2002 Light Truck Incomplete Vehicle Manual

Incomplete Vehicle TypesFor This Manual

DO NOT DESTROY: THIS MANUAL IS REQUIRED BYLAW. KEEP UNTIL THE VEHICLE IS COMPLETED BYTHE FINAL STAGE MANUFACTURER.

Ð

��LIGHT TRUCK

INCOMPLETE VEHICLE MANUAL

February 2002 2C3S–19A268–AB

E-SERIES,EXPLORER& RANGERBASICCHASSIS

E-SERIESCUTAWAY

INCOMPLETEE-SERIESVAN &EXTENDEDWAGON

CHASSISCAB

Bus (Not School Truck MPV Truck (1)FMVSS School Bus (Not (Walk-in Equip.Number Title of Standard Bus) Walk-In Van) Van)

Control Location, Identification andX X X X X101

Illumination

102Transmission Shift Lever Sequence, Starter

X X X X XInterlock & Transmission Braking Effect

103 Windshield Defrosting & Defogging Systems X X X X X104 Windshield Wiping and Washing Systems X X X X X105 Hydraulic and Electric Brake Systems X X X X X106 Brake Hoses X X X X X X

108Lamps, Reflective Devices & Associated

X X X X X XEquipment

109 New Pneumatic Tires X111 Rearview Mirrors X X X X X113 Hood Latch Systems X X X X X114 Theft Protection X(2) X(2)116 Hydraulic Brake Fluids X X X X X X

118Power Operated Window, Partition, and Roof

X(2) X(2) X(2)Panel Systems

119New Pneumatic Tires for Vehicles Other

XThan Passenger Cars

120Tire Selection and Rims for Motor Vehicles

X X X X X XOther Than Passenger Cars

121 Air Brake Systems X X X X124 Accelerator Control Systems X X X X X125 Warning Devices X131 School Bus Pedestrian Safety Devices X201 Occupant Protection in Interior Impact X(2) X(2) X(2) X(2)202 Head Restraints X(2) X(2) X(2) X(2) X(2)

203Impact Protection for the Driver from the

X(2) X(2) X(2) X(2)Steering Control System

204 Steering Control Rearward Displacement X(3) X(3) X(3) X(3)205 Glazing Materials X206 Door Locks and Door Retention Components X X X207 Seating System X X X X X208 Occupant Crash Protection X X X(6)(5) X(6)(5) X(6) X209 Seat Belt Assemblies X210 Seat Belt Assembly Anchorages X X X X X212 Windshield Mounting X(2) X(2) X(2) X(2)213 Child Restraint Systems X X X X X X214 Side Impact Protection X(2)(7) X(2) X(2)(7) X(2)(7)216 Roof Crush Resistance X(4) X(4) X(4) X(4)217 Bus Window Retention and Release X X219 Windshield Zone Intrusion X(2) X(2) X(2) X(2)220 School Bus Rollover Protection X221 School Bus Body Joint Strength X

222School Bus Passenger Seating and Crash

XProtection

225 Child Restraint Anchorage Systems X(8) X(8) X(8) X(8) X(8)301 Fuel System Integrity X(2) X X(2) X(2) X(2)302 Flammability of Interior Materials X X X X X303 Fuel System Integrity of CNG Vehicles X(2) X X(2) X(2) X(2)304 CNG Fuel Container X

PART Vehicle Identification NumberX X X X X

565.4

U.S. MOTOR VEHICLE SAFETY STANDARDS(APPLICATION BY VEHICLE TYPE)

(1) Applicable to Equipment for use on applicable vehicle types.(2) Applicable to vehicles with a GVWR of 4536 kg [10,000 lb] or less.(3) 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.(4)Applicable to vehicles with a GVWR of 2722 kg [6,000 lb] or less.(5) Injury criteria applicable to vehicles with a GVWR of 3856 kg

[8,500 lb] or less and an unloaded vehicle weight of 2495 kg[5,500 lb] or less.

(6) Injury criteria is optional on Walk-in Van-Type Trucks, MotorHomes, vehicles manufactured for operation by persons withdisabilities, etc.

(7) Dynamic Performance Requirements apply to MPV, truck or abus with a GVWR of 2722 Kg [6,000 lb] or less.

(8)Tether anchorages that are installed voluntarily or by regulationmust comply with this Standard.

1

IMPORTANT:

UNITED STATES AND CANADIAN VEHICLES

Alterations to a chassis cab or an incomplete vehicle by someone other than FordMotor Company, or damage in transit, may affect compliance statements that arefurnished in this manual, or representations that are printed on the label that may beaffixed to a chassis cab vehicle.

INTRODUCTION

Information in this manual is furnished pursuant to United States and Canadian safetyregulations or, in some cases where the information is not required by regulation, is furnishedfor the convenience of intermediate or final stage vehicle manufacturers. Incomplete vehiclesmanufactured for sale or importation into the U.S., are specially equipped for the UnitedStates. The descriptions and statements contained in the manual relate only to motor vehiclesafety standards issued under the National Traffic and Motor Vehicle Safety Act of 1966 asamended.

An incomplete vehicle manufactured for sale or importation into Canada is speciallyequipped for Canada. This vehicle conforms to the applicable Canadian Motor VehicleSafety Standards (CMVSS) on the date of manufacture printed on the cover of this manual,and as identified in a CMVSS Table on page 61. Requirements unique to vehicles for usein Canada are identified in the Statements of Conformity and the Canadian Vehiclessection of the manual.

The Emission Certification Information section of this manual contains information regardingconformity to exhaust emission regulations of the United States, Canada, and the State ofCalifornia and fuel economy regulations of the United States.

This manual should not be relied upon with respect to compliance with any regulation of theFederal Highway Administration or regulations issued pursuant to the Occupational Safetyand Health Act (OSHA) or any other federal, state, or local regulations governing theperformance or construction of motor vehicles (except for those requirements shown underthe heading “Warranty and Maintenance,” page 63, “Emission Control Information Label,”page 64 and “Unleaded Gasoline Label,” page 63). It is the responsibility of the final stagemanufacturer to determine applicability and comply with any federal, state, or localrequirements not detailed in this manual.

IMPORTANT:

UNITED STATES VEHICLES

Ford Motor Company has endeavored, whenever possible, to state the specificconditions under which an incomplete vehicle may be completed to conform toeach applicable Federal Motor Vehicle Safety Standard. These specific statementsare intended to aid subsequent stage manufacturers in avoiding instances ofinadvertent noncompliance to particular standards.

Note that the final responsibility for the compliance of the completed vehicle restswith the final stage manufacturer who is required by law to certify, as prescribed bySection 567.5 of Title 49, Code of Federal Regulations, that the completed vehicleconforms to all applicable Federal Motor Vehicle Safety Standards.

INTRODUCTION

2

UNITED STATES VEHICLESGeneral Information ................................................................ 3Directions ............................................................................... 3

VEHICLE DESCRIPTION .......................................................... 4

DEFINITIONS ............................................................................. 6-7

STATEMENTS OF CONFORMITY ............................................. 8-59

CANADIAN VEHICLES

General Information ............................................................... 60CMVSS Statement of Compliance ......................................... 60Vehicle Identification .............................................................. 60Daytime Running Lamp (DRL) .............................................. 60Canadian Radio Frequency Interference (RFI) ..................... 60CMVSS Table ......................................................................... 61

EMISSION CERTIFICATION INFORMATION

Exhaust Emission and Fuel Economy ................................... 62Unleaded Gasoline/Fuel Label ............................................. 63Exterior Noise ........................................................................ 63Warranty and Maintenance ................................................... 63Evaporative Emissions .......................................................... 63Service Engine Soon Warning Light ..................................... 63Emission Control Information Label ...................................... 64California Fuel Vapor Recovery ............................................. 64California Emission Control Label ......................................... 64Radio Frequency Interference (RFI) ...................................... 65

REFERENCE INFORMATION ........................................... Back Cover

TABLE OF CONTENTS

TABLE OF CONTENTS

3

STATEMENTS OF CONFORMITY

The Statements of Conformity section, which begin on page 8of this manual, lists the Federal Motor Vehicle Safety Standardsin effect on the date of manufacture of this incomplete vehiclethat are applicable to the type(s) of completed vehicles intowhich this incomplete vehicle may be manufactured. This dateis shown on the label affixed to the cover of this manual. Thesestatements, in most cases, apply to specific types of incompleteor completed vehicles and identify GVWR and UVW weightranges.

The incomplete vehicle type is identified by the 5th, 6th, and7th digits of the Vehicle Identification Number (VIN); see page4. The completed vehicle types to which this incomplete vehiclemay appropriately be completed is printed on the label, underthe heading “May Be Completed As,” that is affixed to thecover of this document. The Completed Vehicle Types chartson page 5 identifies how various incomplete vehicles with anOptional Prep Packages or a Trim Code, may be completed.

Each statement of conformity is identified by a safety standardnumber located at the left margin. Because there may bemultiple statements of conformity for each safety standard, usecare to select the appropriate statement. Unique CMVSSrequirements will be identified at the conclusion of therepresentations for a particular safety standard.

Compliance statements provided in this manual are of thethree following types. Each compliance statement in thismanual will include a type designation in the title (e.g. (TypeII)):

Type I • A statement that the vehicle, when completed, willconform to the standard if no alterations are madein identified components of the incomplete vehicle.

Type II • A statement of specific conditions of finalmanufacture under which the incomplete vehiclemanufacturer specifies that the completed vehiclewill conform to the standard.

Type III • A statement of conformity with the standard is notsubstantially affected by the design of the incompletevehicle, and that the incomplete vehiclemanufacturer makes no representation as toconformity with the standard.

DOMESTIC SPECIAL ORDER (DSO) VEHICLES

DSO vehicles can be identified by a six digit number with theletters DSO below the digits in the lower right corner of theIncomplete Vehicle Label which is affixed to the driver-doorlock pillar. See the sample label on page 4.

The Statements of Conformity section of this manual includescompliance representations for certain DSO vehicles. Thesevehicles are identified in the charts on page 5. Other DSOvehicles may require additional Statements of Conformitywhich will be in the Supplement Section of this manual.

FORD LIGHT TRUCK ASSISTANCE

Throughout this manual you will find references to informationfound in the Ford Truck Body Builders’ Layout Book. AdditionalDesign Recommendations and specifications are alsoprovided to assist subsequent stage manufacturers incompleting chassis cab and incomplete vehicles. To obtainthe compact disc or a copy of this book (first copy at no charge),please fax a written request and include the desired modelyear, along with your return address (NO P.O. BOXADDRESS, PLEASE) to (734) 414-2971.

The Ford Truck Body Builder Advisory Service may beconsulted regarding information contained in this manual. Call1-877-840-4338 for assistance, or fax inquiries to(313) 594-2633 accompanied by a cover sheet indicating“Attention: Truck Body Builder Advisory Service,” alongwith your name, address, and telephone number.

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 ofTitle 49, Code of Federal Regulations. “Vehicles Manufacturedin Two or More Stages.” Part 568 specifies that final stagemanufacturers must complete vehicles in compliance with allapplicable Federal Motor Vehicle Safety Standards.

Each Chassis Cab (see definition on page 6) manufacturedby Ford has a label affixed to the driver-door lock pillar thatidentifies the following:

The specific Federal Motor Vehicle Safety Standards towhich the Chassis Cab conforms, as of the date ofmanufacture.

The specific Federal Motor Vehicle Safety Standards towhich the Chassis Cab will conform when completed asspecified in this manual.

The date of manufacture (month/year) of the Chassis Cabby Ford Motor Company

DIRECTIONS

IMPORTANT:

To rely on the compliance representations in this manual,the incomplete vehicles must be completed as one of thecompleted vehicle types designated on the label affixed tothe cover of this manual, and must not exceed the specifiedGVWR, GAWRs, or the Unloaded Vehicle Weight limitswhen specified in this manual.

UNITED STATES VEHICLES

•

•

•

4

INCOMPLETE VEHICLE MANUFACTURED BYFORD MOTOR COMPANY

MADE IN U.S.A.GVWR::

FRONT GAWR:

VIN:PSI COLD PSI COLD

WITHTIRESRIMS

WITHTIRESRIMS

REAR GAWR :

EXTERIOR PAINT COLORSWB TYPEGVW BODY TRANS AXLE TAPE SPRINGS

DSO

161 F379 AJ8 E 65 N Y

410047

EQUIPPED WITH THE FORDAMBULANCE PREP PKG.

01/004200LB

1905KGLT215/85R16D16X6K

11000LB/4989KG8250LB

3742KGLT215/85R16D16X6K

65 DUAL1FDKF37MO2KA53769

58

F85B1520472AB

INCOMPLETE VEHICLE MFD. BY FORD MOTOR CO. IN U.S.A.

TYPICAL FSERIES

FRONT GAWRGVWR:

WITH

VIN:

REAR GAWR :WITH TIRES

RIMS

AT AT

AT

EXTERIOR PAINT COLORSWB TYPEGVW BODY TRANS AXLE TAPE SPRINGS

DSO 410047

138 EZ42 DB E 24 N4FF8UB3520472AB

EQUIPPED WITH THE FORDAMBULANCE PREP PKG.

10300LB/4672 KG3900 LB/3538KG:

LT225175R160 TIRESRIMS AT PSI COLD16X6K 55

DATE 01/007800 LB/3538KG

LT225175R16016X6K

75 PSI COLD1FDKE37HZ2HA24638

TYPICAL ECONOLINE

DATE

BAR CODE V.I.N.(CALIFORNIA)

DSOVEHICLE

DATE OFMANUFACTURE

VEHICLE TYPE(SEE CHARTON PAGE 5)

OPTIONALPREP PACKAGE

DATE OFMANUFACTURE

BAR CODE V.I.N.(CALIFORNIA)

DSOVEHICLES

VEHICLE TYPE(SEE CHARTON PAGE 5)

OPTIONALPREP PACKAGE

INCOMPLETE VEHICLE MANUAL COVER

The cover of this manual identifies the four incomplete vehicleconfigurations for which compliance representations arecontained in this manual. Also, a label is affixed to the coverwhich includes the Vehicle Identification Number (VIN) for thespecific vehicle to which this manual belongs. The labelidentifies the following information which pertains only to thevehicle with the corresponding VIN.

• The GVWR.

• The front and rear GAWRs.

• Tire and wheel size.

• Cold tire inflation pressure (PSI).

• Completed vehicle type(s) into which the incompletevehicle may be manufactured.

• Optional prep package when the vehicle is so equipped.

INCOMPLETE VEHICLE LABEL

All E-Series and F-Series Super Duty incomplete vehiclesmanufactured by Ford Motor Company will have an incompletevehicle label affixed to the driver-door lock pillar, except Basic(Stripped) Chassis. The incomplete vehicle label for the Basic(Stripped) Chassis is affixed to the front structure. The samplelabel, shown below is typical of that provided.

The 5th, 6th, and 7th digits of the Vehicle Identification Number(VIN) will identify the incomplete vehicle type. These threedigits are used in the Completed Vehicle Types charts onpage 5.

California Air Resources Board (CARB), requires a VehicleIdentification Number (VIN) Label having a non-contact, bar-code, reading wand capability. The bar-code directly belowthe VIN on the incomplete vehicle label, when provided, willcomply with this regulation. See page 63 for location andother requirements.

OPTIONAL PREP PACKAGES

Incomplete vehicles produced by Ford Motor Company, in someinstances, are equipped with Optional Prep Packages. Theseinclude the Ambulance Prep, School Bus Prep, MotorhomePrep, and Shuttle Bus Prep. The completed vehicle type chartson page 5 will identify incomplete vehicles and the optionalprep packages or trim codes that may be required by Ford iffinal stage manufacturers wish to rely on the Statements ofConformity or, in some cases, preserve the Ford new vehiclewarranty.

If an incomplete vehicle is equipped with an optional preppackage, both the incomplete vehicle label affixed to the vehicleand the label on the front of this manual will identify the PrepPackage.

VEHICLE DESCRIPTION

VEHICLE DESCRIPTION

INCOMPLETE VEHICLE LABEL

TYPICAL F-SERIES

TYPICAL E-SERIES

��

��

5 VEHICLE DESCRIPTION

COMPLETED VEHICLE TYPES

IMPORTANT:Ford Motor Company makes no representation thatthe completed vehicle types listed above are theonly vehicle types appropriate for the incompletevehicles listed. However, if a unit is completed as avehicle type other than as listed above, the State-ments of Conformity may not be applicable.

† Domestic Special Order.(1) Ambulance Prep Package.

(Super Duty F-Series available on narrow frame Chassis Cabmodels only).

(2) School Bus Prep Package.(E-350 available on 9600 lb GVWR SRW, and 10,000 lb GVWRDRW only).

(3) Motorhome Prep Package.(4) Shuttle Bus Prep Package.(5) Recreational Van.(6) Commuter Van Package.

5TH, 6TH, 7THVIN DIGIT

TR

UC

K

TR

UC

K(W

ALK

-IN

VA

N)

MP

V

MP

V(A

MB

ULA

NC

E)

BU

S (

NO

TS

CH

OO

L B

US

)

SC

HO

OL

BU

S

INCOMPLETE VEHICLES COMPLETE VEHICLES

E-SERIESE14 Incomplete E-150 Regular Van X 5E24 Incomplete E-250 Regular Van X 5E27† E-250 Commercial Cutaway XE29 E-250 Basic (Stripped) Chassis XE34 Incomplete E-350 Super Duty Regular Van X 5 1E35 E-350 Super Duty Cutaway X 3 1 4 2E39 E-350 Super Duty Basic (Stripped) Chassis XE45 E-450 Super Duty Cutaway X 3 1 4 2E49 E-450 Super Duty Basic (Stripped) Chassis XE55 E-550 Super Duty Cutaway X 3 1 4S24 Incomplete E-250 Extended Van X 5S31 Incomplete E-350 Super Duty Extended Wagon X 6 6S34 Incomplete E-350 Super Duty Extended Van X 5 1 5SUPER DUTY F-SERIESF20, F34 F-250/350 Chassis Cab Regular Cab 4X2 (SRW) X 1F21, F35 F-250/350 Chassis Cab Regular Cab 4X4 (SRW) X 1F32, F36, F46, F56 F-350/450/550 Chassis Cab Regular Cab 4X2 (DRW) X 1F33, F37, F47, F57 F-350/450/550 Chassis Cab Regular Cab 4X4 (DRW) X 1W20, W34 F-250/350 Chassis Cab Crew Cab 4X2 (SRW) X 1W21, W35 F-250/350 Chassis Cab Crew Cab 4X4 (SRW) X 1W32, W36, W46, W56 F-350/450/550 Chassis Cab Crew Cab 4X2 (DRW) X 1W33, W37, W47, W57 F-350/450/550 Chassis Cab Crew Cab 4X4 (DRW) X 1X20, X34 F-250/350 Chassis Cab Super Cab 4X2 (SRW) X 1X21, X35 F-250/350 Chassis Cab Super Cab 4X4 (SRW) X 1X32, X36 F-350 Chassis Cab Super Cab 4X2 (DRW) X 1X33, X37 F-350 Chassis Cab Super Cab 4X4 (DRW) X 1EXPLORERU69 Explorer Basic (Stripped) Chassis 4X2 XU79 Explorer Basic (Stripped) Chassis 4X4 XRANGERR09 Ranger Electric Basic (Stripped) Chassis X

6

Ambulance – is a vehicle for emergency medical care whichprovides: A driver’s compartment; a patient compartment toaccommodate an Emergency Medical Technician (EMT),Paramedic, and two litter patients (one patient on theprimary cot and secondary patient on folding litter locatedon the squad bench) so positioned that the primary patientcan be given intensive life-support during transit; equipmentand supplies for emergency care at the scene as well asduring transport; two-way radio communication; and, whennecessary, equipment for light rescue/extricationprocedures. The Ambulance shall be designed andconstructed to afford safety, comfort, and avoid aggravationof the patient’s injury or illness. (From Federal SpecificationKKK-A-1822-D). Ford Motor Company also includes withinits definition of ambulance any vehicle that is used fortransporting life-support equipment, for rescue operations,or for non-emergency patient transfer if the engine of thevehicle is equipped with a “throttle kicker” device, whichenables an operator to increase engine speed over normalidle speed when the vehicle is not moving.

B-Pillar – is the vehicle body structure located directly rearwardof each front door. This structure will include the outer panel,all inner panels or reinforcements which support the dooropening, the door latching system, and/or the roof structure(source: Ford Motor Company).

Bus – a motor vehicle with motive power, except a trailer,designed for carrying more than 10 persons.

Bus (Canada) – a vehicle having a designated seatingcapacity of more than 10, but does not include a trailer.

Chassis Cab – an incomplete vehicle, with completedoccupant compartment, that requires only the addition ofcargo-carrying, work performing, or load-bearingcomponents to perform its intended function. (49 CFR,Section 567.3)

Chassis Cab (Canada) – means a vehicle consisting of achassis that is capable of being driven, drawn, or self-propelled, upon which may be mounted a cab, and that isdesigned to receive:

(a) a passenger-carrying or cargo-carrying body includinga body that incorporates a prime mover, or

(b) a work performing structure other than a fifth-wheelcoupling.

Critical Control Item – is a component or procedure whichmay affect compliance with a federal regulation or, whichcould directly affect the safe operation of the vehicle. Theidentifying symbol is an inverted delta ( ). (source: FordMotor Company)

Designated Seating Position – any plan view location capableof accommodating a person at least as large as a 5thpercentile adult female, if the overall seat configurationand design and vehicle design is such that the position islikely to be used as a seating position while the vehicle isin motion, except for auxiliary seating accommodationssuch as temporary or folding jump seats. Any bench orsplit-bench seat in passenger car, truck, or multipurposepassenger vehicle with a GVWR of 10,000 pounds or less,having greater than 50 inches of hip room (measured inaccordance with SAE Standard J1100(a)) shall have notless than three designated seating positions, unless theseat design or vehicle design is such that the center positioncannot be used for seating.

Designated Seating Position (Canada) – any plan viewposition capable of accommodating a person at least aslarge as a 5th percentile adult female, as defined in section100 of Schedule IV, where the overall seat configurationand design and the vehicle design are such that the positionis likely to be used as a seating position while the vehicle isin motion, but does not include any plan view position oftemporary or folding jump seats or other auxiliary seatingaccommodation.

Final Stage Manufacturer – a person who performs suchmanufacturing operations on an incomplete vehicle that itbecomes a completed vehicle. (49 CFR, Section 568.3)

Forward Control – a vehicle configuration in which more thanhalf of the engine length is rearward of the foremost point ofthe windshield base and the steering wheel hub is in theforward quarter of the vehicle length.

Gross Axle Weight Rating (GAWR) – the value specified bythe vehicle manufacturer as the load-carrying capacity of asingle axle system, as measured at the tire-groundinterfaces.

Gross Combination Weight Rating (GCWR) – the valuespecified by the manufacturer as the loaded weight of acombination vehicle.

Gross Vehicle Weight Rating (GVWR) – the value specifiedby the manufacturer as the loaded weight of a single vehicle.

H-Point – the mechanically hinged hip point of a manikin whichsimulated the actual pivot center of the human torso andthigh, described in SAE Recommended Practice J826,“Manikins For Use in Defining Vehicle SeatingAccommodation,” November 1962.

Incomplete Vehicle – an assemblage consisting, as aminimum, 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 thecompleted vehicle, that requires further manufacturingoperations, other than the addition of readily attachablecomponents such as mirrors or tire and rim assemblies, orminor finishing operations, such as painting, to become acompleted vehicle. (49 CFR, Section 568.3)

DEFINITIONS

The following definitions are from Title 49, Code of Federal Regulations, Part 571.3except where noted. Canadian definitions are from Canada Motor Vehicle SafetyRegulations, Section 2(1), and are in italics. Ford Motor Company definitions are forthe purpose of this manual only. Some terms are followed by an abbreviation that isused throughout this manual.

DEFINITIONS

7

Incomplete Vehicle Manufacturer – a person whomanufactures an incomplete vehicle by assemblingcomponents none of which, taken separately constitute anincomplete vehicle. (49 CFR, Section 568.3)

Intermediate Manufacturer – a person, other than theincomplete vehicle manufacturer or the final stagemanufacturer, who performs manufacturing operations onan incomplete vehicle. (49 CFR, Section 568.3)

Multipurpose Passenger Vehicle (MPV) – a motor vehiclewith motive power, except a trailer, designed to carry 10persons or less which is constructed either on a truckchassis or with special features for occasional off-roadoperation.

Multipurpose Passenger Vehicle (MPV) (Canada)– a vehiclehaving a designated seating capacity of 10 or less that isconstructed either on a truck-chassis or with special featuresfor occasional off-road operation, but does not include anair cushion vehicle, all-terrain vehicle, golf-cart, passengercar, or truck.

Prescribed Class (Canada)– a class of vehicles listed inSchedule III.

Seating Reference Point – the manufacturer ’s designreference point which:

(a) Establishes the rearmost normal design driving or ridingposition of each designated seating position in a vehicle;

(b) Has coordinates established relative to the designedvehicle structure;

(c) Simulates the position of the pivot center of the humantorso and thigh; and

(d) Is the reference point employed to position the twodimensional templates described in SAE RecommendedPractice J826. “Manikins for Use in Defining VehicleSeating Accommodation,” November, 1962.

Second Unit Body (SUB) – consists of the body structureand/or all the cargo carrying, work performing, and/or loadbearing components and/or equipment installed by asubsequent stage manufacturer on an incomplete vehicle,such that the incomplete vehicle becomes a completedvehicle. (source: Ford Motor Company)

School Bus – a bus that is sold or introduced in interstatecommerce for purposes that include carrying students toand from school or related events, but does not include abus designed and sold for operation as a common carrier inurban transportation.

School Bus (Canada)– a bus designed or equipped primarilyto carry students to and from school.

Subsequent Stage Manufacturer – is a term which meanseither intermediate or final stage manufacturers or both.(source: Ford Motor Company)

DEFINITIONS

DEFINITIONS

Trimmed Seat – a complete functional seat assembly includingthe 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)

Truck – a motor vehicle with motive power, except a trailer,designed primarily for the transportation of property orspecial purpose equipment.

Truck (Canada)– a vehicle designed primarily for thetransportation of property or equipment but does not includea chassis-cab, crawler-mounted vehicle, trailer, workvehicle, or vehicle designed for operation exclusively offthe public highway.

Truck-Tractor – a truck designed primarily for drawing othermotor vehicles and not so constructed as to carry a loadother than a part of the weight of the vehicle and the load sodrawn.

Truck Tractor (Canada) – a truck designed primarily for drawingother vehicles and not constructed for carrying any loadother than part of the weight of the vehicle and load drawn,and includes a vehicle designed to accept a fifth-wheelcoupling but does not include a crane-equippedbreakdown vehicle.

Unloaded Vehicle Weight (UVW) – the weight of a vehicle withmaximum capacity of all fluids necessary for operation ofthe vehicle, but without cargo, occupants, or accessoriesthat are ordinarily removed from the vehicle when it is not inuse.

Unloaded Vehicle Weight (Canada) – the weight of a vehicleequipped with containers for the fluids necessary for theoperation of the vehicle filled to their maximum capacity butwithout cargo or occupants.

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 afunctional seat assembly without the final trim material (e.g.,cloth, leather, or vinyl) and trim material attachingcomponents. (source: Ford Motor Company)

Walk-In Van – is a step entry city delivery van type vehicle thatpermits a person to enter the vehicle without stooping. Thisdefinition by Ford Motor Company is based on informationappearing in 41 FR 54945, published December 16,1976,and in 42 FR 34288, published July 5,1977.

8

565.4 The statement below is applicable to all incompletevehicle types except the Basic (Stripped) Chassis(Type I):

This vehicle, when completed, will conform toPart 565.4, Vehicle Identification Number, if the vehicleidentification number mounted on the top of theinstrument panel is not removed, altered, or modifiedand no actions are taken by the subsequent stagemanufacturer that would obstruct the readability of theVehicle Identification Number mounted on the top ofthe instrument panel.

565.4 The statements below are applicable to the followingincomplete vehicle types (Type II):

E-Series Basic (Stripped) Chassis

Explorer Basic (Stripped) Chassis

Ranger Basic (Stripped) Chassis

This vehicle, when completed, will conform toPart 565.4, Vehicle Identification Number, if:

The E-Series vehicle identification number printedon the label affixed to the cover of this manual ismounted and displayed in accordance with therequirements of this Standard.

The Explorer or Ranger vehicle identificationnumber printed on the Incomplete Vehicle Label thatis shipped with this vehicle, is mounted anddisplayed in accordance with the requirements ofthis Standard.

101 The statements below are applicable to the followingincomplete vehicle types when equipped with a driverseat (Type I):

Chassis Cab

Incomplete E-Series Van or Wagon

Cutaway

This vehicle, when completed, will conform to Standard101, Controls and Displays if:

The controls, displays, and their identificationssupplied by Ford Motor Company are not removed,relocated, altered, or modified.

The components, wiring, and power supply installedby Ford Motor Company to illuminate any control,display, or their identification are not removed oraltered so as to affect lighting performance.

Components added to the vehicle do not obstructthe driver’s ability to operate or visually locate thecontrols, displays, and their identifications.

The driver-seat is not replaced, relocated, ormodified other than for the addition of seat trim.

Any controls, displays, and illumination added to thisvehicle must conform to the requirements of thisStandard.

101 The statements below are applicable to the followingincomplete vehicle types with no driver-seat (Type II):

Incomplete E-Series Van

Cutaway

This vehicle, when completed will conform to Standard101, Controls and Displays if:

The Seating Reference Point (see definition onpage 7) and the seat back torso angle of the driver-seat when completed or installed by a subsequentstage manufacturer are located as shown in theFigure C page 36, for E-Series type vehicles.

The controls, displays, and their identificationssupplied by Ford Motor Company are not removed,altered, or relocated.

The components, wiring, or power supply installedby Ford Motor Company to illuminate any control,display, or their identification are not removed oraltered so as to affect lighting performance.

Any controls, displays, and illumination added to thisvehicle must conform to the requirements of this Standard.

101 The statement below is applicable to the followingincomplete vehicle types (Type III):




Conformity with Standard 101, Controls and Displays, isnot substantially affected by the design of this incompletevehicle; accordingly, Ford Motor Company makes norepresentation as to conformity with this Standard.

101 Canadian Requirements:

The preceding statements for FMVSS 101 areappropriate compliance representations for CMVSS 101,Location and Identification of Controls and Displays, ifthis incomplete vehicle (identified by the VIN on the frontof the document) was manufactured by Ford MotorCompany for sale or use in Canada.


The following Statements of Conformity apply to vehicles that are produced for sale orimportation into the United States or Canada. The term “Incomplete Vehicle Types” inthese statements refers to the four types of the vehicles illustrated on this manual’s coverand as defined in the Vehicle Description section on page 4.

The number preceding each Statement of Conformity refers to the number designationfor a Part or a Section of Part 571 of the Federal Motor Vehicle Safety Standard. Canadianrepresentations will be at the conclusion of each safety standard number.


PART

PART

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9

102 The statements below are applicable to all incompletevehicle types except the Basic (Stripped) Chassis(Type I):

This vehicle, when completed, will conform to Standard102, Transmission Shift Lever Sequence, Starter Interlock,and Transmission Braking Effect, if no alterations oradjustments are made to:

Automatic Transmission - the transmission, shift cable,transmission outer shift lever, shift cable bracket,vacuum tubes, vacuum pump system, the starterinterlock system, and wiring circuit from the interlockswitch to the power source.

Manual and Automatic Transmission - the transmissionshift decal, knob, or transmission indicator dialidentification.

If an auxiliary transmission is added to this vehicle, itmust conform to the requirements of this Standard.

102 The statements below are applicable to the the followingincomplete vehicle types (Type II):




This vehicle, when completed, will conform to Standard102, Transmission Shift Lever Sequence, Starter Interlock,and Transmission Braking Effect if:

No alterations or adjustments are made to thetransmission, shift cable, transmission outer shift lever,shift cable bracket, vacuum tubes, vacuum pumpsystem, the starter interlock system, and wiring circuitfrom the interlock switch to the power source.

The E-Series Basic (Stripped) Chassis is equipped witha temporary transmission gear selector indicator(PRNDL) which must be replaced with the cluster andtransmission gear selector indicator (PRNDL) that isshipped with the vehicle in the dunnage box and mustbe installed and adjusted following the instructions andspecifications shown in the figure below.

The Explorer Basic (Stripped) Chassis gear selectorindicator is in the instrument cluster which has beentemporarily installed for shipping. When the instrumentcluster is permanently installed, the gear selectorindicator must be installed and adjusted following theinstructions and specifications shown in the figurebelow.

If an auxiliary transmission is added to this vehicle, itmust conform to the requirements of this Standard.


The preceding statements for FMVSS 102 are appropriatecompliance representations for CMVSS 102,Transmission Shift Control Sequence, if this incompletevehicle was manufactured for sale or use in Canada.

1. Route the cable after the instrument cluster is installed in thevehicle. Do not kink the cable. Do not bend the cable to a radiusless than 4.5 inches. Route the cable from the cluster in a counter-clockwise direction, under the steering column, using the screwprovided. Do not wrap the cable around the steering column. Thesteering column shroud installation should not affect the cablerouting or function.

2. Pull on the cable end loop for a functional check. The cable shouldoperate with a similar effort as required prior to routing. Then placethe cable loop on the shift lever retainer pin.

3. Rotate the column shift lever clockwise until it bottoms out in firstgear.

4. Rotate the column shift lever counter-clockwise 2 detents forOverdrive “Oval D” position for 4R100, 4R70W, and 5R55ETransmissions.

5. Install a 3 pound weight, as defined in this illustration, on the end ofthe column shift lever.

6. Center the pointer in the middle of the “Oval D” position by rotatingthe thumb wheel.

7. Remove the 3 pound weight. The pointer must be within thetolerances as defined in this illustration.

8. After the steering column shrouds are installed, the transmissiongear selector indicator (PRNDL) system must be checked forproper operation.

INSTALLATION OF GEAR SELECTOR INDICATOR (PRNDL)


•

•

••

•

•

•

000000

18

H

0 0 0 0

5060

70

80

90

100

10

20

30

40

0MPH

UNLEADED FUEL ONLY

BRAKE

SERVICEENGINE SOON

F

H

C

E

P R N 1

INSTRUMENTCLUSTER

CABLE

STEERINGCOLUMN

CABLE THUMB WHEEL

COLUMN SHIFTLEVER

FRONT OFVEHICLE

CABLE RETENTIONBRACKET

SHIFT LEVERRETAINER PIN

N800705 SCREWTORQUE 20−29 IN.−LB.

[ ] ALL DIMENSIONS ARE INCHES

3.0 − 3.5 LB. WEIGHTHAND TOOL[2.375] 0.25 DIA.

(PRND21)

HOLE: [1.125] DIA.X [2.188] 0.25 DEEP

(PRND21) ADJUSTMENT TOLERANCE

4R100 & 4R70W TRANSMISSION

+

−

+

−

RIGHT LIMITLEFT LIMIT TARGET

D

+−

+−

4R100, 4R70W, & 5R55E TRANSMISSIONS

(PRNDL) ADJUSTMENT TOLERANCE

•

10

105 INFORMATION

Incomplete vehicle weight and dimensional informationrequired for center of gravity calculations are available inthe Ford Source Book. See your local Ford Dealer andrefer to appropriate model year and specific vehicle forrequired information.

Abbreviation definitions and a vehicle diagram to assistwith the equations for the FMVSS 105 segment are shownon page 13 for E-Series and page 15 for F-Series.

105 The statements below are applicable to the E-Seriescutaway when equipped with the School Bus Preppackage and completed as a school bus (Type II):

This vehicle when completed, will conform to Standard105, Hydraulic and Electric Brake Systems, if:

No alterations, modifications, or replacements are madeto the following:

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

Hydro-Boost system

Power Steering pump and lines if used withHydro-boost

Engine belt drive system

The E-350 Unloaded Vehicle Weight (see definition onpage 7) does not exceed the maximum nor is less thanminimum values in Table A page 16. Use the modeldescription, wheelbase, and engine size to identifyappropriate weight.

The E-450 minimum UVW must be at least 4128 kg[9100 lb].

The maximum GAWRs and GVWR, as identified on thecover 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-350only.

Service or parking brake pedal assembly operation mustnot be restricted by any alteration or added components.

The horizontal and vertical center of gravity, of thecompleted vehicle at Unloaded Vehicle Weight, is withinthe minimum and maximum locations as defined in thefollowing chart:


CENTER OF GRAVITY LOCATION DIMENSIONS FOR INCOMPLETE E-SERIES CUTAWAY WITH

SCHOOL BUS PREP PACKAGE

103 The statement below is applicable to all incompletevehicle types except the Basic (Stripped) Chassis (TypeI):

This vehicle, when completed, will conform to Standard103, Windshield Defrosting and Defogging Systems, if noalterations or adjustments are made to heater and blowerassemblies, ducting, operating controls, electrical circuitfrom 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 otherwiseredirect the air flow from the defroster outlets to thewindshield.





Conformity with Standard 103, Windshield Defrosting andDefogging Systems, is not substantially affected by thedesign of this incomplete vehicle; accordingly, Ford MotorCompany makes no representation as to conformity withthis Standard.


The preceding statements for FMVSS 103 are appropriatecompliance representations for CMVSS 103, WindshieldDefrosting and Defogging System, if this incomplete vehiclewas manufactured by Ford Motor Company for sale or usein Canada.

104 The statement below Is applicable to all Incompletevehicle types except the Basic (Stripped) Chassis (TypeI):

This vehicle when completed, will conform to Standard104, Windshield Wiping and Washing Systems, if noalterations are made to the windshield, the windshieldwiping and washing system, including the electrical circuitfrom the windshield wiping and washing motors to thepower source, and if no obstructions are added that restrictor otherwise redirect fluid flow from the washer nozzles tothe windshield.

104 The statement below Is applicable to the followingincomplete vehicle types (Type III):




Conformity with Standard 104. Windshield Wiping andWashing Systems, is not substantially affected by thedesign of this incomplete vehicle; accordingly, Ford MotorCompany makes no representation as to conformity withthis Standard.


The preceding statements for FMVSS 104 are appropriatecompliance representations for CMVSS 104, WindshieldWiping and Washing System, if this incomplete vehiclewas manufactured by Ford Motor Company for sale or usein Canada.

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••

(1) Measured from top of frame at a point midway between thecenterlines of the front and rear axles.

(2) Measured rearward from the centerline of the front axle.

••

••

E-450DRW

mm [in]

E-350DRW

mm [in]

E-350SRW

mm [in]LOCATION

•

•

Vertical Maximum (1)

Horizontal Maximum (2)

Horizontal Minimum (2)

302.0[11.9]

1651.0[65.0]

2159.0[85.0]

2718.0[107.0]

11

105 The statement below is applicable to the followingincomplete vehicle types (T ype III):



Conformity with Standard 105, Hydraulic and ElectricBrake Systems, is not substantially affected by the designof the incomplete vehicle; accordingly Ford MotorCompany makes no representation as to conformity withthis Standard.

105 The statements below are applicable to the followingincomplete vehicle types if the GVWR is under3629 kg [8,000 lb] (Type II):


This vehicle, when completed, will conform to Standard105, Hydraulic and Electric Brake Systems, if:




Vacuum system

Wheels and tires




Any removal of a Ford body or chassis component isaccompanied by the addition of equal weight.

The maximum GAWRs and GVWR, as identified on thecover of this document, are not exceeded with thevehicle weight at Unloaded Vehicle Weight + 400 lbpassenger load.

The service or parking brake pedal assembly operationis not restricted by any alteration or added components.

The E-Series Recreational Van has an UnloadedVehicle Weight that does not exceed the values in TableA on page 16.

The horizontal center of gravity of the Second Unit Body(SUB) is rearward of Lmin† for the appropriate vehicledescription in the table below. Lmin does not apply to aSUB of 120 lb or less when installed rearward of thefront seats and forward of the centerline of the rearaxle. (Do not restrict the E-Series seat travel andprovide seatback clearance to obtain the torso angleas shown in Figure C page 36).

The horizontal center of gravity for the SUB is:

At or forward of the rear axle centerline. The verticalcenter of gravity for the completed vehicle atUnloaded Vehicle Weight + 400 lb passenger loadCGv (Equation A) must not exceed 36.0 inches, whenmeasured from the ground.

Behind the rear axle centerline. The vertical centerof gravity for the completed vehicle at UnloadedVehicle Weight + 400 lb passenger load must fallwithin the appropriate range determined fromTable G, page 18. The value of CGh (Equation B),which approximates the horizontal center of gravityof the completed vehicle, is used in Table G, todetermine the vertical center of gravity limits for thecompleted vehicle. The value CGV (Equation A),which approximates the vertical center of gravity ofthe completed vehicle, must fall within theappropriate range determined from Table G.


† Lmin = the minimum horizontal center of gravity of theSUB measured in inches rearward from the centerlineof the front axle.

HORIZONTAL CENTER OF GRAVITYFORWARD LIMIT TABLE

Vehicle Wheelbase LminMillimeter [inch] Millimeter [inch]

E-150 3505 [138] 1473 [58]E-250 3505 [138] 1524 [60]

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•

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••

•

EQUATION A

CGv =

EQUATION B

CGh =

CGvbWb + CGvcWc + 10,000 Wt

Wt

400 x CGhpWB

Wrb+ Wrc + x WB)) ))

105 (Continued Next Page)

•

12

105 (Continued)

105 The statements below are applicable to the followingincomplete vehicle types except when completed asa school bus, and if the GVWR is between 3629 kg[8,000 lb] and 8618 kg [19,000 lb] inclusive (Type II):


Cutaway






Vacuum system

Wheels and tires




Hydro-boost system

Power steering pump and lines if used withHydro-boost



E-Series Van, Cutaway, and Basic (Stripped) Chassisvehicles with a GVWR of 4536 kg [10,000 lb] or less donot exceed the maximum Unloaded Vehicle Weightvalue in Table A page 16.

E-Series Cutaways and Basic (Stripped) Chassisvehicles conform to the minimum SUB weights foundin Table E, page 18.

The maximum GAWRs and GVWR, as identified on thecover of this document, are not exceeded with thevehicle weight at Unloaded Vehicle Weight + PassengerLoad (P). (See E-Series Passenger Load Table on thispage.)

The service or parking brake pedal assembly operationis not restricted by any alteration or added components.

The SUB horizontal center of gravity must be at orforward of the rear axle centerline for the followingvehicles:

- E-250/350/450 Basic (Stripped) Chassis

- E-250 Cutaway 138 inch WB

- E-350 Super Duty Cutaway (DRW)

- E-450 Super Duty Cutaway

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 GVWRCGv (Equation C) must not exceed 48.0 inches whenmeasured from the ground.

– Behind the rear axle centerline. The vertical center ofgravity for the completed vehicle at GVWR must fallwithin the appropriate range determined from Table Gpage 19. The value of CGh (Equation D), whichapproximates the horizontal center of gravity of thecompleted vehicle, is used in Table G to determinethe vertical center of gravity limits for the completedvehicle. The value of CGv (Equation C) whichapproximates the vertical center of gravity of thecompleted vehicle must fall within the appropriaterange determined from Table G.


E-SERIES PASSENGER LOAD TABLE

GVWR [lb] P [lb]

8,000 - 10,000 400

10,001 - 19,000 500

EQUATION C

CGv =

EQUATION D

CGh =

CGvbWb + CGvc Wc + Wl + 25PGVWR

GVWR

+ Wr l x WBWB

P x CGhpWrb + Wrc +

))

) ) ) )

•••

•

••

•

•

••

•••••••••

•

105 (Continued on page 14)

•

13

Wc = Weight of the vehicle (chassis and cab) (fuel tanksfull) [pounds]. Including option weight.

WB = Vehicle wheelbase [inches].

Wt = Total unladen weight = (Wb + Wc + P)

GVWR = Gross Vehicle Weight Rating of the vehicle[pounds].

WI‡ = Remaining cargo capacity [pounds].

Where: Wl = GVWR - (Wb + Wc + P)

Wrl‡ = Weight of the remaining cargo capacity on the rearwheels [pounds].

CGhI‡ = Horizontal distance from the of the front wheelsto the cargo center of gravity [inches] (taken fromTable C page 18). For many common vehicles,the CGhI is not given in the table, then it may beestimated as the distance from the of the frontwheel to the horizontal midpoint of the cargo area.

SUB = A Second Unit Body consists of the body structureand/or all the cargo carrying, work performing,and/or load bearing components and/orequipment installed by a subsequent stagemanufacturer on an incomplete vehicle, such thatthe incomplete vehicle becomes a completedvehicle.

L† = Horizontal distance in inches between the SUBcenter of gravity and the of the front axle.

P = Passenger load (See E-Series Passenger LoadTable page 12).

CGv = Vertical distance from the ground to the center ofgravity [inches] of the completed vehicle.

CGh = Horizontal distance from of the front wheels tocompleted vehicle center of gravity [inches].

CGvb = Vertical distance from the ground to the center ofgravity of the SUB and/or permanently attachedadded equipment [inches].

CGvc = Vertical distance from the ground to the center ofgravity of the chassis [inches] (including cab iforiginal equipment). (Taken from Table F page 18).

CGhp = Horizontal distance from the of the front wheelsto the P [inches] (passenger load) (taken from TableD page 18).

Wb = Weight of the SUB and/or permanently attachedadded equipment [pounds].

Wrb = Weight on the rear wheels of the SUB and/orpermanently attached added equipment[pounds].

Wrc = Weight at the rear wheels of the vehicle (chassisand cab) (fuel tanks full) [pounds], including optionweight.

FMVSS 105 DEFINITIONS AND CALCULATION ILLUSTRATION FOR INCOMPLETE E-SERIES VEHICLES

† Required for <8000 lb GVWR calculations only.

CL

‡ Required for >8000 lb GVWR calculations only.


CL

CL

WBWrI =

(CGhI)WI

CL

CL

Wc

Wrl Wrb Wb

Wrc Wl

P

CG OF SUB

CG OF COMPLETED VEHICLE

CG OF CHASSISCG h

CG hp

CG vc

WB

CG v

CG vb

W t GVWR

CG hlL

IVM0001

SUB

14STATEMENTS OF CONFORMITY

105 (Continued)

105 The statements below are applicable to the followingincomplete vehicle types if the GVWR is between3629 kg [8,000 lb] and 8618 kg [19,000 lb] inclusive(Type II):

Chassis Cab





Vacuum system

Wheels and tires




Hydro-boost system

Power steering pump and lines if used withHydro-boost



Chassis Cab vehicle with a GVWR of 4536 kg[10,000 lb] or less do not exceed the MaximumUnloaded Vehicle Weight value in Table B, page 17.

The applicable GAWRs and GVWR weights are notexceeded.

The completed vehicle must have a vertical center ofgravity (Equation E) of 48.00 inches or less whenmeasured from the ground.

The front axle curb weight of the completed vehicle(incomplete vehicle weight + min SUB weight, Table H)may be reduced by no more than 10% for SRW or 25%for DRW vehicles, using the front axle ground reactionas manufactured by Ford.

The rear axle curb weight of the completed vehicle(incomplete vehicle weight + min SUB weight, Table H)must be the same or greater than the rear axle groundreaction as manufactured by Ford.

REFERENCE: Equation F can be used to determine thecompleted vehicle’s horizontal center of gravity (CGh).Abbreviation definitions and a vehicle diagram areprovided to assist with the equation on page 15.

CG GVWR [lb] P [lb]

SUPER DUTY F-SERIES PASSENGER LOAD TABLE

hp

61.2 [in]8500-10,000

10,001-19,000

400

500

ALL SEATS

4X2 4X4

39.9 [in] 43.4 [in] CGvp


The preceding statements for FMVSS 105 are appropriatecompliance representations for CMVSS 105, HydraulicBrake Systems, if this vehicle is manufactured for sale oruse in Canada.

•

••••••••••

••

••

•

•

EQUATION E

CGv =GVWR

EQUATION F

CGvbWb + CGvc Wc + Wl + CGvp x P

Wrb + Wrc +

GVWRWB

P x CGhp + Wrl x WBCGh =

))

) )) )

)

)

SUPER DUTY F-SERIES PASSENGER CG TABLEvp

•

15

Wc = Weight of the vehicle (chassis and cab) (fuel tanksfull) [pounds]. Including option weight.

WB = Vehicle wheelbase [inches].

Wt = Total unladen weight = (Wb + Wc + P)

GVWR = Gross Vehicle Weight Rating of the vehicle[pounds].

WI

= Remaining cargo capacity [pounds].

Where: Wl = GVWR - (Wb + Wc + P)

Wrl = Weight of the remaining cargo capacity on therear wheels [pounds].

CGhI = Horizontal distance from the of the front wheelsto the cargo center of gravity [inches]. (Taken fromTable C page 18) for many common vehicles. Ifthe CGhI is not given in the table, then it may beestimated as the distance from the of the frontwheel to the horizontal midpoint of the cargo area.

SUB = A Second Unit Body consists of the body structureand/or all the cargo carrying, work performing,and/or load bearing components and/orequipment installed by a subsequent stagemanufacturer on an incomplete vehicle, such thatthe incomplete vehicle becomes a completedvehicle.

CGhc = Horizontal distance from the of the front wheelsto the center of gravity (inches) of the chassis.

P = Passenger load (See Passenger Load Tablepage 14).

CGv = Vertical distance from the ground to the center ofgravity [inches] of the completed vehicle.

CGh = Horizontal distance from of the front wheels tothe center of gravity [inches] of the completedvehicle.

CGvb = Vertical distance from the ground to the center ofgravity of the SUB and/or permanently attachedadded equipment [inches].

CGvc = Vertical distance from the ground to the center ofgravity of the chassis [inches] (including cab iforiginal equipment). (Taken from Table F,page 18).

CGhp = Horizontal distance from the of the front wheelsto the P (passenger load). (See Passenger LoadTable, page 14).

CG = Vertical distance from the ground to the center ofgravity of the front and rear seat P (passengerweight). (Taken from Passenger CGvp Table,page 14).

Wb = Weight of the SUB and/or permanently attachedadded equipment [pounds].

Wrb = Weight at the rear wheels of the SUB and/orpermanently attached added equipment[pounds].

Wrc = Weight at the rear wheels of the vehicle (chassisand cab) (fuel tanks full) [pounds]. Including optionweight.

FMVSS 105 DEFINITIONS AND CALCULATION ILLUSTRATION FOR INCOMPLETE SUPER DUTY F-SERIES

CL

CL

CL

CL

CL


vp

WBWrI =

(CGhI)WI

W c GVWRW t

W rl W rb W b

W rc W l

P

CG OF SUB

CG OF COMPLETED VEHICLE

CG OF CHASSIS

CG hl

CG h

CG hp

CG vc

WB

CG v

CG vb

CG hc

CG vp

SUB


TABLE AUnloaded Vehicle Weight (UVW)

This Information Does Not Apply To Vehicles Over 4536 kg [10,000 lb]

WHEELBASE MAXIMUMMODELS Millimeter UNLOADED VEHICLE WEIGHTS - Kilogram [pound]

[inch] by Engine Size - Liter [cubic inch]

INCOMPLETE E-SERIES VEHICLES 4.2L [256](3) 4.6L [281] 5.4L [330] 6.8L [413] 7.3LD[444]E-150 Reg. Recreational Van 3505 [138] 2699 [5950](2) 2699 [5950](2) 2699 [5950](2) NA NA

E-250 Reg. Recreational Van 3505 [138] NA NA 3130 [6900] NA NA

E-250 Cutaway SRW 3505 [138] 2676 [5900] NA NA NA NA

E-250 Comm. Basic (Stripped) Chassis SRW 3150 [124] 2676 [5900] NA NA NA NA

E-350 Reg. Van 3505 [138] NA NA 3583 [7900] 3583 [7900] 3583 [7900]

E-350 Extended Van or Extended Wagon 3505 [138] NA NA 3583 [7900] 3583 [7900] 3583 [7900]

E-350 Cutaway SRW(1) 3505 [138] NA NA 3856 [8500] 3856 [8500] 3856 [8500]

E-350 Cutaway DRW(1) 3505 [138] NA NA 3856 [8500] 3856 [8500] 3856 [8500]

E-350 Basic (Stripped) Chassis SRW 3505 [138] NA NA 3946 [8700] NA NA

E-350 Basic (Stripped) Chassis DRW 3505 [138] NA NA 3946 [8700] NA NA

E-350 Basic (Stripped) Chassis SRW 4013 [158] NA NA 3946 [8700] NA NA



(1) E-350 vehicles completed as a School Bus must be equipped with the School Bus Prep Packageand the Unloaded Vehicle Weight must exceed:

- 2540 kg [5600 lb] with single rear wheels (SRW). - 2858 kg [6300 lb] with dual rear wheels (DRW).

(2) 2767 kg [6100 lb] When completed with 6 or less designated seating positions.

(3) 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 64 for additional information.

17

TABLE BThis Weight Information Does Not Apply To Vehicles Over 4536 kg [10,000 lb] GVWR

SECOND UNIT BODY MAX. UNLOADED VEHICLE WEIGHT MAXIMUM LIMITATIONS kilogram [pound]

Center ofSUB Gravity Engine Size - liter [cubic inch]

MODELS Weight Height †kilogram millimeter 5.4L 6.8L 7.3LD[pound] [inch] [330] [413] [444]

F-250 Reg. Chassis Cab (4X2) 816 447 2904 2904 31983480 mm [137 in] WB (56.00� CA) [1800] [17.6] [6400] [6400] [7050]


F-250 Super Chassis Cab (4X2) 816 610 3108 3108 32894013 mm [158 in] WB (56.00� CA) [1800] [24] [6850] [6850] [7250]


F-250 Crew Chassis Cab (4X2) 816 610 3198 3198 34714379 mm [172.4 in] WB (56.00� CA) [1800] [24] [7050] [7050] [7650]








F-350 Reg Chassis Cab (4X2) 816 447 3539 3539 35393576 mm [140.8 in] WB (60.00� CA) [1800] [17.6] [7800] [7800] [7800]

F-350 Reg Chassis Cab (4X4) 635 447 3471 3471 34713576 mm [140.8 in] WB (60.00� CA) [1400] [17.6] [7650] [7650] [7650]

F-350 Super Chassis Cab (4X2) 816 610 3720 3720 37204110 mm [161.8 in] WB (60.00� CA) [1800] [24] [8200] [8200] [8200]

F-350 Super Chassis Cab (4X4) 635 610 3675 3675 36754110 mm [161.8 in] WB (60.00� CA) [1400] [24] [8100] [8100] [8100]




† Vertical dimensions are measured from the top surface of the frame at a distance approximately 304.8 to 457.2 [12 to 18 in] from the rear of the cab.

SUPER DUTY F-SERIES

18

TABLE C

TABLE DCGhp = Horizontal distance from front wheel C to

Passenger Load. (Dimensions are inches) All Super Duty F-Series 61.2

All E-Series† (except E-550) 48.5 E-550 50.0

† Except the E-Series Basic (Stripped) Chassis where thedistance from the of the front axle to the H point of the drivermust be measured.

TABLE FCGVC = Vertical distance ground to chassis CG

(Dimensions are inches)

F-250/350 (4X2) SRW > 8500 lb GVWR = 30.0

F-250/350 (4X4) SRW > 8500 lb GVWR = 31.0

F-350 (4X2) DRW = 30.0

F-350 (4X4) DRW = 31.0

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-450 Cutaway = 26.5

E-550 Cutaway = 29.5

E-250 SRW Basic (Stripped) Chassis = 25.0

E-350/450 Basic (Stripped) Chassis = 26.5

L

CGhl = Horizontal distance from front axle cargo CG:

Model WB (in) CGhl (in)†

† If CGhI is not given in the table or if the location of your cargo isnot in the normal cargo area, then your CGhI may be estimatedas the distance from the of the front wheel to the horizontalmidpoint of the cargo area.

Super Duty F-Series:Regular Cab 137.0 132Regular Cab 140.8 134Regular Cab 164.8 146Regular Cab 188.8 158Regular Cab 200.8 164SuperCab 158.0 153SuperCab 161.8 155Crew Cab 172.4 165Crew Cab 176.2 167Crew Cab 200.2 182

E-Series:Regular Van 138 116Extended Van or Extended Wagon 138 126Cutaway (SRW) 138 121

(DRW) 138 127Comm. Cab/Box Partition (DRW) 158 134RV (DRW) 158 138Comm. No Partition (DRW) 158 143

RV (DRW) 176 153Comm. (DRW) 176 160

†E-550 (DRW) 159.5 145177.5 154191.5 167209.5 182233.5 203

TABLE E

MINIMUM SUB WEIGHT

Except the E-350 E-Series Cutaway completed as a school bussee Table A page 16 for Unloaded Vehicle Weight

MODELS Kilogram[Pound]

E-250/350 Cutaway 6893505mm [138 in] WB [1520]E-350 Cutaway 8264013mm [158 in] WB [1820]E-350 Cutaway 9624470mm [176 in] WB [2120]E-450 Cutaway 8264013mm [158 in] WB [1820]E-450 Cutaway 9624470mm [176 in] WB [2120]E-550 Cutaway 12344051mm [159.5 in] WB [2720]E-550 Cutaway 13704058mm [177.5 in] WB [3020]E-550 Cutaway 15064864mm [191.5 in] WB [3320]E-550 Cutaway 16425321mm [209.5 in] WB [3620]E-550 Cutaway 17785931mm [233.5 in] WB [3920]E-250 Basic (Stripped) Chassis 771

[1700]E-350 Basic (Stripped) Chassis 862All WB [1900]E-450 Basic (Stripped) Chassis 998All WB [2200]

CL

LC

†

††

†

†††


19

Upper Limit Lower Limit

E-250 138 CGv = 1.27 x CGh - 59.0 1.27 x CGh - 77.58600 lb GVWRE-350 (SRW) 138 CGv = 1.27 x CGh - 60.0 1.27 x CGh - 80.0<9600 Ib GVWR 158 CGv = 1.27 x CGh - 69.5 1.27 x CGh - 90.7

TABLE GCGv = Vertical distance from the ground to the completed vehicle center of gravity [inch].

GVWR <8000 lb Use equation A & B, page 11Place the CGh of the vehicle (from equation B) into the appropriate equations below to determine the allowable range ofthe CGv. If the actual CGv (from equation A) is within the range calculated, the center of gravity location is acceptable.

Upper Limit Lower Limit

E-150 138 CGv = 1.39 x CGh - 46.9 1.39 x CGh - 58.7

138 CGv = 1.39 x CGh - 47.1 1.39 x CGh - 59.0

GVWR > 8000 lb to <19000 lb Use equation C & D, page 12Place 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 (fromequation C) is within the range calculated, the center of gravity location is acceptable.

Equation for CG v RangeModel WB

Model WBEquation for CG v Range

E-2507900 lb GVWR



Model and Cab WB Minimum SUBGVWR kg [lb.] Style mm [in] kg [lb]

R/C 3480 [137]

S/C 4013 [158] 172 [380]

C/C 4380 [172.4]

R/C 3480 [137]

S/C 4013 [158]

C/C 4380 [172.4]

F-2503989 [8800]

F-3504491 [9900]�

TABLE HSUPER DUTY F-SERIES VEHICLES MINIMUM SUB WEIGHTS

8800 LB TO 12,500 LB GVWR WIDE FRAMEF-250/350 924mm [36.4 in] Chassis Cabs

F-350Gasoline

5077 [11,200]��Diesel

5216 [11,500]��

190 [420]

SUPER DUTY F-SERIES VEHICLES MINIMUM SUB WEIGHTS9,900 LB TO 19,000 LB GVWR NARROW FRAME

F-350 866mm [34 in] and F-450/550 868mm [34.2 in] Chassis Cabs

Model andGVWR kg [lb]

CabStyle

WBmm [in]

Minimum SUBkg [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]

C/C 4475 [176.2]

204 [450]

190 [420]

190 [420]

F-3504488 [9900]�

F-3505077 [11,200]��

R/C 3576 [140.8]

S/C 4110 [161.8]

R/C4186 [164.8]

4795 [188.8]

204 [450]

227[500]

190 [420]

F-3505667 [12,500](7.3L Diesel)

C/C4475 [176.2]

5085 [200.2]R/C 5100 [200.8] 249 [550]

190 [420]F-450

6800 [15,000]

204 [450]

R/C 3576 [140.8]

4110 [161.8]

R/C4795 [188.8]

C/C5085 [200.2]

227 [500]

204 [450]

190 [420]

F-5507933 [17,500]

F-5508618 [19,000]

R/C5100 [200.8] 249 [550]

4186 [164.8] 204 [450]

4475 [176.2] 190 [420]

Cab StyleR/C = Regular CabS/C = SuperCabC/C = Crew Cab

� GVWR shown for 49 state applications, California models are 90.7 kg [200] less.

4186 [164.8] 204 [450]

�� GVWR shown for 49 state applications, California models are 4990 kg [11,000]

S/C

R/C 5100 [200.8] 249 [550]

21 STATEMENTS OF CONFORMITY

106 The statement below is applicable to all incompletevehicle types (Type I):

This vehicle, when completed, will conform to Standard106, Brake Hoses, if the brake hose assemblies suppliedby Ford Motor Company are not removed, relocated,altered, or modified and if no brake hose assemblies areadded.


The preceding statement for FMVSS 106 is anappropriate compliance representation for CMVSS 106,Brake Hoses, if this incomplete vehicle was manufac-tured for sale or use in Canada.

108 In addition to the statements pertaining to particularincomplete vehicle types which follow on pages 21and 22, the statements immediately below, concerningStandard 108 Lamps, Reflective Devices, andAssociated Equipment are applicable to all incompletevehicle types except the Basic (Stripped) Chassis:

No additional components may be added to the vehiclewhich require the use of tools to remove such components,for access to the headlamp aiming devices as providedby Ford Motor Company.

Daytime Running Lamps (DRL); Light Trucks for sale oruse in Canada are equipped with DRL’s that meet theCanadian DRL requirements. As manufactured forCanada, the F-Series vehicles will meet the FMVSS 108requirements for DRL’s when DRL’s are provided. Asmanufactured for Canada, the E-Series vehicles will notmeet the FMVSS 108 requirement for DRL’s when DRL’sare provided.

CENTER HIGH MOUNTED STOP LAMP (CHMSL) ELECTRICAL CONNECTOR LOCATION

Conformity with Standard FMVSS 108, S.12, HeadlampConcealment Devices, are not substantially affected bythe design of this incomplete vehicle; accordingly, FordMotor Company makes no representation as to conformitywith this Standard.

108 The statement below is applicable to the followingvehicle with a GVWR of 4536 kg [10,000 lb] or less anda vehicle width of 2032 mm [80.00 in] or less (Type II):

Chassis Cab

Cutaway

This vehicle, when completed, will conform to Standard108, Lamps, Reflective Devices, and AssociatedEquipment, if a Center High Mounted Stop Lamp (CHMSL)is installed on a Cutaway or if the Chassis Cab CHMSL,when provided, is obstructed from the rear of thecompleted vehicle it must be replaced with a CHMSL thatmeets all the requirements of this standard and isconnected to the electrical power source as provided byFord Motor Company. See the figure below for circuitlocation.

••

FRONT OFVEHICLE

SUPER DUTY F−SERIES CHASSIS CAB

CHMSLFIXEDCIRCUIT

TO INSTALL "CHMSL"UNWRAP TAPE FROMHARNESS IN THIS AREAAND REMOVE JUMPERCONNECTION TO EXPOSETHE "CHMSL CONNECTOR".

ECONOLINE CUTAWAY

FRONT OFVEHICLE

THE "CHMSL" ELECTRICAL CONNECTION FORAN ECONOLINE BASIC (STRIPPED) CHASSIS ISPROVIDED IN A DETAILED SCHEMATIC WHICHIS PACKAGED WITH THE BODY BUILDERELECTRICAL CONNECTORS.

��

��

THE “CHMSL” ELECTRICAL CONNECTION FORAN E-SERIES BASIC (STRIPPED) CHASSIS ISPROVIDED IN A DETAILED SCHEMATIC WHICHIS PACKAGED WITH THE BODY BUILDERELECTRICAL CONNECTORS.


Wid

th le

ss t

han

2032

mm

[80

in]

Headlamps S S S S

Tail Lamps S S R R

Stop Lamps S S R R

Center High MountedS N R N

Stop Lamp (CHMSL)

License Plate Lamps S S R R

Reflex Reflectors -Side Front S S S S

-SideRear R R R R

-Rear S S R R

Side Marker Lamps -Front S S S S

-Rear R R R R

Back-Up Lamps S S R R

Turn Signal Lamps -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

Veh. Haz. Wrng.S S S S

Flasher

Identification Lamps -Front N(1) S(1) N R

-Rear N R N R

Clearance Lamps -Front N(1) S(3) N R

-Rear N R N R

Parking Lamps S N R N

School Bus Lamps

and Switches N N R R

(School Buses only)

108 The statements below are applicable to the followingincomplete vehicle types (Type II):

Chassis Cab

Cutaway

This vehicle, when completed, will conform to Standard108, Lamps, Reflective Devices, and AssociatedEquipment, if all the required lighting equipment asindicated in Table K on this page (identified by the codesR and S) is designed and installed in accordance withthe requirements of Standard 108 and the directionscontained in this statement. Additionally, if the completedvehicle overall length is 9.14 meters [30 feet] or more,intermediate side marker lamps and reflex reflectors (notsupplied by Ford Motor Company) are also required forcompliance with Standard 108.

The items of equipment which are supplied by Ford MotorCompany (identified by the code S in Table K, on thispage) are designed and installed to conform to all therequirements of Standard 108. The completed vehiclewill conform with these components if the subsequentstage manufacturer does not remove, relocate, alter, ormodify such equipment or modify the power supply orwiring to such equipment, and does not complete thebody in such a configuration as to impair the visibility andconformity to the photometric requirements of the installedlamps and reflective devices.

Specific requirements for lighting and associatedequipment are listed by incomplete vehicle type inTable K on this page.

Lamps, reflective devices, and associated equipmentnecessary to complete the vehicle from an incompletevehicle must conform to the equipment, locations, specialwiring, visibility, photometric, and performancerequirements of Standard 108 and to the applicable SAEstandards or recommended practices referenced orsub-referenced in this Standard.

All electrical equipment added to the vehicle bysubsequent stage manufacturers must conform to thewiring practices set forth in the Electrical Wiring Sectionof the Ford Truck Body Builders’ Layout Book.

TABLE K(Reference Standard 108)

CutawayCompletedAs: Truck,

MPV, Bus, orSchool Bus

Chassis CabCompletedAs: Truckor MPV

DOMESTIC SPECIAL ORDER LIGHTING

Domestic Special Order offers the following delete op-tions which allow the purchase of an incomplete vehiclewithout certain normally supplied lighting equipment.

S Required on completed vehicle and supplied with theincomplete vehicle

R Required on completed vehicle and not supplied with theincomplete vehicle

N Not required for completed vehicle

(1) Supplied on DRW Chassis CabOptional on SRW Chassis Cab

(2) Designed for two turn signal lamps per vehicle side (onefront and rear). If additional lamps are required, replace theturn signal flasher with one having the correct lamp loadrating

(3) If a second unit body width is greater than 2032 mm [80 in]or higher than the chassis cab body. Additional clearancelamps may be required that comply with this standard.

Chassis Cab Truck, MPV Rear CombinationLamp (1)

Chassis Cab Truck, MPV Front Identificationand/or ClearanceLamps

(1) Deletes the rear stop lamp, tail lamp, rear reflex reflector back-up lamp, turn-signal lamp, hazard warning lamp, and associatedequipment on the right hand side of the vehicle.

Comparison of Table K on this page with the incompletevehicle will indicate whether any of the above delete optionsapply. Some delete option equipment may be required onthe completed vehicle in accordance with Standard 108.

Incomplete Completed DeleteVehicle Type Vehicle Type Option


Wid

th 2

032

mm

[80

in] o

r m

ore

Wid

th le

ss t

han

2032

mm

[80

in]

Wid

th 2

032

mm

[80

in] o

r m

ore

••


108 (Continued)

108 The statements below are applicable to the followingincomplete vehicle types (Type I):


This vehicle, when completed, will conform to Standard

108, Lamps, Reflective Devices, and Associated

Equipment, if the subsequent stage manufacturer doesnot:

Remove, alter, replace, or relocate the lightingequipment installed on the incomplete vehicle

Modify the power supply or wiring to such equipment

Add any additional external lighting equipment

Increase the overall width of the vehicle beyond thatof the incomplete vehicle

Complete, modify, or add components to the vehiclein such a manner as to impair the visibility andconformity to the photometric requirements of theinstalled lamps and reflective devices

108 The statement below is applicable to the Basic(Stripped) Chassis (Type III):

E-Series Basic (Stripped) Chassis Explorer Basic (Stripped) Chassis


Conformity with Standard 108, Lamps, Reflective Devices,and Associated Equipment, is not substantially affectedby the design of this incomplete vehicle; accordingly, FordMotor Company makes no representation as to conformitywith this standard. However, Ford Motor Company doesrepresent that the items of lighting equipment, whenprovided in the E-Series dunnage box attached to thechassis, are designed to conform to the requirements ofStandard 108.


The preceding statements for FMVSS 108 are appropriatecompliance representations for CMVSS 108, Lighting,and CMVSS 108.1, Headlamps, if this vehicle ismanufactured for sale or use in Canada, provided:

No component of the Daytime Running Lamp (DRL)system is removed, relocated, or modified.

111 The statements below are applicable to the followingincomplete vehicle types when equipped with a driverseat (including untrimmed seat) and a convex mirroron the passenger-side (Type I):


This vehicle, when completed, will conform to Standard111, Rearview Mirrors, if:

The mirrors and their mounts as supplied by Ford MotorCompany are not removed, relocated, replaced, oraltered, except as noted below.

No structural modifications are made to the body whichwould affect the stability of the mirror mounts.

Any modifications or additions made to this incompletevehicle do not adversely affect the driver’s view tothe rear in the outside mirrors along both sides of thevehicle.

The driver-seat is not replaced, relocated, or modifiedother than for the addition of seat trim.

If any alteration blocks the rear field of view through theinside mirror, FMVSS 111 may require that the vehiclehave a flat glass mirror on the passenger side.

111 The statements below are applicable to the incompleteE-Series Van with no driver-seat when equipped with aconvex mirror on the passenger-side (Type II):


The mirrors and their mounts as supplied by Ford MotorCompany, are not removed, relocated, replaced, oraltered.


The Seating Reference Point (see definition onpage 7) and the seat back torso angle of the driver-seat installed or completed by the subsequent stagemanufacturer are located as shown in Figure Cpage 36 corresponding to the particular incompletevehicle type.

Any modifications or additions made to this incompletevehicle do not adversely affect the driver’s view to therear in the outside mirrors along both sides of thevehicle.

If any alteration blocks the rear field of view through theinside mirror, FMVSS 111 may require that the vehiclehave a flat glass on the passenger side.

•

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••

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•

•

•

••

•

•

••

•

•


111 The statement below is applicable to the followingincomplete vehicle types when not equipped withoutside mirrors (Type III):

Chassis Cab

Cutaway





Conformity with Standard 111, Rearview Mirrors, is notsubstantially affected by the design of this incompletevehicle; accordingly, Ford Motor Company makes norepresentation as to conformity with this Standard.

111 The statements below are applicable to the Cutawaywhen equipped with outside mirrors (Type III):

Conformity with the stability requirements of Standard111, Rearview Mirrors, is not substantially affected by thedesign of this incomplete vehicle; accordingly Ford MotorCompany makes no representation as to conformity withstability requirements of this Standard. However, exceptfor the stability requirement, this vehicle, when completed,will conform to Standard 111, Rearview Mirrors, if:

The outside mirrors and their mounts, as supplied byFord Motor Company, are installed in accordance withthe instructions that accompany them and they are notrelocated, replaced, or altered.

The Cutaway with the School Bus Prep Package iscompleted as a school bus and any outside mirrors(not provided by Ford Motor Company) are installed inconformity with the requirements of Standard 111 forschool buses.

111 The statements below are applicable to the followingincomplete vehicle types when equipped with a flatglass mirror on the passenger-side (Type I):

Chassis Cab



The mirrors and their mounts as supplied by Ford MotorCompany are not removed, relocated, replaced, oraltered.


Any modifications or additions made to the incompletevehicle must not adversely affect the driver’s view tothe rear in the outside mirrors along both sides of thevehicle.


The preceding statements for FMVSS 111 are appropriatecompliance representations for CMVSS 111, RearviewMirrors, if this incomplete vehicle was manufactured forsale or use in Canada.

113 The statement below is applicable to all incompletevehicle types except the Basic (Stripped) Chassis(Type I):

This vehicle, when completed, will conform to Standard113, Hood Latch Systems, if the hood latch system asprovided by Ford Motor Company is not removed oraltered.





Conformity with Standard 113, Hood Latch Systems, isnot substantially affected by the design of this incompletevehicle; accordingly Ford Motor Company makes norepresentation as to conformity with this Standard.


The preceding statements for FMVSS 113 are appropriatecompliance representations for CMVSS 113, Hood LatchSystem, if this incomplete vehicle was manufactured forsale or use in Canada.

114 The statements below are applicable to all incompletevehicle types except the Basic (Stripped) Chassiswhen completed as either a MPV or a Truck with aGVWR of 4536 kg [10,000 lb] or less (Type I):

This vehicle, when completed, will conform to Standard114, Theft Protection, if the following components, to theextent provided by Ford Motor Company, are notremoved, relocated, altered, or modified in any way:

Steering column locking mechanism system

Ignition key/transmission shift interlock locking system

Ignition key-locking system

Key warning buzzer system

If any of the above components are added to the vehiclethey must conform to the requirements of this Standard.

114 The statement below is applicable to the followingincomplete vehicle types (Type I):




The Basic (Stripped) Chassis is designed by Ford MotorCompany to be completed as a walk-in van type vehicle.Walk-in vans are exempt from the requirements ofStandard 114, Theft Protection. See walk-in vandefinition, on page 7.


The preceding statements for FMVSS 114 are appropriatecompliance representations for CMVSS 114, LockingSystem, if this incomplete vehicle was manufactured forsale or use in Canada.

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•

•

•

••

••

••

•••

••

••

•



The statements for Part 565.4 are appropriate compliancerepresentations for CMVSS 115, Vehicle IdentificationNumber, if this incomplete vehicle was manufactured forsale or use in Canada.


This vehicle, when completed, will conform to Standard116, Motor Vehicle Brake Fluids, so long as any brakefluid added or replaced conforms to the DOT 3specifications of the standard and contaminants are notintroduced into the hydraulic brake system.


The preceding statement for FMVSS 116 is anappropriate compliance representation for CMVSS 116,Hydraulic Brake Fluid, if this incomplete vehicle wasmanufactured for sale or use in Canada.

118 The statement below is applicable to all incompletevehicle types not equipped with power windows whencompleted as either a MPV or a Truck with a GVWR of4536 kg [10,000 lb] or less (Type III):

Conformity with Standard 118, Power Operated Window,Partition, and Roof Panel Systems, is not substantiallyaffected by the design of this incomplete vehicle;accordingly, Ford Motor Company makes norepresentation as to conformity with this Standard. If anypower operated window, partition, or roof panel systemsare installed by subsequent stage manufacturers, theymust conform to the requirements of Standard 118.

118 The statement below is applicable to all incompletevehicle types equipped with power windows whencompleted as either a MPV or a Truck with a GVWR of4536 kg [10,000 lb] or less (Type I):

This vehicle, when completed, will conform to Standard118, Power Operated Window, Partition, and Roof PanelSystems, if the power operated windows, motors, wiring,and key and switch activation systems, where providedby Ford Motor Company, are not removed, relocated,altered, or modified in any way. If additional poweroperated window, partition, or roof panel systems areinstalled by subsequent stage manufacturers, they mustconform to the requirements of Standard 118.


The preceding statements for FMVSS 118 are appropriatecompliance representations for CMVSS 118, Power-Operated Window Systems, if this incomplete vehicle wasmanufactured for sale or use in Canada.


All tires supplied by Ford Motor Company are in fullconformity with Standard 119, New Pneumatic Tires forVehicles Other than Passenger Cars.

If additional tires are installed or the existing tires arereplaced by subsequent stage manufacturers, they mustconform to the requirements of Standard 119.

120 The statement below is applicable to all incompletevehicles except for the Basic (Stripped) Chassis (TypeI):

This vehicle, when completed, will conform to the tire andrim selection requirements of Standard 120, TireSelection and Rims for Motor Vehicles Other ThanPassenger Cars, if the tire and rim assemblies and theIncomplete Vehicle Label that is affixed to the vehicle arenot removed, altered, or replaced.

120 The statements below are applicable to the followingincomplete vehicle types (Type II):

E-Series Basic (Stripped) Chassis Explorer Basic (Stripped) Chassis


This vehicle, when completed, will conform to the tire andrim selection requirements of Standard 120, TireSelection and Rims for Motor Vehicles Other ThanPassenger Cars, if:

The tire and rim assemblies, are not removed, altered,or replaced.

The final stage manufacturer must, in accordance withthe requirements of Standard 120 and Part 567 ofTitle 49 Code of Federal Regulations, affix a label tothe completed vehicle indicating tire size, rim size, coldinflation pressure, and the gross axle weight ratings.This information is provided on the label that is affixedto the cover of this manual for E-Series vehicles or thelabel shipped with the Explorer and Ranger vehicles.


The preceding statement for FMVSS 120 is anappropriate compliance representation for CMVSS 120,Tire Selection and Rims for Vehicles Other ThanPassenger Cars, if this incomplete vehicle wasmanufactured for sale or use in Canada, except for thefollowing:

The label information requirements for CMVSS 120are in Section 6 of the Canada Motor Vehicle SafetyRegulations.

•

••

•

•

•


124 The statements below are applicable to all incompletevehicle types (Type I):

This vehicle, when completed, will conform to Standard124, Accelerator Control Systems, if:

No alterations are made to the accelerator control rod,bellcranks, cables, springs, guides, accelerator pedal,mounting hardware, adjustable pedal mechanism, orother components of the accelerator control system asinstalled by Ford Motor Company.

No equipment is added or existing equipment modifiedwhich would restrict operation of the accelerator controlsystem.

Vehicles equipped with electronically controlled, 7.3L,Dl Turbo Diesel have no alterations made to the PedalPosition Sensor and all associated hardware andwiring. See the figure below for componentidentification.


The preceding statement for FMVSS 124 is anappropriate compliance representation for CMVSS 124,Accelerator Control Systems, if this incomplete vehiclewas manufactured for sale or use in Canada.

131 The statement below is applicable to the Cutaway whenequipped with the School Bus Prep Package andcompleted as a school bus (Type III):

Conformity with Standard 131, School Bus PedestrianSafety Devices, is not substantially affected by the designof this incomplete vehicle. Accordingly, Ford MotorCompany makes no representation as to conformity withthis Standard.

ELECTRONIC ACCELERATOR CONTROL

201 The statements below are applicable to all incompletevehicle types except the Basic (Stripped) Chassis ifthe GVWR is 4536 kg [10,000 lb] or less (Type I, II, III):

This vehicle, when completed, will conform to Standard201, Occupant Protection in Interior Impact, if the followingcomponents, as provided by Ford Motor Company, arenot removed, relocated, altered, or modified in any way:

Instrument panel

Interior compartment doors

Sun visors

Arm rests

Seat backs of front seats installed by Ford Motor Companyare designed to meet the seat back requirements ofStandard 201. The seat mounted armrest on an untrimmedfront seat must be completed so as to meet therequirements of this Standard.

If any of the above mentioned components (includingfront seats) are added to the incomplete vehicle by asubsequent stage manufacturer, these components mustconform to the requirements of Standard 201 whereapplicable. When front seats are installed on anIncomplete E-Series Van or Cutaway the installed seatmust be located within the dimensional specifications forthe Seating Reference Point and the torso angle asspecified in Figure C page 36.

Because conformity of a completed vehicle to the seatback requirements of this standard is dependent uponthe location of a seat installed by a subsequent stagemanufacturer to the rear of another seat, Ford makes norepresentation as to compliance of a completed vehicleto the seat back requirements if such a seat is installed.

201 The statement below is applicable to the followingincomplete vehicle types if the GVWR is 4536 kg[10,000 lb] or less (Type I):




The Basic (Stripped) Chassis is designed by Ford MotorCompany to be completed as a walk-in van type vehicle.Walk-in vans are exempt from the requirements ofStandard 201, Occupant Protection in Interior Impact.See walk-in van definition, on page 7.


The preceding statements for FMVSS 201 are appropriatecompliance representations for CMVSS 201, OccupantProtection, if this incomplete vehicle was manufacturedfor sale or use in Canada.

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•

•

•

•


202 The statements below are applicable to the followingincomplete vehicle types if the GVWR is 4536 kg [10,000lb] or less (Type I, II):

Chassis Cab

Incomplete E-Series Van or Wagon when equippedwith front seats

Cutaway when equipped with front seats

This vehicle when completed, will conform to Standard202, Head Restraints, if:

No alterations are made to the head restraints, the seatassemblies and their anchorages, the floor pan, or floorpan reinforcements.

The added seat trim, on vehicles equipped withuntrimmed front seats, is installed so that the physicaldimension requirements for the head restraint, in thisStandard, are met.

Any front outboard passenger seat, added to a cutawayequipped with the School Bus Prep Package and whencompleted as a truck, MPV, or bus (not school bus), mustconform with the requirements of this Standard.

202 The statement below is applicable to the followingincomplete vehicle types if the GVWR is 4536 kg [10,000lb] or less (Type III):

Incomplete E-Series Van with no front seats

Cutaway with no front seats




Conformity with Standard 202, Head Restraints, is notsubstantially affected by the design of this incompletevehicle; accordingly, Ford Motor Company makes norepresentation as to conformity with this Standard.


The preceding statements for FMVSS 202 are appropriatecompliance representations for CMVSS 202, HeadRestraints, if this incomplete vehicle was manufacturedfor sale or use in Canada.

203 The statement below is applicable to all incompletevehicle types except the Basic (Stripped) Chassis ifthe GVWR is 4536 kg [10,000 lb] or less (Type I):

This vehicle, when completed, will conform to Standard203, Impact Protection for the Driver from the SteeringControl System, if the steering control system is notremoved, relocated, altered, or modified in any way andno components or attachments are added to the steeringcontrol system that can catch the driver’s clothing orjewelry during normal driving maneuvers.





The Basic (Stripped) Chassis is designed by Ford MotorCompany to be completed as a walk-in van type vehicle.Walk-in vans are exempt from the impact requirements ofStandard 203, Impact Protection for the Driver from theSteering Control System. See walk-in van definition, onpage 7.


The preceding statements for FMVSS 203 are appropriatecompliance representations for CMVSS 203, DriverImpact Protection, if this incomplete vehicle wasmanufactured for sale or use in Canada. In such a case,the Basic (Stripped) Chassis will comply if no componentsor attachments are added to the steering control systemthat can catch the driver’s clothing or jewelry during normaldriving maneuvers.

204 INFORMATION

Refer to the Design Recommendation section of the FordTruck Body Builders’ Layout Book for Second Unit BodyAttachment information that may aid in designing secondunit bodies and their attachments to be compatible withE-Series and F-Series vehicles.

204 The statements below are applicable to all incompletevehicle types except the Basic (Stripped) Chassis ifthe GVWR is 4536 kg [10,000 lb] or less and theUnloaded Vehicle Weight, when completed, is 2495 kg[5,500 lb] or less (Type II):

This vehicle, when completed, will conform to Standard204, Steering Control Rearward Displacement, if:

The Unloaded Vehicle Weight does not exceed theappropriate weight on Table A page 16, for all the E-Series vehicles, and the weight on Table B page 17,for F-Series Chassis Cab type vehicles.

No components are added which could influence therearward displacement of the steering column.

The steering column, steering intermediate andcoupling shaft, steering wheel, steering gear, steeringlinkage, related structural components, and attachinghardware, as installed by Ford Motor Company, arenot removed, relocated, altered, or modified in anyway.

No alteration or modifications are made to the bodychassis, drivetrain, or front suspension from the B-pillar forward.

204 The statement below is applicable to the followingincomplete vehicle types if the GVWR is 4536 kg [10,000lb] or less and the Unloaded Vehicle Weight, whencompleted, is 2495 kg [5,500 lb] or less (Type I):




The Basic (Stripped) Chassis is designed by Ford MotorCompany to be completed as a walk-in van type vehicle.Walk-in vans are exempt from the requirements ofStandard 204, Steering Control Rearward Displacement.See walk-in van definition, on page 7.


The preceding statements for FMVSS 204 are appropriatecompliance representations for CMVSS 204, SteeringColumn Rearward Displacement, if this incompletevehicle was manufactured for sale or use in Canada.

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•

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•


205 The statement below is applicable to all incompletevehicle types, except the Basic (Stripped) Chassis(Type I):

This vehicle, when completed, will conform to Standard205, Glazing Materials, if no alterations to or replace-ments of the installed glazing materials are made and ifadditional glazing materials installed by a subsequentstage manufacturer conforms to the requirements ofStandard 205.





Conformity with Standard 205, Glazing Materials, is notsubstantially affected by the design of this incompletevehicle: accordingly, Ford Motor Company makes norepresentation as to conformity with this Standard.


The preceding statements for FMVSS 205 are appropriatecompliance representations for CMVSS 205, GlazingMaterials, if this incomplete vehicle was manufacturedfor sale or use in Canada.

206 The statements below are applicable to all incompletevehicle types except the Basic (Stripped) Chassis,when completed as a Truck (Type I):

This vehicle, when completed, will conform to Standard206, Door Locks and Door Retention Components, if noalterations or adjustments are made to the door, doorpillar structure, door locks, door latches, striker plates,hinges, and attaching hardware as installed by Ford MotorCompany.

Any door added to this vehicle by a subsequent stagemanufacturer must be equipped with door locks and doorretention components that conform with this Standard.

206 The statement below is applicable to the followingincomplete vehicle types, when completed as a Truck(Type III):




Conformity with Standard 206, Door Locks and DoorRetention Components, is not substantially affected bythe design of this incomplete vehicle; accordingly, FordMotor Company makes no representation as to conformitywith this Standard.


The preceding statements for FMVSS 206 are appropriatecompliance representations for CMVSS 206, Door

Latches, Hinges, and Locks, if this incomplete vehiclewas manufactured for sale or use in Canada.

207, 208, 209, and 210 INFORMATION

For additional information to assist in designing seats,seat belt systems, and seat belt anchorages that complywith FMVSS 207, 208, 209, and 210 applicable toIncomplete E-Series Van and Cutaway vehicles with nofront seats provided by Ford Motor Company, refer to theDesign Recommendation section of the Ford Truck BodyBuiliders’ Layout Book for Seat and Lap & Shoulder BeltSystem information that is in addition to the statementswhich follow.

207 The statements below are applicable to the followingincomplete vehicle types when equipped with trimmedfront seats (Type I, III):

Chassis Cab


Cutaway

This vehicle, when completed, will conform to Standard207, Seating Systems, if no alterations are made to theseat assemblies, their anchorages, the floor pan, or floorpan reinforcements. Any seating system added to thisvehicle must conform to applicable requirements of thisStandard. When the Cutaway is completed as a schoolbus, see FMVSS 222 also.

If the front seat attaching hardware is removed for anyreason, it must be reinstalled to the specifications in theFigures for E-Series on page 35.

The Incomplete E-Series Recreational Van or theIncomplete E-Series Wagon may have additionalanchorages for rear seats other than the front driver andpassenger seats. These locations apply to specifichardware and designated seating positions used in Fordcompleted vehicles. If these anchorages are used withoutthe appropriate Ford seats, seat belt systems, andhardware, Ford Motor Company makes no representationas to conformity with this Standard.


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207 (Continued)

207 The statements below are applicable to the followingincomplete vehicle types when equipped withuntrimmed front seats (Type II, III):


Cutaway

This vehicle when completed, will conform to Standard

207, Seating Systems, if:

No changes or modifications are made to the front seatframes, latches, hardware, and padding.

The weight of each completely trimmed front seat doesnot exceed the value in Table L on this page.

No modifications are made to the floor pan in the areaof the front seat attachments.

The front seat and seat belt anchorages are notrelocated.

If the front seat attaching hardware is removed for anyreason, it must be reinstalled to the specifications in theFigures for E-Series on page 35.

Any seating systems added to this vehicle must conformto the applicable requirements of this Standard.

The Incomplete E-Series Recreational Van may haveadditional anchorages for rear seats other than the frontdriver and passenger seats. These locations apply tospecific hardware and designated seating positions usedin Ford completed vehicles. If these anchorages are usedwithout the appropriate Ford seats, seat belt systems,and hardware, Ford Motor Company makes norepresentation as to conformity with this Standard.

TABLE LE-SERIES COMPLETED UNTRIMMED SEAT WEIGHT

DESCRIPTION MAX. WEIGHT (lb)

DRIVER-SIDE PASSENGER-SIDE

E-Series Captain’s Chair - Manual Tracks 59.0 61.0

E-Series Captain’s Chair - Manual Tracks - Manual Lumbar 62.0 68.0

E-Series Captain’s Chair - Power Tracks - Manual Lumbar 68.0 N/A

207 The statements below are applicable to the followingincomplete vehicle types with no front seats (Type III):


Cutaway




Conformity with Standard 207, Seating Systems, is notsubstantially affected by the design of this incompletevehicle; accordingly, Ford Motor Company makes norepresentation as to conformity with this Standard.

The Cutaway, when equipped with seat delete option,will include both front seat pedestals, pretensionerrestraint systems, seat tracks, and a temporary driver’sseat. The pretensioner restraint system is attached to theseat track. Therefore, the completed seat assembly mustcomply with the requirements of FMVSS 207 and 210.

The Incomplete E-Series Recreational Van may haveadditional seat anchorages. These locations apply tospecific hardware and designated seating positions usedin Ford completed vehicles. If these anchorages are usedwithout the appropriate Ford seats, seat belt systems,and hardware, Ford Motor Company makes norepresentation as to conformity with this Standard.


The preceding statements for FMVSS 207 are appropriatecompliance representations for CMVSS 207, Anchorageof Seats, if this incomplete vehicle was manufactured forsale or use in Canada.

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208 The statements below are applicable to the IncompleteE-Series Van when equipped with trimmed front seatsoption if the GVWR is 3856 kg [8,500 lb] or less and theUnloaded Vehicle Weight, when completed, is 2495 kg[5,500 lb] or less (Type I, II):

This vehicle, when completed, will conform to Standard208, Occupant Crash Protection, if:

The Unloaded Vehicle Weight does not exceed theappropriate weight on Table A on page 16.

The steering column, steering intermediate andcoupling shaft, steering wheel, steering gear, steeringlinkage, related structural components, and attachinghardware, as installed by Ford Motor Company, arenot removed, relocated, altered, or modified in any way.


The seat belt components installed by Ford MotorCompany are not removed, relocated, or altered. If theseat belt components are temporarily removed for anyreason, they must be reinstalled to the specificationsas shown in Figure A on page 34.

Front seats that have been removed for finalmanufacture are reinstalled to the specifications asshown in the Figures on page 35.

The seat belt warning system, as originally installed, isnot removed, replaced, modified, or altered in any way.

Window or roof modifications do not exceed the definedcut out areas shown in the Figures on pages 38, 39,and 40.

No compressible material is installed between frontseat assembly and the floor pan.

No additional components or modifications are madeto the areas defined at the Occupant Protection Zoneshown in Figure D on page 37.

The Air Bag Supplemental Restraint System asoriginally installed (see Figure E on page 37), is notremoved, relocated, altered, or modified in any way.

The Air Bag Supplemental Restraint System InformationLabels that are affixed to the front sun visors are visible,and not altered, modified, or removed. If the Air BagSupplemental Restraint System Information Labels arenot affixed to the front visors but shipped in dunnage,the following is necessary to meet Standard 208:

The information label must be permanently affixedto each visor in an upright position readable from thedriver’s or passenger’s seating position.

If the label is not visible when the visor is stored (upposition), an Air Bag Alert Label shall be placed onthe visible surface of the visor as specified in Section4.5.1(c) of Standard 208.

No alteration or modifications are made to the body,chassis (including front bumper), drivetrain, bodymounts, or front suspension from the B-pillar forward.

Any front overhead console installed on an IncompleteE-Series is configured as follows:

Front header (full width) overhead consoles mayextend down no more than 2 inches as measuredfrom the Ford installed headliner† and extendrearward no more than 6 inches as measured fromthe midpoint between the Ford installed sun visorinboard retaining clips (vehicle centerline).

Center roof mounted consoles may extend down nomore than 3 inches as measured from the Fordinstalled headliner† and width is limited to 8 inches(4 inches either side of the vehicle centerline).

All overhead consoles are designed andmanufactured to provide friendly surfaces on all sidesand edges which could be contacted by an occupant.

Any seat belt assemblies added to a vehicle must conformto the applicable requirements of this Standard.


† The Headliner Plane is defined on Figure G3 page 39, forvehicles without the Ford headliner.

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208 (Continued)

208 The statements below are applicable to the incompleteE-Series Van when equipped with untrimmed front seatsoption if the GVWR is 3856 kg [8,500 lb] or less and theUnloaded Vehicle Weight, when completed, is 2495 kg[5,500 lb] or less (Type II):


The Unloaded Vehicle Weight does not exceed theappropriate weight on Table A page 16.



The seat belt components installed by Ford MotorCompany are not removed, relocated, or altered. If theseat belt components are temporarily removed for anyreason, they must be reinstalled to the specificationsfor the appropriate vehicle type shown in Figure A onpage 34.

Front seats that have been removed for finalmanufacture are reinstalled to the specifications forappropriate vehicle type as shown in the Figures onpage 35.

The seat belt warning system, as originally installed, isnot removed, relocated, altered, or modified in any way.

The completed front seats are within the SeatingReference Point specifications in Figure C onpage 36.



No additional components or modifications are madeto the areas defined as the Occupant Protection Zoneshown in Figure D on page 37.

The Air Bag Supplemental Restraint System asoriginally installed (see Figure E on page 37), is notremoved, relocated, altered, or modified in any way.

The Air Bag Supplemental Restraint System InformationLabels that are affixed to the front sun visors are visible,and not altered, modified, or removed. If the Air BagSupplemental Restraint System Information Labels arenot affixed to the front visors but shipped in dunnage,the following is necessary to meet Standard 208:



After the front seats and B-pillar trim are installed, theseat belt system components must comply with:

Adjustment requirements specified by s7.1 as theserequirements apply to seat belt fit, to the intersectionof the upper torso belt with the lap belt, and to childseat lockability, and

Latch mechanism requirements specified by s7.2 asthese requirements apply to the accessibility of seatbelt components, and

Latch plate access, retraction, seat belt guides, andhardware requirements specified by s7.4 as theserequirements apply to comfort and conveniencerequirements of the seat belt system.

The seat hardware including the seat back frames arefree of sharp edges to prevent damage to the seat beltwebbing during an impact.

Do not obstruct the E-Series seat belt path in the areaof “Point A” (Figure C, page 36). All seat belt contactablesurfaces must be free of burrs, parting lines, sharpedges, or any other impediment that could impair ordamage the seat belt in load bearing situations.

No alteration or modifications are made to the bodychassis (including front bumper), drivetrain, bodymounts, or front suspension from the B-pillar forward.





Any seat belt assemblies added to this vehicle mustconform to the applicable requirements of this Standard.


† The Headliner Plane is defined on Figure G3 page 39,for E-Series vehicles without the Ford headliner.

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208 The statements below are applicable to the IncompleteE-Series Recreational Van and van with seat deleteoption, if the GVWR is 3856 kg [8,500 lb] or less andthe Unload Vehicle Weight, when completed, is 2495kg [5,500 lb] or less (Type III):

The seat delete option includes front seat pedestals, frontseat tracks, front seat belt and buckle assemblies mountedto the seat tracks, restraint system, fasteners, and atemporary transit seat. Because the permanent seats tobe installed by a subsequent stage manufacturer arecritical to the performance of the completed vehicle andto the dynamic test requirements of Standard 208,Occupant Crash Protection, conformity to this Standardis not substantially affected by the design of thisincomplete vehicle.

Ford offers the following information and guidelines toassist subsequent stage manufacturers who choose toinstall front seat assemblies in Incomplete E-Series Vanvehicles.

The completed front seat assemblies include thefollowing Ford Motor Company components: Seatpedestal, seat tracks, restraint system, and all fastenersprovided, and the fasteners are torqued to thespecifications listed in Figure B on page 35.

The completed front seat assemblies, when installed,will have the same location, construction, and spatialrelationship to the seating system as provided by FordMotor Company.

The Unloaded Vehicle Weight does not exceed theappropriate weight on Table A on page 16.



The seat belt components installed by Ford MotorCompany are not removed, relocated, or altered. If theseat belt components are temporarily removed for anyreason, they must be reinstalled to the specificationsas shown in Figure A on page 34.

The completed front seats are installed to thespecifications as shown in the Figures on page 35.

The seats, seating hardware, seat belt warning system,and all attaching hardware are installed in accordancewith, and comply with, this Standard and Standard 207,Seating Systems.

The completed front seats, when installed, are locatedwithin the dimensional specifications for the SeatingReference Point and the torso angle is positioned asspecified in Figure C on page 36.



No additional components or modifications are madeto the areas defined as the Occupant Protection Zoneshown in Figure D on page 37.

The Air Bag Supplemental Restraint System as installedby Ford Motor Company is not removed, relocated,

modified, or altered in any way as shown in Figure Eon page 37.

The Air Bag Supplemental Restraint System InformationLabels that are affixed to the front sun visors are visibleand not altered, modified, or removed. If the Air BagSupplemental Restraint System Information Labels arenot affixed to the front visors but shipped in dunnage,the following is necessary to meet Standard 208:



After the front seats and B-pillar trim are installed, theseat belt system components must comply with:

The seat belt buckle pretensioner, air bags, andelectronic sensor module are bar coded with a uniqueserial number which is matched to the vehicle VIN.The completed vehicle must contain the same seatbelt buckle pretensioner, air bags, and electronicsensor module that were installed by Ford MotorCompany in the incomplete vehicle.




The seat hardware including the seat back frames arefree of sharp edges to prevent damage to the seat beltwebbing during an impact.

Do not obstruct the E-Series seat belt path in the areaof “Point A” (Figure C, page 36). All seat belt contactablesurfaces must be free of burrs, parting lines, sharpedges, or any other impediment that could impair ordamage the seat belt in load bearing situations.

No alteration or modifications are made to the body,chassis (including front bumper), drivetrain, bodymounts, or front suspension from the B-pillar forward.




† The Headliner Plane is defined on Figure G3 page 40,for E-Series vehicles without the Ford headliner.


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208 The statements below are applicable to the followingincomplete vehicle types when equipped withuntrimmed front seats or seat delete option and eitherthe GVWR is over 3856 kg [8,500 lb], the UnloadedVehicle Weight, when completed, is over 2495 kg[5,500 lb], or the vehicles are manufactured foroperation by persons with disabilities (Type II):


Cutaway


The seat belt components installed by Ford MotorCompany are not removed, relocated, altered, ormodified. If the seat belt components are temporarilyremoved for any reason, they are reinstalled to thespecifications for E-Series shown in Figure A onpage 34 and Figure B on page 35.

After the front seats and B-pillar trim are installed, theseat belt system components comply with:




No actions are taken which would impair the integrityof the seat belt systems and the seat belt warningsystem.

The Air Bag Supplemental Restraint System InformationLabels that are affixed to the front sunvisors are visibleand not altered, modified, or removed.


208 The statement below is applicable to the followingincomplete vehicles when equipped with Ford trimmedfront seats and either the GVWR is over 3856 kg[8,500 lb], the Unloaded Vehicle Weight, whencompleted, is over 2495 kg [5,500 lb], or the vehiclesare manufactured for operation by persons withdisabilities (Type I, II):

Chassis Cab


Cutaway


The seat belts, seat belt warning system, and attachinghardware installed by Ford Motor Company are notremoved, relocated, altered, or modified.

No actions are taken which would impair the integrityof the belt and seat belt warning systems. (A seat beltwarning system is not required for a vehicle with a

GVWR over 4536 kg [10,000 lb] or for a bus).

The Air Bag Supplemental Restraint System InformationLabels that are affixed to the front sunvisors are visibleand not altered, modified, or removed. If the Air BagSupplemental Restraint System Information Labels arenot affixed to the front visors but shipped in dunnage,the following is necessary to meet Standard 208:



Front blocker beams may be removed to allow theinstallation of snow plow attachment hardware. Thetruck must not be operated without either the blockerbeam or snow plow attachment hardware in place. (F-Series chassis cab).


208 The statement below is applicable to the followingvehicle types (Type III):




Conformity with Standard 208, Occupant Crash Protection,is not substantially affected by the design of thisincomplete vehicle; accordingly, Ford Motor Companymakes no representation as to conformity of this vehicle.Any seat belt assemblies added to this vehicle mustconform to the applicable requirements of this Standard.


The preceding statements and supporting figures forFMVSS 208, on pages 30-40, are appropriate compliancerepresentations for CMVSS 208, Seat Belt Installation, ifthis incomplete vehicle was manufactured for sale or usein Canada. In such a case, CMVSS 208 paragraphs (13),(14), and (15) are substituted for the reference to FMVSS208 Section 7.1; CMVSS 208 paragraph (20) should besubstituted for the reference to FMVSS 208 Section 7.2;and CMVSS 208 paragraphs (29), (30), (31), (32), (33),(34), (35), (36), (37), (38), (39), and (40) should besubstituted for the reference to FMVSS 208 Section 7.4.

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WARNING:

VEHICLES OVER 3856 kg (8,500 lb) GVWR AND2495 kg (5,500 lb) UVW ARE EQUIPPED WITHSUPPLEMENTAL RESTRAINT SYSTEMS (AIR BAGS)WHICH ARE STANDARD ON THE DRIVER’S SIDE, ANDSTANDARD OR OPTIONAL FOR THE PASSENGERSIDE. MODIFICATIONS TO THE VEHICLE FORWARD OFTHE CRASH SENSOR THAT IS SHOWN IN FIGURE EOR F PAGE 37, MAY AFFECT THE DEPLOYMENT OFTHE AIR BAG WHEN SO EQUIPPED. REFER TO THEFORD TRUCK BODY BUILDERS’ LAYOUT BOOK FORSNOW PLOW PREPARATION PACKAGES ANDINSTALLATION INSTRUCTIONS WHICH ARECOMPATIBLE WITH AIR BAGS.

•

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CRITICAL CONTROL ITEM

VIEW A

A

VIEW B

B

A VIEW A


IVM0040

FRONT OFVEHICLE

FRONT OFVEHICLE

XC2A-15602B82ADJ. ASY.

PANEL ASY.UPPER

F65B-15602B90COVER ASY.

F7UB-1560262COVER ASY.1 REQ’D. EA. SIDE

N806773-S190NUT - TORQUE40.0 6.0 Nm+

15611B09BELT ANDRETRACTOR ASY.

ALL CUTAWAYMODELS ONLY

368273-S100BOLT - TORQUE40 6 Nm

PANEL ASY. COVERALL WAGON - VAN MODELS ONLYDRIVER - SEAT(LEFT HAND) INSTALLATION

SHIPPING CLIP MUSTREMAIN CLIPPED TOBELT PRIOR TOATTACHMENT TORETRACTOR INTOVEHICLE.

CUTAWAY & VAN MODELS

XC2A-15602B82ADJ. ASY.

F65B-602B90COVER ASY.

F7UB-1560262COVER ASY.1 REQ’D. EA. SIDE

N806773-S190NUT - TORQUE

611B08BELT ANDRETRACTOR ASY.

SHIPPING CLIP MUSTREMAIN CLIPPED TOBELT PRIOR TOATTACHMENT TORETRACTOR INTOVEHICLE.

PANEL ASY.COVER

ALL WAGON - VAN MODELS ONLYPASSENGER SEAT(RIGHT HAND) INSTALLATION

ALL CUTAWAYMODELS ONLY

+

[29.5 4 ftlb]+

[29.5 4 ftlb]+

40.0 6.0 Nm+ [29.5 4 ftlb]+

40.0 6.0 Nm+ [29.5 4 ftlb]+

PIABOLT-TORQUE

40.0 6.0 Nm+[29.5 4 ftlb]+

PIABOLTTORQUE

40.0 6.0 Nm+ [29.5 4 ftlb]+

PIABOLT - TORQUE

40.0 6.0 Nm+ [29.5 4 ftlb]+

PIABOLT-TORQUE

40.0 6.0 Nm+ [29.5 4 ftlb ]+

FIGURE A – E-SERIES FRONT SEAT RESTRAINT SYSTEM

VIEW IN CIRCLE C

BB

A

A

D

D

C

IVM0041

6.0 MIN. CLEARANCE

TO ALL ADJUSTEDPOSITIONS

6.0 MIN.

SEAT BELTWEBBING

6.0 MIN. CLEARANCE

AROUND BELTPERIPHERY AT MAX.TRAVEL POSITIONS

6.0 MIN.

UP POSITION

6.0

3.0

RETRACTOR9.5 RADIUS MIN.

13.0 MIN. FROM

COVER TORELEASE KNOB

2.0 MIN.

(WITH DRINGLOCATED ONSHLDR.BOLT)

1560262 REF.

(3) FULLTHREADEXPOSED

DOWNADJUSTEDPOSITION

UPADJUSTEDPOSITION

6.5 MIN. FROM

RELEASE KNOBTO INTERIOR TRIM

12.5 MIN.

OVERLAP

ALL DIMENSIONS ARE IN MILLIMETERSNOTE:SECTION AA

SECTION BBMAIN VIEW

SECTION DD

FRONT OFVEHICLE

INTERIOR TRIM

[.37 IN]

[.50 IN]

[.25 IN]

[.50 IN]

[.08 IN]

[.24 IN]

[.24 IN]

[.24 IN]

[.24 IN]

[.24 IN]

[.12 IN]

[ ] DIMENSIONS ft-lb OR INCHES


E-SERIES DRIVER (L.H.) SEAT INSTALLATION E-SERIES PASSENGER (R.H.) SEAT INSTALLATION

FIGURE B - E-SERIES FRONT SEAT INSTALLATION

E-SERIES DRIVER (L.H.) SEAT DELETE OPTION

POWER L.H. SHOWN

SEAT ASY.

N802351-S424STUD 2 REQ’D.

M200751TRACK ASY.FRT. ST.

56912-S58SCREW 4.2 x 19TAPPING

N800937-S424NUT & WASHER ASY.2 REQ’D.55.0 8.3 Nm

N620481-S58NUT M8 x 1.75 HEX FLANGETORQUE 25.0 3.8 Nm

N811326-S424SCREW 2 REQ’D.55.0 8.3 Nm+ +

+

611D02ASTUD COVER4 REQ’D.

M2003089SUPPORT ASY.

SWITCH ASY.ST. CONTROL

F7UB-14A699CEWIRING ASYSEATCONTROL FEED

N801078-S424SCREW M8 x 1.25 HEX4 REQ’D.TORQUE 25.0 3.8 Nm+

PIA BOLTTORQUE40.0 6.0 Nm+

IVM0023

JUMPER

F8UB-14A699AAWIRING ASYSEATCONTROL FEEDJUMPER

[29.5 + 4 ft-lb]

[18.4 + 2.8 ft-lb]

[40.6 + 6 ft-lb]

[18.4 + 2.8 ft-lb][40.6 + 6 ft-lb]-

-

--

--

-

-

--

MANUAL R.H. SHOWN

SEAT ASY.

+

N801078-S424SCREW M8x1.25HEX 4 REQ’D.TORQUE25.0 3.8 Nm

A2008167TRACK ASY.

F7UB-1561202APYROTECHNICASY. R.H.

PIA BOLTTORQUE40.0 6.0 Nm+

COVERFRT.ST. PIVOT

36912S58SCREW 4.2 x 19.0TAPPING

N811326-S424-SCREW 2 REQ’D.55.0 8.3 Nm+

N620482-S424-M10 HEX NUT HD.NUT W/WASHER4 REQ’D.



F7UB-1562506ASUPPORT ASY.(R.H. MNL)

F7US-14A699DBWIRE ASY.

F7UB-1561755AHANDLE FRT. ST.TRACK

A2008168TRACK ASY.

IVM0038

+[18.4 2.8 ft-lb]

+[29.5 4 ft-lb]

+[40.6 6 ft-lb]

--

--

--

O

O

PRESS

A

CLEARANCEZONE

CLEARANCEZONE

10

45

O10

O15

SIDE VIEW REAR VIEW

CENTER OF VEHICLEFRONT OF VEHICLE

PRETENSIONER CLEARANCE ZONE

T2007563SEAT

F7UB-1561202ABUCKLE ASY.

A2008170 DRIVERA2008168 PASS.R.H. TRACK

NUTS & BOLTS 4 REQ’D.FOR SHIPPINGPURPOSESONLY


N800937-S424NUT & WASHER ASY.2 REQ’D.55.0 8.3 Nm

A2008169 DRIVERA2008167 PASS.R.H. TRACK


F7UB1567506ASUPPORT ASY.

COVER FRTST. PVT.

PIA BOLTTORQUE40.0 6.0 Nm

N811326-S424SCREW 2 REQ’D.55.0 8.3 Nm

F7U-S14A699DBWIRE ASY.

F7UB1561755AHDL.FRT.ST.TRK.

THE SHADED AREA MUST BE FREE OF OBSTRUCTIONS.THE BUCKLE MOVES DOWNWARD THROUGH THE SHADEDZONE AND MUST NOT CONTACT ANY COMPONENT WHICHMAY DEGRADE ITS PERFORMANCE.

IMPORTANT:

DO NOT INSTALL ADDITIONAL COMPONENTS IN THE SHADEDAREA, OR ALTER OR MODIFY THIS AREA.

VIEW A

+

+

+

IVM0022

[ ] DIMENSIONS ft-lb OR INCHES

[29.5 4 ft-lb]+

[40.6 6 ft-lb]+

[40.6 6 ft-lb]+

--

--

--


SRP INFORMATION POINT A(SEAT POSITION IS 10.0mm [0.39] FORWARD (SEAT POSITION IS AT THE MIDPOINT

OF REARMOST POSITION) OF AVAILABLE TRAVEL) A B C D E F

MIN. MAX. DRIVER - SEAT (VAN AND CUTAWAY) 217.8 105.0 384.2 356.0 67.0 937.4

[8.57] [4.13] [15.13] [14.01] [2.64] [36.90]PASSENGER - SEAT (VAN AND CUTAWAY) 277.3 103.0 377.0 412.0 65.0 960.1

[10.92] [4.06] [14.84] [16.22] [2.56] [37.80]

FIGURE C - E-SERIES SEATING REFERENCE POINT (SRP)

IMPORTANT:

THE TORSO ANGLE IS DETERMINED BYUSING THE METHOD SPECIFIED INSAE J826 (MAY 1987)

POINT A

D

A

FC

[ ] DIMENSIONS ARE INCHES

E EPOINT A POINT A

DRIVER − SEATPASSENGER − SEATCL

VEHICLE

BB

DRIVER SIDE ONLY

TORSO ANGLE

18 DRIVER21 PASSENGER

SEATBASE

SEATBASE

CL OUTSIDEFRONTFASTENER


THE DIMENSIONS IN THIS FIGURE REQUIRE THE VEHICLE TO BE ATDESIGN POSITION. ECONOLINE VAN VEHICLES AT DESIGN POSITIONWILL BE LEVEL FRONT TO REAR, AND SIDE TO SIDE, ON THE UPPERSURFACE OF THE RIBBED FLOOR PANEL FROM THE B−PILLAR REARWARD.


SEAT BACKPIVOT

6.0[0.24] 510.0

[20.08]HEELPOINT

SRP − HAS A 12.7 [0.50] RADIALTOLERANCE PERMITTED FROMBASE SRP


FIGURE D - E-SERIES OCCUPANT PROTECTION ZONE FIGURE E - E-SERIES SUPPLEMENTAL RESTRAINT SYSTEM (Air Bags, Sensors, and Wiring)

FIGURE F - SUPER DUTY F-SERIES OCCUPANT PROTECTION ZONE

DO NOT MODIFY OR ALTER ANY COMPONENTS OR AREASOF THE VEHICLE IN THE VICINITY OF THE COMPONENTSTHAT ARE IDENTIFIED IN THIS ILLUSTRATION.

READINESS

ELECTRONICCRASH SENSORMODULE

CRASHSENSOR

CONNECTOR

STEERING

INDICATOR

COMPARTMENT

AT SAFETY

AIRBAG

WHEELINSTRUMENTPANEL

ENGINE

HARNESS

WALL

AIRBAG

HARNESS

DO NOT INSTALL ADDITIONAL COMPONENTS IN THESHADED AREAS, OR ALTER OR MODIFY THESE AREAS.

BATTERY72 WAYCONNECTOR

AIRBAGDEACTIVATIONSWITCH

PASSENGERAIRBAGMODULE

ELECTRONIC CRASHSENSOR MODULE

DRIVERAIRBAGMODULE

DO NOT INSTALL ADDITIONAL COMPONENTS IN THESHADDED AREAS, OR ALTER OR MODIFY THESE AREAS.

DO NOT MODIFY OR ALTER ANY COMPONENTS OR AREASOF THE VEHICLE IN THE VICINITY OF THE COMPONENTSTHAT ARE IDENTIFIED IN THIS ILLUSTRATION.


FIGURE G1 - BODY PANEL WINDOW REMOVAL AREA – E-SERIES (DRIVER SIDE – L.H.)

CUT LINE

SECTION BB

CUT LINE CUT LINE

SECTION CC

SECTION DD

CUT LINE

CUT LINE

SECTION AA

B

A

FRONT OFVEHICLE

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.

THE SPOTWELDS (X) IN THIS

AREA MUST REMAIN INTACT.

711.2[ 28.00 ]

MAXIMUM

D


711.2[ 28.00 ]

MAXIMUM

DCCA

B


FIGURE G2 - BODY PANEL WINDOW REMOVAL AREA – E-SERIES (PASSENGER SIDE - R.H.)

E

F

FRONT OF

VEHICLE

THE SPOTWELDS ( X ) INTHIS AREA MUST REMAININTACT.

G

NOTE: SHADED AREA REPRESENTS MAXIMUM OPENING IN BODY PANELSTHE SECTIONS SHOWN ARE A LARGER SCALE THAN THE SIDE VIEW

FOR THE PURPOSE OF CLARITY.[ ] DIMENSIONS ARE IN INCHES

CUTLINE

SECTION EE

SECTION FF

CUTLINE

SECTION GG

CUTLINE

533.4[21.00]

MAXIMUM WITHSLIDING DOOR

711.2[28.00]

MAXIMUMWITH CARGO

DOORS

F

GE


FIGURE G3 - ROOF PANEL REMOVAL AREA - E-SERIES

END OF ROOF

EXTENDED VAN

END OF ROOF

EXTENDED VAN

OR WAGON

REGULAR VAN

NOTE: SHADED AREA REPRESENTS MAXIMUM OPENING IN BODY PANELS.


CL

OUTER EDGE

OF TROUGHREGULAR VAN

"B" PILLARREINFORCEMENT

WINDSHIELDHEADER

FORWARDCUT LINE

50.8[2.00]

SECTION ATCL OF ROOR

HEADLINER PLANE, FOR VEHICLES NOT EQUIPPED WITHA FORD HEADLINER, USE A PLANE DETERMINED BY APOINT AT THE LOWER REAR OF THE WINDSHIELD HEADERTO THE MIDPOINT ON THE BPILLAR REINFORCEMENT.

203.2[8.00]

203.2[8.00]

CUTLINE CUT

LINE

FRONT OFVEHICLE

END OF ROOF

CUTAWAY

SECTION ATC OF FLOORL


209 The statements below are applicable to the followingincomplete vehicle types with front seat(s) (Type I):

Chassis Cab


ÿÿÿCutaway

This vehicle, when completed, will conform to Standard209, Seat Belt Assemblies, if:

No alterations or replacements are made to the seatbelt assemblies and attaching hardware.

No action is taken that would impair the integrity of theseat belt system provided.

Any seat belt assemblies added to a vehicle must conformto the requirements of this Standard.

209 The statement below is applicable to the followingincomplete vehicle types with no front seats (Type III):

ÿÿ Incomplete E-Series Van

ÿÿ Cutaway

Conformity with the pelvic restraint, upper torso restraint,release, adjustment, and webbing requirements ofStandard 209, Seat Belt Assemblies as specified in s4.1(b), (c), (e), (g), and (h), respectively, is not substantiallyaffected by the design of this incomplete vehicle;accordingly Ford Motor Company makes norepresentation as to conformity with these requirementsof Standard 209. However, Ford Motor Companyrepresents that the seat belt assemblies provided by FordMotor Company conform to the applicable singleoccupancy hardware, attachment hardware, strap,marking, installation instructions, usage and maintenanceinstructions, workmanship, webbing performance,hardware performance, and assembly performancerequirements detailed in the remaining paragraphs ofthe standard not specified above, provided no alterationsor replacements are made to the seat belt assembliesand attaching hardware, as provided by Ford MotorCompany, and further provided that no action is taken bysubsequent stage manufacturers to impair the integrity ofthe seat belt system provided. Any additional seat beltassemblies installed must conform to the requirementsof this Standard.





Conformity with Standard 209, Seat Belt Assemblies, isnot substantially affected by the design of this incompletevehicle; accordingly Ford Motor Company makes norepresentation as to conformity with this Standard.


The preceding statements for FMVSS 209 are appropriatecompliance representations for CMVSS 209, Seat BeltAssemblies, if this incomplete vehicle was manufacturedfor sale or use in Canada. In such a case, CMVSS 209paragraphs (2) and (3), (4) and (5), (14), (15), and (7) aresubstituted for the reference to FMVSS 209 Sections4.1(b), (c), (e), (g),and (h), respectively.

210 The statements below are applicable to all incompletevehicle types except Basic (Stripped) Chassis (TypeI):

This vehicle, when completed, will conform to Standard210, Seat Belt Assembly Anchorages, if:

No alterations are made to the front seat beltanchorages, front seat belt assemblies, floor pan, floorpan reinforcements, or body mounts.

No alterations are made to the rear cab panel or rooffor the Chassis Cab.

E-Series window or roof modifications do not exceedthe defined cut out areas shown in the Figures on pages38, 39, and 40.

The Incomplete E-Series Van and Cutaway with no frontseats must have completed front seats installed thatconforms to the seat location criteria shown in Figure Con page 36.

The Incomplete E-Series Van, Wagon, and Cutaway musthave a seat belt anchorage system installed for eachadditional designated seating position that conforms tothe applicable requirements of this Standard.

The Incomplete E-Series Recreational Van or the E-Series Wagon may have additional seat belt anchoragesfor designated seating positions other than the front driverand passenger seats. Also, Chassis Cab vehicles mayhave additional seat belt anchorages for designatedseating positions on optional seats not provided onincomplete vehicles. These locations apply to specifichardware and designated seating positions used in Fordcompleted vehicles. If these anchorages are used withoutthe appropriate Ford seats, seat belt systems, andhardware, Ford Motor Company makes no representationas to conformity with this Standard.

The Incomplete E-Series Recreational Van, whenequipped with the seat delete option, will include bothfront seat pedestals, pretensioner restraint systems, seattracks, and a temporary driver’s seat. The pretensionerrestraint system is attached to the seat track, therefore,the completed seat assembly must comply with therequirements of FMVSS 210 and 207.





Conformity with Standard 210, Seat Belt AssemblyAnchorages, is not substantially affected by the design ofthis incomplete vehicle; accordingly, Ford Motor Companymakes no representation as to conformity with thisStandard.


The preceding statements for FMVSS 210 are appropriatecompliance representations for CMVSS 210, Seat BeltAssembly Anchorages, if the incomplete vehicle wasmanufactured for sale or use in Canada.

210.1 Canadian Requirements applicable to all incompletevehicle types with a GVWR of 3856 kg [8,500 lb] or lessand an unloaded vehicle weight of 2495 kg [5,500 lb] orless except Basic Stripped Chassis (Type I):

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210.1 (Continued on Next Page)


This vehicle, when completed, will conform to Standard210.1, User-Ready Tether Anchorages for RestraintSystems, if:

No alternations are made to the front passenger seattether anchorages and access to the anchorages isnot restricted.

For the incomplete E-Series Van and Cutaway with nofront seats:

If a front passenger seat is installed, it must have therequired tether anchor.

If the E-Series is completed as a MultipurposePassenger Vehicle (MPV) and a second forward facingrow of designated seating is installed, for a total of fiveor fewer seating positions, at least two of the secondrow forward facing seats must have the required tether.

If the E-Series is completed for certification as a Truckand a second row of designated seating is installed,then all of the second row seats must have tetheranchors.

If there are more than five designated seating positions,at least three of the forward facing seating positions tothe rear of the first row must have the required tether.

210.1 Canadian Requirements applicable to the followingincomplete vehicle types (Type III):



Conformity with Standard 210.1, User-Ready TetherAnchorages for Restraint Systems, is not substantiallyaffected by the design of these incomplete vehicles;accordingly, Ford Motor Company makes norepresentations as to conformity with this Standard.

212/ Note219

The terms “body” or “body structure,” in the 212 and 219statements that follow, include any equipmentpermanently attached to that body or body structureinstalled by the subsequent stage manufacturer as wellas the basic body or body structure.

212/ INFORMATION219

Refer to the Design Recommendations section in theFord Truck Body Builders’ Layout Book for Second UnitBody Attachment information to aid in designing secondunit bodies and their attachments for compatibility with E-Series and F-Series vehicles.

212/ The statements below are applicable to the following219 Incomplete vehicle types if the GVWR is 4536 kg

[10,000 lb] or less (Type I, II):

Chassis Cab


Cutaway

This vehicle, when completed, will conform to Standard212 Windshield Mounting, and Standard 219, WindshieldZone Intrusion, if:

The following windshield system components, relatedstructural components, and hardware, as installed byFord Motor Company, are not removed, relocated,

altered, or modified in any way except as specified inthis manual:

Windshield and windshield mounting system

Cab and front end structural components includingthe roof, pillars, cowl, cowl reinforcements, hood,doors, fenders, hood restrictors and apronreinforcements, and frame and frame reinforcements

Radio antenna and air cleaner assembly

Doors and hood mounting, hinging, and latchingsystems

Hood ornamentation

Bumper and bumper mounting system †

No alteration or modification made to the incompletevehicle as manufactured by Ford Motor Company andno components or structure installed by a subsequentstage manufacturer results in any loss of windshieldretention (as defined in Standard 212) or anypenetration of the inner surface of the windshield orintrusion into the protected zone (as defined in Standard219) when the vehicle is impacted in any mannerspecified by applicable provisions of Standard 212 orStandard 219. Conformity to Standards 212 and 219for a vehicle having an Unloaded Vehicle Weightgreater than 2,495 kg [5,500 lb] is established by testinga representative vehicle at an Unloaded Vehicle Weightof 2,495 kg [5,500 lb] as permitted by s6.1 (b) and s7.7(b) of Standards 212 and 219, respectively.

Incomplete E-Series Van, E-Series Wagon, andCutaway type vehicles, have an Unloaded VehicleWeight that does not exceed the value designated inTable A page 16 corresponding to the vehicle’s model,wheelbase, and engine size.

For Chassis Cab only:

The front end of the body installed by the subsequentstage manufacturer is located at least 76.2 mm[3.0 in] rearward of the rearmost point of the cab forF-Series.

The body installed by the subsequent stagemanufacturer is mounted securely and so designedthat, when the completed vehicle is impacted in anymanner specified by applicable provisions ofStandards 212 and 219, body deformation ormovement relative to the frame does not result inany separation or loss of body attachment to theframe.

For the Chassis Cab, the maximum SUB weight andSUB center of gravity as installed by the subsequentstage manufacturer and the Unloaded Vehicle Weightdoes not exceed the values specified in Table B page17, corresponding to the incomplete vehicle type,wheelbase, and engine size.

† Temporary removal of the front bumper and front bumpermounting system during manufacture and reinstallation inaccordance with the instructions provided in the Ford TruckShop Manual should not adversely affect the complianceof a completed vehicle to Standards 212 and 219.

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210.1 (Continued)


212/ The statement below is applicable to the following219 incomplete vehicle types if the GVWR is 4536 kg

[10,000 lb] or less (Type I):




The Basic (Stripped) Chassis is designed by Ford MotorCompany to be completed as a walk-in van type vehicle.Walk-in vans are exempt from the requirements ofStandard 212, Windshield Mounting, and Standard 219,Windshield Zone Intrusion.

212/ Canadian Requirements:219

The preceding statements for FMVSS 212/219 areappropriate compliance representations for CMVSS 212,Windshield Mounting, and CMVSS 219 Windshield ZoneIntrusion, if this incomplete vehicle was manufacturedfor sale or use in Canada. In such a case, CMVSS 212and 219 paragraphs (5.1) and (8)(b) are substituted forthe reference to FMVSS 212 and 219 Sections 6.1(b)and 7.7(b) respectively.

213 The statement below is applicable to all incompletevehicle types (Type III):

Conformity with Standard 213, Child restraint systems, isnot substantially affected by the design of the incompletevehicle; accordingly Ford Motor Company makes norepresentation as to conformity with this Standard. Anychild restraint system that is added or incorporated intothe design of a designated seating position must conformto the requirements of this standard.


The preceding statement for FMVSS 213 is anappropriate compliance representation for CMVSS 213,Child Seating and Restraint Systems, if this incompletevehicle was manufactured for sale or use in Canada.

214 The statements below are applicable to the followingvehicle types if the GVWR is 4536 kg [10,000 lb] orless (Type I):

Chassis Cab


This vehicle, when completed, will conform to Standard214, Side Impact Protection, if:

No alterations, modifications, or replacements are madeto the door, surrounding door structure, door hinges,door latches and strikers, or any attaching hardwareas provided by Ford Motor Company.

The Incomplete E-Series Van or Wagon roof or windowmodifications do not exceed the defined cut out areasshown in the Figures on pages 38, 39, and 40,respectively.

214 The statements below are applicable to the E-SeriesCutaway if the GVWR is 4536 kg [10,000 lb] or less(Type I):

This vehicle, if equipped with both front doors asmanufactured by Ford Motor Company when completed,will conform to Standard 214, Side Impact Protection, ifno alterations, modifications, or replacements are madeto the door, surrounding door structure, the entire roofstructure, door hinges, door latches and strikers, or anyattaching hardware provided by Ford Motor Company.

This vehicle if equipped with a driver-side door only whencompleted, will conform to Standard 214, Side ImpactProtection, for that door only if no alterations,modifications, or replacements are made to the door,surrounding door structure, the entire roof structure, doorhinges and strikers, or any attaching hardware providedby Ford Motor Company.

Any side door and surrounding body structure added tothis vehicle, if a designated seating position is lessthan 254 mm [10 in] inboard of that door, must conform tothe requirements of this standard.





The Basic (Stripped) Chassis is designed by Ford MotorCompany to be completed as a walk-in-van type vehicle.Walk-in vans are exempt from the requirements ofStandard 214, Side Impact Protection. See walk-in vandefinition on page 7.


The preceding statements for FMVSS 214 are appropriatecompliance representations for CMVSS 214, Side DoorStrength, if this vehicle is manufactured for sale or use inCanada.

216 The statements below are applicable to the ExplorerBasic (Stripped) Chassis if the GVWR is 2722 kg[6,000 lb] or less (Type III):

Conformity with Standard 216, Roof Crush Resistance,is not substantially affected by the design of thisincomplete vehicle; accordingly Ford Motor Companymakes no representation as to conformity with thisStandard.

Any applicable body structure or component that is addedto this vehicle must conform to the requirements of thisStandard.

217 The statements below are applicable to the incompleteE-Series Van or Wagon when completed as a bus (notschool bus) (Type I):

This vehicle, when completed, will conform to Standard217, Bus Window Retention and Release, if no alterations,modifications, or replacements are made to the doors,window glazing materials, window mounting systems, orthe surrounding door structure as provided by Ford MotorCompany.

Any windows, doors, additional components, oremergency exits added to this vehicle must meet therequirements of this Standard.

217 The statement below is applicable to the Cutaway whencompleted as a bus (including school bus) (Type III):

Conformity with Standard 217, Bus Window Retentionand Release, is not substantially affected by the designof this incomplete vehicle; accordingly Ford MotorCompany makes no representation as to conformity withthis Standard other than that the front door windows willcomply with the s5.1 requirements of this Standard if nomodifications, alterations, or replacements are made to

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217 (Continued on Next Page)

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the window glazing materials, window mountingsystem,or the surrounding door structure as provided byFord Motor Company.


The preceding statements for FMVSS 217 are appropriatecompliance representations for CMVSS 217, BusEmergency 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 saleor use in Canada. In such a case, CMVSS 217 paragraphs(2) and (2.1) are substituted for the reference to FMVSS217 Section 5.1. When an E-Series Cutaway is completedas a School Bus, Ford Motor Company makes norepresentation as to conformity to this Standard.

219 See combined statements under “212/219” for allvehicle types.

220 The statements below are applicable to the Cutawayequipped with the School Bus Prep Package whencompleted as a school bus (Type III):

The Cutaway body structure as manufactured by Ford,does not meet the strength requirements of FMVSS 220,School Bus Rollover Protection; accordingly Ford MotorCompany makes no representation as to conformity ofthe completed vehicle with this Standard.


The preceding statement for FMVSS 220 is alsoappropriate for CMVSS 220, Rollover Protection.

221 The statements below are applicable to the Cutawayequipped with School Bus Prep Package whencompleted as a school bus (Type II):This vehicle when completed, will conform to Standard221, School Bus Body Joint Strength, if;

No alterations or modifications are made to the bodypanel joints as manufactured by Ford Motor Companyfrom the forwardmost point of the windshield rearward.

The passenger first row seating reference point islocated 762.0 mm [30.00 inch] or more, rearward of theback of the Cutaway body.

Any additional maintenance panels or body panel jointsthat are added to this vehicle must comply with therequirements of this regulation.


The preceding statements for FMVSS 221, School BusBody Joint Strength, is also appropriate for vehiclesmanufactured for sale or use in Canada.

222 The statement below is applicable to the Cutawayequipped with the School Bus Prep Package whencompleted as a school bus (Type III):

Conformity with Standard 222, School Bus PassengerSeating and Crash Protection, is not substantially affectedby the design of this incomplete vehicle; accordingly FordMotor Company makes no representation as to conformitywith this Standard.


The preceding statement for FMVSS 222 is alsoappropriate for CMVSS 222, School Bus PassengerSeating and Crash Protection.

225 The statement below is applicable to all incompletevehicle types if the GVWR is 3856 kg [8,500 lb] or less,except Basic Stripped Chassis and vehicles soldexclusively to the U.S. Postal Service. it is alsoapplicable to buses (including school buses) with aGVWR of 4536 kg [10,000 lb] or less (Type I, II):

This vehicle, when completed, will conform to Standard225, Child Restraint Anchorage Systems, if:

No alterations are made to the front passenger seattether anchorages and access to the anchorages isnot restricted.

For the incomplete E-Series Van and Cutaway with nofront seats, if a forward facing front passenger seat isinstalled and there are no additional seating rows, itmust have the required tether anchor.

For the incomplete E-Series Van and Cutaway,completed with not more than two seats to the rear ofthe front row, the forward facing rear seats must havethe required tether anchor.

For the incomplete E-Series Van and Cutaway,completed with three or more forward facing seats tothe rear of the front seats, at least three of the forwardfacing rear seats must have the required tether. If atleast one of the forward facing rear seats is notoutboard, at least one non-outboard forward facing seatmust have a tether. If the vehicle has at least three rowsof forward facing seats, at least one of the forward facingseats in the second row must have the tether.





Conformity with Standard 225, Child Restraint AnchorageSystems, is not substantially affected by the design of thisincomplete vehicle; accordingly, Ford Motor Companymakes no representations as to conformity with thisStandard.

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301 Note

The terms “body” or “body structure”, in the 301 statementsthat follow include not only the basic body or bodystructure but also any equipment permanently attachedto that body or body structure installed by the subsequentstage manufacturer.

301 INFORMATION

The Unloaded Vehicle Weight of the completed vehiclemay significantly affect its capability to meet therequirements of FMVSS 301. Completed vehiclesmanufactured by Ford that are tested to demonstratecompliance with FMVSS 301 are loaded pursuant tos7.1 .6 of the Standard. The test weights of these vehiclescomprise the Unloaded Vehicle Weights including theweights of all available regular production options plusthe loads specified by s7.1.6. These test weights are lessthan the respective designated Gross Vehicle WeightRatings. In addition to the specific statements below, referto the Design Recommendation section of the Ford TruckBody Builders’ Layout Book for Fuel System informationto assist in designing fuel systems and the Second UnitBody Attachment recommendations for information to aidin designing second unit bodies and their attachments tobe compatible with E-Series and F-Series vehicles.

301 In addition to the statements pertaining to particularincomplete vehicle types which follow on pages 44-53,the statements immediately below, concerningStandard 301 Fuel System Integrity, apply to allincomplete vehicle types to be completed with a GVWRof 4536 kg [10,000 lb] or less or the E-450 with SchoolBus Prep Package.

If the push connectors on nylon fuel lines aredisconnected, they must be reconnected as shown inFigure H on this page and the retention clip must bediscarded and replaced with a new clip as specified inFigure H.

The special removal tool shown in Figure J on thispage must be used to open push connectors installedon steel fuel lines if the lines need to be disconnected.The Ford Service Manual will reference the appropriatetool that is available from Ford Customer ServiceDivision.

The push connectors on flexible fuel lines, ifdisconnected, must be reconnected by snapping themback into position and installing the appropriateRetainer as shown in Figure J on this page.

When welding near fuel system components, all metalliccomponents must be adequately shielded andprotected from heat or weld splatter. All non-metalliccomponents must be removed.

301 The statements below are applicable to the followingincomplete vehicle types if the vehicle GVWR is 4536kg [10,000 lb] or less (Type II):


This vehicle, when completed, will conform to Standard301, Fuel System Integrity, if:

The following fuel system components, as installed byFord Motor Company, are not to be removed, relocated,altered, or modified in any way:

Fuel tank and attachment hardware, includingsending unit, vapor valve, fuel tank shield andin-tank electric fuel pump (all gasoline engineapplicatons), and OBD II pressure transducer

Fuel filler cap, pipe, hose, and attachment hardware

Fuel lines, routing, and attachments

Vapor lines and carbon canister - (gasoline engineapplication)

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)

FIGURE H - NYLON FUEL LINE PUSH-CONNECT

FIGURE J - FLEXIBLE FUEL LINE PUSH-CONNECT

NOTE: Some incomplete vehicles are equipped withnylon fuel tubes. In the event that the tubes requirerepair or replacement, only Ford approved partsor their equivalents should be used.

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RETAINER − FUEL TUBEPUSH CONNECTOR

SUPPLY − E9UA−9J278−AARETURN − E9UA−9J278−BA

F65A−9J274−CACOMMON SUPPLY/RETURN

BEFORE OPENING THE FUEL SYSTEM ON VEHICLESWITH EFI ENGINES, RELIEVE FUEL PRESSURE BYFOLLOWING THE INSTRUCTIONS IN THE FORD SHOPMANUAL FOR THE APPROPRIATE MODEL AND MODEL YEAR.

WARNING

REMOVAL TOOL

ECONOLINE:

SUPER DUTY F−SERIES

REMOVAL TOOL

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WARNINGBEFORE OPENING THE FUEL SYSTEM ON VEHICLES WITHEFI ENGINES, RELIEVE FUEL PRESSURE BY FOLLOWINGTHE INSTRUCTIONS IN THE FORD TRUCK SHOP MANUALFOR THE APPROPRIATE MODEL AND MODEL YEAR.

RETENTION CLIPDO NOT REINSTALLALWAYS USE A NEWRETENTION CLIP.

O−RINGS(2 PLACES)

PUSH UNTIL CLICKS

PULL TO VERIFY CONNECTION

FUEL PUSH−CONNECTINSTALLATION INSTRUCTIONS

WARNING

FUEL PUSH−CONNECTINSTALLATION INSTRUCTIONS

CONNECTOR HOUSING

SPACER

BEFORE OPENING THE FUELSYSTEM ON VEHICLES WITH EFIENGINES, RELIEVE FUELPRESSURE BY FOLLOWING THEINSTRUCTIONS IN THE FORDTRUCK SHOP MANUAL FOR THEAPPROPRIATE MODEL ANDMODEL YEAR.

TO INSTALL THE FITTING ONTOTHE TUBE, ALIGN THE FITTING ANDTHE TUBE AXIALLY AND PUSH THEFITTING ONTO THE TUBE ENDWHEN THE FITTING IS ENLARGED, ADEFINITE CLICK WILL BE HEARDWITH RETENTION CLIP INSTALLED,PULL ON FITTING TO MAKE SUREIT IS FULLY ENGAGED.

WARNINGBEFORE OPENING THE FUEL SYSTEMON VEHICLES WITH EFI ENGINES,RELIEVE FUEL PRESSURE BYFOLLOWING THE INSTRUCTIONS INTHE FORD TRUCK SHOP MANUAL FORTHE APPROPRIATE MODEL ANDMODEL YEAR.

FUEL PUSH-CONNECT INSTALLATIONINSTRUCTIONSTO INSTALL THE FITTING ONTO THETUBE, ALIGN THE FITTING AND THETUBE AXIALLY AND PUSH THEFITTING ONTO THE TUBE END.WHEN THE FITTING IS ENGAGED, ADEFINITE CLICK WILL BE HEARD.PULL ON FITTING TO MAKE SURE ITIS FULLY ENGAGED.

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301 (Continued)

No other alteration or modification made to theincomplete vehicle, as manufactured by Ford MotorCompany, and no other components or structureinstalled by a subsequent stage manufacturer result inpenetration, separation, or other damage to the fuelsystem or any portion thereof when the vehicle is testedin any manner specified by applicable provisions ofStandard 301.†

The completed vehicle’s Unloaded Vehicle Weightdoes not exceed the value designated in Table A for E-Series on page 16 corresponding to the incompletevehicle’s model, wheelbase, and engine size.

301 The statements below are applicable to the followingincomplete vehicle types if the vehicle GVWR is4536 kg [10,000 lb] or less (Type II):

Chassis Cab

Cutaway

E-Series Cutaway (DRW and SRW) with DieselEngine and School Bus Preparation Package

E-Series Cutaway (SRW) with Gasoline Engine andSchool Bus Preparation Package

This vehicle, when completed, will conform to Standard301, Fuel System Integrity, if:

The following fuel system components as installed byFord Motor Company are not removed, relocated,altered, or modified in any way except as specified inthe following representations:

Fuel tank(s) and attachment hardware, includingsending unit, vapor valve, fuel tank shield, pressuretransducer, and in-tank electric fuel pump

Fuel filler cap(s), pipe(s), hose(s), and attachmenthardware


Vapor line(s) and carbon canister - (gasoline engineapplication)

† Temporary removal of the front bumper and front bumpermounting system during manufacture and reinstallation inaccordance with the instructions provided in the Ford TruckShop Manual should not adversely affect compliance ofthe completed vehicle to Standard 301.

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 two Outboard Frame Reinforcements, two LowerFrame Flange Reinforcements, and two extra back-to-back crossmembers, all unique to the gasolineengine School Bus Package.

No other alteration or modification made to theincomplete vehicle as manufactured by Ford MotorCompany and no other components or structureinstalled by a subsequent stage manufacturer result inpenetration, separation, or other damage to the fuelsystem or any portion thereof when the vehicle istested in any manner specified by applicableprovisions of Standard 301.†

For the Chassis Cab, the maximum SUB weight andSUB center of gravity as installed by the subsequentstage manufacturer and the Unloaded Vehicle Weightdoes not exceed the values specified in Table B onpage 17, corresponding to the model, wheelbase, andengine size.

For the Cutaway, the completed vehicle’s UnloadedVehicle Weight does not exceed the value designatedin Table A on page 16 corresponding to the model,wheelbase, and engine size.

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FIGURE H - E-SERIES CUTAWAY WITH GASOLINE ENGINE AND SCHOOL BUS PREPARATIONPACKAGE

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OUTBOARDFRAME REINFORCEMENT

OUTBOARDFRAME REINFORCEMENT

BACK-TO-BACKCROSSMEMBERS

LOWER FRAMEFLANGE REINFORCEMENTS


301 The statements below are applicable to the followingincomplete vehicle types if the GVWR Is 4536 kg[10,000 lb] or less (Type II, III):




Conformity with Standard 301, Fuel System Integrity, isnot substantially affected by the design of this incompletevehicle; accordingly Ford Motor Company makes norepresentation as to conformity with this standard.

However, Ford Motor Company has tested completedvehicles incorporating a representative fuel system andframe assembly of a Basic (Stripped) Chassis inaccordance with the procedures of Standard 301 at testweights specified by s7.1.6 of the Standard. The testedvehicles met the applicable requirements of Standard301. This vehicle, when completed, is capable ofcompliance with FMVSS 301, if:

The following fuel system components as installed byFord Motor Company are not removed, relocated,altered, or modified in any way except as specified inthe following representations:

Fuel Tank and attachment hardware, includingsending unit, vapor valve, OBD II pressure transducer,fuel tank shield, and in-tank electric pump

Fuel filler cap, pipe, hose(s), and attachmenthardware


Vapor line(s) and carbon canister

Fuel Filter

No other alteration or modification is made to theincomplete vehicle, as manufactured by Ford MotorCompany, and no other components or structureinstalled by a subsequent stage manufacturer result inpenetration, separation, or other damage to the fuelsystem or any portion thereof when the vehicle istested in any manner specified by applicable provisionsof Standard 301.†

The completed E-Series has an Unloaded VehicleWeight that does not exceed the value designated inTable A on page 16 corresponding to the model,wheelbase, and engine size.

The completed Explorer has an Unloaded VehicleWeight that does not exceed 1819 kg [4010 lb] for the4x2 chassis and 1920 kg [4210 lb] for the 4x4 chassis.

The Electric Ranger, as built by Ford, is powered by abattery. There is no fuel system for propulsion. In theevent a fuel burning hearter is installed by a final stagemanufacturer, Ford Motor Company makes norepresentations as to conformity to FMVSS 301.

An Electric Ranger with fuel fired heaters installed byFord, when completed, is capable of compliance withFMVSS 301, if the following components are not alteredor modified in any way: fuel tank and attachmenthardware including sending unit, fuel tank shield, fuel

† Temporary removal of the front bumper and front bumpermounting system during manufacture, and reinstallation inaccordance with the instructions provided in the Ford TruckShop Manual, should not adversely affect compliance ofthe completed vehicle to Standard 301.

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301 (Continued)

The body installed by a subsequent stage manufacturerand the Ford installed fuel system components arelocated and mounted as follows:

The body is mounted securely and is so designedthat when the completed vehicle is tested in anymanner specified by applicable provisions ofStandard 301,

(a) body components do not contact any fuel systemcomponent at any time (other than at the pointswhere the fuel system is permanently attached tothe body), and,

(b) body deformation or movement relative to theframe does not cause any fuel system componentto be penetrated, disconnected, or otherwisedamaged.

The rear end of the body (excluding the rear bumper)installed by a subsequent stage manufacturer doesnot extend beyond (overhang) the rear edge of thevehicle frame or frame extension. Any extension ofthe vehicle frame must be constructed and attachedso as to perform as a continuation of the vehicleframe when the completed vehicle is tested in anymanner specified by applicable provisions ofStandard 301.

For the Chassis Cab, the front end of the bodyinstalled by the subsequent stage manufacturer islocated at least 76.2mm [3.0 in] rearward of therearmost point of the cab.

The fuel filler cap(s), pipe(s), hose(s) and attachmenthardware are installed as shown in Figure K page49 for E-Series vehicles, and Figures L and M onpages 50 and 51 for F-Series vehicles. Allcomponents must be securely retained to remainintact when the completed vehicle is tested in anymanner specified by applicable provisions ofStandard 301.

For Cutaways equipped with a temporary fuel tank, thefuel tank sending unit must be removed from thetemporary tank and installed in the permanent fuel tank.Prior to the installation of the sending unit, remove theupper tank shield, when provided, and then removethe temporary shipping cover from the permanent fueltank sender opening. The temporary fuel lines to thetemporary tank are removed by snapping off theretention tabs on the push connect clips and slidingout the clips. The temporary shipping lines are not tobe reused. The sending unit is then installed in thepermanent tank by reusing the six special nuts whichretained the shipping cover to the permanent tank andusing the new 0-ring seal that is shipped with the vehiclein a separate package. The six nuts must be torqued asshown in Figure K page 48. Special connecting fuellines, with female metal push connectors, are used toconnect the steel fuel lines to the fuel sender on thetank. The connectors must be snapped securely intoplace and the appropriate Retainer-Fuel Tube PushConnector is installed as shown in Figure J page 45.Then the upper tank shield is reinstalled.

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fillter cap, filler hose, attachment hardware, fuel lines,or fuel line routing.

The body installed by a subsequent stage manufacturerand the Ford installed fuel system components arelocated and mounted as follows:

The body is mounted securely and is so designedthat when the completed vehicle is tested in anymanner specified by applicable provisions ofStandard 301,

(a) body components do not contact any fuel systemcomponent at any time (other than at the pointswhere the fuel system is permanently attachedto the body), and,

(b) body deformation or movement relative to theframe does not cause any fuel systemcomponent to be penetrated, disconnected, orotherwise damaged.

The rear end of the body (excluding the rear bumper)installed by a subsequent stage manufacturer doesnot extend beyond (overhang) the rear edge of thevehicle frame or frame extension. Any extension ofthe vehicle frame must be constructed and attachedso as to perform as a continuation of the vehicleframe when the completed vehicle is tested in anymanner specified by applicable provisions ofStandard 301.

The E-Series Basic (Stripped) Chassis aft-of-axle fuelfiller cap, pipe, hose(s), and attaching hardware areinstalled as shown in Figure K on page 49. Allcomponents must be securely retained to remain intactwhen the completed vehicle is tested in any mannerspecified by applicable provisions of Standard 301.

The Explorer Basic (Stripped) Chassis fuel filler cap,pipe, hose(s), and attaching hardware are installed asshown in Figure N page 52. All components must besecurely retained to remain intact when the completedvehicle is tested in any manner specified by applicableprovisions of Standard 301.

The Basic (Stripped) Chassis is equipped with a FuelShutoff Switch. The switch is located on the column supportstructure for E-Series and the dash area for Explorer, andmust not be relocated, altered, or modified in any way.

301 (Continued on Page 52)

•

•

•

•

•


FIGURE K - E-SERIES CUTAWAY AND BASIC (STRIPPED) CHASSIS FUEL FILLER PIPE AND SENDING UNIT INSTALLATION

TO BACK OFCUTAWAY CAB

OUTBOARD SURFACEOF FRAME RAIL

3149.6 [124.0] + [2.0] [158] WB3606.8 [142.0] + [2.0] [178] WB

FRONT OFVEHICLE

733.4[28.875]

FUEL RETURN

FUEL SUPPLYLINE

AUXILIARY FUEL SUPPLY

FUEL PUMP/FUEL GAUGESENDING UNIT

NOTE: USE A NEW O-RINGGASKET WHEN REINSTALLINGTHE FUEL PUMP/FUEL GAGESENDING UNIT.

ECONOLINE E-350/450 CUTAWAY AND BASIC (STRIPPED)CHASSIS AFT-OF-AXLE FUEL FILLER SYSTEM

A

1

2

3

4

5

6

POINT Z SEEPAGE 58

2641.6 [104.0] + [2.0] [138] WB

C OF FILLER NECKCL

TORQUE SEQUENCE

FRONT OFVEHICLE

TO L OF REARAXLE FORSTRIPPED CHASSISALL W.B.601.4 12.7[23.7 0.5]

+ +

NUT 6 REQ ’D.TORQUE TO13.7 - 17.3 Nm120 - 153 IN.-LB.

NOTES: TORQUE ALL WORM GEAR DRIVENHOSE CLAMPS TO 2.9 - 4.3 NM25 - 38 IN.-LB. [ ] DIMENSIONS ARE INCHES


(DO NOT REMOVE CAPIF NOT IN USE)

FUEL TANK STUDS

FUEL TANK

396.9[15.625]

TOP OFFILLERPIPESUPPORT

40.2[1.583]

ROUTE FILL AND VENTHOSE SO NO LOWSPOTS OCCUR

VIEW A

FUEL TANKFILL PIPE

EXISTING 9.7 DIA. HOLES(USED FOR EXHAUSTON R.H. SIDE)

N611645-S36M10 SELF-TAPPING SCREW(ATTACH TO SOUNDMETAL ON FRAME)

N611131-S36M4 SELF-TAPPINGSCREW

SECURE WITH TIESTRAPS AS REQUIREDTO VENT HOSE

9A099GROUND STRAPFUEL TANK

SCREW 3 REQ ’D.TORQUE TO 2.1- 2.9 Nm18 - 26 IN.-LB.

��

��

��

E-250/350/450 CUTAWAY AND BASIC (STRIPPED)CHASSIS AFT-OF-AXLE FUEL FILLER SYSTEM

FILLER HEIGHT FOR NATURAL GAS IS416.0 [16.38].FILLER HEIGHT FOR E550 AND LOW-PROFILE FILLER PIPE IS 319 [12.56].

�

�


FIGURE L - SUPER DUTY F-SERIES NARROW FRAME FUEL FILLER PIPE INSTALLATION

3576mm[140.8] 4186mm[164.8] 4795mm[188.8] 5100mm[200.8] 4110mm[161.8] 4475mm[176.2] 5085mm[200.2]

MIN 864mm [34.0] 1473mm [58.0] 2083mm [82.0] 2388mm [94.0]

MAX 1029mm [40.5] 1638mm [64.5] 2248mm [88.5] 2553mm [100.5]

MIN 1981mm [78.0] 2591mm [102.0] 3200mm [126.0] 3505mm [138.0]

MAX 2159mm [85.0] 2769mm [109.0] 3378mm [133.0] 3683mm [145.0]

MIN 584mm [23.0] 584mm [23.0] 584mm [23.0] 584mm [23.0]

MAX 787mm [31.0] 787mm [31.0] 787mm [31.0] 787mm [31.0]

MIN 267mm [10.5] 267mm [10.5] 267mm [10.5] 267mm [10.5]

MAX 343mm [13.5] 343mm [13.5] 343mm [13.5] 343mm [13.5]

Remove and discard the Ford installed fuel fill systemcomponents (provided for shipping purposes only)except save and reuse the metal neck and cap assembly.

Use the new hoses, pipes, scuff guards, tie wraps, andclamps provided in the dunnage kit.

The completed fuel fill system must provide a 4 degreeminimum, continous, downward slope to the fuel tank.Additional support may be required to prevent hosesagging which could cause spray or spitback duringnormal fueling operations.

Do not extend the fuel fill system outboard of the secondunit body.

The installation of Tube Extension F81A-9B149-HA willpermit the location aft-of-axle fuel fill housing to be nofurther rearward than the C of the fill hose as it passesthrough the frame.

60 INCH CA 84 INCH CA 108 INCH CA 120 INCH CAWHEELBASE

(CA) BACK OF CAB TO CENTERLINE OF REAR AXLE

Regular CabSuperCabCrew Cab

��

NOT SUPPLIED BY FORD MOTOR COMPANY*

NOTES:

TORQUE ALL WORM GEAR DRIVEN HOSE CLAMPSTO 2.8 - 3.9 NEWTON METERS 25-35 IN-LB


L

A

B

C

D

HOLE INMANUFACTURERS BODY

HOLES

3/16 INCHBLIND RIVET *12 REQ’D

87[3.42]

78[3.07] 48

[1.89]48

[1.89]78

[3.07]

48[1.89]

48[1.89]

105.7[4.16]

67.5[2.66]

48[1.89]

81[3.19]

616[2.42]

75

POINT Z

SECTION UU

U

UVIEW P

BFRONT OFVEHICLE

48[1.89]

48[1.89]

81[3.19]

C

REFER TO CALIFORNIAFUEL VAPOR RECOVERYREQUIREMENT.

VIEW P

C

D

C

D

L OFBRACKET

MAINTAIN 25.4 [1.00] MINIMUM CLEARANCEBETWEEN FUEL FILLER SYSTEM AND THESPRING AND SPRING SHACKLE IN ALLDYNAMIC POSITIONS.

PROTECTIVE SLEEVES AREREQUIRED ON BOTH FILLAND VENT HOSE AT FRAMEOPENING.

USE PROVIDED TIE STRAPSTO SECURE FILL TO VENTHOSES (2 PLACES)

A

FRONT OFVEHICLE

VIEW P

USE PROVIDED TIE STRAPSTO SECURE FILL TO VENTHOSES (2 PLACES)


TOP OF FRAME RAIL

INSTALL GROUNDWIRE TO SOUNDMETAL ON THE

SCREW (3 RE’D.)TORQUE1.7-2.8 NEWTON METERS15-25 IN. LB.

#4 C/MEMBER TO BACKOF CAB

OUTBOARD SURFACEOF FRAME RAIL CL OF FILL PIPE ASY.

AND BRACKET

INSTALL GROUND WIRETO SOUND METAL ONTHE FRAME.

TOP OF FRAME RAILCAT L OF FILL PIPE

SUB

SUPPORT

MIDSHIP FUEL FILL SYSTEM(OPTIONAL ON CHASSIS CAB)

PROTECTIVE SLEEVES AREREQUIRED ON BOTH FILLAND VENT HOSE AT FRAMEOPENING.

STEEL TUBE(DO NOT TRIM)

STEEL TUBE(DO NOT TRIM)

SCREW (3 RE’D.)TORQUE1.7-2.8 NEWTON METERS15-25 IN. LB.

FRAME.

THIS HOSE IS PREFORMED: INSTALL SHORT END TO THEMETAL NECK AND CAP ASSEMBLY;TRIM THE LONG END AS REQUIRED.

12 PLACES

THIS HOSE IS PREFORMED: INSTALL SHORT END TO THEMETAL NECK AND CAP ASSEMBLY;TRIM THE LONG END AS REQUIRED.

CAP1/8 TURNGASSCREW INDIESEL

CAP1/8 TURNGASSCREW INDIESEL

DO NOT TRIMTHIS END


HOLES − 12 PLACES

OF BRACKET

3/16 INCHBLIND RIVET *12 REQ’D

87.0[3.42]

78.0[3.07] 48.0

[1.89]

48.0[1.89]

78.0[3.07]

48.0

48.0[1.89]

105.7[4.16]

67.5[2.66]

48.0[1.89]

81.0[3.19]

616.0[2.42]

75

POINT Z

SECTION U−U

U

UVIEW P

48.0

48.0[1.89]

81.0[3.19]

CL

REFER TO CALIFORNIAFUEL VAPOR RECOVERYREQUIREMENT.

P

C

A

SCREWS (3) REQ’D.TORQUE 1.7−2.8NEWTON METERS[15−25 IN LB]

[1.89]

[1.89]

SUB

TO BACKOF CAB

CL OF FILL PIPE ASY.AND BRACKET

FRONT OFVEHICLE

PROTECTIVE SLEEVES AREREQUIRED ON BOTH FILL ANDVENT HOSE WHERE PASSINGOVER FRAME.

SCREWS (3) REQ’D.TORQUE 1.7 − 2.8NEWTON METERS[15−25] IN. LB.

VENTTUBE


FILL HOSE

#4 CROSSMEMBER

TOP OF FRAME RAIL

TOP OF FRAME RAILCAT L OF FILL PIPE

INSTALL GROUND WIRE TOSOUND METAL ON THE FRAME.

THIS HOSE IS PREFORMED; INSTALL SHORT ENDTO THE METAL NECK AND CAP ASSEMBLY;TRIM THE LONG END AS REQUIRED.

STEEL ELBOWDO NOT TRIM

STEEL ELBOWDO NOT TRIM

CAP1/8 TURN−GASSCREW IN−DIESEL

D

MIN.

MAX.

MIN.

MAX.

MIN.

MAX.

3480mm [137.0]4013mm [158.0]4380mm [172.4]

620mm [24.4]

932mm [36.7]

540mm [21.25]

743mm [29.25]

267mm [10.5]

343mm [13.5]

A

56 INCHCA

WHEELBASE

C

(CA) BACK OF CAB TO CENTERLINE OF REAR AXLE

Regular Cab SuperCab Crew Cab

Remove and discard the Ford installed fuel fill system components(provided for shipping purposes only) except save and reuse themetal neck and cap assembly.

Use the new hoses, pipes, scuff guards, tie wraps, and clampsprovided in the dunnage kit.

The completed fuel fill system must provide a 4 degree minimum,continous, downward slope to the fuel tank. Additional support maybe required to prevent hose sagging which could cause spray orspitback during normal fueling operations.

Do not extend the fuel fill system outboard of the second unit body.

FIGURE M - SUPER DUTY F-SERIES WIDE FRAME FUEL FILLER PIPE INSTALLATION

D

*

NOTES:

TORQUE ALL WORM GEAR DRIVEN HOSE CLAMPSTO 2.8 - 3.9 NEWTON METERS 25-35 IN-LB


NOT SUPPLIED BY FORD MOTOR COMPANY

��


−5005−(REF)FRAME ASY

FRONT OF VEHICLE

−9030−CAP ASY

−9034−FUEL TANKFILL PIPE ASY

PROTECTIVE SLEEVEREQ’D AT TOP OFFRAME

FUEL TANK& SENDER ASY

488.4[19.2]

267.8[10.5]

241.0[9.5]

TOP OFFRAME RAIL

TO L OFREAR AXLE

C


301 (Continued)

301 The statements below are applicable to the E-450 SuperDuty Cutaway when equipped with Diesel Engine andSchool Bus Prep Package and completed as a schoolbus (Type II):

This vehicle when completed will conform to Standard 301,Fuel System Integrity if:

The following fuel components as installed by Ford MotorCompany are not removed, altered, or modified in anyway except as specified in the following representations:

Fuel tank and attachment hardware, including senderunit, vapor valve, 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 requirementsof S7.1.6 (c) does not exceed the GVWR or GAWR’s.

The floor structure of the Second Unit Body and rearbumper are manufactured and installed to thespecifications found in the Figures on pages 53 and 54.

The fill hoses, hose clamps, ground strap, and fuel senderunit must be installed to the specification on Figure K,page 49.

No other alteration or modification made to the incompletevehicle as manufactured by Ford Motor Company and noother components or structure installed by a subsequentstage manufacturer result in penetration, separation, orother damage to the fuel system or any portion thereofwhen the vehicle is tested in any manner specified byapplicable provisions of Standard 301.†

For Cutaways equipped with a temporary fuel tank, thefuel tank sending unit must be removed from thetemporary tank and installed in the permanent fuel tank.Prior to the installation of the sending unit, the temporaryshipping cover must be removed from the permanentfuel tank sender opening. The temporary fuel lines tothe temporary tank are removed by snapping off theretention tabs on the push connect clips and slidingout the clips. The temporary shipping lines are not tobe reused. The sending unit is then installed in thepermanent tank by reusing the six special nuts whichretained the shipping cover to the permanent tank, anduse the new 0-ring seal that is shipped with the vehiclein a separate package. The six nuts must be torquedas shown in Figure K page 49. Special connecting fuellines, with female metal push connectors, are used toconnect the steel fuel lines to the fuel sender on thetank. The connectors must be snapped securely intoplace and the appropriate Retainer-Fuel Tube PushConnector is installed as shown in Figure J page 45.


The preceding statements for FMVSS 301 are appropriatecompliance representations for CMVSS 301, Fuel SystemIntegrity, if this incomplete vehicle was manufactured forsale or use in Canada. In such a case, CMVSS 301paragraphs (5), (6), and (7) are substituted for thereference to FMVSS 301 Section 7.1.6.

•

•

•

•

•

•

•

•

••

•


FIGURE N - EXPLORER BASIC (STRIPPED) CHASSIS FUEL FILL SYSTEM

Torque all worm gear driven hoseclamps to 2.9-4.3 Nm 25-38 IN-LB


��

The completed fuel fill system mustprovide a 4 degrees minimum,continuous, downward slope to thefuel tank. Additional support may berequired to prevent hose saggingwhich could cause spray or spitbackduring normal fueling operations.

Do not extend the fuel fill systemoutboard of the second unit body.

•

THIS POINT MAY VARYBY + 12.5 [.50]


PARTS TO BE FASTENED NUMBER OF FASTENERS SPACING/LOCATIONItem 5 to 15 48 Estimated 101.6mm [4.00] centers on frt and rr flange –Item 6 to 15 48 Estimated 50.8mm [2.00] stagger frt and rr flangeItem 7 to Item 15 47 Estimated 50.8mm [2.00] CentersItem 5 to Items 8 or 9 6 101.6mm [4.00] CentersItem 6 to Items 8 or 9 6 101.6mm [4.00] Centers staggered top to bottom of cross-sillItem 7 to Items 8 or 9 6 101.6mm [4.00] Centers staggered top to bottom of cross-sillItems 8 or 9 to Items 10 or 11 3 on vertical side of item 10 or 11, 1 on bottom flange 3 fasteners are 76.2mm [3.00] CentersItem 16 50.8mm [2.00] Centers

FIGURE P1 - E-SERIES SCHOOL BUS FUEL SYSTEM AND FLOOR STRUCTURE

ITEM PART NAME MATERIAL QUANTITY1 SUPPORT – BODY ISOLATOR TO CROSS SILL L.H. 6.35mm [0.25] HRLC STEEL 12 SUPPORT – BODY ISOLATOR TO CROSS SILL R.H. 6.35mm [0.25] HRLC STEEL 13 BRACKET – SPACER FOR ISOLATOR SUPPORT 6.35mm [0.25] HRLC STEEL 2

TO FRONT CROSS SILL4 BRACKET – SPACER FOR ISOLATOR SUPPORT 6.35mm [0.25] HRLC STEEL 2

TO SECOND CROSS SILL5 SILL – FRONT CROSS 1.9mm [0.075] 14 GA. HRLC STEEL 16 SILL – SECOND CROSS 1.9mm [0.075] 14 GA. HRLC STEEL 17 SILL – THIRD & FOURTH CROSS 1.9mm [0.075] 14 GA. HRLC STEEL 28 GUSSET – CROSS SILL TO OUTER SUPPORT L.H. 1.9mm [0.075] 14 GA. HRLC STEEL 49 GUSSET – CROSS SILL TO OUTER SUPPORT R.H. 1.9mm [0.075] 14 GA. HRLC STEEL 4

10 SUPPORT – CROSS SILL OUTER L.H. 3.0mm [0.120] 11 GA. HRLC STEEL 111 SUPPORT – CROSS SILL OUTER R.H. 3.0mm [0.120] 11 GA. HRLC STEEL 112 BUMPER – REAR 4.7mm [0.187] HRLC STEEL 113 BRACKET – BUMPER TO FRAME L.H. 6.35mm [0.25] HRLC STEEL 114 BRACKET – BUMPER TO FRAME R.H. 6.35mm [0.25] HRLC STEEL 115 FLOOR 1.9mm [0.075] 14 GA. HRLC STEEL 116 HOUSING – FUEL FILL NECK 1.9mm [0.075] 14 GA. HRLC STEEL 1

BLIND RIVET FASTENERSThe components listed below must be attached together with a “Blind Rivet” fastener, 6.3 [.25] diameter with a shear strengthof 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.

8

3

9

11

12

8

19

2

7

9

4

16

FORD PROVIDEDISOLATORS (6)

14

13

10

778.8[30.66]

12.8[.50]

161.4[6.35]

5

9

6 87

25.4[1.00]

TYPICAL

268.0[10.55]164.3

[6.47]

147.8[5.82] 163.8

[6.45]

2375.0[93.5] MINIMUM

FORD PROVIDED12.0mm BOLT (6 REQ’D)TORQUE

3162.3[124.5]

TO BACK OFCUTAWAY BODY

162.1[6.38]

101.6[4.00]

14.0 x 28.0[.55 x 1.10]2 SLOTS IN ITEM#12,13,& 14

416.0[16.38]

241.3[9.50]

OF FRAME

TOTOP

357.1[14.06]

2438.4[96.00]

50.8[2.00]

228.6

[9.00]

MAX

1318.3

[51.90]

114.5[4.50]

EXISTING SLOT

EXISTINGFRAMEHOLES

1/2 BOLT GR5TORQUE 95Nm 70 ft lb

2 PER BOLT

1/2 WASHER

(HARDENED)

70Nm 52 ft lb

, 1/2 NUT GR5

THE FUEL FILE HOLEIN ITEM #15 (FLOOR) MUST BE 3.0 [.12]LARGER THEN BASE OF ITEM #16

WHEELHOUSE

CLEARANCE

MAY BE REMOVED

TO ACCOMMODATE

15


FIGURE P2 - E-SERIES DIESEL SCHOOL BUS FUEL SYSTEM AND FLOOR STRUCTURE

CL

CL

9

10

3

56

1

7

CL

REQUIRED ON #1 OPTIONAL ON #2

EDGE WELD RELIEFCLOSED AFTER FORMING

EDGE WELD FRT.& REAR EDGE

WELD SHEET METALRELIEF AFTER FORMING

GUSSETCROSS SILL TOOUTER SUPPORT R.H. SHOWNL.H. SYMETRICALLY OPPOSITE.

SUPPORT CROSS SILL OUTER L.H. SHOWN.R.H. SYMETRICALLY OPPOSITE.

SUPPORT BODY IS0LATOR TO CROSSSILL L.H.SHOWN. R.H. SYMETRICALLYOPPOSITE.

C

VIEW C

B AVIEW VIEW

B

A

111.1[4.37]

187.5[7.38]

38.1[1.50]

76.2[3.00]

35.0 [ 1.38 ]

95.5[ 3.76 ]

54.0[ 2.13 ]

THIS SURFACE MUST BE FREEOF BURRS OR SHARP EDGES.OPTION ON ITEM#2 R.H.

173.0[ 6.81 ]

14.0 [ 0.55 ] DIA 3 HOLES

24.8[ 0.98 ]

23.1[ 0.91 ]

104.8[ 4.13 ]

177.5[ 6.99 ]

571.7[ 22.51 ]

46.2[ 1.82 ]

15.0[ 0.59 ]

1303.1[ 51.30 ]

552.4[ 21.75 ]

1168.4[ 46.00 ]

44.5[ 1.75 ]

25.0[ 0.98 ]

77.0[ 3.03 ] R

428.8[ 16.88 ]

46.8[ 1.84 ]

1318.3[ 51.90 ]

320.0[ 12.60 ]

102.2[ 4.02 ]

200.0[ 7.87 ]

985.6[ 38.80 ]

492.8[ 19.40 ]

TO OF 36.0 DIA HOLE

13.0[ 0.51 ] DIA 8 HOLES

42.7[ 1.68 ]

8.0[ 0.31 ]49.2

[ 1.94 ]

134.0[ 5.28 ]

67.0[ 2.64 ]

36.0

CL

CL [ 1.42 ] DIA 2 HOLESTO OF SILL

CL

CL

13.0[ 0.51 ] DIA 4 HOLES

46.5[ 1.83 ]

28.1[ 1.11 ]

110.0[ 4.33 ]

37.0[ 1.46 ]

74.0[ 2.91 ]

85.0[ 3.35 ]

170.0[ 6.69 ]

SEE VIEW C FORHOLE DIMENSIONSLOCATION

32.1[ 1.26 ]

125.0[ 4.92 ]

98.0[ 3.86 ]

26.9[ 1.06 ]

CL

4

CLCL

38.6[ 1.52 ]

34.9[ 1.37 ]

110.0[ 4.33 ]

18.0[ 0.71 ]

48.0[ 1.89 ]

122.0[ 4.80 ]

170.0[ 6.69 ]

40.3[ 1.59 ]

172.0[ 6.77 ]

138.8[ 5.46 ]

32.6[ 1.28 ]

71.6[ 3.13 ]

36.1[ 1.42 ]

42.7[ 1.68 ]

425.8[ 16.76 ]

134.0[ 5.28 ]

851.6[ 33.53 ]

13.0[ 0.51 ]DIA 8 HOLES

BOTH ENDS OF ITEMS #5,6,AND 7 CROSS SILLS MUST BEWELDED COMPLETELY TO ITEM #10 LEFTSIDE AND ITEM #11RIGHTSIDE. ALL CROSSSILLS ARE SHOWN WITH OUTSIDE ENDSTHAT WILL ACCOMMODATE A FLUSH FLOOR JOINT WHEN COMPLETED.

RAIL

36.7[ 1.44 ]

13.0[ 0.51 ] DIA 4 HOLES

M12 BOLT & NUT GC 10.9 TORQUE 70 Nm 52 ft lb.M12 BOLT & NUT GC 10.9 TORQUE 70 Nm 52 ft lb.

38.1[1.50]

ON ALL 4 EDGES.

o

14.0 [.55] DIA HOLE

TRIM WITH 45 ANGLETO REMOVE SHARP CORNER

ITEM #3 & #4 ARE WELDED TO ITEM #1 OR #2

THIS SURFACE MUST BE FREEOF BURRS OR SHARP EDGES.

25mm HOLE TO BE CUT OUTFOR NGV LH SIDE ONLY.

NOT REQUIRED ON NGV.



416.0[16.38]

OF FRAME

TOTOP

3

7

9

68

7

4

9

5

9

2375.0[93.5] MINIMUM

FORD PROVIDED12.0mm BOLT (6 REQ’D)TORQUE1318.3

[51.90]70Nm 52 ft lb

WHEELHOUSECLEARANCE

MAY BE REMOVEDTO ACCOMMODATE

10

1115

182.0[7.16]

203.3[8.00]

182.4[7.18]

16

298.5[11.75]

25.4[1.00]

TYPICAL

THE FUEL FILL HOLEIN ITEM #15 (FLOOR) MUST BE 3.0 [.12]LARGER THEN BASE OF ITEM #16

747.5[29.43]

275.8[10.86]

12.8[0.50]

12

14

13

101.6[4.00]

228.6[9.00]

162.1[6.38]

2 PER BOLT

1/2 WASHER(HARDENED)

14.0 x 28.0[.55 x 1.10]2 SLOTS IN ITEM#12,13,& 14

MAX

1/2 BOLT GR5TORQUE 95Nm 70 ft lb

, 1/2 NUT GR5

50.8[2.00]

2438.4[96.00]

357.1[14.06]

241.3[9.50]

3162.3[124.5]

TO BACKOF

CUTAWAYBODY

2

9

9

1

8

FRAME EXTENSION

114.5[4.50]

ADD SLOT AND HOLES DIMENSIONALLYSIMILAR TO THOSE SUPPLIED AT REAR OF FORD SUPPLIED FRAME RAIL.

FRAME INSERT

118.27[4.65]

FIGURE P3 - E-SERIES SCHOOL BUS CNG FUEL SYSTEM AND FLOOR STRUCTURE - AFT AXLE - 158 AND 176 INCH WHEELBASE

PARTS TO BE FASTENED NUMBER OF FASTENERS SPACING/LOCATIONItem 5 to 15 48 Estimated 101.6mm [4.00] centers on frt and rr flange –

50.8mm [2.00] stagger frt and rr flangeItem 6 to 15 48 Estimated 101.6mm [4.00] centers on frt and rr flange –

50.8mm [2.00] stagger frt and rr flangeItem 7 to Item 15 47 Estimated 50.8mm [2.00] CentersItem 5 to Items 8 or 9 6 101.6mm [4.00] CentersItem 6 to Items 8 or 9 6 101.6mm [4.00] Centers staggered top to bottom of crosssillItem 7 to Items 8 or 9 6 101.6mm [4.00] Centers staggered top to bottom of crosssillItems 8 or 9 to Items 10 or 11 3 on vertical side of item 10 or 11, 1 on bottom flange 3 fasteners are 76.2mm [3.00] CentersItems 16 50.8mm [2.00] Centers

ITEM PART NAME MATERIAL QUANTITY1 SUPPORT BODY ISOLATOR TO CROSS SILL L.H. 6.35mm [0.25] HRLC STEEL 12 SUPPORT BODY ISOLATOR TO CROSS SILL R.H. 6.35mm [0.25] HRLC STEEL 13 BRACKET SPACER FOR ISOLATOR SUPPORT TO FRONT CROSS SILL 6.35mm [0.25] HRLC STEEL 24 BRACKET SPACER FOR ISOLATOR SUPPORT TO SECOND 6.35mm [0.25] HRLC STEEL 2

CROSS SILL5 SILL FRONT CROSS 1.9mm [0.075] 14 GA. HRLC STEEL 16 SILL SECOND CROSS 1.9mm [0.075] 14 GA. HRLC STEEL 17 SILL THIRD & FOURTH CROSS 1.9mm [0.075] 14 GA. HRLC STEEL 28 GUSSET CROSS SILL TO OUTER SUPPORT L.H. 1.9mm [0.075] 14 GA. HRLC STEEL 49 GUSSET CROSS SILL TO OUTER SUPPORT R.H. 1.9mm [0.075] 14 GA. HRLC STEEL 4

10 SUPPORT CROSS SILL OUTER L.H. 3.0mm [0.120] 11 GA. HRLC STEEL 111 SUPPORT CROSS SILL OUTER R.H. 3.0mm [0.120] 11 GA. HRLC STEEL 112 BUMPER REAR 4.7mm [0.187] HRLC STEEL 113 BRACKET BUMPER TO FRAME L.H. 6.35mm [0.25] HRLC STEEL 114 BRACKET BUMPER TO FRAME R.H. 6.35mm [0.25] HRLC STEEL 115 FLOOR 1.9mm [0.075] 14 GA. HRLC STEEL 116 HOUSING FUEL FILL NECK 1.9mm [0.075] 14 GA. HRLC STEEL 1


FRAME REINFORCEMENT


FIGURE P4 - E-SERIES CNG SCHOOL FLOOR STRUCTURE – AFT AXLE - 158 AND 176 INCH WHEELBASE

CL

CL

9

10

3

56

1

7

CL


GUSSETCROSS SILL TOOUTER SUPPORT R.H. SHOWNL.H. SYMETRICALLY OPPOSITE.


SUPPORT BODY IS0LATOR TO CROSSSILL L.H.SHOWN. R.H. SYMETRICALLYOPPOSITE.

C

VIEW C

B AVIEW VIEW

B

A

111.1[4.37]

95.5[ 3.76 ]

14.0 [ 0.55 ]

DIA 3 HOLES

24.8[ 0.98 ]

23.1[ 0.91 ]

104.8[ 4.13 ]

177.5[ 6.99 ]

571.7[ 22.51 ]

46.2[ 1.82 ]

15.0[ 0.59 ]

1303.1[ 51.30 ]

1168.4[ 46.00 ]

44.5[ 1.75 ]

409.3[ 16.11 ]

46.8[ 1.84 ]

1318.3[ 51.90 ]

320.0[ 12.60 ]

102.2[ 4.02 ]

200.0[ 7.87 ]

985.6[ 38.80 ]

492.8[ 19.40 ]

TO OF 36.0 DIA HOLE

13.0[ 0.51 ]

DIA 8 HOLES

42.7[ 1.68 ]

8.0[ 0.31 ]49.2

[ 1.94 ]

134.0[ 5.28 ]

67.0[ 2.64 ]

36.0

CL

CL [ 1.42 ] DIA 2 HOLESTO OF SILL

CL

CL

13.0[ 0.51 ] DIA 4 HOLES

46.5[ 1.83 ]

28.1[ 1.11 ]

110.0[ 4.33 ]

37.0[ 1.46 ]

74.0[ 2.91 ]

85.0[ 3.35 ]

170.0[ 6.69 ]

SEE VIEW C FORHOLE DIMENSIONSLOCATION

32.1[ 1.26 ]

125.0[ 4.92 ]

98.0[ 3.86 ]

26.9[ 1.06 ]

CL

4

CLCL

38.6[ 1.52 ]

34.9[ 1.37 ]

110.0[ 4.33 ]

18.0[ 0.71 ]

48.0[ 1.89 ]

122.0[ 4.80 ]

170.0[ 6.69 ]

40.3[ 1.59 ]

172.0[ 6.77 ]

138.8[ 5.46 ]

32.6[ 1.28 ]

71.6[ 3.13 ]

36.1[ 1.42 ]

42.7[ 1.68 ]

425.8[ 16.76 ]

134.0[ 5.28 ]

851.6[ 33.53 ]

13.0[ 0.51 ]DIA 8 HOLES

BOTH ENDS OF ITEMS #5,6,AND 7 CROSS SILLS MUST BEWELDED COMPLETELY TO ITEM #10 LEFTSIDE AND ITEM #11RIGHTSIDE. ALL CROSSSILLS ARE SHOWN WITH OUTSIDE ENDSTHAT WILL ACCOMMODATE A FLUSH FLOOR JOINT WHEN COMPLETED.

RAIL

36.7[ 1.44 ]

13.0[ 0.51 ] DIA 4 HOLES

M12 BOLT & NUT GC 10.9 TORQUE 70 Nm 52 ft lb.M12 BOLT & NUT GC 10.9 TORQUE 70 Nm 52 ft lb.

ON ALL 4 EDGES.

o

14.0 [.55] DIA HOLE

TRIM WITH 45 ANGLETO REMOVE SHARP CORNER

ITEM #3 & #4 ARE WELDED TO ITEM #1 OR #2

552.4[21.78]

60.4[ 2.38 ]

102.0[ 4.02 ]

56.1[ 2.21 ]


PARTS TO BE FASTENED NUMBER OF FASTENERS SPACING/LOCATIONItems 4 to Items 9 48 Estimated 101.6mm [4.00] centers on frt and rr flange –

50.8mm [2.00] stagger frt and rr flangeItems 4 or 5 to Items 6 or 7 6 101.6mm [4.00] CentersItem 6 to Items 8 or 9 6 101.6mm [4.00] Centers staggered top to bottom of cross-sillItems 6 or 7 to Items 8 3 on vertical side of item 8, 1 on bottom flange 3 fasteners are 76.2mm [3.00] Centers

FIGURE P5 - E-SERIES CNG MIDSHIP TANK SCHOOL BUS FUEL SYSTEM AND FLOOR STRUCTURE - 176 INCH WHEELBASE

ITEM PART NAME MATERIAL QUANTITY1 SUPPORT RAIL R.H. 6.35mm [0.25] HRLC STEEL 12 SUPPORTRAIL L.H. 6.35mm [0.25] HRLC STEEL 13 RISER BRACKET 6.35mm [0.25] HRLC STEEL 64 FRONT CROSS 1.9mm [0.075] HRLC STEEL 35 MIDDLE CROSS 1.9mm [0.075] HRLC STEEL 26 GUSSET L.H. 1.9mm [0.075] HRLC STEEL 57 GUSSET R.H. 1.9mm [0.075] HRLC STEEL 58 OUTER SUPPORT 3.0mm [0.120] HRLC STEEL 29 FLOOR (NOT SHOWN) 1.9mm [0.075] HRLC STEEL 1


7 65 6 4

6 6 4

32

8

5

1800[70.9]

1254[49.4]

490.3[19.3] 2375.0

[93.5]

77

773

1

4

6

FORD PROVIDEDM12 BOLT (8 REQ’D)TORQUE 70Nm 52 ft lb


IVM176MID


FIGURE P6 - E-SERIES MIDSHIP SCHOOL BUS CNG FUEL SYSTEM AND FLOOR STRUCTURE - 176 INCH WHEELBASE

110[4.33]42.7

[1.68]

41.7[1.64]

128.3[5.05]

67[2.64]

134[5.28]

65.4[2.57]

13[.51] DIA

67[2.64] TYP

TYP

985.6[38.8]

2369[93.27]

691.7[27.23]

172[6.77]

141.3[5.56]

42.2[1.66]

30.7[1.27]

2369[93.27]

68.4[2.69]

36.1[1.42]

45 2 PLACESO

43.8[1.72]

2 PLACES

10[.39]

2 PLACES

14[.55] DIA

4 HOLES

CL

CL

52[2.04]

10[.39]

571.7[22.51]

106[4.2]

177.5[6.99]

23.1[.91]

24.8[.98]


812.9[32]

86[3.39]

CL

CL

1628[64.09]

2259.1[88.94]

60.4[2.38]

101.8[4.01]

44[1.75]

1800[70.87]

200[7.87]

46.8[1.84]

42.7[1.68]

21.4[.84]86

3.39

36[1.42]

134[5.28]

TYP

67[2.64]

TYP

36.0 DIA 2 HOLES

985.6[38.8]

TO OF 36.0 DIA HOLECL

13[.51]

DIA 8 HOLES

M12 BOLT & NUT GC 10.9(24 REQ’D)TORQUE 70 Nm 52 ft. lb.

VIEW C

C

5

4

3

8

1

7

45 2 PLACESO

43.8[1.72]

2 PLACES

10[.39]

2 PLACES

39.2[1.54] 4 PLACES

2 PLACES

134[5.28]

170[6.69]

13[.51]

3[.12]

12[.47]

14[.55] DIA 4 HOLES

FRONT OF VEHICLE

FRONT OF VEHICLE

FRONT OF VEHICLE

FRONT OF VEHICLE

SEE VIEW C FORHOLE DIMENSIONS

LOCATIONS

BOTH ENDS OF ITEMS #4 AND #5 CROSS SILLS MUST BEWELDED COMPLETELY TO ITEM #8 LEFTSIDE AND ITEM #11RIGHTSIDE. ALL CROSSSILLS ARE SHOWN WITH OUTSIDE ENDSTHAT WILL ACCOMMODATE A FLUSH FLOOR JOINT WHENCOMPLETED.

TRIM WITH 45 ANGLETO REMOVE SHARP CORNER.

SUPPORT BODY ISOLATOR TO CROS SSILL L.H. SHOWN. R.H. SYMETRICALLYOPPOSITE.

GUSSET CROSS SILL TOOUTER SUPPORT R.H. SHOWN.L.H. SYMETRICALLY OPPOSITE.


ITEM #3 IS WELDED TO ITEM #1ON ALL 4 EDGES.

FRONT OF VEHICLE

IVM176MID2


FIGURE P7 - E-SERIES CNG SCHOOL BUS MIDSHIP FUEL SYSTEM AND FLOOR STRUCTURE - 158 INCH WHEELBASE

PARTS TO BE FASTENED NUMBER OF FASTENERS SPACING/LOCATIONItems 4 to Items 9 48 Estimated 101.6mm [4.00] centers on frt and rr flange –

50.8mm [2.00] stagger frt and rr flangeItems 4 or 5 to Items 6 or 7 6 101.6mm [4.00] CentersItem 6 to Items 8 or 9 6 101.6mm [4.00] Centers staggered top to bottom of cross-sillItems 6 or 7 to Items 8 3 on vertical side of item 8, 1 on bottom flange 3 fasteners are 76.2mm [3.00] Centers

ITEM PART NAME MATERIAL QUANTITY1 SUPPORT RAIL R.H. 6.35mm [0.25] HRLC STEEL 12 SUPPORTRAIL L.H. 6.35mm [0.25] HRLC STEEL 13 RISER BRACKET 6.35mm [0.25] HRLC STEEL 64 FRONT CROSS 1.9mm [0.075] HRLC STEEL 35 MIDDLE CROSS 1.9mm [0.075] HRLC STEEL 26 GUSSET L.H. 1.9mm [0.075] HRLC STEEL 57 GUSSET R.H. 1.9mm [0.075] HRLC STEEL 58 OUTER SUPPORT 3.0mm [0.120] HRLC STEEL 29 FLOOR (NOT SHOWN) 1.9mm [0.075] HRLC STEEL 1


7

5

1470[57.9]

952.1[37.5]

526.3[20.7] 2375.0

[93.5]

777

3

FORD PROVIDEDM12 BOLT (8 REQ’D)TORQUE 70Nm 52 ft lb


MINIMUM

3

8

44

4

6

1

2

6

6

7

IVM158MID


FIGURE P8 - E-SERIES CNG SCHOOL BUS MIDSHIP FLOOR STRUCTURE - 158 INCH WHEELBASE

110[4.33]42.7

[1.68]

41.7[1.64]

128.3[5.05]

67[2.64]

134[5.28]

65.4[2.57]

13[.51] DIA

67[2.64] TYP

TYP

985.6[38.8]

2369[93.27]

691.7[27.23]

172[6.77]

141.3[5.56]

42.2[1.66]

30.7[1.27]

2369[93.27]

68.4[2.69]

36.1[1.42]

45 2 PLACESO

43.8[1.72]

2 PLACES

10[.39]

2 PLACES

14[.55] DIA

4 HOLES

CL

CL

52[2.04]

10[.39]

571.7[22.51]

106[4.2]

177.5[6.99]

23.1[.91]

24.8[.98]


503.9[19.84]

86[3.39]

CL

CL

989[38.94]

1887.9[74.33]

60.4[2.38]

101.8[4.01]

44[1.75]

1470[50.87]

200[7.87]

46.8[1.84]

42.7[1.68]

21.4[.84]86

3.39

36[1.42]

134[5.28]

TYP

67[2.64]

TYP

36.0 DIA 2 HOLES

985.6[38.8]

TO OF 36.0 DIA HOLECL

13[.51]

DIA 8 HOLES

M12 BOLT & NUT GC 10.9(24 REQ’D)TORQUE 70 Nm 52 ft. lb.

VIEW C

C

5

4

3

8

1

7

45 2 PLACESO

43.8[1.72]

2 PLACES

10[.39]

2 PLACES

39.2[1.54] 4 PLACES

2 PLACES

134[5.28]

170[6.69]

13[.51]

3[.12]

12[.47]

14[.55] DIA 4 HOLES

FRONT OF VEHICLE

FRONT OF VEHICLE

FRONT OF VEHICLE

FRONT OF VEHICLE

SEE VIEW C FORHOLE DIMENSIONS

LOCATIONS

BOTH ENDS OF ITEMS #4 AND #5 CROSS SILLS MUST BEWELDED COMPLETELY TO ITEM #8 LEFTSIDE AND ITEM #11RIGHTSIDE. ALL CROSSSILLS ARE SHOWN WITH OUTSIDE ENDSTHAT WILL ACCOMMODATE A FLUSH FLOOR JOINT WHENCOMPLETED.

TRIM WITH 45 ANGLETO REMOVE SHARP CORNER.

SUPPORT BODY ISOLATOR TO CROS SSILL L.H. SHOWN. R.H. SYMETRICALLYOPPOSITE.

GUSSET CROSS SILL TOOUTER SUPPORT R.H. SHOWN.L.H. SYMETRICALLY OPPOSITE.

SUPPORT CROSS SILL OUTER L.H. SHOWN .R.H. SYMETRICALLY OPPOSITE.

ITEM #3 IS WELDED TO ITEM #1ON ALL 4 EDGES.

FRONT OF VEHICLE

1801.9[70.94]

IVM158MID2


301.1 Canadian Requirements (Type III):

Standard 301.1, LPG Fuel System Integrity, Ford MotorCompany makes no representation as to conformity withthis Standard.

301.2 Canadian Requirements for all incomplete vehicletypes if the GVWR is 4536 kg [10,000 lb] or less:

The statement for Standard 303 is an appropriatecompliance representation for CMVSS 301.2, CNG FuelSystem Integrity, if the incomplete vehicle wasmanufactured for sale or use in Canada.

301.2 Canadian Requirements for the E-450 Cutaway withthe dedicated Compressed Natural Gas (CNG)package (Type II, III):

The E-450 Cutaway with the dedicated CNG packagewill meet all of the requirements of Standard 301.2, CNGFuel Systems Integrity, provided:

The fuel tanks, fill valves, fuel lines, and shields asinstalled by Ford Motor Company, are not altered ormoved in any way.

The fuel filler is located in accordance with Figure K(which has been drawn for a gasoline fuel system, butthe filler location for natural gas is noted).

In addition, the E-450 Cutaway with the CNG packagehas been designed to allow two additional tanks to beinstalled in the body. With body mounted fuel tanks,compliance with Standard 301.2 is not substantiallyaffected by the design of this incomplete vehicle;accordingly, if tanks are added, Ford Motor Companymakes no representation as to conformity with thisstandard.

302 The statement below is applicable to all incompletevehicle types except the Basic (Stripped) Chassis(Type I):

This vehicle, when completed, will conform with Standard302, Flammability of Interior Materials, if no alterationsare made to those components covered by the Standardwhich are installed by Ford Motor Company and allcomponents covered by Standard 302, which are addedto the incomplete vehicle by subsequent stagemanufacturers meet the flammability requirements of theStandard.





Conformity with Standard 302, Flammability of InteriorMaterials, is not substantially affected by the design ofthis incomplete vehicle; accordingly Ford Motor Companymakes no representation as to conformity with thisStandard.


The preceding statements for FMVSS 302 are appropriatecompliance representations for CMVSS 302,Flammability, if the vehicle was manufactured for sale oruse in Canada.

303 The statement below Is applicable to all incompletevehicle types if the GVWR Is 4536 kg [10,000 lb] orless (Type III):

Conformity with Standard 303, Fuel System Integrity ofCompressed Natural Gas Vehicles, is not substantiallyaffected by the design of this incomplete vehicle;accordingly Ford Motor Company makes norepresentation as to conformity with this Standard.

303 The statements below are applicable to the E-450Cutaway when equipped with the Compressed NaturalGas (CNG) package and School Bus Prep Package,and is completed as a school bus (Type II):

This vehicle when completed will conform to Standard301, Fuel System Integrity if:

The following fuel components as installed by FordMotor Company are not removed, altered, or modifiedin any way except as specified in the followingrepresentations:

Fuel tank and attachment hardware, includingsender unit, and fuel tank shield

Fuel filler valves, pipes, hoses, and attachinghardware

Fuel shut-off switch (Inertia switch)

The completed vehicle when loaded to therequirements of S7.1.6 (c) does not exceed theGVWR or GAWR’s.

The floor structure of the Second Unit Body and rearbumper are manufactured and installed to thespecifications found in the Figure on page 55.

The fill hoses, hose clamps, and fuel sender unitmust be installed to the specification on Figure K,page 49 (which has been drawn for a gasoline fuelsystem, but the filler location for natural gas is noted)

No other alteration or modification made to theincomplete vehicle as manufactured by Ford MotorCompany and no other components or structureinstalled by a subsequent stage manufacturer resultin penetration, separation, or other damage to thefuel system or any portion thereof when the vehicleis tested in any manner specified by applicableprovisions of Standard 301.†


All compressed natural gas tanks supplied by Ford MotorCompany are in full conformity with Standard 304,Compressed Natural Gas Fuel Container.

For tanks not supplied by Ford Motor Company,conformity is not substantially affected by the design ofthis incomplete vehicle; accordingly, Ford makes norepresentation as to conformity with this Standard.

•

•

•••

•

•••

•

•

•

•



GENERAL INFORMATION

Section 6(4) (d) of the Canadian Motor Vehicle SafetyRegulations requires a manufacturer of an incomplete motorvehicle to list the applicable Canadian Motor Vehicle SafetyStandards (CMVSS) to which the incomplete motor vehicleconforms in full at the time of manufacture. The table onpage 63 is provided for this purpose. The Statements ofConformity on pages 8 through 61 of this manual, arecompliance representations based on United States FederalMotor Vehicle Safety Standards (FMVSS) requirements.However, Canadian Motor Vehicle Safety Regulations(CMVSS) representations are provided at the conclusion ofeach safety standard section where appropriate. BecauseCMVSS requirements may differ from FMVSS requirements,Canadian Subsequent Stage Manufacturers should refer tothe Canadian requirements for each safety standard to helpdetermine compliance to a regulation.

CMVSS STATEMENT OF COMPLIANCE

The incomplete vehicle identified by the Vehicle IdentificationNumber VIN) on the cover of this manual and to which thismanual was attached, conforms in full, as manufactured byFord Motor Company to each Canadian Motor Vehicle SafetyStandard designated by an “X” in the appropriate column ofthe table on page 63. The appropriate column is the columnheaded by the illustrated description of the incomplete vehicletype that represents this particular incomplete vehicle. Thetable lists all safety standards in effect on the date ofmanufacture of this incomplete vehicle (shown on the frontcover) applicable to “Chassis Cabs” which, as defined byCanadian Regulations, includes all the incomplete vehiclesdescribed. Compliance with those standards not identified byan “X” and possibly other standards not listed are theresponsibility of the manufacturer who completes the vehicle,when those standards are applicable to the final configurationof the vehicle. Note: Canadian Regulations include vehicleemission standards in the 1100 series as shown.

VEHICLE IDENTIFICATION

Refer to the Vehicle Description section of this manual on page4, for additional information. Incomplete vehicles producedby Ford Motor Company require, for certain applications,optional Prep Packages or trim codes which are listed on theCompleted Vehicle Types charts on page 5.

DAYTIME RUNNING LAMP (DRL)

Compliance representations for CMVSS 108, Lighting andCMVSS 108.1, Headlamps, are on page 23. The followingitems are also required for CMVSS 108 and 108.1 compliance:

The DRL module circuits are not to be altered.

DRL module is not to be repositioned.

The E-Series Basic (Stripped) Chassis is not to be equippedwith more than two headlamps when equipped with a DRLmodule as provided by Ford Motor Company.

CANADIAN RADIO FREQUENCY INTERFERENCE (RFI)INFORMATION

All vehicles powered by spark ignition engines (e.g.: gasoline,natural gas, or propane engines) and manufactured inCanada or for sale or use in Canada are subject to theCanadian “Regulations for the Control of Interference to RadioReception” per Interference-Causing Equipment Standard(ICES-002) and applicable test method according to “CAN/CSA-C108.4-M92”. Violation of these regulations ispunishable by fine or imprisonment. This Ford-built incompletevehicle (if other than a Basic (Stripped) Chassis) was designedand manufactured to be capable of meeting the regulatoryrequirements or such modifications thereof as may have beenauthorized by the Department of Communications. However,because Ford has no control over how this incomplete vehicleis completed by subsequent stage manufacturers, Ford doesnot represent that the completed vehicle incorporating theFord-built components will comply with applicablerequirements.

The following information is supplied to subsequent stagemanufacturers to help them avoid increasing the RFIemissions of this vehicle in the course of completing it.

For any completed vehicle, additional measures may beneeded to adequately suppress RFI emissions. Affectedcomponents could include spark plugs, ignition wires, ignitioncoil, ground straps, ignition component shields, accessorydrive belts, instrument voltage regulator suppressor assembly,and ignition coil suppressor assembly.

More specifically:

All components required to suppress RFI emissions, whichare removed during service, repair, or completion of thevehicle, must be reinstalled in the manner in which theywere installed by Ford.

Shields on ignition coil must remain installed.

Replacement spark plugs, ignition wires, and ignition coilmust be equivalent in their RFI suppression properties tooriginal equipment.

Electrical grounds on all components must be retained.

Metallic components installed on the body or chassis mustbe grounded to the chassis.

Electrical circuits added to the vehicle must not be installednear the high voltage ignition components.

Only “static conductive” accessory drive belts should beused. Fan, water pump, power steering, and other beltsshould be of the OEM type or equivalent that will not buildup a static electrical charge.

Engine compartment wiring must not be rerouted in anymanner.

The Powertrain Control Module (PCM) must not berelocated from the position as installed by Ford MotorCompany.

CANADIAN VEHICLES(Vehicles to be completed for sale or use in Canada)

•

••

••••

••

•

••

CANADIAN VEHICLES

63 STATEMENTS OF CONFORMITYCANADIAN VEHICLES

INCOMPLETECHASSIS E-SERIES

CAB VAN (1) CUTAWAY

101 Control Location and Identification X X(3) X(3)102 Transmission Shift Control Sequence X X X103 Windshield Defrosting and Defogging X X X

104 Windshield Wiping and Washing System X X X106 Brake Hoses X X X X108 Lighting Equipment X

108.1 Headlamps X X X113 Hood Latch System X X X

115 Vehicle Identification Number X X X116 Hydraulic Brake Fluid X X X X120 Tire Selection and Rims for X X X X(4)

Vehicles other than Passenger Cars

121 Air Brake System124 Accelerator Control Systems X X X X205 Glazing Materials X X X

206 Door Latches, Hinges, and Locks X X X207 Anchorage of Seats X X(2) X(2)209 Seat Belt Assemblies X X(2) X(2)

210 Seat Belt Assembly Anchorages X X(2) X(2)210.1 User-Ready Tether Anchorages for Restraint Systems X X(6) X(6)221 School Bus Body Joint Strength X(5)

301.1 LPG Fuel Systems301.2 CNG Fuel Systems X(7)302 Flammability X X X

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 1106 - Although this standard does not apply tothe described incomplete vehicles because it does not applyto “Chassis Cabs”, the exterior noise emissions of thefollowing such vehicles, as manufactured by Ford MotorCompany, conforms to the applicable noise limits of CMVSS1106 (1)(b) for the following vehicles:

Chassis Cab (F-Series)

E-Series Cutaway

Chassis Cab (F-Series) with a GVWR over 4536 kg[10,000 lb] will comply with CMVSS 1106 (b), Interior NoiseEmission requirements for vehicles with a GVWR over4536 kg [10,000 lb], as manufactured by Ford MotorCompany.

(1)E-Series Van type vehicles when equipped withAmbulance Prep Package or Recreational Trim areincomplete vehicles.

(2)The E-Series Van and the Cutaway with RecreationalTrim may not conform in full to Standards 207, 209, and210.

(3)The E-Series Van or Cutaway type vehicle withRecreational Trim and the front seat delete option do notconform in full to Standard 101.

(4)The tire and rim information requirements ofStandard 120 will require a label to be affixed to thecompleted vehicle, by the final stage manufacturer, withtire size, rim size, cold inflation pressure, and gross axleweight ratings.

(5)E-450 Cutaway with School Bus Preparation Package(Option 47S).

(6)The E-Series Van or Cutaway type vehicles, whenequipped with front seat delete option, may not conformin full to Standard 210.1.

(7)E-450 Cutaway with dedicated Compressed Natural Gaspackage.

INCOMPLETE VEHICLE TYPE

CMVSS

••

E-SERIESEXPLORER

BASIC(STRIPPED)

CHASSIS

CMVSS DESCRIPTION


EXHAUST EMISSIONS AND FUEL ECONOMY

Most incomplete light truck vehicle(s) or truck(s) offered bythe Ford Motor Company for 2002 model year will be in the>3856 kg [8,500 lb] classification. Generally, the medium/heavy duty engines used in these vehicles will be certified toFederal, Canadian or California exhaust and evaporativeemissions requirements for medium/heavy duty engines.

Frontal Area and Weight Restrictions:

All 4.2L and some 5.4L heavy duty engines (engines usedin vehicles exceeding 3856 kg [8,500 lb]) are certified tolight duty <3856 kg [8,500 lb] protocol and will requirevehicle weight and frontal area restrictions. The 6.8L HD,7.3L Diesel HD, and some 5.4L HD (49 states only) enginesare not certified to light duty protocol and therefore are notlimited by weight and frontal area restrictions for exhaustemissions. All 4.2L engine vehicles concerned are listed onpage 67 of this manual. If your vehicle is affected, the frontalarea and Unloaded Vehicle Weight information will be found onthe Emissions Control Information decal which is located in the enginecompartment, as well as page 67 of this manual. This engine labelreflects the maximum curb weight as certified by theEnvironmental Protection Agency (EPA) (i.e., basic curb weightplus 33% option weight for a vehicle line within an engine-system combination). The curb weight of the vehicle is allowedto increase beyond the Important Vehicle Information decalmaximum curb weight if the increase is due to the addition ofoptions that have less than 33% installation rate.

Incomplete vehicles using engines which are certified asheavy duty engines will not have frontal area or curb weightrestrictions based on exhaust emissions regulations. It isimportant, however, that the final stage manufacturer observevehicle restrictions from vehicle safety requirements, etc.,which are located elsewhere in this manual. Additionalemissions certification information is contained in the FordTruck Body Builders’ Layout Book for the model year and typeof this incomplete vehicle.

Emission Control Hardware

Any body builder, installer, or subsequent stage manufacturermust also assure that all emission control hardware furnishedwith incomplete vehicles is on the vehicle and is operationaland that applicable instructions for incorporating suchhardware into the completed vehicle’s electrical or mechani-cal systems are strictly followed.

High Altitude Requirements

United States Environmental Protection Agency regulationsfor the 2002 model year do not contain unique emissioncertification requirements for light duty trucks that will be soldor delivered to customers for principal use above 1,219 m[4,000 ft.]. However, some vehicle configurations are restrictedto low altitude applications for principal use below 1,219 m[4,000 ft.].


CAUTION:2002 MODEL YEAR VEHICLES ARE EMISSIONCERTIFIED FOR REGISTRATION IN SPECIFIC AREASOF THE UNITED STATES. FOR EXAMPLE, VEHICLESCERTIFIED AND LABELED FOR SALE IN CALIFORNIACAN NOT BE SOLD IN THE STATES THAT REQUIREFEDERALLY CERTIFIED VEHICLES AND VEHICLESCERTIFIED TO FEDERAL STANDARDS CAN NOT BESOLD IN STATES THAT REQUIRE CALIFORNIACERTIFIED VEHICLES. IT IS THE SUBSEQUENT STAGEMANUFACTURER’S RESPONSIBILITY TO PURCHASEA VEHICLE CERTIFIED FOR THE STATE/AREA IN WHICHTHE VEHICLE WILL BE SOLD. EPA HAS STATED THATUNDER CERTAIN CIRCUMSTANCES THEY WILL NOTENFORCE THESE REQUIREMENTS. FOR FURTHERGUIDANCE CONSULT EPA’S “POLICY ON CROSSBORDER SALES OF CALIFORNIA VEHICLES.”

IMPORTANT:It is the responsibility of the body builder, installer, orsubsequent stage manufacturer to ensure that themaximum completed vehicle curb weight and frontal areaspecified by Ford are not exceeded. If these restrictionsare exceeded, or if the vehicle is modified such that it willnot comply with applicable emission standards throughoutits useful life, the body builder, installer, or subsequentstage manufacturer will be considered a manufacturer forpurposes of complying with U.S. Federal, California, orCanadian exhaust and evaporative emissionrequirements, and Federal fuel economy standards,labeling, and certain other requirements.

If it is necessary to convert a new non-high altitude vehicle forprincipal use at high altitude, a list of corresponding high andlow altitude engine calibrations is available free of chargefrom your local Ford dealer. Service publications indicate howto modify vehicles to conform with appropriate high or lowaltitude U.S. EPA regulations.

Further, to avoid any question of certification coverage,approval of any modification or use of an engine or vehiclewhich may render inoperative any of the emission controlcomponents must be obtained from the United StatesEnvironmental Protection Agency by the manufacturer makingsuch modification or use prior to distribution, sale, offering forsale, introduction, or delivery for introduction of the subjectvehicle into U.S. commerce. Additionally, the manufacturermaking such modification or use must obtain approval fromthe California Air Resources Board if the new vehicle will bedelivered for sale or use in the State of California.

IMPORTANT:To avoid any questions of certification coverage, ordersshould specify whether a high altitude emission system ornon-high altitude emission system is required.

IMPORTANT:For purposes of Government Regulation, a body builder,installer, or any subsequent manufacturer may beconsidered a manufacturer.



UNLEADED GASOLINE LABELRegulations no longer require the manufacturer to affixpermanent labels reading “Unleaded Gasoline Only” or“Unleaded Fuel Only” to vehicles destined for sale in the UnitedStates or Canada. Such labels may however be required forvehicles sold into other markets. It is the responsibility of thebody builder, installer, or any subsequent manufacturer toproperly label vehicles for the market in which they are sold.

EXTERIOR NOISENew vehicles which have a gross vehicle weight rating inexcess of 4536 kg [10,000 lb], include a partially or whollyenclosed operator’s compartment, and are manufactured foruse in the United States, must comply with U.S. EnvironmentalProtection Agency’s exterior noise emission regulations formedium and heavy trucks (40 CFR Part 205, Subpart B) whichestablish a noise emission limit of 80 dB (A).

However, the Basic (Stripped) Chassis as built by Ford is tooincomplete to constitute a regulated vehicle and Ford doesnot represent that it complies with those regulations. Withrespect to the Basic (Stripped) Chassis, it is the responsibilityof the subsequent stage manufacturer of that vehicle at thetime it first conforms to the regulatory definition of “vehicle” tocomply with the requirements imposed upon manufacturersby these regulations.

TAMPERING WITH NOISE CONTROLSFederal law prohibits the removal or rendering inoperative byany person, other than for purposes of maintenance, repair,or replacement, of any device or element of designincorporated into such vehicle for the purpose of noise controlprior to its sale or delivery to the ultimate purchaser or while itis in use. Federal Law also prohibits the use of such vehicleafter such device or element of design has been removed orrendered inoperative by any person.

Among those acts presumed to constitute tampering are theacts listed below:

Removal of fender apron absorbers, fender apronbarriers, underbody noise shields, or acousticalabsorptive material.

Removal of or rendering inoperative the engine speedgovernor so as to allow engine speed to exceedmanufacturer’s specifications.

Removal or modification of air duct, air intake choke orsilencer, air cleaner, or air cleaner element.

Removal of, or rendering inoperative, exhaust systemcomponents including the catalyst inlet pipe, muffler,outlet pipe, resonator, or diffuser.

Removal of the fan shroud. Removal of or renderinginoperative the fan clutch.

New vehicles manufactured for sale in Canada must complywith applicable provisions of Canada Motor Vehicle SafetyStandard 1106, Noise.

Additional noise emissions information is contained in theFord Truck Body Builders’ Layout Book.

WARRANTY AND MAINTENANCEA copy of the appropriate Ford Truck Owners Guide andWarranty Facts Booklet must be installed in every vehicle priorto sale to the ultimate purchaser in order to provide emissionsystems warranty information and maintenance schedules. Italso provides, where required by EPA noise control regulationsfor vehicles having GVWR over 4536 kg [10,000 lb], noiseemissions warranty information, instructions for maintenance,use, and repair of vehicle noise emission control systems, amaintenance record format, and list of prohibited tamperingacts.

EVAPORATIVE EMISSIONSAll 2002 Federal light and heavy duty trucks and all Californiavehicles with gasoline engines are required to comply withevaporative emissions requirements established by theEnvironmental Protection Agency or the California AirResources Board. Production fuel systems supplied onincomplete 2002 model year trucks manufactured by FordMotor Company comply with these requirements. If thesubsequent stage manufacturer adds to or modifies thefuel system in any manner, it becomes the responsibilityof the modifier to assure compliance with the applicableregulations. Refer to the Design Recommendation section ofthe Ford Truck Body Builders’ Layout Book, for additional FuelSystem Evaporative Emissions information.

SERVICE ENGINE SOON WARNING LIGHTThe “Service Engine Soon” warning light is used to indicatemalfunctions of the Electronic Engine Control System andcertain emissions-related components. For all incompletevehicles, except Basic (Stripped) Chassis (which is notequipped with an instrument panel), it is Ford installed andoperational.

The E-Series Basic (Stripped) Chassis vehicles, has thewarning light installed in the instrument cluster, which isshipped in the dunnage box or temporarily installed on theExplorer. If an alternate instrument cluster is utilized, the finalstage manufacturer must install an operational light in theinstrument cluster. This light must glow amber and display themessage “Service Engine Soon”. It should be recognized thatthis light is a requirement of emission certification.

POWER TAKE-OFF CIRCUIT

A wire located under the instrument panel labeled “PowerTake-Off Circuit” is provided to minimize the inadvertentillumination of the “Service Engine Soon” while the PTO isengaged. Refer to the Design Recommendation section ofthe Body Builders’ Layout Book, for Power Take-off Installationsinformation that will locate the Ford provided circuit. Connectthe wire to the Power Take-Off Circuit as instructed and isolatethe wire labeled “Power Take-Off Circuit” from the solenoid toprevent damage to the Power Control Module (PCM).

EXPLORER BASIC (STRIPPED) CHASSIS

The US Postal Explorer Basic (Stripped) Chassis is certifiedas a complete vehicle for emissions. This vehicle is certifiedfor sale in all 50 states when completed in accordance withthe planned design (including frontal area and weights) asagreed to by Ford Motor Company and the US Postal Service.No portion of the emission control system may be modifiedin any way, and all vehicle labels provided by Ford MotorCompany must be installed on the vehicle prior to distributionto the US Postal Service. Vehicle modifications that affectemissions may result in the subsequent stage manufacturerbeing considered the manufacturer of the vehicle for emissioncompliance purposes, including responsibility for in-useemissions, warranty, and recall.

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OZONE DEPLETING SUBSTANCE (ODS)

The Clean Air Act of 1990, Section 611 requires any product(i.e., completed vehicle) containing or manufactured with anyClass I Ozone Depleting Substance on, or after May 15,1993must be identified with a “clearly and conspicuously attachedlabel.”

Ford Motor Company has eliminated Class I ODS from itsmanufacturing processes. All 2002 Ford Truck incompletevehicles will not have Class I ODS content.

Manufacturers, including subsequent stage manufacturers,are required to label their products if the product, includingany component (whether manufactured by that manufactureror not), contains a Class I ODS or if the manufacturer used aClass I ODS in the manufacturing of the product. In the casewhere Ford provides a label saying the incomplete vehiclecontains a Class I ODS that information must be placed on theproduct warning label. (See EPA regulation on wording,placement, size, and combining labels.) In Canada consultthe appropriate Provincial or Territorial Ministry of Environment.

EMISSION CONTROL INFORMATION LABEL

To meet United States Environmental Protection Agencyregulations, the Important Vehicle Information (tune-up andfuel tank capacity) labels must be affixed in a location that isreadily visible after installation and in such a manner that itcannot be removed without destroying or defacing the label.The label shall not be affixed to any equipment that is easilydetached from the vehicle.

When emission control labels are supplied but not attachedto the vehicle (i.e., tune-up label or fuel tank label), they mustbe permanently mounted in a readily visible location to meetthe preceding requirements. In addition, whether the label isalready affixed or to be affixed, no components shall beinstalled which visibly obscure the label in any way that failsto satisfy the visibility requirements described in the CaliforniaEmission Control Label Specifications. For Canadianrequirements consult Section 1100 8 (1) (d) (i), (ii), & (iii), asapplicable.

CALIFORNIA FUEL VAPOR RECOVERY

California regulations require that the vehicle fuel systems bedesigned to accommodate a vapor recovery fueling nozzleincluding unobstructed access to the fill pipe. Fuel filler pipesinstalled per the figures on pages 49 through 53 will complywith the “Specifications For Fill Pipes and Openings of MotorVehicle Fuel Tanks” referenced in Title 13 CaliforniaAdministrative Code provided no part of the aftermarket body,as installed, intrudes within a 254mm [10 in] radius cylinderwhich has its axis parallel to the ground at point “Z” (Figure Kon page 49 illustrates a typical point Z). The cylindrical zoneuses the axis described above, starts at the outer most surfaceof the Ford supplied fuel filler housing, and projects outward(away from the frame). The fuel pipe housing component isshown on the referenced figures and is attached to theaftermarket body via 3/16 inch diameter rivets.

CALIFORNIA MOTOR VEHICLE EMISSION CONTROLLABEL

To meet California emission certification regulations, theEmission Control Information (tune-up) label must be welded,riveted, or otherwise permanently attached to an area withinthe engine compartment or to the engine in such a way that itwill be readily visible to the average person after installationof the engine in a vehicle. In selecting an acceptable location,the manufacturer shall consider the possibility of accidentaldamage (e.g., possibility of tools or sharp instruments comingin contact with the label). The label shall be affixed in such amanner that it cannot be removed without being destroyed ordefaced, and shall not be affixed to any part which is likely tobe replaced during the vehicle’s useful life. For motor vehiclesrated at 3856 kg [8500 lb] GVWR or less, the label shall not beaffixed to any equipment which is easily detached from thevehicle. As used in these specifications, readily visible to theaverage person shall mean that the label shall be readablefrom a distance of 460 mm [18 in] without any obstructionsfrom vehicle or engine parts (including all manufactureravailable optional equipment), except for flexible parts,(e.g., vacuum hoses, ignition wires). Alternately, informationrequired by these specifications to be printed on the labelshall be no smaller than 8 point type size provided that novehicle or engine parts (including all manufacturer availableoptional equipment), except for flexible parts that can be movedout of the way without disconnection, obstruct the label.

Completed vehicles for retail sale in California require amachine-readable vehicle identification number (VIN) bar-code label made of paper, plastic, metal, or other permanentmaterial which shall be affixed in a readily visible location toeither the door-latch post next to the driver’s seating position,the door edge that meets this door-latch post, or above theinstrument panel in a location clearly visible through the lowerleft corner of the windshield.

All incomplete vehicles except Basic (Stripped) Chassistype vehicles will conform to this standard.

Basic (Stripped) Chassis type vehicles:

Conformity with CARB Motor Vehicle Emission ControlLabel specifications for VIN label is not substantially affectedby the design of this incomplete vehicle. Accordingly, FordMotor Company makes no representation as to conformitywith this requirement.

For the VEC† and VIN labels, sufficient clearance shall beprovided to use a non-contact bar-code Reading Wand. Forthe tune-up label and vacuum hose routing diagram label,the label and any adhesives used shall be designed towithstand typical vehicle environment conditions in the areawhere the label is attached for the vehicle’s total expected life.Typical vehicle environmental conditions shall include, butare not limited to, exposure to engine lubricants and coolants(e.g., gasoline, motor oil, brake fluids, water, ethyleneglycol), under hood temperatures, steam cleaning, and paintsor paint solvents.

† Vehicle Emission Control

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RADIO FREQUENCY INTERFERENCE (RFI)

The ignition system on your vehicle (if other than a Basic(Stripped) Chassis) has been designed to be capable ofcompliance with RFI requirements established by theCanadian government. However, because Ford has no controlover how an incomplete vehicle is completed by subsequentstage manufacturers, Ford does not represent that thecompleted vehicle incorporating the Ford-built componentswill comply with those requirements. Any ignition systemcomponent (i.e.: spark plugs, ignition wiring, coil suppressorassembly, etc.) that is replaced should be replaced by thesame Ford Motor company part number or equivalent tomaintain RFI suppression.

While there are currently no RFI regulations in the UnitedStates specifically applicable to automotive ignition systems,all Ford Light Trucks are built with ignition system componentsthe same or equivalent to those supplied on Canadianvehicles.

Ford Motor Company recommends that all ignition systemservice be performed at a Ford authorized service facility tohelp hold RFI emissions levels to a minimum.

Additional RFI information is contained on page 62 of thismanual.

EMISSION CERTIFICATION LIMITATIONS FOR VEHICLESEQUIPPED WITH 4.2L [256 C.I.D.] ENGINE

Devices that emit radio frequency (RF) energy such as AM/FM radios, mobile telecommunications systems (two-wayradios, telephones), and radio controlled security systemsare subject to the rules and regulations of the FederalCommunications Communication (FCC), including 47 CFRParts 2 and 15. Any such system installed in a vehicle shouldcomply with those rules and should be installed only by aqualified technician. In addition, to ensure continuedcompliance with the FCC’s regulations, RF devices must notbe modified or changed in a manner not expressly approvedby Ford Motor Company Mobile Communication Systems. RFdevices particularly, if not properly installed, may adverselyaffect the operation of the vehicle. For example, such systemswhen operated may cause the engine to stumble or stall. Inaddition, such systems themselves may be damaged or theiroperation affected by the operation of the vehicle. (CitizensBand [CB] transceivers, garage door openers, and othertransmitters whose power output is 5 watts or less, ordinarilywill NOT affect vehicle operation.)

Because Ford has no control over the operation ormanufacture of such systems or their installation, Ford cannotassume responsibility for any adverse effects or damage ifthis equipment is used.

TO RELY ON THE EMISSION CERTIFICATION APPROVAL RECEIVED BY FORD, NEITHER THEMAXIMUM UNLOADED VEHICLE WEIGHT NOR ITS ACCOMPANYING MAXIMUM COMPLETEDVEHICLE FRONTAL AREA MAY BE EXCEEDED. IF EITHER FACTOR IS EXCEEDED, THE FINALSTAGE MANUFACTURER IS RESPONSIBLE FOR OBTAINING EMISSION CERTIFICATION FROMTHE ENVIRONMENTAL PROTECTION AGENCY.

WHEELBASE MAXIMUM UNLOADED COMPLETED VEHICLEVEHICLE TYPE MILLIMETER VEHICLE WEIGHT FRONTAL AREA

[INCH] KILOGRAMS [POUNDS] [SQUARE FEET]

NOTE: The maximum unloaded vehicle weight (basic curbweight, plus the weight of options that are installedon vehicles at a rate of 33% or greater, plus the secondunit body weight) and completed vehicle frontal areavalues shown in this table are limits for purposes ofemission certification. See Table A page 16 foradditional information.

NOTE: The values shown are accurate as of the date of initialprinting. See Important Vehicle Information decal,located in the engine compartment, for specific valuesapplicable to your vehicle.

E-250 Cutaway 3505 2676 [59.0] maximum[138] [5900]

E-250 Basic (Stripped) Chassis 3150 2676 [59.0] maximum[124] [5900]



NOTES

NOTES

FORD TRUCK BODY BUILDERS LAYOUT BOOK

Throughout this manual you will find references to information found in the FordTruck Body Builders’ Layout Book. Additional Design Recommendations andspecifications are also provided to assist subsequent stage manufacturers incompleting chassis cab and incomplete vehicles. To obtain the compact disc or acopy of this book (first copy at no charge), please fax a written request and includethe desired model year, along with your street address (NO P.O. BOX ADDRESS,PLEASE) U.S. orders: Fax to (734) 414-2971,

Canadian orders: Fax to (905) 670-1798.

FORD SERVICE PUBLICATIONS

Many Ford Service Publications pertain to a specific Model Year and vehicletypes. The following publications are a few of many manuals which are availablefrom 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 regardinginformation contained in this manual. Call 1-877-840-4338 for assistance or Faxinquiries to (313) 594-2633 accompanied with a cover sheet indicating “Attentionto: Ford Truck Body Builder Advisory Service,” along with your name, addressand telephone number.

REFERENCE INFORMATION

REFERENCE INFORMATION

FORD MOTOR COMPANYTHE AMERICAN ROADDEARBORN, MI 48121

FORD MOTOR COMPANY OF CANADA LIMITEDTHE CANADIAN ROAD

OAKVILLE, ONTARIO L6J 5E4

2002 Light Truck Incomplete Vehicle Manual

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