Transit.2006.5. (04 2006-)

Body and Equipment Mounting Manual
FORD TRANSIT 2006.5
Date of Publication: 12/2012

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 2014
All rights reserved.

Table of Contents
1.15 Hardware—Specifications................37
1 General Information 1.16 Load
Distribution—Specifications............38
1.1 About This Manual..............................6 1.16.1 Load Distribution Calculations - Driver
1.1.1 New for this BEMM publication and Passenger Weight
12/2012.............................................................6 Distribution..................................................38
1.1.2 Introduction....................................................6 1.16.2 Center of Gravity .......................................40
1.1.3 Important Safety Instructions.................6 1.17 Towing...............................................46
1.1.4 Warnings, Cautions and Notes in This 1.17.1 Tow Bar Requirements............................46
Manual.............................................................6 1.17.2 Fitting Instructions for 4.6 Tonne and
1.1.5 How to Use This Manual...........................6 3.5 Tonne HD (derated)..........................46
1.2 Commercial and Legal Aspects..........7 1.17.3 Tow bars.......................................................46
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 2 Chassis
1.2.5 Legal Obligations and Liabilities.............7
1.2.6 General Product Safety
Requirement...................................................7 2.1 Suspension System...........................54
1.2.7 Product Liability............................................8 2.2 Front Suspension..............................55
1.2.8 Restraints System........................................8 2.2.1 Springs and Spring Mounting...............55
1.2.9 Drilling and Welding....................................8 2.3 Rear Suspension...............................56
1.2.10 Minimum Requirements for Brake 2.3.1 Springs and Spring Mounting...............56
system and Load Apportioning Valves 2.3.2 Rear Anti-Roll Bar.....................................56
.............................................................................8 2.4 Wheels and Tires...............................57
1.2.11 Road Safety....................................................8 2.4.1 Wheel Clearance........................................57
1.2.12 Qualified Vehicle Modifier (QVM).........8 2.4.2 Tire Manufacturers....................................57
1.3 Contact Information...........................9 2.4.3 Spare Wheel................................................57
1.4 Conversion Type.................................13 2.4.4 Tire Repair Kit..............................................57
1.5 Conversion Homologation.................19 2.4.5 Painting Road Wheels..............................57
1.6 Electromagnetic Compatibility 2.5 Driveshaft..........................................58
(EMC)................................................20 2.5.1 Power Take Off...........................................58
1.6.1 Suggested Antenna Location.................21 2.6 Brake System.....................................59
1.7 Vehicle Duty Cycle Guidelines...........22 2.6.1 General..........................................................59
1.7.1 Conversion Affect on Fuel Economy 2.6.2 Kerb Mass Data..........................................59
and Performance.......................................22 2.6.3 Brake Hoses General................................59
1.7.2 Vehicle Ride and Handling 2.7 Parking Brake....................................60
Attributes......................................................22 2.8 Hydraulic Brake Actuation.................61
1.8 End of Life Vehicle (ELV) 2.8.1 Load Apportioning Valves.......................61
Directive.............................................23 2.8.2 Front and Rear Brakes..............................61
1.9 Jacking...............................................24 2.9 Anti-Lock Control - Stability
1.10 Lifting................................................26 Assist.................................................62
1.11 Noise, Vibration and Harshness
(NVH)................................................28
1.12 Vehicle Transportation Aids and
Vehicle Storage.................................29 3 Powertrain
1.13 Package and Ergonomics..................30
1.13.1 General Component Package
Guidelines....................................................30 3.1 Engine................................................63
1.13.2 Driver Reach Zones...................................30 3.1.1 Engine Power Curves...............................63
1.13.3 Driver Field of View...................................30 3.1.2 Power and Torque Curves for vehicles
1.13.4 Conversion Affects on Parking built before 26 September 2011...........64
Aids.................................................................30 3.1.3 Power and Torque Curves for vehicles
1.13.5 Aids for Vehicle Entry and Exit..............30 built after 26 September 2011...............74
1.14 Package and 3.2 Engine Cooling..................................82
Ergonomics—Specifications.............31 3.2.1 Auxiliary Heater Systems........................82
1.14.1 Recommended Main Dimensions........31 3.2.2 Auxiliary Heater Installation..................83
1.14.2 Front, Rear and Side Under-run 3.2.3 Air Flow Restrictions.................................83
Protection.....................................................33 3.3 Accessory Drive.................................84
1.14.3 Recommended Main Load Area 3.3.1 Front End Accessory Drives - General
Dimensions for Bulkhead with Information..................................................84
Depression Driver Side............................34 3.3.2 Front End Accessory Drives - Vehicles
1.14.4 Recommended Main Load Area built before 26th September 2011......85
Dimensions for Bulkhead with Full 3.3.3 Front End Accessory Drives - Vehicles
Depression....................................................35 built after 26th September 2011..........89
1.14.5 Recommended Main Load Area 3.4 Clutch.................................................91
Dimensions for Double Cab In Van 3.5 Manual Transmission.......................92
Bulkhead.......................................................36
3
Table of Contents 3.5.1 Manual Transmissions Built Before 4.10.1 Start-Stop - Vehicles built after 26th
26th September 2011................................92 September 2011.........................................144
3.5.2 Manual Transmissions Built After 26th 4.10.2 Vehicle Speed Output (Signal)...........145
September 2011...........................................93 4.10.3 Engine Run Signal (D+
3.6 Exhaust System.................................94 Alternative)...................................................151
3.6.1 Extensions and Optional Exhausts.....94 4.10.4 Engine RPM (Revs Per Minute) Speed
3.6.2 Exhaust Pipes and Supports..................94 Controller.....................................................154
3.6.3 Exhaust Heat Shields................................94 4.10.5 Changing Vehicle Speed Maximum
3.6.4 Diesel Particulate Filter (DPF)...............95 Setting...........................................................158
3.6.5 Vehicle Exhaust Systems - Vans with 4.11 Tachograph.......................................159
Bulkheads......................................................95 4.11.1 Legislation....................................................159
3.7 Fuel System........................................96 4.11.2 Tachograph Mounting.............................160
4.11.3 Fitting a Tachograph to vehicles built
with out Digital Tachograph
Option............................................................162
4 Electrical 4.11.4 Vehicle Configuration change..............163
4.11.5 Calibration and Tachograph
Fitting.............................................................163
4.1 Wiring Installation and Routing 4.12 Information and Entertainment
Guides................................................101 System - General
4.1.1 Wiring Harness Information ..................101 Information—Specifications...........164
4.1.2 General Wiring and Routing...................101 4.12.1 Radio Connector.......................................164
4.1.3 Connector Pin Out Practices.................101 4.12.2 Possible Accessories...............................165
4.1.4 Harness Routing.........................................101 4.13 Cellular Phone...................................167
4.1.5 Grounding.....................................................101 4.14 Exterior Lighting...............................168
4.1.6 Prevention of Squeaks and 4.14.1 Reversing Lamps.......................................168
Rattles............................................................101 4.14.2 Additional External Lamps...................168
4.1.7 Water Leakage Prevention.....................101 4.14.3 Lamps – Hazard / Direction
4.1.8 Wiring Splicing Procedures....................101 Indication.....................................................169
4.1.9 No Drill Zones - Rear Cargo Area........102 4.14.4 Lamps – Front and Rear Fog
4.2 Wiring Harnesses.............................106 Lights.............................................................169
4.2.1 Roof Mounted Front and Rear 4.14.5 Lamps for Wide Vehicles.......................169
Beacons........................................................106 4.14.6 Electrically operated Door Mirrors......169
4.2.2 Wiring Harness Installation and 4.15 Interior Lighting................................170
Routing.........................................................109 4.15.1 Additional Internal Lamps ....................170
4.2.3 Electrics for Tow bar...................................111 4.15.2 Additional 'Theater Lighting' for rear
4.3 Communications Network................115 of vehicle interior.......................................170
4.3.1 CAN-Bus System Description and 4.16 Handles, Locks, Latches and Entry
Interface.........................................................115 Systems.............................................172
4.3.2 Central Junction Box (CJB).....................116 4.16.1 Door Removal or Modification..............172
4.3.3 Circuit Diagram...........................................118 4.16.2 Locking strategy for M2
4.4 Module Communications Conversion....................................................173
Network—Specifications..................119 4.16.3 Central Locking...........................................174
4.4.1 Circit Diagram..............................................119 4.16.4 Third Button on Key Fob.........................176
4.5 Charging System..............................120 4.17 Fuses and Relays...............................177
4.5.1 General Information and Specific 4.17.1 Wiring Specification..................................177
Warnings......................................................120 4.17.2 Auxiliary Fuses, Fuse Box and Relays
4.5.2 System Operation and Component (Fuses - Standard)....................................177
Description ...................................................121 4.17.3 Customer Connection Points................178
4.5.3 Power Management Settings...............123 4.17.4 Ignition Feed................................................179
4.5.4 Electrical Conversions.............................124 4.17.5 Special Vehicle Option (SVO) Auxiliary
4.5.5 Fitting Equipment Containing Electric Fuse Box.......................................................180
Motors............................................................125 4.17.6 Special Vehicle Option (SVO)
4.5.6 Vehicle Electrical Capacity - Switches.......................................................184
Alternator.....................................................125 4.17.7 Additional Ignition, Instrument Panel
4.5.7 Charge Balance Guidelines...................125 Illumination and Air Conditioning On
4.5.8 Circuit Diagrams.........................................125 Signals...........................................................185
4.6 Battery and Cables............................127 4.17.8 Relays and Switches................................186
4.6.1 Battery Information...................................127 4.17.9 Windscreen wipers...................................188
4.6.2 Battery Monitoring Sensor (BMS)......133 4.17.10 Adding Heated Mirrors............................189
4.6.3 Battery Disconnect Switch (Split 4.18 Special Conversions.........................190
Charge Relay).............................................134 4.18.1 Special Vehicle Options (SVO) and
4.6.4 Generator and Alternator.......................138 Aftermarket Kits........................................190
4.7 Climate Control System....................141 4.18.2 Additional Vehicle Signals /
4.8 Instrument Panel Cluster (IPC).......142 Features.........................................................191
4.9 Horn...................................................143 4.18.3 Auto Wipe and Auto Light for Campers
4.10 Electronic Engine Controls...............144 or Vehicles with large over-hangs.....200
4
Table of Contents
4.19 Electrical Connectors and 5.10.3 Roof Ventilation......................................286
Connections.....................................201 5.10.4 Roof Racks.................................................287
4.19.1 Connectors.................................................201 5.11 Airbag Supplemental Restraint
4.19.2 Camper Central Connectors...............202 System (SRS).................................289
4.19.3 Police and Emergency Vehicle 5.11.1 Air Bags.......................................................289
Harness.......................................................207 5.12 Safety Belt System..........................291
4.19.4 Adding Connectors, Terminals and 5.13 Corrosion Prevention......................292
Wiring............................................................215 5.13.1 General........................................................292
4.20 Grounding........................................229 5.13.2 Repairing Damaged Paint....................292
4.20.1 Ground Points...........................................229 5.13.3 Under Body Protection and
Material.......................................................292
5.13.4 Painting Road Wheels...........................292
5.13.5 Contact Corrosion...................................292
5 Body and Paint 5.14 Frame and Body Mounting..............293
5.14.1 Mounting Points and Tubing...............293
5.14.2 Self-Supporting Body Structure.......296
5.1 Body.................................................234 5.14.3 Extended Chassis Frame.....................298
5.1.1 Body Structures - General 5.14.4 Non Standard Rear Chassis Frame
Information................................................234 Extension...................................................299
5.1.2 Welding.......................................................234 5.14.5 Frame Drilling and Tube
5.1.3 Back Panel Removal..............................235 Reinforcing................................................300
5.1.4 Floor 'No Drill Zones' under the Floor 5.14.6 Ancillary Equipment - Sub Frame
Fuel Tank 80L (Optional 103L).........236 Mounting.....................................................301
5.1.5 Integrated Bodies and 5.14.7 Area for Fitting Additional Body
Conversions...............................................237 Attachments to the Rear of the
5.1.6 Chassis Cab................................................241 Bumper........................................................301
5.1.7 Cab Van Floor...........................................248 5.14.8 Water Tank on Camper Vehicles........301
5.1.8 Transit Motorhome Chassis................250
5.1.9 Front End Integrity for Cooling, Crash,
Aerodynamics and Lighting................254
5.1.10 Tipper Bodies............................................255
5.1.11 Tank and Dry Bulk Carriers...................255
5.2 Hydraulic Lifting Equipment..........256
5.2.1 Hydraulic Lifting Equipment for Van,
Bus, Kombi and Chassis Cab..............256
5.3 Racking Systems.............................263
5.3.1 Racking Systems.....................................263
5.4 Body System - General
Information—Specifications..........268
5.4.1 Van Floor - Load Compartment Tie
Downs for Van, Bus and Kombi.........268
5.5 Front End Body Panels....................272
5.5.1 Partitions (Bulkhead) - Driver and
Front Passenger(s) Protection on Van,
Bus and Kombi..........................................272
5.6 Body Closures..................................274
5.6.1 Load Compartment Interior
Lining............................................................274
5.6.2 Plywood Lining/Cladding.....................274
5.6.3 Security, Anti Theft and Locking
System ........................................................274
5.7 Rear View Mirrors............................279
5.7.1 Mirrors for Wide Vehicles......................279
5.8 Seats...............................................280
5.8.1 Van...............................................................280
5.8.2 Windowed Van........................................280
5.8.3 Rear Seat Fixing Positions - Kombi
Van...............................................................280
5.8.4 Seat Frame Fixings - Typical design
principle for Cab Van Floor...................281
5.8.5 Heated Seats.............................................281
5.9 Glass, Frames and Mechanisms.....282
5.9.1 Rear Windows..........................................282
5.9.2 Heated Windshield and Heated Rear
Window......................................................284
5.10 Roof Opening Panel........................285
5.10.1 Roof Cut Out - CAMPERS ONLY.......285
5.10.2 Back Panel and Roof Removal..........285
5
1 General Information 1.1 About This Manual
1.1.1 New for this BEMM publication This manual cannot possibly anticipate all such
12/2012 variations and provide advice or cautions as to
each. Anyone who departs from the instructions
The sections of this manual have been updated provide in this manual must first establish that he
since the last publication of the BEMM 08/2011. It compromises neither his personal safety nor the
is recommended to review this manual in full. For vehicle integrity by his choice of methods, tools or
an overview of the main differences please see components.
below.
4.6 Battery and Cables - Battery Part Numbers 1.1.4 Warnings, Cautions and Notes in
and Usage for vehicles built after 26th September This Manual
table updated.
5.10 Roof Opening Panel - Roof Rack WARNING: Warnings are used to indicate
information updated. that failure to follow a procedure
correctly may result in personal injury.
1.1.2 Introduction CAUTION: Cautions are used to indicate

that failure to follow a procedure
This manual has been written in a format that is correctly may result in damage to the
designed to meet the needs of Vehicle Converters. vehicle or equipment being used.
The objective is to use common formats with the NOTE: Notes are used to provide additional
workshop manual which is used by technicians essential information required to carry out a
worldwide. complete and satisfactory repair.
This guide is published by Ford and provides As you read through this manual, you will come
general descriptions and advice for converting across WARNINGS, CAUTIONS and NOTES.
vehicles.
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 application 1.1.5 How to Use This Manual
of body, equipment and or accessories is key to
ensuring that customer satisfaction is not This manual covers vehicle conversion procedures.
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 portion
takes the form of recommendations to be followed of the vehicle. The manual is divided into five
when vehicle modifications are undertaken. It must groups, General Information, Chassis, Powertrain,
be remembered that certain modifications may Electrical and Body. The number of the group is
invalidate legal approvals and application for the first number of a section number. Each title
re-certification may be necessary. listed in the contents links to the relevant section
of the manual.
Ford cannot guarantee the operation of the vehicle
if non-Ford -approved electrical systems are In some section of the book it may refer you to see
installed. Ford electrical systems are designed and additional sections for information, links have been
tested to function under operational extremes, provided, these links are in blue text.
and have been subjected to the equivalent of ten This manual is also designed to be used as a
years of driving under such conditions. printed document, where there are links page
For availability of options and parts please contact numbers in brackets have been added, which will
your National Sales Company representative or help guide you to the start of the section which
Local Ford Dealer. contains the relevant information.
There is also an alphabetical index at the back of
the manual. As with the contents pages you will
1.1.3 Important Safety Instructions be able to link to sections. To do this just click on
the page number.
Appropriate conversion procedures are essential
for the safe, reliable operation of all vehicles as All left and right-handed references to the vehicle
well as the personal safety of the individual are taken from a position sitting in the driver seat
carrying out the work. looking forward unless otherwise stated.

6 FORD TRANSIT 2006.5
1 General Information
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.
1.2.2 Warranty on Ford Vehicles 1.2.6 General Product Safety

Requirement
Please contact The National Sales Company in
the country where the vehicle will be registered The Vehicle Converter shall ensure that any
for details of the terms of any applicable Ford vehicle it places on the market complies with the
warranty. European General Product safety Directive
2001/95/EC (as amended periodically). The
The Vehicle Converter should warrant its design, Vehicle Converter shall also ensure that any
materials and construction for a period at least alteration it makes to a Ford vehicle or component
equal to any applicable Ford warranty. does not reduce its compliance with the European
The Vehicle Converter must ensure that any General Product Safety Directive.
alteration made to a Ford vehicle or component The Vehicle Converter shall release Ford from all
does not reduce the safety, function, or durability liability for damages resulting from:
of the vehicle or any component.
• Failure to comply with these Body Equipment
The Vehicle Converter shall be solely responsible Mounting directives, in particular warnings.
for any damage resulting from any alteration
made by the Vehicle Converter or any of its agents • Faulty design, production, installation,
to a Ford Vehicle Component. assembly or alteration not originally specified
by Ford.
The Vehicle Converter releases Ford from all
claims by any third party for any cost or loss • Failure to comply with the basic fit for purpose
(including any consequential damages) arising principles inherent in the original product.
from work performed by a Vehicle Converter
unless Ford has given its prior written consent to WARNINGS:
such liability. Do not exceed the gross vehicle mass,
gross train mass, axle plates and trailer
1.2.3 Legal and Vehicle Type Approval plate.
Do not change the tire size or load rating.
• All components embodied on Ford vehicles are
approved to the applicable legal requirements. Do not modify the steering system.
• Ford vehicles have Type Approval for the
intended marketing territories. Excessive heat can build up from the
WARNING: Exception - Incomplete exhaust system, in particular from the
vehicles require further approval when catalytic converter and from the Diesel
completed by the Body Builder. particulate filter (cDPF). Ensure
adequate heat shields are maintained.
• The Transit range has Type Approval for many
Maintain sufficient clearance to hot
territories, although the full range of vehicles
parts.
shown in this manual are not necessarily
released in all territories. Check with your local Do not modify or remove heat protection
Ford National Sales Company representative. shields.
• Significant changes to the vehicle may affect Do not remove labels provided with the
its legal compliance. Strict adherence to the base vehicle. Ensure appropriate
original design intent for brakes, weight visibility
distribution, lighting, occupant safety and
hazardous materials compliance in particular
is mandatory.
FORD TRANSIT 2006.5 Date of Publication: 12/2012 7

1 General Information Do not route any electrical cables with the Do not alter, modify or relocate the airbag,
Antilock Brakes System and Traction sensor and modules of the restraints
Control System cables because of system or any of its components.
extraneous signal risk. It is generally not
Attachments or modifications to the front
recommended to hang electrical cables
end of the vehicle may affect the airbag
off existing looms or pipes.
fire timing and result in uncontrolled
Do not change original location or remove deployment.
warning labels provided with the base
Modifications to the B-Pillar body
vehicle in view to the driver. Ensure that
structure may affect the side airbag fire
labels in view to the driver remain in full
timing and result in uncontrolled side
view to the driver.
airbag deployment.
NOTE: For further information please contact your
Refer to: 5.11 Airbag Supplemental Restraint
local National Sales Company representative, or
System (SRS) (page 289).
Local Ford Dealer. If they are unable to help you
then please contact the Vehicle Converter Advisory
Service at [email protected] 1.2.9 Drilling and Welding
Refer to: 1.3 Contact Information (page 9).
Drilling and welding of frames and body structure
have to be conducted following the guidelines.
1.2.7 Product Liability Refer to: 5.1 Body (page 234).
Welding
The Vehicle Converter shall be liable for any
Refer to: 5.14 Frame and Body Mounting (page 293).
product liability (whether for death, personal injury,
Frame Drilling and Tube Reinforcing.
or property damage) arising from any alteration
to a Ford vehicle or component made by the
Vehicle Converter or any of its agents. Ford shall 1.2.10 Minimum Requirements for
not be liable for any such liability (except as Brake system and Load Apportioning
provided by law). Valves
The Vehicle Converter or equipment manufacturer
is liable for the: It is not necessary or recommended to modify the
load apportioning valves, however, if a special
• Operational reliability and road-worthiness of conversion should require modifications:
the vehicle to its original intent.
• Maintain original settings
• Operational reliability and road-worthiness of
any component or conversion, not listed in • Maintain brake certification load distribution
original Ford documentation. Changes to the Antilock Brake System (ABS),
• Operational reliability and road-worthiness of Traction Control System (TCS) and Electronic
the vehicle as a whole (for example the body Stability Program (ESP) system are not permitted.
changes and/or additional equipment must not
have a negative effect on the driving, braking 1.2.11 Road Safety
or steering characteristics of the vehicle).
• Subsequent damage resulting from the The respective instructions should be strictly
conversion or attachment and installation of observed to maintain operational and road safety
unique components, including unique electrical of the vehicle.
or electronic systems.
• Functional safety and freedom of movement 1.2.12 Qualified Vehicle Modifier
of all moving parts (for example axles, springs, (QVM)
propeller shafts, steering mechanisms, brake
and transmission linkage, retarders). Final stage manufacturers can apply for the Ford
• Functional safety and freedom of the tested Transit Qualified Vehicle Modifier Program (QVM).
and approved flexibility of the body and integral To become a QVM Program Participant, final stage
chassis structure. manufacturers must meet the QVM Program
requirements. For further details about the QVM
Program and for application please contact the
1.2.8 Restraints System Vehicle Converter Advisory Service,
[email protected]
WARNINGS:
Modifications to the restraints system
are not allowed.
Airbag 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 Contact Information
As a manufacturer, we want to provide you with Ford of Italy
the information you need for your vehicle
conversion/modification. If the information you Contact: Michele Montalto - CV Staff Opera-
require is not in this manual or you have further tions Manager
questions, please contact your local National Phone: +39-06-51855332
Sales Company Representative (NSC) or Local
Ford Dealer in your Market. Fax: +39 035 4821331
If your Local National Sales Company E-Mail: [email protected]
Representative or Local Ford Dealer are unable
Postal Via Andrea Argoli 54
to help you, please contact the Vehicle Converter
Address:
Advisory Service at [email protected].
ROME
Ford of Britain
00143
Contact: Jon Kemp - CV Sales and Marketing
ITA
Phone: +44-7860-911453
E-Mail: [email protected] Ford of Ireland
Postal GB-1/673 Contact: Ger Canty - CV Brand Manager
Address: Phone: +353-21-4329276
EAGLE WAY, GB-1 Fax: +353-21-4329216
BRENTWOOD E-Mail: gcanty2@ford
CM13 3BW Postal Elm Court,
GBR Address:
Boreenmanna Road
Ford of Germany
Cork
Contact: Torsten Wagner - CV Brand
IRL
Specialist
Phone: +49-221-9017692 Ford of Spain
Fax: +49-221-9018409 Contact: Jose Manuel Fernandez Pons, - CV
E-Mail: [email protected] Brand Manager
Postal D NH/4A Phone: +34-91-7145143
Address: Fax: +34-91-7145477
Henry Ford Strasse 1 E-Mail: [email protected]
Cologne Postal Edificio Minipark IV Calle Calendula,
50725 Address:
DEU 13 Alcobendas,
Madrid
Ford of France
28109
Contact: Antoine de Finance - CV Brand
ESP
Manager
Phone: +33-1-61016535 Ford of Portugal
Fax: +33-1-61016505 Contact: Luis Filipe Azinheiro - CV Specialist
E-Mail: [email protected] Phone: +351-21-3122450
Postal St Germain Fax: +351-21-3122482
Address:
E-Mail: [email protected]
34 rue de la Croix de Fer
Postal Avenida da Liberdade 249 7 Andar
Saint Germain en Laye Address:
78100 Lisboa
FRA 1250-143
PRT

Ford of Belgium Ford of Denmark
Contact: Jean Vermeiren - CV Brand Manager Contact: Steffen Mamsen - Transit Brand
Manager
Phone: +32-3-8212120
Phone: +45-43-480680
Fax: +32-3-8212199
Fax: +45-43-480565
Postal Hunderenveldlaan
Address: Postal 5 D-E Borupvang
Address:
Brussels
Ballerup
1082
2750
BEL
DNK
Ford of Netherlands
Ford of Finland
Contact: Paul van der Aar - CV Manager
Contact: Juuso Asp - CV Brand Manager
Phone: +31-20-5044711
Phone: +358-9-35170134
Fax: +31-20-5044757
Fax: +358-9-3743081
Postal AMSTERDAM
Address: Postal Malminkaari 9b
Address:
AMSTELDIJK 216
Box 164
AMSTERDAM
Helsinki
1000 AT
FIN-00701
NLD
FIN
Ford of Austria
Ford of Norway
Contact: Philipp Edinger - CV Brand Manager
Contact: Damir Ljubuncic - CV Brand Manager
Phone: +43-50-6581265
Phone: +47-66-997297
Fax: +43-50-6581250
Fax: +47-66-997252
Postal Ford Austria Vienna
Address: Postal Lienga 2
Address:
Hackingerstrasse 5c
P.O.BOX 514
Vienna
KOLBOTN
1140
N-1411
AUT
NOR
Ford of Switzerland
Ford of Sweden
Contact: Marc Brunner - CV Brand Manager
Contact: Niklas Johansson - Field Engineer
Phone: +41-43-2332255
Phone: +46-31-3259861
Fax: +41-43-2332005
Fax: +46-31-3259481
Postal Wallisellen
Address: Postal Ravebergsvagen Angered
Address:
Geerenstrasse 10
Gothenburg
Wallisellen
SE40531
8304
SWE
CHE

Ford of Hungary Ford of Czech Republic
Contact: Zombor Krizsán - CV Brand Manager Contact: Marek Held - CV Brand Manager
Phone: +36-1-4382539 Phone: +420-23-4650119
Fax: +36-1-4382590 Fax: +420-23-4650147
E-Mail: [email protected] E-Mail: [email protected]
Postal FORDHUNGARY Postal Karolinska 654/2
Address: Address:
Obuda Gate Arpad fejedelem u. 26- NILE1 Nile House
28
PRAGUE
Budapest
18600
1023
CZE
HUN
Ford of Russia
Ford of Greece
Contact: Sergey Kirillov - CV Sales and
Contact: John Amarantos - CV Field and Marketing Director
Brand Manager
Phone: +7-495-7459743
Phone: +30-210-5709913
Fax: +7-495-7459750
Postal Ford Motor Hellas SAIC
Postal Leningradskaya Street 39, Khimki
Address:
Address: Building 5
Monemvasias 25 and Akakion 39
MOSCOW
Marousi
141400
151 25
RUS
Attiki
GRC Ford Central & Eastern Europe
Contact: Balázs Págyi - CV Product Specialist
Ford of Poland
Phone: +36-26-802538
Contact: Marcin Marczewski - CV Brand
Fax: +36-26-802-590
Manager
Phone: +48-22-608 6854
Postal 3 Galamb Jozef Utca
Fax: +48-22-6086819
Address:
Szentendre
Postal ul. Tasmowa 7
H-2000
Address:
HUN
Warsaw
02-677 Rest of the World (RoW)
POL Contact: John Dand - Transit Brand Manager
Phone: +44-1277-252073
Fax: +44-1277-252552
Postal GB-1/389
Address:
EAGLE WAY, GB-1
BRENTWOOD
CM13 3BW
GBR

Ford Otosan - Turkey
Contact: Serkan Ozerbay - Transit Brand
Manager
Phone: +90-216-5647211
Postal Kocaeli
Address:
Ihsaniye - Golcuk
41680
TUR
Ford of Australia
Contact: Michael Risby - Project Marketing
Phone: +61-3-83012613
Fax: +61-3-93598944
Postal 1735 Sydney Road
Address:
Campbell Field
VI
3061
AUS
Ford of New Zealand

Contact: NZINFO
Phone: +64-9-2718500
Fax: +64-9-2718573
Postal Private Bag 76912
Address:
Manukau City
2241
NZ

1.4 Conversion Type
NOTE: The following tables are for guidance The BEMM contains general and specific
only. Full reference to the Body and recommendations covering conversions to the
Equipment Mounting Manual should be made new Transit range of vehicles. To assist users
prior to starting any conversion. locate information by conversion type the
following tables contain the relevant links within
NOTE: For any conversions requiring
this Manual.
electrical power.
Refer to: 4.3 Communications Network (page 115).
Refer to: 4.17 Fuses and Relays (page 177).
Camper Conversion
Refer to: 1.14 (page 31).
Refer to: 1.17 Towing (page 46).
Refer to: 2.6 Brake System (page 59).Relocated Handbrake.
Van conver- Refer to: 3.7 Fuel System (page 96).

sion Refer to: 4.6 Battery and Cables (page 127).
Refer to: 4.18 Special Conversions (page 190).
Refer to: 5.1 Body (page 234).Integrated Bodies and Conversions.
Refer to: 5.8 Seats (page 280).Rear Seat Fixings Positions - Kombi.
Refer to: 5.10 Roof Opening Panel (page 285).
Multi Purpose Refer to: 3.7 Fuel System (page 96).
Vehicle
Conversion Refer to: 4.6 Battery and Cables (page 127).
Chassis Refer to: 3.7 Fuel System (page 96).

Conversion Refer to: 4.6 Battery and Cables (page 127).
Refer to: 5.1 Body (page 234).(Cab Van Floor).
Cab Van Floor
Refer to: 5.14 Frame and Body Mounting (page 293).Spare Tire Access and Mounting.

1 General Information Dry Freight
Refer to: 4.6 Battery and Cables (page 127).Also Generator and Alternator.
Flat Bed / Refer to: 4.11 Tachograph (page 159).
Platform
Refer to: 5.1 Body (page 234).Integrated Bodies and Conversions, Hydraulic Lifting
Equipment for Van, Bus, Kombi and Chassis Cab.
Refer to: 4.14 Exterior Lighting (page 168).
Float / Drop- Refer to: 4.11 Tachograph (page 159).
side
Tipper Refer to: 4.11 Tachograph (page 159).
Refer to: 5.1 Body (page 234).Chassis Cab & Tipper.
Refer to: 4.6 Battery and Cables (page 127).(Also Generator and Alternator).
Refer to: 4.11 Tachograph (page 159).
Box Van Refer to: 5.1 Body (page 234).Integrated Bodies and Conversions, Hydraulic Lifting
Refer to: 4.18 Special Conversions (page 190).Auto Wipe and Auto Light for Campers or
Vehicles with large over-hangs
Curtain-side Refer to: 5.1 Body (page 234).Integrated Bodies and Conversions, Hydraulic Lifting
Pantechnicon
Money
Carriers
Refer to: 5.1 Body (page 234).Roof Ventilation.

Dry Freight
Refuse Collec- Refer to: 4.11 Tachograph (page 159).

tion Refer to: 5.1 Body (page 234).Chassis Cab.
Demountable
Refer to: 5.1 Body (page 234).Chassis Cab.
Vehicle Trans- Refer to: 4.11 Tachograph (page 159).

porters Refer to: 5.1 Body (page 234).Chassis Cab.
Vocational Conversion
Mobile Work-
Equipment for Van, Bus, Kombi and Chassis Cab, Racking System.
shops
Refer to: 5.10 Roof Opening Panel (page 285).Roof Racks.
Refer to: 4.18 Special Conversions (page 190).Auto Wipe and Auto Light for Campers
or Vehicles with large over-hangs
Mobile Shops
Equipment for Van, Bus, Kombi and Chassis Cab, Racking System.
/ Offices
Glass Carrying Refer to: 4.11 Tachograph (page 159).
Refer to: 5.1 Body (page 234).Racking System.
Racking
Conversions
Refer to: 5.1 Body (page 234).Racking System.
Recovery Refer to: 5.1 Body (page 234).Chassis Cab.
Vehicles

Passenger Carrying
Refer to: 1.2 Commercial and Legal Aspects (page 7).Restraints System.
Refer to: 4.15 Interior Lighting (page 170).
Taxi Refer to: 5.8 Seats (page 280).
Refer to: 5.9 Glass, Frames and Mechanisms (page 282).
Refer to: 5.10 Roof Opening Panel (page 285).Roof Ventilation.
Refer to: 5.11 Airbag Supplemental Restraint System (SRS) (page 289).
Refer to: 5.1 Body (page 234).Hydraulic Lifting Equipment for Van, Bus, Kombi and Chassis
Cab.
Mobility
Refer to: 5.8 Seats (page 280).
Refer to: 5.10 Roof Opening Panel (page 285).(Roof Ventilation).
Cab.
Coach Built Refer to: 4.15 Interior Lighting (page 170).

Cab.
Wheelchair Refer to: 5.10 Roof Opening Panel (page 285).Roof Ventilation.
Accessible
Cab.
Mini Bus

Refrigerated Vehicles
Refer to: 1.8 End of Life Vehicle (ELV) Directive (page 23).
Van Conver-
Refer to: 4.7 Climate Control System (page 141).
sion
Refer to: 1.8 End of Life Vehicle (ELV) Directive (page 23).
Refer to: 4.6 Battery and Cables (page 127).Also generator and Alternator.
Refer to: 4.7 Climate Control System (page 141).
Box Body
Conversion Refer to: 4.17 Fuses and Relays (page 177).
Compressor Refer to: 3.3 Accessory Drive (page 84).
Installation

1 General Information Emergency Services
Refer to: 3.2 Engine Cooling (page 82).Airflow Restrictions.
Ambulance - Refer to: 4.15 Interior Lighting (page 170).
Front Line
Fire Brigade Refer to: 4.17 Fuses and Relays (page 177).
Armed Forces Refer to: 4.17 Fuses and Relays (page 177).
Police Refer to: 4.17 Fuses and Relays (page 177).


1.5 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 center 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. If they are unable to help you
then please contact the Vehicle Converter
Advisory Service at [email protected]
For additional information on vehicle type
approval
Refer to: 1.2 Commercial and Legal Aspects (page
7).

1 General Information 1.6 Electromagnetic Compatibility (EMC)
WARNINGS: Radio frequency (RF) transmitter
Your vehicle has been tested and certified equipment (for example: cellular
to European legislation relating to telephones, amateur radio transmitters
electromagnetic and so on.) may only be fitted to your
compatibility(72/245/EEC, UN ECE vehicle if they comply with the
Regulation 10 or other applicable local parameters shown in the following
requirements). It is your responsibility to 'Frequency Overview' table. There are no
ensure that any equipment fitted special provisions or conditions for
complies with applicable local legislation. installations or use.
Ensure you have any equipment fitted by Do not mount any transceiver,
properly trained technicians. microphones, speakers, or any other item
in the deployment path of the airbag
system.
Do not fasten antenna cables to original
vehicle wiring, fuel pipes and brake pipes.
Keep antenna and power cables at least
100mm from any electronic modules and
airbags and associated wiring.
Frequency Overview
Frequency Band MHz Maximum Output Power Watts Antenna Position
(Peak RMS)
1-30 50W 1,2,3
30-54 50W 1,2,3
68-87.5 50W 1,2,3
142-176 50W 1,2,3
380-512 50W 1,2,3
806-940 10W 1,2,3
1200-1400 10W 1,2,3
1710-1885 10W 1,2,3
1885-2025 10W 1,2,3

1.6.1 Suggested Antenna Location
NOTE: After the installation of RF transmitters,

check for disturbances from and to all electrical
equipment in the vehicle, both in the standby and
transmit modes.
Check all electrical equipment:
• With ignition ON
• With the engine running
• During a road test at various speeds.
Check that electromagnetic fields generated
inside the vehicle cabin by the transmitter
installed do not exceed human exposure limits
specified in EU directive 2004/40/EC.

1 General Information 1.7 Vehicle Duty Cycle Guidelines
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.
NOTE: For further information contact your local
National Sales Company representative, or Local
Ford Dealer. If they are unable to help you then
please contact the Vehicle Converter Advisory
Service at [email protected]
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
Rear wheel drive is recommended for high traction
in combination with a high trailer weight.
Front wheel drive is recommended for low
conversion weight
1.7.1 Conversion Affect on Fuel

Economy and Performance
Any conversion may effect the fuel consumption
and performance depending on the aerodynamics
and the weight added by the conversion. The
published information for fuel consumption and
performance of the base vehicle therefore may
not be valid. It is advisable to control the weight,
but without deteriorating other vehicle attributes
and functions (especially those related to safety
and durability).
1.7.2 Vehicle Ride and Handling

Attributes
CAUTION: Do not exceed the axle plate,
gross vehicle mass, trailer plate and gross
trailer mass limits.
Due to the displacement of the center of gravity
occurred by the conversion the ride and handling
attributes may be different to the base vehicle.
NOTE: This vehicle should be evaluated for safe
operation prior to sale.

1.8 End of Life Vehicle (ELV) Directive
The European End-of-Life Vehicle (ELV) directive
requires that environmental and recycling aspects
are integrated in the development process of new
components and vehicles. This includes
requirements with respect to:
• The overall recyclability (85%)/recoverability
(95%) of vehicles.
• Limited use of hazardous substances including
the elimination of prohibited substances such
as lead, hexavalent chromium cadmium and
mercury).
• Publication of dismantling information.
• Parts Marking according to the corresponding
ISO Standards: ISO 1043-1, 1043-2 and 11469
for plastics and ISO 1629 for rubber materials.
• Increasing use of recycled materials.
• Producers meet all, or a significant part of, the
costs to take back End-of-Life Vehicles.
In addition to the requirements resulting from the
End-of-Life directive other environmental targets
should be taken into consideration such as:
• Minimizing costs and environmental burden
along the product life-cycle.
• Maximizing use of renewable materials e.g.
natural fibers.
• Minimizing the presence of substances
impacting vehicle interior air quality/clean
compartment or allergenic reactions (please
refer to 'Technischer Überwachungsverein TÜV
TOXPROOF). This refers to aspects like smell,
fogging, toxicity and allergy coming from
material in the interior.
• Eliminate use of prohibited substances which
are listed in the Global Automotive Declarable
Substance List (GADSL) at
http://www.gadsl.org
For continued legal compliance and
environmental performance of all Ford products
it is essential that any conversion of the vehicles
is in compliance with the requirements listed
above.
This is not a complete list of all legal requirements
to be met by every converted vehicle.

1 General Information 1.9 Jacking
NOTE: Make sure that reinforcements are installed
WARNING: Always position the vehicle
to maintain the integrity of the original body
on a hard level surface. If the vehicle must
structure for/at jacking points.
be jacked up on a soft surface use load
spreading blocks under the jack. Always NOTE: Any modifications to the vehicle must be
chock the wheel diagonally opposite the noted in the owner's handbook or new descriptive
jacking point. Failure to follow these literature included with the owner's
instructions may result in personal injury. documentation.
On Cab Van Floor vehicles, the spare wheel winch
CAUTIONS:
is located behind the right hand side rear wheel
It is important that only the correct and can be accessed from the right hand side. The
jacking and support locations are used at access must be ensured under maximum gross
all times. vehicle mass and rear axle load.
Make sure that access to the spare wheel On right hand drive derivatives of camper base
is maintained when converting the vehicle Chassis Cab and Cab Van Floor vehicles, the jack
or relocating the spare wheel. assembly is placed in a temporary location during
transportation of the base vehicle after the
NOTE: When using the vehicle jack, refer to the
conversion. The jack must be assembled and fixed
owner guide for correct operating instructions.
appropriately to the body to ensure safety,
durability and accessibility.
Van, Bus and Kombi (Short Wheelbase [SWB], Medium Wheelbase [MWB], Long Wheelbase
[LWB] and Extended Length)

Chassis Single Cab, Extended Frame Chassis Single Cab, Chassis Double Cab and Extended
Frame Chassis Double Cab

1 General Information 1.10 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 two post lift,
sure the vehicle is secured to the lift using vehicle lift arm adapters must be used
vehicle retention straps to prevent tilting. under the lifting points.
Failure to follow these instructions may when lifting the vehicle with a two post
result in personal injury. lift, the maximum kerb weight must not
be exceeded.
It is important that only the correct lifting
and support locations are used at all
times.
Van, Bus and Kombi (Short Wheelbase [SWB], Medium Wheelbase [MWB], Long Wheelbase
[LWB] and Extended Length)

Chassis Single Cab, Extended Frame Chassis Cab, Chassis Double Cab and Extended Frame
Chassis Double Cab

1 General Information 1.11 Noise, Vibration and Harshness (NVH)
WARNING: Make sure that the modified
vehicle complies with all relevant legal
requirements.
CAUTION: The travel and function of
pedals must not be restricted.
Changes to the powertrain, engine, transmission,
exhaust, air intake system or tires may influence
the exterior noise emission. 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.

1.12 Vehicle Transportation Aids and Vehicle Storage
CAUTIONS: • Where protective film has been applied in
Disconnect the battery if the vehicle is to manufacture it must be left on the vehicle until
be stored for more than 7 days. prepared for delivery but must be removed
after a maximum storage period of six months
Make sure that the protective covers are (film is date stamped to indicate required
not removed from an incomplete vehicle removal date).
until the conversion is started.
• Make sure that all windows, doors, hood, lift
Make sure that components removed gate, tailgate, luggage compartment lid,
during conversion are kept clean and dry. convertible top and roof opening panel are
completely closed and the vehicle is locked.
Make sure that components removed
during conversion are refitted to the The Pre Delivery Inspection (PDI) is the final
same vehicle. opportunity to make sure a battery is fit for
purpose prior the customer taking delivery of their
In addition:
new vehicle. The battery must be checked and
• The windscreen wipers should be lifted off the appropriate action taken prior to the vehicle being
glass and set right up. handed over to the customer. Test results must
• All air intakes should be closed. be recorded on the PDI repair order.
• Increase normal tire pressure by 0.5 bar. Batteries. To make sure the battery is maintained
correctly and to assist in preventing premature
• The hand brake system should not be used. failure, it is necessary to check and recharge the
• Apply suitable wheel chock to prevent roll battery regularly while a vehicle is not in use.
away. Where a battery is left below its optimum charge
level for any length of time, it may result in
A significant risk during storage is deterioration of premature failure of the battery.
vehicle bodywork, therefore, appropriate storage
procedures must be observed, including periodic Action / Time in Monthly Every 3
inspection and maintenance. Storage Months
Claims arising from deterioration caused by
Check Vehicle is
incorrect storage, maintenance or handling are X -
clean
not the responsibility of Ford.
Vehicle Converters must determine their own Remove external
X -
procedures and precautions, particularly where contamination
vehicles are stored in the open as they are Check battery connected disconnected
exposed to any number of airborne contaminants. condition —
The following may be considered a sensible Recharge if
approach to storage: necessary
Short Term Storage: Visually check
X -
• Wherever possible vehicles should be stored tires
in an enclosed, dry, well-ventilated area based Check interior for
on firm, well drained ground which is free of - X
condensation
long grass or weeds and where possible
protected from direct sunlight. Run engine for 5
minutes
• Vehicles must not be parked near, under foliage minimum with air
or close to water as additional protection may - X
conditioning
be necessary for certain areas. switched on,
Long term storage: where applicable
• Battery to be disconnected, but not removed
from the vehicle. To reduce the likelihood of premature battery
• The wiper blades should be removed and failure it is recommended that where:
placed inside the vehicle. Make sure the wiper • A battery is left connected — monthly checks
arms are suitably prevented from resting on should be carried out.
the windscreen. • A battery has been disconnected — no greater
• Wheel trims (where fitted) removed and stored than a 3 monthly check should be carried out.
in the luggage compartment. Refer to: 4.6 Battery and Cables (page 127).
• Engage first gear and release the parking brake
completely. Chock the wheels first if the vehicle
is not on level ground.
• Set climate controls to the "open" position to
provide ventilation, where possible.

1 General Information 1.13 Package and Ergonomics
1.13.1 General Component Package Where additional steps are installed the required
Guidelines ground clearance line is to be maintained.
The Vehicle Converter must make sure that a
WARNING: Do not modify, drill, cut or movable step is set in the stored position when
weld any suspension components, the vehicle is running. The step surface must be
specifically the steering gear system, non-slip.
subframe or anti-roll bars, springs or
shock absorbers including mounting
brackets. Grab Handles
The Vehicle Converter has to ensure that sufficient
clearance is maintained under all drive conditions WARNING: Make sure that the location of
to moving components such as axles, fans, the no-drill zones are checked before
steering, brake system etc. drilling.
The Vehicle Converter is responsible for all CAUTION: Make sure that reinforcements
installed components during the conversion. The are installed to maintain the integrity of
durability has to be confirmed by appropriate test the original body structure.
procedures. Grab handles can be ordered as an option on the
base vehicle. Please check for availability.
1.13.2 Driver Reach Zones NOTE: For further information please contact your
Controls and/or equipment required to be used Local Ford Dealer. If they are unable to help you
while driving should be located within easy reach then please contact the Vehicle Converter Advisory
of the driver so as not to impair driver control. Service at [email protected].
1.13.3 Driver Field of View

WARNING: Make sure that the modified
vehicle complies with all relevant legal
requirements.
1.13.4 Conversion Affects on Parking

Aids
WARNING: Ensure that monitors mounted
in the cabin meet the interior package and
safety requirements.
On conversions requiring a rear camera, the reverse
signal may be taken as described in the electrical
section, described in reversing lamps.
1.13.5 Aids for Vehicle Entry and Exit
Steps
WARNINGS:
Make sure that the modified vehicle
complies with all relevant legal
requirements.
If this modification alters the
homologated dimensions, a new approval
may be necessary.
CAUTION: Make sure that reinforcements
are installed to maintain the integrity of
the original body structure.
Steps can be ordered as an option on the base
vehicle. Please check for availability.

1.14 Package and Ergonomics—Specifications
1.14.1 Recommended Main Dimensions

WARNINGS: NOTE: When extending the length of the frame
rearward of the rear axle, limit the overall rear
Do not modify the wheelbase or add any
overhang to a maximum of 50% of the wheelbase
type of frame extension to vehicles fitted
of the donor vehicle.
with Electronic Stability Program ESP.
If a conversion requires more than 50% overhang,
Do not allow Center of Gravity of the body
please contact one of the below.
and payload to fall behind the rear axle
center line. For further information please contact your local
National Sales Company representative, or Local
NOTE: Extreme rear overhang may encourage
unacceptable loading conditions, which could
unload the front axle producing unacceptable
Service at [email protected].
handling and braking characteristics.
Abbreviations
FWD Front Wheel Drive
RWD Rear Wheel Drive
SWB Short Wheel Drive
MWB Medium Wheel Drive
LWB Long Wheel Drive
EF Extended Frame
SRW Single Rear Wheel
DRW Dual Rear Wheel
RHD Right Hand Drive
MED Medium
mm Millimeters
m Meters

Chassis Cab Body

Dimensions - not to exceed for Chassis Cab body Length
Description SWB MWB LWB EF 3954mm
3137mm 3504mm 3954mm
A Maximum recommended rear over- Maximum 50% overhang provided Center of Gravity of
hang body and payload is not rearwards of rear axle centerline
B Front outside of body Single Cab 1731mm 2098mm 2548mm 2548mm
to rear axle
Double Cab - 1281mm 1731mm 1731mm
C Maximum external Short mirror 2100mm
body width arms
SVO 2.3m 2300mm (This option is not available in all markets)
body option
mirror arms
D Maximum recommended external Maximum allowable by territorial legislation (We recom-
body height RWD and FWD mend up to 2,4m over top of frame).
E Vehicles built after 15th September 2008 require 60mm clearance between the back of the cab
and the body (see item 1 in graphic E74205)
Vehicles built before 15th September 2008 require 25mm clearance between the back of the
cab and the body (see item 2 in graphic E74205)
F 30mm minimum
G Ensure local lighting legislation is maintained
H Under run bar and towing attachment legislation to be maintained
J Frame length behind Single Cab 2679mm 3148mm 3496mm 3980mm
back of cab (not
Double Cab - 2327mm 2679mm 3060mm
including rear light
cross-member)
All dimensions are subject to manufacturing tolerances and refer to min specification models and do
not include additional equipment. The illustrations are for guidance only.
1.14.2 Front, Rear and Side Under-run Front Under run Protection must be designed to
Protection directive ECE 93.00 EU equivalent 2000/40 EC
WARNING: Check local legislation for Rear Under run Protection must be designed to
legal requirements. directive ECE 58.00 EU equivalent 70/221 EC
Side Under run Protection must be designed to
directive ECE 73.00 EU equivalent 89/297 EC

1 General Information 1.14.3 Recommended Main Load Area Dimensions for Bulkhead with Depression
Driver Side
Wheelbase Roof Length 'A' Width 'B' Height 'C' Height 'C'
(mm) (mm) (mm) Low (mm) High
Floor Floor
SWB Low 2280 1380 1330 1230
SWB Medium 2280 1250 1650 1550
MWB Low 2650 1380 1330 1230
MWB Medium 2650 1240 1650 1550
MWB High 2610 1230 1850 1750
LWB Medium 3100 1240 1650 1550
LWB High 3060 1230 1850 1750
EF High 3780 1230 1850 1750

1.14.4 Recommended Main Load Area Dimensions for Bulkhead with Full
Depression
Wheelbase Roof Length 'A' Width 'B' Height 'C' Height 'C'
(mm) (mm) (mm) Low (mm) High
Floor Floor
SWB Low 2280 1380 1330 1230
SWB Medium 2230 1250 1650 1550
MWB Low 2650 1380 1330 1230
MWB Medium 2600 1240 1650 1550
MWB High 2560 1230 1850 1750
LWB Medium 3050 1240 1650 1550
LWB High 3010 1230 1850 1750
EF High 3730 1230 1850 1750

1 General Information 1.14.5 Recommended Main Load Area Dimensions for Double Cab In Van Bulkhead
Wheelbase Roof Length 'A' Width 'B' Height 'C' (mm) Height 'C' (mm)
(mm) (mm) Low Floor High Floor
SWB Low 1480 1380 1330 -
SWB Medium 1430 1250 1650 -
MWB Medium 1670 1240 1650 1550
MWB High 1630 1230 1850 1750
LWB Medium 2120 1240 1650 1550
LWB High 2080 1230 1850 1750
EF High 2800 1230 1850 1750
Right Hand Drive (UK Market Only) includes alternative load box for 8' x 4' sheets
LWB Med + High 2470 1310 300 -

1.15 Hardware—Specifications
Material Specification, Strength and Torque
Standard Hardware and Tightening Torques (Nm) Bolts/Studs: ISO 898-1, Nuts: ISO 898-2
Grade 4.8 Grade 8.8 Grade 10.9
Thread Size Minimum Maximum Minimum Maximum Minimum Maximum
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

1 General Information 1.16 Load Distribution—Specifications
1.16.1 Load Distribution Calculations - Driver and Passenger Weight Distribution

CAUTIONS: NOTE: Over loading of the vehicle could result in
unacceptable ground clearance.
Do not exceed the axle plated weights.
NOTE: The center of mass of the payload should
Do not exceed the gross vehicle weight. be located within the wheelbase of the vehicle.
NOTE: Avoid one-sided load distribution.
Tire manufacturer specification must be NOTE: For further information please contact your
maintained. local National Sales Company representative, or
NOTE: Uneven load distribution could result in Local Ford Dealer. If they are unable to help you
unacceptable handling and braking characteristics. then please contact the Vehicle Converter Advisory
Single and Double Cab

Single and Double Cab Driver and Passenger Weight Distribution
'A' Wheelbase 'B' Front Row 'C' Second Weight distribution Per Person in Kg
(mm) Seats and Row Seats
Driver
On Front Axle On Rear Axle Total
3137 985 - 52 23 75
3504 985 - 55 20 75
- - 1859 39 36 75
3954 985 56 19 75
- - 1859 35 40 75
Dimensions taken from Front Axle (1)
Van and Kombi

Van and Kombi Driver and Passenger Weight Distribution
'A' Wheel- 'B' Front 'C' Second 'D' Third Weight distribution Per Person in Kg
base (mm) Row Seats Row Seats Row Seats
and Driver
On Front On Rear Total
Axle Axle
2933 985 - - 49 26 75
- - 1859 - 24 51 75
- - - 2916 1 74 75
3300 985 - - 52 23 75
- - 1859 - 30 45 75
- - - 2916 26 49 75
3750 985 - - 55 20 75
- - 1859 - 35 40 75
- - - 2916 50 25 75
Dimensions taken from Front Axle (1)
1.16.2 Center of Gravity

The following charts show the Center of Gravity
used for Brake Certification at Kerb and maximum
Gross Vehicle Mass.
Van

Van Center of Gravity Critical Zone to EEC Category N1. Non-ABS
Model Roof Height Laden Gross Vehicle Mass (GVM) with Minimum Kerb + Driver
all passengers (Dimensions mm) Running Order (Dimen-
sions mm)
'A' Min 'B' Max 'C' Center of 'D' Design 'E' Center of
Gravity Max Gravity Max
Short Wheel Base (SWB)
260S Diesel Low 1297 1664 900 1100 770
260S Diesel Medium 1297 1664 900 1119 770
280S Diesel Low 1414 1728 900 1100 770
280S Diesel Medium 1414 1728 900 1119 770
300S Diesel Low 1369 1721 862 1225 770
300S Diesel Medium 1369 1721 862 1224 770
330S Diesel Low 1422 1911 916 1242 770
330S Diesel Medium 1422 1911 916 1240 770
Medium Wheelbase (MWB)
280M Diesel Low 1460 1967 900 1245 770
280M Diesel Medium 1460 1967 954 1265 785
300M Diesel Low 1320 2178 900 1245 770
300M Diesel Medium 1320 2178 954 1265 785
300M Diesel High 1320 2178 954 1281 785
330M Diesel Low 1540 1936 900 1245 770
330M Diesel Medium 1540 1936 954 1406 785
330M Diesel High 1540 1936 954 1420 785
350M Diesel Low 1551 2128 954 1232 785
350M Diesel Medium 1551 2128 954 1400 785
350M Diesel High 1551 2128 954 1412 785
Long Wheel Base (LWB)
300L Diesel Medium 1750 2313 957 1550 800
300L Diesel High 1750 2313 957 1568 800
330L Diesel Medium 1818 2443 957 1549 800
330L Diesel High 1818 2443 957 1566 800
350L Diesel Medium 1762 2418 957 1544 800
350L Diesel High 1762 2418 957 1562 800
All 430 Series up to 2008.25MY have Anti-lock Brake System (ABS) so are not shown on these charts
All 460 series from 2008.25MY onwards have ESP as standard

Single Chassis Cab

Single Chassis Cab Center of Gravity Critical Zone to EEC Category N1. Non-ABS
Model Laden Gross Vehicle Mass (GVM) with all Minimum Kerb + Driver
passengers (Dimensions mm) Running Order Without Float
(Dimensions mm)
Short Wheelbase (SWB) Single Rear Wheel
300S Diesel 1464 1840 916 1119 770
330S Diesel 1521 2044 916 1196 770
Medium Wheelbase (MWB) Single Rear Wheel
300M Diesel 1635 2161 954 1134 785
330M Diesel 1699 2283 954 1411 785
350M Diesel 1752 2253 954 1390 785
Medium Wheelbase (MWB) Dual Rear Wheel
350M Diesel 1752 2253 954 1390 785
Long Wheelbase (LWB) Single Rear Wheel
330L Diesel 1917 2576 957 1619 800
350L Diesel 1858 2776 957 1658 800
Long Wheelbase (LWB) Dual Rear Wheel
350L Diesel 1858 2776 957 1658 800
Extended Frame (EF) Single Rear Wheel
350L Diesel 1858 2768 957 1693 800
Extended Frame (EF) Dual Rear Wheel
350L Diesel 1858 3333 957 1746 800
300,330 Rear Wheel Drive and 330,350 Forward Wheel Drive and M2 Buses have Anti-lock Brake
System (ABS) so are not shown on these charts
All 460 series from 2008.25MY onwards have ESP as standard.

Double Chassis Cab 6 seat
Double Chassis Cab Center of Gravity Critical Zone to EEC Category N1. Non-ABS
Model Laden Gross Vehicle Mass (GVM) with all Minimum Kerb + Driver
passengers (Dimensions mm) Running Order Without Float
(Dimensions mm)
Medium Wheelbase (MWB) Single Rear Wheel
300M Diesel 1635 2036 954 1316 785
330M Diesel 1699 2283 954 1463 785
350M Diesel 1652 2235 954 1460 785
Medium Wheelbase (MWB) Dual Rear Wheel
350M Diesel 1647 2460 954 1497 785
Long Wheelbase (LWB) Single Rear Wheel
330L Diesel 1917 2576 957 1627 800
350L Diesel 1864 2542 957 1632 800
Long Wheelbase (LWB) Dual Rear Wheel
350L Diesel 1858 2776 957 1663 800
Extended Frame (EF) Single Rear Wheel
350L Diesel 1864 2589 957 1738 800
Extended Frame (EF) Dual Rear Wheel
350L Diesel 1858 2937 957 1738 800
All 460 series from 2008.25 onwards have ESP as standard.

Bus
Bus Center of Gravity Critical Zone to EEC Category N1. Non-ABS

Model Roof Height Laden Gross Vehicle Mass (GVM) with Minimum Kerb + Driver
Tourneo all passengers (Dimensions mm) Running Order Without
Float (Dimensions mm)
Short Wheelbase (SWB)
280S Diesel 1414 1624 900 1240 770
All M2 Buses have Anti-lock Brake Systems as standard so are not included on above chart

1 General Information 1.17 Towing
1.17.1 Tow Bar Requirements 2. Place the clamp plates, item 4, inboard of item
1 on either side of the vehicle and locate to side
When a tow bar device is required, the Vehicle member by inserting 3 fixing bolts each side,
Converter should use a Ford approved tow bar. item 4, into holes 'E' shown in graphic E102482.
Secure with 6x M15 nuts to the required
manufactures torque setting.
Load Distribution.
Refer to: 1.9 Jacking (page 24).
1.17.3 Tow bars
Refer to: 4.2 Wiring Harnesses (page 106).
Electrics for Tow bar. For tow bar devices fitted by the vehicle converter
the following applies:
1.17.2 Fitting Instructions for 4.6 Tonne • Tow bar allowances must not exceed those of
and 3.5 Tonne HD (derated) the standard vehicle.
• For attachment of the tow bar, under run bar
and step see the following diagrams .
Van Tow bar
– E74854 Tow bar Chassis Cab, 3.0 - 3.5
The following information refers to graphic tonne.
E102481 and table. – E102482 Tow bar Chassis Cab 4.6 tonne and
Van Tow bar Kit and Fitting Instructions 3.5 tonne HD (derated).
• 1x Item 1 - Tow bar frame assembly with tow – E74855 Tow bar Van, Bus and Kombi 2.8 -
ball hitch, item 2 or 3, with four bolts. 3.5 tonne.
• 6x Item 4 -Side member fixing bolts, 3 each – E102481 Tow bar Van 4.6 tonne and 3.5
side. tonne HD (derated).
1. From below the rear of the vehicle raise up item Use the upper position to fix the tow ball on front
1 and locate between inside face of both side wheel drive vehicles and the lower position to fix
members. on rear wheel drive vehicles.
2. Locate the tow bar frame to side member by • Any modifications to the vehicle must be noted
inserting 3 fixing bolts each side, item 4, into in the owner's handbook or new descriptive
holes 'E' shown in graphic E102481. Secure with literature included with the owner's
6x M15 nuts to the required manufactures documentation.
torque setting. • The maximum allowable tow ball static load
is 112kg on a Van, Bus, Kombi and Chassis Cabs
with GVM up to 3.5 tonne.
Chassis Cab Tow Bar • The maximum allowable tow ball static load
for 4.6 tonne and 3.5 tonne HD (derated) on
The following information refers to graphic Chassis Cabs and Vans is 140kg.
E102482 and table.
• Tow bar installations must meet the
Chassis Cab Tow bar Kit and Fitting Instructions requirements of the EEC Directive 94/20 EC.
• 1x Item 1 - Tow bar frame assembly with tow • Whenever frame drilling is necessary use tube
ball hitch, item 2 or 3, with four bolts. reinforcement.
• 2x Item 4 - Side member clamp plate, 1 each Refer to: 5.14 Frame and Body Mounting (page
side of vehicle. 293).
• 6x Item 5 - Side member fixing bolts, 3 each Mounting Points and Tubing.
side of vehicle.
For any further details and advice please consult
1. From below the rear of the vehicle raise up item your local National Sales Company representative,
1 and locate between inside face of both side or Local Ford Dealer. If they are unable to help you
members. then please contact the Vehicle Advisory Service
at [email protected]

Tow Bar Chassis Cab, 3.0 - 3.5 Tonne
Attachment details for Tow Bar Chassis Cab, 3.0 - 3.5 Tonne
Item Description Item Description
A 115mm D 96mm
B 106mm E 15mm diameter
C 214mm - -

Tow Bar Chassis Cab 4.6 Tonne and 3.5 Tonne HD (derated).
Attachment details for Tow Bar Chassis Cab 4.6 Tonne and 3.5 Tonne HD (derated)
Item Description Item Description Item Description
1 Tow bar frame assembly 5 Side member D 96mm
fixing bolts 3x
each side
2 4.6 tonne Chassis cab tow ball A 115mm E 15mm Diameter
fixing has 4 bolts.
3 3.5 tonne HD (derated) Chassis B 106mm F 74mm
cabs require a swan neck tow ball.
*
4 4.6 tonne unique clamp plate C 267mm - -
required for chassis cab only.
*Note: Tow ball height restricted to 420mm for vehicle categories M1, N1 and M2 when below 3500kg.
No tow ball height restriction applies to N2 category vehicles, for example above 3.5 tonne (for example
4.6 tonne Transit).

Tow Bar Van, Bus and Kombi, 2.8 - 3.5 tonne
Attachment details for Tow Bar Van, Bus and Kombi, 2.8 - 3.5 tonne
1 - RWD Vehicles Description 2 - FWD Vehicles Description
A 110mm A 110mm
B 49mm B 49mm
C 69.5mm C 69.5mm
D 69.5mm D 69.5mm
E 13mm E 13mm
F 23mm F 23mm
G 185mm G 85mm
H 18mm H 18mm

Tow Bar Van 4.6 Tonne and 3.5 Tonne HD (derated)
Attachment details for Tow Bar Van 4.6 Tonne and 3.5 Tonne HD (derated)
1 Tow bar frame assembly C 69.5mm
2 4.6 tonne Van tow ball fixing has 4 bolts. D 69.5mm
3 Derated Vans require a swan neck tow ball. * E 13mm diameter
4 Side member fixing bolts 3x each side F 23mm
A 110mm G 85mm
B 49mm H 18mm
*Note: Tow ball height restricted to 420mm for vehicle categories M1, N1 and M2 when below 3500kg.
No tow ball height restriction applies to N2 category vehicles, for example above 3.5 tonne (for example
4.6 tonne Transit).

Tow Bar Cab Van Floor

A 110mm G 85mm
B 49mm H 18mm
C 69.5mm J 22mm
D 69.5mm K 275mm
E 13mm diameter L 20mm diameter
F 33mm M 77mm
For any extensions including tow bar devices used Tow bar Electrics.
on Cab Van Floor medium wheelbase or long The towing nose mass on Cab Van Floor variants
wheelbase vehicle converters/modifiers need to is 75kg maximum and the trailer mass is 1000kg
use fixing points as in the figure E78717. maximum.

Transit Motor Home Chassis - Fixing option inside chassis rails

A 20mm F diameter 20mm
B 610.63mm G diameter 15mm
C 10mm H 86.07mm
D 78mm J 30.70mm
E 40mm - -

Transit Motor Home Chassis - Fixing option out side edge of chassis rails
Refer to: 5.1 Body (page 234).

Refer to: 5.14 Frame and Body Mounting (page
293).

2 Chassis 2.1 Suspension System
WARNING: Do not modify, drill, cut or
weld any suspension components,
specifically the steering gear system,
brackets.
CAUTION: Modifications to the
suspension system can cause a
deterioration of the vehicle handling
characteristics and durability.
NOTE: For detailed information please contact
the Vehicle Converter Advisory Service at
[email protected]

2 Chassis
2.2 Front Suspension
2.2.1 Springs and Spring Mounting
WARNING: Do not modify, drill, cut or
weld any suspension components,
specifically the steering gear system,
brackets.
CAUTIONS:
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.
Make sure that components loosened or
removed and reinstalled are properly
reassembled and the torque set in
accordance with manufactures
requirements.
NOTE: Do not modify the wheelbase or add any
type of frame extension to vehicles fitted with
Electronic Stability Control, ESC (also known as
Electronic Stability Program, ESP).
NOTE: Do not damage the surface or corrosion
protection of the spring during disassembly and
installation.
NOTE: For detailed information please contact
the Vehicle Converter Advisory Service at
[email protected]

2 Chassis 2.3 Rear Suspension
2.3.1 Springs and Spring Mounting
WARNINGS:
Do not modify, drill, cut or weld any
suspension components, specifically the
steering gear system, sub-frame 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 can not be held responsible.
CAUTIONS:
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.
Make sure that components loosened or
removed and reinstalled are properly
reassembled and the torque set in
accordance with manufactures
requirements.
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.
NOTE: For detailed information contact the
Vehicle Converter Advisory Service at
[email protected]
2.3.2 Rear Anti-Roll Bar

NOTE: Only the following vehicles should have a
rear anti-roll bar. Vehicles built from September
2011:
Rear roll bars are fitted on all 350, 425 and 460
dual rear wheels (DRW) chassis cabs only.

2 Chassis
2.4 Wheels and Tires
2.4.1 Wheel Clearance
The distance from the tire to the mudguard or
wheel arch must be sufficient, even if snow or
anti-skid chains are fitted and the suspension is
fully compressed allowing for axle twist as well.
Please consult the Vehicle Converter Advisory
Service [email protected] for clearance
requirements and data.
NOTE: Make sure that only approved wheels and
/or permissible tire sizes are fitted.
NOTE: Ensure access to the wheel and wheel
jack, and provide sufficient clearance in wheel
arch to allow changing the wheels after
conversion.
For standard wheelhouse dimensions:
(Integral Bodies and Conversions)
2.4.2 Tire Manufacturers

Replacement tires should be of the same make,
size, tread pattern and load rating as the Original
Equipment Manufacturer. Under these conditions
the original tire label should be satisfactory,
however if the specified tires and/or inflation
pressures are changed then a new label should
be affixed over the original label.
2.4.3 Spare Wheel

When converting or relocating the spare wheel,
access must be ensured.
2.4.4 Tire Repair Kit

Choose appropriate storage space for tire repair
kit to ensure easy access in case of puncture. For
more information and usage of the tire repair kit
please refer to the owner's manual.
2.4.5 Painting Road Wheels

CAUTION: Do not paint wheel clamp
surfaces in contact with other wheels,
brake drum or disc, hub and holes, or
surfaces 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.

2 Chassis 2.5 Driveshaft
2.5.1 Power Take Off
Gearbox add-on - Auxiliary Propeller Drive

Shaft
CAUTIONS:
Make sure that an inhibitor is fitted to any
modified vehicle that uses the prop-shaft
to power auxiliary equipment.
The only modification to the engine
control system (throttle, powertrain
control module and fuel pump)
recommended by the manufacturer is the
addition of an engine (RPM) controller.
Do not weld or join onto any part of the
axle assembly.
The transmission oil temperature must
not exceed 130°C during operation of the
Power Take Off.
Where power is to be taken from the prop-shaft
for accessory drive, the engine controller can be
used in the same way as for the Front End
Accessory Drive (FEAD).
Refer to: 3.3 Accessory Drive (page 84).
Exceeding the recommended power take off
ratings may result in the engine over heating.
If the driveshaft is modified, it must be balanced
to a limit of 80gmm at 5000rpm and the
installation must not have universal joint angles
exceeding 4°. The gearbox output included angle
must be no more than 1°.

2 Chassis
2.6 Brake System
2.6.1 General
The Brake System must be fully functional when
the vehicle conversion is completed. The vehicle
brake operating modes must be checked,
including warning system and parking brakes.
Brakes are certified to 71/320EEC and ECE R13
requirements as amended.
WARNING: Do not restrict the airflow and
cooling to the brake system.
CAUTION: Spoilers and wheel covers
must not affect the brake cooling
performance.
NOTE: Do not obstruct the view of the brake fluid
reservoir level.
NOTE: The donor vehicle brake fluid reservoir is
translucent so that it is possible to check the level
of fluid without opening the reservoir which will
reduce the risk of contamination.
The brake fluid reservoir must remain accessible
for servicing and for adding brake fluid.
2.6.2 Kerb Mass Data

2.6.3 Brake Hoses General

CAUTION: Make sure that the front and
rear brake hoses are not twisted and are
correctly located away from body and
chassis components.
Front and rear brake hoses must not rub, chafe or
rest on body or chassis components. There must
be clearance under all operating conditions,
between full compression and extension and full
lock to lock.
Brake lines must not be used to support or secure
any other component.

2 Chassis 2.7 Parking Brake
WARNINGS:
Do not modify the brakes.
Do not splice into the parking brake cable.
CAUTION: Make sure that a new parking

brake cable is fitted if modification to the
wheelbase impacts the existing parking
brake cable.
Local Ford Dealer.

2 Chassis
2.8 Hydraulic Brake Actuation
2.8.1 Load Apportioning Valves
It is not necessary or recommended to modify the
load apportioning valves, however, if a special
conversion should require modification:
• Maintain original settings.
• Maintain brake certification load distribution.
2.8.2 Front and Rear Brakes

WARNINGS:
Do not modify the brakes.
Do not modify the disc in flow and out

flow of cooling air.

2 Chassis 2.9 Anti-Lock Control - Stability Assist
WARNING: Do not modify any part of the
braking system, including Anti Brake
System (ABS), Traction Control System
(TCS) and Electronic Stability Program
(ESP).
Service at [email protected].
NOTE: Effective from 2008.75 Model Year all
vehicles are equipped with ABS and ESP as
Standard.

3 Powertrain
3.1 Engine
• 2.3L Gasoline engine 107kW (145PS) - Vehicles
CAUTION: Make sure to follow the
built before June 2011
equipment suppliers instructions for
safety, warranty and sometimes legal *Available with or without Diesel Particulate Filter
compliance. (DPF).
For electrical supply to auxiliary equipment. Power and Torque curves for vehicles built
after 26 September 2011.
Refer to: 4.5 Charging System (page 120).
Front Wheel Drive (FWD) EU5 Emissions markets
with DPF and EU4 Emissions markets without
3.1.1 Engine Power Curves DPF
Power and Torque curves for vehicles built • Common Rail 2.2L TDCi 74kW (100PS) Diesel
before 26 September 2011. Engine.
• Common Rail 2.2L TDCi 92kW (125PS) Diesel
Front Wheel Drive (FWD) Engine.
• Common Rail 2.2L TDCi 62.5kW (85PS) Diesel • Common Rail 2.2L TDCi 103kW (140PS) Diesel
Engine* Engine.
Engine. Replaced by 85kW (115PSP) Rear Wheel Drive (RWD) EU5 Emissions markets
2009.25MY with DPF and EU4 Emissions markets without
DPF
Engine *. Introduction 2009.25MY - October • Common Rail 2.2L TDCi 74kW (100PS) Diesel
2009 Engine.
• Common Rail 2.2L TDCi 96kW (130PS) Diesel • Common Rail 2.2L TDCi 92kW (125PS) Diesel
Engine. Replaced by 103kW (140PS) Engine.
2008.25MY • Common Rail 2.2L TDCi 100kW (135PS) Heavy
• Common Rail 2.2L TDCi 103kW (140PS) Diesel Duty Emission Diesel Engine.
Engine *. Introduction 2008.25MY - 02 January • Common Rail 2.2L TDCi 114kW (155PS) Diesel
2009. Engine.
Rear Wheel Drive (RWD) Rear Wheel Drive (RWD) EU4 Emissions markets
• Common Rail 2.4L TDCi 74kW (100PS) Diesel without DPF
Engine * • Common Rail 3.2L Puma I5 147kW (200PS)
• Common Rail 2.4L TDCi 85kW (115PS) Diesel Diesel Engine.
Engine * EU4 Emissions, restricted market. For availability
• Common Rail 2.4L TDCi 103kW (140PS) Diesel check with your National Sales Representative or
Engine * local Ford Dealer.
• Common Rail 3.2L Puma I5 147kW (200PS)
Diesel Engine. Introduction 20 August 2007*

3 Powertrain 3.1.2 Power and Torque Curves for vehicles built before 26 September 2011
FWD Common Rail 2.2L TDCi 62.5kW (85PS) Diesel Engine
Item Description
1 Torque Curve Nm - Max Torque = 250Nm at 1500-2200 1/min
2 Power Curve kW - Max Power = 63kW (85PS) at 3500 1/min
A Nm
B 1/min
C kW

3 Powertrain
FWD Common Rail 2.2L TDCi 81kW (110PS) Diesel Engine. Replaced by 85kW (115PS)
Item Description
A Nm
B 1/min
C kW

3 Powertrain
FWD Common Rail 2.2L TDCi 85kW (115PS) Diesel Engine. Introduction - October 2008
Item Description
A Nm
B 1/min
C kW

3 Powertrain
FWD Common Rail 2.2L TDCi 96kW (130PS) Diesel Engine. Replaced by 103kW (140PS)
Item Description
A Nm
B 1/min
C kW

3 Powertrain
FWD Common Rail 2.2L TDCi 103kW (140PS) Diesel Engine. Introduction - January 2009
Item Description
A Nm
B 1/min
C kW

3 Powertrain
RWD Common Rail 2.4L TDCi 74kW (100PS) Diesel Engine
Item Description
2 Power Curve kW - Max Power = 74kW (100HP) at 3500 1/min
A Nm
B 1/min
C kW

3 Powertrain
RWD Common Rail 2.4L TDCi 85kW (115HP) Diesel Engine
Item Description
A Nm
B 1/min
C kW

3 Powertrain
Item Description
A Nm
B 1/min
C kW

3 Powertrain
RWD Common Rail 3.2L Puma I5 147kW (200PS) Diesel Engine. Introduction August 2007
Item Description
A Nm
B 1/min
C kW

3 Powertrain
RWD 2.3L Gasoline Engine 107kW (145PS) - Vehicle built before June 2011
Item Description
1 Torque Curve Nm - Max Torque = 210Nm at 2500 1/min
A HP
B 1/min
C Nm

3 Powertrain 3.1.3 Power and Torque Curves for vehicles built after 26 September 2011
FWD Common Rail 2.2L TDCi 74kW (100PS) Diesel Engine
Item Description
A Nm
B 1/min
C kW

3 Powertrain
FWD Common Rail 2.2L TDCi 92kW (125PS) Diesel Engine.
Item Description
A Nm
B 1/min
C kW

3 Powertrain
FWD Common Rail 2.2L TDCi 103kW (140PS) Diesel Engine.
Item Description
A Nm
B 1/min
C kW

3 Powertrain
Item Description
A Nm
B 1/min
C kW

3 Powertrain
Item Description
A Nm
B 1/min
C kW

3 Powertrain
RWD Common Rail 2.2L TDCi 100kW (135PS) Heavy Duty Emissions Diesel Engine
Item Description
A Nm
B 1/min
C kW

3 Powertrain
Item Description
A Nm
B 1/min
C kW

3 Powertrain
RWD Common Rail 3.2L Puma I5 147kW (200PS) Diesel Engine.
Item Description
A Nm
B 1/min
C kW

3 Powertrain 3.2 Engine Cooling
3.2.1 Auxiliary Heater Systems • Use aluminum or plastic 'T' junction with
swaged or beaded ends to prevent hose blow
WARNINGS: off. Reconnect original coolant tube as shown
Ford coolant additives are necessary for in view E74570 (in this section) with standard
the complete function of the system. Only Ford water hose clip or suitable equivalent
use Ford approved or equivalent specification clip. Ensure interference fit
specification component, to withstand between hose and 'T' joint.
any detrimental effects on the materials. • Tube routing must be secured to the body
structure or suitable brackets avoiding electrical
Do not mount components in front of the
components or wires, hot or moving parts and
grille or in an area of air flow around the
brake or fuel system components.
engine, which could affect the engine
cooling. • Hose must be heat sleeved with appropriate
material if within 100mm of exhaust
CAUTIONS: components (for example, manifold or exhaust
gas recirculating).
Only make connections into the heater
hose between the front cab heater and • The vertical clearance between the critical
water pump return inlet. cooling components (radiator, fan shroud and
radiator brackets) and both the hood inner and
Do not exceed the vehicle's original outer (assembly) panels at design position shall
coolant volume by more than 10%. not be less than 15mm.
Only use the manufacturer recommended • There shall be a minimum clearance of 7mm
(or equivalent specification) coolant between the engine assembly and flexible
additives/anti-freeze. Do not mix coolant components (for example, hoses or wiring
types. harnesses) affixed to front end sheet metal
• Coolant flow to cab heater must have priority hardware, under a maximum engine torque roll
over flow to auxiliary heater or hand wash condition.
facility. NOTE: For further information please contact your
• Coolant tube routing must be below the local National Sales Company representative, or
minimum line of the degas bottle. Local Ford Dealer. If they are unable to help you
service at [email protected]

3 Powertrain
Water Hoses for Auxiliary Heating System
Item Description
1 Connector (aluminum or plastic)
2 Heater hose (maintain heater fluid)
3 Original flow
4 To ancillary equipment
3.2.2 Auxiliary Heater Installation CAUTION: Over heating within the engine
compartment can seriously compromise
Ensure that the exhaust gas from any auxiliary component robustness.
heating system can not be re-circulated into the
vehicle. The exhaust gases must not pass into the NOTE: Please assume under hood environment
engine intake system or the air intake for the is about 130°C when selecting appropriate
passenger compartment ventilation. The heating materials
system should be installed outside the passenger NOTE: For further information please contact
compartment. The location of the heating system your local National Sales Company representative,
should not be in close proximity to movable or Local Ford Dealer. If they are unable to help you
components. Any body reworks which damage then please contact the Vehicle Converter
the paint must be fully protected against Advisory Service at [email protected]
corrosion.
Refer to: 5.13 Corrosion Prevention (page 292).
NOTE: The installation must be in line with the
appropriate legal requirements.
3.2.3 Air Flow Restrictions

WARNING: Do not mount components in
front of the grille or in an area of air flow
around the engine, which could affect the
engine cooling performance.

3 Powertrain 3.3 Accessory Drive
3.3.1 Front End Accessory Drives - CAUTION: Do not fit an additional front
General Information end accessory drive to a vehicle already
equipped with an air-conditioning
When the correct belt is used, tensioning is and compressor.
remains fully automatic for the life of the belt.
When engineering and installing a new front end
CAUTIONS: accessory drive, i.e. belt drive of the crankshaft
pulley, the longitudinal alignment must be within
Only use the manufacturers +/- 0.25mm and angular within +/- 0.33°.
recommended (or equivalent
For most front end accessory drive applications
specification) components.
the longer Regular Production Option air
Make sure that the ancillary pulley -conditioning belt can replace the standard belt
diameter is less than the crankshaft and pulley layout.
pulley diameter.
The maximum power that is available for front end
NOTE: For further information on systems accessory drive applications, in lieu of the air
requiring a unique belt please contact your local conditioning compressor is 26Nm torque at any
National Sales Company representative, or Local engine speed up to a maximum of 6kW.
• Abbreviations
Service at [email protected] • FWD = Front Wheel Drive
The Eigen frequency of the bracket with auxiliary • RWD = Rear Wheel Drive
unit should be above the maximum excitation
frequency of the main excitation order of the
individual engine at engine top speed. On
4-cylinder inline engines, this is the second engine
order.

3 Powertrain
3.3.2 Front End Accessory Drives - Vehicles built before 26th September 2011
RWD 2.4L Diesel Engine - with Air Conditioning
RWD Pulley and Belt Layout on 2.4L Diesel Engine - with Air Conditioning
Item Description
1 Power Steering Pump
2 Fan
3 Idler
4 Vacuum Pump
5 Coolant Pump
6 Compressor (may be replaced by ancillary unit)
7 Crankshaft Pulley
8 Alternator
9 Auto Tensioner

3 Powertrain
FWD 2.3L Gasoline Engine - with Air Conditioning (Not available after June 2011)
FWD Pulley and Belt Layout on 2.3L Gasoline Engine - with Air Conditioning
Item Description
1 Alternator
2 Idler
3 Coolant Pump
5 Compressor (may be replaced by ancillary unit)
6 Crankshaft Pulley
7 Auto Tensioner

3 Powertrain
FWD 2.2L Diesel Engine - with Air Conditioning
FWD Pulley and Belt Layout on 2.2L Diesel Engine - with AC

Item Description
1 Idler
2 Idler
3 Alternator
5 Crankshaft Pulley
6 Auto Tensioner
7 Compressor

3 Powertrain
RWD Pulley and Belt Layout on 3.2L Diesel Engine - with Air Conditioning
Item Description
2 Fan
3 Idler
4 Vacuum Pump
5 Coolant Pump
6 Compressor (may be replace by ancillary unit)
7 Crankshaft Pulley
8 Alternator
9 Auto Tensioner

3 Powertrain
3.3.3 Front End Accessory Drives - Vehicles built after 26th September 2011
FWD 2.2L Diesel Engine - with Air Conditioning
FWD Pulley, Belt Layout, Engine Top Cover and Protective Shields on 2.2L Diesel Engine - with Air
Conditioning
Item Description
1 Idler
2 Idler
3 Alternator
5 Crankshaft Pulley
6 Compressor
7 Auto Tensioner
A Front End Accessory Drive Shield - only Start - Stop
B Engine Top Cover
C Front End Accessory Drive Shield
D Front End Accessory Drive Shield
CAUTION: Front End Accessory Drive NOTE: The shields are there to protect the Front
shields must be maintained at all times. End Accessory Drive system from STONE ingress
If shields are removed, for example when and also protect people from rotating parts under
attaching an ancillary unit, they must be Start - Stop function.
replaced so that it is protected
appropriately.

3 Powertrain
RWD Pulley, Belt Layout, Engine Top Cover and Protective Shields on 2.2L Diesel Engine - with Air
Conditioning
Item Description
1 Alternator
2 Fan
3 Idler
4 Coolant Pump
5 Compressor
6 Crankshaft Pulley
8 Auto Tensioner
A Front End Accessory Drive Shield
B Engine Top Cover
C Start - Stop Shield, only on RWD vehicles. Prevents hand ingress from beneath vehicle into
Front End Accessory Drive belt area.
D Intercooler Duct
CAUTION: Front End Accessory Drive

shields must be maintained at all times.
If shields are removed, for example when
attaching an ancillary unit, they must be
replaced so that it is protected
appropriately.
NOTE: The shields are there to protect the Front
End Accessory Drive system from STONE ingress
and also protect people from rotating parts under
Start - Stop function.

3 Powertrain
3.4 Clutch
The manufacturer does not offer the option of a
reinforced clutch system. The axle ratio available
is dependent on the weight of the specified donor
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 customers order.
Where possible make sure that the base vehicle
is ordered with plant fit options.
NOTE: For Single Mass Flywheel (SMF)
availability or for further information please
contact your local National Sales Company
representative, or Local Ford Dealer. If they are
unable to help you then please contact the
Vehicle Converter Advisory Service at
[email protected]

3 Powertrain 3.5 Manual Transmission
3.5.1 Manual Transmissions Built The following manual transmission is available for
Before 26th September 2011 gasoline engines.
• Rear Wheel Drive (RWD) vehicles
The following manual transmissions are available
for Diesel Engines dependent on the drive. – MT75 Transmission
• Front Wheel Drive (FWD) vehicles WARNING: Do not reroute external

transmission gear shift cables.
– VXT75 transmission
– VMT6 transmission NOTE: All MT82 RWD transmissions are
tachograph compatible.
• Rear Wheel Drive (RWD) vehicles
– MT82 transmission NOTE: All VMT6 FWD transmissions built after
February 2010 are tachograph compatible.
– MT75 transmission
VXT - 5 Speed Manual FWD Transmission

Gear Base Transmis- Overall Transmission and Overall Transmission and Differen-
sion Ratio Differential Drive Ratio for tial Drive Ratio for Vehicles greater
Vehicles less than or equal to than 3000kg GVM
3000kg GVM
1st 3.800 16.074 17.252
2nd 2.136 9.035 9.697
3rd 1.345 5.689 6.106
4th 0.921 3.896 4.181
5th 0.674 2.851 3.060
Reverse 3.727 15.765 16.921
VMT6 - 6 Speed Manual FWD Transmission

3000kg GVM
1st 3.818 16.635 18.819
2nd 2.150 9.368 10.597
3rd 1.276 5.560 6.289
4th 0.868 3.782 4.278
5th 0.943 2.876 3.253
6th 0.789 2.406 2.722
Reverse 1.423 16.571 18.744
MT75 - 5 Speed Manual RWD Transmission

MT82 - 6 Speed Manual RWD and AWD
Transmission Gear Ratio
Gear Ratio 1st 4.200
1 5.441 2nd 2.238
2 2.839 3rd 1.366
3 1.721 4th 1.000
4 1.223 5th 0.763
5 1.000 Reverse 3.600
6 0.794 Please also see BEMM Weight Charts for axle

Reverse 4.935 ratios, available to download/view via Etis website.

3 Powertrain
3.5.2 Manual Transmissions Built WARNING: Do not reroute external
After 26th September 2011 transmission gear shift cables.
NOTE: All MT82 RWD transmissions are
The following manual transmissions are available tachograph compatible.
for Diesel Engines dependent on the drive.
NOTE: All VMT6 FWD transmissions built after
• Front Wheel Drive (FWD) vehicles February 2010 are tachograph compatible.
– VMT6 transmission
• Rear Wheel Drive (RWD) and All Wheel
Drive (AWD) vehicles
– MT82 transmission

3000kg GVM
1st 3.727 16.239 18.370
2nd 1.864 8.121 9.188
3rd 1.121 4.884 5.525
4th 0.780 3.398 3.845
5th 0.844 2.574 2.912
6th 0.683 2.083 2.356
Reverse 1.423 16.176 18.297

MT82 - 6 Speed Manual RWD and AWD
Transmission
Gear Ratio
1 5.441
2 2.839
3 1.721
4 1.223
5 1.000
6 0.794
Reverse 4.935
MT82 - 6 Speed Manual RWD Transmission
MT82 - 6 Speed Manual AWD Transmission
Please also see BEMM Weight Charts for axle

ratios, available to download/view via Etis
website.

3 Powertrain 3.6 Exhaust System
Make sure that sufficient clearance is
3.6.1 Extensions and Optional maintained for all driving conditions to
Exhausts all hot and moving components.
NOTE: Where possible all pipe connections should
CAUTIONS: be designed so that the gas flows from smaller to
Non-standard systems must be tested for larger diameter pipes.
engine back pressure and all legal For some territories a side exhaust is available as
compliance (noise and emissions). a Special Vehicle Option on Chassis Cab.
Make sure that for any pipes that require
bending, the radius of the bend is
minimum 2.5x tube diameter.
Exhaust Pipe Design Principles
Item Description
d diameter
r radius = 2.5d
3.6.2 Exhaust Pipes and Supports

3.6.3 Exhaust Heat Shields
CAUTIONS:
Maintain the original set-up and heat
shields. Exhaust Heat Shields
Do not position any components closer • Catalytic converters, in particular, operate at
than 100mm (minimum clearance) to the high temperatures.
downpipe, the catalytic converter, the • Ensure existing shields are maintained.
diesel particulate filter and any part of
the exhaust system. • Add further shields over exhaust system as
necessary to avoid fire risk.

3 Powertrain
Standard Exhaust Heat Shields
CAUTION: Standard heat shields are

available from your local dealer and can
easily be fitted. Additional heat shields
may be required over the modified
exhaust system, particularly in areas of
close proximity to the floor.
Advisory Service at [email protected].
3.6.4 Diesel Particulate Filter (DPF)

The DPF forms part of the emissions reduction
systems fitted to your vehicle. It filters harmful
diesel particulate's (soot) from the exhaust gas.
Regeneration
WARNING: Do not park or idle your
vehicle over dry leaves, dry grass or other
combustible material. The DPF
regeneration process creates very high
exhaust gas temperatures. The exhaust
will radiate a considerable amount of
heat during and after DPF regeneration
and after you have switched the engine
off. This is a potential fire hazard.
Unlike a normal filter which requires periodic
replacement, the DPF has been designed to
regenerate, or clean itself to maintain operating
efficiency. The regeneration process takes place
automatically. However, some driving conditions
mean that you may need to support the
regeneration process.
If you drive only short distances or your journeys
contain frequent stopping and starting, occasional
trips with the following conditions could assist
the regeneration process:
• Drive your vehicle, preferably on a main road
or motor way, for up to 20 minutes avoiding
prolonged idling, but always observing speed
limits and road conditions.
• Do not switch off the ignition.
• Use a lower gear than normal to maintain a
higher engine speed during this journey, where
appropriate.
3.6.5 Vehicle Exhaust Systems - Vans

with Bulkheads
Vehicles exhaust systems for vans with bulkheads,
Diesel without cDPF, are available in two lengths;
a short length exhaust finishing approximately in
the center of the vehicle, which is standard fit, and
a long exhaust finishing at the rear of the vehicle.
If you are undertaking any modification to the load
compartment of the vehicle, especially in the
lower half of the vehicle, ensure that the most
suitable length of exhaust is used to avoid exhaust
gas ingress into the vehicle.

3 Powertrain 3.7 Fuel System
WARNINGS: • Refit the Ford hose assembly from the fuel
pump to the fuel line.
Do not remove or relocate fuel cooler
when modifying vehicle. • The tube and/or line must be routed
independently and secured to the body
103L fuel tank is supplied with a structure or to suitable brackets.
protection shield. Do not remove
protection shield. CAUTIONS:
Do not cut into the original fuel supply Ensure modifications to vehicle do not
lines. obstruct airflow to fuel cooler.
Make sure that the modified vehicle Make sure that sufficient clearance is
complies with all relevant legal maintained for all driving conditions to
requirements. all hot and moving components.
For auxiliary applications requiring a fuel supply, Make sure that when the port is cut that
it is advisable to use the auxiliary fuel supply port it is smooth with no sharp edges or burrs.
as shown in the figure E78195.
NOTE: Do not fasten anything to existing electrical
• The auxiliary fuel supply port is mounted on the components, wires or fuel lines.
top of the fuel sender unit located on the top
of the fuel tank, for applications such as an NOTE: To ensure the correct functionality of the
auxiliary heater or fuel fired hand wash facility. fuel cooler, sufficient clearances are required
around the fuel cooler for air flow, see figure
• Ensure that a suitable fuel shut-off is fitted in E118767 and table for recommended clearances.
any unique system.

3 Powertrain
Fuel Cooler Clearance Zone for Air Flow
Item Description
1 Center Line Front Wheel Axle
2 Center Line B - Pillar
A 295mm
B 625mm
C 295mm
D 555mm

3 Powertrain
Auxiliary Fuel Supply Port Option - For all vehicles except Campers.
Item Description
1 Original Ford fuel line, CC11-9N126-A_
2 Cut off top of port of diesel delivery module flange leaving 19.64 +/- 0.12mm and carefully insert
heater tube, 8C1V-9T308-A_
3 Fix quick fit connector of fuel line, CC11-9N126-A_, to heater tube
4 Drive Direction

3 Powertrain
Auxiliary Fuel Line Supply Port - For Camper vehicles
Item Description
1 Auxiliary Fuel Line (standard on all Campers)
2 Auxiliary Fuel Supply Connection Port. Recommended mating part: Multilayer PA12 hose/Wall
thickness 1mm / Outer diameter minimum 4mm / min. Pressing length 18mm +/- 1mm.
3 Fuel Take Off is standard with both 80L fuel tank and optional 103L fuel tank.
4 Drive Direction

3 Powertrain
Side View of 80L and103L Fuel Tanks
Item Description
1 80L Fuel Tank - Standard on all Transits
2 103L Fuel Tank option - Only available on Rear Wheel Drive (not short wheel base or petrol
engine) Transits
3 73mm
4 50mm
5 Drive Direction

4 Electrical
4.1 Wiring Installation and Routing Guides
4.1.1 Wiring Harness Information A minimum 25mm clearance is recommended
from all sharp edges and a minimum 35mm
NOTE: Ford Motor Company has no control over clearance of all moving parts of the parking brake
the modification or installation process of the assembly. If these clearances can not be met,
electrical content of auxilliary systems and protect the wires with a convolute.
therefore can take no responsibility for such
installations.
4.1.5 Grounding
The following provides an installation guide for
any electrical modifications or additional systems Drill point screws are not to be used for any ground
being added to the vehicle. The aim is to maintain attachments.
robust integration of auxilliary systems without
• Do not ground to moving structures, for
compromising existing systems, in areas such as
example: doors, deck lids, tailgates, as the
splicing techniques into existing wiring, module
ground return path through the hinges is not
package location and EMC issues. It is also
reliable.
expected that the vehicle converter will test their
installation and comply to all legal and • Do not place more than 2 eyelet terminals
homologation requirements. under a single ground screw.
• Do not place electrical component
attachments or ground screws adjacent to
4.1.2 General Wiring and Routing vehicle fuel tanks or fuel lines.
Temperature requirements: Wiring systems in the
vehicle interior are expected to function over the 4.1.6 Prevention of Squeaks and
temperature ranges of – 40 °C to 85 °C for Rattles
exposure and – 40 °C to 75 °C for function. For
engine compartment and underbody, the Wiring should be positively retained every 150 to
minimum temperature is - 40 °C, while the 250 mm. All connectors should be positively
maximum exposure and operational temperatures retained. Use tapes which do not squeak against
are +125 °C for exposure and 105 °C for metal or plastic.
operational.
Make sure that the insulation is compatible with 4.1.7 Water Leakage Prevention
any fluids it may encounter , for example: gasoline,
oil, antifreeze, brake fluid, transmission fluid and Make sure that drip loops are provided to prevent
power steering fluid. water leakage into the vehicle interior, passenger
If a connector will be located in a hostile and cargo compartments, using wiring assemblies
environment or wet area use a sealed connector. that pass from outside into the vehicle interior.
"Hostile environment" areas include the engine The drip loop is a section of wiring that is
compartment, wheel wells, underbody and doors. deliberately formed and routed BELOW the point
of entry into the vehicle, so that gravity assists in
forming water droplets that escape from the
4.1.3 Connector Pin Out Practices lowest part of the wiring.
When designing a harness to component Wiring from door to passenger compartment,

connection, it is best practice to put the female should be made such that the door entry point is
terminals in the harness side connection and the below the passenger compartment entry point,
male terminals in the component side. When which creates a type of drip loop.
determining connector pin outs, make sure that
power and ground circuits are not in close 4.1.8 Wiring Splicing Procedures
proximity, adjacent, to one another. A minimum
separation of 5 mm between power and ground TYCO-RAYCHEM crimp splices
circuits is required.
4.1.4 Harness Routing

Do not route wires near weld points or weld
flashes. A minimum of 15 mm clearance to any
sheet metal welds under static and dynamic
conditions is required. However, it is best to avoid
routing near weld points or weld flash points at
all times.
In general, the distance between retention points
for wiring not contained in a rigid shield should be
less than 300 mm.

4 Electrical Ford Motor Company strongly advises against the This section shows the 'NO DRILL' zones for the
use of wire splicing due to the variable and rear cargo area, for example: when installing
unpredictable nature of making robust, durable cladding and racking. The areas marked in blue on
and reliable connections. However, if it is deemed the following figures indicate where there is wire
that a wire splice is absolutely unavoidable, it must routing and is to be avoided. The same care should
be made with DuraSeal Heat-Shrinkable, also be taken when using self tapping screws. Not
Environmentally Sealed, Nylon-Insulated all derivatives are shown but the routing is the
Crimp Splices (manufactured by same for roof line and wheel base with regards to
TYCO-RAYCHEM). For example the D406 series. B, C and D pillars or roof bows and doors. Other
As a further process to improve the splice integrity, non electrical systems may also be present, for
the splice should be further sealed with a suitable example: fuel tank under floor so it is important to
heat shrink tubing. See Figure E131081. check before drilling. For additional information
refer to the following links.
4.1.9 No Drill Zones - Rear Cargo Area Refer to: 5.1 Body (page 234).
No Drill Zones -Under the Floor Tank
CAUTION: Do not drill into the vehicle Refer to: 5.4 (page 268).
before checking 'No Drill' zones and Load Compartment Tie Downs
electrical wire routing. Refer to: 5.3 Racking Systems (page 263).
Refer to: 5.6 Body Closures (page 274).
No Drill Zones - Closures
Short Wheel Base, Low Roof with Lift Gate - Right Hand Side

4 Electrical
Short Wheel Base, Low Roof - Lift Gate
Short Wheel Base, Low Roof with Lift Gate - Left Hand Side

4 Electrical
Medium Wheel Base, Medium Roof , Same as High Roof, Double Doors - Right Hand Side
Medium Wheel Base, Medium Roof , Same as High Roof - Double Doors

4 Electrical
Medium Wheel Base, Medium Roof, Same as High Roof, Double Doors - Left Hand Side

4 Electrical 4.2 Wiring Harnesses
4.2.1 Roof Mounted Front and Rear Beacons
Roof Mounted Front and Rear Beacon Wiring Routing (Right Hand Drive Shown)
Item Description
A 6C1V-10A933-C_
B 6C1V-10A933-D_
1 Inline to SVO harness (passenger side)
2 Inline connector
3 Connection to rear beacon
4 Connection to front beacon
The figures E102611 outline the routing for front There are two options available. JZFAB is the single
and rear beacon wiring installations, which should front mounted beacon wiring harness,
be viewed in conjunction with the fitment of the 6C1V-10A933-C_ and JZFAC is the additional rear
Special Vehicle Option (SVO) auxiliary fuse box, mounted beacon harness, 6C1V-10A933-D_. This
if required. Note: there is sufficient length in the is connected at point 2 shown in the above figure
rear harness for the beacon to be positioned on E102611 to a spare connector, Delphi part number
either side. 15326870, shown in the next figure E118454 on the
single beacon wiring harness.
SVO Auxiliary Fuse Box. The fuse box can also be JZFAC is only available with JZFAB.
used with the beacon switch harness For Chassis Cab vehicles, only the JZFAB (front
(6C1V-14A303-D_) and the beacon switch roof mounted beacon wiring) option is available.
(6C1V-13D768-A_).
Contact your National Sales Company
representative or Local Ford Dealer for availability
and options.

4 Electrical
Connector Delphi Part Number 15326870
Item Description
A Ground *
B 12V+ve *
* In-line connector on harness 6C1V-10A933-C_, mating with in-line connector on harness
6C1V-10A933-D_
Connector For Part Number 89FG-14489-ABB
Item Description
1 Ground *
2 12V+ve *
* Connector 89FG-14489-ABB on wiring harnesses 6C1V-10A933-CB/DB to beacon connector
89FG-14A459-ABB
The beacon wiring circuit is fused at 15 Amps and

can support a current supply of 14 Amps. any
increase in this current demand should be met
with the use of an external relay. The connector
89FG-14489-A_ from the harness to the beacon
is shown in figure E118455.

4 Electrical
Connector Delphi Part Number 15326874
Item Description
1 Ground *
2 12V+ve *
* Used for the in-line connection on rear beacon harness and for connecting front beacon harness
to the SVO fuse box.
The connector, Delphi Part Number 15326874 Beacon Switch

shown in figure E118456 connects the SVO Fuse
Box to the wiring assembly (6C1V-10A933-C_). It
is also used on the rear beacon harness
(6C1V-10A933-D_) as the in-line connector mating
with the in-line connector 15326870 on the front
beacon harness 6C1V-10A933-C_.
Item Description
1 Beacon Switch

4 Electrical
4.2.2 Wiring Harness Installation and Routing
Electromagnetic Compatibility (EMC) WARNING: Do not route other wiring

Awareness near/close to electrical cables with the
Anti-lock Brake System and Traction
The installation and routing of Ford wiring Control System cables because of
(including those provided as part of accessory kits extraneous signal risk. It is generally not
such as trailer tow) have been fully-validated and recommended to hang it off existing
have passed the requisite EMC tests. Ford Motor looms or pipes.
Company; however, are not responsible for the
Wiring must be suitably fixed without any
vehicle’s EMC immunity when non-Ford-approved
detrimental effect on other wiring.
systems are installed.
Single or bunched looms must maintain the
following clearances:
• 10mm from static components (unless
clamped to it).
• 250mm from exhaust system.
• 30mm from rotating or moving components.

4 Electrical Routing Wires Through Sheet Metal
Left Hand Drive Dash Panel
Item Description
1 East/West Engine and Tachograph
2 Available
3 Global Site Management antenna
4 Available
5 Available
Wires/looms passing through sheet metal must Typically two sizes of hole are recommended:
be through protective grommets that also ensure • Grommet to suit with hole size 40mm diameter
a watertight seal. Adhesive or tape is not for dash panel – bunched loom.
acceptable.
• Grommet to suit with hole size 30mm diameter
CAUTION: Do not feed additional wires for dash panel – up to three (3) wires.
through existing ‘occupied’ grommets.
WARNING: Holes must permit the
A number of locations in the dash panel have been appropriate connector to pass through.
identified for additional holes to route wires
through. See figures E74496 Left Hand and
E74497 Right Hand Drive Dash Panels for
locations. The selection of suitable locations will
depend on the vehicle specification – please check
that the immediate surrounding area is free from
obstructions and/or components to prevent
damage to critical systems, and that the grommet
will seal properly.

4 Electrical
Right Hand Drive Dash Panel
Item Description
1 East/West Engine and Tachograph
2 Available
3 Global Site Management antenna
4 Available
5 Available
4.2.3 Electrics for Tow bar Vehicles built after September 2007 will require
6C1T-15A416-A*, 6C1T-13B576-A* with
Tow bar electrical system may be ordered as a 6C1T-13B576-D* for 13pin OR 6C1V-13B576-A* if
13-pin DIN connector, as part of the original vehicle 7 pin required. Vehicles built before September
build. 2007 will required an additional harness
6C1T-13N490.
Where it is required to add trailer towing to an
existing vehicle, and to ensure compliance with NOTE: For Van tow bars it is necessary to connect
lighting regulations, the appropriate wiring into the rear lamp unit.
accessory kit can be obtained from your Ford For information, there is no trailer tell-tale in the
Dealer. cluster, and if equipped with the Ford Trailer Tow
Fitment of non-Ford trailer tow wiring is not module, the vehicle’s rear fog lights are disabled
advisable due to Central Junction Box control of when a trailer is hitched-up.
lighting, and meeting legal lighting regulations. A 7-pin trailer tow sub-harness is released by SVO
Contact your local Ford dealer for details of a (part number 6C1V-13B576-A*); currently there
harness that connects to the base vehicle harness. is no 7+7 sub-harness available, but figure E84722
All Transits are provided with a basic trailer tow is a proposal detailing the connectivity from the
interface - this connector is located on the left in-line near the rear of the vehicle. The electrical
hand side of the engine compartment. Some schematics for the 13-pin trailer tow system form
vehicles built after September 2007 will have part of the workshop manual.
trailer tow circuits as part of the 14401 chassis Also
loom. This would therefore not require the 13N490
loom to be fitted. However, the 13B576 looms and Refer to: 1.17 Towing (page 46).
trailer tow module will still be required

4 Electrical
Trailer Tow Connectivity - Trailer Tow, 12N & 12S Sockets
Item Description
A 13N490 Harness
X Tubes
Y Pins
If an FCSD aftermarket trailer tow kit for the WARNING: Depending on the vehicle's
previous model Transit is used, please follow the lighting configuration, the Central
instructions as per the installation manual. For Junction Box (CJB) will not support trailer
connection to the battery (KL30), there are three direction indicators wired directly to the
terminal posts on the Engine junction Box, vehicle's direction indicators. If this is
accessible by removing the black cover. Any KL30 attempted, the relevant CJB circuits may
(permanent B+) trailer tow wires should be shut down or perform illegally.
connected to the foremost stud. For those systems
The Central Junction Box (CJB) does not support
requiring a KL15 (ignition feed), because of the
the incremental load of powering side marker
potential loads, this should be obtained via a relay
lamps on a trailer, if these are required they should
that is energized from an ignition feed, switching
also be driven using separate relays, as above.
a KL30 supply from one of the customer
connection points. NOTE: The trailer detect circuit is part of the Ford
Trailer Tow module – it can not be implemented
The Ford trailer tow system is designed to support
separately – and is only operational on vehicles
one primary set of direction indicators installed on
fitted with power locking and Perimeter or CAT 1
to the trailer (left hand side and right hand side).
alarms.
If additional direction indicators are required, for
example for tall horse boxes, these should be NOTE: If tow bar connectors are not used,
driven using separate relays with the coils being appropriate fixing and cover must be applied for
energized via the respective primary direction protection from water and contaminant ingress.
indicator feeds, and power to the bulbs being
derived from the KL30 (B+) line.

4 Electrical
Trailer Tow Bar Interface Connector for Van, Bus and Kombi
For aftermarket fit, remove the cap from the

4-way connector A on the main harness (14401)
and connect the trailer tow harness (13N490)
connector, as shown in E76102.
Van, Bus and Kombi Connection in Engine Bay

Connector A
1 Not Used
2 KL30 - Battery +
3 KL15 - Ignition
4 Trailer Detect

4 Electrical
Trailer Tow Bar Interface Connector for Chassis Cab (Front Left Hand)
For aftermarket fit, disconnect the existing 16-way

connector B of the underbody harness (14406)
and connect this to connector C on the trailer tow
harness (13N490). Connect the other connector
of the trailer tow harness to the vacant connector
A on the main harness (14401), as shown in E76101.
Chassis Cab Connection in Engine Bay (with Trailer Tow Harness 'C' between Connectors)
Connector A
1 Ground - Float Markers, Right Licence Plate 9 KL30 - Battery +
and Lamps (direction indicator, position/
park lamp, fog lamp, reversing lamp, stop
lamp).
2 Rear Fog Lamps 10 Direction Indicator Right Supply
3 Brake Lamps 11 Licence Plate and Float Marker Lamps
4 Direction Indicator Rear Left Supply 12 Not Used
5 Rear Right Position/Park Lamp 13 Not Used
6 Reversing Lamps 14 Not Used
7 Rear Left Position/Park Lamp 15 Trailer Detect
8 Ground - Left Licence Plate and Lamps 16 KL15 - Ignition
(direction indicator, position lamp, fog lamp,
reversing lamp, stop lamp).

4 Electrical
4.3 Communications Network
4.3.1 CAN-Bus System Description and CAN, Controller Area Network, uses propriety
Interface message sets to communicate between the
devices shown, via Medium Speed (MS), High
WARNING: Do not tamper with, cut into Speed (HS), Private and Public Buses. In addition
or connect to any of the CAN-Bus there is localised application of LIN and ISO 9141
interface wiring or connectors. The K-line serial links.
addition of unapproved CAN-Based
modules could impact the safe operation
of the vehicle.
CAN-Bus System
Item Description
1 High Speed CAN
2 Medium Speed CAN
3 Medium Speed CAN(Multimedia)
4 ISO9141 K-line
5 LIN BUS
6 Private High Speed CAN

4 Electrical
CAN-Bus System (Architecture)
A Central Junction Box (Passenger Junction L Powertrain Control Module
Box)
B Voice Recognition Module/Wireless M Steering Angle Sensor
connection (blue tooth)
C* Audio Control Unit (Radio/CD) N Yaw Rate Sensor
D* Navigation (Radio/CD) P Diagnostic Connector
E Remote Keyless Entry Q Park Aid Mode
F Passive Anti-Theft System R Restraints Control Module
G Rain Sensor S Hybrid Electronic Cluster
H Battery Backed Sounder (BBS) T AWD Control Module
J Interior Motion Sensing (IMS) U Battery Monitoring Sensor Start Battery
K Antilock Brake System V Battery Monitoring Sensor Auxilary
Battery
* Either Audio Control Unit or Navigation Vehicle (Central Junction Box)

configuration shall NOT be modified once
4.3.2 Central Junction Box (CJB) the vehicle has left a Ford production
plant, except for any changes that may
WARNINGS: be carried out using dealership Integrated
diagnostic systems equipment.
Unapproved and/or incorrect connection
to any of the mating wiring can cause Basic vehicle functions (for example: headlights,
either the associated systems to shut front wipers) are available on all Central Junction
down (overload protection), or Boxes (CJBs). Increased vehicle features are
permanent damage to the Central available on the mid- and high-level CJBs, as per
Junction Box itself. the following table:
Central Junction Box (CJB) Incremental Functionality

6C1T-14A073-A_ (low)
6C1T-14A073-B_ (mid) (in addition to low level CJB)
Remote Keyless Entry Reverse Cycling
VIN Identification Slam Locking
Perimeter Alarm Front Fog Lights
Central and double Locking Theatre Dimming (Interior Lights)
Zonal unlocking Heated Windscreen
Auto Locking on drive away Heated Mirrors
Auto Relocking on time out Rear Wipers
Crash Activated unlocking Heated Rear Window(s)
Mis-locking feedback (audible
and visual)
6C1T-14A073-C_ (high) (in addition to mid-level CJB)
Battery Backed Sounder (BBS) Ambient air temperature measure-
ment
Interior Motion Sensor (IMS) Rain Sensor
Zonal opposite door relocking Daytime Running Lights
Configurable unlocking Autolamps
CAT 1 Alarm (BBS, IMS & Rear Fuel Pump Control (petrol only)
Glass Breakage)
Cruise control

4 Electrical
The Central Junction Box (CJB) is the prime
control module in the vehicle’s electrical
architecture. It is responsible for management of
most of the vehicle’s lighting, locking and security
systems. The following chart details the
consequences of overloading of the Central
Junction Box.
Maximum Loads on Central Junction Box

Function Component Load Type Maximum Overload Condition
Load
Battery Discon- Low Side Driver Relay 5A/100msec Output driver damage
nect Switch
Entry Illumina- Low Side Driver Bulb 75W@13V Overheat - output shutdown
tion
Alarm Siren High Side Driver Electro-mechan- 8A normal, 16A/ Overheat - output shutdown
ical horn 10msec in-rush
Accelerator Voltage tracker Logic supply 25mA Output shutdown if more
Pedal than 35mA drawn
Battery Saver Relay Bulb 100W@13V Blown fuse - if bigger fuse
Supply fitted, relay and/or printed
circuit board damaged
Licence Plate Relay Bulb 60W@13V Blown fuse - if bigger fuse
fitted, relay and/or printed
Cluster Dimming High Side Driver Bulb 11W@13V Overheat-output shutdown
Position/Park Relay Bulb 63W@13V Blown fuse - if bigger fuse
Lamp Left Hand fitted, relay and/or printed
Position/Park Relay Bulb 43W@13V Blown fuse - if bigger fuse
Lamp Right fitted, relay and/or printed
Hand circuit board damaged
Turn Indicator Bulb 3x21W@13V Output driver damage
Left Hand
Turn Indicator Bulb 3x21W@13V Output driver damage
Right Hand
Lock/double Relay Latch 15A (fuse Blown fuse - if bigger fuse
lock limited) fitted, relay and/or printed
Unlock Relay Latch 5,42A@13V, Relay and/or printed circuit
2,5mh board damaged

4 Electrical
Central Junction Box - as viewed in-car position
Item Description
A Part label
4.3.3 Circuit Diagram • Additional earth returns should be included to

support new equipment.
When designing electrical circuits, or making
• A supplementary circuit diagram and
alterations, the following must be considered:
accompanying instructions should be added to
• Current rating of wiring, see following the Owner’s Information or a separate Manual
specification chart (Current Rating of Wire supplied with the vehicle for each unique
Sizes). component.
• Any voltage drop in the circuit should not lower NOTE: For further information please contact your
the terminal voltage at consumption point to local National Sales Company representative, or
below 95% of battery voltage. Local Ford Dealer.
• Do not cut into the original loom.

4 Electrical
4.4 Module Communications Network—Specifications
4.4.1 Circit Diagram

Note: The Max Continuous Current (A) values for
30°c and 50°c is a value below the maximum
fuse rating allowed for the cable. This is because
the fuse /cable system values at these
temperatures are the continuous usage where as
the maximum fuse also needs to protect for high
current short term loadings such as electric
motors.
Current Rating of Wire Sizes

Maximum Continuous current (A)
Cross Sectional Area mW/m@20°C 30°c 50°c
0.22 84.8 - -
0.35 54.4 7 4.9
0.5 37.1 11 7.7
0.75 24.7 14 9.8
1 18.5 19 13.5
1.5 12.7 24 17.0
2.5 7.6 32 22.7
4 4.71 42 29.8
6 3.14 54 38.3
10 1.82 73 51.8
16 1.16 98 69.6
25 0.743 129 91.6
35 0.527 158 112
50 0.368 198 140
70 0.259 245 174
95 0.196 292 207
120 0.153 344 244

4 Electrical 4.5 Charging System
4.5.1 General Information and Specific The Transit utilizes multiplexed vehicle electronics
Warnings - it is recommended that the appropriate Ford
proprietary accessory systems are used.
The Transit electrical system is a 12-Volt supply Inappropriate or incorrect connection of additional
with a negative ground return. The alternator and equipment could cause mis-operation, or damage
battery equipment used as standard are designed to the vehicle, and so invalidate any warranty.
for normal operations with the type of engine Additional connection points are provided
fitted. Higher capacity batteries are available as specifically for customer use (except M1 and M2
standard production options and special vehicle Bus and Camper Vans), and are located on the
options. Before installing additional electrical outside of the driver's seat pedestal. Camper
equipment check that the battery capacity, derivatives are provided with single 60 Amp feed
harness load capability, and alternator output are on the outside of the passenger seat pedestal.
suitable for the extra load.
Do not jump-start the vehicle directly from the
The battery capacity and charge available from battery. Use designated jump-start points. Refer
the alternator must be adequate to ensure engine to the owners literature - the wiper motor bracket
cranking in unfavorable climatic conditions but must not be used as a ground as it is isolated
excessive battery capacity could damage the from the body.
starter motor.

4 Electrical
4.5.2 System Operation and Component Description
System Diagram
Item Description
1 Power Control Module (PCM) or Engine Control Module (ECM)
2 Passenger Junction Box (PJB) or Body Control Module (BCM)
3 Battery Monitoring Sensor (BMS) - Where fitted
4 Battery - for Start/Stop application there will be two batteries
5 Electrical consumers
6 Alternator

4 Electrical System Operation - Smart Regenerative Comparison of SRC and Conventional
Charging (SRC) - Introduced 26th Charging
September 2011 (Except Camper and
Thatcham Catagory 1 Vehicles). E140419 demonstrates the difference between
SRC and conventional battery charging.
The largest element of the SRC strategy is stored Conventional charging aims to charge the battery
in the PJB. It receives all of the important to the highest possible levels. During this process
information relating to the battery condition sent the battery temperature is monitored (inferred
by the BMS via the LIN (local interconnect temperature) and the battery must not be
network) data bus. overcharged. By comparison SRC uses the
information from the battery monitoring sensor
Using the information received, the PJB then sends
(voltage, current and direct temperature) to
the set value needed for the alternator charging
maintain, more accurately, the battery at a
voltage via the MS CAN (controller area network)
calibrated state of charge. This means that the
data bus to the PCM/ECM. This then adjusts the
battery has a certain amount of extra charging
value received if necessary and passes it on the
capacity at all times. If the PCM detects that the
alternator via the LIN (Local Interconnect
charge status is above the calibrated value the
Network). The charging voltage is adjusted
alternator charging voltage is reduced, in order to
depending on various parameters, such as the
discharge the battery. If the opposite occurs and
current level of engine efficiency. The smallest
too low a value is detected, the charging value is
possible set value for the alternator voltage (V) is
increased in order to return the battery to the
12.2V, while the maximum charging voltage may
calibrated value.
be anywhere between 14.5V and 14.9V. However,
when the battery is in a refresh phase, the voltage
could occasionally reach up to 15.2V. These refresh
phases are required as the battery charge status
is 80% over long periods of time.

4 Electrical
Smart Regenerative charging and Conventional Charging
Item Description
A State of Charge -SOC
B Conventional Charging
C Regenerative Charging
D Charging continuously
E Charging during deceleration
F Discharge during normal driving
1 High SOC control target
2 Partial SOC control
3 Micro-cycling < 1% SOC
4.5.3 Power Management Settings Factory and Transport modes are only active with
ignition off; with ignition on, the vehicle operates
WARNING: The only method to return the with full functionality. When in Transport mode,
vehicle to Transport Mode is by using a the interior lights, clocks, and power locking and
Ford Diagnostic Service tool with the alarms (where fitted) do not work. It is possible
correct level of security clearance. The to switch from Transport Mode to Normal Mode
Ford dealer has the correct tools and without the use of any ancillary equipment, but
level of security to do this if required. not vice versa. To change mode, the brake pedal
must be depressed five times, and the hazard
There are four Power Management Settings
warning switch operated twice (in any
available; Factory, Transport, Normal and Crash.
combination) within 10 seconds.

4 Electrical If a vehicle is received from the dealer where • The effect of regulations governing the
modules do not seem to be functioning correctly, proposed conversion including National
please contact the dealer as the vehicle may still Legislation in the country of sale.
be in Transport Mode. Transport Mode is mainly • The method of integrating the circuit into the
used to conserve battery life/warranty. The normal base vehicle.
process is for the pre delivery phase to change the
• No additional circuits are to be run alongside
vehicle from Transport Mode to Normal Mode.
the electrical circuits (shown in blue in figure
E84706) associated with the Engine
4.5.4 Electrical Conversions Management System (shown in green in figure
E84706), due to the possible inductive or
WARNING: The fitting of voltage boosters electrostatic coupling of electrical interference.
or other devices to enhance alternator • The base vehicle is equipped with either a single
output are not allowed. The fitting of such or dual battery system (with battery disconnect
devices will not only invalidate vehicle switch). Additional batteries can be fitted in
warranties, but could damage either or conjunction with a battery disconnect switch
both, the alternator and EMS/PCM, and (cut-off relay), described in the section 'Battery
possibly affect vehicle legal compliance. and Cables'. It is important to also read relative
Check local legislation. information on Start-Stop and SRC
Operator requirements for additional and Refer to: 4.6 Battery and Cables (page 127).
specialized electrical equipment varies. The vehicle • When auxiliary electrical systems are added to
converter/modifier must, therefore, consider the the vehicle, it is recommended that the
following points when designing the installation: additional circuits are designed to be used with
• Legality and regulatory conformity of the base the Special Vehicle Option Auxiliary Fuse Box
vehicle. and / or the Link Harnesses, to maintain the
• Drive-ability and serviceability of the base integrity of the electrical system.
vehicle. Refer to: 4.17 Fuses and Relays (page 177).
Electrical circuits associated with Management System
• The materials and installation must meet the • The alternator and Engine Management System
quality standards described in this section. -EMS (also referred to as Powertrain Control
• Any additional equipment or components must Module -PCM) are interdependent.
be designed such that they have no adverse
Electro Magnetic Compatibility - EMC effect on
the vehicle.

4 Electrical
• The alternator should not be used as a source • If welding or cutting is to be performed directly
for a conventional D+ signal. near a control module, it must be removed
before hand.
Refer to: 4.10 Electronic Engine Controls (page
144). • Never connect the negative cable of the welder
near an airbag or a control module.
• Take special care with the routing of existing
electrical looms within the vehicle to avoid • Connect the negative cable of the welder close
damage when fitting additional equipment. to the location of the weld.
Please see below the note concerning installation
of equipment containing an electric motor. 4.5.5 Fitting Equipment Containing
Where vehicles are equipped with a twin battery
Electric Motors
system, no additional connections should be
WARNING: When electric motors are to
made to the terminal posts of the start relevant
be fitted, account must be taken of the
battery. Further connections should only be made
potentially high in-rush currents that a
via the customer connection point.
motor can draw.
Vehicles built before 26th September 2011,
Camper or Thatcham Catagory 1 vehicles, when CAUTION: The following must be
fitting an additional battery, this must be observed:
connected to the auxiliary battery. If high loads • All motors must be driven via relays with
are to be supplied, exceeding the customer contacts rated at least 3 times the maximum
connection point supplies or high in general, rated current of the motor.
especially at ignition off loads, an isolation switch • All motor supply circuits must be individually
disconnect relay should be fitted. This is to protect fused with the proper fuse rating for the motor.
the vehicle start battery from a failed start. • All power wiring must be rated for at least 3
Suitable capacity in the wiring, fuses and times the rating of the motor and installed as
alternator will be required. If unsure of which far away as possible from any existing vehicle
battery to interface with or what system wiring.
requirements are needed, please contact your
local dealer who can advise. • All motors fitted should be fully suppressed to
the relevant sections of Ford specification
Refer to: 4.6 Battery and Cables (page 127). ES-XW7T-1A278-A* to ensure electrical
• Before disconnecting the battery, check interference does not affect the vehicle
availability of radio key code. systems.
• Fuses – when auxiliary electrical systems are • Add EMC emissions statement to CE approval.
to be added to the vehicle it is mandatory that
the additional circuit design includes the 4.5.6 Vehicle Electrical Capacity -
necessary fuses. Alternator
• The Special Vehicle Option auxiliary fuse box
is recommended. WARNING: Do not cut into the alternator
Refer to: 4.17 Fuses and Relays (page 177). wires or use the alternator as a source to
obtain a 'D+ Signal'.
Increased use of comfort and safety electronics
in modern motor vehicles also requires the An engine run signal is available from the Central
greatest attention to be paid during body work. Junction Box by installing a T-piece jumper
Over-voltages produced during welding and in harness (Ford Part Number 6C1V-14A411-F*). For
alignment work during body shell rectification may vehicles built after August 2006, this signal take
cause electronic systems to be damaged. In off point (connector) is standard on all vehicles
particular, the safety instructions for performing and is packed in the IP, behind the glove box.
welding / cutting work on vehicles with airbag Refer to: 4.18 Special Conversions (page 190).
systems must be adhered to.
NOTE: After disconnecting the power supply and 4.5.7 Charge Balance Guidelines
before performing further work, a wait time of up
to 15 minutes must be maintained, depending on The base vehicle is fitted with a 150A alternator.
the vehicle. Work on airbag systems may only be It is recommended to conduct a charge balance
performed by persons who have a relevant calculation in case the conversion comprises a
certificate of competence. high number of electrical consumers or high
Pay attention to the following points: electrical consumption is expected.
• Disconnect all the batteries, including ground
and insulate the negative battery terminal(s). 4.5.8 Circuit Diagrams
• Disconnect the electrical connector at the
airbag control module. For circuit diagrams for Auxiliary Fuse Box
Connections and Standard Ford relays.
• Disconnect the alternator multi-plug prior to
using welding or cutting equipment. Refer to: 4.17 Fuses and Relays (page 177).
Full vehicle wiring and circuit diagrams are in the
Ford Workshop Manual.

4 Electrical NOTE: For further information please contact your

4 Electrical
4.6 Battery and Cables
4.6.1 Battery Information When the battery is installed and connected to
the vehicle's electrical system with no load, the
NOTE: Most front wheel drive vehicles are fitted Closed Circuit Voltage (CCV) must not be less
with a single battery. If a converter intends to add than 12.65 volts for vehicles built before 26th
systems or accessories that will add significant September 2011 or 12.4 volts for vehicles built after
electrical load (particularly at key off), then 26th September 2011.
vehicles fitted with twin batteries should be When the vehicle is released to the customer, the
specified/adopted. CCV must not be less than 12.50 volts for vehicles
In order to protect the battery system from direct built before 26th September 2011 or 12.3 volts for
ground shorts or continuous high current loads, a vehicles built after 26th September 2011.
350 Amp mega fuse is fitted in the pre-fuse box All voltages are to be measured with an accuracy
under the driver’s seat. of: + /– 5% of values published.
This fuse is not repairable – use only a Ford
replacement part.
Surface Charge Dissipation
If a battery (or batteries) is disconnected, there
is no requirement to reprogram the vehicle; the Prior to carrying out manual voltage checks, it is
vehicle retains its ‘normal’ power management necessary to establish that the battery voltage is
setting and remembers exactly what its previous stable and free from surface charges, that could
configuration was (although the central locking be present due to certain engine run conditions
latches may cycle if one of these was opened making the voltage readings unreliable and
manually in the intervening period). With the radio, inaccurate.
all of the settings are retained, but the key code
needs to be entered to restore functionality, and To ensure surface charges are not present the
if the vehicle has a high series cluster, the clock following actions are recommended:
will need resetting. 1. Turn the ignition key to position II and switch
With the ‘always start’ twin battery system, on the headlamps (main beam) and if fitted,
aftermarket battery management systems should the heated front window, rear window demister
no longer be needed unless battery level and the heater blower motor (on position II).
monitoring is a customer requirement. On vehicles Leave the vehicle in this condition for at least
so specified, main vehicle lighting comes from the 1 minute to dissipate what ever surface charge
non-start-relevant battery – the start-relevant is present in the battery.
battery is only engaged when the engine is 2. Turn the ignition key to position 0 and switch
running. Therefore should the customer wish to off the loads; headlamps, heated
have the lights on without the engine running, the windshield/rear window demister and heater
primary, or start-relevant battery will not be blower motor. Leave the vehicle in this
drained. Note: the exception to this is the hazard condition for at least 5 minutes, before taking
warning lights, which for safety/legal reasons are a battery voltage reading.
fed from the start-relevant battery.
Where extra batteries are required on vehicles
with a single battery installation, the battery Delayed Vehicles
disconnect switch (SureStart® relay) and
Vehicles held at the vehicle convertor premises
associated wiring/hardware, fitted as standard
and not in use for longer than 7 days, should have
to vehicles equipped with twin batteries, can be
the battery's negative cable disconnected. Before
added. For compatibility when adding extra
shipping to the customer, the battery negative
batteries a further disconnect switch is
cable must be re-connected and the voltage
recommended. For more information
re-checked. The voltage should be not less than
Refer to: 4.10 Electronic Engine Controls (page 12.5 volts. For additional information
144).
Refer to: 1.12 Vehicle Transportation Aids and
Start /Stop and for Smart Regenerative Charging
Vehicle Storage (page 29).
(SRC)
Battery Charging Procedure
Battery Voltage Requirements and 1. Cold batteries will not readily accept a charge.
Testing Therefore, batteries should be allowed to warm
up to approximately 5°C (41°F) before
To maximize battery life, at the time of arrival at
charging. This may require four to eight hours
the vehicle converter, all batteries must have a
at room temperature depending on the initial
minimum Open Circuit Voltage (OCV) of not less
temperature and battery size.
than 12.75 volts for vehicles built before 26th
September 2011 or 12.5 volts for vehicles built after 2. A battery which has been completely
26th September 2011. discharged may be slow to accept a charge
initially, and in some cases may not accept a

4 Electrical charge at the normal charger setting. When Battery Cable Fixing Torque
batteries are in this condition, charging can be
started by use of the dead battery switch on The battery cables should be fixed to the terminal
chargers that have this facility equipped. posts with a torque of 9.0 Nm -/+ 1.4 Nm for
3. To determine whether a battery is accepting a vehicles without Battery Monitoring Sensor (BMS).
charge, follow the manufacturers instructions Vehicles with BMS use a fixing torque of 6.0 Nm
for the charger, for use of the dead battery -/+ 1.5 Nm. See also 'Battery Monitoring Sensor
switch. If the switch is the spring-loaded type, (BMS)' information later in this section.
it should be held in the ON position for up to
three minutes.
Batteries – Additional – Heavy Duty
4. After releasing the dead battery switch and with
the charger still on, measure the battery High current consumption, for example, tippers
voltage. If it shows 12 volts or higher, the battery and lift mechanisms, additional lighting, may
is accepting a charge and is capable of being require heavier duty batteries (80Ah instead of
recharged. However, it may require up to two 60Ah for twin battery systems) or an additional
hours of charging, with batteries colder than 80Ah battery (single battery systems).
5°C (41°F) before the charge rate is high
enough to show a charge on a ammeter. It has Factory fitted Special Vehicle Options are available
been found that all non-damaged batteries can for heavy-duty and/or extra batteries with the
be charged by this procedure. If a battery battery disconnect switch (split charge relay).
cannot be charged by this procedure, a new one The batteries can be retrofitted.
should be installed.
See figure E74522 - Battery Disconnect Switch
5. A rapid recharge procedure has been developed (Split Charge Relay) Circuit, later in this section.
for recharging batteries that have passed the
Load Test and only need a recharge. This can
be due to in-service no-start battery failures Deep Cycle Battery
(vehicle will not crank due to low battery state
of charge) or battery discharged in vehicle due A Special Vehicle Option is available. Please
to key-off loads. contact your local National Sales Company
6. With the cables then disconnected, the battery representative for availability and details.
can be rapidly recharged by using either of the
• The deep cycle battery is used in conjunction
following methods:
with the battery disconnect switch (split charge
• Carry out a two hour charge using 20A constant relay) in applications where power to ancillary
current (manual setting on charger). circuits would heavily discharge the main
• Carry out a two hour charge using a constant vehicle battery(s).
potential (automatic setting on charger). • Installation should be under the driver's seat.
When the deep cycle battery is installed, the
battery disconnect switch (split charge relay) must
be used.
• When the Deep Cycle Battery is installed it is
recommended that the Special Vehicle Option
auxiliary fuse box is fed from the customer
connection points.

4 Electrical
Battery Part Numbers and Usage for vehicles built before 26th September 2011
Battery Part Number Type Quantity Size

Single Battery FWD
6C16-10655-C_ (Turkey) 700 CCA (80Ah @20 hour rate) 1 T7
6G9N 10655 P_ (Southampton) 700 CCA (80Ah @20 hour rate) 1 T7
Twin Battery RWD and FWD with specific options
6C16-10655-B_ (Turkey) 590 CCA (60Ah @20 hour rate) 2 T6
6G9N 10655 N_ (Southampton) 590 CCA (60Ah @20 hour rate) 2 T6
Twin Battery RWD -except M2 Bus (-29°C Territories and all I5 Engines)
Twin Battery RWD -M2 Bus (-29°C Territories)
6C16-10655-B_ (Turkey) 590 CCA (60Ah @ 20 hour rate) 2 T6
High Performance Deep Cycle Battery Dual or Triple
8C1V-10655-A_ 850 CCA (95Ah @20 hour rate) 1 + A or B H8
(Dual)
2 + A or B H8
(Triple)
A
6C16 - 10655- C (Turkey) 700 CCA (80Ah @ 20 hours rate) 1 T7
B
6G9N - 10655-P (Southampton) 700 CCA (80Ah @ 20 hours rate) 1 T7
8G9N - 10655-P (Southampton) 700 CCA (80Ah @ 20 hours rate) 1 T7
Before investigating if battery changes are

possible contact your National Sales Company
representative or Local Ford Dealer for correct
batteries and configuration.

4 Electrical Battery Part Numbers and Usage for vehicles built after 26th September 2011
Battery Part Number Type Quantity Size

Single Battery 2.2 FWD (without Start-Stop)
Twin Battery 2.2 FWD and RWD (without Start-Stop)
6C16-10655-B_ (Turkey) 590 CCA (60Ah @20 hour rate) 2 T6
Twin Battery 2.2 FWD and RWD (with Start-Stop)
CC1T-10655-B_ (Soton + 700 CCA (75Ah @ 20 hour rate) 2 T7
Turkey)*
Twin Battery 2.2 RWD -except M2 Bus (-29°C Territories without Start-Stop)
Twin Battery RWD -M2 Bus (-29°C Territories without Start-Stop)
6C16-10655-B_ (Turkey) 590 CCA (60Ah @ 20 hour rate) 2 T6
Twin Battery 3.2 RWD
6C16-10655-C_ (Turkey) 700 CCA (80Ah @ 20 hour rate) 2 T7
High Performance Deep Cycle Batteries (All options except M2 Bus, Camper and Nugget). **
8C1V-10655-A_ (Soton + Turkey) 850 CCA (95Ah @ 20 hours rate) Auxilary 1 H8
CC1V-10655-A_(Soton + Turkey) 800 CCA (80Ah @ 20 hour rate) 1 H7
* Can be replaced by BV6N-10655-B_ in service.
**Compatible with SRC and Start-Stop vehicles only.
Any additional or different batteries must be

checked for correct functionality on a Stop-Start
Battery Rules:
or Smart Regenerative Charging (SRC) vehicle.
Refer to: 4.10 Electronic Engine Controls (page WARNING: For vehicles fitted with
144). non-sealed batteries (non-maintenance
Start -Stop and SRC free), it is essential that regular checks
Refer to: 4.5 Charging System (page 120). are made to determine that the
electrolyte (acid) levels are correctly
NOTE: If wrong batteries or incorrect configuration,
maintained.
Start-Stop or SRC may not function correctly.
• Batteries in parallel must be of the same type
and capacity.
Connection of Auxiliary Loads • Starter and deep cycle batteries may only be
mixed through an isolator.
WARNING: Under no circumstances
• For External charging of batteries ensure that
should any additional connections be
the maximum voltage of 14.6V is not exceeded.
made directly to any of the vehicle's
battery terminals. NOTE: The Deep cycle battery fitted has the same
vehicle start characteristics as the lead acid main
For auxiliary customer electrical loads, these must
vehicle start battery. Do not exceed the battery
only be made via the customer connection points
system maximum current draw or continuous
provided (not available on M1, M2 Buses and
current ratings for emission run and at key off. The
Camper vehicles).
deep cycle battery will supply energy for the
It is possible to change the MAXI 60 amp fuse, in additional circuits and is isolated from the vehicle
the Pre-Fuse Box, to a different value if greater start battery at ignition off. Always observe circuit
than 60A is required but the total rating must not set-up outlined in diagram E74522 - Battery
exceed 180A. If greater than 180A is required then Disconnect Switch (Split Charge Relay) Circuit,
contact your local National Sales Company later in this section.
representative for a solution.

4 Electrical
Battery Configurations (with Minor Feature Codes) left hand drive shown
Item Description
A Battery configuration of vehicles built before 26th Sept 2011
B Battery configuration of vehicles built after 26th Sept 2011
1 Driver seat pedestal
2 Passenger seat pedestal
3 Non start relevant battery
4 Start relevant battery
5 Single battery with option to configure for twin battery, with battery disconnect switch and
bus bar (6C1T-14A439-A*) fitted
J Deep cycle battery
HTCAA Single regular production order battery system
HTAAE Twin regular production order battery system
HTCAC Twin special vehicle option battery system
HTCAE Triple special vehicle option battery system
Battery Configuration, Start-Stop and Start-Stop and SRC system functionality cannot
SRC be guaranteed with these configurations. If such
a battery configuration is required, it is
Start-Stop and SRC will operate within recommended not to equip the vehicle with
specification only if a correct battery configuration Start-Stop in the factory so the vehicle should be
is installed in the vehicle. originally ordered without. It will not be possible
NOTE: The following battery configurations are to decommission the Start-Stop and SRC features
NOT compatible with Start-Stop and SRC: due to Homologation, Vehicle Tax and Excise
Requirements.
• Mixed battery types - for example: 1 x AGM and
1 x Flooded. If the battery type on a vehicle with Start-Stop or
SRC is changed to other compatible derivatives,
• Mixed sizes - for example: 1 x 60Ah, 1 x 80Ah. see 'Battery Configuration table for vehicles built
• Battery types other than those listed in the after 26th September 2011', it is required to
'Battery Part Number and Usage Table. reconfigure the vehicle to the new battery types
• Extra batteries than factory fit - for example: from the dealer. Central car configuration can be
3 or more. updated at a dealership.
• If twin Ford battery configured only fitting
single Ford battery.
• If single Ford battery configured, fitting twin
Ford battery.

4 Electrical Additional Batteries When changing from an incompatible battery
configuration to a compatible system, Start-Stop
If additional batteries are added, a disconnect relay and SRC functionality will take some time (ignition
or main manual switch system is advised to isolate off overnight and multiple ignition run cycles) to
the third battery from the Ford fit batteries. It is reestablish full functionality.
recommended to only connect the third battery
to Ford fit batteries and alternator on long motor
way drive cycles or at engine idle. It is not Additional Loads and Charging Systems
recommended to leave connected in traffic or
around town as the Start-Stop functionality may High loads exceeding the customer connection
not work correctly. This is where a third battery point rating of 60A should be fitted via an isolation
maybe connected in parallel, for example: switch or disconnect relay. This is to protect from
Campers/Ambulances. This will ensure the discharging batteries at ignition off. This supply
Start-Stop system is not permanently disabled should also have a dedicated protection fuse of
and allowing some fuel save return. If Start-Stop the correct value. High loads should also be
and SRC functionality is still required, then the third grounded directly to the vehicle body and not the
battery disconnect strategy needs to include negative battery terminal. Connecting to the
complete isolation from the Ford fit battery system negative battery terminal will bypass the BMS and
for repeat ignition cycles. Start-Stop and SRC affect the correct assessment of the battery state
system operation will return to normal of charge. Refer to: 4.6 Battery and Cables. Battery
functionality if this is done. A supplemental Monitoring Sensor.
charging system may be required to solely charge If separate charging systems are added, the ground
the third battery. side of the charger must also be connected to the
The Charge can also be applied to the Ford fit body. Each battery must also have a separate
batteries, all relays/switches connected, but only charger as the batteries are isolated at Ignition off
for an emergency charge. (and two minutes after key-on if the engine is not
running).

4 Electrical
4.6.2 Battery Monitoring Sensor (BMS)
Item Description
1 Battery Monitoring Sensor (BMS) for vehicles start battery
2 Plug-in connection - Local Interconnect Network (LIN) and Battery positive +12 volts (B+) feed
3 Connection to negative terminal of main battery post - see 'Battery Cable Fixing Torque'
4 Jumper Cable (CC1T-14A280-A_) only with twin battery
5 Second BMS, only with second auxiliary battery
It is recommended that the total Ampere

CAUTION: Do not permanently remove
consumption from the auxiliary battery does not
jumper cable (CC1T-14A280-A_) from
exceed 100mA. Note there is approximately 20mA
BMS.
of key off load from existing Ford fit systems. Any
The BMS continuously monitors the condition of third party installations should ideally be activated
the main battery (or twin batteries on a Start-Stop via Ignition or engine RUN. If the equipment is in
vehicle). To do this, it is bolted directly to the sleep mode at Ignition off the total vehicle key off
negative terminal of the battery. It is load of the auxiliary battery should not exceed
recommended that this is not removed. However, 90mA.
if removal is required, please refer to the ETIS
After installation, it is recommended to measure
workshop manual, local Ford dealer or Customer
total key off load to battery with a clamp on
Services.
Ammeter – calibrated and sensitive to milli
The BMS has to be re-calibrated at regular Ampere's (mA). Perform this test after 10 minutes
intervals. This occurs during a rest period at key of key off with all doors shut so that the vehicle
off, when the battery closed-circuit current is less remains in sleep mode.
than 100 mA. The rest period must last for at least
NOTE: Opening the door will interrupt vehicle
three hours. If the system cannot carry out a
sleep mode and the key off load will increase.
re-calibration then it is impossible to confirm the
exact state of charge of the battery. In this case, The following DTC's (Diagnostic Trouble Codes)
the start/stop system may be deactivated. can be set in relation to the BMS
Do not connect third party equipment to the • 0xD007 - 87: Lost Communications BMS 1
vehicle start battery, located at the rear of the • 0xD00F - 87: Lost Communications BMS 2
seat pedestal. Any third party loads should be • 0x91DB - 49: BMS Hardware fault 1
connected to the auxiliary battery using the
customer connection points provided. • 0x93AE - 49: BMS Hardware fault 2

4 Electrical 4.6.3 Battery Disconnect Switch (Split Charge Relay)
Battery Disconnect Switch (Split Charge Relay)

A Central Junction Box (Passenger Junction Box) - 1 Battery Disconnect Switch - Pin 1
Fuse 77
B Battery Disconnect Switch 2 Battery Disconnect Switch - Pin 2
C Pre Fuse Box - Fuse 2 3 Battery Disconnect Switch - Pin 3
D Start Relevant Battery 4 Battery Disconnect Switch - Pin 4
E Non Start Relevant Battery 5 Central junction Box - Pin C4-35
F Pre Fuse Box 6 Central junction Box - Pin C4-34
G Central Junction Box (Passenger Junction Box) 7 Central junction Box - Pin C1-2
Battery Disconnect Switch (Split Charge For vehicles built before 26th September 2011,
Relay) where a vehicle already has a factory fitted twin
battery system, there is no provision or need for a
Where a vehicle is equipped with a single battery, further battery cut-off relay, although additional
a split charge option is available. This allows batteries can still be added in parallel to the non
auxiliary circuits, which would discharge the main start-relevant battery.
battery system, to be connected to an auxiliary
For vehicles built after 26th September 2011,
battery/batteries.
The battery disconnect switch is driven from the
SRC, also
central junction box and is always used with an
auxiliary battery/batteries, and can be fitted by
144).
the vehicle converter. Reconfiguration of the
Start-Stop.
central junction box software by the Ford
dealership is required to support this feature.

4 Electrical
Outputs from the Central Junction Box to • Where the vehicle is configured for twin-battery
the Battery Disconnect Switch for operation, the Central Junction Box will detect
vehicles built before 26th September if the battery disconnect switch is missing (or
2011. has been removed), or the mating connector
short-circuited, and although the vehicle will
The battery disconnect switch is a bistable device, be functional, Diagnostic Trouble Codes will
requiring pulsed outputs to change state (each be generated that will flag-up during service.
pulse has duration of 50 ms (milli second) at Hence if a shorting bar is fitted, the vehicle
battery voltage): needs to be reconfigured (via the Dealership
• C4-34 Pull-in and Dealership Hotline).
• C4-35 Pull-out
Pull-in is activated within 70 ms of switching to Single to Twin Battery Conversion
key position II.
For vehicles built before 26th September 2011 or
Pull-out is activated when switching to key chassis cab campers, there is provision to allow
position I, or 0, and in key position II when no converters to specify a vehicle with twin battery
engine run signal is sensed within 120 seconds. function, but with the flexibility to install a
It is not possible to change state within 500 ms. non-start-relevant battery of their choice. This
comprises pre-fitment of a single battery, a
battery disconnect switch, a temporary shorting
Removal of the Battery Disconnect bar, and the vehicle configured for twin battery
Switch (on twin battery models) and function. When the additional battery is added by
wiring of batteries in parallel for high the converter, the shorting bar must be removed.
current applications. If the additional battery is fitted under the driver’s
seat, the factory-fitted vent tube needs to be
For vehicles equipped with a twin battery system, replaced with a twin vent tube, part number:
wiring of the two batteries in parallel is not VYC1T-10A818-BB. Any further batteries fitted
recommended. If higher current is required, 80Ah will also need appropriate vent tubes.
batteries can be fitted (or a deep cycle 95Ah For vehicles equipped with a single battery, it is
battery in lieu of the non-start relevant battery possible to upgrade to a twin battery system, the
only) vehicles built before 26th September 2011. connector for the battery disconnect switch is
Where a single passenger seat is fitted, further present on all vehicles. In addition to reconfiguring
batteries (1 or 2) can be installed in the pedestal the vehicle for twin battery operation, at a
and added in parallel to the non-start-relevant dealership, the following battery cables and
battery, although due consideration then needs components are required:
to be given to increased current availability in the
event of a short circuit. Additional batteries should For vehicles built after 26th September 2011 any
not be installed under a passenger bench seat. additional or different batteries must be checked
for correct functionality on a Start-Stop or SRC
if this requirement is imperative, it would be vehicle, please
possible to disconnect the battery disconnect
switch and put the start-relevant and Refer to: 4.5 Charging System (page 120).
non-start-relevant batteries in parallel using a SRC, also
shorting bar (available from the Ford Dealership, Refer to: 4.10 Electronic Engine Controls (page
part number 6C1T-14A439-A*). There is one 144).
important consideration when replacing the Start-Stop.
battery disconnect switch with a shorting bar: If a requirement exists (camper conversions for
example), it may be viable to order vehicles
installed with a single battery, a battery
disconnect switch, and a kit of harnesses –
detailed below – to be fitted by the installer.

4 Electrical
Battery Cables and Components
Part Number Description
6C1T-14301-A_ Start relevant battery negative to vehicle ground point cable (right hand)
replaces C_ part
6C1T-14301-E_ Start relevant battery negative to vehicle ground point cable (lefthand)
replaces D_ part
6C1T-14A280-E_ Start relevant battery negative to non-start relevant battery negative cable
6C1T-14300-D_ Pre-fuse box bus bar to non-start-relevant battery positive cable
6C1T-10B728-A_ Battery disconnect switch
8G9N-10655-P_ Second battery
YC1T-10A818-B_ Twin battery vents tube
YC15-10A687-AFW Twin battery sliding cover
CC1T-14A280-B_ Battery negative cable
CC1T-10C652-A_ BMS
W520102-S442 M8 nut for second battery positive cable to pre-fuse box
W520101-S437 M6 nut for negative ground cable to jumper cable
Leisure Batteries The battery disconnect switch (SureStart® relay)

isolates the auxiliary battery/batteries from the
If a converter (camper market) intends to fit their vehicle start battery when the engine is stopped.
leisure battery, the existing battery arrangement Additional batteries should be isolated from the
must be compatible with this. If fitting additional rest of the base vehicle electrical system with a
batteries for leisure applications they must be of supplemental disconnect switch.
the deep cycle type.
The battery disconnect switch, together with
Where required, e.g. for camper conversions, associated wiring and hardware, can be fitted as
gas-sealed battery boxes (with exterior venting) part of an accessory kit (available from your local
are available. Ford part numbers: 6C1T-10N669-A_ Ford dealer) in the pre-fuse box when changing
(left hand); 6C1T-10N669-B_ (right hand); from a single to twin battery system.
6C1T-10N725-A_ (lid).

4 Electrical
Twin Battery Installation with Pre-Fuse Box and Customer Connection Points - vehicles built
before 26th September 2011 shown.
Item Description
1 Pre-Fuse Box
2 Customer Connection Points (Not M1 or M2 buses and Camper Vehicles)

4 Electrical 4.6.4 Generator and Alternator
Torque Curve of Alternator
Diagram E75871 shows the torque in Nm which is NOTE: For equivalent engine revs per minute
required to drive the alternator. The vertical axis (RPM), the alternators revolutions, axis (B) should
(A) shows the torque [Nm] and the horizontal axis be divided by the following factors: 2.66 for diesel
(B) shows the alternators revolutions per minute (2.2L and 2.4L), 2.4 for Gasoline (2.3L).
[1/min]. NOTE: These alternator curves do not show spare
output capacity as this would be dependant on
original vehicle features and options.

4 Electrical
Current in relation to revolutions per minute
Diagram E75872 shows the current (A) in relation

to alternators revolutions (B) per minute [1/min].
This preliminary Bosch performance curve (1)
arose at a temperature of 25°C and a voltage of
13,5V.

4 Electrical
Item Description
1 Temperature 0°C - Voltage 14.1V
Diagram E75873 shows Ford Transit output

performance of alternator according to Ford
Specification with five different temperatures.

4 Electrical
4.7 Climate Control System
WARNING: Do not use propylene glycol
based coolant.
• Never secure hoses or tubes to the
transmission fill or dip stick or to any fuel
system or brake component.
• Do not route heater or refrigerant lines near or
directly over any exhaust system component,
including the exhaust manifolds.
• Avoid routing of hoses in the wheelhouse or
stone kick-up arch. However, if routing is
required in these areas, shield against stone
pecking as appropriate.
• Do not route hoses near sharp edges. Utilize
guards to protect against cutting or chafing.

4 Electrical 4.8 Instrument Panel Cluster (IPC)
WARNING: Do not tamper with, cut into
or connect to any of the CAN-Bus
interface wiring or connectors.
The Transit has a Hybrid electronic Cluster (HEC).
Most of the functions are managed over the
CAN-Bus interface (pins 3-8).

4 Electrical
4.9 Horn
A dual horn may be fitted to the vehicle in place
of the single horn.
Any other aftermarket horn (for example an air
horn) will need to be driven by a separate relay
energised by the horn circuit.

4 Electrical 4.10 Electronic Engine Controls
Typical examples of inhibitors are:
CAUTION: Do not make any additional
connections to the electrical circuits • Ambient temperature outside operating
associated with the engine management window for Start-Stop (0°C to 40°C).
system. • Engine coolant temperature not warmed
NOTE: It is not necessary to disconnect or remove up(value dependent on ambient temp).
engine management modules. • Heated screens are on.
• Insufficient battery charge to sustain a stop
event or too high a current drain or battery is
4.10.1 Start-Stop - Vehicles built after cold or battery failure.
26th September 2011
• Driver's door has been opened and vehicle has
WARNINGS: not been driven over 5 kph since.
• Engine management reason (for example:
Engine may start without warning.
during a cDPF regen event etc.).
• The ABS warning lamp is on or the vehicle is on
Engine may switch off without warning. a steep gradient.
• High electrical load where total vehicle current
Do not lift hood or work on engine with A drain exceeds 50 Ampere.
ignition on.
• Ford Engine RPM (Revs Per Minute) Speed
Do not leave vehicle when engine has shut Controller System is active.
down without first turning off ignition. • Un-recognized batteries fitted or BMS damaged
NOTE: On a Start-Stop vehicle the engine can or removed.
restart without warning, so never work on the • ECO button is pressed (LED illuminated).
vehicle without first switching off the ignition.
• Accelerator pedal or clutch pedal is not
It is very important not to make any modifications released.
to the shielding around exposed moving parts on • Greater than 100mA continuos load on each
the engine, such as the drive belt. battery at ignition off. The BMS will be unable
to correctly assess battery state of charge.
General Information
Stall Recovery / Start Abortion Recovery
Start-Stop is designed to improve fuel economy
and reduce CO2 emissions by automatically Stall recovery is an additional feature available
stopping the vehicle's combustion engine during with start-stop, and is active even if start-stop
idle phases when it is not required for motive itself has been deselected or is inhibited. Under
power, and restarting it when required. stall recovery, an automatic engine restart is
invoked if the clutch pedal is fully depressed
immediately following a vehicle stall, thus enabling
Start-Stop Logic the driver to quickly recover from a stall condition
without needing to cycle the ignition
Automatic engine stops and restarts are controlled key/start-button. Stall recovery is only available
by the Start-Stop logic within the ECM (engine for 5 seconds following a stall.
control module), known as the Start-Stop
scheduler. This is connected to a number of vehicle
and powertrain signals, sensors and switches and Start-Stop De-selection (ECO button with
decides when to shut down and when to restart LED illuminated)
the engine, based on the particular Start-Stop
strategy employed. Stop-in-Neutral is a Start-Stop The Start-Stop function may be deselected by the
strategy applicable to manual transmissions which driver by means of the "ECO" button on the dash
stops the engine, subject to inhibitors, whenever panel. An integral amber LED in the button
the vehicle is stationary AND neutral is selected illuminates to indicate that the function is disabled.
AND the clutch has been fully released. The engine After a key cycle, Start-Stop will be re-enabled.
is restarted on clutch pedal press in neutral. This switch also overrides the 110kph speed limiter.
For instance, pressing the button (LED illuminated)
will inhibit the auto start-stop feature and allow
Inhibitors the vehicle to drive to maximum speed or a higher
speed limit value if also fitted. Pressing the button
Sometimes the engine may not shut down or again (LED not illuminated) will make auto
restart, due to one or more system inhibitors being Start-Stop active and vehicle will be limited to
active. The engine will shutdown only once all 110KPH. These are part of the fuel saving features.
inhibitors are cleared, which maybe some time
after the transmission is shifted to neutral and the
clutch pedal is released.

4 Electrical
Vehicle Modification Considerations The driver's door switch is used to help identify if
the driver has left the vehicle and prevent engine
There are two main considerations: impacts to shutdowns. If any modifications are made to the
start-stop behavior as a result of vehicle door or switch then this functionality may be
modifications and impacts from the Start-Stop affected. If the driver's door is not used then
system. ensure this switch is permanently closed (input
grounded).
The system uses signals from switches/sensors
Impacts to Start-Stop Behavior
on the clutch, brake and accelerator pedals along
Inhibitor occurrence may be increased by vehicle with and the transmission shift mechanism. To
modifications. For example the 12V energy avoid compromising the safety of the system, no
management system on the vehicle is designed electrical connection should be made to any of
to allow the engine to shutdown only if the current these signals.
drain is less than 50A. High current loads
(attached to the secondary battery) may lead to
this threshold being exceeded. In addition engine
Impacts from Start-Stop System
stops will be inhibited if the battery state of charge
Start-Stop is designed to shut down the engine
is below 68%, which may occur if added electrical
when it would otherwise be idling. Some
loads are active during key-off periods. When
modifications may rely upon a running engine to
installing extra peripherals, be aware of the
operate. For example: a tipper truck. Ford's RPM
continuous / quiescent current drain of such
speed controller will automatically inhibit
equipment, even when in Off or Standby mode.
Start-Stop from shutting down the engine.
Any module should not load more than 5 mA
Aftermarket systems do not have this facility so
(milliamps) in electrical load when OFF. If this is
the driver may need to use the ECO button to
the situation, a different battery system should
disable Start-Stop when such devices are being
be considered instead of the standard fit battery
used. The starter relay should never be bypassed
system. The AGM 2 x 95Ah twin system which has
or driven directly. With the Ford-fit RPM controller,
been engineered to work with Start-Stop, should
please be aware that the throttle pedal
be considered if electrical loads will be high at
functionality is different. For instance, if RPM is
Engine Run and Off but total key off load including
active, pressing the throttle pedal will stall the
Ford systems must not exceed 90mA. Please
engine. If an RPM controller is required – it is
contact your local Ford dealer to enquire about
recommended to use the Ford engineered system
this option.
as this is developed with the Start-Stop System.
NOTE: Regardless of the battery configuration, An aftermarket fit system may still have the
key-off load in excess of 100mA for 7 days or more engine switch off when not expected.
will cause Start- Stop to inhibit.
The SVO feature Engine Run signal, which is a
For additional information switched ground signal, on a Start-Stop vehicle
Refer to: 4.6 Battery and Cables (page 127). is only active when the vehicle's engine is actually
Battery Monitoring Sensor. running (for example: not active during an
auto-stop). Any equipment connected to the
The Start-Stop system on Transit employs a Engine Run signal will therefore experience more
modified version of Ford's patented SureStart® cycles that on a conventional vehicle. Such
twin battery system to isolate the vehicle equipment must ensure that it can handle a
electrical system from the effects of the voltage lifetime of 300,000 cycles. A quiet or silent type
transients from increase starter motor warm crank relay may also be required as these increased
cycles. Therefore, when the engine is restarted, cycles may be audible to occupants during Start
the auxiliary battery is connected with a delay Stop Events. Alternatively, consider packaging
timer to avoid the volt drop from these extra warm the control system away from the occupants.
crank cycles. Therefore extra electrical loads
should always connect to the auxiliary battery to All converter fit loads should be connected to
reduce the equipments exposure to these either customer connection points or from the
transient voltage drops. (Customer connection auxiliary battery. Converter fit loads must not be
points and so on). Start-Stop is only designed to connected to the vehicle start battery.
operate with two batteries that are calibrated by
the system. Fitting additional batteries or the 4.10.2 Vehicle Speed Output (Signal)
incorrect type will cause incorrect state of charge
assessment leading to Start-Stop becoming
permanently inhibited and therefore the fuel General Information
saving features lost. This is the same as for an
SRC vehicle. WARNING: Do not interface with the CAN
Refer to: 4.5 Charging System (page 120). (Controller Area Network) for vehicle
SRC. speed.
NOTE: A hard-wired vehicle speed signal is
available but only on a diesel engine vehicles, if
integration is required.

4 Electrical NOTE: Vehicle speed is derived from one of two NOTE: VMT6 transmissions will not support
sources, the wheel speed sensor (for vehicles with fitment of a vehicle speed sensor.
ABS etc.) or the vehicle speed signal – in both The vehicle speed signal is a direct current coupled
cases, these are un-calibrated signals. According square wave that varies in frequency in proportion
to transmission, drive-line and other vehicle to vehicle speed. This provides a square wave-form
parameters that are set, the PCM (Powertrain (50% duty cycle) signal, where a frequency of
Control Module) generates a CAN message of 138Hz equates to 100km/h.
vehicle speed for all vehicle types. There is No
hard-wired vehicle speed signal on gasoline
(petrol) vehicles.
Square Wave Characteristics

Specifications
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%
Pulse Rate 2.2 Hz/MPH (1.3808 Hz/KPH)
Vehicles built before 26th September 2011 In order to avoid electrical issues due to signal loss
and interfacing pin integrity to ensure connector
In the engine compartment there are three compatibility, a pre-crimped wire and terminal,
connectors on the left hand side (viewed from available as part of a wiring accessory kit, should
driving direction), see figure E84714. To access the be used (kit part number KT6C1V-14A411-J*). The
correct connector of the PCM, the shield covering vehicle speed signal is available on pin K1 of the
the connectors must be disassembled. Contact middle (brown) connector, C2. For wire and
your National Sales Company representative or terminal insertion
local Ford Dealer for the removal and installation
Refer to: 4.19 Electrical Connectors and
of the bolts. Security shields fitted with a bolt must
Connections (page 201).
be reinstalled with a new shear bolt
Adding Connectors, Terminals and Wiring, Vehicle
(6M5Y-12B539-A_) after conversion.
Speed Signal, figures E84899, E84900, E84901,
E84720 and E84902.

4 Electrical
Connector Position for Vehicle Speed Signal in the Engine Compartment
Vehicle Speed Connection on Campers - Vehicles built before 26th September 2011
For the central connectors on campers, vehicle

speed access in engine compartment is near the
master cylinder and coolant reservoir.

4 Electrical Vehicles built after 26th September 2011
Connector Position for Vehicle Speed Signal in the Engine Compartment
Item Description
1 PCM - Rear position A, black connector
2 Tape as required
In the engine compartment there are two In order to avoid electrical issues due to signal loss
connectors on the left hand side (viewed from and interfacing pin integrity to ensure connector
driving direction), see figure E140617. The access compatibility, a pre-crimped wire and terminal,
the correct connector of the PCM, the shield available as part of a wiring accessory kit, should
covering the connectors must be disassembled. be used (kit part number KTCC1V-14A411-A_). The
Contact your National Sales Company vehicle speed signal is available on pin 14, on the
representative or local Ford dealer for the removal rear (black) connector. For wire and terminal
and installation of the bolts. Security shields fitted insertion
with shear bolts must be reinstalled with new Refer to: 4.19 Electrical Connectors and
shear bolts (6M5Y-12B539-A* and Connections (page 201).
W714105-S442) after conversion. Adding Connectors, Terminals and Wiring, Vehicle
Speed Signal, figures E140952, E140953, E140954
and E140955.

4 Electrical
Recommended Harness Routing from Dash to Engine Compartment
Item Description
1 Dash to Engine Compartment
2 Tape as required to main harness

4 Electrical
Recommended Harness Routing for Aftermarket Kit - KTCC1V-14A411-A_
Item Description
1 Inline to 14401
2 Tape as required to main harnesses

4 Electrical
4.10.3 Engine Run Signal (D+ Alternative)
Engine-run Signal Connector recommended fitted condition (mating harness not shown)
WARNING: Do not cut into the alternator • The connector between the main vehicle
wires or use the alternator as a source to harness (14401) and the door jumper harness
obtain a 'D+ Signal'. (14A631) Can now be pulled through and
disconnected.
The Engine Run Signal will only support the basic
vehicle system. • The T-piece jumper harness can be inserted
between the two connectors and pushed back
Vehicles built from August 2006 will have a into the body.
suitable ‘fly-lead’ connector (6.3mm flat blade • Drop the glove box fully by depressing the side
receptacle) in the main vehicle harness. This is detents – the single lead with connector
located on the passenger side and can be (6.3mm male terminal) can be pulled through
accessed by dropping the glove box. a square hole in the body-side inner panel,
Vehicles built before August 2006 do not have behind the flexible grommet
this connector. In such instances, for engine run • Re-fitment of the flexible grommet and door
(C4-7 on the central Junction Box), there is a mirror is the reverse of the above process,
dedicated terminal (pin 16) on the passenger-door noting that new shear bolts will be necessary
loom / main loom in-line connector available to for right hand drive vehicle, part number
energize a relay (maximum one (1) relay). A W712939-S422.
T-piece harness (6C1V-14A411-F*) is available
from your Local Ford Dealer to fit between the This engine run signal is ground switching (max.
door / main loom in-line connector. If the vehicle current sink 200mA), for example it provides no
does not have this fitted as a factory-fitted option positive output and is only active under the
(campers, for example, do have this pre-fitted), following conditions:
one way to install this is: For vehicles built before 26th September 2011
• Remove the passenger side mirror on the using • Ignition on
a long-reach M8 socket (note: right hand drive • Engine running
vehicles use shear bolts that will need to be • Alternator giving output
replaced).
• System voltage about 9 volts
• Pull out the flexible grommet between the
body and the door, including the connector For vehicles built before 26th September 2011
shroud behind it. • Engine Running

4 Electrical Due to Start-Stop vehicles, the signal may switch
up to 300,000 times. Provision is required for
control relays switched by this signal to meet this
durability cycle.
Engine Run Signal location, built condition - Passenger side, for vehicles built after August
2006

4 Electrical
Ghost View of Engine Run Jumper Harness (only)
Item Description
1 In-line to 14401 main loom
2 In-line to 14A631 door loom
3 Engine run output (6.3mm male connector), part of T-piece harness (6C1V-14A411-F*)
The fitment of the Special Vehicle Option auxiliary Male and Female connectors with pin for
box will provide a power source for the relay engine run signal shown
(although connection to the engine run pin is still
required).
Where connections are already made to the
engine run signal, it is vital that these connections
remain connected. In this instance, a suitable 'Y'
Jumper link should be used to tap out of the
connection.
If a positive (+12V) engine run signal is required,
this is possible by using the relay contacts to ‘pull
in’ 12V (preferably an ignition feed, KL15).
Engine Run Signal (D+ Alternative) for Item Description

vehicles before August 2006
A Male connector Pin16 - Engine Run Signal
To install the T-piece jumper loom the outer mirror
needs to be removed (remove the cover and 3 x B Female connector Pin16 - Engine Run
M6 screws – Note, for RHD vehicles these are Signal
shear bolts that need to be replaced, part number
W712939-S422). Push out the visible plastic insert
from inside and disconnect connector. Put in the
T-piece jumper loom and reassemble all parts,
replacing the M6 screws as required.

4 Electrical 4.10.4 Engine RPM (Revs Per Minute) the rate of change is 250rpm/sec. Very limited
Speed Controller vehicle speed is allowable while in this mode
(up to 2.5mph approx)
3. Idle Up Speed this mode allows the engines
System Overview normal idle to be increased (in 25 rpm steps)
in the range 900-1200rpm. There is not a
This feature relates to the new generation Transit vehicle speed restriction in this mode as the
launched in 2006 and is available on all diesel intended use is to raise the engine idle to reduce
variants. the likelihood of engine stall when ancillary
This feature enables the engine in the vehicle to equipment is being run from the engine during
be run at elevated RPM speeds. The power from normal drive operations. Eg refrigerator units
the engine can then be used to drive ancillary used to keep the cargo bay cool.
equipment. The ancillary equipment may be NOTE: 3 Speed and Variable speed modes are
powered either via a Front End Accessory Drive available from Nov 2006. Idle up speed mode is
(FEAD) layout (in a similar fashion to the AC introduced from Jan 2007. Any latest generation
compressor), or, on a Rear Wheel Drive (RWD) diesel Transit built before 2007 can be updated
vehicle, via a Power Take Off (PTO) layout by to include Idle up speed with a simple calibration
installing a secondary gearbox between the output update.
shaft of the vehicles primary transmission and the
rear axle with the secondary gearbox transmitting
power either to the rear wheels during normal System Availability
driving or redirecting power to the ancillary
equipment. This feature is built into the latest Powertrain
The maximum power that is available for front end Control Module (PCM) software on all diesel
accessory drive applications, in lieu of the air engine variants.
conditioning compressor, is 26Nm torque at any By default the feature is not enabled unless the
engine speed up to a maximum of 6kW. vehicle is specifically ordered with the feature from
NOTE: A power take off layout can only be the factory.
implemented on vehicles fitted with an ABS Vehicles which have not been ordered with this
braking system. Manual braking systems employ feature may have the feature enabled at a dealer
a transmission speed sensor to determine vehicle via the IDS diagnostics system. The dealer should
speed and the RPM speed control software charge for this service.
contains vehicle speed restrictions which prohibit
RPM speed control operation if vehicle speed is Vehicles fitted with Start-Stop technology may
detected above very low levels (approx 2.5 mph). be converted to RPM speed contrrol, however, the
A vehicle fitted with an ABS braking system derives customer should turn Start-Stop off prior to
vehicle speed via the vehicles wheel speed starting RPM speed control. For more information
sensors, so the transmission can operate normally Refer to: 4.10 Electronic Engine Controls (page
without effecting RPM speed control operation. 144).
The converter should consider any increased Impacts from Start-Stop System.
engine cooling requirements due to the conversion
and running the vehicles engine under load for
extended periods while the vehicle is stationary. How to control this feature
A loop of wire (green/white) is provided in the

3 Modes of Operation main electrical loom to permit control of the RPM
Speed Control software. Cutting this loop will
There are 3 principle modes in which this feature provide two wires to connect a control box to the
can operate, they are: PCM.
1. 3 Speed Mode this provides the end user a The control box needs to switch resistors into the
choice of up to 3 preset RPM values to select circuit across the two green/white wires which
from. The end user cannot easily override these formed the loop prior to being cut. This sort of
values so there is minimal risk of damage to circuit is known as a resistance ladder, see figure
ancillary equipment due to it being run at E88295. The PCM software monitors the
speeds it was not designed for. Very limited green/white wire circuit & when certain
vehicle speed is allowable while in this mode resistance's are detected they are interpreted as
(up to 2.5mph approx) various inputs which control the feature. The
switch box can be located where it is ideally
2. Variable Speed Mode this provides the end required for the vehicle conversion in question,
user with RPM speed ramp up & down buttons. rather than having to be mounted on the
The end user is free to select RPM values Instrument Panel (IP). If the converter chooses to
between 1300-3000rpm in 25rpm steps. A locate the switch box in a location which is subject
single press results in a 25 rpm jump. If a ramp to an adverse environment then the converter
button is held depressed by the end user then should design the switch box to withstand with
these conditions.

4 Electrical
How to locate the green/white loop
The main electrical loom enters the vehicle cab The loom is loosely taped in this location, so the
from the engine bay on the left hand side of the green/white loop should be easy to extract. See
vehicle via a large diameter hole in the engine Figure E88703.
bay/cabin bulkhead. This hole is just above the
left hand front suspension turret. See following
Figure E88307.

4 Electrical Resistance Ladder
Resistance Ladder Circuit
Item Description
1 To Green/White Wire
2 Stop Engine
3 RPM 1 on/off or Variable Control 'Idle'
4 RPM 2 on/off or Variable Control 'Negative (-)'
5 RPM 3 on/off or Variable Control 'Positive (+)'
6 RPM Control Armed or Increased Idle on/off
The resistance ladder circuit acts as a potential • If the control box is located externally on the
divider. The PCM has an internal reference voltage vehicle, the requirement for a key avoids any
of 5 volts. Current passes through an internal 320 passers by being able to put the vehicle into
ohm resistor (not shown above) prior to passing RPM Speed Control mode by simply pressing
through the resistance ladder. There is also a a button.
(second) 220 nF capacitor internally within the • Using a key switch where the key can be
PCM between the 320 ohm resistor and ground removed in either the on or off condition could
(not shown above) and this is to reduce EMC be used as an aid to anti theft. If the operator
effects. uses a key to put the vehicle into RPM Speed
With all the switches open there is a total control mode and then removes the key, then
resistance in the green/white loop of approx 4310 the vehicle cannot quickly and easily be taken
ohms and this corresponds to normal driving out of RPM speed control mode. If a foot pedal
operation (the condition prior to the loop being is pressed while in either the 3 speed or variable
cut). speed modes, the vehicles engine will stall and
therefore the vehicle can not easily be driven
To ensure robust operation, it is recommended for away and stolen.
all switches that a switch debounce specification
is chosen as close to zero ms (milli seconds) as When in 3 speed mode pressing any of the middle
possible. 3 switches (with the feature armed) results in the
engine RPM jumping to the corresponding RPM
Starting from the right of the diagram, when the value held in memory (defaults of 1100, 1600 or
key switch is closed only 2110 ohms is in the circuit 2030rpm) for the 3 switch positions. A second
and the PCM software recognizes this as the RPM consecutive press of the same button returns to
mode being armed and ready for operation (Key normal idle.
switch closed = on, open = off). A key switch is
recommended in this position for a couple of When in variable speed mode the same 3 buttons
reasons: act as ramp up, ramp down and return to idle
selections respectively.
The software in the PCM responds to the change
of state, so it is recommended that these 3 middle
switches be non-latching push button micro
switches. When going from idle to an elevated
RPM the execution of the command will occur as
the button is released. When going to idle the
execution of the command occurs as the button
is pressed.

4 Electrical
The final button (the one on the left in figure How to enter vehicle ‘Learn mode’
E88295) acts as an emergency vehicle engine
stop. It is recommended that this be a red and 1. Make sure that the RPM Speed controller
oversize non-latching micro switch button. The switch box is connected but turned off.
execution of this command will occur as the 2. Start the engine (vehicle out of gear and no
button is pressed. foot pedals being pressed, handbrake on).
All wiring connecting the PCM to the resistance 3. Wait a couple of seconds for the instrument
ladder control box should be shielded and twisted panel start up diagnostic lights to extinguish.
(33 twists/m) to reduce EMC effects. 4. Press and release the clutch pedal.
All resistors should have a tolerance of +/- 5% or 5. Press and release the brake pedal.
better. 6. Repeat steps 4 and 5 a further four times
Switch contact, connectors and loom (loom (clutch & brake pressed a total of five times
between the green/white wires and the control sequentially each).
box) total resistance must be no greater than 5 NOTE: Steps 4 to 6 have to be started within 10
ohm max. seconds of the engine start.
The PCM to resister ladder control switch box The vehicle should now be in ‘learn mode’
loom should not come within 100mm of any other
harness, especially any carrying heavy loads.
Designs which do not require all the button How to Select between modes
switches must still have the complete resistor
network with the switches positioned correctly 1. Enter learn mode (see directions above).
within the network. 2. Arm the RPM speed controller (turn the key
A suitable two way quality connector should be switch to ON).
used to connect the control box to the two If the vehicle is already in 3 speed mode (the initial
green/white wires. default):
3. Press and release the brake pedal five times.
How to change the default settings The vehicle should now be in variable speed
mode. The new settings can be saved and learn
By default, when the feature is first enabled mode exited (see below).
(either via factory order or via dealer IDS tools),
or
it will be set to the 3 speed mode of operation
with preset RPM values of 1100, 1600 & 2030rpm 4. Press and release the brake pedal once.
for the 3 speeds. The vehicle should now be in 3 speed mode. The
There are two methods by which these defaults new settings can be saved and learn mode exited
can be modified: (see below.)
1. via the IDS diagnostics system at a Ford dealer Using this method it is easy to change between
(there may be a charge for this). these two modes of operation for the RPM speed
controller.
Via the IDS system the mode of operation can
freely be changed between any of the 3 principle NOTE: If the engine stalls out at the initial brake
modes of operation, the feature can even be turn pedal input then the vehicle was not in, or has
off (disabled). The 3 default RPM speeds can also dropped out of learn mode and you will have to
be modified within the allowable range for the restart the learn procedure.
mode of operation as detailed in this section.
Via IDS the RPM Speed Controller menu is under How to change the 3 pre-set default RPM
the tool box tab, then Powertrain, then Service values in the 3 speed mode
Functions, then PCM. The IDS on screen menus
will guide the dealer through the options and 1. Enter ‘learn mode’ (see directions above).
setup.
2. Arm the RPM speed controller (turn the key
2. via an inbuilt vehicle ‘learn mode’. switch to ‘on’).
Via the vehicle ‘learn mode’ the 3 speed mode 3. Press and release the brake pedal once.
and the variable speed mode of operation can be 4. Press and release the RPM button that requires
freely interchanged, however it is not possible to re-programming.
select the idle up speed mode via the vehicle 5. Use the accelerator pedal to rev the engine to
'learn mode'. The 3 default RPM speeds can also the new desired RPM speed and hold at this
be modified via 'learn mode'. speed (only speeds between 1200 to 3000
NOTE: It is not possible via either method above, rpm can be selected in 3 speed mode).
to change the step value of 25 rpm per press or 6. Press and release the same RPM button to
the 250 rpm per sec for a held down button, in reset the stored RPM speed to the current
the variable rpm speed engines RPM.
7. Release the accelerator pedal.

4 Electrical 8. Repeat steps 4 to 7 for the remaining RPM • The software monitors the foot pedals, if
buttons. depressed these may stall the engine if in 3
speed mode or variable speed mode (does not
The 3 RPM speeds should now be re-programmed
apply to idle up speed).
to the new RPM speeds. The new settings can be
saved and 'learn mode' exited (see below). • If the control switch box circuitry significantly
exceeds 2110 ohms or there is a short circuit
NOTE: If the engine RPM responds to the initial then RPM speed control will not be possible.
RPM button press, then the vehicle has not entered
‘learn mode’ correctly and you will have to restart • If a PTO conversion has been attempted on a
the procedure. If the engine stalls out at the brake vehicle with a non anti braking system (ABS)
or accelerator pedal inputs then the vehicle was then RPM speed control will fail due to vehicle
not in, or has dropped out of ‘learn mode’ and you speed being registered via a transmission speed
will have to restart the procedure. sensor and / or the need to press the clutch in
order to put the vehicle in gear while in RPM
speed control mode.
How to save new settings and exit from
‘Learn mode’ 4.10.5 Changing Vehicle Speed
Maximum Setting
1. From within the ‘learn mode’ and with the RPM
Speed Control switch box ‘armed’, press the The Vehicle Speed Maximum Setting can be
clutch pedal repeatedly until the engine stalls. changed via the Integrated Diagnostic System
2. Restart the engine and test the new settings, (IDS) menu under the following tabs: Toolbox,
repeat above procedures if necessary. Powertrain, Service, Functions, PCM. The IDS on
NOTE: The engine stalling indicates that the screen menus will guide the dealer through the
settings should have been saved and the vehicle options and setup.
has exited from ‘learn mode’. Learn mode however
is very specific that the exact steps are taken in
the correct order and within certain time limits
otherwise the learn procedure fails and it may take
several attempts to get this order and timing
correct and a successful modification from the
default settings.
Some Reasons why RPM speed Control

operation may stop or fail
The RPM Speed control software monitors vehicle

information during operation in RPM speed control
mode and will drop out of RPM speed control and
/ or stall the engine should any adverse signals be
detected. For example:
• If the engine temperature becomes too hot then
RPM speed control will stop in order to protect
the engine.
• If the engine oil light illuminates then RPM
speed control will stop in order to protect the
engine.
• If the low fuel level light illuminates then RPM
speed control will stop so that the vehicle can
be driven to a refueling point.
• If the vehicle speed exceeds approx 2.5 mph
while in 3 speed or variable speed modes, then
RPM speed control may stop. RPM speed
control should normally be operated with the
hand brake on, but some uses may require a
low level of vehicle ‘creep’ during RPM speed
control operation. Note that there is no sensing
of the park brake on this version of RPM speed
controller to facilitate this type of operation.
• The software monitors for ‘stuck on’ buttons
on the control switch box, this may result in
RPM speed control being halted. A button that
is held down for too long may be registered by
the software as a ‘stuck’ button.

4 Electrical
4.11 Tachograph
NOTE: Siemens VDO are now known as
Continental VDO part of Continental Automotive 4.11.1 Legislation
Group.
It is recommended that any vehicle that requires WARNING: All tachographs require the
a tachograph is sent to an authorised Continental same wiring connections as this is
VDO Tachograph Service Center for system controlled by tachograph legislation.
installation and calibration. There are two types of tachograph available, See
Details of all recommended service centers can below diagrams, E75501 mechanical (MTCO) and
be found on VDO web sites. These sites also E75502 digital (DTCO). The type of tachograph
contain details of current regulations and required by the customer will depend on the
tachograph operation. legislation in the country of use.
Mechanical (MTCO) Tachograph

4 Electrical
Digital (DTCO) Tachograph
Pin Assignment • Speed sensor harness – this is a separate part

which attaches to the instrument panel harness
For detailed information about pin assignments at the junction of the firewall and floor pan,
please contact your local National Sales Company close to the center of the vehicle.
representative or Continental Automotive Group • Instrument panel harness – this contains the
directly. remainder of circuits for the tachograph.
Wiring 4.11.2 Tachograph Mounting

NOTE: Not all instrument panel looms contain Standard Ford installation uses a pod on top of
tachograph wiring. the instrument panel. The tachograph mounts in
The tachograph wiring consists of two parts: the aperture nearest the instrument cluster. Note
the rear mounting bracket in the center of the DIN
aperture in diagram E75503.

4 Electrical
Tachograph Mounting - Double DIN
Item Description
1 Rear Mounting Bracket for Tachograph
Fitted Tachograph

4 Electrical 4.11.3 Fitting a Tachograph to vehicles NOTE: Transits fitted with a VMT6 transmission
built with out Digital Tachograph have a higher labor cost due to gear box
Option modification. The Ford Dealer can provide cost
and timing.
NOTE: Only vehicles fitted with mid to high feature NOTE: The Tachograph units are not supplied by
level harness's will support Tachographs. It is Ford service and are only available by the
recommended for your local Ford Dealer to assess Continental /VDO Calibration Centre. Formerly
compatibility first. known as Siemens/VDO.
Parts required to support aftermarket fitting of a Digital Tachograph

Prefix Base Suffix Name
Mounting Parts
6C11 V046A34 A*w Cover Assembly Instrument Panel Control Opening
85GG A04587 A*w Plate Instrument Panel Radio Cover
4C1T 18923 A* Bracket Radio Receiver
6C11 V045A54 A* Bracket Instrument Panel Center Support
Tachograph Units
6C1T 17A266 A* Tachograph Assembly Digital with Dimmer Switch
6C1T 17A266 C* Tachograph Assembly Digital less Dimmer Switch
Speed Sensor
YC1F 17K321 D* Adapter Assembly Tachograph 5 Speed Manual and VMT6
Drive
4C1T 17K321 B* Adapter Assembly Tachograph 6 Speed Manual
Drive
Wiring Harness
8C1T 14K141 A* Wiring Assembly Tachograph Feed 5 Speed Manual MT75 RWD
8C1T 14K141 B* Wiring Assembly Tachograph Feed 5 Speed Manual VXT75 FWD
8C1T 14K141 C* Wiring Assembly Tachograph Feed 6 Speed Manual MT82 RWD
8C1T 14K141 D* Wiring Assembly Tachograph Feed 6 Speed Manual VMT6
Rivet Blind
- W707993 S437 Rivet Blind 4.8 x 1.2 - 4.8 Grooved 4 Required
Steel
Fitting the Speed Sensor Tachograph Harness Connectors

• Remove the audio head unit for example the
1. Locate the sensor housing radio, navigation or blanking plate. The dealer
2. Remove the protective cap will reinstate. Note: Ensure code is available
3. Fit the speed sensor prior to installation.
4. Fit the supporting wiring harness • Unplug the radio main harness connector and
antenna cable and GPS, if fitted.
• Locate the two rectangular connectors, which
Fitting the Tachograph Unit are taped to the radio harness.
• Pull the connectors through the access hole in
Instrument Drilling Template the instrument panel.
• The document holder needs to be drilled to • Replace the audio head unit.
support the fixings for the Tachograph, wiring
harness access and bezel assembly mountings. • Re-enter Radio Security Key Code.
Fitting Mounting Brackets Tachograph Bezel Cover
• Fit the Tachograph mounting bracket using • Fit Tachograph bezel cover using rivets.
rivets. • Fit the blanking plate to the un-used hole.
NOTE: The Tachograph head unit will be fitted by
the Continental Calibration Center.

4 Electrical
Inside Instrument Panel looking rearward
Item Description
1 Less Tachograph production fit, park location for connector
2 Less Tachograph production fit, park location for second connector
3 Recommended routing when fitting Tachograph
4.11.4 Vehicle Configuration change

For the cluster to obtain the vehicle speed from
the Tachograph the central car configuration
parameter 118 needs to be changed to 0x03 – this
will be done at the Dealer.
118 Tachograph
Less Tachograph HDKAA 0x01 Block 17 byte 7 - Parameter 118
24 Hour Tachograph HDKAB 0x02 Block 17 byte 7 - Parameter 118
Digital Tachograph HDKAD 0x03 Block 17 byte 7 - Parameter 118
4.11.5 Calibration and Tachograph When the Tachograph is in an un-calibrated state

Fitting the vehicle speed indicator in the cluster may not
function or may indicate the incorrect vehicle
The Continental Calibration Centre will order the speed. The cluster within the vehicle will use the
Tachograph and fit the unit to the vehicle. EU speed signal from the Tachograph to drive the
Legal legislation requires that before the vehicle speed gauge and an un-calibrated Tachograph
can be used on the road, the DTCO Tachograph will not report the correct vehicle speed.
must be calibrated. The Digital Tachograph
activation must be completed by an authorized
VDO workshop. The Ford Dealer will organize the
Tachograph Calibration.

4 Electrical 4.12 Information and Entertainment System - General
Information—Specifications
4.12.1 Radio Connector

Multimedia head units, Audio and Navigation, are NOTE: Power for Radio - do not switch the
connected to the instrument panel wiring via the permanent battery feed (KL 15) and ignition feed
Fakra connector see below diagram E74493. (KL 30) on the radio connection. The ignition feed
15 is only used to 'wake up' the radio.
NOTE: There is a co-axial cable (green) for the
roof - mounted AM/FM antenna, and depending On Caravan models a mirror mounted antenna is
on the vehicle, a thin co-axial cable (black) for a specified.
Global Positioning System antenna.
Fakra Connector
Connector A
Pin Pin Pin Pin
1 Right Rear+ 5 Right Rear - 9 CAN + 13 Not Applicable
2 Right Front + 6 Right Front - 10 CAN - 14 Illumination
3 Left Front + 7 Left Front - 11 Keycode Ground 15 Battery +
4 Left Rear+ 8 Left Rear - 12 Ground 16 Ignition Sense
Accessory

4 Electrical
Connector B
1 Mono + 7 Mono -
2 Switched Accessory + 8 Radio Remote Control Ground
3 Auxiliary Left + 9 Auxiliary Left -
4 Auxiliary Right + 10 Auxiliary Right -
5 Phone Transceiver Active 11 -
6 Radio Remote Control + 12 -
Connector C
1 - 7 -
2 - 8 -
3 - 9 -
4 - 10 -
5 Auxiliary 2 Left 11 Auxiliary 2 Right
6 Audio Ground 12 -
Fuse Relay
1 No fuse is fitted to the radio
2 No fuse is fitted to the radio
4.12.2 Possible Accessories NOTE: When this line is pulled low (ground),
radio/CD sound is muted. However, there is no
Due to an issue with system priorities, the audio wire present in the harness as this function is
mute facility enabled via pin B5 does not function normally communicated through the CAN bus.
correctly on vehicles equipped with a Ford Refer to: 4.18 Special Conversions (page 190).
installed telephony system. Adding Connectors, Terminals and Wiring.
The signals from pins C1-2 and C1-3 need to be After Market Hands Free Telephone Kit (Non
controlled via a 2-pole change over relay, which CAN-based) Power should be supplied via a
when energized (when the machinery is in fused battery line and activated by the accessory
operation) causes the signal paths to go open line, pin A16. The mute line from the phone is
circuit. This should not create any diagnostic test connected to Phone Transceiver Active, pin B5.
codes, but there may be a “popping” noise when The audio output from the phone kit should be
the speakers are disconnected and reconnected. fed into pins B1 (+) and B7 (–). The phone audio
Also any changes made to the volume control will is then amplified and diverted through vehicle
not be discernible until the speaker signals are speakers.
restored. This will also cut any audio from the
vehicle’s speaker if a phone conversation (using Refer to: 4.18 Special Conversions (page 190).
the telephony system) is in progress. Adding Connectors, Terminals and Wiring (for
Phone Transceiver Active/Speaker Terminals and
Electric Antenna Activation line, pin B2 Wires).
(Switched Accessory +) is switched: 0 Volts when
the radio is switched off and +12 Volts when the After Market Audio / Navigation (Non
radio is switched on. CAN-based) Power should be supplied via a
fused battery line and activated by accessory line,
Auxiliary Input Accepts a line-out from a pin A16. Auxiliary input is connected as per above.
personal stereo or digital media player. This can
be supported by left channel pin C5 (+) and right NOTE: Vehicle speed and reverse are now CAN
channel pin C11 (+) with a common ground, pin messages and supplied via the vehicle multimedia
C6, wired to a jack plug socket. bus, A9 (+) and A10 (-). There is no hard wired
vehicle speed signal or reverse signal available.
Audio Mute There is a requirement under the
Health and Safety Machinery Directive to mute
the radio when machinery is in operation - this is
necessary to hear audible alarms and signals. Pin
B5 (C3-5 on the electrical schematic) on the
FAKRA interface should be used for this. In order
to maintain system integrity, the mute connection
should be made using kit part number
KT6C1V-14A411-L_

4 Electrical Additional Rear Speakers Camper vehicles, Rear speaker wiring is always present in the
typically, are only equipped with speakers in the instrument panel harness 14K024, but not
front doors, in which case at end-of-line the vehicle necessarily in the harnesses 14401 and
will be programmed for just the front speakers and 14405/14A005 that then take the signals to the
the fade function disabled on the radios. If the rear speaker locations.
radio is set for four speakers, and those at the rear For connecting two additional rear speakers, we
are absent, a fault code will be flagged. The vehicle recommend utilising the 57-way connector, which
would need reconfiguring at a Dealer once is located behind the glove box above the Central
speakers are installed. The radio will output 17W Junction Box, as shown in the next figure. Insert
per channel (left and right); a wire size with a CSA terminals crimped to suitable wires. For the exact
of 0.75 is recommended. connector location
On camper vehicles, a camper rear speaker signal Refer to: 4.18 Special Conversions (page 190).
connector is located in the seat pedestal. Adding Connectors, Terminals and Wiring.
Refer to: 4.18 Special Conversions (page 190). In order to avoid electrical system integrity issues
Camper Central Connectors, with information in due to leakage, and to ensure connector
the pin-outs in the connector table. compatibility, a pre-crimped wire and terminal
should be used.
Adding Connectors, Terminals and Wiring.
57-Way Connector that can be used to connect two additional rear speakers (Left Hand Drive
shown)

4 Electrical
4.13 Cellular Phone
WARNING: Installation of any
non-Ford-approved system is not
recommended and operation with
associated systems cannot be
guaranteed. Any resultant damage will
not be covered under warranty.
Ford offer hands-free and wireless technology
(Bluetooth) phone systems (including voice
recognition) as factory-fit options, these will also
be available as aftermarket accessory kits from
your Ford dealership.
These use the Ford MS CAN multimedia bus to
operate in conjunction with the Ford audio and
navigation systems.

4 Electrical 4.14 Exterior Lighting
Where the following text makes reference to the
addition of wires 4.14.2 Additional External Lamps
(Adding Connectors, Terminals and Wiring). All power for additional exterior lamps must be
taken through the Auxiliary Fuse Box with a
For trailer tow lighting relating to that system. suitable switch and / or relay as required.
Refer to: 4.18 Special Conversions (page 190). Refer to: 4.17 Fuses and Relays (page 177).
(Electrics for Tow bar).
• If CAT 6 directional indicators are to be fitted, the
WARNING: Make sure that the modified Central Junction Box will need to be configured for
vehicle complies with all relevant legal this.
requirements.
• The load on the reversing lamps should not
exceed a total of 3A (42W).
4.14.1 Reversing Lamps
These are hard-wired, activated by the reversing
switch on the transmission and passing through
the Central Junction Box where the signal is
sensed. A marginal increase in current (via a relay
or buffered electrical input) is permissible to trigger
a rear-view camera system, or audible device.
Lighting Loads
Central Junction Controlling Max. Vehicle Head Lamp Long Wheel- Trailer Tow
Box (CJB) Outputs Device Load Leveling base/
Extended
Frame /
Chassis Cab /
Van
Licence Plate Supply Relay (F79) 60W 2x10W - 40W~ -
Position / Parking Relay (F76) 63W 15W 9W 9W^ 10W
Lamp Left (+ (+2x10W)**
Leveling)
Position /Parking Relay (F75) 43W 15W 9W 9W^ 10W**
Lamp Right (+
Leveling)
Direction Indication High Side 63W 21W + 21W* - - -
Front Left Driver
Direction Indication 21W - - -
Rear Left
Direction Indication High Side 63W 21W + 21W* - - -
Front Right Driver
Direction Indication 21W - - -
Rear Right
Symbols used
* Front Dl + Turn Signal Side Repeater
^ Turn Signal Side Marker (5W) + Roof Marker (4W)
~ 6 x Side Marker (5W) + 2 x End Outline Marker (5W)
** Worst cases; Left supply includes Licence Plate
Lighting Fuses
F75 7.5A Position / Park Lamps (+ levelling) Right hand side
F76 7.5A Position / Park Lamps (+ levelling) Left hand side, Trailer tow number plate
F79 7.5A Licence Plate Lamp, Side Marker Lamps

4 Electrical
4.14.3 Lamps – Hazard / Direction
Indication
The maximum permissible load with the standard
system is:
• 3 x 21W – front and rear indicators + side
repeaters (Left Hand Side).
• 3 x 21W – front and rear indicators + side
repeaters (Right Hand Side).
That is:- 63W per side maximum.
4.14.4 Lamps – Front and Rear Fog

Lights
National Regulations regarding inter-connection
with other front and rear fog lights must be
checked before designing the wiring circuit.
For trailer tow for rear fog lighting relating to that
system.
(Electrics for Tow bar).
4.14.5 Lamps for Wide Vehicles
Lamps – End outline and side marker

lamps
All Chassis Cab vehicles are fitted with front

marker lamps on the cab roof as standard, less
roof marker lamps they are optional. Where
additional side marker lamps and rear outline
marker lamps are required to comply with local
regulations, access to the appropriate signals may
be obtained from the licence plate lamps. A
special jumper link is available for this purpose
from the local Ford dealer.
The maximum permissible load with the standard
system is:
NOTE: For various vehicles Cat 6 repeater lamps
must be fitted. See legislation for full details.
• 6 x 5W – side marker
• 2 x 5W – end outline marker
• 2 x 5W – Cat 6
• 2 x 4W – roof marker
4.14.6 Electrically operated Door

Mirrors
WARNING: Do not tamper with the base
system (controlled by Central Junction
Box and multiplex architecture) and any
feeds taken from the associated wiring
or controller.
NOTE: These options are not suitable for
aftermarket or Body Builder fit.

4 Electrical 4.15 Interior Lighting
4.15.1 Additional Internal Lamps Each of these pins on the Central Junction Box can
take a load of 75W. Lights that are controlled by
Additional cabin interior lighting may be obtained the battery save circuit will extinguish 30 to 180
by directly accessing the connector inside the minutes after ignition off (dependent on vehicle
dome lamp in the cab. configuration).
Additional load space interior lighting may be Fluorescent lighting must not be connected to the
obtained by directly accessing the connector inside existing interior cabin of cargo lighting as it is not
the load space lamps in the load space area. compatible with the pulse width modulated
(PWM) lighting circuit and may cause premature
CAUTION: The maximum total internal
failure of the Fluorescent lighting. If Florescent
lamp load must not exceed 5A (75W).
lighting is required, it should be connected to the
Power for the Interior Lights - cabin and cargo Special Vehicle Option (SVO) auxiliary fuse box.
areas – comes from the battery save system
If enhanced bright lights are required for the cargo
(Central Junction Box pin C2-31), and for vehicles
area of a van, it is recommended to fit the Ford
with power locking, the circuit for each area is
SVO Enhanced load space lighting. Option JCMAD
controlled by a separate pin on the Central
and LED lamp part number CC1V-13776-A_. Jumper
Junction Box:
wires will also be required with part number
• Front (cabin) lights, pin C2-22 AC1V-14334-A_/B_/C_ pending on derivative. These
• Rear (cargo) lights, pin C2-27 wire not present are controlled from the side load or rear door being
on chassis cab and cab-van-floor vehicles ajar or manual demand from the dome lamp in
the front cabin. The default setting is 30 minutes
With manual locking vehicles, control of interior from the battery saver system but this can be
lighting is done directly through the door contact changed up to 3 hours. For further information on
switches. All vehicles, however, utilize the battery required parts and configurations to order contact
saver relay to provide power for internal lighting your Local Ford Dealer.
for a limited time.
Enhanced Load Space Lighting
Item Description
A Standard cargo lighting
B Enhanced load space lighting
4.15.2 Additional 'Theater Lighting' connector C2. This is located on the Central
for rear of vehicle interior Junction Box behind the glove box on the
passenger side (please refer to Figures E84705
For chassis cab or cab-van floor (and camper) and E84712).
vehicles, rear lighting is not utilised and so there is Refer to: 4.18 Special Conversions (page 190).
no wire to pin C2-27. However, converters can add (Adding connectors, Terminals and Wiring).
their own lights (up to the max. load) via the
battery save or a separate switchable feed, by
adding a pre-crimped wire and terminal to

4 Electrical
Where higher wattage installations are required,
these should be taken through the SVO Auxiliary
Fuse Box with a suitable switch and/or relay as
required.

4 Electrical 4.16 Handles, Locks, Latches and Entry Systems
4.16.1 Door Removal or Modification It is possible to maintain a certain state by
configuring the Passenger Junction Box (PJB)
In the event of the requirement to remove the connector C3 in the following way.
doors for coach built accessible bus or other • C3-14 Front Left - Ground
derivatives requiring no doors, certain circuits will
need to be linked to insure door ajar warnings do • C3-1 Front Right - Ground
not appear on the Cluster / Hybrid Electronic • C3-13 Rear - Ground
Cluster. The interior light will also stay on if this is
not done. • C3-19 Sliding Left - Leave open
• C3-8 Sliding Right - Leave open

4 Electrical
4.16.2 Locking strategy for M2 Conversion
Addition of diode to wiring
Item Description
A Part Label
B Wire from pin C2-23
C Cut wire close to connector, and insert 15A diode, polarity as shown.

4 Electrical
Detail showing orientation of splice diode
In order to ensure that M2 mini buses converted However, it is possible to add an additional lock(s)
from a van with double locking do not contravene – see also the section covering the ‘third button
M2 PSV regulations, it is necessary to emulate the on key fob’ – but only by utilizing relays (the
M2 bus locks and operating strategy. To electric locks are operated by surface mounted
reconfigure the M2 vehicle from double lock to relays in the Central Junction Box – these are only
single lock, the following rework action is required capable of powering one lock each, in addition to
to provide single lock only: which the output of these devices is
current-sensed to check it is within minimum and
• The addition of the diode, minimum 15 Amp,
maximum limits: I) to verify operation, and ii) as
will prevent double lock activation. If the vehicle
part of the security system). For camper vehicles,
is decommissioned from M2 use, it will be
the Central Junction Box is configured for a chassis
possible to revert back to double locking by;
cab vehicle.
removing the diode and splicing the wire back
to the systems original condition. Depending on functionality required, the pins used
will emulate the basic locking/unlocking operation
Any splicing should be performed using correct
of an existing door. Note, however, that any
procedures and approved in -line connections.
additional locks will not be covered by the vehicle
Soldering should not be used unless directly
alarm or operate Central Junction Box controlled
modifying a printed circuit board.
lighting, etc. It would be necessary to splice into
either the Central Junction Box connector or the
4.16.3 Central Locking in-line connector for the door jumper harness. The
coil of the relay (max. 300mA) should be added
Locking is controlled by the Central Junction Box across the relevant pin and ground (i.e. one relay
module. There is current sensing on certain locking for lock all, one relay for driver door unlock etc).
circuit pins as part of the security system – if these The use of Ford Transit lock mechanisms is
are tampered with, locking cannot be guaranteed. strongly recommended as the Central Junction
Box is designed to drive these latches for the
correct amount of time.
Central Junction 14A631 in-line Drive 14A631 in-line Function

Box Side Passenger Side
C2-7 6 - Driver door unlock
C2-8 * - 6 Passenger door unlock (on
chassis Cab / Cab-Van Floor
only
C2-23 5 5 Deadlock all
C2-24 8 8 Lock all
* On Van, Bus and Kombi vehicles, pin C2-8 unlocks the rear cargo doors or lift gate, and pin C2-12 unlocks
the passenger door.

4 Electrical
Locking ConfigurationsThe following list details 3. N1 lock reconfiguration into M2 locking, i.e. no
specific locking scenarios that have been noted deadlocks – this can be reconfigured to be
by customers: central-locking only by a Ford Dealer (via
Dealership hotline).
1. Raid locking or drive away locking for taxi and
parcel van usage – this is a configurable Drive-away Locking Disable
parameter in the Central Junction Box (Ford Disabling of the drive-away locking feature needs
Dealerships can set this). to be carried out at a dealership using Integrated
2. Slam locking – this is a configurable parameter Diagnostic Systems (IDS). The following
in Central Junction Box (dealerships can only parameter (automatic locking by speed) is
switch off this feature, but not switch on). configured as follows:
• IDS parameter 32 - Change 0x02 [on] to 0x01
[off].
Pins to control Additional Door Locks
Item Description
Pin 7 Driver door unlock
Pin 8 Passenger door unlock (Chassis Cab)
Pin Deadlock all
23
Pin Lock all
24

4 Electrical 4.16.4 Third Button on Key Fob
Pin 12 Controlled by Third Button on the Key Fob
Item Description
Pin 12 Key Fob Signal
Pin 12 on connector C2 of the Central Junction Box

is controlled by the third button on the key fob –
please refer to Figure E84730. This provides a 1
second 12V pulse when pressed once, and if
pressed again within 3 seconds, a further 12V pulse
for ¼ second. (This second pulse is basically an
emulation of the double locking system). This
signal can be used for a variety of converter
applications, subject to load required.
This feature is only available on Chassis Cab
and Cab-Van Floor vehicles, and Campers (but
not Van, Bus or Kombi or Double Chassis Cab)
vehicles that have a high level Central Junction
Box, part number 6C1T-14A073-C*. Pin C2-12 is
part of the circuit protected by a 15A fuse (F78).
NOTE: There are no micro switches, no current
sensing, or any alarm system functionality
associated with this pin, or any lock set driven by
it.
See also Adding Connectors, Terminals and Wiring.

4 Electrical
4.17 Fuses and Relays
4.17.1 Wiring Specification
4.17.2 Auxiliary Fuses, Fuse Box and
When designing wire installations for additional Relays (Fuses - Standard)
equipment use the cable size recommended by
the equipment manufacturer or select a suitable WARNING: No increase in existing vehicle
size from the Current Rating Wire Sizes standard fuse capacity is allowed under
specifications chart. any circumstances. There are no spare
Refer to: 4.4 (page 119). fuses in the Engine Junction Box,
Standard Relay Box or Central Junction
Wiring consists a soft annealed copper core in Box. The vehicle converter/modifier must
accordance with DIN 57201 (VDDE 0201) provide additional fuses as required.
sheathed in Hypalon or irradiated PVC. Please refer to below chart.
For 0,5mm cable an alternative material with
conductor E-CU F20 or F21 in accordance with
DIN 40500 sheathed in cross linked PVC is
available.
Standard Fuses
Part Number Ampere Rating Type Color
1L3T 14A094 A_ 2A MINI Grey
1L3T 14A094 B_ 3A MINI Violet
1L3T 14A094 D_ 5A MINI Tan
1L3T 14A094 E_ 7.5A MINI Brown
1L3T 14A094 F_ 10A MINI Red
1L3T 14A094 G_ 15A MINI Blue
1L3T 14A094 H_ 20A MINI Yellow
1L3T 14A094 J_ 25A MINI Natural

F8SB 14A094 B_ 30A J-CASE Pink
F8SB 14A094 C_ 40A J-CASE Green
XS21 14A094 A_ 60A J-CASE Yellow

2S6T 14A094 B_ 40A MIDI Green
2S6T 14A094 D_ 60A MIDI Yellow
2S6T 14A094 G_ 100A MIDI Blue

4 Electrical 4.17.3 Customer Connection Points
Fuse Locations in Pre Fuse Box (Lid Removed) for Customer Connection Points
With the exception of M1 and M2 Buses, the vehicle Where the load exceeds the above ratings (which
is provided with 3 customer connection points, at can be combined to provide 180A), a separate
the rear of the driver’s seat, which are fitted with take-off is possible directly from the battery clamp
a red cover. Each connection point is individually / post (the non-start-relevant battery for twin
protected by a 60A fuse, located in the Pre-Fuse battery systems), although this is not
Box (PFB). With a dual battery system, these are recommended. In such cases, suitable in-line
connected to the non-start relevant battery. protection needs to be included as part of the
added circuit, for example:- for tipper and tail-lift
Refer to: 4.6 Battery and Cables (page 127).
motors.
CAUTION: When connecting to the
For vehicles built after May 2008, an ignition feed
customer connection points, it is
for use by the customer is present on all vehicles.
advisable to disconnect the battery
For vehicles built before this date, refer to the
ground so as to avoid a short circuit. The
subsequent section: Additional Ignition, Instrument
fixing torque (M5) is 3.5–4.5 Nm.
Panel Illumination and Air Conditioning on Signals.
NOTE: Do not exceed the 60A per fuse rating.

4 Electrical
4.17.4 Ignition Feed
Ignition Connector
Vehicles built from May 2008 will have a suitable

'fly-lead' connector (6.3mm flat blade receptacle)
on a blue-green wire from the main vehicle
harness. this is located on the driver's side and
can be accessed by removing the instrument
panel trim. This wire is capable of supplying up to
1A, and will operate a maximum of 2 conventional
relays.

4 Electrical 4.17.5 Special Vehicle Option (SVO) Auxiliary Fuse Box
SVO Auxiliary Fuse Box - Early Installation (Right Hand Drive shown)
Item Description
1 SVO Auxiliary Fuse Box
2 Mounting Bracket
3 Standard Relay Box
15 Ground Point (GP15)
C1-C7 See Recommended Engine Run Connection Circuit and SVO Auxiliary Fuse Box

4 Electrical
SVO Auxiliary Fuse Box - Later Installation (Right Hand Drive Shown)
Item Description
2 Mounting Bracket
3 Standard Relay Box
15 Ground Point (GP15)
C1-C7 See Recommended Engine Run Connection Circuit and SVO Auxiliary Fuse Box
The Fuse Box (Ford Part number 6C1V-14517-D*) • Ten (F1-F10) fused take-off points
is available as factory-fitted Special Vehicle • One standard power relay (Normally Open),
Option and can be retrofitted. 70A
The SVO Auxiliary Fuse Box must be installed • Six standard micro relays (Change Over), 20A
using the appropriate Ford bracket and power
Fuse ratings of 2, 3, 5, 7.5, 10, 15, 20 are available
feed harness. The bracket is to be fitted to the
for use at continuous loads; a fuse rating of 25
cross car beam fixing bolts, which must be
should only be used for intermittent loads.
re-fastened to the appropriate torque value. see
figure E75087. The SVO Auxiliary Fuse Box, with integrated link
harness, will provide the following connections:
The SVO Auxiliary Fuse Box takes power from the
customer connection points using the power • – Ground
harness, which consists of two 60 amp fused • – Battery +
feeds.
• – Ignition
see diagram E75088 - Recommended Engine Run • – Engine run
Connection Circuit and SVO Auxiliary Fuse Box.
• – Switched interior illumination
Provision is made in the SVO Auxiliary Fuse Box
for the following: The fuse box is connected to the vehicle main
battery(s) but when the deep cycle battery is
installed it is always connected to the deep cycle
battery.

4 Electrical
Recommended Engine Run Connection Circuit and SVO Auxiliary Fuse Box
Item Description
2 Power Mini Relay - 60 Amp
3 Micro Relay - 20 Amp
4 Central Junction Box (C4-7 = Engine Run Pin) via Jumper Harness 6C1V-14A411-F*
5 Ground Point/Earth Terminal(GP15)
C1 Connector - Customer Use see section 4.14 - Special Conversions
C2 Connector - to Switch Harness (6C1V-14A303)
C3 Connector - To Beacon Harness (6C1V-10A993)
C4 Connector - Breakout to Heating, Ventilation and Air Conditioning Harness (6C1T-18B518)
C5 Connector - Breakout to Instrument Panel Harness (6C1T-14K024)
C6 Connector - To Engine Run Connector on (6C1T-14401-**)
C7 Connector - To Customer Connection Points via In-line Harness (6C1V-14300-C*)
The configuration of the Auxiliary Fuse Box is hard There are 10 possible fuse locations in the fuse
wired (as shown in Figure E75088) Auxiliary box. Please refer to the following table (Fuse
devices should be connected via the 16-way Location), which shows how the fuses are divided
connector C1. Most fuse / relay configurations are between the two 60A power feeds. It is possible
available to meet particular requirements. to change the fuse permutations of the 1-10 fuses
for unique requirements and loadings but only
A maximum of 60A is permitted per power feed,
according to the values shown in the Fuse Location
with maximum individual fused circuits of up to
Table. Consideration is required not to exceed the
20A.
total 2 main 60Amp feeds, the 30A sub busbar
feeds or the individual wire maximum fuse circuit
loads.

4 Electrical
Fuse Location
Fuse Position Fuse Value Fed from Main Wire Gauge Max Fuse Fed from Sub
Fitted - Bus Bar 1 or 2 (mm) Bus Bar 1-5
Standard (A) (60A max (30A max
each) each)
1 3 2 1.0 15 1
2 7.5 2 0.5 7.5
3 5 1 1.0 15 2
4 20 1 2.5 20
5 20 2 2.5 20 3
6 15 1 1.0 15 4
7 15 1 1.5 15
8 15 2 1.5 15 5
9 5 2 0.75 10
10 10 2 1.0 15
C1 Interface Connector C2 Connector

A KL15 5A 1 Illumination - Ignition from HVAC
B Relay 4 Coil OUT 2 KL30 3A - Switched 12V supply
C Relay Coil IN 3 Ground
D Relay 4 Switched Power 4 Relay 1 Coil IN - Hand Wash Heater
Switched Circuit. Also requires Engine
E Ground Run Signal to activate
F Relay 6 Coil OUT 5 Relay 3 - Work Lamp Switched Circuit
G Relay 5 Coil OUT 6 Relay 2 - Beacon Switched Circuit
H Relay 1 Switched Power 7 Relay 1 - Water Heater Switched Power
J KL15 20A 8 KL15 5A - Ignition Feed
K KL30 7.5A
L Relay 3 Switched Power
M KL15 Ignition Switch
N Relay Coil IN
P Relay 6 Switched Power
R Relay 5 Switched Power
S KL30 20A

4 Electrical 4.17.6 Special Vehicle Option (SVO) Switches
SVO Switches Configuration

Item Description
1 Work Lamp Switch - Right hand drive only
2 Water Heater Switch - Right hand drive only
3 Beacon Switch - Vehicles with Heated Rear Screen and Start-Stop or Always when Vehicles
have 1 and 2 above. Left and Right hand drive
4 Beacon Switch - Vehicles with Less Heated Rear Screen, Less Start-Stop. Left and Right hand
drive
When a tachograph is fitted with the switches, the For vehicles built after 26th September 2011 the
switches will move to the passenger side of the SVO switches that control relays in the SVO
double DIN auxiliary fuse box are relocated to a double DIN
binnacle, see next figure E140615 - right hand drive
For vehicles built before 26th September 2011 the
shown. Left hand drive switch locations are
SVO switches are located in the main instrument
symmetrically opposite where option is available,
panel switch location,
for example: If the beacon is located in the double
Refer to: 4.2 Wiring Harnesses (page 106). DIN then it is always in the location nearest the
figure E118457 - Beacon Switch. driver.
NOTE: If the double DIN is ordered already and is
to be filled with converter controls and after
market switches, the beacon only option can still
be ordered but will need to be ordered with LESS
heated rear screen.

4 Electrical
4.17.7 Additional Ignition, Instrument Panel Illumination and Air Conditioning
On Signals
8 Pin Connector
Item Description
Pin 4 KL15 (12V ignition feed)
Pin 7 Used instead of Pin 4 on vehicles equipped with Air Conditioning)
Pin 6 Instrument Panel Illumination (12V feed)
Pin 5 Air Conditioning On (12V)*
Access to these feeds can be obtained via a NOTE: *There is NO direct provision for an air
jumper harness (KT6C1V-14A411-H*) that fits into conditioning on signal. When the air-conditioning
the 8-pin in-line connector between the is switched on, 12V is applied to the defrost
instrument panel (14K024) and heater (18B518) compressor switch and the Air conditioning low
harnesses located behind the glove-box. This speed blower relay (both integral to the heating
jumper will provide the following signals through ventilation and air conditioning unit and 18B518
three, single 6.3mm color-coded connectors, wiring), and the Air conditioning cycling switch (in
please refer to Fig. E75089 Heater jumper for the engine bay as part of the 9K499 wiring [via
illumination, ignition and air conditioning on the 14401 and 14K024 harnesses]). Additional
access. load on this line is limited, so air conditioning on
is only available as a signal (300mA) for voltage
It is recommended that these signals are used to
sensing or powering of a relay – powering another
energize relays, or any other device, as long as the
device directly is Not recommended.
maximum current does not exceed 300mA per
function, or 600mA (suitable for powering two Where additional current is required from either
relays) for the ignition feed. output, a standard relay should be used, please
refer to Relay Figures E75017-E75021.
The Special Vehicle Option Auxiliary Fuse Box is
recommended as the most suitable power source
for these relays. Please consult your local National
Sales Company representative for availability.

4 Electrical
Heater Jumper for Ignition, Instrument Panel Illumination and Air Conditioning On Signals
Item Description
1 Ignition, Instrument Panel Illumination and Air Conditioning On Signals
2 C4 - Connection to Heating, Ventilation and Air Conditioning Harness (18B518)
3 C5 - Connection to Instrument Panel Harness (14K024)
4.17.8 Relays and Switches Micro Relay
Relays
Single pole relays must be used under the

conditions:
• Single pole, 2-way (change over) is used to
switch from one circuit to another please refer
to Relay Figures E75017-E75021 for typical relay
circuit diagrams.
• Relays can be installed inside the vehicle or
inside the Special Vehicle Option Auxiliary Fuse
Box.
• The Ford standard relays have a nominal
current of 300mA (max) at 25°C. Relays with
greater loads should not be used.
• For maximum switching currents please refer
to Relay Figures E75017-E75021.

4 Electrical
Micro Relay Parameters
Normally open contacts 20 Amps
Normally closed contacts 16 Amps
Nominal coil current 300 mA (max)
Medium current changeover relay - Part number:6G9T-14B192-B*
Medium current normally open relay - Part number: 6G9T-14B192-A* (pin 4 not present)
Mini relay
Mini Relay Parameters

Normally closed contacts 20 Amps
Nominal coil current 300 mA (max)
Medium current changeover relay - Part number: 6G9T-14B192-D_
Medium current normally open relay - Part number: 6G9T-14B192-C_ (pin 4 not present)
Mini Power Relay
Mini Power Relay Parameters

Nominal coil current 300 mA (MAX)
High current normally open relay - Part number: 6G9T-14B192-E_

4 Electrical Battery Disconnect Switch
Battery Disconnect Switch Relay Parameters

Nominal coil current 3.3 A @ 25°C
High Power Bistable relay - Part number: 6C1T-10B728-A_
In addition to the fuses and relays fitted to the Pre These relays have a different terminal
Fuse Box (PFB), Engine Junction Box (EJB) and arrangement to those fitted throughout the rest
Central Junction Box (CJB), depending on vehicle of the vehicle – if they need to be replaced, only
options, there may be up to 3 relays mounted components with the same Ford part number
directly to the Heating, Ventilation and should be used.
Air-conditioning (HVAC) unit. These relays should
not be tampered with as they affect operation of
the associated system.
Heating, Ventilation and Air-conditioning (HVAC)

Air-conditioning 1 x 82GG-13A025-CA
Fuel-fired Heater without Air-conditioning 2 x 82GG-13A025-CA
Fuel-fired Heater with Air-conditioning* 3 x 82GG-13A025-CA
*In addition to the relays, there is a diode 91AG-10374-B_
Switches and their Illumination For any additional functions, unless the interfacing
module accommodates momentary action
The main instrument panel switches work in switches, it is recommended that latching types
conjunction with the Central Junction Box, and are are used.
momentary action (non-latching) types. The
Search illumination for added switches can be
Central Junction Box is responsible for control
taken from any of the existing switches, by
operation of the respective systems.
connecting to the appropriate feed wire.
Three Switches Available

Ford Part Number Description
6C1V-13D768-A* Rotary light (beacon)
6C1V-13D756-A* Rear work lamp
6C1V-19H218-A* Water faucet (heater)
These Switches are rated for 10A continuous current.
4.17.9 Windscreen wipers The base wiper system should not be tampered
with (controlled by Central Junction Box and
NOTE: Power to wiper motors is limited by the multiplex architecture).
size of the wiring and associated relays. If any Headlamp wash – such installations would need
alternative wiper installation is made, it must have to be controlled via an external timer relay. The
a specification equivalent to Ford components. Special Vehicle Option Auxiliary Fuse Box should
Refer to: 5.9 Glass, Frames and Mechanisms (page be utilized.
282).

4 Electrical
Heated washer jets – aftermarket systems should
be fitted via an ignition feed, via an additional
relay. The Special Vehicle Option Auxiliary Fuse
Box should be utilized.
4.17.10 Adding Heated Mirrors

Subject to the vehicle having appropriate levels
of harnesses (not low variants), it is possible to
add the heated element function to vehicles fitted
with, and configured for power door mirrors only
(without either heated front or rear glass). To do
this, the following components need to be fitted,
and configuration modified using Integrated
Diagnostic Systems, IDS:
Additional Parts
• 3M5T-18C621-A* - Heated rear glass switch
fitted to the I/P
• 6G9T-14B192-A* Mini relay fitted in the
Standard Relay Box as follows:
– For vehicles without CAT 1 alarm position
R17 plus 10A fuse in position F59
– For vehicles with CAT 1 alarm position R22
plus 10A fuse in position F46
Central Car Configuration
• Integrated Diagnostic Systems parameter 144
– Change to 0x02 for Cat 5 vehicles
– Change to 0x04 for Cat 6 vehicles

4 Electrical 4.18 Special Conversions
4.18.1 Special Vehicle Options (SVO)
and Aftermarket Kits
In addition to the trailer tow kits and SVO auxiliary
fuse box already mentioned, a number of other
kits are available to meet customer needs
Special Vehicle Option Harnesses

6C1V-10A933-C_ Front beacon
6C1V-10A933-D_ Rear beacon
6C1V-13B472-A_ Roof mounted, rear turn signal jumper (1 required; needs B_ parts also). Van,
Bus and Kombi only.
6C1V-13B472-B_ Roof mounted, rear turn signal jumper (2 required; needs A_ part also). Van,
Bus and Kombi only.
6C1V-13B576-A_ Trailer tow jumper (7 pin)
6C1V-13B576-B_ Trailer tow jumper for camper / Cab Van Floor (13 pin)
6C1V-14517-D_ SVO auxiliary fuse box
6C1V-14A411-D_ “Nugget” loom, illumination and ignition
6C1V-14A411-K_ “Euroline” Instrument panel jumper
6C1V-14A411-F_ Engine run jumper (between 14401 and 14A631 in A-pillar)
6C1V-14405-A_ Long/medium series with manual locking lift-gate jumper
6C1V-14405-B_ Long series with power locking lift-gate jumper
6C1V-14406-R_ Med Cab Van Floor underfloor harness (with integrated trailer tow wiring)
6C1V-14406-S_ Long Cab Van Floor underfloor harness (with integrated trailer tow wiring)
6C1V-14408-A_ Camper / Cab Van Floor rear lamp extension jumper (chassis cab lamps),
2 required
6C1V-14A303-D_ Beacon switch (from SVO fuse box connector C3)
6C1V-14300-C_ In-line harness to 2 x Customer Connection Points (always required with
SVO auxiliary fuse box)
6C1V-14300-A_ 3rd battery positive
6C1V-14301-A_ 3rd battery negative (ground)
6C1V-14301-B_ Negative (ground) cable for camper, twin battery
6C1V-14301-C_ Negative (ground) cable for camper, single battery
7C1V-14A411-G_ Speaker wire jumper
Aftermarket Kits
AM6C1J-15A416-A_ Trailer tow, 13-pin Van, Bus, Kombi
AM6C1J-15A416-B_ Trailer tow, 7-pin Van, Bus, Kombi
AM6C1J-15A416-C_ Trailer tow, 13-pin Chassis Cab
AM6C1J-15A416-D_ Trailer tow, 7-pin Chassis Cab
* Trailer Tow, 12N & 12S Jumper Harness
KT6C1V-14A411-H_ Ignition, Instrument Panel Illumination and Air Conditioning signals
KT6C1V-14A411-J_ Vehicle Speed Output wiring for vehicles built before 26th September 2011
KTCC1V-14A411-A_ Vehicle Speed Output wiring for vehicles built after 26th September 2011
KT6C1V-14A411-L_ Audio Mute wiring
*Contact your local National Sales Company Representative Refer to: 1.3 Contact Information (page
9).

4 Electrical
4.18.2 Additional Vehicle Signals / NOTE: It is not recommended that signal is used
Features to drive auxiliary equipment directly – a relay (max
300mA) should be used. The existing reverse light
load is close to the threshold and is hard-wired
Reverse Signal through the Central Junction Box for current
sensing to generate the appropriate CAN
A reverse signal is available on the tail light message.
connector. In order to avoid electrical issues due
to leakage, and to ensure connector compatibility,
a mating connector with seals/plugs and
pre-crimped wire & terminal should be used. For
Additional information refer to Adding Connectors,
Terminals and Wiring in this manual.
Chassis Cab (for information only)

Pin Function Wire CSA Color
1 Ground 1.5 Black-Yellow
2 Brake Light 1.5 Violet-White
3 Position/Park Light 0.5 Yellow-Green
4 Direction Indicator 0.75 Green-Orange
5 Reverse Light 0.75 Green-Brown
6 Fog Light 0.75 Red
Van, Bus and Kombi (for information only)

Pin Function Wire CSA Color
1 Reverse Light 0.75 Green-Brown
2 Direction Indicator 0.75 Green-Orange
3 Position/Park Light 0.5 Yellow-Green
4 Brake Light 1.5 Violet-White
5 Ground 1.5 Black-Grey / Black-Green
6 Fog Light 0.75

4 Electrical
Tail Light Connector
Reverse Signal on Tail Light Connector
Item Description
Pin 5 Reverse Signal
In addition, the reverse signal is also available Central Junction Box, figure E84705 (connector
directly from the Central Junction Box (max. C2 Brown) and the following Figure E84724 pin 15.
300mA), but there is no free pin available. The
only way to access this signal at this location
would be via a splice into the existing wire.
Refer to: 4.3 Communications Network (page 115).

4 Electrical
Connector C2
Item Description
Pin 15 Reverse Signal
Third Brake/Stop Light In order to avoid electrical issues due to leakage,

and to ensure connector compatibility, a mating
A signal for a third brake/stop light is also connector with seals/plugs and pre-crimped wire
available on the tail light connector (see Reverse & terminal should be used.
Signal). It can be used directly to feed an LED stop
For connectivity, see following Figure E84725, also
light, or a conventional stop light with a bulb,
the details given in the section for Reverse Signal
maximum 21W.
and in Adding Connectors, Terminals and Wiring.

4 Electrical
Pin for the Third Brake/Stop Light
Item Description
Pin 2 Brake /Stop Light Signal
The use of the trailer tow connector is not

recommended. *IF it must be used, please see the
following figure E4726. This in-line connector can
be found by the left hand tow bar mounting.
Pin Brake Light on Trailer Tow in-line connector at Rear of Vehicle
Item Description
Pin 8 Third Stop Light
If an existing third brake/stop lamp is already

fitted, or if the power exceeds 21W, an intermediate
Additional Position Lights at the Rear of
relay must be used.
the Vehicle
For Van, Bus and Kombi, the signal should be
derived from the 6-way connector to the rear light The feed for position lights only at the rear, bottom
assembly, pin 4. / top, can be taken from the licence plate lighting
connectors: left and right, the maximum load is
10W per side.

4 Electrical
NOTE: Any additional position lights should be The position and parking functions operate
taken from the licence plate lights, and no other independently.
source. When the position lights are extinguished, the side
In order to avoid electrical issues due to leakage, marker and end-outline markers turn off
and to ensure connector compatibility, a mating simultaneously, in line with Inter Regs No 48,
connector with seals/plugs and pre-crimped wire which states the following:
& terminal should be used. See Adding The electrical connections must be such that the
Connectors, Terminals and Wiring. front and rear position lamps, the end-outline
NOTE: Position lamps, front and rear, only marker lamps, if they exist, the side-marker lamps,
function with the lighting switch in positions 1 or if they exist, and the rear registration plate lamp
2; however, the same bulbs are also used for the can only be switched on and off simultaneously.
parking lamps. There are two operating modes This condition does not apply when using front
for the latter, both with the ignition key removed. and rear position lamps, as well as side-marker
lamps when combined or reciprocally
1. Ignition off, master light switch to position ‘P’:
incorporated with said lamps, as parking lamps
all 4 lamps are on.
and when side-marker lamps are permitted to
2. Ignition off, master light switch off, move turn flash.
indicator stalk to either left or right position
and leave in: tell-tale and chime will operate
briefly and parking lamps (2) on the side
selected will be on.
Licence Plate Lamp Connector
Side and End Outline Marker Lights 1. The chassis cab / cab-van-floor camper
underbody harness 14406 has 2 in-line
Side-marker and end-outline lights should be breakout connectors in the middle of the
installed in-line with the relevant vehicle vehicle and in the area of the rear axle that
regulations. Both types of lamp are driven from provide feeds to these lights. Each breakout
the same output on the Central Junction Box, pin will support a 10W load, and will connect with
C2-16. a Ford jumper harness, part number
The number of lights per side that can be 6C1T-15B484-A*, that provides connectors to
supported, without the need for relay-activated each side of the vehicle for side marker lights.
feeds, is typically 4 lights, provided the total load One harness connects to one left and one right
does not exceed 20W, for example: a total side marker light, for example: 5W per side).
additional vehicle load of 40W. There are two
ways to obtain this signal:

4 Electrical NOTE: These breakout connectors are only Side Marker Lights connector
available on cab-van-floor LWB, 2 pairs, MWB, 1
pair and chassis cab LWB, 2 pairs but not on
chassis cab MWB.
2. Alternatively, and/or in addition to, the feed for
the side-marker and end-outline marker lights
can be taken from the connectors to the licence
plate lights, 2-way connector. see also Adding
Connectors, Terminals and Wiring.
NOTE: The feed for side-marker and end-outline
lights must NOT be taken from the position lights
signals. The Central Junction Box output provides
power for the left and right position lights, other
lights including trailer tow, and will NOT accept
any additional load. The side-marker and Item Description
end-outline lights signal must NOT be used for
the roof marker lights. Pin 1 Side Marker Lamps
Rear Side Marker Lamp Harness Connector (Chassis Cab)

4 Electrical
Middle Side Marker Lamp Harness Connector (Chassis Cab)
Roof-Mounted Position/Park Light - Roof-Mounted front Position/Park Light

Front Connector
The lights operate in conjunction with the normal
position/park lights, driven by Central Junction
Box outputs (Left Hand: pin C2-28; Right Hand:
pin C2-20).
The roof marker lights are fitted as standard to
chassis cab vehicles, except those ordered for
camper use; on cab-van-floor vehicles, there is a
connector located in the area of the A-pillar above
the sun visor on the left and right hand sides, that
will provide the appropriate signals. To get access
the roof trim needs to be disassembled. Each
connector is capable of supplying a 5W load.
NOTE: The feed for Roof marker lights must NOT
be taken from the side-marker and end-outline Item Description
lights signal. Pin 1 Position/Park Light Front

4 Electrical
Connector Location for Roof-Mounted Front Position/Park Lights
Also lamp assembly. Without this, bulb outage

detection for turn indicators will be affected,
Refer to: 4.19 Electrical Connectors and
which is a legal requirement.
Connections (page 201).
Adding Connectors, Terminals and Wiring. Additional turn indicators must be powered
through relays (max 300mA), driven by existing
turn lights. The maximum load that the Central
Fog Light Connector Junction Box can drive is 3 x 21W per side (front,
rear and CAT 6 turn indicators); but even if the
Connectors are already part of the wiring if the vehicle is not fitted with the CAT 6 lights, the feeds
vehicle is medium or high spec. (for example with for these should not be used as the Central
electrical side mirrors). The main light switch will Junction Box would need reconfiguring, which
need to be changed for one that includes this could have safety as well as functional
feature. (There are switches with and without front implications.
fog light function).
If supplemental high level turn indicators are
required do not interface directly with the existing
Connecting to Lighting Information systems.
3. Special Vehicle Option beacon switch: wiring
1. Chassis cab end outline marker lights, locations, circuit diagrams and max amperage
recommended circuit and max amperage – see – see Special Vehicle Option auxiliary fuse box
lighting load table. There is NO Ford-released schematic (max current is 15A); there is
harness for this, as the end-outline marker lights provision for the Special Vehicle Option beacon
normally form part of the bodywork. switch in an empty switch location on the
2. Chassis cab LED rear lamp cluster replacement instrument panel.
recommendations, especially turn indicator 4. Rear loom connector detail location and supply
relay implications – see lighting load table. details for retro-fit loom extension for
Generally the use of LED equivalent lighting example:- when extending a medium wheel
systems reduces the electrical load on the base, long wheel base or extended frame
vehicle; however, special care needs to be taken overhang, what connectors do they use to make
with respect to any change to or addition of turn a plug and play loom extension? – for chassis
indicator lights. Depending on the current cab vehicles, there is an Special Vehicle Option
requirements of the LED(s) compared to the extension loom for rear lamps (part number
bulb it is replacing, a ballast resistor may be 6C1V-14408-A*). There is not, at present, a
required, if not already integrated into the LED

4 Electrical
similar loom for Van, Bus and Kombi's, NO CAN message sent to the cluster.
although the appropriate mating connector is Reconfiguration can only be done at a Ford
now tooled, so this would be possible. Dealer.
NOTE: If a vehicle already has a handbrake
warning light in the cluster, or one is installed as
Miscellaneous Systems
per the Ford design, it is not possible to utilize the
wire from the handbrake switch as part of an
Handbrake on - Cluster Warning Light - On
interlock circuit (this is a pull up resistor input that
vehicles built before May 2008, not all vehicles
provides a wetting current of 20mA – anything in
will be fitted with the handbrake warning light
excess of this, for example through additional
(this feature is option and market dependent, and
circuitry, will almost certainly damage the Central
the components making up this system are not
Junction Box). If there is no handbrake switch
fitted). On such vehicles, we do not recommend
installed, it would be possible to add one and
installation of this feature as an aftermarket
utilize this as part of a separate circuit, up to a
addition. There are several reasons for this:
maximum current of 500mA through the switch.
1. Not all circuits carry the requisite wire as a give
Reverse Sensors (Rear Park Aid Module)- The
away:
factory-fit option is a CAN-based system, but for
• The wires might be part of the main vehicle Van, Bus, and Kombi vehicles only. Stand-alone
harness (14401) even if not used – for example systems can be installed (for example for chassis
camper vehicles are normally ordered with cab conversions), but would need to utilize the
power mirrors, and the wires will be present as PTA line of the radio if muting is required.
a give-away.
Add Fuel Fired Heater (FFH) Wiring is only
• The seat pedestal harness (14K076), however, present (give-away) in certain harnesses. There
is vehicle specific – if the handbrake is not part is an aftermarket kit available for this system on
of the specification, it will not be present or current Transit, which could probably be
give-away. This harness would need to be “updated” to suit V347/8. Only available after
changed to the compatible part that also June 2008.
includes the handbrake warning light circuit.
Programmable Fuel Fired Heater (FFH) This
2. The handbrake switch (part number utilizes a timer/control module mounted to the
2F2T-15852-A*) together with its short jumper Instrument Panel, which necessitates having the
harness (6C1T-15K857-A*) would need to be correct instrument panel harness fitted. Retrofit
obtained and fitted. this would be difficult.
3. The handbrake warning light is in all clusters,
For both systems, the appropriate 6C1T-14K132
but unless the vehicle configuration. parameter
harness would be required (suffix -A* for
“parking brake switch” is set, the Central
Programmable FFH, and suffix –B* for Add FFH).
Junction Box will not read this input, and hence

4 Electrical 4.18.3 Auto Wipe and Auto Light for Campers or Vehicles with large over-hangs
Item Description
1 Conversion or Installation rearward (zone 1) where Auto Light and Wipe feature will function
correctly
2 Conversion or Installation forward (zone 2) where Auto light and wipe feature will NOT function
correctly – The feature is not to be specified with the donor or configured OFF by the Ford Dealer.
3 Auto sensor location.
NOTE: The Auto Wipe, Auto Light feature should It is also recommended that the Auto Light main
not be ordered for vehicles that are to be built as switch is changed for a non auto switch. If not
campers or derivatives where the installation changed when selecting auto position (A), the
covers any part shown forward of the vehicle see dipped beam will remain on as the system will
figure E118461. This will affect the auto sensors detect as a missing signal and select a failure
ability to detect light or moisture to the defined mode. Dipped beam will be operated at Ignition
calibration and will not function correctly. on and with Engine RUN. If the wiper is selected
with the light switch in (A) the wiper will work as
In the event that a donor vehicle has been supplied
if intermittent mode has been selected. A Ford
with these features, the dealer can configure the
Dealer can help advise which switch should be
vehicle to manual light and wipe with the following
ordered and fitted, starting with part number
settings.
4M5T-13A024-** (depending on the specification
• Set Central Car Configuration parameter 24 – of the vehicle).
With Rain sensor to 01: (Without Rain sensor)
• Parameter 88 for Auto light should be set to 01:
(Without Auto lights)

4 Electrical
4.19 Electrical Connectors and Connections
4.19.1 Connectors Where wires are required to be extended, break
in points should only be at existing connector
points and only Ford approved connectors should
Cutting into the Original Wiring System be used.
Ford approved link harnesses should be used.
WARNINGS:
Under no circumstances should the CAN
bus be tampered with. This may lead to Unused Connectors
failure of safety critical components such
as Anti-lock Brake System. The harnesses may have a number of unused
connectors – these are dedicated to other
Do not use connectors which cut through
features and options, e.g. heated seats, but are
the outer covering and into the core wire.
not always present depending on level of harness
CAUTION: Only use Ford approved fitted. Ford do not recommend the use of these
connectors. connectors for any other purpose than that
intended by design.
Cutting into vehicle wiring is not permitted
because:
• The base vehicle specification is unsuitable for Power Outlet / Cigar Lighter
incremental loads except in conjunction with
Special Vehicle Option Auxiliary Fuse Box. Both features adopt a 20A fusing strategy. With
• Long term risk of a faulty connection a single battery system, continued loading of
developing. these features will lead to battery drain, and risk
• Potential fire risk from over-loading. vehicle starting. If continuous power is required,
a second battery option should be installed and
All connections into existing wiring must be the customer connection points, where fitted,
permanently insulated. Exterior connections must utilized.
be water-proof.

4 Electrical 4.19.2 Camper Central Connectors
Item Description
A 15- way connector (face view)
(C2-1)
B 6- way connector (face view)
(C2-2)
C Vehicles built before March 2011 - KL30 connector (face view) 60A F60 (SRB)
(C2-3)
D Vehicles built after March 2011 - KL30 connector (face view) 60A F60 (SRB) + Ground
(C2-3)

4 Electrical
Pin Function Wire CSA Color Comments
Connector C2-1 (Item A)
1 Stop lamp (CHMSL) 1.5 Violet/White 21W max
2 Engine Run 0.5 Brown/Yellow 300mA,Ground switching
3 Vehicle Speed 0.5 Violet/Orange 138Hz@100KPH, 50% duty cycle
Output*
4 Lock** 1.5 Grey/Brown Ford lock set (+ve pulse)
5 Unlock** 1.5 Blue/Green Ford lock set (+ve pulse)
6 Not used
7 Interior light feed^^ 0.75 Violet/Red
8 Interior light ground 0.75 Yellow/Grey 75W max, subject to existing
load
9 Not used
10 Not used
11 Not used
12 Air Conditioning 0.75 Violet 300mA (nominal)
request
13 Ignition (KL15) 1.5 Grey 5A F43 (SRB)
14 Not used
15 Reverse signal 0.75 Green/Brown 300mA max
Connector C2-2 (Item B)
1 Not used
2 Rear Speaker Left + 0.75 Brown/Green Twisted pair
3 Rear Speaker Left - 0.75 Brown/Yellow
4 Rear Speaker Right + 0.75 Brown/White twisted pair
5 Rear Speaker Right - 0.75 Brown/Blue
6 Instrument Panel Illu- 0.5 Brown 300mA (nominal)
mination
Connector C2-3 (Item C) Vehicles built before March 2011
1 B+ (KL30) 6.0 Green/Red 60A F60 (SRB)
Connector C2-3 (Item D) Vehicles built after March 2011
1 B+ (KL30) 6.0 Green/Red 60A F60 (SRB)
2 B- 6.0 Black/Yellow Ground
* There is no vehicle speed output wire in the 9K499 harness; if required, insert the taped back,
pre-crimped wire into connector of the Powertrain Control Module. Cavity C2-K1 (vehicles built before
26th September 2011) and Cavity C2 - 14 (vehicles built after 26th September 2011). See additional
BEMM related sections for further details.
** The lock and unlock signals are intended to operate with Ford lock sets, or components with
equivalent function and operational characteristics: – Central Locking: 1.0s pulse; followed by 0.25s
pulse for Double Locking, – Unlocking: 0.25s pulse followed immediately by 1.0s pulse.
^^ Battery saver default time is 30 minutes (alternative configurations: 15, 60 and 90 minutes).
Note:There are no ground wires in either C2-1 or C2-2 auxiliary devices and systems; local grounds
should be used.

4 Electrical
Tyco and Ford part numbers that are used for vehicle connectors, and suggested mating
connectors.
Vehicle Connectors Mating Connectors
Connector Tyco Connector Tyco Terminal Tyco Connector Tyco Terminal
C2-1 15-way 0-926647-1 926882-1 (socket) 1-480710-0 926883-1 (pin)
C2-2 6-way 0-480705-0 926882-1 (socket) 1-480704-0 926883-1 (pin)
Connector Ford Connector Ford Terminal Ford Connector Ford Terminal
C2-3 1-way XR8T-14A64-LA 93BG-14474-YCA XR8T-14A624-NA 93BG-14421-YCA
Connector MTA Connector MTA Terminal MTA Connector MTA Terminal
C2-3 2-way 44.40400 17.07685 44.40300 11.07660
From May 2008, on certain vehicles specified as campers, there will be a central connector arrangement
for use by converters. The details of these interfaces are given in above table, with the connectors located
in the passenger seat pedestal.
WARNING: If multiple systems are to use

this supply, the total system load must
not exceed the 60A short term loading.
For characteristics on continuous loads versus
temperature.
NOTE: On vehicles built before May 2008
connections to KL30 60A supply can be accessed
from either inside the driver's seat pedestal or from
the passenger connection point see figure E118476.
NOTE: On certain vehicles in place of the old
external connection points on the drivers seat
pedestal there is now a cover as shown. Do Not Item Description
Remove this cover.
1 Old External Connection Points Cover on
drivers seat pedestal

4 Electrical
Power Outlet KL30 60A - Internal position on passenger pedestal
Item Description
1 Vehicles built before March 2011 will have a single pin connector for power only. Vehicles built
after March 2011 will have a 2 pin connector, one pin for power and the second pin for ground.
NOTE: The Customer connection point KL30 60A

mounted on the side of the passenger seat
pedestal includes a ground interface on vehicles
built after March 2011. This ground must only be
used for the same circuits as supplied by the KL30
60A supplied within the connector. It is not to
provide grounding for any other supplies. The
mating connector is MTA 44.40400.

4 Electrical
Fuse location for the passenger 60A connection point
The supply for the passenger connection point is

a 'JK' type fuse and located at F60 and is 60A
rated - it is labeled 'SPARE'. This is located on the
passenger side behind the glove box.

4 Electrical
4.19.3 Police and Emergency Vehicle Harness
Location of Optional SVO Instrument Panel Harness
Item Description
4 Two Way Radio Connector - power only (vehicles built before Jan 2011)
For vehicles specified with emergency vehicle Mating connectors and wiring looms to control
wiring, the following details the 9 connectors, devices are available. Please contact the Vehicle
signals and pin configuration, and the mating Advisory Service at [email protected] for details.
connectors.

4 Electrical
2 Way Radio Connector location - Vehicles built after Jan 2011
Item Description
4 Two Way Radio Connector for power and ground supplies - located inside drivers seat pedestal.
A Inline fuse 15A

4 Electrical
1. Blue light connector (STD1) [C40-XF2T-14A624-EB; mating part: XF2T-14A464-FB (EPC)]
Item Description
1 KL 30 (battery +) 1.0 CSA
2 KL 15 (ignition) 0.75 CSA
3 KL 31 (direct ground) 1.5 CSA
4 Horn signal 0.5 CSA
5 KL 30 (battery +) [internal light] 1.0 CSA
6 KL 30 (battery +) [power plug] 1.0 CSA
7 KL 58 (license plate and side light signal) 0.75 CSA
8 Not used (reserved for intermittent high beam)

4 Electrical
2. Navigation connector [C35-F6DB-14489-AGA; mating part: F6DB-14A459-EA (Tyco)]
Item Description
3 Not used
4 Not used
5 Not used
6 Not used
7 Vehicle speed output (VSO) 0.5 CSA
8 Reverse signal 0.75 CSA

4 Electrical
3. UDS (accident recorder) connector [C36-F87B-14489-FA; mating part: E8TB-14A459-AA
(Tyco)]
Item Description
1 Brake light signal 1.5 CSA
2 Not Used
6 Not used
7 Not used
8 Vehicle speed output (VSO) 0.5 CSA - To have vehicle speed on pin 8 please add jumper
harness KT6C1V-14A411-J* for vehicles built before 26th September and KTCC1V-14A411-A for
vehicles built after.
9 High beam signal 0.75 CSA
10 Low beam signal 0.75 CSA
11 Turn indicator right signal 1.0 CSA
12 Turn indicator left signal 1.0 CSA
13 Fog tail lamp signal 0.75 CSA

4 Electrical
4. Two-way radio connector (STD 2) [C37-XR8T-14489-EB; mating part: XR8T-14A459-CB
(Yazaki)]
Item Description
2 Ground 4.0 CSA
3 Ground 2.5 CSA
4 Ground 2.5 CSA
5. Front flasher connector [C43-XW4T-14A464-AUA; mating part: XW4T-14A624-AA (EPC)]
Item Description

4 Electrical
6. Blue light beam connector [C31-91AG-14A464-EAA; mating part: 89FG-14A459-DAA(Molex)]
Item Description
7. Roof ventilation connector [C34-XW4T-14A624-AA; mating part: F808-14A464-MA(EPC)]
Item Description

4 Electrical
8. DISI (panic lock) connector [C39-1F2T-14A464-GA(000); mating part:
F75B-14A624-BA(001)]
Item Description
1 KL 50 (crank) 0.5 CSA
2 Ground signal from handbrake 0.5 CSA
3 Engine run D+ 0.5 CSA
4 No start function 0.5 CSA
5 Key-in signal 1.0 CSA
6 Drive door open contact 0.5 CSA
7 Panic lock 0.5 CSA
8 Ground 0.75 CSA
10 Unlock 0.5 CSA
11 Ground 0.75 CSA

4 Electrical
9. Roof mounted turn indicator rear connector [C2-DPN 15326952; mating part: DPN 15326956]
Item Description
A Not used
B Not used
C Not used
D Not used
E Not used
F Right turn signal 1.0 CSA
G Left turn signal 1.0 CSA
H Not used
J Not used
K Not used
L Not used
M Not used
N Not used
P Right turn feed 0.75 CSA
R Left turn feed 0.75 CSA
S Not used
4.19.4 Adding Connectors, Terminals and Wiring
Additional Rear Speakers
For Information Only

Terminal part number: 1L2T-14421-A* (LHD) 3F2T-14474-R* (RHD)
Connector: 4L5T-14A459-A* (LHD – male) 5L5T-14489-A* (RHD – female)]
Wire size and Color: 0.75 CSA
Right RR+ brown-white
Right RR– brown-blue
Left RR+ brown-green
Left RR– brown-yellow

4 Electrical NOTE: The connectors on the Instrument Panel
harness (14K024) and the main harness (14401)
are reversed between Left Hand Drive (LHD) and
Right Hand Drive (RHD) vehicles, hence different
sets of terminals/wires are required to cover all
the markets.
57-Way Connector - used for connecting two additional Rear Speakers (RHD shown)
Item Description
Pin Speaker Left Positive
44
Pin Speaker Left Negative
45
Pin Speaker Right Positive
46
Pin Speaker Right Negative
47

4 Electrical
Terminal Insertion RHD
1. Withdraw the secondary lock plate by levering 2. Insert the wires with the pre-crimped terminals
up the tabs at the four corners - the lock plate into the correct cavities according to color - the
only needs to be slid back past the first set of terminals are polarized and will only fit one way.
detents.
3. Push back the secondary lock plate so that the

tabs are fully engaged over the four corner detents

4 Electrical Terminal Insertion LHD
1. Pull out secondary lock using pliers.
2. Insert the wires with the pre-crimped terminals

into the correct cavities according to Color – the
terminals are polarized and will only fit one way.

4 Electrical
3. Replace the light grey secondary lock.

4 Electrical Terminal Insertion
Item Description
B5 Audio Mute
1. The wire with the crimped terminal is inserted

into the appropriate vacant cavity in the main
FAKRA connector – the terminal is polarized and
will only fit one way.
4. Replace the blue ‘spacer’ and push home so

that it is flush against the grey secondary lock.
Phone Transceiver Active (PTA), or Audio Mute

for Information Only
Terminal part number: 96AG-14474-RSA (-RZA)
Connector (insert): 3S7T-14489-E*
Wire size and Color: 0.5 CSA, grey-yellow

4 Electrical
Vehicle Speed Signal (VSO) for vehicles built before 26th September 2011

Terminal part number: 96AG-14474-RSA
Wire size and Color: 0.5 CSA, blue-green
Terminal Insertion
1. The furthest of the 3 connectors needs to be 2. Once the middle connector is removed, the
unplugged in order to get access to the middle black cap needs to be removed by first removing
connector, C2 (brown). the cable tie, and then levering up the two detents
on the sides; the cap can then be slid off.
3. There is a grey terminal latching plate that

needs sliding out as far as possible (this plate
retains the terminals in place).

4 Electrical
4. Insert the wire with terminal into cavity K1 –

there is a tab on the terminal that should allow
this to be inserted one way only. This will pierce
the “mat seal”, which is perfectly normal.
Item Description
Pin K1 Vehicle Speed Signal

4 Electrical
5. Slide back the terminal latching plate, refit the
black cap (and refit cable tie as required), and
plug both connectors back into the PCM. Refit any
shields/covers.
Vehicle Speed Signal (VSO) for vehicles built after 26th September 2011
Terminal part number: 96AG-14474-RZA
Wire size and Color: 0.75 CSA, blue
For VSO location

144).
Terminal Insertion
1. Unplug connector from PCM, for location 2. Remove connector by aligning holes (1) with
spindle and applying gentle pressure to release
latch (2).
144).
E140617.

4 Electrical
3. Remove cable tie, then lever retaining clips

outwards and at the same time slide cap off
connector housing.
4. Insert wire with terminal into cavity 14 in

connector

4 Electrical
5. Refit cap and new cable tie. Plug connector
back into PCM. Refit any shields /covers.
Additional ‘Theater Lighting’ for rear of vehicle interior

Terminal part number: 3M5T-14474-DBA
Wire size and Color: 0.75 CSA, white-blue
note: this terminal will accept a wire size of 1.0 CSA; terminal 97BG-14474-ACB should be used for
wire size 1.5 CSA
Terminal Insertion
1. Lever out cream secondary lock along each of

the four sides of the connector, taking care not to
break the plastic.

4 Electrical
2. Secondary lock displaced.
3. Insert the wire with the pre-crimped terminal

into the correct cavity (C2-27) – the terminals are
polarized and will only fit one way.

4 Electrical
Pin 27 on connector C2 for 75W ‘Theater Lighting’
Item Description
Pin Rear Theater Lighting
27
4.Push home the cream secondary lock.
Third button on key fob
For Information only

As per Additional ‘Theater’ Lighting, but the pre-crimped wire is inserted in cavity C2-12.
Terminal part number: 97BG-14474-ACB
Wire size and Color: 1.5 CSA, yellow-violet
Additional Position Lights at the rear

Mating connector part number: 89FG-14A624-AB* Seal: 89FG-10C930-AA (Note: this is a waterproof
connector)
Terminal part number: 93FG-14421-BBA (0.5–1.0 CSA)
Wire size and Color: 0.75 CSA, violet-white (feed); black-yellow (ground)
If larger cross section wire is to be used (1.5–2.5 CSA), the following parts should be used: Terminal
part number: 93FG-14421-BCA Seal: 89FG-10C930-BA.

4 Electrical Connector for licence plate lighting
Item Description
1 Feed
2 Ground
Side (and End Outline) Marker Lights

Mating connector part number: F57B-14A624-F* Seal: integrated in connector
Terminal part number: E7EB-14461-BA
Wire size and Color: 0.75 CSA, violet-white (feed); black-yellow (ground)
Roof-mounted Position/Park Light – Front

Mating connector part number: 89FG-14A624-AB* Seal: N/A
Terminal part number: 93FG-14421-ABA (0.5–1.0 CSA)
Wire size and Color: 0.5 CSA, blue-brown / yellow-grey (feed); black / black-white (ground)
If larger cross section wire is to be used (1.5–2.5 CSA), the following part should be used: Terminal part
number: 93FG-14421-ACA.
Reverse Signal / Third Brake (Stop) Light (For Information Only)
Chassis Cab Only

Pin Function Wire CSA Color Terminal Seal
1 Ground 1.5 Black-Yellow 93FG-14421-BCA 89FG-10C930-BA
2 Brake Light 1.5 Violet-White 93FG-14421-BCA 89FG-10C930-BA
3 Position/Park 0.5 Yellow-Grey 93FG-14421-BBA 89FG-10C930-AA
Light
4 Direction Indicator 0.75 Green-Orange 93FG-14421-BBA 89FG-10C930-AA
5 Reverse Light 0.75 Green-Brown 93FG-14421-BBA 89FG-10C930-AA
6 Fog Light 0.75 Red 93FG-14421-BBA 89FG-10C930-AA
Mating connector part number: 89FG-14A624-AFB.

4 Electrical
4.20 Grounding
4.20.1 Ground Points Ground wires should be brought back to the Ford
ground points provided, please refer to the
CAUTIONS: following figures. For very high current users, it is
Only use the ground points indicated. recommended that the ground connection is
Using alternative points may affect the made directly to the ground point close to the
vehicle integrity. battery ground point.
Make sure that all ground points are Abbreviations used in tables:
tightened to the correct torque. • LHS - Left Hand Side
• RHS - Right Hand Side
• ABS - Anti-Lock Brake System, TCS - Traction
Control System, ESP - Electronic Stability
Program.
• Misc - Miscellaneous
Van, Bus, Kombi Ground Points

4 Electrical
Chassis Cab Ground Points

4 Electrical
Ground Points - Chassis Cabs and Van, Bus, Kombi
Ground Location Fixing Ford Part Number Torque Type Harness
Point Type
(GP)
GP29 Engine Bay LHS Screw W705661 S437M 12NM +/- Misc. Power 14401
M6 1.8 Electric
GP31 Engine Bay RHS Screw W705661 S437M 12NM +/- Misc. Power 14401
M6 1.8 Electric
GP33 A-Pillar LHS Screw W705661 S437M 12NM +/- Misc. Power 14401
M6 1.8 Electric
GP38 A-Pillar RHS Screw W705661 S437M 12NM +/- Misc. Power 14401
M6 1.8 Electric
GP8 Under Driver Seat Screw W706542 S409M 55NM +/- Battery Main 14301
M10 8.3 Ground
GP12* Cab Dash-panel Screw W705661 S437M 12NM +/- Airbag 14401
RHS M6 1.8
GP13 Cab Dash-panel Screw W705661 S437M 12NM +/- Misc. Power 14401
RHS M6 1.8 Electric
GP14 Cross Car Beam Nut M6 W520201 S437 7NM +/- Radio 14K024
LHS 2.0
GP15 Cross Car Beam Nut M6 W520201 S437 7NM +/- Misc. Power 14K024
RHS 2.0 Electric
GP16 Cross Car Beam Nut M6 W520201 S437 7NM +/- Misc. Power 14K024
LHS 2.0 Electric
GP19 Engine Bay LHS Screw W704960 S415 40NM +/- Engine Ground 14303
M10 6.0
GP20* Screw W705661 S437M 12NM +/- ABS/TCS/ESP 9K499
M6 1.8
GP21 Screw W705661 S437M 12NM +/- Power Control 9K499
M6 1.8 Module
GP22 Screw W705661 S437M 12NM +/- Misc. Power 9K499
M6 1.8 Electric
Van, Bus, Kombi only
GP49 D-Pillar LHS Screw W705661 S437M 12NM +/- Misc. Power 14405
M6 1.8 Electric
GP51 D-Pillar RHS Screw W705661 S437M 12NM +/- Misc. Power 14A005
M6 1.8 Electric
Note:Maximum number of eyelets per ground is 2, except those marked with an * the Restraint Control
Module (Airbag) and Anti-lock Brake System (ABS) which have dedicated grounds.
Note:GP8 - Figure E77393 shows cable and eyelet for battery main ground for vehicles built before
26th September 2011. For vehicle built after 26th September 2011 the bolt on the seat pedestal can
still be used as a ground point but the main cable will no longer be at this location.

4 Electrical

4 Electrical

5 Body and Paint 5.1 Body
5.1.1 Body Structures - General Pay attention to the following points:
Information • Disconnect the battery negative clamp and
cover the battery terminal.
When carrying out vehicle
• Disconnect the electrical connector at the
conversions/modifications the following points
airbag control module.
should be considered:
• If welding is to be performed directly near a
• Make sure that the vehicle structural integrity control module, it must be removed
is maintained. beforehand.
• Do not drill into closed frame body members. • Never connect the negative cable of the welder
• Make sure that the design for the body near an airbag or a control module.
alterations or additional structure disperse the • Connect the negative cable of the welder close
load evenly. to the location of the weld.
CAUTION: Uneven load distribution could
result in unacceptable handling and
braking characteristics. Before Welding
• Re-paint metal edges after cutting or drilling. Interior surfaces of new bodywork components
All metal edges must comply with exterior and which will no longer be accessible after installation
interior protection legislation. must be painted beforehand. The welding flanges
• All fixings through the floor, sides or roof must are treated with a special welding primer. The joint
be sealed. areas are not always accessible from inside later.
Refer to: 5.13 Corrosion Prevention (page 292). Therefore, prepare these areas so that no soot is
produced by burning paint during welding.
WARNING: Before drilling the floor, check
the no drill zones. NOTE: In order to ensure that the corrosion
protection produced in production is not destroyed,
See figure E74574 - Floor (No Drill Zones) under the working area must be kept as small as
the Floor Fuel Tank. possible.
• Make sure that fixings in the 'B'-pillar area do NOTE: Do not touch cleaned bare metal any more
not encroach on the seat belts or seat belt reels. with the bare hands. The dampness of your hands
For unique floor fixings, see (Frame Drilling and will corrode the metal.
Tube Reinforcing). Procedure:
Refer to: 5.14 Frame and Body Mounting (page 293). • Remove the primer or paint/zinc layer in the
welding area using a tress wire brush to prevent
For Load Compartment Tie Downs (Load Lashing
the formation of soot from the paint.
Points).
• Thoroughly clean the welding area with a metal
Refer to: 5.4 (page 268). cleaning agent and rub dry.
• Coat the welding flange with welding primer on
5.1.2 Welding all sides and allow to dry.
NOTE: The welding primer must only be applied
Before welding work is performed on a vehicle
thinly to the spot welding area, to minimize
body, all safety measures for the protection of
spattering when welding.
people, modules and electrical components must
be observed. The following points must be noted when
welding:
• Zinc starts to melt at about 420°C.
Electronic Components
• The zinc vaporizes at a temperature of about
Increased use of comfort and safety electronics 900°C.
in modern motor vehicles also requires the greatest • The amount of heating determines the damage
attention to be paid during body work. Over to the zinc coating, and therefore to the
voltages produced during welding and in alignment corrosion protection.
work during body shell rectification may cause • Resistance spot welding is particularly suitable
electronic systems to be damaged. In particular, for welding zinc-coated panels, because no
the safety instructions for performing welding work widespread warming occurs.
on vehicles with airbag systems must be adhered
• With electrolytically zinc-plated panels there
to.
is no need for any special preparation because
NOTE: After disconnecting the power supply and the zinc coating does not need to be removed.
before performing further work, a wait time of up
to 15 minutes must be maintained, depending on
the vehicle. Work on airbag systems may only be
performed by personnel who have a relevant
certificate of competence.

5 Body and Paint
After Welding NOTE: Only apply a small amount of panel
cleaner to the cleaning cloth when cleaning the
During work, body panels are often heated at very area. Make sure that no cleaner reaches the
high temperatures, which results in the destruction connecting flange, so that the welding primer is
of the corrosion protection. not washed away again.
Working of the affected areas is therefore vital: Priming after welding
• Grind the welded seams flat and clean Primer is applied to the welded flanges after
thoroughly with silicone remover. Dry with a cleaning. A check must also be made that the
lint-free cloth. production corrosion protection is present in the
• If the join area is accessible from the inside, the area of the flanges. Any damage must also be
transition area to the paint must be abraded re-primed.
for all types of join so that good adhesion of
the primer is achieved later.
5.1.3 Back Panel Removal
• If the join area is not accessible from the inside,
the cleaning and sanding work is not done. For When planning and specifying the base vehicle
this reason, ensure that there is as little and the conversion, select the Special Vehicle
contamination as possible in the area of the Option, which has a detachable cab back panel.
repair. This allows the cavity wax applied later Please consult your local National Sales
to penetrate the join area without hindrance. Representative for availability.

5 Body and Paint 5.1.4 Floor 'No Drill Zones' under the Floor Fuel Tank 80L (Optional 103L)
Floor 'No Drill Zones' Dimensions(mm)

1 Center line Front Wheel Axle D 1000
2 Center of 'B'-Pillar E 981
3 Center line of vehicle F 728 - for vehicles with standard 80L fuel tank
or 788 for vehicles with optional 103L fuel tank
A 1312 G 290
B 7 H 1180 for vehicles with fuel cooler
C 535 - -

5 Body and Paint
5.1.5 Integrated Bodies and • Unique spare wheel stowage may be required
Conversions if obscured by rear step, check for accessibility.
• The recommended dimensions for
For integral structures such as ambulances or wheelhouses on conversions are outlined in
motor-homes with increased rear overhang built Figures E74528, E74529 and E74530. However,
onto the chassis the following applies: in case a specific conversion requires
• Reduced departure angles, e.g. rear entry step, wheelhouse dimensions smaller than described
should be discussed with the end user / below, please consult the Vehicle Converter
customer. Consider removable components Advisory Service ([email protected]) for an
to avoid damage on ferries or low-loaders. individual solution.
Cab Van Floor Vehicle
Wheelhouse Dimensions for Cab Van Floor Vehicle

A 418mm G* 265mm
B 448mm H 268mm
C 164mm J 242mm
D 194mm K 696mm
E 141° L 89mm
F 197mm r 80mm
1 Center line of Vehicle
X Section through Center of Wheelhouse
* Dimension G is to the bottom of the swage

5 Body and Paint
Transit Motorhome Chassis
Wheelhouse Dimensions for Transit Motorhome Chassis

Rear Track Width 1722 mm Standard 1980 mm Wide
A 418mm G 308mm 308mm
B 448mm H 268mm 268mm
C 164mm J 242mm 242mm
D 194mm K 696mm 827mm
E 141° L 89mm 89mm
F 197mm r 80mm radius 80mm radius

5 Body and Paint
Chassis Cab with single Rear Wheel Axle for Front Wheel Drive and Rear Wheel Drive
Wheelhouse Dimensions for Chassis Cab with Single Rear Wheel Axle for Front and Rear
Wheel Drive Vehicles
A 418mm G 265mm
B 448mm H 268mm
C 164mm J 242mm
D 194mm K 696mm
E 141° L 80mm
F 197mm r 75mm

5 Body and Paint
Chassis Cab with Dual Rear Wheel Drive Axle
Wheelhouse Dimensions for Chassis Cab with Dual Rear Wheel Drive Axle
A 417mm G 436mm
B 445mm H 197mm
C 165mm J 265mm
D 194mm K 403mm
E 141° L 577mm
F 406mm M 27mm
1 Center line of Vehicle r 75mm

5 Body and Paint
4.6T Chassis Cab with Dual Rear Wheel Axle
Wheelhouse Dimensions for 4.6T Chassis Cab with Dual Rear Wheel Drive Axle
A 417mm G 436mm
B 445mm H 197mm
C 165mm J 215mm
D 194mm K 403mm
E 141° L 577mm
F 406mm M 27mm
1 Center line of Vehicle r 75mm
5.1.6 Chassis Cab • Do not drill into closed frame body members.
• Make sure that the design for the body
WARNING: Excessive heat can build up
alterations or additional structure disperse the
from the exhaust system, in particular
load evenly.
from the catalytic converter. Ensure
adequate heat shields are maintained. • Re-paint metal edges after cutting or drilling.
All metal edges must comply with exterior and
CAUTION: Uneven load distribution could interior protection legislation.
result in unacceptable handling and
braking characteristics. • All fixings through the floor, sides or roof must
be sealed.
When carrying out vehicle
conversions/modifications the following points Refer to: 5.13 Corrosion Prevention (page 292).
should be considered: • Ensure that any additional equipment in the
• Make sure that all of the reinforced holes vicinity of the fuel tank will not damage the
provided in the chassis frame top surface are tank in a crash condition.
used for full length bodies or sub-frames, see NOTE: The reinforcement plate in cab back panel
Figures E74860, E74861, E74862, E74863 and to chassis member area must be maintained,
E74696. please refer to Figure E74543.
• Make sure that the vehicle structural integrity
is maintained

5 Body and Paint Please refer also to the following figures: For any conversion structure attached to or
• Figure E74576 - Self Supporting Body Structure, mounted onto the base vehicle cab structure the
figure E74517 - Frame Drilling and Tube following applies:
Reinforcing and figure E74577 - Low floor • Ensure that neither the conversion structure nor
Standard Chassis Frame. the existing vehicle structure get pre-loaded by
the assembly process.
293). • Adhesive jointing is recommended but should
be supplemented with mechanical fasteners
• Figure E74678 - Driver's Standing Head Room to prevent initial peel and long term failure.
Refer to: 5.10 Roof Opening Panel (page 285). • Spread bolt loads to minimize local stress.
Body Attachment Holes in chassis Frame Top Flange Short Wheelbase
Dimensions (mm) for Body Attachment Holes in chassis Frame Top Flange Short Wheelbase
A 19 G 110
B 11 H 1406
C 104 J 665
D 101 K 592
E 804 L 730
F 799 M 506

5 Body and Paint
Body Attachment Holes in chassis Frame Top Flange Medium Wheelbase
Dimensions (mm) for Body Attachment Holes in chassis Frame Top Flange Medium Wheelbase
A 19 J 110
B 11 K 1406
C 100 L 367
D 101 M 665
E 104 N 592
F 804 P 730
G 801 Q 506
H 802 - -

5 Body and Paint
Body Attachment Holes in chassis Frame Top Flange Long Wheelbase
Dimensions (mm) for Body Attachment Holes in chassis Frame Top Flange Long Wheelbase
A 19 K 110
B 11 L 1406
C 100 M 450
D 101 N 367
E 104 P 665
F 800 Q 592
G 797 R 730
H 794 S 506
J 796 - -

5 Body and Paint
Body Attachment Holes in chassis Frame Top Flange Extended Frame
Dimensions (mm) for Body Attachment Holes in chassis Frame Top Flange Extended Frame
A 19 K 110
B 11 L 1406
C 100 M 450
D 101 N 367
E 104 P 665
F 800 Q 592
G 797 R 730
H 794 S 506
J 796 T 386

5 Body and Paint
Sub Frame Attachment to Chassis Frame
Item Description
1 Sub-frame Longitudinal
2 Sub-frame Outriggers
3 Compliant Mount
4 Chassis Frame
5 M10 Bolts and Self Locking Nuts
8 Solid or Fixed Mount
9 Chassis Frame
10 M10 Bolts and Self Locking Nuts

5 Body and Paint
Reinforcement Plate on Single Chassis Cab Vehicles (4.25 tonne)
Reinforcement plate on Single Chassis Cab Vehicles (4.6 tonne)

5 Body and Paint 5.1.7 Cab Van Floor • The body side skirt reinforcements are the main
area where the floor and/or the sidewalls of the
NOTE: Cab Van Floor Models are currently only conversion should be connected to. For this
available for use in Motor Caravan applications. purpose, use the holes and M8 weld nuts
For use in other applications contact your local provided on the top land and on the sides of
National Sales Company representative. the side skirt reinforcements.
Please refer to general advice and warnings for • It is recommended to use additional U-type
Chassis Cab. For the Cab Van Floor vehicle, the fixings around the main rails and cross members
following guidelines apply in addition: for floor fixings wherever possible.
• The Cab Van Floor as an incomplete vehicle • For additional seat fixings behind the cab.
does not offer a self supporting body structure, Refer to: 5.8 Seats (page 280).
you must add a box body. Figure E74532 Typical Design Principle for Cab
• Design a sufficient connection in the B-pillar Van Floor Seat Frame fixing.
area (sidewall to cab connection) as shown in • It is not recommended to cut the side skirt
Figure E74864. For additional bolt locations reinforcement for example a doorstep.
recommendations see figure E125352.
Attachments to the base vehicle.
Self–Supporting Body Structure.
Design Principle of fixing the Box to the 'B'-Pillar
Item Description
1 Forward Direction
2 Not Recommended Fixing of Box to 'B'-pillar
3 Recommended Design Principle of Fixing the Box to 'B'-Pillar (4x fixings)
Make sure that the fixings in the B-Pillar area For the existing holes, see Figure E125352, item 2,
maintain sufficient clearance between the fixings in the B-Pillar that are provided with the base
on the 'B' Pillar and the seat belts or seat belt rest. vehicle, it is recommended a maximum length of
It is recommended that you check the maximum fixing of 10mm.
length of the fixing to avoid any touch conditions.

5 Body and Paint
B-Pillar Clearance Area
Item Description
1 Seat Belt Retractor
2 B-Pillar Lower Hole - Maximum length of fixing is 10mm
3 Driving Direction

5 Body and Paint Spare Tire Access and Mounting
Spare Wheel Winch access on Cab Van Floor Variants
Item Description
1 Spare Wheel Winch
The spare wheel winch on Cab Van Floor variants • It is recommended to fix the converters floor by
is accessible from the side as illustrated in Figure using additional U-type fixings around the main
E74521. Ensure accessibility to the winch with given rails and cross members or by using screws
or especially designed tools after completion of running vertical through floor and rails. To
conversion and advise in owner's manual. eliminate deformation of the rails during
Refer to: 1.9 Jacking (page 24). screwing process. We recommend to use
tubing.
5.1.8 Transit Motorhome Chassis Refer to: 5.14 Frame and Body Mounting (page
293).
NOTE: Transit Motorhome Chassis Models are • For additional seat fixings behind the cab please
currently only available for use in Motorhome refer to
applications. Refer to: 5.8 Seats (page 280).
Please refer to general advice and warnings for Figure E74532 Typical Design Principle for Cab
Chassis Cab. For the Transit Motorhome Chassis Van Floor Seat Frame fixing
vehicle, the following additional guidelines apply: • The Transit Motor Home Chassis offers most
• The Transit Motorhome Chassis as an design flexibility for adding a sidestep.
incomplete vehicle does not offer a self • Due to the wider side overhang compared to
supporting body structure. A box body must the Cab Van Floor at same body width it is
be added. recommended to support vehicle converters
• Design a sufficient connection to the B-pillar floor.
(sidewall to cab connection) by using the 4 Refer to: 5.14 Frame and Body Mounting (page
holes and M8 weld nuts as shown in the Cab 293).
Van Floor figure E74864 and E125352 for • Do not cut or drill into reinforcement plate as
additional, recommended bolt locations. shown in Figure E131485.
• Design for a minimum floor thickness of 37mm • For basic dimensions and weights please refer
solid wood or equivalent. to Figure E131486 and table.

5 Body and Paint
• The Transit Motorhome Chassis offers an • For information on the Transit Motorhome
improved fixing strategy for rear extensions Chassis with standard track and wide track
with or without towbar. The extension can width rear axle please refer to Figure E131488.
either be put into the motorhome chassis rails • When designing the wheel arch, please note
or fixed to the outer side of them. For each that the spare wheel winch nut location on
strategy you must use all 4 fixing locations. Transit Motorhome Chassis is different to Cab
Refer to: 1.17 Towing (page 46). Van Floor. The Transit Motorhome Chassis
Figures E131484 and E131618. spare wheel winch nut is 54mm forward in x
direction and 43mm upwards in y direction to
• For attachment to the base vehicle
that of the Cab Van Floor location, please refer
Refer to: 5.14 Frame and Body Mounting (page to Figure E131487.
293).
Reinforcement Plate on Transit Motorhome Chassis

5 Body and Paint
Transit Motorhome Chassis - Spare Wheel Winch Location

5 Body and Paint
Standard and Wide Track Widths

5 Body and Paint
Transit Motorhome Chassis Track Widths
A Standard Track Width 1722mm
B Wide Track Width 1980mm
Transit Motorhome Chassis - Basic Dimensions and Weights
Description 350M 350L 350EF

A Wheelbase (mm) 3300 3750 3954
B Gross Vehicle Mass GVM (kg) 3500 3500 3500
C Max. Axle load front (kg) 1750 1750 1750
D Max. Axle load rear (kg) 2250 2250 2250
E Max. Trailer load (kg) 1000 1000 1000
F Max.Towing nose mass (kg) 75 75 75
G Standard track width (mm) 1722 1722 *
H Wide track width (mm) 1980 1980 1980
I Max. Rear Overhang/Extension (mm) = 60% of 1980 2250 2372
the wheelbase or the donor vehicle
J Max Body Width (mm) 2300
* For availability please contact your Local Ford Dealer or National Sale Representative.
5.1.9 Front End Integrity for Cooling, Lighting Do not alter the lighting system.
Crash, Aerodynamics and Lighting Crash Do not cut, drill or weld any parts that are
load path relevant in case of crash. Do not add
Cooling Continuous air flow through the front end material in the crash zone. This could affect the
and engine compartment is not to be hindered by crash sensor calibration.
adding any additional equipment. If uncertain
please consult the Vehicle Converter Advisory
Service [email protected].

5 Body and Paint
The side airbag system is not permitted if: • Sub-frame must extend to the back of the cab
• A swiveling device is fitted on the front seats. and attach to all mounting locations, with the
forward end designed to minimize local frame
• A side wall or any other additional material or
stress, please refer to figure E74575 sub-frame
structure is attached to the B-pillar inner
for low floor or other equipment. However it is
and/or outer area.
preferable to mount the sub-frame onto the
Static & Dynamic Sealing and Finishing Ensure mounting brackets with a clearance to the
proper sealing against ingress of water, salt, dust chassis frame top surface.
etc. after cutting or drilling the body. Use Ford • Side tipping loads/forces must be resolved by
approved sealing and finishing material, and the sub-frame. It is not recommended to strain
underbody corrosion protection. the chassis frame.
5.1.11 Tank and Dry Bulk Carriers
5.1.10 Tipper Bodies
Due to the high rigidity of tanks it is necessary to
For tipper conversions single and double Chassis isolate the tank and its sub-frame from the
Cab versions except extended rear chassis frame chassis frame allowing the chassis frame to
can be used. All variants allow single and three naturally flex. Please refer to the following
way tipping. guidelines:
It is recommended to have the tipping system • Mount tank to full length of sub-frame.
operative only when the engine is running. It is also • Mount sub-frame to all chassis frame
recommended to have the master control switch mounting points.
in the security of the cab. According routing of • The rear two sets of chassis frame mounting
wires and hydraulic lines please refer to section brackets should have solid full bolts torque
hydraulic lift. with 100% grip.
Ensure that axle plated weights including the front • The remaining forward location mounts must
axle minimum are not exceeded. be compliant to allow relative chassis frame
For tipper sub-frames please refer to the following to sub-frame deflections.
guidelines: • Sub-frame must extend to the back of the cab
• Design for full length continuous frame with and not contact chassis frame at forward end
mountings for motor, pump unit, reservoir, pivot under worst case deflection.
points and ram. • Compliant mounts should have captive fail
• Use all mounting points on chassis frame to safe through bolts, please refer to Figures
mount sub-frame. E74696 Sub-frame attachment to Chassis
frame and Figure E75880 Rigid or Torsion Stiff
• The rear two sets of chassis frame mounting sub-frame for Chassis Cab, with up to
brackets should have a full torque with 100% plus/minus 12mm compliance, vehicle laden
grip. The attachment to the remaining forward or un-laden whatever is worst case, rated at
chassis frame brackets must be precisely 2.0mm minimum deflection per 200kg mass
located and retained, but allow some relative each.
flexing between the sub-frame and chassis
frame. That is clamp control devices such as • Use two M10 grade 8.8 minimum bolts,
conical washer stacks or machine springs with washers and self lock nuts per chassis frame
self locking fastenings. mount bracket at each solid and compliant
location.
• Very stiff sub-frames may damage the chassis
frame by preventing its natural flexing,
therefore compliant mounts should be captive
fail safe with up to plus and minus 12mm
compliance, vehicle laden or un-laden
whichever is worst case, rated 2mm deflection
minimum per 200kg mass at each chassis
frame forward mount, please see also Figures
E74696 sub-frame attachment to chassis
frame and figure E75880 rigid or torsion stiff
sub-frame for chassis cab.
• Use two M10 grade 8.8 minimum bolts,
washers and self locking nuts at each solid and
compliant chassis frame location.

5 Body and Paint 5.2 Hydraulic Lifting Equipment
5.2.1 Hydraulic Lifting Equipment for • Use suitable clip to fix on vehicle body and sub
Van, Bus, Kombi and Chassis Cab frame.
• Offer master switch in the cab to isolate the
hole system.
General Information
Chassis Cab.
WARNINGS:
Do not to cut away any structural (Frame Drilling and Tube reinforcing)
member.
Equipped vehicles must be designed to
Cranes and Platforms
be stable under “worst case” operating
conditions with support legs extended, if It is recommended to mount Cranes and aerial
fitted. platforms on a full length sub-frame by using all
The vehicle converter/modifier is responsible for: load compartment tie downs for Van, Bus and
• Fitting decals, advising on the safe use of the Kombi as shown in Figure E75874 and all
equipment. reinforced holes on longitudinal rail for Chassis
Cabs as shown in Figure E75880.
• Route electrical and hydraulics separately and
away from original Ford equipment.

5 Body and Paint
Rigid or Torsion Stiff Sub-frame for Van, Bus and Kombi
Item Description
A Compliant Mount
B Fixed Mount

5 Body and Paint
Rigid or Torsion Stiff Sub-frame for Chassis Cab
Item Description
A Compliant mount
B Fixed Mount

5 Body and Paint
Sub-frame Mounted on Floor - Fixed Mount
Item Description
3 Floor of Van
4 Load Compartment Tie Down (Load Lashing Point)
It is recommended to design sub-frames in way

that there is no adverse strain on the vehicle
structure. For fixing elements please refer to
Figures E75875 and E75876 for Van, Bus and
Kombi and Figure E74696 for Chassis Cabs.

5 Body and Paint
Sub-frame Mounted on Floor - Compliant Mount
Item Description
3 Floor of Van
4 Load Compartment Tie Down (Load Lashing Point)
5 Captive Compliant Bush
For Van, Bus and Kombi: • Very stiff sub-frames should not be rigidly
• It is recommended to fix every mount with M8 mounted to the floor, please refer to Figure
bolt grade 8.8 minimum. For load compartment E75876 for an example of a compliant mount.
tie down locations. Compliant bushes should allow up to +/-12mm
movement at a rate of 100kg per 1.0mm
deflection with only the rear pair of load
(Figures E74505 - E74508).
compartment tie down mounting brackets
• It is recommended to fix sub-frame to the floor being fixed.
at the load compartment tie downs only. Any
• Support legs, if required, must be fitted directly
other floor contact should be padded to prevent
to the sub-frame.
local stress and to allow function of compliant
mounts. • Support legs must be designed to prevent any
adverse strain on the vehicle structure when
• It is not recommended to engineer through the
operating the equipment.
floor fixings to clamp around side members.
• If the load compartment tie downs are not CAUTIONS:
suitable see, Frame Drilling and Tube
Reinforcing. Safety devices must ensure the legs are
deployed when operating the lifting
Refer to: 5.14 Frame and Body Mounting (page equipment.
293).
Safety devices must ensure the legs are
stowed and locked away prior to engaging
vehicle drive.

5 Body and Paint
For Chassis Cab: • Stiff sub-frames, for example closed section
• Sub-frame ends must be relieved at forward Longitudinal rigidly connected with similar
end to minimize local contact stress section cross members, may damage the
concentrations, see Figure E74575. chassis frame by preventing its natural flexing.
Therefore compliant mounts should be used
Refer to: 5.14 Frame and Body Mounting (page with up to plus and minus (+/-) 12mm
293). compliance, vehicle laden or un-laden
(However it is recommended to mount the which-ever is worst case, rated at 2.0mm
longitudinal onto the mounting brackets with deflection minimum per 200kg mass at each
a clearance to the chassis frame top surface). chassis frame forward mount, please refer to
Figure E74696 for example of compliant mount
and Figure E75880 for location.
• Each set of brackets must use two M10 bolts
grade 8.8 minimum.
• For safety device on outriggers/legs please
refer to Van, Kombi and Bus.
Hydraulic tail lift
Item Description
A 1000mm
It is recommended to fix lift framework on bottom If mounted asymmetrical to the vehicle center
and on top side by using reinforcing plates and line or if mounted at side load door load capacity
through bolts. It is also recommended to design is up to 500kg at 1000mm from floor edge to
and/or locate the reinforcing plates in a way that center of load. For pillar lifts with adjustable reach
load can be routed into adjacent reinforced body swing jib fixed only to one rear door pillar load
structure. If mounted at rear door symmetrical to capacity is reduced to 100kg at maximum
the vehicle center line load capacity is up to 1000mm reach.
1000kg at 1000mm from floor edge to center of For load conditions as described above additional
load. stabilizing equipment is not necessary. Hydraulic
under-slung tail lifts are not recommended for
Transit Van, bus and Kombi.

5 Body and Paint For Chassis Cab with tail lift design as described
above it is recommended to use unique body
sub-frame for fixing to Chassis Cab structure. For
connection between sub-frame Chassis Cab body
structure please refer to Figure E74696.
For Chassis Cab with under-slung tail lift load
capacity is up to 1000kg at 1000mm from rear end
of chassis frame to center of load if mounted and
functioning on Center line of vehicle. If mounted
and functioning off center line or at the side of the
vehicle load capacity is reduced to 500kg at
1000mm from side/rear end to center of load.
Greater off-sets and/or loads require additional
stabilizing equipment such as outriggers or ground
jacks. It is recommended not to increase vehicle
body stress over limit as given by load factors
above. If uncertain please consult your local
national sales representative or the Vehicle
Converter Advisory Service [email protected].
It is the Vehicle converters responsibility to fit a
decal to the converted vehicle stating that the
equipment must not be used without
outriggers/ground jacks in operating position. It is
also the vehicle converters responsibility to
guarantee safe functioning of the equipment.
For hydraulic tail lifts as used for general loading
or more specialized for wheel-chair lifts please
refer to Figure E75874.

5 Body and Paint
5.3 Racking Systems
5.3.1 Racking Systems • To minimize stress in drip-rail area additional
cross brace roof bows are to be used.
It is recommended to choose Ford Regular
• If linings are planned for the inside of the load
Production Option racking system as shown in
area. All racking through bolts must be
figures E75924, E75925 and E75926. This fully
designed to be accessible through the lining to
crash tested solution can also be ordered as an
the body structure with spreader plate.
aftermarket fix. For further information please
contact your local National Sales Representative. • No load bearing fixing to the lining only.
• For increased crash performance the racking
For alternatively designs the following is
system should be designed with diagonal
recommended see Figures E75921 and E75922.
reinforcements.
• Frames should be rigid, self-supporting and • Vehicle should be equipped with Ford Regular
bolted through the floor using the standard Production Option bulkhead to give best
floor load lashing points at bottom side and protection to driver and front passengers.
also bolted through the body side structure at
roof rail level at upper side. • Preferably, there should be a rack each side to
balance the vehicle load.
• For alternatively fixing through the floor to the
side members please refer also to Figure
E74517 Frame Drilling and Tube Reinforcing.
Ford Regular Production Option Racking System (Left Hand Side Shown)

5 Body and Paint

5 Body and Paint
Design Proposal for non Ford Production Option Racking System (Left Hand Side
Shown)
Racking- Top Attachment, Cross Brace Roof Bow and Through Fixing
Item Description
1 Roof Panel
2 Full Width Cross Brace Bow
3 Through Bolt
4 Rigid, Self Supporting Rack Structure Fixed to Cross Brace Bow at Roof Height
5 Drip Channel

5 Body and Paint
Racking - Floor Fixings to Load Compartment Tie Downs

Item Description
1 Rigid Self-Supporting Racking Frame Work
2 Cross Brace
3 Load Compartment Tie Down

5 Body and Paint
Glass Racking on Outside of Van
Glass Racking on Outside of Van - Through Fixed to Internal Racking (Recommended Minimum )
Item Description
1 Top Load Bearing Attachments (2x)
2 Lower Load Bearing Attachments Through Body side to Internal Racking (2x)
3 New Through Bolts (2 bolts per top attachment and 1 bolt per lower attachment)
For designing glass carrying rack on body side

outer following unique requirements are
recommended:
• Do not fix the rack to the drip rail
• Construct internal rack and bolt through the
body side to the internal rack, see figure
E75923.
• Location in the drip rail gutter, if used, must be
protected to prevent future corrosion.

5 Body and Paint 5.4 Body System - General Information—Specifications
5.4.1 Van Floor - Load Compartment Tie Downs for Van, Bus and Kombi
Load compartment tie downs are available in most For tie down fixing location on the wheel arch refer
markets. If not ordered they can be retrofitted by to figure E103298. The forward load compartment
drilling the floor with care to access the plain M8 tie downs as shown are not available in
weld nuts. For details refer to the following figures combination with side load door(s). For vehicles
E74505, E74506, E74507, E74508 and the table with side load door(s) refer to figure E103316. For
'dimensions to locate compartment tie downs'. dimensions refer to table 'dimensions to locate
compartment tie downs'. In all cases use M8
thread rolling bolts.
Location of Wheel Arch M8 Weld Nut for Short, Medium and Long Wheel Base
Location of Wheel Arch M8 Weld Nut for Extend Frame

5 Body and Paint
Location of M8 Weld Nut in Door Step Area
Location of Underfloor M8 Weld Nuts for Short Wheel Base

5 Body and Paint
Location of Underfloor M8 Weld Nuts for Medium Wheel Base
Location of Underfloor M8 Weld Nuts for Long Wheel Base

5 Body and Paint
Location of Underfloor M8 Weld Nuts for Extended Frame
Dimensions to locate Load Compartment Tie Downs

(mm) Short Wheel Base Medium Wheel Long Wheel Base Extended Frame
Base
1 Center Line of Front Axle
A 1511.7
B High 1271.1 1533.8 1609.3 1609.3
Floor
B Low 1430.0
Floor
C 1609.3 1609.3 1609.3 1609.3
D High 1187.8 1486.4 1860.5 1860.5
Floor
D Low 1096.1
Floor
E 2212.8 2579.8 3029.8 3029.8
F 1312.0
G 261.4
H - 1187.8 1187.8 1187.8
K - 1533.8 1609.3 1609.3
L - - - 3752.8
M - - - 1609.3
Location of M8 Weld Nut in Door Step Area = 31.5mm down from floor to center of Weld nut and
286.8mm from front edge of floor back to centre of weld nut.

5 Body and Paint 5.5 Front End Body Panels
5.5.1 Partitions (Bulkhead) - Driver and Air circulation and body flexing must be also given
Front Passenger(s) Protection on Van, consideration when engineering an alternative
Bus and Kombi bulkhead. It is not recommended to restrict driver’s
or passengers’s seat adjustment travel.
The following two figures show the standard It is the vehicle converter’s responsibility to ensure
bulkhead fixing locations on B-pillar. These are local current legislation, governing bulkheads and
hexagonal holes for M6 thin sheet rivet type nuts. protective window grilles, is met. It is also the
The standard range of Ford Regular Production converter’s responsibility to ensure legal load
Option bulkheads can be retro-fitted at these constraint requirements if using a non Ford Regular
points. Production Option bulkhead.
Ford Regular Production Option bulkheads do have
a clearance between bulkhead and body structure
to allow natural body flexing and an air circulation
from the cab to the rear load space for ventilation
control.
Low Roof Bulkhead Fixing Holes

5 Body and Paint
Medium and High Roof Bulkhead Fixing Holes

5 Body and Paint 5.6 Body Closures
5.6.1 Load Compartment Interior • Use aluminium floor trims.
Lining • Plywood should be water resistant (WBP, water
and boil proof).
Do not damage the lock, hinge, latch or check arm
system (electrical cables, release system) when • It is recommended to use 9mm thickness for
applying interior lining. floors And 6mm thickness for side and door
lining.
Be careful not to damage the weather shield
(water shield covering inner door access hole) For any further details and advice please consult
when removing or applying interior door trim. your local National Sales Company representative
WARNING: Plan fixing points for other then please contact the Vehicle Converters
fitments such as racking to ensure Advisory Service at [email protected]
through bolting can be achieved. Fixing
to the lining material may be inadequate
for normal safe operation of the vehicle. 5.6.3 Security, Anti Theft and Locking
System
The additional weight of the linings on doors may
require additional reinforcements to the door and NOTE: It is not recommended to alter the locking
pillar at the hinge and check mechanism. system or damage the security shielding around
the lock and latch.
5.6.2 Plywood Lining/Cladding However, in case a modification is required for the
conversions, please consult the Vehicle Converter
Advisory Service [email protected].
To avoid locking system security complications, it
is recommended to discuss with the local Ford
dealer prior to modifications taking place.
When removing and reapplying door seals take
care to fit correctly, using the same seals as this
is critical to door closing efforts. Any modification
to the sealing flanges or surfaces will require
consultation with your local Ford dealer or Vehicle
Converter Advisory Service ([email protected]).
This may also include air extraction/venting
adjustments to assist door close efforts if
significant changes to closures are required.
CAUTION: Do not drill into the vehicle
before checking 'No Drill Zones' and The Central Junction Box is designed to work
electrical wire routing. specifically with the Ford Transit lock and latch
mechanisms and therefore drives latches to lock
Refer to: 5.6 Body Closures (page 274). and unlock for specific time periods. Additional
No drill zones on closures. power locking functionality should be based
Refer to: 5.1 Body (page 234). around the use of additional Ford Transit latch
No Drill zones and Racking Systems. mechanisms. Additional latches can be driven via
Refer to: 5.4 (page 268). relays connected in parallel with existing latches.
Load compartment tie downs.
On Chassis Cabs fitted with a high-level Passenger
• Panels should be precision cut by machine, not Junction Box, the cargo door latch driver is not used
by hand jigsaw, to reduce rough edges and by the base vehicle and can be used by Body
splinters. Builders wishing to add power locking capability
• Panels should be pre drilled. to the vehicle load space. This latch can be
• Do not drill through floor panels, use existing controlled via the driver's door key barrel or the
load lashing points when securing the panels. cargo unlock button on the remote key fob
(dependent on vehicle configuration).
• It is recommended that when fitting a plywood
floor that it is joint free. The following figures outline the areas in which it
is not advisable to drill

5 Body and Paint
No Drill Zone - Driver and Passenger Doors
No Drill Zone - Driver and Passenger Doors

Item Description
A 916.5mm
B 106.9mm
C 187.5mm
D 73.2mm

5 Body and Paint
No Drill Zone - Lift-Gate
No Drill Zone - Lift-Gate

Item Description
A 96.2mm
B 72.1mm
C 202.2mm
D 65.8mm

5 Body and Paint
No Drill Zone - Left Hand And Right Hand Side Sliding Doors
No Drill Zone - Left Hand And Right Hand Side Sliding Doors
Item Description
A 221.3mm
B 153.8mm
C 74mm
D 92.9mm

5 Body and Paint
No Drill Zone - Rear Cargo Doors
No Drill Zone - Rear Cargo Doors

Item Description
A 248.9mm
B 66.5mm
C 107.4mm
D 182.9mm

5 Body and Paint
5.7 Rear View Mirrors
5.7.1 Mirrors for Wide Vehicles NOTE: In addition it is necessary to order 2.3m
width pack which includes long arm mirrors and
Vehicles can be ordered with short or with long wide repeater lamps.
arm rear view mirrors on the outer side. Short arm
mirror is homologated up to 2.1m maximum body
width and long arm mirror up to 2.3m maximum
body width, see below Figure E77400, dimension
'X'.

5 Body and Paint 5.8 Seats
NOTE: When reassembling the seat and the seat For installation of non OEM rear seats, the rear
belt use specified bolts and ensure to apply the seats and seat belt systems need to comply with
specified torque. For torque specifications contact the relevant legal requirements and ECE directives.
your local Ford dealer or the Vehicle Converter Also
Advisory Service at [email protected] Refer to: 3.6 Exhaust System (page 94).
Vehicle Exhaust Systems - Vans with Bulkheads.
5.8.1 Van
5.8.3 Rear Seat Fixing Positions -
CAUTION: Do not install seats in the rear
Kombi Van
cargo area of a van.
The following figure shows the second and third
5.8.2 Windowed Van row seat fixing positions in the floor. These
positions are independent of the wheelbase.
The body and floor of a windowed van are not
equipped with the appropriate reinforcements
required for Original Equipment Manufacturers
(OEM) rear seats and seat belt systems. Do not
install original rear seats or rear seat belts.
Rear Floor Kombi Van Seat Fixing Positions
Item Description
1 Front Axle Center Line
2 Floor Height Step on Front wheel Drive Vehicles
3 Second Row Seat
4 Third Row Seat

5 Body and Paint
Rear Floor Seat Fixing Position Dimensions (mm)
A B C D E F G
1787 1372 849 1312 434 1048 752
5.8.4 Seat Frame Fixings - Typical design principle for Cab Van Floor
Cab Van Floor models are currently only available

for use in Motor Caravan applications. 5.8.5 Heated Seats
Rear seats, if assembled by a Vehicle Converter
/ Modifier, need to be tested according to the WARNING: The electrical feed for the
appropriate legal requirements and ECE directives. original heated Ford seat must not be
It is recommended to fix the seat frame at three used for other purposes, e.g. other
locations as shown in Figure E74532 which shows electrical consumers.
the typical design principle for Cab Van Floor seat It is not advisable to retrofit heated seats due to
frame fixings on top and underneath the floor. potential airbag operation or malfunction
Fixings should be carried out as U-type bracket (incorrect configuration).
clinching the cross beam.

5 Body and Paint 5.9 Glass, Frames and Mechanisms
5.9.1 Rear Windows • Cut the outer panel of the body side and door
to within 1mm of the inner panel flange.
For windows, it is recommended to specify the • Do not cut across panel joints or pillars.
base vehicle as a Kombi or Bus body - however,
• Use approved glass for installation according
when converting a van, the following should be
to legal requirements.
adhered to:
WARNING: For rear seat installation
Item Description
A Short Wheel Base
B Medium Wheel Base
C Long Wheel Base
D Extra Long Wheel Base

5 Body and Paint
Section Through Typical Van Body Side for Window Engineering
Item Description
A Horizontal Section Through 'C' Pillar
B Horizontal Section Through Rear Vent Window Hinge Pillar
C Vertical Section Through Side Window (Non Side Load Door)
Section through typical Van Body Side for Window Engineering

1 Glass 4 Window trim strip
2 Adhesive 5 Use standard vent hinge assembly
3 Cut within 0 and 1.5mm of inner body panel flange edge all around

5 Body and Paint 5.9.2 Heated Windshield and Heated
Rear Window
WARNING: The base system should not
be tampered with (controlled by Central
Junction Box and multiplex architecture)
and no feeds taken from the associated
wiring or controller.
These options are not suitable for aftermarket or
Vehicle Converter fit.

5 Body and Paint
5.10 Roof Opening Panel
5.10.1 Roof Cut Out - CAMPERS ONLY
For Chassis Cab, Campers, Motorhome Chassis
and Cab Van Floor vehicles, the Special Vehicle
Option “Roof Cut Out Preparation” is standard.
Figure E74678. Please consult your local National
Sales Company representative for availability.
Chassis Cab with Roof and Back Panel Removed
5.10.2 Back Panel and Roof Removal Use metal fasteners through double thickness
flanges for example with nuts, bolts and spreader
A unique Body Builder application where the plates where possible.
original Ford roof and back panel structure are cut “Pop” type rivet structural value is only as good
away must have a bolt-on reinforcing 'goal post' as the material or thickness of the body panels,
structure or equivalent to resist seat belt pull therefore ensure the application is suitably
loads. engineered.
Where new add-on bodies are attached to the Protect all metal edges to comply with interior
cab for an enclosed walk-through, the body projection legislation. Corrosion protect all cut or
structure must be self-supporting and fixed such drilled metal edges and repair any paint damage.
that no local stress is created in the parent cab
structure.

5 Body and Paint 5.10.3 Roof Ventilation
Sun Roof Retrofit Option
Item Description
1 Local form in Roof Panel (Low Roof Only)
General - Apertures must not cut through roof Ventilation Units -The roof panel can support
bows. Ventilators must prevent direct entry of up to 1kg on an unsupported area of roof. Loads,
water and dust. A shut-off system should be up to a maximum of 25kg must be distributed over
available to prevent fume ingress. Interior and 2 - roof bows.
exterior projection legal requirements must be
Air Conditioning Units - Units weighing more
maintained. than 25kg must be internally supported on cross
Sun Roof -The low roof has provision in the roof brace members distributing the load out to the
swage pattern to accommodate a retrofit glass roof rails.
roof above the driver as shown in the figure
E74679.

5 Body and Paint
5.10.4 Roof Racks
Roof Rack Vehicle Converter Special Fit
Item Description
1 Rear edge of Cab Doors 'B'-Pillar
2 100kg Maximum
3 Maximum roof rack length Short Wheel Base:2500mm / Long Wheel Base 3282mm
4 Maximum Load Height 300mm
5 Drain Channel
6 Roof Rack Supports each side, Short Wheel Base: 3 foot attachments / Long Wheel Base 4
foot attachments
* Maximum 75Kg per attachment foot worst case
Roof racks may be fitted to all van, bus and kombi • The rack is clamped to the drip rail at six (6)
variants as illustrated in figure E75917, providing points per illustration, or alternatively bolted
the following is satisfied: through the roof panel with minimum six (6)
• The carried load does not exceed 100kg (Body M8 bolts, self locking nuts and 3mm X 50mm
Builder to ensure owner’s hand book identifies square spread plates.
this limitation). • The rack leading edge preferably should not
• The carried load does not exceed 300mm load be located forward of the rear edge of the
height (converter to ensure owner’s driver’s door, or “B” pillar as shown.
information book identifies this limitation).
• The load is evenly distributed (converter to
ensure owner’s information book identifies this
limitation).
• The rack and subsequent carried load is
supported in the roof drip rails irrespective of
rack retaining method.
• The unit load on the roof drip, under worst case
loading, must not exceed 75kg per rack foot.

5 Body and Paint Double Cab
The forgoing limitations are based on ensuring

body structure integrity, vehicle handling, braking
and plated axle weights. Such considerations must
also be applied to any double cab applications, in
particular steering, braking and front axle plated
weight and the extra continuous loads on the “A”
pillar, which should not exceed 60 kg total
incremental load.
Ensure that the planned loaded vehicle operates
within its designed Center of Gravity condition. For
details please consult the Vehicle Converter
Advisory Service [email protected]

5 Body and Paint
5.11 Airbag Supplemental Restraint System (SRS)
5.11.1 Air Bags The airbag sensors for side airbags are located at
the bottom of the B-pillar, see figure E74470.
WARNING: Modifications or
Front Seats
reinforcements in the area of the sensors
Side airbags are not compatible with swiveling may affect the side airbag fire timing and
front seats. result in uncontrolled side air bag
deployment.
Do not specify the base vehicle with side airbags
when planning to retrofit a swiveling device on Please note that vehicles not equipped with side
the front seats and/or an armrest on the outer airbags but equipped with front airbags only are
side of the front seats, this may affect the function not affected.
and/or deployment of the side airbags. Drilling or grinding operations in this area are only
permitted when battery cables are disconnected.
Driver and Passenger Front Airbag Deployment Zones

5 Body and Paint
Position of the Side Air Bag Sensor on the Left Hand Side

5 Body and Paint
5.12 Safety Belt System
WARNING: Follow removal and
installation procedures for the seat belt
system to ensure correct function of the
restraints system.
The removal and reinstallation of the seat belt,
restrainer or any component of the seat belt
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 seat belt system as described in
the workshop manual. Please consult your local
National Sales Company representative for further
information.
When removing the seat belt system, a seat belt
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 5.13 Corrosion Prevention
5.13.1 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.
For Welding:
5.13.2 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. For
specifications consult the Vehicle Converter
5.13.3 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 or the Vehicle Converter
5.13.4 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.
5.13.5 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
5.14 Frame and Body Mounting
5.14.1 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 Refer to: 5.13 Corrosion Prevention (page 292).
additional equipment. Always use chassis mounts
as shown in E74575 'Sub Frame for Low Floor or
other Equipment - Chassis Cab'. If additional
fixings are required please follow the
recommendation given in figure E74517. This does
not apply to areas of load applications such as
spring fixings or damper fixings.
Frame Drilling and Tube Reinforcing

5 Body and Paint
1 Alternative top hat chassis closure for 11 Floor-minimum thickness 37mm
4.6 tonne chassis cab.
2 Full Penetration; Full diameter weld each A 30mm to 35mm
side.
3,4,5 Center line of holes / tubing B Diameter 16.5mm maximum
6 Screw C Diameter 11mm
7 Longitudinal rail D 30mm to 35mm
8 Screw nut E 50mm minimum
9 It is recommended to always use a tube F 20mm to 25mm
10 It is recommended to always use - -
washers

5 Body and Paint
Sub Frame for Low Floor or other Equipment - Chassis Cab
Item Description
1 Continuous longitudinal float or body support member
2 Always use both sides of all chassis mounts
3 Cross members
4,5,6 Relief front end and longitudinal if there is a risk of stress concentration in chassis frame from
longitudinal contact
A 5mm (minimum)
B 50mm (minimum)
C 50mm width for all brackets
D Avoid longitudinal contact if possible which may create stress concentration
r 20mm (minimum)

5 Body and Paint 5.14.2 Self-Supporting Body Structure • Each cross member has a suitably engineered
connection to the body side wall (3) or to the
Bodies and structures can be judged as continuous floor frame (5), see Fig. E74576.
self-supporting providing they maintain the • The body side wall or the continuous floor
following rules: frame supports any overhang beyond the
• Cross members are used at each chassis chassis frame, whether on standard frame or
mounting point, please refer to Figures. E74576, extended frame.
E74860, E74861, E74862 and E74803.
Typical Design Principle of a Self-Supporting Body Structure
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
onto the top surface of the chassis frame.
Alternatively, the self-supporting body structure • See Fig.E74577 for a generic vehicle cross
can also be designed as shown in Fig. E74577. section where the cross members and opposing
out riggers are flush with the surface of the
chassis frame side members.
• It is important to the overall function of the
vehicle structure that the out riggers are each
connected to a continuous longitudinal floor
side frame or a structural body side structure
assembly.

5 Body and Paint
Low floor-re-work for guidance only: • Out-rigger outboard ends should be attached
• Engineer unique cross members and to load bearing body side / floor edge frame or
out-riggers spaced at approximately 600mm body side structure (including over wheel
maximum pitch. support).
• Out-rigger moment to be re-acted with • Structural wheel box should maintain
cross-member between chassis frame with longitudinal continuity with a rigid attachment
common through bolts where possible (see to the floor edge frame or to the body side
Figure E74577 Low floor standard chassis structure.
frame) • Floor boards should be substantially attached
• Drill frame and add spacer tubes. to cross members and outriggers, but not to
the chassis frame top surface.
293). • Low floor exhaust heat shields.
Frame Drilling and Tube Reinforcing, Figure Refer to: 3.6 Exhaust System (page 94).
E74517.
Low Floor Standard Chassis Frame
Item Description
1 Vertical center line of vehicle
2 Floor panel
3 Continuous floor edge longitudinal
4 Outrigger
5 Low floor

5 Body and Paint 5.14.3 Extended Chassis Frame • It is the Body Builder's responsibility to mark-up
the owners’ handbook advising the available
General: payload. Axle plated weights and maximum
• Rear overhang extensions are available as allowable axle mass as shown in this manual
Regular Production Option. must not be exceeded.
• Bodies or equipment exceeding the standard • The vehicle should be planned for uniformly
extension length must be supported, please distributed loads.
refer to Figure E74575 low body longitudinal
members or Figure E74576 self-supporting body
structures.

5 Body and Paint
5.14.4 Non Standard Rear Chassis Frame Extension
Item Description
1 Cross member
2 Rear spring hanger
3 4x M10 bolts
4 Spacer tube assembly
5 Flanges removed
6 New flanges for under-run bar
7 2x M10 bolts
8 Spacer tube assembly
9 4.25 tonne (up to March 2008), 4.6 tonne (March 2008 onwards)

5 Body and Paint Extensions longer than the standard Regular • It is recommended that the altered extension
Production Option must comply with the following has a similar closed section, material thickness
guidelines: and properties to the existing chassis frame.
• The original rear cross member and or • An equivalent open section for the extension
under-run bar or equivalent must be assembly is at the vehicle converters discretion.
repositioned at the end of any altered extension • Lightening holes in new extension and cross
to meet legislation, please refer to figure members are discretional.
E74578 Non Regular Production Option rear
• Do not weld original chassis frame except as
chassis frame extensions. Also
specified when adding reinforcing tubes, please
Refer to: 1.17 Towing (page 46). refer to figure E745171.
Figure E74854. • Do not drill the top or bottom surface of the
• The standard fit under-run bar is bolted on as chassis frame, including the flanges turned out,
shown in figure E74578 and figure E74854 as except as recommended above for continuity
mentioned in previous paragraph. of closure.
• The altered extension assembly must include • Any alternative finish such as hot dip galvanizing
a cross member adjacent to the end of the is at the discretion of the Body Builder providing
original chassis frame to replace the relocated it does not have a detrimental effect on the
under-run bar, refer to figure E74577. original Ford product.
• Flat-beds and low bodies built onto Non Refer to: 5.13 Corrosion Prevention (page 292).
Regular Production Option extensions must
have continuous longitudinal members
engineered by the Body Builder or equipment 5.14.5 Frame Drilling and Tube
supplier, refer to figure E74577, to resolve the Reinforcing
worst case moments at rear bump stop.
• Extensions should be secured to the chassis The chassis frame may be drilled and reinforcing
frame sandwiched under the rear spring shackle spacer tubes may be welded in place, providing
bracket utilizing the four (4) bolts and four (4) the following is applied:
holes in the rear of the chassis frame, totaling • Adhere to all details shown in figure E74517.
eight (8) per vehicle side, refer to figure E74578. • Drill and weld only side walls of the chassis
• The four (4) rear most existing holes in the frame.
chassis frame must be sleeved with tubes to • Locate and drill holes accurately, using a drill
prevent chassis frame collapse, refer to figure guide to ensure holes are square to frame
E74578. vertical center line (note: allow for side member
• The spacer tubes should, ideally, be part of a draft angle).
welded bracket and tube assembly to hold the • Drill undersize and ream out to size.
tubes accurately in place, avoiding the need to
weld the tubes in place, refer to figure E74578. • Endeavor to remove all swarf from inside side
member, and treat to prevent corrosion.
• Care must be taken when tightening the spring
shackle bracket bolts and nuts to the correct • Fully weld each end of the tube and grind flat
torque. and square, in groups if applicable. Be aware
of side member draft angle.
Refer to: 1.15 (page 37). • Apply corrosion protection inside and outside
Hardware - Specifications for tightening of the chassis frame.
torques.
• Extensions sleeved over the outside of the Refer to: 5.13 Corrosion Prevention (page 292).
chassis frame will necessitate the removal of • Holes should be in groups of two (2), either
the under-run bar attachment flanges turned vertically spaced at 30 to 35mm from chassis
out at the chassis frame ends. The cut edges frame top and/or bottom surface, or
must be protected against corrosion. horizontally at 50mm minimum pitch, 30 to
35mm from top and/or bottom chassis frame
Refer to: 5.13 Corrosion Prevention (page 292). surface, please refer to figure E74517.
• Drilling of the top flanges turned out is only • Always use M10 bolts with grade 8.8 minimum.
permissible rearward of the spring hanger
brackets, for continuity of the altered extension • Do not position tubes at the medium chassis
closing plate, if required. The diameter of the frame height, this may create “oil canning” of
holes should be 6.0mm maximum. the deep section side walls.
• If the chassis frame includes the inverted top • Where possible, the outrigger moments should
hat closure of the 4.25 (pre 2008.25MY) and be resolved by matching inner cross members
4.6 tonne (2008.25MY onwards) chassis cab between the chassis side members inline with
single/double variant, then a similar closure the outriggers, please refer to figure E74577-
must be included in the extension and sleeved Low Floor.
over the chassis frame. It will be necessary to • A diameter of 16.5mm is the maximum
add two (2) holes and reinforcing tubes in the allowable hole size in the chassis frame side
inverted top hat chassis frame vertically in line wall, irrespective of the usage.
with the group of four (4) holes refer to figure
E74578.

5 Body and Paint
Avoid drilling into closed frame body members to • Fore and after longitudinal bracing must be
avoid the risk of corrosion from swarf. added between the rear-most two (2) cross
members only.
• All chassis frame mounting holes / locations
Drilling and welding of frames and body structure must always be used.
have to be conducted following the guidelines.
Please consult the Vehicle Converter Advisory • All chassis frame mounting bracket fastenings
Service [email protected] for details. must have a full bolt torque with 100% friction
grip.
Welding.
5.14.7 Area for Fitting Additional Body
Attachments to the Rear of the
5.14.6 Ancillary Equipment - Sub Bumper
Frame Mounting
NOTE: With the vehicle on level ground and with
Typical sub-frames and longitudinal members for all measurements taken rear ward of the bumper
flatbed and low or drop-side bodies or equipment bar edge. The area designated for the fitting of
exceeding the standard or regular production attachment is defined as 220mm horizontally by
order frame length should adhere to the following 95mm vertical downward to the road surface,
guidelines: with a max width of 1390mm about vehicle center
• Flat-beds and low bodies mounted on integral line.
longitudinal members (channel or box section It is not the manufactures recommendation to fit
metal – not wood) must use both sides of all additional body attachments (tow bars, steps,
frame mounting brackets, refer to figure bicycle racks & carriers) outside of the designated
E74575. area. In order to comply with the 4.6T vehicle's
• Longitudinal members must be relieved at the permissible departure angle, when operating at
front end if they are to contact the chassis max GVM.
frame top surface, to minimize stress
concentrations, refer to figure E74575.
However, it is preferable to mount the
5.14.8 Water Tank on Camper Vehicles
longitudinal onto the mounting brackets, with
NOTE: It is recommended that a decal or label is
a clearance to the chassis frame top surface.
fitted adjacent to the filler aperture identifying the
• Each set of brackets must use two (2) x M10 correct fluid to be used, for example: 'Water only'
bolts grade 8.8 minimum. for water tanks.
• The rear two (2) sets of chassis frame
mounting holes/locations should have a full
bolt torque with 100% grip. The attachment
to the remaining forward chassis frame holes
/ locations must be precisely located and
retained, but allow some relative flexing
between the sub-frame and chassis frame. For
example, clamp control devices such as conical
washer stacks or machine springs with self
locking fasteners.
• Minimum floor heights will require wheel arch
boxes to clear the rear tires,
Integrated Bodies and Conversions.
• Chassis frame, for example: clamp control
devices such as conical washer stacks or
machine springs with self locking fastenings.
Pedestal mounted low or drop side bodies – not
illustrated.
For bodies or equipment not exceeding the
standard or Regular Production Order chassis
frame length.
For flat-beds and low bodies raised above the
maximum “jounced” tire position to obtain an
uninterrupted flat floor surface see vehicle data
sheets.

Index A Connectors.....................................................................201
Contact Corrosion.......................................................292
About This Manual..........................................................6
Contact Information.......................................................9
Accessory Drive..............................................................84
Conversion Affect on Fuel Economy and
Adding Connectors, Terminals and Wiring.........215
Performance.................................................................22
Adding Heated Mirrors...............................................189
Conversion Affects on Parking Aids.......................30
Additional External Lamps......................................168
Conversion Homologation..........................................19
Additional Ignition, Instrument Panel Illumination
Conversion Type..............................................................13
and Air Conditioning On Signals..........................185
Corrosion Prevention.................................................292
Additional Internal Lamps........................................170
Customer Connection Points..................................178
Additional 'Theater Lighting' for rear of vehicle
interior............................................................................170
Additional Vehicle Signals / Features...................191 D
Aids for Vehicle Entry and Exit.................................30 Diesel Particulate Filter (DPF).................................95
Air Bags..........................................................................289 Door Removal or Modification.................................172
Airbag Supplemental Restraint System Drilling and Welding........................................................8
(SRS)............................................................................289 Driver Field of View.......................................................30
Air Flow Restrictions....................................................83 Driver Reach Zones.......................................................30
Alternative Type Approval.............................................7 Driveshaft.........................................................................58
Ancillary Equipment - Sub Frame Mounting.....301
Anti-Lock Control - Stability Assist........................62
Area for Fitting Additional Body Attachments to E
the Rear of the Bumper..........................................301 Electrical Connectors and Connections..............201
Auto Wipe and Auto Light for Campers or Electrical Conversions................................................124
Vehicles with large over-hangs...........................200 Electrically operated Door Mirrors.........................169
Auxiliary Fuses, Fuse Box and Relays (Fuses - Electrics for Tow bar.....................................................111
Standard)......................................................................177 Electromagnetic Compatibility (EMC).................20
Auxiliary Heater Installation......................................83 Electronic Engine Controls.......................................144
Auxiliary Heater Systems...........................................82 End of Life Vehicle (ELV) Directive..........................23
Engine Cooling................................................................82
B Engine................................................................................63
Engine Power Curves...................................................63
Back Panel and Roof Removal..............................285 Engine RPM (Revs Per Minute) Speed
Back Panel Removal..................................................235 Controller......................................................................154
Battery and Cables......................................................127 Engine Run Signal (D+ Alternative).......................151
Battery Disconnect Switch (Split Charge Exhaust Heat Shields..................................................94
Relay).............................................................................134 Exhaust Pipes and Supports....................................94
Battery Information.....................................................127 Exhaust System.............................................................94
Battery Monitoring Sensor (BMS).........................133 Extended Chassis Frame.........................................298
Body.................................................................................234 Extensions and Optional Exhausts........................94
Body Closures...............................................................274 Exterior Lighting...........................................................168
Body Structures - General Information..............234
Body System - General
Information—Specifications................................268 F
Brake Hoses General....................................................59 Fitting a Tachograph to vehicles built with out
Brake System..................................................................59 Digital Tachograph Option.....................................162
Fitting Equipment Containing Electric
C Motors............................................................................125
Fitting Instructions for 4.6 Tonne and 3.5 Tonne
Cab Van Floor...............................................................248 HD (derated)................................................................46
Calibration and Tachograph Fitting......................163 Floor 'No Drill Zones' under the Floor Fuel Tank
Camper Central Connectors...................................202 80L (Optional 103L)...............................................236
CAN-Bus System Description and Interface......115 Frame and Body Mounting......................................293
Cellular Phone...............................................................167 Frame Drilling and Tube Reinforcing..................300
Center of Gravity...........................................................40 Front, Rear and Side Under-run Protection.........33
Central Junction Box (CJB).......................................116 Front and Rear Brakes..................................................61
Central Locking.............................................................174 Front End Accessory Drives - General
Changing Vehicle Speed Maximum Setting......158 Information...................................................................84
Charge Balance Guidelines......................................125 Front End Accessory Drives - Vehicles built after
Charging System..........................................................120 26th September 2011................................................89
Chassis Cab....................................................................241 Front End Accessory Drives - Vehicles built
Circit Diagram.................................................................119 before 26th September 2011..................................85
Circuit Diagram..............................................................118 Front End Body Panels..............................................272
Circuit Diagrams...........................................................125 Front End Integrity for Cooling, Crash,
Climate Control System.............................................141 Aerodynamics and Lighting..................................254
Clutch..................................................................................91 Front Suspension..........................................................55
Commercial and Legal Aspects..................................7 Fuel System....................................................................96
Communications Network........................................115 Fuses and Relays..........................................................177
Connector Pin Out Practices....................................101
302
Index
G Manual Transmissions Built Before 26th
September 2011..........................................................92
General...................................................................59, 292
Minimum Requirements for Brake system and
General Component Package Guidelines..........30
Load Apportioning Valves.........................................8
General Information and Specific
Mirrors for Wide Vehicles........................................279
Warnings......................................................................120
Module Communications
General...................................................................59, 292
Network—Specifications........................................119
General Product Safety Requirement.....................7
Mounting Points and Tubing.................................293
General Wiring and Routing....................................101
Generator and Alternator........................................138
Glass, Frames and Mechanisms..........................282 N
Grounding.............................................................101, 229 New for this BEMM publication 12/2012................6
Ground Points.............................................................229 No Drill Zones - Rear Cargo Area..........................102
Noise, Vibration and Harshness (NVH)...............28
H Non Standard Rear Chassis Frame
Extension....................................................................299
Handles, Locks, Latches and Entry
Systems........................................................................172
Hardware—Specifications.........................................37 P
Harness Routing..........................................................101 Package and Ergonomics—Specifications..........31
Heated Seats................................................................281 Package and Ergonomics.........................................30
Heated Windshield and Heated Rear Painting Road Wheels.......................................57, 292
Window.......................................................................284 Parking Brake................................................................60
Horn.................................................................................143 Partitions (Bulkhead) - Driver and Front
How to Use This Manual..............................................6 Passenger(s) Protection on Van, Bus and
Hydraulic Brake Actuation.........................................61 Kombi...........................................................................272
Hydraulic Lifting Equipment..................................256 Plywood Lining/Cladding........................................274
Hydraulic Lifting Equipment for Van, Bus, Kombi Police and Emergency Vehicle Harness............207
and Chassis Cab......................................................256 Possible Accessories.................................................165
Power and Torque Curves for vehicles built after
I 26 September 2011....................................................74
Power and Torque Curves for vehicles built
Ignition Feed.................................................................179
before 26 September 2011.....................................64
Important Safety Instructions...................................6
Power Management Settings................................123
Information and Entertainment System -
Power Take Off.............................................................58
General Information—Specifications...............164
Prevention of Squeaks and Rattles......................101
Instrument Panel Cluster (IPC).............................142
Product Liability..............................................................8
Integrated Bodies and Conversions....................237
Interior Lighting............................................................170
Introduction......................................................................6 Q
Qualified Vehicle Modifier (QVM)............................8
J
Jacking..............................................................................24 R
Racking Systems........................................................263
K Radio Connector.........................................................164
Rear Anti-Roll Bar........................................................56
Kerb Mass Data.............................................................59
Rear Seat Fixing Positions - Kombi Van...........280
Rear Suspension..........................................................56
L Rear View Mirrors.......................................................279
Lamps for Wide Vehicles.........................................169 Rear Windows.............................................................282
Lamps – Front and Rear Fog Lights....................169 Recommended Main Dimensions...........................31
Lamps – Hazard / Direction Indication..............169 Recommended Main Load Area Dimensions for
Legal and Vehicle Type Approval..............................7 Bulkhead with Depression Driver Side...............34
Legal Obligations and Liabilities...............................7 Recommended Main Load Area Dimensions for
Legislation.....................................................................159 Bulkhead with Full Depression.............................35
Lifting................................................................................26 Recommended Main Load Area Dimensions for
Load Apportioning Valves..........................................61 Double Cab In Van Bulkhead.................................36
Load Compartment Interior Lining......................274 Relays and Switches.................................................186
Load Distribution—Specifications.........................38 Repairing Damaged Paint.......................................292
Load Distribution Calculations - Driver and Restraints System..........................................................8
Passenger Weight Distribution.............................38 Reversing Lamps........................................................168
Locking strategy for M2 Conversion.....................173 Road Safety......................................................................8
Roof Cut Out - CAMPERS ONLY..........................285
Roof Mounted Front and Rear Beacons............106
M Roof Opening Panel.................................................285
Manual Transmission.................................................92 Roof Racks....................................................................287
Manual Transmissions Built After 26th Roof Ventilation.........................................................286
September 2011..........................................................93
303
Index S Wiring Harness Information.....................................101
Wiring Harness Installation and Routing...........109
Safety Belt System......................................................291
Wiring Installation and Routing Guides...............101
Seat Frame Fixings - Typical design principle for
Wiring Specification.....................................................177
Cab Van Floor.............................................................281
Wiring Splicing Procedures.......................................101
Seats...............................................................................280
Security, Anti Theft and Locking System...........274
Self-Supporting Body Structure...........................296
Spare Wheel....................................................................57
Special Conversions...................................................190
Special Vehicle Options (SVO) and Aftermarket
Kits..................................................................................190
Special Vehicle Option (SVO) Auxiliary Fuse
Box..................................................................................180
Special Vehicle Option (SVO) Switches............184
Springs and Spring Mounting............................55, 56
Start-Stop - Vehicles built after 26th September
2011.................................................................................144
Suggested Antenna Location....................................21
Suspension System......................................................54
System Operation and Component
Description....................................................................121
T
Tachograph Mounting...............................................160
Tachograph....................................................................159
Tank and Dry Bulk Carriers......................................255
Terminology........................................................................7
Third Button on Key Fob............................................176
Tipper Bodies...............................................................255
Tire Manufacturers........................................................57
Tire Repair Kit..................................................................57
Tow Bar Requirements................................................46
Tow bars...........................................................................46
Towing...............................................................................46
Transit Motorhome Chassis....................................250
U
Under Body Protection and Material...................292
V
Van Floor - Load Compartment Tie Downs for
Van, Bus and Kombi................................................268
Van...................................................................................280
Vehicle Configuration change.................................163
Vehicle Duty Cycle Guidelines...................................22
Vehicle Electrical Capacity - Alternator...............125
Vehicle Exhaust Systems - Vans with
Bulkheads......................................................................95
Vehicle Ride and Handling Attributes....................22
Vehicle Speed Output (Signal)..............................145
Vehicle Transportation Aids and Vehicle
Storage............................................................................29
W
Warnings, Cautions and Notes in This Manual.....6
Warranty on Ford Vehicles............................................7
Water Leakage Prevention........................................101
Water Tank on Camper Vehicles............................301
Welding...........................................................................234
Wheel Clearance............................................................57
Wheels and Tires...........................................................57
Windowed Van............................................................280
Windscreen wipers.....................................................188
Wiring Harnesses........................................................106
304

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Body and Equipment Mounting Manual

FORD TRANSIT 2006.5

Date of Publication: 12/2012

© Ford Motor Company 2014

All rights reserved.

1.1.2 Introduction CAUTION: Cautions are used to indicate

Date of Publication: 12/2012

1.2.2 Warranty on Ford Vehicles 1.2.6 General Product Safety

FORD TRANSIT 2006.5 Date of Publication: 12/2012 7

Date of Publication: 12/2012

FORD TRANSIT 2006.5 Date of Publication: 12/2012 9

Date of Publication: 12/2012

FORD TRANSIT 2006.5 Date of Publication: 12/2012 11

Ford of New Zealand

Date of Publication: 12/2012

Van conver- Refer to: 3.7 Fuel System (page 96).

Chassis Refer to: 3.7 Fuel System (page 96).

FORD TRANSIT 2006.5 Date of Publication: 12/2012 13

Date of Publication: 12/2012

Refuse Collec- Refer to: 4.11 Tachograph (page 159).

Vehicle Trans- Refer to: 4.11 Tachograph (page 159).

FORD TRANSIT 2006.5 Date of Publication: 12/2012 15

Coach Built Refer to: 4.15 Interior Lighting (page 170).

Date of Publication: 12/2012

FORD TRANSIT 2006.5 Date of Publication: 12/2012 17

Police Refer to: 4.17 Fuses and Relays (page 177).

Date of Publication: 12/2012

FORD TRANSIT 2006.5 Date of Publication: 12/2012 19

Date of Publication: 12/2012

NOTE: After the installation of RF transmitters,

FORD TRANSIT 2006.5 Date of Publication: 12/2012 21

1.7.1 Conversion Affect on Fuel

1.7.2 Vehicle Ride and Handling

Date of Publication: 12/2012

FORD TRANSIT 2006.5 Date of Publication: 12/2012 23

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FORD TRANSIT 2006.5 Date of Publication: 12/2012 25

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FORD TRANSIT 2006.5 Date of Publication: 12/2012 27

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FORD TRANSIT 2006.5 Date of Publication: 12/2012 29

1.13.3 Driver Field of View

1.13.4 Conversion Affects on Parking

1.13.5 Aids for Vehicle Entry and Exit

Date of Publication: 12/2012

1.14.1 Recommended Main Dimensions

FORD TRANSIT 2006.5 Date of Publication: 12/2012 31

Date of Publication: 12/2012

FORD TRANSIT 2006.5 Date of Publication: 12/2012 33

Date of Publication: 12/2012

FORD TRANSIT 2006.5 Date of Publication: 12/2012 35

Date of Publication: 12/2012

FORD TRANSIT 2006.5 Date of Publication: 12/2012 37

1.16.1 Load Distribution Calculations - Driver and Passenger Weight Distribution

Single and Double Cab

Date of Publication: 12/2012

Van and Kombi

FORD TRANSIT 2006.5 Date of Publication: 12/2012 39

1.16.2 Center of Gravity