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Ford 6C34-19A268-BA Automobile User Manual

1. 5 ee ee eee as eee ieee 5 VEHICLE DESCRIPTION esee 6 5 7 STATEMENTS OF CONFORMITY 8 24 CANADIAN VEHICLES Vehicle Identification 25 Daytime Running Lamp DRL see 25 Canadian Radio Frequency Interference RFI Information 25 EMISSION CERTIFICATION INFORMATION Frontal Area and Weight Restrictions 26 High Altitude Requirements seen 26 Emission Control Hardware essesseeeeeeeeneeneee 26 Unleaded Gasoline Label esen 26 Exterior NOISG 5 o ees a eot 26 Tampering with Noise Controls 27 Warranty and 27 Evaporative Emissions seseeenee e 27 Malfunction Indicator Light MIL eeeeeenne 27 Power Take Off Circuit eseesssesseseeeeneeeeennnnenns 27 Ozone Depleting Substance 9 27 Emission Control Information Label eeeeeee 27 California Fuel Vapor Recovery seseseenne 27 California Motor Vehicle Emission Control Label
2. E E g vehicle overall length is 9 14 meters 30 feet or more Bie 9 E intermediate side marker lamps and reflex reflectors not 2g supplied by Ford Motor Company are also required for st compliance with Standard 108 O Item ZA The items of equipment which are supplied by Ford Motor Headlamps Company identified by the code S in Table H on this i page are designed and installed to conform to all the Tail Lamps S S requirements of Standard 108 The completed vehicle will Stop Lamps S S conform with these components if the subsequent stage Center High Mounted manufacturer does not remove relocate alter or modify Stop Lamp CHMSL S N such equipment or modify the power supply or wiring to License Plate Lamps S S such equipment and does not complete the body in such a configuration as to impair the visibility and conformity Reflex Reflectors Side Front S S to the photometric requirements of the installed lamps Side Rear R R and reflective devices Bear S S Specific requirements for lighting and associated Side Marker Lamps Front S S equipment are listed by incomplete vehicle type in Table Rear R R H on this page Back Up Lamps S S Lamps reflective devices and associated equipment Turn Signal Lamps Front S S necessary to complete the vehicle from an incomplete Rear S S vehicle must conform to the equipment locations Turn Signal Operating Unit S S special wiring visibility photometric and performa
3. 28 Radio Frequency Interference RFI ssseesss 28 REFERENCE INFORMATION Back Cover TABLE OF CONTENTS 2 F SERIES march 2005 DEFINITIONS The following definitions are from Title 49 Code of Federal Regulations 49CFR Parts 567 3 568 3 and 571 3 where noted Canadian definitions are from Canadian Motor Vehicle Safety Regulations CMVSR Section 2 1 and are in italics Ford Motor Company definitions are for the purpose of this manual only Some terms are followed by an abbreviation that is used throughout this manual Ambulance is a vehicle for emergency medical care which provides A drivers compartment a patient compartment to accommodate an Emergency Medical Technician EMT Paramedic and two litter patients one patient on the primary cot and secondary patient on folding litter located on the squad bench so positioned that the primary patient can be given intensive life support during transit equipment and supplies for emergency care at the scene as well as during transport two way radio communication and when necessary equipment for light rescue extrication procedures The Ambulance shall be designed and constructed to afford safety comfort and avoid aggravation of the patient s injury or illness From Federal Specification KKK A 1822 E Ford Motor Company also includes within its definition of ambulance any vehicle that is used for transporti
4. relocated altered or modified in any way except as specified in this manual Windshield and windshield mounting system Cabandfrontend structural components including the roof pillars cowl cowl reinforcements hood doors fenders hood restrictors and apron reinforcements and frame and frame reinforcements Radio antenna and air cleaner assembly Doors and hood mounting hinging and latching systems Hood ornamentation Bumper and bumper mounting system 1 No alteration or modification made to the incomplete vehicle as manufactured by Ford Motor Company and no components or structure installed by a subsequent stage manufacturer results in any loss of windshield retention as defined in Standard 212 or any penetration of the inner surface of the windshield or intrusion into the protected zone as defined in Standard 219 when the vehicle is impacted in any manner specified by applicable provisions of Standard 212 or Standard 219 Conformity to Standards 212 and 219 for a vehicle having an Unloaded Vehicle Weight greater than 2 495 kg 5 500 Ib is established by testing a representative vehicle at an Unloaded Vehicle Weight of 2 495 kg 5 500 Ib as permitted by s6 1 b and s7 7 b of Standards 212 and 219 respectively The front end of the body installed by the subsequent stage manufacturer is located at least 76 2 mm 3 0 in rearward of the rearmost point of the cab Temporary removal of
5. 0 2591mm 102 0 3200mm 126 0 3505mm 138 0 sagging which could cause spray or spitback during normal fueling operations MAX 2159mm 85 0 2769mm 109 0 3378mm 133 0 3683mm 145 0 MIN 584mm 23 0 584mm 23 0 584mm 23 0 584mm 23 0 Do not extend the fuel fill system outboard of the second WC unit body MAX lt renmm 787MM 91 0 767mm IS 9T 4 remm 93 91 The installation of Tube Extension F81A 9B149 HA will VD MIN 267mm 10 5 267mm 10 5 267mm 10 5 267mm 10 5 permit the location aft of axle fuel fill housing to be no MAX 343mm 135 a4amm 13 5 343mm 13 5 343mm 13 5 further rearward than the of the fill hose as it passes through the frame FIGURE A SUPER DUTY F SERIES NARROW FRAME CHASSIS CAB FUEL FILLER PIPE INSTALLATION STATEMENTS OF CONFORMITY 22 F SERIES march 2005 48 0 HOLES 12 PLACES REQUIRED ON BOTH FILL AND VENT HOSE WHERE PASSING OVER FRAME S 3 toad STEEL ELBOW m A DONOTTRIM 775 TR 4 CAP VELIT i d K 1 4 TURN GASOLINE LEV Il SCREW DIESEL SCREWS 3 REQ D TRIM THE LONG END AS REQUIRED 1 89 SUB 8 16 INCH 48 0 48 0 BLIND RIVET 1 89 1 89 n 12 REQ D NIV box m 870 780 Y 105 7 3 42 3 07 48 0 4 16 YY 1 89 48 0 A i Y Ed 7g 1 891 67 5 OF BRACKET 3 07 A d Y POINT Z REFER TO CALIFO
6. 8500 8500 8500 F 350 Crew Cab 4X4 Narrow 610 3766 3766 3766 4475 mm 176 2 in WB 60 CA 24 8300 8300 8300 Vertical dimensions are measured from the top surface of the frame at a distance approximately 304 8 457 2 mm 12 18 inches from the rear of the cab F SERIES march 2005 11 STATEMENTS OF CONFORMITY TABLE G SUPER DUTY F SERIES VEHICLES MINIMUM SECOND UNIT BODY WEIGHTS Model and Configuration Wide Frame Pickup Box Deletes F 250 350 956mm 37 7 in Body Style Wheelbase mm in Minimum SUB Weight kg Ib F 250 350 SRW Regular Cab 3480 137 Super Cab 4013 158 Crew Cab 4379 172 4 172 380 Regular Cab 3480 137 Super Cab 4013 158 Crew Cab 4379 172 4 191 420 Narrow Frame Chassis Cabs F 350 866mm 34 1 in and F 450 550 868mm 34 2 in Model and Configuration Body Style Wheelbase mm in Minimum SUB Weight kg Ib F 350 SRW Regular Cab 3576 140 8 190 420 Super Cab 4110 161 8 190 420 Crew Cab 4475 176 2 172 380 Regular Cab 3576 140 8 190 420 4186 164 8 204 450 Super Cab 4110 161 8 190 420 Crew Cab 4475 176 2 190 420 Regular Cab 3576 140 8 190 420 4186 164 8 204 450 4795 188 8 227 500 5100 200 8 249 550 Super
7. Cab 4110 161 8 190 420 Crew Cab Regular Cab 4475 176 2 190 420 5085 200 2 3576 140 8 204 450 190 240 4186 164 8 204 450 4795 188 8 227 500 5100 200 8 249 550 Super Cab 4110 161 8 190 240 Crew Cab 4475 176 2 190 240 5085 200 2 204 450 STATEMENTS OF CONFORMITY F SERIES march 2005 106 108 The statement below is applicable to the Chassis Cab This vehicle when completed will conform to Standard 106 Brake Hoses if the brake hose assemblies supplied by Ford Motor Company are not removed relocated altered or modified and if no brake hose assemblies are added The statements below concerning Standard 108 Lamps Reflective Devices and Associated Equipment are applicable to the Chassis Cab No additional components may be added to the vehicle which require the use of tools to remove such components for access to the headlamp aiming devices as provided by Ford Motor Company Daytime Running Lamps DRLs Light Trucks for sale or use in Canada are equipped with DRLs that meet the Canadian DRL requirements As manufactured for Canada the F Series vehicles will meet the FMVSS 108 requirements for DRUs when DRLs are provided Conformity with Standard 108 S 12 Headlamp Concealment Devices are not substantially affected by the design of this incomplete vehicle accordingly Ford
8. If the subsequent stage manufacturer adds to or modifies the fuel system in any manner it becomes the responsibility of the modifier to assure compliance with the applicable regulations Refer to the Design Recommendation section of the Ford Truck Body Builders Layout Book for additional Fuel System Evaporative Emissions information MALFUNCTION INDICATOR LIGHT MIL The Malfunction Indicator Light is used to indicate malfunctions of the Electronic Engine Control System and certain emissions related components For all incomplete vehicles except Basic Stripped Chassis which is not equipped with an instrument panel it is Ford installed and operational F SERIES marcn 2005 POWER TAKE OFF CIRCUIT A wire located under the instrument panel labeled Power Take Off Circuit is provided to minimize the inadvertent illumination of the Service Engine Soon while the PTO is engaged Refer to the Design Recommendation section of the Ford Truck Body Builders Layout Book for Power Take off Installations information that will locate the Ford provided circuit Connect the wire to the Power Take Off Circuit as instructed and isolate the wire labeled Power Take Off Circuit from the solenoid to prevent damage to the Power Control Module PCM OZONE DEPLETING SUBSTANCE ODS The Clean Air Act of 1990 Section 611 requires any product i e completed vehicle containing or manufactured with any Class Ozone Depleting S
9. Motor Company makes no representation as to conformity with this Standard ER FRONT OF VEHICLE SUPER DUTY F SERIES CHASSIS CAB CENTER HIGH MOUNTED STOP LAMP CHMSL ELECTRICAL CONNECTOR LOCATION F SERIES march 2005 13 108 The statement below is applicable to the Chassis Cab with a GVWR of 4536 kg 10 000 Ib or less and a vehicle width less than 2032 mm 80 00 in This vehicle when completed will conform to Standard 108 Lamps Reflective Devices and Associated Equipment If the Chassis Cab Center High Mounted Stop Lamp CHMSL when provided is obstructed from the rear of the completed vehicle it must be replaced with a CHMSL that meets all the requirements of this standard and is connected to the electrical power source as provided by Ford Motor Company See the figure below for circuit location STATEMENTS OF CONFORMITY TABLE H 108 D below are applicable to the Chassis Standard 108 Highting Equipment This vehicle when completed will conform to Standard Super Duty 108 Lamps Reflective Devices and Associated F Series Equipment if all the required lighting equipment as Completed indicated in Table H on this page identified by the codes as Truck R and S is designed and installed in accordance with or MPV the requirements of Standard 108 and the directions cT contained in this statement Additionally if the completed
10. PROTECTIVE SLEEVES ARE THIS HOSE IS PREFORMED REQUIRED ON BOTH FILL INSTALL SHORT END TO AND VENT HOSE AT FRAME METAL NECK AND CAP ASSEMBLY OPENING TRIM THE LONG END AS REQUIRED L LET USE PROVIDED TIE STRAPS Nd V STEEL TUBE TO SECURE FILL TO VENT DO NOT TRIM HOSES 2 PLACES MIDSHIP FUEL FILL SYSTEM _TOP OF FRAME RAIL OPTIONAL ON CHASSIS CAB AT OF FILL PIPE NOTES TORQUE ALL WORM GEAR DRIVEN HOSE CLAMPS TO 2 8 3 9 NEWTON METERS 25 35 IN LB DIMENSIONS ARE INCHES NOT SUPPLIED BY FORD MOTOR COMPANY CA BACK OF CAB TO CENTERLINE OF REAR AXLE CONTROL MEM Remove and discard the Ford installed fuel fill system components provided for shipping purposes only except 60 INCH CA 84 INCH CA 108 INCH CA 120 INCH CA WHEELBASE save and reuse the metal neck and cap assembly Regular Cab 3576mm 140 8 4186mm 164 8 4795mm 188 8 5100mm 200 8 SuperCab 4110mm 161 8 Use the new hoses pipes scuff guards tie wraps and Crew Cab 4475mm 176 2 5085mm 200 2 clamps provided in the dunnage kit VA MIN 864mm 34 0 1473mm 58 0 2083mm 82 0 2388mm 94 0 The completed fuel fill system must provide a 4 degree MAX 2 40 5 1638mm 64 5 2248mm 88 5 2553mm 100 5 Minimum continuous downward slope to the fuel tank Additional support may be required to prevent hose VB MIN 1981mm 78
11. The Statements of Conformity section of this manual includes compliance representations for certain VSO vehicles These vehicles are identified in the chart on page 7 FORD TRUCK ASSISTANCE Throughout this manual you will find references to information found in the Ford Truck Body Builders Layout Book Additional Design Recommendations and specifications are also provided to assist subsequent stage manufacturers in completing chassis cab and incomplete vehicles To obtain a free copy of this publication on CD ROM or to receive an order form for additional CD ROM s or books please visit our website at www fleet ford com truckbbas Under Publications select Body Builders Order Forms All dealer requests can be handled online All other U S orders should be faxed to 734 713 2971 Canadian orders should be faxed to 905 670 0844 The Ford Truck Body Builder Advisory Service may be consulted regarding information contained in this manual Call 877 840 4338 Fax 313 594 2633 e E Mail bbasqa ford com or at the BBAS website www fleet ford com truckbbas Include your name company and telephone number with all inquiries If requesting written materials or a CD ROM include your mailing address GENERAL INFORMATION VEHICLE DESCRIPTION INCOMPLETE VEHICLE MANUAL COVER The cover of this manual identifies the incomplete vehicle configuration for which compliance representations are contained in this manual Also a lab
12. X 201 Occupant Protection in Interior Impact X 2 X 2 202 Head Restraints X 2 X 2 203 Impact Protection for the Driver from the Steering Control System X 2 X 2 204 Steering Control Rearward Displacement X 3 X 3 205 Glazing Materials X X X 206 Door Locks and Door Retention Components X X 207 Seating System X X 208 Occupant Crash Protection X 5 6 X 5 6 X 209 Seat Belt Assemblies X X X 210 Seat Belt Assembly Anchorages X X 210 1 User Ready Tether Anchorages for Restraint Systems Canada only X X 210 2 Lower Universal Anchorage Systems for Restraint Systems and Booster Cushions Canada only X X 212 Windshield Mounting X 2 X 2 213 Child Restraint Systems U S only X X X 213 4 Built In Child Restraint System amp Built In Booster Cushions Canada only X X 214 Side Impact Protection X 2 7 X 2 7 219 Windshield Zone Intrusion X 2 X 2 225 Child Restraint Anchorage Systems U S only X 8 X 8 301 Fuel System Integrity X 2 X 2 302 Flammability of Interior Materials X X PART Vehicle Identification Number U S only X X 565 4 1106 Noise Emissions Canada only X X 1 This column identifies Standards that have equipment 6 Injury criteria is optional on Walk in Van Type Trucks Motor component requirements Homes vehicles manufactured for operation by persons with 2 Applicable to vehicles with a GVWR of 4536 kg 10 000 Ib or disabilities eto less 7 Dynamic Performance Requirements apply to MPV truck or a 3 A
13. are the only vehicle types appropriate for the incomplete vehicles listed However if a unit is completed as a vehicle type other than as listed above the Statements of Conformity may not be applicable F SERIES march 2005 7 COMPLETED VEHICLE TYPES STATEMENTS OF CONFORMITY The following Statements of Conformity apply to vehicles that are produced for sale or importation into the United States or Canada The term Incomplete Vehicle Types in these statements refers to the type of the vehicle illustrated on this manual s cover and listed in the chart on page 7 The number preceding each Statement of Conformity refers to the number designation for a Part or a Section of Part 571 of the Federal Motor Vehicle Safety Standard The statements provided for each safety standard number are appropriate compliance representations for each Canadian safety standard number if this incomplete vehicle identified by the VIN on the front of the document was manufactured by Ford Motor Company for sale or use in Canada except as may be noted at the conclusion of each safety standard number PART 102 The statements below are applicable to the Chassis 565 4 The statement below is applicable to all incomplete Cab vehicle types except the Basic Stripped Chassis This vehicle when completed will conform to Standard This vehicle when completed will conform to Part 565 4 102 Transmission Shift Lever Sequence Starter Vehicle Identification Nu
14. attaching components Ford Motor Company Walk In Van a step entry city delivery van type vehicle that permits a person to enter the vehicle without stooping This definition by Ford Motor Company is based on information appearing in 41 FR 54945 published December 16 1976 and in 42 FR 34288 published July 5 1977 Walk In Van Canada a van type of truck in which a person having a height of 1700 mm can enter the occupant compartment in an upright position by a front door fourgon acc s en position debout DEFINITIONS F SERIES march 2005 GENERAL INFORMATION Information in this section is provided pursuant to Title 49 Code of Federal Regulations Part 568 Vehicles Manufactured in Two or More Stages and Section 6 of the Canadian Motor Vehicle Safety Regulations CMVSR Vehicles Manufactured in Stages Part 568 specifies that Final Stage Manufacturers must complete vehicles in compliance with all applicable Federal Motor Vehicle Safety Standards and affix a label to each incomplete vehicle that is completed in accordance with 49CFR567 5 Section 6 6 of the CMVSR provides labeling requirements for vehicles that are to be sold in Canada Each Chassis Cab see definition on page 3 manufactured by Ford Motor Company has a label affixed to the driver door lock pillar that identifies the following The specific Federal Motor Vehicle Safety Standards to which the Chassis Cab conforms as of the date of
15. chassis drivetrain or front suspension from the B pillar forward F SERIES march 2005 17 205 206 207 208 The statement below is applicable to the Chassis Cab This vehicle when completed will conform to Standard 205 Glazing Materials if no alterations to or replacements of the installed glazing materials are made and if additional glazing materials installed by a subsequent stage manufacturer conforms to the requirements of Standard 205 The statements below are applicable to the Chassis Cab when completed as a Truck This vehicle when completed will conform to Standard 206 Door Locks and Door Retention Components if no alterations or adjustments are made to the door door pillar structure door locks door latches striker plates hinges and attaching hardware as installed by Ford Motor Company Any door added to this vehicle by a subsequent stage manufacturer must be equipped with door locks and door retention components that conform with this Standard The statements below are applicable to the Chassis Cab when equipped with trimmed front seats This vehicle when completed will conform to Standard 207 Seating Systems if no alterations are made to the seat assemblies their anchorages the floor pan or floor pan reinforcements Any seating system added to this vehicle must conform to applicable requirements of this Standard The statement below is applicable to the Chassis Cab when equipped
16. fan clutch STATEMENTS OF CONFORMITY 24 F SERIES march 2005 CANADIAN VEHICLES Vehicles to be completed for sale or use in Canada VEHICLE IDENTIFICATION Refer to the Vehicle Description section of this manual on page 6 for additional information Incomplete vehicles produced by Ford Motor Company require for certain applications optional Prep Packages or trim codes which are listed on the Completed Vehicle Types chart on page 7 DAYTIME RUNNING LAMP DRL Compliance representations for CMVSS 108 Lighting and CMVSS 108 1 Headlamps are on page 14 The following items are also required for CMVSS 108 and 108 1 compliance The DRL module circuits are not to be altered DRL module is not to be repositioned CANADIAN RADIO FREQUENCY INTERFERENCE RFI INFORMATION All vehicles powered by spark ignition engines e g gasoline 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 CSA C108 4 M92 Violation of these regulations is punishable by fine or imprisonment This Ford built incomplete vehicle was 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 H
17. flat glass mirror on the passenger side This vehicle when completed will conform to Standard 111 Rearview Mirrors if The mirrors and their mounts as supplied by Ford Motor Company are not removed relocated replaced or altered No structural modifications are made to the body which would affect the stability of the mirror mounts Any modifications or additions made to the incomplete vehicle must not adversely affect the driver s view to the rear in the outside mirrors along both sides of the vehicle The statement below is applicable to the Chassis Cab This vehicle when completed will conform to Standard 113 Hood Latch Systems if the hood latch system as provided by Ford Motor Company is not removed or altered The statements below are applicable to the Chassis Cab when completed as either a MPV or a Truck with a GVWR of 4536 kg 10 000 Ib or less This vehicle when completed will conform to Standard 114 Theft Protection if the following components to the extent provided by Ford Motor Company are not removed relocated altered or modified in any way Steering column locking mechanism system Ignition key transmission shift interlock locking system Ignition key locking system Key warning buzzer system If any of the above components are added to the vehicle they must conform to the requirements of this Standard F SERIES march 2005 15 115 116 118 118 119
18. has no control over how an incomplete vehicle is completed by subsequent stage manufacturers Ford Motor Company does not represent that the completed vehicle incorporating the Ford built components will comply with those requirements Any ignition system component i e spark plugs ignition wiring coil suppressor assembly etc that is replaced should be replaced by the same Ford Motor Company part number or equivalent to maintain RFI suppression While there are currently no RFI regulations in the United States specifically applicable to automotive ignition systems all Ford Motor Company trucks built with an ignition system use the same or equivalent components to those supplied on Canadian vehicles Ford Motor Company recommends that all ignition system service be performed at a Ford authorized service facility to help hold RFI emissions levels to a minimum Additional RFI information is contained on page 25 of this manual Devices that emit radio frequency RF energy such as AM FM radios mobile telecommunications systems two way radios telephones and radio controlled security systems are subject to the rules and regulations of the Federal Communications Communication FCC including 47 CFR Parts 2 and 15 Any such system installed in a vehicle should comply with those rules and should be installed only by a qualified technician In addition to ensure continued compliance with the FCC s regulations RF devices must not b
19. not substantially affected by the design of the incomplete vehicle accordingly Ford Motor Company makes no representation as to conformity with this Standard Any child restraint system that is added or incorporated into the design of a designated seating position must conform to the requirements of this standard The statements below are applicable to the Chassis Cab if the GVWR is 4536 kg 10 000 Ib or less This vehicle when completed will conform to Standard 214 Side Impact Protection if No alterations modifications or replacements are made to the door surrounding door structure door hinges door latches and strikers or any attaching hardware as provided by Ford Motor Company See combined statements under 212 219 for all vehicle types The statement below is applicable to the Chassis Cab This vehicle when completed will conform to Standard 225 Child Restraint Anchorage Systems if No alterations are made to the tether anchorages access to the anchorages is not restricted and no alterations are made to the seat assemblies their anchorages the floor pan or floor pan reinforcements STATEMENTS OF CONFORMITY 20 301 301 301 Note The terms body or body structure in the 301 statements that follow include not only the basic body or body structure but also any equipment permanently attached to that body or body structure installed by the subsequent stage manufacturer I
20. than the chassis cab body additional clearance lamps may be required that comply with this standard STATEMENTS OF CONFORMITY 14 F SERIES march 2005 110 111 111 113 114 U S Requirements The statement below is applicable to all incomplete vehicles with a GVWR of 4536 kg 10 000 Ibs or less with a completion date starting 09 01 2005 This incomplete vehicle does not comply to FMVSS 110 In order to comply the final stage manufacturer must permanently affix a tire placard as specified in paragraph 54 3 of FMVSS 110 typically to the driver s side B pillar See below for placard content and note color and format requirements in S4 3 TIRE AND LOAD INFORMATION D SEE OWNERS MANUAL FOR ADDITIONAL INFORMATION ES The combined weight of occupants and cargo should never exceed XXX kg or XXX Ibs SEATING CAPACITY TOTAL 5 FRONT 2 REAR 3 ORIGINAL TIRE SIZE COLD TIRE INFLATION PRESSURE FRONT P195 70R14 FRONT 200KPA 29PSI REAR P195 70R14 REAR 200KPA 29PSI COMPACT TIRE SIZE COLD TIRE INFLATION PRESSURE NS A The statement below is applicable to the Chassis Cab when not equipped with outside mirrors Conformity with Standard 111 Rearview Mirrors is not substantially affected by the design of this incomplete vehicle accordingly Ford Motor Company makes no representation as to conformity with this Standard The statements below are applicable to the Chassis Cab when equipped with a
21. the addition of readily attachable components such as mirrors or tire and rim assemblies or minor finishing operations such as painting 49CFR568 3 Critical Control Item is a component or procedure which may affect compliance with a federal regulation or which could directly affect the safe operation of the vehicle The identifying symbol is an inverted delta Y Ford Motor Company Cutaway Chassis an incomplete vehicle that has the back of the cab cut out for the intended installation of a structure that permits access from the driver s area to the back of the completed vehicle Ford Motor Company Cutaway Chassis Canada an incomplete vehicle that has the back of the cab cut out for the intended installation of a structure that permits access from the driver s area to the back of the vehicle ch ssis tronqu Designated Seating Position any plan view location capable of accommodating a person at least as large as a 5th percentile adult female if the overall seat configuration and design and vehicle design is such that the position is likely to be used as a seating position while the vehicle is in motion except for auxiliary seating accommodations such as temporary or folding jump seats Any bench or split bench seat in passenger car truck or multipurpose passenger vehicle with a GVWR less than 4 536 kilograms 10 000 pounds or having greater than 50 inches of hip room measured in accordance with SAE Stand
22. 120 Canadian Requirements The statements for Part 565 4 are appropriate compliance representations for CMVSS 115 Vehicle Identification Number if this incomplete vehicle was manufactured for sale or use in Canada The statement below is applicable to the Chassis Cab This vehicle when completed will conform to Standard 116 Motor Vehicle Brake Fluids so long as any brake fluid added or replaced conforms to the DOT 3 specifications of the standard and contaminants are not introduced into the hydraulic brake system The statement below is applicable to the Chassis Cab not equipped with power operated windows partition or roof panel systems and their actuation devices when completed as either a MPV or a Truck with a GVWR of 4536 kg 10 000 Ib or less Conformity with Standard 118 Power Operated Window Partition and Roof Panel Systems is not substantially affected by the design of this incomplete vehicle accordingly Ford Motor Company makes no representation as to conformity with this Standard If any power operated window partition or roof panel systems are installed by subsequent stage manufacturers they must conform to the requirements of Standard 118 The statement below is applicable to the Chassis Cab equipped with power operated windows partition or roof panel systems and their actuation devices when completed as either a MPV or a Truck with a GVWR of 4536 kg 10 000 Ib or less This vehicle when comp
23. AMIC POSITIONS PROTECTIVE SLEEVES ARE REQUIRED ON BOTH FILL AND VENT HOSE AT FRAME OPENING FRONT OF VEHICLE e p CAP 1 4 TURN GASOLINE LEV II SCREW DIESEL SCREW 3 REQ D TORQUE CA 1 7 2 8 NEWTON METERS 15 25 IN LB VIEW THIS HOSE IS PREFORMED INSTALL SHORT END TO THE METAL NECK AND CAP ASSEMBLY U TRIM THE LONG END AS REQUIRED HOLE IN 48 3 TOP OF FRAME RAIL MANUFACTURERS BODY a8 SUB 3 16 INCH 1 89 1 89 BLINDRIVET r Seni qe Cr EE 2p SUPPORT USE PROVIDED TIE STRAPS METAL ON THE 87 78 Y NN 105 7 FRAME TO SECURE FILL TO VENT 3 42 13 07 48 C 4 16 616 STEEL TUBE HOSES 2 PLACES yas poke 2 42 DO NOT TRIM ce dea lr Yee ty 1 89 1 Md 67 5 or 78 1 39 PEN le 2 68 AFT OF AXLE FILL SYSTEM BRACKET 3 07 LAOS POINT Z 9 HOLES 12 PLACES gt 48 ac REFER TO CALIFORNIA 1 89 FUEL VAPOR RECOVERY gt 48 lt REQUIREMENT 1 89 OUTBOARD SURFACE I 81 9 81 Aa OF FRAME RAIL OF FILL PIPE ASY 3 19 8 19 SECTION U AND BRACKET U VIEW P p SCREW 3 REQ D 4 CIMEMBER TOBACK lt lt TORQUE OF CAB 1 7 2 8 NEWTON METERS 15 25 IN LB INSTALL GROUND WIRE TO SOUND METAL ON THE FRAME FRONT OF VEHICLE ut D CAP MEWP 1 4 TURN GASOLINE LEV II SCREW IN DIESEL L DO NOT TRIM THIS END
24. CLE TYPE SEE CHART M ON PAGE 7 1FDLFA7P36EA475 41 i DII M6284 Br Nay EXTERIOR PAINT RC WB BRK at a TPPS R AXLE TR SPR 161 1 72 W H48 MADE IN 8 A UCI V F658 1520472 AA TYPICAL F SERIES CANADA 410047 VSO BAR CODE V I N CALIFORNIA VSO VEHICLE VSO VEHICLE INCOMPLETE VEHICLE INFORMATION LABEL VEHICLE DESCRIPTION 6 F SERIES marcn 2005 COMPLETED VEHICLE TYPES COMPLETED 5TH 6TH 7TH VEHICLES VIN DIGIT INCOMPLETE VEHICLES TRUCK MPV SUPER DUTY F SERIES F20 F30 F34 F 250 350 Regular Cab 4X2 SRW X X F21 F31 F35 F 250 350 Regular Cab 4X4 SRW X X F32 F36 F46 F56 F 350 450 550 Regular Cab 4X2 DRW X X F33 F37 F47 F57 F 350 450 550 Regular Cab 4X4 DRW X X X20 X30 X34 F 250 350 Super Cab 4X2 SRW X X X21 X31 X35 F 250 350 Super Cab 4X4 SRW X X X32 X36 X46 X56 F 350 450 550 Super Cab 4X2 DRW X X X33 X37 X47 X57 F 350 450 550 Super Cab 4X4 DRW X X W20 W30 W34 F 250 350 Crew Cab 4X2 SRW X X W21 W31 W35 F 250 350 Crew Cab 4X4 SRW X X W32 W36 W46 W56 F 350 450 550 Crew Cab 4X2 DRW X X W33 W37 W47 W57 F 350 450 550 Crew Cab 4X4 DRW X X Single Rear Wheels IMPORTANT Ford Motor Company makes no representation that the ROM SEN MSAN yee completed vehicle types listed above
25. DO NOT DESTROY THIS MANUAL IS REQUIRED BY LAW KEEP UNTIL THE VEHICLE IS COMPLETED BY THE FINAL STAGE MANUFACTURER 2006 SUPER DUTY F SERIES INCOMPLETE VEHICLE MANUAL Incomplete Vehicle Types For This Manual Super Duty F Series Chassis Cab March 2005 V6C34 19A268 BA U S amp CANADIAN MOTOR VEHICLE SAFETY STANDARDS Application By Vehicle Type Standard Vehicle Type Equipment Number Title of Standard Truck MPV 1 101 Control Location Identification and Illumination X X 102 Transmission Shift Lever Sequence Starter Interlock amp Transmission Braking Effect X X 1038 Windshield Defrosting amp Defogging Systems X X 104 Windshield Wiping and Washing Systems X X 105 Hydraulic and Electric Brake Systems X X 106 Brake Hoses X X X 108 Lamps Reflective Devices amp Associated Equipment X X X 108 1 Headlamps Canada only X X X 110 Tire Selection and Rims U S only X X X 111 Rearview Mirrors X X 113 Hood Latch Systems X X 114 Theft Protection X 2 X 2 115 Vehicle Identification Number Canada only X X 116 Hydraulic Brake Fluids X X X 118 Power Operated Window Partition and Roof Panel Systems X 2 X 2 119 9 New Pneumatic Tires for Vehicles Other Than Passenger Cars X 120 Tire Selection and Rims for Motor Vehicles Other Than Passenger Cars X X X 124 Accelerator Control Systems X
26. E TO DO SO MAY RESULT IN AN INCOMPLETE VEHICLE THAT IS BUILT WITH AN EMISSIONS SYSTEM AND LABELING THAT ARE NOT IN COMPLIANCE WITH THE REQUIREMENTS OF THE CANADIAN ENVIRONMENTAL PROTECTION ACT FRONTAL AREA AND WEIGHT RESTRICTIONS Starting in 2005 some heavy duty incomplete vehicles are certified using chassis certification protocol and will require vehicle weight and frontal area restrictions to retain emission certification If your vehicle is affected the frontal area and unloaded vehicle weight information will be found on the VECI label which is located in the engine compartment Incomplete vehicles with engines certified using heavy duty engine protocol are not limited by weight and frontal area restrictions for exhaust emissions Itis important that the final stage manufacturer observe vehicle restrictions from vehicle safety requirements etc which are located elsewhere in this manual Additional emissions certification information is contained in the Ford Truck Body Builders Layout Book for the model year and type of this incomplete vehicle IMPORTANT For purposes of Government Regulation a body builder installer or any subsequent manufacturer may be considered a manufacturer EMISSION CERTIFICATION INFORMATION 26 HIGH ALTITUDE REQUIREMENTS United States Environmental Protection Agency regulations for the 2006 model year do not contain unique emission certification requirements for trucks t
27. MVSS 203 are appropriate compliance representations for CMVSS 203 Driver Impact Protection if this incomplete vehicle was manufactured for sale or use in Canada In such a case the Basic Stripped Chassis will comply if no components or attachments are added to the steering control system that can catch the driver s clothing or jewelry during normal driving maneuvers INFORMATION Refer to the Design Recommendation section of the Ford Truck Body Builders Layout Book for Second Unit Body Attachment information that may aid in designing second unit bodies and their attachments to be compatible with F Series vehicles The statements below are applicable to the Chassis Cab if the GVWR is 4536 kg 10 000 Ib or less and the Unloaded Vehicle Weight when completed is 2495 kg 5 500 Ib or less This vehicle when completed will conform to Standard 204 Steering Control Rearward Displacement if The Unloaded Vehicle Weight does not exceed the appropriate weight on Table F page 11 for F Series Chassis Cab type vehicles No components are added which could influence the rearward displacement of the steering column The steering column steering intermediate and coupling shaft steering wheel steering gear steering linkage related structural components and attaching hardware as installed by Ford Motor Company are not removed relocated altered or modified in any way No alteration or modifications are made to the body
28. NFORMATION The Unloaded Vehicle Weight of the completed vehicle may significantly affect its capability to meet the requirements of Standard 301 Completed vehicles manufactured by Ford Motor Company that are tested to demonstrate compliance with Standard 301 are loaded pursuant to s7 1 6 of the Standard The test weights of these vehicles comprise the Unloaded Vehicle Weights including the weights of all available regular production options plus the loads specified by s7 1 6 These test weights are less than the respective designated Gross Vehicle Weight Ratings In addition to the specific statements below refer to the Design Recommendation section of the Ford Truck Body Builders Layout Book for Fuel System information to assist in designing fuel systems and the Second Unit Body Attachment recommendations for information to aid in designing second unit bodies and their attachments to be compatible with Super Duty F Series vehicles In addition to the statements pertaining to particular incomplete vehicle types which follow on pages 20 24 the statements immediately below concerning Standard 301 Fuel System Integrity apply to all incomplete vehicle types to be completed with a GVWR of 4536 kg 10 000 Ib or less f a fuel line is to be disconnected refer to the appropriate Ford Service Manual for proper removal and installation procedures When welding near fuel system components all metallic components must be adequately shiel
29. OR BATTERY r AIRBAG DEACTIVATION SWITCH PASSENGER AIRBAG MODULE I DRIVER AIRBAG MODULE ELECTRONIC CRASH SENSOR MODULE DO NOT INSTALL ADDITIONAL COMPONENTS IN THE SHADED AREAS OR ALTER OR MODIFY THESE AREAS DO NOT MODIFY OR ALTER ANY COMPONENTS OR AREAS OF THE VEHICLE IN THE VICINITY OF THE COMPONENTS THAT ARE IDENTIFIED IN THIS ILLUSTRATION SUPER DUTY F SERIES OCCUPANT PROTECTION ZONE STATEMENTS OF CONFORMITY 18 F SERIES march 2005 209 209 210 The statements below are applicable to the Chassis Cab with front seat s This vehicle when completed will conform to Standard 209 Seat Belt Assemblies if No alterations or replacements are made to the seat belt assemblies and attaching hardware No action is taken that would impair the integrity of the seat belt system provided Any seat belt assemblies added to a vehicle must conform to the requirements of this Standard Canadian Requirements The preceding statements for FMVSS 209 are appropriate compliance representations for CMVSS 209 Seat Belt Assemblies if this incomplete vehicle was manufactured for sale or use in Canada In such a case CMVSS 209 paragraphs 2 and 93 4 and 5 14 15 and 7 are substituted for the re
30. RNIA FUEL VAPOR RECOVERY SCREWS 3 REQ D TORQUE 1 7 2 8 1 89 lt REQUIREMENT NEWTON METERS 81 0 9810 gt 15754 NE LB SECTION U VIEW P TO BACK vip 90 FITTING CONNECT TO OF CAB FRONT OF QUICK CONNECTION ON VAPOR LINE we VEHICLE OF FILL PIPE ASY p OUTBOARD SURFACE AND BRACKET n OF FRAME RAIL SR 34 CROSSMEMBER PROTECTIVE SLEEVES ARE A e FILL HOSE STEEL ELBOW DO NOT TRIM RECIRCULATION TORQUE 1 7 2 8 On z HOSE CLAMP e NEWTON METERS 7 15 25 IN LB S 5 m E 2 PU S _TOP OF FRAME RAIL X lk a AT FILL PIPE THIS HOSE IS PREFORMED INSTALL SHORTEND INSTALL GROUND WIRE TO TO THE METAL NECK AND CAP ASSEMBLY RECIRCULATION SOUND METAL ON THE FRAME STEEL TUBE NOTES CA BACK OF CAB TO CENTERLINE OF REAR AXLE TORQUE ALL WORM GEAR DRIVEN HOSE CLAMPS 56 INCH CA TO 2 8 3 9 NEWTON METERS 25 35 IN LB WHEELBASE DIMENSIONS ARE INCHES Regular Cab 3480mm 137 0 Super Cab 4013mm 158 0 NOT SUPPLIED BY FORD MOTOR COMPANY Crew Cab 4380mm 172 4 VA MIN 620mm 24 4 V CRITICAL CONTROL ITEM MAX 923mm 36 7 i i Remove and discard the Ford installed fuel fill system components Vc MIN 540mm 21 25 provided for shipping purposes only except save and reuse the MAX 743mm 29 25 metal neck and cap assembly Use the new hoses pipes scuff guards tie wraps and clamps WD an eo p
31. affect lighting performance This vehicle when completed will conform to Standard 103 Windshield Defrosting and Defogging Systems if Components added to the vehicle do not obstruct the no alterations or adjustments are made to heater and driver s ability to operate or visually locate the controls blower assemblies ducting operating controls electrical displays and their identifications circuit from the blower assembly to the power source The driver seat is not replaced relocated or modified windshield coolant hoses from the radiator or engine to other than for the addition of seat trim the heater and if no obstructions are added that restrict Any controls displays and illumination added to or otherwise redirect the air flow from the defroster this vehicle must conform to the requirements of this outlets to the windshield Standard 104 The statement below Is applicable to the Chassis Cab This vehicle when completed will conform to Standard 104 Windshield Wiping and Washing Systems if no alterations are made to the windshield the windshield wiping and washing system including the electrical circuit from the windshield wiping and washing motors to the power source and if no obstructions are added that restrict or otherwise redirect fluid flow from the washer nozzles to the windshield STATEMENTS OF CONFORMITY 8 F SERIES march 2005 105 105 INFORMATION Incomplete vehicle weight and dimensional inform
32. apacity of 10 or less that is constructed either on a truck chassis or with special features for occasional off road operation but does not include an air cushion vehicle an all terrain vehicle a golf cart a low speed vehicle a passenger car a three wheeled vehicle a truck or a vehicle imported temporarily for special purposes v hicule de tourisme usages multiples Pickup Box Delete a Chassis Cab incomplete vehicle created by ordering a Pickup Box Delete option on an otherwise completed vehicle Ford Motor Company School Bus a bus that is sold or introduced in interstate commerce for purposes that include carrying students to and from school or related events but does not include a bus designed and sold for operation as a common carrier in urban transportation 49CFR571 3 School Bus Canada a bus designed or equipped primarily to carry students to and from school autobus scolaire Seating Reference Point the unique design H point as defined in SAE J1100 June 1984 which a Establishes the rearmost normal design driving or riding position of each designated seating position in a vehicle b Has X Y and Z coordinates established relative to the designed vehicle structure c Simulates the position of the pivot center of the human torso and thigh and d Is the reference point employed to position the two dimensional drafting template described in SAE J826 May 1987 abbreviated by Ford Mot
33. ard J1100 a shall have not less than three designated seating positions unless the seat design or vehicle design is such that the center position cannot be used for seating 49CFR571 3 abbreviated by Ford Motor Company Designated Seating Position Canada any plan view position capable of accommodating a person at least as large as a 5th percentile adult female as defined in section 100 of Schedule IV where the overall seat configuration and design and the vehicle design are such that the position is likely to be used as a seating position while the vehicle is in motion but does not include any plan view position of temporary or folding jump seats or other auxiliary seating accommodation place assise d sign e Final Stage Manufacturer a person who company that CMVSR performs such manufacturing operations on an incomplete vehicle that it becomes a completed vehicle 49CFR568 3 Gross Axle Weight Rating GAWR the value specified by the vehicle manufacturer as the load carrying capacity of a single axle system as measured at the tire ground interfaces 49CFR571 3 Gross Combination Weight Rating GCWR the value specified by the manufacturer as the loaded weight of a combination vehicle 49CFR571 3 Gross Vehicle Weight Rating GVWR the value specified by the manufacturer as the loaded weight of a single vehicle 49CFR571 3 H Point the mechanically hinged hip point of a manikin which simulates t
34. ate of manufacture printed on the cover of this manual Requirements unique to vehicles for use in Canada are identified in the Statements of Conformity and the Canadian Vehicles page 25 The Emission Certification Information section of this manual contains information regarding conformity to exhaust emission regulations of the United States Canada and the State of California and fuel economy regulations of the United States This manual should not be relied upon with respect to compliance with any regulation of the Federal Highway Administration or regulations issued pursuant to the Occupational Safety and Health Act OSHA or any other federal state or local regulations governing the performance or construction of motor vehicles except for those requirements shown under the heading Unleaded Gasoline Label page 26 Warranty and Maintenance page 27 and Emission Control Information Label page 27 It is the responsibility of the final stage manufacturer to determine applicability and comply with any federal state or local requirements not detailed in this manual IMPORTANT UNITED STATES VEHICLES Ford Motor Company has endeavored whenever possible to state the specific conditions under which an incomplete vehicle may be completed to conform to each applicable Federal Motor Vehicle Safety Standard These specific statements are intended to aid subsequent stage manufacturers in avoiding instances of inadvertent no
35. ation required for center of gravity calculations are available in the Ford Source Book See your local Ford Dealer and refer to appropriate model year and specific vehicle for required information Abbreviation definitions and a vehicle diagram to assist with the equations for the Standard 105 segment are shown on page 10 The statements below are applicable to the Chassis Cab This vehicle when completed will conform to Standard 105 Hydraulic and Electric Brake Systems if No alterations modifications or replacements are made to the following Service or parking brake system Antilock brake system Vacuum system Wheels and tires Brake system indicator lamp and wiring Brake system reservoir labeling Suspension ride height or spring rate Hydro boost system Power steering pump and lines if used with Hydro boost Engine belt drive system Noadditional sound deadener or rust proofing material that may be applied to the vehicle can interfere with proper parking brake cable function No part of add on equipment i e toolboxes flat bed attaching brackets etc can interfere with the movement of parking brake cables or air flow to rear brake assembly Any removal of a Ford body or chassis component is accompanied by the addition of equal weight Chassis Cab vehicles with a GVWR of 4536 kg 10 000 Ib or less do not exceed the Maximum Unloaded Vehicle Weight value
36. ded and protected from heat or weld splatter All non metallic components must be removed NOTE Some incomplete vehicles are equipped with nylon fuel tubes In the event that the tubes require repair or replacement only Ford Motor Company approved parts or their equivalents should be used F SERIES march 2005 301 The statements below are applicable to the Chassis Cab if the vehicle GVWR is 4536 kg 10 000 Ib or less This vehicle when completed will conform to Standard 301 Fuel System Integrity if The following fuel system components as installed by Ford Motor Company are not removed relocated altered or modified in any way except as specified in the representations following this paragraph Fuel tank s and attachment hardware including sending unit vapor valve fuel tank shield pressure transducer and in tank electric fuel pump Fuel filler cap s pipe s hose s and attachment hardware Fuel lines routing and attachments Vapor line s and carbon canister gasoline engine application Fuel pump Fuel filter Fuel water separator fuel filter primer fuel line heater and injection pump diesel engine only Fuel shut off switch inertia switch 137 wheelbase Regular Cab Pickup Box Delete units are modified as follows Bend the lower inboard corner of the left rear outer pillar 90 degrees towards the front of the vehicle along an axi
37. e All other U S orders should be faxed to 734 713 2971 Canadian orders should be faxed to 905 670 0844 FORD SERVICE PUBLICATIONS Many Ford Service Publications pertain to a specific Model Year and vehicle types The following publications are a few of many manuals which are available from Helm Incorporated call 1 800 782 4356 Ford Truck Shop Manuals Ford Towing Manual Ford Electrical amp Vacuum Trouble Shooting Manual Ford Wiring Diagram FORD TRUCK BODY BUILDER ADVISORY SERVICE The Ford Truck Body Builder Advisory Service may be consulted regarding informa tion contained in this manual Call 1 877 840 4338 or e mail bbasqa Q ford com for assistance or Fax inquiries to 313 594 2633 accompanied with a cover sheet indicat ing Attention to Ford Truck Body Builder Advisory Service along with your name address and telephone number F SERIES marcn 2005 REFERENCE INFORMATION FORD MOTOR COMPANY THE AMERICAN ROAD DEARBORN MI 48121 FORD MOTOR COMPANY OF CANADA LIMITED THE CANADIAN ROAD OAKVILLE ONTARIO L6J 5E4
38. e modified or changed ina manner not expressly approved by Ford Motor Company Mobile Communication Systems RF devices particularly if not properly installed may adversely affect the operation of the vehicle For example such systems when operated may cause the engine to stumble or stall In addition such systems themselves may be damaged or their operation affected by the operation of the vehicle Citizens Band CB transceivers garage door openers and other transmitters whose power output is 5 watts or less ordinarily will NOT affect vehicle operation Because Ford Motor Company has no control over the operation or manufacture of such systems or their installation Ford Motor Company cannot assume responsibility for any adverse effects or damage if this equipment is used EMISSION CERTIFICATION INFORMATION 28 F SERIES march 2005 REFERENCE INFORMATION FORD TRUCK BODY BUILDERS LAYOUT BOOK Throughout this manual you will find references to information found in the Ford Truck Body Builders Layout Book Additional Design Recommendations and specifications are also provided to assist subsequent stage manufacturers in completing chassis cab and incomplete vehicles To obtain a free copy of this publication on CD ROM or to receive an order form for additional CD ROM s or books please visit our website at www fleet ford com truckbbas Under Publications select Body Builders Order Forms All dealer requests can be handled onlin
39. e vehicle to the center of gravity inches of the completed pounds vehicle Wi LS zs ii CG Vertical distance from the ground to the center of l Remaining cargo capacity pednest gravity of the SUB and or permanently attached Where W GVWR W W P added equipment inches W Weight of the remaining cargo capacity on the Vertical distance from the ground to the center rear wheels pounds of gravity of the chassis inches including cab CG W if original equipment Taken from Table C page W Mis 9 WB Horizontal distance from the of the front wheels CG Horizontal distance from the of the front wheels to the P passenger load See Table B page to the cargo center of gravity inches Taken 9 from Table A page 9 for many common vehicles If the CG is not given in the table then it may CG Vertical distance from the ground to the center 7 hl P of gravity of the front and rear seat P passenger pe 5 LM E ds weight Taken from Passenger CG Table E TOTAM NME eee ee ON cargo page 9 area Wp Weight of the SUB and or permanently attached SUB F enis s Ed consists of ihe o added equipment pounds structure and or all the cargo carrying wor performing and or load bearing components Wib Weight at the rear wheels of the SUB and or and or equipment installed by a subsequent permanently attached added equipment stage manufacturer on an incomplete vehicle
40. eadily visible location to meet the preceding requirements In addition whether the label is already affixed or to be affixed no components shall be installed which visibly obscure the label in any way that fails to satisfy the visibility requirements described in the California Emission Control Label Specifications For Canadian requirements consult Section 1100 8 1 d i ii amp iii as applicable CALIFORNIA FUEL VAPOR RECOVERY California regulations require that the vehicle fuel systems be designed to accommodate a vapor recovery fueling nozzle including unobstructed access to the fill pipe Fuel filler pipes installed per the figures on pages 22 and 23 will comply with the Specifications For Fill Pipes and Openings of Motor Vehicle Fuel Tanks referenced in Title 18 California Administrative Code provided no part of the aftermarket body as installed intrudes within a 254mm 10 in radius cylinder which has its axis parallel to the ground at point Z Figure A on page 22 illustrates a typical point Z The cylindrical zone uses the axis described above starts at the outer most surface of the Ford supplied fuel filler housing and projects outward away from the frame The fuel pipe housing component is shown on the referenced figures and is attached to the aftermarket body via 3 16 inch diameter rivets EMISSION CERTIFICATION INFORMATION CALIFORNIA MOTOR VEHICLE EMISSION CONTROL LABEL To meet California emission ce
41. ehicle Manufacturer a person company that CMVSR who manufactures an incomplete vehicle by assembling components none of which taken separately constitute an incomplete vehicle 49CFR568 3 Intermediate Manufacturer a person company CMVSR other than the incomplete vehicle manufacturer or the final stage manufacturer who that CMVSR performs manufacturing operations on an incomplete vehicle 49CFR568 3 Motor Home a multi purpose vehicle with motive power that is designed to provide temporary residential accommodations as evidenced by the presence of at least four of the following facilities Cooking refrigeration or ice box self contained toilet heating and or air conditioning system that can function independently of the vehicle engine CMVSR a potable water supply system including a faucet and a sink and a separate 110 125 volt electrical power supply and or an LP gas supply 49CFR571 3 Multifunction School Activity Bus MFSAB a school bus whose purposes do not include transporting students to and from home or school bus stops 49CFR571 3 Multipurpose Passenger Vehicle MPV a motor vehicle with motive power except a low speed vehicle or trailer designed to carry 10 persons or less which is constructed either on a truck chassis or with special features for occasional off road operation 49CFR571 3 Multipurpose Passenger Vehicle MPV Canada a vehicle having a designated seating c
42. el is affixed to the cover which includes the Vehicle Identification Number VIN for the specific vehicle to which this manual belongs The label identifies the following information which pertains only to the vehicle with the corresponding VIN The GVWR The front and rear GAWRs Tire and wheel size e Cold tire inflation pressure kPa PSI Completed vehicle type s into which the incomplete vehicle may be manufactured Optional prep package when the vehicle is so equipped INCOMPLETE VEHICLE INFORMATION LABEL All F Series Super Duty incomplete vehicles manufactured by Ford Motor Company will have an Incomplete Vehicle Information label affixed to the driver door lock pillar The sample labels shown below are typical of that provided The 5th 6th and 7th digits of the Vehicle Identification Number VIN will identify the incomplete vehicle type These three digits are used in the Completed Vehicle Types chart on page 7 California Air Resources Board CARB requires a Vehicle Identification Number VIN Label having a non contact bar code reading wand capability The bar code directly below the VIN on the Incomplete Vehicle Information label when provided will comply with this regulation See page 28 for location and other requirements The Canadian Motor Vehicle Safety Act and Regulations require installation of an Incomplete Vehicle Information label with the National Safety mark on it on vehicles manufact
43. enetrated disconnected or otherwise damaged The rear end of the body excluding the rear bumper installed by a subsequent stage manufacturer does 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 completed vehicle is tested in any manner specified by applicable provisions of Standard 301 The front end of the body installed by the subsequent stage manufacturer is located at least 76 2mm 3 0 in rearward of the rearmost point of the cab The fuel filler cap s pipe s hose s and attachment hardware are installed as shown in Figures A and B on pages 22 and 23 for Super Duty F Series vehicles All components must be securely retained to remain intact when the completed vehicle is tested in any manner specified by applicable provisions of Standard 301 301 Continued on Page 24 Temporary removal of the front bumper and front bumper mounting system during manufacture and reinstallation in accordance with the instructions provided in the Ford Truck Shop Manual should not adversely affect compliance of the completed vehicle to Standard 301 STATEMENTS OF CONFORMITY MAINTAIN 25 4 1 00 MINIMUM CLEARANCE Sd _ OUTBOARD SURFACE BETWEEN FUEL FILLER SYSTEM AND THE C pi OF FRAME RAIL SPRING AND SPRING SHACKLE IN ALL Bee DYN
44. f the location of your cargo is not in the normal cargo area then your CG may be estimated as the distance from the of the front wheel to the horizontal midpoint of the cargo area TABLE B Horizontal distance from front wheel to front passenger load Dimensions are inches All Super Duty F Series 61 2 TABLE C CG Vertical distance from ground to chassis CG Dimensions are inches F 250 350 4X2 SRW gt 8500 Ib GVWR 30 4 F 250 350 4X4 SRW gt 8500 Ib GVWR 31 4 F 350 4X2 DRW 30 4 F 350 4X4 DRW 31 4 F 450 550 4X2 amp 4X4 DRW 35 0 TABLE D SUPER DUTY F SERIES PASSENGER LOAD CG GVWR Ib P Ib 7717 10 000 400 61 2 in 10 001 19 000 500 TABLE E SUPER DUTY F SERIES PASSENGER CG ALL SEATS 4X2 4X4 CG 40 3 in 43 8 in F SERIES march 2005 STATEMENTS OF CONFORMITY FMVSS 105 DEFINITIONS AND CALCULATION ILLUSTRATION FOR INCOMPLETE SUPER DUTY F SERIES P Passenger load See Passenger Load Table D W Weight of the vehicle chassis and cab fuel page 9 tanks full pounds Including option weight CG Vertical distance from the ground to the center WB Vehicle wheelbase inches of gravity nenge of the vehicle W Total unladen weight W W P CG Horizontal distance from of the front wheels GVWR Gross Vehicle Weight Rating of th
45. ference to FMVSS 209 Sections 4 1 b 9c e g and h respectively The statements below are applicable to the Chassis Cab This vehicle when completed will conform to Standard 210 Seat Belt Assembly Anchorages if No alterations are made to the front seat belt anchorages front seat belt assemblies floor pan floor pan reinforcements or body mounts No alternations are made to the rear cab panel or roof for the Chassis Cab Chassis Cab vehicles may have additional seat belt anchorages for designated seating positions on optional seats not provided on incomplete vehicles These locations apply to specific hardware and designated seating positions used in Ford completed vehicles If these anchorages are used without the appropriate Ford seats seat belt systems and hardware Ford Motor Company makes no representation as to conformity with this Standard 210 1 Canadian Requirements The statement below is applicable to the Chassis Cab with a GVWR of 3856 kg 8 500 Ib or less and an unloaded vehicle weight of 2495 kg 5 500 Ib or less This vehicle when completed will conform to Standard 210 1 User Ready Tether Anchorages for Restraint Systems if No alternations are made to the front passenger seat tether anchorages and access to the anchorages is not restricted and no alterations are made to the seat assemblies their anchorages the floor pan or floor pan reinforcements 210 2 Canadian Requiremen
46. hat will be sold or delivered to customers for principal use above 1 219 m 4 000 ft EMISSION CONTROL HARDWARE Any body builder installer or subsequent stage manufacturer must also assure that all emission control hardware furnished with incomplete vehicles is on the vehicle and is operational and that applicable instructions for incorporating such hardware into the completed vehicle s electrical or mechanical systems are strictly followed Further to avoid any question of certification coverage approval of any modification or use of an engine or vehicle which may render inoperative any of the emission control components must be obtained from the United States Environmental Protection Agency by the manufacturer making such modification or use prior to distribution sale offering for sale introduction or delivery for introduction of the subject vehicle into U S commerce Additionally the manufacturer making such modification or use must obtain approval from the California Air Resources Board if the new vehicle will be delivered for sale or use in the State of California UNLEADED GASOLINE LABEL Regulations no longer require the manufacturer to affix permanent labels reading Unleaded Gasoline Only or Unleaded Fuel Only to vehicles destined for sale in the United States or Canada Such labels may however be required for vehicles sold into other markets It is the responsibility of the body builder installer or any sub
47. he actual pivot center of the human torso and thigh described in SAE Recommended Practice J826 Manikins For Use in Defining Vehicle Seating Accommodations November 1962 49CFR571 3 H point Canada the mechanically hinged hip point of a manikin that simulates the actual pivot centre of the human torso and thigh described in SAE Standard J826 APR80 Devices for Use in Defining and Measuring Vehicle Seating Accommodation point H Incomplete Vehicle an assemblage consisting as a minimum of frame and chassis structure power train steering system suspension system and braking system to the extent that those systems are to be part of the completed vehicle that requires further manufacturing operations other than the addition of readily attachable components such as mirrors or tire and rim assemblies or minor finishing operations such as painting to become a completed vehicle 49CFR568 3 F SERIES march 2005 DEFINITIONS Incomplete Vehicle Canada a vehicle a other than a vehicle imported temporarily for special purposes that is capable of being driven and that consists at a minimum of a chassis structure power train steering system suspension system and braking system in the state in which those systems are to be part of the completed vehicle but requires further manufacturing operations to become a completed vehicle or b that is an incomplete trailer v hicule incomplet Incomplete V
48. ignition components Only static conductive accessory drive belts should be used Fan water pump power steering and other belts should be of the OEM type or equivalent that will not build up a static electrical charge Engine compartment wiring must not be rerouted in any manner The Powertrain Control Module PCM must not be relocated from the position as installed by Ford Motor Company CANADIAN VEHICLES EMISSION CERTIFICATION INFORMATION CAUTION U S 2006 MODEL YEAR VEHICLES ARE EMISSION CERTIFIED FOR REGISTRATION IN SPECIFIC AREAS OF THE UNITED STATES FOR EXAMPLE VEHICLES CERTIFIED AND LABELED FOR SALE IN CALIFORNIA CAN NOT BE SOLD IN THE STATES THAT REQUIRE FEDERALLY CERTIFIED VEHICLES AND VEHICLES CERTIFIED TO FEDERAL STANDARDS CAN NOT BE SOLD IN STATES THAT REQUIRE CALIFORNIA CERTIFIED VEHICLES IT IS THE SUBSEQUENT STAGE MANUFACTURER S RESPONSIBILITY TO PURCHASE A VEHICLE CERTIFIED FOR THE STATE AREA IN WHICH THE VEHICLE WILL BE SOLD EPA HAS STATED THAT UNDER CERTAIN CIRCUMSTANCES THEY WILL NOT ENFORCE THESE REQUIREMENTS FOR FURTHER GUIDANCE CONSULT EPA S POLICY ON CROSS BORDER SALES OF CALIFORNIA VEHICLES CANADA IF THE COMPLETED VEHICLE IS INTENDED FOR SALE OR USE IN CANADA THE INTERMEDIATE OR FINAL STAGE MANUFACTURER MUST INSURE THAT THE INCOMPLETE VEHICLE IS ORDERED THROUGH A CANADIAN DEALER OR IS ORDERED FROM FORD MOTOR COMPANY WITH THE APPROPRIATE CANADIAN MARKET OPTION CODE FAILUR
49. in Table F page 11 The applicable GAWRs and GVWR weights are not exceeded The completed vehicle must have a vertical center of gravity Equation A of 48 00 inches or less when measured from the ground The front axle curb weight of the completed vehicle incomplete vehicle weight min SUB weight Table G page 12 may be reduced by no more than 1096 for SRW or 2596 for DRW vehicles using the front axle ground reaction as manufactured by Ford Motor Company The rear axle curb weight of the completed vehicle incomplete vehicle weight min SUB weight Table G page 12 must be the same or greater than the rear axle ground reaction as manufactured by Ford Motor Company REFERENCE Equation B can be used to determine the completed vehicle s horizontal center of gravity CGh Abbreviation definitions and a vehicle diagram are provided to assist with the equation on page 10 EQUATION A COW CF ve w w CG xP B GVWR EQUATION B Px CG Wi Wyo e w x WB CG 2 GVWR TABLE A CG Horizontal distance from front axle to cargo CG Model WB in CG in t Super Duty F Series Regular Cab 137 0 132 Regular Cab 140 8 134 Regular Cab 164 8 146 Regular Cab 188 8 158 Regular Cab 200 8 164 SuperCab 158 0 153 SuperCab 161 8 155 Crew Cab 172 4 165 Crew Cab 176 2 167 Crew Cab 200 2 182 t If CGhl is not given in the table or i
50. ity of a completed vehicle to the seat back requirements of this standard is dependent upon the location of a seat installed by a subsequent stage manufacturer to the rear of another seat Ford Motor Company makes no representation as to compliance of a completed vehicle to the seat back requirements if such a seat is installed If a vehicle is equipped with a Passenger side Air Bag Delete option a right hand passenger seat should never be installed If such a seat is installed Ford Motor Company makes no representation as to the compliance of the completed vehicle to Standard 201 201U U S Requirements Section S6 This vehicle when completed will conform to Standard 201U Occupant Protection in Interior Impact Upper Interior Head Impact Protection if the following com ponents as provided by Ford Motor Company are not removed relocated altered modified or additions added to the A B Rear or other Pillar and Trim and Assist Handles Seat Belt D Rings Adjusters and D Ring Covers and Sling Systems Front or Rear Header and Trim Side Rails Trim Coat Hooks and Ride Handles Upper Roof and Trim Exterior Windshield Trim Exterior Roof Drain Ditches Primary and Secondary Door Body Seals at all door opening locations in the vehicle Sunvisors and attachment hardware Changes to the design Seating Reference Point SRP with modifications to the Seat System If any of the above components a
51. lect the appropriate statement Unique CMVSS requirements will be identified at the conclusion of the representations for a particular safety standard Compliance statements provided in this manual are of the three following types Typel A statement that the vehicle when completed will conform to the standard if no alterations are made in identified components of the incomplete vehicle Type Il A statement of specific conditions of final manufacture under which the incomplete vehicle manufacturer specifies that the completed vehicle will conform to the standard Type Ill A statement of conformity with the standard is not substantially affected by the design of the incomplete vehicle and that the incomplete vehicle manufacturer makes no representation as to conformity with the standard F SERIES march 2005 IMPORTANT To rely on the compliance representations in this manual the incomplete vehicles must be completed as one of the completed vehicle types designated on the label affixed to the cover of this manual and must not exceed the specified GVWR GAWRs or the Unloaded Vehicle Weight limits when specified in this manual VEHICLE SPECIAL ORDER VSO VEHICLES VSO vehicles can be identified by a six digit number with the letters VSO below the digits in the lower right corner of the Incomplete Vehicle Information label which is affixed to the driver door lock pillar See the sample label on page 6
52. leted will conform to Standard 118 Power Operated Window Partition and Roof Panel Systems if the power operated windows motors wiring and key and switch activation systems where provided by Ford Motor Company are not removed relocated altered or modified in any way If additional power operated window partition or roof panel systems are installed by subsequent stage manufacturers they must conform to the requirements of Standard 118 The statement below is applicable to the Chassis Cab All tires supplied by Ford Motor Company are in full conformity with Standard 119 New Pneumatic Tires for Vehicles Other than Passenger Cars If additional tires are installed or the existing tires are replaced by subsequent stage manufacturers they must conform to the requirements of Standard 119 The statement below is applicable to the Chassis Cab This vehicle when completed will conform to the tire and rim selection requirements of Standard 120 Tire Selection and Rims for Motor Vehicles Other Than Passenger Cars if the tire and rim assemblies and the Incomplete Vehicle Information label that is affixed to the vehicle are not removed altered or replaced STATEMENTS OF CONFORMITY 124 The statements below are applicable to the Chassis Cab This vehicle when completed will conform to Standard 124 Accelerator Control Systems if No alterations are made to the accelerator pedal mounting hardware adjustable
53. manufacture The specific Federal Motor Vehicle Safety Standards to which the Chassis Cab will conform when completed as specified in this manual The date of manufacture month year of the Chassis Cab by Ford Motor Company DIRECTIONS STATEMENTS OF CONFORMITY The Statements of Conformity section which begin on page 10 of this manual lists the Federal Motor Vehicle Safety Standards in effect on the date of manufacture of this incomplete vehicle that are applicable to the type s of completed vehicles into which this incomplete vehicle may be manufactured This date is shown on the label affixed to the cover of this manual These statements in most cases apply to specific types of incomplete or completed vehicles and identify GVWR and UVW weight ranges The incomplete vehicle type is identified by the 5th 6th and 7th digits of the Vehicle Identification Number VIN see page 6 The completed vehicle types to which this incomplete vehicle may appropriately be completed is printed on the label under the heading May Be Completed As that is affixed to the cover of this document The Completed Vehicle Types chart on page 7 identifies how various incomplete vehicles with an Optional Prep Packages or a Trim Code may be completed Each statement of conformity is identified by a safety standard number located at the left margin Because there may be multiple statements of conformity for each safety standard use care to se
54. mber if the vehicle identification Interlock and Transmission Braking Effect if no number mounted on the top of the instrument panel is not alterations or adjustments are made to removed altered or modified and no actions are taken by Automatic Transmission the transmission shift cable the subsequent stage manufacturer that would obstruct transmission outer shift lever shift cable bracket the readability of the Vehicle Identification Number vacuum tubes vacuum pump system brake shift mounted on the top of the instrument panel interlock system the starter interlock system and wiring circuit from the interlock switch to the power 101 The statements below are applicable to the Chassis Cab Manual and Automatic Transmission the clutch This vehicle when completed will conform to Standard ignition interlock system if equipped transmission 101 Controls and Displays if shift decal knob or transmission indicator dial T TNT l identification The controls displays and their identifications supplied by Ford Motor Company are not removed relocated If an auxiliary transmission is added to this vehicle it altered or moditied must conform to the requirements of this Standard The components wiring and power supply installed by 103 The statement below is applicable to the Chassis Ford Motor Company to illuminate any control display Cab or their identification are not removed or altered so as to
55. n of snow plow attachment hardware The truck must not be operated without either the blocker beam or snow plow attachment hardware in place Any seat belt assemblies added to this vehicle must conform to the applicable requirements of this Standard STATEMENTS OF CONFORMITY 208 Canadian Requirements The preceding statements and supporting figures for FMVSS 208 on pages 17 18 are appropriate compliance representations for CMVSS 208 Seat Belt Installation if this incomplete vehicle was manufactured for sale or use in Canada In such a case CMVSS 208 paragraphs 13 14 and 15 are substituted for the reference to FMVSS 208 Section 7 1 CMVSS 208 paragraph 20 should be substituted for the reference to FMVSS 208 Section 7 2 and CMVSS 208 paragraphs 29 30 31 32 83 34 85 36 37 38 39 and 40 should be substituted for the reference to FMVSS 208 Section 7 4 WARNING VEHICLES OVER 3856 kg 8 500 Ib GVWR AND 2495 kg 5 500 Ib UVW ARE EQUIPPED WITH SUPPLEMENTAL RESTRAINT SYSTEMS AIR BAGS WHICH ARE STANDARD ONTHE DRIVER S SIDE AND STANDARD OR OPTIONAL FOR THE PASSENGER SIDE MODIFICATIONS TO THE VEHICLE FORWARD OF THE CRASH SENSOR SHOWN BELOW MAY AFFECT THE DEPLOYMENT OF THE AIR BAG WHEN SO EQUIPPED REFER TO THE FORD TRUCK BODY BUILDERS LAYOUT BOOK FOR SNOW PLOW PREPARATION PACKAGES AND INSTALLATION INSTRUCTIONS WHICH ARE COMPATIBLE WITH AIR BAGS 72 WAY CONNECT
56. nce Turn Signal Flasher 2 S S requirements of Standard 108 and to the applicable SAE standards or recommended practices referenced Vehicular Hazard Warning Signal or sub referenced in this Standard Operating Unit 2 B All electrical equipment added to the vehicle by Vehicular Hazard Warning Signal subsequent stage manufacturers must conform to the Flasher S S wiring practices set forth in the Electrical Wiring Section Identification Lamps Front N 1 S 1 of the Ford Truck Body Builders Layout Book Rear N R 108 Canadian Requirements Clearance Lamps Front N 1 S 3 The preceding statements for Standard 108 are Rear N R appropriate compliance representations for CMVSS 108 Parking Lamps S N Lighting and CMVSS 108 1 Headlamps if this vehicle is S Required on completed vehicle and supplied with the manufactured for sale or use in Canada provided incomplete vehicle No component of the Daytime Running Lamp DRL R Required on completed vehicle and not supplied with the System is removed relocated or modified incomplete vehicle N Not required for completed vehicle 1 Supplied on DRW Super Duty F Series Chassis Cab Optional on SRW Super Duty F Series Chassis Cab 2 Designed for two turn signal lamps per vehicle side one front and rear If additional lamps are required replace the turn signal flasher with one having the correct lamp load rating 3 If a second unit body width is greater than 2032 mm 80 in or higher
57. ncompliance to particular standards Note that the final responsibility for the compliance of the completed vehicle rests with the final stage manufacturer who is required by law to certify as prescribed by Section 567 5 of Title 49 Code of Federal Regulations that the completed vehicle conforms to all applicable Federal Motor Vehicle Safety Standards and that all applicable federal state and California emission noise standards are conformed with Ford Motor Company does not make any representation as to the appropriateness of modifications for any particular application other than expressly stated herein Intermediate and final stage manufacturers must exercise proper engineering judgment to determine if a modification is appropriate for their specific application IMPORTANT UNITED STATES AND CANADIAN VEHICLES Alterations to an incomplete vehicle by someone other than Ford Motor Company or damage in transit may affect compliance statements that are furnished in this manual or representations that are printed on the label that may be affixed to a vehicle F SERIES march 2005 1 INTRODUCTION TABLE OF CONTENTS U S amp CANADIAN MOTOR VEHICLE SAFETY STANDARDS 2 eene Inside Cover INTRODUCTION Eee 1 DEFINITIONS n ibd d a teed vty 3 4 GENERAL
58. ner element Removal of or rendering inoperative exhaust system components including the catalyst inlet pipe muffler outlet pipe resonator or diffuser Removal of the fan shroud Removal of or rendering inoperative the fan clutch New vehicles manufactured for sale in Canada must comply with applicable provisions of Canada Motor Vehicle Safety Standard 1106 Noise Additional noise emissions information is contained in the Ford Truck Body Builders Layout Book WARRANTY AND MAINTENANCE A copy of the appropriate Ford Truck Owners Guide and Warranty Facts Booklet must be installed in every vehicle prior to sale to the ultimate purchaser in order to provide emission systems warranty information and maintenance schedules It also provides where required by EPA noise control regulations for vehicles having GVWR over 4536 kg 10 000 Ib noise emissions warranty information instructions for maintenance use and repair of vehicle noise emission control systems a maintenance record format and list of prohibited tampering acts EVAPORATIVE EMISSIONS All 2006 Federal light and heavy duty trucks and all California vehicles with gasoline engines are required to comply with evaporative emissions requirements established by the Environmental Protection Agency or the California Air Resources Board Production fuel systems supplied on incomplete 2006 model year trucks manufactured by Ford Motor Company comply with these requirements
59. ng life support equipment for rescue operations or for non emergency patient transfer if the engine of the vehicle is equipped with a throttle kicker device which enables an operator to increase engine speed over normal idle speed when the vehicle is not moving Ford Motor Company B Pillar is the vehicle body structure located directly rearward of each front door This structure will include the outer panel all inner panels or reinforcements which support the door opening the door latching system and or the roof structure Ford Motor Company Basic Stripped Chassis an incomplete vehicle without occupant compartment that requires the addition of an occupant compartment and cargo carrying work performing or load bearing components to perform its intended function Ford Motor Company Bus motor vehicle with motive power except a trailer designed for carrying more than 10 persons 49CFR571 3 Bus Canada a vehicle having a designated seating capacity of more than 10 but does not include a trailer or a vehicle imported temporarily for special purposes autobus Chassis Cab an incomplete vehicle with completed occupant compartment that requires only the addition of cargo carrying work performing or load bearing components to perform its intended functions 49CFR567 3 Completed Vehicle a vehicle that requires no further manufacturing operations to perform its intended function other than
60. ompleted will conform to Standard 1106 Noise Emissions Section 2 if noise control devices or elements of design are not modified removed or rendered inoperative Examples of such devices or elements of design are Fender apron absorbers fender apron barriers underbody noise shields and acoustic absorption material Engine speed governor or electronic control intended to control maximum engine speed Engine air duct air intake choke or silencer air cleaner and air cleaner element Exhaust system components including the catalyst inlet pipe muffler outlet pipe resonator and diffuser Engine cooling fan and cooling fan clutch 1106 Canadian Requirements The statements below are applicable to the Chassis Cab with GVW ratings of more than 4536 kg 10 000 Ib These vehicles when completed will conform to Standard 1106 Noise Emissions Section 4 if noise control devices or elements of design are not modified removed or rendered inoperative Examples of such devices or elements of design are Fender apron absorbers fender apron barriers underbody noise shields and acoustic absorption material Engine speed governor or electronic control intended to control maximum engine speed Engine air duct air intake choke or silencer air cleaner and air cleaner element Exhaust system components including the catalyst inlet pipe muffler outlet pipe resonator and diffuser Engine cooling fan and cooling
61. or Company Seating Reference Point Canada the unique Design H point as defined in section 2 2 11 1 of SAE Recommended Practice J1100 June 19993 that a establishes the rearmost normal design driving or riding position of each designated seating position taking into account all modes of adjustment horizontal vertical and tilt in a vehicle b has X Y and Z coordinates as defined in section 2 2 8 of SAE Recommended Practice J1100 June 1993 established relative to the designed vehicle structure c simulates the position of the pivot centre of the human torso and thigh and d is the reference point employed to position the H point template with the 95th percentile leg as described in section 3 1 of SAE Standard J826 June 1992 or if that drafting template cannot be positioned the reference point when the seat is in its rearmost adjustment position point de r f rence de position assise Second Unit Body SUB consists of the body structure and or all the cargo carrying work performing and or load bearing components and or equipment installed by a subsequent stage manufacturer on an incomplete vehicle such that the incomplete vehicle becomes a completed vehicle Ford Motor Company Subsequent Stage Manufacturer a term which means either intermediate or final stage manufacturers or both Ford Motor Company Trimmed Seat a complete functional seat assembly including the seat pedes
62. owever because Ford Motor Company has no control over how this incomplete vehicle is completed by subsequent stage manufacturers Ford Motor Company 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 completed vehicle additional measures may be needed to adequately suppress RFI emissions Affected components could include spark plugs ignition wires ignition coils ground straps ignition component shields accessory drive belts instrument voltage regulator suppressor assembly and ignition coil suppressor assembly F SERIES marcn 2005 25 More specifically All components required to suppress RFI emissions which are removed during service repair or completion of the vehicle must be reinstalled in the manner in which they were installed by Ford Motor Company Shields on ignition coils must remain installed Replacement spark plugs ignition wires and ignition coils must be equivalent in their RFI suppression properties to original equipment Electrical grounds on all components must be retained Metallic components installed on the body or chassis must be grounded to the chassis Electrical circuits added to the vehicle must not be installed near the high voltage
63. pedal mechanism or other components of the accelerator control system as installed by Ford Motor Company No equipment is added nor existing equipment modified which would restrict operation of the accelerator control system No alterations are made to the Pedal Position Sensor and all associated hardware and wiring See the figure below for component identification PEDAL POSITION SENSOR IDLE POSITION SENSOR ELECTRONIC ACCELERATOR CONTROL STATEMENTS OF CONFORMITY 16 201 The statements below are applicable to the Chassis Cab with a GVWR of 4536 kg 10 000 Ib or less This vehicle when completed will conform to Standard 201 Occupant Protection in Interior Impact excluding U S Section 6 requirements addressed separately if the following components as provided by Ford Motor Company are not removed relocated altered or modified in any way Instrument panel Interior compartment doors Sun visors Arm rests Seat backs of front seats installed by Ford Motor Company are designed to meet the seat back requirements of Standard 201 The seat mounted armrest on an untrimmed front seat must be completed so as to meet the requirements of this Standard If any of the above mentioned components including front seats are added to the incomplete vehicle by a subsequent stage manufacturer these components must conform to the requirements of Standard 201 where applicable Because conform
64. pounds such that the incomplete vehicle becomes a W Weight at the rear wheels of the vehicle chassis completed vehicle and cab fuel tanks full pounds Including CG Horizontal distance from the of the front wheels option weight to the center of gravity inches of the chassis WB e CG n 5 h CG OF CHASSIS E o CG OF COMPLETED VEHICLE CG he CG OF SUB CG hp e SUB GVWR W rc WI STATEMENTS OF CONFORMITY 10 F SERIES march 2005 TABLE F MAXIMUM UNLOADED VEHICLE WEIGHTS WITH SECOND UNIT BODY This Weight Information Does Not Apply To Vehicles Over 4536 kg 10 000 Ib GVWR MAX UNLOADED VEHICLE WEIGHT SECOND UNIT BODY kilogram pound MAXIMUM 7 mE CENTER OF GRAVITY Engine Size liter cubic inch FRAME HEIGHT 5 4L 6 8L 6 0LD MODELS WIDTH millimeter inch 330 413 363 F 250 Regular Cab 4X2 Wide 447 3120 3120 3334 3480 mm 137 in WB 56 CA 17 6 6880 6880 7350 F 250 Regular Cab 4X4 Wide 447 3302 3302 3493 3480 mm 137 in WB 56 CA 17 6 7280 7280 7700 F 250 Super Cab 4X2 Wide 610 3312 3312 3312 4013 mm 158 in WB 56 CA 24 7300 7300 7300 F 250 Supe
65. pplicable to vehicles with a GVWR of 4536 kg 10 000 Ib or bus with a GVWR of 2722 kg 6 000 Ib or less less and an unloaded vehicle weight of 2495 kg 5 500 Ib or 8 Tether anchors and latch ISO Fix lower anchors that are less installed voluntarily or by regulation must comply with this 4 Applicable to vehicles with a GVWR of 2722 kg 6 000 Ib or Standard less 9 Canadian 119 requirements are found in the Motor Vehicle Tire 5 Injury criteria applicable to vehicles with a GVWR of 3856 kg Safety Standards 8 500 Ib or less and an unloaded vehicle weight of 2495 kg 5 500 Ib or less U S amp CANADIAN MOTOR VEHICLE SAFETY STANDARDS F SERIES marcn 2005 INTRODUCTION Information in this manual is furnished pursuant to United States and Canadian safety regulations or in some cases where the information is not required by regulation is furnished for the convenience of intermediate or final stage vehicle manufacturers Incomplete vehicles manufactured for sale or importation into the U S are specially equipped for the United States The descriptions and statements contained in the manual relate only to motor vehicle safety standards issued under the National Traffic and Motor Vehicle Safety Act of 1966 as amended An incomplete vehicle manufactured for sale or importation into Canada is specially equipped for Canada This vehicle conforms to the applicable Canadian Motor Vehicle Safety Standards CMVSS on the d
66. r Cab 4X4 Wide 610 3403 3403 3493 4013 mm 158 in WB 56 CA 24 7500 7500 7700 F 250 Crew Cab 4X2 Wide 610 3585 3585 3607 tt 4379 mm 172 4 in WB 56 CA 24 7900 7900 7950 d F 250 Crew Cab 4X4 Wide 610 3585 3585 3585 Q 4379 mm 172 4 in WB 56 CA 24 7900 7900 7900 x 9 F 350 Regular Cab 4X2 Wide 447 3120 3120 3334 3480 mm 137 in WB 56 CA 17 6 6880 6880 7350 2 S F 350 Regular Cab 4X4 Wide 447 3302 3302 3515 3480 mm 137 in WB 56 CA 17 6 7280 7280 7750 F 350 Super Cab 4X2 Wide 610 3312 3312 3403 4013 mm 158 in WB 56 CA 24 7300 7300 7500 F 350 Super Cab 4X4 Wide 610 3402 3403 3517 4013 mm 158 in WB 56 CA 24 7500 7500 7750 F 350 Crew Cab 4X2 Wide 610 3606 3606 3606 4379 mm 172 4 in WB 56 CA 24 7950 7950 7950 F 350 Crew Cab 4X4 Wide 610 3606 3606 3606 4379 mm 172 4 in WB 56 CA 24 7950 7950 7950 F 350 Regular Cab 4X2 Narrow 447 3674 3674 3674 3576 mm 140 8 in WB 60 CA 17 6 8100 8100 8100 F 350 Regular Cab 4X4 Narrow 447 3538 3538 3670 3576 mm 140 8 in WB 60 CA 17 6 7800 7800 8090 F 350 Super Cab 4X2 Narrow 610 3739 3739 3739 9 4110 mm 161 8 in WB 60 CA 24 8240 8240 8240 E F 350 Super Cab 4X4 Narrow 610 3739 3739 3739 4110 mm 161 8 in WB 60 CA 24 8240 8240 8240 o F 350 Crew Cab 4X2 Narrow 610 3857 3857 3857 4475 mm 176 2 in WB 60 CA 24
67. re added to the incomplete vehicle by a subsequent stage manufacturer these components must conform to the requirements of Standard 201U where applicable F SERIES march 2005 202 203 203 204 204 The statements below are applicable to the Chassis Cab if the GVWR is 4536 kg 10 000 Ib or less This vehicle when completed will conform to Standard 202 Head Restraints if No alterations are made to the head restraints the seat assemblies and their anchorages the floor pan or floor pan reinforcements The added seat trim on vehicles equipped with untrimmed front seats is installed so that the physical dimension requirements for the head restraint in this Standard are met Any front outboard passenger seat added to a cutaway equipped with the School Bus Prep Package and when completed as a truck MPV or bus not school bus must conform with the requirements of this Standard The statement below is applicable to the Chassis Cab if the GVWR is 4536 kg 10 000 Ib or less This vehicle when completed will conform to Standard 203 Impact Protection for the Driver from the Steering Control System if the steering control system is not removed relocated altered or modified in any way and no components or attachments are added to the steering control system that can catch the driver s clothing or jewelry during normal driving maneuvers Canadian Requirements The preceding statements for F
68. rovided in the dunnage kit MAR Smm as The completed fuel fill system must provide a 4 degree minimum continuous downward slope to the fuel tank Additional support may be required to prevent hose sagging which could cause spray or spitback during normal fueling operations Do not extend the fuel fill system outboard of the second unit body FIGURE B SUPER DUTY F SERIES WIDE FRAME PI CKUP BOX DELETE FUEL FILLER PIPE INSTALLATION F SERIES march 2005 23 STATEMENTS OF CONFORMITY 301 301 302 Continued Canadian Requirements The Canadian loading requirements are provided in Section 3 3 of Test Method 301 Fuel System Integrity revised February 8 2001 and should be substituted wherever references to FMVSS 301 Section 7 1 6 loading requirements have been made in the statements of conformity for Standard 301 The statement below is applicable to the Chassis Cab This vehicle when completed will conform with Standard 302 Flammability of Interior Materials if no alterations are made to those components covered by the Standard which are installed by Ford Motor Company and all components covered by Standard 302 which are added to the incomplete vehicle by subsequent stage manufacturers meet the flammability requirements of the Standard 1106 Canadian Requirements The statements below are applicable to the Chassis Cab with GVW ratings of 4536 kg 10 000 Ib or less These vehicles when c
69. rtification regulations the Emission Control Information tune up label must be welded riveted or otherwise permanently attached to an area within the engine compartment or to the engine in such a way that it will be readily visible to the average person after installation of the engine in a vehicle In selecting an acceptable location the manufacturer shall consider the possibility of accidental damage e g possibility of tools or sharp instruments coming in contact with the label The label shall be affixed in such a manner that it cannot be removed without being destroyed or defaced and shall not be affixed to any part which is likely to be replaced during the vehicle s useful life For motor vehicles rated at 6350 kg 14 000 Ib GVWR or less the label shall not be affixed to any equipment which is easily detached from the vehicle As used in these specifications readily visible to the average person shall mean that the label shall be readable from a distance of 460 mm 18 in without any obstructions from vehicle or engine parts including all manufacturer available optional equipment except for flexible parts e g vacuum hoses ignition wires Alternately information required by these specifications to be printed on the label shall be no smaller than 8 point type size provided that no vehicle or engine parts including all manufacturer available optional equipment except for flexible parts that can be moved out of the way witho
70. s 45 degrees from the cab s horizontal plane see sketch below Spot paint repair the area of bend using standard practices including a Clean the surface b Sand the surface c Prime and topcoat the surface F SERIES march 2005 21 No other alteration or modification made to the incomplete vehicle as manufactured by Ford Motor Company and no other components or structure installed by a subsequent stage manufacturer result in penetration separation or other damage to the fuel system or any portion thereof when the vehicle is tested in any manner specified by applicable provisions of Standard 301 The maximum SUB weight and SUB center of gravity as installed by the subsequent stage manufacturer and the Unloaded Vehicle Weight does not exceed the values specified in Table F on page 11 corresponding to the model wheelbase and engine size The body installed by a subsequent stage manufacturer and the Ford installed fuel system components are located and mounted as follows The body is mounted securely and is so designed that when the completed vehicle is tested in any manner specified by applicable provisions of Standard 301 a body components do not contact any fuel system component at any time other than at the points where the fuel system is permanently attached to the body and b body deformation or movement relative to the frame does not cause any fuel system component to be p
71. sequent manufacturer to properly label vehicles for the market in which they are sold EXTERIOR NOISE New vehicles which have a gross vehicle weight rating in excess of 4536 kg 10 000 Ib include a partially or wholly enclosed operators compartment and are manufactured for use in the United States must comply with U S Environmental Protection Agency s exterior noise emission regulations for medium and heavy trucks 40 CFR Part 205 Subpart B which establish a noise emission limit of 80 dB A F SERIES marcn 2005 TAMPERING WITH NOISE CONTROLS Federal law prohibits the removal or rendering inoperative by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into such vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use Federal Law also prohibits the use of such vehicle after such device or element of design has been removed or rendered inoperative by any person Among those acts presumed to constitute tampering are the acts listed below Removal of fender apron absorbers fender apron barriers underbody noise shields or acoustical absorptive material Removal of or rendering inoperative the engine speed governor so as to allow engine speed to exceed manufacturer s specifications Removal or modification of air duct air intake choke or silencer air cleaner or air clea
72. tal seat track seat base frame seat back recliner mechanism seat padding all attaching hardware and the final trim material i e cloth leather or vinyl Ford Motor Company Truck a motor vehicle with motive power except a trailer designed primarily for the transportation of property or special purpose equipment 49CFR571 3 Truck Canada a vehicle designed primarily for the transportation of property or special purpose equipment but does not include a competition vehicle a crawler mounted vehicle a trailer a work vehicle a vehicle imported temporarily for special purposes or a vehicle designed for operation exclusively off road camion Unloaded Vehicle Weight UVW the weight of a vehicle with maximum capacity of all fluids necessary for operation of the vehicle but without cargo occupants or accessories that are ordinarily removed from the vehicle when it is not in use 49CFR571 3 Unloaded Vehicle Weight Canada the weight of a vehicle equipped with the containers for the fluids necessary for the operation of the vehicle filled to their maximum capacity but without cargo or occupants poids du v hicule sans charge Untrimmed Seat the structure including the seat pedestal seat track seat base frame seat back recliner mechanism seat padding and all attaching hardware required for a functional seat assembly without the final trim material e g cloth leather or vinyl and trim material
73. the front bumper and front bumper mounting system during manufacture and reinstallation in accordance with the instructions provided in the Ford Truck Shop Manual should not adversely affect the compliance of a completed vehicle to Standards 212 and 219 STATEMENTS OF CONFORMITY 212 219 213 214 219 225 The body installed by the subsequent stage manufacturer is mounted securely and so designed that when the completed vehicle is impacted in any manner specified by applicable provisions of Standards 212 and 219 body deformation or movement relative to the frame does not result in any separation or loss of body attachment to the frame The maximum SUB weight and SUB center of gravity as installed by the subsequent stage manufacturer and the Unloaded Vehicle Weight does not exceed the values specified in Table F page 11 corresponding to the incomplete vehicle type wheelbase and engine size Canadian Requirements The preceding statements for FMVSS 212 219 are appropriate compliance representations for CMVSS 212 Windshield Mounting and CMVSS 219 Windshield Zone Intrusion if this incomplete vehicle was manufactured for sale or use in Canada In such a case CMVSS 212 and 219 paragraphs 5 1 and 8 b are substituted for the reference to FMVSS 212 and 219 Sections 6 1 b and 7 7 b respectively The statement below is applicable to the Chassis Cab Conformity with Standard 213 Child restraint systems is
74. ts The statement below is applicable to the Chassis Cab if the GVWR is 3856 kg 8 500 Ib or less This vehicle when completed will conform to Standard 210 2 Lower Universal Anchorage Systems for Restraint Systems and Booster Cushions if No alterations are made to the front passenger seat tether anchorages or LATCH lower anchors and access to the anchorages is not restricted and no alterations are made to the seat assemblies their anchorages the floor pan or floor pan reinforcements F SERIES march 2005 19 212 219 212 219 212 219 Note The terms body or body structure in the 212 and 219 statements that follow include any equipment permanently attached to that body or body structure installed by the subsequent stage manufacturer as well as the basic body or body structure INFORMATION Refer to the Design Recommendations section in the Ford Truck Body Builders Layout Book for Second Unit Body Attachment information to aid in designing second unit bodies and their attachments for compatibility with F Series vehicles The statements below are applicable to the Chassis Cab if the GVWR is 4536 kg 10 000 Ib or less This vehicle when completed will conform to Standard 212 Windshield Mounting and Standard 219 Windshield Zone Intrusion if The following windshield system components related structural components and hardware as installed by Ford Motor Company are not removed
75. ubstance on or after May 15 1993 must be identified with a clearly and conspicuously attached label Ford Motor Company has eliminated Class ODS from its manufacturing processes All 2006 Ford Truck incomplete vehicles will not have Class ODS content Manufacturers including subsequent stage manufacturers are required to label their products if the product including any component whether manufactured by that manufacturer or not contains a Class ODS or if the manufacturer used a Class ODS in the manufacturing of the product In the case where Ford Motor Company provides a label saying the incomplete vehicle contains a Class ODS that information must be placed on the product warning label See EPA regulation on wording placement size and combining labels In Canada consult the appropriate Provincial or Territorial Ministry of Environment EMISSION CONTROL INFORMATION LABEL To meet United States Environmental Protection Agency regulations the Important Vehicle Information tune up and fuel tank capacity labels must be affixed in a location that is readily visible after installation and in such a manner that it cannot be removed without destroying or defacing the label The label shall not be affixed to any equipment that is easily detached from the vehicle When emission control labels are supplied but not attached to the vehicle i e tune up label or fuel tank label they must be permanently mounted in a r
76. ured for sale in Canada A label representative of those installed by Ford Motor Company assembly plants is shown below OPTIONAL PREP PACKAGES Incomplete vehicles produced by Ford Motor Company in some instances are equipped with an optional prep package such as Ambulance Prep The completed vehicle type charts on page 7 will identify incomplete vehicles and the optional prep packages or trim codes that may be required by Ford Motor Company if final stage manufacturers wish to rely on the Statements of Conformity or in some cases preserve the Ford Motor Company new vehicle warranty If an incomplete vehicle is equipped with an optional prep package both the Incomplete Vehicle Information label affixed to the vehicle and the label on the front of this manual will identify the prep package INCOMPLETE VEHICLE MANUFACTURED BY FORD MOTOR COMPANY TRE REAR GAWR 8260LB 3742KG 5R16D TRS en AT 56 b EQUIPPED WITH THE FORD 4 AMBULANCE PREP PKG EXTERIOR PAINT COLORS WB TYPEGVW BODY TRANS AXLE TAPE SPRINGS 161 F379 AJ8 E DATE OF MANUFACTURE _ VEHICLE TYPE SEE CHART ee ON PAGE 7 OPTIONAL a PREP PACKAGE 65 NY VF85B1520472AB TYPICAL F SERIES U S MANUFACTURE INCOMPLETE VEHICLE MANUFACTURED BY a FORD MOTOR COMPANY DIE 01 06 GwvR PNBE 15000LB 6803KG GAWR REAR GAWR PRSE AV PNBE AR VEHI
77. ut disconnection obstruct the label Completed vehicles for retail sale in California require a machine readable Vehicle Identification Number VIN bar code label made of paper plastic metal or other permanent material which shall be affixed in a readily visible location to either the door latch post next to the driver s seating position the door edge that meets this door latch post or above the instrument panel in a location clearly visible through the lower left corner of the windshield Allincomplete vehicles except Basic Stripped Chassis type vehicles will conform to this standard For the Vehicle Emission Control VEC and VIN labels sufficient clearance shall be provided to use a non contact bar code Reading Wand For the tune up label and vacuum hose routing diagram label the label and any adhesives used shall be designed to withstand typical vehicle environment conditions in the area where the label is attached for the vehicle s total expected life Typical vehicle environmental conditions shall include but are not limited to exposure to engine lubricants and coolants e g gasoline motor oil brake fluids water ethylene glycol under hood temperatures steam cleaning and paints or paint solvents RADIO FREQUENCY INTERFERENCE RFI The ignition system on your vehicle has been designed to be capable of compliance with RFI requirements established by the Canadian government However because Ford Motor Company
78. with Ford trimmed front seats and either the GVWR is over 3856 kg 8 500 Ib the Unloaded Vehicle Weight when completed is over 2495 kg 5 500 Ib or the vehicles are manufactured for operation by persons with disabilities This vehicle when completed will conform to Standard 208 Occupant Crash Protection if The seat belts seat belt warning system passenger air bag deactivation switch if so equipped and attaching hardware installed by Ford Motor Company are not removed relocated altered or modified No actions are taken which would impair the integrity of the belt and seat belt warning systems A seat belt warning system is not required for a vehicle with a GVWR over 4536 kg 10 000 Ib The Air Bag Supplemental Restraint System Information Labels that are affixed to the front sunvisors are visible and not altered modified or removed If the Air Bag Supplemental Restraint System Information Labels are not affixed to the front visors but shipped in dunnage the following is necessary to meet Standard 208 The information label must be permanently affixed to each visor in an upright position readable from the driver s or passenger s seating position f the label is not visible when the visor is stored up position an Air Bag Alert Label shall be placed on the visible surface of the visor as specified in Section 4 5 1 c of Standard 208 Front blocker beams may be removed to allow the installatio

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