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Ford Ranger 2020 Mounting Manual Download Page 88

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 87).

Frame Drilling and Welding

E134173

D

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
regulatory standards.

10. Reinforcements should be added to the vehicle

structure where appropriate, to avoid excessive
load concentrations.

FORD 

RANGER

 2020

Date of Publication: 09/2020

5 Body and P

aint

88

Summary of Contents for Ranger 2020

Page 1: ...E306837 FORD Ranger 2020 Body and Equipment Mounting Manual Date of Publication 09 2020 ...

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 2021 All rights reserved ...

Page 3: ...ocedures WLTP Calculation Inputs 21 1 12 7 Vehicle Dimensions Key 22 1 12 8 Recommended Main Load Area Dimensions 22 1 12 9 WLTP Frontal Area Calculation 22 1 12 10 Registration Plates 24 1 13 Package and Ergonomics Specifications 25 1 13 1 Recommended Body Dimensions 25 1 13 2 Chassis Cab Body Basic Dimensions and Weights 28 1 13 3 Kerb Mass and Payload 29 1 13 4 Front Rear and Side Under Run Pro...

Page 4: ... Bulk Carriers 76 5 1 7 Bull Bar Vehicles with Special Equipment Pack and where fitment permitted by territory regulations 76 5 1 8 Roof Racks 77 5 1 9 Canopies 78 5 2 Airbag Supplemental Restraint System SRS 81 5 2 1 Air Bags 81 5 2 2 Supplementary Restraint Sensors Front 84 5 3 Seatbelt Systems 86 5 4 Corrosion Prevention 87 5 4 1 General 87 5 4 2 Repairing Damaged Paint 87 5 4 3 Under Body Prot...

Page 5: ... com It is the vehicle converters responsibility to review the online version for the most current information prior to starting any conversion The BEMM is for European and related markets sourced vehicles For further information please contact your National Sales Company representative or local Ford Dealer If they are unable to help you then please contact the Vehicle Converter Advisory Service a...

Page 6: ...tions provided in this manual must first establish that they compromise neither their personal safety nor the vehicle integrity by their choice of methods tools or components 1 2 3 Warnings Cautions and Notes in This Manual WARNING Warnings are used to indicate that failure to follow a procedure correctly may result in serious injury or death CAUTION Cautions are used to indicate that failure to f...

Page 7: ... to recalculate the CO2 and fuel consumption for any completed vehicle by either using a tool provided by the OEM or contacting the OEM to obtain new values To determine the new values in line with WLTP registered customers will now be able to access Ford s multi stage WLTP calculation tool via ETIS For further information and registration please contact your Ford National sales representative in ...

Page 8: ...l advisor on any questions concerning its legal obligations and liabilities Ford recommends that the Vehicle Converter and Ford Dealer must understand their individual and joint responsibilities in supplying a safe and compliant motor vehicle fitted with safe and compliant accessories 1 3 9 General Product Safety Requirement The Vehicle Converter shall ensure that any vehicle it places on the mark...

Page 9: ...raints System WARNINGS Modifications to the restraints system are not allowed Airbags are explosive For safe removal andstorageduringconversionfollowthe proceduresintheFordworkshopmanual or consult your local National Sales Company representative Do not alter modify or relocate the airbag sensor and modules of the restraints system or any of its components Attachments or modifications to the front...

Page 10: ...tact 34 91 7145143 Phone jmart219 ford com E Mail Ford of Portugal Luis Filipe Azinheiro Contact 351 21 3122450 Phone lazinhei ford com E Mail Ford of Belgium Jean Vermeiren Contact 32 3 8212120 Phone jvermei1 ford com E Mail Ford of Netherlands Daan Koppert Contact 31 20 504711 Phone dkoppert ford com E Mail Ford of Austria Gernot Payer Contact 43 50 6581269 Phone gpayer ford com E Mail Ford of S...

Page 11: ...pe Balázs Págyi Contact 36 26 802538 Phone bpagyi ford com E Mail Rest of the World RoW Duvall Hunter Contact 44 1277 252073 Phone dhunte11 ford com E Mail Ford Otosan Turkey Ford Otosan Call Center Contact 90 216 4443673 Phone iletisim ford com tr E Mail Ford of Australia Jonathon Steele Contact 61 3 85594862 Phone jsteel80 ford com E Mail Ford of New Zealand NZINFO Contact 64 9 2718500 Phone nzi...

Page 12: ...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 FORD RANGER 2020 Date of Publication 09 2020 1 General Information 12 ...

Page 13: ...e local legislation and other requirements NOTE Any radio frequency transmitter equipment in your vehicle such as cellular telephones and amateur radio transmitters must keep to the parameters in the following table We do not provide special provisions or conditions for installations or use E239121 Antenna Position Maximum Output Power Watts Peak RMS Frequency Band MHz 1 50 1 30 2 3 50 50 54 2 3 5...

Page 14: ...here possible make sure that the base vehicle is ordered with any necessary plant fit options A high numeric gear ratio is recommended for vehicles with customer requirements for High payload Trailer tow Frequent stop and go cycles High altitude and gradients Terrain conditions such as found on building and construction sites 1 7 1 Vehicle Ride and Handling Attributes CAUTION Do not exceed the axl...

Page 15: ...ack supplied with this vehicle is only intended for changing wheels Do not use the vehicle jack other 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 is located ...

Page 16: ... instructions may result in serious injury or death CAUTIONS When lifting the vehicle with a two post lift vehicleliftarmadaptersmustbeused under the lifting points When lifting the vehicle with a two post lift the maximum kerb weight must not be exceeded Itisimportantthatonlythecorrectlifting and support locations are used at all times All Vehicles E133943 FORD RANGER 2020 Date of Publication 09 ...

Page 17: ...tem or tires may influence the exterior noise emissions Therefore the exterior noise level of the converted vehicle has to be verified The interior noise levels should not be deteriorated by the conversion Reinforce panels and structures as appropriate to avoid vibrations Consider the usage of sound deadening material on panels Date of Publication 09 2020 FORD RANGER 2020 1 General Information 17 ...

Page 18: ...om 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 must be removed after a maximum storage period of six ...

Page 19: ...the electrical connector Start and stop the engine 4 times to ensure that the Malfunction Indicator Lamp MIL is illuminated and corresponding information message is displayed in the instrument cluster The vehicle can be operated safely with the MAP sensor disconnected during any conversion that the vehicle may be undergoing for example a Motorhome conversion Before the vehicle is handed over to th...

Page 20: ...WARNING Ensurethatmonitorsmounted inthecabinmeettheinteriorpackageand safety requirements On conversions requiring a rear camera the reverse signal may be taken as described in the reversing lamps section Refer to 4 5 Exterior Lighting page 63 1 12 5 Aids for Vehicle Entry and Exit Steps WARNINGS Make sure that the modified vehicle complies with all relevant legal requirements If this modification...

Page 21: ... this section Tire Rolling Resistance Any changes in tires fitted to the completed vehicle must be taken into account The efficiency class and tire class is needed to determine the correct calculation This can be found on the tire label as per the example below E309537 Exceeding Attribute Limits As a requirement of the Vehicle Converter to use the base vehicle approval the Vehicle Converter must s...

Page 22: ...imensions show the range for the minimum to maximum weight range and are for guidance only 1 12 8 Recommended Main Load Area Dimensions E341377 B B A A D D C C E341377 B B A A D D C C D mm C mm B mm A mm Vehicle 5396 755 2214 2518 Single Cab 5396 755 2214 1747 Double Cab 1 12 9 WLTP Frontal Area Calculation NOTE The WLTP calculator can be provided by your National Sales Representative NOTE All sta...

Page 23: ...cle frontal area measurements mm Measurement 1789 A 1860 B 1839 C 1945 D 2214 E Vehicle frontal area configuration Af m Af m Vehicle frontal area configuration 2 873 1 Base vehicle with style side box 0 302 3 175 2 Box Cab Width and Roof Height 0 500 3 373 3 Box 0 5m2 Base 1 000 3 873 4 Box 1m2 Base Date of Publication 09 2020 FORD RANGER 2020 1 General Information 23 ...

Page 24: ...ont of the motor vehicle forward of and 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 front of the vehicle must comply with local regulations Nopartofavehicleregistrationplatemay be obscured by standard equipment regularproductionoptionsorequipment in line with...

Page 25: ... of gravity of the body and payload does not fall outside of the recommended zone Refer to 1 15 page 31 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 clearance zone in accorda...

Page 26: ...Chassis Cab Body Single Cab Illustrated A H B G D F E A J B C G D E E210753 H F FORD RANGER 2020 Date of Publication 09 2020 1 General Information 26 ...

Page 27: ...quirements 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 5 Exterior Lighting page 63 G 30 Clearance between the top of the cab and the body H 1860 Maximum external body width J For WLTP markets this dimensions should be disregarded Refer to the relevant WLTP dimensions Refer to ...

Page 28: ...1 13 2 Chassis Cab Body Basic Dimensions and Weights Chassis Cab Body Single Cab Illustrated C B E A D F C B E A D F E210754 FORD RANGER 2020 Date of Publication 09 2020 1 General Information 28 ...

Page 29: ...Load kg 1755 Rear Axle Load kg 1850 Rear Axle Load kg Vehicles with increased ride height Wildtrak XLT vehicles Wildtrak vehicles Vehicles equipped with Selective Catalytic Reduction System AdBlue 4x4 or increased ride height excluding 2 2L Duratorq TDCi 96kW 130PS built after 03 04 2017 1 13 3 Kerb Mass and Payload WARNING Check local legislation for legal requirements Details of vehicle kerb mas...

Page 30: ...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 specific joint FORD...

Page 31: ...ld result in unacceptable handling and braking characteristics NOTE Over loading of the vehicle could result in unacceptable ground clearance NOTE The center 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 yourlocalNationalSalesCompanyrepresentative or local Fo...

Page 32: ...ver and Passenger Weight Distribution Weight distribution per person Kg B Front row seats and driver mm A Wheelbase mm Total On Rear Axle On Front Axle 75 35 40 1490 3220 FORD RANGER 2020 Date of Publication 09 2020 1 General Information 32 ...

Page 33: ...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 09 2020 FORD RANGER 2020 1 General Information 33 ...

Page 34: ...clusive 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 Added mass includes all added body equipment 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 excee...

Page 35: ...y 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 4x2 vehicles with increased ride height Date of Publication 09 2020 FORD RANGER 2020 1 General Information 35 ...

Page 36: ... 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 4x2 vehicles with increased ride height FORD RANGER 2020 Date of Publication 09 2020 1 General Information 36 ...

Page 37: ...x 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 4x2 vehicles with increased ride height Date of Publication 09 2020 FORD RANGER 2020 1 General Information 37 ...

Page 38: ...ng page 88 1 16 3 Towing capacities NOTE The towing capacities below relate to vehicles with Ford tow bars only NOTE The towing capacities for Gross Vehicle Mass GVM Gross Combined Mass GCM and Maximum Towing Weight MAX Tow are listed in Kilograms Towing capacities MAX Tow GCM GVM FDR Ride Height Drive Transmission Engine 3500 6000 3270 3 55 High 4x4 6 Speed Manual I5 3 2L TDCi 3500 6000 3270 3 73...

Page 39: ... control of your vehicle personal injury or death Trailer Nose Weight Maximum Nose Weight Minimum Nose Weight Towbar Type 165 kg 6 of the towed weight Type 1 4x2 Low Ride Height 225 kg Type 2 1 16 6 Towing Specifications For any further details and advice please consult yourlocalNationalSalesCompanyrepresentative or Local Ford Dealer Date of Publication 09 2020 FORD RANGER 2020 1 General Informati...

Page 40: ...hich Ford Motor Company cannot be held responsible CAUTIONS Modifications to the suspension system can cause a deterioration of the vehicle handling characteristics and durability When carrying out welding work the springs must be covered to protect them against weld splatter Do not touch springs with welding electrodes or welding tongs NOTE Do not modify the wheelbase or add any type of frame ext...

Page 41: ...itions 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 Brake Connection WARNING A pre installed trailer brake wire provides a pulsed brake signal of varying frequencies This pulsed signal is not a direct current DC signal If an aftermarketbrakecontrollerisinstalled thevehicleownerorinstallermustensure ...

Page 42: ...missions engine to the latest E E C E U Regulations or applicable local legislation depending on the completed vehicle category and weight The final weight of a vehicle including the conversion determines whether a vehicle needs a light duty or heavy duty emissions engine The weight is based on the Reference Mass defined as the mass in running order less a 75kg allowance for the driver add a 100kg...

Page 43: ... increases the risk of early life injector failure Procedure for protection from Injector Nozzle Corrosion During the Upfitting Conversion Process Refer to 1 11 Vehicle Transportation Aids and Vehicle Storage page 18 3 2 1FuelFillerPipeShippingBracket if equipped CAUTION The fuel filler pipe shipping mountingbracketoncabchassisvehicles is designed for shipping of the vehicle only The fuel filler p...

Page 44: ...Fuel Filler Pipe Shipping Bracket Super Cab E145839 Fuel Filler Pipe Shipping Bracket Double Cab E213151 FORD RANGER 2020 Date of Publication 09 2020 3 Powertrain 44 ...

Page 45: ...s 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 E145833 A 1 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 utilized 1 Date of Publication 09 2020 FORD RANGER...

Page 46: ...iller 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 FORD RANGER 2020 Date of Publication 09 2020 3 Powertrain 46 ...

Page 47: ...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 be pr...

Page 48: ... 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 ExhaustFluid AdBlue iscontaminated Replace the contaminated fluid immediately The use and refilling of Diesel Exhaust Fluid AdBlue is mandatory for the vehicle to comply with the legal emission requirements The Se...

Page 49: ...aporcan 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 E236052 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 AdBlue fillin...

Page 50: ...E232857 Description Item Diesel Exhaust Fluid AdBlue filler cap A Diesel Exhaust Fluid AdBlue tank B Exhaust system C Diesel Exhaust Fluid AdBlue injector D FORD RANGER 2020 Date of Publication 09 2020 3 Powertrain 50 ...

Page 51: ...35565 B A C Description Item Diesel Exhaust Fluid AdBlue filler A Diesel Exhaust Fluid AdBlue tank B Diesel Exhaust Fluid AdBlue filler hose C Date of Publication 09 2020 FORD RANGER 2020 3 Powertrain 51 ...

Page 52: ... joint created However if it is decided that a wire splice is unavoidable it must be made using DuraSealHeat Shrinkable Environmentally Sealed Nylon Insulated Crimp Splices manufactured by TYCO RAYCHEM For example the D406 series As a further process to improve the splice integrity the splice should be further sealed with a suitable heat shrink tubing See Figure E131081 FORD RANGER 2020 Date of Pu...

Page 53: ...e 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 CAUTIONS Do not rely on the generator to recharge a discharged battery It would take in excess of eight hours of continuous driving with no additiona...

Page 54: ...ttery For this reason charging times must be carefully controlled Fast battery chargers vary widely in design so it is very important to strictly adhere to the equipment manufacturer s instructions A charge of 30A for up to 30 minutes is the most common fast charging application If the battery is very discharged and requires additional restoration an additional charge of 20A for a period up to one...

Page 55: ...g of the batteries during deceleration Refer to Dual Batteries with BMS in this section NOTE Disabling the BMS will negate the fuel economy benefit provided by the BMS NOTE Auxiliary loads must always be connected to the vehicle ground and not to the battery negative terminal NOTE Ensure the auxiliary battery connection is safely secured using suitable fixtures to reduce vibration damage or contac...

Page 56: ... the following methods 1 Use an in vehicle battery charger DC DC converter such as BCDC1220 model from Redarc www redarc com au or similar connected via an additional terminal to the starter post terminal on the B using a 30A fused connection and grounded to the vehicle body in the shown locations NOTE The additional terminal must be installed on top of the starter post terminal using the existing...

Page 57: ...a suitable fused connection must be used If multiple auxiliary loads are required it is recommended that an auxiliary fuse box is fitted to the vehicle For the connection of auxiliary exterior lighting refer to the guidelines given in the exterior lighting section Refer to 4 5 Exterior Lighting page 63 Auxiliary loads for external devices which require an ignition positive IG feed such as Ultra Hi...

Page 58: ...turer Part Number Service Part Number Description TE Tyco Electronics CU5T 14489 XA Connector Molex 7C3T 14474 DA DU2Z 14474 DA Pin 4 2 2 Generator and Alternator Alternator Current Output See your Authorised Ford Dealer to identify the alternator output current specifications for your vehicle FORD RANGER 2020 Date of Publication 09 2020 4 Electrical 58 ...

Page 59: ...e that may block the normal detection zone of the system Remove the add on device to prevent false alerts The parking aid sensing system warns the driver of obstacles within a certain range of your vehicle The system turns on automatically whenever you switch the ignition on The system can be switched off through the information display menu or from the pop up message that appears once you shift t...

Page 60: ...1 Sensor Location NOTE Relocated sensors must be installed in the same position as originally fitted in the bumper bar Make sure that each sensor is installed in the correct corresponding position FORD RANGER 2020 Date of Publication 09 2020 4 Electrical 60 ...

Page 61: ...eft Outer Front Parking Aid Sensor Critical Angles and Heights Inner Sensor Height Outer Sensor Angle Inner Sensor Height Inner Sensor Angle N A within range of 2 4 degrees Less than or equal to 440mm above the ground within range of 2 4 degrees degrees above the horizontal plane Date of Publication 09 2020 FORD RANGER 2020 4 Electrical 61 ...

Page 62: ... network for vehicle speed NOTE A tachograph preparation pack for the integration of a VDO remote mounted tachograph can be ordered to support 4x4 vehicles only For further information please contact your local National Sales Company representative or Authorized Ford Dealer FORD RANGER 2020 Date of Publication 09 2020 4 Electrical 62 ...

Page 63: ...lamps must be mounted in accordance with the guidelines provided this section of the BEMM 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 ...

Page 64: ... C 15 Minimum 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 center of the vehicle F 400mm Maximum distance from outer edge of vehicle to inner edge of lamp G 4 5 2 Rear Fog Lamp NOTE Where only one rear fog lamp is fitted it must be positioned on the vehicle c...

Page 65: ...lamp 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 center of the vehicle F 4 5 3 4 5 4 Rear License Plate Lamp Date of Publication 09 2020 FORD RANGER 2020 4 Electrical 65 ...

Page 66: ...mp 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 center line and center of lamp D 175mm Distance between license plate center line and center of lamp E FORD RANGER 2020 Date of Publication 09 2020 4 Electrical 66 ...

Page 67: ... of trailer sway control In addition to providing the trailer plug functionality the trailer towing module protects the primary electrical circuits of the vehicle from any electrical concern or failure that the customer s trailer may experience For vehicles fitted without a tow bar as standard a genuine Ford accessory trailer tow electrical kit has been developed to enable a tow bar to be installe...

Page 68: ... 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 vehicle converters 4 5 9 center High Mount Stop Lamp CHMSL Canopy Fitment WARNINGS The maximum current load that can be applied to the CHMSL circuit is 1 72A for incandes...

Page 69: ...onnector is then taped back Follow the steps to install the replacement CHMSL lamp housing 1 RemovethecombinationCHMSL CargoLamp following the workshop manual instructions 2 Locate the 3 pin CHMSL Cargo Lamp Connector Cut off the stop lamp circuits pin 1 yellow grey or white blue pin 2 black violet or black yellow or black blue leaving the violet wire pin 3 connected to the 3 pin CHMSL connector 3...

Page 70: ...rtment will allow for a safer install and reduced noise in the passenger compartment Depending on the functionality required the pins used will emulate the basic locking unlocking operation of an existing lock The coil of the additional relays i e one relay for lock all one relay for unlock all should be added across the relevant pin and a suitable ground point Power B for the additional relays sh...

Page 71: ...dges 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 wheel guard envelopes must comply with ECE Regulations For integral structures such as ambulances or motor homes with increas...

Page 72: ...icular from the catalytic converter Ensure adequate heat shields are maintained CAUTION Unevenloaddistributioncould 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...

Page 73: ...e 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 C E F N M H G K L C D E F M L H G J K A B N P E134152 C E F N...

Page 74: ... H G J K C D E134153 L M A B E F H G J K C D E134153 L M Dimensions mm for Body Attachment Holes in Chassis Frame Super Cab 1086 G 16 A 95 H 28 B 1191 J 23 C 509 K 20 D 26 L 1244 E 20 M 1244 F FORD RANGER 2020 Date of Publication 09 2020 5 Body and Paint 74 ...

Page 75: ...ted 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 DynamicSealingandFinishingEnsure 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 Corrosion Prevention page 87 5 1 5 Tipper...

Page 76: ...lease refer to the following guidelines Mount tank 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...

Page 77: ...m 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 book id...

Page 78: ...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 points for the canopy fitment otherwise damage may occur to the load box The return flange on the load box sides should never be cut away be drilled into or be used otherwise for bolting of the canopy The top surface of the load ...

Page 79: ...al 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 09 2020 FORD RANGER 2020 5 Body and Paint 79 ...

Page 80: ...Example of a Sports Bar Fitment E172331 Description Item Front mounting bracket 1 Clamped attachment 2 FORD RANGER 2020 Date of Publication 09 2020 5 Body and Paint 80 ...

Page 81: ...earby 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 center 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 ...

Page 82: ...Driver and Passenger Front Airbag Deployment Zones E D B A F E210764 C Dimensions mm 392 D 260 A 520 E 470 B 544 F 470 C FORD RANGER 2020 Date of Publication 09 2020 5 Body and Paint 82 ...

Page 83: ...Side Airbag C B E134609 A Dimensions mm 550 A 350 B 250 C Curtain Airbag Single cab D C B A E136172 Dimensions mm 250 C 140 A 100 D 40 B Date of Publication 09 2020 FORD RANGER 2020 5 Body and Paint 83 ...

Page 84: ...Super cab D C B A E136173 Dimensions mm 250 C 140 A 100 D 40 B 5 2 2 Supplementary Restraint Sensors Front WARNING Modifications or reinforcements in the area of the front supplementary restraint sensors may affect their operation FORD RANGER 2020 Date of Publication 09 2020 5 Body and Paint 84 ...

Page 85: ...E306212 1 Description Item Front SRS Impact Sensors 1 Date of Publication 09 2020 FORD RANGER 2020 5 Body and Paint 85 ...

Page 86: ...hen removing the seatbelt system a seatbelt webbing forked retainer should be applied to the webbing 200mm below the webbing button stop This prevents a situation where all the webbing runs back into the retractor and the retractor becomes locked When reinstalling fit the retractor to the body first and gently pull the webbing out of the retractor to allow fitment of the D loop Then remove the for...

Page 87: ... all materials are compatible with the relevant Ford specifications and maintain the original performance where possible Some proprietary products affect the original coatings For specifications of corrosion protection materials please consult your local National Sales Company representative 5 4 4 Painting Road Wheels WARNING Do not paint wheel clamp surfaces in contact with other wheels brake dru...

Page 88: ...sis 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 f...

Page 89: ...ports 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 top surface of the chassis frame See figure shown for a generic vehicle cross section where the cross members and oppos...

Page 90: ... 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 87 Drilling and welding of frames and body structure have to be conducted following the program guidelines Please consult the Ford dealer for details 5 5 4AncillaryEquipment SubFra...

Page 91: ...ine 42 Engine Selection for Conversions 42 Engine Types 42 13 65 E Exterior Lighting 63 F Filling the Diesel Exhaust Fluid Tank 49 Frame and Body Mounting 88 Frame Drilling and Tube Reinforcing 90 Front Rear and Side Under Run Protection 29 Front End Integrity for Cooling Crash Aerodynamics and Lighting 75 Fuel Filler Mounting 45 Fuel Filler Pipe Shipping Bracket if equipped 43 Fuel Filler Vent Ho...

Page 92: ...es 39 Towing capacities 38 Towing Requirements 38 Towing Specifications 39 Towing 38 Trailer Brake Connection 41 Trailer Nose Weight 39 Trailer Towing 67 U Under Body Protection and Material 87 V Vehicle Dimensions Key 22 Vehicle Duty Cycle Guidelines 14 Vehicle Ride and Handling Attributes 14 Vehicle Speed Output Tachograph if equipped 62 Vehicle Transportation Aids and Vehicle Storage 18 W Warni...

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