| Description and Operation Introduction With the Transit, Ford has developed a completely new bodywork concept in the commercial vehicle sector. Taking into account all active and passive safety components, current materials or material combinations have been integrated into the overall bodyshell design. The combination of various jointing techniques within the overall bodyshell design makes rationalized repair techniques possible in the service area. Technology and economy have been intentionally balanced, resulting in development of a basic overall platform with the Transit that points the way ahead for current Ford technology. Design features, Transit 2000.5 (01/2000-05/2006) and Transit 2006.5 (04/2006-) The Transit 2000.5 (01/2000-05/2006) will be replaced by the Transit 2006.5 (04/2006-). The bodywork of the two vehicles are identical apart from the front end. Important structural components, particularly at the front end of the vehicle, such as the side member, cross member and hood lock panel have been redeveloped or redesigned. Front cross member and side member, Transit 2000.5 (01/2000-05/2006) From chassis no. 4412103 to 4515866 (manufactured between 15.01.2000 and 15.05.2003), the front cross member is made of plastic. From chassis no. 4515867 (manufactured after 15.05.2003), the front cross member is made of sheet steel. NOTE:Both versions of the front cross member (plastic and sheet steel) are available as spare parts. The cross member is attached to the front ends of the side members using screwed connections. The integral deformation element in the cross member (crash element) absorbs a large proportion of the forces arising from a collision. The subsequent deformation process is pre-determined by 3 designated yield points in the front side members. NOTE:Reshaping and repairs to the front cross member are not permitted. In the event of discernible damage, it must be replaced. It is only possible to partially replace the side members (see subsection 501-27). Cross member and side member 2 — Designated yield points 3 — Area of the deformation elements Front cross member and side member, Transit 2006.5 (04/2006-) The front cross member is made of sheet steel. It is attached to the front ends of the side members using screwed connections, as on the Transit 2000.5 (01/2000-05/2006). NOTE:Reshaping and repairs to the front cross member are not permitted. In the event of discernible damage, it must be replaced. Cross member and side member Arrows — Attachment points (on the inside of the side member, the second screwed connection is covered by the cross member) There is only one integral designated yield point on the outside and inside of the front side members. Front side members with designated yield points Arrows — Designated yield points 1 — Front side member, inside 2 — Front side member, outside It is only possible to partially replace the side members (see subsection 501-27). Hood lock panel, Transit 2000.5 (01/2000-05/2006) The hood lock panel is made of a single piece of plastic and is attached to the bodywork using screwed connections. The screwed connections allow the hood lock panel to be aligned with the bodywork. NOTE:In the event of severe damage (structural damage), the hood lock panel must be replaced. Minor damage (cracks) can be eliminated with a corresponding GFK repair material. Hood lock panel 1 — Fender attachment points 3 — Fender apron panel attachment points 4 — Side member attachment points Hood lock panel, Transit 2006.5 (04/2006-) The hood lock panel is a three-part design and is made of sheet steel. In the event of damage, this modular construction allows individual segments to be replaced. The segments are attached using screwed connections. The screwed connections allow the individual segments of the hood lock panel to be aligned with the bodywork. Hood lock panel Arrows — Attachment and connection points Important information for use during accident repair There follows some important information which is helpful during accident repair work. front fender The fenders are attached to the bodywork using screwed connections. The exterior mirror must be removed before the fender can be removed. Fender attachment points Wiring harness and hose routing During work on the bodywork, such as cutting, grinding or welding, the installation location of the wiring harness and hoses must be taken into account due to the risk of damage. NOTE:The graphic DEE0013350 represents the most important areas in which the wiring harness and hose routing are present in the bodywork. 2 — Windscreen washer system supply hose NVH measures Various NVH components are installed in the A, B and C pillars in order to reduce noise. This reduces the size of the resonance space which the actual cavities present. This has been made possible by the development of new sound deadening technologies and the use of hybrid materials. During servicing, the original insulating elements must be replaced with equivalent insulating elements. The applicable replacement solutions are specified in the repair descriptions. Installation location of NVH elements Side panel seam seal The seam seal for the side panels is applied after painting. This has the advantage that the sealant retains its flexibility and later sealing work is possible without extra painting work. Outer seam seal Corrosion prevention measures All body parts that are liable to corrosion are zinc plated. It is therefore vitally important that the corrosion protection measures are carried out with the greatest care during bodywork repairs. Galvanised steel panels Galvanized and high strength steel panels 1 — Galvanized and high-strength steel panel 3 — High-strength steel panel Sheet metal parts for partial panel replacement repairs The following illustrations represent he current sheet metal parts available for partial panel replacement on all Transit model variants. | 
