Body and Equipment Mounting Manual: FORD Ranger 2019

FORD Ranger 2019
Body and Equipment Mounting Manual
E289759
Date of Publication: 01/2020

The information contained in this publication was correct at the time of going to print. In the interest of development the right is reserved to change
specifications, design or equipment at any time without notice and without incurring any obligations. This publication, or part thereof, may not be
reproduced nor translated without our approval. Errors and omissions excepted.
© Ford Motor Company 2020
All rights reserved.

Table of Contents
1.14.3 Towing Capacities and
1 General Information Specifications.............................................30
1.1 About this Manual...............................5

1.1.1 .............................................................................5
1.1.2 Introduction....................................................5 2 Chassis
1.1.3 Important Safety Instructions.................5
1.1.4 Warnings, Cautions and Notes in This
Manual.............................................................5 2.1 Suspension System............................31
1.1.5 How to Use This Manual...........................5 2.2 Brake System.....................................32
1.1.6 Low Level and High Level 2.2.1 General..........................................................32
Vehicles............................................................6 2.2.2 Brake Hoses.................................................32
1.2 Commercial and Legal Aspects..........7 2.2.3 Trailer Brakes ..............................................32
1.2.1 Terminology....................................................7
1.2.2 Warranty on Ford Vehicles........................7
1.2.3 Legal and Vehicle Type Approval...........7
1.2.4 Alternative Type Approval.........................7 3 Powertrain
1.2.5 Legal Obligations and Liabilities.............7
1.2.6 General Product Safety
Requirement...................................................7 3.1 Fuel System.......................................34
1.2.7 Product Liability............................................8 3.1.1 Fuel Filler Pipe Shipping Bracket (if
1.2.8 Restraints System........................................8 equipped).....................................................34
1.2.9 Drilling and Welding....................................8 3.1.2 Fuel Filler Mounting..................................36
1.2.10 Minimum Requirements for Brake 3.1.3 Fuel Filler Vent Hose................................38
system and Load Apportioning Valves 3.1.4 Long Range Fuel Tanks...........................39
.............................................................................8 3.1.5 Axle Breather Vent Hose.........................39
1.2.11 Road Safety....................................................8
1.3 Conversion Homologation..................9
1.4 Electromagnetic Compatibility
(EMC).................................................10 4 Electrical
1.4.1 ...........................................................................10
1.5 Vehicle Duty Cycle Guidelines............11
1.5.1 Vehicle Ride and Handling 4.1 Wiring Installation and Routing
Attributes........................................................11 Guides................................................40
1.6 Jacking................................................12 4.1.1 Wiring Splicing Procedures...................40
1.7 Lifting.................................................13 4.2 Battery and Cables.............................41
1.8 Noise, Vibration and Harshness 4.2.1 Battery Information...................................41
(NVH).................................................14 4.2.2 Generator and Alternator........................47
1.9 Vehicle Transportation Aids and 4.3 Parking Aid........................................48
Vehicle Storage..................................15 4.3.1 Sensor Location.........................................49
1.10 Package and Ergonomics...................17 4.4 Electronic Engine Controls................51
1.10.1 General Component Package 4.4.1 Vehicle Speed Output (Signal) (Low
Guidelines......................................................17 Level Vehicles Only)..................................51
1.10.2 Driver Reach Zones.....................................17 4.4.2 Vehicle Speed Output (Signal) (High
1.10.3 Driver Field of View.....................................17 Level Vehicles )...........................................57
1.10.4 Conversion Effects on Parking 4.5 Exterior Lighting...............................58
Aids...................................................................17 4.5.1 Rear Combination lamps.......................59
1.10.5 Aids for Vehicle Entry and Exit...............17 4.5.2 Rear Fog Lamp...........................................59
1.10.6 Registration Plates.....................................18 4.5.3 Rear License Plate Lamp.......................60
1.11 Package and 4.5.4 Reversing Lamps, Rear View Camera,
Ergonomics—Specifications.............19 Reversing Alarm (Manual
1.11.1 Recommended Body Dimensions.......19 Transmission).............................................62
1.11.2 Chassis Cab Body - Basic Dimensions 4.5.5 Additional External Lamps - (Low
and Weights................................................20 Level Vehicles Only).................................62
1.11.3 Kerb Mass and Payload............................21 4.5.6 Trailer Towing..............................................63
1.11.4 Front, Rear and Side Under-run 4.5.7 Auxiliary Lighting Loads (Low Level
Protection......................................................21 Vehicles Only).............................................65
1.12 Hardware—Specifications................22 4.5.8 Lamps – Hazard / Direction
1.13 Load Indication......................................................66
Distribution—Specifications............23 4.5.9 Electrically Operated Door
1.13.1 Load Distribution Calculations - Driver Mirrors............................................................66
and Passenger Weight 4.5.10 Centre High Mount Stop Lamp
Distribution...................................................23 (CHMSL) - Canopy Fitment -Low
1.13.2 Center of Gravity........................................26 Level Vehicles.............................................66
1.14 Towing...............................................30 4.5.11 Centre High Mount Stop Lamp
1.14.1 Towing Requirements..............................30 (CHMSL) - Canopy Fitment - High
1.14.2 Towing...........................................................30 Level Vehicles..............................................67
3
Table of Contents 4.6 Handles, Locks, Latches and Entry
Systems..............................................69
4.6.1 Central Locking...........................................69
4.7 Fuses and Relays................................70
4.7.1 Low Level and High Level Vehicles......70
4.7.2 Auxiliary Battery and Fuse Box - Low
Level Vehicles...............................................70
4.7.3 Auxiliary Fuse Box (Vehicles with
Special Equipment Pack) (Low Level
Vehicles Only)................................................71
5 Body and Paint

5.1 Body....................................................74
5.1.1 Body Structures - General
Information....................................................74
5.1.2 Integrated Bodies and
Conversions...................................................74
5.1.3 Chassis Cab...................................................75
5.1.4 Front End Integrity for Cooling, Crash,
Aerodynamics and Lighting....................78
5.1.5 Tipper Bodies...............................................78
5.1.6 Tank and Dry Bulk Carriers......................79
5.1.7 Genuine Ford Accessory Bull Bar..........79
5.1.8 Roof Racks....................................................80
5.1.9 Canopies.........................................................81
5.2 Airbag Supplemental Restraint
System (SRS)....................................84
5.2.1 Air Bags - (Low Level Vehicles)............84
5.2.2 Air Bags - (High Level Vehicles)............87
5.2.3 Supplementary Restraint Sensors
(Front)............................................................90
5.3 Seatbelt Systems – Australia............92
5.4 Corrosion Prevention.........................93
5.4.1 General...........................................................93
5.4.2 Repairing Damaged Paint.......................93
5.4.3 Under Body Protection and
Material...........................................................93
5.4.4 Painting Road Wheels..............................93
5.4.5 Contact Corrosion......................................93
5.5 Frame and Body Mounting................94
5.5.1 Mounting Points and Tubing..................94
5.5.2 Self-Supporting Body Structure...........95
5.5.3 Frame Drilling and Tube
Reinforcing....................................................96
5.5.4 Ancillary Equipment - Sub Frame
Mounting........................................................96
5.5.5 Area for Fitting Additional Body
Attachments to the Rear of the
Bumper. .........................................................96
5.5.6 Water Tank on Camper Vehicles..........96
4
1 General Information
1.1 About this Manual
1.1.1 This manual cannot possibly anticipate all such
variations and provide advice or cautions as to
It is recommended to review this manual in full. each. Anyone who departs from the instructions
The BEMM is a live document which can be viewed provided in this manual must first establish that
on www.etis.ford.com/BEMM or they compromise neither their personal safety nor
http://www.fordtechservice.dealerconnection.com/. the vehicle integrity by their choice of methods,
It is the vehicle converters responsibility to review tools or components.
the online version for the most current information
prior to starting any conversion.
1.1.4 Warnings, Cautions and Notes in
This Manual
1.1.2 Introduction
WARNING: Warnings are used to indicate
NOTE: Printed copies are uncontrolled. that failure to follow a procedure
correctly may result in serious injury or
This manual has been written in a format that is
death.
designed to meet the needs of Vehicle Converters.
The objective is to use common formats with the CAUTION: Cautions are used to indicate
workshop manual which is used by technicians that failure to follow a procedure
worldwide. correctly may result in damage to the
This guide is published by Ford and provides vehicle or equipment being used.
general descriptions and advice for converting NOTE: Notes are used to provide additional
vehicles. These requirements must be complied essential information required to carry out a
with before a Ford Dealer should take delivery of complete and satisfactory repair.
motor vehicle accessories from an external
As you read through this manual, you will come
supplier either for themselves or on behalf of a
across WARNINGS, CAUTIONS and NOTES.
motor vehicle client.
A warning, caution or note is placed at the
It must be emphasized that any change to the
beginning of a series of steps if it applies to
basic vehicle which does not meet the enclosed
multiple steps. If the warning, caution or note only
guideline standards may severely inhibit the ability
applies to one step, it is placed at the beginning
of the vehicle to perform its function. Mechanical
of the specific step (after the step number).
failures, structure failure, component unreliability
or vehicle instability will lead to customer
dissatisfaction. Appropriate design and 1.1.5 How to Use This Manual
application of body, equipment and or accessories
is key to ensuring that customer satisfaction is This manual covers vehicle conversion procedures.
not adversely affected.
The pages at the start of this manual list the
The information contained within this publication content, by group. A group covers a specific
takes the form of recommendations to be portion of the vehicle. The manual is divided into
followed when vehicle modifications are four groups, General Information, Chassis,
undertaken. It must be remembered that certain Electrical, Body and Paint. The number of the
modifications may invalidate legal approvals and group is the first number of a section number.
application for re-certification may be necessary. Each title listed in the contents links to the
Ford cannot guarantee the operation of the relevant section of the manual.
vehicle if non-Ford approved electrical systems In some section of the book it may refer you to
are installed. Ford electrical systems are designed see additional sections for information, links have
and tested to function under operational been provided, these links are in blue text.
extremes, and have been subjected to the
This manual is designed to be used online or as
equivalent of ten years of driving under such
printed material, document links for the online
conditions.
version are also shown with page numbers for the
printed version, this will help guide you to the start
1.1.3 Important Safety Instructions of the section which contains the relevant
information.
Appropriate conversion procedures are essential There is also an alphabetical index at the back of
for the safe, reliable operation of all vehicles as the manual. As with the contents pages you will
well as the personal safety of the individual be able to link to sections. To do this just click on
carrying out the work. the page number.
All left and right-handed references to the vehicle
are taken from a position sitting in the driver seat
looking forward unless otherwise stated.
FORD RANGER 2019 2012 Date of Publication: 01/2020 5

1 General Information 1.1.6 Low Level and High Level Vehicles
WARNING: Prior to work on any vehicle
being undertaken it is critical to identify
the type of electrical architecture the
vehicle at hand is equipped with. Failure
to identify the type of electrical
architecture present on the vehicle prior
to work being undertaken may cause
electrical damage or have safety
implications.
Ford Ranger vehicles are equipped with one of two
electrical architectures.
Refer to: 4.7 Fuses and Relays (page 70).
6 Date of Publication: 01/2020 FORD RANGER 2019 2012

1.2 Commercial and Legal Aspects
1.2.1 Terminology
1.2.4 Alternative Type Approval
NOTE: Any modifications to the vehicle must be
noted in the owner's handbook or new descriptive If significant changes are made the Body Builder
literature included with the owner's must negotiate with the relevant authority. Any
documentation. changes to the vehicle operating conditions must
Vehicle Converter refers to any re-seller altering be advised to the customer.
the vehicle by converting the body and adding or
modifying any equipment not originally specified 1.2.5 Legal Obligations and Liabilities
and or supplied by Ford.
Unique component or similar wording refers to The Vehicle Converter should consult with its legal
non-Ford specified or after sale fitment not advisor on any questions concerning its legal
covered by Ford warranty. obligations and liabilities.
Ford recommends that the Vehicle Converter and
1.2.2 Warranty on Ford Vehicles Ford Dealer must understand their individual and
joint responsibilities in supplying a safe and
Please contact The National Sales Company in compliant motor vehicle fitted with safe and
the country where the vehicle will be registered compliant accessories.
or refer to the vehicle Owner Guide for details of
the terms of any applicable Ford warranty. 1.2.6 General Product Safety
The Vehicle Converter should warrant its design, Requirement
materials and construction for a period at least
equal to any applicable Ford warranty. The Vehicle Converter shall ensure that any
vehicle it places on the market complies with all
The Vehicle Converter must ensure that any local laws, including laws relating to the safe
alteration made to a Ford vehicle or component carriage of loads on public roads. The Vehicle
does not reduce the safety, function, or durability Converter shall also ensure that any alteration it
of the vehicle or any component. makes to a Ford vehicle or component does not
The Vehicle Converter shall be solely responsible reduce its compliance with local regulatory
for any damage resulting from any alteration standards.
made by the Vehicle Converter or any of its agents The Vehicle Converter must provide sufficient
to a Ford Vehicle Component. Load Restraint tie down points or
The Vehicle Converter releases Ford from all compartmentalised storage areas that enable
claims by any third party for any cost or loss the driver to safely carry loads that match the use
(including any consequential damages) arising criteria for which the body was designed.
from work performed by a Vehicle Converter The Vehicle Converter shall release Ford from all
unless Ford has given its prior written consent to liability for damages resulting from:
such liability.
• Failure to comply with these Body Equipment
Mounting directives, in particular warnings.
1.2.3 Legal and Vehicle Type Approval
• Faulty design, production, installation,
• All components embodied on Ford vehicles are assembly or alteration not originally specified
approved to the applicable legal requirements. by Ford.
• Ford vehicles have Type Approval for the • Failure to comply with the basic fit for purpose
intended marketing territories. principles inherent in the original product.
WARNING: Exception - Incomplete WARNINGS:

vehicles require further approval when
Do not exceed the gross vehicle mass,
completed by the Body Builder.
gross combination mass, axle ratings and
• The Ranger range has Type Approval for many trailer rating.
territories, although the full range of vehicles
shown in this manual are not necessarily Do not change the tire size or load rating.
released in all territories. Check with your local
Ford National Sales Company representative. Do not modify the steering system.
• Significant changes to the vehicle may affect
its legal compliance. Strict adherence to the Excessive heat can build up from the
original design intent for brakes, weight exhaust system, in particular from the
distribution, lighting, electrical systems, catalytic converter and from the Diesel
occupant safety and hazardous materials Particulate Filter (DPF). Ensure adequate
compliance in particular is mandatory. heat shields are maintained. Maintain
sufficient clearance to hot parts.

1 General Information Do not modify or remove heat protection Do not alter, modify or relocate the airbag,
shields. sensor and modules of the restraints
system or any of its components.
Do not route any electrical cables with the
Anti-lock Brakes System and Traction Attachments or modifications to the front
Control System cables because of end of the vehicle may affect the airbag
extraneous signal risk. Do not hang fire timing and result in uncontrolled
electrical cables off existing looms or deployment.
pipes.
Modifications to the B-Pillar body
Do not change original location or remove structure may affect the side airbag fire
warning labels provided with the base timing and result in uncontrolled side
vehicle in view to the driver. Ensure that airbag deployment.
labels in view to the driver in the base Refer to: Airbag Supplemental Restraint System
vehicle remain in full view to the driver (SRS) (page ?).
after any conversion.
NOTE: For further information please contact your
local National Sales Company representative, or 1.2.9 Drilling and Welding
Local Ford Dealer.
Drilling and welding of frames and body structures
have to be conducted following the guidelines
1.2.7 Product Liability within this document.
The Vehicle Converter shall be liable for any

product liability (whether for death, personal injury, 1.2.10 Minimum Requirements for
or property damage) arising from any alteration Brake system and Load Apportioning
to a Ford vehicle or component made by the Valves
Vehicle Converter or any of its agents. Ford shall
not be liable for any such liability (except as • It is not necessary or recommended to modify
provided by law). the load apportioning valves, however, if a
special conversion should require modifications,
The Vehicle Converter or equipment manufacturer – Maintain original settings.
is liable for the:
– Maintain brake certification load distribution.
• Operational reliability and road-worthiness of
the vehicle to its original intent. • Changes to the Antilock Brake System (ABS),
Traction Control System (TCS) and Electronic
• Operational reliability and road-worthiness of Stability Program (ESP) system are not
any component or conversion, not listed in permitted.
original Ford documentation.
• Operational reliability and road-worthiness of 1.2.11 Road Safety
the vehicle as a whole (for example the body
changes and/or additional equipment must not The respective instructions should be strictly
have a negative effect on the driving, braking observed to maintain operational and road safety
or steering characteristics of the vehicle). of the vehicle.
• Any damage resulting from the conversion or
attachment and installation of unique
components, including unique electrical or
electronic systems.
• Functional safety and freedom of movement
of all moving parts (for example axles, springs,
propeller shafts, steering mechanisms, brake
and transmission linkage).
• Functional safety and freedom of the tested
and approved flexibility of the body and integral
chassis structure.
1.2.8 Restraints System

WARNINGS:
Modifications to the restraints system
are not allowed.
Airbags are explosive. For safe removal
and storage during conversion follow the
procedures in the Ford workshop manual
or consult your local National Sales
Company representative.

1.3 Conversion Homologation
The Vehicle Converter must observe any statutory
rules and regulations. When the conversion needs
a new approval the following information must
be quoted.
• All dimensional, weight and centre of gravity
data.
• The fixing of the body to the donor vehicle.
• Operating conditions.
The responsible Technical Service may require
additional information and/or testing.
NOTE: For further information please contact
your local National Sales Company representative,
or Local Ford Dealer.

1 General Information 1.4 Electromagnetic Compatibility (EMC)
1.4.1 Keep antenna and power cables at least
100mm from any electronic modules and
WARNINGS: airbags.
Do not place objects or mount equipment NOTE: We test and certify your vehicle to meet
on or near the airbag cover, on the side of local electromagnetic compatibility legislation or
the seatbacks (of the front seats), or in equivalent, where applicable. It is your
front seat areas that may come into responsibility to make sure that any equipment an
contact with a deploying airbag. Failure authorized dealer installs on your vehicle complies
to follow these instructions may increase with local regulatory standards.
the risk of personal injury in the event of
a crash. NOTE: Any radio frequency transmitter equipment
in your vehicle (such as cellular telephones and
Do not fasten antenna cables to original amateur radio transmitters) must keep to the
vehicle wiring, fuel pipes and brake pipes. parameters in the following table. We do not
provide special provisions or conditions for
installations or use.
E239121
Frequency Band MHz Maximum Output Power Watts Antenna Position

(Peak RMS)
1-30 50 1
50-54 50 2, 3
68-88 50 2, 3
142-176 50 2, 3
380-512 50 2, 3
806-870 10 2, 3
NOTE: Check that electromagnetic fields

NOTE: After the installation of radio frequency
generated inside your vehicle cabin by the
transmitters, check for disturbances from and to
transmitter installed do not exceed applicable
all electrical equipment in your vehicle, both in the
human exposure requirements.
standby and transmit modes.
Check all electrical equipment:
• with the ignition ON
• with the engine running
• during a road test at various speeds

1.5 Vehicle Duty Cycle Guidelines
NOTE: For further information contact your
National Sales Company representative, or local
Ford dealer.
It is necessary to take into account the customer
usage profile and the anticipated vehicle duty
cycles of the modified vehicle in order to choose
the appropriate specification of the base vehicle.
It is necessary to select the appropriate drive,
engine, gear ratio, gross vehicle mass, gross train
mass, axle plates and payloads of the base vehicle
to match the customer requirements.
Where possible make sure that the base vehicle
is ordered with any necessary plant fit options.
A high numeric gear ratio is recommended for
vehicles with customer requirements for:
• High payload
• Trailer tow
• Frequent stop-and-go cycles
• High altitude and gradients
• Terrain conditions such as found on building
and construction sites
1.5.1 Vehicle Ride and Handling

Attributes
CAUTION: Do not exceed the axle plate,
gross vehicle mass, trailer plate and
gross trailer mass limits.
Conversions to the base vehicle that change the
center of gravity may affect the ride and handling
attributes.
NOTE: All vehicles should be evaluated for safe
operation prior to sale.

1 General Information 1.6 Jacking
WARNINGS: WARNING: The jack supplied with this
vehicle is only intended for changing
Ensure screwthread is adequately
wheels. Do not use the vehicle jack other
lubricated before use.
than when you are changing a wheel in an
The jack should be used on level firm emergency.
ground wherever possible.
CAUTION: Make sure that access to the
Switch the ignition off and apply park spare wheel is maintained when
brake fully before lifting vehicle. converting the vehicle or relocating the
It is recommended that the wheels of the spare wheel.
vehicle be chocked, and that no person NOTE: When using the vehicle jack, refer to the
should remain in a vehicle that is being owner guide for correct operating instructions.
jacked.
The spare wheel winch is located above the spare
No person should place any portion of wheel and can be accessed from the rear of the
their body under a vehicle that is chassis frame.
supported by a jack. The jack must be assembled and fixed
WARNING: Do not get under a vehicle that appropriately to the body to ensure safety,
is supported by a jack. durability and accessibility.
E166722
Vehicle Jacking Points and Axle Stand Positions
E212163

1.7 Lifting
WARNING: When lifting the vehicle with CAUTIONS:
a two post lift for the removal of the
engine/transmission or rear axle, make When lifting the vehicle with a two post
sure the vehicle is secured to the lift lift, vehicle lift arm adapters must be
using vehicle retention straps to prevent used under the lifting points.
tilting. Failure to follow these When lifting the vehicle with a two post
instructions may result in serious injury lift, the maximum kerb weight must not
or death. be exceeded.
It is important that only the correct lifting
and support locations are used at all
times.
All Vehicles
E133943

1 General Information 1.8 Noise, Vibration and Harshness (NVH)
WARNING: Make sure that the modified
vehicle complies with all relevant legal
requirements.
Changes to the powertrain, engine, transmission,
exhaust, air intake system or tires may influence
the exterior noise emissions. Therefore the exterior
noise level of the converted vehicle has to be
verified.
The interior noise levels should not be deteriorated
by the conversion. Reinforce panels and structures
as appropriate to avoid vibrations. Consider the
usage of sound deadening material on panels.

1.9 Vehicle Transportation Aids and Vehicle Storage
CAUTIONS: • Set climate controls to the "open" position to
Disconnect the battery if the vehicle is to provide ventilation, where possible.
be stored for more than 30 days. • Where protective film has been applied in
manufacture it must be left on the vehicle until
Make sure that the protective covers are
prepared for delivery but must be removed
not removed from an incomplete vehicle
after a maximum storage period of six months
until the conversion is started.
(film is date stamped to indicate required
Make sure that components removed removal date).
during conversion are kept clean and dry. • Make sure that all windows, doors, hood,
Make sure that components removed tailgate and luggage compartment lid are
during conversion are refitted to the completely closed and the vehicle is locked.
same vehicle. The Pre Delivery Inspection (PDI) is the final
Transport Mode includes a calibration opportunity to make sure a battery is fit for
feature to reduce the risk of fuel injector purpose prior to the customer taking delivery of
nozzle corrosion. Exiting Transportation their new vehicle. The battery must be checked
Mode prior to upfi tting/ conversion and appropriate action taken prior to the vehicle
increases the risk of early life injector being handed over to the customer. Test results
failure. must be recorded on the PDI repair order.
In addition: Batteries. To make sure the battery is maintained
correctly and to assist in preventing premature
• The windscreen wipers should be lifted off the failure, it is necessary to check and recharge the
glass and set right up. battery regularly while a vehicle is not in use.
• All air intakes should be closed. Where a battery is left below its optimum charge
level for any length of time, it may result in
• Increase normal tire pressure by 0.5 bar. premature failure of the battery.
• The hand brake system should not be used.
• Apply suitable wheel chocks to prevent roll Action / Time in Monthly Every 3
away. storage Months
A significant risk during storage is deterioration of Check vehicle is X -

vehicle bodywork, therefore, appropriate storage clean
procedures must be observed, including periodic Remove external X -
inspection and maintenance. contamination
Claims arising from deterioration caused by Check battery Connected Disconnected
incorrect storage, maintenance or handling are condition -
not the responsibility of Ford. Recharge if neces-
Vehicle Converters must determine their own sary
procedures and precautions, particularly where
Visually check tires X -
vehicles are stored in the open as they are
exposed to any number of airborne contaminants. Check interior for - X
condensation
The following may be considered a sensible
approach to storage: Run engine until - X
Short Term Storage coolant gauge
reaches temper-
• Wherever possible vehicles should be stored ature (60 ° C) with
in an enclosed, dry, well-ventilated area based aircon switched on,
on firm, well drained ground which is free of where applicable
long grass or weeds and where possible
protected from direct sunlight.
Protection from Injector Nozzle Corrosion
• Vehicles must not be parked near, under foliage During the Upfitting/Conversion ProcessFord
or close to water as additional protection may Engineering has identified a concern with the fuel
be necessary for certain areas. injectors on the 2.0L EcoBlue / Duratorq engine
Long term storage: whereby the injector nozzle can become corroded.
• Battery to be disconnected but not removed This is caused by condensation which forms on
from the vehicle. the nozzle when the engine is new and run
• The wiper blades should be removed and repeatedly for very short periods of time when the
placed inside the vehicle. Make sure the wiper engine is cold (less than 60 degrees centigrade).
arms are suitably prevented from resting on Fuel injectors may fail as a consequence, either
the windscreen. during vehicle storage or early time in service.
• Engage first gear and release the parking brake
completely. Chock the wheels first if the vehicle
is not on level ground.

1 General Information If the vehicle cannot be left in transportation mode Vehicles held in storage for long periods of time
then the procedure to disconnect the Manifold are particularly susceptible to this concern, for
Absolute Pressure Temperature (MAPT) sensor example vehicles awaiting or undergoing a
electrical connector, until the vehicle is prepared conversion.
for delivery to the customer, should be followed To overcome this and protect fuel injectors from
to achieve the same result. early time-in-service failures, the Manifold
Experience shows that vehicles undergoing a Absolute Pressure Temperature (MAPT) must be
conversion where the engine is regularly started disconnected by following the following simple
for short periods of time when cold, are most at procedure.
risk; for example, vehicles undergoing a Procedure for disconnecting the Manifold
Motorhome conversion. Absolute Pressure Temperature (MAPT)
sensor
E350348
• Disconnect the electrical connector. To reduce the likelihood of premature battery
failure it is recommended that where:
• Start and stop the engine 4 times to ensure that
the Malfunction Indicator Lamp (MIL) is • A battery is left connected – monthly checks
illuminated and corresponding information should be carried out.
message is displayed in the instrument cluster. • A battery has been disconnected – no greater
– The vehicle can be operated safely with the than a 3 monthly check should be carried out.
MAP sensor disconnected during any
conversion that the vehicle may be
undergoing, for example a Motorhome
conversion.
• Before the vehicle is handed over to the
customer, the Manifold Absolute Pressure
Temperature (MAPT) must be reconnected
and the engine must be started 4 times to turn
off the Malfunction Indicator Lamp (MIL),
remove the information message and restore
the engine’s normal power and torque outputs.
NOTE: When the Manifold Absolute Pressure
Temperature (MAPT) sensor is disconnected, the
vehicle must only be used at the storage facility
and NOT on public roads.

1.10 Package and Ergonomics
1.10.1 General Component Package On conversions requiring a rear camera, the
Guidelines reverse signal may be taken as described in the
reversing lamps section.
WARNING: Do not modify, drill, cut or
weld any suspension components, Refer to: Exterior Lighting (page ?).
specifically the steering gear system,
subframe or anti-roll bars, springs or 1.10.5 Aids for Vehicle Entry and Exit
shock absorbers including mounting
brackets.
The Vehicle Converter must ensure that sufficient Steps
clearance is maintained under all drive conditions
to moving components such as axles, fans, WARNINGS:
steering, brake system etc. Make sure that the modified vehicle
The Vehicle Converter is responsible for all complies with all relevant legal
installed components during the conversion. The requirements.
durability must be confirmed by appropriate test If this modification alters the
procedures. homologated dimensions, a new
approval may be necessary.
1.10.2 Driver Reach Zones CAUTION: Make sure that reinforcements
are installed to maintain the integrity of
Controls and/or equipment required to be used the original body structure.
while driving should be located within easy reach
Steps can be ordered as an accessory on the base
of the driver so as not to impair driver control.
vehicle. Please check for availability.
Where additional steps are installed the required
1.10.3 Driver Field of View ground clearance line must be maintained.
WARNING: Make sure that the modified The Vehicle Converter must make sure that a
vehicle complies with all relevant legal movable step is set in the stored position when
requirements. the vehicle is running. The step surface must be
non-slip.
1.10.4 Conversion Effects on Parking

Aids Rear View Mirrors
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.

E278311
Item Description
X Maximum Body Width: 1860mm
1.10.6 Registration Plates
Front Registration Plate
WARNINGS:
The mounting of a registration plate to
the front of the vehicle must comply with
local regulatory standards.
No part of a vehicle registration plate may
be obscured by standard equipment,
regular production options or equipment,
in line with local regulatory standards.
The registration plate must be affixed to the front
of the motor vehicle forward of and parallel to the
front ‘Axle’ in line with local regulatory standards.
Rear Registration Plate
WARNINGS:
The mounting of a registration plate to
the rear of the vehicle must comply with
No part of a vehicle registration plate may
be obscured by standard equipment,
regular production options or equipment,
in line with local regulatory standards.
The registration plate must be affixed to the rear
of the motor vehicle in line with local regulatory
standards.

1.11 Package and Ergonomics—Specifications
1.11.1 Recommended Body Dimensions NOTE: When extending the length of the frame
rearward of the rear axle, it is recommended that
WARNINGS: the overall rear overhang is limited to a maximum
of 50% of the wheelbase of the vehicle.
Do not modify the wheelbase or add any
type of frame extension to vehicles fitted NOTE: If a towball is fitted to the vehicle, the body
with Electronic Stability Program (ESP). dimensions must incorporate a towball clearance
zone in accordance with local regulatory
Ensure that any mass added to the standards. For additional information, refer to
vehicle does not compromise vehicle local regulatory standards.
stability.
If a conversion requires more than 50% overhang,
NOTE: Extreme rear overhang may encourage please contact your local National Sales Company
unacceptable loading conditions, which could representative, or Local Ford Dealer.
unload the front axle, producing unacceptable
handling and braking characteristics. Ensure that Load carrying structures should not be mounted
the centre of gravity of the body and payload does onto an existing load tray or load box. Body
not fall outside of the recommended zone. attachment points are provided on the frame.
NOTE: An excessively high centre of gravity could Refer to: Body (page ?).
reduce vehicle stability. Ensure that the centre of
gravity of the body and payload does not fall
outside of the recommended zone.
Refer to: (page ?).
Chassis Cab Body - Single Cab Illustrated
F
H
D E
G
B
A
E278312

Dimensions - not to exceed for Chassis Cab body Length
Description Dimension (mm)
Single Cab Super Cab Double Cab
A Frame length behind back of cab (not including rear
2251 1781 1483
light cross-member)
B Under run bar and towing attachment legislation to be maintained
C Maximum recommended external body height 2400 over the top of frame, provided load
distribution requirements are met
D Front outside of body to rear axle 1241 771 473
E Maximum recommended rear overhang 1610 (50% of vehicle wheelbase),
provided load distribution requirements
are met
F Clearance between the back of the cab and the body 25 Minimum
G Ensure local lighting legislation is maintained Refer to: Exterior Lighting (page ?).
H Clearance between the top of the cab and the body 30
J 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.
1.11.2 Chassis Cab Body - Basic Dimensions and Weights
Chassis Cab Body - Single Cab Illustrated
D F
E278313

Chassis Cab Body - Basic Dimensions and Weights
Description Single Cab Double Cab
A Overall length (mm) 5110
B Overall width - excluding exterior mirrors (mm) 1860
C Overall height 4x2 (mm) 1703 1716
C Overall height 4x4 (mm) 1800-1806 1815 - 1821
D Wheelbase (mm) 3220
*
E Track - front (mm) 1590
**
E Track - front (mm) 1560
*
E Track - rear (mm) 1590
**
E Track - rear (mm) 1560
F Rear Overhang with rear bumper where fitted (mm) 985 1234
*
- Front Axle Load (kg) 1325
**
- Front Axle Load (kg) 1480
*
- Rear Axle Load (kg) 1755
**
- Rear Axle Load (kg) 1850
*
4x2 vehicles with low ride height.
**
4x2 Vehicles with increased ride height / 4x4 vehicles.
1.11.3 Kerb Mass and Payload

WARNING: Check local legislation for
legal requirements.
Details of vehicle kerb mass and payload
capacities can be provided by your local National
Sales Company representative.
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.

1 General Information 1.12 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
M4 1.1 1.4 2.4 3.4
M5 2.2 2.7 4.9 6.7
M6 3.7 4.7 8.5 11.5 11.0 15.0
M8 20.0 28.0 25.0 35.0
M10 41.0 55.0 50.0 70.0
M12 68.0 92.0 95.0 125.0
M14 113 153 150 200
M16 170.0 230.0 230.0 310.0
M18 252.0 317.0 317.5 399.4
M20 345.0 430.0 434.7 541.8
M22 470.0 590.0 592.2 743.4
M24 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.

1.13 Load Distribution—Specifications
1.13.1 Load Distribution Calculations NOTE: Uneven load distribution could result in
- Driver and Passenger Weight unacceptable handling and braking
Distribution characteristics.
CAUTIONS: NOTE: Over loading of the vehicle could result in

unacceptable ground clearance.
Do not exceed the axle ratings.
NOTE: The center of mass of the body equipment
and the payload it contains should be located
Do not exceed the gross vehicle mass. within the dimensions given.
NOTE: Avoid one-sided load distribution.
Tire manufacturer specification must be
maintained. NOTE: For further information please contact
your local National Sales Company representative,
or local Ford dealer.

Single Cab
E278314
Single Cab Driver and Passenger Weight Distribution

'A' Wheelbase 'B' Front row Weight distribution per person (Kg)
(mm) seats and driver
(mm)
On Front Axle On Rear Axle Total
3220 1490 40 35 75

Super Cab
B
C
A
E278316
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)
3220 1490 - 40 35 75
- - 2180 24 51 75

Double Cab
B
C
A
E278315
Double Cab Driver and Passenger Weight Distribution

'A' Wheelbase 'B' Front row 'C' Second row Weight distribution per person (Kg)
(mm) seats and seats (mm)
driver (mm)
3220 1490 - 40 35 75
- - 2310 21 54 75
1.13.2 Center of Gravity "Added mass" includes all added body equipment
and cargo, but excludes passengers seated in
NOTE: Calculations shown are not inclusive of standard cab seating.
tow bar and other dealer fitted accessories. For double cab vehicles, there is a limit to the
The following charts define the recommended added mass that must be observed, in addition to
Centre of Gravity Position for the mass added to not exceeding the gross axle and train weights.
the vehicle by the vehicle converter.

Single Cab
E278317
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)
4x2 1965 3220 740
*
4x2 1965 3435 590
4x4 1965 3435 590
*
4x2 vehicles with increased ride height

Super Cab
E278319
Super Cab Center of Gravity Critical Zone

Model Recommended C of G location for added mass
4x2 2395 3220 740
*
4x2 2365 3435 590
4x4 2365 3435 590
*

Double Cab
E278318
Double Cab Centre of Gravity Critical Zone

Model Recommended C of G location for added mass Max gross added
mass (kg)
4x2 2585 3615 740 700
*
4x2 2435 3615 590 625
4x4 2435 3615 590 700
*

1 General Information 1.14 Towing
1.14.1 Towing Requirements
When a towing device is required, the Vehicle
Converter should use a Ford approved tow bar.
Refer to: (page ?).
Load Distribution.
Refer to: Jacking (page ?).
1.14.2 Towing
WARNINGS:
Do not exceed the Gross Combination
Mass (GCM) or towing capacities for your
specific vehicle. Refer to the vehicles
owner guide for specifications related to
the towing capacities and local regulatory
standards.
Ensure that the trailer towball download
weight falls within the specified range.
Towing trailers beyond the maximum
recommended gross trailer weight
exceeds the limit of your vehicle and
could result in engine damage,
transmission damage, structural damage,
loss of vehicle control, vehicle rollover
and personal injury.
Do not cut, drill, weld or modify the trailer
hitch. Modifying the trailer hitch could
reduce the hitch rating.
Do not exceed the maximum vertical load
on the tow ball. Failure to follow this
instruction could result in the loss of
control of your vehicle, personal injury or
death.
For towing devices fitted by the Vehicle Converter
the following applies:
• Towing capacities must not exceed those of
the unmodified vehicle.
• Any modifications to the vehicle must be noted
in the vehicle owner guide descriptive literature
included with the owners documentation.
• Tow bar installations must meet the
requirements of the local regulatory standards.
• Whenever frame drilling is necessary use tube
reinforcement.
Refer to: 5.5 Frame and Body Mounting (page
94).
1.14.3 Towing Capacities and

Specifications
NOTE: Refer to the vehicles owner guide for
specifications related to the towing capacities and

2 Chassis
2.1 Suspension System
WARNINGS:
Do not modify, drill, cut or weld any
suspension components, specifically the
steering gear system, subframe or
anti-roll bars, springs or shock absorbers
including mounting brackets.
The rear leaf springs are pre-stressed in
manufacture and should not be altered
for rate or height in any way during
vehicle conversion. 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 cannot be held
responsible.
CAUTIONS:
Modifications to the suspension system
can cause a deterioration of the vehicle
handling characteristics and durability.
When carrying out welding work the
springs must be covered to protect them
against weld splatter.
Do not touch springs with welding
electrodes or welding tongs.
NOTE: Do not modify the wheelbase or add any
type of frame extension to vehicles fitted with
Electronic Stability Program (ESP).
NOTE: Do not damage the surface or corrosion
protection of the spring during disassembly and
installation.
NOTE: Do not add any additional axles.

2 Chassis 2.2 Brake System
2.2.1 General
2.2.3 Trailer Brakes
The Brake System must be fully functional when
the vehicle conversion is completed. The vehicle WARNING: A pre-installed trailer brake
brake operating modes must be checked, including wire provides a pulsed brake signal of
warning system and parking brakes. varying frequencies. This pulsed signal is
WARNING: Do not restrict the airflow and not a direct current (DC) signal. The
cooling to the brake system. Ford-approved FLA Trailer Brake
Controller (p/n VGB3Z2C405E) is
NOTE: Do not obstruct the view of the brake fluid compatible with these pulsed signals. If
reservoir level. another aftermarket brake controller is
The brake fluid reservoir must remain accessible installed, the vehicle owner or installer
for servicing and for adding brake fluid. must ensure that it is compatible with all
pulsed signals from the pre-installed
trailer brake wire. Failure to ensure
2.2.2 Brake Hoses compatibility of your brake controller may
result in loss of vehicle control, which
CAUTION: Make sure that the front and could result in serious injury or death. If
rear brake hoses are not twisted and are clarification is required on the
correctly located away from body and specifications of the pulsed signals,
chassis components. please contact your Authorised Ford
Front and rear brake hoses must not rub, chafe or Dealer.
rest on body or chassis or body components. There NOTE: Ford new-vehicle warranty is provided for
must be clearance under all operating conditions, the Ford Licensed Accessory (FLA) Trailer Brake
between full compression and extension and full Controller (TBC) when it is fitted to the vehicle by
lock to lock. a Authorised Ford Dealer (Part Number
Brake lines must not be used to support or secure VGB3Z2C405E). Ford is not responsible for
any other component. warranty and performance of other aftermarket
brake controllers which are not approved by Ford.
Trailer Brake Connection
E275788
NOTE: RHD (right-hand drive) shown, LHD A pre-installed wire is located behind the A-Pillar
(left-hand drive) similar. kick panel and is marked TRAILER BRAKE
CONTROLLER.

2 Chassis
Contact your Authorised Ford Dealer for further
information on Ford Licensed Accessories and the
Ford Approved Trailer Brake Controller.

3 Powertrain 3.1 Fuel System
WARNINGS: Procedure for protection from Injector Nozzle
Make sure that the modified vehicle Corrosion During the Upfitting/Conversion Process:
complies with all relevant legal Refer to: 1.9 Vehicle Transportation Aids and
requirements. Vehicle Storage (page 15).
Do not remove or relocate the fuel cooler
(if equipped) when modifying the vehicle. 3.1.1 Fuel Filler Pipe Shipping Bracket
(if equipped)
CAUTIONS:
Ensure modifications to vehicle do not CAUTION: The fuel filler pipe shipping
obstruct airflow to fuel cooler. mounting bracket on cab chassis vehicles
is designed for shipping of the vehicle
Make sure that sufficient clearance is only.
maintained for all driving conditions to
all hot and moving components. The fuel filler pipe shipping bracket fitted to cab
chassis vehicles is designed to be removed once
Make sure that there are no sharp edges, the body or tray is fitted to the vehicle. The body
including fasteners, pointing towards any or tray must include a fuel filler mounting that
fuel system component. complies with the guidelines in this section. The
The fuel filler pipe must be supported in shipping bracket can be left installed on the vehicle
accordance with the guidelines in this if desired, but only if an additional fuel filler pipe
section. mounting bracket is used in accordance with the
guidelines in this section.
Transport Mode includes a calibration
feature to reduce the risk of fuel injector
nozzle corrosion. Exiting Transportation
Mode prior to upfitting/ conversion
increases the risk of early life injector
failure.
Fuel Filler Pipe Shipping Bracket - Single Cab
E145838

3 Powertrain
Fuel Filler Pipe Shipping Bracket - Super Cab
E145839
Fuel Filler Pipe Shipping Bracket - Double Cab
E213151

3 Powertrain 3.1.2 Fuel Filler Mounting If the vehicle body and mounting bracket does not
provide a grounding path for the fuel filler neck, an
CAUTION: Make sure that the filler neck earth strap must be added, connecting the filler
mounting bracket is made of a conductive neck to the chassis frame.
material, and that it provides a grounding
path for the fuel filler neck.
Fuel Filler Mounting Bracket
E145833
Fuel Filler Mounting Notes

Item Description
A The width of the bracket, where it joins the body to be at least 180 mm
1 All 3x hardware fixation points on the filler neck must be utilised

3 Powertrain
Angle of Filler Neck
B
A
E145836
Filler Neck Installation Dimensions

Item Description
A 2mm minimum bracket thickness
B 30° - angle to be maintained to ensure good flow of fuel when refueling and prevent flow back.

3 Powertrain
Clearance From Vehicle Body
E145835
Item Description
A At least 9mm clearance between the fuel filler cap and vehicle body, in the worst case opening
angle if applicable
3.1.3 Fuel Filler Vent Hose Fuel Filler Vent Breather Cap
• The fuel tank vent hose and breather cap
should be rerouted from the shipped position
to the position described in this document in
order to maintain water wading specifications
and prevent water ingress into the fuel system.
• The supplied fuel tank breather cap must be
used.
• A length of fuel grade flexible hose should be
clipped to the vehicle body, with the open end
at least 600 mm (4x2) or 800 mm (4x4 or 4x2
hi-rider) above ground height. It is
recommended to measure this height when the E212453
vehicle is fully loaded.
NOTE: See your authorised dealer to confirm the
• The fuel tank vent hose should be protected
correct part number for your vehicle.
and positioned away from direct water spray,
wheel splash and mud splash, and water
drainage holes that may be present.
• The fuel tank vent hose breather cap must be
upright with its arrow pointing UP.

3 Powertrain
Example of Fuel Tank Vent Hose Mounting Location
E212452
Item Description
1 Front Lower Head Board of a Load Tray (load tray rotated for clarity)
2 Fuel Tank Vent Hose
3.1.4 Long Range Fuel Tanks

3.1.5 Axle Breather Vent Hose
NOTE: Long Range Fuel Tanks are not engineered
by Ford Motor Company and Ford Motor Company The rear differential breather hose should be
makes no determination as to the fit, finish, quality mounted to the filler neck/vehicle body. Where
or durability of these parts. required due to the fitment of an auxiliary body,
NOTE: Whilst functionality will be improved by aftermarket additions, or the relocation of the fuel
this modification, distance to empty calculations filler, the axle vent hose routing must follow the
may express some discrepancy compared to relocated fuel tank venting. A length of fuel grade
standard parts and calculations. flexible hose should be clipped to the vehicle
body, with the open end at least 600 mm (4x2)
Following installation of a long range fuel tank, or 800 mm (4x4 or 4x2 hi-rider) above ground
distance to empty (DTE) functionality will be height. It is recommended to measure this height
reduced. when the vehicle is fully loaded. A vent breather
To improve system functionality, using IDS/FDRS cap may be used on the axle breather vent hose.
as appropriate:
• Plug IDS/FDRS into vehicle
• Allow IDS/FDRS to read parameters and show
applicable menus
• In Configuration Parameter; Select Fuel Tank
Capacity Volume (Tank Size A);
• Select appropriate option following the
dialogue selections: Fuel Tank Capacity >
Configuration Description
– Standard 80L
– 140L ARB Long Range Tank

4 Electrical 4.1 Wiring Installation and Routing Guides
4.1.1 Wiring Splicing Procedures
TYCO-RAYCHEM crimp splices
E131081
Ford Motor Company strongly advises against the

use of wire splicing due to the variable and
unpredictable nature of the joint created. However,
if it is decided that a wire splice is unavoidable, it
must be made using DuraSeal Heat-Shrinkable,
Environmentally Sealed, Nylon-Insulated
Crimp Splices (manufactured by
TYCO-RAYCHEM). For example the D406 series.
As a further process to improve the splice integrity,
the splice should be further sealed with a suitable
heat shrink tubing. See Figure E131081.

4 Electrical
4.2 Battery and Cables
4.2.1 Battery Information
Battery Charging Procedure
If a battery is disconnected, there is no
requirement to reprogram the vehicle; the vehicle WARNINGS:
retains its ‘normal’ power management setting
and remembers exactly what its previous Always observe the battery charger
configuration was (although the central locking equipment manufacturer’s instructions.
latches may cycle if a door or lock latch was Do not jump/slave start using a battery
opened manually in the intervening period). All charging system from another vehicle.
radio settings will be retained, but the key code
needs to be entered to restore functionality. The Do not overfill a battery as this can cause
clock will need resetting. The window control acid leakage that will result in damage
module will also need to be reset. Refer to the to the vehicle and possible personal
vehicles owner manual for further information. injury.
CAUTIONS:
Battery Voltage Requirements and Do not rely on the generator to recharge
Testing a discharged battery. It would take in
excess of eight hours of continuous
All voltages are to be measured with an accuracy driving with no additional loads placed
of: + /– 5% of published values. on the charging system.
To maximize battery life, at the time of arrival at Make sure that the battery electrolyte
the vehicle converter, all batteries must have a reaches the indicated maximum mark.
minimum Open Circuit Voltage (OCV) of not less
than 12.75 volts. Connect the battery charger cables to the
battery before switching the battery
When the battery is installed and connected to
charger on.
the vehicle's electrical system with no load, the
Closed Circuit Voltage (CCV) must not be less Switch the battery charger off before
than 12.65 volts. When the vehicle is released to disconnecting the battery charger cables
the customer, the CCV must not be less than 12.50 from the battery.
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.
Prior to carrying out manual voltage checks, it is NOTE: The use of the Midtronics GR-590 Battery
necessary to establish that the battery voltage is Management Center, which has been specifically
stable and free from surface charges that could designed for use on silver calcium type batteries
be present due to certain engine run conditions is recommended. Once connected to the battery,
making the voltage readings unreliable and the battery charger detects the state of battery
inaccurate. charge and then applies the appropriate charge
rate and duration. When the battery is fully
To ensure surface charges are not present the
charged, the battery charger switches to stand-by,
following actions are recommended:
keeping the battery in a fully charged state
1. Turn on the headlamps for 5 seconds, or the preventing excessive gassing and overcharging.
parking lamps for 15 seconds. The Midtronics GR-590 Battery Management
2. Turn off all electrical loads (including lamps, Center also incorporates a software program that
fan, heater etc). has the capability to assist in the recovery of
3. Wait 10 minutes. deeply discharged (sulphated) batteries.
NOTE: Charging methods and types of battery
chargers vary widely. Whichever method is utilized
Delayed Vehicles it must be carried out carefully to avoid damage
to the battery and possible personal injury.
Vehicles held at the vehicle convertor premises Specific instructions accompanying each battery
and not in use for longer than 4 days, should have charger and must be followed exactly. Safeguards
the battery's negative cable disconnected. Before provided by the equipment manufacturer should
shipping to the customer, the battery negative not be disregarded by the operator.
cable must be re-connected and the voltage
re-checked. The voltage should be not less than NOTE: A battery which has been stored in a highly
12.5 volts. discharged state may be slow to accept a charge
at first. In such cases the initial charging rate may
be so low that the ammeter on some battery
testers will not show any indication of charge for
5 to 10 minutes.

4 Electrical NOTE: Automatic battery chargers are also NOTE: When connecting and disconnecting the
protected against reverse polarity connection and battery from the vehicle, make sure that the
require no adjustment or monitoring. battery ground cable is disconnected first and
connected last and that all electrical items are
NOTE: Slow-charging will readily restore a battery
switched off. Record the audio unit keycode and
to a full state of charge and, since the charging
preset radio frequencies before disconnecting the
current is relatively low, the possibility of
battery.
overcharging a battery are minimized. The charge
rate used should be approximately equal to 5% 1. Remove the battery.
of the reserve capacity of the battery being 2. Disconnect the battery ground cable
charged (approximately three to six Amps
depending on battery size). The charging current
should be adjusted 10 minutes after initial setting
and again after 1 hour before being left to charge
the battery for between 8 and 12 hours.
40 mm
NOTE: A constant voltage battery charger will
charge a battery at a set maximum voltage. The
voltage used depends upon the design and
condition of the battery charger and the age and
temperature of the battery. This type of battery
charger initially charges at a high rate of current
that reduces as battery voltage is restored. When
using a constant voltage battery charger, the DTZ9722102
charging current should be recorded after five
minutes and the battery charger switched off when NOTE: The maximum battery electrolyte level is
the charging current falls to one–third of the approximately 40 mm below the very top of the
recorded value, or after eight hours whichever battery casing. This corresponds to a point just
occurs first. below the lower rim of the battery casing.
NOTE: Multiple battery chargers are designed to 3. Check that the battery electrolyte reaches the
charge a number of batteries, simultaneously. Of indicated maximum level. Top up with
the two different types of multiple battery chargers distilled/de-ionized water, as necessary.
available, only those that charge batteries in series 4. Connect the positive red clamp from the battery
should be used and it is important that batteries charger to the positive battery terminal.
are of the same or very similar ratings and voltages.
5. Connect the negative black clamp from the
Multiple battery chargers that charge batteries in
battery charger to the negative battery terminal.
parallel are not recommended.
6. Follow the instructions supplied with the
NOTE: The use of a fast (boost) battery charger battery charger to charge the battery.
is not recommended as it can cause damage to a
7. To disconnect the battery charger, reverse the
battery. Fast charging will only restore a battery
connection procedure.
to a state of charge that will enable it to carry out
it’s critical function of cranking the engine. Fast
charging will not restore a battery to a full state of
Battery Cable Fixing Torque
charge and must therefore be followed by a period
of slow charging. Excessively fast charging can The battery cables should be fixed to the terminal
cause damage to a battery. For this reason, posts with a torque of 4.8 Nm -/+ 0.8Nm.
charging times must be carefully controlled. Fast
battery chargers vary widely in design so it is very
important to strictly adhere to the equipment Battery Rules:
manufacturer’s instructions. A charge of 30 amps
for up to 30 minutes is the most common fast WARNINGS:
charging application. If the battery is very
discharged and requires additional restoration, an For vehicles fitted with non-sealed
additional charge of 20 amps for a period up to batteries (non-maintenance free), it is
one and a half hours should be applied. Fast essential that regular checks are made to
charging for a period in excess of two hours determine that the electrolyte (acid)
significantly increases the risk of causing damage levels are correctly maintained.
to the battery. When charging, ensure the battery
charger is securely connected to the
vehicle ground and not to the battery
negative terminal. This is to ensure that
the BMS identifies the battery charge.
• For external charging of batteries ensure that
the maximum voltage of 14.6V is not exceeded.

4 Electrical
Battery Part Numbers and Usage
Ford Plant Type Specifications Size

Standard Duty 75Ah, 750CCA H7
Battery
Thailand
Auto Start - 80Ah, 800CCA, AGM Deep Cycle Technology H7
Stop Battery
If the battery type on a vehicle is changed to other

compatible derivatives it is required to reconfigure
Auxiliary Battery fitted to vehicles with
the vehicle to the new battery types from the
a Battery Monitor System (BMS)
dealer. Central car configuration can be updated
at a dealership.
NOTE: The addition of an auxiliary battery in a
vehicle with BMS would cause both batteries to
not reach a state of full charge. The system will
Battery Monitor System (BMS)
only allow charging of the batteries during
Low Level Vehicles deceleration. Refer to Dual Batteries with Battery
Monitor System (BMS) in this section.
NOTE: Disabling the BMS will negate the fuel
economy benefit provided by the BMS.
NOTE: Auxiliary loads must always be connected
to the vehicle ground and not to the battery
negative terminal.
NOTE: Ensure the auxiliary battery connection is
safely secured using suitable fixtures to reduce
vibration damage or contact with surrounding
components.
For vehicles equipped with BMS, an additional
E181583
battery can be connected using one of the
following methods:
High Level Vehicles 1. Use an in-vehicle battery charger (DC/DC
converter) such as BCDC1220 model from
Redarc (www.redarc.com.au) (or similar),
connected via an additional terminal to the
starter post terminal on the B+ using a 30A
fused connection and grounded to the vehicle
body, in the shown locations.
NOTE: The additional terminal must be installed
on top of the starter post terminal using the
existing nut.
NOTE: The maximum thickness of the additional
terminal being installed on top of the starter post
E223579 terminal must be no more than 2.0 mm.
Ford Ranger vehicles are equipped with a feature NOTE: Ensure the existing nut is reused.
called Battery Monitor System (BMS). This system
measures the battery load in order to efficiently B+ Connection for Auxiliary Battery Charging
charge the battery while improving fuel economy
and emissions.
It is important to ensure any additional electrical
load or accessory is properly grounded to the
vehicle’s body, in order for the system to identify
the additional load. If a connection is made to the
battery negative terminal, the BMS will not identify
the load or charge. This may cause the battery to
be undercharged and consequently not able to
re-start the vehicle.
E251317
The B+ connection should be fixed to the terminal

posts using the existing nut with a torque of 13.5
Nm -/+ 2.1 Nm.

4 Electrical NOTE: Ensure the fused connection is secured
using suitable fixtures to reduce vibration damage
or contact with surrounding components.
Grounding points for in-vehicle battery charger
E251326
Item Description
1 Possible ground connection points using W705661-S901.
The ground point connection should be tightened NOTE: The additional terminal must be installed
to torque of 12 Nm -/+ 1.8 Nm. on top of the starter post terminal using the
2. Request a Ford dealer to disable the BMS. existing nut.
Disabling the BMS enables voltage sensitive NOTE: The maximum thickness of the additional
relay based dual battery systems to work. terminal being installed on top of the starter post
terminal must be no more than 2.0 mm.
Auxiliary Battery fitted to vehicles NOTE: Ensure the existing nut is reused.
without a Battery Monitor System (BMS)
B+ Connection for Auxiliary Battery Charging
negative terminal.
NOTE: Make sure the fused connection is safely
secured using suitable fixtures to reduce vibration
damage or contact with surrounding components.
An auxiliary battery charging system can be
connected using one of the following methods:
1. Use an in-vehicle battery charger (DC/DC
converter) such as BCDC1220 model from
Redarc (www.redarc.com.au) (or similar), E251317
connected via an additional terminal to the
starter post terminal on the B+ using a 30A The B+ connection should be fixed to the terminal
fused connection and grounded to the vehicle posts using the existing nut with a torque of 13.5
body, in the shown locations. Nm -/+ 2.1 Nm.

4 Electrical
NOTE: Make sure the fused connection is secured
using suitable fixtures to reduce vibration damage
or contact with surrounding components.
Grounding points for in-vehicle battery charger
E251326
Item Description
1 Possible ground connection points using W705661-S901.
The grounding point connection should be • For auxiliary customer electrical loads, a
tightened to torque of 12 Nm -/+ 1.8 Nm. suitable fused connection must be used.
• If multiple auxiliary loads are required, it is
recommended that an auxiliary fuse box is
Connection of Auxiliary Loads - Low Level fitted to the vehicle.
Vehicles
• For the connection of auxiliary exterior lighting,
WARNINGS: refer to the guidelines given in the exterior
lighting section.
Make sure all electrical connections and
wiring comply with local regulatory Refer to: Exterior Lighting (page ?).
standards. Auxiliary loads for external devices which require
an ignition feed (such as UHF/CB radios) may be
Under no circumstances should any
connected via a relay energised by the IG+ feed
unfused connections be made directly to
to the Body Control Module.
any of the vehicle's battery terminals.
WARNING: Under no circumstances
An increase in battery drain due to an
should the IG+ feed be used to drive
auxiliary load will void the battery
auxiliary loads directly. A suitable relay
warranty.
must be used.
The Body Control Module is positioned on the
driver's side of the vehicle underneath the dash
negative terminal.
panel.

4 Electrical
IG+ Connection at Body Control Module
2
2
E211057
Item Description
1 Body Control Module
2 IG+ Feed
Connection of Auxiliary Loads - High Level • For auxiliary customer electrical loads, a
Vehicles suitable fused connection must be used.
• If multiple auxiliary loads are required, it is
WARNINGS: recommended that an auxiliary fuse box is
Make sure all electrical connections and fitted to the vehicle.
wiring comply with local regulatory • For the connection of auxiliary exterior lighting,
standards. refer to the guidelines given in the exterior
lighting section.
Under no circumstances should any
unfused connections be made directly to Refer to: Exterior Lighting (page ?).
any of the vehicle's battery terminals. Auxiliary loads for external devices which require
NOTE: Auxiliary loads must always be connected an ignition feed (such as UHF/CB radios) may be
to the vehicle ground and not to the battery connected via a relay energised by a IG+ feed to
negative terminal. the Body Control Module.
WARNING: Under no circumstances
should the IG+ feed be used to drive
auxiliary loads directly. A suitable relay
must be used.
The Body Control Module is positioned on the
driver's side of the vehicle underneath the dash
panel.

4 Electrical
IG+ Connection at Body Control Module
E223580
Item Description
1 Body Control Module
2 IG+ Feed
Part Numbers
Description Part Number / Service Manufacturer
Part Number
Connector CU5T-14489-XA TE (Tyco Electronics)
Pin 7C3T-14474-DA / DU2Z- Molex
14474-DA
4.2.2 Generator and Alternator
Alternator Current Output
See your local authorised dealer to identify the

alternator output current specifications for your
vehicle.

4 Electrical 4.3 Parking Aid
WARNINGS: NOTE: Certain add-on devices installed around
the bumper or fascia may create false alerts. For
To help avoid personal injury, always use
example, large trailer hitches, bike or surfboard
caution when in reverse (R) and when
racks, license plate brackets, bumper covers or
using the sensing system.
any other device that may block the normal
The system may not detect objects with detection zone of the system. Remove the add-on
surfaces that absorb reflection. Always device to prevent false alerts
drive with due care and attention. Failure
The parking aid sensing system warns the driver
to take care may result in a crash.
of obstacles within a certain range of your vehicle.
Traffic control systems, inclement The system turns on automatically whenever you
weather, air brakes, external motors and switch the ignition on. The system can be switched
fans may affect the correct operation of off through the information display menu or from
the sensing system. This may cause the pop-up message that appears once you shift
reduced performance or false alerts. the transmission into reverse (R). If a fault is
present in the system, a warning message appears
The system may not detect small or
in the information display. See the vehicle owner
moving objects, particularly those close
manual for further information on the correct
to the ground.
operation of the parking aid system.
NOTE: Keep the sensors, located on the bumper
Protection assemblies mounted on the front of
or fascia, free from snow, ice and large
the vehicle, such as Bull Bars/Nudge Bars and
accumulations of dirt. If the sensors are covered,
frontal crash and animal strike protection
the system’s accuracy can be affected. Do not
assemblies may require that the front parking aid
clean the sensors with sharp objects
sensors are relocated to a different position than
NOTE: If your vehicle sustains damage to the the original Ford positioning. The below guidelines
bumper or fascia, leaving it misaligned or bent, the and details should be followed to maintain
sensing zone may be altered causing inaccurate suitable operation of the parking aid system by
measurement of obstacles or false alerts. ensuring the sensor detection angles are
maintained in a suitable specification.
Where possible, front parking aid sensors should
not be moved from the original positions on the X,
Y and Z plane. Maintaining the sensors location
on these planes is important for correct operation
of the system.

4 Electrical
Vehicle Location Planes
E292617
4.3.1 Sensor Location

NOTE: Relocated sensors must be installed in
the same position as originally fitted in the bumper
bar. Make sure that each sensor is installed in the
correct corresponding position.

4 Electrical
Front Parking Aid Sensor Location
1 2 3 4
E292623
Sensor Number
Front Right Outer 1
Front Right Inner 2
Front Left Inner 3
Front Left Outer 4
Front Parking Aid Sensor - Critical Angles and Heights

Inner Sensor Inner Sensor Height Outer Sensor Inner Sensor Height
Angle Angle
within range of 2-4 Less than or equal to 440mm within range of 2-4 N/A
degrees* above the ground degrees*
* degrees above the horizontal plane.

4 Electrical
4.4 Electronic Engine Controls
4.4.1 Vehicle Speed Output (Signal) NOTE: A hard-wired vehicle speed signal is
(Low Level Vehicles Only) available if integration is required.
NOTE: The vehicle speed signal is a direct current
General Information coupled square wave that varies in frequency in
proportion to vehicle speed. This provides a square
WARNING: Do not interface with the CAN wave-form (50% duty cycle) signal.
(controller area network) for vehicle
speed.
Circuit hardware
E180281
Square Wave Characteristics - Output signal
Signal Requirements Sunroof Taxi Speed Output

Maximum High Signal Battery Voltage
Minimum High Signal 3.67 Volts
Maximum Low Signal 1.1 Volts
Minimum Low Signal -1.1 Volts
Maximum Ground Offset +/- 1.0 Volts
Rise Time 10μ sec <= tr <= 250μ sec
Fall Time 10μ sec <= tf <= 250μ sec
Duty Cycle 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

4 Electrical Instructions for connection 4. Once the device is connected, reset the BCM
by disconnecting the vehicle battery.
1. The vehicle speed output is available on: 5. Reconnect the vehicle battery.
[connector 3 pin number 52] or [connector 4
6. Turn the ignition ON.
pin 3]. Choose one of the connections and
populate the connector with a terminal and 7. The signal should now be available.
wire. NOTE: Rload should be present and connected
2. The output must be connected to a device with to battery voltage for this function to work.
1k ohms resistance (600 ohms to 2k ohms is
the guideline) in order for it to work. This
protects the BCM (body control module) from For Information Only
overcurrent risk.
3. The output must be connected to a power Terminal part number: 96AG-14474-RSA.
source. Wire size and color: 0.5 CSA, blue - green.

4 Electrical
Terminal Insertion
1 2
E180282
Item Description
1 Connector C3 Pin 52
2 Connector C4 Pin 3
1. Connector C3 or C4 need to be unplugged in 2. Once the connector C3 or C4 is removed, the

order to insert the speed signal terminal. grey 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.

4 Electrical
E180283
E180284
E180285

4 Electrical
E180286
3. There is a red terminal latching plate that

needs to be removed.
E180287
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.
E180293

4 Electrical 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.
E180294
E180295
E180296

4 Electrical
4.4.2 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.

4 Electrical 4.5 Exterior Lighting
WARNINGS: NOTE: Prior to work on any vehicle being
undertaken it is critical to identify the vehicle level
Make sure that the modified vehicle
(low level or high level) by the type of electrical
complies with all local regulatory
architecture the vehicle at hand is equipped with.
standards.
Failure to identify the type of electrical architecture
Make sure all electrical connections and present on the vehicle prior to work being
wiring comply with local regulatory undertaken may cause electrical damage or have
standards. safety implications.
NOTE: Chassis Cab vehicles are supplied with rear Refer to: 4.7 Fuses and Relays (page 70).
combination lamps, license plate lamps and fog
lamps. Where fitted, these lamps must be
mounted in accordance with the following
guidelines.

4 Electrical
4.5.1 Rear Combination lamps
F
G
B
A
E141460
Positioning of Rear Combination Lamps

Description Dimension
A Minimum distance from ground to lower edge of lamp 250mm
B Maximum distance from ground to upper edge of lamp 1200mm
C Minimum angle of obstruction free zone downwards of the lamp 15°
D Minimum angle of obstruction free zone upwards of the lamp 15°
E Minimum angle of obstruction free zone towards the outside of 80°
the vehicle
F Minimum angle of obstruction free zone towards the centre of the 45°
vehicle
G Maximum distance from outer edge of vehicle to inner edge of 400mm
lamp
4.5.2 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.

4 Electrical
B
A
E141472
Positioning of Rear Fog Lamp

A Minimum distance from ground to lower edge of lamp 250mm
B Maximum distance from ground to upper edge of lamp 1000mm
C Minimum angle of obstruction free zone downwards of the lamp 5°
D Minimum angle of obstruction free zone upwards of the lamp 5°
E Minimum angle of obstruction free zone towards the outside of the 25°
vehicle
F Minimum angle of obstruction free zone towards the centre of the 25°
vehicle
4.5.3 Rear License Plate Lamp

4 Electrical
E
E141462
Positioning of Rear License Plate Lamp

A Distance from rear face of license plate to centre of lamp along 35mm
lamp mounting face
B Angle between license plate and lamp mounting face 10°
C Distance between top of rear face of license plate and lamp 35mm
mounting face
D Distance between license plate centre line and centre of lamp 175mm
E Distance between license plate centre line and centre of lamp 175mm

4 Electrical 4.5.4 Reversing Lamps, Rear View 4.5.5 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. Refer
C169 to the Central Junction Box where the signal to Trailer Towing for additional information.
is sensed. A marginal increase in current (via a relay For all other additional exterior lamps, power must
or buffered electrical input) is permissible to be taken through an auxiliary fuse box with a
provide power to a rear-view camera, auxiliary suitable switch and / or relay as required.
reverse lighting, or an audible warning device.
WARNING: Directly splicing into the
vehicle wiring in order to install auxiliary
lamps or other electrical devices may
overload the system and impact the
operation of other vehicle systems.
When installing auxiliary driving lights, power can
be provided via a relay energised by the headlamp
feed.
E210761
Item Description
1 Low beam
2 High beam
Lighting Fuses
F20 10A Headlamp
F75 15A Front fog lamp
F76 10A Reversing lamp

4 Electrical
4.5.6 Trailer Towing When fitting low power LED (light emitting diode)
lamps that require less than 2W, the lamps may
Vehicles with a factory fitted tow bar also come flicker when in use. A trailer patch harness should
with a trailer tow module for lighting and the be used with low power draw LED lamps.
activation of trailer sway control. In addition to
CAUTION: Do not connect the trailer
providing the trailer plug functionality, the trailer
patch harness to the vehicle when the
towing module protects the primary electrical
trailer is not connected.
circuits of the vehicle from any electrical concern
or failure that the customer's trailer may NOTE: The trailer patch harness is available from
experience. your Ford authorised dealer.
NOTE: The trailer tow electrical kit is available NOTE: The trailer detect circuit is part of the Ford
from your Ford authorised dealer. Trailer Tow module, it can only be implemented
on vehicles with power locking and perimeter or
For vehicles fitted without a tow bar as standard,
CAT 1 alarms.
a genuine Ford accessory trailer tow electrical kit
has been developed to enable a tow bar to be The Trailer Tow Module (TTM) can support pure
installed. The kit comprises of the trailer towing LED trailer lamps as long as each circuit exceeds
control module, trailer plug, wiring and associated 500mA, below this and the system will not detect
hardware components. a trailer has been connected and shuts down all
outputs (sleep mode). It is recommended to
Once the kit is installed, the vehicle must then be
target a 550mA minimum load to allow for
configured using a Ford IDS diagnostic tool. This
system tolerances. This would need to be
configuration can be performed by your Ford
obtained with a supplemental load resistor, if the
authorised dealer.
LED lighting circuits are below this threshold.
WARNING: Installation of aftermarket Each output driver could handle a current of 15A
trailer tow electrical kits or directly but it is not recommended to always run to this
splicing into the vehicle wiring in order maximum. A higher current is interpreted as short
to install trailer lamps or other electrical circuit. If a short circuit is detected the related
devices may overload the system and output will be switched off. The following table
impact the operation of other vehicle shows the recommended output maximums per
systems. circuit.
Ford recommends that all trailer tow electrical NOTE: Not all features and outputs are supported
connections use the genuine Ford accessory trailer in all markets. Refer to your authorised Ford Dealer
tow kit. for further information.

4 Electrical
Trailer Tow Module Connections- Low Level Vehicles
Component Feature Current (A) Voltage (V)
Terminal
Min Max Min Max
Number
Connector A
1 Right Direction Indicator 0.5 3 6 -
2 Battery Charge Out - where used - 10 9 16
3 Stop Left 0.5 4 6 -
4 Not used - - - -
5 Not used - - - -
6 Reverse Lamp 0.5 4 6 -
7 Stop Right 0.5 4 6 -
8 Fog Lamp 0.5 2 6 -
9 Not used - - - -
10 Left Direction Indicator 0.5 3 6 -
11 Not used - - - -
12 Position Lamp 0.5 7 6 -
Connector B
1 Not used - - - -
2 Term 30 (Ubat) - 30 6 16
Connector C
1 CAN H - 0.1 6 -
2 CAN L - 0.1 6 -
3 Brake Line In (Vehicle -) - 0.1 6 -
4 Ground - 1 6 -
5 Trailer Detect Output - 0.1 - 16

4 Electrical
Trailer Tow Module Connections- High Level Vehicles
Component Feature Current (A) Voltage (V)
Terminal
Min Max Min Max
Number
Connector A
1 Left Direction Indicator 0.5 3 6 -
2 Right Direction Indicator 0.5 3 6 -
3 Position Lamp 0.5 7 6 -
4 Not used - - - -
5 Reverse Lamp 0.5 4 6 -
6 Battery Charge Out - where used - 10 9 16
7 Stop Lamp 0.5 4 6 -
8 Fog Lamp 0.5 2 6 -
9 Not used - - - -
10 Not used - - - -
11 Not used - - - -
12 Not used - - - -
Connector B
1 B(+) Fuse 87 (40A) BJB - - - -
2 B(+) Fuse 73 (30A) BJB - - - -
Connector C
1 Ground - 1 6 -
2 CAN L - 0.1 6 -
3 CAN H - 0.1 6 -
4 Not used - - - -
4.5.7 Auxiliary Lighting Loads (Low

Level Vehicles Only) Trailer Tow Module (if equipped)
NOTE: Connections for auxiliary lighting loads Connections for auxiliary lighting loads can be
must be low and stable current draw. made via the trailer tow module (TTM) located
under the passenger seat. See Trailer Towing in
this section.
E223617

4 Electrical
TTM Connector - Detail
E231982
4.5.8 Lamps – Hazard / Direction

Indication 4.5.10 Centre High Mount Stop Lamp
(CHMSL) - Canopy Fitment -Low Level
The maximum permissible load with the standard Vehicles
system is:
• 3 x 5W – front and rear indicators + side WARNING: The maximum current load
repeaters (Left Hand Side) that can be applied to the CHMSL circuit
is 1.72A for incandescent globes, and
• 3 x 5W – front and rear indicators + side
0.38A for LED lamps. Do not exceed the
repeaters (Right Hand Side)
rated load.
NOTE: Disable the original vehicle mounted
4.5.9 Electrically Operated Door CHMSL if the canopy CHMSL is intended to be the
Mirrors primary CHMSL.
WARNING: Do not tamper with the base NOTE: The CHMSL circuit is pulse width
system (controlled by Central Junction modulated (PWM).
Box and multiplex architecture) and any NOTE: Check the operation of the CHMSL prior to
feeds taken from the associated wiring customer handover.
or controller.
NOTE: When replacing the factory fitted CHMSL
NOTE: These options are not suitable for with a canopy mounted CHMSL, the same type
aftermarket or Body Builder fit. must be used. Replace a bulb/incandescent type
only with a bulb/incandescent. Replace and LED
type only with an LED type.
When installing a canopy equipped with a CHMSL,
a feed for the CHMSL can be taken from the BCM
(Connector 4, Pin 2).

4 Electrical
1
E229158
Item Description
1 BCM CHMSL Feed (Connector 4, Pin 2).
4.5.11 Centre High Mount Stop Lamp NOTE: Disable the original vehicle mounted
(CHMSL) - Canopy Fitment - High CHMSL if the canopy CHMSL is intended to be
Level Vehicles the primary CHMSL.
NOTE: The CHMSL circuit is pulse width
WARNINGS: modulated (PWM).
The maximum current load that can be NOTE: Check the operation of the CHMSL prior
applied to the CHMSL circuit is 1.72A for to customer handover.
incandescent globes, and 0.38A for LED
lamps. Do not exceed the rated load. NOTE: When replacing the factory fitted CHMSL
with a canopy mounted CHMSL, the same type
Make sure all wiring is insulated and must be used. Replace a bulb/incandescent type
routed securely. only with a bulb/incandescent. Replace and LED
NOTE: The fitment of a canopy to high level type only with an LED type.
vehicles equipped with a combined CHMSL /
Cargo Lamp requires that the cargo lamp feature
be disabled.

4 Electrical When fitting a canopy to vehicles equipped with
a combined CHMSL / Cargo Lamp, the lamp
housing may be impacted by the canopy. Check
the canopy to CHMSL clearance, and if required,
follow the below procedure.
A replacement CHMSL (without cargo lamp
function) needs to be installed. A patch harness
with a 2-pin connector is then spliced into the
vehicles CHMSL circuit wiring allowing a canopy
with an integrated CHMSL to take a stop lamp
circuit feed from the 2-pin connector. The original
3-pin connector is then taped back.
Follow the steps to install the replacement CHMSL
lamp housing:
1. Remove the combination CHMSL / Cargo Lamp
following the workshop manual instructions.
NOTE: When cutting off the stop lamp circuit wires
from the 3-pin CHMSL connector, stagger the cuts
to allow for cleaner and less bulky splice joins.
2. Locate the 3-pin CHMSL / Cargo Lamp
Connector. Cut off the stop lamp circuits (pin 1
yellow-grey or white-blue, pin 2 black-violet or
black-yellow or black-blue) leaving the violet
wire (pin 3) connected to the 3-pin CHMSL
connector.
3. Tape back the 3-pin connector with the violet
coloured wire.
4. Splice the replacement 2-pin connector and
patch harness to the cut wires:
1. Yellow + Grey wire (or alternate color - see
above ) to Yellow + Grey wire.
2. Black + Violet wire (or alternate color - see
above ) to black + Violet wire.
5. Insulate the spliced joins with heat shrink.
6. Route the canopy CHMSL wiring through a
suitable grommet into the passenger
compartment, route it behind the trim panels
and connect it to the replacement 2-pin
connector.
7. Install the replacement CHMSL to the vehicle
following the workshop manual instructions.

4 Electrical
4.6 Handles, Locks, Latches and Entry Systems
4.6.1 Central Locking NOTE: The location of additional relays should
be considered carefully. A suitable mounting
NOTE: Additional locks will not be covered by the location away from the passenger compartment
vehicle alarm or operate BCM controlled lighting. will allow for a safer install and reduced noise in
the passenger compartment.
The central locking function is controlled by the
BCM (located under the instrument panel). The Depending on the functionality required, the pins
vehicle locks are operated by surface mounted used will emulate the basic locking/unlocking
relays in the BCM – these are only capable of operation of an existing lock. The coil of the
powering one lock each. additional relays (i.e. one relay for lock all, one
relay for unlock all) should be added across the
It is possible to add an additional lock(s) with the
relevant pin and a suitable ground point. Power
use of relays triggered by the BCM outputs.
(B+) for the additional relays should be taken
from a suitably fused B+ feed.
Relay selection for installation of an additional
lock(s) must parallel the run time of th BCM
surface mount relays.
BCM Output for Central Locking (Low Level Vehicles)

BCM Pin Circuit Fuse Function
C2280E 1 CPL11 BCM Fuse 70 CTRL MOD. - DOOR LOCK # ALL
LOCK
C2280E 8 CPL13 BCM Fuse 70 CTRL MOD. - DOOR LOCK # ALL
UNLOCK
BCM Output for Central Locking (High Level Vehicles)

BCM Pin Circuit Fuse Function
C2280F 35 CPL11 BCM Fuse 24 CTRL MOD. - DOOR LOCK # ALL
LOCK
C2280F 32 CPL13 BCM Fuse 24 CTRL MOD. - DOOR LOCK # ALL
UNLOCK

4 Electrical 4.7 Fuses and Relays
4.7.1 Low Level and High Level Passenger Compartment Fuse Box - High Level
Vehicles Vehicles
WARNING: Prior to work on any vehicle
being undertaken it is critical to identify
the type of electrical architecture the
vehicle uses. Failure to identify the type
of electrical architecture present on the
vehicle prior to work being undertaken
may cause electrical damage or have
safety implications.
This manual provides information that may or may
not apply depending on the exact vehicle model
the vehicle converter is working on. The PX Ranger
MkII is built in varying specification levels, spread
across two different electrical architecture types.
Identification of which type a vehicle is equipped
with can be aided visually checking the passenger
compartment fuse box.
Passenger Compartment Fuse Box - Low Level

Vehicles
E225624
4.7.2 Auxiliary Battery and Fuse Box -

Low Level Vehicles
NOTE: High level vehicles cannot be fitted with
the factory installed auxiliary battery and fuse box.
An auxiliary battery and associated fuse box is
available as an option on low level vehicles called
a 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.
E133602

4 Electrical
4.7.3 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)
E231508
Item Description
1 Auxiliary Fuse box
Vehicles with Temporary Battery Carrier (Cab Chassis Variant Only) (Low Level Vehicles Only)
(Vehicles with Special Equipment Pack)
E231507
Item Description

4 Electrical
Cab Chassis Vehicles with Tray (Low Level Vehicles Only) (Vehicles with Special Equipment
Pack)
E231509
Item Description
Auxiliary Fuse Specification Chart
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.

4 Electrical
E174549
Fuse Fuse Amp Protected Components

Rating
1 25 Driving lights
2 15 Position lamp
3 10 LED (light emitting diode) beacon lamp
4 15 Work lights
5 20 Spare
6 20 Power point
7 15 Reversing lamp
8 15 Direction indicators, stop lamp
9 5 Crew chief
10 5 Auxiliary battery 'disable' fuse (isolator ground).
11 - Not used
12 - Not used
Relay Chart
Relay Number Protected Components
R1 Work lights
R2 LED beacon lamp
R3 Spare
R4 Position lamp
R5 Direction indicator (left)
R6 Direction indicator (right)
R7 Stop lamp
R8 Not used
R9 Not used

5 Body and Paint 5.1 Body
5.1.1 Body Structures - General • Re-paint metal edges after cutting and drilling.
Information All metal edges must comply with exterior and
interior protection local regulatory standards.
WARNING: All external or internal • All fixings through the floor, sides or roof must
projections must comply with local be sealed.
regulatory standards.
• Make sure that fixings in the 'B'-pillar area do
CAUTION: Load carrying structures not encroach on the seat belts or seat belt reels.
should not be mounted onto an existing
load tray or load box.
5.1.2 Integrated Bodies and
When carrying out vehicle Conversions
conversions/modifications the following points
should be considered: WARNING: All wheelhouse envelopes
• Make sure that the vehicle structural integrity must comply with local regulatory
is maintained. standards.
• Do not drill into closed frame body members. For integral structures such as ambulances or
• Make sure that the design for the body motor-homes with increased rear overhang built
alterations or additional structure disperse the onto the chassis the following applies:
load evenly. • Reduced departure angles, e.g. rear entry step,
should be discussed with the end user /
CAUTION: Uneven load distribution could
customer. Consider removable components to
result in unacceptable handling and
avoid damage on ferries or low-loaders.
braking characteristics.
• 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.

5 Body and Paint
Wheelhouse Envelope
X 1
H
A B
K
C D
r r
L
G
F r
E E
r r
X-X
E134132
Wheel Guard Dimensions

Dimension 215/ 255/ 265/ 265/ Dimension 215/ 255/ 265/ 265/60R18
70R16 70R16 65R17 60R18 70R16 70R16 65R17
*
A 455mm G 190mm
B 425mm H 914mm 915mm 922mm 922mm
C 305mm K 588mm
D 275mm L 30mm
E 110° r 20mm
F 420mm 1 Center line of Vehicle
X Section through Center of Wheel Guard
*
Dimension G is to the bottom of the swage
5.1.3 Chassis Cab When carrying out vehicle conversions /

modifications the following points should be
WARNING: Excessive heat can build up considered:
from the exhaust system, in particular • Make sure that all of the reinforced holes
from the catalytic converter. Ensure provided in the chassis frame top surface are
adequate heat shields are maintained. used for full length bodies or sub-frames, see
CAUTION: Uneven load distribution could figures shown.
result in unacceptable handling and • Make sure that the vehicle structural integrity
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.

5 Body and Paint • Re-paint metal edges after cutting and drilling. For any conversion structure attached to or
All metal edges must comply with exterior and mounted onto the base vehicle cab structure the
interior protection local regulatory standards. following applies:
• All fixings through the floor, sides or roof must • Ensure that neither the conversion structure nor
be sealed. the existing vehicle structure get pre-loaded by
the assembly process.
Refer to: 5.4 Corrosion Prevention (page 93).
• Adhesive jointing is recommended but should
• Ensure that any additional equipment in the be supplemented with mechanical fasteners
vicinity of the fuel tank will not damage the tank to prevent initial peel and long term failure.
in a crash condition.
• Spread bolt loads to minimize local stress.
Body Attachment Holes in Chassis Frame - Single cab
D A
E F G H
N
K
J
K
L M
L M
N
E134152
Dimensions (mm) for Body Attachment Holes in Chassis Frame - Single Cab
Dimension Dimension
A 16 H 1086
B 28 J 95
C 23 K 768
D 20 L 893
E 1244 M 509
F 1244 N 26
G 1244 P 20

5 Body and Paint
Body Attachment Holes in Chassis Frame - Super cab
D A
C
E F G
L
H
J K
E134153
Dimensions (mm) for Body Attachment Holes in Chassis Frame - Super Cab
Dimension Dimension
A 16 G 1086
B 28 H 95
C 23 J 1191
D 20 K 509
E 1244 L 26
F 1244 M 20

5 Body and Paint
Body Attachment Holes in Chassis Frame - Double cab
B
C
A
E F G
H
J K
E134154
Dimensions (mm) for Body Attachment Holes in Chassis Frame - Double cab
Dimension Dimension
A 16 G 1086
B 28 H 95
C 23 J 893
D 20 K 509
E 1244 L 26
F 1244 M 20
5.1.4 Front End Integrity for Cooling, Static & Dynamic Sealing and Finishing Ensure
Crash, Aerodynamics and Lighting proper sealing against ingress of water, salt, dust
etc. after cutting or drilling the body. Use Ford
Cooling Continuous air flow through the front end approved sealing and finishing material, and
and engine compartment is not to be hindered by underbody corrosion protection.
adding any additional equipment. If uncertain Refer to: 5.4 Corrosion Prevention (page 93).
please consult the Ford dealer.
Lighting Do not alter the lighting system.
5.1.5 Tipper Bodies
Crash Do not cut, drill or weld any parts that are
load path relevant in case of crash. Do not add For tipper conversions single and double Chassis
material in the crash zone. This could affect the Cab versions except extended rear chassis frame
crash sensor calibration. can be used. All variants allow single and three
The side airbag system is not permitted if: way tipping.
• A swiveling device is fitted on the front seats. It is recommended to have the tipping system
• A side wall or any other additional material or operative only when the engine is running. It is also
structure is attached to the B-pillar inner and/or recommended to have the master control switch
outer area. in the security of the cab. According routing of
wires and hydraulic lines please refer to section
hydraulic lift.

5 Body and Paint
Ensure that axle plated weights including the front • Compliant mounts should be used, with up to
axle minimum are not exceeded. plus and minus 12mm compliance with the
For tipper sub-frames please refer to the following vehicle laden or un-laden (whichever is worst
guidelines: case). Compliant mounts should be rated with
a minimum of 2mm deflection per 200kg mass
• Design for full length continuous frame with at each chassis frame forward mount.
mountings for motor, pump unit, reservoir, pivot Compliant mounts shall have captive fail safe
points and ram. bolts.
• Use all mounting points on chassis frame to • Use two M10 grade 8.8 minimum bolts,
mount sub-frame. washers and self lock nuts per chassis frame
• Very stiff sub-frames may damage the chassis mount bracket at each solid and compliant
frame by preventing its natural flexing, location.
therefore compliant mounts should be used,
with up to plus and minus 12mm compliance
with the vehicle laden or un-laden (whichever
5.1.7 Genuine Ford Accessory Bull Bar
is worst case). Compliant mounts should be
The Genuine Ford Accessory bull bar includes
rated with a minimum of 2mm deflection per
brackets which are mounting points for driving
200kg mass at each chassis frame forward
lights, aerials, antennas and flags.
mount. Compliant mounts shall have captive
fail safe bolts. WARNINGS:
• Use two M10 grade 8.8 minimum bolts,
washers and self locking nuts at each solid and Follow all accessory manufacturer's
compliant chassis frame location. instructions when connecting
accessories and equipment to the
• Sub-frame must extend to the back of the cab vehicle.
and attach to all mounting locations, with the
forward end designed to minimize local frame Do not fit a non-Ford approved bull bar
stress. It is however, preferable to mount the to your vehicle as this may interfere with
sub-frame onto the mounting brackets with a the operation of the restraint system,
clearance to the chassis frame top surface. including the air bag deployment, and
• Side tipping loads/forces must be resolved by could result in injury to yourself and
the sub-frame. It is not recommended to strain others. Fitment of a bull bar may also
the chassis frame. void the vehicle's compliance with
Australian Design Rules.
Do not modify the front of your vehicle in
5.1.6 Tank and Dry Bulk Carriers any way. This could adversely affect
deployment of the airbags. Failure to
Due to the high rigidity of tanks it is necessary to
adhere to this warning could result in
isolate the tank and its sub-frame from the
serious personal injury or death.
chassis frame allowing the chassis frame to
naturally flex. Please refer to the following After bullbar installation, contact your
guidelines: authorised Ford Dealer to correctly
calibrate the Adaptive Cruise Control
• Mount tank to full length of sub-frame.
Radar Module (if equipped). This is
• Mount sub-frame to all chassis frame required to ensure correct operation of
mounting points. the advanced safety features this vehicle
• The forward location mounts must be offers.
compliant to allow relative chassis frame to
NOTE: Please refer to the electromagnetic
sub-frame deflections.
compatibility (EMC) section in this book before
• Sub-frame must extend to the back of the cab installing any aerials.
and not contact chassis frame at forward end
under worst case deflection.

5 Body and Paint
Bull Bar Accessory Mounting Positions
2 1
E210762
Item Description
1 Aerials, antennas and flag mounting location
2 Driving lights mounting location
Antenna Cables Routing

5.1.8 Roof Racks
WARNINGS:
Ensure that the antenna cables have Roof racks may be fitted to all variants as
sufficient clearance from hot and moving illustrated in figure, providing the following is
parts. satisfied:
Do not fasten the antenna cables to • The carried load does not exceed 80kg (Body
original vehicle wiring, fuel pipes and Builder to ensure owner’s hand book identifies
brake pipes. this limitation).
• The carried load does not exceed 300mm load
Keep the antenna and power cables at height (converter to ensure owner’s information
least 100mm from any electronic modules book identifies this limitation).
and airbags and associated wiring.
• The load is evenly distributed (converter to
NOTE: Make sure the sealing integrity is ensure owner’s information book identifies this
maintained to avoid water ingress into the cabin limitation).
while routing the cables through the grommet.
• The rack and subsequent carried load is
Antenna cables should be routed from the engine supported in the roof drip rails irrespective of
bay into the cabin area through the existing rack retaining method.
grommet. There is a service nib provided on the
grommet.
Refer to Exterior lighting - Additional external
lamps for driving lights cable routing.

5 Body and Paint
Double Cab / Super Cab 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
must also be applied to any double cab and super
cab applications, in particular steering, braking
and front axle ratings and the extra continuous
loads on the “A” pillar, which should not exceed
60 kg total incremental load.
Roof Rack Vehicle Converter Special Fit
1
3 4
E278320
Item Description
1 Rear edge of front attachment point
2 80kg Maximum
3 Maximum roof rack length: within length of drain channel
4 Maximum load height 300mm
5 Drain channel
6 Roof rack supports
5.1.9 Canopies The top surface of the load box sides

should not bear canopy (or other)
structural loading. To be used as a
All Vehicles canopy 'sealing-surface' only.
WARNINGS: Canopy weight and canopy load should
pass through the recommended load box
Only use the recommended attachment structural attachment points.
points for the canopy fitment, otherwise
damage may occur to the load box. NOTE: Usage of clamps for the canopy fitment
are only allowed on the centre and rear portion of
The return flange on the load box sides the load box.
should never be cut away, be drilled into,
or be used otherwise for bolting of the
canopy.

5 Body and Paint NOTE: Use both points from group A and a
minimum of one point from group B as front
structural attachment points.
Load Box Structural Attachment Points
A
B
E170921
Item Description
1 Front structural attachment points
2 Centre structural attachment points
3 Rear structural attachment points
*
4 Top surface of load box sides
*
5 Return flange of load box sides
*
Do not cut, drill, or use these surfaces to bolt the
canopy.

5 Body and Paint
Example of a Sports Bar Fitment
E172331
Item Description
1 Front mounting bracket
2 Clamped attachment

5 Body and Paint 5.2 Airbag Supplemental Restraint System (SRS)
5.2.1 Air Bags - (Low Level Vehicles) The acceleration based airbag sensors for side
airbags are located nearby the bottom of the
C-pillar inner for Super Cab and Double Cab
Front Seats vehicles. The pressure based airbag sensors for
side airbags are located near the centre of the front
Side airbags are not compatible with swivelling doors' inner door sheet metal for all Cab styles.
front seats.
WARNING: Modifications or
Do not specify the base vehicle with side airbags reinforcements in the area of the sensors
when planning to retrofit a swivelling device on may affect the side airbag fire timing and
the front seats and/or an armrest on the outer side result in uncontrolled side air bag
of the front seats, this may affect the function deployment.
and/or deployment of the side airbags.
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
E134101

5 Body and Paint
Dimensions (mm)
A 400 D 660
B 700 E 630
C 700 F 700
Side Airbag
C
A B
E134609
Dimensions (mm)
A 550 C 250
B 350
Curtain Airbag - Single cab
C
D
B
E136172

5 Body and Paint
Dimensions (mm)
A 140 C 250
B 40 D 100
Curtain Airbag - Double cab
B
E134610
Dimensions (mm)
A 140 C 250
B 40 D 100
Curtain Airbag - Super cab
C
D
E136173
Dimensions (mm)
A 140 C 250
B 40 D 100

5 Body and Paint
5.2.2 Air Bags - (High Level Vehicles) The acceleration based airbag sensors for side
airbags are located nearby the bottom of the
C-pillar inner for Super Cab and Double Cab
Front Seats vehicles. The pressure based airbag sensors for
side airbags are located near the centre of the
Side airbags are not compatible with swivelling front doors' inner door sheet metal for all Cab
front seats. styles.
Do not specify the base vehicle with side airbags WARNING: Modifications or
when planning to retrofit a swivelling device on reinforcements in the area of the sensors
the front seats and/or an armrest on the outer may affect the side airbag fire timing and
side of the front seats, this may affect the function result in uncontrolled side air bag
and/or deployment of the side airbags. deployment.
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.

5 Body and Paint
Driver and Passenger Front Airbag Deployment Zones
E C
E210764
Dimensions (mm)
A 260 D 392
B 470 E 520
C 470 F 544

5 Body and Paint
Side Airbag
C
A B
E134609
Dimensions (mm)
A 550
B 350
C 250
Curtain Airbag - Single cab
C
D
B
E136172
Dimensions (mm)
A 140 C 250
B 40 D 100

5 Body and Paint
Curtain Airbag - Double cab
B
E134610
Dimensions (mm)
A 140 C 250
B 40 D 100
Curtain Airbag - Super cab
C
D
E136173
Dimensions (mm)
A 140 C 250
B 40 D 100
5.2.3 Supplementary Restraint

Sensors (Front)
WARNING: Modifications or
reinforcements in the area of the front
supplementary restraint sensors may
affect their operation.

5 Body and Paint
1
E210765
Item Description
1 Front SRS Impact Sensors

5 Body and Paint 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. However if removal
and re-installation of the system is required during
the conversion, follow the removal and installation
guidelines of the seatbelt system as described in
the workshop manual. Please consult your local
National Sales Company representative for further
information.
When removing the seatbelt system, a seatbelt
webbing forked retainer should be applied to the
webbing 200mm below the webbing button stop.
This prevents a situation where all the webbing
runs back into the retractor and the retractor
becomes locked.
When reinstalling, fit the retractor to the body first
and gently pull the webbing out of the retractor to
allow fitment of the D loop. Then remove the
forked retainer. If the retractor is locked, allow a
small amount of webbing to reel back into the
retractor to allow the webbing lock to release. Do
not attempt to release the retractor by pulling on
the webbing with significant force or by manually
interfering with the locking mechanism.

5 Body and Paint
5.4 Corrosion Prevention
5.4.1 General
Avoid drilling into closed frame body members to
avoid the risk of corrosion from swarf.
If drilling is required, however:
• Re-paint metal edges and protect against
corrosion after cutting or drilling operations.
• Endeavor to remove all swarf from inside the
side member and treat to prevent corrosion.
• Apply corrosion protection inside and outside
of the chassis frame.
5.4.2 Repairing Damaged Paint

After cutting or reworking any sheet metal on 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
WARNING: Do not over-coat or
contaminate surfaces of components
such as brakes or catalytic converters.
Ensure all materials are compatible with the
relevant Ford specifications and maintain the
original performance where possible.
Some proprietary products affect the original
coatings. For specifications of corrosion protection
materials, please consult your local National Sales
Company representative.
5.4.4 Painting Road Wheels

WARNING: Do not paint wheel clamp
surfaces in contact with other wheels,
brake drum or disc, hub and holes or
surface under wheel nuts. Any further
treatment in these areas may affect the
wheel clamp performance and the vehicle
safety. Mask the wheel when changing
the color or repairing paint.
5.4.5 Contact Corrosion

When using different materials with a different
electrochemical potential, ensure that materials
are isolated from each other to prevent contact
corrosion caused by a potential difference.
Use appropriate isolation materials.
Where possible, choose materials with low level
of electrochemical potential difference.

5 Body and Paint 5.5 Frame and Body Mounting
5.5.1 Mounting Points and Tubing NOTE: After drilling, deburr and countersink all
holes and remove chips from the frame. Follow
Holes on frame are a result of the production corrosion prevention.
process. They are not designed for fixing additional Refer to: 5.4 Corrosion Prevention (page 93).
equipment. Always use chassis mounts as shown
in sub frame for low floor or other equipment. If
additional fixings are required please follow the
recommendation given in the figure shown. This
does not apply to areas of load applications such
as spring fixings or damper fixings.
Frame Drilling and Welding
E134173
Dimensions (mm) for Body Attachment Holes in Chassis Frame Top Flange Medium Wheelbase
Item Description
A 19 mm
B 11 mm
C 10 mm
D 10 mm
E Do NOT enlarge chassis rail holes, or drill within the surrounding area.
F Do not drill any more than 2 vertical holes in the chassis rail.
1. No Welding is allowed to the Vehicle Structure. 6. Holes must NOT be drilled near side member
2. To make holes in frames do not use a gas flame. profile changes.
Drill holes using sharp drills. 7. Existing holes in top and bottom flanges must
3. Use cold riveting only when attaching brackets NOT be bored out.
with rivets. 8. No more than two holes are to be drilled in a
4. Use high tensile bolts and appropriate nuts vertical line down from the frame web.
when bolted attachments are used. 9. Corrosion protection is to be applied post
• Bolt Specifications : drilling operations to the vehicle. Corrosion
• Metric – Property class 8.8 or 10.9 protection & protective coatings for all
modifications should conform to all local
• Japanese – 7T or 9T
regulatory standards.
• SAE – Grade 8 5.
10. Reinforcements should be added to the vehicle
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.

5 Body and Paint
Typical Design Principle of a Self-Supporting Body Structure
2
1
7
6
E74576
Item Description
1 Use all standard locations with 2x M10 fixings
2 Floor panel
3 Body side frames
4 Floor cross members
5 Continuous floor U-profile frame
6 Longitudinal L-profile
7 Chassis frame rail of base vehicle
8 Vehicle center line of base vehicle
Also see: • This concept is based on a self-supporting

structure where the floor is mounted directly
Refer to: Body (page ?).
onto the top surface of the chassis frame.
• See figure shown for a generic vehicle cross
5.5.2 Self-Supporting Body Structure section where the cross members and
opposing out riggers are flush with the surface
Bodies and structures can be judged as of the chassis frame side members.
self-supporting providing they maintain the
• It is important to the overall function of the
following rules:
vehicle structure that the out riggers are each
• Cross members are used at each chassis connected to a continuous longitudinal floor
mounting point, please refer to figures shown. side frame or a structural body side structure
• Each cross member has a suitably engineered assembly.
connection to the body side wall (3) or to the Low floor-re-work for guidance only:
continuous floor frame (5), see figure shown.
• Engineer unique cross members and
• The body side wall or the continuous floor out-riggers spaced at approximately 600mm
frame supports any overhang beyond the maximum pitch.
chassis frame, whether on standard frame or
extended frame. • Out-rigger moment to be re-acted with
cross-member between chassis frame with
Alternatively, the self-supporting body structure common through bolts where possible.
can also be designed as shown in figure shown.

5 Body and Paint • Drill frame and add spacer tubes. Drilling and welding of frames and body structure
have to be conducted following the program
Refer to: 5.5 Frame and Body Mounting (page
guidelines. Please consult the Ford dealer for
94).
details.
• Out-rigger outboard ends should be attached
to load bearing body side / floor edge frame or
body side structure (including over wheel 5.5.4 Ancillary Equipment - Sub Frame
support). Mounting
• Structural wheel box should maintain
longitudinal continuity with a rigid attachment Typical sub-frames and longitudinal members for
to the floor edge frame or to the body side flatbed and low or drop-side bodies or equipment
structure. exceeding the standard or Regular Production
Order frame length should adhere to the following
• Floor boards should be substantially attached guidelines:
to cross members and outriggers, but not to the
chassis frame top surface. • Flat-beds and low bodies mounted on integral
• Low floor exhaust heat shields. longitudinal members (channel or box section
metal – not wood) must use both sides of all
frame mounting brackets.
5.5.3 Frame Drilling and Tube • Longitudinal members must be relieved at the
Reinforcing front end if they are to contact the chassis
frame top surface, to minimize stress
The chassis frame may be drilled and reinforcing concentrations. It is preferable however, to
spacer tubes may be welded in place, providing mount the longitudinal onto the mounting
the following is applied: brackets, with a clearance to the chassis frame
• Adhere to all details shown in figure. top surface.
• Drill and weld only side walls of the chassis • Each set of brackets must use two (2) x M10
frame. bolts grade 8.8 minimum.
• Locate and drill holes accurately, using a drill • Minimum floor heights will require wheel arch
guide to ensure holes are square to frame boxes to clear the rear tires, see Vehicle Data
vertical center line (note: allow for side member sheets for relevant tire jounce.
draft angle).
• Drill undersize and ream out to size. 5.5.5 Area for Fitting Additional Body
• Endeavor to remove all swarf from inside side Attachments to the Rear of the
member, and treat to prevent corrosion. Bumper.
• Fully weld each end of the tube and grind flat
and square, in groups if applicable. Be aware NOTE: With the vehicle on level ground and with
of side member draft angle. all measurements taken rear ward of the bumper
bar edge: The area designated for the fitting of
• Apply corrosion protection inside and outside attachment is defined as 220mm horizontally by
of the chassis frame. 95mm vertical downward to the road surface, with
Refer to: 5.4 Corrosion Prevention (page 93). a max width of 1390mm about vehicle center line.
• Holes should be in groups of two (2), either It is not the manufactures recommendation to fit
vertically spaced at 30 to 35mm from chassis additional body attachments (Tow bars, Steps,
frame top and/or bottom surface, or Bicycle racks & Carriers) outside of the designated
horizontally at 50mm minimum pitch, 30 to area.
35mm from top and/or bottom chassis frame
surface.
5.5.6 Water Tank on Camper Vehicles
• Always use M10 bolts with grade 8.8 minimum.
• Do not position tubes at the medium chassis NOTE: It is recommended that a decal or label
frame height, this may create “oil canning” of is fitted adjacent to the filler aperture
the deep section side walls. identifying the correct fluid to be used, for
• Where possible, the outrigger moments should example: 'Water only' for water tanks.
be resolved by matching inner cross members
between the chassis side members inline with
the outriggers.
• A diameter of 16.5mm is the maximum
allowable hole size in the chassis frame side
wall, irrespective of the usage.
Avoid drilling into closed frame body members to
avoid the risk of corrosion from swarf.
Refer to: 5.4 Corrosion Prevention (page 93).

Index
A Fuel Filler Mounting.....................................................36
Fuel Filler Pipe Shipping Bracket (if
About this Manual..........................................................5
equipped).....................................................................34
Additional External Lamps - (Low Level Vehicles
Fuel Filler Vent Hose...................................................38
Only)...............................................................................62
Fuel System....................................................................34
Aids for Vehicle Entry and Exit..................................17
Fuses and Relays..........................................................70
Air Bags - (High Level Vehicles)..............................87
Air Bags - (Low Level Vehicles)..............................84
Airbag Supplemental Restraint System G
(SRS).............................................................................84 General......................................................................32, 93
Alternative Type Approval...........................................7 General Component Package Guidelines............17
Ancillary Equipment - Sub Frame Mounting.....96
Area for Fitting Additional Body Attachments
to the Rear of the Bumper......................................96 .........................................................................................5, 10
Auxiliary Battery and Fuse Box - Low Level
Vehicles..........................................................................70 G
Auxiliary Fuse Box (Vehicles with Special General......................................................................32, 93
Equipment Pack) (Low Level Vehicles General Product Safety Requirement.....................7
Only).................................................................................71 Generator and Alternator..........................................47
Auxiliary Lighting Loads (Low Level Vehicles Genuine Ford Accessory Bull Bar...........................79
Only)...............................................................................65
Axle Breather Vent Hose...........................................39
H
B Handles, Locks, Latches and Entry Systems.....69
Hardware—Specifications........................................22
Battery and Cables.......................................................41 How to Use This Manual..............................................5
Battery Information......................................................41
Body...................................................................................74
Body Structures - General Information................74 I
Brake Hoses....................................................................32 Important Safety Instructions....................................5
Brake System.................................................................32 Integrated Bodies and Conversions.......................74
Introduction.......................................................................5
C
Canopies...........................................................................81 J
Center of Gravity...........................................................26 Jacking...............................................................................12
Central Locking.............................................................69
Centre High Mount Stop Lamp (CHMSL) -
Canopy Fitment - High Level Vehicles...............67 K
Centre High Mount Stop Lamp (CHMSL) - Kerb Mass and Payload...............................................21
Canopy Fitment -Low Level Vehicles................66
Chassis Cab Body - Basic Dimensions and
Weights..........................................................................20
L
Chassis Cab....................................................................75 Lamps – Hazard / Direction Indication...............66
Commercial and Legal Aspects.................................7 Legal and Vehicle Type Approval..............................7
Contact Corrosion........................................................93 Legal Obligations and Liabilities...............................7
Conversion Effects on Parking Aids........................17 Lifting.................................................................................13
Conversion Homologation..........................................9 Load Distribution—Specifications.........................23
Corrosion Prevention..................................................93 Load Distribution Calculations - Driver and
Passenger Weight Distribution.............................23
Long Range Fuel Tanks..............................................39
D Low Level and High Level Vehicles...................6, 70
Drilling and Welding.......................................................8
Driver Field of View........................................................17
Driver Reach Zones.......................................................17
M
Minimum Requirements for Brake system and
Load Apportioning Valves.........................................8
E Mounting Points and Tubing....................................94
Electrically Operated Door Mirrors........................66
Electromagnetic Compatibility (EMC).................10
Electronic Engine Controls.........................................51
N
Exterior Lighting............................................................58 Noise, Vibration and Harshness (NVH)................14
F P
Frame and Body Mounting.......................................94 Package and Ergonomics—Specifications..........19
Frame Drilling and Tube Reinforcing....................96 Package and Ergonomics...........................................17
Front, Rear and Side Under-run Protection.........21 Painting Road Wheels................................................93
Front End Integrity for Cooling, Crash, Parking Aid.....................................................................48
Aerodynamics and Lighting...................................78 Product Liability..............................................................8
97
Index R
Rear Combination lamps...........................................59
Rear Fog Lamp...............................................................59
Rear License Plate Lamp...........................................60
Recommended Body Dimensions...........................19
Registration Plates.........................................................18
Repairing Damaged Paint..........................................93
Restraints System...........................................................8
Reversing Lamps, Rear View Camera, Reversing
Alarm (Manual Transmission)...............................62
Road Safety.......................................................................8
Roof Racks......................................................................80
S
Seatbelt Systems — Australia..................................92
Self-Supporting Body Structure.............................95
Sensor Location.............................................................49
Supplementary Restraint Sensors (Front).........90
Suspension System.......................................................31
T
Tank and Dry Bulk Carriers.........................................79
Terminology........................................................................7
Tipper Bodies..................................................................78
Towing Capacities and Specifications..................30
Towing Requirements..................................................30
Towing...............................................................................30
Trailer Brakes...................................................................32
Trailer Towing..................................................................63
U
Under Body Protection and Material.....................93
V
Vehicle Duty Cycle Guidelines....................................11
Vehicle Ride and Handling Attributes......................11
Vehicle Speed Output (Signal) (High Level
Vehicles )........................................................................57
Vehicle Speed Output (Signal) (Low Level
Vehicles Only)................................................................51
Vehicle Transportation Aids and Vehicle
Storage.............................................................................15
W
Warnings, Cautions and Notes in This Manual.....5
Warranty on Ford Vehicles............................................7
Water Tank on Camper Vehicles.............................96
Wiring Installation and Routing Guides................40
Wiring Splicing Procedures.......................................40
98

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FORD Ranger 2019

Body and Equipment Mounting Manual

Date of Publication: 01/2020

© Ford Motor Company 2020

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1.1 About this Manual...............................5

5 Body and Paint

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WARNING: Exception - Incomplete WARNINGS:

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The Vehicle Converter shall be liable for any

1.2.8 Restraints System

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Frequency Band MHz Maximum Output Power Watts Antenna Position

NOTE: Check that electromagnetic fields

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1.5.1 Vehicle Ride and Handling

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Vehicle Jacking Points and Axle Stand Positions

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A significant risk during storage is deterioration of Check vehicle is X -

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1.10.4 Conversion Effects on Parking

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1.10.6 Registration Plates

Front Registration Plate

Rear Registration Plate

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Chassis Cab Body - Single Cab Illustrated

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1.11.2 Chassis Cab Body - Basic Dimensions and Weights

Chassis Cab Body - Single Cab Illustrated

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1.11.3 Kerb Mass and Payload

1.11.4 Front, Rear and Side Under-run

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CAUTIONS: NOTE: Over loading of the vehicle could result in

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Single Cab Driver and Passenger Weight Distribution

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Super Cab Driver and Passenger Weight Distribution

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Double Cab Driver and Passenger Weight Distribution

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Single Cab Center of Gravity Critical Zone

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Super Cab Center of Gravity Critical Zone

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Double Cab Centre of Gravity Critical Zone

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1.14.3 Towing Capacities and

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