Ford - Ranger - Workshop Manual - 2012 - 2012 (4)

Body and Equipment Mounting Manual FORD RANGER 2012 Date of Publication: 12/2013 The information contained in this publication was correct at the time of going to print. In the interest of development the right is reserved to change specifications, design or equipment at any time without notice and without incurring any obligations. This publication, or part thereof, may not be reproduced nor translated without our approval. Errors and omissions excepted. © Ford Motor Company 2014 All rights reserved. 1.1 About This Manual..............................5 1.1.1 New for this BEMM publication 12/2013.............................................................5 1.1.2 Introduction....................................................5 1.1.3 Important Safety Instructions.................5 1.1.4 Warnings, Cautions and Notes in This Manual.............................................................5 1.1.5 How to Use This Manual...........................5 1.2 Commercial and Legal Aspects..........6 1.2.1 Terminology....................................................6 1.2.2 Warranty on Ford Vehicles.......................6 1.2.3 Legal and Vehicle Type Approval...........6 1.2.4 Alternative Type Approval........................6 1.2.5 Legal Obligations and Liabilities............6 1.2.6 General Product Safety Requirement..................................................6 1.2.7 Product Liability............................................7 1.2.8 Restraints System........................................7 1.2.9 Drilling and Welding.....................................7 1.2.10 Minimum Requirements for Brake system and Load Apportioning Valves .............................................................................7 1.2.11 Road Safety....................................................7 1.3 Conversion Homologation..................8 1.4 Electromagnetic Compatibility (EMC)..................................................9 1.4.1 Suggested Antenna Location................10 1.5 Vehicle Duty Cycle Guidelines............11 1.5.1 Conversion Affect on Fuel Economy and Performance.........................................11 1.5.2 Vehicle Ride and Handling Attributes........................................................11 1.6 Jacking................................................12 1.7 Lifting.................................................13 1.8 Noise, Vibration and Harshness (NVH).................................................14 1.9 Vehicle Transportation Aids and Vehicle Storage..................................15 1.10 Package and Ergonomics..................16 1.10.1 General Component Package Guidelines......................................................16 1.10.2 Driver Reach Zones....................................16 1.10.3 Driver Field of View....................................16 1.10.4 Conversion Affects on Parking Aids..................................................................16 1.10.5 Aids for Vehicle Entry and Exit...............16 1.11 Package and Ergonomics—Specifications.............17 1.11.1 Recommended Body Dimensions........17 1.11.2 Chassis Cab Body - Basic Dimensions and Weights..................................................19 1.11.3 Kerb Weights and payload......................21 1.11.4 Front, Rear and Side Under-run Protection......................................................21 1.12 Hardware—Specifications................22 1.13 Load Distribution—Specifications............23 1.13.1 Load Distribution Calculations - Driver and Passenger Weight Distribution...................................................23 1.13.2 Center of Gravity........................................25 1.14 Towing...............................................28 1.14.1 Towing Requirements..............................28 1.14.2 Towing............................................................28 1.14.3 Towing capacities......................................28 1.14.4 1.14.5 Trailer Nose Weight...................................29 Towing Specifications..............................29 2 Chassis 2.1 Suspension System..........................30 2.2 Brake System......................................31 2.2.1 General...........................................................31 2.2.2 Brake Hoses..................................................31 2.2.3 Trailer brakes................................................31 3 Powertrain Table of Contents 1 General Information 3.1 Fuel System.......................................32 3.1.1 Fuel Filler Pipe Shipping Bracket.........32 3.1.2 Fuel Filler Mounting..................................34 3.1.3 Fuel Filler Vent Hose.................................37 4 Electrical 4.1 Battery and Cables............................39 4.1.1 Battery Information..................................39 4.1.2 Auxiliary Battery (Vehicles with Special Equipment Pack).......................41 4.1.3 Generator and Alternator.......................44 4.2 Exterior Lighting................................45 4.2.1 Rear Combination lamps........................45 4.2.2 Rear Fog Lamp...........................................46 4.2.3 Rear License Plate Lamp........................48 4.2.4 Reversing Lamps.......................................49 4.2.5 Additional External Lamps....................49 4.2.6 Additional External Lamps (Vehicles with Special Equipment Pack)............50 4.2.7 Lamps – Hazard / Direction Indication......................................................56 4.2.8 Electrically operated Door Mirrors......56 5 Body and Paint 5.1 Body...................................................57 5.1.1 Body Structures - General Information...................................................57 5.1.2 Integrated Bodies and Conversions..................................................57 5.1.3 Chassis Cab.................................................58 5.1.4 Front End Integrity for Cooling, Crash, Aerodynamics and Lighting..................64 5.1.5 Tipper Bodies..............................................64 5.1.6 Tank and Dry Bulk Carriers.....................64 5.1.7 Bull Bar (Vehicles with Special Equipment Pack)......................................65 5.1.8 Roof Racks...................................................66 5.1.9 Canopies.......................................................67 5.2 Airbag Supplemental Restraint System (SRS)...................................69 5.2.1 Air Bags.........................................................69 3 Table of Contents 4 5.3 Safety Belt System.............................73 5.4 Corrosion Prevention.........................74 5.4.1 General............................................................74 5.4.2 Repairing Damaged Paint........................74 5.4.3 Under Body Protection and Material...........................................................74 5.4.4 Painting Road Wheels...............................74 5.4.5 Contact Corrosion.......................................74 5.5 Frame and Body Mounting.................75 5.5.1 Mounting Points and Tubing...................75 5.5.2 Self-Supporting Body Structure...........76 5.5.3 Frame Drilling and Tube Reinforcing.....................................................77 5.5.4 Ancillary Equipment - Sub Frame Mounting.........................................................77 5.5.5 Area for Fitting Additional Body Attachments to the Rear of the Bumper. ..........................................................77 5.5.6 Water Tank on Camper Vehicles............77 1.1.1 New for this BEMM publication 12/2013 The following sections of the manual have been updated since the last publication of the BEMM 09/2013. Canopies Refer to: 5.1 Body (page 57). 1.1.2 Introduction 1.1.4 Warnings, Cautions and Notes in This Manual WARNING: Warnings are used to indicate that failure to follow a procedure correctly may result in personal injury. CAUTION: Cautions are used to indicate that failure to follow a procedure correctly may result in damage to the vehicle or equipment being used. This manual has been written in a format that is designed to meet the needs of Vehicle Converters. The objective is to use common formats with the workshop manual which is used by technicians worldwide. NOTE: Notes are used to provide additional essential information required to carry out a complete and satisfactory repair. This guide is published by Ford and provides general descriptions and advice for converting vehicles. These requirements must be complied with before a Ford Dealer should take delivery of motor vehicle accessories from an external supplier either for themselves or on behalf of a motor vehicle client. A warning, caution or note is placed at the beginning of a series of steps if it applies to multiple steps. If the warning, caution or note only applies to one step, it is placed at the beginning of the specific step (after the step number). It must be emphasized that any change to the basic vehicle which does not meet the enclosed guideline standards may severely inhibit the ability of the vehicle to perform its function. Mechanical failures, structure failure, component unreliability or vehicle instability will lead to customer dissatisfaction. Appropriate design and application of body, equipment and or accessories is key to ensuring that customer satisfaction is not adversely affected. The information contained within this publication takes the form of recommendations to be followed when vehicle modifications are undertaken. It must be remembered that certain modifications may invalidate legal approvals and application for re-certification may be necessary. Ford cannot guarantee the operation of the vehicle if non-Ford approved electrical systems are installed. Ford electrical systems are designed and tested to function under operational extremes, and have been subjected to the equivalent of ten years of driving under such conditions. 1.1.3 Important Safety Instructions Appropriate conversion procedures are essential for the safe, reliable operation of all vehicles as well as the personal safety of the individual carrying out the work. As you read through this manual, you will come across WARNINGS, CAUTIONS and NOTES. 1 General Information 1.1 About This Manual 1.1.5 How to Use This Manual This manual covers vehicle conversion procedures. The pages at the start of this manual list the content, by group. A group covers a specific portion of the vehicle. The manual is divided into four groups, General Information, Chassis, Electrical, Body and Paint. The number of the group is the first number of a section number. Each title listed in the contents links to the relevant section of the manual. In some section of the book it may refer you to see additional sections for information, links have been provided, these links are in blue text. This manual is designed to be used online or as printed material, document links for the online version are also shown with page numbers for the printed version, this will help guide you to the start of the section which contains the relevant information. There is also an alphabetical index at the back of the manual. As with the contents pages you will be able to link to sections. To do this just click on the page number. All left and right-handed references to the vehicle are taken from a position sitting in the driver seat looking forward unless otherwise stated. This manual cannot possibly anticipate all such variations and provide advice or cautions as to each. Anyone who departs from the instructions provided in this manual must first establish that he compromises neither his personal safety nor the vehicle integrity by his choice of methods, tools or components. FORD RANGER 2012 Date of Publication: 12/2013 5 1 General Information 1.2 Commercial and Legal Aspects 1.2.1 Terminology NOTE: Any modifications to the vehicle must be noted in the owner's handbook or new descriptive literature included with the owner's documentation. Vehicle Converter refers to any re-seller altering the vehicle by converting the body and adding or modifying any equipment not originally specified and or supplied by Ford. Unique component or similar wording refers to non-Ford specified or after sale fitment not covered by Ford warranty. 1.2.2 Warranty on Ford Vehicles Please contact The National Sales Company in the country where the vehicle will be registered or refer to the vehicle Owner Guide for details of the terms of any applicable Ford warranty. The Vehicle Converter should warrant its design, materials and construction for a period at least equal to any applicable Ford warranty. The Vehicle Converter must ensure that any alteration made to a Ford vehicle or component does not reduce the safety, function, or durability of the vehicle or any component. The Vehicle Converter shall be solely responsible for any damage resulting from any alteration made by the Vehicle Converter or any of its agents to a Ford Vehicle Component. The Vehicle Converter releases Ford from all claims by any third party for any cost or loss (including any consequential damages) arising from work performed by a Vehicle Converter unless Ford has given its prior written consent to such liability. If significant changes are made the Body Builder must negotiate with the relevant authority. Any changes to the vehicle operating conditions must be advised to the customer. 1.2.5 Legal Obligations and Liabilities The Vehicle Converter should consult with its legal advisor on any questions concerning its legal obligations and liabilities. Ford recomends 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. 1.2.6 General Product Safety Requirement The Vehicle Converter shall ensure that any vehicle it places on the market complies with all local laws relating to the safe carriage of loads on public roads. The Vehicle Converter shall also ensure that any alteration it makes to a Ford vehicle or component does not reduce its compliance with local design rules. The Vehicle Converter must provide sufficient Load Restraint tie down points or compartmentised storage areas that enable the driver to safely carry loads that match the use criteria for which the body was designed. The Vehicle Converter shall release Ford from all liability for damages resulting from: • Failure to comply with these Body Equipment Mounting directives, in particular warnings. 1.2.3 Legal and Vehicle Type Approval • Faulty design, production, installation, assembly or alteration not originally specified by Ford. • All components embodied on Ford vehicles are approved to the applicable legal requirements. • Failure to comply with the basic fit for purpose principles inherent in the original product. • Ford vehicles have Type Approval for the intended marketing territories. WARNINGS: • • 6 1.2.4 Alternative Type Approval WARNING: Exception - Incomplete vehicles require further approval when completed by the Body Builder. The Ranger range has Type Approval for many territories, although the full range of vehicles shown in this manual are not necessarily released in all territories. Check with your local Ford National Sales Company representative. Significant changes to the vehicle may affect its legal compliance. Strict adherence to the original design intent for brakes, weight distribution, lighting, occupant safety and hazardous materials compliance in particular is mandatory. Date of Publication: 12/2013 Do not exceed the gross vehicle mass, gross train mass, axle plates and trailer plate. Do not change the tire size or load rating. Do not modify the steering system. Excessive heat can build up from the exhaust system, in particular from the catalytic converter and from the Diesel particulate filter (cDPF). Ensure adequate heat shields are maintained. Maintain sufficient clearance to hot parts. Do not modify or remove heat protection shields. FORD RANGER 2012 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 end of the vehicle may affect the airbag fire timing and result in uncontrolled deployment. Do not change original location or remove warning labels provided with the base vehicle in view to the driver. Ensure that labels in view to the driver remain in full view to the driver. NOTE: For further information please contact your local National Sales Company representative, or Local Ford Dealer. 1.2.7 Product Liability The Vehicle Converter shall be liable for any product liability (whether for death, personal injury, or property damage) arising from any alteration to a Ford vehicle or component made by the Vehicle Converter or any of its agents. Ford shall not be liable for any such liability (except as provided by law). The Vehicle Converter or equipment manufacturer is liable for the: • Operational reliability and road-worthiness of the vehicle to its original intent. • Operational reliability and road-worthiness of any component or conversion, not listed in original Ford documentation. • Operational reliability and road-worthiness of the vehicle as a whole (for example the body changes and/or additional equipment must not have a negative effect on the driving, braking or steering characteristics of the vehicle). • Subsequent damage resulting from the conversion or attachment and installation of unique components, including unique electrical or electronic systems. • Functional safety and freedom of movement of all moving parts (for example axles, springs, propeller shafts, steering mechanisms, brake and transmission linkage). • Functional safety and freedom of the tested and approved flexibility of the body and integral chassis structure. Modifications to the B-Pillar body structure may affect the side airbag fire timing and result in uncontrolled side airbag deployment. Refer to: 5.2 Airbag Supplemental Restraint System (SRS) (page 69). 1.2.9 Drilling and Welding Drilling and welding of frames and body structures have to be conducted following the guidelines within this document. 1 General Information Do not route any electrical cables with the Antilock Brakes System and Traction Control System cables because of extraneous signal risk. It is generally not recommended to hang electrical cables off existing looms or pipes. 1.2.10 Minimum Requirements for Brake system and Load Apportioning Valves • It is not necessary or recommended to modify the load apportioning valves, however, if a special conversion should require modifications, – Maintain original settings. – Maintain brake certification load distribution. • Changes to the Antilock Brake System (ABS), Traction Control System (TCS) and Electronic Stability Program (ESP) system are not permitted. 1.2.11 Road Safety The respective instructions should be strictly observed to maintain operational and road safety of the vehicle. 1.2.8 Restraints System WARNINGS: Modifications to the restraints system are not allowed. Airbags are explosive. For safe removal and storage during conversion follow the procedures in the Ford workshop manual or consult your local National Sales Company representative. FORD RANGER 2012 Date of Publication: 12/2013 7 1 General Information 8 1.3 Conversion Homologation The Vehicle Converter must observe any statutory rules and regulations. When the conversion needs a new approval the following information must be quoted. • All dimensional, weight and centre of gravity data. • The fixing of the body to the donor vehicle. • Operating conditions. The responsible Technical Service may require additional information and/or testing. NOTE: For further information please contact your local National Sales Company representative, or Local Ford Dealer. Date of Publication: 12/2013 FORD RANGER 2012 WARNINGS: Your vehicle has been tested and certified to European legislation relating to electromagnetic compatibility (2004/104/EC). It is your responsibility to ensure that any equipment fitted complies with applicable local legislation. Ensure you have any equipment fitted by properly trained technicians. Radio frequency (RF) transmitter equipment (for example: cellular telephones, amateur radio transmitters and so on.) may only be fitted to your vehicle if they comply with the parameters shown in the following 'Frequency Overview' table. There are no special provisions or conditions for installations or use. Do not mount any transceiver, microphones, speakers, or any other item in the deployment path of the airbag system. Do not fasten antenna cables to original vehicle wiring, fuel pipes and brake pipes. Keep antenna and power cables at least 100mm from any electronic modules and airbags and associated wiring. 1 General Information 1.4 Electromagnetic Compatibility (EMC) Frequency Overview Frequency Band MHz Maximum Output Power Watts (Peak RMS) Antenna Position 1-30 50W 1 30-54 50W 1 68-87.5 50W 1 142-176 50W 1 380-512 50W 1 806-940 10W 1 806-940 2W* 1 1200-1400 10W 1 1710-1885 10W 1 1710-1885 1W* 1 1885-2025 10W 1 1885-2025 1W* 1 2400-2500 0.1W Anywhere * Only for GSM/3G cellular phones, with a patch antenna installed inside of the front windscreen FORD RANGER 2012 Date of Publication: 12/2013 9 1 General Information 1.4.1 Suggested Antenna Location The antenna can be mounted on the roof of the vehicle, with the exception of cellular phone car kit antennas which transmit power below 2W. Such low powered systems should have their antenna located at the bottom of the A-pillar behind the trim or on the front windscreen. NOTE: After the installation of RF transmitters, check for disturbances from and to all electrical equipment in the vehicle, both in the standby and transmit modes. Check all electrical equipment: • With ignition ON • With the engine running • During a road test at various speeds. Check that electromagnetic fields generated inside the vehicle cabin by the transmitter installed do not exceed human exposure limits specified in EU directive 2004/40/EC 10 Date of Publication: 12/2013 FORD RANGER 2012 1 General Information 1.5 Vehicle Duty Cycle Guidelines It is necessary to take into account the customer usage profile and the anticipated vehicle duty cycles of the modified vehicle in order to choose the appropriate specification of the base vehicle. It is necessary to select the appropriate drive, engine, gear ratio, gross vehicle mass, gross train mass, axle plates and payloads of the base vehicle to match the customer requirements. Where possible make sure that the base vehicle is ordered with any necessary plant fit options. NOTE: For further information please contact your local National Sales Company representative, or Local Ford Dealer. 1.5.1 Conversion Affect on Fuel Economy and Performance Any conversion may effect the fuel consumption and performance depending on the aerodynamics and the weight added by the conversion. The published information for fuel consumption and performance of the base vehicle therefore may not be valid. It is advisable to control the weight, but without deteriorating other vehicle attributes and functions (especially those related to safety and durability). 1.5.2 Vehicle Ride and Handling Attributes CAUTION: Do not exceed the axle plate, gross vehicle mass, trailer plate and gross trailer mass limits. Due to the displacement of the center of gravity occurred by the conversion the ride and handling attributes may be different to the base vehicle. NOTE: This vehicle should be evaluated for safe operation prior to sale. FORD RANGER 2012 Date of Publication: 12/2013 11 1 General Information 1.6 Jacking WARNINGS: Always position the vehicle on a hard level surface. If the vehicle must be jacked up on a soft surface use load spreading blocks under the jack. Always chock the wheel diagonally opposite the jacking point. Failure to follow these instructions may result in personal injury. The spare wheel winch is located above the spare wheel and can be accessed from the rear of the chassis frame. The jack must be assembled and fixed appropriately to the body to ensure safety, durability and accessibility. Do not get under a vehicle that is supported by a jack. This jack is only intended for changing wheels. CAUTIONS: It is important that only the correct jacking and support locations are used at all times. 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. NOTE: Make sure that reinforcements 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 included with the owner's documentation. 1. Ensure screwthread is adequately lubricated before use. 2. The jack should be used on level firm ground wherever possible. 3. Apply park brake fully before lifting the vehicle. 4. It is recommended that the wheels of the vehicle should be chocked, and no person should remain in a vehicle being jacked. 5. No person should place any portion of their body under a vehicle that is supported by a jack. All Vehicles 12 Date of Publication: 12/2013 FORD RANGER 2012 WARNING: When lifting the vehicle with a two post lift for the removal of the engine/transmission or rear axle, make sure the vehicle is secured to the lift using vehicle retention straps to prevent tilting. Failure to follow these instructions may result in personal injury. CAUTIONS: When lifting the vehicle with a two post lift, vehicle lift arm adapters must be used under the lifting points. When lifting the vehicle with a two post lift, the maximum kerb weight must not be exceeded. It is important that only the correct lifting and support locations are used at all times. All Vehicles FORD RANGER 2012 Date of Publication: 12/2013 1 General Information 1.7 Lifting 13 1 General Information 14 1.8 Noise, Vibration and Harshness (NVH) WARNING: Make sure that the modified vehicle complies with all relevant legal requirements. CAUTION: The travel and function of pedals must not be restricted. Changes to the powertrain, engine, transmission, exhaust, air intake system or tires may influence the exterior noise emission. Therefore the exterior noise level of the converted vehicle has to be verified. The interior noise levels should not be deteriorated by the conversion. Reinforce panels and structures as appropriate to avoid vibrations. Consider the usage of sound deadening material on panels. Date of Publication: 12/2013 FORD RANGER 2012 CAUTIONS: • Disconnect the battery if the vehicle is to be stored for more than 30 days. Make sure that the protective covers are not removed from an incomplete vehicle until the conversion is started. Make sure that components removed during conversion are kept clean and dry. Make sure that components removed during conversion are refitted to the same vehicle. In addition: • The windscreen wipers should be lifted off the glass and set right up. • All air intakes should be closed. • Increase normal tire pressure by 0.5 bar. • The hand brake system should not be used. • Apply suitable wheel chock to prevent roll away. A significant risk during storage is deterioration of vehicle bodywork, therefore, appropriate storage procedures must be observed, including periodic inspection and maintenance. Claims arising from deterioration caused by incorrect storage, maintenance or handling are not the responsibility of Ford. Vehicle Converters must determine their own procedures and precautions, particularly where vehicles are stored in the open as they are exposed to any number of airborne contaminants. The following may be considered a sensible approach to storage: Short Term Storage • Wherever possible vehicles should be stored in an enclosed, dry, well-ventilated area based on firm, well drained ground which is free of long grass or weeds and where possible protected from direct sunlight. • Vehicles must not be parked near, under foliage or close to water as additional protection may be necessary for certain areas. Long term storage: • Battery to be disconnected but not removed from the vehicle. • The wiper blades should be removed and placed inside the vehicle. Make sure the wiper arms are suitably prevented from resting on the windscreen. • Engage first gear and release the parking brake completely. Chock the wheels first if the vehicle is not on level ground. • Set climate controls to the "open" position to provide ventilation, where possible. FORD RANGER 2012 • 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 months (film is date stamped to indicate required removal date). Make sure that all windows, doors, hood, tailgate and luggage compartment lid are completely closed and the vehicle is locked. The Pre Delivery Inspection (PDI) is the final opportunity to make sure a battery is fit for purpose prior to the customer taking delivery of their new vehicle. The battery must be checked and appropriate action taken prior to the vehicle being handed over to the customer. Test results must be recorded on the PDI repair order. 1 General Information 1.9 Vehicle Transportation Aids and Vehicle Storage Batteries. To make sure the battery is maintained correctly and to assist in preventing premature failure, it is necessary to check and recharge the battery regularly while a vehicle is not in use. Where a battery is left below its optimum charge level for any length of time, it may result in premature failure of the battery. Action / Time in Storage Monthly Every 3 Months Check Vehicle is clean X - Remove external contamination X - Check battery condition Recharge if necessary connected disconnected Visually check tires X - Check interior for condensation - X Run engine for 5 minutes minimum with air conditioning switched on, where applicable - X To reduce the likelihood of premature battery failure it is recommended that where: • A battery is left connected – monthly checks should be carried out. • A battery has been disconnected – no greater than a 3 monthly check should be carried out. Date of Publication: 12/2013 15 1 General Information 1.10 Package and Ergonomics 1.10.1 General Component Package Guidelines WARNING: Do not modify, drill, cut or weld any suspension components, specifically the steering gear system, subframe or anti-roll bars, springs or shock absorbers including mounting brackets. The Vehicle Converter has to ensure that sufficient clearance is maintained under all drive conditions to moving components such as axles, fans, steering, brake system etc. The Vehicle Converter is responsible for all installed components during the conversion. The durability has to be confirmed by appropriate test procedures. 1.10.2 Driver Reach Zones Controls and/or equipment required to be used while driving should be located within easy reach of the driver so as not to impair driver control. 1.10.3 Driver Field of View WARNING: Make sure that the modified vehicle complies with all relevant legal requirements. 1.10.4 Conversion Affects on Parking Aids WARNING: Ensure that monitors mounted in the cabin meet the interior package and safety requirements. 16 Date of Publication: 12/2013 On conversions requiring a rear camera, the reverse signal may be taken as described in the electrical section, described in reversing lamps. Refer to: 4.2 Exterior Lighting (page 45). 1.10.5 Aids for Vehicle Entry and Exit Steps WARNINGS: Make sure that the modified vehicle complies with all relevant legal requirements. If this modification alters the homologated dimensions, a new approval may be necessary. CAUTION: Make sure that reinforcements are installed to maintain the integrity of the original body structure. Steps can be ordered as an accessory on the base vehicle. Please check for availability. Where additional steps are installed the required ground clearance line is to be maintained. The Vehicle Converter must make sure that a movable step is set in the stored position when the vehicle is running. The step surface must be non-slip. Rear View Mirrors Rear view mirror is homologated up to 1880 mm maximum body width, see the Figure below, dimension 'X'. FORD RANGER 2012 1.11.1 Recommended Body Dimensions WARNINGS: Do not modify the wheelbase or add any type of frame extension to vehicles fitted with Electronic Stability Program (ESP). Ensure that any mass added to the vehicle does not compromise vehicle stability. NOTE: Extreme rear overhang may encourage unacceptable loading conditions, which could unload the front axle, producing unacceptable handling and braking characteristics. Ensure that the centre of gravity of the body and payload does not fall outside of the recommended zone. NOTE: An excessively high centre of gravity could reduce vehicle stability. Ensure that the centre of gravity of the body and payload does not fall outside of the recommended zone. Refer to: 1.13 (page 23). 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 accordance with local requirements. For additional information, refer to Australian Standard 4177.1 and ECE 55. If a conversion requires more than 50% overhang, please contact one of the below. For further information please contact your local National Sales Company representative, or Local Ford Dealer. 1 General Information 1.11 Package and Ergonomics—Specifications Load carrying structures should not be mounted onto an existing load tray or load box. Body attachment points are provided on the frame. Refer to: 5.1 Body (page 57). NOTE: Single Cab illustrated. FORD RANGER 2012 Date of Publication: 12/2013 17 1 General Information 18 Chassis Cab Body Date of Publication: 12/2013 FORD RANGER 2012 Description A B Single Cab Stretch Cab Double Cab 2251 1781 1483 Frame length behind back of cab (not including rear light cross-member) Under run bar and towing attachment legislation to be maintained C Maximum recommended external body height D Front outside of body to rear axle E Maximum recommended rear overhang F Clearance between the back of the cab and the body G Dimension (mm) 2400 over the top of frame, provided load distribution requirements are met 1241 771 473 1610 (50% of vehicle wheelbase), provided load distribution requirements are met 25 Minimum 1 General Information Dimensions - not to exceed for Chassis Cab body Length Ensure local lighting legislation is maintained. Refer to: 4.2 Exterior Lighting (page 45). H Clearance between the top of the cab and the body J Maximum external body width 30 1880 All dimensions (shown in mm) are subject to manufacturing tolerances and refer to min specification models which do not include additional equipment. The illustrations are for guidance only. 1.11.2 Chassis Cab Body - Basic Dimensions and Weights NOTE: Single Cab illustrated. FORD RANGER 2012 Date of Publication: 12/2013 19 1 General Information 20 Date of Publication: 12/2013 FORD RANGER 2012 Description * Single Cab A Overall length (mm) 5110 B Overall width - excluding exterior mirrors (mm) 1850 C Overall height 4x2 (mm) C Overall height 4x4 (mm) D Wheelbase (mm) 3220 E Track - front 4x2 (mm) 1590 E Track - front 4x4 (mm) 1560 E Track - rear 4x2 (mm) 1590 E Track - rear 4x4 (mm) 1560 F Rear Overhang (mm) 985 - Gross Vehicle Mass GVM (kg) - Gross Vehicle Mass GVM (kg) * 3200 - Front Axle Load (kg) 1325 - Front Axle Load (kg) * 1480 - Rear Axle Load (kg) 1755 - * Rear Axle Load (kg) 1703 Stretch Cab Double Cab 1706 1716 1800-1806 1804 - 1810 1815 - 1821 1 General Information Chassis Cab Body - Basic Dimensions and Weights 2925 1850 Vehicles with increased ride height. 1.11.3 Kerb Weights and payload Details of vehicle kerb weights and payload capacities are given in the vehicle weights table, which is provided as a supplement to this document. Refer to the vehicle weights table for further information. 1.11.4 Front, Rear and Side Under-run Protection WARNING: Check local legislation for legal requirements. Front Under run Protection, Rear Under run Protection and Side Under run Protection must meet the requirements of local design rules. FORD RANGER 2012 Date of Publication: 12/2013 21 1 General Information 22 1.12 Hardware—Specifications Material Specification, Strength and Torque Standard Hardware and Tightening Torques (Nm) Bolts/Studs: ISO 898-1, Nuts: ISO 898-2 Grade 4.8 Grade 8.8 Grade 10.9 Thread Size Minimum Maximum Minimum Maximum Minimum Maximum M4 1.1 1.4 2.4 3.4 M5 2.2 2.7 4.9 6.7 M6 3.7 4.7 8.5 11.5 11.0 15.0 M8 20.0 28.0 25.0 35.0 M10 41.0 55.0 50.0 70.0 M12 68.0 92.0 95.0 125.0 M14 113 153 150 200 M16 170.0 230.0 230.0 310.0 M18 252.0 317.0 317.5 399.4 M20 345.0 430.0 434.7 541.8 M22 470.0 590.0 592.2 743.4 M24 600.0 750.0 756.0 945.0 Date of Publication: 12/2013 FORD RANGER 2012 1.13.1 Load Distribution Calculations - Driver and Passenger Weight Distribution CAUTIONS: Do not exceed the axle plated weights. Do not exceed the gross vehicle weight. Tire manufacturer specification must be maintained. NOTE: Uneven load distribution could result in unacceptable handling and braking characteristics. NOTE: Over loading of the vehicle could result in unacceptable ground clearance. NOTE: The centre of mass of the body equipment and the payload it contains should be located within the dimensions given. NOTE: Avoid one-sided load distribution. NOTE: For further information please contact your local National Sales Company representative, or Local Ford Dealer. Single Cab FORD RANGER 2012 Date of Publication: 12/2013 1 General Information 1.13 Load Distribution—Specifications 23 1 General Information Single Cab Driver and Passenger Weight Distribution 'A' Wheelbase (mm) 'B' Front Row Seats and Driver (mm) 3220 Weight distribution Per Person (Kg) On Front Axle On Rear Axle Total 40 35 75 1490 Double Cab Double Cab Driver and Passenger Weight Distribution 'A' Wheelbase 'B' Front Row (mm) Seats and Driver (mm) 'C' Second Row Seats (mm) Weight distribution Per Person (Kg) On Front Axle On Rear Axle Total 3220 1490 - 40 35 75 - - 2310 21 54 75 Stretch Cab 24 Date of Publication: 12/2013 FORD RANGER 2012 'C' Second Row Seats (mm) Weight distribution Per Person (Kg) On Front Axle On Rear Axle Total 3220 1490 - 40 35 75 - - 2180 24 51 75 1.13.2 Center of Gravity NOTE: Calculations shown are not inclusive of tow bar and other dealer fitted accessories. The following charts define the recommended centre of gravity position for the mass added to the vehicle by the vehicle converter. "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 exceeding the gross axle and train weights. 1 General Information 'A' Wheelbase 'B' Front Row (mm) Seats and Driver (mm) Single Cab Single Cab Center of Gravity Critical Zone Model * Recommended C of G location for added mass 'A' Min (mm) 'B' Max (mm) 'C' Max (mm) 4x2 1965 3220 740 4x2 * 1965 3435 590 4x4 1965 3435 590 Vehicles with increased ride height. FORD RANGER 2012 Date of Publication: 12/2013 25 1 General Information Double Cab Double Cab Centre of Gravity Critical Zone Model * 26 Recommended C of G location for added mass Max gross added mass (kg) 'A' Min (mm) 'B' Max (mm) 'C' Max (mm) 4x2 2585 3615 740 700 4x2 * 2435 3615 590 625 4x4 2435 3615 590 700 Vehicles with increased ride height. Date of Publication: 12/2013 FORD RANGER 2012 1 General Information Stretch Cab Stretch Cab Center of Gravity Critical Zone Model * Recommended C of G location for added mass 'A' Min (mm) 'B' Max (mm) 'C' Max (mm) 4x2 2395 3220 740 4x2 * 2365 3435 590 4x4 2365 3435 590 Vehicles with increased ride height. FORD RANGER 2012 Date of Publication: 12/2013 27 1 General Information 1.14 Towing 1.14.1 Towing Requirements • Towing capacities must not exceed those of the unmodified vehicle. When a towing device is required, the Vehicle Converter should use a Ford approved tow bar. • Any modifications to the vehicle must be noted in the owner's handbook or new descriptive literature included with the owner's documentation. Tow bar installations must meet the requirements of the local design rules. Whenever frame drilling is necessary use tube reinforcement. Refer to: 1.13 (page 23). Load Distribution. Refer to: 1.6 Jacking (page 12). • 1.14.2 Towing • WARNINGS: Do not exceed the Gross Train Weight (GTW) or towing capacities stated in this section. Ensure that the trailer nose weight falls within the specified range. Refer to: 5.5 Frame and Body Mounting (page 75). 1.14.3 Towing capacities NOTE: The towing capacities below relate to vehicles with Ford tow bars only. For towing devices fitted by the Vehicle Converter the following applies: Towing capacities - For Base series Variant Drive Transmission Without trailer brake kg (lbs) With trailer brake kg (lbs) Max. Gross Train Weight kg (lbs) 2.5L Petrol 4X2 Manual 750 (1654) 1500 (3307) 4425 (9755) * Manual 750 (1654) 1500 (3307) 4525 (9976) 4x4 Manual 750 (1654) 1100 (2425) 4125 (9094) 4X2 Manual 750 (1654) 1500 (3307) 4425 (9755) 4x4 Manual 750 (1654) 1500 (3307) 4525 (9976) 4x2 and 4x4 Manual 750 (1654) 1500 (3307) 4700 (10362) 4x2 2.2L Diesel (88kW) 2.2L Diesel (92kW) 2.2L Diesel (110kW) 3.2L Diesel 28 * 4x2 Manual 750 (1654) 1500 (3307) 4425 (9755) * 4x2 and 4x4 Manual 750 (1654) 1500 (3307) 4700 (10362) * Manual 750 (1654) 1500 (3307) 4700 (10362) 4x2 and 4x4 Date of Publication: 12/2013 FORD RANGER 2012 Variant Drive Transmission Without trailer brake kg (lbs) With trailer brake kg (lbs) Max. Gross Train Weight kg (lbs) 2.5L Petrol 4X2 Manual 750 (1654) 2200 (4850) 5125 (11299) * Manual 750 (1654) 1700 (3748) 4900 (10803) 4x4 Manual 750 (1654) 1100 (2425) 4300 (9480) 4X2 Manual 750 (1654) 2200 (4850) 5125 (11299) 4x2 and 4x4 Manual 750 (1654) 1600 (3527) 4800 (10582) 4x2 Manual 750 (1654) 2500 (5512) 5425 (11960) Manual 750 (1654) 1800 (3968) 5000 (11023) * Manual 750 (1654) 3350 (7386) 2 3500 (7716) 1 5950 (13118) 2 6000 (13288) * Auto 750 (1654) 3350 (7386) 2 3500 (7716) 1 5950 (13118) 2 6000 (13288) * Manual 750 (1654) 1800 (3968) 5000 (11023) * Manual 750 (1654) 3350 (7386) 2 3500 (7716) 1 5950 (13118) 2 6000 (13288) * Auto 750 (1654) 3350 (7386) 2 3500 (7716) 1 5950 (13118) 2 6000 (13288) 4x2 2.2L Diesel (88kW & 92kW) 2.2L Diesel (110kW) * * 4x2 (Final drive ratio 3.31) 4x2 and 4x4 (Final drive ratio 3.55) 4x2 and 4x4 3.2L Diesel 4x2 and 4x4 (Final drive ratio 3.31) 4x2 and 4x4 (Final drive ratio 3.55) 4x2 and 4x4 1 1 General Information Towing capacities- For all other series 1 1 1 * Vehicles with increased ride height 1 European vehicles built before 11th March 2013, Australia and New Zealand vehicles built before 1st November 2012 and all non European/Australian/New Zealand vehicles. 2 European vehicles built on or after 11th March 2013 and Australia and New Zealand vehicles built on or after 1st November 2012. 1.14.4 Trailer Nose Weight NOTE: The maximum trailer nose weight values below relate to vehicles with Ford tow bars only. Trailer Nose Weight Region / Vehicle Minimum trailer nose weight Maximum trailer nose weight Australia and New Zealand Vehicles built before 1st November 2012 10% of the towed weight 335 kg Australia and New Zealand Vehicles built on or after 1st November 2012 10% of the towed weight 350 kg Rest of World 6% of the towed weight 225 kg for 4x2 and 4x4 * 165 kg for 4x2 * Vehicles with increased ride height. 1.14.5 Towing Specifications For any further details and advice please consult your local National Sales Company representative, or Local Ford Dealer. FORD RANGER 2012 Date of Publication: 12/2013 29 2 Chassis 2.1 Suspension System WARNINGS: Do not modify, drill, cut or weld any suspension components, specifically the steering gear system, subframe or anti-roll bars, springs or shock absorbers including mounting brackets. The rear leaf springs are pre-stressed in manufacture and should not be altered for rate or height in any way during vehicle conversion. Adding or removing leaves may result in failure or reduced function of the spring as well as other vehicle related issues for which Ford Motor Company can not be held responsible. CAUTIONS: Modifications to the suspension system can cause a deterioration of the vehicle handling characteristics and durability. When carrying out welding work the springs must be covered to protect them against weld splatter. Do not touch springs with welding electrodes or welding tongs. NOTE: Do not modify the wheelbase or add any type of frame extension to vehicles fitted with Electronic Stability Program ESP. NOTE: Do not damage the surface or corrosion protection of the spring during disassembly and installation. NOTE: Do not add any additional axles. 30 Date of Publication: 12/2013 FORD RANGER 2012 2.2.1 General The Brake System must be fully functional when the vehicle conversion is completed. The vehicle brake operating modes must be checked, including warning system and parking brakes. WARNING: Do not restrict the airflow and cooling to the brake system. Front and rear brake hoses must not rub, chafe or rest on body or chassis or body components. There must be clearance under all operating conditions, between full compression and extension and full lock to lock. Brake lines must not be used to support or secure any other component. NOTE: Do not obstruct the view of the brake fluid reservoir level. 2.2.3 Trailer brakes The brake fluid reservoir must remain accessible for servicing and for adding brake fluid. If electric trailer brakes are to be installed, they can be triggered by the brake light switch. The brake light switch is the lower of 2 switches positioned above the brake pedal inside the cabin. The maximum additional load is 1A. 2.2.2 Brake Hoses 2 Chassis 2.2 Brake System CAUTION: Make sure that the front and rear brake hoses are not twisted and are correctly located away from body and chassis components. Item Description 1 Brake Pedal 2 +12V when brake pedal is pressed FORD RANGER 2012 Date of Publication: 12/2013 31 3 Powertrain 3.1 Fuel System WARNINGS: Make sure that the modified vehicle complies with all relevant legal requirements. Do not remove or relocate the fuel cooler when modifying vehicle. CAUTIONS: Ensure modifications to vehicle do not obstruct airflow to fuel cooler. Make sure that sufficient clearance is maintained for all driving conditions to all hot and moving components. Make sure that there are no sharp edges, including fasteners, pointing towards any fuel system component. The fuel filler pipe must be supported in accordance with the guidelines in this section. 3.1.1 Fuel Filler Pipe Shipping Bracket CAUTION: The fuel filler pipe mounting bracket on cab chassis vehicles is designed for shipping of the vehicle only. The fuel filler pipe mounting bracket fitted to cab chassis vehicles is designed to be removed once the body or tray is fitted to the vehicle. The body or tray must include a fuel filler mounting that complies with the guidelines in this section. The shipping bracket can be left installed on the vehicle if desired, but only if an additional fuel filler pipe mounting bracket is used in accordance with the guidelines in this section. Fuel Filler Pipe Shipping Bracket - Single Cab 32 Date of Publication: 12/2013 FORD RANGER 2012 3 Powertrain Fuel Filler Pipe Shipping Bracket - Stretch Cab Fuel Filler Pipe Shipping Bracket - Double Cab FORD RANGER 2012 Date of Publication: 12/2013 33 3 Powertrain 3.1.2 Fuel Filler Mounting CAUTION: Make sure that the filler neck mounting bracket is made of a conductive material, and that it provides a grounding path for the fuel filler neck. Fuel Filler Mounting Bracket Item 34 If the vehicle body and mounting bracket does not provide a grounding path for the fuel filler neck, an earth strap must be added, connecting the filler neck to the chassis frame. Description A 180 mm minimum at the area above the filler neck 1 All 3x hardware fixation points on the filler neck must be utilised Date of Publication: 12/2013 FORD RANGER 2012 3 Powertrain Angle of Filler Neck Item Description A 2mm minimum bracket thickness B 30° FORD RANGER 2012 Date of Publication: 12/2013 35 3 Powertrain 36 Clearance From Vehicle Body Item Description A At least 9mm clearance between the fuel filler cap and vehicle body, in the worst case opening angle if applicable Date of Publication: 12/2013 FORD RANGER 2012 3 Powertrain Axle Breather Hose and Vent Hose Item 1 Description The rear differential breather hose should be mounted to the filler neck/vehicle body 3.1.3 Fuel Filler Vent Hose • • • The fuel tank vent hose should be clipped to the vehicle body, with the open end at least 600mm (4x2) or 800mm (4x4 or vehicles with increased ride height) above ground height. The fuel tank vent hose should be protected and positioned away from direct water spray, wheel splash and mud splash. The fuel tank vent hose must be pointing in a downward direction. • FORD RANGER 2012 The fuel tank vent hose can be mounted in one of the following locations. Date of Publication: 12/2013 37 3 Powertrain Item 38 Description 1 Back of the cab 2 Front of the load tray 3 Underside of the load tray Date of Publication: 12/2013 FORD RANGER 2012 4.1.1 Battery Information If a battery is disconnected, there is no requirement to reprogram the vehicle; the vehicle retains its ‘normal’ power management setting and remembers exactly what its previous configuration was (although the central locking latches may cycle if one of these was opened manually in the intervening period). With the radio, all of the settings are retained, but the key code needs to be entered to restore functionality. The clock will need resetting. Delayed Vehicles Vehicles held at the vehicle convertor premises and not in use for longer than 4 days, should have the battery's negative cable disconnected. Before shipping to the customer, the battery negative cable must be re-connected and the voltage re-checked. The voltage should be not less than 12.5 volts. 4 Electrical 4.1 Battery and Cables Battery Charging Procedure Battery Voltage Requirements and Testing All voltages are to be measured with an accuracy of: + /– 5% of values published. To maximize battery life, at the time of arrival at the vehicle converter, all batteries must have a minimum Open Circuit Voltage (OCV) of not less than 12.75 volts. When the battery is installed and connected to the vehicle's electrical system with no load, the Closed Circuit Voltage (CCV) must not be less than 12.65 volts. When the vehicle is released to the customer, the CCV must not be less than 12.50 volts. Surface Charge Dissipation Prior to carrying out manual voltage checks, it is necessary to establish that the battery voltage is stable and free from surface charges, that could be present due to certain engine run conditions making the voltage readings unreliable and inaccurate. To ensure surface charges are not present the following actions are recommended: 1. Turn the ignition key to position II and switch on the headlamps (main beam) and if fitted, the heated front window, rear window demister and the heater blower motor (on position II). Leave the vehicle in this condition for at least 1 minute to dissipate what ever surface charge is present in the battery. 2. Turn the ignition key to position 0 and switch off the loads; headlamps, heated windshield/rear window demister and heater blower motor. Leave the vehicle in this condition for at least 5 minutes, before taking a battery voltage reading. 1. Cold batteries will not readily accept a charge. Therefore, batteries should be allowed to warm up to approximately 5°C (41°F) before charging. This may require four to eight hours at room temperature depending on the initial temperature and battery size. 2. A battery 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 can be started by use of the dead battery switch on chargers that have this facility equipped. 3. To determine whether a battery is accepting a charge, follow the manufacturers instructions for the charger and the dead battery switch. If the switch is the spring-loaded type, it should be held in the ON position for up to three minutes. 4. After releasing the dead battery switch and with the charger still on, measure the battery voltage. If it shows 12 volts or higher, the battery is accepting a charge and is capable of being recharged. However, it may require up to two hours of charging, with batteries colder than 5°C (41°F) before the charge rate is high enough to show a charge on a ammeter. It has been found that all non-damaged batteries can be charged by this procedure. If a battery cannot be charged by this procedure, a new one should be installed. 5. A rapid recharge procedure has been developed for recharging batteries that have passed the load test and only need a recharge. This can be due to in-service no-start battery failures (vehicle will not crank due to low battery state of charge) or battery discharged in vehicle due to key-off loads. 6. With the cables then disconnected, the battery can be rapidly recharged by using either of the following methods: • Carry out a two hour charge using 20A constant current (manual setting on charger). • FORD RANGER 2012 Carry out a two hour charge using a constant potential (automatic setting on charger). Date of Publication: 12/2013 39 4 Electrical 7. Please connect the battery charger to the vehicle ground - not the battery negative post. This is to ensure the Battery Monitoring System (if fitted) is able to identify the battery charger. Battery Cable Fixing Torque The battery cables should be fixed to the terminal posts with a torque of 4.8 Nm -/+ 0.8Nm. Battery Part Numbers and Usage Ford Plant Battery Supplier Specifications Size Siam GS 60Ah, 590CCA, 105RC (Calcium Technology) T6 First National Battery 48Ah, 590CCA, 105RC (Silver Calcium Technology) T6 Moura 60Ah, 590CCA, 105RC (Silver Calcium Technology) T6 Siam GS 68Ah, 750CCA, 150RC (Calcium Technology) T7 First National Battery 68Ah, 750CCA, 150RC (Silver Calcium Technology) T7 Standard Duty Battery Thailand South Africa South America Heavy Duty Battery Thailand South Africa Auxiliary Battery (2nd Battery/Extra Heavy Duty Battery) South Africa First National Battery 80Ah, 800CCA, 140RC (VRLA AGM Deep Cycle Technology) Battery Monitor System (BMS) H7 NOTE: Disabling the BMS will negate the fuel economy benefit provided by the BMS. For vehicles equipped with BMS, an additional battery can be connected using one of the following methods: 1. Use an in-vehicle battery charger (DC/DC converter) such as BCDC1220 model from Redarc (or similar) and ground it to the vehicle body. 2. Request a Ford dealer to disable the BMS. Disabling the BMS enables voltage sensitive relay based dual battery systems to work. Ford Ranger vehicles are equipped with a new feature called Battery Monitor System (BMS). This system measures the battery load in order to efficiently charge the battery while improving fuel economy and emissions. It is important to ensure any additional electrical load or accessory is properly grounded to the vehicle’s body, in order for the system to identify the additional load. If a connection is done on the battery negative terminal, the BMS will not identify the load or charge. This may cause the battery to be undercharged and consequently not able to re-start the vehicle. Dual Batteries with Battery Monitor System (BMS) WARNING: Under no circumstances should a secondary battery connection be made directly to any of the vehicle's battery terminals. 40 Date of Publication: 12/2013 Connection of Auxiliary Loads WARNING: Under no circumstances should any unfused connections be made directly to any of the vehicle's battery terminals. NOTE: Auxiliary loads must always be connected to the vehicle ground and not to the battery negative terminal. • • • For auxiliary customer electrical loads, 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: 4.2 Exterior Lighting (page 45). FORD RANGER 2012 WARNING: Under no circumstances should the IG+ feed be used to drive auxiliary loads directly. A suitable relay must be used. The Body Control Module is positioned on the driver's side of the vehicle underneath the dash panel. IG+ Connection at Body Control Module Item 4 Electrical Auxiliary loads for external devices which require an ignition feed (such as UHF/CB radios) may be connected via a relay energised by the IG+ feed to the Body Control Module. Description 1 Body Control Module 2 IG+ Feed Battery Rules: • For external charging of batteries ensure that the maximum voltage of 14.6V is not exceeded. WARNINGS: For vehicles fitted with non-sealed batteries (non-maintenance free), it is essential that regular checks are made to determine that the electrolyte (acid) levels are correctly maintained. Ensure the battery charger is properly connected to the vehicle ground and not to the battery negative terminal. This is to ensure that the BMS identifies the battery charge. FORD RANGER 2012 4.1.2 Auxiliary Battery (Vehicles with Special Equipment Pack) NOTE: The addition of an auxiliary battery in a vehicle with BMS would cause both batteries to not reach a state of full charge. The system will only allow charging of the batteries during deceleration. Refer to Dual Batteries with Battery Monitor System (BMS) in this section. Date of Publication: 12/2013 41 4 Electrical Battery specifications Item Specification Battery Type H7 DIN VRLA/AGM Voltage 12V Capacity 80Ah CCC 800A The auxiliary battery is fitted in the load tray near the rear wheel arch for the body style variant. For the cab chassis variants, the auxiliary battery is mounted on a battery carrier which is mounted on the chassis and used for transport of the battery from the plant to the dealer. Auxiliary Battery Carrier (Cab Chassis Variant Only) CAUTION: The vehicle must not be driven on the road while the auxiliary battery is mounted to the frame. NOTE: Carrier has to be removed before delivery to customer. WARNING: Follow the instructions for auxiliary battery tray and cables fitment. 42 Date of Publication: 12/2013 FORD RANGER 2012 4 Electrical Item Description 1 Battery cable (towards main battery) 2 Auxiliary battery ground 3 Auxiliary battery carrier mounting bolts 4 Auxiliary battery fuse box 5 Auxiliary battery 6 Auxiliary battery carrier Instructions for Auxiliary Battery Fitment (Cab Chassis Variant Only) CAUTIONS: It is important to ensure that the auxiliary battery is mounted securely, away from any moving parts and does not interfere with the operation of any closures/tailgate. FORD RANGER 2012 The selected location should be such that electrical components are above the 800mm water wading level and protected during off road excursions. The attachment of the Auxiliary battery should be suitably durable for off road excursions. Date of Publication: 12/2013 43 4 Electrical It is important to ensure that the auxiliary battery fitment does not crush or cause damage to any wiring either part of the auxiliary battery wiring or the vehicle wiring. Make sure that the auxiliary battery cables are away from heat sources, sharp edges and moving parts. It is important that the auxiliary battery is mounted in a suitable location to enable easy access for servicing. NOTE: Avoid damage to the vehicle and the load tray during the auxiliary battery fitment. NOTE: Avoid interference with any operation of the vehicle lighting system. NOTE: Ensure that a good ground location is used; preferably use the ground point provided on chassis rail. The auxiliary battery and carrier must be completely removed from the frame in preparation for fitment to the vehicle tray. The location of the auxiliary battery should be selected considering that the battery and the cables within the tray should be protected from contact with any items that could be placed in the load tray. The selected location should be such that suitable space in the load tray is available for use. 4.1.3 Generator and Alternator Alternator Current Output All vehicles are fitted with 110A alternators. 44 Date of Publication: 12/2013 FORD RANGER 2012 WARNING: Make sure that the modified vehicle complies with all relevant legal requirements. NOTE: Chassis Cab vehicles are supplied with rear combination lamps, license plate lamps and fog lamps. Where fitted, these lamps must be mounted in accordance with the following guidelines. 4.2.1 Rear Combination lamps 4 Electrical 4.2 Exterior Lighting Positioning of Rear Combination Lamps FORD RANGER 2012 Date of Publication: 12/2013 45 4 Electrical Positioning of Rear Combination Lamps Description Dimension A Minimum distance from ground to lower edge of lamp 250mm B Maximum distance from ground to upper edge of lamp 1200mm C Minimum angle of obstruction free zone downwards of the lamp 15° D Minimum angle of obstruction free zone upwards of the lamp 15° E Minimum angle of obstruction free zone towards the outside of the vehicle 80° F Minimum angle of obstruction free zone towards the centre of the vehicle 45° G Maximum distance from outer edge of vehicle to inner edge of lamp 400mm 4.2.2 Rear Fog Lamp NOTE: Where only one rear fog lamp is fitted, it must be positioned on the vehicle centre line, or to the drivers side of the vehicle. 46 Date of Publication: 12/2013 FORD RANGER 2012 4 Electrical Positioning of Rear Fog Lamp Positioning of Rear Fog Lamp Description Dimension A Minimum distance from ground to lower edge of lamp 250mm B Maximum distance from ground to upper edge of lamp 1000mm C Minimum angle of obstruction free zone downwards of the lamp 5° D Minimum angle of obstruction free zone upwards of the lamp 5° E Minimum angle of obstruction free zone towards the outside of the vehicle 25° F Minimum angle of obstruction free zone towards the centre of the vehicle 25° FORD RANGER 2012 Date of Publication: 12/2013 47 4 Electrical 4.2.3 Rear License Plate Lamp Positioning of Rear License Plate Lamp Positioning of Rear License Plate Lamp Description 48 Dimension A Distance from rear face of license plate to centre of lamp along lamp mounting face 35mm B Angle between license plate and lamp mounting face 10° C Distance between top of rear face of license plate and lamp mounting face 35mm D Distance between license plate centre line and centre of lamp 175mm E Distance between license plate centre line and centre of lamp 175mm Date of Publication: 12/2013 FORD RANGER 2012 The reverse lamps are activated by the reverse switch on the transmission and passing through the Central Junction Box where the signal is sensed. A marginal increase in current (via a relay or buffered electrical input) is permissible to trigger a rear-view camera system, or audible device. For all other additional exterior lamps, power must be taken through an auxiliary fuse box with a suitable switch and / or relay as required. WARNING: Directly splicing into the vehicle wiring in order to install auxiliary lamps or other electrical devices may overload the system and impact the operation of other vehicle systems. When installing auxiliary driving lights, power can be provided via a relay energised by the headlamp feed. 4.2.5 Additional External Lamps 4 Electrical 4.2.4 Reversing Lamps When installing auxiliary tail lamps, Ford recommends that power is provided via the trailer plug control module and associated circuitry. Refer to Trailer Tow for additional information. Item Description 1 Low beam 2 High beam Lighting Loads Lamp Controlling Device Vehicle Trailer Tow Number plate lamp Body control module 2x5W Position / Parking lamp Body control module 5W Front direction indicator Body control module 21W - Brake lamps Body control module 21W 28W Rear direction indicator Body control module 21W 24W Reverse lamp Body control module 21W 24W Rear fog lamp Body control module 21W 48W 28W Trailer tow maximum power ratings shown, also see trailer tow below. FORD RANGER 2012 Date of Publication: 12/2013 49 4 Electrical Lighting Fuses F74 20A Headlamp F75 15A Front fog lamp F76 10A Reversing lamp Trailer Tow Vehicles with a factory fitted tow bar also come with a trailer plug control module for lighting. In addition to providing the trailer plug functionality, the trailer plug control 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 installed. The kit comprises of the trailer plug control module, trailer plug, wiring and associated hardware components. Once the kit is installed, the vehicle must then be configured using a Ford IDS diagnostic tool. This configuration can be performed by your Ford authorised dealer. NOTE: The trailer tow electrical kit is available from your Ford authorised dealer. Ford recommends that all trailer tow electrical connections use the genuine Ford accessory trailer tow kit. 50 Date of Publication: 12/2013 WARNING: Installation of aftermarket trailer tow electrical kits or directly splicing into the vehicle wiring in order to install trailer lamps or other electrical devices may overload the system and impact the operation of other vehicle systems. When fitting low power LED (light emitting diode) lamps that require less than 2W, the lamps may flicker when in use. A trailer patch harness should be used with low power LED lamps. CAUTION: Do not connect the trailer patch harness to the vehicle when the trailer is not connected. NOTE: The trailer patch harness is available from your Ford authorised dealer. 4.2.6 Additional External Lamps (Vehicles with Special Equipment Pack) The plastic switch fascia is located at the front of the console. It can house up to four aftermarket switches. Driving Lights, LED beacon lamp and work lights can be powered via the switches on the fascia. A fourth switch is provided as a spare with 20A capacity. FORD RANGER 2012 4 Electrical Item Description 1 U nuts NOTE: Cut out the switch blanks with a suitable tool without damaging the plastic fascia FORD RANGER 2012 Date of Publication: 12/2013 51 4 Electrical 52 Item Description 1 Driving lights switch blank 2 Work lights switch blank 3 LED beacon lamp switch blank 4 Spare switch blank NOTE: The driving lights will only operate when the vehicles high beam is selected. NOTE: The connector for the driving light is located behind the grille. NOTE: The vehicle is equipped with a battery isolator which ensures that the main vehicle battery remains in a charged state and only the auxiliary battery becomes discharged. Once the vehicle is running the isolator will close allowing the auxiliary battery to be charged by the vehicles charging system. NOTE: Discard the sealing end-cap after connecting the driving light connector. Date of Publication: 12/2013 FORD RANGER 2012 4 Electrical Item Description 1 Sealing end-cap 2 Driving light connector NOTE: The light switch connector is located behind the switch fascia in the vehicle. FORD RANGER 2012 Date of Publication: 12/2013 53 4 Electrical Item Description 1 Switch connector Connector Details Connector Pin Color cable Connects to 1 VT/WH Central electronic module control 2 BK/BU Cross car beam ground 3 BK/BU Cross car beam ground 4 BK/BU Cross car beam ground 5 BK/BU Cross car beam ground 8 VT/WH LED beacon lamp Relay (R2) 9 BN/GN Spare populated relay (R3) 10 GN/BN Work lights relay (R1) 11 WH/GN Driving lights relay Connections for the load box lamps, LED Beacon lamp and driving lights are provided by a 16 way connector located at the rear of the auxiliary battery box below the isolator. The connector details are as follows. 54 Date of Publication: 12/2013 FORD RANGER 2012 Color cable Function 16 BK-YE Ground 10 YE-BU Load box lamps +12v 3 WH LED beacon lamp +12v 9 YE-GY Spare +12v 5 GN-BU Reverse lamps +12v (lamp Bar) 4 VT-WH Position / tail lamps +12V (lamp Bar) 7 GY-OG Turn left +12v (lamp Bar) 6 GY-OG Turn right +12v (lamp Bar) 2 YE-GN Brake / stop +12v (lamp Bar) Fuse Fuse Amp Rating Protected Components 1 25 Driving lights 2 15 Position lamp 3 10 LED beacon lamp 4 15 Work lights 5 20 Spare 6 20 Power point 7 15 Reversing lamp 8 15 Direction indicators, stop lamp 9 5 Crew chief 10 5 Disable fuse (isolator ground) 11 - Not used 12 - Not used 4 Electrical Connector Pin Fuse specification chart Auxiliary Fuse Box FORD RANGER 2012 Date of Publication: 12/2013 55 4 Electrical Relay Number Protected Components R1 Work lights R2 LED beacon lamp R3 Spare R4 Position lamp R5 Direction indicator (left) R6 Direction indicator (right) R7 Stop lamp R8 Not used R9 Not used 4.2.7 Lamps – Hazard / Direction Indication The maximum permissible load with the standard system is: • • 3 x 5W – front and rear indicators + side repeaters (Left Hand Side) 3 x 5W – front and rear indicators + side repeaters (Right Hand Side) 4.2.8 Electrically operated Door Mirrors WARNING: Do not tamper with the base system (controlled by Central Junction Box and multiplex architecture) and any feeds taken from the associated wiring or controller. NOTE: These options are not suitable for aftermarket or Body Builder fit. 56 Date of Publication: 12/2013 FORD RANGER 2012 5.1.1 Body Structures - General Information CAUTION: Load carrying structures should not be mounted onto an existing load tray or load box. When carrying out vehicle conversions/modifications the following points should be considered: • • • • • Make sure that the vehicle structural integrity is maintained. Do not drill into closed frame body members. Make sure that the design for the body alterations or additional structure disperse the load evenly. CAUTION: Uneven load distribution could result in unacceptable handling and braking characteristics. Re-paint metal edges after cutting or drilling. All metal edges must comply with exterior and interior protection legislation. All fixings through the floor, sides or roof must be sealed. • Make sure that fixings in the 'B'-pillar area do not encroach on the seat belts or seat belt reels. 5.1.2 Integrated Bodies and Conversions For integral structures such as ambulances or motor-homes with increased rear overhang built onto the chassis the following applies: • Reduced departure angles, e.g. rear entry step, should be discussed with the end user / customer. Consider removable components to avoid damage on ferries or low-loaders. • Unique spare wheel stowage may be required if obscured by rear step, check for accessibility. • The recommended dimensions for wheelhouses on conversions are outlined in the following figure. 5 Body and Paint 5.1 Body Wheelhouse Envelope FORD RANGER 2012 Date of Publication: 12/2013 57 5 Body and Paint Wheelhouse Dimensions Dimension 215/ 70R16 A 455mm G * 190mm B 425mm H 914mm C 305mm K 588mm D 275mm L 30mm E 110° r 20mm F 420mm 1 Center line of Vehicle X Section through Center of Wheelhouse * 255/ 70R16 265/ 65R17 265/ Dimension 65R18 255/ 70R16 255/ 70R16 265/65R17 915mm 922mm 922mm Dimension G is to the bottom of the swage 5.1.3 Chassis Cab • WARNING: Excessive heat can build up from the exhaust system, in particular from the catalytic converter. Ensure adequate heat shields are maintained. • CAUTION: Uneven load distribution could result in unacceptable handling and braking characteristics. • When carrying out vehicle conversions / modifications the following points should be considered: • Make sure that all of the reinforced holes provided in the chassis frame top surface are used for full length bodies or sub-frames, see figures shown. • Make sure that the vehicle structural integrity is maintained. • Do not drill into closed frame body members. • Make sure that the design for the body alterations or additional structure disperse the load evenly. 58 215/ 70R16 Date of Publication: 12/2013 Re-paint metal edges after cutting or drilling. All metal edges must comply with exterior and interior protection legislation. All fixings through the floor, sides or roof must be sealed. Refer to: 5.4 Corrosion Prevention (page 74). Ensure that any additional equipment in the vicinity of the fuel tank will not damage the tank in a crash condition. For any conversion structure attached to or mounted onto the base vehicle cab structure the following applies: • Ensure that neither the conversion structure nor the existing vehicle structure get pre-loaded by the assembly process. • Adhesive jointing is recommended but should be supplemented with mechanical fasteners to prevent initial peel and long term failure. • Spread bolt loads to minimize local stress. NOTE: The following chassis frame images and dimensions are showing the previous Ranger (J97) chassis frame above the new Ranger (P375) chassis frame for comparison purposes. FORD RANGER 2012 5 Body and Paint Body Attachment Holes in Chassis Frame - Single cab FORD RANGER 2012 Date of Publication: 12/2013 59 5 Body and Paint 60 Dimensions (mm) for Body Attachment Holes in Chassis Frame - Single Cab Dimension J97 P375 Dimension J97 P375 A 20 16 H 1024 1086 B 13 28 J - 95 C 13 23 K 568 768 D 20 20 L 1007 893 E 1150 1244 M 496 509 F 1140 1244 N - 26 G 1140 1244 P - 20 Date of Publication: 12/2013 FORD RANGER 2012 5 Body and Paint Body Attachment Holes in Chassis Frame - Double cab FORD RANGER 2012 Date of Publication: 12/2013 61 5 Body and Paint 62 Dimensions (mm) for Body Attachment Holes in Chassis Frame - Double cab Dimension J97 P375 Dimension J97 P375 A 20 16 G 1024 1086 B 13 28 H - 95 C 13 23 J 776 893 D 20 20 K 498 509 E 1130 1244 L - 26 F 1140 1244 M - 20 Date of Publication: 12/2013 FORD RANGER 2012 5 Body and Paint Body Attachment Holes in Chassis Frame - Stretch cab FORD RANGER 2012 Date of Publication: 12/2013 63 5 Body and Paint Dimensions (mm) for Body Attachment Holes in Chassis Frame - Stretch Cab Dimension J97 P375 Dimension J97 P375 A 20 16 G 1024 1086 B 13 28 H - 95 C 13 23 J 776 1191 D 20 20 K 498 509 E 1130 1244 L - 26 F 1140 1244 M - 20 5.1.4 Front End Integrity for Cooling, Crash, Aerodynamics and Lighting • Cooling Continuous air flow through the front end and engine compartment is not to be hindered by adding any additional equipment. If uncertain please consult the Ford dealer. Lighting Do not alter the lighting system. Crash Do not cut, drill or weld any parts that are load path relevant in case of crash. Do not add material in the crash zone. This could affect the crash sensor calibration. The side airbag system is not permitted if: • A swiveling device is fitted on the front seats. • A side wall or any other additional material or structure is attached to the B-pillar inner and/or outer area. Static & Dynamic Sealing and Finishing Ensure proper sealing against ingress of water, salt, dust etc. after cutting or drilling the body. Use Ford approved sealing and finishing material, and underbody corrosion protection. Refer to: 5.4 Corrosion Prevention (page 74). 5.1.5 Tipper Bodies For tipper conversions single and double Chassis Cab versions except extended rear chassis frame can be used. All variants allow single and three way tipping. It is recommended to have the tipping system operative only when the engine is running. It is also recommended to have the master control switch in the security of the cab. According routing of wires and hydraulic lines please refer to section hydraulic lift. Ensure that axle plated weights including the front axle minimum are not exceeded. • • • 5.1.6 Tank and Dry Bulk Carriers Due to the high rigidity of tanks it is necessary to isolate the tank and its sub-frame from the chassis frame allowing the chassis frame to naturally flex. Please refer to the following guidelines: • • • • • For tipper sub-frames please refer to the following guidelines: • • 64 Design for full length continuous frame with mountings for motor, pump unit, reservoir, pivot points and ram. Use all mounting points on chassis frame to mount sub-frame. Date of Publication: 12/2013 Very stiff sub-frames may damage the chassis frame by preventing its natural flexing, therefore compliant mounts should be used, with up to plus and minus 12mm compliance with the vehicle laden or un-laden (whichever is worst case). Compliant mounts should be rated with a minimum of 2mm deflection per 200kg mass at each chassis frame forward mount. Compliant mounts shall have captive fail safe bolts. Use two M10 grade 8.8 minimum bolts, washers and self locking nuts at each solid and compliant chassis frame location. Sub-frame must extend to the back of the cab and attach to all mounting locations, with the forward end designed to minimize local frame stress. It is however, preferable to mount the sub-frame onto the mounting brackets with a clearance to the chassis frame top surface. Side tipping loads/forces must be resolved by the sub-frame. It is not recommended to strain the chassis frame. • 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 and minus 12mm compliance with the vehicle laden or un-laden (whichever is worst case). Compliant mounts should be rated with a minimum of 2mm deflection per 200kg mass at each chassis frame forward mount. Compliant mounts shall have captive fail safe bolts. Use two M10 grade 8.8 minimum bolts, washers and self lock nuts per chassis frame mount bracket at each solid and compliant location. FORD RANGER 2012 The bull bar includes brackets which are mounting points for driving lights, aerials, antennas and flags. WARNING: Follow the accessory manufacturer's instructions to connect the accessory equipment to the vehicle. Item Description 1 Aerials, antennas and flag mounting location 2 Driving lights mounting location Aerial/Antenna Cables Routing WARNINGS: Ensure that the aerial/antenna cables have sufficient clearance from hot and moving parts. Do not fasten the aerial/antenna cables to original vehicle wiring, fuel pipes and brake pipes. FORD RANGER 2012 NOTE: Please refer the electromagnetic compatibility (EMC) section in this book before installation of any aerial and antennas. 5 Body and Paint 5.1.7 Bull Bar (Vehicles with Special Equipment Pack) Keep the aerial/antenna and power cables at least 100mm from any electronic modules and airbags and associated wiring. NOTE: Make sure the sealing integrity is maintained to avoid water ingress into the cabin while routing the cables through the grommet. Date of Publication: 12/2013 65 5 Body and Paint Aerial/Antenna cables should be routed from the engine bay into the cabin area through the existing grommet. There is a service nib provided on the grommet. Refer to Exterior lighting - Additional external lamps for driving lights cable routing. • • The load is evenly distributed (converter to ensure owner’s information book identifies this limitation). The rack and subsequent carried load is supported in the roof drip rails irrespective of rack retaining method. 5.1.8 Roof Racks Double Cab / Stretch Cab Roof racks may be fitted to all variants as illustrated in figure, providing the following is satisfied: The forgoing limitations are based on ensuring body structure integrity, vehicle handling, braking and plated axle weights. Such considerations must also be applied to any double cab and stretch cab applications, in particular steering, braking and front axle plated weight and the extra continuous loads on the “A” pillar, which should not exceed 60 kg total incremental load. • • The carried load does not exceed 80kg (Body Builder to ensure owner’s hand book identifies this limitation). The carried load does not exceed 300mm load height (converter to ensure owner’s information book identifies this limitation). Ensure that the planned loaded vehicle operates within its designed Center of Gravity condition. For details please consult the Ford dealer. Roof Rack Vehicle Converter Special Fit Item 66 Description 1 Rear edge of front attachment point 2 80kg Maximum 3 Maximum roof rack length: Within length of drain channel 4 Maximum Load Height 300mm 5 Drain Channel 6 Roof Rack Supports Date of Publication: 12/2013 FORD RANGER 2012 The top surface of the load box sides should not bear canopy (or other) structural loading. To be used as a canopy 'sealing-surface' only. 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. Canopy weight and canopy load should pass through the recommended load box structural attachment points. NOTE: Usage of clamps for the canopy fitment are only allowed on the centre and rear portion of the load box. NOTE: Use both points from group A and a minimum of one point from group B as front structural attachment points. 5 Body and Paint 5.1.9 Canopies Load Box Structural Attachment Points Item Description 1 Front structural attachment points 2 Centre structural attachment points 3 Rear structural attachment points 4 Top surface of load box sides 5 Return flange of load box sides * * * Do not cut, drill, or use these surfaces to bolt the canopy. FORD RANGER 2012 Date of Publication: 12/2013 67 5 Body and Paint Example of a sports bar fitment Item 68 Description 1 Front mounting bracket 2 Clamped attachment Date of Publication: 12/2013 FORD RANGER 2012 5.2.1 Air Bags Front Seats Side airbags are not compatible with swiveling front seats. Do not specify the base vehicle with side airbags when planning to retrofit a swiveling device on the front seats and/or an armrest on the outer side of the front seats, this may affect the function and/or deployment of the side airbags. The acceleration based airbag sensors for side airbags are located nearby the bottom of the C-pillar inner for RAP and DBL Cab vehicles. The pressure based airbag sensors for side airbags are located near the centre of the front doors' inner door sheet metal for all Cab styles. WARNING: Modifications or reinforcements in the area of the sensors may affect the side airbag fire timing and result in uncontrolled side air bag deployment. Please note that vehicles not equipped with side airbags but equipped with front airbags only are not affected. 5 Body and Paint 5.2 Airbag Supplemental Restraint System (SRS) Drilling or grinding operations in this area are only permitted when battery cables are disconnected. Driver and Passenger Front Airbag Deployment Zones Dimensions (mm) A 400 D 660 B 700 E 630 C 700 F 700 FORD RANGER 2012 Date of Publication: 12/2013 69 5 Body and Paint Side Airbag Driver and Passenger Front Airbag Deployment Zones Dimensions (mm) A 550 B 350 C 250 Curtain Airbag - Single cab Driver and Passenger Front Airbag Deployment Zones 70 Date of Publication: 12/2013 FORD RANGER 2012 A 140 C 250 B 40 D 100 Curtain Airbag - Double cab Driver and Passenger Front Airbag Deployment Zones 5 Body and Paint Dimensions (mm) Dimensions (mm) A 140 C 250 B 40 D 100 Curtain Airbag - Stretch cab Driver and Passenger Front Airbag Deployment Zones FORD RANGER 2012 Date of Publication: 12/2013 71 5 Body and Paint 72 Dimensions (mm) A 140 C 250 B 40 D 100 Date of Publication: 12/2013 FORD RANGER 2012 5 Body and Paint 5.3 Safety Belt System WARNING: Follow removal and installation procedures for the seat belt system to ensure correct function of the restraints system. The removal and reinstallation of the seat belt, restrainer or any component of the seat belt system should be avoided. However if removal and re-installation of the system is required during the conversion, follow the removal and installation guidelines of the seat belt system as described in the workshop manual. Please consult your local National Sales Company representative for further information. When removing the seat belt system, a seat belt webbing forked retainer should be applied to the webbing 200mm below the webbing button stop. This prevents a situation where all the webbing runs back into the retractor and the retractor becomes locked. When reinstalling, fit the retractor to the body first and gently pull the webbing out of the retractor to allow fitment of the D loop. Then remove the forked retainer. If the retractor is locked, allow a small amount of webbing to reel back into the retractor to allow the webbing lock to release. Do not attempt to release the retractor by pulling on the webbing with significant force or by manually interfering with the locking mechanism. FORD RANGER 2012 Date of Publication: 12/2013 73 5 Body and Paint 5.4 Corrosion Prevention 5.4.1 General Avoid drilling into closed frame body members to avoid the risk of corrosion from swarf. If drilling is required, however: • • • Re-paint metal edges and protect against corrosion after cutting or drilling operations. Endeavor to remove all swarf from inside the side member and treat to prevent corrosion. Apply corrosion protection inside and outside of the chassis frame. 5.4.2 Repairing Damaged Paint After cutting or reworking any sheet metal on the vehicle the damaged paint must be repaired. Ensure all materials are compatible with the relevant Ford specifications and maintain the original performance where possible. 5.4.3 Under Body Protection and Material WARNING: Do not over-coat or contaminate surfaces of components such as brakes or catalytic converters. Ensure all materials are compatible with the relevant Ford specifications and maintain the original performance where possible. Some proprietary products affect the original coatings. For specifications of corrosion protection materials, please consult your local National Sales Company representative. 5.4.4 Painting Road Wheels WARNING: Do not paint wheel clamp surfaces in contact with other wheels, brake drum or disc, hub and holes or surface under wheel nuts. Any further treatment in these areas may affect the wheel clamp performance and the vehicle safety. Mask the wheel when changing the color or repairing paint. 5.4.5 Contact Corrosion When using different materials with a different electrochemical potential, ensure that materials are isolated from each other to prevent contact corrosion caused by a potential difference. Use appropriate isolation materials. Where possible, choose materials with low level of electrochemical potential difference. 74 Date of Publication: 12/2013 FORD RANGER 2012 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 74). 5 Body and Paint 5.5 Frame and Body Mounting Frame Drilling and Welding Dimensions (mm)for Body Attachment Holes in chassis Frame Top Flange Medium Wheelbase A 19 D 110 B 11 E Do not drill within 20mm hole, or in the areas shaded in green. C 100 F No more than 2 holes to be drilled in a vertical line. 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. FORD RANGER 2012 6. Holes must NOT be drilled near side member profile changes. 7. Existing holes in top and bottom flanges must NOT be bored out. 8. No more than two holes are to be drilled in a vertical line down from the frame web. 9. Corrosion protection is to be applied post drilling operations to the vehicle. Corrosion protection & protective coatings for all modifications should conform to all local design rules. 10. Reinforcements should be added to the vehicle structure where appropriate, to avoid excessive load concentrations. Date of Publication: 12/2013 75 5 Body and Paint Typical Design Principle of a Self-Supporting Body Structure Item Description 1 Use all standard locations with 2x M10 fixings 2 Floor Panel 3 Body side frames 4 Floor cross members 5 Continuous floor U-profile frame 6 Longitudinal L-profile 7 Chassis frame rail of base vehicle 8 Vehicle center line of base vehicle Also see: • Refer to: 5.1 Body (page 57). 5.5.2 Self-Supporting Body Structure Bodies and structures can be judged as self-supporting providing they maintain the following rules: • Cross members are used at each chassis mounting point, please refer to figures shown. • Each cross member has a suitably engineered connection to the body side wall (3) or to the continuous floor frame (5), see figure shown. • The body side wall or the continuous floor frame supports any overhang beyond the chassis frame, whether on standard frame or extended frame. Alternatively, the self-supporting body structure can also be designed as shown in figure shown. 76 Date of Publication: 12/2013 • • 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 opposing out riggers are flush with the surface of the chassis frame side members. It is important to the overall function of the vehicle structure that the out riggers are each connected to a continuous longitudinal floor side frame or a structural body side structure assembly. Low floor-re-work for guidance only: • Engineer unique cross members and out-riggers spaced at approximately 600mm maximum pitch. • Out-rigger moment to be re-acted with cross-member between chassis frame with common through bolts where possible. FORD RANGER 2012 • • • • Drill frame and add spacer tubes. Refer to: 5.5 Frame and Body Mounting (page 75). Out-rigger outboard ends should be attached to load bearing body side / floor edge frame or body side structure (including 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 attached to cross members and outriggers, but not to the chassis frame top surface. Low floor exhaust heat shields. 5.5.3 Frame Drilling and Tube Reinforcing Drilling and welding of frames and body structure have to be conducted following the program guidelines. Please consult the Ford dealer for details. 5.5.4 Ancillary Equipment - Sub Frame Mounting Typical sub-frames and longitudinal members for flatbed and low or drop-side bodies or equipment exceeding the standard or Regular Production Order frame length should adhere to the following guidelines: • • The chassis frame may be drilled and reinforcing spacer tubes may be welded in place, providing the following is applied: • • • • • • • • • • • • Adhere to all details shown in figure. Drill and weld only side walls of the chassis frame. Locate and drill holes accurately, using a drill guide to ensure holes are square to frame vertical center line (note: allow for side member draft angle). Drill undersize and ream out to size. Endeavor to remove all swarf from inside side member, and treat to prevent corrosion. Fully weld each end of the tube and grind flat and square, in groups if applicable. Be aware of side member draft angle. Apply corrosion protection inside and outside of the chassis frame. Refer to: 5.4 Corrosion Prevention (page 74). Holes should be in groups of two (2), either vertically spaced at 30 to 35mm from chassis frame top and/or bottom surface, or horizontally at 50mm minimum pitch, 30 to 35mm from top and/or bottom chassis frame surface. Always use M10 bolts with grade 8.8 minimum. Do not position tubes at the medium chassis frame height, this may create “oil canning” of the deep section side walls. Where possible, the outrigger moments should be resolved by matching inner cross members between the chassis side members inline with the outriggers. A diameter of 16.5mm is the maximum allowable hole size in the chassis frame side wall, irrespective of the usage. • • Flat-beds and low bodies mounted on integral longitudinal members (channel or box section metal – not wood) must use both sides of all frame mounting brackets. Longitudinal members must be relieved at the front end if they are to contact the chassis frame top surface, to minimize stress concentrations. It is preferable however, to mount the longitudinal onto the mounting brackets, with a clearance to the chassis frame top surface. Each set of brackets must use two (2) x M10 bolts grade 8.8 minimum. Minimum floor heights will require wheel arch boxes to clear the rear tires, see Vehicle Data sheets for relevant tire jounce. 5 Body and Paint • 5.5.5 Area for Fitting Additional Body Attachments to the Rear of the Bumper. NOTE: With the vehicle on level ground and with all measurements taken rear ward of the bumper bar edge: The area designated for the fitting of attachment is defined as 220mm horizontally by 95mm vertical downward to the road surface, with a max width of 1390mm about vehicle center line. It is not the manufactures recommendation to fit additional body attachments (Tow bars, Steps, Bicycle racks & Carriers) outside of the designated area. 5.5.6 Water Tank on Camper Vehicles NOTE: It is recommended that a decal or label is fitted adjacent to the filler aperture identifying the correct fluid to be used, for example: 'Water only' for water tanks. Avoid drilling into closed frame body members to avoid the risk of corrosion from swarf. Refer to: 5.4 Corrosion Prevention (page 74). FORD RANGER 2012 Date of Publication: 12/2013 77 Index A G About This Manual..........................................................5 Additional External Lamps........................................49 Additional External Lamps (Vehicles with Special Equipment Pack)........................................................50 Aids for Vehicle Entry and Exit..................................16 Air Bags.............................................................................69 Airbag Supplemental Restraint System (SRS)..............................................................................69 Alternative Type Approval............................................6 Ancillary Equipment - Sub Frame Mounting.......77 Area for Fitting Additional Body Attachments to the Rear of the Bumper.............................................77 Auxiliary Battery (Vehicles with Special Equipment Pack).........................................................41 General........................................................................31, 74 General Component Package Guidelines.............16 General........................................................................31, 74 General Product Safety Requirement......................6 Generator and Alternator...........................................44 B H Hardware—Specifications..........................................22 How to Use This Manual...............................................5 I Important Safety Instructions.....................................5 Integrated Bodies and Conversions........................57 Introduction........................................................................5 Battery and Cables.......................................................39 Battery Information......................................................39 Body....................................................................................57 Body Structures - General Information.................57 Brake Hoses......................................................................31 Brake System...................................................................31 Bull Bar (Vehicles with Special Equipment Pack)...............................................................................65 J C Lamps – Hazard / Direction Indication.................56 Legal and Vehicle Type Approval..............................6 Legal Obligations and Liabilities................................6 Lifting..................................................................................13 Load Distribution—Specifications...........................23 Load Distribution Calculations - Driver and Passenger Weight Distribution...............................23 Canopies...........................................................................67 Center of Gravity............................................................25 Chassis Cab Body - Basic Dimensions and Weights............................................................................19 Chassis Cab.....................................................................58 Commercial and Legal Aspects.................................6 Contact Corrosion..........................................................74 Conversion Affect on Fuel Economy and Performance...................................................................11 Conversion Affects on Parking Aids........................16 Conversion Homologation............................................8 Corrosion Prevention....................................................74 D Drilling and Welding........................................................7 Driver Field of View........................................................16 Driver Reach Zones........................................................16 E Electrically operated Door Mirrors..........................56 Electromagnetic Compatibility (EMC)....................9 Electronic Engine Controls.............................................. Exterior Lighting.............................................................45 F Frame and Body Mounting.........................................75 Frame Drilling and Tube Reinforcing.......................77 Front, Rear and Side Under-run Protection..........21 Front End Integrity for Cooling, Crash, Aerodynamics and Lighting....................................64 Fuel Filler Mounting......................................................34 Fuel Filler Pipe Shipping Bracket.............................32 Fuel Filler Vent Hose.....................................................37 Fuel System.....................................................................32 Jacking................................................................................12 K Kerb Weights and payload..........................................21 L M Minimum Requirements for Brake system and Load Apportioning Valves...........................................7 Mounting Points and Tubing.....................................75 N New for this BEMM publication 12/2013.................5 Noise, Vibration and Harshness (NVH).................14 P Package and Ergonomics—Specifications............17 Package and Ergonomics............................................16 Painting Road Wheels..................................................74 Product Liability................................................................7 R Rear Combination lamps...........................................45 Rear Fog Lamp...............................................................46 Rear License Plate Lamp...........................................48 Recommended Body Dimensions............................17 Repairing Damaged Paint...........................................74 Restraints System............................................................7 Reversing Lamps...........................................................49 Road Safety........................................................................7 Roof Racks.......................................................................66 S Safety Belt System........................................................73 78 T Index Self-Supporting Body Structure.............................76 Suggested Antenna Location...................................10 Suspension System....................................................30 Tank and Dry Bulk Carriers.......................................64 Terminology......................................................................6 Tipper Bodies................................................................64 Towing capacities........................................................28 Towing Requirements.................................................28 Towing Specifications................................................29 Towing..............................................................................28 Trailer brakes...................................................................31 Trailer Nose Weight.....................................................29 U Under Body Protection and Material....................74 V Vehicle Duty Cycle Guidelines...................................11 Vehicle Ride and Handling Attributes.....................11 Vehicle Speed Output (Signal).................................... Vehicle Transportation Aids and Vehicle Storage............................................................................15 W Warnings, Cautions and Notes in This Manual..............................................................................5 Warranty on Ford Vehicles..........................................6 Water Tank on Camper Vehicles.............................77 79