Ford 6C34-19A268-BA Automobile User Manual

DO NOT DESTROY: THIS MANUAL IS REQUIRED BY
LAW. KEEP UNTIL THE VEHICLE IS COMPLETED BY
THE FINAL STAGE MANUFACTURER.
2006
SUPER DUTY F-SERIES
INCOMPLETE VEHICLE MANUAL
Incomplete Vehicle Types
For This Manual
Super Duty F-Series
Chassis Cab
Ð
March, 2005
6C34-19A268-BA
U.S. & CANADIAN MOTOR VEHICLE SAFETY STANDARDS
(Application By Vehicle Type)
Standard
Number
101
102
103
104
105
106
108
108.1
110
111
113
114
115
116
118
119 (9)
120
124
201
202
203
204
205
206
207
208
209
210
210.1
210.2
212
213
213.4
214
219
225
301
302
PART
565.4
1106
Title of Standard
Control Location, Identification and Illumination
Transmission Shift Lever Sequence, Starter Interlock &
Transmission Braking Effect
Windshield Defrosting & Defogging Systems
Windshield Wiping and Washing Systems
Hydraulic and Electric Brake Systems
Brake Hoses
Lamps, Reflective Devices & Associated Equipment
Headlamps (Canada only)
Tire Selection and Rims (U.S. only)
Rearview Mirrors
Hood Latch Systems
Theft Protection
Vehicle Identification Number (Canada only)
Hydraulic Brake Fluids
Power Operated Window, Partition, and Roof Panel Systems
New Pneumatic Tires for Vehicles Other Than Passenger Cars
Tire Selection and Rims for Motor Vehicles Other Than Passenger Cars
Accelerator Control Systems
Occupant Protection in Interior Impact
Head Restraints
Impact Protection for the Driver from the Steering Control System
Steering Control Rearward Displacement
Glazing Materials
Door Locks and Door Retention Components
Seating System
Occupant Crash Protection
Seat Belt Assemblies
Seat Belt Assembly Anchorages
User-Ready Tether Anchorages for Restraint Systems
(Canada only)
Lower Universal Anchorage Systems for Restraint Systems and
Booster Cushions (Canada only)
Windshield Mounting
Child Restraint Systems (U.S. only)
Built-In Child Restraint System & Built-In Booster Cushions (Canada only)
Side Impact Protection
Windshield Zone Intrusion
Child Restraint Anchorage Systems (U.S. only)
Fuel System Integrity
Flammability of Interior Materials
Vehicle Identification Number (U.S. only)
Noise Emissions (Canada only)
(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 [5,500 lb] or
less.
(4) Applicable to vehicles with a GVWR of 2722 kg [6,000 lb] or
less.
(5) Injury criteria applicable to vehicles with a GVWR of 3856 kg
[8,500 lb] or less and an unloaded vehicle weight of 2495 kg
[5,500 lb] or less.
Vehicle Type
Truck
MPV
X
X
X
X
X
X
X
X
X
X
X
X
X(2)
X
X
X(2)
X
X
X
X
X
X
X
X
X
X
X(2)
X
X
X(2)
X
X
X(2)
X(2)
X(2)
X(3)
X
X
X
X(5)(6)
X
X
X
X
X(2)
X(2)
X(2)
X(3)
X
X
X
X(5)(6)
X
X
X
X
X
X(2)
X
X
X(2)(7)
X(2)
X(8)
X(2)
X
X
X
X(2)
X
X
X(2)(7)
X(2)
X(8)
X(2)
X
X
X
X
Equipment
(1)
X
X
X
X
X
X
X
X
X
X
X
(6) Injury criteria is optional on Walk-in Van-Type Trucks, Motor
Homes, vehicles manufactured for operation by persons with
disabilities, etc.
(7) Dynamic Performance Requirements apply to MPV, truck or a
bus with a GVWR of 2722 kg [6,000 lb] or less.
(8) Tether anchors and latch/ISO Fix lower anchors that are
installed voluntarily or by regulation must comply with this
Standard.
(9) Canadian 119 requirements are found in the Motor Vehicle Tire
Safety Standards.
U.S. & CANADIAN MOTOR VEHICLE SAFETY STANDARDS
F-SERIES (March, 2005)
INTRODUCTION
Information in this manual is furnished pursuant to United States and Canadian
safety regulations or, in some cases where the information is not required by
regulation, is furnished for the convenience of intermediate or final stage vehicle
manufacturers. Incomplete vehicles manufactured for sale or importation into
the U.S., are specially equipped for the United States. The descriptions and
statements contained in the manual relate only to motor vehicle safety standards
issued under the National Traffic and Motor Vehicle Safety Act of 1966 as
amended.
An incomplete vehicle manufactured for sale or importation into Canada is
specially equipped for Canada. This vehicle conforms to the applicable Canadian
Motor Vehicle Safety Standards (CMVSS) on the 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”, page 25.
The Emission Certification Information section of this manual contains
information regarding conformity to exhaust emission regulations of the United
States, Canada, and the State of California and fuel economy regulations of the
United States.
This manual should not be relied upon with respect to compliance with any
regulation of the Federal Highway Administration or regulations issued pursuant
to the Occupational Safety and Health Act (OSHA) or any other federal,
state, or local regulations governing the performance or construction of motor
vehicles (except for those requirements shown under the heading “Unleaded
Gasoline Label,” page 26; “Warranty and Maintenance,” page 27; and “Emission
Control Information Label,” page 27). It is the responsibility of the final stage
manufacturer to determine applicability and comply with any federal, state, or
local requirements not detailed in this manual.
IMPORTANT:
UNITED STATES VEHICLES
Ford Motor Company has endeavored, whenever possible, to state the specific conditions
under which an incomplete vehicle may be completed to conform to each applicable
Federal Motor Vehicle Safety Standard. These specific statements are intended to aid
subsequent stage manufacturers in avoiding instances of inadvertent 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 Section
567.5 of Title 49, Code of Federal Regulations, that the completed vehicle conforms to
all applicable Federal Motor Vehicle Safety Standards and that all applicable federal,
state and California emission/noise standards are conformed with.
Ford Motor Company does not make any representation as to the appropriateness
of modifications for any particular application other than expressly stated herein.
Intermediate and final stage manufacturers must exercise proper engineering judgment
to determine if a modification is appropriate for their specific application.
IMPORTANT:
UNITED STATES AND CANADIAN VEHICLES
Alterations to an incomplete vehicle by someone other than Ford Motor Company, or
damage in transit, may affect compliance statements that are furnished in this manual,
or representations that are printed on the label that may be affixed to a vehicle.
F-SERIES (March, 2005)
1
INTRODUCTION
TABLE OF CONTENTS
U.S. & 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 ................................................... 8-24
CANADIAN VEHICLES
Vehicle Identification ........................................................................ 25
Daytime Running Lamp (DRL) ......................................................... 25
Canadian Radio Frequency Interference (RFI) Information ............. 25
EMISSION CERTIFICATION INFORMATION
Frontal Area and Weight Restrictions ...............................................26
High Altitude Requirements ..............................................................26
Emission Control Hardware ..............................................................26
Unleaded Gasoline Label ............................................................... 26
Exterior Noise ................................................................................. 26
Tampering with Noise Controls .........................................................27
Warranty and Maintenance ............................................................. 27
Evaporative Emissions..................................................................... 27
Malfunction Indicator Light (MIL) ..................................................... 27
Power Take-Off Circuit ......................................................................27
Ozone Depleting Substance (ODS) ..................................................27
Emission Control Information Label ................................................. 27
California Fuel Vapor Recovery ....................................................... 27
California Motor Vehicle Emission Control Label ............................. 28
Radio Frequency Interference (RFI) ................................................ 28
REFERENCE INFORMATION .............................................. Back Cover
TABLE OF CONTENTS
2
F-SERIES (March, 2005)
DEFINITIONS
The following definitions are from Title 49, Code of Federal Regulations (49CFR), Parts 567.3, 568.3 and 571.3
where noted. Canadian definitions are from Canadian Motor Vehicle Safety Regulations (CMVSR), Section
2(1), and are in italics. Ford Motor Company definitions are for the purpose of this manual only. Some terms
are followed by an abbreviation that is used throughout this manual.
Designated Seating Position – any plan view location
capable of accommodating a person at least as large as a
5th percentile adult female, if the overall seat configuration
and design and vehicle design is such that the position is
likely to be used as a seating position while the vehicle is in
motion, except for auxiliary seating accommodations such
as temporary or folding jump seats. Any bench or split-bench
seat in passenger car, truck, or multipurpose passenger
vehicle with a GVWR less than 4,536 kilograms (10,000
pounds), or having greater than 50 inches of hip room
(measured in accordance with SAE 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.
(49CFR568.3)
Gross Axle Weight Rating (GAWR) – the value specified
by the vehicle manufacturer as the load-carrying capacity
of a single axle system, as measured at the tire-ground
interfaces. (49CFR571.3)
Gross Combination Weight Rating (GCWR) – the value
specified by the manufacturer as the loaded weight of a
combination vehicle. (49CFR571.3)
Gross Vehicle Weight Rating (GVWR) – the value specified
by the manufacturer as the loaded weight of a single vehicle.
(49CFR571.3)
H-Point – the mechanically hinged hip point of a manikin
which simulates 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, as a
minimum, of frame and chassis structure, power train,
steering system, suspension system, and braking system,
to the extent that those systems are to be part of the
completed vehicle, that requires further manufacturing
operations, other than the addition of readily attachable
components such as mirrors or tire and rim assemblies, or
minor finishing operations, such as painting, to become a
completed vehicle. (49CFR568.3)
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-E).
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,
other than the addition of readily attachable components,
such as mirrors or tire and rim assemblies, or minor finishing
operations such as painting. (49CFR568.3)
Critical Control Item – is a component or procedure which
may affect compliance with a federal regulation or, which
could directly affect the safe operation of the vehicle. The
identifying symbol is an inverted delta ( ). (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)
F-SERIES (March, 2005)
3
DEFINITIONS
Incomplete Vehicle (Canada) – a vehicle (a) other than a
vehicle imported temporarily for special purposes, that is
capable of being driven and that consists, at a minimum,
of a chassis structure, power train, steering system,
suspension system and braking system in the state in which
those systems are to be part of the completed vehicle,
but requires further manufacturing operations to become
a completed vehicle or (b) that is an incomplete trailer.
(véhicule incomplet)
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. (49CFR568.3)
Intermediate Manufacturer – a person [company (CMVSR)],
other than the incomplete vehicle manufacturer or the
final stage manufacturer, who [that (CMVSR)] performs
manufacturing operations on an incomplete vehicle.
(49CFR568.3)
Motor Home – a multi-purpose vehicle with motive power that is
designed to provide temporary residential accommodations,
as evidenced by the presence of at least four of the following
facilities: Cooking; refrigeration or ice box; self-contained
toilet; heating and/or air conditioning [system that can
function independently of the vehicle engine (CMVSR)]; a
potable water supply system including a faucet and a sink;
and a separate 110-125 volt electrical power supply and/or
an LP gas supply. (49CFR571.3)
Multifunction School Activity Bus (MFSAB) – a school bus
whose purposes do not include transporting students to and
from home or school bus stops. (49CFR571.3)
Multipurpose Passenger Vehicle (MPV) – a motor vehicle
with motive power, except a low-speed vehicle or trailer,
designed to carry 10 persons or less which is constructed
either on a truck chassis or with special features for
occasional off-road operation. (49CFR571.3)
Multipurpose Passenger Vehicle (MPV) (Canada) – a vehicle
having a designated seating 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 lowspeed 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)
DEFINITIONS
Seating Reference Point (Canada) – the unique Design Hpoint, 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,
(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)
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 (March, 2005)
GENERAL INFORMATION
Information in this section is provided pursuant to Title 49, Code
of Federal Regulations, Part 568 – “Vehicles Manufactured in
Two or More Stages”, and Section 6 of the Canadian Motor
Vehicle Safety Regulations (CMVSR) – “Vehicles Manufactured
in Stages.” Part 568 specifies that Final Stage Manufacturers
must complete vehicles in compliance with all applicable
Federal Motor Vehicle Safety Standards and affix a label to
each incomplete vehicle that is completed in accordance with
49CFR567.5. Section 6.6 of the CMVSR provides labeling
requirements for vehicles that are to be sold in Canada.
Each Chassis Cab (see definition on page 3) manufactured by
Ford Motor Company has a label affixed to the driver-door lock
pillar that identifies the following:
• The specific Federal Motor Vehicle Safety Standards to which
the Chassis Cab conforms, as of the date of manufacture.
• The specific Federal Motor Vehicle Safety Standards to which
the Chassis Cab will conform when completed as specified
in this manual.
• The date of manufacture (month/year) of the Chassis Cab
by Ford Motor Company.
DIRECTIONS
STATEMENTS OF CONFORMITY
The Statements of Conformity section, which begin on page 10
of this manual, lists the Federal Motor Vehicle Safety Standards
in effect on the date of manufacture of this incomplete vehicle
that are applicable to the type(s) of completed vehicles into
which this incomplete vehicle may be manufactured. This
date is shown on the label affixed to the cover of this manual.
These statements, in most cases, apply to specific types of
incomplete or completed vehicles and identify GVWR and
UVW weight ranges.
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 six digit number with the
letters VSO below the digits in the lower right corner of the
Incomplete Vehicle Information label which is affixed to the
driver-door lock pillar. See the sample label on page 6.
The Statements of Conformity section of this manual includes
compliance representations for certain VSO vehicles. These
vehicles are identified in the chart on page 7.
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.
FORD TRUCK ASSISTANCE
Throughout this manual you will find references to information
found in the Ford Truck Body Builders Layout Book. Additional
Design Recommendations and specifications are also provided
to assist subsequent stage manufacturers in completing
chassis cab and incomplete vehicles. To obtain a free copy
of this publication on CD-ROM or to receive an order form
for additional CD-ROM’s or books please visit our website at
www.fleet.ford.com/truckbbas. Under Publications select Body
Builders Order Forms. All dealer requests can be handled
online. All other U.S. orders should be faxed to (734) 713-2971.
Canadian orders should be faxed to (905) 670-0844.
Compliance statements provided in this manual are of the
three following types:
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.
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.
The Ford Truck Body Builder Advisory Service may be
consulted regarding information contained in this manual.
Type III • A statement of conformity with the standard is
not substantially affected by the design of the
incomplete vehicle, and that the incomplete vehicle
manufacturer makes no representation as to
conformity with the standard.
• Call (877) 840-4338
• Fax (313) 594-2633
• E-Mail bbasqa@ford.com or at the BBAS website –
www.fleet.ford.com/truckbbas
Include your name, company and telephone number with all
inquiries. If requesting written materials or a CD-ROM, include
your mailing address.
F-SERIES (March, 2005)
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. See page 28 for
location and other requirements.
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
• Tire and wheel size
OPTIONAL PREP PACKAGES
• Cold tire inflation pressure (kPa/PSI)
Incomplete vehicles produced by Ford Motor Company, in
some instances, are equipped with an optional prep package,
such as Ambulance Prep. The completed vehicle type charts
on page 7 will identify incomplete vehicles and the optional
prep packages or trim codes that may be required by Ford
Motor Company if final stage manufacturers wish to rely on
the Statements of Conformity or, in some cases, preserve the
Ford Motor Company new vehicle warranty.
• 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 digits of the Vehicle Identification Number
(VIN) will identify the incomplete vehicle type. These three digits
are used in the Completed Vehicle Types chart on page 7.
INCOMPLETE VEHICLE MANUFACTURED BY
DATE OF
MANUFACTURE
VEHICLE TYPE
(SEE CHART
ON PAGE 7)
DATE : 01/06
FRONT GAWR: 4200LB
1905KG
LT215/85R16D
16X6K
AT 58 PSI COLD
FORD MOTOR COMPANY
MADE IN U.S.A.
GVWR: 11000LB/4989KG
REAR GAWR: 8250LB
WITH 3742KG
WITH
TIRES LT215/85R16D
TIRES
16X6K
RIMS
RIMS
65
AT
PSI COLD DUAL
VIN: 1FDKF37LO6EA53769
OPTIONAL
PREP PACKAGE
EQUIPPED WITH THE FORD
AMBULANCE PREP PKG.
EXTERIOR PAINT COLORS
WB TYPEGVW BODY
F379
161
AJ8
410047
TRANS
E
AXLE TAPE
65
VSO
SPRINGS
BAR CODE V.I.N .
(CALIFORNIA)
VSO
VEHICLE
NY
F85B1520472AB
TYPICAL F-SERIES - U.S.
DATE OF
MANUFACTURE
DATE 01/06
VEHICLE TYPE
(SEE CHART
ON PAGE 7)
VIN: 1FDLF47P36EA47541
1019
VSO
VEHICLE
VSO
TYPICAL F-SERIES - CANADA
INCOMPLETE VEHICLE INFORMATION LABEL
VEHICLE DESCRIPTION
6
F-SERIES (March, 2005)
COMPLETED VEHICLE TYPES
5TH, 6TH, 7TH
VIN DIGIT
SUPER DUTY F-SERIES
F20, F30, F34
F21, F31, F35
F32, F36, F46, F56
F33, F37, F47, F57
X20, X30, X34
X21, X31, X35
X32, X36, X46, X56
X33, X37, X47, X57
W20, W30, W34
W21, W31, W35
W32, W36, W46, W56
W33, W37, W47, W57
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)
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:
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.
F-SERIES (March, 2005)
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.
PART
565.4 The statement below is applicable to all incomplete
vehicle types except the Basic (Stripped Chassis):
This vehicle, when completed, will conform to Part 565.4,
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.
101
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.
STATEMENTS OF CONFORMITY
8
102
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:
• Automatic Transmission – the transmission, shift cable,
transmission outer shift lever, shift cable bracket,
vacuum tubes, vacuum pump system, brake-shift
interlock system, the starter interlock system, and
wiring circuit from the interlock switch to the power
source.
• Manual and Automatic Transmission – the clutchignition interlock system (if equipped), transmission
shift decal, knob, or transmission indicator dial
identification.
If an auxiliary transmission is added to this vehicle, it
must conform to the requirements of this Standard.
103
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.
F-SERIES (March, 2005)
105
105
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.
EQUATION A
CGv =
(
) (
)
CGvbWb + CGvc Wc + Wl + CGvp x P
GVWR
EQUATION B
P x CGhp
Wrb + Wrc +
+ Wrl x WB
WB
CGh =
GVWR
(
(
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
• 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, page 11.
• The applicable GAWRs and GVWR weights are not
exceeded.
• The completed vehicle must have a vertical center
of gravity (Equation A) of 48.00 inches or less when
measured from the ground.
• The front axle curb weight of the completed vehicle
(incomplete vehicle weight + min SUB weight, Table
G, page 12) may be reduced by no more than 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, page 12) must be the same or greater than the rear
axle ground reaction as manufactured by Ford Motor
Company.
REFERENCE: Equation B can be used to determine the
completed vehicle’s horizontal center of gravity (CGh).
Abbreviation definitions and a vehicle diagram are
provided to assist with the equation on page 10.
)
)
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
161.8
155
Crew Cab
172.4
165
Crew Cab
176.2
167
Crew Cab
200.2
182
† 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
of the front wheel to the horizontal
as the distance from the
midpoint of the cargo area.
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]
7717-10,000
400
10,001-19,000
500
TABLE E
SUPER DUTY F-SERIES PASSENGER CGvp
ALL SEATS
CGvp
F-SERIES (March, 2005)
9
4X2
4X4
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
page 9).
Wc
CGv
= Vertical distance from the ground to the center
of gravity [inches] of the completed vehicle.
WB
= Vehicle wheelbase [inches].
CGh
= Horizontal distance from of the front wheels
to the center of gravity [inches] of the completed
vehicle.
Wt
= Total unladen weight = (Wb + Wc + P)
GVWR = Gross Vehicle Weight Rating of the vehicle
[pounds].
CGvb
= Vertical distance from the ground to the center of
gravity of the SUB and/or permanently attached
added equipment [inches].
CGvc
= Vertical distance from the ground to the center
of gravity of the chassis [inches] (including cab
if original equipment). (Taken from Table C, page
9).
CGhp
= Horizontal distance from the of the front wheels
to the P (passenger load). (See Table B, page
9).
CGvp
= 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,
page 9).
Wb
= Weight of the SUB and/or permanently attached
added equipment [pounds].
Wrb
= Weight at the rear wheels of the SUB and/or
permanently attached added equipment
[pounds].
Wrc
= Weight at the rear wheels of the vehicle (chassis
and cab) (fuel tanks full) [pounds]. Including
option weight.
WI
= Weight of the vehicle (chassis and cab) (fuel
tanks full) [pounds]. Including option weight.
= Remaining cargo capacity [pounds].
Where: Wl = GVWR - (Wb + Wc + P)
Wrl
= Weight of the remaining cargo capacity on the
rear wheels [pounds].
WrI =
(CGhI )WI
WB
CGhI
= Horizontal distance from the of the front wheels
to the cargo center of gravity [inches]. (Taken
from Table A page 9) 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.
SUB
= 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.
CGhc
= Horizontal distance from the of the front wheels
to the center of gravity (inches) of the chassis.
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 (March, 2005)
TABLE F
MAXIMUM UNLOADED VEHICLE WEIGHTS WITH SECOND UNIT BODY
(This Weight Information Does Not Apply To Vehicles Over 4536 kg [10,000 lb] GVWR)
CHASSIS CABS
PICKUP BOX DELETES
MODELS
FRAME
WIDTH
SECOND UNIT BODY
MAXIMUM
CENTER OF GRAVITY
HEIGHT†
millimeter [inch]
MAX. UNLOADED VEHICLE WEIGHT
kilogram [pound]
Engine Size – liter [cubic inch]
5.4L
[330]
6.8L
[413]
6.0LD
[363]
F-250 Regular Cab (4X2)
3480 mm [137 in] WB (56" CA)
Wide
447
[17.6]
3120
[6880]
3120
[6880]
3334
[7350]
F-250 Regular Cab (4X4)
3480 mm [137 in] WB (56" CA)
Wide
447
[17.6]
3302
[7280]
3302
[7280]
3493
[7700]
F-250 Super Cab (4X2)
4013 mm [158 in] WB (56" CA)
Wide
610
[24]
3312
[7300]
3312
[7300]
3312
[7300]
F-250 Super Cab (4X4)
4013 mm [158 in] WB (56" CA)
Wide
610
[24]
3403
[7500]
3403
[7500]
3493
[7700]
F-250 Crew Cab (4X2)
4379 mm [172.4 in] WB (56" CA)
Wide
610
[24]
3585
[7900]
3585
[7900]
3607
[7950]
F-250 Crew Cab (4X4)
4379 mm [172.4 in] WB (56" CA)
Wide
610
[24]
3585
[7900]
3585
[7900]
3585
[7900]
F-350 Regular Cab (4X2)
3480 mm [137 in] WB (56" CA)
Wide
447
[17.6]
3120
[6880]
3120
[6880]
3334
[7350]
F-350 Regular Cab (4X4)
3480 mm [137 in] WB (56" CA)
Wide
447
[17.6]
3302
[7280]
3302
[7280]
3515
[7750]
F-350 Super Cab (4X2)
4013 mm [158 in] WB (56" CA)
Wide
610
[24]
3312
[7300]
3312
[7300]
3403
[7500]
F-350 Super Cab (4X4)
4013 mm [158 in] WB (56" CA)
Wide
610
[24]
3402
[7500]
3403
[7500]
3517
[7750]
F-350 Crew Cab (4X2)
4379 mm [172.4 in] WB (56" CA)
Wide
610
[24]
3606
[7950]
3606
[7950]
3606
[7950]
F-350 Crew Cab (4X4)
4379 mm [172.4 in] WB (56" CA)
Wide
610
[24]
3606
[7950]
3606
[7950]
3606
[7950]
F-350 Regular Cab (4X2)
3576 mm [140.8 in] WB (60" CA)
Narrow
447
[17.6]
3674
[8100]
3674
[8100]
3674
[8100]
F-350 Regular Cab (4X4)
3576 mm [140.8 in] WB (60" CA)
Narrow
447
[17.6]
3538
[7800]
3538
[7800]
3670
[8090]
F-350 Super Cab (4X2)
4110 mm [161.8 in] WB (60" CA)
Narrow
610
[24]
3739
[8240]
3739
[8240]
3739
[8240]
F-350 Super Cab (4X4)
4110 mm [161.8 in] WB (60" CA)
Narrow
610
[24]
3739
[8240]
3739
[8240]
3739
[8240]
F-350 Crew Cab (4X2)
4475 mm [176.2 in] WB (60" CA)
Narrow
610
[24]
3857
[8500]
3857
[8500]
3857
[8500]
F-350 Crew Cab (4X4)
4475 mm [176.2 in] WB (60" CA)
Narrow
610
[24]
3766
[8300]
3766
[8300]
3766
[8300]
† Vertical dimensions are measured from the top surface of
the frame at a distance approximately 304.8–457.2 mm
[12–18 inches] from the rear of the cab.
F-SERIES (March, 2005)
11
STATEMENTS OF CONFORMITY
TABLE G
SUPER DUTY F-SERIES VEHICLES MINIMUM SECOND UNIT BODY WEIGHTS
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]
Regular Cab
3576 [140.8]
4186 [164.8]
4110 [161.8]
4475 [176.2]
190 [420]
204 [450]
190 [420]
190 [420]
190 [420]
204 [450]
227 [500]
249 [550]
190 [420]
F-350
DRW
Super Cab
Crew Cab
3576 [140.8]
4186 [164.8]
4795 [188.8]
5100 [200.8]
4110 [161.8]
4475 [176.2]
5085 [200.2]
3576 [140.8]
4186 [164.8]
4795 [188.8]
5100 [200.8]
4110 [161.8]
Regular Cab
F-450
DRW
Super Cab
Crew Cab
Regular Cab
F-550
DRW
Super Cab
4475 [176.2]
5085 [200.2]
Crew Cab
STATEMENTS OF CONFORMITY
12
190 [420]
204 [450]
190 [240]
204 [450]
227 [500]
249 [550]
190 [240]
190 [240]
204 [450]
F-SERIES (March, 2005)
106
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, are not substantially affected
by the design of this incomplete vehicle; accordingly,
Ford Motor Company makes no representation as to
conformity with this Standard.
108
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.
FRONT OF
VEHICLE
CHMSL
FIXED
CIRCUIT
SUPER DUTY F-SERIES CHASSIS CAB
CENTER HIGH MOUNTED STOP LAMP (CHMSL)
ELECTRICAL CONNECTOR LOCATION
F-SERIES (March, 2005)
13
STATEMENTS OF CONFORMITY
TABLE H
Standard 108 Lighting Equipment
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 this 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 this
page) are designed and installed to conform to all the
requirements of Standard 108. The completed vehicle will
conform with these components 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 this 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 sub-referenced 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.
108
Canadian Requirements:
The preceding statements for Standard 108 are
appropriate compliance representations for CMVSS 108,
Lighting, and CMVSS 108.1, Headlamps, if this vehicle is
manufactured for sale or use in Canada, provided:
• No component of the Daytime Running Lamp (DRL)
system is removed, relocated, or modified.
Headlamps
Tail Lamps
Stop Lamps
Center High Mounted
Stop Lamp (CHMSL)
License Plate Lamps
Reflex Reflectors
Side Marker Lamps
– Side Front
– Side Rear
– Rear
– 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(1)
N
N(1)
N
S
S
S(1)
R
S(3)
R
N
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) Supplied on DRW Super Duty F-Series Chassis Cab.
Optional on SRW Super Duty F-Series Chassis Cab.
(2) Designed for two turn signal lamps per vehicle side (one front
and rear). If additional lamps are required, replace the turn
signal flasher with one having the correct lamp load rating.
(3) If a second unit body width is greater than 2032 mm [80 in] or
higher than the chassis cab body, additional clearance lamps
may be required that comply with this standard.
STATEMENTS OF CONFORMITY
14
F-SERIES (March, 2005)
110
U.S. Requirements:
115
The statement below is applicable to all incomplete
vehicles with a GVWR of 4536 kg [10,000 lbs] or less
with a completion date starting 09/01/2005:
This incomplete vehicle does not comply to FMVSS
110. In order to comply, the final stage manufacturer
must permanently affix a tire placard as specified in
paragraph 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.
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.
116
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.
118
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, is not
substantially affected by the design of this incomplete
vehicle; accordingly, Ford Motor Company makes no
representation as to conformity with this Standard. If any
power operated window, partition, or roof panel systems
are installed by subsequent stage manufacturers, they
must conform to the requirements of Standard 118.
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 power
operated window, partition, or roof panel systems are
installed by subsequent stage manufacturers, they must
conform to the requirements of Standard 118.
119
The statement below is applicable to the Chassis
Cab:
All tires supplied by Ford Motor Company are in full
conformity with Standard 119, New Pneumatic Tires for
Vehicles Other than Passenger Cars.
If additional tires are installed or the existing tires are
replaced by subsequent stage manufacturers, they must
conform to the requirements of Standard 119.
120
The statement below is applicable to the Chassis
Cab:
This vehicle, when completed, will conform to the tire
and rim selection requirements of Standard 120, Tire
Selection and Rims for Motor Vehicles Other Than
Passenger Cars, if the tire and rim assemblies and the
Incomplete Vehicle Information label that is affixed to the
vehicle are not removed, altered, or replaced.
TIRE AND LOAD INFORMATION
SEE OWNERS MANUAL FOR ADDITIONAL INFORMATION
The combined weight of occupants and cargo should never exceed XXX kg or XXX lbs.
SEATING CAPACITY
TOTAL : 5
ORIGINAL TIRE SIZE
FRONT
REAR
P195 / 70R14
P195 / 70R14
COMPACT TIRE SIZE
T125/70D15
111
111
113
114
FRONT: 2
REAR: 3
COLD TIRE INFLATION PRESSURE
FRONT
REAR
200KPA, 29PSI
200KPA, 29PSI
COLD TIRE INFLATION PRESSURE
420KPA, 60PSI
The statement below is applicable to the Chassis Cab
when not equipped with outside mirrors:
Conformity with Standard 111, Rearview Mirrors, is not
substantially affected by the design of this incomplete
vehicle; accordingly, Ford Motor Company makes no
representation as to conformity with this Standard.
The statements below are applicable to the Chassis
Cab when equipped with a flat glass mirror on the
passenger-side:
This vehicle, when completed, will conform to Standard
111, Rearview Mirrors, if:
• The mirrors and their mounts as supplied by Ford
Motor Company are not removed, relocated, replaced,
or altered.
• No structural modifications are made to the body which
would affect the stability of the mirror mounts.
• Any modifications or additions made to the incomplete
vehicle must not adversely affect the driver’s view to
the rear in the outside mirrors along both sides of the
vehicle.
The statement below is applicable to the Chassis
Cab:
This vehicle, when completed, will conform to Standard
113, Hood Latch Systems, if the hood latch system as
provided by Ford Motor Company is not removed or
altered.
The statements below are applicable to the Chassis
Cab when completed as either a MPV or a Truck with
a GVWR of 4536 kg [10,000 lb] or less:
This vehicle, when completed, will conform to Standard
114, Theft Protection, if the following components, to
the extent provided by Ford Motor Company, are not
removed, relocated, altered, or modified in any way:
• Steering column locking mechanism system
• Ignition key/transmission shift interlock locking
system
• Ignition key-locking system
• Key warning buzzer system
If any of the above components are added to the
vehicle they must conform to the requirements of this
Standard.
F-SERIES (March, 2005)
15
STATEMENTS OF CONFORMITY
124
The statements below are applicable to the Chassis
Cab:
This vehicle, when completed, will conform to Standard
124, Accelerator Control Systems, if:
• No alterations are made to the accelerator pedal,
mounting hardware, adjustable 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.
201
PEDAL POSITION
SENSOR
IDLE POSITION SENSOR
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.
201U U.S. Requirements (Section S6):
This vehicle when completed, will conform to Standard
201U, Occupant Protection in Interior Impact – Upper
Interior Head Impact Protection, if the following 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
• 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.
ELECTRONIC ACCELERATOR CONTROL
STATEMENTS OF CONFORMITY
16
F-SERIES (March, 2005)
202
203
203
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.
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.
204
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.
204
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
[5,500 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 page 11, for F-Series
Chassis Cab type vehicles.
• No components are added which could influence the
rearward displacement of the steering column.
• The steering column, steering intermediate and
coupling shaft, steering wheel, steering gear, steering
linkage, related structural components, and attaching
hardware, as installed by Ford Motor Company, are not
removed, relocated, altered, or modified in any way.
• No alteration or modifications are made to the body
chassis, drivetrain, or front suspension from the B-pillar
forward.
F-SERIES (March, 2005)
17
205
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.
206
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.
207
The statements below are applicable to the Chassis
Cab when equipped with trimmed front seats:
This vehicle, when completed, will conform to Standard
207, Seating Systems, if no alterations are made to the
seat assemblies, their anchorages, the floor pan, or floor
pan reinforcements. Any seating system added to this
vehicle must conform to applicable requirements of this
Standard.
208
The statement below is applicable to the Chassis
Cab when equipped with Ford trimmed front seats
and either the GVWR is over 3856 kg [8,500 lb], the
Unloaded Vehicle Weight, when completed, is over
2495 kg [5,500 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.
• Front blocker beams may be removed to allow the
installation of snow plow attachment hardware. The
truck must not be operated without either the blocker
beam or snow plow attachment hardware in place.
Any seat belt assemblies added to this vehicle
must conform to the applicable requirements of this
Standard.
STATEMENTS OF CONFORMITY
208
Canadian Requirements:
The preceding statements and supporting figures for
FMVSS 208, on pages 17-18, are appropriate compliance
representations for CMVSS 208, Seat Belt Installation,
if this incomplete vehicle was manufactured for sale or
use in Canada. In such a case, CMVSS 208 paragraphs
(13), (14), and (15) are substituted for the reference to
FMVSS 208 Section 7.1; CMVSS 208 paragraph (20)
should be substituted for the reference to FMVSS 208
Section 7.2; and CMVSS 208 paragraphs (29), (30),
(31), (32), (33), (34), (35), (36), (37), (38), (39), and (40)
should be substituted for the reference to FMVSS 208
Section 7.4.
72 WAY
CONNECTOR
WARNING:
VEHICLES OVER 3856 kg (8,500 lb) GVWR AND
2495 kg (5,500 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, SHOWN BELOW, MAY
AFFECT THE DEPLOYMENT OF THE AIR BAG
WHEN SO EQUIPPED. REFER TO THE FORD TRUCK
BODY BUILDERS LAYOUT BOOK FOR SNOW PLOW
PREPARATION PACKAGES AND INSTALLATION
INSTRUCTIONS WHICH ARE COMPATIBLE WITH AIR
BAGS.
AIRBAG
DEACTIVATION
SWITCH
BATTERY
DRIVER
AIRBAG
MODULE
PASSENGER
AIRBAG
MODULE
ELECTRONIC CRASH
SENSOR MODULE
DO NOT INSTALL ADDITIONAL COMPONENTS IN THE
SHADED AREAS, OR ALTER OR MODIFY THESE AREAS.
DO NOT MODIFY OR ALTER ANY COMPONENTS OR AREAS
OF THE VEHICLE IN THE VICINITY OF THE COMPONENTS
THAT ARE IDENTIFIED IN THIS ILLUSTRATION.
SUPER DUTY F-SERIES OCCUPANT PROTECTION ZONE
STATEMENTS OF CONFORMITY
18
F-SERIES (March, 2005)
209
209
210
The statements below are applicable to the Chassis
Cab with front seat(s):
This vehicle, when completed, will conform to Standard
209, Seat Belt Assemblies, if:
• No alterations or replacements are made to the seat
belt assemblies and attaching hardware.
• No action is taken that would impair the integrity of the
seat belt system provided.
Any seat belt assemblies added to a vehicle must
conform to the requirements of this Standard.
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/ 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.
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.
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 2,495 kg [5,500 lb] is established by
testing a representative vehicle at an Unloaded Vehicle
Weight of 2,495 kg [5,500 lb] as permitted by s6.1 (b)
and s7.7 (b) of Standards 212 and 219, respectively.
• The front end of the body installed by the subsequent
stage manufacturer is located at least 76.2 mm [3.0
in] rearward of the rearmost point of the cab.
The statements below are applicable to the Chassis
Cab:
This vehicle, when completed, will conform to Standard
210, Seat Belt Assembly Anchorages, if:
• No alterations are made to the front seat belt
anchorages, front seat belt assemblies, floor pan, floor
pan reinforcements, or body mounts.
• No alternations are made to the rear cab panel or roof
for the Chassis Cab.
Chassis Cab vehicles may have additional seat belt
anchorages for designated seating positions on optional
seats not provided on incomplete vehicles. These
locations apply to specific hardware and designated
seating positions used in Ford completed vehicles. If
these anchorages are used without the appropriate
Ford seats, seat belt systems, and hardware, Ford Motor
Company makes no representation as to conformity with
this Standard.
210.1 Canadian Requirements:
The statement below is applicable to the Chassis
Cab with a GVWR of 3856 kg [8,500 lb] or less and an
unloaded vehicle weight of 2495 kg [5,500 lb] or less.
This vehicle, when completed, will conform to Standard
210.1, User-Ready Tether Anchorages for Restraint
Systems, if:
• No alternations are made to the front passenger seat
tether anchorages and access to the anchorages is
not restricted, and no alterations are made to the seat
assemblies, their anchorages, the floor pan, or floor
pan reinforcements.
210.2 Canadian Requirements:
The statement below is applicable to the Chassis Cab
if the GVWR is 3856 kg [8,500 lb] or less:
This vehicle, when completed, will conform to Standard
210.2, Lower Universal Anchorage Systems for Restraint
Systems and Booster Cushions, if:
• No alterations are made to the front passenger seat
tether anchorages or LATCH lower anchors, and access
to the anchorages is not restricted, and no alterations
are made to the seat assemblies, their anchorages,
the floor pan, or floor pan reinforcements.
† 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 (March, 2005)
19
STATEMENTS OF CONFORMITY
– The body installed by the subsequent stage
manufacturer is mounted securely and so designed
that, when the completed vehicle is impacted in
any manner specified by applicable provisions
of Standards 212 and 219, body deformation or
movement relative to the frame does not result in
any separation or loss of body attachment to the
frame.
• The maximum SUB weight and SUB center of gravity
as installed by the subsequent stage manufacturer
and the Unloaded Vehicle Weight does not exceed the
values specified in Table F page 11, corresponding to
the incomplete vehicle type, wheelbase, and engine
size.
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.
301
INFORMATION
The Unloaded Vehicle Weight of the completed vehicle
may significantly affect its capability to meet the
requirements of Standard 301. Completed vehicles
manufactured by Ford Motor Company that are tested
to demonstrate compliance with Standard 301 are
loaded pursuant to s7.1.6 of the Standard. The test
weights of these vehicles comprise the Unloaded
Vehicle Weights including the weights of all available
regular production options plus the loads specified by
s7.1.6. These test weights are less than the respective
designated Gross Vehicle Weight Ratings. In addition
to the specific statements below, refer to the Design
Recommendation section of the Ford Truck Body
Builders Layout Book for Fuel System information to
assist in designing fuel systems and the Second Unit
Body Attachment recommendations for information to aid
in designing second unit bodies and their attachments to
be compatible with Super Duty F-Series vehicles.
301
In addition to the statements pertaining to particular
incomplete vehicle types which follow on pages 2024, 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.
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.
213
The statement below is applicable to the Chassis
Cab:
Conformity with Standard 213, Child restraint systems, is
not substantially affected by the design of the incomplete
vehicle; accordingly Ford Motor Company makes no
representation as to conformity with this Standard. Any
child restraint system that is added or incorporated into
the design of a designated seating position must conform
to the requirements of this standard.
214
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.
219
See combined statements under “212/219” for all
vehicle types.
225
The statement below is applicable to the Chassis
Cab:
This vehicle, when completed, will conform to Standard
225, Child Restraint Anchorage Systems, if:
• No alterations are made to the tether anchorages,
access to the anchorages is not restricted, and
no alterations are made to the seat assemblies,
their anchorages, the floor pan, or floor pan
reinforcements.
STATEMENTS OF CONFORMITY
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.
20
F-SERIES (March, 2005)
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 components as installed
by Ford Motor Company are not removed, relocated,
altered, or modified in any way (except as specified in
the representations following this paragraph):
– Fuel tank(s) and attachment hardware, including
sending unit, vapor valve, fuel tank shield, pressure
transducer, and in-tank electric fuel pump
– Fuel filler cap(s), pipe(s), hose(s), and attachment
hardware
– Fuel lines, routing, and attachments
– Vapor line(s) and carbon canister – (gasoline engine
application)
– Fuel pump
– Fuel filter
– Fuel water separator fuel filter/primer, fuel line
heater, and injection pump – (diesel engine only)
– Fuel shut off switch (inertia switch)
• 137" wheelbase Regular Cab Pickup Box Delete units
are modified as follows:
– Bend the lower inboard corner of the left rear outer
pillar 90 degrees towards the front of the vehicle
along an axis 45 degrees from the cab’s horizontal
plane (see sketch below)
– Spot paint repair the area of bend using standard
practices including:
(a) Clean the surface
(b) Sand the surface
(c) Prime and topcoat the surface
• No other alteration or modification made to the
incomplete vehicle as manufactured by Ford Motor
Company and no other components or structure
installed by a subsequent stage manufacturer result
in penetration, separation, or other damage to the
fuel system or any portion thereof when the vehicle is
tested in any manner specified by applicable provisions
of Standard 301.†
• The maximum SUB weight and SUB center of gravity
as installed by the subsequent stage manufacturer
and the Unloaded Vehicle Weight does not exceed the
values specified in Table F on page 11, corresponding
to the model, wheelbase, and engine size.
• The body installed by a subsequent stage manufacturer
and the Ford installed fuel system components are
located and mounted as follows:
– The body is mounted securely and is so designed
that when the completed vehicle is tested in any
manner specified by applicable provisions of
Standard 301,
(a) body components do not contact any fuel system
component at any time (other than at the points
where the fuel system is permanently attached
to the body), and,
(b) body deformation or movement relative to
the frame does not cause any fuel system
component to be penetrated, disconnected, or
otherwise damaged.
– The rear end of the body (excluding the rear bumper)
installed by a subsequent stage manufacturer does
not extend beyond (overhang) the rear edge of the
vehicle frame or frame extension. Any extension
of the vehicle frame must be constructed and
attached so as to perform as a continuation of the
vehicle frame when the completed vehicle is tested
in any manner specified by applicable provisions of
Standard 301.
– The front end of the body installed by the subsequent
stage manufacturer is located at least 76.2mm [3.0
in] rearward of the rearmost point of the cab.
– The fuel filler cap(s), pipe(s), hose(s) and attachment
hardware are installed as shown in Figures A and
B on pages 22 and 23 for Super Duty F-Series
vehicles. All components must be securely retained
to remain intact when the completed vehicle is tested
in any manner specified by applicable provisions of
Standard 301.
301 (Continued on Page 24)
45˚
† 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.
19 mm
[.75 in.]
F-SERIES (March, 2005)
21
STATEMENTS OF CONFORMITY
FRONT OF
VEHICLE
B
CAP
1/4 TURN - GASOLINE - LEV II
SCREW IN - DIESEL
SCREW (3 REQ’D)
TORQUE
1.7-2.8 NEWTON METERS
[15-25 IN. LB.]
U
HOLE IN
MANUFACTURERS BODY
D
VIEW P
THIS HOSE IS PREFORMED:
INSTALL SHORT END TO THE
METAL NECK AND CAP ASSEMBLY;
TRIM THE LONG END AS REQUIRED.
[1.89]
48
48
[1.89]
[1.89]
48
SUB
3/16 INCH
BLIND RIVET *
(12 REQ’D)
SUPPORT
87
[3.42]
CL OF
BRACKET
105.7
[4.16]
78
[3.07]
48
[1.89]
48
[1.89]
67.5
[2.66]
78
[3.07]
HOLES (12 PLACES)
INSTALL GROUND
WIRE TO SOUND
METAL ON THE
FRAME.
75
USE PROVIDED TIE STRAPS
TO SECURE FILL TO VENT
HOSES (2 PLACES)
STEEL TUBE
(DO NOT TRIM)
AFT OF AXLE FILL SYSTEM
REFER TO CALIFORNIA
FUEL VAPOR RECOVERY
REQUIREMENT.
48
[1.89]
U
616
[2.42]
TOP OF FRAME RAIL
POINT Z
48
[1.89]
81
[3.19]
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.
OUTBOARD SURFACE
OF FRAME RAIL
C
81
[3.19]
OUTBOARD SURFACE
OF FRAME RAIL
SECTION U
VIEW P
C
A
#4 C/MEMBER
CL OF FILL PIPE ASY.
AND BRACKET
SCREW (3 REQ’D)
TORQUE
1.7-2.8 NEWTON METERS
[15-25 IN. LB.]
TO BACK
OF CAB
INSTALL GROUND WIRE
TO SOUND METAL ON
THE FRAME.
FRONT OF
VEHICLE
VIEW P
D
CAP
1/4 TURN - GASOLINE - LEV II
SCREW IN - DIESEL
DO NOT TRIM
THIS END
PROTECTIVE SLEEVES ARE
REQUIRED ON BOTH FILL
AND VENT HOSE AT FRAME
OPENING.
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)
MIDSHIP FUEL FILL SYSTEM
(OPTIONAL ON CHASSIS CAB)
TOP OF FRAME RAIL
AT C
L OF FILL PIPE
NOTES:
TORQUE ALL WORM GEAR DRIVEN HOSE CLAMPS
TO 2.8 - 3.9 NEWTON METERS [25-35 IN. LB.]
[ ] DIMENSIONS ARE INCHES
* NOT SUPPLIED BY FORD MOTOR COMPANY
(CA) BACK OF CAB TO CENTERLINE OF REAR AXLE
60 INCH CA
Regular Cab 3576mm [140.8]
Super Cab 4110mm [161.8]
4475mm [176.2]
Crew Cab
A
B
C
D
84 INCH CA
108 INCH CA
120 INCH CA
WHEELBASE
4186mm [164.8] 4795mm [188.8] 5100mm [200.8]
5085mm [200.2]
MIN
864mm [34.0]
1473mm [58.0]
2083mm [82.0]
2388mm [94.0]
MAX
1029mm [40.5]
1638mm [64.5]
2248mm [88.5]
2553mm [100.5]
MIN
1981mm [78.0]
2591mm [102.0]
3200mm [126.0] 3505mm [138.0]
MAX
2159mm [85.0]
2769mm [109.0]
3378mm [133.0] 3683mm [145.0]
MIN
584mm [23.0]
584mm [23.0]
584mm [23.0]
584mm [23.0]
MAX
787mm [31.0]
787mm [31.0]
787mm [31.0]
787mm [31.0]
MIN
267mm [10.5]
267mm [10.5]
267mm [10.5]
267mm [10.5]
MAX
343mm [13.5]
343mm [13.5]
343mm [13.5]
343mm [13.5]
Remove and discard the Ford installed fuel fill 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 fill system must provide a 4 degree
minimum, continuous, downward slope to the fuel tank.
Additional support may be required to prevent hose
sagging which could cause spray or spitback during
normal fueling operations.
Do not extend the fuel fill system outboard of the second
unit body.
The installation of Tube Extension F81A-9B149-HA will
permit the location aft-of-axle fuel fill housing to be no
further rearward than the of the fill hose as it passes
through the frame.
FIGURE A – SUPER DUTY F-SERIES NARROW FRAME CHASSIS CAB FUEL FILLER PIPE INSTALLATION
STATEMENTS OF CONFORMITY
22
F-SERIES (March, 2005)
U
48.0
[1.89]
87.0
[3.42]
CL OF BRACKET
78.0
[3.07]
78.0
[3.07]
3/16 INCH
BLIND RIVET *
(12 REQ’ D)
SUB
48.0
[1.89]
48.0
[1.89]
105.7
[4.16]
48.0
[1.89]
48.0
[1.89]
616.0
[2.42]
75
67.5
[2.66]
48.0
[1.89]
HOLES (12 PLACES)
81.0
[3.19]
POINT Z
REFER TO CALIFORNIA
FUEL VAPOR RECOVERY
REQUIREMENT.
48.0
[1.89]
SCREWS (3 REQ’D)
TORQUE 1.7-2.8
NEWTON METERS
[15-25 IN. LB.]
81.0
[3.19]
SECTION U
U
VIEW P
TO BACK
OF CAB
CL OF FILL PIPE ASY.
AND BRACKET
A
90º FITTING - CONNECT TO
QUICK CONNECTION ON VAPOR LINE
FRONT OF
VEHICLE
OUTBOARD SURFAC E
OF FRAME RAIL
#4 CROSSMEMBER
C
PROTECTIVE SLEEVES ARE
REQUIRED ON BOTH FILL AND
VENT HOSE WHERE PASSIN G
OVER FRAME.
FILL HOSE
RECIRCULATION
HOSE
STEEL ELBOW
DO NOT TRIM
STEEL ELBOW
DO NOT TRIM
CAP
1/4 TURN - GASOLINE - LEV II
SCREW IN - DIESEL
TOP OF FRAME RAIL
D
SCREWS (3 REQ’D)
TORQUE 1.7-2.8
NEWTON METERS
[15-25 IN. LB.]
RECIRCULATION
HOSE CLAMP
TOP OF FRAME RAIL
AT C
L OF FILL PIPE
P
THIS HOSE IS PREFORMED; INSTALL SHORT EN D
TO THE METAL NECK AND CAP ASSEMBLY;
TRIM THE LONG END AS REQUIRED.
RECIRCULATION
STEEL TUBE
INSTALL GROUND WIRE TO
SOUND METAL ON THE FRAME.
NOTES:
(CA) BACK OF CAB TO CENTERLINE OF REAR AXLE
TORQUE ALL WORM GEAR DRIVEN HOSE CLAMPS
TO 2.8 - 3.9 NEWTON METERS [25-35 IN. LB.]
56 INCH CA
Regular Cab
Super Cab
Crew Cab
A
C
D
MIN
WHEELBASE
3480mm [137.0]
4013mm [158.0]
4380mm [172.4]
[ ] DIMENSIONS ARE INCHES
* NOT SUPPLIED BY FORD MOTOR COMPANY
620mm [24.4]
MAX
923mm [36.7]
MIN
540mm [21.25]
MAX
743mm [29.25]
MIN
267mm [10.5]
MAX
343mm [13.5]
Remove and discard the Ford installed fuel fill 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 fill system must provide a 4 degree minimum,
continuous, downward slope to the fuel tank. Additional support may
be required to prevent hose sagging which could cause spray or
spitback during normal fueling operations.
Do not extend the fuel fill system outboard of the second unit body.
FIGURE B – SUPER DUTY F-SERIES WIDE FRAME PICKUP BOX DELETE FUEL FILLER PIPE INSTALLATION
F-SERIES (March, 2005)
23
STATEMENTS OF CONFORMITY
301
(Continued)
301
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.
302
The statement below is applicable to the Chassis
Cab:
This vehicle, when completed, will conform with
Standard 302, Flammability of Interior Materials, if no
alterations are made to those components covered by
the Standard which are installed by Ford Motor Company
and all components covered by Standard 302, which are
added to the incomplete vehicle by subsequent stage
manufacturers meet the flammability requirements of
the Standard.
1106 Canadian Requirements:
The statements below are applicable to the Chassis
Cab with GVW ratings of 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.
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.
STATEMENTS OF CONFORMITY
24
F-SERIES (March, 2005)
CANADIAN VEHICLES
(Vehicles to be completed for sale or use in Canada)
VEHICLE IDENTIFICATION
More specifically:
Refer to the Vehicle Description section of this manual on page
6, for additional information. Incomplete vehicles produced by
Ford Motor Company require, for certain applications, optional
Prep Packages or trim codes which are listed on the Completed
Vehicle Types chart on page 7.
• All components required to suppress RFI emissions, which
are removed during service, repair, or completion of the
vehicle, must be reinstalled in the manner in which they were
installed by Ford Motor Company.
• Shields on ignition coils must remain installed.
• Replacement spark plugs, ignition wires, and ignition coils
must be equivalent in their RFI suppression properties to
original equipment.
DAYTIME RUNNING LAMP (DRL)
Compliance representations for CMVSS 108, Lighting and
CMVSS 108.1, Headlamps, are on page 14. The following items
are also required for CMVSS 108 and 108.1 compliance:
• Electrical grounds on all components must be retained.
• Metallic components installed on the body or chassis must
be grounded to the chassis.
• The DRL module circuits are not to be altered.
• DRL module is not to be repositioned.
• Electrical circuits added to the vehicle must not be installed
near the high voltage ignition components.
CANADIAN RADIO FREQUENCY INTERFERENCE (RFI)
INFORMATION
• 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-C108.4M92”. Violation of these regulations is punishable by fine
or imprisonment. This Ford-built incomplete vehicle was
designed and manufactured to be capable of meeting the
regulatory requirements or such modifications thereof as may
have been authorized by the Department of Communications.
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.
The following information is supplied to subsequent stage
manufacturers to help them avoid increasing the RFI emissions
of this vehicle in the course of completing it.
For any completed vehicle, additional measures may be
needed to adequately suppress RFI emissions. Affected
components could include spark plugs, ignition wires, ignition
coils, ground straps, ignition component shields, accessory
drive belts, instrument voltage regulator suppressor assembly,
and ignition coil suppressor assembly.
F-SERIES (March, 2005)
25
CANADIAN VEHICLES
EMISSION CERTIFICATION INFORMATION
HIGH ALTITUDE REQUIREMENTS
CAUTION:
United States Environmental Protection Agency regulations
for the 2006 model year 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.].
U.S.:
2006 MODEL YEAR VEHICLES ARE EMISSION CERTIFIED
FOR REGISTRATION IN SPECIFIC AREAS OF THE
UNITED STATES. FOR EXAMPLE, VEHICLES CERTIFIED
AND LABELED FOR SALE IN CALIFORNIA CAN NOT
BE SOLD IN THE STATES THAT REQUIRE FEDERALLY
CERTIFIED VEHICLES AND VEHICLES CERTIFIED TO
FEDERAL STANDARDS CAN NOT BE SOLD IN STATES
THAT REQUIRE CALIFORNIA CERTIFIED VEHICLES.
IT IS THE SUBSEQUENT STAGE MANUFACTURER’S
RESPONSIBILITY TO PURCHASE A VEHICLE CERTIFIED
FOR THE STATE/AREA IN WHICH THE VEHICLE WILL
BE SOLD. EPA HAS STATED THAT UNDER CERTAIN
CIRCUMSTANCES THEY WILL NOT ENFORCE THESE
REQUIREMENTS. FOR FURTHER GUIDANCE CONSULT
EPA’S “POLICY ON CROSS BORDER SALES OF
CALIFORNIA VEHICLES.”
EMISSION CONTROL HARDWARE
Any body builder, installer, or subsequent stage manufacturer
must also assure that all emission control hardware furnished
with incomplete vehicles is on the vehicle and is operational
and that applicable instructions for incorporating such hardware
into the completed vehicle’s electrical or mechanical systems
are strictly followed.
Further, to avoid any question of certification coverage,
approval of any modification or use of an engine or vehicle
which may render inoperative any of the emission control
components must be obtained from the United States
Environmental Protection Agency by the manufacturer making
such modification or use prior to distribution, sale, offering for
sale, introduction, or delivery for introduction of the subject
vehicle into U.S. commerce. Additionally, the manufacturer
making such modification or use must obtain approval from
the California Air Resources Board if the new vehicle will be
delivered for sale or use in the State of California.
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.
UNLEADED GASOLINE LABEL
Regulations no longer require the manufacturer to affix
permanent labels reading “Unleaded Gasoline Only” or
“Unleaded Fuel Only” to vehicles destined for sale in the United
States or Canada. Such labels may however be required for
vehicles sold into other markets. It is the responsibility of the
body builder, installer, or any subsequent manufacturer to
properly label vehicles for the market in which they are sold.
FRONTAL AREA AND WEIGHT RESTRICTIONS:
EXTERIOR NOISE
Starting in 2005, some heavy-duty incomplete vehicles are
certified using chassis certification protocol and will require
vehicle weight and frontal area restrictions (to retain emission
certification). If your vehicle is affected, the frontal area and
unloaded vehicle weight information will be found on the VECI
label, which is located in the engine compartment. Incomplete
vehicles with engines certified using heavy-duty engine
protocol are not limited by weight and frontal area restrictions
for exhaust emissions.
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
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).
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.
IMPORTANT:
For purposes of Government Regulation, a body builder,
installer, or any subsequent manufacturer may be considered
a manufacturer.
EMISSION CERTIFICATION INFORMATION
26
F-SERIES (March, 2005)
TAMPERING WITH NOISE CONTROLS
POWER TAKE-OFF CIRCUIT
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.
A wire located under the instrument panel labeled “Power TakeOff Circuit” is provided to minimize the inadvertent illumination
of the “Service Engine Soon” while the PTO is engaged. Refer
to the Design Recommendation section of the Ford Truck
Body Builders Layout Book, for Power Take-off Installations
information that will locate the Ford provided circuit. Connect
the wire to the Power Take-Off Circuit as instructed and isolate
the wire labeled “Power Take-Off Circuit” from the solenoid to
prevent damage to the Power Control Module (PCM).
Among those acts presumed to constitute tampering are the
acts listed below:
OZONE DEPLETING SUBSTANCE (ODS)
The Clean Air Act of 1990, Section 611 requires any product
(i.e., completed vehicle) containing or manufactured with any
Class I Ozone Depleting Substance on, or after May 15,1993
must be identified with a “clearly and conspicuously attached
label.”
• 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.
Ford Motor Company has eliminated Class I ODS from its
manufacturing processes. All 2006 Ford Truck incomplete
vehicles will not have Class I ODS content.
• Removal or modification of air duct, air intake choke or
silencer, air cleaner, or air cleaner element.
• Removal of, or rendering inoperative, exhaust system
components including the catalyst inlet pipe, muffler, outlet
pipe, resonator, or diffuser.
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.
• Removal of the fan shroud. Removal of or rendering
inoperative the fan clutch.
New vehicles manufactured for sale in Canada must comply
with applicable provisions of Canada Motor Vehicle Safety
Standard 1106, Noise.
Additional noise emissions information is contained in the Ford
Truck Body Builders Layout Book.
EMISSION CONTROL INFORMATION LABEL
WARRANTY AND MAINTENANCE
To meet United States Environmental Protection Agency
regulations, the Important Vehicle Information (tune-up and
fuel tank capacity) labels must be affixed in a location that is
readily visible after installation and in such a manner that it
cannot be removed without destroying or defacing the label.
The label shall not be affixed to any equipment that is easily
detached from the vehicle.
A copy of the appropriate Ford Truck Owners Guide and
Warranty Facts Booklet must be installed in every vehicle prior
to sale to the ultimate purchaser in order to provide emission
systems warranty information and maintenance schedules. It
also provides, where required by EPA noise control regulations
for vehicles having GVWR over 4536 kg [10,000 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.
When emission control labels are supplied but not attached
to the vehicle (i.e., tune-up label or fuel tank label), they must
be permanently mounted in a 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.
EVAPORATIVE EMISSIONS
All 2006 Federal light and heavy duty trucks and all California
vehicles with gasoline engines are required to comply
with evaporative emissions requirements established by
the Environmental Protection Agency or the California Air
Resources Board. Production fuel systems supplied on
incomplete 2006 model year trucks manufactured by Ford
Motor Company comply with these requirements. 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.
CALIFORNIA FUEL VAPOR RECOVERY
California regulations require that the vehicle fuel systems be
designed to accommodate a vapor recovery fueling nozzle
including unobstructed access to the fill pipe. Fuel filler pipes
installed per the figures on pages 22 and 23 will comply with
the “Specifications For Fill Pipes and Openings of Motor Vehicle
Fuel Tanks” referenced in Title 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” (Figure A on page 22
illustrates a typical point Z). The cylindrical zone uses the axis
described above, starts at the outer most surface of the Ford
supplied fuel filler housing, and projects outward (away from
the frame). The fuel pipe housing component is shown on the
referenced figures and is attached to the aftermarket body via
3/16 inch diameter rivets.
MALFUNCTION INDICATOR LIGHT (MIL)
The “Malfunction Indicator Light” is used to indicate malfunctions
of the Electronic Engine Control System and certain emissionsrelated components. For all incomplete vehicles, except Basic
(Stripped) Chassis (which is not equipped with an instrument
panel), it is Ford installed and operational.
F-SERIES (March, 2005)
27
EMISSION CERTIFICATION INFORMATION
CALIFORNIA MOTOR VEHICLE EMISSION CONTROL
LABEL
RADIO FREQUENCY INTERFERENCE (RFI)
The ignition system on your vehicle has been designed to
be capable of compliance with RFI requirements established
by the Canadian government. However, because Ford Motor
Company 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.
To meet California emission certification regulations, the
Emission Control Information (tune-up) label must be welded,
riveted, or otherwise permanently attached to an area within
the engine compartment or to the engine in such a way that
it will be readily visible to the average person after installation
of the engine in a vehicle. In selecting an acceptable location,
the manufacturer shall consider the possibility of accidental
damage (e.g., possibility of tools or sharp instruments coming
in contact with the label). The label shall be affixed in such a
manner that it cannot be removed without being destroyed or
defaced, and shall not be affixed to any part which is likely to
be replaced during the vehicle’s useful life. For motor vehicles
rated at 6350 kg [14,000 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.
While there are currently no RFI regulations in the United
States specifically applicable to automotive ignition systems,
all Ford Motor Company trucks built with an ignition system
use the same or equivalent components to those supplied on
Canadian vehicles.
Ford Motor Company recommends that all ignition system
service be performed at a Ford authorized service facility to
help hold RFI emissions levels to a minimum.
Additional RFI information is contained on page 25 of this
manual.
Devices that emit radio frequency (RF) energy such as AM/FM
radios, mobile telecommunications systems (two-way radios,
telephones), and radio controlled security systems are subject
to the rules and regulations of the Federal Communications
Communication (FCC), including 47 CFR Parts 2 and 15. Any
such system installed in a vehicle should comply with those
rules and should be installed only by a qualified technician.
In addition, to ensure continued compliance with the FCC’s
regulations, RF devices must not 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.)
Completed vehicles for retail sale in California require a
machine-readable Vehicle Identification Number (VIN) bar-code
label made of paper, plastic, metal, or other permanent material
which shall be affixed in a readily visible location to either the
door-latch post next to the driver’s seating position, the door
edge that meets this door-latch post, or above the instrument
panel in a location clearly visible through the lower left corner
of the windshield.
• All incomplete vehicles except Basic (Stripped) Chassis type
vehicles will conform to this standard.
For the Vehicle Emission Control (VEC) and VIN labels,
sufficient clearance shall be provided to use a non-contact barcode Reading Wand. For the tune-up label and vacuum hose
routing diagram label, the label and any adhesives used shall
be designed to withstand typical vehicle environment conditions
in the area where the label is attached for the vehicle’s total
expected life. Typical vehicle environmental conditions shall
include, but are not limited to, exposure to engine lubricants
and coolants (e.g., gasoline, motor oil, brake fluids, water,
ethylene glycol), under hood temperatures, steam cleaning,
and paints or paint solvents.
EMISSION CERTIFICATION INFORMATION
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.
28
F-SERIES (March, 2005)
REFERENCE INFORMATION
FORD TRUCK BODY BUILDERS LAYOUT BOOK
Throughout this manual you will find references to information found in the Ford Truck
Body Builders Layout Book. Additional Design Recommendations and specifications
are also provided to assist subsequent stage manufacturers in completing chassis
cab and incomplete vehicles. To obtain a free copy of this publication on CD-ROM or
to receive an order form for additional CD-ROM’s or books please visit our website at
www.fleet.ford.com/truckbbas. Under Publications select Body Builders Order Forms.
All dealer requests can be handled online. All other U.S. orders should be faxed to
(734) 713-2971. Canadian orders should be faxed to (905) 670-0844.
FORD SERVICE PUBLICATIONS
Many Ford Service Publications pertain to a specific Model Year and vehicle types.
The following publications are a few of many manuals which are available from Helm
Incorporated; call: 1-800-782-4356
• Ford Truck Shop Manuals
• Ford Towing Manual
• Ford Electrical & 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 1-877-840-4338 or e-mail bbasqa@ford.com for
assistance or Fax inquiries to (313) 594-2633 accompanied with a cover sheet indicating “Attention to: Ford Truck Body Builder Advisory Service,” along with your name,
address and telephone number.
F-SERIES (March, 2005)
REFERENCE INFORMATION
FORD MOTOR COMPANY
THE AMERICAN ROAD
DEARBORN, MI 48121
FORD MOTOR COMPANY OF CANADA LIMITED
THE CANADIAN ROAD
OAKVILLE, ONTARIO L6J 5E4