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REPAIR MANUAL
WIRING DIAGRAM
BODY & EQUIPMENT MOUNTING MANUAL
TO MODEL INDEX
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
1.10 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
ErgonomicsSpecifications........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
1.12 HardwareSpecifications...........23
1.13 Load
DistributionSpecifications........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
1.14.2
1.14.3
1.14.4
Towing Requirements........................29
Towing...................................................29
Towing capacities...............................29
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
Table of Contents
TO MODEL INDEX
TO MODEL INDEX
1 General Information
1.1 About This Manual
1.1.1 Introduction
FordRanger 2011.5
TO MODEL INDEX
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.
FordRanger 2011.5
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Do not modify the steering 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.
FordRanger 2011.5
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Operating conditions.
FordRanger 2011.5
TO MODEL INDEX
Antenna Position
1-30
50W
30-54
50W
68-87.5
50W
142-176
50W
380-512
50W
806-940
10W
806-940
2W*
1200-1400
10W
1710-1885
10W
1710-1885
1W*
1885-2025
10W
1885-2025
1W*
2400-2500
0.1W
Anywhere
* Only for GSM/3G cellular phones, with a patch antenna installed inside of the front windscreen
FordRanger 2011.5
TO MODEL INDEX
E134105
With ignition ON
FordRanger 2011.5
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FordRanger 2011.5
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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.
FordRanger 2011.5
E140512
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All Vehicles
E133942
FordRanger 2011.5
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Dimensions - not to exceed for Chassis Cab body Length
Description
Single
Cab
Stretch
Cab
Double
Cab
2251
1781
1483
Maximum recommended external body height 2.4m over the top of frame
F
G
H
J
1241
771
473
Clearance between the back of the cab and the 25mm Minimum
body
Ensure local lighting legislation is maintained
Clearance between the top of the cab and the 30mm
body
Maximum external body width
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.
FordRanger 2011.5
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A
E134164
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Chassis Cab Body - Basic Dimensions and Weights
Description
A
Single
Cab
Wheelbase (mm)
1703
Double
Cab
1706
1716
5110
Stretch
Cab
Wheelbase (mm)
3220
1590
1560
1590
1560
985
2925
3200
1325
1480
1755
1850
1815 - 1821
TBC
TBC
TBC
TBC
Model
Double Cab
TBC
TBC
TBC
FordRanger 2011.5
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Stretch Cab
Model
TBC
TBC
TBC
TBC
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1.12 HardwareSpecifications
Material Specification, Strength and Torque
Standard Hardware and Tightening Torques (Nm) Bolts/Studs: ISO 898-1, Nuts: ISO
898-2
Grade 4.8
Thread Size
Grade 8.8
Minimum Maximum
Grade 10.9
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
FordRanger 2011.5
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E133921
3220
FordRanger 2011.5
1490
On Front Axle
On Rear Axle
Total
40
35
75
TO MODEL INDEX
Stretch Cab
A
B
E134584
4x2
2395
3220
740
4x2
2365
3435
590
4x4
2365
3435
590
FordRanger 2011.5
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1.14 Towing
1.14.1 Towing Requirements
1.14.2 Towing
For towing devices fitted by the Vehicle
Converter the following applies:
Drive
Transmission
Without
trailer brake
kg (lbs)
With trailer
brake kg
(lbs)
Trailer nose
weight kg
(lbs)
2.5L Petrol
4X2
Manual
750 (1653.5)
2200 (4850)
250 (551)
2.2L Diesel
(110kW)
4x2
3.2L Diesel
Manual
750 (1653.5)
2500 (5511)
250 (551)
Manual and
Auto
750 (1653.5)
3350 (7385)
335 (738)
4x4
Manual and
Auto
750 (1653.5)
3350 (7385)
335 (738)
4x2
Manual and
Auto
750 (1653.5)
3350 (7385)
335 (738)
4x4
Manual and
Auto
750 (1653.5)
3350 (7385)
335 (738)
4x2
FordRanger 2011.5
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Rest Of World
Variant
Drive
Transmission
Without
trailer brake
kg (lbs)
With trailer
brake kg
(lbs)
Trailer nose
weight kg
(lbs)
2.5L Petrol
4X2
Manual
750 (1653.5)
2200 (4850)
165 (364)
Manual
750 (1653.5)
1700 (3748)
225 (496)
4x4
Manual
750 (1653.5)
1100 (2425)
225 (496)
4X2
Manual
750 (1653.5)
2200 (4850)
165 (364)
4x2
Manual
750 (1653.5)
1600 (3527)
225 (496)
4x4
Manual
750 (1653.5)
1600 (3527)
225 (496)
4x2
2.2L Diesel
(88kW &
92kW)
2.2L Diesel
(110kW)
4x2
Manual
750 (1653.5)
2500 (5511)
165 (364)
Manual
750 (1653.5)
1800 (3968)
225 (496)
Manual
750 (1653.5)
3350 (7385)
225 (496)
4x2
Auto
750 (1653.5)
3350 (7385)
225 (496)
4x4
Manual and
Auto
750 (1653.5)
3350 (7385)
225 (496)
Manual
750 (1653.5)
1800 (3968)
225 (496)
Manual
750 (1653.5)
3350 (7385)
225 (496)
4x2
Auto
750 (1653.5)
3350 (7385)
225 (496)
4x4
Auto
750 (1653.5)
3350 (7385)
225 (496)
3.2L Diesel
FordRanger 2011.5
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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.
FordRanger 2011.5
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4 Electrical
Delayed Vehicles
FordRanger 2011.5
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Battery
Supplier
Specifications
Size
Siam GS
T6
First National
Battery
T6
Moura
T6
Siam GS
T7
First National
Battery
T7
Moura
T7
Battery Rules:
FordRanger 2011.5
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Controlling Device
Vehicle
Trailer Tow
2x5W
5W
21W
Brake lamps
21W
28W
21W
24W
Reverse lamp
21W
24W
21W
48W
28W
Trailer tow maximum power ratings shown, also see trailer tow below.
Lighting Fuses
F74
20A
Headlamp
F75
15A
F76
10A
Reversing lamp
Trailer Tow
Vehicles fitted with a trailer tow as standard also
come with a trailer control module for lighting.
When fitting low power LED lights that require
less than 2W, the lights may flicker when in use.
A trailer patch harness should be used with low
power LED lights.
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.
FordRanger 2011.5
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Wheelhouse Envelope
X
H
A
C
r
E
r
E
X-X
X
E134132
FordRanger 2011.5
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Wheelhouse Dimensions
Dimension
215/
255/
265/
265/ Dimension
70R16 70R16 65R17 65R18
215/
70R16
255/
70R16
255/
70R16
455mm
G*
190mm
425mm
305mm
588mm
275mm
25mm
110
20mm
420mm
265/65R17
922mm
FordRanger 2011.5
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Body Attachment Holes in Chassis Frame - Single cab
J97
A
D
F
D
D
P375
A
C
E
P
N
J
K
E134152
FordRanger 2011.5
TO MODEL INDEX
Dimensions (mm) for Body Attachment Holes in Chassis Frame - Single Cab
Dimension
J97
P375
Dimension
J97
P375
20
16
1024
1086
13
28
95
13
23
568
768
20
20
1007
890
1150
1244
496
505
1140
1244
26
1140
1244
20
FordRanger 2011.5
TO MODEL INDEX
Body Attachment Holes in Chassis Frame - Double cab
A
D
B
C
A
D
M
L
E134154
FordRanger 2011.5
TO MODEL INDEX
Dimensions (mm) for Body Attachment Holes in Chassis Frame - Double cab
Dimension
J97
P375
Dimension
J97
P375
20
16
1024
1024
13
28
95
13
23
776
890
20
20
498
505
1130
1244
26
1140
1244
20
FordRanger 2011.5
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Body Attachment Holes in Chassis Frame - Stretch cab
A
D
B
D
M
L
H
J
E134153
FordRanger 2011.5
TO MODEL INDEX
Dimensions (mm) for Body Attachment Holes in Chassis Frame - Stretch Cab
Dimension
J97
P375
Dimension
J97
P375
20
16
1024
1024
13
28
95
13
23
776
1188
20
20
498
505
1130
1244
26
1140
1244
20
FordRanger 2011.5
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FordRanger 2011.5
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Roof Rack Vehicle Converter Special Fit
2
1
3
E134129
Item
Description
80kg Maximum
Drain Channel
FordRanger 2011.5
TO MODEL INDEX
A
D
E
C
F
E134101
Dimensions (mm)
A
400
660
700
630
700
700
FordRanger 2011.5
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Side Airbag
E134609
Dimensions (mm)
A
550
350
250
C
D
B
E136172
Dimensions (mm)
A
140
250
40
100
FordRanger 2011.5
TO MODEL INDEX
C
D
B
E134610
Dimensions (mm)
A
140
250
40
100
C
D
B
E136173
Dimensions (mm)
A
140
250
40
100
FordRanger 2011.5
TO MODEL INDEX
FordRanger 2011.5
TO MODEL INDEX
FordRanger 2011.5
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F
E
B
E134173
Dimensions (mm)for Body Attachment Holes in chassis Frame Top Flange Medium
Wheelbase
A
19
110
11
100
FordRanger 2011.5
TO MODEL INDEX
Typical Design Principle of a Self-Supporting Body Structure
8
3
2
1
5
7
E74576
Item
Description
Floor Panel
Longitudinal L-profile
Also see:
Refer to: 5.1 Body (page 35).
FordRanger 2011.5
TO MODEL INDEX
Alternatively, the self-supporting body structure
can also be designed as shown in figure shown.
FordRanger 2011.5
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It is not the manufactures recommendation to
fit additional body attachments (Tow bars, Steps,
Bicycle racks & Carriers) outside of the
designated area.
FordRanger 2011.5
Index
TO MODEL INDEX
HardwareSpecifications..................................23
How to Use This Manual.......................................4
B
Battery and Cables..............................................32
Battery Information..............................................32
Body.......................................................................35
Body Structures - General Information............35
C
Center of Gravity..................................................26
Chassis Cab Body - Basic Dimensions and
Weights.................................................................19
Chassis Cab..........................................................36
Commercial and Legal Aspects...........................5
Contact Corrosion...............................................49
Conversion Affect on Fuel Economy and
Performance........................................................10
Conversion Affects on Parking Aids..................16
Conversion Homologation....................................7
Corrosion Prevention..........................................49
I
Important Safety Instructions...............................4
Integrated Bodies and Conversions.................35
Introduction.............................................................4
J
Jacking....................................................................11
K
Kerb Weights.........................................................21
L
Lamps Hazard / Direction Indication..............34
Legal and Vehicle Type Approval.........................5
Legal Obligations and Liabilities............................5
Lifting.......................................................................13
Load DistributionSpecifications......................24
Load Distribution Calculations - Driver and
Passenger Weight Distribution........................24
N
Noise, Vibration and Harshness (NVH)..............14
E
Electrically operated Door Mirrors.....................34
Electromagnetic Compatibility (EMC).................8
Exterior Lighting....................................................34
F
Frame and Body Mounting................................50
Frame Drilling and Tube Reinforcing.................52
Front, Rear and Side Under-run Protection.....22
Front End Integrity for Cooling, Crash,
Aerodynamics and Lighting..............................42
G
General Component Package Guidelines........16
General..................................................................49
General Product Safety Requirement.................5
Generator and Alternator...................................33
54
P
Package and ErgonomicsSpecifications.......17
Package and Ergonomics...................................16
Painting Road Wheels.........................................49
Product Liability.......................................................6
R
Recommended Body Dimensions.....................17
Repairing Damaged Paint...................................49
Restraints System..................................................6
Reversing Lamps.................................................34
Road Safety.............................................................6
Roof Racks............................................................43
S
Safety Belt System...............................................48
Self-Supporting Body Structure.........................51
Suggested Antenna Location..............................9
Suspension System..............................................31
TO MODEL INDEX
T
Index
U
Under Body Protection and Material...............49
V
Vehicle Duty Cycle Guidelines...........................10
Vehicle Ride and Handling Attributes................10
Vehicle Transportation Aids and Vehicle
Storage................................................................15
W
Warnings, Cautions and Notes in This
Manual...................................................................4
Warranty on Ford Vehicles...................................5
Water Tank on Camper Vehicles......................53
55