Ford - Excursion - Workshop Manual - 1999 - 2005

UNDERCARRIAGE INSTALLATION INSTRUCTIONS UNDERCARRIAGE 31219 HARDWARE KIT 61337 FOR MODELS: FORD F-250/350 SUPER DUTY PICKUP (1999-2005) FORD F-450/550 SUPER DUTY PICKUP (1999-2005) FORD EXCURSION (2000-2005) C 64046 7/12/05 INSTALLATION INSTRUCTIONS 1. Remove the plastic bumper fascia and either notch it for reinstallation or remove it permanently from the vehicle. 2. Remove the outside bumper bracket from each side. Retain A label identifying the undercarriage assembly part number and push beam part number is applied to the rear of the push beam. 16 P/N 30042 PUSH BEAM P/N 30037 hardware. NOTE: The blocker beam needs to be removed on 2005 F-250’s/F-350’s and all models for 1999-2004 years for the undercarriage to be installed at the proper height. See attached TSB and recommended pushbeam height to the left. 2005 original bumper brackets can be used on models that do not remove the blocker beam. 3. Position hanger plates (Ref 7 & 8) with the two holes/slots on the outside of the truck frame rail. Secure rear bushing with bolts (Ref 14), washers (Ref 15) and tab nuts (Ref 16). NOTE: Use the access hole in the truck frame to position the tab nut. Finger tighten the fasteners until all undercarriage parts are in place. 4. Position the rodnut (Ref 19) through the front of the truck frame The recommended push beam height for this undercarriage assembly is 12-1/2" from the center of the push beam to level ground. DO NOT exceed 14-1/2" in height for this undercarriage. rail, above the tow hooks, with the front access hole. Secure rod nut to front hole in hanger plates with bolts (Ref 17) and washers (Ref 15). NOTE: It may be necessary to adjust the bumper height to accommodate the rodnut installation. NOTE: The fog lamp harness (if applicable) is routed close to the drivers side hanger plate, do not pinch wire between the hanger plate and truck frame. WARNING: Always perform vehicle undercarriage installations with the keys removed from the vehicle’s ignition. Properly tag the ignition switch to alert others work is being performed on the vehicle. 5. Mount the push beam (Ref 1) square with the bottom of each Most newer trucks are equipped with driver and passenger’s side air bags. DO NOT remove, disable, or reposition any sensory equipment related to the safe operation of the air bags. 6. Level the pushbeam with the floor and torque the hanger plate ALWAYS follow the vehicle manufacturer’s recommendations for installing snowplowing equipment. FAILURE TO COMPLY WITH THE ABOVE WARNINGS MAY RESULT IN SERIOUS INJURY OR DEATH. CAUTION: If your vehicle is equipped with oversize tires, they may come into contact with the undercarriage hanger plates when turning the vehicle. Adjust steering stops if possible. hanger plate using bolts (Ref 11), washers (Ref 12) and nuts (Ref 13). Tighten the pushbeam hardware to torque specifications. hardware. 7. Mark a center point with an 11/16” drill through the top, center bushing on each hanger plate. Drill a pilot hole through the center mark with a smaller bit, and then an 11/16” hole completely through the frame wall on each side of the vehicle. NOTE: Use caution when drilling into the frame, hydraulic or electrical lines may be located inside. 8. Secure top, center hole through bumper brackets, IF blocker beam removed (Ref 9 & 10) with bolts (Ref 17), washers (Ref 15) and rodnut (Ref 18) and tighten to torque specifications. NOTE: Position rodnut through the front of the truck frame rails, above the tow hooks. 9. Replace the bumper fascia, if notched with existing hardware. If your vehicle is equipped with a Blocker Beam™, review the attached Technical Service Bulletin. 10. Position the Light Tower into the mount pockets on the push beam. Each pocket has a lock pin that secures both light tower arms. Pull out and twist each ring handle to temporarily unlock the pins. Place the light tower into the pockets and relock the pins. Mount each Plow Headlight to the light tower with the hardware kit provided. 11. Plug the connectors from the snowplow headlights into the connectors on the vehicle wire harness. Adjust both lights with the plow in the raised position. 2 OF 4 64046-C (31219) 7/12/05 UNDERCARRIAGE PARTS 10 20 19 5 18 62 7 4 1 8 3 16 17 13 15 9 11 REF 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 PN 31219 61337 31105 63161 61269 61309 61000 40079 31221 31220 31229 31230 61018 61026 61020 61437 61064 31112 61253 31181 31109 61376 QTY 1 1 1 1 1 2 2 2 1 1 1 1 8 16 8 2 6 2 4 2 2 4 14 12 DESCRIPTION Asm, Undercarriage Kit, Hardware Ford UC Weldment, Push Beam 3 x 5 x 46 Decal, Push Beam 2-1/4" x 9-3/4" Label, Ford Blocker Beam™ 3” x 6” Ring, Standard Split, 1.48" O.D Spring, Draw Latch Lock Pin Pin, 3/8" DIA. x 1-3/4" SS Weldment, Hanger Plate Pass. Weldment, Hanger Plate Drivers’ Plate, Bumper Bracket Drivers’ Plate, Bumper Bracket Pass. Screw, 1/2-13 x 2” HHCS GR8 YZ Washer, 1/2” USS Hardened Nut, 1/2-13 Top Lock Z Screw, 5/8-11 x 3-1/2” HHCS GR8 YZ Washer, 5/8" SAE Hardened Weldment, 5/8-11 Nut w/ welded tab and washer Screw, 5/8-11 x 5-1/2” HHCS GR8 YZ Rodnut, 5/8-11 X 15” Rodnut, 5/8-11 X 10” Cap, 3/8” I.D. X 1” Blk Vinyl NOTES INCLUDES 1-20 INCLUDES 11-20 If necessary If necessary Note: The reference numbers listed identify parts shown in the illustration above. These numbers are specific to this illustration only. Always review the part number given for proper component identification. Blizzard Corporation reserves the right, under its Continuous Improvement Policy, to change construction or design details and furnish equipment when so altered without reference to illustrations or specifications. 64046-C (31219) 7/12/05 3 OF 4 HEADLIGHT CONVERSION HARNESS GUIDE VEHICLE APPLICATION 2005 F-250/350/450/550 SUPER DUTY PICKUP HEADLIGHT CONNECTOR HEADLIGHT DESCRIPTION HEADLIGHT NUMBERS CONVERSION HARNESS DUAL RECTANGULAR 9008 * HALOGEN LAMP DUAL 6014, H6024, 2B/2D RECTANGULAR/DUAL H6059, 6052, 62220 2000-2005 FORD EXCURSION ROUND HEADLAMP H6054, HP6054 1992-2005 F-250/350 SUPER DUTY PICKUP DUAL RECTANGULAR HB5 COMPOSITE 9007, H9007 62222 HALOGEN DUAL RECTANGULAR 1999-2005 FORD F-450/550 SUPER DUTY HB5 9007, H9007 62222 COMPOSITE PICKUP HALOGEN Note: Headlight conversion harness kits are not included with undercarriages. All headlight conversion harness kits sold separately. *NOTE: These vehicles do NOT require a separate conversion harness. Our new lighting harness plugs directly into these lights and the truck harness. H13 TORQUE SPECIFICATIONS (For reference only) Grade Identification Marking for J429-Grade 5 Bolt SAE J429 – Grade 5 Clamp Loads Tightening Torque (lbs) “Lubricated” “Dry” 1/4-20 2,000 6 ft-lbs 8 ft-lbs 5/16-18 3,350 13 ft-lbs 18 ft-lbs 3/8-16 4,950 23 ft-lbs 31 ft-lbs 7/16-14 6,800 37 ft-lbs 50 ft-lbs 1/2-13 9,050 57 ft-lbs 75 ft-lbs 9/16-12 11,600 82 ft-lbs 109 ft-lbs 5/8-11 14,500 113 ft-lbs 151 ft-lbs 3/4-10 21,300 200 ft-lbs 266 ft-lbs 7/8-9 29,435 321 ft-lbs 430 ft-lbs 1-8 38,600 482 ft-lbs 640 ft-lbs Nominal Thread Size Grade Identification Marking for Metric-Grade 8.8 Bolt Metric Class 8.8 Diameter Clamp Loads Tightening Torque (mm) (Pounds) “Lubricated” “Dry” 5 1,389 3 ft-lbs 5 ft-lbs 6 1,965 6 ft-lbs 8 ft-lbs 7 2,826 10 ft-lbs 13 ft-lbs 8 3,579 14 ft-lbs 19 ft-lbs 10 5,672 28 ft-lbs 37 ft-lbs 12 8,243 49 ft-lbs 65 ft-lbs 14 11,246 77 ft-lbs 103 ft-lbs 16 15,882 125 ft-lbs 167 ft-lbs 18 19,423 172 ft-lbs 229 ft-lbs 20 24,784 244 ft-lbs 325 ft-lbs 4 OF 4 Grade Identification Marking for J429-Grade 8 Bolt SAE J429 – Grade 8 Tightening Torque Clamp Loads (lbs) “Lubricated” “Dry” 1/4-20 2,850 9 ft-lbs 12 ft-lbs 5/16-18 4,700 18 ft-lbs 25 ft-lbs 3/8-16 6,950 32 ft-lbs 44 ft-lbs 7/16-14 9,600 53 ft-lbs 70 ft-lbs 1/2-13 12,800 80 ft-lbs 107 ft-lbs 9/16-12 16,400 115 ft-lbs 154 ft-lbs 5/8-11 20,300 159 ft-lbs 211 ft-lbs 3/4-10 30,100 282 ft-lbs 376 ft-lbs 7/8-9 41,550 454 ft-lbs 606 ft-lbs 1-8 54,540 680 ft-lbs 900 ft-lbs Nominal Thread Size Grade Identification Marking for Metric-Grade 10.9 Bolt Metric Class 10.9 Diameter Tightening Torque Clamp Loads (mm) (Pounds) “Lubricated” “Dry” 5 1,987 5 ft-lbs 7 ft-lbs 6 2,812 8 ft-lbs 11 ft-lbs 7 4,044 14 ft-lbs 19 ft-lbs 8 5,121 20 ft-lbs 27 ft-lbs 10 8,116 40 ft-lbs 53 ft-lbs 12 11,796 70 ft-lbs 92 ft-lbs 14 16,092 111 ft-lbs 148 ft-lbs 16 21,970 173 ft-lbs 231 ft-lbs 18 26,868 238 ft-lbs 317 ft-lbs 20 34,284 338 ft-lbs 450 ft-lbs 64046-C (31219) 7/12/05 TECHNICAL SERVICE BULLETIN All Blizzard Snowplows Issued November 27, 2000 This Technical Service Bulletin (TSB) has been issued for all 2001 and newer model year Ford Super Duty F-250, F-350, F-450, and F-550 snowplow undercarriage installations. These vehicles (starting in October 2000) contain a front BLOCKER BEAM™ as standard equipment. This beam is designed to prevent a car from sliding beneath the higher riding front truck bumper during a frontal collision. WARNING: Removal of the Blocker Beam™, without the installation of the snowplow undercarriage, may affect air bag deployment in a crash. The vehicle should not be operated without either the snowplow undercarriage or the Blocker Beam™ in place. Should a Blocker Beam™ be removed from the front of a Ford Super Duty truck to accommodate the installation of a snowplow, it should be tagged, packaged and supplied to the customer with the completed vehicle, along with reinstallation instructions (see diagram). 1. To install your Blizzard undercarriage on a Ford F-250, F-350, F-450 or F-550 vehicle, first tag the BLOCKER BEAM™ that is to be removed. This tag will serve as a reminder to re-install the beam should the customer ever remove the snowplow undercarriage. Note: Tags are being added to all applicable undercarriage kits as a running change. Contact Customer Service toll free at 1-888- 680-8600 should you wish to receive tags for undercarriages in inventory. 2. Loosen the Blocker Beam™ from both SPRING BRACKETS by removing the three fasteners at each end of the Blocker Beam™. Re-attach the fasteners to either end of the Blocker Beam™ for storage. BLOCKER BEAM™ TAG DRIVER’S SIDE ILLUSTRATION WARNING: Replace Ford® Blocker Beam™ using original vehicle hardware should you remove your snowplow undercarriage. Failure to replace Blocker Beam™, without the installation of a snowplow undercarriage, may affect airbag deployment in a crash. The vehicle should not be operated without either the snowplow undercarriage or Blocker Beam™ in place. SPRING BRACKET Note: This notice affects 2001 and newer Ford® Super Duty F-250, F-350, F-450 and F-550 vehicles. 95 Airpark Boulevard Calumet, MI 49913 [888] 680-8600 www.blizzardplows.com 1185-11-00 REV 05/02 PUSH BEAM LABEL WARNING: Replace Ford® Blocker Beam™ using original vehicle hardware should you remove your snowplow undercarriage. Failure to replace Blocker Beam™, without the installation of a snowplow undercarriage, may affect airbag deployment in a crash. The vehicle should not be operated without either the snowplow undercarriage or Blocker Beam™ in place. Note: This notice affects 2001 and newer Ford® Super Duty F-250, F-350, F-450 and F-550 vehicles. REMOVE THESE FASTENERS BLOCKER BEAM™ 95 Airpark Boulevard Calumet, MI 49913 [888] 680-8600 www.blizzardplows.com BLZ 1031 95 AIRPARK BOULEVARD CALUMET, MI 49913 1183-11-00 REV 07/02 [906] 482-5555 [906] 482-5445 FAX