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"
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 × 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
2.3.2 • 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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