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TABLE OF CONTENTS INTRODUCTION SECTIONS 1 General Information 2 Electrical 3 Installation Considerations 4 Cargo Mounting Considerations 5 Reference Information NOTE: The descriptions and specifications contained in this manual were in effect at the time this manual was approved for printing. Ford Motor Company reserves the right to discontinue models at any time, or change specifications or design without notice and without incurring any obligation. All rights reserved.
SECTION 0 Introduction Contents Introduction.......................................................................................
Introduction 0-1 Introduction Ford Motor Company has assembled this Expedition Special Service Vehicle (SSV) Modifiers Guide to assist vehicle modifiers in producing safe and quality products. Ford believes that safety and quality come first. This book is divided into topics pertinent to modifiers of vehicles.
SECTION 1 General Information Contents Section 1: General Information ........................................................1-1 Important Safety Notice................................................................1-1 Warnings, Notices and Notes ...................................................1-1 Making Safety Devices and Elements Inoperative...................1-2 Special Service Vehicle (SSV) Definition.....................................1-3 Identification Codes ....................................
General Information 1-1 Section 1: General Information Important Safety Notice Note: The descriptions and specifications contained in this guide were in effect at the time this manual was approved for printing. Ford Motor Company reserves the right to discontinue models at any time, or change specifications or design without notice and without incurring obligation.
1-2 General Information Section 1: General Information The following list contains some general warnings that you should follow when you work on a vehicle. WARNING: • Always wear safety glasses for eye protection. • Use safety stands whenever a procedure requires you to be under the vehicle. • Make sure that the ignition switch is always in the OFF position, unless otherwise required by the procedure. • Set the parking brake when working on the vehicle.
General Information 1-3 Section 1: General Information Special Service Vehicle (SSV) Definition Special Service Vehicles (SSV) are offered to fill the special needs of police agencies that a standard patrol car can not. SSV Standard Package Deletes Item Floor console Floor mats Fog lamps Third-row seat Standard Equipment System Powertrain/Functional Exterior Description 5.4L SOHC 3V V8 Engine 6-speed automatic O/D transmission Non-limited slip axle (3.
1-4 General Information Section 1: General Information Standard Equipment System Interior Safety/Security Description Second and third row coat hooks Second row map lights Manual A/C with auxiliary climate controls AM/FM single CD, 6-premium speakers (160-watts peak), driver adjusted speed compensated volume, partitioned audio, rear seat controls and MP3 capability Color-keyed assist handles Auxiliary audio input jack in instrument panel Cargo organizer (Expedition EL only) Column shifter Dome light Vi
General Information 1-5 Section 1: General Information Miscellaneous Options (See sales brochure for complete list of available options) Item Exterior Options Seat Options Description Daytime running lamps (43D) Engine block heater (41H) Heated sideview mirrors (54H) Running boards (4x4 only) (186) First row 40/60 split bench cloth with power adjustable driver’s seat (M) Second row 40/20/40 split bench cloth (N/A with 875 third row seat) (21F) Second and third row bench cloth (requires 574 rear aux A/C
1-6 General Information Section 1: General Information Vehicle Certification (VC) Label Code Positions Position Description 1 Exterior paint code 2 Region code 3 District Special Order (DSO) 4 Wheelbase code 5 Interior trim code 6 Tape/paint pinstripe code 7 Radio code 8 Axle code 9 Transmission code 10 Spring code 11 Powertrain calibration information 2010 Expedition SSV Modifiers Guide, 07/2009
General Information 1-7 Section 1: General Information 1. Exterior Paint Color Code The first set of numbers/letters listed indicate the vehicle primary body color code. The second set of letters/numbers listed (if applicable) indicate a 2-tone or accent body color code. • DX — Dark Blue Pearl • UG — White Platinum • UH — Tuxedo Black Metallic • UJ — Sterling Gray Metallic • UK — Royal Red • UX — Ingot Silver Metallic • YZ — Oxford White 4.
1-8 General Information Section 1: General Information 7. Radio Type • 1 — AM/FM stereo with in-dash, 6-disc CD changer and clock • F — AM/FM stereo CD player, navigation system and clock • S — Premium electric AM/FM stereo CD player • T — Premium AM/FM stereo with in-dash CD changer and clock • U — Premium AM/FM stereo with in-dash, 6-disc CD changer and THX® speaker system • X — AM/FM stereo with in-dash, CD changer and navigation system 8. Axle Ratio Code The axle ratios are: • 15 — 3.
General Information 1-9 Section 1: General Information 11. Powertrain Calibration Information Powertrain calibration information is printed in the lower right corner of the VC label. Only the base calibration information is printed. Revision levels will not appear. Powertrain calibration information is limited to a maximum of 5 characters per line on the VC label. Calibration identification consisting of more than 5 characters will wrap to the second line on the VC label.
1-10 General Information Section 1: General Information New Vehicle Storage — Body • Wash vehicle thoroughly to remove dirt, grease, oil, tar or mud from exterior surfaces and underside of front fender. • Periodically wash vehicles stored in exposed locations. • Touch up exposed raw or primed metal to provide rust protection. • Cover chrome and stainless steel parts with a thick coat of auto wax to prevent discoloration. Rewax as necessary when the vehicle is washed.
General Information 1-11 Section 1: General Information Tire Pressure Monitoring System (TPMS) Principles of Operation The tire pressure monitoring system (TPMS) monitors the air pressure of all 4 regular road tires. The tire pressure sensors, attached to each rim by a metal band located in the drop well, transmit via a 315 Mhz radio frequency signal to the internal antenna of the smart junction box (SJB).
1-12 General Information Section 1: General Information The TPMS, as delivered from the Ford Motor Company, complies with part 15 of the FCC rules and with RS-210 of Industry Canada. Operation is subject to the following 2 conditions: • This device may not cause harmful interference • This device must accept any interference received, including interference that may cause undesired operation.
General Information 1-13 Section 1: General Information As the ambient temperature decreases by 6°C (10°F), tire pressure decreases 7 kPa (1 psi). Adjust the tire pressure by 7 kPa (1 psi) for each 6°C (10°F) ambient temperature drop as necessary to keep the tire at the specified vehicle certification (VC) label pressure. Refer to the following tables to adjust the tire pressure indoors for colder outside temperatures.
SECTION 2 Electrical Contents Section 2: Electrical .........................................................................2-1 Electrical Basics ...........................................................................2-1 Electrical Systems Management ..................................................2-2 Generator Output..........................................................................2-2 Charging Margins .........................................................................
Electrical 2-1 Section 2: Electrical Electrical Basics Inside a vehicle, electricity is supplied through powered wires (commonly called ‘‘hot’’ wires), comparable to the pressurized supply pipes of a plumbing system. At various points along the wires are outlets in the form of lights, switches and receptacles. Turning on a light switch is somewhat like opening a faucet to let water run — an electric current flows through the hot wire to make the light glow.
2-2 Electrical Section 2: Electrical Electrical Systems Management Care must be given in deciding what equipment should be installed into a police vehicle given the power demands of the equipment and the power available from the vehicle. A power load strategy should be developed to minimize the risk of running out of power. Examine the proposed equipment for vehicle installation. Add up the current requirements.
Electrical 2-3 Section 2: Electrical Component Amps Base Miscellaneous Base Loads 16.5 Cooling Cooling Fan (electric fan clutch) 2.2 Climate Control A/C Clutch 3.5 A/C Fan-to-Face — High Speed 18.9 A/C Fan-to-Face — M/H Speed 13.4 Heater Fan-to-Foot — M/H Speed 12.5 Auxiliary Blower — M/H Speed 8.5 Auxiliary Blower — High Speed 9.5 Lighting Exterior and Instrument Panel Lamps (non-dimmable) 7.5 Headlamps — Low Beam 6.4 Headlamps — High Beam (incremental) 7.
2-4 Electrical Section 2: Electrical PCM — Red Area NOTICE: DO NOT make electrical connections to vehicle electrical systems not specifically designed for police equipment installations. Damage to the electrical system can occur. Do not install any components into the PCM or PCM harness. Connecting into this system may affect engine and transmission operation.
Electrical 2-5 Section 2: Electrical • Disconnect the negative battery cable of vehicles stored on site to reduce the possibility of draining the battery by lights or other equipment. • Do not allow control panels attached to the instrument panel to protrude into the driver and passenger air bag deployment zones. For additional information, refer to Section 5: Reference Information in this guide. • Do not install switches and gauges in the driver or passenger knee impact areas.
2-6 Electrical Section 2: Electrical Equipment Grounding Guidelines • Do not ground the body to the transmission or transmission crossmember. Ground accessories to the chassis or the vehicle battery. • Splicing into circuitry relating to the electronic engine and/or transmission control systems is not acceptable because of the adverse effect on the electronic system operation. • Adequately protect electrical connections exposed to the elements.
Electrical 2-7 Section 2: Electrical • Determine the terminal type. Base your decision on wire gauge, current carrying capacity, connector type and insulation type. — Use non-detent low insertion force terminals whenever possible. — Do not use low insertion force female terminals in weather-resistant connectors. — Analyze circuit requirements (signal levels, current, voltage) to determine the correct plating material (such as gold). Use of non-plated terminals is not recommended.
2-8 Electrical Section 2: Electrical • Use 135% of the fuse rating when sizing wiring to protect the circuit in the event of an overload. Fuses will last for 1 hour at 135% of their rating. — Total current draw is the sum of the base vehicle’s circuit current requirement (measured with an ammeter) and the anticipated add-on component current requirements. — Never increase the rating of a factory installed fuse or circuit breaker.
Electrical 2-9 Section 2: Electrical • Use greased or sealed connectors in floor pan troughs which are subject to moisture coming through the carpeting. • Use XLPE insulation for uncovered runs that exceed 305 mm (12 in). Electrical Protection • Correctly route wires away from noise-generating wires or components. However, if routing near noisy wires or plugging into noisy components is unavoidable, additional protection must be designed into the harness.
2-10 Electrical Section 2: Electrical • Scroll — Similar to convolute, but without the ridges. Scroll is used where harness rigidity is required, especially for maintaining critical locator dimensions. Use scroll for short lengths only, as it is quite inflexible. Note: This is not meant to be an all-inclusive list of methods for physically protecting the wires. There are other means of protection available that are not listed.
Electrical 2-11 Section 2: Electrical • Route wires to avoid metal edges, screws, trim fasteners and abrasive surfaces. When such routing is not possible, use protective devices (shields, caps) to protect the wires. Cover metal edges with a protective shield and fasten the wiring within 76 mm (3 in) on each side of the edge (see figure below).
2-12 Electrical Section 2: Electrical Wire Retention and Routing Use the following criteria to determine the location of retainers: • Size and weight of wire bundle. • Holes with poor accessibility that prevent installation of locators. • Movement of wires that can result in abrasion, squeaks and rattles. • When wiring is routed between 2 members where relative motion can occur, the wiring should be secured to each member with enough wire slack to allow flexing without damaging the wire.
Electrical 2-13 Section 2: Electrical For retainer screws, the following guidelines apply: • Avoid using fasteners that are too long for the application or are in an area which might damage vehicle components, including wiring, brake lines, fuel tank and lines, powertrain components, exhaust system and suspension. • Do not use pointed screws for attachments. Also check that screws used in the vicinity of the wiring are blunt-ended.
2-14 Electrical Section 2: Electrical Splices and Repairs For quality splicing and to reduce potential problems, the following guidelines are recommended: • Stagger the splices within a harness to reduce increased harness diameter. Splice only on straight areas as installed, not on bends. • Strip wire ends making sure that individual conductor strands are not damaged. • When soldering, make sure an adequate mechanical joint exists before applying solder. Use only resin-core solder.
Electrical 2-15 Section 2: Electrical 2. Strip wires to appropriate length. 3. Install heat shrink tubing. 4. Twist the wires together. 5. Note: Use resin-core mildly-activated (RMA) solder. Do not use acid-core solder. Solder wires together. 6. Note: Wait for solder to cool before moving wires. Bend wire 1 back in a straight line.
2-16 Electrical Section 2: Electrical 7. Note: Overlap tubing on both wires. Evenly position heat shrink tubing over wire repair. 8. Use a shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing.
Electrical 2-17 Section 2: Electrical 9. Reconnect the battery ground cable. Sealed Connectors Ford Part Number Part Name Class E6FZ-14488-A Butt Connector Gauge: 18-22, Color: Red C E6FZ-14488-B Butt Connector Gauge: 14-16, Color: Blue C E6FZ-14488-C Butt Connector Gauge: 10-12, Color: Yellow C Heat Shrinkable Tubing (Heat Shrink) (Ford Specification ESB-M99D56-A2) Heat shrinkable tubing is available in various diameters for different splice sizes and configurations.
2-18 Electrical Section 2: Electrical 4. Select the appropriate wire slice for the wires to be spliced from Rotunda Wire Splice Kit 164-R5903. 5. Note: Rotunda 164-R5901 Pro-Crimper supplied with the wire splice kit is the only tool that can be used with these splices. Identify the appropriate chamber on the Rotunda Pro-Crimper by matching the wire size on the dies with the wire size stamped on the butt splice. (1) Cavity (2) Indenter 6. Crimp the connector.
Electrical 2-19 Section 2: Electrical 8. Check for acceptable crimp. (1) Crimp should be centered on each end of the butt splice. (2) Wire insulation does not enter butt splice. (3) Wire is visible through inspection hole of splices. 9. Evenly position supplied heat shrink tubing over wire repair. 10. Use shielded heat gun to heat the repaired area until adhesive flows out of both ends of the heat shrink tubing. 11. Reconnect the battery ground cable.
2-20 Electrical Section 2: Electrical Rear Power Window Disable The rear power windows of the Expedition SSV can be disabled by disconnecting the rear window motor connectors (C701 [LH] and C801 [RH]). These connectors are located inside the door, behind the door trim panel. While they are disabled, the master window control switch will not control the rear windows. Refer to Expedition Wiring Diagrams Manual for additional power window wiring information.
SECTION 3 Installation Considerations Contents Section 3: Installation Considerations..............................................3-1 Mobile Radio Installation Guidelines ............................................3-1 General Information ..................................................................3-1 Spotlight Installation Location.......................................................3-4 Push Bumpers ..............................................................................
Installation Considerations 3-1 Section 3: Installation Considerations Mobile Radio Installation Guidelines NOTICE: This information has been prepared for use by persons installing 2-way radio equipment (transmitters and receivers) in vehicles. It has been prepared in accordance with current engineering principles and generally accepted practices, using the best information available at the time of publication.
3-2 Installation Considerations Section 3: Installation Considerations Radio transmitters are regulated by the Federal Communications Commission (FCC) in the United States. Compliance with FCC regulations is the responsibility of the manufacturer and/or user of transmitter equipment and not Ford Motor Company. Installation Guidelines WARNING: Do not mount any transceiver, microphones, speakers or any other item in the deployment path of the airbag system.
Installation Considerations 3-3 Section 3: Installation Considerations Glass-mounted antennas should be kept as high as possible in the center of the rear window or windshield. Some vehicles use glass that contains a thin metallic coating for defrosting or to control solar gain; glass mount antennas may NOT function correctly when mounted on this type of glass. (Ford Privacy Glass contains such a coating.) Also, refer to the antenna manufacturer’s recommendations.
3-4 Installation Considerations Section 3: Installation Considerations If any vehicle radio interaction problems exist after following these guidelines, contact the radio equipment manufacturer for additional assistance. Additional Sources of Information Radio Frequency Interference: How to Find It and Fix It ISBN: 0-87259-375-4, The American Radio Relay League, Inc.
Installation Considerations 3-5 Section 3: Installation Considerations Item Description 1 Side curtain tether anchor bolt hole 2 A-pillar assist handle bracket lower mounting bolt hole 3 Center line 4 Spotlight shaft hole 5 Spotlight mount lower bolt hole 1. Mark a center line between the center of the side curtain tether anchor bolt hole and the A-pillar assist handle bracket lower mounting bolt hole.
3-6 Installation Considerations Section 3: Installation Considerations Siren and Grille Lights The engine cooling system relies on correct airflow through the radiator to keep the engine at its correct operating temperature. When adding sirens and grille lights to a vehicle, make sure this airflow is not obstructed. Reduced airflow could put additional strain on the cooling system and shorten the operational life of related components.
Installation Considerations 3-7 Section 3: Installation Considerations Safety Belt Retractor and Side Impact Sensor Item Description 1 Side impact sensor 2 Front safety belt retractor The front safety belt retractors are located in the base of the B-pillars. The pretensioner located in the buckle is referred to as the ‘‘safety belt buckle pretensioner’’. In the event of an air bag deployment, pretensioners provide improved occupant protection by rapidly removing slack from the safety belt.
3-8 Installation Considerations Section 3: Installation Considerations WARNING: The front side impact sensors are located in the front doors. These are pressure sensors that measure the pressure change in the front door during an impact. Do not mount anything on or in the door. Do not cut any holes in the door sheet metal, trim or water seals. Failure to follow this instruction may cause personal injury.
Installation Considerations 3-9 Section 3: Installation Considerations Driver/passenger air bags affect the way police equipment can be mounted in police vehicles. Any surfaces that could come into contact with an air bag during deployment must not damage the air bag or alter its deployment path. Sharp edges, corners or protrusions could damage the nylon air bag material and reduce the effectiveness of the air bag. Do not mount or place any objects in the deployment path of an air bag.
3-10 Installation Considerations Section 3: Installation Considerations A reset event will set the interior lamps interrupt timer to 0. The reset events for the interior lamps interrupt timer are: turning on the interior lamps by using the dome lamp switch or opening any door (as detected by the door ajar switches). A reset event will set the demand lamps interrupt timer to 0.
SECTION 4 Cargo Mounting Considerations Contents Section 4: Cargo Mounting Considerations .....................................4-1 Cargo Area Equipment Mounting Guide ......................................4-1 Safety Belt Retractor and Side Impact Sensor (if equipped).................................................................................4-1 Auxiliary Climate Control System .............................................4-3 Cargo Loading ...............................................................
Cargo Mounting Considerations 4-1 Section 4: Cargo Mounting Considerations Cargo Area Equipment Mounting Guide NOTICE: When installing equipment, it is important to consider the available clearance between the brake lines and the fastener or component. Any fasteners or static components should allow a minimum of 15 mm (0.60 in) clearance to the brake lines. Any dynamic components should allow for a minimum of 19 mm (0.75 in) clearance to the brake lines.
4-2 Cargo Mounting Considerations Section 4: Cargo Mounting Considerations Item Description 1 Side impact sensor 2 Second row safety belt retractor 3 Third row safety belt retractor The second row safety belt retractors are located in the middle of the C-pillars. The third row safety belt retractors are located in the middle of the D-pillars. • Do not use the safety belt retractor bolts for mounting the partition. • Do not mount any hardware on the C-pillar or D-pillars.
Cargo Mounting Considerations 4-3 Section 4: Cargo Mounting Considerations WARNING: The rear side impact sensors are located in the C-pillars. The installation of hardware must not interfere with the correct operation of the rear side impact sensors. Failure to follow these instructions may result in personal injury. Auxiliary Climate Control System Note: Expedition EL shown, Expedition similar.
4-4 Cargo Mounting Considerations Section 4: Cargo Mounting Considerations Cargo Loading WARNING: Ford recommends that police equipment be both secured and laterally aligned. Hard, stiff or sharp objects, especially when not secured or correctly located, pose a risk to the occupants. Aftermarket organizers that do not adequately deform in rear-impacts can themselves become injury-producing objects. Failure to follow these instructions may result in personal injury.
Cargo Mounting Considerations 4-5 Section 4: Cargo Mounting Considerations • Low Risk Items — These items are soft in feel and pose a low risk of potential injury capability in collisions.
SECTION 5 Reference Information Contents Section 5: Reference Information ....................................................5-1 Engineering Drawings ..................................................................5-1 Air Bag Deployment Interference .............................................5-1 Fuel Lines — Short Wheelbase................................................5-5 Fuel Lines — Long Wheelbase ................................................5-6 Fuel Tank — Cut View, Short Wheelbase ...........
Reference Information 5-1 Section 5: Reference Information Engineering Drawings Air Bag Deployment Interference WARNING: Do not place objects or mount equipment in front of the air bag module cover or in front seat areas that may come in contact with a deploying air bag, dash, tunnel or console-mounted equipment should be placed within the specified zone. Failure to follow these instructions may result in personal injury.
5-2 Reference Information Section 5: Reference Information Figure 1. (1) 250 mm (9.8 in) from center of air bag door (2) 325 mm (12.8 in) from center of air bag door (3) 650 mm (25.6 in) Figure 2.
Reference Information 5-3 Section 5: Reference Information (1) 500 mm (19.7 in) (2) 300 mm (11.8 in) (3) 200 mm (8 in) Figure 3. No objects should be placed between the air bags due to air bag variability. (1) 300 mm (11.8 in) (2) 500 mm (19.7 in) (3) 260 mm (10.25 in) (4) 175 mm (7 in) WARNING: The front side impact sensors are located in the front doors. These are pressure sensors that measure the pressure change in the front door during an impact. Do not mount anything on or in the door.
5-4 Reference Information Section 5: Reference Information Figure 4. The curtain airbag extends from the A-pillar to the D-pillar and from the roof rail to the beltline. • Do not mount equipment to the B-, C- and D-pillars above the beltline. • Do not mount equipment to the A-pillar above the beltline except for spotlights. Refer to Section 3: Installation Considerations, Spotlight Installation Location. • Do not mount equipment on the headliner within 200 mm (8 in) of the side edges.
Reference Information 5-5 Section 5: Reference Information Fuel Lines — Short Wheelbase Item Description 1 Fuel line 2010 Expedition SSV Modifiers Guide, 07/2009
5-6 Reference Information Section 5: Reference Information Fuel Lines — Long Wheelbase Item Description 1 Fuel line 2010 Expedition SSV Modifiers Guide, 07/2009
Reference Information 5-7 Section 5: Reference Information Fuel Tank — Cut View, Short Wheelbase Item Description 1 Evaporative emissions hose 2 Fuel tank 3 Fuel line 2010 Expedition SSV Modifiers Guide, 07/2009
5-8 Reference Information Section 5: Reference Information Fuel Tank — Cut View, Long Wheelbase Item Description 1 Evaporative emissions hose 2 Fuel tank 3 Fuel line 2010 Expedition SSV Modifiers Guide, 07/2009
Reference Information 5-9 Section 5: Reference Information Fuel Tank — Bottom View, Short Wheelbase Item Description 1 Fuel lines 2 Fuel tank 2010 Expedition SSV Modifiers Guide, 07/2009
5-10 Reference Information Section 5: Reference Information Fuel Tank — Bottom View, Long Wheelbase 2010 Expedition SSV Modifiers Guide, 07/2009
Reference Information 5-11 Section 5: Reference Information Item Description 1 Fuel lines 2 Fuel tank Fuel Tank — Top View, Short Wheelbase 2010 Expedition SSV Modifiers Guide, 07/2009
5-12 Reference Information Section 5: Reference Information Fuel Tank — Top View, Long Wheelbase 2010 Expedition SSV Modifiers Guide, 07/2009
Reference Information 5-13 Section 5: Reference Information Fuel Pump Shut-Off Switch Brake Lines NOTICE: When installing equipment, it is important to consider the available clearance between the brake lines and the fastener or component. Any fasteners or static components should allow a minimum of 15 mm (0.60 in) clearance to the brake lines. Any dynamic components should allow for a minimum of 19 mm (0.75 in) clearance to the brake lines.
5-14 Reference Information Section 5: Reference Information Item Description 1 Master cylinder 2 Brake booster 3 Brake lines 4 Brake control module Technical Specifications Item Specification Specification Make: Ford Model: Expedition Special Service Vehicle (SSV) Sales Code: — Engine Displacement Cubic Inches: 330 Liters: 5.
Reference Information 5-15 Section 5: Reference Information Item Specification Specification Torque 365 lb-ft @ 3,750 rpm Battery 750 cca Compression Ratio 9.8:1 Transmission Model: 6R80 Type: 6-speed electronic automatic with lockup torque converter and overdrive. Axle Ratio 3.
5-16 Reference Information Section 5: Reference Information Item Behind Third Row Seat (optional) Specification Specification 0.51 cu m (18 cu ft) (Expedition) or 1.21 cu m (42.6 cu ft) (Expedition EL) EPA Mileage Est. (mpg) City: 16/Highway: 22 Combined: 18 Mileage Est. (km/L) City: 6.8/Highway: 9.3 Combined: 7.
