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.
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
provide 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
five groups, General Information, Chassis,
Powertrain, Electrical and Body. 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 also designed to be used as a
printed document, where there are links page
numbers in brackets have been added, which
will help guide you to the start of 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.
FordTransit 2006.5 (April 2006–)
Date of Publication: 12/2006
1 General Information
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