Ford RANGER 2015 Body And Equipment Mounting Manual
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Ford RANGER 2015 Body And Equipment Mounting Manual

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Body and Equipment Mounting Manual
FORD RANGER 2015
Date of Publication: 02/2017

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  • Page 1 Body and Equipment Mounting Manual FORD RANGER 2015 Date of Publication: 02/2017...
  • Page 2 This publication, or part thereof, may not be reproduced nor translated without our approval. Errors and omissions excepted. © Ford Motor Company 2017 All rights reserved.

  • Page 3: Table Of Contents

    2.2.1 General............33 Commercial and Legal Aspects..7 2.2.2 Brake Hoses..........33 1.2.1 Terminology............7 2.2.3 Trailer Brakes (Low Level 1.2.2 Warranty on Ford Vehicles......7 Vehicles)............33 1.2.3 Legal and Vehicle Type Approval...7 2.2.4 Trailer Brakes (High Level 1.2.4 Alternative Type Approval......7 Vehicles)............34 1.2.5 Legal Obligations and Liabilities.....7 1.2.6...
  • Page 4 5.1.4 Front End Integrity for Cooling, Crash, Aerodynamics and Lighting....89 5.1.5 Tipper Bodies..........89 5.1.6 Tank and Dry Bulk Carriers......90 5.1.7 Genuine Ford Accessory Bull Bar..90 5.1.8 Roof Racks.............91 5.1.9 Canopies............92 Airbag Supplemental Restraint System (SRS)........95 5.2.1 Air Bags - (Low Level Vehicles).....95 5.2.2...

  • Page 5: About This Manual

    02/2017 general descriptions and advice for converting vehicles. These requirements must be complied with before a Ford Dealer should take delivery of It is recommended to review this manual in full. motor vehicle accessories from an external The BEMM is a live document which can be supplier either for themselves or on behalf of a viewed on www.etis.ford.com/BEMM or...

  • Page 6: How To Use This Manual

    Ford Ranger PX MkII vehicles are equipped with one of two electrical architectures. Refer to: 4.4 Fuses and Relays (page 81). Date of Publication: 02/2017...

  • Page 7: Commercial And Legal Aspects

    The Vehicle Converter releases Ford from all Converter shall also ensure that any alteration it claims by any third party for any cost or loss makes to a Ford vehicle or component does not (including any consequential damages) arising reduce its compliance with local design rules.

  • Page 8: Product Liability

    Ford vehicle or component made within this document. by the Vehicle Converter or any of its agents. Ford shall not be liable for any such liability (except as 1.2.10 Minimum Requirements for provided by law).

  • Page 9: Conversion Homologation

    • The fixing of the body to the donor vehicle. • Operating conditions. 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. Date of Publication: 02/2017 FORD RANGER 2015...

  • Page 10: Electromagnetic Compatibility (Emc)

    Do not fasten antenna cables to original vehicle wiring, fuel pipes or brake pipes. Keep antenna and power cables at least 100mm from any electronic modules and airbags and associated wiring. Frequency Overview Date of Publication: 02/2017 FORD RANGER 2015...

  • Page 11: Suggested Antenna Location

    Check all electrical equipment: • With ignition ON • With the engine running • During a road test at various speeds Date of Publication: 02/2017 FORD RANGER 2015...

  • Page 12: Vehicle Duty Cycle Guidelines

    Where possible make sure that the base vehicle is ordered with any necessary plant fit options. NOTE: For further information please contact your local National Sales Company representative, or Local Ford Dealer. 1.5.1 Conversion Effect on Fuel Economy and Performance Any conversion may affect the fuel consumption and performance depending on the aerodynamics and the weight added by the conversion.

  • Page 13: Jacking

    The jack must be assembled and fixed appropriately to the body to ensure safety, WARNING: Do not get under a vehicle durability and accessibility. that is supported by a jack. Vehicle Jacking Points and Axle Stand Positions Date of Publication: 02/2017 FORD RANGER 2015...

  • Page 14: Lifting

    It is important that only the correct lifting and support locations are used at all times. All Vehicles Date of Publication: 02/2017 FORD RANGER 2015...

  • Page 15: Noise, Vibration And Harshness (Nvh)

    The interior noise levels should not be deteriorated by the conversion. Reinforce panels and structures as appropriate to avoid vibrations. Consider the usage of sound deadening material on panels. Date of Publication: 02/2017 FORD RANGER 2015...

  • Page 16: Vehicle Transportation Aids And Vehicle Storage

    Check vehicle is Claims arising from deterioration caused by clean incorrect storage, maintenance or handling are not the responsibility of Ford. Remove external contamination Vehicle Converters must determine their own procedures and precautions, particularly where Check battery...

  • Page 17: Package And Ergonomics

    WARNING: Ensure that monitors NOTE: Overall width with exterior rear view mounted in the cabin meet the interior mirrors extended is 2163 mm. package and safety requirements. Item Description Maximum Body Width: 1860mm Date of Publication: 02/2017 FORD RANGER 2015...

  • Page 18: Registration Plates

    ADR 61/02 Clause 9.1.1.3. The registration plate must be affixed to the rear of the motor vehicle so that no part of such registration plate is more than 1,300 mm from the ground. Date of Publication: 02/2017 FORD RANGER 2015...

  • Page 19: Package And Ergonomics Specifications

    National Sales handling and braking characteristics. Ensure that Company representative, or Local Ford Dealer. the centre of gravity of the body and payload does Load carrying structures should not be mounted not fall outside of the recommended zone.
  • Page 20 Chassis Cab Body - Single Cab Illustrated Date of Publication: 02/2017 FORD RANGER 2015...
  • Page 21 Maximum external body width 1860 All dimensions (shown in mm) are subject to manufacturing tolerances and refer to min specification models which do not include additional equipment. The illustrations are for guidance only. Date of Publication: 02/2017 FORD RANGER 2015...

  • Page 22: Chassis Cab Body - Basic Dimensions And Weights

    1.11.2 Chassis Cab Body - Basic Dimensions and Weights Chassis Cab Body - Single Cab Illustrated Date of Publication: 02/2017 FORD RANGER 2015...

  • Page 23: Kerb Mass And Payload

    1.11.4 Front, Rear and Side Under-run Protection WARNING: Check local legislation for legal requirements. Front Under run Protection, Rear Under run Protection and Side Under run Protection must meet the requirements of local design rules. Date of Publication: 02/2017 FORD RANGER 2015...

  • Page 24: Hardware Specifications

    317.5 399.4 345.0 430.0 434.7 541.8 470.0 590.0 592.2 743.4 600.0 750.0 756.0 945.0 This torque chart is a recommendation and the converter is responsible for the optimal torque for a specific joint. Date of Publication: 02/2017 FORD RANGER 2015...

  • Page 25: Load Distribution-Specifications

    NOTE: Avoid one-sided load distribution. maintained. NOTE: For further information please contact your local National Sales Company NOTE: Uneven load distribution could result in unacceptable handling and braking representative, or Local Ford Dealer. characteristics. Date of Publication: 02/2017 FORD RANGER 2015...
  • Page 26 Super Cab Driver and Passenger Weight Distribution 'A' Wheelbase 'B' Front row 'C' Second Weight distribution per person (Kg) (mm) seats and row seats driver (mm) (mm) On Front Axle On Rear Axle Total 3220 1490 2180 Date of Publication: 02/2017 FORD RANGER 2015...

  • Page 27: Center Of Gravity

    The following charts define the recommended centre of gravity position for the mass added to to not exceeding the gross axle and train weights. the vehicle by the vehicle converter. Date of Publication: 02/2017 FORD RANGER 2015...
  • Page 28 Single Cab Center of Gravity Critical Zone Model Recommended C of G location for added mass 'A' Min (mm) 'B' Max (mm) 'C' Max (mm) 1965 3220 1965 3435 1965 3435 Vehicles with increased ride height. Date of Publication: 02/2017 FORD RANGER 2015...
  • Page 29 Super Cab Center of Gravity Critical Zone Model Recommended C of G location for added mass 'A' Min (mm) 'B' Max (mm) 'C' Max (mm) 2395 3220 2365 3435 2365 3435 Vehicles with increased ride height. Date of Publication: 02/2017 FORD RANGER 2015...
  • Page 30 Recommended C of G location for added mass Max gross added mass (kg) 'A' Min (mm) 'B' Max (mm) 'C' Max (mm) 2585 3615 2435 3615 2435 3615 Vehicles with increased ride height. Date of Publication: 02/2017 FORD RANGER 2015...

  • Page 31: Towing

    6000 kg Auto * Vehicle models with increased ride height. 1.14.4 Trailer Towball Download NOTE: The maximum trailer towball download values below relate to vehicles with Ford tow bars only. Trailer Towball Download Weight Region Minimum Trailer Maximum trailer towball down-...

  • Page 32: Suspension System

    Adding or removing leaves may result in failure or reduced function of the spring as well as other vehicle related issues for which Ford Motor Company can not be held responsible. CAUTIONS:...

  • Page 33: Brake System

    WARNING: Do not restrict the airflow and WARNINGS: cooling to the brake system. Ford is not responsible for warranty or NOTE: Do not obstruct the view of the brake fluid performance of aftermarket brake reservoir level.

  • Page 34: Trailer Brakes (High Level Vehicles)

    Failure to do so may result in loss of vehicle control, which could result in WARNINGS: serious injury or death. Ford is not responsible for warranty or performance of aftermarket brake controllers including during misuse or as a result of customer installation.
  • Page 35 Stop Lamp Signal - Connector C278, Pin 4. +12V when brake pedal is pressed If electric trailer brakes are to be installed, they can be triggered by the stop lamp switch. The maximum additional load is 1A. Date of Publication: 02/2017 FORD RANGER 2015...

  • Page 36: Fuel System

    Fuel Filler Pipe Shipping Bracket - Single Cab Date of Publication: 02/2017 FORD RANGER 2015...
  • Page 37 Fuel Filler Pipe Shipping Bracket - Super Cab Fuel Filler Pipe Shipping Bracket - Double Cab Date of Publication: 02/2017 FORD RANGER 2015...

  • Page 38: Fuel Filler Mounting

    Fuel Filler Mounting Notes Item Description The width of the bracket, where it joins the body to be at least 180 mm All 3x hardware fixation points on the filler neck must be utilised Date of Publication: 02/2017 FORD RANGER 2015...
  • Page 39 Angle of Filler Neck Filler Neck Installation Dimensions Item Description 2mm minimum bracket thickness 30° - angle to be maintained to ensure good flow of fuel when refueling and prevent flow back. Date of Publication: 02/2017 FORD RANGER 2015...

  • Page 40: Fuel Filler Vent Hose

    • The fuel tank vent hose breather cap must be upright with its arrow pointing UP. Date of Publication: 02/2017 FORD RANGER 2015...

  • Page 41: Axle Breather Vent Hose

    NOTE: Refer to the vehicle owner manual for reduction system. further information on the Selective Catalytic The engine may not start if the Diesel Reduction System. ® Exhaust Fluid (AdBlue ) level is low. Make sure it is refilled. Date of Publication: 02/2017 FORD RANGER 2015...

  • Page 42: Filling The Diesel Exhaust Fluid Tank

    NOTE: Immediately wash off any Diesel Exhaust ® (AdBlue )in the fuel tank. This can cause ® Fluid (AdBlue )that has spilled on to a painted engine damage not covered by the surface with mild soapy water. vehicle warranty. Date of Publication: 02/2017 FORD RANGER 2015...
  • Page 43 Item Description Diesel Exhaust Fluid (AdBlue) filler cap Diesel Exhaust Fluid (AdBlue) tank Exhaust system Diesel Exhaust Fluid (AdBlue) injector Date of Publication: 02/2017 FORD RANGER 2015...
  • Page 44 Item Description Diesel Exhaust Fluid (AdBlue) filler Diesel Exhaust Fluid (AdBlue) tank Diesel Exhaust Fluid (AdBlue) filler hose Date of Publication: 02/2017 FORD RANGER 2015...

  • Page 45: Battery And Cables

    12.65 volts. When the vehicle is released to from the battery. the customer, the CCV must not be less than 12.50 volts. NOTE: Ford batteries generally require no maintenance however, in certain conditions, it is possible for the electrolyte in a battery to fall Surface Charge Dissipation below the minimum level.
  • Page 46 20 amps for a period up to one and a half hours should be applied. Fast charging for a period in excess of two hours significantly increases the risk of causing damage to the battery. Date of Publication: 02/2017 FORD RANGER 2015...
  • Page 47 For vehicles equipped with BMS, an additional battery can be connected using one of the following methods: Ford Ranger vehicles are equipped with a feature 1. Use an in-vehicle battery charger (DC/DC called Battery Monitor System (BMS). This converter) such as BCDC1220 model from system measures the battery load in order to Redarc (www.redarc.com.au) (or similar),...
  • Page 48 The ground point connection should be tightened to torque of 12 Nm -/+ 1.8 Nm. Auxiliary Battery fitted to vehicles 2. Request a Ford dealer to disable the BMS. without a Battery Monitor System (BMS) Disabling the BMS enables voltage sensitive relay based dual battery systems to work.
  • Page 49 12 Nm -/+ 1.8 Nm. Connection of Auxiliary Loads - Low Level Vehicles WARNINGS: Make sure all electrical connections and wiring comply with regulations stated in ADR 42/04 Clause 9. Date of Publication: 02/2017 FORD RANGER 2015...
  • Page 50 NOTE: Auxiliary loads must always be connected Make sure all electrical connections and to the vehicle ground and not to the battery wiring comply with regulations stated in negative terminal. ADR 42/04 Clause 9. Date of Publication: 02/2017 FORD RANGER 2015...
  • Page 51 IG+ Connection at Body Control Module Item Description Body Control Module IG+ Feed Part Numbers Description Part Number / Service Manufacturer Part Number Connector CU5T-14489-XA TE (Tyco Electronics) 7C3T-14474-DA / DU2Z- Molex 14474-DA Date of Publication: 02/2017 FORD RANGER 2015...

  • Page 52: Auxiliary Battery (Xl Plus Vehicles)

    (tub) variant. For the cab chassis variants, the auxiliary battery is secured on a temporary battery carrier which itself is mounted on the chassis and used for transport from the plant to the dealer. Date of Publication: 02/2017 FORD RANGER 2015...
  • Page 53 WARNING: Make sure all electrical auxiliary battery is mounted securely, connections and wiring comply with away from any moving parts and does regulations stated in ADR 42/04 Clause not interfere with the operation of any closures/tailgate. Date of Publication: 02/2017 FORD RANGER 2015...
  • Page 54 NOTE: Ensure that a good ground location is routing and security of the auxiliary battery cable used; preferably use the ground point provided location. on the chassis rail. Auxiliary Battery Cable Item Description Auxiliary Battery Cable Date of Publication: 02/2017 FORD RANGER 2015...

  • Page 55: Auxiliary Battery Relocation And Use Of Electrical Harness Extension (Fly Lead) (Xl Plus Vehicles)

    Description Part Number Secondary Battery Harness - Double Cab AB39-14B475-MAA Secondary Battery Harness - Single Cab AB39-14B475-MBA 12 Way In-Line Switch Connector (IP Harness End) 4S7T-14489-VKA IP Switch Panel 4S7T-14A459-VKA Date of Publication: 02/2017 FORD RANGER 2015...

  • Page 56: Electronic Engine Controls

    50% +/- 10% Frequency 1.38 * v (Vehicle speed (CAN) km/h) ± 2% between 1km/h - 250km/h Minimum speed 1.38 Hz (1 kmph) Linearity error <0.3% Max frequency 398 Hz Rload 1 k ohms Date of Publication: 02/2017 FORD RANGER 2015...
  • Page 57 For Information Only protects the BCM (body control module) from overcurrent risk. Terminal part number: 96AG-14474-RSA. 3. The output must be connected to a power source. Wire size and color: 0.5 CSA, blue - green. Date of Publication: 02/2017 FORD RANGER 2015...
  • Page 58 Date of Publication: 02/2017 FORD RANGER 2015...
  • Page 59 Date of Publication: 02/2017 FORD RANGER 2015...
  • Page 60 4. Insert the wire with terminal into cavity C3: 52 or C4: 3 there is a tab on the terminal that should allow this to be inserted one way only. Date of Publication: 02/2017 FORD RANGER 2015...
  • Page 61 5. Slide back the terminal latching plate, refit the and plug both connectors back into the BCM. grey cap (and refit the cable tie as required), Refit any shields/covers. Date of Publication: 02/2017 FORD RANGER 2015...

  • Page 62: Vehicle Speed Output (Signal) (High Level Vehicles )

    WARNING: Do not attempt to take a speed signal output form high level vehicles. A solution to take a speed signal output from the BCM on high level vehicles is not currently available. Date of Publication: 02/2017 FORD RANGER 2015...

  • Page 63: Exterior Lighting

    NOTE: Chassis Cab vehicles are supplied with rear combination lamps, license plate lamps and Refer to: 4.4 Fuses and Relays (page 81). fog lamps. Where fitted, these lamps must be mounted in accordance with the following guidelines. Date of Publication: 02/2017 FORD RANGER 2015...

  • Page 64: Rear Combination Lamps

    Maximum distance from outer edge of vehicle to inner edge of 400mm lamp 4.3.2 Rear Fog Lamp NOTE: Where only one rear fog lamp is fitted, it must be positioned on the vehicle centre line, or to the drivers side of the vehicle. Date of Publication: 02/2017 FORD RANGER 2015...

  • Page 65: Rear License Plate Lamp

    Minimum angle of obstruction free zone upwards of the lamp 5° Minimum angle of obstruction free zone towards the outside of 25° the vehicle Minimum angle of obstruction free zone towards the centre of 25° the vehicle 4.3.3 Rear License Plate Lamp Date of Publication: 02/2017 FORD RANGER 2015...
  • Page 66 Distance between top of rear face of license plate and lamp 35mm mounting face Distance between license plate centre line and centre of lamp 175mm Distance between license plate centre line and centre of lamp 175mm Date of Publication: 02/2017 FORD RANGER 2015...

  • Page 67: Reversing Lamps, Rear View Camera, Reversing Alarm (Manual Transmission)

    4.3.5 Additional External Lamps - Camera, Reversing Alarm (Manual (Low Level Vehicles Only) Transmission) When installing auxiliary tail lamps, Ford The reverse lamps are activated by the reverse recommends that power is provided via the trailer switch on the transmission, through connector plug control module and associated circuitry.

  • Page 68: Trailer Towing

    Ford authorised dealer. experience. NOTE: The trailer detect circuit is part of the Ford NOTE: The trailer tow electrical kit is available Trailer Tow module, it can only be implemented from your Ford authorised dealer.
  • Page 69 Fog Lamp Not used Left Direction Indicator Not used Position Lamp Connector B Not used Term 30 (Ubat) Connector C CAN H CAN L Brake Line In (Vehicle -) Ground Trailer Detect Output Date of Publication: 02/2017 FORD RANGER 2015...

  • Page 70: Additional External Lamps (Vehicles With Special Equipment Pack)

    It can house up to four aftermarket switches. Driving Lights, LED, beacon lamp and work lights can be powered via the switches on the fascia. A fourth switch is provided as a spare with 20A capacity. Date of Publication: 02/2017 FORD RANGER 2015...
  • Page 71 Switch Fascia Cutouts Cut out the switch blanks with a suitable tool without damaging the plastic fascia. Item Description Driving lights switch blank Work lights switch blank LED beacon lamp switch blank Spare switch blank Date of Publication: 02/2017 FORD RANGER 2015...
  • Page 72 Driving Light Connector Location (Vehicles with Special Equipment Pack) Item Description Sealing end-cap Driving light connector Switch Panel Connector (Vehicles with Special Equipment Pack) Item Description Switch connector, located behind the switch fascia in the vehicle. Date of Publication: 02/2017 FORD RANGER 2015...

  • Page 73: Auxiliary Lighting Loads (Vehicles With Special Equipment Pack)

    Driving lights relay Blank (not used) 4.3.8 Auxiliary Lighting Loads (Vehicles with Special Equipment Pack) Connections for auxiliary lighting loads are provided by a 16-Pin connector located near to the auxiliary fuse box. Date of Publication: 02/2017 FORD RANGER 2015...
  • Page 74 NOTE: The temporary battery carrier must Located on the outside of the auxiliary battery removed from the vehicles frame before the assembly, when mounted on the temporary vehicle is operated on the road or in service. battery carrier. Date of Publication: 02/2017 FORD RANGER 2015...
  • Page 75 16-Pin Connector - Cab Chassis with Tray Located on the inside of the auxiliary battery box Connections for auxiliary lighting loads are mounted on the vehicle tray. provided by a 16-Pin connector located near to the auxiliary fuse box. Date of Publication: 02/2017 FORD RANGER 2015...

  • Page 76: Auxiliary Lighting Loads (Vehicles Without Special Equipment Pack) (Low Level Vehicles Only)

    Connections for auxiliary lighting loads can be NOTE: Connections for auxiliary lighting loads made via the trailer tow module (TTM) located must be low and stable current draw. under the passenger seat. See Trailer Towing in this section. Date of Publication: 02/2017 FORD RANGER 2015...
  • Page 77 TTM Connector - Detail 16-Pin Connector (if equipped) Connections for auxiliary lighting loads can be made via the 16-Pin connector located on the rear right chassis rail. Date of Publication: 02/2017 FORD RANGER 2015...

  • Page 78: Lamps Hazard / Direction Indication

    • 3 x 5W front and rear indicators + side or controller. repeaters (Right Hand Side) NOTE: These options are not suitable for aftermarket or Body Builder fit. Date of Publication: 02/2017 FORD RANGER 2015...

  • Page 79: Centre High Mount Stop Lamp (Chmsl) - Canopy Fitment -Low Level Vehicles

    When installing a canopy equipped with a CHMSL, a feed for the CHMSL can be taken from the BCM (Connector 4, Pin 2). Item Description BCM CHMSL Feed (Connector 4, Pin 2). Date of Publication: 02/2017 FORD RANGER 2015...

  • Page 80: Centre High Mount Stop Lamp (Chmsl) - Canopy Fitment - High Level Vehicles

    5. Insulate the spliced joins with heat shrink. 6. Route the canopy CHMSL wiring through a suitable grommet into the passenger compartment, route it behind the trim panels and connect it to the replacement 2-pin connector. Date of Publication: 02/2017 FORD RANGER 2015...

  • Page 81: Fuses And Relays

    Special Equipment Pack. The option code for the Special Equipment Pack is AALSA. The auxiliary battery and fuse box provides electrical outputs for the addition of auxiliary electrical loads to be supplied off the auxiliary battery. Date of Publication: 02/2017 FORD RANGER 2015...

  • Page 82: Auxiliary Fuse Box (Vehicles With Special Equipment Pack) (Low Level Vehicles Only)

    Vehicles with a Load Box (Vehicles with Special Equipment Pack) (Low Level Vehicles Only) Item Description Auxiliary Fuse box Vehicles with Temporary Battery Carrier (Cab Chassis Variant Only) (Low Level Vehicles Only) (Vehicles with Special Equipment Pack) Item Description Auxiliary Fuse box Date of Publication: 02/2017 FORD RANGER 2015...
  • Page 83 NOTE: On delivery of the vehicle, ensure Fuse F10 is engaged into its location correctly. Fuse F10 is intentionally not fully engaged during manufacturing, to prevent depletion of the auxiliary battery during shipping and transit. Date of Publication: 02/2017 FORD RANGER 2015...
  • Page 84 Auxiliary battery 'disable' fuse (isolator ground). Not used Not used Relay Chart Relay Number Protected Components Work lights LED beacon lamp Spare Position lamp Direction indicator (left) Direction indicator (right) Stop lamp Not used Not used Date of Publication: 02/2017 FORD RANGER 2015...

  • Page 85: Body

    • Unique spare wheel stowage may be required if obscured by rear step, check for accessibility. • The recommended dimensions for wheelhouses on conversions are outlined in the following figure. Date of Publication: 02/2017 FORD RANGER 2015...

  • Page 86: Chassis Cab

    • Make sure that the vehicle structural integrity and braking characteristics. is maintained. • Do not drill into closed frame body members. • Make sure that the design for the body alterations or additional structure disperse the load evenly. Date of Publication: 02/2017 FORD RANGER 2015...
  • Page 87 • Spread bolt loads to minimize local stress. Body Attachment Holes in Chassis Frame - Single cab Dimensions (mm) for Body Attachment Holes in Chassis Frame - Single Cab Dimension Dimension 1086 1244 1244 1244 Date of Publication: 02/2017 FORD RANGER 2015...
  • Page 88 Body Attachment Holes in Chassis Frame - Super cab Dimensions (mm) for Body Attachment Holes in Chassis Frame - Super Cab Dimension Dimension 1086 1191 1244 1244 Date of Publication: 02/2017 FORD RANGER 2015...

  • Page 89: Front End Integrity For Cooling, Crash, Aerodynamics And Lighting

    Crash, Aerodynamics and Lighting Ensure proper sealing against ingress of water, salt, dust etc. after cutting or drilling the body. Use Ford approved sealing and finishing material, Cooling Continuous air flow through the front and underbody corrosion protection. end and engine compartment is not to be hindered by adding any additional equipment.

  • Page 90: Tank And Dry Bulk Carriers

    Do not fit a non-Ford approved bull bar to your vehicle as this may interfere with • Side tipping loads/forces must be resolved by the operation of the restraint system, the sub-frame.

  • Page 91: Roof Racks

    There is a service nib provided on the grommet. Refer to Exterior lighting - Additional external lamps for driving lights cable routing. Date of Publication: 02/2017 FORD RANGER 2015...

  • Page 92: Canopies

    Ensure that the planned loaded vehicle operates within its designed Centre of Gravity condition. The forgoing limitations are based on ensuring For details please consult the Ford dealer. body structure integrity, vehicle handling, braking and plated axle weights. Such considerations...
  • Page 93 Front structural attachment points Centre structural attachment points Rear structural attachment points Top surface of load box sides Return flange of load box sides Do not cut, drill, or use these surfaces to bolt the canopy. Date of Publication: 02/2017 FORD RANGER 2015...
  • Page 94 Example of a Sports Bar Fitment Item Description Front mounting bracket Clamped attachment Date of Publication: 02/2017 FORD RANGER 2015...

  • Page 95: Airbag Supplemental Restraint System (Srs)

    Please note that vehicles not equipped with side airbags but equipped with front airbags only are not affected. Drilling or grinding operations in this area are only permitted when battery cables are disconnected. Driver and Passenger Front Airbag Deployment Zones Date of Publication: 02/2017 FORD RANGER 2015...
  • Page 96 Dimensions (mm) Side Airbag Dimensions (mm) Curtain Airbag - Single cab Date of Publication: 02/2017 FORD RANGER 2015...
  • Page 97 Dimensions (mm) Curtain Airbag - Double cab Dimensions (mm) Curtain Airbag - Super cab Dimensions (mm) Date of Publication: 02/2017 FORD RANGER 2015...

  • Page 98: Air Bags - (High Level Vehicles)

    Please note that vehicles not equipped with side airbags but equipped with front airbags only are not affected. Drilling or grinding operations in this area are only permitted when battery cables are disconnected. Date of Publication: 02/2017 FORD RANGER 2015...
  • Page 99 Driver and Passenger Front Airbag Deployment Zones Dimensions (mm) Date of Publication: 02/2017 FORD RANGER 2015...
  • Page 100 Side Airbag Dimensions (mm) Curtain Airbag - Single cab Dimensions (mm) Date of Publication: 02/2017 FORD RANGER 2015...
  • Page 101 Curtain Airbag - Double cab Dimensions (mm) Curtain Airbag - Super cab Dimensions (mm) Date of Publication: 02/2017 FORD RANGER 2015...

  • Page 102: Supplementary Restraint Sensors (Front)

    5.2.3 Supplementary Restraint WARNING: Modifications or Sensors (Front) reinforcements in the area of the front supplementary restraint sensors may affect their operation. Item Description Front SRS Impact Sensors Date of Publication: 02/2017 FORD RANGER 2015...

  • Page 103: Seatbelt Systems - Australia

    5.3 Seatbelt Systems — Australia WARNING: Follow the Ford approved removal and installation procedures for the seatbelt system to ensure correct function of the restraints system. The removal and reinstallation of the seatbelt, restrainer or any component of the seatbelt system should be avoided.

  • Page 104: Corrosion Prevention

    5.4.2 Repairing Damaged Paint 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. 5.4.3 Under Body Protection and Material...

  • Page 105: Frame And Body Mounting

    5. Deburr holes after drilling to fit bolts or rivets. structure where appropriate, to avoid excessive Chamfer 1.0mm x 45 degree on the bolt head load concentrations. side of the hole to facilitate bolt seating. Date of Publication: 02/2017 FORD RANGER 2015...

  • Page 106: Self-Supporting Body Structure

    (5), see figure shown. assembly. • The body side wall or the continuous floor frame supports any overhang beyond the chassis frame, whether on standard frame or extended frame. Date of Publication: 02/2017 FORD RANGER 2015...

  • Page 107: Frame Drilling And Tube Reinforcing

    Drilling and welding of frames and body structure to load bearing body side / floor edge frame have to be conducted following the program or body side structure (including over wheel guidelines. Please consult the Ford dealer for support). details. • Structural wheel box should maintain longitudinal continuity with a rigid attachment 5.5.4 Ancillary Equipment - Sub...
  • Page 108 General..............33, 104 Auxiliary Lighting Loads (Vehicles without General Product Safety Requirement......7 Special Equipment Pack) (Low Level Vehicles Generator and Alternator...........55 Only).................76 Genuine Ford Accessory Bull Bar......90 Auxiliary Lighting Loads (Vehicles with Special Equipment Pack)............73 Axle Breather Vent Hose..........41 Hardware—Specifications.........24 How to Use This Manual..........6...
  • Page 109 Vehicle Ride and Handling Attributes....12 Vehicle Speed Output (Signal) (High Level Vehicles )...............62 Vehicle Speed Output (Signal) (Low Level Vehicles Only).............56 Vehicle Transportation Aids and Vehicle Storage................16 Warnings, Cautions and Notes in This Manual................5 Warranty on Ford Vehicles...........7 Water Tank on Camper Vehicles......107...

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