Ranger design 6540-FTS Installation guide

Type
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
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"
for shelving installation
#92-102 Screw 1"
#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
# 98-118
16×
Lock Washer
1/4"
ZINC
# 98-122
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
# 90-490
Bolt Carriage
5/16"-18 × 1"
ZINC
# 94-104
Hex Nut
5/16" - 18
ZINC
# 92-174
Screw
#10 × 3/4"
ZINC
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"
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
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
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
2.2.4Put 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 × 36.5
70-890 × 41.625
70-890 × 41.625
70-891 × 19.25
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 × 36.5
70-890 × 41.625
70-890 × 41.625
70-891 × 19.25
70-891 × 19.25
2.3.2Put 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
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
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
#92-102 Screw 1"
HARDWARE USED
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.
2.4.1Lift 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

Type
Installation guide

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