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Ford Workshop Service and Repair Manuals

501-27 Front End Sheet Metal Repairs > < Underbody Tolerance Check
Body Repairs - Vehicle Specific Information and Tolerance Checks - Body Tolerance Check Transit 2006.5 (04/2006-)
General Procedures

NOTE:
NOTE:The bodies of the Transit 2000.5 (01/2000-05/2006) and the Transit 2006.5 (04/2006-) are identical in design except for the front end. The specific dimensions of the front end are shown in illustrations E83598 and E83182. All other body dimensions are identical.
  1. When re-alignment work is being carried out, or individual components are being exchanged, the given required values may be taken as guidelines (tolerance ± 3 mm).
  1. NOTE:
    NOTE:Testing the bodywork dimensions does not mean that the usual alignment work is not necessary.
    This makes it possible to reduce the repeated installation and removal of attached components (e.g. doors, glazing, crossmembers etc.) in order to check that the bodywork measurements are correct.
  1. NOTE:
    NOTE:The dimensions shown in illustration E83598 are only valid for the Transit 2000.5 (01/2000-05/2006).
    Body dimensions, front view, Transit 2000.5 (01/2000-05/2006). All dimensions with tolerance ± 3 mm. All dimensions are determined starting from the center of the bolt head using a symmetrically adjusted measuring gauge.

    Measuring points and dimensions

    1 - 3 = 1,565 mm 2 - 3 = 571 mm
    1 - 4 = 571 mm 2 - 4 = 1,565 mm

  1. NOTE:
    NOTE:The dimensions shown in illustration E83182 are only valid for the Transit 2006.5 (04/2006-).
    Body dimensions, front view, Transit 2006.5 (04/2006-). All dimensions with tolerance ± 3 mm. All dimensions are determined starting from the center of the bolt head using a symmetrically adjusted measuring gauge.
    • The measuring points are arranged asymmetrically.
    • Measuring points and dimensions

      1 - 3 = 1,440 mm 2 - 3 = 545 mm
      1 - 4 = 524 mm 2 - 4 = 1,449 mm

  1. Body dimensions, front view. All dimensions with tolerance ± 3 mm. All dimensions are determined starting from the centre of each hole or panel edge using a symmetrically adjusted measuring gauge.

    Measuring points and dimensions

    1 - 2 = 1,826 mm 9 - 10 = 1,106 mm
    3 - 4 = 822 mm 9 - 12 = 1,212 mm
    5 - 6 = 1,605 mm 11 - 12 = 1,106 mm
    7 - 8 = 1,485 mm 13 - 14 = 1,062 mm

  1. Side view, body dimensions. All dimensions with tolerance ± 3 mm. All dimensions are determined starting from the centre of each hole or panel edge using a symmetrically adjusted measuring gauge.

    Measuring points and dimensions

    1 - 2 = 1,347 mm 7 - 8 = 980 mm
    3 - 4 = 1,281 mm 8 - 11 = 1,250 mm
    5 - 6 = 1710 mm (high roof only) 9 - 10 = 1,450 mm

  1. Passenger compartment, body dimensions. All dimensions with tolerance ± 3 mm. All dimensions are determined starting from the centre of each hole or panel edge using a symmetrically adjusted measuring gauge.

    Measuring points and dimensions

    1 - 2 = 1,675 mm 5 - 6 = 1,285 mm
    3 - 4 = 1,702 mm 7 - 8 = 1,725 mm

  1. Rear view, body dimensions. All dimensions with tolerance ± 3 mm. All dimensions are determined starting from the centre of each hole or panel edge using a symmetrically adjusted measuring gauge.

    Measuring points and dimensions

    1 - 2 = 1,452 mm 5 - 6 = 1,645 mm
    1 - 8 = 2,149 mm 7 - 8 = 1,650 mm
    3 - 4 = 1,610 mm 9 - 10 = 1,574 mm

  1. Front and side clearances.

    Clearances and tolerances

    1 = 6.0 mm ± 1.5 mm 7 = 6.0 mm ± 1.6 mm
    2 = 6.0 mm ± 1.6 mm 8 = 6.0 mm ± 1.6 mm
    3 = 6.0 mm ± 3.5 mm 9 = 6.0 mm ± 1.6 mm
    4 = 4.0 mm ± 1.0 mm 10 = 6.0 mm ± 1.6 mm
    5 = 6.0 mm ± 1.6 mm 11 = 6.0 mm ± 1.6 mm
    6 = 6.5 mm ± 1.6 mm

  1. Rear clearances.

    Clearances and tolerances

    1 = 9.0 mm ± 2.0 mm 4 = 13.0 mm ± 2.0 mm
    2 = 6.0 mm ± 2.0 mm 5 = 10.0 mm ± 2.5 mm
    3 = 6.0 mm ± 1.0 mm

501-27 Front End Sheet Metal Repairs > < Underbody Tolerance Check