ford Workshop Repair Guides

Ford Workshop Service and Repair Manuals

501-25G Body Repairs - Noise, Vibration and Harshness > < Paintless Dent Removal
Body Repairs - Vehicle Specific Information and Tolerance Checks - Body and Frame Ranger 2006.5 (05/2006-)
Description and Operation

Frame Dimensions (Underbody Regular Cab 2WD)

Flat-plane dimensions

Straight-line dimensions

Point symbol Designation Hole diameter or bolt or nut size mm {in}
A Cabin mounting bracket No.1 ø27 {1.06}
B Bumper stay bracket ø15 {0.59}
C Tie down hook mounting hole ø13.5 {0.53}
D Front suspension bracket tension rod ø25 {0.98}
E Rebound stopper bracket ø12.5 {0.49}
F Front suspension bracket ø16 {0.63}
G Rebound stopper bracket ø12.5 {0.49}
H Cabin mounting bracket No.2 ø60 {2.36}
I Cabin mounting bracket No.3 ø65 {2.56}
J Box bracket No.1 ø20 {0.79}
K Box bracket No.2 ø16 {0.63}
K’ Box bracket No.2 ø20 {0.79}
L Box bracket No.3 ø16 x 23 {0.63 x 0.91}
L’ Box bracket No.3 ø20 {0.79}
M Box mounting hole ø20 {0.79}
N Front spring hanger ø14 {0.55}
O Dumper bracket M12 {0.47}
P Dumper bracket M12 {0.47}
Q Rear spring hanger ø32 {1.26}

Frame Dimensions (Underbody Double Cab 2WD)

Flat-plane dimensions

Straight-line dimensions

Point symbol Designation Hole diameter or bolt or nut size mm {in}
A Cabin mounting bracket No.1 ø27 {1.06}
B Bumper stay bracket ø15 {0.59}
C Tie down hook mounting hole ø13.5 {0.53}
D Front suspension bracket tension rod ø25 {0.98}
E Rebound stopper bracket ø12.5 {0.49}
F Front suspension bracket ø16 {0.63}
G Rebound stopper bracket ø12.5 {0.49}
H Cabin mounting bracket No.2 ø60 {2.36}
I Cabin mounting bracket No.3 ø65 {2.56}
J Cabin mounting bracket No.4 ø30 {1.18}
K Box bracket No.1 ø16 {0.63}
K’ Box bracket No.1 ø20 {0.79}
L Box bracket No.3 ø16 x 23 {0.63 x 0.91}
L’ Box bracket No.3 ø20 {0.79}
M Box mounting hole ø20 {0.79}
N Front suspension bracket ø48.5 {1.91}
O Front spring hanger ø14 {0.55}
P Dumper bracket M12 {0.47}
Q Dumper bracket M12 {0.47}
R Rear spring hanger ø32 {1.26}

Frame Dimensions (Underbody Stretch Cab {with rear access system} 2WD)

Flat-plane dimensions

Straight-line dimensions

Point symbol Designation Hole diameter or bolt or nut size mm {in}
A Cabin mounting bracket No.1 ø27 {1.06}
B Bumper stay bracket ø15 {0.59}
C Tie down hook mounting hole ø13.5 {0.53}
D Front suspension bracket tension rod ø25 {0.98}
E Rebound stopper bracket ø12.5 {0.49}
F Front suspension bracket ø16 {0.63}
G Rebound stopper bracket ø12.5 {0.49}
H Cabin mounting bracket No.2 ø60 {2.36}
I Cabin mounting bracket No.3 ø65 {2.56}
J Box bracket No.1 ø16 {0.63}
J’ Box bracket No.1 ø20 {0.79}
K Box bracket No.3 ø16 x 23 {0.63 x 0.91}
K’ Box bracket No.3 ø20 {0.79}
L Box mounting hole ø20 {0.79}
M Front spring hanger ø14 {0.55}
N Dumper bracket M12 {0.47}
O Dumper bracket M12 {0.47}
P Rear spring hanger ø32 {1.26}

Frame Dimensions(Underbody Stretch Cab {with rear access systen} Hi-Rider)

Flat-plane dimensions

Straight-line dimensions

Point symbol Designation Hole diameter or bolt or nut size mm {in}
A Cabin mounting bracket No.1 ø27 {1.06}
B Bumper stay bracket ø15 {0.59}
C Tie down hook mounting hole ø13.5 {0.53}
D Rebound stopper bracket ø12.5 {0.49}
E Front suspension bracket ø16 {0.63}
F Rebound stopper bracket ø12.5 {0.49}
G Cabin mounting bracket No.2 ø60 {2.36}
H Cabin mounting bracket No.3 ø65 {2.56}
I Box bracket No.1 ø16 {0.63}
I’ Box bracket No.1 ø20 {0.79}
J Box bracket No.3 ø16 x 23 {0.63 x 0.91}
J’ Box bracket No.3 ø20 {0.79}
K Box mounting hole ø20 {0.79}
L Front suspension bracket ø16.5 {0.65}
M Front suspension bracket ø40 {1.57}
N Front spring hanger ø14 {0.55}
O Dumper bracket M12 {0.47}
P Dumper bracket M12 {0.47}
Q Rear spring hanger ø32 {1.26}

Frame Dimensions (Underbody Double Cab 4WD)

Flat-plane dimensions

Straight-line dimensions

Point symbol Designation Hole diameter or bolt or nut size mm {in}
A Cabin mounting bracket No.1 ø27 {1.06}
B Bumper stay bracket ø15 {0.59}
C Tie down hook mounting hole ø13.5 {0.53}
D Rebound stopper bracket ø12.5 {0.49}
E Front suspension bracket ø16 {0.63}
F Rebound stopper bracket ø12.5 {0.49}
G Cabin mounting bracket No.2 ø60 {2.36}
H Cabin mounting bracket No.3 ø65 {2.56}
I Cabin mounting bracket No.4 ø30 {1.18}
J Box bracket No.1 ø16 {0.63}
J’ Box bracket No.1 ø20 {0.79}
K Box bracket No.3 ø16 x 23 {0.63 x 0.91}
K’ Box bracket No.3 ø20 {0.79}
L Box mounting hole ø20 {0.79}
M Front suspension bracket ø16.5 {0.65}
N Front suspension bracket ø40 {1.57}
O Front spring hanger ø14 {0.55}
P Dumper bracket M12 {0.47}
Q Dumper bracket M12 {0.47}
R Rear spring hanger ø32 {1.26}

FRAME DIMENSIONS (UNDERBODY STRETCH CAB {WITH REAR ACCESS SYSTEM} 4WD)

Flat-plane dimensions

Straight-line dimensions

Point symbol Designation Hole diameter or bolt or nut size mm {in}
A Cabin mounting bracket No.1 ø27 {1.06}
B Bumper stay bracket ø15 {0.59}
C Tie down hook mounting hole ø13.5 {0.53}
D Rebound stopper bracket ø12.5 {0.49}
E Front suspension bracket ø16 {0.63}
F Rebound stopper bracket ø12.5 {0.49}
G Cabin mounting bracket No.2 ø60 {2.36}
H Cabin mounting bracket No.3 ø65 {2.56}
I Box bracket No.1 ø16 {0.63}
I’ Box bracket No.1 ø20 {0.79}
J Box bracket No.3 ø16 x 23 {0.63 x 0.91}
J’ Box bracket No.3 ø20 {0.79}
K Box mounting hole ø20 {0.79}
L Front suspension bracket ø16.5 {0.65}
M Front suspension bracket ø40 {1.57}
N Front spring hanger ø14 {0.55}
O Dumper bracket M12 {0.47}
P Dumper bracket M12 {0.47}
Q Rear spring hanger ø32 {1.26}

Front Body Straight-Line Dimensions (1)

Point symbol Designation Hole diameter or bolt or nut size mm {in}
A Shroud panel datum hole ø7 {0.28}
B Shroud panel datum hole ø7 {0.28}
C Shroud panel datum hole ø7 {0.28}
D Shroud panel datum hole ø7 {0.28}
E Shroud panel datum hole ø6.2 {0.24}
F Crossmember datum hole ø10 {0.39}

Front Body Straight-Line Dimensions (2)

Point symbol Designation Hole diameter or bolt or nut size mm {in}
A Windshield garnish installation square hole 6.8 x 6.8{0.27 x 0.27}
B Windshield garnish installation square hole 6.8 x 6.8{0.27 x 0.27}
C Bonnet hinge installation hole ø12 {0.47}
D Front fender installation hole ø10 {0.39}
E Shroud gusset datum hole ø14 {0.55}
F Cowl panel datum slot ø6.2 x 8{0.24 x 0.31}
F’ Cowl panel datum slot ø6.2 {0.24}
G Shroud panel datum hole ø10 {0.39}

Cabin Side Frame Straight-Line Dimensions (Regular Cab)

Point symbol Designation Hole diameter or bolt or nut size mm {in}
A Wheel apron panel front datum hole ø12 {0.47}
B Shroud panel datum hole ø7 {0.28}
C Windshield garnish installation square hole 6.8 x 6.8{0.27 x 0.27}
D Door hinge installation hole ø12 {0.47}
E Door hinge installation hole ø12 {0.47}
F Side frame outer connection -
G Side frame outer datum hole ø3.2 {0.13}

Cabin Side Frame Straight-Line Dimensions (Double Cab)

Point symbol Designation Hole diameter or bolt or nut size mm {in}
A Wheel apron panel front datum hole ø12 {0.47}
B Shroud panel datum hole ø7 {0.28}
C Windshield garnish installation square hole 6.8 x 6.8{0.27 x 0.27}
D Door hinge installation hole ø12 {0.47}
E Door hinge installation hole ø12 {0.47}
F Side frame outer connection -
G Door hinge installation hole ø12 {0.47}
H Door hinge installation hole ø12 {0.47}
I Side frame outer connection -
J Side frame outer connection -
K Side frame outer datum hole ø3.2 {0.13}

Cabin Side Frame Straight-Line Dimensions (Stretch Cab {with rear access system}, Hi-Rider)

Point symbol Designation Hole diameter or bolt or nut size mm {in}
A Wheel apron panel front datum hole ø12 {0.47}
B Shroud panel datum hole ø7 {0.28}
C Windshield garnish installation square hole 6.8 x 6.8{0.27 x 0.27}
D Door hinge installation hole ø12 {0.47}
E Door hinge installation hole ø12 {0.47}
F Striker installation hole ø7 {0.28}
G Striker installation hole ø13 {0.51}
H Side frame outer datum hole ø5 {0.20}
I Rear access panel hinge installation hole ø12 {0.47}
J Rear access panel hinge installation hole ø12 {0.47}

Room Straight-Line Dimensions (Regular Cab)

Point symbol Designation Hole diameter or bolt or nut size mm {in}
A Harness installation hole ø7 {0.28}
B Front pillar inner datum hole ø10 {0.39}
C Cowl side panel datum hole ø12 {0.47}
D Tunnel reinforcement installation hole ø7 {0.28}
E Rear pillar inner datum hole ø12 {0.47}
F Rear pillar inner datum hole ø12 {0.47}
G Rear pillar inner datum slot ø8 x 12{0.31 x 0.47}
H Striker installation slot ø8.2 x 7.6{0.32 x 0.30}

Room Straight-Line Dimension (Double Cab)

Point symbol Designation Hole diameter or bolt or nut size mm {in}
A Harness installation hole ø7 {0.28}
B Front pillar inner datum hole ø10 {0.39}
C Cowl side panel datum hole ø12 {0.47}
D Tunnel reinforcement installation hole ø7 {0.28}
E Center pillar inner datum hole ø7 {0.28}
F Center pillar inner datum hole ø7 {0.28}
G Center pillar inner datum hole ø7 {0.28}
H Rear pillar inner datum hole ø12 {0.47}
I Rear pillar inner datum slot ø7 x 9{0.28 x 0.35}
J Rear pillar inner datum hole ø6 {0.24}
K Striker installation hole ø10 {0.39}
L Striker installation slot ø8.2 x 7.6{0.32 x 0.30}

Room Straight-Line Dimensions (Stretch Cab {with rear access system}, Hi-Rider)

Point symbol Designation Hole diameter or bolt or nut size mm {in}
A Harness installation hole ø7 {0.28}
B Front pillar inner datum hole ø10 {0.39}
C Cowl side panel datum hole ø12 {0.47}
D Trim installation hole ø10 {0.39}
E Striker installation hole ø7 {0.28}
F Trim installation slot ø10 x 15{0.39 x 0.59}
G Striker installation hole ø13 {0.51}
H Rear pillar inner datum hole ø12 {0.47}
I Pillar trim datum hole ø6 {0.24}
J Pillar trim datum slot ø10 x 20{0.39 x 0.79}
K Tunnel reinforcement datum hole ø7 {0.28}
L - -
M Side frame outer datum hole ø10 {0.39}

Point symbol Designation Hole diameter or bolt or nut size mm {in}
A Harness installation hole ø7 {0.28}
B Front pillar inner datum hole ø10 {0.39}
C Cowl side panel datum hole ø12 {0.47}
D Trim installation hole ø10 {0.39}
E Striker installation hole ø7 {0.28}
F Trim installation slot ø10 x 15{0.39 x 0.59}
G Striker installation hole ø13 {0.51}
H Rear pillar inner datum hole ø12 {0.47}
I Pillar trim datum hole ø6 {0.24}
J Pillar trim datum slot ø10 x 20{0.39 x 0.79}
K - -
L Crossmember No.3 datum hole ø10 {0.39}

501-25G Body Repairs - Noise, Vibration and Harshness > < Paintless Dent Removal