2011-2013 Ford Ranger (PX) Service & Repair Manual

FORD RANGER T6 REPAIR MANUAL WIRING DIAGRAM BODY & EQUIPMENT MOUNTING MANUAL

Date of Publication: 05/2011 TO MODEL INDEX VIEW MAIN INDEX FORD RANGER 2011.5MY BODY AND EQUIPMENT MOUNTING MANUAL

1 General Information 1.1 About This Manual..........................4 1.1.1 Introduction............................................4 1.1.2 Important Safety Instructions..............4 1.1.3 Warnings, Cautions and Notes in This Manual.....................................................4 1.1.4 How to Use This Manual......................4 1.2 Commercial and Legal Aspects.....5 1.2.1 Terminology............................................5 1.2.2 Warranty on Ford Vehicles...................5 1.2.3 Legal and Vehicle Type Approval........5 1.2.4 Alternative Type Approval....................5 1.2.5 Legal Obligations and Liabilities...........5 1.2.6 General Product Safety Requirement..........................................5 1.2.7 Product Liability......................................6 1.2.8 Restraints System.................................6 1.2.9 Drilling and Welding...............................6 1.2.10 Minimum Requirements for Brake system and Load Apportioning Valves ..................................................................6 1.2.11 Road Safety............................................6 1.3 Conversion Homologation.............7 1.4 Electromagnetic Compatibility (EMC).............................................8 1.4.1 Suggested Antenna Location.............9 1.5 Vehicle Duty Cycle Guidelines......10 1.5.1 Conversion Affect on Fuel Economy and Performance.................................10 1.5.2 Vehicle Ride and Handling Attributes...............................................10 1.6 Jacking..........................................11 1.7 Lifting............................................13 1.8 Noise, Vibration and Harshness (NVH)............................................14 1.9 Vehicle Transportation Aids and Vehicle Storage............................15 1.10Package 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........................................21 1.11.4 Front, Rear and Side Under-run Protection.............................................22 1.12Hardware—Specifications...........23 1.13 Load Distribution—Specifications........24 1.13.1 Load Distribution Calculations - Driver and Passenger Weight Distribution............................................24 1.13.2 Center of Gravity.................................26 1.14 Towing.........................................29 1.14.1 Towing Requirements........................29 1.14.2 Towing...................................................29 1.14.3 Towing capacities...............................29 1.14.4 Towing Specifications.........................30 2 Chassis 2.1 Suspension System......................31 4 Electrical 4.1 Battery and Cables......................32 4.1.1 Battery Information.............................32 4.1.2 Generator and Alternator..................33 4.2 Exterior Lighting..........................34 4.2.1 Reversing Lamps................................34 4.2.2 Additional External Lamps.................34 4.2.3 Lamps – Hazard / Direction Indication..............................................34 4.2.4 Electrically operated Door Mirrors...................................................34 5 Body and Paint 5.1 Body.............................................35 5.1.1 Body Structures - General Information...........................................35 5.1.2 Integrated Bodies and Conversions.........................................35 5.1.3 Chassis Cab.........................................36 5.1.4 Front End Integrity for Cooling, Crash, Aerodynamics and Lighting...............42 5.1.5 Tipper Bodies.......................................42 5.1.6 Tank and Dry Bulk Carriers................42 5.1.7 Roof Racks...........................................43 5.2 Air Bag Supplemental Restraint System (SRS)...............................45 5.2.1 Air Bags.................................................45 5.3 Safety Belt System.......................48 5.4 Corrosion Prevention..................49 5.4.1 General .................................................49 5.4.2 Repairing Damaged Paint..................49 5.4.3 Under Body Protection and Material .................................................49 5.4.4 Painting Road Wheels........................49 5.4.5 Contact Corrosion..............................49 5.5 Frame and Body Mounting...........50 5.5.1 Mounting Points and Tubing.............50 5.5.2 Self-Supporting Body Structure........51 5.5.3 Frame Drilling and Tube Reinforcing...........................................52 5.5.4 Ancillary Equipment - Sub Frame Mounting..............................................52 5.5.5 Area for Fitting Additional Body Attachments to the Rear of the Bumper . ...............................................52 5.5.6 Water Tank on Camper Vehicles......53 Table of Contents 3 BACK TO TO FOREWORD & TO MODEL INDEX TO MODEL INDEX Body and Equipment Mounting Manual Ford Ranger 2011.5

1.1 About This Manual 1.1.1 Introduction 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. This guide is published by Ford and provides general descriptions and advice for converting vehicles. These requirements must be complied with before a Ford Dealer should take delivery of motor vehicle accessories from an external supplier either for themselves or on behalf of a motor vehicle client. It must be emphasized that any change to the basic vehicle which does not meet the enclosed 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. 1.1.2 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. 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. 1.1.3 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. NOTE: Notes are used to provide additional essential information required to carry out a complete and satisfactory repair. As you read through this manual, you will come across WARNINGS, CAUTIONS and NOTES. 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). 1.1.4 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. Date of Publication: 05/2011 FordRanger 2011.5 BACK TO CHAPTER INDEX TO MODEL INDEX 1 General Information FORD RANGER 2011.5MY BODY AND EQUIPMENT MOUNTING MANUAL

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. 1.2.3 Legal and Vehicle Type Approval • All components embodied on Ford vehicles are approved to the applicable legal requirements. • Ford vehicles have Type Approval for the intended marketing territories. 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. 1.2.4 Alternative Type Approval 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. • Faulty design, production, installation, assembly or alteration not originally specified by Ford. • Failure to comply with the basic fit for purpose principles inherent in the original product. WARNINGS: Do not exceed the gross vehicle mass, gross train mass, axle plates and trailer plate. Do not change the tire size or load rating. Date of Publication: 05/2011 FordRanger 2011.5 BACK TO CHAPTER INDEX TO MODEL INDEX FORD RANGER 2011.5MY BODY AND EQUIPMENT MOUNTING MANUAL

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. 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. 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. 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. 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. 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 Air Bag Supplemental Restraint System (SRS) (page 45). 1.2.9 Drilling and Welding Drilling and welding of frames and body structures have to be conducted following the guidelines within this document. 1.2.10 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. Date of Publication: 05/2011 FordRanger 2011.5 BACK TO CHAPTER INDEX TO MODEL INDEX FORD RANGER 2011.5MY BODY AND EQUIPMENT MOUNTING MANUAL

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: 05/2011 FordRanger 2011.5 BACK TO CHAPTER INDEX TO MODEL INDEX FORD RANGER 2011.5MY BODY AND EQUIPMENT MOUNTING MANUAL

1.4 Electromagnetic Compatibility (EMC) 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. Frequency Overview Antenna Position Maximum Output Power Watts (Peak RMS) Frequency Band MHz 1 50W 1-30 1 50W 30-54 1 50W 68-87.5 1 50W 142-176 1 50W 380-512 1 10W 806-940 1 2W* 806-940 1 10W 1200-1400 1 10W 1710-1885 1 1W* 1710-1885 1 10W 1885-2025 1 1W* 1885-2025 Anywhere 0.1W 2400-2500 * Only for GSM/3G cellular phones, with a patch antenna installed inside of the front windscreen Date of Publication: 05/2011 FordRanger 2011.5 BACK TO CHAPTER INDEX TO MODEL INDEX FORD RANGER 2011.5MY BODY AND EQUIPMENT MOUNTING MANUAL

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 Date of Publication: 05/2011 FordRanger 2011.5 BACK TO CHAPTER INDEX TO MODEL INDEX FORD RANGER 2011.5MY BODY AND EQUIPMENT MOUNTING MANUAL 1 E134105

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. Date of Publication: 05/2011 FordRanger 2011.5 BACK TO CHAPTER INDEX TO MODEL INDEX FORD RANGER 2011.5MY BODY AND EQUIPMENT MOUNTING MANUAL

2011-2013 Ford Ranger (PX) Service & Repair Manual

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