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Ford Ranger 2015 Body And Equipment Mounting Manual Download Page 105

5.5 Frame and Body Mounting

5.5.1 Mounting Points and Tubing

Holes on frame are a result of the production
process. They are not designed for fixing
additional equipment. Always use chassis mounts
as shown in sub frame for low floor or other
equipment. If additional fixings are required
please follow the recommendation given in the
figure shown. This does not apply to areas of load
applications such as spring fixings or damper
fixings.

NOTE: 

After drilling, deburr and countersink all

holes and remove chips from the frame. Follow
corrosion prevention.

Refer to: 5.4 Corrosion Prevention (page 104).

Frame Drilling and Welding

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

Description

Item

19 mm

A

11 mm

B

10 mm

C

10 mm

D

Do NOT enlarge chassis rail holes, or drill within the surrounding area.

E

Do not drill any more than 2 vertical holes in the chassis rail.

F

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

flame. Drill holes using sharp drills.

3. Use cold riveting only when attaching brackets

with rivets.

4. Use high tensile bolts and appropriate nuts

when bolted attachments are used.
•

Bolt Specifications :

•

Metric – Property class 8.8 or 10.9

•

Japanese – 7T or 9T

•

SAE – Grade 8 5.

5. Deburr holes after drilling to fit bolts or rivets.

Chamfer 1.0mm x 45 degree on the bolt head
side of the hole to facilitate bolt seating.

6. Holes must NOT be drilled near side member

profile changes.

7. Existing holes in top and bottom flanges must

NOT be bored out.

8. No more than two holes are to be drilled in a

vertical line down from the frame web.

9. Corrosion protection is to be applied post

drilling operations to the vehicle. Corrosion
protection & protective coatings for all
modifications should conform to all local
design rules.

10. Reinforcements should be added to the vehicle

structure where appropriate, to avoid excessive
load concentrations.

Date of Publication: 02/2017

FORD 

RANGER

 2015

Summary of Contents for Ranger 2015

Page 1: ...Body and Equipment Mounting Manual FORD RANGER 2015 Date of Publication 02 2017 ...

Page 2: ...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 2017 All rights reserved ...

Page 3: ... 1 11 3 Kerb Mass and Payload 23 1 11 4 Front Rear and Side Under run Protection 23 1 12 Hardware Specifications 24 1 13 Load Distribution Specifications 25 1 13 1 Load Distribution Calculations Driver and Passenger Weight Distribution 25 1 13 2 Center of Gravity 27 1 14 Towing 31 1 14 1 Towing Requirements 31 1 14 2 Towing 31 1 14 3 Towing capacities 31 1 14 4 Trailer Towball Download 31 1 14 5 T...

Page 4: ...sis Cab 86 5 1 4 Front End Integrity for Cooling Crash Aerodynamics and Lighting 89 5 1 5 Tipper Bodies 89 5 1 6 Tank and Dry Bulk Carriers 90 5 1 7 Genuine Ford Accessory Bull Bar 90 5 1 8 Roof Racks 91 5 1 9 Canopies 92 5 2 Airbag Supplemental Restraint System SRS 95 5 2 1 Air Bags Low Level Vehicles 95 5 2 2 Air Bags High Level Vehicles 98 5 2 3 Supplementary Restraint Sensors Front 102 5 3 Sea...

Page 5: ...wide This guide is published by Ford and provides general descriptions and advice for converting vehicles These requirements must be complied with before a Ford Dealer should take delivery of motor vehicle accessories from an external supplier either for themselves or on behalf of a motor vehicle client It must be emphasized that any change to the basic vehicle which does not meet the enclosed gui...

Page 6: ...is manual is designed to be used online or as printed material document links for the online version are also shown with page numbers for the printed version this will help guide you to the start of the section which contains the relevant information There is also an alphabetical index at the back of the manual As with the contents pages you will be able to link to sections To do this just click o...

Page 7: ...all territories Check with your local Ford National Sales Company representative Significant changes to the vehicle may affect its legal compliance Strict adherence to the original design intent for brakes weight distribution lighting electrical systems occupant safety and hazardous materials compliance in particular is mandatory 1 2 4 Alternative Type Approval If significant changes are made the ...

Page 8: ...ting from the conversion or attachment and installation of unique components including unique electrical or electronic systems Functional safety and freedom of movement of all moving parts for example axles springs propeller shafts steering mechanisms brake and transmission linkage Functional safety and freedom of the tested and approved flexibility of the body and integral chassis structure 1 2 8...

Page 9: ...st be quoted All dimensional weight and centre of gravity data The fixing of the body to the donor vehicle Operating conditions The responsible Technical Service may require additional information and or testing NOTE For further information please contact your local National Sales Company representative or Local Ford Dealer Date of Publication 02 2017 FORD RANGER 2015 ...

Page 10: ...uipment for example cellular telephones amateur radio transmitters and so on may only be fitted to your vehicle if they comply with the parameters shown in the following FrequencyOverview table Thereareno special provisions or conditions for installations or use Do not mount any transceiver microphones speakers oranyotheritem in the deployment path of the airbag system Do not fasten antenna cables...

Page 11: ...tion The antenna can be mounted on the roof of the vehicle with the exception of cellular phone car kit antennas which transmit power below 2W Such low powered systems should have their antenna located at the bottom of the A pillar behind the trim or on the front windscreen NOTE After the installation of RF transmitters check for disturbances from and to all electrical equipment in the vehicle bot...

Page 12: ...version Effect on Fuel Economy and Performance Any conversion may affect the fuel consumption andperformancedependingontheaerodynamics 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 th...

Page 13: ...ck WARNING The jack supplied with this vehicle is only intended for changing wheels Donotusethevehiclejackother than when you are changing a wheel in an emergency CAUTION Make sure that access to the spare wheel is maintained when converting the vehicle or relocating the spare wheel NOTE When using the vehicle jack refer to the owner guide for correct operating instructions The spare wheel winch i...

Page 14: ...o follow these instructions may result in serious injury or death CAUTIONS When lifting the vehicle with a two post lift vehicle lift arm adapters must be used under the lifting points When lifting the vehicle with a two post 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 All Vehicles Date of Publication 0...

Page 15: ...in 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 Date of Publication 02 201...

Page 16: ...le Make sure the wiper arms are suitably prevented from resting on the windscreen 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 Where protective film has been applied in manufacture it must be left on the vehicle until prepared for delivery but m...

Page 17: ...rking 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 reversing lamps section Refer to 4 3 Exterior Lighting page 63 1 10 5 Aids for Vehicle Entry and Exit Steps WARNINGS Make sure that the modified vehicle complies with all relevant legal requirements...

Page 18: ...nd parallel to the front Axle so that no part of such registration plate is more than 1 300 mm from the ground Rear Registration Plate WARNINGS The mounting of a registration plate to the rear of the vehicle must comply with ADR 61 02 Clause 9 1 1 1 No part of a vehicle registration plate maybeobscuredbystandardequipment regularproductionoptionsorequipment in line with ADR 61 02 Clause 9 1 1 3 The...

Page 19: ...re that the centre of gravity of the body and payload does not fall outside of the recommended zone Refer to 1 13 page 25 NOTE When extending the length of the frame rearward of the rear axle it is recommended that the overall rear overhang is limited to a maximum of 50 of the wheelbase of the vehicle NOTE If a towball is fitted to the vehicle the body dimensions must incorporate a towball clearan...

Page 20: ...Chassis Cab Body Single Cab Illustrated Date of Publication 02 2017 FORD RANGER 2015 ...

Page 21: ...of body to rear axle D 1610 50 of vehicle wheelbase provided load distribution requirements are met Maximum recommended rear overhang E 25 Minimum Clearance between the back of the cab and the body F Ensure local lighting legislation is maintained Refer to 4 3 Exterior Lighting page 63 G 30 Clearance between the top of the cab and the body H 1860 Maximum external body width J All dimensions shown ...

Page 22: ...1 11 2 Chassis Cab Body Basic Dimensions and Weights Chassis Cab Body Single Cab Illustrated Date of Publication 02 2017 FORD RANGER 2015 ...

Page 23: ... Gross Vehicle Mass GVM kg 1325 Front Axle Load kg 1480 Front Axle Load kg 1755 Rear Axle Load kg 1850 Rear Axle Load kg Vehicles with increased ride height 1 11 3 Kerb Mass and Payload WARNING Check local legislation for legal requirements Details of vehicle kerb mass and payload capacities can be provided by your local National Sales Company representative 1 11 4 Front Rear and Side Under run Pr...

Page 24: ... 1 4 1 1 M4 6 7 4 9 2 7 2 2 M5 15 0 11 0 11 5 8 5 4 7 3 7 M6 35 0 25 0 28 0 20 0 M8 70 0 50 0 55 0 41 0 M10 125 0 95 0 92 0 68 0 M12 200 150 153 113 M14 310 0 230 0 230 0 170 0 M16 399 4 317 5 317 0 252 0 M18 541 8 434 7 430 0 345 0 M20 743 4 592 2 590 0 470 0 M22 945 0 756 0 750 0 600 0 M24 This torque chart is a recommendation and the converter is responsible for the optimal torque for a specifi...

Page 25: ...n could result in unacceptable handling and braking characteristics NOTE Over loading of the vehicle could result in unacceptable ground clearance NOTE The centre of mass of the body equipment and the payload it contains should be located within the dimensions given NOTE Avoid one sided load distribution NOTE For further information please contact your local National Sales Company representative o...

Page 26: ...elbase mm Total On Rear Axle On Front Axle 75 35 40 1490 3220 Super Cab Super Cab Driver and Passenger Weight Distribution Weight distribution per person Kg C Second row seats mm B Front row seats and driver mm A Wheelbase mm Total On Rear Axle On Front Axle 75 35 40 1490 3220 75 51 24 2180 Date of Publication 02 2017 FORD RANGER 2015 ...

Page 27: ...e not inclusive of tow bar and other dealer fitted accessories The following charts define the recommended centre of gravity position for the mass added to the vehicle by the vehicle converter Addedmass includesalladdedbodyequipment and cargo but excludes passengers seated in standard cab seating For double cab vehicles there is a limit to the added mass that must be observed in addition to not ex...

Page 28: ... Gravity Critical Zone Recommended C of G location for added mass Model C Max mm B Max mm A Min mm 740 3220 1965 4x2 590 3435 1965 4x2 590 3435 1965 4x4 Vehicles with increased ride height Date of Publication 02 2017 FORD RANGER 2015 ...

Page 29: ...Gravity Critical Zone Recommended C of G location for added mass Model C Max mm B Max mm A Min mm 740 3220 2395 4x2 590 3435 2365 4x2 590 3435 2365 4x4 Vehicles with increased ride height Date of Publication 02 2017 FORD RANGER 2015 ...

Page 30: ...Zone Max gross added mass kg Recommended C of G location for added mass Model C Max mm B Max mm A Min mm 700 740 3615 2585 4x2 625 590 3615 2435 4x2 700 590 3615 2435 4x4 Vehicles with increased ride height Date of Publication 02 2017 FORD RANGER 2015 ...

Page 31: ... necessary use tube reinforcement Refer to 5 5 Frame and Body Mounting page 105 1 14 3 Towing capacities NOTE The towing capacities below relate to vehicles with Ford tow bars only Towing capacities Max Gross Combination Mass With Trailer Brake Without Trailer Brake Transmissi on Drive Variant 5425 kg 2500 kg 750 kg Manual 4x2 2 2L Diesel 6000 kg 3500 kg 750 kg Manual and Auto 4x2 and 4x4 6000 kg ...

Page 32: ...ssues for which Ford Motor Company can not be held responsible CAUTIONS Modifications to the suspension system can cause a deterioration of the vehicle handling characteristics and durability When carrying out welding work the springsmustbecoveredtoprotectthem against weld splatter Do not touch springs with welding electrodes or welding tongs NOTE Do not modify the wheelbase or add any type of fra...

Page 33: ...ot rub chafe or rest on body or chassis or body 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 2 3 Trailer Brakes Low Level Vehicles WARNINGS Ford is not responsible for warranty or performance of aftermarket brake controllersincludingduringmisuseo...

Page 34: ...RNINGS Ford is not responsible for warranty or performance of aftermarket brake controllersincludingduringmisuseoras a result of customer installation Do not use the adaptive cruise control system when towing a trailer with electric brake controls Aftermarket electric trailer brakes will not operate when you switch the system on because the brakes are electronically controlled Failure to do so may...

Page 35: ... Stop Lamp Switch 2 Stop Lamp Signal Connector C278 Pin 4 12V when brake pedal is pressed 3 If electric trailer brakes are to be installed they can be triggered by the stop lamp switch The maximum additional load is 1A Date of Publication 02 2017 FORD RANGER 2015 ...

Page 36: ... with the guidelines in this section 3 1 1 Fuel Filler Pipe Shipping Bracket if equipped CAUTION The fuel filler pipe shipping mounting bracket on cab chassis vehicles is designed for shipping of the vehicle only The fuel filler pipe shipping bracket fitted to cab chassis vehicles is designed to be removed once the body or tray is fitted to the vehicle The body or tray must include a fuel filler m...

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

Page 38: ...ng bracket does not provide a grounding path for the fuel filler neck an earth strap must be added connecting the filler neck to the chassis frame Fuel Filler Mounting Bracket Fuel Filler Mounting Notes Description Item The width of the bracket where it joins the body to be at least 180 mm A All 3x hardware fixation points on the filler neck must be utilised 1 Date of Publication 02 2017 FORD RANG...

Page 39: ...Filler Neck Installation Dimensions Description Item 2mm minimum bracket thickness A 30 angle to be maintained to ensure good flow of fuel when refueling and prevent flow back B Date of Publication 02 2017 FORD RANGER 2015 ...

Page 40: ... must be used A length of fuel grade flexible hose should be clipped to the vehicle body with the open end at least 600 mm 4x2 or 800 mm 4x4 or 4x2 hi rider above ground height It is recommended to measure this height when the vehicle is fully loaded The fuel tank vent hose should be protected and positioned away from direct water spray wheel splash and mud splash and water drainage holes that may...

Page 41: ...h or disable the selective catalytic reduction system The engine may not start if the Diesel Exhaust Fluid AdBlue level is low Make sure it is refilled The engine may not start if the Diesel Exhaust Fluid AdBlue is contaminated Replace the contaminated fluid immediately The use and refilling of Diesel Exhaust Fluid AdBlue is mandatory for the vehicletocomplywiththelegalemission requirements The Se...

Page 42: ...Inhaling ammonia vapor can cause burning to the eyes throat and nose resulting in watering eyes or severe coughing Do not put Diesel Exhaust Fluid AdBlue inthefueltank Thiscancause engine damage not covered by the vehicle warranty The Diesel Exhaust Fluid AdBlue tank filler neck is located next to the fuel filler neck and has a blue cap Fill the tank using a fluid pump at a Diesel Exhaust Fluid Ad...

Page 43: ...Description Item Diesel Exhaust Fluid AdBlue filler cap A Diesel Exhaust Fluid AdBlue tank B Exhaust system C Diesel Exhaust Fluid AdBlue injector D Date of Publication 02 2017 FORD RANGER 2015 ...

Page 44: ...Description Item Diesel Exhaust Fluid AdBlue filler A Diesel Exhaust Fluid AdBlue tank B Diesel Exhaust Fluid AdBlue filler hose C Date of Publication 02 2017 FORD RANGER 2015 ...

Page 45: ...t be re connected and the voltage re checked The voltage should be not less than 12 5 volts Battery Charging Procedure WARNINGS Always observe the battery charger equipmentmanufacturer sinstructions Do not jump slave start using a battery charging system from another vehicle Donotoverfillabatteryasthiscancause acid leakage that will result in damage to the vehicle and possible personal injury CAUT...

Page 46: ...ery charger is not recommended as it can cause damage to a battery Fast charging will only restore a battery to a state of charge that will enable it to carry out it s critical function of cranking the engine Fast charging will not restore a battery to a full state of charge and must therefore be followed by a period of slow charging Excessively fast charging can cause damage to a battery For this...

Page 47: ...ly grounded to the vehicle s body in order for the system to identify the additional load If a connection is made to the battery negative terminal the BMS will not identify the load or charge This may cause the battery to be undercharged and consequently not able to re start the vehicle Auxiliary Battery fitted to vehicles with a Battery Monitor System BMS NOTE The addition of an auxiliary battery...

Page 48: ...t with a torque of 13 5 Nm 2 1 Nm NOTE Ensure the fused connection is secured using suitable fixtures to reduce vibration damage or contact with surrounding components Grounding points for in vehicle battery charger Description Item Possible ground connection points using W705661 S901 1 The ground point connection should be tightened to torque of 12 Nm 1 8 Nm 2 Request a Ford dealer to disable the...

Page 49: ...ckness of the additional terminal being installed on top of the starter post terminal must be no more than 2 0 mm NOTE Ensure the existing nut is reused B ConnectionforAuxiliaryBatteryCharging The B connection should be fixed to the terminal posts using the existing nut with a torque of 13 5 Nm 2 1 Nm NOTE Make sure the fused connection is secured using suitable fixtures to reduce vibration damage...

Page 50: ...rnal devices which require an ignition feed such as UHF CB radios may be connected via a relay energised by the IG feed to the Body Control Module WARNING Under no circumstances should the IG feed be used to drive auxiliary loads directly A suitable relay must be used The Body Control Module is positioned on the driver s side of the vehicle underneath the dash panel IG Connection at Body Control M...

Page 51: ...feed such as UHF CB radios may be connected via a relay energised by a IG feed to the Body Control Module WARNING Under no circumstances should the IG feed be used to drive auxiliary loads directly A suitable relay must be used The Body Control Module is positioned on the driver s side of the vehicle underneath the dash panel IG Connection at Body Control Module Description Item Body Control Modul...

Page 52: ...pecification Description H7 DIN VRLA AGM Battery Type 12V Voltage 80Ah Capacity 800A CCC CAUTION Thevehiclemustnotbedriven on the road while the auxiliary battery is mounted to the temporary battery carrier When exiting the production plant the auxiliary battery is fitted in the load tray near the rear wheel arch for the style side tub variant For the cab chassis variants the auxiliary battery is ...

Page 53: ...y carrier 6 InstructionsforAuxiliaryBatteryFitment XL Plus Vehicles WARNING Make sure all electrical connections and wiring comply with regulations stated in ADR 42 04 Clause 9 CAUTIONS It is important to ensure that the auxiliary battery is mounted securely away from any moving parts and does not interfere with the operation of any closures tailgate Date of Publication 02 2017 FORD RANGER 2015 ...

Page 54: ...fixing points on the vehicle body NOTE Ensure that sufficient ventilation is provided for the auxiliary battery when located within enclosed spaces NOTE The addition of an auxiliary battery in a vehicle with Battery Monitor System BMS would cause both batteries to not reach a state of full charge The system will only allow charging of the batteries during deceleration Refer to Dual Batteries with ...

Page 55: ...Chassis 1850 mm Double Cab Chassis 1390 mm When used on a vehicle fitted with an aluminium load tray the electrical harness extension is fitted in the shown orientation Electrical Harness Extension Fly Lead Description Item Electrical Harness Extension fly lead 1 Connection to the vehicle harness 2 Connection to the auxiliary wiring harness 3 4 1 4 Generator and Alternator Alternator Current Outpu...

Page 56: ...d This provides a square wave form 50 duty cycle signal Circuit hardware Square Wave Characteristics Output signal Sunroof Taxi Speed Output Signal Requirements Battery Voltage Maximum High Signal 3 67 Volts Minimum High Signal 1 1 Volts Maximum Low Signal 1 1 Volts Minimum Low Signal 1 0 Volts Maximum Ground Offset 10μ sec tr 250μ sec Rise Time 10μ sec tf 250μ sec Fall Time 50 10 Duty Cycle 1 38 ...

Page 57: ...o work This protects the BCM body control module from overcurrent risk 3 The output must be connected to a power source 4 Once the device is connected reset the BCM by disconnecting the vehicle battery 5 Reconnect the vehicle battery 6 Turn the ignition ON 7 The signal should now be available NOTE Rload should be present and connected to battery voltage for this function to work For Information On...

Page 58: ...C4 need to be unplugged in order to insert the speed signal terminal 2 Once the connector C3 or C4 is removed the grey cap needs to be removed by first removing the cable tie and then levering up the two detents on the sides the cap can then be slid off Date of Publication 02 2017 FORD RANGER 2015 ...

Page 59: ...Date of Publication 02 2017 FORD RANGER 2015 ...

Page 60: ...l latching plate that needs to be removed 4 Insert the wire with terminal into cavity C3 52 or C4 3 there is a tab on the terminal that should allow this to be inserted one way only Date of Publication 02 2017 FORD RANGER 2015 ...

Page 61: ...lide back the terminal latching plate refit the grey cap and refit the cable tie as required and plug both connectors back into the BCM Refit any shields covers Date of Publication 02 2017 FORD RANGER 2015 ...

Page 62: ...Level Vehicles WARNING Do not attempt to take a speed signal output form high level vehicles A solution to take a speed signal output from the BCM on high level vehicles is not currently available Date of Publication 02 2017 FORD RANGER 2015 ...

Page 63: ... lamps must be mounted in accordance with the following guidelines NOTE Prior to work on any vehicle being undertaken it is critical to identify the vehicle level low level or high level by the type of electrical architecture the vehicle at hand is equipped with Failure to identify the type of electrical architecture present on the vehicle prior to work being undertaken may cause electrical damage...

Page 64: ...mum angle of obstruction free zone upwards of the lamp D 80 Minimum angle of obstruction free zone towards the outside of the vehicle E 45 Minimum angle of obstruction free zone towards the centre of the vehicle F 400mm Maximum distance from outer edge of vehicle to inner edge of lamp G 4 3 2 Rear Fog Lamp NOTE Where only one rear fog lamp is fitted it must be positioned on the vehicle centre line...

Page 65: ...amp B 5 Minimum angle of obstruction free zone downwards of the lamp C 5 Minimum angle of obstruction free zone upwards of the lamp D 25 Minimum angle of obstruction free zone towards the outside of the vehicle E 25 Minimum angle of obstruction free zone towards the centre of the vehicle F 4 3 3 Rear License Plate Lamp Date of Publication 02 2017 FORD RANGER 2015 ...

Page 66: ...mounting face A 10 Angle between license plate and lamp mounting face B 35mm Distance between top of rear face of license plate and lamp mounting face C 175mm Distance between license plate centre line and centre of lamp D 175mm Distance between license plate centre line and centre of lamp E Date of Publication 02 2017 FORD RANGER 2015 ...

Page 67: ...at power is provided via the trailer plug control module and associated circuitry Refer to Trailer Towing for additional information For all other additional exterior lamps power must be taken through an auxiliary fuse box with a suitable switch and or relay as required WARNING Directly splicing into the vehiclewiringinordertoinstallauxiliary lamps or other electrical devices may overload the syst...

Page 68: ... accessory trailer tow kit When fitting low power LED light emitting diode lamps that require less than 2W the lamps may flicker when in use A trailer patch harness should be used with low power draw LED lamps CAUTION Do not connect the trailer patch harness to the vehicle when the trailer is not connected NOTE The trailer patch harness is available from your Ford authorised dealer NOTE The traile...

Page 69: ... used 2 6 4 0 5 Stop Left 3 Not used 4 Not used 5 6 4 0 5 Reverse Lamp 6 6 4 0 5 Stop Right 7 6 2 0 5 Fog Lamp 8 Not used 9 6 3 0 5 Left Direction Indicator 10 Not used 11 6 7 0 5 Position Lamp 12 Connector B Not used 1 16 6 30 Term 30 Ubat 2 Connector C 6 0 1 CAN H 1 6 0 1 CAN L 2 6 0 1 Brake Line In Vehicle 3 6 1 Ground 4 16 0 1 Trailer Detect Output 5 Date of Publication 02 2017 FORD RANGER 201...

Page 70: ... Lamp 8 Not used 9 Not used 10 Not used 11 Not used 12 Connector B B Fuse 87 40A BJB 1 Not used 2 Connector C 6 1 Ground 1 6 0 1 CAN L 2 6 0 1 CAN H 3 Not used 4 4 3 7 Additional External Lamps Vehicles with Special Equipment Pack The plastic switch fascia is located at the front of the console It can house up to four aftermarket switches Driving Lights LED beacon lamp and work lights can be power...

Page 71: ...outs Cut out the switch blanks with a suitable tool without damaging the plastic fascia Description Item Driving lights switch blank 1 Work lights switch blank 2 LED beacon lamp switch blank 3 Spare switch blank 4 Date of Publication 02 2017 FORD RANGER 2015 ...

Page 72: ...pment Pack Description Item Sealing end cap 1 Driving light connector 2 Switch Panel Connector Vehicles with Special Equipment Pack Description Item Switch connector located behind the switch fascia in the vehicle 1 Date of Publication 02 2017 FORD RANGER 2015 ...

Page 73: ... beam ground BK BU 4 Cross car beam ground BK BU 5 LED beacon Relay R2 VT WH 8 Spare populated relay R3 BN GN 9 Work lights relay R1 GN BN 10 Driving lights relay WH GN 11 Blank not used 12 4 3 8 Auxiliary Lighting Loads Vehicles with Special Equipment Pack Connections for auxiliary lighting loads are provided by a 16 Pin connector located near to the auxiliary fuse box Date of Publication 02 2017...

Page 74: ...16 Pin Connector Vehicles with Temporary Battery Carrier Cab Chassis NOTE The temporary battery carrier must removed from the vehicles frame before the vehicle is operated on the road or in service Located on the outside of the auxiliary battery assembly when mounted on the temporary battery carrier Date of Publication 02 2017 FORD RANGER 2015 ...

Page 75: ... Located on the inside of the auxiliary battery box mounted on the vehicle tray Connections for auxiliary lighting loads are provided by a 16 Pin connector located near to the auxiliary fuse box Date of Publication 02 2017 FORD RANGER 2015 ...

Page 76: ...s 12v YE BU 10 Blank not used 11 Blank not used 12 Blank not used 13 Blank not used 14 Blank not used 15 Ground BK YE 16 4 3 9 Auxiliary Lighting Loads VehicleswithoutSpecialEquipment Pack Low Level Vehicles Only NOTE Connections for auxiliary lighting loads must be low and stable current draw Trailer Tow Module if equipped Connections for auxiliary lighting loads can be made via the trailer tow m...

Page 77: ...onnector Detail 16 Pin Connector if equipped Connections for auxiliary lighting loads can be made via the 16 Pin connector located on the rear right chassis rail Date of Publication 02 2017 FORD RANGER 2015 ...

Page 78: ...nd Side 3 x 5W front and rear indicators side repeaters Right Hand Side 4 3 11 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 Date of Publication 02 2017 FORD RANGER 2015 ...

Page 79: ...d load NOTE Disable the original vehicle mounted CHMSL if the canopy CHMSL is intended to be the primary CHMSL NOTE The CHMSL circuit is pulse width modulated PWM NOTE Check the operation of the CHMSL prior to customer handover WheninstallingacanopyequippedwithaCHMSL a feed for the CHMSL can be taken from the BCM Connector 4 Pin 2 Description Item BCM CHMSL Feed Connector 4 Pin 2 1 Date of Publica...

Page 80: ...rcuit wiring allowing a canopy with an integrated CHMSL to take a stop lamp circuit feed from the 2 pin connector The original 3 pin connector is then taped back Follow the steps to install the replacement CHMSL lamp housing 1 Remove the combination CHMSL Cargo Lamp following the workshop manual instructions NOTE When cutting off the stop lamp circuit wires from the 3 pin CHMSL connector stagger t...

Page 81: ...lectrical architecture types Identification of which type a vehicle is equipped with can be aided visually checking the passenger compartment fuse box Passenger Compartment Fuse Box Low Level Vehicles Passenger Compartment Fuse Box High Level Vehicles 4 4 2 Auxiliary Battery and Fuse Box Low Level Vehicles NOTE High level vehicles cannot be fitted with the factory installed auxiliary battery and f...

Page 82: ...ox Vehicles with Special Equipment Pack Low Level Vehicles Only Description Item Auxiliary Fuse box 1 Vehicles with Temporary Battery Carrier Cab Chassis Variant Only Low Level Vehicles Only Vehicles with Special Equipment Pack Description Item Auxiliary Fuse box 1 Date of Publication 02 2017 FORD RANGER 2015 ...

Page 83: ...y Fuse box 1 Auxiliary Fuse Specification Chart NOTE On delivery of the vehicle ensure Fuse F10 is engaged into its location correctly Fuse F10 is intentionally not fully engaged during manufacturing to prevent depletion of the auxiliary battery during shipping and transit Date of Publication 02 2017 FORD RANGER 2015 ...

Page 84: ...irection indicators stop lamp 15 8 Crew chief 5 9 Auxiliary battery disable fuse isolator ground 5 10 Not used 11 Not used 12 Relay Chart Protected Components Relay Number Work lights R1 LED beacon lamp R2 Spare R3 Position lamp R4 Direction indicator left R5 Direction indicator right R6 Stop lamp R7 Not used R8 Not used R9 Date of Publication 02 2017 FORD RANGER 2015 ...

Page 85: ...ing All metal edges must comply with exterior and interior protection legislation All fixings through the floor sides or roof must be sealed Make sure that fixings in the B pillar area do not encroach on the seat belts or seat belt reels 5 1 2 Integrated Bodies and Conversions WARNING All wheelhouse envelopes mustcomplywithADR42 04 Clause14 For integral structures such as ambulances or motor homes...

Page 86: ...atalytic converter Ensure adequate heat shields are maintained CAUTION Uneven load distribution could result in unacceptable handling and braking characteristics When carrying out vehicle conversions modifications the following points should be considered Make sure that all of the reinforced holes provided in the chassis frame top surface are used for full length bodies or sub frames see figures s...

Page 87: ...base vehicle cab structure the following applies Ensure that neither the conversion structure nor the existing vehicle structure get pre loaded by the assembly process Adhesive jointing is recommended but should be supplemented with mechanical fasteners to prevent initial peel and long term failure Spread bolt loads to minimize local stress Body Attachment Holes in Chassis Frame Single cab Dimensi...

Page 88: ... Chassis Frame Super cab Dimensions mm for Body Attachment Holes in Chassis Frame Super Cab Dimension Dimension 1086 G 16 A 95 H 28 B 1191 J 23 C 509 K 20 D 26 L 1244 E 20 M 1244 F Date of Publication 02 2017 FORD RANGER 2015 ...

Page 89: ...ed if A swiveling device is fitted on the front seats A side wall or any other additional material or structure is attached to the B pillar inner and or outer area Static Dynamic Sealing and Finishing Ensure proper sealing against ingress of water salt dust etc after cutting or drilling the body Use Ford approved sealing and finishing material and underbody corrosion protection Refer to 5 4 Corros...

Page 90: ...to full length of sub frame Mount sub frame to all chassis frame mounting points The forward location mounts must be compliant to allow relative chassis frame to sub frame deflections Sub frame must extend to the back of the cab and not contact chassis frame at forward end under worst case deflection Compliant mounts should be used with up to plus and minus 12mm compliance with the vehicle laden o...

Page 91: ... from the engine bay into the cabin area through the existing grommet There is a service nib provided on the grommet Refer to Exterior lighting Additional external lamps for driving lights cable routing 5 1 8 Roof Racks Roof racks may be fitted to all variants as illustrated in figure providing the following is satisfied The carried load does not exceed 80kg Body Builder to ensure owner s hand boo...

Page 92: ...Special Fit Description Item Rear edge of front attachment point 1 80kg Maximum 2 Maximum roof rack length within length of drain channel 3 Maximum load height 300mm 4 Drain channel 5 Roof rack supports 6 5 1 9 Canopies All Vehicles WARNINGS Only use the recommended attachment pointsforthecanopyfitment otherwise damage may occur to the load box The return flange on the load box sides should never ...

Page 93: ...oup B as front structural attachment points Load Box Structural Attachment Points Description Item Front structural attachment points 1 Centre structural attachment points 2 Rear structural attachment points 3 Top surface of load box sides 4 Return flange of load box sides 5 Do not cut drill or use these surfaces to bolt the canopy Date of Publication 02 2017 FORD RANGER 2015 ...

Page 94: ...Example of a Sports Bar Fitment Description Item Front mounting bracket 1 Clamped attachment 2 Date of Publication 02 2017 FORD RANGER 2015 ...

Page 95: ... the bottom of the C pillar inner for Super Cab and Double Cab vehicles The pressure based airbag sensors for side airbags are located near the centre of the front doors inner door sheet metal for all Cab styles WARNING Modifications or reinforcementsintheareaofthesensors mayaffectthesideairbagfiretimingand result in uncontrolled side air bag deployment Please note that vehicles not equipped with ...

Page 96: ...Dimensions mm 660 D 400 A 630 E 700 B 700 F 700 C Side Airbag Dimensions mm 250 C 550 A 350 B Curtain Airbag Single cab Date of Publication 02 2017 FORD RANGER 2015 ...

Page 97: ...mensions mm 250 C 140 A 100 D 40 B Curtain Airbag Double cab Dimensions mm 250 C 140 A 100 D 40 B Curtain Airbag Super cab Dimensions mm 250 C 140 A 100 D 40 B Date of Publication 02 2017 FORD RANGER 2015 ...

Page 98: ...rby the bottom of the C pillar inner for Super Cab and Double Cab vehicles The pressure based airbag sensors for side airbags are located near the centre of the front doors inner door sheet metal for all Cab styles WARNING Modifications or reinforcementsintheareaofthesensors mayaffectthesideairbagfiretimingand result in uncontrolled side air bag deployment Please note that vehicles not equipped wi...

Page 99: ...Driver and Passenger Front Airbag Deployment Zones Dimensions mm 392 D 260 A 520 E 470 B 544 F 470 C Date of Publication 02 2017 FORD RANGER 2015 ...

Page 100: ...Side Airbag Dimensions mm 550 A 350 B 250 C Curtain Airbag Single cab Dimensions mm 250 C 140 A 100 D 40 B Date of Publication 02 2017 FORD RANGER 2015 ...

Page 101: ...Curtain Airbag Double cab Dimensions mm 250 C 140 A 100 D 40 B Curtain Airbag Super cab Dimensions mm 250 C 140 A 100 D 40 B Date of Publication 02 2017 FORD RANGER 2015 ...

Page 102: ...nt Sensors Front WARNING Modifications or reinforcements in the area of the front supplementary restraint sensors may affect their operation Description Item Front SRS Impact Sensors 1 Date of Publication 02 2017 FORD RANGER 2015 ...

Page 103: ...or further information When removing the seatbelt system a seatbelt webbing forked retainer should be applied to the webbing 200mm below the webbing button stop This prevents a situation where all the webbing runs back into the retractor and the retractor becomes locked When reinstalling fit the retractor to the body first and gently pull the webbing out of the retractor to allow fitment of the D ...

Page 104: ...s Ensure all materials are compatible with the relevant Ford specifications and maintain the original performance where possible Some proprietary products affect the original coatings For specifications of corrosion protection materials please consult your local National Sales Company representative 5 4 4 Painting Road Wheels WARNING Do not paint wheel clamp surfaces in contact with other wheels b...

Page 105: ...the chassis rail F 1 No Welding is Allowed to the Vehicle Structure 2 To make holes in frames do not use a gas flame Drill holes using sharp drills 3 Use cold riveting only when attaching brackets with rivets 4 Use high tensile bolts and appropriate nuts when bolted attachments are used Bolt Specifications Metric Property class 8 8 or 10 9 Japanese 7T or 9T SAE Grade 8 5 5 Deburr holes after drill...

Page 106: ...y side wall 3 or to the continuous floor frame 5 see figure shown The body side wall or the continuous floor frame supports any overhang beyond the chassis frame whether on standard frame or extended frame Alternatively the self supporting body structure can also be designed as shown in figure shown This concept is based on a self supporting structure where the floor is mounted directly onto the t...

Page 107: ...should be resolved by matching inner cross members between the chassis side members inline with the outriggers A diameter of 16 5mm is the maximum allowable hole size in the chassis frame side wall irrespective of the usage Avoid drilling into closed frame body members to avoid the risk of corrosion from swarf Refer to 5 4 Corrosion Prevention page 104 Drilling and welding of frames and body struc...

Page 108: ...s 7 Contact Corrosion 104 Conversion Effect on Fuel Economy and Performance 12 Conversion Effects on Parking Aids 17 Conversion Homologation 9 Corrosion Prevention 104 D Drilling and Welding 8 Driver Field of View 17 Driver Reach Zones 17 E Electrically Operated Door Mirrors 78 Electromagnetic Compatibility EMC 10 Electronic Engine Controls 56 Exterior Lighting 63 F Filling the Diesel Exhaust Flui...

Page 109: ...ted Antenna Location 11 Supplementary Restraint Sensors Front 102 Suspension System 32 T Tank and Dry Bulk Carriers 90 Terminology 7 Tipper Bodies 89 Towing capacities 31 Towing Requirements 31 Towing Specifications 31 Towing 31 Trailer Brakes High Level Vehicles 34 Trailer Brakes Low Level Vehicles 33 Trailer Towball Download 31 Trailer Towing 68 U Under Body Protection and Material 104 V Vehicle...

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