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body and special equipment installation precautions

1. TO RETURN TO INDEX Page 167 MOTOR HOME CHASSIS GENERAL NOTES 4 Adherence to the following suggestions and warnings should not be construed as implying compliance with any particular U S or Canadian regulation See the Incomplete Vehicle Manual IVM for specific information regarding compliance with U S or Canadian regulations 5 The weight of the basic vehicle plus the sum of the weights of a additions to the basic vehicle body and equipment b other cargo c fuel sufficient to fill all tanks and d the maximum number of occupants at 150 lb per occupant must not exceed the GVWR of the vehicle as specified on the incomplete vehicle label attached to the IVM and must be dis tributed so that neither the front or rear GAWR as specified on the incomplete vehicle label is exceeded Also see the IVM for further instructions All heavy equipment installed by the body builder should be placed as close to the floor as practical to maintain a minimum vertical center of gravity Side to side load ing should be as symmetrical as possible about the vehicle longitudinal centerline to prevent vehicle lean and adverse steering and braking characteristics 6 Rear departure angle of 8 8 maximum for the motor home chassis should be maintained to protect the fuel tank at GVWR Rear bumpers or underbody skids should be considered to minimize interference to ground 7 All subsequent manufacturer installed items must b
2. before removing tank Fuel tank clearance to body or frame components is 0 75 inches minimum The size of any flexible body mounts must not be con sidered as part of this clearance Suspension components must clear the fuel tank by 2 00 inches minimum through their functional geometry Unfriendly surfaces by fuel tanks are unacceptable i e any fas tener used to install back up alarm seats etc to floor or chassis components must not point toward fuel tank Revisions and welding to fuel filler pipes filler necks and tanks must be avoided When welding in the vicinity of the system espe cially gasoline remove the tanks and fuel components to prevent accidents When removing tanks for processing tanks should be stored where protected and caps should be installed on all openings Dirt dust will plug fuel filters and could result in engine damage Reinstallation of fuel sender units always requires a new gasket fastener torque of 85 115 in lb is specified Auxiliary generator systems that are installed with their own fuel supply or with a fuel supply provided by means other than using the tank auxiliary port must meet FMVSS requirements Tapping into fuel tanks for an extra fuel source is highly undesirable and FMVSS certification is required An auxiliary fuel port is available on the motor home chassis in tank sender unit assembly The recommended horizontal and vertical location for fuel tank fi
3. sensitive to ambient temperatures Underbody ventilation is critical and temperatures in specific areas should not exceed those listed in the Table see Cooling on the next page 2 4R100 wire harness routing location wire harness locating clips all heat shielding and minimum clearance to the exhaust must be maintained as installed from the assembly plant Failure to main tain minimum clearances may result in heat damage to the wiring assembly and loss of transmission controls 3 For the motor home equipped with automatic transmissions it is mandatory that the shift linkage be readjusted after shift linkage repair engine mount replacement or shimming steering column replacement or repositioning transmission replacement or any repair which could change the linkage adjustment pe WHEELS AND TIRES 1 The 245 70Rx19 5F 18 000 Ib and 20 500 Ib GVWR and the 225 70Rx19 5F 15 700 lb GVWR are the only tires approved for the F Super Duty Class A Motor Home Chassis F53 TO RETURN TO INDEX Page 168 MOTOR HOME CHASSIS F SUPER DUTY CLASS A MOTOR HOME CHASSIS F53 BODY AND SPECIAL EQUIPMENT INSTALLATION PRECAUTIONS Continued COOLING Refer also to Design Recommendations Cooling 1 Cooling inlet area revisions grille bumper slots etc must not significantly alter air flow and should be free from blockage such as spare tires added brackets etc Restricted air flow can result in possible engi
4. NNAGE BOX FUSE PANEL F P IS LOCATED ON 14A032 A WIRE HARNESS PROVIDED IN DUNNAGE BOX POWER NETWORK BOX PNB IS LOCATED ON 12A581 WIRE HARNESS LOCATED IN ENGINE COMPARTMENT 15 700 Ib 18 000 Ib 20 500 Ib FRONT FRONT GAWR 6000 11000 7000 AXLE 7000 11000 7000 5 sranes conenenarewome mm me mom Not Applicable
5. Top Side of Dash Panel Part of 14A318 A w Assy 14 Middle of Vehicle Part of 14405 w Assy 14 16 Rear of Vehicle Part of 14408 w Assy E E S AAA e Park Brake Ground 162 2 Lt Green Red Top Side of Dash Panel Part of 14A318 A w Assy e Radio Feed 137 Yellow Black Siripe Top Side of Dash Panel Part of 14A318 A w Assy F P Pos 17 e RH Turn Signal Only Feeds White Lt Blue Front Side of Dash Panel Part of 14290 w Assy F P Pos 1 and Rear of Vehicle Part of 14408 w Assy e RH Turn w Brake Signal Feeds 5 Orange Lt Blue Rear of Vehicle Part of 14408 w Assy F P Pos 1 NOTES 14A032 14A318 17B587 14408 13A840 AND 18A586 WIRE ASSY S ARE PROVIDED IN DUNNAGE BOX FUSE PANEL F P IS LOCATED ON 14A032 A WIRE HARNESS PROVIDED IN DUNNAGE BOX POWER NETWORK BOX PNB IS LOCATED ON 12A581 WIRE HARNESS LOCATED IN ENGINE COMPARTMENT 0 18 16 16 STE F SUPER DUTY CLASS A MOTOR HOME Page 171 MOTORHOMECHASSIS CHASSIS F53 BODY AND SPECIAL EQUIPMENT INSTALLATION PRECAUTIONS Continued a a a a a a r r z 0A Washer Pump Feed Black White Stripe Front Side of Dash Panel Part of 17B587 w Assy F P Pos 11 Wiper Motor Feed Common Yellow Red Stripe Wiper Motor Feed High White Wiper Motor Feed Ignition Drk Green Wiper Motor Feed Low Drk Blue Orange Stripe Wiper Motor Feed Switch Black Pink Stripe NOTES 14A032 14A318 17B587 14408 13A840 AND 18A586 WIRE ASSY S ARE PROVIDED IN DU
6. ash Panel Part of 144318 A w Assy and Rear of Vehicle Part of 14408 w Assy 1 0 1 3 1 2 Door AlerLamp Ground f croma omose O f e Headlamp Low Beam Feed Left 160 Right 161 K A OH 4 Brown Orange Stripe Top Side of Dash Panel Part of 14401 A w Assy PNB Fuse N 3 3 9 Lt Blue White Stripe Top Side of Dash Panel Part of 14A318 A w Assy PNB Fuse K 18 Black Lt Blue Top Side of Dash Panel Part of 14A318 A w Assy oOo gt Lt Green Black Stripe Front Side of Dash Panel Part of 14290 w Assy F P 35 are NM Dark Brown and White Front Left Side of Dash Panel Part of 14290 w Assy F P 31 10A Dark Green Orange Front Right Side of Dash Panel Part of 14290 w Assy F P 25 10A Yellow Lt Green Front Side of Dash Panel Part of 14290 w Assy PNB Fuse 2 Lt Blue Red Stripe Top Side of Dash Panel Part of 14A318 A w Assy F P Pos 41 Orange Lt Green Top Side of Dash Panel Part of 14A318 A w Assy F P 4 15A and Rear of Vehicle Part of 14408 w Assy e Horn Feed e Instrument Panel Lamp Feed e Interior Lamp Feeds Ground 40 o e LH Turn Signal Only Feeds 3 Lt Green White Stripe Front Side of Dash Panel Part of 14290 w Assy F P Pos 1 and Rear of Vehicle Part of 14408 w Assy e LH Turn w Brake Signal Feeds Lt Green Orange Rear of Vehicle Part of 14408 w Assy F P Pos 1 e Marker Lamp Feeds Park Lamp 16 Front Side of Dash Panel Part of 14290 w Assy PDB 6 20A 16
7. e at least 3 4 inch away from fuel tank s rotating driveline components and all other moving components Also they must be clear of all axle total movements 8 EMISSIONS CONTROLS See the Incomplete Vehicle Manual 9 NOISE REGULATIONS See the Incomplete Vehicle Manual 10 SAFETY CERTIFICATION INFORMATION See the Incomplete Vehicle Manual BODY 1 Any structural member removed from the body or cowl assembly areas except for the dunnage box supports must be replaced or included in the body structure of any special body installed 2 Itis mandatory that the body builder establish a structurally sound combination of body and vehicle structure by securely fastening together the body and the frame This requires a rigid body design and a thoroughly planned system of bolts welds and other fasten ings between the frame and body To ensure structural integrity is maintained the vehicle s front structure must not be modified 3 To avoid interference problems with suspension components body attachments to frame should not protrude below side member flange INSTALLATION PRECAUTIONS 4 An access panel may be provided in the vehicle floor by the body builder to service the in tank fuel pump 5 The body builder should consider the addition of sound insulation to minimize engine and fan noise in the driver compartment FRAME 1 FRAME WEB holes to mount brackets outriggers and sup ports may be drilled in the v
8. eadlamp circuit a separate circuit is provided for the marker lamps Adding the marker lamps to the headlamp circuit can result in an overload of the circuit For full service temperature range the headlamp switch load should not exceed 15 amps Wiring access for lights to be controlled by the headlamp switch are provided at the front of the dash panel and at the rear of the vehicle and are identified by tags attached to these wires Splices and electrical loading fusing and wire size requirements of these circuits must be in accordance with general practices previously identified 3 LIGHTS CONTROLLED BY STOP LAMP SWITCH AND TURN INDICATOR SWITCH NOTE Splicing into the stop lamp switch on vehicles with 4R100 transmissions can interfere with the proper functioning of EEC 4R100 and speed control This can e Affect EFI engine idle speed quality e Prevent the 4R100 torque converter clutch from applying at throttle openings less than half throttle e Prevent the speed control from disengaging upon braking If your application involves splicing into the stop lamp switch of an 4R100 equipped vehicle please call the Truck Body Builders Advisory Service on 1 877 840 4338 The F Super Duty Class A Motor Home Chassis F53 has a mechanical stop lamp switch mounted on the brake pedal arm These switches and associated wiring are designed for a maximum load of 10 5 amps which is less than the fuse in the circuit but ample for normal
9. ening The tailpipe or attenuator of any modified system should be above the departure angle of the finished vehicle 2 Do not remove reposition or otherwise modify any existing OEM chassis or exhaust mounted heat shielding These shields are there to ensure heat protection from underbody components as well as occupant comfort Changes in the exhaust pipe length should be accompanied by a similar lengthening of the heat shielding where it exists Additional underbody heat shielding is required to be installed by the builder as specified in the QVM Motor Home and Transit Bus Guide FUEL SYSTEM 1 The fuel tank for the motor home chassis is located between the frame rails aft of the rear axle and is supported by straps and frame crossmembers The body builder should consider skid plates or protective bars if the body structure does not adequately protect the lower and rear surfaces of the tank WARNING The five gallon throwaway fuel tank used on the motor home chassis is for temporary use only during transit shipping and is to be discarded by body builder Minimum 10 gallon fuel fill on initial fill of aft of axle fuel tank to dilute anticorrosion solution Avoid relocating fuel tanks Relocated fuel tanks must meet FMVSS requirements Use torque specifications and controls for reinstalling tanks refer to service manual To avoid electrical sparking at tank disconnect the battery ground cable s from the vehicle battery ies
10. ertical side rail web with the following restrictions e Material between edge of hole and inside of upper or lower flange must be at least 1 50 e Minimum edge distance between any two holes must be at least twice the diameter of the largest hole e Holes must be no larger than 0 75 in diameter Avoid close vertical succession of fasteners e All attaching fasteners including flat washers must be of high strength steel Grade 8 or metric equivalent 2 FRAME FLANGE holes may be drilled in the horizontal frame flanges with the following restrictions e Material between edge of hole and radius edge of flange must be at least 1 0 e Minimum edge distance between any two holes must be at least twice the diameter of the largest hole e Holes must be no larger than 0 5 in diameter 3 Welding to the frame flange is not recommended welding to the vertical side web is preferred 4 The frame for the motor home chassis is designed to permit re moval ofthe engine andtransmissionout the bottom Thisis fa cilitatedby bolt in No 2andNo 3crossmembers Body builders should not add permanent structures which preclude power train removal ENGINE 1 Engine compartments must be designed to eliminate any air cir culation restriction that would affect the air induction and cooling systems Motor home engine compartments must provide ade quate flow through ventilation to prevent local temperatures from exceeding recommended maximu
11. ller pipe is shown on page 163 of this section Fuel filler and vent hoses must not be exposed to sharp corners and should have a minimum of 1 00 inches clearance to the body and surrounding body and chassis components except frame If fuel filler hoses are in the vicinity of edges or corners then shield abrasion protection should be used Sink traps low spots in fuel filler and or vent hose are unacceptable The recommended horizontal and vertical location for the fuel tank filler pipe is shown on page 163 of this section Lengthening relocating the fuel filler pipe can only be done with the hose supplied in the dunnage box and steel tube provided by the body builder No substitute hose material is allowed Total length of the hose used in the system cannot exceed that of the original hose supplied in the dunnage box Failure to comply may void the evaporative emissions certification ffuel hoses or vent hoses are replaced the new hoses must meet Ford Engineering specifications ESL M2D291 A2 torque specifi cations should be used for hose clamps 25 to 35 in lb Extra connections in the fuel filler hose or vent hose caused by the use of extensions should be avoided Use only the Ford specified fuel cap Caps other than the Ford original such as aftermarket locking gas caps are unacceptable 4 Splicing of fuel lines with clamps and rubber hoses is unacceptable NOTE Motor Home Chassis have P T F E nylon fuel li
12. ltage regulator will be damaged if the connection does not exist when the ignition switch is energized ELECTRONICS Refer to the Electrical Wiring Section for information on the Electronic Engine Control system A C PREP PACKAGE 1 The F Super Duty Class A Motor Home Chassis F53 comes with an R134a non CFC air conditioning prep package for use with a CCOT controlled a c system This package consists of a compressor condenser high side lines with high pressure switch air recirculation baffles and front end accessory drive which are mounted to the chassis and an accumulator dryer with low pressure cutoff switch that is shipped in the dunnage box and is located by the body builder 2 Information on air conditioning refrigerant and lubricant quantities are shown in the Motor Home and Transit Bus Guide Included in the Guide is the charge level determination procedure for a CCOT air conditioning system eT F SUPER DUTY CLASS A MOTOR HOME Page 170 MOTORHOMECHASSIS CHASSIS F53 BODY AND SPECIAL EQUIPMENT INSTALLATION PRECAUTIONS Continued a Purple Stipe Top Sie of Dash Paret Panor taaste wasy e Backup Lamp 140 Black Pink Rear of Vehicle Part of 14408 w Assy F P 32 e Battery Feed 1049 Brown Pink Stripe Top Side of Dash Panel Part of 14A318 A w Assy F P 15 e Blower Motor Feed 181 e Brake Lamp Feeds 511 e Cigarette Lighter Feed 4 e Courtesy Lamp 5 e Daytime Running Lamp 93 3 2 Top Side of D
13. ms Limits for critical engine components are shown in the Table see Cooling on next page 2 No modification of the air cleaner inlet duct is permissible Removal or modification of this duct will affect function of the mass air meter possibly causing driveability problems and in creased tailpipe emissions 3 The electronic speed control system used on the motor home chassis does not require any vacuum source or reservoir F SUPER DUTY CLASS A MOTOR HOME CHASSIS F53 BODY AND SPECIAL EQUIPMENT SUSPENSION AND STEERING 1 No vehicle or component alterations are allowed which restrict or prevent steering wheel column intermediate shaft or coupling assembly collapse stroke travel during crash 2 Relocating the power steering fluid reservoir is not recom mended If the reservoir is moved care must be taken to en sure that the power steering hoses are not kinked hoses should have generous radii Keep the reservoir upright in a vertical position while in the process of relocating it to ensure that no air enters the system 3 If suspension spacers are used between the spring and axle seats to accommodate side to side variations they should not exceed 3 4 inch DRIVELINE 1 No drilling or welding to the front axle I beam is permissible Spe cial equipment mounting or attaching brackets requiring attach ment to the front axle may be clamped to axle I beam only TRANSMISSION 1 Transmission components are
14. ne damage for which the installer may be held liable should any claims arise 2 A minimum frontal grille opening of 370 square inches is required to provide satisfactory engine cooling The grille opening should be directly in front of the radiator or ducted in such a manner to direct airflow through the radiator core 3 Engine and Automatic Transmission temperatures may be affected by motor home front end design Component temperature limitations should not be exceeded See Table below F SUPER DUTY CLASS A MOTOR HOME CHASSIS F53 MAXIMUM ALLOWABLE COMPONENT TEMPERATURE Fuel Rails Pressure Regulator 200F Engine Ignition Sensors 250F EEC Module mounted behind pedals 175F Auto Transmission Sensors 250F Lower Transmission Area mounts gaskets etc 250F NOTE Use only Ford Factory Coolers Heat Exchangers EXHAUST 1 Any changes to the existing exhaust pipe length should be accomplished by welding or use of 3 8 inch U bolt clamps Pipe added to the exhaust outlet must be of 0 053 minimum wall thickness Extending the outlet pipe 10 inches or more requires an additional support bracket of a type similar to those provided with the original chassis WARNING It is mandatory that the side outlet tailpipe configuration be retained when any modification is made to the exhaust system to reduce the possibility of exhaust fume entry through rear openings The pipe outlet should not be located near any vent window door or body op
15. nes In line fuel heaters used on diesel only should be compatible with Ford fuel line fittings including nylon lines When drilling or welding in areas where there are fuel or vapor lines the lines should be removed Bolts installed into the chassis near fuel vapor lines should have protective caps or other means of protection for the lines Kinking or collapsing of fuel or vapor lines while handling or after installation is unacceptable If line has been kinked it must be replaced If carbon canisters are relocated Heat shields should be added if they are located in the vicinity of the catalyst and or muffler e No additional hose can be added to the canister purge lines Lengthening of the system can only be accomplished by replacing one or more of the steel tubes with a longer tube The number of joints and length of hose in the system cannot be increased If any of the hose is damaged it must be replaced with CADBAR II low permiability hose meeting Ford Engineering Specification ESA M2D50 B Failure to comply may void the evaporative emissions certification Fastener torque specs are 14 to 22 ft lb for remounting of canister brackets to frame Avoid routing of fuel or vapor lines near any sharp edges or corners Protect lines if near any sharp edges or corners Do not add auxiliary filters to fuel return lines or auxiliary pumps to fuel supply lines ELECTRICAL All wiring additions and revisions should c
16. omply with procedures described in the Electrical Wiring General Practices on Appendix page 184 NOTE Refer to the table on page 170 for identification of chassis wiring circuits and tagged circuit splice locations After all electrical or vehicle modifications perform the on board diagnostics procedures as described in the powertrain control emissions diagnosis manual to clear all diagnostic trouble codes DTCs Road test vehicle and rerun on board diagnostics to verify that no DTCs are present If DTCs are generated perform the appropriate diagnostic procedures and repairs Vehicle operation engine transmission may be affected if DTCs are not serviced TO RETURN TO INDEX Page 169 MOTOR HOME CHASSIS F SUPER DUTY CLASS A MOTOR HOME CHASSIS F53 BODY AND SPECIAL EQUIPMENT INSTALLATION PRECAUTIONS Continued 1 ADDING LIGHTS OR ELECTRICAL DEVICES Although there are many points in the truck electrical system to connect additional circuits certain connection points provided are recommended for reliability and convenience This section defines the recommended connection points for the F Super Duty Class A Motor Home Chassis F53 models and the maximum electrical loads allowable CAUTION Improper electrical tie ins may affect vehicle operation i e engine transmission Alternative connections or wiring practices are not recommended as certain modifications may result in other circuits becoming nonf
17. st not cause total loads to exceed capabilities of the base vehicle wiring State provincial local laws may regulate the manner in which the fog and driving lamps are used or may require additional equipment for the particular use intended for the vehicle It is the buyer s owner s responsibility to determine the applicability of such laws to the buyer s owner s intended use for the vehicle and to arrange for the installation of required equipment When horns are installed the location must be as high as possible with bell mouth of horn pointed downward NOTE For additional information on Electrical Trailer Tow wiring and devices please refer to the Body Builder Wiring Supplement 5 BATTERIES AND VOLTAGE REGULATOR The battery location must be adequately ventilated accessible for servicing protected from road splash and must also incorporate a shockless mounting If the original equipment battery is replaced by more than one battery or a battery of a larger capacity the battery charging power supply circuit must be checked and revised to carry the additional loads F Super Duty Class A Motor Home Chassis F53 has a separate wire to the EEC IV module to maintain Keep Alive Power and is not affected by the addition of a battery cut off switch The electronic voltage regulator base must always be connected to the battery engine chassis ground when the ignition switch is in either the ON or START position The vo
18. stop lamp loads Under no circumstances are total loads in excess of this value permissible If only turn signal function is desired for the added lights splice into the taillamp loom located at the rear of the vehicle Splice into wires tagged R H turn signal only or L H turn signal only If both the turn signal and stop lamp function are desired for the added lights splice into the taillamp loom at the rear of the vehicle into wires tagged R H turn w brake and L H turn w brake NOTE The turn signal switch used on light trucks has a maximum rated current of 6 5 amps for right and left turning functions and 10 amps for stop lamp function Do not exceed these values on the turn signals The turn signal and emergency flasher system on the F Super Duty Class A Motor Home Chassis F53 utilizes an electronic flasher For the turn signal function the electronic flasher is designed to accommodate five 2 1 amp lights and for the emergency flasher function it is designed to accommodate ten 2 1 amp lights for combination stop turn and trailer lamps NOTE Adding more lights than what is specified above can result in reduced life and performance of the flasher 4 ADDED LIGHTS OR ACCESSORIES CONTROLLED BY ADDED SWITCHES The added electrical switches and wiring must have sufficient electrical capacity for the accessory load and must be protected by appropriate fuses or circuit breakers Also added current draw mu
19. unctional Disconnect the battery negative ground cable and remove it from the battery carrier prior to any vehicle modification Upon completion of body or equipment installation all wiring should be checked for proper routing etc to preclude electrical shorts upon reinstallation of the battery negative cable All electrical power for 12 volt equipment installed by the body builder must be taken off at the battery terminal of the auxiliary battery relay starter relay or locations provided and identified later in this book and must be protected by a fuse circuit breaker or fusible link The vehicle wiring and protection were designed for the following lighting loads additional loads to any circuit must be installed in accordance with the detailed electrical wiring instructions provided later in this book Halogen Headlamp Bulbs 9004 Combination Rear Lamp tail brake turn 10 signal Bulbs 1157 Back up Lamps 1156 Side Marker Bulbs License Plate Illumination Bulbs Interior Dome Bulb 561 Bulbs for Instrument Cluster Illumination 16 Small bulb 37 5 Large bulb 194 2 LIGHTS CONTROLLED BY HEADLAMP SWITCH The headlamp switch on the F Super Duty Class A Motor Home Chassis F53 utilizes one 20 amp fuse for the headlamp high beam circuit and two 10 amp fuses for low beam The vehicle contains a standard daytime running lamp system which operates using low beam reduced intensity NOTE Do not add marker lamps to the h

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