Page 1 Body and Equipment Mounting Manual FordTransit 2006.5 (April 2006 ) Date of Publication: 12/2006...
Page 3: Table Of Contents
1.2 Commercial and Legal Aspects... and Passenger Weight Distribution... 1.2.1 Terminology........... 7 1.16.2 Center of Gravity ....... 46 1.2.2 Warranty on Ford Vehicles....7 1.17 Towing........54 1.2.3 Legal and Vehicle Type Approval..1.17.1 Towing Requirements....... 54 1.17.2 Towing..........54 1.2.4...
Page 4 3.7 Exhaust System......86 4.13.4 Special Vehicle Option Auxiliary Fuse 3.7.1 Extensions and Optional Exhausts..Box............121 4.13.5 Additional Ignition, Instrument Panel 3.7.2 Exhaust Pipes and Supports..... 86 Illumination and Air Conditioning On 3.7.3 Exhaust Heat Shields......86 Signals..........124 3.8 Fuel System.........
Page 5 5.6.2 Heated Windshield and Heated Rear Window..........213 5.7 Roof Opening Panel....214 5.7.1 Driver's Standing Head Room..214 5.7.2 Back Panel Removal......214 5.7.3 Cab Roof Removal......214 5.7.4 Roof Ventilation......... 215 5.7.5 Roof Racks........216 5.8 Air Bag Supplemental Restraint System (SRS)......
Page 6: About This Manual
NOTE: Notes are used to provide additional by technicians worldwide. essential information required to carry out a This guide is published by Ford and provides complete and satisfactory repair general descriptions and advice for converting As you read through this manual, you will come vehicles.
Page 7: Commercial And Legal Aspects
The Vehicle Converter should consult with its the country where the vehicle will be registered legal advisor on any questions concerning its for details of the terms of any applicable Ford legal obligations and liabilities. warranty. The Vehicle Converter should warrant its design, 1.2.6 General Product Safety...
Page 8: Product Liability
(whether for death, personal injury, or property damage) arising from any alteration 1.2.9 Drilling and Welding to a Ford vehicle or component made by the Vehicle Converter or any of its agents. Ford shall Drilling and welding of frames and body structure...
Page 9: Contact Information
Sales Company Representative (NSC) or Local phone: Ford Dealer in your Market. Fax: +33-1-61016505 If your Local National Sales Company Representative or Local Ford Dealer are unable E-Mail: jtaille1@ford.com to help you, please contact the Vehicle Converter Postal St Germain Advisory Service at VCAS@ford.com.
Page 10 Ford of Spain Ford of Netherlands Contact: Marcos Yndurain - Transit Brand Contact: Rob Mulder - Transit Brand Manager Manager Tele- +34-91-7145178 Tele- +31-20-5044714 phone: phone: Fax: +34-91-7145478 Fax: +31-20-5044700 E-Mail: myndurai@ford.com E-Mail: rmulder@ford.com Postal Edificio Minipark IV Calle Calendula,...
Page 11 Ford of Denmark Ford of Sweden Contact: Peter Nielsen - Transit Brand Contact: Christian Lysholm - Transit Brand Manager Manager Tele- +45-43-480680 Tele- +46-31-590850 phone: phone: Fax: +45-43-480565 Fax: +46-31-3259480 E-Mail: pnielse1@ford.com E-Mail: clysholm@ford.com Postal 5 D-E Borupvang Postal Ravebergsvagen Angered...
Page 12 Postal FORDHUNGARY Address: Address: Warsaw Obuda Gate Arpad fejedelem u. 26- 02-222 Budapest 1023 Ford of Czech Republic Contact: Petr Simunek - Transit Brand Manager Rest of the World (RoW) Tele- +420-23-4650119 Contact: John Dand - Transit Brand Manager phone:...
Page 13 3D CAD data in iges format is available on CD-ROM, you can request specific information by contacting the Vehicle Converter Advisory Service by e-mail. The data will be issued by encrypted CD-ROM using the Ford Data Export process FordTransit 2006.5 (April 2006 ) Date of Publication: 12/2006...
Page 14: Conversion Type
1.4 Conversion Type NOTE: The following tables are for The BEMM contains general and specific guidance only. Full reference to the Body recommendations covering conversions to the and Equipment Mounting Manual should new Transit range of vehicles. To assist users be made prior to starting any locate information by conversion type the following tables contain the relevant links within...
Page 15 Dry Freight Refer to: 1.14 (page 34). Refer to: 4.4 Battery and Cables (page 98). (Also Generator and Alternator). Flat Bed / Refer to: 4.8 Tachograph (page 109). Platform Refer to: 5.1 Body (page 175). (Integrated Bodies and Conversions, Hydraulic Lifting Equipment for Van, Bus, Kombi and Chassis Cab).
Page 16 Dry Freight Refer to: 1.14 (page 34). Refer to: 4.4 Battery and Cables (page 98). (Also Generator and Alternator). Money Refer to: 4.8 Tachograph (page 109). Carriers Refer to: 5.1 Body (page 175). (Roof Ventilation). Refer to: 4.11 Exterior Lighting (page 116). Refer to: 4.4 Battery and Cables (page 98).
Page 17 Passenger Carrying Refer to: 1.2 Commercial and Legal Aspects (page 7). (Restraints System). Refer to: 4.11 Exterior Lighting (page 116). Refer to: 4.12 Interior Lighting (page 118). Taxi Refer to: 5.5 Seats (page 209). Refer to: 5.6 Glass, Frames and Mechanisms (page 211). Refer to: 5.7 Roof Opening Panel (page 214).
Page 18 Passenger Carrying Refer to: 5.1 Body (page 175). (Hydraulic Lifting Equipment for Van, Bus, Kombi and Chassis Cab). Refer to: 4.11 Exterior Lighting (page 116). Refer to: 4.12 Interior Lighting (page 118). Mini Bus Refer to: 5.5 Seats (page 209). Refer to: 5.6 Glass, Frames and Mechanisms (page 211).
Page 19 Camper Conversion Refer to: 1.14 (page 34). Refer to: 1.16 (page 44). Refer to: 1.17 Towing (page 54). Refer to: 2.6 Brake System (page 62). (Relocated Handbrake). Refer to: 3.8 Fuel System (page 88). Van conver- Refer to: 4.4 Battery and Cables (page 98). sion Refer to: 4.14 Special Conversions (page 131).
Page 20 Refrigerated Vehicles Refer to: 1.8 End of Life Vehicle (ELV) Directive (page 26). Refer to: 1.14 (page 34). Refer to: 4.4 Battery and Cables (page 98). (Also Generator and Alternator). Van Conver- Refer to: 4.5 Climate Control System (page 106). sion Refer to: 4.13 Fuses and Relays (page 119).
Page 21 Emergency Services Refer to: 1.14 (page 34). Refer to: 3.2 Engine Cooling (page 75). (Airflow Restrictions). Refer to: 4.4 Battery and Cables (page 98). (Also Generator and Alternator). Refer to: 4.11 Exterior Lighting (page 116). Ambulance - Refer to: 4.12 Interior Lighting (page 118). Front Line Refer to: 4.13 Fuses and Relays (page 119).
Page 22 Emergency Services Refer to: 1.14 (page 34). Refer to: 3.2 Engine Cooling (page 75). (Airflow Restrictions). Refer to: 4.4 Battery and Cables (page 98). (Also Generator and Alternator). Refer to: 4.11 Exterior Lighting (page 116). Police Refer to: 4.12 Interior Lighting (page 118). Refer to: 4.13 Fuses and Relays (page 119).
Page 23: Conversion Homologation
The responsible Technical Service may require additional information and/or testing. NOTE: For further information please contact your local National Sales Company representative, or Local Ford Dealer. If they are unable to help you then please contact the Vehicle Converter Advisory Service at VCAS@ford.com.
Page 24: Electromagnetic Compatibility (Emc)
1.6 Electromagnetic Compatibility (EMC) The base vehicle has been tested and certified • Make sure that any additional power feed is to all relevant legislation relating to taken directly from the SVO fuse box (when Electromagnetic Compatibility. All retrofitted available) or a recommended connection equipment must also comply with the relevant point.
Page 25: Vehicle Duty Cycle Guidelines
NOTE: For further information please contact your local National Sales Company representative, or Local Ford Dealer. If they are unable to help you then please contact the Vehicle Converter Advisory Service at VCAS@ford.com.
Page 26: End Of Life Vehicle (Elv) Directive
NOTE: For further information please contact your local National Sales Company representative, or Local Ford Dealer. If they are unable to help you then please contact the Vehicle Converter Advisory Service at VCAS@ford.com.
Page 27: Jacking
1.9 Jacking NOTE: Make sure that reinforcements are WARNING: Always position the installed to maintain the integrity of the original vehicle on a hard level surface. If body structure for/at jacking points. the vehicle must be jacked up on a NOTE: Any modifications to the vehicle must soft surface use load spreading blocks under the jack.
Page 28 Chassis Single Cab, Extended Frame Chassis Single Cab, Chassis Double Cab and Extended Frame Chassis Double Cab TIE0009946 FordTransit 2006.5 (April 2006 ) Date of Publication: 12/2006...
Page 29: Lifting
1.10 Lifting WARNING: When lifting the vehicle CAUTIONS: with a two post lift for the removal when lifting the vehicle with two of the engine/transmission or rear post lift, vehicle lift arm adapters axle, make sure the vehicle is must be used under the lifting secured to the lift using vehicle points.
Page 30 Chassis Single Cab, Extended Frame Chassis Cab, Chassis Double Cab and Extended Frame Chassis Double Cab. E0013886 FordTransit 2006.5 (April 2006 ) Date of Publication: 12/2006...
Page 31: Noise, Vibration And Harshness (Nvh)
1.11 Noise, Vibration and Harshness (NVH) WARNING: Make sure that the modified vehicle complies with all relevant legal requirements. CAUTION: The travel and function of pedals must not be restricted. Changes to the powertrain, engine, transmission, exhaust, air intake system or tyres may influence the exterior noise emission.
Page 32: Vehicle Transportation Aids And Vehicle Storage
1.12 Vehicle Transportation Aids and Vehicle Storage CAUTIONS: Disconnect the battery if the vehicle is to be stored for more than 30 days. Make sure that the protective covers are not removed from an incomplete vehicle until the conversion is started.
Page 33: Package And Ergonomics
NOTE: For further information please contact your local National Sales Company WARNING: Make sure that the representative, or Local Ford Dealer. If they are modified vehicle complies with all unable to help you then please contact the relevant legal requirements.
Page 34: Package And Ergonomics Specifications
NOTE: For further information please contact extension to vehicles fitted with your local National Sales Company representative, Interactive Vehicle Dynamics or Local Ford Dealer. If they are unable to help (IVD)/Electronic Stability Program you then please contact the Vehicle Converter Advisory Service at VCAS@ford.com.
Page 35 Chassis Cab Body E74205 FordTransit 2006.5 (April 2006 ) Date of Publication: 12/2006...
Page 36: Recommended Nominal Body Lengths For Chassis Cab Models
Dimensions - not to exceed for Chassis Cab body Length Wheelbase Short Wheel- Medium Wheel- Long Wheel- base 3137 base 3504 base 3954 Maximum recommended rear Maximum allowable by territorial legislation overhang (requires self supporting body or continuous sub frame). Front outside of body to rear axle 1706 2073...
Page 37 Explanation of terms used in body lengths Nominal (Rearward Biased) Body Lengths- Recommended for best overall weight distri- bution and payload latitude. Nominal (rearward biased) body lengths are recommended when tail- lifts, rear mounted cranes, tow bars or rear mounted equipment are fitted. Nominal (rearward biased) body lengths assume a typical back of cab to interface of body bulkhead dimension is 100mm Nominal Uniformly Distributed Load (UDL) Body Lengths- is the maximum length of a typical Float / Dropside body maintaining UDL loading without exceeding individual axle plating,...
Page 38: Front, Rear And Side Under-Run Protection
Double Chassis Cab Drivetrain Body Length (Internal) Model Wheelbase Transmission Rear Axle Nominal Nominal (Rearward (UDL) Biased) Medium Wheel- Rear Wheel Drive Dual rear Wheel 2450 2700 base Rear Wheel Drive Single Rear 2400 2400 Wheel Front Wheel Drive Single Rear 2400 2400 Wheel...
Page 39: Recommended Main Load Area Dimensions For Bulkhead With Depression Driver Side
1.14.4 Recommended Main Load Area Dimensions for Bulkhead with Depression Driver Side E74204 Wheelbase Roof Length 'A' Width 'B' Height 'C' Height 'C' (mm) (mm) (mm) Low (mm) High Floor Floor Short Wheelbase 2230 1380 1330 1230 Short Wheelbase Medium 2280 1250 1650...
Page 40: Recommended Main Load Area Dimensions For Bulkhead With Full Depression
1.14.5 Recommended Main Load Area Dimensions for Bulkhead with Full Depression E74206 Wheelbase Roof Length 'A' Width 'B' Height 'C' Height 'C' (mm) (mm) (mm) Low (mm) High Floor Floor Short Wheelbase 2280 1380 1330 1230 Short Wheelbase Medium 2230 1250 1650 1550...
Page 41: Recommended Main Load Area Dimensions For Double Cab In Van Bulkhead
1.14.6 Recommended Main Load Area Dimensions for Double Cab In Van Bulkhead E77081 FordTransit 2006.5 (April 2006 ) Date of Publication: 12/2006...
Page 42 Wheelbase Roof Length 'A' Width 'B' Height 'C' Height 'C' (mm) (mm) (mm) Low (mm) High Floor Floor Short Wheelbase 1480 1380 1330 Short Wheelbase Medium 1430 1250 1650 Medium Wheelbase Medium 1670 1240 1650 1550 Medium Wheelbase High 1630 1230 1850 1750...
Page 43: Hardware Specifications
1.15 Hardware—Specifications Material Specification, Strength and Torque Standard Hardware and Tightening Torques (Nm) Bolts/Studs: ISO 898-1, Nuts: ISO 898-2 Grade 4.8 Grade 8.8 Grade 10.9 Thread Size Minimum Maximum Minimum Maximum Minimum Maximum 11.5 11.0 15.0 20.0 28.0 25.0 35.0 41.0 55.0 50.0...
Page 44: Load Distribution Specifications
NOTE: For further information please contact Do not exceed the gross vehicle your local National Sales Company representative, weight or Local Ford Dealer. If they are unable to help Tire manufacturer specification must you then please contact the Vehicle Converter be maintained.
Page 45 Single and Double Cab E74207 Single and Double Cab Driver and Passenger Weight Distribution 'A' Wheel- 'B' Front 'C' Second Weight distribution Per Person in Kg base (mm) Row Seats Row Seats and Driver On Front On Rear Axle Total Axle 3137 3504...
Page 46: Center Of Gravity
Van and Kombi E74208 Van and Kombi Driver and Passenger Weight Distribution 'A' Wheel- 'B' Front 'C' Second 'D' Third Weight distribution Per Person in base (mm) Row Seats Row Seats Row Seats and Driver On Front On Rear Total Axle Axle 2933...
Page 47 E76890 FordTransit 2006.5 (April 2006 ) Date of Publication: 12/2006...
Page 48 Van Center of Gravity Critical Zone to EEC Category N1. Non-ABS Model Roof Laden Gross Vehicle Mass (GVM) Minimum Kerb + Driver Height with all passengers (Dimensions Running Order (Dimensions 'A' Min 'B' Max 'D' High 'G' High Standard Center Design Standard Center...
Page 49 Model Roof Laden Gross Vehicle Mass (GVM) Minimum Kerb + Driver Height with all passengers (Dimensions Running Order (Dimensions 300L High 1750 2313 1365 1568 Diesel 330L Medium 1818 2443 1365 1549 Diesel 330L High 1818 2443 1365 1566 Diesel 350L Medium 1762...
Page 50 Single Chassis Cab Center of Gravity Critical Zone to EEC Category N1. Non-ABS Model Laden Gross Vehicle Mass Minimum Kerb + Driver Running Order (GVM) with all passengers Without Float (Dimensions mm) (Dimensions mm) 'A' Min 'B' Max 'D' High 'G' High Standard Center of...
Page 51 Double Chassis Cab 6 seat E75931 FordTransit 2006.5 (April 2006 ) Date of Publication: 12/2006...
Page 52 Double Chassis Cab Center of Gravity Critical Zone to EEC Category N1. Non-ABS Model Laden Gross Vehicle Mass (GVM) with Minimum Kerb + Driver all passengers (Dimensions mm) Running Order Without Float (Dimensions mm) 'A' Min 'B' Max 'D' High 'G' High Standard Center of...
Page 53 E76530 Bus Center of Gravity Critical Zone to EEC Category N1. Non-ABS Model Roof Laden Gross Vehicle Mass (GVM) Minimum Kerb + Driver Tourneo Height with all passengers (Dimensions Running Order Without Float (Dimensions mm) 'A' Min 'B' Max 'E' Design Standard Standard Vehicle...
Page 54: Towing
When a towing device is required, the Vehicle Converter should use a Ford approved tow bar. • Any modifications to the vehicle must be noted Refer to: 1.16 (page 44).
Page 55 Van Floor Medium wheelbase or Long Wheelbase vehicles, please consult your local National Sales Company representative, or Local Ford Dealer. If they are unable to help you then please contact the Vehicle Advisory Service at VCAS@ford.com FordTransit 2006.5 (April 2006 )
Page 56 Tow Bar Cab Van Floor E78717 The towing nose mass on Cab Van Floor variants is 75kg maximum and the trailer mass is 1000kg maximum For any extentions including towing devices used on Cab Van Floor medium wheelbase or long wheelbase vehicle converters/modifiers need to use fixing points as in the figure E78717 Refer to: 4.14 Special Conversions (page 131).
Page 57: Suspension System
CAUTION: Modifications to the suspension system can cause a deterioration of the vehicle handling characteristics and durability. NOTE: For detailed information please contact the Vehicle Converter Advisory Service at VCAS@ford.com. FordTransit 2006.5 (April 2006 ) Date of Publication: 12/2006...
Page 58: Front Suspension
Interactive Vehicle Dynamics (IVD) NOTE: Do not damage the surface or corrosion protection of the spring during disassembly and installation. NOTE: For detailed information please contact the Vehicle Converter Advisory Service at VCAS@ford.com. FordTransit 2006.5 (April 2006 ) Date of Publication: 12/2006...
Page 59: Rear Suspension
NOTE: For detailed information please contact the Vehicle Converter Advisory Service at VCAS@ford.com. 2.3.2 Rear Anti-Roll Bar Remove the rear anti-roll bar on Chassis Cabs, except on: • 330 and 350 Front Wheel Drive Chassis Cabs...
Page 60: Wheels And Tires
Please consult the Vehicle Converter Advisory Service VCAS@ford.com for clearance requirements and data. NOTE: Make sure that only approved wheels and /or permissible tire sizes are fitted For standard wheelhouse dimensions.
Page 61: Driveshaft
2.5 Driveshaft 2.5.1 Power Take Off Gear Box add-on - Auxiliary Propeller Drive Shaft CAUTIONS: Make sure that an inhibitor is fitted to any modified vehicle that uses the prop-shaft to power auxillary equipment. The only modification to the engine control system (throttle, powertrain control module and fuel pump) recommended by the manufacturer...
Page 62: Brake System
2.6.2 Kerb Mass Data NOTE: For further information please contact your local National Sales Company representative, or Local Ford Dealer. If they are unable to help you then please contact the Vehicle Converter Advisory Service at VCAS@ford.com. 2.6.3 Brake Hoses General...
Page 63: Parking Brake
NOTE: For further information please contact your local National Sales Company representative, or Local Ford Dealer. If they are unable to help you then please contact the Vehicle Converter Advisory Service at VCAS@ford.com.. Recommended Relocated Parking Brake Lever location E76770 FordTransit 2006.5 (April 2006 )
Page 64: Hydraulic Brake Actuation
Maintain brake certification load distribution NOTE: For further information please contact your local National Sales Company representative, or Local Ford Dealer. If they are unable to help you then please contact the Vehicle Converter Advisory Service at VCAS@ford.com. 2.8.2 Front and Rear Brakes...
Page 65: Anti-Lock Control - Stability Assist
Interactive Vehicle Dynamics (IVD)System. NOTE: For further information please contact your local National Sales Company representative, or Local Ford Dealer. If they are unable to help you then please contact the Vehicle Converter Advisory Service at VCAS@ford.com. FordTransit 2006.5 (April 2006 )
Page 66: Engine
3.1 Engine • Common Rail 2.2L TCI 62.5kW (85HP) Diesel CAUTION: Make sure to follow the Engine equipment suppliers instructions for • Common Rail 2.2L TCI 81kW (110HP) Diesel safety, warranty and sometimes Engine legal compliance • Common Rail 2.2L TCI 96kW (130HP) Diesel For electrical supply to auxiliary equipment.
Page 67 Common Rail 2.2L TCI 62.5kW (85HP) Diesel Engine 1000 1500 2000 2500 3000 3500 4000 4500 E75910 Item Description 1/min Bore: 86mm / Stoke: 94.6mm Max. Torque 250Nm at 1500 - 2200 Max.Power 62.5kW (85HP) at 3500 1/min 1/min FordTransit 2006.5 (April 2006 ) Date of Publication: 12/2006...
Page 68 Common Rail 2.2L TCI 81kW (110HP) Diesel Engine 1000 1500 2000 2500 3000 3500 4000 4500 E75911 Item Description 1/min Bore: 86mm / 94.6mm Max. Torque 285Nm at 1750 - 2250 Max.Power 81kW (110HP) at 3500 1/ 1/min FordTransit 2006.5 (April 2006 ) Date of Publication: 12/2006...
Page 69 Common Rail 2.2L TCI 96kW (130HP) Diesel Engine 1000 1500 2000 2500 3000 3500 4000 4500 E75912 Item Description 1/min Bore: 86mm / Stroke: 94.6mm Max. Torque 310Nm at 1600 - 2500 Max.Power 96kW (130HP) at 3500 1/min 1/min FordTransit 2006.5 (April 2006 ) Date of Publication: 12/2006...
Page 70 Common Rail 2.4L TCI 74kW (100HP) Diesel Engine 1000 1500 2000 2500 3000 3500 4000 4500 E75913 Item Description 1/min Bore: 89.9mm / Stroke: 94.6mm Max.Torque 285Nm at 1600 - 2200 Max. Power 74kW (100HP) at 3500 1/ 1/min FordTransit 2006.5 (April 2006 ) Date of Publication: 12/2006...
Page 71 Common Rail 2.4L TCI 85kW (115HP) Diesel Engine 1000 1500 2000 2500 3000 3500 4000 4500 E75914 Item Description 1/min Bore: 89.9mm / Stroke: 94.6mm Max. Torque 310Nm at 1750 - 2000 Max. Power 85kW (115HP) at 3500 1/min 1/min FordTransit 2006.5 (April 2006 ) Date of Publication: 12/2006...
Page 72 Common Rail 2.4L TCI 103kW (140HP) Diesel Engine 1000 1500 2000 2500 3000 3500 4000 4500 E75915 Item Description 1/min Bore: 89.9mm / Stroke: 94.6mm Max. Torque 375Nm at 2000 - 2250 Max. Power 103kW (140HP) at 3500 1/min 1/min FordTransit 2006.5 (April 2006 ) Date of Publication: 12/2006...
Page 73 2.3L Gasoline engine 107kW (145HP) 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500 E75916 Item Description 1/min FordTransit 2006.5 (April 2006 ) Date of Publication: 12/2006...
Page 74 Bore: 89.9mm / Stroke: 91.0mm Max. Torque 210Nm at 2500 1/min Max. Power 107kW (145HP) at 5500 1/min FordTransit 2006.5 (April 2006 ) Date of Publication: 12/2006...
Page 75: Engine Cooling
National Sales Company facility. representative, or Local Ford Dealer. If they are unable to help you then please contact the • Coolant tube routing must be below the base Vehicle Converter Advisory service at of the degas bottle.
Page 76: Auxiliary Heater Installation
NOTE: For further information please contact your local National Sales Company representative, Refer to: 5.10 Corrosion Prevention (page 221). or Local Ford Dealer. If they are unable to help NOTE: The installation must be in line with the you then please contact the Vehicle Converter appropriate legal requirements Advisory Service at VCAS@ford.com.
Page 77: Accessory Drive
For most front end accessory drive applications your local National Sales Company the longer Regular Production Option air representative, or Local Ford Dealer. If they are -conditioning belt can replace the standard belt unable to help you then please contact the and pulley layout.
Page 78 Front End Accessory Drive Assembly on 2.4l Diesel Engine E74218 Pulley and Belt Layout on 2.4l Diesel Engine Item Description Power Steering Pump Idler Vacuum Pump Coolant Pump Compressor (may be replace by ancillary unit) Crankshaft Pulley Alternator Auto Tensioner FordTransit 2006.5 (April 2006 ) Date of Publication: 12/2006...
Page 79: Front End Accessory Drive 2.2L Diesel
Front End accessory Drive Assembly on 2.3l Petrol Engine E74219 Pulley and Belt Layout on 2.3l Petrol Engine Item Description Alternator Idler Coolant Pump Power Steering Pump Compressor (may be replaced by ancillary unit) Crankshaft Pulley Auto Tensioner 3.3.2 Front End Accessory Drive When engineering and installing a new front end 2.2l Diesel accessory drive, i.e.
Page 80 Front End Accessory drive Assembly on 2.2l Diesel Engine E74220 Pulley and Belt Layout on 2.2l Diesel Engine Item Description Idler Idler Alternator Power Steering Pump Crankshaft Pulley Auto Tensioner Compressor FordTransit 2006.5 (April 2006 ) Date of Publication: 12/2006...
Page 81: Electronic Engine Controls
3.4 Electronic Engine Controls CAUTION: Do not make any additional connections to the electrical circuits associated with the engine management system NOTE: It is not necessary to disconnect or remove engine management modules. FordTransit 2006.5 (April 2006 ) Date of Publication: 12/2006...
Page 82: Clutch
NOTE: For further information please contact your local National Sales Company representative, or Local Ford Dealer. If they are unable to help you then please contact the Vehicle Converter Advisory Service at VCAS@ford.com. FordTransit 2006.5 (April 2006 )
Page 83: Manual Transmission
3.6 Manual Transmission The following manual transmissions are available The following manual transmission is available for diesel engines dependent on the drive. for gasoline engines . • Front Wheel Drive vehicles • Rear Wheel Drive vehicles VXT 75 transmission MT 75 transmission •...
Page 84 MT82 - 6 Speed Manual Rear Wheel Drive Transmission E76033 MT82 Ratio of Single Gears Gear Ratio 5.441 2.839 1.721 1.223 1.000 0.794 Reverse 3.750 FordTransit 2006.5 (April 2006 ) Date of Publication: 12/2006...
Page 85 MT75 - 5 Speed Manual Rear Wheel Drive Transmission E76034 Gear Ratio 4.200 2.238 1.366 1.000 0.763 Reverse 3.600 FordTransit 2006.5 (April 2006 ) Date of Publication: 12/2006...
Page 86: Exhaust System
• Ensure existing shields are maintained that the original Ford design (100mm • Add further shields over exhaust system as minimum). necessary to avoid fire risk. FordTransit 2006.5 (April 2006 )
Page 87 NOTE: For further information please contact your local National Sales Company representative, or Local Ford Dealer. If they are unable to help you then please contact the Vehicle Converter Advisory Service at VCAS@ford.com.
Page 88: Fuel System
3.8 Fuel System WARNINGS: • Refit the Ford hose assembly from the fuel pump to the fuel line. Do not cut into the original fuel • The tube and/or line must be routed supply lines independently and secured to the body Make sure that the modified vehicle structure or to suitable brackets.
Page 89 Auxiliary Fuel Supply Port E78195 Item Description Ford Motor Company Part Cut off top of Port on tank cap Insert tube into port and fix connector to tank cap Drive Direction FordTransit 2006.5 (April 2006 ) Date of Publication: 12/2006...
Page 90: Communications Network
4.1 Communications Network 4.1.1 CAN-Bus System Description CAN uses propriety message sets to and Interface communicate between the devices shown, via Medium Speed (MS), High Speed (HS), Private WARNING: Do not tamper with, cut and Public Buses. In addition there is localised into or connect to any of the application of LIN and ISO 9141 K-line serial links.
Page 91: Central Junction Box (Cjb)
CAN-Bus System (Architecture) Central Junction Box (Passenger Junction Antilock Brake System Box) Voice Recognition Module/Wireless Powertrain Control Module connection (blue tooth) Audio Control Unit (Radio/CD) Steering Angle Sensor Navigation (Radio/CD) Yaw Rate Sensor Remote Keyless Entry Diagnostic Connector Passive Anti-Theft System Park Aid Mode Rain Sensor Restraints Control Module...
Page 92 The Central Junction Box (CJB) is the prime control module in the vehicle’s electrical architecture. It is responsible for management of most of the vehicle’s lighting, locking and security systems. The following chart details the consequences of overloading of the Central Junction Box.
Page 93: Circuit Diagram
National Sales Company point to below 95% of battery voltage. representative, or Local Ford Dealer. • Do not cut into the original loom. FordTransit 2006.5 (April 2006 ) Date of Publication: 12/2006...
Page 94: Module Communications Network Specifications
4.2 Module Communications Network—Specifications 4.2.1 Circit Diagram Current Rating of Wire Sizes Maximum Continuous current (A) Cross Sectional Area mW/m@20°C 30°c 50°c 0.22 84.8 0.35 54.4 37.1 0.75 24.7 18.5 13.5 12.7 17.0 22.7 4.71 29.8 3.14 38.3 1.82 51.8 1.16 69.6 0.743...
Page 95: Charging System
Inspection process at the Ford dealership, the The Transit utilizes multiplexed vehicle electronics vehicle is reconfigured to normal operation. - it is recommended that the appropriate Ford proprietary accessory systems are used. 4.3.3 Electrical Conversions Inappropriate or incorrect connection of...
Page 96 Electrical circuits associated with Management System E84706 WARNING: The fitting of voltage • The base vehicle will be equipped with a single boosters or other devices to or dual battery system (with battery disconnect enhance alternator output are not switch). Additional batteries can be fitted in allowed.
Page 97: Fitting Of Equipment Containing An Electric Motor
National Sales Company must be connected via a blocking representative, or Local Ford Dealer. If they are diode or relay to prevent “back unable to help you then please contact the Electro Motive Force (EMF)” being Vehicle Converter Advisory Service at applied to the auxiliary terminal.
Page 98: Battery And Cables
This fuse is not repairable use only a Ford A Special Vehicle Option is available. Please replacement part. contact your local National Sales Company representative for availability and details.
Page 99 The Battery Disconnect Switch is a bistable the vehicle converter. Reconfiguration of the device, requiring pulsed outputs to change state central junction box software by the Ford (each pulse has duration of 50 ms at battery Dealership is required to support this feature.
Page 100 Pull-out is activated when switching to key non-start-relevant batteries in parallel using a position I, or 0, and in key position II when no shorting bar (available from the Ford Delerships, engine run signal is sensed within 120 secs. part number 6C1T-14A439-A*). There is one It is not possible to change state within 500 ms.
Page 101 SVO Battery Configurations (with Minor Feature Codes) E84707 Item Description Driver Side Passenger Side Non Start Relevant Battery Start Relevant Battery Configured for Twin Battery, with Battery Disconnect Switch and Bus Bar fitted Deep Cycle Battery NOTE: AALFL - The converter should remove the bus bar after installation of their non start relevant batteries FordTransit 2006.5 (April 2006 )
Page 102 Dual Battery Installation with Pre-Fuse Box and Customer Connection Points E74475 Item Description Pre-Fuse Box Customer Connection Points (Not M1 or M2 buses) Start Relevant Battery - connection to this battery is not permitted Battery Access Points For auxiliary customer loads, only connect to the customer connection points provided (not on M1 and M2 Buses).
Page 103: Generator And Alternator
4.4.2 Generator and Alternator Torque Curve of Alternator 2000 4000 6000 8000 10000 12000 14000 16000 18000 20000 E75871 Diagram E75871 shows the torque in Nm which NOTE: For equivalent engine revs per minute is required to drive the alternator. The vertical (RPM), the alternators revolutions, axis (B) should axis (A) shows the torque [Nm] and the horizontal be divided by the following factors: 2.66 for diesel...
Page 104 Current in relation to revolutions per minute 2000 4000 6000 8000 10000 12000 14000 16000 E75872 Diagram E75872 shows the current (A) in relation to alternators revolutions (B) per minute [1/min]. This preliminary Bosch performance curve (1) arose at a temperature of 25°C and a voltage of 13,5V.
Page 105 Temperature 27°C - Voltage 13.8V Temperature 60°C - Voltage 13.5V Temperature 93°C - Voltage 13.1V Temperature 115°C - Voltage 12.9V Diagram E75873 shows Ford Transit output performance of alternator according to Ford Specification with five different temperatures. FordTransit 2006.5 (April 2006 )
Page 106: Climate Control System
4.5 Climate Control System WARNING: Do not use propylene glycol based coolant • Never secure hoses or tubes to the transmission fill or dip stick or to any fuel system or brake component • Do not route heater or refrigerant lines near or directly over any exhaust system component, including the exhaust manifolds.
Page 107: Instrument Cluster
4.6 Instrument Cluster WARNING: Do not tamper with, cut into or connect to any of the CAN-Bus interface wiring or connectors. The Transit has a Hybrid electronic Cluster (HEC). Most of the functions are managed over the CAN-Bus interface (pins 3-8) FordTransit 2006.5 (April 2006 ) Date of Publication: 12/2006...
Page 108: Horn
4.7 Horn A dual horn may be fitted to the vehicle in place of the single horn. Any other aftermarket horn (for example an air horn) will need to be driven by a separate relay energised by the horn circuit. FordTransit 2006.5 (April 2006 ) Date of Publication: 12/2006...
Page 109: Tachograph
4.8 Tachograph The factory-fit Tachograph option uses a Siemens VDO system. It is recommended, 4.8.1 Legislation therefore, that any vehicle that requires a tachograph is sent to an authorised Siemens WARNING: All tachographs require VDO Tachograph Service Centre for system the same wiring connections as this installation and calibration.
Page 110: Tachograph Mounting
Siemens VDO directly. 4.8.2 Tachograph Mounting Wiring Standard Ford installation uses a pod on top of NOTE: Not all instrument panel looms contain the instrument panel. The tachograph mounts in tachograph wiring.
Page 111 Tachograph Mounting - Double DIN E75503 Item Description Rear Mounting Bracket for Tachograph Tachograph Speed Sensor Mounting The tachograph requires a dedicated speed sensor mounted to the transmission. The position varies depending on the transmission type. Vehicles specified without tachograph may not have the appropriate sensor mounting position FordTransit 2006.5 (April 2006 ) Date of Publication: 12/2006...
Page 112: Information And Entertainment System - General Information Specifications
4.9 Information and Entertainment System - General Information—Specifications 4.9.1 Radio Connector Multimedia head units (Audio and Navigation) are NOTE: Power for Radio - do notswitch the connected to the instrument panel wiring via the permanent battery feed (KL 15) and ignition feed Fakra connector see below diagram E74493 (KL 30) on the radio connection.
Page 113: Possible Accessories
Connector B Mono + Mono - Switched Accessory + Radio Remote Control Ground Auxiliary Left + Auxiliary Left - Auxiliary Right + Auxiliary Right - Phone Transceiver Active Radio Remote Control + Connector C Auxiliary 2 Left Auxiliary 2 Right Audio Ground Fuse Relay no fuse is fitted to the radio...
Page 114 Rear speaker wiring is always present in the Junction Box, as shown in the next figure. Insert instrument panel harness (14K024), but not terminals crimped to suitable wires. For the exact necessarily in the harnesses (14401 and connector location 14405/14A005) that then take the signals to the Refer to: 4.14 Special Conversions (page 131).
Page 115: Cellular Phone
Ford dealership. These use the Ford MS CAN multimedia bus to operate in conjunction with the Ford audio and navigation systems. FordTransit 2006.5 (April 2006 )
Page 116: Exterior Lighting
4.11 Exterior Lighting Where the following text makes reference to the addition of wires 4.11.2 Additional External Lamps Refer to: 4.14 Special Conversions (page 131). All power for additional exterior lamps must be (Adding Connectors, Terminals and Wiring) taken through the Auxiliary Fuse Box with a WARNING: Make sure that the suitable switch and / or relay as required.
Page 117: Lamps Hazard / Direction Indication
A special jumper link is available for this purpose from the local Ford dealer. The maximum permissible load with the standard system is: NOTE: For various vehicles Cat 6 repeater lamps must be fitted.
Page 118: Interior Lighting
4.12 Interior Lighting 4.12.1 Additional Internal Lamps Additional cabin interior lighting may be obtained by directly accessing the connector inside the dome lamp in the cab. Additional load space interior lighting may be obtained by directly accessing the connector inside the load space lamps in the load space area.
Page 119: Fuses And Relays
4.13 Fuses and Relays 4.13.1 Wiring Specification 4.13.2 Auxiliary Fuses, Fuse Box When designing wire installations for additional and Relays (Fuses - Standard) equipment use the cable size recommended by the equipment manufacturer or select a suitable WARNING: No increase in existing size from the Current Rating Wire Sizes vehicle standard fuse capacity is specifications chart.
Page 120: Customer Connection Points
4.13.3 Customer Connection Points Fuse Locations in Pre Fuse Box (Lid Removed) for Customer Connection Points E78999 With the exception of M1 and M2 Buses, the NOTE: Do not exceed the 60A per fuse rating. vehicle is provided with 3 customer connection Where the load exceeds the above ratings (which points, at the rear of the driver’s seat, which are can be combined to provide 180A), a separate...
Page 121: Special Vehicle Option Auxiliary Fuse Box
4.13.4 Special Vehicle Option Auxiliary Fuse Box Special Vehicle Option Auxiliary Fuse Box - Early Installation (Right Hand Drive Shown) E75087 Item Description Special Vehicle Option Auxiliary Fuse Box Mounting Bracket Standard Relay Box Ground Point (GP15) C1-C7 See Recommended Engine Run Connection Circuit and Special Vehicle Option Auxiliary Fuse FordTransit 2006.5 (April 2006 ) Date of Publication: 12/2006...
Page 122 Ground Point (GP15) C1-C7 See Recommended Engine Run Connection Circuit and Special Vehicle Option Auxiliary Fuse The Fuse Box (Ford Part number 6C1V-14517-D_) see diagram E75088 - Recommended Engine is available as factory-fitted Special Vehicle Option Run Connection Circuit and Special Vehicle and can be retrofitted.
Page 123 Recommended Engine Run Connection Circuit and Special Vehicle Option Auxiliary Fuse Box E75088 Item Description Special Vehicle Option Auxiliary Fuse Box Power Mini Relay Micro Relay Central Junction Box (C4-7 = Engine Run Pin) via Jumper Harness 6C1V-14A411-F_ Ground Point/Earth Terminal(GP15) Connector - Customer Use Connector - to Switch Harness (6C1V-14A303) Connector - To Beacon Harness (6C1V-10A993)
Page 124: Additional Ignition, Instrument Panel Illumination And Air Conditioning On Signals
Fuse Location Fuse Position Power Feed 1 (Maximum Power Feed 2 (Maximum 60A) 60A) The total sum of fuses marked * is not to exceed 40A The Special Vehicle Option Auxiliary Fuse Box, with integrated link harness, will provide the 4.13.5 Additional Ignition, following connections: Instrument Panel Illumination and...
Page 125 8 Pin Connector - for Ignition, Instrument Panel Illumination and Air Conditioning On Signals E84713 Item Description Pin 4 KL15 (12V ignition feed) Pin 7 Used instead of Pin 4 on vehicles euipped with Air Conditioning) Pin 6 Instrument Panel Illumination (12V feed) Pin 5 Air Conditioning On (12V)* It is recommended that these signals are used...
Page 126 Heater Jumper for Ignition, Instrument Panel Illumination and Air Conditioning On Signals - Early Installation E75089 Item Description Ignition, Instrument Panel Illumination and Air Conditioning On Signals C4 - Connection to Heating, Ventilation and Air Conditioning Harness (18B518) C5 - Connection to Instrument Panel Harness (14K024) FordTransit 2006.5 (April 2006 ) Date of Publication: 12/2006...
Page 127: Relays And Switches
• Relays can be installed inside the vehicle or inside the Special Vehicle Option Auxiliary Fuse Box. E75017 • The Ford standard relays have a nominal current of 300mA (max) at 25°C. Relays with greater loads should not be used. • For maximum switching currents please refer to Relay Figures E75017-E75021.
Page 128 Micro Relay Parameters Normally open contacts 20 amps Normally closed contacts 16 amps Nominal coil current 300 mA (max) Medium current changeover relay - Part number:6G9T-14B192-B_ Medium current normally open relay - Part number: 6G9T-14B192-A_ (pin 4 not present) Mini relay E75018 Mini Relay Parameters Normally open contacts...
Page 129 Ford part number types are used. should be used. Three switches are available:...
Page 130: Windscreen Wipers
NOTE: Power to wiper motors is limited by the size of the wiring and associated relays. If any alternative wiper installation is made, it must have a specification equivalent to Ford components. Refer to: 5.6 Glass, Frames and Mechanisms (page 211).
Page 131: Special Conversions
4.14 Special Conversions 4.14.1 Vehicle Speed Output Note:- (Signal) • A hard-wired vehicle speed signal is only available on diesel engine vehicles. At present, this information is only readily available • Vehicle speed is derived from one of two as a CAN message. However, on Diesel vehicles sources, the wheel speed sensor (for vehicles it is possible to access a hard-wired output.
Page 132: Engine Run Signal (D+ Alternative)
(6C1V-14A411-F*) is available from your This engine run signal is ground switching (max. Local Ford Dealer to fit between the door / main current sink 200mA), for example it provides no loom in-line connector. If the vehicle does not...
Page 133: Connectors
In-line to 14401 main loom In-line to 14A631 door loom Engine run output (6.3mm male connector), part of T-piece harness (6C1V-14A411-F*) 4.14.3 Connectors CAUTION: Only use Ford approved connectors Cutting into vehicle wiring is not permitted Cutting into the Original Wiring...
Page 134: Installation And Routing Guides
Ford do not recommend the use of these connectors for any other purpose than that intended by design.
Page 135 • 10mm from static components (unless A number of locations in the dash panel have clamped to it). been identified for additional holes to route wires through. See figures E74496 Left Hand and • 250mm from exhaust system. E74497 Right Hand Drive Dash Panels for •...
Page 136: Electrics For Tow Bar
Tow bar electrical system may be ordered as a For information, there is no trailer tell-tale in the 13-pin DIN connector, as part of the original cluster, and if equipped with the Ford Trailer Tow vehicle build. module, the vehicle’s rear fog lights are disabled when a trailer is hitched-up.
Page 137 Description 13N490 Harness Tubes Pins The Ford trailer tow system is designed to The Central Junction Box (CJB) does not support one primary set of direction indicators support the incremental load of powering side installed on to the trailer (left hand side and right marker lamps on a trailer, if these are required hand side).
Page 138 Trailer Tow Bar Interface Connector for Van, Bus and kombi E76102 Van, Bus and kombi Connection in Engine Bay Connector A Not Used KL30 - Battery + KL15 - Ignition Trailer Detect FordTransit 2006.5 (April 2006 ) Date of Publication: 12/2006...
Page 139 Trailer Tow Bar Interface Connector for Chassis Cab E76101 Chassis Cab connection in Engine Bay (with Jumper between Connectors) Connector B Ground - Float Markers, Right Licence KL30 - Battery + Plate and Lamps (direction indicator, posi- tion lamp, fog lamp, reversing lamp, stop lamp).
Page 140: Ground Points
Dynamics System (ESP - Electronic Stability Program) Ground wires should be brought back to the Ford • Misc - Miscellaneous ground points provided, please refer to the following figures. For very high current users, it is...
Page 141 Ground Points Table - Van, Bus, Kombi Ground Location Fixing Ford Part Torque Type Harness Point Type Number (GP) GP29 Engine Bay LHS Screw W705661 S437M 12NM +/- Misc. Power 14401 Electric GP31 Engine Bay RHS Screw W705661 S437M 12NM +/- Misc.
Page 142 Chassis Cab Ground Points E75016 FordTransit 2006.5 (April 2006 ) Date of Publication: 12/2006...
Page 143 Ground Points Table - Chassis Cab Ground Location Fixing Ford Part Torque Type Harness Point Type Number (GP) GP29 Engine Bay LHS Screw W705661 S437M 12NM +/- Misc. Power 14401 Electric GP31 Engine Bay RHS Screw W705661 S437M 12NM +/- Misc.
Page 144 E77395 E77396 E77397 FordTransit 2006.5 (April 2006 ) Date of Publication: 12/2006...
Page 145 E77398 13 12 E77399 FordTransit 2006.5 (April 2006 ) Date of Publication: 12/2006...
Page 146: Special Vehicle Options (Svo) And Aftermarket Kits
4.14.7 Special Vehicle Options In addition to the trailer tow kits and SVO fuse box (SVO) and Aftermarket Kits already mentioned, a number of other kits are under development to meet customer needs The following Special Vehicle harnesses and aftermarket kits are available: Special Vehicle Option (SVO) Harnesses 6C1V-10A933-C_ Front beacon...
Page 147: Additional Vehicle Signals / Features
4.14.8 Additional Vehicle Signals NOTE: It is not recommended that signal is used / Features to drive auxiliary equipment directly a relay (max 300mA) should be used. The existing reverse light load is close to the threshold and is Reverse Signal hard-wired through the Central Junction Box for current sensing to generate the appropriate CAN A reverse signal is available on the tail light...
Page 148 Trailer Light Connector E84716 In addition, the reverse signal is also available Reverse Signal on Tail Light Connector directly from the Central Junction Box (max. 300mA), but there is no free pin available. For details, please refer to Figure E84705, connector C2 (Brown) Refer to: 4.1 Communications Network (page 90).
Page 149 Connector C2 E84724 Item Description Reverse Signal Third Brake/Stop Light Pin for the Third Brake/Stop Light A signal for a third brake / stop light is also available on the tail light connector (see Reverse Signal). It can be used directly to feed an LED stop light, or a conventional stop light with a bulb (maximum 21W)* In order to avoid electrical issues due to leakage,...
Page 150 Pin Brake Light on Trailer Tow in-line connector at Rear of Vehicle E84726 Item Description Pin 8 Third Stop Light *If an existing third brake/stop lamp is already 1. Ignition off, master light switch to position ‘P’: fitted, or if the power exceeds 21W, an all 4 lamps are on.
Page 151 Each breakout will support a 10W load, and will connect with a Ford jumper harness (part number 6C1T-15B484-A*) that provides connectors to each side of the vehicle for side marker lights (one harness connects to one left and one right side marker light, for example:- 5W per side).
Page 152 Rear Side Marker Lamp Harness Connector (Chassis Cab) E84891 Middle Side Marker Lamp Harness Connector (Chassis Cab) E84892 FordTransit 2006.5 (April 2006 ) Date of Publication: 12/2006...
Page 153 Connectors are already part of the wiring if the see lighting load table. There is NO vehicle is medium or high spec. (for example with Ford-released harness for this, as the electrical side mirrors). The main light switch will end-outline marker lights normally form part need to be changed for one that includes this of the float.
Page 154 Central per the Ford design, it is not possible to utilize the Junction Box would need reconfiguring, which wire from the handbrake switch as part of an...
Page 155 (i.e. one relay for lock all, one chassis cab vehicle. relay for driver door unlock etc.) The use of Ford Transit lock mechanisms is strongly recommended as the Central Junction Box is designed to drive these latches for the correct amount of time.
Page 156 Pins to control Additional Door Locks E84719 Item Description Pin 7 Driver door unlock Pin 8 Passenger door unlock (Chassis Cab) Deadlock all lock all FordTransit 2006.5 (April 2006 ) Date of Publication: 12/2006...
Page 157: Engine Rpm (Revs Per Minute) Speed Controller
Third Button on Key Fob Pin 12 Controlled by Third Button on the Key Fob E84730 Item Description Key Fob Signal Pin 12 on connector C2 of the Central Junction Box is controlled by the third button on the key 4.14.9 Engine RPM (Revs Per fob please refer to Figure E84730.
Page 158 System Availability NOTE: A power take off layout can only be implemented on vehicles fitted with an ABS This feature is built into the latest Powertrain braking system. Manual braking systems employ Control Module (PCM) software on all diesel a transmission speed sensor to determine vehicle engine variants.
Page 159 Main Electrical Loom Location (green / white loop) E88307 The loom is loosely taped in this location, so the green/white loop should be easy to extract. See Figure E88703 FordTransit 2006.5 (April 2006 ) Date of Publication: 12/2006...
Page 160 Resistance Ladder Resistance Ladder Circuit E88295 Item Description To Green / White Wire Stop Engine RPM 1 on / off or Variable Control 'Idle' RPM 2 on / off or Variable Control 'Negative (-)' RPM 3 on / off or Variable Control 'Positive (+)' RPM control Armed or Increased Idle on / off The resistance ladder circuit acts as a potential •...
Page 161 Alternatively can be modified: 4. Press & release the brake pedal once 1. via the IDS diagnostics system at a Ford dealer The vehicle should now be in 3 speed mode. (there may be a charge for this) The new settings can be saved & learn mode 2.
Page 162: Adding Connectors, Terminals And Wiring
How to change the 3 pre-set default Some Reasons why RPM speed RPM values in the 3 speed mode Control operation may stop or fail 1. Enter ‘learn mode’ (see directions above) The RPM Speed control software monitors vehicle information during operation in RPM 2.
Page 163 For Information Only Terminal part number: 1L2T-14421-A* (LHD) 3F2T-14474-R* (RHD) Connector: 4L5T-14A459-A* (LHD male) 5L5T-14489-A* (RHD female)] Wire size and Color: 0.75 CSA Right RR+ brown-white Right RR brown-blue Left RR+ brown-green Left RR brown-yellow 57-Way Connector - used for connecting two additional Rear Speakers (RHD shown) E84709 Item...
Page 164 Terminal Insertion RHD 1. Withdraw the secondary lock plate by levering up the tabs at the four corners - the lock plate only needs to be slid back past the first set of detents E84893 2. Insert the wires with the pre-crimped terminals into the correct cavities according to color - the terminals are polarized and will only fit one way.
Page 165 Terminal Insertion LHD 1. Pull out secondary lock using pliers E84895 2. Insert the wires with the pre-crimped terminals into the correct cavities according to Color – the terminals are polarized and will only fit one way E84896 FordTransit 2006.5 (April 2006 ) Date of Publication: 12/2006...
Page 166 3. Replace the light grey secondary lock E84897 4. Replace the blue ‘spacer’ and push home so that it is flush against the grey secondary lock E84898 Phone Transceiver Active (PTA), or Audio Mute for Information Only Terminal part number: 96AG-14474-RSA (-RZA) Connector (insert): 3S7T-14489-E* Wire size and Color: 0.5 CSA, grey-yellow FordTransit 2006.5 (April 2006 )
Page 167 Terminal Insertion 1. The wire with the crimped terminal is inserted into the appropriate vacant cavity in the main FAKRA connector – the terminal is polarized and will only fit one way. E84731 Item Description Audio Mute E85032 Vehicle Speed Signal For Information Only Terminal part number: 96AG-14474-RSA Wire size and Color: 0.5 CSA, blue-green...
Page 168 Terminal Insertion 1. The furthest of the 3 connectors needs to be unplugged in order to get access to the middle connector, C2 (brown). 2. Once the middle connector is removed, the black cap needs to be removed by first removing the cable tie, and then levering up the two detents on the sides; the cap can then be slid off E84899 3.
Page 169 4. Insert the wire with terminal into cavity K1 – there is a tab on the terminal that should allow this to be inserted one way only. This will pierce the “mat seal”, which is perfectly normal E84901 E84720 Item Description Vehicle Speed Signal FordTransit 2006.5 (April 2006 )
Page 170 5. Slide back the terminal latching plate, refit the black cap (and refit cable tie as required), and plug both connectors back into the PCM. Refit any shields / covers E84902 Additional ‘Theater Lighting’ for rear of vehicle interior For Information Only Terminal part number: 3M5T-14474-DBA Wire size and Color: 0.75 CSA, white-blue note: this terminal will accept a wire size of 1.0 CSA;...
Page 171 2. Secondary lock displaced E84904 3. Insert the wire with the pre-crimped terminal into the correct cavity (C2-27) – the terminals are polarized and will only fit one way E84905 FordTransit 2006.5 (April 2006 ) Date of Publication: 12/2006...
Page 172 Pin 27 on connector C2 for 75W ‘Theater Lighting’ E84712 Item Description Rear Theater Lighting 4. Push home the cream secondary lock Third button on key fob For Information only As per Additional ‘Theater’ Lighting, but the pre-crimped wire is inserted in cavity C2-12. Terminal part number: 97BG-14474-ACB Wire size and Color: 1.5 CSA, yellow-violet Engine Run Signal (D+ Alternative)
Page 173 Male and Female connectors with pin for engine run signal shown E84721 Item Description Male connector Pin16 - Engine Run Signal Female connector Pin16 - Engine Run Signal Additional Position Lights at the rear For Information only Mating connector part number: 89FG-14A624-AB* Seal: 89FG-10C930-AA (Note: this is a waterproof connector) Terminal part number: 93FG-14421-BBA (0.5 1.0 CSA) Wire size and Color: 0.75 CSA, violet-white (feed);...
Page 174 Roof-mounted Position Light – Front For Information Only Mating connector part number: 89FG-14A624-AB* Seal: N/A Terminal part number: 93FG-14421-ABA (0.5 1.0 CSA) Wire size and Color: 0.5 CSA, blue-brown / yellow-grey (feed); black / black-white (ground) If larger cross section wire is to be used (1.5 2.5 CSA), the following part should be used: Terminal part number: 93FG-14421-ACA Reverse Signal / Third Brake (Stop) Light (For Information Only) Chassis Cab Only...
Page 175: Body
5.1 Body 5.1.1 Body Structures - General • Re-paint metal edges after cutting or drilling. Information All metal edges must comply with exterior and interior protection legislation. When carrying out vehicle • All fixings through the floor, sides or roof must conversions/modifications the following points be sealed.
Page 176 Floor 'No Drill Zones' under the Floor Fuel Tank. E74574 Item Description Center line Front Wheel Axle Center of 'B'-Pillar Floor 'No Drill Zones' Dimensions(mm) 1312 1312 1000 FordTransit 2006.5 (April 2006 ) Date of Publication: 12/2006...
Page 177: Back Panel Removal
For integral structures such as ambulances or described below, please consult the Vehicle motor-homes with increased rear overhang built Converter Advisory Service (VCAS@ford.com) onto the chassis the following applies: for an individual solution. Cab Van Floor Vehicle...
Page 178 Chassis Cab with single Rear Wheel Axle for Front Wheel Drive and Rear Wheel Drive E74529 Wheelhouse Dimensions for Chassis Cab with Single Rear Wheel Axle for Front and Rear Wheel Drive Vehicles 418mm 268mm 448mm 242mm 164mm 696mm 194mm 89mm 141°...
Page 179: Chassis Cab
Chassis Cab with Dual Rear Wheel Drive Axle E74530 Wheelhouse Dimensions for Chassis Cab with Dual Rear Wheel Drive Axle 417mm 141° 445mm 197mm 406mm 265mm 436mm 403mm 165mm 577mm 194mm 27mm Center line of Vehicle 75mm Section through Centre of Wheelhouse 5.1.4 Chassis Cab CAUTION: Uneven load distribution could result in unacceptable...
Page 180 WARNING: Excessive heat can build • Refer to: 5.11 Frame and Body Mounting (page up from the exhaust system, in 222). particular from the catalytic (Figure E74576 - Self Supporting Body converter. Ensure adequate heat Structure, Figure E74517 - Frame Drilling and shields are maintained.
Page 181 Body Attachment Holes in chassis Frame Top Flange Medium Wheelbase E74861 Dimensions (mm)for Body Attachment Holes in chassis Frame Top Flange Medium Wheelbase 1406 FordTransit 2006.5 (April 2006 ) Date of Publication: 12/2006...
Page 182 Body Attachment Holes in chassis Frame Top Flange Long Wheelbase E74862 Dimensions (mm)for Body Attachment Holes in chassis Frame Top Flange Long Wheelbase 1406 FordTransit 2006.5 (April 2006 ) Date of Publication: 12/2006...
Page 183 Body Attachment Holes in chassis Frame Top Flange Extended Frame E74863 Dimensions (mm)for Body Attachment Holes in chassis Frame Top Flange Extended Frame 1406 FordTransit 2006.5 (April 2006 ) Date of Publication: 12/2006...
Page 184 Sub Frame Attachment to Chassis Frame E74696 Item Description Sub-frame Longitudinal Sub-frame Outriggers Compliant Mount Chassis Frame M10 Bolts and Self Locking Nuts Sub-frame Outriggers Sub-frame Longitudinal Solid or Fixed Mount Chassis Frame M10 Bolts and Self Locking Nuts FordTransit 2006.5 (April 2006 ) Date of Publication: 12/2006...
Page 185: Cab Van Floor
Reinforcement Plate on Single Chassis Cab Vehicles E74543 5.1.5 Cab Van Floor • It is recommended to use additional U-type fixings around the main rails and cross NOTE: Cab Van Floor Models are currently only members for floor fixings wherever possible. available for use in Motor Caravan applications.
Page 186: Hydraulic Lifting Equipment For Van, Bus, Kombi And Chassis Cab
5.1.6 Hydraulic Lifting Equipment • Route electrical and hydraulics separately and for Van, Bus, Kombi and Chassis away from original Ford equipment • Use suitable clip to fix on vehicle body and sub frame • Offer master switch in the cab to isolate the...
Page 187 Rigid or Torsion Stiff Sub-frame for Van, Bus and Kombi E75874 Item Description Compliant Mount Fixed Mount FordTransit 2006.5 (April 2006 ) Date of Publication: 12/2006...
Page 188 Rigid or Torsion Stiff Sub-frame for Chassis Cab E75880 Item Description Compliant mount Fixed Mount FordTransit 2006.5 (April 2006 ) Date of Publication: 12/2006...
Page 189 Sub-frame Mounted on Floor - Fixed Mount E75875 Item Description Sub-frame Longitudinal Sub-frame Outriggers Floor of Van Load Compartment Tie Down (Load Lashing Point) It is recommended to design sub frames in way that there is no adverse strain on the vehicle structure.
Page 190 Sub-frame Mounted on Floor - Compliant Mount E75876 Item Description Sub-frame Longitudinal Sub-frame Outriggers Floor of Van Load Compartment Tie Down (Load Lashing Point) Captive Compliant Bush For Van, Bus and Kombi: • Very stiff sub-frames should not be rigidly mounted to the floor, please refer to Figure •...
Page 191 • Sub-frame ends must be relieved at forward • Stiff sub-frames, for example closed section end to minimize local contact stress Longitudinal rigidly connected with similar concentrations, see Figure E74575. section cross members, may damage the chassis frame by preventing its natural flexing. Refer to: 5.11 Frame and Body Mounting (page Therefore compliant mounts should be used 222).
Page 192: Partitions (Bulkhead) - Driver And Front Passenger(S) Protection On Van, Bus And Kombi
M6 thin sheet rivet type nuts. capacity is up to 1000kg at 1000mm from rear The standard range of Ford Regular Production end of chassis frame to center of load if mounted Option bulkheads can be retro-fitted at these and functioning on centre line of vehicle.
Page 193 Medium and High Roof Bulkhead Fixing Holes E75920 FordTransit 2006.5 (April 2006 ) Date of Publication: 12/2006...
Page 194: Racking Systems
5.1.8 Racking Systems Ford Regular Production Option Racking System (Left Hand Side Shown) E75924 E75925 FordTransit 2006.5 (April 2006 ) Date of Publication: 12/2006...
Page 195 • Vehicle should be equipped with Ford Regular also bolted through the body side structure Production Option bulkhead to give best at roof rail level at upper side.
Page 196 Design Proposal for non Ford Production Option Racking System (Left Hand Side Shown) E75921 Racking- Top Attachment, Cross Brace Roof Bow and Through Fixing Item Description Roof Panel Full Width Cross Brace Bow Through Bolt Rigid, Self Supporting Rack Structure Fixed to Cross Brace Bow at Roof Height Drip Channel FordTransit 2006.5 (April 2006 )
Page 197 E75922 Racking - Floor Fixings to Load Compartment Tie Downs Item Description Rigid Self-Supporting Racking Frame Work Cross Brace Load Compartment Tie Down FordTransit 2006.5 (April 2006 ) Date of Publication: 12/2006...
Page 198: Front End Integrity For Cooling, Crash, Aerodynamics And Lighting
Do not alter the lighting system. Continuous air flow through the front end and engine compartment is not to be hindered by adding any additional equipment. If uncertain please consult the Vehicle Converter Advisory Service VCAS@ford.com. FordTransit 2006.5 (April 2006 ) Date of Publication: 12/2006...
Page 199: Tipper Bodies
Finishing cab and attach to all mounting locations, with the forward end designed to minimize local Use Ford approved sealing and finishing material, frame stress, please refer to Figure E74575 and underbody corrosion protection. Sub-frame for low floor or other equipment.
Page 200: Body System - General Information Specifications
5.2 Body System - General Information—Specifications 5.2.1 Van Floor - Load Compartment Tie Downs for Van ,Bus and Kombi Plain M8 weld nuts are supplied as standard on right hand drive vehicles and available to order as an option on left hand drive vehicles. Alternatively the floor can be drilled, with care, to access the weld nuts.
Page 201 Location of Underfloor M8 Weld Nuts for Medium Wheel Base E74506 Location of Underfloor M8 Weld Nuts for Long Wheel Base E74507 FordTransit 2006.5 (April 2006 ) Date of Publication: 12/2006...
Page 202 Location of Underfloor M8 Weld Nuts for Extended Frame E74508 Dimensions to locate Load Compartment Tie Downs (mm) Short Wheel Base Medium Wheel Long Wheel Base Extended Frame Base Center Line of Front Axle 1511.7 1430.0 1533.8 1432.0 1609.3 1609.3 1609.0 1609.0 1609.3...
Page 203: Body Closures
5.3.1 Load Compartment Interior To avoid locking system security complications, Lining it is recommended to discuss with the local Ford dealer prior to modifications taking place. Do not damage the lock or latch system (electrical cables, release system) when applying The Central Junction Box is designed to work interior lining.
Page 204 No Drill Zone - Driver and Passenger Doors E74856 No Drill Zone - Driver and Passenger Doors Item Description 916.5mm 106.9mm 187.5mm 73.2mm FordTransit 2006.5 (April 2006 ) Date of Publication: 12/2006...
Page 205 No Drill Zone - Lift-Gate E74857 No Drill Zone - Lift-Gate Item Description 96.2mm 72.1mm 202.2mm 65.8mm FordTransit 2006.5 (April 2006 ) Date of Publication: 12/2006...
Page 206 No Drill Zone - Left Hand And Right Hand Side Sliding Doors E74858 No Drill Zone - Left Hand And Right Hand Side Sliding Doors Item Description 221.3mm 153.8mm 74mm 92.9mm FordTransit 2006.5 (April 2006 ) Date of Publication: 12/2006...
Page 207 No Drill Zone - Rear Cargo Doors E74859 No Drill Zone - Rear Cargo Doors Item Description 248.9mm 66.5mm 107.4mm 182.9mm FordTransit 2006.5 (April 2006 ) Date of Publication: 12/2006...
Page 208: Rear View Mirrors
5.4 Rear View Mirrors 5.4.1 Mirrors for Wide Vehicles NOTE: In addition it is necessary to order wide repeater lamps for 2.3m width pack. Vehicles can be ordered with short or with long arm rear view mirrors on the outer side. Short arm mirror is homologated up to 2100mm maximum body width and long arm mirror up to 2300mm maximum body width, see below Figure...
Page 209: Seats
5.5 Seats 5.5.1 Rear Seat Fixings Positions the following figure shows the second and third - Kombi row seat fixing in the floor. These holes and positions are independent of the wheelbase. CAUTION: Do not install seats in the Refer to: 5.6 Glass, Frames and Mechanisms rear cargo area of a Van.
Page 210: Heated Seats
It is not advisable to retrofit heated seats due to potential airbag operation or malfunction WARNING: The electrical feed for the (incorrect configuration). original heated Ford seat must not be used for other purposes, e.g. other electrical consumers FordTransit 2006.5 (April 2006 )
Page 211: Glass, Frames And Mechanisms
5.6 Glass, Frames and Mechanisms 5.6.1 Rear Windows • Cut the outer panel of the body side and door to within 1mm of the inner panel flange. For windows, it is recommended to specify the • Do not cut across panel joints or pillars. base vehicle as a Kombi or Bus body - however, •...
Page 212 Section through typical Van Body Side for Window Engineering E74533 Item Description Horizontal Section Through 'C'-Pillar Horizontal Section Through Rear Vent Window Hinge Pillar Vertical Section Through Side Window (Non Side Load Door) Section through typical Van Body Side for Window Engineering Glass Window trim strip Adhesive...
Page 213: Heated Windshield And Heated Rear Window
These options are not suitable for aftermarket or Vehicle Converter fit. NOTE: For further information please contact your local National Sales Company representative, or Local Ford Dealer. If they are unable to help you then please contact the Vehicle Converter Advisory Service at VCAS@ford.com.
Page 214: Roof Opening Panel
E74678 5.7.2 Back Panel Removal A unique Body Builder application where the original Ford roof and back panel structure are cut away must have a bolt-on reinforcing 'goal When planning, select the Special Vehicle Option, post' structure or equivalent to resist seat belt which has a detachable cab back panel (Chassis pull loads.
Page 215: Roof Ventilation
Use metal fasteners through double thickness Ventilators must prevent direct entry of water flanges for example with nuts, bolts and spreader and dust. plates where possible. A shut-off system should be available to prevent “Pop” type rivet structural value is only as good fume ingress.
Page 216: Roof Racks
75kg per rack foot. Ensure that the planned loaded vehicle operates within its designed Center of Gravity condition. For details please consult the Vehicle Converter Advisory Service VCAS@ford.com. FordTransit 2006.5 (April 2006 ) Date of Publication: 12/2006...
Page 217 Roof Rack Vehicle Converter Special Fit E75917 Item Description Rear edge of Cab Doors 'B'-Pillar 100Kg Maximum Maximum roof rack length Short Wheel Base:2500mm / Long Wheel Base 3282mm Maximum Load Height 300mm Drain Channel Roof Rack Supports each side, Short Wheel Base: 3 foot attachments / Long Wheel Base 4 foot attachments Maximum 75Kg per attachment foot worst case FordTransit 2006.5 (April 2006 )
Page 218: Air Bag Supplemental Restraint System (Srs)
5.8 Air Bag Supplemental Restraint System (SRS) 5.8.1 Air Bags The airbag sensors for side airbags are located nearby the bottom of the B-pillar WARNING: Modifications or Front Seats reinforcements in the area of the sensors may affect the side airbag Side airbags are not compatible with swiveling fire timing and result in uncontrolled front seats.
Page 219 Position of the Side Air Bag Sensor on the Left Hand Side E74470 FordTransit 2006.5 (April 2006 ) Date of Publication: 12/2006...
Page 220: Safety Belt System
5.9 Safety Belt System WARNING: Follow removal and installation procedures for the seat belt system to ensure correct function of the restraints system. The removal and reinstallation of the seat belt, strainer or any component of the seat belt system should be avoided.
Page 221: Corrosion Prevention
After cutting or reworking any sheet metal on the vehicle the damaged paint must be repaired. Ensure all materials are compatible with the relevant Ford specifications and maintain the original performance where possible. Consult the Vehicle Converter Advisory Service VCAS@ford.com for specifications.
Page 222: Frame And Body Mounting
5.11 Frame and Body Mounting 5.11.1 Mounting Points and Tubing Frame Drilling and Tube Reinforcing E74517 Item Description Alternative top hat chassis closure for 4.25 tonne chassis double cab. Full Penetration; Full diameter weld each side. FordTransit 2006.5 (April 2006 ) Date of Publication: 12/2006...
Page 223 Sub Frame for Low Floor or other Equipment E74575 Item Description Continuous longitudinal float or body support member Always use both sides of all chassis mounts Cross members Relief front end and longitudinal if there is a risk of stress concentration in chassis frame from longitudinal contact 5mm (minimum) 50mm (minimum)
Page 224: Self-Supporting Body Structure
Typical Design Principle of a Self-Supporting Body Structure E74576 Item Description Use all standard locations with 2x M10 fixings Floor Panel Body side frames Floor cross members Continuous floor U-profile frame Longitudinal L-profile Chassis frame rail of base vehicle Vehicle center line of base vehicle Also see.
Page 225 • This concept is based on a self-supporting • It is important to the overall function of the structure where the floor is mounted directly vehicle structure that the out riggers are each onto the top surface of the chassis frame. connected to a continuous longitudinal floor side frame or a structural body side structure •...
Page 226: Extended Chassis Frame
5.11.3 Extended Chassis Frame • Flat-beds and low bodies built onto Non Regular Production Option extensions must have continuous longitudinal members General: engineered by the Body Builder or equipment • Rear overhang extensions are available as supplier (please refer to Figure. E74577) to Regular Production Option.
Page 227 Non Standard Chassis Frame Extension E74578 Item Description Cross member Rear spring hanger 4x M10 bolts Spacer tube assembly Flanges removed New flanges for under-run bar 2x M10 bolts Spacer tube assembly 4.25 tonne FordTransit 2006.5 (April 2006 ) Date of Publication: 12/2006...
Page 228: Frame Drilling And Tube Reinforcing
5.11.6 Ancillary Equipment - Sub Builder providing it does not have a detrimental Frame Mounting effect on the original Ford product. Refer to: 5.10 Corrosion Prevention (page 221). Typical sub-frames and longitudinal members for flatbed and low or drop-side bodies or equipment 5.11.5 Frame Drilling and Tube...
Page 229: Spare Tire Access And Mounting
5.11.7 Spare Tire Access and For flat-beds and low bodies raised above the Mounting maximum “jounced” tyre position to obtain an uninterrupted flat floor surface see vehicle data sheets. Refer to: 1.9 Jacking (page 27). • Fore and after longitudinal bracing must be The spare wheel winch on Cab Van Floor variants added between the rear-most two (2) cross is accessible from the side as illustrated in Figure...
Page 230 Conversion Affect on Fuel Economy and Performance............. Conversion Affects on Parking Aids....About This Manual..........Accessory Drive..........Conversion Homologation....... Conversion Type..........Adding Connectors, Terminals and Wiring..Corrosion Prevention........Additional 'Theatre Lighting' for rear of vehicle Customer Connection Points......interior............... Additional External Lamps....... Additional Ignition, Instrument Panel Illumination and Air Conditioning On Signals....
Page 231 Generator and Alternator....... Glass, Frames and Mechanisms....Ground Points..........Noise, Vibration and Harshness (NVH)... Non Standard Rear Chassis Frame Extension. Hardware—Specifications....... Heated Seats........... Heated Windshield and Heated Rear Window. Package and Ergonomics—Specifications..Horn..............Package and Ergonomics....... How to Use This Manual........Painting Road Wheels......
Page 232 Vehicle Electrical Capacity - Alternator... Vehicle Ride and Handling Attributes....Vehicle Speed Output (Signal)......Vehicle Transportation Aids and Vehicle Storage.............. Warnings, Cautions and Notes in This Manual.. Warranty on Ford Vehicles........Wheel Clearance..........Wheels and Tires..........Windscreen wipers.......... Wiring Specification...........

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