Ranger design 6540-FTS Installation guide

INSTALLATION GUIDE

6540-FTS FLOOR

Ford Transit ( 130" Wheelbase )

QUICK START GUIDE

REQUIRED ITEMS

2

PERSONS

q 1.1 Setup............................................................................................................................................... 3 - 4

Phase 1 - Assembly

Phase 2 - Installation

q Cordless Impact

q Tape Measure

q Rubber Mallet

q 7/16" Socket

q 1/2" Socket

q Plus Nut Tool

q 13mm Socket

q 3/8" Impact Bit

q Square Impact Bit

q Marker

q 3/8" Drill Bit

q Drill Collar ( Set at 1/2" )

q 1" Hole Saw

q Wood Saw

q 2.1 Install Preparation............................................................................................................................

q 2.2 Floor Installation w/o Plastic Floor...................................................................................................

q 2.3 Floor Installation w/ Plastic..............................................................................................................

q 2.4 How To Install Shelving In Ranger Design Floor..............................................................................

5 - 7

8 - 13

14 - 19

20

For technical support, contact us at 1-800-565-5321 6540-FTS Installation Guide | REV. B3 | Page 3

PHASE 1 – ASSEMBLY

1.1 SETUP

1.1.1 Unpack components; compare with the bill of materials.

1.1.2 Verify all parts are present.

Item No. Description Qty.

65-408 Floor Panel ( Front ) 1

65-409 Floor Panel ( Middle ) 1

65-410 Floor Panel ( Rear ) 1

70-890 × 36.5 Extrusion Machined ( 36 - 1/2" ) 2

70-890 × 41.625 Extrusion Machined ( 41 - 5/8" ) 2

70-891 × 19.25 Extrusion Machined ( 19 - 1/4" ) 2

EN-881 × 53-00 I Beam Extrusion ( 53" ) 1

EN-881 × 59.375-00 I Beam Extrusion ( 59 - 3/8" ) 1

EN-882 × 5-00 Sill Extrusion ( 5" ) 1

EN-882 × 21.875-00 Sill Extrusion ( 21 - 7/8" ) 1

EN-882 × 33.875-00 Sill Extrusion ( 33 - 7/8" ) 1

EN-882 × 41-00 Sill Extrusion ( 41" ) 1

96-6014 Install Fastener Kit 1

BILL OF MATERIALS

65-410

EN-882 × 5-00

EN-882 × 21.875-00 EN-882 × 41-00

EN-882 × 33.875-00

65-409

EN-881 × 53-00

EN-881 × 59.375-00

70-890 × 36.5

70-890 × 36.5 70-890 × 41.625

70-890 × 41.625 70-891 × 19.25

70-891 × 19.25

65-408

For technical support, contact us at 1-800-565-5321 6540-FTS Installation Guide | REV. B3 | Page 4

96-6014 Fastener Kit Fastener Install

1.1.3 Fastener kits.

16×

#90-114 Hex Bolt 1/4" × 1"

#94-130 Plus Nut

#98-118 Lock Washer

#98-157 Spacer

#98-112 Flat Washer

6× for shelving installation

#90-490 Carriage Bolt 5/16" × 1"

#94-104 Hex Nut

#98-116 Lock Washer

#98-122 Flat Washer

14×

#92-200 Screw 3/4"

6× for shelving installation

#92-102 Screw 1"

6×

#92-200 Screw 3/4"

# 98-112

Flat Washer

1/4", O.D. 3/4"

ZINC

16×

# 98-116

Flat Washer

5/16", O.D. 7/8"

ZINC

6×

# 98-118

16×

Lock Washer

1/4"

ZINC

# 98-122

6×

Lock Washer

5/16"

ZINC

# 90-114

16×

Hex Bolt

1/4"-20 × 1"

ZINC

# 94-130 Plus Nut

1/4" - 20

16×

# 98-157

16×

Spacer

0.375" ID, 1" OD, 0.250"

Thick Nylon

# 92-200

Screw

#10 × 3/4"

ZINC

14×

# 92-102

Screw

#14 × 1"

ZINC

6×

# 90-490

Bolt Carriage

5/16"-18 × 1"

ZINC

6×

# 94-104

Hex Nut

5/16" - 18

ZINC

6×

# 92-174

Screw

#10 × 3/4"

ZINC

6×

For technical support, contact us at 1-800-565-5321 6540-FTS Installation Guide | REV. B3 | Page 5

PHASE 2 – INSTALLATION

2.1 INSTALL PREPARATION

4 - 3/4"

1 - 11/16"

1 - 1/2"

Cut this if the vehicle has

side plastic sill.

Cut this if the vehicle has

side plastic sill.

Cut this if the vehicle has

rear plastic sill.

TOOLS

q Tape Measure

q Wood Saw

2.1.1 Cut the oor panels if the vehicle has plastic sill.

NOTE: Don’t do this step if the vehicle has no plastic sill.

65-410 65-409 65-408

For technical support, contact us at 1-800-565-5321 6540-FTS Installation Guide | REV. B3 | Page 6

3 - 5/8"

Cut this if the vehicle has

partition.

TOOLS

q Tape Measure

q Aluminum Cutter

2.1.2 Cut the 41" for oor partition.

NOTE: Don’t do this step if your not installing Ranger Design partition on top of the Ranger Design oor.

FOR VAN WITH RANGER DESIGN PARTITION WITH FLOOR BRACKET ONLY

EN-882 × 41-00

For technical support, contact us at 1-800-565-5321 6540-FTS Installation Guide | REV. B3 | Page 7

2.1.3 Remove the D-rings on the vehicle if needed.

TOOLS

q Cordless Impact

q 13mm Socket

Remove the D-rings if

needed.

Remove the Sliding door plastic sill.

NOTE: Don’t do this step if the vehicle has no plastic sill.

For technical support, contact us at 1-800-565-5321 6540-FTS Installation Guide | REV. B3 | Page 8

2.2.1 Lift the three oor panels into the van, starting with the front panel, and attach together with the two

EN-881 I beam extrusions.

PHASE 2 – INSTALLATION

2.2 FLOOR INSTALLATION W/O PLASTIC SILL

65-40865-40965-410

Rubber Mallet

EN-881 × 53-00 EN-881 × 59.375-00

TOOLS

q Rubber Mallet

NOTE: Make sure that the I beam extrusions are centered to the oor panels.

Center the I beam extrusions to

the panels.

For technical support, contact us at 1-800-565-5321 6540-FTS Installation Guide | REV. B3 | Page 9

2.2.2 Screw the side sill to the oor panels.

TOOLS

q Cordless Impact

q 3/8" Impact Bit

#92-200 Screw 3/4"

HARDWARE USED

5×

EN-882 × 41-00

For technical support, contact us at 1-800-565-5321 6540-FTS Installation Guide | REV. B3 | Page 10

2.2.3 Screw the rear sill to the oor panel.

TOOLS

q Cordless Impact

q 3/8" Impact Bit

#92-200 Screw 3/4"

HARDWARE USED

9×

EN-882 × 5-00 EN-882 × 21.875-00EN-882 × 33.875-00

For technical support, contact us at 1-800-565-5321 6540-FTS Installation Guide | REV. B3 | Page 11

2.2.4 • Put the 36 - 1/2", 41 - 5/8" and 19 - 1/4" extrusions in place, then mark all the holes.

• Remove the extrusions, then drill all the marks.

TOOLS

q Marker

Mark all the holes

NOTE: Before drilling, ensure that you will not hit any critical parts of the vehicle like the Gas tank,

Wiring Harness and Hose.

70-890 × 36.5

70-890 × 41.625

70-891 × 19.25

TOOLS

q Cordless Drill

q 3/8" Drill Bit

q Drill Collar ( Set at 1/2" )

q 1" Hole Saw

NOTE: If the mark is on the plastic cover,

use 1" hole saw to drill the plastic

cover, then use 3/8" drill bit with

drill collar to drill the floor.

For technical support, contact us at 1-800-565-5321 6540-FTS Installation Guide | REV. B3 | Page 12

TOOLS

q Plus Nut Tool

HARDWARE USED

16×

#94-130 Plus Nut .250

2.2.5 Attach plus nuts on the holes.

For technical support, contact us at 1-800-565-5321 6540-FTS Installation Guide | REV. B3 | Page 13

2.2.6 Attach the 36 - 1/2", 41 - 5/8" and 19 - 1/4" extrusions.

TOOLS

q Cordless Impact

q 7/16" Socket

HARDWARE USED

16×

#90-114 Hex Bolt 1/4" × 1"

#94-130 Plus Nut ( Aready Installed )

#98-118 Lock Washer

#98-157 Spacer

#98-112 Flat Washer

For technical support, contact us at 1-800-565-5321 6540-FTS Installation Guide | REV. B3 | Page 14

2.3.1 Lift the three oor panels into the van, starting with the front panel, and attach together with the two

EN-881 I beam extrusions.

PHASE 2 – INSTALLATION

2.3 FLOOR INSTALLATION W/ PLASTIC SILL

65-40865-40965-410

Rubber Mallet

EN-881 × 53-00 EN-881 × 59.375-00

TOOLS

q Rubber Mallet

Center the I beam extrusions to

the panels.

NOTE: • Make sure that you did step 2.1.1 on Page 5.

• Make sure that the I beam extrusions are centered to the oor panels.

For technical support, contact us at 1-800-565-5321 6540-FTS Installation Guide | REV. B3 | Page 15

TOOLS

q Marker

Mark all the holes

TOOLS

q Cordless Drill

q 3/8" Drill Bit

q Drill Collar ( Set at 1/2" )

q 1" Hole Saw

NOTE: If the mark is on the plastic cover,

use 1" hole saw to drill the plastic

cover, then use 3/8" drill bit with

drill collar to drill the floor.

70-890 × 36.5

70-890 × 41.625

70-891 × 19.25

2.3.2 • Put the 36 - 1/2", 41 - 5/8" and 19 - 1/4" extrusions in place, then mark all the holes.

• Remove the extrusions, then drill all the marks.

NOTE: Before drilling, ensure that you will not hit any critical parts of the vehicle like the Gas tank,

Wiring Harness and Hose.

For technical support, contact us at 1-800-565-5321 6540-FTS Installation Guide | REV. B3 | Page 16

TOOLS

q Plus Nut Tool

HARDWARE USED

16×

#94-130 Plus Nut .250

2.3.3 Attach plus nuts on the holes.

For technical support, contact us at 1-800-565-5321 6540-FTS Installation Guide | REV. B3 | Page 17

2.3.4 Screw the 3 rear sills to the oor panel.

TOOLS

q Cordless Impact

q 3/8" Impact Bit

#92-200 Screw 3/4"

HARDWARE USED

9×

EN-882 × 5-00 EN-882 × 21.875-00EN-882 × 33.875-00

For technical support, contact us at 1-800-565-5321 6540-FTS Installation Guide | REV. B3 | Page 18

2.3.5 Cut the shim on the hole of the plastic sill.

CUT

FROM TO

For technical support, contact us at 1-800-565-5321 6540-FTS Installation Guide | REV. B3 | Page 19

2.3.6 Reinstall the OEM plastic sill, then screw the sill to the oor.

TOOLS

q Cordless Impact

q Square Impact Bit

#92-174 Screw 3/4"

HARDWARE USED

6×

For technical support, contact us at 1-800-565-5321 6540-FTS Installation Guide | REV. B3 | Page 20

PHASE 2 – INSTALLATION

2.4 HOW TO INSTALL SHELVING IN RANGER DESIGN FLOOR

#94-104 Hex Nut

#98-116 Lock Washer

#98-122 Flat Washer

#90-490 Carriage Bolt 5/16" × 1"

HARDWARE USED

2×

#92-102 Screw 1"

HARDWARE USED

2×

TOOLS

q Cordless Impact q 3/8" Impact Bit

q 1/2" Socket q 5/16" Drill Bit

Enlarge the hole that aligned to the mounting track using 3/8" drill bit.

2.4.1 • Lift the shelving unit inside the van, then put it in place.

• Enlarge the holes in the shelving end panels that aligned to the mounting tracks using 3/8" drill bit.

• Install the shelving unit to the oor mounting track by sliding bolts in the mounting tracks,

and putting screws in the last rear hole of the end panels of the shelving unit.

NOTE: After installing the shelf unit to the floor install the shelf brackets to the vehicle.

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Ranger design 6540-FTS Installation guide

Ranger design 6540-FTS Installation guide

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