Transcript
U.S. MOTOR VEHICLE SAFETY STANDARDS (APPLICATION BY VEHICLE TYPE) Bus School FMVSS (Not School Bus Number Title of Standard Bus) Control Location, Identification and 101 X X Illumination Transmission Shift Lever Sequence, Starter 102 X X Interlock & Transmission Braking Effect 103 Windshield Defrosting & Defogging Systems X X 104 Windshield Wiping and Washing Systems X X 105 Hydraulic Brake Systems X X 106 Brake Hoses X X Lamps, Reflective Devices & Associated 108 X X Equipment 109 New Pneumatic Tires 111 Rearview Mirrors X X 113 Hood Latch Systems X X 114 Theft Protection 116 Hydraulic Brake Fluids X X Power Operated Window, Partition, and Roof 118 Panel Systems New Pneumatic Tires for Vehicles Other 119 Than Passenger Cars Tire Selection and Rims for Motor Vehicles 120 X X Other Than Passenger Cars 121 Air Brake Systems X X 124 Accelerator Control Systems X X 125 Warning Devices 131 School Bus Pedestrian Safety Devices X 201 Occupant Protection in Interior Impact X(2) X(2) 202 Head Restraints X(2) X(2) Impact Protection for the Driver from the 203 X(2) X(2) Steering Control Systern 204 Steering Control Rearward Displacement X(4) X(4) 205 Glazing Materials 206 Door Locks and Door Retention Components 207 Seating System X X 208 Occupant Crash Protection X X 209 Seat Belt Assemblies 210 Seat Belt Assembly Anchorages X X 212 Windshield Mounting X(2) X(2) 213 Child Restraint Systems X X 214 Side Impact Protection X(2) X(2) 216 Roof Crush Resistance X(5) 217 Bus Window Retention and Release X X 219 Windshield Zone Intrusion X(2) X(2) 220 School Bus Rollover Protection X 221 School Bus Body Joint Strength X(3) School Bus Passenger Seating and Crash 222 X Protection 301 Fuel System Integrity X(2) X 302 Flammability of Interior Materials X X 303 Fuel System Integrity of CNG Vehicles X(2) X 304 CNG Fuel Container X X PART Vehicle Identification Number X X 565 (Applicable to incomplete vehicles as well)
Truck (Not Walk-in Van)
MPV
Truck (1) (Walk-in Equip. Van)
X
X
X
X
X
X
X X X X
X X X X
X X X X
X
X
X
X
X
X X X(2) X
X X X(2) X
X X
X(2)
X(2)
X(2)
X
X
X
X X
X
X
X X
X
X X
X
X X(2) X(2)
X(2) X(2)
X(2) X(2)
X(2)
X(2)
X(4)
X(4)
X X X
X X X
X X X
X X(2) X X(2) X(5)
X X(2) X X(2) X(5)
X
X(2)
X(2)
X(2) X X(2) X
X(2) X X(2) X
X(2) X X(2) X
X
X
X
X
X
X X
X
X(5)
FMVSS 107 and FMVSS 211 have been rescinded by NHTSA. FMVSS 112 has been rescinded by NHTSA and the requirements transferred to FMVSS 108. FMVSS 115 requirements transferred to Part 565. (1) Applicable to Equipment for use on applicable vehicle types. (4) Applicable to vehicles with a GVWR of 4536 kg [10,000 lb] or less (2) Applicable to vehicles with a GVWR of 4536 kg [10,000 lb] or less. and an unloaded vehicle weight of 2495 kg [5,500 lb] or less. (3) Applicable to vehicles with a GVWR over 4536 kg [10,000 lb] (5) Applicable to vehicles with a GVWR of 2722 kg [6,000 lb] or less.
X
INTRODUCTION Information in this manual is furnished pursuant to United States and Canadian safety regulations or, in some cases where the information is not required by regulation, is furnished for the convenience of intermediate or final stage vehicle manufacturers. Incomplete vehicles manufactured for sale or importation into the U.S., are specially equipped for the United States. The descriptions and statements contained in the manual relate only to motor vehicle safety standards issued under the National Traffic and Motor Vehicle Safety Act of 1966 as amended. An incomplete vehicle manufactured for sale or importation into Canada is specially equipped for Canada. This vehicle conforms to the applicable Canadian Motor Vehicle Safety Standards (CMVSS) on the date of manufacture printed on the cover of this manual, and as identified in a CMVSS Table on page 58. Requirements unique to vehicles for use in Canada are identified in the Statements of Conformity and the Canadian Vehicles section of the manual. The Emission Certification Information section of this manual contains information regarding conformity to exhaust emission regulations of the United States, Canada, and the State of California and fuel economy regulations of the United States. This manual should not be relied upon with respect to compliance with any regulation of the Federal Highway Administration or regulations issued pursuant to the Occupational Safety and Health Act (OSHA) or any other Federal, state, or local regulations governing the performance or construction of motor vehicles (except for those requirements shown under the heading “Warranty and Maintenance,” page 60, “Emission Control Information Label,” page 61 and “Unleaded Gasoline Label,” page 60).
IMPORTANT: UNITED STATES VEHICLES Ford Motor Company has endeavored, whenever possible, to state the specific conditions under which an incomplete vehicle may be completed to conform with each applicable Federal Motor Vehicle Safety Standard. These specific statements are intended to aid subsequent stage manufacturers in avoiding instances of inadvertent noncompliance to particular standards. Note that the final responsibility for the compliance of the completed vehicle rests with the final stage manufacturer who is required by law to certify, as prescribed by Section 567.5 of Title 49, Code of Federal Regulations, that the completed vehicle conforms to all applicable Federal Motor Vehicle Safety Standards.
IMPORTANT: UNITED STATES AND CANADIAN VEHICLES Alterations to a chassis cab or an incomplete vehicle by someone other than Ford Motor Company, or damage in transit, may affect compliance statements that are furnished in this manual, or representations that are printed on the label that may be affixed to a chassis cab vehicle.
1
INTRODUCTION
UNITED STATES VEHICLES (Vehicles to be completed for sale or use in the United States)
GENERAL INFORMATION Information in this section is provided pursuant to Part 568 of Title 49, Code of Federal Regulations. “Vehicles Manufactured in Two or More Stages”. Part 568 specifies that final stage manufacturers must complete vehicles in compliance with all applicable Federal Motor Vehicle Safety Standards.
•
The specific Federal Motor Vehicle Safety Standards to which the Chassis Cab will conform when completed as specified in this manual.
•
The date of manufacture (month/year) of the Chassis Cab by Ford Motor Company
Each Chassis Cab (see definition on page 7) manufactured by Ford has a label affixed to the driver-door lock pillar that identifies the following: •
The specific Federal Motor Vehicle Safety Standards to which the Chassis Cab conforms, as of the date of manufacture.
DIRECTIONS STATEMENTS OF CONFORMITY The Statements of Conformity section, which begin on page 9 of this manual, lists the Federal Motor Vehicle Safety Standards in effect on the date of manufacture of this incomplete vehicle that are applicable to the type(s) of completed vehicles into which this incomplete vehicle may be manufactured. This date is shown on the label affixed to the cover of this manual. These statements, in most cases, apply to specific types of incomplete or completed vehicles and identify GVWR and UVW weight ranges.
IMPORTANT: To rely on the compliance representations in this manual, the incomplete vehicles must be completed as one of the completed vehicle types designated on the label affixed to the cover of this manual, and must not exceed the specified GVWR, GAWRs or the Unloaded Vehicle Weight limits when specified in this manual.
The incomplete vehicle type is identified by the 5th, 6th & 7th digits of the Vehicle Identification Number (VIN); see page 4. The completed vehicle types to which this incomplete vehicle may appropriately be completed is printed on the label, under the heading “May Be Completed As,” that is affixed to the cover of this document. The Completed Vehicle Types charts on pages 5 and 6 identifies how various incomplete vehicles with Optional Prep Packages may be completed.
DOMESTIC SPECIAL ORDER (DSO) VEHICLES DSO Vehicles can be identified by a six digit number with the letters DSO below the digits in the lower right corner of the Incomplete Vehicle Label which is affixed to the driver-door lock pillar. See the sample label on page 4. The Statements of Conformity section of this manual includes compliance representations for certain DSO vehicles. These vehicles are identified in the charts on pages 5 and 6. Other DSO vehicles may require additional Statements of Conformity which will be in the Supplement Section of this manual.
Each statement of conformity is identified by a safety standard number located at the left margin. Because there may be multiple statements of conformity for each safety standard, use care to select the appropriate statement. Unique CMVSS requirements will be identified at the conclusion of the representations for a particular safety standard.
FORD LIGHT TRUCK ASSISTANCE Throughout this manual you will find references to information found in the Ford Truck Body Builders Layout Book. To obtain a copy of this book (first copy at no charge), please fax a written request and include the desired model year, along with your return address (NO P.O. BOX ADDRESS, PLEASE) to (313) 459-6861.
Compliance statements provided in this manual are of the three following types: Type I • A statement that the vehicle, when completed, will conform to the standard if no alterations are made in identified components of the incomplete vehicle.
The Ford Truck Body Builder Advisory Service may be consulted regarding information contained in this manual. Call 1-800-635-5560 for assistance, or fax inquiries to (313) 337-2754 accompanied by a cover sheet indicating “Attention: Truck Body Builder Advisory Service,” along with your name, address and telephone number.
Type II • A statement of specific conditions of final manufacture under which the manufacturer specifies that the completed vehicle will conform to the standard. Type III • A statement of conformity with the standard is not substantially affected by the design of the incomplete vehicle, and that the incomplete vehicle manufacturer makes no representation as to conformity with the standard.
3
UNITED STATES VEHICLES
VEHICLE DESCRIPTION INCOMPLETE VEHICLE MANUAL COVER
The 5th, 6th & 7th digits of the Vehicle Identification Number (VIN) will identify the incomplete vehicle type. These three digits are used in the Completed Vehicle Types charts on pages 5 and 6. Additional VIN information is available in the Ford Source Book for the appropriate model year.
The cover of this manual identifies the four incomplete vehicle configurations for which compliance representations are contained in this manual. Also, a label is affixed to the cover which includes the Vehicle Identification Number (VIN) for the specific vehicle to which this manual belongs. The label identifies the following information which pertains only to the vehicle with the corresponding VIN.
California Air Resources Board (CARB), requires a Vehicle Emission Control Label with a vehicle identification number (VIN) having a non-contact, bar-code, reading wand capability. The bar-code directly below the VIN on the incomplete vehicle label will comply with this regulation.
• The GVWR • The front and rear GAWRs • Tire and wheel size
OPTIONAL PREP PACKAGES
• Cold tire inflation pressure (PSI)
Incomplete vehicles produced by Ford Motor Company, in some instances, are equipped with Optional Prep Packages. These include the Ambulance Prep, School Bus Prep and RV Prep Packages. The completed vehicle type charts on pages 5 and 6, will identify incomplete vehicles and the optional prep packages that may be required by Ford if final stage manufacturers wish to rely on the Statements of Conformity or, in some cases, preserve the Ford new vehicle warranty.
• Completed vehicle type(s) into which the incomplete vehicle may be manufactured. • Optional prep package when the vehicle is so equipped. INCOMPLETE VEHICLE LABEL Each incomplete vehicle manufactured by Ford Motor Company will have an incomplete vehicle label affixed to the driver-door lock pillar, except the Basic (Stripped) Chassis. The incomplete vehicle label for the Basic (Stripped) Chassis is located inside this manual’s protective plastic bag. The sample label, shown below is typical of that provided. A detailed explanation of all label information is available in the Ford Source Book for the appropriate model year, at your local Ford Dealer. DATE OF MANUFACTURE
VEHICLE TYPE (SEE CHART ON PAGE 6) OPTIONAL PREP PACKAGE
If an incomplete vehicle is equipped with an optional prep package, both the incomplete vehicle label affixed to the vehicle and the label on the front of this manual will identify the Prep Package.
INCOMPLETEVEHICLEMANUFACTUREDBY FORD MOTOR COMPANY MADE IN U.S.A. DATE: 01/98 GVWR• 11000LB/4989KG REAR GAWR: 8250LB FRONT GAWR: 4200LB 1905KG WITH WITH 3742KG LT215/85R16D TIRES TIRES LT215/85R16D 16X6K RIMS RIMS 16X6K AT 58 PSI COLD AT 65 PSI COLD DUAL
VIN:
SA MP LE
BAR CODE V.I.N. (CALIFORNIA)
1FDKF37MOWKA53769
EQUIPPED WITH THE FORD AMBULANCE PREP PKG.
410047 DSO
EXTERIOR PAINT COLORS WB 161
TYPE-GVW BODY F379 AJ8
DSO VEHICLE
TRANS AXLE TAPE SPRINGS E 65 NY P FOTA–152O4A1O-EA
TYPICAL F-SERIES VEHICLE TYPE (SEE CHART ON PAGE 5) OPTIONAL PREP PACKAGE
INCOMPLETE VEHICLE MFD. BY FORD MOTOR CO. IN U.S.A. GVWR: 10300LB/4672KG DATE: 01/98 FRONT GAWR: 3900 LB/1769KG REAR GAWR:7800LB/3538KG WITH LT225/75R16D TIRES WITH LT225/75R16D TIRES 16X6K RIMS AT 55 PSI COLD 16X6K RIMS VIN: 1FDKE37HZWHA24638 AT 75 PSI COLD
SA MP LE
EQUIPPED WITH THE FORD AMBULANCE PREP PKG.
EXTERIOR PAINT COLORS WB 138
TYPE-GVW BODY EZ42 DB
DSO 410047
TRANS AXLE TAPE SPRINGS E 24 N4F
P F8UA–15204A10-EA
TYPICAL ECONOLINE INCOMPLETE VEHICLE LABEL
VEHICLE DESCRIPTION
4
DATE OF MANUFACTURE
BAR CODE V.I.N. (CALIFORNIA)
DSO VEHICLE
COMPLETED VEHICLE TYPES
E14 E24 E27* E29 E30
X X
E37
E-350 ECONOLINE COM. CUTAWAY
X
X E-350 ECONOLINE COM. BASIC (STRIPPED) CHASSIS E-SUPER DUTY RV CUTAWAY X E-SUPER DUTY COM. CUTAWAY
S24 S31 S34
INCOMPLETE E-250 ECONO. SUPER CARGO VAN INCOMPLETE E-350 ECONO. SUPER WAGON INCOMPLETE E-350 ECONO. SUPER CARGO VAN
SCHOOL BUS
BUS (NOT SCHOOL BUS)
MPV (AMBULANCE)
X X X
X X X X
X X X
X
X
X X
E47
MPV†
X
X
E39 E40
X X
X X X X X X X
X INCOMPLETE E-350 ECONOLINE REG. CARGO VAN
TRUCK (WALK-IN VAN)
X X X
X E34
MAY BE COMPLETED AS
TRUCK
RV PREP
INCOMPLETE E-150 ECONO. REG. CARGO VAN INCOMPLETE E-250 ECONO. REG. CARGO VAN E-250 ECONOLINE COM. CUTAWAY E-250 ECONOLINE BASIC (STRIPPED) CHASSIS E-350 ECONOLINE RV CUTAWAY
SCHOOL BUS PREP
OPTIONAL PREP PACKAGE AMBULANCE PREP
INCOMPLETE ECONOLINE VEHICLES 5TH 6TH 7TH VIN DIGIT
X X X
X X X X X X X X
X X
X X X
X X X X
X X X
* Domestic Special Order (DSO) † To be completed as a Multipurpose Passenger Vehicle (MPV) the incomplete vehicle must be equipped with the RV Prep Package or School Bus Prep Package except: S31, Incomplete E350 Econoline Super Wagon.
IMPORTANT: Ford Motor Company makes no representation that the Completed vehicle types listed above are the only vehicle types appropriate for the incomplete vehicles listed. However, if a unit is completed as a vehicle type other than as listed above, the Statements of Conformity may not be applicable.
5
VEHICLE DESCRIPTION
COMPLETED VEHICLE TYPES INCOMPLETE SUPER DUTY F-SERIES VEHICLES
OPTIONAL PREP PACKAGE
5TH 6TH 7TH VIN DIGIT
AMBULANCE PREP
F20 F21 F32
F-250 REG. CAB CHASSIS CAB 4X2 (SRW) F-250 REG. CAB CHASSIS CAB 4X4 (SRW) F-350 REG. CAB CHASSIS CAB 4X2 (DRW)
X
F33
F-350 REG. CAB CHASSIS CAB 4X4 (DRW)
X
F34 F35 F36
F-350 CHASSIS CAB REG. CAB 4X2 (SRW) F-350 CHASSIS CAB REG. CAB 4X4 (SRW) F-350 CHASSIS CAB REG. CAB 4X2 (DRW)
X
F37
F-350 CHASSIS CAB REG. CAB 4X4 (DRW)
X
F46
F-450 CHASSIS CAB REG. CAB 4X2 (DRW)
X
F47
F-450 CHASSIS CAB REG. CAB 4X4 (DRW)
X
F56
F-550 CHASSIS CAB REG. CAB 4X2 (DRW)
X
F57
F-550 CHASSIS CAB REG. CAB 4X4(DRW)
X
W20 W21 W32 W33 W34 W35 W36 W37 W46 W47 W56 W57 X20 X21 X32
F-250 CREW CAB CHASSIS CAB 4X2 (SRW) F-250 CREW CAB CHASSIS CAB 4X4 (SRW) F-350 CREW CAB CHASSIS CAB 4X2 (DRW) F-350 CREW CAB CHASSIS CAB 4X4 (DRW) F-350 CHASSIS CAB CREW CAB 4X2 (SRW) F-350 CHASSIS CAB CREW CAB 4X4 (SRW) F-350 CHASSIS CAB CREW CAB 4X2 (DRW) F-350 CHASSIS CAB CREW CAB 4X4 (DRW) F-450 CHASSIS CAB CREW CAB 4X2 (DRW) F-450 CHASSIS CAB CREW CAB 4X4 (DRW) F-550 CHASSIS CAB CREW CAB 4X2 (DRW) F-550 CHASSIS CAB CREW CAB 4X4 (DRW) F-250 SUPERCAB CHASSIS CAB 4X2 (SRW) F-250 SUPERCAB CHASSIS CAB 4X4 (SRW) F-350 SUPERCAB CHASSIS CAB 4X2 (DRW)
X
X33
F-350 SUPERCAB CHASSIS CAB 4X4 (DRW)
X
X34 X35 X36
F-350 CHASSIS CAB SUPERCAB 4X2 (SRW) F-350 CHASSIS CAB SUPERCAB 4X4 (SRW) F-350 CHASSIS CAB SUPERCAB 4X2 (DRW)
X37
F-350 CHASSIS CAB SUPERCAB 4X4(DRW)
X X X
IMPORTANT: Ford Motor Company makes no representation that the Completed vehicle types listed above are the only vehicle types appropriate for the incomplete vehicles listed. However, if a unit is completed as a vehicle type other than as listed above, the Statements of Conformity may not be applicable.
VEHICLE DESCRIPTION
6
MAY BE COMPLETED AS
TRUCK
X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X
MPV (AMBULANCE)
X X
X X
X X X X
X X
X X
DEFINITIONS The following definitions are from Title 49, Code of Federal Regulations, Section 571.3 except where noted. Canadian definitions are from Canada Motor Vehicle Safety Regulations, Section 2(1), and are in italics. Ford Motor Company definitions are for the purpose of this manual only. Some terms are followed by an abbreviation that is used throughout this manual. Designated Seating Position– any plan view location capable of accommodating a person at least as large as a 5th percentile adult female, if the overall seat configuration and design and vehicle design is such that the position is likely to be used as a seating position while the vehicle is in motion, except for auxiliary seating accommodations such as temporary or folding jump seats. Any bench or split-bench seat in passenger car, truck or multipurpose passenger vehicle with a GVWR less than 10,000 pounds, having greater than 50 inches of hip room (measured in accordance with SAE Standard J1100(a)) shall have not less than three designated seating positions, unless the seat design or vehicle design is such that the center position cannot be used for seating.
Ambulance– is a vehicle for emergency medical care which provides: A driver’s compartment; a patient compartment to accommodate an Emergency Medical Technician (EMT/ Paramedic and two litter patients (one patient on the primary cot and secondary patient on folding litter located on the squad bench) so positioned that the primary patient can be given intensive life-support during transit; equipment and supplies for emergency care at the scene as well as during transport; two-way radio communication; and, when necessary, equipment for light rescue/extrication procedures. The Ambulance shall be designed and constructed to afford safety, comfort, and avoid aggravation of the patient’s injury or illness. (From Federal Specification KKK-A-1822-D). Ford Motor Company also includes within its definition of ambulance any vehicle that is used for transporting life-support equipment, for rescue operations, or for non-emergency patient transfer if the engine of the vehicle is equipped with a “throttle kicker” device, which enables an operator to increase engine speed over normal idle speed when the vehicle is not moving.
Designated Seating Position (Canada)– any plan view position capable of accommodating a person at least as large as a 5th percentile adult female, as defined in section 100 of Schedule IV, where the overall seat configuration and design and the vehicle design are such that the position is likely to be used as a seating position while the vehicle is in motion, but does not include any plan view position of temporary or folding jump seats or other auxiliary seating accommodation.
B-Pillar– is the vehicle body structure located directly rearward of each front door. This structure will include the outer panel, all inner panels or reinforcements which support the door opening, the door latching system and/or the roof structure (source: Ford Motor Company).
Final Stage Manufacturer– a person who performs such manufacturing operations on an incomplete vehicle that it becomes a completed vehicle. (49 CFR, Section 568.3)
Bus– a motor vehicle with motive power, except a trailer, designed for carrying more than 10 persons.
Forward Control– a vehicle configuration in which more than half of the engine length is rearward of the foremost point of the windshield base and the steering wheel hub is in the forward quarter of the vehicle length.
Bus (Canada)– a vehicle having a designated seating capacity of more than 10, but does not include a trailer. Chassis Cab– an incomplete vehicle, with completed occupant compartment, that requires only the addition of cargocarrying, work performing or load-bearing components to perform its intended function. (From Title 49 Code of Federal Regulations, Section 567.3)
Gross Axle Weight Rating (GAWR)– the value specified by the vehicle manufacturer as the load-carrying capacity of a single axle system, as measured at the tire-ground interfaces. Gross Combination Weight Rating (GCWR)– the value specified by the manufacturer as the loaded weight of a combination vehicle.
Chassis Cab (Canada)– means a vehicle consisting of a chassis that is capable of being driven, drawn or selfpropelled, upon which may be mounted a cab, and that is designed to receive:
Gross Vehicle Weight Rating (GVWR)– the value specified by the manufacturer as the loaded weight of a single vehicle.
(a) a passenger-carrying or cargo-carrying body including a body that incorporates a prime mover, or
H-Point– the mechanically hinged hip point of a manikin which simulated the actual pivot center of the human torso and thigh, described in SAE Recommended Practice J826, “Manikins For Use in Defining Vehicle Seating Accommodation,” November 1962.
(b) a work performing structure other than a fifth-wheel coupling. Critical Control Item– is a component or procedure which may affect compliance with a federal regulation or, which could directly affect the safe operation of the vehicle. is the identifying symbol. (source: Ford Motor Company)
Incomplete Vehicle- an assemblage consisting, as a minimum, of frame and chassis structure, power train, steering system, suspension system, and braking system, to the extent that those systems are to be part of the completed vehicle, that requires further manufacturing operations, other than the addition of readily attachable components such as mirrors or tire and rim assemblies, or minor finishing operations, such as painting, to become a completed vehicle.
7
DEFINITIONS
DEFINITIONS Incomplete Vehicle Manufacturer– a person who manufactures an incomplete vehicle by assembling components none of which, taken separately constitute an incomplete vehicle. (49 CFR, Section 568.3)
Trimmed Seat– a complete functional seat assembly including the seat pedestal, seat track, seat base frame, seat back, recliner mechanism, seat padding, all attaching hardware and the final trim material (i.e., cloth, leather or vinyl). (source: Ford Motor Company)
Intermediate Manufacturer– a person, other than the incomplete vehicle manufacturer or the final stage manufacturer, who performs manufacturing operations on an incomplete vehicle. (49 CFR, Section 568.3)
Truck– a motor vehicle with motive power, except a trailer, designed primarily for the transportation of property or special purpose equipment.
Multipurpose Passenger Vehicle (MPV)– a motor vehicle with motive power, except a trailer, designed to carry 10 persons or less which is constructed either on a truck chassis or with special features for occasional off-road operation.
Truck (Canada)– a vehicle designed primarily for the transportation of property or equipment but does not include a chassis-cab, crawler-mounted vehicle, trailer, work vehicle or vehicle designed for operation exclusively off the public highway.
Multipurpose Passenger Vehicle (MPV) (Canada)– a vehicle having a designated seating capacity of 10 or less that is constructed either on a truck-chassis or with special features for occasional off-road operation, but does not include an air cushion vehicle, all-terrain vehicle, golf-cart, passenger car or truck.
Truck-Tractor– a truck designed primarily for drawing other motor vehicles and not so constructed as to carry a load other than a part of the weight of the vehicle and the load so drawn. Truck Tractor (Canada)– a truck designed primarily for drawing other vehicles and not constructed for carrying any load other than part of the weight of the vehicle designed to accept a fifth-wheel coupling but does not include a crane-equipped breakdown vehicle.
Prescribed Class (Canada)– a class of vehicles listed in Schedule III. Seating Reference Point– the manufacturer’s design reference point which:
Unloaded Vehicle Weight (UVW)– the weight of a vehicle with maximum capacity of all fluids necessary for operation of the vehicle, but without cargo, occupants, or accessories that are ordinarily removed from the vehicle when it is not in use.
(a) Establishes the rearmost normal design driving or riding position of each designated seating position in a vehicle; (b) Has coordinates established relative to the designed vehicle structure;
Unloaded Vehicle Weight (Canada)– the weight of a vehicle equipped with containers for the fluids necessary for the operation of the vehicle filled to their maximum capacity but without cargo or occupants.
(c) Simulates the position of the pivot center of the human torso and thigh; and (d) Is the reference point employed to position the two dimensional templates described in SAE Recommended Practice J826. “Manikins for Use in Defining Vehicle Seating Accommodation,” November, 1962.
Untrimmed Seat– the structure including the seat pedestal, seat track, seat base frame, seat back, recliner mechanism, seat padding and all attaching hardware required for a functional seat assembly without the final trim material (e.g., cloth, leather or vinyl) and trim material attaching components. (source: Ford Motor Company)
Second Unit Body (SUB)– consists of the body structure and/or all the cargo carrying, work performing, and/or load bearing components and/or equipment installed by a subsequent stage manufacturer on an incomplete vehicle, such that the incomplete vehicle becomes a completed vehicle. (source: Ford Motor Company)
Walk-In Van– is a step entry city delivery van type vehicle that permits a person to enter the vehicle without stooping. This definition by Ford Motor Company is based on information appearing in 41 FR 54945, published December 16,1976, and in 42 FR 34288, published July 5,1977.
School Bus– a bus that is sold, or introduced in interstate commerce, for purposes that include carrying students to and from school or related events, but does not include a bus designed and sold for operation as a common carrier in urban transportation. School Bus (Canada)– a bus designed or equipped primarily to carry students to and from school. Subsequent Stage Manufacturer– is a term which means either intermediate or final stage manufacturers or both. (source: Ford Motor Company)
DEFINITIONS
8
STATEMENTS OF CONFORMITY The following Statements of Conformity apply to vehicles that are produced for sale or importation into the United States or Canada. The term “Incomplete Vehicle Types” in these statements refers to the four types of the vehicles illustrated on this manual’s cover and as defined in the Vehicle Description section on page 4. The number preceding each Statement of Conformity refers to the number designation of a Federal Motor Vehicle Safety Standard. Canadian representations will be at the conclusion of each safety standard number.
PART 565 The statement below is applicable to all incomplete vehicle types except the Basic (Stripped) Chassis:
101 The statements below are applicable to the following incomplete vehicle types with no driver-seat: ■ Incomplete Econoline Van
This vehicle, when completed, will conform to Part 565, Vehicle Identification Number, if the vehicle identification number mounted on the top of the instrument panel is not removed, altered or modified and no actions are taken by the subsequent stage manufacturer that would obstruct the readability of the vehicle identification number mounted on the top of the instrument panel.
■ Cutaway This vehicle, when completed will conform to Standard 101, Controls and Displays if: • The Seating Reference Point (see definition on page 8) and the seat back torso angle of the driverseat when completed or installed by a subsequent stage manufacturer are located as shown in the Figure C page 37, for Econoline type vehicles.
PART 565 The statement below is applicable to the Basic (Stripped) Chassis:
• The controls, displays and their identifications supplied by Ford Motor Company are not removed, altered or relocated.
This vehicle, when completed, will conform to Part 565, Vehicle Identification Number, if the vehicle identification number printed on the label affixed to the cover of this manual is mounted and displayed in accordance with the requirements of this Standard.
• The components, wiring or power supply installed by Ford Motor Company to illuminate any control, display or their identification are not removed or altered so as to affect lighting performance.
101 The statements below are applicable to the following incomplete vehicle types when equipped with a driver seat:
Any controls, displays and illumination added to this vehicle must conform to the requirements of this Standard.
■ Chassis Cab ■ Incomplete Econoline Van or Super Club Wagon
101 The statement below is applicable to the Basic (Stripped) Chassis:
■ Cutaway This vehicle, when completed, will conform to Standard 101, Controls and Displays if:
Conformity with Standard 101, Controls and Displays, is not substantially affected by the design of this incomplete vehicle; accordingly, Ford Motor Company makes no representation as to conformity with this Standard.
• The controls, displays and their identifications supplied by Ford Motor Company are not removed, relocated, altered or modified.
101 Canadian Requirements:
• The components, wiring and power supply installed by Ford Motor Company to illuminate any control, display or their identification are not removed or altered so as to affect lighting performance.
The preceding statements for FMVSS 101 are appropriate compliance representations for CMVSS 101, Location and Identification of Controls and Displays, if this incomplete vehicle (identified by the VIN on the front of the document) was manufactured by Ford Motor Company for sale or use in Canada.
• Components added to the vehicle do not obstruct the driver’s ability to operate or visually locate the controls, displays, and their identifications. • The driver-seat is not replaced, relocated or modified other than for the addition of seat trim. Any controls, displays and illumination added to this vehicle must conform to the requirements of this Standard.
9
STATEMENTS OF CONFORMITY
102 The statements below are applicable to all incomplete vehicle types except the Basic (Stripped) Chassis:
102 Canadian Requirements: The preceding statements for FMVSS 102 are appropriate compliance representations for CMVSS 102, Transmission Shift Control Sequence, if this incomplete vehicle was manufactured for sale or use in Canada.
This vehicle, when completed, will conform to Standard 102, Transmission Shift Lever Sequence, Starter Interlock and Transmission Braking Effect, if no alterations or adjustments are made to:
103 The statement below is applicable to all incomplete vehicle types except the Basic (Stripped) Chassis:
• Automatic Transmission - the transmission, shift cable, transmission outer shift lever, shift cable bracket, vacuum tubes, vacuum pump system, the starter interlock system and wiring circuit from the interlock switch to the power source.
If an auxiliary transmission is added to this vehicle, it must conform to the requirements of this Standard.
This vehicle, when completed, will conform to Standard 103, Windshield Defrosting and Defogging Systems, if no alterations or adjustments are made to heater and blower assemblies, ducting, operating controls, electrical circuit from the blower assembly to the power source, windshield, coolant hoses from the radiator or engine to the heater, and if no obstructions are added that restrict or otherwise redirect the air flow from the defroster outlets to the windshield.
102 The statements below are applicable to the Basic (Stripped) Chassis:
103 The statement below is applicable to Basic (Stripped) Chassis:
This vehicle, when completed, will conform to Standard 102, Transmission Shift Lever Sequence, Starter Interlock and Transmission Braking Effect if:
Conformity with Standard 103, Windshield Defrosting and Defogging Systems, is not substantially affected by the design of this incomplete vehicle; accordingly, Ford Motor Company makes no representation as to conformity with this Standard.
• Manual and Automatic Transmission - the transmission shift decal, knob or transmission indicator dial identification.
• No alterations or adjustments are made to the transmission, shift cable, transmission outer shift lever, shift cable bracket, vacuum tubes, vacuum pump system, the starter interlock system and wiring circuit from the interlock switch to the power source.
103 Canadian Requirements: The preceding statements for FMVSS 103 are appropriate compliance representations for CMVSS 103, Windshield Defrosting and Defogging System, if this incomplete vehicle was manufactured by Ford Motor Company for sale or use in Canada.
• The Basic (Stripped) Chassis is equipped with a temporary transmission gear selector indicator (PRND21) which must be replaced with the cluster and transmission gear selector indicator (PRND21) that is shipped with the vehicle in the dunnage box and installed and adjusted following the instructions and specifications shown in the figure below. If an auxiliary transmission is added to this vehicle, it must conform to the requirements of this Standard. [ ] ALL DIMENSIONS ARE IN INCHES
1. Route the cable after the instrument cluster is installed in the vehicle. Do not kink the cable. Do not bend the cable to a radius less than 4.5 inches. Route the cable from the cluster in a counterclockwise direction, under the steering column, using the screw provided. Do not wrap the cable around the steering column. The steering column shroud installation should not affect the cable routing or function. 2. Pull on the cable end loop for a functional check. The cable should operate with a similar effort as required prior to routing. Then place the cable loop on the shift lever retainer pin. 3. Rotate the column shift lever clockwise until it bottoms out in first gear. 4. Rotate the column shift lever counter-clockwise 2 detents for Overdrive “Oval D” position for 4R100 & 4R70W Transmission. 5. Install a 3 pound weight, as defined in this illustration, on the end of the column shift lever. 6. Center the pointer in the middle of the “Oval D” position by rotating the thumb wheel. 7. Remove the 3 pound weight. The pointer must be within the tolerances as defined in this illustration. 8. After the steering column shrouds are installed, the transmission gear selector indicator (PRND21) system must be checked for proper operation. 4R100 & 4R70W TRANSMISSION
INSTALLATION OF GEAR SELECTOR INDICATOR (PRND21) STATEMENTS OF CONFORMITY
10
104 The statement below Is applicable to all Incomplete vehicle types except the Basic (Stripped) Chassis:
105 The statements below are applicable to the Econoline cutaway when equipped with the School Bus Prep package and completed as a school bus:
This vehicle when completed, will conform to Standard 104, Windshield Wiping and Washing Systems, if no alterations are made to the windshield, the windshield wiping and washing system, including the electrical circuit from the windshield wiping and washing motors to the power source and if no obstructions are added that restrict or otherwise redirect fluid flow from the washer nozzles to the windshield.
This vehicle when completed, will conform to Standard 105, Hydraulic Brake Systems, if: • No alterations, modifications or replacements are made to the following: – Service or parking brake system – Antilock brake system – Vacuum system
104 The statement below Is applicable to the Basic (Stripped) Chassis:
– Wheels and tires – Brake system indicator lamp and wiring
Conformity with Standard 104. Windshield Wiping and Washing Systems, is not substantially affected by the design of this incomplete vehicle; accordingly, Ford Motor Company makes no representation as to conformity with this Standard.
– Brake system reservoir labeling – Suspension ride height or spring rate – Hydro-Boost system – Power Steering pump and lines if used with Hydroboost
104 Canadian Requirements: The preceding statements for FMVSS 104 are appropriate compliance representations for CMVSS 104, Windshield Wiping and Washing System, if this incomplete vehicle was manufactured by Ford Motor Company for sale or use in Canada.
– Engine belt drive system • The E-350 Unloaded Vehicle Weight (see definition on page 8) does not exceed the maximum nor is less than minimum values in Table J page 17. Use the model description, wheelbase and engine size to identify appropriate weight.
105 INFORMATION Incomplete vehicle weight and dimensional information required for center of gravity calculations are available in the Ford Source Book. See your local Ford Dealer and refer to appropriate model year and specific vehicle for required information.
• The E-Super Duty minimum UVW must be at least 1451 kg [3200 lb]. • The maximum GAWRs and GVWR, as identified on the cover of this document, are not exceeded. • The transverse center of gravity is less than 50.8 mm [2.0 in] either side of the vehicle centerline for E-350 only.
Abbreviation definitions and a vehicle diagram to assist with the equations for the FMVSS 105 segment are shown on page 14 for Econoline and Page 16 for Super Duty F-Series.
• The horizontal and vertical center of gravity, of the completed vehicle at Unloaded Vehicle Weight, is within the minimum/maximum locations as defined in the following chart:
TABLE A CENTER OF GRAVITY LOCATION DIMENSIONS FOR INCOMPLETE ECONOLINE CUTAWAY WITH SCHOOL BUS PREP PACKAGE E-350 E-350 E-SD LOCATION SRW DRW DRW mm [in] mm [in] mm [in] 300.0 526.0 Vertical Maximum (1) [11.8] [20.7] 2159.0 2489.0 Horizontal Maximum (2) [85.0] [98.0] 1651.0 Horizontal Minimum (2) [65.0] (1) Measured from top of frame at a point midway between the centerlines of the front and rear axles. (2) Measured rearward from the centerline of the front axle.
• Service or parking brake pedal assembly operation must not be restricted by any alteration or added components.
11
STATEMENTS OF CONFORMITY
105 The statements below are applicable to the following incomplete vehicle types if the GVWR is under 3629 kg [8,000 lb]:
• The horizontal center of gravity for the SUB is: – At or forward of the rear axle centerline. The vertical center of gravity for the completed vehicle at Unloaded Vehicle Weight + 400 lb passenger load CG v (Equation A) must not exceed 36.0 inches, when measured from the ground.
■ Incomplete Econoline Van This vehicle, when completed, will conform to Standard 105, Hydraulic Brake Systems, if: • No alterations, modifications or replacements are made to the following:
– Behind the rear axle centerline. The vertical center of gravity for the completed vehicle at Unloaded Vehicle Weight + 400 lb passenger load must fall within the appropriate range determined from Table S, page 20. The value of CGh (Equation B), which approximates the horizontal center of gravity of the completed vehicle, is used in Table S, page 20, to determine the vertical center of gravity limits for the completed vehicle. The value CG V (Equation A), which approximates the vertical center of gravity of the completed vehicle, must fall within the appropriate range determined from Table S, page 20.
– Service or parking brake system – Antilock brake system – Vacuum system – Wheels and tires – Brake system indicator lamp and wiring – Brake system reservoir labeling – Suspension ride height or spring rate • Any removal of a Ford body or chassis component is accompanied by the addition of equal weight. • The Econoline vehicles equipped with RV Prep Package have an Unloaded Vehicle Weight that does not exceed the values in Table J on page 17, or be within the weight percentages in Table K page 17.
TABLE C EQUATION A
• The maximum GAWRs and GVWR, as identified on the cover of this document, are not exceeded with the vehicle weight at Unloaded Vehicle Weight + 400 lb passenger load.
CGv =
• The service or parking brake pedal assembly operation is not restricted by any alteration or added components.
CGvbWb + CGvcWc + 10,000 Wt EQUATION B
• The horizontal center of gravity of the Second Unit Body (SUB) is rearward of Lmin† for the appropriate vehicle description in the table below. Lmin does not apply to a SUB of 120 lb or less when installed rearward of the front seats and forward of the centerline of the rear axle. (Do not restrict the Econoline seat travel and provide seatback clearance to obtain the torso angle as shown in Figure C page 37).
CGh =
(Wrb+ Wrc +(400WBx CGhp))x WB Wt
105 (Continued Next Page)
TABLE B HORIZONTAL CENTER OF GRAVITY FORWARD LIMIT TABLE Vehicle Wheelbase Lmin Millimeter [inch] Millimeter [inch] E-150 3505 [138] 1473 [58] E-250 3505 [138] 1524 [60]
†
STATEMENTS OF CONFORMITY
12
Lmin = the minimum horizontal center of gravity of the SUB measured in inches rearward from the centerline of the front axle.
105 (Continued)
• The horizontal center of gravity for the SUB is: – At or forward of the rear axle centerline. The vertical center of gravity for the completed vehicle at GVWR CGv (Equation C) must not exceed 48.0 inches when measured from the ground. – Behind the rear axle centerline. The vertical center of gravity for the completed vehicle at GVWR must fall within the appropriate range determined from Table S page 20. The value of CG h (Equation D), which approximates the horizontal center of gravity of the completed vehicle, is used in Table S to determine the vertical center of gravity limits for the completed vehicle. The value of CG v (Equation C) which approximates the vertical center of gravity of the completed vehicle must fall within the appropriate range determined from Table S.
105 The statements below are applicable to the following incomplete vehicle types except when completed as a school bus, and if the GVWR is between 3629 kg [8,000 lb] and 6804 kg [15,000 lb] inclusive: ■ Incomplete Econoline Van or Super Club Wagon ■ Cutaway ■ Basic (Stripped) Chassis This vehicle, when completed, will conform to Standard 105, Hydraulic Brake Systems, if: • No alterations, modifications, or replacements are made to the following: – Service or parking brake system – Antilock brake system – Vacuum system – Wheels and tires
TABLE D
– Brake system indicator lamp and wiring – Brake system reservoir labeling
EQUATION C
– Suspension ride height or spring rate – Hydro-boost system
CGv =
– Power steering pump and lines if used with Hydro-boost
CGvbWb + CGvc(Wc + Wl) + 25P GVWR
– Engine belt drive system • Any removal of a Ford body or chassis component is accompanied by the addition of equal weight.
EQUATION D
• Econoline Van, Cutaway and Basic (Stripped) Chassis vehicles with a GVWR of 4536 kg [10,000 lb] or less do not exceed the maximum Unloaded Vehicle Weight value in Table J page 17.
CGh
(Wrb + Wrc +( =
P x CGhp + Wr l x WB WB GVWR
)
)
• Cutaways and Basic (Stripped) Chassis vehicles conform to the minimum SUB weights found in Table P, page 19. • The maximum GAWRs and GVWR, as identified on the cover of this document, are not exceeded with the vehicle weight at Unloaded Vehicle Weight + Passenger Load (P). (See Econoline Passenger Load Table on this page.)
TABLE E ECONOLINE PASSENGER LOAD TABLE GVWR [lb]
• The service or parking brake pedal assembly operation is not restricted by any alteration or added components. • The SUB horizontal center of gravity must be at or forward of the rear axle centerline for the following vehicles:
P [lb]
8,000 - 10,000
400
10,001 - 15,000
500
- E-250/350 Basic (Stripped) Chassis - E-250 Cutaway 138 inch WB - E-350 Cutaway (DRW) - E-Super Duty Cutaway
13
STATEMENTS OF CONFORMITY
FMVSS 105 DEFINITIONS AND CALCULATION ILLUSTRATION FOR INCOMPLETE ECONOLINE VAN, SUPER CLUB WAGON, CUTAWAY AND BASIC STRIPPED CHASSIS V†
= Vertical Center of Gravity of SUB in inches above top of frame at cab back panel for chassis cab vehicles or top of cargo floor for Incomplete Van vehicles.
Wrb
= Weight on the rear wheels of the SUB and/or permanently attached added equipment [pounds].
L†
= Horizontal distance in inches between the SUB center of gravity and the CL of the front axle.
Wrc
= Weight at the rear wheels of the vehicle (chassis and cab) (fuel tanks full) [pounds]. Including option weight.
Wul†
= Unloaded Vehicle Weight [pounds] consisting of the curb with SUB plus 400 lb located in the front driver/passenger location.
Wc
= Weight of the vehicle (chassis and cab) (fuel tanks full) [pounds]. Including option weight.
WB
= Vehicle wheelbase [inches].
Wrul†
= Rear weight component of the Unloaded Vehicle Weight [pounds] Wul.
Wt
= Total unladen weight = (Wb + Wc + P)
P
= Passenger load (See Table E page 13).
CGv
= Vertical distance from the ground to the center of gravity [inches] of the completed vehicle. = Horizontal distance from CL of the front wheels to completed vehicle center of gravity [inches].
CGh CGvb
CGvc
CGhp
Wb
GVWR = Gross Vehicle Weight Rating of the vehicle [pounds]. W‡
Where: Wl = GVWR - (Wb + Wc + P) Wrl‡
= Vertical distance from the ground to the center of gravity of the SUB and/or permanently attached added equipment [inches]. (See the Calculation Suggestions on page 19.)
= Weight of the remaining cargo capacity on the rear wheels [pounds]. (CGhI)WI WrI = WB
CGhI‡ = Horizontal distance from the CL of the front wheels to the cargo center of gravity [inches]. (Taken from Table M page 19) for many common vehicles. If the CGhI is not given in the table, then it may be estimated as the distance from the CL of the front wheel to the horizontal midpoint of the cargo area.
= Vertical distance from the ground to the center of gravity of the chassis [inches] (including cab if original equipment). (Taken from Table R page 19). = Horizontal distance from the CL of the front wheels to the P (passenger load) (taken from Table N page 19).
SUB
= Weight of the SUB and/or permanently attached added equipment [pounds].
† Required for <8000 lb GVWR calculations only.
STATEMENTS OF CONFORMITY
= Remaining cargo capacity [pounds].
I
= A Second Unit Body consists of the body structure and/or all the cargo carrying, work performing, and/or load bearing components and/or equipment installed by a subsequent stage manufacturer on an incomplete vehicle, such that the incomplete vehicle becomes a completed vehicle.
‡ Required for >8000 lb GVWR calculations only.
14
105 (Continued) 105 The statements below are applicable to the following incomplete vehicle types if the GVWR is between 3629 kg [8,000 lb] and 8618 kg [19,000 lb] inclusive:
TABLE F SUPER DUTY F-SERIES PASSENGER LOAD TABLE
■ Chassis Cab This vehicle, when completed, will conform to Standard 105, Hydraulic Brake Systems, if:
CGhp
• No alterations, modifications, or replacements are made to the following:
61.2 [in]
GVWR [lb]
P [lb]
8500-10,000
400
10,001-19,000
500
– Service or parking brake system – Antilock brake system – Vacuum system – Wheels and tires – Brake system indicator lamp and wiring
TABLE G
– Brake system reservoir labeling
ALL SEATS
– Suspension ride height or spring rate 4X2
– Hydro-boost system – Engine belt drive system
CGvp
4X4
39.9 [in]
43.4 [in]
• Any removal of a Ford body or chassis component is accompanied by the addition of equal weight. • Chassis Cab vehicle with a GVWR of 4536 kg [10,000lb] or less do not exceed the Maximum Unloaded Vehicle Weight value in Table L, page 18. • The applicable GAWRs and GVWR weights are not exceeded.
TABLE H
• The front and rear axle curb weights of the completed vehicle must be the same or greater than the curb weights including minimum SUB weights shown in Table T, pages 20 and 21, as manufactured by Ford. • The completed vehicle must have a vertical center of gravity (Equation E) of 48.00 inches or less when measured from the ground with the following condition:
EQUATION E
CGv =
– The horizontal center of gravity of the completed vehicle (Equation F) must be forward of the rear axle centerline.
15
GVWR
EQUATION F
105 Canadian Requirements: The preceding statements for FMVSS 105 are appropriate compliance representations for CMVSS 105, Hydraulic Brake Systems, if this vehicle is manufactured for sale or use in Canada.
CGvbWb + CGvc(Wc + Wl) + (CGvp) x P
CGh =
(Wrb + Wrc +(
P x CGhp
WB GVWR
) + W ) x WB rl
STATEMENTS OF CONFORMITY
FMVSS 105 DEFINITIONS AND CALCULATION ILLUSTRATION FOR INCOMPLETE SUPER DUTY F-SERIES P
= Passenger load (See Table F, page 15).
Wt
CGv
= Vertical distance from the ground to the center of gravity [inches] of the completed vehicle. = Horizontal distance from CL of the front wheels to the center of gravity [inches] of the completed vehicle.
GVWR = Gross Vehicle Weight Rating of the vehicle [pounds].
CGh
CGvb
CGvc
CGhp
Wb
= Weight of the SUB and/or permanently attached added equipment [pounds].
Wrb
= Weight at the rear wheels of the SUB and/or permanently attached added equipment [pounds].
Wrc
= Weight at the rear wheels of the vehicle (chassis and cab) (fuel tanks full) [pounds]. Including option weight.
Wc
= Weight of the vehicle (chassis and cab) (fuel tanks full) [pounds]. Including option weight.
WB
= Vehicle wheelbase [inches].
= Remaining cargo capacity [pounds].
Wrl‡
= Weight of the remaining cargo capacity on the rear wheels [pounds].
Where: Wl = GVWR - (Wb + Wc + P)
WrI =
(CGhI)WI WB
CGhI‡ = Horizontal distance from the CL of the front wheels to the cargo center of gravity [inches]. (Taken from Table M page 19) for many common vehicles. If the CGhI is not given in the table, then it may be estimated as the distance from the CL of the front wheel to the horizontal midpoint of the cargo area.
= Vertical distance from the ground to the center of gravity of the chassis [inches] (including cab if original equipment). (Taken from Table R, page 19). = Horizontal distance from the CL of the front wheels to the P (passenger load). (Taken from Table F, page 15). = Vertical distance from the ground to the center of gravity of the front seat P (passenger weight). (Taken from Passenger Load Table G, page 15).
W‡ I
= Vertical distance from the ground to the center of gravity of the SUB and/or permanently attached added equipment [inches]. (See the Calculation Suggestions Section on page 19).
CGvp
= Total unladen weight = (Wb + Wc + P)
SUB
CGhc
= A Second Unit Body consists of the body structure and/or all the cargo carrying, work performing, and/or load bearing components and/or equipment installed by a subsequent stage manufacturer on an incomplete vehicle, such that the incomplete vehicle becomes a completed vehicle. = Horizontal distance from the CL of the front wheels to the center of gravity (inches) of the chassis.
‡ Required for >8000 lb GVWR calculations only.
STATEMENTS OF CONFORMITY
16
TABLE J Unloaded Vehicle Weight (UVW) This Information Does Not Apply To Vehicles Over 10,000 Pounds GVWR MODELS
WHEELBASE Millimeter [inch]
INCOMPLETE ECONOLINE VEHICLES E-150 Reg. Van w/RV Conv. E-250 Req. Van w/RV Conv. E-250 Super Van w/RV Conv. E-250 Reg. & Super Van (HD) w/RV Conv. E-250 Cutaway SRW E-250 Comm. Basic (Stripped) Chassis SRW E-350 Reg. Van E-350 Super Van or Super Club Wagon E-350 Cutaway SRW † E-350 Cutaway DRW † E-350 Comm. Basic (Stripped) Chassis SRW E-350 Comm. Basic (Stripped) Chassis DRW E-350 Comm. Basic (Stripped) Chassis SRW E-350 Comm. Basic (Stripped) Chassis DRW E-350 Comm. Basic (Stripped) Chassis DRW
3505 3505 3505 3505 3505 3150 3505 3505 3505 3505 3505 3505 4013 4013 4470
MAXIMUM UNLOADED VEHICLE WEIGHTS - Kilogram [pound] by Engine Size - Liter [cubic inch]
★4.2L [256] 4.6L [281] 5.4L [329] 6.8L [414] 7.3LD[444] [138] 2699 [5950] 2699 [5950] 2699 [5950] NA NA [138] NA NA 3130 [6900] NA NA [138] NA NA 3130 [6900] NA NA [138] NA NA 3130 [6900]‡ NA NA [138] 2676 [5900] NA NA NA NA [124] 2676 [5900] NA NA NA NA [138] NA NA 3583 [7900] 3583 [7900] 3583 [7900] [138] NA NA 3583 [7900] 3583 [7900] 3583 [7900] [138] NA NA 3856 [8500] 3856 [8500] 3856 [8500] [138] NA NA 3856 [8500] 3856 [8500] 3856 [8500] [138] NA NA 3946 [8700] NA NA [138] NA NA 3946 [8700] NA NA [158] NA NA 3946 [8700] NA NA [158] NA NA 3946 [8700] NA NA [176] NA NA 3946 [8700] NA NA
† Vehicles completed as a School Bus must be equipped with the School Bus Prep Package and the Unloaded Vehicle Weight must exceed: - 2540kg [5600 lb] with single rear wheels (SRW). - 2858 kg [6300 lb] with dual rear wheels (DRW). ‡ 3357kg [7400 lb] When completed as a Class B motorhome. ★
Maximum unloaded vehicle weight values shown in this Table are limits for purposes of FMVSS conformity only. The frontal area of the completed vehicle may limit the maximum Unloaded Vehicle Weight based on emission certification with the 4.2L engine. See the chart on page 62 for additional information.
TABLE K FMVSS 105 Unloaded Vehicle Weight Variable for Econoline Vehicles with a GVWR less than 3629 [8000 lb] This procedure requires that both the %FLL and %FV (weight percentages calculated in item 7) are between 44% and 57% for E-150 van and between 40% and 60% for E-250 van.
Prior to utilizing the formulas below, the completed vehicle must be weighed with all the fluids at capacity (including a full tank of fuel). Obtain the front component weight (weight between both front tires and the ground), the rear weight component (weight between both rear tires and the ground), and the total vehicle weight. 1. FLL (Front Lightly Loaded weight) = Front Weight Component + 259 lb 2. RLL (Rear Lightly Loaded weight) = Rear Weight Component + 141 lb 3. TLL (Total Lightly Loaded weight) = Total Vehicle Weight + 400 lb 4. FP (Front Proportional weight) =
GVWR x Front GAWR
Front GAWR + Rear GAWR
5. RP (Rear Proportional weight) = GVWR - FP
17
6. To determine the factor FV (Front Variable) use the following: - If FLL is greater than FP then FV = FLL - If RLL is greater than RP then FV = GVWR - RLL - If FLL is less than or equal to FP and RLL is less than or equal to RP then FV= FP 7. Calculate the weight percentage as follows: • %FLL = FLL x 100 TLL • %FV = FV x 100 GVWR
STATEMENTS OF CONFORMITY
TABLE L This Weight Information Does Not Apply To Vehicles Over 10,000 Pounds GVWR SUPER DUTY F-SERIES
MODELS
SECOND UNIT BODY LIMITATIONS MAXIMUM Center of SUB Gravity Overall Weight Height† Height† Kilogram Millimeter Millimeter [pound] [inch] [inch]
MAX. UNLOADEDVEHICLEWEIGHT Kilogram [pound] Engine Size - Liter [cubic inch] 5.4L [330]
6.8L [415]
7.3LD [444]
F-250 Reg. Chassis Cab (4X2) 3480 mm [137 in] WB
816 [1800]
406 [16]
No Limit
2904 [6400]
2904 [6400]
3198 [7050]
F-250 Reg. Chassis Cab (4X4) 3480 mm [137 in] WB
816 [1800]
406 [16]
No Limit
3130 [6900]
3130 [6900]
3345 [7350]
F-250 Super Chassis Cab (4X2) 4013 mm [158 in] WB
816 [1800]
406 [16]
1575 or less [62 or less]
3108 [6850]
3108 [6850]
3289 [7250]
F-250 Super Chassis Cab (4X4) 4013 mm [158 in] WB
816 [1800]
406 [16]
1575 or less [62 or less]
3289 [7250]
3289 [7250]
3493 [7700]
F-250 Crew Chassis Cab (4X2) 4379 mm [172.4 in] WB
816 [1800]
406 [16]
1575 or less [62 or less]
3198 [7050]
3198 [7050]
3471 [7650]
F-250 Crew Chassis Cab (4X4) 4379 mm [172.4 in] WB
816 [1800]
406 [16]
1575 or less [62 or less]
3391 [7475]
3391 [7475]
3584 [7900]
F-350 Reg Chassis Cab (4X2) 3576 mm [140.8 in] WB
816 [1800]
406 [16]
No Limit
3539 [7800]
3539 [7800]
3539 [7800]
F-350 Chassis Cab (4X4) 3576 mm [140.8 in] WB
635 [1400]
406 [16]
No Limit
3471 [7650]
3471 [7650]
3471 [7650]
F-350 Super Chassis Cab (4X2) 4110 mm [161.8 in] WB
816 [1800]
406 [16]
1575 or less [62 or less]
3720 [8200]
3720 [8200]
3720 [8200]
F-350 Super Chassis Cab (4X4) 4110 mm [161.8 in] WB
635 [1400]
406 [16]
1575 or less [62 or less]
3675 [8100]
3675 [8100]
3675 [8100]
F-350 Crew Chassis Cab (4X2) 4475 mm [176.2 in] WB
816 [1800]
406 [16]
1575 or less [62 or less]
3834 [8450]
3834 [8450]
3834 [8450]
F-350 Crew Chassis Cab (4X4) 4475 mm [176.2 in] WB
635 [1400]
406 [16]
1575 or less [62 or less]
3766 [8300]
3766 [8300]
3766 [8300]
†
Vertical dimensions are measured from the top surface of the frame at the rear of the cab.
STATEMENTS OF CONFORMITY
18
105 SECOND UNIT BODY, CENTER OF GRAVITY CALCULATION SUGGESTIONS: In the case where the rear weight of the SUB and/or added equipment must be reduced and the CGv is found to be below the allowed minimum CGv1, it may be possible to bring the vehicles into compliance by moving the CG h forward. Forward movement of the CG h can be accomplished by: •
Redistributing the weight of the SUB and/or added equipment.
•
Adding permanently attached ballast forward of the CGh. In order to reduce the rear weight, the ballast must be forward of the front axle. (Caution must be taken not to exceed the GVWR or front GAWR of the vehicle.)
CGvb =
CGvb1(Wb1) + CGvb2(Wb2) + ... + CGvbn(Wbn) Wb1 + Wb2 +... + Wbn
and the horizontal CG location of the combined SUB and added equipment is: (Wrb1 + Wrb2 + ... + Wrbn) WB CG = Wb1 + Wb2 + ... + Wbn hb The front/rear weight break down can be found with the use of the following equation: CGhb (Wb1+Wb2 + ... +Wbn) Wrb = WB Conversely the front weight component of the SUB and added equipment is: Wfb = (Wb1+Wb2 + ... +Wbn) - Wrb
The following general equations can be used to find the center of gravity of the SUB and added equipment when there are several elements making up the CG. NOTE: Removal of the components/body parts would be represented by a negative weight being used in these calculations. TABLE M CGhl = Horizontal distance from front axle cargo CG: Model WB (in) CGhl (in)† Super Duty F-Series: -Regular Cab -Regular Cab -Regular Cab -Regular Cab -SuperCab -SuperCab -Crew Cab -Crew Cab Econoline: -Regular Van †Super Van or Super Club Wagon †RV Cutaway (SRW) (DRW) (DRW) (DRW) †Comm. Cutaway (SRW) with Cab/Box Partition without Cab/Box Partition
137.0 140.8 164.8 200.8 158.0 161.8 172.4 176.2
132 134 146 164 153 155 165 167
138 138 138 138 158 176 138 158 138 158 176
116 126 121 127 138 153 121 134 127 143 160
TABLE P MINIMUM SUB WEIGHT Except Econoline Cutaway completed as a school bus see Table J page 17 for Unloaded Vehicle Weight MODELS E-350 Cutaway 3505mm [138 in] WB E-350 Cutaway 4013mm [158 in] WB E-350 Cutaway 4470mm [176 in] WB E-Super Duty, Cutaway 4013mm [158 in] WB E-Super Duty, Cutaway 4470mm [176 in] WB E-250 Basic (Stripped) Chassis E-350 Basic (Stripped) Chassis All WB
† If CGhI is not given in the table or if the location of your cargo is not in the normal cargo area, then your CGhI may be estimated as the distance from the C L of the front wheel to the horizontal midpoint of the cargo area.
Kilogram [Pound] 281 [620] 372 [820] 431 [950] 826 [1820] 962 [2120] 771 [1700] 862 [1900]
TABLE R CGVC = Vertical distance ground to chassis CG (Dimensions are in inches) Super Duty F-250/350 (4X2) SRW > 8500 lb GVWR = 30.0 Super Duty F-250/350 (4X4) SRW > 8500 lb GVWR = 31.0 Super Duty F-350 (4X2) DRW
= 30.0
Super Duty F-350 (4X4) DRW
= 31.0
Super Duty F-450/550 (4X2 & 4X4) DRW
= 35.0
E-150 & E-250 Van <8000 lb GVWR
= 28.5
E-250/350 SRW Van or Wagon >8000 lb GVWR
= 32.0
E-250/E-350 Cutaway
= 28.0
E-Super Duty Cutaway
= 26.5
E-250 SRW Basic (Stripped) Chassis
= 25.0
E-350 Basic (Stripped) Chassis
= 26.5
TABLE N CGhp = Horizontal distance from front wheel CL to Passenger Load. (Dimensions are in inches) All Super Duty F-Series All Econoline†
61.2 48.5
† Except Basic (Stripped) Chassis where the distance from the CL of the front axle to the H point of the driver must be measured.
19
STATEMENTS OF CONFORMITY
TABLE S CGv = Vertical distance from the ground to the completed vehicle center of gravity [inch]. GVWR <8000 lb Use equation A & B, page 12 Place the CGh of the vehicle (from equation B) into the appropriate equations below to determine the allowable range of the CGv. If the actual CGv (from equation A) is within the range calculated, the center of gravity location is acceptable. Model
WB
Equation for CGv Range Upper Limit
Lower Limit
E-150
138
CGv = 1.39 x CGh - 46.9
1.39 x CGh - 58.7
E-250 7900 lb GVWR
138
CGv = 1.39 x CGh - 47.1
1.39 x CGh - 59.0
GVWR > 8000 lb to < 15000 lb Use equation C & D, page 13 Place the CGh of the vehicle (from equation D) into the appropriate equations below to determine the allowable range of the CGv. If the actual CGv (from equation C) is within the range calculated, the center of gravity location is acceptable. Model
WB
Equation for CGv Range Upper Limit Lower Limit
E-250 8600 lb GVWR
138
CGv = 1.27 x CGh - 59.0
1.27 x CGh - 77.5
E-350 (SRW) <9600 Ib GVWR
138 158
CGv = 1.27 x CGh - 60.0 CGv = 1.27 x CGh - 69.5
1.27 x CGh - 80.0 1.27 x CGh - 90.7
TABLE T SUPER DUTY F-SERIES VEHICLES 8800 LB TO 19,000 LB GVWR AND MINIMUM SUB WEIGHTS Chassis Cabs (Wide Frame) 924mm [36.4 in] Model and GVWR Kg [lb.]
F-250 3989 [8800]
F-350 5077 [11,200]
Cab Style
Cab Style
WB mm [in]
R/C
3480 [137]
S/C
4013 [158]
C/C
4380 [172.4]
R/C
3480 [137]
S/C
4013 [158]
C/C
4380 [172.4]
Minimum SUB Kg [lb]
172 [380]
190 [420]
GVWR shown for 49 state applications, California models are 200 lbs. less.
R/C = Regular Cab S/C = SuperCab C/C = Crew Cab
(Continued Next Page)
STATEMENTS OF CONFORMITY
20
TABLE T SUPER DUTY F-SERIES VEHICLES 8800 LB TO 19,000 LB GVWR AND MINIMUM SUB WEIGHTS F-350 866mm [34 in] and F-450/550 868mm [34.2 in] Chassis Cabs (Narrow Frame) Model and GVWR Kg [lb]
F-350 4488 [9900]
Cab Style
WB mm [in]
Minimum SUB Kg [lb]
R/C
3576 [140.8]
453 [1000]
S/C
4110 [161.8]
317 [700]
C/C
4475 [176.2]
172 [380]
R/C
3576 [140.8]
S/C
4110 [161.8]
R/C
4186 [164.8]
204 [450]
C/C
4475 [176.2]
190 [420]
R/C
3576 [140.8]
S/C
4110 [161.8]
R/C
4186 [164.8]
204 [450]
C/C
4475 [176.2]
190 [420]
3576 [140.8]
190 [420]
4186 [164.8]
204 [450]
C/C
4475 [176.2]
190 [420]
R/C
5100 [200.8]
249 [550]
3576 [140.8]
190 [420]
4186 [164.8]
204 [450]
C/C
4475 [176.2]
190 [420]
R/C
5100 [200.8]
249 [550]
R/C
5100 [200.8]
249 [550]
190 [420] F-350 5077 [11,200]
190 [420] F-350 5667 [12,500] (7.3L Diesel)
R/C F-450 6800 [15,000]
R/C F-550 7933 [17,500]
F-550 8613 [19,000] Cab R/C S/C C/C
Style = Regular Cab = SuperCab = Crew Cab
GVWR shown for 49 state applications, California models are 200 lbs. less
21
STATEMENTS OF CONFORMITY
106 The statement below is applicable to all incomplete vehicle types:
Daytime Running Lamps (DRL) - Light Trucks for sale or use in Canada are equipped with DRL’s that meet the Canadian DRL requirements. As manufactured for Canada, these vehicles will not meet the FMVSS 108 requirements for DRL’s when DRL’s are provided.
This vehicle, when completed, will conform to Standard 106, Brake Hoses, if the brake hose assemblies supplied by Ford Motor Company are not removed, relocated, altered or modified and if no brake hose assemblies are added.
Conformity with Standard FMVSS 108, S.12, Headlamp Concealment Devices, are not substantially affected by the design of this incomplete vehicle; accordingly, Ford Motor Company makes no representation as to conformity with this Standard.
106 Canadian Requirements: The preceding statement for FMVSS 106 is an appropriate compliance representation for CMVSS 106, Brake Hoses, if this incomplete vehicle was manufactured for sale or use in Canada.
108 The statement below is applicable to the following vehicle with a GVWR of 4536 kg [10,000 lb] or less and a vehicle width less than 2032 mm [80.00 in] or less:
107 Standard 107, Reflecting Surfaces has been rescinded for vehicles manufactured for sale or use in the U.S. by the NHTSA effective May 6, 1996.
■ Chassis Cab ■ Cutaway
107 Canadian Requirements:
This vehicle, when completed, will conform to Standard 108, Lamps, Reflective Devices, and Associated Equipment, if a Center High Mounted Stop Lamp (CHMSL) is installed on a Cutaway or if the Chassis Cab provided CHMSL is obstructed from the rear of the completed vehicle it must be replaced with a CHMSL that meets all the requirements of this standard and is connected to the electrical power source as provided by Ford Motor Company. See the figure below for circuit location.
CMVSS 107, Reflecting Surfaces has been rescinded for vehicles manufactured for sale or use in Canada by Transport Canada effective October 2, 1996. 108 In addition to the statements pertaining to particular incomplete vehicle types which follow on pages 23 and 24, the statements immediately below, concerning Standard 108 Lamps, Reflective Devices, and Associated Equipment are applicable to all incomplete vehicle types except the Basic (Stripped) Chassis: No additional components may be added to the vehicle which require the use of tools to remove such components, for access to the headlamp aiming devices as provided by Ford Motor Company.
CHMSL FIXED CIRCUIT
SUPER DUTY F-SERIES CHASSIS CAB
ECONOLINE CUTAWAY
FIGURE A - CENTER HIGH MOUNTED STOP LAMP (CHMSL) ELECTRICAL CONNECTOR LOCATION
STATEMENTS OF CONFORMITY
22
TABLE A (Reference Standard 108)
TABLE B DOMESTIC SPECIAL ORDER LIGHTING
Chassis Cab Cutaway Completed Completed As: Truck As: Truck, or MPV MPV, Bus or School Bus
Domestic Special Order offers the following delete options which allow the purchase of an incomplete vehicle without certain normally supplied lighting equipment.
Width Width Width Width
>
< 2032
<
>
Incomplete Vehicle Type
Completed Vehicle Type
Chassis Cab
Truck, MPV
Rear Combination Lamp (1)
Chassis Cab
Truck, MPV
Front Identification and/or Clearance Lamps
2032 2032 2032
mm
mm
mm
mm
[80 in.] [80 in.] [80 in.] [80 in.] Headlamps
S
S
S
S
Tail Lamps
S
S
R
R
Stop Lamps
S
S
R
R
S
N(1)
R
N
S
S
R
R
Center High Mounted Stop Lamp (CHMSL) License Plate Lamps
Delete Option
(1) Deletes the rear stop lamp, tail lamp, rear reflex reflector backup lamp, turn-signal lamp, hazard warning lamp, and associated equipment on the right hand side of the vehicle.
Comparison of Table A on this page with the incomplete vehicle will indicate whether any of the above delete options apply. Some delete option equipment may be required on the completed vehicle in accordance with Standard 108.
Reflex Reflectors -Side Front
S
S
S
S
-SideRear
R
R
R
R
-Rear
S
S
R
R
-Front
S
S
S
S
■ Chassis Cab
-Rear
R
R
R
R
■ Cutaway
S
S
R
R
-Front
S
S
S
S
-Rear
S
S
R
R
Turn Signal Operating Unit
S
S
S
S
Turn Signal Flasher (2)
S
S
S
S
Veh. Haz. Wrng. Oper. Unit
S
S
S
S
S
S
S
S
-Front
N(1)
S(1)
N
R
This vehicle, when completed, will conform to Standard 108, Lamps, Reflective Devices and Associated Equipment, if all the required lighting equipment as indicated in Table A on this page (identified by the codes R and S) is designed and installed in accordance with the requirements of Standard 108 and the directions contained in this statement. Additionally, if the completed vehicle overall length is 9.14 meters [30 feet] or more, intermediate side marker lamps and reflex reflectors (not supplied by Ford Motor Company) are also required for compliance with Standard 108.
-Rear
N
R
N
R
-Front
N(1)
S(1)
N
R
-Rear
N
R
N
R
S
N
R
N
N
N
R
R
Side Marker Lamps Back-Up Lamps Turn Signal Lamps
Veh. Haz. Wrng. Flasher Identification Lamps Clearance Lamps Parking Lamps
108 The statements below are applicable to the following incomplete vehicle types:
The items of equipment which are supplied by Ford Motor Company (identified by the code S in Table A, on this page) are designed and installed to conform to all the requirements of Standard 108. The completed vehicle will conform with these components if the subsequent stage manufacturer does not remove, relocate, alter, or modify such equipment or modify the power supply or wiring to such equipment, and does not complete the body in such a configuration as to impair the visibility and conformity to the photometric requirements of the installed lamps and reflective devices.
School Bus Lamps and Switches (School Buses only)
S Required on completed vehicle and supplied with the incomplete vehicle
Specific requirements for lighting and associated equipment are listed by incomplete vehicle type in Table A on this page.
R Required on completed vehicle and not supplied with the incomplete vehicle
Lamps, reflective devices, and associated equipment necessary to complete the vehicle from an incomplete vehicle must conform to the equipment, locations, special wiring, visibility, photometric and performance requirements of Standard 108 and to the applicable SAE standards or recommended practices referenced or subreferenced in this Standard.
N Not required for completed vehicle (1) Supplied on Chassis Cab (2) Designed for two turn signal lamps per vehicle side (one front and rear). If additional lamps are required, replace the turn signal flasher with one having the correct lamp load rating
All electrical equipment added to the vehicle by subsequent stage manufacturers must conform to the wiring practices set forth in the Electrical Wiring Section of the Ford Truck Body Builders Layout Book. 108 (Continued Next Page)
23
STATEMENTS OF CONFORMITY
111 The statements below are applicable to the following incomplete vehicle types when equipped with a driver seat (including untrimmed seat) and a convex mirror on the passenger-side:
108 (Continued) 108 The statements below are applicable to the following incomplete vehicle types: ■ Incomplete Econoline Van or Super Club Wagon
■ Chassis Cab
This vehicle, when completed, will conform to Standard
■ Incomplete Econoline Van or Super Club Wagon
108, Lamps, Reflective Devices and Associated
This vehicle, when completed, will conform to Standard 111, Rearview Mirrors, if:
Equipment, if the subsequent stage manufacturer does not:
• The mirrors and their mounts as supplied by Ford Motor Company are not removed, relocated, replaced or altered, except as noted below.
• Remove, alter, replace or relocate the lighting equipment installed on the incomplete vehicle
• No structural modifications are made to the body which would affect the stability of the mirror mounts.
• Modify the power supply or wiring to such equipment. • Add any additional external lighting equipment
• Any modifications or additions made to this incomplete vehicle do not adversely affect the driver’s view to the rear in the outside mirrors along both sides of the vehicle.
• Increase the overall width of the vehicle beyond that of the incomplete vehicle • Complete, modify or add components to the vehicle in such a manner as to impair the visibility and conformity to the photometric requirements of the installed lamps and reflective devices
• The driver-seat is not replaced, relocated or modified other than for the addition of seat trim. • The overall width of the body mounted to a Super Duty F-Series Chassis Cab equipped with Low Mount Western convex right hand mirror does not exceed 80 inches.
108 The statement below is applicable to the Basic (Stripped) Chassis: Conformity with Standard 108, Lamps, Reflective Devices, and Associated Equipment, is not substantially affected by the design of this incomplete vehicle; accordingly, Ford Motor Company makes no representation as to conformity with this standard. However, Ford Motor Company does represent that the items of lighting equipment provided in the dunnage box attached to the chassis are designed to conform to the requirements of Standards 108.
If any alteration blocks the rear field of view through the inside mirror, FMVSS 111 may require that the vehicle have a flat glass on the passenger side. NOTE: A flat glass, passenger-side, Low Mount Western mirror (pad number E3TZ-17723-A) is available for Chassis-Cab vehicles from your Ford Dealer.
108 Canadian Requirements: The preceding statements for FMVSS 108 are appropriate compliance representations for CMVSS 108, Lighting, and CMVSS 108.1, Headlamps, if this vehicle is manufactured for sale or use in Canada, provided:
111 The statements below are applicable to the incomplete Econoline Van with no driver-seat when equipped with a convex mirror on the passenger-side:
• No component of the Daytime Running Lamp (DRL) system is removed, relocated, or modified.
This vehicle, when completed, will conform to Standard 111, Rearview Mirrors, if: • The mirrors and their mounts as supplied by Ford Motor Company, are not removed, relocated, replaced or altered. • No structural modifications are made to the body which would affect the stability of the mirror mounts. • The Seating Reference Point (see definition on page 8) and the seat back torso angle of the driverseat installed or completed by the subsequent stage manufacturer are located as shown in Figure C page 37 corresponding to the particular incomplete vehicle type. • Any modifications or additions made to this incomplete vehicle do not adversely affect the driver’s view to the rear in the outside mirrors along both sides of the vehicle. If any alteration blocks the rear field of view through the inside mirror, FMVSS 111 may require that the vehicle have a flat glass on the passenger side.
STATEMENTS OF CONFORMITY
24
111 The statement below is applicable to the following incomplete vehicle types when not equipped with outside mirrors:
112 Standard 112, Headlamp Concealment Devices has been rescinded and transfers requirements to FMVSS 108 for vehicles manufactured for sale or use in the U.S. by the NHTSA effective October 24, 1996.
■ Chassis Cab
112 Canadian Requirements: The statement below is applicable to all incomplete vehicle types:
■ Cutaway ■ Basic (Stripped) Chassis ■ Incomplete Econoline Van
This vehicle when completed, will conform to CMVSS 112, Headlamp Concealment Devices, and is not substantially affected by the design of this incomplete vehicle; accordingly, Ford Motor Company makes no representation as to conformity with CMVSS 112, if this incomplete vehicle was manufactured for sale or use in Canada.
Conformity with Standard 111, Rearview Mirrors, is not substantially affected by the design of this incomplete vehicle; accordingly, Ford Motor Company makes no representation as to conformity with this Standard. 111 The statements below are applicable to the Cutaway when equipped with outside mirrors: Conformity with the stability requirements of Standard 111, Rearview Mirrors, is not substantially affected by the design of this incomplete vehicle; accordingly Ford Motor Company makes no representation as to conformity with stability requirements of this Standard. However, except for the stability requirement, this vehicle, when completed, will conform to Standard 111, Rearview Mirrors, if:
113 The statement below is applicable to all incomplete vehicle types except the Basic (Stripped) Chassis: This vehicle, when completed, will conform to Standard 113, Hood Latch Systems, if the hood latch system as provided by Ford Motor Company is not removed or altered. 113 The statement below is applicable to the Basic (Stripped) Chassis:
• The outside mirrors and their mounts, as supplied by Ford Motor Company, are installed in accordance with the instructions that accompany them and they are not relocated, replaced or altered.
Conformity with Standard 113, Hood Latch Systems, is not substantially affected by the design of this incomplete vehicle; accordingly Ford Motor Company makes no representation as to conformity with this Standard.
• For the Cutaway with the School Bus Prep Package, when completed as a school bus, and any outside mirrors (not provided by Ford Motor Company) are installed in conformity with the requirements of Standard 111 for school buses.
113 Canadian Requirements: The preceding statements for FMVSS 113 are appropriate compliance representations for CMVSS 113, Hood Latch System, if this incomplete vehicle was manufactured for sale or use in Canada.
111 The statements below are applicable to the following incomplete vehicle types when equipped with a flat glass mirror on the passenger-side:
114 The statements below are applicable to all incomplete vehicle types except the Basic (Stripped) Chassis when completed as either a MPV or a Truck with a GVWR of 4536 kg [10,000 lb] or less:
■ Chassis Cab ■ Incomplete Econoline Van
This vehicle, when completed, will conform to Standard 114, Theft Protection, if the following components to the extent provided by Ford Motor Company are not removed, relocated, altered or modified in any way:
This vehicle, when completed, will conform to Standard 111, Rearview Mirrors, if: • The mirrors and their mounts as supplied by Ford Motor Company are not removed, relocated, replaced or altered.
• Steering column locking mechanism system • Ignition key/transmission shift interlock locking system
• Any modifications or additions made to the Incomplete Vehicle must not adversely affect the driver’s view to the rear in the outside mirrors along both sides of the vehicle.
• Ignition key-locking system • Key warning buzzer system If any of the above components are added to the vehicle they must conform to the requirements of this Standard.
111 Canadian Requirements: The preceding statements for FMVSS 111 are appropriate compliance representations for CMVSS 111, Rearview Mirrors, if this incomplete vehicle was manufactured for sale or use in Canada.
114 (Continued Next Page)
25
STATEMENTS OF CONFORMITY
114 (Continued)
118 Canadian Requirements: The preceding statements for FMVSS 118 are appropriate compliance representations for CMVSS 118, PowerOperated Window Systems, if this incomplete vehicle was manufactured for sale or use in Canada.
114 The statement below is applicable to the Basic (Stripped) Chassis when completed as a Truck with a GVWR of 4536 kg [10,000 lb] or less: The Commercial Basic (Stripped) Chassis is designed by Ford Motor Company to be completed as a walk-in van type vehicle. Walk-in vans are exempt from the requirements of Standard 114, Theft Protection. See walk-in van definition, on page 8.
120 The statement below is applicable to all incomplete vehicle types: This vehicle, when completed, will conform to the tire and rim selection requirements of Standard 120, Tire Selection and Rims for Motor Vehicles Other Than Passenger Cars, if the tire or rim assemblies and the Incomplete Vehicle Label affixed to all vehicles, (except the Basic (Stripped) Chassis), are not removed, altered or replaced. For the Basic (Stripped) Chassis, the final stage manufacturer must, in accordance with the requirements of Standard 120 and Part 567 of Title 49 Code of Federal Regulations, either affix a label indicating tire size, rim size and cold inflation pressure information and gross axle weight ratings that are printed on the label affixed to the cover of this manual, or affix the Incomplete Vehicle Label included in the plastic bag along with this Incomplete Vehicle Manual.
114 Canadian Requirements: The preceding statements for FMVSS 114 are appropriate compliance representations for CMVSS 114, Locking System, if this incomplete vehicle was manufactured for sale or use in Canada. 115 Canadian Requirements: The statements for Part 565 are appropriate compliance representations for CMVSS 115, Vehicle Identification Number, if this incomplete vehicle was manufactured for sale or use in Canada. 116 The statement below is applicable to all incomplete vehicle types:
120 Canadian Requirements: The preceding statement for FMVSS 120 is an appropriate compliance representation for CMVSS 120, Tire Selection and Rims for Vehicles Other Than Passenger Cars, if this incomplete vehicle was manufactured for sale or use in Canada, except for the following:
This vehicle, when completed, will conform to Standard 116, Motor Vehicle Brake Fluids, so long as any brake fluid added or replaced conforms to the DOT 3 specifications of the standard, and contaminants are not introduced into the hydraulic brake system.
• The label information requirements for CMVSS 120 are in Section 6 of the Canada Motor Vehicle Safety Regulations.
116 Canadian Requirements: The preceding statement for FMVSS 116 is an appropriate compliance representation for CMVSS 116, Hydraulic Brake Fluid, if this incomplete vehicle was manufactured for sale or use in Canada. 118 The statement below is applicable to all incomplete vehicle types not equipped with power windows when completed as either a MPV or a Truck with a GVWR of 4536 kg [10,000 lb] or less: Conformity with Standard 118, Power Operated Window, Partition, and Roof Panel Systems, is not substantially affected by the design of this incomplete vehicle; accordingly, Ford Motor Company makes no representation as to conformity with this Standard. If any power operated window, partition, or roof panel systems are installed by subsequent stage manufacturers, they must conform to the requirements of Standard 118. 118 The statement below is applicable to all incomplete vehicle types equipped with power windows when completed as either a MPV or a Truck with a GVWR of 4536 kg [10,000 lb] or less: This vehicle, when completed, will conform to Standard 118, Power Operated Window, Partition, and Roof Panel Systems, if the power operated windows, motors, wiring, and key and switch activation systems, where provided by Ford Motor Company, are not removed, relocated, altered or modified in any way. If additional power operated window, partition, or roof panel systems are installed by subsequent stage manufacturers, they must conform to the requirements of Standard 118.
STATEMENTS OF CONFORMITY
26
124 The statements below are applicable to all incomplete vehicle types:
201 The statements below are applicable to all incomplete vehicle types except the Basic (Stripped) Chassis if the GVWR is 4536 kg [10,000 lb] or less:
This vehicle, when completed, will conform to Standard 124, Accelerator Control Systems, if:
This vehicle, when completed, will conform to Standard 201, Occupant Protection in Interior Impact, if the following components as provided by Ford Motor Company, are not removed, relocated, altered or modified in any way:
• No alterations are made to the accelerator control rod, bellcranks, cables, springs, guides, accelerator pedal, mounting hardware or other components of the accelerator control system as installed by Ford Motor Company.
• Instrument panel • Interior compartment doors
• No equipment is added, or existing equipment is modified, which would restrict operation of the accelerator control system.
• Sun visors • Arm rests Seat backs of front seats installed by Ford Motor Company are designed to meet the seat back requirements of Standard 201. The seat mounted armrest on an untrimmed front seat must be completed so as to meet the requirements of this Standard.
• Vehicles equipped with electronically controlled, 7.3L, Dl Turbo Diesel have no alterations made to the Pedal Position Sensor and all associated hardware and wiring. See the figure below for component identification.
If any of the above mentioned components (including front seats) are added to the incomplete vehicle by a subsequent stage manufacturer, these components must conform to the requirements of Standard 201 where applicable. When front seats are installed on an Incomplete Econoline Van or Cutaway the installed seat must be located within the dimensional specifications for the Seating Reference Point and the torso angle as specified in Figure C page 37.
124 Canadian Requirements: The preceding statement for FMVSS 124 is an appropriate compliance representation for CMVSS 124, Accelerator Control Systems, if this incomplete vehicle was manufactured for sale or use in Canada.
Because conformity of a completed vehicle to the seat back requirements of this standard is dependent upon the location of a seat installed by a subsequent stage manufacturer to the rear of another seat, Ford makes no representation as to compliance of a completed vehicle to the seat back requirements if such a seat is installed. 201 The statement below is applicable to the Basic (Stripped) Chassis if the GVWR is 4536 kg [10,000 lb] or less: Conformity with Standard 201, Occupant Protection in Interior Impact, is not substantially affected by the design of this incomplete vehicle, accordingly Ford Motor Company makes no representation as to conformity with this Standard. 201 Canadian Requirements: The preceding statements for FMVSS 201 are appropriate compliance representations for CMVSS 201, Occupant Protection, if this incomplete vehicle was manufactured for sale or use in Canada.
ELECTRONIC ACCELERATOR CONTROL 131 The statement below is applicable to the Cutaway when equipped with the School Bus Prep Package and completed as a school bus: Conformity with Standard 131, School Bus Pedestrian Safety Devices, is not substantially affected by the design of this incomplete vehicle, accordingly, Ford Motor Company makes no representation as to conformity with this Standard.
27
STATEMENTS OF CONFORMITY
202 The statements below are applicable to the following incomplete vehicle types if the GVWR is 4536 kg [10,000 lb] or less:
203 The statement below is applicable to the Basic (Stripped) Chassis if the GVWR Is 4536 kg [10,000 lb] or less:
■ Chassis Cab
The Commercial Basic (Stripped) Chassis is designed by Ford Motor Company to be completed as a walk-in van type vehicle. Walk-in vans are exempt from the impact requirements of Standard 203, Impact Protection for the Driver from the Steering Control System. See walk-in van definition, on page 8.
■ Incomplete Econoline Van or Wagon when equipped wIth front seats ■ Cutaway when equipped with front seats This vehicle when completed, will conform to Standard 202, Head Restraints, if:
203 Canadian Requirements:
• No alterations are made to the head restraints, the seat assemblies and their anchorages, the floor pan, floor pan reinforcements.
The preceding statements for FMVSS 203 are appropriate compliance representations for CMVSS 203, Driver Impact Protection, if this incomplete vehicle was manufactured for sale or use in Canada. In such a case, the Commercial Basic (Stripped) Chassis will comply if no components or attachments are added to the steering control system that can catch the driver’s clothing or jewelry during normal driving maneuvers.
• The added seat trim, on vehicles equipped with untrimmed front seats, is installed so that the physical dimension requirements for the head restraint, in this Standard are met. Any front outboard passenger seat, added to a cutaway equipped with the School Bus Prep Package and when completed as a truck, MPV or bus (not school bus), must conform with the requirements of this Standard.
204 INFORMATION Please refer to the Second Unit Body Attachment design recommendations beginning on page 78 for information to aid in designing second unit bodies and their attachments to be compatible with Econoline and Super Duty F-Series vehicles.
202 The statement below is applicable to the following incomplete vehicle types if the GVWR is 4536 kg [10,000 lb] or less: ■ Incomplete Econoline Van with no front seats ■ Cutaway with no front seats
204 The statements below are applicable to all incomplete vehicle types except the Basic (Stripped) Chassis if the GVWR is 4536 kg [10,000 lb] or less and the Unloaded Vehicle Weight, when completed, is 2495 kg [5,500 lb] or less:
■ Basic (Stripped) Chassis Conformity with Standard 202, Head Restraints, is not substantially affected by the design of this incomplete vehicle; accordingly, Ford Motor Company makes no representation as to conformity with this Standard.
This vehicle, when completed, will conform to Standard 204, Steering Control Rearward Displacement, if:
202 Canadian Requirements: The preceding statements for FMVSS 202 are appropriate compliance representations for CMVSS 202, Head Restraints, if this incomplete vehicle was manufactured for sale or use in Canada.
• The Unloaded Vehicle Weight does not exceed the appropriate weight on Table J page 17, for all the Econoline vehicles, and the weight on Table L page 18, for Super Duty F-Series Chassis Cab type vehicles.
203 The statement below is applicable to all incomplete vehicle types except the Basic (Stripped) Chassis if the GVWR is 4536 kg [10,000 lb] or less:
• No components are added which could influence the rearward displacement of the steering column. • The steering column, steering intermediate and coupling shaft, steering wheel, steering gear, steering linkage, related structural components and attaching hardware as installed by Ford Motor Company are not removed, relocated, altered or modified in any way.
This vehicle, when completed , will conform to Standard 203, Impact Protection for the Driver from the Steering Control System, if the steering control system is not removed, relocated, altered or modified in any way and no components or attachments are added to the steering control system that can catch the driver’s clothing or jewelry during normal driving maneuvers.
• No alteration or modifications are made to the body chassis, drivetrain or front suspension from the B-pillar forward. 204 The statement below is applicable to the Basic (Stripped) Chassis if the GVWR is 4536 kg [10,000 lb] or less and the Unloaded Vehicle Weight, when completed, is 2495 kg [5,500 lb] or less: The Commercial Basic (Stripped) Chassis is designed by Ford Motor Company to be completed as a walk-in van type vehicle. Walk-in vans are exempt from the requirements of Standard 204, Steering Control Rearward Displacement. See walk-in van definition, on page 8. 204 Canadian Requirements: The preceding statements for FMVSS 204 are appropriate compliance representations for CMVSS 204, Steering Column Rearward Displacement, if this incomplete vehicle was manufactured for sale or use in Canada.
STATEMENTS OF CONFORMITY
28
205 The statement below is applicable to all incomplete vehicle types, except the Basic (Stripped) Chassis:
207, 208, 209 and 210 INFORMATION For additional information to assist in designing seats, seat belt systems and seat belt anchorages that comply with FMVSS 207, 208, 209 and 210 applicable to Incomplete Econoline Van, and Cutaway vehicles with no front seats provided by Ford Motor Company refer to the Seat and Lap & Shoulder Belt System design recommendations on page 64, in addition to the statements which follow.
This vehicle, when completed, will conform to Standard 205, Glazing Materials, if no alterations to or replacements of the installed glazing materials are made, and if additional glazing materials installed by a subsequent stage manufacturer conform to the requirements of Standard 205. 205 The statement below is applicable to the Basic (Stripped) Chassis:
207 The statements below are applicable to the following incomplete vehicle types when equipped with trimmed front seats:
Conformity with Standard 205, Glazing Materials, is not substantially affected by the design of this incomplete vehicle: accordingly, Ford Motor Company makes no representation as to conformity with this Standard.
■ Chassis Cab ■ Incomplete Econoline Van or Super Club Wagon
205 Canadian Requirements:
■ Cutaway
The preceding statements for FMVSS 205 are appropriate compliance representations for CMVSS 205, Glazing Materials, if this incomplete vehicle was manufactured for sale or use in Canada.
This vehicle, when completed, will conform to Standard 207, Seating Systems, if no alterations are made to the seat assemblies, their anchorages, the floor pan, floor pan reinforcements. Any seating system added to this vehicle must conform to applicable requirements of this Standard. When the Cutaway is completed as a school bus, see FMVSS 222 also.
206 The statements below are applicable to all incomplete vehicle types except the Basic (Stripped) Chassis, when completed as a Truck:
If the front seat attaching hardware is removed for any reason, it must be reinstalled to the specifications in the Figures for Econoline on page 36.
This vehicle, when completed, will conform to Standard 206, Door Locks and Door Retention Components, if no alterations or adjustments are made to the door, door pillar structure, door locks, door latches, striker plates, hinges and attaching hardware as installed by Ford Motor Company.
The Incomplete Econoline Van equipped with the RV Prep Package or the Incomplete Econoline Super Club Wagon may have additional anchorages for rear seats other than the front driver and passenger seats. These locations apply to specific hardware and designated seating positions used in Ford completed vehicles. If these anchorages are used without the appropriate Ford seats, seat belt systems and hardware, Ford Motor Company makes no representation as to conformity with this Standard.
Any door added to this vehicle by a subsequent stage manufacturer must be equipped with door locks and door retention components that conform with this Standard. 206 The statement below is applicable to the Basic (Stripped) Chassis when completed as a Truck: Conformity with Standard 206, Door Locks and Door Retention Components, is not substantially affected by the design of this incomplete vehicle; accordingly, Ford Motor Company makes no representation as to conformity with this Standard.
207 (Continued Next Page)
206 Canadian Requirements: The preceding statements for FMVSS 206 are appropriate compliance representations for CMVSS 206, Door Latches, Hinges and Locks, if this incomplete vehicle was manufactured for sale or use in Canada.
29
STATEMENTS OF CONFORMITY
207 (Continued)
207 The statements below are applicable to the following incomplete vehicle types with no front seats:
207 The statements below are applicable to the following incomplete vehicle types when equipped with untrimmed front seats:
■ Incomplete Econoline Van ■ Cutaway
■ Incomplete Econoline Van
■ Basic (Stripped) Chassis
■ Cutaway
Conformity with Standard 207, Seating Systems, is not substantially affected by the design of this incomplete vehicle; accordingly, Ford Motor Company makes no representation as to conformity with this Standard.
This vehicle when completed, will conform to Standard 207, Seating Systems, if: • No changes or modifications are made to the front seat frames, latches, hardware and padding.
The RV Cutaway, when equipped with seat delete option, will include both front seat pedestals, pretensioner restraint systems, seat tracks and a temporary driver’s seat. The pretensioner restraint system is attached to the seat track, therefore, the completed seat assembly must comply with the requirements of F/CMVSS 207 and 210.
• The weight of each completely trimmed front seat does not exceed the value in Table A on this page. • No modifications are made to the floor pan in the area of the front seat attachments. • The front seat and seat belt anchorages are not relocated.
The Incomplete Econoline Van equipped with the RV Prep Package may have additional seat anchorages. These locations apply to specific hardware and designated seating positions used in Ford completed vehicles. If these anchorages are used without the appropriate Ford seats, seat belt systems and hardware, Ford Motor Company makes no representation as to conformity with this Standard.
If the front seat attaching hardware is removed for any reason, it must be reinstalled to the specifications in the Figures for Econoline on page 36. Any seating systems added to this vehicle must conform to the applicable requirements of this Standard. The Incomplete Econoline Van, when equipped with the RV Prep Package, may have additional anchorages for rear seats other than the front driver and passenger seats. These locations apply to specific hardware and designated seating positions used in Ford completed vehicles. If these anchorages are used without the appropriate Ford seats, seat belt systems and hardware, Ford Motor Company makes no representation as to conformity with this Standard.
207 Canadian Requirements: The preceding statements for FMVSS 207 are appropriate compliance representations for CMVSS 207, Anchorage of Seats, if this incomplete vehicle was manufactured for sale or use in Canada.
TABLE A ECONOLINE COMPLETED UNTRIMMED SEAT WEIGHT DESCRIPTION
MAX. WEIGHT (lb) DRIVER-SIDE
PASSENGER-SIDE
Econoline Captain’s Chair - Manual Tracks
59.0
61.0
Econoline Captain’s Chair - Manual Tracks - Manual Lumbar
62.0
68.0
Econoline Captain’s Chair - Power Tracks - Manual Lumbar
68.0
N/A
STATEMENTS OF CONFORMITY
30
208 The statements below are applicable to the Incomplete Econoline Van when equipped with trimmed front seats option if the GVWR is 3855 kg [8,500 lb] or less and the Unloaded Vehicle Weight, when completed, is 2495 kg [5,500 lb] or less:
to the areas defined at the Occupant Protection Zone shown in Figure A on page 38. • The Air Bag Supplemental Restraint System as originally installed (see Figure B on page 38), is not removed, relocated, altered or modified in any way.
This vehicle, when completed, will conform to Standard 208, Occupant Crash Protection, if:
• The Air Bag Supplemental Restraint System Information Labels that are affixed to the front sun visors are visible, and not altered, modified or removed.
• The Unloaded Vehicle Weight does not exceed the appropriate weight on Table J on page 17.
• No alteration or modifications are made to the body, chassis (including front bumper), drivetrain, body mounts or front suspension from the B-pillar forward.
• The steering column, steering intermediate and coupling shaft, steering wheel, steering gear, steering linkage, related structural components and attaching hardware as installed by Ford Motor Company are not removed, relocated, altered or modified in any way.
• Any front overhead console installed on an Incomplete Econoline is configured as follows: – Front header (full width) overhead consoles may extend down no more than 2 inches as measured from the Ford installed headliner† and extend rearward no more than 6 inches as measured from the midpoint between the Ford installed sun visor inboard retaining clips (vehicle centerline).
• No components are added which could influence the rearward displacement of the steering column. • The seat belt components installed by Ford Motor Company are not removed, relocated or altered. If the seat belt components are temporarily removed for any reason, they must be reinstalled to the specifications as shown in Figure A on page 35.
– Center roof mounted consoles may extend down no more than 3 inches as measured from the Ford installed headliner† and width is limited to 8 inches (4 inches either side of the vehicle centerline).
• Front seats that have been removed for final manufacture are reinstalled to the specifications as shown in the Figures on page 36.
– All overhead consoles are designed and manufactured to provide friendly surfaces on all sides and edges which could be contacted by an occupant.
• The seat belt warning system, as originally installed, is not removed, replaced, modified or altered in any way.
Any seat belt assemblies added to a vehicle must conform to the applicable requirements of this Standard.
• Window or roof modifications do not exceed the defined cut out areas shown in the Figures on pages 39, 40 and 41. • No compressible material is installed between front seat assembly and the floor pan.
208 (Continued Next Page)
• No additional components or modifications are made
† The Headliner Plane is defined on Figure C page 41, for vehicles without the Ford headliner.
31
STATEMENTS OF CONFORMITY
208 (Continued)
• After the front seats and B-pillar trim are installed, the seat belt system components must comply with:
208 The statements below are applicable to the incomplete Econoline Van when equipped with untrimmed front seats option if the GVWR is 3855 kg [8,500 lb] or less and the Unloaded Vehicle Weight, when completed, is 2495 kg [5,500 lb] or less:
– Adjustment requirements specified by s7.1 as these requirements apply to seat belt fit, to the intersection of the upper torso belt with the lap belt, and to child seat lockability, and – Latch mechanism requirements specified by s7.2 as these requirements apply to the accessibility of seat belt components, and
This vehicle, when completed, will conform to Standard 208, Occupant Crash Protection, if: • The Unloaded Vehicle Weight does not exceed the appropriate weight on Table J page 17.
– Latch plate access, retraction, seat belt guides and hardware requirements specified by s7.4 as these requirements apply to comfort and convenience requirements of the seat belt system.
• The steering column, steering intermediate and coupling shaft, steering wheel, steering gear steering linkage, related structural components and attaching hardware as installed by Ford Motor Company are not removed, relocated, altered or modified in any way.
• No point on the surface of the seat back in the area of its front outboard “corner” lies within the space defined as “Point A”, with the seat at mid-track positions and the torso angle is positioned as specified. See Figure C on page 37.
• No components are added which could influence the rearward displacement of the steering column. • The seat belt components installed by Ford Motor Company are not removed, relocated or altered. If the seat belt components are temporarily removed for any reason, they must be reinstalled to the specifications for the appropriate vehicle type shown in Figure A on page 35.
• No alteration or modifications are made to the body chassis (including front bumper), drivetrain, body mounts or front suspension from the B-pillar forward. • Any front overhead console installed on an Incomplete Econoline is configured as follows: – Front header (full width) overhead consoles may extend down no more than 2 inches as measured from the Ford installed headliner† and extend rearward no more than 6 inches as measured from the midpoint between the Ford installed sun visor inboard retaining clips (vehicle centerline).
• Front seats that have been removed for final manufacture are reinstalled to the specifications for appropriate vehicle type as shown in the Figures on page 36. • The seat belt warning system, as originally installed, is not removed, relocated, altered or modified in any way.
– Center roof mounted consoles may extend down no more than 3 inches as measured from the Ford installed headliner† and width is limited to 8 inches (4 inches either side of the vehicle centerline).
• The completed front seats are within the Seating Reference Point specifications in Figure C on page 37. • Window or roof modifications do not exceed the defined cut out areas shown in the Figures on pages 39, 40 and 41.
– All overhead consoles are designed and manufactured to provide friendly surfaces on all sides and edges which could be contacted by an occupant.
• No compressible material is installed between front seat assembly and the floor pan.
Any seat belt assemblies added to this vehicle must conform to the applicable requirements of this Standard.
• No additional components or modifications are made to the areas defined as the Occupant Protection Zone shown in Figure A on page 38. • The Air Bag Supplemental Restraint System as installed by Ford Motor Company is not removed, relocated, modified or altered in any way as shown in Figure B on page 38.
208 (Continued Next Page)
• The Air Bag Supplemental Restraint System Information Labels that are affixed to the front sun visors are visible, and not altered, modified or removed.
† The Headliner Plane is defined on Figure C page 41, for Econoline vehicles without the Ford headliner.
STATEMENTS OF CONFORMITY
32
• The Air Bag Supplemental Restraint System as installed by Ford Motor Company is not removed, relocated, modified or altered in any way as shown in Figure B on page 38.
208 The statements below are applicable to the Incomplete Econoline Van with RV Prep Package, and seat delete option, if the GVWR is 3855 kg [8,500 lb] or less and the Unload Vehicle Weight, when completed, is 2495 kg [5,500 lb] or less:
• The Air Bag Supplemental Restraint System Information Labels that are affixed to the front sun visors are visible, and not altered, modified or removed.
The seat delete option includes front seat pedestals, front seat tracks, front seat belt and buckle assemblies mounted to the seat tracks, restraint system, fasteners and a temporary transit seat. Because the permanent seats to be installed by a subsequent stage manufacturer are critical to the performance of the completed vehicle and to the dynamic test requirements of Standard 208, Occupant Crash Protection, conformity to this Standard is not substantially affected by the design of this incomplete vehicle.
• After the front seats and B-pillar trim are installed, the seat belt system components must comply with: – The seat belt buckle pretensioner, air bags and electronic sensor module are bar coded with a unique serial number which is matched to the vehicle VIN. The completed vehicle must contain the same seat belt buckle pretensioner, air bags and electronic sensor module that were installed by Ford Motor Company in the incomplete vehicle.
Ford offers the following information and guidelines to assist subsequent stage manufacturers who choose to install front seat assemblies in Incomplete Econoline Van vehicles.
– Adjustment requirements specified by s7.1 as these requirements apply to seat belt fit, to the intersection of the upper torso belt with the lap belt, and to child seat lockability, and
• The completed front seat assemblies include the following Ford Motor Company components: Seat pedestal, seat tracks, restraint system and all fasteners provided, and are torqued to the specifications listed in Figure B on page 36.
– Latch mechanism requirements specified by s7.2 as these requirements apply to the accessibility of seat belt components, and – Latch plate access, retraction, seat belt guides and hardware requirements specified by s7.4 as these requirements apply to comfort and convenience requirements of the seat belt system.
• The completed front seat assemblies, when installed, will have the same location, construction and spatial relationship to the seating system as provided by Ford Motor Company.
• The seat hardware including the seat back frames are free of sharp edges to prevent damage to the seat belt webbing during an impact.
• The Unloaded Vehicle Weight does not exceed the appropriate weight on Table J on page 17. • The steering column, steering intermediate and coupling shaft, steering wheel, steering gear, steering linkage, related structural components and attaching hardware as installed by Ford Motor Company are not removed, relocated, altered or modified in any way.
• No point on the surface of the seat back in the area of its front outboard “corner” lies within the space defined as “ Point A”, with the seat at mid-track position and the torso angle is positioned as specified. See Figure C on page 37, for Econoline.
• No components are added which could influence the rearward displacement of the steering column.
• No alteration or modifications are made to the body, chassis (including front bumper), drivetrain, body mounts or front suspension from the B-pillar forward.
• The seat belt components installed by Ford Motor Company are not removed, relocated or altered. If the seat belt components are temporarily removed for any reason, they must be reinstalled to the specifications as shown in Figure A on page 35.
• Any front overhead console installed on an Incomplete Econoline is configured as follows: – Front header (full width) overhead consoles may extend down no more than 2 inches as measured from the Ford installed headliner† and extend rearward no more than 6 inches as measured from the midpoint between the Ford installed sun visor inboard retaining clips (vehicle centerline).
• The completed front seats are installed to the specifications as shown in the figures on page 36. • The seats, seating hardware, seat belt warning system and all attaching hardware are installed in accordance with, and comply with this Standard and Standard 207, Seating Systems.
– Center roof mounted consoles may extend down no more than 3 inches as measured from the Ford installed headliner† and width is limited to 8 inches (4 inches either side of the vehicle centerline).
• The completed front seats, when installed, are located within the dimensional specifications for the Seating Reference Point, and torso angle is positioned as specified in Figure C on page 37.
– All overhead consoles are designed and manufactured to provide friendly surfaces on all sides and edges which could be contacted by an occupant.
• Window or roof modifications do not exceed the defined cut out areas shown in the Figures on pages 39, 40 and 41.
Any seat belt assemblies added to this vehicle must conform to the applicable requirements of this Standard.
• No compressible material is installed between front seat assembly and the floor pan.
208 (Continued Next Page)
• No additional components or modifications are made to the areas defined as the Occupant Protection Zone shown in Figure A on page 38.
† The Headliner Plane is defined on Figure C page 41, for Econoline vehicles without the Ford headliner.
33
STATEMENTS OF CONFORMITY
208 The statements below are applicable to the following incomplete vehicle types when equipped with untrimmed front seats or seat delete option, and either the GVWR is over 3855 kg [8,500 lb] or the Unloaded Vehicle Weight when completed, is over 2495 kg [5,500 lb] or vehicles manufactured for operation by persons with disabilities:
208 The statement below is applicable to the following incomplete vehicles when equipped with Ford trimmed front seats and either the GVWR is over 3855 kg [8,500 lb] or the Unloaded Vehicle Weight, when completed, is over 2495 kg [5,500 lb] or vehicles manufactured for operation by persons with disabilities:
■ Incomplete Econoline Van
■ Chassis Cab
■ Cutaway
■ Incomplete Econoline Van or Super Club Wagon
This vehicle, when completed, will conform to Standard 208, Occupant Crash Protection, if:
■ Cutaway This vehicle, when completed, will conform to Standard 208, Occupant Crash Protection, if:
• The seat belt components installed by Ford Motor Company are not removed, relocated, altered or modified. If the seat belt components are temporarily removed for any reason, they are reinstalled to the specifications for Econoline shown in Figure A on page 35 and Figure B on page 36.
• The seat belts, seat belt warning system and attaching hardware installed by Ford Motor Company are not removed, relocated, altered or modified.
• After the front seats and B-pillar trim are installed, the seat belt system components comply with:
• No actions are taken which would impair the integrity of the belt and seat belt warning systems. (A seat belt warning system is not required for a vehicle with a GVWR over 4536 kg [10,000 lb] or a bus).
– Adjustment requirements specified by s7.1 as these requirements apply to seat belt fit, to the intersection of the upper torso belt with the lap belt, and to child seat lockability, and
• The Air Bag Supplemental Restraint System as installed by Ford Motor Company is not removed, relocated, altered or modified in any way as shown in Figures B and C on page 38.
– Latch mechanism requirements specified by s7.2 as these requirements apply to the accessibility of seat belt components, and
• The Air Bag Supplemental Restraint System Information Labels that are affixed to the front sunvisors are visible, and not altered, modified or removed.
– Latch plate access, retraction, seat belt guides and hardware requirements specified by s7.4 as these requirements apply to comfort and convenience requirements of the seat belt system.
208 The statement below is applicable to the Basic (Stripped) Chassis: Conformity with Standard 208, Occupant Crash Protection, is not substantially affected by the design of this incomplete vehicle; accordingly, Ford Motor Company makes no representation as to conformity of this vehicle. Any seat belt assemblies added to a vehicle must conform to the applicable requirements of this Standard.
• No actions are taken which would impair the integrity of the seat belt systems and the seat belt warning system. • The Air Bag Supplemental Restraint System as installed by Ford Motor Company is not removed, relocated, altered or modified in any way.
208 Canadian Requirements:
• The Air Bag Supplemental Restraint System Information Labels that are affixed to the front sunvisors are visible, and not altered, modified or removed.
The preceding statements and supporting figures for FMVSS 208, on pages 31-41, are appropriate compliance representations for CMVSS 208, Seat Belt Installation, if this incomplete vehicle was manufactured for sale or use in Canada. In such a case, CMVSS 208 paragraphs (19), (21), and (22) are substituted for the reference to FMVSS 208 Section 7.1; CMVSS 208 paragraph (30) should be substituted for the reference to FMVSS 208 Section 7.2; and CMVSS 208 paragraphs (39), (40), (41), (42), (43), (44), (45), (46), (47), (48), (49), and (50) should be substituted for the reference to FMVSS 208 Section 7.4.
Any seat belt assemblies added to this vehicle must conform to the applicable requirements of this Standard.
STATEMENTS OF CONFORMITY
34
F7UB-602B82 ADJ. ASY.
F65B-15602B90 COVER ASY. F7UB- 15602B82 ADJ. ASY.
F65B-602B90 COVER ASY.
PANEL ASY. UPPER F7UB-1560262 COVER ASY. 1 REQD. EA. SIDE N806773-S190 NUT-TOROUE 40.0 ± 6.0 Nm
FRONT OF
CUT-AWAY & VAN MODELS F7UB-1560262 COVER ASY. 1 REQD. EA.SIDE
FRONT OF
VEHICLE
VEHICLE 15611B09 BELT & RETRACTOR ASY.
N806773-S190 NUT-TORQUE 40.0 ± 6.0 Nm 611B08 BELT & RETRACTOR ASY. SHIPPING CLIP MUST REMAIN CLIPPED TO BELT PRIOR TO ATTACHMENT OF RETRACTOR INTO VEHICLE.
ALL CUT-AWAY MODELS ONLY 368273-S100 BOLT TOROUE 25-34 FT. LB. 40 ± 6 Nm
VIEW
A VIEW
SHIPPING CLIP MUST REMAIN CLIPPED TO BELT PRIOR TO ATTACHMENT OF RETRACTOR INTO VEHICLE.
A
A VIEW
PANEL ASY. COVER
ALL WAGON - VAN MODELS ONLY DRIVER - SEAT (LEFT HAND) INSTALLATION
PANEL ASY. COVER
ALL CUT-AWAY MODELS ONLY
B
ALL WAGON - VAN MODELS ONLY PASSENGER SEAT (RIGHT HAND) INSTALLATION
CRITICAL CONTROL ITEM
CRITICAL CONTROL ITEM
RETRACTOR 9.5 R. MIN. 6.0
12.5 MIN. 6.5
3.0 UP POSITION
13.0 MIN.
(3) FULL THREAD EXPOSED
SECTION D-D
C
VIEW IN CIRCLE C
A
2.0 MIN. (WITH D-RING LOCATED ON SHLDR. BOLT)
6.0 MIN. 6.0 MIN. CLEARANCE AROUND BELT PERIPHERY AT MAX. TRAVEL POSITIONS
A
B B
SEAT BELT WEBBING
D
6.0 MIN. 6.0 MIN. ALL POSITIONS
D MAIN VIEW
SECTION A-A
NOTE: ALL DIMENSIONS ARE IN MILIMETERS
SECTION B-B
FIGURE A – ECONOLINE FRONT SEAT RESTRAINT SYSTEM 35
STATEMENTS OF CONFORMITY
SEAT ASY. SEAT ASY.
N801078-S424 SCREW M8 X 1.25 HEX 4 REQD. TORQUE 25.0 ± 3.8 NM
PIA BOLT TORQUE
40.0±6.0N m
A2008167 TRACK ASY.
M2007501 TRACK ASY. FRT. ST. N801078-S424 SCREW M8 X 1.25 HEX 4 REQ’D. TORQUE 25.0 ± 3.8 Nm
F7UB-1561202-A PYROTECHNIC ASY. R.H.
56912-S58 SCREW 4.2 X 19 TAPPING
F7UB- 14A699-A WIRE ASY. – ST. CONTROL
A2008168 TRACK ASY.
PIA BOLT TORQUE 40.0 ± 6.0 Nm
F7UB-1561755-A HANDLE FRT. ST. TRACK
COVER-FRT. ST. PIVOT 36912-S58 SCREW 4.2 X 19.0 TAPPING N802351-S424 STUD 2 REQD.
F7US-14A699-DB WIRE ASY. SWITCH ASY. ST. CONTROL M2003089 SUPPORT ASY. 611D02-A STUD COVER 4 REQD.
N811326-S424 SCREW 2 REQ’D. 55.0 ± 8.3 Nm
POWER LH. SHOWN
N800937-S424 NUT & WASHER ASY. 2 REQD. 55.0 ± 8.3 Nm N802351-S424 STUD 2 REQD. N620481-S58 NUT M8 X 1.75 HEX FLANGE TORQUE 25.0 ± 3.8 Nm 4 REQD.
F7UB-1562506A SUPPORT ASY. (R.H. MNL.)
N620482-S424 M10 HEX NUT HD N811326-S424 NUT w/WASHER SCREW 4 REQD. 2 REQD. 55.0 ± 8.3 Nm
611D02-A STUD COVER 4 REQD.
MANUAL R.H. SHOWN
FIGURE B-2 - ECONOLINE PASSENGER (R.H.) SEAT INSTALLATION
FIGURE B-1 - ECONOLINE DRIVER (L.H.) SEAT INSTALLATION T2007563 SEAT
F7UB-1561202-A BUCKLE ASY.
CLEARANCE ZONE 10° 15°
10°
CLEARANCE ZONE 45°
SCREWS 4 REQD. FOR SHIPPING PURPOSES ONLY
PIA BOLT TORQUE 40.0 ± 6.0 Nm
611D02-A STUD COVER 4 REQD.
A2008170 DRIVER A2008168 PASS. R.H. TRACK
SIDE VIEW N800937-S424 NUT & WASHER ASY. 2 REQD. 55.0 ± 8.3 Nm FRONT OF
REAR VIEW CENTER OF VEHICLE
VEHICLE
VIEW A
PRETENSIONER CLEARANCE ZONE GVR. FRT. ST. PVT. N811326-S424 SCREW 2 REQD. 55.0 ± 8.3 Nm F7US- 14A699-DB WIRE ASY.
A2008169 DRIVER A2008167 PASS. R.H. TRACK N802351-S424 STUD 2 REQD. F7UB-1567506-A SUPPORT ASY.
DO NOT INSTALL ADDITIONAL COMPONENTS IN THE SHADED AREA, OR ALTER OR MODIFY THIS AREA.
F7UB-1561755-A HDL. FRT. ST. TRK.
FIGURE B - ECONOLINE DRIVER (L.H.) SEAT DELETE OPTION
STATEMENTS OF CONFORMITY
IMPORTANT: THE SHADED AREA MUST BE FREE OF OBSTRUCTIONS. THE BUCKLE MOVES DOWNWARD THROUGH THE SHADED ZONE AND MUST NOT CONTACT ANY COMPONENT WHICH MAY DEGRADE ITS PERFORMANCE.
36
SRP INFORMATION (SEAT POSITION IS 10.0mm [0.39] FORWARD OF REARMOST POSITION) A B DRIVER - SEAT (VAN AND CUTAWAY)
217.8 [8.57] 277.3 [10.92]
PASSENGER - SEAT (VAN AND CUTAWAY)
E
POINT A (SEAT POSITION IS AT THE MIDPOINT OF AVAILABLE TRAVEL) D E F MIN. MAX. 356.0 67.0 937.4 [14.01] [2.64] [36.90] 412.0 65.0 960.1 [16.22] [2.56] [37.80]
C
105.0 [4.13] 103.0 [4.06]
384.2 [15.13] 377.0 [14.84]
THE TORSO ANGLE IS DETERMINED BY USING THE METHOD SPECIFIED IN SAE J826 (MAY 1987)
E
D
POINT A
POINT A
CL OUTSIDE FRONT FASTENER
18½ DRIVER 21½ PASSENGER TORSO ANGLE POINT A
A
F
SEAT BASE
SEAT BASE B
C
B
CL OUTSIDE FRONT FASTENER
CL OUTSIDE FRONT FASTENER
PASSENEGER - SEAT
6.0 [0.24]
510.0 [20.08]
SEAT BACK PIVOT
DRIVER - SEAT
CL
SRP = HAS A 12.7 [.50] RADIAL TOLERANCE PERMITTED FROM BASE SRP
VEHICLE FRONT VIEW
IMPORTANT: DRIVER SIDE ONLY THE DIMENSIONS IN THIS FIGURE REQUIRE THE VEHICLE TO BE AT DESIGN POSITION. ECONOLINE VAN VEHICLES AT DESIGN POSITION [ ] DIMENSIONS ARE IN INCHES WILL BE LEVEL FRONT TO REAR, AND SIDE TO SIDE, ON THE UPPER SURFACE OF THE RIBBED FLOOR PANEL FROM THE B-PILLLAR REARWARD.
FIGURE C - ECONOLINE SEATING REFERENCE POINT (SRP) 464.0 [18.27]
464.0 [18.27] 55.0 [2.17]
299.3 [11.78]
CL REAR
CL
OUTBOARD SEAT TO FLOOR FASTENER
VEHICLE
IMPORTANT: THE DIMENSIONS IN THIS FIGURE REQUIRE THE VEHICLE TO BE AT DESIGN POSITION. THIS VEHICLE IS AT DESIGN POSITION WHEN THE RAISED PORTION OF THE PICKUP BOX FLOOR RIBS ARE LEVEL IN ALL DIRECTIONS.
SRP HAS A 10.0 [.39] RADIAL TOLERANCE PERMITTED FROM BASE SRP (NOTE: SRP IS WHEN THE SEAT POSITION IS AT THE REARMOST TRAVEL)
[ ] DIMENSIONS ARE IN INCHES
FIGURE D - F-SERIES SEATING REFERENCE POINT (SRP) 37
STATEMENTS OF CONFORMITY
INSTRUMENT PANEL HARNESS
ELECTRONIC SENSOR MODULE
STEERING WHEEL
AIR BAG
AIR BAG READINESS INDICATOR CONNECTOR AT SAFETY WALL
ENGINE COMPT. HARNESS
CRASH SENSOR
DO NOT MODIFY OR ALTER ANY COMPONENTS OR AREAS OF THE VEHICLE IN THE VICINITY OF THE COMPONENTS THAT ARE IDENTIFIED IN THIS ILLUSTRATION.
DO NOT INSTALL ADDITIONAL COMPONENTS IN THE SHADED AREAS, OR ALTER OR MODIFY THESE AREAS.
FIGURE A - ECONOLINE OCCUPANT PROTECTION ZONE FIGURE B - ECONOLINE SUPPLEMENTAL RESTRAINT SYSTEM (Air Bags, Sensors and Wiring) 72 WAY CONNECTOR
BATTERY
AIRBAG DEACTIVATION SWITCH
DRIVER AIRBAG MODULE
ELECTRONIC CRASH SENSOR MODULE
FIGURE C - SUPER DUTY F-SERIES OCCUPANT PROTECTION ZONE
STATEMENTS OF CONFORMITY
PASSENGER AIRBAG MODULE
38
CUT LINE
CUT LINE
CUT LINE
SECTION A-A
SECTION C-C THE SPOTWELDS (X) IN THIS AREA MUST REMAIN INTACT.
711.2 [28.00] MAXIMUM
B
711.2 [28.00] MAXIMUM
B A
A
C
C
D
D
FRONT OF VEHICLE
NOTE: SHADED AREA REPRESENTS MAXIMUM OPENING IN BODY PANELS. * THE SECTIONS SHOWN ARE A LARGER SCALE THAN THE SIDE VIEW FOR THE PURPOSE OF CLARITY.
CUT LINE
[ ] DIMENSIONS ARE IN INCHES
SECTION D-D
CUT LINE
SECTION B-B
FIGURE A - BODY PANEL WINDOW REMOVAL AREA – ECONOLINE (DRIVER SIDE – L.H.)
39
STATEMENTS OF CONFORMITY
CUT LINE
SECTION F-F
CUTLINE
CUTLINE
SECTION E-E
SECTION G-G THE SPOTWELDS (X) IN THIS AREA MUST REMAIN INTACT.
F 533.4 [21.00] MAXIMUM WITH SLIDING DOOR
F E
G
E
G
711.2 [28.00] MAXIMUM WITH CARGO DOORS
FRONT OF VEHICLE NOTE: SHADED AREA REPRESENTS MAXIMUM OPENING IN BODY PANELS. * THE SECTIONS SHOWN ARE A LARGER SCALE THAN THE SIDE VIEW FOR THE PURPOSE OF CLARITY. [ ] DIMENSIONS ARE IN INCHES
FIGURE B - BODY PANEL WINDOW REMOVAL AREA – ECONOLINE (PASSENGER SIDE - R.H.)
STATEMENTS OF CONFORMITY
40
END OF ROOF – SUPER VAN
OUTER EDGE OF TROUGH
END OF ROOF – REGULAR VAN
CL “B” PILLAR REINFORCEMENT WINDSHIELD HEADER
50.8 [2.00]
203.2 [8.00]
FORWARD CUT LINE
CUT LINE
SECTION AT CL OF ROOF
REGULAR VAN HEADLINER PLANE, for vehicles not equipped with a Ford headliner, use a plane determined by a point at the lower rear of the Windshield Header to the midpoint on the B-Pillar reinforcement.
203.2 [8.00] CUT LINE SUPER VAN OR WAGON
FRONT OF VEHICLE [ ] DIMENSIONS ARE IN INCHES
ECONOLINE NOTE: SHADED AREA REPRESENTS MAXIMUM OPENING IN BODY PANELS.
FIGURE C - ROOF PANEL REMOVAL AREA
41
STATEMENTS OF CONFORMITY
209 The statements below are applicable to the following incomplete vehicle types with front seat(s):
• No alterations are made to the rear cab panel or roof for the Chassis Cab.
■ Chassis Cab
• Window or roof modifications do not exceed the defined cut out areas shown in the Figures on pages 39, 40 and 41 respectively for Incomplete Econoline Van with RV Prep or Ambulance Prep Packages, or the Econoline Super Club Wagon.
■ Incomplete Econoline Van or Club Wagon ■ Cutaway This vehicle, when completed, will conform to Standard 209, Seat Belt Assemblies, if:
The Incomplete Econoline Van and Cutaway with no front seats must have completed front seats installed that conforms to the seat location criteria shown in Figure C on page 37.
• No alterations or replacements are made to the seat belt assemblies and attaching hardware. • No action is taken that would impair the integrity of the seat belt system provided.
The Incomplete Econoline Van, Super Club Wagon and Cutaway must have a seat belt anchorage system installed for each additional designated seating position that conforms to the applicable requirements of this Standard.
Any seat belt assemblies added to a vehicle must conform to the requirements of this Standard. 209 The statement below is applicable to the following incomplete vehicle types with no front seats:
The Incomplete Econoline Van equipped with the RV Prep Package, and the Econoline Super Club Wagon may have additional seat belt anchorages for designated seating positions other than the front driver and passenger seats. Also, Chassis Cab vehicles may have additional seat belt anchorages for designated seating positions on optional seats not provided on incomplete vehicles. These locations apply to specific hardware and designated seating positions used in Ford completed vehicles. If these anchorages are used without the appropriate Ford seats, seat belt systems and hardware, Ford Motor Company makes no representation as to conformity with this Standard.
■ Incomplete Econoline Van ■ Cutaway Conformity with the pelvic restraint, upper torso restraint, release, adjustment, and webbing requirements of Standard 209, Seat Belt Assemblies as specified in s4.1 (b), (c), (e), (g) and (h), respectively, is not substantially affected by the design of this incomplete vehicle; accordingly Ford Motor Company makes no representation as to conformity with these requirements of Standard 209. However, Ford Motor Company represents that the seat belt assemblies provided by Ford Motor Company conform to the applicable single occupancy hardware, attachment hardware, strap, marking, installation instructions, usage and maintenance instructions, workmanship, webbing performance, hardware performance, and assembly performance requirements detailed in the remaining paragraphs of the standard not specified above, provided no alterations or replacements are made to the seat belt assemblies and attaching hardware, as provided by Ford Motor Company and further provided that no action is taken by subsequent stage manufacturers to impair the integrity of the seat belt system provided. Any additional seat belt assemblies installed must conform to the requirements of this Standard.
210 The statement below is applicable to the Basic (Stripped) Chassis: Conformity with Standard 210, Seat Belt Assembly Anchorages, is not substantially affected by the design of this incomplete vehicle; accordingly, Ford Motor Company makes no representation as to conformity with this Standard. The RV Cutaway, when equipped with seat delete option, will include both front seat pedestals, pretensioner restraint systems, seat tracks and a temporary driver’s seat. The pretensioner restraint system is attached to the seat track, therefore, the completed seat assembly must comply with the requirements of F/CMVSS 210 and 207. 210 Canadian Requirements:
209 The statement below is applicable to the Basic (Stripped) Chassis:
The preceding statements for FMVSS 210 are appropriate compliance representations for CMVSS 210, Seat Belt Assembly Anchorages, if the incomplete vehicle was manufactured for sale or use in Canada.
Conformity with Standard 209, Seat Belt Assemblies, is not substantially affected by the design of this incomplete vehicle; accordingly Ford Motor Company makes no representation as to conformity with this Standard.
211 Standard 211, Wheel Nuts, Wheel Discs and Hub Caps has been rescinded for vehicles manufactured for sale or use in the U.S. by the NHTSA effective June 5, 1996.
209 Canadian Requirements: The preceding statements for FMVSS 209 are appropriate compliance representations for CMVSS 209, Seat Belt Assemblies, if this incomplete vehicle was manufactured for sale or use in Canada. In such a case, CMVSS 209 paragraphs (2) and (3), (4) and (5), (14), (15) and (7) are substituted for the reference to FMVSS 209 Sections 4.1(b), (c), (e), (g),and (h), respectively.
211 Canadian Requirements: CMVSS 211, Wheel Nuts, Wheels Discs and Hub Caps has been rescinded for vehicles manufactured for sale or use in Canada by Transport Canada effective September 7, 1997.
210 The statements below are applicable to all incomplete vehicle types except the Basic (Stripped) Chassis: This vehicle, when completed, will conform to Standard 210, Seat Belt Assembly Anchorages, if: • No alterations are made to the front seat belt anchorages, front seat belt assemblies, the floor pan, floor pan reinforcements, body mounts.
STATEMENTS OF CONFORMITY
42
• Incomplete Econoline Van, Econoline Super Club Wagon and Cutaway type vehicles, have an Unloaded Vehicle Weight that does not exceed the value designated in Table J page 17 corresponding to the vehicle’s model, wheelbase and engine size.
212/ Note 219 The terms “body” or “body structure” in the 212 and 219 statements that follow, include not only the basic body or body structure, but also any equipment permanently attached to that body or body structure installed by the subsequent stage manufacturer.
• For Chassis Cab only: – The front end of the body installed by the subsequent stage manufacturer is located at least 76.2 mm [3.0 in] rearward of the rearmost point of the cab for Super Duty F-Series.
212/ INFORMATION 219 Please refer to the Second Unit Body Attachment recommendations beginning on page 78 for information to aid in designing second unit bodies and their attachments to be compatible with Econoline and Super Duty F-Series vehicles.
– The body installed by the subsequent stage manufacturer is mounted securely and so designed that, when the completed vehicle is impacted in any manner specified by applicable provisions of Standards 212/219, body deformation or movement relative to the frame does not result in any separation or loss of body attachment to the frame.
212/ The statements below are applicable to the following 219 Incomplete vehicle types If the GVWR Is 4536 kg [10,000 lb] or less:
• For the Chassis Cab, the maximum SUB weight, center of gravity, height of the body, as installed by the subsequent stage manufacturer and the Unloaded Vehicle Weight does not exceed the values specified in Table L page 18, corresponding to the incomplete vehicle type, wheelbase and engine size.
■ Chassis Cab ■ Incomplete Econoline Van or Super Club Wagon ■ Cutaway This vehicle, when completed, will conform to Standard 212 Windshield Mounting, and Standard 219, Windshield Zone Intrusion, if:
212/ The statement below is applicable to the Basic 219 (Stripped) Chassis if the GVWR is 4536 kg [10,000 lb] or less:
• The following windshield system components, related structural components and hardware as installed by Ford Motor Company are not removed, relocated, altered or modified in any way except as specified in this manual:
The Commercial Basic (Stripped) Chassis is designed by Ford Motor Company to be completed as a walk-in van type vehicle. Walk-in vans are exempt from the requirements of Standard 212, Windshield Mounting, and Standard 219, Windshield Zone Intrusion.
– Windshield and windshield mounting system – Cab and front end structural components including the roof, pillars, cowl, cowl reinforcements, hood, doors, fenders, hood restrictors and apron reinforcements, frame and frame reinforcements
212/ Canadian Requirements: 219
– Radio antenna and air cleaner assembly
The preceding statements for FMVSS 212/219 are appropriate compliance representations for CMVSS 212, Windshield Mounting, or CMVSS 219 Windshield Zone Intrusion, if this incomplete vehicle was manufactured for sale or use in Canada. In such a case, CMVSS 212/219 paragraphs (5.1) and (8)(b) are substituted for the reference to FMVSS 212/219 Sections 6.1(b) and 7.7(b) respectively.
– Doors and hood mounting, hinging and latching systems – Hood ornamentation – Bumper and bumper mounting system † • No alteration or modification made to the incomplete vehicle as manufactured by Ford Motor Company and no components or structure installed by a subsequent stage manufacturer result in any loss of windshield retention (as defined in Standard 212), or any penetration of the inner surface of the windshield or intrusion into the protected zone (as defined in Standard 219) when the vehicle is impacted in any manner specified by applicable provisions of Standard 212 or Standard 219. Conformity to Standards 212/219 for a vehicle having an Unloaded Vehicle Weight greater than 2,495 kg [5,500 lb] is established by testing a representative vehicle at an Unloaded Vehicle Weight of 2,495 kg [5,500 lb] as permitted by s6.1 (b) and s7.7 (b) of Standards 212/219, respectively.
† Temporary removal of the front bumper and front bumper mounting system during manufacture and reinstallation in accordance with the instructions provided in the Ford Truck Shop Manual, should not adversely affect the compliance of a completed vehicle to Standards 212/219.
43
STATEMENTS OF CONFORMITY
214 Canadian Requirements:
213 The statement below is applicable to all incomplete vehicle types:
The preceding statements for FMVSS 214, are appropriate compliance representations for CMVSS 214, Side Door Strength, if this vehicle is manufactured for sale or use in Canada.
Conformity with Standard 213, Child restraint systems, is not substantially affected by the design of the incomplete vehicle; accordingly Ford Motor Company makes no representation as to conformity with this Standard. Any child restraint system that is added or incorporated into the design of a designated seating position must conform to the requirements of this standard.
217 The statements below are applicable to the incomplete Econoline Van or Super Club Wagon when completed as a bus (not school bus):
The preceding statement for FMVSS 213 is an appropriate compliance representation for CMVSS 213, Child Seating and Restraint Systems, if this incomplete vehicle was manufactured for sale or use in Canada.
This vehicle, when completed, will conform to Standard 217, Bus Window Retention and Release, if no alterations, modifications, or replacements are made to the doors, window glazing materials, window mounting systems and the surrounding door structure as provided by Ford Motor Company.
214 The statements below are applicable to the following vehicle types if the GVWR is 4536 kg [10,000 lb] or less:
Any windows, doors, additional components, or emergency exits added to this vehicle must meet the requirements of this Standard.
213 Canadian Requirements:
■ Chassis Cab
217 The statement below is applicable to the Cutaway when completed as a bus (including school bus):
■ Incomplete Econoline Van or Super Club Wagon
Conformity with Standard 217, Bus Window Retention and Release, is not substantially affected by the design of this incomplete vehicle; accordingly Ford Motor Company makes no representation as to conformity with this Standard other than that the front door windows will comply with the s5.1 requirements of this Standard if no modifications, alterations or replacements are made to the window glazing materials, window mounting system or the surrounding door structure as provided by Ford Motor Company.
This vehicle, when completed, will conform to Standard 214, Side Impact Protection, if: • No alterations, modifications or replacements are made to the door, surrounding door structure, door hinges, door latches and strikers, or any attaching hardware as provided by Ford Motor Company. • The Incomplete Econoline Van or Wagon roof or window modifications do not exceed the defined cut out areas shown in the Figures on pages 39, 40 and 41, respectively.
217 Canadian Requirements:
214 The statements below are applicable to the Econoline Cutaway if the GVWR is 4536 kg [10,000 lb] or less:
The preceding statements for FMVSS 217 are appropriate compliance representations for CMVSS 217, Bus Emergency Exit and Window Retention and Release, when a vehicle is completed as a Bus (not School Bus) and if this incomplete vehicle was manufactured for sale or use in Canada. In such a case, CMVSS 217 paragraphs (2) and (2.1) are substituted for the reference to FMVSS 217 Section 5.1. When an Econoline Cutaway is completed as a School Bus, Ford Motor Company makes no representation as to conformity to this Standard.
This vehicle, if equipped with both front doors as manufactured by Ford Motor Company when completed, will conform to Standard 214, Side Impact Protection, if no alterations, modifications or replacements are made to the door, surrounding door structure, the entire roof structure, door hinges, door latches and strikers, or any attaching hardware provided by Ford Motor Company. This vehicle if equipped with a driver-side door only when completed, will conform to Standard 214, Side Impact Protection, for that door only if no alterations, modifications or replacements are made to the door, surrounding door structure, the entire roof structure, door hinges and strikers, or any attaching hardware provided by Ford Motor Company. Any side door and surrounding body structure added to this vehicle, if a designated seating position is within 254 mm [10 in] inboard of that door, must conform to the requirements of this standard. 214 The statement below is applicable to the Basic (Stripped) Chassis if the GVWR is 4536 kg [10,000 lb] or less: The Commercial Basic (Stripped) Chassis is designed by Ford Motor Company to be completed as a walk-in-van type vehicle. Walk-in vans are exempt from the requirements of Standard 214, Side Impact Protection. See walk-in van definition on page 8.
STATEMENTS OF CONFORMITY
44
219 See combined statements under “212/219” for all vehicle types.
222 The statement below is applicable to the Cutaway equipped with the School Bus Prep Package when completed as a school bus:
220 The statements below are applicable to the Cutaway equipped with the School Bus Prep Package when completed as a school bus:
Conformity with Standard 222, School Bus Passenger Seating and Crash Protection, is not substantially affected by the design of this incomplete vehicle; accordingly Ford Motor Company makes no representation as to conformity with this Standard.
The Cutaway body structure as manufactured by Ford, does not meet the strength requirements of FMVSS 220, School Bus Rollover Protection; accordingly Ford Motor Company makes no representation as to conformity of the completed vehicle with this Standard.
222 Canadian Requirements: The preceding statement for FMVSS 222 is also appropriate for CMVSS 222, School Bus Passenger Seating and Crash Protection.
220 Canadian Requirements: The preceding statement for FMVSS 220 is also appropriate for CMVSS 220, Rollover Protection.
45
STATEMENTS OF CONFORMITY
• The push connectors on flexible fuel lines, if disconnected, must be reconnected by snapping them back into position and installing the appropriate Retainer as shown in Figure B, on this page.
301 Note The terms “body” or “body structure”, in the 301 statements that follow include not only the basic body or body structure but also any equipment permanently attached to that body or body structure installed by the subsequent stage manufacturer.
• When welding near fuel system components, all metallic components must be adequately shielded and protected from heat or weld splatter. All non-metallic components must be removed.
301 INFORMATION The Unloaded Vehicle Weight of the completed vehicle may significantly affect its capability to meet the requirements of FMVSS 301. Completed vehicles manufactured by Ford that are tested to demonstrate compliance with FMVSS 301 are loaded pursuant to s7.1 .6 of the Standard. The test weights of these vehicles comprise the Unloaded Vehicle Weights including the weights of all available regular production options plus the loads specified by s7.1 .6. These test weights generally are less than the respective designated Gross Vehicle Weight Ratings. In addition to the specific statements below for Ford incomplete vehicles, please refer to the Fuel System Design Recommendations on pages 65 to 67, for information to assist in designing fuel systems. Please refer to the Second Unit Body Attachment recommendations beginning on page 78 for information to aid in designing second unit bodies and their attachments to be compatible with Econoline and Super Duty F-Series vehicles.
NOTE:
301 The statements below are applicable to the following incomplete vehicle types if the vehicle GVWR is 4536 kg [10,000 lb] or less: ■ Chassis Cab ■ Cutaway This vehicle, when completed, will conform to Standard 301, Fuel System Integrity, if: • None of the following fuel system components as installed by Ford Motor Company are removed, relocated, altered or modified in any way except as specified in this manual:
301 In addition to the statements pertaining to particular incomplete vehicle types which follow on pages 46-50, the statements immediately below, concerning Standard 301 Fuel System Integrity, apply to all incomplete vehicle types to be completed with a GVWR of 4536 kg [10,000 lb] or less.
– Fuel tank(s) and attachment hardware, including sending unit, vapor valve, fuel tank shield, pressure transducer and in-tank electric fuel pump – Fuel filler cap(s), pipe(s), hose(s) and attachment hardware – Fuel lines, routing and attachments
• If the push connectors on nylon fuel lines are disconnected, they must be reconnected as shown in Figure A on this page, and the retention clip must be discarded and replaced with a new clip as specified in Figure A.
– Vapor lines(s) and carbon canister - (gasoline engine application) – Fuel pump – Fuel filter
• The special removal tool shown in Figure B on this page, must be used to open push connectors installed on steel fuel lines, if the lines need to be disconnected. The appropriate tool is available from Ford Customer Service Division.
– Fuel water separator fuel filter/primer, fuel line heater and injection pump - (diesel engine only) – Fuel shut off switch (Inertia switch)
RETAINER – FUEL TUBE PUSH CONNECTOR
WARNING BEFORE OPENING THE FUEL SYSTEM ON VEHICLES WITH EFI ENGINES, RELIEVE FUEL PRESSURE BY FOLLOWING THE INSTRUCTIONS IN THE FORD TRUCK SHOP MANUAL FOR THE APPROPRIATE MODEL AND MODEL YEAR.
ECONOLINE: SUPPLY – E9UA-9J278–AA RETURN – E9UA-9J278–BA
SUPER DUTY F-SERIES: F65A-9J274-CA COMMON SUPPLY/RETURN
FUEL PUSH-CONNECT INSTALLATION INSTRUCTIONS TO INSTALL THE FITTING ONTO THE TUBE, ALIGN THE FITTING AND THE TUBE AXIALLY AND PUSH THE FITTING ONTO THE TUBE END. WHEN THE FITTING IS ENGAGED, A DEFINITE CLICK WILL BE HEARD WITH RETENTION CLIP INSTALLED, PULL ON FITTING TO MAKE SURE IT IS FULLY ENGAGED.
WARNING BEFORE OPENING THE FUEL SYSTEM ON VEHICLES WITH EFI ENGINES, RELIEVE FUEL PRESSURE BY FOLLOWING THE INSTRUCTIONS IN THE FORD SHOP MANUAL FOR THE APPROPRIATE MODEL AND MODEL YEAR.
FIGURE B - FLEXIBLE FUEL LINE PUSH-CONNECT
FIGURE A - NYLON FUEL LINE PUSH-CONNECT STATEMENTS OF CONFORMITY
Some incomplete vehicles are equipped with nylon fuel tubes. In the event that the tubes require repair or replacement, only Ford approved parts or their equivalents should be used.
46
– For Cutaways without the frame spacer body mounting system (Commercial Cutaways), the body installed by the subsequent stage manufacturer includes a floor of at least 1.37mm [0.054 in] thick cold rolled steel (or equivalent strength material) with five hat section lateral crossmembers of 127.0mm [5.0 in] overall width fabricated from at least 2.08mm [0.082 in] thick cold rolled steel (or equivalent strength material) with 25.4mm [1.0 in] flanges welded to the underside of the floor and attached through the 35.6mm [1.40 in] nominal diameter mounting holes in the upper flanges of the frame rails by ten 12.7mm [0.5 in - 13 UNC] grade 8 bolts (and nuts) torqued to 81.3 - 88.1 Newton - meters [60-65 ft.-lb.]; 63.5mm [2.5 in] diameter washers of at least 4.55mm [0.179 in] thick cold rolled steel (or equivalent strength material) are required under each bolt head and nut used and the minimum distance between the bottom of the floor and the top of the frame is 102.6mm [4.04 in].
• No other alteration or modification made to the incomplete vehicle as manufactured by Ford Motor Company and no other components or structure installed by a subsequent stage manufacturer result in penetration, separation, or other damage to the fuel system or any portion thereof when the vehicle is tested in any manner specified by applicable provisions of Standard 301.† • For the Chassis Cab, the maximum SUB weight, center of gravity, height of the body, as installed by the subsequent stage manufacturer and the Unloaded Vehicle Weight does not exceed the values specified in Table L on page 18, corresponding to the model, wheelbase and engine size. • For the Cutaway, the completed vehicle’s Unloaded Vehicle Weight does not exceed the value designated in Table J on page 17 corresponding to the model, wheelbase and engine size. • The body installed by a subsequent stage manufacturer and the Ford installed fuel system components are located and mounted as follows:
• For Chassis Cabs to be completed as Truck-Tractors, the inside of frame mid-ship fuel filler cap, pipe, hose and attachment hardware attached to the fuel tank as received, should be used as a permanent installation only if they are securely retained to remain intact and to prevent contact with any vehicle component when tested in any manner specified by applicable provisions of Standard 301.
– The body is mounted securely and is so designed that when the completed vehicle is tested in any manner specified by applicable provisions of Standard 301, 1. body components do not contact any fuel system component at any time (other than at the points where the fuel system is permanently attached to the body), and,
• For Cutaways equipped with a temporary fuel tank, the fuel tank sending unit must be removed from the temporary tank and installed in the permanent fuel tank. Prior to the installation of the sending unit, the temporary shipping cover must be removed from the permanent fuel tank sender opening. The temporary fuel lines to the temporary tank are removed by snapping off the retention tabs on the push connect clips and sliding out the clips. The temporary shipping lines are not to be reused. The sending unit is then installed in the permanent tank by reusing the six special nuts which retained the shipping cover to the permanent tank, and use the new 0-ring seal that is shipped with the vehicle in a separate package. The six nuts must be torqued as shown in Figure C page 52. Special connecting fuel lines, with female metal push connectors are used to connect the steel fuel lines to the fuel sender on the tank. The connectors must be snapped securely into place and the appropriate Retainer-Fuel Tube Push Connector is installed as shown in Figure B page 46.
2. body deformation or movement relative to the frame does not cause any fuel system component to be penetrated, disconnected or otherwise damaged. – The rear end of the body (excluding the rear bumper) installed by a subsequent stage manufacturer does not extend beyond (overhang) the rear edge of the vehicle frame or frame extension. Any extension of the vehicle frame must be constructed and attached so as to perform as a continuation of the vehicle frame when the completed vehicle is tested in any manner specified by applicable provisions of Standard 301. – For the Chassis Cab, the front end of the body installed by the subsequent stage manufacturer is located at least 76.2mm [3.0 in] rearward of the rearmost point of the cab. – The midship or aft-of-axle fuel filler cap(s), pipe(s), hose(s) and attachment hardware are installed as shown in Figure C page 52 for Econoline vehicles, and Figures D and E on pages 53 and 54 for ChassisCab type vehicles. All components must be securely retained to remain intact when the completed vehicle is tested in any manner specified by applicable provisions of Standard 301.
301 (Continued Next Page)
† Temporary removal of the front bumper and front bumper mounting system during manufacture, and reinstallation in accordance with the instructions provided in the Ford Truck Shop Manual, should not adversely affect compliance of the completed vehicle to Standard 301.
47
STATEMENTS OF CONFORMITY
301 The statements below are applicable to the Econoline Super Duty Cutaway when equipped with the School Bus Prep Package and completed as a school bus. This vehicle when completed will conform to Standard 301, Fuel System Integrity if: • None of the following fuel components as installed by Ford Motor Company are removed, altered or modified in any way except as specified in this manual: – Fuel tank and attachment hardware, including sender unit, vapor valve, pressure transducer (OBD II gas) and fuel tank shield – Fuel filler cap, pipe, hoses and attaching hardware – Fuel pump – Fuel filter – Fuel water separator, fuel filter/primer, fuel line heater and injection pump – Fuel shut-off switch (Inertia switch) • The completed vehicle when loaded to the requirements of S7.1.6 (c) does not exceed the GVWR or GAWR’s. • The floor structure of the Second Unit Body is manufactured and installed to the specifications, found in the Figures on pages 49 & 50. • The fill hoses, hose clamps, ground strap and fuel sender unit must be installed to the specification on Figure C, page 52. • No other alteration or modification made to the incomplete vehicle as manufactured by Ford Motor Company and no other components or structure installed by a subsequent stage manufacturer result in penetration, separation, or other damage to the fuel system or any portion thereof when the vehicle is tested in any manner specified by applicable provisions of Standard 301.† • For Cutaways equipped with a temporary fuel tank, the fuel tank sending unit must be removed from the temporary tank and installed in the permanent fuel tank. Prior to the installation of the sending unit, the temporary shipping cover must be removed from the permanent fuel tank sender opening. The temporary fuel lines to the temporary tank are removed by snapping off the retention tabs on the push connect clips and sliding out the clips. The temporary shipping lines are not to be reused. The sending unit is then installed in the permanent tank by reusing the six special nuts which retained the shipping cover to the permanent tank, and use the new 0-ring seal that is shipped with the vehicle in a separate package The six nuts must be torqued as shown in Figure C page 52. Special connecting fuel lines, with female metal push connectors are used to connect the steel fuel lines to the fuel sender on the tank. The connectors must be snapped securely into place and the appropriate Retainer-Fuel Tube Push Connector is installed as shown in Figure B page 46.
† Temporary removal of the front bumper and front bumper mounting system during manufacture, and reinstallation in accordance with the instructions provided in the Ford Truck Shop Manual, should not adversely affect compliance of the completed vehicle to Standard 301.
STATEMENTS OF CONFORMITY
48
ITEM 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.
PART NAME
MATERIAL
SUPPORT – BODY ISOLATOR TO CROSS SILL L.H. SUPPORT – BODY ISOLATOR TO CROSS SILL R.H. BRACKET – SPACER FOR ISOLATOR SUPPORT TO FRONT CROSS SILL BRACKET – SPACER FOR ISOLATOR SUPPORT TO SECOND CROSS SILL SILL – FRONT CROSS SILL – SECOND CROSS SILL – THIRD & FOURTH CROSS GUSSET – CROSS SILL TO OUTER SUPPORT L.H. GUSSET – CROSS SILL TO OUTER SUPPORT R.H. SUPPORT – CROSS SILL OUTER L.H. SUPPORT – CROSS SILL OUTER R.H. BUMPER – REAR BRACKET – BUMPER TO FRAME L.H. BRACKET – BUMPER TO FRAME R.H. FLOOR HOUSING – FUEL FILL NECK
QUANTITY
6.35mm [0.25] HRLC STEEL 6.35mm [0.25] HRLC STEEL 6.35mm [0.25] HRLC STEEL
1 1 2
6.35mm [0.25] HRLC STEEL
2
1.9mm [0.075] 14 GA. HRLC STEEL 1.9mm [0.075] 14 GA. HRLC STEEL 1.9mm [0.075] 14 GA. HRLC STEEL 1.9mm [0.075] 14 GA. HRLC STEEL 1.9mm [0.075] 14 GA. HRLC STEEL 3.0mm [0.120] 11 GA. HRLC STEEL 3.0mm [0.120] 11 GA. HRLC STEEL 4.7mm [0.187] HRLC STEEL 6.35mm [0.25] HRLC STEEL 6.35mm [0.25] HRLC STEEL 1.9mm [0.075] 14 GA. HRLC STEEL 1.9mm [0.075] 14 GA. HRLC STEEL
1 1 2 4 4 1 1 1 1 1 1 1
BLIND RIVET FASTENERS The components listed below must be attached together with a “Blind Rivet” fastener, 6.3 [.25] diameter with a shear strength of 3600 lb and tensile strength of 2000 lb, or equivalent weld. Each fastener will require a 6.91 [.272] to 6.63 [.261] dia. hole.
PARTS TO BE FASTENED Item 5 to 15 Item 6 to 15 Item 7 to Item 15 Item 5 to Items 8 or 9 Item 6 to Items 8 or 9 Item 7 to Items 8 or 9 Items 8 or 9 to Items 10 or 11 Item 16
NUMBER OF FASTENERS
SPACING/LOCATION
48 Estimated 48 Estimated 47 Estimated 6 6 6 3 on vertical side of item 10 or 11, 1 on bottom flange
101.6mm [4.00] centers on frt and rr flange – 50.8mm [2.00] stagger frt and rr flange 50.8mm [2.00] Centers 101.6mm [4.00] Centers 101.6mm [4.00] Centers staggered top to bottom of cross-sill 101.6mm [4.00] Centers staggered top to bottom of cross-sill 3 fasteners are 76.2mm [3.00] Centers 50.8mm [2.00] Centers
FORD PROVIDED 12.0mm BOLT (6 REQ’D) TORQUE 70Nm [52 ft lb]
1318.3 [51.90] 2375.0 [93.5] MINIMUM
778.8 [30.66]
161.4 [6.35]
164.3 [6.47]
9 9
12.8 [.50]
7 6
25.4 [1.00] TYPICAL
16
268.0 [10.55]
2
8
5
147.8 [5.82]
9
1
7
163.8 [6.45]
15
11 8 114.5 [4.50]
9
4
3
MAY BE REMOVED TO ACCOMMODATE WHEELHOUSE CLEARANCE 3162.3 [124.5] TO BACK OF CUTAWAY BODY
THE FUEL FILL HOLE IN ITEM #15 (FLOOR) MUST BE 3.0 [.12] LARGER THAN BASE OF ITEM #16 1/2 BOLT GR5, 1/2 NUT GR5 TORQUE 95Nm 70 ft lb
10
1/2 WASHER (HARDENED) 2 PER BOLT 14.0 X 28.0 [.55 X 1.10] MAX 2 SLOTS IN ITEM #12, 13 & 14
2438.4 [96.00
8 357.1 [14.06]
12 14 416.0 [16.38]
241.3 [9.50]
TO TOP OF FRAME
13 162.1 [6.38]
EXISTING SLOT
EXISTING FRAME HOLES FORD PROVIDED ISOLATORS (6)
101.6 [4.00] 228.6 [9.00]
50.8 [2.00]
[ ] DIMENSIONS ARE IN INCHES
FIGURE A - E-SUPER DUTY SCHOOL BUS FUEL SYSTEM AND FLOOR STRUCTURE 49
STATEMENTS OF CONFORMITY
BOTH ENDS OF ITEMS #5, 6, AND 7 CROSS SILLS MUST BE WELDED COMPLETELY TO ITEM #10 LEFTSIDE AND ITEM #11 RIGHTSIDE. ALL CROSS-SILLS ARE SHOWN WITH OUTSIDE ENDS THAT WILL ACCOMMODATE A FLUSH FLOOR JOINT WHEN COMPLETED.
7 36.1 [1.42] 71.6 [3.13]
851.6 [33.53]
C
C L RAIL 425.8 [16.76]
170.0 [6.69] 85.0 [3.35] 74.0 [2.91] 37.0 [1.46]
5
32.1 [1.26]
26.9 110.0 [1.06] [4.33] CL C L
98.0 [3.86]
42.7 [1.68] 36.7 [1.44] 170.0 [6.69] 122.0 [4.80] 48.0 [1.89] 125.0 18.0 [0.71] [4.92] C L
3
28.1 [1.11]
32.6 [1.28] 138.8 110.0 [5.46] [4.33]
C L
34.9 [1.37]
6
40.3 [1.59]
172.0 [6.77]
4
38.6 [1.52]
13.0 DIA 4 HOLES [0.51] M12 BOLT & NUT GC 10.9 TORQUE 70Nm 52 ft lb
14.0 [.55] DIA HOLE
134.0 [5.28] 13.0 DIA 8 HOLES [0.51]
13.0 [0.51] DIA 4 HOLES M12 BOLT & NUT GC 10.9 TORQUE 70 Nm [52 ft lb]
[ ] DIMENSIONS ARE IN INCHES
SEE VIEW C FOR HOLE DIMENSIONS LOCATION 985.6 TO C OF 36.0 DIA HOLE L [38.50]
102.2 [4.02]
492.8 TO C L OF SILL 36.0 [1.42] DIA 2 HOLES [19.40] 42.7 [1.68]
200.0 [7.87]
320.0 [12.60] 134.0 [5.28] 67.0 [2.64]
8.0 [0.31] 49.2 [1.94] 13.0 [0.51] DIA 8 HOLES
1318.3 [51.90]
46.8 [1.84]
10 SUPPORT – CROSS SILL OUTER L.H. SHOWN. R.H. SYMMETRICALLY OPPOSITE
VIEW C 1303.1 [51.30]
46.2 [1.82]
1168.4 [46.00]
C L
24.8 [0.98]
552.4 [21.75]
9
44.5 [1.75]
CL
15.0 [0.59]
B
TRIM WITH 45° ANGLE TO REMOVE SHARP CORNER 571.7 [22.51]
77.0 [3.03] R
428.8 [16.88]
25.0 [0.98]
23.1 [0.91]
1 ITEM #3 & #4 ARE WELDED TO ITEM #1 OR #2 ON ALL 4 EDGES
SUPPORT – BODY ISOLATOR TO CROSS SILL L.H. SHOWN. R.H. SYMMETRICALLY OPPOSITE.
177.5 [6.99]
WELD SHEET METAL RELIEF AFTER 104.8 FORMING [4.13]
GUSSET – CROSS SILL TO OUTER SUPPORT R.H. SHOWN. L.H. SYMMETRICALLY OPPOSITE.
A
EDGE WELD FRT. & REAR EDGE
95.5 [3.76]
EDGE WELD RELIEF CLOSED AFTER FORMING
173.0 [6.81]
THIS SURFACE MUST BE FREE OF BURRS OR SHARP EDGES. OPTION ON ITEM #2 R.H.
C L 38.1 [1.50] 76.2 [3.00]
111.1 [4.37] 187.5 [7.38]
38.1 [1.50]
54.0 [2.13]
35.0 [1.38] REQ ON #1 – OPTIONAL ON # 2 14.0 DIA 3 HOLES [0.55]
VIEW A
VIEW B
FIGURE A - E-SUPER DUTY SCHOOL BUS FUEL SYSTEM AND FLOOR STRUCTURE
STATEMENTS OF CONFORMITY
50
• No other alteration or modification made to the incomplete vehicle as manufactured by Ford Motor Company and no other components or structure installed by a subsequent stage manufacturer result in penetration, separation, or other damage to the fuel system or any portion thereof when the vehicle is tested in any manner specified by applicable provisions of Standard 301.
301 (Continued) 301 The statements below are applicable to the following incomplete vehicle types if the GVWR Is 4536 kg [10,000 lb) or less: ■ Incomplete Econoline Van or Super Club Wagon This vehicle, when completed, will conform to Standard 301, Fuel System Integrity, if: • The following fuel system components as installed by Ford Motor Company are not to be removed, relocated, altered or modified in any way: – Fuel tank and attachment hardware, including sending unit, vapor valve, fuel tank shield and in-tank electric fuel pump (all gasoline engine applications), OBD II pressure transducer – Fuel lines, routing and attachments – Vapor lines, carbon canister, and fuel vapor separator (gasoline engine only) – Fuel pump – Fuel filter – Fuel water separator, fuel filter/primer, fuel line heater and injection pump - (diesel engine only) – Fuel shut off switch (Inertia switch)
• The completed vehicle’s Unloaded Vehicle Weight does not exceed the value designated in Table J on page 17 corresponding to the model, wheelbase, and engine size. • The body installed by a subsequent stage manufacturer and the Ford installed fuel system components are located and mounted as follows: – The body is mounted securely and is so designed that when the completed vehicle is tested in any manner specified by applicable provisions of Standard 301, (a) body components do not contact any fuel system component at any time (other than at the points where the fuel system is permanently attached to the body), and, (b) body deformation or movement relative to the frame does not cause any fuel system component to be penetrated, disconnected, or otherwise damaged.
• No other alteration or modification made to the incomplete vehicle as manufactured by Ford Motor Company and no other components or structure installed by a subsequent stage manufacturer may result in penetration, separation, or other damage to the fuel system or any portion thereof when the vehicle is tested in any manner specified by applicable provisions of Standard 301.† (See footnote on page 47).
– The rear end of the body (excluding the rear bumper) installed by a subsequent stage manufacturer does not exceed beyond (overhang) the rear edge of the vehicle frame or frame extension. Any extension of the vehicle frame must be constructed and attached so as to perform as a continuation of the vehicle frame when the completed vehicle is tested in any manner specified by applicable provisions of Standard 301.
• The completed vehicle’s Unloaded Vehicle Weight does not exceed the value designated in Table J for Econoline on page 17 corresponding to the incomplete vehicle’s model, wheelbase and engine size.
– The aft-of-axle fuel filler cap, pipe, hose(s) and attachment hardware are installed as shown in Figure C on page 52 for Econoline vehicles. All components must be securely retained to remain intact when the completed vehicle is tested in any manner specified by applicable provisions of Standard 301.
301 The statements below are applicable to the Basic (Stripped) Chassis if the GVWR is 4536 kg [10,000 lb] or less: Conformity with Standard 301, Fuel System Integrity, is not substantially affected by the design of this incomplete vehicle; accordingly Ford Motor Company makes no representation as to the conformity with this standard.
– For a Basic (Stripped) Chassis without the body mounting system (metal spacers and rubber isolators provided by Ford Motor Company must use a body structure from the centerline of the rear axle rearward as follows: the body installed by the subsequent stage manufacturer includes a floor of at least 1.37mm [0.054 in] thick cold rolled steel (or equivalent strength material) with five hat section lateral crossmembers of 127.0mm [5.0 in] overall width fabricated from at least 2.08mm [0.082 in] thick cold rolled steel (or equivalent strength material) with 25.4mm [1.0 in] flanges welded to the underside of the floor and attached through the 35.6mm [1.40 in] nominal diameter mounting holes in the upper flanges of the frame rails by ten 12.7mm [0.5 in - 13 UNC] grade 8 bolts and nuts torqued to 81.3-88.1 N.m [60-65 ft-lb.]; 63.5mm [2.5 in] diameter washers of at least 4.55mm [0.179 in] thick cold rolled steel (or equivalent strength material) are required under each bolt head and nut used and the minimum distance between the bottom of the floor and the top of the frame is 102.6mm [4.04 in].
However, Ford Motor Company has tested completed vehicles incorporating a representative fuel system and frame assembly of a Basic (Stripped) Chassis in accordance with the procedures of Standard 301 at test weights specified by s7.1 .6 of the Standard, and the tested vehicles met the applicable requirements of Standard 301. This vehicle, when completed, is capable of compliance with FMVSS 301, if: • None of the following fuel system components as installed by Ford Motor Company are removed, relocated, altered, or modified in any way except as specified in this manual. – Fuel Tank and attachment hardware, including sending unit, vapor valve, OBD II pressure transducer, fuel tank shield and in-tank electric pump – Fuel filler cap, pipe, hose(s) and attachment hardware – Fuel lines, routing and attachments – Vapor line(s) and carbon canister – Fuel Filter
301 (Continued on Page 55)
51
STATEMENTS OF CONFORMITY
TOP OF FILLER PIPE SUPPORT
ROUTE FILL AND VENT HOSE SO NO LOW SPOTS OCCUR 965.2 [38.0]
FRONT OF VEHICLE
SCREW (3) REQ’D TORQUE 2.1 - 2.9 Nm [18 - 26 IN. LB. ]
631.7 [24.87] SECURE WITH TIE STRAPS AS REQUIRED TO VENT HOSE
TO BACK OF CUTAWAY CAB FUEL TANK
B 319.0 [12.56]
FRONT OF VEHICLE
AUXILIARY FUEL SUPPLY (DO NOT REMOVE CAP IF NOT IN USE)
EXISTING 9.7 DIA HOLES ( USED FOR EXHAUST ON R.H. SIDE)
AUXILIARY FUEL SUPPLY (DO NOT REMOVE CAP IF NOT IN USE)
POINT Z SEE PAGE 53 FUEL TANK FILL PIPE TOP OF FRAME RAIL
SCREW & WASHER (6) REQD. TORQUE 7.6 - 10.4 Nm [67 - 92 IN. LB.]
FUEL RETURN
FUEL PUMP/FUEL GAUGE SENDING UNIT FUEL TANK BOLT RING FUEL SUPPLY LINE
FRONT OF VEHICLE
TO CL OF REAR CL OF FILLER NECK AXLE FOR STRIPPED CHASSIS OUTBOARD SURFACE OF ALL W.B. FRAME RAIL 601.4 ± 12.7 [23.7] ± [0.5]
NUT (6) REQ’D TORQUE 13.7-17.3 Nm [120-153 IN. LB.]
FUEL RETURN
2641.6 [104.0] ± [2.0] [138] W.B 3149.6 [124.0] ± [2.0] [158] WB 3606.8 [142.0] ± [2.0] [178] WB
TORQUE SEQUENCE
WORM GEAR DRIVEN HOSE CLAMPS TORQUE 2.9 - 4.3 Nm [25-38 IN. LB.]
E-250 CUTAWAY MIDSHIP FUEL FILLER SYSTEM
VIEW B
TO BACK OF CUTAWAY CAB
N611131-S36 M4 SELF-TAPPING SCREW N611645-S36 M10 SELF-TAPPING SCREW (ATTACH TO SOUND METAL ON FRAME)
FUEL PUMP/FUEL GAUGE SENDING UNIT
FUEL SUPPLY LINE NOTE: USE A NEW O-RING GASKET WHEN REINSTALLING THE FUEL PUMP/FUEL GAUGE SENDING UNIT.
AUXILIARY FUEL SUPPLY (DO NOT REMOVE CAP IF NOT IN USE)
733.4 [28.875] SCREW (3) REQ’D TORQUE 2.1 - 2.9 Nm [18-26 IN. LB.]
FUEL TANK STUDS
VIEW A TOP OF FILLER PIPE SUPPORT 396.9 [15.625]
FRONT OF VEHICLE
FUEL TANK SECURE WITH TIE STRAPS AS REQUIRED TO VENT HOSE
A
TORQUE SEQUENCE POINT Z SEE PAGE 53 FUEL TANK FILL PIPE ROUTE FILL AND VENT HOSE SO NO LOW SPOTS OCCUR 9A099 GROUND STRAP FUEL TANK
N611131-S36 M4 SELF-TAPPING SCREW N 611645-S36 M10 SELF-TAPPING SCREW (ATTACH TO SOUND METAL ON FRAME)
40.2 [1.583]
EXISTING 9.7 DIA HOLES (USED FOR EXHAUST ON R.H. SIDE)
[ ] DIMENSIONS ARE IN INCHES WORM GEAR DRIVEN HOSE CLAMPS TORQUE 2.9 - 4.3 Nm [25 - 38 IN. LB.]
CRITICAL CONTROL ITEM
ECONOLINE E-350 CUTAWAY AND BASIC (STRIPPED) CHASSIS AFT-OF-AXLE FUEL FILLER SYSTEM
FIGURE C - ECONOLINE CUTAWAY AND BASIC (STRIPPED) CHASSIS FUEL FILLER PIPE AND SENDING UNIT INSTALLATION
STATEMENTS OF CONFORMITY
52
NOTES: TORQUE ALL WORM GEAR DRIVEN HOSE CLAMPS TO 2.8 - 3.9 NEWTON METERS 25-35 IN-LB [ ] DIMENSIONS ARE IN INCHES
*
NOT SUPPLIED BY FORD MOTOR COMPANY
CRITICAL CONTROL ITEM
Fuel fill system installed by Ford is for shipping purposes only. Remove from vehicle, discard hoses and clamps, and retain steel portion and cap for use with fill pipe kit provided. Use new hoses, pipe, scuff guards, tie wraps and clamps provided in kit to connect fuel fill system from tank to unit body as shown. Fuel fill and vent hoses provided in kit may require trimming as shown in figure. The resulting trimmed filler system should provide a continous downward slope to the fuel tank while avoiding kinks which restrict fuel flow. Additional support may be required to prevent sagging or mis-orientation. Failure to do so will result in spray or spit-back during the fueling operations.
(CA) BACK OF CAB TO CENTERLINE OF REAR AXLE 60 IN CA
84 IN CA WHEELBASE
120 IN CA
Regular Cab 3576mm[140.8] 4186mm[164.8] 5100mm[200.8] 4110mm[161.8] SuperCab 4475mm[176.2] Crew Cab
A B C D
MIN
864mm [34.0]
1473mm [58.0]
MAX
1029mm [40.5]
1638mm [64.5] 2553mm [100.5]
2388mm [94.0]
MIN
1981mm [78.0]
2591mm [102.0] 3505mm [138.0]
MAX †
2159mm [85.0]
2769mm [109.0] 3683mm [145.0]
MIN
584mm [23.0]
584mm [23.0]
584mm [23.0]
MAX ††
787mm [31.0]
787mm [31.0]
787mm [31.0]
MIN †††
267mm [10.5]
267mm [10.5]
267mm [10.5]
MAX†††† 343mm [13.5]
343mm [13.5]
343mm [13.5]
†, ††, †††, †††† SEE PAGE 55 FOR FOOTNOTES
FIGURE D - SUPER DUTY F-SERIES NARROW FRAME FUEL FILLER PIPE INSTALLATION
53
STATEMENTS OF CONFORMITY
NOTES:
(CA) BACK OF CAB TO CENTERLINE OF REAR AXLE 56 INCH CA WHEELBASE Regular Cab SuperCab Crew Cab
A
C
620mm [24.4]
MAX.
932mm [36.7]
MIN.
540mm [21.25]
MAX.
743mm [29.25]
MIN.
267mm [10.5]
MAX.
343mm [13.5]
D
[ ] DIMENSIONS ARE IN INCHES
*
3480mm [137.0] 4013mm [158.0] 4380mm [172.4]
MIN.
TORQUE ALL WORM GEAR DRIVEN HOSE CLAMPS TO 2.8 - 3.9 NEWTON METERS 25-35 IN-LB
NOT SUPPLIED BY FORD MOTOR COMPANY
CRITICAL CONTROL ITEM
Fuel fill system installed by Ford is for shipping purposes only. Remove from vehicle, discard hoses and clamps, and retain steel portion and cap for use with fill pipe kit provided. Use new hoses, pipe, scuff guards, tie wraps and clamps provided in kit to connect fuel fill system from tank to unit body as shown. Fuel fill and vent hoses provided in kit may require trimming as shown in figure. The resulting trimmed filler system should provide a continous downward slope to the fuel tank while avoiding kinks which restrict fuel flow. Additional support may be required to prevent sagging or misorientation. Failure to do so will result in spray or spit-back during the fueling operations.
FIGURE E - SUPER DUTY F-SERIES WIDE FRAME FUEL FILLER PIPE INSTALLATION
STATEMENTS OF CONFORMITY
54
(Continued From Page 55 - Footnotes) †
†††
It may be necessary to change the orientation of the steel elbow (long end pointing outboard) in order to achieve the maximum dimension. SWR narrow bodies will not allow this orientation change and therefore will not achieve this maximum dimension. If greater maximum dimensions are desired, the fuel filler housing can be placed no further rearward than the designed frame fuel filler opening. This will entail fabricating a straight steel jumper tube with the same diameter and stop end bead dimensions found on the steel elbow provided in the kit. Only the Ford approved hoses provided in the kit can be used to accommodate any modifications.
††††
Minimum dimensions have been tested to ensure proper fuel filling performance. If design constraints require a lower minimum “D” dimension, a lower dimension can be used as long as the filler systems maintains at least a 4 degree constant downward slope to the fuel tank. The addition of a fuel filler support to prevent fuel hoses from moving or sagging is necessary to ensure a continuous downward slope for both fill and vent hoses. This is essential at this lower dimension for proper fuel filling performance. Larger maximum dimensions are allowable if the hose length provided will reach the desired position.
NOTE: The above options apply to the maximum “B” dimension on vehicles with an aft-ofaxle fuel tank.
††
Do not extend fuel fill system outboard of Second Unit Body.
SUPER DUTY F-SERIES NARROW FRAME FUEL FILLER PIPE INSTALLATION - FOOTNOTES
301 (Continued) 302 The statement below is applicable to the Basic (Stripped) Chassis:
The basic (Stripped) Chassis is equipped with a Fuel Shutoff Switch. The switch is located on the column support structure, and must not be relocated, altered, or modified in any way.
Conformity with Standard 302, Flammability of Interior Materials, is not substantially affected by the design of this incomplete vehicle; accordingly Ford Motor Company makes no representation as to conformity with this Standard.
301 Canadian Requirements: The preceding statements for FMVSS 301 are appropriate compliance representations for CMVSS 301, Fuel System Integrity, if this incomplete vehicle was manufactured for sale or use in Canada. In such a case, CMVSS 301 paragraphs (5),(6), and (7) are substituted for the reference to FMVSS 301 Section 7.1.6.
302 Canadian Requirements: The preceding statements for FMVSS 302 are appropriate compliance representations for CMVSS 302, Flammability, if the vehicle was manufactured for sale or use in Canada.
301.1 Canadian Requirements:
303 The statement below Is applicable to all incomplete vehicle types if the GVWR Is 4536 kg [10,000 lb] or less:
Standard 301.1, LPG Fuel System Integrity, Ford Motor Company makes no representation as to conformity with this Standard.
Conformity with Standard 303, Fuel System Integrity of Compressed Natural Gas Vehicles, is not substantially affected by the design of this incomplete vehicle; accordingly Ford Motor Company makes no representation as to conformity with this Standard.
301.2 Canadian Requirements: The statement for Standard 303 is an appropriate compliance representation for CMVSS 301.2 CNG Fuel System Integrity, if the incomplete vehicle was manufactured for sale or use in Canada.
304 The statement below is applicable to all incomplete vehicle types: Conformity with Statement 304, Compressed Natural Gas Fuel Container, is not substantially affected by the design of this incomplete vehicle; accordingly Ford Motor Company makes no representation as to conformity with this Standard.
302 The statement below is applicable to all incomplete vehicle types except the Basic (Stripped) Chassis: This vehicle, when completed, will conform with Standard 302, Flammability of Interior Materials, if no alterations are made to those components covered by the Standard which are installed by Ford Motor Company and all components covered by Standard 302, which are added to the incomplete vehicle by subsequent stage manufacturers meet the flammability requirements of the Standard.
55
STATEMENTS OF CONFORMITY
CANADIAN VEHICLES (Vehicles to be completed for sale or use in Canada) GENERAL INFORMATION
CANADIAN RADIO FREQUENCY INTERFERENCE (RFI) INFORMATION
Section 6(4) (d) of the Canadian Motor Vehicle Safety Regulations requires a manufacturer of an incomplete motor vehicle to list the applicable Canadian Motor Vehicle Safety Standards (CMVSS) to which the incomplete motor vehicle conforms in full at the time of manufacture. The table on page 58 is provided for this purpose. The Statements of Conformity on pages 9 through 55 of this manual, are compliance representations based on United States Federal Motor Vehicle Safety Standards (FMVSS) requirements. However, Canadian Motor Vehicle Safety Regulations (CMVSS) representations are provided at the conclusion of each safety standard section where appropriate. Because CMVSS requirements may differ from FMVSS requirements, Canadian Subsequent Stage Manufacturers should refer to the Canadian requirements for each safety standard to help determine compliance to a regulation.
All vehicles powered by spark ignition engines (e.g.: gasoline or propane engines) and manufactured in Canada or for sale or use in Canada are subject to the Canadian “Regulations for the Control of Interference to Radio Reception” per InterferenceCausing Equipment Standard (ICES-002) and applicable test method according to “CAN/CSA-C108.4-M92”. Violation of these regulations is punishable by fine or imprisonment. This Ford-built incomplete vehicle (if other than a Basic (Stripped) Chassis) was designed and manufactured to be capable of meeting the regulatory requirements or such modifications thereof as may have been authorized by the Department of Communications. However, because Ford has no control over how this incomplete vehicle is completed by subsequent stage manufacturers, Ford does not represent that the completed vehicle incorporating the Ford-built components will comply with applicable requirements.
CMVSS STATEMENT OF COMPLIANCE
The following information is supplied to subsequent stage manufacturers to help them avoid increasing the RFI emissions of this vehicle in the course of completing it.
The incomplete vehicle identified by the Vehicle Identification Number VIN) on the cover of this manual and to which this manual was attached, conforms in full, as manufactured by Ford Motor Company to each Canadian Motor Vehicle Safety Standard designated by an “X” in the appropriate column of the table on page 58. The appropriate column is the column headed by the illustrated description of the incomplete vehicle type that represents this particular incomplete vehicle. The table lists all safety standards in effect on the date of manufacture of this incomplete vehicle (shown on the front cover) applicable to “Chassis Cabs” which, as defined by Canadian Regulations, includes all the incomplete vehicles described. Compliance with those standards not identified by an “X” and possibly other standards not listed are the responsibility of the manufacturer who completes the vehicle, when those standards are applicable to the final configuration of the vehicle. Note: Canadian Regulations include vehicle emission standards in the 1100 series as shown.
For any completed vehicle, additional measures may be needed to adequately suppress RFI emissions. Affected components could include spark plugs, ignition wires, ignition coil, ground straps, ignition component shields, accessory drive belts, instrument voltage regulator suppressor assembly and ignition coil suppressor assembly. More specifically: •
All components required to suppress RFI emissions, which are removed during service, repair or completion of the vehicle, must be reinstalled in the manner in which they were installed by Ford.
•
Shields on ignition coil must remain installed.
•
Replacement spark plugs, ignition wires, and ignition coil must be equivalent in their RFI suppression properties to original equipment.
VEHICLE IDENTIFICATION
•
Electrical grounds on all components must be retained.
Refer to the Vehicle Description section of this manual on page 4, for additional information. Incomplete Vehicles produced by Ford Motor Company require, for certain applications, optional Prep Packages which are listed on the Completed Vehicle Types charts on pages 5 and 6.
•
Metallic components installed on the body or chassis must be grounded to the chassis.
•
Electrical circuits added to the vehicle must not be installed near the high voltage ignition components.
•
Compliance representations for CMVSS 108, Lighting and CMVSS 108.1, Headlamps, are on page 24. The following items are also required for CMVSS 108 and 108.1 compliance:
Only “static conductive” accessory drive belts should be used. Fan, water pump, power steering and other belts should be of the OEM type or equivalent that will not build up a static electrical charge.
•
Engine compartment wiring must not be rerouted in any manner.
•
The DRL module circuits are not to be altered.
•
•
DRL module is not to be repositioned.
The Powertrain Control Module (PCM) must not be relocated from the position as installed by Ford Motor Company.
•
Basic (Stripped) Chassis is not to be equipped with more than two headlamps when equipped with a DRL module as provided by Ford Motor Company.
DAYTIME RUNNING LAMP (DRL)
57
CANADIAN VEHICLES
CANADIAN MOTOR VEHICLE SAFETY STANDARD (CMVSS) TABLE (Vehicles to which the Incomplete Motor Vehicle conforms in full at the time of manufacture are designated by X’s) CMVSS CMVSS DESCRIPTION
INCOMPLETE VEHICLE TYPE
CHASSIS CAB
INCOMPLETE ECONOLINE VAN (1)
CUTAWAY
BASIC (STRIPPED) CHASSIS
101 102 103
Control Location and Identification Transmission Shift Control Sequence Windshield Defrosting and Defogging
X X X
X(3) X X
X(3) X X
104 105 106
Windshield Wiping and Washing System Hydraulic Brake Systems Brake Hoses
X X X
X X X
X X X
Lighting Equipment Headlamps
X
X X
X
112 113 115
Headlamp Concealment Devices Hood Latch System Vehicle Identification Number
X X X
X X X
X X X
116 120
Hydraulic Brake Fluid Tire Selection and Rims for Vehicles other than Passenger Cars
X X
X X
X X
X X(4)
121 124 205
Air Brake System Accelerator Control Systems Glazing Materials
X X
X X
X X
X
206 207 209
Door Latches, Hinges and Locks Anchorage of Seats Seat Belt Assemblies
X X X
X X(2) X(2)
X X(2) X(2)
210 301.1 301.2
Seat Belt Assembly Anchorages LPG Fuel Systems CNG Fuel Systems
X
X(2)
X(2)
302
Flammability
X
X
X
1100
Vehicle Emissions
X
X
X
108 108.1
X X
X
NOTE: CMVSS 107 has been rescinded by Transport Canada. CMVSS 211 has been rescinded by Transport Canada CMVSS 1106 - Although this standard does not apply to the described incomplete vehicles because it does not apply to “Chassis Cabs”, the exterior noise emissions of the following such vehicles, as manufactured by Ford Motor Company, conforms to the applicable noise limits of CMVSS 1106 (1)(b) for the following vehicles:
(1)Econoline Van type vehicles when equipped with Ambulance Prep Package and RV Prep Package are incomplete vehicles. (2)The Econoline Van and Cutaway type vehicles, when equipped with the RV Prep Package, may not conform in full to Standards 207, 209 and 210.
• Chassis Cab (Super Duty F-Series)
(3)The Econoline Van and Cutaway type vehicles when equipped with the RV Prep Package and no front seats do not conform in full to Standard 101.
• Econoline Cutaway Chassis Cab (F-Series) with a GVWR over 4536 kg [10,000 lb], will comply with CMVSS 1106 (b) Interior Noise Emission requirements for vehicles with a GVWR over 4536 kg [10,000 lb], as manufactured by Ford Motor Company.
CANADIAN VEHICLES
(4) The tire and rim information requirements of Standard 120 will be met when the Incomplete Vehicle Label is affixed to the driver-door. This label is shipped with this manual in the plastic bag.
58
EMISSION CERTIFICATION INFORMATION Incomplete vehicles using engines which are certified as heavy duty engines will not have frontal area or curb weight restrictions based on exhaust emissions regulations. It is important, however, that the final stage manufacturer observe vehicle restrictions from vehicle safety requirements, etc., which are located elsewhere in this manual. Additional emissions certification information is contained in the Ford Truck Body Builders Layout Book for the model year and type of this incomplete vehicle.
CAUTION: 1999 MODEL YEAR VEHICLES ARE EMISSION CERTIFIED FOR REGISTRATION IN SPECIFIC AREAS OF THE UNITED STATES. FOR EXAMPLE, VEHICLES CERTIFIED AND LABELED FOR SALE IN CALIFORNIA CAN NOT BE SOLD IN THE STATES THAT REQUIRE FEDERALLY CERTIFIED VEHICLES AND VEHICLES CERTIFIED TO FEDERAL STANDARDS CAN NOT BE SOLD IN STATES THAT REQUIRE CALIFORNIA CERTIFIED VEHICLES. IT IS THE SUBSEQUENT STAGE MANUFACTURER’S RESPONSIBILITY TO PURCHASE A VEHICLE CERTIFIED FOR THE STATE/AREA IN WHICH THE VEHICLE WILL BE SOLD. EPA HAS STATED THAT UNDER CERTAIN CIRCUMSTANCES THEY WILL NOT ENFORCE THESE REQUIREMENTS. FOR FURTHER GUIDANCE CONSULT EPA’S “POLICY ON CROSS BORDER SALES OF CALIFORNIA VEHICLES.”
Emission Control Hardware Any body builder, installer or subsequent stage manufacturer must also assure that all emission control hardware furnished with incomplete vehicles is on the vehicle and is operational and that applicable instructions for incorporating such hardware into the completed vehicle’s electrical or mechanical systems are strictly followed.
EXHAUST EMISSIONS AND FUEL ECONOMY
High Altitude Requirements
Most incomplete light truck vehicle(s) or truck(s) offered by the Ford Motor Company for 1999 model year will be in the >3855 kg [8,500 lb] classification. Generally, the medium/heavy duty engines used in these vehicles will be certified to Federal, Canadian or California exhaust and evaporative emissions requirements for medium/heavy duty engines.
United States Environmental Protection Agency regulations for the 1999 model year do not contain unique emission certification requirements for light duty trucks that will be sold or delivered to customers for principal use above 1,219 m [4,000 ft.]. However, some vehicle configurations are restricted to low altitude applications for principal use below 1,219 m [4,000 ft.].
Frontal Area and Weight Restrictions:
IMPORTANT: To avoid any questions of certification coverage, orders should specify whether a high altitude emission system or non-high altitude emission system is required.
All 4.2L and some 5.4L heavy duty engines (engines used in vehicles exceeding 3855 kg [8,500 lb]) are certified to light duty <3855 kg [8,500 lb] protocol and will require vehicle weight and frontal area restrictions. The 6.8L HD, 7.3L Diesel HD and some 5.4L HD (49 states only) engines are not certified to light duty protocol and therefore are not limited by weight and frontal area restrictions for exhaust emissions. All 4.2L engine vehicles concerned are listed on page 62 of this manual. The 5.4L engine vehicles concerned are the E-250 SVL/RVL, 3900 kg- [8600 lb] GVWR vehicles. If your vehicle is affected, the frontal area and Unloaded Vehicle weight information will be found on the Emissions Control Information decal which is located in the engine compartment, as well as page 62 of this manual. This engine label reflects the maximum curb weight as certified by the Environmental Protection Agency (EPA) (i.e., basic curb weight plus 33% option weight for a vehicle line within an engine-system combination). The curb weight of the vehicle is allowed to increase beyond the Important Vehicle Information decal maximum curb weight if the increase is due to the addition of options that have less than 33% installation rate.
If it is necessary to convert a new non-high altitude vehicle for principal use at high altitude, a list of corresponding high and low altitude engine calibrations is available free of charge from your local Ford dealer. Service publications indicate how to modify vehicles to conform with appropriate high or low altitude U.S. EPA regulations. Further, to avoid any question of certification coverage, approval of any modification or use of an engine or vehicle which may render inoperative any of the emission control components must be obtained from the United States Environmental Protection Agency by the manufacturer making such modification or use prior to distribution, sale, offering for sale, introduction, or delivery for introduction of the subject vehicle into U.S. commerce. Additionally, the manufacturer making such modification or use must obtain approval from the California Air Resources Board if the new vehicle will be delivered for sale or use in the State of California.
IMPORTANT: It is the responsibility of the body builder, installer or subsequent stage manufacturer to ensure that the maximum completed vehicle curb weight and frontal area specified by Ford are not exceeded. If these restrictions are exceeded, or if the vehicle is modified such that it will not comply with applicable emission standards throughout its useful life, the body builder, installer or subsequent stage manufacturer will be considered a manufacturer for purposes of complying with U.S. Federal, California or Canadian exhaust and evaporative emission requirements, and Federal fuel economy standards, labeling, and certain other requirements.
IMPORTANT: For purposes of Government Regulation, a body builder, installer, or any subsequent manufacturer may be considered a manufacturer.
59
EMISSION CERTIFICATION INFORMATION
UNLEADED GASOLINE LABEL Regulations no longer require the manufacturer to affix permanent labels reading “Unleaded Gasoline Only” or “Unleaded Fuel Only” to vehicles destined for sale in the United States or Canada. Such labels may however be required for vehicles sold into other markets. It is the responsibility of the body builder, installer or any subsequent manufacturer to properly label vehicles for the market in which they are sold.
WARRANTY AND MAINTENANCE A copy of the appropriate Ford Truck Owners Guide and Warranty Facts Booklet must be installed in every vehicle prior to sale to the ultimate purchaser in order to provide emission systems warranty information and maintenance schedules. It also provides, where required by EPA noise control regulations for vehicles having GVWR over 4536 kg [10,000 lb], noise emissions warranty information, instructions for maintenance, use and repair of vehicle noise emission control systems, a maintenance record format, and list of prohibited tampering acts.
EXTERIOR NOISE New vehicles which have a gross vehicle weight rating in excess of 8619 kg [19,000 lb], include a partially or wholly enclosed operator’s compartment, and are manufactured for use in the United States, must comply with U.S. Environmental Protection Agency’s exterior noise emission regulations for medium and heavy trucks (40 CFR Part 205, Subpart B) which establish a noise emission limit of 80 dB (A).
EVAPORATIVE EMISSIONS All 1999 Federal light and heavy duty trucks and all California vehicles with gasoline engines are required to comply with evaporative emissions requirements established by the Environmental Protection Agency or the California Air Resources Board. Production fuel systems supplied on incomplete 1999 model year trucks manufactured by Ford Motor Company comply with these requirements. If the subsequent stage manufacturer adds to or modifies the fuel system in any manner, it becomes the responsibility of the modifier to assure compliance with the applicable regulations. See page 68 for EPA guidelines on upgrading fuel vapor control systems.
However, the Basic (Stripped) Chassis as built by Ford is too incomplete to constitute a regulated vehicle, and Ford does not represent that it complies with those regulations. With respect to the Basic (Stripped) Chassis, it is the responsibility of the subsequent stage manufacturer of that vehicle at the time it first conforms to the regulatory definition of “vehicle” to comply with the requirements imposed upon manufacturers by these regulations.
SERVICE ENGINE SOON WARNING LIGHT The “Service Engine Soon” warning light is used to indicate malfunctions of the Electronic Engine Control System and certain emissions-related components. For all incomplete vehicles, except Basic (Stripped) Chassis (which is not equipped with an instrument panel), it is Ford installed and operational.
TAMPERING WITH NOISE CONTROLS Federal law prohibits the removal or rendering inoperative by any person, other than for purposes of maintenance, repair or replacement, of any device or element of design incorporated into such vehicle for the purpose of noise control, prior to its sale or delivery to the ultimate purchaser or while it is in use, or the use of such vehicle after such device or element of design has been removed or rendered inoperative by any person.
The Basic (Stripped) Chassis vehicles, has the warning light installed in the instrument cluster, which is shipped in the dunnage box. If an alternate instrument cluster is utilized, the final stage manufacturer must install an operational light in the instrument cluster. This light must glow amber and display the message “Service Engine Soon”. It should be recognized that this light is a requirement of emission certification.
Among those acts presumed to constitute tampering are the acts listed below: • Removal of fender apron absorbers, fender apron barriers, underbody noise shields or acoustical absorptive material. • Removal of or rendering inoperative the engine speed governor, so as to allow engine speed to exceed manufacturer’s specifications.
POWER TAKE-OFF CIRCUIT A wire located under the instrument panel labeled “Power Take-Off Circuit” is provided to minimize the inadvertent illumination of the “Service Engine Soon” while the PTO is engaged. See Figure A, page 77 of this manual for circuit location. Connect the wire to the Power Take-Off Circuit as instructed in the Ford Body Builders Book and isolate the wire labeled “Power Take-Off Circuit” from the solenoid to prevent damage to the Power Control Module (PCM).
• Removal or modification of air duct, air intake choke or silencer, air cleaner or air cleaner element. • Removal of, or rendering inoperative, exhaust system components including the catalyst inlet pipe, muffler, outlet pipe, resonator or diffuser. • Removal of the fan shroud. Removal of or rendering inoperative the fan clutch. New vehicles manufactured for sale in Canada must comply with applicable provisions of Canada Motor Vehicle Safety Standard 1106, Noise. Additional noise emissions information is contained in the Ford Truck Body Builders Layout Book.
EMISSION CERTIFICATION INFORMATION
60
OZONE DEPLETING SUBSTANCE (ODS)
CALIFORNIA MOTOR VEHICLE EMISSION CONTROL LABEL
The Clean Air Act of 1990, Section 611 requires any product (i.e., completed vehicle) containing or manufactured with any Class I Ozone Depleting Substance on, or after May 15,1993 must be identified with a “clearly and conspicuously attached label.”
To meet California emission certification regulations, the Emission Control Information (tune-up) label must be welded, riveted or otherwise permanently attached to an area within the engine compartment or to the engine in such a way that it will be readily visible to the average person after installation of the engine in a vehicle. In selecting an acceptable location, the manufacturer shall consider the possibility of accidental damage (e.g., possibility of tools or sharp instruments coming in contact with the label). The label shall be affixed in such a manner that it cannot be removed without being destroyed or defaced, and shall not be affixed to any part which is likely to be replaced during the vehicle’s useful life. For motor vehicles rated at 3855 kg [8500 lb] GVWR or less, the label shall not be affixed to any equipment which is easily detached from the vehicle. As used in these specifications, readily visible to the average person shall mean that the label shall be readable from a distance of 460 mm [18 in] without any obstructions from vehicle or engine parts (including all manufacturer available optional equipment), except for flexible parts, (e.g., vacuum hoses, ignition wires). Alternately, information required by these specifications to be printed on the label shall be no smaller than 8 point type size provided that no vehicle or engine parts, (including all manufacturer available optional equipment), except for flexible parts that can be moved out of the way without disconnection obstruct the label.
Ford Motor Company has eliminated Class I ODS from its manufacturing processes. All 1999 Ford Truck incomplete vehicles will not have Class I ODS content. Manufacturers, including subsequent stage manufacturers, are required to label their products if the product, including any component (whether manufactured by that manufacturer or not), contains a Class I ODS or if the manufacturer used a Class I ODS in the manufacturing of the product. In the case where Ford provides a label saying the incomplete vehicle contains a Class I ODS that information must be placed on the product warning label. (See EPA regulation on wording, placement, size and combining labels.) In Canada consult the appropriate Provincial or Territorial Ministry of Environment. EMISSION CONTROL INFORMATION LABEL To meet United States Environmental Protection Agency regulations, the Important Vehicle Information (tune-up and fuel tank capacity) labels must be affixed in a location that is readily visible after installation and in such a manner that it cannot be removed without destroying or defacing the label. The label shall not be affixed to any equipment that is easily detached from such vehicle.
Completed vehicles for retail sale in California require a machine-readable vehicle identification number (VIN) bar-code label made of paper, plastic, metal or other permanent material which shall be affixed in a readily visible location to either the door-latch post next to the driver’s seating position, the door edge that meets this door-latch post, or above the instrument panel in a location clearly visible through the lower left corner of the windshield.
When emission control labels are supplied but not attached to the vehicle (i.e., tune-up label or fuel tank label), they must be permanently mounted in a readily visible location to meet the preceding requirements. In addition, whether the label is already affixed or to be affixed, no components shall be installed which visibly obscure the label in any way that fails to satisfy the visibility requirements described in the California Emission Control Label Specifications. For Canadian requirements consult Section 1100 8 (1) (d) (i), (ii), & (iii), as applicable.
•
All Incomplete Vehicles except Basic (Stripped) Chassis Type Vehicles will conform to this standard.
•
Basic (Stripped) Chassis Type Vehicles: Conformity with CARB Motor Vehicle Emission Control Label specifications for VIN label is not substantially affected by the design of this incomplete vehicle. Accordingly, Ford Motor Company makes no representation as to conformity with this requirement. To assist a subsequent stage manufacturer with conforming to this specification Ford is providing a label which will accompany this manual inside the protective plastic bag.
CALIFORNIA FUEL VAPOR RECOVERY California regulations require that the vehicle fuel systems be designed to accommodate a vapor recovery fueling nozzle including unobstructed access to the fill pipe. Fuel filler pipes installed per the figures on pages 52, 53, and 54 will comply with the “Specifications For Fill Pipes and Openings of Motor Vehicle Fuel Tanks” referenced in Title 13 California Administrative Code provided no part of the aftermarket body, as installed, intrudes within a 254mm [10 in] radius cylinder which has its axis parallel to the ground at point “Z”. The cylindrical zone uses the axis described above, starts at the outer most surface of the Ford supplied fuel filler housing, and projects outward (away from the frame). The fuel pipe housing component is shown on the referenced figures and is attached to the aftermarket body via 4.76 mm [0.188 in] diameter rivets. Fuel filler pipes installed using the alternative bracket shown on pages 53 and 54, will comply with the above California vapor recovery regulations provided the aftermarket body does not interfere with the access zone as defined by the California Air Resources Board, and the areas adjacent to this opening cannot foreseeably damage the nozzle bellows or face plate of nozzles during insertion, latching, disposing or removal.
For the VEC† and VIN labels, sufficient clearance shall be provided to use a non-contact bar-code Reading Wand. For the tune-up label and vacuum hose routing diagram label, the label and any adhesives used shall be designed to withstand for the vehicle’s total expected life, typical vehicle environment conditions in the area where the label is attached. Typical vehicle environmental conditions shall include, but are not limited to, exposure to engine lubricants and coolants (e.g., gasoline, motor oil, brake fluids, water, ethylene glycol), under hood temperatures, steam cleaning, and paints or paint solvents. † Vehicle Emission Control
61
EMISSION CERTIFICATION INFORMATION
RADIO FREQUENCY INTERFERENCE (RFI)
Devices that emit radio frequency (RF) energy such as AM/ FM radios, mobile telecommunications systems (two-way radios, telephones) and radio controlled security systems are subject to the rules and regulations of the Federal Communications Communication (FCC), including 47 CFR Parts 2 and 15. Any such system installed in a vehicle should comply with those rules and should be installed only by a qualified technician. In addition, to ensure continued compliance with the FCC’s regulations, RF devices must not be modified or changed in a manner not expressly approved by Ford Motor Company Mobile Communication Systems. RF devices particularly, if not properly installed, may adversely affect the operation of the vehicle. For example, such systems when operated may cause the engine to stumble or stall. In addition, such systems themselves may be damaged, or their operation affected by the operation of the vehicle. (Citizens Band [CB] transceivers, garage door openers, and other transmitters whose power output is 5 watts or less, ordinarily will NOT affect vehicle operation.)
The ignition system on your vehicle (if other than a Basic (Stripped) Chassis) has been designed to be capable of compliance with RFI requirements established by the Canadian government. However, because Ford has no control over how an incomplete vehicle is completed by subsequent stage manufacturers, Ford does not represent that the completed vehicle incorporating the Ford-built components will comply with those requirements. Any ignition system component (i.e.: spark plugs, ignition wiring, coil suppressor assembly, etc.) that is replaced should be replaced by the same Ford Motor company part number or equivalent, to maintain RFI suppression. While there are currently no RFI regulations in the United States specifically applicable to automotive ignition systems, all Ford Light Trucks are built with ignition system components the same or equivalent to those supplied on Canadian vehicles. Ford Motor Company recommends that all ignition system service be performed at a Ford authorized service facility to help hold RFI emissions levels to a minimum.
Because Ford has no control over the operation or manufacture of such systems, or their installation, Ford cannot assume responsibility for any adverse effects or damage if this equipment is used.
Additional RFI information is contained on page 57 of this manual.
EMISSION CERTIFICATION LIMITATIONS FOR VEHICLES EQUIPPED WITH 4.2 L [256 C.I.D.] ENGINE TO RELY ON THE EMISSION CERTIFICATION APPROVAL RECEIVED BY FORD, NEITHER THE MAXIMUM UNLOADED VEHICLE WEIGHT NOR ITS ACCOMPANYING MAXIMUM COMPLETED VEHICLE FRONTAL AREA MAY BE EXCEEDED. IF EITHER FACTOR IS EXCEEDED, THE FINAL STAGE MANUFACTURER IS RESPONSIBLE FOR OBTAINING EMISSION CERTIFICATION FROM THE ENVIRONMENTAL PROTECTION AGENCY.
VEHICLE TYPE
WHEELBASE MILLIMETER [INCH]
MAXIMUM UNLOADED VEHICLE WEIGHT KILOGRAMS [POUNDS]
COMPLETED VEHICLE FRONTAL AREA [SQUARE FEET]
E-250 Cutaway
3505 [138]
2676 [5900]
[53.0] maximum
E-250 Basic (Stripped) Chassis
3150 [124]
2676 [5900]
[59.0] maximum
NOTE: The maximum unloaded vehicle weight (basic curb NOTE: The values shown are accurate as of the date of initial weight, plus the weight of options that are installed on printing. See Important Vehicle Information decal, vehicles at a rate of 33% or greater, plus the second located in the engine compartment, for specific values unit body weight) and completed vehicle frontal area applicable to your vehicle. values shown in this table are limits for purposes of emission certification. See Table J on page 17 for additional information.
EMISSION CONTROL INFORMATION
62
DESIGN RECOMMENDATIONS INFORMATION Ford urges careful consideration of the recommendations that follow. They are based on analyses of component and vehicle tests, actual service situations, and engineering judgments. Disregard of these recommendations may affect the durability, reliability, handling and performance characteristics of a completed vehicle and may result in elevated underbody temperatures, increase the potential for fire, or may affect the safety of the occupants in the event of an accident.
The completed vehicle in the “Loaded” condition must not exceed the front GAWR, rear GAWR, or the GVWR. (“Loaded” means the completed vehicle weight with the maximum fluid capacity necessary for vehicle operation, plus 150 lb for each designated seating position, and an additional allowance for any cargo weight advertised by the manufacturer). The GAWRs and GVWR are on the label affixed to the cover of this manual. Subsequent Stage Manufacturers are encouraged to contact t h e F o r d Tr u c k B o d y B u i l d e r A d v i s o r y S e r v i c e o n 1-800-635-5560 if they have any questions concerning these recommendations.
These recommendations are supplemental to U.S. and Canadian Motor Vehicle Safety compliance representations provided earlier in the manual. Also, additional information is provided in the Ford Truck Body Builders Layout Book and Ford Truck Shop Manual, which may be helpful to subsequent stage manufacturers.
AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM Some Trucks produced by Ford Motor Company are equipped with an Air Bag Supplemental Restraint System (SRS). Vehicles equipped with this system will have the words “AIR BAG” and an air bag symbol on the VIN plate located on the top driver-side corner of the instrument panel. System components are shown in their vehicle locations on page 38 of this manual.
3. Remove fasteners retaining air bag module to steering wheel. Disconnect driver air bag connector and remove the bag from steering wheel. Place the bag on a flat surface with trim cover facing upward. Connect an Air Bag Simulator (Part # 105-R0012 in the Rotunda Tool catalog) to the air bag connector on the wire harness in the steering wheel.
Detailed system and service information will be found in The Ford Truck Service Manual for the appropriate type and model year. Ford Motor Company urges the subsequent stage manufacturers to become familiar with this system prior to modifying vehicles that are so equipped.
4. Disconnect passenger air bag module connector and replace it with an Air Bag Simulator (Part # 105-R0012 in the Rotunda Tool catalog) to the air bag connector on the wire harness in the I/P. 5. Reconnect all negative battery cable(s). B.
CAUTION: DO NOT REMOVE THE STEERING COLUMN, STEERING WHEEL AND AIR BAG MODULE AS AN ASSEMBLY FROM THE VEHICLE UNLESS (1) THE COLUMN IS LOCKED TO PREVENT ROTATION, OR (2) THE LOWER END OF STEERING SHAFT IS SECURED (e.g. by wire) IN SUCH A WAY THAT THE STEERING WHEEL CANNOT BE ROTATED.
2. Wait 1 minute for backup power supply to deplete stored energy. 3. Remove Air Bag Simulator and reconnect driver air bag connector. Position driver air bag on steering wheel and secure with two fasteners (10 mm). Tighten fasteners to 2.7-3.7 Nm [24-32 in-lb]. 4. Remove Air Bag Simulator and reconnect passenger air bag connector to passenger air bag module.
THE SEAT BELT BUCKLE PRETENSIONER, AIR BAGS AND ELECTRONIC SENSOR MODULE ARE BAR CODED WITH A UNIQUE SERIAL NUMBER WHICH IS MATCHED TO THE VEHICLE VIN. THE COMPLETED VEHICLE MUST CONTAIN THE SAME SEAT BELT BUCKLE PRETENSIONER, AIR BAGS AND ELECTRONIC SENSOR MODULE THAT WERE INSTALLED BY FORD MOTOR COMPANY IN THE INCOMPLETE VEHICLE.
5. Reconnect all negative battery cable(s). 6. PROVE-OUT the system. C.
If electrical work is performed in the steering column area, the instrument panel or the air bag system, the system must be deactivated to avoid unwanted deployment of the air bag. To do this, follow the procedure below: A.
Reactivation Procedure 1. Disconnect all negative battery cable(s).
Deactivation Procedure 1. Disconnect all negative battery cable(s). 2. Wait 1 minute. This is the time required for backup power supply in diagnostic monitor to deplete its stored energy.
63
Prove-Out System Procedure Prove-out system means to turn the ignition switch from OFF to RUN and visually monitor the air bag indicator. The air bag will light continuously for approximately six seconds and then turn off. If an air bag system fault is present, the indicator will either fail to light, remain lit continuously or light in a flashing manner. The flashing manner may not occur until approximately 30 seconds after the ignition switch has been turned from OFF to RUN. This is the time required for the diagnostic monitor to complete the testing of the air bag system. If the air bag indicator is inoperative and an air bag system fault exists, a tone will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator will need to be serviced before further diagnosis can be done.
DESIGN RECOMMENDATIONS
OCCUPANT PROTECTION SYSTEM INFORMATION
6. Seating system components should be free of sharp edges to prevent damage to seat belt systems when the belts could potentially contact the seating system components.
The following recommendations are intended to assist in the design of seats and seat belt systems capable of meeting the requirements of the F/CMVSS 207, 208, 209 and 210 except for front seating positions for vehicles having a GVWR of 3855 kg [8500 lb] or less and an Unloaded Vehicle Weight of 2495 kg [5500 lb] or less. These recommendations are based on testing and analyses performed by Ford Motor Company.
7. Seats should be mounted with appropriate fasteners in the mounting holes provided since these holes are located to utilize floor pan structural reinforcements. (See Figures on page 36 of this manual.) 8. If additional holes are required for any reason, their locations should be carefully selected so that the structural integrity of the floor pan will not be compromised and to prevent damage to other components located below the floor.
Ford cautions subsequent stage manufacturers to note the definition of “Designated Seating Position” on page 7. If a position can reasonable be used by a 5th percentile adult female for seating and the overall seat configuration and vehicle design make it likely that the position will be used by an occupant while the vehicle is in motion, then the position must be considered to be a “Designated Seating Position” for determination of compliance to U.S. and Canadian motor vehicle safety standards.
9. Seating systems should be designed to be compatible with the seat belt systems, so as to permit proper adjustment, allow for occupant movement and provide convenient accessibility of the restraint system buckle release. 10. Seats not designated for occupancy while the vehicle is in motion, must be conspicuously labeled as such.
Seat and seat belt systems may take many forms, this list of recommendations can not cover all possibilities. Strict adherence to these suggestions will not ensure that systems will comply with F/CMVSS 207, 208, 209 and 210. Responsibility for determining compliance to appropriate F/CMVSS regulations is that of the final stage manufacturer. Accordingly, Ford Motor Company makes no representation as to the appropriateness of any particular recommendation in its specific application of a particular design or act of intermediate or final stage manufacture.
LAP AND SHOULDER BELT SYSTEMS 1. The front seats are equipped with a pyrotechnic buckle pretensioner. The buckle pretensioner reduces slack in the lap and shoulder safety belt by pulling the buckle downward. The buckle pretensioners and air bags operate on the same sensors and will function simultaneously. 2. Additional lap and shoulder belt assemblies, including retractors and hardware, must comply with the requirements of F/CMVSS 208 and 209.
To confidently verify compliance with F/CMVSS 207, 208, 209 and 210, the testing of representative systems to applicable F/CMVSS 207, 208, 209 and 210 procedures is recommended. Questions regarding compliance with F/CMVSS regulations should be directed to your legal counsel, the National Highway Traffic Safety Administration, or Transport Canada.
3. Additional lap and shoulder belt system anchorages must comply with the requirements of F/CMVSS 210. 4. Lap and shoulder belt systems that are attached to seat frame or base may affect compliance of the seating system with the requirements of F/CMVSS 207.
SEAT SYSTEMS 1. For Incomplete Econoline Vans and Cutaways with a GVWR over 3855 kg [8500 lb] purchased with the front seat delete option, Ford strongly recommends following the practices specified in the compliance representations for F/CMVSS 208 that apply to Incomplete Econoline Vans with a GVWR of 3855 kg [8,500 lb] or less and completed units Unloaded Vehicle Weight of 2495 kg [5,500 lb] or less that are purchased without front seats. (Refer to page 33 of this manual for these compliance representations.)
5. Ford lap and shoulder belts, retractors and attaching hardware should not be altered or modified in any way. The reinstallation of these components should follow the instructions and specifications on page 35, or those in the appropriate Ford Truck Shop Manual. 6. Lap and shoulder belt assemblies should be compatible with the seat systems and anchorages so that lap belts will be properly positioned about the occupant’s pelvis to provide proper adjustment and fit. The buckle and buckle release are properly located with respect to the occupant and must comply with the requirements of F/CMVSS 208.
2. Any additional seats and seat anchorages installed by subsequent stage manufacturers must meet F/CMVSS 207 requirements and specifications.
7. Seat belt warning system activation/deactivation, where applicable, should be provided by the lap and shoulder belt assembly.
3. Do not modify or alter Ford furnished seating or occupant restraint system. When utilizing the Ford seat delete package, care must be taken to insure proper function of the seat adjuster latching mechanism, electrical wiring and seat belt buckle pretensioner. Refer to Bulletin Q-48 for wire routing. 4. If any seats or seat belts have been removed during manufacture, reinstall them in accordance with the instructions and specifications found in Figures on pages 35 and 36 for Econoline, or the applicable Ford Truck Shop Manual.
THE SEAT BELT BUCKLE PRETENSIONER, AIR BAGS AND ELECTRONIC SENSOR MODULE ARE BAR CODED WITH A UNIQUE SERIAL NUMBER WHICH IS MATCHED TO THE VEHICLE VIN. THE COMPLETED VEHICLE MUST CONTAIN THE SAME SEAT BELT BUCKLE PRETENSIONER, AIR BAGS AND ELECTRONIC SENSOR MODULE THAT WERE INSTALLED BY FORD MOTOR COMPANY IN THE INCOMPLETE VEHICLE.
5. Seating systems that include the attachment of lap belt or shoulder belt assemblies should also consider the requirements of F/CMVSS 210 as part of the seating system.
DESIGN RECOMMENDATIONS
64
OCCUPANT PROTECTION SYSTEM OCCUPANT PROTECTION ZONE AND OVERHEAD CONSOLE
console specifications that apply to Incomplete Econoline Vans with a GVWR of 3855 kg [8500 lb] or less and completed units have an Unloaded Vehicle Weight of 2495 kg [5500 lb] or less. (Refer to page 32 of this manual for these compliance representations.)
For vehicles completed with an Unloaded Vehicle Weight (UVW) greater than 2495 kg [5500 lb], Ford strongly recommends following the practices in the compliance representations for F/CMVSS 208 regarding overhead
FUEL SYSTEM INFORMATION The following recommendations are intended to assist in the design and completion of the fuel system capable of meeting the requirements of F/CMVSS 301. These recommendations are based on testing and analyses performed by Ford Motor Company. Since completed vehicles may take many forms, this list of recommendations can not cover all possibilities. Strict adherence to these suggestions will not ensure that the completed vehicle will comply with F/CMVSS 301. The responsibility for determining compliance to F/CMVSS 301 regulations is that of the final stage manufacturer. Accordingly, Ford Motor Company makes no representations as to the appropriateness of any particular recommendation in its specific application to a particular design or act of intermediate or final stage manufacture. To verify compliance with F/CMVSS 301, testing of representative vehicles to applicable F/CMVSS 301 procedures may be necessary. Questions regarding compliance with F/CMVSS regulations should be directed to your legal counsel, the National Highway Traffic Safety Administration or Transport Canada. WARNING: BEFORE OPENING THE FUEL SYSTEM ON VEHICLES WITH EFI ENGINES, RELIEVE FUEL PRESSURE BY FOLLOWING THE INSTRUCTIONS IN THE FORD TRUCK SHOP MANUAL FOR THE APPROPRIATE MODEL AND MODEL YEAR. WHEN WELDING NEAR FUEL SYSTEM COMPONENTS, ALL METALLIC COMPONENTS SHOULD BE ADEQUATELY SHIELDED AND PROTECTED FROM HEAT OR WELD SPLATTER. ALL NON-METALLIC COMPONENTS SHOULD BE REMOVED. REMOVAL OR REINSTALLATION OF ANY FORD FUEL SYSTEM COMPONENT SHOULD BE PERFORMED TO THE SPECIFICATIONS AND INSTRUCTIONS FOUND IN THE FORD TRUCK SHOP MANUAL FOR THE APPROPRIATE MODEL AND MODEL YEAR. (EXCEPT FOR ECONOLINE VAN AFT-OF-AXLE TANK INSTALLATIONS, SEE THE NOTE BELOW.)
A. NEW FUEL TANKS 1. The fuel tank should be designed with as few openings and connections as possible. Openings and connections generally should be located on the upper surface of the fuel tank. 2. Fuel tanks should be fitted with an evaporation control valve having the means to close if the vehicle is rotated about a longitudinal axis pursuant to F/CMVSS 301. See recommendation on page 68. 3. The tank should be of simple configuration minimizing sharp surface transitions and protrusions which may be required for attachment or function. 4. The tank should be strong enough to withstand, instantaneous internal pressure imposed in the event of crash situations. 5. Hoses connected to the tank should be sufficiently flexible to permit small movements of the tank relative to fixed mounting surfaces, without rupture or disconnection of such hoses in the event of crash situations. 6. Fuel tank and or fuel lines must not be connected “in series” (so that one tank supplies another). 7. Emission regulations may require an OBD II fuel tank pressure sensor for the evaporative system. Any new fuel tank must be tested and comply with all evaporative emission regulations. 8. Package new tank away from heat sources such as exhaust. B. NEW FUEL TANK RETENTION SYSTEMS 1. The retention system should attach the fuel tank to the frame, between the frame rails, and below the body of the vehicle with sufficient clearance for normal body to frame movement under loaded conditions. 2. A retention system should restrict fuel tank movement in all possible directions to prevent contact or rupture with rigid or sharp objects, and the disconnection of fuel system tubes and hoses under crash conditions. Retention straps should avoid sharp edges and tank supports should be designed with fuel tank compatible surfaces and edges to the fuel tank.
Any alteration or modification of a vehicle’s fuel or evaporative system may affect the vehicle’s compliance with applicable federal and/or state emission laws, including on-board diagnostics (OBDII) and evaporative emissions requirements and may also effect vehicle performance (driveability, idle quality, etc.). Vehicle modifiers are responsible for ensuring that a vehicle, as modified, complies with all applicable emissions regulations and for obtaining any necessary federal or state approval or certification relating to vehicle modification or sale of add-on or auxiliary parts. ECONOLINE VAN AFT-OF-AXLE FUEL TANK A Fuel System Modification Kit is available for some Econoline products for removing the midship fuel tank and adding an aft-of-axle fuel tank. For technical assistance, and which vehicles apply, contact the Ford Truck Body Builder Advisory Service. This kit is distributed for Ford Component Sales by: United Group Inc., 13800 Laurel Dr., Lake Forest, IL 60045. Phone: (847) 816-7100 or (800) 223-7003 FAX: (847) 816-7111
3. System fasteners and attachments should be designed to retain the tank during deflections incurred in crash situations. TEMPORARY 7.5 GALLON FUEL TANK Vehicles equipped with a 7.5 gallon temporary fuel tank (for transit shipping only) will require the subsequent stage manufacturer to dispose of this tank in an appropriate manner. The permanent aft-of-axle tank requires a 10 gallon minimum initial fuel fill to dilute the Ford provided anticorrosion solution in the tank.
65
DESIGN RECOMMENDATIONS
C. FUEL FILL SYSTEM ISOLATOR FILL NECK
1. Fill system should be sufficiently flexible to prevent possible rupture or disconnection resulting from movement of the fuel tank relative to frame during crash situations.
LINOLEUM/CARPET
BODY SIDE PANEL
2. Any appliance or hardware attachments to the body in the area of a fuel system component should be designed, positioned and secured so as not to impact any fuel system component during crash situations.
FLOORING
FUEL FILLER
3. The fuel filler opening area of the body should provide adequate sealing from the vehicle interior because holes or cracks in this area may allow fuel vapors to enter the vehicle interior. Openings should be sealed with a product which is fuel resistant. See Figure B on this page.
FRAME
FIGURE B - BODY MOUNTED FUEL FILLER OPENINGS 5. Fill openings should be recessed, and caps, when installed, should be inside the normal body plane.
4. The metal outer end of the fuel fill neck tube provided by Ford must be properly grounded to the chassis to dissipate any electrostatic charge that may be produced and so reduce the possibility of a spark during fueling. A fill neck support made of metal would provide a ground path if directly mounted on the chassis. If the filler neck support is made of plastic or other non-metallic material, a ground strap or wire must connect the metal end of the fuel filler neck and a metal chassis component.
6. Whenever possible, the fill system should pass under the body rather than through it. Where passing through floors and sides, the fill system should be shielded and have adequate clearance to surrounding structure. 7. Be sure that the fuel tank filler cap is the correct Ford designated part. Provide adequate hand clearance for cap installation and correct sealing of the cap to filler pipe.
AVOID “SINK TRAPS” IN THE FUEL FILLER HOSE
8. The recommended horizontal and vertical location for the fuel tank filler pipe is shown in Figures on pages 52, 53, and 54.
PROTECT FROM SHARP EDGE
9. When installing accessories or equipment, avoid exposure of fuel and vapor hoses to surfaces with sharp edges (see Figure A on this page), or to high temperature surfaces (near hot exhaust or coolant). Also avoid installations which result in the exposure of these lines to road debris or undercoating, except as specified in this manual. (See Figure B on page 70.)
SINK TRAP TRAPPED FUEL
10. Install or route fuel tank filler hoses and filler vent hoses as follows:
SINK TRAPS AVOID FUEL FILLER KINKED DUE TO IMPROPER ROUTING
AVOID FILLER VENT KINKED DUE TO IMPROPER ROUTING
ISOLATOR - FILL NECK
a. Avoid sags below the horizontal which allow fuel puddling (i.e., avoid sink traps) see Sink Traps in Figure A. Fuel trapped in low spots can be expelled when the cap is removed, even if the tank is nearly empty. b. Avoid pinches or kinks, as they restrict fuel filling or venting. Hose length may require adjusting depending on second unit body width. See Kinked Fuel Fill System, Figure A.
FRAME
c. Do not place adjacent hardware such that it may cut or otherwise damage the filler neck and vent hoses and cause fuel or vapor leakage (i.e. avoid unfriendly surfaces) see Hostile Surfaces, Figure A.
KINKED FUEL FILL SYSTEM
d. Keep the flow of fuel continuously downward from the inlet of the fuel filler pipe all the way to the tank.
AVOID JAGGED EDGE OPENING
e. The filler hose and vent hose must be clear of moving suspension components so as to prevent abrasion which can result in fuel leakage. They should maintain a minimum of 1 inch clearance to body and surrounding chassis components, except where the hoses and protective sleeve material pass through the designed frame opening.
FILLER VENT
FUEL FILLER
FRAME SPACER
f. Be certain that all clamps are secure and properly located.
FRAME
g. The fuel filler and filler vent hoses should not contain fittings or connections other than those incorporated in the original design, or should they be interconnected with each other in any way.
HOSTILE SURFACES
FIGURE A - FUEL FILL SYSTEM INSTALLATION CONDITIONS TO BE AVOIDED DESIGN RECOMMENDATIONS
h. Ford released parts should be used.
66
D. FUEL TUBES. HOSES AND PUMPS
12. Be certain that the vent valves on top of the fuel tanks are seated and secure; do not dislodge or damage them when mounting the second unit body. If they are unseated, fuel leakage may occur. If damaged, the vapor vent system may not function, resulting in increased fuel tank pressure.
1. Do not reroute or change the attachment of fuel lines or fuel vapor hoses. Doing so may alter the vehicle’s ability to comply with F/CMVSS 301 Fuel System Integrity, and may adversely affect vehicle performance by increasing the amount of heat absorbed by the fuel system or restricting its venting.
13. If a fuel sender is removed for any reason, use a new gasket when it is reinstalled so as to prevent fuel leaks. Be certain the fuel sender is seated and secure on the top of each fuel tank. Do not step upon or place weight upon the sender during vehicle manufacture. (See Figure C on page 52.)
2. Tubes and hoses should be routed away from and not attached to members that will move or deform during crash situations. 3. Tubes and hoses must be sufficiently flexible to avoid rupture or disconnection resulting from movement of the engine relative to the frame during crash situations.
14. Fuel filters installed in the fuel supply line must be of sufficient size to be non-restrictive to fuel flow and placed so as to be protected from exposure to exhaust heat and physical damage. Ford replacement fuel filters are recommended. Filters are not to be installed in the fuel return line.
4. Tubes and hoses should be routed away from hot regions and sharp objects, and should be retained adequately to prevent movement into such regions or against such objects. 5. Do not add fuel or vapor line flow restrictors as they can cause engine fuel starvation or abnormally high fuel tank pressures.
15. Temporary shipping fuel lines are not to be reused. They should be disposed of in an appropriate manner. 16. Fuel system components which are disconnected during manufacturing, should be capped or plugged promptly to prevent possible contamination.
6. Do not install auxiliary fuel pumps. This could cause the engine to run rich, producing additional exhaust heat. 7. If the push connectors on nylon fuel lines are disconnected, they must be reconnected as shown in Figure A page 46, and the retention clip must be discarded and replaced with a new clip as specified in Figure A.
E.
Precautions similar to those described in this Fuel System section should be taken in the design and positioning of a fuel system for auxiliary fuel powered equipment. The auxiliary fuel powered equipment should be securely mounted so as to withstand forces during crash situations.
8. The special removal tool shown in Figure B page 46, must be used to open push connectors installed on flexible fuel lines, if the lines need to be disconnected. The tool is available from Ford Customer Service Division.
Econoline Cutaway, Super Duty F-Series, and Basic (Stripped) Chassis aft-of-axle fuel tanks are equipped with an auxiliary fuel port in the fuel sender unit. The purpose is to provide a fuel supply for fuel powered accessories such as generator sets. Econoline Van vehicles may have an optional auxiliary fuel port which is located on the midship fuel tank sender unit.
9. The push connectors on flexible fuel lines, if disconnected, must be reconnected by snapping them back into position and installing the appropriate Retainer as shown in Figure B page 46. BODY SILL
FUEL SYSTEM ACCESS FOR AUXILIARY FUEL POWERED EQUIPMENT
Final stage manufacturers that utilize the auxiliary fuel port must install a check valve because of onboard fuel system diagnostics (OBDII). The system may affect the vehicle’s compliance with applicable federal and/or state emissions laws. Additional detailed information is available in Bulletin Q-42. To obtain a copy contact the Ford Truck Body Builder Advisory Service.
PINCHED HOSE
FUEL TANK
All auxiliary fuel ports have a safety cap which must remain in place until a fuel consuming accessory is installed. Econoline Van vehicles equipped with the auxiliary fuel port have a braided jumper hose which provides access without removing the fuel tank. A cap removal tool is provided on the jumper line immediately behind the cap and must be removed and reversed before it can be used to remove the cap.
FUEL VAPOR VENT LINES 10. Avoid pinching or kinking of any fuel vapor hose. (See figure above.) 11. Each of the fuel line and fuel vapor hose retention clips provided by Ford must be used in original factory locations to prevent misplacement or movement of the lines.
A push connector F7UA-9J274-AA, available from your local Ford dealer, will attach to the auxiliary fuel port and accept a 1/4 inch hose and clamp. Refer to the Statements of Conformity for F/CMVSS-301 requirements on pages 46-55, for push connector removal and installation, and auxiliary port locations.
67
DESIGN RECOMMENDATIONS
FUEL SYSTEM EVAPORATIVE EMISSIONS The following suggestions are intended to assist in the design of gasoline fuel vapor control systems capable of meeting Federal Evaporative Emissions Standards. All Ford vehicles are equipped with evaporative emission control systems which are certified to the applicable standards. If the subsequent stage manufacturer adds to or modifies the gasoline fuel system in any manner, it becomes the responsibility of the subsequent stage manufacturer to assure compliance with the applicable standards.
VSa =
The EPA requires that hoses for the vapor routing be at least as impermeable to hydrocarbon vapors as that which is used by Ford. Ford uses rubber hose per standard WSL-M96D33-A4. Typical Ford vapor lines for auxiliary tanks from a vapor valve at the top of the tank, to a short length of rubber hose, to 0.5 inch l.D. steel tubing, to another short length of rubber hose, and finally to a “Y” which connects to the standard tank vapor line.
The Environmental Protection Agency (EPA) has provided evaporative emission control system design upgrade requirements for federally regulated vehicles over 3855 kg [8,500 lb] GVWR weight classes in 40 CFR-86.088-35 (g)(2). The following requirements are applicable when adding fuel tank capacity beyond the maximum specified on the label: 1) upgrade the vapor storage capacity in accordance with the formula below, and 2) notify the EPA of the change. Note that California has unique evaporative emission regulations and adherence to the EPA upgrade requirements does not satisfy California certification requirements. Subsequent stage manufacturers performing fuel system modifications to California vehicles must certify the vehicle as modified, to California evaporative emission standards.
The EPA requires that additional vapor device(s) be installed in series with the existing system such that the existing storage device(s) are between the fuel tank(s) and the new storage device(s). The existing storage device(s) should be routed to the new storage device(s) such that the existing storage device(s) are no longer vented to the atmosphere. The elevation of the original storage device(s) should be equal to or lower than the new storage device(s). Ford suggests that the diameter of the hose used to connect the additional storage device be large enough so as not to restrict purge flow which cleans out the canisters (0.5-inch l.D. hose from an existing one canister system, and 0.625 inch l.D. hose from an existing two canister system in parallel).
A. EPA VAPOR STORAGE UPGRADE REQUIREMENTS The additional amount of fuel tank vapor storage material required can be determined according to the following formula:
[
VSa = VSi x T Volume f Max Volume i where: VSi =
T Volume f =
The minimum final additional vapor storage material required in grams. Additional vapor storage material can be purchased at a local Ford dealer using the Ford Service Part Number (2800ml-F75Z-9D653-A). Additional vapor storage material must have the same absorbent characteristics as that used by Ford Motor Company.
] – VSi
B. EPA NOTIFICATION OF EVAPORATIVE EMISSION CONTROL SYSTEM UPGRADE
Initial amount of vapor storage material in grams installed on the vehicle. The initial amount of vapor storage can be determined by examining the vehicle. For Super Duty F-Series, carbon canisters will be mounted in the engine compartment on the driver side. For E-Series, carbon canisters will be mounted inside the frame between the #3 and #4 crossmembers. Ford vehicles will be equipped with one or two cylindrical shaped canister(s).
A written statement that the system has been upgraded should be forwarded to the EPA. The body of the letter should indicate that the provisions of 40 CFR 86.085-35(g)(2)(i)-(iv) have been complied with. A brief description of the modification may also be included. The correct mailing address for the agency is: Director of Certification Office of Mobile Source Air Pollution Control U.S. Environmental Protection Agency 2565 Plymouth Rd. Ann Arbor, MI 48105
Final fuel tank capacity rating of the vehicle after the addition of the new fuel tank(s). This volume would be equal to the volume equipped with the vehicle plus the volume desired added.
IMPORTANT: Upgrading the evaporative emission system does not eliminate the necessity for compliance with the applicable safety requirements of FMVSS 301. A final stage manufacturer is responsible to certify the completed vehicle with any additional fuel tank(s) or any modification to the fuel system. The complete vehicle must conform to all applicable safety regulations.
Max Volume i = The Maximum fuel tank volume as specified on the VECI† label. The Super Duty F-Series label can be found in the engine compartment on the passenger side radiator support. The E-Series label can be found on the underside of the hood on the driver’s side.
C. E-250 – 124” BASIC (STRIPPED) CHASSIS RELOCATION OF RESERVOIR AND BRACKET ASSEMBLY
The Econoline Basic (Stripped) Chassis label can be found in the dunnage box and should be installed on the completed vehicle consistent with the guidelines on page 60.
See detail on page 89.
† Vehicle Emission Control Information.
DESIGN RECOMMENDATIONS
68
ELECTRICAL SYSTEM 9. Interior wiring not exposed to high temperatures may be SAE approved, general purpose wire.
Information in this section is supplementary to the Electrical Section of the Ford Truck Body Builders Layout Book, which includes detailed instructions, diagrams and system descriptions for general wiring, Electronic Engine Control (EEC) and adding electrical devices.
10. When adding auxiliary marker lamps on Super Duty F-Series Chassis Cab with dual rear wheels, tap in to the wiring connector provided on the left hand fender apron. This circuit is controlled by the headlamp switch through a relay to handle auxiliary marker lamp loads.
1. Selected Econoline and Super Duty F-Series vehicles are equipped with a number of conveniently located electrical wiring taps. These taps are fused, having locations under the instrument panel, in the engine compartment, behind the driver-seat and at the rear of the frame. Illustrations, schematics and half connectors (pigtails) for these taps will be provided in a cardboard box shipped with each vehicle. The connector, at the rear of the frame, is provided to support trailer wiring requirements or the Second Unit Body (SUB) additions.
11. Ground the second unit body to the frame in at least two locations, and if required, add an additional frame to engine ground cable to increase the ground path to the battery. 12. Splicing into circuitry relating to the electronic engine/ transmission control systems is not acceptable because of the adverse effect on the electronic system operation. 13. Batteries must be disconnected before welding to body and chassis components. Note that disconnecting the batteries will result in a memory loss on electronic engine/ transmission controlled vehicles. The vehicle will require several miles of driving in various driving modes to restore its memory and regain optimum operating conditions.
2. The Ford starting and the charging system should not be altered. 3. The completed vehicle total electrical load must not exceed the maximum output of the alternator. 4. Do not route or attach electrical wires to fuel lines.
14. Electrical connections exposed to the elements should be appropriately protected.
5. Engine compartment wiring must not be rerouted in any manner.
15. Do not ground the body to the transmission or transmission crossmember.
6. The electronic engine and transmission control modules require battery power to be supplied at all times so as to maintain the keep alive memory. Keep this in mind when installing load disconnect switches or solenoids.
16. Ignition circuit of any engine should not be altered. 17. Alternator circuit wiring must not be altered by cutting, soldering, or splicing. 18. Center High Mounted Stop Lamp (CHMSL) wiring taps are provided on Econoline Cutaway, Basic (Stripped) Chassis and Super Duty F-Series Chassis Cab vehicles. See the figure on page 22.
7. The 7.3L diesel engine requires two batteries wired in parallel for proper starting operation and must not be isolated.
19. Aero type headlamps are plastic and have protective coatings which can be damaged by solvents or tape. Refer to the Owner Guide for proper cleaning procedures.
8. Ford recommends that all additional under hood and underbody wiring: • be cross-linked polyethylene or equivalent high temperature insulation wire 125°C [257°F] minimum rating
20. For Super Duty F-Series (4) 14 ga. pass through circuits are located under the center of the I/P and on the LH fender apron. These circuits provide a means to interface with the engine compartment and frame wiring without drilling through the dash panel and installing a wire harness grommet to prevent water leaks.
• meet SAE specifications J1128 type SXL • meet SAE J1127 type SGX for battery cables • be protected with nylon convoluted tubing • be located so as to avoid or minimize restriction of airflow through the engine compartment, underbody and fuel system • be of sufficient length to be properly routed, so as not to interfere with operating zones of such components as throttle or transmission linkage • not be routed near the exhaust system or any other source of high heat; melted insulation can result in electrical shorts and system failure • be routed away from hostile surfaces and sharp edges and be secured in its intended location • be protected by rubber grommets when it passes through body or frame openings • be protected from electrical shorts by fuses or circuit breakers • be routed 38 mm [1.5 in] away from engine
69
DESIGN RECOMMENDATIONS
EXHAUST SYSTEM 6.
WARNING – VEHICLE OPERATING TEMPERATURES SOME TRUCKS OF FORD MOTOR COMPANY MAY EXHIBIT HIGH ENGINE COMPARTMENT AND EXHAUST SYSTEM TEMPERATURES IN CERTAIN OPERATING MODES. COMPONENTS, INCLUDING EXHAUST HEAT SHIELDING SYSTEMS, HAVE BEEN INSTALLED ON SOME VEHICLES IN OUR ASSEMBLY PLANTS IN AN EFFORT TO PROVIDE PROTECTION AGAINST SUCH TEMPERATURES. AFTERMARKET EQUIPMENT INSTALLERS, OR INTERMEDIATE AND FINAL STAGE MANUFACTURERS ARE RESPONSIBLE FOR PROVIDING THERMAL PROTECTION (e.g., UNDERBODY HEAT SHIELDS) FOR ANY STRUCTURE OR EQUIPMENT ADDED TO THE VEHICLE AND SHOULD NOT REMOVE ANY COMPONENTS OR EXHAUST HEAT SHIELDING INSTALLED ON THE VEHICLE BY FORD. 1.
2.
3.
4.
5.
7. 8.
Do not substitute exhaust system components or add to those furnished by Ford, except as noted below. Such a substitution or addition may adversely affect engine performance or emissions system effectiveness. Do not change the position or routing of the exhaust system components. Such a change may affect the amount of heat transferred to body, chassis or powertrain components, particularly fuel system components. Specifically, do not add dual exhausts or reroute exhaust components to the left side of the vehicle. Do not remove or modify the existing shields. Ford underbody heat shields are installed on vehicles to provide heat protection for the vehicle floor and body mounting system, and must remain in place on the completed vehicle. (See Figure A on this page). Exhaust heat shields should be added by a body builder, and should extend far enough beyond the exhaust system components to protect underbody surfaces from heat radiated at any angle. Add shields over the muffler and exhaust pipe kick-up areas. Do not remove Ford furnished exhaust clamps and hangers. Verify that they are secure.
An additional exhaust hanger should be installed, if appropriate, to support extended tailpipe length necessitated by body dimensions. Do not make a rigid connection of the exhaust system to the body. Do not apply body undercoating on the fuel tank, fuel fill hose and fuel fill vent hoses. The extra insulation on these components may cause excessive heat build-up and/or possible material incompatibility concerns. (See Figure B on this page)
FIGURE B 9.
10.
11.
12. 13.
DO NOT APPLY UNDERCOATING IN SHADED AREA
Do not apply body undercoating within twelve inches of the area directly above the exhaust, on any components within twelve inches of the exhaust, or to any part of any exhaust system. Undercoating will smoke or burn if subjected to high heat. (See Figure B) Extensions to the exhaust outlet pipe should direct exhaust away from the body to minimize the possibility of fumes entering the vehicle. Extensions should also protrude beyond the vertical body surface. Install all underbody plumbing for heaters, air conditioners, and other accessories so that they are not installed against sharp surfaces or jagged edges. Protect from exhaust heat when routing. Use only stainless steel for any exhaust system modifications or additions. Exhaust system revisions should consider thermal expansion of materials and the affect on design clearances.
SHIELD CONFIGURATION MAY VARY WITH VEHICLE TYPE OR ENGINE SELECTION FIGURE A - UNDERBODY MOUNTED HEAT SHIELDS FOR VANS DESIGN RECOMMENDATIONS
70
COOLING SYSTEM 1. Equipment such as flashing lights and sirens, spare tires, or any other accessories should not be installed in the grille area forward of the radiator or air cleaner air inlet. Doing so restricts proper air flow through the radiator and engine compartments. Econoline and Super Duty F-Series are illustrated in the figure below.
6. The radiator and fan shroud should not be used as structural members and additional components should not be attached.
2. For proper engine cooling, do not alter, change the locations of, or remove the original equipment fan, fan clutch and shroud. 3. Maintain a 50/50, OAT antifreeze only, to water ratio when adding or modifying the heater system or auxiliary heater system. A 60/40 antifreeze to water ratio may be necessary during winter months in very cold climates. For the remainder of the year, however, a 50/50 ratio should be maintained. If ethylene glycol is used for more than 50 miles or 1 hour of engine operation, a slight degradation of cooling performance may occur due to a chemical reaction. OAT coolant is preferred for top cooling performance.
7.
Revisions to the Front End Accessory Drive System may affect the cooling system/component performance and are not recommended.
8.
Do not alter or modify the automatic transmission water bypass system.
9.
The minimum radiator grille opening (excluding all grille parts) for the Econoline Basic (Stripped) Chassis to provide optimum cooling for the engine is: • Commercial Basic (Stripped) Chassis 300 square inches.
10. Equipment, hazardous materials markers or placards must not obstruct the airflow to the radiator or the air cleaner inlet on the Basic (Stripped) Chassis. 11. The Basic (Stripped) Chassis engine compartment must be designed to eliminate any air circulation restriction that would affect the air induction or cooling systems. An engine compartment must provide adequate flow through ventilation to prevent local air temperature from exceeding recommended maximums.
4. Use worm gear drive clamps only. 5. Upper radiator hoses and heater hoses which are added or replaced should be EPDM - Kevlar composition. Lower radiator hoses should be EPDM - Rayon composition.
ACCESSORIES SHOULD NOT BLOCK AIRFLOW IN SHADED AREAS
KEEP THIS AREA CLEAR
ECONOLINE
ENGINE COOLING RADIATOR AIR CONDITONER CONDENSER
SUPER DUTY F-SERIES
FIGURE A - FRONTAL AREA REQUIRING UNRESTRICTED AIRFLOW
71
DESIGN RECOMMENDATIONS
CLIMATE CONTROL SYSTEM The Final Stage Manufacturer must attach a label (next to Ford’s A/C Tag on the vehicle) showing the amount of PAG Oil and R-134a Refrigerant that has been added.
1. An Auxiliary Heater A/C Connector Package can be either standard or optional on Econoline vehicles for connecting auxiliary climate control systems to the Ford system. The following items are important for the maximum efficiency of the combined systems:
5. The A/C compressor will cycle during the defrost mode. A refrigerant shutoff valve for the auxiliary system may impair compressor lubrication.
• The connector tubes are under the floor directly below the driver seat.
6. R134-A charged A/C systems should use barrier type A/C hose. Barbed fittings and external clamping may not be compatible with this type of hose. Swaged, permanent fittings on this type of hose are recommended.
• The heater supply tube is identified with a white paint dot and should be connected to the lowest connection port on the auxiliary heater core. • The A/C connector tubes have a 20 X 1 .5-6g metric thread for high pressure and 24 X 2.0-6g metric thread for low pressure.
7. Use only worm gear drive clamps on heater hose.
• If the vehicle is equipped with the auxiliary heater-air conditioner, do not operate the front A/C system prior to the addition of an auxiliary system. The system oil could settle in the connector tubes and not provide lubrication to the compressor. See Bulletin Q-47. To obtain a copy contact the Truck Body Builder Advisory Service.
9. Auxiliary heater and air conditioning systems hose routings must consider the following:
8. NEVER ATTACH ANY COMPONENT TO THE TRANSMISSION FILLER AND DIPSTICK TUBE.
• Dynamic engine roll or any system component which has an operating zone. Make sure there is adequate clearance. (e.g., transmission downshift linkage, steering column shift linkage.)
• The Ford provided auxiliary blower switch requires electric relay for high speed blower operation. Additional detailed information is available in Bulletin Q-19. To obtain a copy contact the Truck Body Builder Advisory Service.
• Do not route heater or A/C hoses directly over or near the exhaust system. • Do not route hoses by attaching to the engine.
2. R134-A charged A/C systems must use PAG type lubricating oil YN-12-B Ford part number F2AZ-19577-C. Always use the same refrigerant and lubricating oil as originally equipped by Ford.
• Use only metallic Y and T type fittings. • Do not route hose in wheelhouse area. • No routing by sharp edges or moving component parts. There must be shield protection from any potential abrasive source.
3. Maintain a 4% suspended oil ratio in the A/C system for proper compressor lubrication.
• When routing in stone kickup area, lines should be protected by shields. Minimize use of concentric protective heater hose shields. Limit length of concentric hose shields to 12 inch maximum.
4. Econoline A/C and Refrigerant Oil System are classified into the following (3) types: A/C System
R-134a, lbs.
PAG Oil, oz.
1. Front Only (a)
2.75
9(a)
2. Front w/Prep. Unit
2.75
13
3. Front & Aux. Unit
4.0
13
Notes: (a) Must add 1-oz Oil for each 4-oz of R-134a above Ford’s charge.
DESIGN RECOMMENDATIONS
72
FORD BODY COMPONENTS 1. Modifications to doors, roof or body side panels may have an effect on F/CMVSS 208, 210, 212, 214, 219 and 301 compliance. Refer to the Statements of Conformity section of this manual for compliance representations.
8. Fasteners added to the floor should not point at the fuel tank or should have an appropriate shield. Components with sharp edges should have an appropriate shield to eliminate the possibility of fuel tank penetrations in crash situations.
2. Running boards or entry steps should use a mounting system that will attach only to the body. The Ford body to frame isolators allow body movement which may loosen fasteners. A combined frame and body mounting system may cause frame Noise, Vibration and Harshness (NVH) transfer through such a mounting system into the body.
9. Components added to the Econoline engine cover should allow for easy removal. Refer to the Statements of Conformity, Figure A page 38, for Occupant Protection Zone requirements for the engine cover and other affected areas.
3. Protect trimmed or modified body sheet metal from corrosion by using Butyl Sealer C9AZ-19554-B or equivalent.
10. The Econoline engine cover seal requires that carpeting and insulation should be installed as shown in the figure below.
4. Temporary mounting pads may eliminate chipping and scratches when accessories are installed.
11. Power operated windows, a partition, or roof panel systems when added to a vehicle with a GVWR of 4536 kg [10,000 lb] or less must comply with the requirements of F/CMVSS 118. Refer to the Statements of Conformity page 26.
5. Select materials which will not have a corrosive action with each other. 6. Additional fresh air vents should be located so that engine exhaust can not be inducted into the vehicle.
12. When a second unit body (SUB) or rear closure panel is attached directly to the cutaway body, difficulty may be experienced when closing doors due to air pressure build up. It is recommended that vent(s) be installed which will allow “ONE WAY” pressure release from the inside of the cab to the outside. Recommended minimum size of the venting is 36 square inches.
7. When adding holes to the floor of the vehicle, consideration must be given to all components below the floor. The use of drill stops is recommended. A pattern for a floor template, which will locate the Econoline van fuel tank, is available from the Ford Truck Body Builder Advisory Service.
ENGINE COVER
ENGINECOVER INSULATION
SEAL (RUBBER) CARPET FLOOR PAN
TYPICAL SECTION CARPETING INSTALLATION AT ENGINE COVER
INSULATION [ ] DIMENSION ARE IN INCHES
FIGURE A - ECONOLINE ENGINE COVER SEAL
73
DESIGN RECOMMENDATIONS
SUSPENSION AND STEERING SYSTEM NOTICE — VEHICLE HANDLING INFORMATION
3. The steering gear, intermediate shaft, coupling shaft, linkage, column, and steering wheel should not be altered or relocated. Steering linkage travel should not be restricted.
The weight of the body structure and its center of gravity location (both longitudinally and vertically), as well as the weight and positioning of the cargo load are important to the handling of the completed vehicle. Subsequent stage manufacturers should note that matching a body to a chassis in a manner appropriate for the intended use of the vehicle is the responsibility of the final stage manufacturer. Following the representations of this manual with respect to center of gravity locations and body weights for compliance with Federal or Canada Motor Vehicle Safety Standards is only part of the task of producing a completed vehicle that handles appropriately in service.
4. Ford front and rear GAWRs and GVWR, must not be exceeded. 5. Front or rear suspension components should not be drilled, cut, welded or relocated for any reason. 6. Welding to the frame in the steering gear area is not recommended. 7. If rear suspension spacers are used between the spring and axle seats to accommodate side to side variations, they should not exceed 0.375 inch. The spacers should not exceed the profile of the axle spring seat. Additional spacing may adversely affect driveline angles and axle system package clearances. Also, spring stress limits may be affected by excess jounce travel.
The final stage manufacturer is responsible for verifying that the front wheel toe is within Ford Specifications on completed vehicles. The steering wheel clear vision (horizontal or level orientation of the steering wheel) should also be maintained when resetting wheel toe. These specifications are found in the general suspension section of the Ford Shop Manual. 1.
8. Do not use any suspension component as a welding ground. 9. When welding or cutting near suspension components, shield and protect all springs and rubber components from heat penetration and welding splatter.
The front end alignment warranty policy for incomplete vehicles is based on the completed vehicle remaining within the OEM weight ratings, vehicle attitude, suspension and wheel/tire guidelines and other characteristics affecting wheel alignments. Exceeding or modifying these restrictions may jeopardize the related warranty.
10. Any add-on device mounted on the steering column, shroud, multifunction switch or gear selector lever, must not affect steering column angles, tilt mechanism (if so equipped), range of operation or steering column mounting hardware. Any such device must not interfere with steering column collapse and/or stroke travel during crash situations.
2. Modifications made by subsequent stage manufacturers, particularly those that significantly affect vehicle ride heights, may cause vehicle control problems during excessively sharp turns or other abrupt steering maneuvers, possibly leading to rollover or other accidents that could result in serious injury.
WHEELS AND TIRES 1. Use only wheels with the same load capacity, rim width, rim offset, and mounting configuration as those originally installed on the vehicle. Consult an authorized Ford Dealer for correct wheel load capacity, size and usage. Wheels used must comply with F/CMVSS 120. Use of any other size or type wheel or tire other than those originally installed on the vehicle as manufactured by Ford may adversely affect load carrying capacity, handling, bearing life, ride, braking performance, speedometer/odometer accuracy, automatic transmission (4R100 or 4R70W) shift timing, and tire/wheel clearance of the body and chassis.
WARNING: SOME AFTER MARKET WHEEL ASSEMBLIES MAY NOT BE COMPATIBLE WITH SOME VEHICLES AND SHOULD NOT BE USED. USE OF INCOMPATIBLE WHEEL ASSEMBLIES MAY RESULT IN WHEEL FRACTURES, SEPARATION, WITH THE POTENTIAL FOR AN ACCIDENT AND INJURY TO OCCUPANTS. FORD RECOMMENDS THAT ONLY WHEEL ASSEMBLIES APPROVED AND RELEASED BY FORD MOTOR COMPANY FOR THE VEHICLE MODEL SHOULD BE USED.
2. Use only tires with the equivalent load carrying capacity as those originally installed on the vehicle. Use only tires of a type and size that are recommended by the vehicle manufacturer and are compatible with the wheel installed on the vehicle. Do not over/under-inflate tires, always maintain proper tire pressure. Never mix radial, bias-belted, or conventional bias type tires and avoid mixing P-metric tires with alpha numeric tires whenever possible. Consult an authorized Ford Dealer for correct tire load capacity, type, size, and inflation pressure for the vehicle. Tires used must conform to FMVSS 109 (passenger car type tires) or FMVSS 119 (non-passenger car type tires) in the United States or to the Motor Vehicle Tire Safety Regulations in Canada.
WARNING: RETORQUE ALL LUG NUTS TO SPECIFICATION. IT IS IMPERATIVE THAT THE DEALER RETORQUE ALL WHEEL LUG NUTS ON ALL VEHICLES PRIOR TO DELIVERY TO THE FINAL VEHICLE PURCHASER. DUAL REAR VEHICLES MAY BE SHIPPED WITH THE OUTER REAR WHEELS REMOVED AND, THEREFORE, THE DEALER MUST ASSURE THAT THE LUG NUTS ARE RETORQUED TO THE PROPER SPECIFICATION BEFORE THE VEHICLE IS DELIVERED TO THE FINAL VEHICLE PURCHASER. IMPROPERLY TIGHTENED LUG NUTS COULD LOOSEN AND ALLOW THE WHEEL TO COME OFF WHILE THE VEHICLE IS IN MOTION CAUSING LOSS OF CONTROL.
DESIGN RECOMMENDATIONS
74
WHEELS AND TIRES 1. If you loosen or remove wheel lug nuts for any reason, or have in your possession a vehicle at any of the mileage intervals listed in the Wheel Lug Nut Table below, check the lug nut torque and if required, re-torque to the specifications as listed in the following table.
VEHICLE TYPE
WHEEL LUG NUT TABLE WHEEL LUG MILEAGE NUT TORQUE
ECONOLINE E-150 E-250 E-350 Single rear wheel E-350, E-Super Duty Dual rear wheel F-250, F-350 Single rear wheel F-350, F-450 & F-550 Dual rear wheels
KM 800
MILES 500
Nm 135
Ft/Lb 100
800
500
190
140
160 800
100 500
190
140
800
500
200
147
160 800
100 500
200
147
FRAME 5. Do not modify or alter the convoluted frame sections in the area behind the front bumper. Modifications or alterations could have an adverse affect on vehicle performance in a crash situation.
1. Holes that would weaken the frame sidemember should not be drilled in the frame. Holes are not to be drilled in the sidemember’s top or bottom flange. 2. Holes to mount brackets, out-riggers and supports, may be drilled in the vertical frame side rail web with the following restrictions:
6. No wheelbase alterations are approved on any Super Duty F-Series vehicles. 7. A wheelbase alteration and frame extension for Econoline Cutaway Super Duty Bulletin Q-18 is available with detailed guidelines from the Ford Body Builder Advisory Service. Any deviation from the original vehicle specification will become the responsibility of the subsequent stage manufacturer or installer. This may affect transmission operation and durability.
• Material between edge of hole and inside of upper or lower flange must not be less than 1.50 inch for low carbon steel (36,000 P.S.I. yield). • The minimum edge distance between any two holes up to 0.625 inch diameter must be 1.00 inch. For larger than 0.625 inch diameter holes, the minimum edge distance must be 1.5 times the diameter of the largest hole.
8. Recommend the use of OEM front tow hooks only. See Ford Towing Manual FCS-12141-99 for towing instructions.
• No holes will be allowed to exceed 0.75 inch in diameter. • Avoid close vertical succession of fasteners.
9. To prevent collapse of the frame side rail flanges, when U-bolts are used for the attachment of bodies to the truck chassis, vertical spacer bars must be used between the upper and lower flanges at each U-bolt.
• All attaching fasteners, including flat washers, must be of high strength steel (Grade 8). 3. When welding is performed anywhere on the vehicle, precautionary measures should be taken to prevent damage to electrical system wiring or components. Prior to welding, any parts which could be damaged by excessive temperatures should be removed or adequately shielded. Also prior to welding, disconnect both batteries and battery cables, then the ABS module, then the PCM. The welding ground clamp should be positioned as close to the affected welding area as possible. Computer processors should be removed if welding is to be done within their close proximity. Welding cables should never be allowed to lay on, near, or across any electrical wiring or electronic component during welding. After welding, when parts are cool, carefully inspect wiring and electrical components for shorts or other damage which could draw excessive currents and possibly cause an electrical system short when the battery is reconnected.
10. On unitized body vehicles, bottom sides of structural members must not be drilled. 11. The Super Duty F-Series 200.8 inch WB Chassis Cab modifications should consider the following: • The “L” reinforcement on each frame sidemember is 7.1 mm [0.28 inch] thick and will increase the frame width from the back of the cab to the rear spring-front bracket. • DO NOT WELD ON THE FRAME REINFORCEMENT. Use compression type fasteners when attaching any component to the frame in the reinforcement area. 12. The Incomplete Econoline Cutaway Super Duty requires the removal of the L. H. Rear Shock Absorber Gusset when access to the fuel, brake lines or electrical harness may be required.
4. When welding low carbon steel side rails (36,000 P.S.I. yield strength), emphasis should be placed upon weld application techniques to avoid stress risers that may adversely affect frame operating stresses. When welding within 4 inches of any crossmember rivet, remove the rivets and replace with grade 8 bolt/nuts.
13. The Incomplete Econoline Cutaway Super Duty 176-inch WB vehicles equipped with a 55-gallon fuel tank will require an 18-inch minimum frame extension to provide for an adequate departure angle.
75
DESIGN RECOMMENDATIONS
ENGINE 1. Refer to the Emission Certification Information section in this manual on pages 59 to 62 prior to making modifications to any engine component that could affect the emission certification.
7. When the 7.3L DI Turbo Diesel Engine requires an extended high idle device (throttle kicker), idle RPM should be through a Ford Standard Corporate Protocol serial data communication link or with a Ford approved device. Do not tap into the electrical circuits attached to the Pedal Position Sensor (PPS) or the Idle Position Switch (IPS) on the accelerator control. Do not bypass the electrical circuits attached to the PPS or IPS. See figure on page 27 for component identification.
2. Gasoline engine conversion guidelines for Liquified Petroleum Gas (LPG) or Compressed Natural Gas (CNG) are in the Ford Truck Body Builder Layout Book. 3. The engine should not be operated with the hood up or removed. This may allow excessive unforced air to circulate that could adversely affect the cooling system.
8. Installation of any gasoline engine speed governor is permissible provided the governor design is compatible with each respective throttle body for the individual engine application and it does not exceed specified engine maximum RPM. It must also meet all noise and engine emission requirements. Governor installations may affect electronically controlled transmissions. Contact Ford Body Builder Advisory Service before installing.
4. Adding aftermarket Turbocharging or Supercharging may void the powertrain warranty and may void other related component warranties. 5. Do not use manual throttle kickers. 6. When using electric throttle kickers on gasoline engines, set the high idle RPM as low as possible to obtain required performance. (Refer to Super Duty F-Series Body Builder’s Book for Minimum and Maximum idle RPM recommendations). The idle speed must be set when the engine is at normal operating temperature and under normal load; this RPM setting should be affixed to the vehicle; and should be checked after the 2000 mile breakin engine tune up.
POWER TAKE-OFF CIRCUIT A wire located under the instrument panel labeled “Power Take-Off Circuit” is provided to minimize the inadvertent illumination of the “Service Engine Soon” while the PTO is engaged. See Figure A, Page 77 of this manual for circuit location. Connect the wire to the Power Take-Off Circuit as instructed in the Ford Body Builders Book and isolate the wire labeled “Power Take-Off Circuit” from the solenoid to prevent damage to the Power Control Module (PCM).
TRANSMISSION 7. Vacuum throttle control line must not be bent, kinked, or restricted. NOTE: Vacuum operated accessories must have a separate engine vacuum source. Vacuum measurement must be within engine specifications.
1. The transmission oil filler tube and dipstick must not be altered by bending, lengthening, or shortening, and must be readily accessible in the engine compartment for checking lubricant level. NEVER ATTACH ANY COMPONENT TO THE TRANSMISSION FILLER AND DIPSTICK TUBE.
8. Transmission service identification tags must not be removed or destroyed. If the transmission is reworked or replaced, tag should be attached to new transmission.
2. The installed engine angle must not be altered. The relative position of engine and transmission to shift linkage must not be altered.
9. Electronically controlled automatic transmission wire harness routing location, wire harness locating clips, all heat shielding, and clearance to the exhaust must be maintained as installed from the assembly plant.
3. Transmission vent must not be altered, pinched, collapsed, or the vent opening must not be restricted or relocated.
10. The manual transmission filler plug should not be obstructed, preventing easy checking of lube level or filling.
4. Adequate tool clearance and suitable access openings for transmission adjustments must be provided. Transmission removal provisions must also be considered.
11. Body structures should not be less than 1.00 inch from the rectangular vent holes on the top surface of the manual transmission housing.
5. Transmission oil cooler lines should not be kinked, bent, or restricted. All oil cooler lines must be properly retained with adequate clips. The truck-type external oil cooler must not be “boxed in” so as to prevent adequate air circulation. Use only with Ford factory coolers.
12. Bulletins Q-14 and Q-18 contain additional detailed information on modifications which may affect transmissions. To obtain a copy, contact the Ford Truck Body Builder Advisory Service on 1-800-635-5560.
6. Transmission shift cable, transmission outer shift lever and shift cable bracket must not be altered and must have provisions for adjusting tool clearance. A severe duty (booted) shift cable is available as a service part from Ford Dealers for Super Duty F-Series vehicles which experience extensive off-road use.
DESIGN RECOMMENDATIONS
76
POWER TAKE-OFF INSTALLATIONS allowed with 4R100 transmission). Driveline Modification Bulletin Q-14 is available from the Ford Truck Body Builder Advisory Service for your reference.
1. The F250/350/450/550 ZF 5-Speed and 6-Speed heavy duty manual overdrive transmissions as well as the 4R100 automatic overdrive transmission will accommodate a direct mount gear driven PTO. (Note: The 4R100 PTO provision is an option available with 6.8L and 7.3L engine applications only.
5. Consider the potential effect on engine compartment and underbody temperatures with the operation of the PTO systems utilizing high idle duty cycles. Refer to the Engine Design Recommendations #3 and #6 on Page 76.
2. Gear driven PTO systems should consider RPM and power requirements of the system, along with driveline operating angles, operating clearances and PTO engagement systems.
6. A wire located under the instrument panel labeled “Power Take-Off Circuit” is provided to minimize the inadvertent illumination of the “Service Engine Soon” light while the PTO is engaged. (See Figure A below for circuit location). This circuit must be completed by the Body Builder in accordance with guidelines referenced in the Super Duty F-Series Body Builders Layout Book to prevent possible damage to Power Control Module (PCM).
3. Belt driven PTO systems are allowed on 7.3L applications. Adaption of these systems on 5.4L/6.8L applications require the purchase of an auxiliary crankshaft bearing support bracket. These installations should not interrupt the Ford front end accessory drive system and should consider clearance for engine roll and component movement during normal operation. A separate drive belt, direct from the engine crankshaft pulley, should be considered where possible for these type of systems.
7. Contact the Ford Truck Body Builder Advisory Service (1-800-635-5560) or advice on stationary vehicle power takeoff applications. 8. Additional information is available in the Truck Power Takeoff Data section of the Ford Truck Body Builders Layout Book.
4. Split driveshaft PTO systems should consider the affect on the vehicle driveline. (Note: These systems are not
IMPORTANT: The manufacturer of the PTO system and the installer are responsible for any effects that the system has on the vehicle or the operation of the vehicle
POWER TAKE-OFF CIRCUIT
FIGURE A - POWER TAKE-OFF CIRCUIT LOCATION
DRIVELINE 1. Bulletin Q-14, “Guidelines for Modifying Light Truck Drivelines,” is available from the Ford Truck Body Builder Advisory Service. Any deviation from Ford specifications may adversely affect powertrain system operation including engine and transmission, or component reliability. Subsequent stage manufacturers, or installers, are responsible to maintain Ford specifications in the completion of such modifications. Bulletin Q-14 can assist the subsequent stage manufacturers with this responsibility.
2. Rear axle vent and hose, if installed, must not be bent, pinched, or obstructed so that normal “breathing” of the rear axle is provided. 3. On all rear axle assemblies, additional bracket bars or supports must not be welded to the axle assembly. Attachment of any equalizing-type trailer hitch or auxiliary suspension systems (springs) must not be attached to the rear axle assembly.
77
DESIGN RECOMMENDATIONS
SECOND UNIT BODY ATTACHMENT INFORMATION
UNDERBODY HEAT MANAGEMENT
The following recommendations are intended to assist in the design of second unit bodies and body mounting systems that will control second unit body movement with respect to the Ford supplied chassis when tested to the procedures specified in F/CMVSS 204, 208, 212, 219 and 301. These recommendations are based on testing and analyses performed by Ford Motor Company.
1. Underbody longitudinal or lateral air movement should not be restricted. Frame spacers designed by the intermediate and final stage manufacturer should provide for adequate airflow over the frame. 2. No portion of the floor pan should drop below the body sills, nor should the underbody structure drop below the top surfaces of the number 3 and 4 crossmembers. These conditions can result in reduced airflow, pinched fuel lines or vapor hoses which can raise the temperature of underbody components and increase fuel system pressure.
Second Unit Bodies (SUB) and their body mounting systems may take many forms, and the following recommendations cannot cover all the possibilities. Strict adherence to these recommendations will not assure that the completed vehicle will comply with F/CMVSS 204, 208, 212, 219, and 301. The final stage manufacturer who installs a second unit body on the chassis is responsible for compliance to the above mentioned regulations. Accordingly, Ford Motor Company cannot represent that these recommendations are appropriate for every specific application of a second unit body, the body mounting system or act of a subsequent stage manufacturer.
3. Any interior floor underlayment or insulation in the near vicinity of the exhaust system, without benefit of the Ford provided heat shields, must be capable of withstanding 371°C [700°F] (and 482°C [900°F] in close proximity to the catalyst) during normal operating conditions. Additionally, any under chassis mounted components within 101.6 mm [4.00 inches] of the exhaust system must be compatible with these temperatures.
To verify compliance of a particular second unit body and selected body mounting system with F/CMVSS 204, 208, 212, 219, and 301, the testing of a representative vehicle to the applicable procedures of the above regulations is recommended. Questions regarding compliance with F/CMVSS regulations should be directed to your legal counsel, the National Highway Traffic Safety Administration or Transport Canada.
The subsequent stage manufacturer should also consider the following situations, which may adversely affect heat management. • Poor vehicle service or lack of maintenance • Deviation from a 50/50 ethylene glycol based antifreeze (coolant) to water ratio • Exceeding Ford GVW and GCW ratings • Malfunctioning systems such as exhaust or engine
SECOND UNIT BODY STRUCTURES
• Altering, changing, removing Ford engine fan and shroud
The structural design and materials used in the construction of second unit bodies must be sufficient to help control collapse of the body and prevent disengagement from the chassis when tested in accordance with the specifications of F/CMVSS 204, 208, 212, 219 and 301. Steel or aluminum structures are recommended, however, wood or composite materials may require additional reinforcements to provide the structural integrity required for actual crash testing. SUB structures should not extend beyond (overhang) the end of the chassis (frame sidemembers).
• Blocked radiator grille area (spare tire, bicycles, etc.) • Use of throttle kickers 4. Second Unit Body exterior panels, tool boxes, running boards, structures or skirting that extend below the bottom of the frame, may affect underbody temperatures. The final stage manufacturer should verify that underbody temperatures of the completed vehicle are compatible with all vehicle’s components when under conditions that consider the projected vehicle duty cycle and vehicle loading. 5. Full-width mudflaps should not be installed, as they restrict airflow under the vehicle and can also increase underbody temperatures.
SECOND UNIT BODY FUEL SYSTEM COMPONENTS SUB floor and bulkhead structures must accommodate the Ford fuel fill system and suggested design clearances. Fill neck locations and all F/CMVSS 301 compliance representations are in the Statements of Conformity section of this manual, see pages 46-55, and refer to the Design Recommendations on pages 65-68 for additional detailed information.
6. Added structure or equipment should not restrict air circulation in the engine compartment/underbody. 7. Added body vents, especially powered vents, should be located away from the fuel filler and venting areas and exhaust to avoid fuel fumes and vapors entering the interior of the vehicle.
SECOND UNIT BODY ELECTRICAL
8. Use of wood in construction should be eliminated where at all possible. If used, wood should be adequately protected from moisture and heat. Shields should be added if wood is installed near exhaust components.
Some electrical power sources are identified in the Design Recommendations, Electrical System section of this manual on page 69, and the F/CMVSS 108 compliance representations are on pages 22-24 of this manual. Additional information is available in the Ford Truck Body Builders Layout Book.
DESIGN RECOMMENDATIONS
78
ECONOLINE CUTAWAY SUB MOUNTING SYSTEM
The attachment of the SUB to the Cutaway body should consider the following:
Ford provides optional SUB mounting spacers which will isolate the SUB from the frame. The SUB should be attached to these spacers using all the provided holes in the spacer with a suggested minimum 7/16-14 UNC grade 8 fastener. These fasteners should be directed away from any fuel system component or should not extend 25.4 mm [1.00 in] below the spacer flange. The location of these spacers are shown in the Ford Truck Body Builders Layout Book. The rubber isolators on the spacers are capable of 19.0 mm [0.75 in] movement in spherical zone from a static (design) position, which is the same for the isolators that mount the Cutaway body to frame. A similar isolator system for the SUB, as used on the Cutaway body is recommended. This will minimize squeaks, raffles, and water or air leaks at the mounting surface of the SUB, to Cutaway body. The Ford optional spacers will accommodate the recommended fuel fill neck installation as shown in Figure C page 52, and a recommended 101.6 mm [4 in] minimum clearance between the frame and the bottom of the SUB (except at the rear axle kick-up area).
1. Blind installation of self expanding nut type fasteners can be located in the zone as defined in the figure, on this page, and should allow for functional expansion, and be equally spaced. The body edge flange may also be used for fasteners provided the center of the required hole is 1.5 times the hole diameter from the edge of the panel. These recommendations apply to both B-pillar attachment. 2. Removal of the access panel and fasteners at the lower area of the B-pillar will allow for flush mounting of the SUB. This opening should be completely covered and sealed from obvious climatic conditions. 3. Roof attachments should be equally spaced and are permitted on the flange provided. The center of the required holes should be 1.5 times the hole diameter from the edge of the flange. 4. Floor attachments should be equally spaced and are permitted on the flange provided. The center of the required holes should be 1.5 times the hole diameter from the edge of the panel.
Vehicles not equipped with the Ford optional spacers, have 34.8 mm [1.37 in] diameter holes on the upper flange of the frame sidemembers for body to frame isolators. The density/ durometer, size, and quantity of these isolators should be based on the SUB weight plus the projected payload of the completed vehicle, within the limits of the GAWRs and GVWR, as determined by the final stage manufacturer.
5. Washers or doublers should be considered to increase bearing surface under a fastener, decrease sheet metal fatigue, squeaks, rattles, and increase joint integrity. 6. Gaskets or sealers installed between the Cutaway body and the SUB should consider the displacement and stabilization of such materials when clamped, and the affect on joint integrity.
Econoline Cutaway Super Duty vehicles have a transmission mounted parking brake. SUB structures should clear this component by 25.4 mm [1.00 in] minimum.
Second unit body mounting components not provided by Ford must be installed on the frame in areas as shown on page 87 of this manual. Additional information is available in the Ford Truck Body Builders Layout Book.
[176-in] WB vehicles equipped with a 55-gallon fuel tank will require an 457 mm [18-in] minimum frame extension to provide for an adequate departure angle.
Second Unit Body Attachment Continued Next Page
BLIND FASTENERS INSTALLATION ZONE
50.0 [1.97]
ACCESS PANELS FRONT OF VEHICLE
45.0 [1.77]
10.0 [.40] [ ] DIMENSION ARE IN INCHES
FIGURE A - ECONOLINE CUTAWAY BODY TO SECOND UNIT BODY ATTACHMENT 79
DESIGN RECOMMENDATIONS
F-SUPER DUTY SECOND UNIT BODY MOUNTING TECHNIQUES FOR CHASSIS CAB (WIDE FRAME)
SUB Mounting Techniques #1 and #2 for 56” CA with SUB Weight 1800 lbs or Less
The intent of the illustrations shown in Figures A thru D on pages 82-84 is to offer an expanded range of Second Unit Body (SUB) mounting design recommendations for Super Duty F-Series trucks with a 1422 mm [56 in] Cab to Axle (CA) design.
These SUB mountings were tested by Ford Motor Company and found to be capable of complying with F/CMVSS requirements. The sketches in Figures on pages 82 and 83 depict SUB mounting techniques that are recommended to vehicle alterers.
This information is intended to assist in the design of Second Unit Bodies and body mounting systems that will control SUB movement with respect to the Ford supplied chassis when tested to the procedures specified in F/CMVSS 204, 208, 212, 219, and 301.
SUB Mounting Technique #3 for 56” CA with SUB Weight 1800 lbs or Less A third alternative mounting scheme is a top bolted mounting technique. This top bolted SUB mounting is recommended for the Super Duty F-Series pickup trucks with a 1422 mm [56 in] CA. This technique uses the existing pickup box mounting holes to mount a SUB weighing 3960 kg [1800 lb] or less provided the SUB is mounted in a similar fashion to Ford’s pickup box. These mountings should use the same number of OEM fasteners and OEM locations. Figure C on page 84 depicts this technique.
Second Unit Bodies (SUB) and their body mounting systems may take many forms, and the following recommendations cannot cover all the possibilities. Strict adherence to these recommendations will not assure that the completed vehicle will comply with F/CMVSS 204, 208, 212, 219, and 301. The final stage manufacturer who installs a second unit body on the chassis is responsible for compliance to the above mentioned regulations. Accordingly, Ford Motor Company cannot represent that these recommendations are appropriate for every specific application of a second unit body, the body mounting system or act of a subsequent stage manufacturer.
SUB Mounting Technique #4 for 56” CA with SUB Weight Over 1800 lbs This technique embodies the Front and Rear Shear plate attachment as depicted in SUB Mounting Techniques #1 and #2, but requires addition of U-bolts for further attachment. Figures E and F on page 85 depicts this technique.
To verify compliance of a particular second unit body and selected body mounting system with F/CMVSS 204, 208, 212, 219, and 301, the testing of a representative vehicle to the applicable procedures of the above regulations is recommended. Questions regarding compliance with F/CMVSS regulations should be directed to your legal counsel, the National Highway Traffic Safety Administration or Transport Canada.
Chassis Cab (Narrow Frame) The intent of the illustrations in Figures E and F on page 85 show the SUB mounting design recommendations for Super Duty F-Series Trucks with a 60”, 84” or 120” Cab to Axle (CA). Shear plate holes are pre-punched on all chassis cab frames.
(Continued Next Page)
DESIGN RECOMMENDATIONS
80
DETAILS OF ALTERNATIVE SECOND UNIT BODY MOUNTING TECHNIQUES
SUB Mounting Technique #3 - Pickup box attachment - Six, 5/8 inch diameter, Grade 8 flange nuts and bolts that utilize the existing pickup box holes in the top frame flanges. See Figure C on page 84.
The following SUB mounting design recommendations are methods of attachment that are intended to minimize SUB movement under crash situations. The following items are important factors in the performance of the system:
SUB Mounting Technique #4 - (56” CA with SUB weight over 1800 lbs.) - Same as Technique #1 except with addition of U-bolts as shown in Figure D on page 84.
1. The forwardmost surface of the SUB is located at least 76.2 mm [3.0 in] behind the rearmost surface of the cab. Refer to the statements of conformity for F/CMVSS 212/ 219 and F/CMVSS 301.
4. For Super Duty F-Series Chassis Cab vehicles with a 60”, 84” or 120” CA. It is recommended that the front shear plate mounting holes as provided on each chassis, be used. Refer to Ford Truck Body Builders Layout Book for dimensions. Same front and rear shear plate attachments as SUB Mounting Technique #1 or #2 with a 5/8 inch diameter U-bolt spaced every 24 to 36 inches. See Figure E on page 85. When U-bolts are used, vertical spacers must be between the upper and lower frame flanges at each U-bolt to prevent collapse of the flanges. See Figure F on page 85. U-bolt torque must be checked every six months.
2. The frame to SUB spacers must provide adequate space to allow a proper fuel filler pipe installation on pickup box delete models as shown in Figures on pages 53 and 54. 3. The following are SUB mounting instructions for a SUB weight of 3960 kg [1800 lb] or less and a 56 inch CA: SUB Mounting Technique #1 - Front Shear plate attachment - Two, 5/8 inch diameter, Grade 8 bolts, nuts, and washers in the OEM frame. One, 5/8 inch diameter, Grade 8 bolt, nut, and washer with a 1/4 inch equivalent weld bead around three sides of the shear plate and the SUB mounting frame, skip welded at the shear plate corners. See Figure A, View A, on page 82. Do not weld the shear plates to the frame.
The following items are important factors in the performance of the system: •
The spacer should have a slight taper which starts at the front of the SUB frame. See Figures on pages 82 and 83.
SUB Mounting Technique #1 - Rear Shear plate attachment - Three, 5/8 inch diameter, Grade 8 bolts, nuts, and washers in the OEM frame. One 5/8 inch diameter, Grade 8 bolt, nut, and washer with a 1/4 inch equivalent weld bead around three sides of the shear plate and the SUB mounting frame skip welded at the shear plate corners. See Figure A, View B, on page 82. Do not weld the shear plates to the frame.
•
Front shear plates should be angled forward approximately 45 to 60 degrees from the horizontal. Front shear plates should be a sufficient distance from the front of the SUB to allow for frame flexing, i.e., front shear plates should be placed behind the tapered section of the spacer.
•
Use 5/8 inch diameter, Grade 8 bolts, nuts, and washers that attach the shear plates to the OEM vehicle and SUB frames.
SUB Mounting Technique #2 - Front Shear plate attachment - Two, 5/8 inch diameter, Grade 8 bolts, nuts, and washers in the OEM frame. Two 5/8 inch diameter, Grade 8 bolts, nuts, and washers in the SUB mounting frame. See Figure B, View C, on page 83.
•
60-65 ft-lb torque for the 5/8 inch diameter, Grade 8 bolts, nuts, and washers.
•
Direct the threaded end of the bolts away from any fuel, brake or electrical system component.
It is important to note that the final-stage manufacturer still has the final responsibility to determine F/CMVSS 204, 208, 212, 219, and 301 rationale for the vehicle in question. The final-stage manufacturer should use prior engineering analysis, vehicle crash tests, actual field crash data, and the SUB unit manufacturer design information to determine the vehicle certification rationale as stated in the previous sentence.
SUB Mounting Technique # 2 - Rear Shear plate attachment - Three 5/8 inch diameter, Grade 8 bolts, nuts, and washers in the OEM frame. Two 5/8 inch diameter, Grade 8 bolts, nuts, and washers in the SUB mounting frame. See Figure B, View D, on page 83.
(Continued Next Page)
81
DESIGN RECOMMENDATIONS
Second Unit Body Attachment Continued Recommended Shear Plate Attachment for Second Unit Bodies weighing 1800 lb or less with a 56” CA
SUB LONGITUDINAL FRAME FRONT SHEAR PLATE MAT’L 3/8” HRLC STEEL SPACER
SUB LONGITUDINAL FRAME REAR BRACKET MAT’L 3/8” HRLC STEEL BUMPER ATTACHMENT
OEM FRAME OEM FRAME TAPERED SPACER
5/8” DIA. GRADE 8 BOLTS/NUTS/WASHERS 3 REQD. TORQUED TO 60-65 FT.-LB.
5/8” DIA. GRADE 8 BOLTS/NUTS/WASHERS 4 REQD. TORQUED TO 60-65 FT.-LB.
ALL HOLES 0.64” DIA.
ALL HOLES 0.64” DIA.
NOTE: DIMENSIONS ARE IN INCHES
NOTE: DIMENSIONS ARE IN INCHES
DRAWING DEPICTS SUB LONGITUDINAL FRAME WITH ONE 5/8” DIA. BOLT AND 1/4” WELD BEAD AROUND THE PERIMETER OF THE SHEAR PLATE.
DRAWING DEPICTS SUB LONGITUDINAL FRAME WITH ONE 5/8” DIA. BOLT AND 1/4” WELD BEAD AROUND THE PERIMETER OF THE SHEAR PLATE.
IF THE SHEAR PLATE IS NOT WELDED ON THE SUB LONGITUDINAL FRAME, TWO 5/8” DIA. BOLTS WOULD BE NECESSARY TO ATTACH THE SHEAR PLATE TO THE LONGITUDINAL FRAME.
IF REAR BRACKET AND SUB FRAME ARE NOT WELDED, TWO 5/8” DIA. GRADE 8 BOLTS WILL BE NECESSARY TO ATTACH REAR BRACKET TO SUB FRAME. THREE 5/8” DIA. GRADE 8 BOLTS/NUTS/WASHERS ARE NEEDED TO ATTACH THE REAR BRACKET TO OEM FRAME.
VIEW B
VIEW A
LEFT REAR BRACKET (SUB LONGITUDINAL FRAME) RIGHT REAR BRACKET IS A MIRROR IMAGE.
LEFT FRONT SHEAR PLATE (SUB LONGITUDINAL FRAME) RIGHT SHEAR PLATE IS A MIRROR IMAGE.
FIGURE A – SUPER DUTY F-SERIES SUB MOUNTING TECHNIQUE #1
DESIGN RECOMMENDATIONS
82
(Continued Next Page)
Recommended Shear plate attachment for Second Unit Bodies weighing 1800 lb or less with a 56”CA
SUB CROSS-SILL FRAME RAILS
SUB CROSS-SILL FRAME RAILS SPACER
TAPERED SPACER REAR BRACKET BUMPER ATTACHMENT MAT’L 3/8” HRLC STEEL
FRONT SHEAR PLATE MAT’L 3/8” HRLC STEEL OEM FRAME
OEM FRAME
5/8” DIA. GRADE 8 BOLTS/NUTS/WASHERS 4 REQD. TORQUED TO 60-65 FT.-LB.
5/8” DIA. GRADE 8 BOLTS/NUTS/WASHERS 5 REQD. NUTS TORQUED TO 60-65 FT.-LB. ALL HOLES 0.64” DIA.
ALL HOLES 0.64” DIA.
NOTE: ALL DIMENSIONS ARE IN INCHES
NOTE: ALL DIMENSIONS ARE IN INCHES
DRAWING DEPICTS SUB CROSS-SILL FRAME WITH TWO 5/8” DIA. BOLTS ATTACHING THE REAR BRACKET TO SUB FRAME, THREE 5/8” DIA. GRADE 8 BOLTS/NUTS/ WASHERS ARE NEEDED TO ATTACH THE REAR BRACKET TO THE OEM FRAME.
DRAWING DEPICTS SUB CROSS-SILL FRAME WITH TWO 5/8” DIA. BOLTS.
VIEW C
VIEW D
LEFT FRONT SHEAR PLATE (SUB CROSS-SILL FRAME) RIGHT SHEAR PLATE IS A MIRROR IMAGE.
LEFT REAR BRACKET (SUB CROSS-SILL FRAME) RIGHT REAR BRACKET IS A MIRROR IMAGE.
FIGURE B - SUPER DUTY F-SERIES SUB MOUNTING TECHNIQUE #2
83
(Continued Next Page)
DESIGN RECOMMENDATIONS
Recommended for Second Unit Bodies Weighing 1800 lb or Less with a 56” CA
NOTE: ALL DIMENSIONS ARE IN INCHES
FIGURE C - SUPER DUTY F-SERIES SUB MOUNTING TECHNIQUE #3 Recommended Shear plate attachment for Second Unit Bodies weighing over 1800 lb with a 56”CA
FIGURE D - SUPER DUTY F-SERIES SUB MOUNTING TECHNIQUE #4
DESIGN RECOMMENDATIONS
84
FIGURE E - SUPER DUTY F-SERIES CHASSIS CABS SUB MOUNTING TECHNIQUE FOR 60”, 84”, & 120” CA Same front and rear shear plate attachment as SUB mounting techniques #1 and #2 with a U-bolt spaced every 24 to 36 inches. Torque 5/8” U-bolts to 60-65 Ft. Lb. Do not notch the
frame flanges to make the U-bolts fit. Place a spacer in between the frame flanges to provide proper U-bolt torque.
SPACER
TYPICAL INSTALLATION (VIEW SHOWING INBOARD SIDE OF RAIL)
FIGURE F - SUB FRAME SPACER U-BOLT Where wraparound body attachments (such as U-bolts) are used, the frame sidemembers must have flange reinforcement spacers to avoid flange damage when full torque is applied to attaching bolts. Spacers must be cut out to clear brake lines, fuel lines, wiring, etc. If metal spacers are used, no welding to frame sidemembers is permitted.
Body attachments that wrap around the frame must maintain adequate clearance to OEM fuel systems and suspension components.
Tapered hardwood spacers between vocational-body sill and frame sidemember flanges are recommended.
A minimum of one set of shear plates per side is recommended. Also, one set of side shift plates should be attached to vocational-body sills per side.
Periodic checking of body attachments for torque retention is highly recommended.
85
DESIGN RECOMMENDATIONS
Second Unit Body Attachment (Continued) E-250/E-350 COMMERCIAL BASIC (STRIPPED) CHASSIS SECOND UNIT BODY
Front body bolsters should be attached to the frame sidemember as far forward as possible. They should be welded to the web of the frame sidemember immediately to the rear of the front radiator and cowl support structure as shown in the figure on this page, View A. Front bolsters should not be bolted to the frame sidemember in this area since there is no access to the inside surface of the frame sidemember.
A full length structural body should be attached to the chassis utilizing a system of body bolsters bolted and welded to the chassis frame sidemember as shown in the figure on this page. Rear body bolsters extend along the parallel sections of the frame sidemember as shown in figure on this page. Rear body bolsters should be bolted to the top flange of the frame sidemember using the existing 35.5 mm [1.40 in] diameter holes as shown in the figure on this page, View B.
Each front bolster should be rigidly connected to the corresponding rear bolster through the body floor or a tie bar. Do not weld to the flanges of the side rail. Refer to the welding precautions in the Frame section of these Design Recommendations on page 75.
Bolsters attachment in the rear axle kick-up area can be accomplished by bolting shear plates to the web of the frame sidemember as shown in the figure on this page, View C. The maximum size hole that may be drilled in the frame web is 19 mm [0.75 in] diameter. Refer to the drilling precautions in the Frame section of these Design Recommendations on page 75.
BODY CROSSMEMBER BOLT ATTACHMENT 0.5 INCH GRADE 8
[11.00] [8.00]
[4.75]
Z
FRONT BOLSTER WELD WELD
REAR BOLSTER
FRAME SIDE RAIL
FRAME SIDE RAIL
SECT. Z
Z
VIEW IN CIRCLE B
FRONT RADIUS ARM
VIEW IN CIRCLE C REAR WHEEL CENTERLINE
CUT OUT BOLSTER TO CLEAR CROSSMEMBERS
VIEW IN CIRCLE A
FRONT BOLSTER
TIE BAR
REAR BOLSTER
BOLT ATTACHMENT
RADIATOR COWL SUPPORT STRUCTURE TIE BAR
B
A NOTE: DIMENSIONS ARE SUGGESTED AND MAY BE REVISED AT THE BODY BUILDERS DISCRETION.
C
[ ] DIMENSIONS ARE IN INCHES
FIGURE G - E-250 / 350 COMMERCIAL BASIC (STRIPPED) CHASSIS SECOND UNIT BODY INSTALLATION DESIGN RECOMMENDATIONS
86
SECOND UNIT BODY MOUNTING PERMISSABLE IN THIS AREA. ADD CHAFING PROTECTION TO ANY COMPONENT WHICH MAKES CONTACT WITH CARBON CANISTER HOSES 4.00
C L #4 CROSSMEMBER
CL #3 CROSSMEMBER
NO COMPONENT ATTACHED TO FLANGES OR WEB OF SIDE MEMBER IN THIS AREA 24.50
NO COMPONENT ATTACHED TO FLANGES OR WEB OF SIDE MEMBER IN THIS AREA
FRONT OF VEHICLE DUAL CANISTER LOCATION USED WITH 55 GAL. FUEL TANK ON 158" WB 176" WB CUTAWAY / BASIC (STRIPPED) CHASSIS
NO COMPONENT ATTACHED TO FLANGES OR WEB OF SIDE MEMBER IN THIS AREA C L #4 CROSSMEMBER
20.50
FRONT OF VEHICLE SINGLE CANISTER LOCATION USED WITH 37 GAL. FUEL TANK ON 124” WB 138” WB 158” WB 176” WB CUTAWAY / BASIC (STRIPPED) CHASSIS
NO COMPONENT ATTACHED TO FLANGES OR WEB OF SIDE MEMBER IN THIS AREA 19.00
SINGLE REAR CANISTER LOCATION FOR ECONOLINE VAN AND CLUB WAGON
FRONT OF VEHICLE
#5 CROSSMEMBER
FRONT OF VEHICLE
E-250/350 SUPERVAN/WAGON SHOWN
NOTE: ALL DIMENSIONS SHOWN ARE IN INCHES
FIGURE A - CARBON CANISTER LOCATIONS / ECONOLINE VEHICLES
87
DESIGN RECOMMENDATIONS
FRONT OF VEHICLE JUMPER F7US-9E498-BA NOTE: AFTER INSTALLATION SECURE TO FRAME
284 REF. N804178-S309 (13mm HEX) NUT & WASHER ASY. M8 X 1.25 HEX HD. TORQUE 17.5 ± 2.7Nm (2) REQD.
9 31.2 .3 386
.2 512
DRILL AT ASY. 10mm DIA. HOLE
.5 672
EXISTING REMOVE AND RELOCATE TO REAR POSITION AS SHOWN
NEW LOCATION
FIGURE A - E-250 - 124 INCH WB BASIC (STRIPPED) CHASSIS ONLY VACUUM SYSTEM RESERVOIR & BRACKET ASSEMBLY RELOCATION
89
DESIGN RECOMMENDATIONS
AMBULANCE BUILDER GUIDELINES GUIDELINES
A FORD VEHICLE IS SUITABLE FOR MANUFACTURE INTO AN AMBULANCE ONLY IF EQUIPPED WITH A FORD AMBULANCE PREPARATION PACKAGE. FORD URGES AMBULANCE MANUFACTURERS TO FOLLOW THE RECOMMENDATIONS FURNISHED IN THIS INCOMPLETE VEHICLE MANUAL, THE FORD TRUCK BODY BUILDERS LAYOUT BOOK (AND ANY PERTINENT SUPPLEMENTS), AND THE QUALIFIED VEHICLE MODIFIER (Q.V.M.) GUIDELINES.
1. All Underbody Heat Management statements on page 78 apply to completed ambulance type vehicles. 2. Data concerning the effect of hood louvers is inconclusive. If a Body Builder chooses to add them, the opening should be directed rearward to avoid recirculating discharged hot air through the radiator. Remember, the vehicle interior vent air enters the passenger compartment at the base of the windshield. Louvers may direct heated air or fumes toward this opening. Removal of the underhood insulation may affect Exterior Noise compliance. See the Exterior Noise information on page 60.
USING A FORD VEHICLE WITHOUT THE FORD AMBULANCE PREPARATION PACKAGE TO PRODUCE AN AMBULANCE VOIDS THE FORD WARRANTY AND COULD RESULT IN ELEVATED UNDERBODY TEMPERATURES, FUEL OVERPRESSURIZATION AND THE RISK OF FUEL EXPULSION AND FIRES.
3. To deal with exceptionally high electrical loads, Ford vehicles with the Ambulance Prep Package are equipped with a 215 amp alternator, dual batteries and heavy duty wiring to handle higher current loads. Added wiring should be of sufficient capacity to handle the higher current loads. The alternator should not be modified or altered.
VEHICLES EQUIPPED WITH FORD AMBULANCE PREPARATION PACKAGES HAVE LABELS LOCATED ON (THE INSIDE) DRIVER-DOOR LOCK PILLAR THAT STATE THAT THE VEHICLE IS SO EQUIPPED. (See Page 4.)
4. Added body vents, especially powered vents, should be located away from the fuel filler, fuel venting areas and exhaust to avoid fuel fumes and vapors entering the interior of the vehicle.
INFORMATION
5. Equipment such as flashing lights and sirens, spare tire, or any other accessories should not be installed in the grille area forward of the radiator or air cleaner air inlet. Doing so restricts proper air flow through the radiator and engine compartment, with the exception of a siren or lights which may be mounted to the front bumper. Also, they may not exceed 90 square inches each or 180 square inches combined in area. See Figure A on this page.
Ford urges careful consideration of the recommendations that follow. They are based on analyses of component and vehicle tests, actual service situations, and engineering judgments. Disregard of these recommendations may affect the durability, reliability, handling and performance characteristics of a completed vehicle and may elevate underbody temperatures and/or increase the potential for fire, or may affect the safety of the occupants in the event of an accident.
6. An ambulance is not to be used as a tow vehicle.
These recommendations are supplemental to U.S. and Canadian Motor Vehicle Safety compliance representations provided earlier in this manual. Additional information is also provided in the Ford Truck Body Builders Layout Book and Ford Truck Shop Manual which may be helpful to subsequent stage manufacturers. Subsequent Stage Manufacturers are encouraged to contact the Ford Light Truck Body Builder Advisory Service on 1-800-635-5560 if they have any questions concerning these recommendations. ACCESSORIES SHOULD NOT BLOCK AIRFLOW IN SHADED AREAS
KEEP THIS AREA CLEAR
ECONOLINE
ENGINE COOLING RADIATOR AIR CONDITIONER CONDENSER
FIGURE A - FRONTAL AREA REQUIRING UNRESTRICTED AIRFLOW
AMBULANCE BUILDER GUIDELINES
88
SUPER DUTY F-SERIES
SUPPLEMENTS
SUPPLEMENTS
90
SUPPLEMENTS
91
SUPPLEMENTS
SUPPLEMENTS
SUPPLEMENTS
92
REFERENCE INFORMATION
FORD TRUCK BODY BUILDERS LAYOUT BOOK To obtain a copy of this book (first copy at no charge), please fax a written request and include the desired model year, along with your street address (NO P.O. BOX ADDRESS, PLEASE) fax to (313) 414-2971.
FORD SOURCE BOOK This book is available for review with your local Ford Dealer; to purchase a copy, send your request and return address to: Ford Motor Company Education and Training Department 300 Renaissance Center P.O. Box 43334 Detroit, Michigan 48243
FORD SERVICE PUBLICATIONS Many Ford Service Publications pertain to a specific Model Year and vehicle types. The following publications are a few of many manuals which are available from Helm Incorporated; call: 1-800-782-4356 • Ford Truck Shop Manuals • Ford Towing Manual • Ford Electrical & Vacuum Trouble Shooting Manual • Ford Wiring Diagram
FORD TRUCK BODY BUILDER ADVISORY SERVICE The Ford Truck Body Builder Advisory Service may be consulted regarding information contained in this manual. Call 1-800-635-5560 for assistance or Fax inquiries to (313) 337-2754 accompanied with a cover sheet indicating “Attention to: Ford Truck Body Builder Advisory Service,” along with your name, address and telephone number.
REFERENCE INFORMATION
