FORD Ranger 2019

Body and Equipment Mounting Manual

E289759

Date of Publication: 07/2018

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 2018

All rights reserved.

 Table of Contents
1.14.1 Towing Requirements..............................30
1 General Information 1.14.2 Towing...........................................................30
1.14.3 Towing capacities.....................................30
1.1 About this Manual...............................5 1.14.4 Trailer Towball Download........................31
1.1.1 New for this BEMM publication 1.14.5 Towing Specifications...............................31
07/2018............................................................5
1.1.2 Introduction....................................................5
1.1.3 Important Safety Instructions.................5
1.1.4 Warnings, Cautions and Notes in This 2 Chassis
Manual.............................................................5
1.1.5 How to Use This Manual...........................5
1.1.6 Low Level and High Level 2.1 Suspension System...........................32
Vehicles............................................................6 2.2 Brake System.....................................33
1.2 Commercial and Legal Aspects..........7 2.2.1 General..........................................................33
1.2.1 Terminology....................................................7 2.2.2 Brake Hoses.................................................33
1.2.2 Warranty on Ford Vehicles........................7 2.2.3 Trailer Brakes ..............................................33
1.2.3 Legal and Vehicle Type Approval...........7
1.2.4 Alternative Type Approval.........................7
1.2.5 Legal Obligations and Liabilities.............7
1.2.6 General Product Safety 3 Powertrain
Requirement...................................................7
1.2.7 Product Liability............................................8
1.2.8 Restraints System........................................8 3.1 Fuel System.......................................35
1.2.9 Drilling and Welding....................................8 3.1.1 Fuel Filler Pipe Shipping Bracket (if
1.2.10 Minimum Requirements for Brake equipped).....................................................35
system and Load Apportioning Valves 3.1.2 Fuel Filler Mounting...................................37
.............................................................................8 3.1.3 Fuel Filler Vent Hose................................39
1.2.11 Road Safety....................................................8 3.1.4 Axle Breather Vent Hose........................40
1.3 Conversion Homologation..................9
1.4 Electromagnetic Compatibility
(EMC).................................................10
1.4.1 Electromagnetic Compatibility.............10 4 Electrical
1.5 Vehicle Duty Cycle Guidelines...........12
1.5.1 Conversion Effect on Fuel Economy
and Performance........................................12 4.1 Battery and Cables.............................41
1.5.2 Vehicle Ride and Handling 4.1.1 Battery Information...................................41
Attributes.......................................................12 4.1.2 Generator and Alternator........................47
1.6 Jacking................................................13 4.2 Electronic Engine Controls...............48
1.7 Lifting.................................................14 4.2.1 Vehicle Speed Output (Signal) (Low
1.8 Noise, Vibration and Harshness Level Vehicles Only).................................48
(NVH).................................................15 4.2.2 Vehicle Speed Output (Signal) (High
1.9 Vehicle Transportation Aids and Level Vehicles )...........................................54
Vehicle Storage..................................16 4.3 Exterior Lighting................................55
1.10 Package and Ergonomics...................17 4.3.1 Rear Combination lamps.......................56
1.10.1 General Component Package 4.3.2 Rear Fog Lamp...........................................56
Guidelines......................................................17 4.3.3 Rear License Plate Lamp........................57
1.10.2 Driver Reach Zones.....................................17 4.3.4 Reversing Lamps, Rear View Camera,
1.10.3 Driver Field of View.....................................17 Reversing Alarm (Manual
1.10.4 Conversion Effects on Parking Transmission).............................................59
Aids...................................................................17 4.3.5 Additional External Lamps - (Low
1.10.5 Aids for Vehicle Entry and Exit...............17 Level Vehicles Only).................................59
1.10.6 Registration Plates.....................................18 4.3.6 Trailer Towing.............................................60
1.11 Package and 4.3.7 Auxiliary Lighting Loads (Low Level
Ergonomics—Specifications.............19 Vehicles Only).............................................62
1.11.1 Recommended Body Dimensions.......19 4.3.8 Lamps – Hazard / Direction
1.11.2 Chassis Cab Body - Basic Dimensions Indication......................................................63
and Weights................................................20 4.3.9 Electrically Operated Door
1.11.3 Kerb Mass and Payload............................21 Mirrors............................................................63
1.11.4 Front, Rear and Side Under-run 4.3.10 Centre High Mount Stop Lamp
Protection......................................................21 (CHMSL) - Canopy Fitment -Low
1.12 Hardware—Specifications................22 Level Vehicles..............................................63
1.13 Load 4.3.11 Centre High Mount Stop Lamp
Distribution—Specifications............23 (CHMSL) - Canopy Fitment - High
1.13.1 Load Distribution Calculations - Driver Level Vehicles.............................................64
and Passenger Weight 4.4 Handles, Locks, Latches and Entry
Distribution...................................................23 Systems.............................................66
1.13.2 Center of Gravity........................................26 4.4.1 Central Locking..........................................66
1.14 Towing...............................................30 4.5 Fuses and Relays...............................67

3
Table of Contents 4.5.1 Low Level and High Level Vehicles.......67
4.5.2 Auxiliary Battery and Fuse Box - Low
Level Vehicles...............................................67
4.5.3 Auxiliary Fuse Box (Vehicles with
Special Equipment Pack) (Low Level
Vehicles Only)..............................................68

5 Body and Paint

5.1 Body.....................................................71
5.1.1 Body Structures - General
Information.....................................................71
5.1.2 Integrated Bodies and
Conversions....................................................71
5.1.3 Chassis Cab...................................................72
5.1.4 Front End Integrity for Cooling, Crash,
Aerodynamics and Lighting....................75
5.1.5 Tipper Bodies................................................75
5.1.6 Tank and Dry Bulk Carriers......................76
5.1.7 Genuine Ford Accessory Bull Bar..........76
5.1.8 Roof Racks.....................................................77
5.1.9 Canopies........................................................78
5.2 Airbag Supplemental Restraint
System (SRS).....................................81
5.2.1 Air Bags - (Low Level Vehicles)..............81
5.2.2 Air Bags - (High Level Vehicles)............84
5.2.3 Supplementary Restraint Sensors
(Front).............................................................87
5.3 Seatbelt Systems – Australia...........89
5.4 Corrosion Prevention.........................90
5.4.1 General...........................................................90
5.4.2 Repairing Damaged Paint.......................90
5.4.3 Under Body Protection and
Material..........................................................90
5.4.4 Painting Road Wheels..............................90
5.4.5 Contact Corrosion......................................90
5.5 Frame and Body Mounting.................91
5.5.1 Mounting Points and Tubing...................91
5.5.2 Self-Supporting Body Structure...........92
5.5.3 Frame Drilling and Tube
Reinforcing....................................................93
5.5.4 Ancillary Equipment - Sub Frame
Mounting........................................................93
5.5.5 Area for Fitting Additional Body
Attachments to the Rear of the
Bumper. .........................................................93
5.5.6 Water Tank on Camper Vehicles...........93

4
 1 General Information
1.1 About this Manual
1.1.1 New for this BEMM publication Ford cannot guarantee the operation of the
07/2018 vehicle if non-Ford approved electrical systems
are installed. Ford electrical systems are designed
It is recommended to review this manual in full. and tested to function under operational
The BEMM is a live document which can be viewed extremes, and have been subjected to the
on www.etis.ford.com/BEMM or equivalent of ten years of driving under such
http://www.fordtechservice.dealerconnection.com/. conditions.
It is the vehicle converters responsibility to review
the online version for the most current information
prior to starting any conversion. For an overview 1.1.3 Important Safety Instructions
of the main differences please see below.
Appropriate conversion procedures are essential
The following sections of the manual have been for the safe, reliable operation of all vehicles as
updated to support the Model Year 19 Ranger well as the personal safety of the individual
MCA: carrying out the work.
• Trailer Brake Controller implementation. This manual cannot possibly anticipate all such
Refer to: 2.2 Brake System (page 33). variations and provide advice or cautions as to
each. Anyone who departs from the instructions
• Battery Specifications.
provided in this manual must first establish that
Refer to: 4.1 Battery and Cables (page 41). they compromise neither their personal safety nor
• Electromagnetic Compatibility (EMC) the vehicle integrity by their choice of methods,
Specifications. tools or components.
Refer to: 1.4 Electromagnetic Compatibility
(EMC) (page 10). 1.1.4 Warnings, Cautions and Notes in
• Towing Specifications. This Manual
Refer to: Towing (page ?). WARNING: Warnings are used to indicate
• that failure to follow a procedure
correctly may result in serious injury or
death.
1.1.2 Introduction
CAUTION: Cautions are used to indicate
NOTE: Printed copies are uncontrolled. that failure to follow a procedure
correctly may result in damage to the
This manual has been written in a format that is vehicle or equipment being used.
designed to meet the needs of Vehicle Converters.
The objective is to use common formats with the NOTE: Notes are used to provide additional
workshop manual which is used by technicians essential information required to carry out a
worldwide. complete and satisfactory repair.
This guide is published by Ford and provides As you read through this manual, you will come
general descriptions and advice for converting across WARNINGS, CAUTIONS and NOTES.
vehicles. These requirements must be complied A warning, caution or note is placed at the
with before a Ford Dealer should take delivery of beginning of a series of steps if it applies to
motor vehicle accessories from an external multiple steps. If the warning, caution or note only
supplier either for themselves or on behalf of a applies to one step, it is placed at the beginning
motor vehicle client. 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
1.1.5 How to Use This Manual
of the vehicle to perform its function. Mechanical
This manual covers vehicle conversion procedures.
failures, structure failure, component unreliability
or vehicle instability will lead to customer The pages at the start of this manual list the
dissatisfaction. Appropriate design and content, by group. A group covers a specific
application of body, equipment and or accessories portion of the vehicle. The manual is divided into
is key to ensuring that customer satisfaction is four groups, General Information, Chassis,
not adversely affected. Electrical, Body and Paint. The number of the
group is the first number of a section number.
The information contained within this publication
Each title listed in the contents links to the
takes the form of recommendations to be
relevant section of the manual.
followed when vehicle modifications are
undertaken. It must be remembered that certain In some section of the book it may refer you to
modifications may invalidate legal approvals and see additional sections for information, links have
application for re-certification may be necessary. been provided, these links are in blue text.

FAPA FORD RANGER 2019 2019 Date of Publication: 07/2018 5

1 General Information 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.

1.1.6 Low Level and High Level Vehicles

WARNING: Prior to work on any vehicle
being undertaken it is critical to identify
the type of electrical architecture the
vehicle at hand is equipped with. Failure
to identify the type of electrical
architecture present on the vehicle prior
to work being undertaken may cause
electrical damage or have safety
implications.
Ford Ranger PX MkII vehicles are equipped with
one of two electrical architectures.
Refer to: 4.5 Fuses and Relays (page 67).

6 Date of Publication: 07/2018 FORD RANGER 2019 2019 FAPA

 1 General Information
1.2 Commercial and Legal Aspects
1.2.1 Terminology
1.2.4 Alternative Type Approval
NOTE: Any modifications to the vehicle must be
noted in the owner's handbook or new descriptive If significant changes are made the Body Builder
literature included with the owner's must negotiate with the relevant authority. Any
documentation. changes to the vehicle operating conditions must
Vehicle Converter refers to any re-seller altering be advised to the customer.
the vehicle by converting the body and adding or
modifying any equipment not originally specified 1.2.5 Legal Obligations and Liabilities
and or supplied by Ford.
Unique component or similar wording refers to The Vehicle Converter should consult with its legal
non-Ford specified or after sale fitment not advisor on any questions concerning its legal
covered by Ford warranty. obligations and liabilities.
Ford recommends that the Vehicle Converter and
1.2.2 Warranty on Ford Vehicles Ford Dealer must understand their individual and
joint responsibilities in supplying a safe and
Please contact The National Sales Company in compliant motor vehicle fitted with safe and
the country where the vehicle will be registered compliant accessories.
or refer to the vehicle Owner Guide for details of
the terms of any applicable Ford warranty. 1.2.6 General Product Safety
The Vehicle Converter should warrant its design, Requirement
materials and construction for a period at least
equal to any applicable Ford warranty. The Vehicle Converter shall ensure that any
vehicle it places on the market complies with all
The Vehicle Converter must ensure that any local laws, including laws relating to the safe
alteration made to a Ford vehicle or component carriage of loads on public roads. The Vehicle
does not reduce the safety, function, or durability Converter shall also ensure that any alteration it
of the vehicle or any component. makes to a Ford vehicle or component does not
The Vehicle Converter shall be solely responsible reduce its compliance with local design rules.
for any damage resulting from any alteration The Vehicle Converter must provide sufficient
made by the Vehicle Converter or any of its agents Load Restraint tie down points or
to a Ford Vehicle Component. compartmentalised storage areas that enable
The Vehicle Converter releases Ford from all the driver to safely carry loads that match the use
claims by any third party for any cost or loss criteria for which the body was designed.
(including any consequential damages) arising The Vehicle Converter shall release Ford from all
from work performed by a Vehicle Converter liability for damages resulting from:
unless Ford has given its prior written consent to
such liability. • 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
• All components embodied on Ford vehicles are by Ford.
approved to the applicable legal requirements. • Failure to comply with the basic fit for purpose
• Ford vehicles have Type Approval for the principles inherent in the original product.
intended marketing territories.
WARNINGS:
WARNING: Exception - Incomplete
Do not exceed the gross vehicle mass,
vehicles require further approval when
gross combination mass, axle ratings and
completed by the Body Builder.
trailer rating.
• The Ranger range has Type Approval for many
territories, although the full range of vehicles Do not change the tire size or load rating.
shown in this manual are not necessarily
released in all territories. Check with your local Do not modify the steering system.
Ford National Sales Company representative.
• Significant changes to the vehicle may affect Excessive heat can build up from the
its legal compliance. Strict adherence to the exhaust system, in particular from the
original design intent for brakes, weight catalytic converter and from the Diesel
distribution, lighting, electrical systems, Particulate Filter (DPF). Ensure adequate
occupant safety and hazardous materials heat shields are maintained. Maintain
compliance in particular is mandatory. sufficient clearance to hot parts.

FAPA FORD RANGER 2019 2019 Date of Publication: 07/2018 7

1 General Information Do not modify or remove heat protection Do not alter, modify or relocate the airbag,
shields. sensor and modules of the restraints
system or any of its components.
Do not route any electrical cables with the
Anti-lock Brakes System and Traction Attachments or modifications to the front
Control System cables because of end of the vehicle may affect the airbag
extraneous signal risk. Do not hang fire timing and result in uncontrolled
electrical cables off existing looms or deployment.
pipes.
Modifications to the B-Pillar body
Do not change original location or remove structure may affect the side airbag fire
warning labels provided with the base timing and result in uncontrolled side
vehicle in view to the driver. Ensure that airbag deployment.
labels in view to the driver in the base Refer to: 5.2 Airbag Supplemental Restraint
vehicle remain in full view to the driver System (SRS) (page 81).
after any conversion.
NOTE: For further information please contact your
local National Sales Company representative, or 1.2.9 Drilling and Welding
Local Ford Dealer.
Drilling and welding of frames and body structures
have to be conducted following the guidelines
1.2.7 Product Liability within this document.

The Vehicle Converter shall be liable for any

product liability (whether for death, personal injury, 1.2.10 Minimum Requirements for
or property damage) arising from any alteration Brake system and Load Apportioning
to a Ford vehicle or component made by the Valves
Vehicle Converter or any of its agents. Ford shall
not be liable for any such liability (except as • It is not necessary or recommended to modify
provided by law). the load apportioning valves, however, if a
special conversion should require modifications,
The Vehicle Converter or equipment manufacturer – Maintain original settings.
is liable for the:
– Maintain brake certification load distribution.
• Operational reliability and road-worthiness of
the vehicle to its original intent. • Changes to the Antilock Brake System (ABS),
Traction Control System (TCS) and Electronic
• Operational reliability and road-worthiness of Stability Program (ESP) system are not
any component or conversion, not listed in permitted.
original Ford documentation.
• Operational reliability and road-worthiness of 1.2.11 Road Safety
the vehicle as a whole (for example the body
changes and/or additional equipment must not The respective instructions should be strictly
have a negative effect on the driving, braking observed to maintain operational and road safety
or steering characteristics of the vehicle). of the vehicle.
• Any 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.

8 Date of Publication: 07/2018 FORD RANGER 2019 2019 FAPA

 1 General Information
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.

FAPA FORD RANGER 2019 2019 Date of Publication: 07/2018 9

1 General Information 1.4 Electromagnetic Compatibility (EMC)
1.4.1 Electromagnetic Compatibility Keep antenna and power cables at least
100mm from any electronic modules and
WARNINGS: airbags.
Do not place objects or mount equipment NOTE: We test and certify your vehicle to meet
on or near the airbag cover, on the side of electromagnetic compatibility legislation (UNECE
the seatbacks (of the front seats), or in Regulation 10 or other applicable local
front seat areas that may come into requirements). It is your responsibility to make sure
contact with a deploying airbag. Failure that any equipment an authorized dealer installs
to follow these instructions may increase on your vehicle complies with applicable local
the risk of personal injury in the event of legislation and other requirements.
a crash.
NOTE: Any radio frequency transmitter equipment
Do not fasten antenna cables to original in your vehicle (such as cellular telephones and
vehicle wiring, fuel pipes and brake pipes. amateur radio transmitters) must keep to the
parameters in the following table. We do not
provide special provisions or conditions for
installations or use.

E239120

E239122

10 Date of Publication: 07/2018 FORD RANGER 2019 2019 FAPA

 1 General Information
E239121

Frequency Band MHz Maximum Output Power Antenna Position

Watts (Peak RMS)
1-30 50 1
50-54 50 2, 3
68-88 50 2, 3
142-176 50 2, 3
380-512 50 2, 3
806-870 10 2, 3

NOTE: After the installation of radio frequency

transmitters, check for disturbances from and to
all electrical equipment in your vehicle, both in
the standby and transmit modes.
Check all electrical equipment:
• with the ignition ON
• with the engine running
• during a road test at various speeds.
NOTE: Check that electromagnetic fields
generated inside your vehicle cabin by the
transmitter installed do not exceed applicable
human exposure requirements.

FAPA FORD RANGER 2019 2019 Date of Publication: 07/2018 11

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
combination mass, axle ratings 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 Effect on Fuel

Economy and Performance
Any conversion may affect 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 rating,
gross vehicle mass, trailer rating and
gross trailer mass limits.
Due to the displacement of the center of gravity
caused by the conversion the ride and handling
attributes may be different to the base vehicle.
NOTE: The vehicle should be evaluated for safe
operation prior to sale.

12 Date of Publication: 07/2018 FORD RANGER 2019 2019 FAPA

 1 General Information
1.6 Jacking
WARNINGS: WARNING: The jack supplied with this
vehicle is only intended for changing
Ensure screwthread is adequately
wheels. Do not use the vehicle jack other
lubricated before use.
than when you are changing a wheel in
The jack should be used on level firm an emergency.
ground wherever possible.
CAUTION: Make sure that access to the
Switch the ignition off and apply park spare wheel is maintained when
brake fully before lifting vehicle. converting the vehicle or relocating the
It is recommended that the wheels of the spare wheel.
vehicle be chocked, and that no person NOTE: When using the vehicle jack, refer to the
should remain in a vehicle that is being owner guide for correct operating instructions.
jacked.
The spare wheel winch is located above the spare
No person should place any portion of wheel and can be accessed from the rear of the
their body under a vehicle that is chassis frame.
supported by a jack. The jack must be assembled and fixed
WARNING: Do not get under a vehicle appropriately to the body to ensure safety,
that is supported by a jack. durability and accessibility.

E166722

Vehicle Jacking Points and Axle Stand Positions

E212163

FAPA FORD RANGER 2019 2019 Date of Publication: 07/2018 13

1 General Information 1.7 Lifting
WARNING: When lifting the vehicle with CAUTIONS:
a two post lift for the removal of the
engine/transmission or rear axle, make When lifting the vehicle with a two post
sure the vehicle is secured to the lift using lift, vehicle lift arm adapters must be used
vehicle retention straps to prevent tilting. under the lifting points.
Failure to follow these instructions may When lifting the vehicle with a two post
result in serious injury or death. 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

E133943

14 Date of Publication: 07/2018 FORD RANGER 2019 2019 FAPA

 1 General Information
1.8 Noise, Vibration and Harshness (NVH)
WARNING: Make sure that the modified
vehicle complies with all relevant legal
requirements.
Changes to the powertrain, engine, transmission,
exhaust, air intake system or tires may influence
the exterior noise emissions. 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.

FAPA FORD RANGER 2019 2019 Date of Publication: 07/2018 15

1 General Information 1.9 Vehicle Transportation Aids and Vehicle Storage
CAUTIONS: • Where protective film has been applied in
Disconnect the battery if the vehicle is to manufacture it must be left on the vehicle until
be stored for more than 30 days. prepared for delivery but must be removed after
a maximum storage period of six months (film
Make sure that the protective covers are is date stamped to indicate required removal
not removed from an incomplete vehicle date).
until the conversion is started.
• Make sure that all windows, doors, hood,
Make sure that components removed tailgate and luggage compartment lid are
during conversion are kept clean and dry. completely closed and the vehicle is locked.
Make sure that components removed The Pre Delivery Inspection (PDI) is the final
during conversion are refitted to the same opportunity to make sure a battery is fit for
vehicle. purpose prior to the customer taking delivery of
their new vehicle. The battery must be checked
In addition:
and appropriate action taken prior to the vehicle
• The windscreen wipers should be lifted off the being handed over to the customer. Test results
glass and set right up. must be recorded on the PDI repair order.
• All air intakes should be closed. Batteries. To make sure the battery is maintained
• Increase normal tire pressure by 0.5 bar. correctly and to assist in preventing premature
failure, it is necessary to check and recharge the
• The hand brake system should not be used. battery regularly while a vehicle is not in use.
• Apply suitable wheel chocks to prevent roll Where a battery is left below its optimum charge
away. level for any length of time, it may result in
premature failure of the battery.
A significant risk during storage is deterioration of
vehicle bodywork, therefore, appropriate storage Action / Time in Monthly Every 3
procedures must be observed, including periodic storage Months
inspection and maintenance.
Check vehicle is X -
Claims arising from deterioration caused by
clean
incorrect storage, maintenance or handling are not
the responsibility of Ford. Remove external X -
Vehicle Converters must determine their own contamination
procedures and precautions, particularly where Check battery Connected Disconnected
vehicles are stored in the open as they are exposed condition -
to any number of airborne contaminants. Recharge if neces-
The following may be considered a sensible sary
approach to storage: Visually check tires X -
Short Term Storage Check interior for - X
• Wherever possible vehicles should be stored in condensation
an enclosed, dry, well-ventilated area based on
firm, well drained ground which is free of long Run engine for 5 - X
grass or weeds and where possible protected minutes minimum
from direct sunlight. with air conditioning
switched on, where
• Vehicles must not be parked near, under foliage applicable
or close to water as additional protection may
be necessary for certain areas.
To reduce the likelihood of premature battery
Long term storage: failure it is recommended that where:
• Battery to be disconnected but not removed • A battery is left connected – monthly checks
from the vehicle. should be carried out.
• The wiper blades should be removed and • A battery has been disconnected – no greater
placed inside the vehicle. Make sure the wiper than a 3 monthly check should be carried out.
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.

16 Date of Publication: 07/2018 FORD RANGER 2019 2019 FAPA

 1 General Information
1.10 Package and Ergonomics
1.10.1 General Component Package On conversions requiring a rear camera, the
Guidelines reverse signal may be taken as described in the
reversing lamps section.
WARNING: Do not modify, drill, cut or
weld any suspension components, Refer to: Exterior Lighting (page ?).
specifically the steering gear system,
subframe or anti-roll bars, springs or 1.10.5 Aids for Vehicle Entry and Exit
shock absorbers including mounting
brackets.
The Vehicle Converter must ensure that sufficient Steps
clearance is maintained under all drive conditions
to moving components such as axles, fans, WARNINGS:
steering, brake system etc. Make sure that the modified vehicle
The Vehicle Converter is responsible for all complies with all relevant legal
installed components during the conversion. The requirements.
durability must be confirmed by appropriate test If this modification alters the
procedures. homologated dimensions, a new
approval may be necessary.
1.10.2 Driver Reach Zones CAUTION: Make sure that reinforcements
are installed to maintain the integrity of
Controls and/or equipment required to be used the original body structure.
while driving should be located within easy reach
Steps can be ordered as an accessory on the base
of the driver so as not to impair driver control.
vehicle. Please check for availability.
Where additional steps are installed the required
1.10.3 Driver Field of View ground clearance line must be maintained.
WARNING: Make sure that the modified The Vehicle Converter must make sure that a
vehicle complies with all relevant legal movable step is set in the stored position when
requirements. the vehicle is running. The step surface must be
non-slip.

1.10.4 Conversion Effects on Parking

Aids Rear View Mirrors

WARNING: Ensure that monitors NOTE: Overall width with exterior rear view
mounted in the cabin meet the interior mirrors extended is 2163 mm.
package and safety requirements.

FAPA FORD RANGER 2019 2019 Date of Publication: 07/2018 17

1 General Information

E278311

Item Description
X Maximum Body Width: 1860mm

1.10.6 Registration Plates The registration plate must be affixed to the rear
of the motor vehicle so that no part of such
registration plate is more than 1,300 mm from the
Front Registration Plate ground.
WARNINGS:
The mounting of a registration plate to
the front of the vehicle must comply with
ADR 61/02 Clause 9.1.1.2.
No part of a vehicle registration plate may
be obscured by standard equipment,
regular production options or equipment,
in line with ADR 61/02 Clause 9.1.1.3.
The registration plate must be affixed to the front
of the motor vehicle forward of and parallel to the
front ‘Axle’ so that no part of such registration
plate is more than 1,300 mm from the ground.

Rear Registration Plate

WARNINGS:
The mounting of a registration plate to
the rear of the vehicle must comply with
ADR 61/02 Clause 9.1.1.1.
No part of a vehicle registration plate may
be obscured by standard equipment,
regular production options or equipment,
in line with ADR 61/02 Clause 9.1.1.3.

18 Date of Publication: 07/2018 FORD RANGER 2019 2019 FAPA

 1 General Information
1.11 Package and Ergonomics—Specifications
1.11.1 Recommended Body Dimensions NOTE: When extending the length of the frame
rearward of the rear axle, it is recommended that
WARNINGS: the overall rear overhang is limited to a maximum
of 50% of the wheelbase of the vehicle.
Do not modify the wheelbase or add any
type of frame extension to vehicles fitted NOTE: If a towball is fitted to the vehicle, the body
with Electronic Stability Program (ESP). dimensions must incorporate a towball clearance
zone in accordance with local requirements. For
Ensure that any mass added to the additional information, refer to ADR 62/02.
vehicle does not compromise vehicle
stability. If a conversion requires more than 50% overhang,
please contact your local National Sales Company
NOTE: Extreme rear overhang may encourage representative, or Local Ford Dealer.
unacceptable loading conditions, which could
unload the front axle, producing unacceptable Load carrying structures should not be mounted
handling and braking characteristics. Ensure that onto an existing load tray or load box. Body
the centre of gravity of the body and payload does attachment points are provided on the frame.
not fall outside of the recommended zone. Refer to: 5.1 Body (page 71).
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).

Chassis Cab Body - Single Cab Illustrated

F
H

D E
G

B
A

E278312

FAPA FORD RANGER 2019 2019 Date of Publication: 07/2018 19

1 General Information
Dimensions - not to exceed for Chassis Cab body Length
Description Dimension (mm)
Single Cab Super Cab Double Cab
A Frame length behind back of cab (not including rear
2251 1781 1483
light cross-member)
B Under run bar and towing attachment legislation to be maintained
C Maximum recommended external body height 2400 over the top of frame, provided load
distribution requirements are met
D Front outside of body to rear axle 1241 771 473
E Maximum recommended rear overhang 1610 (50% of vehicle wheelbase),
provided load distribution requirements
are met
F Clearance between the back of the cab and the body 25 Minimum
G Ensure local lighting legislation is maintained Refer to: Exterior Lighting (page ?).
H Clearance between the top of the cab and the body 30
J Maximum external body width 1860
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

Chassis Cab Body - Single Cab Illustrated

D F

E278313

20 Date of Publication: 07/2018 FORD RANGER 2019 2019 FAPA

 1 General Information
Chassis Cab Body - Basic Dimensions and Weights
Description Single Super Cab Double
Cab Cab
A Overall length (mm) 5110
B Overall width - excluding exterior mirrors (mm) 1860
C Overall height 4x2 (mm) 1703 1706 1716
C Overall height 4x4 (mm) 1800-1806 1804 - 1810 1815 - 1821
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) 2925
*
- 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) 1850
*
Vehicles with increased ride height.

1.11.3 Kerb Mass and Payload

WARNING: Check local legislation for
legal requirements.
Details of vehicle kerb mass and payload
capacities can be provided by your local National
Sales Company representative.

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.

FAPA FORD RANGER 2019 2019 Date of Publication: 07/2018 21

1 General Information 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
This torque chart is a recommendation and the converter is responsible for the optimal torque for a
specific joint.

22 Date of Publication: 07/2018 FORD RANGER 2019 2019 FAPA

 1 General Information
1.13 Load Distribution—Specifications
1.13.1 Load Distribution Calculations NOTE: Uneven load distribution could result in
- Driver and Passenger Weight unacceptable handling and braking
Distribution characteristics.

CAUTIONS: NOTE: Over loading of the vehicle could result in

unacceptable ground clearance.
Do not exceed the axle ratings.
NOTE: The centre of mass of the body equipment
and the payload it contains should be located
Do not exceed the gross vehicle mass. within the dimensions given.
NOTE: Avoid one-sided load distribution.
Tire manufacturer specification must be
maintained. NOTE: For further information please contact
your local National Sales Company representative,
or Local Ford Dealer.

FAPA FORD RANGER 2019 2019 Date of Publication: 07/2018 23

1 General Information
Single Cab

E278314

Single Cab Driver and Passenger Weight Distribution

'A' Wheelbase 'B' Front row Weight distribution per person (Kg)
(mm) seats and driver
(mm)
On Front Axle On Rear Axle Total
3220 1490 40 35 75

24 Date of Publication: 07/2018 FORD RANGER 2019 2019 FAPA

 1 General Information
Super Cab

B
C
A

E278316

Super Cab Driver and Passenger Weight Distribution

'A' Wheelbase 'B' Front row 'C' Second Weight distribution per person (Kg)
(mm) seats and row seats
driver (mm) (mm)
On Front Axle On Rear Axle Total
3220 1490 - 40 35 75
- - 2180 24 51 75

FAPA FORD RANGER 2019 2019 Date of Publication: 07/2018 25

1 General Information
Double Cab

B
C
A

E278315

Double Cab Driver and Passenger Weight Distribution

'A' Wheelbase 'B' Front row 'C' Second row Weight distribution per person (Kg)
(mm) seats and seats (mm)
driver (mm)
On Front Axle On Rear Axle Total
3220 1490 - 40 35 75
- - 2310 21 54 75

1.13.2 Center of Gravity "Added mass" includes all added body equipment
and cargo, but excludes passengers seated in
NOTE: Calculations shown are not inclusive of standard cab seating.
tow bar and other dealer fitted accessories. For double cab vehicles, there is a limit to the
The following charts define the recommended added mass that must be observed, in addition to
centre of gravity position for the mass added to not exceeding the gross axle and train weights.
the vehicle by the vehicle converter.

26 Date of Publication: 07/2018 FORD RANGER 2019 2019 FAPA

 1 General Information
Single Cab

E278317

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.

FAPA FORD RANGER 2019 2019 Date of Publication: 07/2018 27

1 General Information
Super Cab

E278319

Super 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.

28 Date of Publication: 07/2018 FORD RANGER 2019 2019 FAPA

 1 General Information
Double Cab

E278318

Double Cab Centre of Gravity Critical Zone

Model 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.

FAPA FORD RANGER 2019 2019 Date of Publication: 07/2018 29

1 General Information 1.14 Towing
1.14.1 Towing Requirements Do not cut, drill, weld or modify the trailer
hitch. Modifying the trailer hitch could
When a towing device is required, the Vehicle reduce the hitch rating.
Converter should use a Ford approved tow bar.
For towing devices fitted by the Vehicle Converter
Refer to: (page ?). the following applies:
Load Distribution.
• Towing capacities must not exceed those of
Refer to: Jacking (page ?). the unmodified vehicle.
• Any modifications to the vehicle must be noted
1.14.2 Towing in the owner's handbook or new descriptive
literature included with the owner's
WARNINGS: documentation.
Do not exceed the Gross Combination • Tow bar installations must meet the
Mass (GCM) or towing capacities stated requirements of the local design rules.
in this section. • Whenever frame drilling is necessary use tube
reinforcement.
Ensure that the trailer towball download
weight falls within the specified range. Refer to: 5.5 Frame and Body Mounting (page
91).
Towing trailers beyond the maximum
recommended gross trailer weight
WARNINGS exceeds the limit of your 1.14.3 Towing capacities
vehicle and could result in engine
damage, transmission damage, structural NOTE: The towing capacities below relate to
damage, loss of vehicle control, vehicle vehicles with Ford tow bars only.
rollover and personal injury.

30 Date of Publication: 07/2018 FORD RANGER 2019 2019 FAPA

 1 General Information
Variant Transmissio Drive FDR Gross Max Tow Max Tow
n Combina- Without With Trailer
tion Mass Trailer Brake
Brake
1
2.0L TDCi 6-Speed 2WD 3.55 6000 kg 750 kg 3500 kg
Diesel Manual 2
Transmission 2WD 3.55 5425 kg 750 kg 2500 kg
4WD 3.55 6000 kg 750 kg 3500 kg
1
10-Speed 2WD 3.31 6000 kg 750 kg 3500 kg
Automatic 1
Transmission 4WD 3.31 6000 kg 750 kg 3500 kg
1
2.0L TDCi Bi- 6-Speed 4WD 3.31 6000 kg 750 kg 3500 kg
Turbo Diesel Manual
Transmission
1
10-Speed 2WD 3.31 6000 kg 750 kg 3500 kg
Automatic 1
Transmission 4WD 3.31 6000 kg 750 kg 3500 kg
3
4WD 3.73 5350 kg 750 kg 2500 kg
1
2.2L TDCi 6-Speed 2WD 3.15 5000 kg 750 kg 2500 kg
Diesel Manual 2
Transmission 2WD 3.15 5425 kg 750 kg 2500 kg
1
4WD 3.55 6000 kg 750 kg 3500 kg
1
6-Speed 2WD 3.73 6000 kg 750 kg 3500 kg
Automatic 1
Transmission 4WD 3.73 6000 kg 750 kg 3500 kg
1
3.2L TDCi 6-Speed 2WD 3.55 6000 kg 750 kg 3500 kg
Diesel Manual
Transmission
1
6-Speed 2WD 3.73 6000 kg 750 kg 3500 kg
Automatic 1
Transmission 4WD 3.73 6000 kg 750 kg 3500 kg
1
Vehicles with increased ride height (High Rider).
2
Vehicles with low ride height (Std).
3
Raptor.

1.14.4 Trailer Towball Download NOTE: The maximum trailer towball download
values below relate to vehicles with Ford tow bars
WARNING: Do not exceed the maximum only.
vertical load on the tow ball. Failure to
follow this instruction could result in the
loss of control of your vehicle, personal
injury or death.

Trailer Towball Download Weight

Region Minimum Trailer Maximum Trailer Towball down-
Towball Download load
Australia 10% of the towed weight 350 kg

1.14.5 Towing Specifications

For any further details and advice please consult
your local National Sales Company representative,
or Local Ford Dealer.

FAPA FORD RANGER 2019 2019 Date of Publication: 07/2018 31

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.

32 Date of Publication: 07/2018 FORD RANGER 2019 2019 FAPA

 2 Chassis
2.2 Brake System
2.2.1 General
2.2.3 Trailer Brakes
The Brake System must be fully functional when
the vehicle conversion is completed. The vehicle WARNING: A pre-installed trailer brake
brake operating modes must be checked, wire provides a pulsed brake signal of
including warning system and parking brakes. varying frequencies. This pulsed signal
WARNING: Do not restrict the airflow and is not a direct current (DC) signal. The
cooling to the brake system. Ford-approved FLA Trailer Brake
Controller (p/n VGB3Z2C405E) is
NOTE: Do not obstruct the view of the brake fluid compatible with these pulsed signals. If
reservoir level. another aftermarket brake controller is
The brake fluid reservoir must remain accessible installed, the vehicle owner or installer
for servicing and for adding brake fluid. must ensure that it is compatible with all
pulsed signals from the pre-installed
trailer brake wire. Failure to ensure
2.2.2 Brake Hoses compatibility of your brake controller
may result in loss of vehicle control,
CAUTION: Make sure that the front and which could result in serious injury or
rear brake hoses are not twisted and are death. If clarification is required on the
correctly located away from body and specifications of the pulsed signals,
chassis components. please contact your Authorised Ford
Front and rear brake hoses must not rub, chafe or Dealer.
rest on body or chassis or body components. NOTE: Ford new-vehicle warranty is provided for
There must be clearance under all operating the Ford Licensed Accessory (FLA) Trailer Brake
conditions, between full compression and Controller (TBC) when it is fitted to the vehicle by
extension and full lock to lock. a Authorised Ford Dealer (Part Number
Brake lines must not be used to support or secure VGB3Z2C405E). Ford is not responsible for
any other component. warranty and performance of other aftermarket
brake controllers which are not approved by Ford.

Trailer Brake Connection

E275788

NOTE: RHD (right-hand drive) shown, LHD A pre-installed wire is located behind the A-Pillar
(left-hand drive) similar. kick panel and is marked TRAILER BRAKE
CONTROLLER.

FAPA FORD RANGER 2019 2019 Date of Publication: 07/2018 33

2 Chassis Contact your Authorised Ford Dealer for further
information on Ford Licensed Accessories and the
Ford Approved Trailer Brake Controller.

34 Date of Publication: 07/2018 FORD RANGER 2019 2019 FAPA

 3 Powertrain
3.1 Fuel System
WARNINGS: The fuel filler pipe must be supported in
Make sure that the modified vehicle accordance with the guidelines in this
complies with all relevant legal section.
requirements.
Do not remove or relocate the fuel cooler 3.1.1 Fuel Filler Pipe Shipping Bracket
(if equipped) when modifying the (if equipped)
vehicle.
CAUTION: The fuel filler pipe shipping
CAUTIONS: mounting bracket on cab chassis vehicles
is designed for shipping of the vehicle
Ensure modifications to vehicle do not
only.
obstruct airflow to fuel cooler.
The fuel filler pipe shipping bracket fitted to cab
Make sure that sufficient clearance is
chassis vehicles is designed to be removed once
maintained for all driving conditions to
the body or tray is fitted to the vehicle. The body
all hot and moving components.
or tray must include a fuel filler mounting that
Make sure that there are no sharp edges, complies with the guidelines in this section. The
including fasteners, pointing towards shipping bracket can be left installed on the
any fuel system component. 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

E145838

FAPA FORD RANGER 2019 2019 Date of Publication: 07/2018 35

3 Powertrain
Fuel Filler Pipe Shipping Bracket - Super Cab

E145839

Fuel Filler Pipe Shipping Bracket - Double Cab

E213151

36 Date of Publication: 07/2018 FORD RANGER 2019 2019 FAPA

 3 Powertrain
3.1.2 Fuel Filler Mounting If the vehicle body and mounting bracket does
not provide a grounding path for the fuel filler
CAUTION: Make sure that the filler neck neck, an earth strap must be added, connecting
mounting bracket is made of a the filler neck to the chassis frame.
conductive material, and that it provides
a grounding path for the fuel filler neck.

Fuel Filler Mounting Bracket

E145833

Fuel Filler Mounting Notes

Item Description
A The width of the bracket, where it joins the body to be at least 180 mm
1 All 3x hardware fixation points on the filler neck must be utilised

FAPA FORD RANGER 2019 2019 Date of Publication: 07/2018 37

3 Powertrain
Angle of Filler Neck

B
A

E145836

Filler Neck Installation Dimensions

Item Description
A 2mm minimum bracket thickness
B 30° - angle to be maintained to ensure good flow of fuel when refueling and prevent flow back.

38 Date of Publication: 07/2018 FORD RANGER 2019 2019 FAPA

 3 Powertrain
Clearance From Vehicle Body

E145835

Item Description
A At least 9mm clearance between the fuel filler cap and vehicle body, in the worst case opening
angle if applicable

3.1.3 Fuel Filler Vent Hose Fuel Filler Vent Breather Cap
• The fuel tank vent hose and breather cap
should be rerouted from the shipped position
to the position described in this document in
order to maintain water wading specifications
and prevent water ingress into the fuel system.
• The supplied fuel tank breather cap must be
used.
• A length of fuel grade flexible hose should be
clipped to the vehicle body, with the open end
at least 600 mm (4x2) or 800 mm (4x4 or 4x2
hi-rider) above ground height. It is
recommended to measure this height when E212453
the vehicle is fully loaded.
NOTE: See your authorised dealer to confirm the
• The fuel tank vent hose should be protected
correct part number for your vehicle.
and positioned away from direct water spray,
wheel splash and mud splash, and water
drainage holes that may be present.
• The fuel tank vent hose breather cap must be
upright with its arrow pointing UP.

FAPA FORD RANGER 2019 2019 Date of Publication: 07/2018 39

3 Powertrain
Example of Fuel Tank Vent Hose Mounting Location

E212452

Item Description
1 Front Lower Head Board of a Load Tray (load tray rotated for clarity)
2 Fuel Tank Vent Hose

3.1.4 Axle Breather Vent Hose

The rear differential breather hose should be
mounted to the filler neck/vehicle body. Where
required due to the fitment of an auxiliary body,
aftermarket additions, or the relocation of the fuel
filler, the axle vent hose routing must follow the
relocated fuel tank venting. A length of fuel grade
flexible hose should be clipped to the vehicle body,
with the open end at least 600 mm (4x2) or 800
mm (4x4 or 4x2 hi-rider) above ground height. It
is recommended to measure this height when the
vehicle is fully loaded. A vent breather cap may be
used on the axle breather vent hose.

40 Date of Publication: 07/2018 FORD RANGER 2019 2019 FAPA

 4 Electrical
4.1 Battery and Cables
4.1.1 Battery Information
Battery Charging Procedure
If a battery is disconnected, there is no
requirement to reprogram the vehicle; the vehicle WARNINGS:
retains its ‘normal’ power management setting
and remembers exactly what its previous Always observe the battery charger
configuration was (although the central locking equipment manufacturer’s instructions.
latches may cycle if a door or lock latch was Do not jump/slave start using a battery
opened manually in the intervening period). All charging system from another vehicle.
radio settings will be retained, but the key code
needs to be entered to restore functionality. The Do not overfill a battery as this can cause
clock will need resetting. The window control acid leakage that will result in damage
module will also need to be reset. Refer to the to the vehicle and possible personal
vehicles owner manual for further information. injury.

CAUTIONS:
Battery Voltage Requirements and Do not rely on the generator to recharge
Testing a discharged battery. It would take in
excess of eight hours of continuous
All voltages are to be measured with an accuracy driving with no additional loads placed
of: + /– 5% of published values. on the charging system.
To maximize battery life, at the time of arrival at Make sure that the battery electrolyte
the vehicle converter, all batteries must have a reaches the indicated maximum mark.
minimum Open Circuit Voltage (OCV) of not less
than 12.75 volts. Connect the battery charger cables to the
battery before switching the battery
When the battery is installed and connected to
charger on.
the vehicle's electrical system with no load, the
Closed Circuit Voltage (CCV) must not be less Switch the battery charger off before
than 12.65 volts. When the vehicle is released to disconnecting the battery charger cables
the customer, the CCV must not be less than 12.50 from the battery.
volts. NOTE: Ford batteries generally require no
maintenance however, in certain conditions, it is
possible for the electrolyte in a battery to fall
Surface Charge Dissipation below the minimum level.
Prior to carrying out manual voltage checks, it is NOTE: The use of the Midtronics GR-590 Battery
necessary to establish that the battery voltage is Management Center, which has been specifically
stable and free from surface charges that could designed for use on silver calcium type batteries
be present due to certain engine run conditions is recommended. Once connected to the battery,
making the voltage readings unreliable and the battery charger detects the state of battery
inaccurate. charge and then applies the appropriate charge
rate and duration. When the battery is fully
To ensure surface charges are not present the
charged, the battery charger switches to stand-by,
following actions are recommended:
keeping the battery in a fully charged state
1. Turn on the headlamps for 5 seconds, or the preventing excessive gassing and overcharging.
parking lamps for 15 seconds. The Midtronics GR-590 Battery Management
2. Turn off all electrical loads (including lamps, Center also incorporates a software program that
fan, heater etc). has the capability to assist in the recovery of
3. Wait 10 minutes. deeply discharged (sulphated) batteries.
NOTE: Charging methods and types of battery
chargers vary widely. Whichever method is utilized
Delayed Vehicles it must be carried out carefully to avoid damage
to the battery and possible personal injury.
Vehicles held at the vehicle convertor premises Specific instructions accompanying each battery
and not in use for longer than 4 days, should have charger and must be followed exactly. Safeguards
the battery's negative cable disconnected. Before provided by the equipment manufacturer should
shipping to the customer, the battery negative not be disregarded by the operator.
cable must be re-connected and the voltage
re-checked. The voltage should be not less than NOTE: A battery which has been stored in a highly
12.5 volts. discharged state may be slow to accept a charge
at first. In such cases the initial charging rate may
be so low that the ammeter on some battery
testers will not show any indication of charge for
5 to 10 minutes.

FAPA FORD RANGER 2019 2019 Date of Publication: 07/2018 41

4 Electrical NOTE: Automatic battery chargers are also NOTE: When connecting and disconnecting the
protected against reverse polarity connection and battery from the vehicle, make sure that the
require no adjustment or monitoring. battery ground cable is disconnected first and
connected last and that all electrical items are
NOTE: Slow-charging will readily restore a battery
switched off. Record the audio unit keycode and
to a full state of charge and, since the charging
preset radio frequencies before disconnecting the
current is relatively low, the possibility of
battery.
overcharging a battery are minimized. The charge
rate used should be approximately equal to 5% 1. Remove the battery.
of the reserve capacity of the battery being 2. Disconnect the battery ground cable
charged (approximately three to six Amps
depending on battery size). The charging current
should be adjusted 10 minutes after initial setting
and again after 1 hour before being left to charge
the battery for between 8 and 12 hours.
40 mm
NOTE: A constant voltage battery charger will
charge a battery at a set maximum voltage. The
voltage used depends upon the design and
condition of the battery charger and the age and
temperature of the battery. This type of battery
charger initially charges at a high rate of current
that reduces as battery voltage is restored. When
using a constant voltage battery charger, the DTZ9722102
charging current should be recorded after five
minutes and the battery charger switched off when NOTE: The maximum battery electrolyte level is
the charging current falls to one–third of the approximately 40 mm below the very top of the
recorded value, or after eight hours whichever battery casing. This corresponds to a point just
occurs first. below the lower rim of the battery casing.
NOTE: Multiple battery chargers are designed to 3. Check that the battery electrolyte reaches the
charge a number of batteries, simultaneously. Of indicated maximum level. Top up with
the two different types of multiple battery chargers distilled/de-ionized water, as necessary.
available, only those that charge batteries in series 4. Connect the positive red clamp from the battery
should be used and it is important that batteries charger to the positive battery terminal.
are of the same or very similar ratings and voltages.
5. Connect the negative black clamp from the
Multiple battery chargers that charge batteries in
battery charger to the negative battery terminal.
parallel are not recommended.
6. Follow the instructions supplied with the
NOTE: The use of a fast (boost) battery charger battery charger to charge the battery.
is not recommended as it can cause damage to a
7. To disconnect the battery charger, reverse the
battery. Fast charging will only restore a battery
connection procedure.
to a state of charge that will enable it to carry out
it’s critical function of cranking the engine. Fast
charging will not restore a battery to a full state of
Battery Cable Fixing Torque
charge and must therefore be followed by a period
of slow charging. Excessively fast charging can The battery cables should be fixed to the terminal
cause damage to a battery. For this reason, posts with a torque of 4.8 Nm -/+ 0.8Nm.
charging times must be carefully controlled. Fast
battery chargers vary widely in design so it is very
important to strictly adhere to the equipment Battery Rules:
manufacturer’s instructions. A charge of 30 amps
for up to 30 minutes is the most common fast WARNINGS:
charging application. If the battery is very
discharged and requires additional restoration, an For vehicles fitted with non-sealed
additional charge of 20 amps for a period up to batteries (non-maintenance free), it is
one and a half hours should be applied. Fast essential that regular checks are made to
charging for a period in excess of two hours determine that the electrolyte (acid)
significantly increases the risk of causing damage levels are correctly maintained.
to the battery. When charging, ensure the battery
charger is securely connected to the
vehicle ground and not to the battery
negative terminal. This is to ensure that
the BMS identifies the battery charge.
• For external charging of batteries ensure that
the maximum voltage of 14.6V is not exceeded.

42 Date of Publication: 07/2018 FORD RANGER 2019 2019 FAPA

 4 Electrical
Battery Part Numbers and Usage

Ford Plant Type Specifications Size

Standard Duty 75Ah, 750CCA H7
Battery
Thailand
Auto Start - 80Ah, 800CCA, AGM Deep Cycle Technology H7
Stop Battery
Standard Duty 75Ah, 750CCA H7
Battery
Sth Africa
Auto Start - 80Ah, 800CCA, AGM Deep Cycle Technology H7
Stop Battery
Standard Duty 75Ah, 750CCA H7
Sth America
Battery

If the battery type on a vehicle is changed to other It is important to ensure any additional electrical
compatible derivatives it is required to reconfigure load or accessory is properly grounded to the
the vehicle to the new battery types from the vehicle’s body, in order for the system to identify
dealer. Central car configuration can be updated the additional load. If a connection is made to the
at a dealership. 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
Battery Monitor System (BMS) re-start the vehicle.

Low Level Vehicles

Auxiliary Battery fitted to vehicles with
a Battery Monitor System (BMS)

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.
NOTE: Disabling the BMS will negate the fuel
economy benefit provided by the BMS.
E181583 NOTE: Auxiliary loads must always be connected
to the vehicle ground and not to the battery
negative terminal.
High Level Vehicles
NOTE: Ensure the auxiliary battery connection is
safely secured using suitable fixtures to reduce
vibration damage or contact with surrounding
components.
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 (www.redarc.com.au) (or similar),
connected via an additional terminal to the
E223579 starter post terminal on the B+ using a 30A
fused connection and grounded to the vehicle
Ford Ranger vehicles are equipped with a feature body, in the shown locations.
called Battery Monitor System (BMS). This system NOTE: The additional terminal must be installed
measures the battery load in order to efficiently on top of the starter post terminal using the
charge the battery while improving fuel economy existing nut.
and emissions.
NOTE: The maximum thickness of the additional
terminal being installed on top of the starter post
terminal must be no more than 2.0 mm.
NOTE: Ensure the existing nut is reused.

FAPA FORD RANGER 2019 2019 Date of Publication: 07/2018 43

4 Electrical B+ Connection for Auxiliary Battery Charging The B+ connection should be fixed to the terminal
posts using the existing nut with a torque of 13.5
Nm -/+ 2.1 Nm.
NOTE: Ensure the fused connection is secured
using suitable fixtures to reduce vibration damage
or contact with surrounding components.

E251317

Grounding points for in-vehicle battery charger

E251326

Item Description
1 Possible ground connection points using W705661-S901.
The ground point connection should be tightened An auxiliary battery charging system can be
to torque of 12 Nm -/+ 1.8 Nm. connected using one of the following methods:
2. Request a Ford dealer to disable the BMS. 1. Use an in-vehicle battery charger (DC/DC
Disabling the BMS enables voltage sensitive converter) such as BCDC1220 model from
relay based dual battery systems to work. Redarc (www.redarc.com.au) (or similar),
connected via an additional terminal to the
starter post terminal on the B+ using a 30A
Auxiliary Battery fitted to vehicles fused connection and grounded to the vehicle
without a Battery Monitor System (BMS) body, in the shown locations.
NOTE: The additional terminal must be installed
NOTE: Auxiliary loads must always be connected
on top of the starter post terminal using the
to the vehicle ground and not to the battery
existing nut.
negative terminal.
NOTE: The maximum thickness of the additional
NOTE: Make sure the fused connection is safely
terminal being installed on top of the starter post
secured using suitable fixtures to reduce vibration
terminal must be no more than 2.0 mm.
damage or contact with surrounding components.
NOTE: Ensure the existing nut is reused.

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 4 Electrical
B+ Connection for Auxiliary Battery Charging The B+ connection should be fixed to the terminal
posts using the existing nut with a torque of 13.5
Nm -/+ 2.1 Nm.
NOTE: Make sure the fused connection is secured
using suitable fixtures to reduce vibration damage
or contact with surrounding components.

E251317

Grounding points for in-vehicle battery charger

E251326

Item Description
1 Possible ground connection points using W705661-S901.
The grounding point connection should be An increase in battery drain due to an
tightened to torque of 12 Nm -/+ 1.8 Nm. auxiliary load will void the battery
warranty.
Connection of Auxiliary Loads - Low Level NOTE: Auxiliary loads must always be connected
Vehicles to the vehicle ground and not to the battery
negative terminal.
WARNINGS: • For auxiliary customer electrical loads, a
Make sure all electrical connections and suitable fused connection must be used.
wiring comply with regulations stated in • If multiple auxiliary loads are required, it is
ADR 42/04 Clause 9. recommended that an auxiliary fuse box is
fitted to the vehicle.
Under no circumstances should any
unfused connections be made directly to • For the connection of auxiliary exterior lighting,
any of the vehicle's battery terminals. refer to the guidelines given in the exterior
lighting section.
Refer to: Exterior Lighting (page ?).

FAPA FORD RANGER 2019 2019 Date of Publication: 07/2018 45

4 Electrical Auxiliary loads for external devices which require WARNING: Under no circumstances
an ignition feed (such as UHF/CB radios) may be should the IG+ feed be used to drive
connected via a relay energised by the IG+ feed to auxiliary loads directly. A suitable relay
the Body Control Module. 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

2
2

E211057

Item Description
1 Body Control Module
2 IG+ Feed

Connection of Auxiliary Loads - High Level • For auxiliary customer electrical loads, a
Vehicles suitable fused connection must be used.
• If multiple auxiliary loads are required, it is
WARNINGS: recommended that an auxiliary fuse box is
Make sure all electrical connections and fitted to the vehicle.
wiring comply with regulations stated in • For the connection of auxiliary exterior lighting,
ADR 42/04 Clause 9. refer to the guidelines given in the exterior
lighting section.
Under no circumstances should any
unfused connections be made directly to Refer to: Exterior Lighting (page ?).
any of the vehicle's battery terminals. Auxiliary loads for external devices which require
NOTE: Auxiliary loads must always be connected an ignition feed (such as UHF/CB radios) may be
to the vehicle ground and not to the battery connected via a relay energised by a IG+ feed to
negative terminal. the Body Control Module.
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.

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 4 Electrical
IG+ Connection at Body Control Module

E223580

Item Description
1 Body Control Module
2 IG+ Feed

Part Numbers
Description Part Number / Service Manufacturer
Part Number
Connector CU5T-14489-XA TE (Tyco Electronics)
Pin 7C3T-14474-DA / DU2Z- Molex
14474-DA

4.1.2 Generator and Alternator

Alternator Current Output

See your local authorised dealer to identify the

alternator output current specifications for your
vehicle.

FAPA FORD RANGER 2019 2019 Date of Publication: 07/2018 47

4 Electrical 4.2 Electronic Engine Controls
4.2.1 Vehicle Speed Output (Signal) NOTE: A hard-wired vehicle speed signal is
(Low Level Vehicles Only) available if integration is required.
NOTE: The vehicle speed signal is a direct current
General Information coupled square wave that varies in frequency in
proportion to vehicle speed. This provides a square
WARNING: Do not interface with the CAN wave-form (50% duty cycle) signal.
(controller area network) for vehicle
speed.

Circuit hardware

E180281

Square Wave Characteristics - Output signal

Signal Requirements Sunroof Taxi Speed Output

Maximum High Signal Battery Voltage
Minimum High Signal 3.67 Volts
Maximum Low Signal 1.1 Volts
Minimum Low Signal -1.1 Volts
Maximum Ground Offset +/- 1.0 Volts
Rise Time 10μ sec <= tr <= 250μ sec
Fall Time 10μ sec <= tf <= 250μ sec
Duty Cycle 50% +/- 10%
Frequency 1.38 * v (Vehicle speed (CAN) km/h) ± 2% between
1km/h - 250km/h
Minimum speed 1.38 Hz (1 kmph)
Linearity error <0.3%
Max frequency 398 Hz
Rload 1 k ohms

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 4 Electrical
Instructions for connection 4. Once the device is connected, reset the BCM
by disconnecting the vehicle battery.
1. The vehicle speed output is available on: 5. Reconnect the vehicle battery.
[connector 3 pin number 52] or [connector 4
6. Turn the ignition ON.
pin 3]. Choose one of the connections and
populate the connector with a terminal and 7. The signal should now be available.
wire. NOTE: Rload should be present and connected
2. The output must be connected to a device with to battery voltage for this function to work.
1k ohms resistance (600 ohms to 2k ohms is
the guideline) in order for it to work. This
protects the BCM (body control module) from For Information Only
overcurrent risk.
3. The output must be connected to a power Terminal part number: 96AG-14474-RSA.
source. Wire size and color: 0.5 CSA, blue - green.

FAPA FORD RANGER 2019 2019 Date of Publication: 07/2018 49

4 Electrical Terminal Insertion

1 2

E180282

Item Description
1 Connector C3 Pin 52
2 Connector C4 Pin 3

1. Connector C3 or C4 need to be unplugged in 2. Once the connector C3 or C4 is removed, the

order to insert the speed signal terminal. grey cap needs to be removed by first removing
the cable tie, and then levering up the two
detents on the sides; the cap can then be slid
off.

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 4 Electrical
E180283

E180284

E180285

FAPA FORD RANGER 2019 2019 Date of Publication: 07/2018 51

4 Electrical

E180286

3. There is a red terminal latching plate that needs

to be removed.

E180287

4. Insert the wire with terminal into cavity C3: 52

or C4: 3 – there is a tab on the terminal that
should allow this to be inserted one way only.

E180293

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 4 Electrical
5. Slide back the terminal latching plate, refit the and plug both connectors back into the BCM.
grey cap (and refit the cable tie as required), Refit any shields/covers.

E180294

E180295

E180296

FAPA FORD RANGER 2019 2019 Date of Publication: 07/2018 53

4 Electrical 4.2.2 Vehicle Speed Output (Signal)
(High Level Vehicles )
WARNING: Do not attempt to take a speed
signal output form high level vehicles.
A solution to take a speed signal output from the
BCM on high level vehicles is not currently
available.

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 4 Electrical
4.3 Exterior Lighting
WARNINGS: NOTE: Prior to work on any vehicle being
undertaken it is critical to identify the vehicle level
Make sure that the modified vehicle
(low level or high level) by the type of electrical
complies with all relevant legal
architecture the vehicle at hand is equipped with.
requirements.
Failure to identify the type of electrical
Make sure all electrical connections and architecture present on the vehicle prior to work
wiring comply with local regulations. being undertaken may cause electrical damage
NOTE: Chassis Cab vehicles are supplied with or have safety implications.
rear combination lamps, license plate lamps and Refer to: 4.5 Fuses and Relays (page 67).
fog lamps. Where fitted, these lamps must be
mounted in accordance with the following
guidelines.

FAPA FORD RANGER 2019 2019 Date of Publication: 07/2018 55

4 Electrical 4.3.1 Rear Combination lamps

F
G

B
A

E141460

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 80°
vehicle
F Minimum angle of obstruction free zone towards the centre of the 45°
vehicle
G Maximum distance from outer edge of vehicle to inner edge of lamp 400mm

4.3.2 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.

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 4 Electrical
F

B
A

E141472

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 25°
the vehicle
F Minimum angle of obstruction free zone towards the centre of the 25°
vehicle

4.3.3 Rear License Plate Lamp

FAPA FORD RANGER 2019 2019 Date of Publication: 07/2018 57

4 Electrical

E141462

Positioning of Rear License Plate Lamp

Description Dimension
A Distance from rear face of license plate to centre of lamp along 35mm
lamp mounting face
B Angle between license plate and lamp mounting face 10°
C Distance between top of rear face of license plate and lamp 35mm
mounting face
D Distance between license plate centre line and centre of lamp 175mm
E Distance between license plate centre line and centre of lamp 175mm

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 4 Electrical
4.3.4 Reversing Lamps, Rear View 4.3.5 Additional External Lamps -
Camera, Reversing Alarm (Manual (Low Level Vehicles Only)
Transmission)
When installing auxiliary tail lamps, Ford
The reverse lamps are activated by the reverse recommends that power is provided via the trailer
switch on the transmission, through connector plug control module and associated circuitry.
C169 to the Central Junction Box where the signal Refer to Trailer Towing for additional information.
is sensed. A marginal increase in current (via a For all other additional exterior lamps, power must
relay or buffered electrical input) is permissible be taken through an auxiliary fuse box with a
to provide power to a rear-view camera, auxiliary suitable switch and / or relay as required.
reverse lighting, or an audible warning device.
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.

E210761

Item Description
1 Low beam
2 High beam

Lighting Fuses
F20 10A Headlamp
F75 15A Front fog lamp
F76 10A Reversing lamp

FAPA FORD RANGER 2019 2019 Date of Publication: 07/2018 59

4 Electrical 4.3.6 Trailer Towing When fitting low power LED (light emitting diode)
lamps that require less than 2W, the lamps may
Vehicles with a factory fitted tow bar also come flicker when in use. A trailer patch harness should
with a trailer tow module for lighting and the be used with low power draw LED lamps.
activation of trailer sway control. In addition to
CAUTION: Do not connect the trailer
providing the trailer plug functionality, the trailer
patch harness to the vehicle when the
towing module protects the primary electrical
trailer is not connected.
circuits of the vehicle from any electrical concern
or failure that the customer's trailer may NOTE: The trailer patch harness is available from
experience. your Ford authorised dealer.
NOTE: The trailer tow electrical kit is available NOTE: The trailer detect circuit is part of the Ford
from your Ford authorised dealer. Trailer Tow module, it can only be implemented
on vehicles with power locking and perimeter or
For vehicles fitted without a tow bar as standard,
CAT 1 alarms.
a genuine Ford accessory trailer tow electrical kit
has been developed to enable a tow bar to be The Trailer Tow Module (TTM) can support pure
installed. The kit comprises of the trailer towing LED trailer lamps as long as each circuit exceeds
control module, trailer plug, wiring and associated 500mA, below this and the system will not detect
hardware components. a trailer has been connected and shuts down all
outputs (sleep mode). It is recommended to target
Once the kit is installed, the vehicle must then be
a 550mA minimum load to allow for system
configured using a Ford IDS diagnostic tool. This
tolerances. This would need to be obtained with
configuration can be performed by your Ford
a supplemental load resistor, if the LED lighting
authorised dealer.
circuits are below this threshold.
WARNING: Installation of aftermarket Each output driver could handle a current of 15A
trailer tow electrical kits or directly but it is not recommended to always run to this
splicing into the vehicle wiring in order to maximum. A higher current is interpreted as short
install trailer lamps or other electrical circuit. If a short circuit is detected the related
devices may overload the system and output will be switched off. The following table
impact the operation of other vehicle shows the recommended output maximums per
systems. circuit.
Ford recommends that all trailer tow electrical NOTE: Not all features and outputs are supported
connections use the genuine Ford accessory trailer in all markets. Refer to your authorised Ford Dealer
tow kit. for further information.

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 4 Electrical
Trailer Tow Module Connections- Low Level Vehicles
Component Feature Current (A) Voltage (V)
Terminal
Min Max Min Max
Number
Connector A
1 Right Direction Indicator 0.5 3 6 -
2 Battery Charge Out - where used - 10 9 16
3 Stop Left 0.5 4 6 -
4 Not used - - - -
5 Not used - - - -
6 Reverse Lamp 0.5 4 6 -
7 Stop Right 0.5 4 6 -
8 Fog Lamp 0.5 2 6 -
9 Not used - - - -
10 Left Direction Indicator 0.5 3 6 -
11 Not used - - - -
12 Position Lamp 0.5 7 6 -
Connector B
1 Not used - - - -
2 Term 30 (Ubat) - 30 6 16
Connector C
1 CAN H - 0.1 6 -
2 CAN L - 0.1 6 -
3 Brake Line In (Vehicle -) - 0.1 6 -
4 Ground - 1 6 -
5 Trailer Detect Output - 0.1 - 16

FAPA FORD RANGER 2019 2019 Date of Publication: 07/2018 61

4 Electrical
Trailer Tow Module Connections- High Level Vehicles
Component Feature Current (A) Voltage (V)
Terminal
Min Max Min Max
Number
Connector A
1 Left Direction Indicator 0.5 3 6 -
2 Right Direction Indicator 0.5 3 6 -
3 Position Lamp 0.5 7 6 -
4 Not used - - - -
5 Reverse Lamp 0.5 4 6 -
6 Battery Charge Out - where used - 10 9 16
7 Stop Lamp 0.5 4 6 -
8 Fog Lamp 0.5 2 6 -
9 Not used - - - -
10 Not used - - - -
11 Not used - - - -
12 Not used - - - -
Connector B
1 B(+) Fuse 87 (40A) BJB - - - -
2 B(+) Fuse 73 (30A) BJB - - - -
Connector C
1 Ground - 1 6 -
2 CAN L - 0.1 6 -
3 CAN H - 0.1 6 -
4 Not used - - - -

4.3.7 Auxiliary Lighting Loads (Low

Level Vehicles Only) Trailer Tow Module (if equipped)
NOTE: Connections for auxiliary lighting loads Connections for auxiliary lighting loads can be
must be low and stable current draw. made via the trailer tow module (TTM) located
under the passenger seat. See Trailer Towing in
this section.

E223617

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 4 Electrical
TTM Connector - Detail

E231982

4.3.8 Lamps – Hazard / Direction

Indication 4.3.10 Centre High Mount Stop Lamp
(CHMSL) - Canopy Fitment -Low Level
The maximum permissible load with the standard Vehicles
system is:
• 3 x 5W – front and rear indicators + side WARNING: The maximum current load
repeaters (Left Hand Side) that can be applied to the CHMSL circuit
is 1.72A for incandescent globes, and
• 3 x 5W – front and rear indicators + side
0.38A for LED lamps. Do not exceed the
repeaters (Right Hand Side)
rated load.
NOTE: Disable the original vehicle mounted
4.3.9 Electrically Operated Door CHMSL if the canopy CHMSL is intended to be
Mirrors the primary CHMSL.
WARNING: Do not tamper with the base NOTE: The CHMSL circuit is pulse width
system (controlled by Central Junction modulated (PWM).
Box and multiplex architecture) and any NOTE: Check the operation of the CHMSL prior
feeds taken from the associated wiring to customer handover.
or controller.
NOTE: When replacing the factory fitted CHMSL
NOTE: These options are not suitable for with a canopy mounted CHMSL, the same type
aftermarket or Body Builder fit. must be used. Replace a bulb/incandescent type
only with a bulb/incandescent. Replace and LED
type only with an LED type.
When installing a canopy equipped with a CHMSL,
a feed for the CHMSL can be taken from the BCM
(Connector 4, Pin 2).

FAPA FORD RANGER 2019 2019 Date of Publication: 07/2018 63

4 Electrical

E229158

Item Description
1 BCM CHMSL Feed (Connector 4, Pin 2).

4.3.11 Centre High Mount Stop Lamp NOTE: Disable the original vehicle mounted
(CHMSL) - Canopy Fitment - High CHMSL if the canopy CHMSL is intended to be the
Level Vehicles primary CHMSL.
NOTE: The CHMSL circuit is pulse width
WARNINGS: modulated (PWM).
The maximum current load that can be NOTE: Check the operation of the CHMSL prior to
applied to the CHMSL circuit is 1.72A for customer handover.
incandescent globes, and 0.38A for LED
lamps. Do not exceed the rated load. NOTE: When replacing the factory fitted CHMSL
with a canopy mounted CHMSL, the same type
Make sure all wiring is insulated and must be used. Replace a bulb/incandescent type
routed securely. only with a bulb/incandescent. Replace and LED
NOTE: The fitment of a canopy to high level type only with an LED type.
vehicles equipped with a combined CHMSL / Cargo
Lamp requires that the cargo lamp feature be
disabled.

64 Date of Publication: 07/2018 FORD RANGER 2019 2019 FAPA

 4 Electrical
When fitting a canopy to vehicles equipped with
a combined CHMSL / Cargo Lamp, the lamp
housing may be impacted by the canopy. Check
the canopy to CHMSL clearance, and if required,
follow the below procedure.
A replacement CHMSL (without cargo lamp
function) needs to be installed. A patch harness
with a 2-pin connector is then spliced into the
vehicles CHMSL circuit wiring allowing a canopy
with an integrated CHMSL to take a stop lamp
circuit feed from the 2-pin connector. The original
3-pin connector is then taped back.
Follow the steps to install the replacement
CHMSL lamp housing:
1. Remove the combination CHMSL / Cargo Lamp
following the workshop manual instructions.
NOTE: When cutting off the stop lamp circuit
wires from the 3-pin CHMSL connector, stagger
the cuts to allow for cleaner and less bulky splice
joins.
2. Locate the 3-pin CHMSL / Cargo Lamp
Connector. Cut off the stop lamp circuits (pin
1 yellow-grey or white-blue, pin 2 black-violet
or black-yellow or black-blue) leaving the violet
wire (pin 3) connected to the 3-pin CHMSL
connector.
3. Tape back the 3-pin connector with the violet
coloured wire.
4. Splice the replacement 2-pin connector and
patch harness to the cut wires:
1. Yellow + Grey wire (or alternate color - see
above ) to Yellow + Grey wire.
2. Black + Violet wire (or alternate color - see
above ) to black + Violet wire.
5. Insulate the spliced joins with heat shrink.
6. Route the canopy CHMSL wiring through a
suitable grommet into the passenger
compartment, route it behind the trim panels
and connect it to the replacement 2-pin
connector.
7. Install the replacement CHMSL to the vehicle
following the workshop manual instructions.

FAPA FORD RANGER 2019 2019 Date of Publication: 07/2018 65

4 Electrical 4.4 Handles, Locks, Latches and Entry Systems
4.4.1 Central Locking NOTE: The location of additional relays should be
considered carefully. A suitable mounting location
NOTE: Additional locks will not be covered by the away from the passenger compartment will allow
vehicle alarm or operate BCM controlled lighting. for a safer install and reduced noise in the
passenger compartment.
The central locking function is controlled by the
BCM (located under the instrument panel). The Depending on the functionality required, the pins
vehicle locks are operated by surface mounted used will emulate the basic locking/unlocking
relays in the BCM – these are only capable of operation of an existing lock. The coil of the
powering one lock each. additional relays (i.e. one relay for lock all, one
relay for unlock all) should be added across the
It is possible to add an additional lock(s) with the
relevant pin and a suitable ground point. Power
use of relays triggered by the BCM outputs.
(B+) for the additional relays should be taken from
a suitably fused B+ feed.
Relay selection for installation of an additional
lock(s) must parallel the run time of th BCM
surface mount relays.

BCM Output for Central Locking (Low Level Vehicles)

BCM Pin Circuit Fuse Function
C2280E 1 CPL11 BCM Fuse 70 CTRL MOD. - DOOR LOCK # ALL
LOCK
C2280E 8 CPL13 BCM Fuse 70 CTRL MOD. - DOOR LOCK # ALL
UNLOCK

BCM Output for Central Locking (High Level Vehicles)

BCM Pin Circuit Fuse Function
C2280F 35 CPL11 BCM Fuse 24 CTRL MOD. - DOOR LOCK # ALL
LOCK
C2280F 32 CPL13 BCM Fuse 24 CTRL MOD. - DOOR LOCK # ALL
UNLOCK

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 4 Electrical
4.5 Fuses and Relays
4.5.1 Low Level and High Level Passenger Compartment Fuse Box - High
Vehicles Level Vehicles
WARNING: Prior to work on any vehicle
being undertaken it is critical to identify
the type of electrical architecture the
vehicle uses. Failure to identify the type
of electrical architecture present on the
vehicle prior to work being undertaken
may cause electrical damage or have
safety implications.
This manual provides information that may or
may not apply depending on the exact vehicle
model the vehicle converter is working on. The PX
Ranger MkII is built in varying specification levels,
spread across two different electrical architecture
types. Identification of which type a vehicle is
equipped with can be aided visually checking the
passenger compartment fuse box.

Passenger Compartment Fuse Box - Low

Level Vehicles

E225624

4.5.2 Auxiliary Battery and Fuse Box

- Low Level Vehicles
NOTE: High level vehicles cannot be fitted with
the factory installed auxiliary battery and fuse
box.
An auxiliary battery and associated fuse box is
available as an option on low level vehicles called
a Special Equipment Pack. The option code for
the Special Equipment Pack is AALSA. The
auxiliary battery and fuse box provides electrical
outputs for the addition of auxiliary electrical
loads to be supplied off the auxiliary battery.
E133602

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4 Electrical 4.5.3 Auxiliary Fuse Box (Vehicles with Special Equipment Pack) (Low Level
Vehicles Only)

Vehicles with a Load Box (Vehicles with Special Equipment Pack) (Low Level Vehicles Only)

E231508

Item Description
1 Auxiliary Fuse box

Vehicles with Temporary Battery Carrier (Cab Chassis Variant Only) (Low Level Vehicles Only)
(Vehicles with Special Equipment Pack)

E231507

Item Description
1 Auxiliary Fuse box

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 4 Electrical
Cab Chassis Vehicles with Tray (Low Level Vehicles Only) (Vehicles with Special Equipment
Pack)

E231509

Item Description
1 Auxiliary Fuse box

Auxiliary Fuse Specification Chart

NOTE: On delivery of the vehicle, ensure Fuse F10

is engaged into its location correctly. Fuse F10 is
intentionally not fully engaged during
manufacturing, to prevent depletion of the
auxiliary battery during shipping and transit.

FAPA FORD RANGER 2019 2019 Date of Publication: 07/2018 69

4 Electrical

E174549

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 Auxiliary battery 'disable' fuse (isolator
ground).
11 - Not used
12 - Not used

Relay Chart
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

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 5 Body and Paint
5.1 Body
5.1.1 Body Structures - General • Re-paint metal edges after cutting or drilling.
Information All metal edges must comply with exterior and
interior protection legislation.
WARNING: All external or internal • All fixings through the floor, sides or roof must
projections must comply with ADR be sealed.
42/04, Clause 11.
• Make sure that fixings in the 'B'-pillar area do
CAUTION: Load carrying structures not encroach on the seat belts or seat belt
should not be mounted onto an existing reels.
load tray or load box.
When carrying out vehicle 5.1.2 Integrated Bodies and
conversions/modifications the following points Conversions
should be considered:
• Make sure that the vehicle structural integrity WARNING: All wheelhouse envelopes
is maintained. must comply with ADR 42/04, Clause 14.
• Do not drill into closed frame body members. For integral structures such as ambulances or
• Make sure that the design for the body motor-homes with increased rear overhang built
alterations or additional structure disperse the onto the chassis the following applies:
load evenly. • Reduced departure angles, e.g. rear entry step,
should be discussed with the end user /
CAUTION: Uneven load distribution could
customer. Consider removable components
result in unacceptable handling and
to avoid damage on ferries or low-loaders.
braking characteristics.
• 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.

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5 Body and Paint
Wheelhouse Envelope

X 1
H
A B
K
C D
r r
L
G
F r
E E

r r

X-X

E134132

Wheelhouse Dimensions
Dimensio 215/ 255/ 265/ 265/ Dimension 215/ 255/ 255/ 265/65R17
n 70R16 70R16 65R17 65R18 70R16 70R16 70R16
*
A 455mm G 190mm
B 425mm H 914mm 915mm 922mm 922mm
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
*
Dimension G is to the bottom of the swage

5.1.3 Chassis Cab When carrying out vehicle conversions /

modifications the following points should be
WARNING: Excessive heat can build up considered:
from the exhaust system, in particular • Make sure that all of the reinforced holes
from the catalytic converter. Ensure provided in the chassis frame top surface are
adequate heat shields are maintained. used for full length bodies or sub-frames, see
CAUTION: Uneven load distribution could figures shown.
result in unacceptable handling and • Make sure that the vehicle structural integrity
braking characteristics. 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.

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 5 Body and Paint
• Re-paint metal edges after cutting or drilling. For any conversion structure attached to or
All metal edges must comply with exterior and mounted onto the base vehicle cab structure the
interior protection legislation. following applies:
• All fixings through the floor, sides or roof must • Ensure that neither the conversion structure
be sealed. nor the existing vehicle structure get
pre-loaded by the assembly process.
Refer to: 5.4 Corrosion Prevention (page 90).
• Adhesive jointing is recommended but should
• Ensure that any additional equipment in the be supplemented with mechanical fasteners
vicinity of the fuel tank will not damage the to prevent initial peel and long term failure.
tank in a crash condition.
• Spread bolt loads to minimize local stress.

Body Attachment Holes in Chassis Frame - Single cab

D A

E F G H

N
K
J

K
L M
L M
N

E134152

Dimensions (mm) for Body Attachment Holes in Chassis Frame - Single Cab
Dimension Dimension
A 16 H 1086
B 28 J 95
C 23 K 768
D 20 L 893
E 1244 M 509
F 1244 N 26
G 1244 P 20

FAPA FORD RANGER 2019 2019 Date of Publication: 07/2018 73

5 Body and Paint
Body Attachment Holes in Chassis Frame - Super cab

D A

C
E F G

L
H

J K

E134153

Dimensions (mm) for Body Attachment Holes in Chassis Frame - Super Cab
Dimension Dimension
A 16 G 1086
B 28 H 95
C 23 J 1191
D 20 K 509
E 1244 L 26
F 1244 M 20

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 5 Body and Paint
Body Attachment Holes in Chassis Frame - Double cab

B
C
A

E F G

H
J K
E134154

Dimensions (mm) for Body Attachment Holes in Chassis Frame - Double cab
Dimension Dimension
A 16 G 1086
B 28 H 95
C 23 J 893
D 20 K 509
E 1244 L 26
F 1244 M 20

5.1.4 Front End Integrity for Cooling, Static & Dynamic Sealing and Finishing Ensure
Crash, Aerodynamics and Lighting proper sealing against ingress of water, salt, dust
etc. after cutting or drilling the body. Use Ford
Cooling Continuous air flow through the front approved sealing and finishing material, and
end and engine compartment is not to be hindered underbody corrosion protection.
by adding any additional equipment. If uncertain Refer to: 5.4 Corrosion Prevention (page 90).
please consult the Ford dealer.
Lighting Do not alter the lighting system.
5.1.5 Tipper Bodies
Crash Do not cut, drill or weld any parts that are
load path relevant in case of crash. Do not add For tipper conversions single and double Chassis
material in the crash zone. This could affect the Cab versions except extended rear chassis frame
crash sensor calibration. can be used. All variants allow single and three
The side airbag system is not permitted if: way tipping.
• A swiveling device is fitted on the front seats. It is recommended to have the tipping system
• A side wall or any other additional material or operative only when the engine is running. It is also
structure is attached to the B-pillar inner recommended to have the master control switch
and/or outer area. in the security of the cab. According routing of
wires and hydraulic lines please refer to section
hydraulic lift.

FAPA FORD RANGER 2019 2019 Date of Publication: 07/2018 75

5 Body and Paint Ensure that axle plated weights including the front • Compliant mounts should be used, with up to
axle minimum are not exceeded. plus and minus 12mm compliance with the
vehicle laden or un-laden (whichever is worst
For tipper sub-frames please refer to the following
case). Compliant mounts should be rated with
guidelines:
a minimum of 2mm deflection per 200kg mass
• Design for full length continuous frame with at each chassis frame forward mount.
mountings for motor, pump unit, reservoir, pivot Compliant mounts shall have captive fail safe
points and ram. bolts.
• Use all mounting points on chassis frame to • Use two M10 grade 8.8 minimum bolts, washers
mount sub-frame. and self lock nuts per chassis frame mount
• Very stiff sub-frames may damage the chassis bracket at each solid and compliant location.
frame by preventing its natural flexing, therefore
compliant mounts should be used, with up to
plus and minus 12mm compliance with the
5.1.7 Genuine Ford Accessory Bull Bar
vehicle laden or un-laden (whichever is worst
The Genuine Ford Accessory bull bar includes
case). Compliant mounts should be rated with
brackets which are mounting points for driving
a minimum of 2mm deflection per 200kg mass
lights, aerials, antennas and flags.
at each chassis frame forward mount.
Compliant mounts shall have captive fail safe WARNINGS:
bolts.
• Use two M10 grade 8.8 minimum bolts, washers Follow all accessory manufacturer's
and self locking nuts at each solid and instructions when connecting accessories
compliant chassis frame location. and equipment to the vehicle.
• Sub-frame must extend to the back of the cab Do not fit a non-Ford approved bull bar to
and attach to all mounting locations, with the your vehicle as this may interfere with the
forward end designed to minimize local frame operation of the restraint system,
stress. It is however, preferable to mount the including the air bag deployment, and
sub-frame onto the mounting brackets with a could result in injury to yourself and
clearance to the chassis frame top surface. others. Fitment of a bull bar may also void
• Side tipping loads/forces must be resolved by the vehicle's compliance with Australian
the sub-frame. It is not recommended to strain Design Rules.
the chassis frame. Do not modify the front of your vehicle in
any way. This could adversely affect
deployment of the airbags. Failure to
5.1.6 Tank and Dry Bulk Carriers adhere to this warning could result in
serious personal injury or death.
Due to the high rigidity of tanks it is necessary to
isolate the tank and its sub-frame from the chassis After bullbar installation, contact your
frame allowing the chassis frame to naturally flex. authorised Ford Dealer to correctly
Please refer to the following guidelines: calibrate the Adaptive Cruise Control
Radar Module (if equipped). This is
• Mount tank to full length of sub-frame.
required to ensure correct operation of
• Mount sub-frame to all chassis frame mounting the advanced safety features this vehicle
points. offers.
• The forward location mounts must be
NOTE: Please refer to the electromagnetic
compliant to allow relative chassis frame to
compatibility (EMC) section in this book before
sub-frame deflections.
installing any aerials.
• Sub-frame must extend to the back of the cab
and not contact chassis frame at forward end
under worst case deflection.

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 5 Body and Paint
Bull Bar Accessory Mounting Positions

2 1

E210762

Item Description
1 Aerials, antennas and flag mounting location
2 Driving lights mounting location

Antenna Cables Routing

5.1.8 Roof Racks
WARNINGS:
Ensure that the antenna cables have Roof racks may be fitted to all variants as
sufficient clearance from hot and moving illustrated in figure, providing the following is
parts. satisfied:

Do not fasten the antenna cables to • The carried load does not exceed 80kg (Body
original vehicle wiring, fuel pipes and Builder to ensure owner’s hand book identifies
brake pipes. this limitation).
• The carried load does not exceed 300mm load
Keep the antenna and power cables at height (converter to ensure owner’s
least 100mm from any electronic information book identifies this limitation).
modules and airbags and associated
wiring. • The load is evenly distributed (converter to
ensure owner’s information book identifies this
NOTE: Make sure the sealing integrity is limitation).
maintained to avoid water ingress into the cabin
• The rack and subsequent carried load is
while routing the cables through the grommet.
supported in the roof drip rails irrespective of
Antenna cables should be routed from the engine rack retaining method.
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.

FAPA FORD RANGER 2019 2019 Date of Publication: 07/2018 77

5 Body and Paint Double Cab / Super Cab Ensure that the planned loaded vehicle operates
within its designed Centre of Gravity condition. For
The forgoing limitations are based on ensuring details please consult the Ford dealer.
body structure integrity, vehicle handling, braking
and plated axle weights. Such considerations must
also be applied to any double cab and super cab
applications, in particular steering, braking and
front axle ratings and the extra continuous loads
on the “A” pillar, which should not exceed 60 kg
total incremental load.

Roof Rack Vehicle Converter Special Fit

1
3 4

E278320

Item 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

5.1.9 Canopies The top surface of the load box sides

should not bear canopy (or other)
structural loading. To be used as a canopy
All Vehicles 'sealing-surface' only.
WARNINGS: Canopy weight and canopy load should
pass through the recommended load box
Only use the recommended attachment structural attachment points.
points for the canopy fitment, otherwise
damage may occur to the load box. NOTE: Usage of clamps for the canopy fitment
are only allowed on the centre and rear portion of
The return flange on the load box sides the load box.
should never be cut away, be drilled into,
or be used otherwise for bolting of the
canopy.

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 5 Body and Paint
NOTE: Use both points from group A and a
minimum of one point from group B as front
structural attachment points.

Load Box Structural Attachment Points

A
B

E170921

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.

FAPA FORD RANGER 2019 2019 Date of Publication: 07/2018 79

5 Body and Paint
Example of a Sports Bar Fitment

E172331

Item Description
1 Front mounting bracket
2 Clamped attachment

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 5 Body and Paint
5.2 Airbag Supplemental Restraint System (SRS)
5.2.1 Air Bags - (Low Level Vehicles) The acceleration based airbag sensors for side
airbags are located nearby the bottom of the
C-pillar inner for Super Cab and Double Cab
Front Seats vehicles. The pressure based airbag sensors for
side airbags are located near the centre of the
Side airbags are not compatible with swivelling front doors' inner door sheet metal for all Cab
front seats. styles.
Do not specify the base vehicle with side airbags WARNING: Modifications or
when planning to retrofit a swivelling device on reinforcements in the area of the sensors
the front seats and/or an armrest on the outer may affect the side airbag fire timing and
side of the front seats, this may affect the function result in uncontrolled side air bag
and/or deployment of the side airbags. 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.

Driver and Passenger Front Airbag Deployment Zones

E134101

FAPA FORD RANGER 2019 2019 Date of Publication: 07/2018 81

5 Body and Paint
Dimensions (mm)
A 400 D 660
B 700 E 630
C 700 F 700

Side Airbag

C
A B

E134609

Dimensions (mm)
A 550 C 250
B 350

Curtain Airbag - Single cab

C
D

B
E136172

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 5 Body and Paint
Dimensions (mm)
A 140 C 250
B 40 D 100

Curtain Airbag - Double cab

B
E134610

Dimensions (mm)
A 140 C 250
B 40 D 100

Curtain Airbag - Super cab

C
D

E136173

Dimensions (mm)
A 140 C 250
B 40 D 100

FAPA FORD RANGER 2019 2019 Date of Publication: 07/2018 83

5 Body and Paint 5.2.2 Air Bags - (High Level Vehicles) The acceleration based airbag sensors for side
airbags are located nearby the bottom of the
C-pillar inner for Super Cab and Double Cab
Front Seats vehicles. The pressure based airbag sensors for
side airbags are located near the centre of the front
Side airbags are not compatible with swivelling doors' inner door sheet metal for all Cab styles.
front seats.
WARNING: Modifications or
Do not specify the base vehicle with side airbags reinforcements in the area of the sensors
when planning to retrofit a swivelling device on may affect the side airbag fire timing and
the front seats and/or an armrest on the outer side result in uncontrolled side air bag
of the front seats, this may affect the function deployment.
and/or deployment of the side airbags.
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.

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 5 Body and Paint
Driver and Passenger Front Airbag Deployment Zones

E C

E210764

Dimensions (mm)
A 260 D 392
B 470 E 520
C 470 F 544

FAPA FORD RANGER 2019 2019 Date of Publication: 07/2018 85

5 Body and Paint
Side Airbag

C
A B

E134609

Dimensions (mm)
A 550
B 350
C 250

Curtain Airbag - Single cab

C
D

B
E136172

Dimensions (mm)
A 140 C 250
B 40 D 100

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 5 Body and Paint
Curtain Airbag - Double cab

B
E134610

Dimensions (mm)
A 140 C 250
B 40 D 100

Curtain Airbag - Super cab

C
D

E136173

Dimensions (mm)
A 140 C 250
B 40 D 100

5.2.3 Supplementary Restraint

Sensors (Front)
WARNING: Modifications or
reinforcements in the area of the front
supplementary restraint sensors may
affect their operation.

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5 Body and Paint

E210765

Item Description
1 Front SRS Impact Sensors

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 5 Body and Paint
5.3 Seatbelt Systems — Australia
WARNING: Follow the Ford approved
removal and installation procedures for
the seatbelt system to ensure correct
function of the restraints system.
The removal and reinstallation of the seatbelt,
restrainer or any component of the seatbelt
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 seatbelt system as described in
the workshop manual. Please consult your local
National Sales Company representative for further
information.
When removing the seatbelt system, a seatbelt
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.

FAPA FORD RANGER 2019 2019 Date of Publication: 07/2018 89

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.

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 5 Body and Paint
5.5 Frame and Body Mounting
5.5.1 Mounting Points and Tubing NOTE: After drilling, deburr and countersink all
holes and remove chips from the frame. Follow
Holes on frame are a result of the production corrosion prevention.
process. They are not designed for fixing Refer to: 5.4 Corrosion Prevention (page 90).
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

E134173

Dimensions (mm) for Body Attachment Holes in Chassis Frame Top Flange Medium Wheelbase
Item Description
A 19 mm
B 11 mm
C 10 mm
D 10 mm
E Do NOT enlarge chassis rail holes, or drill within the surrounding area.
F Do not drill any more than 2 vertical holes in the chassis rail.

1. No Welding is Allowed to the Vehicle Structure. 6. Holes must NOT be drilled near side member
2. To make holes in frames do not use a gas profile changes.
flame. Drill holes using sharp drills. 7. Existing holes in top and bottom flanges must
3. Use cold riveting only when attaching brackets NOT be bored out.
with rivets. 8. No more than two holes are to be drilled in a
4. Use high tensile bolts and appropriate nuts vertical line down from the frame web.
when bolted attachments are used. 9. Corrosion protection is to be applied post
• Bolt Specifications : drilling operations to the vehicle. Corrosion
• Metric – Property class 8.8 or 10.9 protection & protective coatings for all
modifications should conform to all local
• Japanese – 7T or 9T
design rules.
• SAE – Grade 8 5.
10. Reinforcements should be added to the vehicle
5. Deburr holes after drilling to fit bolts or rivets. structure where appropriate, to avoid excessive
Chamfer 1.0mm x 45 degree on the bolt head load concentrations.
side of the hole to facilitate bolt seating.

FAPA FORD RANGER 2019 2019 Date of Publication: 07/2018 91

5 Body and Paint
Typical Design Principle of a Self-Supporting Body Structure

7
6
E74576

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: • This concept is based on a self-supporting

structure where the floor is mounted directly
Refer to: 5.1 Body (page 71).
onto the top surface of the chassis frame.
• See figure shown for a generic vehicle cross
5.5.2 Self-Supporting Body Structure section where the cross members and opposing
out riggers are flush with the surface of the
Bodies and structures can be judged as chassis frame side members.
self-supporting providing they maintain the
• It is important to the overall function of the
following rules:
vehicle structure that the out riggers are each
• Cross members are used at each chassis connected to a continuous longitudinal floor
mounting point, please refer to figures shown. side frame or a structural body side structure
• Each cross member has a suitably engineered assembly.
connection to the body side wall (3) or to the Low floor-re-work for guidance only:
continuous floor frame (5), see figure shown.
• Engineer unique cross members and out-riggers
• The body side wall or the continuous floor spaced at approximately 600mm maximum
frame supports any overhang beyond the pitch.
chassis frame, whether on standard frame or
extended frame. • Out-rigger moment to be re-acted with
cross-member between chassis frame with
Alternatively, the self-supporting body structure common through bolts where possible.
can also be designed as shown in figure shown.

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 5 Body and Paint
• Drill frame and add spacer tubes. Drilling and welding of frames and body structure
have to be conducted following the program
Refer to: 5.5 Frame and Body Mounting (page
guidelines. Please consult the Ford dealer for
91).
details.
• Out-rigger outboard ends should be attached
to load bearing body side / floor edge frame or
body side structure (including over wheel 5.5.4 Ancillary Equipment - Sub Frame
support). Mounting
• Structural wheel box should maintain
longitudinal continuity with a rigid attachment Typical sub-frames and longitudinal members for
to the floor edge frame or to the body side flatbed and low or drop-side bodies or equipment
structure. exceeding the standard or Regular Production
Order frame length should adhere to the following
• Floor boards should be substantially attached guidelines:
to cross members and outriggers, but not to
the chassis frame top surface. • Flat-beds and low bodies mounted on integral
• Low floor exhaust heat shields. longitudinal members (channel or box section
metal – not wood) must use both sides of all
frame mounting brackets.
5.5.3 Frame Drilling and Tube • Longitudinal members must be relieved at the
Reinforcing front end if they are to contact the chassis
frame top surface, to minimize stress
The chassis frame may be drilled and reinforcing concentrations. It is preferable however, to
spacer tubes may be welded in place, providing mount the longitudinal onto the mounting
the following is applied: brackets, with a clearance to the chassis frame
• Adhere to all details shown in figure. top surface.
• Drill and weld only side walls of the chassis • Each set of brackets must use two (2) x M10
frame. bolts grade 8.8 minimum.
• Locate and drill holes accurately, using a drill • Minimum floor heights will require wheel arch
guide to ensure holes are square to frame boxes to clear the rear tires, see Vehicle Data
vertical center line (note: allow for side sheets for relevant tire jounce.
member draft angle).
• Drill undersize and ream out to size. 5.5.5 Area for Fitting Additional Body
• Endeavor to remove all swarf from inside side Attachments to the Rear of the
member, and treat to prevent corrosion. Bumper.
• Fully weld each end of the tube and grind flat
and square, in groups if applicable. Be aware NOTE: With the vehicle on level ground and with
of side member draft angle. all measurements taken rear ward of the bumper
bar edge: The area designated for the fitting of
• Apply corrosion protection inside and outside attachment is defined as 220mm horizontally by
of the chassis frame. 95mm vertical downward to the road surface,
Refer to: 5.4 Corrosion Prevention (page 90). with a max width of 1390mm about vehicle center
• Holes should be in groups of two (2), either line.
vertically spaced at 30 to 35mm from chassis It is not the manufactures recommendation to fit
frame top and/or bottom surface, or additional body attachments (Tow bars, Steps,
horizontally at 50mm minimum pitch, 30 to Bicycle racks & Carriers) outside of the designated
35mm from top and/or bottom chassis frame area.
surface.
• Always use M10 bolts with grade 8.8 minimum.
5.5.6 Water Tank on Camper Vehicles
• Do not position tubes at the medium chassis
frame height, this may create “oil canning” of NOTE: It is recommended that a decal or label
the deep section side walls. is fitted adjacent to the filler aperture
• Where possible, the outrigger moments should identifying the correct fluid to be used, for
be resolved by matching inner cross members example: 'Water only' for water tanks.
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 90).

FAPA FORD RANGER 2019 2019 Date of Publication: 07/2018 93

Index A Front, Rear and Side Under-run Protection..........21
Front End Integrity for Cooling, Crash,
About this Manual...........................................................5
Aerodynamics and Lighting.....................................75
Additional External Lamps - (Low Level Vehicles
Fuel Filler Mounting.......................................................37
Only)................................................................................59
Fuel Filler Pipe Shipping Bracket (if
Aids for Vehicle Entry and Exit...................................17
equipped)......................................................................35
Air Bags - (High Level Vehicles)..............................84
Fuel Filler Vent Hose....................................................39
Air Bags - (Low Level Vehicles)................................81
Fuel System.....................................................................35
Airbag Supplemental Restraint System
Fuses and Relays...........................................................67
(SRS)................................................................................81
Alternative Type Approval.............................................7
Ancillary Equipment - Sub Frame Mounting......93 G
Area for Fitting Additional Body Attachments to General......................................................................33, 90
the Rear of the Bumper............................................93 General Component Package Guidelines.............17
Auxiliary Battery and Fuse Box - Low Level General......................................................................33, 90
Vehicles...........................................................................67 General Product Safety Requirement......................7
Auxiliary Fuse Box (Vehicles with Special Generator and Alternator............................................47
Equipment Pack) (Low Level Vehicles Genuine Ford Accessory Bull Bar.............................76
Only)................................................................................68
Auxiliary Lighting Loads (Low Level Vehicles
Only)................................................................................62 H
Axle Breather Vent Hose............................................40 Handles, Locks, Latches and Entry Systems......66
Hardware—Specifications..........................................22
B How to Use This Manual...............................................5
Battery and Cables........................................................41
Battery Information.......................................................41 I
Body.....................................................................................71 Important Safety Instructions.....................................5
Body Structures - General Information..................71 Integrated Bodies and Conversions.........................71
Brake Hoses.....................................................................33 Introduction........................................................................5
Brake System..................................................................33
J
C Jacking................................................................................13
Canopies...........................................................................78
Center of Gravity............................................................26
Central Locking..............................................................66 K
Centre High Mount Stop Lamp (CHMSL) - Kerb Mass and Payload................................................21
Canopy Fitment - High Level Vehicles................64
Centre High Mount Stop Lamp (CHMSL) - L
Canopy Fitment -Low Level Vehicles..................63
Chassis Cab Body - Basic Dimensions and Lamps – Hazard / Direction Indication.................63
Weights...........................................................................20 Legal and Vehicle Type Approval...............................7
Chassis Cab......................................................................72 Legal Obligations and Liabilities.................................7
Commercial and Legal Aspects..................................7 Lifting..................................................................................14
Contact Corrosion........................................................90 Load Distribution—Specifications...........................23
Conversion Effect on Fuel Economy and Load Distribution Calculations - Driver and
Performance..................................................................12 Passenger Weight Distribution...............................23
Conversion Effects on Parking Aids.........................17 Low Level and High Level Vehicles.....................6, 67
Conversion Homologation............................................9
Corrosion Prevention...................................................90 M
Minimum Requirements for Brake system and
D Load Apportioning Valves..........................................8
Drilling and Welding........................................................8 Mounting Points and Tubing......................................91
Driver Field of View.........................................................17
Driver Reach Zones.........................................................17 N
New for this BEMM publication 07/2018................5
E Noise, Vibration and Harshness (NVH).................15
Electrically Operated Door Mirrors..........................63
Electromagnetic Compatibility (EMC)..................10 P
Electromagnetic Compatibility.................................10
Electronic Engine Controls........................................48 Package and Ergonomics—Specifications...........19
Exterior Lighting.............................................................55 Package and Ergonomics............................................17
Painting Road Wheels.................................................90
Product Liability...............................................................8
F
Frame and Body Mounting.........................................91
Frame Drilling and Tube Reinforcing......................93

94
 Index
R
Rear Combination lamps..........................................56
Rear Fog Lamp..............................................................56
Rear License Plate Lamp...........................................57
Recommended Body Dimensions..........................19
Registration Plates.......................................................18
Repairing Damaged Paint........................................90
Restraints System..........................................................8
Reversing Lamps, Rear View Camera, Reversing
Alarm (Manual Transmission)..............................59
Road Safety......................................................................8
Roof Racks.......................................................................77

S
Seatbelt Systems — Australia................................89
Self-Supporting Body Structure............................92
Supplementary Restraint Sensors (Front).........87
Suspension System.....................................................32

T
Tank and Dry Bulk Carriers........................................76
Terminology.......................................................................7
Tipper Bodies.................................................................75
Towing capacities........................................................30
Towing Requirements................................................30
Towing Specifications..................................................31
Towing..............................................................................30
Trailer Brakes..................................................................33
Trailer Towball Download..........................................31
Trailer Towing................................................................60

U
Under Body Protection and Material...................90

V
Vehicle Duty Cycle Guidelines..................................12
Vehicle Ride and Handling Attributes....................12
Vehicle Speed Output (Signal) (High Level
Vehicles )......................................................................54
Vehicle Speed Output (Signal) (Low Level
Vehicles Only).............................................................48
Vehicle Transportation Aids and Vehicle
Storage...........................................................................16

W
Warnings, Cautions and Notes in This
Manual..............................................................................5
Warranty on Ford Vehicles...........................................7
Water Tank on Camper Vehicles............................93

95