap may be used on the axle breather vent hose.


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4.1 Wiring Installation and Routing Guides

4.1.1 Wiring Splicing Procedures

TYCO-RAYCHEM crimp splices

E131081

Ford Motor Company strongly advises against theuse of wire splicing due to the variable andunpredictable nature of the joint created. However,if it is decided that a wire splice is unavoidable, itmust be made using DuraSeal Heat-Shrinkable,Environmentally Sealed, Nylon-InsulatedCrimp Splices (manufactured byTYCO-RAYCHEM). For example the D406 series.As a further process to improve the splice integrity,the splice should be further sealed with a suitableheat shrink tubing. See Figure E131081.


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4.2 Battery and Cables

4.2.1 Battery Information

If a battery is disconnected, there is norequirement to reprogram the vehicle; the vehicleretains its ‘normal’ power management settingand remembers exactly what its previousconfiguration was (although the central lockinglatches may cycle if a door or lock latch wasopened manually in the intervening period). Allradio settings will be retained, but the key codeneeds to be entered to restore functionality. Theclock will need resetting. The window controlmodule will also need to be reset. Refer to thevehicles owner manual for further information.

Battery Voltage Requirements andTesting

All voltages are to be measured with an accuracyof: + /– 5% of published values.To maximize battery life, at the time of arrival atthe vehicle converter, all batteries must have aminimum Open Circuit Voltage (OCV) of not lessthan 12.75 volts.When the battery is installed and connected tothe vehicle's electrical system with no load, theClosed Circuit Voltage (CCV) must not be lessthan 12.65 volts. When the vehicle is released tothe customer, the CCV must not be less than 12.50volts.

Surface Charge Dissipation

Prior to carrying out manual voltage checks, it isnecessary to establish that the battery voltage isstable and free from surface charges that couldbe present due to certain engine run conditionsmaking the voltage readings unreliable andinaccurate.To ensure surface charges are not present thefollowing actions are recommended:1. Turn on the headlamps for 5 seconds, or the

parking lamps for 15 seconds.2. Turn off all electrical loads (including lamps,

fan, heater etc).3. Wait 10 minutes.

Delayed Vehicles

Vehicles held at the vehicle convertor premisesand not in use for longer than 4 days, should havethe battery's negative cable disconnected. Beforeshipping to the customer, the battery negativecable must be re-connected and the voltagere-checked. The voltage should be not less than12.5 volts.

Battery Charging Procedure

WARNINGS:Always observe the battery chargerequipment manufacturer’s instructions.Do not jump/slave start using a batterycharging system from another vehicle.Do not overfill a battery as this can causeacid leakage that will result in damageto the vehicle and possible personalinjury.

CAUTIONS:Do not rely on the generator to rechargea discharged battery. It would take inexcess of eight hours of continuousdriving with no additional loads placedon the charging system.Make sure that the battery electrolytereaches the indicated maximum mark.Connect the battery charger cables to thebattery before switching the batterycharger on.Switch the battery charger off beforedisconnecting the battery charger cablesfrom the battery.

NOTE: Ford batteries generally require nomaintenance however, in certain conditions, it ispossible for the electrolyte in a battery to fallbelow the minimum level.NOTE: The use of the Midtronics GR-590 BatteryManagement Center, which has been specificallydesigned for use on silver calcium type batteriesis recommended. Once connected to the battery,the battery charger detects the state of batterycharge and then applies the appropriate chargerate and duration. When the battery is fullycharged, the battery charger switches to stand-by,keeping the battery in a fully charged statepreventing excessive gassing and overcharging.The Midtronics GR-590 Battery ManagementCenter also incorporates a software program thathas the capability to assist in the recovery ofdeeply discharged (sulphated) batteries.NOTE: Charging methods and types of batterychargers vary widely. Whichever method is utilizedit must be carried out carefully to avoid damageto the battery and possible personal injury.Specific instructions accompanying each batterycharger and must be followed exactly. Safeguardsprovided by the equipment manufacturer shouldnot be disregarded by the operator.NOTE: A battery which has been stored in a highlydischarged state may be slow to accept a chargeat first. In such cases the initial charging rate maybe so low that the ammeter on some batterytesters will not show any indication of charge for5 to 10 minutes.


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NOTE: Automatic battery chargers are alsoprotected against reverse polarity connection andrequire no adjustment or monitoring.NOTE: Slow-charging will readily restore a batteryto a full state of charge and, since the chargingcurrent is relatively low, the possibility ofovercharging a battery are minimized. The chargerate used should be approximately equal to 5%of the reserve capacity of the battery beingcharged (approximately three to six Ampsdepending on battery size). The charging currentshould be adjusted 10 minutes after initial settingand again after 1 hour before being left to chargethe battery for between 8 and 12 hours.NOTE: A constant voltage battery charger willcharge a battery at a set maximum voltage. Thevoltage used depends upon the design andcondition of the battery charger and the age andtemperature of the battery. This type of batterycharger initially charges at a high rate of currentthat reduces as battery voltage is restored. Whenusing a constant voltage battery charger, thecharging current should be recorded after fiveminutes and the battery charger switched off whenthe charging current falls to one–third of therecorded value, or after eight hours whicheveroccurs first.NOTE: Multiple battery chargers are designed tocharge a number of batteries, simultaneously. Ofthe two different types of multiple battery chargersavailable, only those that charge batteries in seriesshould be used and it is important that batteriesare of the same or very similar ratings and voltages.Multiple battery chargers that charge batteries inparallel are not recommended.NOTE: The use of a fast (boost) battery chargeris not recommended as it can cause damage to abattery. Fast charging will only restore a batteryto a state of charge that will enable it to carry outit’s critical function of cranking the engine. Fastcharging will not restore a battery to a full state ofcharge and must therefore be followed by a periodof slow charging. Excessively fast charging cancause damage to a battery. For this reason,charging times must be carefully controlled. Fastbattery chargers vary widely in design so it is veryimportant to strictly adhere to the equipmentmanufacturer’s instructions. A charge of 30 ampsfor up to 30 minutes is the most common fastcharging application. If the battery is verydischarged and requires additional restoration, anadditional charge of 20 amps for a period up toone and a half hours should be applied. Fastcharging for a period in excess of two hourssignificantly increases the risk of causing damageto the battery.

NOTE: When connecting and disconnecting thebattery from the vehicle, make sure that thebattery ground cable is disconnected first andconnected last and that all electrical items areswitched off. Record the audio unit keycode andpreset radio frequencies before disconnecting thebattery.1. Remove the battery.2. Disconnect the battery ground cable

DTZ9722102

40 mm

NOTE: The maximum battery electrolyte level isapproximately 40 mm below the very top of thebattery casing. This corresponds to a point justbelow the lower rim of the battery casing.3. Check that the battery electrolyte reaches the

indicated maximum level. Top up withdistilled/de-ionized water, as necessary.

4. Connect the positive red clamp from the batterycharger to the positive battery terminal.

5. Connect the negative black clamp from thebattery charger to the negative battery terminal.

6. Follow the instructions supplied with thebattery charger to charge the battery.

7. To disconnect the battery charger, reverse theconnection procedure.

Battery Cable Fixing Torque

The battery cables should be fixed to the terminalposts with a torque of 4.8 Nm -/+ 0.8Nm.

Battery Rules:

WARNINGS:For vehicles fitted with non-sealedbatteries (non-maintenance free), it isessential that regular checks are made todetermine that the electrolyte (acid)levels are correctly maintained.When charging, ensure the batterycharger is securely connected to thevehicle ground and not to the batterynegative terminal. This is to ensure thatthe BMS identifies the battery charge.

• For external charging of batteries ensure thatthe maximum voltage of 14.6V is not exceeded.


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Battery Part Numbers and Usage

SizeSpecificationsTypeFord PlantH775Ah, 750CCAStandard Duty

BatteryThailand

H780Ah, 800CCA, AGM Deep Cycle TechnologyAuto Start -Stop Battery

If the battery type on a vehicle is changed to othercompatible derivatives it is required to reconfigurethe vehicle to the new battery types from thedealer. Central car configuration can be updatedat a dealership.

Battery Monitor System (BMS)

Low Level Vehicles

E181583

High Level Vehicles

E223579

Ford Ranger vehicles are equipped with a featurecalled Battery Monitor System (BMS). This systemmeasures the battery load in order to efficientlycharge the battery while improving fuel economyand emissions.It is important to ensure any additional electricalload or accessory is properly grounded to thevehicle’s body, in order for the system to identifythe additional load. If a connection is made to thebattery negative terminal, the BMS will not identifythe load or charge. This may cause the battery tobe undercharged and consequently not able tore-start the vehicle.

Auxiliary Battery fitted to vehicles witha Battery Monitor System (BMS)

NOTE: The addition of an auxiliary battery in avehicle with BMS would cause both batteries tonot reach a state of full charge. The system willonly allow charging of the batteries duringdeceleration. Refer to Dual Batteries with BatteryMonitor System (BMS) in this section.NOTE: Disabling the BMS will negate the fueleconomy benefit provided by the BMS.NOTE: Auxiliary loads must always be connectedto the vehicle ground and not to the batterynegative terminal.NOTE: Ensure the auxiliary battery connection issafely secured using suitable fixtures to reducevibration damage or contact with surroundingcomponents.For vehicles equipped with BMS, an additionalbattery can be connected using one of thefollowing methods:1. Use an in-vehicle battery charger (DC/DC

converter) such as BCDC1220 model fromRedarc (www.redarc.com.au) (or similar),connected via an additional terminal to thestarter post terminal on the B+ using a 30Afused connection and grounded to the vehiclebody, in the shown locations.

NOTE: The additional terminal must be installedon top of the starter post terminal using theexisting nut.NOTE: The maximum thickness of the additionalterminal being installed on top of the starter postterminal must be no more than 2.0 mm.NOTE: Ensure the existing nut is reused.

B+ Connection for Auxiliary Battery Charging

E251317

The B+ connection should be fixed to the terminalposts using the existing nut with a torque of 13.5Nm -/+ 2.1 Nm.


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NOTE: Ensure the fused connection is securedusing suitable fixtures to reduce vibration damageor contact with surrounding components.

Grounding points for in-vehicle battery charger

E251326

DescriptionItemPossible ground connection points using W705661-S901.1

The ground point connection should be tightenedto torque of 12 Nm -/+ 1.8 Nm.2. Request a Ford dealer to disable the BMS.

Disabling the BMS enables voltage sensitiverelay based dual battery systems to work.

Auxiliary Battery fitted to vehicleswithout a Battery Monitor System (BMS)

NOTE: Auxiliary loads must always be connectedto the vehicle ground and not to the batterynegative terminal.NOTE: Make sure the fused connection is safelysecured using suitable fixtures to reduce vibrationdamage or contact with surrounding components.An auxiliary battery charging system can beconnected using one of the following methods:1. Use an in-vehicle battery charger (DC/DC

converter) such as BCDC1220 model fromRedarc (www.redarc.com.au) (or similar),connected via an additional terminal to thestarter post terminal on the B+ using a 30Afused connection and grounded to the vehiclebody, in the shown locations.

NOTE: The additional terminal must be installedon top of the starter post terminal using theexisting nut.NOTE: The maximum thickness of the additionalterminal being installed on top of the starter postterminal must be no more than 2.0 mm.NOTE: Ensure the existing nut is reused.

B+ Connection for Auxiliary Battery Charging

E251317

The B+ connection should be fixed to the terminalposts using the existing nut with a torque of 13.5Nm -/+ 2.1 Nm.


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NOTE: Make sure the fused connection is securedusing suitable fixtures to reduce vibration damageor contact with surrounding components.

Grounding points for in-vehicle battery charger

E251326

DescriptionItemPossible ground connection points using W705661-S901.1

The grounding point connection should betightened to torque of 12 Nm -/+ 1.8 Nm.

Connection of Auxiliary Loads - Low LevelVehicles

WARNINGS:Make sure all electrical connections andwiring comply with local regulatorystandards.Under no circumstances should anyunfused connections be made directly toany of the vehicle's battery terminals.An increase in battery drain due to anauxiliary load will void the batterywarranty.

NOTE: Auxiliary loads must always be connectedto the vehicle ground and not to the batterynegative terminal.

• For auxiliary customer electrical loads, asuitable fused connection must be used.

• If multiple auxiliary loads are required, it isrecommended that an auxiliary fuse box isfitted to the vehicle.

• For the connection of auxiliary exterior lighting,refer to the guidelines given in the exteriorlighting section.Refer to: Exterior Lighting (page ?).

Auxiliary loads for external devices which requirean ignition feed (such as UHF/CB radios) may beconnected via a relay energised by the IG+ feedto the Body Control Module.

WARNING: Under no circumstancesshould the IG+ feed be used to driveauxiliary loads directly. A suitable relaymust be used.

The Body Control Module is positioned on thedriver's side of the vehicle underneath the dashpanel.


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IG+ Connection at Body Control Module

1

2

1

E211057

2

DescriptionItemBody Control Module1IG+ Feed2

Connection of Auxiliary Loads - High LevelVehicles

WARNINGS:Make sure all electrical connections andwiring comply with local regulatorystandards.Under no circumstances should anyunfused connections be made directly toany of the vehicle's battery terminals.

NOTE: Auxiliary loads must always be connectedto the vehicle ground and not to the batterynegative terminal.

• For auxiliary customer electrical loads, asuitable fused connection must be used.

• If multiple auxiliary loads are required, it isrecommended that an auxiliary fuse box isfitted to the vehicle.

• For the connection of auxiliary exterior lighting,refer to the guidelines given in the exteriorlighting section.Refer to: Exterior Lighting (page ?).

Auxiliary loads for external devices which requirean ignition feed (such as UHF/CB radios) may beconnected via a relay energised by a IG+ feed tothe Body Control Module.

WARNING: Under no circumstancesshould the IG+ feed be used to driveauxiliary loads directly. A suitable relaymust be used.

The Body Control Module is positioned on thedriver's side of the vehicle underneath the dashpanel.


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IG+ Connection at Body Control Module

E223580

1

2

DescriptionItemBody Control Module1IG+ Feed2

Part Numbers

ManufacturerPart Number / ServicePart Number

Description

TE (Tyco Electronics)CU5T-14489-XAConnectorMolex7C3T-14474-DA / DU2Z-

14474-DAPin

4.2.2 Generator and Alternator

Alternator Current Output

See your local authorised dealer to identify thealternator output current specifications for yourvehicle.


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4.3 Parking AidWARNINGS:

To help avoid personal injury, always usecaution when in reverse (R) and whenusing the sensing system.The system may not detect objects withsurfaces that absorb reflection. Alwaysdrive with due care and attention. Failureto take care may result in a crash.Traffic control systems, inclementweather, air brakes, external motors andfans may affect the correct operation ofthe sensing system. This may causereduced performance or false alerts.The system may not detect small ormoving objects, particularly those closeto the ground.

NOTE: Keep the sensors, located on the bumperor fascia, free from snow, ice and largeaccumulations of dirt. If the sensors are covered,the system’s accuracy can be affected. Do notclean the sensors with sharp objectsNOTE: If your vehicle sustains damage to thebumper or fascia, leaving it misaligned or bent, thesensing zone may be altered causing inaccuratemeasurement of obstacles or false alerts.

NOTE: Certain add-on devices installed aroundthe bumper or fascia may create false alerts. Forexample, large trailer hitches, bike or surfboardracks, license plate brackets, bumper covers orany other device that may block the normaldetection zone of the system. Remove the add-ondevice to prevent false alertsThe parking aid sensing system warns the driverof obstacles within a certain range of your vehicle.The system turns on automatically whenever youswitch the ignition on. The system can be switchedoff through the information display menu or fromthe pop-up message that appears once you shiftthe transmission into reverse (R). If a fault ispresent in the system, a warning message appearsin the information display. See the vehicle ownermanual for further information on the correctoperation of the parking aid system.Protection assemblies mounted on the front ofthe vehicle, such as Bull Bars/Nudge Bars andfrontal crash and animal strike protectionassemblies may require that the front parking aidsensors are relocated to a different position thanthe original Ford positioning. The below guidelinesand details should be followed to maintainsuitable operation of the parking aid system byensuring the sensor detection angles aremaintained in a suitable specification.Where possible, front parking aid sensors shouldnot be moved from the original positions on the X,Y and Z plane. Maintaining the sensors locationon these planes is important for correct operationof the system.


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Vehicle Location Planes

X

E292617

Z

Y

X

E292617

Z

Y

4.3.1 Sensor Location

NOTE: Relocated sensors must be installed inthe same position as originally fitted in the bumperbar. Make sure that each sensor is installed in thecorrect corresponding position.


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49

Front Parking Aid Sensor Location

1 4321 432

E292623

NumberSensor1Front Right Outer2Front Right Inner3Front Left Inner4Front Left Outer

Front Parking Aid Sensor - Critical Angles and Heights

Inner Sensor HeightOuter SensorAngle

Inner Sensor HeightInner SensorAngle

N/Awithin range of 2-4degrees*

Less than or equal to 440mmabove the ground

within range of 2-4degrees*

* degrees above the horizontal plane.


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4.4 Electronic Engine Controls

4.4.1 Vehicle Speed Output (Signal)(Low Level Vehicles Only)

General Information

WARNING: Do not interface with the CAN(controller area network) for vehiclespeed.

NOTE: A hard-wired vehicle speed signal isavailable if integration is required.NOTE: The vehicle speed signal is a direct currentcoupled square wave that varies in frequency inproportion to vehicle speed. This provides a squarewave-form (50% duty cycle) signal.

Circuit hardware

E180281

Square Wave Characteristics - Output signal

Sunroof Taxi Speed OutputSignal RequirementsBattery VoltageMaximum High Signal3.67 VoltsMinimum High Signal1.1 VoltsMaximum Low Signal-1.1 VoltsMinimum Low Signal+/- 1.0 VoltsMaximum Ground Offset10μ sec <= tr <= 250μ secRise Time10μ sec <= tf <= 250μ secFall Time50% +/- 10%Duty Cycle1.38 * v (Vehicle speed (CAN) km/h) ± 2%between 1km/h - 250km/h

Frequency

1.38 Hz (1 kmph)Minimum speed<0.3%Linearity error398 HzMax frequency1 k ohmsRload


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Instructions for connection

1. The vehicle speed output is available on:[connector 3 pin number 52] or [connector 4pin 3]. Choose one of the connections andpopulate the connector with a terminal andwire.

2. The output must be connected to a device with1k ohms resistance (600 ohms to 2k ohms isthe guideline) in order for it to work. Thisprotects the BCM (body control module) fromovercurrent risk.

3. The output must be connected to a powersource.

4. Once the device is connected, reset the BCMby disconnecting the vehicle battery.

5. Reconnect the vehicle battery.6. Turn the ignition ON.7. The signal should now be available.NOTE: Rload should be present and connectedto battery voltage for this function to work.

For Information Only

Terminal part number: 96AG-14474-RSA.Wire size and color: 0.5 CSA, blue - green.


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Terminal Insertion

E180282

1 2

DescriptionItemConnector C3 Pin 521Connector C4 Pin 32

1. Connector C3 or C4 need to be unplugged inorder to insert the speed signal terminal.

2. Once the connector C3 or C4 is removed, thegrey cap needs to be removed by first removingthe cable tie, and then levering up the twodetents on the sides; the cap can then be slidoff.


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E180283

E180284

E180285


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E180286

3. There is a red terminal latching plate thatneeds to be removed.

E180287

4. Insert the wire with terminal into cavity C3: 52or C4: 3 – there is a tab on the terminal thatshould allow this to be inserted one way only.

E180293


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55

5. Slide back the terminal latching plate, refit thegrey cap (and refit the cable tie as required),

and plug both connectors back into the BCM.Refit any shields/covers.

E180294

E180295

E180296


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4.4.2 Vehicle Speed Output (Signal)(High Level Vehicles )

WARNING: Do not attempt to take aspeed signal output form high levelvehicles.

A solution to take a speed signal output from theBCM on high level vehicles is not currentlyavailable.


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57

4.5 Exterior LightingWARNINGS:

Make sure that the modified vehiclecomplies with all local regulatorystandards.Make sure all electrical connections andwiring comply with local regulatorystandards.

NOTE: Chassis Cab vehicles are supplied with rearcombination lamps, license plate lamps and foglamps. Where fitted, these lamps must bemounted in accordance with the followingguidelines.

NOTE: Prior to work on any vehicle beingundertaken it is critical to identify the vehicle level(low level or high level) by the type of electricalarchitecture the vehicle at hand is equipped with.Failure to identify the type of electrical architecturepresent on the vehicle prior to work beingundertaken may cause electrical damage or havesafety implications.Refer to: 4.7 Fuses and Relays (page 70).


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4.5.1 Rear Combination lamps

A B

D

C

G

E

F

A B

D

C

G

E

F

E141460

Positioning of Rear Combination Lamps

DimensionDescription250mmMinimum distance from ground to lower edge of lampA1200mmMaximum distance from ground to upper edge of lampB

15°Minimum angle of obstruction free zone downwards of the lampC15°Minimum angle of obstruction free zone upwards of the lampD80°Minimum angle of obstruction free zone towards the outside of

the vehicleE

45°Minimum angle of obstruction free zone towards the centre of thevehicle

F

400mmMaximum distance from outer edge of vehicle to inner edge oflamp

G

4.5.2 Rear Fog Lamp

NOTE: Where only one rear fog lamp is fitted, itmust be positioned on the vehicle centre line, orto the drivers side of the vehicle.


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59

AB

AB

D

C

E

F

E141472

Positioning of Rear Fog Lamp

DimensionDescription250mmMinimum distance from ground to lower edge of lampA

1000mmMaximum distance from ground to upper edge of lampB5°Minimum angle of obstruction free zone downwards of the lampC5°Minimum angle of obstruction free zone upwards of the lampD

25°Minimum angle of obstruction free zone towards the outside of thevehicle

E

25°Minimum angle of obstruction free zone towards the centre of thevehicle

F

4.5.3 Rear License Plate Lamp


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E

D

E

D

E141462

C

B

A

Positioning of Rear License Plate Lamp

DimensionDescription35mmDistance from rear face of license plate to centre of lamp along

lamp mounting faceA

10°Angle between license plate and lamp mounting faceB35mmDistance between top of rear face of license plate and lamp

mounting faceC

175mmDistance between license plate centre line and centre of lampD175mmDistance between license plate centre line and centre of lampE


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4.5.4 Reversing Lamps, Rear ViewCamera, Reversing Alarm (ManualTransmission)

The reverse lamps are activated by the reverseswitch on the transmission, through connectorC169 to the Central Junction Box where the signalis sensed. A marginal increase in current (via a relayor buffered electrical input) is permissible toprovide power to a rear-view camera, auxiliaryreverse lighting, or an audible warning device.

4.5.5 Additional External Lamps -(Low Level Vehicles Only)

When installing auxiliary tail lamps, Fordrecommends that power is provided via the trailerplug control module and associated circuitry. Referto Trailer Towing for additional information.For all other additional exterior lamps, power mustbe taken through an auxiliary fuse box with asuitable switch and / or relay as required.

WARNING: Directly splicing into thevehicle wiring in order to install auxiliarylamps or other electrical devices mayoverload the system and impact theoperation of other vehicle systems.

When installing auxiliary driving lights, power canbe provided via a relay energised by the headlampfeed.

E210761

1

2

DescriptionItemLow beam1High beam2

Lighting FusesHeadlamp10AF20Front fog lamp15AF75Reversing lamp10AF76


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4.5.6 Trailer Towing

Vehicles with a factory fitted tow bar also comewith a trailer tow module for lighting and theactivation of trailer sway control. In addition toproviding the trailer plug functionality, the trailertowing module protects the primary electricalcircuits of the vehicle from any electrical concernor failure that the customer's trailer mayexperience.NOTE: The trailer tow electrical kit is availablefrom your Ford authorised dealer.For vehicles fitted without a tow bar as standard,a genuine Ford accessory trailer tow electrical kithas been developed to enable a tow bar to beinstalled. The kit comprises of the trailer towingcontrol module, trailer plug, wiring and associatedhardware components.Once the kit is installed, the vehicle must then beconfigured using a Ford IDS diagnostic tool. Thisconfiguration can be performed by your Fordauthorised dealer.

WARNING: Installation of aftermarkettrailer tow electrical kits or directlysplicing into the vehicle wiring in orderto install trailer lamps or other electricaldevices may overload the system andimpact the operation of other vehiclesystems.

Ford recommends that all trailer tow electricalconnections use the genuine Ford accessory trailertow kit.

When fitting low power LED (light emitting diode)lamps that require less than 2W, the lamps mayflicker when in use. A trailer patch harness shouldbe used with low power draw LED lamps.

CAUTION: Do not connect the trailerpatch harness to the vehicle when thetrailer is not connected.

NOTE: The trailer patch harness is available fromyour Ford authorised dealer.NOTE: The trailer detect circuit is part of the FordTrailer Tow module, it can only be implementedon vehicles with power locking and perimeter orCAT 1 alarms.The Trailer Tow Module (TTM) can support pureLED trailer lamps as long as each circuit exceeds500mA, below this and the system will not detecta trailer has been connected and shuts down alloutputs (sleep mode). It is recommended totarget a 550mA minimum load to allow forsystem tolerances. This would need to beobtained with a supplemental load resistor, if theLED lighting circuits are below this threshold.Each output driver could handle a current of 15Abut it is not recommended to always run to thismaximum. A higher current is interpreted as shortcircuit. If a short circuit is detected the relatedoutput will be switched off. The following tableshows the recommended output maximums percircuit.NOTE: Not all features and outputs are supportedin all markets. Refer to your authorised Ford Dealerfor further information.


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Trailer Tow Module Connections- Low Level Vehicles

Voltage (V)Current (A)FeatureComponentTerminalNumber MaxMinMaxMin

Connector A-630.5Right Direction Indicator1

16910-Battery Charge Out - where used2-640.5Stop Left3----Not used4----Not used5-640.5Reverse Lamp6-640.5Stop Right7-620.5Fog Lamp8----Not used9-630.5Left Direction Indicator10----Not used11-670.5Position Lamp12

Connector B----Not used1

16630-Term 30 (Ubat)2Connector C

-60.1-CAN H1-60.1-CAN L2-60.1-Brake Line In (Vehicle -)3-61-Ground4

16-0.1-Trailer Detect Output5


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Trailer Tow Module Connections- High Level Vehicles

Voltage (V)Current (A)FeatureComponentTerminalNumber MaxMinMaxMin

Connector A-630.5Left Direction Indicator1-630.5Right Direction Indicator2-670.5Position Lamp3----Not used4-640.5Reverse Lamp5

16910-Battery Charge Out - where used6-640.5Stop Lamp7-620.5Fog Lamp8----Not used9----Not used10----Not used11----Not used12

Connector B----B(+) Fuse 87 (40A) BJB1----B(+) Fuse 73 (30A) BJB2

Connector C-61-Ground1-60.1-CAN L2-60.1-CAN H3----Not used4

4.5.7 Auxiliary Lighting Loads (LowLevel Vehicles Only)

NOTE: Connections for auxiliary lighting loadsmust be low and stable current draw.

Trailer Tow Module (if equipped)

Connections for auxiliary lighting loads can bemade via the trailer tow module (TTM) locatedunder the passenger seat. See Trailer Towing inthis section.

E223617


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TTM Connector - Detail

E231982

4.5.8 Lamps – Hazard / DirectionIndication

The maximum permissible load with the standardsystem is:• 3 x 5W – front and rear indicators + side

repeaters (Left Hand Side)• 3 x 5W – front and rear indicators + side

repeaters (Right Hand Side)

4.5.9 Electrically Operated DoorMirrors

WARNING: Do not tamper with the basesystem (controlled by Central JunctionBox and multiplex architecture) and anyfeeds taken from the associated wiringor controller.

NOTE: These options are not suitable foraftermarket or Body Builder fit.

4.5.10 Centre High Mount Stop Lamp(CHMSL) - Canopy Fitment -Low LevelVehicles

WARNING: The maximum current loadthat can be applied to the CHMSL circuitis 1.72A for incandescent globes, and0.38A for LED lamps. Do not exceed therated load.

NOTE: Disable the original vehicle mountedCHMSL if the canopy CHMSL is intended to be theprimary CHMSL.NOTE: The CHMSL circuit is pulse widthmodulated (PWM).NOTE: Check the operation of the CHMSL prior tocustomer handover.NOTE: When replacing the factory fitted CHMSLwith a canopy mounted CHMSL, the same typemust be used. Replace a bulb/incandescent typeonly with a bulb/incandescent. Replace and LEDtype only with an LED type.When installing a canopy equipped with a CHMSL,a feed for the CHMSL can be taken from the BCM(Connector 4, Pin 2).


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E229158

1

DescriptionItemBCM CHMSL Feed (Connector 4, Pin 2).1

4.5.11 Centre High Mount Stop Lamp(CHMSL) - Canopy Fitment - HighLevel Vehicles

WARNINGS:The maximum current load that can beapplied to the CHMSL circuit is 1.72A forincandescent globes, and 0.38A for LEDlamps. Do not exceed the rated load.Make sure all wiring is insulated androuted securely.

NOTE: The fitment of a canopy to high levelvehicles equipped with a combined CHMSL /Cargo Lamp requires that the cargo lamp featurebe disabled.

NOTE: Disable the original vehicle mountedCHMSL if the canopy CHMSL is intended to bethe primary CHMSL.NOTE: The CHMSL circuit is pulse widthmodulated (PWM).NOTE: Check the operation of the CHMSL priorto customer handover.NOTE: When replacing the factory fitted CHMSLwith a canopy mounted CHMSL, the same typemust be used. Replace a bulb/incandescent typeonly with a bulb/incandescent. Replace and LEDtype only with an LED type.


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67

When fitting a canopy to vehicles equipped witha combined CHMSL / Cargo Lamp, the lamphousing may be impacted by the canopy. Checkthe canopy to CHMSL clearance, and if required,follow the below procedure.A replacement CHMSL (without cargo lampfunction) needs to be installed. A patch harnesswith a 2-pin connector is then spliced into thevehicles CHMSL circuit wiring allowing a canopywith an integrated CHMSL to take a stop lampcircuit feed from the 2-pin connector. The original3-pin connector is then taped back.Follow the steps to install the replacement CHMSLlamp housing:1. Remove the combination CHMSL / Cargo Lamp

following the workshop manual instructions.NOTE: When cutting off the stop lamp circuit wiresfrom the 3-pin CHMSL connector, stagger the cutsto allow for cleaner and less bulky splice joins.2. Locate the 3-pin CHMSL / Cargo Lamp

Connector. Cut off the stop lamp circuits (pin 1yellow-grey or white-blue, pin 2 black-violet orblack-yellow or black-blue) leaving the violetwire (pin 3) connected to the 3-pin CHMSLconnector.

3. Tape back the 3-pin connector with the violetcoloured wire.

4. Splice the replacement 2-pin connector andpatch harness to the cut wires:1. Yellow + Grey wire (or alternate color - see

above ) to Yellow + Grey wire.2. Black + Violet wire (or alternate color - see

above ) to black + Violet wire.5. Insulate the spliced joins with heat shrink.6. Route the canopy CHMSL wiring through a

suitable grommet into the passengercompartment, route it behind the trim panelsand connect it to the replacement 2-pinconnector.

7. Install the replacement CHMSL to the vehiclefollowing the workshop manual instructions.


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4.6 Handles, Locks, Latches and Entry Systems

4.6.1 Central Locking

NOTE: Additional locks will not be covered by thevehicle alarm or operate BCM controlled lighting.The central locking function is controlled by theBCM (located under the instrument panel). Thevehicle locks are operated by surface mountedrelays in the BCM – these are only capable ofpowering one lock each.It is possible to add an additional lock(s) with theuse of relays triggered by the BCM outputs.

NOTE: The location of additional relays shouldbe considered carefully. A suitable mountinglocation away from the passenger compartmentwill allow for a safer install and reduced noise inthe passenger compartment.Depending on the functionality required, the pinsused will emulate the basic locking/unlockingoperation of an existing lock. The coil of theadditional relays (i.e. one relay for lock all, onerelay for unlock all) should be added across therelevant pin and a suitable ground point. Power(B+) for the additional relays should be takenfrom a suitably fused B+ feed.Relay selection for installation of an additionallock(s) must parallel the run time of th BCMsurface mount relays.

BCM Output for Central Locking (Low Level Vehicles)

FunctionFuseCircuitPinBCMCTRL MOD. - DOOR LOCK # ALL

LOCKBCM Fuse 70CPL111C2280E

CTRL MOD. - DOOR LOCK # ALLUNLOCK

BCM Fuse 70CPL138C2280E

BCM Output for Central Locking (High Level Vehicles)

FunctionFuseCircuitPinBCMCTRL MOD. - DOOR LOCK # ALL

LOCKBCM Fuse 24CPL1135C2280F

CTRL MOD. - DOOR LOCK # ALLUNLOCK

BCM Fuse 24CPL1332C2280F


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4.7 Fuses and Relays

4.7.1 Low Level and High LevelVehicles

WARNING: Prior to work on any vehiclebeing undertaken it is critical to identifythe type of electrical architecture thevehicle uses. Failure to identify the typeof electrical architecture present on thevehicle prior to work being undertakenmay cause electrical damage or havesafety implications.

This manual provides information that may or maynot apply depending on the exact vehicle modelthe vehicle converter is working on. The PX RangerMkII is built in varying specification levels, spreadacross two different electrical architecture types.Identification of which type a vehicle is equippedwith can be aided visually checking the passengercompartment fuse box.

Passenger Compartment Fuse Box - Low LevelVehicles

E133602

Passenger Compartment Fuse Box - High LevelVehicles

E225624

4.7.2 Auxiliary Battery and Fuse Box -Low Level Vehicles

NOTE: High level vehicles cannot be fitted withthe factory installed auxiliary battery and fuse box.An auxiliary battery and associated fuse box isavailable as an option on low level vehicles calleda Special Equipment Pack. The option code forthe Special Equipment Pack is AALSA. Theauxiliary battery and fuse box provides electricaloutputs for the addition of auxiliary electrical loadsto be supplied off the auxiliary battery.


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4.7.3 Auxiliary Fuse Box (Vehicles with Special Equipment Pack) (Low LevelVehicles Only)

Vehicles with a Load Box (Vehicles with Special Equipment Pack) (Low Level Vehicles Only)

E231508

1

DescriptionItemAuxiliary Fuse box1

Vehicles with Temporary Battery Carrier (Cab Chassis Variant Only) (Low Level Vehicles Only)(Vehicles with Special Equipment Pack)

E231507

1



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71

Cab Chassis Vehicles with Tray (Low Level Vehicles Only) (Vehicles with Special EquipmentPack)

E231509

1


Auxiliary Fuse Specification Chart

NOTE: On delivery of the vehicle, ensure Fuse F10is engaged into its location correctly. Fuse F10 isintentionally not fully engaged duringmanufacturing, to prevent depletion of the auxiliarybattery during shipping and transit.


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E174549

Protected ComponentsFuse AmpRating

Fuse

Driving lights251Position lamp152LED (light emitting diode) beacon lamp103Work lights154Spare205Power point206Reversing lamp157Direction indicators, stop lamp158Crew chief59Auxiliary battery 'disable' fuse (isolator ground).510Not used-11Not used-12

Relay Chart

Protected ComponentsRelay NumberWork lightsR1LED beacon lampR2SpareR3Position lampR4Direction indicator (left)R5Direction indicator (right)R6Stop lampR7Not usedR8Not usedR9


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5.1 Body

5.1.1 Body Structures - GeneralInformation

WARNING: All external or internalprojections must comply with localregulatory standards.CAUTION: Load carrying structuresshould not be mounted onto an existingload tray or load box.

When carrying out vehicleconversions/modifications the following pointsshould 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 theload evenly.

CAUTION: Uneven load distribution couldresult in unacceptable handling andbraking characteristics.

• Re-paint metal edges after cutting and drilling.All metal edges must comply with exterior andinterior protection local regulatory standards.

• All fixings through the floor, sides or roof mustbe sealed.

• Make sure that fixings in the 'B'-pillar area donot encroach on the seat belts or seat belt reels.

5.1.2 Integrated Bodies andConversions

WARNING: All wheelhouse envelopesmust comply with local regulatorystandards.

For integral structures such as ambulances ormotor-homes with increased rear overhang builtonto the chassis the following applies:• Reduced departure angles, e.g. rear entry step,

should be discussed with the end user /customer. Consider removable components toavoid damage on ferries or low-loaders.

• Unique spare wheel stowage may be requiredif obscured by rear step, check for accessibility.

• The recommended dimensions for wheelhouseson conversions are outlined in the followingfigure.


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Wheelhouse Envelope

r

B H

K

L

A

C D

E E

X 1

X

X-X

FG

rr

r r

E134132

Wheel Guard Dimensions265/60R18265/

65R17255/

70R16215/

70R16Dimension265/

60R18265/

65R17255/

70R16215/

70R16Dimension

190mmG*455mmA

922mm922mm915mm914mmH425mmB588mmK305mmC30mmL275mmD20mmr110°ECenter line of Vehicle1420mmF

Section through Center of Wheel GuardX* Dimension G is to the bottom of the swage

5.1.3 Chassis Cab

WARNING: Excessive heat can build upfrom the exhaust system, in particularfrom the catalytic converter. Ensureadequate heat shields are maintained.CAUTION: Uneven load distribution couldresult in unacceptable handling andbraking characteristics.

When carrying out vehicle conversions /modifications the following points should beconsidered:• Make sure that all of the reinforced holes

provided in the chassis frame top surface areused for full length bodies or sub-frames, seefigures shown.

• Make sure that the vehicle structural integrityis maintained.

• Do not drill into closed frame body members.• Make sure that the design for the body

alterations or additional structure disperse theload evenly.


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• Re-paint metal edges after cutting and drilling.All metal edges must comply with exterior andinterior protection local regulatory standards.

• All fixings through the floor, sides or roof mustbe sealed.

Refer to: 5.4 Corrosion Prevention (page 93).• Ensure that any additional equipment in the

vicinity of the fuel tank will not damage the tankin a crash condition.

For any conversion structure attached to ormounted onto the base vehicle cab structure thefollowing applies:• Ensure that neither the conversion structure nor

the existing vehicle structure get pre-loaded bythe assembly process.

• Adhesive jointing is recommended but shouldbe supplemented with mechanical fastenersto prevent initial peel and long term failure.

• Spread bolt loads to minimize local stress.

Body Attachment Holes in Chassis Frame - Single cab

C

E F

NM

HG

K

L

C

D

E F

ML

HG

J

K

A

B

N

P

E134152

C

E F

NM

HG

K

L

C

D

E F

ML

HG

J

K

A

B

N

P

E134152

Dimensions (mm) for Body Attachment Holes in Chassis Frame - Single Cab

DimensionDimension1086H16A

95J28B768K23C893L20D509M1244E26N1244F20P1244G


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Body Attachment Holes in Chassis Frame - Super cab

A

B

E F

H

G

J K

C

D

E134153

L

M

A

B

E F

H

G

J K

C

D

E134153

L

M

Dimensions (mm) for Body Attachment Holes in Chassis Frame - Super Cab

DimensionDimension1086G16A

95H28B1191J23C509K20D26L1244E20M1244F


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Body Attachment Holes in Chassis Frame - Double cab

A

B

E F G

H KJ

C

D

E134154

L

M

A

B

E F G

H KJ

C

D

E134154

L

M

Dimensions (mm) for Body Attachment Holes in Chassis Frame - Double cab

DimensionDimension1086G16A

95H28B893J23C509K20D26L1244E20M1244F

5.1.4 Front End Integrity for Cooling,Crash, Aerodynamics and Lighting

Cooling Continuous air flow through the front endand engine compartment is not to be hindered byadding any additional equipment. If uncertainplease consult the Ford dealer.Lighting Do not alter the lighting system.Crash Do not cut, drill or weld any parts that areload path relevant in case of crash. Do not addmaterial in the crash zone. This could affect thecrash sensor calibration.The side airbag system is not permitted if:• A swiveling device is fitted on the front seats.• A side wall or any other additional material or

structure is attached to the B-pillar inner and/orouter area.

Static & Dynamic Sealing and Finishing Ensureproper sealing against ingress of water, salt, dustetc. after cutting or drilling the body. Use Fordapproved sealing and finishing material, andunderbody corrosion protection.Refer to: 5.4 Corrosion Prevention (page 93).

5.1.5 Tipper Bodies

For tipper conversions single and double ChassisCab versions except extended rear chassis framecan be used. All variants allow single and threeway tipping.It is recommended to have the tipping systemoperative only when the engine is running. It is alsorecommended to have the master control switchin the security of the cab. According routing ofwires and hydraulic lines please refer to sectionhydraulic lift.


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Ensure that axle plated weights including the frontaxle minimum are not exceeded.For tipper sub-frames please refer to the followingguidelines:• Design for full length continuous frame with

mountings for motor, pump unit, reservoir, pivotpoints and ram.

• Use all mounting points on chassis frame tomount sub-frame.

• Very stiff sub-frames may damage the chassisframe by preventing its natural flexing,therefore compliant mounts should be used,with up to plus and minus 12mm compliancewith the vehicle laden or un-laden (whicheveris worst case). Compliant mounts should berated with a minimum of 2mm deflection per200kg mass at each chassis frame forwardmount. Compliant mounts shall have captivefail safe bolts.

• Use two M10 grade 8.8 minimum bolts,washers and self locking nuts at each solid andcompliant chassis frame location.

• Sub-frame must extend to the back of the caband attach to all mounting locations, with theforward end designed to minimize local framestress. It is however, preferable to mount thesub-frame onto the mounting brackets with aclearance to the chassis frame top surface.

• Side tipping loads/forces must be resolved bythe sub-frame. It is not recommended to strainthe chassis frame.

5.1.6 Tank and Dry Bulk Carriers

Due to the high rigidity of tanks it is necessary toisolate the tank and its sub-frame from thechassis frame allowing the chassis frame tonaturally flex. Please refer to the followingguidelines:• Mount tank to full length of sub-frame.• Mount sub-frame to all chassis frame

mounting points.• The forward location mounts must be

compliant to allow relative chassis frame tosub-frame deflections.

• Sub-frame must extend to the back of the caband not contact chassis frame at forward endunder worst case deflection.

• Compliant mounts should be used, with up toplus and minus 12mm compliance with thevehicle laden or un-laden (whichever is worstcase). Compliant mounts should be rated witha minimum of 2mm deflection per 200kg massat each chassis frame forward mount.Compliant mounts shall have captive fail safebolts.

• Use two M10 grade 8.8 minimum bolts,washers and self lock nuts per chassis framemount bracket at each solid and compliantlocation.

5.1.7 Genuine Ford Accessory Bull Bar

The Genuine Ford Accessory bull bar includesbrackets which are mounting points for drivinglights, aerials, antennas and flags.

WARNINGS:Follow all accessory manufacturer'sinstructions when connectingaccessories and equipment to thevehicle.Do not fit a non-Ford approved bull barto your vehicle as this may interfere withthe operation of the restraint system,including the air bag deployment, andcould result in injury to yourself andothers. Fitment of a bull bar may alsovoid the vehicle's compliance withAustralian Design Rules.Do not modify the front of your vehicle inany way. This could adversely affectdeployment of the airbags. Failure toadhere to this warning could result inserious personal injury or death.After bullbar installation, contact yourauthorised Ford Dealer to correctlycalibrate the Adaptive Cruise ControlRadar Module (if equipped). This isrequired to ensure correct operation ofthe advanced safety features this vehicleoffers.

NOTE: Please refer to the electromagneticcompatibility (EMC) section in this book beforeinstalling any aerials.


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Bull Bar Accessory Mounting Positions

2 1

E210762

DescriptionItemAerials, antennas and flag mounting location1Driving lights mounting location2

Antenna Cables Routing

WARNINGS:Ensure that the antenna cables havesufficient clearance from hot and movingparts.Do not fasten the antenna cables tooriginal vehicle wiring, fuel pipes andbrake pipes.Keep the antenna and power cables atleast 100mm from any electronic modulesand airbags and associated wiring.

NOTE: Make sure the sealing integrity ismaintained to avoid water ingress into the cabinwhile routing the cables through the grommet.Antenna cables should be routed from the enginebay into the cabin area through the existinggrommet. There is a service nib provided on thegrommet.Refer to Exterior lighting - Additional externallamps for driving lights cable routing.

5.1.8 Roof Racks

Roof racks may be fitted to all variants asillustrated in figure, providing the following issatisfied:• The carried load does not exceed 80kg (Body

Builder to ensure owner’s hand book identifiesthis limitation).

• The carried load does not exceed 300mm loadheight (converter to ensure owner’s informationbook identifies this limitation).

• The load is evenly distributed (converter toensure owner’s information book identifies thislimitation).

• The rack and subsequent carried load issupported in the roof drip rails irrespective ofrack retaining method.


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Double Cab / Super Cab

The forgoing limitations are based on ensuringbody structure integrity, vehicle handling, brakingand plated axle weights. Such considerationsmust also be applied to any double cab and supercab applications, in particular steering, brakingand front axle ratings and the extra continuousloads on the “A” pillar, which should not exceed60 kg total incremental load.

Ensure that the planned loaded vehicle operateswithin its designed Centre of Gravity condition.For details please consult the Ford dealer.

Roof Rack Vehicle Converter Special Fit

E278320

13 4

6

5

2

DescriptionItemRear edge of front attachment point180kg Maximum2Maximum roof rack length: within length of drain channel3Maximum load height 300mm4Drain channel5Roof rack supports6

5.1.9 Canopies

All Vehicles

WARNINGS:Only use the recommended attachmentpoints for the canopy fitment, otherwisedamage may occur to the load box.The return flange on the load box sidesshould never be cut away, be drilled into,or be used otherwise for bolting of thecanopy.

The top surface of the load box sidesshould not bear canopy (or other)structural loading. To be used as acanopy 'sealing-surface' only.Canopy weight and canopy load shouldpass through the recommended load boxstructural attachment points.

NOTE: Usage of clamps for the canopy fitmentare only allowed on the centre and rear portion ofthe load box.


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NOTE: Use both points from group A and aminimum of one point from group B as frontstructural attachment points.

Load Box Structural Attachment Points

E170921

A

B

B

DescriptionItemFront structural attachment points1Centre structural attachment points2Rear structural attachment points3Top surface of load box sides*4

Return flange of load box sides*5

*Do not cut, drill, or use these surfaces to bolt thecanopy.


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Example of a Sports Bar Fitment

E172331

DescriptionItemFront mounting bracket1Clamped attachment2


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5.2 Airbag Supplemental Restraint System (SRS)

5.2.1 Air Bags - (Low Level Vehicles)

Front Seats

Side airbags are not compatible with swivellingfront seats.Do not specify the base vehicle with side airbagswhen planning to retrofit a swivelling device onthe front seats and/or an armrest on the outer sideof the front seats, this may affect the functionand/or deployment of the side airbags.

The acceleration based airbag sensors for sideairbags are located nearby the bottom of theC-pillar inner for Super Cab and Double Cabvehicles. The pressure based airbag sensors forside airbags are located near the centre of the frontdoors' inner door sheet metal for all Cab styles.

WARNING: Modifications orreinforcements in the area of the sensorsmay affect the side airbag fire timing andresult in uncontrolled side air bagdeployment.

Please note that vehicles not equipped with sideairbags but equipped with front airbags only arenot affected.Drilling or grinding operations in this area are onlypermitted when battery cables are disconnected.

Driver and Passenger Front Airbag Deployment Zones

E

D

B

A

C

F

E134101


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Dimensions (mm)660D400A630E700B700F700C

Side Airbag

CB

E134609

A

Dimensions (mm)250C550A

350B

Curtain Airbag - Single cab

DC

B

A

E136172


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Dimensions (mm)250C140A100D40B

Curtain Airbag - Double cab

D

C

B

A

E134610


Curtain Airbag - Super cab

DC

B

A

E136173



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5.2.2 Air Bags - (High Level Vehicles)

Front Seats

Side airbags are not compatible with swivellingfront seats.Do not specify the base vehicle with side airbagswhen planning to retrofit a swivelling device onthe front seats and/or an armrest on the outerside of the front seats, this may affect the functionand/or deployment of the side airbags.

The acceleration based airbag sensors for sideairbags are located nearby the bottom of theC-pillar inner for Super Cab and Double Cabvehicles. The pressure based airbag sensors forside airbags are located near the centre of thefront doors' inner door sheet metal for all Cabstyles.

WARNING: Modifications orreinforcements in the area of the sensorsmay affect the side airbag fire timing andresult in uncontrolled side air bagdeployment.

Please note that vehicles not equipped with sideairbags but equipped with front airbags only arenot affected.Drilling or grinding operations in this area are onlypermitted when battery cables are disconnected.


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Driver and Passenger Front Airbag Deployment Zones

E

D

B

A

F

E210764

C

Dimensions (mm)392D260A520E470B544F470C


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Side Airbag

CB

E134609

A

Dimensions (mm)550A350B250C

Curtain Airbag - Single cab

DC

B

A

E136172



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Curtain Airbag - Double cab

D

C

B

A

E134610


Curtain Airbag - Super cab

DC

B

A

E136173


5.2.3 Supplementary RestraintSensors (Front)

WARNING: Modifications orreinforcements in the area of the frontsupplementary restraint sensors mayaffect their operation.


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1

E210765

DescriptionItemFront SRS Impact Sensors1


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5.3 Seatbelt Systems — AustraliaWARNING: Follow the Ford approvedremoval and installation procedures forthe seatbelt system to ensure correctfunction of the restraints system.

The removal and reinstallation of the seatbelt,restrainer or any component of the seatbeltsystem should be avoided. However if removaland re-installation of the system is required duringthe conversion, follow the removal and installationguidelines of the seatbelt system as described inthe workshop manual. Please consult your localNational Sales Company representative for furtherinformation.When removing the seatbelt system, a seatbeltwebbing forked retainer should be applied to thewebbing 200mm below the webbing button stop.This prevents a situation where all the webbingruns back into the retractor and the retractorbecomes locked.When reinstalling, fit the retractor to the body firstand gently pull the webbing out of the retractor toallow fitment of the D loop. Then remove theforked retainer. If the retractor is locked, allow asmall amount of webbing to reel back into theretractor to allow the webbing lock to release. Donot attempt to release the retractor by pulling onthe webbing with significant force or by manuallyinterfering with the locking mechanism.


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5.4 Corrosion Prevention

5.4.1 General

Avoid drilling into closed frame body members toavoid the risk of corrosion from swarf.If drilling is required, however:• Re-paint metal edges and protect against

corrosion after cutting or drilling operations.• Endeavor to remove all swarf from inside the

side member and treat to prevent corrosion.• Apply corrosion protection inside and outside

of the chassis frame.

5.4.2 Repairing Damaged Paint

After cutting or reworking any sheet metal on thevehicle the damaged paint must be repaired.Ensure all materials are compatible with therelevant Ford specifications and maintain theoriginal performance where possible.

5.4.3 Under Body Protection andMaterial

WARNING: Do not over-coat orcontaminate surfaces of componentssuch as brakes or catalytic converters.

Ensure all materials are compatible with therelevant Ford specifications and maintain theoriginal performance where possible.Some proprietary products affect the originalcoatings. For specifications of corrosion protectionmaterials, please consult your local National SalesCompany representative.

5.4.4 Painting Road Wheels

WARNING: Do not paint wheel clampsurfaces in contact with other wheels,brake drum or disc, hub and holes orsurface under wheel nuts. Any furthertreatment in these areas may affect thewheel clamp performance and the vehiclesafety. Mask the wheel when changingthe color or repairing paint.

5.4.5 Contact Corrosion

When using different materials with a differentelectrochemical potential, ensure that materialsare isolated from each other to prevent contactcorrosion caused by a potential difference.Use appropriate isolation materials.Where possible, choose materials with low levelof electrochemical potential difference.


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5.5 Frame and Body Mounting

5.5.1 Mounting Points and Tubing

Holes on frame are a result of the productionprocess. They are not designed for fixing additionalequipment. Always use chassis mounts as shownin sub frame for low floor or other equipment. Ifadditional fixings are required please follow therecommendation given in the figure shown. Thisdoes not apply to areas of load applications suchas spring fixings or damper fixings.

NOTE: After drilling, deburr and countersink allholes and remove chips from the frame. Followcorrosion prevention.Refer to: 5.4 Corrosion Prevention (page 93).

Frame Drilling and Welding

E134173

D

Dimensions (mm) for Body Attachment Holes in Chassis Frame Top Flange Medium WheelbaseDescriptionItem

19 mmA11 mmB10 mmC10 mmDDo NOT enlarge chassis rail holes, or drill within the surrounding area.EDo not drill any more than 2 vertical holes in the chassis rail.F

1. No Welding is allowed to the Vehicle Structure.2. To make holes in frames do not use a gas flame.

Drill holes using sharp drills.3. Use cold riveting only when attaching brackets

with rivets.4. Use high tensile bolts and appropriate nuts

when bolted attachments are used.• Bolt Specifications :• Metric – Property class 8.8 or 10.9• Japanese – 7T or 9T• SAE – Grade 8 5.

5. Deburr holes after drilling to fit bolts or rivets.Chamfer 1.0mm x 45 degree on the bolt headside of the hole to facilitate bolt seating.

6. Holes must NOT be drilled near side memberprofile changes.

7. Existing holes in top and bottom flanges mustNOT be bored out.

8. No more than two holes are to be drilled in avertical line down from the frame web.

9. Corrosion protection is to be applied postdrilling operations to the vehicle. Corrosionprotection & protective coatings for allmodifications should conform to all localregulatory standards.

10. Reinforcements should be added to the vehiclestructure where appropriate, to avoid excessiveload concentrations.


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Typical Design Principle of a Self-Supporting Body Structure

E74576

1

2

3

4

5

67

8

DescriptionItemUse all standard locations with 2x M10 fixings1Floor panel2Body side frames3Floor cross members4Continuous floor U-profile frame5Longitudinal L-profile6Chassis frame rail of base vehicle7Vehicle center line of base vehicle8

Also see:Refer to: Body (page ?).

5.5.2 Self-Supporting Body Structure

Bodies and structures can be judged asself-supporting providing they maintain thefollowing rules:• Cross members are used at each chassis

mounting point, please refer to figures shown.• Each cross member has a suitably engineered

connection to the body side wall (3) or to thecontinuous floor frame (5), see figure shown.

• The body side wall or the continuous floorframe supports any overhang beyond thechassis frame, whether on standard frame orextended frame.

Alternatively, the self-supporting body structurecan also be designed as shown in figure shown.

• This concept is based on a self-supportingstructure where the floor is mounted directlyonto the top surface of the chassis frame.

• See figure shown for a generic vehicle crosssection where the cross members andopposing out riggers are flush with the surfaceof the chassis frame side members.

• It is important to the overall function of thevehicle structure that the out riggers are eachconnected to a continuous longitudinal floorside frame or a structural body side structureassembly.

Low floor-re-work for guidance only:• Engineer unique cross members and

out-riggers spaced at approximately 600mmmaximum pitch.

• Out-rigger moment to be re-acted withcross-member between chassis frame withcommon through bolts where possible.


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• Drill frame and add spacer tubes.Refer to: 5.5 Frame and Body Mounting (page

94).• Out-rigger outboard ends should be attached

to load bearing body side / floor edge frame orbody side structure (including over wheelsupport).

• Structural wheel box should maintainlongitudinal continuity with a rigid attachmentto the floor edge frame or to the body sidestructure.

• Floor boards should be substantially attachedto cross members and outriggers, but not to thechassis frame top surface.

• Low floor exhaust heat shields.

5.5.3 Frame Drilling and TubeReinforcing

The chassis frame may be drilled and reinforcingspacer tubes may be welded in place, providingthe following is applied:• Adhere to all details shown in figure.• Drill and weld only side walls of the chassis

frame.• Locate and drill holes accurately, using a drill

guide to ensure holes are square to framevertical center line (note: allow for side memberdraft angle).

• Drill undersize and ream out to size.• Endeavor to remove all swarf from inside side

member, and treat to prevent corrosion.• Fully weld each end of the tube and grind flat

and square, in groups if applicable. Be awareof side member draft angle.

• Apply corrosion protection inside and outsideof the chassis frame.Refer to: 5.4 Corrosion Prevention (page 93).

• Holes should be in groups of two (2), eithervertically spaced at 30 to 35mm from chassisframe top and/or bottom surface, orhorizontally at 50mm minimum pitch, 30 to35mm from top and/or bottom chassis framesurface.

• Always use M10 bolts with grade 8.8 minimum.• Do not position tubes at the medium chassis

frame height, this may create “oil canning” ofthe deep section side walls.

• Where possible, the outrigger moments shouldbe resolved by matching inner cross membersbetween the chassis side members inline withthe outriggers.

• A diameter of 16.5mm is the maximumallowable hole size in the chassis frame sidewall, irrespective of the usage.

Avoid drilling into closed frame body members toavoid the risk of corrosion from swarf.Refer to: 5.4 Corrosion Prevention (page 93).

Drilling and welding of frames and body structurehave to be conducted following the programguidelines. Please consult the Ford dealer fordetails.

5.5.4 Ancillary Equipment - Sub FrameMounting

Typical sub-frames and longitudinal members forflatbed and low or drop-side bodies or equipmentexceeding the standard or Regular ProductionOrder frame length should adhere to the followingguidelines:• Flat-beds and low bodies mounted on integral

longitudinal members (channel or box sectionmetal – not wood) must use both sides of allframe mounting brackets.

• Longitudinal members must be relieved at thefront end if they are to contact the chassisframe top surface, to minimize stressconcentrations. It is preferable however, tomount the longitudinal onto the mountingbrackets, with a clearance to the chassis frametop surface.

• Each set of brackets must use two (2) x M10bolts grade 8.8 minimum.

• Minimum floor heights will require wheel archboxes to clear the rear tires, see Vehicle Datasheets for relevant tire jounce.

5.5.5 Area for Fitting Additional BodyAttachments to the Rear of theBumper.

NOTE: With the vehicle on level ground and withall measurements taken rear ward of the bumperbar edge: The area designated for the fitting ofattachment is defined as 220mm horizontally by95mm vertical downward to the road surface, witha max width of 1390mm about vehicle center line.It is not the manufactures recommendation to fitadditional body attachments (Tow bars, Steps,Bicycle racks & Carriers) outside of the designatedarea.

5.5.6 Water Tank on Camper Vehicles

NOTE: It is recommended that a decal or labelis fitted adjacent to the filler apertureidentifying the correct fluid to be used, forexample: 'Water only' for water tanks.


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AAbout this Manual..........................................................5Additional External Lamps - (Low Level Vehicles

Only)...............................................................................62Aids for Vehicle Entry and Exit..................................17Air Bags - (High Level Vehicles)..............................87Air Bags - (Low Level Vehicles)..............................84Airbag Supplemental Restraint System

(SRS).............................................................................84Alternative Type Approval...........................................7Ancillary Equipment - Sub Frame Mounting.....96Area for Fitting Additional Body Attachments

to the Rear of the Bumper......................................96Auxiliary Battery and Fuse Box - Low Level

Vehicles..........................................................................70Auxiliary Fuse Box (Vehicles with Special

Equipment Pack) (Low Level VehiclesOnly).................................................................................71

Auxiliary Lighting Loads (Low Level VehiclesOnly)...............................................................................65

Axle Breather Vent Hose...........................................39

BBattery and Cables.......................................................41Battery Information......................................................41Body...................................................................................74Body Structures - General Information................74Brake Hoses....................................................................32Brake System.................................................................32

CCanopies...........................................................................81Center of Gravity...........................................................26Central Locking.............................................................69Centre High Mount Stop Lamp (CHMSL) -

Canopy Fitment - High Level Vehicles...............67Centre High Mount Stop Lamp (CHMSL) -

Canopy Fitment -Low Level Vehicles................66Chassis Cab Body - Basic Dimensions and

Weights..........................................................................20Chassis Cab....................................................................75Commercial and Legal Aspects.................................7Contact Corrosion........................................................93Conversion Effects on Parking Aids........................17Conversion Homologation..........................................9Corrosion Prevention..................................................93

DDrilling and Welding.......................................................8Driver Field of View........................................................17Driver Reach Zones.......................................................17

EElectrically Operated Door Mirrors........................66Electromagnetic Compatibility (EMC).................10Electronic Engine Controls.........................................51Exterior Lighting............................................................58

FFrame and Body Mounting.......................................94Frame Drilling and Tube Reinforcing....................96Front, Rear and Side Under-run Protection.........21Front End Integrity for Cooling, Crash,

Aerodynamics and Lighting...................................78

Fuel Filler Mounting.....................................................36Fuel Filler Pipe Shipping Bracket (if

equipped).....................................................................34Fuel Filler Vent Hose...................................................38Fuel System....................................................................34Fuses and Relays..........................................................70

GGeneral......................................................................32, 93General Component Package Guidelines............17

.........................................................................................5, 10

GGeneral......................................................................32, 93General Product Safety Requirement.....................7Generator and Alternator..........................................47Genuine Ford Accessory Bull Bar...........................79

HHandles, Locks, Latches and Entry Systems.....69Hardware—Specifications........................................22How to Use This Manual..............................................5

IImportant Safety Instructions....................................5Integrated Bodies and Conversions.......................74Introduction.......................................................................5

JJacking...............................................................................12

KKerb Mass and Payload...............................................21

LLamps – Hazard / Direction Indication...............66Legal and Vehicle Type Approval..............................7Legal Obligations and Liabilities...............................7Lifting.................................................................................13Load Distribution—Specifications.........................23Load Distribution Calculations - Driver and

Passenger Weight Distribution.............................23Long Range Fuel Tanks..............................................39Low Level and High Level Vehicles...................6, 70

MMinimum Requirements for Brake system and

Load Apportioning Valves.........................................8Mounting Points and Tubing....................................94

NNoise, Vibration and Harshness (NVH)................14

PPackage and Ergonomics—Specifications..........19Package and Ergonomics...........................................17Painting Road Wheels................................................93Parking Aid.....................................................................48Product Liability..............................................................8

Index

97

RRear Combination lamps...........................................59Rear Fog Lamp...............................................................59Rear License Plate Lamp...........................................60Recommended Body Dimensions...........................19Registration Plates.........................................................18Repairing Damaged Paint..........................................93Restraints System...........................................................8Reversing Lamps, Rear View Camera, Reversing

Alarm (Manual Transmission)...............................62Road Safety.......................................................................8Roof Racks......................................................................80

SSeatbelt Systems — Australia..................................92Self-Supporting Body Structure.............................95Sensor Location.............................................................49Supplementary Restraint Sensors (Front).........90Suspension System.......................................................31

TTank and Dry Bulk Carriers.........................................79Terminology........................................................................7Tipper Bodies..................................................................78Towing Capacities and Specifications..................30Towing Requirements..................................................30Towing...............................................................................30Trailer Brakes...................................................................32Trailer Towing..................................................................63

UUnder Body Protection and Material.....................93

VVehicle Duty Cycle Guidelines....................................11Vehicle Ride and Handling Attributes......................11Vehicle Speed Output (Signal) (High Level

Vehicles )........................................................................57Vehicle Speed Output (Signal) (Low Level

Vehicles Only)................................................................51Vehicle Transportation Aids and Vehicle

Storage.............................................................................15

WWarnings, Cautions and Notes in This Manual.....5Warranty on Ford Vehicles............................................7Water Tank on Camper Vehicles.............................96Wiring Installation and Routing Guides................40Wiring Splicing Procedures.......................................40

Inde

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Documents

FORD Ranger 2019 Body and Equipment Mounting Manual