pickup box removal / alterations
Contents
1. Body Builders Layout Book PICKUP BOX REMOVAL ALTERATIONS PICKUP BOX REMOVAL INDEX PICKUP BOX REMOVAL Page Design Recommendations 2 7 Models amp Wheel Tire Data Super Duty F Series 22222 8 Ranger a aa a aE ae S EEE 9 Filler Pipe Location amp Dimensions Ranger 10 Rear Lamp Installation Ranger 222222222 11 lt www fleet ford com truckbbas 2010 MODEL YEAR 2 PICKUP BOX REMOVAL PARTI Introduction The following information is presented in three parts for vehicle alterers who intend to remove pickup boxes from certain Rangers and Super Duty F Series pickup trucks and install aftermarket second unit bodies on these vehicles For vehicle alterers in California see important information on page 6 concerning alteration of vehicles with a GVWR of 8500 Ib or less for sale registration or use in California Part details those Ranger and Super Duty F Series pickup models that may be altered by removal of the pickup box and installation of aftermarket second unit bodies and indicates where specific questions should be directed Part II provides information concerning the obligations and responsibilities of vehicle alterers with respect to United States and Canada Motor Vehicle Safety Standards F CMVSS Part Ill provides information for vehicle alterers with respect to United States California and Canada exhaust emissions evapor2. 2010 MODEL YEAR 2 The weight in pounds of the Second Unit Body SUB installed must be within the range specified in Tables A pages 7 8 corresponding to the particular pickup truck model and not greater than the weight in pounds calculated using the following formula SUB WEIGHT LIMIT Unloaded Vehicle Weight UVW Original Equipment Manufacturer OEM Curb Weight Pickup Box Options Removed Super Duty F Series Step Bumper 74 lb e Pickup Box see Table A Spare Wheel and Tire see Table B Ranger SuperCab Step Bumper 37 lb e Pickup Box see Table A e Spare Wheel and Tire see Table B Alterers must not remove alter or modify in any way the Ranger Ford factory installed frame mounted trailer hitch receiver Any Ranger Second Unit Body SUB must be attached using 10 attachment points with fasteners of equivalent size and grade of those removed from the Ford factory installed pickup box NOTES 1 For vehicles with a GVWR of 10 000 Ib or less and an unloaded vehicle weight of 5500 Ib or less 2 Injury criteria is applicable to vehicles with a GVWR of 8500 Ib or less and an unloaded vehicle weight of 5500 Ib or less 3 Applicable to vehicles with a GVWR of 10 000 Ib or less 4 Dynamic Performance Requirements apply to MPV Truck or a Bus with a GVWR of 2722 Kg 6000Ib or less for FMVSS only 5 Standard 135 applied to vehicles with a GVWR o
3. e The vehicle as produced by Ford meets F CMVSS No 111 Compliance to F CMVSS No 111 may be affected however by removal of the pickup box and installation of a Second Unit Body SUB even though the mirror system has not been altered A discussion of compliance with respect to each mirror type follows Sail Mounted Type Outside Mirror on Super Duty F Series or Ranger Pickup Provided the mirrors driver s seat and cab are not altered the mirror system will continue to meet Standard No 111 if the overall width of the Second Unit Body SUB is no wider than the pickup box and if the view of the roadway behind the vehicle through the inside mirror is not totally blocked off If the SUB blocks the view through the inside mirror a flat glass mirror is required on the passenger s side in place of the convex mirror on vehicles to be sold in the United States Vehicles for sale in Canada may be equipped with the convex mirror on the passenger s side when the SUB blocks the view through the inside mirror If the SUB is wider than the pickup box both the driver s side and passengers side mirrors may have to be replaced with mirrors providing a wider view to the rear Trailer Tow Mirrors on Super Duty F Series These mirrors will continue to meet Standard No 111 provided the mirrors the driver s seat and the cab are not altered ED www fleet ford com truckbbas Body Builders Layout Book PICKUP BOX R
4. 2082 2128 2148 2199 and 301 respectively NOTE Federal Motor Vehicle Safety Standard FMVSS and Canadian Motor Vehicle Safety Standard CMVSS No 204 are not applicable to a vehicle with an unloaded vehicle weight greater than 5500 Ib F CMVSS No 208 injury criteria are applicable only to vehicles with a GVWR of 8500 Ib or less and an unloaded vehicle weight of 5500 Ib or less Conformity to Federal Motor Vehicle Safety Standard FMVSS and Canadian Motor Vehicle Safety Standard CMVSS No 212 and 219 for vehicles having a gross vehicle weight rating as defined in 49 CFR Part 571 3 no greater than 10 000 Ib is established for representative vehicles at a vehicle weight provided by Sections S6 1 b and S7 7 b of FMVSS No 212 and 219 respectively and provided by Sections 5 1 and 8 of CMVSS No 212 and 219 respectively e The second unit body installed shall be mounted securely and so designed that when the altered vehicle is impacted in any manner specified by applicable provisions of F CMVSS No 2129 and 219 second unit body deformation or movement relative to the frame does not result in any separation or loss of body attachment to the frame e The second unit body installed and the required fuel system components identified below shall be located and mounted as follows 2010 MODEL YEAR The second unit body shall be mounted securely and is so designed that when the altered vehicle i
5. DRW F 350 10 200 19 5 x 6 0 Aluminum Wheel F450 550 DRW F 350 DRW 12 000 19 5 x 6 0 RW Steel Wheel DRW 260 19 5 x 6 75 K Steel Wheel DRW F 250 x 9400 F 250 9400 LT245 75R17 ae ne ees 08 F 350 10 000 LT275 65R18 F 350 10 200 LT275 70R18 SuperCab F 350 I 10 400 225 70Rx19 5 F 350 I 10 000 Average weight of all tire brands type offered in that size F 350 10 000 Motorhome F 350 10 200 F 350 10 600 F 350 DRW 12 400 F 350 DRW 12 600 F 250 9400 F 250 9600 F 250 9600 F 250 9800 F 350 10 000 F 350 10 000 F 350 10 200 F 350 10 600 Crew Cab F 350 10 000 F 350 i 10 000 F 350 10 400 F 350 I 10 800 F 350 DRW 12 400 F 350 DRW I 12 600 F 350 DRW i 12 600 F 350 DRW j 12 600 Vertical height measured from the top surface of the frame at the rear of the cab Maximum SUB center of gravity CG shown in this table is only allowable if F MVSS 105 criteria are satisfied per calculation in the Safety Emission section of this book Weight shown is maximum allowable for safety certification for vehicles with a GVWR less than or equal to 10 000 Ibs b c www fleet ford com truckbbas body Builders Layout book 9 PICKUP BOX REMOVAL ALTERATIONS 2010 PICKUP BOX REMOVAL MODEL YEAR RANGER MODELS amp WHEEL TIRE DATA TABLE A RANGER SUPERCAB MODELS AVAILABLE FOR PICKUP BOX REMOVAL TABL
6. The revised additional requirements are summarized as follows General Upfit Requirements e Except for a service body upfit with a rear bumper there must not be any components that tie a second unit body SUB to the frame rearward of rear spring s rear hanger shackle brackets Note that components for lateral support may be bolted or welded to either the chassis only or the second unit body only e A service body upfit with a rear bumper attached via a bracket that ties the second unit body SUB to the frame must not exceed 6 35mm 0 25 in gauge thickness Additional Requirements for Platform Stake Body Upfits e For platform stake body upfits only second unit body SUB longitudinal rail supports must not exceed 6 35mm 0 25 in gauge thickness e To obtain pass thru compliance to Standard 301 for a platform stake body upfit the factory installed 12 5K rated frame mounted trailer hitch receiver must be removed and replaced with a 16K trailer hitch receiver Ford Engineering Part Number BC34 19D521 B Ford Service Part Number BC3Z 17D826 B The trailer tow capability of the vehicles remain unchanged as specified in the vehicle owner s guide and the Ford Motor Company 2010 RV and Trailer Towing Guide Any questions should be directed to the Body Builder Advisory Service at www fleet ford com truckbbas 2010 MODEL YEAR Cont d next page 4 PICKUP BOX REMOVAL PART II Co
7. the vehicle alterer is required to certify the vehicle to FICMVSS 105 or 135 Brakes F CMVSS No 2040 Steering Control Rearward Displacement F CMVSS No 212 9 Windshield Mounting F CMVSS No 214909 Side Impact Protection and F CMVSS 219 Windshield Zone Intrusion and F CMVSS No 3019 Fuel System Integrity in addition to compliance with any other F CMVSS affected by the vehicle s alteration www fleet ford com truckbbas 4 Body Builders Layout Book PICKUP BOX REMOVAL ALTERATIONS DESIGN RECOMMENDATIONS Cont d For a chassis certified pickup truck having a GVWR of up to 14 000 Ib other than those for sale registration or use in California the alterer does not add more than 500 Ib to the maximum unloaded vehicle weight specified in Table A pages 7 8 corresponding to the particular pickup model a IMPORTANT Some of the preceding conditions are based in part on statements made by C N Freed of the Environmental Protection Agency EPA in a letter of July 13 1979 to M H McBride legal counsel of the Recreation Vehicle Industry Association That letter explained EPA s policy concerning alterers of complete 1980 and later model year light duty trucks in the context of EPA s Advisory Circular No 64 a March 7 1977 publication that provides guidance on the need for separate certification of vehicles modified after Original manufacture but prior to sale and delivery to the ultimate pur
8. Accelerating Highway Vehicles March 1992 Under the Canada Motor Vehicle Safety Standards a heavy duty vehicle is a bus a Chassis Cab a multipurpose passenger vehicle or a truck having a gross vehicle weight rating of more than 6000 Ib but not a passenger car However Transport Canada s tabulation of CMVSS indicates that CMVSS No 1106 does not apply to incomplete vehicles unless the incomplete vehicle is fitted with a cab and has a GVWR more than 10 000 Ib 4356 kg A pickup truck listed in tables on pages 7 8 if altered only by the removal of the pickup box including optional equipment attached to the pickup box and rear bumper if so equipped is designed and built to conform to the applicable exterior noise emission limits of CMVSS NO 1106 subsection 2 b The alterer is of course responsible for determining that the vehicle as altered complies with CMVSS No 1106 WARNING VEHICLE OPERATING TEMPERATURES Some trucks of Ford Motor Company may exhibit high engine compartment and exhaust system temperatures in some operating modes Components including exhaust heat shielding systems have been installed on some vehicles in our assembly plants in an effort to provide protection against such temperatures Subsequent aftermarket installers manufacturers are responsible for providing thermal protection e g underbody heat shields for any structure equipment added to the vehicle and should not remove any
9. Conditions numbered 1 2 3 and 4 under Section A entitled Exhaust and Evaporative Emission Requirements pages 4 5 and those under Section C entitled California Fuel Vapor Recovery as they apply to light duty trucks and medium duty vehicles 2 The vehicle alterer does not increase the vehicle s unloaded vehicle weight by more than 10 over the maximum curb weight unloaded vehicle weight specified in tables on pages 7 8 corresponding to the particular pickup model does not increase the frontal area by more than 10 or does not provide a combination increase of weight plus frontal area of more than 14 NOTE The maximum unloaded vehicle weight specified in tables on pages 7 8 for California is the curb weight the basic curb weight plus the weight of options of greater than 33 installation rate 2010 MODEL YEAR NOTE If the weight in pounds of the altered vehicle exceed the maximum unloaded vehicle weight specified in tables on pages 7 8 corresponding to the particular pickup truck model the vehicle alterer is required to certify the vehicle to F CMVSS No 105 or 135 Brakes F CMVSS No 204 Steering Control Rearward Displacement if the unloaded vehicle weight is 5500 Ib or less F CMVSS No 208 if the unloaded vehicle weight is 55 Ib or less F CMVSS No 212 Windshield Mounting F CMVSS No 219 Windshield Zone Intrusion and F CMVSS No 301 Fuel System Integrity in addit
10. F CMVSS No 210 F CMVSS No 21490 F CMVSS No 302 Seat Belt Assemblies Seat Belt Anchorages Side Impact Protection Flammability of Interior Materials With respect to the second unit body installed and the above mentioned safety standards it is the responsibility of the vehicle alterer to assure conformity with all applicabl requirements It is the responsibility of the vehicle alterer to determine which other safety standards if any their vehicles must comply with NOTE See statements for F CMVSS No 105 and 135 Hydraulic Brake implications of modifications alterations to completed vehicles including pickup box removal vehicles in the Safety Emission section Certification Labeling Requirements For altered vehicles in the United States the vehicle alterer is required to affix an additional label containing the information shown in the Safety Emissions section NOTE The safety standard certification label which is affixed to the drivers door latch pillar of the pickup truck by Ford Motor Company must not be removed For altered vehicles in Canada the vehicle alterer is required to affix a label containing the information shown inthe Safety Emissions section NOTE A vehicle alterer may be a manufacturer according to the definition of manufacturer contained in the Canadian Motor Vehicle Safety Act PART Ill Information concerning United States and Canada Exhaust Emissions Evaporative Emi
11. components exhaust heat shielding installed on the vehicles by Ford Also the added structure equipment should not restrict air circulation in the engine compartment or underbody See applicable sections under Ambulance Builders Guidelines in the Design Recommendations section Any interior floor underlayment or insulation in the near vicinity of the exhaust system without benefit of the Ford provided heat shields must be capable of withstanding 371 C and 482 C 900 F in close proximity to the catalyst during normal operating conditions Additionally any under chassis mounted component within 4 inches of the exhaust system must be compatible with these temperatures IMPORTANT INFORMATION CONCERNING ALTERATION OF LIGHT DUTY TRUCKS AND CHASSIS CERTIFIED MEDIUM DUTY VEHICLES WITH A GVWR OF UP TO 14 000 LB FOR SALE REGISTRATION OR USE IN CALIFORNIA Ranger SuperCab pickup trucks listed in Table A on page 8 and manufactured by Ford Motor Company for sale registration or use in California can be altered by removal of the pickup box including items attached to the pickup box and rear bumper if So equipped and installation of a second unit body if all of the following conditions are satisfied For additional information concerning noise control laws and regulations issued by the Federal U S Government as well as some states and municipalities see Vehicle Noise Regulations in the Safety Emissions section 1
12. AR sale registration or use in California Federal law specifies that a light duty truck is any vehicle with a GVWR of 8500 Ib or less that has a vehicle curb weight of 6000 Ib or less and a basic vehicle frontal area of 45 square feet or less which is designed primarily for transporting property or is a derivative of such a vehicle or is designed primarily for transporting persons and has a capacity of more than 12 persons or is available with special features enabling off street or off highway operation and use All complete and some incomplete heavy duty vehicles up to 14 000 lbs GVWR are emission certified to the chassis certification provisions of 40 CFR Part 86 Subpart S and the requirements amp restrictions of Subpart S apply All heavy duty engines in some incomplete vehicles having a GVWR of 8500 to 14 000 Ib GVWR and all vehicles over 14 000 lb GVWR for the United States and Canada have been certified to the applicable U S Federal or Canadian exhaust or California exhaust and evaporative emissions requirements for heavy duty engines Ranger SuperCab and Super Duty F Series pickup truck models listed in Tables A on pages 7 8 if altered by removal of the pickup box including items attached to the pickup box rear bumper if so equipped and installation of a second unit body may not require recertification to applicable Federal California or Canadian emissions requirements if the following condit
13. E B RANGER TIRE AND WHEEL DATA Second Unit Body Limits Wheel Size Wheel only Weight Ib Weight Max Height Maximum 15x6 0JJ base argent steel Complete 15 x 7 0 JJ WB GVWR Max Cg Overall Vehicle ET Description Drive in Ib Ib in in UVWR Ib 230 SuperCab silver styled steel silver aluminum 16 x 7 0 JJ 15 x 7 0 JJ 16 x 7 0 JJ P235 75R 15SL 28 2 P225 70R 15SL 24 1 P245 75R 16SL 30 8 31X10 5R15 43 2 5 spokle cast aluminum 8 hole forged aluminum 15 x 7 0 JJ chrome steel 5 spoke cast aluminum a b Vertical height measured from the top surface of the frame at the rear of the cab Maximum Second Unit Body SUB weight for any model is the lesser of two values shown below e The value listed here or e The value determined by SUB WEIGHT MAX UVW OEM Wet Curb Weight Pickup Box Options Removed Maximum SUB weights and center of gravity CG shown in this table are only allowable if F MVSS 135 criteria are satisfied per calculation Safety Emission section of this book Rear step bumper 37 Ib Spare tire and wheel assembly Table B Models without rear jumpseats c d e Models with rear jumpseats www fleet ford com truckbbas lt Body Builders Layout Book 10 PICKUP BOX REMOVAL ALTERATIONS PICKUP BOX REMOVAL RANGER FILLER PIPE LOCATION amp DIME
14. EAR LAMP ASSEMBLY 8 353473 S36 CLIP 2 REQUIRED 2 E4TZ 13405 C LEFT HAND REAR LAMP ASSEMBLY 9 384646 S GROMMET 4 REQUIRED FOR 4 x 2 MODELS 3 C7TZ 13406 A LICENSE PLATE BRACKET 2 REQUIRED 4 x 4 MODELS SPLIT LINE INGROMMET 4 EOTZ 13470 C RIGHT HAND MOUNTING BRACKET MUST BE AT TOP IN VERTICAL POSITION 5 EOTZ 13471 A LEFT HAND MOUNTING BRACKET 10 34661 S36 NUT AND WASHER ASSEMBLY 4 REQUIRED 6 34659 S36M NUT AND WASHER ASSEMBLY 4 REQUIRED TORQUE TO 12 20 POUND FEET TORQUE TO 3 7 POUND FEET 11 E8TZ 13A409 A WIRING HARNESS CONNECT TO MAIN WIRING ASSEMBLY 7 55653 S36 BOLT 4 REQUIRED BB0220 www fleet ford com truckbbas REAR LAMP ASSEMBLY INSTALLATION AND PARTS LIST RANGER ONLY
15. EMOVAL ALTERATIONS DESIGN RECOMMENDATIONS Cont d e If the front bumper and bumper mounting system are removed temporarily the front bumper and bumper mounting system must be reinstalled in accordance with the instructions provided in the Ford Truck Service Manual If the front bumper and bumper mounting system are replaced the replacement front bumper and bumper mounting system must not result in steering column rearward displacement of more than 5 inches as defined in F CMVSS No 204 any increases in injury criteria as defined in F CMVSS No 208 any additional loss of windshield retention as defined in F CMVSS No HAV any penetration of the Inner surface of the windshield or intrusion into the protected zone as defined in F CMVSS No 219 9 or loss of fuel system integrity as defined in F CMVSS No 301 when the vehicle is impacted in any manner specified by applicable provisions of those standards NOTE The second unit body added by the vehicle alterer may have to conform to other safety standards as well For example any glazing used in the second unit body must conform to F CMVSS No 205 Glazing Materials Additionally if the second unit body is equipped with any passenger seating positions the following safety standards may be applicable as well F CMVSS No 206 F CMVSS No 207 F CMVSS No 2082 Door Locks and Retention Seating Systems Occupant Crash Protection F CMVSS No 209
16. MENTS FOR F CMVSS 301 Ref BBAS Quality Bulletin Q183 2010 MY Vehicles Built Through August 31 2009 Vehicles with a Ford Motor Company manufacturer build date up to and including August 31 2009 will comply with F CMVSS Standard 301 if guidelines and recommendations are followed as specified in the 2010 Body Builders Layout Book Information is also available in the 2010 Super Duty F Series Incomplete Vehicle Manual January 2009 edition Standard 301 pass thru compliance guidelines relative to the fuel system chassis and trailer hitch receiver The IVM is available at www fleet ford com truckobbas under the Publications tab ED www fleet ford com truckbbas Body Builders Layout Book PICKUP BOX REMOVAL ALTERATIONS DESIGN RECOMMENDATIONS Cont d 2010 MY Vehicles built on or after September 1 2009 Vehicles with a Ford Motor Company manufacturer build date on or after September 1 2009 are required to comply to a revised F CMVSS Standard 301 that is effective September 1 2009 Vehicles will comply if guidelines and recommendations are followed as specified in the 2010 Truck Body Builders Layout Book Information is also available in the 2010 Super Duty F Series Incomplete Vehicle Manual August 2009 edition Standard 301 pass thru compliance guidelines relative to the fuel system chassis and trailer hitch receiver The IVM is available at www fleet ford com truckbbas under the Publications tab
17. NSIONS a FRONT OF VEHICLE NOTES PROVIDE ADEQUATE SUPPORT OF FUEL FILLER AND VENT HOSES TO ENSURE A CONTINUOUS DOWNWARD SLOPE FROM FUEL INLET TO TANK RECOMMENDED 2 DEGREES TO BACK OF CAB FUEL FILL OF FILL PIPE ASY AND BRACKET W709654 S424 SCR amp WSHR M4 2x1 41x22 0 HEX TAP 4 C MEMBER VENT TUBE SCREWS 3 REQD TORQUE 2 3 3 32 Nm 20 29 INLB PD FILL TUBE FES lt Ric ATTACH GROUND STRAP TO UPPER STEEL PORTION OF FUEL FILL NECK TOP OF FRAME RAIL DO NOT TRIM STEEL END N BB0445 2004 www fleet ford com truckbbas SUPERCAB 198 7 8 C SUPERCAB 443 17 4 SUPERCAB 224 8 8 USE COMPONENTS FROM FUEL FILL SYSTEM INSTALLED BY FORD REMOVE FROM VEHICLE HOSES CLAMPS AND CAP FOR USE WITH FILL PIPE KIT USE NEW HOSES PIPE STEEL PORTION TIE WRAPS AND CLAMPS PROVIDED IN KIT TO CONNECT FUEL FILL SYSTEM FROM TANK TO UNIT BODY AS SHOWN FUEL FILL AND VENT HOSES PROVIDED IN KIT MAY REQUIRE TRIMMING AS SHOWN IN FIGURE THE RESULTING TRIMMED FILLER SYSTEM SHOULD PROVIDE A DIRECT DOWNWARD SLOPE TO THE FUEL TANK FROM THE METAL PIPE WHILE AVOIDING KINKS WHICH RESTRICT FUEL FLOW ADDITIONAL SUPPORT MAY BE REQUIRED TO PREVENT SAGGING OR MIS ORIENTATION FAILURE TO DO SO WILL RESULT IN SPRAY OR SPIT BACK DURING THE FUELING OPERATIONS V CRITICAL CONTROL ITEM 2010 MODEL YEAR D TORQUE ALL WORM GEAR DRIVEN HOSE CLAMP
18. S TO 2 7 3 7 Nm 24 38 IN LB NOTE DIMENSIONS ARE INCHES 11 PICKUP BOX REMOVAL LEFT HAND REAR LAMP ASSEMBLY RANGER REAR LAMP INSTALLATION Body Builders Layout Book PICKUP BOX REMOVAL ALTERATIONS 2010 MODEL YEAR INSTALLATION FOR AX es fT I INSTALLATION FOR RANGER AE ODES RIGHT HAND 1 x 3 REAR LAMP ASSEMBLY NOTE SEs WIRE HARNESS ROUTING DIFFERENCES BETWEEN 4 x 2 AND 4x 4 MODELS 6 11 8 9 A I 4 x S N RANGER 4 x 4 MODELS N E SPY LEFT HAND RIGHT HAND REAR LAMP 1 x REAR LAMP ASSEMBLY ASSEMBLY SERVICE PART NUMBERS PART DESCRIPTION SERVICE PART NUMBERS PART DESCRIPTION 1 E4TZ 13404 C RIGHT HAND R
19. ative emissions and RFI requirements and California requirements with regard to fuel vapor recovery RANGER REGULAR CAB PICKUP BOX REMOVAL WILL AFFECT COMPLIANCE WITH THE DYNAMIC PERFORMANCE REQUIREMENTS OF F CMVSS NO 214 SIDE IMPACT PROTECTION FOR VEHICLES WITH A GVWR OF 2722 KG 6000 LB OR LESS Vehicle alterers who intend to modify vehicles as described above may use the information and conditions provided herein to assist them in determining whether modified vehicles comply with applicable regulatory requirements Alternatively the vehicle alterer may desire to employ other limits or conditions than those provided herein IT IS THE RESPONSIBILITY OF THE VEHICLE ALTERER TO ASSURE COMPLIANCE AND CERTIFICATION OF THE ALTERED VEHICLE TO THE APPLICABLE SAFETY AND OR EMISSIONS INCLUDING NOISE AND RFI REQUIREMENTS Specific questions concerning compliance and or certification to safety standards and emissions and fuel economy regulations should be directed to the vehicle alterer s legal counsel or the United States National Highway Traffic Safety Administration FMVSS and Federal Fuel Economy Standards and requirements the Canada Ministry of Transport CMVSS emissions and noise regulations the Canada Department of Communications Canadian RFI regulations the United States Environmental Protection Agency EPA United States emission requirements or the California Air Resources Board California em
20. chaser The maximum second unit body weights provided in tables on pages 7 8 are calculated in accordance with the definition of maximum vehicle weight provided in the July 13 1979 letter The referenced letter provides that alterers of complete light duty trucks need not recertify such vehicles for emission control purposes if 1 the altered vehicles conform in all material respects to the design specifications in the original manufacturer s application for certification and 2 the weight of the altered vehicle including the weight of fuel at nominal tank capacity is no more than 500 Ib above the maximum vehicle weight The letter further states that no frontal area restrictions will apply to alterers who comply with conditions a and b above Alterers who do not comply with these conditions will be considered manufacturers under the Clean Air Act and will be required to assure that the altered vehicles are certified Questions concerning EPA s policies with respect to alterers of completed vehicles should be directed to legal counsel or the Environmental Protection Agency b NOTE For a pickup truck having a GVWR of 10 000 Ibs or less If the weight of the altered vehicle exceeds the maximum unloaded vehicle weight specified in Table A corresponding to the particular pickup truck model and non California engine transmission combination the vehicle alterer is required to certify the vehicl
21. dition the FCC s rules may require the device to be tested and found to comply with various RF interference emissions limits before it may be marketed The FCC established different limits according to the particular use and installation of RF devices In some cases a grant of equipment authorization from the FCC also must be obtained before and RD device may be marketed To ensure continued compliance with the FCC s requirements the owner user custom manufacturer or service technician must not modify or change the RF device in a manner not expressly approved by Ford Motor Company Such modifications could void the authority to operate the device NOTES 1 For vehicles with a GVWR of 10 000 Ib or less and an unloaded vehicle weight of 5500 Ib or less 2 Injury criteria is applicable to vehicles with a GVWR of 8500 Ib or less and an unloaded vehicle weight of 5500 lb or less 3 Applicable to vehicles with a GVWR of 10 000 Ib or less 4 Dynamic Performance Requirements apply to MPV Truck or a Bus with a GVWR of 2722 Kg 60001b or less for FMVSS only 5 FICMVSS 135 is applicable to vehicles with a GVWR of 3500 Kg 7716 Ib or less F CMVSS 105 is applicable to vehicles with GVWR over 3500 Kg 7716 lb Cont d next page 7 PICKUP BOX REMOVAL PART Ill Cont d 2 CANADIAN RADIO FREQUENCY INTERFERENCE RFI INFORMATION All vehicles powered by spark ignition engines e g gasoline
22. e to F CMVSS No 105 or 135 Brakes F CMVSS No 204 Steering Control Rearward Displacement if the unloaded vehicle weight is 5500 Ib or less F CEMVSS No 208 Occupant Crash Protection if the GVWR is 8500 Ib or less and the unloaded vehicle weight is 5500 Ib or less F CEMVSS No 212 Windshield Mounting F CMVSS No 21499 Side Impact Protection F CMVSS No 219 Windshield Zone Intrusion and F CMVSS No 301 Fuel System Integrity in addition to compliance with any other F CMVSS affected by the vehicle s alteration See next page for important information concerning alteration of light duty trucks and chassis certified medium duty vehicles rated at 14 000 lb GVWR or less for sale registration or use in California B High Altitude Emissions Vehicles sold for principal use in high altitude areas must comply with the High Altitude Regulations United States Environmental Protection Agency regulations contain unique emission certification requirements for trucks that will be sold or delivered to customers for principal use above 4 000 feet 1219 meters Certain new vehicles cannot be sold to customers who intend to use them principally at high altitudes TO AVOID ANY QUESTION OF CERTIFICATION COVERAGE ORDERS SHOULD SPECIFY WHETHER A HIGH ALTITUDE EMISSION SYSTEM OR A NON HIGH ALTITUDE EMISSION SYSTEM IS REQUIRED C California Fuel Vapor Recovery California regulations require that vehicle fuel systems be designed to acco
23. engine only Fuel lines routing and attachments excluding fuel filler cap filler pipe filler hose s and filler system attachment hardware which must be removed and replaced Vapor line s and carbon canister s Fuel pump Fuel filter and attachment Air cleaner assembly Safety belts Front seat head restraints Electrical grounds on all components must be retained The Powertrain Control Module PCM and Catalyst and Exhaust System Trailer hitch receiver e Any alteration or modification made to the vehicle as manufactured by Ford Motor Company and any components or structure installed by the vehicle alterer must not result in steering column rearward displacement of more than 5 inches as defined in F CMVSS No 204 0 no modification to the Hydraulic Brake System that would affect compliance to F CMVSS No 105 or 1359 an increase in injury potential for front outboard seating positions as defined in FICMVSS No 208 any additional loss of windshield retention as defined in F CMVSS No 212 0 any change in the performance requirements of F CMVSS 21499 any penetration of the inner surface of the windshield or intrusion into the protected zone as defined in F CMVSS No 219 9 or loss of fuel system integrity as defined in F CMVSS No 301 when the vehicle is tested in any manner specified by applicable provisions of F CMVSS Nos 105 1359 204
24. f 3500 Kg 7716 Ib or less Standard 105 applies to vehicles with a GVWR over 3500 Kg 7716 Ib These lamps and reflectors are available from Ford in the form of rear lamp assemblies and are the same as those installed on Ford chassis cab models Cont d next page 3 PICKUP BOX REMOVAL PARTI II Cont d RANGER SUPERCAB PICKUP BOX REMOVAL REQUIREMENTS FOR F CMVSS 301 Ref BBAS Quality Bulletin Q183 The Ranger SuperCab will conform to F CMVSS Standard 301 Fuel System Integrity provided the vehicle is altered only by the removal of the pickup box including all equipment attached to the pickup box and rear bumper system followed by the installation of an aftermarket Second Unit Body SUB The fuel fill system must be installed as specified in this book The factory fuel system and associated components can not be removed nor modified and all fuel system clearances must meet recommendations contained within the Body Builders Layout Book Additionally the following requirements must also be adhered to e Alterers must not remove alter nor modify in any way the Ford Motor Company factory installed frame mounted trailer hitch receiver e The Second Unit Body SUB must be attached using 10 attachment points with fasteners of an equivalent size and grade to those removed from the Ford Motor Company installed pickup box F250 350 PICKUPS WITH GVWR RATINGS OF 10 000 LBS OR LESS PICKUP BOX REMOVAL REQUIRE
25. ion to any other F CMVSS to which conformity is affected by the vehicle s alteration 3 No axle ratio tire size or tire type changes are made that would increase the drivetrain ratio by more than five percent Altered vehicles which do not satisfy these conditions may not be sold offered or delivered for sale or registered in California unless the altered vehicle is certified by the California Air Resources Board pursuant to all applicable emissions requirements The vehicle alterer is responsible for obtaining such certification Questions regarding these requirements should be directed to your legal counsel or the California Air Resources Board body Builders Layout book 8 PICKUP BOX REMOVAL ALTERATIONS 2010 PICKUP BOX REMOVAL MODEL YEAR SUPER DUTY F SERIES MODELS amp WHEEL TIRE DATA TABLE A SUPER DUTY F SERIES MODELS AVAILABLE FOR PICKUP BOX REMOVAL TABLE B SUPER DUTY F SERIES TIRE AND WHEEL WEIGHTS aaa an Ka 3 Wheel Size Wheel only Weight Ib M kinum Complete 17x7 5 Steel Wheel F250 350 SRW mn F WB 9 AL 8L AL Body Style Drive in ama E e Leas abi 5 F 250 9000 17x6 5 Aluminum Wheel F350 DRW i F 250 9200 18x8 0 Steel Wheel F250 350 SRW I F 350 I 10 000 I 18x8 0 Aluminum Wheel F250 350 SRW Regular Gab F 350 10 000 18x8 0 Chrome Clad F250 350 SRW F 350 U 10 100 19 5 x 6 0 Steel Wheel F450 550
26. ions are satisfied 1 None of the emission control hardware furnished with the pickup truck is deleted modified or rendered inoperable A listing of such hardware is provided in the Emission Control Modifications section in the Safety Emission section of this book NOTES 1 For vehicles with a GVWR of 10 000 Ib or less and an unloaded vehicle weight of 5500 Ib or less 2 Injury criteria is applicable to vehicles with a GVWR of 8500 Ib or less and an unloaded vehicle weight of 5500 Ib or less 3 Applicable to vehicles with a GVWR of 10 000 Ib or less 4 Dynamic Performance Requirements apply to MPV Truck or a Bus with a GVWR of 2722 Kg 6000lb or less for FMVSS only Cont d next page 6 PICKUP BOX REMOVAL PART III Cont d 2 The Super Duty F Series fuel filler kit that is supplied with the vehicles ordered with pickup box delete option number 66D or available through Ford dealers Installation must be as shown in the Super Duty F Series section Filler system attachment hardware for Ranger SuperCab in kit 9B149 is shown installed in this section on following pages 3 The alterer does not exceed the limitations listed in Safety Emissions pages under Curb Weight and Frontal Area Restrictions Note If the weight of the altered vehicle exceeds the maximum unloaded vehicle weight specified in Table A pages 7 8 corresponding to the particular pickup truck model and engine combination
27. issions and fuel ED www fleet ford com truckbbas Body Builders Layout Book PICKUP BOX REMOVAL ALTERATIONS DESIGN RECOMMENDATIONS vapor recovery requirements and the vehicle noise emission control authorities if any in the state and locality in which the vehicle is sold If you have technical product related questions concerning some aspect of the vehicle alteration a representative of Ford Motor Company will be happy to talk with you Please contact your regional sales office or phone the Ford Truck Body Builders Advisory Service directly at 1 877 840 4338 Models Available for Pickup Box Removal The models listed in Table A page 7 Super Duty F Series and Table A page 8 Ranger SuperCab may be altered by removing the pickup boxes and installing aftermarket second unit bodies For Ranger SuperCab vehicles available for pickup box removal Ford Motor Company specifies that they shall be equipped with front and rear stabilizer bars Limitations on the second unit bodies that may be installed as well as other vehicle conditions are also specified in Table A and in the Safety Emissions section PART Il Information Concerning United States and Canada Safety Standards The vehicle alterer is responsible for certifying the altered vehicle pursuant to Title 49 of the Code of Federal Regulations Sections 567 7 and 568 8 in the United States or pursuant to Section 9 of the Canadian Motor Vehicles Safety Regu
28. lations in Canada As Outlined in these requirements the vehicle alterer must ascertain which F CMVSS are affected by the alteration and subsequently provide certification that the altered vehicle conforms to all affected safety standards In the information that follows Ford has endeavored to provide sufficient instructions and guidelines to the vehicle alterer for certifying that the vehicle conforms to all F CMVSS affected by the vehicle alteration Information pertaining to Certification Labeling Requirements for the altered vehicle is outlined in page 4 Federal and Canadian Motor Standards Compliance Conformity to the following FMVSS FMVSS and Canadian Motor Vehicle Safety Standards CMVSS are affected by the removal of the pickup box and rear bumper and installation of an aftermarket second unit body F CMVSS No 1059 Vehicle Safety Hydraulic Brakes F CMVSS No 108 F CMVSS No 111 F CMVSS No 135 F CMVSS No 204 Lighting Equipment Rear view Mirrors Light Vehicle Brakes Steering Control Rearward Displacement Occupant Crash Protection Windshield Mounting Side Impact Protection Windshield Zone Intrusion Fuel System Integrity F CMVSS No 208 F CMVSS No 212 F CMVSS No 21490 F CMVSS No 219 F CMVSS No 301 For Motor Company represents that in the case of a Ranger SuperCab or Super Duty F Series pickup truck listed in Table A page 7 S
29. licable to vehicles with a GVWR of 8500 Ib or less and an unloaded vehicle weight of 5500 Ib or less 3 Applicable to vehicles with a GVWR of 10 000 Ib or less 4 Dynamic Performance Requirements apply to MPV Truck or a Bus with a GVWR of 2722 Kg 6000lb or less for FMVSS only 5 Standard 135 applied to vehicles with a GVWR of 3500 Kg 7716 Ib or less Standard 105 applies to vehicles with a GVWR over 3500 Kg 7716 Ib Cont d next page 5 PICKUP BOX REMOVAL PART II Cont d e The front end of the second unit body installed shall be located at least three inches rearward of the rearmost point of the cab on Super Duty F Series and at least 1 4 inches rearward of the rearmost point of the cab on Ranger SuperCab models e The vehicle as produced by Ford meets the Center High Mounted Stop Lamp CHMSL requirements of Standard 108 Lighting Compliance to these criteria may be affected by the installation of a Second Unit Body SUB if the SUB blocks the view of the CHMSL mounted on the back of the cab When this happens the subsequent manufacturer must install a CHMSL on the SUB that meets FMVSS 108 An electrical feed for installation of a CHMSL on the SUB is provided and is located inside the rearmost crossmember near the end of the left frame rail on the Super Duty F Series models For the Ranger directions are given in Ford Bulletin Q 28 CHMSL Precautions and Guidelines for Adding or Locating
30. mmodate a new vapor recovery fueling nozzle including unobstructed access to the fill pipe Fuel filler pipes installed per Super Duty F Series section of this book will comply with the Specifications for Fill Pipes and Openings of Motor Vehicle Fuel Tanks referenced in Title 13 California Administrative Code providing no part of the second unit body as installed intrudes within the access zone defined in CARB regulation 13 CCR 2235 Fuel filler pipes installed using the alternate bracket shown on the figures in Super Duty F Series section of this book will comply with the above California vapor recovery regulations provided the second unit body installed does not interfere with the access zone 2010 MODEL YEAR D Radio Frequency Interference RFI 1 UNITED STATES RADIO FREQUENCY INTERFERENCE RFI INFORMATION Devices that emit radio frequency RF energy such as AM FM radios and radio controlled theft alarms marketed for sale or use in the United States are subject to the rules and regulations of the Federal Communications Commission FCC 47 C F R Parts 2 and 15 These rules specify the following conditions of operation This device complies with Part 15 of the FCC rules Operation is subject to the following two conditions 1 This device may not cause interference and 2 The device must accept any interference received including interference that may cause undesired operation In ad
31. natural gas or propane engines and manufactured in Canada or for sale or use in Canada are subject to the Canadian Regulations for the Control of Interference to Radio Reception per Interference Causing Equipment Standard ICES 002 and applicable test method according to CAN CSE C108 4 M92 Violation of these regulations is punishable by fine or imprisonment Ford built vehicles were designed and manufactured to be capable of meeting the regulatory requirements or such modifications thereof as may have been authorized by the Department of Communications However because Ford has no control over how an altered vehicle is completed by subsequent stage manufacturers Ford does not represent that the completed vehicle incorporating the Ford built components will comply with applicable requirements The following information is supplied to subsequent stage manufacturers to help them avoid increasing the RFI emissions of this vehicle in the course of completing it For any altered vehicle additional measures may be needed to adequately suppress RFI emissions Affected components could include spark plugs electronic engine control module ground straps ignition component shields accessory drive belts and instrument voltage regulator suppressor assembly More specifically e All components required to suppress RFI emissions which are removed during service repair or completion of the vehicle must be reinstalled in
32. nt d Example A vehicle alterer wants to remove the pickup box and rear step bumper from a Super Duty F 250 Regular Cab 4x4 137 inch WB model with a 5 4L engine automatic transmission and air conditioning having a curb weight of 6200 Ib and install a 600 pound Second Unit Body SUB First Table A on page 7 specifies that the maximum SUB weight is 1800 Ib Since the SUB weight is 600 Ib this condition is satisfied Second the SUB weight must not exceed the SUB WEIGHT LIMIT calculated below SUB WEIGHT LIMIT Maximum Complete Unloaded Vehicle Weight UVW minus the unloaded vehicle weight as delivered OEM curb weight plus pickup box weight removed plus weight of removed options 6900 6200 380 74 1154 Ib The 600 Ib SUB is less than 1154 Ib and accordingly may appropriately be installed as planned The vehicle alterer must either select a lighter weight SUB reduce the OEM accessory weights for the vehicle or both if the SUB is heavier than the maximum limit 1 OEM Curb Weight includes Base Vehicle Weight with full fuel engine and transmission weight and all OEM accessory weights ordered or installed Refer to the appropriate Truck Source Book or the CD version of this publication for weight data 2 Options removed include step bumpers or similar OEM options permanently removed from the vehicle 3 The center of gravity height and overall height of the second unit body installed by the altere
33. r must not exceed the values specified in Table A pages 361 362 corresponding to the particular pickup model Center of gravity height and overall height of the second unit body are measured from the top surface of the frame at the rear of the cab 4 The altered vehicle s unloaded vehicle weight see Definitions in Safety Emission section must not exceed the values designated in Table A pages 361 362 corresponding to the pickup truck s model and non California engine transmission combination www fleet ford com truckbbas Body Builders Layout Book PICKUP BOX REMOVAL ALTERATIONS DESIGN RECOMMENDATIONS Cont d These instructions must be followed in the vehicle alteration The following components as installed by Ford Motor Company are not to be removed relocated altered or modified in any way Steering column steering shaft steering wheel and related structural components and attachment hardware Windshield and windshield mounting system Cab and front end structural components including the roof pillars cowl cowl reinforcements hood doors fenders hood restrictors and apron reinforcements and frame and frame reinforcements Radio antenna Doors and hood mounting hinging and latching systems Hood and fender ornamentation Fuel tank and attachment hardware including sending unit and vapor valve fuel tank shield and in tank electric fuel pump for gasoline
34. s tested in any manner specified by applicable provisions of F CMVSS No 301 a Second unit body components shall not contact any fuel system component other than at the points where the fuel system is permanently attached to the second unit body and b Second unit body deformation or movement relative to the frame shall not cause any fuel system component to be penetrated disconnected or otherwise damaged The rear end of the second unit body excluding the rear bumper installed shall not extend beyond overhang the rear edge of the vehicle frame or frame extension Any extension of the vehicle frame must be constructed and attached so as to perform as a continuation of the vehicle frame when the altered vehicle is tested in any manner specified by applicable provisions of F CMVSS No 301 See the Design Recommendations Second Unit Body SUB attachment section of this book for additional information The fuel filler cap filler pipe filler hose s and filler system attachment hardware for vehicles with diesel engines and for vehicles with gas engines shall be installed as shown in the Super Duty F Series section and shall be securely retained to remain intact when the vehicle is tested in any manner specified by applicable provisions of F CMVSS No 3019 NOTES 1 For vehicles with a GVWR of 10 000 Ib or less and an unloaded vehicle weight of 5500 Ib or less 2 Injury criteria is app
35. ssions RFI and Noise and California Fuel Vapor Recovery Requirements Refer also to pages within the Safety Emissions section THE INFORMATION HEREIN IS PROVIDED AS GUIDANCE ONLY IT IS THE RESPONSIBILITY OF THE VEHICLE ALTERER TO ASSURE COMPLIANCE OF THE ALTERED VEHICLE WITH THE APPLICABLE EMISSION REQUIREMENTS A copy of the appropriate Ford Truck Owner s Guide and Warranty Facts Booklet is installed in the altered pickup truck prior to sale to the ultimate purchaser in order to provide emission systems warranty information and maintenance schedules Note Whether Ford Motor Company or the alterer is responsible for emission warranty claims depends on among other things whether the vehicle failed to comply with applicable warranty provisions because of modifications made by the alterer or because of the original design and manufacture of the vehicle Questions concerning requirements and policies with respect to alterers of completed vehicles should be directed to body builders legal counsel the Environmental Protection Agency or the California Air Resourses Board A Exhaust and Requirements Ranger SuperCab completed trucks have been certified to the applicable U S Federal California or Canadian exhaust and evaporative emissions requirements See Safety Emissions section for important information on altering vehicles with an 8500 Ib GVWR or less to be for Evaporative Emission 2010 MODEL YE
36. the manner in which they were installed by Ford e Shields on ignition coil must remain installed e Replacement of spark plugs ignition wires and ignition coil must be equivalent in their RFI suppression properties to original equipment e Electrical grounds on all components must be retained e Metallic components installed on the body or chassis must be grounded to the chassis e Electrical circuits added to the vehicle must not be installed near the high voltage ignition components ED www fleet ford com truckbbas Body Builders Layout Book PICKUP BOX REMOVAL ALTERATIONS DESIGN RECOMMENDATIONS Cont d e Only static conductive accessory drive belts should be used Fan water pump power steering and other belts should be on the OEM type or equivalent that will not build up a static electrical charge e Engine component wiring must not be rerouted in any manner e The Powertrain Control Module PCM must not be relocated from the position as installed by Ford Motor Company E Noise Canadian Motor Vehicle Safety Standard CMVSS Section 1106 Noise Emissions prescribes maximum permissible exterior sound levels of 83 dB A for heavy duty vehicles with a GVWR between 6001 and 10 000 lb where such levels are measured in accordance with SAE Recommended Practice Standard J986a Sound Level for Passenger Cars and Light Trucks August 1994 or SAE Standard J1470 Measurement of Noise
37. uper Duty F Series and Table A page 8 Ranger SuperCab this vehicle as altered will conform to the requirements of the previously listed safety standards provided the vehicle is altered only by the removal of the pickup box including optional equipment attached to the pickup box and rear bumper if so equipped and the installation of an aftermarket Second Unit Body SUB in accordance with the following conditions 1 The following lighting components must be designed and installed on the altered vehicle in accordance with the requirements of F CMVSS No 108 Lamps Reflective Devices and Associated Equipment Tail Lamps Stop Lamps License Plate Lamps Back Up Lamps Rear Side Marker Lamps Front and Rear Identification Lamps for vehicles over Rear Turn Signal Lamps 80 inches in width Rear Side Marker Lamps Front and Rear Clearance Rear Side Reflex Reflectors Lamps for vehicles over Reflectors 80 inches in width Center High Mounted Stop Lamp if second unit body blocks view of the CHMSL on the back of the cab another CHMSL must be added The items of lighting equipment including wiring and power supply on the cab of the pickup truck must not be removed modified replaced or altered Further the second unit body installed by the vehicle alterer must not impair the visibility and conformity to the photometric requirements of the lamps and reflective devices installed on the cab of the pickup truck
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