5 Carroceria e pintura

5 Body and Paint 5.1 Body 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 couldresultinunacceptablehandling 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. Wheelhouse Envelope X A B C D r r E E X E134132 FordRanger 2011.5 • 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. 1 H K L G F X-X Date of Publication: 05/2011

Wheelhouse Dimensions Dimension 215/ 255/ 265/ 265/ Dimension 70R16 70R16 65R17 65R18 A 455mm B 425mm C 305mm D 275mm E 110° F 420mm X Section through Center of Wheelhouse * 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 couldresultinunacceptablehandling 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. FordRanger 2011.5 215/ 255/ 255/ 265/65R17 70R16 70R16 70R16 G* 190mm H 914mm 915mm 922mm 922mm K 588mm L 25mm r 20mm 1 Center line of Vehicle • 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 49). • 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. Date of Publication: 05/2011

Body Attachment Holes in Chassis Frame - Single cab J97 D C F E D K J P375 D E J K E134152 FordRanger 2011.5 B A D G H D L M B A C F G H P N L M Date of Publication: 05/2011

Dimensions (mm) for Body Attachment Holes in Chassis Frame - Single Cab Dimension J97 P375 Dimension J97 P375 A 20 16 B 13 28 C 13 23 D 20 20 E 1150 1244 F 1140 1244 G 1140 1244 FordRanger 2011.5 H 1024 1086 J - 95 K 568 768 L 1007 890 M 496 505 N - 26 P - 20 Date of Publication: 05/2011

Body Attachment Holes in Chassis Frame - Double cab C D H D H E134154 FordRanger 2011.5 B A D F G E D J K B C A E F G M L J K Date of Publication: 05/2011

Dimensions (mm) for Body Attachment Holes in Chassis Frame - Double cab Dimension J97 P375 Dimension J97 P375 A 20 16 B 13 28 C 13 23 D 20 20 E 1130 1244 F 1140 1244 FordRanger 2011.5 G 1024 1024 H - 95 J 776 890 K 498 505 L - 26 M - 20 Date of Publication: 05/2011

Body Attachment Holes in Chassis Frame - Stretch cab C E D D H E134153 FordRanger 2011.5 B A D F G D J K B A C F G E M L J K Date of Publication: 05/2011

Dimensions (mm) for Body Attachment Holes in Chassis Frame - Stretch Cab Dimension J97 P375 Dimension J97 P375 A 20 16 B 13 28 C 13 23 D 20 20 E 1130 1244 F 1140 1244 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 49). 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. For tipper sub-frames please refer to the following guidelines: • 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. FordRanger 2011.5 G 1024 1024 H - 95 J 776 1188 K 498 505 L - 26 M - 20 • 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. 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: • 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. Date of Publication: 05/2011

• Compliant mounts should be used, with up • The load is evenly distributed (converter to to plus and minus 12mm compliance with the ensure owner’s information book identifies vehicle laden or un-laden (whichever is worst this limitation). 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. 5.1.7 Roof Racks Roof racks may be fitted to all variants as illustrated in figure, providing the following is satisfied: • 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). FordRanger 2011.5 • The rack and subsequent carried load is supported in the roof drip rails irrespective of rack retaining method. Double Cab / Stretch Cab 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. Ensure that the planned loaded vehicle operates within its designed Center of Gravity condition. For details please consult the Ford dealer. Date of Publication: 05/2011

Roof Rack Vehicle Converter Special Fit 1 E134129 Item 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 FordRanger 2011.5 2 3 4 5 6 Description Date of Publication: 05/2011

5.2 Air Bag Supplemental Restraint System (SRS) 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. Driver and Passenger Front Airbag Deployment Zones D E F E134101 Dimensions (mm) A 400 B 700 C 700 FordRanger 2011.5 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. Drilling or grinding operations in this area are only permitted when battery cables are disconnected. A B C D 660 E 630 F 700 Date of Publication: 05/2011

Side Airbag Driver and Passenger Front Airbag Deployment Zones A E134609 Dimensions (mm) A 550 B 350 Curtain Airbag - Single cab Driver and Passenger Front Airbag Deployment Zones C B E136172 Dimensions (mm) A 140 B 40 FordRanger 2011.5 C B C 250 A D C 250 D 100 Date of Publication: 05/2011

Curtain Airbag - Double cab Driver and Passenger Front Airbag Deployment Zones B E134610 Dimensions (mm) A 140 B 40 Curtain Airbag - Stretch cab Driver and Passenger Front Airbag Deployment Zones B E136173 Dimensions (mm) A 140 B 40 FordRanger 2011.5 A C D C 250 D 100 A C D C 250 D 100 Date of Publication: 05/2011

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. FordRanger 2011.5 Date of Publication: 05/2011

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. FordRanger 2011.5 Date of Publication: 05/2011

5.5 Frame and Body Mounting 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. Frame Drilling and Welding A B E134173 Dimensions (mm)for Body Attachment Holes in chassis Frame Top Flange Medium Wheelbase A 19 B 11 C 100 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. FordRanger 2011.5 NOTE: After drilling, deburr and countersink all holes and remove chips from the frame. Follow corrosion prevention. Refer to: 5.4 Corrosion Prevention (page 49). C D F E D 110 E Do not drill within 20mm hole, or in the areas shaded in green. F No more than 2 holes to be drilled in a vertical line. 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: 05/2011

Typical Design Principle of a Self-Supporting Body Structure 8 7 E74576 Item 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 35). FordRanger 2011.5 3 2 1 4 5 6 Description 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. Date of Publication: 05/2011

Alternatively, the self-supporting body structure • Holes should be in groups of two (2), either can also be designed as shown in figure shown. vertically spaced at 30 to 35mm from chassis frame top and/or bottom surface, or • 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. • Drill frame and add spacer tubes. Refer to: 5.5 Frame and Body Mounting (page 50). • 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 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 49). FordRanger 2011.5 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. Avoid drilling into closed frame body members to avoid the risk of corrosion from swarf. Refer to: 5.4 Corrosion Prevention (page 49). 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: 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. 5.5.5 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. Date of Publication: 05/2011

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. FordRanger 2011.5 Date of Publication: 05/2011

A H About This Manual..................................................4 Hardware—Specifications..................................23 Index Additional External Lamps..................................34 Aids for Vehicle Entry and Exit............................16 Air Bags..................................................................45 Air Bag Supplemental Restraint System (SRS)....................................................................45 Alternative Type Approval.....................................5 Ancillary Equipment - Sub Frame Mounting....52 Area for Fitting Additional Body Attachments to the Rear of the Bumper....................................52 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 D Drilling and Welding................................................6 Driver Field of View...............................................16 Driver Reach Zones..............................................16 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 How to Use This Manual.......................................4 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 Distribution—Specifications......................24 Load Distribution Calculations - Driver and Passenger Weight Distribution........................24 M Minimum Requirements for Brake system and Load Apportioning Valves...................................6 Mounting Points and Tubing..............................50 N Noise, Vibration and Harshness (NVH)..............14 P Package and Ergonomics—Specifications.......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

T Tank and Dry Bulk Carriers................................42 Terminology............................................................5 Tipper Bodies.......................................................42 Towing capacities...............................................29 Towing Requirements........................................29 Towing Specifications.........................................30 Towing...................................................................29 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 Index 55