Mitsubishi Fuso FE, FG 2007 Technical Manual – Factory Body Mounting Data

Description

I’ve been wrenching on trucks for more years than I care to count, and if you’re planning to mount a body on a Mitsubishi Fuso FE or FG chassis without the factory body builder drawings, you’re asking for trouble. This Mitsubishi Fuso FE, FG 2007 Technical Manual is the official document that Mitsubishi Fuso intended for body builders and mechanics who need exact clearances, torque specs for frame modifications, and legal compliance data. No aftermarket reprint — this is the original OEM file, 168 pages of schematics, clearance tables, and regulatory warnings that will keep your build legal and safe.

Clearance Between Body and Chassis Components

You want to know if your body will clear the engine, transmission, axle, or exhaust? Part I opens with clearance measurements for every critical area. Section 1.2 covers clearance around the engine, 1.3 through 1.6 detail transmission clearance — above, below, and behind the transmission. The manual gives you dimensions for both automatic and manual transmission models. If you’re mounting a body on an FE85 with a manual transmission, you’ll find the specific data in the chassis cab drawing for that variant. Ignoring these clearances means a body that rubs, overheats, or fails inspection. The factory tolerances are on page 3 of the PDF — check them before you cut a single bracket.

What Does the FMVSS Compliance Section Tell You?

Page 2 and 3 contain the Federal Motor Vehicle Safety Standards (FMVSS) compliance information. Mitsubishi Fuso sells the FE and FG as incomplete vehicles. That means you, as the body builder, are legally responsible for certifying compliance after mounting your body. The manual includes the list of FMVSS and CMVSS standards the chassis partially meets, and a clear explanation of what you need to do to stay legal. If you modify the frame, brake lines, or electrical system, you take on the liability. I’ve seen shops skip this section and later face recall issues. Do not skip it.

Modifying Chassis Frames: Drilling and Welding Guidelines

Section 3 of Part I is titled “CAUTION IN MODIFYING CHASSIS FRAMES.” It spells out exactly where you can drill side rails, crossmembers, and what welding is allowed. Section 3.1 covers drilling frames in general, 3.2 gets into side rail specifics — hole size limits, spacing, and distance from edges. Section 3.4 tells you what welding processes are acceptable. There’s even a subsection on shortening or extending the frame within the wheelbase (3.6). If you’re adding a sub-frame or mounting equipment on the side rail, read 3.8 first. This is not generic advice — it’s the factory’s own engineering rules. Ignore them and you risk cracking a frame rail under load.

Electrical Wiring for Body Equipment

Section 6 covers electrical wiring for the body. It tells you how to tap into the chassis power source, where to install switches and relays, and how to run additional wiring without overloading circuits. The manual specifies the power source for body equipment (6.2) and how to install switches for specially equipped bodies (6.3). If you’re adding work lights, a lift gate, or a refrigeration unit, you need this to avoid voltage drops or fire hazards. The Mitsubishi Fuso FE FG 1990 Service Manual – Section: Heater and Mitsubishi Fuso FE FG 1991 Service Manual – Section: Heater cover older models, but this 2007 Technical Manual gives you the current electrical specs for the FE and FG.

Brake Lines: Making Additional Tubes

Brake line modifications are a safety-critical operation. Section 8 gives you the chassis tubing form and dimension specifications (8.1), then walks you through making additional tubes (8.2) and running additional lines (8.3). The manual includes flare types, tube material specs, and routing clearances. Do not guess on brake line lengths — use the drawings in Part II to match the OEM tube paths. If you’re working with a manual transmission model, the Manual Transmission section in the chassis cab drawings provides the specific transmission mount location that affects brake line routing. Likewise, the Manual Transmission data is referenced in the clearance tables. Get those lines right the first time — no one wants a brake failure on a loaded truck.

Frame Section Modulus Diagrams and Their Importance

Part II contains frame section modulus diagrams for every FE and FG variant: FE8□DDZ, FE8□DEZ, FE8□DGZ, FE8□DJZ, FE85DKZ, FE84DHW, and FG84DF6. These diagrams show the frame rail strength at key points. If you’re mounting a heavy body or adding a sub-frame, you need these to calculate whether the frame can handle the load. The manual also includes spring data and vehicle sprung weight (Section 7.3). A 2007 FUSO FE/FG 2008 Owner’s Manual won’t have this engineering data — only this Technical Manual does.

FAQ

Does this manual include engine torque specifications?

No. This manual focuses on body mounting, not engine disassembly.

Can I use this manual to modify the frame?

Yes. Sections 3.1 through 3.9 cover drilling, welding, frame extension, and reinforcement. The manual gives exact hole sizes, distances from rail edges, and welding procedures approved by Mitsubishi Fuso. It also warns against modifications that could violate FMVSS compliance. For example, Section 3.5 warns that extending rear overhang beyond factory limits may affect rear axle weight distribution and requires a structural analysis. Follow these guidelines and you keep your certification valid. If you deviate, assume full liability.

Related Manuals

• Mitsubishi Fuso FE FG 1990 Service Manual – Section: Heater
• Mitsubishi Fuso FE FG 1991 Service Manual – Section: Heater
• FUSO FE/FG 2008 Owner’s Manual

If you’re serious about doing this job right, Access the Factory Manual. Get the complete 168-page document with all the chassis cab drawings, frame data, and legal certifications — the same PDF Mitsubishi Fuso provides to its authorized body builders.