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Ford TRANSIT 2016.75 Mounting Manual Download Page 281

5.15 Frame and Body Mounting

5.15.1 Mounting Points and Tubing

The holes on the frame are a result of the
production process. They are not designed for
fixing additional equipment. If additional fixings
to the chassis frame are required please follow
the recommendation given in figure E176204. 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: 5.14 Corrosion Prevention (page 280).

Frame Drilling and Tube Reinforcing

E176204

3

2

3

2

E

X

X

A

B

C

D

1

1

Description

Item

Description

Item

Diameter 16.5mm maximum

B

Full Penetration; Full diameter weld
each side

1

Diameter 11mm

C

Center line of holes/tubing

2

30mm to 35mm

D

Center line of holes/tubing

3

50mm minimum

E

30mm to 35mm

A

Date of Publication: 03/2018

FORD 

TRANSIT

 2016.75

5 Body and P

aint

281

EU

Summary of Contents for TRANSIT 2016.75

Page 1: ...Body and Equipment Mounting Manual FORD TRANSIT 2016 75 Date of Publication 03 2018...

Page 2: ...evelopment 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 no...

Page 3: ...tection Wheel Guards and Rear Registration Plate 30 1 14 7 Vehicle Dimensions Key 31 1 14 8 Recommended Main Load Area Dimensions 32 1 14 9 Chassis Cab Body 36 1 15 Hardware Specifications 38 1 16 Loa...

Page 4: ...mendations 137 4 4 12 Generator and Alternator 139 4 5 Climate Control System 145 4 6 Instrument Panel Cluster IPC 146 4 7 Horn 147 4 8 Electronic Engine Controls 148 4 8 1 Start Stop 148 4 8 2 Engine...

Page 5: ...g Systems 255 5 4 Body System General Information Specifications 258 5 4 1 Load Compartment Tie Downs 258 5 5 Front End Body Panels 259 5 5 1 Partitions Bulkhead Driver and Front Passenger s Protectio...

Page 6: ...he vehicle converters responsibility to review the online version for the most current information prior to starting any conversion This BEMM is for European and related markets sourced vehicles This...

Page 7: ...ided These links are in blue text This manual is also designed to be used as a printed document where there are links page numbers in brackets have been added which will help guide you to the start of...

Page 8: ...e Vehicle Converters are advised to check whether the fitment of parts require either Type Approval or Individual Vehicle Approval before the vehicle is registered Type Approval requires a Conformity...

Page 9: ...tic converter and from the Diesel particulatefilter DPF Ensureadequate heat shields are maintained Maintain sufficient clearance to hot parts Do not modify or remove heat protection shields Do not rem...

Page 10: ...or Weld Boron steel parts see figure E167660 in the welding section of this manual Drilling and welding of frames and body structure have to be conducted following the guidelines in Welding and Frame...

Page 11: ...Prolongeau CV Brand Manager Contact 33 1 61016547 Phone sprolong ford com E Mail St Germain Postal Address 34 rue de la Croix de Fer Saint Germain en Laye 78100 FRA Ford of Italy Michele Montalto CV S...

Page 12: ...Wallisellen Postal Address Geerenstrasse 10 Wallisellen 8304 CHE Ford of Denmark Bent Steen Jenson CV Brand Manager Contact 45 43 480621 Phone bjense23 ford com E Mail 5 D E Borupvang Postal Address...

Page 13: ...Mail Karolinska 654 2 Postal Address NILE1 Nile House Prague 18600 CZE Ford of Russia Evgeniy Gnusov CV Sales and Marketing Contact 7 495 7459700 x2226 Phone egnusov ford com E Mail Leningradskaya Str...

Page 14: ...teel80 ford com E Mail 1735 Sydney Road Postal Address Campbellfield VIC 3061 AUS Ford of New Zealand NZINFO Contact 64 9 2718500 Phone nzinfo ford com E Mail Private Bag 76912 Postal Address Manukau...

Page 15: ...tented 10 mode programmable battery guard system capable of protecting Ford third party battery A540 Converter High Power Supply System Meets heavy power take off requirements by equipping vehicles wi...

Page 16: ...Body page 227 Integrated Bodies and Conversions Transit Motorhome Chassis Refer to 5 8 Rear View Mirrors page 268 Door Mirrors Refer to 5 11 Airbag Supplemental Restraint System SRS page 273 Refer to...

Page 17: ...8 Special Conversions page 189 Auto Wipe and Auto Light for Vehicles with Large Over Hangs Refer to 4 4 Battery and Cables page 110 Generator and Alternator Money Carriers Refer to 4 9 Tachograph page...

Page 18: ...13 Roof page 277 Roof Racks Refer to 4 18 Special Conversions page 189 Auto Wipe and Auto Light for Vehicles with Large Over Hangs Refer to 4 4 Battery and Cables page 110 Generator and Alternator Gla...

Page 19: ...age 179 Refer to 5 9 Seats page 269 Refer to 5 10 Glass Frames and Mechanisms page 271 Refer to 5 13 Roof page 277 Refer to 5 11 Airbag Supplemental Restraint System SRS page 273 Refer to 5 2 Hydrauli...

Page 20: ...onditions The responsible Technical Service may require additional information and or testing NOTE For further information please contact your National Sales Company representative or local Ford deale...

Page 21: ...erview 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 fa...

Page 22: ...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 v...

Page 23: ...d Performance Any conversion may affect the fuel consumption andperformancedependingontheaerodynamics and the weight added by the conversion The published information for fuel consumption for the inco...

Page 24: ...o 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...

Page 25: ...are installed to maintain the integrity of the original body structure for at jacking points NOTE Any modifications to the vehicle must be noted in the owner s handbook or new descriptive literature i...

Page 26: ...370 E170181 Position the head of the vehicle jack under the rear leaf spring directly behind the rear wheel Rear Wheel Drive Vehicles T410 and Over E171406 Position the head of the vehicle jack under...

Page 27: ...tinpersonalinjury CAUTIONS When lifting the vehicle with 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 we...

Page 28: ...r 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...

Page 29: ...side the vehicle Make sure the wiper arms are suitably prevented from resting on the windscreen Wheel trims where fitted should be removed and stored in the luggage compartment Engage first gear manua...

Page 30: ...ents are installed to maintain the integrity of the original body structure Power side steps can be ordered as an option on the base vehicle Please check for availability Where additional steps are in...

Page 31: ...54 2195 2197 7797 7577 L5 4522 Double Chassis Cab H1 2203 2227 5767 5572 L2 3504 2203 2218 6204 6022 L3 3954 2208 2220 6587 6404 L4 3954 2198 2211 7612 7394 L5 4522 All dimensions are subject to manuf...

Page 32: ...ehicle 1700 1392 2872 L2 H2 FWD SRW 1600 1392 2872 L2 H2 RWD SRW 1700 1392 3322 L3 H2 FWD SRW 1600 1392 3322 L3 H2 RWD SRW L2 3 3m Wheel Base L3 3 75m Wheel Base L4 3 75m Wheel Base FWD Front Wheel Dr...

Page 33: ...W 1925 1386 3327 L3 H3 FWD SRW 1825 1386 3327 L3 H3 RWD SRW 1825 1386 4050 L4 H3 RWD SRW 1868 1154 4064 L4 H3 RWD DRW L2 3 3m Wheel Base L3 3 75m Wheel Base L4 3 75m Wheel Base FWD Front Wheel Drive R...

Page 34: ...mm Vehicle 520 1789 1818 1392 2038 L2 H2 FWD 520 1789 1718 1392 2038 L2 H2 RWD 520 2239 1818 1392 2488 L3 H2 FWD 520 2239 1718 1392 2488 L3 H2 RWD L2 3 3m Wheel Base L3 3 75m Wheel Base FWD Front Whe...

Page 35: ...2 2038 L2 H3 RWD 2238 1798 520 1889 2055 1392 2488 L3 H3 FWD 2238 1698 520 1889 1955 1392 2488 L3 H3 RWD 2961 1698 520 2612 1955 1392 3211 L4 H3 RWD SRW 2961 1698 520 2612 1955 1154 3211 L4 H3 RWD DRW...

Page 36: ...erhang may encourage unacceptable loading conditions which could unload the front axle producing unacceptable handling and braking characteristics NOTE When extending the length of the frame rearward...

Page 37: ...75mm Single Cab Frame length behind back of cab not including rear light cross member J 4149 3159 2777 2327 Double Cab It is recommended to ensure that a minimum departure angle of 14 at RGAWR of the...

Page 38: ...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 43...

Page 39: ...emoved from the vehicle This may influence the steering characteristics handling behavior and the brake performance Lateral Position It is important to keep the Center of Gravity laterally within give...

Page 40: ...reparation and it results in lower accuracy Initially the vehicle weights needs to be measured in a horizontal position Afterwards the front is lifted and weights measured again The higher it is lifte...

Page 41: ...ht kg mG mV mH Total Mass INCLINED VEHICLE kg m V Front Axle Weight kg m H Rear Axle Weight mm H Height Lift deg Inclination Angle see figure E146623 mm Center of Gravity Height Z see figure E146624 I...

Page 42: ...n horizontal direc tion X H Distance rear axle to CoG projected in horizontal direc tion arc sin Inclination angle XH1 Front part of distance rear axle to CoG horizontal XH2 Rear part of distance rear...

Page 43: ...und plane can be determined using the sumofmomentsaroundfrontandrearwheel center E146628 The following equations apply E146629 Using the rule of proportion leads to the Center of Gravity height formul...

Page 44: ...vices fitted by the vehicle converter the following applies Tow bar allowances must not exceed those of the standard vehicle For attachment of the tow bar under run bar and step see the following figu...

Page 45: ...Tow Bar Van Bus and Kombi E175744 1 3 4 5 5 6 6 3 4 2 A B C D F F E G G H K J 7 Date of Publication 03 2018 FORD TRANSIT 2016 75 1 General Information 45 EU...

Page 46: ...60mm J 15mm diameter F 361 4mm C The low position two fixing holes should be used for attaching the tow ball to vehicles with 16 inch wheels and the mid position two fixing holes should be used for at...

Page 47: ...nd bolts each side M12 x 1 75 x 100 Torque 103NM 15 4 15mm Diameter F 115mm A The low two fixing positions should be used for attaching the tow ball to vehicles with 16 inch wheels and the mid two fix...

Page 48: ...4x fixing bolts 2 Reinforcement clamp plate 3 Side member with 3x fixing nuts and bolts each side M12 x 1 75 x 100 Torque 103NM 15 4 22mm D 115mm A 74mm E 106mm B 15mm Diameter F 267mm C Vehicles buil...

Page 49: ...SCRIPTION ITEM 941mm A 222mm B 257mm C 35mm D WARNING To ensure functionality of Trailer Sway Control TSC please make sure that the tow ball is within zone D as shown in figure E203004 From center of...

Page 50: ...assis for Camper Conversion Only E167540 H A B G C D F E DESCRIPTION ITEM 20mm A 314mm B 30mm C 77 5mm D 20mm Diameter E 13mm Diameter F 86mm G 32mm H FORD TRANSIT 2016 75 Date of Publication 03 2018...

Page 51: ...tonne GVM 2 500kg maximum towing The maximum allowable tow ball static load is 350kg on LWB EL Van DRW Single Cab and Double Cab chassis models 4 5 tonne GVM 3 500kg maximum towing A minimum tow ball...

Page 52: ...LWB EL Van SRW 3 5 Tonne and 12 Seat Bus 4 1 Tonne H K B F G G F A D E C J H K B F G G F A D E C J 2 2 7 4 6 5 1 E201168 3 3 5 6 FORD TRANSIT 2016 75 Date of Publication 03 2018 EU 1 General Informat...

Page 53: ...5 x 100 Torque 115 5Nm 4 2x fixing nuts each side 5 Reuse 2x fixing bolts each side in holes G M12 x 100 Torque 103 15Nm 6 1x Anti rattle pin Torque 150 5Nm 7 58mm K 12mm diameter G 135 84mm D 514mm A...

Page 54: ...LWB EL Van DRW 4 5 Tonne H K B F G G F A D E C J H K B F G G F A D E C J 2 2 7 4 6 5 1 E201168 3 3 5 6 FORD TRANSIT 2016 75 Date of Publication 03 2018 EU 1 General Information 54...

Page 55: ...5 x 100 Torque 115 5Nm 4 2x fixing nuts each side 5 Reuse 2x fixing bolts each side in holes G M12 x 100 Torque 103 15Nm 6 1x Anti rattle pin Torque 150 5Nm 7 58mm K 12mm diameter G 135 84mm D 514mm A...

Page 56: ...ch side M12 x 1 75 x 100 Torque 115 5Nm 2 Reinforcement clamp plate each side 3 Fixing nut each side 4 1x Anti rattle pin Torque 150 5Nm 5 22mm D 115mm A 74mm E 106mm B 15mm Diameter F 267mm C Vehicle...

Page 57: ...mpers is not permitted as the changes in vehicle dynamicperformancecanaffecttheESP system CAUTION Modifications to the suspension system can cause a deterioration of the vehicle handling characteristi...

Page 58: ...gs 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...

Page 59: ...vehicle dynamicperformancecanaffecttheESP system CAUTIONS When carrying out welding work the springs must be covered to protect them against weld splatter Do not touch springs with welding electrodes...

Page 60: ...oad wheel and tire to your vehicle To restore the correct operation of the system you must have the repaired road wheel and tire refitted to the vehicle NOTE If fitting new tires you must ensure that...

Page 61: ...sion oil temperature must notexceed130 Cduringoperationofthe 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...

Page 62: ...ake 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...

Page 63: ...urposes only if the Reference Mass used for completed vehicle type approval is Not exceeding 2840kg a light duty engine may be specified for N1 and N2 vehicles Greater than 2840kg a heavy duty engine...

Page 64: ...0 140 160 180 200 220 240 260 280 300 320 340 360 4500 1000 1500 2000 2500 3000 3500 4000 1 2 Description Item Torque Curve Nm Max Torque 360Nm at 1375 2000 1 min 1 Power Curve kW Max Power 77kW 105PS...

Page 65: ...0 160 180 200 220 240 260 280 300 320 340 360 380 400 1000 1500 2000 2500 3000 3500 4000 4500 1 2 Description Item Torque Curve Nm Max Torque 385Nm at 1500 2000 1 min 1 Power Curve kW Max Power 96kW 1...

Page 66: ...160 180 200 220 240 260 280 300 320 340 360 380 400 420 1000 1500 2000 2500 3000 3500 4000 4500 1 2 Description Item Torque Curve Nm Max Torque 405Nm at 1750 2500 1 min 1 Power Curve kW Max Power 125k...

Page 67: ...30 140 160 180 200 220 240 260 280 300 320 340 360 1000 1500 2000 2500 3000 3500 4000 4500 1 2 Description Item Torque Curve Nm Max Torque 360Nm at 1500 2000 1 min 1 Power Curve kW Max Power 77kW 105P...

Page 68: ...0 160 180 200 220 240 260 280 300 320 340 360 380 400 1000 1500 2000 2500 3000 3500 4000 4500 1 2 Description Item Torque Curve Nm Max Torque 385Nm at 1500 2500 1 min 1 Power Curve kW Max Power 96kW 1...

Page 69: ...160 180 200 220 240 260 280 300 320 340 360 380 400 420 1000 1500 2000 2500 3000 3500 4000 4500 1 2 Description Item Torque Curve Nm Max Torque 405Nm at 1750 2500 1 min 1 Power Curve kW Max Power 125k...

Page 70: ...prevent hose blow off Reconnect original coolant tube as shown in view E74570 in this section with standard Ford water hose clip or suitable equivalent specification clip Ensure interference fit betw...

Page 71: ...hich damage the paint must be fully protected against corrosion Refer to 5 14 Corrosion Prevention page 280 NOTE The installation must be in line with the appropriate legal requirements 3 2 3 Air Flow...

Page 72: ...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 CAUTION Do not fit an a...

Page 73: ...t and Protective Shield on FWD 2 0L Diesel Engine with Air Conditioning Description Item Alternator 1 Idler 2 HPAS Pump 3 AC Compressor 4 Crankshaft Pulley 5 Water Pump 6 Tensioner 7 Front End Accesso...

Page 74: ...lley Belt Layout Engine Top Cover on 2 0L Diesel Engine with Air Conditioning Description Item Alternator 1 Idler 2 HPAS Pump 3 AC Compressor 4 Crankshaft Pulley 5 Water Pump 6 Tensioner 7 Engine Top...

Page 75: ...r shift cables Tachographs cannot be fitted into 6F55 transmissions Do not change external electrical connectors 6F55 6 Speed Automatic FWD Transmission Overall Ratio Final Drive 3 65 Base Transmissio...

Page 76: ...ble 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...

Page 77: ...h 2 754 2 417 2 570 2 785 0 844 5th 2 229 1 956 2 080 2 254 0 683 6th 17 306 15 190 16 150 17 503 1 423 Reverse MT82 6 Speed Manual RWD and AWD Transmission RWD Gear Set A Gear OverallTransmis sion Ra...

Page 78: ...VMT6 6 Speed Manual FWD Transmission E224692 MT82 6 Speed Manual RWD Transmission E224693 FORD TRANSIT 2016 75 Date of Publication 03 2018 EU 3 Powertrain 78...

Page 79: ...iameter pipes Exhaust Pipe Design Principles E74569 r d Description Item diameter d radius 2 5d r 3 7 2 Exhaust Pipes and Supports CAUTIONS Maintain the original set up and heat shields Do not positio...

Page 80: ...e location as indicated in figure E244745 Forcorrectplacementthebody cross members should be taken as reference Apply part to clean and even surface for maximum bonding and durability The part should...

Page 81: ...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...

Page 82: ...pipe from tank Remove bolts securing the three tank straps Lower the fuel tank to gain access to the top see Figure E224457 for fitting auxiliary fuel line To refit fuel tank Lift fuel tank ensuring n...

Page 83: ...1 9N126 A 1 Auxiliary fuel line has a female connector TI LOCC QC 7 89 fitted as standard It is recommended to use a 7 89 male adapter mating part manufacturer TI Automotive GmbH For further informati...

Page 84: ...uxiliary fuel line has a male end adapter TI LOCC QC 7 89 fitted as standard with a female fuel spillage block connector It is recommended to use a 7 89 female connector mating part manufacturer TI Au...

Page 85: ...m 35mm clearance of all moving parts of the parking brake assembly If these clearances cannot be met protect the wires with a convolute For conversions with walkthroughs it is recommended to provide a...

Page 86: ...eakage into the vehicle interior passenger and cargo compartments using wiring assemblies that pass from outside into the vehicle interior The drip loop is a section of wiring that is deliberately for...

Page 87: ...368 50 0 316 0 306 0 290 0 344 0 333 0 315 60 0 254 0 248 0 243 0 270 0 264 0 259 70 0 193 0 189 0 185 0 204 0 200 0 196 95 0 152 0 149 0 146 0 159 0 159 0 153 120 When designing wire installations fo...

Page 88: ...to route wires through See figure E145360 view from engine bay for locations The number of suitable locations will depend on the vehicle specification The grommets in locations 1 and 2 shown in figur...

Page 89: ...care should also be taken when using self tapping screws Not all derivatives are shown but the routing is the same for roof line and wheel base with regards to B C and D pillars or roof bows and doors...

Page 90: ...Precautionary Drill Zones L3 H2 Left Hand Side E167562 Precautionary Drill Zones L3 H2 Right Hand Side E167563 FORD TRANSIT 2016 75 Date of Publication 03 2018 EU 4 Electrical 90...

Page 91: ...Precautionary Drill Zones L3 H3 Left Hand Side E167564 Precautionary Drill Zones L3 H3 Right Hand Side E167565 Date of Publication 03 2018 FORD TRANSIT 2016 75 4 Electrical 91 EU...

Page 92: ...ll Zones L4 H3 Right Hand Side E167560 4 1 13 Electrics for Tow Bar Trailer Tow Module and Harnesses Van Bus and Kombi Vehicles E145361 4 3 1 2 5 2 4 FORD TRANSIT 2016 75 Date of Publication 03 2018 E...

Page 93: ...gure E185972 2 BK3T 13B576 G Trailer Tow Socket Jumper 3 GK3T 14406 E Fuel Tank Harness 4 GK3T 14401 Main Harness with Trailer Tow Module connectors B and C see figure E185972 5 Tow bar electrical sys...

Page 94: ...higher current is interpreted as short circuit If a short circuit is detected the related output will be switched off The following table shows the recommended output maximums per circuit Trailer Tow...

Page 95: ...rcuit detection 30A If trailer tow system is to be added the correct wiring and module needs to be ordered The vehicle needs to have Central Car Configuration CCC programmed to the correct parameters...

Page 96: ...y Brown 11 KL30 Power 9 Blue Red 9 KL15 Ignition 10 Grey Yellow 10 Ignition Ground KL15 11 Black Violet 8 Trailer Detect 12 Not Used Not Used Power Ground 13 Black Violet 16 Trailer Tow 13 Pin Socket...

Page 97: ...ition 3x 4 Recommended 12V Socket Position 5 NOTE Fix over length of the wiring on a secure area of the vehicle NOTE The 12V socket bracket can stay in its original position when the socket is mounted...

Page 98: ...dules could impact the safe operation of the vehicle CAN Controller Area Network uses propriety message sets to communicate between the devices shown via Medium Speed MS High Speed HS Private and Publ...

Page 99: ...Parking Aid Module PAM Auxiliary Heater Control Module AHCM Passive Anti Theft System PATS Sync Gen 1 APIM G1 Running Board Control Module Power Step RBM Sync Gen 2 inc DM6 MFD APIM G2 Restraints Con...

Page 100: ...tself Vehicle BCM configuration must NOT be modified once the vehicle has left a Ford production plant except for any changes that may be carried out using dealership integrated diagnostic systems equ...

Page 101: ...Width Modulation Mirror Turn Lamp Left Output Shutdown 42W Bulb High Side Pulse Width Modulation Mirror Turn Lamp Right Output Shutdown 27W Bulb LED High Side Pulse Width Modulation Licence Plate Mar...

Page 102: ...9 Tachograph Micro 3 7 5A F20 PTC Heater Micro 3 5A F21 Not Used Spare Micro 3 5A F22 Delayed Accessory Radio Power Inverter Micro 2 10A F23 Locking Central Lock Double Lock Micro 2 20A F24 Not Used S...

Page 103: ...to ensure engine cranking in unfavorable climatic conditions even after fitment of additional electrical equipment The Transit utilizes multiplexed vehicle electronics it is recommended that the appr...

Page 104: ...ontrol Module PCM or Engine Control Module ECM 1 Body Control Module BCM 2 Battery Monitoring Sensor BMS Where fitted 3 Battery Twin batteries are available as an upgrade or driven by specific feature...

Page 105: ...for fuel used During this condition the battery supports the electrical loads This function can be turned off by the Start Stop Switch or using the hardwire input as detailed later in this section of...

Page 106: ...ehicle Interface Connector A608 and a link from the Hardwire Input to the chosen switch and ground point but must not be a permanent ground The grounding should only occur for a duration of the third...

Page 107: ...the proposed conversion including National Legislation in the country of sale The method of integrating the circuit into the base vehicle No additional circuits are to be run alongside the electrical...

Page 108: ...e 191 Safety Increased use of comfort and safety electronics in modern motor vehicles also requires the greatest attention to be paid during body work Over voltages produced during welding and in alig...

Page 109: ...CE approval 4 3 7 Vehicle Electrical Capacity Alternator WARNING Do not cut into the alternator wires The alternator is LIN controlled It doesnothaveaconventionalD engine start signal line 4 3 8 Charg...

Page 110: ...protection Ensure batteries are charged in a designatedchargingareathatiscorrectly ventilated Vehicles with Start Stop require an AGM battery You must replace the battery withoneofexactlythesamespecif...

Page 111: ...low as 7V for 100ms Followed by a period of voltage ripple providing an output to bring the voltage back to 12 3V This can be up to 5 seconds All third party fit modules must be robust to handle warm...

Page 112: ...be found later in this section Refer to 4 8 Electronic Engine Controls page 148 and Refer to 4 3 Charging System page 103 Battery Voltage Requirements and Testing As part of the Converter process and...

Page 113: ...ry which has been completely discharged may be slow to accept a charge initially and in some cases may not accept a charge at the normal charger setting When batteries are in this condition charging c...

Page 114: ...4 3 Battery Rules Batteries in parallel must be of the same type and capacity and listed in the Ford battery table Third party batteries and loads are to be isolated from the standard Ford system at k...

Page 115: ...ply at Key off If twin Ford battery configured only fitting single Ford battery If single Ford battery configured fitting twin Ford battery Start Stop and SRC system functionality cannot be guaranteed...

Page 116: ...direct connection of such chargers to this battery is required Connection to the auxiliary battery also reduces the number of crank micro cycling that a third party battery will be exposed to on a Sta...

Page 117: ...onvert Fit Third Party Battery Installation to Existing Ford Power Supply Architecture Example Only E225363 A K L M B J E D H C F G Date of Publication 03 2018 FORD TRANSIT 2016 75 4 Electrical 117 EU...

Page 118: ...tion The third party eyelet must be a tight fit within the battery clamp slot and have a maximum Cross Sectional Area CSA for current flow The cable CSA must be oversized Refer to 4 1 Wiring Installat...

Page 119: ...ommended routed in parallel to 12V supply for EMC compliance When in Engine Run unrequited systems should be turned off to help the alternator supply the main load of the third party system This infor...

Page 120: ...the negative battery terminal Connecting to the negative battery terminal will bypass the BMS and affect the correct assessment of the battery state of charge Refer to BMS section in this manual If se...

Page 121: ...e power relay when a low voltage is detected or a specific time point is reached Efficiently controls the Ford SRC and Start StopInhibittoreceivemaximumcharging to the third party batteries whilst pro...

Page 122: ...Line Fuse S Body control module BCM E Mode Wires T Power Control Module PCM F Immediate Relay close U Alternator G Immediate Relay Open V Starter Motor H Third Party SRC Inhibit Load Active W FPBG Int...

Page 123: ...ndard Flooded No Third Party Battery 3 90 12 0 Twin Standard Flooded With Third Party Battery 4 60 12 0 Single AGM No Third Party Battery 5 120 12 0 Single AGM With Third Party Battery 6 90 11 8 Twin...

Page 124: ...mpty 3 Black Grey B Converter Battery Sense Line 4 Empty 5 Grey Mode Configuration Pin 6 6 Green Mode Configuration Pin 7 7 Blue Mode Configuration Pin 8 8 Blue Grey SRC Inhibit Converter Request Inpu...

Page 125: ...This allows time for the alternator to ramp up to full charge voltage Isolation of the relay will occur immediately when the ignition signal is detected if a mains charger is connected to the system p...

Page 126: ...ld value for 30 seconds This assessment is required to ensure there is no instant voltage drop in the system because of an initial start of high power equipment or cranking The Power Isolation Warning...

Page 127: ...Over Voltage when it is higher than 15 8V Sleep Mode The system will be active when it sees ignition position 2 signal from position zero or key out When ignition position 2 is deactivated the key off...

Page 128: ...Engine Run Alternator Protection OOOO RRRR Low Voltage Cut Off G Not Triggered Power Isolation Warning OOOOO Triggered G Not Detected External Charger Engine Off O O 13 5V Detected O R R IGN2 Detecte...

Page 129: ...ity at ignition ON or OFF may lead to a clicking sound of the relay opening and closing as part of its strategy The end operator may need to be advised of this condition The main 12V feed supply is ta...

Page 130: ...lamp in the CAB area The system cannot be ordered as factory fit option or retrofitted with the Ford 150 Watt inverter as it utilizes the same package space However this system can power a 2 000 watt...

Page 131: ...ment The engine off Load Active Input should not be used on loads less than 20A This is due to the load drop below this value being close to actual SOC of the battery where this is below energy requir...

Page 132: ...seated sealed properly making sure the harness does not obstruct or interfere with the handbrake cable and assemble edge clip to handbrake bracket 8 Fit Handbrake Connector 9 Fit Relay Holder 10 Secur...

Page 133: ...sed 13 Red Mode Configuration Pin 14 14 Black Mode Configuration Pin 15 15 Grey Yellow Ignition KL15 12V 16 New Harness Routing Inside Drivers Seat Pedestal E227394 A B 15 14 17 15 16 14 175A Mega Fus...

Page 134: ...nal Third Party Power Connection 12V E252619 1 2 3 1 Remove M8 Nut 2 Place Third Party Power Cable Eyelet onto M8 Stud 3 Secure M8 Nut to Torque 12Nm 1 8 FORD TRANSIT 2016 75 Date of Publication 03 20...

Page 135: ...last for at least three hours If the system cannot carry out a re calibration then it is unable to establish the correct state of charge of the battery In this case the Start Stop system may be deacti...

Page 136: ...single battery cannot be converted into a Start Stop derivative Battery Cables and Components A vehicle ordered with a single battery can be converted to twin standard batteries or to High Performanc...

Page 137: ...SRC in this section and Charging Systems to configure charge mode HIGH CONTINUOUS POWER TAKE OFF 30A 240A for example Ambulance High Load Main tenance Vehicle Refrigeration DO NOT ALLOW BATTERY DISCH...

Page 138: ...city AGM 600 times the battery Ah capacity For example For an 80Ah Standard Flooded Battery 30 x 80Ah 2400Ah of battery turnover is available for the converter to use during the battery life 3 years T...

Page 139: ...hows the torque Nm and the horizontal axis B shows the alternators revolutions per minute 1 min NOTE For equivalent engine revs per minute RPM the alternators revolutions axis B should be divided by t...

Page 140: ...age 13 8V 2 Temperature 60 C Voltage 13 5V 3 Temperature 93 C Voltage 13 1V 4 Temperature 115 C Voltage 12 9V 5 Diagram E225423 shows the alternator output performance at five different temperatures I...

Page 141: ...000 12000 14000 A B Diagram E225421 shows the torque in Nm which is required to drive the alternator The vertical axis A shows the torque Nm and the horizontal axis B shows the alternators revolutions...

Page 142: ...age 13 8V 2 Temperature 60 C Voltage 13 5V 3 Temperature 93 C Voltage 13 1V 4 Temperature 115 C Voltage 12 9V 5 Diagram E225424 shows the alternator output performance at five different temperatures I...

Page 143: ...000 12000 14000 A B Diagram E225422 shows the torque in Nm which is required to drive the alternator The vertical axis A shows the torque Nm and the horizontal axis B shows the alternators revolutions...

Page 144: ...Voltage 13 8V 2 Temperature 60 C Voltage 13 5V 3 Temperature 93 C Voltage 13 1V 4 Temperature 115 C Voltage 12 9V 5 Diagram E225425 shows the alternator output performance at five different temperatur...

Page 145: ...J1 8 EVAP Temp Sensor Input J1 9 Not Used connected to ground on Printed Circuit Board Assembly J1 10 Heated Front Screen Button Input J1 11 Heated Front Screen Indicator LED Output J1 12 Not Used con...

Page 146: ...Instrument Cluster Wire Color Description Connector Pin C1 Yellow Violet Fuel Sender 1 Violet Low Washer Fluid 2 Grey Red Positive Power supply 3 Twisted White Green High Speed CAN Low 4 Green Blue Hi...

Page 147: ...7 Horn Any other aftermarket horn for example an air horn will need to be driven by a separate relay energized by the horn circuit Date of Publication 03 2018 FORD TRANSIT 2016 75 4 Electrical 147 EU...

Page 148: ...leased The engine is restarted on clutch pedal press in neutral Inhibitors Sometimes the engine may not shut down or will request auto restart due to one or more system inhibitors being active The eng...

Page 149: ...Start Stop becoming permanently inhibited and therefore the fuel saving features lost This is the same as for Smart Regenerative Charging SRC Refer to 4 3 Charging System page 103 SRC The driver s do...

Page 150: ...use is to raise the engine idle to reduce the likelihood of engine stall when ancillary equipment is being run from the engine during normal drive operations For example Refrigerator units used to ke...

Page 151: ...The harness is loosely taped in this location so that the green white loop 1 can be easy to extract Figure E175155 shows right hand drive A and left hand drive B Refer to Workshop Manual for removal o...

Page 152: ...can be accessed through the bottle holder see figure E251008 Refer to Workshop Manual for removal of trim On right hand drive vehicles B the loop is taped to the harness which feeds the 64 way main in...

Page 153: ...operation Key switch closed off open on Note this is the reverse situation of vehicles with 2 2L engine A key switch is recommended in this position for a couple of reasons If the control box is loca...

Page 154: ...eature can even be turn off disabled The 3 default RPM speeds can also be modified within the allowable range for the mode of operation as detailed in this section Via IDS the RPM Speed Controller men...

Page 155: ...e procedures if necessary Reasons why RPM speed Control operation may stop or fail The RPM Speed control software monitors vehicle informationduringoperationinRPMspeedcontrol mode and will drop out of...

Page 156: ...RPM Speed Control check with your local Ford dealer for availability of option OCR allows the driver operator to manually perform a DPF regeneration while the vehicle is stationary after confirming t...

Page 157: ...require the same wiring connections as this is controlled by tachograph legislation NOTE Digital Tachograph DTCO is the legal requirement for Europe Digital DTCO Tachograph E75502 Pin Assignment For...

Page 158: ...4 9 2 Tachograph Harness Mounting E167575 FORD TRANSIT 2016 75 Date of Publication 03 2018 EU 4 Electrical 158...

Page 159: ...Sensor Harness Routing FWD E145371 1 2 2 4 3 3 Description Item Main Harness 1 Tachograph Speed Sensor Harness 2 Clips 3 Sensor into Transmission 4 Date of Publication 03 2018 FORD TRANSIT 2016 75 4 E...

Page 160: ...on the base vehicle 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 Advi...

Page 161: ...CAS ford com 4 9 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 don...

Page 162: ...NOTE Pre Equipment Pack less speakers does not have wiring between the roof mounted AM FM DAB antenna and the co axial cable that connects to the AHU If planning to retrofit an AHU you will need to o...

Page 163: ...O O 10 Speakers Tourneo Only X X X X X Single AM FM Antenna X X AM FM DAB TMC with Active Splitter X X X Single AM FM DAB Antenna X X X X X X X X X X Less GPS Antenna X GPS Antenna X X X X X Less GPSM...

Page 164: ...9 Output Left Front Speaker 22 Output Left Front Speaker 10 Output Right Front Speaker 23 Output Right Front Speaker 11 Output Right Rear Speaker 24 Output Right Rear Speaker 12 Pins 7 and 19 are for...

Page 165: ...Output Right Front Speaker 23 Output Right Front Speaker 11 Output Right Rear Speaker 24 Output Right Rear Speaker 12 26 Pin Connector 8476 1 544128 1 E147212 1 14 13 26 26 Pin Connector Type Descript...

Page 166: ...Pin Connector E167585 6 1 Description Item Battery 1 PADI Voltage Ignition 2 PADI ON 3 PADI OFF 4 LIN 5 Ground 6 4 10 4 Additional Rear Speakers Rear speaker wiring is always present in the instrument...

Page 167: ...Left Rear 21 Brown Yellow Left Rear 9 Rear Speakers In line connector 14401 14K024 40 43 42 41 E146834 Description Item Rear Speaker Left White Green Pin 40 Rear Speaker Left Brown Yellow Pin41 Rear S...

Page 168: ...r 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...

Page 169: ...ator Side Repeater each side 15W 30W High Side Driver Daytime Running Lamps each side 110W 110W Relay Front Fog Lamps 42W 42W High Side Driver Rear Fog Lamps License Plate and Marker Lamps not to exce...

Page 170: ...ghting Regulations ECE R48 Parking lamp based on the finished vehicle dimension certain vehicles are not allowed to have the single or two side parking light function Where necessary the parking light...

Page 171: ...89 V Mating Connector 4S7T 14A459 V Mating Connector 4S7T 14A459 V Stop Turn Right Outboard Pin 1 Turn Lamp Right Rear Pin 1 Park Rear Left Pin 2 Stop Turn Right Outboard Pin 2 Turn Lamp Left Rear Pin...

Page 172: ...688 1 2 Side Marker Lamps Van Bus and Kombi Harness GK3T 14A333 Connector AU5T 14A464 P Mating Connector AU5T 14A624 T License Plate Lamp Pin 1 Ground Pillar D Right Pin 2 FORD TRANSIT 2016 75 Date of...

Page 173: ...arkers Harness GK3T 13A409 Harness GK3T 13A409 Connector 3M5T 14489 B Connector F3LB 14489 M License Plate Lamps Marker Lamps Pin 1 License Plate Lamps Marker Lamps Pin 1 Ground Pillar D Right Left Pi...

Page 174: ...Rear Pin 2 Fog Lamp Rear Pin 7 Stop Lamp Pin 3 Reverse Lamp Pin 8 Park Lamp Rear Pin 4 B License Plate Lamp Connector 7T4T 14A624 A on Harness 14406 Ground Frame Middle Pin 3 License Plate Lamp Pin 1...

Page 175: ...hassis Cabs Main Harness A Side Marker Interface Connector B Mating Service Kit for Interface Connector GK3T 12663 E License Plate Lamp Left Pin 1 Not Used Pin 2 Not Used Pin 3 Ground Frame Middle Lef...

Page 176: ...eletal Chassis Harness GK3T 14406 16 pin Connector See figure E178934 1 License Plate Lamps 2 5 Rear Lamps 3 4 See Rear Lamps Chassis Cab table for further details TransitMotorhomeChassisandFordSkelet...

Page 177: ...ibility a mating connector with seals plugs and pre crimped wire and terminal should be used For connectivity see figure E176695 The Third Brake lamp feed can be accessed from the Third Brake Lamp Con...

Page 178: ...exist and the rear registration plate lamp can only be switched on and off simultaneously This condition does not apply when using front and rear position lamps as well as side marker lamps when comb...

Page 179: ...o switch off Open the door or lift gate at the rear of the vehicle Any interior lights that switch on are in the rear cargo or rear zone If fluorescent lighting is required it must not be connected to...

Page 180: ...ealer ForfurtherinformationrefertoWorkshop Manual or Owner s Manual NOTE Do not obstruct the cruise control radar see clearance zone 2 in Figure E184084 NOTE Do not paint the front grill of the vehicl...

Page 181: ...try is significantly altered a new calibration for the camera sensor needs to be made E186104 2 1 Description Item Lane keeping system camera located behind the interior rear view mirror trim 1 View c...

Page 182: ...nto either the BCM connector or the in line connector for the door jumper harness The coil of the relay max 300mA should be added across the relevant pin and ground i e one relay for lock all one rela...

Page 183: ...ngle Chassis Cab Transit Motorhome Chassis and Ford Skeletal Chassis Pin 3 on R11 of the Junction Box is controlled by the third button on the key fob This provides a 12V pulse when pressed The signal...

Page 184: ...objects and 100mm away from high switch loads NOTE It is recommended that the RKE TPMS has a dedicated ground wire and ground stud do not splice with other modules The RKE TPMS receiver is fed via a c...

Page 185: ...Junction Box EJB Standard Relay Box SRB or Body Control Module BCM The vehicle converter modifier must provide additionalfusesasrequired Pleaserefer to Ford Fuse table in this section NOTE Only use F...

Page 186: ...ow 20A DG9T 14A094 K White 25A DG9T 14A094 L Green 30A DG9T 14A094 M M Case Fuse Grey 15A DG9T 14A094 A Light Blue 20A DG9T 14A094 B White 25A DG9T 14A094 C Pink 30A DG9T 14A094 D Green 40A DG9T 14A09...

Page 187: ...rent of 300mA max at 25 C Relays with higher loads should not be used For maximum switching currents please refer to Relay Figures E75017 E75021 Micro Relay E75017 1 4 2 5 3 1 2 3 5 4 Micro Relay Para...

Page 188: ...nt 4 17 3 Windscreen Wipers The base wiper system should not be tampered with controlled by BCM and multiplex architecture with LIN technology NOTE Power to wiper motors is limited by the size of the...

Page 189: ...paration Pack Jumper Harness BK3V 10A933 B Beacon Preparation Pack LHD GK3V 14659 B Beacon Preparation Pack RHD GK3V 14659 C Utility Vehicle Switch Pack LHD GK3V 14659 D Utility Vehicle Switch Pack RH...

Page 190: ...that a donor vehicle has been supplied with these features the dealer can configure the vehicle to manual light and wipe with the following settings Set Central Car Configuration parameter 24 With Ra...

Page 191: ...rom over loading All connections into existing wiring must be permanently insulated Exterior connections must be water proof and with a drip loop Where wires are required to be extended break in point...

Page 192: ...y used and should not be touched Contact your local Ford dealer or National Sales Company representative for details of the kit E145358 shows the left hand drive situation On a right hand drive vehicl...

Page 193: ...onnector Tyco Terminal Tyco Connector Connector 926883 1 pin 1 480710 0 926882 1 socket 0 926647 1 15 way C2 1 926883 1 pin 1 480704 0 926882 1 socket 0 480705 0 6 way C2 2 MTA Terminal MTA Connector...

Page 194: ...to Trans Output NEUTRAL 12 10A F21 SRB Grey Yellow 0 75 Ignition KL15 13 Grounded SRC Start Stop disabled Violet Grey 0 5 SRC Start Stop Inhibitor 14 12V 300mA max Green Brown 0 75 Reverse signal 15 C...

Page 195: ...eat Buckle 2 Way Connector Figure E169183 item A Comments Color Wire CSA Function Pin Black Grey 0 5 Central Module Sensor Seat Belt Buckle 1 Green Blue 0 5 Sensor Seat Belt Buckle Front Drivers Side...

Page 196: ...be exceeded in any situation this includes the total of the Ford System and Third Party System requirements Unused wires in the service kit must have cable ends insulated to avoid shorting on any gro...

Page 197: ...less of vehicle variant for example Start Stop or SRC The signal will not be present when Key states OFF 0 Accessory 1 Run but Engine OFF 2 Crank 3 Key in Run position where Start Stop vehicle has aut...

Page 198: ...face Connector 1 3 Ground 4 C3 2 Way Radio Connector 5 Auxiliary Fuse Panel within the Pre Fuse Box lid not shown 6 Vehicle Interface Connector 2 7 Only suitable to be used with Ford Programmable Batt...

Page 199: ...rface Connector 1 3 Ground 4 C3 2 Way Radio Connector 5 Auxiliary Fuse Panel within the Pre Fuse Box lid not shown 6 Vehicle Interface Connector 2 7 Only suitable to be used with Ford Programmable Bat...

Page 200: ...ee figures E175190 and E175191 The mating connector for the C1 is DELPHI 15326956 The fuse ratings relays and circuits are shown in figure E152950 and table A service kit KTBK2V 14A411 A can be ordere...

Page 201: ...Auxiliary Fuse Panel Circuit Diagram E152950 Date of Publication 03 2018 FORD TRANSIT 2016 75 4 Electrical 201 EU...

Page 202: ...Output C1 P 15A Fuse F6 R5 Output C1 R 15A Fuse F7 Vehicle Speed C1 S 10A Fuse F8 R1 Output C2 1 20A Fuse F9 Ground C2 2 5A Fuse F10 Switch Illumination C2 3 15A Fuse F11 R3 Coil IN C2 4 Not Used F12...

Page 203: ...n conjunction with the fitment of the beacon switch BK2V 13D768 A see figures E175194 and E175195 for Switches and see figure E152950 for Auxiliary Fuse Panel Circuit Diagram shown in this section The...

Page 204: ...con Connector 3 Aux 2 Connector 4 C1 Mating Connector 5 C2 Mating Connector 6 The Utility Vehicle Switch Pack harness is always on the passenger side of the vehicle and connects via the C1 and C2 mati...

Page 205: ...output NOTE The Aux 2 switch must have the engine running before it will give an output The output will be switched off during an engine auto off Start Stopvehicle Theotherswitches Beacons and Aux 1 a...

Page 206: ...Switch options A Right Hand Drive Switch options B Beacon 1 Aux 1 Part of Utility Vehicle Switch Pack A607 2 Aux 2 Part of Utility Vehicle Switch Pack A607 3 Interior Light Switch M2 Bus with Beacon...

Page 207: ...A GK3V 14659 C see note Note If Beacons are required on an M2 Bus then BK3V V045L70 B must be ordered instead of BK2V V045L70 A or BK2V V045L70 D and fitted in place of the Interior Light Switch Asse...

Page 208: ...Specification Vehicle Interface Connector 5 Connectors are taped back on the harness under the carpet behind the drivers seat pedestal 6 60A fuse connections on drivers seat pedestal final installatio...

Page 209: ...tion A608 for production fit and cannot be updated after the vehicle is built The connector is located behind the glove box as shown in E175196 It provides access to multiple signals power and ground...

Page 210: ...SRC Start Stopdeactiv ated Not available until 2013 SRC Start Stop Inhibit 0 50 23 NA Door Open Ground 50 ohms LHS Sliding Door Ajar 0 50 24 NA DoorClosed Ground 50ohms Passenger Door Ajar 0 50 25 30...

Page 211: ...ctor is removed vehicle will not start Ignition switch 3M5T 11572 A is required for key in signal KL Terminology Ignition Position 2 KL15 B Always 12V KL30 Chassis or Body Ground KL31 Crank Start Posi...

Page 212: ...erface WARNING It is not allowed to transmit DATAonanyoftheCANlines Thesystem provided to splice into the 125kb s MS CAN Bus is for modules that will read only If messages are transmitted from a third...

Page 213: ...n be spliced into with third party twisted pairs of at least 3 twists per 50mm and a minimum of 0 3m to a maximum of 2m stub length to module CAN Low is the Grey Orange wire CAN High is the Violet Ora...

Page 214: ...to the added module or splice Physical Interface of spliced in EDS Requirements Units Maximum Nominal Minimum Parameter Ohm 132 120 108 Impedance mili Ohm meter 175 Resistance nano Second meter 5 5 S...

Page 215: ...art on the CAN Bus The maximum wiring length for each type of network is defined in the following table Maximum CAN Network Lengths SAE J1962 Connector to Furthest Terminating ECU Between terminating...

Page 216: ...e stub is 1m long the second can be less than 0 9m or between 1 1m and 2m Stub Topologies Stubs connected to stubs are not allowed If multiple nodes need to be connected to a single stub then the node...

Page 217: ...Conducted Immunity CI 280 Electrostatic Discharge CI 270 C Immunity to Voltage Overstress 24V applied to CAN H and CAN L Additionally the capacitance of the component measured at 2 5V reverse bias sh...

Page 218: ...o cover all the markets For information on rear speakers Refer to 4 10 page 162 Unused Connectors The harnesses may have a number of unused connectors these are dedicated to other features and options...

Page 219: ...t torque NOTE The Ground Point GP numbers are only for reference to show the location of the GP Ground wires should be brought back to the Ford ground points provided please refer to the following fig...

Page 220: ...7 8 E167590 E168874 25 24 19 14 15 16 13 17 18 10 12 11 9 23 22 20 21 E167591 FWD E222648 32 RWD E222646 33 FORD TRANSIT 2016 75 Date of Publication 03 2018 EU 4 Electrical 220...

Page 221: ...AWD E222647 34 37 38 E229033 27 26 35 28 E167593 30 31 29 E167592 RHS Wheel Arch E178887 39 40 E228191 41 42 E228194 43 Date of Publication 03 2018 FORD TRANSIT 2016 75 4 Electrical 221 EU...

Page 222: ...Ground Points E228189 7 8 13 39 15 4 5 3 36 2 1 38 33 32 34 37 9 10 12 11 17 18 19 20 21 6 41 42 49 40 14 16 24 22 23 25 44 45 37 38 E229033 E228192 42 6 41 FORD TRANSIT 2016 75 Date of Publication 03...

Page 223: ...cription Item All ground points are the same as Van Bus Kombi except GP6 A Additional ground points Locations 1 and 2 use the outer rail positions only M8 threadless weld nuts requiring M8 thread roll...

Page 224: ...45 44 E229037 E175119 1 2 6 5 3 4 FORD TRANSIT 2016 75 Date of Publication 03 2018 EU 4 Electrical 224...

Page 225: ...LHS GP19 14K024 Misc Power Electric Cross Car Beam LHS GP20 14K024 Misc Power Electric Cross Car Beam LHS GP21 14K024 14C007 Misc Power Electric Cross Car Beam LHS GP22 14K024 Misc Power Electric Cro...

Page 226: ...Module Frame Middle Left GP49 Ground Points Van Bus Kombi and Transit Motorhome Chassis and Ford Skeletal Chassis 14406 PEM Fuel Pump Control Module Frame Middle Left GP43 Ground Points Chassis Cab a...

Page 227: ...to be paid during body work Over voltages produced during welding and in alignment work during body shell rectification may cause electronic systems to be damaged In particular the safety instructions...

Page 228: ...with a lint free cloth If the join area is accessible from the inside the transition area to the paint must be abraded for all types of join so that good adhesion of the primer is achieved later If th...

Page 229: ...5 1 3 Boron Steel Parts Boron Steel Parts Precautionary Drill or Weld Zones E167660 Date of Publication 03 2018 FORD TRANSIT 2016 75 5 Body and Paint 229 EU...

Page 230: ...5 K Floor Precautionary Drill Zone Dimensions mm Center line Front Wheel Axle 1 Center of B Pillar 2 Center line of vehicle 3 Fuel Filler Driver s side B Pillar 4 UREA Tank 5 1250 A 1055 B 665 C 390...

Page 231: ...r of B Pillar 2 Center line of vehicle 3 Fuel Filler Driver s side B Pillar 4 UREA Tank 5 1250 A 970 B 580 C 390 D 70 E 2455 F 1270 G 260 H 195 J 730 k 5 1 6 Integrated Bodies and Conversions For inte...

Page 232: ...ned in Figures E74529 E74530 and E167664 However in case a specific conversion requires wheelhouse dimensions smaller than described please contact your National Sales Company representative or local...

Page 233: ...4mm 362mm G 302mm 302mm H 236mm 236mm J 803mm 696mm K 72mm 72mm L 75mm radius 75mm radius r1 75mm radius 75mm radius r2 50mm radius 50mm radius r3 42mm radius 42mm radius r4 Center line of Vehicle 1 S...

Page 234: ...Center of Wheelhouse X Chassis Cab with Dual Rear Wheel Drive Axle r r r E74530 E E A B G F C D H J M K L X 1 X X X Wheelhouse Dimensions for Chassis Cab with Dual Rear Wheel Drive Axle 436mm G 418mm...

Page 235: ...ction legislation All fixings through the floor sides or roof must be sealed Refer to 5 14 Corrosion Prevention page 280 Ensure that any additional equipment in the vicinity of the fuel tank will not...

Page 236: ...of this manual Body Attachment Holes Chassis Frame Top Flange L2 Wheelbase D E F G H J K L E167668 A B C Body Attachment Holes Chassis Frame Top Flange L2 Wheelbase 367 G 19 A 665 H 11 B 592 J 100 C...

Page 237: ...oles Chassis Frame Top Flange L3 Wheelbase 450 G 19 A 367 H 11 B 665 J 100 C 592 K 800 D 730 L 108 E 506 M 1407 F Dimensions in mm For wheelbase dimensions see Vehicle Dimension Key table in Package a...

Page 238: ...es Chassis Frame Top Flange L4 Wheelbase 367 H 19 A 665 J 11 B 592 K 100 C 730 L 800 D 506 M 108 E 561 N 1407 F 450 G Dimensions in mm For wheelbase dimensions see Vehicle Dimension Key table in Packa...

Page 239: ...Chassis Frame Top Flange L5 Wheelbase 367 H 19 A 568 J 11 B 665 K 100 C 592 L 800 D 730 M 108 E 993 N 1407 F 500 P 450 G Dimensions in mm For wheelbase dimensions see Vehicle Dimension Key table in P...

Page 240: ...EXCEPT attachment hole 1 which must be used a special anti rotation bolt is available EK31 101D80 A It is recommended to use this special bolt in both the inner first positions 1 and 4 see figure E176...

Page 241: ...5 37 A 3 1 B 2 Description Item Anti rotation bolt EK31 101D80 A_ A Cut out in lower rail of second unit body to allow tool access to tighten bolt B Anti rotation bolt 1 Locking Grip Washer 2 Anti rot...

Page 242: ...second unit body to a Medium Wheelbase MWB Double Chassis Cab not all the attachment points are accessible position 1 shown in figure E167673 is obscured by the fuel tank and can be omitted All other...

Page 243: ...itudinal 1 Sub frame Outriggers 2 Compliant Mount 3 Chassis Frame 4 M10 Bolts and Self Locking Nuts 5 Sub frame Outriggers 6 Sub frame Longitudinal 7 Solid or Fixed Mount 8 Chassis Frame 9 M10 Bolts a...

Page 244: ...Skeletal Chassis are incomplete vehicles and do not offer a self supporting body structure A box body or equivalent structure must be added and appropriate attachments to the frame and cabin must be...

Page 245: ...haust components or areas exposed to potential fuel spillage It is recommended to fix the converters floor by using additional U type fixings around the main rails and cross members or by using screws...

Page 246: ...6 F 1356 1356 1356 G 1442 1442 1442 H 1580 1580 1580 I 2020 2020 2020 J 430 430 430 K Dimensions in mm For attachment to the base vehicle Refer to 1 17 Towing page 44 For basic dimensions and weights...

Page 247: ...rack Widths E131488 A B Description Item Standard Track Width 1759mm Transit Motorhome Chassis and Ford Skeletal Chassis A Wide Track Width 1980mm Transit Motorhome Chassis only B Date of Publication...

Page 248: ...ed to ensure that a minimum departure angle of 14 at RGAWR Rear Gross Axle Weight Rating of the converted vehicle and for any additional part of the conversion is maintained The maximum width of a veh...

Page 249: ...mp control devices such as conical washer stacks or machine springs with self locking fastenings Very stiff sub frames may damage the chassis frame by preventing its natural flexing therefore appropri...

Page 250: ...BodyMounting page281 The vehicle converter is responsible for Fitting decals advising on the safe use of the equipment Route electrical and hydraulics separately and away from original Ford equipment...

Page 251: ...Design Principle Ridgid or Torsion Stiff Sub frame for Chassis Cab E175999 B A Description Item Compliant Mount A Fixed Mount B Date of Publication 03 2018 FORD TRANSIT 2016 75 5 Body and Paint 251 EU...

Page 252: ...mbi It is recommended to fix every mount with M8 bolt grade 8 8 minimum It is not recommended to engineer through the floor fixings to clamp around side members Refer to 5 15 Frame and Body Mounting p...

Page 253: ...d with similar section cross members may damage the chassis frame by preventing its natural flexing Therefore appropriate compliant mounts should be used Please refer to figure E176546 Each set of bra...

Page 254: ...oints Refer to 4 19 Electrical Connectors and Connections page 191 Greater off sets and or loads require additional stabilizing equipment such as outriggers or ground jacks If uncertain please consult...

Page 255: ...area additional cross brace roof bows are to be used If linings are planned for the inside of the load area All racking through bolts must be designed to be accessible through the lining to the body...

Page 256: ...Recommended Fixing Locations E176000 A Description Item Low roof vehicles do not have this fixing location A FORD TRANSIT 2016 75 Date of Publication 03 2018 EU 5 Body and Paint 256...

Page 257: ...following unique requirements are recommended Construct the internal structure and bolt through the body side to the external structure see figure E176512 Internal structures should be rigid self supp...

Page 258: ...ns these are all D rings as shown in E146219 Not all vehicles will have all locations shown it will depend on the base vehicle For additional information refer to the Owner s Manual and for additional...

Page 259: ...e cab to the rear load space for ventilation control Air circulation and body flexing must be also given consideration when engineering an alternative bulkhead It is not recommended to restrict driver...

Page 260: ...High Roof Bulkhead Fixing Holes E176197 FORD TRANSIT 2016 75 Date of Publication 03 2018 EU 5 Body and Paint 260...

Page 261: ...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 doo...

Page 262: ...D H F G E B A E171391 Description Item 300mm A 55mm on Right Hand Drive vehicles 35mm on Left Hand Drive vehicles B 190mm C 150mm D 100mm E 140mm F 200mm G 70mm H FORD TRANSIT 2016 75 Date of Publica...

Page 263: ...D H A B F E G E171392 Description Item 300mm A 35mm on Right Hand Drive vehicles 55mm on Left Hand Drive vehicles B 190mm C 150mm D 60mm E 140mm F 200mm G 90mm H Date of Publication 03 2018 FORD TRAN...

Page 264: ...orshown lefthanddoorsymmetricallyopposite I H F C G J D E B A E171393 Description Item 550mm A 350mm B 150mm C 550mm D 150mm E 200mm F 650mm G 450mm H 350mm I 750mm J FORD TRANSIT 2016 75 Date of Publ...

Page 265: ...o Drill Zone Rear Cargo Doors H2 F B C A D E G E171394 Description Item 320mm A 340mm B 170mm C 920mm D 200mm E 520mm F 300mm G Date of Publication 03 2018 FORD TRANSIT 2016 75 5 Body and Paint 265 EU...

Page 266: ...o Drill Zone Rear Cargo Doors H3 C B A E171395 F D E G Description Item 550mm A 340mm B 170mm C 920mm D 200mm E 520mm F 300mm G FORD TRANSIT 2016 75 Date of Publication 03 2018 EU 5 Body and Paint 266...

Page 267: ...o not drill into the vehicle before checking the Precautionary No Drill Zones and electrical wire routing Refer to Wiring Installation and Routing Guides page Refer to 5 6 Body Closures page 261 Refer...

Page 268: ...hicle width to 2375mm For non European Union territories please refer to local legislation For Australia and New Zealand please refer to ADR43 Vehicle regulations Short Arm Mirrors are specified on al...

Page 269: ...r seats the rear seats and seat belt systems need to comply with the relevant legal requirements and ECE directives or ADR 3 4 5 or applicable local legislation Refer to 3 7 Exhaust System page 79 Veh...

Page 270: ...Fixing Location mm Item Front Axle 1 Center line of vehicle 2 1630 A 1504 B 1060 C 895 D 845 E 670 F 520 G 1225 H 425 I 88 J 88 K 1027 L FORD TRANSIT 2016 75 Date of Publication 03 2018 EU 5 Body and...

Page 271: ...he Vehicle Converter Advisory Service at VCAS ford com 5 10 2 Rear Windows For windows it is recommended to specify the base vehicle as a Kombi or Bus body however when converting a van the following...

Page 272: ...4 Description Item Horizontal Section Through C Pillar A Vertical Section Through Side Window Non Side Load Door B Glass 1 Adhesive 2 Cut within 0 and 1 5mm of inner body panel flange edge all around...

Page 273: ...not place stickers or decals over the airbag covers as this may impair airbag deployment NOTE It is recommended to specify a base vehicle without airbags if planning modifications in this area SideAir...

Page 274: ...ated at the bottom of the B pillars see figure E145412 and in the front door behind the speaker see figure E167680 WARNINGS Modifications or reinforcements in the area of the sensors may affect the si...

Page 275: ...Front Sensor E167679 Side Sensor E145412 Door Sensor E167680 Date of Publication 03 2018 FORD TRANSIT 2016 75 5 Body and Paint 275 EU...

Page 276: ...d 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 reins...

Page 277: ...g must be distributed over the full length of the roof rails between the roof bows Air Conditioning Units Units weighing more than 25kg must be internally supported on cross brace members distributing...

Page 278: ...may be fitted to all Van Bus and Kombi variants providing the following is satisfied The load of a single attachment under worst case loading must not exceed 31 75kg as long as the total carried load...

Page 279: ...on of the M8 bolt into the roof is 16mm see A in figure E176163 Read and follow the manufacturer s instructions when fitting a roof rack It is recommended that the rack leading edge should not be loca...

Page 280: ...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 produ...

Page 281: ...fixings or damper fixings NOTE After drilling deburr and countersink all holes and remove chips from the frame Follow corrosion prevention Refer to 5 14 Corrosion Prevention page 280 Frame Drilling a...

Page 282: ...Item Description Item It is recommended to always use a tube 4 Screw 1 It is recommended to always use washers Size minimum equal to lower rail width 5 Longitudinal rail 2 Floor minimum thickness 37mm...

Page 283: ...chassis mounts 2 Cross members 3 Relief front end and longitudinal if there is a risk of stress concentration in chassis frame from longitudinal contact 4 5 6 5mm minimum A 50mm minimum B 50mm width...

Page 284: ...rame Typical Design Principle of a Self Supporting Body Structure E74576 1 2 3 4 5 6 7 8 Description Item Use all standard locations with 2x M10 fixings 1 Floor Panel 2 Body side frames 3 Floor cross...

Page 285: ...ding over wheel support Structural wheel box should maintain longitudinal continuity with a rigid attachment to the floor edge frame or to the body side structure Floor boards should be substantially...

Page 286: ...E176203 Non Regular Production Option rear chassis frame extensions Also see Refer to 1 17 Towing page 44 figure E167538 The standard fit under run bar is bolted on as shown in figure E176203 and figu...

Page 287: ...corrosion protection inside and outside of the chassis frame Refer to 5 14 Corrosion Prevention page 280 Holes should be in groups of two either vertically spaced at 30 to 35mm from chassis frame top...

Page 288: ...ced tire position to obtain an uninterrupted flat floor surface see vehicle data sheets Fore and after longitudinal bracing must be added between the rear most 2 cross members only All chassis frame m...

Page 289: ...eight Test Procedure 40 Center of Gravity Position 39 Central Locking 182 Changing Vehicle Speed Maximum Setting 156 Charge Balance Guidelines 109 Charging System 103 Chassis Cab Body 36 Chassis Cab 2...

Page 290: ...Introduction 7 J Jacking 25 Jacking Kit 60 K Kerb Mass Data 62 L Lamps for Wide Vehicles 170 Lamps Front and Rear Fog Lamps 170 Lamps Hazard Direction Indication 169 Lane Keeping System 181 Legal and...

Page 291: ...it 60 Tow Bar Requirements 44 Tow Bar Types for AUS and NZL specification vehicles 51 Tow Bar Types for EU specification vehicles 44 Towing 44 Trailer Tow Connectivity 96 Trailer Tow Electric A055 97...

Page 292: ......

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