DO NOT DESTROY: THIS MANUAL IS REQUIRED BY LAW. KEEP UNTIL THE VEHICLE IS COMPLETED BY THE FINAL STAGE MANUFACTURER.
U.S. & CANADA MOTOR VEHICLE SAFETY STANDARDS (APPLICATION BY VEHICLE TYPE) Standard Number 101 102 103 104 105 106 108 108.1 110 111 113 114 115 116 118 119 120 124 131 135 201 202 203 204 205 206 207 208 209 210 210.1 210.
U.S. & CANADA MOTOR VEHICLE SAFETY STANDARDS (APPLICATION BY VEHICLE TYPE) (Continued from Inside Front Cover) Standard Number 220 221 222 225 301 302 PART 565.4 1106 Title of Standard School Bus Rollover Protection School Bus Body Joint Strength School Bus Passenger Seating and Crash Protection Child Restraint Anchorage Systems (U.S. only) Fuel System Integrity Flammability of Interior Materials Vehicle Identification Number (U.S.
INTRODUCTION Information in this manual is furnished pursuant to United States and Canadian safety regulations or, in some cases where the information is not required by regulation, is furnished for the convenience of intermediate or final stage vehicle manufacturers. Incomplete vehicles manufactured for sale or importation into the U.S., are specially equipped for the United States.
TABLE OF CONTENTS DEFINITIONS .................................................................................... 4-5 GENERAL INFORMATION.................................................................... 6 Directions........................................................................................... 6 VEHICLE DESCRIPTION ..................................................................... 7 COMPLETED VEHICLE TYPES .............................................................
DEFINITIONS The following definitions are from Title 49, Code of Federal Regulations, Parts 567.3, 568.3 and 571.3 where noted. Canadian definitions are from Canada Motor Vehicle Safety Regulations, Section 2(1), and are in italics. Ford Motor Company definitions are for the purpose of this manual only. Some terms are followed by an abbreviation that is used throughout this manual.
Incomplete Vehicle (Canada) – a vehicle (a) other than a vehicle imported temporarily for special purposes, that is capable of being driven and that consists, at a minimum, of a chassis structure, power train, steering system, suspension system and braking system in the state in which those systems are to be part of the completed vehicle, but requires further manufacturing operations to become a completed vehicle or (b) that is an incomplete trailer.
GENERAL INFORMATION Information in this section is provided pursuant to Part 568 of Title 49, Code of Federal Regulations. “Vehicles Manufactured in Two or More Stages.” Part 568 specifies that final stage manufacturers must complete vehicles in compliance with all applicable Federal Motor Vehicle Safety Standards, and Section 6 of the Canadian Motor Vehicle Safety Regulations (CMVSR), Vehicles Manufactured in Stages. Section 6.
VEHICLE DESCRIPTION INCOMPLETE VEHICLE MANUAL COVER California Air Resources Board (CARB), requires a Vehicle Identification Number (VIN) Label having a non-contact, barcode, reading wand capability. The bar-code directly below the VIN on the incomplete vehicle label, when provided, will comply with this regulation. See page 51 for location and other requirements.
COMPLETED VEHICLE TYPES 1 1 4 2 3 1 4 2 5 6 5 1 6 5 SCHOOL BUS 6 5 5 6 5 3 6 X X X X X X (1) Ambulance Prep Package (2) School Bus Prep Package - E-350 available on 9600 lb GVWR Single Rear Wheels (SRW), and 11,500 lb GVWR Dual Rear Wheels (DRW) only (3) Motorhome Prep Package (4) Shuttle Bus Prep Package (5) Recreational Van (6) Center Aisle Seat Prep Package IMPORTANT: Ford Motor Company makes no representation that the completed vehicle types listed above are the only vehicle types approp
STATEMENTS OF CONFORMITY The following Statements of Conformity apply to vehicles that are produced for sale or importation into the United States or Canada. The term “Incomplete Vehicle Types” in these statements refers to the three types of the vehicles illustrated on this manual’s cover and listed in the chart on page 8. The number preceding each Statement of Conformity refers to the number designation for a Part or a Section of Part 571 of the Federal Motor Vehicle Safety Standard.
102 The statements below are applicable to all incomplete vehicle types except the Basic (Stripped) Chassis: This vehicle, when completed, will conform to Standard 102, Transmission Shift Lever Sequence, Starter Interlock, and Transmission Braking Effect, if no alterations or adjustments are made to the transmission, shift cable, transmission outer shift lever, shift cable bracket, vacuum tubes, vacuum pump system, brakeshift interlock system, starter interlock system, wiring circuit from the interlock swi
103 The statement below is applicable to all incomplete vehicle types except the Basic (Stripped) Chassis: This vehicle, when completed, will conform to Standard 103, Windshield Defrosting and Defogging Systems, if no alterations or adjustments are made to heater and blower assemblies, ducting, operating controls, electrical circuit from the blower assembly to the power source, windshield, coolant hoses from the radiator or engine to the heater, and if no obstructions are added that restrict or otherwise r
105 The statements below are applicable to the following incomplete vehicle types if the GVWR is between 3500 kg [7716 lb] and 3629 kg [8000 lb]: • Incomplete E-Series Van or Wagon This vehicle, when completed, will conform to Standard 105, Hydraulic and Electric Brake Systems, if: • No alterations, modifications, or replacements are made to the following: – Service or parking brake system – Antilock brake system – Vacuum system – Wheels and tires – Brake system indicator lamp and wiring – Brake system res
105 (Continued) 105 The horizontal center of gravity for the SUB is: – At or forward of the rear axle centerline. The vertical center of gravity for the completed vehicle at GVWR CGv (Equation C) must not exceed 48.0 inches when measured from the ground. – Behind the rear axle centerline. The vertical center of gravity for the completed vehicle at GVWR must fall within the appropriate range determined from Table E page 16.
FMVSS 105 & 135 DEFINITIONS AND CALCULATION ILLUSTRATION FOR INCOMPLETE E-SERIES VEHICLES L† = Horizontal distance in inches between the SUB center of gravity and the of the front axle. Wc = Weight of the vehicle (chassis and cab) (fuel tanks full) [pounds]. Including option weight. P = Passenger load (See E-Series Passenger Load Table page 13). WB = Vehicle wheelbase [inches]. CGv = Vertical distance from the ground to the center of gravity [inches] of the completed vehicle.
TABLE A Maximum Unloaded Vehicle Weight (UVW) for Incomplete Vehicles When Completed (2) (This Information Does Not Apply To Vehicles Over 4536 kg [10,000 lb] GVWR) Model E-150 Regular Van E-150 Regular Wagon E-250 Regular and Extended Van E-350 Regular and Extended Van E-350 Regular and Extended Wagon E-350 Cutaway E-350 Basic (Stripped) Chassis SRW E-350 Basic (Stripped) Chassis DRW E-350 Basic (Stripped) Chassis SRW E-350 Basic (Stripped) Chassis DRW E-350 Basic (Stripped) Chassis DRW Wheelbase Millime
TABLE C TABLE F CGhl = Horizontal distance from front axle to cargo CG: CGVC = Vertical distance from ground to chassis CG (Dimensions are inches) Model Regular Van †Extended Van or Extended Wagon †Cutaway (SRW) (DRW) †Comm. Cab/Box Partition (DRW) †RV (DRW) †Comm. No Partition (DRW) †RV (DRW) †Comm.
106 The statement below is applicable to all incomplete vehicle types: This vehicle, when completed, will conform to Standard 106, Brake Hoses, if the brake hose assemblies supplied by Ford Motor Company are not removed, relocated, altered, or modified and if no brake hose assemblies are added.
TABLE G Standard 108 Lighting Equipment 108 The statements below are applicable to the following incomplete vehicle type: • Cutaway This vehicle, when completed, will conform to Standard 108, Lamps, Reflective Devices, and Associated Equipment, if all the required lighting equipment as indicated in Table G on this page (identified by the codes D, R and S) is designed and installed in accordance with the requirements of Standard 108 and the directions contained in this statement.
108 (Continued) 108 The statements below are applicable to the following incomplete vehicle type: • E-Series Basic (Stripped) Chassis: Conformity with Standard 108, Lamps, Reflective Devices, and Associated Equipment, is not substantially affected by the design of this incomplete vehicle; accordingly, Ford Motor Company makes no representation as to conformity with this standard.
111 113 The statements below are applicable to the following incomplete vehicle type when equipped with a flat glass mirror on the passenger-side: • Incomplete E-Series Van This vehicle, when completed, will conform to Standard 111, Rearview Mirrors, if: • The mirrors and their mounts as supplied by Ford Motor Company are not removed, relocated, replaced, or altered. • No structural modifications are made to the body which would affect the stability of the mirror mounts.
124 The statements below are applicable to all incomplete vehicle types: This vehicle, when completed, will conform to Standard 124, Accelerator Control Systems, if: • No alterations are made to the accelerator pedal, mounting hardware, adjustable pedal mechanism, or other components of the accelerator control system as installed by Ford Motor Company. • No equipment is added nor existing equipment modified which would restrict operation of the accelerator control system.
• The horizontal center of gravity for the SUB is: – At or forward of the rear axle centerline. The vertical center of gravity for the completed vehicle at Unloaded Vehicle Weight + 397 lb passenger load CGv (Equation A) must not exceed 36.0 inches, when measured from the ground. – Behind the rear axle centerline. The vertical center of gravity for the completed vehicle at Unloaded Vehicle Weight + 400 lb passenger load must fall within the appropriate range determined from Table E, page 16.
202 The statements below are applicable to the following incomplete vehicle types if the GVWR is 4536 kg [10,000 lb] or less: • Incomplete E-Series Van or Wagon when equipped with front seats • Cutaway when equipped with front seats This vehicle when completed, will conform to Standard 202, Head Restraints, if: • No alterations are made to the head restraints, the seat assemblies and their anchorages, the floor pan, or floor pan reinforcements.
205 The statement below is applicable to all incomplete vehicle types, except the Basic (Stripped) Chassis: This vehicle, when completed, will conform to Standard 205, Glazing Materials, if no alterations to or replacements of the installed glazing materials are made and if additional glazing materials installed by a subsequent stage manufacturer conforms to the requirements of Standard 205.
207 207 (Continued) 207 The statements below are applicable to the following incomplete vehicle types when equipped with untrimmed front seats: • Incomplete E-Series Van • Cutaway This vehicle when completed, will conform to Standard 207, Seating Systems, if: • No changes or modifications are made to the front seat frames, latches, hardware, and padding. • The weight of each completely trimmed front seat does not exceed the value in Table H on this page.
208 NOTE An RCM (crash sensor and restraints control module) is located under the driver's seat. Care must be used to avoid damage to the RCM and sensor wiring during removal or reinstallation of the driver's seat. Refer to Figure E on page 33.
208 (Continued) • The Air Bag Supplemental Restraint System as originally installed (see Figure E on page 33), is not removed, relocated, altered, or modified in any way. • The Air Bag Supplemental Restraint System Information Labels that are affixed to the front sun visors are visible, and not altered, modified, or removed.
208 • Any front overhead console installed on an Incomplete E-Series is configured as follows: – Front header (full width) overhead consoles may extend down no more than 2 inches as measured from the Ford installed headliner† and extend rearward no more than 6 inches as measured from the midpoint between the Ford installed sun visor inboard retaining clips (vehicle centerline).
• The Air Bag Supplemental Restraint System as installed by Ford Motor Company (see Figure E on page 33) is not removed, relocated, modified or altered in any way. Ford technical bulletin procedures for relocating the floor-mounted restraints delete resistor and bracket may be followed for vehicles that have an option that deletes the front passenger restraint system.
FRONT OF VEHICLE 3C24-15602B82 ADJ. ASY. 3C24-15602B82 ADJ. ASY. PIA BOLT TORQUE 47.5 ± 7.2 Nm [35 ± 5 ft-lb] F65B-15602B90 COVER ASY. F65B-602B90 COVER ASY. PANEL ASY. UPPER CUTAWAY & VAN MODELS 3C24-1560262 COVER ASY. 1 REQ’D. EA. SIDE 3C24-1560262 COVER ASY. 1 REQ’D. EA. SIDE FRONT OF VEHICLE N806773-S190 NUT TORQUE 40.0 ± 6.0 Nm [29.5 ± 4 ft-lb] PIA BOLT TORQUE 47.5 ± 7.2 Nm [35 ± 5 ft-lb] 15611B09 BELT AND RETRACTOR ASY. N806773-S190 NUT TORQUE 40.0 ± 6.0 Nm [29.
SEAT ASY. SEAT ASY. PIA BOLT TORQUE + 6.0 Nm 35.0 + 4 ft-lb] [29.5 N801078-S58 SCREW M8x1.25 HEX 4 REQ’D. TORQUE 25.0 + - 3.8 Nm [18.4 + - 2.8 ft-lb] 4C24-15618B47-AA TRACK ASY. N801078-S424 SCREW M8 x 1.25 HEX 4 REQ’D. + 3.8 Nm TORQUE 25.0 [18.4 + 2.8 ft-lb] 2C24-1561701-A POWER TRACK A FRT. ST. F8UB-14A699-A WIRING ASYSEAT CONTROL FEED JUMPER XC2A-1561202-A PYROTECHNIC ASY. R.H. IC24-15618B46-B TRACK ASY. 2C241561755A HANDLE FRT. ST. TRACK 56912-S58 SCREW 4.2 x 19 TAPPING PIA BOLT TORQUE + 5.
SRP INFORMATION POINT A (SEAT POSITION IS 10.0mm [0.39 IN] FORWARD OF REARMOST POSITION) (SEAT POSITION IS AT THE MIDPOINT OF AVAILABLE TRAVEL) DRIVER – SEAT (VAN AND CUTAWAY) PASSENGER – SEAT (VAN AND CUTAWAY) A B C 217.8 [8.57] 277.3 [10.92] 105.0 [4.13] 103.0 [4.06] 384.2 [15.13] 377.0 [14.84] D MIN. 356.0 [14.01] 412.0 [16.22] E MAX. 67.0 [2.64] 65.0 [2.56] F 937.4 [36.90] 960.1 [37.
RESTRAINT CONTROL MODULE UNDER DRIVER'S SEAT ���������� ����� ������� ��������� ������ �������� ����� ������ ������ ��������� ��������� ���������� �������������� ���������������� ������������ ��������� ��������� ���� ����� ����� ������ ������ ����������� ������� ���������������������������������������������� ������������������������������������������������ ����������������������������������������� DO NOT RELOCATE.
CUT LINE CUT LINE CUT LINE SECTION CC SECTION BB CUT LINE CUT LINE SECTION AA SECTION DD 711.2 [ 28.00 ] MAXIMUM 711.2 [ 28.00 ] MAXIMUM THE SPOTWELDS (X) IN THIS B AREA MUST REMAIN INTACT. B A A C C D D FRONT OF VEHICLE NOTE: SHADED AREA REPRESENTS MAXIMUM OPENING IN BODY PANELS. THE SECTIONS SHOWN ARE A LARGER SCALE THAN THE SIDE VIEW FOR THE PURPOSE OF CLARITY. [ ] DIMENSIONS ARE INCHES FIGURE G1 – BODY PANEL WINDOW REMOVAL AREA – E-SERIES (DRIVER SIDE – L.H.
CUTLINE SECTION FF CUTLINE CUTLINE SECTION GG SECTION EE THE SPOTWELDS ( X ) IN THIS AREA MUST REMAIN INTACT. F F 533.4 [21.00] MAXIMUM WITH SLIDING DOOR E E G 711.2 [28.00] MAXIMUM WITH CARGO DOORS G FRONT OF VEHICLE NOTE: SHADED AREA REPRESENTS MAXIMUM OPENING IN BODY PANELS THE SECTIONS SHOWN ARE A LARGER SCALE THAN THE SIDE VIEW FOR THE PURPOSE OF CLARITY. [ ] DIMENSIONS ARE IN INCHES FIGURE G2 – BODY PANEL WINDOW REMOVAL AREA – E-SERIES (PASSENGER SIDE – R.H.
END OF ROOF EXTENDED VAN END OF ROOF REGULAR VAN OUTER EDGE OF TROUGH END OF ROOF CUTAWAY CL "B" PILLAR REINFORCEMENT WINDSHIELD HEADER 50.8 [2.00] 203.2 [8.00] SECTION AT CL OF ROOF FORWARD CUT LINE CUT LINE REGULAR VAN 203.2 [8.00] CUT LINE EXTENDED VAN OR WAGON HEADLINER PLANE, FOR VEHICLES NOT EQUIPPED WITH A FORD HEADLINER, USE A PLANE DETERMINED BY A POINT AT THE LOWER REAR OF THE WINDSHIELD HEADER TO THE MIDPOINT ON THE BPILLAR REINFORCEMENT.
209 The statements below are applicable to the following incomplete vehicle types with front seat(s): • Incomplete E-Series Van or Wagon • Cutaway This vehicle, when completed, will conform to Standard 209, Seat Belt Assemblies, if: • No alterations or replacements are made to the seat belt assemblies and attaching hardware. • No action is taken that would impair the integrity of the seat belt system provided. Any seat belt assemblies added to a vehicle must conform to the requirements of this Standard.
212/ Note 219 The terms “body” or “body structure,” in the 212 and 219 statements that follow, include any equipment permanently attached to that body or body structure installed by the subsequent stage manufacturer as well as the basic body or body structure. 210.1 (Continued) This vehicle, when completed, will conform to Standard 210.
212/ The statement below is applicable to the following 219 incomplete vehicle type if the GVWR is 4536 kg [10,000 lb] or less: • E-Series Basic (Stripped) Chassis The Basic (Stripped) Chassis is designed by Ford Motor Company to be completed as a walk-in van type vehicle. Walk-in vans are exempt from the requirements of Standard 212, Windshield Mounting, and Standard 219, Windshield Zone Intrusion.
219 See combined statements under “212/219” for all vehicle types. 220 The statements below are applicable to the Cutaway equipped with the School Bus Prep Package when completed as a school bus: The Cutaway body structure as manufactured by Ford, does not meet the strength requirements of FMVSS 220, School Bus Rollover Protection; accordingly Ford Motor Company makes no representation as to conformity of the completed vehicle with this Standard.
301 Note The terms “body” or “body structure”, in the 301 statements that follow include not only the basic body or body structure but also any equipment permanently attached to that body or body structure installed by the subsequent stage manufacturer. 301 INFORMATION The Unloaded Vehicle Weight of the completed vehicle may significantly affect its capability to meet the requirements of FMVSS 301.
OUTBOARD FRAME REINFORCEMENT BACK-TO-BACK CROSSMEMBERS OUTBOARD FRAME REINFORCEMENT LOWER FRAME FLANGE REINFORCEMENTS FIGURE H – E-SERIES CUTAWAY WITH GASOLINE ENGINE AND SCHOOL BUS PREPARATION PACKAGE 301 (Continued) – Fuel lines, routing, and attachments – Vapor line(s) and carbon canister – (gasoline engine application) – 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 Out
301 301 (Continued) • The body installed by a subsequent stage manufacturer and the Ford installed fuel system components are located and mounted as follows: – The body is mounted securely and is so designed that when the completed vehicle is tested in any manner specified by applicable provisions of Standard 301, (a) body components do not contact any fuel system component at any time (other than at the points where the fuel system is permanently attached to the body), and, (b) body deformation or moveme
• The body installed by a subsequent stage manufacturer and the Ford installed fuel system components are located and mounted as follows: – The body is mounted securely and is so designed that when the completed vehicle is tested in any manner specified by applicable provisions of Standard 301, (a) body components do not contact any fuel system component at any time (other than at the points where the fuel system is permanently attached to the body), and, (b) body deformation or movement relative to the fra
302 301 (Continued) 301 The statements below are applicable to the over 4536 kg [10,000 lb] GVWR E-350 DRW and E-450 Cutaway when equipped with Diesel Engine and School Bus Prep Package and completed as a school bus: This vehicle when completed will conform to Standard 301, Fuel System Integrity if: • The following fuel components as installed by Ford Motor Company are not removed, altered, or modified in any way except as specified in the following representations: – Fuel tank and attachment hardware, in
ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 PART NAME SUPPORT – BODY ISOLATOR TO CROSS SILL L.H. SUPPORT – BODY ISOLATOR TO CROSS SILL R.H. BRACKET – SPACER FOR ISOLATOR SUPPORT TO FRONT CROSS SILL BRACKET – SPACER FOR ISOLATOR SUPPORT TO SECOND CROSS SILL SILL – FRONT CROSS SILL – SECOND CROSS SILL – THIRD & FOURTH CROSS GUSSET – CROSS SILL TO OUTER SUPPORT L.H. GUSSET – CROSS SILL TO OUTER SUPPORT R.H. SUPPORT – CROSS SILL OUTER L.H. SUPPORT – CROSS SILL OUTER R.H.
BOTH ENDS OF ITEMS #5, 6, AND 7 CROSS SILLS MUST BE WELDED COMPLETELY TO ITEM #10 LEFTSIDE AND ITEM #11 RIGHTSIDE. ALL CROSSSILLS ARE SHOWN WITH OUTSIDE ENDS THAT WILL ACCOMMODATE A FLUSH FLOOR JOINT WHEN COMPLETED. 7 36.1 [ 1.42 ] 71.6 [ 3.13 ] 851.6 [ 33.53 ] CL RAIL C 425.8 [ 16.76 ] 5 170.0 [ 6.69 ] 42.7 [ 1.68 ] 36.7 [ 1.44 ] 170.0 [ 6.69 ] 122.0 [ 4.80 ] 48.0 [ 1.89 ] 18.0 [ 0.71 ] 32.1 [ 1.26 ] 85.0 [ 3.35 ] 74.0 [ 2.91 ] 37.0 [ 1.46 ] 110.0 [ 4.33 ] 26.9 [ 1.06 ] 98.0 [ 3.86 ] 125.
CANADIAN VEHICLES (Vehicles to be completed for sale or use in Canada) VEHICLE IDENTIFICATION More specifically: Refer to the Vehicle Description section of this manual on page 7, for additional information. Incomplete vehicles produced by Ford Motor Company require, for certain applications, optional Prep Packages or trim codes which are listed on the Completed Vehicle Types charts on page 8.
EMISSION CERTIFICATION INFORMATION CAUTION: IMPORTANT: U.S.: It is the responsibility of the body builder, installer, or subsequent stage manufacturer to ensure that the maximum completed vehicle curb weight and frontal area specified by Ford are not exceeded.
EXTERIOR NOISE EVAPORATIVE EMISSIONS New vehicles which have a gross vehicle weight rating in excess of 4536 kg [10,000 lb], include a partially or wholly enclosed operator’s compartment, and are manufactured for use in the United States, must comply with U.S. Environmental Protection Agency’s exterior noise emission regulations for medium and heavy trucks (40 CFR Part 205, Subpart B) which establish a noise emission limit of 80 dB (A).
CALIFORNIA FUEL VAPOR RECOVERY For the Vehicle Emission Control (VEC) and VIN labels, sufficient clearance shall be provided to use a non-contact barcode Reading Wand. For the tune-up label and vacuum hose routing diagram label, the label and any adhesives used shall be designed to withstand typical vehicle environment conditions in the area where the label is attached for the vehicle’s total expected life.
SUPPLEMENTS 52 E-SERIES (May, 2004)
REFERENCE INFORMATION FORD TRUCK BODY BUILDERS LAYOUT BOOK Throughout this manual you will find references to information found in the Ford Truck Body Builders Layout Book. Additional Design Recommendations and specifications are also provided to assist subsequent stage manufacturers in completing chassis cab and incomplete vehicles. To obtain a free copy of this publication on CD-ROM or to receive an order form for additional CD-ROM’s or books please visit our website at www.fleet.ford.com/truckbbas.
FORD MOTOR COMPANY THE AMERICAN ROAD DEARBORN, MI 48121 FORD MOTOR COMPANY OF CANADA LIMITED THE CANADIAN ROAD OAKVILLE, ONTARIO L6J 5E4
