Ford - F Series - Workshop Manual - 2013 - 2013

DO NOT DESTROY: THIS MANUAL IS REQUIRED BY LAW. KEEP UNTIL THE VEHICLE IS COMPLETED BY THE FINAL STAGE MANUFACTURER. 2013 SUPER DUTY F-SERIES INCOMPLETE VEHICLE MANUAL Incomplete Vehicle Types For This Manual Super Duty F-Series Chassis Cab February, 2012 DC34-19A268-AA U.S. & CANADIAN MOTOR VEHICLE SAFETY STANDARDS (Application By Vehicle Type) Vehicle Type Equipment Standard Number Title of Standard Truck MPV (1) 101 Controls and Displays X X 102 Transmission Shift Lever Sequence, Starter Interlock, and Transmission Braking Effect X X 103 Windshield Defrosting and 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, and Associated Equipment X X X 108.1 Headlamps (Canada only) X X X 110 Tire Selection and Rims for Motor Vehicles with a GVWR of 4,536 kilograms (10,000 pounds) or less (U.S. only) X(2) X(2) X(2) 111 Rearview Mirrors X X 113 Hood Latch System X X 114 Theft Protection and Rollaway Prevention X(2) X(2) 115 Vehicle Identification Number (Canada only) X X 116 Motor Vehicle Brake Fluids X X X 118 Power-Operated Window, Partition, and Roof Panel Systems X(2) X(2) 119 (7) New Pneumatic Tires for Motor Vehicles with a GVWR of more than 4,536 kilograms (10,000 pounds) X(8) 120 Tire Selection and Rims for Motor Vehicles with a GVWR of more than 4,536 kilograms (10,000 pounds) X(8) X(8) X(8) 124 Accelerator Control Systems X X 126 Electronic Stability Control Systems X (2) X(2) X(2) 138 Tire Pressure Monitoring Systems X(2) X(2) X(2) 139 New Pneumatic Radial Tires for Light Vehicles X(2) 201 Occupant Protection in Interior Impact X(2) X(2) 202a 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 Systems X X 208 Occupant Crash Protection X(4)(6) X(4)(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(6) X(6) 212 Windshield Mounting X(2) X(2) 213 Child Restraint Systems (U.S. only) X X X 213.4 Built-In Child Restraint System & Built-In Booster Cushions (Canada only) X X 214 Side Impact Protection X(2)(5) X(2)(5) 219 Windshield Zone Intrusion X(2) X(2) 225 Child Restraint Anchorage Systems (U.S. only) X(6) X(6) 301 Fuel System Integrity X(2) X(2) 301.1 LPG Fuel System Integrity (Canada only) X X 301.2 CNG Fuel System Integrity (Canada only) X X 302 Flammability of Interior Materials X X 303 Fuel System Integrity of Compressed Natural Gas Vehicles (U.S. only) X(2) X(2) 304 Compressed Natural Gas Fuel Container Integrity (U.S. only) X X 305 Electric-Powered Vehicles: Electrolyte Spillage and Electrical Shock Protection X X X 403 Platform Lift Systems for Motor Vehicles X 404 Platform Lift Installations in Motor Vehicles X X PART Parts and Accessories Necessary for Safe Operation – Liquid Fuel Tanks 393.67 X X X PART 565 Vehicle Identification Number (VIN) Requirements (U.S. only) X X 1106 Noise Emissions (Canada only) X X (1) This column identifies Standards that have equipment/component requirements. (2) Applicable to vehicles with a GVWR of 4536 kg [10,000 lb] or less. (3) Applicable to vehicles with a GVWR of 4536 kg [10,000 lb] or less and an unloaded vehicle weight of 2495 kg [5500 lb] or less. (4) Injury criteria are applicable to vehicles with a GVWR of 3856 kg [8500 lb] or less and an unloaded vehicle weight (UVW) of 2495 kg [5500 lb] or less except in the U.S., walk-in van-type trucks and vehicles designed to be sold exclusively to the U.S. Postal Service and, in Canada, vehicles manufactured for operation by persons with disabilities. (5) Dynamic Performance Requirements apply to MPV, truck or a bus with a GVWR of 2722 kg [6000 lb] or less. (6) Applicable to vehicles with GVWR with 3856 kg [8500 lbs] or less (and Canada only: UVW of 2495 kg [5500 lbs] or less), and to buses, including school bus, with a GVWR of 4536 kg [10,000 lb] or less. (7) Canadian 119 requirements are found in the Motor Vehicle Tire Safety Standards. (8) Applicable to vehicles with a GVWR greater than 4536 kg [10,000 lb] (U.S. only). U.S. & CANADIAN MOTOR VEHICLE SAFETY STANDARDS F-SERIES (February, 2012) 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 date 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” sections of this manual. 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 in the “Information Certification Information” section of this manual under the heading “Unleaded Gasoline Label,” “Warranty and Maintenance,” and “Emission Control Information Label.” 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 noncompliance 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 Title 49, Code of Federal Regulations, Part 567.5, 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 (February, 2012) 1 INTRODUCTION TABLE OF CONTENTS U.S. & CANADIAN MOTOR VEHICLE SAFETY STANDARDS ........................................................ Inside Cover INTRODUCTION .................................................................................... 1 DEFINITIONS ...................................................................................... 3-4 GENERAL INFORMATION..................................................................... 5 Directions............................................................................................ 5 VEHICLE DESCRIPTION....................................................................... 6 COMPLETED VEHICLE TYPES..............................................................7 STATEMENTS OF CONFORMITY ................................................... 8-27 CANADIAN VEHICLES Vehicle Identification......................................................................... 28 Daytime Running Lamp (DRL)......................................................... 28 Canadian Radio Frequency Interference (RFI) Information............. 28 EMISSION CERTIFICATION INFORMATION Frontal Area and Weight Restrictions................................................29 High Altitude Requirements...............................................................29 Emission Control Hardware...............................................................29 Unleaded Gasoline Label................................................................ 29 Exterior Noise.................................................................................. 30 Tampering with Noise Controls..........................................................30 Warranty and Maintenance.............................................................. 30 Evaporative Emissions..................................................................... 30 Malfunction Indicator Light (MIL).......................................................30 Ozone Depleting Substance (ODS)...................................................30 Vehicle Emission Control Information Label..................................... 30 California Heavy-Duty Diesel Engine Idling Requirements ..............30 California Fuel Vapor Recovery........................................................ 31 California Motor Vehicle Emission Control Label.............................. 31 Radio Frequency Interference (RFI)................................................. 31 SUPPLEMENTS.....................................................................................32 REFERENCE INFORMATION .................................... Inside Back Cover TABLE OF CONTENTS 2 F-SERIES (February, 2012) 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 driver’s 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-F). Ford Motor Company also includes within its definition of ambulance any vehicle that is used for transporting life-support equipment, for rescue operations, or for nonemergency 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 – a 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 cargocarrying, 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. (49CFR567.3) 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 ( ). (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. (châssis tronqué) 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 F-SERIES (February, 2012) 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 Standard 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 désignée) Final-Stage Manufacturer – a person who [company that (CMVSR)] performs such manufacturing operations on an incomplete vehicle that it becomes a completed vehicle. (49CFR567.3) 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 the 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, at a minimum, of chassis (including the frame) structure, power train, steering system, suspension system, and braking system, to the state that those systems are to be part of the completed vehicle, but requires further manufacturing operations to become a completed vehicle. (49CFR567.3) 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. (véhicule incomplet) 3 DEFINITIONS Incomplete Vehicle Manufacturer – a person [company that (CMVSR)] who manufactures an incomplete vehicle by assembling components none of which, taken separately, constitute an incomplete vehicle. (49CFR567.3) Intermediate Manufacturer – a person [company (CMVSR)], other than the incomplete vehicle manufacturer or the final stage manufacturer, who [that (CMVSR)] performs manufacturing operations on a vehicle manufactured in two or more stages. (49CFR567.3) 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 capacity 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. (véhicule de tourisme à 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 twodimensional drafting template described in SAE J826 (May 1987). (abbreviated by Ford Motor Company) Seating Reference Point (Canada) – the unique Design H-point, as defined in section 2.2.11.1 of SAE Recommended Practice J1100 (June 1993), 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, DEFINITIONS (b) has X, Y and Z coordinates, as defined in section 2.2.3 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 référence 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) Service Body – a type of Second Unit Body (SUB) that incorporates structural side and rear panels that extend below frame rail height. (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 pedestal, 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 crawlermounted 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 véhicule 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 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 à accès en position debout) 4 F-SERIES (February, 2012) 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. DIRECTIONS STATEMENTS OF CONFORMITY The “Statements of Conformity” section 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. 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. 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. VEHICLE SPECIAL ORDER (VSO) VEHICLES VSO vehicles can be identified by a 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 labels on the following page. The Statements of Conformity section of this manual includes compliance representations for certain VSO vehicles. These vehicles are identified in the Completed Vehicle Types chart. Other VSO vehicles may require additional Statements of Conformity which would be included in a Supplemental Section of this manual. 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 select 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 (49CFR568.4): FORD TRUCK ASSISTANCE Type I • A statement that the vehicle, when completed, will conform to the standard if no alterations are made in identified components of the incomplete vehicle. 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 incomplete vehicles. The Ford Truck Body Builders Layout Book may be accessed via the web at www.fleet.ford.com/ truckbbas under the “Publications” tab. Type II • 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 III • A statement that conformity with the standard cannot be determined based upon the components supplied on the incomplete vehicle, and that the incomplete vehicle manufacturer makes no representation as to conformity with the standard. F-SERIES (February, 2012) The Ford Truck Body Builder Advisory Service may be consulted regarding information contained in this manual. • Call (877) 840-4338 • E-mail via the web at www.fleet.ford.com/truckbbas under the “Contact Us” tab 5 GENERAL INFORMATION VEHICLE DESCRIPTION INCOMPLETE VEHICLE MANUAL COVER California Air Resources Board (CARB), requires a Vehicle Identification Number (VIN) Label having a non-contact, barcode, reading wand capability. The bar-code directly below the VIN on the Incomplete Vehicle Information label, when provided, will comply with this regulation. The cover of this manual identifies the incomplete vehicle configuration for which compliance representations are contained in this manual. Also, a label 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 Canadian Motor Vehicle Safety Act and Regulations require installation of an Incomplete Vehicle Information label with the National Safety mark on it on vehicles manufactured for sale in Canada. A label representative of those installed by Ford Motor Company assembly plants is shown below. • The GVWR • The front and rear GAWRs OPTIONAL PREP PACKAGES • Tire and wheel size 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” chart 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. • 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. 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. The 5th, 6th, and 7th positions of the Vehicle Identification Number (VIN) will identify the incomplete vehicle type. These three positions are used in the Completed Vehicle Types chart on page 7. DATE OF MANUFACTURE XX/XX VEHICLE TYPE (SEE CHART ON PAGE 7) BAR CODE V.I.N . (CALIFORNIA) XXXX XXXXXXXXXXXXX OPTIONAL PREP PACKAGE EQUIPPED WITH THE FORD AMBULANCE PREP PKG. 410047 VSO VSO VEHICLE TYPICAL F-SERIES - U.S. XX/XX DATE OF MANUFACTURE VEHICLE TYPE (SEE CHART ON PAGE 7) VSO VEHICLE TYPICAL F-SERIES - CANADA INCOMPLETE VEHICLE INFORMATION LABEL VEHICLE DESCRIPTION 6 F-SERIES (February, 2012) COMPLETED VEHICLE TYPES 5TH, 6TH, 7TH VIN DIGIT SUPER DUTY F-SERIES F2A, F3A, F3E F2B, F3B, F3F F3C, F3G, F4G, F5G F3D, F3H, F4H, F5H X2A, X3A, X3E X2B, X3B, X3F X3C, X3G, X4G, X5G X3D, X3H, X4H, X5H W2A, W3A, W3E W2B, W3B, W3F W3C, W3G, W4G, W5G W3D, W3H, W4H, W5H INCOMPLETE VEHICLES F-250/350 Regular Cab 4X2 (SRW)* F-250/350 Regular Cab 4X4 (SRW) F-350/450/550 Regular Cab 4X2 (DRW)** F-350/450/550 Regular Cab 4X4 (DRW) F-250/350 Super Cab 4X2 (SRW) F-250/350 Super Cab 4X4 (SRW) F-350/450/550 Super Cab 4X2 (DRW) F-350/450/550 Super Cab 4X4 (DRW) F-250/350 Crew Cab 4X2 (SRW) F-250/350 Crew Cab 4X4 (SRW) F-350/450/550 Crew Cab 4X2 (DRW) F-350/450/550 Crew Cab 4X4 (DRW) Ford Motor Company makes no representation that the completed vehicle types listed above 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. (February, 2012) TRUCK MPV X X X X X X X X X X X X X X X X X X X X X X X X * SRW – Single Rear Wheels ** DRW – Dual Rear Wheels IMPORTANT: F-SERIES COMPLETED VEHICLES 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. 101 102 The statements below are applicable to the Chassis Cab: This vehicle, when completed, will conform to Standard 101, Controls and Displays if: • The controls, displays, and their identifications supplied by Ford Motor Company are not removed, relocated, altered, or modified. • The components, wiring, and power supply installed by Ford Motor Company to illuminate any control, display, or their identification are not removed or altered so as to affect lighting performance. • Components added to the vehicle do not obstruct the driver’s ability to operate or visually locate the controls, displays, and their identifications. • The driver-seat is not replaced, relocated, or modified other than for the addition of seat trim. Any controls, displays, and illumination added to this vehicle must conform to the requirements of this Standard. The statement below is applicable to the Chassis Cab: This vehicle, when completed, will conform to Standard 103, Windshield Defrosting and Defogging Systems, if no alterations or adjustments are made to heater and blower assemblies, ducting, operating controls, electrical circuit from the blower assembly to the power source, windshield, coolant hoses from the radiator or engine to the heater, and if no obstructions are added that restrict or otherwise redirect the air flow from the defroster outlets to the windshield. 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. 105 The statements below are applicable to the Chassis Cab: This vehicle, when completed, will conform to Standard 102, Transmission Shift Lever Sequence, Starter Interlock, and Transmission Braking Effect, if no alterations or adjustments are made to the transmission, shift cable, transmission outer shift lever, shift cable bracket, vacuum tubes, vacuum pump system, brakeshift interlock system, starter interlock system, wiring circuit from the interlock switch to the power source, and transmission gear selector indicator (PRNDL). If an auxiliary transmission is added to this vehicle, it must conform to the requirements of this Standard. STATEMENTS OF CONFORMITY 103 8 INFORMATION Incomplete vehicle weight and dimensional information 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. F-SERIES (February, 2012) 105 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 – Wheelbase EQUATION A GVWR        ) ( ( ) TABLE A CGhl = Horizontal distance from front axle to cargo CG: Model WB (in) CGhl (in)† 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 185.8 167 SuperCab 161.8 155 Crew Cab 172.4 165 Crew Cab 176.2 167 Crew Cab 200.2 182 Ford Motor Company provides Type I and Type II FMVSS/CMVSS 105 compliance statements for vehicles built to factory standard or optional specifications. Suspension ride height and/or spring rate modifications are factors that may affect compliance to this Standard. If an alterer or final stage manufacturer modifies the suspension ride height or spring rate of the factory-equipped vehicle, then they are responsible for engineering analysis or physical testing to ensure compliance and sign-off to Standard 105. † If CGhI is not given in the table or if the location of your cargo is not in the normal cargo area, then your CGhI may be estimated as the distance from the of the front wheel to the horizontal midpoint of the cargo area. • No additional 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 lb] or less do not exceed the Maximum Unloaded Vehicle Weight value in Table F. • 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) may be reduced by no more than 10% for SRW or 25% 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) 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. (February, 2012) ) EQUATION B P x CGhp Wrb + Wrc + + Wrl x WB WB CGh =       GVWR *NOTE: F-SERIES ( CGvbWb + CGvc Wc + Wl + CGvp P CGv = TABLE B CGhp = Horizontal distance from front wheel to front passenger load. (Dimensions are inches) All Super Duty F-Series = 61.2 TABLE C CGVC = Vertical distance from ground to chassis CG (Dimensions are inches) F-250/350 (4X2) SRW > 8500 lb GVWR = 30.4 F-250/350 (4X4) SRW > 8500 lb GVWR = 31.4 F-350 (4X2) DRW = 30.4 F-350 (4X4) DRW = 31.4 F-450/550 (4X2 & 4X4) DRW = 35.0 TABLE D SUPER DUTY F-SERIES PASSENGER LOAD CGhp 61.2 [in] GVWR [lb] P [lb] 8800-10,000 400 10,001-19,500 500 TABLE E SUPER DUTY F-SERIES PASSENGER CGvp ALL SEATS 9 4X2 4X4 CGvp 40.3 [in] 43.8 [in] STATEMENTS OF CONFORMITY FMVSS 105 DEFINITIONS AND CALCULATION ILLUSTRATION FOR INCOMPLETE SUPER DUTY F-SERIES P = Passenger load (See Passenger Load Table D). Wt = Total unladen weight = (Wb + Wc + P) CGh = Horizontal distance from of the front wheels to the center of gravity [inches] of the completed vehicle. WI = Remaining cargo capacity [pounds]. Wrl = Weight of the remaining cargo capacity on the rear wheels [pounds]. CGv CGvb CGvc CGhp CGvp Wb Wrb Wrc Wc WB = Vertical distance from the ground to the center of gravity [inches] of the completed vehicle. GVWR = Gross Vehicle Weight Rating of the vehicle [pounds]. Where: Wl = GVWR - (Wb + Wc + P) = Vertical distance from the ground to the center of gravity of the SUB and/or permanently attached added equipment [inches]. = Vertical distance from the ground to the center of gravity of the chassis [inches] (including cab if original equipment). (Taken from Table C). CGhI = Horizontal distance from the of the front wheels to the P (passenger load). (See Table B). = Vertical distance from the ground to the center of gravity of the front and rear seat P (passenger weight). (Taken from Passenger CGvp Table E). SUB = Weight of the SUB and/or permanently attached added equipment [pounds]. = Weight at the rear wheels of the SUB and/ or permanently attached added equipment [pounds]. = Weight at the rear wheels of the vehicle (chassis and cab) (fuel tanks full) [pounds]. Including option weight. CGhc = Weight of the vehicle (chassis and cab) (fuel tanks full) [pounds]. Including option weight. WrI = (CGhI)WI WB = Horizontal distance from the of the front wheels to the cargo center of gravity [inches]. (Taken from Table A) for many common vehicles. If the CGhI is not given in the table, then it may be estimated as the distance from the of the front wheel to the horizontal midpoint of the cargo area. = A Second Unit Body 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. = Horizontal distance from the of the front wheels to the center of gravity (inches) of the chassis. = Vehicle wheelbase [inches]. WB CG hl CG OF CHASSIS CG h CG OF COMPLETED VEHICLE CG hc CG OF SUB SUB CG hp P CG vb CG vp CG v CG vc Wc Wt GVWR W rl STATEMENTS OF CONFORMITY 10 W rb Wb W rc Wl F-SERIES (February, 2012) TABLE F MAXIMUM UNLOADED VEHICLE WEIGHTS (UVW) WITH SECOND UNIT BODY (SUB) ( FMVSS 301 FUEL SYSTEM COMPLIANCE ) (Note: This information does not apply to vehicles over 4536 kg [10,000 lb] GVWR) Model / Cab Frame Width SUB Maximum CG Height above Frame mm [in] (1) Drive Maximum UVW kg [lb] Engine 6.2L Gas 6.7L Diesel PICKUP BOX DELETE / REMOVAL 447 [17.6] F-250/350 Regular Cab F-250/350 SuperCab Wide 4x2 4x4 610 [24.0] F-250/350 Crew Cab 3547 [7819] 3547 [7819] 3547 [7819] 3515 [7749] 3905 [8608] 3905 [8608] 3769 [8308] 3769 [8308] 3769 [8308] 3769 [8308] 3769 [8308] 3769 [8308] CHASSIS CAB 447 [17.6] F-250/350 Regular Cab F-250/350 SuperCab Narrow 4x2 4x4 610 [24.0] F-250/350 Crew Cab (1) Vertical dimensions are measured from the top surface of the frame at a distance approximately 304.8-457.2 mm [12--18 in] from the rear of the cab. F-SERIES (February, 2012) 11 STATEMENTS OF CONFORMITY TABLE G SUPER DUTY F-SERIES VEHICLES MINIMUM SECOND UNIT BODY WEIGHTS (FMVSS 105 BRAKE COMPLIANCE) Wide Frame Pickup Box Deletes F-250/350 956mm [37.7 in] Model and Configuration F-250/350 SRW F-350 DRW Body Style Wheelbase mm [in] Regular Cab 3480 [137] Super Cab 4013 [158] Crew Cab 4379 [172.4] Regular Cab 3480 [137] Super Cab 4013 [158] Crew Cab 4379 [172.4] Minimum SUB Weight kg [lb] 172 [380] 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 [lb] F-350 SRW Regular Cab Super Cab Crew Cab 3576 [140.8] 4110 [161.8] 4475 [176.2] 190 [420] 190 [420] 172 [380] 3576 [140.8] 4186 [164.8] 4110 [161.8] 190 [420] 204 [450] 190 [420] 4719 [185.8] 214 [470] 4475 [176.2] 190 [420] 5085 [200.2] 204 [450] 3576 [140.8] 4186 [164.8] 4795 [188.8] 190 [420] 204 [450] 227 [500] 5100 [200.8] 4110 [161.8] 249 [550] 190 [420] 4719 [185.8] 4475 [176.2] 5085 [200.2] 214 [470] 190 [420] 204 [450] 3576 [140.8] 4186 [164.8] 4795 [188.8] 190 [420] 204 [450] 227 [500] 5100 [200.8] 4110 [161.8] 249 [550] 190 [420] 4719 [185.8] 214 [470] Regular Cab F-350 DRW Super Cab Crew Cab Regular Cab F-450 DRW Super Cab Crew Cab Regular Cab F-550 DRW Super Cab Crew Cab STATEMENTS OF CONFORMITY 12 4475 [176.2] 190 [420] 5085 [200.2] 204 [450] F-SERIES (February, 2012) 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. 108 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 (DRL’s); Light Trucks for sale or use in Canada are equipped with DRL’s that meet the Canadian DRL requirements. As manufactured for Canada, the F-Series vehicles will meet the FMVSS 108 requirements for DRL’s when DRL’s are provided. Conformity with Standard 108, S.12, Headlamp Concealment Devices, cannot be determined based upon the components supplied on of this incomplete vehicle; accordingly, Ford Motor Company makes no representation as to conformity with this Standard. FRONT OF VEHICLE 108 CHMSL FIXED CIRCUIT 110 SUPER DUTY F-SERIES CHASSIS CAB CENTER HIGH MOUNTED STOP LAMP (CHMSL) ELECTRICAL CONNECTOR LOCATION 108 The statements below are applicable to the Chassis Cab: This vehicle, when completed, will conform to Standard 108, Lamps, Reflective Devices, and Associated Equipment, if all the required lighting equipment as indicated in Table H on next page (identified by the codes R and S) is designed and installed in accordance with the requirements of Standard 108 and the directions contained in this statement. Additionally, if the completed vehicle overall length is 9.14 meters [30 feet] or more, intermediate side marker lamps and reflex reflectors (not supplied by Ford Motor Company) are also required for compliance with Standard 108. The items of equipment which are supplied by Ford Motor Company (identified by the code S in Table H, on next page) are designed and installed to conform to all the applicable requirements of Standard 108. The completed vehicle, with these components installed, will conform to Standard 108 if the subsequent stage manufacturer does not remove, relocate, alter, or modify such equipment or modify the power supply or wiring to such equipment, and does not complete the body in such a configuration as to impair the visibility and conformity to the photometric requirements of the installed lamps and reflective devices. Specific requirements for lighting and associated equipment are listed by incomplete vehicle type in Table H on next page. Lamps, reflective devices, and associated equipment necessary to complete the vehicle from an incomplete vehicle must conform to the equipment, locations, special wiring, visibility, photometric, and performance requirements of Standard 108 and to the applicable SAE standards or recommended practices referenced or subreferenced in this Standard. All electrical equipment added to the vehicle by subsequent stage manufacturers must conform to the wiring practices set forth in the Electrical Wiring Section of the Ford Truck Body Builders Layout Book. Canadian Requirements: The preceding statements for Standard 108 are appropriate compliance representations for CMVSS 108, Lighting, if this vehicle is manufactured for sale or use in Canada. U.S. Requirements: The statement below is applicable to all incomplete vehicles with a GVWR of 4536 kg [10,000 lbs] or less: 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 S4.3 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 The statement below is applicable to the Chassis Cab with a GVWR of 4536 kg [10,000 lb] 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. F-SERIES (February, 2012) 13 STATEMENTS OF CONFORMITY 111 TABLE H Standard 108 Lighting Equipment Headlamps Tail Lamps Stop Lamps Center High Mounted Stop Lamp (CHMSL) License Plate Lamps Reflex Reflectors – Side Front – Side Rear – Rear Side Marker Lamps – Front – Rear Back-Up Lamps Turn Signal Lamps – Front – Rear Turn Signal Operating Unit Turn Signal Flasher (2) Vehicular Hazard Warning Signal Operating Unit Vehicular Hazard Warning Signal Flasher Identification Lamps – Front – Rear Clearance Lamps – Front – Rear Parking Lamps Width 2032 mm [80 in] or more Item Width less than 2032 mm [80 in] Super Duty F-Series Completed as Truck or MPV S S S S S S S S S R S S R S S S S S N S S R S S R S S S S S S S S N N N N S S S(1) R S(1) R N 111 113 114 S Required on completed vehicle and supplied with the incomplete vehicle. R Required on completed vehicle and not supplied with the incomplete vehicle. N Not required for completed vehicle. (1) Cab-mounted clearance lamps, as supplied, do not adequately indicate overall width of the vehicle per requirements of F/CMVSS 108; additional clearance lamps will be required. Additional Identification lamps may be required on the Second Unit Body if the SUB is higher than the Chassis Cab. (2) All chassis cab vehicles, including pickup box deletes, are configured to provide the function of a variable-load turn signal flasher. STATEMENTS OF CONFORMITY 115 116 14 The statement below is applicable to the Chassis Cab when not equipped with outside mirrors: Conformity with Standard 111, Rearview Mirrors, cannot be determined based upon the components supplied on 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 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 System, 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 lb] or less: This vehicle, when completed, will conform to Standard 114, Theft Protection and Rollaway Prevention, 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. 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. F-SERIES (February, 2012) 118 118 119 120 124 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 lb] or less: Conformity with Standard 118, Power-Operated Window, Partition, and Roof Panel Systems, cannot be determined based upon the components supplied on 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 lb] or less: This vehicle, when completed, 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 poweroperated window, partition, or roof panel systems are installed by subsequent stage manufacturers, they must conform to the requirements of Standard 118. ELECTRONIC ACCELERATOR CONTROL (Typical) 126 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 Motor Vehicles with a GVWR of more than 4536 kilograms [10,000 pounds]. 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 with a GVWR of more than 4,536 kilograms [10,000 pounds], if the tire and rim assemblies and the Incomplete Vehicle Information label that is affixed to the vehicle are not removed, altered, or replaced. 138 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 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. F-SERIES (February, 2012) 15 The statement below is applicable to the Chassis Cab, including Pickup Box Delete, if the vehicle GVWR is 4536 kg [10,000 lb] or less: This vehicle, when completed, will conform to Standard 126, Electronic Stability Control Systems, if: • The vertical center of gravity (CGv) is less than or equal to 42.6" and no modifications have been made to the components of the braking system, suspension system, wheels and tires. Completed vehicle weight should not exceed Maximum Unloaded Vehicle Weights (UVW) as shown in Table F on page 11. If the vertical center of gravity (CGv) of the vehicle is above 42.6", Ford Motor Company makes no representation as to conformity with this Standard. The statement below is applicable to all single rear wheel (SRW) incomplete vehicle types if the GVWR is 4536 kg [10,000 lb] or less (if equipped): The Tire Pressure Monitoring System (TPMS) is subject to interference from the addition of metallic structures between the wheel-mounted sensor transmitters and the on-board receiver. Additionally, TPMS is subject to interference from added equipment or devices that emit radio frequency (RF) energy. This vehicle, when completed, will conform to Standard 138, Tire Pressure Monitoring Systems, if: • No alterations are made to the tire pressure sensors (valve stems), wheels, tires, recommended tire pressures, Body Control Module (BCM - if equipped), Radio Frequency Receiver (RFR - if equipped), Tire Pressure Module (TPM - if equipped), instrument cluster, instrument panel wiring, or software calibrations • Wheel bases are not lengthened beyond 176 inches • No equipment that emits radio frequency (RF) energy is added to the vehicle • After vehicle manufacture, the function of the Tire Pressure Monitoring System is verified to be in accordance with FMVSS 138 and in accordance with information provided in the vehicle's Owner Guide STATEMENTS OF CONFORMITY 139 201 The statement below is applicable to all incomplete vehicle types: All tires supplied by Ford Motor Company are in full conformity with Standard 139, New Pneumatic Radial Tires for Light Vehicles. If additional tires are installed or the existing tires are replaced by subsequent stage manufacturers, they must conform to the requirements of Standard 139. 201U U.S. Requirements (Section S6): This vehicle when completed, will conform to Standard 201U, Occupant Protection in Interior Impact – Section 6, Requirements for Upper Interior Head Impact Protection, if the following com­ponents 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 • Canopy Air Curtain (if equipped) • 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 are added to the incomplete vehicle by a subsequent stage manufacturer, these components must conform to the requirements of Standard 201U where applicable. The statements below are applicable to the Chassis Cab with a GVWR of 4536 kg [10,000 lb] 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 conformity 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. 202a The statements below are applicable to the Chassis Cab if the GVWR is 4536 kg [10,000 lb] 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. 203 203 STATEMENTS OF CONFORMITY 16 The statement below is applicable to the Chassis Cab if the GVWR is 4536 kg [10,000 lb] 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 FMVSS 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. F-SERIES (February, 2012) 204 204 205 206 207 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. 208 The statements below are applicable to the Chassis Cab if the GVWR is 4536 kg [10,000 lb] or less and the Unloaded Vehicle Weight, when completed, is 2495 kg [5500 lb] 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 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 chassis, drivetrain, or front suspension from the B-pillar forward. 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. 208 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. (February, 2012) Canadian Requirements: The preceding statements 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), (33), (34), (35), (36), (37), (38), (39), and (40) should be substituted for the reference to FMVSS 208 Section 7.4. WARNING: The statements below are applicable to the Chassis Cab when equipped with Ford 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. F-SERIES The statement below is applicable to the Chassis Cab when equipped with Ford trimmed front seats and either the GVWR is over 3856 kg [8500 lb], the Unloaded Vehicle Weight, when completed, is over 2495 kg [5500 lb], 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 lb] ). • 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. – If 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. Any seat belt assemblies added to this vehicle must conform to the applicable requirements of this Standard. VEHICLES OVER 3856 kg [8500 lb] GVWR AND 2495 kg [5500 lb] UVW ARE EQUIPPED WITH SUPPLEMENTAL RESTRAINT SYSTEMS (AIR BAGS) WHICH ARE STANDARD ON THE DRIVER’S SIDE, AND STANDARD OR OPTIONAL FOR THE PASSENGER SIDE. MODIFICATIONS TO THE VEHICLE FORWARD OF THE CRASH SENSOR 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. 17 STATEMENTS OF CONFORMITY 209 209 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. 210 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 reference 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. AIRBAG DEACTIVATION SWITCH DRIVER AIRBAG MODULE PASSENGER AIRBAG MODULE ELECTRONIC CRASH SENSOR MODULE DO NOT INSTALL ADDITIONAL COMPONENTS IN THE SHADED AREAS, NOR ALTER OR MODIFY THESE AREAS. DO NOT MODIFY NOR ALTER ANY COMPONENTS OR AREAS OF THE VEHICLE IN THE VICINITY OF THE COMPONENTS THAT ARE IDENTIFIED IN THIS ILLUSTRATION. DO NOT MODIFY NOR ALTER THE FRONT CRASH SENSOR LOCATED UNDER THE RADIATOR ON THE FRONT LOWER TIE BAR. SUPER DUTY F-SERIES OCCUPANT PROTECTION SUPER DUTY F-SERIESZONE OCCUPANT PROTECTION ZONE & SUPPLEMENTAL RESTRAINT SYSTEM (AIRBAGS, SENSORS AND WIRING) STATEMENTS OF CONFORMITY 18 F-SERIES (February, 2012) 210.1 Canadian Requirements: • 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. – 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, corresponding to the incomplete vehicle type, wheelbase, and engine size. The statement below is applicable to the Chassis Cab with a GVWR of 3856 kg [8500 lb] or less and an unloaded vehicle weight of 2495 kg [5500 lb] or less. This vehicle, when completed, will conform to Standard 210.1, User-Ready Tether Anchorages for Restraint Systems, if: • No alterations are made to the passenger seat tether anchorages or LATCH lower anchors, 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. 212/ Note 219 The terms “body” or “body structure,” in the 212 and 219 statements that follow, include any equipment permanently attached to that body or body structure installed by the subsequent stage manufacturer as well as the basic body or body structure. 212/ Canadian Requirements: 219 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. 212/ INFORMATION 219 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. 213 The statement below is applicable to the Chassis Cab: Conformity with Standard 213, Child Restraint Systems, cannot be determined based upon the components supplied on 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. 212/ The statements below are applicable to the Chassis 219 Cab if the GVWR is 4536 kg [10,000 lb] 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, relocated, altered, or modified in any way except as specified in this manual: – Windshield and windshield mounting system – Cab and front end structural components including the roof, pillars, cowl, cowl reinforcements, hood, doors, fenders, hood restrictors and apron reinforcements, and frame and frame reinforcements – Radio antenna and air cleaner assembly – Doors and hood mounting, hinging, and latching systems – Hood ornamentation – Bumper and bumper mounting system † • 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 2495 kg [5500 lb] is established by testing a representative vehicle at an Unloaded Vehicle Weight of 2495 kg [5500 lb] as permitted by S6.1 (b) and S7.7 (b) of Standards 212 and 219, respectively. 214 219 225 The statements below are applicable to the Chassis Cab if the GVWR is 4536 kg [10,000 lb] 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 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, and no seats are added. Because the addition of seats would change compliance with this Standard, Ford Motor Company makes no representations as to conformity with this Standard for any vehicle that has seats added by the intermediate or final stage manufacturers. † 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 the compliance of a completed vehicle to Standards 212 and 219. F-SERIES (February, 2012) 19 STATEMENTS OF CONFORMITY 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. INFORMATION The Unloaded Vehicle Weight of the completed vehicle may significantly affect its capability to meet the requirements of Standard 301, Fuel System Integrity. 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 Recommendations” 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, 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 lb] or less: • If 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 shielded 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. 301 The statements below are applicable to the Chassis Cab if the vehicle GVWR is 4536 kg [10,000 lb] or less: This vehicle, when completed, will conform to Standard 301, Fuel System Integrity, if: • The following fuel system and frame 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 301 – 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) – Trailer hitch receiver on Pickup Box Delete vehicles (Sales Code 66D) Pickup Box Delete vehicles (Sales Code 66D) incorporate an outboard LH frame-mounted bracket (Ref: Figure A1) required as part of pickup truck Standard 301 compliance. Ford recommends that this bracket not be removed for SUB installation, however, if there is an interference with a service body upfit it may be removed and still maintain Standard 301 compliance. All other SUB upfits, including platform & stake bodies, require this bracket remain attached as installed by Ford Motor Company. Chassis Cab vehicles (non-Pickup Box Deletes) with a GVWR of 4536 kg [10,000 lb] or less require installation of a blocker beam receiver assembly as described in Figure A2 or A3. 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 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 penetrated, disconnected, or otherwise damaged. – 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. (Continued on next page) † 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 20 F-SERIES (February, 2012) FRONT OF FRONT OF VEHICLE VEHICLE Frame-mounted bracket Frame-mounted bracket (long version shown) (long version shown) FIGURE A1 – LH FRAME-MOUNTED BRACKET REQUIRED ON NON-SERVICE APPLICATION SECOND UNIT BODY FIGURE A1 A1 –– LH LH FRAME-MOUNTED FRAME-MOUNTED BRACKET BRACKET REQUIRED REQUIRED ON APPLICATION SECOND FIGURE ON NON-SERVICE NON-SERVICE APPLICATION SECOND UNIT UNIT BODY BODY (SUB) INSTALLATIONS (E.G., STAKE, PLATFORM, ETC.) (PICKUP BOX DELETE ONLY) (SUB) INSTALLATIONS INSTALLATIONS (E.G., (E.G.,STAKE, STAKE,PLATFORM, PLATFORM,ETC.) ETC.)(PICKUP (PICKUPBOX BOX DELETE DELETE ONLY) ONLY) (SUB) Side Plate: HSLAS-F Side Plate: HSLAS-F Grade 60 [60 ksi] Grade 60 [60 ksi] Thickness: 6 mm [0.24 in] Thickness: 6 mm [0.24 in] FRONT OF FRONT OF VEHICLE VEHICLE 229 mm [9.0 in] 229 mm [9.0 in] Minimum Setback Minimum Setback Crossbeam and Side Supports Crossbeam and Side Supports 3” Structural tube 3” Structural tube ASTM A500 Grade B ASTM A500 Grade B Thickness: 6 mm [0.24 in] Thickness: 6 mm [0.24 in] M18 PC 10.9 bolt M18 PC 10.9 bolt (4 bolts each side, (4 bolts each side, total 8 bolts) total 8 bolts) M18 PC 10.9 bolt M18 PC 10.9 bolt (3 bolts each side, (3 bolts each side, total 6 bolts) total 6 bolts) 302/304 Stainless Steel Tether (1 tether cable each 302/304 Stainless Steel Tether (1 tether cable each side side between between extension extension and and side side plate, plate, total total 2 2 tethers) tethers) CONTACT CONTACT BBAS BBAS @ @ www.fleet.ford.com/truckbbas www.fleet.ford.com/truckbbas FOR FOR CAD CAD DATA DATA & & INSTALLATION INSTALLATION INSTRUCTIONS INSTRUCTIONS FIGURE A2 –– BLOCKER BLOCKER BEAM ASSEMBLY FIGURE REQUIRED ON SUPER DUTY DUTY CHASSIS CHASSIS CAB CAB WITH WITH GVWR GVWR OF OF 4536 4536 KG KG FIGURE A2 A2 – BLOCKER BEAM BEAM ASSEMBLY ASSEMBLY REQUIRED REQUIRED ON ON SUPER SUPER DUTY CHASSIS CAB WITH GVWR OF 4536 KG [10,000 LB] OR LESS (CHASSIS CAB ONLY) [10,000LB] OR LESS (CHASSIS CAB ONLY) [10,000 LB] OR LESS (CHASSIS CAB ONLY) F-SERIES (November, 2009) F-SERIES 2009) F-SERIES(November, (February, 2012) 21 2121 STATEMENTS OF CONFORMITY STATEMENTS CONFORMITY STATEMENTS OFOF CONFORMITY 2" Hitch Receiver Ford Service Part Number: BC3Z-19D520-B FIGURE A3 – HITCH RECEIVER FOR F-350 SRW CHASSIS CAB 301 301 (Continued) – Except for a service body upfit with a rear bumper, there must not be any components that tie a second unit body (SUB) to the frame rearward of rear spring’s rear hangar/shackle brackets. Note that components for lateral support may be bolted or welded to either the chassis (only) or the second unit body (only). – A service body upfit with a rear bumper attached via a bracket that ties the second unit body (SUB) to the frame must not exceed 6.35mm [0.25 in] gauge thickness. – For platform/stake body upfits only, second unit body (SUB) longitudinal rail supports must not exceed 6.35mm [0.25 in] gauge thickness nor exceed inertial properties of: Area: 1300mm2 [2.02 in2] Inertia about the lateral axis (lyy): 3.2E+6 mm4 Inertia about the vertical axis (lzz): 2.5E+5 mm4 – 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 B, C and D. 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. STATEMENTS OF CONFORMITY 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. 301.1 Canadian Requirements: This incomplete vehicle does not comply with CMVSS Standard 301.1, LPG Fuel System Integrity. Ford Motor Company makes no representation as to conformity with this Standard. 301.2 Canadian Requirements: This incomplete vehicle does not comply with CMVSS Standard 301.2, CNG Fuel System Integrity. Ford Motor Company makes no representation as to conformity with this Standard. 302 22 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. • All components covered by Standard 302 which are added to the incomplete vehicle by subsequent stage manufacturers meet the flammability requirements of the Standard. F-SERIES (February, 2012) 303 304 305 403 404 U.S. Requirements: The statement below is applicable to the Chassis Cab if the GVWR is 4536 kg [10,000 lb] or less: This incomplete vehicle does not comply with Standard 303, Fuel System Integrity of Compressed Natural Gas Vehicles. Ford Motor Company makes no representation as to conformity with this Standard. 1106 Canadian Requirements: The statements below are applicable to the Chassis Cab with GVW ratings of 4536 kg [10,000 lb] or less: These vehicles, when completed, 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. The statement below is applicable to the Chassis Cab: This incomplete vehicle does not comply with Standard 304, Compressed Natural Gas Fuel Container Integrity. Ford Motor Company makes no representation as to conformity with this Standard. The statement below is applicable to all incomplete vehicle types if the GVWR is 4536 kg [10,000 lb] or less: This incomplete vehicle does not comply with Standard 305, Electric-Powered Vehicles: Electrolyte Spillage and Electrical Shock Protection. Ford Motor Company makes no representation as to conformity with this Standard. The statement below is applicable to the Chassis Cab: This incomplete vehicle does not comply with Standard 403, Platform Lift Systems for Motor Vehicles. Ford Motor Company makes no representation as to conformity with this Standard. The statements below are applicable to the Chassis Cab with GVW ratings of more than 4536 kg [10,000 lb]: 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 fan clutch. The statement below is applicable to the Chassis Cab: This incomplete vehicle does not comply with Standard 404, Platform Lift Installations in Motor Vehicles. Ford Motor Company makes no representation as to conformity with this Standard. Part Parts and Accessories Necessary for Safe 393.67 Operation – Liquid Fuel Tanks The 40 gallon fuel tank supplied on a Ford Chassis Cab will conform to the Part 393.67, Parts and Accessories Necessary for Safe Operation – Liquid Fuel Tanks, if the fuel tank as provided by Ford Motor Company is not altered on the completed vehicle. Part The statement below is applicable to all incomplete 565 vehicle types except the Basic (Stripped Chassis): This vehicle, when completed, will conform to Part 565, Vehicle Identification Number, if the vehicle identification number mounted on the top of the instrument panel is not removed, altered, or modified and no actions are taken by the subsequent stage manufacturer that would obstruct the readability of the Vehicle Identification Number mounted on the top of the instrument panel. (February, 2012) Canadian Requirements: U.S. Requirements: F-SERIES 1106 23 STATEMENTS OF CONFORMITY 3/16 INCH BLIND RIVET * (12 REQ’ D) SUB !* *! ')) 616.0 [2.42] Builders Layout Book 75 *! R DUTY F-SERIES DELETE – WIDE FRAME STALLATION – GASOLINE ENGINE ARE LL AND SSING SCREWS (3 REQ’D) TORQUE 5.4 NEWTON METERS [48 8 IN. LB.] !' !' SECTION U VIEW P OUTBOARD SURFACE OF FRAME RAIL FRONT OF VEHICLE TO BACK OF CAB U 48 [1.9] SCREWS (3) REQ'D TORQUE 5.4 ± .9 Nm [48 ± 8 IN. LB.] 48 [1.9] MEMBER 87 [3.4] ATION MP ONNECT TO TION ON 78 [3.1] SUB FILL HOSE 100 [3.9] 48 [1.9] 48 78 [1.9] [3.1] PROTECTIVE SLEEVES ARE REQUIRED ON BOTH FILL AND VENT HOSE WHERE PASSING 3/16 OVER INCH FRAME. BLIND RIVET * (12 REQʼ D) 616.0 [2.42] #4 CROSSMEMBER RECIRCULATION HOSE CLAMP 90º FITTING - CONNECT TO QUICK CONNECTION ON VAPOR LINE 75 55 [2.2] OF BRACKET ULATION PHON DEVICE D FOR FLEX GINE LOCATED 2011 MODEL YEAR 48 [1.9] 81 [3.2] 48 [1.9] 81 [3.2] HOLES – 12 PLACES U POINT Z REFER TO CALIFORNIA FUEL VAPOR RECOVERY REQUIREMENT SECTION U VIEW P CAP - 1/4 TURN RECIRCULATION HOSE SCREWS (3 REQʼD) TORQUE 5.4ANTI ± .9 – SIPHON DEVICE NEWTON METERS REQUIRED FOR FLEX [48 ± 8 IN. LB.] FUEL ENGINE LOCATED IN HOSE INSTALL GROUND WIRE TO SOUND METAL ON THE FRAME. P RECIRCULATION STEEL TUBE THIS HOSE IS PREFORMED; INSTALL SHORT END TO THE METAL NECK AND CAP ASSEMBLY; TRIM THE LONG END AS REQUIRED. NOTES: WHEELBASE NOTES: (56 Inch CA) TORQUE ALL WORM GEAR DRIVEN HOSE CLAMPS (CA) BACK OF CAB TO CENTERLINE OF REAR AXLE TORQUE ALL WORM GEAR DRIVEN HOSE CLAMPS 3480 TO 4.8 ± 8 NEWTON METERS [43 ± 7 IN. LB.] Regular Cab TO 4.8 8 NEWTON METERS [43 7 IN. LB.] [137.0] 56 IN. CA [ ] DIMENSIONS ARE INCHES 4013 [ ] DIMENSIONS ARE INCHES Super Cab [158.0] WHEELBASE * NOT SUPPLIED BY FORD MOTOR COMPANY 4380 * NOT SUPPLIED BY FORD MOTOR COMPANY Crew Cab [172.4] 3480 Regular Cab [137.0] MODEL FUEL FILLER CUP LOCATION Super Cab 620 MIN [24.4] Crew Cab A 932 MAX [36.7] MIN 540 MIN A [21.3] C MAX 743 MAX [29.2] MIN 267 MIN C [10.5] D MAX 343 MAX [13.5] MIN CAD= Dimension from back of cab to rear axle MAX 4013 [158.0] 4380 [172.4] 620 [24.4] 932 [36.7] 540 [21.3] 743 [29.2] 267 of[10.5] 343 [13.5] Remove and discard the Ford installed fuel fill system components discardonly) the Ford installed fuelreuse ll system (provided forRemove shippingand purposes except save and the components (provided for shipping purposes only) except save and reuse the metal neck and cap assembly. metal neck and cap assembly. Use the new hoses, pipes, scuff guards, tie wraps, and clamps provided in the Usedunnage the new kit. hoses, pipes, scuff guards, tie wraps, and clamps provided the dunnage kit. The completed fuel fillinsystem must provide a 4 degree minimum, continuous, The downward slopefuel to the fuel tank. Additional mayminimum, completed ll system must providesupport a 4 degree be required continuous, to prevent hose saggingslope whichtocould cause spray or downward the fuel tank. Additional support may spitback during normal fueling operations. be required to prevent hose sagging which could cause spray or spitback normal fueling of operations. Do not extend the fuelduring fill system outboard the second unit body. Do not extend the fuel ll system outboard of the second unit body. FIGURE B – SUPER DUTY F-SERIES WIDE FRAME PICKUP BOX DELETE FUEL FILLER PIPE INSTALLATION (GASOLINE) STATEMENTS OF CONFORMITY STATEMENTS OF CONFORMITY 24 24 F-SERIES (February, 2012) NOTE - [ ] DIMENSIONS ARE INCHES. !) )! &(( 616.0 [2.42] Builders Layout Book 75 )! DUTY F-SERIES DELETE – WIDE FRAME TALLATION – GASOLINE ENGINE !& ON SCREWS (3 REQ’D) TORQUE 5.4 NEWTON METERS [48 8 IN. LB.] !& SECTION U TO BACK OF CAB RECIRCULATION HOSE CLAMP FRONT OF VEHICLE 90º FITTING - CONNECT TO QUICK CONNECTION ON VAPOR LINE U THIS HOSE IS PREFORMED; INSTALL SHORT END TO THE METAL NECK AND CAP ASSEMBLY; TRIM THE LONG 87 78 END AS REQUIRED. [3.4] [3.1] NECT TO ON ON 48 [1.9] SCREWS (3) REQ'D TORQUE 5.4 ± .9 Nm [48 ± 8 IN. LB.] 48 [1.9] FILL HOSE SUB 100 [3.9] 48 [1.9] 48 78 [1.9] [3.1] PROTECTIVE SLEEVES ARE 3/16 INCH REQUIRED ON BOTH FILL AND BLIND RIVET * (12 REQʼ D) VENT HOSE WHERE PASSING OVER FRAME. 616.0 [2.42] 75 55 [2.2] #4 CROSSMEMBER OF BRACKET ATION ON DEVICE FOR FLEX NE LOCATED 2011 MODEL YEAR VIEW P RE AND SING MBER 3/16 INCH BLIND RIVET * (12 REQ’ D) SUB 48 [1.9] 81 [3.2] RECIRCULATION HOSE HOLES – 12 PLACES 48 [1.9] 81 [3.2] POINT Z REFER TO CALIFORNIA FUEL VAPOR RECOVERY REQUIREMENT U CAP - 1/4 TURN - DIESEL (GREEN) INCLUDES ‘ULTRA LOW SULFUR DIESEL FUEL ONLY’ ON COVER OUTBOARD SURFACE OF FRAME RAIL SCREWS (3 REQʼD) TORQUE 5.4 ± .9 NEWTON METERS [48 ± 8 IN. LB.] SECTION U P VIEW P RECIRCULATION STEEL TUBE INSTALL GROUND WIRE TO SOUND METAL ON THE FRAME. NOTES: WHEELBASE MODEL (CA) BACK OF CAB TO OF REAR AXLE (56CENTERLINE Inch CA) Regular Cab 3480 [137.0] Super Cab 4013 [158.0] Crew CabRegular Cab 4380 [172.4] 56 IN. CA WHEELBASE Super Cab FUEL FILLER CUP LOCATION Crew Cab MIN A A C C D MAX MIN MAX MIN MIN MAX MAX MIN 620 [24.4] 932 [36.7] 540 [21.3] 743 [29.2] 267 [10.5] 343 [13.5] MIN MAX D MAX CA = Dimension from back of cab to rear axle 3480 [137.0] NOTES: TORQUE ALL WORM GEAR DRIVEN HOSE CLAMPS TORQUE ALL WORM GEAR DRIVEN HOSE CLAMPS TO 4.8 8 NEWTON METERS [43 7 IN. LB.] TO 4.8 ± 8 NEWTON METERS [43 ± 7 IN. LB.] [ ] DIMENSIONS ARE INCHES [ ] DIMENSIONS ARE INCHES * NOT SUPPLIED BY FORD MOTOR COMPANY * NOT SUPPLIED BY FORD MOTOR COMPANY 4013 [158.0] 4380 [172.4] 620 [24.4] 932 [36.7] 540 [21.3] 743 [29.2] 267 [10.5] 343 of [13.5] andFord discard the Ford fuel ll system components Remove andRemove discard the installed fuel installed fill system components for shipping purposes only) and except save (provided for(provided shipping purposes only) except save reuse theand reuse the metal and cap assembly. metal neck and capneck assembly. the pipes, new hoses, pipes, scuff guards, tieclamps wraps, and clamps Use the newUse hoses, scuff guards, tie wraps, and provided in the provided in the dunnage kit. dunnage kit. Thefuel completed fuel ll system provideminimum, a 4 degree minimum, The completed fill system must providemust a 4 degree continuous,slope downward slope to the fuel tank. Additional continuous, downward to the fuel tank. Additional support may support may be required to hose sagginghose which could cause beprevent required to prevent sagging which spray could or cause spray or spitback during normal fueling operations. spitback during normal fueling operations. Do not extend fill system outboard of the secondofunit Dothe notfuel extend the fuel ll system outboard thebody. second unit body. FIGURE C – SUPER DUTY F-SERIES WIDE FRAME PICKUP BOX DELETE FUEL FILLER PIPE INSTALLATION (DIESEL) STATEMENTS OF CONFORMITY F-SERIES (February, 2012) 24 25 STATEMENTS OF CONFORMITY NOTE - [ ] DIMENSIONS ARE INCHES. OUTBOARD SURFACE OF FRAME RAIL FRONT OF VEHICLE MAINTAIN 25.4 [1.00] MINIMUM CLEARANCE BETWEEN FUEL FILLER SYSTEM AND THE SPRING AND SPRING SHACKLE IN ALL DYNAMIC POSITIONS. PROTECTIVE SLEEVES ARE REQUIRED ON BOTH FILL AND VENT HOSE AT FRAME OPENING. TO BACK OF CAB GAS ONLY. WHITE PAINT DOT ON VENT HOSE INDICATES FLAME ARRESTOR REQUIRED FOR FLEX FUEL ENGINES. FLAME ARRESTOR MUST BE IN CONTACT WITH METAL TUBE. CAP - 1/4 TURN - DIESEL (GREEN) INCLUDES ‘ULTRA LOW SULFUR DIESEL FUEL ONLY’ ON COVER VIEW P INSTALL SHORT END TO THE METAL NECK AND CAP ASSEMBLY; TRIM THE LONG END AS REQUIRED. TOP OF FRAME RAIL $ ( (" INSTALL GROUND WIRE TO SOUND METAL ON THE FRAME. ( "( STEEL TUBE (DO NOT TRIM) USE PROVIDED TIE STRAPS TO SECURE FILL TO VENT HOSES (2 PLACES) ( "( GAS ONLY. FLAME ARRESTOR IN STEEL FILL TUBE; REQUIRED FOR FLEX FUEL ENGINE. ( ## AFT OF AXLE FILL SYSTEM CL OF FILL PIPE ASY. AND BRACKET ( ( $ #4 C/MEMBER OUTBOARD SURFACE OF FRAME RAIL GAS ONLY. WHITE PAINT DOT ON VENT HOSE INDICATES FLAME ARRESTOR REQUIRED FOR FLEX FUEL ENGINES. FLAME ARRESTOR MUST BE IN CONTACT WITH METAL TUBE. TO BACK OF CAB INSTALL GROUND WIRE TO SOUND METAL ON THE FRAME. CAP - 1/4 TURN - DIESEL (GREEN) INCLUDES ‘ULTRA LOW SULFUR DIESEL FUEL ONLY’ ON COVER FRONT OF VEHICLE DO NOT TRIM THIS END THIS HOSE IS PREFORMED: INSTALL SHORT END TO THE METAL NECK AND CAP ASSEMBLY; TRIM THE LONG END AS REQUIRED. USE PROVIDED TIE STRAPS TO SECURE FILL TO VENT HOSES (2 PLACES) STEEL TUBE (DO NOT TRIM) PROTECTIVE SLEEVES ARE REQUIRED ON BOTH FILL AND VENT HOSE AT FRAME OPENING. VIEW P TOP OF FRAME RAIL AT CL OF FILL PIPE GAS ONLY. FLAME ARRESTOR IN STEEL FILL TUBE; REQUIRED FOR FLEX FUEL ENGINE. MIDSHIP FUEL FILL SYSTEM (OPTIONAL ON CHASSIS CAB) NOTES: TORQUE ALL WORM GEAR DRIVEN HOSE CLAMPS TO 4.8 8 NEWTON METERS [43 7 IN. LB.] [ ] DIMENSIONS ARE INCHES * NOT SUPPLIED BY FORD MOTOR COMPANY Remove and discard the Ford installed fuel ll system components (provided for shipping purposes only) except save and reuse the metal neck and cap assembly. Use the new hoses, pipes, scuff guards, tie wraps, and clamps provided in the dunnage kit. The completed fuel ll 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 ll system outboard of the second unit body. The installation of Tube Extension F81A-9B149-HA will permit the location aft-of-axle fuel ll housing to be no further rearward than the of the ll hose as it passes through the frame. FIGURE A – SUPER DUTY F-SERIES NARROW FRAME CHASSIS CAB FUEL FILLER PIPE INSTALLATION FIGURE D – SUPER DUTY F-SERIES NARROW FRAME CHASSIS CAB FUEL FILLER PIPE INSTALLATION STATEMENTS OF CONFORMITY 23 26 STATEMENTS OF CONFORMITY F-SERIES (February, 2012) FRONT OF VEHICLE VIEW P 3/16 INCH BLIND RIVET * (12 REQ’ D) SUB 616.0 [2.42] 75 SECTION U VIEW P VIEW P FRONT OF VEHICLE NOTES: TORQUE ALL WORM GEAR DRIVEN HOSE CLAMPS TO 4.8 8 NEWTON METERS [43 7 IN. LB.] Remove and discard the Ford installed urea fill system components (provided for shipping purposes only) except save and reuse the metal neck and cap assembly. [ ] DIMENSIONS ARE INCHES * NOT SUPPLIED BY FORD MOTOR COMPANY Use the new hoses, pipes, scuff guards, tie wraps, and clamps provided in the dunnage kit. The completed urea fill system must provide a 2 degree minimum, continuous, downward slope to the urea tank. Additional support may be required to prevent hose sagging which could cause spray or spitback during normal filling operations. Do not extend the urea fill system outboard of the second unit body. FIGURE E – SUPER DUTY F-SERIES UREA FILLER PIPE INSTALLATION F-SERIES (February, 2012) 27 STATEMENTS OF CONFORMITY CANADIAN VEHICLES (Vehicles to be completed for sale or use in Canada) VEHICLE IDENTIFICATION 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. Refer to the “Vehicle Description” section of this manual for additional information. Incomplete vehicles produced by Ford Motor Company may require optional Prep Packages or trim codes for certain applications listed on the Completed Vehicle Types chart on page 7. • 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. DAYTIME RUNNING LAMP (DRL) Compliance representations for CMVSS 108, Lighting and CMVSS 108.1, Headlamps, are in the “Statements of Conformity” section of this manual. • Electrical grounds on all components must be retained. • Metallic components installed on the body or chassis must be grounded to the chassis. CANADIAN RADIO FREQUENCY INTERFERENCE (RFI) INFORMATION • Electrical circuits added to the vehicle must not be installed near the high voltage 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. 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-C108.4‑06, Limits and Methods of Measurement.” Violation of these regulations is punishable by fine or imprisonment. This Fordbuilt 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. However, 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. • 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. Additional guidance for installing two-way mobile radios can be found via the web at www.fordemc.com/docs/download/ Mobile_Radio_Guide.pdf. 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. CANADIAN VEHICLES 28 F-SERIES (February, 2012) EMISSION CERTIFICATION INFORMATION CAUTION: IMPORTANT: For purposes of Government Regulation, a body builder, installer, or any subsequent manufacturer may be considered a manufacturer. U.S.: 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.” IMPORTANT: It is the responsibility of the body builder, installer, or subsequent stage manufacturer to ensure that the maximum completed vehicle curb weight and frontal area specified by Ford are not exceeded. If these restrictions are exceeded, or if the vehicle is modified such that it will not comply with applicable emission standards throughout its useful life, the body builder, installer, or subsequent stage manufacturer will be considered a manufacturer for purposes of complying with U.S. Federal, California, or Canadian exhaust and evaporative emission requirements, and Federal fuel economy standards, labeling, and certain other requirements. 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. Failure 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. HIGH ALTITUDE REQUIREMENTS United States Environmental Protection Agency regulations do not contain unique emission certification requirements for trucks that will be sold or delivered to customers for principal use above 1,219 m [4,000 ft.]. EMISSION CONTROL HARDWARE FRONTAL AREA AND WEIGHT RESTRICTIONS: 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. It is 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. The following Frontal Area and Weight Restrictions apply to the completed vehicle: • 6.2L with Pickup Box Delete option [NOTE: Export vehicles use U.S. emissions] – Maximum frontal area - 6.69 m2 [72.0 ft2] (SRW/DRW) – DRW maximum completed curb weight - 4809 kg [10,603 lb] 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 subsequent manufacturer to properly label vehicles for the market in which they are sold. EXTERIOR NOISE Note: Frontal area requirement includes the cab and second unit body. The completed vehicle must meet Maximum UVW weight for a GVWR of 4536 kg [10,000 lb] or less. (February, 2012) 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 • 6.7L with Pickup Box Delete option [NOTE: Euro II /Euro III emissions not affected by restrictions] – GVWR less than or equal to 4536 kg [10,000 lb] Maximum frontal area - 3.76 m2 [40.5 ft2] – GVWR greater than 4536 kg [10,000 lb] Maximum frontal area - 4.74 m2 [51.0 ft2] – DRW maximum completed curb weight - 4763 kg [10,500 lb] F-SERIES 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. 29 New vehicles which have a gross vehicle weight rating in excess of 4536 kg [10,000 lb], include a partially or wholly enclosed operator’s compartment, and are manufactured for EMISSION CERTIFICATION INFORMATION 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). except Basic (Stripped) Chassis (which is not equipped with an instrument panel), the MIL is Ford-installed and operational in the instrument panel. OZONE DEPLETING SUBSTANCE (ODS) TAMPERING WITH NOISE CONTROLS The Clean Air Act of 1990, Section 611 requires any product (i.e., completed vehicle) containing or manufactured with any Class I Ozone Depleting Substance on, or after May 15,1993 must be identified with a “clearly and conspicuously attached label.” 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. Ford Motor Company has eliminated Class I ODS from its manufacturing processes. All Ford Truck incomplete vehicles will not have Class I 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 I ODS or if the manufacturer used a Class I ODS in the manufacturing of the product. In the case where Ford Motor Company provides a label saying the incomplete vehicle contains a Class I 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. 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 cleaner element. VEHICLE EMISSION CONTROL INFORMATION LABEL To meet United States Environmental Protection Agency regulations, the Vehicle Emission Control Information (VECI) label 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. • 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. When the VECI label is supplied, but not attached to the vehicle, it must be permanently mounted in a readily 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), & (iii), as applicable. 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 Guide 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 lb], 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. CALIFORNIA HEAVY-DUTY DIESEL ENGINE IDLING REQUIREMENTS The California Air Resources Board approved a regulatory measure, effective January 1, 2008, to further reduce emissions of toxics and criteria pollutants by limiting idling of new diesel engine trucks with a gross vehicle weight rating (GVWR) greater than 14,000 pounds, with vocational exemptions for certain buses, school buses, recreational vehicles, medium duty vehicles, military tactical vehicles and authorized emergency vehicles, as defined in various California Vehicle Code sections. The regulation primarily requires manufacturers of new California certified 2008 and subsequent model-year diesel engines in these trucks to either incorporate a system that automatically shuts the engine down after five minutes of continuous idling or to meet clean-idle emission requirements. EVAPORATIVE EMISSIONS All 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 trucks manufactured by Ford Motor Company comply with these requirements. 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. A Super Duty F-Series diesel engine incomplete vehicle with a GVWR greater than 14,000 pounds, as manufactured by Ford Motor Company to be sold as a California emission labeled vehicle, has a “Clean Idle” engine decal certifying compliance to California diesel engine idle emission regulations. Should modifications be made by a final stage vehicle manufacturer to the diesel engine emissions system on vehicles with a GVWR greater than 14,000 pounds, compliance to California clean-idle requirements may be compromised; it is the responsibility of the final stage manufacturer to comply with California emission regulations. MALFUNCTION INDICATOR LIGHT (MIL) The “Malfunction Indicator Light” is used to indicate malfunctions of the engine’s emission control system and certain powertrain emissions-related components. For all incomplete vehicles, 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 EMISSION CERTIFICATION INFORMATION 30 F-SERIES (February, 2012) installed as shown in Figures B, C and D will comply with the “Specifications For Fill Pipes and Openings of Motor Vehicle Fuel Tanks” referenced in Title 13 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” (Figures B, C and D illustrate 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. Company 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. CALIFORNIA MOTOR VEHICLE EMISSION CONTROL LABEL 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. To meet California emission certification regulations, the Vehicle Emission Control Information (VECI) 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 lb] 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 without disconnection, obstruct the label. Additional RFI information is contained in the “Canadian Vehicles” section 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 be modified or changed in a 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. Completed vehicles for retail sale in California require a machine-readable Vehicle Identification Number (VIN) barcode 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. Additional guidance for installing two-way mobile radios can be found via the web at www.fordemc.com/docs/download/ Mobile_Radio_Guide.pdf. • All incomplete vehicles except Basic (Stripped) Chassis type vehicles will conform to this standard. For the VECI and VIN labels, sufficient clearance shall be provided to use a non-contact bar-code Reading Wand. For the VECI 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 F-SERIES (February, 2012) 31 EMISSION CERTIFICATION INFORMATION SUPPLEMENTS SUPPLEMENTS 32 F-SERIES (February, 2012) 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. The Ford Truck Body Builders Layout Book can be accessed via the web at www.fleet.ford.com/truckbbas under the “Publications” tab. FORD SERVICE PUBLICATIONS Many Ford Service Publications pertain to specific Model Year and vehicle types. Ford Service Publications are available by subscription via the web at www.motorcraft.com. 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 & Vacuum Trouble Shooting Manual • Ford Wiring Diagram FORD TRUCK BODY BUILDER ADVISORY SERVICE The Ford Truck Body Builder Advisory Service may be consulted regarding information contained in this manual. Call toll free 877-840-4338 or e-mail via the web at www.fleet.ford.com/truckbbas under the “Contact Us” tab. F-SERIES (February, 2012) REFERENCE INFORMATION FORD MOTOR COMPANY THE AMERICAN ROAD DEARBORN, MI 48121 FORD MOTOR COMPANY OF CANADA LIMITED THE CANADIAN ROAD OAKVILLE, ONTARIO L6J 5E4